BendPak RS7580H603, Installation And Operation Manual

Page 1: ...te or repair this equipment without reading this manual and the important safety instructions shown inside 1645 Lemonwood Dr Santa Paula CA 93060 USA Toll Free 1 800 253 2363 Tel 1 805 933 9970 Fax 1 805 933 9160 www bendpak com PLEASE READ THE ENTIRE CONTENTS OF THIS MANUAL PRIOR TO INSTALLATION AND OPERATION BY PROCEEDING YOU AGREE THAT YOU FULLY UNDERSTAND AND COMPREHEND THE FULL CONTENTS OF TH...

Page 2: ...ntroller Software 19 24 Section 12 Maintenance 25 33 Common Problem Solving 34 35 Parts List and Electric Diagrams 36 44 Warranty 45 Maintenance Inspection Records 46 47 NOTE Every effort has been taken to ensure complete and accurate instructions have been included in this manual however possible product updates revisions and or changes may have occurred since this printing BendPak Ranger reserve...

Page 3: ...ly 3 Confirm voltage before connecting power to your machine or serious damage to the motor electronics will result BREATHABLE AIR WARNING This compressor pump is NOT equipped and should NOT be used as is to supply breathing quality air For any application of air for human consumption you must fit the air compressor pump with suitable in line safety and alarm equipment This additional equipment is...

Page 4: ...t has internal arcing or sparking parts which should not be exposed to flammable vapors This machine should not be located in a recessed area or below floor level 13 Tanks rust from moisture build up which weakens the tank Make sure to drain tank regularly and inspect peri odically for unsafe conditions such as rust formation and corrosion 14 STAY ALERT Watch what you are doing Use common sense Be...

Page 5: ... mixture by passing the air though the Separation Cartridge core The compressed air has a final oil level of 3ppm The oil is then filtered and returned to the reciprocating screw assembly for reuse via an oil return tube fitted with a valve assembly to limit the loss of pressure in the compressed air line COOLING After the oil is separated from the compressed air it is routed to the after cooler T...

Page 6: ...TION PowerCool is a powerful synthetic lubri cant that s designed to help rotary screw air compressors reach maximum performance The PowerCool unique formulation has a 2 year 8 000 hour useful lifespan to save you money otherwise spent on disposal fees Other lubricants can require changing up to 8 times as often as PowerCool The carryover is up to 75 lower than mineral oils and PAOs which means le...

Page 7: ...top of the main distribution air line so that moisture cannot enter the outlet INSTALLING A SHUT OFF VALVE A shut off valve should be installed on the discharge port of the Compressor to control the air flow and iso late the components for maintenance The valve should be located between the tank and the piping system When creating a permanently installed system to distribute compressed air find th...

Page 8: ... All external piping requires approved support systems All piping should be connected to the compressor out line in such a manner as to keep any condensation from running back towards the compressor When an air drier is installed in the pipeline an air tank reservoir is recommended as the compressed air temperature will be lowered prior to entering the dry ing system and therefore increase the eff...

Page 9: ...ger size wire should be used to prevent excessive line voltage drop The additional wire cost is very small compared with the cost of repairing or replacing a motor electrically starved by the use of supply wires which are too small Improperly grounded electrical components are shock hazards Make sure all the components are properly grounded to prevent death or serious injury This product must be g...

Page 10: ...t start upon first startup then likely the sequence of the three phase wiring is incorrect Check the Failure history as outlined in the Trouble Shooting to confirm phase problem 2 Reverse the two phases of power input DO NOT alter the wiring of the motor or starter GUARDING SECTION 8 PRE OPERATION INSPECTION ALL MAINTENANCE PANELS MUST BE INSTALLED DURING NORMAL OPERATION ALL MOVING PARTS MUST BE ...

Page 11: ... lubricating oil into Air End through the Intake Valve 4 Rotate the Pulley on the Screw Air End by hand a couple of complete rotations counterclockwise to ensure the Air End is not locked and lubricated properly See Fig 8 1 5 Make sure all oil enters Air End 6 Make sure Intake Valve closes when released OIL LEVEL INSPECTION 1 Remove the Access panel on the Oil Separator Side of the Compressor See ...

Page 12: ...tton will pop back out The Compressor cannot be restarted until the failure has been cleared and the Restart Delay time 90 seconds has expired 3 The Compressor cannot be restarted until the failure has been cleared and the Restart Delay time 90 seconds default has expired DAILY STARTUP PROCEDURE Before start up a Check the operating button to see if it is in normal condition b Make sure there are ...

Page 13: ... be between the upper and lower red line indicated on the Oil Level Site Glass See Fig 9 3 3 Fill with PowerCool Synthetic Air Compressor Lubricant if necessary and inspect the O Ring on the Oil Fill Plug before tightening START UP PROCEDURE 1 Make sure any installed valves are open 2 Turn on the Power The LCD Display will show a welcoming message and then the Display will indicate Compressor s ST...

Page 14: ... the compressor immediately SECTION 10 LCD CONTROLLER PANEL OPERATION The LCD CONTROLLER panel is used to monitor and adjust the Parameters of the Screw Compressor The Parameters are set at the factory and it is recommended to leave most of the settings at their factory default values The values most likely to require adjustment by the end user are described below The Complete Menu Hierarchy is av...

Page 15: ...temp in degrees Celsius STATE Indicates Current Motor State P Indicates PSI ADD0001 Indicates Network Address 0 S Indicates number of seconds remaining if in a DELAY STATE NEAR Indicates Local Control NEAR or Remote Control Far RUN PARAMETER Use the RUN PARAMETER menu to view or monitor the compressor settings while running in any state The settings cannot be changed or modified in this view but c...

Page 16: ...e No Password is required to modify the Date 1 From the Main screen 2 Press ê Enter to access the Main Menu Selection 3 Press ê to move the black cursor over the menu item FACTORY PARA 4 Press è 5 Press ê or é to highlight and choose DATA 6 Press è 7 The number will blink indicating it is modifiable Use the ê or é button to change the values of the selected parameter month day year Press the S but...

Page 17: ...s the Main Menu Selection 3 Press ê to move the black cursor over the menu item USER PARA 4 Press è 5 Press ê to choose LAN SEL EN 6 Press è CHANGING THE MAXIMUM AND MINIMUM SYSTEM PRESSURE SETTINGS The maximum and minimum pressure in the system have already been pre set by the factory The Maximum allowable pressure in the system is 150 PSI 1 034Mpa The compressor will run in a Loaded State buildi...

Page 18: ...ION OR WORK NEAR THE MOTOR AND ENSURE LOCK OUT AND TAG OUT PROCEDURES HAVE BEEN PERFORMED DO NOT PERFORM ANY MAINTENANCE OR INSTALLATION OF ANY COMPONENTS WITH OUT FIRST ENSURING THAT ELECTRICAL POWER HAS BEEN DISCONNECTED AT THE SOURCE OR PANEL AND CANNOT BE RE ENERGIZED UNTIL ALL MAINTENANCE AND OR INSTALLATION PROCEDURES ARE COMPLETED PSI Mpa Bar kg cm2 1 0 007 0 07 0 07 25 0 172 1 72 1 76 50 0...

Page 19: ...ME i THIS RUN TIME x H xx M ii THIS LOADING TIME x H xx M THIS RUN TIME is the total amount of time the compressor has been running in any state during the most recent cycle THIS LOADING TIME is the amount of time the compressor has been running in LOADED STATE in the most recent Cycle These hour counters can be reset under FACTORY PARAMETERS d MAINTENANCE PARAMETER RUN TIME SET i OIL FILTER 0000 ...

Page 20: ...ME 2009 11 17 W 2 00 00 00 H M SEC Can be reset from this screen 3 CUSTOMER PARAMETER Modifies Values Password Required a SET P T i LOADING xx xx Mpa Pressure at which Compressor will switch to LOADED STATE To build pressure NOT APPLICABLE ii UNLOADING xx xx Mpa Pressure at which Compressor will switch to Unload State Not Build Pressure NOT APPLICABLE NOTE Maximum and minimum pressure is set using...

Page 21: ...LY Amount of time the Compressor will wait after pressing Stop or off button before shutting down vii START DELAY TIME 0100S CHANGE BY FACTORY AUTHORIZED TECHNICIAN ONLY Amount of time the Compressor will wait after pressing on button before starting up c OPERATION MODE CHANGE BY FACTORY AUTHORIZED TECHNICIAN ONLY i ON OFF MODE 1 NEAR FAR Compressor Control mode NEAR Compressor is controlled by se...

Page 22: ... hours counter v GREASE RESET 0000H Clear reset Grease hours counter f MAX LIFE SET MAX TIME SET i Oil 0000H Set the amount of time for Oil Reminder Alarm ii O G 0000H Set the amount of time for O G Reminder Alarm iii Gas 0000H Set the amount of time for Gas Reminder Alarm iv Lube 0000H Set the amount of time for Lube Reminder Alarm v Grease 0000H Set the amount of time for Grease Reminder Alarm g...

Page 23: ...for proper oil lubrication while running in Unloaded State g CLR LOAD TIME 0000H Resets Clears the Total Load Time Clock h CLR TOTAL TIME 0000H Resets Clears the Total Run Time Clock i CLR FAULT RECORD 0000 Resets Clears the Fault Record History j UNBALANCE SCOPE 0010 Time to trigger fault if unbalance load is detected k LACK PHASE STOP 000 50S Amount time before compressor stops when a Lack of Ph...

Page 24: ...s less than 5s E Overload anti time limitation protection time unit s See the following table The multiple I actual value I Set value When the running current of the motor is 1 2 3 0 times of the set value the overload multiple and action delay time will be accordance with the following table Temperature Protection When the actual detected temperature is higher than the set temperature the protect...

Page 25: ...ronments or severe demand applications First 500 operating hours first Maintenance Check the quality of oil The oil may be reused after being filtered cleanly Otherwise replace it Replace the oil filter Replace the intake filter Replace the oil separation filter Check the wear of belt pulley and the alignment of the motor and Air End pulleys Every 2000 Hours Replace the oil filter Replace the inta...

Page 26: ...tly and drain off any water from the bottom of the oil Tank Drain fluid until water stops flowing and only oil flows See Fig 12 3 2 The oil level must be above the upper red line after the compressor is off has been stopped for thirty minutes The oil level when the compressor is running must be between the upper and lower red line indicated on the Oil Level Site glass See Fig 12 4 3 Fill with Powe...

Page 27: ...ary unscrew the Oil Filter counter clock wise See Fig 12 8 3 Clean the threads and seat and then apply a light layer of clean oil to the face of the Oil Filter seat See Fig 12 9 4 Screw the new Oil Filter on clockwise and hand tighten only AIR OIL SEPARATION FILTER REPLACEMENT PROCEDURE 1 Remove the Access panel on the Rear Side of the Compressor NOTE The Oil Separation Tank needs to be unbolted a...

Page 28: ...gnetic Control Valve mounted on the side The Intake Control Valve controls load shedding noise reduction depressurization on off adjustment The Valve also adjusts to maintain a minimum amount of pressure 0 2 0 3Mpa to keep the minimum amount of Lubricating Oil in the Air end The Air Intake Valve should be inspected at 4000hrs Pay close attention to the white seal rings if worn cracked or damaged r...

Page 29: ...e 2 Open the Oil Fill Plug 3 Open the Drain Ball Valve and drain used oil into an approved container and dispose of in accordance with local regulations See Fig 12 17 4 Close Drain Ball Valve 5 Use a clean funnel fill the Oil Separation tank with PowerCool Synthetic Air Compressor Lubricant 6 Install and tighten the Oil Fill Plug 7 The oil level must be above the upper red line after the compresso...

Page 30: ... Loosen the Motor mounting bolts See Fig 12 20 3 Using a straight edge or square and or level adjust the motor until the Motor pulley and Air End Pulley are in the same vertical and horizontal plane Shims may be required See Fig 12 21 4 Tighten the Mount Bolts and adjust Pulley Tension as described in procedure below DRIVE BELT ADJUSTMENT AND REPLACEMENT Drive Belt Adjustment 1 Locate the Drive Be...

Page 31: ...r will sound an alarm and stop the machine the local failure displays xxx sensor failure INTERLOCK PROTECTIONS The Host is running and the air exhaust temperature reaches the fan starting temperature but the Fan does not run the controller alarm will sound and the Local Failure displays Fan is stopped ALARMS AND NOTICES Text Display Tips 1 Air Filter Alarm tips Check the alarm using the switch sig...

Page 32: ...pera ture The normal temperature is between 70 C and 105 C Voltage and current Check the voltage and current Within 1 2 times of that of the rated current Air Filter Cleaning Replace the filter element only Drainage in gas and oil barrel Water drainage Discharge from the oil dis charge valve Dustproof gauze cleaning and maintenance Take out and clean Pipeline system Check the situa tion of oil lea...

Page 33: ...ontent Maintenance cycle Remarks NOTES refers to parts that are maintained by users refers to parts that are entrusted to service center refers to parts that must be replaced after the new machine running continuously for 500 hours then replace them after 3000 hours work The maintenance parts are those whose working time are less than 6000 hours PROCESSING METHOD OF LONG TERM SHUTDOWN EQUIPMENT SH...

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Page 36: ...36 RS7580H603 SCREW COMPRESSOR PARTS LIST ...

Page 37: ...37 RS7580H603 SCREW COMPRESSOR PARTS LIST ...

Page 38: ...38 RS7580H603 SCREW COMPRESSOR PARTS LIST ...

Page 39: ... 1 34 Plastic panel 1 11 Cooling fan 1 35 Display control panel 1 12 The protective cover of the cooler fan 1 36 Emergency stop switch 1 13 cooler 1 37 90 adjustable connector 1 14 Head cover plate 1 38 Main return pipe of air end 1 15 Fan cover plate 1 39 Air inlet valve 1 16 Discharge pipe straight connector 1 40 Host machine 1 17 Discharge pipe of oil gas barrel 1 41 Oil inlet straight connecto...

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