ROTARY SCREW

STATIONARY AIR COMPRESSOR

MODELS
CL15SS-CL20SS-CL25SS-CL30SS
CL15CUB-CL20CUB-CL25CUB-CL30CUB

OPERATION AND
MAINTENANCE MANUAL

CompAir LeROI
P.O. Box 927
211 E. Russell Road
Sidney, OH 45365-0927

Telephone: +01 (937) 498-2500 CL15SS-CL20SS-CL25SS-CL30SS

Facsimile: +01 (937) 492-3923 CL15CUB-CL20CUB-CL25CUB-CL30CUB
4391x,4393x,4394,x4395x,4396x
A Siebe Group Company 0897

THIS PAGE LEFT INTENTIONALLY BLANK.

1
TABLE OF CONTENTS

SAFETY NOTICE ................................................................................................................................ 4

FORWARD......................................................................................................................................... 6

WARNINGS PERTAINING TO AIR SYSTEM......................................................................................... 7

SPARE PARTS................................................................................................................................... 8

SECTION I - GENERAL INFORMATION

Air End......................................................................................................................................... 9
Air and Oil Flow............................................................................................................................. 9
Control Function.......................................................................................................................... 10
Modulating Control....................................................................................................................... 10
High Temperature Shutdown Switch .............................................................................................. 10
Safety Shutdown ......................................................................................................................... 10
Check High Air Temperature......................................................................................................... 10
Component Function.................................................................................................................... 11
Intake Valve ................................................................................................................................ 11
Air Receiver/Oil Reservoir ............................................................................................................. 11
Minimum Pressure/Check Valve ................................................................................................... 12
Separator Drain Line .................................................................................................................... 12
Blow Down (Dump) Valve ............................................................................................................. 12
Return Air Bleed Back Valve......................................................................................................... 12
Control Pressure Regulator Valve.................................................................................................. 12

SECTION II - COMPAIRTROLLER ..................................................................................................... 14

Service Menu .............................................................................................................................. 17
Factory Menu.............................................................................................................................. 18

SECTION III - SPECIFICATIONS - GENERAL

Specifications Chart..................................................................................................................... 20
Lubrication - Compressor ............................................................................................................. 21
Lubrication - Electric Motor........................................................................................................... 21
Table I - Typical Lubricant Specifications ....................................................................................... 22

SECTION IV - INSTALLATION
Mounting and Space Requirements............................................................................................... 23
Table II - Dimensions and Weights ................................................................................................ 23
Electrical Supply ......................................................................................................................... 23
Air Supply to Compressor (Cooling and Compression) .................................................................... 24
Table III - Minimum Cooling Air Flow with Aftercooler....................................................................... 24
Discharge Piping ......................................................................................................................... 24
Checks to be Made at Initial Start Up ............................................................................................ 25
Installation Diagram ..................................................................................................................... 26

SECTION V - OPERATION AND PREVENTIVE MAINTENANCE

Start Up...................................................................................................................................... 27

2
Shut Down.................................................................................................................................. 27
Preventive Maintenance................................................................................................................ 27
Daily .......................................................................................................................................... 27
Every 200 Hours.......................................................................................................................... 28
Every 1000 Hours ........................................................................................................................ 28

SECTION VI - CONTROLS AND ADJUSTMENT PROCEDURES

Controls...................................................................................................................................... 29
Modulating Control - Control Pressure Regulator (CPR) Valve Adjustments....................................... 29

SECTION VII - SERVICE PROCEDURES - COMPONENTS

Control Pressure Regulator Valve Service ...................................................................................... 31
Intake Valve Service..................................................................................................................... 31
Minimum Pressure/Check Valve Service........................................................................................ 32
Blow Down (Dump) Valve ............................................................................................................. 33
Oil Separator Service ................................................................................................................... 33
Air End....................................................................................................................................... 34
Air End Input Shaft Oil Seal Replacement...................................................................................... 34
Fan Drive Shaft Oil Seal Replacement ........................................................................................... 35
Compressor Drive System............................................................................................................ 35
Belt Installation and Adjustment.................................................................................................... 36
Pulley Alignment ......................................................................................................................... 36

SECTION VIII - SERVICE DIAGNOSIS

Service Diagnosis........................................................................................................................ 37

SECTION IX - PARTS (SECOND HALF)

Air/Oil Reservoir, Oil Piping ............................................................................................................ 7
Air Cleaner, Intake Valve .............................................................................................................. 11
Oil Cooler ................................................................................................................................... 15
Control Piping SS........................................................................................................................ 17
Drive, Bedplate, Motor.................................................................................................................. 21
Airend Assembly........................................................................................................................... 3
Airend Plumbing............................................................................................................................ 5
Control Piping (SS)...................................................................................................................... 15
Control Piping (Cub)..................................................................................................................... 17
Decals........................................................................................................................................ 29
Microcontroller ............................................................................................................................ 31
Auto/Dual Control ........................................................................................................................ 33
Starter........................................................................................................................................ 21
Air Receiver Assembly................................................................................................................. 23
Enclosure ................................................................................................................................... 25

SECTION X - DRAWINGS ................................................................................................................. 35

3
SAFETY NOTICE
CompAir LeROI strives through constant research and development to provide this equipment with
every necessary safety device. This manual contains numerous “Warnings,” “Cautions” and “Notes”
intended to protect the equipment from damage and the operator from injury. However, none of
these is a substitute for safe operating procedures. Extreme care must be exercised when
operating or servicing this equipment.

The operator/serviceman should:

1. Learn all that can be learned about this equipment.

2. Develop safe working habits.
3. Never operate a unit without guards and shields in place.
4. Never operate a unit that is not properly grounded.
5. Never service a unit without disconnecting and locking out the electrical power supply
unless following specific operation manual instructions.
6. Never service a unit with air pressure in the air receiver-oil reservoir unless following
specific operation manual instructions.
7. Take all necessary precautions, when adjusting controls, etc., to prevent electrical shock.

WARNINGS
u AIR DELIVERED BY THESE COMPRESSORS MUST NOT BE USED AS BREATHING AIR!
u DON’T PLAY WITH COMPRESSED AIR!
u DON’T POINT AIR HOSES AT ANYONE!
u DON’T USE COMPRESSED AIR TO BLOW DIRT FROM CLOTHING!

At close range, compressed air, at the pressures these units develop, can put out eyes, burst ear
drums, cause serious skin blisters and other injuries.

Check Pressure Relief Valves daily to make certain they are working properly. An over pressurized
air receiver has the potential destructive force of a small bomb which can kill or seriously injure
persons nearby.

A CAREFUL OPERATOR
IS THE BEST INSURANCE
AGAINST AN
ACCIDENT

4
Safety instructions in this manual will appear as follows:

DANGER Danger is used to indicate the presence of a

hazard which will cause severe personal
injury, death or substantial property damage
if the warning is ignored.

WARNING Warning is used to indicate the presence of

a hazard which can cause severe personal
injury, death, or substantial property damage
if the warning is ignored.

CAUTION Caution is used to indicate the presence of a

hazard which will or can cause minor
personal injury or property damage if the
warning is ignored.

NOTICE Notice is used to notify people of installation,

operation, or maintenance of information
which is important but not hazard related.

5
FORWARD
This manual contains vital information for the safe use and efficient operation of this unit. It must be
read carefully and understood before installing, operating or servicing the unit. Failure to adhere to
the instructions and warnings will expose operator or service personnel to the risk of serious injury
or death.

WARNINGS RELATING TO THE COMPRESSOR

1. This machine was designed to perform within specific operating parameters, and was
thoroughly tested at the factory prior to shipment. Do not deviate from the recommended
operating parameters. Such improper operation will subject the machine to conditions beyond
its design capabilities, and will expose the operator and bystanders to the risk of injury or
death, and the machine to damage or failure.

2. When performing maintenance on the compressor, the compressor must be shut down and
isolated both electrically and mechanically by means of a discharge isolation valve to prevent
pressurizing from an external source. Do not reply upon check valves to provide complete
protection from the air system when more than one compressor is installed in the air system.

3. Disconnect this equipment from all power sources before opening the electrical enclosure for
any purpose. The enclosure contains exposed parts at high voltage which can cause severe
electric shock and burns if contacted, exposing service personnel to the risk of injury to death.

4. Do not bypass or tamper with the discharge temperature switch. If the compressor shuts
down due to high discharge temperature, contact a qualified service agency immediately.
Overriding the discharge temperature switch can cause a machine malfunction, fire or other
damage, and expose the operator and bystanders to the risk of injury or death.

6
WARNINGS RELATING TO AIR SYSTEMS
1. All service piping to and from the compressor must take into account pressure, temperature,
vibration, corrosion and chemical resistance. Special attention should be given to the
compatibility of the lubricant used and the system piping and accessories.

2. Do not use plastic bowls on line filters without metal guards. Synthetic lubricants and the
additives used in mineral oils collected in the bowl can weaken the bowl materials causing
them to rupture. For greater reliability and safety, metal bowls should be used on any
pressurized system. Review of your plant air line system is recommended.

Do not use discharge air as breathing air. Severe injury or death will result. Consult a filtration
specialist for additional filtration and treatment equipment needed to meet health and safety
standards for breathing air.

7
SPARE PARTS
CompAir LeROI supplies replacement parts for these compressors, and a complete parts list is
included in this manual. Order parts from your authorized CompAir LeROI distributor.

NOTE: For prompt and accurate service please have model and serial number available when
ordering parts.

CAUTION
Use only genuine CompAir LeROI replacement parts. The use of other than genuine parts may
cause machine malfunctions, exposing the operator to injury and the machine to damage. The use
of other than genuine parts will also void the CompAir LeROI warranty.

NOTICE
The use of non CompAir LeROI lubricants in this compressor may void the warranty.

This manual is complete at the time of printing. However, machines assembled after the printing
may include functionally equivalent components substituted for original components described in
the manual. CompAir LeROI reserves the right to make such component substitutions without
modifying this manual.

8
9
SECTION I
GENERAL INFORMATION
This manual includes installation, operating supported by a single row roller bearing. This
instructions and maintenance and service allows the rotors or cylinder to freely expand
procedures for the Model 15, 20, 25, and 30 or contract due to changes in temperature
SS and CUB air compressor units. without affecting critical running clearances.

An explanation of the model code follows: AIR AND OIL FLOW

Example: CL20 CUB Air circulates through the system beginning

CL-CompAir LeROI at the air cleaner, passing through the intake
valve and into the air end where it is
20 - Horsepower required to drive the air end compressed. During compression oil is
injected into the air end (and air) to provide
CUB - Modulation control cooling, sealing and lubrication. From the air
end compressed air (and oil) is discharged at
This series of air compressor units are rated pressure into the unit air receiver/oil
electric motor driven, oil flooded, single stage, reservoir.
rotary screw type.

These compressors are air cooled with the oil

cooler and aftercooler mounted as an
assembly.

AIR END (Figure 1)

The air end (male rotor) is belt driven. The

female rotor is driven by the male rotor
because the rotors are meshed. Figure 2
shows the direction of rotor rotation and the
air/oil flow through the air end. Note that the
air flow through the air end is between the
rotors and the inside diameter of the cylinder
bore.

FIGURE 2 - AIR/OIL FLOW - TYPICAL

Separation of oil from the air, which was

injected into the air end during compression,
begins in the unit air receiver/oil reservoir.
From 90 to 95% of the oil is separated from
FIGURE 1 - AIR END
the air with a decrease in air velocity,
changes in flow direction, adequate baffling
Each rotor is mounted with two angular
and proper location of the air receiver/oil
contact ball bearings at the rear or discharge
reservoir inlet port.
end. The front or inlet end of each rotor is

9
The control pressure regulator valve will, at
Final air/oil separation is obtained using a the maximum operating pressure, hold the
composition material “can” type separator intake valve completely closed, fully
element to provide nearly oil free air at the unloaded.
separator out or service connection. Oil
collected by the separator element is A plant system or additional storage receiver
returned to the system by a filter equipped may not be required for modulating control
separator drain line. units provided the unit is tanked mounted.

To prevent over pressuring the air received/oil If air demand varies widely (short periods of
reservoir, an air pressure relief valve is high demand with short periods of low or no
installed in the received/reservoir. This demand) a system storage receiver is
pressure relief valve is located on the desirable and recommended to prevent too
upstream or wet side of the separator frequent cycling of the controls. (Bed plate
element. mounted units only).

Oil flows, forced by air pressure, from the air HIGH TEMPERATURE SHUT DOWN
receiver/oil reservoir through the cooler and SWITCH (Figure 9)
filter and its injected into the air end to
provide cooling, sealing and lubrication. The high air temperature shut down switch is
located in the discharge cavity of the rear
Oil injection temperatures for these units bearing retainer on the air end.
should be 130°F or above depending on
ambient air temperature. This is a normally closed temperature
sensitive switch. The purpose of this switch is
Air flow to/through the air end is controlled by to shut the unit down in the event the air
the intake valve. When there is a demand for temperature at the air end discharge rises
air, up to the rated capacity of the air end, the above 230° ± 5°F.
intake valve will be open (air end fully loaded.)
When there is no demand for air the intake CAUTION
valve will be closed (air end fully unloaded.) THE CAUSE OF A SHUT DOWN DUE TO
HIGH AIR/OIL TEMPERATURE MUST BE
CONTROL FUNCTION CORRECTED BEFORE RESTARTING THE
MODULATING CONTROL UNIT.
(Cub, Upper Range Modulation)
To restart a unit, allow the unit to cool to
To obtain modulating control, a control automatically reset the high temperature shut
pressure regulator valve is used. The control down switch.
pressure regulator valve partially or fully
unloads the air end in direct proportion to air SAFETY SHUTDOWN
demand.
CHECK HIGH AIR TEMPERATURE
As air demand is reduced (unit air received
pressure rises), the control pressure regulator There is a high discharge air temperature
valve will gradually close the intake valve. shutdown function built into the control on
When the demand for air is less than the each compressor. It is factory pre-set at
rated capacity of the air end, the control 230°. This function should be checked at
pressure regulator valve will hold the intake regular intervals for proper operation, once a
valve partially closed causing the air end to month is recommended.
deliver air in direct proportion to demand. PROCEDURE:
When/if there is no demand for air, both the
unit and storage receiver pressures will rise to 1. Block off the cooling air discharge.
the maximum operating pressure. 2. The compressor discharge temperature
will rise at a rapid rate. Shutdown should

10
occur when the discharge temperature The air receiver/oil reservoir provides an oil
reaches the pre-set maximum discharge sump, primary oil separation and a mounting
air temperature setting. location for the separator element. The
separator element is mounted at the top of
FIGURE 5 the air receiver/oil reservoir and held in place
by the receiver/reservoir cover.

1. Restriction indicator (separator)

2. Oil Filler
3. Restriction Indicator (Oil Filter)
4. Separator Drain Line
FIGURE 6
5. Oil Level Sight Gage
6. Drain Valve
1. Drain Line Filter
7. Air Receiver/Oil Reservoir
2. Check Valve
8. Oil Cooler/Aftercooler
3. Sight Gage
9. Oil Sample Valve
4. Separator Drain Line
10. Oil Filter
5. Air Cleaner
11. Discharge Tube
6. Restriction Indicator
7. Intake Valve
COMPONENT FUNCTION
8. Air End
9. Control Bleed Orifice
Piping and wiring diagrams have been
10. Return Air Bleed Back Valve
provided to assist in locating components on
the unit and determining component function.
Other components which are mounted on the
The following explanation of component
receiver/reservoir are the minimum pressure
function will assist in determining if the
check valve, with piping, pressure relief valve,
compressor is operating properly.
and blow down valve.

MINIMUM PRESSURE/CHECK VALVE

INTAKE VALVE
The minimum pressure/check valve is located
The intake valve is located on top of the air
on the air receiver/oil reservoir cover at the
end. The primary purpose of the intake valve
separator out port.
is to control air flow to the air end. The
The purpose of this valve is to maintain
secondary purpose of the intake valve is to
minimum air pressure in the air receiver/oil
check reverse air/oil flow when the unit is
reservoir.
shut down.
The valve consists of a spring loaded piston
AIR RECEIVER/OIL RESERVOIR
which opens when air pressure reaches
approximately 65 psi and maintains a

11
minimum pressure of 60 to 70 psi in the air This normally closed valve is opened by
receiver/oil reservoir regardless of service or control pressure when the unit is running
distribution piping pressure. unloaded.

In addition, this valve checks the return flow of When the unit is running unloaded (intake
air from the system receiver (storage tank valve closed) a small amount of air is allowed
and/or distribution system) when the to “bleed back” from the air receiver/oil
compressor is stopped or running unloaded. reservoir through the air end.

NOTE CONTROL PRESSURE REGULATOR

COMPRESSOR SHOULD NOT BE VALVE (Cub, Upper Range Modulation
OPERATED AT A MINIMUM PRESSURE Only)
FOR EXTENDED PERIODS. EXCESSIVE
OIL LOSS WILL RESULT. The control pressure regulator valve is located
on the unit air intake valve.
SEPARATOR DRAIN LINE
The purpose of this valve is to furnish control
The separator drain line is mounted on the air pressure to operate the intake valve for
receiver/oil reservoir cover. This tube extends modulating control.
down into and touches the bottom of the
separator element. This valve senses unit air receiver-oil reservoir
air pressures between 100 and 110 psi
The other end of the drain line is connected to (approximately) and opens or closes the
a low pressure port on the air end. intake valve to control air delivery based on
demand.
The drain line is equipped with a filter, a
check valve and a flow sight gage. The higher the unit receiver/reservoir air
pressure, the higher the control pressure and
The filter prevents foreign matter from entering the more the intake valve is closed (low
the air end. The check valve allows free flow demand).
of air/oil from the separator to the air end but
prevents reverse air/oil flow at shut down. The The lower the unit receiver/reservoir air
sight gage may be used to assist with service pressure, the lower the control pressure and
diagnosis. the more the intake valve is opened (high
demand).
BLOW DOWN (DUMP) VALVE
When the unit air receiver/reservoir pressure
The air receiver/oil reservoir blow down or falls below 100 psi (approximately) the control
dump valve is located on the air inlet valve. pressure regulator can no longer maintain
control pressure. This allows the intake valve
This is a normally closed valve which is to fully open (fully load).
opened by air pressure.

This valve is opened by air pressure from the NOTE

intake valve when he unit is shut down. THE CONTROL PRESSURE REGULATOR
VALVE, ON SOME UNITS, MAY BE
Blow down (dump) air flows to atmosphere ADJUSTED TO OBTAIN A MAXIMUM OF
through the air cleaner. 150 PSI FULL LOAD PRESSURE. THE
CONTROL OPERATION AS DESCRIBED
RETURN AIR BLEED BACK VALVE ABOVE WOULD THEN WORK BETWEEN
150-160 PSI (APPROXIMATELY).
The return air bleed back valve is mounted on
the intake valve. CHECK THE SPECIFICATIONS FOR EACH
UNIT TO OBTAIN THE MAXIMUM

12
OPERATING PRESSURE BEFORE
MAKING ADJUSTMENTS.

13
SECTION II
COMPAIR TROLLER
The following is provided.
The Micro Controller used on the CL • Indication that air filter needs service
compressors is designed to accept three (3) • Indication that oil filter needs service
analog inputs and eight (8) digital inputs. • Motor overload shutdown and
From these inputs and the logic stored in the indication
processor, the following functions are • Ability to wire to a remote start/stop
supported: location
• Provide an emergency stop circuit
From Analog Inputs: • Metal in oil fault indication (optional)
• Line Pressure
• Sump Pressure Digital outputs are provided as follows:
• Discharge Temperature 1. Energize starter contactors (Star + Delta
contactors when Star Delta starters are
The following is provided: used).
• Constantly monitors and displays 2. Load/Unload solenoid valve.
system pressure 3. Drain solenoid (field connected)
• Monitors sump pressure and 4. Remote alarm (field connected)
displays if selected.
• Monitors discharge temperature and The following additional information is
displays if selected. provided by the software.
• Monitors separator differential • Metric or English units (factory set)
pressure and displays if selected. • Running hours
• Loads and unloads basic system • Loaded hours
pressure (provides indication as to • Shutdown stop delay timer
load/unload). • High temperature alarm
• Provides over pressure warning and
indication. The following information is set by service
• Provides over pressure shutdown personnel at time of oil and filter service:
and indication. • Service hours oil
• Monitors separator element • Service hours filters (service
differential pressure and gives personnel will set service hours and
indication and warning that service processor will count down to preset
limit is exceeded (at 15 psi) and interval)
shuts unit down (at 25 psi).
• From temperature digital input, User Variable Parameters:
display will indicate impending high • Load/Unload Pressure
temperature fault and shut down unit • Auto restart delay (if set at “0” will
when fault point is exceeded. not allow unit to automatically restart
after power failure; however, a value
From Digital Inputs: provided will actuate restart after
• High oil filter differential power failure in the time in seconds
• High inlet filter differential provided).
• Motor overload protection • Off delay timer
• Remote start (field installed) • Drain cycle timer
• Remote stop (field installed) Dwell time
• Emergency stop Spit time
• Spare (capable of interfacing with
sequence panel driven by digital OPERATION
load/unload signal)
• Metal in oil circuit fault (optional) At power-up, if all operating parameters are
normal, the display will read “READY”.

14
The “Select” Button will scroll through several
parameters. This may be done any time if Settings may be changed by pressing UP or
compressor is running or not running. The DOWN button until desired valve shows on
parameters are displayed as follows: display. Press “STOP” to set new value.
Display will stop flashing.
DISPLAY LED’S (FUNCTION)
READY After desired parameters are set, push reset
to return to normal display.
XX Line Pres (PSI)
XX Compressor Temp (°F) NORMAL START
XX Sump Pres (PSI)
XX Line & Sump (Oil Sep. D/P, When “READY” is indicated on display and
PSI) “START” button is pushed, unit will
XX Run/Load Hrs (Total/Hrs Alt) immediately start and load after 3 seconds. If
XX Run/Load Hrs (Load/Hrs Alt) system pressure is above cut-in pressure,
XXXX Service Hrs (Fltrs/Hrs Alt) display will show “STDBY”. Unit will start
XXXX Service Hrs (Oil/Hrs Alt) when pressure falls below cut-in pressure.

When compressor is stopped, the user menu NORMAL STOP

may be selected by holding in both “UP” and
“DOWN” arrow keys for 10 seconds. When all When “STOP” button is pushed, stop
LED’s flash, push “UP” arrow key to display sequence will commence. Unit will continue
“01”. Then hold down “STOP” key until to run for 10 seconds while unload and blow
display stops flashing. Push “SELECT” to down commence. The unit will stop after 10
scroll thru menu. seconds, display will show “blodn” until unit
sump pressure drops below 40 psi. Display
DISPLAY LED’S FUNCTION will indicate “READY”.

XXX Line Pres Unloaded Set EMERGENCY STOP

Point
XXX Line Pres Load Set Point Unit will stop immediately.
XX Run/Load Hrs Moist Sol. Valve
“Spit” Time FAULT CONDITIONS
XX Service Hrs Moist Sol. Valve
“Dwell” time ALARM
*X Auto Restart En. Auto Restart in
XX Seconds The following indications will be observed;
** XX Auto Restart En. Auto Stop Time however, the compressor will continue to
Min. operate:

* This function is auto restart after DISPLAY LED CONDITION

power failure. Set to time in seconds
to activate this function. Setting to (FLASHES SLOWLY)
“0” de-activates function.
Act. Press. Sump Press. High Sump
** Auto time out, in minutes, after Press.
unloaded for set period of time. Alarm
Compressor stops and displays Act. Temp. Comp. Temp. High Disch.
“STDBY” (STANDBY) and will Temp.
restart on falling pressure below Alarm
“LOAD” set point. Act. Diff. Line Press/ High Sep.
Press. Alarm Diff. Press
Time can be set between 5 and 240 Alarm
minutes. “dpAir” High Inlet

15
Filter Diff. THE OVERLOAD LOCATED IN THE
Pressure STARTER ENCLOSURE.
“dpOil” High Oil
Filter Diff.
Pressure
*Oil Service Hrs Oil Life
Expired
*Fltrs. Service Hrs Filter Life
Expired
FEFLT Metal in Oil
(Optional)

* LED and Display flash alternately.

The following faults will be indicated and

cause unit to shut down or not start:

DISPLAY LED CONDITION

(FLASHES RAPIDLY)

Act. Press. Sump Press. High Sump

Pressure
Act. Temp. Comp. Temp. High Disch.
Temp.
Act. Diff. Line Press./ High Sep.
Sump Press. Diff. Press.
“TRIP” Motor Overload Motor Over-
load
--- Sump/Comp. Transducer
Pressure Fault
--- Comp. Temp. Temp.
Probe Fault

Each of the above alarms/fault conditions

indicate that the compressor is being
operated at or near its designed parameters.
Each of the above alarms will require service
or maintenance personel to locate the source
causing the alarm, repair and reset the
compressor returning it to normal operating
condition.

Pressing the “Reset” button on the face of the

controller will allow the unit to be restarted in
most cases, should the unit shut down
because of a fault.

To reset the service hours for oil or filters see

the “Service Menu” portion of this manual.

NOTE
A MOTOR OVERLOAD “TRIP” ALARM
WILL REQUIRE MANUALLY RESETTING

16
SERVICE MENU

To set the service timers in the CompAirTroller (CAT) the service menu must be accessed. To
access the menu and set times, proceed as follows.

When the compressor is stopped, the service menu is accessed by holding in both “UP”↑ and
“Down”↓ arrow keys simultaneously for ten (10) seconds. When all LED’s flash, push “UP” ↑ arrow
key until “18” shows in display, then push “STOP” key until display stops flashing. Display will
alternate between timer and hours remaining, until service is required.

DISPLAY LED FUNCTION

FLTRS/XXXX Service Hours Filter Service Hours

OIL/XXXX Service Hours Oil Service Hours

To set hours push “UP” ↑ or “DOWN”↓ key until desired hours are shown on display, then push
“STOP” button to set. After desired values are displayed, push “RESET” to exit menu. Menu will be
canceled after 60 seconds if no key activity is performed.

17
FACTORY MENU
In the event that a CompAirTroller (CAT) has to be replaced additional programming to that done by
user and service personnel is required.

After the unit is powered up the “Factory Menu” is accessed by holding in both “UP”↑ and “DOWN”↓
arrow keys simultaneously for ten (10) seconds. When all LED’s flash, push “UP” ↑ arrow key until
“48” shows in display, then push “STOP” key until display stops flashing.

The Factory Menu can now be observed by pushing the Select Button.

DISPLAY LED FUNCTION

PSI/bar Line Pressure Pressure Units

FAHr/cELS Compressor Temperature Temperature Units
XXXX Compressor Temperature Alarm Temperature

*AlAr/Coutr Aux. Contact Configuration

tP-XX Compressor Configuration Model

(Ref. Table B)

Stopt/XXX Stop Delay after Stop pushed

(Normal Stop)

Total/XXXX Running/Loaded Hours Hour Meter

Load/XXXX Running/Loaded Hours Hour Meter

Scroll through the menu by pushing select and set the following function. Setting the functions is
done by pushing the “UP” ↑ and “DOWN”↓ arrow keys.

• Pressure Units
• Temperature Units
• Compressor Configuration Model Number (see table on next page)
• Total Hours
• Loaded Hours

The stop delay may be altered if other than the normal ten seconds is desired.

* The auxiliary contact configuration is used when a sequencer is used or remote annunciation is
required.

Coutr For sequencer use

AlAR For alarm circuit

Push reset after above parameters are entered to exit menu.

Set service timers by entering service menu.

Display will indicate “READY”. Unit is ready to start.

18
COMPRESSOR CONFIGURATION MODELS
(FACTORY PRESET PARAMETERS)

TABLE B

Unload
Blow Time Design Run Starts
Y/D Down Before P P P Press. on Accel. per Max.
Model Time Time Stop Load Unload Max Limit Time Time Hour Temp
1 2.0 10 10 90 100 125 110 15 3 4 230
2 4.0 10 10 90 100 125 110 5 2 8 230
3 1.0 10 10 90 100 125 110 5 2 8 230
4 2.0 10 10 100 110 135 120 15 3 4 230
5 4.0 10 10 100 110 135 120 5 2 8 230
6 1.0 10 10 100 110 135 120 5 2 8 230
7 2.0 10 10 115 125 150 135 15 3 4 230
8 4.0 10 10 115 125 150 135 5 2 8 230
9 1.0 10 10 115 125 150 135 5 2 8 230
10 2.0 10 10 140 150 175 160 15 3 4 230
11 4.0 10 10 140 150 175 160 5 2 8 230
12 1.0 10 10 140 150 175 160 5 2 8 230

19
SECTION III
SPECIFICATIONS - GENERAL

MODEL CL15SS,CUB CL20SS,CUB CL25SS,CUB CL30SS,CUB

Type Rotary Screw Rotary Screw Rotary Screw Rotary Screw

Stages One One One One

Type of Drive Belt Belt Belt Belt
Motor Shaft Speed, RPM 1750 1750 1750 1750
Male Rotor Speed, RPM (100 psi) 2140 2790 3454 4158
Female Rotor/Fan Speed
RPM (100 psi) 1427 1853 2300 2769
Male Rotor Speed, RPM (125 psi) 1890 2434 3013 3742
Female Rotor/Fan Speed
RPM (125 psi) 1260 1621 2006 2492
Male Rotor Speed, RPM (150 psi) 2112 2672 3341
Female Rotor/Fan Speed
RPM (150 psi) 1406 1779 2225

Rated Delivery, CFM at 100 psi 65 85 105 125

Rated Delivery, CFM at 125 psi 57 68 90 110
Rated Delivery, CFM at 150 psi 50 75 95

Minimum Working Pressure, 80 80 80 80

(psi Gage) (5.44) (5.44 Bar) (5.44 Bar) (5.44 Bar)
Minimum Pressure Valve Set, 70 70 70 70
(psi Gage) (4.76 Bar) (4.76 Bar) (4.76 Bar) (4.76 Bar)
Oil Reservoir Capacity,
U.S. Gallon 3.5 3.5 3.5 3.5
Air Receiver - Oil Reservoir
Maximum Working Pressure 200 200 200 200
(psi Gage)
Pressure Relief Valve Setting 170 170 170 170
Oil Filter Change Interval, Hours 1000 1000 1000 1000

Air Cleaner Type......................................................................................................... Dry Type

Air Cleaner Change Interval, Hours .......................................................................... As Required

NOTICE
OBSERVE THE AIR CLEANER RESTRICTION INDICATOR. CHANGE ELEMENT WHEN
INDICATOR SHOWS RED. UNDER DIRTY OPERATING CONDITIONS, THE AIR CLEANER
ELEMENT WILL REQUIRE CHANGING MORE OFTEN.

20
CAUTION
CONDITIONS IN WHICH THE UNIT IS RUNNING MAY REQUIRE CHANGING THE OIL FILTER
MORE OFTEN. ALWAYS RENEW THE OIL FILTER AT EACH OIL CHANGE.

An oil filter restriction indicator is provided so that the pressure drop across the filter, (filter
condition) may be checked. When/if the indicator shows red, (rated pressure, normal operating
temperature) change the filter.

Oil Separator Element Change Interval........................................................................as required.

An oil separator restriction indicator is provided so that the pressure drop across the separator
element may be checked.

CAUTION
ALWAYS CHECK THE SEPARATOR DRAIN LINE, DRAIN LINE CHECK VALVE (INSTALLED
POSITION AND CONDITION) AND DRAIN LINE FILTER FOR DAMAGE OR PLUGGING BEFORE
CONDEMNING A SEPARATOR ELEMENT.

OBSERVE THE SEPARATOR ELEMENT RESTRICTION INDICATOR.

IF THE INDICATOR SHOWS RED, RENEW THE SEPARATOR ELEMENT. (RATED

PRESSURE, NORMAL OPERATING TEMPERATURE.)

LUBRICATION - COMPRESSOR The responsibility for testing and evaluating

useful oil life is left to the oil manufacturer
The useful life of compressor oil depends on and/or the compressor end user.
the quality of the oil and the conditions in
which the unit is operating. It is recommended that LeROI SSL-50 or
(partial synthetic) SSL-46 synthetic lubricant
For these reasons oil and oil filter change be used.
intervals are to be determined by oil sampling
and analysis. Either of these lubricants may be obtained,
conveniently packaged, from your nearest
Oil sampling and analysis is recommended LeROI distributor.
every 200 hours or compressor operation at
least until an oil/oil filter change pattern or If SSL-50 or SSL-46 is not available, contact
schedule is established. your local lubricant supplier for a lubricant
which meets the specifications in Table I.
The quality of the oil is left to the oil
manufacturer. LUBRICATION - ELECTRIC MOTOR

Refer to the motor manufacturer’s

recommendation for motor bearing lubrication.

21
TABLE 1
TYPICAL LUBRICANT SPECIFICATIONS
Non-Detergent Turbine or Hydraulic Oil or Synthetic PAO (polyalphaolefin) Lubricant
Viscosity at 100°F................................................................................................ 160-200 SSU
Viscosity at 0°F ......................................................................................... 11,000 SSU or Less
Minimum Viscosity Index ......................................................................................................90
Pour Point, °F..20° lower than lowest expected starting temperature Minimum Flash Point, °F .. 400
Rust Inhibitor....SSTM, D665 (latest) No rust after 24 hours sea water Oxidation Inhibitor....ASTM,
D943 (latest) Neutral No. 2.0 or less after 1000 hours
Anti-Foam Additive...............ASTM, D892 (latest) 3 cycles stability nil

22
SECTION IV
INSTALLATION
CL15-30 SS, CUB
MOUNTING AND If there is danger of the unit being moved out
SPACE REQUIREMENTS of position for any reason, it may be loosely
bolted to the mounting surface.
A suitable smooth floor should be provided for
placing the compressor. Adequate space must be provided to service
the unit once it is installed. All units must be
A special foundation is not required unless positioned at least 24” away from a wall or
the floor or other mounting surface is other obstruction on all sides to allow
extremely rough or unable to support the adequate cooling air circulation and service
weight of the unit. The unit should sit level. It access.
is advisable to use shims, as required, to
make certain the tank feet (or Bed plate) are Table II shows the approximate overall
resting firmly on the mounting surface. dimensions and weights which may be used
for selecting a suitable location for the
compressor.

TABLE II
DIMENSIONS AND WEIGHTS
TANK MOUNT (120 GAL.)
MODEL LENGTH, IN. WIDTH, IN. HEIGHT, IN. WEIGHT, LBS.
CL15SS,CUB 69.0 33.43 62.43 1075
CL20SS,CUB 69.0 33.43 62.43 1125
CL25SS,CUB 69.0 33.43 62.43 1175
CL30SS,CUB 69.0 33.43 62.43 1200
BED PLATE MOUNT
CL15SS,CUB 50.0 33.42 34.0 700
CL20SS,CUB 50.0 33.42 34.0 750
CL25SS,CUB 50.0 33.42 34.0 800
CL30SS,CUB 50.0 33.42 34.0 825
ENCLOSED
CL15SS,CUB 54.5 49.0 40.0 860
CL20SS,CUB 54.5 40.0 40.0 1002
CL25SS,CUB 54.5 49.0 40.0 1144
CL30SS,CUB 54.5 49.0 40.0 1286

ELECTRICAL SUPPLY breaker so that electrical power may be

disconnected while the unit is being serviced.
An adequate electrical power supply of the
correct voltage must be provided. All control The fuse line disconnect should be located
enclosure wiring has been completed at the and mounted in accordance with all state,
factory. This includes magnetic starter wiring local and national regulations.
for units furnished with starter. Units furnished
without a starter require wiring the starter on The unit must be properly grounded to provide
the job site. adequate ground fault protection. As a guide,
it is suggested that the ground wire be equal
The electrical supply should be equipped with in size to one of the conductors which feeds
a fused line disconnect switch or circuit the compressor motor circuit. Make certain

23
the ground wire connections are clean and building should be located away from
tight. contaminants such as engine exhaust,
gases, steam and other harmful vapors.
The wire used to feed the compressor circuit
should be selected and sized based on the Also, the opening to the building must be
following conditions: protected from rain, snow and other air borne
debris by hoods as well as being located
1. Motor full load amperage plus service above the ground/roof to prevent other foreign
factor. matter pick up. For a typical ducting
2. Ambient temperature in the area where arrangement refer to Figure 10.
the wire is located.
3. Length of wire Both inlet and outlet ducts must be sized so
4. Insulation type that they are restriction free. Where ambient
temperatures are below 32°F (inlet air) the
This information may be found in the latest temperature may be tempered by controlled
edition of the National Electrical Code. recirculation. This may be accomplished by
using adjustable louvers (or duct dampers) to
When installing a unit in a “Hazardous admit warm air from the outlet duct back into
Location”; that is in a location where fire or the inlet duct at a controlled rate.
explosion is a definite hazard, refer to the
appropriate section of the National Electrical If duct filters are used, the filters must be
Code for further information. restriction free. Typical furnace filter material
may be used.
CAUTION
IN ALL CASES, THE LOCAL, STATE, AND Table III shows the air flow in cubic feet per
NATIONAL ELECTRICAL CODES MUST minute (CFM) required for cooling:
BE STRICTLY FOLLOWED.
TABLE III
AIR SUPPLY TO COMPRESSOR
(COOLING AND COMPRESSION) MINIMUM COOLING AIR FLOW

Air supplied to the compressor should be free MODEL FLOW, CFM

of contaminants such as paint spray mist and
vapors, and other chemical vapors as well as CL15SS,CUB 1900
normally air borne dust and dirt particles. CL20SS,CUB 2650
CL25SS,CUB 3300
Inlet air to the unit may vary slightly in CL30SS,CUB 3850
temperature without adversely affecting the
performance of the compressor. However, DISCHARGE PIPING
ambient air temperature should be maintained
between 32° and 100°F to obtain desirable It is recommended that all bed plate units be
performance. equipped with a system receiver or storage
tank. The nominal size of the storage tank
The air filter supplied with the compressor should be 200 gallons.
has an adequate flow capacity for most
applications. In particularly dirty locations WARNING
clean air may be ducted in from a clean air THE SYSTEM STORAGE RECEIVER
source or special air cleaners may be MUST BE EQUIPPED WITH A PRESSURE
installed. Generally, most adverse conditions RELIEF VALVE WITH THE CORRECT
may be overcome by regular servicing of the PRESSURE RELIEF SETTING AND FLOW
filter furnished with the unit. CAPACITY. THE RELIEF SETTING MUST
When bringing outside air into the NEVER EXCEED THE MAXIMUM
compressor building for cooling and/or ALLOWABLE WORKING PRESSURE AS
compression the air inlet to the compressor STATED ON THE VESSEL NAMEPLATE.

24
THIS IS A REQUIREMENT OF THE ASME air end for correct rotation.
CODE AND STATE REGULATIONS TO
PREVENT AN OVER PRESSURE NOTICE
CONDITION WHICH COULD CAUSE ROTATION OF THE AIR END IS CORRECT
PERSONAL INJURY OR DEATH. WHEN THE INPUT DRIVE SHAFT TURNS
COUNTER CLOCKWISE WHEN VIEWING
A tank mounted compressor should be THE AIR END FROM THE DRIVESHAFT
located as near the air usage point as END. (FAN - CLOCKWISE).
possible. Piping should be as short and as
direct as possible with a minimum number of If rotation is incorrect, open the line
elbows and fittings. Never reduce aftercooler disconnect switch and rewire the power
or discharge line size. Never install dryers or feed line at the compressor to obtain
filters (except a moisture separator on correct direction of rotation. After
aftercooled units) in the aftercooler or rewiring return to Steps 3 and 4 to
discharge line. double check rotation and correct as
required.
Manual shut off valves should also be 5. Close the system isolation valve.
included in the service piping so that the 6. Open the drop leg valve.
compressor and/or system receiver may be
isolated from the rest of the system to permit WARNING
servicing the compressor. AIR ESCAPING TO ATMOSPHERE IS
NOISY. ALWAYS WEAR EAR
It is also necessary to install a drop leg and PROTECTION TO PROTECT HEARING
valve in the service piping. Refer to Figure 10 AGAINST HIGH INTENSITY NOISE.
for a typical piping arrangement.
7. Start the unit.
All piping must be adequately supported to 8. Slowly close the system drop leg valve
prevent excessive strain on the compressor, and observe that when the system
receiver, or plant storage receiver. receiver pressure reaches the full unload
pressure (110, 120, 135, or 160 psi) the
CHECKS TO BE MADE AT unit is fully unloaded (no additional
INITIAL START UP increase in receiver pressure; intake
valve closed) the blow down (dump)
1. Make certain that all electrical and air valve has opened lowering unit receiver
connections have been properly made. pressure.
2. Check the compressor reservoir oil level 9. Slowly open and close the drop leg
and correct as required. (Use correct valve to cycle the controls. If the controls
type of oil) operate as described, the unit is ready
3. Close the line disconnect switch. for use.

BE ALERT!

A CAREFUL OPERATOR

IS THE BEST INSURANCE

AGAINST AN ACCIDENT!!
4. Jog the compressor motor by actuating
the START switch and immediately
pushing the STOP switch. Observe the

25
26
SECTION V
OPERATION AND PREVENTIVE MAINTENANCE
Satisfactory performance of a stationary
screw air compressor requires a good It is possible, however, to obtain information
preventive maintenance program. about the wear characteristics of the machine
with continued oil testing. The oil test
The following information is provided as a performed should include analyzing the
guide for such a program. particulate matter in the oil sample, as well
as testing for oxidation inhibitors and anti-rust
START UP additives.

Daily start up may be accomplished as As an example, an increase in cast iron

follows: particles in an oil sample may give advance
1. Drain the condensate (water) from the warning of excessive wear. This information
oil reservoir. Close the drain valve could possibly prevent damaging the entire
securely when oil appears. unit beyond repair, without periodic
2. Check the compressor oil reservoir oil disassembly and visual inspections.
level.
Normally the oil analysis sheet will list the
NOTICE results of the oil test, in addition to
THE RESERVOIR IS FULL WHEN THE OIL recommendations of the analyzing laboratory
LEVEL REACHES THE BOTTOM OF THE showing what maintenance is required.
FILLER HOLE. IF OIL COVERS THE SIGHT
GAGE IT IS SAFE TO OPERATE THE The following information is furnished as a
UNIT. guide to the critical limits of items which are
listed in an oil analysis sheet.
3. Operate the air receiver-oil reservoir
pressure relief valve manually to make Viscosity increase............. 10% over new oil
certain it will open. Neutral No. Increase ......... 0.5% over new oil
4. Make certain adequate ventilation is Total solids by weight ....................... 0.21%
provided. Oxidation, by weight, oxidized material..11%
5. Open the service valve which connects Sediment, by volume ........................ 0.21%
the unit to the system receiver Water, by volume ...............................0.5%
(distribution piping) and actuate the
START switch to start the unit. DAILY
6. Observe all indicators and gages for
proper reading. If the indicators read 1. Check the air cleaner and service as
normally, the unit may be continued in required.
service.
NOTICE
SHUT DOWN ALWAYS DRAIN CONDENSATE AFTER
THE UNIT HAS BEEN SHUT DOWN FOR A
1. Allow the unit to fully unload. REASONABLE LENGTH OF TIME
2. Push the stop switch to shut the unit (USUALLY OVER NIGHT) ALLOWING THE
down. WATER TO SETTLE.

PREVENTIVE MAINTENANCE 2. Check the compressor oil reservoir oil

level. Add correct type of oil as required.
Regular testing of oil as specified in the DO NOT OVER FILL.
following maintenance guide is intended to
assist in establishing oil and oil filter change NOTICE
intervals.

27
FILL UNTIL OIL REACHES THE BOTTOM OIL SAMPLES MAY BE OBTAINED FROM
OF THE FILLER HOLE. OIL MUST BE THE OIL RESERVOIR (AT FILLER, NOT
ADDED IF IT DOES NOT COVER THE DRAIN) OR FROM THE OIL SYSTEM
SIGHT GAGE. SAMPLE VALVE LOCATED NEAR THE
OIL FILTER.
3. Operate air receiver - oil reservoir and
system receiver pressure relief valves EVERY 1000 HOURS
manually to make certain they operate
properly before starting the unit. 1. Repeat Daily and 200 hour service as
4. Visually inspect all air and oil lines and applicable.
fittings for leaks. This includes the air 2. Change compressor oil filter element.
cleaner and any inlet piping of the air
induction system. Correct leaks as
required.
5. Start and run the unit at rated full load
pressure long enough to reach normal
operating temperature.
6. Observe the air cleaner restriction
indicator. If the restriction indicator
shows a red “flag”, the air cleaner
element must be cleaned or renewed.
7. With the unit running, observe the oil
filter restriction indicator. If indicator
shows red, replace filter.
8. With the unit running, observe the
separator element restriction indicator. If
the indicator shows red it indicates the
separator element is restricted. If the
restriction is caused by dirt or other
foreign matter, renew the separator
element.

NOTICE
OIL SATURATION CAN CAUSE
EXCESSIVE RESTRICTION ACROSS A
SEPARATOR ELEMENT. ALWAYS
CHECK THE SEPARATOR DRAIN TUBE
AND LINE. THE CHECK VALVE
(INSTALLATION AND CONDITION) AND
CLEAN THE DRAIN LINE FILTER BEFORE
CONDEMNING A SEPARATOR ELEMENT.

EVERY 200 HOURS

1. Repeat daily service as applicable.

2. Remove surface dirt and dust from the
exterior surfaces of the oil cooler and
aftercooler, if required. (Air cooled units)
3. Obtain an oil sample from the
compressor oil system and have the
sample analyzed for condition. Change
oil and oil filter, if required, based
onresults of the oil analysis.
NOTICE

28
SECTION VI
CONTROLS AND ADJUSTMENT PROCEDURES
CONTROLS 1. Install/connect pressure test gages
(minimum pressure range 200 psi), if
Adjustment to all controls are made very required, in place of the existing air
carefully at the factory. However, it may be pressure gages.
necessary to make certain adjustments at 2. Connect a pressure test gage with a
the time the unit is installed, to fit specific minimum range of 100 psi in the control
applications, or after repair or replacement of pressure line near the air intake valve.
components.
WARNING
The control pressure regulator valve (CPR) is AIR ESCAPING TO ATMOSPHERE IS
the only control device which may require NOISY. WEAR EAR PROTECTION TO
adjustment. PROTECT HEARING AGAINST HIGH
INTENSITY NOISE.
CAUTION
DO NOT EXCEED THE RATED MAXIMUM 3. Open the drop leg or receiver vent valve.
FULLY LOAD OPERATING PRESSURE OF Start the unit. Slowly close the drop leg
ANY UNIT. REFER TO “SPECIFICATIONS”, or vent valve to raise both the unit and
SECTION II. system receiver air pressure to 80 psi,
approximately. Allow the unit to run long
MODULATING CONTROL - CONTROL enough to reach normal operating
PRESSURE REGULATOR (CPR) VALVE temperature.
ADJUSTMENT (Figure 11) 4. Adjust the service (drop leg or vent)
valve to maintain a constant rated full
To change the pressure at which the CPR load pressure. (i.e. 100, 125 or 150 psi).
(control pressure regulator) valve will fully
unload the compressor, loosen the adjusting
screw locknut and turn the adjusting screw in CAUTION
(clockwise) to increase of out CHECK SECTION II OF THIS MANUAL TO
(counterclockwise) to decrease pressure. OBTAIN INFORMATION ABOUT
Tighten the locknut securely when finished. MAXIMUM OPERATING PRESSURE AND
AIR END SPEED.

5. Observe the pressure test gage

connected in the control pressure line.
Loosen the adjusting screw locknut and
adjust the control pressure regulator
(CPR) valve by turning the adjusting
screw out (counterclockwise) until a
pressure of 3 to 5 psi is observed on the
control line test gage.
6. Then turn the CPR valve adjusting
screw in (clockwise) far enough to obtain
a control pressure of zero. (No control
air bleed). Securely tighten adjusting
FIGURE 11 - CONTROL PRESSURE screw locknut.
REGULATOR VALVE 7. Cycle the controls by adjusting the
service (drop leg or vent) valve to raise
the lower both unit and system receiver
air pressure.
Follow this procedure:

29
Observe that the CPR valve control
pressure (modulated) rises and unloads
the compressor at the rated full unload
pressure.

8. Shut the unit down and remove all test

equipment. Restart, check for and
correct any leaks.

30
SECTION VII
SERVICE PROCEDURES - COMPONENTS

CONTROL PRESSURE REGULATOR The intake valve may be obtained as a

VALVE SERVICE (Figure 11) complete assembly, if required. Service parts
are available, however, to repair the intake
The control pressure regulator valve is valve is desired.
furnished tighter as a complete unit, or may
be serviced with a diaphragm assembly and Do not attempt to disassemble or reassemble
valve seat. an intake valve while it is mounted on the air
end. Loose or broken parts could accidentally
Installation of the diaphragm and seat may be drop into the air end causing further difficulty.
accomplished as follows:
1. Disconnect the bypass line from the
1. Remove the control pressure regulator base of the air cleaner assembly and
from the unit. Mark all tubing thread the air cleaner assembly out of
disconnected to aid in correct the intake valve.
reassembly.
2. Loosen the adjusting screw locknut and FIGURE 12 - INTAKE VALVE
turn the screw counterclockwise to
release spring pressure on the
diaphragm.
3. Support the hexagon body in a bench
vise or other suitable fixture. With a
wrench unthread the bonnet from the
body and remove the bonnet.
4. Remove the spring guide and spring
from the body.
5. Remove the diaphragm assembly from
the body and discard.
6. Remove the valve seat from the valve
body. Discard the valve seat.
1. Valve Body
7. Clean the remaining parts thoroughly.
2. Retainer Ring
8. Lubricate the new valve seat with
3. Seal
silicone grease. (Suggest Dow Corning
4. Valve Plate
55M). Install the new valve set in the
5. Spacer
valve body, centered over the hole, with
6. Spring
the small chamfer on the outside
7. Spring
diameter down.
8. Piston
9. Install the new diaphragm in the body.
9 Seal
Reinstall the spring and spring guide in
10. Spring
the body.
11. Cap
10. Install the bonnet in the body and tighten
securely.
2. Disconnect all control air lines (tubes)
from the intake valve. CAREFULLY
The control pressure regulator valve may now
MARK THESE LINES TO AID IN
be mounted on the unit and adjusted
CORRECT REASSEMBLY.
according to instructions in Section VI of this
3. Remove the intake valve to air end
manual.
attaching capscrews and remove the
intake valve and gasket from the air end.
INTAKE VALVE SERVICE
Discard the gasket.

NOTICE

31
COVER THE AIR END INLET PORT TO deform the o-ring seal.
PREVENT FOREIGN MATTER FROM 15. Install the two operating piston springs
ENTERING THE CYLINDER. into the valve body.
16. Coat the threads of the piston (spring)
4. Using a flat bladed tool remove the valve retaining cap with Locktite 271 or
plate seal ring (o-ring) retaining ring. equivalent. Thread the retaining cap into
Remove the seal ring. Discard seal ring. the valve body and tighten securely.
5. Lift and remove the valve plate as- 17. Coat the valve plate assembly piston
sembly and spring from the valve body. and valve body bore with silicone
6. Using the correct size socket wrench lubricant (suggest Dow Corning 55M)
unthread and remove the piston and install the spring and valve plate
retaining cap from the valve body. assembly into the valve body.
7. Lift and remove both piston springs (one 18. Install the valve plate seal in the valve
large, one small) from the valve body. body. Make certain that the seal ring is
8. Lift and remove the operating piston firmly seated in the groove. Reinstall the
assembly from the valve body. Remove seal retaining ring.
the piston seal ring (o-ring) from the 19. Using a new gasket, install the intake
piston. valve on the air end. Tighten the
9. Thoroughly clean all parts. Make certain attaching capscrews securely.
the air passage in the valve body and 20. Reinstall the air cleaner assembly on the
the air holes in the piston assembly are intake valve.
clean. 21. Reconnect all control air lines to the
10. Inspect all parts for wear or damage. intake valve. Tighten all fittings securely.
(Chipped, score marks, etc.) Replace
worn or damaged parts as required.

If the valve plate assembly must be

disassembled to replace parts, etc., continue
with Step 11. If the valve plate assembly is
suitable for reuse, proceed to Step 12.

11. To disassemble the valve plate

assembly proceed as follows:
a. Clamp the piston section of the plate
assembly in a soft (wood, brass) jaw
vise.
b. With he correct size hexagon
socket head capscrew (allen)
wrench unthread the valve plate
retaining capscrew from the piston.
c. Remove the valve plate and spacer FIGURE 13
from the piston. MINIMUM PRESSURE/CHECK VALVE
d. Reassemble in reverse order. Make
certain that the spacer is in place 1. Valve Body
and that the socket head capscrew 2. Piston
is securely tightened. 3. Cap
12. Install a new o-ring seal on the operating 4. Shim
piston. 5. Large Spring
13. Lubricate the piston o-ring seal and 6. Small Spring
piston bore with a silicone lubricant. 7. Seal
(Suggest Dow corning 55M or 8,9,10. Valve Assembly
equivalent).
14. Install the operating piston into the valve MINIMUM PRESSURE/CHECK
body bore. Take care not to cut or

32
VALVE SERVICE piston, with the spring, in the large
piston.
The minimum pressure valve may be 12. Lubricate the o-ring seal on the piston
purchased as an assembly if required. with a silicone base lubricant. (Example,
Service parts are available, however, to Dow Corning 55M).
repair/overhaul this valve. This valve may be 13. Reinstall the check valve and piston
serviced as follows: assembly in the valve body. Take care
not to damage the o-ring seal during
1. Remove the service control piping from installation.
the minimum pressure valve. 14. Install the large spring in the valve body
2. Remove the valve from the air on top of the piston. Reinstall spring
receiver/oil reservoir cover. shim(s).
3. Clamp the valve securely in a vertical 15. Lightly coat the cap thread with
position (cap end up) in a suitable fixture “Locktite” 271 (or equivalent) and install
(bench vise). the cap (compress the spring) by
4. With a suitable wrench remove the valve threading the cap into the valve body.
cap from the valve body. Torque the cap to 60-70 ft. Lbs.
16. Reinstall the minimum pressure valve on
WARNING the air receiver - oil reservoir cover. Use
THE SPRING BENEATH THE CAP IS a good grade of pipe thread sealer on all
UNDER PRESSURE. EXERCISE EXTREME pipe threads. Tighten securely. Do not
CARE WHEN REMOVING CAP TO over tighten.
PREVENT IT FROM FLYING OFF. 17. Reconnect the service and control piping
to the valve using pipe thread sealer on
5. Remove the spring from the body. the pipe threads. Tighten service piping
securely. Do not over tighten.
NOTICE
SAVE SPRING SHIM(S), WASHERS, IF BLOW DOWN (DUMP) VALVE
ANY, FOR REUSE.
The blow down (dump) valve is furnished as a
6. Insert a suitable tool (wood stick) into complete assembly. No service is required.
the inlet port of the valve and push the
piston and valve assembly upward and OIL SEPARATOR SERVICE
out of the body.
7. Remove the check valve piston from An oil separator element may be removed as
inside the larger piston. Take care not to follows:
lose the small spring.
8. Remove the o-ring seal from the large 1. Remove the separator out (service)
piston and discard the seal. piping separator drain piping and control
9. Thoroughly clean all remaining parts. piping from the air receiver/oil reservoir
Visually inspect all parts for damage or cover.
wear. Replace as required.
NOTICE
NOTICE MARK OR TAG THE PIPING/FITTINGS TO
THE CHECK VALVE ASSEMBLY (ITEMS MAKE CERTAIN THEY WILL BE
8, 9 AND 10, FIGURE 13) IS FURNISHED RECONNECTED CORRECTLY.
ONLY AS A COMPLETE ASSEMBLY.
CHECK THE PLASTIC (TEFLON) SEAT ON 2. Remove the receiver/reservoir cover to
THE VALVE ASSEMBLY CAREFULLY flange nuts and washers. Remove the
FOR DAMAGE. REPLACE VALVE cover.
ASSEMBLY AS REQUIRED. 3. Lift and remove the element from the air
receiver/oil reservoir.
10. Install a new o-ring on the larger piston.
11. Reassemble the small check valve

33
To install a new separator element, reverse input shaft.
the above removal sequence. Make certain 5. Remove the oil seal face insert, with o-
the flange and cover surfaces are clean. ring seal, from the seal retainer. Discard
the face insert, with o-ring seal.
Make certain the element flange gaskets 6. Thoroughly clean all remaining parts.
have a grounding staple. Torque the separator Make certain all gasket material is
to flange capscrews evenly and securely to removed from the seal cover and front
44 ft. Lbs. Make certain, also, that the retainer mating surfaces.
separator drain tube touches the bottom of 7. Lubricate the new seal face insert with
the element. (Make a new tube, if clean compressor oil and install the
necessary). insert in the seal retainer.
8. Lubricate the rotary seal assembly with
For information concerning the conditions clean compressor oil, including the
which indicate a separator element is carbon ring, and install the seal spring
defective refer to the service diagnosis chart, guide, spring, and seal assembly on the
Section VII. input shaft.

DANGER CAUTION
RECEIVER/RESERVOIR COVER BE CAREFUL NOT TO SCRATCH THE
RETAINING STUDS AND NUTS ARE SEAL FACE INSERT OR SCRATCH OR
SPECIAL. DO NOT SUBSTITUTE BREAK THE CARBON RING OR THE SEAL
COMMON BOLTS OR NUTS IN PLACE OF ASSEMBLY. WIPE THE LAPPED
THESE SPECIAL STUDS AND NUTS. (MATING) SURFACES OF THE SEAL
INSERT AND CARBON RING WITH A
AIR END CLEAN LINT FREE CLOTH BEFORE
INSTALLING THE SEAL RETAINER.
The air end for these units is serviced only as
a complete assembly using a new or factory
rebuilt air end.

Parts available for field service include the

input shaft rotary oil seal and the fan drive
shaft rotary seal.

Rebuild kits are available for air ends

exceeding the warranty period.

AIR END INPUT SHAFT OIL SEAL

REPLACEMENT (Figure 14)

To replace a rotary seal, proceed as follows:

1. Loosen rocker base spring retainer and

rotate motor toward the compressor to
relieve drive belt tension.
2. Remove the compressor input shaft
drive pulley. Remove belt guard and
disconnect oil lines.
3. Remove the seal retainer (front cover) to
front retainer attaching capscrews and FIGURE 14
remove the cover with outer seal. AIR END INPUT & FAN SHAFT OIL SEAL
Discard outer seal.
4. Remove the oil seal assembly, including 1. Seal Face Insert
the spring and spring guide, from the 2. Carbon Ring

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3. Shaft Seal Assembly 8. Lubricate the new seal face insert with
4. Spring clean compressor oil and install the seal
5. Spring Guide retainer.
6. Outer Seal 9. Lubricate the rotary seal assembly with
clean compressor oil, including the
9. Using a new gasket, carefully reinstall carbon ring, and install the seal spring
the seal retainer, retainer capscrews and guide, spring, and seal assembly on the
tighten securely. Install a new outer seal fan drive shaft.
on the shaft. Lubricate the outer seal
as necessary to make certain it slides NOTICE
freely on the shaft and bottoms on the BE CAREFUL NOT TO SCRATCH THE
seal retainer. SEAL FACE INSERT OR SCRATCH OR
10. Reinstall the compressor pulley and BREAK THE CARBON RING OF THE SEAL
align with motor pulley. (See Section VI, ASSEMBLY. WIPE THE LAPPED
“Pulley Alignment”). (MATING) SURFACES OF THE SEAL
11. Reinstall and tighten drive belts by INSERT AND CARBON RING WITH A
repositioning the motor. (See Section VI, CLEAN LINT FREE CLOTH BEFORE
“Belt Tensioning”). INSTALLING THE SEAL RETAINER.
12. Recheck pulley alignment and drive belt
tension and correct as required. 10. Using a new gasket, carefully reinstall
13. Run the unit and check for air or oil the seal retainer, retainer attaching
leaks and correct as required. capscrews and tighten securely. Install a
new outer seal on the shaft. Lubricate
FAN DRIVE SHAFT OIL outer seal as necessary to make certain
SEAL REPLACEMENT (Figure 14) it slides freely on the shaft and bottoms
on the seal retainer.
The fan drive shaft rotary oil seal may be 11. Reinstall the fan on the fan drive shaft.
replaced as follows: Tighten the fan hub set screws securely.
12. Install the shroud to frame attaching
1. Remove the fan guard to shroud bolts and tighten securely. Reinstall fan
attaching capscrews. Remove fan guard shroud cover.
halves. 13. Reinstall the fan guard on the shroud.
2. Remove the shroud to frame attaching Tighten attaching capscrews securely.
and cover bolts. Remove shroud cover 14. Following the start up procedure, start
and fan shroud if necessary. and run the unit long enough to reach
3. Loosen the fan hub to fan drive shaft set normal operating temperature. Check for
screws (there are two) and pull or tap and correct all leaks.
the fan off the shaft.
4. Remove the oil seal retainer to rear Servicing or replacement of control valves or
bearing retainer attaching capscrews switches, shut down switches and the oil
and remove the seal retainer with outer cooler do not require specific instructions for
seal. Discard outer seal. disassembly and assembly.
5. Remove the oil seal assembly, including
spring and spring guide, from the fan WARNING
drive shaft. Discard the seal assembly. WHENEVER A UNIT IS BEING SERVICED,
6. Remove the oil seal face insert, with o- MAKE CERTAIN THAT AIR PRESSURE
ring seal, from the seal retainer. Discard HAS BEEN BLED DOWN AND THE
the face insert, with o-ring seal. ELECTRICAL POWER ISOLATED FROM
7. Thoroughly clean all remaining parts. THE COMPRESSOR.
(Retainer, seal cavity, shaft, etc.)
Remove all traces of gasket material COMPRESSOR DRIVE SYSTEM
from the seal retainer and rear retainer
mating surfaces. Check the condition of The V-belt drive systems installed in the CL
the shaft and remove all nicks and burrs. compressor were designed for optimum

35
performance for specific combinations of
motor horsepower and system pressure
requirements. Initial belt tensioning will
rapidly drop off during the first fifty to one
hundred hours of compressor operation.
Therefore, belt tension should be monitored
daily during this period to minimize belt wear.

A belt that is too loose will slip, causing

excessive heat and accelerated wear. Belts
that are too tight will cause an overload FIGURE 15
condition on motor and/or compressor
bearings. Check the pulley alignment by placing a
straight edge against the side of the drive
BELT INSTALLATION AND ADJUSTMENT pulleys and measure to the edge of the belts
at points A and B. If these two
When installing new belts, do not pry the measurements are the same, the pulleys are
belts over the pulley grooves. The proper correctly aligned.
installation method follows:
If these two measurements are not the same,
1. Disconnect and lock out all electrical reposition the pulleys to obtain correct
power to the compressor. alignment.
2. Remove the front panel to allow access
to the belt drive and remove the front
belt guard.
3. Loosen and remove the nut from the
threaded rod on the spring tensioning
belt adjustment device, located next to
airend on the airend mounting plate.
4. Push motor over toward the airend,
allowing the complete assembly to pivot
on the base. Remove the old belts.
5. Install new belts. Tilt motor assembly
back away from airend as far as
possible. Reinstall nut and washer on
threaded rod and tighten until the bottom
of the spring cover is within 1/8” - 1/4”
from the pivoting airend mounting base.
Check belt tension to make sure tension FIGURE 16
is correct. Loosen or tighten nut to
compress spring as required.
6. Restore electrical power and restart the
compressor to check correct tracking of
the belts.
7. Replace the front belt guard and front
panel.

PULLEY ALIGNMENT

Realignment of pulleys is not required during

normal belt service, however, if pulleys, motor
or airend positions are changed realignment
of pulleys should be done by following
method.

36
SECTION VIII
SERVICE DIAGNOSIS

MALFUNCTION POSSIBLE CAUSE REMEDY

Motor will not run 1. Blown branch circuit fuse. 1. Renew fuse(s).

2. Blown line disconnect fuse 2. Renew fuse(s) or reset

or tripped circuit breaker. circuit breaker.

3. Blown control circuit fuse(s). 3. Renew control circuit

fuse(s).

4. Magnetic starter overload 4. Reset overload relay(s).

relay tripped.

5. Loose or broken wires. 5. Check and repair or replace

(Motor or control) broken wire(s) and
connection(s).

6. Defective or damaged 6. Check components. Renew

control circuit components. as required.
(Relays, temperature
switches, etc.)

7. Damaged motor. 7. Repair or replace motor.

Air end will not rotate. 1. Defective or damaged air 1. Replace air end.
end.

Motor will not rotate. 1. Defective or damaged motor. 1. Replace or repair motor.

Air end/motor will not 1. Low line voltage or 1. Have qualified electrician
come up to full speed inadequate power check and correct power
before starter overload supply. supply.
trips.

2. Starting against pressure. 2. Check and correct cause of

Unit receiver not blown unit receiver not blowing
down. down. (Blow down valve:
controls).

Compressor fails to 1. Clogged or restricted air 1. Clean or renew air filter

provide sufficient air filter element. element.
for demands.
2. Excessive distribution 2. Correct air leaks as required.
system leakage.

3. Air demand exceeds 3. Reduce air demand. Install

compressor capacity. additional compressors.

37
MALFUNCTION POSSIBLE CAUSE REMEDY
Compressor fails 4. Motor not running up to 4. Check power supply to motor
continued. speed. and correct as required.

5. Drive belts loose and 5. Replace and/or retention

slipping. drive belts.

6. Damaged or excessively 6. Repair or replace intake

worn intake valve. valve.

7. Air supply to compressor 7. Properly ventilate compressor

room or enclosure room or enclosure.
inadequate.

Compressor fails to 1. Control bleed orifice 1. Clean control bleed orifice.

pump (load) or is slow plugged.
to load after running
unloaded. 2. Sticky intake valve operating 2. Disassemble, clean or replace
parts. faulty intake valve parts as
required.

Compressor stops but 1. Faulty blow down valve. 1. Renew blow down valve.
air receiver/oil reservoir
does not blow down.

Excessive compressor 1. Clogged or restricted 1. Clean or replace line and/or

oil consumption. separator drain line or filter. filter.

2. External oil leaks. 2. Inspect for and correct all

external oil leaks.

3. Incorrect oil installed in 3. Refer to oil specifications.

compressor. Drain unit and install correct
oil.

4. Oil reservoir over filled. 4. Drain to correct oil level.

5. Low pressure operation. 5. Operate at correct pressure

(80 psi minimum)

6. Defective separator element. 6. Renew separator element.

Oil blows out blow 1. Clogged or restricted 1. Clean or replace line and/or
down valve when separator drain line or filter. filter.
blow down valve
actuates. 2. Defective blow down valve. 2. Replace blow down valve.

3. defective separator element. 3. Replace separator element.

Air receiver-oil 1. Incorrect or insufficient 1.

reservoir pressure control pressure due to:
relief valve actuates.
a. Clogged or restricted a. Clean replace supply

38
MALFUNCTION POSSIBLE CAUSE REMEDY
Air receiver-oil control pressure or control lines
continued regulator valve supply
and control air lines.

b. Incorrectly adjusted b. Adjust controls.

control pressure regulator
valve.

c. Dirty, clogged, or c. Clean, repair or replace

damaged control regulator valve.
pressure regulator valve.

2. Worn or damaged intake 2. Disassemble, inspect, clean

valve. and repair intake valve.

3. Incorrect pressure relief 3. Install correct pressure

valve installed. relief valve.

4. Damaged or worn pressure 4. Renew pressure relief

relief valve. valve.

5. Restricted separator element. 5. Renew separator element.

Unit shut down caused 1. Air end discharge 1.

by air end discharge or temperature too high due to:
or separator out high
temperature. a. Insufficient oil in oil a. Fill reservoir too correct
reservoir. level with recommended
oil.

b. Compressor operating b. Adjust to correct

above maximum pressure.
recommended pressure.

c. Dirty or clogged oil c. Clean or replace oil

cooler inside or out. cooler.

2. Faulty high temperature 2. Renew high temperature

shut down switch. shut down switch.

3. Low compressor oil flow. 3.

a. Check for restricted

oil filter. Change
element as required.

b. Check for and correct

cause of restriction in
oil system including
hoses, fitting tubes, etc.

39