Compressed Air Systems 15 HP Electric Reciprocating Compressor User manual

Owners Manual
Introduction
Congratulations on the purchase of your new air compressor. The air compressor is precision built from the finest
materials using the finest state of the art design, and high tech engineering available today. Quality, performance
and trouble free operation will assure you a dependable supply of air power on demand
15 HP Electric Reciprocating Compressor
Compressed Air Systems, LLC 2626 Skyway Drive Grand Prairie, TX, 75052 1-800-531-9656 Fax [phone]
www.compressed-air-systems.com
Simplicity. It’s What We Do.
CAUTION READ THIS MANUAL CAREFULLY before operating or servicing this air compressor, to
familiarize yourself with the proper safety, operation, and standard operating procedures of this unit.
FAILURETO COMPLYWITH INSTRUCTIONS IN THIS MANUAL COULD RESULT INTHE VOIDING OF YOUR
WARRANTY, AND PERSONAL INJURY, AND/OR PROPERTY DAMAGE. THE MANUFACTURER OF THIS
AIR COMPRESSOR WILL NOT BE LIABLE FOR ANY DAMAGE BECAUSE OF FAILURE TO FOLLOW THE
INSTRUCTIONS IN THIS MANUAL. By following the instructions and recommendations in this manual you
will ensure a longer and safer service life of your air compressor.
If you have questions or need clarification about this manual or your compressor call 800-531-9656
Do not operate compressor outdoors in wet weather
Check www.compressed-air-systems.com for most up to date manual and compressor service and technical information

SAFETY PRECAUTIONS AND WARNINGS
Listed are some, but not all safety precautions that must be observed with compressors and
compressed air systems. 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 com-
pressor.
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 shut-
off 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 person-
al injury, death and property damage.
Never use plastic pipe, rubber hose, or soldered joints in any part of the compressed air system. Fail-
ure 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.
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15 HP Electric Reciprocating Compressor

WARNING: Never apply air pressure to compressor crank case, always make sure crank case vent
is clear and free from obstructions. Adding pressure to the crank case can cause serious bodily
injury or death.
WARNING: Never operate a compressor in a moving vehicle or towable object in motion. Doing
so can damage the compressor, compressor drive components, or auxiliary parts on the compres-
sor package. Operating the compressor in a moving vehicle or towable object can cause serious
bodily injury or death.
WARNING: Check function of safety valves, weekly to insure proper function, replace immediately
if faulty or damaged.
Warning (Compressors Packaged with NEMA 7 Components)
Compressed Air Systems, LLC certifies that the electric motor, electrical enclosure and electrical
conduit are rated for NEMA7/hazardous locations. (Only for applicable packages with NEMA7
added components)
Air compressors have multiple moving parts and potential points of contact that could create
an ignition source. The compressor pumps are manufactured with ferrous metals and in some
cases multiple moving parts can come in contact with one another causing an ignition source.
Compressed Air Systems LLC does not guarantee this will not occur. Lack of maintenance or care
can result in conditions that could also cause ignition sources. Compressed Air Systems, LLC only
guarantees that the electric motor, electrical enclosure and electrical conduit are rated for NEMA7
hazardous location. Compressed Air Systems LLC accept no other responsibility for the rating of
the package.
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15 HP Electric Reciprocating Compressor

Troubleshooting Chart
NOTE: TROUBLESHOOTING PROBLEMS MAY HAVE SIMILAR CAUSES AND SOLUTIONS
Problem Possible causes 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
You should always contact an authorized service center before attempting to fix or
repair your air compressor
Always make sure electrical power is off before removing any inspection covers or plates
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15 HP Electric Reciprocating Compressor

Troubleshooting Chart (continued)
NOTE: TROUBLESHOOTING PROBLEMS MAY HAVE SIMILAR CAUSES AND SOLUTIONS
Problem Possible causes 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
recommended 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) compressor oil
for cold weather conditions
2. Move compressor to a warmer
location
3. Put a heat lamp on compressor
to maintain above freezing
temperatures
You should always contact an authorized service center before attempting to fix or
repair your air compressor
Always make sure electrical power is off before removing any inspection covers or plates
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15 HP Electric Reciprocating Compressor

Troubleshooting Chart (continued)
NOTE: TROUBLESHOOTING PROBLEMS MAY HAVE SIMILAR CAUSES AND SOLUTIONS
Problem Possible causes 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
NOTE: Low Voltage-Low voltage can cause a multitude of problems. The most common cause of low volt-
age is when the wire size supplying the power 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 sup-
ply 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 electrician should be contacted
to evaluate and correct the problem according to the Nation Electric Code. Other Symptoms of low voltage
can be flickering lights and computer screen when the compressor tries to turn on.
You should always contact an authorized service center before attempting to fix or
repair your air compressor
Always make sure electrical power is off before removing any inspection covers or plates
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15 HP Electric Reciprocating Compressor

Compressor Maintenance
Warning: To avoid personal injury, always shut OFF the main power supply and
disconnects to the compressor, relive all air pressure from the system, and check
electrical system with electrical probe before starting any service or maintenance
on the compressor.
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
draining the tank.
Check Pump Oil Level- All units have a sight glass the
oil level non running 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: this will 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 ensure proper cooling and prevents rust
and corrosion on critical parts.
Check safety Valves: this is don’t to ensure they are not
stuck in place and operating properly.
Elite Units Check auto tank drain for proper function
Monthly:
Inspect complete air system for leaks: this is done to
make sure the compressor does not get out of its duty
cycle due to air leak in the system.
Inspect Oil for Contamination: this is done to ensure
that harmful deposits do not build up in the oil.
Check belt tension: this is done to ensure the belt
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 or 500 hrs (whichever comes first):
Change Oil: this is done to ensure that the compres-
sor has proper oil level and that the oil in the machine
does not deteriorate past factory specifications.
Inspect Valve assemblies: this is done to prevent pre-
mature failure and clean out and carbon that can form
in older valves.
*Elite Units. Clean auto tank drain strainer and check
for proper function.
Inspect pressure switch for proper function.
Inspect check valve for proper function and remove
any carbon accumulation 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 com-
pressor. Shut OFF main power and turn OFF discon-
nect. 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.
NOTE: Maintaining proper oil level and performing oil
changes at proper intervals is necessary for the proper
function of the air compressor system. The best oil for you
air compressor is CAS30100 full synthetic reciprocating
compressor oil.
Your average vehicle travels 30,000 highway mikes in 500
hrs or 15,000 city miles in 500 hrs at 210ºF or less.
In the same 500 hrs/3 months a reciprocating compres-
sors operating temperature may exceed 350ºF.
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15 HP Electric Reciprocating Compressor

Adjusting Belt Tension
Pulley Alignment
Proper belt tension and pulley alignment must be maintained for maximum drive efficiency and for maxi-
mum 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 carefully 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 ex-
ists
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.
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
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15 HP Electric Reciprocating Compressor

Description of Compressor
What is a reciprocating compressor
A reciprocating compressor is a piston type pump which develops pressure 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 com-
pressor 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) compressors.
When the air drawn from the atmosphere is compressed first to an intermediate 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 generally 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 automati-
cally stopping and starting the compressor as the air pressure reaches a maximum preset pressure (cut out)
and then drops to a minimum presser pressure (cut in).
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15 HP Electric Reciprocating Compressor

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 machinery.
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).
NOTE: 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.
IMPORTANT: If voltage supplied to the compressor is below 208 volts the unit need
a 200 Volt drive motor and 208-230-460 Volt should not be used below 208 volts.
Improper lifting can result in component or
system damage or personal injury. Follow
good shop practices and safety procedures
!
CAUTION
Under no circumstances should a compressor be placed
in an area that may be exposed to a flammable, toxic,
volatile or corrosive atmosphere nor should flammable,
toxic, volatile or corrosive agents be stored near the
compressor.
!
CAUTION
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15 HP Electric Reciprocating Compressor

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 de-
grees F or fall below 30 degrees unless an electric motor rated for a higher temperature 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.
MOUNTING
The use of the factory supplied rubber vibration isolation pads, or other factory supplied vibration isolation
mounting equipment is required for tank warranty from the original tank manufacturer. The compressor
should never be left on original shipping material for installation. 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 110 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 compressed air system.
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.
On Electric compressors all electrical connections must be wired and
installed per NEC (National Electric Code) (See the back of the manual for
NEC code) and all local applicable codes for full electric component
warranty. Failure to do so can void compressor electrical warranty.
For compressor tank to have full manufacturer warranty. The tank must
be installed properly on manufacturer supplied vibration pads per
compressor manual. Failure to do so can void compressor tank warranty
and cause tank cracks or failures.
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15 HP Electric Reciprocating Compressor

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 com-
pressor 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 with-
out having to spring or twist into position. Adequate expansion loops or bends should be installed to pre-
vent 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 prevent expansion strains.
Safety valves are to protect system integrity in accor-
dance with ASME Codes and ANSI B19.3 safety stan-
dards. Failure to use safety valves of the proper capacity
and pressure will cause severe personal injury or death.
!!!
DANGER
NOTE: 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.
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 dampen-
ers, and discharge silencers.
Failure to properly size, set and install pressure relief valves can be fatal.
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15 HP Electric Reciprocating Compressor

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.
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.
!
CAUTION
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.
ELECTRICAL
Before installation, the electrical supply should be checked for adequate wire size and transformer capac-
ity. 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 unbalance 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 pres-
sure range. Improper installation of the electrical system can cause the motor to overheat or a short circuit
to occur.
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15 HP Electric Reciprocating Compressor

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 be-
yond its service factor.
FAILURE TO HEED THESE WARNINGS MAY RESULT IN SERIOUS INJURY OR DEATH,
PROPERTY DAMAGE AND/OR MECHANICAL FAILURE
Relieve compressor and system air pressure by opening the appropriate manual
relief valve prior to servicing. Failure to relieve all system pressure may result in
severe personal injury, death and property damage.
!
CAUTION
!
CAUTION
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 locat-
ed in the receiver and discharge valve in the head of the compressor.
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.
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15 HP Electric Reciprocating Compressor

Guards must be fastened in place before starting the compressor
and never removed before cutting off and locking out the main
power supply.
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 bearing life will be
abnormally reduced.
Removal or painting over safety labels will result in uninformed conditions. This
may result in personal injury or property damage. Warnings signs and labels shall
be provided with enough light to read, conspicuously 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 available to the
operator and maintenance personnel. If for any reason any part of the manual be-
comes illegible or if the manual is lost, have it replaced immediately. The instruction
manual should be periodically read to refresh one’s memory, it may prevent a seri-
ous or fatal accident.
!
CAUTION
!
CAUTION
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.
DRIVES
It is important that the compressor and motor pulleys are aligned properly and the V belt is correctly ten-
sioned. Improper pulley alignment and belt tension are causes for motor overloading, excessive vibration,
and premature belt and/or bearing failure.
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15 HP Electric Reciprocating Compressor

ALWAYS MAKE SURE POWER IS OFF BEFORE WIRING COMPRESSOR
Punch out hole in starter box for power inlet.
Place power
line 1 under
set screw
Place power
line 2 under
set screw
Place power
line 3 under
set screw
Remove Starter
lid cover
Place ground wire
under washer
Check all fitting to make sure that they are tight and place
cover back on starter box before checking for correct rota-
tion. If rotation is incorrect swap line 1 and line 3 to reverse
rotation
1
2
3
4
3 Phase Piston Compressor Wiring Diagram
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15 HP Electric Reciprocating Compressor

Installation Diagram
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15 HP Electric Reciprocating Compressor

Start Up Preparation & Procedures
The following check list shall be adhered to before putting the compressor into operation.
FAILURE TO PERFORM THE CHECKS MAY RESULT IN SERIOUS INJURY OR DEATH, PROPERTY DAMAGE
AND/OR MECHANICAL FAILURE. DISCONNECT AND LOCK OUT POWER SUPPLY.
1. Remove all loose pieces and tools around the compressor installation.
2. Check oil level in crankcase, add as necessary.
3. Check all pressure connections for tightness and leaks.
4. Check to make sure all safety relief valves are in place and operational.
5. Check to be sure all guards are in place and securely mounted.
6. Check fuses, circuit breakers and thermal overloads for proper size.
7. Open all manual shut-off valves (block valves) at and beyond the compressor discharge.
8. On all 3 phase units, after all of the above conditions have been satisfied, jog the starter switch button to
check the rotational direction of the compressor. It should agree with the rotation arrow on the flywheel/
pulley (counter clockwise, facing the shaft).
The following procedures should be followed for start-up of a new installation, or after changes have been
made to an existing installation, and/or after service repair work has been performed.
1. Instructions in addition to those contained within this manual, supplied by manufacturers of supporting
equipment, must also be read and understood before start-up.
2. Check oil level in crankcase.
3. Drain moisture from air receiver and traps.
4. Start compressor and watch for excessive vibration or strange noises. If either is observed,
stop the compressor immediately and correct.
5. Check air receiver or system pressure.
6. Manually activated safety relief valves by pulling ring or lever.
7. Check operation of controls.
8. After two days of operation check belt tension, air piping for leaks, and crankcase oil level.
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15 HP Electric Reciprocating Compressor

Stopping for Maintenance or Service
The following procedure should be followed to maximize safety when preparing for maintenance
or service.
1. Disconnect and lock-out the main power switch and hang a sign at the switch Informing of the unit be-
ing serviced.
2. Close shut-off valve (block valve) between receiver and compressor, or receiver and Plant air system, to
prevent any back-up of air flow into the area to be serviced.
3. Lock open manual vent valve and wait for the pressure in the area to be serviced (compressor, receiver,
etc.) to be completely relieved before starting service. The Manual vent valve may be the drain valve in
the receiver. NEVER remove a plug to relieve the pressure.
4. Open all manual drain valves within the area to be serviced.
5. Wait for the unit to cool before starting service, (temperatures at 125 degrees F can burn the skin), some
surface temperatures exceed 400 degrees F when the compressor is working).
6. Clean up all oils spills immediately to prevent slipping.
Never assume the compressor is ready for maintenance
or service because it is stopped. The automatic stop-
start control may start the compressor at any time!
!
CAUTION
Compressed Air Systems, LLC 1-800-531-9656 Fax [phone] www.compressed-air-systems.com
15 HP Electric Reciprocating Compressor

Maintenance Procedures Review
CERTIFICATE OF LIMITED WARRANTY
All component parts on this compressor are warranted to be free of defects, workmanship and material for a period of one
year. Transportation charges are the responsibility of purchaser. This warranty extends to the original purchaser of the com-
pressor only.
There are no express warranties except as contained in this limited warranty statement and implied warranties, including
those of merchantability and fitness for a particular purpose, are limited to the period of warranty.
Our liability is limited solely to replacement of nonconforming parts as set forth herein and does not include any liability for
any incidental, consequential, or other damages of any kind. This warranty gives you specific legal rights, and you may also
have other rights which vary from state to state.
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
draining the tank.
Check Pump Oil Level- All units have a sight glass the
oil level non running 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: this will 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 ensure proper cooling and prevents rust
and corrosion on critical parts.
Check safety Valves: this is don’t to ensure they are not
stuck in place and operating properly.
Elite Units Check auto tank drain for proper function
Monthly:
Inspect complete air system for leaks: this is done to
make sure the compressor does not get out of its duty
cycle due to air leak in the system.
Inspect Oil for Contamination: this is done to ensure
that harmful deposits do not build up in the oil.
Check belt tension: this is done to ensure the belt
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 or 500 hrs (whichever comes first):
Change Oil: this is done to ensure that the compres-
sor has proper oil level and that the oil in the machine
does not deteriorate past factory specifications.
Inspect Valve assemblies: this is done to prevent pre-
mature failure and clean out and carbon that can form
in older valves.
*Elite Units. Clean auto tank drain strainer and check
for proper function.
Inspect pressure switch for proper function.
Inspect check valve for proper function and remove
any carbon accumulation 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 com-
pressor. Shut OFF main power and turn OFF discon-
nect. 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.
NOTE: Maintaining proper oil level and performing oil
changes at proper intervals is necessary for the proper
function of the air compressor system. The best oil for you
air compressor is CAS30100 full synthetic reciprocating
compressor oil.
Your average vehicle travels 30,000 highway mikes in 500
hrs or 15,000 city miles in 500 hrs at 210ºF or less.
In the same 500 hrs/3 months a reciprocating compres-
sors operating temperature may exceed 350ºF.
Compressed Air Systems, LLC 1-800-531-9656 Fax [phone] www.compressed-air-systems.com
15 HP Electric Reciprocating Compressor