Operator Manual 200-2909 Revision A Electric Two–Stage Air Compressors NOTE: These units require a magnetic starter. These air compressors require a magnetic starter, to prevent motor damage in the event of a thermal overload. WARNING: Read and understand all safety precautions in this manual before operating. Failure to comply with instructions in this manual could result in personal injury, property damage, and/or voiding of your warranty.
TABLE OF CONTENTS SAFETY GUIDELINES........................................................... 2-4 OPERATING INSTRUCTIONS................................................. 8 GLOSSARY OF TERMS........................................................... 4 MAINTENANCE................................................................... 9-11 OVERVIEW............................................................................ 4-5 SERVICE INTERVAL..............................................................
IMPORTANT SAFETY INSTRUCTIONS RISK TO BREATHING/ INHALATION HAZARD. Always wear MSHA/NIOSH approved, properly fitting face mask or respirator and work in a well ventilated area when using tools that generate dust. Some dust created by power sanding, grinding, drilling and other construction activities contains chemicals known (to the State of California) to cause cancer, birth defects or other reproductive harm.
IMPORTANT SAFETY INSTRUCTIONS CAUTION: Drain the moisture from the tank on a daily basis. A clean, dry tank will help prevent corrosion. Pull the tank safety valve ring daily to ensure that the valve is functioning properly, and to clear the valve of any possible obstructions. To provide proper ventilation for cooling, the compressor must be kept a minimum of 12 inches (31 cm) from the nearest wall, in a well–ventilated area.
NOTE: These units require a magnetic starter. Fig. 1 B Magnetic starters that are not factory mounted on the compressor can be mounted on the wall if desired. Mount as close to compressor as possible. Size the wires, protect them with conduit, and provide branch circuit protection per the National Electrical Code. A E D C ASSEMBLY ASSEMBLING THE COMPRESSOR This compressor was shipped with oil in the pump crankcase. Check oil before operating the air compressor, see Check Oil under Maintenance.
TYPICAL INSTALLATION WARNING: Compressor may vary from one shown. A B C D E F G H J K L M N P R T U Risk of bursting, resulting in injury. Never use plastic pipe for compressed air. CAUTION: Never use lubricator for paint spraying or similar applications. To remove this moisture, run the main air line downhill to a moisture trap and drain. Air/water filters should also be installed in the positions shown.
COMPRESSOR CONTROLS Main Power Disconnect Install a main power disconnect switch in the power line to the compressor, near the compressor’s location. It is operated manually, but when it is in the ON position, the compressor will start up or shut down automatically based on air demand. ALWAYS operate this switch to OFF when the compressor is not being used.
OPERATING INSTRUCTIONS BREAK-IN OF THE PUMP SHUTDOWN 1. 2. 3. NOTE: The pump is shipped with break-in oil which should be changed after the first 8 hours of operation. 1. 2. 3. Make sure the power is connected at the power panel. Check the oil level in the pump (see “Checking the Oil” in the maintenance section). Open the petcock (see C). CAUTION: Escaping air and moisture can propel debris that may cause eye injury. Wear safety goggles when opening petcock.
MAINTENANCE guard removed. Serious injury could occur from contact with moving parts. MAINTENANCE WARNING: This unit starts automatically. ALWAYS shut off the main power disconnect, and bleed all pressure from the system before servicing the compressor, and when the compressor is not in use. Do not use the unit with the shrouds or belt guard removed. Serious injury could occur from contact with moving parts. Regular maintenance will ensure trouble–free operation.
MAINTENANCE NOTE: Once the motor pulley has been moved from its factory set location, the grooves of the flywheel and pulley must be aligned to within 1/16” to prevent excessive belt wear. To check pulley alignment, remove the belt guard and place a straightedge (see A) against the pump flywheel (see B) (See Fig. 9). Measure and record the distance from the straightedge to the edge of the drive belt at point C.
MAINTENANCE 7. Apply thread sealant to the check valve threads and reinstall into the tank by turning clockwise. Make sure it is the same orientation as when it was removed. 8. Replace the bleeder tube and tighten compression nut. 9. Replace the transfer tube and tighten compression nuts. 10. Perform the “Break-in of the pump” procedure in the Operating Instructions to make sure there are no leaks and the check valve is working properly.
TROUBLESHOOTING Note: Troubleshooting problems may have similar causes and solutions. PROBLEM POSSIBLE CAUSE SOLUTION Excessive current draw trips circuit breaker or motor reset switch Low voltage/motor overload Check that power supply is adequate and that compressor is on a dedicated circuit. Drive belt tension too tight Readjust belt tension. Restricted air passages Inspect and replace transfer tubes or the check valve, (see “To replace or clean check valve” in the maintenance section).
