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Anest Iwata EPM Series Manual

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Installation, Instruction and
Maintenance Manual
EPM Series Air Compressor
This
manual
WARNINGS,
instructions. Read and understand the
instructions manual carefully before use
and retains it for reference
MODEL
SERIAL NO.
DISTRIBUTOR
PURCHASE DATE
OPERATION COMMENCED
contains
IMPORTANT
CAUTIONS
and
other

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Summary of Contents for Anest Iwata EPM Series

  • Page 1 Installation, Instruction and Maintenance Manual EPM Series Air Compressor This manual contains IMPORTANT WARNINGS, CAUTIONS other instructions. Read and understand the instructions manual carefully before use and retains it for reference MODEL SERIAL NO. DISTRIBUTOR PURCHASE DATE OPERATION COMMENCED...
  • Page 2 In addition to the descriptions in the manual, if the user fails to follow the operation and maintenance procedures in the manual for the operation and maintenance, or dismantles and modifies the machine by itself, or uses the parts not specified by Anest Iwata Motherson Company, the user shall loss the right for claims.
  • Page 3 Safety Warning Signs In this manual, the operations and items related to safety are identified for their risks, and they are classified based on the severity of machine damages and the level of injuries caused due to the operations. They are represented and described in boldface with the following signs respectively. “Caution”...
  • Page 4 Safety Tips Please read the following information carefully before operating and using the compressors Warning The risks are present in the compressed air and compressed air system! If you fail to follow the operating procedures and safety precautions in the operation manual, there maybe accidents and injuries to yourself or other persons! Before operating and maintaining the compressors, you must read carefully and understand...

  • Page 5: Table Of Contents

    Content Chapter1 Safety Rules..................Chapter 2 Introduction to System Functions ........... Chapter 3 Installation and Acceptance.............. Chapter 4 Operating Procedures................ Chapter 5 Parameter Setting and Adjustment of Working Conditions ..Chapter 6 Maintenance and Service..............Chapter 7 Troubleshooting...

  • Page 6: Chapter1 Safety Rules

    Chapter 1 Safety Rules 1. General rules The following listed safety measures and safety precautions are only a part of the items which have to be followed for operating the compressors and compressed air system, but are not complete. Warning If you fail to follow the following safety measures, the injuries, property loss or compressor damages will be caused.
  • Page 7 10) Follow the stipulations in the maintenance and repair procedures and periodically inspect all safety devices, ensuring that they are in a good condition. 11) It is never allowed to have the high-temperature protection switch (probe) with the short circuit, blockage or being removed.
  • Page 8 1) If the compressed air produced by the compress or is directly applied for respiration or food processing, then the severe injuries or death will be caused. The compressed air applied for the above purposes shall meet the stipulations in the OSHA 29 CFR1910.134 or FDA 21XDE178.3570 standard. 2) Avoid the skin contact and swallowing the lubricating oil(fluid).

  • Page 9: Chapter 2 Introduction To System Functions

    Procedures in the operation manual. If you have the difficult problems which are not mentioned in the operation manual, please contact the local agent of Anest Iwata Motherson Company or the After-Sales Service Department of Anest Iwata Motherson Company.
  • Page 10 2. Compressor airend and compression cycle The compressor airend is a very important component in the Anest Iwata Motherson compressor unit. The carefully designed single-stage oil-injected cooling and lubricating screw compressor can provide the stable compressed air without air flow ripple. Compared with other brand compressor airends, the unique property of the end selected by the Screw is the extremely high mechanical reliability and durability, and the working component achieves requirements of the “inspection-...
  • Page 11 Therefore, the modification is not allowed unless it is permitted by Anest Iwata Motherson Company. A minimum pressure valve is installed in the downstream of the outlet of oil-gas separator tank and its function is to ensure that a minimum tank pressure will be established in the tank when the compressor is normally operating, ensuring the normal operation of the lubricating oil circuit.
  • Page 12 The after-cooler is applied to reduce the discharge temperature of compressed air and consequently make most of water in the compressed air condense and separate, reducing the water content in the compressed air and avoiding the problem caused by water content in the downstream air. Due to the different cooling method, the after-cooler is classified into two types: air cooling and water cooling.
  • Page 13 Fig2.3 Compressor Cooling and Lubricant System The oil filter consists of a filter base and replaceable spin-on filter core (depending on the size of the model, there may be two or three filter cores) with a built-in by-pass valve which will ensure the unblocked oil circuit and normal operation of the compressor in case that the filter core is dirty or the viscosity of the oil is too high.
  • Page 14 operation of compressor, the radiating fins of cooler shall be kept clean and the maximum operating ambient temperature of compressor shall not exceed 43℃. During the daily maintenance, the surface of cooler shall be periodically cleaned. If necessary, the high-temperature pressurized water not above 3.5 bars can be applied to wash it.
  • Page 15 Do not think if the compressor is not operating, then the maintenance operation on it will be safe, as the compressor may be in the “Standby” status and can start at any time. Please strictly follow all related stipulations in “Maintenance and Service Procedures”.
  • Page 16 7. Electrical system and automatic protection See Fig. 2-6. Electrical system is the system which realize compressor start, stop, parameter display and automatic protection. The system includes the motor, industrial control panel, instrument, contactor, transformers, cables terminals, inverter and various protection switch etc. “Caution”: The related documents are attached when the unit leaves factory.
  • Page 17 compressor stop, when these unexpected situation happen,the compressor will stop automatically, and send fault message. Warning High voltage will cause severe injury and death. Please cut down the power supply before maintaining the electrical apparatus or opening the electrical control box. Warnin Do not remove, bridge, or damage the high-temperature safety switch.

  • Page 18: Chapter 3 Installation And Acceptance

    Chapter 3 Installation and Acceptance 1.Installation, acceptance and storage: In the process from the delivery of machine to the installation in position on site, the correct shutdown maintenance and service contribute to the completion and normal operation of equipment. Therefore, the machine shall be inspected immediately for the damages caused during transportation when it is received.
  • Page 19 down due to over-heat. The spatial dimensions and shape of compressor room shall be carefully considered, to prevent the hot air discharge capacity by cooling fan from circulating in the machine room and consequently causing the rising of operating ambient temperature. In principle, all stationary type screw compressors from Screw are provided for indoor installation and application.
  • Page 20 environment. The accumulated water in the bottom of the parts and components such as oil-gas tank, cooler (especially the water cooler), steam-water separator, pipeline water filter shall be drained out. Individual major parts and components of unit and joints shall be inspected periodically and clean them to ensure no leakage and rust signs.
  • Page 21 If the system requires both a large volume of air and a short time, it’s recommended to install a gas storage ） barrel for buffer to reduce the times of transition from no-load to working load, which may benefit a lot to the air compressor.
  • Page 22 The safety valve shall be located before the potential blockage points, including (but not limited to) the check valve, heat exchanger and discharge silencer. In theory, the safety valve shall be directly connected to the pipes or vessels which bear the pressure, instead of being connected via the pipes. The discharged gas from safety valve shall be led to the safety place far away from the people.
  • Page 23 installation and connection. The local drainage standard and the requirements from the compressor shall be met. It shall be absolutely ensured that the connection of water supply and drainage pipes are correct. “Caution ”: The water temperature regulating valve is located in the water discharge pipe. “Warning”...
  • Page 24 steel-plate straight ruler, Put the gauge Compressor Moto Horizontal view Fig.4 Preliminarycalibration Fine calibration: As shown in Fig. 5, use a small vice or loop chain to fix two micrometer gauges on a half-coupling, or use the magnetic micrometer gauge base. Move a probe to the slight upper position on the end face of the other half-coupling, to measure the angular deviation;...
  • Page 25 The calculation of the distance required for the motor adjustment is described as follows: 1) Measure the revolving diameter D of the probe of “angle” micrometer gauge (relatively smaller than the diameter of half-coupling). It is assumed to be 152mm in that example. 2) Measure the distance L between two mounting bolts in the front and rear of motor.
  • Page 26 support leg in the tail end of motor. For operation, the motor is lifted by the crowbar or hoisting equipment, as shown in Fig. 7. After the adjustment is completed, tighten the mounting bolts as per the order shown in Fig. 8. After the mounting bolts are tightened, use the micrometer gauge to inspect whether the error is within the controlled range.
  • Page 27 9.2 Dismounting for EPM2 motor 1. Put in Copper Sheet-----Remove stator 2. Loose rotor and remove it.

  • Page 28: Chapter 4 Operating Procedures

    “ Warning” ： Please don’t dismount EPM2 motor unless it’s professional technician, The EPM2 motor has strong magnetism, please don’t let your electronic device like cell phone or electrical device to close it. It’s forbidden for the people who use heart pacemaker to dismount and fix it.
  • Page 29 10) Inspect whether all covers and protection devices are safe and secure. 11) Inspect whether the specifications or control current setting of the fuse, breaker and thermal overload protection device is proper and the setting are correct. 12) For the water cooling unit, inspect the water inlet and discharge pipes and ensure that their connections are correct and secure and that the cooling water is turned on.
  • Page 30 Chapter 5 Parameter Setting Please refer to the PLC Manual.

  • Page 31: Chapter 6 Maintenance And Service

    2.1 Lubricating oil of compressor The screw air compressor designed and manufactured by Anest Iwata Motherson can use the Semi-synthetic oil and synthetic oil listed in the below table. Every delivered compressor unit has a lubricating oil tag to indicate the type of lubricating oil filled in the unit.
  • Page 32 6000 ≤43℃ For the compressor unit with standard configuration, the Anest Iwata Motherson lubricating oil is generally added for the delivery. The lubricating oil is the specialized oil for the screw compressor, which is provided specially by the manufacturer. It can provide the reliable operation and a long change interval.
  • Page 33 interface of oil filter. It will exactly reflect the current quality of lubricating oil. New machine is started and operate for 600 hours; Operate every 2000 hours; When the abnormal conditions such as the high oil consumption, oil leakage at shaft seal, and airend locking occur.
  • Page 34 Apply a thin layer of lubricating oil on the surface of new shim. Tighten the filter core by hand for 1/2 - 3/4 turn. Start the machine again and inspect whether the leakage occurs. Warning To reduce the possibility of the damages of filter core to a minimum, only the products provided by Screw Company can be used, because other substitutes may not match the pressure in the unit.
  • Page 35 Every time the vacuum switch of air filter acts, or when the pressure loss reaches 25” water column, or when the indicator is lit, the filter core shall be maintained. When it operates every 500 hours or 3 months, the air filter shall be inspected for the damages and the air inlet system shall be inspected for the sealing;...
  • Page 36 core in the oil-gas separator will not be required. If the following conditions occur to the machine, then it will be required to replace the element of oil-gas separator: The pressure differential switch of separator acts and the pressure differential between the front and rear sides exceeds 1.0kg.
  • Page 37 The Screw compressor from Anest Iwata Motherson Compressor is equipped with an oil return pipeline to match the shaft seal assembly, so that the whole shaft seal has the triple-sealing function. The oil return pipeline shall be inspected for the maintenance and replacement of shaft seal.
  • Page 38 3. Serviceplan Every day Record the operating status of machine every day. See Table 6-2 for the detailed contents of record. Clean the dust-collecting bag of air filter or the inlet silencing chamber. It is not allowed to start the machine without air filter.
  • Page 39 temperature Discharge ≤95℃ temperature Green area Oil level Drainage period of 1-2 seconds electronic water discharge valve 6) Preparations for the long-term shutdown If the interval between shutdown and restart is relatively long, please turn on the manual switch of the (electronic) water (waste-water) discharge valve before the shutdown, and allow the draining period not to be less than 5 minutes, ensuring...
  • Page 40 4. Maintenance Standards...

  • Page 41: Chapter 7 Troubleshooting

    Chapter 7 Troubleshooting...
  • Page 42 Failure 2: Oil over-consumption...
  • Page 43 Failure 3: Overload or blockage of main motor...
  • Page 44 Failure 4: Abnormal shutdown during operation...
  • Page 45 Failure 5: Low air output...
  • Page 46 Failure 6: No indication on display screen...
  • Page 47 Failure 7: Indicating the data without starting (failing to start)
  • Page 48 Failure 8: Too low pressure in air tank Failure 9: Too high pressure in air tank...
  • Page 49 Failure 10: Frequent blockages in oil/air separator...
  • Page 50 Failure 11: Frequent blockages in oil filter Failure 12: Frequent blockages in air filter...
  • Page 51 Failure 13: Excessive water content in compressed air at discharge end Failure 14: Abnormal opening of safety valve...
  • Page 52 Failure 15: Abnormal noises in the air compressor Failure 16: Oil injection in suction valve during shutdown...
  • Page 53 For any details reach us at: Head Office: +91-120-4600-500/510/511/512/518 Anest Iwata Motherson Pvt. Ltd. North +91-9910394044 +91-9871362399 B-123 & 124, Sector-63, Noida - 201301, East +91-9899553261 +91-9990023423 Distt. Gautam Budh Nagar, UP, India. West +91-9899553276 +91-9899553648 Email: anestiwata@aim.motherson.com Web: www.aimcompressors.com...