BendPak RS7580H603 Manuale del proprietario

INSTALLATION AND OPERATION MANUAL

SHIPPING DAMAGE CLAIMS

When this equipment is shipped, title passes

to the purchaser upon receipt from the carrier.

Consequently, claims for the material damaged in

shipment must be made by the purchaser against

the transportation company at the time shipment

is received.

BE SAFE

Your new Compressor was designed and built with

safety in mind. However, your overall safety can be

increased by proper training and thoughtful

operation of this equipment. DO NOT operate or

repair this equipment without reading this manual and

the important safety instructions shown inside.

1645 Lemonwood Dr.

Santa Paula, CA. 93060, USA

Toll Free 1-800-253-2363

Tel: 1-805-933-9970

Fax: 1-805-933-9160

www.bendpak.com

PLEASE READ THE ENTIRE CONTENTS OF THIS MANUAL PRIOR TO

INSTALLATION AND OPERATION. BY PROCEEDING YOU AGREE THAT

YOU FULLY UNDERSTAND AND COMPREHEND THE FULL CONTENTS OF

THIS MANUAL. FORWARD THIS MANUAL TO ALL OPERATORS. FAILURE TO

OPERATE THIS EQUIPMENT AS DIRECTED MAY CAUSE INJURY OR DEATH.

REV A 03-21-16

p/n 5900177

Keep this operation manual near the

machine at all times. Make sure that ALL

USERS read this manual .

ROTARY-SCREW AIR COMPRESSOR 7.5 HP

MODEL:

RS7580H603

2

Section 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Section 2: General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Section 3: General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Section 4: Installation and Inspection Before Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Section 5: Requirements for Air Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Section 6: Floor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Section 7: Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 10

Section 8: Pre-Operation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 10 - 12

Section 9: Daily Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 - 14

Section 10: LCD Controller Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 - 18

Section 11: Controller Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 - 24

Section 12: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 - 33

Common Problem Solving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . 34 - 35

Parts List and Electric Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 - 44

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Maintenance/Inspection Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 - 47

NOTE:

Every effort has been taken to ensure complete and accurate instructions have been included in this manual, however, possible

product updates, revisions and or changes may have occurred since this printing. BendPak Ranger reserves the right to change

specications without incurring any obligation for equipment previously or subsequently sold.

Not responsible for typographical errors.

TABLE OF CONTENTS

3

SECTION 1

Our Screw Compressor units are intended to provide

compressed air to power pneumatic tools, operate spray

equipment and supply air for pneumatic valves and

actuators. A small amount of oil carryover is present in the

compressed air stream. The compressed air has a nal oil

level of < 3ppm. Applications requiring higher levels of air

free of oil vapor should have the appropriate filter installed.

The Screw compressor units are to be mounted per the

instructions provided on a solid floor. Any other use of these

units will void the warranty and the manufacturer will not be

responsible for problems or damages resulting from such

misuse.

SAFETY GUIDELINES

This manual contains information that is very important

to know and understand. This information is provided for

SAFETY and to PREVENT EQUIPMENT PROBLEMS.

To help recognize this information, observe the following

symbols.

Watch for this symbol: It Means: Immediate hazards which

will result in severe personal injury or death.

Watch for this symbol: It Means: Hazards or unsafe practices

which could result in severe personal injury or death.

Watch for this symbol: It Means: Hazards or unsafe

practices which may result in minor personal injury or

product or property damage.

INTRODUCTION

1. Carefully remove the crating and packing materials.

Be careful when cutting steel banding material as items may

become loose and fall causing personal harm or injury.

2. Check the voltage, phase and proper amperage

requirements for the motor shown on the motor plate.

Wiring should be performed by a certified electrician only.

3.

Confirm voltage before connecting power to your machine

or serious damage to the motor/electronics will result.

BREATHABLE AIR WARNING

This compressor/pump is NOT equipped and should NOT

be used “as is” to supply breathing quality air. For any

application of air for human consumption, you must fit

the air compressor/pump with suitable in-line safety and

alarm equipment. This additional equipment is neces-

sary to properly filter and purify the air to meet minimal

specifications for Grade D breathing as described

in Compressed Gas Association Commodity

Specification G 7.1 - 1966, and OSHA 29 CFR 1910.

134.

DISCLAIMER OF WARRANTIES

In the event the compressor is used for the purpose of

breathing air application and proper in-line safety and

alarm equipment is not simultaneously used, existing

warranties are void, and the company disclaims any

liability whatsoever for any loss, personal injury or damage!

UNPACKING

After unpacking the unit, inspect carefully for any damage

that may have occurred during transit. Make sure to tighten

fittings, bolts, etc., before putting unit into service.

Do not operate unit if damaged during shipping, handling

or use. Damage may result in bursting and cause injury or

property damage.

Failure to follow danger, warning, and caution instructions

may lead to serious personal injury or death to operator

or bystander or damage to property. Do not operate this

machine until you read and understand all the dangers,

warnings and cautions in this manual.

For additional copies or further information, contact:

BendPak Inc. / Ranger Products

1645 Lemonwood Dr.,

Santa Paula, CA. 93060

1-805-933-9970

www.bendpak.com

Tel: (805) 933-9970

Toll Free: (800) 253-2363

Support: (800) 253-2363 Ext. 196

Customer Service Fax: (805) 933-1128

To order parts: (800) 253-2363 Ext. 191

4

SECTION 2

GENERAL SAFETY PRECAUTIONS

Since the air compressor and other components

(material pump, spray guns, filters, lubricators, hoses, etc.)

may be under high pressure and be subject to explosions,

the following safety precautions must be observed at all

times:

1. READ AND UNDERSTAND all safety warning procedures

before installation and operation.

2. KEEP HANDS AND FEET CLEAR. Remove hands and

feet from any moving parts.

3. KEEP WORK AREA CLEAN. Cluttered work areas invite

injuries.

4. Consider work area environment. Do not expose

equipment to rain . DO NOT use in damp or wet locations.

Keep area well lighted.

5. ONLY TRAINED OPERATORS should operate this

equipment. All non-trained personnel should be kept away

from work area. Never let non-trained personnel come in

contact with, or operate machine.

6. USE MACHINE CORRECTLY. Use machine in the proper

manner. Never use adapters other than what is approved by

the manufacturer.

7. DO NOT override or disable safety valves and/or devices.

8. NEVER operate compressor without a belt

guard or Side covers in place This unit can start

automatically without warning. Personal injury

or property damage could occur from contact

with moving parts.

9. DRESS PROPERLY. Non-skid steel-toe footwear is

recommended when operating machine.

10. GUARD AGAINST ELECTRIC SHOCK. This equipment

must be grounded while in use to protect the operator from

electric shock. Never connect the green power

cord wire to a live terminal. This is for ground

only. Follow all local electrical and safety

codes as well as the United States National

Electrical Codes (NEC) and Occupational

Safety and Health Act (OSHA).

11. The motor on this machine contains high voltage.

Disconnect power at the receptacle before performing any

electrical repairs. Secure plug so that it cannot be

accidentally plugged in during service.

12. RISK OF EXPLOSION. This equipment

has internal arcing or sparking parts which

should not be exposed to flammable vapors.

This machine should not be located in a

recessed area or below floor level.

13. Tanks rust from moisture build-up, which weakens the

tank. Make sure to drain tank regularly and inspect peri-

odically for unsafe conditions such as rust formation and

corrosion.

14. STAY ALERT. Watch what you are doing. Use common

sense. Be aware.

15. CHECK FOR DAMAGED PARTS. Check for condition of

all moving parts, breakage of parts or any condition that may

affect the machines operation. Do not use if any component

is broken or damaged.

16. An ASME code safety relief valve with a setting no

higher than the Maximum Allowable Working Pressure

(MAWP) of the tank MUST remain installed on this

compressor to protect the pressurized components from

bursting. Maximum operating pressure is 150 psi. Do not

operate with pressure switch or pilot valves set higher than

150 psi. Never attempt to adjust ASME safety valve. Keep

safety valve free from paint and other accumulations.

17. NEVER remove safety related components or device

from the machine. Do not use if safety related components

are damaged or missing.

18. Before each use, inspect compressed air system and

electrical components for signs of damage, deterioration,

weakness or leakage. Repair or replace defective items

before using.

19. Check all fasteners at frequent intervals for proper

tightness.

20. Compressor parts may be hot even if

the unit is stopped. Keep fingers away from

a running compressor; fast moving and hot

parts will cause injury and/or burns.

21. If the equipment should start to vibrate abnormally,

STOP the engine/motor and check immediately for the

cause. Vibration is generally an indication of trouble.

22. To reduce fire hazard, keep engine/motor exterior free

of oil, solvent, or excessive grease.

22. Never attempt to repair or modify a tank. Welding,

drilling or any other modification will weaken the tank

resulting in damage from rupture or explosion. Always

replace worn, cracked or damaged tanks. Drain liquid from

tank daily.

5

SPRAYING PRECAUTIONS

1. Fast moving air will stir up dust and debris which may

be harmful. Release air slowly when draining moisture or

depressurizing the compressor system.

2. Do not spray flammable materials

in vicinity of open flame or near ignition

sources including the compressor unit. Do

not smoke when spraying paint, insecti-

cides, or other flammable substances.

3. Use a face mask/respirator when

spraying and spray in a well ventilated area

to prevent health and fire

hazards.

4. Do not direct paint or other sprayed material at the

compressor. Locate compressor as far away from the

spraying area as possible to minimize over spray

accumulation on the compressor.

5. When spraying or cleaning with solvents or toxic

chemicals, follow the instructions provided by the chemical

manufacturer.

SECTION 3

GENERAL OVERVIEW

The BendPak Hush-Quiet™ RS7580H603 Rotary Screw

Air Compressor produces well over twice the CFM of

conventional, reciprocating piston compressors.

The RS7580H603 is engineered for high performance,

efciency, reliability and blessed silence to meet the

excessive demands of high-volume automotive

shops and dealerships like yours.

WORKING PRINCIPLES

COMPRESSION: Air is drawn through the Air Intake

Filter and Intake Control Valve then, the twin rotary screws

compress the air smoothly and efciently. At the same time,

oil is injected into the compressing cavity to cool and

lubricate the screw assembly.

OIL SEPARATION: The compressed air and oil

mixture is then run through the air and oil separation

cartridge. The majority of the oil is separated out from the

compressed air by gravity and centrifugal force. The

remaining oil mist is removed from the air oil mixture by

passing the air though the Separation Cartridge core.

The compressed air has a nal oil level of < 3ppm.

The oil is then ltered and returned to the

reciprocating screw assembly for reuse via an oil return

tube tted with a valve assembly to limit the loss of

pressure in the compressed air line.

COOLING: After the oil is separated from the

compressed air it is routed to the after cooler. The

compressed air temperature is lowered by 7 -10°C/ 4-7°F

above the ambient temperature. A minimum pressure valve

is used to guarantee that at startup there is always the

minimum pressure needed to maintain oil pressure for

operation. A check valve prevents the compressed, cooled,

air from owing backwards through the separation

element.

SYSTEM CONTROLS

The goal of the control system is the regulation of the air

intake during all phases of operation and startup. The

Control System is comprised of intake valve, work

piston, magnetic valve and pressure gauge.

STARTUP: The spring loaded intake valve requires

minimum pressure to open and generate enough

pressure to get the lubricating oil owing to the

reciprocating screws at startup.

LOAD: At load the vacuum within the compressor keeps

the intake valve open, and the system pressure

increases.

FULL LOAD: When the oil separation pressure

chamber reaches 0.4MPa the pressure valve opens to al-

low the compressed air to ow out.

NO LOAD: When the pressure of the outow line

reaches the desired rated pressure, the pressure switch

opens the magnetic valve and the system pressure drops

to the minimum required to maintain a proper ow of the

lubricating oil.

CONDENSATION: At lower operating temperatures the

amount of water that can condense into the oil is higher.

The Compressor is equipped with a thermostatic valve set

to 70° C (158*F), oil will not pass through the oil cooler until

it reaches the set temperature of 70° C /158°F.

6

The Compressor is best operated in a clean,

temperature controlled environment. If the compressor

is going to be operated with an air intake temperature

below 5°C / 41°F an anti-condensation apparatus is

required and the oil separation element should be

heated.

OVERHEATING: If the ambient temperature is above

40°C,/ 104°F or the compressor is operating in an area

near a heat source, the compressors cooling capacity

may not be adequate enough to prevent damage to the

compressor. In that case, the intake air may need to be

cooled or plumbed to and draw air from a ltered outside

air source.

If the work load is consistently below 100% of the

compressor’s rated full load, a higher ambient operating

pressure temperature may be satisfactory. The

maximum internal working temperature is 105°C / 221

°F, operating above this temperature will cause the

compressor to stop working and may cause permanent

damage.

DISCHARGE TEMPERATURE: Discharge temperature

is measured at the vent frame end of the compressor.

The Discharge temperature will vary according to

operating and environmental conditions, temperature,

load percentage, the cleanliness of the oil, cleanliness

of the intake lter and the cleanliness of the oil lter.

The normal discharge temperature is between 70°C and

90°C / 158°- 194°F When the compressor starts up from

a cold condition, the discharge temperature will quickly

rise to 85°C / 185°F, then the thermostatic valve will

open and close to regulate the discharge

temperature.

LUBRICATION: PowerCool is a powerful synthetic lubri-

cant that’s designed to help rotary screw air compressors

reach maximum performance. The PowerCool unique \

formulation has a 2-year / 8,000-hour useful lifespan

to save you money otherwise spent on disposal fees.

Other lubricants can require changing up to 8 times as

often as PowerCool. The carryover is up to 75% lower

than mineral oils and PAOs, which means less uid for

makeup and reduced contamination. All this results in

superior compressor performance, which in turn leads to

lower costs from excellent cooling and superior

efciency.

SECTION 4

INSTALLATION AND INSPECTION

BEFORE OPERATION

LOCATION REQUIREMENTS:

Disconnect, tag and lock out power source then

release all pressure from the system before attempting

to install, service, relocate or perform any maintenance.

Do not lift unit by attaching any lifting device onto

the outside case. DO NOT lift or move unit without

appropriately rated forklift, pallet jack or other lift-

ing device. There are slots in the base frame of the

compressor for the forklift or pallet jack forks. (See Fig. 4.1)

Never use the wood shipping pallet for mounting the

compressor.

Install and operate unit at least 39” / 1m from any

obstructions in a clean, well ventilated area. This will

ensure an unobstructed flow of air to cool compressor

and allow adequate space for maintenance.

The surrounding air temperature should not exceed

100° F / 38° C. Do not locate the compressor air inlet

near steam, paint spray, sandblast areas or any other

source of contamination.

NOTE:

If compressor operates in a hot, moist environment,

supply compressor pump with clean, dry outside air.

Supply air should be piped in from external sources.

Fig. 4.1

7

The compressor should be located in a clean, dust free,

well ventilated location.

Ambient operating temperature should be greater than 41°

F / 5° C to allow for the minimum required oil lubrication.

Compressor should be located on a solid level surface.

The Compressor location should be well ventilated and

precautions should be taken to exhaust the warm exhaust

air outside of the compressor building and or prevent the

warm exhaust air from being drawn into the air intake or

increasing the ambient temperature of the compressor

building or room.

SECTION 5

REQUIREMENTS FOR AIR PIPING

Any tube, pipe or hose connected to the unit must be able

to withstand the temperature generated and retain the pres-

sure. All pressurized components of the air system, tube,

pipe or hose must have a pressure rating higher than or

equal to 200 psi or bursting could result and injury occur.

Connect the piping system to any accumulation tank using

the same size fitting as the discharge port.

Pipe thread lubricant must be used on all male pipe threads,

and all joints are to be made up tight, since small leaks in the

piping system are the largest single cause of high operating

costs. All piping should be sloped to an accessible drain

point and all outlets should be taken off from the top of the

main distribution air line so that

moisture cannot enter the outlet.

INSTALLING A SHUT-OFF VALVE

A shut-off valve should be installed on the discharge

port of the Compressor to control the air flow and iso-

late the components for maintenance. The valve should

be located between the tank and the piping system.

When creating a permanently installed system to

distribute compressed air, find the total length of the

system and select pipe size from the chart.

Bury underground lines below the frost line and avoid

pockets where condensation can gather and freeze.

Apply air pressure to the piping installation and make sure

all joints are free from leaks BEFORE underground lines

are covered. Before putting the compressor into service,

find and repair all leaks in the piping, fittings and connec-

tions.

The diameter of the discharge pipe should be a least the

same as that of the compressor’s output pipe.

All pipe and connectors should be able to bear the

rated pressure and be rated for compressed air delivery

and comply with all local building and safety codes.

THE AIR NEEDS TO BE FREE OF TOXIC

FUMES OR GASES, INFLAMMABLE GAS OR

EXPLOSIVE GAS. DO NOT STORE TOXIC,

VOLATILE, CORROSIVE OR FLAMMABLE

AGENTS NEAR THE COMPRESSOR.

NEVER USE PLASTIC (PVC) PIPE FOR

COMPRESSED AIR. SERIOUS INJURY OR

DEATH COULD RESULT.

THE COMPRESSOR SHOULD NOT BE LOCATED

OUTDOORS. THE AIR INTAKE OF ANY

BUILDING OR ENCLOSED STRUCTURE MUST

BE FILTERED TO HELP ELIMINATE

THE DUST IN THE AIR.

8

The conguration should meet the requirements for the ve-

locity of compressed air.

The pressure drop of the pipeline must exceed the set

pressure by 5% or more.

Use the minimum amount of bends to ensure the

smoothest airow as possible. If the pipeline run is long,

the diameter of the pipe should be increased.

Prevent any condensation from owing into any

equipment by installing the pipeline run with a minimum

slope of 1-2˚ with drain valves located at the low spots.

Slope piping so that it drains towards a drop leg or

moisture trap away from the compressor.

Consideration of future emergencies, temporary

compressor and maintenance needs of equipment should

be incorporated into the pipeline design and may include

bypass lines, shut off valves, air take off locations, strain

on the piping due to dead weight of the pipe, expansion

and contraction of the pipe, strains for internal pressure.

An air oil separator should be installed at the head of the

pipeline.

A one way valve is mounted on the exit line of the

compressor.

The compressor has integrated anti vibration devices and

does not have any support for the air pipeline. All

external piping requires approved support systems. All

piping should be connected to the compressor out line in

such a manner as to keep any condensation from running

back towards the compressor.

When an air drier is installed in the pipeline, an air tank/

reservoir is recommended as the compressed air

temperature will be lowered prior to entering the dry-

ing system and therefore increase the efcien-

cy and lower the energy use of the drying system.

A flexible hose or coupling should be installed between

the compressor and the service piping/ and or the tank;

and the tank and the service piping.

Failure to properly install the tank can lead to cracks at

the welded joints and possible bursting.

SECTION 6

FLOOR MOUNTING

The compressor should be bolted onto a flat, even,

concrete floor or on a separate concrete foundation.

If installing the optional Air Tank, Anti-vibration pads

should be used between the tank legs and the floor.

When using anti-vibration pads, do not draw bolts tight.

Allow the pads to absorb vibrations. (See Fig. 6.1)

SECTION 7

ELECTRICAL CONNECTIONS

Fig. 6.1

DO NOT PERFORM ANY MAINTENANCE OR

INSTALLATION OF ANY COMPONENTS

WITHOUT FIRST ENSURING THAT ELECTRICAL

POWER HAS BEEN DISCONNECTED AT

THE SOURCE OR PANEL AND CANNOT BE

RE-ENERGIZED UNTIL ALL

MAINTENANCE AND/OR INSTALLATION

PROCEDURES ARE COMPLETED.

9

Overheating, short circuiting and fire damage will result from

inadequate wiring. Wiring must be installed in

accordance with National Electrical Code and local codes

and standards that have been set up covering electrical

apparatus and wiring.

POWER: Standard Requirements; 230V, 3Phase, 60HZ,

Grounded.

Be certain that adequate wire sizes are used, and that:

1. Service is of adequate ampere rating.

2. The supply line has the same electrical characteristics

(voltage, cycles and phase) as the motor.

3. The line wire is the proper size and that no other

equipment is operated from the same line. The chart below

gives minimum recommended wire sizes for compressor

installations.

Recommended wire sizes may be larger than the

minimum set up by local ordinances. If so, the larger size

wire should be used to prevent excessive line voltage

drop. The additional wire cost is very small compared

with the cost of repairing or replacing a motor electrically

“starved” by the use of supply wires which are too small.

Improperly grounded electrical components are shock

hazards. Make sure all the components are properly

grounded to prevent death or serious injury.

This product must be grounded.

Grounding reduces the risk of electrical

shock by providing an escape wire for

the electric current if short circuit occurs.

This product must be installed and oper-

ated with a power cord or cable that has

a grounding wire.

The base of the unit has holes in it for routing of the

power cord. (See Fig. 7.1)

1. Remove the Access panel on the Power Control

Box Side of the Compressor. (See Fig. 7.2)

ALL WIRING AND ELECTRICAL CONNECTIONS

MUST BE PERFORMED BY A QUALIFIED

ELECTRICIAN. INSTALLATION MUST BE IN

ACCORDANCE WITH LOCAL AND

NATIONAL CODES.

Fig. 7.1

Fig. 7.2

10

2. Route the power cable through the bottom of the

Power Control Box and to the Terminal Block as shown

below. (See Fig. 7.3 )

3. Connect the Power Source Wires to the incoming

Power Terminal Block. (See Fig. 7.4)

DIRECTION OF MOTOR ROTATION

MOTOR ROTATION: The 3 Phase power must be

connected properly to the compressor to ensure the motor

is rotating in the right direction. The compressor controller is

fitted with phase detection to prevent damage to the

compressor In the event of miss-connection of the three

phase power.

1. If the motor does not start upon first startup, then likely

the sequence of the three phase wiring is incorrect. Check

the Failure history as outlined in the Trouble Shooting to

confirm phase problem.

2. Reverse the two phases of power input. DO NOT alter

the wiring of the motor or starter.

GUARDING

SECTION 8

PRE-OPERATION INSPECTION

ALL MAINTENANCE PANELS MUST BE

INSTALLED DURING NORMAL OPERATION.

ALL MOVING PARTS MUST BE GUARDED. ALL

ELECTRICAL COVERS MUST BE INSTALLED

BEFORE TURNING ON THE POWER.

Fig. 7.3

Fig. 7.4

DO NOT PERFORM ANY MAINTENANCE OR

INSTALLATION OF ANY COMPONENTS

WITHOUT FIRST ENSURING THAT ELECTRICAL

POWER HAS BEEN DISCONNECTED AT

THE SOURCE OR PANEL AND CANNOT BE

RE-ENERGIZED UNTIL ALL

MAINTENANCE AND/OR INSTALLATION

PROCEDURES ARE COMPLETED.

11

INSPECTION OF THE SCREW AIR END

1. Rotate the Pulley on the Screw Air End by hand a cou-

ple of complete rotations counterclockwise to ensure the

Air End is not locked and is pre-lubricated. (See Fig. 8.1)

IF COMPRESSOR HAS NOT BEEN IN USE

FOR MORE THAN TWO MONTHS OR STORED

FOR A LONG PERIOD OF TIME, PERFORM

THE FOLLOWING STEPS:

Refer to Maintenance, Section 12 for details on Intake

Valve Assembly.

1. Remove the Air Intake Filter Housing and Filter.

2. Open the Intake Valve by pressing down gently on

top of the Intake Valve to open and hold open.

(See Fig. 8.2)

3. Then pour .5 quart (.5 litre) of lubricating oil into

Air End through the Intake Valve.

4. Rotate the Pulley on the Screw Air End by hand a

couple of complete rotations counterclockwise to ensure

the Air End is not locked and lubricated properly.

(See Fig. 8.1)

5. Make sure all oil enters Air End.

6. Make sure Intake Valve closes when released.

OIL LEVEL INSPECTION

1. Remove the Access panel on the Oil Separator Side

of the Compressor. (See Fig. 8.3)

2. The oil level must be above the upper red line after

the compressor is off has been stopped for thirty minutes

The oil level when the compressor is running must be

between the upper and lower red line indicated on the Oil

Level Site glass. (See Fig. 8.4 & 8.5)

Fig. 8.1

Fig. 8.2

LOCK OUT SOURCE AND RELIEVE PRESSURE

BEFORE SERVICING.

Fig. 8.3

Oil Fill Plug

Oil Level

Site Glass

Fig. 8.4

12

3. Fill with PowerCool Synthetic Air Compressor

Lubricant if necessary and inspect the O-Ring on the Oil

Fill Plug before tightening.

TRANSMISSION INSPECTION:

Belt Inspection.

1. Remove the Access panel on the right side Drive Belt

Side of the Compressor.

2. Check that all drive belts are in the pulley grooves.

Adjust the tension of belts through the adjusting Bolt on

motor. (See Fig. 8.6)

(See Belt maintenance on page 28 for Belt adjustment

details.)

STOP VALVE INSPECTION

Check if the stop valve is open.

SECTION 9

DAILY OPERATION

EMERGENCY STOP

1. To immediately stop the Compressor press the

Emergency Stop Button to cut off the power supply of the

controller and contactor power. (See Fig. 9.1)

2. To Reset Emergency Stop; Twist Emergency Stop

Button clockwise, The Emergency Stop Button will pop

back out. The Compressor cannot be restarted until the

failure has been cleared and the Restart Delay time (90

seconds) has expired.

3. The Compressor cannot be restarted until the failure

has been cleared and the Restart Delay time (90 seconds

default) has expired.

DAILY STARTUP PROCEDURE:

Before start up:

a) Check the operating button to see if it is in normal

condition.

b) Make sure there are no abnormal noise vibration or

oil leakage.

c) Check the instruments of pressure gauge, oil

thermometer, ammeter, indicator light, etc are in

Fig. 8.6

DO NOT OVER FILL. OVER FILLING CAN CAUSE

A HIGH LEVEL OF OIL IN THE COMPRESSED AIR.

DO NOT UNDER FILL. UNDER FILLING CAN CAUSE

OVER HEATING AND DAMAGE.

Minimum Oil Level

when stopped

and cold

Minimum Oil Level

while running

Fig. 8.5

IN THE EVENT OF ANY TROUBLE OR

OPERATION PROBLEM NOT DETECTED

AND TERMINATED BY THE CONTROL SOFTWARE.

THE COMPRESSOR CAN BE SHUT DOWN BY

PRESSING THE EMERGENCY STOP BUTTON.

Emergency Stop

Button

Fig. 9.1

13

normal condition.

d) Check the oil return pipe to see if it is in normal

condition.

e) Check the pressure of the automatic stop.

f) Check the unloading valve to see if it is deating or

not when the machine stopped. Check also the

exhaust temperature.

g) Check the voltage and electric current to see if they

are in normal condition.

h) Check, clean and replace the safety valve if

necessary.

i) Record the voltage, current, air pressure, exhaust

temperature and oil level every day and take notes

of the working time, maintenance status and

abnormalities per shift.

ATTENTION:

Don’t open oil drain ball valve until ve

minutes after stopping the compressor.

1. Open the oil drain valve slightly and drain off any

water from the bottom of the oil Tank. Drain uid until

water stops owing and only oil ows. (See Fig. 9.2 )

2. The oil level must be above the upper red line after

the compressor is shut off and has been stopped for

thirty minutes. The oil level when the compressor is

running must be between the upper and lower red line

indicated on the Oil Level Site Glass. (See Fig. 9.3 )

3. Fill with PowerCool Synthetic Air Compressor

Lubricant if necessary and inspect the O-Ring on the Oil

Fill Plug before tightening.

START UP PROCEDURE:

1. Make sure any installed valves are open.

2. Turn on the Power; The LCD Display will show a

welcoming message and then the Display will indicate

Compressor’s STATE: NORMAL STOP.

3. Press the ON Button; The compressor will begin

the Delayed Start countdown, once the delayed time is

reached the Compressor will start up automatically. If

necessary pressing the STOP Button during the delayed

Start Countdown will Stop the delayed start Countdown

and place the Compressor in the STATE: NORMAL

STOP. (The compressor will not be able to be restarted

for at least ninety seconds (default) after it has been

stopped for any reason.)

4. After starting up: Watch the pressure on the control

panel. Check operating temperature and the general

conditions inside the compressor.

The Compressor will run in the STATE: AUTO LOADING

until the preset system pressure is reached. The

Minimum Oil Level

when stopped

and cold

Minimum Oil Level

while running

Fig. 9.3

Fig. 9.2

14

Compressor will continue to run in the STATE: AUTO

UNLOADING until the system pressure falls below the

preset minimum pressure.

The Compressor maintains the preset system

pressure by moving from the STATE: AUTO LOADING,

pressuring the system, to the STATE: AUTO UNLOADING;

not building any pressure.

Use the monitoring features to monitor pressure, power and

other compressor running values to ensure the Compressor

is operating normally. See The Parameter Section of this

Manual for details on setting pressures and monitoring run-

ning parameters.

The Compressor should run smoothly with no excess

vibrations.

ATTENTION:

Do not restart compressor up within 90 Seconds after

compressor has been stopped. Release all pressure

within AIR OIL separation element before restarting.

Avoid compressor start up when there is back

pressure in the system.

SHUT DOWN PROCEDURE:

1. Press the OFF button, the compressor will move to

STATE: READY STOP. The Controller will countdown the

Remaining delay until the Compressor will stop and then

shut down the Compressor when the set time is reached.

If the compressor has begun the stop sequence, Press the

Emergency Stop Button if you need to stop the compressor

immediately.

SECTION 10

LCD CONTROLLER PANEL

OPERATION

The LCD CONTROLLER panel is used to monitor and

adjust the Parameters of the Screw Compressor.

The Parameters are set at the factory and it is

recommended to leave most of the settings at their

factory default values.

The values most likely to require adjustment by the end

user are described below.

The Complete Menu Hierarchy is available at the end of

this section.

The Factory Parameters and some of the Customer

Parameters should only be adjusted by a factory trained

service Technician.

LCD CONTROLLER PANEL OVERVIEW

BUTTON DESCRIPTION

START Start Button; Press this button to

start the Compressor.

STOP Stop Button: Press this button to

stop the Compressor.

Set Button: Press this button to conrm the

input data to be saved after modication of

the data.

Down Button: Press this button to lower

the value during data modication. Press

this button to select a menu option during

menu selection.

DO NOT ASSUME THAT THE COMPRESSOR

CAN NOT STARTUP IF THE MOTOR IS NOT

RUNNING. CONFIRM THE STATE OF THE

COMPRESSOR BEFORE PERFORMING ANY

OPERATION, INSPECTION OR WORK NEAR THE

MOTOR AND ENSURE LOCK OUT AND TAG OUT

PROCEDURES HAVE BEEN PERFORMED.

IN THE EVENT OF ANY TROUBLE OR

OPERATION PROBLEM NOT TERMINATED BY

THE CONTROL SOFTWARE. THE COMPRESSOR

CAN BE SHUT DOWN BY PRESSING

THE EMERGENCY STOP BUTTON.

S

15

Up Button: Press this button to raise the value

during data manipulation. Press this button to

select a menu option during menu selection.

Right Button: This button can be used as

cursor during the data modication and as

conrm button during menu selection.

Escape Button: Press this button to return to

the menu operation or to previous page.

STATUS DISPLAY AND OPERATION:

1. When the unit is powered up, the Display interface

will display the welcome screen as follows:

AFTER FIVE SECONDS THE DISPLAY WILL CHANGE:

AIR T: Indicates air temp in degrees Celsius.

STATE: Indicates Current Motor State.

P: Indicates PSI

ADD0001: Indicates Network Address.

0 S: Indicates number of seconds remaining if

in a “DELAY STATE”

NEAR: Indicates Local Control (NEAR) or

Remote Control. (Far)

RUN PARAMETER

Use the RUN PARAMETER menu to view or monitor the

compressor settings while running in any state.

The settings cannot be changed or modied in this view

but can be changed from other menus.

To view the RUN PARAMETER: MOTORS CURRENT:

1. From the Main screen:

2. Press ê Enter to access the Main Menu Selection.

3. Press ê or é to move the black cursor over the

menu “RUN PARAMETER” and then press è .

4. Press ê or é to highlight MOTORS CURRENT.

5. Press è .

5. The display will show the amount of AMPS drawn

S

16

per leg for the HOST (Main Motor) and the FAN (Cooling

Fan).

6. Press the RETURN button “RT” and return to the

upper menu or the main screen.

NOTE:

The display will automatically return to the main

screen after several seconds of inactivity.

To view the other RUN PARAMETERS such as the

TOTAL RUN TIME, THIS RUN TIME, MAINTENANCE

PARAMETER, HISTORY FAULT, PRODUCTION DATE

and THIS FAULT, return to the upper level menus and

use the same method used to view MOTORS CURRENT

parameters to view the other settings.

CALENDAR SETTING

To adjust the Date; (No Password is

required to modify the Date).

1. From the Main screen:

2. Press ê Enter to access the Main Menu Selection.

3. Press ê to move the black cursor over the menu

item “FACTORY PARA.”

4. Press è .

5. Press ê or é to highlight and choose “DATA”.

6. Press è .

7. The number will blink indicating it is modiable. Use

the ê or é button to change the values of the

selected parameter (month, day, year). Press the “S”

button to conrm and save the data after nishing the

modication.

DEFAULT “PASSWORD”

Some of the settings require a pin code, the factory

default password you can use is 1688.

Use the ê or é buttons to enter the numbers.

CHANGING THE “PASSWORD”

To reset the Password.

1. From the Main screen:

2. Press ê Enter to access the Main Menu Selection.

17

3. Press ê or é to highlight the menu item

“USER PARAMETER”.

4. Press è .

5. Press ê or é to highlight the menu item “NEW

USER PASSWORD” . Located on the Third row down.

6. Press è .

7. Use the ê or é button to change the values of the

selected parameter. Press the “S” button to conrm and

save the data after nishing the modication.

LANGUAGE SETTING

To choose Language Settings:

1. From the Main Screen:

2. Press ê Enter to access the Main Menu Selection.

3. Press ê to move the black cursor over the menu

item “USER PARA.”

4. Press è .

5. Press ê to choose “LAN. SEL: EN”

6. Press è .

CHANGING THE MAXIMUM AND

MINIMUM SYSTEM PRESSURE

SETTINGS

The maximum and minimum pressure in the system have

already been pre-set by the factory. The Maximum

allowable pressure in the system is 150 PSI (1.034Mpa).

The compressor will run in a Loaded State (building

pressure) until it reaches the Maximum Pressure Setting

value.

The compressor will run in an Unloaded State

(Running but not building pressure) until the pressure in

the system falls below the Minimum Pressure Setting.

18

The Range Value represents the amount of pressure

below the Maximum Pressure Setting that will trigger the

Compressor to change from Unloaded State (not building

pressure or Normal Off State to Loaded State Building

Pressure).

Example:

Max Pressure is set at: 150 PSI / 1.034 Mpa

Range Value set at: 25 PSI / .172 Mpa.

The Minimum Pressure is 125 PSI / .862 Mpa

(150 Max) - (Range 25 PSI) = Min 125 PSI

Use the Chart below to convert PSI to Mpa.

DO NOT ASSUME THE COMPRESSOR

CAN NOT STARTUP IF THE MOTOR

IS NOT RUNNING. CONFIRM THE STATE OF

THE COMPRESSOR BEFORE PERFORMING ANY

OPERATION, INSPECTION OR WORK NEAR THE

MOTOR AND ENSURE LOCK OUT AND TAG OUT

PROCEDURES HAVE BEEN PERFORMED.

DO NOT PERFORM ANY MAINTENANCE OR

INSTALLATION OF ANY COMPONENTS WITH OUT

FIRST ENSURING THAT ELECTRICAL POWER HAS

BEEN DISCONNECTED AT THE SOURCE OR PANEL

AND CANNOT BE RE-ENERGIZED UNTIL ALL

MAINTENANCE AND/OR INSTALLATION

PROCEDURES ARE COMPLETED.

PSI Mpa Bar kg/cm2

1 0.007 0.07 0.07

25 0.172 1.72 1.76

50 0.345 3.45 3.52

75 0.517 5.17 5.27

100 0.689 6.89 7.03

110 0.758 7.58 7.73

120 0.827 8.27 8.44

130 0.896 8.96 9.14

140 0.965 9.65 9.84

145 1.000 10.00 10.19

150 1.034 10.34 10.55

160 1.103 11.03 11.25

To Convert Psi to Mpa

Multiply: Psi x .006894757 = Mpa

To Convert Psi to Kg/cm2

Multiply: Psi x .070307 = Kg/cm2

To Convert Psi to Bar

Multiply: Psi x .06894757 = Bar

19

SECTION 11

CONTROLLER SOFTWARE MENU HIERARCHY

1) RUN PARAMETER (Displays Values Only)

a. MOTORS CURRENT

i. AMPS/LEG

Current (Amps) R S T

HOST x.x x.x x.x

FAN x.x x.x x.x

This setting displays the number of amps drawn per supply leg.

HOST: The amps being drawn by the main electric motor.

FAN: The amps being drawn by the cooling Fan.

b. TOTAL RUN TIME

i. TOTAL RUN TIME: x H xx M

ii. LOADING TIME: x H xx M

TOTAL RUN TIME is the total amount of time the compressor has been running.

LOADING TIME is the amount of time the compressor has been running in LOADED STATE.

These hour counters can be reset under FACTORY PARAMETERS.

c. THIS RUN TIME

i. THIS RUN TIME: x H xx M

ii. THIS LOADING TIME: x H xx M

THIS RUN TIME is the total amount of time the compressor has been running in any state during the

most recent cycle

THIS LOADING TIME is the amount of time the compressor has been running in LOADED STATE in the

most recent Cycle.

These hour counters can be reset under FACTORY PARAMETERS.

d. MAINTENANCE PARAMETER

RUN TIME SET

i. OIL FILTER 0000 0000

ii. O-G FILTER 0000 0000

iii. GAS FILTER 0000 0000

iv. LUBE 0000 0000

v. GREASE 0000 0000

The RUN TIME for each maintenance item is the amount of time since the maintenance item has been

reset, and ideally performed, changed or replaced.

The SET TIME is the amount of time set for a reminder alarm to go off to remind to change, perform or

replace the maintenance item.

These hour counters can be reset under FACTORY PARAMETERS.

20

e. HISTORY FAULT –

DISPLAYS “FAULT HISTORY”

f. PRODUCTION DATE, NUM

i. PROD DATE: 2009:xx:xx

ii. SERIAL NUMBER: xxxxxxxx

DISPLAYS THE PRODUCTION DATE AND SERIAL NUMBER.

These hour counters can be reset under FACTORY PARAMETERS.

g. THIS FAULT-

DISPLAYS “CURRENT FAULT STATUS”

These faults can be cleared by xing fault.

2) CALENDAR- (DISPLAYS /MODIFY CURRENT DATE AND TIME, NO PASSWORD REQUIRED)

DATE & TIME

2009-11-17

W-2

00: 00: 00

H M SEC

Can be reset from this screen

3) CUSTOMER PARAMETER (Modies Values)( Password Required)

a. SET P.T.

i. LOADING – xx.xx Mpa

Pressure at which Compressor will switch to LOADED STATE

(To build pressure). (NOT APPLICABLE)

ii. UNLOADING – xx.xx Mpa

Pressure at which Compressor will switch to Unload State.

(Not Build Pressure) (NOT APPLICABLE)

(NOTE: Maximum and minimum pressure is set using the PRESSURE SWITCH Mounted behind the

Power Control Box.)

iii. FAN START- x °C

The Oil temperature at which fan will turn on.

iv. FAN STOP - x °C

The Oil temperature at which fan will turn off.

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