Page 3 - Contents; Variable Speed Drive; Each compressor cabinet has built-in VSD compartment
Polar Air Rotary Screw Compressors 1 Contents Page No Variable Speed Drive Information .............. 1 Model Specification Charts ..................... 2-3 Safety Information ....................................... 4 Tag Definitions ......................................... 4 Basic Guidelines ........
Page 6 - Safety; CAUTION indicates a potentially
Operating Instructions 4 Safety This manual contains very important information on SAFETY and how to PREVENT EQUIPMENT PROBLEMS. The following will help in understanding this information: DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY...
Page 7 - Inspection; Make sure pallet-mounted; Remove shipping brackets from
Polar Air Rotary Screw Compressors 5 Inspection Prior to using the compressor, check for external damage that might have occurred during transit. Make sure pallet-mounted compressors are firmly secured to the pallet before moving. NEVER attempt to move a compressor that is not secure or serious inju...
Page 8 - Installation; This unit must be kept; In environments where fine dust; 4 inches sides and back; and anchored securely; Tank Sizing Guideline: Tank; Piping
Operating Instructions 6 Installation Area Exhaust air from this unit can be used to supplement environment heat. Install unit in separate room then create duct system as shown in figure 3. 1. Install compressor in a clean, well ventilated and well lit area. Make sure air inlet is away from exhaust ...
Page 9 - Test entire piping system; Oil Check; DO NOT OVERFILL. Residual
Polar Air Rotary Screw Compressors 7 Minimum Pipe Size For Compressed Air Lines Pipe Size Shown in inches) Length Of Piping System SCFM 25 ft. 50 ft. 100 ft. 250 ft. 20 3/4 3/4 3/4 1 40 3/4 1 1 1 60 3/4 1 1 1 100 1 1 1 1-1/4 125 1-1/4 1-1/4 1-1/2 1-1/2 150 1-1/2 2 2 2 200 2 2 2 2 3. Install appropri...
Page 10 - Electrical Installation; VSD
Operating Instructions 8 Use only Polar Air oil, model no. Oil003. For food manufacturing applications, use model no. Oil001. Use of any other product will cause product damage and void the warranty. Refer to warranty statement for oil requirements. Electrical Installation TO PREVENT DEATH OR SERIOU...
Page 11 - Motor Rotation; System Description; Lubrication Process; System Components; PLC (Programmable Logistical Controller); any; Maintenance Notifications
Polar Air Rotary Screw Compressors 9 Motor Rotation After electrical installation is complete, check the direction of the motor rotation. 1. Lightly push START and STOP buttons on the instrument panel. View unit while facing the drive pulleys (from the back). Check directional arrows on air end of p...
Page 12 - Main screen starting point.
Operating Instructions 10 Setting: o C/ o F; BAR/PSI; Language; Time/Date 1. Main screen starting point. 2. Press the Up arrow for setting temperature scale, gauge pressure, language, time & date. 3. Press the Enter button to see the current flashing temperatures scale, o C (Celcius) or o F (Fah...
Page 13 - Working Pressures; Press both Up & Down Arrows; Clock Timer Settings
Polar Air Rotary Screw Compressors 11 Working Pressures These pressures settings are the compressor’s operating pressure settings, Top Range Transducer, High Pressure Alarm, Stop Pressure, etc. (See chart on page 13 of PLC manual.) 1. To access these settings, start with the main screen shown below....
Page 14 - Working Timer - Unloading Delay; It’s recommended not set the
Operating Instructions 12 Working Timer - Unloading Delay To reduce wear & tear of the compressor components, an unloading delay time is set in the controls that shuts-down the compressor after the unloading delay time has counted down. If the compressor is running in slow periods of the day, th...
Page 15 - CAF; First screen for resetting alarms.
Polar Air Rotary Screw Compressors 13 Following replacement times are important for safe operation. Remember to clear lifetime and reset maintenance timer after replacements are made. Refer to PLC manual for more details. Maintenance Notifications Component (PLC) Lifetime (hrs) Air Filter CAF 4000 O...
Page 16 - Resetting Maintenance Alarms (Continued); . This is the screen for
Operating Instructions 14 Resetting Maintenance Alarms (Continued) 12. Press Down Arrow and CHANGE OIL FILTER shows in the display. Press Enter. 13. Using Enter move over to NO and use the Up Arrow to change it to YES then press Enter and hours are reset. 14. Press Down Arrow and CHANGE SEP. (Separa...
Page 18 - Mechanical Components; Using lock key, remove
Operating Instructions 16 Mechanical Components 1. Drive Motor Drive motor is 4 pole with low RPM (1750). This motor is also capable of variable speed drive as a standard feature. The motor is 12 lead, Y delta soft starting for low amp draw. Overload protection is installed for safety. Normal electr...
Page 19 - It is important to
Polar Air Rotary Screw Compressors 17 Mechanical Components (Continued) 2. Variable Speed Drive (Energy saving device) Ready Cabinet This cabinet has allocated space and cooling fan to house variable speed drive components. To convert to Variable speed drive, contact Polar Air customer service for m...
Page 20 - Refer to
Operating Instructions 18 Mechanical Components (Continued) 7. Exhaust Probe (Continued) It is important to keep the circulating fan and cooler fins clean to prevent the compressor from shutting down. Low air pressure can be used to blow them off or if needed, use water-based solvent to clean. 8. Oi...
Page 21 - Actuates oil lubrication of the air end.; After Cooler; allow modifications to; Serious injury could result.; permit smoking in the area.
Polar Air Rotary Screw Compressors 19 Mechanical Components (Continued) 14. Check Valve (Continued) a) Actuates oil lubrication of the air end. b) Regulates air flow through the air separator filter to prevent damage to the separator filter element. Air flow begins when pressure in the air / oil sep...
Page 22 - Initial Checks
Operating Instructions 20 Safety Rules (Continued) 9. Stop compressor and disconnect power if a hazardous condition arises. 10. Wear snug fitting clothing and confine long hair when around compressor. Keep all body parts and clothing away from couplings, fans and other moving parts of the equipment....
Page 23 - Maintenance; persons are
Polar Air Rotary Screw Compressors 21 Start-Up 1. Slightly open drain valve on air/oil separator tank to drain any condensed water. Failure to do this shortens service life of lubricating oil and destroy the bearings. Be sure to close valve after draining water. 2. Check “Emergency Stop” function by...
Page 24 - personal injury could result.
Operating Instructions 22 Safety Steps (Continued) 1. Make sure repairs are done in a clean, dry, well lighted and ventilated area. 2. When cleaning, use air pressure less than 30 psig (2.1bar). Also use effective chip guarding and personal protective equipment per OSHA standard 29 CFR 1910.242 (b)....
Page 25 - Use only Polar Air oil, model; Belts
Polar Air Rotary Screw Compressors 23 Use only Polar Air oil, model no.Oil003. For food manufacturing applications, use model no. Oil001. Use of any other product causes product damage and voids the warranty. Refer to warranty statement for oil requirements. Failure to perform regular oil changes ma...
Page 26 - Maintenance Schedule
Daily Check oil level Check coolant level Check safety valve Drain condensed water Weekly Clean air filter Check belt tension General unit cleaning 500 hrs. Change lubricating oil (after first 500 hrs.) Replace oil filter Grease electric motor bearings Blow-out radiator 1000 hr...
Page 27 - Troubleshooting Chart; Problem Possible
Polar Air Rotary Screw Compressors 25 Troubleshooting Chart Problem Possible Causes Resolutions Compressor will not start (Electric failure light is on) 1. Power supply problem 1. Check complete circuit for proper voltage, ensure all electrical connections are secure; once power is restored, press E...
Page 29 - Problem; Resolutions
Polar Air Rotary Screw Compressors 27 Troubleshooting Chart Problem Possible Causes Resolutions Line pressure exceeds upper preset safety limit (Continued) 5. High pressure shut-down preset is incorrectly programmed 5. Reset to proper setting. Refer to PLC manual. 6. Additional compressor piped into...
Page 36 - Warranty Statement
Operating Instructions 34 Warranty Statement EATON COMPRESSOR AND FABRICATION CO., INC. (and each of its subsidiaries, including POLAR AIR COMPRESSORS, INC.) makes the following Warranties: 1. THAT EACH ROTARY SCREW AIR COMPRESSOR PUMP TO BE FREE FROM DEFECTS IN MATERIAL, WORKMANSHIP, AND PARTS FOR ...
