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CAP-215
APRIL, 2003
REV. D
OIL-LESS COMPRESSOR
OPERATION AND INSTRUCTION
MANUAL
OIL-LESS
COMPRESSOR MODELS
OL 512 SINGLE STAGE 3 H.P.
OL 512 SINGLE STAGE 5 H.P.
OL 524 TWO STAGE 5 H.P.
OL 812 SINGLE STAGE 7 1/2 H.P.
OL 812 SINGLE STAGE 10 H.P.
CAUTION
Before installing this compressor, read and understand
the safety precautions contained within this manual
CURTIS - TOLEDO, INC.
1905 Kienlen Avenue, St. Louis, Missou
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Instruction Manual Oil-Less Compressors TABLE OF CONTENTS Safety................................................................................................................................................... i Safety Precautions............................................................................................................................... i,ii Receiving Delivery...........................................................................................................
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Instruction Manual Oil-Less Compressors TABLE OF CONTENTS (CONT’D) 8. INSTALLATION OPERATION................................................................................................................. 23 8.1. INSTALLATION OF THE COMPRESSOR............................................................................................... 23 8.1.1. NATURAL VENTILATION........................................................................................................................ 2
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Instruction Manual Oil-Less Compressors Fig. 19 2 STAGE COMPRESSOR DIMENSIONS (070308-1015)........................................................................... 33 Fig. 20 1 STAGE COMPRESSOR DIMENSIONS (070307-1015)........................................................................... 35 Fig. 21 1 STAGE COMPRESSOR DIMENSIONS (077734).................................................................................... 36 Fig. 22 D51.2, DIAGRAM & SPARE PARTS LIST OF CYLINDER, PIST
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CAP-215 Instruction Manual Oil-Less Compressors INTRODUCTION THIS MANUAL CONTAINS OPERATION AND MAINTENANCE SCHEDULES FOR THE OIL-LESS COMPRESSOR MODELS: OL 512 OL 524 OL 812 ALL INSTRUCTIONS SHOULD BE OBSERVED AND CARRIED OUT IN THE ORDER LAID DOWN TO PREVENT DAMAGE AND PREMATURE WEAR TO THE EQUIPMENT AND THE COMPRESSORS SERVED BY IT. WHILE EVERY EFFORT IS MADE TO ENSURE THE ACCURACY OF THE PARTICULARS CONTAINED
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CAP-215 Instruction Manual Oil-Less Compressors SAFETY At Curtis-Toledo, Inc. safety is a primary concern. Beginning with the design stage, safety is built into every "Curtis Compressor". It is the purpose of this manual to pass along the "safety first" concept to you by providing safety precautions throughout its pages. “WARNING!”, "CAUTION!", and "DANGER!" are displayed in large bold capital letters to call attention to areas of vital concern. They represent different degree
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CAP-215 Instruction Manual Oil-Less Compressors DANGER! • Do not install a shutoff valve in the compressor Air used for breathing or food processing must meet discharge line without first Installing a pressure relief O.S.H.A. 29 C.F.R. 1910.134 or F.D.A. 21 C.F.R. 178.350 valve of proper size and design between the shutoff regulations. Failure to do so will cause severe injury or valve and the compressor. death. • Do not use plastic pipe, rubber hose, or lead-tin W
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CAP-215 Instruction Manual Oil-Less Compressors RECEIVING DELIVERY Immediately upon receipt of compressor equipment and prior to 3. Read the compressor nameplate to verify the model completely uncrating, the following steps should be taken: and size ordered. 1. Inspect compressor equipment for damage that may have 4. Read the motor nameplate to be sure the motor is occurred during shipment. If any damage is found, demand an compatible with your electrical conditions (vol
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CAP-215 Instruction Manual Oil-Less Compressors ELECTRICAL SUPPLY REQUIREMENTS The electrical installation of this unit should be performed by a result in physical harm and/or property damage. Do not by- qualified electrician with knowledge of the National Electrical pass motor overcurrent protection. Code (N.E.C.), O.S.H.A. code and/or any local or state codes having precedence. DANGER! High voltage may cause personal injury or death, per Before installation, the electr
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CAP-215 Instruction Manual Oil-Less Compressors All inlet piping should be at least the same size (or larger) in REMOTE INLET FILTERS diameter as the inlet connection to the compressor. For every 10 feet of inlet piping or every 900 bend, increase the inlet Depending on the size of the compressor and the size and piping diameter by one pipe size. The inlet piping must be construction of the room in which the unit operates, the air inlet thoroughly clean inside. Remove al
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CAP-215 Instruction Manual Oil-Less Compressors SYSTEM COMPONENTS installed between the manual shutoff valve and the compressor. Efficiency and safety are the primary concerns when selecting components for compressed air systems. Products of inferior quality can not only hinder performance of the unit, but could PRESSURE RELIEF VALVES cause system failures that result in bodily harm or even death. Pressure relief valves aid in preventing system failures by Select only
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CAP-215 Instruction Manual Oil-Less Compressors SYSTEM COMPONENTS (CONTINUED) WARNING! WARNING! Never exceed the designed pressure for the system or Never assume a compressor is safe to work on just overload the motor beyond its Maximum Amp Draw. because it is not operating. It may be in the automatic stand-by mode and may restart any time. Follow all safety • Full Load Amps x Service Factor = Max-imum Amp precautions outlined in STOPPING FOR MAINTENANCE. Draw. • F
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CAP-215 Instruction Manual Oil-Less Compressors PULLEY ALIGNMENT & BELT TENSION Setting Belt Tension Improper pulley alignment and belt tension are causes for 2. Determine the amount of deflection (in inches) required to motor overloading, excessive vibration and premature belt measure deflection force (in pounds) by multiplying the span and/or bearing failure. To prevent this from happening, check length x 1/64 (i.e. 32" span length x 1/64 = 1/2" of deflection the pulley
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CAP-215 Instruction Manual Oil-Less Compressors 1. GENERAL 1.1. PURPOSE AND SHORT DESCRIPTION The 1-stage oil-less compressor model OL 512, and OL 812, as well as the 2-stage oil-less compressor model OL 524, are used to compress air in the pressure ranges up to 110 psi (1-stage compressor models) to 220 psi (2-stage compressor models) All compressors operate with three cylinders and are air-cooled (Fig. 1 to Fig. 4). The cylinders are set in Y- configuration, allowing
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CAP-215 Instruction Manual Oil-Less Compressors Fig. 1: OL 512 (single stage), rear view 1 Cooler Manifold 5 Fan/flywheel 2 After-cooler 6 Final Separator (optional) 3 Cylinder 1st stage 7 Intake filter 4 Valve head 1st stage 8 Condensate drain valve (optional with #6) 2
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CAP-215 Instruction Manual Oil-Less Compressors Fig. 2: OL 512 (single stage), left side view 1 Cooler Manifold 4 Intake filter 2 After-cooler 5 Valve Head 3 Final Separator (optional) 6 Fan/flywheel 3
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CAP-215 Instruction Manual Oil-Less Compressors Fig. 3: OL 524 (2-stage), rear view 1 Valve head 2nd stage 9 Intermediate cooler 2 Safety valve 1st stage 10 Manifold 1st stage 3 Intermediate cooler 11 Final separator 4 Manifold 2nd stage 12 Maintenance indicator 5 Cylinder 1st stage 13 Valve head 1st stage 6 Valve head 1st stage 14 Intake filter 7 Intermediate separator 15 Condensate drain valve 8 Fan/flywheel 4
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CAP-215 Instruction Manual Oil-Less Compressors Fig. 4: OL 524 (2-stage), left side view 1 Final separator 6 Valve head 2nd stage 2 Manifold 7 Cylinder 2nd stage 3 After-cooler 8 Fan/flywheel 4 Intermediate separator (option) 9 Cylinder 1st stage 5 Intake filter 10 Vale head 1st stage 5
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CAP-215 Instruction Manual Oil-Less Compressors Fig. 5: OL 812 (single stage), rear view 1 Cylinder 1st stage 4 Ventilator/flywheel 2 After-cooler 5 Final separator 3 Intake filter 6 Maintenance indicator a) position of automatic condensate drain (optional) 6
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CAP-215 Instruction Manual Oil-Less Compressors Fig. 6: OL 812 (single stage), left side view 1 Cooler manifold 2 After-cooler 3 Final separator 7
