EMAX HULK POWER HS05V080Y1 (01) PDF MANUAL

EMAX HULK POWER HS05V080Y1 (01) PDF SUMMARY:

What are the model numbers of the stationary air compressors covered in the manual?

The stationary air compressor model numbers are: HI05V080Y1, HS05V080Y1, HI07V080Y1, HS07V080Y1, HI07V080V1, and HS07V080V1.

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What is the maximum PSI for these compressors?

The maximum PSI is 175.

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What are the no-load pump and motor speeds?

The no-load pump speed is 790 RPM, and the no-load motor speed is 1750 RPM.

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What is the specified tank outlet size and tank size?

Tank outlet size is 1" NPT FEMALE, Tank Size is 80 Gallon.

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What is the specified Air Delivery @100PSI?

5HP-18CFM, 7.5HPY-24CFM, and 7.5HPV-32CFM.

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What are the key safety precautions related to breathable air?

Never use air from this compressor for breathing air except in full compliance with OSHA Standards 29 CFR 1910 and any other Federal, State, or Local codes or regulations. Also, do not use airline anti-icer systems in air lines supplying respirators or other equipment used to produce breathable air, and do not discharge air from these systems in unventilated or other confined areas. Death or serious injury can result from inhaling compressed air without using proper safety equipment.

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What should be done with pressurized components before each use?

Pull the ring on the ASME-rated relief valve to ensure it is functional. Do not attempt to open the valve while the machine is under pressure.

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What type of environment should the compressor be installed in?

The compressor should be installed in a clean, dry, and well-lit area. The installation area should maintain a temperature range between 35°F and 110°F.

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What should be done if the ambient temperature drops below 32°F?

If the ambient temperature drops below 32°F, protect safety/relief valves and drain valves from freezing. Never operate the compressor with temperatures below 15°F or above 125°F.

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How much clearance space should be around the compressor?

Allow sufficient space around the compressor for maintenance access and adequate airflow. Mount the unit with the belt guard (pulley and flywheel) side to the wall, leaving a minimum of 15 inches of clearance.

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What if the operating environment is dusty or acidic?

If acid is used in the operating environment or the air is dust-laden, pipe the intake to outside fresh air. Increase the pipe size by 1/8" for every 20 feet of run. Install a protective hood at the outside air intake location to prevent debris and foreign objects from blocking the intake pipe.

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What type of motor is recommended for environments with excessive water, oil, dirt, acid, or alkaline fumes?

A TEFC (totally enclosed, fan-cooled) motor is highly recommended.

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What should be done with overhead pipes?

Insulate cold water or other low-temperature pipes that pass overhead to avoid condensation dripping on the compressor.

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What locations are unsuitable for compressor installation?

Do not install the compressor in a boiler room, paint spray room, or area where sandblasting occurs. Make sure the inlet air is away from exhaust fumes or other toxic, noxious, or corrosive fumes or substances.

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What should be done if the installation area is not flat?

Use shims to level the compressor.

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What are the safety steps to ensure proper lifting using a forklift?

Make sure lift operator stays aware while moving the compressor. Be sure to uncrate the compressor prior to movement. This will allow a visual reference for the balance of the unit. Be sure the load is secure and well balanced before moving the compressor. Make sure the forks are fully engaged and level prior to lifting or moving the unit. Keep the unit/load as low as possible while moving and refrain from quick changes in direction. For all other forklift safety standards/regulations please reference OSHA 1910.178- Powered industrial trucks.

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How do you anchor the compressor?

1. Make sure the compressor is in the desired location and the anti-vibration pads are under the feet of the compressor.
2. Using the holes in the feet as guides, drill the holes for the anchor bolts through the vibration pads and into the concrete.
3. Thoroughly clean each hole. Go in straight; do not let the drill wobble. Use a carbide bit (conforming to ANSI B212.15). The diameter of the drill bit must be the same as the diameter of the anchor bolt. If you are using a 3/8-inch diameter anchor bolt, for example, use a 3/8 inch diameter drill bit. If a vacuum is not available, use a wire brush, hand pump, or compressed air. DO NOT ream the hole. DO NOT make the hole any wider than the drill bit made it.
4. Put the Washer and Nut into place; make sure the top of the Nut is flush with the top of the anchor bolt, then insert the anchor bolt into the hole.
5. Hammer or mallet the anchor bolt down into the hole. Stop hammering when the washer is snug against the top of the foot.
6. Tighten each nut clockwise; DO NOT overtighten. DO NOT use an impact to tighten the anchors.

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What are the recommended anchor bolt specifications?

Wedge anchors; 3/8 in width by 3.5 in length.

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What are the key electrical safety guidelines?

Follow all NEC and local codes for electrical wiring. Allow only authorized service personnel or certified electricians to install electrical components. Put the unit on a dedicated circuit and make sure no other electrical equipment is wired into it. The unit must be properly grounded; do not connect ground to air or cooling lines. Ensure incoming service has adequate ampere rating and do not use mixed wire sizes when wiring the unit.

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What precautions should be taken when wiring units with magnetic starters?

Do not install power directly to the pressure switch. This can cause fire and possible injury/property damage.

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What is a proper wire diagram for a Single phase unit, magnetic starter?

PRESSURE SWITCH, POWER SUPPLY 208/230 VOLT, A1, A2, 1L1, 3L2, 5L3, T1, T2, T3, NC95, NC96, and MOTOR.

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What are the wire and breaker requirements?

Voltage should not vary more than 10%.

Motor Horsepower	Breaker Size (Amps)	Wire Size (50ft or less)*	Wire Size (More than 50ft)	Peak Start Amps (Locked Rotor)
5	40	8 gauge	Consult Electrician	135
7.5 Y	50	6 gauge	Consult Electrician	210
7.5 V	50	6 gauge	Consult Electrician	240
*Wire size distances are from unit to the panel where the breaker is housed.
CAUTION: Under sizing wires and/or breakers can cause damage to the unit, possible injury to personnel, and void your warranty.

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What are the key steps for piping installation?

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). Flow-limiting valve are listed by pipe size and rated CFM. Select appropriate valves according to manufacturer’s recommendations. Use a flexible connector between compressor tank and dryer/piping system to minimize noise, vibration, pump wear, and to prevent damage to the unit or piping system. Install ASME code safety valves and ensure piping system is equipped with adequate condensate drains.

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What is the minimum pipe size for compressed air lines?

CFM	25ft	50ft	100ft	250ft
20	¾	¾	¾	1
40	¾	¾	1	1
60	¾	1	1	1
100	1	1	1	1-1/4
125	1 – ¼	1 – 1/4	1 – ¼	1 – ½

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What are some examples of recommended air system setups?

• Closed-loop system: Install tee fitting in piping from air to minimize pressure drop and allow air flow in two directions.
• Air Drop: Install a tee fitting with the branch to the top to minimize condensation.

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What materials should not be used for piping?

Never use plastic (PVC) pipe for compressed air. Piping MUST have a pressure rating of 200 PSI or greater.

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What should be done before the first use of the compressor?

Check for proper oil level. Oil level should be to the center of the red circle in the sight glass. Oil level WILL SLIGHTLY LOWER once the unit turns on and oil begins to circulate. Check for proper belt tension. There should be ½ inch of belt slack/deflection. Inspect belts for frays or an excess buildup of black rubber dust, indicating belt wear.

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How to ensure proper belt tension?

Proper belt tension is determined by pressing midway between the motor pulley and the pump flywheel. There should be 1/2" Deflection.

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How do you check the safety valves?

Check proper operation of all pop-off safety valves on the unit. Pull rings on valves to ensure they move and are free of any obstructions. DO NOT pull the safety valve on the tank if there is air in the tank!

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What should be inspected regarding air lines and electrical wiring?

Inspect all air lines/piping for proper for secure fit and corrosion or line degradation. With the unit locked out (power off at the source), ensure all electrical wiring, including all terminals, are in good condition and free of buildup, fraying, cracks, or discoloration.

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What else needs to be checked for?

Ensure the unit is secured in place. Remove any loose items from around/on the compressor. Check the unit for any oil leaks. Unit should NEVER be operated without the belt guard in place. Inspect Flywheel for cracks or missing fins.

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What are the steps for the initial operation of the compressor?

1. Once the inspection is completed, open your discharge port (outlet ball valve). This should already be connected to your shop airline system.
2. Ensure all personnel are clear of the compressor and aware that it is being started.
3. Turn the selector on your pressure switch to AUTO. This will start your compressor and allow it to fill. The tank will fill to 175 PSI, and unless otherwise noted, will shut off. The unit will begin pumping again once the tank is drained down to approximately 135 PSI.

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What are the average pump-up times?

Horsepower	Tank size (gallons)	Average pump-up time (empty to full 175 PSI) times may vary +/- 20%
5	80	7 min 15 seconds
7.5 Y	80	6 min 30 seconds
7.5 V	80	4 min 45 seconds

*Pump up times are based on averages. Altitude, ambient temp and barometric pressure can affect times.

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What is the general maintenance schedule?

Item	Frequency	Comment
Cleanliness	Daily	Keep the compressor and the surrounding area clean. Wipe off oil, spills, and dirt/dust.
Oil Level	Daily	Check oil level while the unit is OFF. If oil is low, add to the fill point. If the level is high, drain off oil.
Tank Pressure	Daily	Check the unit for air leaks.
Tank	Daily	Drain the tank daily at the end of use. DO NOT attempt to store air for prolonged periods of time. The electrical cost is minuscule compared to replacing a rusted-out or ruptured tank. DO NOT attempt to repair a damaged tank.
Anchors	Weekly	Ensure anchors are holding the unit securely and are not loose.
Anti-Vibration Pads	Weekly	Check for wear. Verify they are in place and not damaged or rotted.
Belt	Monthly	Verify belt tension. Replace if excessively loose or damaged.
Environment	Quarterly	Air temperature should not exceed recommended levels. Humidity, where compressor is stored, should not exceed 70%. Consider relocating compressor if these conditions cannot be met.
Wiring	Semi Annually	Have an electrician check connection from power supply and all subsequent connections on the unit.
Tank	Yearly	Inspect for rust or corrosion. DO NOT attempt to repair a damaged tank.
Entire Unit	Yearly	Lock unit out and detail clean.
Air Filter(s)*	See Comments	Air filters should be changed after the first 100-hour break-in period and every 90 days after that. The frequency will increase in environments with air contaminants such as dust, paint, dirt, etc.
Oil*	See Comments	Oil should be changed after the first 100-hour break-in period and every 90 days after that. This will increase in frequency depending on actual compressor use and hours unit is running.

*Frequency of these changes are a generalization and may be subject to change based on compressor environment, hours, and application.

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What type of oil should be used?

It is strongly advised to use only Airbase Industries piston compressor oil. Oil used in the compressor must fall under the following criteria: synthetic, SAE grade 30, non-detergent, and piston compressor oil.

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How should oil be disposed of?

Compressor oil is not trash and MUST NOT be disposed of in regular trash or discarded into the environment. You MUST dispose of waste oil from your unit per all applicable federal, state, and/or local codes.

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What should I do if the compressor does not run?

Check the unit power supply. Verify incoming voltage from the power supply to the unit. Check that breakers are functioning correctly. Verify wiring is connected correctly and not loose.

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What should I do if the Compressor cycles frequently?

Check for leaks in facility/shop air lines or air system. Check for stuck tools or machine leaks. Check pressure settings and PSI cycle settings on switch.

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What should I do if the compressor does not reach pressure?

Check unit is not running in continuous run. Check CFM consumption of machines to ensure they do not exceed compressor capability. Check tools for CONSTANT CFM rating, not average. Average ratings do not reflect consumption and are often 66% lower than actual CFM consumption. Check for leaks in air lines or on unit.

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What should I do if the oil level is low?

Verify oil level while unit is off and cool. Top oil off and monitor oil level. If it drops again, check for oil leaks, and check if correct oil is being used.

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What should I do if the Compressor is running loud?

Ensure anchor bolts are in use and are snug. Check vibration pads for excess wear, replace as needed. Ensure unit is not hard lined to the air system. The unit should be connected by flexible hose to air systems to prevent vibration noise. Check oil pressure if there is no oil pressure shut unit down and contact customer support.

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What should I do if the Compressor will not shut off?

Check incoming power location. If wired incorrectly, power is going directly to the motor and can cause tank damage. Shut the unit down and verify the wire diagram. If the problem continues, contact customer support.

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What should I do if the magnetic starter has kicked off?

Verify duty cycle on unit. It should not exceed 60-40 run/rest cycle if it does consider upsizing unit and/or tank size. Thermal overloads are designed to protect the motor from overheating. Overusing unit can cause thermal overloads to trip. Allow the unit to cool, reset magnetic starter, and continue use. If the problem occurs again, contact customer support.

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What should I do if I’m getting oil blow-by?

Verify pump has passed the break-in time: 150-200 hours of active run time. Ensure the unit is not running in continuous mode prior to the break-in period being completed (this can cause an increase in blow-by during the break-in). For cases after break-in period, contact customer support.