TECH WEST INC. Manufacturers of Dental Vacuum and Air Systems 2625 N. Argyle Ave. Fresno, CA 93727 (559) 291-1650 (800) 428-7139 FAX (559) 348-9677
ULTRA CLEAN OILLESS COMPRESSOR INSTALLATION AND SERVICE MANUAL TECH WEST INC. Manufacturers of Dental Vacuum and Air Systems 2625 N. Argyle Ave. Fresno, CA 93727 (559) 291-1650 (800) 428-7139 FAX (559) 348-9677
ULTRA CLEAN OILLESS COMPRESSOR INSTALLATION AND SERVICE MANUAL This manual is for the installation and service of Tech West s Ultra Clean Oilless Compressors. CONTENTS Installation Location Requirements 1 Figure 1: Wire and Breaker Sizes 1 Ultra Clean Oilless Installation Steps 2 Ultra Clean Oilless Compressor Connections 3 Ultra Clean Oilless Start Up 4 Ultra Clean Oilless Maintenance 5 Ultra Clean Oilless Compressor Motor Assembly Breakdown 6-8 Desiccant Dryer Parts Breakdown 9-10 Gauge and Moisture Indicator Assembly Breakdown 11 Single Ultra Clean Oilless Compressor Assembly 12 Dual Ultra Clean Oilless Compressor Assembly 13 Triple Ultra Clean Oilless Compressor Assembly 14 TROUBLE SHOOTING Single Compressor Trouble Shooting 15-16 Dual Compressor Trouble Shooting 17-18 Triple Compressor Trouble Shooting 19-20 Air Line Sizing Chart 21 Maintenance & Service 22-23 Notes Sheet
ULTRA CLEAN OILLESS COMPRESSOR INSTALLATION 1. OILLESS COMPRESSOR LOCATION REQUIREMENTS The Ultra Clean Oilless Compressor location should be level, accessible and well ventilated. If the Ultra Clean Oilless Compressor will be located in a confined space, provide adequate ventilation. Electrical (1) Line voltage must be within the limits of Figure 1 below. (Install a buck-boost transformer if line voltage is not between these values.) Provide a separate line for each motor. Circuit breaker switches must be 20-40 amp depending on model and voltage necessary. (2) Local code may require you to provide one quick disconnect (safety switch) for each compressor motor. (3) See Figure 1 below for breaker size and line voltage. CAUTION - Voltage must be 208/245 V or motor damage may occur. CAUTION - Voltage must be 110/120 V or motor damage may occur. Figure 1: Recommended Wire and Breaker Size Model Voltage Amperage Wire Size Recommended (Gauge) Breaker Size Single Head Compressors ACO2S1 110/115 14.5 12 20 ACO2S2 208/230 7.2 12 20 ACO4S2 208/230 12.3 12 20 Dual Head Compressors ACO4D2 208/230 14.4 10 30 ACO8D2 208/230 24.6 10 30 Triple Head Compressors ACO6T2 208/230 21.6 10 30 1
2 ULTRA CLEAN OILLESS COMPRESSOR INSTALLATION 2. INSTALLATION STEPS This dental Compressor should only be installed by qualified personnel. Should any questions arise during the installation, call Tech West Technical Support between the hours of 7:00 a.m. to 4:00 p.m. (Pacific Standard Time). Place the compressor in a clean, dry, well ventilated area, on a solid, level surface. Consider sound level and insulate as needed. Be sure that adequate ventilation is available as the compressor is air cooled. Ambient temperature in the equipment room should be within the temperature range of 40 degrees Fahrenheit minimum to 100 degrees Fahrenheit maximum. (a) Check the shipping carton for damage. This could detect damage to the unit which might otherwise be overlooked. Remove cardboard shipping carton. (b) Remove the Oilless Compressor from its shipping skid. Inspect the unit for damage. Oilless Compressors are shipped bolted to a pallet. This pallet is intended for shipping only and should be discarded. (c) Remove installation kit attached to pallet. It should contain the following: (4) Isolation Feet (1) Alternate Air Hookup Hose (1) 6 Flexible Air Hose (d) Install isolation feet on tank legs. (e) Move compressor into place and level by observing bubble level on compressor platform. (f) Wiring instructions: (1) Have all electrical connections made by qualified personnel only. All connections should be in accordance with local codes. (2) Use the chart on page 1 to help determine the proper line and breaker size for the unit that is being installed. (g) Install the air line from the compressor tank to the building supply. (h) Install the 3/4 flex alternate air hose from the compressor to a fresh air supply. 2
2 ULTRA CLEAN OILLESS COMPRESSOR INSTALLATION 3. CONNECTIONS Figure 2 Electrical Connection to disconnect and electrical panel 220 v (110 v / 220 v ) on the single models only Dryer Purge Connection Air Out Connection to building supply line Alternate Air Connection to fresh air supply 3
2 ULTRA CLEAN OILLESS COMPRESSOR INSTALLATION 4. SAFETY PRECAUTIONS Keep fingers, foreign objects and clothing free from rotating parts and do not touch hot surfaces. Never attempt to service an operating unit. Isolate unit from system pressure and relieve backpressure before servicing Disconnect all power before servicing. The thermal protector in single phase motors automatically starts motor when device resets. USE OF THIS PRODUCT IN OR NEAR EXPLOSIVE ATMOSPHERES, OR FOR PUMPING MIXTURES OTHER THAN ATMOSPHERIC AIR MAY CAUSE AN EXPLOSION OR FIRE, RESULTING IN PERSONAL INJURY OR DEATH. 2 5. START-UP STEPS (a) Make sure the shut-off valve from the compressor tank is closed. (b) Turn the breaker from the panel to the ON position. (c) Turn power ON from the toggle switch on the compressor. Compressor should run quietly and vibration free. The storage tank should start to build pressure. (d) The compressor will run until the pressure gauge reads 100 psi. The compressor then will automatically shut off and the dryer will purge with a quick blast of air. (e) Using soapy water, check the compressor plumbing hook ups for leaks. Repair leaks if needed. (f) Pressure test the entire plumbing system for leaks. Use the storage tank pressure gauge to monitor a pressure drop. After the plumbing system has been pressurized for 30 minutes, re-check the gauge for pressure drop. If there is a drop in pressure, find and repair all leaks in the office plumbing. (g) Complete and mail in the warranty card for the compressor within ten days of installation. AIR LEAKS ARE THE MAIN CAUSE OF COMPRESSOR FAILURES. 4
2 ULTRA CLEAN OILLESS COMPRESSOR INSTALLATION 6. GENERAL SERVICE INFORMATION For parts and service on VX series products contact the nearest authorized Tech West distributor. To expedite appropriate service, be prepared to provide the unit model number, identification number, and serial number found on the nameplate located on the front of the unit motor. Component life operating at continuous duty & maximum pressure Life of the rings and skirts is difficult to predict due to many conditions which directly influence wear. Some of these conditions may include ambient air temperature, air cleanliness, operating pressure, piston stroke on the particular model being utilized, duty cycle, maintenance of filters, etc. Because of these various factors it is appropriate to generalize on component wear life and choose some conservative estimates for most standard applications. With these conditions in mind, we recommend the following preventative maintenance schedule. RECOMMENDED MAINTENANCE FOR VX MODELS Minor Service Kits, Piston Rings & Springs, Skirts, Etc. Major Replacement Kit, Piston & Rod Assemblies Replace inlet Filter HOURS Cont. Duty Maximum Pressure 8,000 Hours 12,000 Hours 4,000 Hours TIME Based on 100% Duty Cycle 12 months 18 months 6 months 7. PERIODIC SERVICING MONTHLY SERVICING (a) Remove the purge bucket and empty as needed (b) Crack the drain petcock on the bottom of the storage tank to check for water and drain if needed. (c) Check moisture indicator to see that it is still BLUE. If it is pink, it is time to service the air dryer. (d) Check pump-up times of the compressor. (e) Check intake air supply filters. Replace filters as needed. YEARLY SERVICING (a) Repeat all of the monthly servicing. (b) Replace the dessicant in the air dryer. (c) Replace the alternate air filter. (d) Replace the intake filters on the Oilless compressor head. (Part #s (1HP: TIF-100) (2HP: TIF-200)) (e) Replace the moisture indicator on the compressor. (Part #: MI -100) (f) Check the coalescing filter and change if needed. (Part #: CFE-375) 5
ULTRA CLEAN OILLESS COMPRESSOR PARTS LIST OIL-FREE COMPRESSOR MOTOR 1HP KEY PART. DESCRIPTION UNIT 1 TOM-1-115 OILLESS COMPRESSOR MOTOR 1HP 115V 1 2 TOM-1-230 OILLESS COMPRESSOR MOTOR 1HP 230V 1 3 TFF-100 FRONT FAN ASSY. 1 HP 1 4 TFC-100 FRONT FAN COVER 1 HP 1 5 TPA-100 PISTON ASSEMBLY COMPLETE 1 HP 1 6 TCA-100 CYLINDER ASSEMBLY COMPLETE 1 HP 1 7 TAF-100 AIR FILTER ASSEMBLY COMPLETE 1 HP 1 8 TIF-100 AIR FILTER ELEMENT ONLY H HP 1 9 POVA-100 POP OFF SAFETY VALVE 1 OIL-FREE COMPRESSOR MOTOR 2HP KEY PART. DESCRIPTION UNIT 9 POVA-100 POP OFF SAFETY VALVE 1 10 TOM-2-230 OILLESS COMP MOTOR 2 HP 230V 1 11 TFF-200 FRONT FAN ASSY 2 PH 1 12 TFC-200 FRONT FAN COVER 2 HP 1 13 TPA-200 PISTON ASSEMBLY COMPLETE 2 HP 1 14 TCA-200 CYLINDER ASSEMBLY COMPLETE 2 HP 1 15 TAF-200 AIR FILTER ASSEMBLY COMPLETE 2 HP 1 16 TIF-200 AIR FILTER ELEMENT ONLY 2 HP 1 6
8 7 6 9 5 2 1 3 4 OIL-FREE COMPRESSOR 1HP 7
15 16 9 14 13 10 11 12 OIL-FREE COMPRESSOR 2HP 8
3 6 5 2 4 1 7 REAR VIEW ASSEMBLY AND PARTS LIST KEY PART. DESCRIPTION UNIT 1 CV-375 3/8 CHECK VALVE 2 2 CPT-100 COMPRESSOR PURGE TANK 1 3. CV-250 1/4 CHECK VALVE 1-3 4 HA-10-250 1/4 HOSE ASSEMBLY - 10 LONG 1 5 DPC-1 DRYER PRE COOLER SINGLE COMPRESSOR 1 6 DPC-2 DRYER PRE COOLER DUAL & TRIPLE COMPRESSOR 1 7 RFV-100 RUBBER MOUNTING FEET 4 9
5 NEW DESICCANT AIR DRYER ASSEMBLY 3 9 2 1 6 7 9 4 KEY PART. DESCRIPTION UNIT 1 DSV-115 115V PURGE SOLEID VALVE 1 2 DSV-230 230V PURGE SOLEID VALVE 1 3 AS-500 1/2 FILTER ASSY 1 4 RDC-100 REPLACEMENT DESSICANT TANK 1 5 MV-250 METERING VALVE 1 6 SN-250-CL STAINLESS STEEL NIPPLE 1/4 3 7 FE-4-6 FLAIR FITTING 1/4 X 3/8 1 8 VB-250 BALL VALVE 1/4 1 9 BT-250 BRASS TEE 1/4 2 10 PFE-4-2 POLY FLO FITTING 1 11 MSD-100 MOLECULAR-SIERE 1 LB 2 12 MSD-200 ACTIVATED ALUMINA 1 LB 2 8 10
SINGLE COMPRESSOR CONFIGURATION 2 7 8 5 4 1 30 40 50 60 7 20 8 10 90 0 100 psi 3 2 DUAL AND TRIPLE COMPRESSOR CONFIGURATION 6 5 7 4 0 0 50 60 70 80 1 20 10 90 100 3 0 GAUGE AND CUT-OFF ASSEMBLY KEY PART. DESCRIPTION UNIT 1 CPG-250 COMPRESSOR GAUGE 1 2 BV-250 1/4 BALL VALVE 1 3 MI-100 MOISTURE INDICATOR 1 4 FA-4-4 1/4 FLARE HOSE FITTING 1 5 BN-250-CL 1/4 BRASS CLOSE NIPPLE 1 6 BT-250 1/4 BRASS TEE 1 7 BSE-250 1/4 BRASS ELBOW 1 8 BPC-4 1/4 BRASS CROSS 1 11
6 7 15 16 8 3 2 10 11 9 5 12 18 4 19 1 13 14 SINGLE ULTRA CLEAN OILLESS COMPRESSOR 17 KEY PART. DESCRIPTION UNIT 1 SBHA-21-375 STEEL BRAID HOSE ASSEMBLY 1 2 SBHA-7.5-375E STEEL BRAID HOSE ASSEMBLY 1 3 SBHA-11-375E STEEL BRAID HOSE ASSEMBLY 1 4 FPH-375 PURGE FLEX HOSE CLEAR PER FT 5 PFT-250 POLY FLO TUBE 1/4 PER FT 6 PFT-625 POLY FLO TUBE 5/8 PER FT 7 CFA-375 COALESCING FILTER 3/8 1 8 CFE-375 COALESCING FILTER ELEMENT ONLY 1 9 DPB-100 DRYER PURGE BUCKET 1 10 IRC-GAST RUBBER MOUNTING FEET 4 11 CPT-100 COMPRESSOR PURGE TANK 1 12 RDC-100 REPLACEMENT DESICCANT CARTRIDGE 1 13 DSV-115 PURGE VALVE SOLEID VALVE 115V 1 14 DSV-230 PURGE VALVE SOLEID VALVE 230V 1 15 TOM-1-115 OILLESS MOTOR 1 HP 115V 1 16 TOM-1-230 OILLESS MOTOR 1 HP 230V 1 17 RFV-100 RUBBER MOUNTING FEET 4 18 PSC-2 PRESSURE SWITCH 1 19 POVA-100 SAFETY POP OFF VALVE 1 12
16 6 7 8 15 3 13 11 2 5 10 18 19 9 12 4 1 14 DUAL ULTRA CLEAN OILLESS COMPRESSOR 17 KEY PART. DESCRIPTION UNIT 1 SBHA-21-375 STEEL BRAID HOSE ASSEMBLY 1 2 SBHA-10-375E STEEL BRAID HOSE ASSEMBLY 1 3 SBHA-9-375E STEEL BRAID HOSE ASSEMBLY 1 4 FPH-375 PURGE FLEX HOSE CLEAR PER FT 5 PFT-250 POLY FLO TUBE 1/4 PER FT 6 PFT-625 POLY FLO TUBE 5/8 PER FT 7 CFA-375 COALESCING FILTER 3/8 1 8 CFE-375 COALESCING FILTER ELEMENT ONLY 1 9 DPB-100 DRYER PURGE BUCKET 1 10 RIC-GAST RUBBER MOUNTING FEET 8 11 CPT-100 COMPRESSOR PURGE TANK 1 12 RDC-100 REPLACEMENT DESICCANT CARTRIDGE 1 13 CV-250 1/4 CHECK VALVE 2 14 DSV-230 PURGE VALVE SOLEID VALVE 230V 1 15 SBHA-18-375 STEEL BRAID HOSE ASSEMBLY 2 16 TOM-1-230 OILLESS MOTOR 1 HP 230V 2 17 RFV-100 RUBBER MOUNTING FEET 4 18 PSC-3 PRESSURE SWITCH 1 19 POVA-100 SAFETY POP OFF VALVE 1 13
6 16 7 15 8 13 2 3 11 9 5 10 18 19 12 4 1 14 TRIPLE ULTRA CLEAN OILLESS COMPRESSOR 17 KEY PART. DESCRIPTION UNIT 1 SBHA-21-375 STEEL BRAID HOSE ASSEMBLY 1 2 SBHA-10-375E STEEL BRAID HOSE ASSEMBLY 1 3 SBHA-9-375E STEEL BRAID HOSE ASSEMBLY 1 4 FPH-375 PURGE FLEX HOSE CLEAR PER FT 5 PFT-250 POLY FLO TUBE 1/4 PER FT 6 PFT-625 POLY FLO TUBE 5/8 PER FT 7 CFA-375 COALESCING FILTER 3/8 1 8 CFE-375 COALESCING FILTER ELEMENT ONLY 1 9 DPB-100 DRYER PURGE BUCKET 1 10 RIC-GAST RUBBER MOUNTING FEET 12 11 CPT-100 COMPRESSOR PURGE TANK 1 12 RDC-100 REPLACEMENT DESICCANT CARTRIDGE 1 13 CV-250 1/4 CHECK VALVE 3 14 DSV-230 PURGE VALVE SOLEID VALVE 230V 1 15 SBHA-18-375 STEEL BRAID HOSE ASSEMBLY 3 16 TOM-1-230 OILLESS MOTOR 1 HP 230V 3 17 RFV-100 RUBBER MOUNTING FEET 6 18 PSC-3 PRESSURE SWITCH 1 19 POVA-100 SAFETY POP OFF VALVE 1 14
DOES AIR COMPRESSOR RUN? Does compressor run for a few seconds, chugs, then stops? Does compressor pressurize from 80 to 100 psi in less than 2 minute with no air being used? GO ON TO THE NEXT PAGE. Check voltage at the valve and make sure valve is closed. Clean or replace. Replace intake filter. Defective head, contact Tech West. Trouble Shooting Chart Single Ultra Clean Oilless Compressor Is the moisture indicator pink? Service dryer and replace moisture indicator. Check voltage supplied to the compressor. Does compressor cycle with no air being used? Does purge valve system function properly? Does air bleed out the purge valve when unit is running? Does unloader valve pressure switch or float assembly seat while running? Locate and repair. Are there leaks in compressor or in office piping system? Note: Close shut off valve. Pump up tank to 100 psi. If pressure is maintained for 15-20 min., leak is in office lines. 1. Locate and repair leaks. 2. Ventilate if room is above 100 deg. F. 3. Contact compressor may be undersized. Does compressor run too hot or too frequent? Check for proper voltage. Use buckboost if needed. Single Ultra Clean Oilless Compressor Diagram Is intake filter clogged? Does air leak from unloader valve or the purge muffler continuously until unit cycles again? Is there sufficient pressure build-up with head discharge line removed? Defective head, contact Tech West. Make sure that the dryer valve is closing properly. 15
115v 230v GO ON TO THE NEXT PAGE. Blockage in air line locate & repair. Install Tech West transformer. COMPRESSOR DOES T RUN OR RUNS FOR ONLY A FEW SECONDS. Does head run with discharge line disconnected? Is there sufficient voltage at disconnect box? TE: Voltage should be + or - 10% of rating. Wiring Diagram Single Ultra Clean Oilless Compressor Is there sufficient voltage at motor terminals while motor tries to start? CHECK FOR: 1. Broken or loose wire. 2. Defective pressure switch. 3. Defective ON/OFF switch. 4. Excessive voltage drop across power lines. Replace defective capacitors. Is there resistance rise across the capacitors? TE: Short capacitor leads. Check resistance rise. If no resistance rise, replace. Turn power off. Remove fan guard. Try turning fan by hand. If it doesn t turn, contact head may be frozen. 16
GO ON TO THE NEXT PAGE. DOES AIR COMPRESSOR RUN? Check voltage at the valve and make sure valve is closed. Clean or replace. Replace intake filter. Defective head, contact Tech West. Locate and repair. Trouble Shooting Chart Twin Ultra Clean Oilless Compressor Is the moisture indicator pink? Service dryer and replace moisture indicator. Does compressor run for a few seconds, chugs, then stops? Does compressor pressurize from 80 to 1000 psi in less than 1 minute with no air being used? Check voltage supplied to the compressor. Does compressor cycle with no air being used? Does unloader valve system function properly? Does air bleed out the relief valve? 1. Locate and repair leaks. 2. Ventilate if room is above 100 deg. F. 3. Contact compressor may be undersized. Does compressor run too hot or too frequent? Check for proper voltage. Use buckboost if needed. Does unloader valve pressure switch or float assembly seat while running? Locate and repair. Are there leaks in compressor or in office piping system? Note: Close shut off valve. Pump up tank to 100 psi. If pressure is maintained for 15-20 min., leak is in office lines. Dual Ultra Clean Oilless Compressor Diagram Is intake filter clogged? Does air leak from unloader valve or the purge muffler continuously until unit cycles again? Is there sufficient pressure build-up with head discharge line removed? Defective head, contact Tech West. Make sure that the dryer valve is closing properly. Is there a blockage in air lines? 17
230v GO ON TO THE NEXT PAGE. Blockage in air line locate & repair. Install Tech West transformer. COMPRESSOR DOES T RUN OR RUNS FOR ONLY A FEW SECONDS. Does head run with discharge line disconnected? Is there sufficient voltage at disconnect box? TE: Voltage should be + or - 10% of rating. Wiring Diagram Dual Ultra Clean Oilless Compressor Is there sufficient voltage at motor terminals while motor tries to start? CHECK FOR: 1. Broken or loose wire. 2. Defective pressure switch. 3. Defective ON/OFF switch. 4. Excessive voltage drop across power lines. Replace defective capacitors. Is there resistance rise across the capacitors? TE: Short capacitor leads. Check resistance rise. If no resistance rise, replace. Turn power off. Remove fan guard. Try turning fan by hand. If it doesn t turn, contact head may be frozen. 18
GO ON TO THE NEXT PAGE. DOES AIR COMPRESSOR RUN? Check voltage at the valve and make sure valve is closed. Clean or replace. Replace intake filter. Defective head, contact Tech West. Locate and repair. Trouble Shooting Chart Triple Ultra Clean Oilless Compressor Is the moisture indicator pink? Service dryer and replace moisture indicator. Does compressor run for a few seconds, chugs, then stops? Does compressor pressurize from 80 to 1000 psi in less than 1 minute with no air being used? Check voltage supplied to the compressor. Does compressor cycle with no air being used? Does unloader valve system function properly? Does air bleed out the relief valve? 1. Locate and repair leaks. 2. Ventilate if room is above 100 deg. F. 3. Contact compressor may be undersized. Does compressor run too hot or too frequent? Check for proper voltage. Use buckboost if needed. Does unloader valve pressure switch or float assembly seat while running? Locate and repair. Are there leaks in compressor or in office piping system? Note: Close shut off valve. Pump up tank to 100 psi. If pressure is maintained for 15-20 min., leak is in office lines. Triple Ultra Clean Oilless Compressor Diagram Is intake filter clogged? Does air leak from unloader valve or the purge muffler continuously until unit cycles again? Is there sufficient pressure build-up with head discharge line removed? Defective head, contact Tech West. Make sure that the dryer valve is closing properly. Is there a blockage in air lines? 19
Wiring Diagram Triple Ultra Clean Oilless Compressor CHECK FOR: 1. Broken or loose wire. 2. Defective pressure switch. 3. Defective ON/OFF switch. 4. Excessive voltage drop across power lines. Is there sufficient voltage at motor terminals while motor tries to start? GO ON TO THE NEXT PAGE. TE: Short capacitor leads. Check resistance rise. If no resistance rise, replace. Is there resistance rise across the capacitors? TE: Voltage should be + or - 10% of rating. Blockage in air line locate & repair. Install Tech West transformer. COMPRESSOR DOES T RUN OR RUNS FOR ONLY A FEW SECONDS. Does head run with discharge line disconnected? Is there sufficient voltage at disconnect box? Replace defective capacitors. 230v Turn power off. Remove fan guard. Try turning fan by hand. If it doesn t turn, contact head may be frozen. 20
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