Xstream AC7580B Operation Manual Download

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operation

manual

Model #

AC7580B

AC7580B3

AC7580S

AC7580S3

AC1080S

AC1080SQ

CAUTION READ THIS MANUAL CAREFULLY

before operating or servicing this

air compressor, to familiarize yourself with the proper safety, operation, and standard
operating procedures of this unit.

FAILURE TO COMPLY WITH INSTRUCTIONS IN

THIS MANUAL COULD RESULT IN THE VOIDING OF YOUR WARRANTY, AND
PERSONAL INJURY, AND/OR PROPERTY DAMAGE. THE MANUFACTURER
OF THIS AIR COMPRESSOR WILL NOT BE LIABLE FOR ANY DAMAGE
BECAUSE OF FAILURE TO FOLLOW THE INSTRUCTIONS IN THIS MANUAL.

By following the instructions and recommendations in this manual you will ensure a
longer and safer service life of your air compressor.

Summary of Contents for AC7580B

Page 1: ...ing procedures of this unit FAILURE TO COMPLY WITH INSTRUCTIONS IN THIS MANUAL COULD RESULT IN THE VOIDING OF YOUR WARRANTY AND PERSONAL INJURY AND OR PROPERTY DAMAGE THE MANUFACTURER OF THIS AIR COMPRESSOR WILL NOT BE LIABLE FOR ANY DAMAGE BECAUSE OF FAILURE TO FOLLOW THE INSTRUCTIONS IN THIS MANUAL By following the instructions and recommendations in this manual you will ensure a longer and safe...

Page 2: ... owner s manual thoroughly will help avoid any personal injury or damage to your pump By knowing how best to operate this machine you will be better positioned to show others who may also operate the unit You can refer back to the manual at any time to help troubleshoot any specific operating functions so store it with the machine at all times Attention Read through the complete manual prior to th...

Page 3: ... line 1 866 770 1711 for information on servicing always provide the product model and identification numbers You will need to locate the model and serial number for the pump and record the information in the places provided below Date of Purchase Dealer Name Dealer Phone Product Identification Numbers Model Number Serial Number ...

Page 4: ... 9 Oil Filter 9 Air Oil Separator 10 Minimum Pressure Valve 10 Cooling 10 Head Load of Compressor 11 Controls Installation 11 General 11 Foundation 11 Room 11 Air Intake Receiving Compressor 12 Receiving and Uncrating your Compressor Compressor Installation 13 Location 13 Mounting 13 Induction System 14 Cooling Air Discharge 14 Electrical 14 Unpacking and Handling 15 Storage Guidelines 15 Guidelin...

Page 5: ...ilter 21 Element Inspection and Replacement 22 Oil Filter 22 Oil Filter Replacement 22 Air Oil Separator 22 Separator Element Replacement 23 Lubricant 23 Lubricant Specifications 23 Oil Analysis 24 Checking Oil Level and Adding Compressor Oil 24 Changing Compressor Lubricant 25 Oil Return Sight Glass 25 Minimum Pressure Valve 25 To Check the Belts 25 Fan Compressor Diagram 26 Wiring Diagrams Troub...

Page 6: ...ments 33 Adjusting Belt Tension 33 Pulley Alignment Maintenance 34 Stopping for Maintenance or Service 35 Daily 35 Weekly 35 Monthly 35 Every 3 Months 35 Yearly 36 Storage of Compressor 36 Safety Procedures table of contents ...

Page 7: ...am of any shutoff valve block valve heat exchanger orifice or any potential blockage point Failure to install a safety relief valve could result in rupturing or explosion of some compressor or safety component Do not change the pressure setting of the safety relief valve restrict the function of the safety relief valve or replace the safety valve with a plug Over pressurization of some system or c...

Page 8: ...ile there ispower to the unit You should always turn the power off to the compressor unit before performing and kind of service to the machine If you have any questions please contact the factory for clarifications before making any changes to the delivered state of the compressor warning Compressed Air from this machine is not suitable for breathing and will cause death or server personal injury ...

Page 9: ... air filter oil filter and the air oil separator element Air Filter The air filter is a high efficiency ring style located on top of the inlet valve of the compressor It will provide nearly constant efficiency of filtration at all load conditions The element has a high dirt holding capacity for a long life It is specially treated to be insensitive to heat cold water and oil Oil Filter The oil filt...

Page 10: ... heat loads and cooling airflow rates that must be accommodated Head Load of Compressor The compressor is an oil flooded unit The oil lubricates seals and cools the internals of the compressor In cooling it picks up the heat generated by the compression process and the mechanical friction from the bearings So the oil must be cooled to within 60 degrees Fahrenheit of the ambient temperature The aft...

Page 11: ... be mounted on vibration reduction pads Room The room should be of adequate size to provide full access to the machine for routine maintenance It should have ventilation to keep the room as cool as possible Operating at elevated temperatures will cause nuisance overload and temperature shutdowns Room temperature should not exceed 1100 F Air Intake To achieve the longest filter and lubricant life a...

Page 12: ...nameplate to be sure the compressor is the model and size ordered 4 Read the motor nameplate to be sure the motor is compatible with your electrical conditions Volts Phase Hertz note Standard motors are open drip proof with a maximum ambient temperature rating of 104 degrees F They are not suitable for salt laden corrosive dirty wet or explosive environments caution Improper lifting can result in ...

Page 13: ...e floor use the bolts as guide pins and do not tighten the bolts The rubber pads are used to absorb machine vibration and cannot work effectively if bolted tightly Induction System Do not locate the compressor where it could ingest or ignite toxic explosive or corrosive vapors ambient air temperatures exceeding 104 degrees F water or extremely dirty air Ingestion of any of the above noted atmosphe...

Page 14: ...ectrical shutdowns Always connect the compressor to its power source through a fusible disconnect and insure the unit is properly grounded Unpacking and Handling Occasionally damage will occur during shipping Be sure to carefully inspect the unit before unpacking After unpacking before you sign the receiver if anything damage has occurred document it with the trucking firm immediately Contact your...

Page 15: ...ure At the end of the storage period follow the uncrating and start up procedures If the unit has been stored for more than eighteen months you should contact Compressed Air Systems before restarting the compressor Guidelines The air pressure drop between the compressor and the point of use is not recoverable Pipe size should be large enough that the pressure drop does not exceed 10 between the ai...

Page 16: ...e main disconnect switch and ensure that there is no power to the unit 2 Review the installation instructions to see that everything is complete 3 Inspect for visible signs of damage that could have happened during shipment or installation 4 Make certain protective coverings required for shipment or painting are removed from the compressor 5 Fill the sump to the proper oil level Do not overfill if...

Page 17: ...ould be mounted independently of the compressor and anchored as necessary to limit vibration and prevent expansion strains SAFETY VALVES Safety valves are pressure relief valves and should be sized and purchased with a pressure setting to protect the weakest link in the system Never change the pressure setting only the safety valve manufacturer is qualified to make a change Safety valves are to be...

Page 18: ...ow voltage corrected to prevent excessive current draw Compressors must be equipped with a properly wired magnetic motor starter or a pressure switch rated to carry the full motor current load The coil which engages and disengages the contact points in the motor starter is controlled by the pressure switch Never attempt to bypass the pressure switch or adjust it past the factory set pressure range...

Page 19: ...pliance with OSHA Safety and Health Standards 29 CFR 1910 219 in OSHA manual 2206 and any state or local code Drives It is important that the compressor and motor pulleys are aligned properly and the V belt is correctly tensioned Improper pulley alignment and belt tension are causes for motor overloading excessive vibration and premature belt and or bearing failure CAUTION Guards must be fastened ...

Page 20: ...ned for legibility Do not remove any warning caution or instructional material attached 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 if the manual is lost have it replaced immediately The instruction manual should be periodically read to refresh one s memory it may ...

Page 21: ...m harmful dirt being ingested into the oil system It needs to be looked at periodically for clogging or holes The period for theses inspections is dependent on the environment the machine is in For optimum life it is recommended that an air filter restriction indicator be used Service simply based on hours is not recommended Element Inspection and Replacement Switch off the unit and disconnect the...

Page 22: ...h a clean rag 5 Apply a light film of oil to the new gasket 6 Hand tighten the new element until the new gasket is seated in the gasket groove 7 Continue tightening by hand an additional to turn 8 Reconnect power and restart the machine to check for leaks Air Oil Separator The air oil separator should be changed every 2000 hours or when there is excessive oil vapor in the discharge air danger Hot ...

Page 23: ...u receive a detailed report showing the lubricant condition wear metals and contaminants Changes in this information over time provides the basis for predictive compressor maintenance Saving you unplanned machine downtime and unnecessary oil changes Lubricant Specifications If you choose not to use CAS RS8000 for optimum life and warranty service your lubricant must meet the following specificatio...

Page 24: ...ant 1 Switch off the unit and disconnect the power to prevent accidental restarting 2 Allow one minute after stopping the compressor for settling and the pressure to relieve 3 Remove any dirt from around the fill cap and then remove the fill cap If the lubricant appear dirty or has a foul smell it should be replaced 4 Drain the lubricant from the bottom of the air oil receiver Oil will drain more ...

Page 25: ...fan immediately To Check the Belts 1 Switch off the unit and disconnect the power to prevent accidental restarting 2 Allow one minute after stopping the compressor for settling and the pressure to relieve 3 Remove the belt guard 4 Inspect for any fraying or cracking of the belts If there is any replace the belts 5 Check the tension It should be about 1 64 per inch of span between the sheaves 6 To ...

Page 26: ...ower line 1 under set screw Place power line 2 under set screw Place power line 3 under set screw Place ground wire under washer 1 2 3 4 Check all fitting to make sure that they are tight and place cover back on box before checking for correct rotation If rotation is incorrect swap line 1 and line 3 to reverse rotation compressor diagram ...

Page 27: ... Place 1 of the incoming power lines under the starter screw shown Place ground wire behind washer for a proper ground Place the other incoming power line under the starter screw shown 3 4 Once the steps are complete make sure all connections are tight and place cover back on the box before turning the machine on compressor diagram ...

Page 28: ...ssor motor contact Place 2nd incoming power wire in position 2 on compressor motor contact Place ground wire under washer 4 Put cover back on electric panel before checking for proper rotation If rotation is incorrect swap wires in position 1 3 to change the rotation Once rotation is correct place all panels back on compressor Place incoming power wires through wiring port on the bottom of the uni...

Page 29: ... temperature switch for proper operation 6 Check system pressure Unit starts then immediately stalls 1 Pressure switch out of adjustment 2 Temperature switch activated 3 Loose electrical supply wires 4 Motor overloads tripped 5 Low voltage 6 Incorrect compressor rotation 1 Check pilot valve to make sure it is in the proper position 2 Replace compressor pilot valve 3 Check and clean compressor pump...

Page 30: ...lenoid for proper function CFM Flow air flow seems low 1 Restricted air intake filter 2 Inlet valve partially closed 3 Air pressure set to high 4 Insufficient oil flow 5 Solenoid valve malfunction Excessive oil consumption 1 Over filled sump 2 Broken oil line 3 Plugged oil return line 4 Damaged or dirty separator 5 Excessive unloaded compressor run time 1 Check sump for proper oil level 2 Check al...

Page 31: ...osed 3 Air pressure set to high 4 Insufficient oil flow 5 Solenoid valve malfunction 1 Change separator 2 Clean oil cooler 3 Check pressure switch 4 Check incoming voltage 5 Check air end and motor for proper function a b b c d e f g h i j k l m n o p q r s t Compressor Breakdown troubleshooting breakdown FILTER ...

Page 32: ...RF12 11 8 O IAT EM3311T 3PHASE IAT L1510T 1PHASE P IAT PSB20 Q IAT ST25 200 R IAT ET20M21T2B Part Number A IAT 300559 VERT IAT 300569 HORZ B IAT ZB4 BD2 IAT ZB4 B2101 C IAT 20TE2504 D IAT R 9206 E IAT NK30 SEE AIREND DIAGRAM F IAT ST25 200 G IAT BG5X18X32 H IAT R 14366 I IAT R 9213 J IAT R 12476 K IAT 8911DPSG53V09 3PHASE IAT 8911DPSG52V09 1PHASE L IAT 3VX530 M IAT 2 3V8 00 N IAT RF12 11 8 O IAT E...

Page 33: ... Pulley Alignment The figure to the side shows 3 examples of misaligned pulleys To check pulley alignment remove the belt guard and place a straightedge against the compressor flywheel measure and record the distance from the straightedge to the edge of the drive belt Then measure the distance to the edge of the drive belt on the motor pulley at the same edge As long as both points measure the sam...

Page 34: ...rting service The Manual vent valve may be the drain valve in the receiver NEVER remove a plug to relieve the pressure 5 Open all manual drain valves within the area to be serviced 6 Wait for the unit to cool before starting service temperatures at 125 degrees F can burn the skin some surface temperatures exceed 400 degrees F when the compressor is working 7 Clean up all oils spills immediately to...

Page 35: ...his helps to ensure proper cooling and prevents rust and corrosion on critical parts Check safety Valves this is don t to ensure they are not stuck in place and operating properly Monthly Inspect complete air system for leaks this is done to make sure the compressor does not get out of its duty cycle due to air leak in the system Inspect Oil for Contamination this is done to ensure that harmful de...

Page 36: ...the compressor and drain all the moisture from the bottom of the tank Weekly Clean the oil If the oil appears contaminated by moisture or dirt change immediately Check the belts Turn off the compressor and inspect the belts for dam age excessive wear and correct tension Replace if necessary Test the safety valve Pull the ring on the safety valve Air should escape and then reset In the event the co...

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Page 40: ...If you need assistance with the assembly or operation of your Compressor please call 1 866 770 1711 ...

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