GLOBAL INDUSTRIAL GVW10V080V13 Stationary Compressor User Manual

User’s manual
Customer Service US: 1-800-645-2986
WATER COOLED STATIONARY 10HP
ELECTRIC AIR COMPRESSOR MODEL(S):
GVW10V080V13-208-230
E05PSRVW10V080VXXXW
GVW10V080V3-230
E05PSRVW10V080V208W
GVW10V080V3-460
E05PSRVW10V080V460W

SAFTEY INFORMATION

1: Safety Symbols
The definitions below describe the level of severity for each section. Please read the manual and pay attention to these symbols.

| This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
---|---
DANGER| DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury
WARNING| WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury
CAUTION| Caution indicates a hazard with a low level of risk which, if not avoided, could result in minor or moderate injury.
NOTICE| Indicates information considered important, but not hazard- related.
Symbol| Designation / Explanation
V| Volts (voltage)
A| Amperes (current)
Hz| Hertz (frequency, cycles per second)
W| Watt (power)
lb| Pounds (weight)
Min| Minutes (time)
5| Seconds (time)
HMI/Touch Screen| Operator Interface (Human Machine Interface)
PLC| Controller (Programmable Logic Controller)
| Alerts user to read manual
| Alerts user to wear eye protection
| Alerts user of lockout / tagout device
| Alerts user of burst/explosive hazard
| Alerts user of electrical hazard
| Alerts user of belt drive hazard
| Alerts user of hot pressurized liquid/steam hazard
| Alerts user of hand crush warning

CALIFORNIA PROPOSITION 65

WARNING: This product or its power cord may contain chemicals known to the state of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
Safety

1. Allow only trained, authorized persons who have read and understood these operating instructions to use this equipment. Failure to follow the instructions, procedures and safety precautions in this manual can result in accidents and injuries.
2. NEVER start or operate the compressor under unsafe conditions. Tag the compressor, disconnect, and lock out all power to it to prevent accidental start-up until the condition is corrected.
3. Install, use, and operate the compressor only in full compliance with all pertinent OSHA regulations and all applicable Federal, State & Local codes, standards, and regulations.
4. NEVER modify the compressor and/or controls in any way.

Keep a first aid kit in a convenient place. Seek medical assistance promptly in case of injury. Avoid infection by caring for any small cuts and burns promptly.
DANGER
Failure to follow instructions and safety guidelines laid out in this manual can result in serious injury or death. Ensure all users of this product read and understand this manual. Store the manual near the compressor for ease of reference. If the manual becomes damaged or illegible contact the manufacturer for a replacement.
DANGER
Death or serious injury can result from inhaling compressed air without using proper safety equipment. See OSHA standards on safety.
Pressurized Components
This equipment is supplied with an ASME designed and rated pressure vessel protected by an ASME rated relief valve. Pull the ring before each use to ensure the valve is functional. DO NOT attempt to open the valve while the machine is under pressure. See figure on the right. CAUTON
Do not pull with pressure in the system. Escaping gasses may be under pressure and may violently release.
Personal Protective Equipment
Be sure all Be sure all operators and others around the compressor and its controls comply with all applicable OSHA, Federal, State and Local regulations, codes, and standards relating to personal protective equipment. This includes respiratory protective equipment, protection for the extremities, protective clothing, protective shields and barriers, electrical protective equipment, and personal hearing protective equipment.
Read all manuals and information supplied for this unit carefully. Be thoroughly familiar with all inspection and operation guidelines. Only persons that have read and understand this manual should operate the compressor.

Features

Compressors come in many shapes and sizes. Our units have several features that may or may not be present on your unit. These features may be purchased after the fact in kit form. This guide will explain the use and benefit of these features.
Belt Tensioner

1. Allows the belt to be properly tightened with the turn of a few bolts versus manually loosening and moving the motor by hand and ‘guess’ adjusting.
2. Allows for fine tuning of pulley and flywheel alignment quickly and accurately.
3. Belt tensioners can be purchased after the fact but may require some other assembly items to install correctly. Consult your sales team for more information.

Continuous Run
Smart air units are equipped with an electronic solenoid that controls idle and operation is controlled automatically through the variable speed drive and programmable logic controller (PLC) based on PSI and down time settings.

1. The pump is cooled during the free spin state since there is no compression load.
2. Increased recovery time due to the unit being in an idle state versus it being a complete recovery.
3. Wear on your motor is decreased as the unit is already in motion and will not need to overcome zero movement and fight tank compression.

Auto Drain
Auto drains are preset timer valves that allow tank moisture to be vented as long as they are powered. The enemy of every compressor/air system is moisture. The auto drain removes some of the hassle of this by allowing the user to set a timer and walk away from the unit with the peace of mind that their system is protected.

1. The drain works off a conventional 120V outlet.
2. Timer has built in intervals that can be customized to the user’s needs.
3. Has a manual shut off for service and maintenance.
4. The drain filter MUST be cleaned weekly to prevent drain blockage.
5. Drain time knob, marked as ON:SEC, corresponds to how long the drain will run for when it comes on. This is listed in seconds.
6. Drain interval knob, marked as OFF: MIN, corresponds to how long between cycles. Or how long the drain will be OFF before it comes on again.
7. The drain attaches to a ½” NPT female connection.
8. The vent can blow to atmosphere. Or piped to a remote drain or collection system through use of the ½” FNPT threaded vent.
9. A drain system can also be equipped by the user to muffle automatic drain sounds.
10. The drain is also equipped with a TEST button to check function.

Auto drains are not equipped on all units; however, they can be purchased after the fact or during the initial compressor purchase. The piping leaving the tank from factory is ¼” pipe. If purchased after the fact, be sure to ask for a coupler to help complete the installation (PN: FITTING009).
Radiator/Cooler

1. An electric fan forced air/water radiator designed to cool air prior to it entering the storage tank.
2. This radiator also cools water that circulates via a water pump through the compressor pump.
3. This decrease in air temperature prevents moisture build up in air systems the unit is connected to.
4. The system is powered through the PLC enclosure and does not require an external power supply.
5. Radiator and fan assembly are mounted on the side of the compressor on a raised platform connected to the compressor pump.

CAUTON
Hot pressurized fluid can cause serious burns and injury. Never open while hot.
Open slowly!
Variable Speed Drive (VSD/VFD)
Smart Air VSD, or Variable Speed Drive units are a new technology designed to be energy efficient. The VSD allows the unit to run to the exact compressed air demand. The unit works similarly to a classic compressor with the air compressor pump connected to an electric motor which pumps air into the tank however, in this case, the electric motor is connected to a variable speed drive that controls the RPM’s of the electric motor. The drive itself is connected to a Programmable Logic Controller or PLC which works in combination with a pressure transducer to read exact tank pressure.
The VSD works like the cruise control in your car. The VSD changes the electric frequency or hertz that are sent to the electric motor. By changing the electronic frequency going to the motor, you change the RPMs of the electric pump ergo the speed at which the
pump is rotating is also decreased. The user can easily set pre-determined tank pressure ranging from 100 to 175 PSI. To maximize energy savings the compressor should be programmed to have a 10 PSI differential. This differential is highly important and has a direct relation to energy savings. For every 10 PSI of pressure increase you will use five percent more power to operate the compressor. Classic compressors max out around seven starts per hour before you will begin to see symptoms of motor damage. This does not happen on a VSD equipped unit as power is controlled digitally and not pulled through magnetic contacts that can wear over time.
Units equipped with VSD’s reduce peak starting amps by 700% or 7 times less than the full load run amps or FLA. This reduced amp load allows the motor to run at a much lower temperature. The startup in rush of amps is one of the leading causes of heat buildup in an electric motor due to the motor being forced to pull full RPM in under one second. This not only uses a large amount of energy but can lead to premature motor failure. For example, a standard single phase 7.5 Horsepower pulls 220 peak amps at  start up versus the same horsepower unit equipped with a VSD will now peak at around 30 amps. The low starting amps allows for a much lower starting/running temps and permits endless cycling of the compressor without worry. The low amp draw also translates to huge energy savings.
When a VSD equipped unit starts it gradually brings the motor to full RPM speed over a predetermined period of time which is programmed into the VSD itself. The compressor pump on the unit is equipped with unloaders which stop compression when engaged.
These unloaders are activated during start up until the motor is at peak RPM. This eliminates excess starting amp draw across your electrical switchgear as well. This feature is handy especially when your power requirements are close to being maxed out and/or very minimal.
Our VSD unit is the combination of the latest piston compressor technology and energy efficiency. This means that if the compressor is in operation for five to eight hours a day, then the full cost of the compressor can be recouped within one to two years of operation based off energy savings alone. Our VSD units have an energy calculator built into the program and the only thing required of the user is to input your kW hour cost. After the user inputs the data, the VSD will display the savings in dollars or even euros if desired.

Basic Nomenclature

Nomenclature

ITEM

| PART|

PN IF APPLICABLE

---|---|---
1| 3/4” BARBED FITTING| FITTING082
2| 24V IDLE SOLENOID| SOLENOID700
3| IDLE VENT BREATHER| BREATHER005
4| RADIATOR SUPPORT BRACKET| BRACKET068
5| 1” HEATER HOSE| HOSE002
6| 3/8 STREET L| FITTING215
7| FAN MOUNTING SHROUD| SHROUD001
8| 1” STREET L| FITTING029
9| 24V DC RADIATOR FAN| FAN076
10| DUAL CORE AIR/WATER RADIATOR| RADIATOR028A
11| BRAIDED MAIN LINE| HOSE025
12A| MOLDED COOLANT HOSE IN| HOSE700
12B| MOLDED COOLANT HOSE OUT| HOSE701
13| BELT GUARD BRACING| GUARDBRACE001
14| WATER LINE TEE CONNECTOR| TEE700
15| WATER LINE ELBOW| ELBOW700
16| ¼” COPPER LINE FOR HEAD UNLOADERS| TUBING001G30
17| MOTOR POWER SUPPLY WIRE|
18| WIFI ANTENNA|
19| BELT TENTIONER| TENTIONER004PC
20| VFD AND CONTROLLER BRACKET| BRACKET73G01
21| TOUCH SCREEN HMI|
22| 90 DEGREE CONDUIT CONNECTOR|
23| CONDUIT|
24| STR CONDUIT CONNECTOR|
25| WATER LINE ELBOW| ELBOW700
26| MOTOR WIRE ENCLOSURE|
27| COOLANT LEVEL SIGHTGLASS W/FLOAT|

Installation Area

1. Install compressor in clean, dry, and well-lit area. Be sure installation area can maintain a temperature range between 35˚ – 110˚ F.
   CAUTON
   If ambient temperature drops below 32˚F, be sure to protect safety/relief valves, water lines and drain valves from freezing. NEVER operate compressor with temperatures below 15˚F or above 125˚F.

2. Allow sufficient space around the compressor for maintenance access and adequate airflow. Mount unit with the belt guard (pulley and flywheel) side to the wall and leave a minimum of 15 inches of clearance.

3. If acid is used in the operating environment or air is dust laden, pipe intake to outside fresh air. Increase pipe size by 1/8”’ for every 20ft of run. Be sure to install a protective hood at the outside air intake location to prevent debris and foreign objects from blocking the intake pipe.

4. In operating environments where excessive water, oil, dirt, acid, or alkaline fumes are present, a TEFC (totally enclosed, fan cooled) motor is highly recommended. Check nameplates for motor type.

5. Insulate cold water or other low temperature pipes that pass overhead to avoid condensation dripping on the compressor.

6. In environments where fine dust is common such as granite, marble, or concrete plants the unit must be installed in a separate room with its own dedicated ventilation system.
   DANGER DO NOT install compressor in boiler room, paint spray room, area with flammable particulates (i.e., sawdust), area where sandblasting occurs. Make sure inlet air is away from exhaust fumes or other toxic, noxious, or corrosive fumes or substances.

7. If the unit is in an enclosed space, it requires proper ventilation as the ambient air temp where the compressor is located CANNOT exceed 115 degrees F.

8. Use shims to level the compressor if the installation area is not flat. This will help prevent excessive vibration and premature pump wear.

Lifting and Movement/Forklift

1. Make sure lift operator stays aware while moving the compressor.
2. Be sure to uncrate the compressor prior to movement. This will allow a visual reference for the balance of the unit.
3. Be sure the load is secure and well balanced before moving the compressor.
4. Make sure the forks are fully engaged and level prior to lifting or moving the unit.
5. Keep the unit/load as low as possible while moving and refrain from quick changes in direction.
6. For all other forklift safety standards/regulations please reference OSHA 1910.178- Powered industrial trucks.

WARNING
Compressors, especially vertical units, are exceptionally top heavy. Take care when moving and do not make fast or sudden moves during transport.

General Lifting Information

1. Carefully inspect all lifting equipment and ensure it is in good condition. Rated capacity of lifting equipment must exceed compressor weight. NEVER lift with undersized or damaged equipment.

2. If using lifting equipment, ensure all lifting points are in good condition and tighten any loose nuts or bolts before lifting.

3. A sling MUST be used when moving the compressor with a helicopter or other airborne equipment. Be sure to follow OSHA standards 1910 subpart N.

4.  Use guide ropes or equivalent to prevent twisting or swinging of the compressor while it is in the air and NEVER attempt to lift the
   unit in high winds. Keep compressor as low to the ground as possible.

5. Keep all persons away from the compressor when it is lifted. DO NOT allow persons under the compressor while it is being lifted.

6. DO NOT use bolts or other hooks on individual components to move the compressor.

7. When moving and or placing the compressor ensure it is on/across a surface that can hold the combined weight of the compressor and the loading equipment.

WARNING
Do NOT operate the unit if damaged during shipping, handling or use. Damage may result in bursting and may cause injury to persons or property damage. If the unit is received with damage, please contact customer support as soon as possible.
Anchoring
To ensure proper and safe operation of the compressor the unit is required to be anchored to a flat, smooth, concrete floor.
Compressors are also required to be on ¼ inch (6.35mm) MAXIMUM thick rubber anti-vibration pads.
WARNING
Do NOT operate the compressor on the shipping pallet. Compressor must be removed before use! Using the compressor on the shipping pallet can lead to pallet collapse causing the equipment to fall over. This also leads to excess vibration in the tank possibly causing tank failures.
Recommended anchor Bolt specifications: wedge anchors; 3/8 in width by 3.5 in length.
How to Anchor the Compressor

Use a carbide bit (conforming to ANSI B212.15).
The diameter of the drill bit must be the same as the diameter of the anchor bolt. If you are using a 3/8-inch diameter anchor bolt, for example, use a 3/8 inch diameter drill bit.

| 1. Make sure the compressor is in the desired location and the anti- vibration pads are under the feet of the compressor.
2. Using the holes in the feet as guides, drill the holes for the anchor bolts through the vibration pads and into the concrete.
3. Go in straight; do not let the drill wobble.
4. Go in straight; do not let the drill wobble.
---|---
1. Thoroughly clean each hole.
2. If a vacuum is not available, use a wire brush, hand pump, or compressed air.
3. DO NOT ream the hole. DO NOT make the hole any wider than the drill bit made it.
1. Put the Washer and Nut into place, make sure the top of the Nut is flush with the top of the anchor bolt, then insert the anchor bolt into the hole.
2. Hammer or mallet the anchor bolt down into the hole.
3. Stop hammering when the washer is snug against the top of the foot.
4. Tighten each nut clockwise, DO NOT over tighten. DO NOT use an impact to tighten the anchors.

Electrical

1. Follow all NEC and local codes for electrical wiring. Allow only authorized service personnel or certified electricians to install electrical components.
2. Put unit on a dedicated circuit and make sure no other electrical equipment is wired into it. Failure to wire unit on an independent circuit can cause circuit overload and/or imbalance in motor phasing. Install proper No Fuse Breaker (NFB) according to the chart listed below. You may also reference NEC and local codes for additional support.
3. Ensure incoming service has adequate ampere rating.
4. Do not use mixed wire sizes when wiring the unit.
5. The unit must be properly grounded. DO NOT connect ground to air or cooling lines.

DANGER
Be sure only trained and authorized personnel install and maintain this compressor in accordance with all applicable federal, local, and state codes, standards, and regulations. Follow all NEC (National Electric Code) standards especially those concerning equipment grounding conductors. Unit is equipped with dual power sources. Prior to service verify all power is locked out and removed from the unit to prevent death or serious injury and possible damage to the unit. Improperly grounded electrical components are shock hazards. Make sure all components are properly grounded to prevent death or serious injury.

Wiring the Compressor

1. Voltage should not vary more than 12% to ensure proper operation of the compressor.
2. Wire size and breaker requirements SINGLE PHASE OPERATION:
   Motor Horsepower| Breaker Size (Amps)| **Wire Size (50ft or less)*| Wire Size (More than 50ft)**
   ---|---|---|---
   5| 40| 10| Consult Electrician
   7.5| 50| 8| Consult Electrician
   10| 60| 8| Consult Electrician
   15| 80| 6| Consult Electrician
3. Wire size and breaker requirements 208/230 VOLT THREE PHASE OPERATION:
   Motor Horsepower| Breaker Size (Amps)| Wire Size (50ft or less)*| Wire Size (More than 50ft)**
   ---|---|---|---
   5| 25| 12| Consult Electrician
   7.5| 40| 10| Consult Electrician
   10| 50| 8| Consult Electrician
   15| 60| 6| Consult Electrician
4. Wire size and breaker requirements 460 VOLT THREE PHASE OPERATION:
   Motor Horsepower| Breaker Size (Amps)| Wire Size (50ft or less)*| Wire Size (More than 50ft)**
   ---|---|---|---
   5| 15| 14| Consult Electrician
   7.5| 20| 12| Consult Electrician
   10| 25| 10| Consult Electrician
   15| 30| 10| Consult Electrician

*Wire size distances are from unit to the panel where the breaker is housed.
**CAUTION: Under sizing wires and/or breakers can cause damage to the unit, possible injury to personnel, and void your warranty.

5. Incoming power is wired into the PLC/HMI located on the front of the unit. This is the control box that houses the touch panel.
6. When facing the front of the compressor (Pressure switch/pressure gauge side) rotation should be clockwise. Rotation direction is programmed in the VSD and cannot be adjusted by user.
7. Wiring:

CAUTON
***Ensure to verify the compressor has the correct voltage capabilities before wiring! Voltage tolerances are specific to each compressor setup, NOT all compressors have multi-phase options. Check the compressor identification tag to certify voltage requirements and available option on your specific model. Improper installation WILL void compressor warranty.

Piping (Safety steps)

1. Install appropriate flow-limiting valves as necessary according to pipe size(s) used and run lengths. This will reduce pressure in case of hose failure, per OSHA Standard 29 CFR 1926.302(b)(7).

2. Flow-limiting valve are listed by pipe size and rated CFM. Select appropriate valves according to manufacturer’s recommendations.

3. Use a flexible connector between compressor tank and dryer/piping system to minimize noise, vibration, pump wear, and to prevent damage to the unit or piping system.

4. Install ASME code safety valves and ensure piping system is equipped with adequate condensate drains.
   DANGER
   NEVER install a shut off valve such as a glove or gate valve between the pump discharge and the air tank unless an ASME rated safety valve rated for the correct pressure is installed in the line between the valve and the compressor pump.

5. Minimum pipe size for compressed air lines: (Pipe sizes are shown in inches)
   CFM| 25ft| 50ft| 100ft| 250ft
   ---|---|---|---|---
   20| ¾| ¾| ¾| 1
   40| ¾| ¾| 1| 1
   60| ¾| 1| 1| 1
   100| 1| 1| 1| 1 – ¼
   125| 1 – ¼| 125| 1 – ¼| 1 – ½

6. Air systems should be checked daily for leaks. This helps to prevent unnecessary load on the compressor and helps increase energy savings.

7. Examples of air systems: Closed loop system: Install tee fitting in piping from air to minimize pressure drop and to allow air flow in two directions.

8. Make sure any tube, pipe, fitting, or hose connected to the unit can withstand operating temperatures and retain pressure.

9. Never use reducers in discharge piping. Keep all piping and fittings the same size in the piping system.

WARNING
Never use plastic (PVC) pipe for compressed air. Serious injury or death could result. Piping MUST have a pressure rating of 200 PSI or greater.

Variable Frequency Drive and Logic Controller (VFD/PLC/HMI)

Main Screen

Menus and Controls

Overview screen for general compressor monitoring.
• Air Pressure
• Oil Pressure
• Total Powered on Time (Hours)
• Total Run Time (Hours)
• Motor Data
o Horsepower (HP)
o Amperage (A)
o Hertz (Hz)
• Valve, Fan, Pump, Oil Heater Indicators
• Oil, Water Temperatures
• Service Indicator
• Pause/Run Control (Overrides Schedule)
| Monitor :
Live and historical data for:
• Air Pressure
• Utilized Horsepower
• Present Time- Live Data
• Cursor Time- Historical Time
o Searchable by control buttons
o Searchable by date selection
| Alarms:
Complete record of all alarms, errors, and warnings.
| Schedule:
Screen allows run time based on days of the week. Start time and stop time are set for each day.
Override: Always Run will override current schedule and allow the compressorto energize on demand.
**NOTE*
Pause/Run Control button on Home Screen overrides these settings.
| Language:
Select appropriate language button for touch display.
| Unit Settings:
Select appropriate air pressure and temperature units.
| Clock Settings:
User defined time.
| Air Settings:
Set values for air pressure control.
High-High Pressure Setting: Pressure setting to not safely exceed.
Adaptive Pressure Mode (APM):
• APM Upper Pressure
• APM Target Pressure
• APM Lower Pressure
• APM Idle OFF delay
| Oil Setting:**
Set values for oil settings.
Oil Pressure Settings:
• High Pressure Limit
• Low Pressure Limit
• Delay Time: Oil pressure check
Oil Temperature Settings:
• Oil Temp Limit
• Heater Shut Off
• Maximum Time
|

Water Setting:
Set values for water settings.
Water Pump Settings:
• Pump ON Time
• Pump OFF Time
Water Temperature Settings:
• Water Temp Limit
• Fan Pump Enable
• Fan/Pump Shut off

| Contact Info:

Wireless Access

1. Ensure router is supplied with power.
2. Connect ethernet cord from the controller on the bottom of the enclosure to the WAN port on the router.
3. The first and last light on the router should light up.
4. On a smart device, connect to WiFi network: Airbase
5. Default password: Air1000@
6. Open a web browser and enter http://192.168.8.10
   a. Username: administrator
   b. Password: password

You should now be able to access and visually see the status of your compressor.

Pre-Use and Inspection

1. The unit is shipped with pump break-in oil and should be ready to operate. Be sure to check for proper oil level before running the compressor. Break in oil should be changed after 100 Hours of operation (active pumping time). See maintenance section for more information on oil changes and frequency.
   Oil level should be to the center of the red circle in the sight glass. Oil level WILL drop once the unit turns on and oil begins to circulate.

2. Check for proper belt tension. There should be ½ inch of belt slack/deflection. Refer to the maintenance section if adjustment is necessary. The deflection is found by using a tension checker and should be calculated by taking the distance between the two shafts (roughly 16 inches) times the force used to get the ½ of deflection which in this case is 10lbs. from the manufacturer. The total load would then be 160 lbs. per belt.

3. Inspect belts for frays or unit for an excess buildup of black rubber dust indicating belt wear. NOT pull the safety valve on the tank if there is air in the tank!

4. Inspect all air lines/piping for proper for secure fit and corrosion or line degradation. DO NOT operate the compressor with damaged lines. DO NOT use damaged or cracked air lines as a rupture could result in damage/injury to personnel or property.

5. WITH UNIT LOCKED OUT (power off at source i,e. the electrical panel/disconnect) ensure all electrical wiring, including all terminals, are in good condition and are free of buildup, fraying, cracks or discoloration replace as needed.

6. Check tightness of bolts securing wiring in place.

7. Ensure unit is secured in place and has not shifted. Verify anchor bolts are in place and are in good condition.

8. Remove any loose items from around/on compressor to avoid damage to the unit. Examples would be loose clothing items, rags, papers, bottles, or any item that may have been placed on the unit.

9. Check unit for any oil leaks. If leaks are found contact the manufacturer for further instructions.

10. Unit should NEVER be operated without the belt guard in place.

11. Inspect Flywheel for cracks or missing fins. NEVER operate a unit with a damaged flywheel; serious injury or death could result. If you suspect your flywheel may have been damaged, contact technical assistance and DO NOT allow the machine to be  operated.

12. Coolant level verified. Coolant level float should be within 2 inches of the top of the coolant sight window.

Operation

Read all manuals and information supplied for this unit carefully. Be thoroughly familiar with all inspection and operation guidelines. Only persons that have read and understand this manual should operate the compressor.

1. Once the inspection is completed, open your discharge port (outlet ball valve). This should already be connected to your shop airline system.
2. Ensure all personnel are clear of the compressor and aware that it is being started.
3. Press the icon on the VFD controller. This will start your compressor and allow it to fill, or set the desired schedule. The tank will fill to 150 PSI and go to idle for 10-30 seconds and then will shut off. The unit will begin pumping again once the tank is drained down to approximately 140 PSI. Unit idle and spool up will vary based on approximate air usage.
4. Oil pressure on start-up will vary due to ambient temperatures but should not exceed 120 PSI. Once the unit is allowed to run a few cycles and come to optimal operating temperature, oil pressure should stabilize at 20-40 PSI. If the oil pressure remains high or drops too low, it can be adjusted by following the adjustment guide later in the manual.

Maintenance
DANGER
Prior to performing any maintenance on the compressor, ensure compressor is disconnected from its power source and cannot be re-energized until the maintenance to be performed is complete. DO NOT perform maintenance with pressure in the tank. Relieve pressure prior to maintenance being started.
Maintenance Schedule
The table below is a generalized maintenance schedule based on the normal usage of a compressor. Your specific needs may vary based on operating environment and duty. Compressor maintenance must be performed as described in the maintenance schedule, failure to do may lead to compressor/component breakdown and void compressor warranty.

Item

| Frequency|

Comment

---|---|---
Cleanliness| Daily| Keep the compressor and the surrounding area clean. Wipe off oil, spills, and dirt/dust.
Oil Level| Daily| Check oil level while the unit is OFF. If oil is low add to fill point. If level is high, drain off oil.
Coolant Level| Daily| Check coolant level while unit is OFF and cool.
Tank Pressure| Daily| Check unit for air leaks.
Tank| Daily| Drain the tank daily at the end of use. DO NOT attempt to store air for prolonged periods of time. The electrical cost is minuscule compared to replace a rusted out or ruptured tank. DO NOT attempt to repair a damaged tank.
Anchors| Weekly| Ensure anchors are holding the unit securely and are not loose.
Anti-Vibration Pads| Weekly| Check for wear. Verify they are in place and not damaged or rotted.
VSD| Weekly| Blow off VSD drive. Remove dust and debris from vents, wipe down screen.
Belt| Monthly| Verify belt tension. Replace if excessively loose or damaged.
Radiator| Monthly| Split radiator/air side bottom petcock open and moisture allowed to drain if any.
Environment| Quarterly (four times per year)| Air temperature should not exceed recommended levels. Humidity where compressor is stored should not exceed 70%. Consider relocating compressor if these conditions cannot be met.
Wiring| Semi Annually (twice a year)| Have an electrician check connection from power supply and all subsequent connections on the unit.
Tank| Yearly| Inspect for rust or corrosion. DO NOT attempt to repair a damaged tank.
Entire Unit| Yearly| Lock unit out and detail clean.
Coolant| Every 3 years| Coolant should be drained and replaced every three years.
Air Filter(s)| See Comments| Air filters should be changed after the first 100-hour break in period and every 90 days after that. The frequency will increase in environments with air contaminants such as dust, paint, dirt, etc.
Oil| See Comments| Oil should be changed after the first 100-hour break in period and every 90 days after that. This will increase in frequency depending on actual compressor use and hours unit is running.
Oil Filter*| See Comments| The oil filter on the unit should be pulled and cleaned with every oil change.

*Frequency of these changes are a generalization and may be subject to change based on compressor environment, hours, and application.
Oil Change Oil Choice
It is strongly advised to use only Airbase Industries piston compressor oil. Check with your warranty/extended warranty guidelines to verify oil selection and use. Oil used in the compressor must fall under the following criteria: synthetic, SAE grade 30, non-detergent, piston compressor oil.
Oil Disposal
Compressor oil is not trash and MUST NOT be disposed of in regular trash or discarded into the environment. You MUST dispose of waste oil from your unit per all applicable federal, state, and/or local codes. Failure to do so may damage the environment and subject yourself and/or your business to fines and legal issues.
Oil Pressure Adjustment

Troubleshooting

Some unit issues can be fixed simply by verifying the following guide. It is advised to go through the guide prior to calling technical support to help expedite the assistance process.

Issue|

Action

---|---
Compressor does not run| Check unit power supply. Verify incoming voltage from power supply to unit. Check that breakers are functioning correctly. Verify wiring is connected correctly and not loose.
Ensure both the VSD and the controller have power.
Compressor cycles frequently| Check for leaks in facility/shop air lines or air system. Check for stuck tools or machine leaks. Check pressure settings and PSI cycle settings on switch.
Compressor does not reach pressure| Check CFM consumption of machines to ensure they do not exceed compressor capability. Check tools for CONSTANT CFM rating, not average. Average ratings do not reflect consumption and are often 66% lower than actual CFM consumption.
Check for leaks in air lines or on unit.
Oil level low| Verify oil level while unit is off and cool. Top oil off and monitor oil level. If it drops again check for oil leaks and check correct oil is being used
Compressor is running loud| Ensure anchor bolts are in use and are snug. Check vibration pads for excess wear, replace as needed.
Ensure unit is not hard lined to air system. Unit should be connected by flexible hose to air systems to prevent vibration noise.
Check oil pressure if there is no oil pressure shut unit down and contact customer support.
VSD (Mitsubishi) errors| For any drive errors contact customer support. DO NOT contact Mitsubishi as you will be redirected.
Oil blow by| Verify pump has passed the break in time: 150-200 hours of active run time. Ensure unit is not running in continuous mode prior to break in period being completed (this can cause increase blow by during break in). For cases after break in period contact customer support.
External error (PLC)| Verify system has oil pressure. If there is no pressure, contact customer support for further assistance. If there is pressure, check the security of the wire leaving the top of the oil pump,
CAUTION: UNIT MAY BE HOT! If wires are secure and in place verify PLC display is showing oil pressure accurate to what the oil pressure gauge is displaying, if not contact customer support.

MAINTENANCE LOG

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