2 Stage Oil Flooded Type

Reciprocating Air Compressors

Installation & Operation

Maintenance Manual

Models CRAC-D5H CRAC-D7.5H CRAC-D10H CRAC-D15H CRAC-D20H

CRAC-D5V CRAC-D7.5V

CRAC01-02 Rev. REL.

Model Number: Serial Number: FILL IN COMPLETELY AT INSTALLATION

Coaire Technologies Corporation 8740 Pioneer Blvd., Santa Fe Springs, CA 90670 ◊ TEL.(562)463-3935 ◊ (562)463-4928

website: www.coaire.com ■ e-mail: sales@coaire.com/support@coaire.com Printed in U.S.A. FORM CM-AD02

FEB. 2002

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SAFETY AND PRECAUTIONS Before you install the air compressor you should take the time to carefully read all the instructions contained in this manual. Electricity and compressed air have the potential to cause severe personal injury or property damage. Before installing, wiring, starting, operating or making any adjustments, identify the components of the air compressor using this manual as a guide. The operator should use common sense and good working practices while operating and maintaining this unit. Follow all procedures and piping accurately. Understand the starting and stopping sequences. Check the safety devices in accordance with the following procedures contained in this manual. Maintenance should be done by qualified personnel, accurately with proper tools. Follow the maintenance schedule as outlined in the manual to ensure problem free operation after start up.

SAFETY PRECAUTIONS BEFORE INSTALLING THE COMPRESSOR OR PERFORMING ANY MAINTENANCE READ THIS

MANUAL CAREFULLY. WARNINGS

COMPRESSED AIR AND ELECTRICITY ARE DANGEROUS. BEFORE DOING ANY WORK ON THIS UNIT, BE SURE

THE ELECTRICAL SUPPLY HAS BEEN SHUT OFF(LOCKED AND TAGGED) AND THE ENTIRE COMPRESSOR

SYSTEM HAS BEEN VENTED OF ALL PRESSURE.

1. Do not remove the cover, loosen or remove any fittings, connections or devices when this unit is operating or in operation. Hot liquid and air that are contained within this unit under pressure can cause severe injury or death.

2. The compressor has high and dangerous voltage in the motor, the starter and control box. All installations must be in accordance with recognized electrical procedure. Before working on the electrical system, ensure that the system's power has been shut off by use of a manual disconnect switch. A circuit breaker or fuse switch must be provided in the electrical supply line to be connected to the compressor. The preparation work for installation of this unit must be done in suitable grounds, maintenance clearance and lighting arrestors for all electrical components.

3. Do not operate the compressor at a higher discharge pressure than those specified on the compressor nameplate. If so an overload will occur. This condition will result in electric motor compressor shutdown.

4. Use only safety solvent for cleaning the compressor and auxiliary equipment. 5. Install a manual shut off valve(isolation type) in the discharge line for service work. 6. Whenever pressure is released through the safety valve during operation, it is due to excessive pressure

in the system. The cause of excessive pressure should be checked and immediately corrected. 7. Before doing any mechanical work on the compressor, a) Shut down the unit. b) Electrically isolate the compressor by use of the manual disconnect switch in the power line to the unit.

Lock and tag the switch so that it cannot be operated. c) Release all compressed air within the system and isolate the unit from any other sources of air. 8. Allowing the unit lubricants to enter into the plant air system must be avoided at all times. Air line

separators, which are properly selected and installed, can reduce any liquid carry-over close to zero. 9. Before starting the compressor, the maintenance instructions should be thoroughly read and understood. 10. After maintenance work is completed, covers must be securely closed. 11. For questions contact your distributor before proceeding.

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1. INSTALLATION AND OPERATION INSTRUCTIONS

INSTALLATION AND LOCATION 1. Installation: Install the compressor in a covered, well ventilated area, free of dust, toxic

gases, humidity or any other kind of pollution. The compressor should be located no closer than 32”(800mm) from a wall or any other obstacle that could interfere with the air flow through the fan. This distance will also make maintenance easer. Place the compressor on a level surface. Rotation of the flywheel must be in the direction of the arrow cast into flywheel. The maximum ambient temperature recommended while working is 113 degree F(45 degree C). If necessary install an exhaust fan to guarantee proper ventilation and fresh air to dissipate heat. Before making the electrical connections, check oil level and top-up lubricating oil. For type of oil, see table at the end of these instructions.

2. Electrical connection: The country’s valid electrical standards must be followed regarding Low Voltage Electrical Installation.

OPERATION 1. Initial start procedure: Before turning on the compressor, check the crankcase oil level.

It must be in the middle of the OIL LEVEL SIGHT. As to the type of oil to be used and the recommended change intervals, check at “Lubrication” and as to its volume, check the Technical Data Table.

2. Start: Turn on the electrical start key and let your compressor run for about 10(ten) minutes, what will keep the tank’s internal pressure or compressed air around 20 psig. This will optimize a homogeneous lubrication of the parts.

2. MAINTENANCE

WARNING

Turn off power before servicing and be sure the air tank is unloaded. These instructions are based

on normal operating conditions. If the compressor is located in an exceedingly dust area, increase

the frequency of all inspections.

DAILY - Inspect the compressor visually. - Check oil level and add some if necessary, before turning the compressor on. - Drain moisture from the pipe system. - Be sure there is no excessive or unusual vibration or noise.

WEEKLY - Remove and clean intake air filter; do not wash the filter element. - Check the V-belt for tightness. Belt tension should be adjusted to allow approximately

3/8” to ½” (9 to 13 mm) deflection with normal thumb pressure. - Clean cylinders externally, cylinder head, tubing, and tank. - Safety valve should be tested manually to see if it is working properly.

MONTHLY - Check entire system for air leakage around fittings, etc. by using water

and soap lather. - Check the pressure switch operation. - Check for oil contamination and change it if necessary.

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QUARTERLY - Change the air filter element every 300 working hours or quarterly whichever occurs

first. - Fasten cap screws and nuts as required. - Change oil more frequently if compressor is located in very dirty environment. - On the 7 ½, 10 and 15HP compressor pumps, the concentric valves must be inspected

and cleaned between 800 and 1000 service hours. - Compressors’ Suction and Discharge Valves are subject to normal wear and are to be

checked and even replaced after about 1000 service hours, accruing to operation conditions.

- WHILE RUNNING IN A PERIOD OF ABOUT 100 WORKING HOURS THE OIL LEVEL SHOULD BE CAREFULLY CHECKED.

ANNUALLY - Test and calibrate the pressure switch, pressure gauge and safety valve according to

their own technical standards. These parts must be removed from the tank and pump to be tested.

- Inspect and clean the suction and discharge valve(s) plate(s) every 1000 (one thousand) working hours whichever occurs first, located between the cylinder and its cover and, if necessary, replace it(them) according to the operation conditions.

LUBRICATION

- The first oil change should be made after 8 hours of operation. - The second oil change after 40 hours of operation. - The third and following exchanges should be made after 200 hours of operation, or 60

(sixty) days, whichever occurs first.

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NOTE

USE ONLY COLUBE

Check with your distributor for special applications

RECOMMENDED LUBRICANT OILS FOR COAIRE AIR PUMPS

AMBIENT TEMPERATURE

Below 32 Deg. F

(Below 0 Deg C)

32 Deg. F to 68 Deg. F

(0 Deg. C to 20 Deg. C)

68 Deg. F to 113 Deg. F

(20 Deg. C to 45 Deg. C)

SAE 10W

Or

ISO 32

SAE 20W

Or

ISO 68

SAE 30

Or

ISO 100

CRAC-D10 only

AMBIENT TEMPERATURE

Below 32 Deg. F

(Below 0 Deg C)

32 Deg. F to 68 Deg. F

(0 Deg. C to 20 Deg. C)

68 Deg. F to 104 Deg. F

(20 Deg. C to 40 Deg. C)

SAE 10W

Or

ISO 32

SAE 20W

Or

ISO 68

SAE 40

Or

ISO 150

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V-BELT V-Belts Trouble Shooting

7

Check alignment

8

Install Belts

TECHNICAL DATA HORIZONTAL TYPE

Models Motor

(HP)

Piston

Displaceme

nt

(cfm)

Free Air

Delivery

(cfm)

Volts

Phase

Pressure

Setting

(psig)

Air

Receiver

(Gal.)

Air

Outlet

(Inch)

Dimensions Weight

(lbs) Width Depth Height

CRAC-D5H 5 20 16.0 230V/1Ph

or 230/460V/3Ph

145-175 80 3/ 4” 70” 23” 44 520

CRAC-D7.5H 7.5 30 24.0 230/460V/3Ph 145-175 80 3/ 4” 70” 23” 44 550

CRAC-D10H 10 40 32.0 230/460V/3Ph 145-175 120 1” 70” 26” 52” 790

CRAC-D15H 15 60 48.0 230/460V/3Ph 145-175 120 1” 70” 28” 56” 835

CRAC-D20H 20 80 64.0 230/460V/3Ph 145-175 120 1” 70” 28” 66” 950

VERTICAL TYPE

Models Motor

(HP)

Piston

Displaceme

nt

(cfm)

Free Air

Delivery

(cfm)

Volts

Phase

Pressure

Setting

(psig)

Air

Receiver

(Gal.)

Air

Outlet

(Inch)

Dimensions Weight

(lbs) Width Depth Height

CRAC-D5V 5 20 16.0 230V/1Ph

or 230/460V/3Ph

145-175 80 3/ 4” 36” 24” 70” 430

CRAC-D7.5V 7.5 30 24.0 230/460V/3Ph 145-175 80 3/ 4” 36” 24” 70” 530

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PUMP PARTS LIST

MSV-20MAX for CRAC-D5 MOTOR

(HP)

Max.

PRESSURE

(psig)

RPM DISPLACEMENT

(cfm) Belt

Oil

CAP.

(lit.)

MOTOR PULLEY@60Hz

2 POLES 4 POLES

mm / inch mm / inch

5 175 1050 20 1-A 1.0 128 / 5.04 216 / 8.5

* Part available in the market-not sold by COAIRE

10

MSV-30 MAX for CRAC-D7.5 MOTOR

(HP)

Max.

PRESSURE

(psig)

RPM DISPLACEMENT

(cfm) Belt

Oil

CAP.

(lit.)

MOTOR PULLEY@60Hz

2 POLES 4 POLES

mm / inch mm / inch

7.5 175 960 30 2-A 0.85 115 / 4.53 226 / 8.89

* Part available in the market-not sold by COAIRE

11

MSV-40 SA for CRAC-D10 MOTOR

(HP)

Max.

PRESSURE

(psig)

RPM DISPLACEMENT

(cfm) Belt

Oil

CAP.

(lit.)

MOTOR PULLEY@60Hz

2 POLES 4 POLES

mm / inch mm / inch

10 175 790 40 2-B 1.4 - 190/7.5

* Part available in the market-not sold by COAIRE

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MSV-60 MAX for CRAC-D15 MOTOR

(HP)

Max.

PRESSURE

(psig)

RPM DISPLACEMENT

(cfm) Belt

Oil

CAP.

(lit.)

MOTOR PULLEY@60Hz

2 POLES 4 POLES

mm / inch mm / inch

15 175 1065 60 2-B 1.5 162 / 6.4

* Part available in the market-not sold by COAIRE

13

MSWV-80 MAX for CRAC-D20 MOTOR

(HP)

Max.

PRESSURE

(psig)

RPM DISPLACEMENT

(cfm) Belt

Oil

CAP.

(lit.)

MOTOR PULLEY@60Hz

2 POLES 4 POLES

mm / inch mm / inch

20 175 910 80 2-B 4.4 145 / 5.7

* Part available in the market-not sold by COAIRE

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LIMITED WARRANTY

All component parts on your COAIRE air compressors are warranted to be free of defects in workmanship and material for a period of one year. Transportation charges are responsibility of the purchaser. This warranty extends to the original purchaser of the compressor only. There are no express warranties except as contained in this limited warranty statement and implied warranties, including those of merchantability and fitness for a particular purpose, are limited to the period of warranty. Our liability is limited solely to replacement of nonconforming parts as set forth herein and does not include any liability for any incidental, consequential, or other damages of any kind. This warranty gives you specific legal rights, and you may also have other rights that vary from state to state.

For complete line of additional product information, please contact your local COAIRE distributor.

DISTRIBUTED BY

COAIRE Technologies reverse the right to make changes, at any time without notice as a result of our commitment to continuous improvement.

Coaire Technologies, Corporation 8740 Pioneer Blvd., santa Fe Springs, CA 90670 ◊ TEL.(562)463-3935 ◊ (562)463-4928

website: www.coaire.com ■ e-mail: sales@coaire.com/support@coaire.com