Electrical... 5 Start-up... 6 Digital Pressure Switch Programming and Instructions... 7 Maintenance... 8 PRODUCT NUMBERING SYSTEM PHASE SERIES

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2 TABLE OF CONTENTS Product Numbering System and Specifications... Safety... Receiving and Inspection... Installation... Electrical... 5 Start-up... 6 Digital Pressure Switch Programming and Instructions... 7 Maintenance... 8 Valves and Switches... 8 Air Compressor Basics... 8 Warranty... 9 Parts Diagram... 0 Troubleshooting...Back Cover INTRODUCTION The compressor you have purchased is a combination of nearly 00 different components, all of which have been carefully designed, engineered, and assembled to ensure a long, dependable, trouble-free life. The product has been fully tested at the factory and has gone through quality-control inspection prior to shipping. Like any mechanical piece of equipment, it is necessary to fully understand the proper use of its operation and application. Misuse of this valuable and helpful air-power source may shorten its expected life as well as void the warranty of the entire unit. We ask you take the time to read this manual to ensure the dependable service you can expect from your C-Aire compressor. Failure to do so can cause serious injury and may void all warranties. Please take special notice of the safety precautions and safety information contained in this manual. Compressed air, like electricity, is a very helpful and necessary tool. However, compressed air can be extremely dangerous and harmful when it is not understood or is misused. PRODUCT NUMBERING SYSTEM S6 R LD PD HD SD 300 LD 60 6 MOUNTING OPTIONS B: Baseplate H: Horizontal Tank V: Vertical Tank (Only on S500 and larger) R: Riser Mount SERIES HD: Heavy Duty (5,000+ hour life) SD: Standard Duty (5,000+ hour life) LD: Light Duty (,000+ hour life) PHASE : Single Phase 3: Three Phase VOLTAGE 5 (Available on S500 and smaller) 30 (08/30v) 60 ADDITIONAL OPTION P: Prewired Power Cord S: Prewired Magnetic Starter U: 30-0psi Adjustable Pressure Switch D: Digital Pressure Switch (Also available in PU and SU) Not all combinations are possible. SET PRESSURE IN SECONDS INCLUDES MOUNTING BRACKET AND 30 STEEL BRAIDED FLEX HOSE Listings: Pressure Switch: USA: UL 508 Canada: C. No. Compressor: USA: UL 50 3rd Edition Canada: C. No SPECIFICATIONS: HP SYSTEM CAPACITY PRESSURE SWITCH CFM PUMP CYLINDERS VOLTS PHASE RUNNING AMPS BREAKER SIZE OUTLET DIMENSIONS WEIGHT 0 PSI 6 GALLONS 0 PSI 5 GALLONS 0 PSI 00 GALLONS ADJUSTABLE: 5-55PSI FACTORY SET AT 5-0PSI MINIMUM DIFFERENTIAL: 5PSI CYLINDER, OIL FREE CERAMIC COMPOSITE AMP RECOMMENDED 3/ NPT 7 x0.5 x7 38 LBS.

3 SAFETY DEFINITIONS DANGER: Indicates a hazardous situation that, if not avoided, will result in death or serious injury. WARNING: Indicates a hazardous situation that, if not avoided, could result in death or serious injury. CAUTION: Indicates a situation that will or could cause minor injury or property damage. GENERAL PRECAUTIONS Read the Owner s Manual before operating. DANGER: Do not use compressed air for breathing air applications. Beware of high voltage: disconnect lockout/tagout electric supply before servicing. Ground compressor per codes. WARNING: Beware of high-pressure air: do not bypass, modify, or remove safety/relief valves. Beware of hot surfaces: allow unit to cool before servicing. Do not operate with safety guards removed. CAUTION: Never operate the compressor near flammable liquids or vapors. Do not direct the air stream at body. Drain tank air every day to decrease risk of bursting. NOTE: Per UL 50:6.7 C-Aire recommends a maximum of 70% duty cycle for its compressors. RECEIVING AND INSPECTION Upon receipt, inspect the unit for damage and missing parts. If either is apparent, make notations on the delivery receipt, before signing the receipt. Ask the carrier how to file a claim for shipping damages. If concealed damage is discovered (after receiving the unit), notify the carrier within 5 days of receipt, in writing. INSTALLATION SELECTING A LOCATION: C-Aire compressors are to be installed and operated in a clean, dry, well-lighted, and well-ventilated area. Mounts to risers.5 -, concrete or cinder block walls or studs on a drywall. Provide at least 00 cubic feet of fresh air per hp. Ideal operating temperatures are between 3 F and 00 F. Avoid excessively humid areas, as moisture may form in the pump, producing sludge and causing moving parts to wear prematurely. NOTE: The dry pipe/sprinkler system compressor is to be installed in accordance with the Standard for Installation of Sprinkler Systems, NFPA 3. CAUTION: If temperatures consistently drop below 3 F, install the compressor in a heated area. (INSTALLATION CONTINUED ON NEXT PAGE)

4 CAUTION: Never operate the compressor in temperatures below 0 F or above 0 F. WARNING: A compressor should never be used in an area where toxic, corrosive, or volatile agents may be present. MOUNTING THE COMPRESSOR CAUTION: Remove the compressor from the shipping packaging before mounting. CAUTION: Do not mount riser mount unit horizontally. MOUNT TO RISER. Install mounting bracket on riser. Hang unit on mounting bracket 3. Bolt unit to mounting bracket. Install air filter assembly 3 (INSTALLATION CONTINUED ON NEXT PAGE)

5 MOUNT TO CINDER BLOCK/CONCRETE WALL C-Aire compressors are to be installed and operated in a clean, dry, well-lighted, and well-ventilated area.. Hammer drill holes for hollow wall anchor. Put hollow wall anchor into holes 3. Tap hollow wall anchor into cinder block with hammer. Attach mounting bracket to wall with bolt and washer into anchor 5. Locate hangers on back of unit 6. Hang unit onto the mounting bracket 7. Slip bolt through unit to mounting bracket 8. Tighten bolt to unit and mounting bracket 9. Install air filter assembly (INSTALLATION CONTINUED ON NEXT PAGE)

6 MOUNT TO DRYWALL C-Aire compressors are to be installed and operated in a clean, dry, well-lighted, and well-ventilated area.. Attach xs to studs in drywall. Attach mounting bracket to wall with bolt and washer into anchor 3. Hang unit onto the mounting bracket. Slip bolt through unit to mounting bracket 5. Tighten bolt to unit and mounting bracket 6. Install air filter assembly INLET AND DISCHARGE PIPING CAUTION: Do not operate unit without inlet-air filtration. If the air is dirty, pipe the filter to a source of clean air. Do not install piping with a diameter lower than that of the pump intake. CAUTION: Do not use PVC plastic in the discharge line. Use hand-welded or threaded steel or copper pipes and cast-iron fittings that are safe for the discharge pressure and temperature. ELECTRICAL WARNING: Compressor installation must be performed by a qualified electrician in accordance with the National Electrical Code (NEC) or the Canadian Electrical Code (CEC), the National Electrical Safety Code (NESC) OSHA code, and/or any local or state codes having precedence. 5 Be sure of proper wire sizing and that the circuit breaker and the distance from the breaker is within suggested range. (ELECTRICAL CONTINUED ON NEXT PAGE)

7 Confirm your electrical-supply voltage matches what is required for the motor. WARNING: The compressor must be grounded. Grounding reduces the risk of electric shock. Certain C-Aire models are equipped with a cord that has a grounding wire with a grounding plug. The plug must be plugged into an outlet that is installed and grounded in accordance with all local codes and ordinances. WARNING: Improper installation of the grounding plug will result in a risk of electric shock. When repair or replacement of the cord or plug is required, do not connect the grounding wire to either flat-blade terminal. The insulated wire with a green outer surface and yellow stripes is the grounding wire. NOTE: The installation, electric motor, wiring, and all electrical controls must be in accordance with NFPA National Electric Code, National Electric Safety Code, and state and local codes. Failure to abide by the national, state, and local codes may result in physical harm and/or property damage. DANGER: High voltage may cause personal injury or death. Disconnect and lockout/tagout, per OSHA regulation 90.7, all electrical power supplies before opening the electrical enclosure or servicing. DANGER: Never assume a compressor is safe to work on if it is not operating. It could restart at any time. Always disconnect/ lockout/tagout before servicing. CAUTION: Dry pipe sprinkler compressor must be wired to a reliable power source to be compliant with NFPA 3. WIRE TO POWER SOURCE WIRE TO MOTOR WIRING DIAGRAM PRESSURE SWITCH WIRE COLOR CODE BLACK WHITE BLACK WHITE UNLOADER GROUND BLOCK RED BLACK WHITE BROWN BLACK WHITE PRESSURE SWITCH START UP NOTE: There is no need to break-in your compressor. It has been tested and run at the factory by qualified personnel. When operating the compressor for the first time, do the following:. Perform an inspection of the compressor to ensure there are no obstructions that might interfere with moving parts.. Release any remaining tank pressure by slowly opening the manual drain valve. 3. Connect the compressor to the power source (the compressor will start). (STARTUP CONTINUED ON NEXT PAGE) 6

8 DIGITAL PRESSURE SWITCH PROGRAMMING AND INSTRUCTIONS. SCREEN DISPLAY/OPERATION When the air compressor is first powered on, PSI light is illuminated, press the MODE button. SCREEN DISPLAY/SETTING PRESSURE Use these three buttons to set maximum and minimum pressure: A. MODE B. UP ARROW C. DOWN ARROW STEP : Press the MODE button once, the number will display on the screen. You can now set the maximum pressure you would like using the UP ARROW button or DOWN ARROW button. The maximum pressure is displayed on the screen. The setting range is: 0-55psi. STEP : Press the MODE button again, the number will display on the screen. You can now set the minimum pressure you would like using the UP ARROW button or DOWN ARROW button. The minimum pressure is displayed on the screen. The setting range is: 5-50psi. There is a 5psi differential on the settings so if you would like to change maximum/minimum pressure settings, change the low or minimum pressure setting first and then set the high or maximum pressure. Otherwise the 5psi differential will not allow you to change the pressure settings. EXAMPLE: The maximum pressure setting is set at psi and the minimum pressure is set at 7psi. If you wish to change the maximum pressure to 0 and minimum pressure to 5. Press the mode button until you see the number and minimum pressure of 7 on the screen. Change the setting to 5 using DOWN ARROW button. Next press the MODE button once again to see the number and maximum pressure of on the screen. Use the DOWN ARROW button to change the setting to 0. If you try to set the maximum pressure first the digital pressure switch will not allow you to change the number to 0 because that would cause the drop to be below the 5psi differential. THE COMPRESSOR WILL BEGIN RUNNING WITH YOUR PRESSURE SET RANGE.. LOCKING/UNLOCKING THE PRESSURE SETTINGS When you have the maximum and minimum pressure set to numbers you want, you can lock the settings so they cannot be changed. A. Press and hold for 5 seconds, both the MODE button and MINIMUM PRESSURE button simultaneously. B. The SETTINGS LOCKED button will light up. C. The settings are now locked. To unlock the maximum and minimum pressure settings so they can be changed. A. Press and hold for 5 seconds, both the MODE button and MINIMUM PRESSURE button simultaneously. B. The SETTINGS LOCKED button will become unlit. C. The settings are now unlocked. D. Proceed with STEP and STEP above. 3. DISPLAY RUNNING AMPS A. Press the UP ARROW button once. The running amps will display (the compressor must be running to see the correct amps).. DISPLAY VOLTS A. Press the UP ARROW button once. The volts will display. 7

9 MAINTENANCE WARNING: Before performing maintenance, release air pressure from the system and disconnect/lockout/tagout the main power supply. WEEKLY MAINTENANCE Drain moisture from your air compressor s tank WEEKLY! CAUTION: Open the drain valve slowly to release the moisture, as pressure in the tank can cause the moisture to expel at very high velocity. Check for any unusual noises, vibrations, or permanent leaks from the unloader valve. BIANNUAL MAINTENANCE TURN OFF POWER, and check and tighten all electrical connections. Change air-intake filter(s). Check to make sure all bolts are tight. VALVES AND SWITCHES AIR COMPRESSOR BASICS Best practices: Tank mounted, direct driven compressors Tank mounted = reserve supply of air Air Source Adjustable: 5-55psi System pressure varies depending on size of system Digital Pressure Switch Eliminates The Need For Air Pressure Maintenance Device Low Pressure Dry Pipe Valve Water in system 8

10 WARRANTY C-Aire Inc. warrants its compressors to be free from defects in material and workmanship subject to the following provisions: STANDARD WARRANTY DURATION: months from date of purchase. WHAT THE WARRANTY COVERS DURING THE WARRANTY DURATION: All components on the compressor except for those items listed in the section titled What is excluded from warranty coverage. WHAT IS EXCLUDED FROM THE WARRANTY COVERAGE: A) Air intake filters and compressor oil, which are maintenance items. B) Failure due to improper installation, including absence of mounting pads, and insufficient power. C) Oil leaks will be covered under warranty for a period of 60 days from purchase. D) Freight damaged items. (REJECT THE SHIPMENT or note damage on Bill of Lading) E) Any labor, freight or transportation charges that are not pre-approved by C-Aire. F) Labor charges incidental to the installation, electrical connections, repair, service, adjustment, removal, or replacement. G) Misuse or abuse. H) C-AIRE HAS NO OBLIGATION UNDER THESE WARRANTIES OR OTHERWISE (REGARDLESS OF THE FORM OF ACTION) FOR SPECIAL, INDIRECT, CONSEQUENTIAL OR INCIDENTAL DAMAGES, INCLUDING WITHOUT LIMITATION, LOSS OF USE, LOST PROFITS, LOST INCOME, WHETHER SUFFERED BY THE BUYER OR A THIRD PARTY. HEAVY DUTY SERIES WARRANTY: C-Aire warrants its compressor pumps from the Heavy Duty Series (noted by the HD in its part number) to be free from defects in material and workmanship for a period of 36 months from the date of purchase. The 3 year warranty for HD units only covers the compressor pump. All other components are covered under the Standard Warranty Duration, which is months from date of purchase. C-AIRE S OBLIGATIONS: C-Aire will repair or replace, at C-Aire s option, defective parts, pay reasonable labor costs of replacing or repairing the defective part, and pay ground freight for the return of defective parts and shipment of the replacement part(s). ALL LABOR AND FREIGHT MUST BE PRE-APPROVED AND ARRANGED BY C-AIRE. PURCHASER S OBLIGATION: ) Properly install and start up the compressor using the checklist located at the back of this Owner s Manual. (Keep Installation Checklist for future reference.) ) Ensure the compressor is sized properly for the application. (the compressor should run no more than 30 minutes/day on average after initial system fill.) 3) Maintain proof of purchase and Installation Checklist. WARRANTY CLAIMS: Please contact C-Aire at or Please have your completed Installation Checklist available. 9

11 ITEM NO. PART NO. RM 60R-000 RM 60R RM 60R-0003 RM 60R RM 60R RM 60R RM 60R RM 60R RM 60R RM 60R-000 RM 60R-00 RM 60R-00 3 RM 60R-003 RM 60R-00 5 RM 60R RM 60R RM 60R RM 60R RM 60R RM 60R-000 RM 60R-00 RM 60R-00 3 RM 60R-003 RM 60R-00 5 RM 60R RM 60R RM 60R RM 60R RM 60R RM 60R RM 60R RM 60R RM 60R RM 60R RM 60R RM 60R RM 60R RM 60R RM 60R RM 60R-000 RM 60R-00 RM 60R-00 3 RM 60R-003 RM 60R-00 5 RM 60R RM 60R RM 60R RM 60R RM 60R RM 60R RM 60R RM 60R RM 60R RM 60R RM 6R RM 6R RM 6R RM 6R RM 6R RM 6R RM 6R RM 6R RM 6R RM 6R RM 6R EL D RM 6R RM 6R RM 6R RM 6R-0076 ITEM NO Description QTY Plastic Cover Filter Cover Filter Element Filter Base O Ring ø5 Gasket Pipe Hexagon Socket Screw Cylinder Head Gasket M*8 Screw Locking Block Valve Plate Valve Disc Valve Plate Washer M*8 Screw O Ring Cylinder M6*6 Screw ITEM NO Air Compressor Exploded Parts Diagram S6R-LD-5PD Description QTY ITEM NO. Description QTY ITEM NO. Description QTY Pressure Plate Piston Ring Connecting Rod Bearing Hexagon Socket Screw Crankcase Bushing Capacitor M*60 Stud ø Spring Washer Protecting Cover Self-tapping Screw Fan Blade ø Outside Spring Crank Throw Stator Capacitor Cover Power Cord Metal Hose Check Valve Safety Valve Strain Relief Drain Valve Hex Screw Washer Mounting Plate Nut Vibration Dampener Washer Nut Connection Box Connection Box Cover Bolt M* Flat Washer ø Terminal Screw Elbow Bolt M*0 Flat Washer ø Round Bolt M8*0 Flat Washer ø Wiring Terminal Digital Pressure Switch Solenoid Valve Studs M*6 Tank Mounting Bracket Rotor Bearing ø5 Outside Spring M*0 Screw 0

12 - Compressor will not operate - Knock occurs while compressor is loading - Tank does not hold pressure when compressor is turned off - Tank pressure builds up slowly - Fuses or breaker trip - Reset mechanism cuts out repeatedly. Fuses of proper size blow. TROUBLESHOOTING - No electrical power - Loose wire connections - Pressure switch not making contact - Overload/stripped - Connection rod bearings - Wrist pins, wrist pin bearings - Loose connecting rod nut - Suction and discharge valves - Check all fittings - Make sure Petcock is closed - Faulty Check Valve - Dirty air filter - Blown cylinder head gasket - Worn or broken suction/discharge valves - Air leaks - Wrong size fuses or breaker - Wrong size wire - Motor starting under load - Loose wires - Compressor is being overworked - Variable overload on compressor started needs adjusting - Motor overload - Malfunctioning or improperly adjusted pressure switch or pilot valve - High ambient temperature - Turn on power - Tighten connection - See pressure switch adjustment - Reset overload - Replace rod - Replace complete piston assembly - Tighten - Replace Valves - WARNING: Bleed tank. Disassemble Check Valve assembly, clean or replace faulty parts. - DANGER: Do not disassemble Check Valve with air in tank - Clean or replace filter element - Install new gasket - Install new valve - Tighten joints - Check fuse/breaker size - Check volts/amps - Make sure pump is unloading when compressor shuts off - Check electrical connections - Compressor should not run more than 6 out of 0 minutes on average - Call C-Aire - Shut down immediately to avoid damage - Adjust or replace - Provide ventilation - Overheating compressor - Poor ventilation - Relocate compressor - Internal pump problem - Have unit serviced - Water in air receiver - Condensation in the air receiver - Drain daily or install an Automatic Tank Drain MODEL SERIAL # MFG. # Make a permanent record of the Model and Serial Number of your compressor by filling in the fields above. You ll save time and expense by including this reference identification on replacement part orders. 380 West st Street, Dresser, WI 5009 // // //