California Air Tools 20040SMAD Ultra Quiet & Oil Free Smart Air Compressor

Introduction

Thank you for purchasing a California Air Tools, Inc. Air Compressor. Please contact us if you have any questions.

Record the model and serial numbers indicated on your air compressor's nameplate:

• Model No.: [Field for Model Number]
• Serial No.: [Field for Serial Number]
• Date of Purchase: [Field for Date]
• Store/Dealer: [Field for Store/Dealer]

Local Service Center Information:

For service or repair parts, contact the California Air Tools Customer Service Department:

• Phone: 1-866-409-4581
• Online: WWW.CALIFORNIAAIRTOOLS.COM

When contacting customer service, please provide:

• Model number and Serial number
• Part number(s) from the parts list
• A brief description of the trouble

Do not return your air compressor for service or parts to the store/dealer where purchased.

Important Safety Instructions

Safety Messages & Signal Words:

DANGER: Indicates an immediate hazardous situation which, if not avoided, will result in death or serious injury to the operator or to bystanders.

WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury to the operator or to bystanders.

CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor injury to the operator or to bystanders.

NOTICE: Indicates a situation which, if not avoided, may result in damage to product components or other property.

Electrical Safety (SHOCK)

There is a danger of electric shock. Use only undamaged electrical cords. Do not touch bare wires or receptacles. Do not operate the air compressor in wet weather or in wet conditions. Do not touch the air compressor or cords if hands or feet are wet. Ensure all cords are free of damage before connecting to the power supply. Ensure you have a sufficient electrical supply for the motor's requirements. Improper installation of the grounding plug can result in a risk of electric shock. The product must be grounded. It is equipped with a cord having a grounding wire with an appropriate grounding plug. Plug into an outlet that is properly installed and grounded in accordance with local codes and ordinances. Use only on a nominal 220-V circuit with a properly installed and grounded outlet. Do not use an adapter.

Risk of Cutting

Moving parts can cause severe trauma. Keep hands and feet away from rotating parts, tie up long hair, remove jewelry, and do not wear loose clothing.

Risk to Breathing

Dust or dust-like particulates from activities like power-sanding, sawing, grinding, or drilling can contain harmful contaminants. Always use the air compressor in a well-ventilated and clean area. Never breathe the air directly from the compressor or air hose, as it is not suitable for breathing. Always wear approved safety equipment, such as properly-fit face masks or respirators, when performing dust-creating activities. If you feel ill from breathing, stop and seek medical attention immediately.

Flying Objects

Flying objects can cause injury to the eyes, head, and other body parts. Air-powered equipment and tools can propel items at high speed. Always wear approved head and eye protection. Never point the air stream at any body part, person, or animal. Ensure others maintain a safe distance. Do not move the compressor when the air tank is under pressure. Never use air hoses to pull or move the compressor. Keep the compressor on a flat surface.

Hot Surface

Air compressor surfaces become hot during operation. Do not touch hot surfaces, as they can cause severe burns. Do not touch the cylinder head; its cooling fins and delivery pipe become hot. Allow the compressor to cool before touching. Do not place a storage cover on the unit during operation; only cover after it has thoroughly cooled down.

Fire / Explosion Risk

Use caution to minimize risk of fire or explosion. Sparks from the motor and pressure switch are normal. If sparks contact vapors from gasoline or solvents, they may ignite. Abrasive tools can create sparks that ignite flammable materials. Always operate the air compressor a safe distance away from flammable items in well-ventilated areas. Never exceed the maximum rated pressure.

Improper care can lead to the air tank bursting or exploding. Drain the air tank daily or after each use to prevent moisture buildup. Rust can weaken the tank and cause leaks or bursting; replace a rusted tank immediately. Do not attempt to repair the air tank by welding, drilling, or modifying it. If the air tank develops a leak, replace it immediately. Never repair, weld, or modify the air tank or its attachments. Never make adjustments to factory-set pressures. Never exceed manufacturer's maximum-allowable pressure rating attachments. Due to extreme heat, do not use plastic pipe or lead tin solder joints for a discharge line.

Duty Cycle Note: The compressor is designed for intermediate usage and should not run continuously for more than 60 minutes at a time. Intermediate ON/OFF usage during a standard workday is acceptable with an average 70/30 operating duty cycle.

Air Compressor Components & Parts List

Refer to the diagram for component locations. The following table lists the parts:

Pre-Operation Checklist

Package Contents & Assembly

Package contents:

• Air Compressor
• 20040SMAD Owner's Manual
• MDR2i Smart Controller Owner's Manual
• 3' (feet) 8mm Tubing OD (for Automatic Drain Valve)
• Air Filters (4)
• Air Filter Intake Tubes (4), 8mm OD

Assembly:

Install the 4 Air Filters and 4 Air Intake Tubes.

1. Attach the air filters to the top rear sides of BOTH motor head's threaded 1/2" ports.
2. Screw the air filters clockwise until secure (hand tighten only). Push (press fit) the 4" air filter intake tube into the air filter port/hole (8mm OD). Repeat for the other intake tube. Note: orientation of the intake tubes does not matter, they may point any direction.

Operation

Inspect for Damage

Before using the air compressor, ensure the air tank is not damaged, inspect all parts for damage, and check that all pipes are firmly connected. Do not use if any damage is found. If damaged, have an authorized service center inspect and test the unit.

Save Packaging

IMPORTANT: Save all outside packaging in case you need to return the product for service or repair.

Compressor Location

Use on Flat Surface: For proper operation, place on a flat surface with an incline no greater than 15 degrees. Secure the compressor by bolting down or using earthquake strapping to prevent accidental falling.

Maintain a Clear Area:

It is very important that the air compressor is positioned so there is adequate airflow around the machine. There must be at least 2 feet of obstacle-free space surrounding and above the air compressor.

Use in Areas with Clean Air:

For proper operation and longevity, ensure the air drawn into the compressor is clean. Do not use in areas where dust or particulates are present, as this will damage the motor and impair operation. Always use the air filter, properly installed.

Electrical Power

Electrical Power Requirements: Refer to the serial label for voltage and amperage requirements. Ensure a sufficient electrical supply. Use a dedicated 20 Amp Circuit or an 8000 Watt (running) Generator. The compressor requires 13-14 Amps for startup. Low voltage or an overload circuit can trip the motor's overload protection.

Electrical Extension Cords: Use caution when using extension cords. Use a heavy-duty cord no more than 25' (7.6 m) long and at least 14 gauge. Using an excessively long or thin-wired cord can cause severe damage to the motor. Use only a 3-wire extension cord with a 3-blade grounding plug. An undersized cord results in voltage drop, power loss, and overheating. When in doubt, use a heavier gauge cord.

Dedicated Circuit: Use a dedicated 20 (or 25/30) Amp Circuit for 220 Volts 60 Hertz 1-Phase (acceptable operating range 215-240 volts).

Operating the Air Compressor

This air compressor features a compact structure, stable performance, high airflow rate, and easy operation and maintenance. It produces no oil in the airflow, making it suitable for situations where oil in the airflow is an issue. The motor directly drives the pistons and can function without lubrication for extended periods.

Assembly:

1. Connect an air supply hose (not supplied, featuring an Industrial Male (1/4" NPT) adapter/couple) to the Industrial Female (1/4" NPT) push-to-connect quick coupler on the air compressor.
2. Connect 8mm tubing to the Auto Drain Valve port at the bottom of the unit (press fit) to allow water removal.
3. Ensure the power supply is operating normally (220 Volts 60 Hertz 20 Amp Outlet).
4. Insert the power supply cord into the power supply socket.

Test Run:

1. Plug the power supply cord into a 220 volt 60hz 1-phase power supply socket (215v – 250v range).
2. Attach an air hose gun or pneumatic tool (e.g., CAT-376 item; not supplied) to the 1/4" Industrial Female Push-To-Connect air port.
3. Press and hold the SMART switch OK button for 4 seconds to turn ON the air compressor.
4. Both motor/pumps should start. Pressure will rise. When pressure reaches 120 PSI (+/- 5 PSI), the Smart pressure switch will automatically turn the motor/pumps off. This indicates the compressor is working normally. (Working Pressure: 90-120 PSI; adjustable up to 105 PSI Kick-On; 130 PSI Kick-Off maximum. Refer to Smart Controller Manual for adjustments).

Daily Operation:

Starting the compressor:

1. Press & hold the SMART switch OK button for 4 seconds to turn ON the air compressor.
2. Attach an air hose gun or tool (e.g., CAT-376 item; not supplied) to the 1/4" Industrial Female Push-To-Connect Air Port.
3. Ensure both air filters are attached to the motor/pump.
4. Plug the power supply cord into a power supply socket.
5. Press & hold the SMART switch OK button for 4 seconds to turn ON.
6. Allow the two motors to run and the tank to fill until the motor/pumps stop and turn off.
7. To regulate air flow: While the compressor is running, turn "On" your tool and turn the regulator knob to the right to increase pressure. Turn pressure up until the desired pressure is reached.
8. Operate air tool normally. (Working Pressure: 90-120 PSI; adjustable up to 105 PSI Kick-On; 130 PSI Kick-Off maximum).

Shutting down the compressor:

1. Press & hold the SMART switch OK button for 4 seconds to turn the compressor OFF.
2. Unplug the power supply cord.
3. Release pressure from the tank using an air hose gun/kit or pneumatic tooling.

Releasing Air from Tank:

Unplug the power supply cord and release air from the tank:

• Pull the Safety Relief Valve ring to release air from the tank (suggested for initial testing or emergencies only).
• Expel air from the compressor using a connected Air Hose Gun/Tool (e.g., CAT-376 item; not supplied). This is the recommended method for regular operations.

Note: If there is an air leak, the Smart Controller will reset and the motor may automatically turn back on. If the compressor fails to start or you detect an air leakage, deactivate it, release air from the tank, unplug the power supply cord, and contact Customer Support.

Maintenance

Automatic Drain Tank Operation

The California Air Tools EZ-1 Automatic Drain Valve is designed to eliminate water by draining the air tank regularly. Attach 8mm drain tube and route into a container. Automatic draining occurs when the compressor is first turned on (opens for 3 seconds, then closes) or after the motor/pumps run continuously for 2 minutes (opens for 3 seconds, then closes).

Note: A manual drain bypass port allows manual water removal and internal strainer cleaning if the auto drain clogs. CAUTION: Do not open while the tank has air pressure!

Cleaning or Changing the Air Filter

The air filter reduces noise and prevents particulates from entering and damaging the compressor. A clogged filter reduces air intake and performance. Filters must be cleaned or replaced regularly.

1. Open the lid on the air filter, then remove the air filter element.
2. To clean the element, blow off or brush off dirt and dust.
3. If clogged, replace with a new air filter.

Testing for Leaks

Ensure all connections are tight but do not overtighten. Small leaks reduce performance. To test, spray soapy water on suspected areas. If bubbles appear, replace the part.

Cleaning

Clean items with a soft brush or a moistened cloth using a biodegradable solvent. Do not use flammable liquids like gasoline or alcohol. Keep parts clean from dirt and dust for better performance.

SMART Controller Features

The MDR2i OLED Smart Pressure Switch offers remote monitoring and control. Refer to the MDR 2i Smart Controller Manual for details on features such as:

• Programmable ON/OFF Times
• Pressure ON/OFF Levels
• Unloader Relay Delay
• AutoDrain Time and Drain Valve Time
• Overcurrent Limit
• Pressure Units (bar/PSI)
• Total Active (Motor-Pump) Running Hours

Storage

Before storing for a prolonged period:

1. Turn off the power supply.
2. Disconnect the power cord and wrap it around the compressor handle to reduce damage risk.
3. Pull the safety relief valve to release all pressure from the air tank (normally opens above 140 PSI).
4. Clean the air compressor to remove all dirt and dust.
5. Cover the air compressor with a cover to protect it from dust and moisture.
6. Do not stack items on or around the compressor, as damage could occur.

CAUTION: TO REDUCE THE RISK OF ELECTRIC SHOCK, DO NOT EXPOSE TO RAIN. STORE INDOORS.

Troubleshooting

Specifications

Electrical Circuit

A diagram illustrates the electrical circuit, showing connections for the pressure switch, overload protector, motor, solenoid valve, and capacitor, with grounding indicated.

Air Passage Drawing

A diagram shows the air passage flow, including air intake, compressor, check valve, tank, pressure switch, safety valve, regulator, pressure gauge, filter, and ball valve.

MDR2i Controller/Pressure Switch Wiring

A wiring diagram details the connections for the power cord, motor/compressor, unloader valve, and auto drain, using terminal labels like L, N, PE, U1, V1, EV, NC, COM, NO.

California Air Tools Inc. Limited Warranty

This warranty is limited to Air Compressors distributed by California Air Tools, Inc., 8560 Siempre Viva Road, San Diego, CA 92154.

Limited Warranty

California Air Tools Inc. will repair or replace, free of charge, to the original retail customer who purchased the compressor from an authorized dealer, distributor, or dealer's dealer in North America. This warranty does not transfer to subsequent owners. California Air Tools Inc. will repair or replace, at its option, any parts proven by an authorized service center to be defective in material or workmanship under normal use during the applicable warranty period. Transportation charges are the customer's responsibility. Replaced parts become the property of California Air Tools Inc.

Limited Warranty Periods

• Non-commercial / Non-rental (personal use): 1 year parts and labor
• Commercial / Rental (income/business use): 1 year parts and labor

The warranty period begins on the date of retail purchase by the original purchaser.

Disclaimers, Limitations of Remedies & Exclusions

This warranty provides specific legal rights, and customers may have other rights varying by state. To the fullest extent permitted by law, this limited warranty is exclusive and in lieu of all other warranties, including implied warranties of merchantability or fitness for a particular purpose. California Air Tools Inc. disclaims and excludes all other warranties.

Limitations of Remedies

California Air Tools Inc. shall not be liable for any other obligations or liabilities, including those arising from breach of contract, warranty, negligence, tort, or strict liability, with respect to the air compressor or California Air Tools Inc.'s acts or omissions. California Air Tools Inc. shall not be liable for incidental, compensatory, punitive, consequential, indirect, special, or other damages, including loss of use, income, time, sales, injury to personal property, or any other form of consequential damage or economic loss.

Exclusions

This limited warranty does not apply to or cover accessories, or products subject to:

• Improper setup, installation, or storage.
• Lack of proper maintenance and service.
• Accident, damage, abuse, or misuse.
• Abnormal operating conditions or applications.
• Repair or modification by customer or third party without written consent.
• Use under conditions or in applications not recommended by California Air Tools Inc.
• Normal wear.
• Use of accessories or attachments not recommended by California Air Tools Inc.
• Acts of God.

The application of these exclusions is determined at the sole discretion of California Air Tools Inc.

Maintenance & Troubleshooting Guide

California Air Tools provides a Maintenance & Troubleshooting Guide on their website: WWW.CALIFORNIAAIRTOOLS.COM. Visit the website for valuable information and videos.

Service or Parts

Warranty service is available by showing your original receipt to an Authorized California Air Tools Service Center. For customer service inquiries, call 1-866-409-4581 or visit WWW.CALIFORNIAAIRTOOLS.COM. Navigate to the "Contact Us" tab and click on "Service & Parts" for the fastest service.