CAP200 REV H JUNE 2017 MASTERLINE SERIES Page 1 of 46 ___________________ Model ___________________ Serial # Please have your unit’s model and serial number ready when calling for service. The model # is found on the tank decal and the serial number is located on the compressor nameplate. For all air compressor support requests, please contact your local distributor.
CAP200 REV H JUNE 2017 ML Series PRESSURE LUBRICATED RECIPROCATING AIR COMPRESSOR Installation and Operations Manual
MASTERLINE SERIES Page 2 of 46 CAP200 REV H JUNE 2017 Table of Contents Read Me First Section 1 Installation Section 2 Wiring Diagrams Section 3 Start Up Section 4 Maintenance Section 5 Troubleshooting Section 6 Safety Precautions ............................................................................................. 3-4 System Diagram ................................................................................................ 5-7 Receiving .........................................
MASTERLINE SERIES Page 3 of 46 CAP200 REV H JUNE 2017 READ ME FIRST Safety Precautions The owner, lessor or operator of any compressor unit manufactured by FS Curtis, Inc. is hereby warned that failure to observe all safety precautions may result in serious injury of personnel and/or damage to property. FS Curtis, Inc.
MASTERLINE SERIES Page 4 of 46 CAP200 REV H JUNE 2017 Turn off and lockout/tagout the main power disconnect switch before attempting to work or perform any maintenance. Do not attempt to service any part of this unit while it is running. Ensure that service personnel are properly trained before attempting to service any part of the electrical system. Do not operate the unit with any of its safety guards, shields or screens removed.
CAP200 REV H JUNE 2017 MASTERLINE SERIES Page 5 of 46 System Diagram Simplex Units 2 1 3 4 5 6 1 Air Intake 4 Magnetic Starter 2 Air Compressor 5 Pressure Switch 3 Intercooler 6 Vibration Pads with hardware mounts Exact orientation of system components may vary. Please see your model's general arrangement diagram for a precise configuration of system components. Fig. (1) Simplex, two stage air compressor process.
CAP200 REV H JUNE 2017 MASTERLINE SERIES Page 6 of 46 Duplex Units 3 2 1 5 4 5 1 Air Intake 4 Alternator 2 Air Compressor 5 Pressure Switch 3 Intercooler 6 Vibration Isolator Pads 3 2 1 Exact orientation of your system's components may be different from the layout in the figure. Please see your model's general arrangement for a precise configuration of system components. Fig. (2) Duplex unit system diagram. Refer to the simplex diagram for a description of the compression cycle.
CAP200 REV H JUNE 2017 MASTERLINE SERIES Page 7 of 46 Large Industrial 1 4 2 3 1 Air Intake 2 Air Compressor 3 Intercooler 4 Electric Motor Exact orientation of your system's components may vary. Factory Note: Single stage compressors installed options not shown. do not have an intercooler. Please see your model's general arrangement for a precise configuration of systemcomponents. Fig (3). Base mounted large industrial units.
MASTERLINE SERIES Page 8 of 46 CAP200 REV H JUNE 2017 INSTALLATION IMPORTANT NOTICE Abide by all applicable state, local and regulations when mounting and installing the compressor. Failure to do so may result in injury or death and will void the manufacturer’s warranty. Contact your local government for more information. CAUTION! Improper lifting can result in component or system damage or personal injury. Follow good shop practices and safety procedures when moving the unit.
MASTERLINE SERIES Page 9 of 46 CAP200 REV H JUNE 2017 FREIGHT DAMAGE The transportation industry has adopted a modification with regard to the handling of obvious and concealed damage claims. Therefore, it is extremely important that you examine every carton and crate as soon as you receive it. If there is any obvious damage to the shipping container, have the delivering carrier sign the freights bill, noting the apparent damage, and request a damage report.
CAP200 REV H JUNE 2017 MASTERLINE SERIES Page 10 of 46 Installation Procedure Step 1 – Select a proper location for installation Select a clean, dry, well lit area with a rigid floor strong enough to support the compressor and with adequate ventilation. Avoid placement of the compressor in an area that is excessively hot, dusty, humid or contaminated with foreign gases such as ammonia or acid fumes. The unit should never be operated at ambient temperatures above 104°F or below 32°F.
CAP200 REV H JUNE 2017 MASTERLINE SERIES Page 11 of 46 Fig (6) Large Industrial Base Mount MODEL Fig (7) Masterline Base Mount DIMENSION (INCHES) Weight A (lb) D96 25.75 C79 25.75 D97 B n/a C MODEL DIMENSION (INCHES) Weight A B C (lb) 17.375 350 C150H 64.75 32.375 20 2700 n/a 17.375 400 C200 64.75 32.375 20 3000 25.75 n/a 17.375 675 C200S 64.75 32.375 20 3000 C89 25.75 n/a 17.375 775 C260H 64.75 32.
CAP200 REV H JUNE 2017 MASTERLINE SERIES Page 12 of 46 Step 4 – Install Vibration Isolator pads and mount the compressor Exposure to excessive vibrations can significantly shorten the life of the compressor. FS Curtis highly recommends mounting the unit on vibration isolator pads and the compressor should NEVER be operated without being securely fastened to the ground. Using a level, please check for proper alignment of the compressor.
CAP200 REV H JUNE 2017 MASTERLINE SERIES Page 13 of 46 Recommended Installation – Use concrete anchor bolt 2 1 4 3 6 5 8 7 Fig.
MASTERLINE SERIES Page 14 of 46 CAP200 REV H JUNE 2017 Step 5 – Tighten the fasteners Incrementally tighten the mounting bolts evenly in a cross pattern. If necessary, after start up, continue incrementally tightening the mounting bolts in a crossing pattern until vibrations have been reduced to an acceptable level. After vibrations have been minimized, loosen ONE mounting bolt.
MASTERLINE SERIES Page 15 of 46 CAP200 REV H JUNE 2017 Post Installation Checklist WARNING! Failure to perform the post installation checklist may result in mechanical failure, property damage, serious injury or even death. Steps 1 through 9 should be performed prior to connecting the unit to a power source. If any condition on the checklist is not satisfied, make the necessary adjustments or corrections before starting the compressor. 1.
MASTERLINE SERIES Page 16 of 46 CAP200 REV H JUNE 2017 Electrical Requirements TANK MOUNTED UNITS The electrical installation of this unit should only be performed by a qualified electrician with knowledge of the National Electrical Code (N.E.C.), O.S.H.A. code and/or any local or state codes having precedence. All FS Curtis tank-mounted compressors come with a factory installed, pre-wired starter, if you wish to provide your own starter, please contact your local distributor for more information.
CAP200 REV H JUNE 2017 MASTERLINE SERIES Page 17 of 46 Wiring Diagrams: Simplex Single Phase and 3 Phase TURN OFF / TAGOUT POWER BEFORE SERVICING 1 2 3 1 2 3 4 5 L1 L2 L3 Overload relay Reset switch 4 5 Fig.
CAP200 REV H JUNE 2017 MASTERLINE SERIES Page 18 of 46 Wiring Diagrams: Duplex Dual Source Alternator TURN OFF / TAGOUT POWER BEFORE SERVICING 3 2 1 3 2 1 1 2 3 L1 L2 L3 Fig. (13) Duplex dual source alternator panel. NOTE: See Following page for Duplex Wiring Diagram.
MASTERLINE SERIES Page 19 of 46 Wiring Diagrams: Masterline Duplex 5hp – 30hp TURN OFF / TAGOUT POWER BEFORE SERVICING CAP200 REV H JUNE 2017
MASTERLINE SERIES Page 20 of 46 Wiring Diagrams: Large Industrial with Solenoid Valve 50hp – 125hp TURN OFF / TAGOUT POWER BEFORE SERVICING CAP200 REV H JUNE 2017
MASTERLINE SERIES Page 21 of 46 Wiring Diagrams: Large Industrial with Solenoid Valve, Fully Packaged 50hp – 125hp TURN OFF / TAGOUT POWER BEFORE SERVICING CAP200 REV H JUNE 2017
MASTERLINE SERIES Page 22 of 46 Wiring Diagrams: Large Industrial with Pilot Valve 50hp – 125hp TURN OFF / TAGOUT POWER BEFORE SERVICING CAP200 REV H JUNE 2017
MASTERLINE SERIES Page 23 of 46 Wiring Diagrams: ASSD and Solenoid Valve: 5hp – 40hp TURN OFF / TAGOUT POWER BEFORE SERVICING CAP200 REV H JUNE 2017
MASTERLINE SERIES Page 24 of 46 Wiring Diagrams: Dual Control: 5hp – 40hp TURN OFF / TAGOUT POWER BEFORE SERVICING CAP200 REV H JUNE 2017
MASTERLINE SERIES Page 25 of 46 Wiring Diagrams: Ultra Pack 5hp – 7.
MASTERLINE SERIES Page 26 of 46 CAP200 REV H JUNE 2017 Start Up Pre Start Check List WARNING! Do not proceed until the PRE-STARTING CHECKLIST and sub-section has been read and is thoroughly understood. 1. Check oil level in crankcase for proper level. 2. Drain liquid from the air receiver and moisture trap (if so equipped). 3. Check system pressure. Do not operate the compressor in excess of the A.S.M.E. pressure vessel rating for the receiver or the service rating of the compressor, whichever is lower.
MASTERLINE SERIES Page 27 of 46 CAP200 REV H JUNE 2017 START-UP If the compressor is equipped with an automatic start-stop control (with pressure switch unloading), it is automatically unloaded upon starting, and will automatically load after attaining running speed. Simply throw the power switch to start the unit. For engine driven compressors equipped with a pilot valve, the pilot valve must be manually unloaded prior to starting the compressor.
MASTERLINE SERIES Page 28 of 46 CAP200 REV H JUNE 2017 The unloaders are of “O” ring and piston type with pressure and over travel compensating spring. This in turn contacts the valve which has a built in unloader fork and return spring. To check to see if unloader is stuck open or closed the action can be viewed on the low-pressure cylinders by removing air inlet filter and elbow and watching the operation through the inlet opening.
MASTERLINE SERIES Page 29 of 46 CAP200 REV H JUNE 2017 Maintenance For the first weeks, the compressor needs time to “break in.” The belt requires time to stretch and fit into the surface of the pulleys. The piston rings need time to seat themselves into the cylinder walls, and bearings need to wear into place. For the first 100 hours or so, the compressor will consume higher than normal amounts of oil until the break in process is complete.
MASTERLINE SERIES Page 30 of 46 CAP200 REV H JUNE 2017 Maintenance Schedule To assure maximum performance and service life of your compressor, a routine maintenance schedule should be developed. A sample schedule has been included to help you develop a maintenance schedule designed for your particular application. Time frames may need to be shortened in harsher environments or during periods of extremely heavy use.
CAP200 REV H JUNE 2017 MASTERLINE SERIES Page 31 of 46 Oil FS Curtis MasterLine compressors require a break in period and are factory filled with the needed lubricant for the break in period. After the break in period is complete, drain the oil and replace with required oil for your compressor listed below. FS Curtis manufactures two different lubrication systems for Masterline compressors. The compressors D96, D97, C79, C89, C98, and C100 use an oiling ring system.
MASTERLINE SERIES Page 32 of 46 CAP200 REV H JUNE 2017 Oil Pressure Large Industrials (C200 and up) Base mounted large industrial units are equipped with a factory installed oil pump and oil pressure gauge. Proper oil pressure readings are as follows Oil Gauge Pressure Normal Pressure .......................... 26 to 30 PSIG Normal Pressure (C260H) ........... 30 to 40 PSIG Minimum Pressure ....................... 20 PSIG Switch Cutoff Pressure ................
CAP200 REV H JUNE 2017 MASTERLINE SERIES Page 33 of 46 Low Oil Guard (D96, C79, D97, C89, C98) To help prevent catastrophic damage, FS Curtis provides an option for a Low Oil Guard, which prevents the unit from starting when the oil level has dropped below the low oil mark on the sight glass or dipstick, see Fig (12) for proper oil level. FS Curtis’s low oil guard utilizes a magnetic float switch. The low oil guard is rated for 300VAC MAXIMUM.
CAP200 REV H JUNE 2017 MASTERLINE SERIES Page 34 of 46 Bolt Torques Masterline Compressors D96 Consult exploded assembly for part # Head Bolt C79 C89 Size Torque (ft*lb) Size Torque (ft*lb) Size Torque (ft*lb) 3/8-16 25 3/8-16 25 5/8-11UNC x 4 1/2 140 Cylinder to Case 7/16-14 24 7/16-14 24 HHCS 5/8-11UNC x 1 3/4 68 Connecting Rod 3/8-24 28 3/8-24 28 HHCS 3/8-24UNF x 2 3/4 15 Intercooler -- - -- - HHCS 1/2-13UNC x 4 1/2 HHCS 1/2-13UNC x 3 3/4 50 Side Door 5/16-18 7 5
CAP200 REV H JUNE 2017 MASTERLINE SERIES Page 35 of 46 Bolt Torques Large Industrial Compressors C100 C150 C200 Consult exploded assembly for part # Head to cylinder Size Torque (ft*lb) Size Torque (ft*lb) Size Torque (ft*lb) 3/4-10 160 3/4-10 160 5/8-11 140 Cylinder to Case 3/4-10 140 3/4-10 140 3/4-10 140 Discharge Flange 5/8-11 80 5/8-11 80 5/8-11 80 Connecting Rod 5/8-18 110 5/8-18 110 1/2-20 65 Intercooler* 1/2-13 37 1/2-13 37 1/2-13 37 Side Door 5/16-18
CAP200 REV H JUNE 2017 MASTERLINE SERIES Page 36 of 46 BELT TENSION CAUTION: Over tightening the v-belt(s) will result in overloading of the motor, and/or belt and pulley failure. A loose belt will result in an unstable speed, premature belt wear, “throwing” belts and a high amp draw. To change tension, turn the adjusting bolt at the end of the base, shown in figure 15. Retighten motor hold-down bolts. Grease both the motor and compressor pulleys once a year with lithium ball bearing grease.
CAP200 REV H JUNE 2017 MASTERLINE SERIES Page 37 of 46 Compressor Pulley DIRECTION OF APPLIED FORCE Motor Pulley Fig. (16) Proper belt tensioning 3. At the center of the span, perpendicular to the belt, apply pressure to the outer surface of the belt tension gauge as shown in figure (13). Apply force to the belt until the rubber ring on the deflection gauge is located at the original position of the belt. Record the reading on the belt tension gauge and compare to the chart.
CAP200 REV H JUNE 2017 MASTERLINE SERIES Page 38 of 46 INSTRUCTIONS UNLOADER PILOT VALVE FUNCTION VV1002 Pilot Valve senses receiver (tank) pressure when the receiver pressure rises to the preset “unload” valve setting, the ball opens passing high pressure air to the compressor unloading device. When the receiver pressure drops to the preset “load” valve setting, the ball closes venting the compressorunloading device to atmosphere.
CAP200 REV H JUNE 2017 MASTERLINE SERIES Page 39 of 46 MAIN BEARING The main bearings are of the tapered roller type and must be shimmed or adjusted for end play as follows: 0.0005” to .002” for compressors D96, C79, C89 and D97. 0.0005” to .003” for compressors C98 and C100 0.002” to .004” for compressors C150, C200 and C260 0.004” to .006” for compressors C300 Maintenance Parts and Rebuild Kits To order replacement parts for routine maintenance, please contact your local distributor.
CAP200 REV H JUNE 2017 MASTERLINE SERIES Page 40 of 46 Troubleshooting If your problem is not caused after working through the checklist below, please contact your local distributor.
CAP200 REV H JUNE 2017 MASTERLINE SERIES Page 41 of 46 Problem Cause Remedy Manual drain not fully closed Close the drain cock (standard model) Automatic drain not fully closed (if Clean or replace automatic drain applicable) 7 8 Low discharge pressure Excessive wear belt Clogged air filter / intake Replace the filter Leaks in air distribution system Check fittings, bushings and connections for leaks Clogged air distribution system Clean air distribution system
CAP200 REV H JUNE 2017 MASTERLINE SERIES Page 42 of 46 Maintenance Check off List NOTE: Please keep a record of changes and have this list available when calling technical service.
CAP200 REV H JUNE 2017 MASTERLINE SERIES Page 43 of 46 Maintenance Check off List NOTE: Please keep a record of changes and have this list available when calling technical service.
CAP200 REV H JUNE 2017 MASTERLINE SERIES Page 44 of 46 Maintenance Check off List NOTE: Please keep a record of changes and have this list available when calling technical service.
MASTERLINE SERIES Page 45 of 46 NOTES CAP200 REV H JUNE 2017
MASTERLINE SERIES Page 46 of 46 NOTES CAP200 REV H JUNE 2017
Curtis-Toledo, Inc. 1905 Kienlen Avenue | St. Louis, Missouri 63133 314-383-1300 or 800-925-5431 www.fscurtis.com | info@fscurtis.
