Northstar M47500A.2 Owners Manual

M47500A.2

ITEM NUMBER: 47500 & 47501 SERIAL NUMBER: _____________

Owner’s Manual

Electric Stationary Air Compressor

(230V, single phase/60 gallon, 3 HP and 5 HP)

Instructions for Installation/Set-up, Operation, Maintenance, & Storage

This NorthStar® belt-driven compressor has a single-stage 2-cylinder pump (Model 47500) or single-stage 3-cylinder pump (Model 47501), made with heavy-duty cast iron cylinders for long life, and a compact design rated for 135 maximum PSI. Its continuous-duty rating ensures long-lasting performance, and its cast iron pump head ensures superior heat dissipation.

Read and understand this Owner’s Manual completely before using. Keep this manual for future review. Failure to properly set up, operate and maintain the compressor in accordance with this manual could result in serious injury or death to operator or bystanders.

WARNING: SPECIAL HAZARDS

 Injection Injury: High-pressure air stream can pierce skin and underlying tissues, leading to serious injury and possible

amputation. Such an injection injury can result in blood poisoning and/or severe tissue damage.

 Flying Debris: High-pressure air stream can cause flying debris and possible surface damage.  Not For Breathing Air: NorthStar compressors are NOT designed, intended, or approved for supplying breathing air. No

compressed air should be used for breathing unless air is treated in accordance with applicable standards.

 Fire/Explosion: Sparks from air powered tool heads or attachments can ignite fuel or other flammable liquids or vapors in

the vicinity. Exceeding the maximum pressure for air tools or attachments could cause them to explode.

 Burns: Compressor pump, motor and discharge tubing are hot surfaces that can cause burn injuries.  Electric Shock: Operating equipment in wet conditions or where not properly grounded can cause electric shock.

Detailed safety information about these hazards appears throughout this manual.

Equipment Protection Quick Facts

Inspect Upon Delivery: FIRST! Inspect for missing or damaged components. See “Initial Set-Up” section for where

to report missing or damaged parts.

Check Pump Oil: Pump is shipped with oil. Check the pump oil level before starting. See “Preparing for Operation” section of this Owner’s Manual for capacity and viscosity.

Use Mechanical Lifting Equipment: Compressor is shipped on a pallet and is too heavy to handle manually. Use proper lifting equipment for unloading and moving to installation site.

Install Using a Qualified Electrician: All wiring, grounding, and electrical connections must be made by a qualified electrician. Install according to local and national codes.

Install a Regulator: We recommend installing a regulator on the compressor at each distribution point to maintain constant pressure in the outlet hose line and provide reduced pressure appropriate for air tool being used. Run Pump Unloaded for Break-in Period: Before initial use, open ball valve and run compressor for 30 minutes to break in pump parts. Follow Maintenance Schedule: Pump, air filter, and tank require periodic inspection and servicing to provide efficient function and long life. See “Maintenance Schedule” for frequency of servicing.

Table of Contents

Equipment Protection Quick Facts ........................................................................................................................................ 1

Table of Contents ........................................................................................................................................................ 2

About Your Air Compressor ....................................................................................................................................... 4

Specifications .............................................................................................................................................................. 5

Component Identification ........................................................................................................................................... 6

Safety Signal Words .................................................................................................................................................... 7

Hazard Signal Word Definitions ............................................................................................................................................ 7

Safety Labeling ............................................................................................................................................................ 8

Safety Decal Locations ......................................................................................................................................................... 8

Safety Decals ........................................................................................................................................................................ 9

Initial Set-Up .............................................................................................................................................................. 10

Step 1. Inspect & Unpack ...................................................................................................................................................... 10

Step 2. Assembly ................................................................................................................................................................... 10

Attach Air Filter.................................................................................................................................................................... 10

Attach Regulator (Recommended) ...................................................................................................................................... 10

Step 3. Select Suitable Location ........................................................................................................................................... 11

Step 4. Permanent Mounting ................................................................................................................................................ 11

Step 5. Installing Distribution Piping ................................................................................................................................... 12

Step 6. Wiring Installation ..................................................................................................................................................... 12

Electric Compatibility ........................................................................................................................................................... 12

Wire Size ............................................................................................................................................................................. 12

Circuit Breaker .................................................................................................................................................................... 13

Pressure Switch Wiring ....................................................................................................................................................... 13

............................................................................................................................................................................................ 13

Grounding ........................................................................................................................................................................... 13

Model #47500 and #47501 (230 Volt; 3 / 5 HP) .................................................................................................................. 14

*Circuit Breaker ................................................................................................................................................................... 14

**Wire Size .......................................................................................................................................................................... 14

*Voltage .............................................................................................................................................................................. 14

*Circuit Breaker ................................................................................................................................................................... 15

**Wire Size .......................................................................................................................................................................... 15

*Voltage .............................................................................................................................................................................. 15

Operation ................................................................................................................................................................... 16

Follow Operation Safety Rules ............................................................................................................................................. 16

Prepare for Operation ............................................................................................................................................................ 16

Check/Add Oil to the Pump ................................................................................................................................................. 16

Proper Air Hose and Tool Use .............................................................................................................................................. 17

Pressure Control Related Devices ...................................................................................................................................... 17

Compressor - Tool Requirements ....................................................................................................................................... 17

Attaching/Disconnecting Air Hose and Tools ...................................................................................................................... 17

Using Compressor for Spraying ........................................................................................................................................... 18

Flammable Materials ........................................................................................................................................................... 18

Moisture in Compressed Air ................................................................................................................................................ 18

Shutdown ............................................................................................................................................................................... 18

Procedure ........................................................................................................................................................................... 18

For Malfunction During Operation ....................................................................................................................................... 18

Maintenance & Repair ............................................................................................................................................... 19

Maintenance Schedule Summary ............................................................................................................................. 19

Detailed Instructions – Maintenance & Repair ........................................................................................................ 19

Inspect Safety/Relief Valve ................................................................................................................................................. 19

Inspect Air Filter .................................................................................................................................................................. 19

Keep Compressor Clean ..................................................................................................................................................... 19

Inspect Compressor for Air Leaks ....................................................................................................................................... 20

Change Pump Oil ................................................................................................................................................................ 20

Drain Receiver Tank and Inspect Tank ............................................................................................................................... 20

Check Drive Belt for Tension and Alignment....................................................................................................................... 20

Keep Compressor Clean ..................................................................................................................................................... 21

Troubleshooting ........................................................................................................................................................ 22

Parts List – Model 47500 Rev A.2 ............................................................................................................................. 23

Parts List – Model 47500 Rev A.2 ............................................................................................................................. 24

792363 Pump Exploded View ................................................................................................................................... 25

792363 Pump Parts List ............................................................................................................................................ 26

792363 Pump Kit List ................................................................................................................................................ 27

Parts List – Model 47501 Rev A.2 ............................................................................................................................. 28

Parts List – Model 47501 Rev A.2 ............................................................................................................................. 29

792373 Pump Parts List ............................................................................................................................................ 30

792373 Pump Parts List ............................................................................................................................................ 31

792373 Pump Parts List ............................................................................................................................................ 32

Appendix A: Lubricants and Compatibility ............................................................................................................. 33

Alternate Lubricants ............................................................................................................................................................ 33

Limited Warranty ....................................................................................................................................................... 34

About Your Air Compressor

Thank you for purchasing a NorthStar air compressor! It is designed for long life, dependability, and top performance.

Intended Use. Provides compressed air used primarily for operating air tools and pressurizing other objects that require high air pressure, such as tires. Do not use for low-pressure objects such as balloons, air mattresses, and sport balls, which can explode quickly and easily. Special precautions are necessary when used for cleaning to prevent flying debris hazards. It is not to be used to supply breathing air.

Supplies Required. Normal operation will require you to supply:

 Pressure regulator (recommended)  Pump oil  Personal protection equipment

See “Specifications” section for more detail.

Site Location. Install in enclosed building only. See

“Select Suitable Location” on page 11 for more

information.

Personal Protection. Wear safety apparel during operation, including safety glasses with side and top protection.

Adult Control Only. Only trained adults should set up and operate the air compressor. Do not let children operate.

Under The Influence. Never operate, or let anyone else operate, the air compressor while fatigued or under the influence of alcohol, drugs, or medication.

Keep this manual for reference and review.

ATTENTION: Rental Companies and Private Owners who loan this equipment to others!

All persons to whom you rent/loan this air compressor must have access to and read this Owner’s Manual. Keep this manual with the air compressor at all times and advise all persons who will operate the machine to read it. You must also provide personal instruction on how to safely set-up and operate the air compressor and remain available to answer any questions a renter/borrower might have. Owner’s Manuals are available from NorthStar at 1-800-270-0810.

For any questions, comments, problems or part orders, call NorthStar at 1-800-270-0810.

Specifications

MODEL

Model #

47500

47501

FLOW OUTPUT

Max. Pressure Rating

135 PSI

Volume Rating @ 90PSI

11.3 CFM

15.5 CFM

Receiver Capacity

60 gal.

Power Requirements

Dedicated NEMA

Receptacles

6-30R

Volts

230V

Amps

20A

30A

Motor

Horsepower

3 HP

5 HP

DIMENSIONS / COMPONENTS

Length

24.25”

Width

23”

Height

71”

63”

Weight

251 lbs.

340 lbs.

Mounting Hole Diameter

.56”

Suggested Mount Bolt

Diameter

7/16”

SUPPLIES REQUIRED (not included)

Pump Oil

(shipped with oil, but refills

required)

SAE 30 non-detergent pump oil

(#4043)

SAE 30 non-detergent pump oil

(#4043)

Pump Oil Capacity

15.6 oz.

23.7 oz.

Component Identification

1. Lifting Eyes: May also be used as tie down locations.

2. Pressure Gauge: Air filled gauge. Shows pressure in

receiver tank.

3. Ball Valve: On/Off control for pressurized air supply from

receiver tank (not the output pressure). A regulator and/or quick connect fittings can attach to its ½” NPT outlet. A regulator should be installed for pressure regulation purposes.

4. Air Receiver / Storage Tank: 80 gallon ASME certified

tank.

5. Tank Drain Valve: Used to remove moisture from air after

compressor is shut off and air emptied from tank. Drain moisture daily after each use.

6. ASME Safety/Check Valve: Automatically releases air if

tank exceeds preset pressure max. of 200 PSI. A check valve is a pressure release port. Pull valve pin to relieve pressure from receiver tank.

7. Pressure Switch-Auto/Off switch: In AUTO

position, compressor shuts off automatically when tank pressure reaches maximum preset pressure (approximately 135 PSI). In OFF position, compressor will not operate. Switch should be in OFF position when connecting or disconnecting power cord from electrical outlet. NEVER attempt to adjust this pressure switch.

8. Discharge Tube: Carries compressed air from pump to

safety/check valve, and then to the storage tank. It becomes very hot during use and can cause severe burns. Never touch.

9. Unloader: Vents discharge air to atmosphere in start/stop

operation.

10. Magnetic Oil Drain Plug: Removal allows for drainage of

oil from pump. Attracts metal particles that could damage pump.

11. Air Compressor Pump: Shipped with oil.

12. Compressor Air Filter: Keep clean and particle free. See

“Pump Explosion and Pump Parts List” for replacement

part number.

13. Belt Guard: Covers belt, engine pulley and flywheel.

NEVER operate compressor without belt guard in place.

1 2 4

Safety Signal Words

DANGER

WARNING

CAUTION

NOTICE

Hazard Signal Word Definitions

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

DANGER (red) indicates a hazardous situation, which if not avoided, will result in death or serious injury.

WARNING (orange) indicates a hazardous situation, which if not avoided, could result in death or serious injury.

CAUTION (yellow), used with the safety alert symbol, indicates a hazardous situation, which if not avoided, could result in minor or moderate injury.

CAUTION (yellow), without the safety alert symbol, is used to address practices not related to personal injury.

NOTICE is used to address practices not related to personal injury.

Safety Labeling

On-Product Warning Labels

Location

Part numbers

Description

792161

Air Compressor Instructions

792174

Breathing Hazard

792175

Belt Hazard

792176

Burn Hazard

792177

Corrosion Hazard

789060

Electrical Shock Hazard

2 3 6

Safety Decal Locations

WARNING:

ALWAYS make sure safety labels are in place and in good condition. If a safety label is missing or not legible, order new labels from NorthStar Product Support at 1-800-270-0810.

Safety Decals

To order replacement safety labels, call NorthStar Product Support

at 1-800-270-0810.

Initial Set-Up

Plastic plug

Base

Air Filter Housing

Washer

Wing Nut

Grip here to tighten

Step 1. Inspect & Unpack

Upon receipt, inspect air compressor for missing or damaged parts. Verify that it is the compressor you ordered.

See “Component Identification” section of this manual for a diagram of the compressor and its components.

 For missing or damaged components, please

contact NorthStar Product Support at 1-800-270-

0810.

 If complete, fill out product serial number

information. See “Limited Warranty” section of this manual.

Step 2. Assembly

Attach Air Filter

1. Remove air filter from manual bag.

2. Remove plastic plug from air compressor inlet.

(Figure 1)

Figure 3

Figure 4

5. Replace air filter housing and washer. Secure

with wing nut, hand tighten only. (Figure 5)

Figure 1

3. Unscrew wing nut, remove washer and air filter

housing from base. (Figure 2)

Figure 2

4. Screw base into air compressor inlet as shown.

Tighten with appropriate tool on specified location. (Figure 3 & Figure 4)

Figure 5

Attach Regulator (Recommended)

We recommend using a regulator with this compressor since the pre-set tank pressure ranges between 105 and 135 PSI and is usually greater than what is needed by tools.

Without the addition of a regulator, the pressure switch will maintain a tank pressure within the pre-set range that has a max of 135 PSI. This is considered an overly high pressure for many tools. A user-installed regulator can maintain a lower constant pressure in the outlet hose line and prevent over pressurization of tools.

WARNING: Bursting hazard

Too much air pressure causes a hazardous risk of bursting. Check the manufacturer’s maximum pressure rating for air tools and accessories. Regulators must never be set to exceed the maximum pressure rating of tank or tools.

Step 3. Select Suitable Location

WARNING: Lifting hazard

The compressor is heavy. Ensure that proper lifting equipment is available to unload and move compressor to installation site.

Location Criteria:

 Enclosed building only.  Where no flammable vapors, dusts, and gases

are present.

 At least 15” away from walls and other objects.  Away from other heat-generating equipment.  Away from dusty/dirty conditions.  In a well illuminated area.  Where proper wire size is already, or can be

made, available.

Positioning:

 The compressor should be mounted on a dry,

firm, and level surface. It must sit level and be stabilized since it will slide or shift during operation if not secured.

Airflow:

 Provide access to adequate, clean and

unobstructed airflow for cooling and air supply.

 Remember the supply air is passing through the

compressor supply hoses and tools. These can be damaged or have a shortened life if unclean air is present or air filter is not clean and functioning properly.

 Do not allow debris to accumulate or block

airflow.

 Do not operate with a tarp, blanket, or cover

surrounding the machine, which blocks air flow.

 Do not place any objects against or on top of the

unit, which can also block airflow or damage unit.

Electrical:

 MUST be connected to a 230 Volt, single-phase

outlet having operating capacity of 20 amp (Model #47500, 3 HP) or 30 amp (Model #47501, 5 HP).

Wiring:

 Proper wire size should take into consideration

length from distribution panel.

 See Step 6, “Wiring Installation” for more

information.

Ideal operating temperatures:

 40 and 100F (4 and 37C).

Operating Limitations:

 15F (-9C) or above 125F (52C).

If temperatures consistently drop below 32 F (0C), install within an enclosed heated building. If this is not possible, protect the safety/relief and drain valves from freezing.

Note: Excessive moisture is likely to occur if unit is stored in an unheated area subject to large temperature changes. Moisture forming in pump can produce sludge in the oil, causing parts to wear out prematurely. Excessive condensation on the pump when it cools down is a sign that this may be occurring.

Step 4. Permanent Mounting

You will permanently mount the compressor after selecting the location in Step 3.

1. On a concrete pad or other stable mounting platform, drill 3 holes according to the mounting dimensions given in the diagram below. (Figure 6)

Figure 6

2. Unbolt the compressor feet by removing the

fasteners. Discard them after removal. (Figure

Figure 7

3. Lift and remove the compressor from the pallet

using a hoist and lifting eyes provided.

4. Situate unit in chosen location and bolt in place.

(Use 7/16” bolts and washers. Make sure bolts are long enough to provide a good anchor point.) Bolt it in place to prevent unit from

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