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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.
Instruction Manual Oil-Less Compressors TABLE OF CONTENTS Safety......................................................................................................................... .......................... i Safety Pr ecauti ons................
Instruction Manual Oil-Less Compressors TABLE OF CONTENTS (CONT’D) 8. INSTALLATION OPERAT ION...................................................................................................... ........... 23 8.1. INSTALLATION OF THE CO MPRESSOR..
Instruction Manual Oil-Less Compressors Fig. 19 2 STAGE COMPRESSO R DIMENSIONS (070308- 1015)........................................................................... 33 Fig. 20 1 STAGE COMPRESSOR DI MENSIONS (070307-1015) ..........................
CAP-215 Instruction Manual Oil-Less Compressors INTRODUCTION THIS MANUAL CONTAINS O PERATION 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.
CAP-215 i Instruction Manual Oil-Less Compressors SAFETY At Curtis-Toledo, Inc. safety is a primar y concern. Beginning w ith the design stage, safety is built into every "Curtis Compre ssor". It is the purpose of this manual to pass along the "safety first" concept to y ou by prov iding safety precautions throughout its pages .
CAP-215 ii Instruction Manual Oil-Less Compressors DANGER! A ir used for breathing or food processing must meet O.S.H.A . 29 C.F.R. 1910.134 or F.D.A. 21 C.
iii CAP-215 Instruction Manual Oil-Less Compressors RECEIVING DELIVERY Immediately upon receipt of compressor equipment and prior to completely uncrating, the follow ing steps should be taken: 1. Inspect compressor equipment for damage that may have occurred during shipment.
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 know l edge of the National Electrical Code (N.E.C.), O.S.H.A. code and/or any local or state codes having precedence.
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 whic h 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 the inlet piping as short and direct as possible.
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 perfo rmance of the unit, but could cause system failures that result in bodily harm or even death.
CAP-215 vii Instruction Manual Oil-Less Compressors SYSTEM COMPONENTS (CONTINUED) WARNING! Never exceed the designed pressure for the system or ove rload the motor beyond its Maximum A mp Draw. • Full Load A mps x Serv ice Factor = Max-imum A mp Draw .
viii CAP-215 Instruction Manual Oil-Less Compressors PULLEY ALIGNMENT & BELT TENSION Setting Belt Tension Improper pulley alignment and bel t tension are causes for motor overloading, excessive vibration and premature belt and/or bearing failure. To prevent this from happening, check the pulley alignment and belt tension on a regular basis.
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 mod.
CAP-215 Instruction Manual Oil-Less Compressors Fig. 1: OL 512 (single stage), rear view 1 Cooler Manifold 2 After-cooler 3 Cylinder 1st stage 4 Valve head 1st stage 5 Fan/flywheel 6 Final Separator (.
CAP-215 Instruction Manual Oil-Less Compressors Fig. 2: OL 512 (single stage), left side view 1 Cooler Manifold 2 After-cooler 3 Final Separator (optional) 4 Intake filter 5 Valve Head 6 Fan/flywheel .
CAP-215 4 Instruction Manual Oil-Less Compressors Fig. 3: OL 524 (2-stage), rear view 1 Valve head 2nd stage 2 Safety valve 1st stage 3 Intermediate cooler 4 Manifold 2nd stage 5 Cylinder 1st stage 6 .
CAP-215 5 Instruction Manual Oil-Less Compressors Fig. 4: OL 524 (2-stage), left side view 1 Final separator 2 Manifold 3 After-cooler 4 Intermediate separator (option) 5 Intake filter 6 Valve head 2n.
CAP-215 6 Instruction Manual Oil-Less Compressors Fig. 5: OL 812 (single stage), rear view 1 Cylinder 1st stage 2 After-cooler 3 Intake filter a) position of automatic condensate drain (optional) 4 Ve.
CAP-215 7 Instruction Manual Oil-Less Compressors Fig. 6: OL 812 (single stage), left side view 1 Cooler manifold 2 After-cooler 3 Final separator.
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 c o m p r e s s o r 1.
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 t he outside air via the intake filter (14) and the crankcase and compressed to an intermediate pressure of approx.
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.
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.
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.
CAP-215 Instruction Manual Oil-Less Compressors 2. INTAKE FILTER 2.1. DESCRIPTION A dry micronic filter is used to filter in take 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 inte rvals according to maintenance schedule in chapter 9.
CAP-215 14 Instruction Manual Oil-Less Compressors 3. INTERMEDIATE AND FINAL SEPARATOR 3.1. FUNCTIONAL DESCRIPTION OF INTERMED IATE SEPARATOR (2-STAGE MODELS ONLY) The intermediate separator (Fig. 9) is mounted after the two first stages of the 2-stage oil-less compressor.
CAP-215 15 Instruction Manual Oil-Less Compressors 3.2. FUNCTIONAL DESCRIPTION OF FINAL SEPARATOR A final separator is mounted after the three first st ages of the single-stage oil-less compressor and after the second stage of the 2-stage oil-less compressor.
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.
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 st age 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 is malfunctioning.
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 t he 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 according to chapter 4.
CAP-215 19 Instruction Manual Oil-Less Compressors 5. AUTOMATIC CONDENSATE DRAIN 5.1. DESCRIPTION The condensate drain valve should drain the final separat or (1 -stage compressor) or the intermediate and final separator (2-stage compressor) every 15 minutes or earlier if necessary.
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 equippe.
CAP-215 21 Instruction Manual Oil-Less Compressors 7. SAFETY REGULATIONS 7.1. GENERAL.
CAP-215 22 Instruction Manual Oil-Less Compressors.
CAP-215 23 Instruction Manual Oil-Less Compressors 8. INSTALLATION OPERATION 8.1. INSTALLATI ON OF THE COMPRESSOR Remove all plastic protective plugs and caps before Installing compressor. The oil-less compressor should be installed so that t here is no vibration, e.
CAP-215 24 Instruction Manual Oil-Less Compressors 8.1.1. Natural ventilation As warm air rises, adequate wall openings should be provi ded 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 opening.
CAP-215 25 Instruction Manual Oil-Less Compressors 8.1.2. Forced ventilation Forced ventilation facilitates a reduced variation in temper ature. It is achieved, for example by using an exhaust air fan.
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.
CAP-215 27 Instruction Manual Oil-Less Compressors 9. MAINTENANCE SCHEDULE 9.1. MAINTENANCE INTERVALS Int erv al Mai ntenanc e W or k Sec. 1/2 hour af ter start -up Manual c hec k of v al v e f unc t .
CAP-215 28 Instruction Manual Oil-Less Compressors 10. STORAGE, PRESERVATION 10.1. GENERAL If the oil-less compressor is to be put out of service for more than six months , the unit should be preserved in accordance with the following instructions: Make sure the compressor is kept indoors in a dry, dust fr ee room.
CAP-215 29 Instruction Manual Oil-Less Compressors 11. REPAIR INSTRUCTIONS 11.1. GENERAL Preventive maintenance usually involv es replacing the gaskets and sealing rings as well as carrying out the maintenance work.
CAP-215 30 Instruction Manual Oil-Less Compressors 12. TROUBLE-SHOOTING T RO UBL E CAUSE REMED Y Compr esso r Compr essor does not r eac h Condensat e drai n v alv e( s) and/ Ti ghten and reseal f ina.
CAP-215 31 Instruction Manual Oil-Less Compressors 13. TABLES 13.1. TIGHTENING TORQUE VALUES Unless otherw ise specified in text, the follow ing torque values apply. All valve head screws require torque w rench tightening! The torque values indicated are valid for bolts in gr eased condition.
CAP-215 32 Instruction Manual Oil-Less Compressors NOTE: Please refer to Chapter 9 of instruction manual for maintenance schedule. Operating hours Ai r fi lte r ca rtrid g e cleaned Ai r fi lte r ca r.
CAP-215 33 Instruction Manual Oil-Less Compressors 13. MAINTENANCE RECORD NOTE: Please refer to Chapter 9 of instruction manual for maintenance schedule.
CAP-215 Fig. 19: 2-stage compressor dimensions (070308-1015) 34.
CAP-215 35 Fig. 20: 1-stage compressor dimensions (070307-1015).
CAP-215 36 Fig. 21: 1-stage compressor dimensions (077734).
CAP-215 Cylinder, Piston and Intake Valve Fig. 22 Note: Quantities shown are per cylinder Spare parts sets Cylinder, pi ston and intake valve D51.2 Class 0 2 5 Pos.
CAP-215 Cylinder, Piston and Intake Valve Fig. 23 Note: Quantities shown are per cylinder Spare parts sets Cylinder, pi ston and intake valve D52.4 Class 0 2 5 Pos.
CURTIS – TOLEDO, INC. 1905 KIENLEN AVE., ST. LOUIS, MO 63133 TEL. (314) 383-1300 FAX (314) 381-1439 E-MAIL: CURTISCOMP@AOL.COM.
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