CAP-246

JULY, 2007
REV. L

CURTIS-TOLEDO
OPERATOR’S MANUAL &
PARTS LIST

K/S Series
Belt Driven Rotary Screw Compressors

KS25
KS25A
KS30
KS30A
KS40
KS40A
KS50
KS50A

WARNING
Personal injury and/or equipment damage will result by failing to pay attention
to the vital safety information and instructions in this manual.
Carefully read, understand, and retain all safety information and instructions
before operating this compressor.

Curtis-Toledo, Inc.
1905 Kienlen Ave. St. Louis, MO 63133
phone: 314/383-1300 fax: 314/381-1439 Email: [email protected]
 General Unit Specifications

KS25 KS30 KS40 KS50

Horsepower 25 30 40 50
Capacity
@100 psi cfm 106 125 188 222
@125 psi cfm 102 118 169 209
@150 psi cfm 90 104 147 182
@175 psi cfm 78 98 126 168

Oil System
gal 2.65 2.9 3.1 6.6
Capacity

Dimensions
Length in 34 34 53 45
Width in 34 34 34 54
Height in 52 52 52 60
Weight lbs 750 790 970 1430

Dba 73 73 73 73

Air
npt 1 1 1 1-1/2
Connection

Ambient o Minimum: 35oF

F
Temperature Maximum: 105oF
Cooling Air
cfm 2125 2125 3200 4250
Flow

DANGER
Compressed air from this machine is not suitable for breathing and will
cause death or severe personal injury.

Consult a filtration specialist for proper treatment.

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Table of Contents
1.0 Safety..................................................................................................... 1-1

2.0 Description
2.1 Compressor ......................................................................................... 2-1
2.2 Air/Oil System ...................................................................................... 2-1
2.3 Cooling................................................................................................. 2-2
2.4 Controls................................................................................................ 2-2
2.5 Instrumentation .................................................................................... 2-3

3.0 Installation
3.1 Site Requirements ............................................................................... 3-1
3.2 Guidelines for Compressed Air Systems ............................................. 3-4
3.3 Unpacking and Handling...................................................................... 3-4
3.4 Storage ................................................................................................ 3-5
3.5 Wiring Diagram & Component Layouts................................................ 3-7
3.6 Installation Drawing.............................................................................. 3-20
3.7 Remote Operation…………………………………………………………. 3-21
3.8 External Alarm……………………………………………………………… 3-22

4.0 Operation
4.1 Preparation for Initial Start-up .............................................................. 4-1
4.2 Normal Start-up.................................................................................... 4-2
4.3 Normal Stopping .................................................................................. 4-2
4.4 Emergency Stopping............................................................................ 4-2
4.5 Dual Control Operation ........................................................................ 4-2

5.0 Maintenance
5.1 Maintenance Intervals.......................................................................... 5-1
5.2 Air Filter................................................................................................ 5-2
5.3 Oil Filter................................................................................................ 5-2
5.4 Air/Oil Separator .................................................................................. 5-3
5.5 Renewal Elements ............................................................................... 5-4
5.6 Lubricant .............................................................................................. 5-4
5.7 Thermostatic Valve .............................................................................. 5-6
5.8 Minimum Pressure Valve ..................................................................... 5-6
5.9 M6 Controller ....................................................................................... 5-7
5.10 Belts ..................................................................................................... 5-14
5.11 Fan....................................................................................................... 5-16
5.12 Motor.................................................................................................... 5-16
5.13 Air end/Motor removal ……………………………………………………..5-18

6.0 Troubleshooting ................................................................................................ 6-1

7.0 Maintenance Log .............................................................................................. 7-1

8.0 Parts listing

KS 25 thru KS 40......................................................................................... 8-1
KS 50........................................................................................................... 8-17
Maintenance Kits......................................................................................... 8-31
Pressure Range Kits……………………………………………………………. 8-32
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1.0 COMPRESSOR SAFETY PRECAUTIONS

An air compressor is a rotating piece of machinery and the same common sense
safety precautions should be observed as with any piece of machinery.
Carelessness of operation or maintenance is hazardous to personnel.

In addition to the obvious safety rules that should be followed with this type of
machinery, we are recommending the following additional safety precautions.

1. Read and understand all instructions completely before operating this

compressor.
2. Pull the main electrical disconnect switch and disconnect separate control
lines, if used, prior to attempting to work or perform maintenance on this unit.
3. Do not attempt to remove any pressurized system parts without first relieving
the pressure within the unit.
4. Do not attempt to service any part while the machine is in operation.
5. Do not operate the compressor at pressures in excess of its rating indicated
on the compressor nameplate.
6. Do not operate the compressor at speeds in excess of its rating indicated on
the compressor nameplate.
7. Do not remove guards, shields, or screens while the compressor is operating.
If removed for maintenance replace before resuming operation.
8. Observe the delivery pressure gauge daily to be sure the automatic control
system is operating within proper limits.
9. Periodically check all safety and relief devices for proper operation.
10. Do not play with compressed air. Pressurized air can cause serious injury to
personnel.
11. Be sure that no tools, rags, or loose parts are left on the compressor or drive
parts.
12. Do not use flammable solvents for cleaning parts.
13. Exercise cleanliness during maintenance and when making repairs. Keep dirt
away from parts and exposed openings by covering with a clean cloth or Kraft
paper.
14. Do not install a shut-off valve in the discharge line without installing a
pressure relief valve between the shut-off and the compressor package.
15. Install pressure relief valves in any isolatable piping in the plant system.
16. Do not operate the compressor in areas where there is the possibility of
ingesting flammable or toxic gases.
17. Never disconnect (or jumper) the high air temperature switch and operate the
machine.
18. Know what the mode of operation the compressor is in before working around
it. The power may be on, but the machine not running if it is in auto restart
mode.

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19. Check hoses for any signs of wear or deterioration before each use and make
certain that all connections are secure.

Make sure to investigate the code requirements to ensure compliance prior to

operating the compressor.

The owner, lessor, or operator of this compressor is hereby notified and

forewarned that any failure to observe these safety precautions may result in
injury and/or property damage.

Curtis-Toledo does not state as fact and does not mean to imply the preceding
list of safety precautions is all-inclusive, and that the observance of this list will
prevent all injuries or equipment damage.

Curtis-Toledo expressly disclaims responsibility or liability for any injury or

damage caused by failure to follow these specified precautions or by failure to
exercise ordinary caution and due care required in operating or handling the
compressor even though not expressly specified here.

Throughout the manual various safety concerns will be brought to your attention
with boxes containing one of the following notations:

Danger is used to indicate the presence of a hazard that

DANGER will cause severe personal injury or death, or substantial
property damage.

Warning is used to indicate the presence of a hazard,

WARNING which can cause severe personal injury, or substantial
property damage.

Caution is used to indicate the presence of a hazard,

CAUTION which can cause personal injury, or property damage.

Notice is used to inform you of installation. Operation,

or maintenance information that is important but not of
a hazardous nature.

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Obligatory to read instruction manual

Danger: Maintenance work (consult instruction manual)

Danger: Electric circuits

Forbidden to remove protective covering and safety devices

Danger: Heat. Do not touch hot areas

Danger: Low temperature – Follow instruction manual

Danger: Components & Equipment under high pressure

Danger: Automatic functioning. Start – up without warning

Danger: Hot or noxious gases outlet: unbreathable

On: Start – up switch

Off: Stop switch

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2.0 Description
2.1 Compressor
The compressor assembly is a positive displacement, oil flood lubricated, and
helical rotary screw type unit employing a single stage of compression. The
components include housing or stator, two rotors or screws, bearings and
bearing supports.

In operation the two helical grooved rotors mesh to compress air. Inlet air
entering the compressor becomes trapped between the lobes of the rotors.
As the rotors turn this trapped volume of air is reduced in volume or
compressed and is pushed to the discharge end of the compressor. This
process delivers smooth flowing air at full pressure to the receiver.

During the compression cycle, oil is injected into the compressor for the
purposes of lubricating, cooling, and sealing. Compressed air laden with oil
leaves the compressor through a discharge port designed to give optimum
performance within the desired pressure range.

2.2 Air/Oil System

The air/oil system consists of an inlet air filter, oil filter, air/oil separator, oil
cooler, aftercooler, and thermovalve.

Air Filter
The air filter is a high efficiency two-stage style filter. It will provide nearly
constant efficiency of filtration at all load conditions. The element has a high
dirt holding capacity for a long life. It is specially treated to be insensitive to
heat, cold, water, and oil. The changeout of the air filter is indicated in two
ways. First is at 2000-hour maintenance interval. The second if prior to this
time the filter becomes plugged; a maintenance light will indicate the need for
immediate attention.

Oil Filter
The oil filter is a 10-micron spin-on style. It is sized to maintain system
cleanliness and to give good service life. The filter contains a bypass to
insure that there is oil flow on startup. The restriction created at the filter will
have a direct effect on the operating temperature of the compressor. So you
must be sure to maintain it. The maintenance interval is set at 1000 hours of
operation.

Air/Oil Separator
The purpose of the separator is to remove aerosols. Its performance will be
affected by the vapor pressure of the oil, the operating temperature of the
unit, operating pressure of the unit and the operating cycle. The maintenance
interval is set at 4000 hours of operation.

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Minimum Pressure Valve

As the compressed air leaves the compressor it goes through a minimum
pressure valve. When the compressor is running, this is set to maintain at
least 50 psig in the air/oil separator. This is to insure that there is sufficient oil
to the compressor injection. It is also necessary to provide good air/oil
separation.
The valve also acts as a check valve to prevent back flow into the compressor
from the plant system.

2.3 Cooling
The compressor has an air-cooled oil cooler and aftercooler as standard. The
following are the heat loads and cooling airflow rates that must be
accommodated.

Air
Req'd
Model Heat
Flow
Load
B/min Cfm

KS25 950 2125

KS30 1200 2125

KS40 1550 3200

KS50 2000 4250

KS60 2400 4250

The compressor is an oil-flooded unit. The oil lubricates, seals, and cools the
internals of the compressor. In cooling it picks up the heat generated by the
compression process and the mechanical friction from the bearings, so the oil
must be cooled to within 60ºF above ambient temperature. There are also
further radiative heat losses to the room.

2.4 Controls
The KS series of units is equipped with a normally closed inlet valve with the
closure plate acting as a check valve. When the unit is started the inlet valve
opens and the unit builds up pressure. After startup, the inlet valve is
controlled by a simple on/off action.
From a safety standpoint the unit is equipped with a high air temperature
shutdown, high-pressure shutdown, compressor motor overload, and fused
disconnect. The unit of course has an ASME rated pressure relief valve.

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2.5 Instrumentation
The KS Compressor is equipped with a microprocessor-based controller.
It monitors the compressor temperature and operating pressure, as well as
functioning as the units air pressure switch and maintenance reminder.
It will also indicate unit shutdown faults.

2.6 Lubricating Oil

Your KS Compressor is factory filled with RS8000, Curtis Lube Plus ISO 46,
synthetic oil. This high quality Curtis Lube Plus lubricant is specially blended
to our specification to extend the life of your compressor and keep it running
at peak efficiency.

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3.0 Installation
3.1 Site Requirements
General
THE KS SERIES IS DESIGNED FOR INDOOR APPLICATIONS ONLY. Allow at least
three (3) feet clearance on all sides of the compressor to facilitate maintenance as well as
free circulation of air. Unit should be located in a clean, well-lighted area that will not
have an ambient air temperature below 40ْ F or exceed 105ْ F, provisions must be made
for proper ventilation so that the temperature of the room will not exceed 105ْ F.

Foundation
Your Curtis-Toledo rotary screw compressor does not require a special foundation.
However, it is necessary that the floor is level and the frame adequately supported.
Consult the ‘SPECIFICATIONS’ section of this manual for the compressor weight and
dimensions. We do recommend that the compressor be bolted to the floor.

Room
The room should be of adequate size to provide full access to the machine for routine
maintenance. It should have ventilation to keep the room as cool as possible. It is
recommended that the air handling system be designed to permit no more than a 10ْ F
rise in room temperature. Operating at elevated temperatures will cause nuisance
overload and temperature shutdowns.

Recommended Minimum
Model
Room Air Flow

KS25 3000 cfm

KS30 3175 cfm

KS40 4600 cfm

KS50 6000 cfm

Air Intake
To achieve the longest filter and lubricant life and the least maintenance you need to
supply the compressor with the cleanest air possible. It must not contain any flammable
or toxic gases. These will be concentrated by the compressor, and could result in
personal injury or death and property damage.

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DANGER
Inlet containing reactive gases will cause the failure of the lubricant
and compressor.
Insure an air supply that is well clear of any reactive gas source.

Cooling Air Discharge

The cooling air discharge must be restriction free. Any louvers or ducting must not
exceed the allowed static head shown in the specifications. Above this a booster fan will
be required. Consult a local HVAC contractor for recommendations prior to installation.
Excessive restriction to the cooling air discharge will cause the unit to operate at elevated
temperatures that could result in high temperature shutdowns. Ducting of cooling air to
the unit is not generally recommended.

CAUTION
Inadequate airflow will cause the compressor to run
hot, can damage the compressor, and increase the
amount of oil carryover.

The room temperature should not rise more than 10oF

and the cooling air discharge must not be restricted.

Electrical
A qualified electrician in compliance with standards and local codes should do all
electrical wiring. Be sure to investigate the local requirements before installing the
compressor.

The power supply should be adequate and free of parasitic loads that will cause an under
voltage condition during the operation of the compressor, otherwise there will be nuisance
electrical shutdowns. Though the unit has a disconnect on it, we recommend that one be
installed away from the machine and insure the unit is properly grounded.

We recommend the use of time delay fuses in a fusible disconnect for isolating the unit.
This disconnect should be located so an operator can disconnect the unit without nearing
the unit, in case of an emergency. We also recommend the use of a lockout/tagout
Program to help insure safety during maintenance of the compressor. Per the National
Electric Code the time delay fuses should be sized at 175% of the FLA. Consult the
Code if you want to use another style of branch circuit protection.

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NOTES

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3.2 Guidelines for Compressed Air Systems
• The air pressure drop between the compressor and the point of use is not recoverable.
• Pipe size should be large enough that the pressure drop does not exceed 10% between
the air receiver and the point of use. Generally keep the compressed flow at around
1500-2250 feet/minute velocity.

compressed capacity
pipe diameter = 13.5 ×
pipe velocity

Compressed capacity = compressor output / the compression ratio

• Arrange the air distribution piping to avoid the following types of strains:
1. Strains that is due to the dead weight of the pipe itself.
2. Strains that is due to expansion or contraction of the piping due to temperature.
3. Strains due to internal pressure within the pipe.
• Design inlet and discharge piping for smooth airflow.
• Plan for future emergencies and establish an area of the loop to install a temporary
compressor.
• Consider bypass lines around all items that may require future maintenance.
• Use loop-piping systems if possible, both around the plant and within work areas.
• Consider a second receiver at the end of the line or opposite side of the loop.
• Locate runs away from the main header close to the point of application. This limits the
pressure drop through hose.
• Take air off the top of the header to prevent carryover of condensed moisture to tools.
• Slope piping so that it drains toward a drop leg or moisture trap away from the
compressor.

3.3 Unpacking and Handling

Occasionally damage will occur during shipping. Be sure to carefully inspect the unit
before unpacking and after unpacking before you sign the receiver. If any has occurred,
document it with the trucking firm immediately. Contact your Curtis-Toledo representative
for assistance.

To move your compressor to its installation site we recommend that you leave the unit on
its shipping skid as long as possible. The forks should be extended the width of the
compressor and padding should be placed between the compressor and the fork truck
boom.

If it is necessary to lift the compressor with a crane, we recommend the use of spreader
bar and chains. The spreader bar should be greater than the width of the compressor
and padding placed on the edges to prevent chain damage.

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Procedure for Handling Damaged Shipments

1. The customer, at the receiving point, MUST inspect each shipment for damage.
2. If the shipment is damaged, the customer should so note it on the freight bill.
3.The customer should request an inspector from the freight company to inspect the
equipment immediately. It is best to send a confirming letter with the following
information:
a. Freight bill number.
b. Date delivered - shipper's name & address.
c. Description of item(s) damaged.
d. Description of damage (a Polaroid picture if possible).
e. A copy of your invoice for the equipment.
4. After inspection, (before the inspector leaves):
a. Get a copy of the inspection report.
b. Request the unit be shipped back "free astray".
c. Request a credit for the original freight bill.
5. Call the factory and:
a. Get a Return Material Authorization (RMA number).
b. Give a purchase order for repair. The purchase order should refer to the item and
trucker claim.
6. We will accept the shipment back, repair (under normal conditions) and return it within
(7) seven working days.
7. We will invoice the customer for the repair, which will then become part of your claim.
The invoice must be presented to the trucking claim department along with their claim
form.
8. We suggest if the trucker does not pay within 30 days that you call and / or write the
ICC making a formal complaint of poor service. Also advise Curtis Toledo in writing
for follow-up.

If damage can be repaired at the receiving point, follow Procedure 1, steps 1 through 4a.
Repair the unit and make out a detailed invoice to the trucker showing labor hours, labor
rate, materials used, and cost of materials,

3.4 Storage
In some cases it may necessary to store the compressor for extended periods of several
months before placing the unit in operation. When this is required do the following:
1. Cover and seal all machine openings to prevent the entrance of water and dirt.
2. Cover all openings in open drip proof motors to prevent the entrance of rodents.
3. If the storage conditions are below freezing, drain off the aftercooler, traps, water-
cooled heat exchangers and attendant piping. We do not recommend outside
storage.

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4. Cover with a waterproof tarpaulin that can easily be removed for in storage
maintenance.
5. While in storage, every two to three months rotate the compressor and motor by hand
to prevent flat spots on the bearings that will lead to premature failure.

At the end of the storage period, follow the uncrating and start-up procedures. If the unit
has been stored for more than eighteen months you should contact Curtis-Toledo before
restarting the compressor.

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3.5 Wiring Diagrams & Component Layouts

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200V, 60 Hz

I.D DESCRIPTION SIZE C-T P/N. KS25 KS30 KS40 KS50

Q1 ROTARY DRIVE 1450576A 1 1
COMPLTETE
Q1 CIRCUIT BREAKER 3P,80A 1450576B 1
Q1 HANDLE WITH MASKING 1450576C 1 1 1 1
PLATE
Q1 CIRCUIT BREAKER 3P, 100A 1450577B 1

Q1 CIRCUIT BREAKER 3P, 125A 1450578B 1

Q1 CIRCUIT BREAKER 3P,150A 1450811B 1

Q1 ROTARY DRIVE 1450578A 1 1
COMPLETE
K1-K2 CONTACTOR 3P, 24Vac 1450564 2

K1-K2 CONTACTOR 3P, 24Vac 1450565 2 2

K1-K2 CONTACTOR 3P,24Vac 1450812 2

K3 CONTACTOR 3P, 24Vac 1450561 1

K3 CONTACTOR 3P, 24Vac 1450563 1 1

K3 CONTACTOR 3P,24Vac 1450813 1

K2-K3 AUX. CONTACT 1 NC+1 NO 1450558 2 2 2

K4 THERMAL RELAY 36-45A 1450570 1

K4 THERMAL RELAY 36-50A 1450571 1

K4 THERMAL RELAY 57-75A 1450573 1

K4 THERMAL RELAY 70-90A 1450814 1

Q2,Q3 CIRCUIT BREAKER 1P, 2A 1450584 2

Q2,Q3 CIRCUIT BREAKER 1P, 5A 1450626 2 2

Q4,Q7,Q8 CIRCUIT BREAKER 1P, .5A 1450783 3 3 3 3

Q5…Q6 CIRCUIT BREAKER 1P, 6A 1450585 2 2 2

TRANSFORMER, 0-200-230-460V in
TR1 0-24\0-110V out 1450708 1
100VA
TR1 TRANSFORMER, 0-200-230-460V in
1450709 1 1
200VA 0-24\0-110V out

X1 TERMINAL BOARD 4mmq 1450589 2 2 2

X1 TERMINAL BOARD 2.5 mmq 1450588 17 17 17

EMERGENCY PUSH
S1 BUTTON
1 NC 1450575 1 1 1
3 PHASE SEQUENCE VOLTAGE
A2 RELAY 220VAC 1450631 1 1 1

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230V 60Hz

I.D DESCRIPTION SIZE C-T P/N. KS25 KS30 KS40 KS50

SO1 MAIN SWITCH 3P, 100A 1450610 1

SO1 SHAFT EXT. PIECE 1450611 1

SO1 DOOR INTERLOCK 1450607 1

HANDLE
MOTOR CONTROL 3P+1NC+1NO
Q1 PROTECTION 45-63A 1450580 1
Q1 ROTARY DRIVE 1450576A 1
COMPLT.
Q1 CIRCUIT BREAKER 3P, 80A 1450576B 1
Q1 HANDLE WITH 1450576C 1 1 1
MASKING PLATE
Q1 ROTARY DRIVE 1450578A 1 1
COMPLT.
Q1 CIRCUIT BREAKER 3P, 125A 1450578B 1 1

K1-K2 CONTACTOR 3P, 24Vac 1450563 2

K1-K2 CONTACTOR 3P, 24Vac 1450565 2 2

K1-K2 CONTACTOR 3P, 24Vac 1450566 2

K3 CONTACTOR 3P, 24Vac 1450561 1

K3 CONTACTOR 3P, 24Vac 1450563 1 1

K3 CONTACTOR 3P, 24Vac 1450564 1

K2-K3 AUXILIARY CONTACT 1 NC+1 NO 1450558 2 2 2 2

K4 THERMAL RELAY 28-40A 1450569 1

K4 THERMAL RELAY 36-50A 1450571 1

K4 THERMAL RELAY 45-63A 1450572 1

K4 THERMAL RELAY 70-90A 1450574 1

Q2…Q3 CIRCUIT BREAKER 1P, 4A 1450624 2 2 2 2

Q4,Q7,Q8 CIRCUIT BREAKER 1P, .5A 1450783 3 3 3 3

Q5…Q6 CIRCUIT BREAKER 1P, 6A 1450585 2 2 2 2

TR1 TRANSFORMER 0-200-230-460V in

1450709 1 1 1 1
200 VA 0-24\0-110V out

X1 TERMINAL BOARD 4mmq 1450589 2 2 2 2

X1 TERMINAL BOARD 2.5 mmq 1450588 17 17 17 17

X3 TERMINAL BOARD 10 mmq 1450766 12 12 12 N/A

S1 EMERGENCY PUSH
1 NC 1450575 1 1 1 1
BUTTON
3 PHASE SEQUENCE
A2 VOLTAGE RELAY 220VAC 1450631 1 1 1 1

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460V 60Hz

I.D DESCRIPTION SIZE C-T P/N KS25 KS30 KS40 KS50

SO1 MAIN SWITCH 3P, 63A 1450608 1

SO1 MAIN SWITCH 3P, 80A 1450609 1 1

SO1 MAIN SWITCH 3P,100A 1450610 1

SO1 SHAFT EXT. PC. 1450611 1 1 1 1

SO1 DOOR INTERLOCK 1450607 1 1 1 1

HANDLE
MOTOR CONTROL 3P+1NC+1NO
Q1 PROTECTION 22-32A
1450581 1
MOTOR CONTROL 3P+1NC+1NO
Q1 PROTECTION 28-40A
1450582 1
MOTOR CONTROL 3P+1NC+1NO
Q1 PROTECTION 36-52A
1450583 1
MOTOR CONTROL 3P+1NC+1NO
Q1 PROTECTION 45-63A
1450580 1
K1-K2 CONTACTOR 3P, 24Vac 1450560 2
K1-K2 CONTACTOR 3P, 24Vac 1450562 2 2
K1-K2 CONTACTOR 3P, 24Vac 1450563 2
K3 CONTACTOR 3P, 24Vac 1450559 1
K3 CONTACTOR 3P, 24Vac 1450561 1 1
K3 CONTACTOR 3P, 24Vac 1450562 1
K2-K3 AUXILIARY CONTACT 1 NC+1 NO 1450558 2 2 2 2
K4 THERMAL RELAY 17-22A 1450567 1
K4 THERMAL RELAY 18-25A 1450568 1
K4 THERMAL RELAY 28-40A 1450569 1
K4 THERMAL RELAY 36-45A 1450570 1
Q2-Q3 CIRCIUT BREAKER 1P, 1A 1450625 2 2 2
Q2-Q3 CIRCIUT BREAKER 1P, 2A 1450584 2
Q4,Q7,Q8 CIRCIUT BREAKER 1P, .5A 1450783 3 3 3 3
Q5…Q6 CIRCIUT BREAKER 1P, 6A 1450585 2 2 2 2
TRANSFORMER 0-200-230-460V in
TR1
100 VA 0-24\0-110V out
1450708 1 1 1
TRANSFORMER 0-200-230-460V in
TR1
200 VA 0-24\0-110V out
1450709 1
X1 TERMINAL BOARD 4mmq 1450589 2 2 2 2
X1 TERMINAL BOARD 2.5 mmq 1450588 17 17 17 17
EMERGENCY PUSH
S1
BUTTON
1 NC 1450575 1 1 1 1
3 PHASE SEQUENCE
A2
VOLTAGE RELAY
480VAC 1450707 1 1 1 1

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3.6 Installation Diagram – Remote Tank

REF. DESCRIPTION
1 COMPRESSOR
2 TANK
3 DRYER
4 FLEXIBLE HOSE
5 FLEXIBLE HOSE
6 CENTRIFUGAL SEPARATOR
7 AUTOMATIC COND. DISCHARGE
8 CERAMIC FILTER
9 COALESCING FILTER
10 ACTIVE CARBON FILTER
11 DIFFERENTIAL MANOMETER

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OPERATOR’S MANUAL
KS10-50
3.7 Supplement Installation Instructions for Remote Operation

1.) Turn off power to compressor at electrical supply source.

2.) Lock out and tag out electrical supply source.
3.) Disconnect switch on front panel of compressor must be in the off position before
removing.
4.) Refer to the electrical section in the operator’s manual for the information regarding
the External Start-Stop connections.
5.) KS 10-20 compressor, remove jumper wire between terminals X1-1 and X1-2.
KS 25-50 compressor, remove jumper wire between terminals X1-1 and X1-9.
6.) The remote start-stop controller is to be a maintained 2-position NO in the “stop”
position. Connect the wires from the remote device for the KS10-20 to terminals X1-1
and X1-2 and the wires for the KS25-50 to terminals X1-1 and X1-9.
7.) Before running the compressor with the remote start-stop control, it is necessary to
change the program in Menu 1.
8.) To access Menu 1, refer to Section 5 Page 8 of the KS10-50 HP Operator’s Manual.
9.) WARNING: Before turning on the power to access Menu 1, be sure that the remote
control device is in the “Stop” position. The Local/Remote mode for Menu 1 is set for
Local from the factory. Change the program to Etn for Remote using the instructions
in the manual.
10.) To start the compressor from the remote control start-stop, turn the switch to the start
position and compressor will start.
11.) To shut compressor off, turn remote control start-stop to the stop position.
KS10-20 Will shutdown immediately.
KS25-50 Timed unload and shutdown.
12.) With the program in the Remote setting, it is possible to start and stop the
compressor remotely or stop the compressor at the compressor control pad.
NOTE: The compressor will not start from the compressor control while the controller
is set for remote.
13.) To start the compressor from the remote device after stopping the compressor at the
control pad, turn the remote device to the stop position and then back to start. The
compressor will start.
14.) To start and stop the compressor from the control pad on the compressor, Menu 1
must be programmed for Local.
NOTE: In this mode it is necessary to have the remote control device in the start
position or the compressor will not start.

LV604
07-25-02

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OPERATOR’S MANUAL
KS10-50
3.8 Supplement Installation Instructions for External Alarm

1.) Turn off power to compressor at electrical supply source.

2.) Lock out and tag out electrical supply source.
3.) Disconnect switch on front panel of compressor must be in the off position before
removing.
4.) Refer to the electrical section in the operator’s manual fro the information regarding
the External Alarm connections.
5.) KS10-20 compressor, connect power supply to terminal X1-3, connect External Alarm
to terminal X1-4. Connect the other half of the External Alarm to Neutral.
6.) KS25-50 compressor, connect power supply to terminal X1-15, connect External
Alarm to terminal X1-16. Connect the other half of the External Alarm to Neutral.
7.) Before using the external alarm mode, it is necessary to check the setting in Menu 30.
8.) Turn on power to compressor at power source and turn on disconnect switch on front
panel of compressor.
9.) To access Menu 30, refer to Section 5 Page 10 of the KS10-50 HP Operator’s
Manual.
10.) Menu 30 is factory set for Alert mode (Alr KS10-20), (ALERt KS25-50). With the
External Alarm device connected, the alarm device is deactivated when the
compressor is running and there are no pre-warning, maintenance advisories or fault
shut downs. In the event that there is a pre-warning, maintenance advisory or fault
shut down, the Alarm device will be activated.
11.) To clear Alarm shut downs, push the Reset button. To clear pre-warning and
maintenance advisories push RESET & OFF together.

LV607
07-30-02

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4.0 Operation
Every Curtis-Toledo compressor has been operated and thoroughly tested and
inspected prior to shipment. However there is the possibility that damage may
occur in shipping. For this reason, it is recommended that the unit be carefully
inspected for evidence of damage or malfunction before installation and during
the first hours of operation.

4.1 Preparation for Initial Start-up

1. Pull the main disconnect switch and ensure that there is no power to the
unit.

WARNING
Electrical shock can cause injury or death.
Open main disconnect and lockout power before working inside the control
box.

2. Review the installation instructions to see that everything is complete.

3. Inspect for visible signs of damage that could have happened during
shipment or installation.

CAUTION
Loose electrical connections can cause damage to the machine and may
cause personal injury.

Check and tighten electrical connections prior to the first time start-up or
after major maintenance.

4. Remove from its shipping skid and make sure protective coverings
required for shipment are removed from the compressor.
5. Check the sump for proper oil level and add oil if necessary.
6. Check fittings for tightness.
7. Reconnect the main disconnect.
8. Refer to control section and check out panel components.
9. Turn the disconnect switch on the unit to on position. If indicated by the
controller reverse L1 and L2 connections to obtain the proper phase
relationship.
10. Start the unit and run for several minutes, confirming the operating
pressure switch setting (No less than 15 psi differential), operating
temperature, and room temperature rise. Reset the pressure switch as
necessary, then shutdown. Check the oil level and add if necessary to
compensate for filling the system.

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11. If the room temperature has risen over 10 degrees, additional ventilation
of the room will be necessary.

CAUTION
Operation of the compressor continuously at elevated temperatures will
reduce lubricant life and deteriorate some components leading to machine
failure.
Run the compressor in environments between 60ºF and 90ºF for optimum unit
life.

12. Begin normal operation.

WARNING: High temperature operation can cause damage to equipment or

personal injury. Do not repeatedly restart the unit after high temperature
stops operation. Find and correct the malfunction before resuming
operation.

4.2 Normal Start-up

1. Drain off condensate from the sump and check the oil level. Refill as
necessary.
2. Check for any oil leaks. Correct as necessary.
3. Press the ON button.

4.3 Normal Stopping

1. Press the OFF button.
2. After the unit has exhausted its contained pressure it will shutdown.

4.4 Emergency Stopping

1. Push the emergency stop button.
2. Pull the main disconnect if possible

4.5 Dual Control Operation

The timer should not be set below 10 minutes on the 25-40 horsepower and
20 minutes on the 50 and 60 horsepower, so the motor manufacturer
recommendation of starts per hour is not exceeded.

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5.0 Maintenance
5.1 Maintenance Intervals
1. Check the sump for the correct oil level.
2. Drain condensate from air receiver.
Daily or Every 8
3. Check the pressure reading to insure proper operating point
Hours
4. Check controls for proper operation.
5. Regulate tension of belts after the first 2 working hours, KS50.
1. Inspect the air filter element for clogging or holes.
2. Drain the condensate from the sump. Depending on the
humidity this may be necessary daily. Prior to draining the
compressor should be shutdown for two hours to allow water
and oil to separate.
3. Check the pressure relief valve for operation. This valve is
Weekly
factory set and no attempt should be made to readjust it.
4. Check the machine for oil leaks, loose fasteners, and
connections. Also note hose condition and replace if necessary.
5. Clean the cabinet filter mats, standard on KS50.
6. Clean external filters, if applicable.
7. Belts-first check after 50 hrs for proper tensioning, KS50.
Initial - 30 days or 1. Change oil filter element.
100 hours
1. Change oil filter element.
2. Inspect air filter element.
3. Check the belts for signs of wear and replace as necessary.
4. Clean motor and ventilation openings.
5. Take oil sample if applicable. *
6. Check hoses for signs of wear or deterioration. **
Every 6 months or
7. Test high temperature shut down switch. Remove side or back
1000 hours
panel. Start unit, run until switch trips at 220 Ü 5°F, re-install
panel, and reset control panel. Ready for normal operation.
8. Remove, clean and lubricate R20 piston valve (inlet valve
manifold). Use Parker Super-O-Lube or equal. For location see
Sect. 8, Pg 11, Item 23 or Sect. 8, Pg 14 Item 26.

1. Change air filter element.

2. Observe overall condition of unit – clean if necessary.
3. Check electrical connections.
Every 12 months or
4. Observe unit for proper load/unload cycle.
2000 hours
5. Clean oil scavenger line orifice.
6. Regrease the motor bearings.

1. Change the air/oil separator.

Every 12 months or
2. Check V-belt alignment.
4000 hours
Every 12 months or 1. Change the compressor oil. (Synthetic oil – RS8000)
8000 hours
* Oil sample required with extended life warranty program. (synthetic oil only)
** Replace as necessary or every 5 years.
Note: Maintenance schedule should be reduced by half if operating at 200º F or above, or
in dirty ambients, or with frequent cold starts.

For Oil Life versus Operating Temperature, see chart “Section 5.4”.

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5.2 Air Filter

The air filter is the primary protection of the compressor from harmful dirt being
ingested into the oil system. It needs to be looked at weekly for clogging or holes.
The period for these inspections is dependent on the environment the machine is in.

Element Inspection and Replacement

1. Switch off the unit, disconnect the power, and lock and tag to prevent accidental
starting.
2. Allow one minute after stopping for the system to settle and the pressure to be
relieved.
3. Loosen the wingnut that secures the cover, and remove the cover.
4. Loosen the wingnut that secures the element and remove the element.
5. Place a bright light inside the element to inspect for damage or leak holes.
Discard any element that shows the slightest hole.
6. Inspect all the gaskets and gasket contact surfaces of the housing. Correct any
faulty conditions immediately.
7. Clean the housing with a damp cloth. Do not attempt to blow out dirt with
compressed air.
8. Place a new element in the housing and re-secure in place with the wingnut.
9. Replace the cover and tighten the wingnut.
10. Reset the filter service advisory in the controller and the machine will be ready for
operation.

5.3 Oil Filter

The oil filter in the compressor system is a full flow replaceable canister type.
Initially the filter should be replaced after 100 hours of operation, then every 1000
hours. This element protects the compressor bearings from grit and dirt ingression
throughout the system. A dirty filter will cause an oil flow restriction that can result in
high oil temperature and a unit shutdown.

DANGER
Hot oil under pressure will cause severe injury, death, or property damage.

Be sure the compressor is shutdown and pressure relieved before

attempting to remove the oil filter, separator, oil fill, or change the oil.

Oil Filter Replacement

1. Switch off the unit, disconnect the power, and lockout and tag to prevent
accidental starting.
2. Allow one minute after stopping for the system to settle and the pressure to be
relieved.
3. Using a strap wrench, remove the old element and gasket.
4. Clean the gasket surface with a clean rag.
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5. Apply a light film of oil to the new gasket.
6. Hand tighten the new element until the new gasket is seated in the gasket
groove.
7. Continue tightening by hand an additional ½ to ¾ turn.
8. Reconnect power and reset filter service advisory.
9. Restart the machine to check for leaks.

5.4 Air/Oil Separator

The air/oil separator should be changed every 4000 hours, once a year, or when
there is excessive oil vapor in the discharge air, or as indicated by a maintenance
indicator, which ever occurs first. Higher temperature operation can cause the
element to plug faster. Consistent operation in temperatures over 180 oF will require
more frequent separator element changes.

DANGER
Hot oil under pressure will cause severe injury, death, or property damage.

Be sure the compressor is shutdown and pressure relieved before

attempting to remove the oil filter, separator, oil fill, or change the oil.

Separator Element Replacement (KS25 thru KS40)

1. Switch off the unit, disconnect the power, and lockout and tag to prevent
accidental starting.
2. Allow one minute after stopping for the system to settle and the pressure to be
relieved.
3. Using a strap wrench, remove the old element and gasket.
4. Clean the gasket surface with a clean rag.
5. Apply a light film of oil to the new gasket.
6. Hand tighten the new element until the new gasket is seated in the gasket
groove.
7. Continue tightening by hand an additional ½ to ¾ turn.
8. Reconnect power, reset separator service advisory.
9. Restart the machine to check for leaks.

Separator Element Replacement (KS50)

1. Switch off the unit, disconnect the power, and lockout and tag to prevent accidental
starting.
2. Allow one minute after stopping for the system to settle and the pressure to be
relieved.
3. Disconnect the air hose and tubing at the sump head. The lines going to the inlet
valve will require a 14mm wrench, the scavenge line a 12 mm, and the air hose a 2
inch.
4. With a 22mm wrench remove the sump head bolts.
5. Remove the separator element.
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6. If any gasket material has remained on the sump or the sump head it must be
cleaned off.
7. Install the new element. Do not remove the staple from the element gasket it is part
of the grounding system.
8. Reinstall the bolts and lines. The bolts should be torqued to 75-80 ft-lbs.
9. Reconnect the power, reset separator service advisory.
10. Restart the machine to check for leaks.

5.5 Renewal Element Part Numbers

Model Air Filter Oil Filter Separator 4000 Hour Kit

KS25 1450084 1450390 1450059 520027
KS30 1450084 1450390 1450059 520027
KS40 1450085 1450390 1450059 520033
KS50 1450200 1450390 1450202 520036

Use only genuine Curtis renewal parts. Substitute parts can reduce the
performance and void the warranty.

5.6 Lubricant
Your compressor has been filled and tested with a high quality synthetic compressor
lubricant. It has the advantage of extended service life, high temperature operation,
easy start-up when cold, reduced sludge and lacquer buildup, and is completely
compatible with all seals, gaskets, and other compressor materials.

When operating in severe conditions it will be necessary to change the lubricant

more frequently. Temperature of operation has the most significant effect on the life
of the lubricant. The following chart shows the decrease in interval based on
temperature.

Discharge Temperature RS8000

Up to 180oF 8000 hrs
180 to 190oF 6000 hrs
190 to 200oF 4000 hrs
200 to 210oF 2000 hrs

To eliminate confusion concerning what type of lubricant to use, always use Curtis
RS8000 Lubricants. If other lubricants are used, failures due to lubrication are not
warrantable.

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CAUTION
Plugged filters, coolers, and orifices can result from mixing different
lubricants and conditioners. This will also void the warranty.

Be sure to use only Curtis Lubricants in refilling your compressor.

Oil Analysis
Oil analysis is an excellent tool to add to your compressor maintenance program. At
regular intervals you submit lubricant samples to a qualified laboratory. From this you
receive a detailed report showing the lubricant condition, wear metals, and
contaminants. The rate that these measurements change over time provides the
basis for predictive compressor maintenance. Saving you from unplanned machine
downtime and unnecessary oil changes.

DANGER
Hot oil under pressure will cause severe injury, death, or property damage.

Be sure the compressor is shutdown and pressure relieved before

attempting to remove the oil filter, separator, oil fill, or change the oil.

Checking Oil Level and Adding Compressor Oil

1. Switch off the unit, disconnect the power, and lockout and tag to prevent
accidental restarting.
2. Allow one minute after stopping the compressor for settling and the pressure to
relieve.
3. Remove any dirt from around the fill cap, then remove the fill cap.
4. Inspect the cap for damage and cleanliness. Replace if necessary.
5. The oil should be half way in the sight glass. Replace the cap securely. Never
put the cap on without tightening it immediately.

Changing Compressor Lubricant

1. Switch off the unit, disconnect the power, and lockout and tag to prevent
accidental restarting.
2. Allow one minute after stopping the compressor for settling and the pressure to
relieve.
3. Remove any dirt from around the fill cap, then remove the fill cap. If the lubricant
appears dirty or has a foul smell it should be replaced.
4. Drain the lubricant from the bottom of the air/oil receiver. Oil will drain more
quickly and completely if it is warm from operation.
5. Close all drains and replace with fresh compressor oil to the proper level.
6. Replace the fill cap and run the unit.
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7. Switch off the unit and disconnect the power to prevent accidental restarting.
8. Allow one minute after stopping the compressor for settling and the pressure to
relieve.
9. Remove the fill cap to see if more lubricant should be added and to insure that
there are no leaks.

5.7 Thermostatic Valve

The thermostatic valve is a non-adjustable temperature control valve. On the
compressor we use this valve to mix hot and cold oil. It will begin to open at 127oF
and be full open at 131oF. This insures that the system temperature is above the
pressure condensation point and there is minimal accumulation of water.

The renewal kit for this valve is 1450237.

To repair this valve:

1. Switch off the unit, disconnect the power, and lockout and tag to prevent
accidental starting.
2. Place a spill pan under the valve/filter assembly.
3. Make sure that all pressure is relieved from the system. Loosening the fill cap is
an easy way to insure that the pressure is totally relieved.
4. Remove the retaining cap from the valve block.
5. Remove the cap and the internal parts. Take care to note the orientation of the
spring, piston and element.
6. Reassemble with the renewal parts.
7. Replace any volume of oil lost with fresh oil. Also replace the fill cap, if this was
used to insure relief of the system pressure.
8. Return unit to service.

5.8 Minimum Pressure Valve

The minimum pressure valve is a non-adjustable spring biased check valve. It has
been designed to maintain a minimum sump pressure of 50 psig. If the pressure is
allowed too get too low, the oil carryover rate will increase and the separator could
be damaged.

Air exiting the vent hole in the cap of the valve indicates an o-ring failure and it
needs to be replaced. The air leaking into the spring cavity where the vent is located
will change the operation of the valve.

The renewal kit for KS25 – KS40 is 1450218A.

The renewal kit for KS50 is 1450239.

To repair this valve:

1. Switch off the unit, disconnect the power, and lockout and tag to prevent
accidental starting.
2. Place a spill pan under the valve.

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3. Make sure that all pressure is relieved from the system. Loosening the fill cap is
an easy way to insure that the pressure is totally relieved.
4. Remove the cap at the top of the valve. It is spring loaded so be careful that it
does not fly off.
5. Remove piston and seat.
6. Inspect the valve body for scratches and deterioration of the seating surfaces.
7. Replace old parts with the renewal parts and re-assemble the valve.
8. If you loosened the fill plug to insure pressure relief, replace it and tighten.
9. Return the unit to service.

5.9 M6 Controller

Control Panel
1 view button 10 led functioning hours
2 on button 11 maintenance led
3 off button 12 clogged air filter
4 scroll up button 13 motor thermic led
5 scroll down button 14 automatic cycle led
6 reset button 15 functioning status led
7 display “5 digit” 16 line network led
8 pressure led 17 emergency button
9 temperature led 18 disconnect

Button Functions
1- View push for scrolling through the selected menu
2- ON push for starting the compressor
3- OFF push for delayed stopping of the compressor. Factory
set 30 sec. unload time.
4- Up Arrow push to increase the value of the display
5- Down Arrow push to decrease the value of the display

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6- RESET push to reset the controller after correcting alarm
condition.
6 & 3 - RESET & OFF push together to reset service hours after maintenance.
Changing Settings
For safety reasons you can only change the settings in the controller when the
compressor is stopped.

Basic menu – Push view button to scroll through Basic Menu

Parameter Function
Pressure Line pressure is displayed
Temperature Temperature is being displayed
Running hours Total running hours are being displayed
Hour loaded Total loaded hours are being displayed
Oil life time Remaining hours to oil service are being displayed
Air filter Remaining hours to air filter service are being displayed
Oil filter time Remaining hours to oil filter service are being displayed
Separator time Remaining hours to separator service are being displayed

Menu 1
- push off button to stop machine
- push up and down buttons until blinking lights appear
- push up button to 1 (to select menu 1)
- push view button to scroll to selected display
- push up or down button to select display mode
- push up (raise) or down (lower) any adjustable setting
- push reset button after blinking stops to confirm and exit settings menu

Menu 1

Parameter Command Default Min. Max.

Max pressure From this level the machine starts 145 PSI 80 PSI 202 PSI
working offload 5.5 bAr 13.9 bAr
Min Pressure From this level the machine starts 116 PSI 80 PSI 202 PSI
working load 5.5 bAr 13.9 bAr
Pressure Units Selection of the pressure unit PSI bAr PSI
Temperature FAHr cELS FAHr
Selection of the temperature unit
Units
Local/Remote Selection of remote or local Loc Loc Etn
control
Auto Restart Time StArt 20: Automatic restart of the StoP StoP StArt240
machine after a power failure; 240 sec.
StoP: manual restart
Run on Timer Auto: The amount of time that Auto 3 cont Auto 60
(auto) the motor keeps on running idle 3 min. 60 min.
before it stops
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Cont: the compressor works
continually with a load/unload
cycle when requested

Menu 2 or 15
- push off button to stop machine
- push up and down buttons until blinking lights appear
- push up button to 2 or 15 (to select menu 2 or 15)
- push view button to scroll to selected display
- push up (raise service hours) or down (lower service hours)
- push reset button after blinking stops to confirm and exit settings menu

Menu 2

Display Message Function Default Min. Max.

General check – oil level, filter cleaning,
S.06 250 0 250
belt tensioning.

Menu 15

Default
Display
Function Synthetic Min. Max.
Message
Oil
S.01 Change oil 8000 0 8000
S.02 Change air filter element 2000 0 2000
S.03 Change oil filter 1000 0 1000
S.04 Change separator element 4000 0 4000
Code number for connection
Add 1 1 32
of more compressors

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Menu 30
- push off button to stop machine
- push up and down buttons until blinking lights appear
- push up button to 30 (to select menu 30)
- push off button & hold for 5 seconds to complete entry into menu 30
- push view button to selected display
- push up (raise settings) or down (lower settings)
- push reset button after blinking stops to confirm and exit settings menu

* High-pressure shutdown is 10 psi above pressure setting. Access menu 30 to

increase over pressure shutdown before increasing unload pressure setting.

Menu 30

Parameter Function Default Min. Max.

* Pressure shutdown The pressure limit on which the 13.9 bar 6 bar 14.9 bar
level machine is shut down 202 psi 87 psi 216 psi
Min. Pressure 5.5 bar O bar 14.9 bar
Min. Set pressure
80 psi 0 psi 216 psi
Temperature The temperature limit on which the 104ºC 90ºC 110ºC
Shutdown / Warning machine is shutdown. 220ºF 194ºF 230ºF
Automatically the warning level is
set 3ºC / 5ºF lower
Status relay Alarm: the relay is not powered ALErt ALErt Contr
until an error or fault occurs
Control: the relay is powered
when the machine is available
(meaning: the start button has
been pushed and there are no
errors on the machine.)
Type According to the type selection the tP-2 tP-2 tP-19
certain parameters are set
automatically.

Machine Type Table:

The settings listed in the table below are automatically loaded once machine type in
menu 30 has been selected.
Max.
Control Auto- Delayed No- Blow
Machine Power Program Star/delta Starts
Unit restart Stop load Down
Model Type (Sec) in 1
Type (sec) (sec) Time (sec)
HP KW hour
KS 25- 18.5-
50 30 M6 tp2 5 20 5 3 6 20
Note – For tp2 model, maintenance hours are:
S.01 8000, S.02 2000, S.03 1000, S.04 4000 and S.06 250

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Menu 30B
- push off button to stop machine
- push up and down buttons until blinking lights appear
- push up button to 30 (to select menu 30)
- push on & off buttons together & hold for 5 seconds to enter menu 30B
- push view button to selected display
- push up (raise settings) or down (lower settings)
- push reset button after blinking stops to confirm and exit settings menu

Menu 30B

Parameter Function Default Min. Max.

Running hours Total amount of the machine’s Run 0 0 sec 100000
running hours sec
Loaded hours Total amount of the hours that the LoAd 0 0 sec 100000
machine has been working loaded sec
Start delta time The start delta time is the transition St.dLt 5.0 1 sec 40 sec
time when is passed from the star
relay to the delta relay
Stop time The unload run time is the time Stop.t 30 1 sec 60 sec
that the motor keeps on running
after the stop button has been
pushed. By stopping the machine
in this way, internal pressure is
decreased and it will prevent oil
from foaming
Auto t Minimum unload time Auto.t 3 0 sec 20 sec
Starts / hour This safety function prevents the Start 6 0 30
compressor from starting too often
within a time span of 1 hour. The
airmaster keeps the motor running
in case the maximum number of
starts per hour has been reached.
Manual start and stop commands
are always executed when they
are given but every manual start
command is also taken into
account when the remaining
available starts per hours are
calculated.
This protection allows a shorter run
on timer setting in order to stop the
motor faster if the air consumption
stops while the motor protection
remains.

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Menu 30B (cont’d)

Parameter Function Default Min. Max.

Blow down time Initiate a blow down timer to allow bLodn 20 15 sec 240
the motor to stop completely and sec
completely blow down the internal
pressure.

Menu 45
- push off button to stop machine
- push up and down buttons until blinking lights appear
- push up button to 45 (to select menu 45)
- push off button & hold for 5 seconds to enter menu 45
- push view button to selected display
- push up or down to change settings
- push reset button after blinking stops to confirm and exit settings menu

Menu 45 (DIAGNOSTIC ONLY, FACTORY SET, DO NOT CHANGE OR MODIFY.)

Parameter Function Default Min. Max.

Digital Changing configuration of Normally Normally Normally
input 1 input 1 Closed Closed Closed
Digital Changing configuration of Normally Normally Normally
input 2 input 2 Open Open Closed
Digital Changing configuration of Normally Normally Normally
input 3 input 3 Closed Open Closed
Digital Changing configuration of Normally Normally Normally
input 4 input 4 Closed Open Closed
Digital Changing configuration of Normally Normally Normally
input 5 input 5 Closed Open Closed
Digital Changing configuration of Normally Normally Normally
input 6 input 6 Open Open Closed
Digital Changing configuration of Normally Normally Normally
input 7 input 6 Open Open Closed
Digital Changing configuration of Normally Normally Normally
input 8 input 6 Closed Open Closed

Messages
Alarms
The following are shutdowns that are indicated with an alphanumeric message
and a fast blinking LED. (Stop the compressor)
A01- Max Oil Temperature
The oil temperature has exceeded 220º F
A03- Motor Overload
The motor overload has tripped.
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A04- Phase Error, Wrong Rotation

The electric power phases have been reversed from the initial machine
setup, or missing phases, power supply < 20% stop.
A05- Emergency Stop Button Pushed
The emergency stop button has been pushed.
A07- Temperature Probe Failure (air end)
The temperature probe is broken or the electrical connection to it has
been interrupted.
A10- Control Card failure
An element of the control card has failed or fuse failure.
A12- High Air/Oil Separator Pressure
The pressure in the sump has reached the over pressure setting.
A13- Pressure Transducer Failure
The probe is broken or the electrical connection to it has been
interrupted.
A14- Power Failure
The power to the unit was interrupted and the unit will restart after 20
seconds, provided “START 20” is programmed in menu 1.
A25- High Air Temperature
The air temperature has exceeded 212° F.

Warnings
The following are warnings that are indicated with an alphanumeric message and
a slow blinking LED:
a01- Inlet Air Filter/ Oil Filter Plugged
The air filter has become dirty prior to its normal filter changeout.
a02- Residual pressure in air/oil separator
1. The sump has not completely blown down.
2. If either Q4 or Q5 circuit breaker has tripped and the ON button has
been pushed.
a03- High Oil Temperature Warning
The temperature has reached 215°F and shutdown is imminent.

Maintenance
The following are reminders that are indicated with an alphanumeric message:
S.01 - change the compressor oil, this appears at 8000 hours.
S.02 - change the air filter, this appears at 2000 hours.
S.03 - change the oil filter, this appears at 1000 hours.
S.04 - change the separator element, this appears at 4000 hours.
S.06 - general inspection, clean cooler, check oil level, drain moisture from
sump, overall visual machine check, appears at 250 hours.

Section 5 Page 13
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Operations and Maintenance Manual

5.10 Belts
Routine examination of the drive system is recommended to insure maximum
compressor life. The belts need to be checked for wear and stretch.

To check the belts:

1. Switch off the unit, disconnect the power, and lockout and tag to prevent
accidental restarting.
2. Allow one minute after stopping the compressor for settling and the pressure to
relieve.
3. Remove the belt guard.
4. Inspect for any fraying or cracking of the belts. If there is any replace the belts.
5. Check the tension. The deflection should be about 1/64” per inch of span
between the sheaves with about 4 pounds of force perpendicular to the belt.

To change the belts: (KS25 thru KS40)

1. Switch off the unit, disconnect the power, and lockout and tag to prevent
accidental restarting.
2. Allow one minute after stopping the compressor for settling and the pressure to
relieve.
3. Remove the belt guard.
4. Loosen the bolts (7) holding the air end to the side rails.
5. Loosen the puller bolts (6) and slide the air end toward the motor.
6. Remove the belts.
7. Replace with new belts.
8. Set the initial tension by sliding the air end back to its original position using the
puller bolts and tighten the air end hold down bolts. The deflection should be
about 1/64” per inch of span between the sheaves with about 6 pounds of
downward force.

Section 5 Page 14
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Operations and Maintenance Manual

To change the belts: (KS50)

1. Switch off the unit, disconnect the power, and lockout and tag to prevent accidental
restarting.
2. Allow one minute after stopping the compressor for settling and the pressure to
relieve.
3. Remove the belt guard.
4. Loosen the bolt on the tensioner to reduce the tension on the belts.
5. Remove the belts.
6. Replace with new belts.
7. Tighten the bolt on the tensioner so that the indicator on the tensioner is in the green
zone.

Sheave Alignment
Any degree of sheave misalignment will result in a reduction of belt life.
Misalignment whether parallel or angular should not exceed 1/16”.

Parallel misalignment occurs when the shafts are parallel, but the face of the
sheaves is not in alignment. Angular misalignment occurs when the shafts are not
parallel.

An easy and effective method for checking the alignment in both directions is to use
an accurate straight edge.

1. Switch off the unit, disconnect the power, and lockout and tag to prevent
accidental restarting.
2. Allow one minute after stopping the compressor for settling and the pressure to
relieve.
3. Remove the belt guard.
Section 5 Page 15
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Operations and Maintenance Manual

4. Lay the straight edge across the face of the motor sheave and check the
alignment with the air end sheave.

5. Then lay the straight edge across the face of the air end sheave and check the
alignment with the motor sheave.
6. If the alignment gap is greater than 1/16” in either direction, loosen the belts as
outlined in changing belts section and align the sheaves.
7. Reset the tension on the belts
8. Return the unit to operation.

5.11 Fan
Check the fan for cracking, loose rivets, and bent or loose blades. Make sure that it
is securely mounted and tighten the mounting screws if loose. Replace a damaged
fan immediately.

5.12 Motor
The motors on the air compressor require routine attention too. Every 1000
hours of operation or six months, whichever comes first, check that the motor is
clean and ventilation openings are clear.

The second area to maintain to insure long motor life is bearing lubrication.
Bearing grease will lose its lubricating ability over time, not suddenly. The type of
grease used, the temperature of operation, and the speed of the motor effect the
life of the bearing lubrication. You should re-grease the bearings every 2000 hrs
or once a year. Units in severe duty (dusty locations or high ambient
temperatures) the time interval is 1000 hours.

A high quality ball or roller bearing grease with the following characteristics
should be used:

Section 5 Page 16
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Operations and Maintenance Manual

Standard Service Hi-Temperature Service
Soap Type Lithium Lithium
Grease Viscosity
400 – 550 475 – 525
SSU at 100oF
Worked Penetration 265 – 296 220 – 240
N-H Bomb min hrs for 20
750 1000
psi drop at 210oF
Bleeding, max weight %
10 3
in 500 hrs at 212oF
Rust Inhibiting Yes Yes

CAUTION
Over greasing is a major cause of bearing and motor failure.
Make sure not to over grease or to introduce any contaminants during
greasing.

WARNING
Rotating machinery can cause injury or death. Open main disconnect,
tag and lockout power supply to the starter before working on the
electric motor

To regrease the bearings:

Switch off the unit, disconnect the power, and lockout and tag to prevent accidental
restarting.
1. Clean grease fittings.
2. Remove the relief plug and free the hole of hardened grease.
3. Add grease with hand operated grease gun until it appears at the shaft hole in
the end plate or the relief plug outlet.
4. Re-connect the power, and run the unit for 20 minutes without the relief plug in
place.
5. Switch off the unit, disconnect the power, and lockout and tag to prevent
accidental restarting.
6. Re-install the grease relief plug.
7. Return unit to service.

Section 5 Page 17
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Operations and Maintenance Manual

5.13 AIR END/MOTOR REMOVAL

Section 5 Page 18
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Operations and Maintenance Manual

6.0 Troubleshooting

Compressor will not start a. No power

b. Fuses blown in the control circuit.
c. Motor overload latch not reset.
d. Heaters not installed in starter.
e. Loose or missing wires or components
in the control circuit.
f. Low voltage e.g. using 230 volt in a 460
volt system.
g. Faulty temperature switch.
h. Suction valve does not close.
i. Pressure in oil separator tank.

Unit starts – but shuts down immediately a. Pressure switch or timer failure.
b. Incorrect heaters or adjusted too low in
starter.
c. High Air Temperature switch open due
to restricted oil flow.
d. Loose or missing electrical components.
e. Pressure switch set too high.
f. Motor overloads trip out.
g. Low voltage.

Compressor does not build up to the a. Inlet valve partially closed.

desired pressure. b. Belt slippage.
c. Restricted inlet air cleaner.
d. Excessive air demand.
e. Defective pressure gauge.
f. Pressure switch set too low.
g. Excessive pressure drop across the
separator element.
h. Solenoid valve stuck open.
i. Air end malfunction – excessive
clearance or rotor movement.
j. Compressor sized too small.
k. Safety valve keeps discharging.

Section 6 Page 1
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Operations and Maintenance Manual

Compressor will not load a. Pressure switch set too low

b. Inlet valve will not open.
c. Faulty solenoid valve.

Capacity (delivery) is below stated a. Restricted inlet air filter.

amount b. Inlet valve partially closed.
c. Air pressure set too high.
d. Insufficient oil flow.
e. Solenoid valve malfunction.
f. Belt slippage.
g. Leakage in air system.
h. Worn air end.

Compressor surges a. Erratic air demand.

b. Customer air system too small for
demands.
c. Faulty minimum pressure valve.
d. Pressure switch differential too low for
the system conditions.
e. Loose electrical connection between the
controller and the solenoid valve.
f. Faulty pressure transducer.
g. Faulty solenoid valve.
h. Faulty pressure relief valve.

Excessive Oil Consumption a. Overfilled sump.

b. Broken oil line.
c. Plugged oil return line.
d. Operating below rated pressure.
e. Damaged or dirty separator.
f. Lightly loaded or excessive load/unload
cycles.
g. Using incorrect oil.

Section 6 Page 2
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Operations and Maintenance Manual

High Temperature Shutdown a. Elevated ambient temperature.

b. Low sump oil level.
c. Plugged oil filter.
d. Restricted cooling airflow.
e. Clogged heat exchanger.
f. Thermal bypass is leaking
g. Faulty high air temperature switch.
h. Delivery pressure set too high.
i. Panels are open.
j. Exhaust air is restricted.

High power consumption a. Plugged separator.

b. Plugged aftercooler.
c. Improper air pressure switch setting.
d. Too low of a line voltage.
e. Electrical phase imbalance.
f. Imminent motor failure.
g. Imminent air end failure
h. Belt slippage
i. Loose electrical connection

Safety valve discharges a. Over pressure switch not set correctly.

b. Inlet valve not closing properly in
relation to air demand.
c. Plugged separator.
d. Faulty minimum pressure check valve.
e. Faulty safety valve.
f. Incorrect set point on safety valve

Section 6 Page 3
 CAP-246

7.0 Maintenance Log

Model: _____________________ Serial Number: _____________________

Changed Greased Checked

Hourmeter Motor Cleaned Fitting
Date Air Oil
Reading Oil Separator Bearings Cooler Tightness
Filter Filter

Section 7 Page 1
 CAP-246

NOTES

Section 7 Page 2
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Operations and Maintenance Manual

8.0 Parts list

Frame

Section 8 Page 1
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Operations and Maintenance Manual

Parts List For Frame

ITEM
DESCRIPTION QTY. KS25 KS30 KS40
NO.
1 FRAME 1 1450000 < 1450001
2 PANEL 1 1450003 < 1450443
3 SUCTION PANEL SER.NO. 52312 1 1450248 < 1450339
3A SUCTION PANEL SER.NO. 52359 - 52360 1 N/A N/A 1450764
3B SUCTION PANEL SER.NO. 52411 AND LATER 1 N/A N/A 1450761
4 DOOR 1 1450246 < <
5 COVER SER.NO. 52312 1 1450416 1450415 1450253
5A COVER SER.NO. 52359 - 52360 1 N/A N/A 1450417
5B COVER SER. NO. 52411 AND LATER 1 N/A N/A 1450762
6 PANEL 1 1450005 < <
7 RIGHT PANEL 1 1450249 < <
8 PANEL 1 1450247 < <
9 PANEL 1 1450366 < <
10 CONTROL PANEL PLATE 1 1450007 < <
11 COVER SUPPORT 1 1450008 < <
12 SILENCER PANEL 1 1450009 < <
13 DOOR LOCK 4 1450010 < <
14 DECAL 1 1450392 < <
15 CONTROLLER – M6 1 1450381 < <
16 LEFT SIDE BELT TENSIONING SLIDE 1 1450360 < 1450014
17 RIGHT SIDE BELT TENSIONING SLIDE 1 1450015 < 1450016
18 PUSH BUTTON (EMERGENCY STOP) 1 1450017 < <

Section 8 Page 2
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Operations and Maintenance Manual

Motor/Air End Assembly

17 16
6

9 8
2
7
18

14 10
19
1
12
5

4
13 11 15

Section 8 Page 3
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Operations and Maintenance Manual

Parts List For Motor/Air End Assembly

ITEM
DESCRIPTION QTY. KS25 KS30 KS40
NO.
1 ELECTRIC MOTOR – 200 V 1 1450387 1450388 1450389
1 ELECTRIC MOTOR – 230/460 V 1 1450382 1450384 1450385
1 ELECTRIC MOTOR – 460 V 1 1450382 1450384 1450385
2 COMPRESSOR 1 CS624 < CS625
3 MOTOR PULLEY BUSHING
4 MOTOR PULLEY
5 BELT SEE TABLE 1
6 COMPRESSOR PULLEY
7 COMPRESSOR PULLEY BUSHING
8 RODS 2 1450026 < <
9 SELF LOCKING NUT – M12 2 1450027 < <
10 PROTECTION GRID 1 1450028 < <
11 FAN SHAFT 1 1450357 < 1450405
12 M6 x 20 STOP DOWEL 1 1450031 < <
13 FAN 1 1450505 < 1450033
14 BRACKET 1 1450034 < 1450035
15 VIBRATION DAMPER 4 1450036 < <
16 GROMMET 1 1450037 < <
17 GROMMET BUSHING 1 1450038 < 1450039
18 WASHER – D40 4 1450472 < <
19 FAN PROTECTION GRID 1 1450041 < <

Section 8 Page 4
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Operations and Maintenance Manual

ITEM KS25 KS30 KS40
DESCRIPTION
NO QTY PART NO. QTY PART NO. QTY PART NO.
3 MOTOR PULLEY BUSHING 1 1450042 1 1450042 1 1450043
4 MOTOR PULLEY 1 1450046 1 1450044 1 1450359
100
5 BELT 3 1450050 3 1450048 3 1450048
PSI
6 COMPRESSOR PULLEY 1 1450053 1 1450053 1 1450784
7 COMPRESSOR PULLEY BUSHING 1 1450055 1 1450055 1 1450056
3 MOTOR PULLEY BUSHING 1 1450042 1 1450042 1 1450043
4 MOTOR PULLEY 1 1450046 1 1450044 1 1450359
125
5 BELT 3 1450050 3 1450048 3 1450048
PSI
6 COMPRESSOR PULLEY 1 1450052 1 1450052 1 1450409
7 COMPRESSOR PULLEY BUSHING 1 1450055 1 1450055 1 1450056
3 MOTOR PULLEY BUSHING 1 1450042 1 1450042 1 1450043
4 MOTOR PULLEY 1 1450047 1 1450046 1 1450046
150
5 BELT 3 1450545 3 1450050 3 1450048
PSI
6 COMPRESSOR PULLEY 1 1450052 1 1450053 1 1450047
7 COMPRESSOR PULLEY BUSHING 1 1450055 1 1450055 1 1450056
3 MOTOR PULLEY BUSHING 1 1450042 1 1450042 1 1450043
4 MOTOR PULLEY 1 1450046 1 1450047 1 1450358
175
5 BELT 3 1450048 3 1450545 3 1450048
PSI
6 COMPRESSOR PULLEY 1 1450358 1 1450052 1 1450047
7 COMPRESSOR PULLEY BUSHING 1 1450056 1 1450055 1 1450056
Table 1: sheaves, bushings, and belts

Section 8 Page 5
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Operations and Maintenance Manual

NOTES

Section 8 Page 6
Curtis-Toledo Rotary Compressor
Operations and Maintenance Manual
Oil Separating Filter Assembly

6 29 34 28
35 30
4
33

29
34 14,14A
3

7
5
8
2 31
32
1 25 26 27
24
9 10 23
22
21

20
11 13
19

12 18
17
16
36
15

Section 8 Page 7
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Operations and Maintenance Manual

Parts List For Oil Separating Filter Assembly
ITEM
DESCRIPTION QTY. KS25 KS30 KS40
NO.
1 OIL SEPARATING TANK 1 1450364 < <
2 90º JOINT – 3/8” 1 1450058 < <
3 OIL SEPARATING CARTRIDGE 1 1450059 < <
4 FILTER HEAD (COMPLETE) 1 1450060 < <
5 SAFETY VALVE 150 PSI 1 VV406 < RN42810-1
150 PSI 1 VV406 < RN42810-1
175 PSI RN42811 < <
200 PSI RN42812 < <
6 PIPE OIL SEPARATING FILTER 1 1450780 < <
7 OIL FILLING TAP 1 1450377 < <
8 OIL TAP GASKET 1 1450063 < <
9 90º JOINT – 1/4” x 8 1 1450064 < <
10 RISLAN PIPE – D8 1 1450065 < <
11 OIL DISCHARGING TAP & GASKET 1 1450066 < <
12 OIL DISCHARGING TAP – 3/8” 1 1450067 < <
13 90º JOINT – 3/8” 1 1450058 < <
14 MINIMUM PRESSURE VALVE 1 1450069 < <
14A MINIMUM PRESSURE VALVE KIT 1 1450218A < <
15 D.1 1/4” INJECTOR 1 1450070 < <
16 132V. “O” RING 1 1450071 < <
17 SEAL CAP 1 1450072 < <
18 T-BODY – 1 1/4” x 1” x 1” 1 1450073 < <
19 SPRING CAP 1 1450074 < <
20 MINIMUM PRESSURE VALVE PISTON 1 1450075 < <
21 3081 VITON O-RING 1 1450076 < <
22 3125 VITON O-RING 1 1450077 < <
23 MINIMUM PRESSURE VALVE PLUG 1 1450078 < <
24 MAIN SPRING 1 1450079 < <
25 BLANK HOLDER VALVE PLATE 1 1450080 < <
26 M6 NUT 1 1450081 < <
27 M6 x 20 STOP DOWEL 1 1450031 < <
28 T JOINT – 3/8” 1 1450340 < <
29 JOINT- 1-1/4” 2 1450778 < <
30 HIGH TEMPERATURE SWITCH 1 1450341 < <
31 ADAPTOR 1 VAA790 < <
32 SEAL FOR ADAPTOR 1 VAA791 < <
33 T-JOINT - 1-1/4” 1 1450779 < <
34 GASKET “FPM” 2 1450781 < <
35 PIPE ASSY. OIL SEPARATING FILTER 1 1450782 < <
36 O-RING 1 1450810 < <

Section 8 Page 8
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Operations and Maintenance Manual

Air Circuit

Section 8 Page 9
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Operations and Maintenance Manual

Parts List For Air Circuit

ITEM
DESCRIPTION QTY. KS25 KS30 KS40
NO.
1 SUCTION FILTER ASSEMBLY 1 1450082 < 1450083
2 SUCTION FILTER CARTRIDGE 1 1450084 < 1450085
3 CLAMP SUCTION FILTER 1 1450086 < <
4 CLAMP 2 1450089 < 1450214
5 PIPE 1 1450818 < <
7 ELEC. INDIC. CLOGGED FILTER 1 1450092 < <
8 SUCTION VALVE 1 1450342 < 1450343
9 GASKET FOR SUCTION VALVE 1 1450095 < 1450096
10 90º JOINT – 1/8” x 6 1 1450097 < <
11 UNION JUNCTION 1 1450819 < <
12 CALIBRATED HOLE FOR OIL DRAIN 1 1450099 < <
13 STAINLESS STEEL PIPING – D6 x 1 1 1450100 < <
14 JOINT – 3/8” D6 1 1450101 < <
15 90º JOINT – 1/8” x 8 4 1450102 < <
16 RISLAN PIPE – D8 1 1450065 < <
17 D.1/4” – 1/8” JUNCTION 1 1450820 < <
18 1” NIPPLE WITH HOLE 1 1450104 < <
19 PRESSURE TRANSDUCER 1 1450192 < <
19A PRESSURE TRANSDUCER 1 1450821 < <
20 AIR GAUGE 1 1450106 < <
21 SUCTION FILTER SLEEVE 1 N/A N/A 1450344
22 RISLAN PIPE – D6 1 1450103 < <
23 JOINT – 1/8” x 8 2 1450470 < <
24 T-JOINT 1 1450229 < 1450469
25 SUCTION VALVE REBUILD KIT (NOT SHOWN) 1 1450394 < 1450395
26 GASKET, COPPER 1 1450809 < <
27 PRESSURE TRANSDUCER CONNECTOR 1 1450835 < <

Section 8 Page 10
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Operations and Maintenance Manual

Suction Valve
(KS 20 – KS 30)

NOTE! ALL PARTS NOT LABELED, REFER TO PART KITS, SECTION 8 PAGE 13

Section 8 Page 11
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Operations and Maintenance Manual

Parts List For Suction Valve

ITEM
DESCRIPTION QTY. KS25 KS30
NO.
1 FILTER COVER CONNECTION R20V 1 1450689 <
2 SCREW T.C.E.I. M6 X 10 2 1450637 <
3 CASING REGULATOR – R20 1 1450654 <
4 DISCHARGING VALVE RSV 1 1450691 <
5 CYLINDER VALVE R20 1 1450655 <
6 PISTON VALVE R20 1 1450656 <
7 PLUG CYLINDER R20 1 1450657 <
8 SEEGER D.42 I 1 1450701 <
9 WASHER D.8 1 1450642 <
10 GALVANIZED NUT M8 1 1450638 <
11 SET SCREW STOPED TCEI M8 X 35 1 1450702 <
12 O-RING OR2075 R20EI 1 1450697 <
13 90° JOINT – 1/8” X 6 1 1450097 <
14 SCREW T.C.E.I. 1 M8 X 40 2 1450635 <
15 CASING BLOCK R20 1 1450659 <
16 RISLEN HOSE D.6 X 4 1 1450103 <
17 REDUCTION RING I 51 1 1450690 <

Section 8 Page 12
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Operations and Maintenance Manual

Suction Valve
(KS 20 – KS 30)

SPARE PART KITS KS20-30

REF PART NO. DESCRIPTION
1450342 COMPLETE VALVE
A 1450836 BODY KIT GASKETS
B 1450837 CONTROL UNIT KIT GASKETS
E+D 1450498 SOLENOID VALVE + COIL
D 1450473 COIL
F 1450838 ISG UNIT
G 1450839 ISG KIT GASKETS
H 1450840 RSV KIT GASKETS
I 1450691 RSV UNIT
A+B+G+H 1450394 SPARE PARTS KIT
L 1450659 CONTROL UNIT

Section 8 Page 13
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Operations and Maintenance Manual

Suction Valve
(KS 40 – KS50)

NOTE! ALL PARTS NOT LABELED, REFER TO PART KITS, SECTION 8 PAGE 16

Section 8 Page 14
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Operations and Maintenance Manual

Parts List For Suction Valve
ITEM
DESCRIPTION QTY. KS40 KS50
NO.
1 FILTER COVER CONNECTION R40 1 1450663 <
2 T.C.E.I. M6 X 15 UNI5931 8.8 SCREW 5 1450643 <
3 BODY VALVE R40 1 1450664 <
5 ENGRAILED WASHER D.6 1 1450640 <
6 GUIDE SHUTTER VMC GH15 – R40 1 1450646 <
7 DISCHARGING VALVE RSV 1 1450691 <
8 R40 CYLINDER VALVE 1 1450670 <
9 POLE R40 1 1450671 <
10 PISTON R40 1 1450667 <
11 STOPPER R40 1 1450673 <
12 SEEGER I 60 UNI7437 1 1450674 <
13 STOPED T.C.E.I. M8 X 35 1 1450702 <
14 GALVANIZED NUT – M8 1 1450638 <
15 GROWER WASHER D.8 1 1450642 <
16 PLUG VALVE R20 1 1450658 <
17 SCREW T.C.E.I. M8 X 50 2 1450636 <
18 90° JOINT – 1/8” X 6 1 1450097 <
19 RISLAN HOSE D.6 X 4 1 1450103 <
20 NUT – M6 1 1450081 <
21 SCREW OF MINIMUM PRESSURE R40 1 1450678 <
22 GROWER WASHER D.6 1 1450641 <
23 PK16 GASKET 1 1450679 <
24 SPRING ISG – 1 1 1450651 <
25 PISTON VALVE R20 1 1450652 <

Section 8 Page 15
Curtis-Toledo Rotary Compressor
Operations and Maintenance Manual
Suction Valve
(KS 40-60)

SPARE PART KITS KS40-60

REF PART NO. DESCRIPTION
1450343 COMPLETE VALVE
A 1450841 BODY KIT GASKETS
B 1450842 CONTROL UNIT KIT GASKETS
E+D 1450498 SOLENOID VALVE + COIL
D 1450473 COIL
F 1450843 ISG UNIT
G 1450844 ISG KIT GASKETS
H 1450840 RSV KIT GASKETS
I 1450691 RSV UNIT
A+B+G+H 1450395 SPARE PARTS KIT
L 1450677 CONTROL UNIT

Section 8 Page 16
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Operations and Maintenance Manual

Oil Circuit

Section 8 Page 17
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Operations and Maintenance Manual

Parts List For Oil Circuit

ITEM
DESCRIPTION QTY. KS25 KS30 KS40
NO.
1 COOLING RADIATOR 1 1450108 1450109 1450110
2 D.3/4” – 1/2” JUNCTION 6 1450111 < <
3 HOSE 1 1450370 < 1450372
4 HOSE 1 1450368 < <
5 STEEL HOSE 1 1450353 < 1450115
6 JUNCTION 1 1450116 < 1450117
7 REINFORCED HOSE – 1” 1 1450118 < <
8 D.3/4” M.F. UNION 1 1450119 < 1450822
9 D.1” – 3/4” JUNCTION 1 1450120 < 1450823
10 REINFORCED HOSE – 1 1/4” 1 1450121 < <
11 NIPPLE/JUNCTION 2 1450122 < 1450123
12 WASHER 2 1450124 < 1450235
13 NIPPLE 1 1450125 < 1450122
14 WASHER 2 1450126 < <
15 HOSE 1 1450373 < 1450374
16 OIL FILTER CARTRIDGE 1 1450390 < <
17 O.R. GROMMET 1 1450130 < 1450131
18 FLANGE 1 1450132 < 1450133
19 THERMOSTATIC VALVE 1 1450134 < <
20 BULB - 55º C/131º F 1 1450135 < <
20A PISTON 1 1450236 < <
21 HOSE – 1/2” 1 1450368 < <
22 PROBE JOINT 1 1450183 < <
23 PROBE 1 1450137 < <
24 WASHER 5 1450054 < <
25 SPRING 1 1450211 < <

Section 8 Page 18
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Operations and Maintenance Manual

Frame

Section 8 Page 19
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Operations and Maintenance Manual

Parts List For Frame

ITEM
DESCRIPTION QTY. KS50
NO.
1 FRAME 1 1450824
2 PANEL 1 1450159
3 SUCTION PANEL 1 1450250
4 DOOR 1 1450256
5 COVER 1 1450413
6 PANEL 1 1450164
7 RIGHT PANEL 1 1450255
8 PANEL 1 1450254
9 PANEL 1 1450361
10 CONTROL PANEL 1 1450367
11 COVER SUPPORT 1 1450160
12 SILENCER PANEL 1 1450369
13 DOOR LOCK 4 1450215
14 DECAL 1 1450393
15 CONTROLLER – M6 1 1450381
16 PUSH BUTTON (EMERGENCY STOP) 1 1450017
17 HAND GRIP 2 1450213
18 SUCTION PANEL COVER 1 1450251
19 FILTER PANEL 1 1450881D
20 PROTECTION NET FOR FAN 1 1450153
21 PROTECTION PANEL 1 1450154

Section 8 Page 20
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Operations and Maintenance Manual

Motor/Air End Assembly

5A

Section 8 Page 21
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Operations and Maintenance Manual

Parts List For Motor/Air End Assembly

ITEM NO. DESCRIPTION QTY. KS50

1 ELECTRIC MOTOR – 230/460 V 1 1450386

1 ELECTRIC MOTOR – 460 V 1 1450386
1 ELECTRIC MOTOR – 200 V 1 1450826
2 COMPRESSOR 1 CS625
3 COMPRESSOR PULLEY
4 BELT SEE TABLE 2
5 MOTOR PULLEY
5A MOTOR PULLEY BUSHING
6 SUCTION VALVE 1 1450343
8 BUSHING 2 1450827
9 SPRING 1 1450143
10 BEARING 1 1450212
11 PIN 1 1450206
12 TEFLON WASHER 1 1450166
13 FAN 1 1450148
14 VIBRATION DAMPER 4 1450165
15 GROMMET 1 1450037
16 GROMMET BUSHING 1 1450039
17 FAN SHAFT 1 1450352
18 CLAMP SUCTION FILTER 2 1450828
19 COMPRESSOR PULLEY BUSHING SEE TABLE 2
20 4187 V. “O” RING 1 1450131
21 PIPE 1 1450170
22 BOLT 1 1450147
23 ELEC. INDIC. CLOGGED FILTER 1 1450092
225 PIVOT ABOVE BELT TIGHT 1 1450549
227 PIVOT BELOW BELT TIGHT 1 1450550
228 AIR END SUPPORT 1 1450552
229 SUPPORT SCREW AIR END 1 1450551
230 PLAIN WASHER – 33x16.5x3 1 1450553
231 TENSIONING WASHER 1 1450548

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ITEM KS50
DESCRIPTION
NO. QTY PART NO.
3 COMPRESSOR PULLEY 1 1450140
4 BELT 4 1450799
100
5 MOTOR PULLEY 1 1450794
PSI
5A MOTOR PULLEY BUSHING 1 1450797
19 COMPRESSOR PULLEY BUSHING 1 1450056
3 COMPRESSOR PULLEY 1 1450140
125 4 BELT 4 1450198
PSI 5 MOTOR PULLEY 1 1450150
19 COMPRESSOR PULLEY BUSHING 1 1450056
3 COMPRESSOR PULLEY 1 1450140
150 4 BELT 4 1450197
PSI 5 MOTOR PULLEY 1 1450536
19 COMPRESSOR PULLEY BUSHING 1 1450056
3 COMPRESSOR PULLEY 1 1450140
175
4 BELT 4 1450541
PSI
5 MOTOR PULLEY 1 1450538
5A MOTOR PULLEY BUSHING 1 1450763
19 COMPRESSOR PULLEY BUSHING 1 1450056
Table 2: sheaves, bushings, and belts

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NOTES

Section 8 Page 24
Curtis-Toledo Rotary Compressor CAP-246

Operations and Maintenance Manual

Oil Separating Filter Assembly

Section 8 Page 25
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Parts List For Oil Separating Filter Assembly

ITEM
DESCRIPTION QTY. KS50
NO.
1 OIL SEPARATING TANK 1 1450363
2 OIL SEPARATING CARTRIDGE 1 1450202
3 SEPARATION FILTER SEAL 2 1450167
4 OIL FILLING TAP 1 1450377
5 SAFETY VALVE 150 PSI 1 RN42815
150 PSI 1 RN42815
175 PSI RN42816
200 PSI RN42817
6 OIL TAP GASKET 1 1450063
7 1 1/2” NIPPLE 1 1450177
8 MINIMUM PRESSURE VALVE 1 1450207
8A MINIMUM PRESSURE VALVE KIT 1 1450239
9 90° JOINT – 1/8” 1 1450184
10 D.1/4” – 1/8” JUNCTION 1 1450107
11 OIL DISCHARGING TAP & GASKET 1 1450190
12 OIL DISCHARGING TAP – 1/2” 1 1450189
13 PRESSURE TRANSDUCER 1 1450821
14 D.1/2” INJECTOR 1 1450178
15 T JOINT – 1/2” 1 1450181
16 D.1/4” – 1/2” JUNCTION 1 1450188
17 PRESSURE SWITCH 1 1450191
18 90º JOINT – 1/4” x 8 2 1450064
19 RISLAN PIPE – D8 x 6 1 1450216
20 T JOINT – 1/4” 1 1450182
21 AIR GUAGE 1 1450345
22 D. 1 1/2” – 1 1/4” INJECTOR 1 1450346
23 ADAPTOR 1 VAA761

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Operations and Maintenance Manual

Air Circuit

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Parts List For Air Circuit

ITEM
DESCRIPTION QTY. KS50
NO.
1 SUCTION FILTER 1 1450203
2 CLAMP SUCTION FILTER 1 1450833
3 SUCTION FILTER CARTRIDGE 1 1450200
4 90º JOINT – 3/8” x 8 1 1450462
5 GASKET FOR SUCTION VALVE 1 1450096
6 90º JOINT – 3/8” x 6 1 1450187
7 RISLAN PIPE – D8 x 6 1 1450216
8 RISLAN PIPE – D8 2 1450065
9 90º JOINT – 1/4” x 8 2 1450102
10 90º JOINT – 1/4” x 6 1 1450834
11 D.1/2” – 1/4” JUNCTION 1 1450188
12 D.1/8” INJECTOR 1 1450348
13 CALIBRATED HOLE FOR OIL DRAIN 1 1450349
14 FILTER 1 1450204
15 D. 1/2” – 3/8” INJECTOR 1 1450350
16 UNION JUNCTION 1 1450098
17 STAINLESS STEEL PIPING D6 x 1 1 1450100
18 HIGH TEMPERATURE SWITCH 1 1450341
20 D. 3/8” – 1/8” JUNCTION 1 1450351
21 T JOINT – 1/4” x 8 1 1450458
22 90º JOINT – 1/8” x 8 1 1450102
23 JOINT – 1/8” x 8 2 1450470
24 SUCTION VALVE REBUILD KIT (NOT SHOWN) 1 1450395

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Curtis-Toledo Rotary Compressor CAP-246

Operations and Maintenance Manual

Oil Circuit

Section 8 Page 29
Curtis-Toledo Rotary Compressor CAP-246

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Parts List For Oil Circuit

ITEM
DESCRIPTION QTY. KS50
NO.
1 COOLING RADIATOR 1 1450161
2 D.3/4” JUNCTION 7 1450179
3 D.3/4” x 1550 HOSE 3 1450371
4 STEEL HOSE 1 1450145
5 D.1 1/2” – 1” JUNCTION 1 1450175
6 SPRING 1 1450211
7 REINFORCED D.1 1/4” x 750 HOSE 1 1450169
8 90º JOINT – D.1 1/2” 1 1450174
9 D.1” – 1 1/4” JUNCTION 1 1450176
10 REINFORCED D.1 1/2” x 550 HOSE 1 1450168
11 1 1/2” NIPPLE 1 1450177
12 D.50 WASHER 1 1450235
13 D.3/4” – 1/2” JUNCTION 1 1450111
14 WASHER 1 1450126
15 WASHER 5 1450054
16 OIL FILTER CARTRIDGE 1 1450390
17 4187 V. “O” RING 1 1450131
18 FLANGE 1 1450133
19 THERMOSTATIC VALVE 1 1450134
20 BULB - 55º C/131º F 1 1450135
20A PISTON 1 1450236
21 D.3/4” – 820 HOSE 1 1450375
22 PROBE JOINT 1 1450183
23 PROBE 1 1450137
24 NIPPLE, 1 1/2 BSPT X 1 1/2 NPT (NOT SHOWN) (COOLER OUTLET) 1 1450615
25 COUPLING, 1 1/2" PIPE (NOT SHOWN) (COOLER OUTLET) 1 VA16HA

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MAINTENANCE KITS
4,000 HOUR KIT
WORKING PRESSURE
MODEL
100 PSI 125 PSI 150 PSI 175 PSI
KS25 520027 < < <
KS30 520027 < < <
KS40 520033 < < <
KS50 520036 < < <
KIT INCLUDES

(1) SEPARATOR ELEMENT

(4) OIL FILTER ELEMENTS
(2) AIR FILTER ELEMENTS
(2) SEPARATOR FILTER SEAL (KS50)
8,000 HOUR KIT
WORKING PRESSURE
MODEL
100 PSI 125 PSI 150 PSI 175 PSI
KS25 520028 < < <
KS30 520028 < < <
KS40 520034 < < <
KS50 520037 < < <
KIT INCLUDES

(2) SEPARATOR ELEMENT

(8) OIL FILTER ELEMENTS
(4) AIR FILTER ELEMENTS
(4) SEPARATOR FILTER SEAL (KS50)
12,000 HOUR KIT
WORKING PRESSURE
MODEL
100 PSI 125 PSI 150 PSI 175 PSI
KS25 520029 520029 520049 520050
KS30 520032 520032 520051 520052
KS40 520035 520035 < <
KS50 520059 520038 520053 520054
KIT INCLUDES:

(3) SEPARATOR ELEMENT

(12) OIL FILTER ELEMENTS
(6) AIR FILTER ELEMENTS
(1) INLET VALVE KIT
(1) THERMOSTATIC VALVE KIT
(1) MINIMUM PRESSURE VALVE KIT
“V” BELTS
(6) SEPARATOR FILTER SEALS (KS50)

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PRESSURE RANGE CONVERSION

KITS
WORKING PRESSURE
MODEL
100 PSI 150 PSI 175 PSI
KS25 1450788 1450749 1450750
KS30 1450789 1450751 1450752
KS40 1450790 1450753 1450754
KS50 1450791 1450755 1450756

NOTE:
1. CONVERSION KITS TO CONVERT STANDARD UNITS FROM 125 PSI TO 100
PSI, 150 PSI, 175 PSI.
2. ANY PRESSURE CHANGE FROM 125 PSI REQUIRES OVER PRESSURE
SWITCH ADJUSTMENT, SEE SECTION 5 PAGE 10 * HIGH PRESSURE
SHUTDOWN.

EXTERNAL SUCTION FILTER KITS

EXTERNAL SUCTION
MODEL
FILTER KITS
KS25 1450886
KS30 1450886
KS40 1450887

Section 8 Page 32
 Curtis-Toledo, Inc.
1905 Kienlen Ave. St. Louis, MO. 63133
Phone: 314-383-1300 fax: 314-381-1439
Email: [email protected]
Website: www.curtistoledo.com