EMAX Piston Air Compressors 1
Operating Instructions ELECTRIC OPERATED, PISTON COMPRESSORS EMAX designs and manufactures products for safe operation. However, operators and maintenance persons are responsibile 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.
EMAX Piston Air Compressors Contents Operation .......................................................13 Safety Rules.....................................13-14 Start-Up ...............................................14 Continuous Run Feature .....................15 Maintenance ..................................................15 Safety Steps ..................................15-16 Belt Adjustment....................................16 Changing Oil .........................................17 Safety Valve ...
Operating Instructions EMAX Electric Operated, Two-Stage, 15-25 Hp Piston Air Compressors EP15V120Y3 EP15H120Y3 EP20H120V3 EP25H120V3 15 Hp 15 Hp 20 Hp 25 Hp Three Phase Three Phase Three Phase Three Phase SCFM @ 175 psi 52.0 52.0 68.0 89.
EMAX Piston Air Compressors Safety This manual contains very important information to know and understand. This is provided for SAFETY and to PREVENT EQUIPMENT PROBLEMS. To help understand this information, observe the following: DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
Operating Instructions Breathable Air 1. NEVER use air from this compressor for breathable air except in full compliance with OSHA Standards 29 CFR 1910 and any other Federal, State or Local codes or regulations. Death or serious injury can result from inhaling compressed air without using proper safety equipment. See OSHA standards on safety equipment. DANGER 2. DO NOT use airline anti-icer systems in air lines supplying respirators or other equipment used to produce breathable air.
EMAX Piston Air Compressors Forklift Safety 1. Make sure lift operator stays aware while moving compressor. 2. Be sure load is secure and well balanced before moving the compressor. 3. Make sure forks are fully engaged and level before lifting or moving compressor. 4. Keep load as low as possible and observe safe operating practices. Lifting Safety 1. Carefully inspect all lifting equipment and make sure it is in good condition. Rated capacity should exceed compressor weight.
Operating Instructions Installation Area 1. Install compressor in a clean, dry and well-lit area. Be sure installation area can maintain a temperature range between 35˚ - 110˚ F. CAUTION If ambient temperature drops below 32˚F, be sure to protect safety/relief valves and drain valves from freezing. NEVER operate compressor with temperatures below 15˚F or above 125˚F. 2. Allow sufficient space around compressor for maintenance access and adequate airflow.
EMAX Piston Air Compressors Piping / Tank Installation 1. Place tank feet on 1/4” thick rubber pads. Thicker padding will increase vibration and the possibility of cracking the tank or other unit damage. Do not place unit on dirt floor or uneven surface. 2. Fasten anchor bolts snugly but do not overtighten so normal vibration will not damage unit. DANGER Compressor unit is top heavy and must be bolted to solid, flat surface to avoid falling and premature pump wear.
Operating Instructions Minimum Pipe Size For Compressed Air Lines (Pipe size shown in inches) 7. For permanent installations of compressed air systems, determine total length of system and select correct pipe size. Make sure underground lines are buried below frost line and avoid areas where condensation could build up and freeze. 8. Test entire piping system before underground lines are buried. Be sure to find and repair all leaks before using compressor.
EMAX Piston Air Compressors 1. Plug auto drain into 120V outlet. 2. Set timers to desired settings. See figure 4. If drain is used for multiple units, increase timer settings as needed. 3. Use test button to check proper operation. Refer to maintenance section for proper care. Electronic Safety Be sure only trained and authorized personnel install and maintain this compressor in accordance with all applicable federal, state and local codes, standards and regulations.
Operating Instructions Improperly grounded electrical components are shock hazards. Make sure all the components are properly grounded to prevent death or serious injury. DANGER 9. Make sure proper overload protection for the motor is installed. Wiring Installation Install power leads into terminals opposite motor wires. When wiring unit with magnetic starter, do not install power directly to pressure switch to avoid possible fire and property damage. WARNING 5hp – use #8 wire Wire Sizes 7.
EMAX Piston Air Compressors Three Phase Motors (See figure 7) 1. Connect first power lead to 1L1. 2. Connect second power lead to 3L2. 3. Connect third power lead to 5L3. 4. Connect ground wire to existing motor ground wire. 5. Check for proper motor rotation. When facing motor shaft, pulley should turn counterclockwise. If rotation is reversed, turn off power then switch two power leads. CAUTION Ensure wiring is installed according to voltage required for proper motor operation (220V or 460V).
Operating Instructions 2. NEVER allow modifications to compressor structure or controls. 3. Keep all ignition sources away from exposed electrical parts. 4. Keep all persons clear of compressor during start-up and operation. 5. NEVER operate the compressor with the fan, coupling or other guards removed. 6. DO NOT engage in horseplay with air hoses as death or serious injury may result. 7. Make sure to provide adequate ventilation and use proper lubricant while operating the compressor.
EMAX Piston Air Compressors Always make sure main power is off before touching belts or other moving parts of compressor. WARNING 3. Lightly push power switch to make sure system is working. 4. If motor shaft is not turning counterclockwise, disconnect power to terminal block then exchange any two of the three power leads. Re-check rotation. Continuous Run Feature (if equipped) For heavy use applications such as sandblasting, the continuous run feature is available.
Operating Instructions 3. Relieve all internal pressure prior to opening any line, fitting, hose, valve, drain plug, connection or other component, such as filters and line oilers, and before refilling optional air line anti-icer systems with antifreeze compound. 4. Keep electrical wiring, including all terminals and pressure connectors in good condition. Replace any wiring that has cracked, cut, or otherwise damaged insulation. Replace terminals that are worn, discolored or corroded.
EMAX Piston Air Compressors 4. Do not splash lubricating oil on belts or pulleys when adjusting or replacing belts. Changing Oil All units are shipped with break-in oil. Change oil within first 50 hours or 30 days of operation, whichever comes first. DO NOT use automotive type oil. NOTICE Use only Airbase Industries Oil (PN: APOL03000G1). Use of any other product will cause product damage and void the warranty. Change oil every 90 days or if oil becomes milky.
Operating Instructions Maintenance Schedule Troubleshooting Chart Problem Low air pressure Overheating Possible Causes Resolutions 1. 2. Clogged inlet filter Air leak(s) in system 1. 2. 3. 3. 4. Application exceeds rated air output of compressor Cylinder head valves not sealing 5. Insufficient power 5. 1. Duty cycle exceeded 1. 2. Improper rotation 2. 3. 4. 5. 6. 3. Head valve(s) not seating properly 4.
EMAX Piston Air Compressors Warranty Statement Emax, INC. (also known as EATON-MAX, Inc. and each of its subsidiaries) makes the following Warranties: 1. 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. Emax (and each of its subsidiaries) is not responsible for downtime during warranty service.
Operating Instructions Operating Instructions SPLASH LUBRICATED AIR COMPRESSOR PUMPS Airbase Industries designs and manufactures products for safe operation. However, operators and maintenance persons are responsibile 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. Contents Model Specification Charts.............................
EMAX Piston Air Compressors SINGLE STAGE Splash Lubricated, Air Compressor Pumps APP2V0313S APP3Y0518S APP2V0732S 3HP 5HP 7.5HP 13 18 32 CFM @ Pressure (100 psi) 10.2 14.1 18 Max PSI 145 145 145 Noise DB(A) 75 75 74 NPT 1/2” NPT 1/2” NPT 3/4” Pump RPM 850 950 680 Bolt Pattern 8-3/16 x 4-5/8 8-1/4 x 5-1/4 10-1/4 x 5-3/8 15 x 10 x 13 18 x 15 x 12 18 x 15 x 12 Weight (lbs.
Operating Instructions Safety Information This manual contains very important information to know and understand. This is provided for SAFETY and to PREVENT EQUIPMENT PROBLEMS. To help understand this information, observe the following: DANGER Danger indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING Warning indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
EMAX Piston Air Compressors 2. DO NOT use air line anti-icer systems in air lines supplying respirators or other equipment used to produce breathable air. DO NOT discharge air from these systems in unventilated or other confined areas. Personal Protective Equipment Be sure all operators and others around the compressor and its controls comply with all applicable OSHA, Federal, State and Local regulations, codes and standards relating to personal protective equipment.
Operating Instructions 3. If acid is used in operating environment or air is dust laden, pipe intake to outside, fresh air. Increase pipe size by one size for every 20 feet of run. Be sure to install protective hood around intake filter. 4. In operating environments where excessive water, oil, dirt, acid or alkaline fumes are present, a TEFC (totally enclosed, fan cooled) motor is recommended. Check nameplate for motor type. 5. Allow sufficient space around compressor pump for maintenance access.
EMAX Piston Air Compressors 3. Cap fitting on cylinder heads if not using pilot valve for continuous run port. 4. Make sure there is a 1/4” copper tube (unloader tube) installed from tank check valve to unloader on pressure switch. This relieves head pressure when compressor stops for easier restart. See figure 2. 5. Use proper pulley for motor. Refer to Pulley Size Chart for correct sizing. 6. Install belts. There should be 1/2” slack for proper belt tension. See figure 3. 7.
Operating Instructions 8. Install appropriate ASME code safety valves and make sure piping system is equipped with adequate condensate drains. See figure 4. Never install a shut-off valve such as a glove or gate valve, between the pump discharge and the air tank unless a safety valve is installed in the line between valve and pump. WARNING 9. Make sure any tube, pipe or hose connected to the unit can withstand operating temperatures and retain pressure.
EMAX Piston Air Compressors Operation Safety Rules 1. Make sure all operators receive product training, read and understand all instructions. Keep all flammable, combustible, poisonous and noxious materials away from operating area. Make sure there are no oily rags, trash, leaves, litter or other combustible materials in operating area. Keep suitable, fully charged fire extinguishers nearby when servicing and operating the compressor. WARNING 2.
Operating Instructions 11. DO NOT use air tools that are rated below the maximum rating of the compressor. Select air tools, air hoses, pipes, valves, filters and other fittings accordingly. DO NOT exceed manufacturer’s rated safe operating pressures for these items. 12. Make sure all hose connections are adequately secured to prevent tools or hose ends from being accidentally disconnected. Start-Up 1. This unit may or may not contain oil when shipped.
EMAX Piston Air Compressors 3. Relieve all internal pressure prior to opening any line, fitting, hose, valve, drain plug, connection or other component, such as filters and line oilers, and before refilling optional air line anti-icer systems with antifreeze compound. Compressor components can become hot during operation. Avoid bodily contact with hot liquids, hot surfaces and sharp edges and corners.
Operating Instructions Maintenance Schedule Troubleshooting Chart Problem Low air pressure Overheating Possible Causes Resolutions 1. 2. Clogged inlet filter Air leak(s) in system 1. 2. 3. 3. 4. Application exceeds rated air output of compressor Cylinder head valves not sealing 5. Insufficient power 5.
EMAX Piston Air Compressors Warranty Statement Airbase Industries makes the following WARRANTY STATEMENT: 1. THAT EACH BARE COMPRESSOR PUMP UNIT TO BE FREE FROM DEFECTS IN MATERIAL, WORKMANSHIP, AND PARTS FOR 2 YEARS FOR THE UNIT FROM THE DATE OF PURCHASE. Airbase Industries (and each of its subsidiaries) is not responsible for downtime during warranty service. If downtime is necessary, it is the Purchaser’s discretion and obligation (at Purchaser’s expense) to have a redundant COMPRESSOR PUMP.
Operating Instructions 13
EMAX Piston Air Compressors EC10 (10 HP V-4) PARTS IN DETAILS Item Part No. Part Description UNIT QTY Item Part No. Part Description UNIT QTY 1 GASKET040 COPPER GASKET PCS 10 54 CYLINDER011 CYLINDER PCS 2 2 3 4 5 6 7 8 9 10 11 12 13 VALVE040 RETAINER004 NUTS014 UNLOADER002 RETAINER006 SPRING001 BOLT017 ORING013 BUSHING057 ELBOW003 VALVE041 RETAINER003 VALVE,INTAKE RETAINER,INT., 1.100 LONG NUT,LOCKING,M6-1.0 FORK, UNLOADER RETAINER, UNLODER SPRING, UNLOAD,1.
