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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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