IMC IMCAHB-10 Series Operation Manual

Air compressor machinery

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IMCAHB-10 Series of Air Compressor

Machinery

INTERNATIONAL MACHINE CONCEPTS WELCOMES YOU TO YOUR NEW

MACHINE

Operation Manual: Date 2015. Version 1. Serial Number

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Page 1 IMCAHB-10 Series of Air Compressor Machinery INTERNATIONAL MACHINE CONCEPTS WELCOMES YOU TO YOUR NEW MACHINE Operation Manual: Date 2015. Version 1. Serial Number...
Page 2: Table Of Contents
CONTENTS Chapter 1 Machine Description Uncrating Instructions Installation Electrical and Pneumatic connections Chapter 2 Compressor dimensions Chapter 3 Operation Instruction The air process The process of the lubrication oil Safe protection system and warming devices Control system Operation Computer control Chapter 4 Malfunctions (Faults) and their rectification Table of possible faults...
Page 3: Machine Description
Chapter 1 Machine Description 1. The brief introduction of a oil screw type air compressor The oil screw type compressor is characterized by reliable operation performance, less wearing parts, low vibration, low noise and high efficiency. During the compression course, the compressor continuously injects lubrication oil into a compression chamber and bearings by means of the pressure difference generated.
Page 4 (2) Intermeshing An electric motor, drives the main rotor through the coupling, or belts. As the two rotors are intermeshed with each other, the main rotor directly drives the sub rotor to rotate together. The cooling lubrication oil is directly injected into the intermeshing part via a nozzle, from the lower part of the casing of the compressor.
Page 5: Uncrating Instructions
During the conveyance course, the intermeshing surface is gradually moved toward the air exhaust end. Namely, the space between the intermeshing surface and the tooth grooves between the air exhaust ports gradually becomes small. The air in the tooth grooves is gradually compressed, and the pressure is increased. This course is called ‘the compression course’.
Page 6: Installation
an oil coating on the surface to safeguard the machine from corrosion. This can now be removed with a very light detergent. The non-stainless steel parts should be re-oiled to prevent rusting taking place after cleaning. Do not leave the machine wet. The machine is top-heavy and as such, care should be taken when handling the machine and removing it from its wooden pallet.
Page 7  Pneumatic connections should take place as the designated connection. The air should not be less than 6Bar while the machine is operational. Air should be free of water and contaminants.  The machine should be placed on level ground. After installing the machine, check if the machine is level by Level Instrument.
Page 8 decreasing the air exhaust temperature. The air with relative low temperature and less moisture content can enter into the dryer again, which can reduce the load of the dryer. Follow directional arrow at the top of the coalescing filter to ensure proper air flow direction.
Page 9: Electrical And Pneumatic Connections
Electrical and Pneumatic connections This machine requires only a single phase connection and earth wire  DISCLAIMER IMC will not be held responsible fir incorrect installation and subsequent failure of the machine due to any installation procedure not being followed.
Page 10: Compressor Dimensions
Chapter 2 2.1 Compressor dimensions Chapter 3 3.1 The air process After dust is removed from the air by the suction filter, the air enters into a suction valve to be compressed and mixed with the lubrication oil. The mixed oil and compressed air enters into an air / oil separator tank, then passes through an oil fine separator, a minimum pressure valve, a rear-part cooler and then a water separator and enters into the usable air flow.
Page 11 after servicing. And then the operating time of the machine is modified every 2000 hours. The air compressor can automatically give an alarm to remind the user to replace the air filter on the suction valve. After replacing the air suction filter, the user must modify the resetting time of the air suction filter on the PLC as ‘zero’...
Page 12 The Flow Chart of AH10A Compressor System...
Page 13 The oil separator filter. Please refer to the details of the oil / separator filter located in the drawings in this manual. Safety valve. When the pressure in the oil / separator tank is over 175 PSI or 12.1 bar, the ASME certified safety valve will open immediately, which facilitates the pressure to fall below the air exhaust pressure.
Page 14: The Process Of The Lubrication Oil
the load of the dryer. A larger tank also reduces the cycling of the suction valve. A general rule; for every CFM the compressor produces you will need at minimum 1.2 gallons of air storage. Refrigerated Dryer (optional) / coalescing filter (optional) The refrigerated dryer can remove moisture content.
Page 15 been operated for 500 hours for the first time, then the oil and the oil filter are set to be replaced each 2000 hours. The settings on the control must be modified after the filtering core is replaced for the first time. The presetting time of the oil filter is modified as 2000 hours.
Page 16: Safe Protection System And Warming Devices
The replacing period of the lubrication oil is generally set as 2000 hours. The lubrication oil needs to be replaced after the new oil / air separator tank has been operated for the initial 500 hours. The settings on the control must be modified after the filtering core is replaced for the first time.
Page 17: Control System
If the electric motors are found to be overloaded during the operation, the user should immediately get in touch with the manufacturer. High exhaust temperature parameter. The highest air exhaust temperature set for the system is 210 F and 98.8 C. If the temperature exceeds 210 F and 98.8 C, the system will automatically switch off the power.
Page 18 separator tank is gradually increased to 0.2Mpa, the suction valve is all opened. Therefore, the pressure in the oil-gas barrel is increased rapidly, and the compressor is started to run in full load. When the pressure is increased to over 0.3Mpa, the minimum pressure valves are all opened and the air is output.
Page 19: Operation
3.5 Operation Rules of safety operation: The operator should establish the rules of safety operation in details to avoid injury, accidents and machine damage. The following are suggestions for reference: The operator should receive strict training beforehand and read up and understand specifications;...
Page 20 stop the machine and inspect the machine if he finds abnormal voice, vibration or oil leakage. The air exhaust temperature should be maintained between 70 degrees Celsius 158 degrees Fahrenheit and 95 Celsius and 203 degrees Fahrenheit. In 10-15 seconds after the pushbutton ‘OFF’ is pressed, a time switch is run, and the electric motor will be halted.
Page 21: Computer Control
The operator should inspect instruments and record the values of voltage, current, air pressure, the air exhaust temperature and the oil level which are provided for reference in the future. Long term stoppage or non use. If the machine has been stopped for a long time, please care for the machine according to the following methods.
Page 22 Conditions: Surrounding temperature: Between 32 degrees Fahrenheit or 0 degrees Celsius and 104 degrees Fahrenheit and 40 degrees Celsius. Relative moisture： Should not exceed 95% On-site conditions: the place has no notable shake, shock vibration, intense magnetic field and intense electric field. The installation place should have no explosion medium, dangerous medium, deep-etching metal and gas damaging the insulation.
Page 23 The adjusting range of excess pressure delay time: 0-99 minutes; The adjusting range of restarting-up delay time: 0-99 minutes; The adjusting range of machine-halt delay time: 0-99 minutes; (M) The adjusting range of timing drainage spacing time: 0-99 minutes; (N) The adjusting range of timing drainage time: 0-99 seconds; (O) Input range of the use time of the filters: 0-9999 hours;...
Page 24: Malfunctions (Faults) And Their Rectification
Chapter 4 4.1.1 Malfunctions (Faults) and their rectification Fault Rectification Machines will not switch on Check power supply to machine Check main isolator is in a reset position Check emergency stop is not pushed(turned) Machine is on, but the machine will not run Have you pushed the Start push button Main motor should be running, if not, main motor could be faulty.
Page 25 The compressor automatically trips because Trouble Shoot: of high running current (the electric failure 1. The voltage is too low. lamp is alight). 2 .The air exhaust pressure has been too high. 3. The specification of the lubrication oil has been incorrect.
Page 26 into the suction valve. The air exhaust temperature is lower than Trouble Shoot: the normal value (being lower than 75℃) 1. The compressor has no load too long. 2. There has been deviation in the display of the temperature sensor. Resolutions: 1 .The excess pressure motor stoppage time should be reset.
Page 27 8. The specification of the lubrication oil has been incorrect. Resolutions: 1. The oil surface should be inspected and released to be between H and L. 2. The orifice should be assembled and cleaned. 3. The air exhaust pressure should be inspected. If necessary, the air exhaust pressure should be regulated.
Page 28 5. The suction valve should be assembled and cleaned. After that, the lubrication oil grease should be injected into the suction valve. 6. After the minimum pressure valve is assembled, whether the valve base and a check valve plate are worn out should be inspected. 7.
Page 29 5. The vent valve has been leaked. Resolutions: 1. The air inlet filter should be cleaned or replaced. 2. The suction valve should be assembled and cleaned. After that, the lubrication oil should be injected into the suction valve. 3. The minimum pressure valve should be assembled.
Page 30 not should be inspected. If being blocked, the suction valve should be assembled and cleaned. After that, the lubrication oil grease should be injected into the suction valve. 3. The three direction magnetic valve should be inspected. If necessary, the three direction magnetic valve should be replaced.
Page 31 (4) Considerations for lubrication oil A sample of the oil can be sent to our company to have the oil tested, and the quality of the lubrication oil is determined after the oil has been used for 1000 hours (B) Do not exceed life of oil lubricant, the oil should be replaced on time.
Page 32 Maintenance and Safety Guidelines Proper maintenance is required to maintain function and longevity of the AIRHORSE rotary screw compressor. Maintenance is mandatory to insure all aspects of AIRHORSE warranty will be covered. Warning ! Prior to any service, the compressor must be locked and tagged out. This compressor must not be maintenance while under power, moving belts and pullies are hazardous when machine is powered.
Page 33: Electrical Diagrams
Chapter 6 6.1 Electrical Diagrams...