Installation & Operation Maintenance Manual - …

1 2 Stage Oil Flooded Type Reciprocating Air Compressors Installation & Operation Maintenance Manual Models CRAC-D5H CRAC-D10H CRAC-D15H CRAC-D20H CRAC-D5V CRAC01-02 Rev. REL. Model Number: Serial Number: FILL IN COMPLETELY AT Installation Coaire Technologies Corporation 8740 Pioneer Blvd., Santa Fe Springs, CA 90670 TEL.(562)463-3935 (562)463-4928 website: e-mail: Printed in FORM CM-AD02 FEB. 2002 2 SAFETY AND PRECAUTIONS Before you install the air compressor you should take the time to carefully read all the instructions contained in this Manual .

2 Electricity and compressed air have the potential to cause severe personal injury or property damage. Before installing, wiring, starting, operating or making any adjustments, identify the components of the air compressor using this Manual as a guide. The operator should use common sense and good working practices while operating and maintaining this unit. Follow all procedures and piping accurately. Understand the starting and stopping sequences. Check the safety devices in accordance with the following procedures contained in this Manual . Maintenance should be done by qualified personnel, accurately with proper tools. Follow the Maintenance schedule as outlined in the Manual to ensure problem free Operation after start up.

3 SAFETY PRECAUTIONS BEFORE INSTALLING THE compressor OR PERFORMING ANY Maintenance READ THIS Manual CAREFULLY. WARNINGS COMPRESSED AIR AND ELECTRICITY ARE DANGEROUS. BEFORE DOING ANY WORK ON THIS UNIT, BE SURE THE ELECTRICAL SUPPLY HAS BEEN SHUT OFF(LOCKED AND TAGGED) AND THE ENTIRE compressor SYSTEM HAS BEEN VENTED OF ALL PRESSURE. 1. Do not remove the cover, loosen or remove any fittings, connections or devices when this unit is operating or in Operation . Hot liquid and air that are contained within this unit under pressure can cause severe injury or death. 2. The compressor has high and dangerous voltage in the motor, the starter and control box. All installations must be in accordance with recognized electrical procedure.

4 Before working on the electrical system, ensure that the system's power has been shut off by use of a Manual disconnect switch. A circuit breaker or fuse switch must be provided in the electrical supply line to be connected to the compressor . The preparation work for Installation of this unit must be done in suitable grounds, Maintenance clearance and lighting arrestors for all electrical components. 3. Do not operate the compressor at a higher discharge pressure than those specified on the compressor nameplate. If so an overload will occur. This condition will result in electric motor compressor shutdown. 4. Use only safety solvent for cleaning the compressor and auxiliary equipment. 5. Install a Manual shut off valve(isolation type) in the discharge line for service work.

5 6. Whenever pressure is released through the safety valve during Operation , it is due to excessive pressure in the system. The cause of excessive pressure should be checked and immediately corrected. 7. Before doing any mechanical work on the compressor , a) Shut down the unit. b) Electrically isolate the compressor by use of the Manual disconnect switch in the power line to the unit. Lock and tag the switch so that it cannot be operated. c) Release all compressed air within the system and isolate the unit from any other sources of air. 8. Allowing the unit lubricants to enter into the plant air system must be avoided at all times. Air line separators, which are properly selected and installed, can reduce any liquid carry-over close to zero.

6 9. Before starting the compressor , the Maintenance instructions should be thoroughly read and understood. 10. After Maintenance work is completed, covers must be securely closed. 11. For questions contact your distributor before proceeding. 31. Installation AND Operation INSTRUCTIONS Installation AND LOCATION 1. Installation : Install the compressor in a covered, well ventilated area, free of dust, toxic gases, humidity or any other kind of pollution. The compressor should be located no closer than 32 (800mm) from a wall or any other obstacle that could interfere with the air flow through the fan. This distance will also make Maintenance easer. Place the compressor on a level surface. Rotation of the flywheel must be in the direction of the arrow cast into flywheel.

7 The maximum ambient temperature recommended while working is 113 degree F(45 degree C). If necessary install an exhaust fan to guarantee proper ventilation and fresh air to dissipate heat. Before making the electrical connections, check oil level and top-up lubricating oil. For type of oil, see table at the end of these instructions. 2. Electrical connection: The country s valid electrical standards must be followed regarding Low Voltage Electrical Installation . Operation 1. Initial start procedure: Before turning on the compressor , check the crankcase oil level. It must be in the middle of the OIL LEVEL SIGHT. As to the type of oil to be used and the recommended change intervals, check at Lubrication and as to its volume, check the Technical Data Table.

8 2. Start: Turn on the electrical start key and let your compressor run for about 10(ten) minutes, what will keep the tank s internal pressure or compressed air around 20 psig. This will optimize a homogeneous lubrication of the parts. 2. Maintenance WARNING Turn off power before servicing and be sure the air tank is unloaded. These instructions are based on normal operating conditions. If the compressor is located in an exceedingly dust area, increase the frequency of all inspections. DAILY - Inspect the compressor visually. - Check oil level and add some if necessary, before turning the compressor on. - Drain moisture from the pipe system. - Be sure there is no excessive or unusual vibration or noise. WEEKLY - Remove and clean intake air filter; do not wash the filter element.

9 - Check the V-belt for tightness. Belt tension should be adjusted to allow approximately 3/8 to (9 to 13 mm) deflection with normal thumb pressure. - Clean cylinders externally, cylinder head, tubing, and tank. - Safety valve should be tested manually to see if it is working properly. MONTHLY - Check entire system for air leakage around fittings, etc. by using water and soap lather. - Check the pressure switch Operation . - Check for oil contamination and change it if necessary. 4 QUARTERLY - Change the air filter element every 300 working hours or quarterly whichever occurs first. - Fasten cap screws and nuts as required. - Change oil more frequently if compressor is located in very dirty environment.

10 - On the 7 , 10 and 15HP compressor pumps, the concentric valves must be inspected and cleaned between 800 and 1000 service hours. - Compressors Suction and Discharge Valves are subject to normal wear and are to be checked and even replaced after about 1000 service hours, accruing to Operation conditions. - WHILE RUNNING IN A PERIOD OF ABOUT 100 WORKING HOURS THE OIL LEVEL SHOULD BE CAREFULLY CHECKED. ANNUALLY - Test and calibrate the pressure switch, pressure gauge and safety valve according to their own technical standards. These parts must be removed from the tank and pump to be tested. - Inspect and clean the suction and discharge valve(s) plate(s) every 1000 (one thousand) working hours whichever occurs first, located between the cylinder and its cover and, if necessary, replace it(them) according to the Operation conditions.