The air compressor system shall be a turnkey, packaged appliance designed to deliver high pressure breathing air in compliance with the most current NFPA and CGA quality standards and refill SCBA and SCUBA cylinders. It must include the high pressure air compressor, electric motor, air purifier, fill station and all operating and cylinder fill controls as specified below. The system must also be designed to incorporate an integral air storage system as specified below. All of these components shall be completely assembled and tested by the manufacturer as a system and incorporated within a single appliance requiring only electrical power supply to operate. The system shall be designed so that all cylinder refilling and operating controls and performance indicators are located on panels at the front of the appliance allowing "at sight" operator monitoring. The appliance shall comply with the currently applicable OSHA specifications as well as state and local electrical codes. The compressor design shall not permit the venting of oil contaminated air to the atmosphere.

The external construction of the high pressure breathing air compressor shall be appliance-like. All structure fasteners shall be concealed and all access panels shall include concealed hinges and push button latches. One full height door shall be provided for maintenance access to the compressor. The door shall include a shutdown switch to prevent exposure to running gear in the event it is opened while the compressor is running. A full length access door for fill station panel maintenance shall also be provided.

The cabinet configuration shall permit installation with the rear "against the wall" and include an ambient air flow control design that directs the necessary volume to cool the compressor. The cooling system shall also include an integral top discharge extractor to completely vent the resulting hot air out of the cabinet.

All high pressure air plumbing shall be rated for 6000 PSI working pressure and utilize seamless stainless steel tubing. All high pressure air plumbing connections shall use compression fit design fittings.

The ambient air filter element shall be located in a housing installed directly on the compressor inlet with an opening suitable for outside air intake piping.

The electrical control system shall include components with UL, NEMA or IEC approval and housed within a NEMA 1 enclosure.

II.  Compressor

The ambient air intake and compression shall be through an air-cooled, reciprocating, three-stage compressor designed for continuous duty at 6000 PSI working pressure with a charging rate of 14.0 CFM. The air compressor design shall include a heavy-duty crankcase supporting the crankshaft with ball bearings on each end. Lubrication shall be accomplished by controlled splash of oil from the crankcase sump aided by pressure induced migration from the totally sealed crankcase. The crankcase shall be piped back to the inlet cylinder to maintain proper crankcase pressure and eliminate any discharge of oil contaminated air to the atmosphere. The cylinder arrangement shall be a balanced "V" configuration featuring double-acting, ringed pistons assuring maximum balance and air volume delivery efficiency while operating at a maximum compressor speed of 1700 RPM.

Each stage of compression shall be protected with a safety relief valve. The cylinders shall include cooling fins to dissipate heat into the cooling air flow from the compressor's integral flywheel fan. Individually mounted coolers shall be located after each compression stage to cool the discharged air to 18° F. above ambient temperature. Accumulated condensation from cooling the compressed air shall be collected in moisture separators mounted on the compressor and piped to an automatic, timed drain system for proper collection and disposal. Prior to shutdowns, the compressor shall be allowed to run unloaded (with opened drains) for a timed period (Purge Cycle) in order to purge all cylinders, separators and crankcase of damaging condensation that develops as compressors cool down.

III.  Electric Motor

The compressor shall be v-belt driven by a NEMA design 10 HP, open drip proof electric motor wired for the electrical conditions as shown below:

The motor shall be located under the compressor and driven via v-belt drive arrangement utilizing a hinged motor base to facilitate belt tension adjustment. The compressor and motor base shall include neoprene mounts to isolate vibration from the appliance.

IV.  Electrical Control System

The breathing air compressor shall include all the necessary controls to assure efficient and safe operation and monitor performance. The control system shall be of an anti-flutter circuit design and include a latched fault protection circuit to prevent automatic restarting after an abnormal fault has occurred. As a minimum, the control system must include the following:

• Air pressure switch to automatically start and stop the compressor based on demand.
• High air temperature shutdown switch and gauge with thermowell and sensor that measures temperature directly from the air stream. Cylinder surface sensors are not acceptable.
• Low oil level shutdown switch.
• Magnetic, across-the-line starter with electric motor overload protection.
• Compressed air electronic carbon monoxide (CO) detector with pre-set warning and shutdown limits. (A)
• Compressed air electronic moisture (H2O) detector with pre-set warning and shutdown limits. (B)
• AirMonitor including CO and H2O electronic detectors with pre-set warning and shutdown limits. (C)

V.  Instrumentation

The control system must include clearly labeled monitoring devices to indicate normal and fault shutdown operating conditions. These shall be mounted on a steel control panel located at the front of the appliance. The panel shall be painted in a matte shade with a textured finish to eliminate glare and enhance the visibility of gauges and indicators.

The compressor’s instrumentation panel shall be engineered for quick and convenient access to all key electrical control components, eliminating the need to use the appliance maintenance access door. Pressure gauges, indicator lights, and all optional instruments shall be accessible for routine maintenance and adjustments from a hinged, “knockdown” sub-panel located within the main control panel surface.

The compressor shall also include a condensate purge test switch in order to verify proper operation of the automatic condensate drain system on demand.

As a minimum, the instrumentation required is as follows:

• Compressor interstage and final pressure gauges.
• Hourmeter.
• Compressor final stage temperature gauge.
• Illuminated power selector (on/off) switch.
• Normal high air pressure shutdown indicator light.
• Purge cycle indicator light and test switch.
• General fault shutdown indicator light.
• Emergency stop button.
• Inlet filter restriction indicator, mounted on compressor's 1st stage intake.
  Digital CO monitor panel with actual content display in parts per million (PPM) and prompter software keypad for calibration. A flow panel with factory plumbed calibration gases shall be included. (A)
  Digital H2O monitor panel with actual content display in PPM. (B)
  Digital CO and H2O panel with actual content display in PPM and prompter software keypad for CO monitor calibration. A flow panel with factory plumbed calibration gases shall be included. (C)

VI.  Air Purification System

The high pressure air purification system shall be a multi-chamber arrangement that utilizes disposable cartridges manufactured to provide breathing air that meets or exceeds NFPA and CGA Grade "E" specifications and all other equivalent and recognized standards in use worldwide.

All system components shall be rated for 6000 PSI working pressure. All chambers in the system shall be constructed of 304 stainless steel to enhance safety and corrosion resistance.

The purification system shall be sized to process 15,000 cubic feet of air at 80° F. and compressed to 6000 PSI between cartridge changes.
The purification system shall be sized to process 35,000 cubic feet of air at 80° F. and compressed to 6000 PSI between cartridge changes.

 The system shall include the following:

• Final separator chamber connected to the automatic condensate drain system.
• Check valve to prevent back pressure to the compressor.
• One (1) purifier cartridge chamber.
• Pressure maintaining valve to assure that the system is maintained pressurized in order to attain the rated processing capacity of the air purification cartridge.
• Adjustable start/stop control pressure switch.
• Safety relief valve
• Panel mounted manual isolation valve and purifier mounted drain valve to relieve the system pressure for maintenance.
• Stem-mounted gauge for system pressure verification.
• Visual CO/H2O indicator.

The system shall be designed so that filling cannot occur in the event that the disposable cartridge is not installed.

VII. High Pressure Air Storage

The breathing air storage system shall be integral to the appliance and include all the cylinders, plumbing and hardware installed in accordance with all current ASME or DOT codes, as specified below:

Two (2) DOT 4500 PSI cylinders each with a capacity of 444 cubic feet of air at 4500 PSI. The piping of air storage shall be arranged for bulk filling.
Two (2) DOT 4500 PSI cylinders each with a capacity of 444 cubic feet of air at 4500 PSI. The piping of air storage shall be arranged for cascade filling.
Three (3) DOT 4500 PSI cylinders each with a capacity of 444 cubic feet of air at 4500 PSI. The piping off air storage shall be arranged for bulk filling.
Three (3) DOT 4500 PSI cylinders each with a capacity of 444 cubic feet of air at 4500 PSI. The piping of air storage shall be arranged for cascade filling.
Four (4) DOT 4500 PSI cylinders each with a capacity of 444 cubic feet of air at 4500 PSI. The piping off air storage shall be arranged for bulk filling.
Four (4) DOT 4500 PSI cylinders each with a capacity of 444 cubic feet of air at 4500 PSI. The piping of air storage shall be arranged for cascade filling.
Two (2) DOT 6000 PSI cylinders each with a capacity of 509 cubic feet of air at 6000 PSI. The piping of air storage shall be arranged for bulk filling.
Two (2) DOT 6000 PSI cylinders each with a capacity of 509 cubic feet of air at 6000 PSI. The piping of air storage shall be arranged for cascade filling.
Three (3) DOT 6000 PSI cylinders each with a capacity of 509 cubic feet of air at 6000 PSI. The piping of air storage shall be arranged for bulk filling.
Three (3) DOT 6000 PSI cylinders each with a capacity of 509 cubic feet of air at 6000 PSI. The piping of air storage shall be arranged for cascade filling.
Four (4) DOT 6000 PSI cylinders each with a capacity of 509 cubic feet of air at 6000 PSI. The piping of air storage shall be arranged for bulk filling.
Four (4) DOT 6000 PSI cylinders each with a capacity of 509 cubic feet of air at 6000 PSI. The piping of air storage shall be arranged for cascade filling.
Two (2) ASME 6000 PSI cylinders each with a capacity of 525 cubic feet of air at 6000 PSI. The piping of air storage shall be arranged for bulk filling.
Two (2) ASME 6000 PSI cylinders each with a capacity of 525 cubic feet of air at 6000 PSI. The piping of air storage shall be arranged for cascade filling.
Three (3) ASME 6000 PSI cylinders each with a capacity of 525 cubic feet of air at 6000 PSI. The piping of air storage shall be arranged for bulk filling.
Three (3) ASME 6000 PSI cylinders each with a capacity of 525 cubic feet of air at 6000 PSI. The piping of air storage shall be arranged for cascade filling.
Four (4) ASME 6000 PSI cylinders each with a capacity of 525 cubic feet of air at 6000 PSI. The piping of air storage shall be arranged for bulk filling.
Four (4) ASME 6000 PSI cylinders each with a capacity of 525 cubic feet of air at 6000 PSI. The piping of air storage shall be arranged for cascade filling.

VIII. SCBA/SCUBA Cylinder Fill Enclosure

The appliance shall include an integral fill enclosure for filling two (2) SCBA/SCUBA cylinders simultaneously or separately. The enclosure shall be designed to contain the impact of suddenly expanded high pressure air and all displaced fragments in the unlikely event of a cylinder or fill component rupture.

The loading door must be designed to be trapped inside the fill enclosure cabinet frame when closed and include an automatic, safety interlock to prevent filling unless the loading door is completely closed. A safety relief valve, to prevent over pressurizing SCBA/SCUBA cylinders above 4750 PSIG, shall also be included.

The fill station must allow the fill process to be accomplished from the front. The front loading door shall be designed so that, when opened, the SCBA/SCUBA cylinder holder sleeves tilt forward to ease loading and minimize operator fatigue. Two (2) fill whips, each fitted with a cylinder fill adapter and shut-off valve, shall be located within the enclosure.

The access door control shall include an air actuator handle designed to operate a pneumatic cylinder to open and close the access door. For opening, the handle shall lower the access door, releasing it from behind the cabinet frame and allowing the operator to pull the door forward to load and unload SCBA/SCUBA cylinders. For closing, the access door is rotated up to the vertical position and the handle shall then raise and trap it behind the cabinet frame. When fully raised, the door trips the safety interlock allowing air to flow to the fill station.

The access door shall be supported on the enclosure frame with an adjustable bearing bushing on each side assuring a balanced, smooth rotation and effortless operation when opening and closing. A gas strut shall secure the assembly to the enclosure so that it does not require operator support when opening or closing and to cushion the access door landing when opened.

In order to minimize operator handling of pressurized components, a bleed valve shall be located on the control panel to relieve all fill hoses of pressure after opening the front loading door and before disconnection from the SCBA/SCUBA cylinders.

All air flow components and indicators must be labeled and mounted on a steel control panel on the front of the unit and located above the fill enclosure. The air management panel shall be of a modular design that enhances functional clarity for operators. The right hand side of the panel, as viewed by the operator, shall be dedicated to all components required to control pressure and refilling of SCBA/SCUBA cylinders . When specified, the left hand side, as viewed by the operator, shall be committed to all components required for air storage management. The panel shall be painted in a matte shade with a textured finish to eliminate glare and enhance the visibility of gauges and indicators.

IX. SCBA/SCUBA Cylinder Fill Controls

The SCBA/SCUBA cylinder fill control system shall include a regulated panel with all the components, devices and piping arrangement necessary to direct supplied compressed high pressure breathing air to an air storage system and the SCBA/SCUBA cylinders being filled. Additionally, an auxiliary outlet to fill remote air storage systems shall be provided.

A cascade control system shall be included for the number of banks specified below. The cascade control system shall permit filling or drawing down each air storage cylinder, independently of each other, while filling SCBA/SCUBA cylinders. An air storage by-pass valve shall be included to permit filling SCBA/SCUBA cylinders or through the auxiliary outlet directly from the compressor. (E)

The control system shall include a dual regulator package for safely filling SCBA/SCUBA cylinders at two (2) different pre-set pressures. The package shall include installation of the standard and an additional regulator behind the panel at pre-set pressures. A selector button located at the control panel shall be required to select air flow from the regulator with the highest pre-set pressure. A pneumatic actuator valve shall return the air flow to the low pressure regulator after every high pressure fill cycle. (F)

An additional "dedicated fill circuit" shall be included to safely fill SCBA/SCUBA cylinders at a different pressure that that flowing from the main control panel regulator(s). The "dedicated fill circuit" shall include an adjustable, pre-set regulator installed behind the control panel plumbed directly to a dedicated fill whip and adapter located in the fill enclosure and a separate panel mounted flow valve and gauge.
*Panel mounted fill whip bleed will be lost with this selection. Individual bleeds on fill adaptor whips will be substituted. (G)

As a minimum, the air control panel must include the following:

• Inlet pressure gauge.
• Adjustable, 0-6000 psi self-relieving regulator.
• Regulator outlet pressure gauge.
• Storage fill/by-pass (E) valve.
• SCBA/SCUBA cylinder(s) fill control valve.
• SCBA/SCUBA cylinder(s) fill pressure gauge.
• SCBA/SCUBA cylinder(s) panel mounted bleed valve.
• Auxiliary outlet with flow control valve and CGA fitting.
• Two (2) bank cascade control with a single valve and gauge per bank. (E)
  Three (3) bank cascade control with a single valve and gauge per bank. (E)
  Four (4) bank cascade control with a single valve and gauge per bank. (E)
  Two (2) bank cascade control with “To” and “FROM” valves and gauge per bank. (E)
  Three (3) bank cascade control with “To” and “FROM” valves and gauge per bank. (E)
  Four (4) bank cascade control with “To” and “FROM” valves and gauge per bank. (E)
  Dual regulator high pressure selector button. (F)
  "Dedicated fill circuit" flow valve and gauge (G)

X. Aerie Plus+ Package

When specified, the breathing air system shall include a features package designed to limit sound emission (76 dB), expand performance monitoring capabilities and include the necessary components for outside air intake with filter monitoring.

As a minimum, the package shall include the following:

• Noise abatement insulation limiting noise emission to 76 dB at one meter.
• Full compressor shutdown indicator light package consisting of:
  Normal high pressure shutdown indicator light.
  High compressed air temperature shutdown indicator light.
  Low oil level shutdown indicator light.
  Maintenance access "door ajar" shutdown indicator light.
  General fault shutdown indicator light.
• Illuminated compressor instrument and fill station flow control panels.
• Compressor air inlet housing and filter element with connections for outside air intake piping and inlet air filter restriction indicator.