Polar Air PP05H080I1 User Manual

Polar Air Electric Operated, Piston Compressors
1

Polar Air PP05H080I1 Specifications

General

Brand	Polar Air
Model	PP05H080I1
Category	Air Compressor
Language	English

Summary

Description and Component Identification

Description and Component Identification

Identifies key components of the air compressor unit through labeled diagrams for general understanding.

Safety Information

Safety Symbols and Definitions

Explains the meaning of DANGER, WARNING, CAUTION, and NOTICE symbols used throughout the manual for safety.

Basic Operating Guidelines

Provides fundamental safety rules for operating the compressor, emphasizing trained personnel and compliance.

California Proposition 65 Warning

Warns about chemicals known to the state of California to cause cancer and birth defects.

Safety Information (Continued)

Breathable Air Safety

Details safety precautions when using compressor air for breathing applications, adhering to OSHA standards.

Pressurized Components Safety

Information on the ASME-designed pressure vessel and safety relief valve operation and testing.

Personal Protective Equipment (PPE)

Specifies required personal protective equipment for operators and personnel around the compressor.

Inspection

Pre-Use Inspection Procedures

Instructions for inspecting the compressor for external damage and checking moving parts before operation.

Pallet-Mounted Compressor Safety

Emphasizes securing pallet-mounted compressors before moving to prevent injury or damage.

Forklift Unloading Precautions

Guidelines for safe unloading using a forklift, referencing Figure 1 for procedure.

Inspection (Continued)

Forklift Safety Procedures

Detailed steps for safe operation of forklifts when moving the compressor unit.

Lifting Safety Procedures

Comprehensive guidelines for safely lifting the compressor using appropriate equipment and methods.

Installation

Installation Area Requirements

Specifies ideal environmental conditions, temperature range, and clearance for compressor installation.

Piping Safety Steps

Safety guidelines for installing piping, including flow-limiting valves per OSHA standards.

Installation (Continued)

Piping and Tank Installation Guidelines

Instructions for securing the tank, using flexible connectors, and installing safety valves and drains.

Basic Piping Diagram Explained

Explanation of the basic piping diagram showing air tank, ball valve, coalescing filter, air dryer, and water drain.

Shut-off Valve Installation Warning

Caution against installing shut-off valves between pump discharge and air tank without a safety valve.

Plastic Pipe Usage Warning

Strong warning against using plastic (PVC) pipe for compressed air due to severe risk.

Installation (Continued)

Compressed Air Line Sizing

Provides a chart and guidance for selecting the correct pipe size based on SCFM and piping system length.

Closed Loop Installation Diagram

Illustrates a closed loop system for compressed air lines, showing tee fittings and air drops.

Electronic Auto Drain Setup

Instructions for installing and operating the electronic auto drain feature for compressor units.

Electronic Safety

Auto Drain Feature Operation

Details the operation of the auto drain feature, including plug-in, timer settings, and test button.

Electrical Installation and Safety Standards

Emphasizes compliance with NEC standards, dedicated circuits, proper wiring, and grounding for electrical safety.

Electronic Safety (Continued)

Electrical Grounding and Shock Hazard Warning

Highlights the critical importance of proper grounding to prevent shock hazards and ensure safety.

Wiring Installation Procedures

Step-by-step instructions for connecting power leads to terminals for single-phase motors, with and without magnetic starters.

Single Phase Wiring Diagrams

Illustrates wiring diagrams for single-phase motors, both with and without magnetic starters, for proper installation.

Operation

Three Phase Wiring Diagrams

Diagrams and instructions for wiring three-phase motors, including power lead connections and rotation checks.

General Operation Safety Rules

Essential safety rules for operating the compressor, including fire safety and keeping the area clear.

Operation (Continued)

Prohibited Actions During Operation

Lists actions to avoid during operation, such as modifications, removing guards, and horseplay with air hoses.

Compressed Air Discharge Safety

Warning to keep persons clear of compressed air discharge points and to vent relief valves properly.

Air Tool and Hose Rating Guidelines

Advice on selecting air tools, hoses, and fittings that match the compressor's rating and pressure.

Start-Up Procedures

Initial Oil Level Check

Instructions to check the oil level in the site glass before operating the compressor.

Belt Tension Check

Guidance on checking and adjusting belt tension, ensuring 1/2 inch slack.

Operation (Continued)

Continuous Run Feature Operation

Explains how to engage and stop the continuous run feature for heavy-duty applications.

Maintenance

Maintenance Safety Steps

Critical safety measures for performing maintenance, including power lockout and pressure release.

Maintenance (Continued)

General Maintenance Safety

Safety precautions for performing maintenance, including handling hot components and electrical safety.

Belt Adjustment Procedure

Detailed steps for inspecting and adjusting belt tension, including deflection measurement.

Maintenance (Continued)

Changing Compressor Oil

Guidance on oil change intervals, the correct type of oil to use, and when to check for milky oil.

Safety Valve Operation Check

Instructions for checking the safety valve's operation and warnings about tampering with it.

Daily Tank Drain Procedure

Instructions for daily draining of the tank and traps, and cleaning the auto drain filter if equipped.

Maintenance Schedule

Daily Maintenance Tasks

Check oil level, check for unusual operation, drain tank and traps.

Weekly Maintenance Tasks

Clean air filter, general unit cleaning, check for unusual operation.

Monthly Maintenance Tasks

Tighten bolts, check air leaks, check belts, inspect oil, check unloading lines.

Quarterly Maintenance Tasks

Change oil, inspect valve assemblies.

Troubleshooting

Troubleshooting Low Air Pressure

Identifies common causes of low air pressure and provides solutions for each.

Troubleshooting Overheating

Lists potential causes for compressor overheating and offers resolutions for each issue.

Warranty Information

Compressor Pump Warranty Details

Details the 5-year warranty for the compressor pump unit, including lubricant and service kit requirements.

Compressor Unit Warranty Details

Outlines the 5-year pump and 2-year unit warranty, including labor and specific compliance conditions.

Warranty Exclusions and Void Conditions

Lists common exclusions, service items not covered, and conditions that will void the warranty.

Safety Information

Safety Symbols and Definitions

Explains the meaning of DANGER, WARNING, CAUTION, and NOTICE symbols used throughout the manual for safety.

Basic Operating Guidelines

Provides fundamental safety rules for operating the compressor, emphasizing trained personnel and compliance.

Breathable Air Safety

Details safety precautions when using compressor air for breathing applications, adhering to OSHA standards.

Safety Information (Continued)

Personal Protective Equipment (PPE)

Specifies required personal protective equipment for operators and personnel around the compressor.

Inspection

Pre-Use Inspection Procedures

Instructions for inspecting the compressor for external damage and checking moving parts before operation.

Shipping Damage Warning

Warning that operating a unit damaged during shipping, handling, or use can cause injury or property damage.

Installation

Installation Area Requirements

Specifies ideal environmental conditions, temperature range, and clearance for compressor installation.

Installation (Continued)

Piping Safety Steps

Safety guidelines for installing piping, including flow-limiting valves per OSHA standards.

Tank Installation and Securing

Instructions for placing tank feet on pads, snugging anchor bolts, and warnings about improper tank installation.

Pump Installation and Connections

Guidance on mounting the pump to the tank and connecting tubing for unloader systems.

Installation (Continued)

Unloader Line Installation

Instructions for installing the unloader tube from the check valve to the pressure switch for easier restart.

Pulley Size Chart

A chart providing pulley sizes for electric motors and gas engines based on RPM and HP.

Belt Tension and Pulley Check

Guidance on proper belt tension (1/2 inch slack) and using the correct pulley for the motor.

Operation

Operational Cautions

Warnings against shut-off valves without safety valves and exceeding recommended pressures or speeds.

Start-Up Procedures

Pre-Start Checks

Pre-start checks including oil level, free rotation, belt tension, clear area, and correct rotation direction.

Operation (Continued)

General Operation Safety Rules

Essential safety rules for operating the compressor, including fire safety and keeping the area clear.

Proper Oil Level Check

Instructions to check the oil level in the sight glass before operating the compressor.

Maintenance

Maintenance Safety Steps

Critical safety measures for performing maintenance, including power lockout and pressure release.

Maintenance Schedule

Daily Maintenance Tasks

Check oil level, check for unusual operation, drain tank and traps.

Weekly Maintenance Tasks

Clean air filter, general unit cleaning, check for unusual operation.

Monthly Maintenance Tasks

Tighten bolts, check air leaks, check belts, inspect oil, check unloading lines.

Troubleshooting

Troubleshooting Low Air Pressure

Identifies common causes of low air pressure and provides solutions for each.

Troubleshooting Overheating

Lists potential causes for compressor overheating and offers resolutions for each issue.

Warranty Information

Compressor Pump Warranty Details

Details the 2-year warranty for the compressor pump unit, including lubricant and service kit requirements.

Warranty Void Conditions

Lists conditions that will void the warranty, such as exceeding duty cycle and improper installation environments.

Introduction

Manual Reading Importance

Emphasizes the importance of carefully reading instructions for maximum performance and trouble-free operation.

Inspection

Transit Damage Check

Check for possible damage during transit and ensure the pulley turns freely by hand.

Installation

Location Requirements

Select a clean, dry, well-lit location, insulate pipes, avoid specific rooms, and ensure proper airflow.

Hooking Up the Pump

Pump Mounting and Connections

Mount pump to tank, connect main feed tube to check valve, and run tubing for unloader systems.

Hooking Up the Pump (Continued)

Unloader Line and Pressure Switch Connection

Connect tube from check valve to unloader on pressure switch to relieve head pressure for easier restart.

Oil Filling and Level Check

Fill crankcase with specified synthetic oil to the center of the sight glass.

Pulley and Belt Installation

Size the correct motor pulley, install belts with 1/2 inch play for proper tension.

Motor Rotation Check

Ensure pump runs counter-clockwise when facing the pulley side for correct rotation.

Operation and Care

Air Intake and Pipe Connection

Notes on intake filters, using flexible connectors for piping to minimize noise and vibration.

Operational Cautions

Warnings against shut-off valves without safety valves and exceeding recommended pressures or speeds.

Tank Installation Precautions

Guidelines for tank feet placement on pads, snugging anchor bolts, and avoiding dirt floors.

Starting Procedures

Pre-start checks including oil level, free rotation, belt tension, clear area, and correct rotation direction.

Daily Care

Daily Checks and Drains

Check oil level, drain air receiver, and listen for unusual noises or vibrations.

Monthly Care

Monthly Checks and Tightening

Check and tighten bolts, air connections, and V-belts for alignment and tightness.

Maintenance-Trouble Shooting-Repairs

Slow Pumping or Insufficient Pressure

Troubleshooting guide for low air pressure issues, listing causes like clogged filters and leaking valves.

Overheating Causes and Solutions

Identifies common causes of overheating such as reverse rotation, poor ventilation, and low oil.

Limited Five-Year Warranty

Compressor Unit Warranty Terms

Details the 5-year warranty for compressor units, including parts and labor, and specific maintenance requirements.

Warranty Void Conditions

Lists conditions that will void the warranty, such as exceeding duty cycle and improper installation environments.