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INSTALLATION AND OPERATION MANUAL
ROTARY-SCREW AIR COMPRESSOR 7.5 HP
MODEL:
RS7580H603
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.
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.
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.
Keep this operation manual near the
machine at all times. Make sure that ALL
USERS read this manual .
1645 Lemonwood Dr.
Santa Paula, CA. 93060, USA
Toll Free 1-800-253-2363
Tel: 1-805-933-9970
Fax: 1-805-933-9160
REV A 03-21-16
p/n 5900177
www.bendpak.com
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Summary of Contents for BendPak RS7580H603
- Page 1 REV A 03-21-16 p/n 5900177 INSTALLATION AND OPERATION MANUAL ROTARY-SCREW AIR COMPRESSOR 7.5 HP MODEL: RS7580H603 Keep this operation manual near the machine at all times. Make sure that ALL USERS read this manual . SHIPPING DAMAGE CLAIMS BE SAFE...
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Page 2: Table Of Contents
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 specifications without incurring any obligation for equipment previously or subsequently sold. -
Page 3: Section 1: Introduction
INTRODUCTION For additional copies or further information, contact: 1. Carefully remove the crating and packing materials. BendPak Inc. / Ranger Products 1645 Lemonwood Dr., Santa Paula, CA. 93060 1-805-933-9970 www.bendpak.com... -
Page 4: Section 2: General Safety
SECTION 2 12. RISK OF EXPLOSION. This equipment has internal arcing or sparking parts which GENERAL SAFETY PRECAUTIONS should not be exposed to flammable vapors. This machine should not be located in a recessed area or below floor level. Since the air compressor and other components (material pump, spray guns, filters, lubricators, hoses, etc.) 13. -
Page 5: Section 3: General Overview
0.4MPa the pressure valve opens to al- conventional, reciprocating piston compressors. low the compressed air to flow out. The RS7580H603 is engineered for high performance, NO LOAD: When the pressure of the outflow line efficiency, reliability and blessed silence to meet the... -
Page 6: Section 4: Installation And Inspection Before Operation
SECTION 4 The Compressor is best operated in a clean, INSTALLATION AND INSPECTION temperature controlled environment. If the compressor BEFORE OPERATION is going to be operated with an air intake temperature below 5°C / 41°F an anti-condensation apparatus is LOCATION REQUIREMENTS: required and the oil separation element should be heated. -
Page 7: Section 5: Requirements For Air Piping
The compressor should be located in a clean, dust free, Any tube, pipe or hose connected to the unit must be able well ventilated location. 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. -
Page 8: Section 6: Floor Mounting
SECTION 6 The configuration should meet the requirements for the ve- locity of compressed air. FLOOR MOUNTING The pressure drop of the pipeline must exceed the set pressure by 5% or more. The compressor should be bolted onto a flat, even, concrete floor or on a separate concrete foundation. - Page 9 This product must be grounded. Grounding reduces the risk of electrical ALL WIRING AND ELECTRICAL CONNECTIONS shock by providing an escape wire for MUST BE PERFORMED BY A QUALIFIED the electric current if short circuit occurs. ELECTRICIAN. INSTALLATION MUST BE IN This product must be installed and oper- ACCORDANCE WITH LOCAL AND ated with a power cord or cable that has...
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Page 10: Section 8: Pre-Operation Inspection
2. Reverse the two phases of power input. DO NOT alter the wiring of the motor or starter. GUARDING 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. - Page 11 Then pour .5 quart (.5 litre) of lubricating oil into Air End through the Intake Valve. Rotate the Pulley on the Screw Air End by hand a LOCK OUT SOURCE AND RELIEVE PRESSURE couple of complete rotations counterclockwise to ensure BEFORE SERVICING.
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Page 12: Section 9: Daily Operation
STOP VALVE INSPECTION Check if the stop valve is open. Minimum Oil Level SECTION 9 when stopped and cold DAILY OPERATION IN THE EVENT OF ANY TROUBLE OR OPERATION PROBLEM NOT DETECTED Minimum Oil Level while running AND TERMINATED BY THE CONTROL SOFTWARE. Fig. - Page 13 normal condition. Fig. 9.3 d) Check the oil return pipe to see if it is in normal condition. e) Check the pressure of the automatic stop. Minimum Oil Level Check the unloading valve to see if it is deflating or when stopped not when the machine stopped.
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Page 14: Section 10: Lcd Controller Operation
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, IN THE EVENT OF ANY TROUBLE OR pressuring the system, to the STATE: AUTO UNLOADING;... - Page 15 Up Button: Press this button to raise the value during data manipulation. Press this button to Use the RUN PARAMETER menu to view or monitor the select a menu option during menu selection. compressor settings while running in any state. The settings cannot be changed or modified in this view Right Button: This button can be used as but can be changed from other menus.
- Page 16 per leg for the HOST (Main Motor) and the FAN (Cooling Fan). 5. Press ê or é to highlight and choose “DATA”. 6. Press the RETURN button “RT” and return to the upper menu or the main screen. 6. Press è . 7.
- Page 17 3. Press ê or é to highlight the menu item “USER PARAMETER”. 4. Press è . 5. Press ê to choose “LAN. SEL: EN” 4. Press è . 5. Press ê or é to highlight the menu item “NEW USER PASSWORD” . Located on the Third row down. 6.
- Page 18 The Range Value represents the amount of pressure Use the Chart below to convert PSI to Mpa. below the Maximum Pressure Setting that will trigger the Compressor to change from Unloaded State (not building kg/cm2 pressure or Normal Off State to Loaded State Building Pressure).
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Page 19: Section 11: Controller Software
SECTION 11 CONTROLLER SOFTWARE MENU HIERARCHY 1) RUN PARAMETER (Displays Values Only) a. MOTORS CURRENT AMPS/LEG Current (Amps) HOST 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. - Page 20 e. HISTORY FAULT – DISPLAYS “FAULT HISTORY” PRODUCTION DATE, NUM PROD DATE: 2009:xx:xx 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 fixing fault. 2) CALENDAR- (DISPLAYS /MODIFY CURRENT DATE AND TIME, NO PASSWORD REQUIRED) DATE &...
- Page 21 b. SET TIME i. HOST START TIME – 0008S (CHANGE BY FACTORY AUTHORIZED TECHNICIAN ONLY.) When using the controller to protect the motor the time set here can not match the impulse starting current of the motor. Time set here must be longer than that of the STAR DELAY TIME plus LOAD DELAY TIME.
- Page 22 iv. BLOCKING NUM EA: 0016 v. BLOCK LOAD P: 2.00 Mpa vi. BLOCK UNLOAD P: 2.00 Mpa vii. BLOCK DELAY: 200S e. CLR LIFE TIME i. OIL RESET- 0000H Clear/reset Oil hours counter. ii. O/G RESET- 0000H Clear/reset Oil/G hours counter. iii.
- Page 23 4) FACTORY PARAMETER DO NOT CHANGE UNLESS INSTRUCTED TO DO SO BY A FACTORY TECHNICIAN. a. HOST RATED CUR: 38.0A Max amp draw allowed for electrical motor before auto shut off. b. FAN RATED CUR: Max amp draw allowed for fan motor before auto shut off. c.
- Page 24 MEASUREMENT RANGE OFTHE DISPLAY D) Unbalance Protection: If the current difference between any of the two phases reaches a percentage of 60~ 70 % the activation time is less than 5s. A) Oil Temperature of Oil: -20 ~ 150°C ; E) Overload anti-time limitation protection Accuracy : ±...
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Page 25: Section 12: Maintenance
MAINTENANCE PRESSURIZED CAN CAUSE SEVERE INJURY. MAINTENANCE ITEMS AND MAINTENANCE PERIODS LOCK OUT SOURCE AND Bendpak Rotary Screw Compressors require regular RELIEVE PRESSURE maintenance. Regular maintenance will provide long BEFORE SERVICING. Compressor component life and long term trouble free operation. - Page 26 Every 4000 hours. Perform the 2000 Hours procedures and: Minimum Oil Level Replace the lubricating oil. when stopped Check the minimum-pressure control valve. and cold Check all electrical connections. Check main bolts, main nuts and connectors are tight. Check all maintenance panel clasps for proper operation.
- Page 27 Fig. 12.8 ENSURE THAT NO FOREIGN OBJECTS OR DEBRIS FALLS INTO THE INTAKE AREA DURING MAINTENANCE PROCEDURES. 3. Check the condition of intake filter, either blow it clean with compressed air or replace if necessary. (See Fig. 12.7) 3. Clean the threads and seat and then apply a light Fig.
- Page 28 FEATURES OF THE INTAKE CONTROL VALVE Fig. 12.10 The Intake Control Valve consists of a valve body, valve gate, piston, cylinder, spring, gasket. There is a Control Plate and an Electromagnetic Control Valve mounted on the side. The Intake Control Valve controls load shedding, noise reduction, depressurization, on/off adjustment.
- Page 29 OIL CHANGE PROCEDURE 3. Remove and replace the Valve Body Top Gasket. Remove the Valve. (See Fig. 12.14) ATTENTION: Fig. 12.14 Replace the Oil more frequently when the dust level and the operating temperature are Gasket Valve high, in severe operating environments or severe demand applications.
- Page 30 Fig. 12.19 Fig. 12.21 Minimum Oil Level when stopped and cold Minimum Oil Level while running 4. Tighten the Mount Bolts and adjust Pulley Tension as described in procedure below. DRIVE BELT ADJUSTMENT AND 8. Start the compressor. Check the oil level while REPLACEMENT running and add oil as required.
- Page 31 sound an alarm and stop the machine; the Local Failure Fig. 12.24 displays “Pressure too High”. SENSOR FAILURE PROTECTION: If the Pressure Sensor or the Temperature Sensor Cable is broken, the controller will sound an alarm and stop the machine: the local failure displays “xxx sensor failure”.
- Page 32 Maintenance cycle Remarks Checking Working content Day Week Month Half Items Year Year Years Fastener Check the bolts The bolts and transmission components can’t fall off or transmission loosen. components Coupling Check the Concentricity is normal with coupling no damage Strainer of No sundries oil return...
- Page 33 Maintenance cycle Remarks Checking Working content Day Week Month Half Items Year Year Years Mechanical Checking the The quantity of oil leakage is seal for the leakage less than 1.5g/h host machine Motor Checking the More than 2MΩ when the insulation isulation voltage is 500V...
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Page 36: Parts List And Electric Diagrams
RS7580H603 SCREW COMPRESSOR PARTS LIST... - Page 37 RS7580H603 SCREW COMPRESSOR PARTS LIST...
- Page 38 RS7580H603 SCREW COMPRESSOR PARTS LIST...
- Page 39 List of the parts of Permanent magnet synchronous type screw RS7580H603 SCREW COMPRESSOR PARTS LIST machine S.N. Name Quantity S.N. Name Quantity front shutter Oil mirror Vertical shaft on left Oil inlet plug of side of the front shutter Oil-gas barrel...
- Page 40 RS7580H603 SCREW COMPRESSOR PARTS LIST...
- Page 41 RS7580H603 SCREW COMPRESSOR PARTS LIST...
- Page 42 RS7580H603 COMPRESSOR ELECTRIC DIAGRAM...
- Page 43 RS7580H603 COMPRESSOR ELECTRIC DIAGRAM...
- Page 44 RS7580H603 COMPRESSOR ELECTRIC DIAGRAM...
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Page 46: Maintenance/Inspection Records
MAINTENANCE / INSPECTION RECORDS ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________... - Page 47 MAINTENANCE / INSPECTION RECORDS ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________ ____________________________________________________________________...
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