ULTRA CLEAN ROCKY COMPRESSOR - Tech West · · 2015-08-06The Ultra Clean Rocky Compressor...

2625 N. Argyle Ave. • Fresno, CA 93727(559) 291-1650 • (800) 428-7139 • FAX (559) 348-9677

TECH WEST INC.Manufacturers of Dental Vacuum

and Air Systems

ULTRA CLEANROCKY COMPRESSOR

INSTALLATION

AND SERVICE

MANUAL Revised 4-15

ULTRA CLEANROCKY COMPRESSOR

INSTALLATION AND SERVICE MANUALThis manual is for the installation and service of Tech West’s Ultra Clean Rocky Compressors.

CONTENTSInstallation

Location Requirements 2

Figure 1: Wire and Breaker Sizes 2

Ultra Clean Rocky Installation Steps 3

Ultra Clean Rocky Compressor Connections 4

Ultra Clean Rocky Start Up 5

Ultra Clean Rocky Maintenance 6

Ultra Clean Rocky Compressor Motor Assembly Breakdown 7-8

Coalescing Filter Assembly Breakdown 9

Tank Breakdown 10

Desiccant Dryer Parts Breakdown 11

Gauge and Moisture Indicator Assembly Breakdown 12

Wiring Diagram 13

Dual Ultra Clean Rocky Compressor Assembly 14

Triple Ultra Clean Rocky Compressor Assembly 15

Quad Ultra Clean Rocky Compressor Assembly 16

Maintenance Schedule 17

TROUBLE SHOOTING

Dual Rocky Compressor Trouble Shooting 18-19

Triple Rocky Compressor Trouble Shooting 20-21

Air Line Sizing Chart 22Maintenance/Service and notes 23-25

1

ULTRA CLEAN ROCKY COMPRESSORINSTALLATION

1. ROCKY COMPRESSOR LOCATION REQUIREMENTS

The Ultra Clean Rocky Compressor location should be level, accessible and well ventilated.

If the Ultra Clean Rocky Compressor will be located in a confined space, provide adequate ventilation.

Electrical

(1) Line voltage must be within the limits of Figure 1 below. (Install a “buck-boost transformer” if line voltage is not between these values.) Circuit breaker switches must be 20 - 30 amp depending on model and voltage necessary.

(2) Local code may require you to provide a quick disconnect (safety switch) for the compressor.

(3) See Figure 1 below for breaker size and line voltage.

CAUTION - Voltage must be 208/240 V or motor damage may occur.

CAUTION - Voltage must be 110/120 V or motor damage may occur.

2

Figure 1: Recommended Wire and Breaker Size

Dual Head Compressors

Model Voltage Amperage Wire Size Recommended(Gauge) Breaker Size

ACOR2D1 110/120 11 12 20

ACOR2D2 208/230 8 12 20

ACOR2D1Q 110/120 11 12 20

ACOR2D2Q 208/230 8 12 20

ACOR3T2 208/230 12 12 20

ACOR3T2Q 208/230 12 12 20

ACOR4Q2 208/230 16 10 30

Triple Head Compressors

Quad Head Compressors


2

2. INSTALLATION STEPS

This dental compressor should only be installed by qualified personnel. Should any questions ariseduring the installation, call Tech West Technical Support between the hours of 7:00 a.m. to 4:00 p.m.(Pacific Standard Time).

Place the compressor in a clean, dry, well ventilated area, on a solid, level surface. Consider soundlevel and insulate as needed. Be sure that adequate ventilation is available as the compressor is aircooled. Ambient temperature in the equipment room should be within the temperature range of 40degrees Fahrenheit minimum to 100 degrees Fahrenheit maximum.

(a) Check the shipping carton for damage. This could detect damage to the unit which might otherwise be overlooked. Remove cardboard shipping carton.

(b) Remove the Oilless Compressor from its shipping skid. Inspect the unit for damage.Oilless Compressors are shipped bolted to a pallet. This pallet is intended for shipping only and should be discarded.

(c) Remove installation kit attached to pallet. It should contain the following:

(4) Isolation Feet(1) Alternate Air Hookup Hose(1) 5’ Flexible Air Hose

(d) Install isolation feet on tank legs.

(e) Move compressor into place and level by observing bubble level on compressor platform.

(f) Wiring instructions:

(1) Have all electrical connections made by qualified personnel only. All connections should be in accordance with local codes.

(2) Use the chart on page 1 to help determine the proper line and breaker size for the unit that is being installed.

(g) Install the air line from the compressor tank to the building supply.

(h) Install the 1” flex alternate air hose from the compressor to a fresh air supply.

3

0

10

20

3040 50

607

8

90100

psi

Electrical Connection to disconnect and electrical panel

(110 v / 220 v)

Air OutConnection to building

supply line

4


2

3. CONNECTIONS

Alternate Air Connection

to fresh air supply

Figure 2

Dryer PurgeConnection

5


2

4. SAFETY PRECAUTIONS

• Keep fingers, foreign objects and clothing free from rotating parts and do not touch hot surfaces.

• Never attempt to service an operating unit.

• Isolate unit from system pressure and relieve backpressure before servicing

• Disconnect all power before servicing. The thermal protector in single phase motors automatically starts motor when device resets.

USE OF THIS PRODUCT IN OR NEAR EXPLOSIVE ATMOSPHERES, OR FOR

PUMPING MIXTURES OTHER THAN ATMOSPHERIC AIR MAY CAUSE AN

EXPLOSION OR FIRE, RESULTING IN PERSONAL INJURY OR DEATH.

2

5. START-UP STEPS

(a) Make sure the shut-off valve from the compressor tank is closed.

(b) Turn the breaker from the panel to the “ON” position.

(c) Turn power “ON” from the toggle switch on the compressor. Compressor should run quietly and vibration free. The storage tank should start to build pressure.

(d) The compressor will run until the pressure gauge reads 100 psi. The compressor then will automatically shut off and the dryer will purge with a quick blast of air.

(e) Using soapy water, check the compressor plumbing hook ups for leaks. Repair leaks if needed.

(f) Pressure test the entire plumbing system for leaks. Use the storage tank pressure gauge to monitor a pressure drop. After the plumbing system has been pressurized for 30 minutes, re-check the gauge for pressure drop. If there is a drop in pressure, find and repair all leaks in the office plumbing.

(g) Complete and mail in the warranty card for the compressor within ten days of installation.

AIR LEAKS ARE THE MAIN CAUSE OF COMPRESSOR FAILURES.

6

7. PERIODIC SERVICING

MONTHLY SERVICING

(a) Remove the purge bucket and empty as needed(b) Crack the drain petcock on the bottom of the storage tank to check for water and drain if needed.(c) Check moisture indicator to see that it is still “BLUE”. If it is pink, it is time to service the air dryer.(d) Check pump-up times of the compressor.(e) Check intake air supply filters. Replace filters as needed.

YEARLY SERVICING

(a) Repeat all of the monthly servicing.(b) Replace the dessicant air dryer. (Part #: RDC-100)(c) Replace the alternate air filter. (Part #: TIF-100)(e) Replace the moisture indicator on the compressor. (Part #: MI -100)(f) Check the coalescing filter and change if needed. (Part #: CFEO-375)


2

6. GENERAL SERVICE INFORMATION

For parts and service on Rocky series products contact the nearest authorized Tech West distribu-tor. To expedite appropriate service, be prepared to provide the unit model number, identificationnumber, and serial number found on the nameplate located on the front of the unit motor.

Component life operating at continuous duty & maximum pressure will shorten the life of the ringsand skirts. It is difficult to predict due to many conditions which directly influence wear. Some ofthese conditions may include ambient air temperature, air cleanliness, operating pressure, pistonstroke on the particular model being utilized, duty cycle, maintenance of filters, etc.

Because of these various factors it is appropriate to generalize on component wear life and choosesome conservative estimates for most standard applications.

With these conditions in mind, we recommend the following preventative maintenance schedule.

RECOMMENDED MAINTENANCEFOR ROCKY MODELS

Minor Service Kits, Piston Cups & Valves, Skirts, Etc.

Major Replacement Kit, Piston & Rod Assemblies

Replace inlet Filter

HOURS

Cont. DutyMaximum Pressure

8,000 Hours

12,000 Hours

4,000 Hours

TIME

Based on 100%Duty Cycle

12 months

18 months

6 months

KEY PART NO. DESCRIPTION UNIT

13 CV-250D 1/4 CHECK VALVE 1

16 GOM-075R-115 OILLESS MOTOR 3/4 HP 115V 1-4

17 GOM-075R-230 OILLESS MOTOR 3/4 HP 230V 1

20 BE-4 BRASS ELBOW 1/4” 2

21 FE-4-6 BRASS FLAIR ELBOW 1/4” X 3/8 1

22 BN-1.50 BRASS NIPPLE 1/4” X 1 1/2 1

7

ULTRA CLEAN ROCKY COMPRESSORPARTS LIST

ROCKY OIL-FREE COMPRESSOR MOTOR

21

20

1617

13

22

8


1 RCF-100 COOLING FAN 2

2 RFS-100 FAN SHROUD 2

3 RRP-100 RETAINER PLATE 2

4 RPC-100 PISTON CUP 2

5 RVS-100 VALVE PLATE SET 2

6 RCOR-100 CYLINDER O-RING 2

7 RHOR-100 HEAD 0-RING 2

8 RCT-100 CROSS OVER TUBE 2

9 RCVS-100 COMPLETE VALVE PLATE ASSEMBLY 2

ROCKY OIL-FREE MOTOR 3/4HPBREAKDOWN 5

5

3

7

8

2

9

4

1

6

9

ROCKY FILTER ASSEMBLY

1

2

3


1 CFAO-375 COALESCING FILTER ASSEMBLY 3/8 1

2 CFEO-375 COALESCING FILTER ELEMENT 3/8 1

3 CFBP-375 COALESCING FILTER BOWL 1

10

ROCKY REAR VIEW TANK ASSEMBLY AND PARTS LIST


1 CV-375D-100 3/8 CHECK VALVE MALE TO FEMALE CONNECTION 1-4

2 CPT-100 COMPRESSOR PURGE TANK 1

4 HA-10-250 1/4 HOSE ASSEMBLY - 10” LONG 1

5 DPC-1 DRYER PRE COOLER DUAL COMPRESSOR 1

6 DPC-2 DRYER PRE COOLER TRIPLE & QUAD COMPRESSOR 1

7 RFV-100 RUBBER MOUNTING FEET 4

8 CV-500D-100 1/2 CHECK VALVE 1

4

1

2

18

7

56

11

ROCKY DESICCANT AIR DRYER ASSEMBLY

KE

YP

AR

T N

O.

DE

SC

RIP

TIO

NU

NIT

1D

SV

-115

115V

PU

RG

E S

OL

EN

OID

VA

LVE

1

2D

SV

-230

230V

PU

RG

E S

OL

EN

OID

VA

LVE

1

3A

S-5

001/

2 F

ILT

ER

AS

SY

1

4R

DC

-100

RE

PL

AC

EM

EN

T D

ES

SIC

AN

T T

AN

K1

5M

V-2

50M

ET

ER

ING

VA

LVE

1

6S

N-2

50-C

LS

TAIN

LE

SS

ST

EE

L N

IPP

LE

1/4

3

7F

E-4

-6F

LA

IR F

ITT

ING

1/4

X 3

/81

8B

V-2

50B

AL

L V

ALV

E 1

/41

9B

T-25

0B

RA

SS

TE

E 1

/42

10F

PH

-375

CL

EA

R P

UR

GE

HO

SE

PE

R F

OO

T

11M

SD

-100

MO

LE

CU

LA

R-S

IEV

E

1 L

B2L

BS

12M

SD

-200

AC

TIV

AT

ED

AL

UM

INA

1 L

B2L

BS

13C

V-2

50D

1/4

CH

EC

K V

ALV

E1

4

3

5

6

9

7

8

9

12

13

1211

INSIDETANK

ELEMENT

10

12

0

10

20

3040 50

60

7

8

90100

psi

100

90

80

706050

0

0

20

10

0

2

4

4

3

3

2

5

5

8

6

7

7

1

1


1 CPG-250 COMPRESSOR GAUGE 1

2 BV-250 1/4” BALL VALVE 1

3 MI-100 MOISTURE INDICATOR 1

4 FA-4-4 1/4” FLARE HOSE FITTING 1

5 BN-250-CL 1/4” BRASS CLOSE NIPPLE 1

6 BT-250 1/4” BRASS TEE 1

7 BSE-250 1/4” BRASS ELBOW 1

8 BPC-4 1/4” BRASS CROSS 1

ROCKY GAUGE AND CUT-OFF ASSEMBLY

DUAL COMPRESSOR CONFIGURATION

TRIPLE & QUADCOMPRESSOR CONFIGURATION

13

ROCKY WIRING DIAGRAMS

WIRING DIAGRAM WITH SOUND COVER AND 24v SWITCH

ROCKY DUAL WITHOUT SOUND COVER

14

0

10

20

3040 50

607

8

90100

psi

8

16

17

18

19

7

5

12

94


1 SBHA-21-375 STEEL BRAID HOSE ASSEMBLY 1

3 DSV-115 PURGE VALVE SOLENOID VALVE 115v 1

4 FPH-375 PURGE FLEX HOSE CLEAR PER FT

5 ZZACS61 1/4 HOSE ASSEMBLY PER FT

6 PFT-500 POLY FLO TUBE 1/2 PER FT

7 CFAO-375 COALESCING FILTER 3/8 1

8 CFEO-375 COALESCING FILTER ELEMENT ONLY 1

9 DPB-100 DRYER PURGE BUCKET 1

10 RIC-GAST RUBBER MOUNTING FEET 8


12 RDC-100 REPLACEMENT DESICCANT CARTRIDGE 1

13 CV-250D 3/8 CHECK VALVE 2

14 DSV-230 PURGE VALVE SOLENOID VALVE 230V 1





19 PSC-3 PRESSURE SWITCH 1

DUAL ULTRA CLEAN ROCKY COMPRESSOR

314

11

13

6

15

10

1

15


















TRIPLE ULTRA CLEAN ROCKY COMPRESSOR

8

16

17

7

5

12

94

14

6

1

18

10

1315

16


















QUAD ULTRA CLEAN ROCKY COMPRESSOR

8

16

17

7

5

12

94

14

6

1

10

13

18 10

15

17

Maintenance & Service SuppliesService scheduled for: Service items needed:

18

DO

ES

AIR

C

OM

PR

ES

SO

RR

UN

?

Doe

s co

mpr

esso

r ru

nfo

r a

few

sec

onds

,“c

hugs

”, t

hen

stop

s?

Doe

s co

mpr

esso

r pr

es-

suriz

e fr

om 8

0 to

100

psi i

n le

ss t

han

2m

inut

e w

ith n

o ai

rbe

ing

used

?

Doe

s co

mpr

esso

rcy

cle

with

no

air

bein

g us

ed?

YE

SN

OY

ES

NO

GO

ON

TO

TH

E N

EX

TP

AG

E.

Are

the

re le

aks

inco

mpr

esso

r or

inof

fice

pipi

ng s

yste

m?

Doe

s ai

rbl

eed

out

the

purg

eva

lve

whe

nun

it is

ru

nnin

g?

Cle

an

or

repl

ace.

Rep

lace

inta

ke

filte

r.

NO

NO

Che

ck v

olta

ge a

tth

e va

lve

and

mak

e su

re v

alve

iscl

osed

.

Doe

sun

load

erva

lve

pres

-su

re s

witc

hor

flo

atas

sem

bly

seat

whi

leru

nnin

g?

NO

YE

S

Trou

ble

Shoo

ting

Char

tD

ual

Ult

ra C

lean

Ro

cky

Co

mp

ress

or

Dua

l Ultr

a Cl

ean

Roc

ky C

ompr

esso

r

YE

S

0

10203040

50607 8 90

100

psi

Is t

he m

oist

ure

indi

cato

r pi

nk?

YE

S

Is in

take

filte

rcl

ogge

d?

Is t

here

suf

ficie

ntpr

essu

re b

uild

-up

with

hea

d di

scha

rge

line

rem

oved

?

YE

S

NO

Def

ectiv

ehe

ad,

cont

act

Tech

Wes

t.

No

te:

Clo

sesh

ut o

ff va

lve.

Pum

p up

tan

k to

100

psi.

If pr

es-

sure

is m

ain-

tain

ed f

or 1

5-20

min

., le

ak is

inof

fice

lines

.

YE

SLo

cate

and

repa

ir.

NO

NO

Doe

s pu

rge

valv

esy

stem

func

tion

prop

erly

?

YE

S

Doe

s co

m-

pres

sor

run

too

hot

or t

oofr

eque

nt?

NO

Che

ck f

or p

rope

rvo

ltage

. U

se b

uck-

boos

t if

need

ed.

NO

1. L

ocat

e an

d re

pair

leak

s.2.

Ven

tilat

e if

room

isab

ove

100

deg.

F.

3. C

onta

ct c

ompr

esso

rm

ay b

e un

ders

ized

.

YE

S

YE

S

Ser

vice

dry

er a

ndre

plac

e m

oist

ure

indi

cato

r.

YE

S

Che

ck v

olta

ge

supp

lied

to t

he

com

pres

sor.

YE

S

Def

ectiv

ehe

ad,

cont

act

Tech

Wes

t.

YE

S

NO

Doe

s ai

r le

akfr

om u

nloa

der

valv

e or

the

purg

e m

uffle

rco

ntin

uous

lyun

til u

nit

cycl

esag

ain?

Mak

e su

re t

hat

the

drye

r va

lve

is c

los-

ing

prop

erly

.

19

CHECK FOR:1. Broken or loose

wire.2. Defective pressure

switch.3. Defective ON/OFF

switch.4. Excessive voltagedrop across power

lines.NOTE: Voltageshould be + or -10% of rating.

Is there sufficientvoltage at motorterminals while

motor tries to start?

GO ON TOTHE NEXT

PAGE.

COMPRESSORDOES NOT RUNOR RUNS FORONLY A FEWSECONDS.

YES

Does headrun with dis-charge line

disconnected?

NO

Is there suffi-cient voltageat disconnect

box?

Blockage inair line locate

& repair.

YES

Install Tech West

transformer.

NOYES NO

YES

Is thereresistance

rise acrossthe capaci-

tors?

YES

Replacedefective

capacitors.

NO

Turn power off.Remove fan guard.Try turning fan byhand. If it doesn’tturn, contact head

may be frozen.

NOTE:Short capacitor

leads. Check resis-tance rise. If noresistance rise,

replace.

Du

al U

ltra

Cle

an R

ock

y C

om

pre

sso

rROCKY DUAL WITHOUT SOUND COVER

20

Doe

s co

mpr

esso

r ru

nfo

r a

few

sec

onds

,“c

hugs

”, t

hen

stop

s?

Doe

s co

mpr

esso

r pr

es-

suriz

e fr

om 8

0 to

100

0ps

i in

less

tha

n 1

min

ute

with

no

air

bein

g us

ed?

Doe

s co

mpr

esso

rcy

cle

with

no

air

bein

g us

ed?

YE

SN

OY

ES

GO

ON

TO

TH

E N

EX

TP

AG

E.

Are

the

re le

aks

inco

mpr

esso

r or

inof

fice

pipi

ng s

yste

m?

Cle

an

or

repl

ace.

Rep

lace

inta

ke

filte

r.

NO

NO

YE

S

Trou

ble

Shoo

ting

Char

tTr

iple

Ult

ra C

lean

Ro

cky

Co

mp

ress

or

Trip

le U

ltra

Clea

n R

ocky

Com

pres

sor

Is in

take

filte

rcl

ogge

d?

Is t

here

suf

ficie

ntpr

essu

re b

uild

-up

with

hea

d di

scha

rge

line

rem

oved

?

YE

S

NO

Def

ectiv

ehe

ad,

cont

act

Tech

Wes

t.

No

te:

Clo

sesh

ut o

ff va

lve.

Pum

p up

tan

k to

100

psi.

If pr

es-

sure

is m

ain-

tain

ed f

or 1

5-20

min

., le

ak is

inof

fice

lines

.

YE

SLo

cate

and

repa

ir.

NO

Def

ectiv

ehe

ad,

cont

act

Tech

Wes

t.

YE

S

NO

Loca

tean

d re

pair.

YE

S

Is t

here

abl

ocka

ge in

air

lines

?

YE

SN

O

Is t

he m

oist

ure

indi

cato

r pi

nk?

NO

Doe

sun

load

erva

lve

syst

emfu

nctio

npr

oper

ly?

YE

S

Doe

s co

m-

pres

sor

run

too

hot

or t

oofr

eque

nt?

NO

Che

ck f

or p

rope

rvo

ltage

. U

se b

uck-

boos

t if

need

ed.

NO

1. L

ocat

e an

d re

pair

leak

s.2.

Ven

tilat

e if

room

isab

ove

100

deg.

F.

3. C

onta

ct c

ompr

esso

rm

ay b

e un

ders

ized

.

YE

S

Ser

vice

dry

er a

ndre

plac

e m

oist

ure

indi

cato

r.

YE

S

NO

Che

ck v

olta

ge a

tth

e va

lve

and

mak

e su

re v

alve

iscl

osed

.

Doe

sun

load

erva

lve

pres

-su

re s

witc

hor

flo

atas

sem

bly

seat

whi

leru

nnin

g?

Che

ck v

olta

ge s

up-

plie

d to

the

co

mpr

esso

r.

YE

S

Doe

s ai

rbl

eed

out

the

relie

fva

lve?

NO

YE

S

YE

S

Doe

s ai

r le

akfr

om u

nloa

der

valv

e or

the

purg

e m

uffle

rco

ntin

uous

lyun

til u

nit

cycl

esag

ain?

Mak

e su

re t

hat

the

drye

r va

lve

is c

los-

ing

prop

erly

.

DO

ES

AIR

C

OM

PR

ES

SO

RR

UN

?

21

Trip

le U

ltra

Cle

an R

ock

y C

om

pre

sso

r

CHECK FOR:1. Broken or loose

wire.2. Defective pressure

switch.3. Defective ON/OFF

switch.4. Excessive voltagedrop across power

lines.

NOTE: Voltageshould be + or -10% of rating.

Is there sufficientvoltage at motorterminals while

motor tries to start?

GO ON TOTHE NEXT

PAGE.

COMPRESSORDOES NOT RUNOR RUNS FORONLY A FEWSECONDS.

Does headrun with dis-charge line

disconnected?

NO

Is there suffi-cient voltageat disconnect

box?

Blockage inair line locate

& repair.

YES

Install Tech West

transformer.

NO

NO

YES

Is thereresistance

rise acrossthe capaci-

tors?

YES

Replacedefective

capacitors.

NO

Turn power off.Remove fan guard.Try turning fan byhand. If it doesn’tturn, contact head

may be frozen.

NOTE:Short capacitor

leads. Check resis-tance rise. If noresistance rise,

replace.

WIRING DIAGRAM WITH SOUND COVER AND 24v SWITCH

YES

YES

23

Maintenance & Service / Notes

24


25


2625 N. Argyle Ave. • Fresno, CA 93727(559) 291-1650 • (800) 428-7139 • FAX (559) 348-9677

TECH WEST INC.Manufacturers of Dental Vacuum

and Air Systems

ULTRA CLEAN ROCKY COMPRESSOR - Tech West · · 2015-08-06The Ultra Clean Rocky Compressor...

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Transcript of ULTRA CLEAN ROCKY COMPRESSOR - Tech West · · 2015-08-06The Ultra Clean Rocky Compressor...