INDEX

Sr. Particulars Page no.

Screw Compressor
1 Warranty & Liability limitation 2
2 Summary 3
3 Attention items in operation 5
4 Lubricant characteristics 6
5 Installation requirements 7
6 Check for the mechanical parts 8
7 Operation 8
8 Daily maintenance 9
9 Operating conditions and instructions 11
10 Operation by air adjustment 12
11 Fault resolution table 13
12 Operation 15
13 Maintainance 16
14 Schedule of the Maintenance Plan 17
Refrigerated Air Dryer
15 Installllation 19
16 Opration 21
17 Maintainance 23
18 Point to fix the breakdown 24
Empire Compressors should never be operated beyond its capabilities or in any way
which does not comply with the instructions contained in this operating and
maintenance guide.

Empire Compressor Pvt. Ltd. will decline any responsibility if these instructions are
not respected.

 INSTALLATION INSTRUCTIONS

 For the guarantee to be valid, the unit must be assembled in covered premises
with temperatures not exceeding : Mini: + 0 C (frost free) Maxi: + 45 C

 You must also have :

 2 meter space around the compressor

 In a dusty environment, pre-filtering the room's air intake and a special filter on
the machine's ventilation inlets.

 Air compressor should be installed in a solid level of the ground. The ground can
withstand the weight of the air compressor.

 The position of outlet valve.

1
 Warranty & Liability limitation

A. Use only authorized parts.

B. Any Damage or malfunction caused by the use of unauthorized parts is not

covered by Warranty or product Liability.

C. The manufacturer does not accept any liability for any damage arising for
modification, addition or conversions made without the manufacturers approval
in writing.

D. This instruction book describes how to handle the machines to ensure safe
operation, optimum efficiency and long service life.

E. Read this book before putting the machine into operation to ensure correct
handling,operation and proper maintenance from the beginning. The maintenance
schedule comprises measures for keeping the machine in good condition.

F. Keep the book available for the operator and make sure that the machine is
operated and that maintenance is carried out according to the instructions.

G. Repairs must be carried out by trained personnel from Empire Compressor PVT.
LTD. who can be contacted for any further information.In all correspondence
mention the type and the serial number, shown on the data plate.For all data not
mentioned in the text, see sections "Preventive maintenance schedule" and
"Principal data".

The company reserves the right to make changes without prior notice.

2
Summary
 Empire Compressor PVT. LTD. make series is stationary type oil injected screw
air compressor driven by electric motor, including air-cooled direct driven by
screw compressor . Empire air compressors are rugged in the structure design. It
has characteristics of compact structure, easy maintenance, unique appearance,
high efficiency, low energy consumption, low noise and long lifespan, etc.
Features and theory of Empire oil Injected screw air compressor
 Air end of Empire oil injected screw air compressor has characteristics of high
stability, low wearing parts, good power balance, low vibration, low noise, high
efficiency, long lifespan, etc.
 Low air end wear due to adaptation of large rotor & large bearings.
 Superior performance of air end: extreme little leak gap.
Compressing theory of screw air compressor:
Inlet process : Air entry is designed to be a compression chamber to make sufficient
air intake. When rotor rotates and rotor slots rotates to inlet end wall opening, its
space is the largest, at this time, rotor slots space has a connection with free air at air
inlet. Because when delivering air, air in slots is completely discharged, slots lie in
vacuum states. When rotating to the air inlet, air outside is inhaled, flowing into rotor
slots along the axial direction. When air completely fills the whole slots, following the
rotor's rotating, the tooth face of male rotor starts to engage with the tooth slots of the
female rotor, and is completed gradually, until the engagement.

Oil system
In air oil separators, most of the oil is separated from the air and oil mixture by
centrifugal or collision ways. The rest of oil is separated by the air oil separator
element. The oil separated is collected at the bottom of the air oil separator. Fan start
running in accordance with the detected temperature higher than the fan start
temperature ,then fan stop running when temperature dropped to below the fan stop
temperature. The fan starts again when the exhaust temperature is higher than the fan
start temperature once again, and this cycle continues back and forth.
Cooling system
The air cooled system includes an integrated air after-cooler and oil cooler, supplied
With high-efficiency cooled air by an axial flow fan (part of the compressors).
Silencing system
Screw compressors have a unique silencing system. The shock isolator inside
effectively reduces the noise by shocking. The inner wall of the acoustic shield pastes
special acoustic sponge and maisy air inlet is designed to effectively reduce the noise
to the minimum.

3
Running condition
The purpose of the control system is to control the opening degree of the air inlet
valve and make sure of the normal flow of the air. The system consists of a set of
microcomputer control system, an air inlet valve, a solenoid valve and two sensors.

Starting up
Start up the air compressor when all preperation is completed. Then the motor starts
and the main valve of intake is closed. So only a small amount of air can pass
throught the small hole in the valve plate of the air inlet valve. Air compressor startup
under light load. The initial stage of the system pressure of oil-gas seperation barrel is
established.
Loading
Starting about 7 seconds later the motor turns into a triangle. 2 seconds later, the
solenoid valve on the intake valve gets power. Then the valve is fully open and a large
number of air goes into the air compressor. The air compressor enters into a situation
of full load. When the pressure of the oil-gas separation reach es or exceeds 0.4MPa,
the minimum pressure valve will open. Then the unit begins to supply gas outward.
This state will last as long as the pressure of system is lower than the set point of the
unloading pressure.
Unload
If the gas consumption is less than the amount of the compressor, the exhaust pressure
of the unit will reach or exceed the unloading pressure.Body setting value, at this time
through the microcomputer controller control, the solenoid valve is lost, the main
valve of the intake valve closed.Stop a lot of air intake, only a small amount of air
through the valve plate on the small holes into the compressor, the minimum pressure
valve clearance closed, will use the gas pipeline isolation compressor with the user,
and the vent valve is opened, the oil barrel pressure release down to 0.25~0.35MPa so
that the power consumption is reduced, but also to maintain the oil system in the
circulation of lubricating oil.
During the unloading operation, if the discharge pressure drops to the set value of the
loading pressure, the microcomputer control Solenoid valve, solenoid valve main
valve of the intake valve and re open, the valve closed, the unit Into the load running
state.
If the unloading control part of the failure or improper settings, the unit can no longer
under normal system pressure unloading, The safety valve on the oil barrel will take
off, release the system pressure, to avoid the risk of system pressure is too high.At this
point should be immediately cut off, check the inlet valve and the controller settings
whether correct.

4
Stop
Normal Stop:
If the compressor is required to stop gas supply, the stop button should be pressed,
and the compressor will enter the stop condition. When the main valve inlet valve
closed, vent valve open, releasing oil barrel pressure, after about 30 seconds,
compressor Shut down.
Fault Stop:
When the compressor appears any electrical and over temperature failure, the
microcomputer controller will immediately stop. At this point should be based on the
troubleshooting, and then press the reset button to restart.
Emergency Stop:
If any abnormal situation occurs shall immediately press the emergency stop button,
so that the compressor immediately stop to avoid loss. After shutdown in a timely
manner to remove the fault, and then reset the boot.
Attention items in operation
To observ whether there is abnormal sound and vibrations if this occurs immidiatly
shut down.
During operation shall not bo loosened in the group any pipeline, bolt and screw.
To observe the oil level, the oil level is too low, immediately refueling
The operator should do a good job of running the record.
Air inlet temperature
The designed operating temperature of Screw air compressor is between 5 degree C to
45 degree C, the measuring point is the air inlet point.High temperature above 45
degree C need to put orders specially.
Condensation- low temperature
In the place where it is very high in humidity and very low in operating temperature,
condensation water is easily gathered in the oil. Empire air compressors are equipped
with a temperature control valve. The temperature is designed to be 70°C (the
temperature needed by evaporation of the saturated vapour), and when the oil
temperature is above it, oil will pass through the oil cooler. In the area where the
ambient temperature is under 5°C, when using the compressor, heater is needed to add
an under air oil bucket (please contact the Technical Dept.)

5
Overheated·high temperature
If the ambient temperature is above 45 ·C, or installed in the room which has a boiler
in it, when using the compressor, inhaled air must be brought from outside. The
highest operating temperature of CompTech air compressor is 105 ·C. When the
temperature is above 105 ·C, the air compressor would stop automatically. When the
temperature is above 105 ·C all the time, we must find the reason for the error
according to the manual or contact with the Customer Service Dept.
Delivery temperature
The measuring point of the delivery temperature of the air compressor is set at the
vent. The delivery temperature changes according to the ambient temperature,
cleanliness of the cooler, cleanliness of the inlet air filter and cleanliness of the oil
filter. The normal operating temperature should be between 75·C to 85·C. When
starting in cold condition, the delivery temperature increases to 85·C covering quickly,
the the axial fan starts working decreasing the fan until stop .the oil temperature
returns to 75·C
Lubricant characteristics
Oil special for Empire screw air compressor has the characteristics below,
Low Bubbling, nonvolatile
Strong resistance to emulsification
High antioxidation and antiwear properties
High viscosity index
Good antiwear lubricity, anti vesicular nature and water separability
Temperature of solidifying point ·30 ·C, prevent solidifying, reduce energy Flash
temperature 248·C, avoid carbon build-up, reduce energy
Oil special for Empire screw air compressors is the uniquely matched special oil for
air compressors according to the working theory of Empire screw air compressors.
So in order to guarantee the normal use of the air compressor, please select oil special
for Empire screw air compressors. The problems caused by other brands of oil
used by customers, Empire Compressor Pvt. Ltd. is of no responsibility.
Preliminary instructions
Before installing the air compressor, please check carefully whether there is damage
during transportation reasons. If there is obvious damage, please instantly contact the
Customer Service Dept. of Empire Compressor Pvt. Ltd.

6
Installation requirements
Put the air compressor in clean, dustless and draughty conditions of no poisonous Gas
/ inflammables / explosives, and where it is convenient for proper maintenance.
Empire makes an air compressor cannot be used outside except a shed is provided to
Protect it from rain & sun. All the air compressors should be installed inside.
If the outside conditions are bad and dusty, the crude filtering net should be installed
in the air inlet of the room to reduce the dust content inside.
The ambient temperature must be above 5 °c to ensure the normal cycle of the
lubricant.
Proper space should be provided around the compressor. The distance is good to be 1
meter from the wall to be convenient for the operators to operate, maintain and
check.
The air compressor must be put on the horizontal and rigid ground, no need for the
bolts to fix it. Do not install the air compressor near/around a hot environment. The
hot air exhausted by the exhaust duct can not be inhaled directly into the drier, which
lightens the load of the drier and saves the energy.
The ideal pipe matched is to make the main pipeline around the whole workshop
which needs to use the air. So the compressed air of each aspect can be got at any
place, and it is convenient for check and cutoff when installing suitable valve in the
main line around.
Requirements and check for electric device
The wires in all the air compressors have passed the testing by the factory. The wires
outside to switch inthe air compressor must be the ones produced by qualified
manufacturers. Based on the input power needed by the compressor unit, correctively
select the wire specification. When the wire is long, the wire loss should be in
consideration. At this time, the wire diameter should be added more and meet the start
and operation of the air compressor.
For compressors of large air delivery, one single set of power supply systems Should
be considered in case of affecting the normal working of other equipment when the
compressor starts.
Before supplying electricity to the air compressor, the supply voltage should be the
same with the rated operational voltage of the compressor.
Reliable ground wire should be arranged well to avoid the danger caused by the
electricity leak.

7
Check for the mechanical parts

Check for the screw air end

Whirl the coupling of the screw air end in two different directions, to ensure the screw
air ends Unlocked.
After the air compressor is not in use for over two months or is stocked for some time,
the air inlet valve should be opened. Half a liter of the oil special for Empire air
compressors should be added in through the air inlet control valve.
When reconnecting the air inlet pipe, make sure the pipe orifice sealed.
Check for the oil level
Open the side door, we can center the oil Glass on the air oil separation bucket. The
oil level cannot be under the bottom line of the oil scale. while in running condition.
(The highest oil level is visible in the oil level indicator.
Add stated oil. Make The lid of the oil pouring orifice close. Make Sure of rightly
sealing of the sealed ring.
Operation
Start process
Check if the oil level is correct or not, the oil level must be in the middle of the oil
scale.
Exhaust the condensate water in the air receiver.
Make sure the gate valve is open.
Press the start button; (the air compressor has no automatic start, the flashing of the
operating light indicates the delayed start)
Check the main shaft steering of the compressor. There is the sign of the direction
arrow on the compressor. The compressor direction must be the same as the sign of
the direction arrow. If the direction is incorrect, please press the red emergency stop
button at once to stop the compressor, and cut off the compressor from the power
supply
Operation process
Normal operation works after start. Check each operation parameter during it.
When unusual sound and abnormal vibration occur, the compressor should be stopped
at once.
The pressure exists in the pipeline and vessel in operation. The bolts or connections of
the pipeline should not be loosened.
In long term operation, if the oil level on the oil level indicator cannot be seen, and
the delivery temperature goes up gradually, the compressor should be instantly
stopped. After stopping for ten minutes, check the oil level. If it is not enough, add
lubricant again until there is no pressure in the inner system.
In operation, make records of pressure, temperature and oil level, etc. parameters
every day for reference of later maintenance and check.

8
Stop process
Press the stop button, in about 10 to 30 seconds, the compressor will stop.
Daily maintenance
Check the lubricant oil level of the compressor. If the oil level is very low, oil must be
added. Check that connections are not loose if there are any bolts, or nuts loosened or
damaged.
After the compressor starts, check if the values on the LCD screen are normal. Check
if there is any oil leak of the compressor, if there is, please stop instantly and deal
with it after releasing all the inner pressure of the Compressor.
After maintenance, please fully check if it is equipped again and set well, if each
fastener and sealing pieces are rightly installed.
Oil drain ball valves can be opened after the compressor stops for five minutes.
When the air compressor is operating or has pressure, please do not carry out
any maintenance or repair.
Replacement and regulation of spare parts
Maintenance method of air filter
Open the air filter housing.
Take out of the filter element.
Check the conditions of the air filter element (replace if it is not good).
Do not blow air to the filter in order to clean it.
Replace the new element and install properly.
Close the air filter housing cover.

Maintenance method of oil filter

Twist the oil filter off with a clamp.
Clean the interface.
Place an oil sheet on the surface of the new filter sealed ring.
Tighten the new filter with clamps until the gasket is sealed.
Check if it leaks after starting the compressor.
Maintenance method of air oil separator element
Open the service side-door.
Loosen the end connected the pipe and the minimum pressure valve.
Loosen the pipeline on the air oil separation bucket shell cover, remember and ensure
the correct installation.
Loosen the clamp bolts on the air oil separation bucket.
Carefully lift up the cover plate, clean the oil return pipe.
Take out the air oil separation bucket element.
Replace the new air oil separation bucket and gasket.
Install in reverse steps, pay attention to check the length of the oil return pipe.
Use torque spanner, tighten the bolts of cover plate of the air oil separation bucket.

9
Characteristics and maintenance method for air inlet control valve
The air inlet control valve mainly consists of valve body, valve, piston, cylinder,
spring and sealed ring, etc. Its side is equipped with a control block and control
solenoid valve, gathered with functions of on/off regulation, unload, silencing,
dropping pressure and stop vent, etc. When unloading, a small quantity of air is
released through the small hole in the valve to balance the inhaled air content of the
small hole of the air inlet control valve and make the pressure in the separation oil
tank keep 0.2-0.4 MPa, and maintain the normal lubricant cycle. The working of the
loading and unloading of the inlet control valve is automatically controlled by the
pressure sensor and solenoid valve of the regulation system. The flexibility of the
motion is very important for the reliability of the compressor. So, the air inlet control
valve should be maintained regularly to keep a reliable of the air compressor reliable.
When maintaining, the spare parts should be removed. Check the wear of each
friction surface. Pay special attention to check the surface of the grommet. If any
break or crack, it should be replaced by new parts. In reinstalling,each spare part
should be cleaned and lubricant must be coated on the friction surface of the metal
parts.
Maintenance method for minimum pressure control valve
Twist off the cover, beware of the spring in the valve.
Take off the cover. Check the O-ring on the piston. Replace if worn out.
Check the sealed ring. Replace if worn out.
Reinstall these in reverse direction of taking apart with lubricant of high Temperature

Replacing method of lubricant

Stop the compressor.
Connect up the oil drain pipe, open the ball valve, and drain the oil into the waste oil
collection bucket.
Close the oil drain ball valve, open the filling oil cover, refill in the new oil until the
oil level goes in the middle of the oil scale.
Close the filling oil cover. Pay attention to check if the O-ring is in the correct place.
Start the compressor. After running for some time, check the oil level. If it is low,
properly add some more oil. When the operating temperature is high or dusty, the
replacing time interval of the oil should be shortened relevantly. When the air
compressor stops for thirty minutes, the oil level is in the middle of the oil scale. The
lowest oil level: Check when the compressor is in running condition, the oil level
should be higher than center.
The oil level should be about the centre of the oil level indicator while compressor is
in running condition.

10
Operating conditions and instructions
Save/Use conditions:
Saving environment: Temperature -20oC - +70oC, dry condition.
Use Environment Temperature:-10 °C-+60 "C
Relative humidity: 5%-95%, No condensation.
Other Requirements: No gas existing to corrode metal and damage Insulation, no
significant vibration, strong magnetic field and electric field.
Operation of controller
Phase sequence protection: Wrong phase can not start, Phase-failure protection
time is
less than 1 second, 16 seconds protection time of imbalance phase.
Motor overload protection:
The protection time is less than 60 seconds when motor current is 1.2 times than the
rated current.
The protection time is less than 48 seconds when motor current is 1.3 times than the
rated current.
The protection time is less than 24 seconds when motor current is 1.5 times than the
rated current.
The protection time is less than 8 seconds when motor current is 1.6times than the
rated current.
The protection time is less than 5 seconds when motor current is 2.0 times than the
rated current.
Emergency time, over temperature, over pressure action time is less than 1 second.

11
Operation by air adjustment
Machine must be stopped before you set parameters. In this condition, pressing
«SET» key can set parameters otherwise view only.

No. Parameter Default Define

Name

1 Loading 0.5 Continuous twice press «SET» at the current page,

pressure Mpa

2 Unloading 8Mpa Continuous twice press «SET» at the current page,

pressure

3 Pressure set 0.65 Constant pressure, Continuous twice press «SET»

Mpa at the

4 Y-time 15 s The time for Y- delay

5 Non-Load time 10 min Reach Unloading pressure, the motor running time

6 Load On time 15 s Motor started, Load solenoid valve delay time

7 Stage time 15 s Any two compressor interval time of start and stop
when

8 Stop time 15 s The delay time by pressing stop key in to real stop

9 Count time 15 s The delay time by pressing stop to restart

10 Fan stop 75°C The temperature of fan stop

temperature

11 Fan start 85°C The temperature of fan start

temperature

12 Runmode set Air Normal use chooses an air adjust term, when gas
Consumption is low. Choose power adjust term

Notes
Don't use the emergency stop key as the stop button.
Signal cable link or plug must be acted if the controller without power or after power
failure or will lead to the damage to the electronic components
When equipment is running, modifying the controller parameters are not allowed.
Equipment exterior must be well grounded, and not short-circuit the signal line to
ground.Installation must be separated from the signal line and power line to reduce
interference, when long-distance link the communication lines need to use shielded
cable and ensure good grounding.

12
Fault resolution table
Fault Possible reason Possible Solution

Unable to start Fuse burnt Ask electric serviceman to check

(electric fault) Relay overload
Too low voltage
Air end error
Phase sequence
relay broken
Contactor jammed

Air delivery Shortage of Please stop the compressor and add

temperature is high, lubricant oil
automatic tripping Shortage of cooling Check the capacity of in and out
operation of the air water water pipes
compressor High temperature of Check the temperature of inlet water
cooling water Add air discharge, improve the
High ambient environment
temperature Check the temperature of the inlet
Oil cooler blocked and outlet. The normal pressure
Incorrect lubricant differential is 5~8°C. If it is under
Plate-fin heat 5oC, the oil cooler may be blocked
exchanger is not and should be cleaned
clean Replace the oil special
Oil filter blocked Clean with air of low pressure
Cooling fan error Replace
Temperature sensor Replace
error Replace

High oil content in the Too high oil level. Check the oil level and properly
air, short lubricant Oil return pipeline discharge
adding cycle blocked. Disassemble and clean
Too low delivery Regulate the pressure
pressure. Replace
Air oil separator Replace with new spring
broken and out of
work.
Pressure retaining
valve
spring fatigues.

Unable to operate full Solenoid valve error Replace

loaded Air inlet valve Take off and clean, then add
doesn't work well lubricant. Check whether the control
Pressure retaining pipeline is fluent or not
valve doesn't work Take off and check whether the
well valve base and check valve have
Circuit board error worn down. If so, replace them
Pressure sensor error Replace
Replace

13
Unable to unload.In unload Air inlet valve doesn't Take off and clean,
condition, gauge pressure still work well then add lubricant
keeps the working pressure or go Leak solenoid valve Check and replace if
on rising, safety valve works out of work or leak necessary
pipeline blocked Replace
Circuit board error

Air delivery reduces Air inlet filter blocked Clean or replace

Air inlet valve doesn't Take off and clean,
work well later add
Air oil separator lubricantReplace
blocked Check and replace if
Leak solenoid or necessary
pipeline leaks Replace
Air filter blocked

Frequent empty and load Pipeline leaks Check leak point and
Too low differential lock
pressure Reset
Unsteady air Increase air receiver
consumption capacity

When compressor stops, oil mist Air inlet valve close Check and replace if
comes out from the air pipeline insufficiently or necessary
seizure Check the reason
Load stop Check and replace if
Pressure retaining necessary
valve leaks Check and replace if
Bleed valve doesn't necessary
bleed

14
OPERATION
Air hoses shall be of correct size and suitable for the working pressure. Never use
frayed, damaged or deteriorated hoses. Use only the correct type and size of hose end
fittings and connections. When blowing through a hose or airline, ensure that the open
end is held securely. A free end will whip and may cause injury. Make sure that a
hose is fully depressurized before disconnecting it. Never play with compressed air.
Do not apply it to your skin or direct an air stream at people. Never use it to clean dirt
from your clothes. When using it to clean equipment, do so with extreme caution and
use eye protection.
The compressor is not considered as capable of producing air of breathing quality. For
breathing air quality, the compressed air must be adequately purified according to
local legislation and standards.
Never operate the units when there is a possibility of taking in flammable or toxic
fumes.
Never operate the units at pressures below or in excess of their limit ratings as
indicated on the Principal Data sheet.
Keep all bodywork doors shut during operation. The doors may be opened for short
periods only, e.g. to carry out checks. Wear ear protectors when opening a door.
People staying in environments or rooms where the sound pressure level reaches or
exceeds 90 dB(A) shall wear ear protectors.
Periodically check that:
All guards are in place and securely fastened
All hoses and/or pipes inside the unit are in good condition, secure and not rubbing
There are no leaks
All fasteners are tight
All electrical leads are secure and in good order
Safety valves and other pressure-relief devices are not obstructed by dirt or paint
Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in
good repair, free of wear or abuse
If warm cooling air from compressors is used in air heating systems, e.g. to warm up a
workroom, take precautions against air pollution and possible contamination of the
breathing air.
Do not remove any of, or tamper with, the sound-damping material.

15
MAINTENANCE
Maintenance and repair work shall only be carried out under supervision of someone
qualified for the job.
 Use only the correct tools for maintenance and repair work.
 Use only genuine spare parts.
 All maintenance work, other than routine attention, shall only be undertaken
when the unit is stopped, the main power supply is switched off and the machine
has cooled down.
 Take positive precaution to ensure that the unit cannot be started inadvertently. In
addition, a warning sign bearing a legend such as "work in progress; do not start"
shall be attached to the starting equipment.
 Before removing any pressurized component, effectively isolate the unit from all
sources of pressure and relieve the entire system of pressure.
 Never use flammable solvents or carbon tetrachloride for cleaning parts. Take
safety precautions against toxic vapours of cleaning liquids.
 Scrupulously observe cleanliness during maintenance and repair. Keep dirt away
by covering the parts and exposed openings with a clean cloth, paper or tape.
 Make sure that no tools, loose parts or rags are left in or on the unit.
 Before clearing the unit for use after maintenance or overhaul, check that
operating pressures, temperatures and time settings are correct and that the
control and shut-down devices function correctly. If removed, check that the
coupling guard of the compressor drive shaft has been reinstalled.
 Protect the motor, air filter, electrical and regulating components, etc. to prevent
moisture from entering them, e.g. when steam-cleaning.
MAINTENANCE PACKAGE:
The company promises that the maintains package is 100% pure diamond brand spare
parts which can reduce the user maintence budget. All the parts are included that need
to be done during the maintaince.

16
Schedule of the Maintenance Plan
BEFORE ANY OPERATION ON THE MACHINE READ CAREFULLY
USE AND MAINTENANCE MANUAL

BEFORE INSTALLATION CHECK POWER SUPPLY

BEFORE ANY MAINTENANCE DISCONNECT THE MACHINE

FROM POWER SUPPLY AND COMPRESSED AIR PIPING

CHECK OIL LEVEL AT SWITCHED ON MACHINE EVERY 50 h

IF NECESSARY DRAIN CONDENSATE FROM OIL RECEIVER OR WEEKLY
WHEN MACHINE IS COLD
CLEAN THE AIR & OIL COOLER

REPLACE THE OIL FILTER First 2000 h

REPLACE THE AIR FILTER Then every
4000h

REPLACE THE OIL EVERY 4000 h

REPLACE THE AIR.OIL SEPARATION

USE RECOMMENDED COOLANT DO NOT MIX DIFFERENT TYPE OF COOLANT

TIMES OF MAINTENANCE ARE RECOMMENDED FOR WELL VENTILATED AND
CLEN AREAS
INTENSIFY THE MAINTENANCE FOR DUSTY AREAS

17
Refrigerated
Air Dryer

18
 INSTALLATIONS

The installation includes inspection, carrying, placing, airconnection, power wire

connection, etc. To insure the user's right andthe service life of the dryer, please read
the contents below carefully.
1. Please check if the dryer has been damaged during transportation after opened
the packing. To check the accessory according to thePacking list, if any assort
& detection, please notify the agent withwritten form within 2 days.

2. Porterage
a. The fork can carry the dryer by the bores on thebase of the dryer.
b. b. To be sure the fork capacity can meet the request.
c. Keep the machine in balance, and avoid theinclination or handstand, handle
with care

 Forbid using forked vehicle to carry from side, if do it machine will fell
down and lead to the
Damage the machine and personnel.

3. Placing

a. The ground should be a strong and tough cement ground or stability of

level to have no the Vibration’s Ground and the strength must bear the
weight of the machine enough.
b. The machine and surroundings objects should keep 1 meter above
Distance, the drain, airiness& the Space for maintenance shall be
considered.
c. c. Any placing at the moisture, the causticity, outdoor, high heat or the
Dust are not allowed.

4. Compressed air tube conjunction

a. To avoid too long tube, too many link knot & to0 small diameter, inorder
to prevent pressure decline.
b. Considering to the pipeline sketch match to set between the compressed
airtreatment equipment.
c. To install a by-pass valve in the inlet and outlet of the dryer, in favourable
to testand fix.
d. Advise you to set filter when install the pipeline, in order to filt the oiland
the impurity.
e. Install the pipeline, advise you to set the waterspout at the end of the
pipeline orthe low place, and Drain the water timing

19
 5. Power wire installation
a. According to the nameplate, the user shall prepare the circuit
breakerand fuse
b. Please connect the ground line or other protective switch for thesafety.
c. Be sure the voltage is correct and the juncture is tight after
circuitconjunctions complete, please tight
again when the shipment cause the power wire to be loose.
f. to choose the section diameter of the power wire should base on the
Electricity on the nameplate.

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 OPERATIONS

The user shall know the operations of machine contain the item of start, stop, debug
and record for the components, and learn to observe and record the number on the
meter.
1. Chart of Principle for Machine

2. Work Principal
a. The compressed air with the moisture and high heat flow into the front cooler
(Special for the high temperature, and then flow into heat exchanger after the
heat cropped away, and to exchange the heat with the cool air from the
evaporator, so the temperature of the compressed air debase.
b. The air fell down temperature flow into evaporator and exchange heatwith the
refrigerant, the heat
will be moved the compressed air will becool soon the moisture in the moist
air condense to water drop, and aredischarged out from the auto drain by the
gas and water separator.
c. The dried air flows through the air heat exchanger and exchange with the inlet
high temperature air,
the temperature of cool air raisedafter absorbed the inlet heat air. The outlet air
temperature will be raiseafter flew into the second condenser and high heat
Freon exchanger, toinsure the outlet air pipe no dewdrop, Fully utilize of the
source of coolOutlet air, reducing the refrigerant system's bear and insure the
quality ofthe outlet air.

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3. The instruction of the main machine instrument and controlling switch
Main instrument succeed by air pressure gauge. Freon-high pressure gauge,
Freon-low pressure; Control electrical source by ON/OFF according to
refrigeration electrical source button, high or low protect switch for the freeze
system, and antifreezing switch composes.Its function synopsis lain as follows.
3.1 Main instrument
a. Air pressure gauge (stainless steel frame) fit in instrument board used
to show compress air pressure of the machine. Mpa and
Kg/cm²representative unit of pressure. When you read the unit of
pressure, look at the opposite scale value add to the unit?
b. Freon-high pressure gauge(red frame ) fit in meter board, used to show
the pressure and temperature of freeze system, Psi and Kg/cm2 under
the meter is pressure's unit, C is temperature's unit when you read the
unit of the pressure, look at the opposite scale value add to pressure's
unit when you look at the temperature of the dew point,please base on
the variety of the Freon on the name plate.
c. Freon-low pressure (blue frame), fit in meter board, used to showlow
pressure or temperature, it built up several scale, and the way tolook
into the temperature is the same as the high-pressure meter.
3.2 Main instrument
a. ON/OFF press button fit on to machine board, main use to control
therunning and stopping
b. The high-low pressure protected switch for the refrigeration system
use to control the pressure of the high pressure side and the lowside,
avoid the damage which from the over pressure of themachine. (Press
“RESET" to restoration)
c. Antifreezing switch install in the machine, use to control the
condensation pressure of the machine avoid the condensationpressure
too low, cause the evaporator stop.

Remarks: the model is different, the component is different it is based

on the real thing
4. Operation
4.1. To check the items below before operating
a. Power supply, phase, frequency shall accord with convention(refer
to nameplate), and the electric wire connect tight.
b. The pipe of the system connects tight.
c. Place dryer well, the ambient temperature shall meet request.
d. Check the refrigeration system pressure. when it lower than 25
Psig.please check the ambient temperature if it is not based on the
low ambient temperature please contact us or the wholesaler.
e. Ball valve in front of the auto drain valve should be opened. In
order to improve the quality of the air, please open the
aircompressor and let it run steady, then put in the compress air.
4.2 Starting and Running
a. Send the power to the control box ,press ‘on’ the control panel
which have the power protected switch and control protected
switch ,then press ‘ON’ on the ON/OFF button, the machine
contact well indicator light, and compressor running. Normally the

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 freon low -pressure scale between At 60-85 Psig .( applicable for
R-22). R-134 freon should press between at 24-45psig. If over,
please base on the 4.4 to adjust.
b. When compressor running placidity the Freon-high pressure arrow
go up between 140 and 280psig. R-22) R-134a Freon will show
between 120 and 240psig. When the Freon's pressure too high,
please check the condenser, the inlet temperature of the dryer and
the
ambient temperature.
c. When high pressure lower than 140Psig antifreezing switch as
operation, condensation fan stop running, in order to keep normal
running. If sets of long issues of running competent please check
the refrigeration system is not leak down and the ambient
temperature is too low.
 In order to avoid compressor damaged, not to start frequency,
if re-start
need to wait more than 3 minutes.
 The valve has been regulated in the factory: to avoid
unnecessary damage. don't regulate it except technician
(except manual drain)
4.3. Stopping
a. Close the power before stop the air compressor.
b. Press 'OFF' before close the compressor, the machine stop running.
C. Cut off the power. (Do not cut off the power if the machines have
heating protected Component in winter)
Stop the compressed air after to stop the dryer, discharge the
compressed air in the pipe completely to be sure there is no
moisture, in order to insure the air quality.

5. Maintenance
Put the maintenance in order to ensure to the machine can move in gear and
quality of air, it can detach in to daily and to moment.
5.1 Daily maintenance
a. Checking the back of machine to be sure the condensation is clean, in
order to avoid the caloric to emanate.
b. After the machine platform starts and the compressed air is entered, check
the working pressure is normal
c. Check the auto drain to be sure it can drain water after the compress air is
running normally.
d. Please open the drain valve to out the water every week two or more times.
e. Please open the manual drain valve two or more times every day.
f. When the ambient temperature is over 40 C. please improve it .or it will
cause the machine into trouble.

5.2 Sections of maintenance's item

a. Every two weeks or the back of the condenser have too much dust use the
dry compress air or brush to clean the back of the condenser (look at the
picture)

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 b. Per month it need to check auto drain to be sure normal, such as working
abnormal (drain off water or it is be bad to drain -off water) please
washing (wash method according to drain off water drain protect).
c. Check every three month whether fan vane work as hot wind as alike bad
shaking instance.
d. Every year check and tight all the bolt and the fixed setting.
e. Every year check ,clean and tight all the electric conjunction.

6. POINTS TO FIX THE BREAKDOWN

There are six factors caused the breakdown by air dryer itself and
outside reasons.

6.1 The pressure fall too sharp

CONDITION CAUSES BREAKDOWN FIXING

The pipeline valve is not full
opened Full open the valve
The pipe diameter is too narrow Increase the pipe diameter
The pipeline is too long and too Design the pipeline system
The fitted pipe more link knot
sysytem is out again
of order Over two compressors parallel air
Design the pipeline system
dryers can't fit well
again
Filter stoppage in the pipeline Renew or clean the filter
More leaks of pipeline contact Check the link points
Temperature or pressure switch is
Renew or check the circuit
poor
correct the switch

Expansion valve or hot gas by-pass Renew or check if the circuit is

The condensed is breakdown stoppage, correct the switch
water is freezing
in evaporator Radiator unit direct to the wind Improve ventilation

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 6.2 Air dryer cannot dispel water well

CONDITION CAUSES BREAKDOWN FIXING

By pass valve isn’t full opened Fasten by pass valve
The air doesn't pass the air dryer Full open the inlet valve of the dryer

The fitted pipe Dryer isn't put on the level

system is Place the dryer level
abnormal
Auto drainer inclines
Place the dryer level
Discharge pipeline is Higher
than auto drainer Set the discharge pipeline again
Air flow
volume over
Pressure fall too much Redesign the air compressed system
Drainage Drainer is poor or
system is electromagnetic valve is
abnormal breakdown clean or renew

The front valve of drainer isn't

full opened Be sure the valve is full opened

The dew point temperature is Regulate the, water flow switch, hot gas
too high/low by-pass valve
Evaporator The ambient/inlet temperature is
temperature stop using when the temperature is
over low
meter indicates lower than 20C
abnormal Inlet temperature is over high Add a after cooler

surrounding air is foul, choose a suitable place or improve the

ventilation is poor ventilation

Freon leaks, cooling is poor in

efficiency Fix the leaks, fill up with FREON.

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