FScurtis CA series User manual

CAP600
REV C APRIL 2013
CA/CT Series
TWO STAGE RECIPROCATING AIR COMPRESSORS
Installation and
Operations Manual

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______________________ _____________________
Model Serial #
Please have your unit’s model and serial number ready when calling for
service. The model # is found on the tank decal and the serial number is
located on the compressor nameplate.
For Customer Service, Technical Service, or to order replacement parts,
please contact your local distributor.
FS Curtis, Inc.
1905 Kienlen Avenue, St. Louis, Missouri 63133
phone: [phone] fax: [phone]
email: [e-mail] website: www.fscurtis.com

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Table of Contents
Read Me First Section 1
Safety Precautions............................................................................................................3-4
System Diagram...............................................................................................................5-6
Installation Section 2
Receiving .............................................................................................................................7
Freight Damage....................................................................................................................8
Installation Procedure ....................................................................................................9-12
Post Installation Checklist..................................................................................................13
Electrical Requirements.....................................................................................................14
Wiring Diagrams Section 3
Simplex, 1 phase and 3 phase............................................................................................15
Duplex, dual source ...........................................................................................................16
Start Up Section 4
Pre-Start Checklist.............................................................................................................17
Start-Up Procedure.............................................................................................................18
Maintenance Section 5
Shut Down Procedure........................................................................................................19
Maintenance Schedule.......................................................................................................20
Oil ......................................................................................................................................21
Low Oil Guard...................................................................................................................22
Bolt Torques.......................................................................................................................23
Belt Tension.................................................................................................................24-25
Maintenance Parts List.......................................................................................................26
Troubleshooting Section 6
Troubleshooting Guide ................................................................................................27-28
Maintenance Checklists.....................................................................................................29

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READ ME FIRST
Safety Precautions
The owner, lessor or operator of any compressor unit manufactured by FS Curtis, Inc. is hereby warned that
failure to observe all safety precautions may result in serious injury of personnel and/or damage to property.
FS Curtis, Inc. neither states as fact, nor in any way implies that this list of safety precautions is an all-inclusive
list, the observance of which will prevent all damage to property or injury to personnel.
Every reasonable effort has been taken to ensure that complete and correct instructions have been included in
this manual. However, possible updates and changes may have occurred since this printing. FS Curtis, Inc.
reserves the right to change specifications, without incurring any obligation for equipment previously or
subsequently sold.
Compressors and/or units are assembled to comply with the customer’s purchase order and in compliance with
FS Curtis, Inc. specifications; alteration must not be made to the compressor or unit without FS Curtis’ written
approval.
DANGER!
Air used for breathing or food processing must meet O.S.H.A 29 C.F.R. 1910.134
or F.D.A. 21 C.F.R. 178.350 regulations. Failure to do so will cause severe injury
or death.
WARNING!
Compressors are precision high-speed mechanical equipment requiring caution
in operation to minimize hazard to property and personnel. Listed below are
some safety precautions that must be observed.
•Use of FS Curtis Compressors to transfer toxic, radioactive, flammable, or explosive
substances is prohibited.
•Do not install the compressor in an area where there is a risk of exposure to explosive
gases or combustible dusts, such as flours, starches, coke, coal dust, etc. or in close
proximity to corrosive substances.
•Release all air pressure from the system before working on the unit and red tag all
electrical control switches.
•Do not assume it is safe to operate on a compressor simply because it is not running, it
could restart at any time. Throw the disconnect to ensure the compressor does not
start.
•Do not operate compressor on a shipping skid or any other unapproved mounting
surfaces.
•Do not by-pass motor over-current protection.

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•Do not change the setting or in any way affect the operation of the safety valves.
•Turn off and lockout/tagout the main power disconnect switch before attempting to work
or perform any maintenance.
•Do not attempt to service any part of this unit while it is running.
•Ensure that service personnel are properly trained before attempting to service any part
of the electrical system.
•Do not operate the unit with any of its safety guards, shields or screens removed.
•Do not remove or paint over any DANGER!, WARNING!, CAUTION!, or instructional
materials attached to the compressor. Lack of information regarding hazardous
conditions can cause property damage or personal injury.
•Do not change the pressure setting of the pressure relief valve, restrict the function of
the pressure relief valve, or replace the pressure relief valve with a plug.
•Do not install a shutoff valve in the compressor discharge line without first installing a
pressure relief valve of proper size and design between the shutoff valve and the
compressor.
•Do not use plastic pipe, unapproved rubber hose, or lead-tin soldered joints in any part
of the compressed air system.
•Alterations must not be made to this compressor without FS Curtis’ expressed, written
approval.
•Do not operate the compressor in excess of the A.S.M.E. pressure vessel rating for the
receiver or the service rating of the compressor, whichever is lower.
•Surface temperatures can exceed 400 °F, power off the unit and allow it to cool before
touching any surface of the compressor.
• 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 becomes
illegible or the manual is lost, contact your local distributor.
•Your State and/or local OSHA regulations may require a Pressure Vessel Permit to
operate this equipment. Obtaining a permit is the sole responsibility of the owner,
lessor or operator of the equipment. Contact your State/Local OSHA for more
information.

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System Diagram
Simplex Units
1
2
3
4
5
6
Air Intake
Air Compressor
Intercooler
Magnetic Starter
Pressure Switch
Vibration Pads with
hardware mounts
1
Exact orientation of system components
may vary. Please see your model's general
arrangement diagram for a precise
configuration of system components.
6
2 3 4 5
Fig. (1) Simplex, two stage air compressor process.
FS Curtis manufactures a broad array of compressor configurations to satisfy the needs of our
diverse customer base. Despite this diversity, all FS Curtis two stage compressor
configurations work off the same basic cycle. Air is drawn into the compressor through the air
intake and filter assembly. The air enters the first stage, a low pressure chamber where it is
compressed the first time. As air is compressed, its temperature increases, this hot air then
enters the intercooler where the temperature is reduced.
Next, the cooled air enters the second stage, a high pressure chamber where the air is
compressed a second time to even higher pressures and discharged into the tank. An Ultra
Pack option can be purchased with an installed air-cooled after-cooler which, after the second
compression stage, cools the air to a 20°F approach temperature before being stored in the
tank.
When the compressor has filled the tank to its pressure rating, the pressure switch disengages
which turns off the motor, preventing the tank from over pressurizing. Finally, the tank has a
ball valve which is opened or closed by the operator and lets air out of the tank, the ball valve
is depicted in Fig (1) in the “open” position.

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Duplex Units
1
2
3
4
5
6
Air Intake
Air Compressor
Intercooler
Alternator
Pressure Switch
Vibration Isolator pads
with hardware mounts
2
Exact orientation of your system's
components may be different from t e
layout in t e figure. Please see your model's
general arrangement diagram for a precise
configuration of system components.
1 1 23 345 5
6
Fig. (2) Duplex unit system diagram.
Refer to the simplex diagram for a description of the compression cycle.
Duplex units operate in much the same way as simplex units, only there are two compressors.
The key difference is in the pressure switch and starter. In a duplex unit, there are two
pressure switches, a “lead” pressure switch and a “lag” pressure switch set 10 psi lower than
the lead switch. The alternator utilizes both compressors to fill the tank. Once the tank
approaches the cutoff “lag” pressure, the alternator selects one compressor to be the “lag”
compressor and cycles it off, using only the “lead” compressor to provide the remaining
pressure. The alternator then cycles between both compressors, switching the “lead” and “lag”
compressor and ensuring roughly equal wear between them. If air usage exceeds the output
of a single compressor, the alternator utilizes both the “lead” and the “lag compressor to fulfill
operating conditions, once again cycling off the “lag” compressor when its cutoff pressure is
reached.

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INSTALLATION
IMPORTANT NOTICE
Abide by all applicable state, local and regulations when mounting and
installing the compressor. Failure to do so may result in injury or death
and will void the manufacturer’s warranty. Contact your local government
for more information.
CAUTION!
Improper lifting can result in component or system damage or personal injury.
Follow good shop practices and safety procedures when moving the unit.
Receiving
Immediately upon receipt of compressor equipment and prior to completely uncrating, the
following steps should be taken:
1. Inspect compressor equipment for damage that may have occurred during shipment. If any
damage is found, demand an inspection from the carrier. Ask the carrier how to file a claim
for shipping damages. (Refer to FREIGHT DAMAGE for complete details.) Shipping
damage is not covered by FS Curtis’s compressor warranty.
2. Ensure that adequate lifting equipment is available for moving the compressor equipment
and clear a path to the installation location to avoid damage to property or compressor.
3. Turn off & lock out the electrical disconnect switch before working on the unit to prevent the
unit from starting unexpectedly.
4. Read the outfit nameplate to verify the model and size ordered.
5. Read the motor nameplate to be sure the motor is compatible with your electrical conditions
(volts, phase, and hertz).
6. Read the pressure relief valve nameplate to be sure it does not exceed the working
pressure of the compressor or any other component in the system.
7. Read and understand the safety precautions contained within this manual. The successful
and efficient operation of compressor equipment depends largely upon the amount of care
taken to install and maintain the equipment. FS Curtis strongly recommends that any or all
person(s) in charge of installing, maintaining, or servicing one of our compressors read and
understand the entire contents of this manual and the respective compressor installation
and operating instruction manual in order to perform such duties safely and efficiently.
8. Remove all packing plastic, foam and shipping related materials.

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FREIGHT DAMAGE
The transportation industry has adopted a modification with regard to the handling of obvious
and concealed damage claims. Therefore, it is extremely important that you examine every
carton and crate as soon as you receive it. If there is any obvious damage to the shipping
container, have the delivering carrier sign the freights bill, noting the apparent damage, and
request a damage report.
If concealed damage is discovered at a later date, the carrier must be notified within 15 days of
initial receipt of freight. Contact the carrier as soon as possible, giving them an opportunity to
inspect the shipment at the premises where the original delivery was made. Retain all
containers and packing for inspection by the carrier. Do not move the freight. Request an
inspector and claim number, then contact freight carrier
Concealed shipping damage is not covered by the FS-Curtis warranty.
A claim form can be requested from the carrier. Your claim will need to be substantiated with
the following documents.
Original bill of lading
Original paid freight bill
Original invoice or certified copy
Other particulars obtainable in proof of loss or damage (photos, damage inspection
report, etc.)
We suggest these instructions be circulated to your shipping and receiving personnel.

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Installation Procedure
Step 1 – Select a proper location for installation
Select a clean, dry, well lit area with a rigid floor strong enough to support the compressor and
with adequate ventilation. Avoid placement of the compressor in an area that is excessively
hot, dusty, humid or contaminated with foreign gases such as ammonia or acid fumes.
The unit should never be operated at ambient temperatures above 104°F or below 32°F. If the
ambient temperature is below 40°F, FS Curtis recomm ends using Arctic oil. Maintenance
checks are required daily, thus three (3) feet of space needs to be provided around the
compressor for proper inspection.
Note – If the unit or air intake is to be located outdoors, please contact your local
distributor for additional instructions.
Step 2 – Remove the skid
Remove and discard the shipping skid. The compressor should NEVER be operated on a
skid.
Step 3 – Prepare the mounting surface
See Fig. (3) and Fig. (4) for the compressor’s mounting pattern and prepare the surface
accordingly. See Table (2) for acceptable installation methods
B
A
D
Fig. (3) Horizontal bolt hole pattern Fig. (4) Vertical bolt hole pattern
Horizontal
Tank
(gallons)
A
(in) B (in) Base Hole Size (in) Recommended Bolt Diameter
(in)
Vertical Tank
(gallons) D (in) Hole Size (in) Recommended Bolt Diameter
(in)
30 17.75 23 9/16 1/2" 60 17 9/16 1/2”
80 17.75 40 9/16 1/2” 80 (CT line) 17 9/16 1/2"
120 22 40 9/16 1/2” 80 (CA Line) 22.5 11/16 5/8”
200 28 40 7/8 3/4” 120 26.375 11/16 5/8”
240 40 54 3/4 5/8”
Table (1) Bolt hole mounting patterns for various tank sizes.

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Acceptable Mounting
Unacceptable Mounting
•
Concrete Anchor Bolts
•Threaded Rod or Floor Stud
•Steel flooring or supports (provided unit
is bolted down and isolator pads are
used)
•
Skid Mounted
•Unanchored
•Bare Floor (no vibration pads)
Table (2) Compressor mounting methods
If you wish to utilize an installation method other than the approved methods described in
Table (2), please contact your local distributor. FS Curtis neither states as fact, nor implies
that the above list of Acceptable/Unacceptable mounting is all-inclusive. Contact your local
distributor for more information.
Step 4 – Install Vibration Isolator pads and mount the compressor
Exposure to excessive vibrations can significantly shorten the life of the compressor. FS
Curtis highly recommends mounting the unit on vibration isolator pads and the compressor
should NEVER be operated without being securely fastened to the ground.
Using a level, please check for proper alignment of the compressor. Uneven installation will
unbalance the compressor leading to excessive noise, vibrations, and wear. Place a steel
shim between the concrete and vibration pads and shim down as necessary for leveling. Level
the compressor so it can be bolted down securely. Before tightening the bolts, check to see
that all four feet are resting on the foundation. See fig (5) for mounting instructions for a floor
stud, and see fig (6) for mounting instructions for an anchor bolt.
FLANGE NUT
Leave loose & lock
wit a back-up nut
RECEIVER FOOT
ISOLATOR BACKING
PLATE OR SHIMS IF
NECESSARY
ISOLATOR
ANCHORED
FLOOR
STUD
FLANGE NUT
Leave loose & lock
wit a back-up nut
RECEIVER FOOT
ISOLATOR BACKING
PLATE OR SHIMS IF
NECESSARY
ISOLATOR
ANCHORED
FLOOR
STUD
Fig. (5) Anchored Floor Stud installation

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Recommended Installation – Use concrete anchor bolt
1
2
34
56
7
8
Fig. (6) Recommended Installation Method
1 Mounting bolt, see Table (3) for recommended sizes
2 Flat washer, sized for bolt
3 Compressor Base
4 Vibration Isolator Pads
5 Steel Shim (as necessary for leveling)
6 Concrete floor, see local codes for recommended
concrete thickness and hole drilling depth
7 Heavy duty double expansion machine bolt anchor shield
8 1” diameter hole
Table (3) Anchor Bolt specifications

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Step 5 – Tighten the fasteners
Incrementally tighten the mounting bolts evenly in a cross pattern. With unit running, continue
incrementally tightening the mounting bolts in a crossing pattern until vibrations have been
reduced to an acceptable level. After vibrations have been minimized, loosen ONE mounting
bolt. The unit expands and contracts with changes in temperature, leaving ONE bolt loosened
will allow for thermal expansion of the unit, reducing thermal stresses and vibrations on the
tank. If after loosening one bolt the vibrations get worse, retighten bolt and select a different
fastener. Excessive vibrations can damage equipment.
Step 6 – Install piping network
Run a clean pipe to the tank discharge opening, bushing up or down as necessary with clean
bushings and fittings. Note that the more bushings and fittings placed in the air distribution
system, the greater the opportunity for air leaks and breaks. FS Curtis recommends the
installation of drip legs in the distribution piping.
Always install a safety relief valve in the distribution line between the compressor unit and in-
line shutoff valves. If more than one compressor pumps into a common system, a check valve
in the distribution line of each compressor unit is recommended to prevent moisture from
entering the cylinder head(s) when one compressor is idle. A globe or gate valve (WOG rated)
installed in the discharge line will allow compressor isolation from plant air system for
compressor maintenance. (Note: A safety relief valve should be located between the
compressor and the globe/gate valve.)
Step 7 – Install Compressor Intake (IF APPLICABLE)
If the compressor intake is to be located away from the unit, please use the following
instructions to ensure safe and efficient operation.
Run a clean pipe to the compressor suction opening, bushing up or down as necessary with
clean bushings and fittings. Note that the more bushings and fittings placed in the intake line,
the greater opportunity for air leaks and breaks. If the run is over 10 feet in length, use a larger
pipe diameter to avoid excessive pressure drops. When installing the pipes, please pitch the
piping down and slightly away from the intake, to ensure that debris and condensation drains
away from the compressor.
MOUNTING MOBILE UNITS
Gas engine driven compressors mounted to truck beds should be fastened to the truck bed in
such a way so as not to create any stress to the air receiver tank, isolator pads are required for
warranty purposes. Truck beds, characteristically, have a tendency to flex and could cause
damage to the receiver tank if the tank is fastened directly to the truck bed. It is the User’s
responsibility to provide an adequate means of fastening the unit in these applications.

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Post Installation Checklist
WARNING!
Failure to perform the post installation checklist may result in mechanical
failure, property damage, serious injury or even death.
Steps 1 through 9 should be performed prior to connecting the unit to a power source. If any
condition on the checklist is not satisfied, make the necessary adjustments or corrections
before starting the compressor.
1. Remove all installation tools from the compressor and check for installation debris.
Abrasive dust can seriously damage the air intake and belt assemblies.
2. All FS Curtis compressors are shipped from the factory filled with the required amount of
Curtis Lube Plus Compressor Lubricant specially formulated for Curtis Compressors. The
oil level should register in the center of the oil sight glass or between the high and low
marks on the dipstick. For additional lubricant contact your authorized Curtis distributor.
Failure to use authorized lubricant will void the manufacturer’s warranty.
3. Check inlet-piping installation.
4. Check all pressure connections for tightness.
5. Make sure all pressure relief valves in the air distribution are correctly installed.
6. Make sure all guards are in place and securely mounted.
7. Open all manual shutoff valves at and beyond the compressor and tank discharges.
8. Check and tighten all connections (mechanical and electrical) as they may have loosened
during shipment.
9. After all the above conditions have been satisfied, the unit can be connected to the proper
power source.

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Electrical Requirements
The electrical installation of this unit should only be performed by a qualified electrician with
knowledge of the National Electrical Code (N.E.C.), O.S.H.A. code and/or any local or state
codes having precedence.
All FS Curtis compressors come with a factory installed, pre-wired starter, if you wish to
provide your own starter, please contact your local distributor for more information. Check the
electrical supply for voltage, phase, and frequency to see that they match the nameplate
stampings on the motor, magnetic starter, solenoids, and other controls.
Before attempting to service electrical systems, ensure that maintenance personal are properly
qualified, and service procedures comply with NFPA 70-1984, National Electrical Code,
National Electrical Safety Code, as well as any applicable state and local regulations. Failure
to abide by the national, state and local codes may result in physical harm and/or property
damage and will void the manufacturer’s warranty.
DANGER!
High voltage may cause personal injury or death, per O.S.H.A. regulations 1910.137,
disconnect and lockout/tagout all electrical power supplies before opening the electrical
enclosure or servicing.
WARNING!
Never assume a compressor is safe to work on just because it is not currently operating.
It could restart at any time. Follow all safety precautions outlined in the Safety
Precautions section.
NEMA electrical enclosures and components must be appropriate to the area installed.
Safety and efficiency are the primary concerns when selecting components for compressed air
systems. Products of inferior quality can not only hinder performance of the unit, but could
cause system failures that result in bodily harm or even death. Select only top quality
components for your system. Call your local FS Curtis Distributor for quality parts and
professional advice.
CAUTION!
Turn off and lockout/tagout the main power disconnect switch before
attempting to install the unit.
NOTE: At installation, the customer is to provide disconnect, branch circuit over-current
protection, and grounding between the power supply and the electrical control enclosure in
accordance with the National Electric Code and/or any local codes.

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Wiring Diagrams:
Simplex Single Phase and 3 Phase
TURN OFF / TAGOUT POWER BEFORE SERVICING
3
2
1
5
4
Fig (7) Simplex Starter
95 96
OL
Pressure
Switch
Power Supply
to L1 and L2
MS1
Motor
Jumper T2 to L3
M
L2
L3
L1 OL
21
T3
T2
T1
95 96
OL
Pressure
Switch
Power Supply to
L1, L2, and L3
MS1
Motor
M
L2
L3
L1 OL
21
T3
T2
T1
Fig (8) Single Phase wiring diagram Fig (9) Three phase wiring diagram
NOTE: The above wiring diagrams are valid for standard models only. Contact your local distributor for wiring
diagrams for factory installed options
1 L3
2 L2
3 L1
4 Overload relay
5 Reset switch

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Wiring Diagrams:
Duplex Dual Source Alternator
TURN OFF / TAGOUT POWER BEFORE SERVICING
1
2
3
1
2
3
Fig (10) Duplex dual source alternator panel.
NOTE: Unit wiring diagram is located on the inside front cover of the alternator panel.
If, over time, the diagram becomes illegible, please contact your local distributor.
1 L1
2 L2
3 L3

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Start Up
Pre Start Checklist
WARNING!
Do not proceed until the PRE-STARTING CHECKLIST and sub-section has been
read and is thoroughly understood.
1. Check oil level in crankcase for proper level.
2. Drain liquid from the air receiver and moisture trap (if so equipped).
3. Check system pressure. Do not operate the compressor in excess of the A.S.M.E.
pressure vessel rating for the receiver or the service rating of the compressor, whichever is
lower.
4. Check cooling fan rotation. Fan blades of the compressor flywheel force ambient air across
fins of the intercooler and cylinder heads.
5. Check all pressure relief valves for proper operation.
6. Check control system for proper operation and to ensure all connections (mechanical and
electrical) are properly tightened.
7. Jog the starter switch to check the rotational direction of the compressor. The flywheel
should rotate in the counterclockwise direction (as viewed when facing the flywheel).
INITIAL STARTING & OPERATION
This instruction manual, as well as any instructions supplied by manufacturers of supporting
equipment, should be read and understood prior to starting the compressor. If there are any
questions regarding any part of the instructions, please call your local FS Curtis distributor.
With the pre-starting checklist completed and satisfied, close the disconnect switch and start
the compressor (for electric units) or engage the starter (for gas units). Watch and listen for
excessive vibration and strange noises. If either exists, stop the compressor, look for and
correct the problem before re-starting.
Observe compressor operation closely for the first eight hours of operation. If any abnormal
conditions are witnessed, stop the compressor and correct the problem. After two days of
operation check belt tension, oil level, and inspect the system for leaks. Additionally, all
electrical connections and mechanical fasteners should be checked for tightness and torqued
as needed.

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For the first weeks, the compressor needs time to “break in.” The belt requires time to stretch
and fit into the surface of the pulleys. The piston rings need time to seat themselves into the
cylinder walls, and bearings need to wear into place. For the first 100 hours or so, the
compressor will consume higher than normal amounts of oil until the break in process is
complete.
FIRST MONTH MAINTENANCE
•Check oil level at the beginning of every week, fill as needed, see oil subsection.
•Check belt tension at the beginning of each week and tighten as required, see belt
tension subsection.
•Check bolts, pulley clamp screws, and jam nuts for tightness. Torque if necessary (see
bolt torques subsection)
START-UP
If the compressor is equipped with an automatic start-stop control (with pressure switch
unloading), it is automatically unloaded upon starting, and will automatically load after attaining
running speed. Simply throw the power switch to start the unit.
All gas units are equipped with pilot valve controls and should be manually unloaded prior to
start up. To manually unload the compressor in order to achieve an unloaded start, release
the pilot valve lever BEFORE starting the compressor.
Pilot
Valve
Fig (11) Pilot valve location

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Maintenance
Shut Down Procedure
The following procedures should be followed when stopping the compressor for maintenance
or service.
WARNING!
Never assume a compressor is safe to work on just because it is not operating.
It could start at any time.
1. Per O.S.H.A. regulation 1910.147; The Control of Hazardous Energy Source
(Lockout/Tagout); disconnect and lockout the main power source. Display a sign in clear
view at the main power switch that the compressor is being serviced.
2. Isolate the compressor from the compressed air supply by closing the manual shutoff valve
upstream and downstream from the compressor. Display a sign in clear view at the shutoff
valve stating that the compressor is being serviced.
3. Lock open a pressure relief valve within the pressurized system to allow the system to be
completely de-pressurized. 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 to service. (Temperatures of 125°F can burn skin.
Some surface temperatures exceed 350°F when the com pressor is operating.