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operation manual

Model #

AC5080B

AC5080B3

CAUTION READ THIS MANUAL CAREFULLY

before operating or servicing this air compressor, to familiarize yourself with the proper safety, operation, and standard operating procedures of this unit. FAILURE TO COMPLY WITH INSTRUCTIONS IN

THIS MANUAL COULD RESULT IN THE VOIDING OF YOUR WARRANTY, AND

PERSONAL INJURY, AND/OR PROPERTY DAMAGE. THE MANUFACTURER

OF THIS AIR COMPRESSOR WILL NOT BE LIABLE FOR ANY DAMAGE

BECAUSE OF FAILURE TO FOLLOW THE INSTRUCTIONS IN THIS MANUAL.

By following the instructions and recommendations in this manual you will ensure a longer and safer service life of your air compressor.

2

table of contents

Introduction

4

Using the Operator’s Manual

Product Identification

5

Record Identification Numbers

Safety

6

Safety Precautions and Warnings

Troubleshooting

7

Troubleshooting Chart

Compressor Maintenance

10

Maintenance

11

Storage

Adjustments & Alignment

12

Adjusting Belt Tension

12

Pulley Alignment

Description of Compressor

13

What is a reciprocating compressor?

13

Description of Cooling

13

Description of Controls

Pre-Operation

14

Receiving and uncrating of your compressor

14

Compressor Installation

14

Location

14

Mounting

15

Induction System

15

Noise

15

Piping Fitup

16

Safety Valves

16

Pressure Vessels

16

Electrical

17

Pressure Switch

17

Manual Relief and Shutoff Valves

17

Guards

18

Drives

table of contents

Wiring Diagrams

19

1 Phase Piston Compressor

Installation

20

Installation Diagram

Start Up Preparation

21

Start Up Preparation

Maintenance

22

Stopping for Maintenance or Service

23

Daily

23

Weekly

23

Monthly

23

Every 3 Months

24

Storage of Compressor

Parts Breakdown

25

7.5HP Parts Breakdown

27

CA1 and CA1U

3

introduction

Attention: Read through the complete manual prior to the initial use of your

Compressor

Using the Operator’s manual

The operating manual is an important part of your Compressor and should be read thoroughly before initial use, and referred to often to make sure adequate safety and service concerns are being addressed.

Reading the owner’s manual thoroughly will help avoid any personal injury or damage to your pump. By knowing how best to operate this machine you will be better positioned to show others who may also operate the unit.

You can refer back to the manual at any time to help troubleshoot any specific operating functions, so store it with the machine at all times.

4

product identification

Record Identification Numbers

Compressor

If you need to contact an Authorized Dealer or Customer Service line

(1-866-770-1711) for information on servicing, always provide the product model and identification numbers.

You will need to locate the model and serial number for the pump and record the information in the places provided below.

Date of Purchase:

Dealer Name:

Dealer Phone:

Product Identification Numbers

Model Number:

Serial Number:

5

safety

Safety Precautions and Warnings

Listed are some, but not all safety precautions that must be observed with compressors. Failure to follow any of these warnings may result in severe personal injury, death, property damage and/or compressor damage.

• Air from this compressor will cause severe injury or death if used for breathing or food processing.

• Air used for these processes must meet OSHA 29 CFR 1910 or FDA

21 178.3570 regulations.

• This compressor is designed for use in the compression of normal atmospheric air only. No other gases, vapors or fumes should be exposed to the compressor intake, nor processed through the compressor.

• Disconnect all power supplies to the compressor plus any remote controllers prior to servicing the unit.

• Relieve all pressure internal to the compressor prior to servicing.

• Do not depend on check valves to hold system pressure.

• A properly sized safety valve must be installed in the discharge piping ahead (upstream) of any shutoff valve (block valve), heat exchanger, orifice or any potential blockage point. Failure to install a safety relief valve could result in rupturing or explosion of some compressor or safety component.

• Do not change the pressure setting of the safety relief valve, restrict the function of the safety relief valve, or replace the safety valve with a plug.

• Over pressurization of some system or compressor component can occur, resulting in severe personal injury, death and property damage.

• Never use plastic pipe, rubber hose, or soldered joints in any part of the compressors. Failure to ensure system compatibility with compressor piping is dangerously unsound.

• Never use a flammable or toxic solvent for cleaning the air filter or any parts.

• Do not attempt to service any part while the compressor is operating.

• Do not operate the compressor at pressures in excess of its rating.

• Do not remove any guards while the compressor is operating.

• Observe gauges daily to ensure compressor is operating properly.

• Follow all maintenance procedures and check all safety devices on schedule.

• Compressed air is dangerous, do not play with it.

• Use the correct lubricant at all times.

6

troubleshooting

Troubleshooting Chart

NOTE: Troubleshooting problems may have similar causes and solutions.

ALWAYS MAKE SURE ELECTRICAL POWER IS OFF BEFORE

REMOVING ANY INSPECTION COVERS OR PLATES

You should always contact an authorized service center before attempting to fix or repair your air compressor

Problem

Compressor stalls

Possible Cause

Breaker Trips 1. Low Voltage supply

2. Motor overloads tripped

3. Restricted air passages

4. Loose wires at contact points

5. Seized Pump

1. Low voltage supply to compressor

2. Loose compressor belts

3. Bad check valve

4. Seized compressor pump

Low Discharge

Pressure

Compressor pump knocking

1. Air leaks in shop

2. Leaking valves

3. Restricted air intake

4. Blown gaskets/seals

5. Worn piston rings or cylinder

1. Loose motor pulley or compressor flywheel.

2. Low oil level in compressor pump.

3. Carbon build up on valve and piston.

Solutions

1. Check that incoming power wire size is adequate for compressor

2. Check that compressor is on dedicated circuit

3. Adjust belt tension

4. Check wire connections to make sure they are tight

5. Inspect transfer tubes and, check valve

1. Check compressor power supply for adequate breaker and wire size

2. Inspect check valve for proper operation

3. Tighten belts

4. Check compressor for proper oil level.

1. Tighten or replace leaking fittings, or joints

2. Clean or replace air filter

1. Tighten pulley or flywheel.

2. Keep oil level at recommended level for proper operation.

3. Only use factory recommended oil.

7

troubleshooting

Troubleshooting Chart (continued)

NOTE: Troubleshooting problems may have similar causes and solutions.

ALWAYS MAKE SURE ELECTRICAL POWER IS OFF BEFORE

REMOVING ANY INSPECTION COVERS OR PLATES

You should always contact an authorized service center before attempting to fix or repair your air compressor

Problem

Excessive oil discharge in air

(All Compressors have a small amount of oil carry over in compression)

Compressor

Overheating

Excessive Belt

Wear

Possible Cause

1. Worn piston rings or cylinder.

2. Restricted air intake.

3. Oil level to high.

4. Compressor has exceeded it duty cycle.

1. Poor ventilation

2. Dirty cooling surfaces

3. Compressor is out of its operating duty cycle

1. Pulley out of alignment

2. Improper belt tension

3. Pulley damaged of loose

Compressor wont start in Cold weather

1. Bad check valve

2. Compressor has wrong grade oil

3. Control lines frozen

Solutions

1. Clean or replace air filters.

2. Reduce oil level to recommended amount.

3. Reduce compressor duty cycle

(repair leaks or add another unit to handle the excess demand)

1. Relocate compressor to any area with better ventilation (at least 18 inches from the nearest wall)

2. Clean all cooling surfaces

3. Reduce compressor duty cycle

(repair leaks or add another unit to handle the excess demand)

1. Realign pulley with flywheel

2. Re adjust belt tension

1. Use IS 100 (30W) compressor oil for cold weather conditions

2. Move compressor to a warmer location

3. Put a heat lamp on compressor to maintain above freezing temperatures

8

troubleshooting

Troubleshooting Chart (continued)

NOTE: Troubleshooting problems may have similar causes and solutions.

ALWAYS MAKE SURE ELECTRICAL POWER IS OFF BEFORE

REMOVING ANY INSPECTION COVERS OR PLATES

You should always contact an authorized service center before attempting to fix or repair your air compressor

Problem Possible Cause

Compressor

Motor Hums wont start

Unit has power but wont run

1. Fuse or Breaker blown in main panel (or fuse in fused disconnect if applicable)

2. Low voltage to compressor

3. Compressor starting with head pressure

4. Power leads in motor or magnetic starter loose

5. Starter or Pressure switch contacts corroded or broken

1. Starter tripped

2. Starter coil out

3. Pressure switch closed

4. Low Oil monitor tripped (Elite units)

5. Motor or Pump locked up

Compressor

Chatters (run and stops in a short period of time)

1. Pressure switch connection corroded

2. Starter is not getting enough voltage to close coil

3. Low oil switch tripping

Solutions

1. Re-set breaker or replace blown fuse

2. Inspect check valve for proper operation

3. Check all power wire lead to solid connection

4. Replace starter and Pressure switch

1. Re-set starter

2. Replace starter and Pressure switch

3. Check unit for proper oil level

4. Replace motor or pump

1. Replace pressure switch

2. Check unit voltage

3. Check the oil level in the unit

NOTE: Low Voltage-Low voltage can cause a multitude of problems. The most common cause of low voltage is when the wire size supplying the power to the compressor is too small. The longer the run of wire the larger the diameter must be to overcome the inherent voltage loss caused by the wire resistance. The supply voltage at the main panel could also be low as supplied by you local power company or you may have too many other pieces of equipment running off the same panel. You local electrician should be contacted to evaluate and correct the problem according to the Nation Electric Code. Other Symptoms of low voltage can be flickering lights and computer screen when the compressor tries to turn on.

9

compressor maintenance

Warning: To avoid personal injury, always shut OFF the main power supply and disconnects to the compressor, relive all air pressure from the system, and check electrical system with electrical probe before starting any service or maintenance on the compressor.

Daily:

Drain the Receiver- condensation will accumulate in the tank daily, and should be drained at least once a day. This is done to reduce corrosions of the tank from the inside. Always wear protective eye wear when draining the tank.

Check Pump Oil Level - All units have a sight glass the oil level non running units should be no lower than ½ way on the sight glass if it is lower then you need to add oil until it is at least ½ way up the sight glass.

Check unit for any unusual noise or vibrations.

Weekly:

Clean air filter to ensure that no dirt or heavy particulate makes its way into the compressors valve assemblies.

Clean external parts of compressor and electric motor, this helps to ensure proper cooling and prevents rust and corrosion on critical parts.

Check safety valves to ensure they are not stuck in place and are operating properly.

Elite units

Check auto tank drain for proper function.

Monthly:

Inspect complete air system for leaks to make sure the compressor does not get out of its duty cycle due to air leak in the system.

Inspect oil for contamination to ensure that harmful deposits do not build up in the oil.

Check belt tension, to ensure the belts do not fail pre-maturely. Tighten them as needed to ensure they do not slip. If belts are loose, tighten per instructions on next page. Failure to tighten can cause pre-mature belt failure.

Every 3 months:

Change oil to ensure that the compressor has proper oil level and that the oil in the machine does not deteriorate past factory specifications.

Inspect valve assemblies to prevent premature failure and clean out and carbon that can form in older valves.

*Elite units clean auto tank drain strainer and check for proper function.

10

compressor maintenance storage

Inspect pressure switch for proper function.

Inspect check valve for proper function and remove any carbon accumulation to prevent premature failure.

*Clean belt guard coolers (if equipped).

Storage of Compressor:

Before storing the compressor for a prolonged period of time, use a blow gun to clean all debris from compressor. Shut OFF main power and turn

OFF disconnect. Drain tank pressure, clean air filter, drain old oil and replace with new oil. Cover the unit to prevent dust and moisture from collecting on the unit.

11

adjustments & alignment

Adjusting Belt Tension

Proper belt tension and pulley alignment must be maintained for maximum drive efficiency and for maximum belt life. The correct tensions exists if a deflection of ½ inch occurs by placing 10lbs of force midway between the motor pulley and the compressor flywheel. This deflection can be adjusted by the following procedure. The pulley should be carefully aligned with the flywheel and set screws should be kept tight.

1. Remove the belt guard.

2. Loosen the motor mounting bolts.

3. Shift the motor to the point where the correct deflection exists.

4. Retighten the motor mounting belts.

5. Check to ensure that the tension remain correct after tightening.

6. Re-install the belt guard. All moving parts must be guarded.

NOTE: Drive belt tension and pulley alignment are done at the same time. They are discussed separately for clarity.

Pulley Alignment

The figure to the side shows 3 examples of misaligned pulleys. To check pulley alignment, remove the belt guard and place a straightedge against the compressor flywheel, measure and record the distance from the straightedge to the edge of the drive belt. Then measure the distance to the edge of the drive belt on the motor pulley at the same edge. As long as both points measure the same distance the pulleys will be aligned if not you will need to move the pulley until its in alignment this may take a few tries. To re-align the pulley follow the steps below.

1. Loosen the motor mounting bolts.

2. Remove the belt guard.

3. Loosen the set screw on the motor pulley.

4. Align the motor pulley with the compressor flywheel.

5. Re-tighten the motor pulley set screws.

6. Adjust the proper belt tension.

7. Re-tighten the motor mounting bolts.

8. Re-install the belt guard.

ANGULAR

MISALIGNMENT

PUMP

FLYWHEEL

STRAIGHT EDGE

PARALLEL

MISALIGNMENT

DRIVE

BELT

EDGE

MOTOR

PULLY

PULLEY GROOVE

AXIAL

MISALIGNMENT

DRIVE

BELT

EDGE

A B C

12

description of compressor

What is a reciprocating compressor?

A reciprocating compressor is a piston type pump which develops pressure from the action of a piston moving through a cylinder. The cylinder, or cylinders, may be vertical, horizontal or angular.

When air is drawn in from the atmosphere and compressed to its final pressure in a single stroke, the compressor is referred to as a “single stage” pump. Single stage units normally are used in the 90 to 125 PSI range and are available as single or multi-cylinder (twin cylinder) compressors.

When the air drawn from the atmosphere is compressed first to an intermediate pressure, and then further compressed to a higher pressure, it is done in a “two stage” pump. These cylinders are unequal in size and the first stage always takes place in the larger, low pressure cylinder. From there it passes through the inner cooler to the smaller, high pressure cylinder. The cycle is completed as the air then moves through the after cooler and discharge line into the tank. Two stage compressors are generally used for pressure ranges from 100 to 175 PSI and deliver more air per horsepower at these pressures. This increase in efficiency is partially due to the heat dissipated as the air passes through the inner cooler.

Description Of Cooling

Our compressors are cooled by fan blades, incorporated into the driven sheave (pulley), blowing air across the intercooler, after cooler, and cylinder head.

Description Of Controls

Stop/Start Receiver or plant air system pressure is controlled within limits by a pressure switch automatically stopping and starting the compressor as the air pressure reaches a maximum preset pressure (cut out) and then drops to a minimum presser pressure (cut in).

13

pre-operation

Receiving and Uncrating of your Compressor

Before uncrating the compressor the following steps should be taken.

1. Immediately upon receipt of the equipment, it should be inspected for damage that may have occurred during shipment. If any damage is found, demand an inspection immediately by an inspector from the carrier. Ask him how to file a claim for damages. (See Appendix “A” for

Details).

2. Insure that adequate lifting equipment is available for moving the machinery.

3. Read the compressor nameplate to be sure the compressor is the model and size ordered.

4. Read the motor nameplate to be sure the motor is compatible with your electrical conditions. (Volts-Phase-Hertz).

NOTE: Standard motors are open drip proof with a maximum ambient temperature rating of 104 degrees F. They are not suitable for salt laden, corrosive, dirty, wet, or explosive environments.

WARNING

Improper lifting can result in component or system damage or personal injury. Follow good shop practices and safety procedures.

Compressor Installation

Location

Locate the compressor in an indoor area that is clean, dry, well lighted, and well ventilated, with sufficient space for safe and proper inspection and maintenance. Ambient temperatures should not exceed 104 degrees F or fall below 30 degrees unless an electric motor rated for a higher temperature is used. Inspection and maintenance checks are required daily, therefore, ample space is required around the compressor.

The compressor must not be installed closer than fifteen inches from a wall or from another compressor to allow ample circulation or air across the compressor cylinders and head, and through the coolers if they are part of the system. Additional safety can be achieved by locating the pulley guard next to the wall.

Mounting

We recommend the use of rubber pads or isolators between the tank legs and the floor. If a shim is required to level the unit, place it between the pad and floor. If you bolt the unit to the floor, use the bolts as guide pins and do not tighten the bolts. The rubber pads are used to absorb machine vibration and cannot work effectively if bolted tightly.

14

pre-operation

Induction System

Do not locate the compressor where it could ingest or ignite toxic, explosive or corrosive vapors, ambient air temperatures exceeding 104 degrees F, water or extremely dirty air. Ingestion of any of the above noted atmospheres by the compressor could jeopardize the performance of the equipment and all personnel exposed to the total compressor.

Depending on the size of the compressor and the size and construction of the compressor room it may be necessary to locate the air pickup point outside the room. Destructive pulsations can be induced by reciprocating compressors that will damage walls and break windows. Pulsation can be minimized by adding a pulsation dampener on the inlet side of the compressor

CAUTION

Under no circumstances should a compressor be placed in an area that may be exposed to a toxic, volatile or corrosive atmosphere nor should toxic, volatile or corrosive agents be stored near the compressor.

Noise

Noise is a potential health hazard that must be considered. There are local and federal laws specifying maximum acceptable noise levels that must not be exceeded. Most of the noise from a reciprocating compressor originates from the air inlet point. Excessive noise can be greatly reduced by installing an intake noise silencer

Piping Fitup

Care must be taken to avoid assembling the piping in a strain with the compressor. It should line up without having to spring or twist into position. Adequate expansion loops or bends should be installed to prevent undue stresses at the compressor resulting from the changes between hot and cold conditions. Pipe support should be mounted independently of the compressor and anchored as necessary to limit vibration and prevent expansion strains.

DANGER

Safety valves are to protect system integrity in accordance with ASME

Codes and ANSI B19.3 safety standards. Failure to use safety valves of the proper capacity and pressure will cause severe personal injury or death.

NOTE:

Standard motors are open drip proof with a maximum ambient temperature rating of 104 degrees F. They are not suitable for salt laden, corrosive, dirty, wet, or explosive environments.

15

pre-operation

SAFETY VALVES

Safety valves are pressure relief valves and should be sized and purchased with a pressure setting to protect the weakest link in the system. Never change the pressure setting, only the safety valve manufacturer is qualified to make a change.

Safety valves are to be place ahead of any potential blockage point which included but is not limited to, shutoff valves, heat exchangers, pulsation dampeners, and discharge silencers.

DANGER

Failure to properly size, set & install pressure relief valves can be fatal.

CAUTION

ASME coded pressure vessels must not be modified, welded, repaired, reworded or subjected to operation conditions outside the nameplate ratings. Such actions will negate code status, affect insurance status and may cause severe personal injury, death, and property damage.

Pressure Vessels

Air receiver tanks and other pressure containing vessels such as, but not limited to, pulsation bottles, heat exchangers, moisture separators and traps, shall be in accordance with ASME Boiler and Pressure Vessel

Code Section VIII and ANSI B19.3 Safety Standards.

CAUTION

The installation, wiring, and all electrical controls must be in accordance with ANSI C1 National Electric Code, ANSE C2 National

Electric Safety Code, state and local codes. All electrical work should be performed by a qualified electrician. Failure to abide by the national, state and local codes may result in physical and/or property damage.

ELECTRICAL

Before installation, the electrical supply should be checked for adequate wire size and transformer capacity. During installation a suitable fused or circuit breaker disconnect switch should be provided. Where a 3 phase motor is used to drive a compressor, any unreasonable voltage unbalance between the legs must be eliminated and any low voltage corrected to prevent excessive current draw. Compressors must be equipped with a properly wired magnetic motor starter or a pressure switch rated to carry the full motor current load. The coil which engages and disengages the contact points in the motor starter is controlled by the pressure switch. Never attempt to bypass the pressure switch or adjust it past the factory set pressure range. Improper installation of the electrical system can cause the motor to overheat or a short circuit to occur.

16

pre-operation

CAUTION

Electric power always exists inside the pressure switch when there is electric power at the compressor package. Either a qualified electrician should make the pressure adjustments or the electric power supply should be disconnected and locked out before making any adjustment.

NEVER

exceed the designed pressure for the system or overload the motor beyond its service factor.

FAILURE TO HEED THESE WARNINGS MAY RESULT IN SERIOUS

INJURY OR DEATH, PROPERTY DAMAGE AND/OR MECHANICAL

FAILURE

PRESSURE SWITCH

The pressure switch is automatic in operation and is adjusted to start and stop the unit at the minimum and maximum desired air receiver pressure by cutting in and out the power to the electric motor. On some models, the pressure switch incorporates a release valve, which releases air between the check valve located in the receiver and discharge valve in the head of the compressor.

CAUTION

Relieve compressor and system air pressure by opening the appropriate manual relief valve prior to servicing. Failure to relieve all system pressure may result in severe personal injury, death & property damage.

Manual Relief and Shutoff Valves

Install a manual relief valve to vent the compressor to atmosphere. In those instances where the air receiver tank services a single compressor, the manual relief valve can be installed on the receiver. When a manual shut- off valve, and a safety relief valve installed upstream from the manual relief valve. These valves are to be designed and installed as to permit maintenance to be performed in a safe manner. Never substitute a check valve for a manual shut-off valve (block valve) if the purpose is to isolate the compressor from a system for servicing.

CAUTION

Guards must be fastened in place before starting the compressor and never removed before cutting off & locking out the main power supply.

Guards

All mechanical action or motion is hazardous in varying degrees and needs to be guarded. Guarding shall be in compliance with OSHA

Safety and Health Standards 29 CFR 1910.219 in OSHA manual 2206 and any state or local code.

17

pre-operation

CAUTION

Excessive speed of the compressor or driver can be lethal. Never operate the compressor beyond the manufacturer’s recommendation.

Bursting of the flywheel may be the greatest threat because the normal guard may not contain all the pieces. Crankshaft and connecting rod breakage is a possibility and compressor efficiency, valve life and bearing life will be abnormally reduced.

Drives

IIt is important that the compressor and motor pulleys are aligned properly and the V belt is correctly tensioned. Improper pulley alignment and belt tension are causes for motor overloading, excessive vibration, and premature belt and/or bearing failure.

CAUTION

Removal or painting over safety labels will result in uninformed conditions. This may result in personal injury or property damage. Warnings signs and labels shall be provided with enough light to read, conspicuously located and maintained for legibility. Do not remove any warning, caution, or instructional material attached!

Provisions should be made to have the instruction manual readily available to the operator and maintenance personnel. If for any reason any part of the manual becomes illegible or if the manual is lost, have it replaced immediately. The instruction manual should be periodically read to refresh one’s memory, it may prevent a serious or fatal accident.

18

wiring diagram

1 PHASE PISTON COMPRESSOR WIRING DIAGRAM

ALWAYS MAKE SURE POWER IS OFF BEFORE WIRING COMPRESSOR

1

Punch out hole in starter box for power inlet

2

Remove starter lid cover

Place 1 of the incoming power lines under the starter screw shown

3

Place ground wire behind washer for a proper ground

Place the other incoming power line under the starter screw shown

4

Once the steps are complete make sure all connections are tight and place starter cover back on the box, before turning the machine on.

19

installation

INSTALLATION DIAGRAM

WARNING

ALWAYS turn main power disconnect off, shut off power at power panel, and drain all air pressure from tank before servicing unit.

FEEDER LINE

AIR-FLOW

BYPASS BYPASS

1/4 TURN

SHUT-OFF

VALVE

DRAIN LEG

MOISTURE

TRAP WITH

DRAIN

AIR DRYER and/or

AF TERCOOLER

PUMP

RECEIVER

AIR-FLOW

LINE FILTER

NON-LUBRICATED

SUPPLY LINE

PRESSURE

SWITCH

MOTOR

DRIP-TEE with drain

AIR/WATER FILTER with PETCOCK

REGULATOR with gauge

QUICK COUPLER

MAGNETIC STARTER

RESET SWITCH

AIR HOSE TO

AIR TOOL

LUBRICATOR

CAUTION: NEVER use for paint spraying or similar applications.

1/4 TURN

SHUT-OFF

VALVE

FLEXIBLE

AIR-LINE

MAIN DISCONNECT

(ON/OFF)

MAGNETIC STARTER: Those not factory mounted on the compressor can be mounted on the wall. Mount as close to compressor as possible.

Sire the wires, protect them with conduit, and provide branch circuit protection per the National Electrical

Code.

POWER PANEL

CAUTION

For paint spraying or similar applications, a non-lubricated supply line must be used.

Shim tank so the pump is level within 1/8” per lineal foot MAXIMUM to distribute oil properly. Fasten to floor and NEVER force tank feet to floor without shims when tightening.

To remove moisture from air line, the main feeder line must run downhill to drain-leg at a rate of 1/4” tp 1” every 10 feet.

NOTICE

Recommended pipe and fittings: Black iron pipe no smaller than tank outlet size (NPT). For system over 100 feet in length, increase by one pipe size.

20

start up preparation

The following check list shall be adhered to before putting the compressor into operation.

FAILURE TO PERFORM THE CHECKS MAY RESULT IN SERIOUS

INJURY OR DEATH, PROPERTY DAMAGE AND/OR MECHANICAL

FAILURE. DISCONNECT AND LOCK OUT POWER SUPPLY.

1. Remove all loose pieces and tools around the compressor installation.

2. Check oil level in crankcase, add as necessary.

3. Check all pressure connections for tightness and leaks.

4. Check to make sure all safety relief valves are in place and operational.

5. Check to be sure all guards are in place and securely mounted.

6. Check fuses, circuit breakers and thermal overloads for proper size.

7. Open all manual shut-off valves (block valves) at and beyond the compressor discharge.

8. On all 3 phase units, after all of the above conditions have been satisfied, jog the starter switch button to check the rotational direction of the compressor. It should agree with the rotation arrow on the flywheel/pulley (counter clockwise, facing the shaft).

The following procedures should be followed for start-up of a new installation, or after changes have been made to an existing installation, and/or after service repair work has been performed.

1. Instructions in addition to those contained within this manual, supplied by manufacturers of supporting equipment, must also be read and understood before start-up.

2. Check oil level in crankcase.

3. Drain moisture from air receiver and traps.

4. Start compressor and watch for excessive vibration or strange noises.

If either is observed, stop the compressor immediately and correct.

5. Check air receiver or system pressure.

6. Manually activated safety relief valves by pulling ring or lever.

7. Check operation of controls.

8. After two days of operation check belt tension, air piping for leaks, and crankcase oil level.

21

maintenance

Stopping for Maintenance or Service

CAUTION

Never assume the compressor is ready for maintenance or service because it is stopped. The automatic stop start control may start the compressor at any time!

The following procedure should be followed to maximize safety when preparing for maintenance or service.

9. 1. Disconnect and lock-out the main power switch and hang a sign at the switch Informing of the unit being serviced.

10. 2. Close shut-off valve (block valve) between receiver and compressor, or receiver and Plant air system, to

11. prevent any back-up of air flow into the area to be serviced.

12. 3. Lock open manual vent valve and wait for the pressure in the area to be serviced (compressor, receiver,

13. etc.) to be completely relieved before starting service. The

Manual vent valve may be the drain valve in

14. the receiver. NEVER remove a plug to relieve the pressure.

15. 4. Open all manual drain valves within the area to be serviced.

16. 5. Wait for the unit to cool before starting service, (temperatures at 125 degrees F can burn the skin), some

17. surface temperatures exceed 400 degrees F when the compressor is working).

18. 6. Clean up all oils spills immediately to prevent slipping.

22

maintenance

Daily:

Drain the Receiver- condensation will accumulate in the tank daily, and should be drained at least once a day. This is done to reduce corrosions of the tank from the inside. Always wear protective eye wear when draining the tank.

Check Pump Oil Level- All units have a sight glass the oil level non running units should be no lower than ½ way on the sight glass if it is lower then you need to add oil until it is at least ½ way up the sight glass.

Check unit for any unusual noise or vibrations.

Weekly:

Clean air filter: this will ensure that no dirt or heavy particulate makes its way into the compressors valve assemblies.

Clean external parts of compressor and electric motor: this helps to ensure proper cooling and prevents rust and corrosion on critical parts. Check safety Valves: this is don’t to ensure they are not stuck in place and operating properly.

Elite Units

Check auto tank drain for proper function

Monthly:

Inspect complete air system for leaks: this is done to make sure the compressor does not get out of its duty cycle due to air leak in the system.

Inspect Oil for Contamination: this is done to ensure that harmful deposits do not build up in the oil. Check belt tension: this is done to ensure the belt do not fail pre-maturely, tighten them as needed to ensure they do not slip. If belts are loose, tighten per instructions on next page. Failure to tighten can cause pre-mature belt failure.

Every 3 months:

Change Oil: this is done to ensure that the compressor has proper oil level and that the oil in the machine does not deteriorate past factory specifications.

Inspect Valve assemblies: this is done to prevent premature failure and clean out and carbon that can form in older valves.

23

maintenance

*Elite Units.

Clean auto tank drain strainer and check for proper function.

Inspect pressure switch for proper function. Inspect check valve for proper function and remove any carbon accumulation to prevent premature failure. *Clean belt guard coolers (if equipped).

Storage of Compressor:

Before storing the compressor for a prolonged period of time, use a blow gun to clean all debris from compressor.

Shut OFF main power and turn OFF disconnect. Drain tank pressure, clean air filter, drain old oil and replace with new oil. Cover the unit to prevent dust and moisture from collecting on the unit.

24

F

E

D

C

parts breakdown

7.5HP PARTS BREAKDOWN

G

I

H

B

J

K

L

M

N

O

P

Q

A

25

parts breakdown

7.5HP PARTS BREAKDOWN

Description

A Automatic Tank Drain (Elite only)

B Check Valve

C Low Oil Monitor (Elite Only)

D Inner Cooler Safety Valve

E Compressor pump

F Compressor pump intake filter

G Discharge safety valve

Part Number

A

IAT-300559 (VERT.)

IAT-300569 (HORZ.)

B B. IAT-PSB20

C IAT-3353102-D

D IAT-031-0057

E IAT-BG5X20X32EU

F

IAT-ST25-70

G

IAT-CA1 (BASIC)

IAT-CA1E (ELITE)

I Belts

J Belt guard

K Electric motor pulley

L Motor pulley hub

M Electric motor

N Magnetic Starter

O Pressure switch

P Pressure gauge

Q Compressor tank

H IAT-019-0023 H1. IAT-14

I IAT-ST25-250

J IAT-B70

K IAT-LP2B775H

L

IAT-M3218T (3 PHASE)

IAT-131537.00 (1 PHASE)

M

IAT-CTD34X34

IAT-8911DPSG13V09 (230 VOLT 3 PHASE)

IAT-8911DPSG13V06 (480 3 PHASE

)

IAT-8911DSG32V09 (230 VOLT 1 PHASE)

N IAT-LF10-1H3

O IAT-PF1/4TEE

P IAT-ST25-200

Q IAT-WV1

26

CA1 and CA1U

parts breakdown

C

W

H

T

A

L

B

Performance

Motor

Pressure

HP

KW

PSI

Bar

Cylinders

Piston LP

Piston HP

Stroke inch mm inch mm inch mm

RPM

Displacement

Air Delivered

DCFM m3/m

ACFM m3/m

Efficiency %

Flywheel Dia.

inch mm

Groove Type

7.5

5.48

145

1.0

2

4.13

105

2.16

55

3.5

89

1100

29.9

.85

21.7

.62

72.5

17

430

1/B

8.5

6.10

175

1.21

2

4.13

105

2.16

55

3.5

89

1400

31

.88

21.7

.62

70

17

430

1/B

Dimensions

A inch mm

B

C inch mm inch mm

L

W

H inch mm inch mm inch mm

QTY 20’ container

QTY 40’ container

20

508

102

225

144

216

7.75

197

5.63

144

9.0

229

18

457

17

432

27

parts breakdown

CA1 and CA1U Parts Breakdown

28

5-7.5 hp Electric

8-15 hp Gas/Diesel

Two stage

Cast iron

Model CA1

parts breakdown

22 046-0167

23 059-0159

24 059-0167

25 046-0178

26 059-0163

27 046-0166

28 042-0055

29 055-0051

30 062-0004

31 058-0084

32 050-0030

33 019-0097

34 019-0023

35 046-0169

36 032-0031

37 056-0018

38 058-0086

39 146-0015

40 082-0014

41 136-0046

42 082-0012

43 083-0009

44 031-0057

Item CAS #

1 049-0027

2 053-0051

3 051-0053

4 045-0044

5 046-0168

6 059-0166

7 046-0179

8 051-0054

9 046-0227

10 077-0071

11 044-0037

12 059-0156

13 060-0061

14 047-0054

15 043-0098

16 062-0006

17 077-0069

18 054-0119

19 052-0027

20 048-0054

21 054-0179

Part Description

708000 Crankcase

709000 Crankshaft

050170 Bearing set front

701000 Front bearing carrier

070163 Gasket front cap

110117 Capscrew hex M8x20

060068 Seal - shaft

050172 Bearing set rear

070172 Gasket rear cap

728004 Centrifugal adapter plate

713002 Flywheel 16 7/8”

110104 Capscrew skt HD M6x20

1

1

4

070201 Gasket copper 14

705000 Rod connecting aluminum w/bushing 2

727000 Valve assembly - LP inlet 2

160004 Plug oil fill 3/4” NPT

020146 Cover crankcase side

200100 Snapring internal

729000 Wristpin - LP piston

720000 Piston LP 105mm

719064 Piston ring set LP

1

1

1

4

1

2

1

1

1

21

1

1

1

1

Qty

1

070162 Gasket cylinder to crankcase

110107 Capscrew hex 10 x 25

110111 Capscrew hex 12 x 70

070171 Gasket sight glass

110108 Capscrew hex 16 x 80

070161 Gasket cylinder head

710000 Head cylinder

723003 Spring unloader

160005 Plug oil drain 3/8” NPT

120058 Nut adjustment lock

711000 Cylinder

712000 Filter inlet assembly

712114 Filter element

070164 Gasket side cover

731004 Flanged sight glass

703007 Breather

120060 Nut hex - M16

080029 Key flywheel

706004 Aftercooler

722005 Valve safety 75 PSI

706000 Intercooler

706002 Elbow aftercooler

704000 Elbow valve and unloader

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

6

8

29

30

parts breakdown

45 046-0171

46 048-0081

47 051-0055

48 043-0100

49 046-0177

49 046-0176

49 046-0175

50 078-0011

51 054-0178

52 052-0028

53 060-0063

54 060-0063

55 043-0094

56 136-0007

57 043-0100

58 059-0158

59 077-0073

60 059-0154

61 058-0082

62 058-0083

63 060-0070

64 063-0006

65 059-0157

66 046-0172

67 046-0173

68 043-0095

69 046-0174

70 060-0069

71 064-0022

72 060-0062

73 077-0070

74 096-0009

75 107-0015

76 114-0012

77 046-0183

070166 Gasket unloader cover

720002 Piston - HP

050122 Insert rod - bearing half

727001 Valve assembly - HP inlet

090095 Shim .015 Brg Adjustment

090094 Shim .010 Brg Adjustment

090093 Shim .005 Brg Adjustment

728003 Plunge unloader

719088 Set HP piston rings

729006 Wristpin HP piston

130060 Lockwasher 10

070203 Gasket copper

727003 Spacer inlet valve

722007 Valve safety 200 PSI ASME

727002 Valve assy HP/LP discharge

110106 Capscrew SKT head 8 x 25

727136 Cover valve

110102 Capscrew SKT head M10 x 45

727134 Retainer inlet valve

737135 Retainer discharge valve

130058 Lockwasher 8

160002 Bushing reducing 3/4” x 1/4” FNPT

110105 Capscrew hex M8 x 85

070167 Gasket aftercooler

070169 Gasket intercooler

727004 Spacer discharge valve

070170 Gasket valve cover

130057 Lockwasher 16

160003 Elbow street 90 degrees 1/4”

070202 Copper valve seat gasket

701029 Cap rear

728000 Weight unloader

100100 Pin - hinge

728002 Holder unloader

070245 Gasket Set and/or and/or

5

1

2

3

1

2

2

1

1

1

4

2

2

2

2

3

4

4

3

4

3

1

2

1

4

6

1

1

1

1

1

A/R and/or

31

If you need assistance with the assembly or operation of your compressor please call

1-866-770-1711

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