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CPVS 75
User Manual
24 pgs898.63 Kb0

Chicago Pneumatic CPVS 75, CPVS 50, CPVS 60, CPVS 40 User Manual

Instruction Manual EN
CP COMPRESSOR
Model CPVS 40 - 50 - 60 - 75
62 305 258 65 ed00
CPVS 50
The CP Compressors should never be operated beyond its capabilities
or in any way which does not comply with the instructions contained
in this operating and maintenance guide.
Chicago Pneumatic Compressors will decline any responsibility
if these instructions are not respected.
This equipment has been factory tested and satisfies normal
operating conditions: they must not be exceeded
as this would place the machine under abnormal stress and effort.
INSTALLATION INSTRUCTIONS
For the guarantee to be valid, the unit must be assembled in covered
premises with temperatures not exceeding :
Mini: + 36 °F (frost free)
Maxi: + 104 °F
You must also have:
1 meter space around the compressor
-
low ventilation (fresh air) proportionate to the ventilation flow necessary for the machine and protected
from any infiltration of humidity (splashes of water during bad weather) and all pollution
-
top insulation or extraction to ensure reversal of the flow of warm air and evacuation of the heat to
outside the equipment room
-
a link from the condensation water evacuation pipe to the drain discharger
-
in dusty environment, pre-filtering the room's air intake and a special filter
on the machine's ventilation inlets
TECHNICAL DATA
VARIABLE SPEED MACHINES
CPVS Model 40 50 60 75
VERSION CPVS (as per ISO 1217 ed 1996)
Nominal pressure at full flow PSI 58 102 138 58 102 138 58 102 138 58 102 138
Actual flow* cfm 195.1 194.5 166.4 239.1 234.1 204.4 291.2 280.2 244.7 374.3 342.3 304.8
Motor power hp 40 50 60 75
Ø Pressure outlet (F) NPT 1.5" 1.5" 1.5" 1.5"
Capacity gal 5,8 5,8 5,8 5,8
Carryover ppm 3 3 3 3
Noise level at 3,3ft dB(A) 65 66 67 70
(according to ISO 2157 + 3db(A))
* Suction pressure : 14.5 PSI absolute - Relative humidity : 0 % - Ambient temperature : 68 °F
- Effective delivery pressure : 102 PSI, 109 PSI, 138 PSI or 181 PSI (effective)
Dimensions (in) L x Wx H 75x37,4x69,3 75x37,4x69,3 75x37,4x69,3 75x37,4x69,3
Approximate weight lbs 1874 1995 2226 2679
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Chicago Pneumatic Compressors
CPVS Model 40 50 60 75
Motor power (hp) 40 50 60 75
Main Voltage 460 Volt / 3 / 60 Hz
Nominal current (A) 69 81 89 125
Power supply cable AWG 4 AWG 3 AWG 1 AWG 0
Fuse protection (Type RK5) 80 100 125 150
Connection of the electric plate to an external control box
• Install an RC filter on the KM1 coil.
• Install an RC filter on the KM2 coil.
• All connections between external parts and the compressor must be carried out using a shielded cable, which must be grounded at one of its ends.
WARNING: the operation connection cables between the different elements must never follow the same path as the existing power cords. A separate installation from the power cords must be carried out.
• Install an RC filter on all the relay coils of the external operation units.
Chicago Pneumatic Compressors 62 305 258 65
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Page 3
CONTENTS
Space requirement and installation diagram : CPVS Model 40-50-60-75 ......................................................................................... 5
Section 1 - Description .................................................................................................................................................................................. 6
A - General Information ...................................................................................................................................................................... 6
B - Respect of the environment and prevention of pollution ............................................................................................................. 6
C - Standard equipment ...................................................................................................................................................................... 6
D - Definition of the pictograms ........................................................................................................................................................ 7
E - Electronic board ............................................................................................................................................................................ 7
Section 2 - Installation ................................................................................................................................................................................... 8
A - Handling ....................................................................................................................................................................................... 8
B - Room ............................................................................................................................................................................................ 8
C - Assembly....................................................................................................................................................................................... 8
D - Air discharge piping ..................................................................................................................................................................... 8
E - Condensate drain pipes ................................................................................................................................................................. 8
F - Electric cabling ............................................................................................................................................................................. 9
Section 3 - Implementation ......................................................................................................................................................................... 10
A - Preparation for start-up ............................................................................................................................................................... 10
B - First start-up ............................................................................................................................................................................... 10
C -Discharge pressure adjustment .................................................................................................................................................... 10
D - Parallel compressor assembly ..................................................................................................................................................... 10
E - Safety .......................................................................................................................................................................................... 10
Section 4 - Operation ................................................................................................................................................................................... 11
A - Air and oil circuits ...................................................................................................................................................................... 11
Section 5 - Options ....................................................................................................................................................................................... 12
A - Level detection bleed valve ........................................................................................................................................................ 12
B - Advanced filtration to the compression air inlet......................................................................................................................... 12
C - Pre-filtration panels .................................................................................................................................................................... 13
D - Automatic restarting ................................................................................................................................................................... 14
E - Remote starting and stopping ..................................................................................................................................................... 14
F - Rotation direction indicator - Phase controller ........................................................................................................................... 14
G - Centrifugal separator .................................................................................................................................................................. 15
Section 6 - Specific information for CPVS 40-50-60-75 ........................................................................................................................... 16
A - Description ................................................................................................................................................................................. 16
B - Safety .......................................................................................................................................................................................... 16
C - Installation .................................................................................................................................................................................. 16
D - Commissioning ........................................................................................................................................................................... 17
E - Operating incidents ..................................................................................................................................................................... 19
Section 7 - Maintenance .............................................................................................................................................................................. 20
A - Oil level and change ................................................................................................................................................................... 21
B - Air filter ...................................................................................................................................................................................... 21
C - Turbine........................................................................................................................................................................................ 21
D - Oil and air cooler ........................................................................................................................................................................ 22
E - Oil separator ................................................................................................................................................................................ 22
F - Oil return pipe ............................................................................................................................................................................. 22
G - Draining condensation water ...................................................................................................................................................... 22
H - Temperature safety tests ............................................................................................................................................................. 22
I - Refastening electric connections .................................................................................................................................................. 22
J - Decommissioning the compressor at the end of its useful life .................................................................................................... 22
Section 8 - Operating incidents .................................................................................................................................................................. 23
A - Main incidents ............................................................................................................................................................................ 23
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Chicago Pneumatic Compressors
Space requirement and installation diagram : CPVS Model 40-50-60-75 (see page 2 - installation instructions)
Fig. 1
75
3.9
Airoutlet
1"1/2NPT AIRDELIVERY
1/4" NPT
Drain
3.9
2
44
5.9
Airinlet
Airinlet
16
7.6
66.5
66.5
25.8
Airoutlet
69,3
7.6
37.4
A
*:
POWERSUPPLY
CPVS 40 14.7 CPVS 50 19.6 CPVS 60-75 27
Dimensions (in)
36
Type A
*
dia. 2.2
24.9
4.8
23
Airinletwithoutdeflector
29.3
15.3
27
Airoutlet
16 16
2.7
13.413.4
R10.6
18.7
Chicago Pneumatic Compressors 62 305 258 65
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Page 5
Section 1 - Description
A - General Information
The Chicago Pneumatic Compressors CP model air compressor is a compressed air unit and is presented as an entire unit completely assembled and tested. It is driven by an electric motor and enclosed in a sound proof cowling which is necessary for proper cooling.
The compression element is a single-stage, oil-refrigerated, ro­tary screw compressor. The oil is stored in a vertical tank, which is fitted with an oil separator.
The compression element and the motor are fixed to the frame using silent blocks.
B - Respect of the environment and
prevention of pollution
1 - Maintenance of the machine
Make sure that the used components of the machine (waste oil, oil and air filters, oil separators, etc...) are disposed of according to national and local regulations.
2 - Condensate bleed pipe
Make sure that the condensates (water, oil) are drained and treated according to national and local regulations.
3 - End of life of the machine
Make sure that the machine as a whole is disposed of according to national and local regulations ( See F Section 7 and J Section 8 ).
C - Standard equipment
In its standard version, the covered unit includes:
- Operating components:
1. A twinned screw-type compressor.
2. An electric motor: 3600 rpm, short-circuit rotor, 230/460V
or 575V voltage according to the model.
3. Star delta starting.
4. A direct drive or gearbox drive .
5. Air and oil tank in compliance with applicable legislation
ASME
6. "All or nothing" regulation for the aspiration vent.
7. A greasing system using the circuit's differential pressure,
thus avoiding the need for an oil pump.
8. An oil separator based oil separation system.
9. A heat discharge system : oil and compressed air radiator
with forced ventilation.
10. A dry air filter.
11. An oil filter.
12. A command and control electronic board.
- Safety devices:
1. A safety valve mounted on the oil reservoir.
2. An thermal protection device for the motor, situated in the starting box, to protect the motor from excessive overload.
3. An air temperature sensor that stops the compressor when the temperature rises abnormally or during an oil cooling defect.
- Control devices:
1. A minimum pressure valve located at the oil tank outlet, just beyond the oil separator, which guarantees minimum pressure in the lubrication circuit.
2. Automatic draining allowing the unit to be exposed to the atmosphere when stopping to thus ensure empty start up which relieves the motor,
3. An oil level gauge on the front panel ( see fig. 19).
4. An electronic controller including:
– a control keyboard, – the main safety and control indications.
5. The pressure sensor ensures control over the compressed air flow.
The CP compressed air unit has been designed, produced and tested in accordance with the following recommendations, codes and standards :
- machine safety : European Directive 98/37/CE, 91/368/CEE and 93/68/CEE.
- pressure vessels: European Directive for simple pressure vessels n° 87/404/CEE.
- electrical equipment :
• electrical equipment : European Directive Low tension
73/23/CEE.
• electromagnetic compatibility European Directive: 89/336/CEE, 92/31/CEE.
- performance levels: ISO 1217 : 1996.
- noise level : ISO 2157 + 3db(A)
- European Directive 97/23/EC " Pressure Equipment Directive ".
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Chicago Pneumatic Compressors
D - Definition of the pictograms
Typical examples of pictograms valid for CP Compressors:
1. Water outlet
2. Manual condensation water draining
3. Water inlet
4. Automatic condensation water draining
5. Unplug and decompress the compressor before maintenance
6. Hot parts
DANGER
This symbol identifies immediate hazards which will result in severe personal injury, death or substantial property damage.
CAUTION
Identifies hazards or unsafe practies which could result in minor personal injury or property damage.
DANGER
This symbol identifies life threatening electrical voltage levels which will result in severe personal injury or death. All electrical work must be performed by a qualified electrician.
CAUTION
This symbol identifies hot surfaces which coold result in personal injury or property damage.
E - Electronic board
See the specific instructions for a description of the electronic plate, together with operating instructions : Notice N° 62 305 169 xx for version CPVS
Chicago Pneumatic Compressors 62 305 258 65
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Page 7
Section 2 - Installation
A - Handling
Prevailing wind
The CPVS Compressor must always be handled with care. It may be lifted either with a forklift truck or by means of a travelling crane. In the latter case, precautions must be taken so as not to damage the unit's cowling.
B - Room
The CPVS is designed to operate in a frost-free environment, supplied with air at a temperature of no more than 104 °F. The premises must be well-aired and as close as possible to the place where the compressed air is used. A space must be left around the unit, for cleaning and maintenance purposes. It is very important for the compressor to have an abundant supply of fresh air. (see page 2).
If operating the compressor causes the ambient temperature to rise above 104 °F, the warm air leaving the radiator must be discharge outside.
COMMENT
When the atmosphere is contaminated by organic or mineral dust or by corrosive chemical emanations the following precautions must be taken:
1. Provide another air inlet as close as possible to the compressor suction.
2. Use an additional filter. (see options Section 5), on the machine's ventilation intakes.
Installation with heat dispersion sleeve
If the operation of the compressor increases the ambient temperature above 104 °F, it is necessary to discharge the hot air leaving the radiator to the exterior by means of the sleeve.
L
V
Compressor
Flexible fitting
Fig. 2b - Sleeve with an elbow
V maxi = 18.04 ft/s
(Ratio of volume flow rate of the ventilation to the sleeve
cross section)
L maxi = 32.8 ft (without mechanical extractor)
Cross section of room air inlet > 2 x Duct outlet cross section
2 elbows accepted with large radius of curve and fluid
guidance vanes
Ratio (Length/Width of sleeve) maxi = 1.6
Make sure that no outside air, especially if humid, can be fed back into the machine and damage electric and electronic components or rust metal parts.
The maximum admissible pressure loss of the sleeve should not exceed 30 Pa (0.12 in CE). In case of higher value, provide an additional ventilation (mechanical extractor) with a flow equivalent to that of the machine.
Prevailing wind
L
V
Flexible fitting
Compressor
Fig. 2a - Sleeve with roof outlet
d
L
CPVS 40 2860 2.6
CPVS 50 2860 2.6
CPVS 60 3920 3.6
CPVS 75 5300 4.9
Ventilation Duct minimum cross section
flow rate ( d ≤ L ≤ 1,6d )
cfm sqf
C - Assembly
Put the unit on a stable surface. The CPVS does not need foundations. Any flat surface that can support its weight will be sufficient (industrial floor).
D - Air discharge piping
The diameter of the air discharge pipe must be at least 2"NPT.Current legislation requires that a valve which is lockable in the closed position be installed at the air box outlet, connected to the compressor by a union and flexible line to allow it to be cut off during maintenance.
E - Condensate drain pipes
A separator with automatic solenoid valve drain is provided inside the set ( see Section 5-K) to remove the condensate at the final cooler outlet and stop the compressor pipe condensate return lines. Connect the discharge pipe to a condensate manifold.(see B Section 1)
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Chicago Pneumatic Compressors
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