36
PRE-STARTUP CHECKLIST
WARNING: Failure to perform the pre-start-up
checklist may result in mechanical failure, property
damage, serious personal injury, or even death.
Steps 1-14 must be performed prior to connecting
the unit to a power source.
1.
Become familiar with the function of all piping
associated with the compressor. Know the use
of each line, valve and control device!
2.
Verify that actual operating conditions will match
conditions the unit was originally designed for.
If conditions do not match, contact your local
representative or the factory.
3
Remove all tools from the compressor and check
for installation debris. Loose tools/debris may
be thrown upon start-up and injure personnel.
4.
Check motor pulley and compressor sheaves for
alignment and proper belt tension. Typically 1/4”
to 3/8” belt de
fl
ection is acceptable. Contact the
belt manufacturer for more details.
5.
Manually rotate compressor sheave through
several full rotations to be sure there is no
mechanical interference felt.
6.
Check inlet piping installation and all pressure
connections for tightness.
7.
Make sure all pressure relief valves are properly
installed and free to operate.
8.
Be sure all belt guards are in place and
secure.
9.
Check fuses, circuit breakers and thermal
overloads for proper sizing.
10. Open all manual shut-off valves downstream of
the compressor discharge.
11. Fill water cooling system (if applicable), and
check for leaks. Purge of air.
12. Check oil levels in crankcase. If low,
fi
ll with
a high quality non-detergent oil of the proper
viscosity.
13. Check for loose connections or loose
fasteners.
14. DOUBLE CHECK ALL THE ABOVE!
15. Connect unit to a proper power source.
INITIAL STARTUP AND
OPERATION (AMBIENT AIR
COMPRESSORS)
Ambient Air Compressors are compressors whose inlet
source is the ambient air surrounding the compressor.
All air compressors are broken in and tested at the
factory prior to shipment. In most cases, it is not
necessary to perform any special start-up procedures
on a new compressor. Occasionally the unit may
need an extended amount of ‘break-in’ time to seat
the piston rings and create proper wear patterns.
Units that have been in storage for an extended
length of time may require special attention. Refer to
sections in this manual on Inspection After Extended
Storage, and Compressor Storage, or contact the local
representative or the factory.
With the pre-start-up checklist completed and satis
fi
ed,
turn the compressor on brie
fl
y (1-2 seconds) to check
the direction of rotation. Be sure it agrees with the
rotation arrow embossed on the compressor sheave
(counterclockwise when viewed from the
fl
ywheel side
of the compressor). If the compressor is not turning in
the proper direction, it will not achieve oil pressure and
will shut down. Fix the problem before re-starting.
Start the compressor. Watch and listen for excessive
vibration and strange noises. If either exist, stop the
compressor immediately.
Watch the oil pressure gauge to be sure the oil
pressure is adequate. Oil pressure should rise to
working pressure within 10-15 seconds. If there is
a question about oil pressure, stop the compressor
and investigate. Refer to Section 4, “Maintenance
and Troubleshooting” for assistance if operation is
not normal.
Check the air receiver pressure gauge or system
pressure gauges for proper readings. If inadequate
or excessive air pressure conditions occur, shutdown
the compressor.
Observe the compressor operation closely for the
fi
rst
hour of operation and then frequently (every 1/2 hour)
for the next seven hours. As the compressor comes
to normal operating conditions, temperature distortion
may cause changes in the operating parameters,
excessive vibration or previously unnoticed noises.
THIS IS NOT NORMAL. Shutdown the compressor
and investigate the problem.
Test each shutdown device, unloader device, dump
valve and safety valve. Record the actual setpoints
and adjust as necessary.
After the
fi
rst eight hours of operation, the compressor