Owners Manual - Compressed Air Systems
Contents
1. Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com 50 60 HP Electric Rotary Screw Compressor Rotary Screw Compressor Installation Sheet Date of Installation Compressor Model Installation Company Compressor Serial Installation Technician Compressor Voltage Site Electrical Phase Site Voltage Compressor Electrical breaker size Incoming Voltage at motor start up Incoming Voltage at max operating pressure Incoming power connected to Magnetic Starter Compressor Rotation Correct Motor amps at Max operating Pressure Compressor Max Operating Pressure Compressor tank drain functional Unit inspected for Air leaks Unit inspected for Oil leaks Unit location O Indoors O Outdoors Put N A if pressure not applicable to installed unit Unit tank fill time 0 125psi Unit tank fill time 0 150psi Unit tank fill time 0 175psi Unit Cooling Fan Pulls air through cooler Push s air through cooler Compressor Temperature switch reading Before install After install Unit unloads at max operating pressure and begins to release sump pressure Belt tension checked Vibration Pads properly installed Compressed Air Systems LLC 12. Introduction Congratulations on the purchase of your new air compressor The air compressor is precision built from the finest materials using the finest state of the art design and high tech engineering available today Quality performance and trouble free operation will assure you a dependable supply of air power on demand Check www compressed air systems com for most up to date manual and compressor service and technical information 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 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 If you have questions or need clarification about this manual or your compressor call 800 531 9656 Compressed Air Systems Simplicity It s What We Do Compressed Air Systems LLC 2626 Skyway Drive Grand Prairie TX 75052 1 800 531 9656 Fax 972 352 6364 www compressed air systems com 50 60 HP Electric Rotary Screw Compressor SAFETY PRECAUTIONS AND WARNINGS Listed are some but not all safety precautions that must be observed with compressors and compressed air systems Failure to follow any of these warnings may result in severe personal injury
3. Place a new element in the housing Replace the cover and tighten the nut Reset the filter indicator and the machine will be ready for operation If the compressor is turned off before being fully unloaded it can cause the unit to discharge oil into the air filter housing causing it to stop up or become contaminated Oil Filter The oil filter in the compressor system is a full flow replaceable canister type Initially the filter should be replaced after 50 hours of operation Then every 500 hours or sooner as indicated by a maintenance gauge This element protects the compressor bearings from grit and dirt ingression throughout the system A dirty filter will cause an oil flow restriction that can result in high oil temperature and a unit shutdown Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com 50 60 HP Electric Rotary Screw Compressor Hot oil under pressure will cause severe injury death or property damage Be sure the compressor is shutdown and pressure relieved before attempting to remove the oil filter separator oil fill or change the oil Oil Filter Replacement 1 Switch off the unit and disconnect the power to prevent accidental starting 2 Allow one minute after stopping for the system to settle and the pressure to be relieved 3 Using a strap wrench remove the old element and gasket 4 Clean the gasket surface with a clean rag Apply a light film of oil to th
4. 800 531 9656 Fax 972 352 6364 www compressed air systems com 50 60 HP Electric Rotary Screw Compressor NEC National Electric Code Reccomendations All data is based on what NEC code reccomends for the given motors at given voltages Single Phase Motors HP Voltage Reccomened Breaker Reccomended Wire size Reccomened Fusible Switch 2 115 50 10 30 2 230 25 14 20 3 115 70 8 50 3 230 35 12 25 5 230 60 10 40 7 5 230 80 8 60 10 230 90 6 60 Wire sized is based on 30ft or less run from main panel NEC reccomends copper wire type THW THW 2 THHW THHN THWN XHHW THWN 2 or ZHHW 2 Solid copper wire is not reccomened Before servicing the compressor or installing any part confirm the power is off to the compressor to prevent electrical shock If there are any questions or concerns contact factory at 1 800 531 9656 or 972 352 6304 Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com 50 60 HP Electric Rotary Screw Compressor NEC National Electric Code Reccomendations All data is based on what NEC code reccomends for the given motors at given voltages Single Phase Motors HP Voltage Reccomened Breaker Reccomended Wire size 2 208 15 14 2 230 15 14 2 480 15 14 3 208 20 14 3 230 20 14 3 480 15 14 5 208 35 12 5 230 30 14 5 480 15 14 7 5 208 50 10 7 5 230 45 10 7 5 480 20 14 10 208 60 8 10 230 60 10 10 480 25 14 15 208 90 6 15 230 80 6 15 480 40 10 20 208 100 4 20 230 90 4 20 480 6
5. Con sult the factory for any other areas of installation This air compressor is a rotating piece of equipment and should not be worked on or serviced while there is power to the unit You should always turn the power off to the compressor unit before performing and kind of service to the machine If you have any questions please contact the factory for clarifications before mak ing any changes to the delivered state of the compressor This rotary screw compressor is a constantly running air compressor It DOES NOT START AND STOP The compressor will only turn off for high temperature high pres sure over amperage of electrical systems timer limit reached The owner lesser or operator of this compressor is hear by notified and forewarned that any failure to ob serve these safety precautions in this manual may result in injury damage to the unit or death Compressed Air Systems expressly disclaims responsibility or liability for any injury or damage caused by failure to follow these specified precautions or by failure to exercise that ordinary caution and due care required in opera tion or handling the compressor even though not expressly specified here If you have any questions con tact the factory immediately at 1 800 531 9656 Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com 50 60 HP Electric Rotary Screw Compressor Descriptions Compressor The compressor assembly is a positive d
6. 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 eyewear when draining the tank Check Airend Oil Level remove oil fill cap and check for proper level Oil should be half way up the at the bottom or half way up the threads on the oil fill Check Oil Cooler check cooler for proper air flow to keep unit cool clean if necessary 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 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 en sure that harmful deposits do not build up in the oil Chec
7. not recoverable Pipe size should be large enough that the pressure drop does not exceed 10 between the air receiver and the point of use Arrange the air distribution piping to avoid the fol lowing types of strain Strains that are due to dead weight of the pipe itself Strains that are due to expansion or contraction of the piping due to temperature Strains due to internal pressure within the pipe Design inlet and discharge piping for smooth air flow Plan for future emergencies and establish an area of the loop to install a temporary compressor Consider a second receiver at the end of the line or opposite side of the loop Use loop piping systems if possible both around the plant and within the loop Consider a second receiver at the end of the line or opposite side of the loop Locate runaways from the main header close to the point of application Take air off the top of the header to prevent carry over of condensed moisture to tools Slope piping so that it drains toward a drop leg or moisture trap away from the compressor WARNING Reverse rotation will cause air end damage Exchange leads L1 and L2 if reverse rotation Operation Every Compressed Air Systems LLC compressor has been operated and thoroughly tested at the factory prior to shipment The test assures that the com pressor will deliver its rated capacity and is in good working order However there is the possibility that da
8. 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 pres sure range Improper installation of the electrical system can cause the motor to overheat or a short circuit to occur Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com 50 60 HP Electric Rotary Screw Compressor 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 be yond 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 locat ed in the receiver and discharge valve in the head of the compressor Relieve compressor and system air pressure by opening the appr
9. 0 10 25 208 110 3 25 230 100 4 25 480 70 8 30 208 125 2 30 230 110 3 30 480 80 8 40 208 175 1 ought 40 230 150 1 40 480 90 6 50 230 200 2 ought 50 480 100 4 60 230 225 3 ought 60 480 110 3 75 230 250 250 75 480 125 1 100 230 350 350 100 480 200 1 ought Wire sized is based on 30ft or less run from main panel NEC reccomends copper wire type THW THW 2 THHW THHN THWN XHHW THWN 2 or ZHHW 2 Solid copper wire is not reccomened Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com Compressed Air Systems LLC 2626 Skyway Drive Grand Prairie TX 75052 1 800 531 9656 Fax 972 352 6364 Simplicity It s What We Do
10. 2 6364 www compressed air systems com 50 60 HP Electric Rotary Screw Compressor Heat Load of Compressor MODEL TOTAL HEAT LOAD REQUIRED FLOW The compressor is an oil flooded unit The oil lubricates seals and cools the internals of the compressor In cooling it picks up the heat generated by the compression process and the mechanical friction from the bearings So the oil must be cooled to within 60 degrees Fahrenheit of the ambient temperature The after cooler has been designed for a minimum approach of 15 degrees F Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com 50 60 HP Electric Rotary Screw Compressor Controls The RS series of units is equipped with a normally closed inlet valve This means that when the unit is start ed the inlet valve remains closed while the unit builds up pressure by means of a bypass line After startup the inlet valve is controlled by a simple on off action of a pressure switch working with a solenoid valve For instrumentation the unit has a discharge temperature gauge air pressure gauge Installation General The standard RS series was designed for indoor applications For outdoor applications consult the factory for modifications Failure to obtain factory approval will void the warranty Foundation Your Compressed Air Systems LLC rotary screw compressor does not require a special foundation However it is necessary that the floor be level and the f
11. Viscosity 1000F cST 46 Viscosity 2100F cST 7 93 Viscosity Index 100 or more Pour Point F 20 or less Flash Point F 400 or more Fire Point F 450 or more Rust Test ASTM FG 665 A amp B Pass Oxidation Test ASTM0 D943 1500 Emulsion Test ASTM D1401 10 Min Foam Test ASTM Pass Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com Oil Analysis Oil analysis is an excellent tool to add to your compressor maintenance program At regular in tervals you submit lubricant samples to a qualified laboratory From this you receive a detailed report showing the lubricant condition wear metals and contaminants Changes in this information over time provides the basis for predictive compres sor maintenance Saving you unplanned machine downtime and unnecessary oil changes Oil Cap Oil Drain Line 50 60 HP Electric Rotary Screw Compressor Checking Oil Level and Adding Compressor Oil 1 Switch off the unit and disconnect the power to prevent accidental restarting 2 Allow one minute after stopping the compres sor for settling and the pressure to relieve 3 Remove any dirt from around the fill cap then remove the fill cap 4 Inspect the o ring in the cap for damage and cleanliness Replace if necessary 5 The oil should be between the bottom of the neck and the o ring groove 6 Replace the cap securely Never put the cap on without tightening immediately Changing Compressor Lubrica
12. ammable 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 Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com 50 60 HP Electric Rotary Screw Compressor WARNING Compressed Air from this machine is not suitable for breathing and will cause death or server personal injury CONSULT AN AIR FILTRATION SPECIALIST FOR PROPER TREATMENT FOR BREATHING AIR SYSTEMS This Compressed Air Systems industrial rotary screw compressor is an electric motor driven single stage he lical rotary screw compressor It is sold as a complete package mounted on a steel base This unit can come with options of being tank mounted Enclosure mounted or Enclosure tank mounted The package includes the compressor air end electric motor motor controls air intake system cooling system SMART contact capacity control system air oil separator and instrumentation Installation requires only electric power and a service line Compressed Air Systems design for the compressors is for indoor installation
13. arranted to be free of defects work manship and material for a period of one year Trans portation charges are the responsibility of the purchaser This warranty extends to the original purchaser of the compressor only There are NO express warranties except other than those contained in this limited warranty statement Covered in the one year period of the warranty are de fective parts due to defects in the original part only The compressor warranty is void in the cases of abuse lack of proper service in correct application in correct installation and neglect Standard compressor warranty covers defective parts and labor for the one year period Industrial Electric stationary compressors may be repaired on site as long as the compressor is not located further than 50 miles from the service center The pur chaser is responsible for any additional travel expense past 50 miles from the service center Gas Diesel engine driven compressors must be repaired at the closest service center to the compressor The pur chaser is responsible for any travel expense if they do not wish to bring the compressor to the service center ALL SPECIALTY COMPRESSOR WARRANTY SERVICE MUST BE PERFORMED AT THE CLOS EST SERVICE CENTER TO THE COMPRESSOR Specialty compressor any compressor package with op tions other than those that apply to the standard model number in the catalog Ue AN T IMITED Y WARRANTY The compressor ai
14. ary Screw Compressor 50 60 HP Rotary Screw Breakdown p af Description Part Number A Compressor base plate A IAT A85921 B Electric motor B _IAT G150040 60 SOHP IAT G150042 60HP C Cooler fan motor C IAT R 15438FAN D Compressor magnetic starter D IAT CTK 100 3 125A IAT CRC 125 100 240 E Emergency shut off switch E IAT XB4BT42 E On Off Switch F IAT ZB4 BD2 IAT ZB4 B2101 G Pressure gauge G IAT PSL20 H Temperature switch gauge H IAT 20TE2504 l Air Oil Cooler I IAT R 15438 J Air discharge hose J 1AT MX20 20FJ 60 K Belt guard K IAT BG40X24X6 i Airend intake filter L IAT R 12017 M Airend separator M IAT R 12101 N Sump safety valve N IAT SF50 200 O Airend control solenoid O IAT 20TE2504 P Airend oil lines P NK160 CONTROL SOLENOID Q Airend oil filter Q IAT R 1161 R Airend R IAT NK160 S Belt S IAT R3VX710 5 ik Motor pulley T _IAT 5 3V8 00 Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com 50 60 HP Electric Rotary Screw Compressor Stopping for Maintenance or Service 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 1 Disconnect and lock out the main power switch and hang a sign at the switch Informing of the unit bein
15. ay 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 It is important that the compressor and motor pulleys are aligned properly and the V belt is correctly ten sioned Improper pulley alignment and belt tension are causes for motor overloading excessive vibration and premature belt and or bearing failure 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 be comes 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 seri ous or fatal accident Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com 50 60 HP Electric Rotary Screw Compressor Normal Operation Start Up Drain off condensate from the sump and check the oil level Refill as necessary Check for any oil leaks Correct as necessary On water cooled units turn on the water Pre
16. d air systems com 50 60 HP Electric Rotary Screw Compressor 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 The installation wiring and all electrical controls must be in ac cordance 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 capac ity 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
17. d tightly INDUCTION SYSTEM Do not locate the compressor where it could ingest or ignite toxic explosive or corrosive vapors ambient air temperatures exceeding 110 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 compressed air system 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 For compressor tank to have full manufacturer warranty The tank must be installed properly on manufacturer supplied vibration pads per compressor manual Failure to do so can void compressor tank warranty and cause tank cracks or failures On Electric compressors all electrical connections must be wired and installed per NEC National Electric Code See the back of the manual for NEC code and all local applicable codes for full electric component warranty Failure to do so can void compressor electrical warranty Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com 50 60 HP Electric Rotary Screw Compressor Installation Continued Cooling Air Discharge The cooling air discharge must be restriction free Any louvers or ducting must not exceed a quarter of an inch static head Above this a booster fan will be required C
18. 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 com pressor 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 shut off 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 person al injury death and property damage Never use plastic pipe rubber hose or soldered joints in any part of the compressed air system Fail ure to ensure system compatibility with compressor piping is dangerously unsound Never use a fl
19. e It has been designed to maintain a minimum sump pressure of 85 psig If the pressure is allowed to get too low the oil car ryover rate will increase and the separator could be damaged To Check the Belts 1 Switch off the unit and disconnect the power to prevent accidental restarting 2 Allow one minute after stopping the compres sor for settling and the pressure to relieve Remove the belt guard 4 Inspect for any fraying or cracking of the belts If there is any replace the belts 5 Check the tension It should be about 1 64 per inch of span between the sheaves 6 To Change the Belts 7 Switch off the unit and disconnect the power to prevent accidental restarting 8 Allow one minute after stopping the compres sor for settling and the pressure to relieve 9 Remove the belt guard 10 Loosen the motor hold down bolts and the puller bolt and slide the motor toward the air end 11 Remove the belt 12 Replace with new belt 13 Set the initial by sliding the motor back to its original position using the puller bolt and tighten the motor hold down bolts Fan Check the fan for cracking loose rivets and bent or loose blades Make sure that it is securely mounted and tighten the mounting screws if loose Replace a damaged fan immediately Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com 50 60 HP Electric Rotary Screw Compressor 50 60 HP Rotary Screw Wiri
20. e compressor and drain all the moisture from the bottom of the tank WEEKLY CHECK THE OIL If the oil appears contaminated by moisture or dirt change immediately CHECK THE BELTS Turn off the compressor and inspect the belts for damage excessive wear and correct tension Replace if necessary TEST THE SAFETY VALVE Pull the ring on the safety valve Air should escape and then reset In the event the compressor ran over pressure the safety valve would reduce the tank pressure to a safe level Never run the unit without this safety valve or attempt to adjust it GENERAL INSPECTION Check the overall operation of the unit Tighten any loosen bolts inspect for air leaks and inspect for any unusual noises or vibrations INSPECT COMPRESSOR INTAKE NEVER use gasoline thinners or other flammable solutions to clean valves or related parts Check to be sure the valves are seated against the sealing surface around each port If the valves are not sealing compressor capacity will be severely reduced Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com cO WARR CERTIFICATE oF L Rotary Screw Compressors All component parts on this compressor installed by the manufacturer are w
21. e new gasket 6 Hand tighten the new element until the new gasket is seated in the gasket groove 7 Continue tightening by hand an additional 1 2 to 34 turn 8 Reconnect power and restart the machine to check for leaks Air Oil Separator The air oil separator should be changed every 2000 hours or when there is excessive oil vapor in the discharge air Separator Element Replacement 1 Switch off the unit and disconnect the power to prevent accidental starting 2 Allow one minute after stopping for the system to settle and the pressure to be relieved 3 Using a strap wrench remove the old element and gasket 4 Clean the gasket surface with a clean rag Apply a light film of oil to the new gasket 6 Hand tighten the new element until the new gasket is seated in the gasket groove 7 Continue tightening by hand and additional v2 to turn 8 Reconnect power and restart the machine to check for leaks Lubricant Your compressor has been filled and tested with CAS RS8000 a high quality compressor lubricant It is a PAO with the advantage of extended service life high temperature operation easy start up when cold reduced sludge and lacquer buildup and is completely compatible with all seals gaskets and other compressor materials Lubricant Specifications If you choose not to use CAS RS8000 for optimum life and warranty service your lubricant must meet the following specification Grade ISO 46
22. e of the spreader bar and chains The spreader bar should be greater than the width of the compressor and padding is placed on the edges to prevent chain damage Consult the installation drawing at the end of this section for the center of gravity Storage In some cases it may be necessary to store the compressor for extended periods of several months before placing the unit in operation When this is required do the following Cover and seal all machine openings to prevent the entrance of water and dirt Cover all openings in open drip proof motors to prevent the entrance of rodents If the storage conditions are below freezing drain the after cooler traps water cooled heat exchanges and attendant piping We do not recommend outside storage Cover with a waterproof tarpaulin that can easily be removed for in storage maintenance While in storage every two or three months rotate the compressor and motor by hand to prevent flat spots on the bearings that will lead to premature failure At the end of the storage period follow the uncrating and start up procedures If the unit has been stored for more than eighteen months you should contact Compressed Air Systems before restarting the compressor Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com 50 60 HP Electric Rotary Screw Compressor Guidelines for Compressed Air Systems The air pressure drop between the compressor and the point of use is
23. g compressor originates from the air inlet point Excessive noise can be greatly reduced by installing an intake noise silencer 50 60 HP Electric Rotary Screw Compressor PIPING FITUP Care must be taken to avoid assembling the pip ing ina 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 compres sor 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 Safety valves are to protect system integrity in accor dance with ASME Codes and ANSI B19 3 safety stan dards Failure to use safety valves of the proper capacity and pressure will cause severe personal injury or death 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 Failure to properly size set and install pressure relief valves can be fatal Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compresse
24. g serviced 2 Close shut off valve block or ball valve between compressor and main supply air tank or air lines This is the valve installed to isolate the air compressor for maintenance or service The valve is placed in the system during installation for the purpose of servicing the compressor and to not allow shop or work ing air back into the compressor during service See note for turning compressor off while under a load or compressing air 3 Lock open manual vent valve and wait for the pressure in the area to be serviced compressor receiver etc to be completely relieved before starting service The Manual vent valve may be the drain valve in the receiver NEVER remove a plug to relieve the pressure 4 Open all manual drain valves within the area to be serviced Wait for the unit to cool before starting service temperatures at 125 degrees F can burn the skin some surface temperatures exceed 400 degrees F when the compressor is working 6 Clean up all oils spills immediately to prevent slipping Note If the compressor is turned off before being fully unloaded it can cause the unit to discharge oil into the air filter housing and could cause the air filter element to become contaminated This may happen when using the emergency shut off button and or the on off switch Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com 50 60 HP Electric Rotary Screw Compressor Compressor
25. give good service life The housing is equipped with a bypass to insure that there is oil flow on startup The restriction cre ated at the filter will have a direct effect on the operating temperature of the compressor So you must be sure to maintain it Air Oil Separator This unit utilizes a spin on air oil separator to make maintenance much more convenient than the element in vessel design This does not diminish its operating efficiency In fact the separation of the element from the pre separation tank enhances the performance The purpose of the separator is to remove aerosols The vapor pressure of the oil the operating temperature of the unit operating pressure of the unit and the operating cycle will affect its performance Minimum Pressure Valve As the compressed air leaves the compressor it goes through a minimum pressure valve This is set to maintain at least 85 psig 586kPa in the sump when the compressor is running This is to insure that there is pressure to force the oil out of the sump and through the oil system so that sufficient oil is injected into the compressor It is also necessary to provide good air oil separation The valve acts as a check valve to prevent back flow into the compressor from the plant system Cooling The compressor has an air cooled and after cooler as standard The following are the heat loads and cool ing airflow rates that must be accommodated Compressed Air Systems LLC 1 800 531 9656 Fax 972 35
26. he compressor Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com 50 60 HP Electric Rotary Screw Compressor 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 de grees 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 The use of the factory supplied rubber vibration isolation pads or other factory supplied vibration isolation mounting equipment is required for tank warranty from the original tank manufacturer The compressor should never be left on original shipping material for installation 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 bolte
27. hermal by pass leaking Faulty temperature switch Restricted air intake filter Inlet valve partially closed Air pressure set to high Insufficient oil flow Solenoid valve malfunction Solutions Check sump for proper oil level Check all lines for cracks Replace separator _ Adda timer to the system Lower ambient temperature around compressor Check unit for proper oil level Replace oil filter Clean oil cooler Check thermal bypass for proper operation Check temperature switch for proper operation Change separator Clean oil cooler Check pressure switch Check incoming voltage Check air end and motor for proper function Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com Adjusting Belt Tension 50 60 HP Electric Rotary Screw Compressor Proper belt tension and pulley alignment must be maintained for maximum drive efficiency and for maxi mum belt life The correct tensions exists if a deflection of 2 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 ex ists 4 Retighten the motor mounting belts Check to e
28. isplacement oil flood lubricated helical rotary screw type unit employing a single stage of compression The components include housing or stator two rotors or screws bearings and bearing supports In operation two helical grooved rotors mesh to compress air Inlet air entering the compressor becomes trapped between the lobes of the rotors As the rotors turn this trapped volume of air is reduced in volume or compressed and is pushed to the discharge end of the compressor This process delivers smooth flowing air at full pressure to the receiver During the compression cycle oil is injected into the compressor for the purposes of lubricating cooling and sealing Compressed air laden with oil leaves the compressor through a discharge port designed to provide optimum performance within the desired pressure range AIR OIL System The air oil system is almost completely contained within the compressor housing Within or directly at tached to the housing are the air filter oil filter and the air oil separator element Air Filter The air filter is a high efficiency ring style located on top of the inlet valve of the compressor It will provide nearly constant efficiency of filtration at all load conditions The element has a high dirt holding capacity for along life It is specially treated to be insensitive to heat cold water and oil Oil Filter The oil filter is a 10 micron spin on style It is sized to maintain system cleanliness and to
29. k belt tension this is done to ensure the belt do not fail pre maturely tighten them as needed to ensure they do not slip Every 3 months every 500hrs Change oil filter 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 Yearly every 2000 hrs Change oil change with only CAS RS 8000 Clean Oil Cooler this is done to ensure adequate cooling for the compressor air end Storage of Compressor before storing the com pressor 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 Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com 50 60 HP Electric Rotary Screw Compressor Maintenance Procedures Review SAFETY PROCEDURES Adherence to safe working procedures are important to Service personnel at the time of servicing and to those who may at a later date be around the compressor and the system it serves Routine maintenance insures trouble free operation and protects your investment All warranties are void if maintenance is neglected DAILY CHECK THE OIL LEVEL Oil should be half up or at the bottom of the threads on the fill spout DRAIN THE TANK Turn off the power to th
30. mage may occur in shipping For this reason it is recommended that the unit be carefully inspected for evidence of damage or malfunction before in stallation and during the first hours of operation Preparation for Initial Start Up Pull the main disconnect switch and ensure that there is no power to the unit 2 Review the installation instructions to see that everything is complete 3 Inspect for visible signs of damage that could have happened during shipment or installation 4 Make certain protective coverings required for shipment or painting are removed from the compressor 5 Fill the sump to the proper oil level Do not over fill if it is drain to proper level Tighten the fill cap securely 6 Reconnect the main disconnect 7 Refer to control section and check out panel components 8 Jog the motor press start and stop in quick succession and check for the correct direction of rotation Reverse LS1 and L2 connections if incorrect 9 Start the unit and run for several minutes then shutdown Check the oil level and add if neces sary to compensate for filling the system 10 Begin normal operation Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com NOISE Noise is a potential health hazard that must be considered There are local and federal laws specify ing maximum acceptable noise levels that must not be exceeded Most of the noise from a reciprocat in
31. ng ALWAYS MAKE SURE POWER IS OFF BEFORE WIRING COMPRESSOR Punch out hole in starter box for power inlet Place power Place power Place power line 1 under line2under line 3 under Remove wiring set screw set screw set screw contacts lid Place ground wire Check all fitting to make sure that they are tight and place cover under washer back on box before checking for correct rotation If rotation is incorrect swap line 1 and line 3 to reverse rotation Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com 50 60 HP Electric Rotary Screw Compressor Troubleshooting Chart NOTE TROUBLESHOOTING PROBLEMS MAY HAVE SIMILAR CAUSES AND SOLUTIONS You should always contact an authorized service center before attempting to fix or repair your air compressor ALWAYS MAKE SURE ELECTRICAL POWER IS OFF BEFORE REMOVING ANY INSPECTION COVERS OR PLATES Problem Possible causes Compressor Will Not Start No power Fuse blown in control circuit Motor overloads not tripped or nor reset Loose incoming or power connection wires Low voltage to unit Faulty temperature switch Temperature switch tripped High pressure switch tripped Unit starts them immediately stalls 1 Pressure switch out of adjustment Temperature switch activated Loose electrical supply wires Motor overloads tripped Low voltage Incorrect compressor rotation Low Discharge Pressure 5 Plugged separator 6 Plugged oil c
32. nsure that the tension remain correct after tightening 6 Re install the belt guard All moving parts must be guarded SPAM _ 17 DEFLECTION Sal 1 lb FORCE 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 Se Oy ee US Loosen the motor mounting bolts Remove the belt guard Loosen the set screw on the motor pulley Align the motor pulley with the compressor flywheel Re tighten the motor pulley set screws Adjust the proper belt tension Re tighten the motor mounting bolts Re install the belt guard Compressed Air Systems LLC 1 800 531 9656 Pde Le Wia Guit al KALI oe et Laie 2 ie A oT _ _ aa oT ae l i a a Pye ee FLYWHEEL eect EA PULLEY Fax 972 352 6364 www compressed air systems com 50 60 HP Electric Rot
33. nt Regular maintenance of the oil filter and the air filter will help prolong the life of the lubricant 1 Switch off the unit and disconnect the power to prevent accidental restarting 2 Allow one minute after stopping the compres sor for settling and the pressure to relieve 3 Remove any dirt from around the fill cap and then remove the fill cap If the lubricant appears dirty or has a foul smell it should be replaced 4 Drain the lubricant from the bottom of the air oil receiver Oil will drain more quickly and com pletely if is warm from operation 5 Close all drains and replace with fresh CAS RS8000 to the proper level 6 Replace the fill cap and run the unit 7 Switch off the unit and disconnect the power to prevent accidental restarting 8 Allow one minute after stopping the compres sor for settling and the pressure to relieve 9 Remove the fill cap to see if more lubricant should be added and to insure that there are no leaks Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com 50 60 HP Electric Rotary Screw Compressor Oil Return Sight Glass During loaded operation there should be a visible flow in the sight glass If there are no droplets vis ible then the orifice in this line needs to be checked for plugging Oil not returned ends up in the plant air system Minimum Pressure Valve Then minimum pressure valve is a non adjustable spring biased check valv
34. onsult a local HVAC contractor for recommendations prior to installation Excessive restriction to the cooling air discharge will cause the unit to operate at elevated temperatures that could result in high temperature shutdowns Ducting of cooling air to the unit is not generally recommended Electrical A qualified electrician in compliance with standards and local codes should do all electrical wiring Be sure to investigate the local requirements before installing the compressor The power supply should be adequate and free of parasitic loads that will cause an under voltage condition during the operation of the compressor otherwise there will be nuisance electrical shutdowns Always connect the compressor to its power source through a fusible disconnect and insure the unit is properly grounded Unpacking and Handling Occasionally damage will occur during shipping Be sure to carefully inspect the unit before unpacking After unpacking before you sign the receiver if anything damage has occurred document it with the trucking firm immediately Contact your Compressed Air Systems LLC representative for assistance To move your compressor to its installation site we recommend that you leave the unit on its shipping skid as long as possible The forks should be extended the width of the compressor and padding should be placed between the compressor and the truck boom If it is necessary to lift the compressor with a crane we recommend the us
35. ooler 7 Improper pressure switch setting 8 Low incoming power voltage 9 Electrical phase imbalance 10 Possible airend or motor failure Solutions Check power supply for adequate voltage Check fuses Make sure all power wires are tight at connections Check voltage supply to make sure it is high enough to run the electric system Check temperature switch for proper operation Check system pressure Check compressor power supply for adequate breaker and wire size Inspect check valve for proper l operation Tighten belts Check compressor for proper oil level Tighten compressor belts to recommended specifications Check compressor voltage supply Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com Troubleshooting Chart continued 50 60 HP Electric Rotary Screw Compressor NOTE TROUBLESHOOTING PROBLEMS MAY HAVE SIMILAR CAUSES AND SOLUTIONS You should always contact an authorized service center before attempting to fix or repair your air compressor ALWAYS MAKE SURE ELECTRICAL POWER IS OFF BEFORE REMOVING ANY INSPECTION COVERS OR PLATES Compressor does not build up to pressure Compressor will not load to compress air CFM Flow air flow seems low Possible causes Air leaks in shop Inlet valve malfunction Compressor belts slipping Air demand exceeds compressor output Pressure switch set to low Solenoid valve malf
36. opriate manual relief valve prior to servicing Failure to relieve all system pressure may result in severe personal injury death and 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 Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com 50 60 HP Electric Rotary Screw Compressor Guards must be fastened in place before starting the compressor and never removed before cutting off and 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 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 m
37. rame adequately supported Consult the SPECIFICATIONS section of this manual for the compressor weight and dimensions We do recommend that the compressor be bolted to the floor We reccommend the compressor be mounted on vibration reduction pads Room The room should be of adequate size to provide full access to the machine for routine maintenance It should have ventilation to keep the room as cool as possible Operating at elevated temperatures will cause nuisance overload and temperature shutdowns Room temperature should not exceed 110 F Air Intake To achieve the longest filter and lubricant life and the least maintenance you need to supply the compres sor with the cleanest air possible It must not contain any flammable or toxic gases These will be concen trated by the compressor and could result in personal injury or death and property damage Inlet containing reactive gases will cause the failure of the lubricant and compressor Insure an air supply that is well clear of any reactive gas source If it is necessary to take air from a remote source the piping should be at least the diameter of the air filter inlet For distance over twenty feet the diameter needs to be enlarged to reduce the restriction This pipe should also be corrosion resistant and free from scale and dirt The inlet should also be covered to prevent rain and small animals from entering Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compre
38. rend is covered by a 2 year war ranty to be free from defects from manufacturing This does not cover abuse neglect improper service mis application or improper installation An oil sample must be submitted with any airend warranty claim for verification The purchaser must use only Compressed Air Systems synthetic rotary screw oil in the compres sor for the duration of the warranty Airend the rotors and bearings of the compressor BEFORE WARRANTY SERVICE IS PERFORMED CONTACT MANUFACTURER TECH SUPPORT FOR FASTEST SOLUTION Warranty labor for the first year is only covered for work performed Monday Friday 8am 5pm excluding all major US holidays Optional 5 year airend warranty To be applicable for this option the purchaser must purchase a Full year Rotary Screw compressor service kit at the same time as the compressor and a subsequent kit every year afterwards for a total of 5 kits during the compressor warranty period The purchaser must use only Compressed Air Systems synthetic rotary screw oil in the compressor for the duration of the warranty The warranty covers the airend of the compressor for a period of 5 years parts replacement only from any defect due to manufacturing The warranty does not cover wear and tear abuse neglect improper service mis application or improper application BEFORE WARRANTY SERVICE IS PERFORMED CONTACT MANUFACTURER TECH SUPPORT FOR FASTEST SOLUTION
39. ss the start button Stopping 1 Make sure the compressor is fully unloaded before step 2 Unload the compressor by closing the service valve this is a ball or block valve placed in the system during compressor installation between the compressor and operating airlines for service and maintenance reasons 2 After the unit has exhausted its contained pressure this takes about 30 seconds push the stop button Emergency Stopping Push the stop button Pull the main disconnect if possible Air Filter The air filter is the primary protection of the compressor from harmful dirt being ingested into the oil sys tem It needs to be looked at periodically for clogging or holes The period for theses inspections is depen dent on the environment the machine is in For optimum life it is recommended that an air filter restriction indicator be used Service simply based on hours is not recommended Element Inspection and Replacement Switch off the unit and disconnect the power to prevent accidental starting Allow one minute after stopping for the system to settle and the pressure to be relieved Loosen the nut that secures the cover and remove the cover Remove the element Place a bright light inside the element to inspect for damage or leak holes Inspect all gaskets and gasket contact surfaces of the housing Correct any faulty conditions immediately Clean the housing with a damp cloth Do not attempt to blow out dirt with compressed air
40. ssed air systems com 50 60 HP Electric Rotary Screw Compressor 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 Insure that adequate lifting equipment is available for moving the machinery Read the compressor nameplate to be sure the compressor is the model and size ordered Read the motor nameplate to be sure the motor is compatible with your electrical conditions Volts Phase Hertz IMPORTANT If voltage supplied to the compressor is below 208 volts the unit need a 200 Volt drive motor Motors rated at 208 230 460 Volt should not be used below 208 volts 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 Improper lifting can result in component or system damage or personal injury Follow good shop practices and safety procedures Under no circumstances should a compressor be placed in an area that may be exposed to a flammable toxic volatile or corrosive atmosphere nor should flammable toxic volatile or corrosive agents be stored near t
41. unction Compressor rotors damaged Pressure switch set to high Inlet valve malfunction Faulty solenoid Restricted air intake filter Inlet valve partially closed Air pressure set to high Insufficient oil flow Solenoid valve malfunction Solutions Find and fix shop air leaks l Check inlet valve for proper function Check air usage requirements on machinery and check for shop air leaks Check pressure switch for proper setting Check solenoid for proper function Check pressure switch for proper setting Check inlet valve for proper function Check solenoid for proper function Compressed Air Systems LLC 1 800 531 9656 Fax 972 352 6364 www compressed air systems com 50 60 HP Electric Rotary Screw Compressor Troubleshooting Chart continued NOTE TROUBLESHOOTING PROBLEMS MAY HAVE SIMILAR CAUSES AND SOLUTIONS You should always contact an authorized service center before attempting to fix or repair your air compressor ALWAYS MAKE SURE ELECTRICAL POWER IS OFF BEFORE REMOVING ANY INSPECTION COVERS OR PLATES Problem Excessive oil consumption High temperature shutdown High amperage draw Possible causes 1 Over filled sump Broken oil line Plugged oil return line Damaged or dirty separator Excessive unloaded compressor run time High ambient air temperature around compressor Low oil level in compressor Plugged oil filter Restricted air flow over cooler T
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