BE AC5080B User manual

user manual
AC5080B
AC7580B
vertrical air
compressor
BEPOWEREQUIPMENT
.COM

2 3
table of contents
Introduction
4 Using the Operator’s Manual
Product Identification
5 Record Identification Numbers
Safety
6 Safety Precautions and Warnings
Troubleshooting
7 Troubleshooting Chart
Compressor Maintenance
10 Maintenance
11 Storage
Adjustments & Alignment
12 Adjusting Belt Tension
12 Pulley Alignment
Description of Compressor
13 What is a reciprocating compressor?
13 Description of Cooling
13 Description of Controls
Pre-Operation
14 Receiving and uncrating of your compressor
14 Compressor Installation
14 Location
14 Mounting
15 Induction System
15 Noise
15 Piping Fitup
16 Safety Valves
16 Pressure Vessels
16 Electrical
17 Pressure Switch
17 Manual Relief and Shutoff Valves
17 Guards
18 Drive
table of contents
Installation
19 Installation Diagram
Start Up Preparation
20 Start Up Preparation
Maintenance
21 Stopping for Maintenance or Service
22 Daily
22 Weekly
22 Monthly
22 Every 3 Months
23 Storage of Compressor
Parts Breakdown
24 CA1 and CA1U

4 5
Using the Operator’s manual
The operating manual is an important part of your Compressor. It should
be read thoroughly before initial use, and referred to often to make sure
adequate safety and service concerns are being addressed.
Reading the owner’s manual thoroughly will help avoid any personal injury
or damage to your pump. By knowing how best to operate this machine you
will be better positioned to show others who may also operate the unit.
You can refer back to the manual at any time to help troubleshoot any
specific operating functions, so store it with the machine at all times.
Attention: Read through the complete
manual prior to the initial use of your
Compressor
introduction product identification
Record Identification Numbers
COMPRESSOR
If you need to contact an Authorized Dealer or Customer Service line
(1-855-850-6668) for information on servicing, always provide the
product model and identification numbers.
You will need to locate the model and serial number for the pump and
record the information in the places provided below.
Date of Purchase:
Dealer Name:
Dealer Phone:
Product Identification Numbers
Model Number:
Serial Number:
WARNING: This product can expose you to
chemicals including lead, which is known to the
State of California to cause cancer and birth
defects or other reproductive harm. For more
information, go to www.P65Warnings.ca.gov.
Wash hands after handling.

6 7
safety
Safety Precautions and Warnings
Listed are some, but not all safety precautions that must be observed
with compressors. Failure to follow any of these warnings may result
in severe personal injury, death, property damage and/or compressor
damage.
• Air from this compressor will cause severe injury or death if used for
breathing or food processing.
• Air used for these processes must meet OSHA 29 CFR 1910 or FDA
21 178.3570 regulations.
• This compressor is designed for use in the compression of normal
atmospheric air only. No other gases, vapors or fumes should be
exposed to the compressor intake, nor processed through the
compressor.
• Disconnect all power supplies to the compressor plus any remote
controllers prior to servicing the unit.
• Relieve all pressure internal to the compressor prior to servicing.
• Do not depend on check valves to hold system pressure.
• A properly sized safety valve must be installed in the discharge piping
ahead (upstream) of any shutoff valve (block valve), heat exchanger,
orifice or any potential blockage point. Failure to install a safety relief
valve could result in rupturing or explosion of some compressor or
safety component.
• Do not change the pressure setting of the safety relief valve, restrict the
function of the safety relief valve, or replace the safety valve with a plug.
• Over pressurization of some system or compressor component can
occur, resulting in severe personal injury, death and property damage.
• Never use plastic pipe, rubber hose, or soldered joints in any part of the
compressors. Failure to ensure system compatibility with compressor
piping is dangerously unsound.
• Never use a flammable or toxic solvent for cleaning the air filter or any
parts.
• Do not attempt to service any part while the compressor is operating.
• Do not operate the compressor at pressures in excess of its rating.
• Do not remove any guards while the compressor is operating.
• Observe gauges daily to ensure compressor is operating properly.
• Follow all maintenance procedures and check all safety devices on
schedule.
• Compressed air is dangerous, do not play with it.
• Use the correct lubricant at all times.
troubleshooting
Troubleshooting Chart
NOTE: Troubleshooting problems may have similar causes and solutions.
Problem Possible Cause Solutions
Breaker Trips 1. Low Voltage supply
2. Motor overloads tripped
3. Restricted air passages
4. Loose wires at contact points
5. Seized Pump
1. Check that incoming
power wire size is adequate for
compressor
2. Check that compressor is on
dedicated circuit
3. Adjust belt tension
4. Check wire connections to
make sure they are tight
5. Inspect transfer tubes and,
check valve
Compressor
stalls
1. Low voltage supply to
compressor
2. Loose compressor belts
3. Bad check valve
4. Seized compressor pump
1. Check compressor power
supply for adequate breaker and
wire size
2. Inspect check valve for proper
operation
3. Tighten belts
4. Check compressor for proper
oil level.
Low Discharge
Pressure
1. Air leaks in shop
2. Leaking valves
3. Restricted air intake
4. Blown gaskets/seals
5. Worn piston rings or cylinder
1. Tighten or replace leaking
fittings, or joints
2. Clean or replace air filter
Compressor
pump knocking
1. Loose motor pulley or
compressor flywheel.
2. Low oil level in compressor
pump.
3. Carbon build up on valve and
piston.
1. Tighten pulley or flywheel.
2. Keep oil level at recommended
level for proper operation.
3. Only use factory recommended
oil.
WARNING
ALWAYS MAKE SURE ELECTRICAL POWER IS OFF BEFORE
REMOVING ANY INSPECTION COVERS OR PLATES.
You should always contact an authorized service center before
attempting to fix or repair your air compressor

8 9
Problem Possible Cause Solutions
Excessive oil
discharge in air
(All Compressors
have a small
amount
of oil carry over
in compression)
1. Worn piston rings or cylinder.
2. Restricted air intake.
3. Oil level to high.
4. Compressor has exceeded it
duty cycle.
1. Clean or replace air filters.
2. Reduce oil level to recom-
mended amount.
3. Reduce compressor duty cycle
(repair leaks or add another unit
to handle the excess demand)
Compressor
Overheating
1. Poor ventilation
2. Dirty cooling surfaces
3. Compressor is out of its
operating duty cycle
1. Relocate compressor to any
area with better ventilation (at
least 18 inches from the nearest
wall)
2. Clean all cooling surfaces
3. Reduce compressor duty cycle
(repair leaks or add another unit
to handle the excess demand)
Excessive Belt
Wear
1. Pulley out of alignment
2. Improper belt tension
3. Pulley damaged of loose
1. Realign pulley with flywheel
2. Re adjust belt tension
Compressor wont
start in Cold
weather
1. Bad check valve
2. Compressor has wrong grade oil
3. Control lines frozen
1. Use IS 100 (30W) compres-
sor oil
for cold weather conditions
2. Move compressor to a warmer
location
3. Put a heat lamp on compressor
to maintain above freezing
temperatures
troubleshooting
Troubleshooting Chart (continued)
NOTE: Troubleshooting problems may have similar causes and solutions.
Troubleshooting Chart (continued)
NOTE: Troubleshooting problems may have similar causes and solutions.
troubleshooting
Problem Possible Cause Solutions
Compressor
Motor Hums
wont
start
1. Fuse or Breaker blown in
main panel (or fuse in fused
disconnect if applicable)
2. Low voltage to compressor
3. Compressor starting with
head
pressure
4. Power leads in motor or
magnetic starter loose
5. Starter or Pressure switch
contacts corroded or broken
1. Re-set breaker or replace
blown
fuse
2. Inspect check valve for proper
operation
3. Check all power wire lead to
solid connection
4. Replace starter and Pressure
switch
Unit has power
but wont run
1. Starter tripped
2. Starter coil out
3. Pressure switch closed
4. Low Oil monitor tripped (Elite
units)
5. Motor or Pump locked up
1. Re-set starter
2. Replace starter and Pressure
switch
3. Check unit for proper oil level
4. Replace motor or pump
Compressor
Chatters (run
and
stops in a short
period of time)
1. Pressure switch connection
corroded
2. Starter is not getting enough
voltage to close coil
3. Low oil switch tripping
1. Replace pressure switch
2. Check unit voltage
3. Check the oil level in the unit
NOTICE
Low Voltage-Low voltage can cause a multitude of problems. The most
common cause of low voltage is when the wire size supplying the pow-
er to the compressor is too small. The longer the run of wire the larger
the diameter must be to overcome the inherent voltage loss caused by
the wire resistance. The supply voltage at the main panel could also be
low as supplied by you local power company or you may have too many
other pieces of equipment running off the same panel. You local electri-
cian should be contacted to evaluate and correct the problem accord-
ing to the Nation Electric Code. Other Symptoms of low voltage can be
flickering lights and computer screen when the compressor tries to turn
on.

10 11
compressor maintenance
Daily:
Drain the Receiver- condensation will accumulate in the tank daily, and
should be drained at least once a day. This is done to reduce corrosions
of the tank from the inside. Always wear protective eye wear when drain-
ing the tank.
Check Pump Oil Level - All units have a sight glass the oil level non run-
ning units should be no lower than ½ way on the sight glass if it is lower
then you need to add oil until it is at least ½ way up the sight glass.
Check unit for any unusual noise or vibrations.
Weekly:
Clean air filter to ensure that no dirt or heavy particulate makes its way
into the compressors valve assemblies.
Clean external parts of compressor and electric motor, this helps to en-
sure proper cooling and prevents rust and corrosion on critical parts.
Check safety valves to ensure they are not stuck in place and are operat-
ing properly.
Elite units Check auto tank drain for proper function.
Monthly:
Inspect complete air system for leaks to make sure the compressor does
not get out of its duty cycle due to air leak in the system.
Inspect oil for contamination to ensure that harmful deposits do not build
up in the oil.
Check belt tension, to ensure the belts do not fail pre-maturely. Tighten
them as needed to ensure they do not slip. If belts are loose, tighten per
instructions on next page. Failure to tighten can cause pre-mature belt
failure.
Every 3 months:
Change oil to ensure that the compressor has proper oil level and that
the oil in the machine does not deteriorate past factory specifications.
Inspect valve assemblies to prevent premature failure and clean out and
carbon that can form in older valves.
*Elite units clean auto tank drain strainer and check for proper function.
WARNING
To avoid personal injury, always shut OFF the main power supply and
disconnects to the compressor, relive all air pressure from the sys-
tem, and check electrical system with electrical probe before starting
any service or maintenance on the compressor.
Inspect pressure switch for proper function.
Inspect check valve for proper function and remove any carbon accumu-
lation to prevent premature failure.
*Clean belt guard coolers (if equipped).
Storage of Compressor:
Before storing the compressor for a prolonged period of time, use a blow
gun to clean all debris from compressor. Shut OFF main power and turn
OFF disconnect. Drain tank pressure, clean air filter, drain old oil and
replace with new oil. Cover the unit to prevent dust and moisture from
collecting on the unit.
storage

12 13
adjustments & alignment
Adjusting Belt Tension
Proper belt tension and pulley alignment must be maintained for maxi-
mum drive efficiency and for maximum belt life. The correct tensions
exists if a deflection of ½ inch occurs by placing 10lbs of force midway
between the motor pulley and the compressor flywheel. This deflection
can be adjusted by the following procedure. The pulley should be care-
fully aligned with the flywheel and set screws should be kept tight.
1. Remove the belt guard.
2. Loosen the motor mounting
bolts.
3. Shift the motor to the point
where the correct deflection
exists.
4. Retighten the motor
mounting belts.
5. Check to ensure that the
tension remain correct after tightening.
6. Re-install the belt guard. All moving parts must be guarded.
NOTE: Drive belt tension and pulley alignment are done at the same
time. They are discussed separately for clarity.
Pulley Alignment
The figure to the side shows 3 examples of misaligned pulleys. To check
pulley alignment, remove the belt guard and place a straightedge against
the compressor flywheel, measure and record the distance from the
straightedge to the edge of the drive belt. Then measure the distance to
the edge of the drive belt on the motor pulley at the same edge. As long
as both points measure the same distance the pulleys will be aligned if
not you will need to move the pulley until its in alignment this may take a
few tries. To re-align the pulley follow the steps below.
1. Loosen the motor mounting bolts.
2. Remove the belt guard.
3. Loosen the set screw on the motor pulley.
4. Align the motor pulley with the compressor
flywheel.
5. Re-tighten the motor pulley set screws.
6. Adjust the proper belt tension.
7. Re-tighten the motor mounting bolts.
8. Re-install the belt guard.
ANGULAR
MISALIGNMENT
PARALLEL
MISALIGNMENT
PULLEY GROOVE
AXIAL
MISALIGNMENT
PUMP
FLYWHEEL
STRAIGHT EDGE
MOTOR
PULLY
DRIVE
BELT
EDGE
DRIVE
BELT
EDGE
A B C
What is a reciprocating compressor?
A reciprocating compressor is a piston type pump which develops pres-
sure from the action of a piston moving through a cylinder. The cylinder,
or cylinders, may be vertical, horizontal or angular.
When air is drawn in from the atmosphere and compressed to its final
pressure in a single stroke, the compressor is referred to as a “single
stage” pump. Single stage units normally are used in the 90 to 125 PSI
range and are available as single or multi-cylinder (twin cylinder) com-
pressors.
When the air drawn from the atmosphere is compressed first to an inter-
mediate pressure, and then further compressed to a higher pressure, it is
done in a “two stage” pump. These cylinders are unequal in size and the
first stage always takes place in the larger, low pressure cylinder. From
there it passes through the inner cooler to the smaller, high pressure
cylinder. The cycle is completed as the air then moves through the after
cooler and discharge line into the tank. Two stage compressors are gen-
erally used for pressure ranges from 100 to 175 PSI and deliver more air
per horsepower at these pressures. This increase in efficiency is partially
due to the heat dissipated as the air passes through the inner cooler.
DESCRIPTION OF COOLING
Our compressors are cooled by fan blades, incorporated into the driven
sheave (pulley), blowing air across the intercooler, after cooler, and
cylinder head.
DESCRIPTION OF CONTROLS
Stop/Start Receiver or plant air system pressure is controlled within
limits by a pressure switch automatically stopping and starting the com-
pressor as the air pressure reaches a maximum preset pressure (cut out)
and then drops to a minimum presser pressure (cut in).
description of compressor

14 15
RECEIVING AND UNCRATING OF YOUR COMPRESSOR
Before uncrating the compressor the following steps should be taken.
1. Immediately upon receipt of the equipment, it should be inspected
for damage that may have occurred during shipment. If any damage
is found, demand an inspection immediately by an inspector from the
carrier. Ask him how to file a claim for damages. (See Appendix “A” for
Details).
2. Insure that adequate lifting equipment is available for moving the ma-
chinery.
3. Read the compressor nameplate to be sure the compressor is the
model and size ordered.
4. Read the motor nameplate to be sure the motor is compatible with
your electrical conditions. (Volts-Phase-Hertz).
Compressor Installation
LOCATION
Locate the compressor in an indoor area that is clean, dry, well lighted, and
well ventilated, with sufficient space for safe and proper inspection and
maintenance. Ambient temperatures should not exceed 104 degrees F
or fall below 30 degrees unless an electric motor rated for a higher tem-
perature is used. Inspection and maintenance checks are required daily,
therefore, ample space is required around the compressor.
The compressor must not be installed closer than fifteen inches from a wall
or from another compressor to allow ample circulation or air across the
compressor cylinders and head, and through the coolers if they are part of
the system. Additional safety can be achieved by locating the pulley guard
next to the wall.
pre-operation
WARNING
Improper lifting can result in component or system damage or personal
injury. Follow good shop practices and safety procedures.
NOTICE
Standard motors are open drip proof with a maximum ambient
temperature rating of 104 degrees F. They are not suitable for salt
laden, corrosive, dirty, wet, or explosive environments.
MOUNTING
We recommend the use of rubber pads or isolators between the tank legs
and the floor. If a shim is required to level the unit, place it between the
pad and floor. If you bolt the unit to the floor, use the bolts as guide pins
and do not tighten the bolts. The rubber pads are used to absorb machine
vibration and cannot work effectively if bolted tightly.
INDUCTION SYSTEM
Do not locate the compressor where it could ingest or ignite toxic,
explosive or corrosive vapors, ambient air temperatures exceeding 104
degrees F, water or extremely dirty air. Ingestion of any of the above noted
atmospheres by the compressor could jeopardize the performance of the
equipment and all personnel exposed to the total compressor.
Depending on the size of the compressor and the size and construction
of the compressor room it may be necessary to locate the air pickup point
outside the room. Destructive pulsations can be induced by reciprocating
compressors that will damage walls and break windows. Pulsation can be
minimized by adding a pulsation dampener on the inlet side of the
compressor.
pre-operation
NOISE
Noise is a potential health hazard that must be considered. There are
local and federal laws specifying maximum acceptable noise levels that
must not be exceeded. Most of the noise from a reciprocating compressor
originates from the air inlet point. Excessive noise can be greatly reduced
by installing an intake noise silencer
PIPING FITUP
Care must be taken to avoid assembling the piping in a strain with the
compressor. It should line up without having to spring or twist into posi-
tion. Adequate expansion loops or bends should be installed to prevent
undue stresses at the compressor resulting from the changes between
hot and cold conditions. Pipe support should be mounted independently
of the compressor and anchored as necessary to limit vibration and pre-
vent expansion strains.
CAUTION
Under no circumstances should a compressor be placed in an area that
may be exposed to a toxic, volatile or corrosive atmosphere nor should
toxic, volatile or corrosive agents be stored near the compressor.

16 17
pre-operation
PRESSURE VESSELS
Air receiver tanks and other pressure containing vessels such as, but
not limited to, pulsation bottles, heat exchangers, moisture separators
and traps, shall be in accordance with ASME Boiler and Pressure Vessel
Code Section VIII and ANSI B19.3 Safety Standards.
CAUTION
ASME coded pressure vessels must not be modified, welded, repaired,
reworded or subjected to operation conditions outside the nameplate
ratings. Such actions will negate code status, affect insurance status
and may cause severe personal injury, death, and property damage.
CAUTION
The installation, wiring, and all electrical controls must be in ac-
cordance with ANSI C1 National Electric Code, ANSE C2 National
Electric Safety Code, state and local codes. All electrical work should
be performed by a qualified electrician. Failure to abide by the national,
state and local codes may result in physical and/or property damage.
DANGER
Failure to properly size, set & install pressure relief valves can be fatal.
SAFETY VALVES
Safety valves are pressure relief valves and should be sized and
purchased with a pressure setting to protect the weakest link in the
system. Never change the pressure setting, only the safety valve
manufacturer is qualified to make a change. Safety valves are to be
place ahead of any potential blockage point which included but is not
limited to, shutoff valves, heat exchangers, pulsation dampeners, and
discharge silencers.
DANGER
Safety valves are to protect system integrity in accordance with ASME
Codes and ANSI B19.3 safety standards. Failure to use safety valves
of the proper capacity and pressure will cause severe personal injury or
death.
NOTICE
Standard motors are open drip proof with a maximum ambient
temperature rating of 104 degrees F. They are not suitable for salt
laden, corrosive, dirty, wet, or explosive environments.
PRESSURE SWITCH
The pressure switch is automatic in operation and is adjusted to start
and stop the unit at the minimum and maximum desired air receiver
pressure by cutting in and out the power to the electric motor. On some
models, the pressure switch incorporates a release valve, which releases
air between the check valve located in the receiver and discharge valve
in the head of the compressor.
ELECTRICAL
Before installation, the electrical supply should be checked for adequate
wire size and transformer capacity. During installation a suitable fused or
circuit breaker disconnect switch should be provided. Where a 3 phase
motor is used to drive a compressor, any unreasonable voltage unbal-
ance between the legs must be eliminated and any low voltage corrected
to prevent excessive current draw. Compressors must be equipped with
a properly wired magnetic motor starter or a pressure switch rated to
carry the full motor current load. The coil which engages and disengages
the contact points in the motor starter is controlled by the pressure
switch. Never attempt to bypass the pressure switch or adjust it past the
factory set pressure range. Improper installation of the electrical system
can cause the motor to overheat or a short circuit to occur.
CAUTION
Electric power always exists inside the pressure switch when there is
electric power at the compressor package. Either a qualified electrician
should make the pressure adjustments or the electric power supply
should be disconnected and locked out before making any adjustment.
NEVER exceed the designed pressure for the system or overload the
motor beyond its service factor. FAILURE TO HEED THESE WARN-
INGS MAY RESULT IN SERIOUS INJURY OR DEATH, PROPERTY
DAMAGE AND/OR MECHANICAL FAILURE
pre-operation
CAUTION
Relieve compressor and system air pressure by opening the appropri-
ate manual relief valve prior to servicing. Failure to relieve all system
pressure may result in severe personal injury, death & property damage.
GUARDS
All mechanical action or motion is hazardous in varying degrees and
needs to be guarded. Guarding shall be in compliance with OSHA
Safety and Health Standards 29 CFR 1910.219 in OSHA manual 2206
and any state or local code.

18 19
CAUTION
Excessive speed of the compressor or driver can be lethal. Never
operate the compressor beyond the manufacturer’s recommendation.
Bursting of the flywheel may be the greatest threat because the normal
guard may not contain all the pieces. Crankshaft and connecting rod
breakage is a possibility and compressor efficiency, valve life and bear-
ing life will be abnormally reduced.
CAUTION
Removal or painting over safety labels will result in uninformed condi-
tions. This may result in personal injury or property damage. Warnings
signs and labels shall be provided with enough light to read, conspicu-
ously located and maintained for legibility. Do not remove any warning,
caution, or instructional material attached!
Provisions should be made to have the instruction manual readily avail-
able to the operator and maintenance personnel. If for any reason any
part of the manual becomes illegible or if the manual is lost, have it re-
placed immediately. The instruction manual should be periodically read
to refresh one’s memory, it may prevent a serious or fatal accident.
DRIVES
IIt is important that the compressor and motor pulleys are aligned prop-
erly and the V belt is correctly tensioned. Improper pulley alignment and
belt tension are causes for motor overloading, excessive vibration, and
premature belt and/or bearing failure.
pre-operation
MANUAL RELIEF AND SHUTOFF VALVES
Install a manual relief valve to vent the compressor to atmosphere. In
those instances where the air receiver tank services a single compressor,
the manual relief valve can be installed on the receiver. When a manual
shut- off valve, and a safety relief valve installed upstream from the
manual relief valve. These valves are to be designed and installed as to
permit maintenance to be performed in a safe manner. Never substitute
a check valve for a manual shut-off valve (block valve) if the purpose is to
isolate the compressor from a system for servicing.
CAUTION
Guards must be fastened in place before starting the compressor and
never removed before cutting off & locking out the main power supply.
installation
INSTALLATION DIAGRAM
NOTICE
Recommended pipe and fittings: Black iron pipe no smaller than tank
outlet size (NPT). For system over 100 feet in length, increase by one
pipe size.
CAUTION
For paint spraying or similar applications, a non-lubricated supply line
must be used.
Shim tank so the pump is level within 1/8” per lineal foot MAXIMUM
to distribute oil properly. Fasten to floor and NEVER force tank feet to
floor without shims when tightening.
To remove moisture from air line, the main feeder line must run downhill
to drain-leg at a rate of 1/4” tp 1” every 10 feet.
WARNING
ALWAYS turn main power disconnect off, shut off power at power
panel, and drain all air pressure from tank before servicing unit.
QUICK COUPLER
AIR HOSE TO
AIR TOOL
NON-LUBRICATED
SUPPLY LINE
DRAIN LEG
FEEDER LINE
BYPASS BYPASS
1/4 TURN
SHUT-OFF
VALVE
1/4 TURN
SHUT-OFF
VALVE
MAGNETIC STARTER: Those not factory mounted on
the compressor can be mounted on the wall. Mount as
close to compressor as possible.
Sire the wires, protect them with conduit, and provide
branch circuit protection per the National Electrical
Code.
LINE FILTER
AIR-FLOW
AIR DRYER and/or
AF TERCOOLER MOTOR
PUMP
RECEIVER
FLEXIBLE
AIR-LINE
MAGNETIC STARTER
RESET SWITCH
REGULATOR
with gauge LUBRICATOR
CAUTION: NEVER use for paint
spraying or similar applications.
AIR/WATER FILTER
with PETCOCK
DRIP-TEE
with drain
MAIN DISCONNECT
(ON/OFF)
POWER PANEL
PRESSURE
SWITCH
MOISTURE
TRAP WITH
DRAIN
AIR-FLOW