Air Compressor - Groz engineering tools pvt ltd Reciprocating Air Compressor.pdf · Air Compressor RAC/7.5-22/270 FIG. 3 RAC/5.5-22/200 FIG. 2 DUAL MATERIAL CONSTRUCTION Worlds only

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INSTRUCTION MANUALS2310, REV A

Air Compressor

RAC/7.5-22/270FIG. 3

RAC/5.5-22/200FIG. 2

DUAL MATERIAL CONSTRUCTION Worlds only compressor with a unique dual material construction

The cylinder block is made up of cast iron that prevents wear & tear thus imparting longevity to the unit

Crankcase & cylinder head are made from aluminium – Compact design and choice of aluminium as a raw material helps in efficient cooling of the unit. Aluminium crankcase keeps the oil in the sump cooler thus enhancing the performance of the unit.

EFFICIENT VENTILATIONLarger flywheel keeps air directed towards the cylinder for faster heat dissipation & efficient ventilation

High Pressure Cylinder with a higher temperature is placed closer to the flywheel which further helps in faster cooing of the unit

Output tubing designed to pass from the front of the flywheel, further reducing the temperature of the air in the tank

IN-LINE DESIGNCompact & Superior to “V “type construction: air flow in the in-line design is directed towards both the cylinders uniformly keeping maximum temperature within check as compared to the” V” type construction where air flow is directed towards one side of the “V”

MOTORClass “F” insulation, motor is designed as per EURO norms

AIR FILTEREasy maintenance & replaceable sponge type air filter is easily washable

BUILT IN STARTERProtects the unit from sudden voltage fluctuation & enables usage with varying voltages

INTERCOOLERIn multiple-stage version: Reduces the temperature of compressed air which improves efficiency by reducing power consumption.

BOLTED DESIGN BASE PLATEMakes it convenient to assemble or dis-assemble the compressor unit from the tank. Bolted design also eliminates possibility of rust as compared to a welded design

SAFETy VALVESIn-built safety valves for releasing excess pressure

Oil sight glass for controlling the oil level

Drainage port for emptying the condensate collected in the tank

Caged belt and pulley assembly for enhanced safety in operation

Electric Motor

Pressure Switch

Pressure Gauge

Protective Cage

Belt DriveAir Filter

Intercooler

Safety Valve

Base

Receiver Tank

RAC/3-21/150FIG. 1

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WARNING1. Never touch moving parts: Never place your hands, fingers

or other body parts near the compressor’s moving parts.

2. Never operate without all guards in place: Never operate this compressor without all guards and safety features in place and in proper working order. If maintenance or servicing requires removal of a guard or safety features, be sure to replace the guards or safety feature before resuming operation of the compressor.

3. Always wear Eye protection: Always wear safety goggles or equivalent eye protection. Compressed air must never be aimed at anyone or any part of the body.

4. Protect yourself against electric shock: Prevent body contact with the grounded surfaces such as pipes, radiators, ranges and refrigeration enclosures. Never operate the compressor in damp or wet locations.

5. Disconnect the compressor: Always disconnect the compressor from the power source and remove the compressed air from the air tank before servicing, inspecting, maintaining, cleaning, replacing or checking any parts.

6. Avoid unintentional starting: Do not carry the compressor while it is connected to its power source or when the air tank is filled with compressed air. Be sure the knob of the pressure switch is in “OFF” position before connecting the compressor to its power source.

7. Store compressor properly: When not in use, the compressor should be placed in a dry place. Keep out of reach of children.

8. Keep work area clean: Cluttered areas invite injuries. Clear all work areas of unnecessary tools, debris, furniture etc.

9. Dress Properly: Do not wear loose clothing or jewellery. They can be caught in the moving parts of the compressor.

10. Don’t abuse cord: Keep cord away from heat, oil and sharp edges.

11. Maintain compressor with care: Follow instructions for lubricating, inspect cords periodically and if damaged, have them repaired by authorized service personnel.

12. Outdoor use extension cords: When compressor is used in outdoors, choose extension cords intended for use outdoors use only.

13. Stay alert: Do not operate compressor when you are tired.

14. Handle compressor correctly: Operate the compressor according to the instructions provided herein. Never allow the compressor to be operated by children, individuals unfamiliar with its operation or unauthorized personnel.

15. Keep all screws, bolts and covers tightly in place. Check their condition periodically.

16. Keep motor air vent clean: The motor air vent must be kept clean so that air flows freely at all times.

17. Operate the compressor at the rated voltage: Operate the compressor at voltages specified on the specification plate. If using the compressor at higher voltage than the rated voltage. It will result in abnormal fast motor revolution and may damage the unit and burn the motor.

18. Never use a compressor which is defective or operating abnormally: If the compressor appears to be operating unusually, making strange noises, or otherwise appears defective, stop using it immediately and arrange for repairs by a authorized service centre.

19. Do not wipe plastic parts with solvent: Solvents such as gasoline, thinner, benzene, carbon tetrachloride and alcohol may damage and crack plastic parts. Do not

SPECIFICATIONS

RAC/3-21/150 RAC/3-21/150-1 RAC/3-21/200 RAC/3-21/200-1 RAC/5.5-22/200 RAC/7.5-22/270

MOTOR RATING 2.2 KW 2.2 KW 2.2 KW 2.2 KW 4 KW 5.5 KW

3 HP 3 HP 3 HP 3 HP 5.5 HP 7.5 HP

CYLINDER 2 2 2 2 2 2

STAGE 1 1 1 1 2 2

AIR RECEIVER CAPACITY

150 litres 150 litres 200 litres 200 litres 200 litres 270 litres

AIR DISPLACEMENT 350 LPM 350 LPM 350 LPM 350 LPM 550 LPM 830 LPM

12.4 CFM 12.4 CFM 12.4 CFM 12.4 CFM 19.5 CFM 29 CFM

FAD (FREE DELIVERY)

190 LPM 190 LPM 190 LPM 190 LPM 4400 LPM 620 LPM

6.7 CFM 6.7 CFM 6.7 CFM 6.7 CFM 15.53 CFM 22 CFM

MAX. PRESSURE12 BAR 12 BAR 12 BAR 12 BAR 12 BAR 12 BAR

175 PSI 175 PSI 175 PSI 175 PSI 175 PSI 175 PSI

NOISE LEVEL 74±3 db (A) 74±3 db (A) 74±3 db (A) 74±3 db (A) 75±3 db (A) 76±3 db (A)

DIMENSIONS

1360 mm 1360 mm 1360 mm 1360 mm 1460 mm 1600 mm

460 mm 460 mm 460 mm 460 mm 460 mm 500 mm

990 mm 990 mm 990 mm 990 mm 1000 mm 1040 mm

WEIGHT 115 kg 115 kg 115 kg 115 kg 158 kg 192 kg

CLASS OF INSULATION F F F F F F

ELECTRIC SUPPLY400 V, 3 Phase, 50 Hz.

230 V, Single Phase

400 V, 3 Phase, 50 Hz.

230 V, Single Phase

400 V, 3 Phase, 50 Hz.

400 V, 3 Phase, 50 Hz.

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FIG. 5

INSTALLATION1. POSITIONING

1. Remove the compressor from its packing, make sure it is in perfect condition. (See FIG. 4)

FIG. 4

wipe them with such solvents. Wipe plastic parts with a soft cloth lightly dampened with soapy water and dry thoroughly.

20. Use only genuine replacement parts: Duplicate parts may void your warranty and can lead to malfunction and resulting injuries.

21. Do not modify the compressor: Always contact the service centre for any repairs. Unauthorized modification may not only impair the compressor performance but may also result in accident or injury to repair personnel who do not have any technical knowledge about the compressor.

22. Turn off the pressure switch when the compressor is not in use: When the compressor is not in use, turn the knob of the pressure switch OFF, disconnect it from the power source and open the drain valve to discharge the water and compressed air from the tank.

23. Never touch hot surface: To reduce the risk of burns, do not touch tubes , heads, cylinders and motors.

24. Do not direct air stream at body at body of a person or an animal.

25. Drain tank: Drain tank daily or after 4 hours of use. Open drain and tilt compressor to empty accumulated water.

26. Do not stop the compressor by pulling out the plug. Use the “AUTO/OFF” knob of pressure switch.

GROUNDING INSTRUCTIONS

This compressor should be grounded whw use to protect the operator from electric shock. The compressor is equipped with a three-pole conductor cord and three-prong grounding type plug to fit the proper grounding type receptacle. The green (or green and yellow) conductor in the cord is the grounding wire.

WARNINGNever connect the green (or green and yellow) wire to a live terminal.

WARNINGTake care while transporting the compressor, do not overturn it or lift it with hooks or ropes. (See FIG. 5)

WARNINGNever use this compressor with a damaged or frayed electrical cord or extension cord. Inspect all electrical cords regularly. Never use near water or in any environment where electric shock is possible.

EXTENSION CORD

Use only three extension cords that have three-prong grounding type plugs and three-pole receptacles that accept the compressor’s plug. Replace or repair damaged cord. Make sure your extension cord is in good condition. When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating.Table shows the correct size to use depending on cord length and specification plate amp rating.

HP KW 220/230 V 110/120 V

(mm2) (mm2)

2,5 - 3 1,8 – 2,2 4 -

HP KW 230 V 380/400V

(mm2) (mm2)

2-3-4 1,5-2,2-3 2,5 1.5

5,5 4 4 2.5

7,5 5,5 6 2.5

The diameter of the extension cable of the 3-phase compressors must be in proportion to its length: see table (tab 2)

Tab. 2 SECTION VALID FOR A MAX LENGTH OF 20 mt three- phase

2. Position the compressor on a flat surface or on a maximum permissible inclination of 10°, in a well aired place, protected against atmospheric agents and not in a place subjected to explosion hazards.

3. If the surface is inclined and smooth, check if the compressor moves while in operation- if it does, secure the compressor with two wedges.

4. If the surface is a bracket or a shelf top, make sure it does not fall, securing it in a suitable way.

5. To ensure good ventilation and efficient cooling, the compressor’s belt guard must be at least 1m away from any wall.

Tab.1 SECTION VALID FOR A MAX LENGTH OF 20 mt single- phase

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1 2

3 4 5

6 7

8

9

10

11 12 13

MAXMIN

MAXMIN

MAXMIN

A

B

Single phase compressor is supplied with an electrical cable and a two-pole+earth plug. The compressor must be connected to a grounded power socket (See FIG. 6)

2. ELECTRICAL CONNECTION

FIG. 6

FIG. 7

Three phase compressor must be installed by a specialized technician. Three-phase compressors are supplied without a plug. Connect a plug with screw on grommet and securing collar (See FIG. 7) to the cable.

WARNINGWrong connections can result in motor rotating in reverse direction, which can damage the internal components of the compressing unit.

ADjUSTING THE PRESSURE RANGE

DRAINING THE CONDENSATE

1. Unscrew the drain valve present at the bottom of the air receiver tank (FIG. 12).

2. Allow all the water to flush out through the drain valve.

3. Screw the drain valve back.

Note: Drain valve can also be used to empty the tank.

Black Lid

FIG. 11

FIG. 12

CLEANING OR REPLACING THE FILTER

FIG. 13

2. Clean / Replace the filter element a. Pull out the Sponge filter element and soak it into a

water bucket and retract and squeeze till all the water content is squeezed out.

b. Replace the sponge Filter element with a new element, if required.

3. Reassemble the filter unit.17

15

18

19

21 22

14 16

20

23

A

B

OPERATING THE COMPRESSOR

1. Before starting the compressor, check that the electricity supply to the compressor is in accordance with the specification label on the compressor tank (FIG. 8).

FIG. 8

FIG. 9

FIG. 10

3. Compressors works on a pressure range of 2 Bar. The default setting of the compressor is max. 8 bar and min. 6 bar.

4. Pressure switch automatically switches OFF the compressor when the pressure inside the tank reaches 8 bar and it automatically switches ON again when it reaches 6 bar.

Note: The pressure range can be varied with the help of the screw inside starter unit. (Refer “Adjusting the pressure range“)

5. Manually push the On/Off button down to switch off the compressor when not in use.

IMPORTANT (ONLy IN 3HP COMPRESSORS)

2. Compressor can be switched ON by pulling the plug on the pressure switch (FIG. 9).

The motors of the belt drive series compressors are supplied with a manually resetting amperometric thermal-breaker, located on the terminal board cover. When the breaker is tripped, wait for a few minutes and then reset the breaker manually (See FIG. 10).

1. Remove the black lid present on the top of the pressure switch cover next to the On/ Off pressure switch (FIG. 11).

2. Unscrew the bolt inside the lid hole and pull out the cover. 3. Tighten or loosen the hexagonal bolt using a size 10

spanner depending on the pressure requirement.

For Example: If the compressor has 8 bar maximum switch Off limit and 6 bar minimum switch On limit, this can also be changed to 7 bar maximum and 5 bar minimum. Remember that the range will always be of 2 bar between the maximum and the minimum level.

Note: 1. Clockwise rotation of the hexagonal bolt increases

the maximum pressure and anticlockwise rotation will decrease the maximum pressure.

2. Start the compressor to check the maximum switch Off

limit then release the pressure to check the switch On limit. Repeat step 1 to reach the desired pressure setting (For this pressure can be seen on the pressure gauge mounted on the tank

1. Unscrew the nut on the air filter to disassemble the filter body (FIG. 13).

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MAINTENANCE

Before attempting any maintenance jobs on the compressor, make sure of the following

• Master power switch is in “switched off” position. • Make sure there is no pressure inside the air tank. Refer

“Draining the condensate”.

OIL CHANGES – TOPPING UP WITH OIL

2. Pour oil into the upper hole of the oil sump until it reaches the centre red point on the oil lever indicator (FIG. 15).

3. Push the dip stick back into the oil sump hole.

FIG. 14

FIG. 15

The compressor is filled with synthetic oil.

1. Unscrew the drain plug on the oil sump, allow all the oil to flow out, and re-screw the plug (FIG. 14).

Note: Once a week: check oil level in the oil sump and see if it needs topping up.

For operation at ambient temperature in the range -5°C to +40°C, use synthetic oil. The advantage of this oil is that is does not lose its characteristics either in winter or summer.

Do not drain used oil into the sewer or dispose off in the environment.

FOR OIL CHANGES

TyPE OF OIL: Mineral Multi-grade (SAE 15 W40) with 100 hours duty.

Synthetic Oil with 500 hours duty.

INSPECTION SCHEDULE MAINTENANCE ACTION

EVERY 50 OPERATING HRS

Drain the water condensate collected in the air receiver using the Drain valve.

Clean the air filter element (required only when the compressor is used in dusty environment).

Check the oil level in the Oil level indicator and refill up to the max level indicator if required.


Clean the air filter element (even if the compressor is not used in dusty environment).

Change the lubricating oil if normal lubricating oil is used.

Use a belt dressing spray to increase the operating life of the belt.

Fill the oil only upto the max. level indicator.

EVERY 500 OPERATING HRSTHERE IS NO OUTPUT

Change the air filter element.

Check the operation of the compressor at rated Pressure.

Check all the couplers and fasteners for proper tightness.

Change the lubricating oil if Synthetic lubricating oil is used.

Fill the oil only upto the max level indicator.


Check the operation of the compressor at rated pressure.

Change the air filter element.

Change the lubricating oil if Synthetic lubricating oil is used.

Fill the oil only upto the max level indicator.

MAINTENANCE INSTRUCTION

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PRObLEM POSSIbLE CAUSE SOLUTION

Air losses. This trouble may be due to poor tightening of the check valves.

Discharge all pressure from the tank.

Unscrew the hexagon-head of the valve (A).

Carefully clean both the rubber disk (B) and its seat..

Refit all parts accurately.

These can be caused by poor tightening of joint. Check all joints by wetting them with soapy water and probing for any leaks.

Compressor turns but does not load. Pulley drive compressors: (See Fig. 13)this may be due to failure of the valves F1 and F2 or of a seal (D1 – D2).

Replace the damaged part.

Compressor not starting. Power supply is not according to the model. Use supply according to the data plate.

Power cable extensions are not of adequate diameter or length.

Refer “Extension cord Table”.

Oil deficiency in compressor. Top up the oil refer “oil changes”.

Is power supplied to the electrical line? Check the electric supply .

Compressor not stopping If the compressor does not stop when maximum pressure is reached, the tank safety valve may not be working.

To repair the valve, contact your nearest service centre.

There is no air output Air filter may be blocked Clean or replace the filter

Pulley rotating in opposite direction 3 phase connections might be reversed. Get the connections changed by an trained electrician.

RAC/3-21/150 &RAC/3-21/200FIG. 18

MAINTENANCE INSTRUCTION

EXPLODED VIEW

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REPAIR KIT

PART LIST

REFERENCE NO. DESCRIPTION QTY.

1 Tank 1

2 Pressure Switch Kit 1

2.1 Locking Nut 1

2.2 Joint 1

2.3 Joint 1

2.4 Joint 1

2.5 Pressure Gauge 1

2.6 Safety Valve 1

2.7 Pressure Switch 1

2.8 Infeed Cable 1

3 Screw Kit 1

3.1 Washer 3

3.2 Screw 1

3.3 Screw 2

3.4 Nut 4

3.5 Nut 4

3.6 Washer 4


3.7 Screw 4

3.8 Screw 4

3.9 Screw 4

4 Motor/Pulley Kit 1

5 Belt Guard Kit 1

6 Joint 1

7 Plug 1

8 Plug 1

9 Valve 1

10 Drain Valve 1

11 Base 1

12 Check Valve 1

13 Rilsan Hose 1

14 Infeed Hose 1

15 Belt 1

16 Belt Guard Support 1

17 Pump Unit 1

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REPAIR PART LIST

PART NO. SR. NO. DESCRIPTION QTY. SUPPLY CONDITION

KIT/RPR/PLT/CT/150-10(pump head valve plate kit)

1.1 Valve Plate 2 loose

1.2 Valve 4

1.3 Gasket 1

KIT/RPR/GST/CT/150-10(pump gasket kit)

2.1 Gasket 1 loose

2.2 Gasket 1

2.3 Gasket 1

KIT/RPR/PST/CT/150-10(connecting rod and piston kit)

3.1 Connection Rod 2 loose

3.2 Piston Pin 2

3.3 Piston 2

3.4 Piston Rings Kit 2

3.5 Rings 4

KIT/RPR/SWH/CT/150-10(pressure switch kit)

4.1 Locking Nut 1 loose

4.2 Joint 1

4.3 Joint 1

4.4 Plug 1


4.6 Safety Valve 1


4.8 Infeed Cable 1

KIT/RPR/SWH/AC-3/CT/150-10(pressure switch kit)

5.1 Pressure Switch Kit 1

5.2 Joint 1 loose

5.3 Plug 2


5.5 Pressure Switch/ Motor Cable 1

5.6 Infeed Cable 1


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RAC/5.5-22/200FIG. 19

REFERENCE N0. DESCRIPTION QTY.

1 Pump Unit 1


2.1 Joint 1

2.2 Plug 2


2.4 Pressure Switch/Motor Cable 1

2.5 Infeed Cable 1

3 Screw Kit 1

3.1 Washer 4

3.2 Washer 12

3.3 Washer 2

3.4 Washer 4

3.5 Screw 2

3.6 Nut 2

3.7 Screw 2

3.8 Screw 4

3.9 Vite M10x30 Uni-5739 6

3.10 Screw 14


3.11 Nut 1


5 Belt Guard Kit 1

6 Base 1

7 Tank 1

8 Joint 1

9 Plug 1

10 Plug 1

11 Pressure Gauge 1

12 Valve 1

13 Drain Valve 1

14 Check Valve 1

15 Safety Valve 1

16 Rilsan Hose 1

17 Infeed Hose 1

18 Belt 1


PART LIST

EXPLODED VIEW

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REPAIR KIT

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KIT/RPR/FLT/CT/200-10(intake filter kit)

1.1 Filter Cover 1 loose

1.2 Filter Base 1

1.3 Filtering Element 2

1.4 Screw 1

KIT/RPR/PST/LP/CT/200-10(LP conn. rod/piston kit)

2.1 Low Pressure Ring 1 loose

2.2 Piston 1

2.3 Piston Pin 1

2.4 Internal Snapring 2

2.5 Con Rod 1

KIT/RPR/PST/HP/CT/200-10(HP conn. rod/piston kit)

3.1 High Pressure Ring 1 loose

3.2 Piston 1

3.3 Con Rod 1

3.4 Piston Pin 1

3.5 Internal Snap Ring 2

KIT/RPR/SCR/CT/200-10(screw kit)

4.1 Screw 6 loose

4.2 Screw 1

4.3 Screw 12

4.4 Washer 1

4.5 Screw 1

4.6 Washer 1

4.7 Screw 8

4.8 Screw 6

4.9 Screw 6

KIT/RPR/GST/CT/200-10(gasket kit)

5.1 Gasket 1 loose

5.2 Gasket 3

5.3 Gasket 1

5.4 Gasket 1

5.5 Oil Seal 1

5.6 Gasket 1

5.7 Gasket 1

KIT/RPR/PLT/CT/200-10(valve plate kit)

6.1 Plate 2 loose

6.2 Valve 2

6.3 Valve 4

6.4 Gasket 1

KIT/RPR/SWH/CT/200-10(pressure switch kit)

7.1 Joint 1 loose

7.2 Joint 1

7.3 Plug 2

7.4 Plug 1


7.6 Pressure Switch/ Motor Cable 1

7.7 Infeed Cable 1


REPAIR PART LIST

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RAC/7.5-22/270FIG. 20


1 Pump Unit 1


2.1 Joint 1

2.2 Plug 2


2.4 Pressure Switch/Motor Cable 1

2.5 Infeed Cable 1


4 Belt Guard Kit 1

5 Base 1

6 Tank 1

7 Joint 1

8 Joint 2

9 Plug 1

10 Plug 1

11 Pressure Gauge 1

12 Valve 1

13 Drain Valve 1


14 Check Valve 1

15 Safety Valve 1

16 Rilsan Hose 1

17 Extension Hose 1

18 Infeed Hose 1

19 Belt 2


21 Screw Kit 1

21.1 Washer 2

21.2 Washer 4

21.3 Washer 12

21.4 Washer 5

21.5 Screw 5

21.6 Nut 3

21.7 Screw 6

21.8 Screw 4

21.9 Screw 4

21.10 Nut 14

PART LIST

EXPLODED VIEW

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REPAIR KIT

REPAIR PART LIST


KIT/RPR/PST/LP/CT/270-10(LP conn. rod/piston kit)

1.1 Low Pressure Piston Ring 1 loose

1.2 Piston 1

1.3 Piston Pin 1


1.5 Con Rod 1

1.6 Nut 2

1.7 Bearing 1

Groz Engineering Tools (P) Ltd.Groz Net Industries

Village Kherki Daula, National Highway-8, Gurgaon-122001, Haryana, INDIA

Tel +91.124.282.7734/40, 2827777 Fax +91.124.2827980, 2827986 E-Mail [email protected] Url www.groz-tools.com

The GROZ name, GROZ logo and the mark are trademarks of Groz Engineering Tools (P) Ltd., India

KIT/RPR/PST/HP/CT/270-10(HP conn. rod/piston kit)

2.1 High pressure Ring 1 loose

2.2 Piston 1

2.3 Con Rod 1

2.4 Piston Pin 1


2.6 Nut 2

2.7 Bearing 1

KIT/RPR/SCR/CT/270-10(screw kit)

3.1 Screw 6 loose

3.2 Screw 6

3.3 Screw 8

3.4 Screw 6

3.5 Screw 1

3.6 Screw 2

3.7 Screw 1

3.8 Washer 1

3.9 Washer 1

KIT/RPR/GST/CT/270-10(gasket kit)

4.1 O-Ring 2 loose

4.2 Oil Seal 1

4.3 Gasket 3

4.4 Gasket 1

4.5 Gasket 1

4.6 Gasket 1

KIT/RPR/PLT/CT/270-10(valve plate kit)

5.1 Valve Plate 2 loose

5.2 Gasket 1

5.3 Valve 4

5.4 Valve 2

KIT/RPR/FLT/CT/270-10(intake filter kit)

6.1 Filter Base 1

6.2 Filtering Element 2

6.3 Filter Cover 1

6.4 Screw 1

KIT/RPR/SWJ/CT/270-10(pressure switch kit)

7.1 Joint 1 loose

7.2 Plug 2


7.4 Pressure Swich/Motor Cable 1

7.5 Infeed Cable 1


7.7 Safety Valve 1

Documents

Air Compressor - Groz engineering tools pvt ltd Reciprocating Air Compressor.pdf · Air Compressor RAC/7.5-22/270 FIG. 3 RAC/5.5-22/200 FIG. 2 DUAL MATERIAL CONSTRUCTION Worlds only