ultra clean oilless compressor

Transcription

ULTRA CLEAN
OILLESS COMPRESSOR
INSTALLATION
AND SERVICE
MANUAL
Revised 4-15
TECH WEST INC.
Manufacturers of Dental Vacuum
and Air Systems
2625 N. Argyle Ave. • Fresno, CA 93727
(559) 291-1650 • (800) 428-7139 • FAX (559) 348-9677
.
ULTRA CLEAN
OILLESS COMPRESSOR
INSTALLATION AND SERVICE MANUAL
This manual is for the installation and service of Tech West’s Ultra Clean Oilless Compressors.
CONTENTS
Installation
Location Requirements
2
Figure 1: Wire and Breaker Sizes
2
Ultra Clean Oilless Installation Steps
3
Ultra Clean Oilless Compressor Connections
4
Ultra Clean Oilless Start Up
5
Ultra Clean Oilless Maintenance
6
Ultra Clean Oilless Compressor Motor Assembly Breakdown
7-8
Coalescing Filter Parts Breakdown
9
Desiccant Dryer Parts Breakdown
10-11
Gauge and Moisture Indicator Assembly Breakdown
12
Single Ultra Clean Oilless Compressor Assembly
13
Dual Ultra Clean Oilless Compressor Assembly
14
Triple Ultra Clean Oilless Compressor Assembly
15
TROUBLE SHOOTING
Single Compressor Trouble Shooting
16-17
Dual Compressor Trouble Shooting
18-19
Triple Compressor Trouble Shooting
20-21
Air Line Sizing Chart
Maintenance & Service
22
23-24
Notes Sheet
1
ULTRA CLEAN OILLESS COMPRESSOR
INSTALLATION
1. OILLESS COMPRESSOR LOCATION REQUIREMENTS
The Ultra Clean Oilless Compressor location should be level, accessible and well ventilated.
If the Ultra Clean Oilless Compressor will be located in a confined space, provide adequate ventilation.
Electrical
(1)
Line voltage must be within the limits of Figure 1 below. (Install a “buck-boost
transformer” if line voltage is not between these values.) Provide a separate line for
each motor. Circuit breaker switches must be 20 - 30 amp depending on model
and voltage necessary.
(2)
Local code may require you to provide one quick disconnect (safety switch) for each
compressor motor.
(3)
See Figure 1 below for breaker size and line voltage.
CAUTION - Voltage must be 208/240 V or motor damage may occur.
CAUTION - Voltage must be 110/130 V or motor damage may occur.
Figure 1: Recommended Wire and Breaker Size
Model
Voltage
Amperage
Wire Size
(Gauge)
Recommended
Breaker Size
14.5
7.2
12
12
20
20
14.4
10
30
21.6
10
30
Single Head Compressors
ACO2S1
ACO2S2
110/115
208/230
Dual Head Compressors
ACO4D2
208/230
Triple Head Compressors
ACO6T2
208/230
2
INSTALLATION
2
2. INSTALLATION STEPS
This dental compressor should only be installed by qualified personnel. Should any questions arise
during the installation, call Tech West Technical Support between the hours of 7:00 a.m. to 4:00 p.m.
(Pacific Standard Time).
Place the compressor in a clean, dry, well ventilated area, on a solid, level surface. Consider sound
level and insulate as needed. Be sure that adequate ventilation is available as the compressor is air
cooled. Ambient temperature in the equipment room should be within the temperature range of 40
degrees Fahrenheit minimum to 100 degrees Fahrenheit maximum.
(a) Check the shipping carton for damage. This could detect damage to the unit which might
otherwise be overlooked. Remove cardboard shipping carton.
(b) Remove the Oilless Compressor from its shipping skid. Inspect the unit for damage.
Oilless Compressors are shipped bolted to a pallet. This pallet is intended for shipping only
and should be discarded.
(c) Remove installation kit attached to pallet. It should contain the following:
(4) Isolation Feet
(1) Alternate Air Hookup Hose
(1) 5’ Flexible Air Hose
(d) Install isolation feet on tank legs.
(e) Move compressor into place and level by observing bubble level on compressor platform.
(f) Wiring instructions:
(1) Have all electrical connections made by qualified personnel only. All connections
should be in accordance with local codes.
(2) Use the chart on page 1 to help determine the proper line and breaker size for
the unit that is being installed.
(g) Install the air line from the compressor tank to the building supply.
(h) Install the 1” flex alternate air hose from the compressor to a fresh air supply.
3
INSTALLATION
2
3. CONNECTIONS
Figure 2
Electrical Connection
to disconnect and
electrical panel
220 v
(110 v / 220 v ) on the
single models only
Dryer Purge
Connection
Air Out
Connection to building
supply line
Alternate Air
Connection
to fresh air supply
4
INSTALLATION
2
4. SAFETY PRECAUTIONS
• Keep fingers, foreign objects and clothing free from rotating parts and do not touch hot surfaces.
• Never attempt to service an operating unit.
• Isolate unit from system pressure and relieve backpressure before servicing.
• Disconnect all power before servicing. The thermal protector in single phase motors
automatically starts motor when device resets.
USE OF THIS PRODUCT IN OR NEAR EXPLOSIVE ATMOSPHERES, OR FOR
PUMPING MIXTURES OTHER THAN ATMOSPHERIC AIR MAY CAUSE AN
EXPLOSION OR FIRE, RESULTING IN PERSONAL INJURY OR DEATH.
2
5. START-UP STEPS
(a) Make sure the shut-off valve from the compressor tank is closed.
(b) Turn the breaker from the panel to the “ON” position.
(c) Turn power “ON” from the toggle switch on the compressor. Compressor should run quietly
and vibration free. The storage tank should start to build pressure.
(d) The compressor will run until the pressure gauge reads 100 psi. The compressor then will
automatically shut off and the dryer will purge with a quick blast of air.
(e) Using soapy water, check the compressor plumbing hook ups for leaks. Repair leaks if needed.
(f) Pressure test the entire plumbing system for leaks. Use the storage tank pressure gauge to
monitor a pressure drop. After the plumbing system has been pressurized for 30 minutes,
re-check the gauge for pressure drop. If there is a drop in pressure, find and repair all leaks
in the office plumbing.
(g) Complete and mail in the warranty card for the compressor within ten days of installation.
AIR LEAKS ARE THE MAIN CAUSE OF COMPRESSOR FAILURES.
5
INSTALLATION
2
6. GENERAL SERVICE INFORMATION
For parts and service on VX series products contact the nearest authorized Tech West distributor. To
expedite appropriate service, be prepared to provide the unit model number, identification number,
and serial number found on the nameplate located on the front of the unit motor.
Component life operating at continuous duty & maximum pressure
Life of the rings and skirts is difficult to predict due to many conditions which directly influence wear.
Some of these conditions may include ambient air temperature, air cleanliness, operating pressure,
piston stroke on the particular model being utilized, duty cycle, maintenance of filters, etc.
Because of these various factors it is appropriate to generalize on component wear life and choose
some conservative estimates for most standard applications.
With these conditions in mind, we recommend the following preventative maintenance schedule.
RECOMMENDED MAINTENANCE
FOR VX MODELS
HOURS
Cont. Duty
Maximum Pressure
TIME
Based on 100%
Duty Cycle
Minor Service Kits, Piston Rings & Springs, Skirts, Etc.
8,000 Hours
12 months
Major Replacement Kit, Piston & Rod Assemblies
12,000 Hours
18 months
Replace inlet Filter
4,000 Hours
6 months
7. PERIODIC SERVICING
MONTHLY SERVICING
(a) Remove the purge bucket and empty as needed
(b) Crack the drain petcock on the bottom of the storage tank to check for water and drain if needed.
(c) Check moisture indicator to see that it is still “BLUE”. If it is pink, it is time to service the air dryer.
(d) Check pump-up times of the compressor.
(e) Check intake air supply filters. Replace filters as needed.
YEARLY SERVICING
(a) Repeat all of the monthly servicing.
(b) Replace the dessicant air dryer.(Part #: RDC-100)
(c) Replace the alternate air filter. (Part #: TIF-100)
(d) Replace the intake filters on the Oilless compressor head. (Part #: TIF-100))
(e) Replace the moisture indicator on the compressor. (Part #: MI-100)
(f) Check the coalescing filter and change if needed. (Part #: CFEO-375)
6
PARTS LIST
See next page for numbered part identification
OIL-FREE COMPRESSOR MOTOR 1HP
KEY
PART NO.
DESCRIPTION
1
TOM-1-115
OILLESS COMPRESSOR MOTOR 1HP 115V
1
2
TOM-1-230
OILLESS COMPRESSOR MOTOR 1HP 230V
1
3
TFF-100
FRONT FAN ASSY. 1 HP
1
4
TFC-100
FRONT FAN COVER 1 HP
1
5
TPA-100
PISTON ASSEMBLY COMPLETE 1 HP
1
6
TCA-100
CYLINDER ASSEMBLY COMPLETE 1 HP
1
7
TAF-100
AIR FILTER ASSEMBLY COMPLETE 1 HP
1
8
TIF-100
AIR FILTER ELEMENT ONLY H HP
1
9
POVT-100
POP OFF SAFETY VALVE
1
7
UNIT
PARTS LIST
8
7
9
6
5
2
1
3
4
8
SINGLE COMPRESSOR CONFIGURATION
2
7
5
8
4
30
40 50
1
60
7
20
8
10
0
psi
90
100
2
3
DUAL AND TRIPLE
COMPRESSOR CONFIGURATION
5
6
4
7
50 60
0
1
70
80
0
90
20
100
3
10
0
GAUGE AND CUT-OFF ASSEMBLY
KEY
PART NO.
1
CPG-250
2
DESCRIPTION
UNIT
COMPRESSOR GAUGE
1
BV-250
1/4” BALL VALVE
1
3
MI-100
MOISTURE INDICATOR
1
4
FA-4-4
1/4” FLARE HOSE FITTING
1
5
BN-250-CL
1/4” BRASS CLOSE NIPPLE
1
6
BT-250
1/4” BRASS TEE
1
7
BSE-250
1/4” BRASS ELBOW
1
8
BPC-4
1/4” BRASS CROSS
1
9
3
5
6
2
4
1
7
REAR VIEW ASSEMBLY AND PARTS LIST
KEY
PART NO.
1
CV-375MF-100
2
CPT-100
3.
CV-375D-100
4
HA-10-250
5
DESCRIPTION
UNIT
3/8” CHECK VALVE MALE TO FEMALE CONNECTION
1
COMPRESSOR PURGE TANK
1
3/8” CHECK VALVE
1-3
1/4 HOSE ASSEMBLY - 10” LONG
1
DPC-1
DRYER PRE COOLER SINGLE COMPRESSOR
1
6
DPC-2
DRYER PRE COOLER DUAL & TRIPLE COMPRESSOR
1
7
RFV-100
RUBBER MOUNTING FEET
4
10
9
8
7
11
DSV-230
AS-500
RDC-100
MV-250
SN-250-CL
FE-4-6
BV-250
BT-250
PFH-375
MSD-100
MSD-200
CV-250D
3
4
5
6
7
8
9
10
11
12
13
9
2
6
DSV-115
13
1
1
10
1/4 CHECK VALVE
ACTIVATED ALUMINA 1 LB
MOLECULAR-SIEVE 1 LB
1
2LBS
2LBS
PER FOOT
2
1
1
3
1
1
1
1
1
UNIT
3
CLEAR DRAIN HOSE
BRASS TEE 1/4
BALL VALVE 1/4
FLAIR FITTING 1/4 X 3/8
STAINLESS STEEL NIPPLE 1/4
METERING VALVE
REPLACEMENT DESSICANT TANK
1/2 FILTER ASSY
230V PURGE SOLENOID VALVE
115V PURGE SOLENOID VALVE
DESCRIPTION
INSIDE
TANK
ELEMENT
PART NO.
11 12
KEY
5
NEW DESICCANT AIR DRYER ASSEMBLY
4
2
1
3
2
FILTER ASSEMBLY
KEY
PART NO.
1
CFAO-375
COALESCING FILTER ASSEMBLY 3/8
DESCRIPTION
1
2
CFEO-375
COALESCING FILTER ELEMENT 3/8
1
3
CFBP-375
COALESCING FILTER BOWL
1
12
UNIT
6
7
15
16
8
3
11
2
10
20
9
12
5
18
4
19
17
13
1
14
SINGLE ULTRA CLEAN OILLESS COMPRESSOR
KEY
PART NO.
DESCRIPTION
UNIT
1
SBHA-21-375
STEEL BRAID HOSE ASSEMBLY
1
2
SBHA-7.5-375E
1
3
SBHA-11-375E
4
FPH-375
PURGE FLEX HOSE CLEAR
5
ZZACS61
1/4 HOSE ASSMEBLY
6
PFT-625
7
CFAO-375
8
CFEO-375
9
DPB-100
10
RIC-GAST
1
PER FT
1
POLY FLO TUBE 5/8
PER FT
COALESCING FILTER 3/8
1
COALESCING FILTER ELEMENT ONLY
1
DRYER PURGE BUCKET
1
4
11
CPT-100
1
12
RDC-100
REPLACEMENT DESICCANT CARTRIDGE
1
13
DSV-115
PURGE VALVE SOLENOID VALVE 115V
1
14
DSV-230
1
15
TOM-1-115
OILLESS MOTOR 1 HP 115V
1
16
TOM-1-230
17
RFV-100
18
PSC-3
19
POVA-100
20
CV-125D
1
4
PRESSURE SWITCH
1
SAFETY POP OFF VALVE
1
1/8 CHECK VALVE
1
13
16
6
7
8
15
13
3
11
2
20
10
18
5
19
9
12
4
1
14
17
DUAL ULTRA CLEAN OILLESS COMPRESSOR
KEY
PART NO.
DESCRIPTION
UNIT
1
SBHA-21-375
1
2
SBHA-10-375E
1
3
SBHA-9-375E
1
4
FPH-375
5
ZZACS61
1/4 HOSE ASSEMBLY
PER FT
1
6
PFT-625
7
CFAO-375
1
8
CFEO-375
1
DRYER PURGE BUCKET
1
8
9
DPB-100
10
RIC-GAST
POLY FLO TUBE 5/8
PER FT
11
CPT-100
1
12
RDC-100
1
13
CV-375D-100
3/8 CHECK VALVE
2
14
DSV-230
15
SBHA-18-375
16
TOM-1-230
17
RFV-100
18
PSC-3
19
POVA-100
20
CV-125D
1
2
2
4
PRESSURE SWITCH
1
1
1/8 CHECK VALVE
1
14
6
16
7
15
13
8
3
2
11
20
10
18
5
19
9
12
4
1
KEY
14
PART NO.
17
TRIPLE ULTRA CLEAN OILLESS COMPRESSOR
DESCRIPTION
UNIT
1
SBHA-21-375
1
2
SBHA-10-375E
1
3
SBHA-9-375E
1
4
FPH-375
5
ZZACS61
1/4 HOSE ASSEMBLY
PER FT
1
6
PFT-625
7
CFA0-375
POLY FLO TUBE 5/8
PER FT
1
8
CFE0-375
1
9
DPB-100
DRYER PURGE BUCKET
10
RIC-GAST
1
12
11
CPT-100
1
12
RDC-100
1
13
CV-375D-100
3/8 CHECK VALVE
3
14
DSV-230
15
SBHA-18-375
16
TOM-1-230
17
RFV-100
18
PSC-3
19
POVA-100
20
CV-125D
1
3
3
4
PRESSURE SWITCH
1
1
1/8 CHECK VALVE
1
15
16
GO ON TO
THE NEXT
PAGE.
Defective
head,
contact
Tech West.
Replace
intake
filter.
Clean
or
replace.
Check voltage at
the valve and
make sure valve is
closed.
NO
YES
NO
YES
DOES AIR
COMPRESSOR
RUN?
Is there sufficient
pressure build-up
with head
discharge line
removed?
NO
Is intake
filter
clogged?
YES
Does
unloader
valve pressure switch
or float
assembly
seat while
running?
NO
Does air
bleed out
the purge
valve when
unit is
running?
YES
YES
Check voltage supplied to the
compressor.
YES
Does compressor run
for a few seconds,
“chugs”, then stops?
Defective
head,
contact
Tech West.
Locate and
repair.
NO
NO
YES
Make sure that the
dryer valve is closing properly.
YES
Does air leak
from unloader
valve or the
purge muffler
continuously
until unit cycles
again?
NO
Are there leaks in
compressor or in
office piping system?
NO
Does compressor pressurize from 80 to 100
psi in less than 2
minute with no air
being used?
Note: Close
shut off valve.
Pump up tank to
100 psi. If pressure is maintained for 15-20
min., leak is in
office lines.
YES
1. Locate and repair
leaks.
2. Ventilate if room is
above
100 deg. F.
3. Contact compressor
may be undersized.
NO
YES
Does compressor run
too hot or too
frequent?
YES
Does
purge valve
system
function
properly?
NO
Is the moisture
indicator pink?
NO
Service dryer and
replace moisture
indicator.
Check for proper
voltage. Use buckboost if needed.
YES
Single Ultra Clean Oilless Compressor Diagram
YES
Does compressor
cycle with no air
being used?
Single Ultra Clean Oilless Compressor
Trouble Shooting Chart
Wiring Diagram
Single Ultra Clean Oilless Compressor
230v
115v
GO ON TO
THE NEXT
PAGE.
COMPRESSOR
DOES NOT RUN
OR RUNS FOR
ONLY A FEW
SECONDS.
YES
Blockage in
air line locate
& repair.
YES
Does head
run with discharge line
disconnected?
NO
Install
Tech West
transformer.
NO
Is there sufficient voltage
at disconnect
box?
Is there sufficient
voltage at motor
terminals while
motor tries to start?
YES
YES
NOTE: Voltage
should be + or 10% of rating.
Replace
defective
capacitors.
NO
Is there
resistance
rise across
the capacitors?
YES
Turn power off.
Remove fan guard.
Try turning fan by
hand. If it doesn’t
turn, contact head
may be frozen.
17
NO
CHECK FOR:
1. Broken or loose
wire.
2. Defective pressure
switch.
3. Defective ON/OFF
switch.
4. Excessive voltage
drop across power
lines.
NOTE:
Short capacitor
leads. Check resistance rise. If no
resistance rise,
replace.
18
GO ON TO
THE NEXT
PAGE.
Locate
and repair.
Defective
head,
contact
Tech West.
Replace
intake
filter.
Clean
or
replace.
Check voltage at
the valve and
make sure valve is
closed.
YES
NO
YES
NO
YES
DOES AIR
COMPRESSOR
RUN?
Is there a
blockage in
air lines?
YES
Is there sufficient
pressure build-up
with head
discharge line
removed?
NO
Is intake
filter
clogged?
YES
Does
unloader
or float
assembly
seat while
running?
NO
Does air
bleed out
the relief
valve?
YES
NO
compressor.
YES
Does compressor run
for a few seconds,
Defective
head,
contact
Tech West.
Locate
and repair.
NO
NO
YES
Make sure that the
YES
Does air leak
from unloader
valve or the
purge muffler
continuously
until unit cycles
again?
NO
Are there leaks in
compressor or in
NO
psi in less than 1
minute with no air
being used?
Note: Close
shut off valve.
Pump up tank to
min., leak is in
office lines.
YES
leaks.
above
100 deg. F.
may be undersized.
NO
YES
Does compressor run
too hot or too
frequent?
YES
Does
unloader
valve system
function
properly?
NO
Is the moisture
indicator pink?
NO
Service dryer and
replace moisture
indicator.
Check for proper
YES
Dual Ultra Clean Oilless Compressor Diagram
YES
Does compressor
cycle with no air
being used?
Dual Ultra Clean Oilless Compressor
Wiring Diagram
Dual Ultra Clean Oilless Compressor
208/230v
GO ON TO
THE NEXT
PAGE.
COMPRESSOR
DOES NOT RUN
OR RUNS FOR
ONLY A FEW
SECONDS.
YES
Blockage in
air line locate
& repair.
YES
Does head
disconnected?
NO
Install
Tech West
transformer.
NO
at disconnect
box?
Is there sufficient
voltage at motor
terminals while
YES
YES
NOTE: Voltage
Replace
defective
capacitors.
NO
Is there
resistance
rise across
the capacitors?
YES
Turn power off.
Remove fan guard.
Try turning fan by
turn, contact head
may be frozen.
19
NO
CHECK FOR:
1. Broken or loose
wire.
switch.
3. Defective ON/OFF
switch.
drop across power
lines.
NOTE:
Short capacitor
resistance rise,
replace.
20
GO ON TO
THE NEXT
PAGE.
Locate
and repair.
Defective
head,
contact
Tech West.
Replace
intake
filter.
Clean
or
replace.
Check voltage at
the valve and
make sure valve is
closed.
YES
NO
YES
NO
YES
DOES AIR
COMPRESSOR
RUN?
Is there a
blockage in
air lines?
YES
Is there sufficient
pressure build-up
with head
discharge line
removed?
NO
Is intake
filter
clogged?
YES
Does
unloader
or float
assembly
seat while
running?
NO
Does air
bleed out
the relief
valve?
YES
NO
compressor.
YES
Does compressor run
for a few seconds,
Defective
head,
contact
Tech West.
Locate
and repair.
NO
NO
YES
Make sure that the
YES
Does air leak
from unloader
valve or the
purge muffler
continuously
until unit cycles
again?
NO
Are there leaks in
compressor or in
NO
psi in less than 1
minute with no air
being used?
Note: Close
shut off valve.
Pump up tank to
min., leak is in
office lines.
YES
leaks.
above
100 deg. F.
may be undersized.
NO
YES
Does compressor run
too hot or too
frequent?
YES
Does
unloader
valve system
function
properly?
NO
Is the moisture
indicator pink?
NO
Service dryer and
replace moisture
indicator.
Check for proper
YES
Triple Ultra Clean Oilless Compressor Diagram
YES
Does compressor
cycle with no air
being used?
Triple Ultra Clean Oilless Compressor
Wiring Diagram
Triple Ultra Clean Oilless Compressor
208/230v
GO ON TO
THE NEXT
PAGE.
COMPRESSOR
DOES NOT RUN
OR RUNS FOR
ONLY A FEW
SECONDS.
YES
Blockage in
air line locate
& repair.
YES
Does head
disconnected?
NO
Install
Tech West
transformer.
NO
at disconnect
box?
Is there sufficient
voltage at motor
terminals while
YES
YES
NOTE: Voltage
Replace
defective
capacitors.
NO
Is there
resistance
rise across
the capacitors?
YES
Turn power off.
Remove fan guard.
Try turning fan by
turn, contact head
may be frozen.
21
NO
CHECK FOR:
1. Broken or loose
wire.
switch.
3. Defective ON/OFF
switch.
drop across power
lines.
NOTE:
Short capacitor
resistance rise,
replace.
Maintenance & Service / Notes
22
23
24
25
Manufacturers of Dental Vacuum
and Air Systems
2625 N. Argyle Ave. • Fresno, CA 93727
(559) 291-1650 • (800) 428-7139 • FAX (559) 348-9677

ultra clean oilless compressor

Transcription

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