Oil-injected rotary screw compressors

People. Passion. Performance.

CPF 200-125 460/220V-60Hz - YD

BRY190070/UTO-1
BRY190156/ACA-1
CP

Instruction manual
 Compressor Instruction Manual

CPF-150, CPF-175, CPF-200

Copyright Statement

Any non-authorized use or copy of its contents or any part thereof is prohibited.

This refers especially to trademarks, model names, part numbers and data.

This manual is valid for compressors with serial number greater than BQD108496.
No. 1093 1387 37 - Ed. 01 01/2020

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STORAGE, CONSERVATION AND TRANSPORT CONDITIONS
1. Introduction 3. Conservation after installation
The non-painted surface of all out-of-service compressors, 1. Run the unit at least twice a week, for a minimum of 30
whether installed or waiting installation, is subject to oxidation minutes and operate the load/relief system a few times.
and corrosion.
2. Stop the unit, close the outlet valve and open the
The corrosion level ranges according to the environment condensate drains (after the air cooler and condensate
conditions (temperature, humidity etc.) and the care taken for separator manual). Ensure none of the drains is clogged.
storing and conserving the unit.
3. Close the drains after 02 minutes.
Therefore, it is impossible to establish the period in which the
unit can be stored without rust damage. NOTES:

The higher the humidity and the longer the stopping and/ 1. This oil should be removed prior to the technical start-
or storage period, the more care must be taken. For CPF up of the equipment, otherwise, a “hydrolock” could
compressors, in addition to the precautions for the compressor, form, causing irreparable damage to the compressor
specific preventive measures should be taken for the electric unit.
motor, according to the manufacturer’s instructions.
2. This instruction does not provide for cases of aggressive
Compressors are not normally expected to be out of service or environment, which should be analyzed individually.
stored for long periods, so they are shipped ready for storage
for a maximum of 75 days from the date of manufacture. After 4. Movement and transport
that, the procedure described in 2 should be followed.
If the unit is to be moved or transported, the original fittings
Should the compressor be out of service for more than one and guards must be reinstalled to immobilize the vibration
week, follow the instructions in item 3. dampers and the engine and compressor assembly.

2. 
Storage and conservation prior to The compressor can be handled with a forklift using the
installation openings in the frame. The forklift must have capacity
suitable for the sizes and weight of the compressor. The
1. Store the compressor in a clean, dry, well-ventilated compressor may also be lifted by inserting beams into the
environment, free of dust and humidity. openings. Make sure that the beams are properly fixed and
equally spaced on both sides of the frame. Ropes/chains must
2. The entire lower section of the compressor should stand be kept parallel to the bodywork by means of an expander,
on a flat, vibration-free floor. not touching it in order not to damage the compressor. Lifting
equipment should be placed so that the compressor is raised
3. Ensure that there is no water in the grate, plastic cover perpendicular, slightly and without twisting.
or any part of the bodywork or base of the unit.

4. Remove the intake valve and fill the compressor unit

with the lubricating oils recommended by Chicago
Pneumatic (see note 1).

5. Reinsert the intake valve.

6. Rotate the coupling 10 turns once a month, to change

the position of the compressor element bearings balls
and rollers. In case there is no access to the motor shaft,
remove the rear motor cover for access through the
motor fan.

7. Should the compressor be stored for more than 6

months, the oil, oil filter and separator element should
be replaced. For engine, check engine manufacturer’s
instructions on material delivered (on CD) with
compressor. Pay attention to the engine resistance
connection, if any, to avoid inside the engine.

2
WARRANTIES
Chicago Pneumatic ensures to the Buyer free repair for products, its components or accessories, sold and manufactured by our
company that eventually present proven manufacturing defects, for the period and pursuant to the conditions indicated below,
provided that such defects do not result from improper use or by fault of the Buyer.

Warranty periods are counted from the date the invoice(s) are issued, considering:

a. for stationary or portable compressors: for eighteen (18) months after invoice issue or twelve (12) months after technical
delivery, whichever occurs first, and twenty-four (24) months for the compressor.

b. for other equipment: for eighteen (18) months after invoice issue or twelve (12) months after technical delivery, whichever
occurs first.

No repair, modification or replacement under the warranty will extend the terms indicated above, whether for the equipment or
for its replaced accessories or components.

Warranties provided for this instrument refer only to components manufactured at our facilities. Each manufacturer is solely
responsible for the warranties for parts, engines and accessories manufactured them.

Effectiveness of these warranties is conditioned to immediate written communication of the defect verified by the Buyer to
Chicago Pneumatic, and any intervention on the product or equipment by the Buyer or third parties must not be done, under
penalty of voiding the warranty.

Our products are coated according to ISO 12944 standard; our corrosion class is “C3 medium”.

Warranty will become void in case of:

a. stationary compressors installed or assembled by the Buyer without inspection and approval by Chicago Pneumatic;
except for CPM models.
b. lack of Technical Delivery by Chicago Pneumatic;
c. inappropriate or incorrect maintenance of equipment or products, including: (i) non-authorized modifications; and (ii)
non-compliance with maintenance instructions provided by Chicago Pneumatic, poor or irregular lubrication;
d. use of non-original parts or accessories, or not approved by Chicago Pneumatic;
e. inappropriate or incorrect use of equipment or products;
f. work overload not been previously authorized in written by Chicago Pneumatic;
g. normal wear and tear of equipment or products;
h. damage arising from Act of God or force majeure, such those resulting from fires, floods, depredation, strikes, rampage
or similar harmful actions, among others;
i. inappropriate transport, irregular or extended storage periods by the Buyer; and
j. the Buyer is in arrears or default of payments set in the Purchase and Sale Agreement.

No manufacturing defect shall be considered a fair reason for Buyer non-compliance with the obligations under this instrument
and included proposal.

Services related to these warranties will be performed in workshops previously authorized by Chicago Pneumatic; and the
Buyer is responsible for delivering and retrieving products at/from these locations, and for the respective transport and insurance
expenses. At Chicago Pneumatic’s sole discretion, the warranted services may be provided at the Buyer’s facilities. In such
case, all expenses related to mileage and air tickets, travel time, food and accommodation of technicians and/or mechanics shall
be borne by the Buyer.

3
CONTENTS
1 Safety precautions����������������������������������������������������������5 5 Operating instructions ������������������������������������������������43
1.1 Safety icons������������������������������������������������������������5 5.1 Initial start������������������������������������������������������������43
1.2 Safety precautions during installation��������������������5 5.2 Before starting������������������������������������������������������44
1.3 Safety precautions during operation����������������������6 5.3 Start-up����������������������������������������������������������������44
1.4 Safety precautions during maintenance or repair��7 5.4 During operation��������������������������������������������������45
5.5 Display check������������������������������������������������������45
2 General description��������������������������������������������������������9
5.6 Manual load/relief������������������������������������������������46
2.1 Introduction������������������������������������������������������������9
5.7 Stop����������������������������������������������������������������������46
2.2 Regulating system������������������������������������������������10
5.8 Removal from service������������������������������������������47
2.3 Special Features ��������������������������������������������������11
5.9 Use of air tank������������������������������������������������������47
3 Graphic controller��������������������������������������������������������12 5.10 Storage conditions������������������������������������������������47
3.1 Controller ������������������������������������������������������������12 5.10.1 Introduction����������������������������������������������47
3.2 Control panel��������������������������������������������������������13 5.10.2 Storage and conservation prior to
3.3 Icons used������������������������������������������������������������14 installation������������������������������������������������47
3.4 Main screen����������������������������������������������������������17 5.10.3 Conservation after installation ����������������48
3.5 Accessing menus��������������������������������������������������19 5.10.4 Movement and transport��������������������������48
3.6 Input menu ����������������������������������������������������������19
6 Maintenance������������������������������������������������������������������48
3.7 Outputs menu ������������������������������������������������������20
6.1 Preventive maintenance program������������������������48
3.8 Counters ��������������������������������������������������������������21
6.2 Motors������������������������������������������������������������������50
3.9 Selecting the control mode����������������������������������21
6.3 Oil specifications��������������������������������������������������51
3.10 Service menu��������������������������������������������������������22
6.3.1 Chicago Pneumatic ROTAIR Plus����������51
3.11 Regulation menu��������������������������������������������������24
6.3.2 Chicago Pneumatic CP-46 ����������������������51
3.12 Event history menu����������������������������������������������24
6.3.3 CP-46 F����������������������������������������������������51
3.13 Week timer menu ������������������������������������������������25
6.3.4 Oil filter change����������������������������������������51
3.14 Test Menu������������������������������������������������������������29
6.4 Oil change������������������������������������������������������������51
3.15 Modification of general parameters ��������������������30
6.5 Storage after installation��������������������������������������52
3.16 General Menu������������������������������������������������������30
6.6 Service kits����������������������������������������������������������52
3.17 User Password Menu ������������������������������������������31
6.7 Filter disposal������������������������������������������������������52
3.18 Access key Menu ������������������������������������������������31
6.8 Safety valve����������������������������������������������������������52
3.19 Programmable Parameters ����������������������������������32
3.20 Start-up����������������������������������������������������������������34 7 Troubleshooting������������������������������������������������������������53
3.21 During operation��������������������������������������������������34 7.1 Troubleshooting ��������������������������������������������������53
3.22 Automatic restart��������������������������������������������������35
8 Technical data ��������������������������������������������������������������55
3.23 Stop����������������������������������������������������������������������35
3.24 Removal from service������������������������������������������36 9 Instructions for using the air-oil separator vessel ����56
4 Installation��������������������������������������������������������������������37 10 Environmental information����������������������������������������57
4.1 Dimensional drawing ������������������������������������������37
4.2 Installation suggestions��������������������������������������39
4.3 Electric Diagrams������������������������������������������������41
4.4 Cable size, fuses and circuit breaker settings������41
4.5 Pictographs����������������������������������������������������������42

4
1 Safety precautions Precautions during installation
1. The machine must only be lifted using suitable
1.1 Safety icons equipment and in accordance with applicable safety
Explanation regulations. Loose or pivoting parts must be securely
fastened before lifting. It is strictly forbidden to dwell
Life-threatening or stay in the risk zone under a lifted load. Lifting
acceleration and deceleration must be kept within safe
Warning limits. Wear a safety helmet when working in the area of
overhead or lifting equipment.
Important note 2. Place the machine where the ambient air is as cool and
clean as possible. If necessary, install a suction duct.
1.2 Safety precautions during installation Never obstruct the air inlet. Care must be taken to
minimize the entry of moisture at the inlet air.
All responsibility for any damage or injury resulting
from neglecting these precautions, or non-observance 3. Any blanking flanges, plugs, caps and desiccant bags
of the normal caution and care required for must be removed before connecting the pipes.
installation, operation, maintenance and repair, even 4. Air hoses must be of correct size and suitable for the
if not expressly stated, will be disclaimed by Chicago working pressure. Never use frayed, damaged or worn
Pneumatic. hoses. The distribution pipes and connections must have
proper size and be suitable for the working pressure.
General precautions
5. The aspirated air must be free of flammable fumes,
1. The operator must employ safe working practices
vapors or particles, such as solvents, that can lead to
and observe all related work safety requirements and
internal fire or explosion.
regulations.
6. Arrange the air intake so that loose clothing worn cannot
2. If any of the following statements does not comply with
be sucked in.
the applicable legislation, the stricter of the two shall
apply. 7. Ensure that the discharge pipe from the compressor to
the aftercooler or the air net is free to expand under heat
3. Installation, operation, maintenance and repair work
and that it is not in contact with or close to flammable
must only be performed by authorized, trained and
materials.
specialized technicians.
8. No external force can be exerted on the air outlet valve;
4. The compressor is not considered capable of producing
the connected pipe must be free of strain.
breathable air. To obtain breathable air, the compressed
air must be adequately purified according to the 9. If remote control is installed, the machine must bear a
applicable legislation and standards. clear sign stating: DANGER: This machine is remotely
controlled and may start without warning. The operator
5. Before any maintenance, repair, adjustment or any
has to make sure that the machine is stopped and that
other non-routine checks, stop the compressor, press
the isolating switch is open and locked before any
the emergency stop button, switch off the power and
maintenance or repair. As a further safeguard, persons
depressurize the compressor. In addition, the isolating
switching on remotely controlled machines shall take
switch must be opened and locked.
adequate precautions to ensure that there is no one
6. Never play with compressed air. Do not apply air to checking or working on the machine. To this end, a
your skin or direct an air stream at people. Never use suitable notice shall be affixed to the start equipment.
air to clean dirt from your clothes. When using the air to
10. Air-cooled machines must be installed in such a way
clean equipment, do so with extreme caution and wear
that an adequate flow of cooling air is available and that
eye protection.
the exhausted air does not recirculate to the compressor
7. The owner is responsible for maintaining the unit in or cooling air inlet.
safe operating condition. Parts and accessories shall be
replaced if unsuitable for safe operation.

5
11. The electrical connections must correspond to the must only be performed by authorized, trained and
applicable codes. The machines must be earthed and specialized technicians.
protected against short circuits by fuses in all phases. A
4. The compressor is not considered capable of producing
lockable power isolating switch must be installed near
breathable air. To obtain breathable air, the compressed
the compressor.
air must be adequately purified according to the
12. On machines with automatic start/stop system or if applicable legislation and standards.
the automatic restart function after power failure is
5. Before any maintenance, repair, adjustment or any
activated, a sign stating “This machine may start without
other non-routine checks, stop the compressor, press
warning” must be affixed near the instrument panel.
the emergency stop button, switch off the power and
13. In multiple compressor systems, manual valves must be depressurize the compressor. In addition, the isolating
installed to isolate each compressor. Non-return valves switch must be opened and locked.
(check valves) must not be relied upon for isolating
6. Never play with compressed air. Do not apply
pressure systems.
air to your skin or direct an air stream at people.
14. Never remove or tamper with the safety devices, guards Never use air to clean dirt from your clothes. When
or insulation fitted on the machine. Every vessel or using the air to clean equipment, do so with extreme
auxiliary installed outside the machine to contain air caution and wear eye protection.
above atmospheric pressure must be protected by a
pressure relieving device or devices as required. Precautions during operation
15. Piping and other parts with a temperature above 80 °C 1. Use only the correct type and size of hose end fittings
(176 °F) that may be accidentally touched in normal and connections. When blowing through a hose or air
operation must be guarded or insulated. Other high line, ensure that the open end is held securely. A free end
temperature piping must be clearly marked. will whip and may cause injury. Make sure that a hose is
fully depressurized before disconnecting it.
16. For water-cooled machines, the cooling water system
installed outside the machine has to be protected by 2. Persons switching on remotely controlled machines
a safety device with set pressure according to the shall take adequate precautions to ensure that there is
maximum cooling water inlet pressure. no one checking or working on the machine. To this
end, a suitable notice shall be affixed to the remote start
17. If the ground is not level or can be subject to variable equipment.
inclination, consult the manufacturer.
3. Never operate the machine when there is a possibility of
Also consult following safety precautions: Safety taking in flammable or toxic fumes, vapors or particles.
precautions during operation and Safety precautions
during maintenance. 4. Never operate the machine below or in excess of its
These precautions apply to machines processing or limit ratings.
consuming air or inert gas. Processing of any other 5. Keep all bodywork doors shut during operation. The
gas requires additional safety precautions typical to doors may be opened for short periods only, e.g., to
the application not included herein. carry out routine checks. Wear ear protectors when
Some precautions are general and cover several opening a door.
machine types and equipment; hence, some statements
may not apply to your machine. 6. People staying in environments or rooms where the
sound pressure level reaches or exceeds 90 dB(A) shall
1.3 Safety precautions during operation wear ear protectors.
7. Periodically check that:
All responsibility for any damage or injury resulting
from neglecting these precautions, or non-observance •• All guards are in place and securely fastened
of the normal caution and care required for installation, •• All hoses and/or pipes inside the machine are in good
operation, maintenance and repair, even if not expressly condition, secure and not rubbing
stated, will be disclaimed by the manufacturer. •• There are no leaks
General precautions •• All fasteners are tight
•• All electrical leads are secure and in good order
1. The operator must employ safe working practices
and observe all related work safety requirements and •• Safety valves and other pressure relief devices are
regulations. not obstructed by dirt or paint
•• Air outlet valve and air net, i.e., pipes, couplings,
2. If any of the following statements does not comply with
manifolds, valves, hoses, etc. are in good condition,
the applicable legislation, the stricter of the two shall
not worn or damaged
apply.
8. If warm cooling air from compressors is used in heating
3. Installation, operation, maintenance and repair work
systems, e.g., to warm up a workroom, take precautions

6
 against air pollution and possible contamination of Precautions during maintenance or repair
breathing air.
1. Always wear safety glasses.
9. Do not remove any of or tamper with the sound-damping
2. Use only the correct tools for maintenance and repair
material.
work.
10. Never remove or tamper with the safety devices, guards
3. Use only genuine spare parts.
or insulation fitted on the machine. Every pressure vessel
or auxiliary installed outside the machine to contain 4. All maintenance work shall only be undertaken when
air above atmospheric pressure must be protected by a the machine has cooled down.
pressure relieving device or devices as required.
5. A warning sign stating “Work in progress; do not start”
Also consult following safety precautions: Safety shall be attached to the starting equipment.
precautions during operation and Safety precautions 6. Persons switching on remotely controlled machines
during maintenance. shall take adequate precautions to ensure that there is
These precautions apply to machines processing or no one checking or working on the machine. To this
consuming air or inert gas. Processing of any other end, a suitable notice shall be affixed to the remote start
gas requires additional safety precautions typical to equipment.
the application not included herein.
Some precautions are general and cover several 7. Close the compressor air outlet valve before connecting
machine types and equipment; hence, some statements or disconnecting a pipe.
may not apply to your machine. 8. Before removing any pressurized component, effectively
isolate the machine from all sources of pressure and
1.4 Safety precautions during maintenance or depressurize the entire system.
repair
9. Never use flammable solvents or carbon tetrachloride
All responsibility for any damage or injury resulting for cleaning parts. Take safety precautions against toxic
from neglecting these precautions, or non-observance vapors of cleaning liquids.
of the normal caution and care required for installation,
10. Scrupulously observe cleanliness during maintenance
operation, maintenance and repair, even if not expressly
and repair. Keep dirt away by covering the parts and
stated, will be disclaimed by the manufacturer.
exposed openings with a clean cloth, paper or tape.
General precautions 11. Never weld or perform any operation involving heat
1. The operator must employ safe working practices and near the oil system. Oil tanks must be completely
observe all related local work safety requirements and purged, e.g., by steam cleaning, before carrying out
regulations. such operations. Never weld on, or in any way modify,
pressure vessels.
2. If any of the following statements does not comply with
the applicable legislation, the stricter of the two shall
apply.
3. Installation, operation, maintenance and repair work
must only be performed by authorized, trained and
specialized technicians.
4. The compressor is not considered capable of producing
breathable air. To obtain breathable air, the compressed
air must be adequately purified according to the local
legislation and standards.
5. Before any maintenance, repair, adjustment or any
other non-routine checks, stop the compressor, press
the emergency stop button, switch off the power and
depressurize the compressor. In addition, the isolating
switch must be opened and locked.
6. Never play with compressed air. Do not apply air to
your skin or direct an air stream at people.
Never use air to clean dirt from your clothes. When
using the air to clean equipment, do so with extreme
caution and wear eye protection.

7
12. Whenever there is an indication or any suspicion that Also consult following safety precautions: Safety
an internal part of a machine is overheated, the machine precautions during operation and Safety precautions
shall be stopped but no inspection covers shall be during maintenance.
opened before sufficient cooling time has elapsed; this These precautions apply to machines processing or
is to avoid the risk of spontaneous ignition of the oil consuming air or inert gas. Processing of any other
vapor when air is admitted. gas requires additional safety precautions typical to
13. Never use a light source with open flame for inspecting the application not included herein.
the interior of a machine, pressure vessel etc. Some precautions are general and cover several
machine types and equipment; hence, some statements
14. Make sure that no tools, loose parts or rags are left in or may not apply to your machine.
on the machine.
15. All regulating and safety devices shall be maintained
with due care to ensure that they function properly They WARNING: Cancer and Reproductive Harm – [Link].
should not be disabled.
16. Before clearing the machine for use after maintenance or
overhaul, check that operating pressures, temperatures
and time settings are correct. Check that all control
and shut-down devices are fitted and that they function
correctly. If removed, check that the coupling guard of
the compressor drive shaft has been reinstalled.
17. Every time the separator element is replaced, examine
the discharge pipe and the inside of the oil separator
vessel for carbon deposits; if excessive, the deposits
should be removed.
18. Protect the motor, air filter, electrical and regulating
components etc. to prevent moisture from entering
them, e.g., when steam cleaning.
19. Make sure that all sound-damping material and vibration
dampers, e.g., on the bodywork and in the air inlet and
outlet systems of the compressor, is in good condition.
If damaged, replace it by genuine material from the
manufacturer to prevent the sound pressure level from
increasing.
20. Never use caustic solvents that can damage materials of
the air net, e.g., polycarbonate bowls.
21. The following safety precautions are stressed when
handling lubricant:
•• Never inhale refrigerant vapors. Check that the
working area is adequately ventilated; if required,
use breathing protection.
•• Always wear special gloves. In case of refrigerant
contact with the skin, rinse the skin with water. If
liquid refrigerant contacts the skin through clothing,
never tear off or remove the latter; flush abundantly
with fresh water over the clothing until all refrigerant
is flushed away; then seek medical first aid.
22. Protect hands to prevent injury from hot machine parts,
e.g., during oil drainage.

8
2 General description
2.1 Introduction
CPF-150, CPF-175 and CPF-200 models are single-stage, oil-injected screw, gearbox driven by an electric motor with sound-
insulated bodywork.
The models with “S” abbreviations are air-cooled, and those with “SW”, water-cooled.
The compressors are available for a maximum working pressure of: 7, 8, 10 or 13 bar (e)
They essentially feature:

•• Air filter
•• Compressor element
•• Air vessel / Oil separator
•• Air cooler
•• Oil cooler
•• Drive motor
•• Gear box
•• Inlet / regulation assembly
•• ES4000 control system
•• Safety devices

9
2.2 Regulating system
Flow diagram

Flow diagram

Reference Designation
A To air cooler
B To/from oil cooler

10
Regulating system
The compressor is controlled by ES4000 controller (1).
The controller maintains the net pressure within programmable limits by automatically loading and unloading the compressor,
according to the air consumption. It also protects the compressor and monitors components subject to service.

Unloading
If the air consumption is less than the air output of the compressor, the net pressure increases. When the net pressure reaches
the work pressure upper limit (unloading pressure), solenoid valve (5) is de-energized by ES4000 controller (1). The plunger of
the valve (5) returns by spring force:

Stage Description
1 The valve (5) plunger cuts the supply of vessel pressure toward the chamber (2).
2 The control pressure present in the chamber (2) is vented to atmosphere. The unloading valve (4) plunger (3) is moved
by the pressure in the air vessel, allowing pressure to pass from the air vessel to the chamber (6).
3 The valve (7) is pushed up, the closing air inlet.
4 A small air flow continues to be drawn through the channel (8) and is expelled from the vessel through the channel
(10) to the air inlet.
5 Air flow is stopped (0%) and the compressor runs unloaded, while the chamber (6) maintains a constant overpressure
(vessel unload pressure minus Unloading Valve (4) pressure drop).

Loading
When the net pressure decreases to the work pressure lower limit (loading pressure), solenoid valve (5) is energized. The
plunger of the valve (5) advances by spring force:

Stage Description
1 The valve (5) plunger opens the supply of vessel pressure toward the chamber (2). The plunger (3) of the unloading
valve (4) moves, closing the air pressure passage to the chamber (6).
2 The valve (7) moves downwards, as the pressure in the chamber (6) drops below atmospheric pressure, opening the
air inlet to the compressor element.
3 Air flow is resumed (100%) and the compressor runs loaded, while the piston-bar-valve assembly is only surrounded
by atmospheric pressure.

2.3 Special Features

The compressor supplied herein has the following special features:
-- Special certifications: ASME/CRN and CSA/UL
-- Air/oil separator must be ASME/CRN-certified.
-- Special electric motor:
WEG W22 – IE3 Premium efficiency.
460V voltage
-- UL-certified electrical system components
-- Export packaging.

11
3 Graphic controller Air-cooled compressors will also be stopped in the event of
overload of the fan motor.
3.1 Controller Before remedying, consult the Safety precautions.

Shutdown warning
A shutdown warning level is a programmable level below the
shutdown level.
If one of the measurements exceeds the programmed shutdown
warning level, this will also be indicated to warn the operator
before the shutdown level is reached.

Service warning
If the service timer exceeds a programmed value, this will
be indicated on the display to warn the operator to carry out
some service actions.
View of the ES 4000 Advanced controller
Automatic restart after voltage failure
Introduction The controller has a built-in function to automatically restart
The electronic controller has the following functions: the compressor when the voltage is restored after voltage
failure.
•• Controlling the compressor
•• Protecting the compressor Provided the controller is in the automatic operation
•• Monitoring components subject to service mode, the compressor will automatically restart when
the supply voltage to the module is restored.
•• Automatic restart after voltage failure
Automatic control of the compressor
The controller maintains the net pressure within
programmable limits by adjusting the motor speed. A number
of programmable settings, e.g., the unloading and loading
pressures, the minimum stop time and the maximum number
of motor starts are taken into account.
The controller stops the compressor whenever possible to
reduce the power consumption and restarts it automatically
when the net pressure decreases. If the expected unloading
period is too short, the compressor is kept running to prevent
too short standstill periods.

Protecting the compressor

Shutdown
If the compressor element outlet temperature exceeds the
programmed shutdown level, the compressor will be stopped.
This will be indicated on the display of the controller. The
compressor will also be stopped in case of overload of the
drive motor.

12
3.2 Control panel
Detailed description

Function keys of the controller

Reference Designation Function

1 Function Shows icons and operating conditions.
2 Automatic operation symbol
Indicates that the controller is automatically controlling the
compressor: the compressor is loaded, unloaded, stopped
3 LED, automatic operation
and restarted depending on the air consumption and the
limitations programmed in the controller.
4 Warning symbol
5 LED, warning Is lit if a warning condition exists.
6 Voltage symbol
7 LED, voltage on Indicates that the voltage is switched on.
8 Service symbol
9 LED, service Is lit when service is needed.
This button starts the compressor. Automatic operation LED
10 Start button
(3) lights up. The Controller is operative.
This button is used to stop the compressor. Automatic
11 Stop button
operation LED (3) goes out.
12 Scroll buttons Use these buttons to scroll through the menu.
13 Enter button Use this button to confirm the last action.
Use this button to go to previous screen or to end the current
14 Escape button
action.

13
3.3 Icons used
Status icons

Function Icon Function

Compressor status When the compressor is stopped, the icon stands still.
When the compressor is running, the icon is rotating.

Motor stopped

Running unloaded

Running loaded

Machine control mode Local start/stop

Remote start/stop

LAN control

Automatic restart after Automatic restart after voltage failure is active

voltage failure

Week timer Week timer is active

Active protection Emergency stop

functions

Shutdown

Warning

Service Service required

14
Main screen view Value lines preview icon

Graphic preview icon

General icons No communication/network problem

Invalid

Input icons

Icon Description
Pressure

Temperature

Digital input

Special protection

Input icons

Icon Drain
Filter

Engine

Description

Compressor element (LP, HP etc.)

Dryer

Cooler

Frequency converter

15
 Expansion module failed

Network problem

General alarm

Menu icons

Icon Description
Inputs

Outputs

Guards (Shutdown warnings)

Counters

Test

Regulation (Settings)

Service

Event history (saved data)

Access key / User password

Network

Setpoint

Information

Week timer

General

16
Scroll arrows

Icon Description
Up

Down

3.4 Main screen

Function
The main screen is the screen automatically displayed when the voltage is switched on and one of the buttons is pressed. It is
automatically turned off after a few minutes if no button is pressed.
Generally, 5 different main screen views can be chosen:
1. Two value lines
2. Four value lines
3. Graphic (High resolution)
4. Graphic (Medium resolution)
5. Graphic (Low resolution)
Screens with two or four value lines
This type of Main screen has the value of 2 or 4 settings (see Input menu section).

Typical main display (2-value lines), fixed speed Typical main display (4-value lines), fixed speed
compressors compressors

(1) Compressor outlet

(2) Element outlet
(3) Load, ... (text varies with actual compressor status)
(4) Menu
(5) Running Hours
(6) Load relay (one of the input signals of fixed speed compressors)
Flow (compressors with frequency converter)

•• Section A shows information about compressor operation (for example, outlet pressure or compressor outlet temperature).
In compressors with a frequency converter, the degree of load (flow) is displayed as a percentage of the maximum flow.

17
• Section B shows status icons. The following types of icons When Chart (High resolution) is selected, the chart displays
are displayed in this field: the variation of the selected input (in this case, the pressure)
• Fixed icons per minute. The actual value is also displayed. The screen
These icons are always displayed on the main screen shows the last 4 minutes.
and cannot be selected with the cursor (for example, The selector button (icon) to select other screens is changed to
Stopped or running compressor, Compressor Status a small Chart and highlighted (active).
(running, unloading or stopped motor)).
• Option icons
These icons are only displayed if the respective function
is activated (for example, week timer, automatic restart
after voltage failure etc.).
• Warning icons
These icons are displayed if an abnormal condition
occurs (warnings, shutdowns, service etc.).
To access more information about the displayed icons, When Chart (Medium resolution) is selected, the chart
select the icon in question using the scroll buttons and displays the variation of the selected input per hour. The
press Enter. screen displays the last 4 hours.
• Section C is designated as the status bar
This bar displays the text corresponding to the selected
icon.
• Section D displays the action buttons. These buttons are
used to:
• Access and define settings
• Reset a motor overload, service message or emergency
stop
When Chart (Low resolution) is selected, the chart displays
• Access all data collected by the controller
the variation of the selected input per day. The screen displays
The function of the buttons depends on the menu displayed. the progress in the last 10 days.
The most common functions are:
Selecting a main screen view
Designation Function To switch between different screen layouts, select the
Menu To go to the menu rightmost icon in the control icon row (see the value line
Modify To modify programmable parameters display icon or chart display icon in the Icons used section)
Reset To reset a timer or message and press Enter. A screen similar to the following will appear:

To activate an action button, highlight the button using the

scroll buttons and press Enter. To return to the previous menu,
press Escape.
Chart views
Instead of displaying values, you can also display a chart of
one of the input signals (see Input menu section) as a function
of time.

Select the desired layout and press Enter. See also the Input
menu section.

18
3.5 Accessing menus Procedure
Description On the main screen (see Main Screen):
When the voltage is switched on, the main screen automatically • Move the cursor to the Menu button and press the Enter
displays (see Main screen section): button.
• Using the scroll buttons, move the cursor to the Inputs
icon, as shown in the following screen:

• To access the menu screen, select the Menu (4) button

using the scroll buttons.
• Press Enter to select the menu. The following screen is
• Press the Enter button. A screen similar to the following
displayed:
will appear:

• The screen displays several icons. Each icon indicates

a menu item. By default, the pressure parameter icon
(Regulation) is selected. The status bar displays the menu Figure text
name corresponding to the selected icon. (1) Inputs
• Use the scroll buttons to select an icon. (2) Compressor outlet
• Press Escape to return to the main screen. (3) Element outlet
(4) Ambient Air
3.6 Input menu
(5) Emergency stop
Menu icon, Inputs
• The screen displays a list of all inputs, with their respective
icons and readings.
• If an input is in warning or shutdown, the original icon is
replaced, respectively, by the warning or shutdown icon (in
this case, the shutdown icon and the warning icon shown
Function above).
• To display the actual value of the measured data (analog
A small chart icon, displayed below an item in the list, means
inputs) and digital input status (for example, emergency
that this input signal is displayed in the chart on the main
stop contact, motor overload relay etc.).
screen. Any analog input can be selected.
• To select the digital input to be displayed in the main
screen chart.

19
Selecting another input signal as the main chart signal
With the Modify button active (light gray background on the
screen above), press Enter on the controller. A screen similar
to the following will appear:

(1): Set as main chart signal

3.7 Outputs menu

Menu icon, Outputs
The first item in the list is highlighted. In this example, Net
pressure is selected (chart icon).
To change it, press Enter again, and a warning window will
appear:

Function
To access the information about the actual status of some
outputs, such as the status of the fan overload contact (for air-
cooled compressors), emergency stop contact etc.
Procedure
On the main screen (see Main Screen):
• Move the cursor to the Menu button and press the Enter
Press Enter again to remove this input from the chart. A button.
confirmation window will appear: • Move the cursor to the Outputs icon (see section below).

Select Yes to remove or No to exit the current action. • Press the Enter button. A screen similar to the following
Similarly, another input signal can be highlighted and selected will appear:
as the main signal of the chart:

Outputs screen (typical)

20
Figure text

(1) Outputs
(2) Fan Motor
(3) Blow-off
(4) General Shutdown
(5) Automatic Operation

• The screen displays a list of all outputs, with their respective

icons and readings.
If an output is in warning or shutdown, the original icon is Figure text
replaced, respectively, by the warning or shutdown icon. (1) Counters
(2) Running Hours
3.8 Counters
(3) No. of Motor Starts
Menu icon, Counters (4) Load Relay
(5) VSD 1-20% RPM in % (percentage of time
the motor speed was between 1 and 20%)
(compressors with frequency converter)
The screen displays a list of all counters, with their respective
Function actual readings.

To access: Note: the example above refers to a compressor driven

by frequency converter. For fixed speed compressor, the
• Running hours
displayed screen will be slightly different.
• Loading hours
• Number of motor starts
3.9 Selecting the control mode
• Number of hours the controller was on
• Number of load cycles Function
Procedure To select the control mode: for example, if the compressor is
in local control, remote control or controlled via a Local Area
On the main screen (see Main Screen):
Network (LAN).
• Move the cursor to the Menu button and press the Enter
button. Procedure
• Using the scroll buttons, move the cursor to the Counters On the main screen, ensure the Menu button (1) is selected:
icon (see section below).

Then use the scroll buttons to access the Status icons (see
• Press the Enter button. A screen similar to the following Main screen) and select the Regulation icon (2). When the
will appear: icon is active, it is highlighted with a gray background.

21
Press Enter: • Using the scroll buttons, move the cursor to the Service
icon (see section below).

Three options are available:

• Local control • Press the Enter button. The following screen is displayed:
• Remote control
• LAN control

Figure text
After selecting the intended control mode, press Enter on the (1) Service
controller to confirm the selection. The new setting is now (2) Overview
displayed on the main screen. See the Icons used section for
(3) Service Plan
the meaning of the icons.
(4) Next Service
3.10 Service menu (5) History

Menu icon, Service • Scroll down to select the desired item and press Enter to
see the details, as explained below.

Overview

Function
• To reset the service plans that are performed.
• To check when the next service plans should be performed.
• To know what service plans were performed before.
• To modify the scheduled service intervals.
Figure text
Procedure
On the main screen (see Main Screen): (1) Overview
• Move the cursor to the Menu button and press the Enter (2) Running Hours
button. (3) Real Time Hours
(4) Reset

22
Example of service level (A): Modifying a service plan
The numbers shown on the left are the scheduled service Depending on operation conditions, service intervals may
intervals. For service interval A, the scheduled number of need to be modified. To do so, use the scroll buttons to select
running hours is 4000 hours (top row, green) and the scheduled the value to modify. A screen similar to the following will
number of real time hours is 8760 hours, which corresponds appear:
to a year (second row, blue). This means the controller will
issue a service warning when it reaches 4000 running hours or
8760 real time hours, whichever occurs first. Consider that the
real-time hour counter is not interrupted when the controller
is off.
The numbers next to the bars are the number of hours left
for the next service intervention. In the example above, the
compressor has just started, which means that there are still
4000 running hours or 8299 hours left for the next service
intervention.

Service plans Press the Enter button. The following screen is displayed:
Several service operations are grouped (called Level A, Level
B etc.). Each level represents a number of service actions to
be performed at the intervals defined in the controller.
When a service plan interval is reached, a message appears
on the screen.
After performing the service actions at the corresponding
levels indicated, the timers must be reset.
On the Service menu above, select Service Plan (3) and press
Enter. The following screen is displayed:

Modify the value as needed using the scroll buttons  or  and

press Enter to confirm.
Note: The running hours can be modified in 100-hour steps,
real time hours can be modified in 1-hour steps.

Figure text

(1) Service Plan

(2) Level
(3) Running Hours
(4) Real Time Figure text
(5) Modify
(1) Next Service
(2) Level
(3) Running Hours
(4) Actual
In the example above, service level A is set to 4000 running
hours, of which 0 hour has elapsed.

23
History Figure text
The History screen lists all past service actions, sorted by (1) Regulation
date. The date at the top is the date of the most recent service
(2) Unloading pressure 1
action. To see the details of a completed service action (for
example, service level, running hours or real time hours), use (3) Loading pressure 1
the scroll buttons to select the desired action and press Enter. (4) Unloading pressure 2
(5) Loading pressure 2
3.11 Regulation menu (6) Modify
Menu icon, Setpoint
• The screen displays the actual unloading and loading
pressure parameters for both pressure ranges. To change
parameters, move the cursor to the Modify button and
press Enter. The following screen is displayed:

Function
On fixed speed compressors, the operator can set two different
pressure ranges. This menu is also used to select the active
pressure range.

Procedure
On the main screen (see Main Screen):
• Move the cursor to the Menu button and press the Enter
button. • The first row of the screen is highlighted. Use the scroll
buttons to select the parameter to be changed and press
• Using the scroll buttons, move the cursor to the Setpoint
Enter. The following screen is displayed:
icon (see section below).

• Press the Enter button. The following screen is displayed:

• The upper and lower limits of the parameter are displayed
in gray; the actual value is displayed in black. Use the
scroll buttons  or  to change the parameters as needed
and press Enter to accept.
Change the other parameters if required, as described above.

3.12 Event history menu

Menu icon, Event History

24
Function • To set timed switching commands for the net pressure
range.
To access data from last shutdown and last emergency stop.
• Four different week schemes can be set.
Procedure • A cycle of weeks can be set; one week cycle is a 10-week
On the main screen (see Main Screen): sequence. For each week of the cycle, one of the four set
• Move the cursor to the Menu button and press the Enter week schemes can be selected.
button. Procedure
• Using the scroll buttons, move the cursor to the Event
On the main screen (see Main Screen):
History icon (see section below).
• Move the cursor to the Menu button and press the Enter
button.
• Use the scroll buttons to select the timer icon (see section
below).

• Press the Enter button.

The last shutdown and emergency stop cases are listed.

• Press Enter. The following screen is displayed:

Example of Event History screen

• Scroll down the items to select the desired shutdown or
emergency stop event.
• Press Enter to access the date, time and other information
that reflected the status of the compressor when this
Figure text
shutdown or emergency stop occurred.
(1) Week Timer
3.13 Week timer menu (2) Week Action Schemes
Menu icon, Week Timer (3) Week Cycle
(4) Status
(5) Week Timer Inactive
(6) Remaining Running Time
The first item in this list is highlighted. Select the desired item
and press Enter on the controller to modify.
Function
• To set timed start/stop commands for the compressor. Setting week schemes
• Select Week Action Schemes and press Enter. A new
window will appear. The first item in the list is highlighted
in red. Press Enter on the controller to modify Week Action
Scheme 1

25
 • A new warning window will appear. Select an action from
this list with the scroll buttons on the controller. Then press
Enter to confirm.

(1) Week Action Schemes

(2) Week Action Scheme 1
(3) Week Action Scheme 2
(1) Monday
(4) Week Action Scheme 3
(2) Actions
(5) Week Action Scheme 4
(3) Remove
(4) Start-up
(5) Stop
(6) Pressure Setpoint 1
(7) Modify

• A new window will appear. The action is now displayed in

the first day of the week.

(1) Week Action Scheme 1

(2) Monday
(3) Tuesday
(4) Wednesday
(5) Thursday
(6) Friday
(7) Saturday
(8) Sunday (1) Monday
(2) Start-up
• A new window will appear. The Modify button is selected.
Press Enter on the controller to create an action. (3) Save
(4) Modify

• To set the time, use the scroll buttons on the controller and
press Enter to confirm.

(1) Monday
(2) Modify

26
 (1) Monday
(2) Start-up
(3) Save
(4) Modify

• A warning window will appear. Use the

scroll button  or  to change the hour value.
Use the scroll button  or  to change the minutes.

(1) Monday
(3) Are you sure?
(4) No
(5) Yes
(6) Save
(7) Modify

• Press Escape to exit this window. The action is displayed

(1) Monday under the day for which it is planned.
(2) Start-up
(3) Save
(4) Modify

• Press Escape on the controller. The Modify button is

selected. Use the scroll buttons to select Save.

(1) Week Action Scheme 1

(2) Monday - Start
(3) Tuesday
(4) Wednesday
(5) Thursday

(1) Monday (6) Friday

(2) Start-up (7) Saturday

(3) Save (8) Sunday

(4) Modify
• Press Escape on the controller to exit this screen.
• A new warning window will appear. Use the scroll buttons
Setting the week cycle
on the controller to select the right actions. Press Enter to
confirm. One week cycle is a 10-week sequence. For each week of the
cycle, one of the four set week schemes can be selected.
• Select Week Cycle from the list in the Week Timer main
menu.

27
 (1) Week Cycle
(2) Week 1
(3) Week Action Scheme 1
(4) Week Action Scheme 2
(5) Week Action Scheme 3
(6) Modify

• Checking the Week Timer status.

Use the Escape button on the controller to return to the
Week Timer main menu. Select Week Timer status.
(1) Week Timer
(2) Week Action Schemes
(3) Week Cycle
(4) Status
(5) Week Timer Inactive
(6) Remaining Running Time

• A list of 10 weeks is displayed.

(1) Week Timer

(2) Week Action Schemes
(3) Week Cycle
(4) Status
(5) Week Timer Inactive
(6) Remaining Running Time

• A new window will appear. Select Week 1 to define the

(1) Week Cycle Week Timer as active.
(2) Week 1
(3) Week 2
(4) Week 3
(5) Week 4
(6) Modify

• Double press Enter on the controller to modify the first

week.
• A new window will appear. Select the action, for example:
Week Action Scheme 1
(1) Week Timer
(2) Week
(3) Week Timer Inactive
(4) Week 1

• Press Escape on the controller to exit this window. The

status indicates that Week 1 is active.

28
 (1) Week Timer
(2) Week Action Schemes
(3) Remaining Running Time

3.14 Test Menu

Test Menu

(1) Week Timer

(2) Week Action Schemes
(3) Week Cycle Function
(4) Status • To perform a display test, i.e. to check that display and
(5) Remaining Running Time LEDs are still intact.

Procedure
• Press Escape on the controller to return to the Week Timer
main menu. Select Remaining Running Time from the list On the main screen (see Main Screen):
and press Enter on the controller to modify. • Move the cursor to the Menu button and press the Enter
button.
• Using the navigation buttons, move the cursor to the Test
icon (see section below).

(1) Week Timer

(2) Week Action Schemes • Press the Enter button; The following screen appears:
(3) Week Cycle
(4) Status
(5) Remaining Running Time

• This timer is used when the week timer is set and, for
certain reasons, the compressor must continue to operate
for 1 hour, for example. This option can be set in this
screen. This timer is prior to the action of the Week Timer.

Figure text

(1) Test
(2) Safety Valve Test .
(3) Not allowed
(4) Audit Date

29
• The safety valve may only be tested by authorized 3.16 General Menu
personnel and must be protected by a safety code.
Menu icon, General
• Select the display test item and press the Enter button. A
screen appears to inspect the display; At the same time, all
LEDs are lit.

3.15 Modification of general parameters

Menu Icon, Parameters
Function
This menu covers a list of general parameters:
• Language
• Time
• Date
Function • Date Format
• Units
Present and change many general parameters.
Procedure
Procedure
On the sub-menu screen (see Modification of general
On the main screen (see Main Screen):
parameters),
• Move the cursor to the Menu button and press the Enter
• Using the navigation buttons, move the cursor to the
button.
General icon (see section below).
• Using the navigation buttons, move the cursor to the
Parameter icon (see section below).

• Press the Enter button. A screen similar to the following

will appear:
• Press the Enter button. A second menu screen will appear:

Figure text
• This sub-menu screen shows many icons again. The User
Password icon is selected by default. In addition, the (1) General
status bar displays the menu name that corresponds to the (2) Language in Use
selected icon.
(3) Time
(4) Date
(5) Date Format
(6) Modify

30
• A screen similar to the one above appears with a selection • Select the Activate button and press the Enter button.
bar over the first item (Language). Use the navigation • Then complete the User Password and press the Enter
button  to select the parameter to be changed and press button; A confirmation window will appear.
the Enter button.
• Type the password again and press the Enter button to
• To change, select Modify by using the navigation buttons confirm.
and press the Enter button.
• A warning appears on the screen. Use the  or  button to
select the desired parameter and press the Enter button to
confirm.

Figure text

(1) User Password

(2) Inactive
(3) Activate
3.17 User Password Menu
Manu icon, Password
3.18 Access key Menu
Menu icon, Access Key

Function
The end customer may activate and select a personal password
Once the password option is enabled, it is impossible for Function
unauthorized persons to change parameters.
The Menu screen only presents some basic icons. Access Key
Procedure with the proper access code allows the user to view more
icons or access more parameters.
On the sub-menu screen (see Modification of general
parameters), Procedure
• Using the navigation buttons, move the cursor to the User On the sub-menu screen (see Modification of general
Password icon (see section above). parameters),
• Using the navigation buttons, move the cursor to the
Access Key icon (see section above).

• Press the Enter button. The following screen is displayed.

• There are three access levels.

• 0: You can view a basic set of parameters without requiring
a password.

31
• 1: You can change a basic set of parameters.
• 2: You can view and modify additional parameters.
• The Access Level can be changed through the Modify button. A warning window will be prompted to enter an Access Key.

3.19 Programmable Parameters

Parameters: relief / load pressures

Minimum Factory default Maximum

parameter setting parameter
see Compressor see Compressor see Compressor
Discharge / load pressures
data data data

Parameters: Variable Speed Activation

Minimum Factory default Maximum

parameter setting parameter
Radial engine running time sec ND ND ND
Load Delay Time (Star/Delta) sec ND ND ND
Number of motor starts starts/day ND ND ND
Minimum shutdown time sec 10 10 30
Scheduled Shutdown Time sec 0 3 20
Power Recovery Time (ARAVF) sec 30 30 3600
Restart Delay sec 0 0 1200
Communication Timeout sec 10 30 60

Protections

Minimum Factory default Maximum

parameter setting parameter
Compressor output temperature (operating ˚C 50 113 119
cutoff warning level) ˚F 122 235 246
Compressor output temperature (operating ˚C 111 120 120
cutoff level) ˚F 232 248 248

32
Assistance Plan
The built-in service timer gives a service warning message after a prescheduled time period has elapsed.
See also the Maintenance program section.
Contact your supplier if a timer parameter needs to be modified. See Access/Modification section of the service timer parameters.
Ranges cannot exceed nominal ranges and must logically match.

Terminology

Term Explanation
ARAVF Auto Restart After Voltage Failure. Refer to Controller section.
Power recovery This is the period within which the current has to be restored for automatic restart. It is accessible if
time automatic restart is enabled. To activate the automatic restart function, contact your supplier.
Restart Delay This parameter allows programming so that compressors are not all restarted at the same time after
a power failure (active ARAVF).
Compressor output The regulator does not accept inconsistent parameters, e.g. If the warning level is set to 95 ˚C
temperature (203 ˚F), the lower limit for the operating cutoff level changes to 96 ˚C (204 ˚F). The recommended
difference between the warning level and the operating cutoff level is 10 ˚C (18 ˚F).
Delay in operating This is the period during which the signal must exist before the compressor is turned off. If you need
cutoff signal to set this parameter to another value, contact your supplier.
Minimum shutdown After automatically stopping, the compressor remains idle for the minimum downtime, regardless of
time the air line pressure. Contact your supplier if a parameter shorter than 20 seconds is required.
Relief / load The regulator does not accept illogical parameters; e.g. if discharge pressure is set to 7.0 bar(e) (101
pressure psi (g)), the upper limit for the load pressure changes to 6.9 bar(e) (100 psi (g)). The recommended
minimum pressure difference between load and discharge is 0.6 bar (9 psi (g)).

33
3.20 Start-up 3.21 During operation
Procedure Notes
For the position of the air outlet valve and drain The operator should employ all relevant safety
connections, see the Introduction section. precautions. See also the Troubleshooting section.

Removing the front panel (service panel) during

operation will automatically shut down the unit after a
certain period of time, depending on the compressor
version.
Keep doors closed during operation; they can be
opened for short periods of time to perform checks.

When the engines are stopped and the LED (3)

(automatic operation) is lit, the engines can be started
automatically.

Regulator

ES 4000 Advanced Control Panel

Step Action
- Turn on the power. Check if the voltage LED
(7) lights up.
- Open the air outlet valve.
- Press the starter button (10) on the control
panel. The compressor starts and the
automatic operation LED (3) lights up.
After the radial engine operation time end
(Y-time, see Parameters in the Modifiable
Parameters section), the drive motor
ES 4000 Advanced Control Panel
will change from star to delta and the
compressor will start running under load.

34
Checking the oil level 3.23 Stop
Regulator

Oil level sight glass position

ES 4000 Advanced Control Panel
Check the oil level regularly. During operation, the oil level
must be between the lower section and center of the sight glass Step Action
(Gl). If the level is too low, stop the compressor, wait until it
has stopped, depressurize the oil system by unscrewing the oil - Press the stop button (11). The automatic
operation LED (3) turns off and the
filler plug (FC) one turn and wait a few minutes. Remove the
compressor stops after 30 seconds of relief
plug and fill in with oil until the sight glass is full. Install and operation.
tighten the plug (FC).
- To stop the compressor in an emergency,
3.22 Automatic restart press the emergency stop button.
The alarm LED (5) flashes.
Description • Solve the cause of the problem and unlock
The electronic controller has a built-in function to the button by pulling it out.
automatically restart the compressor when power is restored • Go to the Stop icon on the display using
after a voltage drop. the navigation buttons (12) and press the
Select button. Press the reset button. Do
Each time the compressor is turned off, the emergency not use the emergency stop button for
stop button must be pressed or the power disconnect normal stop!
switch opened. - Close the air outlet valve (AV).
- Press the test button on the top of the
electronic water drain(s) until the air system
between the air system tank and the outlet
valve is completely depressurized. See
Automatic drain section.
Turn off the power.
- If available, open the compressor
condensate drain valve (Dm) to completely
drain the watertrap.

35
3.24 Removal from service
Procedure

Step Action
- Stop the compressor and close the air outlet
valve.
- Turn off the power and disconnect the
compressor from the power supply.
- If available, open the condensate drain
valve(s) (Dm).
- Close and depressurize the air network
section connected to the outlet valve.
Disconnect the air outlet pipe of the
compressor from the air network.
- Drain the oil.
- Drain the condensate circuit and disconnect
the condensate piping from the condensate
network.

36
4 Installation
4.1 Dimensional drawing
Compressor dimensions

CPVS150
CPF150

Dimensional CPF-150

37
 CPF200

Dimensional CPF-175 and CPF-200

38
4.2 Installation suggestions
Example of compressor room

Example of a compressor room for air refrigerated CPF compressors

39
Stage Description For British/American units:
1 Install the compressor on a horizontal position that In air-cooled compressors: Qv = 2618.5 N/dT
properly supports the weight of the compressor. In water cooled compressors: Qv = 284.5 N/
For ventilation alternative 1 (indicated as Alt. 1), dT Qv = Required ventilation capacity, in cfm
the minimum distance between the top part of the N = Compressor input power, in hp (for Pack
frame and the ceiling is 1200 mm (47.2 in.). compressors) N = Compressor input power, in
2 Remove the plastic plug (if supplied) from the hp + heat dissipated by the dryer, in hp (for Full-
compressor air outlet pipe and place the air outlet Feature compressors)
valve (to be supplied by the customer) on the pipe. dT = Compressor room temperature rise If the
Close the valve and connect it to the network. cooling air ducts are installed, the maximum
3 The pressure drop over the air outlet pipe can be allowable pressure drop over the ducts is 30
calculated as follows: Pa (0.12 in. of water column). The maximum
For SI units: pressure drop depends on the room temperature.
dp = (Lx450xQc1.85)/(d5 xp) dp = Pressure drop The fan capacity must correspond to the
(maximum recommended = 0.1 bar) p = Absolute compressor fan capacity at a load height equal to
pressure at compressor outlet, in bar(a) Qc = the pressure drop caused by the cooling air outlet
Compressor free air throughput, in l/s ducts. Consult Chicago Pneumatic.
For British/American units: 5 Remove the plastic plugs (if supplied) from
dp = (L x Qc1 85)/(1470 x d5 x p) dp = Pressure the condensate outlets and install the manual
drop (maximum recommended = 1.45 psi)
condensate drain valve. Place the drain piping
p = Absolute pressure at compressor outlet, in psig
towards the condensate collector. Drain pipes
Qc = Compressor free air throughput, in cfm It is
should not immerse in the water from the drain
recommended that the compressor air outlet pipe be
connected to the top part of the main air network colector. It is recommended to provide a hopper
pipe to minimize transfer of possible condensate to allow visual inspection of the condensate flow.
waste. As a basic method, the following formula 6 Location of the ES4000 regulator.
can be used to calculate the recommended air 7 See Dimension of electric cables for the
network volume: recommended size of power cables. Check if
V = (30 x C xpx Q) / Dp C = Correction factor
the electrical connections comply with local
Dp = Pressure difference between discharge and
legislation. The installation must be earthed and
load pressures, in bar (minimum recommended =
0.6) p = Absolute pressure at compressor inlet, in
protected against short circuits by fuses in all
bar Q = Compressor free air throughput in l/s V = phases. A disconnect switch must be installed
Recommended air network volume in l near the compressor.
Correction Factors Customer may install a water shutoff valve and
Air consumption divided by Correction a water drain valve on the compressor water
compressed air production factor C inlet and outlet pipe. If water shutoff valves are
0.9 0.10 installed, a safety device shall be installed at the
0.8 0.15
0.7 0.20 pressure set according to the maximum cooling
0.5 0.25 water inlet pressure between the compressor
0.3 0.20 water outlet pipe and the shutoff valve. When
0.2 0.15
0.1 0.10 operating the unit, the operator must make sure
that the cooling water system cannot be blocked.
4 The inlet grates and the fan must be installed to
The above also applies to the energy recovery
prevent any recirculation of the cooling air to the
cooling system. Remove the plastic plugs (if
compressor. The maximum air speed through the
grates is 5 m/s (16.5 ft/s). The ventilation required
supplied) from the compressor water pipes and
to limit the compressor room temperature can be connect the pipes to the cooling water circuit.
calculated as follows:
For water-cooled compressors, the cooling water system
For SI units: In air-cooled compressors: Qv = 0.92 installed outside the compressor has to be protected by a
N/dT In water cooled compressors: Qv = 0.1 N/ safety device with set pressure according to the maximum
dT Qv = Required ventilation capacity, in m3/s cooling water inlet pressure.
N = Compressor input power, in kW (for Pack
compressors) N = Compressor input power, in kW
+ heat dissipated by the dryer, in kW (for Full-
Feature compressors) dT = Compressor room
temperature rise

40
4.3 Electric Diagrams
See electrical diagram 1093 1387 35 that is included in the machine CD.

4.4 Cable size, fuses and circuit breaker settings

Attention
Sizing performed in accordance with NBR 5410 for the following conditions:
Local regulations will apply if more stringent than the values proposed below;
Insulated conduits or unipolar cables in conduit over the wall;
The voltage drop may not exceed 4% of the rated voltage. It may be necessary to use cables longer than those indicated to
meet this requirement;
Maximum cable length = 30 m;
Maximum ambient temperature = 40°C;
For other conditions, sections should be resized

Recommended cables, fuses and adjustments for CPF (YD) compressors

Length Power Adjustment Adjustment Adjustment Rec. fuse Rec. Cables

F21 Q15 Q16 . .
CPF-150 380V-60Hz 139A 9A Not applicable 3x (2x250A) 2x (3x95 + 50mm2)
CPF-150 440V-60Hz 120A 7.8A Not applicable 3x (2x250A) 2x (3x70 + 35mm2)
CPF-175 380V-60Hz 162A 9A 9A 3x (2x315A) 2x (3x120 + 70mm2)
CPF-175 440V-60Hz 140A 7.8A 7.8A 3x(2x250A) 2x (3x95 + 50mm2)
CPF-200 380V-60Hz 188A 9A 9A 3x (2x315A) 2x (3x150 + 95mm2)
CPF-200 440V-60Hz 163A 7.8A 7.8A 3x(2x315A) 2x (3x120 + 70mm2)
CPF-200 460V-60Hz 163A 7.8A 7.8A 3x(2x315A) 2x (3x120 + 70mm2)

41
4.5 Pictographs

Ref. Designation
13 Automatic condensate drain 21 Tightening torques for steel (Fe) or brass (CuZn) screws
14 Automatic condensate drain for oil/water separator 22 See Instruction Manual before performing lubrication.
(OSD type)
15 Manual condensate drain 23 Turn off the power before removing the protective cover
inside the electrical compartment
16 Stop the compressor prior to perform any maintenance 24 Lubricate joints, screw the filters and tighten by hand
or repair operations. (approx. half turn)
17 Warning: energized 25 See Instruction Manual prior to perform any maintenance
or repair
18 Read the Instruction Manual before starting the 26 Cooling water inlet
compressor
19 Turn off power and depressurize the compressor prior 27 Cooling water outlet
to perform any maintenance or repair
20 Before wiring the compressor, refer to the Instruction 28 Oil outlet
Manual to check the direction of engine rotation.

42
5 Operating instructions 3 If the compressor has not been used in the last
6 months, it is recommended to increase the
5.1 Initial start lubrication of the compressor element before
starting. Fill the compressor element as described
The operator should employ all relevant safety in the Oil Change section (paragraph Filling the
precautions. compressor element with oil).
Turn off the power before performing any repairs. 4 Check if the compressor is filled with oil: the oil
level gauge pointer should be in the green section
(see Oil Change section).
Transport/lifting
The compressor can be moved with a forklift using the grooves Protection during transport
in the frame. Make sure the forks appear on the other side
of the frame. The compressor can also be lifted by inserting
beams into the grooves. Make sure the beams do not slide
and are at equal distance from the frame. Chains must be kept
parallel to the frame by means of chain expanders, in order
not to damage the compressor. The lifting equipment must
be positioned so the compressor is lifted in perpendicular
position. Lift slowly and avoid twisting.

General preparations for CPF compressors

Transport fittings for CPF compressors

Step Action
1 Gear compartment brackets, engine support
and air tank brackets are fixed to the frame,
immobilizing the vibration dampers during
transport.
2 Remove bolts (1) from gear compartment brackets
and engine support.
3 Remove the brackets installed near the air tank
brackets.
Plug to fill the compressor element at initial start
Electrical compartment
Step Action
1 Install the compressor; see sections Dimensional Step Action
drawing, Installation suggestion and Size of 1 Check if the electrical connections comply with
electrical cables. local legislation. The installation must be earthed
2 Attach labels near the control panel to warn the and protected by fuses in all phases. A disconnect
operator that: switch must be installed.
• the compressor may start automatically after a 2 Check proper connection of transformers.
power failure
• the compressor starts and stops automatically
• the compressor can be remotely controlled

43
Start-up 5.3 Start-up
Step Action Warning
1 Close the drain valves (see section Cooling and The operator should employ all relevant safety
condensate system). precautions.
2 Turn on the power.
3 Start the compressor and stop it immediately. Step Action
Check the direction of rotation of the drive motor
1 Press the start button (10). The compressor runs in
when the engine is almost stopped. To determine
the relief condition.
the direction of engine rotation, see the fan
through the grating at the opposite end of the The automatic operation LED (3) lights up.
motor drive. The correct direction of rotation is 2 Approx. after 10 seconds (programmable), the
indicated by an arrow on the gear compartment compressor starts running under load. The display
and fan cover. On air-cooled compressors, check message (1) changes from “Automatic Unloading”
the direction of rotation of the fan motor - the to “Automatic Loading”.
fan is visible through the grating on the air intake
panel (see section Dimensional drawing). The
correct direction of rotation is indicated by arrows
on the inside plate of the fan.
4 If the direction of rotation is incorrect, push
the emergency stop button, turn off the power
and reverse two of the input power lines. If the
direction of rotation of the fan motor is wrong,
consult your Chicago Pneumatic Customer Center.
5 Run the compressor for a few minutes and check
if it operates normally.

5.2 Before starting

Control panel

Ref. Name
A Air inlet temperature, in °C
B Condensation temperature in °C
C Effective working pressure in bar
D Relative air humidity, in %

Step Action
1 Turn on the power. The voltage LED (7) lights up.
2 Close the condensate drain valves (see section
Cooling and condensate system).
3 Open the air outlet valve.
4 Check the oil level gauge (see section Oil
Change). The pointer must be in the green section,
or in the orange section.

44
5.4 During operation 5.5 Display check
Warning Warning

The operator should employ all relevant safety Before carrying out any maintenance, repair or
precautions. adjustment, stop the compressor, press the emergency
stop button and switch off the voltage. Close the air
In case of oil leaks inside or outside the machine,
outlet valve and open manual condensate drain valve.
the operator must stop the machine immediately and
consult a qualified technician to solve the problem.
The machine should not be reused until the problem Step Action
is solved. 1 Check display readings and messages regularly.
Normally, the main display is shown, indicating
Control panel
the compressor outlet pressure, compressor status,
and functions of keys below the display.
2 Always check the display and solve the problem if
the alarm LED (5) is lit or flashing.
3 The display shows a service message if the
range of a service plan has been exceeded, or if a
service level of a monitored component has been
exceeded. Carry out the service actions of the
indicated service plans, or replace the component
and reset the corresponding timer.
4 Regularly check the current status of the
compressor by pressing the down arrow key on
the main screen.

Main menu example

“Status Data” →
Step Action
“Measured Data” ↓
1. When the automatic operation LED (3) is lit, the “Counters”
engine start and stop are controlled automatically. “Prin Screen”
2. Check readings on display (1). F1 F2 F3
3. To relieve the compressor manually, press the Main display example
“Empty” key. To put the compressor back into
automatic operation, press the “Load” key. Main display of CPF compressors
“Compressor Outlet” 7.5 bar
If the compressor is stopped, it can start “Automatic Load” ↓
automatically. “Menu” “Empty”
F1 F2 F3

45
5.6 Manual load/relief 5.7 Stop
Control panel Notice

After pressing the stop button (11), the compressor

operates in relief for 30 seconds. The compressor stops
after this time. During this time, a start command is
ignored.
After stopping, the compressor is prevented from
starting within a programmable time (20 seconds). A
start command executed during this minimum stop
time will be memorized; the automatic operation LED
lights up. The compressor starts once the minimum
stop time has elapsed.

Step Action
1 Press the scheduled stop button (11). The LED
(3) goes out. The message “Scheduled Stop” is
Main display example displayed. The compressor runs in relief for 30
seconds and then stops.
Main display of CPF compressors
2 To stop the compressor in an emergency, press
“Compressor Outlet” 7.5bar(109psi) the button (S2). The alarm LED (5) flashes. After
. troubleshooting, unlock the button by pulling it
“Automatic Load” ↓ out.
“Menu” “Empty” 3 Close the air outlet valve.
F1 F2 F3
4 Open the condensate drain valves. For
Automatic operation compressors equipped with electronic water
drains, press the test buttons on the top section of
Normally the compressor runs automatically, i.e., the
the electronic drains until the air system between
electronic regulator controls the automatic loading, relief,
the air tank and the air outlet valve is fully
stop and restart of the compressor. Then, the LED (3) lights
depressurized.
up.
5 Turn off the power.
Manual relief 6 In water cooled compressors, close the water
Press the “Empty” key (F3); LED (3) goes out. The message shutoff valves.
“Manual Empty” appears on the display. The compressor
continues to operate in relief unless manually reloaded.

Manual load
Press the “Load” key (F3); LED (3) lights up. The “Load”
command does not force the compressor to load, but returns
the compressor to automatic operation; The compressor will
execute loading if the air network pressure drops below the
set level.

46
5.8 Removal from service 6 Use only the oil specified by the manufacturer.
Turning off the compressor 7 Make sure to completely depressurize the tank
before opening the drain plug or filler plug.
At the end of the compressor operation cycle, proceed as
8 This tank and other pressurized parts are designed
follows: and built to ensure an operational life cycle of
over 20 years and an infinite number of pressure
Step Action loading cycles. A visual inspection (for damage,
1 Stop the compressor and close the air outlet valve. unauthorized changes etc.) of the tank (outside
and inside) is recommended every 5 years.
2 Turn off the power and disconnect the compressor
Make sure the tank is completely depressurized
from the power supply. and insulated before performing an internal
3 Depressurize the compressor by opening the drain inspection.
valve and unscrewing the oil filler plug one turn. 9 At each inspection also check the oil drain hose.
For compressors equipped with electronic water Replace it if there are signs of wear or damage.
drains, press the test buttons on the top section of
the electronic drains until the air system between 5.10 Storage conditions
the air tank and the air outlet valve is fully
depressurized. 5.10.1 Introduction
4 Close and depressurize the air network section The non-painted surface of all out-of-service compressors,
connected to the outlet valve. Disconnect the whether installed or waiting installation, is subject to oxidation
air outlet pipe of the compressor from the air and corrosion.
network. The corrosion level ranges according to the environment
5 Drain the oil and condensate circuits. In water conditions (temperature, humidity etc.) and the care taken for
cooled compressors, drain the water circuits. storing and conserving the unit.
6 Disconnect the compressor condensate piping Therefore, it is impossible to establish the period in which the
from the condensate drain network. unit can be stored without rust damage.
7 In water cooled compressors, disconnect the The higher the humidity and the longer the stopping and/
compressor cooling water pipes. or storage period, the more care must be taken. For CPF
compressors, in addition to the precautions for the compressor,
5.9 Use of air tank specific preventive measures should be taken for the electric
motor, according to the manufacturer’s instructions.
Instructions
Compressors are usually not expected to remain out of service
Step Action or stored for long periods, which is why they leave the factory
1 This equipment may contain pressurized air and ready to be stored for a maximum period of 75 days from the
oil; be aware of this potential hazard in case of date of manufacture; after this period the procedure in item
misuse. 5.10.2 should be followed.
2 It must only be used as a compressed air/oil Should the compressor be out of service for more than one
separator and should be operated within specified week, proceed as described in item 5.10.3.
limits.
5.10.2 Storage and conservation prior to
3 Changes to this equipment must not be made by installation
means of hard welding, drilling, grinding or other
mechanical working methods without written 1. Store the compressor in a clean, dry, well-ventilated
permission of the manufacturer. If a pressurized environment, free of dust and humidity.
part is damaged, regardless of the cause, the 2. The entire lower section of the compressor should stand
whole part must be replaced. on a flat, vibration-free floor.
4 For the oil separator tank: the original screws
3. Make sure there is no water in the crate, plastic cover or
must be used after opening it for inspection. The
any part of the unit’s bodywork or base.
screws must be removed and replaced with the
correct tool. The screws must be tightened using a
torque of 355 Nm (+/- 85 Nm). Damaged screws
should not be reused. O-rings must be replaced.
5 The safety valve is designed so that the pressure
does not permanently exceed the maximum
allowable operating pressure of the tank except
for short pressure fluctuations up to 1.1 times the
design pressure.

47
5.10.3 Conservation after installation 6 Maintenance
1. Run the unit at least twice a week, for a minimum of 30
minutes and operate the load/relief system a few times. 6.1 Preventive maintenance program
2. Stop the unit, close the outlet valve and open the Warning
condensate drains (after the air cooler and condensate
separator manual). Ensure none of the drains is clogged. Before any maintenance, repair or adjustment
operation, follow the procedure below:
3. Close the drains after 02 minutes. • Stop the compressor.
4. Rotate the coupling 10 turns once a month, to change • Press the emergency stop button (S2).
the position of the compressor element bearings balls • Close the air outlet valve and open manual
and rollers. In case there is no access to the motor shaft, condensate drain valves.
remove the rear motor cover for access through the • For compressors equipped with electronic water
motor fan. drains, press the test buttons on the top section of
the electronic drains until the air system between
5. Should the compressor be stored for more than 6 the air tank and the air outlet valve is fully
months, the oil, oil filter and separator element should depressurized.
be replaced. For the motor, check engine manufacturer’s • Turn off the power.
instructions on material delivered (on CD) with • Open and block the disconnecting switch.
the compressor. Pay attention to the engine resistor The operator should employ all relevant safety
connection, if any, to avoid humidity inside the engine. precautions.
NOTE:
This instruction does not provide for cases of aggressive Warranty – Product Liability
environment, which should be analyzed individually. Use only authorized parts. No damages or defects caused by
5.10.4 Movement and transport the use of non-authorized parts are covered by the Product
Liability Warranty.
If the unit is to be moved or transported, the original fittings
and guards must be reinstalled to immobilize the vibration General
dampers and the motor and compressor assembly. During assistance operations, replace all joints, O-rings and
The compressor can be handled with a forklift using the washers.
openings in the frame. The forklift must have capacity
suitable for the sizes and weight of the compressor. The
compressor may also be lifted by inserting beams into the
openings. Make sure that the beams are properly fixed and
equally spaced on both sides of the frame. Ropes/chains must
be kept parallel to the bodywork by means of an expander,
not touching it in order not to damage the compressor. Lifting
equipment should be placed so that the compressor is raised
perpendicular, slightly and without twisting.

48
 List of Tasks for CPF150-200 (CPVS) compressors

10
3 4

13
11
9

17
2 15
14
8
10
1 7 6 16

12

MAINTENANCE TASKS
POINTS PERIOD ACTIVITIES
I A B C D
1 Check work pressure setting X X X X X
8 Check the oil level and top it up, if needed. X X X X X
Daily
16 Check operation of condensate drains X X X X X
1 Check temperatures and pressures X X X X X
2, 11 Check operation of the admission valve X X X X
Internally and externally clean the unit X X X X
2000 hours or Externally clean oil and air coolers X X X X
6 months Check all adjustments set in the CP-Tronic module X X X X
Replace air and oil filter X X X X
8 Replace the lubricating oil (1) X X X X
9 Replace the lubricating oil (2) X X X
Motors Lubricate bearings of electric motor(s) (3) X X X
Replace the air/oil separator filter X X
10 Review minimum pressure valve X X
3 Review intake valve X X
7 6000 hours or Review oil check valve X X
6 2 years Review air check valve X X
10 Review transition valve X X
15 Review condensate separator X X
10 Replace thermostatic valve X X
Gearbox Replace rubber coupling X
Motors 24000 hours Replace bearings of electric motors (4) X
17 Review the e compressor element and gearbox X

Notes:
(1) – Every 2000 hours for Rotair
(2) – Every 4000 hours for Rotair Plus (factory default). Electric motor lubrication should be performed with up to 3000 hours.
(3) – Lubricate bearings of motor(s) according to the data on the plate.
(4) – Based on predictive analysis.
Types of maintenance may vary according to the use of compressors and conditions in the workplace.

49
 When operating in a dusty environment, inspect air filters at shorter intervals.
Always use Chicago Pneumatic filters.
The separator element must also be replaced when the pressure difference on the element exceeds 0.8 bar (12 psi).
Check the pressure drop when the compressor is running under load and preferably with a stable working pressure.
Damaged hoses must be replaced immediately.
Service contracts
Chicago Pneumatic Customer Centers have a wide range of service contracts tailored to your needs:
• An Inspection Plan
• A Preventive Maintenance Plan
• A Total Responsibility Plan
Contact your Customer Center to agree a service contract tailored to your needs. It ensures operating efficiency, minimizes
downtime and reduces operating costs.

Assistance Plan
Several service operations are grouped (called Level A, Level B, Level C...). Each level represents a number of service actions
to be performed at intervals defined in the ES4000 regulator.
When a level is reached, a message appears on the display. After performing all service actions, reset the interval timers using
the “Reset” key in the “Service” menu. Contact Chicaco Pneumatic’s Authorized Technical Service.

6.2 Motors
Warning
Stop the compressor and switch off the power. The operator should employ all relevant safety precautions.
Never mix lubricants of different brands or types.
Fan motors
The fan motor bearings are lubricated to ensure a long service life. Fan motor bearings must be replaced after 20000 hours of
operation.

Interval
Compressor Interval End
Brand Grease Amount Opposite end Amount
type of motor drive
of motor drive

CPF WEG - 3000 h 34 g 3000 h 34 g

50
6.3 Oil specifications 6.4 Oil change
6.3.1 Chicago Pneumatic ROTAIR Plus Warning
“Chicago Pneumatic ROTAIR Plus” - mineral with
The operator should employ all relevant safety
antioxidant, anti-corrosive, defoaming additives etc.
precautions.
For Chicago Pneumatic standard use in rotary compressors
with oil injection under moderate operating conditions.
For a life cycle of 3000 hs. This oil lasts long and provides
excellent lubrication as long as the values in the table below
are complied with.
6.3.2 Chicago Pneumatic CP-46
Chicago Pneumatic CP-46 - synthetic with antioxidant, anti-
corrosive, defoaming additives etc.
It can be used in compressors where there are more extreme
operating and environmental conditions, where the CP-46
does not meet oil life requirements.
For a life cycle of 6000 hs.
6.3.3 CP-46 F Procedure
Chicago Pneumatic CP-46 F - commonly used in compressors 1. Run the compressor until warm. Stop the compressor,
applied to food, pharmaceutical and other sector companies. close the air outlet valve and switch off the voltage.
Wait a few minutes and depressurize the system by
Notice loosening the vent plug on top of the air tank to allow
pressure to be relieved. Wait until all the pressure in the
Never mix oils of different brands or types.
system has been relieved.

6.3.4 Oil filter change 2. Drain the oil by removing the drain plug from the hose
attached to the bottom of the air tank.
1. Stop the compressor, turn off the voltage and unscrew
the plug (5-Fig.3.5) one turn to allow any pressure in the Oil filter change
system to be relieved. 1. Use an oil collector to prevent spillage. Unscrew the oil
2. Insert a container to collect the oil and prevent it from filters (6).
dirtying the equipment. Remove the oil filters (1- 2. Clean the filter seats on the collector.
Fig.3.5).
3. Lubricate new filter joints and screw the filters in place
3. Clean the mounting site of the filters in the housing. until the joints contact the seats. Then tighten manually.
Lubricate joints on new filters and manually screw them
back until joints fit into housings. 4. Loosen the air inlet hose (8) and pour 3 liters of oil into
the compressor element. After filling the element, refit
4. Tighten the filler plug (5-Fig.3.5). the air inlet hose (8) and pour 3 liters of oil into the
5. Reschedule the oil filter service warning using the compressor element. After filling the element, refit the
“Reset” key in the “Service” submenu. air inlet hose (8).
6. Refer to “ES400 Controller User Manual”, “SERVICE Filling the air tank with oil
Submenu” section.
1. Refit and tighten the air tank oil drain plug.
2. Remove the filler plug (FC).
3. Fill the air tank with oil until the level reaches the filler
neck.
4. Refit and tighten the filler plug (FC) and the vent plug
on top of the air tank.
5. Run the compressor loaded for a few minutes.

51
6. Stop the compressor and wait a few minutes. 6.6 Service kits
7. Depressurize the system by loosening the vent plug on
top of the air tank to allow pressure to be relieved. General
8. Remove the filler plug and fill the air tank with oil until Service kits contain all parts required to service the equipment
the level reaches the filler neck. and offer the benefit of genuine Chicago Pneumatic parts,
9. Tighten the filler plug (FC). maintaining lower maintenance costs. All service kits are
listed in the corresponding List of Spare Parts.
Reseting ES4000 controller
Chicago Pneumatic Rotair Plus
Control panel
Rotair Plus can be ordered in the following amounts:
• 5 liter gallon: 6215 7144 00
• 20 liter gallon: 6215 7145 00
• 209 liter barrel: 6215 7146 00
See Oil specifications section.

Chicago Pneumatic CP-46

CP-46 can be ordered in the following amounts:
• 5 liter gallon: 1031 4012 78
• 18.9 liter gallon: 1031 4012 61
• 209 liter barrel: 1031 4013 97
See Oil specifications.

After performing all service actions of the “Scheduled Service 6.7 Filter disposal
Plan”, reset the service warning as follows: The filters used must be disposed of in a safe and
1. Press the “Menu” key in the display (1). environmentally friendly manner, always in accordance with
2. Press key (12) until “Service” is followed by an arrow the applicable local environmental standards and legislation.
pointing to the right. Activate the menu by pressing the Warranty and Product Liability
key (13).
3. Press the key (12) until “Scheduled Service Plan” is Use only genuine parts authorized by Chicago Pneumatic. No
followed by an arrow pointing to the right, then activate damages or defects caused by the use of non-authorized parts
by pressing the key (13). are covered by the Product Liability Warranty.
4. Press the “Reset” (14) key; the timer will be set to 0.
6.8 Safety valve
6.5 Storage after installation
Warning
Procedure
Stop the compressor and switch off the voltage.
Run the compressor twice a week, for example, until warm. The operator should employ all relevant safety
Load and unload the compressor sometimes to operate the precautions. Never run the compressor without safety
unloading/loading system components. valves.
If the compressor is stored and not run periodically,
Testing
protective measures must be taken. Contact Chicaco
Pneumatic’s Authorized Technical Service. The valve can be tested on a separate compressed air line.
If the valve does not open at the set pressure (see section
Safety valve parameters), contact the Authorized Chicago
Pneumatic Technical Assistance.

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7 Troubleshooting
7.1 Troubleshooting
Warning

Before carrying out any maintenance, repair work or adjustment, stop the compressor, press the emergency stop button
and switch off the voltage. Close the air outlet valve and open manual condensate drain valves.
Open and block the disconnecting switch.
The operator should employ all relevant safety precautions.

Control panel

Problems and solutions

A service message is shown in the display

Stop the compressor and carry out the service actions displayed. Reset the message:
• Press the “Menu” key in the display (1).
• Press key (12) until the message “Assistência” is followed by an arrow pointing to the right. Activate the menu by pressing
the key (13).
• Press the “Reset” (14) key; the timer will be set to 0.

A shutdown warning message is shown in the display

The alarm LED lights up to indicate that the outlet temperature of compressor elements is too high. The message disappears
immediately after the cause of the problem is eliminated.

The unit switches off

The alarm LED flashes to indicate that the outlet temperature is too high or that the motor overload relay has tripped. Solve
the problem. It may be necessary to reset the display after troubleshooting: press the "Reset" (2) key; the message "Todas as
Funções de Proteção OK" (All Protection Features OK) will be displayed, and then the compressor can be restarted.

Excessive oil consumption

Request compressor inspection to the Authorized Chicago Pneumatic Technical Assistance

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Condition Problem Solution
Request compressor inspection to the Discharge pipe of condensate trap Check and correct, if necessary.
Authorized Chicago Pneumatic Technical clogged.
Assistance
Malfunction of the condensate trip Remove the float assembly, clean and
float valves. check.

Condition Problem Solution

Compressor air flow or pressure below Air consumption exceeding Check the equipment connected.
normal. compressor air flow.
Clogged air filters. Replace filters.
Air leak. Check and correct.

Condition Problem Solution

Compressor element outlet temperature or Low level oil. Check and correct.
outlet air temperature above normal.
Oil coolers clogged. Perform external cleaning.
Air coolers clogged. Perform external cleaning.
In air-cooled compressors, Check and correct, if necessary.
insufficient cooling air or cooling air
temperature too high.

54
8 Technical data
Data for 7 bar (100 psi) CPF compressors of 60 Hz

Units CPF-150 CPF-175 CPF-200

Maximum working pressure, CPF Pack bar(e) 7.4 7.4 7.4
Maximum working pressure, CPF Pack psig 107.3 107.3 107.3
Nominal working pressure bar(e) 6.9 6.9 6.9
Nominal working pressure psig 100 100 100
Motor shaft speed r/min 1780 1780 1780
Input power, CPF Pack kW 131 148 176
Oil capacity, CPF l 66 80 90
Acoustic pressure level, CPF dB(A) 81 75 84

Data for 8 bar (125 psi) CPF compressors of 60 Hz

Units CPF-150 CPF-175 CPF-200

Maximum working pressure, CPF Pack bar(e) 9.1 9.1 9.1
Maximum working pressure, CPF Pack psig 132 132 132
Nominal working pressure bar(e) 8.6 8.6 8.6
Nominal working pressure psig 125 125 125
Motor shaft speed r/min 1780 1780 1780
Input power, CPF Pack kW 132 148 177
Oil capacity, CPF l 66 80 90
Acoustic pressure level, CPF dB(A) 81 75 84

Data for 10 bar (150 psi) CPF compressors of 60 Hz

Units CPF-150 CPF-175 CPF-200

Maximum working pressure, CPF Pack bar(e) 10.9 10.9 10.9
Maximum working pressure, CPF Pack psig 132 132 132
Nominal working pressure bar(e) 10.4 10.4 10.4
Nominal working pressure psig 125 125 125
Motor shaft speed r/min 1780 1780 1780
Input power, CPF Pack kW 131 150 176
Oil capacity, CPF l 66 80 90
Acoustic pressure level, CPF dB(A) 81 75 84

Data for 13 bar (200 psi) CPF compressors of 60 Hz

Units CPF-150 CPF-175 CPF-200

Maximum working pressure, CPF Pack bar(e) 14 14 14
Maximum working pressure, CPF Pack psig 202 202 202
Nominal working pressure bar(e) 13.5 13.5 13.5
Nominal working pressure psig 195 195 195
Motor shaft speed r/min 1780 1780 1780
Input power, CPF Pack kW 131 195 178
Oil capacity, CPF l 66 80 90
Acoustic pressure level, CPF dB(A) 81 75 84

55
9 Instructions for using the air-oil separator vessel
1. This vessel may contain pressurized air and may be potentially dangerous if the equipment is misused.
2. It should only be used as an air-oil separator and must be operated within the limits specified on the data plate.
3. No change must be made to the vessel by welding, drilling or other mechanical methods without the written consent of
the manufacturer.
4. If the safety valve needs to be replaced, it must follow the manufacturer’s specification in full.
5. Use only the oil specified by the manufacturer.
6. In case of equipment misuse (too low oil temperature or long shut-off interval), certain amount of condensate may build
up in the oil separator vessel, which must be properly drained. To do this, disconnect the equipment from the mains,
wait until it cools and depressurize. Drain the condensate through the oil drain valve, located at the bottom of the air-oil
separator vessel.
The local legislation may require periodic inspection of the air-oil separator vessel.

56
10 Environmental information
Check the Environmental Information file recorded on the manual CD provided with the Chicago Pneumatic equipment. This
file has guidance on environmental aspects involved in use of Chicago Pneumatic equipment.

57
NOTES
NOTES
NOTES
NOTES
NOTES
Chicago Pneumatic Brasil LTDA.
Rua São Paulo, 147 - Alphaville Empresarial - Barueri - São Paulo - Brazil
Phone: (011) 2189-3900
CNPJ: 51.609.568/0001-45
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