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Curtis OL 524 manual

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Table of contents for the manual

  • Page 1

    CAP-215 APRIL, 2003 REV. D OIL-LESS COMPRESSOR OPERATION AND INSTRUCTION MANUAL OIL-LESS COMPRESSOR MODELS OL 512 SINGLE STAGE 3 H.P. OL 512 SINGLE STAGE 5 H.P. OL 524 TWO STAGE 5 H.P. OL 812 SINGLE STAGE 7 1/2 H.P. OL 812 SINGLE STAGE 10 H.P. CAUTION Before installing this compressor, read and understand the safety precautions contained within thi[...]

  • Page 2

    Instruction Manual Oil-Less Compressors TABLE OF CONTENTS Safety......................................................................................................................... .......................... i Safety Pr ecauti ons............................................................................................................. .....[...]

  • Page 3

    Instruction Manual Oil-Less Compressors TABLE OF CONTENTS (CONT’D) 8. INSTALLATION OPERAT ION...................................................................................................... ........... 23 8.1. INSTALLATION OF THE CO MPRESSOR............................................................................................ ... 23 8[...]

  • Page 4

    Instruction Manual Oil-Less Compressors Fig. 19 2 STAGE COMPRESSO R DIMENSIONS (070308- 1015)........................................................................... 33 Fig. 20 1 STAGE COMPRESSOR DI MENSIONS (070307-1015) ........................................................................... 35 Fig. 21 1 STAGE COMPR ESSOR DIMENSIO NS ( 0777[...]

  • Page 5

    CAP-215 Instruction Manual Oil-Less Compressors INTRODUCTION THIS MANUAL CONTAINS O PERATION AND MAINTENANCE SCHEDULES FOR THE OIL-LESS COMPRESSOR MODELS: OL 512 OL 524 OL 812 ALL INSTRUCTIONS SHOULD BE OBSERVED AND CARRIED OUT IN THE ORDER LAID DOWN TO PREVENT DAMAGE AND PREMATURE WEAR TO THE EQUIPMENT AND THE COMPRESSORS SERVED BY IT. WHILE EVERY[...]

  • Page 6

    CAP-215 i Instruction Manual Oil-Less Compressors SAFETY At Curtis-Toledo, Inc. safety is a primar y concern. Beginning w ith the design stage, safety is built into every "Curtis Compre ssor". It is the purpose of this manual to pass along the "safety first" concept to y ou by prov iding safety precautions throughout its pages .[...]

  • Page 7

    CAP-215 ii Instruction Manual Oil-Less Compressors DANGER! A ir 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 w ill cause severe injury or death. WARNING! Compressors are precision hi gh speed mechanical equipment requiring caution in operation to minimize haza[...]

  • Page 8

    iii CAP-215 Instruction Manual Oil-Less Compressors RECEIVING DELIVERY Immediately upon receipt of compressor equipment and prior to completely uncrating, the follow ing 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 car[...]

  • Page 9

    CAP-215 iv Instruction Manual Oil-Less Compressors ELECTRICAL SUPPLY REQUIREMENTS The electrical installation of this unit should be performed by a qualified electrician with know l edge of the National Electrical Code (N.E.C.), O.S.H.A. code and/or any local or state codes having precedence. Before installation, the electrical supply should be che[...]

  • Page 10

    CAP-215 v Instruction Manual Oil-Less Compressors REMOTE INLET FILTERS Depending on the size of the compressor and the size and construction of the room in whic h the unit operates, the air inlet may have to be located outside of the room. If it is necessary to remotely install the air filter , make the inlet piping as short and direct as possible.[...]

  • Page 11

    vi CAP-215 Instruction Manual Oil-Less Compressors SYSTEM COMPONENTS Efficiency and safety are the primary concerns when selecting components for compressed air systems. Products of inferior quality can not only hinder perfo rmance of the unit, but could cause system failures that result in bodily harm or even death. Select only top quality compone[...]

  • Page 12

    CAP-215 vii Instruction Manual Oil-Less Compressors SYSTEM COMPONENTS (CONTINUED) WARNING! Never exceed the designed pressure for the system or ove rload the motor beyond its Maximum A mp Draw. • Full Load A mps x Serv ice Factor = Max-imum A mp Draw . • Full Load A mps (FLA ) & Service Factor can normally be found on motor nameplate. WARNI[...]

  • Page 13

    viii CAP-215 Instruction Manual Oil-Less Compressors PULLEY ALIGNMENT & BELT TENSION Setting Belt Tension Improper pulley alignment and bel t tension are causes for motor overloading, excessive vibration and premature belt and/or bearing failure. To prevent this from happening, check the pulley alignment and belt tension on a regular basis. At [...]

  • Page 14

    CAP-215 1 Instruction Manual Oil-Less Compressors 1. GENERAL 1.1. PURPOSE AND SHORT DESCRIPTION The 1-stage oil-less compressor model OL 512, and OL 812, as well as the 2-stage oil-less compressor model OL 524, are used to compress air in the pressure ranges up to 110 psi (1-stage compressor models) to 220 psi (2-stage compressor models) All compre[...]

  • Page 15

    CAP-215 Instruction Manual Oil-Less Compressors Fig. 1: OL 512 (single stage), rear view 1 Cooler Manifold 2 After-cooler 3 Cylinder 1st stage 4 Valve head 1st stage 5 Fan/flywheel 6 Final Separator (optional) 7 Intake filter 8 Condensate drain valve (optional with #6) 2[...]

  • Page 16

    CAP-215 Instruction Manual Oil-Less Compressors Fig. 2: OL 512 (single stage), left side view 1 Cooler Manifold 2 After-cooler 3 Final Separator (optional) 4 Intake filter 5 Valve Head 6 Fan/flywheel 3[...]

  • Page 17

    CAP-215 4 Instruction Manual Oil-Less Compressors Fig. 3: OL 524 (2-stage), rear view 1 Valve head 2nd stage 2 Safety valve 1st stage 3 Intermediate cooler 4 Manifold 2nd stage 5 Cylinder 1st stage 6 Valve head 1st stage 7 Intermediate separator 8 Fan/flywheel 9 Intermediate cooler 10 Manifold 1st stage 11 Final separator 12 Maintenance indicator 1[...]

  • Page 18

    CAP-215 5 Instruction Manual Oil-Less Compressors Fig. 4: OL 524 (2-stage), left side view 1 Final separator 2 Manifold 3 After-cooler 4 Intermediate separator (option) 5 Intake filter 6 Valve head 2nd stage 7 Cylinder 2nd stage 8 Fan/flywheel 9 Cylinder 1st stage 10 Vale head 1st stage[...]

  • Page 19

    CAP-215 6 Instruction Manual Oil-Less Compressors Fig. 5: OL 812 (single stage), rear view 1 Cylinder 1st stage 2 After-cooler 3 Intake filter a) position of automatic condensate drain (optional) 4 Ventilator/flywheel 5 Final separator 6 Maintenance indicator[...]

  • Page 20

    CAP-215 7 Instruction Manual Oil-Less Compressors Fig. 6: OL 812 (single stage), left side view 1 Cooler manifold 2 After-cooler 3 Final separator[...]

  • Page 21

    8 CAP-215 Instruction Manual Oil-Less Compressors 1.2. DESIGN AND MODE OF OPERATION 1.2.1 DESIGN The design of the oil-less compressor is shown in Fig. 1 to Fig. 4. For drawings refer to the annex of this manual. Fig. 7: Position of stages at 2-stage c o m p r e s s o r 1.2.2. Mode of Operation 1-stage compressor The positions stated refer to Fig. [...]

  • Page 22

    CAP-215 9 Instruction Manual Oil-Less Compressors 2-stage compressor The position stated refer to Fig. 3. The two first stages (5) of the oil-less compressor draw in t he outside air via the intake filter (14) and the crankcase and compressed to an intermediate pressure of approx. 60 to 70 ps i. The compressed air is cooled back to the original tem[...]

  • Page 23

    CAP-215 10 Instruction Manual Oil-Less Compressors 1.3. TECHNICAL DATA 1 -stage compressor No. of stages Intake volume b) Intake pressure Delivery Operating pressure, max. No. of cylinders Cylinder bore Piston stroke Speed Weight Drive input c) Compressor rotation Min./max. ambient temperature OL 512 1 31.8 cfm atmospherical 17 cfm at 110 psi 110 p[...]

  • Page 24

    CAP-215 11 Instruction Manual Oil-Less Compressors Technical Data 1 -stage compressor No. of stages Intake volume f) Intake pressure Delivery Operating pressure, max. No. of cylinders Cylinder bore Piston stroke Speed Weight Drive input g) Compressor rotation Min./max. ambient temperature OL 812 1 48 cfm atmospherical 31.6 cfm at 110 psi 110 psi 3 [...]

  • Page 25

    CAP-215 12 Instruction Manual Oil-Less Compressors 1.4. ELECTRICAL DATA Electrical Intake filter control Operating voltage max. Electrical power consumption Temperature sensor (option) Operating voltage max. U max Nominal response temperature NAT Tolerance Cold resistance PTC resistance (U KI =2.5 V) PTC resistance temperature NAT-T PTC resistance [...]

  • Page 26

    CAP-215 Instruction Manual Oil-Less Compressors 2. INTAKE FILTER 2.1. DESCRIPTION A dry micronic filter is used to filter in take air (Fig. 8). The intake filter is equipped with a replaceable filter cartridge . 2.2. INTAKE FILTER MAINTENANCE The filter cartridge must be serviced at regular inte rvals according to maintenance schedule in chapter 9.[...]

  • Page 27

    CAP-215 14 Instruction Manual Oil-Less Compressors 3. INTERMEDIATE AND FINAL SEPARATOR 3.1. FUNCTIONAL DESCRIPTION OF INTERMED IATE SEPARATOR (2-STAGE MODELS ONLY) The intermediate separator (Fig. 9) is mounted after the two first stages of the 2-stage oil-less compressor. The separator is designed to remove excess water which resu lts from the coo[...]

  • Page 28

    CAP-215 15 Instruction Manual Oil-Less Compressors 3.2. FUNCTIONAL DESCRIPTION OF FINAL SEPARATOR A final separator is mounted after the three first st ages of the single-stage oil-less compressor and after the second stage of the 2-stage oil-less compressor. Separation is achieved by means of centrifugal action provided by a baffle (4 ). A sintere[...]

  • Page 29

    CAP-215 16 Instruction Manual Oil-Less Compressors 4. VALVES 4.1. FUNCTIONAL DESCRIPTION OF 1 st STAGE The valve head of the first stage forms the top part of the cylinder. The intake valve is fitted on the top of the piston. The pressure valve is mounted between valve head and cylinder. Note that the valves are operated by the flow of the air. On [...]

  • Page 30

    CAP-215 17 Instruction Manual Oil-Less Compressors 4.3. INITIAL OPERATIONAL CHECK OF VALVES If the intake pipe to the valve head of the second st age heats up excessively, and the first stage safety valve relieves, either the intake valve of the second stage or the pressure valve of the first stage is malfunctioning. It is therefore necessary to re[...]

  • Page 31

    CAP-215 18 Instruction Manual Oil-Less Compressors 4.5. CHANGING THE VALVES OF THE 1 ST STAGE The intake valve of the 1st stage is integrated into t he top part of the piston. The pressure valve is fitted between valve head and cylinder. Changing the pressure valve Change pressure valve of 1st stage according to chapter 4.6. Changing the Intake val[...]

  • Page 32

    CAP-215 19 Instruction Manual Oil-Less Compressors 5. AUTOMATIC CONDENSATE DRAIN 5.1. DESCRIPTION The condensate drain valve should drain the final separat or (1 -stage compressor) or the intermediate and final separator (2-stage compressor) every 15 minutes or earlier if necessary. Furthermore, condensate is drained a fter each operation (stand st[...]

  • Page 33

    CAP-215 20 Instruction Manual Oil-Less Compressors 6. COOLING SYSTEM 6.1. GENERAL Cooling of the oil-less compressor is twice as efficient because of their mode of operation: The compressor is equipped with a flywheel which draw s the cooling air through the flywheel cover from the surroundings and thus cools the cylinder, both intercool ers and th[...]

  • Page 34

    CAP-215 21 Instruction Manual Oil-Less Compressors 7. SAFETY REGULATIONS 7.1. GENERAL[...]

  • Page 35

    CAP-215 22 Instruction Manual Oil-Less Compressors[...]

  • Page 36

    CAP-215 23 Instruction Manual Oil-Less Compressors 8. INSTALLATION OPERATION 8.1. INSTALLATI ON OF THE COMPRESSOR Remove all plastic protective plugs and caps before Installing compressor. The oil-less compressor should be installed so that t here is no vibration, e.g. from the drive motor. - If possible install compressor in such a manner that the[...]

  • Page 37

    CAP-215 24 Instruction Manual Oil-Less Compressors 8.1.1. Natural ventilation As warm air rises, adequate wall openings should be provi ded for cooling air intake (next to the floor) and for cooling air outlet (next to/ in the ceiling). The compressor should be positioned right next to the air inlet opening. Fig. 16: Installation with natural venti[...]

  • Page 38

    CAP-215 25 Instruction Manual Oil-Less Compressors 8.1.2. Forced ventilation Forced ventilation facilitates a reduced variation in temper ature. It is achieved, for example by using an exhaust air fan. The following information is to determine the size of the exhaust air fan: V = required cooling air stream in ft 3 /h for a drop in temperature of 1[...]

  • Page 39

    CAP-215 26 Instruction Manual Oil-Less Compressors 8.2. ELECTRICAL INSTALLATION For installation of electrical equipment attend to the following: Follow the National Electric Code or local Electric code in providing, fusing, and disconnect switches. Check electrical supply for voltage, phase, and frequency to see that they match the nameplate stamp[...]

  • Page 40

    CAP-215 27 Instruction Manual Oil-Less Compressors 9. MAINTENANCE SCHEDULE 9.1. MAINTENANCE INTERVALS Int erv al Mai ntenanc e W or k Sec. 1/2 hour af ter start -up Manual c hec k of v al v e f unc t i on ( at f ir st oper at i on and m ai nt enanc e 4 wor k 250 operat i ng hours Check al l connec t i ons f or l eak age -- 50 - 250 operat i ng hour[...]

  • Page 41

    CAP-215 28 Instruction Manual Oil-Less Compressors 10. STORAGE, PRESERVATION 10.1. GENERAL If the oil-less compressor is to be put out of service for more than six months , the unit should be preserved in accordance with the following instructions: Make sure the compressor is kept indoors in a dry, dust fr ee room. Only cover the compressor with pl[...]

  • Page 42

    CAP-215 29 Instruction Manual Oil-Less Compressors 11. REPAIR INSTRUCTIONS 11.1. GENERAL Preventive maintenance usually involv es replacing the gaskets and sealing rings as well as carrying out the maintenance work. Repair work can be carried out on the oil-less compresso r to a certain extent, however certain repair work requires experience and sk[...]

  • Page 43

    CAP-215 30 Instruction Manual Oil-Less Compressors 12. TROUBLE-SHOOTING T RO UBL E CAUSE REMED Y Compr esso r Compr essor does not r eac h Condensat e drai n v alv e( s) and/ Ti ghten and reseal f inal pressure or f i t t i ngs leak i ng Prem at ur e open i ng of f inal s af et y C lean f i nal saf et y v al v e and r e- v al v e adj ust Pi ston r [...]

  • Page 44

    CAP-215 31 Instruction Manual Oil-Less Compressors 13. TABLES 13.1. TIGHTENING TORQUE VALUES Unless otherw ise specified in text, the follow ing torque values apply. All valve head screws require torque w rench tightening! The torque values indicated are valid for bolts in gr eased condition. Replace self-retaining nuts on reassembly 13.2. TORQUE S[...]

  • Page 45

    CAP-215 32 Instruction Manual Oil-Less Compressors NOTE: Please refer to Chapter 9 of instruction manual for maintenance schedule. Operating hours Ai r fi lte r ca rtrid g e cleaned Ai r fi lte r ca rtrid g e changed V-belt, fan wheel drive chec ked V-belt, fan wheel drive adjusted V-belt, fan wheel drive changed V-belt, compress or drive chec ked [...]

  • Page 46

    CAP-215 33 Instruction Manual Oil-Less Compressors 13. MAINTENANCE RECORD NOTE: Please refer to Chapter 9 of instruction manual for maintenance schedule. Oper at i ng hour s Air f ilt er cartridge cl eaned Air f ilt er cartridge changed V-bel t, f an w heel dri v e chec k ed V-bel t, f an w heel dri v e adj usted V-bel t, f an w heel dri v e change[...]

  • Page 47

    CAP-215 Fig. 19: 2-stage compressor dimensions (070308-1015) 34[...]

  • Page 48

    CAP-215 35 Fig. 20: 1-stage compressor dimensions (070307-1015)[...]

  • Page 49

    CAP-215 36 Fig. 21: 1-stage compressor dimensions (077734)[...]

  • Page 50

    CAP-215 Cylinder, Piston and Intake Valve Fig. 22 Note: Quantities shown are per cylinder Spare parts sets Cylinder, pi ston and intake valve D51.2 Class 0 2 5 Pos. Part No. Designation Weight (kg) Dimensions 1 CCC1512 Cylinder and piston assembly Ø85 2 CCC1513 Piston assembly 3 9 3 CCC1466 Intake valve assembly 4 CCC1619 Countersunk screw 5 CCC15[...]

  • Page 51

    CAP-215 Cylinder, Piston and Intake Valve Fig. 23 Note: Quantities shown are per cylinder Spare parts sets Cylinder, pi ston and intake valve D52.4 Class 0 2 5 Pos. Part No. Designation Weight (kg) Dimensions 1 CCC1512 Cylinder and piston assembly Ø85 2 CCC1513 Piston assembly 2 6 3 CCC1466 Intake valve assembly 4 CCC1619 Countersunk screw 5 CCC15[...]

  • Page 52

    CURTIS – TOLEDO, INC. 1905 KIENLEN AVE., ST. LOUIS, MO 63133 TEL. (314) 383-1300 FAX (314) 381-1439 E-MAIL: CURTISCOMP@AOL.COM[...]