General Air L36575, LT36575, L425100, LT425100, L620100 Installation, Operation And Maintenance Manual

Call 1-800-345-8207

or visit our web site for our complete product listing

www.GeneralAirProducts.com

Base and Tank Mounted Lubricated Compressors

version 1.1

01-2011

Installation, Operation and

Maintenance Manual

L & LT Series

Table of Contents

1-800-345-8207

Section 1 - Safety & Warnings

1.1 Safety Guidelines

1.2 General Safety Information

1.3 Safety Notes

Section 2 - Receiving

Section 3 - Installation Location

Section 4 - Mounting

Section 5 - Lubrication

Section 6 - Piping

6.1 - Piping Instructions

6.2 - L Series Base Mounted Lubricated Compressor Installation Drawing

6.3 - LT Series Tank Mounted Lubricated Compressor Installation Drawing

Section 7 - Wiring

7.1 - Wiring Instructions

7.2 - Lubricated Compressor Single & 3 Phase Wiring Drawing (IEC Version)

7.3 - Lubricated Compressor Single & 3 Phase Wiring Drawing (NEMA Version)

Section 8 - Maintenance Instructions

Section 9 - Troubleshooting Guide

Section 10 - Warranty Policy

IMPORTANT: ALL INFORMATION SUBJECT TO CHANGE WITHOUT NOTICE.

Consult factory for the most up to date version of this manual - 1-800-345-8207.

If there are any questions regarding installation, operation, or maintenance of this compressor, please
call 800-345-8207

1-800-345-8207

Section 1 - Safety & Warnings

1.1 Safety Guidelines

This manual contains information that is very important to know and understand. This information is provided for SAFETY
and to PREVENT EQUIPMENT PROBLEMS. To help recognize this information, observe the following symbols.

Danger indicates an imminently hazardous situation which, if not avoided, WILL
result in death or serious injury.

Warning indicates a potentially hazardous situation which, if not avoided COULD
result in death or serious injury.

Caution indicates a potentially hazardous situation which, if not avoided, MAY result
in minor or moderate injury.

Notice indicates important information, that if not followed may cause damage to
equipment.

1.2 General Safety Information

1. Read all manuals included with this product carefully. Be thoroughly familiar with the controls and the
proper use of the equipment

2. Follow all local electrical and safety codes as well as National Electrical Codes (NEC), Occupational
Safety and Health Act (OSHA), and National Fire Protection Association (NFPA)

3. Only persons familiar with these rules of safe operation should be allowed to use the equipment.

4. Keep visitors away and NEVER allow children in the work area.

5. Wear safety glasses and use hearing protection when operating the unit.

6. Do not stand on or use the unit as a handhold.

7. Periodic inspection and test of this equipment is required. Consult your installer and local codes to
meet all requirements.

8. Check all fasteners at frequent intervals for proper tightness.

DANGER

WARNING

CAUTION

NOTICE

DANGER

1.3 Safety Notes

- This compressor is not equipped and should NOT be used “as is” to supply breathing
quality air.

- Motors, electrical equipment and controls can cause electrical arcs that will ignite
flammable gas or vapor. Never operate or repair in or near flammable gas or vapor.

Never store flammable liquids or gasses near the compressor.

- These compressors are suitable for pumping only atmospheric air. As defined in
Compressed Gas Association Pamphlet G-7, page 3, atmospheric air is a mixture of
elements and compounds where nitrogen and oxygen comprise more than 99% with all
other trace gasses comprising less than 1%. Do not use this compressor in

contaminated environments or for pumping mixtures other than atmospheric air.

- Compressed air contains liquid water and is saturated with water vapor, which can
freeze when surrounding temperatures are lower than 32

o

F (0oC). Component selection

to minimize the effects of water vapor must be considered.

WARNING

WARNING

WARNING

1-800-345-8207

Section 3 - Installation Location

Locate the compressor in a clean, well ventilated area where air is relatively cool, clean and dry. A110oF (35oC) maximum
and 40

o

F (4.5oC) minimum temperature for surrounding and inlet air are recommended. Provide at least 12 to 18 inches of
clearance from any wall or other obstruction that will interfere with airflow through the flywheel. The flywheel is located
inside the belt guard. Blocking airflow through the flywheel may cause the compressor to over heat. Do not place the
compressor in an area of excessive heat, such as near a boiler.

- DO NOT connect compressor intake to freezer room. Call 800-345-8207 for more

information.

Section 2 - Receiving

Your compressor is inspected at the factory and packaged to protect against shipping damage. When the compressor is
unpacked, inspect for damage or missing parts. All claims should be settled directly with the freight company.

- Do not operate this compressor if damaged during shipment, handling or use. Any

damage may result in failure and cause injury or property damage.

WARNING

NOTICE

Section 4 - Mounting

The compressor must be mounted to a firm level base. Permanent installations should be bolted to the base using the bolt
holes provided. Always shim the unit level before bolting it to the floor. Vibration isolators (Part #: KVP4X4) are
recommended. When using vibration isolator pads, do not draw bolts tight. Allow the pads to absorb vibrations. It is
recommended that a flexible hose (Part #: P1202MP) be installed between the compressor and service piping to reduce
vibration and the likelihood of damage to the compressor.

Section 5 - Lubrication

Specially formulated compressor oil (Part #: APC01Q) is shipped with each unit. This oil should be used to initially fill the
oil reservoir and for maintenance oil changes. Do not overfill the oil reservoir. Over-filling the reservoir will result in oil
leaking from the reservoir breather during operation.

Model Number Oil Volume

L(T)20033 8 ounces
L(T)29050 8 ounces

L(T)36575 12 ounces
L(T)425100 12 ounces
L(T)620100 7 ounces
L(T)900150 7 ounces

L(T)1220200 7 ounces
L(T)1300300 7 ounces
L(T)1600300 1 1/2 quarts
L(T)2000500 1 1/2 quarts
L(T)2500500 1 1/2 quarts

NOTICE

- Compressors are shipped without oil
installed. Add oil provided before

operation.

NOTICE

- All lubricated compressors have an oil
site glass. Oil should be filled until the
sight glass is 1/2 to 2/3 full.

1-800-345-8207

Section 6 - Piping

6.1 Piping Instructions

- Compressed air contains liquid water and is saturated with water vapor, which can
freeze when surrounding temperatures are lower than 32oF (0oC). Component
selection to minimize the effects of water vapor must be considered.

WARNING

6.1.1 - All Lubricated Compressors:

Piping between the compressor, accessory items and the sprinkler system should be at least 1/2” internal diameter to
minimize pressure drop from the compressor to the system. Larger pipe size may be required by code and may be
substituted with no adverse effects. Smaller pipe size must not be used. Smaller pipe size will restrict the compressor flow,
lowering capacity and cause the compressor / motor to work harder which shortens the compressor / motor life. All piping
connected to the compressor must be fully supported and not transfer any loads to the compressor.

The compressor outlet piping should contain an accessible drain. As a minimum a manual drain may be used, but an
automatic drain (Part #: CDF2000) is recommended to remove excess water.

6.1.2 - On Base Mounted Units (L Series):

If an AMD-2 (General Air Products model air maintenance device) is used to operate the compressor motor, allow sufficient
distance between the compressor and AMD-2 to ensure that the maximum temperature at the AMD-2 is 200

o

F or less. The

relief valve shipped with each unit must be installed between the compressor and AMD-2.
General Air Products recommends that all compressors 2 HP and larger are tank mounted. Failure to either tank mount

these compressors or to install according to the installation drawing (Section 6.2 of this manual), will cause overpressure
of the compressor and overheating of the motor.

- Failure to install a relief valve between the compressor and AMD can cause over
pressure of the compressor and blown head gaskets.

6.1.3 - On Tank Mounted Units (LT Series):

A relief valve is mounted on the compressor ’s tank. This valve will open at a preset value above the pressure switch
setting to prevent excess tank pressure in the event of switch failure.

If an AMD-1 (General Air Products model air maintenance device) is used, allow sufficient distance between the
compressor and AMD-1 to ensure that the maximum at the AMD-1 is 200

o

F or less.

A manual tank drain is provided on the bottom of each tank mounted compressor. Moisture accumulated in the tank must
be drained weekly. An automatic drain (Part #: CDF2000) is recommended in areas of high humidity.

- Do not attempt to change the safety relief valve setting.

- Accumulation of condensed water in the system can cause corrosion of components
and reduction of system capacity.

- Warranty is void if a separate check valve is not installed to prevent water backflow to
compresor.

CAUTION

WARNING

NOTICE

NOTICE

1-800-345-8207

Section 6 - Piping

6.2 L Series Base Mounted Lubricated Compressor Installation Drawing

1-800-345-8207

Section 6 - Piping

6.3 LT Series Tank Mounted Lubricated Compressor Installation Drawing

Section 7 - Wiring

1-800-345-8207

7.1 Wiring Instructions

- Wiring should be in accordance with the national electrical code and any local codes
or regulations. Have a competent electrician ensure that the voltage supplied
matches the compressor voltage.

- Inadequate wiring size can cause insufficient voltage at the compressor during start-

up. Overheating and damage can result to the motor and controls.

- Failure to use the pressure switch may result in overpressure of the compressor or
other components in the system. Overpressure of the compressor can result in blown
head gaskets or other damage.

WARNING

CAUTION

NOTICE

The supply wire must be of adequate size and no other equipment should be connected to the same line. The table
below lists the recommended wire size for each model based on a 100’ run. Consult factory for longer runs.

Minimum Recommended Wire Size

Model # 1 Phase 3 Phase

L(T)20033 10 12
L(T)29050 8 12

L(T)36575 8 12
L(T)425100 6 12
L(T)620100 6 12
L(T)900150 6 10

L(T)1220200 4 10
L(T)1300300 4 8
L(T)1600300 2 8
L(T)2000500 2 6
L(T)2500500 2 6

The motor must be wired to a pressure switch which controls starting (cut in pressure) and stopping (cut out pressure) of
the motor. A motor starter with current protection is recommended to protect the motor from overload conditions. Running
two phases through a pressure switch is not recommended.

The motors supplied are multiple voltage motors. Verify the internal motor leads are connected for the voltage being
supplied to the unit. To verify or change internal voltage connections remove the cover plate located on the rear side of the
motor and reconnect the wire leads as shown on the motor’s wiring diagram.

An arrow on the belt guard indicates the direction of the rotation of the compressor. If the compressor rotates in the
opposite direction, reverse the rotation of the motor. Direction of rotation of single phase motors is controlled by internal
re-connection of the motor leads as shown on the motors nameplate. Interchanging any two incoming supply wires
reverses rotation of three phase motors.

7.1.1 On Tank Mounted Units (LT Series):

The standard pressure switch is factory set at 30 psig cut in and 40 psig cut out. Higher settings may require a larger motor
on the compressor. Consult General Air Products by calling 800-345-8207 before adjusting the pressure switch.

Section 7 - Wiring

7.2 Lubricated Compressor Single & 3 Phase Wiring Drawing (IEC Version)

1-800-345-8207

Section 7 - Wiring

7.3 Lubricated Compressor Single & 3 Phase Wiring Drawing (NEMA Version)

1-800-345-8207

Section 8 - Maintenance Instructions

1-800-345-8207

WARNING

Disconnect, tag and lock out power source then release all pressure from the system
before attempting to install, service, relocate or perform any service.

The following instructions are based on normal operation. If the compressor is in an excessively dusty area, increase
frequency of maintenance checks.

Weekly:

- Check oil level

- Drain condensate from receiver and traps

- Check for unusual noise or vibration

- Clean air filters

- Clean all external parts of the compressor and motor

Monthly:

- Manually test safety relief valve

- Inspect air system for leaks

- Inspect oil for contamination and change if necessary

- Check for belt tension and wear

- Check pulley set screws for tightness

- Tighten nuts and cap screws as required

Quarterly:

- Change oil

- Change filters

If there are any questions regarding installation,
operation, or maintenance of this compressor,
please call 800-345-8207

Section 9 - Troubleshooting Guide

Symptom Possible Cause(s) Corrective Action

Motor hums and runs
slowly or not at all.

1. Low or no voltage

2. Shortened or open motor winding

3. Defective check or unloader valve

4. Defective pressure switch - contacts

will not close

1. Check voltage during start. Voltage must be within +/­10% of nominal voltage to start motor. Increase wire
size if necessary to lower voltage drop.

2. Replace motor

3. Replace check valve or unloader valve

4. Repair or replace pressure switch

Reset mechanism cuts
out or fuses blow
repeatedly

1. Insufficient voltage to motor

2. Pressure switch set too high

3. Wrong fuse size

4. Piping too restrictive

5. Defective motor

1. Check voltage during start. Voltage must be within +/­10% of nominal voltage to start motor. Increase wire
size if necessary to lower voltage drop.

2. Consult factory, adjust or replace

3. Be sure fuses, heaters and/or overloads are properly
rated or set

4. Add receiver vessel or increase pipe volume after
compressor

5. Replace motor

Unit short cycles
repeatedly

1. Piping too restrictive

2. Air leaks

1. Add receiver vessel or increase pipe volume after
compressor

2. Repair leaks

Compressor
overheating

1. Dirty intake filter

2. Wrong motor rotation

3. Air flow to fan on flywheel blocked

1. Clean intake filter

2. Correct rotation

3. Clean air flow to fan or relocate unit

Excessive noise in
operation

1. Loose pulley, flywheel, belt guard

2. Lack of oil in crankcase

3. Compressor mounting loose

1. Tighten

2. Check for damage to bearings, replenish oil

3. Shim and tighten

Milky oil in reservoir

1. Water flow from system into

compressor

2. Water condensing in crankcase due

to high humidity

1. Inspect system check valve. repair or replace as
necessary.

2. Pipe air intake to less humid area. Run pump
continuously for one hour and recheck

System pressure builds
slowly

1. Compressor sized incorrectly

2. Leaks or restrictions in piping

3. Dirty intake filter

4. Blown head gasket

1. Check system size and compressor sizing

2. Correct leaks and remove restrictions

3. Clean intake filter

4. Replace head gasket

Section 10 - Warranty Policy

GENERAL PROVISIONS & LIMITATIONS
General Air Products, Inc. (the "Company") warrants to each origi­nal purchaser ("Purchaser") of its new products from the Company
or its Authorized Distributor that such products are, at the time of
delivery to the Purchaser, made with good materials and workman­ship. No warranty is made with respect to:

1. Any product, which has been repaired or altered in such
a way, in the Companies judgment, as to affect the
product adversely.

2. Any product, which has, in the Companies judgment been
subjected to negligence, accident, improper storage,
improper installation or application.

3. Any product, which has not been operated or maintained
in accordance with the recommendations of the
Company.

4. Components or accessories manufactured, warranted
and serviced by others.

5. Any reconditioned or prior owned product.

Claims for items described in 4. above should be submitted direct­ly to the manufacturer.

WARRANTY PERIOD
The Company's obligation under this Warranty is limited to repair
or, at its option, replacing during normal business hours at the
designated facility of the Company, any part that in its judgment
proved not to be as warranted within the applicable Warranty
Period as follows.

COMPONENTS
All non-consumable components are warranted for 12 months from
the date of purchase. Consumables are not covered under
warranty. The unit must have been installed by either a factory
authorized distributor or agent in accordance with the factory
recommendations taking into account all other local site conditions
not originally noted to the factory. The unit must be operated and
maintained in accordance with the Factory recommendations and
original design conditions. Failure to provide such proof of the
above may void warranty.

LABOR TRANSPORTATION & INSPECTION
The Company will repair or replace any product or part thereof
which in the Companies judgment is proved to be not as warrant­ed. Labor costs are not covered under warranty.

All costs of transportation of product, labor or parts claimed not to
be as warranted and, of repaired or replaced parts to or from
factory shall be borne by purchaser. The Comp any may require the
return of any part claimed not to be as warranted to one of its
facilities as designated by the Company, transportation prepaid by
Purchaser, to establish a claim under this warranty.

Replacement parts provided under the terms of the warranty are
warranted for the remainder of the Warranty Period of the product
upon which installed to the same extent as if such parts were
original components.

DISCLAIMER
THE FOREGOING WARRANTY IS EXCLUSIVE AND IT IS
EXPRESSLY AGREED THAT, EXCEPT AS TO TITLE, THE
COMPANY MAKES NO OTHER WARRANTIES, EXPRESSED
OR IMPLIED OR STATUTORY, INCLUDING ANY IMPLIED
WARRANTY OR MERCHANTABILITY.

THE REMEDY PROVIDED UNDER THIS WARRANTY SHALL BE
THE SOLE, EXCLUSIVE AND ONLY REMEDY AVAILABLE TO
THE PURCHASER AND IN NO CASE SHALLTHE COMPANY BE
SUBJECT TO ANY OTHER OBLIGATIONS OR LIABILITIES.
UNDER NO CIRCUMSTANCES SHALL THE COMPANY BE
LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL OR
CONSEQUENTIAL DAMAGES, EXPENSES, LOSSES OR
DELAYS HOWSOEVER CAUSED.

No statement, representation, agreement, or understanding, oral
or written, made by any agent, distributor, representative or
employee of the Company which is not contained in this Warranty
will be binding upon the company unless made in writing and
executed by an officer of the Company.

This warranty shall not be effective as to any claim which is not
presented within 30 days after the date upon which the product is
claimed not to have been as warranted. Any action for breach of
this warranty must be commenced within one year after the date
upon which the cause of action occurred.

Any adjustment made pursuant to this warranty shall not be
construed as an admission by the Company that any product was
not as warranted.

PROMPT DISPOSITION & RETURNS POLICY
The Company will make a good faith effort for prompt correction or
other adjustment with respect to any product, which proves to be
defective within the warranty period. Before returning any product,
write or call the distributor, agent or authorized company from
which the product was purchased, describing defect and giving
date and number of original invoice, a well as proof of Factory
supplied consumables and proof of scheduled maintenance. No
products will be accepted for return without the Company issuing a
“Returned Goods Authorization” (RGA) to the Purchaser and
unless accompanied by a properly authorized RGA request form
initiated by the Purchaser. Return freight must be prepaid and each
returned product must have the RGA number clearly marked on
the product. Title and risk of loss pass to buyer upon delivery to the
common carrier.

PRODUCT SUITABILITY
Many States, Localities and Countries have codes and regulations
governing sales, construction, installation, and/or use of products
for certain purposes, which may vary from those in neighboring
areas. While General Air Products, Inc. attempts to assure that its
products comply with such codes, it cannot guarantee compliance,
and cannot be responsible for how the product is installed or used?
Before purchase and use of a product, please review the product
application, and national and local codes and regulations, and be
sure that the product, installation, and use will comply with them.

REV:4/22/11

General Air Products, Inc.

118 Summit Drive
Exton, PA 19341
P: 610-524-8950
F: 610-524-8965