Page 2 - Instruction Manual Oil-Less Compressors; TABLE OF CONTENTS; vii; STAGE)........................................................................................
Instruction Manual Oil-Less Compressors TABLE OF CONTENTS Safety................................................................................................................................................... i Safety Precautions.......................................................................
Page 7 - ii
CAP-215 ii Instruction Manual Oil-Less Compressors DANGER! Air used for breathing or food processing must meet O.S.H.A. 29 C.F.R. 1910.134 or F.D.A. 21 C.F.R. 178.350 regulations. Failure to do so will cause severe injury or death. WARNING! Compressors are precision high speed mechanical equipment r...
Page 8 - iii
iii CAP-215 Instruction Manual Oil-Less Compressors RECEIVING DELIVERY Immediately upon receipt of compressor equipment and prior to completely uncrating, the following steps should be taken: 1. Inspect compressor equipment for damage that may have occurred during shipment. If any damage is found, d...
Page 9 - iv; This unit must be grounded.; codes; may; AIR INLET SYSTEM
CAP-215 iv Instruction Manual Oil-Less Compressors ELECTRICAL SUPPLY REQUIREMENTS The electrical installation of this unit should be performed by a qualified electrician with knowledge of the National Electrical Code (N.E.C.), O.S.H.A. code and/or any local or state codes having precedence. Before i...
Page 10 - REMOTE INLET FILTERS; COMPRESSED AIR DISCHARGE SYSTEM; Typical Drop Leg & Component Location; device using the air. Manual; shutoff valves, protected by
CAP-215 v Instruction Manual Oil-Less Compressors REMOTE INLET FILTERS Depending on the size of the compressor and the size and construction of the room in which the unit operates, the air inlet may have to be located outside of the room. If it is necessary to remotely install the air filter, make t...
Page 11 - vi
vi CAP-215 Instruction Manual Oil-Less Compressors SYSTEM COMPONENTS 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 cause system failures that result in bodily ha...
Page 12 - F can burn skin. Some surface
CAP-215 vii Instruction Manual Oil-Less Compressors SYSTEM COMPONENTS (CONTINUED) WARNING! Never exceed the designed pressure for the system or overload the motor beyond its Maximum Amp Draw. • Full Load Amps x Service Factor = Max-imum Amp Draw. • Full Load Amps (FLA) & Service Factor can norma...
Page 13 - viii; Setting Belt Tension
viii CAP-215 Instruction Manual Oil-Less Compressors PULLEY ALIGNMENT & BELT TENSION Setting Belt Tension Improper pulley alignment and belt tension are causes for motor overloading, excessive vibration and premature belt and/or bearing failure. To prevent this from happening, check the pulley a...
Page 14 - PURPOSE AND SHORT DESCRIPTION
CAP-215 1 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)...
Page 21 - DESIGN AND MODE OF OPERATION
8 CAP-215 Instruction Manual Oil-Less Compressors 1.2. DESIGN AND MODE OF OPERATION 1.2.1 DESIGN The design of the oil-less compressor is shown in Fig. 1 to Fig. 4. For drawings refer to the annex of this manual. Fig. 7: Position of stages at 2-stage compressor 1.2.2. Mode of Operation 1-stage compr...
Page 22 - Fig 8: Function of non-return valve
CAP-215 9 Instruction Manual Oil-Less Compressors 2-stage compressor The position stated refer to Fig. 3. The two first stages (5) of the oil-less compressor draw in the outside air via the intake filter (14) and the crankcase and compressed to an intermediate pressure of approx. 60 to 70 psi. The c...
Page 23 - DATA
CAP-215 10 Instruction Manual Oil-Less Compressors 1.3. TECHNICAL DATA 1 -stage compressor No. of stages Intake volume b) Intake pressure Delivery Operating pressure, max. No. of cylinders Cylinder bore Piston stroke Speed Weight Drive input c) Compressor rotation Min./max. ambient temperature OL 51...
Page 24 - Technical Data
CAP-215 11 Instruction Manual Oil-Less Compressors Technical Data 1 -stage compressor No. of stages Intake volume f) Intake pressure Delivery Operating pressure, max. No. of cylinders Cylinder bore Piston stroke Speed Weight Drive input g) Compressor rotation Min./max. ambient temperature OL 812 1 4...
Page 25 - Electrical Intake filter control; Operation characteristic PTC temperature sensor
CAP-215 12 Instruction Manual Oil-Less Compressors 1.4. ELECTRICAL DATA Electrical Intake filter control Operating voltage max. Electrical power consumption Temperature sensor (option) Operating voltage max. U max Nominal response temperature NAT Tolerance Cold resistance PTC resistance (U KI =2.5 V...
Page 26 - FILTER; Turn filter element; Use recommended spare element VGB 596 only.
CAP-215 Instruction Manual Oil-Less Compressors 2. INTAKE FILTER 2.1. DESCRIPTION A dry micronic filter is used to filter intake air (Fig. 8). The intake filter is equipped with a replaceable filter cartridge. 2.2. INTAKE FILTER MAINTENANCE The filter cartridge must be serviced at regular intervals ...
Page 27 - INTERMEDIATE AND FINAL SEPARATOR
CAP-215 14 Instruction Manual Oil-Less Compressors 3. INTERMEDIATE AND FINAL SEPARATOR 3.1. FUNCTIONAL DESCRIPTION OF INTERMEDIATE SEPARATOR (2-STAGE MODELS ONLY) The intermediate separator (Fig. 9) is mounted after the two first stages of the 2-stage oil-less compressor. The separator is designed t...
Page 28 - FUNCTIONAL DESCRIPTION OF FINAL SEPARATOR; provided additionally to remove dirt contamination.; DRAIN
CAP-215 15 Instruction Manual Oil-Less Compressors 3.2. FUNCTIONAL DESCRIPTION OF FINAL SEPARATOR A final separator is mounted after the three first stages of the single-stage oil-less compressor and after the second stage of the 2-stage oil-less compressor. Separation is achieved by means of centri...
Page 29 - FUNCTIONAL DESCRIPTION OF 1; STAGE
CAP-215 16 Instruction Manual Oil-Less Compressors 4. VALVES 4.1. FUNCTIONAL DESCRIPTION OF 1 st STAGE The valve head of the first stage forms the top part of the cylinder. The intake valve is fitted on the top of the piston. The pressure valve is mounted between valve head and cylinder. Note that t...
Page 30 - GENERAL INSTRUCTIONS FOR CHANGING THE VALVES; clean with soft brush.
CAP-215 17 Instruction Manual Oil-Less Compressors 4.3. INITIAL OPERATIONAL CHECK OF VALVES If the intake pipe to the valve head of the second stage heats up excessively, and the first stage safety valve relieves, either the intake valve of the second stage or the pressure valve of the first stage i...
Page 31 - CHANGING THE VALVES OF THE 1; STAGE VALVES AND VALVES OF 1ST STAGE PRESSURE VALVE
CAP-215 18 Instruction Manual Oil-Less Compressors 4.5. CHANGING THE VALVES OF THE 1 ST STAGE The intake valve of the 1st stage is integrated into the top part of the piston. The pressure valve is fitted between valve head and cylinder. Changing the pressure valve Change pressure valve of 1st stage ...
Page 32 - AUTOMATIC CONDENSATE DRAIN
CAP-215 19 Instruction Manual Oil-Less Compressors 5. AUTOMATIC CONDENSATE DRAIN 5.1. DESCRIPTION The condensate drain valve should drain the final separator (1 -stage compressor) or the intermediate and final separator (2-stage compressor) every 15 minutes or earlier if necessary. Furthermore, cond...
Page 33 - COOLING SYSTEM; the flywheel and are powered by the driving motor.
CAP-215 20 Instruction Manual Oil-Less Compressors 6. COOLING SYSTEM 6.1. GENERAL Cooling of the oil-less compressor is twice as efficient because of their mode of operation: The compressor is equipped with a flywheel which draws the cooling air through the flywheel cover from the surroundings and t...
Page 34 - REGULATIONS
CAP-215 21 Instruction Manual Oil-Less Compressors 7. SAFETY REGULATIONS 7.1. GENERAL
Page 36 - OPERATION; instance through an opening in the wall.
CAP-215 23 Instruction Manual Oil-Less Compressors 8. INSTALLATION OPERATION 8.1. INSTALLATION OF THE COMPRESSOR Remove all plastic protective plugs and caps before Installing compressor. The oil-less compressor should be installed so that there is no vibration, e.g. from the drive motor. - If possi...
Page 37 - ventilation
CAP-215 24 Instruction Manual Oil-Less Compressors 8.1.1. Natural ventilation As warm air rises, adequate wall openings should be provided for cooling air intake (next to the floor) and for cooling air outlet (next to/ in the ceiling). The compressor should be positioned right next to the air inlet ...
Page 39 - INSTALLATION; motor, magnetic starter solenoids, and other control devices.; first; flywheel to ensure that all parts are turning free.; PROCEDURE
CAP-215 26 Instruction Manual Oil-Less Compressors 8.2. ELECTRICAL INSTALLATION For installation of electrical equipment attend to the following: Follow the National Electric Code or local Electric code in providing, fusing, and disconnect switches. Check electrical supply for voltage, phase, and fr...
Page 40 - SCHEDULE
CAP-215 27 Instruction Manual Oil-Less Compressors 9. MAINTENANCE SCHEDULE 9.1. MAINTENANCE INTERVALS Interv al Maintenance W ork Sec. 1/2 hour after start-up Manual check of v alv e function (at first operation and maintenance 4 work 250 operating hours Check all connections for leakage -- 50 - 250...
Page 42 - INSTRUCTIONS; maintenance
CAP-215 29 Instruction Manual Oil-Less Compressors 11. REPAIR INSTRUCTIONS 11.1. GENERAL Preventive maintenance usually involves replacing the gaskets and sealing rings as well as carrying out the maintenance work. Repair work can be carried out on the oil-less compressor to a certain extent, howeve...
Page 43 - TROUBLE
CAP-215 30 Instruction Manual Oil-Less Compressors 12. TROUBLE-SHOOTING TROUBLE CAUSE REMEDY Compressor Compressor does not reach Condensate drain valve(s) and/ Tighten and reseal final pressure or fittings leakingPremature opening of final safety Clean final safety valve and re- valve adjust Piston...
Page 44 - TIGHTENING TORQUE VALUES; Tighten valve head and cylinder bolts/nuts; Hex and allen head
CAP-215 31 Instruction Manual Oil-Less Compressors 13. TABLES 13.1. TIGHTENING TORQUE VALUES Unless otherwise specified in text, the following torque values apply. All valve head screws require torque wrench tightening! The torque values indicated are valid for bolts in greased condition. Replace se...
Page 45 - Operating hours
CAP-215 32 Instruction Manual Oil-Less Compressors NOTE: Please refer to Chapter 9 of instruction manual for maintenance schedule. Operating hours Air filter cartridgecleanedAir filter cartridgechangedV-belt, fan wheeldrive checkedV-belt, fan wheeldrive adjustedV-belt, fan wheeldrive changedV-belt, ...
Page 46 - RECORD
CAP-215 33 Instruction Manual Oil-Less Compressors 13. MAINTENANCE RECORD NOTE: Please refer to Chapter 9 of instruction manual for maintenance schedule. Operating hours Air filter cartridgecleanedAir filter cartridgechangedV-belt, fan wheeldriv e checkedV-belt, fan wheeldriv e adjustedV-belt, fan w...
Page 50 - Note: Quantities shown are per cylinder; Spare parts sets
CAP-215 Cylinder, Piston and Intake Valve Fig. 22 Note: Quantities shown are per cylinder Spare parts sets Cylinder, piston and intake valve D51.2 Class 0 2 5 Pos. Part No. Designation Weight (kg) Dimensions 1 CCC1512 Cylinder and piston assembly Ø85 2 CCC1513 Piston assembly 3 9 3 CCC1466 Intake va...
