Chapter 1. General Rules and Specifications of AirHorse rotary screw air compressor ‘The brief introduction of a oil screw type a The oil screw type compressor is characterized by relisble operation perfor compressor noise and high efficiency. During the compression course, the co compression chamber and bearings by means of the pressure difference generat effects as following (1). Lubrication effect: the lubrication oil can form oil film between rotors, which avoid the cont reduce friction (2) Sealing effect: the oil film generated by the lubrication oil can have the effect of sealing the compressed arr, which} improves the volumetric efficiency of the compressor. | |. the compression course is almost (3) Cooling effect: as the lubrication oil absorbs a large quantity of compression he: the the same as the course of isothermal compression, wivich reduces the specific power of the compressor, Moreove lubrication oil also can reduce the noise generated by high frequency compression ‘The structure of the engine body of the oil screw type air compressor (1). The basic structure AirHorse has adopted the oil screw type ait compressor which is a two shaft positive replacement rotary type compressor. An air inlet is opened on the upper air end of the air end casing, and an air outlet is opened at the lower Part of the casing. A pair of high precision main (male) rotor and sub (female) rotors is horizontally and parallel installed in the internal part of the casing The main (male) rotor has five shaped teeth while the sub (female) rotor hhas six shaped teeth. The main rotor has relatively large diameter, and the sub rotor has relatively small diameter. The shaped tecth are in the helix-shaped and circle around the outer edges of the rotors. The teeth of the shape teeth and outer edges are intermeshed with each other. The ends of the main rotor and sub rotor are supported by bearings. Air intake ends have one roller bearing, and air exhaust ends have two tapered roller bearings which are installed symmetrically. In total, the engine body of the compressor has two kinds. One kind of the engine body is a belt driven type engine body, and the other kind of the engine body is direct-fastened driven type engine body. The direct-fastened driven type engine body utilizes one coupling to combine the power source of an electric motor and, the main engine body together and improves the rotary speed of the main rotor through one group of high precision increasing gears. However, the belt driven type engine body has no the increasing gears. The belt driven type rotary ja pulleys through belt drive, which are manufactured according to rpm speed and screw compressor powers proportion to the horse power of the unit. (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. Oil is mixed with the air, takes along the heat generated by compression and reaches the cooling effect. Meanwhile, the cooling lubrication oil forms the oil film, which prevents the direct metal contact between the rotors and prevents the clearance between the sealing rotors and between the rotors and the casing. The injected lubrication oil can also reduce the noise generated | by the compression in high speed. Because of the difference of the air exhaust pressure, all the weight of the injected | oil is 5-10 times larger than that of the air. |A) @) | © ©) 3. The compression principles of the screw type compressor The course of absorbing the air. An air suction port on the air suction side of the screw type compressor is designed as the compression chamber can fully absorb the air, However, the screw type compressor has a suction valve and an internal check valve to prevent air back flow, The intake valve is regu ited from a sylinoid valve which opens and closes the suction valve, When id as the rotors are the rotors are rotated, the space of the tooth grooves of the main rotor and sub rotor is maxin rotated into an open intake end wall, At that time, the space of the tooth grooves cin the rotors is produced with the free air in the air inlet. Therefore, the air in the tooth groove is totally taken out when the air is exhausted. After the air is completely exhausted, the tooth grooves are still under a vacuum state, When the rotors are rotated into the air inlet, the outside air is absorbed and flows into the tooth grooves of the main rotor and the sub rotor. When the air is, full in the tooth grooves, the air intake side end surfaces of the rotors are rotated away from the air inlet of the casing, and the air between the tooth grooves is sealed. The above course is called as the ‘the course of absorbing the ai ‘The course of sealing and conveyance. When the main rotor and the sub rotor complete air suction, the tooth peaks of the main rotor and sub rotor and the casing will be sealed together. At that time, the air is sealed in the tooth groove and eliminates back flow. This course is called ‘the sealing course’. The two rotors are continuously rotated. The tooth peaks and the tooth grooves are inosculated with each other at the air suction end. The inosculating surface is gradually moved toward the air exhaust end. This course is called as ‘the conveyance course” ‘The course of compression and injecting oil 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’. Meanwhile, the lubrication oil is also injected into the compression chamber to be mixed with the air, because of this action of the pressure difference when the air is compressed. The course of the air exhaust When the intermeshing end surface of the rotors is rotated and with the air exhaust ports of the casing (the pressure of the compressed air is the highest at this time), the compressed air starts being exhausted until the intermeshing surface between the tooth peaks and the tooth grooves is moved to the air exhaust end surfaces. At that time, the space between the intermeshing surface between the two rotors and the tooth grooves, between the air exhaust port of the casing is zero. Then the course of the air exhaust” is completed. Meanwhile, the length between the intermeshing surface of the rotors and the tooth grooves between the air inet of the casing reaches the maximum length. However, the course of absorbing the air is continuing, (1), The course of absorbing the air; (2). The course of s ance: (3), The course of compression id injecting oil; (4). The course of ait exhaust.Chapter 2. Installation of the air compressor 1. Installation Prior to installation Inspect compressor prior to any use, check for external damage that may occur during transit. A forklift may be necessary fo unloading your new AIRHORSE compressor, please use all forklift safety measures and require a certified forklift operato operates the fork lift. Refer to diagrams below for forklift operation including wood block on forks to prevent damage. The selection of installation pl (1) The compressor room should have adequate space and sound ligl (2) The selected place should have low relative humidity, less dust, clean air and sound ventilation. (3) The surrounding temperature of the selected place must be lower than 45 degrees Celsius and 113 degrees Fahrenheit. And never lower than 0 Celsius and 33 Fahrenheit. (4) If installing in a dusty or dirty environment it is recommended to install in a separate clean and well ventilated room or environment. It is imperative to the overall performance and longevity of the unit and warranty coverage, (5) Allow at least fifteen inches or 75 mm space around the compressor to ensure easy access for maintenance. (6) Allow at least three feet or one meter of space at front or head of the compressor. 2. Piping your compressor (1) The considerations of the tubing and air pipelines (A): When the main pipelines are tube, the degree of the inclination of the pipelines should be 1-2°, which offer advantage for draining the condensed water in the pipelines. (B) The pressure fall of the tube pipelines must not be 5% greater than the set pressure of the compressor. Therefore, Isthe Felative large designed pipe diameter must be selected when the tubing is implemented this will avord large (C)__ Sub-line pipelines must extend out of the top ends of the main pipelines, which do not allow the condensed water in the pipelines to flow into the working machine or reflow into the compressor. (D) The tools needing to be lubricated must be installed with a three-element assembly (an air water-filtering filter, a pressure regulator and an oil feeder) to maintain the service life of the tools. (E) Any lines run from the main line must be smaller in size than the main line. Otherwise, there is the mixed flow at the adapters, which causes pressure drop. (F) If there is purification and cushion equipment behind the air compressor, such as an air storage tank and a dryer. ‘The ideal tubing must be ‘air compressor + the air storage tank + coalescing filter + the inlet side of the dryer’ so that the air storage tank can filter out part of the condensed water. Meanwhile, the air storage tank also has the function of 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. (G)_If the use level of the air in the system is very high in a short period of time. One air storage tank may not be sufficient, and a second tank will be necessary for the high air demand. (H) Limit the use of pipelines and valves as much as possible to reduce the loss of the pressure. @® Closed loop piping system is the proffered piping system. This will allow a shorter distance for the air to travel which will reduce air pressure loss. 2) The base (A) The base must be built on the hard flat surface. (B) _ If the air compressor is installed above the first floor of a building, vibration insulation must be implemented. therefore, the vibration is prevented from being transmitted to the lower floors or resonance vibration is prevented from being generated, which offers safety for the air compressor and the building. (C) A Screw type air compressor generates very small vibration; therefore, the base insulation may not be necessary. (3) Air cooling system 3. ‘The general specifications and precautions for electric appliances a) @) @) drops in pressure However, the ground on which the Screw type air compressor is placed must be a hard and level surface. The air cooled compressor is cooled with oil and oil cooler. Oil level must be full on sight glass located the air oil separator tank. Unit should be tumed off to reflect correct oil reading. For best results check oil after at least two hour shut off, this allows air and oil to separate providing a more accurate reading. Please use AIRHORSE oil and do not mix oils, to ensure warranty is validated. Using improper oil can cause rotors to varnish and can cause pump failure. Compressor room must have adequate ventilation and space for servicing the unit. (See installation) Air cooled oil cooler / after cooler must remain clean and allow adequate air flow through the cooler th the oil to cool properly. allows Wire in accordance to NEC and local jurisdi ion codes, Only authorized AIRHORSE service personnel or a certified electrician should install electrical components. The correct diameter or gauge of the wire must be selected according to the power and or amp load of the compressor, including the distance between compressor and power supply. Amp load information is located on the motor Identification name tag, Use proper breaker or fuse size for power supply to compressor. 16(4) (5) © a” This unit must not be wired in parallel with any other electrical equipment. This unit must be on its own dedicated circuit. Failure to wire unit independently can cause circuit overload and or an imbalance in the phasing. The proper no fuse breaker (NFB) must be arranged according to the KW of the compressor to maintain the electric power system for safety. Always confirm correct voltage. The ground wire of the electric motor or the system must be actually arranged, and the ground wire must not be directly connected with air delivery pipes or water-cooling pipes. A properly ground wire must be connected to the electrical box in the rotary screw electrical cabinet. Failure to follow this procedure may result in injury or death. : Normally, the current must not be 3% higher than the rated current if the three-phase current motor is operated under overload. If the three phase current is unbalanced, the ratio between the lower phase current and the highest phase current must not be over 5%. Meanwhile, the voltage drop must not be 5% less than the rated voltage.Chapter 3. The system process 1. The system process The air process (refer to the flow charts of the systems in various models) (A) After dust is removed from the air by the suction filter, the air enters into a suction valve to be compressed and (B) (c) 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. The description of each module of a passage of main air supply An air suction filter ‘The air suction filter is a dry type paper filter, the filtration of the AIRHORSE intake air filter is 10pm. The intake filter is replaced each 2000 hours; however after the first 500 hours of use the air filter must be changed. Please use the computer parameters as a guide for servicing your AIR HORSE rotary screw compressor and remember to set computer to back to zero 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’ it is recommended to change filters with greater frequency if compressor has been exposed to dit or dust. A suction valve (C) Starting the empty compressor When the compressor has started, the suction valve is under a closed state, which facilitates the compressor to be started up under low load. Therefore, the load of the electric motor is reduced when the motor is started up, which offers lower load levels for normal operation of the electric motor. (D) The conversion between the empty compressor and the full compressor After the compressor has started, the suction valve is opened immediately, the compressor is converted to capacity for air compression, and namely, the compressor is under the state of normal operation, The automatic pressure relief of the machine is stopped and the built in intemal check valve prevents air from flowing back into the air / oil separator tank. (E) After the machine shuts down, the suction valve can rapidly relieve the air pressure of the air/ oil separator tank so that the electric motor will not be overloaded during start up. Meanwhile, the compressed air in the air / oil separator tank can prevent back flow, back flow causes the’rotors to be rolled back and the air containing the oil is injected out ftom the air suction filter, A temperature sensitive exhaust air probe, located atthe air outlet of the rotary screw casing. When the air exhaust temperature is too high, the air end may be damaged, and the system will automatically shut down, The high shut down safety temperature is generally set at 230 degrees F and 110 C. The temperature of the air exhaust can be read on a display panel located on the PLC.‘The Flow Chart of AH7.SA/10A Compressor System yy ouy | 4sjow ouoape ue ‘AA URE phadipqy emmsow ( Huy Qyfel--$-------- aNBNIEUYT 55m y—fnnnnnnnnnnn yoyno ye uy! 9P%V ] | sassep joarop r ‘ecu moepve " (| somos anssaidy 9 | 1 KKpoq euue ue 4p Aaynd yea y euBue Ph PIU BUYnoose ( Tor BARNET" 000 Pano BUY iid 0 sosuas eunssaud y : ie nen aunssad WnWjUW y) () F) @) (H) a The oil /air separator tank Oil level glasses are installed at the side of the oil / air separator tank. The oil level must not be lower than the high oil level of an oil level indicator, when unit is shut down. When the machine is operated, the oil level line must be between the high oil level line and the lowest oil level line. An oil drain valve is installed under the air oil separator tank. The oil drain valve must be tured on slightly to drain the condensed water in the oil / air separator tank this drain valve will also be used to gather oil for oil analysis. 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, thé ASME certified safety valve will ‘open immediately, which facilitates the pressure to fall below the air exhaust pressure. The ASME certified safety valve must not be regulated because the safety valve has been pre set and sealed ‘The blow down valve. ‘The blow down valve is a two-way valve normally opened. When the machine is shut down or the compressor is empty, the vent valve is opened and relieves the pressure in the air / oil separator tank which ensures the compressor will not be started under load. A minimum pressure check valve is positioned at the oll fine separator on the oil /air separator tank. The starting pressure is set at over 43.5 PSI / 3 bar. The functions of the minimum pressure valve are as follows: a) The minimum pressure check valve performs the oil lubrication of the air end. This minimum pressure check valve allows back pressure for the air / oil separator tank the back pressure is needed for proper circulation and lubrication of the il tothe air end. b) The minimum pressure check valve also slows the air flowing through the air separator filter, this is necessary to prevent damage to the separator filter element. Air flow is dependant on a minimuin pressure within the ar / oil separator tank and will only start after the pressure reaches over 43.5 PSI /3 bar. ‘The final use of a minimum pressure check valve is to keep back flow from the air receiver tank into the air / oil separator tank. After cooler ‘The air exiting the oil / air separator tank enters the minimum pressure check valve and enters the after cooler. ‘The fan on the air cooled after cooler radiator, pumps ambient air and blows it through the radiator cores. These cores absorb heat from the exhaust of the rotary screw pump, heat is discharged from the screw cabinet via the fan, This process generally reduces air temperature by 60 degrees F and 15 degrees C. The air cooled screw compressor is relatively sensitive to the environmental temperature, Therefore, the ventilation conditions must be noted when selecting an operating environment for your unit. ‘The air storage tank (optional) ‘The tank can store a certain quantity of air and functions as cushion. Furthermore, the output pressure of the tank is relatively stable. Meanwhile, the tank can reduce the temperature that is compressed, remove moisture content, dust ‘and impurities in the and also can reduce 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. The coalescing filter removes oil droplets and impurities in theCompressed air The reffigerated dyer 7 coalescing filter operates best with an automatic drain that removes water condensation collected during the air drying process. (2). The process of the lubrication oil (refer to the flow charts of systems in various models) a) @) The description of the oil-injection process Because the pressure in the oil / air separator, the lubrication oil is pressed into the oil cooler. After the lubrication oil is cooled in the cooler, the particles of impurities in the lubrication are removed via an oil filter, and then the lubrication oil is divided into two parts. One part of the lubrication is injected into the compression chamber from the lower end of the engine body. The compressed air is cooled. And the other part of the lubrication oil is passed through the two ends of the engine body and is used to lubricate a bearing unit and a driver gear. The two parts of the lubrication oil meets at the bottom of the compression chamber again and be drained out with the compressed air. The oil mixed compressed air enters into the oil / air separator together with the lubrication oil. Most of the oil is initially separated. The remaining air containing oil mist is passed through the oil fine separator again, and the remaining oil is removed. The compressed air enters into the reat-part cooler through the minimum pressure valve, is cooled and then can be sent for use. The description of each module on the oil path: (2) The oil cooler ‘The cooling method of the oil cooler is the same with that of the air rear-part cooler. If the environment is bad, fins of the cooler will be easily covered with dust and influences the cooling effect, and the air exhaust temperature will be too high and will cause trip. Therefore, at that time, the dust on the surface of the fins must be blown off, use of the low-pressure compressed air. If the surfaces of the fins can not be blown clean. Solvent must be used to clean them. The heat dissipation surfaces of the cooler must be ‘maintained clean. (b) The oil filter The oil filter is a paper filter. The function of the oil filter is to remove the impurities in the oil, such as metal particles and oil inferior substances. The filtering precision is 10 PPM. The oil filter has sound protection action for the bearings and the rotors. The filter core of the oil filter is generally sct to be replaced each 2000 hours. The oil and the oil filter need be replaced after the new compressor has 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. Meanwhile, the resetting time of the oil filter is modified as ‘zero’. The ait compressor will automatically give an alarm to remind the user to replace the filtering core after the machine has been operated for 2000 hours. The resetting time of the oil filter should be modified as ‘zero’ after the user has replaced the oil filtering core. If the environment is dirty or dusty the replacing time must be shortened according to the situation. (©) The oil fine separator The filtering core of the fine separator is made of multiple-layer fine glass fibers. The mist oil air contained in the compressed air is almost completely removed through the oil fine separator. The sizes of the oil particles can be controlled to be less than 0.1jim. The oil content can be lower than 3PPm. In the normal operation, the oil fine separator can be used for about 4000 hours. The quality of the lubrication oil and the conditions surrounding influence the service life of the oil fine separator. If the pollution of the surrounding is serious, the front air filter can be retrofitted. In the case of the selection of the lubrication oil, the special oil of the screw type compressor manufactured by our company must be adopted. Fake oil or reproducing oil must not be used. The safety valve and the minimum pressure valve are installed on an outlet of the oil fine separator. The compressed air is exhausted from the safety valve and the minimum@) a) 4000 hours. When the machine has been operated for 4000 hours, the air compressor will automatically Ive and passed through the cooler. Replace time for the oil fine separator is generally set as oil content core. The user must modify the resetting time of rive an alarm to remind the user to replace a ing_an oil content core. If the use surrounding is bad, the the oil fine separator as ‘zero’ after repl replacing time must be shortened according to the situat tered by the oil fine separator is converged in a small round groove at the center and reflows to The oil the inlet side of the engine body through an oil-return pipe, which can prevent the filtered lubrication oil from being exhausted with the air again, (@) Oil / Air separator tank The oil / air separator tank is a steel pressure container and is used to store the lubrication oil and separate the compressed air and the lubrication oil. Lubrication oil is separated by the compressed air containing a large quantity of the lubrication oil from the host machine through the collision in the oil-gas barrel. The separated lubrication oil is cooled through the cooler, passed through the filter and conveyed to the host machine. 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. After the initial $00 hour oil change, the time of the lubrication oil is modified as 2000 hour’. Meanwhile, the resetting time of the lubrication oil is modified as ‘zero’, and then the operating time of the oil / air separator tank is modified as 2000 hours. The air compressor will automatically give an alarm to remind the user to replace the oil filtering core after the machine has operated for 2000 hours. The user must modify the resetting time of the lubrication oil as ‘zero’ after replacing the oil filtering core. If the compressor is used in a dirty or dusty environment the ‘must be changed prior to the 2000 hours suggested in this manual. The cooling system The cold air is absorbed through a circulation fan. The cooling effect is reached after the heat exchange between the cold air, the compressed air and the lubrication oil is implemented. The highest allowable surrounding temperature of the cooling system is 45 degrees Celsius and 112 Fahrenheit. If the surrounding temperature is over 45celsius and 112 degrees Fahrenheit, the system may fail. Proper ventilation is imperative to insure temperature is within guidelines of this manual Safe protection system and warming devices. ‘The overload protection of the electrie motors There are two main ¢lectric motors in the air compressor system. One is a drive main electric motor of the compressor, and the other is a cooling circulation fan electric motor. Under the general state, the operation current of the electric motors will not be 3% higher than the rated current (for example, because of the reasons such as the voltage fall and i of the electri the unbalance three phase). When the operation curr notors exceeds the set upper limit, an over current protection device will automatically switch off the main power, and the air compressor stops. At that time, the air compressor cannot be started without being reset, The resetting method is that the setting switch is pressed down by hand. Generally speaking, the reasons for electric motor overloads are as Follows (A). Human operation error: for example, the s the air exhaust pressure by himself, or the improper regulation of the system (B) Mechanical failures: | |je motors, the phase failure operation of the electric motors, no actions For example, the internal loss of the el of the safety valve, the setting failure of the system and the blocking of the oil fine separator. If the clectrie motors are found to be overloaded during the operation, the user should immediately get if touch with the manufacturer. | (2) 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. Generally speaking, there are many reasons why the air exhaust temperature is too high. But the most common reason is oil cooler failure, If the heat dissipation fan is blocked by dust. the cold cooling air cannot freely flow through the cooler and the temperature of the lubrication oil will gradually increase, which causes the compressor to automatically shut down because of high temperature. Therefore, the dust on the heat dissipation fins of the oil cooler radiator must be cleaned and or blown free of dust and dirt. If the blockage on the fins cannot be blown clean, cleaning solution or solvent should be used to clean the fins. The highest designed surrounding temperature of the compressor is 116 F. Higher room temperature will increase exhaust temperature and sound ventilation will help reduce temperature providing a healthier environment for your AIRHORSE screw compressor. (3) Warming devices - This system has five kinds of devices in total. The time that the suction filter needs to be replaced, the time that the oil filter needs to be replaced, the time that the oil fine filter needs to be replaced, the time that the lubrication oil needs to bbe replaced and the time that motor grease needs to be replaced are all displayed on the display panel. The user must replace spares in the shortest time. Otherwise, the performance of the air compressor and the safe operation of the compressor will be influenced. The relative resetting time needs to be modified as ‘zero’ after the replacements. . Control system and electric circuit (1) The control system (A) Starting the electric motor utilizing the Y delta starting. During the start-up of the electric motor, a (three directional) magnetic valve is powered on; the suction valves are all closed allowing the unit to start under no load; air release blow down valves are all opened. At that time the air intake suction valve side closes and becomes a high vacuum, The lubrication oil is implemented by the pressure difference between the vacuum of the compression chamber and the pressure in the air / oil separator tank. (B) After start up, and the motor reaches full running speed the compressor will gradually fill the air oil separator tank. The pressure in the oil / air separator tank will lubricate the compressor with oil from the pressure produced. After the control becomes in the total pressure dynamic rotation, the (three direction) magnetic valve is powered on, which facilitates the pressure in the oil / air separator tank to be increased gradually. When the pressure in the oil / air 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 he minimum pressure valves are all opened and the air is output. increased to over 0.3Mpa (C)__ Heavy load operation / no-load operation When the air exhaust pressure reaches the set upper limit of the system, the power is cut off; the (three direction) magnetic valve is closed; the suction valve is further closed; meanwhile, the air release valves are all opened. ‘The air in the oil / air separator tank is exhausted to the atmosphere. At that time, the compressor is operated under no-load state. The needed lubrication oil is guaranteed by the pressure difference between the vacuum andthe pressure in the oil-gas barrel. When the pressure of the pipeline system falls to the set lower limit of the system, the power is connected again; the (three direction) magnetic valve is opened again; all the suction valyes are also opened. Meanwhile, the vent valve i (D) Machine Stoppage After the Stop pushbutton *OFF* is pressed down, the (three direction) magnetic valve is powered off and closed; meanwhile, the vent valves are all opened, and the air in the oil / air separator tank is exhausted into the atmosphere. When the pressure in the oil / air separator tank is reduced, the electric motor stops. (E) Emergency Stop When the air exhaust temperature is more than 100 Celsius and 212 Fahrenheit, the over current protection device is engaged because of the overload of the electric motor, the power will be cut off and the electric motor will stop immediately; meanwhile, the (three direction) magnetic valve and the sucti the vent valves are all opened. Only when abnormal situation occurs during the operation, the emergency stop pushbutton is allowed to be pressed. (F) An automatic shutdown system under no-load and too-long operation state When the volume of the used air of the system is reduced, the compressor is maintained to be operated under no-load state. When the time of the no-load operation exceeds the set time, the air compressor will automatically shut down, and the electric motor stops being operated. When the volume of the used air of the system is increased, the pressure of the system will be decreased, and the air compressor will automatically run to supplement the air. The electric motor should not be started more than twice each hour. The operator can set the time of the automatic shutdown system under no-load and too-long operation state by The electric circuit The electric control of the air compressor can be divided into two systems. One is an internal control system, and the other is the starting panel. The starting panel is a Y-Delta starting control generally needed. The control part is computer control. The computer control is not introduced in this chapter in details because of the relative complexity of the internal circuit and the control. If there is any failure, please contact the service department at AIRHORSE. closed, and the compressor is operated under load. n valve are also closed, and | oe aa Controller oe ee | FG ve ok Ul ‘ |Rules of safety operat Chapter 4. Operation The operator should establish the rules of safety operation in details to avoid injury, accidents and machine damage The following are sugg i) @) 8) (4) () ©) | jons for reference: | rict training beforehand and read up and understand specifications; | The machine installation, use and operation should abide by the national and local relative laws; The operator should receive Strictly prohibit the structure of the assembly and the control method from being changed, without written permission of the manufacturer; | The operator should stop the machine and cut off power if he finds any abnormal situation; | ‘There should not be flammable, combustible, poisonous and mordant gas in the surrounding area, | ‘The operator must stop, unload the compressor and cut off the power before the maintenance and regulation of the | assembly Trial run, starting-up and machine stoppage. aM Q) (4) (5) (6) @ (8) 9) (10) The vent valve automatic ‘The inspection before starting the compres The power wire and the ground wire are connected with the compressor. Whether the main voltage is correct or not should be tested. Whether the three phase power is correct or not should be tested. The operator should inspect whether the oil level in the barrel is between the high oil level H and the lower oil level L or not, If the trial run is implemented after the compressor has been received by the user for a long time, about 0.5 liters of the lubrication oil should be added into the suction valve. Furthermore, the operator should rotate the compressor for a number of times by hand to prevent the parts in the compressor from being burnt down because of oil shortage after the starting-up. Please particularly note that foreign matters should not be fallen into the engine body. of the compressor to prevent the engine body of the compressor from being damaged. The cooling system is inspected. ‘The operator should press the push button ‘emergence stop’ immediately within several seconds after pressing the pushbutton ‘ON’. He should inspect whether the rotation direction is correct or not (for example, the direction of the arrow), if the rptation direction is incorrect, the operator should exchange any two wires among the three wires. The air compressor begins operation after the pushbutton ‘ON’ is pressed again. After the finish of no-load time delay, the pushbutton ‘loading-unloading’ is pressed, and the state of ‘loading’ is displayed on the display panel The operator should judge whether the designations of the display panel are normal or not. He must press the pushbutton ‘emergence stop’ immediately and stop the machine and inspect the machine i 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 Fahrenhi In 10-15 seconds after the pushbutton ‘OF! This is to prevent th is pressed, a time switch is run, and the electric motor will be halted. ir compressor from being directly halted under heavy-load state. | ly discharges air after the pushbutton ‘OFF" is pressed. r ‘The operator should actually inspect the compressor to avoid serious failure of the compressor before start up, a) ‘The oil / air separator tank and the manual drain valve of the water separator are opened, and the cold condensed \e stopp water occurred during the sage is discharged, If this is neglected, the service life of the lubrication oil nd the bearings will be destroyed. Please note that an oil discharge valve must be closed | immediately when the oil is discharged. will be shortened@ Tie operator should inspect whether the oil level is between the high oif Tevel Hand the Tower oif Tevel L. The lubrication oil must not be mixed. Only AIRHORSE oil or oil authorized by AIRHORSE is authorized for use When the lubrication oil is supplemented, the cover of the oil filling port can be opened only when there is no pressure in the system, The operator can observe the oil level after ten minutes when the compressor has shut down. The oil level may be slightly lower than the oil level of a stopped machine, Important Notes a) 2) @) @) ) The machine should be stopped when there is abnormal noise or vibration during the operation. Because there is pressure in both the pipelines and containers during operation, the pipelines or plugs must not be loosened, and the unnecessary valves should not be opened. If the oil level on the oil level indicator is found to be lower than the lowest line of the oil level glasses during the long-term operation, the operator must stop the machine immediately. After ten minutes when the machine is stopped, the lubrication oil should be supplemented. There is condensed water in the back part of the cooler, so the condensed water is discharged each day or an automatic drain valve is installed. Otherwise, the moisture content will be taken to the system. 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. a @) 8) If the machine has been stopped for over three weeks, the operator should care for the compressor according to the following methods: (A) The electric equipment such as the control panel of the electric motor should be wrapped up with plastic paper or oil paper to avoid moisture. (B) The water in the oil cooler and the back cooler should be completely drained. (C)_ The operator should clear all failures to for proper operation in the future. . (D) The condensed water in the oil / air separator tank, oil cooler and back cooler should be drained out after several days when the machine is not in use. If the machine has not ran for more than two months, the operator should care for the compressor according to the following methods: (A) The operator should further deal with the compressor according to the following methods. (B) _ All ports should be sealed to avoid moisture and dust (C)_ The safety valve and the control panel must be wrapped (D) Lubrication oil should be replaced before the machine has stopped and the machine should run for 30 minutes. The condensed water in the oil / air separator tank and the oil cooler must be drained in two or three days after that (E) The cooling water should be completely drained. (F) The machine should be moved to a dry place with minimal dust or dirt. ‘The procedures of restarting the machine (A) The plastic paper or the oil paper on the machine platform should be removed (B) The insulation of the electric motor should be measured to be over IMQ. (C) Other procedures should be the same with the steps of the trial run. ith the oil paper or an equivalent to avoid rust.Chapter 5. Computer control 1. Introduction: This computer contro! of the screw compressor adopts the advanced CPU. The computer can intelligently monitor and control the start-up, and vario failures of the air compressor. Conditions: (A) Surrounding temperature: Between 32 degrees Fahrenheit or 0 degrees Celsius and 104 degrees Fahrenheit and 40 degrees Celsius, (B) Rela (©) 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 fe moisture: Should not exceed 95% the insulation. The main features and functions: (A) The screw compressor has full automatic intelligent operation, the LCD display, has touch type keypads and direct-viewing for convenient operation. (B) The computer control can continuously monitor, display and control the air exhaust pressure and the air exhaust temperature according to the preset parameters. (C) The computer can preset and control the delay time of star delta transformation, star delta starting-up, star delta machine stoppage, star delta drainage and star delta overpressure during operation. (D) The computer will display and process various on-site failures. (E) The computer will accumulate and store operation time, loading time, off-loading time and the use filters for a long time. (F) The user can adjust preset parameters and accumulated time at will through the computer during the operation of the compressor. e of various (G) The user can modify the parameters and store them for a long time according to requirements, (H) The computer has a draw-out type terminal connection, which is convenient and reliable. (1) the computer has the remote/local selection control (J) The computer has linkage/independent operation. (K) The computer has RS-485 telecommunication function, which can realize multi-computer telecommunication with the computer. 3. The main technical parameters: (A) Working voltage: AC230V 3%, 460V(-15%>+10%) 60HZ; (B) The power consumption of this microcomputer: <10W; (C) Output method: the contact output of a relay, 220V, 3A; (D) _ Input method: passive normally open contact; (£) Display method: dot matrix liquid erystal character display, backlight; (F) The control range of the air exhaust pressure: 0-16.00BAR | (G)_ The control range of the air exhaust temperature: -10°C-120 °C (H) The range of accumulated running time: 0-999999 (1) The adjusting range of star delt () The adjusting range of excess pressure delay time: 0-99 minutes; (K) The adjusting range of restarting-up delay time: 0-99 minutes; ours, 5-99 seconds; transformation t 28oO (M ~ (oO) (P) @ The adjusting range of machine-halt delay time: 0-99 minutes; ‘The adjusting range of timing drainage spacing time: 0-99 minutes; The adjusting range of timing drainage time: 0-99 seconds; Input range of the use time of the filters: 0.9999 hours; Input method of temperature sensors: PT platinum resistor: Input method of @ pressure sensor: two-line type pressure sensor with 4-20 milliamps ere (0-16BAR). 4. Installation and connections (refer to the details of the circuit diagram with the microcomputer) 5. Use and operation (refer to the details of the use manual of the microcomputer control)1. The specifications and maintenance fe aM @) Chapter 6. Maintenance and Inspection jubrication oil Specifications of the recommended lubrication oil. The lubrication oil has a decisive impact on the performance of the oil lubricated rotary screw pump. Warranty requires use of only AIRHORSE authorized oil, ‘The factors influencing the oil exchanging time: (A). Bad ventilation and high surrounding temperature. (B). High humidity. (C). Operation or storage in a dirty and or dusty environment. (D). The mixture of different lubrication oils. The steps of oil change. (A) To insure that water is not present in oil, the oil temperature must be increased to avoid condensation. A good operation temperature for the oil is 160-180 degrees F. (B) Allow a few minutes after shutdown to change oil, this will ease pressure and allow for a more efficient oil change. (© After the lubrication oil is drained completely, the oil drain valve should be closed. The oil filling port should be opened, and new oil should be injected into the oil filling port. Note: all the lubrication oil in the system should be drained completely, such as the lubrication oil in the pipeline, the lubrication oil in the cooler and the lubrication oil in the oil / air separator tank. (D) New oil should be added. (A) «© (4) iderations for lubrication oil A sample of the oil can be sent to AIRHORSE 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. Failure to change Oil within the guidelines in this manual may cause failure of the compressor and eliminate all warranty safeguards, il should be changed annually regardless of hours of operation. An annual oil change is mandatory for warranty and life of compressor. Warming! ONLY USE AIRHORSE OIL OR OIL AUTHORIZED IN WRITING BY A(RHORSECORP. 2. The regulation of the belt All belt type AIRHORSE compressors should be inspected after the first 30 hours of operation. After the first 30 hours, please inspect belt at 1,000 hour intervals. A spring activated belt tensioner is utilized to keep constant and consistent belt tension. A quarter inch slack is necessary to maintain proper belt life, Always replace all belts at the same time, do not replace belts independently. Note: ifthe belt is regulated or replaced, the lubrication oil should not be splashed on the belts or belt pulleys. ay Q) GB) 303. Regulating Pressure 1, The regulation of the system pressure ‘The system pressure is set before the system goes out of the factory. The pressure difference can be regulated according to the on-site use situation. (The parameters are set according to the specifications of the computer control) 4. Regulation of the safety valve The discharge pressure of the safety valve is generally set at 175 PSI / 12.1 Bar. The ASME safety valve is sealed and certified by ASME code. This valve should not be reset or tampered with under any circumstance. 5. Steps for replacing the oil fine separator (1) External air oil separator filter (A) Always tum off power and lock out and tag air compressor prior to any replacement service. (B) Before changing oil air separator filter all air pressure should be drained from the air oil separator tank through the oil drain at the bottom of the air oil separator tank. (C) The oil fine separator should be replaced by a new oil fine separator. 31Chapter 7. Maintenance and Safety Guidelines Proper maintenance is requited to maintain function and longevity of the AIRHORSE rotary screw compressor. Maintenance ‘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 whi under power, moving belts and pullies are hazardous when machine is powered. All pressure must be released durit any maintenance. 1, Daily maintenance (1) The compressor must be inspected daily before operation. (2) First 500 hours of operation: When the new compressor is used for the first time, the filtering core of the oil filter, the air filtering core and t lubrication oil should be replaced after 500 hours of operation. (3) 1,000 hours of operation (A) The motion of the suction valve, additionally injected into the suction valve. (B) The air filer should be cleaned. (©) The filtering core of the oil filter should be inspected and or replaced. (4) 2,000 or 6 months of operation: (A) __ All the pipelines should be inspected. (B) The lubrication oil should be replaced, and oil crust should be cleaned, (C) Sight glasses should be inspected and disassembled to be cleaned. (5) 4,000 hours or 1 year of operation: (A) _ The suction valve should be cleaned. (B) The three direction magnetic valve should be inspected, (C) The oil fine separator should be replaced. (D) The minimum pressure valve should be inspected. (E) The air filtering core and the filtering core of the oil filter should be replaced. (F) The lubrication oil should be replaced. (G) Lubricant grease should be additionally injected into the electric motor at the front and rear bearings. Do r over grease these bearings. (H) The motion of the magnetic contactor must be inspected. tension rod and moving parts should be inspected, and the grease 2. Trouble shooting and analyses. The chart provided gives possible trouble shooting cause and effect scenarios. This is a simple guide that may assist mnosing problems with your IRHORSE yoiary screw compressor. 1. Inspect wires for loose connections; 2. Inspect pipelines; 3. Inspect for damage caused by overheating or short circuit.Teme Problem Trouble Shoot Resolutions | ar) The compressor will | 1. A fuse wire has been shorted out. |}, An electrician or AIRHORSE dealer should be | | not start 2. Aprotection relay has opened. asked to inspect and replace the fuse wire, | (An clectric failure | 3. Aninitiating elay has failed. | > an ctectician of AIRHORSE dealer should be | lamp i aight) 4. A starting pushbutton has poor | ached to inspect and replace the protection relay | 5. Thevotageasbeentootow, | 3 Mtsstrcan or AIRHORSE deater shouldbe ae sere asked to inspect and replace the initiating relay. 7. Theengine body has filed. 4, An electrician or AIRHORSE dealer should be S.A phase failure protection relay | 29669 10 inspect and replace the starting has opened. pushbutton. 5, Anelectrician or AIRHORSE dealer should be asked to inspect and change the voltage. 6. An electrician AIRHORSE dealer should be asked to inspect and replace the electric motor. 7. The engine body should be moved by hand. If it cannot be moved, please contact your AIRHORSE service representative. 8. Power wires and all connections should be inspected. | The compressor | 1. The voltage is too Tow, T An eleciriclan should be asked to Inspect and automatically ips | 2 -The sir exhaust pressure has been | change the voltage because of high | too high. 2, The pressure should be inspected. If the pressure running current (the | 3. The specification of the lubrication | exceeds the set pressure, the set value of the pressure electric failure lamp | oil has been incorrect. and the pressure sensors should be inspected. is alight) 4, The transmission belts have become | 3. The lubrication oil number should be inspected, and loose. the lubrication oil should be replaced. 5. The oil fine separator has been | Please refer to 5-1 section. blocked. 4, The transmission belts should be inspected and (the pressure of the lubrication | regulated. oil is too high) 5, The oil fine separator should be replaced. 6. The body of the compressor has | 6. The engine body should be moved by hand. Ifit can failed not be moved, please contact your AIRHORSE dealer Tay} The running current | T. The air consumption has been too | 1. The air consumption should be inspected. IF is tower than the | much (the pressure has been run | necessary, the number of the compressor should be normal value, under the set value) . increased. 2. The air filter has been blocked. 2, The air filter should be cleaned or replaced. 3 The motion of the suction valve has | 3. The suction valve should be disassembled and been bad (a butterfly valve has been | cleaned, and the lubrication oil should be injected into blocked and can not be moved) the suetion valve Tay] The air exhaust | 1 The compressor fas no Toad too | 1 The excess pressure motor stoppage time should be temperature is lower than the normal value lower than Jong. 2. There has been deviation in the display of the temperaure 3. The temperature sensor should be replaced.(5) The air exhaust temperature is high, The compressor automatically trips. The failure indicates that the temperature of the air exhaust is high (being more than 110°C) 1. The quantity of the lubrication oil should be inadequate. 2. The surrounding temperature should be high, 3. The cooler should be blocked 4, The specification of the lubrication oil should be incorrect. $. The oil filter should be blocked. 6. The wind-cooling fan has failed Tif the oil level is inspected to be lower than the lowest oil level line, please stop the motor and add the lubrication oil until the highest oil level line is reached, 2. The air exhaust should be increased. The room temperature should be decreased. 3. The cooler should be cleaned 4, The lubrication oil number should be inspected, and the lubication oil should be replaced, Please refer to 5-1 section. 5. The oil filter should be replaced 6. The wind-cooling fan should be replaced. © The oil content in the air is high. The period of the addition of the lubrication oil is shortened. The filter smokes when the compressor has no load. 1, The oil surface has been too high. 2. An orifice of an oil return pipe has been blocked. 3. The air exhaust pressure has been low. 4, The check function of the suction valve has failed. 5. The oil fine separator has been damaged. 6.A spring of the minimum valve has fatigued. 7. An oil-retum check valve has failed. 8. The specification of the ubrication oil has been incorrect. T. The ol 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. 4, The suction valve should be inspected and further replaced if necessary. 5. The oil fine separator should be replaced by a new one. 6. The spring should be replaced. 7. The oil-retumn check valve should be replaced by anew one. 8, The oil number should be inspected, and the oil should be replaced. Please refer to 5-1 section, a) The compressor can not be run with full load. T. The pressure sensor has failed. 2. The three direction magnetic valve has failed 3. An electric control has failed. 4, The timing relay has failed. 5. The motion of the suction valve has been not sound, 67 Pressure valve has been not motion of the minimum sound, 7. Awater-filtering cup has air leakage. T. The pressure sensor should be replaced by a new one. 2. The three direction magnetic valve should be replaced by anew one. 3. The electric control should be replaced by a new one. 4, An electrician should be asked to replace the timing relay. 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. TThe record chart of the AIRHORSE rotary screw air compressor Date: 34The control pipelines have leakage. 7, Whether the waterfiltering cup has leakage all the time or not should be inspected 8. The position of the leakage should be inspected and locked up. | There can not be empty compressor. The gauge pressure is still maintained at 1. The pressure sensor has failed. 2. The motion of the suction valve has not been sound. T. The pressure sensor should be inspected. If necessary, the pressure sensor should be replaced, 2. The suction valve should be assembled and not been sound, the working pressure | 3. A draining solenoid valve cleaned. After that, the lubrication oil should be or continues to be has failed (electric coils have injected into the suction valve. increased, The been burnt down). 3. The draining solenoid valve should be safety valve acts. 4. An air flow regulating film inspected and further be replaced if necessary. plate has been damaged. 4. The air flow regulating film plate should be | 5. The discharge orifice has inspected and replaced. | been too small, 5. The diameter of the orifice should be enlarged moderately. 9) The amount of air of | 1. An air inlet filter has been 1. The air inlet filter should be cleaned or the compressor is blocked. replaced, lower than normal | 2. The motion of the suction _| 2. The suction valve should be assembled and value. valve has not been sound. cleaned. After that, the lubrication oil should be 3. The motion of the minimum | injected into the suction valve. | pressure valve has not been 3. The minimum pressure valve should be sound, assembled. After that, whether the base and a 4. The oil fine separator has | back valve plate have been worn out or not been blocked. should be inspected. If being fatigued, the spring | 5. The vent valve has been should be replaced. | leaked. 4, The oil fine separator should be inspected. If | necessary, the oil fine separator should be replaced. 5. The vent valve should be inspected. If necessary, the vent valve should be replaced. (C0) |The empiy T. The pipelines have leaked, | 1. The leakage position should be inspected and | compressor and the | 2. The pressure difference has | locked. : | full compressor are | been set too low. 2. The pressure difference should be reset (being | frequent. 3. The air consumption has general 0.2Mpa). been unstable. 3. The volume of the air storage tank should be increased, (11) |The oil mist flies out | 1. The suction valve has been | 1. The suction valve should be inspected. If ofthe air filter when | leaked necessary, the suction valve should be replaced. the machine halts. | 2, The full compressor has 2. Whether the suction valve has been blocked halted or not should be inspected. If being blocked, the 3. The motion of the three suction valve should be assembled and cleaned. direction magnetic valve has | After that, the lubrication oil grease should be injected into the suction valve.The electric circuit has been incorrect. 5. The minimum pressure valve hhas been leaked. 6. The vent valve has not been discharged. 3. The three direction magnetic valve should be inspected. If necessary, the three direction ‘magnetic valve should be replaced, 4, An electrician should be asked to inspect and replace the electric circuit. 5. The minimum pressure valve should be inspected and replaced. 6. The vent valve should be inspected. If necessary, the vent valve should be replaced 36