Product Manual - Air Compressors Direct

Product Manual - Air Compressors Direct
ARSeries
AirCompressor
Manual
0715
1312208400
TABLE OF CONTENTS
PAGE
1
Safety Guidelines - Definitions
Before Using the Air Compressor
2
When Installing or Moving the Compressor
Before Each Use
3
Follow Safety Precautions for Electrical Connection
Plan Ahead to Protect Your Eyes, Hands, Face & Ears
When Operating
4
Spraying Precautions
Perform These Maintenance Operations
5
Typical Compressor Installation
Glossary
6
Wiring
7-8
Starting the Compressor
9
Troubleshooting Guide
10
Troubleshooting (Cont.)
SAFETY GUIDELINES - DEFINITIONS
Safety is a combination of common sense, staying alert and knowing how your compressor works.
Read this manual to understand this compressor.
DANGER
means if safety information is not followed someone will be seriously injured or killed
WARNING
means if safety information is not followed someone could be seriously injured or killed
CAUTION
means if safety information is not followed someone may be seriously injured or killed
IMPORTANT SAFETY INSTRUCTIONS
Save these instructions
Improper operation or maintenance of this product could result in serious injury and property
damage. Read and understand all warnings and operation instructions before using this compressor.
Before using the air compressor
Things you should know
Inspect your work area
Air compressors are utilized in a variety of air
1. Keep work area clean.
system applications. Because air compressors
and other components (hoses, connectors, air
2. Cluttered areas and benches invite accidents.
tools, spray guns, etc.) make up a high pressure
Floors must not be slippery from wax or dust.
pumping system, the following safety precautions should be observed at all times.
Inspect your compressor
Only persons familiar with these rules of
safe operation should use the air
compressor.
1. To reduce the risk of injury from accidental
starting, turn switch off and disconnect the
power before checking it.
1. Read the instruction manual carefully before
attempting to assemble, disassemble or
operate your system. Be thoroughly familiar
with the controls and the proper use of the
equipment.
2. If any part is missing, bent or broken in any
way, or any electrical part does not work properly, keep the compressor off and disconnected.
3. Check hoses for weak or worn condition
before each use, making certain all connections
2. Review and understand all safety instructions
are secure. Do Not use if defect is found.
and operating procedures in this manual.
WARNING
3. Review the maintenance methods for this
compressor (See “Maintaining Your
Compressor” section).
Do not operate compressor if damaged during
shipping, handling or use. Damage may result
in bursting and cause injury or property damage.
DANGER
This compressor is Not designed for and should
not be used in breathing air applications.
Page 1
When installing or moving the compressor
WARNING
6. A minimum clearance of 18 inches between
the compressor and a wall is required
because objects could obstruct airflow.
This compressor is extremely top heavy. The
compressor must be bolted to the floor with
vibration pads before operating to prevent
equipment damage, injury or death. Do Not
tighten bolts completely as this may
cause stress to the tank welds. Chart 1a.
7. The compressor should be located where it can
be directly wired to a circuit breaker. The
compressor should be wired by a qualified
electrician.
To reduce the risk of a dangerous
environment
8. Never store flammable liquids or gases in
the vicinity of an operating compressor.
1. Keep work area well lit.
2. Operate compressor in a well-ventilated
area free from flammable liquids and vapors.
3. Operate compressor in a ventilated area so
that compressor may be properly cooled and
the surrounding air temperature will not be
more than 100°F.
9. Do Not locate the compressor air inlet near
steam, paint spray, sandblasting areas or
any other source of contamination. The
debris could damage the motor and pump.
WARNING
Never use plastic (PVC) pipe for compressed
air. Serious injury or death could result.
4. Never use a compressor in a wet
environment.
CAUTION
Never use the shipping skid for mounting the
compressor.
5. Protect material lines and air lines from
damage or puncture. Keep hose and
wires away from sharp objects, chemical
spills, oil, solvents and wet floors.
NOTICE
WARNING
Do Not secure compressor with toggle bolts
into drywall. Drywall sheeting or plaster will not
support the weight of the compressor.
Electric air compressors are not suitable for
outdoor installation.
Gasoline air compressors must be operated
outdoors, sheltered from the weather.
WARNING
WARNING
Shut off gas when not in use. Risk of fire or
gas leaking into crankcase or carburetor.
Never install a shut off valve between the compressor pump and tank. Personal injury and/or
equipment damage could occur.
Tank Outlet Size: 1/4" NPT for 20 & 26 Gallon Portables, 3/8” NPT for Twin Tank
1/2" NPT for 60 Gallon Units, 3/4" NPT for 80, 120 Gallon and Duplex
Before each use
Inspect your work area
Inspect your compressor
1. Keep work area clean. Cluttered areas and
benches invite accidents.
1. To reduce the risk of injury from accidental
starting, turn the switch off and disconnect
power.
2. The floor must not be slippery from wax or
dust.
Flat
Washer
Floor
Vibration Pad
Compressor
Leg
Shim
(If Necessary)
Lag Bolt
Chart 1a
2. If any part is missing, bent or broken in any
way, or any electrical part does not work
properly, keep the compressor off and disconnect power. Do Not use if defect is found.
3. Check hoses for weak or worn condition
before each use, making certain all connections are secure. Do Not use if a defect is
found.
Page 2
Follow the safety precautions for electrical connections
1. Follow all local electrical and safety codes,
as well as the National Electric Code (NEC)
and the Occupational Safety and Health
Act (OSHA).
3. Protect wires from contact with sharp objects.
CAUTION
2. Wiring and fuses should follow electrical
codes, current capacity and be properly
grounded.
All electrical connections should be made by
a qualified electrician.
Plan ahead to protect your eyes, hands, face and ears
Dress for safety
1. Wear safety glasses (meeting ANSI Z87.1 or
in Canada CSA Z94.3-99) and use hearing
protection when operating the unit. Everyday
glasses are not safety glasses.
WARNING
Be careful when touching the exterior of compressor, pump, motor and air lines; they may
become hot enough to cause injury.
2. Wear shoes to prevent shock hazards.
WARNING
3. Tie back long hair.
Never operate the compressor without a
beltguard. The compressor can start automatically without warning. Personal injury or
property damage could occur from contact
with moving parts.
Pay attention to your hands
WARNING
Keep fingers away from running compressor.
Fast moving and hot parts may cause injury
and/or burns.
CAUTION
The compressor may be hot even if the unit is
stopped.
WARNING
Use of a mask or respirator per chemical
manufacturers’ instructions may be necessary if there is a chance of inhaling toxic fumes.
Read mask and respirator instructions carefully. Consult a safety expert if you are not
sure about the use of certain masks or
respirators.
When operating
WARNING
1. Do not exceed the pressure rating of any
component of the system.
2. Release pressure within the system slowly
to prevent flying dust and debris.
3. If the equipment starts to abnormally vibrate,
STOP the compressor immediately and
check for the cause.
Never change the safety valve or pressure
switch settings. Keep safety valve free from
paint and other accumulations. See compressor
specification decal for maximum operating
pressure. Do not operate with the pressure
switch set higher than the maximum operating
pressure.
Page 3
Spraying precautions
WARNING
1. Do Not spray in the vicinity of open flames
or other places where a spark can cause
ignition. Do Not smoke when spraying
paint, insecticides, or other flammable
substances.
Never point a spray gun at yourself or any
other person or animal. Accidental discharge
may result in serious injury.
Reduce the risk of dangerous
environment
Be informed about the materials you use
1. When spraying with solvents or toxic chemicals, follow the instructions provided by the
chemical manufacturer. Consult a safety
expert if unsure about the use of masks or
respirators.
WARNING
Extreme caution should be taken when
spraying flammable liquids as the spark from
a motor or pressure switch may cause a fire
or explosion. Ample ventilation must be
provided.
2. If the material you intend to spray contains
trichloreoethane and methylene chloride, do
not use accessories that contain aluminum or
galvanized materials, as these chemicals can
react with galvanized components causing
corrosion and weakening equipment. Use
stainless steel accessories.
WARNING
Spray in a well ventilated area to keep fumes
from collecting and causing serious injury and
fire hazards.
Perform these maintenance operations
1. Do regular maintenance; keep all nuts, bolts,
and screws tight, to be sure equipment is in
safe working condition.
2. Inspect tank yearly for rust, pin holes or any
other imperfections that could cause it to
become unsafe.
4. Drain tanks of moisture after each day’s use.
If unit will not be used for awhile, it is best to
leave the drain cock open until such time as it
is to be used. This will allow moisture to
completely drain out and help prevent
corrosion of inside of tank.
5. Always disconnect from power source before
working on or near a motor, or its connected
load. If power disconnect point is out-ofsight, secure it in the “OFF” position and tag it
to prevent unexpected application of power.
WARNING
NEVER attempt to repair or modify a tank!
Welding, drilling or any other modification will
weaken the tank resulting in damage from
rupture or explosion. Always replace worn,
cracked or damaged tanks.
WARNING
3. Clean electrical equipment with an approved
cleaning agent, such as a dry, non-flammable cleaning solvent.
Disconnect power and depressurize system
before servicing air compressor. Slightly open
drain cock after shutting off compressor.
Daily
Monthly
(Make sure the main power is off.) Check the belts
for tension. Belts should not move up and down
when the compressor runs and when stopped,
should not have more than ½ in of play when
depressed. Be careful not to over tighten belts
during adjustment.
Check oil level at sight glass. Oil level should
be 1/2 to slightly higher in the oil sight glass.
Drain moisture from tank.
Verify the pressure switch unloader is
working by listening for a brief hissing sound
when the compressor shuts off.
Visually check the compressor for loose parts,
excessive noise or vibration. Tighten any
necessary part.
Remove and check air filter, replace if necessary.
Change oil every 3 months or 300 hours. A
compressor grade non-detergent oil should be
used.
Page 4
TYPICAL COMPRESSOR INSTALLATION
WIRING
GLOSSARY OF TERMS
Air Filter
Pressure Switch
Porous element contained within a metal or
plastic housing attached to the compressor
cylinder head which removes impurity from the
intake air of the compressor.
Device which automatically controls the on/off
cycling of the compressor. It stops the
compressor when the cut-off pressure in
the tank is reached and starts the compressor
when the air pressure drops below the cut-in
pressure.
Air Tank
PSI (Pounds per Square Inch)
Cylindrical component which contains the
compressed air.
Check Valve
Measurement of the pressure exerted by the
force of air. The actual psi is measured by a
pressure gauge on the compressor.
Device which prevents compressed air from
flowing back from the air tank to the compressor pump.
Pump
Electric Motor
Device which produces the compressed air
with a reciprocating piston contained within a
cylinder.
Device which provides the rotational force
necessary to operate the compressor pump.
Safety Valve
Pressure Gauge
Device which prevents air pressure in the air
tank from rising over a predetermined limit.
Device which shows the tank or regulated
pressure of the compressed air.
Thermal Overload Switch
Device, integrated into the electric motor winding,
which automatically “shuts off” the compressor
if the temperature of the electric motor exceeds
a predetermined limit.
Page 5
WIRING
WIRING
WARNING
ALL ELECTRICAL WIRING SHOULD BE DONE
BY A QUALIFIED ELECTRICIAN
General Information
DO NOT MAKE CONNECTIONS
AT THE PRESSURE SWITCH
(Units with Magnetic Starters)
Single Phase
Adequate wiring and motor protection
Incoming power should
should be provided for all stationary
be connected to L1 and
compressors. Wiring used for other
L2 at the Top of the
machinery should not be used. A
Magnetic Starter.
qualified electrician familiar with local
electrical codes in your area should be
used. Size supply wiring per NEC (National
Electric Code) requirements.
WARNING
To reduce the risk of electrical hazards, fire
hazards or damage to the compressor, use
proper circuit protection. Your compressor
is wired at the factory for operation using
the voltage shown. Connect the compressor
to a power source with the correct breaker
size.
CAUTION
Overheating, short circuiting and fire damage
will result from inadequate wiring.
Three Phase
Incoming power
should be
connected to
L1, L2 & L3 at
the Top of the
Magnetic Starter.
Overload
Adjustment
WARNING
Electrical connections must be properly
grounded. Ground connections should be
connected at the grounding screw.
+
Duplex Wiring
(Inside Controller on the Bottom)
-
For Models Without Magnetic Starter
Incoming power
should be connected
to the posts
marked (LINE)
Do Not Make
Connections On
Prewired Posts
Marked (MOTOR)!
Electrical connections
must be properly
grounded. Ground
connections should be
connected at a
grounding screw.
Single Phase
Three Phase
Page 6
STARTING THE COMPRESSOR
STARTING THE COMPRESSOR
Prior to actually running the compressor,
check the following items:
Crankcase oil - Make sure the sight glass
shows ½ full or slightly above.
Make sure all rags, tools, oil, etc. are away
from the unit.
Open the air system to free it of any pressure.
Switch the compressor on for a few
revolutions to make sure the rotation is
correct. Correct rotation is clockwise
when facing the sight glass on the pump.
Operate the compressor for a few minutes
unloaded (air system open) then allow the
compressor to pump up. Make sure the
electrical pressure switch properly switches
off the compressor according to the setting
desired. 175 for Two Stage.
(135 psi - Single Stage or 165 psi - RCP-561VNS)
CAUTION
Make sure the pressure in the tank does
not exceed its rating. Single Stage units - 135 psi
Two Stage units at a maximum of 175 psi.
(165 for Model RCP-561VNS)
If the pressure gauge indicates a pressure that
is higher than these maximum pressures,
shut off compressor immediately and call
your distributor.
(Duplex Models)
Alternating Running Procedure
Initial power to the controller takes about 5 seconds to power up and run
Motor A will start and then Motor B after a 10 second delay
Both motors will run until unit reaches cutoff pressure (175 psi)
Each time the unit starts after initial start, the “Lead” motor will alternate
If the unit runs for more than 5 minutes, the second Motor will come on and run
until the unit reaches cutoff pressure
The second motor will also come on if the air demand is higher than one pump/
motor can produce and the pressure drops to around 135 psi (10 sec. delay)
A or B Running Procedure
By selecting A or B on the switch, either Pump/Motor A or Pump/Motor B will
operate independently, as a simplex compressor.
Normal
Operation
Page 7
(Gas Drive Models)
PLEASE REFER TO YOUR ENGINE OPERATION MANUAL FOR PROPER STARTING
INSTRUCTIONS.
GASOLINE DRIVEN COMPRESSORS ARE EQUIPPED WITH A COLD START
VALVE FOR LOADLESS STARTS.
NOTE: IN SOME INSTANCES, IT STILL
MAY BE NECESSARY LIFT THE TOGGLE ON THE UNLOADER/PILOT VALVE
TO RELIEVE THE HEAD PRESSURE. See Page 11
Battery Connection Instructions for Electric Start Engines
Note:Make sure to follow instructions carefully to avoid a short and possible damage
to the starter solenoid and/or battery.
1. Connect the positive (+) terminal on the battery to the starter solenoid.
2. Connect the negative (-) terminal on the battery to an engine mounting bolt or other
acceptable ground connection.
Always connect the positive(+) battery cable to the starter solenoid before connecting
the negative(-) battery cable.
NUMBER 2 WIRE OR LARGER IS REQUIRED
(-)
(+)
BATTERY
(12 Volt)
Starter Solenoid
GROUND
Cold Start Procedure (Gasoline Engine Units)
Warning: Do Not Operate Gasoline Engine
Units in an Enclosed Area
· Release any remaining tank pressure by slowly opening the
manual drain valve.
· Turn on the engine gasoline supply.
· Put the choke in the “On” position
· Close the service valve and put Unloader lever in the “unload”
(A) position for Briggs and Stratton and Honda engine driven
models, or the “load” (B) position for Kohler engine models.
· Start the engine, release the choke, and allow the engine to
warm up for two to three minutes.
· Return the unloader lever to the “load” (B) position on Briggs
and Stratton and Honda driven models.
Note: Turn the gasoline supply off when the compressor is
not being used
Page 8
TROUBLESHOOTING GUIDE
Low discharge pressure 1. Compressor too small for
application
2. Air leaks
3. Restricted intake air
4. Blown gasket(s)
5. Broken or misaligned valves
1. Reduce air demand or use a compressor
with more air capacity.
2. Listen for air leaks. Apply a soap solution
to all fittings and connections. Bubbles
will form at points of leakage. Tighten
or replace fittings or connections.
3. Clean or replace air filter.
4. Replace necessary gaskets.
5. Remove head and inspect for broken or
misaligned valves. Replace valves, if
necessary.
!
Excessive noise
“knocking”
1. Loose drive pulley or flywheel
2. Low on oil
3. Worn connecting rod or
connecting rod bearing
4. Noisy check valve
CAUTION
Install a new head gasket
each time head is removed
1. Tighten drive pulley or flywheel bolt.
2. Check for proper oil level. Low or dirty
oil may cause bearing damage.
3. Replace connecting rod and/or connecting
rod bearings.
4. Replace check valve.
!
DANGER
Do not remove check valve
with air pressure in tank
Excessive oil carryover
1. Worn piston rings
2. Restricted intake air
3. Too much oil in compressor
4. Incorrect oil viscosity
1. Replace with new piston rings.
2. Clean or replace air filter.
3. Drain oil to proper oil level.
4. Use a quality non-detergent 30 or 40wt
oil specified for each model (Page 4).
Water in tank and/or
discharge line
1. Normal. Amount of water will
increase as humidity in the
air increases.
1. Drain tank at least once per day.
2. Add an inline filter to reduce moisture in
in the air line.
Will not run or motor
hums
1. Low voltage
1. Check voltage with volt meter across both
legs of incoming power. Check reset button
on motor.
2. Malfunctioning pressure switch 2. Repair or replace pressure switch.
3. Malfunctioning check valve
3. Replace check valve or pressure switch.
!
Breaker or reset
repeatedly trips
Do not remove check valve
with air pressure in tank
1. Make sure the breaker is sized properly.
See page 6 in this manual.
2. Check voltage with volt meter across both
2. Low voltage
legs of incoming power.
3. Replace motor.
3. Malfunctioning motor
4. Check all electrical connections.
4. Loose electrical connections
5. Malfunctioning pressure switch 5. Adjust or replace pressure switch.
6. Replace check valve.
6. Malfunctioning check valve
1. Incorrect breaker size
!
Tank does not hold
pressure when not
running and shut off
valve is closed
DANGER
1. Malfunctioning check valve
Page 9
Do not remove check valve
with air pressure in tank
1. Replace check valve.
!
2. Loose fittings or connections
3. Crack or pin hole in tank
DANGER
not remove check valve
DANGER Do
with air pressure in tank
2. Tighten or replace fittings or connections.
3. Replace tank. Do not attempt to repair tank.
TROUBLESHOOTING GUIDE (Continued)
Pressure switch unloader constantly
leaking air
1. Malfunctioning check valve
Pressure switch not
unloading
1. Malfunctioning pressure
switch
1. Replace check valve if unloader bleeds
constantly.
!
1. Replace pressure switch if it does not release
air pressure briefly when unit shuts off.
!
Excessive vibration
1. Improper installation
2. Loose belts
3. Misaligned flywheel or
drive pulley
not remove check valve
DANGER Do
with air pressure in tank
DANGER
Do not remove pressure
switch with air pressure in
tank
1. Make sure unit is mounted on a level surface
with vibration pads.
2. Replace belts. Align and tighten properly.
3. Align flywheel and drive pulley.
Overheating
1. Compressor too small for
application
2. Cooling surfaces dirty
3. Improper cooling
1. Reduce air demand or use a compressor
with more air capacity.
2. Clean all cooling surfaces of dirt and dust.
3. Install compressor in an area with adequate
cool dry air.
Will Not Start
(Elite and QP)
1. Unit Low on Oil
2. Exhaust Fan Not Working
1. Add Oil to Proper Level
2. Reset Thermal Overload
Page 10
Warranty Statement
The Company warrants that the Equipment manufactured by it and delivered hereunder shall be free from defects in material and
workmanship for a period of twelve (12) months from the date of initial start-up, or eighteen (18) months from the date of shipment
from the manufacturer, whichever occurs first. The foregoing warranty period shall apply to all Equipment, except for the following: (A) all
two stage reciprocating stationary models are warranted for the earlier of twenty-four (24) months from the date of initial operation or thirty
(30) months from date of shipment from the manufacturer. (B) Replacement parts will be warranted for three (3) months from the date of
shipment from the manufacturer. Should the failure to conform to this warranty be reported in writing to the Company within said
period, the Company shall, at its option, correct such non - conformity by suitable repair to such Equipment, or furnish a
replacement part F.O.B point of shipment, provided that the Purchaser has installed, maintained, and operated such Equipment in
accordance with good industry practices, and has complied with specific recommendations of the Company.
Accessories and
equipment furnished by the Company, but manufactured by others, shall carry whatever warranty the manufacturer conveyed to the
Company and which can be passed on to the Purchaser. The Company shall not be liable for any repairs, replacements, or adjustments
to the Equipment, or any costs of labor performed by the Purchaser without the Company’s prior written approval.
The Company makes no performance warranty unless specifically stated within its proposal, and the effects of corrosion, erosion, and
normal wear and tear are specifically excluded from the Company’s warranty. In the event performance warranties are expressly
included, the Company’s obligation shall be to correct in the manner and for the period of time provided above
This warranty does not apply to electric motors or gasoline engines. These are covered by the Original Manufacturer’s Warranty and
should be returned (by the customer) to their authorized service center for service..
THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER,
EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED. THIS WARRANTY SUPERSEDES ALL
PREVIOUS WARRANTY STATEMENTS.
Correction by the Company of non-conformities, whether patent or latent, in the manner and for the period of time provided above, shall
constitute fulfillment of all liabilities of the Company and its distributors for such non-conformities with respect to, or arising out of such
Equipment.
LIMITATION OF LIABILITY
THE REMEDIES OF THE PURCHASER SET FORTH HEREIN ARE EXCLUSIVE, AND THE TOTAL LIABILITY OF THE COMPANY,
ITS DISTRIBUTORS AND SUPPLIERS WITH RESPECT TO CONTRACT OR THE EQUIPMENT AND SERVICES FURNISHED IN
CONNECTION WITH THE PERFORMANCE OR BREACH THEREOF, OR FROM THE MANUFACTURE, SALE, DELIVERY,
INSTALLATION, REPAIR OR TECHNICAL DIRECTION COVERED OR FURNISHED UNDER CONTRACT, WHETHER BASED
ON CONTRACT, WARRANTY, NEGLIGENCE, INDEMNITY, STRICT LIABILITY OR OTHERWISE, SHALL NOT EXCEED THE
PURCHASE PRICE OF THE EQUIPMENT UPON WHICH SUCH LIABILITY IS BASED.
THE COMPANY, ITS DISTRIBUTORS AND ITS SUPPLIERS SHALL IN NO EVENT BE LIABLE TO THE PURCHASER, ANY
SUCCESSORS IN INTEREST, OR ANY BENEFICIARY OR ASSIGNEE OF THE CONTRACT FOR ANY
CONSEQUENTIAL, INCIDENTAL, INDIRECT, SPECIAL OR PUNITIVE DAMAGES ARISING OUT OF THIS CONTRACT OR ANY
BREACH THEREOF, OR ANY DEFECT IN, OR FAILURE OF, OR MALFUNCTION OF THE EQUIPMENT, WHETHER OR NOT
BASED ON LOSS OF USE, LOST PROFITS OR REVENUE, INTEREST, LOST GOODWILL, WORK STOPPAGE, IMPAIRMENT
OF OTHER GOODS, LOSS BY REASON OF SHUTDOWN OR NON-OPERATION, COST OF PURCHASE OF REPLACEMENT
POWER, OR CLAIMS OF PURCHASER OR CUSTOMERS OF PURCHASER FOR SERVICE INTERRUPTION, WHETHER OR NOT
SUCH LOSS OR DAMAGE IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, INDEMNITY, STRICT LIABILITY OR OTHERWISE.
Atlas Copco Compressors LLC
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