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OIL-LESS COMPRESSOR
OPERATION AND INSTRUCTION
MANUAL
OIL-LESS
COMPRESSOR MODELS
OL 512
SINGLE STAGE
OL 512
SINGLE STAGE
OL 524
TWO STAGE
OL 812
SINGLE STAGE
OL 812
SINGLE STAGE
Before installing this compressor, read and understand
the safety precautions contained within this manual
CURTIS - TOLEDO, INC.
1905 Kienlen Avenue, St. Louis, Missouri 63133,
PHONE(314)383-1300 ----- FAX (314)381-1439
CAUTION
3 H.P.
5 H.P.
5 H.P.
7 1/2 H.P.
10 H.P.
CAP-215
APRIL, 2003
REV. D
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Table of Contents
Summary of Contents for Curtis OL 512
- Page 1 OL 812 SINGLE STAGE CAUTION Before installing this compressor, read and understand the safety precautions contained within this manual CURTIS - TOLEDO, INC. 1905 Kienlen Avenue, St. Louis, Missouri 63133, PHONE(314)383-1300 ----- FAX (314)381-1439 3 H.P. 5 H.P. 5 H.P.
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Page 2: Table Of Contents
Instruction Manual Oil-Less Compressors TABLE OF CONTENTS Safety... Safety Precautions... Receiving Delivery... Freight Damage... Installation... Electrical Supply Requirements... Start-up Procedures... Air Inlet Systems... Compressed Air Discharge System... System Components... Stopping for Maintenance... Pulley Alignment and Belt Tensioning... GENERAL... PURPOSE AND SHORT DESCRIPTION... 1.1. - Page 3 TORQUE SEQUENCE... 13.3. MAINTENANCE SCHEDULE... TABLE OF FIGURES Fig. 1 OL 512, REAR VIEW... Fig. 2 OL 512, LEFT SIDE VIEW... Fig. 3 OL 524, REAR VIEW... Fig. 4 OL 524, LEFT SIDE VIEW... Fig. 5 OL 812, REAR VIEW...
- Page 4 Instruction Manual Oil-Less Compressors Fig. 19 2 STAGE COMPRESSOR DIMENSIONS (070308-1015)... Fig. 20 1 STAGE COMPRESSOR DIMENSIONS (070307-1015)... Fig. 21 1 STAGE COMPRESSOR DIMENSIONS (077734)... Fig. 22 D51.2, DIAGRAM & SPARE PARTS LIST OF CYLINDER, PISTON & INTAKE VALVE ………………….. Fig.
- Page 5 WHILE EVERY EFFORT IS MADE TO ENSURE THE ACCURACY OF THE PARTICULARS CONTAINED IN THIS MANUAL, THE MANUFACTURING COMPANY WILL NOT, UNDER ANY CIRCUMSTANCES, BE HELD LIABLE FOR ANY INACCURACIES OR THE CONSEQUENCES THEREOF. OL 512 OL 524 OL 812 INTRODUCTION CAP-215...
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Page 6: Safety
Instruction Manual Oil-Less Compressors At Curtis-Toledo, Inc. safety is a primary concern. Beginning with the design stage, safety is built into every "Curtis Compressor". It is the purpose of this manual to pass along the "safety first" concept to you by providing safety precautions throughout its pages. - Page 7 • Transfer of toxic, dangerous, flammable or explosive substances using Curtis-Toledo products Is at the User's risk. • Turn off and lockout/tagout the main power disconnect switch before attempting to work or perform any maintenance.
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Page 8: Receiving Delivery
If any damage is found, demand an inspection from the carrier. Ask the carrier how to file a claim for shipping damages. (Refer to FREIGHT DAMAGE for complete details.) Shipping damage is not covered by Curtis- Toledo's compressor warranty. CAUTION! Improper lifting can result in component or system damage or personal Injury. -
Page 9: Electrical Supply Requirements
AIR INTAKE A clean, cool and dry air supply is essential to the satisfactory operation of your Curtis-Toledo air compressor. The standard air filter that the compressor is equipped with when leaving the factory is of sufficient size and design to meet normal conditions, when properly serviced, in accordance with the maintenance section of this manual. -
Page 10: Compressed Air Discharge System
Instruction Manual Oil-Less Compressors REMOTE INLET FILTERS Depending on the size of the compressor and the size and construction of the room in which 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: System Components
However, it adjustment is required (by qualified electrician) refer to instructions inside cover of switch housing, The maximum discharge pressure for the various models are established by the Curtis performance data. Do not set the pressure switch or regulators to exceed the design limit. -
Page 12: Stopping For Maintenance
Instruction Manual Oil-Less Compressors SYSTEM COMPONENTS (CONTINUED) WARNING! Never exceed the designed pressure for the system or overload the motor beyond its Maximum Amp Draw. • Full Load Amps x Service Factor = Max-imum Amp Draw. • Full Load Amps (FLA) & Service Factor can normally be found on motor nameplate. -
Page 13: Maintenance Schedule
Instruction Manual Oil-Less Compressors PULLEY ALIGNMENT & BELT TENSION Improper pulley alignment and belt 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 this time, inspect both the motor and compressor pulleys for oil, grease, nicks or burrs. -
Page 14: General
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 compressors operate with three cylinders and are air-cooled (Fig. -
Page 15: Table Of Figures Fig. 1 Ol 512, Rear View
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) -
Page 16: Fig. 2 Ol 512, Left Side View
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 CAP-215... -
Page 17: Fig. 3 Ol 524, Rear View
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... -
Page 18: Fig. 4 Ol 524, Left Side View
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 CAP-215... -
Page 19: Fig. 5 Ol 812, Rear View
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 CAP-215... -
Page 20: Fig. 6 Ol 812, Left Side View
CAP-215 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: Design And Mode Of Operation
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. 1.2.2. Mode of Operation 1-stage compressor The positions stated refer to Fig. -
Page 22: Fig. 8 Function Of Non-Return Valve
CAP-215 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 the outside air via the intake filter (14) and the crankcase and compressed to an intermediate pressure of approx. 60 to 70 psi. The compressed air is cooled back to the original temperature in the intermediate coolers (3) and is then lead to a manifold (10). -
Page 23: Nd Stage)
(rpm) and max. final pressure f) at max. speed 1,000 min. (rpm) g) at 1,000 min. (rpm) and max. final pressure Subject to change without prior notice OL 512 31.8 cfm atmospherical 17 cfm at 110 psi 110 psi 3.3 inches 2 inches 960 min. -
Page 24: Technical Data
Instruction Manual Oil-Less Compressors Technical Data 1 -stage compressor No. of stages Intake volume Intake pressure Delivery Operating pressure, max. No. of cylinders Cylinder bore Piston stroke Speed Weight Drive input Compressor rotation Min./max. ambient temperature Subject to change without prior notice OL 812 48 cfm atmospherical... -
Page 25: Electrical Data
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 Nominal response temperature NAT Tolerance Cold resistance PTC resistance (U =2.5 V) PTC resistance temperature NAT-T PTC resistance (U =2.5 V) at PTC resistance temperature NAT+T... -
Page 26: Intake Filter
Instruction Manual Oil-Less Compressors INTAKE FILTER 2.1. DESCRIPTION A dry micronic filter is used to filter intake 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 intervals according to maintenance schedule in chapter 9. For this purpose an optical maintenance indicator is mounted on the intake filter (Fig. -
Page 27: Intermediate And Final Separator
Instruction Manual Oil-Less Compressors INTERMEDIATE AND FINAL SEPARATOR 3.1. FUNCTIONAL DESCRIPTION OF INTERMEDIATE 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 results from the cooling down after the compressing process and thus to provide the next stage with a cleaned medium. -
Page 28: Functional Description Of Final Separator
Instruction Manual Oil-Less Compressors 3.2. FUNCTIONAL DESCRIPTION OF FINAL SEPARATOR A final separator is mounted after the three first stages 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 sintered metal filter (2) is provided additionally to remove dirt contamination. -
Page 29: Valves
Instruction Manual Oil-Less Compressors VALVES 4.1. FUNCTIONAL DESCRIPTION OF 1 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. -
Page 30: 4.3. Initial Operational Check Of Valves
Instruction Manual Oil-Less Compressors 4.3. INITIAL OPERATIONAL CHECK OF VALVES If the intake pipe to the valve head of the second stage 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 remove the valve head and to check and clean these valves, or to replace them as necessary. -
Page 31: Changing The Valves Of The 1St Stage
Instruction Manual Oil-Less Compressors 4.5. CHANGING THE VALVES OF THE 1 The intake valve of the 1st stage is integrated into the 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. -
Page 32: Automatic Condensate Drain
Instruction Manual Oil-Less Compressors AUTOMATIC CONDENSATE DRAIN 5.1. DESCRIPTION The condensate drain valve should drain the final separator (1 -stage compressor) or the intermediate and final separator (2-stage compressor) every 15 minutes or earlier if necessary. Furthermore, condensate is drained after each operation (stand still drainage). A solenoid valve is installed as a condensate drain valve, which is open when it does not receive any power. -
Page 33: Cooling System
Instruction Manual Oil-Less Compressors 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 draws the cooling air through the flywheel cover from the surroundings and thus cools the cylinder, both intercoolers and the after-cooler. -
Page 34: General
Instruction Manual Oil-Less Compressors SAFETY REGULATIONS 7.1. GENERAL CAP-215... - Page 35 CAP-215 Instruction Manual Oil-Less Compressors...
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Page 36: Installation Operation
Instruction Manual Oil-Less Compressors INSTALLATION OPERATION 8.1. INSTALLATION OF THE COMPRESSOR Remove all plastic protective plugs and caps before Installing compressor. The oil-less compressor should be installed so that there is no vibration, e.g. from the drive motor. - If possible install compressor in such a manner that the compressor fan can get fresh air from outside, for instance through an opening in the wall. -
Page 37: Natural Ventilation
Instruction Manual Oil-Less Compressors 8.1.1. Natural ventilation As warm air rises, adequate wall openings should be provided 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. -
Page 38: Forced Ventilation
CAP-215 Instruction Manual Oil-Less Compressors 8.1.2. Forced ventilation Forced ventilation facilitates a reduced variation in temperature. 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 /h for a drop in temperature of 18°F p = ∆p = resistance in pa. -
Page 39: Electrical Installation
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 stampings on the motor, magnetic starter solenoids, and other control devices. -
Page 40: Maintenance Schedule
Instruction Manual Oil-Less Compressors MAINTENANCE SCHEDULE 9.1. MAINTENANCE INTERVALS Interval 1/2 hour after start-up 250 operating hours 50 - 250 operating hours Service intake filter (according to degree of pollution), never wash 4,000 operating hours (at least every 3 years) 10,000 operating hours (at least every 3 years) 20,000 operating hours... -
Page 41: Storage, Preservation
Instruction Manual Oil-Less Compressors 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 free room. Only cover the compressor with plastic if it is certain that no condensation will form under the sheet. -
Page 42: Repair Instructions
Instruction Manual Oil-Less Compressors REPAIR INSTRUCTIONS 11.1. GENERAL Preventive maintenance usually involves replacing the gaskets and sealing rings as well as carrying out the maintenance work. Repair work can be carried out on the oil-less compressor to a certain extent, however certain repair work requires experience and skill. -
Page 43: Trouble-Shooting
Instruction Manual Oil-Less Compressors TROUBLE-SHOOTING TROUBLE Compressor Compressor does not reach final pressure Compressor output insufficient Safety valves between individual stages releasing pressure Compressor running too hot Control does not switch off, final pressure safety valve relieving Final pressure safety valve defective Replace safety valve Automatic: Condensate Drain (optional) Drain valves do not close Drain valves do not open... -
Page 44: Tables
Instruction Manual Oil-Less Compressors TABLES 13.1. TIGHTENING TORQUE VALUES Unless otherwise specified in text, the following torque values apply. All valve head screws require torque wrench tightening! The torque values indicated are valid for bolts in greased condition. Replace self-retaining nuts on reassembly Bolt or Screw Hex and allen head... - Page 45 CAP-215 Instruction Manual Oil-Less Compressors NOTE: Please refer to Chapter 9 of instruction manual for maintenance schedule. Operating hours Air filter cartridge cleaned Air filter cartridge changed V-belt, fan wheel drive checked V-belt, fan wheel drive adjusted V-belt, fan wheel drive changed V-belt, compressor drive checked...
- Page 46 Instruction Manual Oil-Less Compressors MAINTENANCE RECORD NOTE: Please refer to Chapter 9 of instruction manual for maintenance schedule. Operating hours Air filter cartridge cleaned Air filter cartridge changed V-belt, fan wheel drive checked V-belt, fan wheel drive adjusted V-belt, fan wheel drive changed V-belt, compressor drive checked...
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Page 47: Fig. 19 2 Stage Compressor Dimensions (070308-1015)
CAP-215 Fig. 19: 2-stage compressor dimensions (070308-1015) -
Page 48: Fig. 20 1 Stage Compressor Dimensions (070307-1015)
CAP-215 Fig. 20: 1-stage compressor dimensions (070307-1015) -
Page 49: Fig. 21 1 Stage Compressor Dimensions (077734)
CAP-215 Fig. 21: 1-stage compressor dimensions (077734) -
Page 50: Fig. 22 D51.2, Diagram & Spare Parts List Of Cylinder, Piston & Intake Valve
Spare parts sets Class Pos. Part No. 0 2 5 CCC1512 Cylinder and piston assembly CCC1513 Piston assembly CCC1466 Intake valve assembly CCC1619 Countersunk screw CCC1555 Fixation nut CCC1554 Reed valve CCC1634 Cylinder pin CCC1468 Piston ring CCC1565 Circlip CCC1566 Piston ring CCC1552 Piston CCC1536 Cylinder CCC1637 Hex nut, self-locking, NM8... -
Page 51: Fig. 23 D52.4, Diagram & Spare Parts List Of Cylinder, Piston & Intake Valve
Spare parts sets Class Pos. Part No. 0 2 5 CCC1512 Cylinder and piston assembly CCC1513 Piston assembly CCC1466 Intake valve assembly CCC1619 Countersunk screw CCC1555 Fixation nut CCC1554 Reed valve CCC1634 Cylinder pin CCC1468 Piston ring CCC1565 Circlip CCC1566 Piston ring CCC1552 Piston CCC1536 Cylinder CCC1637 Hex nut, self-locking, NM8... - 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...