Pentair Aquatic Eco-Systems Sweetwater AQ3 Manual

2395 Apopka Blvd. •Apopka, FL 32703 •Phone: [phone] •Fax: [phone] •[e-mail] •PentairAES.com
Oilless Rotary Vane Compressor
Operating and Maintenance Instructions
(Part Nos. AQ3–AQ93)
Part No. Serial Number Date Purchased

Table of Contents
Page
Safety Messages ............................................................................................. 2
Guidelines for Product Use ........................................................................ 2
Operation Guidelines .................................................................................... 2
Installation ............................................................................................. 2
Plumbing............................................................................................... 3
Starting ................................................................................................. 3
General Maintenance .................................................................................... 3
Flushing the Muffler System .................................................................. 3
Vane Replacement................................................................................ 3
Frequently Asked Questions (FAQ) ......................................................... 4
Troubleshooting Chart ................................................................................. 4
Exploded View of Compressors ................................................................ 5
Standard Warranty ......................................................................................... 5
Safety Messages
Safety is important to us. We have included safety messages
throughout this manual and for your protection. Please read
and follow all directions.
A safety message has a safety alert symbol
followed by an explanation of what the hazard
is, what can happen and what you should do
to avoid injury. This is the safety alert symbol:
The safety alert symbol and "WARNING" or "CAUTION" will precede
all safety messages:
WARNING
You will be killed or seriously injured if you don't follow
instructions.
2395 Apopka Blvd. •Apopka, FL 32703 •Phone: [phone] •Fax: [phone] •[e-mail] •PentairAES.com
CAUTION
You can be killed or seriously injured if you don't follow
instructions.
• Do not pump flammable or explosive gases or use in an atmosphere
that contains such gases.
• Protect all surrounding items from exhaust air. This exhaust air can
become very hot.
• Corrosive gases and particulate material will damage the unit. Water
vapor, oil-based contaminants or other liquids must be filtered out.
• Do not flush with kerosene or other combustible solvents.
ELECTRICAL SHOCK HAZARD
Disconnect electrical power at the circuit breaker or fuse box before
installing this product. Install where it will not come into contact with
water or other liquids and where it will be weather protected. Electrically
ground this product. Failure to follow these instructions can result in
death, fire or electrical shock.
Guidelines for Product Use
• Pump only clean, dry air.
• Operate at 32-104°F (0-40°C).
• Protect unit from dirt, foreign material and moisture.
• Never lubricate oilless air compressors.
• Use of petroleum or hydrocarbon products will reduce carbon
vane life.
Operation Guidelines
Installation
Make sure the wiring is done by a qualified electrician familiar with
NEMA MG2 safety standards, national electric code and all local safety
codes. Select fuses, motor protective switches or thermal protective
switches to provide protection. Fuses act as short circuit protection for
the motor, not as protection against overload. Incoming line fuses help
to withstand the motor's starting current. Motor starters with thermal
magnetic overload or circuit breakers protect the motor from overload
or reduced voltage conditions. The wiring diagram attached to the
product provides required electrical information.
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2395 Apopka Blvd. •Apopka, FL 32703 •Phone: [phone] •Fax: [phone] •[e-mail] •PentairAES.com
Check that power source is correct to properly operate the dual-voltage
motor. All dual-voltage motors are shipped from the factory wired for
115V unless otherwise requested.
Make sure that installation clearances do not block air flow. Blocking air
flow over the product in any way can cause the product to overheat.
WARNING
Product surfaces become very hot during operation; allow them to cool
before handling.
The air stream from this product may contain solid or liquid material
that can cause eye or skin damage; wear proper eye protection.
Failure to follow these instructions can result in burns, eye injury or other
serious injury.
Each model has an automatic thermal protector that shuts the motor
off if it overheats. The motor will restart without warning once the
protector resets itself upon cooling.
This product can be installed in any orientation. To minimize noise
and vibration, the unit should be mounted on a solid surface that
will not resonate. We recommend the use of shock mounts or
vibration isolation material. Inlet noise can be minimized by attaching
an optional muffler.
Plumbing
Remove plugs from the IN and OUT ports. Connect with pipe
and fittings that are the same size or larger than the product's
threaded ports.
Starting
If the compressor is extremely cold, allow it to warm to room temperature
before starting. If the motor fails to start or slows down when under
load, shut it off and unplug it. Check that the supply voltage agrees with
the motor post terminals and motor data name plate, and make sure
the motor is turning in the proper direction. Vane life will be drastically
reduced if the motor is not operating properly. Vanes can break or be
damaged if the motor runs in the wrong direction.
General Maintenance
WARNING
When servicing, all power to the motor must be discharged
and the plug disconnected. All rotating components must
be at a standstill.
Make sure that pressure and vacuum are released from the product
before starting maintenance. Check intake and exhaust filters after the
first 500 hours of operation. Clean filters, and determine how frequently
filters should be checked during future operation. This procedure in
particular will help the product's performance and service life.
1. Remove the end plate and filters. Inspect filters for rips, tears, cuts,
brittleness and excessive foreign material.
2. Clean filters if in good condition with compressed air. Reinspect for
wear conditions. Set filters aside.
3. Check the filter/muffler for compacted debris. If debris is present,
replace the filter/muffler.
4. Check the condition of O-ring. It should be soft and flexible. Replace
if it is not.
5. Remove and inspect the muffler box (not all models have a muffler
box). Clean the box and set it aside.
6. Check the gasket for cracks or tears. Install new gasket if any cracks
or tears exist.
7. Replace the muffler box.
8. Reinstall filters or install new filters if required. Reinstall the end plate.
Flushing the Muffler Assembly
Should excessive dirt, foreign particles, moisture or oil be permitted
to enter the compressor, the vanes will act sluggish or even break.
Flushing the muffler assembly should remove these materials. Do not
use kerosene or other combustible solvents. Use flushing solvent (part
no. AQ255) liberally to clean muffler parts.
Vane Replacement
Pentair Aquatic Eco-Systems recommends carbon vane replacement
at nine-month intervals to ensure trouble-free operation of your
compressor. The following tools are required: 3/8" or 7/16" socket/
wrench, small hammer and antiseize compound.
1. Remove the two end caps from the front of the muffler box (if
applicable) and the five muffler box bolts, being careful not to
damage the gasket.
If the gasket is torn, scrape it off with a sharp knife and replace.
2. Tap the box with a small hammer to loosen it. Do not pry with a
screwdriver.
3. Remove the six bolts holding the end plate to the body. Remove
the end plate. Do not remove the rotor or loosen any of the electric
motor through bolts.
4. Check that vanes are moving freely in and out of vane slots.
Replace any vane if more than 50% extends past the vane slot.
Top clearance (between rotor and body) may be adjusted by
loosening body bolts and lightly tapping on the compressor
body while turning the rotor. About .004 inch—this paper's
thickness—works well.
5. Remove vanes and clean both sides with fine emery cloth. Clean the
end plate with fine emery cloth.
6. Flush vanes, body, rotor and end plate with solvent (part no.
AQ255), and remove all solvent from each part.
VANES
VANES
ANGLED EDGE MUST
BE THIS WAY
ANGLED EDGE MUST
BE THIS WAY
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2395 Apopka Blvd. •Apopka, FL 32703 •Phone: [phone] •Fax: [phone] •[e-mail] •PentairAES.com
7. Check the body, rotor and end plate for scoring. If each part is clean
and shows no signs of scoring, reinstall parts. If scoring is present,
replace with new part(s) or contact Pentair Aquatic Eco-Systems
for service.
8. Insert new vanes as shown below.
Top clearance (between rotor and body) may be adjusted by
loosening body bolts and lightly tapping on the compressor body
while turning the rotor. About .004 inch—this paper's thickness—
works well.
Reassemble by reversing the previous directions. Pentair AES
always recommends using an antiseize lubricant on each bolt to
ensure its easy removal for the next vane replacement. Bolts should be
reinstalled and tightened in a similar manner to replacing the lug nuts
on a vehicle wheel. Start with one bolt and move to the right, skipping
one and tightening the next.
When reinstalling the muffler box (if applicable), be certain to install the
center bolt first to ensure proper gasket alignment. Before replacing the
muffler box, plug your compressor in for a quick sound check of the
valve rotation. If an unusual sound or stopping of the rotor takes place,
disconnect and recheck the vane replacement.
Frequently Asked Questions (FAQ)
Is my compressor running too hot?
It is normal for a motor to run hot to the touch because the shell
transfers heat away from the motor windings.
However, improved materials used in motor manufacturing make
the "too-hot-to-touch" test obsolete. The best way to determine if
a motor is operating properly is to check the ampere (amp) draw.
Each motor has a nameplate listing full-load amps (FLA). If the tested
amp draw does not exceed the nameplate rating, its internal or
external cooling fan is working (if so equipped), and the ambient air
temperature around the motor is below 104°F (40°C). The motor is
probably not running hot, even though it is too hot to touch.
Even so, make sure that there is plenty of air flow around the motor,
and keep the area around the motor clear so that there is no blockage
of air flow to the motor. Also keep paint and other flammable materials
away from the motor.
How much will it cost to operate my compressor?
The cost of operation will depend on the length of time the compressor
is run each day. The following example is for a typical 1-hp, single-phase
compressor operated 24 hours a day at $.08 per kWh. The cost per
kWh will vary from location to location. Check your electric bill for the
cost per kWh.
9.7 amps x 115 volts = 1,115.5 watts (amps & volts are on motor nameplate)
1,115.5 watts x 1,000 = 1.116 kW
1.116 kW x 24 hrs = 26.77 kWh
26.77 kWh x $.08 per kWh = $2.14 per day
Why is my compressor so noisy?
Compressor noise can be the result of vibration or mechanical noise.
1. Vibration is the intensification of normal compressor noise.
The noise should decrease if the compressor is firmly attached
to the foundation or if the compressor is completely isolated by
using a rubberized or cushioned base.
2. Mechanical noise is typically a high-pitched squealing sound.
The most common causes include worn motor bearings and
rubbing of the impeller against the compressor housing.
What causes my compressor to turn off by itself?
Check to make sure the proper voltage is supplied to the compressor.
Most compressors are dual voltage, meaning that they are capable of
using either 115V or 230V. The motor may have been wired for 230V.
If you are using 115V, you will need to change the wiring (see wire
diagram on the motor nameplate). Contact a licensed electrician if
you need help with wiring modifications.
A high-temperature switch will turn the motor off if it overheats.
The switch will automatically reset itself and turn on after the motor
cools. If this overheating and restarting cycle continues for a period
of time, the temperature switch will ultimately fail. This cycle will also
shorten the life of the motor.
High amp draw results in overheating. High amperage is caused by
the following:
1. Low voltage. Usually caused by power supply wire being undersized
and/or wire being too long. Extension cords are not recommended
to power larger compressors. If you believe that this may be the
problem, contact a licensed electrician to check your installation.
2. Motor is locked up. Something may be lodged in the impeller,
causing parts to bind.
3. Worn motor bearings.
The compressor may be set up with an automatic timer that will control
the run time so that you don't have to manually turn the compressor
on and off.
Troubleshooting Chart
Low
Pressure
High
Pressure
Compressor
Overheat
Motor
Overload
Problem Cause
and Solution
X X X Filter dirty. Clean or
replace.
XAt
Compressor X X
Plugged or collapsed
pressure line. Inspect
and repair.
XVanes sticking. Clean
or replace.
XVanes worn. Replace.
XShaft seal worn.
Replace.
X X X Debris in compressor.
Inspect and clean.
X X X
Motor not wired
correctly. Check
wiring diagram
and line voltage.
Should you require service or repair parts, contact Pentair Aquatic
Eco-Systems at 877-347-4788 from 8 AM to 7 PM Monday to
Thursday and 8 AM to 5 PM Friday. Have your part and serial
numbers handy, and our technical staff will gladly help you resolve
any problems.
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Exploded View of Compressor
Ref Description
1 Body
2 Vane
3 Shroud
4End Plate
5 Gasket
6Muffler Box
7 Rotor
8 Crush Ring
9 Muffler
10 Inlet Check Valve
LIMITED WARRANTY
Pentair Aquatic Eco-Systems, Inc. (PAES) warrants that its products
shall, at the time of delivery and for a period of twelve (12) months
thereafter, except for filters, be free from l defects in materials and
workmanship; and, if any such product shall prove to be defective
in material or workmanship under normal intended usage and
maintenance during the warranty period, upon examination by PAES
or its authorized representative, then PAES shall repair or replace, at
its sole option, such defective products at its own expense; provided,
however, that the Purchaser shall be required to ship each such
defective product, freight prepaid, to PAES’ designated facility. The
warranty on products and/or components not manufactured by PAES,
is limited to the warranty, if any, provided by the original manufacturer
of said product or component. PAES sole warranty in regard to
any components or products that are not manufactured by it shall
be limited to the repair or replacement of the product, as set
forth herein, with the condition that the Purchaser first return such
defective item, freight prepaid, to PAES’ designated facility. After
PAES has made an inspection of the product, and has confirmed that
there is a defect in the manufacture of the product, a credit will be
issued to Purchaser’s account. PAES HAS MADE NO AFFIRMATION
OF FACT AND HAS MADE NO PROMISE RELATING TO THE
GOODS BEING SOLD THAT HAS CREATED OR AMOUNTED TO AN
EXPRESS WARRANTY OR THAT THE GOODS CONFORM TO ANY
AFFIRMATION OR PROMISE. PAES DISCLAIMS ANY IMPLIED
WARRANTY OF MERCHANTIBILITY AND FITNESS. PAES SHALL
NOT BE RESPONSIBLE FOR ANY CONSEQUENTIAL DAMAGES
RESULTING FROM ANY PRODUCT DEFECT. THERE ARE NO
WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON
THE FACE HEREOF.
This Warranty does not extend to any Equipment that have been
subjected to:
1. Damage caused by careless handling, improper repackaging, or
shipping.
2. Damage due to misapplication, misuse, abuse or failure to properly
operate equipment.
3. Damage caused by improper installation or storage.
4. Damage due to unauthorized product modifications or repairs.
5. Damage caused by negligence, or failure to properly maintain
products.
6. Accidental damage, re, acts of God, or other circumstances outside the
control of PAES.
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2395 Apopka Blvd. •Apopka, FL 32703 •Phone: [phone] •Fax: [phone] •[e-mail] •PentairAES.com
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