Jun-Air 86, 87R User Manual

Compressor

WWW.JUN-AIR.COM

ISO 9001 CERTIFIED

Model 86/87R System

86R-4B, 87R-4B, 87R-15B, 87R-25B

6190755

6190755 (Rev A) 86/87R Compressor System User Guide

Table Of Contents

Section Page Number

Declaration of Conformity 3 Operating Manual 4 Diagrams / Schematics 8 Exploded Views 11 Parts and Accessories 19 Technical Data & Specifications 21 Pictures & Illustrations 26

We reserve the right to make any alterations which may be due to any technical improvements

Printed in the USA

86/87R Compressor System User Guide 6190755 (Rev A)

Declaration of Conformity

Konformitätsbescheinigung

Certi cat de Conformité

Declaración de Conformidad

Conformiteitsverklaring

Overensstemmelseserklæring

GB  e manufacturer Gast Manufacturing, Inc. declares that the compressor is in conformity with:

• 2009/105/EC Council Directive relating to Simple Pressure Vessels

• 2006/42/EC Machinery Directive

• 2004/108/EC EMC Directive

• 2006/95/EC Low Voltage Directive

• 2011/65/EU RoHS 2 Directive

• 2012/19/EU WEEE Directive

• 1907/2006 and 340/2008 REACH Regulation

DE Der Hersteller Gast Manufacturing, Inc. bescheinigt, dass der Kompressor entspricht:

• 2009/105/EC Richtlinie der einfachen Druckbehälter

• 2006/42/EC Richtlinie zur Sicherheit von Maschinen

• 2004/108/EC Richtlinie der Elektromagnetischen Verträglichkeit

• 2006/95/EC Richtlinie für Niederspannung

• 2011/65/EU RoHS Directive

• 2012/19/EU WEEE Directive

• 1907/2006 and 340/2008 REACH Regulativ

FR Le fabricant Gast Manufacturing, Inc. déclare que le compresseur est conforme aux directives suivantes:

• 2009/105/EC Directive relative aux appareils à pression simple

• 2006/42/EC Directive sur la sécurité des machines

• 2004/108/EC Directive sur la compatibilité électro-magnétique

• 2006/95/EC Directive sur les basses-tensions

• 2011/65/EU Directive RoHS

• 2012/19/EU Directive DEEE

• 1907/2006 et 340/2008 Réglementation REACH

ES El fabricante Gast Manufacturing, Inc. declara que el compresor está conforme con:

• 2009/105/EC Directiva en relación a recipientes a presión simple

• 2006/42/EC Directiva de Seguridad de maquinaria

• 2004/108/EC Directiva de Compatibilidad eléctrica magnética

• 2006/95/EC Directiva de baja tensión

• 2011/65/EU Directiva de RoHS

• 2012/19/EU Directiva de WEEE

• 1907/2006 and 340/2008 Reglamento REACH

NL De fabrikant Gast Manufacturing, Inc. verklaart dat de compressor in overeenstemming is met:

• 2009/105/EC Richtlijn voor eenvoudige drukvaten

• 2006/42/EC Machinerichtlijn

• 2004/108/EC Richtlijn inzake Electromagnetische Compatibilitet

• 2006/95/EC Laagspanningsrichtlijn

• 2011/65/EU RoHS Richtlijn

• 2012/19/EU WEEE Richtlijn

• 1907/2006 and 340/2008 REACH Verordening

DK Producenten Gast Manufacturing, Inc. bekræ er hermed at kompressoren er i overensstemmelse med:

• 2009/105/EC Direktivet vedrørende simple trykbeholdere

• 2006/42/EC Maskindirektivet

• 2004/108/EC EMC-direktivet

• 2006/95/EC Lavspændingsdirektivet

• 2011/65/EU RoHS Direktivet

• 2012/19/EU WEEE Direktivet

• 1907/2006 and 340/2008 REACH Forordningen

Printed in the USA

6190755 (Rev A) 86/87R Compressor System User Guide

Operating manual

Information

Please note that you can ﬁnd the pictures and ﬁgures we are referring to in the back of the manual

Important - read this ﬁrst!

Please read the following information and operating instructions included with this product before use. This information is for your safety and it is important that you follow these instructions. It will also help prevent damage to the product. Failure to operate the unit in accordance with the instructions or using JUN-AIR unauthorized spare parts can cause damage to the unit and could cause serious injury.

CAUTION: To reduce risk of electric shock

• Only authorized service agents should carry out service. Removing parts or attempting repairs can create an electric shock. Refer all servicing to qualiﬁed service agents.

• If this unit is supplied with a three-pin plug, connect with a properly earthed outlet only.

WARNING: To reduce risk of electrocution

• Do not use this unit with electrical voltages other than stated on the rating plate.

• Never leave this product unattended when plugged in.

• Always unplug this unit immediately after use.

• Store in a dry place.

• Do not use this product in or near liquid or where it can fall or be pulled into water or other liquids.

• Do not reach for this product if it has fallen into liquid. Unplug immediately.

• This unit is not weatherproof. Never operate outdoors in the rain or in a wet area.

DANGER: To reduce risk of explosion or ﬁre

• During spraying with combustible liquids risk of explosion may arise, particularly in

closed rooms

• Do not use this product in or near explosive atmospheres or where aerosol products are being used.

• Do not pump any other gases other than atmospheric air.

• Do not pump combustible liquids or vapours with this product; do not use it in or near areas with combustible or explosive liquids or vapours.

• Do not use this unit near naked ﬂames.

CAUTION: To prevent injury

• Compressed air can be dangerous; do not direct airﬂow at a persons head or body.

• Always keep the system out of reach of children.

• Never operate this product if it has a damaged power lead or plug, if it has been dropped or damaged, or if it has fallen into water. Return the product to a service centre for examination and repair.

• Keep the electrical cable away from hot surfaces.

• Ensure all openings are kept free of restriction and never place the system on a soft surface where the openings may be blocked. Keep all openings free from dust, dirt and other particles.

• Never insert ﬁngers or any other objects into fans.

• This unit is thermally protected and can automatically restart when the overload resets.

• Wear safety glasses, when servicing this product.

• Use only in well ventilated areas.

• This product may only be connected to units or tools with a max. pressure higher or equal to that of the system.

• The surface of the system can get hot. Do not touch system system during operation.

Failure to observe the above safety precautions could result in severe bodily injury, including death in extreme cases.

IMPORTANT: General directions for use

• Protect the system against rain, moisture, frost and dust.

• The system is constructed and approved for a max. pressure as stated under Technical Speciﬁcations.

• Do not operate system at ambient temperatures exceeding 40°C/104°F or falling below 5°C/41°F.

• If the supply lead on the system is defective, an authorized JUN-AIR distributor or other qualiﬁed personnel must carry out the repair.

GOOD BAD

Min. 5°C/41°F • Max. 40°C/104°F

Warranty

Provided that the operational instructions, maintenance, and service have been carried out, your JUN-AIR system is guaranteed against faulty material or workmanship for 2 years.

The air receiver is guaranteed for 5 years. The guarantee does not cover damage caused by violence, misuse, incorrect repairs or use of unoriginal spare parts. Costs of transportation of parts/equipment are not covered by the guarantee. JUN-AIR’s Conditions for Sale and Delivery will generally apply. Gast Manufacturing, Inc. A/S reserves the right to change technical speciﬁcations/ constructions.

Contents of box

Your system should be delivered in a clean and undamaged box. If not, contact your distributor immediately. The box should contain the following:

• 1 86/87R-XB system

• 1 system operating manual & 1 ﬁlter/regulator manual

• Individually packaged or attached ﬁlter/regulator

• 100 cm x 6 mm tube for ﬁlter/regulator autodrain line

Installation

Your JUN-AIR system is very easy to operate. Observe the following simple instructions and you will get many years’ service from your unit.

• Visually inspect unit for shipping damage, contact your supplier immediately if you think the unit may have been damaged.

Warning!

To avoid the risk of electric shock, do not install the system in areas where it may get in contact with water or other liquids. In which case protection is required.

• Use only pressure pipes tolerating a constant temperature of min. 150 Ensure that the pressure pipes have a sufﬁcient internal diameter to avoid pressure loss in the system. Check for leaks.

We reserve the right to make any alterations which may be due to any technical improvements

Printed in the USA

86/87R Compressor System User Guide 6190755 (Rev A)

• Install product on a rigid level surface maintaining a minimum of 6 in/15 cm clearance all around the unit and a 12 in/30 cm clearance above the system.

• Sufﬁcient cooling from the surroundings is important. Place the system in a dustfree, dry and cool, yet frostfree, room. Do not install in a closed cupboard, unless adequate openings for ventilation are available on top and bottom (minimum 500 cm²/77.5 in² each). If the system is placed under a table, a minimum of 12 cm/5 in free height must be available above the system or an opening of Ø30cm/11.8 inches, corresponding to the top of the system, may be cut in the table. Ensure that the system stands ﬁrmly on the ﬂoor.

• The intake air may be supplied from another place (for instance outside).

Ensure that hoses for the intake are sufﬁcient to avoid performance loss

and that any alternate ﬁlter used has the same micron rating (50μm) as the JUN-AIR intake ﬁlter.

Electrical installation

Warning!

Incorrect electrical connection may result in electric shock. The electrical connection must be carried out in accordance with local electrical regulations and by qualified electrical engineers.

Note! Earthing of all AC models must be ensured during installation. The capacitor

must be earthed, as failure to do so may cause electric shock when touched. Plug the system into an earthed socket of nominal voltage and ensure that fusing is adequate.

Adjustment of pressure switch

Warning!

If maximum pressure is exceeded, reduced lifetime may result. Contact JUN-AIR for information on operation at higher pressure.

• All systems may run at 100% continuous operation, but 50% operation is recommendable to prolong lifetime.

• The system should be sized so that the tank is capable of supplying air 100% of the time and the compressors only run at 50%.

• Do not lubricate the oil-less system with oil, as this will destroy important components.

• Start the system using the 0/1 switch on the pressure switch. The system will automatically switch off at the preset pressure. If the system does not start it may be due to pressure in the receiver, and the system will then start automatically when the pressure reduces to approx. 6 bar/87 psi.

• Adjustment of pressure (see back of manual)

A: Max. pressure adjustment (cut-out) B: Differential adjustment (cut-in) The cut-in pressure (normally 6 bar) is set by adjustment of differential

screw B. Turn clockwise to reduce cut-in pressure. The cut-out pressure is set by even adjustment of the two screws A. (Cut-in pressure + differential = cut-out pressure). Turn clockwise to increase cut-out pressure. The switch is normally factory set for operation at 6-8 bar (approx. 90-120 psi).

Fault ﬁnding and repair

AC models

• For electrical connection, refer to schematic in back of this manual.

• Check system serial number label for frequency and voltage to ensure that it corresponds to the voltage and frequency used for the system. The voltage stated on the system plate: 120/240V (/) means that the system can operate at 120V or 240V, but this requires recoupling of the internal wiring from the electrical system (see the electrical diagrams). 220-230V (-) means that the system may operate within the range of 220V to 230V without recoupling of the internal wiring.

• Capicitor is wired to motor via terminal box on side of motor.

• Accessorries are wired through the system pressure switch.

Operation

• If the temperature of the system is extremely low (for instance after transportation or stocking), allow system to get to room temperature before switching on the system.

• Do not use system for compression of liquids and dangerous gasses, such as petrol vapour and solvents.

Important

This system is only suitable for atmospheric air.

• Do not remove protection covers during operation as it may cause electric shock or risk of other personal injury (ie: terminal box, pressure switch).

• Ensure that system is correct for air supply ﬂow required, see Technical Speciﬁcations.

• Open the outlet cock on the receiver and connect equipment.

Important!

Switch off and isolate from electrical supply before removing any parts from the system. Empt y air receiver of air before dismantling parts of system unit’s pressure system.

1. System does not start: a) No power from mains. Check fuses and plug. b) Breakage or loose joints in electrical connections. c) Defective capacitor. d) The thermal protection has switched off the pump due to overheating.

When cooled the pump will automatically turn on at a suitable operation temperature. Go through the points in step 5.

e) The system has not been unloaded and there is back pressure. Make

sure that the system is unloaded each time it stops. f) The pump is locked. g) Pressure in the air receiver is too high for activation of the pressure

switch. The pressure switch makes circuit only when pressure has

dropped to preset start pressure. Empty receiver.

2. System does not start, makes a buzzing sound followed by a

clicking noise (cannot start against high pressure):

a) Leaky non-return valve. Remove the ﬂexible pressure pipe and clean

to ﬁnd out whether air leaks from the valve. If so, clean or replace. 3 System works, but pressure does not increase: a) Intake ﬁlter clogged. Replace. b) Leaks in ﬁttings, tubes or pneumatic equipment. Check with soapy water

or by letting unit stay overnight with disconnected mains. Pressure drop is

not to exceed 1 bar. c) Cups are worn out. Check and replace if neccessary. d) Defective valve plate. Contact your JUN-AIR distributor. e) Burr or failure in non-return valve which is creating a ﬂow restriction.

Printed in the USA

6190755 (Rev A) 86/87R Compressor System User Guide

4. Loud noise from system:

a) Dirt or failure in non-return valve. Clean or replace.

5. System gets very hot:

a) Leaks. See above b) Too high ambient temperature. Ensure adequate ventilation if the

vacuum pump is installed in a cabinet.

c) Overloaded. Ensure system is correct model for work load.

6. System starts when no air is being tapped:

a) Leaks. Step 3 - b

7. System does not switch on against pressure or does not switch off at max. pressure:

a) Defective pressure switch. Replace.

Non-return valve Maintenance (NRV)

· Once a year.

· Switch off system on the main switch and pull out the plug.

· Pull the ring at the end of the safety valve (see back of manual).

Warning:

Loud noise!

· Let pressure fall to 0 bar. The pressure is to be read on the pressure

gauge for receiver pressure (see back of manual).

· If the system is mounted with a TÜV-approved safety valve, the receiver is

emptied by loosening the screw at the end of the safety valve

· Dismount non-return valve from receiver

· Disassemble non-return valve and remove O-ring from piston

· Clean non-return valve.

· Mount new O-rings and re-assemble non-return valve (Two O-rings in non-

return valve)

WARNING: To Avoid Serious Burns: Do not touch surface during operation.

Preventive maintenance

Weekly

Drain condensate from air receiver. If equipped with autodrain, this will take place automatically, however, drain bottle has to be emptied.

If compressor is ﬁtted with outlet ﬁlter, check and empty for water by pressing the black button at the bottom. If ﬁtted with autodrain, this will take place automatically.

Check motor, air tubes, hoses and equipment for leaks, and check the pumping time.

Clean unit or wipe with a soft, damp cloth. If necessary, use parafﬁn on rag to remove sticky adhesions. Dust and dirt prevent cooling.

Check intake ﬁlter. Clean or replace if necessary. Minimum every 2000 hours

Replace silencer (intake ﬁlter), if necessary

Check the O-ring in the non-return valve and replace, if necessary.

Note! Empty receiver of air before dismounting.

Check ﬁlter regulator, clean or replace as neccessary

Test the safety valve by gently pulling the ring with pressure in the receiver.

Filters and non-return valves should be serviced every 2000 hours. The JUN-AIR basic service kit (identiﬁed in the accessories portion of this manual) can be purchased to accommodate.

The comprehensive service kit includes components to maintain the system’s compressor (cups, valves, o-rings, cylinders) as well as the systems ﬁlter elements, unloader valve, silencer, & NRV.

Comprehensive service kits should be utilized every 8000 hours.

Any solenoid accessories on the system should be serviced every 12000 hours.

Monthly Annually 2000 Hours

Indicates package should be handled with these symbols pointing up.

FRAGILE: Handle package with care.

Indicates this package must be kept dry.

Check the Pumping Time

The pumping time indicates the condition of the compressor provided that there are no leaks in the system where the compressed air may leak. Test the compressor as follows:

1. Empty the air receiver of compressed air ( the pressure gauge shows 0 Bar)

2. Close the outlet on the air receiver and check that the drain cock is closed.

3. Start the compressor and note how long it takes until it switches off. Ensure that the pressure in the air receiver is 8bar/120 psi as deviations may

indicate the wrong results (see technical Speciﬁcations for pumping time)

Important!

Always test the compressor when cold as the time indicated refers to the pumping time of a cold compressor. The pumping time of a warm compressor is much longer and consequently, the result would be misleading.

We reserve the right to make any alterations which may be due to any technical improvements

Printed in the USA

86/87R Compressor System User Guide 6190755 (Rev A)

Pressure vessel

Pressure tested at: All sizes:

Directions for use

Application Receiver for compressed air. Receiver speciﬁcations See name plate. Installation Tubes, etc. must be installed with

suitable materials. Placement Observe the working temperature

of the receiver. Ensure sufﬁcient room for inspection

and maintenance. The receiver must be kept in a

horizontal position. Corrosion protection The surface treatment must be

maintained as required. Internal inspection at least every

5 years. Drain condensate at least once a week. Alternation/repair No welding must be made on

pressurised parts. Safety valve Ensures that PS rating will not be

exceeded. Never adjust to a higher pressure

than PS. The capacity of the valve must be

calculated in accordance with the volume of air supplied by the compressor.

(PS = Maximum working pressure of the receiver. This is speciﬁed on the system's serial number label.)

16.5 - 24BAR

Printed in the USA

PROJECTION:

JUN-AIR

TLB

WEIGHT:

MATERIAL:

PROJECT NO:

TITLE

MADE FROM:

8/7/14

APPROVED

DRAWN

SIZE

1 OF 1

DRAWING NUMBER

XB6782

SCALE

1:1

SHEET

REV

GAST /

PROPRIETARY INFORMATION

THIS DRAWING EMBODIES A PROPRIETARY DESIGN

OWNED BY IDEX,INC. AND IS SUBMITTED UNDER A

CONFIDENTIAL RELATIONSHIP. EXCEPT USES EXPRESSLY

GRANTED IN WRITING, ALL RIGHTS ARE RESERVED BY IDEX

INC.

08/7/2014

-----

DATE

ECN

GEOMETRIC TOLERANCING PER: ASME Y14.5M-1994

DO NOT SCALE DRAWING

TOLERANCES UNLESS OTHERWISE SPECIFIED

WHERE USED:

SOURCE CODE:

ELECTRICAL DRAWING 87R BASICS 120V

YELLOW/GREEN

(GREEN)

BLUE

PRESSURE SWITCH

BROWN

BLUE

BROWN

GROUND

(N)

(L1)

ORANGE

RED

YELLOW

BROWN

μF

CAPACITOR

OUT

MOTOR 1

WHITE

BLUE

COOLER BOX

AUTOMATIC DRAIN

PRESSURE RELIEF

μF

CAPACITOR

MOTOR 2

BLACK

INSULATE

GREEN

INSULATE

(N)

(L1)

ORANGE

RED

YELLOW

BROWN

WHITE

BLUE

BLACK

2 3

6190755 (Rev A) 86/87R Compressor System User Guide

86/87R- XB Wiring Schematics

120VAC - 60Hz

PRESSURE

RELIEF

(L1)

BLACK

120V/60Hz

(L2)

WHITE

YELLOW/GREEN

PRESSURE SWITCH

Legend

: AUTO DRAIN

OUT

AUTOMATIC

DRAIN

OUT

: FAN

:CAPACITOR

COOLER

BOX

(L2)

(L1)

BLUE

WHITE

BLACK

MOTOR 2

RED

MOTOR 1

BLACK

BLUE

(L1)

BLACK

WHITE

(L2)

WHITE

(GREEN)

GROUND

RED

:EARTH

:TERMINAL CLIP

:MOTOR PROTECTION

:ADDITIONAL FEATURES

BROWN

YELLOW

30 μFCAPACITOR

ORANGE

YELLOW

ORANGE

BROWN

30 μFCAPACITOR

We reserve the right to make any alterations which may be due to any technical improvements

Printed in the USA

PROJECTION:

JUN-AIR

TLB

WEIGHT:

MATERIAL:

PROJECT NO:

TITLE

MADE FROM:

8/7/14

APPROVED

DRAWN

SIZE

1 OF 1

DRAWING NUMBER

XB6790

SCALE

1:1

SHEET

REV

GAST /

PROPRIETARY INFORMATION

THIS DRAWING EMBODIES A PROPRIETARY DESIGN

OWNED BY IDEX,INC. AND IS SUBMITTED UNDER A

CONFIDENTIAL RELATIONSHIP. EXCEPT USES EXPRESSLY

GRANTED IN WRITING, ALL RIGHTS ARE RESERVED BY IDEX

INC.

08/7/2014

-----

DATE

ECN

GEOMETRIC TOLERANCING PER: ASME Y14.5M-1994

08/15/2014

DO NOT SCALE DRAWING

TOLERANCES UNLESS OTHERWISE SPECIFIED

WHERE USED:

SOURCE CODE:

ELECTRICAL DRAWING 87R BASICS 230V

YELLOW/GREEN

(GREEN)

BLUE

PRESSURE SWITCH

BROWN

BLUE

BROWN

GROUND

(N)

(L1)

ORANGE

RED

YELLOW

BROWN

μF

CAPACITOR

OUT

MOTOR 1

WHITE

BLUE

COOLER BOX

AUTOMATIC DRAIN

PRESSURE RELIEF

μF

CAPACITOR

MOTOR 2

BLACK

INSULATE

GREEN

INSULATE

(N)

(L1)

ORANGE

RED

YELLOW

BROWN

WHITE

BLUE

BLACK

2 3

86/87R Compressor System User Guide 6190755 (Rev A)

86/87R- XB Wiring Schematics

120VAC / 230VAC - 50Hz or 60Hz

230V/50-60Hz

(N)

(L1)

BLUE

PRESSURE

RELIEF

AUTOMATIC

DRAIN

BROWN

OUT

YELLOW/GREEN

PRESSURE SWITCH

Legend

: AUTO DRAIN

OUT

: FAN

:CAPACITOR

COOLER

BOX

MOTOR 2

(N)

(L1)

WHITE

YELLOW

BLUE

BROWN

GREEN

ORANGE

RED

BLACK

INSULATE

MOTOR 1

BROWN

(L1)

WHITE

YELLOW

BLUE

(N)

BLUE

BROWN

(GREEN)

GROUND

GREEN

ORANGE

RED

BLACK

INSULATE

:EARTH

:TERMINAL CLIP

:MOTOR PROTECTION

:ADDITIONAL FEATURES

30 μFCAPACITOR

Printed in the USA

30 μFCAPACITOR

+ 18 hidden pages

Jun-Air 86, 87R User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual