Campbell Hausfeld TX2101

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Description

Aircompressorunitsareintended

toprovidecompressedairtopower

pneumatictools,operatesprayguns

andsupplyairforpneumaticvalvesand

actuators.Thepumpssuppliedwith

theseunitshaveoillubricatedbearings.

Asmallamountofoilcarryoveris

presentinthecompressedairstream.

Applicationsrequiringairfreeofoil

vaporshouldhavetheappropriate

filterinstalled.Theaircompressorunits

aretobemountedpertheinstructions

providedonasolidfloor.Anyotheruse

oftheseunitswillvoidthewarranty

andthemanufacturerwillnotbe

responsibleforproblemsordamages

resultingfromsuchmisuse.Refertothe

enclosedReplacementPartsManualto

identifycompressorassinglestageor

two-stage.

SafetyGuidelines

Thismanualcontainsinformation

thatisveryimportanttoknow

andunderstand.Thisinformation

isprovidedforSAFETYandto

PREVENTEQUIPMENTPROBLEMS.

Tohelprecognizethisinformation,

observethefollowingsymbols.

 Dangerindicates

 animminently

hazardoussituationwhich,ifnot

avoided,WILLresultindeathor

seriousinjury.

 Warningindicates

 apotentially

hazardoussituationwhich,ifnot

avoided,COULDresultindeathor

seriousinjury.

 Cautionindicates

 apotentially

hazardoussituationwhich,ifnot

avoided,MAYresultinminoror

moderateinjury.

 Noticeindicates

 important

information,thatifnotfollowed,

maycausedamagetoequipment.

AirCompressors

RecordtheModelNo.,SerialNo.and

dateofpurchaseinthespacebelow.

ModelNo. ______________________

SerialNo. ______________________

Dateofpurchase _________________

Retainthesenumbersfor

futurereference.

Pleasereadandsavetheseinstructions.Readcarefullybeforeattemptingtoassemble,install,operateormaintainthe

productdescribed.Protectyourselfandothersbyobservingallsafetyinformation.Failuretocomplywithinstructions

couldresultinpersonalinjuryand/orpropertydamage!Retaininstructionsforfuturereference.

SeeWarrantyonpage10forimportantinformationaboutcommercialuseofthisproduct.

OperatingInstructions TF2101,TF2111,TQ3010,TQ3011,TX2101,TX2118

REMINDER:Keepyourdatedproofofpurchaseforwarrantypurposes!

Attachittothismanualorfileitforsafekeeping.

Unpacking

Whenunpackingunit,inspectcarefully

foranydamagethatmayhaveoccurred

duringtransit.Makesureanyloose

fittings,bolts,etc.,aretightenedbefore

puttingunitintoservice.Incaseof

questions,damagedormissingparts,

pleasecall1-800-543-6400forcustomer

assistance.Havetheserialnumber,

modelnumber,andpartslist(with

missingpartscircled)beforecalling.

DONOTRETURN

THEPRODUCTTO

THERETAILER!

 Donotoperate

 unitifdamaged

duringshipping,handlingoruse.

Damagemayresultinburstingand

causeinjuryorpropertydamage.

READ&FOLLOWALLINSTRUCTIONS

SAVETHESEINSTRUCTIONS

DONOTDISCARD

GeneralSafety

CALIFORNIAPROPOSITION65

 Thisproductorits

 powercordmay

containchemicals,includinglead,

knowntotheStateofCalifornia

tocausecancerandbirthdefects

orotherreproductiveharm.Wash

handsafterhandling.

 Youcan

 create

dustwhenyoucut,sand,

drillorgrindmaterials

suchaswood,paint,

metal,concrete,cement,orother

masonry.Thisdustoftencontains

chemicalsknowntocausecancer,

birthdefects,orotherreproductive

harm.Wearprotectivegear.

STOP�

IN255005AV2/12©2012

BreathableAirWarning

Thiscompressor/pumpisNOT

equippedandshouldNOTbe

used“asis”tosupplybreathing

qualityair.Foranyapplicationof

airforhumanconsumption,you

mustfittheaircompressor/pump

withsuitablein-linesafetyand

alarmequipment.Thisadditional

equipmentisnecessaryto

properlyfilterandpurifytheair

tomeetminimalspecifications

forGradeDbreathingas

describedinCompressed

GasAssociationCommodity

SpecificationG7.1,OSHA29

CFR1910.134,and/orCanadian

StandardsAssociations(CSA).

DISCLAIMEROFWARRANTIES

Intheeventthecompressoris

usedforthepurposeofbreathing

airapplicationandproperin-line

safetyandalarmequipment

isnotsimultaneouslyused,

existingwarrantiesarevoid,and

themanufacturerdisclaimsany

liabilitywhatsoeverforanyloss,

personalinjuryordamage.

All manuals and user guides at all-guides.com

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Summary

Operating Instructions

Safety Guidelines Overview

Provides crucial safety information and symbols for hazard recognition.

General Safety Warnings

Highlights critical safety precautions and warnings for operating the compressor.

Breathable Air Warning

Warns against using the compressor for breathing air without proper filtration.

General Safety Precautions

Operational Safety Rules

Covers general safety rules for operating the compressor, including personal protection and environment.

Electrical Installation and Motor Setup

Wiring and Grounding Procedures

Instructions for safe and correct wiring, electrical connections, and grounding.

Motor Hookup and Starter Installation

Operation Details and Maintenance

Tank and Lubrication Maintenance

Maintenance Schedule and Troubleshooting

Troubleshooting Common Issues

A chart listing common symptoms, their possible causes, and corrective actions.

Summary

Operating Instructions

Safety Guidelines Overview

Provides crucial safety information and symbols for hazard recognition.

General Safety Warnings

Highlights critical safety precautions and warnings for operating the compressor.

Breathable Air Warning

Warns against using the compressor for breathing air without proper filtration.

General Safety Precautions

Operational Safety Rules

Covers general safety rules for operating the compressor, including personal protection and environment.

Electrical Installation and Motor Setup

Wiring and Grounding Procedures

Instructions for safe and correct wiring, electrical connections, and grounding.

Motor Hookup and Starter Installation

Operation Details and Maintenance

Tank and Lubrication Maintenance

Maintenance Schedule and Troubleshooting

Troubleshooting Common Issues

A chart listing common symptoms, their possible causes, and corrective actions.

This document describes the TF2101, TF2111, TQ3010, TQ3011, TX2101, TX2118 Air Compressors, providing comprehensive information on their function, specifications, usage, and maintenance.

Function Description:

The air compressor units are designed to supply compressed air for various applications, including powering pneumatic tools, operating spray guns, and actuating pneumatic valves. These units feature oil-lubricated pumps, which means a small amount of oil carryover will be present in the compressed air stream. For applications requiring oil-free air, an appropriate filter must be installed. The compressors are intended for mounting on a solid floor according to the provided instructions. Any other use voids the warranty and absolves the manufacturer of responsibility for issues arising from misuse. The manual also references an enclosed Replacement Parts Manual for identifying whether the compressor is a single-stage or two-stage unit.

Important Technical Specifications:

Maximum Operating Pressure:
- Two-stage compressors: 175 PSI
- Single-stage compressors: 135 PSI
ASME Safety Relief Valve Setting:
- Two-stage compressors: No higher than 200 PSI
- Single-stage compressors: No higher than 150 PSI
- The safety valve in the intercooler does not provide system protection.
Pump Maximum Safe Pressure Rating:
- Two-stage: 200 PSI
- Single-stage: 150 PSI
Minimum Pipe Size for Compressed Air Line (in inches) based on CFM and Length of Piping System (in feet):
- 10 CFM: 1/2" for 25-100 ft, 3/4" for 250 ft
- 20 CFM: 3/4" for 25-100 ft, 1" for 250 ft
- 40 CFM: 3/4" for 25 ft, 1" for 50-250 ft
- 60 CFM: 3/4" for 25 ft, 1" for 50-250 ft
- 100 CFM: 1" for 25-250 ft (1-1/4" for 250 ft)
Minimum Wire Size (75°C Copper Wire) based on HP and Phase:
- Single Phase 230V:
  - SPL: 10 AWG
  - 5.0 HP: 8 AWG
  - 7.5 HP: 8 AWG
  - 10.0 HP: 8 AWG
- Three Phase 208/230V:
  - 5.0 HP: 12 AWG
  - 7.5 HP: 10 AWG
  - 10.0 HP: 12 AWG
  - 15.0 HP: 6 AWG
  - 25.0 HP: 3 AWG
- Three Phase 460/575V:
  - 5.0 HP: 14 AWG
  - 7.5 HP: 12 AWG
  - 10.0 HP: 10 AWG
  - 15.0 HP: 8 AWG
Motor Frame Sizes:
- R56HZ, Y56Y, L143T: Include built-in overload protection.
- 184T, 215T, 254T, 284T: Do NOT have built-in overload protection; a magnetic starter is required.
Oil Type: Single-viscosity, ISO100, non-detergent compressor oil (part number ST126700AV, Mobil 1® 5W30 or 10W30 synthetic oil may also be used). Using other oil types may shorten pump life and damage valves.

Usage Features:

Safety Guidelines: Emphasizes reading all instructions, observing local and national electrical/safety codes (NEC, OSHA, CSA), and ensuring only qualified persons operate the compressor. It warns against operating near flammable materials, without a beltguard, and with damaged components. Personal protective equipment (safety glasses, hearing protection, face mask/respirator for spraying) is recommended.
Breathable Air Warning: Explicitly states that the compressor/pump is NOT equipped to supply breathing quality air "as is." For human consumption, suitable in-line safety and alarm equipment (filters, purifiers) meeting Grade D breathing specifications (Compressed Gas Association Commodity Specification G 7.1, OSHA 29 CFR 1910.134, and/or Canadian Standards Associations) must be fitted. Failure to do so voids existing warranties.
Unpacking and Installation: Instructions for inspecting the unit upon arrival, tightening loose fittings, and contacting customer assistance for damaged or missing parts. It advises against returning the product to the retailer. Installation requires bolting the tank to a flat, even concrete floor or foundation, using vibration isolators (MP367700AJ for horizontal, MP345700AJ for vertical units) without overtightening bolts. A flexible hose or coupling should be used between the tank and service piping when isolators are present. The unit should be installed at least 24 inches from obstructions in a clean, well-ventilated area with ambient temperatures not exceeding 100°F.
Piping: Recommends installing a shut-off valve on the tank's discharge port to control airflow, located between the tank and the piping system. Crucially, a shut-off valve must NOT be installed between the compressor pump and the tank. Plastic (PVC) pipe is forbidden for compressed air. All tubes, pipes, or hoses must withstand the generated temperature and pressure, with pressure ratings equal to or higher than the ASME safety valve setting.
Wiring and Grounding: All wiring and electrical connections must be performed by a qualified electrician, adhering to local and national codes. Proper grounding is essential to prevent electrical shock. Motor hookup and starter installation details are provided, including requirements for branch circuit protection and overload protection (either built-in or requiring a magnetic starter).
Direction of Rotation: Critical for unit life, the flywheel must rotate counterclockwise when facing its side. Wiring information for counterclockwise rotation is typically on the motor nameplate.
Operation:
- Oil Fill: Units are shipped without oil. Crankcase must be filled with specified compressor oil to the center of the sight gauge or maximum mark on the dipstick before operation. Oil should only be added through the oil fill plug.
- Break-In Period: The compressor should run continuously for one hour with the drain valve completely open to allow proper seating of piston rings.
- Moisture in Compressed Air: Explains that moisture will condense in the tank, especially in humid conditions or during continuous use. This condensation can cause issues like water spots in paint jobs or clogging in sandblasting guns. A filter in the air line, near the gun, helps eliminate moisture.
- Pressure Switch: The unit starts and stops based on preset pressure switch settings (max 175 PSI for two-stage, 135 PSI for single-stage). The pressure switch includes an unloader valve for easy motor starting.
- Continuous Run Operation: Requires a separate unloading device installed between the pump and the tank, replacing the existing check valve.
- Crankcase Breather: Normal for some oil to accumulate at the breather opening during severe conditions or initial start-up, diminishing with run time.

Maintenance Features:

General Maintenance: Disconnect, tag, and lock out power source, then release all pressure before any maintenance.
Daily Checks: Check air filter, oil level, and ASME safety valve. The safety valve should be pulled daily to ensure it snaps back; if it leaks or is stuck, it must be replaced. Tampering with the safety valve is prohibited.
Tank Maintenance: Inspect annually for cracks near welds. If cracks are found, remove pressure immediately and replace the tank. Drain liquid from the tank daily.
Compressor Lubrication: Change oil after the first 50 hours of operation, then every three months or 500 hours, whichever comes first. Pressure-lubricated pumps also have an oil filter.
Air Filter: Never run without or with a clogged air filter. Clean with compressed air; do not wash or oil. Replace if it cannot be cleaned. A dirty filter increases oil consumption and discharge air contamination.
Intercooler (Two-Stage Compressors Only): Check weekly for secure fittings and tightness. Blow dirt, dust, and accumulations from fins. Wear gloves due to sharp fins.
Components: Monthly, use light air pressure to blow dust and foreign material from cylinder head, motor, fan blades, air lines, intercooler, and tank.
Belts: Check tension every three months (3/8 to 1/2 inch deflection with thumb pressure). Align belts using a straight edge against the flywheel face.
Storage: Store in a normal position in a cool, protected area for short periods.
Troubleshooting Chart: Provides common symptoms, possible causes, and corrective actions for issues like excessive noise, milky oil, excessive oil consumption, water in discharge air, air blowing out of inlet, insufficient pressure, tank not holding pressure, excessive belt wear, slow tank pressure build-up, ASME safety valve popping, and unloader valve malfunctions.
Service Record: A dedicated section for recording maintenance performed and replacement components required, including date.

Warranty:

A one-year limited warranty from the date of purchase covers parts and labor for substantial defects in material and workmanship. Implied warranties are limited to the duration of the original purchase. Exclusions include incidental/consequential loss, damage from accident/abuse/neglect, pre-delivery service, normal wear items (motor, check valve, pressure switch, regulator, gauges, hoses, belts, air filter, gaskets, seals, etc.), damage from incorrect oil or contamination, inadequate filter maintenance, and modifications to safety devices. Specific exclusions apply to lubricated compressors regarding oil type and maintenance. Labor, service calls, or transportation charges after the first year for stationary compressors are not covered. The purchaser is responsible for providing proof of purchase and maintenance records, contacting Campbell Hausfeld for warranty service, and ensuring reasonable care and accessibility for service.