Joy TWISTAIR III User manual

OPERATOR’S MANUAL
JOY@
TWISTAIR”lll
ROTARY SCREW COMPRESSOR
TA MODELS 300 thru 750
MCT-126
FORM NO. MCT-126

OPERATOR’S MANUAL
JOY@
TWISTAIR@LU
Rotary Screw Compressor
THIS MANUAL CONTAINS VITAL
INFORMATION FOR THE SAFE
USE AND EFFICIENT OPERATION
OF THIS UNIT. CAREFULLY READ
THE OPERATOR’S MANUAL
BEFORE STARTING THE UNIT.
FAILURE TO ADHERE TO THE IN-
STRUCTIONS COULD RESULT IN
SERIOUS BODILY INJURY.
TA Models 300 thru 750
JOY MANUFACTURING COMPANY
INDUSTRIAL COMPRESSOR GROUP
MICHIGAN CITY, INDIANA 46360
@Joy MANUFACTURING COMPANY 1986
FORM NO. MCT-126
Printed in U.S.A.
FPS1-5/86

DISCHARGE AIR USED FOR BREATHING.
WILL CAUSE SEVERE INJURY OR DEATH.
CONSULT FILTRATION SPECIALIST FOR
ADDITIONAL FILTRATION AND TREATMENT
EQUIPMENT TO MEET HEALTH AND SAFETY
STANDARDS.

TABLE OF CONTENTS
Page
Specifications ................................ i
SECTION1 DESCRIPTION AND
INSTALLATION
Introduction .................................
Description .................................. 1
Compressor &Motor .......................... 2
Compressor Lubrication System . . . . . . . . . . . . . . 3
Minimum Pressure Valve.... .................. 4
Air/OilSeparator&OilSump.. ................. 4
Oil Return Line ............................... 5
Oil Filter .................................... 5
Oil Cooling System ........................... 5
Air Cooling System ........................... 6
Cooling Water(Water-Cooled Units Only) ......... 6
Reset Operator ............................... 7
Instrument Panel ............................. 7
Air-Oil Separator ........................... 7
Delivery Air Temperature .................... 7
Discharge Air Pressure ...................... 7
Delivery Air Pressure ........................ 7
Start Button ............................... 7
Stop ButtoN ............................... 7
Load/UnloadButton ........................ 7
Indicator Lights ............................ 7
High Discharge Temperature. ................ 8
Hourmeter ................................ 8
Control Center ............................... 8
Electrical Control Wiring ....................... 9
Control System ..............................
Control System Components.. ................. 9
Control Valve .............................. 9
Blowdown Valve ............................ 9
Double Check Valve(A) ...................... 9
Double Check Valve(B) ...................... 9
Air Pressure Switch ......................... 9
Unloader Valve ............................. 10
High DischargeTemperature Switch ........... 10
Control Relay .............................. 10
Dual Control ............................... 10
Coupling .................................. 11
INSTALLATION .............................. 11
Receiving ................................... 11
Handling .................................... 11
Location .................................... 11
Foundation .................................. 12
Electrical Connections ........................ 12
Air Intake Piping ............................. 12
Discharge Piping ............................. 13
Page
Heated Moisture SeparatorWith Trap ............ 13
AIR COMPRESSOR OPERATING
PRECAUTIONS ............................ 14
SAFETY DECALS ............................. 15
INSTALLATION DRAWINGS ................. 16-19
WIRING DIAGRAMS ........................ 20-26
SECTION2 OPERATION
Introduction .................................
Preparation forlnitial Start-Up ..................
Normal Starting ..............................
Normal Stopping .............................
Emergency Shut-Down ........................
Restart After Power Failure.. ..................
Restart After Safety CircuitShut-Down ...........
Preparation For Storage And Start-Up
After Prolonged Storage ...................
SECTION3 LUBRICATION, MAINTENANCE
AND ADJUSTMENT
LUBRICATION ...............................
Prime Lubricant Characteristics ..............
Oil .......................................
Oil Sump Capacity ..........................
Adding or Changing Oil ......................
Motor .....................................
Initial Oil Change ...........................
PERIODIC MAINTENANCE SCHEDULE ..........
Access Doors &Enclosure Removal ...........
Air Intake Filter ............................
Oil Filter ..................................
Air/OilSeparator ...........................
Thermal Valve .............................
Oil Return Line Sight Flow..... ..............
Control Valve ..............................
Air Pressure Switch .........................
Time Delay Relay ...........................
Minimum Pressure Check Valve ...............
MAINTENANCE SCHEDULE ...................
SECTION4 TROUBLE SHOOTING ANDTESTING
Introduction .................................
Automatic Shutdown ..........................
Frequent Separator Plug-UporCollapse ..........
TROUBLE SHOOTING CHART... ...............
SECTION5 OPTIONAL EQUIPMENT
1
1
1
2
2
2
2
2
1
1
1
2
2
2
2
3
4
4
6
6
6
6
6
7
7
7
8
1
1
1
2

SPECIFICATIONS
20 COMPRESSORMODEL TA-300 TA-340 TA-370 TA-400 TA-450 TA-480 TA-51OTA-590 TA-630 TA-600 TA-690 TA-751
20 COMPRESSOR: CFM 300 335 _ ____—.
370 400 445 470 495 590 625 590 _ _ 680 720
Delivery (CFM) CMM 8.5 9.5 10.5 11.3 12.6 13.3 14.0 16.7 17.7 16.7 19.2 20.4
Maximum Operating PSIG 150 125 _ _ _ _ _ ____ _ 110 150 125 110 150 125 110 150 125 110
Pressure (PSIG) BARS 10 8.6 7.5 10 8.6 7.5 10 8.6 7.5 10 8.6 7.5
Minimum Operating PSIG 70 70 70 70 70 70 70 70 70 70 70 70
Pressure (PSIG) BARS 55 5 5 5 5 5 5 55 5 5
Normal Control Range (PSI) Psl 10 10 10 10 10 10 10 10 10 10 10 10
BARS .7 .7 .7 .7 .7 .7 .7 .7 .7 .7 .7 .7
Ambient Operating IFAHRENHEIT I35° F. to 1100 F.
Temperature Range CELSIUS 2c. to43c.
Oil Sump Capacity GALLONS 25 25
LITERS 94.6 94.6
Weight (Wet) Base Model POUNDS 2835 2985
Air Cooled KILOGRAMS 1286 1354
Length INCHES 96 96
MILLIMETERS 2438 2438
Width INCHES 54 54
MILLIMETERS 1372 1372
Height INCHES 51.5 51.5
MILLIMETERS 1308 1308
MOTOR, Compressor Drive: HP 75 100
Horsepower KW 56 74.6
25
94.6
3320
1506
102
2591
66
1676
56.5
1435 -
125
93.3
25
94.6
3540
1606
102
2591
66
1676
56.5
1435
150
112
Current 3Phase 60 Hertz
Voltage 200, 230, 460, 575
-.
Type Squirrel Cage Induction
Standard Enclosure Open Drip Proof
MOTOR, Fan: (Aircooled HP 2 3 35
(With Aftercooler) KW 1.49 2.24 2.24 3.73
Type Squirrel Cage Induction
Standard Enclosure TEFC TEFC TEFC TEFC
WATER COOLED UNITS — GPM 16 21 27 32
Water Flow Rate LPS 1.0 1.3 1.7 2.0
Maximum Water Inlet FAHRENHEIT 95° F. 95° F. 95 “F. 95° F.
Tern perat ure CELSIUS 27° C. 27° C. 27° C. 27° C.
Evacuation Fan -- HP .5 .5 .5 .5
(Enclosed Only) KW .37 .37 .37 .37
Joy Manufacturing Company reserves the right to alter or improve the design or construction of its machinery as described
herein and to furnish it, when so altered, without reference to the illustrations in this bulletin.

SECTION 1
DESCRIPTION AND INSTALLATION
JOY@
Twls
Rotary Scr
FIGURE 1
TA MODELS 300 THRU 750
INTRODUCTION
o
/
//
The JOY@ Rotary Screw Compressor is an electric motor-driven, SinGle-staGe, screw-tYPe,
heavy-duty air compressor. It is sold as acomplete package unit mounteD on a Steel base. See
Figure 1. The package includes the compressor, motor, air intake system, electrical starting
unit, control system, cooling system, air/oil separator, and instrument panel. Installation re-
quires only the connection of electric power, aservice line; and when applicable, awater line
and drain.
There are several models of Rotary Screw Compressors covered in this manual. Refer to
“Specifications” for the air delivery capability, horsepower, and operating pressure of each
unit. All models are available either air or water cooled. They are intended for indoor installa-
tion. Although the unit is generally totally enclosed, it can be ordered without enclosure.
/
83-35A

PAGE 2SECTION 1
AIR DISCHARGE
FIGURE 2
Cut-A way View of Compressor Unit
DESCRIPTION
FIGURE 3
82-24 Principles of Compression 74-61A
The complete operating unit consists of the following major components.
1.
2.
3.
4.
5.
6.
Compressor and motor
Oil sump/separator
Oil cooling system
Air cooling system
Electrical control
Instrument panel
COMPRESSOR COMPRESSOR AND MOTOR
The compressor assembly is apositive displacement, oil flood lubricated, screw type unit
employing one stage of compression to achieve the desired pressure. Components include a
housing (stator), two screws (rotors), bearings and bearing supports. See Figure 2. The male
rotor has four lobes and the female has six.
In operation, two helically grooved rotors (Figure 2) mesh to compress air. Inlet air entering
the casing is compressed as the male lobes roll down the female grooves, pushing trapped at-
mospheric air along and compressing it in one stage of compression. This process delivers
smooth-flowing air at full pressure to the receiver.
To illustrate the compression sequence, consider the action of the male lobe as similar to a
ball. In Figure 3, one compression cycle has been isolated for simplication. As ahelix rotates,
the ball (male lobe) meshes with the groove to start acompression cycle with trapped at-
mospheric air (A). As the bail moves down the groove, air is compressed (B). The compressed air
is discharged as the ball reaches the end of the groove (C). Atmospheric air fills in behind the
ball preparing the groove for another compression cycle as rotation continues and the male
lobe again meshes with the groove.

SECTION 1PAGE 3
WATER COOLED MOOELS
IWATER [N\ AFTjRCOOLER ~
AAIR INTAKE
VALV~\~
COMPRESSOR
OIL RETURN LINE
SIGHT FLOW
~AIR-OIL
mOIL
=WATER
A,R.o,L/=
SEPARATOR SUMP
FIGURE 4
Air and Oil Flow Diagram
-.. —
UIL FILTER
During the compression cycle, oil is injected into the compressor for the purpose of
lubricating, cooling, and sealing. Compressed air laden with oil leaves the compressor unit
through adischarge port which is designed to give optimum performance within the desired
discharge pressure range.
Related components to the compressor assembly include the air filter, the inlet valve, and a full
flow oil filter. The air filter is atwo-stage, dry type with apleated paper replaceable element.
The inlet valve (Figure 2) is pneumatically operated. It functions in response to the control
system which regulates the amount of valve opening and closing in proportion to the air demand.
Pressure Differential System
Sump pressure and air end suction pressure create conditions necessary for oil to flow. This
system reduces the package horsepower by eliminating the oil pump.
83-31
Compressor Lubrication System
The oil that is directed to the compressor from the oil sump serves three purposes:
1. Lubricates the rotating parts and bearings.
2. Serves as acooling agent for the compressed air to maintain the discharge
temperature within 100 Deg. F. of ambient temperature.
3. Helps assure high efficiency and maximum air delivery by sealing running
clearances.

PAGE 4SECTION 1
,/
FIGURE 5
Major Compressor Components (Water Cooled Model Without Enclosure Shown)
10
83-32A
1. Aftercooler 5. Oil Sump 9. Compressor Motor
2. Oil Cooler 6. Air Intake Filter
3. Oil Filter 10. Lifting
7. Instrument Panel 11. Inlet Valve
4. Minimum Pressure Valve 8. Control Center 12. Air End
As oil passes through the compressor, it mixes with the air being compressed and is
discharged with the compressed air into the oil sump. Here the oil accumulates, then moves on
to be filtered, and finally returns through the oil cooler for recirculation through the com-
pressor– completing the cycle.
The flow schematic, Figure 4, illustrates air/oil separation and the circulation of oil in an air
or water cooled system.
MINIMUM PRESSURE VALVE
The function of the minimum pressure valve (See Figures 4 and 5) is to insure maximum oil
flow upon start-up, also it maintains proper velocity for high efficiency of air/oil separator. It
also acts as acheck valve; in the event the compressor is manifolded with other compressors,
it will not be pressurized during shutdown.
AIR/OIL SEPARATOR AND SUMP
Compressed, oil-laden air enters the oil sump directly from the compressor discharge
through alarge unrestricted pipe to apoint well above the oil level of the sump. See Figure 4. As
the oil-laden air enters the sump, much of the oil is separated from the air by centrifugal action.
The oil then runs downward and accumulates at the bottom of the sump for recirculation.
An air/oil separator is located in the upper portion of the oil sump. When air is demanded at
the service line, it first passes through the separator element which is the final stage of oil
separation. Any oil that does pass through the element will collect at the bottom of the
separator and be removed by the oil return line (Figure 4).

SECTION 1PAGE 5
FIGURE 6
Air Cooled Oil Cooler
3\ ~DIRECTION OF
+
//-
\
21DIRECTION OF
FAN ROTATION
‘and Aftercooler 83-33
1. Fan 3. Aftercooler
2. Fan Motor 4. Oil Cooler
OIL RETURN LINE
The oil return line is provided to remove any oil accumulation from the bottom of the
separator and return it to the compressor. Asemi-clear tubing is provided in this line to observe
the oil flow daily. Under loaded conditions, oil bubbles will continuously trickle through the tub-
ing. If the tubing shows full of oil or no oil flow at all, it is asign that oil is not being drained.
OIL FILTER
The oil filter is the replaceable element type. It is equipped with abuilt in maintenance in-
dicator which signals when aclogging element requires changing. If the oil filter plugs very rapid-
ly, an internal bypass will continue to allow oil to flow to the compressor.
OIL COOLING SYSTEM
The prime components of the oil cooling system include athermal valve and oil cooler. The
thermal valve is located in the oil cooler piping and is designed to be fully open until the oil
temperature reaches approximately 135 Deg. F., thus allowing the oil to bypass the cooler and
maintain adesirable oil temperature for operaton in cool or humid am bients. This decreases
the probability of water build up in the sump. Above 135 Deg. F., the thermal valve gradually
strokes to allow cooled oil from the cooler to mix with the hotter oil from the sump to maintain
the discharge air temperature approximately 100 Deg. F. over ambient. The discharge air
temperature is also dependent on the ambient air temperature, the quantity of oil for injection;
and if water cooled, the temperature and quantity of cooling water supplied.
The oil cooler may be either air or water cooled. If air cooled, afinned heat exchanger is used
and a fan provides cooling air circulation through the exchanger. When water cooled, ashell
and tube bundle cooler is used and a cooling water supply is required. See Figures 5 and 6.
COOLING

PAGE 6SECTION 1
FIGURE 7
Instrument Panel 82-28A
1. Service Separator 7. Start Button/Run Indicator
2. Delivery Air Temperature 8. Start Button/Power On Indicator
3. Rotor Coolant Injection Pressure 9. High Discharge Temperature
4. Discharge Air Temperature 10. Load/Unload
5. Discharge Air Pressure 11. Hourmeter
6. Delivery Air Pressure
AIR COOLING SYSTEM
This system contains an aftercooler and a moisture separator with automatic condensate
trap. The aftercooler is used to reduce the temperature of the compressed air and remove
moisture before it reaches the service lines. Depending on the configuration, the cooling
medium used for aftercooling may be air or water and will be connected in series with the oil
cooler. If air cooled, afinned, radiator type aftercooler is used. Water cooled units are provided
with ashell and tube bundle aftercooler. See Figure 4.
In reducing the air temperature at the aftercooler, moisture is condensed out of the air and then
separated by action of the moisture separator. Water and other impurities removed accumulate
at the moisture trap and are automatically eliminated. Condensate should be piped to an “open”
drain avoiding freezing conditions. Keep the line the same size as the connection provided. The
line should be pitched slightly downward away from the installation being careful not to create a
trap in the piping. See Section 5for suggested installation. To accommodate varying applica-
tions, the separator trap must be piped exterior to the machine during installation.
COOLING WATER (Water Cooled Units Only)
An adequate supply of clean water must be available to the oil cooler and the aftercooler. The
use of dirty or scale forming water should be avoided. Dirty water clogs tubes and reduces cool-
ing efficiency.
Connect the supply and discharge water piping to the points indicated in Figures 14 thru 15A.
The discharge line should be provided with avalve for shutting off the water supply.
For units without atemperature regulating valve the discharge water should flow into an
open funnel to allow temperature checks. Excessive temperature will indicate an overheated
condition due to insufficient cooling water or as outlined in “Automatic Shut-down” –Section
4. Water flow should be adjusted to maintain the discharge air temperature approximately
IOO” F. above ambient. Also see “Periodic Maintenance Schedule.”

SECTION 1PAGE 7
INSTRUMENT PANEL CONTROLS AND INSTRUMENTATION
The instrument panel (Figure 7) contains all the necessary gauges and instruments for opera-
tion. Following is an explanation of their use.
Start Button
The “Start” button (8, Figure 7) will start the compressor providing the main disconnect is
connected and the safety circuit is cleared.
Stop Button
The Stop button (9, Figure 7) will stop the compressor at any time. When the stop button is
pushed, the “Run” light will go out and the stop light will become lighted.
The reset feature of this button is connected to the compressor’s safety circuit. Whenever
the compressor shuts down due to amalfunction detected by the safety circuit, it will be
necessary that the trouble be corrected and that the stop-reset button be pushed before
another start is tried.
TO RESET
Loadllfnload Button
“ETC.” HOLD STOP/RESET BUTTON IN FOR 2-3 SECONDS.
The “load/unload” (Figure 7) button permits the operator to unload the compressor at
anytime during operation. It is recommended that under normal conditions the machine be
unloaded prior to stopping.
Hourmeter
The “hourmeter” (Figure 7) records the accumulated total hours of compressor operation. It
serves to determine when periodic inspections and maintenance should be performed.
Reset Operator
The reset operator is provided to reset the motor overloads. Whenever the compressor shuts
down due to the tripping of the motor overloads, it will be necessary that the trouble be corrected
and that the reset button be pushed before another start is tried.
STANDARD
Service Separator
The service separator gauge (1, Figure 7) warns that the maximum recommended pressure dif-
ferential of the separator element has been reached and the element should be serviced.
Discharge Air Temperature
This gauge (4, Figure 7) indicates the temperature of the air/oil mixture immediately after final
compression. Normal temperature in operation is approximately 100 Deg. F. above ambient.
Discharge Air Pressure
The discharge pressure gauge (5, Figure 7) is ameasure of the pressure in the sump.
OPTIONAL
Delivery Air Temperature
The delivery air temperature gauge (2, Figure 7) measures the temperature of air being delivered
into your system. Acomparison of this reading to the discharged temperature reading gives you a
performance measure on the aftercooler. Adrop off in this performance would indicate
maintenance requirement on coolant side.
Delivery Air Pressure
The delivery air pressure gauge (6, Figure 7) measures the pressure being delivered in your
system. Acomparison of this reading with discharge pressure indicates aftercooler performance.
An increase in the difference will indicate ablockage on the air side requiring maintenance.
Rotor Coolant Injection Temperature
This gauge (3, Figure 7) shows the temperature of the oil just prior to injection into the com-
pression chamber. Normal temperature in operation is approximately 40-60 Deg. F. below the air
discharge temperature.
GAUGES

PAGE 8SECTION 1
rMO DULATIOh —
I
!
I I
I
u40 lUO
4———————
3——————
2“-’ /\
CAPACITY (%) 5’
FIGURE 8
Modulation Control Diagram 69-60A FIGURE 9
Control Center
1.Fan Motor Starter 9.
2. Time Delay Relay 10.
3. Control Relay 11.
4. Terminal Board 12.
5. Temperature Switch 13.
6. Stop Button/Power On Indicator 14.
7. Start Button/Run Indicator 15.
8. Load Unload Button 16.
t- 7
L
8
9
86-1
High Air Temperature
Hourmeter
Fuse
Control Transformer
Reset Button
Main Motor Starter
Fuse Holder
Fuse
Indicator Lights
When main power is made available to the compressor, the stop light will light up. This
notifies the operator that there is power to the compressor and that it can be started at any
time. When the compressor is started, the stop light will go OFF and the “Run” light will go ON.
There are times, with atime delay relay, that the compressor will run for aperiod of time and
then shut itself off. The “Run” light will continue to stay ON, however, which means that the
compressor could start at any time.
DO NOT PERFORM MAINTENANCE ON MACHINE WHEN THE “RUN LIGHT” IS ON, AS
THE MACHINE COULD START WITHOUT WARNING. FAILURE TO COMPLY WITH THIS
WARNING MAY CAUSE SERIOUS BODILY HARM.
High Discharge Temperature
If this red light (10, Figure 7) comes ON, it signals that the compressor was overheated (235
Deg. F.) and automatic shutdown has occurred. Its function and compressor shutdown is af-
fected by the High Air Discharge Temperature Switch and probes.
CONTROL CENTER
The Control Center (Figure 9) is designed as aNEMA 12 standard. It houses the electrical
components which support starting and automatic operation. Items included will depend upon
the compressor model and options.
Electrical Control Wiring
All electrical control wiring (main motor, fan motor, and high air temperature probes) is wired
in Iiquid-tite flexible metal conduit to keep oil and dust out of electrical system.

SECTION 1PAGE 9
ALOCKABLE DOOR IS PROVIDED FOR SAFETY PURPOSES. THE DOOR SHOULD ONLY
BE OPENED BY A QUALIFIED ELECTRICIAN. BE CAREFUL OF ELECTRICAL
WHEN DOOR IS OPEN. FAILURE TO COMPLY WITH THIS WARNING MAY
SERIOUS BODILY HARM.
CONTROL SYSTEM
SHOCK
CAUSE
The compressor control system (Figure 10) is designed to match output capacity to the air
demand by operating the inlet valve. As the air demand varies within the control range the inlet
valve will modulate the intake air flow to the necessary capacity. See Figure 8.
The primary components that govern the operation of the inlet valve are the control valve, air
pressure switch, and unloader valve (Figure 10). In operation, let us assume that the com-
pressor is to operate at 110 psig maximum pressure. On start-up, the inlet valve will be fully
open. As compression commences, pressure rises. At 100 psi, the control valve will begin to
send asecondary pressure to the inlet valve which will start to close the inlet valve. Thus, as
discharge pressure increases, capacity diminishes. See ato bFigure 8. If discharge pressure
should drop, control valve pressure will decrease, allowing the inlet valve to move open and
capacity to increase. Between 100 psi and 110 psi, output capacity will modulate between 40
percent and 100 percent.
At 110 psig, the unloader valve is de-energized by the air pressure switch and sends
discharge pressure to close the inlet valve –reducing capacity to OO/O.(See cto d). At 100 psig,
the air pressure switch energizes the unloader valve, allowing the inlet valve to open and
capacity to go to 1000/.. (See dto a).
At shut-down, the inlet valve is closed and the blow-down valve is de-energized. This relieves
unit pressure.
CONTROL SYSTEM COMPONENTS
Following is an explanation of the function served by components in the control system
(Refer to Figures 7 and 10).
Control Valve
The control valve provides the control air signal required to operate the inlet valve when
discharge pressure is in the “normal control range.” (See Figure 10 and Section 3 – “Control
Valve” for additional details.
Blow-Down Valve
The blow-down valve serves to relieve the compressor system of pressure upon shut-down
and while operating “unloaded.” [t functions in response to the air pressure switch.
Double Check Valve (A)
This device differentiates between control pressures for load and unload sequences. During
the load cycle it supplies the inlet valve with modulating service pressure. During the unload cy-
cle it supplies the inlet valve with unloading control air via the double-check valve (B).
Double Check Valve (B)
This device differentiates between sump and service pressures for control air pressure. In us-
ing the higher of the two pressures for control, the unit will vent the air trapped in the sump to
atmosphere through the blow-down valve on all shutdowns.
Air Pressure Switch
The air pressure switch functions in response to discharge pressure to ciose or open the
electrical circuit to the unioader valve, This action causes the unloader valve to pneumatically
ciose the inlet valve and “unioad” the compressor; or, to vent the unloading air line to at-
mosphere and allow the compressor to “load.”
When control pressure rises to the top setting of the pressure switch, the electrical circuit to
the unloader vaive is opened and the compressor “unioads.” When control pressure drops to
the lower setting, the circuit is closed and the compressor “loads.”
CONTROLS

PAGE 10 SECTION 1
A
ET
FIGURE 10
Control Circuit Diagram And Components /
COMPRESSOR
VALVE
86-13
Unloader Valve
The unloader valve is a3-way, normally open, solenoid valve that functions in response to the
air pressure switch to pneumatically operate the inlet valve and the blowdown valve.
High Air Discharge Temperature Switch
The high air discharge temperature switch (6, Figure 9) functions in the compressor safety
circuit to effect shutdown should operating temperature become excessive (235 Deg. F.). Ared
warning light on the panel will light simultaneously with shutdown.
Control Relay
The function of the control relay is the primary control of the compressor and all its circuitry.
The start-stop push button latches the compressor “on” through acontrol relay contact in
parallel with the start push button. Any one of three failure modes may shut down the com-
pressor. They are high air temperatures, main motor and fan motor overload, and loss of com-
pressor control or main power. All of these, as well as the stop push button, de-energize the
control relay, stopping the compressor. To restart, the start push button must be manually ac-
tuated. After high air temperature shutdown, the stop-reset push button and then the start push
button must be manually actuated. After motor overload, the appropriate reset button and then
the start push button must be manually actuated.
Dual Control (Time Delay Relay Shutdown)
Atime delay relay (3, Figure 9) will automatically shut down the compressor after apre-
determined interval of unloaded operation. This interval is factory set for 20 minutes which is the
minimum setting recommended. Automatic re-start will occur at the low limit of the air pressure
switch control range.
The 20 minute minimum delay interval is based on the motor manufacturers’ recommenda-
tion of three starts per hour.
Any reloading during the timing interval will reset the timer to zero. The green “Run” light on
the control center will be lit when the machine is in ashutdown interval.
DO NOT PERFORM MAINTENANCE ON MACHINE WHEN THE “RUN LIGHT” IS ON, AS
THE MACHINE COULD START WITHOUT WARNING. FAILURE TO COMPLY WITH THIS
WARNING MAY CAUSE SERIOUS BODILY HARM.

SECTION 1PAGE 11
Pad
\
With Fork Lift
FIGURE 11
Compressor Handling
D*
/
-...-. / \ I7
Pad >
%f
With Shop Crane
85-29
Coupling (Compressor to Motor)
The coupling assembly used to drive the compressor unit is of the flexible type. It is provided
to compensate for minor misalignment and to accept torsional stress as necessary in opera-
tion. Also, it is prealigned and not subject to readjustment.
INCORRECT COUPLING SPACE CAN CAUSE PREMATURE COUPLING, BEARING ANDIOR
SHAFT SEAL FAILURE. MAKE SURE THE COUPLING HUBS ARE SPACED PER JOY
SPECIFICATION.
Coupling Spacing
While coupling alignment is insured by the registered C-flanging to the motor care still must
be taken in reassembling the coupling. If the hubs are too close together detrimental
preloading of bearings and shaft seals will result. Conversely if the hubs are too far apart the
elastomeric cushions will become overloaded promoting early coupling failure.
The correct spacing from motor face to back of coupling hub is 0.250 inches. On the air side
the spacing from face to the back of the hub is 0.3125 inches. The set screws should be tighten-
ed to torque value after assembly of the compressor-motor assembly.
INSTALLATION
MACHINE DAMAGE CAN OCCUR DUE TO IMPROPER LIFTING.
DO NOT LIFT MACHINE WITH THE MOTOR EYEBOLT
RECEIVING
(Refer to Figure 13 and 13A)
For shipment, the compressor is encased in aprotective crate. Upon receiving, remove the
crating and inspect the unit for signs of damage in shipment. If there is shipment damage the
carrier should be notified immediately.
Refer to “Specifications” for compressor weight and dimensions.
HANDLING
With Fork Lift Truck
The unit can be moved with afork lift truck. Be sure that the forks extend completely through the
width of the unit*, and be sure to apply pad material to the enclosure to prevent any damage.
With Shop Crane
To move the unit with ashop crane, steel wire ropes can be used but spreader bars must also be
used to prevent the wire rope from exerting aforce against the top of the enclosure, and be sure to
apply pad material to the enclosure to prevent any damage.
LOCATION
The compressor is designed for indoor operation in ambient temperatures ranging from 35 Deg.
F. to 110 Deg. F. In selecting the location for the compressor, it is important that there is an ample
supply of cool, clean, well-circulated air. Do not set the unit with an air-cooled oil cooler closer than
48 inches from awall or other obstruction which would restrict the free flow of air through the
cooler. Agood circulation of air through the cooler is important. For additional information refer to
Figures 14 and 15A.
If contaminated air containing acid, paint, corrosive matter, toxic fumes, etc. is present, then
aclean outside source of air must be provided for the compressor air intake.

PAGE 12 SECTION 1
AIR FILTER
COMPRESSOR
UNIT rE~’R
/
/
COOLING
FIGURE 12 AIR IN
Air Circulation Through Enclosed Unit w’
/
/
83-30
FOUNDATION
No special foundation is required. It is only necesary that the units frame be located on a
floor that provide the necessary contact and support. It is recommended that the unit be bolted
to the floor.
ELECTRICAL CONNECTIONS
Have electrical connections to the power source made by acompetent electrician in accor-
dance with local codes.
The electrical source must have the same characteristics and voltage as indicated on the
motor nameplate and as is called for on the compressor nameplate.
IT IS EXTREMELY IMPORTANT THAT THE WIRING IS INSTALLED PROPERLY TO ASSURE
CORRECT ROTATION OF THE COMPRESSOR AS INDICATED BY THE DIRECTION OF THE
ROTATION ARROW ON THE COUPLING HOUSING (4, FIGURE 11). ANY FAN POWERED
BY THE UNIT MUST ALSo BE OBSERVED FOR PROPER ROTATION (FIGURE 6).
FAILURE TO COMPLY WITH THIS WARNING MAY CAUSE SERIOUS BODILY HARM.
Unit must be grounded
Ground from ground connection behind control center on main frame to ametal, cold water
pipe or other good ground. Use #4 or larger (Figure 5).
Complete connection details for the electrical wiring are provided in Figures 16 thru 17A.
AIR INTAKE PIPING
Aclean air supply is desirable for the satisfactory operation of your JOY compressor. Where
alternate sources of intake air are available, select the source supplying the cleanest air. The
standard air filter with which the compressor is equipped is of sufficient size and design to
meet all normal operating conditions.

SECTION 1PAGE 13
When an outside air intake source is used, aflexible sleeve should be provided to connect
the filter inlet to the inlet piping. The machine should be located as close as possible to the in-
take source because arestriction at the inlet will result in acapacity loss for the machine. It is
not intended that the filter be removed except for maintenance. In making up this installation,
consideration should be given to the following:
1. Keep the piping as short and direct as possible.
2. Piping size must be at least as large as the inlet opening.
3. MAKE ABSOLUTELY SURE THAT INLET PIPING IS CLEANED AFTER FABRICATION.
4. Consider using corrosion resistant piping such as plastic, aluminum, etc.
5. Support piping properly so that its weight is carried by supports and not by compressor.
6. See that there are no leaks in the intake piping which would permit the entrance of dirt.
DISCHARGE PIPING TO SERVICE LINES
As previously stated, the compressor should be located as closely as possible to the point of
compressed air usage. However, whatever piping is used in the distribution system should be
constructed to offer aminimum amount of resistance to air flow between the compressor and
point of use. Long radius elbows and pipe of sufficient size should be used. In no case should
the piping be of smaller size than the discharge opening.
In cases where the compressor is in the same line as areciprocating compressor, asurge
volume chamber must be installed in the line between the two compressors to dampen pulsa-
tions.
If the compressor is discharging into aplant system that has other compressors in the
system, it is recommended that agate valve be placed in the discharge line from the com-
pressor. This is to isolate the unit for service. The valve should be of the same size as the
discharge pipe. The use of acheck valve is not recommended.
AN OVER PRESSURED MACHINE CAN CAUSE INJURY, DEATH, AND WILL CAUSE SEALS
TO BLOW. INSTALL ASAFETY VALVE BETWEEN THE COMPRESSOR AND RELIEF GATE
VALVE.
HEATED MOISTURE SEPARATOR WITH TRAP
Units provided with an aftercooler will include astandard separator with trap. See “Air Cool-
ing Group” –Section 1. Aheated moisture separator can be supplied for those applications
where the separator may be subjected to freezing conditions.
\
N.C! VALVE DISCHARGE PIPE
,--–>—.— J.. ––__. .__ —— —____ L——.-—-.
,,, I
‘––l J–– L.F–– —— ‘- ————————– L-. ‘,
$,;-” !, . .
1,
i: 7-A- ‘1
COMPRESSOR AIR DISCH ‘1 MEN5t0Ns MOISTURE SEPARATOR SEPARA1OR W/HEAIIR
MODEL SIZE PIPE SIZE .8 PARTNuMBER PAR1 NuMBER
1,0300/0480 281/8 14’ 00543275 000. 005432750008
1.05 10/0750 1 1 t
21/2 I93/6 [,7,,7[ 005432750005 I0034327S 0009 ix
,f=z;:’’~:.--.---{i;-,.‘ ‘<’$;,::’~::
u———+—————— Lr——
N.O. VALVE f-
,Y ~
/
N. O. VALVE
OISCHARGE AIR
FROM COMPRESSOR
;}. J
MOISTURE SEPARATOR
WITH TRAP *2’
50 WATT ,11 OVOLT ELEMEN J’
IMODELS WITH HEATER ONLY) ‘[ ‘2.5
3/4 N.P. T. ORAIN PIPING MUST
BE PITCHEO OOWNWARO FROM
SEPARATOR
FIGURE 13
Moisture Separtor W/Trap Installation 80-60A

PAGE 14 SECTION 1
PRECAUTIONSAIR COMPRESSOR OPERATING
AND SAFETY PRECAUTIONS
Because an air compressor is ahigh-speed, rotating piece of machinery, the same common
sense safety precautions should be observed as with any piece of machinery of this type where
carelessness in operation or maintenance is hazardous to personnel.
In addition to the many obvious safety rules that should be followed with this type of
machinery, we are suggesting additional safety precautions as listed below:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Pull main disconnect switch and disconnect any separate control lines, if used, before
attempting to work or perform maintenance on the unit.
Do not attempt to remove any compressor parts without first relieving the entire system
of pressure.
Do not attempt to service any part while machine is operating.
Do not operate the compressor at pressures iri excess of its rating as indicated on the
compressor nameplate.
Do not operate the compressor at speeds in excess of its rating as indicated on the com-
pressor nameplate.
Do not remove any guards, shields, or screens while the compressor is operating.
Observe terminal pressure gauge daily to be sure automatic control system is governing
compressor operation within proper limits.
Periodically check all safety devices for proper operation.
Do not play with compressed air. Pressurized air can cause serious injury to personnel.
Be sure no tools, rags, or loose parts are left on the compressor or drive parts.
Do not use flammable solvents for cleaning parts.
Exercise cleanliness during maintenance and when making repairs. Keep dirt away from
parts by covering parts and exposed openings with clean cloth or kraft paper.
Do not operate the compressor without guards, shields, and screens in place.
Do not install ashut-off valve in the discharge line without installing asafety relief valve
in the line between the shut-off valve and the compressor discharge.
Do not operate compressor in areas where there is apossibility of ingesting flammable
or toxic fumes.
Never disconnect (or jumper) high air temperature switch and operate the machine.
Know what mode amachine is in before working around it. The Power can be on and a
machine may not be running, as the machine may be in AUTO RESTART MODE.
Pressure vessels (receivers, aftercoolers, intercoolers) may require ASME Code stamping to
meet local codes. Investigate code requirements before operation to make sure all re-
quirements have been met.
The owner, lessor, or operator of the compressor is hereby notified and forewarned that any
failure to observe these safety precautions may result in damage or injury.
Joy Manufacturing Company expressly disclaims responsibility or liability for any injury or
damage caused by failure to observe these specified precautions or by failure to exercise that
ordinary caution and due care required in operating or handling the compressor even though
not expressly specified above.
IT IS IMPORTANT THAT THE COMPRESSOR OIL BE OF ARECOMMENDED TYPE AND
THAT THIS OIL, AS WELL AS THE AIR FILTER, OIL FILTER AND AIR/OIL SEPARATOR
ELEMENTS BE INSPECTED AND REPLACED AS STATED IN THIS MANUAL. FAILURE TO
COMPLY WITH THIS WARNING MAY CAUSE SERIOUS BODILY HARM.
DISCHARGE AIR USED FOR BREATHING.
WILL CAUSE SEVERE INJURY OR DEATH.
CONSULT FILTRATION SPECIALIST FOR ADDITIONAL
FILTRATION AND TREATMENT EQUIPMENT TO MEET
HEALTH AND SAFETY STANDARDS.

SECTION 1PAGE 15
The following decals are designed to warn the user of potential hazards and to protect
against personal injury and property damage. Locate each safety decal on the machine and
adhere to instructions. Also, review additional safety information that is located throughout
this book.
1
‘~ DANGER I
4
//
Hot oil under pressure.
Will cause severe personal
injury or death.
Shutdown compressor and
relieve system of all
pressure before removing
valves, caps, and plugs.
01228378 0058
1A DANGER I
discharge air used for
breathing.
Will cause severe injury or
death.
consult filtration specialist
for additional filtration and
treatment equipment ta
meet health and safety
standards.
aI228378 0067
See Section 3
Pages 2 and 6
‘~ CAUTION I
@
—
—
—
—
—
Machine damage.
Can occur due to improper
lifting.
Da not lift machine with
the motor eyebalt.
01228378 aa59
See Section 1
Page 11
1A CAUTION I
.
Reverse rotation of cam-
pressar and fan,
Will cause machine
damage.
Check for correct rotation
af compressor and fan.
See operator’s monuol.
a 122a37e 0063
See Section 1
Page 12
I
Read the aperator’s manual
befare starting this unit.
Failure to adhere to instruc-
tions can result in severe
personal Injury.
Replacement mnnuals can
be purchased from
Joy Manufacturing Company
900 S. Woodland Avenue
Michigan City, IN 46360
0Itze37e 0062
@-‘
Assemble connecting plugs
la aftercooler before start-
ing unit.
Failure to da so will result
in loss of water from un
plugged apenlngs.
SAFETY
DECALS
-iIgh valtag6/.l.ctrlcti
shock.
:an cause severe Injury
jr death.
jround unit and dlscannect
III power supplles to unit
>efore opening anclasure.
01228378 0071
See Section 1
Pages 8 and 9
Unlf can automatically
restart.
Will cause personal Injury
Know mode of operation
before working on or
near the machine.