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Eaton Compressor Rotary Screw Compressor

36

Line pressure exceeds upper 
preset safety limit 

(Continued)

Air exhaust temperature lower 
than normal

Excessive air exhaust 
temperature causing 
compressor to shutdown

Excessive oil consumption

2.   High pressure shut-down preset

 

is incorrectly programmed

2.   Additional compressor piped into  
 

system causing preset to be  

 exceeded

5.   Reset to proper setting. Refer to PLC
 manual.

6.   Reset additional compressor pressure
 

settings to 145 psi or lower

1.   Reset Motor shut-down time in PLC

2.   Reset to proper setting. Refer to PLC
 manual

3.

 

Replace temperature sensor

1.   Add oil

2.   Drain all oil & replace with Airbase    
 

Industries compressor oil only.

3.

 

Replace oil filter

4.  Check for air exhaust blockage. Increase
 

area ventilation

5.  Clean cooler

6.  Replace temperature sensor

7. 

Replace Thermo valve

8.  Replace cooling fan

1.   Clear blockage; clean orifice

2.   Change air/oil filter

3.  Drain and change oil. 

Use only Airbase  

 

Industries oil, model no. Oil003. For  

 

food manufacturing applications, use  

 

model no. Oil001. Use of any other  

 

product causes product damage   

 

and voids the warranty. Refer to    

 

warranty statement for oil  

 

 requirements.

1.   Clogged return/scavage line or
 orifice

2.   Damaged or improperly functioning   
 

air/oil separator filter

3.  Excessive foaming

1.   Low oil level

2.   Incorrect oil used

3.

 

Blocked oil filter

4.  Surrounding temperature too high

5.  Blocked cooler

6.  Temperature sensor malfunction

7. 

75HP & above-Bad Thermo valve

8.  Cooling fan failure

1.   Compressor running under noload
 excessively

2.   Incorrect fan temperature 
 

parameter setting in PLC

3.

 

Temperature sensor malfunction

Problem

Possible Causes

Resolutions

Содержание PRS0070001

Страница 1: ...Operating Instructions 1 ...

Страница 2: ... 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 ...

Страница 3: ...lChecks 27 Start Up 28 PowerOutages 28 Storage 29 RestartingProcedure 29 Maintenance 29 Safety Steps 29 30 LubricatingOil 30 ChangingOil 30 OilCapacities 31 Belts 31 SystemPressure 32 SafetyValve 32 Air OilSeparatorFilter 32 OPTIONAL Cabinet Intake Filter s 32 Maintenance Schedule 33 Troubleshooting 34 38 Wiring Diagrams 39 Warranty 43 Variable Speed Drive The variable speed drive is an auxiliary ...

Страница 4: ... 1 Oil Capacity 1 1 3gal 3 8 L 1 1 3 gal 3 8 L 1 1 3gal 3 8 L 1 1 3 gal 3 8 L 1 1 2 gal 6 L 1 1 2 gal 6 L Dimensions 26 x34 x43 26 x34 x43 26 x34 x43 34 x24 x43 32 x37 x50 32 x37 x50 Weight lbs 562 562 562 562 788 804 L W H inches Model No PRS0250003 PRS0300003 PRS0400003 PRS0500003 PRS0600003 Description Three Phase Dual Voltage Three Phase Dual Voltage Three Phase Dual Voltage Three Phase Dual V...

Страница 5: ...50003 PRS1000003 PRS1250003 PRS1500003 PRS1750003 PRS2000003 Description Three Phase Dual Voltage Three Phase Dual Voltage Three Phase Dual Voltage Three Phase Dual Voltage Three Phase Dual Voltage Three Phase Dual Voltage Motor 75HP 100HP 125HP 150HP 175HP 200HP Amp Draw 230V 180 460V 90 230V 240 460V 120 230V 300 460V 150 230V 360 460V 180 230V 420 460V 210 230V 480 460V 240 RPM 1750 1750 1750 1...

Страница 6: ...ing protective shields and barriers electrical protective equipment and personal hearing equipment Breathable Air Pressurized Components Personal Protective Equipment CALIFORNIA PROPOSITION 65 This product or its power cord may contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling WARNING Basic Guidelines 1 Allow o...

Страница 7: ...operating practices 1 Carefully inspect all lifting equipment and make sure it is in good condition Rated capacity should exceed compressor weight The lifting hook has a functional safety latch or equivalent and is properly attached to lifting feature 2 Make sure lifting points are in good condition and tighten any loose nuts or bolts before lifting 3 Use provided lifting feature or appropriate sl...

Страница 8: ...er OSHA Standard 29 CFR 1926 302 b 7 2 Flow limiting valves are listed by pipe size and rated CFM Select appropriate valves accordingly in accordance with the manufacturer s recommendations 3 Do not install check valve as compressor has internal check valve Installation Area Piping Exhaust air from this unit can be used to supplement environment heat Install unit in separate room then create duct ...

Страница 9: ...ate condensate drains on piping system 2 Never use reducers in discharge piping Keep all piping and fittings the same size in the piping system to help prevent pressure drops Never use plastic PVC pipe for compressed air Serious injury or death could result Installing WARNING Minimum Pipe Size For Compressed Air Lines Pipe size shown in inches SCFM 20 40 60 100 125 150 200 25 ft 3 4 3 4 3 4 1 1 1 ...

Страница 10: ...ll be in the compressor The above capacities can be used for guidelines but use the upper arrow fill line on the sight glass See page 7 Over filling causes oil to blowout the inlet valve and through the air filter also oil could push past the separation system resulting in oil in the air lines Use only Airbase Industries Oil SKU OIL003 For food manufacturing applications use SKU OIL001 Use of any ...

Страница 11: ...Install surge protection device between power supply and compressor electrical cabinet 7 Make sure to install properly sized breakers and fuses 8 The unit must be properly grounded DO NOT connect ground wire to air or cooling lines Connect ground wire to grounding lug in the compressor electrical cabinet IMPROPERLY GROUNDED ELECTRICAL COMPONENTS ARE SHOCK HAZARDS MAKE SURE ALL THE COMPONENTS ARE P...

Страница 12: ...amber and are drained out with the compressed air The PLC is the compressor controller and has a display screen for system information The electric circuitry of the PLC can be divided into two systems One is for the starting panel to configure Y Delta starting The other is for internal computer controls and is explained in more detail in the PLC manual If there is any failure contact Eaton Compres...

Страница 13: ...Celcius or oF Fahrenheit Use the Up Down arrows to change if desired and then press Enter to set the value Now the current flashing gauge pressure setting BAR metric or PSI Am Std shows in display Use the Up Down arrows to change if desired and then press Enter to set the value Press the Up arrow for setting temperature scale gauge pressure language time date 3 4 2 1 ...

Страница 14: ...then press enter The current date day of week and time now shows in the display Starting with the flashing date use the Up Down Arrows to change the setting and then press Enter Now the next parameter flashes and it can be changed The day of the week is shown by Day 1 Monday Day 2 Tuesday etc The current time can be set hours minutes 24 hour time Once set press the Enter button to return to the ma...

Страница 15: ...he Up Down Arrows Press Enter again to confirm the setting Press Down Arrow to see and or change the other pressure settings Once satisfied with all settings press Down Arrow until you are back to the Main Screen Press both Up Down Arrows again if the wrong password is entered NOTICE 4 3 5 6 This feature allows the operator to set the start and stop times in 24 hour time of the compressor every da...

Страница 16: ... when the low pressure setting is reached the compressor automatically starts again Enter in the 6 Digit Password 6 6 6 6 6 6 by using the Up Arrow to set the digit to 6 then press Enter to move to the next digit and press the Up Arrow to set to 6 repeat until last digit is set to 6 then press Enter To view or set the unload delay time start with the main screen shown below Press the two arrow key...

Страница 17: ...using the Up Down Arrows Press Enter again to confirm the setting See chart on page 17 of PLC manual Once satisfied with all settings press Down Arrow until you are back to the Main Screen Press the two arrow keys at the same time to bring up the Password Level Selection Press down arrow 2 times to select Level 3 then press enter First screen for resetting alarms 4 5 7 6 Component PLC Lifetime hrs...

Страница 18: ...00 using the Up Down Arrows Then using the Enter button change NO to YES then press Enter and hours are reset Arrow down to 6 OIL FILTER HOURS and press Enter CHANGE AIR FILTER shows in the display and press Enter Press Down Arrow and CHANGE OIL FILTER shows in the display Press Enter Using Enter move over to NO and use the Up Arrow to change it to YES then press Enter and hours are reset 8 11 9 1...

Страница 19: ...row and CHANGE OIL FILTER shows in the display but the first Line is C This is the screen for the oil life Press Enter Press Down Arrow and CHECK COMPRESSOR shows in the display Check belt condition and belt tension Give your compressor a good overlook noting any changes since last machine maintenance Press Enter Using Enter move over to NO and use the Up Arrow to change it to YES then hit Enter a...

Страница 20: ...r move over to NO and use the Up Arrow to change it to YES then hit Enter and it resets the hours After resetting the Bearing Lubricant timer you can return to the Main Screen by Pressing the Down Arrow until you are back to the Main Screen Press Down Arrow and BEARING LUBRICATE shows in the display Press Enter 19 21 22 20 Resetting Maintenance Alarms Continued ...

Страница 21: ...sons but if the current spikes the overload protection causes the motor s to stop If this happens the motors must be reset manually If motor overload protection is caused by any other reason contact Eaton Compressor immediately Drive Motor 1 Reasons for tripped overload protection a Operator error Improper regulation of air exhaust pressure or other parts of the system b Branch circuit not sized c...

Страница 22: ... electrical shock could result A Using lock key remove electrical panel from unit B Locate BLUE reset button on relay attached to K1 contactor Example of relay on larger units C Once motor has cooled press in on BLUE button WARNING If motor overload protection is caused by any other reason contact Eaton Compressor immediately ...

Страница 23: ...hods are available so appropriate features can be selected for different air demands It is important to monitor air demand since it takes 15 more power to operate compressor for every 10 PSI of pressure increase Two rotor shafts are mounted on bearings parallel to each other in the machine casing The casing has an air inlet at the top and an air outlet at the bottom The shafts have precisely machi...

Страница 24: ...eel pressure vessel used to store lubricating oil and to separate the compressed air and the lubricating oil An oil sight gauge is installed on one end of the air oil separator tank Make sure oil level is at high oil level indicator when unit is shut down During operation the oil level should stay between the high oil level line and the lowest oil level line After the machine has been shut down fo...

Страница 25: ...sorbed in the radiator cores is discharged from the screw cabinet because of the cooling fan and generally reduces air temperature by 60 F 15 C If ambient air temperature exceeds 112 F 45 C the system may overheat It is important to operate the compressor in a well ventilated area for the cooling process to be effective optional not shown The air storage tank can serve as cushion to keep output pr...

Страница 26: ...ant or other combustible substances 8 Shut off compressor and allow it to cool before checking or adding lubricant or when refilling air line anti icer systems with antifreeze compound Keep sparks flames and other ignition sources away and DO NOT permit smoking in the area 9 Stop compressor and disconnect power if a hazardous condition arises 10 Wear snug fitting clothing and confine long hair whe...

Страница 27: ...y of clean water for 15 minutes then contact eye doctor immediately Never store antifreeze compound in confined areas 1 Make sure compressor is properly grounded and verify voltage is correct especially when using a three phase power 2 Double check internal control transformer before applying power to unit Make sure wiring is correct to avoid damage to circuitry and PLC Refer to wiring diagram fig...

Страница 28: ...ervice for assistance 4 Press ON button to begin operation After unit starts a time delay of approximately 5 seconds occurs and a LOADING message displays on PLC screen This means the pump is operating and the compressor is building pressure 5 Monitor display panel for normal readings such as amp draw and voltage Push OFF button if there are any abnormal sounds vibration or oil leakage 6 Check tha...

Страница 29: ...ondensed water in the oil air separator tank and the oil cooler 2 3 days later d Move machine to a clean dry place 1 Remove any wrappings from system components 2 Ensure electric motor is properly insulated 3 Perform initial checks then follow procedures for start up Storage Restarting Procedure Safety Steps Maintenance To avoid shock and serious personal injury disconnect tag and lock out power s...

Страница 30: ...ood condition Replace any wiring that has cracked cut or otherwise damaged insulation Replace terminals that are worn discolored or corroded Keep all terminals and pressure connectors clean and tight 6 Keep all body parts and any hand held tools or other conductive objects away from exposed live parts of the electrical system When making repairs or adjustments stand on a dry insulated surface and ...

Страница 31: ...on the sight glass See page 7 Over filling causes oil to blowout the inlet valve and through the air filter also oil could push past the separation system resulting in oil in the air lines Oil Capacities 7 5 10 HP 5 liters 1 gal 2 5 pints 15 20 HP 6 liters 1 gal 4 6 pints 25 30 HP 11 liters 2 gal 7 25 pints 40 60 HP 20 liters 5 gal 2 25 pints 75 100 HP 30 liters 7 gal 7 4 pints 125 150 HP 70 liter...

Страница 32: ...ture may be very hot Use caution when changing filter WARNING 1 Relieve all air pressure from air oil separator tank then wait approximately 5 10 minutes before replacing filter 2 Replace air oil separator filter Do not attempt to clean Current rotary screw compressors can now be ordered with air intake filters which reduce the amount of airborne debris being pulled into the unit thus reducing the...

Страница 33: ...e air filter Replace oil filter 2000 hrs 6 months Change oil replace oil filter Blow out radiator Grease electric motor bearings Check tighten all electrical connections terminals Check belt tension Inspect all piping Thoroughly clean sight glass 4000 hrs 1 year Change oil replace filter Replace air filter Replace air oil separator filter Grease electric motor bearings Blow out radiator Check belt...

Страница 34: ...e all electrical connections are secure once power is restored press Enter button on controls 2 Replace fuse s as needed 3 Check for correct voltage and make sure all fuses are functioning 4 Check fault history on PLC Arrow down to 9 ALARMS then press Enter button Arrow down to see all faults up to 20 Refer to page 18 of PLC manual for fault listing and causes 5 Have electrician or Eaton Compresso...

Страница 35: ...e solenoid valve 4 Defective blow down valve 1 Decrease air consumption or increase number of compressors in system 2 Clean or replace air filter 3 Disassemble and clean suction valve Apply lubricating oil to valve 4 Adjust pressure regulator to proper settings Refer to PLC manual 5 Disassemble and clean solenoid valve Replace if needed Check for proper voltage 220V required 6 Check maintenance pa...

Страница 36: ...st blockage Increase area ventilation 5 Clean cooler 6 Replace temperature sensor 7 Replace Thermo valve 8 Replace cooling fan 1 Clear blockage clean orifice 2 Change air oil filter 3 Drain and change oil Use only Airbase Industries oil model no Oil003 For food manufacturing applications use model no Oil001 Use of any other product causes product damage and voids the warranty Refer to warranty sta...

Страница 37: ...pect clean 4 Install after cooler 5 Slope drain line away from trap Install drip leg 6 Contact Eaton Compressor 1 Adjust belt tension or replace belts 2 Replace bearing Contact Eaton Compressor 3 Install enclosure panels 4 Inspect tighten 5 Remove shipping brackets 1 High pressure shut down preset is improperly programmed 2 Defective pressure relief 3 Clogged air oil separator filter 1 Motor overl...

Страница 38: ...sion or replace belts 5 Remove shipping brackets 1 Adjusted belt tension 2 Align sheaves 3 Replace belts 4 Use ONLY OEM parts 1 Replace fuse or reset breaker 2 Replace E Stop button 1 Remove check valve 2 Bypass dryer if available allow dryer to thaw if symptom persist make adjustments to dryer 3 Replace filter 1 Check valve installed between compressor storage tank 2 Dryer frozen up restricting a...

Страница 39: ...Operating Instructions 39 ...

Страница 40: ...Eaton Compressor Rotary Screw Compressor 40 ...

Страница 41: ...Operating Instructions 41 ...

Страница 42: ...Eaton Compressor Rotary Screw Compressor 42 ...

Страница 43: ...s or any caustic or abrasive matter that may be ingested into the pump or installing the unit in an enclosed area where lack of cooling ventilation is present such as in boiler or equipment rooms where the ambient air exceeds 100 F THAT EACH COMPRESSOR UNIT TO BE FREE FROM DEFECTS IN MATERIAL WORKMANSHIP AND PARTS FOR 5 YEARS FOR THE COMPRESSOR PUMP AND 2 YEARS ON THE REMAINDER OF THE UNIT FROM TH...

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