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CAP600

REV C APRIL 2013

CA/CT

Series

TWO STAGE RECIPROCATING AIR

COMPRESSORS

Installation and
Operations Manual

Содержание 1075HT12

Страница 1: ...CAP600 REV C APRIL 2013 CA CT Series TWO STAGE RECIPROCATING AIR COMPRESSORS Installation and Operations Manual ...

Страница 2: ...ling for service The model is found on the tank decal and the serial number is located on the compressor nameplate For Customer Service Technical Service or to order replacement parts please contact your local distributor FS Curtis Inc 1905 Kienlen Avenue St Louis Missouri 63133 phone 1 800 925 5431 fax 314 381 1439 email info curtistoledo com website www fscurtis com ...

Страница 3: ...llation Checklist 13 Electrical Requirements 14 Wiring Diagrams Section 3 Simplex 1 phase and 3 phase 15 Duplex dual source 16 Start Up Section 4 Pre Start Checklist 17 Start Up Procedure 18 Maintenance Section 5 Shut Down Procedure 19 Maintenance Schedule 20 Oil 21 Low Oil Guard 22 Bolt Torques 23 Belt Tension 24 25 Maintenance Parts List 26 Troubleshooting Section 6 Troubleshooting Guide 27 28 M...

Страница 4: ...ust not be made to the compressor or unit without FS Curtis written approval DANGER Air 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 will cause severe injury or death WARNING Compressors are precision high speed mechanical equipment requiring caution in operation to minimize hazard to property and personnel Listed ...

Страница 5: ...he compressor discharge line without first installing a pressure relief valve of proper size and design between the shutoff valve and the compressor Do not use plastic pipe unapproved rubber hose or lead tin soldered joints in any part of the compressed air system Alterations must not be made to this compressor without FS Curtis expressed written approval Do not operate the compressor in excess of...

Страница 6: ... The air enters the first stage a low pressure chamber where it is compressed the first time As air is compressed its temperature increases this hot air then enters the intercooler where the temperature is reduced Next the cooled air enters the second stage a high pressure chamber where the air is compressed a second time to even higher pressures and discharged into the tank An Ultra Pack option c...

Страница 7: ...y difference is in the pressure switch and starter In a duplex unit there are two pressure switches a lead pressure switch and a lag pressure switch set 10 psi lower than the lead switch The alternator utilizes both compressors to fill the tank Once the tank approaches the cutoff lag pressure the alternator selects one compressor to be the lag compressor and cycles it off using only the lead compr...

Страница 8: ...ing the compressor equipment and clear a path to the installation location to avoid damage to property or compressor 3 Turn off lock out the electrical disconnect switch before working on the unit to prevent the unit from starting unexpectedly 4 Read the outfit nameplate to verify the model and size ordered 5 Read the motor nameplate to be sure the motor is compatible with your electrical conditio...

Страница 9: ...eipt of freight Contact the carrier as soon as possible giving them an opportunity to inspect the shipment at the premises where the original delivery was made Retain all containers and packing for inspection by the carrier Do not move the freight Request an inspector and claim number then contact freight carrier Concealed shipping damage is not covered by the FS Curtis warranty A claim form can b...

Страница 10: ...tion Note If the unit or air intake is to be located outdoors please contact your local distributor for additional instructions Step 2 Remove the skid Remove and discard the shipping skid The compressor should NEVER be operated on a skid Step 3 Prepare the mounting surface See Fig 3 and Fig 4 for the compressor s mounting pattern and prepare the surface accordingly See Table 2 for acceptable insta...

Страница 11: ... highly recommends mounting the unit on vibration isolator pads and the compressor should NEVER be operated without being securely fastened to the ground Using a level please check for proper alignment of the compressor Uneven installation will unbalance the compressor leading to excessive noise vibrations and wear Place a steel shim between the concrete and vibration pads and shim down as necessa...

Страница 12: ...unting bolt see Table 3 for recommended sizes 2 Flat washer sized for bolt 3 Compressor Base 4 Vibration Isolator Pads 5 Steel Shim as necessary for leveling 6 Concrete floor see local codes for recommended concrete thickness and hole drilling depth 7 Heavy duty double expansion machine bolt anchor shield 8 1 diameter hole Table 3 Anchor Bolt specifications ...

Страница 13: ...ended to prevent moisture from entering the cylinder head s when one compressor is idle A globe or gate valve WOG rated installed in the discharge line will allow compressor isolation from plant air system for compressor maintenance Note A safety relief valve should be located between the compressor and the globe gate valve Step 7 Install Compressor Intake IF APPLICABLE If the compressor intake is...

Страница 14: ...amount of Curtis Lube Plus Compressor Lubricant specially formulated for Curtis Compressors The oil level should register in the center of the oil sight glass or between the high and low marks on the dipstick For additional lubricant contact your authorized Curtis distributor Failure to use authorized lubricant will void the manufacturer s warranty 3 Check inlet piping installation 4 Check all pre...

Страница 15: ...r s warranty DANGER High voltage may cause personal injury or death per O S H A regulations 1910 137 disconnect and lockout tagout all electrical power supplies before opening the electrical enclosure or servicing WARNING Never assume a compressor is safe to work on just because it is not currently operating It could restart at any time Follow all safety precautions outlined in the Safety Precauti...

Страница 16: ...and L2 MS1 Motor Jumper T2 to L3 M L2 L3 L1 OL A2 A1 T3 T2 T1 95 96 OL Pressure Switch Power Supply to L1 L2 and L3 MS1 Motor M L2 L3 L1 OL A2 A1 T3 T2 T1 Fig 8 Single Phase wiring diagram Fig 9 Three phase wiring diagram NOTE The above wiring diagrams are valid for standard models only Contact your local distributor for wiring diagrams for factory installed options 1 L3 2 L2 3 L1 4 Overload relay...

Страница 17: ...Alternator TURN OFF TAGOUT POWER BEFORE SERVICING 1 2 3 1 2 3 Fig 10 Duplex dual source alternator panel NOTE Unit wiring diagram is located on the inside front cover of the alternator panel If over time the diagram becomes illegible please contact your local distributor 1 L1 2 L2 3 L3 ...

Страница 18: ... The flywheel should rotate in the counterclockwise direction as viewed when facing the flywheel INITIAL STARTING OPERATION This instruction manual as well as any instructions supplied by manufacturers of supporting equipment should be read and understood prior to starting the compressor If there are any questions regarding any part of the instructions please call your local FS Curtis distributor ...

Страница 19: ...belt tension at the beginning of each week and tighten as required see belt tension subsection Check bolts pulley clamp screws and jam nuts for tightness Torque if necessary see bolt torques subsection START UP If the compressor is equipped with an automatic start stop control with pressure switch unloading it is automatically unloaded upon starting and will automatically load after attaining runn...

Страница 20: ...power switch that the compressor is being serviced 2 Isolate the compressor from the compressed air supply by closing the manual shutoff valve upstream and downstream from the compressor Display a sign in clear view at the shutoff valve stating that the compressor is being serviced 3 Lock open a pressure relief valve within the pressurized system to allow the system to be completely de pressurized...

Страница 21: ...ssor DAILY MAINTENANCE Check oil level Check oil for discoloration and filth Drain oil and replace if required Drain drip legs and traps in air distribution system Open drain cock located at the bottom of the tank to relieve condensation Check for oil leaks WEEKLY MAINTENANCE Manually operate the pressure relief valves to be certain they are working Clean the cooling surfaces of the intercooler an...

Страница 22: ...cation the compressor shall not be operated below the minimum or above the maximum R P M recommended for the various models 2 Maintain oil level mid way between the upper and lower lines of the crankcase sight gage Fig 12 Oil sight glass reading 3 Stop compressor to add and gauge oil 4 Do not fill above the upper line and do not operate compressor with oil level below the lower line OIL CAPACITIES...

Страница 23: ... just because it is not currently operating It could restart at any time Follow all safety precautions outlined in the Safety Precautions section Turn off and lockout tagout the main power disconnect switch before attempting to perform maintenance on the unit 1 PARTS LIST LOW OIL GUARD NEW DESIGN ITEM DESCRIPTION QTY PART 1 10 32 x 1 2 FILLISTER HEAD SCREW 8 VH03CD 2 LOW OIL SWITCHPLATE COVER 1 CM...

Страница 24: ...10 1 5 320 23 1 Rear Cover M10 1 5 280 20 25 M8 1 25 300 21 7 M10 1 5 280 20 25 M10 1 5 280 20 25 Inlet and Outlet Push Covers M8 1 25 225 16 3 M8 1 25 225 16 3 M10 1 5 M8 1 25 320 23 1 225 16 3 Table 5 Challenge air bolt torque specifications MODEL NO FLYWHEEL BOLTS FAN BOLTS TORQUE FT LBS TORQUE IN LBS TORQUE FT LBS TORQUE IN LBS E57 23 276 E50 40 480 E71 45 540 24 288 E15 50 600 24 288 Table 6 ...

Страница 25: ...local auto parts or hardware store 1 2 Fig 14 Motor mounts and take up bolt BELT TENSIONING INSTRUCTIONS 1 Loosen the motor mounting bolts but do NOT remove the nuts See fig 12 for the mounting bolt locations Do NOT attempt to adjust the take up bolt before loosening all of the motor mounting bolts attempting to do so will damage the unit 2 Consult Table 7 for the appropriate deflection and tensio...

Страница 26: ...at the original position of the belt Record the reading on the belt tension gauge and compare to the chart Reset the rubber ring on the belt tension gauge before taking another reading 5 Adjust the take up bolt to tighten or loosen the belt tension as required 6 Finger tighten ONE motor mounting bolt Using a straight edge check that pulleys are aligned and adjust motor as necessary 7 Finger tighte...

Страница 27: ...r 2601694830 2601694840 2601694810 2601694880 Valve Gasket Kit wearable parts 2601693870 2601693880 2601693890 2601693910 Ring Kit all rings 2601694650 2601694690 2601694720 2601694750 Lower End Kit contains Gasket Kit Valve Kit and Ring Kit 2601694580 2601694600 2601694530 2601694550 Table 9 Routine Maintenance Parts and Rebuild Kits for Challenge Air compressors CT REBUILD KITS CT55 Kit Number C...

Страница 28: ...pping Incorrect voltage Change the oil Use correct oil Increase ambient temperature above 40 F See 6 Contact distributor 4 Excessive Vibrations Vibration pads not installed Unit not leveled Unit not securely fastened Install vibration pads Level unit with metal shims Check for loose bolts on foundation compressor and motor 5 Compressor overheats Ambient air temperature too high Degraded oil Incorr...

Страница 29: ...ust Working pressure too high Worn or misaligned pulley Adjust belt tension Use correct belt Eliminate dust or relocate unit Lower working pressure Replace or realign pulley 9 Lubricant appears milky Water in the crankcase Incorrect oil Water contaminated oil Water leaking back through discharge valve Compressor not running long enough to prevent condensation Use correct oil Replace oil Re pipe wi...

Страница 30: ...cklist NOTE Please keep a record of changes and have this list available when calling technical service OIL CHANGED Initials Date Changed Oil Low y n Initials Date Changed Oil Low y n BELT TENSIONING Initials Date Checked Measurement Initials Date Checked Measurement ...

Страница 31: ...his list available when calling technical service Valve Inspected Initials Date Checked Initials Date Checked Air Leak Checks Initials Date Checked Comments Initials Date Checked Comments Air Filter Initials Date Replaced Initials Date Replaced Intercooler Aftercooler Cleaning Initials Date Checked Initials Date Checked ...

Страница 32: ...Curtis Toledo Inc 1905 Kienlen Avenue St Louis Missouri 63133 314 383 1300 or 800 925 5431 www fscurtis com info fscurtis com ...

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