Page 1
®
Oil-Less Piston Compressors
P3-M / P5-M / P7-M / P10-M / P15-M
Operating Instructions
255517 (Rev. 5) 05/2018
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CONSTRUCTION
Ohio Medical® oil-less piston compressors are designed to compress only
atmospheric air. They are typically used in “clean” applications, including medical
air and laboratory air, as they are completely free of oil. Neither the pumping
chamber nor the lower crankcase contain oil. Oil should never be added by the
user. They are not intended for use on gas compression applications. Service
should be performed only by qualied personnel.
WARNING
When operating, these compressors generate high levels of heat; therefore, never
touch the discharge tubing, cylinder, and cylinder head while the compressor is
operating and shortly after compressor shutdown. Severe injury could result from
touching these hot surfaces.
The compressors are powered by electrical motors; therefore, there is a danger of
injury or death due to electrical shock. Always make sure that the power is turned
off and locked out prior to performing service on these compressors.
INSTALLATION
Ohio Medical LLC® (OMC) compressors are air cooled units and must be installed
in an area with proper ventilation. The compressor’s ywheel also acts as a fan.
A minimum of 1 foot around each compressor module and three (3) feet clearance
around the system is recommended for proper ventilation. The acceptable ambient
temperature range is 40° to 104°F.
The compressor’s location should be dry and free of dust or corrosive vapors.
Make sure that the compressor is level and securely fastened to a frame or the
oor. Improper fastening may result in excessive vibration.
V-BELT ADJUSTMENT
Prior to starting the compressor, check the drive belt from the motor to the
compressor’s ywheel. Both the motor pulley and compressor ywheel should be
clean and free of grease to prevent belt slippage or abrasiveness.
Proper belt tension is important for both performance and long term service. If the
belt is too tight, it can result in excessive wear of the motor bearing. If the belt is
too loose, it can result in belt slippage, reduced compressor efciency, or a broken
belt.
To check belt tension, press down on the belt at the mid point between the motor
and compressor. A deection of approximately ½ to ¾ of an inch is appropriate.
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OPERATION
Check the following items prior to starting up the compressor:
1. Make sure that the electrical lines and connections comply with local
electrical codes. This includes making sure that the proper size wire is
used for the selected voltage and amp draw of the compressor’s motor.
Make sure that electrical connections are tight. Loose connections can
cause injury, create excessive amp draw and premature wear of
components.
2. Make sure that all mounting bolts are tightened and that the compressor
module is properly mounted to its base.
3. Check the belt tension as described above to make sure that it is not too
loose or too tight.
4. Make sure that the compressor is rotating in the proper direction, as
indicated by the arrow on the motor. This can be accomplished by
temporarily “bumping” the power to the motor and observing the direction
of rotation. If the compressor is rotating in the wrong direction, reverse
the polarity of any two (2) of the three (3) electrical leads to the motor.
PERIODIC MAINTENANCE
Check Items HR
Intake lter, lter
elements blocked
or dirty
V-belt loosen
Bolt (Nut) loosen
Valve assembly
leaking
Compression
ring
Guide ring
Must Do
Ball bearing
Spin bearing
Cylinder
250
(1 month)
○
○
○
3000
(12 months)
○
○ ○ ●
○ ○ ●
○ ○ ●
○ ○ ●
○ ○ ○
Remarks: 1. ○ = Check/Maintain
2. ● = Replace
6000
(24 months)
8000
(30 months)
Instructions
Clean or replace element
Correct and follow instructions
in operation manual
Fasten bolts(nuts) with proper
tools
Inspect and clean spare parts
Test for leaks
Check/Replace
Check/Replace
Check/Replace
Check/Replace
Check/Replace
3255517 (Rev. 5) 05/2018
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1. Periodic maintenance is essential for proper operation and long term
service of your compressed air system. Follow the recommended service intervals
as listed in the table below. When performing maintenance on your compressor, it
is best to keep a maintenance log sheet to keep a record of service intervals and
repairs.
2. Both compression rings and guide rings should be inspected periodically
for wear. The attached table provides dimensions for both new rings, as well as
the minimum acceptable thicknesses of rings after use. Rings that are deteriorated
beyond these dimensions or at recommended service intervals should be replaced.
Part numbers for all rings are provided in the parts lists in this manual.
Ø82 Ø95
Spare Parts
Compression
ring
Guide
ring
Compression
ring
Guide
ring
The radius direction
thickness of new
6.5 2.4 7.5 2.4
pieces (mm)
The radius direction
thickness of friction
4.9 1.7 5.9 1.7
limit (mm)
3. When providing service on the compressor, make sure that the power to
the unit is turned off and locked out and that the pressure in the system has been
released.
4. When removing parts, keep them in a clean working environment, free of
dust and dirt. Pay close attention to the order in which the parts were removed.
5. Attention must also be given to the direction of the compression rings and
guide rings. If not replaced in the proper positions, performance of the compressor
will be less than expected. Please refer to the attached illustration for the correct
positioning of the rings.
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6. Also inspect the sealed bearings. They are lled from the factory with
heat resistant grease. Inspect the seals of the bearings, making sure that they are
capable of retaining the grease. Also make sure that the bearing is free to turn .
If the seals appear worn and unable to hold grease, or if the bearing is difcult to
turn, the bearing should be replaced. Part numbers are provided in the parts list
section of this manual.
7. When reassembling the compressor, make sure to tighten all bolts, screws,
and nuts.
8. If the compressor has been sitting idle for more than six (6) weeks, it is
recommended that the compressor be run in a “no load” condition monthly for at
least 30 minutes.
TROUBLESHOOTING
The table below includes common potential problems associated with piston
compressors and suggested solutions.
Problem Possible
Drain valve leaking
Valve pressure gauge
Defective pressure gauge
Intake lter blocked
Unloading
system
leaking
Pipe or air cooler leaking
Solenoid valve leaking
Piston ring or cylinder worn
Safe valve leaking
V-belt loosen or worn
Unloading system leaking
Compressor running, but…
Abnormal
pressure
Defective pressure gauge
Pressure switch worked
improperly
Fault unloading system
Defective solenoid valve
Check Repair Replace
✓ ✓ ✓
✓ ✓ ✓
Action
✓ ✓
✓ ✓
✓
✓ ✓
✓ ✓
✓ ✓
✓ ✓
✓ ✓
✓
✓ ✓
✓ ✓
✓ ✓
5255517 (Rev. 5) 05/2018
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The next section includes troubleshooting assistance for complete oil-less air
systems, such as those found in hospitals and labs.
IF YOUR SYSTEM IS DOING THIS:
1. Experiencing High Dew Point, as indicated by the Dew Point Monitor
WE SUGGEST YOU CHECK THIS:
A. If your system has refrigerated dryers, check the condensation trap drain and
verify that it is functioning properly. The condensation trap drain should be serviced
once a year; if the condensation trap is not draining off the condensed vapor, the
down stream dew point could begin to rise. Also, if your dryer is equipped with a
mechanical drain, you may consider a conversion to an automatic electronic drain.
B. Check the lter element of the condensation trap. This lter element could
be plugged with contaminants or saturated. The lter element could also have
a bad seat, allowing moisture past it, causing a high dew point condition. The
condensation trap lter should be replaced at least once a year or more, depending
on conditions and demand.
C. The refrigerated dryer could be low on Freon charge. The refrigerated dryer
works by cooling the evaporator coil and allowing air to pass over it. If the dryer is
low on Freon, it will not cool properly and will reduce the amount of condensation
taking place.
D. The dryer’s condenser coils could be clogged, preventing adequate air ow
over them. This can be corrected by blowing out the debris and making sure that
the coils are clean.
E. The dryer may be old and beyond economic repair. It may need to be replaced.
F. In some cases, especially with small compressors on intermittent duty, the load
on the dryer may be too low for the dryer to work properly. If that is the case,
bleeding air down stream or using a cycling refrigerated dryer may solve the dew
point problem.
G. On multiplex systems, a high dew point condition could be created by operating
two dryers at once. Each dryer should be sized to handle 100% system capacity;
operating two dryers at once will create a low load condition as described in point
F. above. Operating a single dryer with adequate air ow across it could solve
the problem.
H. The sensor in the system’s dew point monitor could need to be replaced or the
entire dew point monitor may need to be replaced if it is beyond repair.
6 255517 (Rev. 5) 05/2018
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I. If your system is equipped with desiccant dryers, the desiccant beads may need
to be replaced. Over time the beads lose their ability to absorb water vapor and
need to be replaced.
IF YOUR SYSTEM IS DOING THIS:
2. Providing Low Performance
WE SUGGEST YOU CHECK THIS:
A. The compressor could have a clogged inlet lter. This is a replacement item
that could restrict air ow to the compressor. Less air in means less compressed
air out.
B. The system’s inlet isolation valve could be partially closed or fully closed. In
order to provide adequate air ow, the isolation valve must be completely open.
Restricting the ow through the valve will result in poor performance.
C. The system’s refrigerated dryer could be frozen, restricting air ow through it.
To correct the situation, the dryer will need to be brought back to proper operating
temperature and the source of the problem corrected.
D. The compressor itself may have worn compression rings or worn valves. If
either components are worn, the compressor will not be able to compress the air
to the desired pressure, resulting in unacceptable performance. The compressor
will need to be rebuilt or replaced if it is beyond economic repair.
IF YOUR SYSTEM IS DOING THIS:
3. Experiencing frequent starts and stops
WE SUGGEST YOU CHECK THIS:
A. The system may be equipped with a storage tank that is too small for the
demand. The tank acts as a “buffer” between the compressor and the point of
demand. If the tank is too small, the compressor will start and stop excessively to
keep up with demand.
B. The total demand may be more than anticipated for the system design. Similar
to point A above, the facility demand may exceed what the compressor and storage
tank were designed to provide. This may be corrected by up-sizing existing
compressors or adding another compressor and larger storage tank.
C. The system’s pressure switches may be set too close together. The wider
the pressure switch settings, the longer the compressor will have in the off cycle
between starts. With close pressure switch settings, the compressor will frequently
start to maintain the desired pressure.
7255517 (Rev. 5) 05/2018
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IF YOUR SYSTEM IS DOING THIS:
4. Shutting down due to high temperature
WE SUGGEST YOU CHECK THIS:
A. The compressor may be running continuously for long periods of time. Many
compressors are designed for intermittent operation and will overheat if run too
long. This could be caused by a defective pressure switch, which is not allowing
the compressor to shut off when adequate pressure is attained.
B. The temperature switch itself could be defective. Its job is to protect the
compressor from excessive heat by shutting it down. If the switch is providing a
false temperature reading, it could be shutting down the compressor prematurely.
In such cases, the switch may need to be replaced.
C. The compressor may have worn rings or intake/discharge valves. As mentioned
above, if these components are worn, the compressor will not create adequate
pressure, resulting in long run times and excessive heat.
IF YOUR SYSTEM IS DOING THIS:
5. Experiencing high amp draw and motor trip out
WE SUGGEST YOU CHECK THIS:
A. Low line voltage. Power consumption is a function of line voltage and amperage
draw (P=I x E). If the facility’s line voltage dips below required levels, the pump
and motor may draw excessive amps, resulting in excessive heat and motor trip
out.
B. The motor starter could have a defective contactor. Such a situation would not
allow the contactor to handle the proper level of amperage, causing it to interrupt
power to the motor prematurely.
C. There could be a loose wire in the main power feed or the circuit to the pump
motor. Loose or inadequate wire connections will cause excessive resistance and
subsequent high amp draw.
D. A weak motor. If the pump’s motor is old, it could become weak due to numerous
occasions of heating and cooling. The motor may need to be replaced.
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IF YOUR SYSTEM IS DOING THIS:
6. Lag Alarm Going Off (Multiplex Systems)
WE SUGGEST YOU CHECK THIS:
A. One of the system’s compressors may be defective and unable to build adequate
pressure and ow. This will cause the system to trigger the lag pump to meet
demand, setting off the lag alarm.
B. One of the system’s compressors or motors may have failed for any reason.
This could be due to heat shutdown, a failed motor or other cause. To meet
demand, the pressure switch would cause the lag pump to be actuated, resulting
in the lag alarm.
C. The pressure switches could be set too close or they could be defective. When
multiple pressure switches are used, setting the switches too close together could
make the lag compressor come on too quickly, which would trigger the alarm. A
faulty switch could also cause the lag compressor to come on with the same result.
D. The system may be undersized for the facility’s demand. Many systems are
designed with one compressor reserved for backup. However, if the total demand
is too high for the system, all compressors could be actuated, resulting in a lag
alarm.
IF YOUR SYSTEM IS DOING THIS:
7. Desiccant Dryer Going Into Switching Failure
WE SUGGEST YOU CHECK THIS:
A. The repressurization valve could be malfunctioning. If the repressurization
valve is not functioning properly, a transducer in each tower would identify the
abnormal pressure condition and put the dryer into a switching failure mode. The
repressurization valve would either need to be rebuilt and/or replaced.
B. The purge valve could be malfunctioning. If the purge valve is not functioning
properly, a transducer in each tower would identify the abnormal pressure condition
and put the dryer into a switching failure mode. The purge valve would either need
to be rebuilt and/or replaced.
C. The dryer could have a defective transducer. This would identify a false
abnormal pressure condition putting the dryer in a switching failure mode. The
transducer would need to be replaced.
9255517 (Rev. 5) 05/2018
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TORQUE VALUES FOR COMPRESSOR ASSEMBLY
COMPONENT SIZE FT. LB.
CYLINDER HEAD TO CYLINDER M10 X P1.5 35 +0 -2
CYLINDER HEAD TO VALVE SEAT M8 X 1.25 20 +0 -2
BEARING CASE TO CRANKCASE M10 X P1.5 33 +2 -2
FLYWHEEL TO CRANK M12 X P1.75 28 +2 -2
CYLINDER TO CRANKCASE M10 X P1.5 28 +2 -2
PISTON TO PISTON PIN M6 X P1 9.5 +0 -2
OUTLET CUSHION PLATE TO VALVE SEAT M5 X P.8 3.8 +.2 -.2
INLET VALVE PLATE TO VALVE SEAT M5 X P.8 3.8 +.2 -.2
FAN TO FLYWHEEL OR COUPLING SEAT M10 X P1.5 30 +0 -2
FILTER ASSEMBLY TO CRANKCASE M6 X P1 .5 +0 -.03
PARTS AND ACCESSORIES
MODEL: P3-M
COMPRESSOR PARTS
PART # DESCRIPTON QUANTITY
230122 VALVE REBUILD KIT 2
230123 RING KIT 2
230112 UNLOADER KIT 4
230124 PISTON PIN KIT 2
230125 GASKET KIT 2
230126 CONNECTING ROD ASSBY. 2
230116 AIR BREATHER KIT 1
230127 PISTON 2
230128 BEARING 1
230129 BEARING 1
MODULE PARTS
230106 BARE COMPRESSOR 1
244269 3 HP MOTOR 1
245759 DRIVE BELT 2
246029 UNLOADER SOLENOID 1
211038 TEMPERATURE SWITCHES 2
233751 INLET FILTER, 1” 1
233915 INLET FILTER ELEMENT 1
247546 CHECK VALVE--1" 1
232260 RELIEF VALVE, 1/4" (125 PSI) 1
10 255517 (Rev. 5) 05/2018
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MODEL: P5-M
COMPRESSOR PARTS
MODULE PARTS
MODEL: P7-M
COMPRESSOR PARTS
PART # DESCRIPTON QUANTITY
230110 VALVE REBUILD KIT 2
230111 RING KIT 2
230112 UNLOADER KIT 4
230113 PISTON PIN KIT 2
230114 GASKET KIT 2
230115 CONNECTING ROD ASSBY. 2
230116 AIR BREATHER KIT 1
230118 PISTON 2
230119 BEARING 1
230120 BEARING 1
230100 BARE COMPRESSOR 1
244271 5 HP MOTOR 1
245826 DRIVE BELT 2
246029 UNLOADER SOLENOID 1
211038 TEMPERATURE SWITCHES 2
233751 INLET FILTER, 1" 1
233915 INLET FILTER ELEMENT 1
247546 CHECK VALVE--1" 1
232260 RELIEF VALVE, 1/4" (125 PSI) 1
PART # DESCRIPTON QUANTITY
230110 VALVE REBUILD KIT 3
230111 RING KIT 3
230112 UNLOADER KIT 6
230113 PISTON PIN KIT 3
230114 GASKET KIT 3
230115 CONNECTING ROD ASSBY. 3
230117 AIR BREATHER KIT 1
230118 PISTON 3
230121 BEARING 1
230120 BEARING 1
MODULE PARTS
230102 BARE COMPRESSOR 1
244271 7.5 HP MOTOR 1
245789 DRIVE BELT 3
246029 UNLOADER SOLENOID 1
211038
233753 INLET FILTER, 1 1/2" 1
233915 INLET FILTER ELEMENT 1
247546 CHECK VALVE--1" 1
232260 RELIEF VALVE, 1/4" (125 PSI) 1
TEMPERATURE SWITCHES 3
11255517 (Rev. 5) 05/2018
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MODEL: P10-M
COMPRESSOR PARTS
MODULE PARTS
MODEL: P15-M
COMPRESSOR PARTS
PART # DESCRIPTON QUANTITY
230110 VALVE REBUILD KIT 3
230111 RING KIT 3
230112 UNLOADER KIT 6
230113 PISTON PIN KIT 3
230114 GASKET KIT 3
230115 CONNECTING ROD ASSBY. 3
230117 AIR BREATHER KIT 1
230118 PISTON 3
230121 BEARING 1
230120 BEARING 1
230102 BARE COMPRESSOR 1
244272 10 HP MOTOR 1
245789 DRIVE BELT 3
246029 UNLOADER SOLENOID 1
211038 TEMPERATURE SWITCHES 3
233753 INLET FILTER, 1 1/2" 1
233915 INLET FILTER ELEMENT 1
247546 CHECK VALVE--1" 1
232260 RELIEF VALVE, 1/4" (125 PSI) 1
PART # DESCRIPTON QUANTITY
230110 VALVE REBUILD KIT 4
230111 RING KIT 4
230112 UNLOADER KIT 8
230113 PISTON PIN KIT 4
230114 GASKET KIT 4
230115 CONNECTING ROD ASSBY. 4
230117 AIR BREATHER KIT 1
230118 PISTON 4
230121 BEARING 2
MODULE PARTS
230101 BARE COMPRESSOR 1
244273 15 HP MOTOR 1
245766 DRIVE BELT 3
246029 UNLOADER SOLENOID 1
211038 TEMPERATURE SWITCHES 4
233870
233872 INLET FILTER ELEMENT 1
247546 CHECK VALVE--1" 1
232260 RELIEF VALVE, 1/4" (125 PSI) 1
12 255517 (Rev. 5) 05/2018
100-0224
INLET FILTER, 2" 1
Page 13
Compressor Spare Parts List – P3-M
No. Description Qty No. Description Qty
1 Seat plate assembly 1 22 Tube fitting 2
2 Compressor body 1 23 Discharge pipe 1
3 Set bolt 4 24 Set bolt 3
4 Spring Washer 4 25 Spring washer 3
5 Motor seat assembly 2 26 Square head plugs 1
6 Cooler combination 1 27 Square head plugs 1
7 Set bolt 4 28 Un loading tube 1
8 Spring washer 4 29 Bell brass fittings 1
9 Safety net portfolio 1 30 Rubber V-belt 3
10 Fixed plate 1 31 Motor pulley 1
11 Set bolt 2 32 Arrow mark sticker 1
12 Spring washer 2 33 Inall sticker 1
13 Safety net fixed false 1 34 Set bolt 2
14 Set bolt 8 35 Operating manual 1
15 Spring washer 8 36 Bare compressor parts diagrams 1
16 Belt cover bracket 1 37 Certificate of compliance 1
17 Belt cover bracket 1 38 PP Adherent bags 1
18 Aluminum rivets 2 39 Cotton yarn string 1
19 Brass combination 1 40 Set nut 2
20 Tube fitting 1 41 Set bolt 2
21 Tube fitting assembly 1
13255517 (Rev. 5) 05/2018
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Compressor Spare Parts List – P5-M
No. Description Qty No. Description Qty
1 Seat plate assembly 1 22 Tube fitting 2
2 Compressor body 1 23 Discharge pipe 1
3 Set bolt 4 24 Set bolt 3
4 Spring Washer 4 25 Spring washer 3
5 Motor seat assembly 2 26 Square head plugs 1
6 Cooler combination 1 27 Square head plugs 1
7 Set bolt 4 28 Un loading tube 1
8 Spring washer 4 29 Bell brass fittings 1
9 Safety net portfolio 1 30 Rubber V-belt 2
10 Fixed plate 1 31 Motor pulley 1
11 Set bolt 2 32 Arrow mark sticker 1
12 Spring washer 2 33 Inall sticker 1
13 Safety net fixed false 1 34 Set bolt 2
14 Set bolt 8 35 Operating manual 1
15 Spring washer 8 36 Bare compressor parts diagrams 1
16 Belt cover bracket 1 37 Certificate of compliance 1
17 Belt cover bracket 1 38 PP Adherent bags 1
18 Aluminum rivets 2 39 Cotton yarn string 1
19 Brass combination 1 40 Set nut 2
20 Tube fitting 1 41 Set bolt 2
21 Tube fitting assembly 1
15255517 (Rev. 5) 05/2018
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16 255517 (Rev. 5) 05/2018
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Compressor Spare Parts List – P7-M & P10-M
No. Description Qty No. Description Qty
1 Seat plate assembly 1 22 Tube fitting 2
2 Compressor body 1 23 Discharge pipe 1
3 Set bolt 4 24 Set bolt 3
4 Spring Washer 4 25 Spring washer 3
5 Motor seat assembly 2 26 Square head plugs 1
6 Cooler combination 1 27 Square head p0lugs 1
7 Set bolt 4 28 Unloading tube 1
8 Spring washer 4 29 Bell brass fittings 1
9 Safety net portfolio 1 30 Rubber V-belt 2
10 Fixed plate 1 31 Motor Pulley 1
11 Set bolt 2 32 Arrow mark sticker 1
12 Spring washer 2 33 Inall sticker 1
13 Safety net fixed false 2 34 Set bolt 2
14 Set bolt 8 35 Operating manual 1
15 Spring washer 8 36 Bare compressor parts diagrams 1
16 Belt cover bracket 1 37 Certificate of compliance 1
17 Aluminum rivets 2 38 PP adherent bags 1
18 Brass combination 1 39 Cotton yearn string 1
19 Tube fitting 1 40 Set nut 2
20 Tube fitting assembly 1 41 Set bolt 2
21 Tube fitting 2
17255517 (Rev. 5) 05/2018
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Compressor Spare Parts List – P15-M
No. Description Qty No. Description Qty
1 Seat plate assembly 1 23 Set bolt 3
2 Compressor body 1 24 Spring washer 3
3 Set bolt 4 25 Square head plugs 1
4 Spring washer 4 26 Square head plugs 1
5 Cooler combination 1 27 Unloading tube 1
6 Set bolt 4 28 Bell brass fittings 1
7 Spring washer 4 29 Rubber V-belt 3
8 Safety net portfolio 1 30 Motor pulley 1
9 Fixed plate 1 31 Arrow mark sticker 1
10 Set bolt 2 32 Inall sticker 1
11 Spring washer 2 33 Spring washer 4
12 Safety net fixed false 2 34 Set bolt 4
13 Set bolt 8 35 Set bolt 4
14 Spring washer 8 36 Set bolt 2
15 Safety net fixed false 1 37 Operating manual 1
16 Aluminum rivets 2 38 Bare compressor parts diagrams 1
17 Brass combination 1 39 Certificate of compliance 1
18 Tube fitting 1 40 PP adherent bags 1
19 Tube fitting assembly 1 41 Cotton yearn string 1
20 Tube fitting assembly 1 42 Set nut 2
21 Tube fitting 3 43 Set bolt 2
22 Discharge pipe 1
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®
North America
United States
Customer Service, Distribution Center
Technical Support, Sales and Service
Equipment Service Center
Ohio Medical LLC
1111 Lakeside Drive
Gurnee, IL 60031 USA
P: +1 866 549 6446
F: +1 847 855 6218
www.ohiomedical.com
© 2018 Ohio Medical LLC. This document contains information that is proprietary and condential to Ohio Medical
LLC. Use of this information is under license from Ohio Medical LLC. Any use other than that authorized by Ohio
Medical LLC is prohibited. Ohio Medical, the Ohio Medical logo, are registered trademarks of Ohio Medical LLC.
255517 (Rev. 5) 05/2018
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