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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.
operation manual
Model #
AC7580B
AC7580B3
AC7580S
AC7580S3
AC1080S
AC1080SQ
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Table of Contents
Related Manuals for Xstream AC7580B
Summary of Contents for Xstream AC7580B
- Page 1 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.
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Page 2: Introduction
introduction Attention: Read through the complete manual prior to the initial use of your Compressor Using the Operator’s manual The operating manual is an important part of your Compressor and should be read thoroughly before initial use, and referred to often to make sure adequate safety and service concerns are being addressed. -
Page 3: Product Identification
product identification Record Identification Numbers Compressor If you need to contact an Authorized Dealer or Customer Service 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. -
Page 4: Table Of Contents
table of contents Introduction Using the Operator’s Manual Product Identification Record Identification Numbers Safety Safety Precautions and Warnings Description Compressor Air/Oil System Air Filter Oil Filter Air/Oil Separator 10 Minimum Pressure Valve 10 Cooling 10 Head Load of Compressor 11 Controls Installation 11 General 11 Foundation... - Page 5 table of contents 16 Preparation for Initial Start-Up 17 Noise 17 Piping Fitup 17 Pressure Vessels 18 Electrical 18 Pressure Switch 19 Manual Relief and Shutoff Valves 19 Guards 19 Drives Pre-Operation 21 Start Up Preparation and Procedures 21 Stopping 21 Emergency Stopping 21 Air Filter 21 Element Inspection and Replacement...
- Page 6 table of contents Adustments and Alignments 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...
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Page 7: Safety
safety Safety Precautions and Warnings Listed are some, but not all safety precautions that must be observed with compressors and compressed air systems. Failure to follow any of these warnings may result in severe personal injury, death, property damage and/or compressor damage. Air from this compressor will cause severe injury or death if used for breathing or food processing. - Page 8 safety WARNING Compressed Air from this machine is not suitable for breathing and will cause death or server personal injury . Consult an air filtration specialist for proper treatment for breathing This Compressed Air Systems industrial rotary screw compressor is an electric motor driven single stage helical rotary screw compressor.
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Page 9: Description
description Descriptions Compressor The compressor assembly is a positive displacement, oil flood lubricated, helical rotary screw type unit employing a single stage of compression. The components include housing or stator, two rotors or screws, bearings and bearing supports. In operation two helical grooved rotors mesh to compress air. Inlet air entering the compressor becomes trapped between the lobes of the rotors. -
Page 10: Minimum Pressure Valve
description Minimum Pressure Valve As the compressed air leaves the compressor it goes through a minimum pressure valve. This is set to maintain at least 85 psig (586kPa) in the sump when the compressor is running. This is to insure that there is pressure to force the oil out of the sump and through the oil system so that sufficient oil is injected into the compressor. -
Page 11: Controls
description Controls The RS series of units is equipped with a normally closed inlet valve. This means that when the unit is started, the inlet valve remains closed while the unit builds up pressure by means of a bypass line. After startup the inlet valve is controlled by a simple on/off action of a pressure switch working with a solenoid valve. -
Page 12: Receiving Compressor
receiving compressor Receiving and uncrating your compressor Before uncrating the compressor the following steps should be taken. Immediately upon receipt of the equipment, it should 1. be inspected for damage that may have occurred during shipment. If any damage is found, demand an inspection immediately by an inspector from the carrier. -
Page 13: Compressor Installation
compressor installation Location Locate the compressor in an indoor area that is clean, dry, well lighted, and well ventilated, with sufficient space for safe and proper inspection and maintenance. Ambient temperatures should not exceed 104 degrees. For fall below 30 degrees unless an electric motor rated for a higher temperature is used. -
Page 14: Cooling Air Discharge
compressor installation Cooling Air Discharge The cooling air discharge must be restriction free. Any louvers or ducting must not exceed a quarter of an inch static head. Above this a booster fan will be required. Consult a local HVAC contractor for recommendations prior to installation. -
Page 15: Storage
installation/guidelines Storage In some cases it may be necessary to store the compressor for extended periods of several months before placing the unit in operation. When this is required do the following: Cover and seal all machine openings to prevent the entrance of water and dirt. -
Page 16: Guidelines
guidelines Guidelines Locate runaways from the main header close to the point of application. Take air off the top of the header to prevent carryover of condensed moisture to tools. Slope piping so that it drains toward a drop leg or moisture trap away from the compressor. -
Page 17: Piping Fitup
guidelines Noise Noise is a potential health hazard that must be considered. There are local and federal laws specifying maximum acceptable noise levels that must not be exceeded. Most of the noise from a reciprocating compressor originates from the air inlet point. Excessive noise can be greatly reduced by installing an intake noise silencer. -
Page 18: Pressure Switch
guidelines DANGER The installation, wiring, and all electrical controls must be in accordance with ANSI C1 National Electric Code, ANSE C2 National Electric Safety Code, state and local codes. All electrical work should be performed by a qualified electrician. Failure to abide by the national, state and local codes may result in physical and/or property damage. -
Page 19: Manual Relief And Shutoff Valves
guidelines Manual Relief And Shutoff Valves Install a manual relief valve to vent the compressor to atmosphere. In those instances where the air receiver tank services a single compressor, the manual relief valve can be installed on the receiver. When a manual shut- off valve, and a safety relief valve installed upstream from the manual relief valve. - Page 20 guidelines CAUTION Removal or painting over safety labels will result in uninformed conditions This may result in personal injury or property damage. Warnings signs and labels shall be provided with enough light to read, conspicuously located and maintained 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.
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Page 21: Pre-Operation
pre-operation Start Up Preparation & Procedures Drain off condensate from the sump and check the oil level. Refill as necessary. Check for any oil leaks. Correct as necessary. On water cooled units, turn on the water. Press the start button. Stopping 1. -
Page 22: Oil Filter
pre-operation Reset the filter indicator and the machine will be ready for operation. If the compressor is turned off before being fully unloaded it can cause the unit to discharge oil into the air filter housing causing it to stop up or become contaminated. -
Page 23: Lubricant
pre-operation Lubricant Your compressor has been filled and tested with CAS RS8000, a high quality compressor lubricant. It is a PAO with the advantage of extended service life, high temperature operation, easy start-up when cold, reduced sludge and lacquer buildup, and is completely compatible with all seals, gaskets, and other compressor materials. -
Page 24: Checking Oil Level And Adding Compressor Oil
pre-operation Checking Oil Level and Adding Compressor Oil 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, then remove the fill cap. -
Page 25: Oil Return Sight Glass
pre-operation Oil Return Sight Glass During loaded operation there should be a visible flow in the sight glass. If there are no droplets visible then the orifice in this line needs to be checked for plugging. Oil not returned ends up in the plant air system. Minimum Pressure Valve Then minimum pressure valve is a non-adjustable spring biased check valve. -
Page 26: Compressor Diagram
compressor diagram ALWAYS MAKE SURE POWER IS OFF BEFORE WIRING COMPRESSOR Punch out hole in starter box for power inlet. Remove wiring contacts lid Place power line 2 under set screw Place power Place power line 1 under line 3 under set screw set screw Place ground wire... - Page 27 compressor diagram ALWAYS MAKE SURE POWER IS OFF BEFORE WIRING COMPRESSOR Punch out hole in starter box for power inlet. Remove Starter lid cover Place ground wire behind washer for a proper ground Place 1 of the incoming Place the other incoming power lines under the power line under the starter screw shown...
- Page 28 compressor diagram ALWAYS MAKE SURE POWER IS OFF BEFORE WIRING COMPRESSOR Place incoming power wires through wiring port on the bottom of the unit Remove panels and electrical cover Place 1 of the Place 2nd incoming incoming power power wire in position 2 lines under the on compressor motor starter screw...
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Page 29: Troubleshooting
troubleshooting Troubleshooting Chart NOTE: Troubleshooting problems may have similar causes and solutions. ALWAYS MAKE SURE ELECTRICAL POWER IS OFF BEFORE REMOVING ANY INSPECTION COVERS OR PLATES You should always contact an authorized service center before attempting to fix or repair your air compressor. Problem Possible Cause Solutions... - Page 30 troubleshooting Problem Possible Cause Solutions Compressor 1. Air leaks in shop 1. Find and fix shop air leaks does not build 2. Inlet valve malfunction 2. Check inlet valve for proper up to 3. Compressor belts slipping function pressure 4. Air demand exceeds 3.
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Page 31: Compressor Breakdown
troubleshooting/breakdown Problem Possible Cause Solutions High amperage 1. Restricted air intake filter 1. Change separator draw 2. Inlet valve partially closed 2. Clean oil cooler 3. Air pressure set to high 3. Check pressure switch 4. Insufficient oil flow 4. Check incoming voltage 5. -
Page 32: Breakdown List
breakdown list 5 HP open parts 7.5 HP open parts 10 HP open parts Description Description Description 80 gallon tank 80 gallon tank 80 gallon tank On/Off Switch On/Off Switch On/Off Switch Oil Temp Switch/Gauge Oil Temp Switch/Gauge Oil Temp Switch/Gauge Oil filter Oil filter Oil filter... -
Page 33: Adjusting Belt Tension
adjustments & alignment Adjusting Belt Tension Proper belt tension and pulley alignment must be maintained for maximum drive efficiency and for maximum belt life. The correct tensions exists if a deflection of ½ inch occurs by placing 10lbs of force midway between the motor pulley and the compressor flywheel. -
Page 34: Maintenance
maintenance Stopping for Maintenance or Service CAUTION Never assume the compressor is ready for maintenance or service because it is stopped. The automatic stop/start control may start the compressor at any time! The following procedure should be followed to maximize safety when preparing for maintenance or service. -
Page 35: Daily
maintenance Daily: Drain the Receiver- condensation will accumulate in the tank daily, and should be drained at least once a day. This is done to reduce corrosions of the tank from the inside. Always wear protective eyewear when draining the tank. -
Page 36: Storage Of Compressor
maintenance Storage of Compressor: Before storing the compressor for a prolonged period of time, use a blow gun to clean all debris from compressor. Shut OFF main power and turn OFF disconnect. Drain tank pressure, clean air filter, drain old oil and replace with new oil. - Page 40 If you need assistance with the assembly or operation of your Compressor please call 1-866-770-1711...
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