Old Generation Rotary Screw Air Compressor - Operating Instructions

ROTARY SCREW
COMPRESSORS
Operating Instructions
Polar Air designs and manufactures products for safe operation. However,
operators and maintenance persons are responsible 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.
Base mount
Rotary Screw Compressor
Base mount unit with vertical auxillary air storage tank
Fully packaged unit with air dryer (vertical tank)
Fully packaged unit with air dryer (horizontal tank)
PMNR000001 111005.08.13 Rev. 0.2 (EM-RTS units)

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Polar Air Rotary Screw Compressors
Contents
Page No.
Variable Speed Drive Information . . . . . . . . . 2
Model Specification Charts . . . . . . . . . . . . . 2-3
Safety Information . . . . . . . . . . . . . . . . . . . 4
Tag Definitions . . . . . . . . . . . . . . . . . . . . 4
Basic Guidelines . . . . . . . . . . . . . . . . . . . . 4
Breathable Air . . . . . . . . . . . . . . . . . . . . 4
Pressurized Components . . . . . . . . . . . . . . 4
Personal Protective Equipment . . . . . . . . . . 4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 4
Forklift Safety . . . . . . . . . . . . . . . . . . . . . 4
Lifting Safety . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 5
Area . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety Steps . . . . . . . . . . . . . . . . . . . . . . 6
Installing . . . . . . . . . . . . . . . . . . . . . . . . 6
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . 6
Electrical Installation . . . . . . . . . . . . . . . . 7
Motor Rotation . . . . . . . . . . . . . . . . . . . . 8
System Description . . . . . . . . . . . . . . . . . . . 8
Air Process . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication Process . . . . . . . . . . . . . . . . . . 8
System Components . . . . . . . . . . . . . . . . . . . 8
PLC (Programmable Logisitical Control) . . . 8
Mechanical Components . . . . . . . . . . . 9-11
Operation . . . . . . . . . . . . . . . . . . . . . . . . 12
Safety Rules . . . . . . . . . . . . . . . . . . . . . 12
Initial Checks . . . . . . . . . . . . . . . . . . . . 12
Start Up . . . . . . . . . . . . . . . . . . . . . . . . 13
Storage . . . . . . . . . . . . . . . . . . . . . . . . . 13
Restarting Procedure . . . . . . . . . . . . . . . . 13
Maintenance . . . . . . . . . . . . . . . . . . . . . . 14
Safety Steps . . . . . . . . . . . . . . . . . . . . . 14
Lubricating Oil . . . . . . . . . . . . . . . . . . . . 14
Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
System Pressure . . . . . . . . . . . . . . . . . . . 15
Safety Valve . . . . . . . . . . . . . . . . . . . . . 15
Air/Oil Separator Filter . . . . . . . . . . . . . . 15
Maintenance Schedule . . . . . . . . . . . . . . . . . 16
Troubleshooting . . . . . . . . . . . . . . . . . . 17-21
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . 20
Variable Speed Drive
The variable speed drive is an auxillary feature avail-
able on all Polar Air compressors. A variable speed
drive or VSD will save energy consumption and wear
on the electric motor. The VSD regulates amp draw
during start-up and motor speed during operation
according to air demand.
All Polar Air compressors are equipped with a VSD
compliant motor, ventilated electrical box and ad-
equate space in compressor cabinet for easy installa-
tion. The electronic controller (PLC) for the compres-
sor unit, has a 4-20 milliamp control signal built-in
to control VSD speed reference. The PLC can provide
start/stop command and display any fault codes for
the VSD device.
To convert to Varible speed drive,
contact Polar Air customer service
for more information, 1-877-283-7614.
Be sure to install VSD in a clean, dust-free
environment.
VSD Device
Wiring access area
Dedicated Cooling Fan
Each compressor cabinet has built-in VSD compartment

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Model No. PRS0070001 PRS0100001 PRS0070003 PRS0100003 PRS0150003 PRS0200003
Description Single Phase Single Phase Three Phase Three Phase Three Phase Three Phase
Dual Voltage Dual Voltage Dual Voltage Dual Voltage
Motor 7.5HP 10HP 7.5HP 10HP 15HP 20HP
Amp Draw 32 40
230V: 18 230V: 24 230V: 36 230V: 48
460V: 9 460V: 12 460V: 18 460V: 24
RPM 1750 1750 1750 1750 1750 1750
Voltage 208/230 208/230 208/230/460/575 208/230/460/575 208/230/460/575 208/230/460/575
SCFM @ 100 PSI 29 45 29 45 62 85
Start Type Magnetic Starter Magnetic Starter Y-Delta & VSD Y-Delta & VSD Y-Delta & VSD Y-Delta & VSD
Drive Type Belt Belt Belt Belt Belt Belt
Air End Model B40 B40 B40 B40 B60 B60
Noise DB(a) 62 64 62 64 67 69
Outlet Size NPT 3/4” NPT 3/4” NPT 3/4” NPT 3/4” NPT 1” NPT 1”
Oil Capacity 1 gal. 1 gal. 1 gal. 1 gal. 2.5 gal. 2.5 gal.
Dimensions 33 x 24 x 42 33 x 24 x 42 33 x 24 x 43 34 x 24 x 43 36 x 31 x 49 36 x 31 x 49
Weight (lbs.) 880 930 880 930 1210 1260
Shipping Weight 928 986 928 986 1270 1330
Polar Air Rotary Screw Systems: 5 Hp - 20 Hp (VSD Compliant)
Model PRS0250003 PRS0300003 PRS0400003 PRS0500003 PRS0600003
Description Three Phase Three Phase Three Phase Three Phase Three Phase
Dual Voltage Dual Voltage Dual Voltage Dual Voltage Dual Voltage
Motor 25 HP 30 HP 40 HP 50 HP 60 HP
Amp Draw
230V: 60

230V: 72

230V: 96 230V: 120 230V: 144
460V: 30 460V: 36 460V: 48 460V: 60 460V: 72
RPM 1750 1750 1750 1750 1750
Voltage 208/230/460/575 208/230/460/575 208/230/460/575 208/230/460/575 208/230/460/575
SCFM @ 100 PSI 108 129 188 235 261
Start Type Y-Delta & VSD Y-Delta & VSD Y-Delta & VSD Y-Delta & VSD Y-Delta & VSD
Drive Type Belt Belt Belt Belt Belt
Air End Model B101 B101 CA116D B170 B170
Noise DB(a) 73 75 79 79 81
Outlet Size NPT 1” NPT 1” NPT 1-1/4” NPT 1-1/4” NPT 1-1/4”
Oil Capacity 2.5 gal. 2.5 gal. 3 gal. 4 gal. 4 gal.
Dimensions 43 x 38 x 57 43 x 38 x 57 48 x 44 x 61 53 x 50 x 65 53 x 50 x 65
Weight (lbs.) 1440 1540 1910 2420 2860
Shipping Weight 1500 1600 1970 2490 2928
Polar Air Rotary Screw Systems: 25 Hp - 60 Hp (VSD Compliant)
L•W•H
(inches)
L•W•H
(inches)

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Safety
This manual contains very important information to
know and understand. This is provided for SAFETY
and to PREVENT EQUIPMENT PROBLEMS. To help un-
derstand this information, observe the following:
Danger indicates an imminently
hazardous situation which, if not
avoided, will result in death or serious injury.
Warning indicates a potentially
avoided, could result in death or serious injury.
Caution indicates a potentially
avoided, may result in minor or moderate injury.
Notice indicates important infor-
mation, that if not followed, may
cause damage to equipment.
Basic Guidelines
CALIFORNIA PROPOSITION 65
This product or its power cord may
contain chemicals known to the
State of California to cause cancer and birth defects or
other reproductive harm. Wash hands after handling.
1. Allow only trained, authorized persons who
have read and understood these operating
instructions to use this compressor. Failure
to follow the instructions, procedures and
safety precautions in this manual can result
in accidents and injuries.
2. NEVER start or operate the compressor under
unsafe conditions. Tag the compressor,
disconnect and lock out all power to it to
prevent accidental start-up until the condi-
tion is corrected.
3. Install, use and operate the compressor only
in full compliance with all pertinent OSHA
regulations and all applicable Federal, State
& Local Codes, standards and regulations.
4. NEVER modify the compressor and/or controls
in any way.
5. Keep a first aid kit in a convenient place.
Seek medical assistance promptly in case
of injury. Avoid infection by caring for any
small cuts and burns promptly.
MANUAL
Read all manuals included with this
product carefully. Be thoroughly
familiar with the controls and the
proper use of the equipment.
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.
2. DO NOT use air line anti-icer systems in air
lines supplying respirators or other equip-
ment used to produce breathable air. DO NOT
discharge air from these systems in unventi-
lated or other confined areas.
Pressurized Components
This equipment is supplied with a ASME designed
pressure vessel protected by an ASME rated relief
valve. Pull the ring before each use to make sure
the valve is functional. Refer to figure 10. DO
NOT attempt to open valve while the machine is
under pressure.
Personal Protective Equipment
Be sure all operators and others around the
compressor and its controls comply with all appli-
cable OSHA, Federal, State and Local regulations,
codes and standards relating to personal protec-
tive equipment. This includes respiratory protec-
tive equipment, protection for the extremities,
protective clothing, protective shields and barri-
ers, electrical protective equipment, and personal
hearing protective equipment.
Inspection
Inspect compressor prior to any use. Check for exter-
nal 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 as serious injury or
property damage could occur.
A forklift may be necessary for unloading the Polar
Air compressor. Use all forklift safety measures and
require a certified forklift operator. Refer to figure 1
for safe unloading procedure.
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.

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3. Make sure forks are fully engaged and tipped
back 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. Make sure lifting hook
has a functional safety latch or equivalent and is
properly attached to lifting feature.
2. Make sure lifting points are in good condition and
tighten any loose nuts or bolts before lifting.
3. Use provided lifting feature or appropriate sling. A
sling must be used when moving compressor with a
helicopter or other air-borne equipment. Be sure to
follow OSHA standards 29 CFR 1910 Subpart N.
4. Use guide ropes or equivalent to prevent twisting
or swinging of the compressor while it is in the
air and NEVER attempt to lift in high winds. Keep
compressor as low to the ground as possible.
5. Keep persons away and make sure no one is under
the compressor while it is lifted.
6. Only use lifting features provided for entire com-
pressor package. NEVER use bolts or other hooks on
invididual components to move the compressor.
7. Make sure to put compressor on a level surface that
can support the weight of the compressor and load-
ing equipment.
Do not operate unit if damaged
during shipping, handling or use.
Damage may result in bursting and cause injury or
property damage.
Remove shipping brackets from
each corner of mounting base
before operating compressor. Refer to figure 2.
Installation
Area
Exhaust air from this unit can be used to supple-
ment 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 fumes or other toxic, noxious or corro-
sive fumes or substances. Installation area must
maintain low relative humidity and a temperature
range between 35˚ - 110˚ F. This unit must be
kept under roof and away from rain, snow, etc.
In environments where fine dust
is common, such as granite or
concrete plants, it is imperative the installation of
this compressor is in a separate area with
dedicated ventilation. Failure to provide dust free
operating area will void the warranty.
Figure 1: Use Lumber to Protect Compressor
Lumber
Figure 2: Remove Shipping Brackets
Compressor Enclosure
Mounting Base
Shipping Bracket
(Remove 4)
Figure 3: Utilize Exhaust Heat
Rotary Screw
Compressor
Cabinet
Fresh Air
Inlet
(Keep
Open)
Vent To Outside
(Open/Close)Vent To Shop
(Open/Close)
For Cold Weather Use:
Open shop vent and close outside vent to
use exhaust heat from compressor.
For Warm Weather Operation:
Close shop vent and open outside vent to
divert exhaust heat outdoors.

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2. Allow at least 24 inches of clear space
around the sides and back and at least 3 feet
in front of the compressor.
This compressor unit is equipped
with internal rubber vibration
isolators. To avoid internal pump damage, DO NOT
use an additional rubber mounting surface when
installing compressor.
3. Make sure compressor base is on a hard, flat
surface and anchored securely.
4. If installation is above the first story of a
building, use appropriate vibration insulation.
Tank Sizing Guideline: Tank
capacity must be at least 1.2
gallons for every CFM of air produced by compressor.
This will minimize wear on internal pump parts.
Piping Safety Steps
1. Install appropriate flow-limiting valves as
necessary according to pipe size(s) used and
run lengths. This will reduce pressure in case
of hose failure, per OSHA Standard 29 CFR
1926.302(b)(7).
2. Flow-limiting valves are listed by pipe size
and rated CFM. Select appropriate valves
accordingly, in accordance with the manufac-
turer’s recommendations.
Installing
1. Install piping as shown in Figure 4. Refer to fig-
ure 5 for recommended closed loop installation.
2. Make sure any tube, pipe or hose connected to
the unit can withstand operating temperatures
and retain pressure.
Never use plastic (PVC) pipe for
compressed air. Serious injury or
death could result.

3. Install appropriate ASME code safety valves
and make sure piping system is equipped with
adequate condensate drains.
4. Never use reducers in discharge piping. Keep all
piping and fittings the same size in the piping
system.
5. 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.
6. Test entire piping system before underground
lines are buried. Be sure to find and repair all
leaks before using compressor.
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
Rotary Screw
Compressor
Cabinet
Ball
Valve
Ball Valve
Water Drain Valve
Air
Storage
Tank
Air Dryer
Coalescing Filter
with Auto Drain
To Shop
Piping
Water trap
with drain
Air Drop
(typ.)
Air Drop:
Install tee fitting with branch to top
to minimize condensation in air drop
PLAN VIEW
Closed loop system
Install tee fitting
in piping from air
supply to minimize
pressure drop and to
allow airflow in two
directions.
ELEVATION
From
Compressor
From Compressor
To Air Tool
Figure 4: Basic Piping Diagram
Figure 5: Closed Loop Installation
3. Do not install check valve. Compressor
has internal check valve.

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Oil Check
This unit is shipped with oil in it and should be
ready to operate. Be sure to check for proper oil
level before operating the compressor. Compressor
must be off at least 45 min. - 1 hr. before check-
ing to ensure accurate reading. Refer to figure 6.
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
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. Follow
all NEC (National Electric Code) standards especially
those concerning equipment grounding conductors.
1. Follow all NEC and local codes for electrical wiring.
Allow only authorized Polar Air service person or
certified electrician to install electrical components.
2. Put unit on dedicated circuit and make sure
no other electrical equipment is wired into
it. Failure to wire unit on independent circuit
can cause circuit overload and/or imbalance
in motor phasing. Install proper No Fuse
Breaker (NFB) according to kW output of
compressor.
3. Ensure incoming service has adequate am-
pere rating.
4. Ensure supply line has the same electrical
characteristics (voltage, cycles and phase) as
the machine.

5. Refer to amp load information on motor tag
and use correctly sized wiring. Be sure to
consider distance between power supply and
machine.
6. Install surge protection device between power
supply and compressor electrical cabinet.
7. Make sure to install properly sized breakers and
fuses.
8. The unit must be properly grounded. DO NOT
connect ground wire to air or cooling lines.
Connect ground wire to grounding lug in the
compressor electrical cabinet.
Improperly grounded electrical
components are shock hazards.
Make sure all the components are
properly grounded to prevent
death or serious injury.
Figure 6: Sight Glass for Lubricating Oil
Oil level must be
maintained between
the two red lines
during operation and
while loaded
Air/Oil Tank
Sight Glass
Figure 7: Wiring Diagram
A1
KM5
KM3
M1 PE
M
3
KM2 KM1 KM4
40
Inverter
Run
Main Motor
TB3
(Notice 2)
TB4
(Notice 2)
Inverter
Fault
37 22 14
PE E R
L1 L2 L3
S TCOM AI2
+24V LI1 U V WRIA RIC
L1
L1 L2 L3
L2 L3
B C
CT1
TB1
TB
QF
a
b
c
o
B C
CT2
a
b
c
o
M2
M
3
Fan Motor

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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). Pulleys should
turn counter clockwise.
2. If motor shaft is not turning counter clock-
wise, disconnect power to terminal block
then exchange any two of the three power
leads. Re-check rotation.
System Description
The Polar Air compressor is highly efficient and pro-
vides reliable performance with low wear parts, low vi-
bration and quiet operation. An electric motor, which
is controlled by a Programmable Logisitical Controller
(PLC), runs the compressor and is actuated with a belt
drive system. The belt drive system utilizes pulleys to
connect the motor to the main rotor shaft, or a direct
drive coupling system.
Air Process
Air enters the system through the suction valve which
has a suction filter to remove dust. The air is mixed
with the lubricating oil and flows into the air/oil
separator tank. It passes through an air/oil separator
filter then through a minimum pressure check valve.
Air then passes through an air cooled after cooler
then into storage tank.
Lubrication Process
Pressure in the oil / air separator presses lubricating
oil into the oil cooler. The oil is cooled and filtered
then divided into two parts. One part is injected into
the compression chamber from the lower end of the
rotary compressor body to cool the compressed air.
The other part passes through the two ends of the
compressor body and is used to lubricate internal roll-
er bearings of rotary compressor pump and gear drive.
The two parts meet at the bottom of the compression
chamber and are drained out with the compressed air.
System Components
PLC (Programmable Logisitical Controller)
The PLC is the compressor controller and has a
display screen for system information. The electric
circuitry of the PLC can be divided into two systems.
One is for the starting panel to configure Y Delta
starting. The other is for internal computer controls
and is explained in more detail in the PLC manual. If
there is any failure, contact Polar Air service depart-
ment. Refer to figure 8 for explanation of buttons.
Maintenance Notifications
There are five automatic maintenance notifications
built into the Polar Air compressor system designed
to signify when maintenance is due for certain com-
ponents. An alarm will sound and a message will be
displayed on the control panel. Refer to the follow-
ing chart for the components that have automatic
maintenance notifications and their factory set
lifetimes.
1 ON Button: Press this button to start compressor.
2 OFF Button: Press this button to stop compressor.
3 M (Save Data): Press this button to confirm and save input
after changes have been made.
4 Down Scroll Menu: Press this button to scroll down through
menus while changing settings or making menu selections.
5 Up Scroll Menu: Press this button to scroll up through
menus while changing settings or making menu selections.
6 Cursor/Confirm Button: This button can be used as a cursor
while changing settings and to confirm a menu selection.
7 RT Return/Reset Button: Press this button to return to a
previous menu OR press and hold for approximately 5 seconds
to reset any fault or error codes.
8 Emergency Stop: Use only for emergency to stop compressor
immediately. Use normal stop at all other times.
Factory Set Password: 0518
1 2 3 4 5 6 7 8
Figure 8: PLC Control Buttons

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Maintenance Notifications
Component (PLC Name) Lifetime
Oil Filter (Oil) 0600 hrs.*
Air/Oil Separator Filter (O-G) 4000 hrs.
Air Filter (Gas) 0600 hrs.
Lubricating Oil (Lube) 0600 hrs.*
Motor Bearing Grease (Grease) 2000 hrs.
* Values shown above are factory set for max. lifetime parameters.
After initial oil change, max. lifetime parameters can be reset. Refer
to PLC manual for more details.
Following replacement times is important for safe
operation. Remember to clear lifetime and reset to 0
hours after replacements are made. The menu selec-
tion needed for this setting is found by scrolling to:
“Customer Parameter” then, “Clear Lifetime”
Refer to PLC manual for more details.
Figure 9: Mechanical System Components
8, 15
9
1
5
2
3
4
6
10
14
11
7
13
12
Side View End View
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 fea-ture. The
motor is 12 lead, Y delta soft starting for low amp draw.
Overload protection is installed for safety. Normal electric
current can fluctuate slightly for various reasons but if the
current spikes, the overload protec-tion will cause the motor(s)
to stop. If this happens, the motors must be reset manually.
Some reasons for overload protection:
a) Operator error: Improper regulation of air ex-
haust pressure or other parts of the system.
b)
Mechanical failures:
• Internal motor failure
• Improper motor phasing
• System setting error
• Blocked air/oil separator filter.
If motor overload protection is caused by any
other reason, contact Polar Air immediately.
2. Variable Speed Drive (Energy saving device)
Ready Cabinet
This cabinet has allocated space and cooling
fan to house varible speed drive component. To
convert to Varible speed drive, contact Polar Air
customer service for more information, 1-877-
283-7614.
3. Air Suction Filter (Air Intake)
A dry type paper filter with filtration of 10 ppm. Replace
after first 600 hours of operation; then every 500-600
hours, depending on environment. Refer to the computer
controls of the compressor to monitor operating time and
remember to reset counter to 0 when filter is replaced.
There is an automatic alarm that can be set to remind
operator of service times.
Branch circuit not sized properly.
c)

10
4. Suction Valve
A butterfly valve that opens and closes during
operation. When PLC calls for air, the suction valve
opens through a solenoid valve to allow compres-
sor to load. When air pressure reaches preset max
level, the PLC closes the suction valve allowing
compressor to pull vacuum and not compress air or
unload.
5. Regulation Modulation Control
This device is included on all 100-200 hp models as an energy
saving feature for applications with duty cycles of 50% or
more. The device keeps amp load lower by maintaining motor
operation so consistent air pressure is delivered under heavy
work loads. Units with lower duty cycles should use online/
offline (min./max. pressure) control. Both control methods are
available so appropriate feature can be selected for different
air demands. It is important to monitor air demand since it
takes 15% more power to operate compressor for every 10 PSI of
pressure increase.
6. Air End
The air end has two rotor shafts mounted on
bearings parallel to each other in the machine
casing. The casing has an air inlet at the top
and an air outlet at the bottom. The shafts have
precisely machined, helical shaped screw threads
which work together to compress air. Air com-
pression occurs through a four course process:
1. Absorption
The position and shape of the rotor shafts
allow maximum air intake from the inlet port.
As the shafts turn, the air is forced to move
between the grooves of the screw threads.
2. Sealing and Conveyance
The air is sealed within the grooves of the screw
threads and conveyed, or moved, through the
machine casing toward the air outlet.
3. Compression and Lubrication
The rotor shaft screw threads are designed
with decreasing space between the grooves.
As the air is moved through them, it be-
comes pressurized and actuates the lubrica-
tion process. Lubricating oil is pressurized
and injected into the compression chamber
during operation for the following reasons:
a. To form protective film on rotors to avoid
contact and reduce friction.
b. To seal in the compressed air to improve
compressor efficiency.
c. To absorb heat to maintain optimal power.
d. To reduce operating noise.
4. Exhaust
When the air has reached the end of the
rotor shafts, it is fully pressurized and ex-
hausted into the air tank. As the rotors turn,
the compression process continues.
7. Exhaust Probe
The probe is temperature sensitive and located
at the air outlet of the rotary screw casing. When
exhaust temperature exceeds 210˚F (98.8˚C), the
system will automatically power OFF. The temper-
ature of the air exhaust can be read on a display
panel located on the PLC. Common reasons for
excessive exhaust temperatures:
• low oil level
• inoperable exhaust fan
• improper ventilation causing ambient air
temperature to be too hot
• clogged oil filter or radiator.
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. Oil Cooler
The oil cooler function is to cool the hot oil from
compressor pump and return oil to the air oil
separator tank. It is important to keep the cooler
fins clean to prevent the compressor from high
temperature shut down. Low air pressure can be
used to blow them off or if needed, use water-
based solvent to clean.
9. Oil Filter
The oil filter is a paper filter with a filtration of
10 PPM. It removes impurities and protects the
bearings and rotors. The filter core should be
replaced every 2000 hours or annually, which-
ever comes first. Replace oil and filter after first
600 hours of operation. Refer to the computer
controls of the compressor to monitor operating
time and remember to reset to 0 when filter is
replaced. There is an automatic alarm that can be
set to remind operator of service times.
10. Air/Oil Separator Tank
The air/oil separator tank is a steel pressure vessel
used to store lubricating oil and to separate the
compressed air and the lubricating oil. An oil sight
gauge is installed on one end of the air/oil separa-
tor tank. Make sure oil level is at high oil level in-

11
dicator when unit is shut down. During operation,
the oil level should stay between the high oil level
line and the lowest oil level line. A drain valve is
installed under the air/oil separator tank. Open
drain valve after machine has been shut down for
an hour slightly to drain condensed water in the
tank. This drain valve can also be used to gather
oil for oil analysis. Refer to warranty statement for
analysis requirements.
Replace lubricating oil after first 600 hours of
operation, then every 4000 hours or more often
if needed. Refer to the computer controls of
the compressor to monitor operating time and
remember to reset to 0 when filter is replaced.
There is an automatic alarm that can be set to
remind operator of service times.
11. Air/Oil Separator Filter
During the process of air compression from pump,
air and oil are mixed together to lubricate, seal
and cool compressor rotors. This air and oil is
tranferred to air/oil separator tank and then
the air/oil separtor filter removes oil mist from
the compressed air. The filter core is made of
multiple-layer fine glass fibers. The filter reduces
the oil partical size and can lower content to less
than 3 PPM. During normal operation, the air/oil
separator filter can be used for about 4000 hours
or annually, whichever comes first. Refer to the
computer controls of the compressor to monitor
operating time and remember to reset to 0 when
filter is replaced. There is an automatic alarm that
can be set to remind operator of service times.
12. Safety Valve
The ASME certified safety valve on the air/oil
separator tank is set to open when the pressure
exceeds 175 PSI (12.1 bar). NEVER attempt to
operate machince without ASME safety valve.
13. Blow Down Valve
The blow down valve is a two-way valve normally
open. When the machine is shut down or the
compressor is unloaded, the vent valve opens
and relieves pressure in the air/oil separator tank
to ensure the compressor will not be started
under load.
14. Check Valve
A minimum pressure check valve is installed after
the air oil separator filter. The starting pressure is
set at over 43.5 PSI (3 bar). The functions of the
minimum pressure valve are as follows:
a) Acuates oil lubrication of the air end.
b) Regulates air flow through the air separa-
tor filter to prevent damage to the separator
filter element. Air flow begins when pressure
in the air / oil separator tank reaches 43.5
PSI (3 bar).
c) Prevents back flow from the air receiver tank
into the air / oil separator tank. This compo-
nent serves as a built-in check valve. No ad-
ditional check valve is needed for installation.
15. After Cooler
The air flows through the check valve then enters
the after cooler. The fan on the air cooled after
cooler radiator draws in ambient air and blows
it through the radiator cores to reduce heat in
the compressed air and lubricating oil exhausted
from the rotary screw pump. The heat absorbed
in the radiator cores is discharged from the screw
cabinet because of the cooling fan and generally
reduces air temperature by 60˚F (15˚C). If ambi-
ent air temperature exceeds 112˚F (45˚C), the
system may overheat. It is important to operate
the compressor in a well ventilated area for the
cooling process to be effective.
16. Air Storage Tank (optional, not shown)
The air storage tank can serve as cushion to keep out-
put pressure relatively stable. It can also reduce oper-
ating temperature, remove moisture content, provide
cleaner air and reduce the load of the dryer. A larger
tank also reduces the cycling of the suction valve. As
a guideline, for every CFM the compressor produces, a
minimum of 1.2 gal. of air storage is needed.
17. Refrigerated Dryer/Coalescing Filter (optional,
not shown)
The refrigerated dryer removes moisture content.
The coalescing filter removes oil droplets and
impurities in the compressed air. The refrigerated
dyer / coalescing filter operates best with an
automatic drain that removes water condensation
collected during the air drying process.

12
Operation
Safety Rules
1. Make sure all operators receive product train-
ing, 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.
2. NEVER allow modifications to compressor
structure or controls.
3. Keep all ignition sources away from exposed
live electrical parts.
4. Keep all persons clear of compressor during
start-up and operation.
This unit can automatically start!
Before attempting any repairs or
adjustments, disconnect, lock out
and verify all power is off to all
circuits to minimize the
possibility of accidental start-up
or operation. This is especially important for
remotely controlled compressors.
5. NEVER operate the compressor with the fan,
coupling or other guards removed or with
access doors open.
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. If lubricant or other combustible
substances are spilled, clean up immediately.
8. When checking or adding lubricant or when
refilling air line anti-icer systems with
antifreeze compound, shut off compressor
and allow it to cool. Keep sparks, flames
and other ignition sources away and DO NOT
permit smoking in the vicinity.
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.
11. Keep hands, feet, floor controls and walking
surfaces clean and dry.

Keep all persons away from the
discharge opening of hoses or
tools or other points of
compressed air discharge. If the
machine is installed in an enclosed
area, be sure to vent the relief
valve outside of the structure or to an unoccupied
area.
12. 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.
13. Make sure all hose connections are adequate-
ly secured to prevent tools or hose ends from
being accidentally disconnected.
14. Coolants and lubricants used in this com-
pressor contain chemicals that can harmful
or fatal. Take care to avoid accidental inges-
tion and/or skin contact. In case of inges-
tion, seek medical treatment promptly. Wash
with soap and water after skin contact.
15. Antifreeze compound used in air line anti-
icer systems contains methanol which is
harmful or fatal if swallowed. Avoid contact
with the skin or eyes and avoid breathing
the fumes. Wear goggles or a full face shield
when adding antifreeze compound to air line
anti-icer systems.
• If swallowed, induce vomiting and call a
physician immediately.
• In case of eye contact, wash eyes with
plenty of clean water for 15 minutes then
contact eye doctor immediately.
• Never store antifreeze compound in con-
fined areas.
Initial Checks
Be sure to make physical checks of the compressor to
avoid serious failure before start up.
1. Make sure compressor is properly grounded
and verify voltage is correct, especially when
using a three phase motor.
2. Double check internal control transformer
before applying power to unit. Make sure
wiring is correct to avoid damage to circuitry
and PLC. Refer to wiring diagram, figure 7.
3. Check for correct oil level. To avoid overfill-
ing, check for correct oil level after machine
has been stopped for at least 10 minutes. If

13
oil needs to be added, make sure all pres-
sure is relieved before opening fill port. Use
only Polar Air lubricating oil. Also make sure
oil level does not drop below low level line
on site glass during operation. If it does,
stop compressor immediately, let rest for 10
minutes, then add oil.
Air/Oil Separator tank is a
pressurized component. To avoid
serious injury, be sure system
pressure is relieved before
removing fill plug. Be aware oil
temperature may be very hot. Use
caution when opening fill plug.

4. If compressor has sat idle for some time, add
approx. 0.5 L of Polar Air Rotary Screw lubri-
cating oil to suction valve. Then hand rotate
compressor several times to prevent equip-
ment damage. Check to ensure no foreign
matter has entered the system.
5. Make sure shipping brackets have been re-
moved. Refer to figure 2 in installation section.
6. Ensure all pipes and plugs are tight before
starting compressor.
Start Up
1. Slightly open drain valve on air/oil separator
tank to drain any condensed water. Failure to do
this will shorten service life of lubricating oil and
destroy the bearings. Be sure to close valve after
draining water.
2. Check “Emergency Stop” function by pressing the
button shortly after pressing ON button.
3. Do not operate the machine if there is any abnor-
mal noise or vibration during operation. Call Polar
Air service for assistance.
4. Press ON button to begin operation. After unit
starts, a time delay of approximately 5 seconds
will occur and a “LOADING” message will display
on PLC screen. This means the pump is operating
and the compressor is building pressure.
5. Monitor display panel for normal readings
such as amp draw and voltage. Push OFF but-
ton if there are any abnormal sounds, vibra-
tion or oil leakage.
6. Check that oil exhaust temperature is main-
tained between 160˚ - 180˚ F (70˚ - 95˚ C).
Cooling fan will cycle as needed to cool oil
temperature.
7. After OFF button is pressed, the motor will
continue to run for approx. 10-15 seconds
and blow down valve will automatically dis-
charge pressure from air/oil separator tank.
This is to prevent the air compressor from
stopping under heavy-load.
8. Record these instrument readings on a regu-
lar basis and retain for future reference:
• Voltage
• Current
• Air pressure
• Air exhaust temperature
• Oil level
• Maintenance parameter
Storage
1. If the machine is stopped for over three
weeks:
a) Wrap electrical equipment such as the con-
trol panel with plastic or oil paper to avoid
condensation.
b) Completely drain water in the oil cooler, the
back cooler and the oil/air separator tank.
c) Make sure any unsafe conditions are clearly
stated or repaired.
2. If the machine is not run for more than two
months:
a) Seal all ports to prevent moisture or dust
accummulation.
b) Wrap safety valve and control panel with
oil paper or an equivalent to avoid rust.
c) Replace lubricating oil then run machine
for 30 minutes. Drain condensed water
in the oil / air separator tank and the oil
cooler 2-3 days later.
d) Move machine to a clean, dry place.
Restarting Procedure
1. Remove any wrappings from system compo-
nents.
2. Ensure electric motor is properly insulated.
3. Perform initial checks then follow procedures
for start up.

14
Maintenance
Safety Steps
Disconnect, tag and lock out power
source then release all pressure from
the system before attempting to
install, service, relocate or perform
ANY maintenance.
When performing service in any
enclosure large enough to hold a
man, inform others then be sure
to tag and keep open any access
doors. Before closing and latching
access doors, make sure all
persons are clear from enclosure.
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 guard-
ing and personal protective equipment per
OSHA standard 29 CFR 1910.242 (b).
3. Relieve all internal pressure prior to opening
any line, fitting, hose, valve, drain plug, con-
nection or other component, such as filters
and line oilers, and before refilling optional
air line anti-icer systems with antifreeze
compound.
4. Keep sound reducing material, any external
surfaces of the air compressor or internal
surfaces of the enclosure free from fluids and
build-up. Clean with water based industrial
cleaner or steam clean as necessary. Remove
then replace sound reducing materials as
needed to clean all surfaces. Immediately re-
place any sound reducing material with torn
or punctured protective covering to prevent
accumulation of liquids or build-up inside
the material. NEVER use flammable solvents
for cleaning purposes.
5. Keep electrical wiring, including all terminals
and pressure connectors in good condition.
Replace any wiring that has cracked, cut, or
otherwise damaged insulation. Replace ter-
minals that are worn, discolored or corroded.
Keep all terminals and pressure connectors
clean and tight.
6. Keep all body parts and any hand-held
tools or other conductive objects away from
exposed live parts of the electrical system.
When making repairs or adjustments, stand
on a dry, insulated surface and DO NOT con-
tact any other portion of the compressor.
7. DO NOT leave compressor unattended with
exposed electrical components. Be sure to
tag and disconnect all power if temporary
absence is necessary.
Compressor components can
become hot during operation.
Avoid bodily contact with hot
liquids, hot surfaces and sharp
edges and corners.
Lubricating Oil
To avoid water condensation during operation, keep
oil temperature between 160-180˚ F. Failure to do so
will cause pump damage. Contact Polar Air service if
temperature drops below 160˚ F.
Changing Oil:
1. Shut down compressor and allow machine to
set for 5-10 minutes.
pressurized component. To avoid
serious injury, be sure system
pressure is relieved before
removing fill cap. Be aware oil
temperature may be very hot. Use
caution when changing oil.
2. Drain oil completely. Be sure to include oil in
system piping, cooler and air/oil separator
tank. Close drain valve.
3. Remember to remove and change oil filter.
Be careful to avoid hot oil during replace-
ment.
4. Open oil fill port and add new oil.

Failure to perform regular oil
changes may cause equipment
damage and will void warranty. Oil must be
changed annually regardless of hours used.

15
Belts
To avoid serious personal
injury, be sure to relieve all
system pressure then lock out
power and tag compressor to
prevent unexpected movement
of the unit.
Inspect belt tension after first 30 hours of
operation then at every 1,000 hours.
1. Check belt tension on each individual belt
in the center of each pulley, and should
have ¼”deflection up and ¼” deflection
down, for ½” total.
2. Always replace all belts with the same
brand, at the same time. Make sure belts
are unimatched. Do not replace belts
independently.
3. Do not splash lubricating oil on belts or
pulleys when adjusting or replacing belts.
System Pressure
System pressure is factory set but can be regulated
depending on operating conditions. Refer to
computer control specifications for setting
adjustments or PLC operating manual.
NOTES:
Safety Valve
TO AVOID SERIOUS
INJURY OR DEATH, NEVER
ATTEMPT TO REGULATE
OR TAMPER WITH SAFETY
VALVE. VALVE IS SEALED
AND CERTIFIED BY ASME CODE AND IS
DESIGNED TO RELIEVE SYSTEM
PRESSURE WHEN NECESSARY.
Air/Oil Separator Filter
pressurized component. To
avoid serious injury, be
sure system pressure is
relieved before removing
filter. Be aware oil
temperature may be very hot. Use caution
when changing filter.
1. Relieve all air pressure from air/oil
separator tank, then wait approximately 5-
10 minutes before replacing filter.
2. Replace air/oil separator filter. Do not
attempt to clean.

16
Maintenance Schedule
Daily
Weekly
500 hrs.
1000 hrs.
2000 hrs. / 6 months
4000 hrs. / 1 year
Check oil level
Check coolant level
Clean air filter
Check belt tension
Change lubricating oil (after first 500 hrs.)
Replace oil filter
Inspect and lubricate suction valve
Check belt tension
Change air filter
Blow out radiator
Grease electric motor bearings
Check and tighten all electrical
connections/terminals
Change oil and replace filter
Replace air filter
Replace air/oil separator filter
Blow out radiator
Check belt tension
Check and tighten all electrical
connections/terminals
Check safety valve
Drain condensed water
General unit cleaning
Clean/replace air filter
Replace oil filter
Check belt tension
Inspect all piping
Thouroughly clean sight glasses
Clean suction valve
Inspect 3 direction magnetic
valve
Inspect minimum pressure valve
Inspect motion of magnetic
contactor
Blow out radiator
Notes

17
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
2. Blown circuit fuse and/or
internal fuse
2. Replace fuse(s) as needed
3. Insufficient power to PLC 3. Check for correct voltage and make sure all
fuses are functioning
4. Fault is present 4. Check fault history on PLC:
Arrow down to RUN PARAMETER, then
choose fault function. Refer to PLC manual
for fault listing and resolution.
5. Poor contact on START
pushbutton
5. Have electrician or Polar Air dealer inspect
and replace pushbutton
6. Failed electric motor 6. Have electrician or Polar Air dealer inspect
and replace motor
7. Failed compressor pump 7. Attempt to move by hand to check for free
movement of pump. If not possible, contact
Polar Air service
TURN OFF POWER before
attempting to move pump. Watch for
moving parts. Do not
pinch fingers in pulley.
Compressor shuts
down under
compression
mode/while loading
1. Fault is present 1. Check fault history on PLC:
Arrow down to RUN PARAMETER, then
choose fault function. Refer to PLC manual
for fault listing and resolution.
2. Loss of Control Voltage 2. Reset. If trouble persists, check line
pressure does not exceed maximum
operating pressure of the compressor
(specified on nameplate)
3. Low incoming Voltage 3. Wire size for power supply too small.
Contact local power company.

18
Problem Problem Causes Resolutions
Air pressure is too low
while loading/Won’t load 1. Air demand too high 1. Decrease air consumption or increase
number of compressors in system
2. Blocked air filter 2. Clean or replace air filter
3. Suction valve not opening
properly which reduces
incoming air flow
3. Disassemble and clean suction valve.
Apply lubricating oil to valve
4. Improperly adjusted pressure
regulator
4. Adjust pressure regulator to proper
settings. Refer to PLC manual
5. Load solenoid not operating
properly
5. Disassemble and clean solenoid valve.
Replace if needed. Check for proper
voltage – 220V required
6. Improper maintenance/Failed to
reset hours
6. Check maintenance parameter. Make sure
operating time does not exceed preset limit
7. Low oil level 7. Add oil
8. V-belts slipping 8. Adjust belt tension
9. Air leak 9. Check compressor & complete air system
for air leaks
10. Compressor running in unload
mode
10. Check pressure settings in PLC; make sure
unload pressure is set properly
Line pressure exceeds
upper preset safety limit 1. Control system leak causing
pressure signals to be lost.
1. Check pressure sensor for leaks and/or air
restriction. Repair as needed.
2. Defective pressure sensor 2. Check for damage to diaphragm and
contacts. Replace if necessary.
3. Defective solenoid valve 3. Replace valve
4. Defective blow-down valve 4. Check that sump pressure is exhausted to
the atmosphere when machine is
unloaded. Repair or replace if necessary
5. High pressure shut-down preset
is incorrectly programmed
5. Reset to proper setting. Refer to PLC
manual.
6. Additional compressor piped
into system causing preset to be
exceeded
6. Reset additional compressor pressure
settings to 145 psi or lower

19
Air exhaust temperature
lower than normal
1. Compressor running under no-
load excessively
1. Reset Motor shut-down time in PLC
2. Incorrect fan temperature
parameter setting in PLC
2. Reset to proper setting. Refer to PLC
manual
3. Temperature sensor malfunction 3. Replace temperature sensor
Excessive air exhaust
temperature causing
compressor to shut-down
1. Low oil level 1. Add oil
2. Incorrect oil used 2. Drain all oil & replace with Polar Air
compressor oil only
3. Blocked oil filter 3. Replace oil filter
4. Surrounding temperature too
high
4. Check for air exhaust blockage. Increase
area ventilation
5. Blocked cooler 5. Clean cooler
6. Temperature sensor malfunction 6. Replace temperature sensor
7. 75HP & above-Bad Thermo
valve
7. Replace Thermo valve
8. Cooling fan failure 8. Replace cooling fan
Excessive oil
consumption
1. Clogged return/scavage line or
orifice
1. Clear blockage; clean orifice
2. Damaged or improperly
functioning air/oil separator filter
2. Change air/oil filter
3. Excessive foaming 3. Drain and change oil. 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
4. Oil level too high 4. Drain oil then check at sight glass for
proper level
5. Lubrication system leak 5. Check all pipes, connections and
components. Repair as needed
6. Low minimum pressure in
separator tank
6. Minimum pressure should be 65 psi
(4.5bar)
Pressure relief valve
opens repeatedly
1. High pressure shut-down preset
is improperly programmed
1. Reprogram high pressure safety setting to
155 psi (10.7bar)
2. Defective pressure relief 2. Replace valve.
3. Clogged air/oil separator filter 3. Replace filter

20
Unit shut-down with
Motor Overload Fault
Error
1. Motor overload protection tripped 1. Allow unit to cool; reset overload protection;
check the overload setting on relay
2. PLC detected a higher amperage
than programmed setpoint
2. Check amperage setting in PLC
3. Bad wire connections causing
over amperage of motor
3. Turn unit off and check unit for loose or bad
connections
Water in air system
1. Defective moisture
separator/Drain trap
1. Inspect & clean if required; Replace
separator if necessary
2. Trap drain or drain piping
blocked
2. Inspect & clean
3. After cooler core dirty 3. Inspect & clean
4. No after cooler on unit 4. Install after cooler
5. Drain line/drip leg incorrectly
installed
5. Slope drain line away from trap; Install drip
leg
6. No refrigerated or desiccant
dryer in air system
6. Contact Eaton Compressor
Excessive noise level
1. V-belts slipping 1. Adjust belt tension or replace belts
2. Compressor defective (Bearing
failure or rotor contact)
2. Replace bearing; Contact Eaton
Compressor
3. Enclosure panels not in place 3. Install enclosure panels
4. Loose component mounting 4. Inspect & tighten
5. Shipping brackets in place 5. Remove shipping brackets
Excessive vibration
1. Loose component mounting 1. Inspect & tighten
2. Motor or compressor bearing
failure
2. Replace bearing; Contact Eaton
Compressor
3. External sources 3. Check for other sources of vibration, other
than the compressor
4. V-belts slipping 4. Adjust belt tension or replace belts
5. Shipping brackets in place 5. Remove shipping brackets

21
Black residue on belt
guards
1. V-belts loose 1. Adjusted belt tension
2. Sheave misaligned 2. Align sheaves
3. Excessive belt wear 3. Replace belts
4. Using non-OEM belt 4. Use ONLY OEM parts
Shaft seal leak
1. Defective shaft seal 1. Replace or contact Eaton Compressor
“FAIL TO STOP” error
(PLOTS PLC only) 1. Generic fault error 1. Access fault history to find specific error –
Refer to PLC manual
During start-up, PLC
shows normal running
functions, but
compressor not running
1. Blown fuse/breaker for control
voltage
1. Replace fuse or reset breaker
2. Faulty E-Stop button – causing
break in control voltage circuit
2. Replace E-Stop button
3. PLC has changed Run Mode in
the factory parameter
3. Verify if unit is VSD or Fixed Speed; Set
Run Mode parameter back to factory
specs, VSD (V/F) or Fixed (Commercial F)
Low air pressure in
storage tank while
compressor maintains
programmed air
pressure
1. Check valve installed between
compressor & storage tank
1. Remove check valve
2. Dryer frozen-up restricting air
flow
2. Bypass dryer, if available; allow dryer to
thaw; if symptom persist, make
adjustments to dryer
3. Inline filter between compressor
& storage tank is clogged
3. Replace filter
NOTES:

22
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 10 YEARS ON THE ROTARY SCREW AIR COMPRES-
SOR PUMP FROM THE DATE OF PURCHASE. Eaton Compressor and Fabrication Co., Inc. (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 UNIT. This warranty applies to rotary screw rotors and bearings.
The electric motor carries a five year warranty and a 2 year warranty on the rest of the compressor unit. The screw compressor MUST have Eaton Compressor and Fabrication Co.,
Inc. Lubricant Synthetic exclusively, the same which must be purchased from Eaton Compressor and Fabrication Co., Inc. (Mixing different brands of oil will void this warranty and
cause the rotors to varnish). All air filters, oil filters, and oil separator filters must be purchased from Eaton Compressor and Fabrication Co., Inc. and the screw compressor must
have Eaton Compressor and Fabrication Co., Inc. Synthetic Rotary Screw oil, purchased exclusively from Eaton Compressor and Fabrication Co., Inc., for this warranty to apply.
Annual participation in all oil programs are required by original purchaser of the unit outlined by the following:
a) Purchase an oil sample kit for oil analysis by Eaton Compressor and Fabri-
cation Co., Inc.
b) Oil sample kit contains 20 oil sample containers. One (1) oil sample is to
be sent for analysis by an Eaton Compressor oil analysis laboratory every
six (6) months so oil can be tested twice yearly.
c) Oil samples are obtained by draining 4 ozs. of oil into container then
mailing sample container to laboratory address provided in oil sample kit.
d) The laboratory will perform an oil analysis then email a report to email ad-
dress required when oil sample is provided.
e) Provide annual proof of purchase for oil/filter service kit.
f) Maintain proper oil level in unit at all times. If the unit runs out of oil, this
warranty is void.

Failure of original purchaser to comply with any of the above conditions pertaining to oil analysis with void the complete unit warranty.
A full detailed maintenance schedule must be sent to Eaton Compressor and Fabrication Co., Inc. once a year with the total service completed quarterly, outlining each air filter,
oil filter and oil change with the total hours on the unit after each maintenance was performed.
Failure to fully comply with this warranty and fully comply with the manual herein will void this warranty.
Exclusions to this warranty also include all normal wear and tear items, including, but not limited to the bearings, rotors, valves, belts, shaft seal and load/unload solenoids.
2. THAT EACH BARE COMPRESSOR PUMP UNIT TO BE FREE FROM DEFECTS IN MATERIAL, WORKMANSHIP, AND PARTS FOR 5 YEARS FOR THE UNIT FROM THE DATE OF PURCHASE. Eaton
Compressor and Fabrication Co., Inc. (and each of its subsidiaries) is not responsible for downtime during warranty service. If downtime is necessary, it is the Purchaser’s discre-
tion and obligation (at Purchaser’s expense) to have a redundant UNIT. Warranty repairs shall not include freight costs. Purchaser is responsible for returning unit to Eaton Com-
pressor and Fabrication Co., Inc. This pump must have Eaton Compressor and Fabrication Co., Inc. lubricant Synthetic exclusively, the same which must be purchased from Eaton
Compressor and Fabrication Co., Inc. (Mixing different brands of oils will void the pump warranty). A service kit must be purchased from Eaton Compressor and Fabrication Co.,
Inc. for this warranty to apply. Service kits contain an air filter and synthetic oil that must be changed annually. Annual proof of purchase of all oil programs must be maintained
by the original purchaser of the compressor pump. If the unit runs out of oil, this warranty is void. Failure to fully comply with this warranty and fully comply with the manual
herein will void this warranty.
Exclusions include: service such as OIL CHANGES, FILTER REPLACEMENTS, GASKET TIGHTENING TO CORRECT OIL SEEPAGE or DRIVE BELT TIGHTENING and VALVE CLEANING and are
not covered under warranty.
Warranty shall be void under the following conditions: Failure to routinely change oil and to maintain a clean filter, or exceeding 70% duty cycle resulting in overheating and
excessive wear and tear, or exposing electrical components to rain or water, or installing the unit in a hostile environment such as acid vapors or any caustic or abrasive matter that
may be ingested into the pump, or installing the unit in an enclosed area where lack of cooling ventilation is present, such as in boiler or equipment rooms where the ambient air
exceeds 100˚F.
3. THAT EACH COMPRESSOR UNIT TO BE FREE FROM DEFECTS IN MATERIAL, WORKMANSHIP, AND PARTS FOR 5 YEARS FOR THE COMPRESSOR PUMP AND 2 YEARS ON THE REMAINDER
OF THE UNIT FROM THE DATE OF PURCHASE. The UNIT also carries a 1-year labor warranty. Eaton Compressor and Fabrication Co., Inc. (and each of its subsidiaries) is not re-
sponsible 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.
Warranty repairs shall not include freight costs. Purchaser is responsible for returning unit to Eaton Compressor and Fabrication Co., Inc. This pump MUST have Eaton Compressor
and Fabrication Co., Inc. Lubricant Synthetic exclusively, the same which must be purchased from Eaton Compressor and Fabrication Co., Inc. (Mixing different brands of oil will
void this warranty). A service kit must be purchased from Eaton Compressor and Fabrication Co., Inc. for this warranty to apply. Service kits contain an air filter and synthetic oil
that must be changed annually. Annual proof of purchase of all oil programs must be maintained by the original purchaser of the compressor unit. If the unit runs out of oil, this
warranty is void. Failure to fully comply with this warranty and fully comply with the manual herein will void this warranty.
Warranty shall be void under the following conditions: Failure to routinely change oil and to maintain a clean filter, or exceeding 70% duty cycle resulting in overheating and
excessive wear and tear, or exposing electrical components to rain or water, or installing the unit in a hostile environment such as acid vapors or any caustic or abrasive matter that
may be ingested into the pump, or installing the unit in an enclosed area where lack of cooling ventilation is present, such as in boiler or equipment rooms where the ambient air
exceeds 100˚F.
4. THAT EACH DRYER UNIT TO BE FREE FROM DEFECTS IN MATERIAL, WORKMANSHIP, AND PARTS FOR 5 YEARS on the HEAT EXCHANGER AND 2 YEARS ON THE DRYER UNIT FROM THE
DATE OF PURCHASE. Eaton Compressor and Fabrication Co., Inc. (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 DRYER UNIT. Warranty repairs shall not include freight costs. Purchaser is responsible for
returning unit to Eaton Compressor and Fabrication Co., Inc. Each DRYER UNIT must have a coalescing filter attached to the intake of the dryer to remove any oil or dirt before air
enters the dryer. Failure to install coalescing filter will void the warranty.
5. GENERAL PROVISIONS: Eaton Compressor and Fabrication Co., Inc. (and each of its subsidiaries) is not responsible for downtime during warranty service. If downtime is neces-
sary, it is the Purchaser’s discretion and obligation (at Purchaser’s expense) to have a redundant compressor. Warranty repairs shall not include freight costs. If necessary, the
Purchaser is responsible for returning unit and/or applicable part(s) to Eaton Compressor and Fabrication Co., Inc.
Further Exclusions include failure to fully and completely follow the guidelines set forth in the manual. Of specific note is where a product is used where granite and/or concrete
work is performed or conditions are dusty and the product is required to be housed in a separate room from the adverse conditions where the product has access to fresh air
intake.
Parts used for warranty purposes must be supplied by Eaton Compressor and Fabrication Co., Inc. Warranty work will be performed by an approved Eaton Compressor and
Fabrication Co., Inc. Technician. If any maintenance (other than routine maintenance) is performed by a non-approved Eaton Compressor and Fabrication Co., Inc. Techni-
cian, written pre-approval must be obtained from Eaton Compressor and Fabrication Co., Inc. to prevent voiding this Warranty. Failure to fully comply with this warranty and
fully comply with the manual herein will void this warranty.
All warranties are nontransferable.
The Oil Purchase Program is effective as of January 1, 2011.

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