Curtis OL 512, OL 812, OL 524 User Manual
OIL-LESS COMPRESSOR
OPERATION AND INSTRUCTION
MANUAL
OIL-LESS
COMPRESSOR MODELS
OL 512 SINGLE STAGE 3 H.P.
OL 512 SINGLE STAGE 5 H.P.
OL 524 TWO STAGE 5 H.P.
CAP-215
APRIL, 2003
REV. D
OL 812 SINGLE STAGE 7 1/2 H.P.
OL 812 SINGLE STAGE 10 H.P.
CAUTION
Before installing this compressor, read and understand
the safety precautions contained within this manual
1905 Kienlen Avenue, St. Louis, Missouri 63133,
PHONE(314)383-1300 ----- FAX (314)381-1439
CURTIS - TOLEDO, INC.
TABLE OF CONTENTS
1.
1.1.
1.2.
1.2.1
1.2.2.
1.3.
1.4.
2.
2.1.
2.2.
3.
3.1.
3.1.1.
3.1.2.
3.2.
3.2.1.
3.2.2.
4.
4.1.
4.2.
4.3.
4.4.
4.5.
4.6.
5.
5.1.
5.2.
6.
6.1.
7.
7.1.
Safety................................................................................................................................................... i
Safety Precautions............................................................................................................................... i,ii
Receiving Delivery............................................................................................................................... iii
Freight Damage.................................................................................................................................... iii
Installation............................................................................................................................................ iii
Electrical Supply Requirements............................................................................................................ iv
Start-up Procedures.............................................................................................................................. iv
Air Inlet Systems.................................................................................................................................. iv,v
Compressed Air Discharge System....................................................................................................... v
System Components............................................................................................................................ vi, vii
Stopping for Maintenance..................................................................................................................... vii
Pulley Alignment and Belt Tensioning................................................................................................... viii
GENERAL................................................................................................................................................. 1
PURPOSE AND SHORT DESCRIPTION.................................................................................................. 1
DESIGN AND MODE OF OPERATION..................................................................................................... 8
DESIGN.................................................................................................................................................... 8
MODE OF OPERATION (1ST STAGE)…....................................................................................................... 8
MODE OF OPERATION (2ND STAGE)……………………………………………………………………………. 9
TECHNICAL DATA................................................................................................................................... 10,11
ELECTRICAL DATA.................................................................................................................................. 12
INTAKE FILTER........................................................................................................................................ 13
DESCRIPTION.......................................................................................................................................... 13
INTAKE FILTER MAINTENANCE............................................................................................................. 13
INTERMEDIATE AND FINAL SEPARATOR.............................................................................................. 14
FUNCTIONAL DESCRIPTION OF INTERMEDIATE SEPARATOR (2-STAGE COMPRESSSOR ONLY). 14
CONDENSATE DRAIN............................................................................................................................. 14
INTERMEDIATE SEPARATOR MAINTENANCE...................................................................................... 14
FUNCTIONAL DESCRIPTION OF FINAL SEPARATOR........................................................................... 15
CONDENSATE DRAIN............................................................................................................................. 15
FINAL SEPARATOR MAINTENANCE....................................................................................................... 15
VALVES.................................................................................................................................................... 16
FUNCTIONAL DESCRIPTION OF 1st STAGE......................................................................................... 16
FUNCTIONAL DESCRIPTION OF 2nd STAGE......................................................................................... 16
INITIAL OPERATIONAL CHECK OF VALVES............................................................................................ 17
GENERAL INSTRUCTIONS FOR CHANGING THE VALVES................................................................... 17
CHANGING THE VALVES OF THE 1st STAGE........................................................................................ 18
CHANGING 2nd STAGE VALVES AND VALVES OF 1st STAGE PRESSURE VALVE............................. 18
AUTOMATIC CONDENSATE DRAIN........................................................................................................ 19
DESCRIPTION.......................................................................................................................................... 19
FUNCTION............................................................................................................................................... 19
COOLING SYSTEM.................................................................................................................................. 20
GENERAL................................................................................................................................................. 21
SAFETY REGULATIONS.......................................................................................................................... 21
GENERAL................................................................................................................................................. 21
Instruction Manual Oil-Less Compressors
Instruction Manual Oil-Less Compressors
TABLE OF CONTENTS (CONT’D)
8. INSTALLATION OPERATION................................................................................................................. 23
8.1. INSTALLATION OF THE COMPRESSOR............................................................................................... 23
8.1.1. NATURAL VENTILATION........................................................................................................................ 24
8.1.2. FORCED VENTILATION......................................................................................................................... 25
8.2. ELECTRICAL INSTALLATION................................................................................................................ 26
8.3. OPERATION............................................................................................................................................. 26
8.3.1. PREPARATION FOR OPERATION........................................................................................................... 26
8.3.2. STARTING THE COMPRESSOR.............................................................................................................. 26
8.4. SHUT-DOWN PROCEDURE..................................................................................................................... 26
9. MAINTENANCE SCHEDULE.................................................................................................................... 27
9.1. MAINTENANCE INTERVALS.................................................................................................................... 27
9.2. MAINTENANCE RECORD........................................................................................................................ 27
10. STORAGE, PRESERVATION................................................................................................................... 28
10.1. GENERAL................................................................................................................................................ 28
10.2. PREPARATION......................................................................................................................................... 28
10.3. PREVENTIVE MAINTENANCE DURING STORAGE................................................................................ 28
10.4. REACTIVATING THE COMPRESSOR...................................................................................................... 28
11. REPAIR INSTRUCTIONS......................................................................................................................... 29
11.1. GENERAL................................................................................................................................................. 29
12. TROUBLE-SHOOTING............................................................................................................................. 30
13. TABLES.................................................................................................................................................... 31
13.1. TIGHTENING TORQUE VALUES............................................................................................................. 31
13.2. TORQUE SEQUENCE.............................................................................................................................. 31
13.3. MAINTENANCE SCHEDULE.................................................................................................................... 32,33
TABLE OF FIGURES
Fig. 1 OL 512, REAR VIEW.................................................................................................................................. 2
Fig. 2 OL 512, LEFT SIDE VIEW.......................................................................................................................... 3
Fig. 3 OL 524, REAR VIEW.................................................................................................................................. 4
Fig. 4 OL 524, LEFT SIDE VIEW.......................................................................................................................... 5
Fig. 5 OL 812, REAR VIEW.................................................................................................................................. 6
Fig. 6 OL 812, LEFT SIDE VIEW.......................................................................................................................... 7
Fig. 7 POSITION OF STAGES AT 2-STAGE COMPRESSOR.............................................................................. 8
Fig. 8 FUNCTION OF NON-RETURN VALVE....................................................................................................... 9
Fig. 9 OPERATION CHARACTERISTIC............................................................................................................... 12
Fig. 10 INTAKE FILTER.......................................................................................................................................... 13
Fig. 11 INTERMEDIATE-/FINAL SEPARATOR....................................................................................................... 14
Fig. 12 VALVE OPERATION 1st STAGE................................................................................................................ 16
Fig. 13 VALVE OPERATION 2nd STAGE............................................................................................................... 16
Fig. 14 VALVE HEAD 1st STAGE........................................................................................................................... 18
Fig. 15 VALVE HEAD 2nd STAGE.......................................................................................................................... 18
Fig. 16 INSTALLATION WITH NATURAL VENTILATION....................................................................................... 24
Fig. 17 INSTALLATION WITH FORCED VENTILATION........................................................................................ 25
Fig. 18 TORQUE SEQUENCE................................................................................................................................ 31
Instruction Manual Oil-Less Compressors
Fig. 19 2 STAGE COMPRESSOR DIMENSIONS (070308-1015)........................................................................... 33
Fig. 20 1 STAGE COMPRESSOR DIMENSIONS (070307-1015)........................................................................... 35
Fig. 21 1 STAGE COMPRESSOR DIMENSIONS (077734).................................................................................... 36
Fig. 22
Fig. 23
D51.2, DIAGRAM & SPARE PARTS LIST OF CYLINDER, PISTON & INTAKE VALVE …………………..
D52.4, DIAGRAM & SPARE PARTS LIST OF CYLINDER, PISTON & INTAKE VALVE …………………..
37
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Instruction Manual Oil-Less Compressors
INTRODUCTION
THIS MANUAL CONTAINS OPERATION AND MAINTENANCE
SCHEDULES FOR THE OIL-LESS COMPRESSOR MODELS:
OL 512
OL 524
OL 812
ALL INSTRUCTIONS SHOULD BE OBSERVED AND CARRIED
OUT IN THE ORDER LAID DOWN TO PREVENT DAMAGE AND
PREMATURE WEAR TO THE EQUIPMENT AND THE COMPRESSORS
SERVED BY IT.
WHILE EVERY EFFORT IS MADE TO ENSURE THE ACCURACY
OF THE PARTICULARS CONTAINED IN THIS MANUAL, THE
MANUFACTURING COMPANY WILL NOT, UNDER ANY
CIRCUMSTANCES, BE HELD LIABLE FOR ANY INACCURACIES
OR THE CONSEQUENCES THEREOF.
INTRODUCTION
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Instruction Manual Oil-Less Compressors
SAFETY
At Curtis-Toledo, Inc. safety is a primary concern. Beginning with the design stage, safety is built into every "Curtis Compressor". It is
the purpose of this manual to pass along the "safety first" concept to you by providing safety precautions throughout its pages.
“WARNING!”, "CAUTION!", and "DANGER!" are displayed in large bold capital letters to call attention to areas of vital concern. They
represent different degrees of hazard seriousness, as stated below. The safety precaution is spelled out in bold upper and lower case
letters.
DANGER!
Immediate hazards which result in severe
personal injury or death.
WARNING!
Hazards or unsafe practices that could result In
personal injury or death.
CAUTION!
Hazards or unsafe practices which could result
In minor personal injury, product or property
damage.
Each section of the operating instruction manual, as well as any instructions supplied by manufacturers of supporting equipment, should
be read and understood prior to starting the compressor. If there are any questions regarding any part of the instructions, please call
your local Curtis-Toledo Distributor, or the Curtis-Toledo factory before creating a potentially hazardous situation. Life, limb, or
equipment could be saved with a simple phone call, (314) 383-1300.
SAFETY PRECAUTIONS
The owner, lessor or operator of any compressor unit
manufactured by Curtis-Toledo, Inc. is hereby warned that
failure to observe all safety precautions may result in serious
injury to personnel and/or damage to property.
Curtis-Toledo, Inc. neither states as fact, nor in any way implies
that this list of safety precautions is an all inclusive list, the
observance of which will prevent all damage to property or
injury to personnel.
Every reasonable effort has been taken to ensure that
complete and correct instructions have been included in this
manual. However, possible updates and changes may have
occurred since this printing. Curtis-Toledo, Inc. reserves the
right to change specifications, without incurring any obligation
for equipment previously or subsequently sold.
Compressors and/or units are assembled to comply with the
customer's purchase order and in compliance with CurtisToledo, Inc. specifications; alteration must not be made to the
compressor or unit without Curtis-Toledo written approval.
Provisions must be made by the owner, lessor or operator to
have a pressure reducing regulator valve with air gauge in
each service line to supply safe and proper air pressure for the
various use and applications.
When supplying air pressure direct from air compressor to a
tire chuck for public or operator use to inflate tires and so forth,
a safety precaution sign in large bold print must be posted in
plain view at tire chuck location, "DANGER, AIR PRESSURE
FROM THIS CHUCK MAY EXCEED SAFE PRESSURE FOR
TIRES AND RELATED EQUIPMENT". A hand operated
gauge must be used to measure and not exceed safe inflated
pressure.
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Instruction Manual Oil-Less Compressors
DANGER!
Air used for breathing or food processing must meet
O.S.H.A. 29 C.F.R. 1910.134 or F.D.A. 21 C.F.R. 178.350
regulations. Failure to do so will cause severe injury or
death.
WARNING!
Compressors are precision high speed mechanical
equipment requiring caution in operation to minimize
hazard to property and personnel. There are many
obvious safety rules that must be observed in the
operation of this type of equipment. Listed below (in no
particular order) are some additional safety precautions
that must be observed.
• Transfer of toxic, dangerous, flammable or explosive
substances using Curtis-Toledo products Is at the
User's risk.
• Turn off and lockout/tagout the main power
disconnect switch before attempting to work or
perform any maintenance.
• Do not attempt to service any part of this unit while It
Is running.
• Relieve the system of all pressure before attempting
to service any part of the unit.
• Do not operate the unit with any of its safety guards,
shields, or screens removed.
• Do not remove or paint over any DANGER!,
WARNING!, CAUTION!, or Instructional materials
attached to the compressor. Lack of Information
regarding hazardous conditions can cause property
damage or personal Injury.
• Periodically check all pressure relief valves for proper
operation.
• Do not change the pressure setting of the pressure
relief valve, restrict the function of the pressure relief
valve, or replace the pressure relief valve with a plug.
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• Do not install a shutoff valve in the compressor
discharge line without first Installing a pressure relief
valve of proper size and design between the shutoff
valve and the compressor.
• Do not use plastic pipe, rubber hose, or lead-tin
soldered joints In any part of the compressed air
system.
• Alterations must not be made to this compressor
without Curtis-Toledo's approval.
• Be sure that all tools, shipping and Installation debris
have been removed from the compressor and
Installation site prior to starting the compressor.
• Do not operate the compressor in excess of the
A.S.M.E. pressure vessel rating for the receiver or the
service rating of the compressor, whichever is lower.
• Make a general overall inspection of the unit daily and
correct any unsafe situations.
• "Horseplay" of any kind involving compressed air is
dangerous and can cause very serious injury to the
participants.
• Do not touch the compressor during or after
operation-it may be HOT
• 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 the manual is lost,
have it replaced immediately. The instruction manual
should be read periodically to refresh one's memory.
It may prevent a serious or fatal accident.
• It is recommended sufficient clean-up equipment be
provided and proper maintenance be performed to
ensure clean, dry, oil-free air for instrumentation.
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Instruction Manual Oil-Less Compressors
RECEIVING DELIVERY
Immediately upon receipt of compressor equipment and prior to
completely uncrating, the following steps should be taken:
1. Inspect compressor equipment for damage that may have
occurred during shipment. If any damage is found, demand an
inspection from the carrier. Ask the carrier how to file a claim
for shipping damages. (Refer to FREIGHT DAMAGE for
complete details.) Shipping damage is not covered by CurtisToledo's compressor warranty.
CAUTION!
Improper lifting can result in component or system damage or
personal Injury. Follow good shop practices and safety
procedures when moving the unit.
2. Ensure that adequate lifting equipment is available for
moving the compressor equipment.
FREIGHT DAMAGE
The transportation industry has adopted a modification with
regard to the handling of obvious and concealed damage
claims. Therefore, it is extremely important that you examine
every carton and crate as soon as you receive it. If there is any
obvious damage to the shipping container, have the delivering
carrier sign the freight bill, noting the apparent damage, and
request a damage report.
INSTALLATION
Curtis-Toledo's air compressors should be installed in an area
that is clean, well lighted, and adequately ventilated.
Inspection and maintenance checks are required daily.
Therefore, sufficient space needs to be provided around the
compressor for safe and proper inspection, cleaning, and
maintenance.
The compressor must not be installed closer than 15 inches to
a wall, or 24 inches to another compressor. This allows ample
circulation of air across the compressor cylinders, heads and
cooler (if so equipped). If at all possible, the pulley drive
system (i.e. motor pulley, compressor pulley, belts and guard)
should be located next to a wall to minimize any danger
created by the drive system while the compressor is operating.
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3. Read the compressor nameplate to verify the model
and size ordered.
4. Read the motor nameplate to be sure the motor is
compatible with your electrical conditions (volts, phase, hertz).
5. Read the pressure relief valve nameplate to be sure it does
not exceed the working pressure of the compressor or any
other component in the system.
6. Read and understand the safety precautions contained
within this manual. The successful and efficient operation of
compressor equipment depends largely upon the amount of
care taken to install and maintain the equipment. CurtisToledo
strongly recommends that any or all person(s) in charge of
installing, maintaining, or servicing one of our compressors
read and understand entire contents of this manual and the
respective compressor installation and operating instruction
manual in order to perform such duties safely and efficiently.
If concealed damage is discovered at a later date, the carrier
must be notified within 15 days of initial receipt of freight.
Contact the carrier as soon as possible, giving them an
opportunity to inspect the shipment at the premises where the
delivery was made. Do not move the damaged freight from the
premises where the original delivery was made. Retain all
containers and packing for inspection by the carrier.
Due to standard motor limitations, it is recommended that the
compressor be operated in temperatures under 104° F. In cold
climates, the compressor should be installed in a heated
building.
CAUTION!
Do not operate this compressor in ambient temperatures lower
than -15° F. A crankcase heater is recommended for a
compressor that is to operate In temperatures under 32° F.
WARNING!
Under no circumstances should a compressor be used in an area
that may be exposed to toxic, volatile, or corrosive atmosphere,
Do not store toxic, volatile, or corrosive agents near the
compressor
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Instruction Manual Oil-Less Compressors
ELECTRICAL SUPPLY REQUIREMENTS
The electrical installation of this unit should be performed by a
qualified electrician with knowledge of the National Electrical
Code (N.E.C.), O.S.H.A. code and/or any local or state codes
having precedence.
Before installation, the electrical supply should be checked for
adequate wire size and transformer capacity. A suitable circuit
breaker or fused disconnect switch should be provided. When
a 3-phase motor is used to drive a compressor, any
unreasonable voltage imbalance between the legs must be
eliminated and any low voltage corrected to prevent excessive
current draw. Note: This unit must be grounded.
The installation, electric motor, wiring, and all electrical controls
must be in accordance with NFPA 70-1 84 National Electric
Code, National Electric Safety Code, state and local codes.
Failure to abide by the national,
state and local codes may
START-UP PROCEDURES
If the compressor is equipped with an automatic start-stop
control (with pressure switch unloading), it is automatically
unloaded upon starting, and will automatically load after
attaining running speed. If the compressor is equipped with a
constant speed control (pilot valve unloading), it is necessary to
manually unload the compressor, if there is pressure in the
discharge line, in order to achieve an unloaded start. The
compressor must be manually loaded after the compressor has
attained full running speed; thereafter, it functions automatically
to maintain operation pressure until the unit is shut off.
AIR INLET SYSTEM
AIR INTAKE
A clean, cool and dry air supply is essential to the satisfactory
operation of your Curtis-Toledo air compressor. The standard
air filter that the compressor is equipped with when leaving the
factory is of sufficient size and design to meet normal
conditions, when properly serviced, in accordance with the
maintenance section of this manual.
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result in physical harm and/or property damage. Do not bypass motor overcurrent protection.
DANGER!
High voltage may cause personal injury or death, per
O.S.H.A. regulations 1910.137, disconnect and
lockout/tagout all electrical Dower supplies before
opening the electrical enclosure or servicing.
WARNING!
Never assume a compressor is safe to work on just
because it Is not operating. It could restart at any time.
Follow all safety precautions outlined. NEMA electrical
enclosures and components must be appropriate to the
area Installed.
Close the disconnect switch and start the compressor.
Observe the direction of rotation, which should be
counterclockwise when viewed from the flywheel side of the
compressor on all models. For single-phase units, the
direction of rotation is determined by the motor nameplate
instructions, and is adjusted at the factory. For three-phase
units, if the rotation is incorrect, stop the unit and interchange
any two of the three wires to the motor at the disconnect
switch. This will reverse the direction of rotation of the motor
and compressor .
If, however. the compressor is to be installed in a location
where considerable dust, dirt and other
contaminants are prevalent, consult your Curtis Toledo
Distributor for advice and optional filters. It is the User's
responsibility to provide adequate filtration for those conditions.
Oil bath filters are not to be used. Warranty will be void if a
failure is determined to be caused by inadequate filtration.
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Instruction Manual Oil-Less Compressors
REMOTE INLET FILTERS
Depending on the size of the compressor and the size and
construction of the room in which the unit operates, the air inlet
may have to be located outside of the room. If it is necessary
to remotely install the air filter, make the inlet piping as short
and direct as possible. Remotely installed air filters can lead to
vibrations in the inlet piping. These vibrations can be
minimized by adding a pulsation dampener in the inlet piping
between the remote inlet filter(s) and the compressor.
If the Intake is piped to outside atmosphere, a hooded filter
should be installed to prevent water or snow from being
ingested into the compressor.
COMPRESSED AIR DISCHARGE SYSTEM
CAP-215
All inlet piping should be at least the same size (or larger) in
diameter as the inlet connection to the compressor. For every
10 feet of inlet piping or every 900 bend, increase the inlet
piping diameter by one pipe size. The inlet piping must be
thoroughly clean inside. Remove all weld slag, rust or dirt.
Galvanized pipe with threaded or flanged fittings is preferred.
CAUTION!
Never locate the compressor air inlet system where toxic,
volatile or corrosive vapors, air temperatures exceeding
104°F., water, or extremely dirty air could be ingested. These
types of atmospheres could adversely affect the performance
of the compressor system.
Typical Drop Leg & Component Location
The discharge piping should be of the same diameter as the
compressor discharge connection, or sized so that the
pressure drop at any point in the system does not exceed 10%
of the air receiver pressure. Install auxiliary air receivers near
heavy loads or at the far end of a Iong system. This will insure
sufficient pressure if the use is intermittent, or sudden large
demands are placed on the system.
Discharge piping should slope to a drop leg (refer to TYPICAL
DROP LEG & COMPONENT LOCATION) or moisture trap to
provide a collection point where moisture can be easily
removed. All service line outlets should be installed above the
moisture traps to prevent moisture from entering the tool or
device using the air. Manual
shutoff valves, protected by
pressure relief valves, should be installed at all service
line outlets to eliminate leakage while the tools are not in use.
As with any piping, all parts of the discharge piping should fit so
as not to create any stress between the piping and
components.
WARNING!
Never join pipes or fittings with lead-tin soldering. Welded or
threaded steel pipes and cast iron fittings, designed for the
pressures and temperatures, are recommended.
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Instruction Manual Oil-Less Compressors
SYSTEM COMPONENTS
Efficiency and safety are the primary concerns when selecting
components for compressed air systems. Products of inferior
quality can not only hinder performance of the unit, but could
cause system failures that result in bodily harm or even death.
Select only top quality components for your system. Call your
local Curtis-Toledo Distributor for quality parts and professional
advise.
DRIVE PULLEYS
Drive pulleys must be properly aligned and drive belt tension
set to specifications (refer to PULLEY ALIGNMENT & BELT
TENSION). Improper pulley alignment and belt tension can
cause motor overloading, excessive vibration, and premature
belt and/or bearing failure.
DANGER!
Excessive compressor RPM's (speed) could cause a pulley to
burst. In an Instant, the pulley could separate Into fragments
capable of penetrating the belt guard and causing bodily harm
or death. Do not operate the compressor above the
recommended RPM.
GUARDS
All mechanical action or motion is hazardous in varying
degrees and needs to be guarded. Guards should be designed
to achieve the required degree of protection and still allow full
air flow from the compressor sheave across the unit. Guards
shall be in compliance with OSHA safety and health standards
29 CFR 1910.219 in OSHA manual 2206 and any state or local
codes.
WARNING!
Guards must be fastened in place before starting the
compressor and never removed before cutting off and locking
out the main power supply.
CHECK VALVES
Check valves are designed to prevent back-flow of air pressure
in the compressed air system (air flows freely in one direction
only). The check valve must be properly sized for air flow and
temperature. Do not rely upon a check valve to isolate a
compressor from a pressurized tank or compressed air delivery
system during maintenance procedures!
MANUAL SHUTOFF VALVES
Manual shutoff valves block the flow of air pressure in either
direction. This type of valve can be used to isolate a
compressor from pressurized system, provided the system is
equipped with a pressure relief valve capable of being
manually released. The pressure relief valve should be
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installed between the manual shutoff valve and the
compressor.
PRESSURE RELIEF VALVES
Pressure relief valves aid in preventing system failures by
relieving system pressure when compressed air reaches a
determined level. They are available in various pressure
settings to accommodate a range of applications. A check
valve and pressure relief valve are required in all compressor
discharge lines. Pressure relief valves are preset by the
manufacturer and under no circumstances should the setting
be changed by anyone other than the manufacturer.
DANGER!
Pressure relief valves are designed to protect compressed air
systems in accordance with ASME B19 safety standards.
Failure to provide properly sized pressure relief valves may
cause property damage, severe personal injury or even death.
PRESSURE SWITCH
The pressure switch detects the demand for compressed air
and allows the motor to start. When the demand is satisfied,
the unit stops. Pressure switches provided by Curtis-Toledo
are pre-set at the factory and usually do not require
adjustment. However, it adjustment is required (by qualified
electrician) refer to instructions inside cover of switch housing,
WARNING!
The maximum discharge pressure for the various models
are established by the Curtis performance data. Do not
set the pressure switch or regulators to exceed the design
limit.
WARNING!
Electric power always exists Inside the pressure switch
whenever the compressor package is connected to a
power supply. Be careful not to touch any electrical leads
when setting the pressure switch.
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Instruction Manual Oil-Less Compressors
SYSTEM COMPONENTS (CONTINUED)
WARNING!
Never exceed the designed pressure for the system or
overload the motor beyond its Maximum Amp Draw.
• Full Load Amps x Service Factor = Max-imum Amp
Draw.
• Full Load Amps (FLA) & Service Factor can normally
be found on motor nameplate.
STOPPING FOR MAINTENANCE
The following procedures should be followed when stopping the
compressor for maintenance or service.
WARNING!
Never assume a compressor Is safe to work on just because It
Is not operating. It could start at any time.
1. Per O.S.H.A. regulation 1910.147: The Control of
Hazardous Energy Source (Lockout/Tagout), disconnect and
lockout the main power source. Display a sign in clear view at
the main power switch that the compressor is being serviced.
2. Isolate the compressor from the compressed air supply by
closing a manual shutoff valveupstream and downstream from
WARNING!
Never assume a compressor is safe to work on just
because it is not operating. It may be in the automatic
stand-by mode and may restart any time. Follow all safety
precautions outlined in STOPPING FOR MAINTENANCE.
the compressor. Display a sign in clear view at the shutoff
valve stating that the compressor is being serviced.
3. Lock open a pressure relief valve within the pressurized
system to allow the system to be completely de-pressurized.
NEVER remove a plug to relieve the pressure!
4. Open all manual drain valves within the area to be serviced.
5. Wait for the unit to cool before starting to service.
(Temperatures of 125°F can burn skin. Some surface
temperatures exceed 350°F when the compressor is
operating.)
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Instruction Manual Oil-Less Compressors
PULLEY ALIGNMENT & BELT TENSION
Setting Belt Tension
Improper pulley alignment and belt tension are causes for
motor overloading, excessive vibration and premature belt
and/or bearing failure. To prevent this from happening, check
the pulley alignment and belt tension on a regular basis.
At this time, inspect both the motor and compressor pulleys for
oil, grease, nicks or burrs. Clean or replace pulleys if
necessary. Make sure the pulleys are securely fastened. Align
the compressor pulley with the motor or engine pulley. Drive
belt grooves of both pulleys should be in line with each-other.
Belt tension should be measured and adjusted to provide
smooth operation. Step-by-step procedures are provided here
to correctly measure and set the drive belt tension:
1. Measure the span length of the drive. (Refer to
MAINTENANCE SCHEDULE.) See instructions in the
respective model manual.
2. Determine the amount of deflection (in inches) required to
measure deflection force (in pounds) by multiplying the span
length x 1/64 (i.e. 32" span length x 1/64 = 1/2" of deflection
required to measure deflection force).
3. Lay a straightedge across the top outer surface of a drive
belt from pulley to pulley.
4. At the center of the span, perpendicular to the belt, apply
pressure to the outer surface of the belt with a belt tension
gauge. Force the belt to the predetermined deflection (refer to
Step 2). Record the reading on the belt tension gauge and
compare to the chart. The deflection force reading should be
within the minimum and maximum values shown. Adjust
belt(s) accordingly. A new belt (or new belt set) should be
initially tensioned 1/3 greater than the maximum valve.
5. Recheck the tension of the new belts several times in the
first 50 hours of operation and adjust if necessary. Thereafter,
check belt tension on a regular basis.
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Instruction Manual Oil-Less Compressors
1. GENERAL
1.1. PURPOSE AND SHORT DESCRIPTION
The 1-stage oil-less compressor model OL 512, and OL 812, as well as the 2-stage oil-less compressor model
OL 524, are used to compress air in the pressure ranges up to 110 psi (1-stage compressor models) to 220 psi
(2-stage compressor models)
All compressors operate with three cylinders and are air-cooled (Fig. 1 to Fig. 4). The cylinders are set in
Y- configuration, allowing for a small compact design.
A special feature of these models are that they operate without any oil in the crankcase. This is the result of the
following construction characteristics:
- friction treated surface of the cylinders
- PTFE (polytetrafluoride ethylene) compound coated piston guiding surfaces
- piston rings made exclusively from special PTFE compound.
These compressor models need very little maintenance because of their oil-less operation, therefore an oil
change or a special condensate disposal is not necessary.
The outstanding characteristic of this compressor model is their long life which is the result of
- low friction and low wear of cylinders and pistons
- the corrosion resistant material used for all parts coming into contact with the air stream
- optimal cooling of all moving parts (air intake through crankcase).
The oil-less compressor standard equipment:
- After-cooler for each cylinder and each manifold
- Air filter maintenance indicator
1
CAP-215
Instruction Manual Oil-Less Compressors
Fig. 1: OL 512 (single stage), rear view
1 Cooler Manifold
2 After-cooler
3 Cylinder 1st stage
4 Valve head 1st stage
5 Fan/flywheel
6 Final Separator (optional)
7 Intake filter
8 Condensate drain valve (optional with #6)
2
CAP-215
Instruction Manual Oil-Less Compressors
Fig. 2: OL 512 (single stage), left side view
1 Cooler Manifold
2 After-cooler
3 Final Separator (optional)
4 Intake filter
5 Valve Head
6 Fan/flywheel
3
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