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Operating Instructions
ROTARY SCREW
COMPRESSORS
Polar Air 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.
08.29.13 Rev. 0.2
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Table of Contents
Related Manuals for Emax PRS0070001
Summary of Contents for Emax PRS0070001
- Page 1 Operating Instructions ROTARY SCREW COMPRESSORS Polar Air 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.
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Page 3: Table Of Contents
Polar Air Rotary Screw Compressors Contents Page No Page No Working Timer – Unloading Delay ..12 Variable Speed Drive Information ....1 Maintenance Notifications ...... 13 Model Specification Charts ..... 2-3 Resetting Maintenance Alarms ..13-15 Safety Information ........4 Mechanical Components .... -
Page 4: Model Specification Charts
Operating Instructions Polar Air Rotary Screw Systems: 5 Hp - 20 Hp (VSD Compliant) Model No. PRS0070001 PRS0100001 PRS0070003 PRS0100003 PRS0150003 PRS0200003 Description Single Phase Single Phase Three Phase Three Phase Three Phase Three Phase Dual Voltage Dual Voltage Dual Voltage Dual Voltage Dual Voltage Motor 7.5HP 10HP 7.5HP 10HP 15HP 20HP Amp Draw... - Page 5 Polar Air Rotary Screw Compressors Polar Air Rotary Screw Systems: 75 Hp - 200 Hp (VSD Compliant) Model No. PRS0750003 PRS1000003 PRS1250003 PRS1500003 PRS1750003 PRS2000003 Description Three Phase Three Phase Three Phase Three Phase Three Phase Three Phase Dual Voltage Dual Voltage Dual Voltage Dual Voltage Dual Voltage Dual Voltage Motor 75HP 100HP 125HP 150HP 175HP...
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Page 6: Safety Information
Operating Instructions 3. Install, use and operate the compressor Safety only in full compliance with all pertinent This manual contains very important information OSHA regulations and all applicable on SAFETY and how to PREVENT Federal, State & Local codes, standards EQUIPMENT PROBLEMS. -
Page 7: Inspection
Polar Air Rotary Screw Compressors 3. Use provided lifting feature or appropriate Inspection sling. A sling must be used when moving Prior to using the compressor, check for external compressor with a helicopter or other air- damage that might have occurred during transit. borne equipment. -
Page 8: Installation
Operating Instructions Installation 2. Clearances around compressor. At least: 24 inches sides and back Area Exhaust air from this unit can be used to 3 feet in front of compressor. supplement environment heat. Install unit in This compressor unit is equipped separate room then create duct system as shown in with internal rubber vibration isolators. -
Page 9: Oil Check
Polar Air Rotary Screw Compressors Ball 3. Install appropriate ASME code safety To Shop Ball Valve Piping valves and adequate condensate drains on Valve piping system. 4. Never use reducers in discharge piping. Rotary Keep all piping and fittings the same size Screw Storage in the piping system to help prevent... -
Page 10: Electrical Installation
Operating Instructions Wiring for Variable Speed Drive or typical Wye- Labels on Delta Start. See page 1 for advantages of VSD. tank show proper oil levels. Oil Wye-Delta Start should be near bottom of sight tube when running. Figure 6: Sight Tube for Lubricating Oil Use only Polar Air oil, model no. -
Page 11: Motor Rotation
Polar Air Rotary Screw Compressors Motor Rotation Lubrication Process After electrical installation is complete, check Pressure in the oil/air separator presses lubricating the direction of the motor rotation. oil into the oil cooler. The oil is cooled and 1. Lightly push START and STOP filtered then divided into two parts. -
Page 12: Setting: O C/ O F; Bar/Psi; Lang; Time/Date
Operating Instructions Setting: F; BAR/PSI; Language; Time/Date 4. Now the current flashing gauge pressure setting, BAR (metric) or PSI (Am. Std) shows in display. Use the Up & Down 1. Main screen starting point. arrows to change, if desired, and then press Enter to set the value. -
Page 13: Working Pressures
Polar Air Rotary Screw Compressors Working Pressures 4. Arrow down to 0)WORKING These pressures settings are the compressor’s PRESSURES and press Enter. operating pressure settings, Top Range Transducer, High Pressure Alarm, Stop Pressure, etc. (See chart on page 13 of PLC manual.) 1. -
Page 14: Working Timer - Unloading Delay
Operating Instructions Working Timer - Unloading Delay Enter in the 6 Digit Password 6 6 6 6 6 6, by To reduce wear & tear of the compressor using the Up Arrow to set the digit to 6 then press components, an unloading delay time is set in the Enter to move to the next digit, and press the Up controls that shuts-down the compressor after the... -
Page 15: Maintenance Notifications
Polar Air Rotary Screw Compressors Following replacement times are important for 8. Enter in the 6 Digit Password 6 6 6 6 6 6, safe operation. Remember to clear lifetime and by using the Up Arrow to set the digit to 6 reset maintenance timer after replacements are then press Enter to move to the next digit, made. - Page 16 Operating Instructions Resetting Maintenance Alarms (Continued) 12. Press Down Arrow and CHANGE OIL 16. Press Down Arrow and CHANGE OIL FILTER shows in the display. Press Enter. FILTER shows in the display, but the first Line is C--=. This is the screen for the oil life.
- Page 17 Polar Air Rotary Screw Compressors Resetting Maintenance Alarms (Continued) 21. Using Enter move over to NO and use the 19. Using Enter move over to NO and use the Up Arrow to change it to YES then hit Up Arrow to change it to YES then hit Enter and it resets the hours.
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Page 18: Mechanical Components
Operating Instructions Mechanical Components Side View End View Figure 9: Mechanical Systems Components 1. Drive Motor Resetting Overload Protection Drive motor is 4 pole with low RPM (1750). This motor is also capable of variable speed Disconnect, tag & lock out drive as a standard feature. - Page 19 Polar Air Rotary Screw Compressors Mechanical Components (Continued) A. Absorption 2. Variable Speed Drive (Energy saving device) The position and shape of the rotor shafts Ready Cabinet allow maximum air intake from the inlet This cabinet has allocated space and cooling port.
- Page 20 Operating Instructions Mechanical Components (Continued) Use only Polar Air oil, model no. 7. Exhaust Probe (Continued) Oil003. For food manufacturing applications, use It is important to keep the circulating fan and model no. Oil001. Use of any other product cooler fins clean to prevent the compressor causes product damage and voids the warranty.
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Page 21: Operation
Polar Air Rotary Screw Compressors Mechanical Components (Continued) Operation 14. Check Valve (Continued) a) Actuates oil lubrication of the air end. Safety Rules b) Regulates air flow through the air 1. Make sure all operators receive product separator filter to prevent damage to the training, read and understand all separator filter element. -
Page 22: Initial Checks
Operating Instructions Safety Rules (Continued) Initial Checks 9. Stop compressor and disconnect power if a Be sure to make physical checks of the com- hazardous condition arises. pressor to avoid serious failure before start-up. 10. Wear snug fitting clothing and confine 1. -
Page 23: Start-Up
Polar Air Rotary Screw Compressors Start-Up Storage 1. Slightly open drain valve on air/oil 1. If the machine is stopped for over three separator tank to drain any condensed weeks: water. Failure to do this shortens service a) Wrap electrical equipment such as the life of lubricating oil and destroy the control panel with plastic or oil paper bearings. -
Page 24: Lubricating Oil
Operating Instructions Safety Steps (Continued) Compressor components can 1. Make sure repairs are done in a clean, dry, become hot during operation. well lighted and ventilated area. Avoid bodily contact with hot 2. When cleaning, use air pressure less than liquids, hot surfaces and sharp 30 psig (2.1bar). -
Page 25: Belts
Polar Air Rotary Screw Compressors Air/Oil Separator Filter Use only Polar Air oil, model no.Oil003. For food manufacturing applications, Air/Oil Separator tank is a use model no. Oil001. Use of any other product pressurized component. To causes product damage and voids the warranty. avoid serious injury, be Refer to warranty statement for oil requirements. -
Page 26: Maintenance Schedule
Maintenance Schedule Daily Check oil level Check safety valve Check coolant level Drain condensed water Weekly Clean air filter General unit cleaning Check belt tension 500 hrs. Change lubricating oil (after first 500 hrs.) Grease electric motor bearings ... -
Page 27: Troubleshooting Chart
Polar Air Rotary Screw Compressors Troubleshooting Chart Problem Possible Causes Resolutions Compressor will not start (Electric failure light is 1. Power supply problem 1. Check complete circuit for proper voltage, ensure all electrical connections are secure; once power is restored, press Enter button on controls. - Page 28 Operating Instructions Troubleshooting Chart Problem Possible Causes Resolutions Compressor shuts 2. Loss of Control Voltage 2. Reset-Press Enter button on controls. If down under trouble persists, check line pressure does compression not exceed maximum operating pressure of mode/while loading the compressor (specified on nameplate) (Continued) 3.
- Page 29 Polar Air Rotary Screw Compressors Troubleshooting Chart Problem Possible Causes Resolutions Line pressure exceeds upper preset safety limit 5. High pressure shut-down preset 5. Reset to proper setting. Refer to PLC (Continued) is incorrectly programmed manual. 6. Additional compressor piped 6.
- Page 30 Operating Instructions Troubleshooting Chart Problem Possible Causes Resolutions Excessive oil 4. Oil level too high 4. Drain oil then check at sight glass for consumption proper level (Continued) 5. Lubrication system leak 5. Check all pipes, connections and components. Repair as needed 6.
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Page 31: Wiring Diagrams
Polar Air Rotary Screw Compressors Troubleshooting Chart Problem Possible Causes Resolutions Excessive vibration 1. Loose component mounting 1. Inspect & tighten 2. Motor or compressor bearing 2. Replace bearing; Contact Eaton failure Compressor 3. External sources 3. Check for other sources of vibration, other than the compressor 4. - Page 32 Operating Instructions...
- Page 33 Polar Air Rotary Screw Compressors...
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- Page 35 Polar Air Rotary Screw Compressors...
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Page 36: Warranty
Operating Instructions Warranty Statement EATON COMPRESSOR AND FABRICATION CO., INC. (and each of its subsidiaries, including POLAR AIR COMPRESSORS, INC.) makes the following Warranties: 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.
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