BORMANN BAT5002 Air Compressor Instruction Manual

**BORMANN BAT5002 Air Compressor Instruction Manual

**

General safety instructions

Please read and save these instructions . Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference.

Short Description: Oilless compressors are designed for do-it-yourselfers with a variety of home and automotive jobs. These units operate without oil. Compressed air from this unit will contain moisture. Install a water filter or air dryer if application requires dry air.

Safety Guidelines: This manual contains information that is very important to know and understand. This information is provided for SAFETY and to PREVENT EQUIPMENT PROBLEMS. To help recognize this information, observe the following symbols.

DANGER: indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury.
WARNING: indicates a potentially hazardous situation which, if not avoided, COULD result in death or serious injury.
CAUTION: indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury.
NOTICE: indicates important information, that if not followed, MAY cause damage to equipment.

Unpacking: After unpacking the unit, inspect carefully for any damage that may have occurred during transit. Make sure to tighten fittings, bolts, etc., before putting unit into service. In case of questions, damaged or missing parts, please call for customer service.

Record the Model No., Serial No. and date of purchase located on the base below the pump in the space below. Model No. Date Code Date of purchase Retain these numbers for future reference. assistance. Have the date code, model number, and parts list (with missing parts circled before calling.)

Since the air compressor and other components used (filters, lubricators, hoses, etc.), make up a high pressure pumping system, the following safety precautions must be observed at all times:

DANGER: Breathable Air Warning: This compressor/pump is not equipped accordingly and should not be used “as is” to supply breathing quality air. For any application of air for human consumption, the air compressor/pump will need to be fitted with suitable in-line safety and alarm equipment. This additional equipment is necessary to properly filter and purify the air to meet minimal specifications for Grade D breathing as described in Compressed Gas Association Commodity Specification G 7.1 -1966, OSHA 29 CFR 1910. 134, and/or Canadian Standards Associations (CSA). DISCLAIMER OF WARRANTIES In the event the compressor is used for the purposes of breathing air application and proper-in-line safety and alarm equipment is not simultaneously used, existing warranties shall be voided.

1. Read all instructions included with this product carefully. Be thoroughly familiar with the controls and the proper use of the equipment,

2. Follow all local electrical and safety codes as well as in the US, National Electrical Codes (NEC) and Occupational Safety and Health Act (OSHA),

3. Only persons well acquainted with these rules of safe operation should be allowed to use the compressor.

4. Keep visitors away and NEVER allow children in the work area.

5. Wear safety glasses and use hearing protection when operating the pump or unit.

6. Do not stand on or use the pump or unit as a handhold.

7. Before each use, inspect compressed air system and electrical components for signs of damage, deterioration, weakness or leakage. Repair or replace defective items before using.

8. Check all fasteners at frequent intervals for proper tightness.
   REMINDER: Keep your dated proof of purchase for warranty purposes! Attach it to this manual or file it for safekeeping.
   WARNING: Motors, electrical equipment and controls can cause electrical arcs that will ignite a flammable gas or vapor. Never operate or repair in or near a flammable gas or vapor. Never store flammable liquids or gases in the vicinity of the compressor.
   CAUTION: Compressor parts may be hot even if the unit is stopped.

9. Keep fingers away from a running compressor; fast moving and hot parts will cause injury and/or burns.

10. If the equipment should start to abnormally vibrate, STOP the engine/motor and check immediately for the cause. Vibration is generally a warning of trouble.

11. To reduce fire hazard, keep engine/motor exterior free of oil, solvent, or excessive grease.
    Never remove or attempt to adjust safety valve. Keep safety valve free from paint and other accumulations.
    DANGER: Never attempt to repair or modify a tank! Welding, drlling or any other modification will weaken the tank resulting in damage from rupture or explosion. Always replace worn or damaged tanks.
    WARNING: Drain liquid from tank daily.

12. Tanks rust from moisture build-up, which weakens the tank. Make sure to drain tank daily and inspect periodically for unsafe conditions such as rust formation and corrosion.

13. Fast moving air will stir up dust and debris which may be harmful. Release air slowly when draining moisture or depressurizing the compressor system.

14. Indoor use only.

15. To reduce the risk of electrical shock, do not expose to rain. Store indoors.
    SPRAYING PRECAUTIONS
    WARNING: Do not spray flammable materials in vicinity of open flame or near ignition sources including the compressor unit.

16. Do not smoke when spraying paint, insecticides, or other flammable substances.

17. Use a face mask/ respirator when spraying and spray in a well ventilated area to prevent health and fire hazards.

18. Do not direct paint or other sprayed material at the compressor. Locate compressor as far away from the spraying area as possible to minimize overspray accumulation on the compressor.

19. When spraying or cleaning with solvents or toxic chemicals, follow the instructions provided by the chemical manufacturer.

Installation

LOCATION: It is extremely important to use the compressor in a clean, well ventilated area where the surrounding air temperature will not be more than 100°F.
A minimum clearance of 18 inches between the compressor and a wall is required because objects could obstruct air flow.

CAUTION Do not locate the compressor air inlet near steam, paint spray, sandblast areas or any other source of contamination. This debris will damage the motor.

GROUNDING INSTRUCTIONS This product is for use on a nominal 220 volt circuit and has a grounding plug that looks like the plug illustrated in Fig.

1. Make sure the product is connected to an outlet having the same configuration as the plug. This product must be grounded. In the event of an electrical short circuit, grounding reduces risk of electrical shock by providing an escape wire for electric current. This product is equipped with a cord having a grounding wire with an appropriate grounding plug. Plug must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances.

Technical Data

DANGER Improper use of grounding plug can result in a possible risk of El
DANGER Do not use a grounding adapter with this product!

1. If repair or replacement of cord or plug is necessary, do not connect grounding wire to either flat blade terminal. The wire with insulation having an external surface that is green (with or without yellow stripes) is the grounding wire. Never connect green (or green and yellow) wire to a live terminal.
2. Check with a qualified electrician or serviceman if grounding instructions are not completely understood, or if in doubt as to whether product is properly grounded. Do not modify plug provided; if it will not fit outlet, have proper outlet installed by a qualified electrician. Overheating, short circuiting and fire damage will result from inadequate wiring, etc.

Operation

Definition of Terms ASME Safety Valve – This valve automatically releases air if the tank pressure exceeds the preset maximum. Handle – Designed to move the compressor. Drain Valve – This valve is located on the bottom of the tank. Use this valve to drain moisture from the tank daily to reduce the risk of corrosion. Reduce tank pressure below 10 psi, then drain moisture from tank daily to avoid tank corrosion. Drain moisture from tank by opening the drain valve located underneath the tank. LUBRICATION This is an oilless product and DOES NOT require lubrication to operate.

BEFORE FIRST STARTUP BREAK-IN PROCEDURE
(Complete this procedure before using compressor for the first time. Once completed, it is not necessary to repeat.)

1. Do not attach a hose or any other fitting to the compressor.
2. Turn on/off switch to OFF position.
3. Plug in power cord.
4. Turn on/off switch to ON position. Allow compressor to run for 5 minutes.
5. Turn on/off switch to OFF position.
6. Unplug power cord.

BEFORE EACH STARTUP OPERATING PROCEDURE

1. Connect air hose to open port located below pressure gauge.

2. Attach the necessary fitting or tool to open end of air hose.

3. Turn on/off switch to OFF position.

4. Plug in power cord.

5.  If using inflation needles/nozzles: Attach air hose with inflation fitting to the object you are going to inflate. While holding inflation fitting firmly in place, turn on/off switch to ON position. Allow compressor to inflate the object.
   Turn off compressor and remove inflation fitting.

6. If using tire chuck or tool: Once chuck or tool is attached to air hose, turn on/off switch to ON position and allow compressor to run until it automatically shuts off. When using tire chuck to inflate tires, observe gauge reading on compressor and periodically check tire pressure with a separate tire gauge to prevent over inflation.

ON/OFF cycling of compressor In the ON position, the compressor pumps air into the tank. When a shut-off (preset “cut-out”) pressure is reached, the compressor automatically shuts off. If the compressor is left in the ON position and air is depleted from the tank by use of a tire chuck, tool, etc., the compressor will restart automatically at its preset “cut-in” pressure. When a tool is being used continuously, the compressor will cycle on and off automatically. In the OFF position, the pressure switch cannot function and the compressor will not operate. Make sure switch is in OFF position when connecting or disconnecting power cord from electrical outlet.

ASME SAFETY VALVE
WARNING the safety valve! Do not remove or attempt to adjust.

Check the safety valve by performing the following steps:

1. Plug the compressor in and run until shut off pressure is reached (see Operating Procedure).
2. Wearing safety glasses, pull the ring on the safety valve to release pressure from compressor tank. Use your other hand to deflect fast-moving air from being directed toward your face.
3. The safety valve should automatically close at approximately 40-50 PSI. If the safety valve does not allow air to be released when you pull on the ring, or if it does not close automatically, it MUST be replaced.

Maintenance

WARNING: Disconnect power source then release all pressure from the system before attempting to install, service, relocate or perform any maintenance.
Check compressor often for any visible problems and follow maintenance procedures each time compressor is used. Safety valve must be replaced if it cannot be actuated or it leaks air after ring is released. 

MOISTURE IN COMPRESSED AIR Moisture in compressed air will form into droplets as it comes from an air compressor pump. When humidity is high or when a compressor is in continuous use for an extended period of time, this moisture will collect in the tank. When using a paint spray or sandblast gun, this water will be carried from the tank through the hose, and out of the gun as droplets mixed with the spray material.

IMPORTANT: This condensation will cause water spots in a paint job, especially when spraying other than water based paints. If sandblasting, it will cause the sand to cake and clog the gun, rendering it ineffective. A filter in the air line (MP3105), located as near to the gun as possible, will help eliminate this moisture.

1. Turn compressor off and release pressure from system. (To release pressure from system, pull ring on ASME safety valve. Deflect escaping air by shielding valve with one hand as you pull ring with other hand.) Pull ring until tank is empty.
   CAUTION A large amount of fast moving air will be released when the safety valve is opened with pressure in the tank. Wear ANSI approved 287.1 safety glasses.

2. Drain moisture from tank by opening drain valve underneath tank. Tilt tank to remove all moisture.

3. Clean dust and dirt from tank, air lines and pump cover while compressor is still OFF. LUBRICATION This is an oilless type compressor requiring no lubrication.

LUBRICATION

This is an oilless type compressor requiring no lubrication.

THERMAL OVERLOAD PROTECTOR
CAUTION This compressor is equipped with an automatic reset thermal overload protector which will shut off motor if it becomes overheated. If thermal overload protector shuts motor OFF frequently, make sure that the compressor is used in a clean, well-ventilated area where temperature will not exceed 100° F.

CAUTION If the thermal overload protector is actuated, the motor must be allowed to cool down before start-up is possible. The motor will automatically restart without warning if left plugged into electrical outlet and unit is turned on.

STORAGE

1. Drain tank of moisture.
   WARNING Drain moisture from tank daily. Failure to drain tank can result in weakening due to rust and bursting.

2. When not in use, store compressor in a cool dry place.

3. Disconnect hose and hang open ends down to allow any moisture to drain.

Troubleshooting Chart

1.  Switched in OFF position
2.   No electrical power at wall outlet
3.  Compressor has reached automatic shut-off pressure
4.   Motor overheated
5.  Pressure switch bad

|

1.  Make sure compressor is plugged in and switch is ON
2.  Check circuit breaker or fuse at electrical panel
3.  Release air from tank until compressor restarts automatically
4.  Allow compressor to cool for approximately 30 min- utes so thermal overload switch will reset. Make sure compressor is run in a clean, well-ventilated are whre temperature will not exceeed 100 oF.
5.  Replace pressure switch

Thermal overload protector cuts out repeatedly|

1.  Lack of proper ventilation/room temperature too high
2.  Compressor valves failed

|

1.  Move compressor to a clean, well ventilated area where temperature will not exceed 100oF.
2.  Replace pump assembly

Knocks, rattles, excessive vibration|

1.  Tank not level
2.  Defective bearing on eccentric or motor shaft
3.  Cylinder or piston ring is worn or scored

|

1.  Shim tank to level position
2.  Replace pump assembly
3.  Replace pump assembly

Tank pressure drops when compressors shuts off|

1.  Loose drain valve
2.  Check valve leaking
3.  Loose connections (fittings, tubing etc)

|

1.  Tighten drain valve
2.  Replace check valve
3.  Check all connections with soap and water solution. If a leak is detected, tighten. Or remove fitting and apply pipe tape to threads and reassemble.

DANGER Do not disassemble check valve. With air in tank, bleed tank first.

Compressor runs continuously and air output is lower than normal/low discharge pressure|

1.  Excessive air usage, compressor too small
2.  Loose connections (fiiting, tubing, etc) 3 Broken inlet valves
3.  Piston ring worn

|

1.  Decrease usage or purchase unit with higher air delivery (SCFM)
2.  Check all connections with soap and water solution. If a leak is detected, tighten. Or remove fitting and apply pipe tape to threads and reassemble.
3.  Replace pump assembly
4.  Replace piston assembly

Excessive moisture in discharge air|

1.  Excessive water in tank
2.  High humidity

|

1.  Drain tank, tilt tank to remove moisture
2.  Move to area of less humidity. Use airl line filter

NOTE Water condensation is not caused by compres sor malfunction.

Compressor runs continuously and safety valve opens as pressure rises|

1.  Defective pressure swatch
2.  Defective safety valve

|

1.  Replace pressure switch
2.  Replace safety valve with genuine replacement part.

Excessive starting and stopping|

1.  Excessive condensation in tank
2.  Loose connections (fittings, tubing, etc)

|

1.  Drain more often
2.  Check all connections with soap and water solution. If a leak is detected, tighten. Or remove fitting and apply pipe tape to threads and reassemble.

The manufacturer reserves the right to make minor changes to product design and technical specifications without prior notice unless these changes significantly affect the performance and safety of the products. The parts described / illustrated in the pages of the manual that you hold in your hands may also concern other models of the manufacturer’s product line with similar features and may not be included in the product you just acquired.

Please note that our equipment has not been designed for use in commercial, trade or industrial applications. Our warranty will be voided if the machine is used in commercial, trade or industrial businesses or for equivalent purposes.

To ensure the safety and reliability of the product and the warranty validity, all repair, inspection, repair or replacement work, including maintenance and special adjustments, must only be carried out by technicians of the authorized service department of the manufacturer.

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