# Tool Tutorial

(Link to PDF Tool Tutorial)

## Pressures and Regulators

⛔ Do not adjust pressures of regulators or the air compressor. Start a conversation on Discord or [file a maintenance request](https://www.protohaven.org/maintenance/ "https://www.protohaven.org/maintenance/") if you have a need not addressed below.

There is a regulator manifold on the outlet of the tank that has 3 regulators. We found that there are needs that require supplying at 3 different pressures. Also adding this manifold allows us to store higher pressure air in the tank reducing the duty cycle of the compressor and buffering more air to cover high demand bursts.

Below is the current set pressures and flow rates.

<div class="section_highlight_wrapper" id="bkmrk-compressor-%26-tank-13"><div class="level2"><div class="table sectionedit3"><table class="inline"><tbody><tr class="row0"><td class="col0">Compressor &amp; Tank</td><td class="col1">139-145 PSI</td><td class="col2">&gt;20 SCFM</td></tr><tr class="row1"><td class="col0">[CNC Plasma Torch](https://docs.google.com/document/d/1HsnTzNlTf9TIs3LJG4QiWopLCF-V6dtggwUBYh_ohIM/edit?usp=sharing "https://docs.google.com/document/d/1HsnTzNlTf9TIs3LJG4QiWopLCF-V6dtggwUBYh_ohIM/edit?usp=sharing")</td><td class="col1">135 PSI</td><td class="col2">10 SCFM</td></tr><tr class="row2"><td class="col0">[Sand Blaster](https://docs.google.com/document/d/112TET4cJDh7Fsg_i3Sz1wWPevySFR8Ml90wAZxndKaI/edit?usp=sharing "https://docs.google.com/document/d/112TET4cJDh7Fsg_i3Sz1wWPevySFR8Ml90wAZxndKaI/edit?usp=sharing")</td><td class="col1">125 PSI</td><td class="col2">15 SCFM</td></tr><tr class="row3"><td class="col0">Shop Air</td><td class="col1">80 PSI</td><td class="col2">??</td></tr></tbody></table>

</div></div></div>The math gets tricky from hare, for example if the Plasma was cutting a long job and the sand blaster was at almost a full duty cycle, and someone was powder coating the consumption would outrun the compressor. But the tank would have a buffer before the tank drained to below 135 PSI starving out the plasma. How long would that take? Calculus knows. I don’t.

<div class="section_highlight_wrapper" id="bkmrk-"></div>## Usage

🚫 Do not open the compressor cabinet without following the appropriate power lockout procedures specified below. The machine can turn on automatically and could cause serious injury.

🚫 Do not bypass or ignore Lockout Tagout procedures to energize the equipment.

⚠️To avoid fires, keep all flammable, combustible, poisonous and noxious materials away from operating area. Make sure there are no oily rags, trash, leaves, litter or other combustible materials in the operating area. Keep suitable, fully charged fire extinguishers nearby when servicing and operating the compressor.

⚠️Wear appropriate eye and hearing protection before using air tools.

<div class="section_highlight_wrapper" id="bkmrk--1"></div>### Controls

⛔ Members shouldn’t need to adjust any settings on the air compressor, [Fill out a maintenance request](https://www.protohaven.org/maintenance/ "https://www.protohaven.org/maintenance/") if you would like to have a change made.

<div class="section_highlight_wrapper" id="bkmrk--2"></div>### Tank

<div class="section_highlight_wrapper" id="bkmrk-120-gallon-%2819.26-cu"><div class="level3">- <div class="li">120 Gallon (19.26 cubic feet)</div>
- <div class="li">Max Allowable Working Pressure 200PSI @ 400F</div>
- <div class="li">Not to operate below 20F</div>
- <div class="li">Inspected and certified in 2012</div>

</div></div>I don’t think there is a regulation that these tanks have to be inspected. They would need to be in NY but not California PA seems to have no rules like those states.

<div class="section_highlight_wrapper" id="bkmrk--3"></div>### Air Paths and Routing

The Air compressor connects to the storage tank. From the tank there is a ¾” pipe to the regulator manifold. There are 3 regulators. The first one connected to the hard piping shop air. The second goes to the sand blaster, and the third goes to the cnc plasma.

The manifold has a shop air coupler on it. This connected the hose for the woodshop which is hung on a hook by the CNC router.

The hard pipe coupler behind the plasma table has a 4:1 manifold on it. 2 hoses are connected to it. One goes to a hook in the welding area and one to a hook in the machine shop.

The Hard pipe traverses the shop overhead and there are two more couplers connected to hoses on hooks. One in the plastics area and one for the powder coating booth.

The hard pipe has several roughed out runs that are currently incomplete. That can be used to extend hard piping to the woodshop. Metalshop, spray booth, and the studio side of the woodshop.

<div class="section_highlight_wrapper" id="bkmrk--4"></div>## Troubleshooting

[Page 34](https://www.manualslib.com/manual/1571102/Eaton-Prs0100001.html?page=34#manual "https://www.manualslib.com/manual/1571102/Eaton-Prs0100001.html?page=34#manual") of the manual has a troubleshooting guide.

<div class="section_highlight_wrapper" id="bkmrk--5"></div>## Maintenance

<span style="background-color: rgb(241, 196, 15);">TODO - sort into maintenance log</span>

[Maintenance History](https://airtable.com/shrb58zUuDBmcmTNQ/tblZbQcalfrvUiNM6?filter_Equipment+Record=Air+Compressor "https://airtable.com/shrb58zUuDBmcmTNQ/tblZbQcalfrvUiNM6?filter_Equipment+Record=Air+Compressor")

⚠️ AUTHORIZED MAINTENANCE GROUP ONLY ⚠️

<div class="section_highlight_wrapper" id="bkmrk-air-filter-last-chan"><div class="level2">- <div class="li">Air Filter Last Changed: Feb 23, 2023</div>
- <div class="li">Oil Filter Last Changed: July 10, 2022</div>
- <div class="li">Separator Filter Last Changed: July 10, 2022</div>
- <div class="li">Belts last changed: November 15, 2022</div>
- <div class="li">Oil Last Changed: Feb 23, 2023</div>

</div></div>If you are part of the maintenance group please log on to the #maintenance channel of our Discord server to:

<div class="section_highlight_wrapper" id="bkmrk-perform-a-maintenanc"><div class="level2">- <div class="li">Perform a Maintenance Action</div>
- <div class="li">Request a Maintenance Purchase</div>
- <div class="li">Review complete Maintenance Logs for each machine</div>
- <div class="li">Generally chit-chat about maintenance</div>

</div></div>### Warnings

🚫Do not use the E-Stop for routine stopping of the compressor. Use the control panel to stop the compressor before energizing equipment..

⚠️This unit can automatically start! Before attempting any repairs or adjustments, disconnect, lock out and verify all power is off to all circuits to minimize the possibility of accidental startup or operation. This is especially important for remotely controlled compressors. Serious injury could result.

⚠️ *When cleaning, use air pressure less than 30 psig (2.1bar)*. Also use effective chip guarding and personal protective equipment per OSHA standard 29 CFR 1910.242 (b) Tools The following should be in a Maintenance tool kit for the printer

<div class="section_highlight_wrapper" id="bkmrk-cabinet-key-oil-funn"><div class="level3">- <div class="li">Cabinet Key</div>
- <div class="li">Oil Funnel</div>
- <div class="li">ShopVac</div>
- <div class="li">Air Hose</div>
- <div class="li">Crescent Wrench for oil fill port</div>

</div></div>### Replacement Parts List

<div class="section_highlight_wrapper" id="bkmrk-compressor-oil%3A%C2%A0oil0"><div class="level3">- <div class="li">Compressor Oil: [Oil003](https://eatoncompressor.com/product/air-compressor-oil-synthetic-rotary-screw-oil003/ "https://eatoncompressor.com/product/air-compressor-oil-synthetic-rotary-screw-oil003/") Our compressor has a 1.3 gallon capacity</div>
- <div class="li">There is almost 2 gallons in the Machine Shop Cabinet</div>
- <div class="li">Air Intake Filter: [Filter006](https://eatoncompressor.com/product/air-compressor-filter-rotary-screw-filter006/ "https://eatoncompressor.com/product/air-compressor-filter-rotary-screw-filter006/")</div>
- <div class="li">Separator Filter: [Filter009](https://eatoncompressor.com/product/air-compressor-filter-separator-rotary-screw-series-filter009/ "https://eatoncompressor.com/product/air-compressor-filter-separator-rotary-screw-series-filter009/")</div>
- <div class="li">Oil Filter [Filter070](https://eatoncompressor.com/product/air-compressor-filter-mann-filter070/%20-%20Belt009 "https://eatoncompressor.com/product/air-compressor-filter-mann-filter070/ - Belt009")</div>
- <div class="li">Belts: [Gates Metric XPZ1120](https://www.grainger.com/product/GATES-Metric-V-Belt-XPZ-1NJV8?gucid=N:N:PS:Paid:GGL:CSM-2296:9JMEDM:20500731&gclid=Cj0KCQiApb2bBhDYARIsAChHC9sdQHSjAgNcn8w1uZeqUK-4ygw9gs54EOp-nBnXjQg355oPEBx7pEAaAjoHEALw_wcB&gclsrc=aw.ds "https://www.grainger.com/product/GATES-Metric-V-Belt-XPZ-1NJV8?gucid=N:N:PS:Paid:GGL:CSM-2296:9JMEDM:20500731&gclid=Cj0KCQiApb2bBhDYARIsAChHC9sdQHSjAgNcn8w1uZeqUK-4ygw9gs54EOp-nBnXjQg355oPEBx7pEAaAjoHEALw_wcB&gclsrc=aw.ds")</div>

</div></div>### Circuit and Breaker Information

The Air Compressor is plugged into a receptacle on the left side of the air tank. The plug can be unplugged when you need to de-energize the air compressor. The circuit for the air compressor is in the shop electric panel which is located behind the plasma table. The circuit breaker is a 3 phase 30A circuit in sports 10,12,14

<div class="section_highlight_wrapper" id="bkmrk--6"></div>### Lockout Tagout Procedure

In order to have safe maintenance please follow these steps when opening the access panels on the air compressor.

<div class="section_highlight_wrapper" id="bkmrk-stop-the-compressor-"><div class="level3">1. <div class="li">Stop the compressor with the red button on the control panel. Don’t use the e-stop.</div>
2. <div class="li">Unplug compressor from wall receptacle.</div>
3. <div class="li">Put a lockout tag on the power plug.</div>

</div></div>### Checking and Filling Oil

There is a window on the back right side of the machine, with a light you will be able to observe the oil level in a sight glass. The machine needs to be stopped for at least 10 minutes before checking the oil level.

If the oil is below halfway it needs to be topped off. Turn off the machine with the above approved lockout procedure. Use the cabinet key to take off the right side panel.

When the machine is stopped it has a valve to automatically unload pressure from this part of the system. You don’t have to worry about pressure in the sump if the machine is stopped and the unload valve is working properly

On the oil sump you will see a 1” hex nut fill cap. Use a crescent wrench to remove this cap. Use the funnel so that oil is more than half but not more than ¾ full in the sight glass. Put the cap back on, attach the side of the cabinet and turn the compressor back on.

<div class="section_highlight_wrapper" id="bkmrk--7"></div>### Checking and Draining Moisture

<div class="section_highlight_wrapper" id="bkmrk-use-hearing-protecti"><div class="level3">- <div class="li">Use hearing protection it can be very loud.</div>
- <div class="li">There is a drain valve on the pipe manifold below the regulators. Open the valve and purge any water that has accumulated.</div>
- <div class="li">On the bottom of the tank there is a second valve, purge any water that has accumulated in the bottom of the tank.</div>
- <div class="li">If there is more than a small mist of moisture file a tool report that the air compressor dryer may not be working.</div>

</div></div>### Maintenance Schedule

<span style="background-color: rgb(241, 196, 15);">TODO - sort into maintenance books</span>

<div class="section_highlight_wrapper" id="bkmrk-daily-check-that-the"><div class="level3">- <div class="li">Daily</div>
    - <div class="li">Check that the compressor area is free of all flammable, combustible, poisonous and noxious materials in the operating area.</div>
    - <div class="li">Check for proper oil level</div>
    - <div class="li">Drain any condensate from manifold, tank, receiver and traps</div>
    - <div class="li">Check for any unusual noise or vibration</div>
    - <div class="li">Check that the fire extinguisher is nearby and charged.</div>
- <div class="li">Weekly</div>
    - <div class="li">Clean air filter</div>
    - <div class="li">Clean all external parts of compressor and dryer</div>
    - <div class="li">Check for unusual noises or vibration</div>
- <div class="li">Monthly</div>
    - <div class="li">Inspect the entire air system for leaks.</div>
    - <div class="li">Inspect dust accumulation on radiator fan and clean if necessary.</div>
    - <div class="li">Inspect oil for contamination and change if necessary</div>
    - <div class="li">Check belt tension and wear</div>
    - <div class="li">Belt tension on each individual belt in the center of each pulley, and should have ¼“deflection up and ¼” deflection down, for ½“ total.</div>
- <div class="li">6 Months</div>
    - <div class="li">Inspect all Piping</div>
    - <div class="li">Clean Sight Glass</div>
    - <div class="li">Check and Tighten all electrical connections</div>
- <div class="li">Yearly</div>
    - <div class="li">Change oil separator filter every 4000 hours</div>
    - <div class="li">Changes oil filter every 4000 hours</div>
    - <div class="li">Change oil</div>
    - <div class="li">Clean Suction Valve</div>

</div></div>## Appendix

<div class="section_highlight_wrapper" id="bkmrk--8"></div>### Calculating Consumption SCFM for any operating pressure

[https://www.youtube.com/watch?v=Ky\_5SDoKkgc](https://www.youtube.com/watch?v=Ky_5SDoKkgc "https://www.youtube.com/watch?v=Ky_5SDoKkgc")

Protohaven is 915 ft above Sea Level with a resulting atmospheric pressure of 14.2 PSI

Operating SCFM = Rated SCFM Operating Pressure + 14.2Rated Pressure + 14.2

For Supply SCFM flip the division problem putting rated pressure as the numerator.

<div class="section_highlight_wrapper" id="bkmrk-psi-on-copper-pipes-"><div class="level3">- <div class="li">[PSI on copper pipes](https://www.ehow.com/info_12157484_pressure-limits-copper-pipe.html "https://www.ehow.com/info_12157484_pressure-limits-copper-pipe.html")</div>
- <div class="li">[Compressed Air Tanks Explained - Sizing, Ratings, Portable Vs Stationary - About Air Compressors.com (about-air-compressors.com)](https://www.about-air-compressors.com/air-tanks/ "https://www.about-air-compressors.com/air-tanks/")</div>

</div></div>**t = V (p1-p2)/C pa**

Where:

<div class="section_highlight_wrapper" id="bkmrk-v-%3D-volume-of-the-re"><div class="level3">- <div class="li">V = volume of the receiver tank (cubic feet)</div>
- <div class="li">t = time for the receiver tank to go from upper to lower pressure limits (sec/min)</div>
- <div class="li">C = free air needed ([scfm](https://www.about-air-compressors.com/difference-between-scfm-for-tools-and-compressors/ "https://www.about-air-compressors.com/difference-between-scfm-for-tools-and-compressors/"))</div>
- <div class="li">pa = atmospheric pressure (14.696 psia)</div>
- <div class="li">p1 = maximum tank pressure (psia)</div>
- <div class="li">p2 = minimum tank pressure (psia)</div>

</div></div>This formula can then be rearranged to give you an approximate ideal volume of your receiver tank:

**V = t C Pa/(p1-p2)**

t=19.26 (133/100)/25 14.2