NAPA Industrial Manual.cdr

Rev0411

Service and Support: 866-869-3114

Models:

Pt# 1312100743

Air Compressor

Manual

TABLE OF CONTENTS

PAGE

1 Safety Guidelines - Definitions

Before Using the Air Compressor

2 When Installing or Moving the Compressor

Before Each Use

3 Follow Safety Precautions for Electrical Connection

Plan Ahead to Protect Your Eyes, Hands, Face & Ears

When Operating

4 Spraying Precautions

Perform These Maintenance Operations

5 Typical Compressor Installation

Glossary

6 Wiring

7 Starting the Compressor

8 Fully Packaged and QP Compressor Section

9 Troubleshooting Guide

10 Troubleshooting (Cont.)

WARNING

Safety is a combination of common sense, staying alert and knowing how your compressor works.

Read this manual to understand this compressor.

CAUTION

DANGER

SAFETY GUIDELINES - DEFINITIONS

means if safety information is not followed someone will be seriously injured or killed

means if safety information is not followed someone may be seriously injured or killed

means if safety information is not followed someone could be seriously injured or killed

IMPORTANT SAFETY INSTRUCTIONS

Save these instructions

Before using the air compressor

Improper operation or maintenance of this product could result in serious injury and property

damage. Read and understand all warnings and operation instructions before using this compressor.

Air compressors are utilized in a variety of air

system applications. Because air compressors

and other components (hoses, connectors, air

tools, spray guns, etc.) make up a high pressure

pumping system, the following safety pre-

cautions should be observed at all times.

Only persons familiar with these rules of

safe operation should use the air

compressor.

1. Read the instruction manual carefully before

attempting to assemble, disassemble or

operate your system. Be thoroughly familiar

with the controls and the proper use of the

equipment.

2. Review and understand all safety instructions

and operating procedures in this manual.

3. Review the maintenance methods for this

compressor (See “Maintaining Your

Compressor” section).

Things you should know Inspect your work area

1. Keep work area clean.

2. Cluttered areas and benches invite accidents.

Floors must not be slippery from wax or dust.

1. To reduce the risk of injury from accidental

starting, turn switch off and disconnect the

power before checking it.

2. If any part is missing, bent or broken in any

way, or any electrical part does not work prop-

erly, keep the compressor off and disconnected.

3. Check hoses for weak or worn condition

before each use, making certain all connections

are secure. Do Not use if defect is found.

Do not operate compressor if damaged during

shipping, handling or use. Damage may result

in bursting and cause injury or property damage.

This compressor is Not designed for and should

not be used in breathing air applications.

Inspect your compressor

WARNING

Page 1

DANGER

When installing or moving the compressor

This compressor is extremely top heavy. The

compressor must be secured to the floor

before operating to prevent equipment

damage, injury or death. The compressor must

be mounted on vibration pads. Do Not tighten

bolts completely as this may cause stress to

the tank welds.

To reduce the risk of a dangerous

environment

1. Keep work area well lit.

2. Operate compressor in a well-ventilated

area free from flammable liquids and vapors.

3. Operate compressor in a ventilated area so

that compressor may be properly cooled and

the surrounding air temperature will not be

more than 100°F.

4. Never use a compressor in a wet

environment.

5. Protect material lines and air lines from

damage or puncture. Keep hose and

wires away from sharp objects, chemical

spills, oil, solvents and wet floors.

Do Not secure compressor with toggle bolts

into drywall. Drywall sheeting or plaster will not

support the weight of the compressor.

WARNING

Page 2

6. A minimum clearance of 18 inches between

the compressor and a wall is required

because objects could obstruct airflow.

7. The compressor should be located where it can

be directly wired to a circuit breaker. The

compressor should be wired by a qualified

electrician.

8. Never store flammable liquids or gases in

the vicinity of an operating compressor.

9. Do Not locate the compressor air inlet near

steam, paint spray, sandblasting areas or

any other source of contamination. The

debris could damage the motor and pump.

Never use plastic (PVC) pipe for compressed

air. Serious injury or death could result.

Never use the shipping skid for mounting the

compressor.

This compressor is not intended for outdoor

installation.

Never install a shut off valve between the compres-

sor pump and tank. Personal injury and/or

equipment damage could occur.

WARNING

CAUTION

NOTICE

WARNING

Before each use

1. Keep work area clean. Cluttered areas and

benches invite accidents.

2. The floor must not be slippery from wax or

dust.

1. To reduce the risk of injury from accidental

starting, turn the switch off and disconnect

power.

2. If any part is missing, bent or broken in any

way, or any electrical part does not work

properly, keep the compressor off and dis-

connect power. Do Not use if defect is found.

3. Check hoses for weak or worn condition

before each use, making certain all connect-

ions are secure. Do Not use if a defect is

found.

Inspect your work area Inspect your compressor

Note: Tank Outlet Size: 30 Gallon Gas Drive - 1/2” NPT

80 and 120 Gallon Electric - 3/4” NPT

Duplex - 1” NPT

Follow the safety precautions for electrical connections

Page 3

WARNING

CAUTION

WARNING

Plan ahead to protect your eyes, hands, face and ears

1. Wear safety glasses (meeting ANSI Z87.1 or

in Canada CSA Z94.3-99) and use hearing

protection when operating the unit. Everyday

glasses are not safety glasses.

2. Wear shoes to prevent shock hazards.

3. Tie back long hair.

Keep fingers away from running compressor.

Fast moving and hot parts may cause injury

and/or burns.

1. Follow all local electrical and safety codes,

as well as the National Electric Code (NEC)

and the Occupational Safety and Health

Act (OSHA).

2. Wiring and fuses should follow electrical

codes, current capacity and be properly

grounded.

3. Protect wires from contact with sharp objects.

All electrical connections should be made by

a qualified electrician.

Dress for safety

Be careful when touching the exterior of comp-

ressor, pump, motor and air lines; they may

become hot enough to cause injury.

Never operate the compressor without a

beltguard. The compressor can start auto-

matically without warning. Personal injury or

property damage could occur from contact

with moving parts.

The compressor may be hot even if the unit is

stopped.

Use of a mask or respirator per chemical

manufacturers’ instructions may be neces-

sary if there is a chance of inhaling toxic fumes.

Read mask and respirator instructions care-

fully. Consult a safety expert if you are not

sure about the use of certain masks or

respirators.

Pay attention to your hands

WARNING

CAUTION

WARNING

When operating

1. Do not exceed the pressure rating of any

component of the system.

2. Release pressure within the system slowly

to prevent flying dust and debris.

3. If the equipment starts to abnormally vibrate,

STOP the compressor immediately and

check for the cause.

WARNING

Never change the safety valve or pressure

switch settings. Keep safety valve free from

paint and other accumulations. See compressor

specification decal for maximum operating

pressure. Do not operate with the pressure

switch set higher than the maximum operating

pressure.

Page 5

WIRING

TYPICAL COMPRESSOR INSTALLATION

GLOSSARY OF TERMS

Air Filter

Porous element contained within a metal or

plastic housing attached to the compressor

cylinder head which removes impurity from the

intake air of the compressor.

Air Tank

Cylindrical component which contains the

compressed air.

Check Valve

Device which prevents compressed air from

flowing back from the air tank to the compres-

sor pump.

Electric Motor

Device which provides the rotational force

necessary to operate the compressor pump.

Pressure Gauge

Device which shows the tank or regulated

pressure of the compressed air.

Pressure Switch

Device which automatically controls the on/off

cycling of the compressor. It stops the

compressor when the cut-off pressure in

the tank is reached and starts the compressor

when the air pressure drops below the cut-in

pressure.

PSI (Pounds per Square Inch)

Measurement of the pressure exerted by the

force of air. The actual psi is measured by a

pressure gauge on the compressor.

Pump

Device which produces the compressed air

with a reciprocating piston contained within a

cylinder.

Safety Valve

Device which prevents air pressure in the air

tank from rising over a predetermined limit.

Thermal Overload Switch

Device, integrated into the electric motor winding,

which automatically “shuts off” the compressor

if the temperature of the electric motor exceeds

a predetermined limit.

Flex

Hose

Air

Dryer

To Air System

Vibration Pads

Spraying precautions

Page 4

Perform these maintenance operations

1. Do Not spray in the vicinity of open flames

or other places where a spark can cause

ignition. Do Not smoke when spraying

paint, insecticides, or other flammable

substances.

1. When spraying with solvents or toxic chemi-

cals, follow the instructions provided by the

chemical manufacturer. Consult a safety

expert if unsure about the use of masks or

respirators.

2. If the material you intend to spray contains

trichloreoethane and methylene chloride, do

not use accessories that contain aluminum or

galvanized materials, as these chemicals can

react with galvanized components causing

corrosion and weakening equipment. Use

stainless steel accessories.

WARNING

Never point a spray gun at yourself or any

other person or animal. Accidental discharge

may result in serious injury.

Reduce the risk of dangerous

environment

WARNING

Extreme caution should be taken when

spraying flammable liquids as the spark from

a motor or pressure switch may cause a fire

or explosion. Ample ventilation must be

provided.

WARNING

Spray in a well ventilated area to keep fumes

from collecting and causing serious injury and

fire hazards.

Be informed about the materials you use

1. Do regular maintenance; keep all nuts, bolts,

and screws tight, to be sure equipment is in

safe working condition.

2. Inspect tank yearly for rust, pin holes or any

other imperfections that could cause it to

become unsafe.

NEVER attempt to repair or modify a tank!

Welding, drilling or any other modification will

weaken the tank resulting in damage from

rupture or explosion. Always replace worn,

cracked or damaged tanks.

3. Clean electrical equipment with an approved

cleaning agent, such as a dry, non-flam-

mable cleaning solvent.

Daily

Check oil level at sight glass. Oil level should

be 1/2 to slightly higher in the oil sight glass.

Drain moisture from tank.

Verify the pressure switch unloader is

working by listening for a brief hissing sound

when the compressor shuts off.

Visually check the compressor for loose parts,

excessive noise or vibration. Tighten any

necessary part.

WARNING

4. Drain tanks of moisture after each day’s use.

If unit will not be used for awhile, it is best to

leave the drain cock open until such time as it

is to be used. This will allow moisture to

completely drain out and help prevent

corrosion of inside of tank.

5. Always disconnect from power source before

working on or near a motor, or its connected

load. If power disconnect point is out-of-

sight, secure it in the “OFF” position and tag it

to prevent unexpected application of power.

Disconnect power and depressurize system

before servicing air compressor. Slightly open

drain cock after shutting off compressor.

Monthly

(Make sure the main power is off.) Check the belts

for tension. Belts should not move up and down

when the compressor runs and when stopped,

should not have more than ½ in of play when

depressed. Be careful not to over tighten belts

during adjustment.

Remove and check air filter, replace if necessary.

Change oil every 3 months or 300 hours. A

compressor grade non-detergent oil should be

used. Part # 82-6020

WARNING

Page 6

To reduce the risk of electrical hazards, fire

hazards or damage to the compressor, use

proper circuit protection. Your compressor

is wired at the factory for operation using

the voltage shown. Connect the compressor

to a power source with the correct breaker

size.

Adequate wiring and motor protection

should be provided for all stationary

compressors. Wiring used for other

machinery should not be used. A

qualified electrician familiar with local

electrical codes in your area should be

used. Size supply wiring per NEC (National

Electric Code) requirements.

WIRING

ALL ELECTRICAL WIRING SHOULD BE DONE

BY A QUALIFIED ELECTRICIAN

General Information

Electrical connections must be properly

grounded. Ground connections should be

connected at the grounding screw.

Overheating, short circuiting and fire damage

will result from inadequate wiring.

WARNING

CAUTION

WIRING

Single Phase

Three Phase

Ground

Incoming power should

be connected to L1 and

L2 at the Top of the

Magnetic Starter.

Incoming power

should be

connected to

L1, L2 & L3 at

the Top of the

Magnetic Starter.

DO NOT MAKE CONNECTIONS

AT THE PRESSURE SWITCH

DUPLEX

Power should be brought into the

left hand starter. Do not bring power

to both starters.

Page 7

Note:Make sure to follow instructions carefully to avoid a short and possible damage

to the starter solenoid and/or battery.

1. Connect the positive (+) terminal on the battery to the starter solenoid.

2. Connect the negative (-) terminal on the battery to an engine mounting bolt or other

acceptable ground connection.

Always connect the positive(+) battery cable to the starter solenoid before connecting

the negative(-) battery cable.

NUMBER 2 WIRE OR LARGER IS REQUIRED

(Gas Drive Models)

Battery Connection Instructions for Electric Start Engines

PLEASE REFER TO YOUR ENGINE OPERATION MANUAL FOR PROPER STARTING

INSTRUCTIONS.

NAPA GASOLINE DRIVEN COMPRESSORS ARE EQUIPPED WITH A COLD START

VALVE FOR LOADLESS STARTS. THERE IS NO NEED TO MANUALLY UNLOAD

AIR PRESSURE.

BATTERY

(12 Volt)

(+)(-)

GROUND

Starter Solenoid

STARTING THE COMPRESSOR

Prior to running the compressor, check

the following items:

Crankcase oil - Make sure the sight glass

shows ½ full or slightly above.

Make sure all rags, tools, oil, etc. are away

from the unit.

Open the air system to free it of any pressure.

Switch the compressor on for a few

revolutions to make sure the rotation is

correct. Correct rotation is clockwise

when facing the sight glass on the pump.

Operate the compressor for a few minutes

unloaded (air system open) then allow the

compressor to pump up. Make sure the

electrical pressure switch properly switches

off the compressor according to the setting

desired. (175 PSI Max)

Make sure the pressure in the tank does

not exceed its rating. Maximum of 175 psi. If

the pressure gauge indicates a pressure that

is higher than these maximum pressures,

shut off compressor immediately and call

866-869-3114.

STARTING THE COMPRESSOR

CAUTION

QP Compressors

QP and fully packaged models come equipped with low oil level switches and automatic tank

drains. The QP models also include protection against over-heating.

Page 8

Low Oil Level Switch

OIL

Target Oil Level

Oil Vent

Plug

The function of the low oil level switch

is to keep the air compressor from

starting if the oil level drops beyond

a certain point.

For compressors outfitted with the

low oil level switch, the oil should

in the top 1/3 of the oil sight glass.

When changing or adding oil, it is

important to remove the Oil Vent

Plug to allow for the oil to flow

completely into the switch.

(Please Note: If overfilled, oil will flow out

of the oil vent hole)

Thermal Protection - QP Models

If the cooling fan were to fail or

internal temperature were to reach

170°F the QP models are outfitted

with a thermal fuse.

When tripped, the fuse can be reset.

The canopy will need to be removed

to reset the thermal fuse.

Location of Fuse

(Inside Canopy

Behind Fan)

Press to

Reset

The QP comes equipped with sound attenuating enclosure. For maintenance, the canopy and

side foam pieces will need to be removed.

To remove the canopy, simply remove the 6 fasteners and lift the canopy straight up and off.

QP and Fully Packaged Compressors

Page 9

DANGER

Low discharge pressure

1. Reduce air demand or use a compressor

with more air capacity.

2. Listen for air leaks. Apply a soap solution

to all fittings and connections. Bubbles

will form at points of leakage. Tighten

or replace fittings or connections.

3. Clean or replace air filter.

4. Replace necessary gaskets.

5. Remove head and inspect for broken or

misaligned valves. Replace valves, if

necessary.

Install a new head gasket

each time head is removed

1. Tighten drive pulley or flywheel bolt.

2. Check for proper oil level. Low or dirty

oil may cause bearing damage.

3. Replace connecting rod and/or connecting

rod bearings.

4. Replace check valve.

with air pressure in tank

1. Replace with new piston rings.

2. Clean or replace air filter.

3. Drain oil to proper oil level.

4. Use a quality non-detergent 30 or 40wt

oil specified for each model (Page 4).

1. Drain tank at least once per day.

2. Add an inline filter to reduce moisture in

in the air line.

1. Check voltage with volt meter across both

legs of incoming power. Check reset button

on motor.

2. Repair or replace pressure switch.

3. Replace check valve or pressure switch.

Do not remove check valve

with air pressure in tank

1. Make sure the breaker is sized properly.

See page 6 in this manual.

2. Check voltage with volt meter across both

legs of incoming power.

3. Replace motor.

4. Check all electrical connections.

5. Adjust or replace pressure switch.

6. Replace check valve.

Do not remove check valve

with air pressure in tank

1. Replace check valve.

Do not remove check valve

with air pressure in tank

2. Tighten or replace fittings or connections.

3. Replace tank. Do not attempt to repair tank.

Do not remove check valve

1. Compressor too small for

application

2. Air leaks

3. Restricted intake air

4. Blown gasket(s)

5. Broken or misaligned valves

DANGER

1. Loose drive pulley or flywheel

2. Low on oil

3. Worn connecting rod or

connecting rod bearing

4. Noisy check valve

1. Worn piston rings

2. Restricted intake air

3. Too much oil in compressor

4. Incorrect oil viscosity

1. Normal. Amount of water will

increase as humidity in the

air increases.

1. Low voltage

2. Malfunctioning pressure switch

3. Malfunctioning check valve

1. Incorrect breaker size

2. Low voltage

3. Malfunctioning motor

4. Loose electrical connections

5. Malfunctioning pressure switch

6. Malfunctioning check valve

Tank does not hold

pressure when not

running and shut off

valve is closed

Breaker or reset

repeatedly trips

Will not run or motor

hums

Water in tank and/or

discharge line

Excessive oil carryover

Excessive noise

“knocking”

TROUBLESHOOTING GUIDE

1. Malfunctioning check valve

2. Loose fittings or connections

3. Crack or pin hole in tank

CAUTION

Page 10

1. Replace pressure switch if it does not release

air pressure briefly when unit shuts off.

Do not remove pressure

switch with air pressure in

tank

1. Make sure unit is mounted on a level surface

with vibration pads.

2. Replace belts. Align and tighten properly.

3. Align flywheel and drive pulley.

1. Reduce air demand or use a compressor

with more air capacity.

2. Clean all cooling surfaces of dirt and dust.

3. Install compressor in an area with adequate

cool dry air.

1. Malfunctioning check valve

Overheating

TROUBLESHOOTING GUIDE (Continued)

Pressure switch un-

loader constantly

leaking air

1. Replace check valve if unloader bleeds

constantly.

Do not remove check valve

with air pressure in tank

DANGER

Pressure switch not

unloading

1. Malfunctioning pressure

switch

DANGER

Excessive vibration

1. Compressor too small for

application

2. Cooling surfaces dirty

3. Improper cooling

1. Improper installation

2. Loose belts

3. Misaligned flywheel or

drive pulley

Will Not Start

(Elite and QP)

1. Unit Low on Oil

2. Exhaust Fan Not Working

1. Add Oil to Proper Level

2. Reset Thermal Overload

The Company warrants that the Equipment manufactured by it and delivered hereunder shall be free from defects in material and

workmanship for a period of twelve (12) months from the date of initial start-up, or eighteen (18) months from the date of shipment

from the manufacturer, whichever occurs first. The foregoing warranty period shall apply to all Equipment, except for the following: (A) all

two stage reciprocating stationary models are warranted for the earlier of twenty-four (24) months from the date of initial operation or thirty

(30) months from date of shipment from the manufacturer. (B) Replacement parts will be warranted for three (3) months from the date of

shipment from the manufacturer. Should the failure to conform to this warranty be reported in writing to the Company within said

period, the Company shall, at its option, correct such non - conformity by suitable repair to such Equipment, or furnish a

replacement part F.O.B point of shipment, provided that the Purchaser has installed, maintained, and operated such Equipment in

accordance with good industry practices, and has complied with specific recommendations of the Company. Accessories and

equipment furnished by the Company, but manufactured by others, shall carry whatever warranty the manufacturer conveyed to the

Company and which can be passed on to the Purchaser. The Company shall not be liable for any repairs, replacements, or adjustments

to the Equipment, or any costs of labor performed by the Purchaser without the Company’s prior written approval.

The Company makes no performance warranty unless specifically stated within its proposal, and the effects of corrosion, erosion, and

normal wear and tear are specifically excluded from the Company’s warranty. In the event performance warranties are expressly

included, the Company’s obligation shall be to correct in the manner and for the period of time provided above

This warranty does not apply to electric motors or gasoline engines. These are covered by the Original Manufacturer’s Warranty and

should be returned (by the customer) to their authorized service center for service..

THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER,

EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY

AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED. THIS WARRANTY SUPERSEDES ALL

PREVIOUS WARRANTY STATEMENTS.

Correction by the Company of non-conformities, whether patent or latent, in the manner and for the period of time provided above, shall

constitute fulfillment of all liabilities of the Company and its distributors for such non-conformities with respect to, or arising out of such

Equipment.

LIMITATION OF LIABILITY

THE REMEDIES OF THE PURCHASER SET FORTH HEREIN ARE EXCLUSIVE, AND THE TOTAL LIABILITY OF THE COMPANY,

ITS DISTRIBUTORS AND SUPPLIERS WITH RESPECT TO CONTRACT OR THE EQUIPMENT AND SERVICES FURNISHED IN

CONNECTION WITH THE PERFORMANCE OR BREACH THEREOF, OR FROM THE MANUFACTURE, SALE, DELIVERY,

INSTALLATION, REPAIR OR TECHNICAL DIRECTION COVERED OR FURNISHED UNDER CONTRACT, WHETHER BASED

ON CONTRACT, WARRANTY, NEGLIGENCE, INDEMNITY, STRICT LIABILITY OR OTHERWISE, SHALL NOT EXCEED THE

PURCHASE PRICE OF THE EQUIPMENT UPON WHICH SUCH LIABILITY IS BASED.

THE COMPANY, ITS DISTRIBUTORS AND ITS SUPPLIERS SHALL IN NO EVENT BE LIABLE TO THE PURCHASER, ANY

SUCCESSORS IN INTEREST, OR ANY BENEFICIARY OR ASSIGNEE OF THE CONTRACT FOR ANY

CONSEQUENTIAL, INCIDENTAL, INDIRECT, SPECIAL OR PUNITIVE DAMAGES ARISING OUT OF THIS CONTRACT OR ANY

BREACH THEREOF, OR ANY DEFECT IN, OR FAILURE OF, OR MALFUNCTION OF THE EQUIPMENT, WHETHER OR NOT

BASED ON LOSS OF USE, LOST PROFITS OR REVENUE, INTEREST, LOST GOODWILL, WORK STOPPAGE, IMPAIRMENT

OF OTHER GOODS, LOSS BY REASON OF SHUTDOWN OR NON-OPERATION, COST OF PURCHASE OF REPLACEMENT

POWER, OR CLAIMS OF PURCHASER OR CUSTOMERS OF PURCHASER FOR SERVICE INTERRUPTION, WHETHER OR NOT

SUCH LOSS OR DAMAGE IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, INDEMNITY, STRICT LIABILITY OR OTHERWISE.

Warranty Statement

Atlas Copco Compressors

1800 Overview Drive

Rock Hill, SC 29730

866-869-3114