Operating Instructions ROTARY SCREW COMPRESSORS EMAX designs and manufactures products for safe operation. However, operators and maintenance persons are responsible for maintaining safety. All safety precautions are included to provide a guideline for minimizing the possibility of accidents and property damage while equipment is in operation. Keep these instructions for reference.
EMAX Rotary Screw Compressors Contents Page No. Variable Speed Drive Information . . . . . . . . . 2 Lubrication Process . . . . . . . . . . . . . . . . . 8 Model Specification Charts . . . . . . . . . . . . . 2-3 System Components . . . . . . . . . . . . . . . . . . . 8 Safety Information . . . . . . . . . . . . . . . . . . . 4 PLC (Programmable Logisitical Control) . . . . 8 Tag Definitions . . . . . . . . . . . . . . . . . . . . 4 Mechanical Components . . . . . . . . . . . .
Operating Instructions EMAX Rotary Screw Systems: 5 Hp - 20 Hp (VSD Compliant) Model No. ERS0070001 ERS0100001 ERS0070003 ERS0100003 ERS0150003 ERS0200003 Single Phase Single Phase Description Three Phase Dual Voltage Three Phase Dual Voltage Three Phase Dual Voltage Three Phase Dual Voltage 7.5HP 10HP 15HP 20HP 230V: 18 460V: 9 230V: 24 460V: 12 230V: 36 460V: 18 230V: 48 460V: 24 Motor 7.
EMAX Rotary Screw Compressors Safety Breathable Air 1. NEVER use air from this compressor for breathable air except in full compliance with OSHA Standards 29 CFR 1910 and any other Federal, State or Local codes or regulations. Death or serious injury can result from inhaling compressed air without using proper safety equipment. See OSHA standards on safety equipment. This manual contains very important information to know and understand. This is provided for SAFETY and to PREVENT EQUIPMENT PROBLEMS.
Operating Instructions 3. Make sure forks are fully engaged and tipped back before lifting or moving compressor. 4. Keep load as low as possible and observe safe operating practices. Mounting Base Compressor Enclosure Shipping Bracket (Remove 4) Figure 2: Remove Shipping Brackets Installation Area Exhaust air from this unit can be used to supplement environment heat. Install unit in separate room then create duct system as shown in figure 3. 1.
EMAX Rotary Screw Compressors 2. Allow at least 24 inches of clear space around the sides and back and at least 3 feet in front of the compressor. This compressor unit is equipped with internal rubber vibration isolators. To avoid internal pump damage, DO NOT use an additional rubber mounting surface when installing compressor. Minimum Pipe Size For Compressed Air Lines (Pipe size shown in inches) Length Of Piping System 3. Make sure compressor base is on a hard, flat surface and anchored securely. 4.
Operating Instructions Oil level must be maintained between the two red lines during operation and while loaded Air/Oil Tank QF Sight Glass L1 L2 L3 TB L1 L2 L3 TB1 PE E COM AI2 L1 L2 L3 R S T CT1 A1 Figure 6: Sight Glass for Lubricating Oil +24V LI1 RIA RIC 40 37 22 14 Inverter Run Inverter Fault a b c o U V W CT2 a b c o B C B C Oil Check This unit is shipped with oil in it and should be ready to operate. Be sure to check for proper oil level before operating the compressor.
EMAX Rotary Screw Compressors Motor Rotation Lubrication Process Pressure in the oil / air separator presses lubricating oil into the oil cooler. The oil is cooled and filtered then divided into two parts. One part is injected into the compression chamber from the lower end of the rotary compressor body to cool the compressed air. The other part passes through the two ends of the compressor body and is used to lubricate internal roller bearings of rotary compressor pump and gear drive.
Operating Instructions * Values shown above are factory set for max. lifetime parameters. Maintenance Notifications Component After initial oil change, max. lifetime parameters can be reset. Refer (PLC Name) Lifetime Oil Filter (Oil) 0600 hrs.* Air/Oil Separator Filter (O-G) 4000 hrs. Air Filter (Gas) 0600 hrs. Lubricating Oil (Lube) 0600 hrs.* (Grease) 2000 hrs. Motor Bearing Grease to PLC manual for more details. Following replacement times is important for safe operation.
EMAX Rotary Screw Compressors 4. Suction Valve A butterfly valve that opens and closes during operation. When PLC calls for air, the suction valve opens through a solenoid valve to allow compressor to operate. When air pressure reaches preset max level, the PLC closes the suction valve allowing compressor to pull vacuum and not compress air. 4. Exhaust 7. Exhaust Probe The probe is temperature sensitive and located at the air outlet of the rotary screw casing.
Operating Instructions 14. Check Valve dicator when unit is shut down. During operation, the oil level should stay between the high oil level line and the lowest oil level line. A drain valve is installed under the air/oil separator tank. Open drain valve after machine has been shut down for an hour slightly to drain condensed water in the tank. This drain valve can also be used to gather oil for oil analysis. Refer to warranty statement for analysis requirements.
EMAX Rotary Screw Compressors Operation Keep all persons away from the discharge opening of hoses or tools or other points of compressed air discharge. If the machine is installed in an enclosed area, be sure to vent the relief valve outside of the structure or to an unoccupied area. Safety Rules 1. Make sure all operators receive product training, read and understand all instructions. Keep all flammable, combustible, poisonous and noxious materials away from operating area.
Operating Instructions oil needs to be added, make sure all pressure is relieved before opening fill port. Use only EMAX lubricating oil. Also make sure oil level does not drop below low level line on site glass during operation. If it does, stop compressor immediately, let rest for 10 minutes, then add oil. ton if there are any abnormal sounds, vibration or oil leakage. 6. Check that oil exhaust temperature is maintained between 160˚ - 180˚ F (70˚ - 95˚ C).
EMAX Rotary Screw Compressors Maintenance exposed live parts of the electrical system. When making repairs or adjustments, stand on a dry, insulated surface and DO NOT contact any other portion of the compressor. Safety Steps Disconnect, tag and lock out power source then release all pressure from the system before attempting to install, service, relocate or perform ANY maintenance. 7. DO NOT leave compressor unattended with exposed electrical components.
Operating Instructions Safety Valve NEVER attempt to regulate or tamper with safety valve. Valve is sealed and certified by ASME code and is designed to relieve system pressure when necessary. Use adjusting nuts to keep spring cups against each other. If spring shows between cups, the belt is too loose. Adjusting Nuts Tension Spring Check proper operation of safety valve before each use. Refer to figure 11. If valve does not open manually, replace immediately.
EMAX Rotary Screw Compressors Maintenance Schedule Daily Weekly Check oil level Check safety valve Check coolant level Drain condensed water Clean air filter General unit cleaning Check belt tension 500 hrs. 1000 hrs. 2000 hrs. / 6 months Change lubricating oil (after first 500 hrs.
Operating Instructions Troubleshooting Chart Problem Compressor will not start (Electric failure lamp is on) Possible Causes Resolutions 1. Power supply problem 1. Check complete circuit for proper voltage, ensure all electrical connections are secure 2. Blown circuit fuse and/or internal fuse 2. Replace fuse(s) as needed 3. Insufficient power to PLC 3. Check for correct voltage and make sure all fuses are functioning 4. Fault is present 4.
EMAX Rotary Screw Compressors Troubleshooting Chart Problem Air pressure is too low Line pressure exceeds upper preset safety limit Air exhaust temperature is lower than normal Air exhaust temperature is excessive causing compressor to shut-down Possible Causes Resolutions 1. Air demand too high 1. Decrease air consumption or increase number of compressors in system 2. Blocked air filter 2. Clean or replace air filter 3. Suction valve not opening properly which reduces incoming air flow 3.
Operating Instructions Troubleshooting Chart Problem Possible Causes Resolutions Air exhaust temperature is excessive causing compressor to shut-down (continued) 6. Cooling fan failure 6. Replace cooling fan 7. Temperature sensor malfunction 7. Replace temperature sensor Excessive oil consumption 1. Clogged return/scavage line or orifice 1. Clear blockage, clean orifice 2. Damaged or improperly functioning air/oil separator filter 2. Change air/oil separator filter 3.
EMAX Rotary Screw Compressors Warranty Statement Emax, INC. (also known as EATON-MAX, Inc. and each of its subsidiaries) makes the following Warranties: 1. THAT EACH ROTARY SCREW AIR COMPRESSOR PUMP TO BE FREE FROM DEFECTS IN MATERIAL, WORKMANSHIP, AND PARTS FOR 10 YEARS ON THE ROTARY SCREW AIR COMPRESSOR PUMP FROM THE DATE OF PURCHASE. Emax (and each of its subsidiaries) is not responsible for downtime during warranty service.
