CAS45RS and CAS45RS-CW

Transcription

1 CAS45RS and CAS45RS-CW 45 CFM / 150 PSIG HYDRAULIC-DRIVEN, OPEN CENTER, 12V & 24V, (OPTIONAL) COLD- WEATHER, ROTARY SCREW COMPRESSOR INSTALLATION, OPERATION, MAINTENANCE AND PARTS MANUAL NOTE This publication contains the latest information available at the time of preparation. Every effort has been made to ensure accuracy. Iowa Mold Tooling Co., Inc. reserves the right to make design change modifications or improvements without prior notification. Read this manual before installing, operating or servicing this equipment. Failure to comply with the operation and maintenance instructions in this manual WILL VOID THE EQUIPMENT WARRANTY. NOTE Use only Vanair Vanguard Premium Synthetic Oil and Genuine Vanair Parts. Inspect and replace damaged components before operation. Substituting non-vanair oil or non-genuine Vanair filter components WILL VOID THE COMPRESSOR WARRANTY! KEEP THE MANUAL WITH THE VEHICLE Iowa Mold Tooling Co., Inc. 500 Highway 18 West Garner, Iowa Phone: Fax: Iowa Mold Tooling Co., Inc. All rights reserved. NOTE Making unauthorized modifications to the system components WILL VOID THE WARRANTY! Always inform Vanair Manufacturing, Inc., before beginning any changes to the CAS45S system. P/N rev0 Effective Date: JANUARY 2018

2 NOTICE TO CUSTOMER This manual is the final version and some of the information and specifications are subject to change without notice.

3 TABLE OF CONTENTS TABLE OF CONTENTS TABLE OF CONTENTS... I SECTION 1: SAFETY GENERAL INFORMATION DANGERS, WARNINGS CAUTIONS AND NOTES DANGERS WARNINGS CAUTIONS NOTES SAFETY DECALS DISPOSING OF MACHINE FLUIDS...3 SECTION 2: SPECIFICATIONS...5 TABLE 2A: IMT CAS45RS & CAS45RS-CW SPECIFICATIONS...5 TABLE 2B: PRIME LUBRICANT CHARACTERISTICS...6 TABLE 2C: RECOMMENDED TORQUE SPECIFICATIONS...6 SECTION 3: INSTALLATION MACHINE PACKAGE RECEIPT/INSPECTION GENERAL INSTRUCTIONS DETERMINING THE COMPRESSOR UNIT MOUNTING LOCATION HYDRAULIC SYSTEM OVERVIEW HYDRAULIC SYSTEM FILTRATION HYDRAULIC OIL RESERVIOR DETERMINING RESERVOIR SIZE DETERMINING RESERVOIR SHAPE MANDATORY RESEROIR FEATURES... 9 Continued on next page... MANUAL # REV.0 PAGE - I

4 TABLE OF CONTENTS IMT CAS45RS AND CAS45RS-CW SECTION 3: INSTALLATION (CONTINUED) RECOMMENDED RESERVOIR OPTIONS RESERVOIR FEATURES TO AVOID RECOMMENDED HYDRAULIC SYSTEM SPECIFICATIONS STANDARDS GUIDELINES INSTALLATION MACHINE LOCATION CLEARANCES MOUNTING SERVICE CONNECTIONS ELECTRICAL CONNECTIONS HYDRAULIC SUPPLY CIRCUIT ROUTING...11 Figure 3-4A: Dimension Diagram - CAS45RS Open Center Without Thermal Valve Figure 3-4B: Dimension Diagram - CAS45RS Open Center With Thermal Valve SECTION 4: OPERATION GENERAL INFORMATION PURPOSE OF CONTROLS Figure 4-1: Main Machine Component Locations NORMAL OPERATION INITIAL START-UP PROCEDURE: PRE-CHECKS ROUTINE START-UP PROCEDURE ROUTINE SHUT-DOWN PROCEDURE Figure 4-5: Controller Screen Identification and Navigation OPERATING CONDITIONS EXTREME CONDITION OPERATION SECTION 5: MAINTENANCE GENERAL INFORMATION MACHINE MAINTENANCE SCHEDULE REPLACEMENT PARTS TABLE 5A: ROUTINE MAINTENANCE SCHEDULE PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES Continued on next page... PAGE - II MANUAL # REV.0

5 TABLE OF CONTENTS SECTION 5: MAINTENANCE (CONTINUED) ALIGNMENT SETTING THE MINIMUM PRESSURE VALVE COMPRESSOR THERMAL VALVE SERVICING THE SYSTEM CIRCUIT BREAKER, FUSE AND RELAY SAFETY SHUTDOWN SYSTEMS PRESSURE RELIEF VALVE REPLACING THE DRIVE COUPLING REPLACING THE DRIVE COUPLING ELEMENT COUPLING ASSEMBLY HUB ALIGNMENT CHECK COUPLING MAINTENANCE STORAGE AND INTERMITTENT USE INTERMITTENT USE LONG TERM STORAGE SECTION 6: TROUBLESHOOTING GENERAL INFORMATION...33 Figure W-1: Serial Plate / Serial Number Location TROUBLESHOOTING GUIDE...34 SECTION 7: ILLUSTRATED PARTS LIST PARTS ORDERING PROCEDURE...37 TABLE 7A: RECOMMENDED SPARE PARTS LIST COMPRESSOR REPLACEMENT PARTS COOLER ASSEMBLY (NO THERMAL VALVE) COOLER ASSEMBLY (WITH THERMAL VALVE) FRAME AND CANOPY ASSEMBLY HOSE & TUBING ASSEMBLY - OPEN CENTER; NO THERMAL VALVE HOSE & TUBING ASSEMBLY - OPEN CENTER; WITH THERMAL VALVE DISPLAY AND CONTROLLER ASSEMBLY HYDRAULIC MANIFOLD ASSEMBLY - OPEN CENTER DECALS - PART 1 OF DECALS - PART 2 OF A SCHEMATIC DIAGRAM - HYDRAULIC OIL FLOW, OPEN CENTER...54 Continued on next page... MANUAL # REV.0 PAGE - III

6 TABLE OF CONTENTS IMT CAS45RS AND CAS45RS-CW SECTION 7: ILLUSTRATED PARTS LIST (CONT.) 7.11B SCHEMATIC DIAGRAM - HYDRAULIC OIL FLOW, OPEN CENTER WITH THERMAL VALVE ELECTRICAL SCHEMATIC HOSE INSTALLATION GUIDE TABLE 7C: MAINTENANCE TRACKING LOG PAGE - IV MANUAL # REV.0

7 SECTION 1: SAFETY SECTION 1: SAFETY 1.1 GENERAL INFORMATION The products provided by Iowa Mold Tooling Co., Inc. are designed and manufactured for safe operation and maintenance. But it is ultimately the responsibility of the users and maintainers for safe use of this equipment. Part of this responsibility is to read and be familiar with the contents of this manual before operation or performing maintenance actions. 1.2 DANGERS, WARNINGS, CAUTIONS AND NOTES These boxes are labeled clearly with the title block listing either Danger, Warning, Caution, or other non-safety issue. They draw attention to specific issues that are pertinent to the safe and correct operation of the machine. The symbols shown and defined in Section 1: Safety are used throughout this manual and on the machine to call attention to, and identify, possible hazards. The international warning symbol (shown above) is used on all decals, labels and signs that concern information pertaining to bodily harm. When you see the international warning symbol, pay extremely careful attention, and follow the given instructions or indications to avoid any possible hazard DANGERS DANGER Identifies actions or conditions which will cause death, severe injury, or equipment damage or destructive malfunctions. Keep tools or other conductive objects away from live electrical parts. Never touch electrical wires or components while the machine is operating. They can be sources of electrical shock WARNINGS WARNING Identifies actions or conditions which may cause death, severe injury, or equipment damage or destructive malfunctions. DO NOT EVER use this compressor as a breathing air source. IMT disclaims any and all liabilities for damage or loss due to fatalities, personal injuries resulting from the use of an IMT compressor to supply breathing air. DO NOT perform any modifications to this equipment without prior factory approval. DO NOT operate the compressor or any of its systems if there is a known unsafe condition. Disable the equipment by disconnecting it from its power source. Install a lock-out tag to identify the equipment as inoperable to other personnel. DO NOT operate the compressor with any by-pass or other safety systems disconnected or rendered inoperative. DO NOT operate the equipment while you are under the influence of alcohol or drugs. DO NOT operate the equipment while you are feeling ill. DO NOT attempt to service the equipment while it is operating. Before performing maintenance, or replacing parts, relieve the entire system pressure, after the system has blown down, by opening a service valve which will vent all pressure to the atmosphere. After that, remove any remaining residual pressure by Manual # Rev.0 PAGE - 1

8 SECTION1: SAFETY IMT CAS45RS AND CAS45RS-CW slowly opening the fill cap. Remove all electrical power. NOTE Slowly remove fill cap to vent compressor sump pressure. DO NOT use the compressor for purposes other than for which it is intended. High pressure air can cause serious and even fatal injuries. DO NOT operate the compressor outside of its specified pressure and speed ratings. (See Section 2: Specifications or refer to the equipment data plate.). DO NOT use flammable solvents or cleaners for cleaning the compressor or its parts. DO NOT operate the compressor in areas where flammable, toxic, or corrosive fumes, or other damaging substance can be ingested by the compressor intakes. Keep arms, hands, hair and other body parts, and clothing away from fans, drive shafts, and other moving parts. DO NOT wear jewelry, unbuttoned cuffs, ties, or loose-fitting clothing when you are working near moving/rotating parts. ALWAYS confine long hair when working near moving/rotating parts. NEVER operate the equipment while wearing a headset to listen to music or the radio. Wear personal protective equipment such as gloves, work shoes, and eye and hearing protection as required for the task at hand. DO NOT operate the compressor with any guards removed or damaged, or other safety devices inoperative. DO NOT operate the compressor in enclosed or confined spaces where ventilation is restricted or closed-off. Ensure that hoses connected to service valves are fitted with correctly sized and rated flow limiting devices which comply with applicable codes. Pressurized broken or disconnected hoses can whip, causing injuries or damage. DO NOT use tools, hoses, or equipment that have maximum ratings below that of this compressor. Keep metal tools, and other conductive objects away from live electrical components. Before performing maintenance or repair operations on the compressor, ensure that all power has been removed and been locked out to prevent accidental application. DO NOT assume that because the compressor is in a STOPPED condition that hydraulic power has been removed. Use this compressor only to compress atmospheric air. Use of this equipment as a booster pump and/or to compress any other gaseous or aerosol substance constitutes improper use. It can also cause damage or injuries. Such misuse will also void the warranty. Install, operate, and maintain this equipment in full compliance with all applicable OSHA, other Federal, state, local codes, standards, and regulations. When lifting objects, be aware of proper lifting techniques to avoid injury. ALWAYS read and follow safety related precautions found on containers of hazardous substances CAUTIONS CAUTION Identifies actions or conditions which will or can cause injuries, equipment damage or malfunctions. Check all safety devices for proper operation on a routine basis. Ensure that no tools, rags, or other objects are left on compressor drive systems or near intakes. Keep the equipment clean when performing maintenance or service actions. Cover openings to prevent contamination. DO NOT operate the compressor if cooling air is not available (fan/cooler not operating) or if lubricant levels are below their specified minimum levels. Ensure all plugs, hoses, connectors, covers, and other parts removed for maintenance actions are replaced before applying power to the compressor. PAGE - 2 Manual # Rev.0

9 SECTION 1: SAFETY Avoid touching hot surfaces and components. Ensure that electrical wiring, terminals; hoses and fittings are kept in serviceable condition through routine inspections and maintenance. Replace any damaged or worn components NOTES NOTE Additional information (or existing information) which should be brought to the attention of operators/maintainers affecting operation, maintenance, or warranty requirements. Note boxes are usually listed to convey and give focus to a distinct piece of information, which is not directly related to a safety issue, but is necessary to understand machine function and operation. Special note referrals in the manual may be contained in a box titled with an IMPORTANT banner, as shown below, and may also contain the WARNING symbol, should the information be linked to a safety issue: 1.3 SAFETY DECALS Safety decals are placed onto, or located near, system components that can present a hazard to operators or service personnel. All pertinent decals listed in Section 7.10, Decals are located near a component which is subject to respect in terms of safety precautions. Always heed the information noted on the safety decals. WARNING DO NOT REMOVE OR COVER ANY SAFETY DECAL. Replace any safety decal that becomes damaged or illegible. 1.4 DISPOSING OF MACHINE FLUIDS Always dispose of machine fluids under the guidance of all applicable local, regional and/ or federal law. IMT encourages recycling when allowed. For additional information, consult the container label of the fluid in question. IMPORTANT Additional, CRUTIAL information (or existing information) which should be brought to the attention of operators/maintainers affecting operation, maintenance, or warranty requirements. Manual # Rev.0 PAGE - 3

10 SECTION 1: SAFETY IMT CAS45RS AND CAS45RS-CW BLANK PAGE PAGE - 4 Manual # Rev.0

11 SECTION 2: SPECIFICATIONS SECTION 2: SPECIFICATIONS TABLE 2A: IMT CAS45RS & CAS45RS-CW SPECIFICATIONS GENERAL SYSTEM INFORMATION SPECIFICATION RATINGS Capacity 150 psig): 45 Air pressure rating (psig): 150 Speed of compressor 100 psig): 4500 Hydraulic motor RPM 4500 Hydraulic flow 120 F hydraulic oil temperature): 11.0 Hydraulic pressure 100/150 compressor psig): 100 / 150 II Maximum compressor oil temperature 240 F Maximum hydraulic oil temperature 160 F COMPRESSOR Type: Encapsulated, Oil-injected, Rotary Screw Compressor oil tank capacity: 4 U.S. Quarts (3.7L) Compressor overheating protection: Shut Down at 240 F Air inlet system: Dry-type, Single Stage Filter Drive coupling: Direct Drive, Flex Jaw Coupling Hydraulic motor: Gear Type PACKAGE Main frame: Formed Aluminum with Bolt-down Provision Electrical supply: 12V Standard; 24V Optional Electrical connections: Deutsch 6-pin Round Supply connections (customer hook-up): Hydraulic: Oil In = #12 3/4, 37 JIC Hydraulic: Oil Out = #16 1, 37 JIC Case Drain: #6 3/8 JIC Air Out: #12 3/4 JIC Electrical: 12V DC (Standard) 24V DC (Optional) I Refer to Section 3.4, Hydraulic System Requirements, for additional speed requirement information. II Hydraulic relief valve setting is 3200 psi. Recommended hydraulic system pressure: 2600 psi continuous, 3000 psi intermittent. Table continued on next page Manual # Rev.0 PAGE - 5

12 SECTION 2: SPECIFICATIONS IMT CAS45RS AND CAS45RS-CW TABLE 2A: IMT CAS45RS & CAS45RS-CW SPECIFICATIONS GENERAL SYSTEM INFORMATION SPECIFICATION PACKAGE (continued) Enclosure: Sheet Metal with Service Access Cooler: Hydraulic Oil Cooler/Radiator Core - Electric Fan Dimensions: 33.6" L x 21.00" W x H Weight: 196 lbs (dry) NOTE: For cold weather machines: Cracking Pressure : 50 PSI NOTE: Shift Temperature: 100 F NOTE: For machine installation clearances, refer to Figure 3-2, Minimum Installation Clearances, in Section 3, Installation. NOTE: Specifications are subject to change without notice. TABLE 2B: PRIME LUBRICANT CHARACTERISTICS Viscosity Flash point Pour Point Contains 178 SUS at 100 F (38 C) 457 F (236 C) -49 F (-45 C) Rust and Oxidation Inhibitors and Detergents TABLE 2C: RECOMMENDED TORQUE SPECIFICATIONS TYPE DESCRIPTION: SAE 5 3 line ID marks SAE 8 6 line ID marks Bolt Diameter Thread / inch Dry Oiled Dry Oiled 1/ / / / PAGE - 6 Manual # Rev.0

13 SECTION 3: INSTALLATION SECTION 3: INSTALLATION 3.1 MACHINE PACKAGE RECEIPT/INSPECTION Upon receipt of the machine package, inspect the exterior of the shipping crate for signs of shipping/transit damage. Any damage should be reported immediately to the shipping company. NOTE Before fully unpacking the unit, inspect the component parts, supports and loosepacked parts to ensure that there have been no internal movements of assemblies or components, which may have been damaged during shipment. Access the roof panel to inspect the component parts and supports. Remove manual from inside of canopy. Should any damage be discovered during package inspection, contact the shipping company immediately. 3.2 GENERAL INSTRUCTIONS This section provides general guidance for locating and preparing the IMT CAS45RS compressor package for operation. Each installation is unique and can be affected by location, ventilation, and other factors such as electrical and hydraulic power supply availability and location. WARNING Before performing maintenance or repair operations on the compressor, ensure that all power has been removed and locked out to prevent accidental application. DO NOT assume that because the compressor is in a STOPPED condition that power has been removed. WARNING Install, operate, and maintain this equipment in full compliance with all applicable OSHA, other Federal, state, local codes, standards, and regulations. WARNING Do not install in any enclosed space without first contacting IMT. WARNING Grounding must consist of a minimum two (2) gauge wire between the instrument panel, the machine, and the truck chassis. NOTE Although much of the information given in this installation section is detailed, these guidelines should be considered as referential material only, due to the diverse possibilities of the end user s vehicle make, model and year, and the unit model specifications. NOTE Install electrical components (circuit breakers, pressure switches, toggle switches, etc.) in locations where exposure to water or moisture will be most minimized. NOTE Contact IMT at (641) Fax: (641) to report missing items, incorrect part numbers, or other discrepancies. Manual # Rev.0 PAGE - 7

14 SECTION 3: INSTALLATION IMT CAS45RS AND CAS45RS-CW 3.3 DETERMINING THE COMPRESSOR UNIT MOUNTING LOCATION When determining the location to mount the CAS45RS unit, the following criteria must be taken into consideration: Refer to Section 3.5, Installation. The location must allow for the machine dimensions (Figures 3-3A through 3-3D), and additional space requirements for minimum cooling, access and maintenance. The mounting surface must be level and able to accommodate the four [4] mounting bolts of the base frame. Refer to Figures 3-3A through 3-3D for mounting hole location dimensions. The mounting surface must be able to support the units weight (196 lbs.). The external display must be easily visible to the operator. It is recommended, for most installations, to mount the compressor on the driver s side of the vehicle. The unit should be situated in such a manner that the fan (rear) and intake side (front) are not obstructed. Do not place the compressor in any location where it can intake exhaust fumes, dust or debris. 3.4 HYDRAULIC SYSTEM OVERVIEW IMPORTANT IMT highly recommends consulting a hydraulic supply expert for specifying the correct hydraulic supply components for vehicle-side integration (including oil reservoir size, hydraulic pressure relief, hose size, etc.) for your application. IMPORTANT Contaminated hydraulic fluid allowed to enter the pump will cause malfunction of the pump controls. Hydraulic system hoses must be flushed and cleaned prior to being connected to the unit. Refer to Figures 3-3A through 3-3D for hydraulic pump system connections. Please take into consideration the following: The hydraulic flow and pressure requirements of the system. A continuous hydraulic load is necessary when compressor is running. The duty cycle and ambient operating temperatures. Other hydraulic equipment which may share that same hydraulic supply system (IMT recommends a dedicated pump and hydraulic circuit). WARNING Follow all applicable safety recommendations as outlined in Section 1: Safety of this manual. WARNING Improperly, or non-connected lines will damage the equipment. The hydraulic hoses must be run to the machine. Verify that hoses are hooked up properly to ensure proper flow. Also, verify that the hoses are laid out properly so that no chafing or kinking of the hoses is possible. Refer to Section 7.16, Hose Installation Guide, for assistance with proper hose layout and connecting functions. NOTE The temperature of the hydraulic oil should not exceed 160 F due to the rating of the IMT-supplied hydraulic motor HYDRAULIC SYSTEM FILTRATION IMT recommends using a 10 micron oil filter on the hydraulic oil return line. Flow rating of the filter must be equal to, or greater than, the maximum GPM at which the system will be operated. PAGE - 8 Manual # Rev.0

15 SECTION 3: INSTALLATION HYDRAULIC OIL RESERVOIR DETERMINING RESERVOIR SIZE In a conventional hydraulic system, minimum tank size, in gallons, should be equal to the maximum GPM flow rate, times two (x 2) DETERMINING RESERVOIR SHAPE A KEY A B IMPORTANT Use only a filter that is specifically intended for hydraulic systems. The reservoir structure should be tall and narrow rather than shallow and broad (Figure 3-1). A tall, narrow tank is recommended because: 1. The oil level is well above suction line opening, avoiding the possibility of drawing air into the pump due to a vortex or whirlpool effect within the tank during operation flow. DESCRIPTION B PREFERRED SHAPE: TALL AND NARROW SHAPE TO AVOID: BROAD AND SHALLOW Figure 3-1: Reservoir Design Shape 2. Allows for better oil level tolerance level of the system if vehicle operates at an unusual (slightly off level) vehicle angle. 3. To keep return flow well below the surface so it does not break the surface and cause aeration (cavitation) of the oil MANDATORY RESERVOIR FEATURES The reservoir should incorporate the following design features: In terms of location of the reservoir tank within the hydraulic system, note that the hydraulic pump s inlet line (suction line out from the reservoir to the pump) should be located near the bottom of the tank, well below the oil level. The suction line should protrude a minimum of two (2 ) inches into the reservoir to keep it away from potential contaminant surface buildup. A baffle or baffles should be included to prevent sloshing, or centrifugal motion of the oil; the goal is to break up direct flow of the oil from the return point to the suction point. This allows for the cooling action contact with the tanks inner surfaces, and promote separation of any air or contaminants that interact with the flowing oil. An ideal baffle design would position several (but not too many) baffles to promote an S shape flow within the reservoir, as viewed from above. The area of the end gaps should be at least twice the area of the suction line diameter. A drain port with plug, situated at the lowest point of the reservoir, is needed to assure complete draining. It should be installed using an adapter or housing which does not protrude above the inner surface of the floor of the tank. It should be visible and accessible for removal, with sufficient space available for catching the waste oil. If the return line entrance to the tank is located near the top, it should be extended downward within the tank to minimize foaming and aeration of the circulating oil. This extends oil integrity, which in turn helps to maintain system performance and reliability. Manual # Rev.0 PAGE - 9

16 SECTION 3: INSTALLATION IMT CAS45RS AND CAS45RS-CW An in-line filter on the return line is needed to protect the system against contaminants being introduced into the oil. The filter should be mounted externally from the reservoir in a location that allows for easy of service access. A breather and fill cap is needed at the oil fill port, which needs to be located above the system oil level. The breather cap acts to both filter air that is drawn into the reservoir as the oil level diminishes, and bleeds air out as the level is regained. This maintains constant atmospheric pressure in the air volume within the reservoir. A sight-glass provides a direct visual indication of the oil level without having to open, or otherwise access, the reservoir RECOMMENDED RESERVOIR OPTIONS Although not essential for an adequately functioning reservoir, the following components will contribute to maximize the hydraulic system s efficiency and maintain a quality operational level. Magnetic drain plug: Attracts and concentrates ferrous contaminants at the drain plug source for easier accessibility and removal when cleaning tank interior. A temperature gauge: Located in approximation to, or built in to, the sight glass assembly allows for temperature reading at a glance. Filler port strainer: Prevents large contaminant particles from blending with system oil when adding new oil. Return line diffuser (splash) plate reduces velocity of oil flow before return oil stream merges with the main reservoir oil volume. A reservoir heater: For those systems that are exposed to cold climate ambients, having the ability to preheat the hydraulic oil prior to start up will make for easier startups, and reduce the strain of warming up the system under adverse cold conditions RESERVOIR FEATURES TO AVOID A strainer used to screen the suction line is not recommended for systems designed for mobile equipment use. Having equipment that likely experiences long suction lines, cold startups and non-tracked or infrequent maintenance practices may cause this strainer to potentially promote system strain (cavitation) than prolong fluid integrity through filtration. A pressurized reservoir is not recommended for vehicles, as its complexity invites too much potential for loss of system reliability if it is not properly maintained RECOMMENDED HYDRAULIC SYSTEM SPECIFICATIONS WARNING Do not operate machine without hydraulic system completely assembled. Refer to Figures 3-3A through 3-3D. Flow controller is optional to reduce flow if necessary. Consult IMT. HYDRAULIC LINES The following is a minimum requirement and NO quick disconnects may be used. Lines are to be kept as straight and short as possible. Pressure port = Standard, #12, 3/4 hose (located at manifold block) Load sense = #4 JIC = 1/4 hose (Used for closed center system only) Pressure relief/case drain = #6 JIC = 3/8 hose Hydraulic suction = Standard, #16, 1 hose STANDARDS GUIDELINES Hydraulic pressure relief factory set at 3200 psi. PAGE - 10 Manual # Rev.0

17 SECTION 3: INSTALLATION 3.5 INSTALLATION MACHINE LOCATION It is vital to locate the machine so that there is no restriction of cooling air through the enclosure (Refer to Figure 3-2). Cooling air enters the enclosure at the rear (cooler) package end of the machine, passes through the cooler and exits through vents in the upper sides and the front CLEARANCES A KEY A B C D E Refer to Figure 3-2. Ensure that adequate surrounding clearance space exists around the machine to allow for adequate cooling ventilation through the canopy shroud, unobstructed service access, and a clear B DESCRIPTION BACK SIDE CLEARANCE = 10 MINIMUM LEFT SIDE CLEARANCE = 10 MINIMUM FRONT SIDE CLEARANCE = 10 MINIMUM I RIGHT SIDE CLEARANCE = 10 MINIMUM TOP SIDE (OVER HEAD) CLEARANCE = MINI- MUM, FOR (OPENED) HOOD ACCESS I The front (control panel) side may need additional clearance for both access to the service panel there, and/or access to view the controller panel. Figure 3-2: Minimum Installation Clearances C E D view of the control panel. An approximate recommendation of ten (10) inches clearance, minimum, is needed for proper cooling circulation, plus any additional service access room included where needed MOUNTING Mounting surface or support should be adequate for the weight of the machine (196 lbs.), and should be level for normal operation. Mounting holes are located in the frame footing for four (4) 1/2 hold down bolts SERVICE CONNECTIONS Refer to Figure 3-3A through 3-3D. Service connections are conveniently grouped at the lower rear section of the unit in the base frame ELECTRICAL CONNECTIONS Refer to Figure 3-3A through 3-3D. This system is offered with either 12V DC or 24V DC circuits HYDRAULIC SUPPLY CIRCUIT Refer to schematic drawings in Sections 7.15A through 7.15D. It is recommended that the compressor unit possesses a separate pump/flow/return hydraulic circuit to other hydraulic equipment. This is to prevent the possibility of pressure/flow drops that may occur if other hydraulically-powered equipment is activated during compressor operation, which may in turn, cause the compressor to stall out. Alternatively, use of a diverter valve will permit hydraulics to power different equipment selectively ROUTING Refer to Figures 3-3A through 3-3D, and the wiring diagram. Ensure that all supply hoses and electrical wiring are correctly specified, adequately supported, and do not touch or rest on any sharp edges. Wiring should be protected with split loom to prevent corrosion, and consequently, loss due to down time. Manual # Rev.0 PAGE - 11

18 SECTION 3: INSTALLATION IMT CAS45RS AND CAS45RS-CW DISCLAIMER If machine package is to be mounted within a confined space such as beneath a canopy, the unit must have a minimum of ten (10) inch clearances on the front and back sides for ventilation ID_r1 Figure 3-3A: Dimension Diagram - CAS45RS Open Center Without Thermal Valve PAGE - 12 Manual # Rev.0

19 SECTION 3: INSTALLATION DISCLAIMER If machine package is to be mounted within a confined space such as beneath a canopy, the unit must have a minimum of ten (10) inch clearances on the front and back sides for ventilation ID_r1 Figure 3-3B: Dimension Diagram - CAS45RS Open Center With Thermal Valve Manual # Rev.0 PAGE - 13

20 SECTION 3: INSTALLATION IMT CAS45RS AND CAS45RS-CW BLANK PAGE PAGE - 14 Manual # Rev.0

21 SECTION 4: OPERATION SECTION 4: OPERATION 4.1 GENERAL INFORMATION A comprehensive array of controls and safety systems are built into the CAS45RS hydraulic compressor system. Refer to Figure 4-1 for a general overview to identify and locate the system s main components. Becoming familiar with the functional instrumentation, as given in Section 4.2, Purpose of Controls, will help the operator recognize and interpret the readings or malfunctions which will call for service or indicate the beginning of a problem. IMPORTANT If start-up and shut-down procedures are not followed, damage to the system and its components may occur. 4.2 PURPOSE OF CONTROLS CONTROL OR INDICATOR Discharge Air Pressure Screen Discharge Air Temperature Screen Hour Meter Screen Fault Reset Screen Oil Fill/Level Plug Minimum Pressure/Check Valve Pressure Transducer Inlet Solenoid Valve Air Inlet Valve Hydraulic Pressure Relief Valve Hydraulic Solenoid Valve Air Pressure Relief Valve PURPOSE Continuously monitors service line discharge air pressure. Will activate shutdown if over-pressure occurs. Continuously monitors service line discharge temperature. Will activate shutdown if over-temperature occurs. Indicates accumulated hours of operation for planning and logging service schedules. Fault message appears if over temperature or over pressure condition is encountered. Button must be pressed to clear. Check/fill compressor oil level. Maintains minimum operating pressure and prevents back flow when unloaded/shutdown. Controls operating pressure; prevents loaded start. Opens/closes inlet valve in response to pressure transducer. Opens/closes in response to air demand and acts as check valve upon unload/ shutdown to prevent oil blow back into filter. Relieves hydraulic pressure to return line in event of hydraulic over-pressure condition. Responds to activation circuit to direct flow to compressor motor or to return line. Opens sump pressure to atmosphere in case of air over-pressure condition. Manual # Rev.0 PAGE - 15

22 SECTION 4: OPERATION IMT CAS45RS AND CAS45RS-CW A B N Q R P S COVER REMOVED FOR CLARIT Y C D E G F H J K L M Z Y X W V U E T KEY DESCRIPTION KEY DESCRIPTION A COOLER AND FAN ASSEMBLY N CONTROLLER MODULE B COMPRESSOR SEPARATOR ELEMENT P COMPRESSOR AIR FILTER HOUSING C RELAY Q COMPRESSOR PRESSURE RELIEF V ALVE D MINIMUM PRESSURE VALVE R DRIVE COUPLING ELEMENT E PRESSURE TRANSDUCER (x 2) S LIFTING BAIL F THERMAL VALVE ASSEMBLY I T COMPRESSOR OIL FILTER ELEMENT G AIR INLET CONTROL SOLENOID U COMPRESSOR OIL FILL PORT / CAP H COMPRESSOR SIGHT GLASS V CONTROLLER DISPLAY PANEL J COMPRESSOR UNIT W COMPRESSOR OIL DRAIN K HYDRAULIC MOTOR X HYDRAULIC OIL RETURN (TO TANK) L SOLENOID (12V or 24V) Y HYDRAULIC MOTOR CASE DRAIN M DISCHARGE AIR OUTLET Z HYDRAULIC OIL SUPPLY (TO MOTOR) I Thermal valve is included only with specified thermal valve option machines. Figure 4-1: Main Machine Component Locations PAGE - 16 Manual # Rev.0

23 SECTION 4: OPERATION 4.3 NORMAL OPERATION Following is an overview of the normal operation of the IMT CAS45RS hydraulic compressor system from start-up to shutdown. This overview of a typical sequence of events may not cover all situations INITIAL START-UP PROCEDURE: PRE-CHECKS KEY A B C IMPORTANT If start-up and shut-down procedures are not followed, damage to the system and its components may occur. Following are step-by-step instructions for the initial start-up of the CAS45RS hydraulic compressor system: 1. Ensure the compressor is positioned on a level surface so that the proper amounts of oil can be added, if required. 2. Unit should be bolted down. WARNING Do not rely on hoses to hold the module in position. 3. Ensure all hose connections are tight and wiring connections correct and tight. B C DESCRIPTION RED COMPRESSOR FILL CAP FILL CAP BLEED VENT GROOVE Open/crack cap slightly to allow bleed vent to relieve pressure A Figure 4-2: Pressure Relief 4. Check compressor oil level (refer to Figures 4-2 and 4-3). NOTE An alternate compressor oil level check can be accomplished via the compressor sight glass. Refer to Table 5A, Key #1, in Section 5, Maintenance for details. WARNING DO NOT remove caps, plugs and/or other components when compressor is running or pressurized. Stop compressor and depressurize system prior to maintenance of system. Relieve the entire system pressure by opening the service valve, which will vent all pressure to the atmosphere. Wear personal protective equipment such as gloves, work boots, and eye and hearing protection as required for the task at hand. Add or drain if necessary to accomplish the recommended compressor oil level. 5. Ensure hydraulic oil to pump inlet, and prime if necessary. 6. Ensure service valve on compressor is closed. 7. Engage hydraulic system (PTO or hydraulic supply) and allow hydraulic oil to circulate back to tank. When solenoid is activated, oil should quickly circulate to the hydraulic motor on the compressor, and start producing air. 8. Check for leaks. 9. Refer to Figure 4-5. Press the START button on the Controller, and wait for the Main Screen (default is the Pressure Screen). Check pressure and temperature screens. Pressure may need adjustment to achieve desired operating pressure. Refer to Section 5, Table 5A: Routine Maintenance Schedule. 10. Partly open service valve to load compressor and allow to warm up. Monitor temperature; The ideal Manual # Rev.0 PAGE - 17

24 SECTION 4: OPERATION IMT CAS45RS AND CAS45RS-CW 12. Close service valve. B E C A 13. Disengage hydraulic system. 14. Allow all air to vent to atmosphere. Check compressor oil level and top off if necessary. Inspect for and correct any leaks; tighten any loose fittings ROUTINE START-UP PROCEDURE D IMPORTANT KEY A B DESCRIPTION COMPRESSOR OIL FILL CAP (RED) OIL FILL PORT (cut-away view with cap removed) If start-up and shut-down procedures are not followed, damage to the system and its components may occur. C D E HIGH LEVEL MARK (top of thread/port) LOW LEVEL MARK (bottom thread of port) I ACCEPTABLE OIL LEVEL RANGE I When level is low, add oil as needed. NOTE: DO NOT mix different types of oil; mixing different types of oil will void the warranty. For complete oil change maintenance, refer to Table 5A in Section 5, Maintenance. Figure 4-3: Compressor Oil Check operating temperature should be between 180 F (82 C) and 220 F (104 C); approximately 100 degrees over ambient temperature. NOTE: May be higher in high ambient conditions. 11. Cycle compressor on/off with service valve to ensure operation is working. 1. Ensure the compressor is positioned on a level surface so that the proper amounts of oil can be added, if required. 2. Close the air service valve. 3. Engage the hydraulic system (PTO or hydraulic supply). This will activate the compressor. 4. Allow machine to warm up for several minutes before operating ROUTINE SHUT-DOWN PROCEDURE IMPORTANT If start-up and shut-down procedures are not followed, damage to the system and its components may occur. A B C D E F G H KEY DESCRIPTON PURPOSE A DISPLAY SCREEN Displays functional attributes of chosen controller task. B START BUTTON Starts the machine. C STOP BUTTON Cuts off power / stops the machine immediately. D NAVIGATION PAD Where applicable, allows for sub-navigation on multiple line function screens. E DATA BUTTON Shows the Data screen on the display. F ESCAPE BUTTON Takes the operation back to the initial start screen (see Figure 4-5). G OK CONTROL Takes the operation back to the initial start BUTTON screen (see Figure 4-5). H LED INDICATOR When lit (green) indicates panel is in operating state. Figure 4-4: Operation Control Panel PAGE - 18 Manual # Rev.0

25 SECTION 4: OPERATION A B 1 MAIN (DEFAULT) SCREEN KEY SCREEN DESCRIPTION A INITIAL SCREEN PRE-SCREEN: This automatic screen appears when the controller is first initiated. It remains for a few seconds, then changes to the Controller Revision Screen. B CONTROLLER REVISION SCREEN PRE-SCREEN: This screen shows the current version of the Display and Controller software. It remains for a few seconds, then changes to the Main Screen. 1 MAIN SCREEN This is the default screen (Pressure Screen). It shows the current pressure status of the machine. Pressing ESC from any other screen will bring this screen up. 2 SETTING ADJUSTMENT DISPLAY SCREEN 3 CUT-IN/CUT-OUT PRESSURE SCREEN This screen displays information; it is not possible to make adjustments from this screen. This screen shows, and allows the operator to change, the preset cut-in and cut-out pressures for the range of operation. 4 SERVICE CONTACT SCREEN This screen shows the support phone number to contact the IMT Service Department. 5 TEMPERATURE SCREEN This screen shows the current (running) temperature of the machine Figure 4-5: Controller Screen Identification and Navigation Manual # Rev.0 PAGE - 19

26 SECTION 4: OPERATION IMT CAS45RS AND CAS45RS-CW IMPORTANT Do not stop the engine suddenly! Stop the engine after approximately five (5) minutes of unloaded idling. 1. Close service valve. 2. Allow compressor system to unload and cool down for approximately five (5) minutes. 3. Shut off hydraulic power supply OPERATING CONDITIONS 1. Operate only in well-ventilated areas. 2. Ensure there are no obstructions of cooling air intakes and outlets around the machine. 3. Do not leave anything resting on top of the machine. Hot cooling air will generate high heat and must not be restricted. 4. Operate machine with the top cover closed. 5. Refer to specifications for operating parameters EXTREME CONDITION OPERATION When operating in extreme hot or cold conditions, extra attention should be given to any indications that could lead to a serious problem. Machine review and maintenance check schedules should be more frequent than the normal suggestions given in Section 5, Table 5A: Routine Maintenance Schedule. IMPORTANT Be sure to leave sufficient room around the machine for cooling air circulation during operation. There must be a minimum of ten (10) inches for the cooler intake, and ten (10) inches for the sides and rear. Heated air must be able to vent away from the intake. PAGE - 20 Manual # Rev.0

27 SECTION 5: MAINTENANCE SECTION 5: MAINTENANCE 5.1 GENERAL INFORMATION A good maintenance program is the key to long compressor life. This section contains a program that, when adhered to, should keep the compressor in top operating condition. However, it should be understood that these intervals are for normal operation in a good clean environment. More frequent inspections, oil changes and general maintenance should be carried out in dusty environments, high ambient temperatures, heavy load applications or extended light load conditions. Follow the prescribed periodic maintenance schedules given in Table 5A: Routine Maintenance Schedule, in this section as recommended. Failure to follow the prescribed periodic maintenance at the recommended intervals will impair the package safety, performance characteristics, shorten the package s life, and will negatively affect the warranty coverage of the package. IMPORTANT It is important to keep in mind that operating the compressor package in a severe environment may require more frequent service intervals than prescribed in the periodic maintenance schedule. Before starting the compressor system, inspect the machine package for any suspect condition that may cause a safety hazard or hamper operation. Replace damaged components with Genuine IMT Replacement Parts. WARNING Follow all applicable safety recommendations as outlined in Section 1: Safety of this manual. WARNING DO NOT remove caps, plugs and/or other components when compressor is running or pressurized. Stop compressor and de-pressurize system prior to maintenance of system. Wear personal protective equipment such as gloves, work shoes, and eye and hearing protection as required for the task at hand. WARNING DO NOT work on any electrical components unless the battery is disconnected. WARNING Follow the prescribed periodic maintenance (PM) schedule as recommended. Perform the required PM schedule at recommended intervals. Failure to follow this prescribed periodic maintenance at the recommended intervals will impair the package safety, performance characteristics, shorten the package s life, and will negatively affect the warranty coverage of the package. CAUTION Compressors and drive motors generate heat and create hot surfaces. Use caution when operating or servicing the compressor system. Some surfaces and components may be hot. IMPORTANT It is important that the compressor oil be of the recommended type and that it is inspected and replaced together with the oil filter and air filters, and (when necessary) the coalescer separator in accordance with this manual. Manual # Rev.0 PAGE - 21

28 SECTION 5: MAINTENANCE IMT CAS45RS AND CAS45RS-CW IMPORTANT DO NOT mix oils of different types. Use only original IMT equipment filters. Mixing of different types of oils, or using non-imt equipment filters will VOID THE WARRANTY. 5.2 MACHINE MAINTENANCE SCHEDULE Refer to Table 5A: Routine Maintenance Schedule. A routine maintenance schedule based on time and/or hours logged, is given in Table 5A. The intervals are determined from machine usage under typical operation conditions. However, the operator must be aware that operating conditions will vary depending on such things as specific customer requirements, environmental temperatures and cleanliness of the ambient air. With this in mind, the specifications given in Table 5A should be used as a guideline instead of a fixed agenda. A safe approach to routine maintenance would be to perform the given maintenance task more frequently under harsher conditions. IMT provides a routine maintenance parts list in Section 7, Table 7A. Should a non-routine part need replacement or servicing, peruse the various parts list illustrations in Section 7 to help determine the exact part and part number in question. Our parts and service departments are ready to assist in identifying and/or replacing non-routine parts. For assistance in obtaining routine maintenance or replacement parts, consult Section 7.1, Parts Ordering Procedure, and Table 7A: Recommended Spare Parts List. 5.3 REPLACEMENT PARTS Replacement parts should be purchased through your local IMT representative or where the compressor system was purchased. If, for any reason, parts are not available in this manner, they can be purchased through IMT directly. NOTE For assistance when ordering new replacement parts, consult Section 7.1, Parts Ordering Procedure, and Table 7A: Recommended Spare Parts List. Iowa Mold Tooling Co., Inc. 500 Highway 18 West Garner, Iowa Phone: Fax: NOTE If additional spare parts are being stored for future use, make certain that they are stored in proper containers that allow for protection against contamination, and kept in a clean area of moderate temperature reading. For information on storing the machine package for periods of non-use, consult Section , Long Term Storage. PAGE - 22 Manual # Rev.0

29 SECTION 5: MAINTENANCE TABLE 5A: ROUTINE MAINTENANCE SCHEDULE WARNING Before performing maintenance: Shut down machine, relieve all system pressure and lock out all power, as per the Safety Section of this manual. If machine is hot, allow package to cool before removing any panel. NOTE THAT THE SYSTEM CAN BE STARTED REMOTELY: Always clearly tag the start-up instrumentation against accidental system. start-ups during maintenance. MAINTENANCE INTERVALS Hourly, Calendar Period or Controller Messagewhichever comes first TABLE 5B: ROUTINE REPLACEMENT KIT ORDER INFORMATION I KEY NO. DESCRIPTION PART NO. QTY 1 Oil, Rotary Screw Compressor (gallon) II Element, Replacement for Compressor Air Filter Element, Replacement for Compressor Oil Filter Element, Replacement for Compressor Separator I If working in dusty or dirty conditions, reduce the recommended time intervals between servicing by half for engine and compressor oil replacement, and engine and compressor filter servicing. II Use only IMT Rotary Screw Oil and Genuine IMT Parts. Substituting non-imt oil or non-imt genuine filter components will VOID THE COMPRESSOR WARRANTY! Inspect and replace damaged components before operation. Compressor system fill capacity is approximately four (4) quarts of oil. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE MACHINE SERIAL NUMBER. After 8 Hours or Daily After Initial 50 Hours After 500 Hours or Annually KEY TASK DESCRIPTION ACTION TO TAKE / REFERENCE 1 Before starting, check compressor oil level. CAUTION BEFORE REMOVING THE CAP: Pressure relief - In order to remove any residual air in the sump, first crack the fill cap [ ] slightly until the vent groove [ ] shows above the thread line of the cap for a few seconds. This will bleed any remaining air pressure to atmosphere. NOTE: Ensure vehicle is situated on a level surface before checking oil level. Add oil if necessary. REFERENCE: Optimal Oil Level [ ] I Oil Fill Port [ ] Sight Glass [ ] I Optimal oil level: AT PORT - lies in the area between the bottom of the threaded portion of the oil fill port and the edge of the oil fill port rim. AT SIGHT GLASS - lies between 1/4 and 3/4 intervals of the visible (glass) area; both give the same level of the sump. ORDER: Replacement oil no (gallon container). 2 Check for any leaks or loose bolts. 3 After starting, check pressure reading for correct operating pressure. 4 Check for leaks. 5 Inspect ventilation openings Tighten if necessary. Allow compressor to warm up, and verify that the levels are all within their recommended ranges. Refer to Section 2, Specifications, for pressure operating range. Visually note any leaks or evidence of leaks around the compressor unit and hose connections. Tighten any loose connection point where needed. Repair or replace any damaged part. Ensure openings are not blocked or clogged with debris. Clear any congestion from the machine ventilation areas before operating the machine. Continued on next page Manual # Rev.0 PAGE - 23

30 SECTION 5: MAINTENANCE IMT CAS45RS AND CAS45RS-CW TABLE 5A: ROUTINE MAINTENANCE SCHEDULE WARNING Before performing maintenance: Shut down machine, relieve all system pressure and lock out all power, as per the Safety Section of this manual. If machine is hot, allow package to cool before removing any panel. NOTE THAT THE SYSTEM CAN BE STARTED REMOTELY: Always clearly tag the start-up instrumentation against accidental system. start-ups during maintenance. MAINTENANCE INTERVALS Hourly, Calendar Period or Controller Messagewhichever comes first TABLE 5B: ROUTINE REPLACEMENT KIT ORDER INFORMATION I KEY NO. DESCRIPTION PART NO. QTY 1 Oil, Rotary Screw Compressor (gallon) II Element, Replacement for Compressor Air Filter Element, Replacement for Compressor Oil Filter Element, Replacement for Compressor Separator I If working in dusty or dirty conditions, reduce the recommended time intervals between servicing by half for engine and compressor oil replacement, and engine and compressor filter servicing. II Use only IMT Rotary Screw Oil and Genuine IMT Parts. Substituting non-imt oil or non-imt genuine filter components will VOID THE COMPRESSOR WARRANTY! Inspect and replace damaged components before operation. Compressor system fill capacity is approximately four (4) quarts of oil. PLEASE NOTE: WHEN ORDERING PARTS, INDICATE MACHINE SERIAL NUMBER. After 8 Hours or Daily After Initial 50 Hours After 500 Hours or Annually KEY TASK DESCRIPTION ACTION TO TAKE / REFERENCE 6 clean and inspect the compressor air intake filter REFERENCE: Air Filter Element [ ] Replace if membrane is worn, contains tears or pinholes, or if filter is damaged. For details on ordering and changing the compressor air filter, refer to Key #8 in this table. 7 Change compressor oil and oil filter element IMPORTANT Refer to the CAUTION note instruction in Key #1 before removing the fill port cap. NOTE: The compressor oil is the key to a long useful life of the air compressor system. Dirt and other foreign matter can be introduced into the compressor system through the air intake. A clean air filter will ensure that the compressor is protected. REFERENCE: Oil Filter Element [ ] Oil Filter Seal Ring [ ] Oil Level Sight Glass [ ] Oil Drain Hose [ ] Oil Fill Port [ ] Optimal Oil Level [ ] I I Optimal oil level: AT PORT - lies in the area between the bottom of the threaded portion of the oil fill port and the edge of the oil fill port rim. AT SIGHT GLASS - lies between 1/4 and 3/4 intervals of the visible (glass) area; both give the same level of the sump. ORDER: For initial 50 hour interval, order compressor oil filter replacement element no , and replacement oil no (gallon container). PROCEDURE CONTINUED ON NEXT PAGE... Continued on next page PAGE - 24 Manual # Rev.0