Compact Operator Manual

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CompAir UK Ltd
ABCDEF
OPERATOR HANDBOOK
for a
COMPACT
Lightweight Aircooled
Breathing Air Compressor
In any correspondence please quote: JOB NUMBER:

MACHINE NUMBERS: 5403.
PUBLICATION NUMBER: 98407/1078/02/11/02
ISSUE DATE: NOVEMBER 2002
CUSTOMER ORDER NUMBER:
CompAir UK Ltd. Ranelagh Road IPSWICH ENGLAND IP2 0AQ

Telephone: +44 (0) 1473 602222 Fax: +44 (0) 1473 601704 Parts Fax: +44 (0) 1473 601282 Service +44 (0) 1473 556027
www.CompAir.com e-mail: Ipswich@CompAir.com
CompAir UK Ltd
DECLARATION OF CONFORMITY
CERTIFICATE 'A' CATEGORY 1
98/37/EEC ( Known as the ‘Machinery Directive’ )
BS EN292: ( Safety of Machinery )
BS EN1012-1 ( Compressors - Safety Requirements )
We COMPAIR UK LIMITED
of RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ
declare that under our sole responsibility for supply / manufacture, the machinery described below,
Machine Type Rotary Compressor Reciprocating Compressor

Other Pressure Equipment.
Model No. _________________________ Serial No.________________________________
is in conformity with the essential Health and Safety Requirements identified in the above
directives.
This machine/equipment is exempt from 97/23/EC the Pressure Equipment Directive, reference
Article 1 clauses 3.3 & 3.6.
IPSWICH, ENGLAND
Signature and name of responsible person
DATE __________________ ENGINEERING DIRECTOR

Position
Notified Body:
Lloyds Register
European Directive Services UK
Hiramford
Middlemarch Office Village
Coventry.
CV4 4FJ
(Notified Body Reference: 0038)
Conformity assessment procedure: Module H (H1 where appropriate)
Language.
English.
French.
German.
Spanish.
Italian.
Dutch.
conformityPED-A
COMPRESSOR LOG SHEET REF. NO.
COMPRESSOR PRIME MOVER INSTALLED AT OIL GRADE USED:
TYPE: TYPE: CHECK OIL LEVEL
SPEED: B.H.P. CHECK WATER IN/OUT TEMPERATURE
SERIAL NO: DRIVE: DATE INSTALLED: CHECK COOLING FAN BLADES
FINAL FINAL AIR SERVICE
DATE TIME *HOURS STAGE STAGE STAGE PRESSURES PRESSURE PLAN REMARKS SEE SIGNED
RUN TEMP.°C TEMP.°C #(BAR - PSI) #(BAR - PSI) NUMBER OVER FOR MORE
#50/100 1 2 3 4 5
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
6500
7000
7500
8000
8500
9000
9500
10000
10500
11000
11500
12000
12500
*FILL IN HOURS RUN AS DETAILED ON SERVICE PLAN FOR PARTICULAR COMPRESSOR TYPE
# DELETE AS NECESSARY - † FILL IN APPROPRIATE STAGE TRIP TEMPERATURE READING
SERVICE ENGINEER TO SIGN & FILL IN ANY OTHER COMMENTS IN REMARKS COLUMN
SERVICE TELEPHONE +44 (0) 1473 556027 - PARTS +44 (0) 1473 601282
logsheetm.doc
DATE REMARKS DATE REMARKS
logsheetm.doc
CompAir UK Ltd SAFETY SECTION
Page 1
OPERATOR MANUAL - 5000 SERIES AIR

COMPRESSORS
CONTENTS
Page
Ownership Data 2
Foreword 3
Safety Procedures 5
WARNING
The use of replacement parts or lubricating oils not supplied,
recommended or approved by CompAir UK Ltd Ipswich, or the failure to
maintain this equipment in accordance with the maintenance instructions,
may invalidate the WARRANTY, cause equipment failure, create unsafe or
hazardous conditions or result in damage to the equipment.
CompAir UK Ltd Ipswich cannot accept responsibility for damage,

injury or failure caused by these situations.
USE ONLY
CompAir UK Ltd Ipswich
GENUINE PARTS
AND
AUTHORISED SERVICE AGENTS
09/10/02 safety5.doc Page 1

Page 2
OWNERSHIP DATA
TECHNICAL DATA
It is recommended that details taken from the compressor and motor nameplates are recorded below.
Model Type: Motor Serial Number:
Serial Number Motor RPM:
Year: Motor kW:
Maximum Pressure: Motor V. Ph. Hz:
Compressor Lubricant: Motor Bearing Grease:

(if applicable)
Capacity M³/hr - CFM Notes:
CompAir UK Ltd Ipswich CONTACT DETAILS
Contact Name: Sales Telephone: +44 (0) 1473 602222
Address: Notes:
CompAir UK Ltd
Ranelagh Road
Ipswich IP2 0AQ
ENGLAND
Telephone: +44 (0) 1473 602222 Fax: +44 (0) 1473 601704
Contact Names: Parts Telephone: +44 (0) 1473 602222

Parts Fax: +44 (0) 1473 601282
Contact Names: Service: +44 (0) 1473 556027
For any comments or queries about the contents of this MANUAL please write to CompAir UK Ltd.
Ranelagh Road, Ipswich 1P2 0AQ. England marked for the attention of Mr. Dennis Beeton, Technical
Publications Engineer.
Page 2 09/10/02 safety5.doc

Page 3
FOREWORD
CompAir UK Ltd Ipswich H5000 Series compressors are designed and manufactured to give optimum
performance, with long life and reliability.
SPECIAL ATTENTION
The STANDARD BUILD of all CompAir UK Ltd (Ipswich Operations) products are not intended for use in
either Explosive or Potentially Explosive Atmospheres as defined in Directive 95/9/EC.
An Explosive atmosphere is a mixture with air, under atmospheric conditions, of flammable gases, vapours,
hazes or dusts in which, after ignition has occurred, combination propagates to the entire unburned mixture
and may cause a hazard.
A Potential Explosive atmosphere is an atmosphere, which could become explosive due to local
conditions.
This Manual will help you to obtain the best performance from your compressor. It provides the information
required to install, commission and operate the compressor and carry out regular maintenance schedules,
which will ensure the maximum satisfactory service life.
Included within the Manual is a comprehensive Parts List to allow the user to order spare parts for servicing.
Servicing facilities and the supply of genuine replacement parts are provided through a world-wide network
of CompAir Companies and CompAir UK Ltd Distributors, backed by the Service and Parts Departments at
CompAir UK Ltd, Ipswich (UK) tel: +44 (0) 1473 602222. fax: +44 (0) 1473 601704. Customer Service +44
(0) 1473 556027 or Parts fax: +44 (0) 1473 601282.
The information in this Manual was correct at the time of printing but modifications to parts and procedures
may be made without notice which could affect the servicing requirements of the compressor. Before any
servicing or maintenance work is undertaken the user is advised to contact the local CompAir Company or
CompAir UK Ltd Distributor for revised or up-dated information.
In any communication concerning the compressor it is essential to quote the MODEL, SERIAL No.
and any CONTRACT Ref.
It is important this Manual is retained with the compressor for reference and should remain with the
compressor if it is sold or transferred to another user. Ensure that the new user is made fully aware of the
need to study the Safety Section and any Warnings for safe operation given throughout the text.
Protect the environment by using only approved method of disposal of condensates lubricating oil etc.
Please note: a. Throughout the Manual all pressures quoted are gauge pressures.
b. Whilst recyclable materials are used as far as possible, please ensure when
disposing of condensate, spent oil, used filter elements and any discarded parts or
waste material of any kind make sure that there is no pollution to any natural water-
course, drain system and that no burning waste takes place which could cause
pollution of the atmosphere.

Page 4
CAUTION
Use only CompAir UK Ltd Ipswich Genuine Parts when carrying out routine maintenance or repair. The
use of replacement parts or lubricating oils not supplied or recommended by CompAir UK Ltd Ipswich can
lead to expensive failures, which will not be covered by warranty.
Substitution of parts not manufactured or approved by CompAir UK Ltd Ipswich can create a potential
personnel hazard.
This is a High Pressure Compressor, for safe and reliable operation use only
genuine CompAir UK Ltd Ipswich Parts
To ensure continued trouble free operation it is important that periodic servicing is carried out in accordance
with the information given in this manual - refer to the “Maintenance Section”.
Conditions of CompAir UK Ltd Ipswich warranty are stated in our Conditions of Sale. Details of warranty for a
particular unit may be obtained from the local CompAir Company or authorised Distributor.

Page 5
SAFETY PROCEDURES
Page
General.............................................................................. 7
Warnings, Cautions and Notes........................................ 7
General Safety Precautions ............................................. 7
Installation Precautions ................................................... 8
Operational Precautions .................................................. 8
Maintenance and Repair Precautions ............................. 9
Precautions in the Event of Fire..................................... 10

Page 6
SAFETY
• WARRANTY
The Conditions of the CompAir UK Ltd Ipswich Warranty are set out in the Standard Conditions of
Sale.
• MAINTENANCE
To ensure continued trouble free operation of the compressor it is important that periodic maintenance
and servicing are carried out in accordance with the information given in the "Maintenance" section of
this Manual. If any replacement or repair is needed use genuine CompAir UK Ltd Ipswich parts.
∗ WARNING
The use of replacement parts or lubricating oils not supplied or approved by
CompAir UK Ltd Ipswich may lead to failures in service which would not be
covered by warranty.
Any unauthorised modifications or failure to maintain this equipment in accordance with maintenance
instructions may make it unsafe. The use of replacement parts not supplied by CompAir UK Ltd Ipswich
may create hazardous conditions over which CompAir UK Ltd Ipswich has no control.
Such hazardous conditions may lead to accidents that can be life threatening, cause substantial bodily injury
or result in damage to the equipment. CompAir UK Ltd Ipswich can bear no responsibility for equipment
for which unapproved replacement parts are included.
SPECIAL NOTE:
THE FOLLOWING HEALTH AND SAFETY PRECAUTIONS MUST BE READ IN CONJUNCTION WITH
ANY OTHER MANUFACTURERS EQUIPMENT SUPPLIED.

Page 7
SAFETY
1. GENERAL
CompAir UK Ltd Ipswich compressor safety relates

to the document BS EN1012-1 Compressors and
Vacuum Pumps - Safety requirements and the UK RISK OF DANGER
Pressure Systems Health & Safety Regulations S.I.
No. 128.
• Most accidents which occur during the operation

and maintenance of machinery result of failure RISK OF ELECTRIC SHOCK
to observe basic safety rules or precautions.
Recognising a situation that is potentially
hazardous can often prevent an accident.
• When handling, operating or carrying out

maintenance on the unit, personnel must RISK OF HIGH PRESSURE
observe safe engineering practices and all
relevant local regulations. The attention of users
is drawn to the Health and Safety at Work Act
1974, and the regulations of the Institution of
Electrical Engineers.
RISK OF HOT SURFACE
• CompAir UK Ltd cannot anticipate every
possible circumstance, which might represent a
potential hazard. The WARNINGS in this
manual are therefore not all inclusive. If the user
employs an operating procedure, an item of
equipment or a method of working which is not RISK OF GAS EXHAUST
specifically recommended by CompAir UK Ltd
then they must ensure that the unit will not be
damaged or made unsafe and that there is no
risk to persons or property.
• Failure to observe these precautions given

under "Safety Precautions" may be considered CONSULT MANUAL
dangerous practice or misuse of the compressor
3. GENERAL SAFETY PRECAUTIONS
• Read and understand all WARNINGS,
CAUTION AND MANDATORY LABELS on the • When using cleaning solvents, local Health and
unit before operating or carrying out Safety Regulations must be complied with.
maintenance or servicing. Provide good ventilation and use suitable
protection such as a breathing filter mask, safety
2. WARNINGS, CAUTIONS & NOTES glass, protective apron and gloves.
• The following details for this Safety Section • Safety footwear should be compulsory in all
relate to the ESSENTIAL SAFETY workshops. Safety helmets must be worn if there
REQUIREMENTS referred to in Directive is any risk of falling objects.
89/392/EEC, Amended 91/286/EEC.
• If using compressed air for cleaning
purposes, ensure safety regulations are
complied with and appropriate clothing
worn.
• Warnings call for attention to operation
procedures involving specific hazards which • Never direct compressed air onto your skin or at
could cause injury or death and are identified by other people. Never use compressed air to clean
the following:- loose dirt from clothing.

Page 8
3. GENERAL SAFETY PRECAUTIONS (Cont.) be guarded or insulated. Other high temperature

• Before releasing compressed air through a hose pipework should be clearly marked and all
make sure the free end is held securely so that it pipework should be clearly marked.
cannot whip and cause injury.
5. OPERATIONAL PRECAUTIONS
• Avoid injury by using a hoist to lift heavy loads. • Competent personnel under a qualified
Check that all chains, hooks, shackles and supervisor must only operate the compressor.
slings are in good condition and are of the
correct capacity. They must be tested and • Do not operate compressor with any removable
approved according to local safety regulations. inspection cover removed e.g. crankcase doors,
valve covers etc.
• Cables, chains or ropes should never be applied
to lifting eyes. Always use an appropriate
• Never remove or tamper with safety devices,
shackle or hook, properly positioned. Arrange
guards or insulation materials.
lifting cables so that there are no sharp bends.
Use a spreader bar to avoid side loads on
• The compressor must only be operated at the
hooks, eyes and shackles and never leave a
supply voltage and frequency for which it is
heavy load unattended.
designed. Always isolate power before
maintenance or servicing.
• When a load is on a hoist stay clear of the
danger area beneath and around it. Keep lifting
• When mains power is ON, lethal voltages are
acceleration and speed within safe limits.
present in the electrical circuits and extreme
caution is need when essential work is carried
4. INSTALLATION PRECAUTIONS
out on the electrical system. ALWAYS
• Competent personnel under a qualified CONSULT A QUALIFIED ELECTRICIAN
supervisor must only carry out installation work. BEFORE ANY SUCH ESSENTIAL WORK.
• A fused isolator switch must be fitted between • Do not open starter compartment to touch
the main power supply and the compressor. electrical components while voltage is applied
unless it is necessary for measurement, test or
• Precautions must be taken to ensure that no adjustment. Such work should always be
injury is caused to passers-by through loose carried out by a qualified. Electrician with
clothing being sucked into compressor intake. appropriates tools and protection against an
electrical hazard.
• Ensure that the discharge pipe from the
compressor to the user pipework, receiver or • If the unit is equipped with a Remote Control
storage is free to expand and that no flammable device, attach warning notices stating "THIS
material is within the vicinity. If any such material UNIT CAN BE STARTED REMOTELY" in
is close-by take steps to preclude ignition. prominent locations, one on the outside of the
unit, the other inside the control compartment.
• A manual shut-off valve should be fitted in the
discharge line to allow the compressor to be • As a further safeguard, take adequate
isolated. Non return valves cannot be relied precautions that no one is working or checking
upon for isolating parts from a pressure system. the unit before attempting to switch on remotely
A safety valve must be installed between any controlled equipment. Attach a "CHECK THAT
compressor unit and the isolating valve. ALL PERSONNEL ARE CLEAR OF UNIT
BEFORE STARTING" or similar notice.
• A pressure-reliving device must be fitted to
every pressure vessel, or equipment containing • Compressed air and gas piping, together with
air or gas above atmospheric pressure. Never cooling water piping and other parts, with
remove or tamper with safety devices, guards or surface temperature greater than 70°C and may
insulation fitted. In order to limit the risk of be accidentally touched, should be guarded or
Legionnaires Disease, CompAir UK LTD advise insulated.
caution with the use of cooling towers for water
cooling the compressor. Closed circuit or direct
mains cooling is preferred.
• Pipework or other parts with a surface

temperature above 70°C, which may be
accidentally touched in normal operation, must

Page 9
• Wash the area with limewater and avoid

5. OPERATION PRECAUTIONS (Cont.) breathing any fumes. If contamination of the skin
• If there is any indication that the compressor is occurs washes with limewater and seeks
overheating it must be shutdown. (A high air or medical advice.
gas temperature switch is fitted as standard to
guard against operating with excessive Pre-Maintenance Operation
temperature). Beware of burns from hot oil and
water when working on a unit recently shutdown. • 1. Isolate the compressor from the main
electrical supply. Lock the isolator in the OFF
• Do not operate the unit when guards provided position and remove fuses.
for protection for all rotating and reciprocating
parts have been removed for essential
maintenance. Secure guards following any • 2. Attach a label " WORK IN PROGRESS - DO
servicing or repair. NOT APPLY VOLTAGE".
• Local noise regulations must be observed. Ear • 3. Close the isolating valve between the
defenders are suggested by Noise at Work compression unit and user's pipework. Close the
Regulations 1989 when the level is greater than isolating valve in the cooling water inlet pipe.
85 dB A at one meter. Be aware high noise Attach a label "WORK IN PROGRESS - DO
levels can interfere with communication. NOT OPEN".
6. MAINTENANCE & REPAIR PRECAUTIONS

• Competent persons under qualified supervisor • 4. Check that all pressurised gas trapped in the
must carry out maintenance repair and system is released to atmosphere or safely to
modifications. gas storage. Check that all pressure gauges
register zero.
• The compressor will have a preserving oil
applied to interior surfaces (Oil lubricated • 5. Ensure that the cooling water system has
models). Oil free models will have desiccant been drained.
bags in valve covers and distance pieces.
• 6. Check that the drain valve on the delivery
• Handling components such as seals, gaskets
manifold is clear and gas pressure has been
and diaphragms should not present a personnel
released.
hazard. Preservation oils again should not
present a personnel hazard if handled under
normal handling practices. • 7. Check that all interstage drains are open to
ensure any gas trapped between stages has
• Whilst compressors are asbestos free, treat all been released.
damaged gaskets as asbestos - when the
Asbestos at work regulations apply. • Stand clear of all valve covers when removing
the securing screws.
• Viton 'O' seals under normal operating
conditions are safe. • When removing valve covers for valve
replacement, ensure a minimum of two threads
• However, should there be a fire within the is left engaged on the valve cover securing
compressor or these seals are likely to exceed a screws. Lever the valve cover until the 'O' seal is
temperature of 300°C the material will disengaged from the port in the cylinder head.
decompose. Remove the securing screws and take out valve
cover.
• Degraded Viton gives off Hydrogen Fluoride
fumes and if in contact with the skin an acid • Use only lubricating oils and greases
formed causes severe burns. approved by CompAir UK LTD to avoid
potential hazards especially the risk of
• If Viton seals appear charred or gummy do not explosion or fire and the possibility of
touch with unprotected hands: use neoprene or decomposition or generation of hazardous
PVC gloves. gases.
• Always clean oil spills from the surrounding floor

before and after maintenance work.

Page 10
6. MAINTENANCE & REPAIR (Cont.) • Keep the compressor clean at all times.
• Make sure all instructions concerning operation • Protect components and exposed openings by
and maintenance are strictly followed and that covering with a clean cloth or tape during repair
the complete unit, with all accessories and or maintenance work.
safety devices, is kept in good order.
• Protect the motor, intake, electrical and
• The accuracy of pressure gauges and regulation components against the entry of
temperature switches should be regularly moisture e.g. steam cleaning.
checked at least 13 month intervals and
thoroughly examined at least every 48 months. • Precautions must be taken when carrying out
They must be renewed or service exchanged welding or any repair operation which generates
when acceptable tolerances are exceeded. flames or sparks. The adjacent components
must be screened with non-flammable material
• Protection devices should be tested at each and if oil present, the system must first be
regular service interval and replaced or service cleansed thoroughly by steam cleaning.
exchanged if not functioning correctly. The
maximum pressure for safety valves under fault • Condensate (oil and water mixture from
conditions is 1.10 times the set pressure, the set compression process) must be regarded as
pressure being a minimum of 1.05 times the trade effluent and is therefore not suitable for
maximum operating pressure to ensure seat discharge into a surface water sewer, soakaway
tightness. or watercourse.
• Never use a light source with an open flame for PROTECT THE ENVIRONMENT USE APPROVED
inspection. METHODS OF DISPOSAL.
• Before dismantling any part of the compressor 7. PRECAUTIONS IN THE EVENT OF FIRE
be sure that all heavy movable parts are secure.
• Use extreme caution when handling
components that have been subjected to fire or
• After completion of any maintenance or repair very high temperature. Some components may
ensure that no tools, loose items or rags are left
contain fluoroelastomer materials, which
on or inside the compressor.
decompose under these conditions to form
highly corrosive residues. Skin contact can
• Do not use any flammable liquid to clean valves, cause painful and penetrating burns resulting in
filter elements, cooler passages, pipe bores or permanent skin and tissue damage.
any component carrying a flow of air or gas
during normal operation. If chlorinated
hydrocarbon substances are used for cleaning, This is a high pressure Compressor
safety precautions must be taken against toxic use only:
vapours, which may be released. GENUINE
CompAir UK Ltd Ipswich
PARTS
DO NOT USE CARBON TETRACHLORIDE.
• Precautions must be taken against using acids,

alkalis and chemical detergents for cleaning
machined parts. These materials cause irritation
and are corrosive to the skin, eyes, nose and
throat. Avoid splashes and wear suitable
protective clothing and safety glasses. Do not
breathe mists. Ensure water and soap is readily
available.
• When disposing of condensate, old oil, used

filter elements and other parts and waste
material of any kind make sure that there is no
pollution to any drain or natural water course
and that no burning of waste takes place which
could cause pollution of the atmosphere.

CompAir UK Ltd PUBLICATION 98407.1078/O&M/02/11/02
Page 1
AMENDMENT RECORD
ISSUE No MOD Note No M/C SERIAL No./”M” No DATE PAGE No
1 NEW NEW JULY 01 ALL
2 Correct Oil type to ALUSYNT 750 PLUS or ANDEROLL 755 NOV 02 5
1078.doc
Page 2
1078.doc
Page 3
CONTENTS
CERTIFICATE OF CONFORMITY/INCORPORATION
COMPRESSOR LOG SHEET
SAFETY SECTION
AMENDMENTS PAGE 1
INDEX PAGE 3
TECHNICAL DATA PAGE 5
SETTING UP PAGE 6
INSTALLATION & OPERATION PAGE 6
COMPRESSOR PAGE 7
ELECTRIC MOTOR PAGE 8
COMBUSTION ENGINE PAGE 8
STARTING UP THE COMPRESSOR PAGE 9
MAINTENANCE INSPECTIONS PAGE 10
OPERATING & ROUTINE MAINTENANCE PAGE 11
SERVICING PAGE 13
FAULT GUIDE PAGE 15
SAFETY WARNINGS PAGE 17
ILLUSTRATED PARTS LIST PAGE 18
PRESSURE SWITCH PAGE 21
ELECTRICAL DIAGRAM THREE PHASE MOTOR 60Hz PAGE 22
ELECTRICAL DIAGRAM THREE PHASE MOTOR 50Hz PAGE 23
ELECTRICAL DIAGRAM SINGLE PHASE MOTOR PAGE 24
COMPRESSOR EXPLODED VIEW PAGE 25
BASEPLATE ASSEMBLY PAGE 26
PETROL ENGINE PAGE 27
THREE PHASE ELECTRIC MOTOR PAGE 27
ACCESSORIES PAGE 27
SINGLE PHASE ELECTRIC MOTOR PAGE 28
HOSE CONNECTIONS PAGE 28
1078.doc
Page 4
1078.doc
Page 5
TECHNICAL DATA
DIMENSIONS (approx.) LENGTH/WIDTH/HEIGHT mm. 700/350/420

(with electric motors) mm. 600/380/420
WEIGHTS (approx.) With 4 Hp three-phase elect. motor 44 Kg.

With 5.5 Hp combustion engine 43 Kg.
With 3 Hp single-phase elect. motor 46 Kg.
OTHER DATA Cylinders 4
Stages of compression 4
1st stage bore 78 mm.
2nd stage bore 38 mm.
3rd stage bore 19 mm.
4th stage bore 9.5 mm.
PULLEYS Compressor 130 mm.
4 Hp three-phase elect. motor 95 mm.
5.5 Hp combustion engine 75 mm.
3 Hp single-phase elect. motor 70 mm.
DRIVE BELTS 4 Hp three-phase elect. motor 'A' 35"
5.5 Hp combustion engine 'A' 34"
3 Hp single-phase elect. motor 'A' 34"
R.P.M. Compressor 1600/2200
4 Hp three-phase elect. motor 2850
5.5 Hp combustion engine 3800
3 Hp single-phase elect. motor 2850
PRESSURES Max. running pressure 300/250 bar
Intermediate 1st stage 4 - 5 bar
Intermediate 2nd stage 15 - 20 bar
Intermediate 3rd stage 55 - 70 bar
Intermediate 4th stage 200 - 250 bar
LUBRICATION Oil type ALUSYNT 750 PLUS or approx. 260 g.
(Oil spray) ANDEROLL 755 approx. 300 sq. cm.
INCLINATION Maximum permitted in all directions 10 °
(max. oil level)
TEMPERATURE Permitted working environment from +5 to 35°C
COMPRESSOR CAPACITY Normal litres/hours at 15°C L/H 6000 +/- 5%
(at 2200 R.P.M. at sea level
COMPRESSOR CAPACITY Normal litres/hour at 15°C L/H 4500 +/- 5%

(at 1600 R.P.M.) at sea level
1078.doc
Page 6
SETTING UP
List of Instructions
1. The compressor and engine are delivered without oil. Ensure the units are filled with the correct
lubricant before running.
2. Check the power supply network voltage is correct for the electric motor. If it is three-phase it is
arranged for operation at 380 V, when not requested otherwise.
3. If the compressor is new, or has been idle for some time, manually turn the pump over a few
times by rotating the cooling fan.
4. Always warm up the compressor for around 2-3 minutes before use without a load (leaving all of the
condensation drains open).
5. Open the bottle connection valves only when the pressure is equal or slightly higher than that of the
bottles, so as not to damage the filters.
6. During operation, periodically exhaust the condensation every 1/2 hour by using the manual
drains.
7. At the end of use, run the compressor without a load, with all of the condensation drains open
(the manual ones as well) for several minutes in order to eliminate all of the residual moisture
and to avoid internal rusting.
8. Perform the maintenance operations, oil changing and filter replacement at the prescribed
intervals. Top-up with same type of oil and change the lubricant every 6 months, even if the
running period for an oil change has not been reached.
INSTALLATION AND OPERATION

Installation
The compressor must be placed, as far as is possible, on a flat surface in a well aired place free from dust,
fumes, pollution and/toxic exhausts.
The minimum distance from the walls on the fan side must be at least 50 cm. and 2 m. from the opposite
side.
Remember that where there is a very find sand (desert type sand for example), special intake filters must be
used.
If installed in an enclosed area:
- the internal temperature must not exceed 30°C

- the intake duct must be taken outside by means of a tube at least 20 mm. in diameter which is
- not longer than 2 metres
- the external temperature must not exceed 35°C; If diesel or combustion motors are used, their
- exhausts must be led to the outside.
It is preferable to position the compressor outdoors and:
- to position it so that the wind disperses the exhaust gasses (danger of inhaling toxic gasses)
- to suitably protect it from excessive heat and bad weather.
1078.doc
Page 7
COMPRESSOR
The compressor is despatched without oil. First of all add the right amount of lubricant.
A tin of special oil, with the writing "COMPRESSOR OIL" is sent with the compressor.
The lubricant must be at the level of and no higher than the upper reference mark on the dip-stick.
An excess of oil not only creates the danger of over pressure in the crankcase but can also give excessive
oil consumption. The lower reference mark on the dip-stick indicates the minimum oil level for the lubrication
of the compressor. Use only the special oil from our Company or other good brands of oil which are not toxic,
emulsifiable and which have good rust preventive properties (danger of rusting particularly for the third and
fourth stage steel components with consequent seizing).
The oil level must be checked every day and at least after every 4 hours of operation. If the compressor is
new, or has not been used for a long time, it should be turned over by hand using the fan, in order to
distribute a layer of lubricant onto the moving parts.
If the compressor does not rotate, it should be checked and serviced.
If everything is normal, start the compressor and let it idle (condensation drain valves open) for around 2-3
minutes.
Prolonged idling (10 minutes or more) should be avoided to prevent excessive oil migrating into the
cylinders.
Always start the compressor with the drains open to reduce the initial starting torque.
It is always better for the compressor to start operation with the unloaded (without pressure) in order to
reduce the torque of the initial start and to bring the moving parts up to temperature so that the design play is
reached for operation.
If installed in an excessively dusty environment, the intake filter could become blocked and the machine will
overheat in a short period of time.
The operation of the compressor in unsuitable surroundings and failure to observe suitable precautions could
cause serious damage (piston seizure, premature component wear). Failures caused by the above are easily
recognisable when the machine is stripped and automatically nullify the guarantee conditions.
Oil Filler
Drain Cock Dipstick
1078.doc
Page 8
ELECTRIC MOTOR
If the compressor is the electric motor version make sure that the main power supply characteristics
correspond to the data shown on the electric motor and in particular:
- the type of power supply (single-phase - three-phase)

- the voltage
- the frequency
- the power.
Variations in voltage of more or less than 10% compared to the reference voltage can cause serious damage
to the windings of the motor.
Remember that the power requirement at start-up is 3-4 times the nominal requirement for around 0.5
seconds and it is therefore recommended that the system can deliver 30% more than the power indicated on
the motor plate.
Check that the electrical system is earthed and that the size of the wire is adequate (not less than 3 sq.mm.
It is good working practice to place a main switch with suitably rated fuses in the line from your electrical
system to the motor.
If the power requirement is very close to the power available, do not run other items from the same supply.
If the electric motor is three-phase check that the direction of rotation is correct (the fan must direct the air
flow towards the compressor).
The electric motor is equipped with a motor protection switch, complete with START-STOP buttons as well
as a thermal cut-out reset button.
WARNING:
If the motor is changed (from combustion to electric or vice-versa) it is necessary to invert the wires on the
terminal strip of the pressure switch. Consult the diagram of the pressure switch enclosed in this manual.
COMBUSTION ENGINE
WARNING: -The combustion engine is supplied without oil.
Before running, fill the crankcase with the correct amount of lubricant, by using the can supplied with the
machine, carrying the writing " OIL FOR COMBUSTION ENGINE".
The viscosity is SAE 15 - 45.
Check the directions of use and maintenance handbook of the engine before start-up, remembering that
normal and not "lead free" petrol must be used.
Check the oil level frequently (at least every 4 hours).
It is important that the engine is run at 1800-2000 r.p.m. for 2-3 minutes (the accelerator at half travel) so as
to bring it up to the correct temperature for operation. For filling take the lever to the end of the travel (3800
r.p.m. approx.).
1078.doc
Page 9
STARTING UP THE COMPRESSOR

Before starting-up the compressor, make sure that the condensation drain valves are open.
When the compressor is cold after turning by hand it should be given 2-3 short starts by pressing the start
button and stop button almost immediately after to circulate the oil.
If the machine has a single-phase motor, pause in between each start, so as not to damage the starting
condensers.
Run the machine for 2-3 minutes with the drains open before bringing up to load.
Filling the Bottles
Connect the hose to the bottle leaving the valve closed; we strongly recommend against filling bottles which
still contain high pressure air if the compressor has not reached the working pressure (possible damage to
the fourth stage).
Remember to warm up the compressor for a least 2-3 minutes with drains open to remove condensation.
When the compressor has reached the bottle pressure, only now open the charging valve.
The machine, which is equipped with a pressure switch, stops automatically when filling is complete. If this
pressure switch does not work, the safety switch on the fourth stage will open thus preventing over pressure.
The pressure switch is calibrated in the factory to stop the machine when the pressure reaches 210
atmospheres, however, it may be manually adjusted by the operator up to 250 Atm. In this case the safety
valve of the fourth stage must also be re-calibrated (260 - 270 bar).
WARNING:
If the motor is changed (from combustion to electric or vice-versa) it is necessary to invert the wires on the
terminal strip of the pressure switch. Consult the pressure switch diagram enclosed in this manual.
Disconnecting the Groups
To disconnect the bottle groups:
- close the bottle taps

- open the condensation exhausts to depressurise the line and the compressor
- disconnect the groups
Purging the Condensation
At the end of every filling or after every 30 minutes of operation, it is necessary to manually open the drain
valves of the third and fourth stages to remove condensate.
The amount of condensate which collects, depends solely on the percentage of humidity in the atmosphere
and not on the condition of the compressor.
The whitish colour of the condensation does not indicate a water/oil emulsion, but rather a high oxygen
content in the water due to the pressure.
Measures to adopt after use:
At the end of use, idle the compressor for 2-3 minutes, with all of the condensation drains open. This
operation removes any moisture which may collect and cause rusting.
1078.doc
Page 10
Air Bottles
It is good working practice to immerse the bottles in water during filling. This helps cool the bottles and
reduce the amount the pressure drops after filling.
Before Filling the Bottles
Make sure that they have been properly tested: under current Italian law, testing is obligatory for bottles after
4 years from new and every two years after that. The deadline is indicated by the inscription of the month
and the year between the badge of the republic and the trade name of the authorised operation centre.
If it is necessary to reduce the pressure in a bottle, open the valve slightly so that the fall in pressure is
gradual.
Rapid discharges cause condensation on the inner walls of the bottles with the possible build up of extremely
dangerous corrosion.
Oxygen Bottles
Never fill bottles which have previously been filled with pure oxygen - danger of explosion.
Flexible Tubes
Check the general condition of the high pressure flexible tubes and replace them when the threads are worn
or if splits are noticed in the sheaths.
MAINTENANCE INSPECTIONS
Drive Belts
The tension is correct, when the deflection in the centre of the belt is as indicated in the figure. Insufficient
tension causes a reduction in output, vibration, belt slip and premature wear. Excessive tension causes an
increase in the load with consequent bearing wear and excessive start-up torque. The tension is adjusted
through the 4 bolts which connect the motors to the baseplate which run in slots. The pulleys of the
compressor and motor must be aligned. Alignment is adjusted moving the motor pulley along the shaft.
Span
Pressure
Deflection = 0.015mm
for every mm. of span
1078.doc
Page 11
Safety Valves
The safety valves are calibrated in the factory.
We advise DO NOT dismantle or tamper with them.
A safety valve blowing normally indicates a fault. The compressor should be stopped and the fault
investigated. Never try to correct a fault by raising the set pressure of the valves.
Inspection of the pipes-gaskets
Check the pipe-gasket seals.
In the absence of other faults, a loss in compressor performance can be caused by air leaks. To test, take
the machine up to pressure, and having stopped it, if check:
The pipe connections: tighten moderately; if the leak does not stop replace the connection
and check the condition of the thread.
From the coils; replace if necessary.

From under head gaskets; if necessary inspect and/or replace them.
If crankcase leakage is excessive, this could indicate worn pistons, worn or broken piston rings requiring
major service.
OPERATING & ROUTINE MAINTENANCE

Oil
It is advisable to give the compressor a general overhaul after 300 hours of operation.
Correct periodical maintenance during use will prevent premature wear and stoppages due to faults.
Oil:
- this should be checked every day before starting the compressor and at least after every 4-5
hours of operation.
- It should be changed, with the machine still hot, at least every 100 hours or every 12 months.
- if the compressor works in very hot climates or continuously, the oil should be changed more
frequently (at around every 50 hours).
To drain the used lubricant, use the ball valve located under the block. When draining is complete, re-close
the valve and refill with new oil through the upper plug. (See figure on page).
Filter Cartridges
The cartridge should be replaced after every 30 hours of operation. After this time its chemical substances
are no longer active. Particularly dry, or polluted air reduces the life of the filter system proportionally and in
this case it should be replaced sooner.
1078.doc
Page 12
To replace the cartridge:
-make sure all pressure is released from the filter pack.
-unscrew the four upper screws of the filter with the 6

mm. hexagonal spanner provided.
- lift up the cover and remove the old cartridge.
- introduce the new cartridge into the housing.
-check the cleanliness and condition of the screw threads in

the filter pack. Tighten the four screws evenly by hand then
firm down with the spanner provided. Do not overtighten.
WARNING:
Worn or damaged threads are dangerous.
If the compressor is equipped with a micronic filter, its

average life is around 100 - 200 hours, after which it also
should be replaced.
Intake Filter
The filter is normally equipped with a single body filter screwed directly onto the intake. The filter cartridge
should be replaced every 300 hours. In dusty conditions the filter life is approximately halved.
Condensation Separators
These are designed to be maintenance free. However, every 100 hours they should be cleaned inside.
To perform this it is necessary to:
- unscrew the four smallest screws in the flanges, located on the upper and lower parts of the filter
pack and extract the two separators.
- clean the insides of the filters, removing dirt and condensation deposited on their walls.
- blow compressed air through the passages of the separators to free the baffles from oil and water
residues.
- lubricate the 'O' ring gaskets with Vaseline oil and remount without excessive force.
- check the condition of the threads, reposition the flanges and tighten with care. Do not overtighten.
Intake and Compression Valves
Every 250-300 hours, clean the suction and delivery valves in each stage.
We advise these operations are carried out by qualified personnel during general servicing.
If the compressor remains idle for periods longer than 4-5 weeks, extra maintenance is necessary in order to
prevent damage and problems.
1078.doc
Page 13
1. Compressor
- remove the oil breather pipe no. 35 from the connection on the head of the 1st stage.
- inject around 3cc of compressor oil into the connection and let the compressor run for around 2
minutes.
- reconnect the pipe and cover the compressor, making sure to check that the area is dry and aired.
2. Combustion Engine
- remove the spark plug and introduce around 3 cc of engine oil into the cylinder head through the
hole, turn the engine over several times using the start-up cable.
- replace the spark plug.
Breather Pipe
SERVICING
Work on the valves.
Valve servicing should be carried out by qualified personnel using the correct tools.
The intake and delivery valves are positioned on the cylinder heads, under the fins, (apart from the 4th
stage).
1. Dismounting: In order to reach them, it is necessary to:-
- disconnect the coils

- unscrew the Allen key screws which connect the compression stages to the block
- remove the finning.
The valves are positioned in the heads and to remove them, exert moderate pressure from the
bottom upwards, through the air passage holes from the head (with the exception of the 1st stage
which are grouped on a sealed valve carrier plate).
To gain access to the 4th stage valve it is necessary to unscrew the seal head with a 30 mm.
spanner, (once the exist coil of the 4th stage has been disconnected).
2. Maintenance
- check that the Viton 'O' ring gasket is in good condition, if not, replace it
- clean the parts of the valve which are encrusted
- replace all valve plates and springs.
1078.doc
Page 14
3. Final Inspection
When the valves have been remounted and replaced in the head seats, check that they are tight
by blowing compressed air into the exist of each of them.
The same operation should be repeated at the entrance to the valves. Their operation is correct,
if the small plate does not offer resistance to the passage of the air.
Work on the Cylinders and Pistons
We strongly recommend that due to the high precision of the parts and the delicacy of some of the
operations, only persons with the necessary experience should work directly on the cylinders and pistons.
Ordering Spare Parts
Orders for spare parts must be accompanied by the following documentation:
- the compressor model and its serial number as well as the year of purchase
- the quantity, description, drawing number and code of the part requested
- the name or company name, complete address and VAT or tax code number.
1078.doc
Page 15
FAULT GUIDE
COMPRESSOR
PROBLEM PROBABLE CAUSE REMEDY
Does NOT turn over - Rust on the stages 1. Remove the belts:
If the compressor turns over freely,
the problem is in the motor.
- Blocked valves If it continues not to turn over call
CompAir UK Ltd Ipswich Service
Department
- Blocked motor 2. Remove the spark plug from the

motor:
If it begins to move, keep trying
after putting some oil in through the
spark plug hole to release it.
Turns over but is very stiff - The belts are too tight - Check the tension of the belts
- High engine compression - Remove the spark plug; if the
resistance decreases, turn over
several times by hand at the
compressor and then replace the
spark plug.
Turns over roughly - Slack belts - Tighten the belts.
- Pulleys not aligned - Align the pulleys.
Loss of output - Leaks from the pipe work and/or - Identify the leaks and eliminate
from the gaskets. them.
- Intake filter blocked. - Clean and/or substitute them.
- Leaking safety valves. - Adjust the valves.
- Leaks from the lines. - Replace the lines.
- Worn pistons and cylinder - Have the compressor overhauled
- Damaged intake or compression - Overhaul or substitute the valves.
Does NOT pump - Damaged or broken intake or
compression valves. - Proceed as above.
- Broken con-rod. - Call CompAir UK Ltd Ipswich
Service Department
Safety Valve Blowing - Broken suction or delivery valve. - The fault is generally in the stage
successive to the one for which the
safety valve has operated.
- Service the valves.
Excessive oil consumption - Worn pistons and cylinders. - Call CompAir UK Ltd Ipswich
- Worn rings. Service Department
A smell of oil in the - Condensation separators NOT - Drain condensation.
compressed air. emptied.
- Carbon deposits on the valves. - Clean the valves.
- Filter cartridge used up. - Replace filter cartridge.
1078.doc
Page 16

High compressor temp. - Dirty cooling fins and coils. - Clean coils and fins.
- Incorrect fan rotation direction. - Correct the fan rotation direction
on the poles of the three-phase
electric motor.
- Original fan replaced with an - Mount an original fan.
unsuitable one.
- Unsuitable type of oil. - Drain the oil in the sump and refill
with more suitable oil.
- Lack of oil. - Top-up the oil.
- Excessively high ambient temp. - Stop the compressor.
(Max. allowed 35°C).
Knocking is heard in the - Worn bearings or connection rod - Call CompAir UK Ltd Ipswich
compressor which stops bushes causing excessive play. Service Department
when the pressure
increases.
ELECTRIC MOTOR

Does not start. - No electrical supply - Check the main electric board.
- Fuses missing or blown. - Check and/or replace the fuses.
- Motor protection relay - Press the reset button on the
intervention motor protection relay.
- Check the pressure switch or
- Pressure switch failure or filter release the pressure.
pack under pressure.
Tries to start but then stops. - Insufficient cable section. - Have the electrical system and/or
- Insufficient supply power. motor checked by expert
- One phase missing. personnel.
Overheats and the r.p.m. - Belts too tight. - Adjust the voltage.
drops. - Voltage too low (check with a volt - Disconnect any other electrical
meter). items from the system and retry.
- Call a specialist.
PETROL ENGINE

Turns over but does not - Check that there is fuel in the - Add fuel if missing.
start. tank
- Check that the engine switching - Put the accelerator lever in the
on is not in the OFF position (to correct position.
earth).
- Oil missing in the crankcase. - Add oil to restore the level.

(Red pilot light on)
- Malfunction or pressure switch - Control the pressure switch and

intervention. release the pressure.
ATTENTION: - DO NOT DISASSEMBLE THE COMPRESSOR IF YOU ARE NOT SUFFICIENTLY

COMPETENT.
1078.doc
Page 17
IMPORTANT SAFETY NOTICE

The machines are safe and do not pose any risk to your health and safety if used in the correct way and in
compliance with the instruction manual.
All of the moving parts have been arranged so that they cannot be touched accidentally (couplings,
flywheels, pulleys, drive belts etc.) Do not remove the protection devices with the machine running and do
not use the compressor without having restored the safety conditions.
Everything which is connected to the machine must be suitable for the pressures and load capacities in use
(pipes, connections, additional safety devices, joints, etc.) It is also necessary to remember all of the
prescriptions and regulations concerning safety in the workplace.
Before every maintenance job or disassembly, isolate the machine from auxiliary equipment and disconnect
the electrical power supply cables. When working with three-phase electrical current, pay great attention to
the voltage.
Always release all pressure present in the machine and that in the pipework and tanks connected and
belonging to it but which are not concerned with the operations you wish to perform.
Always carefully check the condition of the threads, especially of the frequently dismounted parts such as
filters and tanks. Do not remount components which have damaged external threads and above all those
with damaged or worn internal ones. The danger exists that they are no longer capable of supporting the
high pressures with consequent danger to persons and things. Do not make holes in pressure vessels,
without having consulted the constructor, for whatever reason.
Do not tamper with the machine to make it work beyond the designed maximum working pressure trusting in
the planned safety and test margins. This is absolutely forbidden and dangerous.
Remember that as a precautionary measure, after 4 years it must be checked at a pressure equal to 1.5 that
of the filter pack pressure.
The seals created with viton 'O' rings are perfectly safe at the temperatures at which the compressor
normally works.
However, if the fins suffer fire damage or if the temperature of 300°C is exceeded, the viton material does
not burn but decomposes emitting hydrogen fluoride fumes. If these fumes come into contact with water they
may react to form hydrofluoridic acid which provokes serious blistering when in contact with the skin.
If the seals appear to be burned or rubbery, do not touch these parts, or the parts around them with the
hands unless neoprene or PVC gloves are worn.
Wash the area with water containing lime and avoid breathing in the fumes. Should contact be made with the
skin, wash with water and go immediately to a first aid centre.
1078.doc
Page 18
1
ILLUSTRATED PARTS LIST

ITEM NO. DRAWING DESCRIPTION QUANTITY
NO.
1 - CRANKCASE 1
2 - DRAIN TAP 1
3 - OIL FILLER 1
4 - DIP STICK 1
5 - CRANKSHAFT 1
6 98076.1121 BEARING MAIN 3
7 98504.1362 'O' RING BEARING COVER O/E 1
8 - BEARING COVER O/E 1
9 98505.1032 OIL SEAL O/E 2
10 - CAP HEAD SCREW 8
12 - DISTANCE PIECE SHORT 1
13 - BALANCE WEIGHT 1
14 - DISTANCE PIECE LONG 1
16 98504.1363 'O' RING BEARING COVER D/E 1
17 - BEARING COVER D/E 1
20 - PULLEY 1
21 - HEX. HEAD SCREW 1
22 - 1ST STAGE CONN ROD 1
23 98076.1122 BEARING B/E 4
24 98076.1123 BEARING S/E 2
25 - PISTON 1ST STAGE 1
26 - GUDGEON PIN & CIRCLIPS 1
27 98477.1161 1ST STAGE PISTON RING SET 1
28 98504.1355 1ST STAGE CYLINDER 'O' RING 2
29 - 1ST STAGE CYLINDER 1
30 98650.1955 1ST STAGE VALVE ASSY. 1
31 - 1ST STAGE CYLINDER COVER 1
34 98262.1237 SUCTION FILTER 1
35 - CRANKCASE BREATHER TUBE 1
36 - COOLER COIL 1ST STAGE 1
37 PIPE CLAMP 1
38 - 2ND STAGE CONN ROD 1
41 - 2ND STAGE PISTON 1
42 - 2ND STAGE GUDGEON PIN 1
43 98477.1162 2ND STAGE PISTON RING KIT 1
44 98504.1356 2ND STAGE CYLINDER 'O' RING 2
45 - 2ND STAGE CYLINDER 1
46 - 2ND STAGE VALVE COVER 1
47 98650.1958 2ND STAGE SUCTION VALVE 1
48 98650.1956 2ND STAGE DELIVERY VALVE 2
49 - 2ND STAGE CYLINDER COVER 1
50 - HEAD SEAL SCREWS 4
51 - COOLER COIL 2ND STAGE 1
52 - PIPE CLAMP 1
53 - 3RD/4TH STAGE CONN ROD 2
54 98076.1124 BEARING S/E 2
56 - 3RD STAGE PISTON GUDGEON PIN 1
57 - 3RD STAGE PISTON 1
58 98477.1163 3RD STAGE PISTON RING SET 1
59 98504.1360 3RD STAGE CYLINDER 'O' RING 4
60 - 3RD STAGE CYLINDER 1
61 - LINER 1
62 - 3RD STAGE VALVE COVER ASSY. 1
63 - NOT USED
1078.doc
Page 19

NO.
64 - 3RD STAGE CYLINDER COVER 1
66 - 3RD STAGE COOLER COIL 1
67 - PIPE CLAMPS 1
68 - TUBE ASSY. 3RD STAGE 1
72 - 4TH STAGE PISTON GUDGEON PIN 1
73 98443.1001 4TH STAGE PLUNGER/LINER ASSY. 1
74 98504.1357 'O' RING 4TH STAGE CYLINDER 1
75 - 4TH STAGE CYLINDER 1
76 98504.1358 4TH STAGE 'O' RING 1
77 - 4TH STAGE CYLINDER 1
78 98518.1093 4TH STAGE VALVE SPRING 1
79 - 4TH STAGE VALVE COVER 1
81 - 4TH STAGE COOLER COIL 1
82 - PIPE CLAMPS 1
83 - FAN 1
84 FAN HUB CAP 1
85 - SNORKEL TUBE BRACKET 1
86 - SNORKEL UNION 1
87 98262.1235 SNORKEL FILTER 1
88 - PVC EXTENSION TUBE 2
90 - BASEPLATE 1
91 - ANTI-VIBRATION MOUNT 4
93 - BELT GUARD 1
94 - RUBBER MOUNTING PLATE 1
95 - FIXING SCREWS 5
96 - TRANSPORT HANDLE 1
97 - FIXING SCREWS 8
100 - FAN GUARD 1
103 - CROSS HEAD SCREWS 2
104 - FILTER BODY 1
106 - PRESSURE SWITCH 1
107 - 4TH STAGE SAFETY VALVE 1
109 - CONDENSATE DRAIN VALVE 2
110 - SEPARATOR BOTTOM COVER 1
111 98650.1957 3RD STAGE VALVE 1
112 - 4TH STAGE SEPARATOR TOP COVER 1
113 98262.1236 FILTER CARTRIDGE 1
114 98504.1359 FILTER CARTRIDGE 'O' RING 1
115 - FILTER CARTRIDGE PLUG 1
117 98315.1176 FILTER HOSE ASSY. 1
118 98318.1005 BOTTLE CONNECTION 1
119 - FRONT MOUNTING BRACKET 1
120 - REAR MOUNTING BRACKET 1
121 - NUTS 8
122 - HOSE BLANKING CONNECTOR 1
1078.doc
Page 20

NO.
123 - 5.5 HP HONDA ENGINE 1
124 - 'A' 75 PULLEY 1
125 98080.1476 COMBUSTION ENGINE BELT 1
126 98384.1026 COMBUSTION ENGINE OIL 1
127 - 4 HP 220/380 50 HZ MOTOR 1
128 - 'A' 95 PULLEY FOR THREE PHASE 1
129 98080.1477 THREE PHASE MOTOR BELT 1
130 - THREE PHASE CONTROL PANEL 1
131 - 380 V REMOTE SWITCH 1
132 - THERMAL CUT-OUT SWITCH 7.5 - 10.2 A 1
133 - START BUTTON 1
134 - STOP BUTTON 1
135 - 3 HP 220 V 50 HZ MOTOR 1
136 - PULLEY FOR SINGLE PHASE 1
137 98080.1475 BELT FOR SINGLE PHASE 1
138 - SINGLE PHASE CONTROL UNIT 1
139 - 220 V REMOTE SWITCH 1
140 - 13.5 - 20 A THERMAL CUT-OUT SWITCH 1
141 - START CONDENSER 1
142 - PHASE CONDENSER 1
144 - STOP BUTTON 1
145 98384.1025 1 LT. COMPRESSOR OIL 1
146 - COMPRESSOR COVER 1
147 - TOOL KIT 1
148 - COMPRESSOR PACKAGING 1
149 - 2 METRE HIGH PRESSURE LINE 1
152 - 1 METRE TRANSFER LINE 1
153 - 220 V 50 HZ HOUR COUNTER 1
154 - 380 V 50 HZ HOUR COUNTER 1
155 - PRESSURE GAUGE 1
156 - 200 BAR DIN CONNECTOR 1
157 - 300 BAR DIN CONNECTOR 1
158 - SELF PROTECTING CONNECTOR 1
159 - INTERNATIONAL DIN ADAPTOR 1
160 - INTERNATIONAL DIN ADAPTOR 1
161 - 220/380 60 HZ THREE PHASE MOTOR 1
162 - PULLEY FOR THREE PHASE 60 HZ M. 1
163 98080.1475 BELT FOR THREE PHASE 60 HZ M. 1
164 - THREE PHASE CONTROL UNIT 1
165 - 380 V 60 HZ REMOTE SWITCH 1
166 - 7.5 - 10.2 A THERMAL SWITCH 1
168 - STOP BUTTON 1
169 - SINGLE PHASE 220 V 60 HZ MOTOR 1
170 - PULLEY FOR 220 V 60 HZ M. 1
171 98080.1476 BELT FOR 220 V 60 HZ M. 1
172 - SINGLE PHASE CONTROL UNIT 1
173 - 220 V 60 HZ REMOTE SWITCH 1
174 - 13.5 - 20 A THERMAL CUT-OUT SWITCH 1
176 - PHASE CONDENSER 1
178 - STOP BUTTON 1
1078.doc
Page 21
PRESSURE SWITCH
T
V
NA
C
NC
C3
NA NC
2 1
T
A NPT
30 x 30 37
with electric motor connect the wires to nos. 1 and 3

with combustion engine connect wires to nos. 2 and 3
V = pressure switch adjustment screws.
1078.doc
Page 22
ELECTRICAL DIAGRAM FOR COMPRESSOR

EQUIPPED WITH A THREE PHASE MOTOR 60HZ
N LABEL TYPE DESCRIPTION

01 M1 MOTOR B3 2 POLE 260/440 VAC 3 KW 60Hz
02 RT1 THERMAL SWITCH LOVATO 7-10 A
03 K1 REMOTE CONTROL S. LOVATO AC3 5.5 KW BOB 440 VAC
04 PRS PRESSURE SWITCH AIR 150/300 BAR
05 PA NC BUTTON COMPRESSOR STOP BUTTON D.22
MUSHROOM TYPE
06 PM NA BUTTON COMPRESSOR START BUTTON D.22
07 F FUSE 2 AMP
08 T TRANSFORMER 440VOLTS TO 220 VOLTS
1078.doc
Page 23

EQUIPPED WITH A THREE PHASE MOTOR
R
S
T
N
F
K1
PA
PM
K1
RT1
RT1
U
PRS
K1
M1
M1
90C
PE
2/M
2/F
2/F
GND 2/G
COMPONENT NAMES
N LABEL TYPE DESCRIPTION

01 M1 MOTOR B3 2 POLE 220/380 VAC 3 KW
02 RT1 THERMAL SWITCH LOVATO 7-10 A
03 K1 REMOTE CONTROL S. LOVATO AC3 5.5 KW BOB 380 VAC
04 PRS PRESSURE SWITCH AIR 150/300 BAR
05 PA NC BUTTON COMPRESSOR STOP BUTTON D.22
MUSHROOM TYPE
06 PM NA BUTTON COMPRESSOR START BUTTON D.22
07 F FUSE 2 AMP
1078.doc
Page 24

EQUIPPED WITH A SINGLE PHASE MOTOR
220V ac
50Hz
R
N
PE
13
PM K1
14
K1
1 3 5
PM
2 4 6
PRS
RT1 95
RT1
96
K1
C1 C2
M1
OG1
COMPONENT NAMES
N LABEL DESCRIPTION
01 M1 SINGLE PHASE MOTOR B3 220V 50 HZ. KW 2.2
02 RT1 THERMAL RELAY 13.5 - 20 A
03 K1 REMOTE CONTROL SWITCH 3.2 KW, AC3, 220 VOLTS
04 PM START BUTTON
05 PA STOP BUTTON
06 PRS DIFFERENTIAL PRESSURE SWITCH WHICH CAN BE SET
AT DIFFERENT PRESSURE)
07 C1 CONDENSER 40 MICRO FARADS 250 VOLTS
08 C2 CONDENSER 156 MICRO FARADS 250 VOLTS
09 0G 1 CENTRIFUGE LIMIT SWITCH (RPM M1) 90% = NOMINAL RPM
1078.doc
49
50
65
51
48 47
46
64
52 10
62 45 17
77 3 16
61 60 58 41
4 6
43
21
48 42 6
20
66 57
24 38 9 35
59 23 88
56 14
13 27
54 53 23 23 12
1 24 26
67
10 53 22
2 34
23 87
25 16
5 54
72
6 74
7
8 29
9 85
75 73 28
81
76
COMPRESSOR ASSEMBLY
30 86
31
77 33
68 37
83 78
84 80
79
82 36
Page 25
1078.doc
Page 26
BASEPLATE ASSEMBLY
116
115
114
103
113
110
117
112
118
109
97
104 95
111
101
110 92
106 96
107 121
94
97
97 119
120
122
93
121
90
91
95
1078.doc
Page 27
PETROL ENGINE
THREE PHASE ELECTRIC MOTOR
AND ACCESSORIES
126 145
123
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1078.doc
Page 28
SINGLE PHASE ELECTRIC MOTOR

HOSE CONNECTIONS
AND PACKING
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1078.doc
WARNING
The use of replacement parts or lubricating oils not supplied, recommended or approved
by CompAir UK Ltd. Ipswich, may lead to failure in service which would not be covered
by the warranty.
Any unauthorised modifications or failures to maintain this equipment is accordance with

the manufacturers maintenance instructions may make it unsafe. The use of replacement
parts not supplied by or recommended by CompAir UK Ltd may create unsafe and
hazardous conditions or result in damage to the equipment over which CompAir UK Ltd
has no control. Such hazardous conditions may lead to accidents that can be life
threatening, cause substantial bodily injury or result in damage to the equipment.
CompAir UK Ltd can bear no responsibility for equipment in which unapproved

replacement parts are included.
GENUINE PARTS
CompAir UK Ltd
Use Reavellite compressor lubricant.

Advantages:
• Longer life.
• Longer time between oil changes.
• Longer valve life.
• Can be used in new or old compressors.
• Reduces carbon build up.
• Reduces oil consumption.
CompAir UK Ltd
Sales, Service and Parts
Ranelagh Road
Ipswich
IP2 0AE
England
Telephone: +44 (0) 1473 602222
Customer Service: +44 (0) 1473 556027
Fax: +44 (0) 1473 601704
Parts Fax: +44 (0) 1473 601282
www.CompAir.com
e-mail: Ipswich@CompAir.com

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CompAir UK Ltd TO VIEW CONTENTS

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ADDITIONALLY IN SOME CIRCUMSTANCES INFORMATION CAN BE OBTAINED BY

In any correspondence please quote: JOB NUMBER:

CompAir UK Ltd. Ranelagh Road IPSWICH ENGLAND IP2 0AQ

of RANELAGH ROAD, IPSWICH, ENGLAND IP2 0AQ

Machine Type Rotary Compressor Reciprocating Compressor

Model No. _________________________ Serial No.________________________________

DATE __________________ ENGINEERING DIRECTOR

Conformity assessment procedure: Module H (H1 where appropriate)

OPERATOR MANUAL - 5000 SERIES AIR

CompAir UK Ltd Ipswich cannot accept responsibility for damage,

CompAir UK Ltd Ipswich

09/10/02 safety5.doc Page 1

Model Type: Motor Serial Number:

Serial Number Motor RPM:

Year: Motor kW:

Maximum Pressure: Motor V. Ph. Hz:

Compressor Lubricant: Motor Bearing Grease:

Capacity M³/hr - CFM Notes:

CompAir UK Ltd Ipswich CONTACT DETAILS

Contact Name: Sales Telephone: +44 (0) 1473 602222

Contact Names: Parts Telephone: +44 (0) 1473 602222

Contact Names: Service: +44 (0) 1473 556027

Page 2 09/10/02 safety5.doc

09/10/02 safety5.doc Page 3

Page 4 09/10/02 safety5.doc

09/10/02 safety5.doc Page 5

Page 6 09/10/02 safety5.doc

CompAir UK Ltd Ipswich compressor safety relates

• Most accidents which occur during the operation

• When handling, operating or carrying out

• Failure to observe these precautions given

09/10/02 safety5.doc Page 7

3. GENERAL SAFETY PRECAUTIONS (Cont.) be guarded or insulated. Other high temperature

• Pipework or other parts with a surface

Page 8 09/10/02 safety5.doc

• Wash the area with limewater and avoid

6. MAINTENANCE & REPAIR PRECAUTIONS

• Always clean oil spills from the surrounding floor

09/10/02 safety5.doc Page 9

• Precautions must be taken against using acids,

• When disposing of condensate, old oil, used

Page 10 09/10/02 safety5.doc

COMPRESSOR LOG SHEET

TECHNICAL DATA PAGE 5

INSTALLATION & OPERATION PAGE 6

ELECTRIC MOTOR PAGE 8

COMBUSTION ENGINE PAGE 8

STARTING UP THE COMPRESSOR PAGE 9

MAINTENANCE INSPECTIONS PAGE 10

OPERATING & ROUTINE MAINTENANCE PAGE 11

FAULT GUIDE PAGE 15

SAFETY WARNINGS PAGE 17

ILLUSTRATED PARTS LIST PAGE 18

PRESSURE SWITCH PAGE 21

ELECTRICAL DIAGRAM THREE PHASE MOTOR 60Hz PAGE 22

ELECTRICAL DIAGRAM THREE PHASE MOTOR 50Hz PAGE 23

ELECTRICAL DIAGRAM SINGLE PHASE MOTOR PAGE 24

COMPRESSOR EXPLODED VIEW PAGE 25

BASEPLATE ASSEMBLY PAGE 26

PETROL ENGINE PAGE 27

Model No. _ Serial No.________