Porter-Cable CPFAC2600P, CFBN220 Instruction Manual

Pancake Compressor
Instruction
manual
Part No. A09777-051-0
®
FRANÇAIS : PAGE 41
To learn more about Porter-Cable
visit our website at:
http://www.porter-cable.com
Copyright © 2005 Porter-Cable Corporation
PROFESSIONAL POWER TOOLS
MODEL
CPFAC2600P
CFBN220
The Model and Serial No. plate is located on the main housing of the tool. Record these numbers in the spaces below and retain for future reference.
Model No. ______________________________________
Type ___________________________________________
Serial No. ______________________________________
IMPORTANT
Please make certain that the person who is to use this equipment carefully reads and understands these instructions before starting operations.
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A09777
SAFETY GUIDELINES - DEFINITIONS
Indicates an imminently hazardous
situation which, if not avoided, will result in death or serious injury.
Indicates a potentially hazardous situation
which, if not avoided, could result in
death or serious injury.
Indicates a potentially hazardous situation
which, if not avoided, may result in minor
or moderate injury.
Used without the safety alert symbol
indicates a potentially hazardous situation which, if not avoided, may result in
property damage
.
This manual contains information that is important for you to know and understand. This information relates to protecting
YOUR SAFETY and
PREVENTING EQUIPMENT PROBLEMS. To help you recognize this
information, we use the symbols below. Please read the manual and pay attention to these symbols.
IMPORTANT SAFETY INSTRUCTIONS
Some dust created by power sanding, sawing, grinding,
drilling, and other construction activities contains chemicals known (to the State of California) to cause cancer, birth defects or other reproductive harm. Some example of these chemicals are:
lead from lead-based paints
crystalline silica from bricks and cement and other masonry products
arsenic and chromium from chemically-treated lumber Your risk from these exposures varies, depending on how often you do this
type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, always wear MSHA/NIOSH approved, properly fitting face mask or respirator when using such tools.
When using air tools, basic safety precautions should always be followed to reduce the risk of of personal injury.
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A09777
IMPORTANT SAFETY INSTRUCTIONS
Save these instructions
Improper operation or maintenance of this product could result in serious injury and property damage. Read and understand all warnings and operation instructions before using this equipment.
HAZARD
WARNING: Risk of explosion or fire
How To Prevent It
What Could Happen
It is normal for electrical contacts within the motor and pressure switch to spark.
If electrical sparks from compressor come into contact with flammable vapors, they may ignite, causing fire or explosion.
Restricting any of the compressor ventilation openings will cause serious overheating and could cause fire.
Unattended operation of this product could result in personal injury or property damage. To reduce the risk of fire, do not allow the compressor to operate unattended.
Always operate the compressor in a well ventilated area free of combustible
materials, gasoline, or solvent vapors.
If spraying flammable materials, locate compressor at least 20 feet away from spray area. An additional length of hose
may be required.
Store flammable materials in a secure location away from compressor.
Never place objects against or on top of compressor. Operate compressor in an
open area at least 12 inches away from any wall or obstruction that would restrict the flow of fresh air to the ventilation openings.
Operate compressor in a clean, dry well ventilated area.
Do not operate unit
indoors or in any confined area. Always remain in attendance
with the
product when it is operating.
Always disconnect electrical power by moving pressure switch lever to the off position and drain tank daily or after each use.
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A09777
WARNING: Risk of Bursting
Air Tank: The following conditions could lead to a weakening of the tank, and result in a violent tank explosion and could cause property damage or serious injury.
How To Prevent It
What Could Happen
WARNING: Risk from Flying Objects
The compressed air stream can cause soft tissue damage to exposed skin and can propel
dirt, chips, loose particles,
and small objects at high speed, resulting in property damage or personal injury.
Always wear ANSI Z87.1 approved safety glasses with side shields when using the compressor.
Never point any nozzle or sprayer toward
any part of the body or at other
people or animals. Always turn the compressor off and
bleed pressure from the air hose and tank
before attempting maintenance, attaching tools or accessories.
HAZARD
HAZARD
Drain tank daily or after each use. If tank
develops a leak, replace it immediately with a new tank or replace the entire compressor.
Failure to properly drain condensed water from tank, causing rust and thinning of the steel tank.
Modifications or attempted repairs to the tank.
Unauthorized modifications to the unloader valve, safety valve, or any other components which control tank pressure.
Never drill into, weld, or make any modifications to the tank or its
attachments.
Excessive vibration can weaken the air tank and cause rupture or explosion
The tank is designed to withstand specific operating pressures. Never make
adjustments or parts substitutions to alter the factory set operating pressures.
For essential control of air pressure,
you must install a pressure regulator and pressure gauge to the air outlet (if not equipped) of your compressor. Follow the
equipment manufacturers recommendation and never exceed the maximum allowable pressure rating of attachments. Never use
compressor to inflate small low pressure objects such as children’s toys, footballs, basketballs, etc.
ATTACHMENTS & ACCESSORIES:
Exceeding the pressure rating of air tools, spray guns, air operated
accessories, tires, and other inflatables can cause them to explode or fly apart, and could result in serious injury.
How To Prevent It
What Could Happen
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A09777
WARNING: Risk to Breathing
WARNING: Risk of Electrical Shock
HAZARD
HAZARD
Your air compressor is powered by electricity. Like any other electrically powered device, If it is not used properly it may cause electric shock.
Repairs attempted by unqualified personnel can result in serious injury or death by electrocution.
Electrical Grounding: Failure to provide adequate grounding to this product could result in serious injury or death from electrocution.
See grounding instructions.
Never operate the compressor outdoors when it is raining or in wet conditions.
Never operate compressor with protective covers removed
or damaged.
Any electrical wiring or repairs required on this product should be performed by authorized service center personnel in accordance with national and local electrical codes.
Make certain that the electrical circuit
to which the compressor is connected
provides proper electrical grounding, correct voltage and adequate fuse protection.
Sprayed materials such as paint, paint
solvents, paint remover, insecticides, weed killers, may contain harmful
vapors and poisons.
Work in an area with good cross ventilation. Read and follow the safety instructions provided on the label or safety data sheets for the materials you are spraying. Use a NIOSH/MSHA approved respirator designed for use
with your specific application.
How To Prevent It
What Could Happen
How To Prevent It
What Could Happen
The compressed air directly from your compressor is not safe for breathing. The air stream may contain carbon
monoxide, toxic vapors, or solid particles from the tank. Breathing these contaminants can cause serious injury or death.
Air obtained directly from the compressor should never be used to supply air for human consumption. In order to use air
produced by this compressor for breathing, suitable filters and in-line
safety equipment must be properly installed. In-line filters and safety equipment used in conjunction with the compressor must be capable of treating air to all applicable local and federal codes prior to human consumption.
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A09777
WARNING: Risk of Burns
Touching exposed metal such as the
compressor head or outlet tubes,
can
result in serious burns.
Never touch any exposed metal parts on compressor during or immediately after operation. Compressor will remain hot for several minutes after operation.
Do not reach around protective shrouds or attempt maintenance until unit has been allowed to cool.
WARNING: Risk from Moving Parts
Never operate the compressor with guards or covers which are damaged or removed.
Moving parts such as the pulley, flywheel, and belt can cause serious injury if they come into contact with you
or your clothing.
WARNING: Risk of Falling
A portable compressor can fall from a table, workbench, or roof c
ausing damage to the compressor and could result in serious injury or death to the operator.
Always operate compressor in a stable secure position to prevent accidental movement of the unit. Never operate compressor on a roof or other elevated position. Use additional air hose to reach high locations.
HAZARD
HAZARD
HAZARD
Any repairs required on this product should be performed by authorized service center personnel.
Attempting to operate compressor
with
damaged or missing parts or
attempting to repair compressor with protective shrouds removed can expose you to moving parts and can result in
serious injury.
How To Prevent It
What Could Happen
How To Prevent It
What Could Happen
How To Prevent It
What Could Happen
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A09777
Review and understand all instructions and warnings in this manual.
Become familiar with the operation and controls of the air compressor.
Keep operating area clear of all persons,
pets, and obstacles. Keep children away from the air
compressor at all times
.
Do not operate the product when fatigued or under the influence of alcohol or drugs. Stay alert at all times.
Never defeat the safety features of this
product.
Equip area of operation with a fire extinguisher.
Do not operate machine with missing, broken, or unauthorized parts.
WARNING: Risk of Unsafe Operation
Unsafe operation of your air compressor could lead to serious injury or death to you or others.
HAZARD
WARNING: Risk of Serious Injury or Property Damage
When Transporting Compressor
Oil can leak or spill and could result in
fire or breathing hazard; serious injury or death can result. oil leaks will damage carpet, paint or other surfaces in vehicles or trailers.
Always place COMPRESSOR on a
protective mat when transporting
to protect against damage to vehicle from leaks. Remove COMPRESSOR from vehicle immediately upon arrival at your destination.
(Fire, Inhalation, Damage to Vehicle Surfaces)
HAZARD
SAVE THESE INSTRUCTIONS
How To Prevent It
What Could Happen
How To Prevent It
What Could Happen
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A09777
GLOSSARY
DUTY CYCLE
Accessories for this unit are available at the store the unit was purchased.
ACCESSORIES
Become familiar with these terms before operating the unit.
CFM: Cubic feet per minute. SCFM: Standard cubic feet per
minute; a unit of measure of air delivery.
PSIG: Pounds per square inch gauge; a unit of measure of pressure.
Code Certification: Products that bear one or more of the following marks: UL, CUL, ETL, CETL, have been evaluated by OSHA certified independent safety laboratories and meet the applicable Underwriters Laboratories Standards for Safety.
Cut-In Pressure:
While the motor is off, air tank pressure drops as you continue to use your accessory.
When the tank pressure drops to a certain low level the motor will restart automatically. The low pressure at which the motor automatically restarts is called "cut-in" pressure.
Cut-Out Pressure:
When an air compressor is turned on and begins to run, air pressure in the air tank begins to build. It builds to a certain high pressure before the motor automatically shuts off - protecting your air tank from pressure higher than its capacity. The high pressure at which the motor shuts off is called "cut-out" pressure.
Branch Circuit: Circuit carrying electricity from electrical panel to outlet.
This air compressor pump is capable of running continuously. However, to prolong the life of your air compressor, it is recommended that a 50%-75%
average duty cycle be maintained; that is, the air compressor pump should not run more than 30-45 minutes in any given hour.
SPECIFICATIONS
Model Nos. CPFAC2600P
CFBN220
Bore 1.875" Stroke 1.250" Voltage-Single Phase 120 Minimum Branch Circuit Requirement 15 amps Fuse Type Time Delay Air Tank Capacity (Gallon) 6 Approximate Cut-in Pressure 120 PSIG Approximate Cut-out Pressure 150 PSIG SCFM @ 40 PSIG 3.7 SCFM @ 90 PSIG 2.6
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A09777
ASSEMBLY
Unpacking
1. Remove unit from carton and discard all packaging.
2. Make sure the outlet being used
has the same configuration as
the
grounded plug.
DO NOT USE AN
ADAPTER. See illustration.
3. Inspect the plug and cord before
each use. Do not use if there are signs of damage.
4. If these grounding instructions
are not completely understood, or if in doubt as to whether the compressor is properly grounded, have the installation checked by
a qualified electrician.
Risk of
Electrical Shock. IMPROPER GROUNDING CAN RESULT IN ELECTRICAL SHOCK.
Do not modify the plug provided. If it does not fit the available outlet, a correct outlet should be installed by a qualified electrician.
Repairs to the cord set or plug MUST be made by a qualified electrician.
GROUNDING INSTRUCTIONS
Risk of Electrical
Shock. In the event of a short circuit, grounding reduces the risk of shock by providing an escape wire for the electric current. This air compressor must be properly
grounded.
The portable air compressor is equipped with a cord having a grounding wire with an appropriate grounding plug (see following illustrations).
1. The cord set and plug with this
unit contains a grounding pin. This plug MUST be used with a grounded outlet.
IMPORTANT: The outlet being used must be installed and grounded in accordance with all local codes and ordinances.
INSTALLATION
HOW TO SET UP YOUR UNIT
Grounding Pin
Grounded Outlets
Plug
Location of the Air Compressor
Locate the air compressor in a clean, dry and well ventilated area.
The air compressor should be located at least 12" away from the wall or other obstructions that will interfere with the flow of air.
The air compressor pump and shroud are designed to allow for proper cooling. The ventilation openings on the compressor are necessary to maintain proper operating temperature. Do not place rags or other containers on or near these openings.
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A09777
Extension Cords
Using extension cords is not recommended. The use of extension cords will cause voltage to drop resulting in power loss to the motor and overheating.
Instead of using an extension cord, increase the working reach of the air hose by attaching another length of hose to its end. Attach additional lengths of hose as needed.
If an extension cord must be used, be sure it is:
a 3-wire extension cord that has
a 3-blade grounding plug, and a 3-slot receptacle that will accept the plug on the product
in good condition
no longer than 50 feet
14 gauge (AWG) or larger. (Wire
size increases as gauge number decreases. 12 AWG and 10 AWG may also be used. DO NOT USE 16 OR 18 AWG.)
Voltage and Circuit Protection
Refer to the specification chart for the voltage and minimum branch circuit requirements.
Risk of Opertion.
Certain air compressors can be operated on a 15 amp circuit if the following conditions are met.
1. Voltage supply to circuit must
comply with the National Electrical Code.
2. Circuit is not used to supply any
other electrical needs.
3. Extension cords comply with
specifications.
4. Circuit is equipped with a 15 amp
circuit breaker or 15 amp time delay fuse. NOTE: If compressor is connected to a circuit protected by fuses, use only time delay fuses. Time delay fuses should be marked "D" in Canada and "T" in the US.
If any of the above conditions cannot be met, or if operation of the compressor repeatedly causes interruption of the power, it may be necessary to operate it from a 20 amp circuit. It is not necessary to change the cord set.
Outlet Pressure Gauge: The outlet pressure gauge indicates the air pressure available at the outlet side of the regulator. This pressure is controlled by the regulator and is always less than or equal to the tank pressure.
Regulator: Controls the air pressure shown on the outlet pressure gauge. Pull the knob out and turn clockwise to increase pressure and counterclockwise to decrease pressure. When the desired pressure is reached push knob in to lock in place.
Cooling System (not shown): This compressor contains an advanced design cooling system. At the heart of this cooling system is an engineered fan. It is perfectly normal for this fan to blow air through the vent holes in large amounts. You know that the cooling system is working when air is being expelled.
Air Compressor Pump (not shown): Compresses air into the air tank. Working air is not available until the compressor has raised the air tank pressure above that required at the air outlet.
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A09777
Description of Operation
Become familiar with these controls before operating the unit.
On(I)/Off(O) Switch: Place this switch in the ON (I) position to provide automatic power to the pressure switch and OFF (O) to remove power at the end of each use.
Pressure Switch
(not shown): The
pressure switch automatically starts the motor when the air tank pressure drops below the factory set "cut-in" pressure. It stops the motor when the air tank pressure reaches the factory set "cut-out" pressure.
Safety Valve: If the pressure switch does not shut off the air compressor at its "cut-out" pressure setting, the safety valve will protect against high pressure by "popping out" at its factory set pressure (slightly higher than the pressure switch "cut-out" setting).
Tank Pressure Gauge:
The tank pressure gauge indicates the reserve air pressure in the tank.
OPERATION
Know Your Air Compressor
READ THIS OWNER’S MANUAL AND SAFETY RULES BEFORE OPERATING YOUR UNIT. Compare the illustrations with your unit to familiarize yourself with the location of various controls and adjustments. Save this manual for future reference.
On(I)/Off(O) Switch
Safety Valve
Tank Pressure Gauge
Outlet Pressure Gauge
Regulator
Quick Connect
2.
Plug the power cord into the correct branch circuit receptacle. (Refer to Voltage and Circuit Protection paragraph in the Installation section of this manual.)
3. Open the drain valve (counter­clockwise) fully to permit air to escape and prevent air pressure build up in the air tank during the break-in period.
4. Move the On/Off switch to ON (I) position. The compressor will start.
5. Run the compressor for 15 minutes. Make sure the drain valve is open and there is minimal air pressure build-up in tank.
6. After 15 minutes, close the drain valve by turning clockwise. The air receiver will fill to "cut-out" pressure and the motor will stop.
The compressor is now ready for use.
Drain Valve:
The drain valve is located at the base of the air tank and is used to drain condensation at the end of each use.
Check Valve:
When the air compressor is operating, the check valve is "open", allowing compressed air to enter the air tank. When the air compressor reaches "cut-out" pressure, the check valve "closes", allowing air pressure to remain inside the air tank.
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A09777
Check Valve
How to Use Your Unit
How to Stop:
1. Set the On/Off switch to OFF (O).
Before Each Start-Up:
1. Set the On/Off switch to OFF (O).
2. Pull the regulator knob out and turn counterclockwise to set the outlet pressure to zero.
3. Attach hose and accessories.
NOTE: The hose or accessory will require a quick connect plug if the air outlet is equipped with a quick connect socket.
Before Starting
Break-in Procedure
Risk of Unsafe
Operation. Serious damage may result if the following break-in instructions are not closely followed.
This procedure is required before
the air compressor is put into service and when the check valve or a complete compressor pump has been replaced.
1. Make sure the On/Off switch is in
the OFF (O) position.
Drain Valve
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A09777
How to Start:
1.
Set the On/Off switch to ON (I) and allow tank pressure to build. Motor will stop when tank pressure reaches "cut-out" pressure.
2. Pull the regulator knob out and turn clockwise to increase pressure. When the desired pressure is reached push knob in to lock in place.
The compressor is ready for use.
Risk of Bursting.
Too much air pressure causes a hazardous risk of bursting. Check the manufacturer’s maximum pressure rating for air tools and accessories. The regulator outlet pressure must never exceed the maximum pressure rating.
MAINTENANCE
Customer Responsibilities
Daily or after each use
Before each use
Check Safety Valve Drain Tank
NOTE: See "Operation" section for the location of controls.
Unit cycles
automatically when power is on. When performing maintenance, you may be exposed to voltage sources, compressed air, or moving parts. Personal injuries can occur. Before performing any maintenance or repair, disconnect power source from the compressor and bleed off all air pressure.
To Check Safety Valve
If the safety valve
does not work properly, over-pressurization may occur, causing air tank rupture or an explosion.
1. Before starting compressor, pull
the ring on the safety valve to make sure that the safety valve operates freely. If the valve is stuck or does not operate smoothly, it must be replaced with the same type of valve.
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A09777
To Drain Tank
1. Set the On/Off switch to OFF (O).
2. Pull the regulator knob out and turn counterclockwise to set the outlet pressure to zero.
3. Remove the air tool or accessory.
4. Pull ring on safety valve allowing air to bleed from the tank until tank pressure is approximately 20 psi. Release safety valve ring.
5. Drain water from air tank by opening drain valve on bottom of tank.
Water will
condense in the air tank. If not drained, water will corrode and weaken the air tank causing a risk of air tank rupture.
6. After the water has been drained,
close the drain valve. The air compressor can now be stored.
NOTE: If drain valve is plugged, release all air pressure. The valve can then be removed, cleaned, the reinstalled.
To Replace or Clean Check Valve
1. Release all air pressure from air tank. See "To Drain Tank" in the Maintenance section.
2. Unplug unit.
3. Remove the hose by removing the hose clamp. NOTE: The hose clamp is not reusable. You must purchase a new hose clamp, see the Parts List Manual or purchase a standard hose clamp at a local hardware store.
SERVICE AND ADJUSTMENTS
Risk of Unsafe Operation. Unit cycles automatically when
power is on. When servicing, you may be exposed to voltage sources, compressed air, or moving parts. Before servicing unit unplug or disconnect electrical supply to the air compressor, bleed tank of pressure, and allow the air compressor to cool.
ALL MAINTENANCE AND REPAIR OPERATIONS NOT LISTED MUST BE PERFORMED BY TRAINED SERVICE TECHNICIAN.
4. Unscrew the check valve (turn counter-clockwise) using a socket wrench.
Check Valve
Hose Clamp
5. Remove pump mounting screws securing pump (one on each side).
6. Carefully slide pump from brackets and out of the way.
7. Using an adjustable wrench or 5/8" wrench remove the regulator manifold.
8. Apply pipe sealant to new regulator man
ifold and assemble,
tighten with wrench.
9. Reapply pipe sealant to gauges, quick connect, and safety valve.
10. Reassemble all components in reverse order of removal. Make sure to orient gauges to read correctly and use wrenches to tighten all components.
To Replace Regulator
1. Release all air pressure from air tank. See "To Drain Tank" in the Maintenance section.
2. Unplug unit.
3. Using an adjustable wrench or specified wrench remove the gauges (7/16" wrench), quick connect (13/16" wrench), and safety valve (9/16" wrench) from the regulator manifold.
4. Remove the hose by removing the hose clamp. NOTE: The hose clamp is not reusable. You must purchase a new hose clamp, see the Parts List Manual or purchase a standard hose clamp at a local hardware store.
5. Make sure the valve disc moves freely inside the check valve and the spring holds the disc in the upper, closed position. The check valve may be cleaned with a solvent, such as paint and varnish remover.
6. Apply sealant to the check valve threads. Reinstall the check valve (turn clockwise).
7. Replace hose and new hose clamp.
8. Perform the Break-in Procedure. See "Break-in Procedure" in the Operation section.
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A09777
Quick Connect
Safety Valve
Regulator Manifold
Hose Clamp
Regulator Manifold
Pump shown moved out of the way
Regulator Manifold
Gauges
Pump Mounting Screw
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A09777
STORAGE
Before you store the air compressor, make sure you do the following:
1. Review the "Maintenance" section on the preceding pages and perform scheduled maintenance as necessary.
2. Set the On/Off switch to OFF (O) and unplug unit.
3. Turn the regulator counterclockwise and set the outlet pressure to zero.
4. Remove the air tool or accessory.
5. Pull ring on safety valve allowing air to bleed from the tank until tank pressure is approximately 20 psi. Release safety valve ring.
6. Drain water from air tank by opening drain valve on bottom of tank.
Risk of Bursting.
Water will condense in the air tank. If not drained, water will corrode and weaken the air tank causing a risk of air tank rupture.
7. After the water has been drained,
close drain valve by turning clockwise.
NOTE: If drain valve is plugged, release all air pressure. The valve can then be removed, cleaned, then reinstalled.
8.
Protect the electrical cord and
air hose from damage (such as being stepped on or run over). Wind them loosely around the compressor handle.
9. Store the air compressor in a
clean and dry location.
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A09777
TROUBLESHOOTING
Performing repairs may expose voltage sources, moving
parts or compressed air sources. Personal injury may occur. Prior to attempting any repairs, unplug the air compressor and bleed off all air tank air pressure.
PROBLEM
CAUSE
CORRECTION
Pressure switch does not shut off motor when compressor reaches "cut­out" pressure.
Pressure switch "cut-out" too high.
Move On/Auto/Off lever to the "Off" position, if the outfit does not shut off contact a Trained Service Technician.
Contact a Trained Service Technician.
Excessive tank pressure - safety valve pops off.
Tube fittings are not tight enough.
Tighten fittings where air can be heard escaping. Check fittings with soapy water solution. Do Not
Overtighten.
Air leaks at fittings.
Air leaks in air tank or at air tank welds.
Defective air tank. Air tank must be replaced.
Do not repair the leak.
Do not
drill into, weld or otherwise modify air tank or it will weaken. The tank can rupture or explode.
Air leaks between head and valve plate.
Leaking seal.
Contact a Trained Service Technician.
Possible defect in safety valve.
Operate safety valve manually by pulling on ring. If valve still leaks, it should be replaced.
Air leak from safety valve.
Possible defect in safety valve.
Operate safety valve manually by pulling on ring. If valve still leaks, it should be replaced.
Knocking Noise.
18 - ENGA09777
Regulator will not shut off air outlet.
Damaged regulator
Replace
PROBLEM
CAUSE
CORRECTION
It is normal for "some" pressure drop to occur.
If there is an excessive amount of pressure drop when the accessory is used, adjust the regulator following the instructions in the "Description of Operation" paragraph in the "Operation Section.
NOTE: Adjust the regulated pressure under flow conditions (while accessory is being used).
Compressor is not supplying enough air to operate accessories.
Prolonged excessive use of air.
Compressor is not large enough for air requirement.
Hole in hose.
Check valve restricted.
Air leaks.
Decrease amount of air usage.
Check the accessory air requirement. If it is higher than the SCFM or pressure supplied by your air compressor, you need a larger compressor.
Check and replace if required.
Remove and clean, or replace.
Tighten fittings.
Damaged regulator
Replace
Regulator knob has continuous air leak.
Pressure reading on the regulated pressure gauge drops when an accessory is used.
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