Compressed Air Systems 7.5hp User manual

Introduction. Congratulations on the purchase of your new air compressor. The air compressor is precision
built from the nest materials using the nest 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
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.
FAILURE TO COMPLY WITH INSTRUCTIONS IN THIS MANUAL COULD RESULT IN THE 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 clarication 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
Owners
Manual
5-15 HP Electric
Rotary Screw Compressors
Simplicity. It’s What We Do.
compressed-air-systems.com | 1-800-531-9656 | Fax [phone]
Compressed Air Systems

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 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 shut-o valve (block valve),
heat exchanger, orice 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 compressed air system.
Failure to ensure system compatibility with compressor piping is dangerously unsound.
Never use a ammable or toxic solvent for cleaning the air lter 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.
Always wear proper safety equipment when using compressed air.
Always install compressor to all local applicable electric codes.
WARNING: Read all installation steps in install guide, and compressor package manual prior to
un-crating or installing compressor package. Failure to do so can result in personal injury or damage
to compressor package.
NOTICE: All compressor air receivers should be inspected by a certied pressure vessel technician
at least once per year, to check for leaks, weak points in the metal or any other deformity of the air
receiver. If at any time a receiver appears out of conformance with ASME/CRN certication or a
deformity is believed to have developed no matter how minor it may appear the tank should be
locked out of service immediately and replaced with a certied ASME/CRN certied air receiver
immediately before the compressor can be put back into service. The receivers should have a
general inspection weekly as part of normal service.
Compressed Air Systems, LLC 1-800-531-9656 Fax [phone] www.compressed-air-systems.com
5-15 HP Electric Rotary Screw Compressors

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: Always wear proper protective eyewear,, hearing protection and safety clothing when
working around the compressor package. No loose or baggy clothing should be worn around
compressor package at any time.
WARNING: On Electric motor powered air compressors make sure electrical system is up to National
Electric Code (NEC) prior to installing compressor system. Failure to install a compressor with a proper
NEC electrical system can cause personal injury, compressor package damage and void compressor
package warranty
NOTICE: To ensure full compressor tank warranty all tank mounted compressor packages must be
mounted on factory approved vibration isolation pads. A compressor should NEVER be installed while
still on or in its original packaging. Failure to properly install the compressor system with approved
vibration isolation pads will result in the compressor tank warranty being void.
WARNING: Compressed Air Systems compressors can operate at pressures from 0-250psi depending
on the compressor package design and build specications. Always verify that the system the
compressor is installed into can handle the maximum operational pressure the compressor. NEVER
install a compressor in a system that can not handle the compressors maximum operating pressure.
WARNING: Compressed air is extremely dangerous when not properly used or installed. Always make
sure a trained compressed air professional has looked over the air system prior to use. Improper
installation or use of compressed air can cause bodily injury or death. NEVER pressurize an object that
was not designed to be pressurized. Pressurizing objects not properly engineered for the maximum
operating pressure of the compressor system can cause 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 com-
pressor 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 certies 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.
Compressed Air Systems, LLC 1-800-531-9656 Fax [phone] www.compressed-air-systems.com
5-15 HP Electric Rotary Screw Compressors

Descriptions
This Compressed Air Systems industrial rotary screw
compressor is an electric motor driven single stage
helical rotary screw compressor. It is sold as a complete
package mounted on a steel base. This unit can come
with options of being tank mounted, Enclosure
mounted or Enclosure tank mounted. The package
includes the compressor air end, electric motor, motor
controls, air intake system, cooling system, SMART
contact capacity control system, air/oil separator, and
instrumentation. Installation requires only electric
power and a service line.
This air compressor is a rotating piece of equipment
and should not be worked on or serviced while there is
power to the unit. You should always turn the power o
to the compressor unit before performing and
kind of service to the machine. If you have any questions
please contact the factory for clarications before
making any changes to the delivered state of the
compressor.
The owner, lesser, or operator of this compressor is hear
by notied and forewarned that any failure to observe
these safety precautions in this manual may result in
injury, damage to the unit or death.
Compressed Air Systems expressly disclaims
responsibility or liability for any injury or damage caused
by failure to follow these specied precautions or by
failure to exercise that ordinary caution and due care
required in operation or handling the compressor even
though not expressly specied here. If you have any
questions contact the factory immediately at
1-800-531-9656
COMPRESSOR
The compressor assembly is a positive displacement,
oil ood lubricated, helical rotary screw type unit
employing a single stage of compression. The
components include housing or stator, two rotors or
screws, bearings and bearing supports.
In operation two helical grooved rotors mesh to
compress air. Inlet air entering the compressor becomes
trapped between the lobes of the rotors. As the rotors
turn, this trapped volume of air is reduced in volume or
compressed and is pushed to the discharge end of the
compressor. This process delivers smooth owing air at
full pressure to the receiver.
During the compression cycle, oil is injected into the
compressor for the purposes of lubricating, cooling,
and sealing. Compressed air laden with oil leaves
the compressor through a discharge port designed
to provide optimum performance within the desired
pressure range.
AIR/OIL SYSTEM
The air/oil system is almost completely contained within
the compressor housing. Within or directly attached
to the housing are the air lter, oil lter and the air/oil
separator element.
AIR FILTER
The air lter is a high eciency ring style located on
top of the inlet valve of the compressor. It will provide
nearly constant eciency of ltration at all load
conditions. The element has a high dirt holding capacity
for a long life.
It is specially treated to be insensitive to heat, cold,
water, and oil.
OIL FILTER
The oil lter is a 10-micron spin-on style. It is sized to
maintain system cleanliness and to give good
service life. The housing is equipped with a bypass to
insure that there is oil ow on startup. The restriction
created at the lter will have a direct eect on the
operating temperature of the compressor. So you must
be sure to maintain it.
AIR/OIL SEPARATOR
This unit utilizes a spin-on air/oil separator to make
maintenance much more convenient than the element
in vessel design. This does not diminish its operating
eciency. In fact the separation of the element from
the pre-separation tank enhances the performance.
The purpose of the separator is to remove aerosols. The
vapor pressure of the oil, the operating temperature
of the unit, operating pressure of the unit and the
operating cycle will aect its performance.
MINIMUM PRESSURE VALVE
As the compressed air leaves the compressor it goes
through a minimum pressure valve. This is set to
maintain at least 85 psig (586kPa) in the sump when
the compressor is running. This is to insure that there
is pressure to force the oil out of the sump and through
the oil system so that sucient oil is injected into the
compressor. It is also necessary to provide good air/oil
separation. The valve acts as a check valve to prevent
back ow into the compressor from the plant system.
Compressed Air Systems, LLC 1-800-531-9656 Fax [phone] www.compressed-air-systems.com
5-15 HP Electric Rotary Screw Compressors

COOLING
The compressor has an air-cooled and after-cooler as
standard. The following are the heat loads and cooling
airow rates that must be accommodated.
The compressor is an oil ooded unit. The oil lubricates,
seals, and cools the internals of the compressor.
In cooling it picks up the heat generated by the
compression process and the mechanical friction from
the bearings. So the oil must be cooled to within 60
degrees Fahrenheit of the ambient temperature.
The after-cooler has been designed for a minimum
approach of 15 degrees F
MODEL TOTAL HEAT LOAD B/Min REQUIRED FLOW CFM
5-7.5hp 805 1767
10hp 1064 2335
15hp 1587 3483
20hp 2104 4619
25hp 2727 5985
30hp 3250 7134
40hp 4256 9341
50hp 5325 11,700
60hp 6390 14,040
75hp 7988 17,550
100hp 10,650 23,400
125hp 13,313 29,250
150hp 15,975 35,100
200hp 21,300 46,800
250hp 26,625 58,500
300hp 31,950 70,200
HEAT LOAD OF COMPRESSOR
Compressed Air Systems, LLC 1-800-531-9656 Fax [phone] www.compressed-air-systems.com
5-15 HP Electric Rotary Screw Compressors

Controls
The RS series of units is equipped with a normally closed
inlet valve. This means that when the unit is started,
the inlet valve remains closed while the unit builds up
pressure by means of a bypass line. After startup the
inlet valve is controlled by a simple on/o action of a
pressure switch working with a solenoid valve.
For instrumentation the unit has a discharge
temperature gauge, air pressure gauge.
Installation
GENERAL
The standard RS series was designed for indoor
applications. For outdoor applications consult the
factory for modications. Failure to obtain factory
approval will void the warranty.
FOUNDATION
Your Compressed Air Systems LLC rotary screw
compressor does not require a special foundation.
However, it is necessary that the oor be level
and the frame adequately supported. Consult
the SPECIFICATIONS section of this manual for the
compressor weight and dimensions. We do recommend
that the compressor be bolted to the oor. We
reccommend the compressor be mounted on vibration
reduction pads
ROOM
The room should be of adequate size to provide full
access to the machine for routine maintenance. It
should have ventilation to keep the room as cool as
possible. Operating at elevated temperatures will cause
nuisance overload and temperature shutdowns. Room
temperature should not exceed 1050F.
AIR INTAKE
To achieve the longest lter and lubricant life and the
least maintenance you need to supply the compressor
with the cleanest air possible. It must not contain any
ammable or toxic gases. These will be concentrated by
the compressor, and could result in personal injury or
death and property damage.
CAUTIONCAUTION
!
Inlet containing reactive gases will cause the failure of the lubricant and
compressor.
Insure an air supply that is well clear of any reactive gas source.
If it is necessary to take air from a remote source, the piping should be at least the diameter of the air lter inlet.
For distance over twenty feet the diameter needs to be enlarged to reduce the restriction. This pipe should also be
corrosion resistant and free from scale and dirt. The inlet should also be covered to prevent rain and small animals
from entering.
Compressed Air Systems, LLC 1-800-531-9656 Fax [phone] www.compressed-air-systems.com
5-15 HP Electric Rotary Screw Compressors

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.
CAUTIONCAUTION
!
Under no circumstances should a compressor be placed in an area that
may be exposed to a ammable, toxic, volatile or corrosive atmosphere
nor should ammable, toxic, volatile or corrosive agents be stored near
the compressor.
CAUTIONCAUTION
!
Improper lifting can result in component or system damage or
personal injury.
Follow good shop practices and safety procedures
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/
her how to le a claim for damages. (Never attempt to move compressor without proper lifting equipment).
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).
Compressed Air Systems, LLC 1-800-531-9656 Fax [phone] www.compressed-air-systems.com
5-15 HP Electric Rotary Screw Compressors

Compressor Installation
LOCATION
Locate the compressor in an indoor area that is clean,
dry, well lighted, and well ventilated, with sucient
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 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 24
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 oor. If you bolt the
unit to the oor, use the bolts as guide pins and do not
tighten the bolts. The rubber pads are used to absorb
machine vibration and cannot work eectively 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.
Compressed Air Systems, LLC 1-800-531-9656 Fax [phone] www.compressed-air-systems.com
5-15 HP Electric Rotary Screw Compressors

Installation Continued
COOLING AIR DISCHARGE
The cooling air discharge must be restriction free. Any
louvers or ducting must not exceed a quarter of an inch
static head. Above this a booster fan will be required.
Consult a local HVAC contractor for recommendations
prior to installation. Excessive restriction to the cooling
air discharge will cause the unit to operate at elevated
temperatures that could result in high temperature
shutdowns.
Ducting of cooling air to the unit is not generally
recommended.
ELECTRICAL
A qualied electrician in compliance with standards and
local codes should do all electrical wiring. Be sure to
investigate the local requirements before installing the
compressor.
The power supply should be adequate and free
of parasitic loads that will cause an under voltage
condition during the operation of the compressor,
otherwise there will be nuisance electrical shutdowns.
Always connect the compressor to its power source
through a fusible disconnect and insure the unit is
properly grounded.
UNPACKING AND HANDLING
Occasionally damage will occur during shipping. Be
sure to carefully inspect the unit before unpacking.
After unpacking before you sign the receiver, if anything
damage has occurred, document it with the trucking
rm immediately. Contact your Compressed Air Systems
LLC. representative for assistance.
To move your compressor to its installation site we
recommend that you leave the unit on its shipping skid
as long as possible. The forks should be extended the
width of the compressor and padding should be placed
between the compressor and the truck boom.
If it is necessary to lift the compressor with a crane, we
recommend the use of the spreader bar and chains.
The spreader bar should be greater than the width of
the compressor and padding is placed on the edges to
prevent chain damage. Consult the installation drawing
at the end of this section for the center of gravity.
STORAGE
In some cases it may be necessary to store the
compressor for extended periods of several months
before placing the unit in operation. When this is
required do the following:
Cover and seal all machine openings to prevent the
entrance of water and dirt.
Cover all openings in open drip proof motors to prevent
the entrance of rodents.
If the storage conditions are below freezing; drain
the after cooler, traps, water-cooled heat exchanges
and attendant piping. We do not recommend outside
storage.
Cover with a waterproof tarpaulin that can easily be
removed for in-storage maintenance.
While in storage, every two or three months, rotate the
compressor and motor by hand to prevent at spots on
the bearings that will lead to premature failure.
At the end of the storage period, follow the uncrating
and start-up procedures. If the unit has been stored
for more than eighteen months, you should contact
Compressed Air Systems before restarting the
compressor.
Compressed Air Systems, LLC 1-800-531-9656 Fax [phone] www.compressed-air-systems.com
5-15 HP Electric Rotary Screw Compressors

Guidelines for Compressed Air Systems
7The air pressure drop between the compressor and
the point of use is not recoverable.
7Pipe size should be large enough that the pressure
drop does not exceed 10% between the air receiver
and the point of use.
7Arrange the air distribution piping to avoid the
following types of strain:
7Strains that are due to dead weight of the pipe itself.
7Strains that are due to expansion or contraction of the
piping due to temperature.
7Strains due to internal pressure within the pipe.
7Design inlet and discharge piping for smooth
airow.
7Plan for future emergencies and establish an area of
the loop to install a temporary compressor.
7Consider a second receiver at the end of the line or
opposite side of the loop.
7Use loop-piping systems; if possible, both around the
plant and within the loop.
7Consider a second receiver at the end of the line or
opposite side of the loop.
7Locate runaways from the main header close to the
point of application.
7Take air o the top of the header to prevent carryover
of condensed moisture to tools.
7Slope piping so that it drains toward a drop leg or
moisture trap away from the compressor.
Operation
Every Compressed Air Systems LLC compressor has been
operated and thoroughly tested at the factory prior to
shipment. The test assures that the compressor will
deliver its rated capacity and is in good working order.
However, there is the possibility that damage may occur
in shipping. For this reason, it is recommended that
the unit be carefully inspected for evidence of damage
or malfunction before installation and during the rst
hours of operation.
PREPARATION FOR INITIAL STARTUP
1. Pull the main disconnect switch and ensure that
there is no power to the unit.
2. Review the installation instructions to see that
everything is complete.
3. Inspect for visible signs of damage that could have
happened during shipment or installation.
4. Make certain protective coverings required for
shipment or painting are removed from the
compressor.
5. Fill the sump to the proper oil level. Do not
overll, if it is, drain to proper level. Tighten the ll
cap securely.
6. Reconnect the main disconnect.
7. Refer to control section and check out panel
components.
8. “Jog” the motor (press start and stop in quick
succession) and check for the correct direction of
rotation. Reverse LS1 and L2 connections if incorrect
9. Start the unit and run for several minutes, then
shutdown. Check the oil level and add, if
necessary, to compensate for lling the system.
10. Begin normal operation
Reverse rotation will cause air end damage. Exchange leads L1 and L2,
if reverse rotation.
CAUTIONCAUTION
!
Compressed Air Systems, LLC 1-800-531-9656 Fax [phone] www.compressed-air-systems.com
5-15 HP Electric Rotary Screw Compressors