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FOR

LG

OPERATION MANUAL SERIES SCREW AIR COMPRESSOR R
OPERATION
MANUAL
SERIES
SCREW
AIR COMPRESSOR
R

KAISHAN CO., LTD MADE IN CHINA

 

Motor power

(kw/hp)

Air delivery

(m

3 /min)

Working

Rotating speed

(r/min)

Weight

(kg)

 

Model

pressure

(Mpa)

Dimension

LG-1.7/7

   

1.7

0.7

6500

   

LG-1.6/8

11/15

 

1.6

0.8

6100

450

1060×800×1350

LG-1.5/10

 

1.5

1.0

5400

LG1.2/13

   

1.2

1.3

4700

   

LG-2.4/7

   

2.4

0.7

8400

   

LG-2.3/8

15/20

 

2.3

0.8

8000

500

1060×800×1350

LG-2.2/10

 

2.2

1.0

7300

LG-1.7/13

   

1.7

1.3

6600

   

×LG-3/7

   

3.0

0.7

3740

   

LG-2.9/8

18.5/25

 

2.9

0.8

3600

600

1190×880×1380

LG-2.6/10

 

2.6

1.0

3300

LG-2.2/13

   

2.2

1.3

2850

   

LG-3.6/7

   

3.6

0.7

4470

   

LG-3.4/8

22/30

 

3.4

0.8

4200

650

1060×800×1350

LG-3.2/10

 

3.2

1.0

3800

LG-2.6/13

   

2.6

1.3

3330

   

LG-5.2/7

   

5.2

0.7

5800

   

LG-5.0/8

30/40

 

5.0

0.8

5600

900

1300×1100×1650

LG-4.2/10

 

4.2

1.0

5000

LG-3.6/13

   

3.6

1.3

4440

   

LG-6.2/7

   

6.2

0.7

4300

   

LG-6.0/8

37/50

 

6.0

0.8

4100

1050

1300×1100×1650

LG-5.3/10

 

5.3

1.0

3760

LG-4.5/13

   

4.2

1.3

3300

   

LG-7.4/7

   

7.4

0.7

5150

   

LG-7.1/8

45/60

 

7.1

0.8

4900

1150

1300×1100×1650

LG-6.5/10

 

6.5

1.0

4500

LG-5.6/13

   

5.6

1.3

4000

   

LG-10.4/7

   

10.4

0.7

5450

   

LG-10/8

55/75

 

10

0.8

5100

1600

1630×1280×1790

LG-8.3/10

 

8.3

1.0

4600

LG-12.5/7

   

12.5

0.7

6550

   

LG-12/8

75/100

 

12

0.8

6200

1800

1630×1280×1790

LG-10.5/10

 

10.5

1.0

5800

LG-14.5/7G

   

14.5

0.7

2970

   

LG-12/10G

75/100

 

12

1.0

1480

1800

2400×1500×1900

LG-10/13G

 

10

1.3

2970

LG-16.5/7G

90/120

 

16.5

0.7

2970

1900

2760×1340×1710

LG-14.5/10G

 

14.5

1.0

2970

LG-12/13G

90/120

 

12

1.3

2970

1900

 

LG-20/7G

110/150

 

20

0.7

2970

2300

2760×1340×1710

LG-17/10G

 

17

1.0

2970

1

LG-15/13G

 

15

1.3

2970

   

LG-22/8G

 

22

0.8

2970

   

LG-20/10G

132/180

20

1.0

2970

2400

2760×1340×1710

LG-17/13G

17

1.3

2970

LG-21/12G

160/220

21

1.2

2970

2500

2760×1340×1710

LG-20/13G

20

1.3

2970

Note: The Gin the model indicates that the machine is coupling transmission and the others are V-belt transmission. We accept all kinds of special order.

Charter

Section one: Introduction Compare to the reciprocating air compressor, the screw air compressor has much more advanced performance such as little vibration;low noise;high efficiency and so on. 1)It simplifies its mechanic structure by injecting lubrication oil constantly to the compression chamber with the pressure difference generated by itself. 2) The oil it injects can form the oil film between the rotors, so the main motor can drive the subsidiary rotor directly without the help of high precision synchronous gear.

3)

The injected oil can enhance the air-tightness.

4)

The lubricating oil could absorb large amount of compression heat, so even if the compression ratio

reaches 16 high, the head temperature can control below the point that carbonisation and degeneration of lubricating oil.

5)

The lubricating oil can weak the noise that caused by high-frequency compression.

6)

It lubricates the pneumatic tool with little oil injected in the compressed air.

Section two: The frame structure 1.Basic frame structure Our LG series oil-injection screw air compressor is a kind of double axis capacity rotating air compressor, the air-inlet port at the top of the machine's cover and the air-discharge port at the bottom, there are two high precision rotors be fixed parallely and horizontally inside of the machine, one is main rotor and the other is subsidiary one, There are 5 teeth in the main rotor and 6 teeth in the subsidiary one; the main rotor with bigger diameter; the teeth surround the rotor in twist shape and two rotors' tooth meshing together. The rotors support by the bearing and the transmission type is V-belt or coupling driven. 2. Meshing The motor rotates the main rotor through the transmission system. The cooling lubricating oil be sprayed into the meshing part, mixed with the air to take away the heat, and formed oil film, which can protect the rotors from be damaged by serious friction and decrease noise. For different discharge pressure the weight of oil-injected is about 5-10 times more than the air weight.

Suction stroke

Sealing an d transit stroke

F ig.1
F ig.1

C om pressing and oil injecting stroke

Discharging stroke

2

1)Suction stroke There is no air inlet and air discharge valve sets on the screw air compressor, a regulating valve controls the air inlet. When the teeth-ditch space of the two rotors rotate to the air inlet end, its space is the biggest, the outside air be sucked into the vacuum teeth-ditch space after it full of air, the rotor 's air-inlet end will rotate away the air inlet port and seal the space. This is called course of suction. 2)Sealing and transit stroke After the suction stroke finished, the teeth peak part of the rotors will sealing with the machine cover and the air in the teeth ditch space will not outflow. This is the course of “sealing”. The two rotors go on rotating their teeth ditch and teeth peak will integrate together at the suction end and the matching surface will rotate towards the discharge end gradually. This is called transit course. 3)Compressing and oil injecting stroke In the course of transit, the matching surface move to the discharge, the air between the matching surface and the discharge port being compressed gradually and the pressure rise up quickly. This is called compressing course and in this course the lubricating oil be injected into the compressing room then mix with the air by the force of pressure. 4)Discharging stroke When the rotor's discharge port end connect with the machine cover (now the pressure is the highest), the compressed air begin to be discharged, till the matching surface move to the discharge end, now there is no teeth-ditch space, this is the discharging stroke and same time.

Charter III

Section one: Location of installation

A suitable location of installation is very important for excellent performance and long service life of air compressor. The location of installation should be convenient for maintenance to avoid any abnormal operation of air compressor due to poor circumstance. Following is guide for location choice:

1)Good daylight and enough lighting for easy maintenance.

2)

Low humidity, non-erosion, non-metal spay, little dust and good ventilation.

3)

If the factory circumstance is poor with more dust, one ventilation duct from compressor suction to clean

air space is necessary, the duct should be easily dismantled and maintained; the size of the duct please refer to

dimension of compressor size. 4) There should be enough space for easy maintenance. At least one and half meters clear space around air compressor, two meters or more top clear space is required. 5) If the air compressor was installed in enclose space, one exhaust fan should be equipped to exhaust the hot air from heat exchange in the room. 6) If the circumstance temperature is too high (above 40 ). Recommend taking measure to keep low air temperature (avoid direct daylight, open door and window etc.) to avoid abnormal stop due to high temperature. Whereas, the circumstance temperature is too low ( less 0), should pay more attention to the risk of lubrication oil freezing.

Section two: Piping, Foundation and Cooling system

1. Piping laying 1)Laying piping should pay more attention on any extra stress on cooler. To avoid any welding spark fall into air compressor cause damage inner parts. 2)Main pipe should be laid with down tilt about 10-20 degree, this design will favour to drain out any condense in piping (the piping should be fixed with screw plug for regularly draining). 3)The diameter of the piping should be not smaller than diameter of outlet on air compressor. Should use less elbow and valves as soon as possible to reduce any more pressure lose in piping. 4)Diameter of main piping should avoid any reducing and enlarging. If we have to reduce or enlarge the

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diameter of main piping, reduce should be applied. Otherwise, turbulence will occur at location of connector and cause large pressure lose, meantime the service life of piping will be shorted due to air punching. 5)Branch piping should be arranged from top of main piping to avoid condense in main piping flow into air compressor. 6)Recommend installing one air storage tank after discharge port. This design can reduce the frequency of start and stop and extend the service life of machinery and electrics. 7)If there are air tank and air dryer etc. after discharging port of air compressor, good design of air flow should be“air compressor”+“air tank”+“air drier”. Air tank can cool down the compressed air from air compressor to remove most of water in air. The cooled and less water content air flow into air drier will reduce the load of drier. 8)Under 1.5Mpa pressure, the velocity of air in piping should be less 15m/s in order to avoid too much pressure loss. 9)One good main piping layout should be around the workshop, and fit some valves on the line in order to get air supply from two direction at any branch line. If air consumption of one branch line suddenly increases, above design can avoid apparent pressure turbulence. Also this design is convenient for maintenance as we can cut the air supply by valves easily.

2. Foundation (1)The foundation should base on hard earth or cement floor. And the floor should be even to avoid any extra vibration due to tilt. (2)If air compressor is installed on the ceiling floor, should pay more attention to vibration prevention. One sheet rubber gasket with 10mm thickness should be laid under the air compressor to stop vibration and resonance.

Cooling system

Section three:

Electrics and safety

1.With the model of air compressor, to choose suitable cable and air current breaker. Too small capacity of cable will cause burning out and other risk due to over current. 2.Recommend independent electrical power supply and avoid sharing power supply with other different electrical appliances. If share power supply, over current and unbalance current between three phases will cause air compressor over load and trip. Especially, for big power compressor 3.Selecting power supply should ensure the voltage of power is same with rating voltage of air compressor. 4.Earth cable should be laid for electrical motor and electrical system to avoid any risk due to grounding. Keep in mind don't connect earth cable to air discharging piping. At running condition, the difference between actual power voltage and rating voltage should be less 5%. Frequency difference should be less 1%. The difference between each current of three phases and average current of three phases should be less 10%.

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C ha rte r IV

S ection o ne : S yste m flow c h art(22 kw a n
S ection o ne :
S yste m flow c h art(22 kw a n d b e low )
Solenoid
valve
Inleta ir
filter
A ir filte r p re ssure g ap sw itch
A
ir inlet co ntrol valve
P
ressu re
sw itch
C
om p re ss or
P ressu re
b
od y
kee p va lve
R
eta in in g va lve
S a fety va lve
V - b e lt
pres su re ga p sw itch
press u re gap sw itch
O il
a irch a m b e r
Oil
a ir filter
M o tor
O
il&a ircha m ber
T
h e rm a l co n tro llin g v alve
O
ilco o le r
S yste m flow cha rt(30 kw )
Solenoid valve
P
ressu re
Inleta ir
sw itch
filter
A ir filte r p re ssure g ap sw itch
A
ir inlet co ntrol valve
Solenoid valve
O
ilc o o ler
O
il filte r
C
om p re ss or
P ressu re
R
eta in in g
b
od y
kee p va lve
valve
S afety
valve
O ilfilter pressu re
O
ilfilte r p res su re
gap sw itch
G
a p sw itch
V-belt
O il&air
s eparator
M otor
O il&a ircham ber
T
herm a lcon tro lling valve
O ilco oler

5

S yste m flow c ha rt(3 7kw an d ab o ve) Solenoid valve
S
yste m flow c ha rt(3 7kw an d ab o ve)
Solenoid valve
P ressu re
Inleta ir
sw itch
filter
A ir filte r p re ssure g ap sw itch
R eve rse prop ortio n
A
ir inlet co ntrol valve
S e le ctvalve
C om p re ssor
P ressu re
b od y
R eta in in g
kee p va lve
valve
S a fety va lve
press u re ga p sw itc h
V - b elt
O il
a ir filter
O il&air
M otor
separator
O
il&a ircha m b e r
T herm a lcontro lling v alve
R elief valve
O ilcooler
O ilfilter
O ilfilter pres su re
gap sw itch

Section two : Flow charter of system After being filtrated by the air filter the air enter into the compressing room through suction unload valve, and

mix with the lubricating oil.

After being compressed the mixture will be discharged into the oil & air chamber, and in the chamber most of oil in mixture will be removed out, then the fine oil separator will separate the oil and air further. Finally, the

clean compressed air will flow into service system through minimum pressure valve, back cooler. 1. Function of major components on the airflow

A.

Inlet air filter

The

filter is dry paper type; the mesh hole is about 10um. Its main function is to collect the dust in the air to

prevent screw rotor from tear down, also prevent oil filter and separator from fouling frequently.

B. Suction unload valve

Suction unload valve is most important component; it can control the output by controlling the quantity of air

into compressor. It be consist of suction valve, orifice, discharge port and valve etc, depending on air pressure

in the system, loading-unloading solenoid valve and reverse proportion valve will control the suction control

valve by opening with full open, crack open or close to change the quantity of inlet air and keep the pressure

in

the system steady by infinitely variable control. This will save electrical power consumption.

C

.Oil & air chamber

The oil & air chamber have two functions. One is the separating out the oil from the mixture; the other is

storing lubricating oil avoid the hot oil taking part in the next circle immediately, which can low down the discharging temperature. There is the oil-level indicator on the chamber.

D. Fine oil separator

Please read the detail instruction about the fine oil separator in the“lubricating oil system”.

E. Minimum pressure valve

Connect with the discharge port of fine oil separator; the start-pressure has been set to 0.4-0.5Mpa. Its functions are as following:

a. Provide the necessary pressure that make sure lubricating -circle can work prior to other systems when the machine started.

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b. The oil & air chamber will not work until the pressure reaches 0.4Mpa, so the velocity of air could be slow

down, the oil be separated completely and also the chamber can avoid being damaged due to huge pressure

gap.

c. Retaining function: retaining the compressed air from flowing back after stop and the low pressure in the oil

& air chamber.

F. Back cooler

The compressed air from the minimum pressure valve flow into the back cooler, The back cooler connected with the oil cooler, both of the coolers are the plate-fin frame. The cooling fan suck in the cold air then cooling the cooler's fin. Generally, the air temperature after cooling is about 15 degrees over environmental

temperature plus.

G. Thermal sensor

Thermal sensor is to monitor the discharge temperature and display the result on the instrument panel. The

situation eg. Oil loss, less oil or worse cooling, the discharge temperature may become over normal value. The air compressor will stop working when the discharge temperature reaches the setting stop pressure. Please don't adjust the setting stop pressure at will.

2. Lubricating oil system

1) Instruction of lubricating oil system The pressure in the air & oil chamber press out the lubricating oil, after cooling by the temperature-control valve and oil cooler, and filtrated by the oil filter the oil divided into two flows, one flow being sprayed into the compressing room to cooling the compressed air; the other is into the both sides of the machine and lubricating the bearing sets. Then all the lubricating oil gets together at the bottom of the compressing room and being discharged from the discharge port.

After being discharged to the air & oil chamber, most of the oil subsided to the bottom of the compressing room, after being filtrated by the fine oil filter further, the remain mixture will take part in the next circle. 2) Oil- injected volume control The oil not only can lubricating the machine but also can take away the heat. The volume of the oil sprayed can affect the performance of the air compressor directly. The volume has been set before leaving the factory please don't adjust it by yourself! 3) Instruction of oil current system

a. Temperature monitor valve

The main function: control the discharge temperature by controlling the lubricating oil's temperature that injected into the air end avoid the lubricating oil coagulated in the oil & air chamber. At the beginning , the temperature of lubricating oil is very low , the valve closed and the cold oil be injected into the air end

directly ; when the temperature of lubricating oil reaches 70 ℃,the valve will open gradually ,and will all open when the temperature reaches 76,and all the oil will be spayed to the air end after being cooled by the oil cooler. Some models of our air compressors don't have this valve, it control the oil temperature by controlling the fan's motor when the discharge temperature reaches 80, the fan will work, when it lower than the 65, the

fan will stop working. b .Oil cooler Oil cooler and back cooler are connected together; keep more than 2m distance between the cooler and the barrier to make sure good ventilation. The pin of the cooler is easy to be damaged by dust, which may result in high discharge temperature even stop, so, the fins must be cleaned regularly.

c. Oil filter

The filter 's filtrating precision is about 10μ-15μ,it's used for get rid of the sundries like dust and so on to keep the bearing and the rotor working normally .If the filter blocked, the oil volume may not enough and result in high discharge temperature even stop.

d.Fine oil separator The core of separator is made from multi-layer special fibres, which can separate almost all the oil from the compressed air. The diameter of oil granule can be controlled under 0.1μm ,and oil content can be controlled under 3PPm e.Oil -retaining valve All the remain oil are collected in the center of the oil filter 's core and then be leaded to the air end through the oil return- tube this is for preventing the lubricating oil from being discharged together with the compressed air. In order to avoid the oil in the compressing room flow back (there is pressure gap when

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unloading), a single direction valve be set at the oil -return -tube, the user should check whether the throttling hole blocked if the oil consumption increases suddenly in the cross of running. Section three: Air current control system 1.Normal running

1)Starting

Before starting, both of the air- inlet- unload valve and the load- solenoid- valve are closed, after starting, some air be sucked into from throttling hole on the air- inlet- unload valve, under the force of minimum pressure valve, the pressure in the oil & air chamber increases gradually then spray the lubricating oil into the air end to lubricating the machine. 2)Loading running Several seconds later than the star-start, the load solenoid-valve begin to work after contacting the power, the pressure in the air could get through and the minimum pressure valve open, the compressed air be discharged. When the system pressure reach the setting limit of the reverse proportion valve, the valve will work and adjust the air supply volume, keep the balance between the air-supply volume and air-consumption, this is the infinitely-variable air inlet volume adjustment function. 3)Unloading running Air pressure will get upper-limit of set value on "CPU" controller. Meantime the loading solenoid valve will close due to no current. This action will cause suction valve automatically close due to losing control air pressure. Same time, the relief valve open to release the pressure in oil & air chamber (circulate to suction). The compressor will get in un-loading condition. If the system pressure reaches the lower limit set by the microcomputer- controller the machine will unload and run again. After the work finished, press the stop button, the machine will enter into the unloading running state, and stop running after several seconds. 2.Instruction of air current control parts A. Load solenoid- valve Normally closed solenoid- valve, control the loading and unloading B. Release valve When unload running or stop state, the valve will open to release the pressure in the oil & air chamber and make the air compressor running with low load or make sure the air compressor restart without load . C.Reverse proportion valve This valve will act after the pressure in system is over setting pressure, higher the input pressure (system pressure) is, lower the output pressure will be; the lower output pressure will cause suction control valve get smaller opening which controlled by reciprocation of air cylinder. The smaller opening will lead to smaller quantity of inlet air and decrease output of compressor to tally with air consumption by infinitely variable control. Following can do set control pressure:

Lift up and lose the black cap of reverse proportion valve, turn clockwise the pressure will be higher; whereas, turn counterclockwise the pressure will be lower. After setting, push down the black cap to prevent setting screw from turning due to vibration. The setting pressure should be lower than rating discharging pressure. If the setting pressure is higher than unloading setting pressure on CPU controller, Only unloading function will be actuated but without displacement variable. D.Select valve This valve will exchange the air supply of output control, two side of valve stem were acted by different pressure, top side is from system after pressure control valve; bottom side is from air container before pressure control valve. Higher-pressure air from above location will become control air in the system. E.Safety valve This valve is one safety component in the system, when air pressure in container is 5% higher than rating discharging pressure, the relief valve will poop out to low the pressure in the container under rating pressure. The setting pressure of safety valve was pre-set before delivery. Never adjust the setting value. When safety valve pooping, should stop compressor immediately to investigate the cause and rectified. Safety valve should be checked regularly, this could be done easily as following:

When compressor is running with full capacity (rating discharging pressure or near rating discharging pressure), lift up the ring on the top of safety valve a little. If compressed air flash out, that means the function is normal. F.Pressure sensor

8

Pressure sensor detect the pressure after second fine oil separator, the pressure will display on control panel.“CPU”controller will compare this pressure with the up and low limit and act on loading solenoid valve to control loading and un-loading. G.Pressure gauge Pressure gauge gives the pressure before second fine oil separator in container. Because there is pressure loss after air pass separator, pressure control valve and piping. The pressure on gauge is higher than pressure on control panel (may be lower during unloading). The difference between these two pressures should be monitored continuously, if the pressure difference is more than 0.1 Mpa, the second fine oil separator should be renewed. H. Thermal sensor The thermal sensor detects the temperature in way of compressor discharge port. This temperature will display on control panel. Heating sensitive component is PT100 resistant with and high accuracy advantage. Without oil, insufficient oil or poor cooling, the discharging air will become over high temperature. The compressor will automatically stop when discharging compressed air temperature get to setting alarm temperature on“CPU”controller. By different model of compressor, the setting alarm on“CUP”is pre-set at 105, 110or 115. This setting temperature should not be changed with permit. Section four: “CPU” controller 1. Instruction of button on controller Screw type air compressor made by our company is equipped with Model: 100LCD (dimension: 164mm x 102mm)or Model: 200 with dimension 250mm x 150mm. 1). Model: 100 LCD as fig. 3.

D isch arg in g air te m p e rature : 80 ℃ S
D
isch arg in g air te m p e rature : 80 ℃
S
u pp ly air p ressu re: 0 .6 M p a
S
tatus :
stop .
0
sec on d
local
RT
ON
O FF
M

Fig. 3

ON---- start: push this button start compressor. OFF----stop:push this button stop compressor. M-----setting:after reset the data, push button to enter and save the setting. -----shfit up:when reset the data, increase the number on menu status, as select button. -----shfit down:when reset the data, decrease the number on menu status, as select button. as select button.

-----shift right or enter: when reset the data, shift digit. on menu status as enter.

9

RT-----Esc or reset on menu push this button to return last menu. when trouble, push this button

2) M od el: 200 L C D as fig .4

to reset

I D ischargin g airtem p erature: 80℃ Supply air pressure :0.80 M pa O
I
D ischargin g airtem p erature: 80℃
Supply air pressure :0.80 M pa
O
Status:
stop.
0
secon d
local
S
C

Fig.4

I---- start: push this button start compressor. O----stop:push this button stop compressor. S----setting:after reset the data, push button to enter and save the setting.

-----shfit up:when reset the data, increase the number on menu status as select button. -----shfit down:when reset the data, decrease the number on menu status as select button. as select button.

-----shift right or enter: when reset the data, shift digit on menu status as enter.

↑↓----manually loading and unloading: under manual control, push this button to load and

Unload

within setting pressure area.

----Esc or reset on menu push this button to return last menu when trouble ,push this to reset

button

# The operation instruction in detail on model: 100 as following. For Model: 200 please refer to above button function instruction.

10

B . status and operation

th e display as fo llow ing after pow er on.

W e lcom e to use

Scre w typ e co m pres sor

A fter 5 se co nds follow in g w indo w w illbe o n LC D

Discharging air tem perature:20

Supply air pressure:0.6M pa

Status:stop

Local

P ush “↓” to enter follow ing w in dow :

a.R unnin g data review

C alendar C ustom er data M aker data
C alendar C ustom er data M aker data
C
alendar
C
ustom er data
M
aker data

push ↑ or ↓to shift the black scroll. H ighlight the “running data” m enu .Then push → to

fo llow ing w indow :

Totalrunning hours R u nning hours this tim e M aintenance data

Totalrunning hours

R u nning hours this tim e

M aintenance data

P ush “→” to follow ing w indow :

C

urren t(A ): R . S. T

C

om presso r:56 .1 56.2 56.0

Fan

4.1 . 4.1 4.1

When last stage window is displayed, there is no highlight scroll. Push “RT” to exit or return to main menu. The window will return to main menu automatically with further operation for seconds. Use “↑” “↓” shift button, enter button “→” and exit button RT, we can monitor running data , for example, total running hours, running hours this time, maintenance information, trouble history, date of delivery and trouble on spot etc. Also can return to last menu. B. Calendar and time push or to shift the highlight black scroll on calendarmenu, then push the enter button “→”. Following window will be displayed

21stFeb2004 W eekday:0 12 hours46 m iniutes59 second.

21stFeb2004

W eekday:0

12 hours46 m iniutes59 second.

When stopping, the date and time can be reset as per following procedure: push“↑”or “↓”to shift the highlight scroll on the data need to reset. Then push“→”to display highlight digit. At this moment push“↑”

11

and“↓”to

button to save and exit.“↑”or“↓”will restore highlight black scroll. And“→”button act as exit. C. Customer data 1). Reset the data

change the data.“→”button become shift left and right now, after reset all data, pushM

Notice:

Refer to above data setting procedure, we can monitor and reset customer data. For example, change up limit

the highlight scroll oncustomer datamenu. Then push enter“→”.

Cannot change any data setting when compressor is running or relay to stop.

shift

of pressure: push“↑”or“↓”to Display following window

Startand stop relay setting O peration m odelsetting Interlock datasetting

Startand stop relay setting O peration m odelsetting

Interlock datasetting

Low lim it ofpressure:0.6M pa Tem perature offan start:80℃ Tem peratu re offan stop:70℃

Low lim it ofpressure:0.6M pa Tem perature offan start:80℃

Tem peratu re offan stop:70℃

At this status customer datacan be reviewed. Push enter “→”again, following window will be displayed and customer password required before reset the data.(Customer password can be changed on customer datamenu.)

E n ter passw ord ******

On this window, the cursor will be on screen, “↑” and “↓” will function as increasing and decreasing and “→” function as shift to change the data setting. At last push Mbutton to save and exit. The window will be as following:

U p lim it of pressure: 0.8M pa Low lim it ofpressure:0.6M pa fan start tem perature: 80 fan stop tem perature: 70

Mark on top-right corner means on customer datastatus.

“↑”and“↓”will restore highlight scroll again,“→”button as enter. When scroll onup limit of pressure, push“→”.The cursor will be on screen. Use“↑”and“↓”to decrease and increase the number. And use

“→” to shift left or right.

After resetting pushMto save. The cursor will disappear.“↑”and“↓”

will restore highlight scroll again,“→”button as enter to change other data continuously. After all resetting completed, pushMreturn to last stage menu or main menu. Other customer data can be set accordingly. 2) Customer data and function

Main menu

Second menu

Initial setting

Function

Pre-set

of

Up pressure limit

*** Mpa

Unloading pressure setting

pressure

and

Low pressure limit

*** Mpa

Loading pressure setting

temperature

Fan start temperature

***

Fan start. Non fan or fan no need protect, this setting will be120

Fan stop temperature

***

Fan stop.

12

Start and stop relay

Compressor

start

0008

second

This time should be enough long to skip the start current of motor. This relay should be not shorter than phase relay +loading relay

relay

 
 

Fan start relay

0006

second

This time should be enough to skip the start current of motor.

Phase relay

0006

second

Reducing voltage start time.

 

Loading relay

0002

second

After reducing voltage start, the relay time to loading

Unloading relay

0020

minutes

Continuous

running

time

without

 

load.

After

that

will

stop

automatically.

Stop relay

0010

second

When stopping, compressor should run without loading before stop.

Stop and start relay setting

Start relay time

0100

seconds

Compressor should be idling at least this time before restart After stopping or stopping due to without loading,

Standby relay time

0000

seconds

Additional function

 

Drain open relay time

0002

seconds

Under automatic drain model. The drain valve will keep open for this setting time

Drain stop relay time

0010

minutes

Under automatic drain model. Drain at this time intervals.

Operation

Start and stop control model

Local control

Under remote control. Can start and stop by both local and remote control

model setting

Capacity

control

Automatic

Under manual control. Loading and unloading will be only controlled by button.

model

---------Continue----------

 

Communication

Unavailable

At this model, communication is unavailable

model

Communication

0255

Communication address

code

Group data

Group status

Main

Group running work as main compressor or standby compressor, main compressor will control standby one.

setting

compressor

Group Start and stop

In turn

 

Working hours for exchange

9999 hours

 

Number

of

0000

 

compressor

Low pressure limit of group

***Mpa

 

Up pressure limit of group

***Mpa

 

13

 

Group relay time

0000

 

second

Maintenance

Oil separator

0000

hours

Replacing the filter can initial running hours

interval setting

Second

oil

0000

hours

Replacing the filter can initial running hours

separator

 

Air filter

0000

hours

Replacing the filter can initial running hours

Lubricating oil

0000

hours

Renewing lubricating oil can initial running hours

Grease

0000

hours

Renewing grease can initial running hours

Maximum

Oil separator

9999

hours

When setting 0. The alarm of oil separator will be deactivated

service life

 

setting

Second

oil

9999

hours

When setting 0. The alarm of second oil separator will be deactivated

separator

 

Air filter

9999

hours

When setting 0. The alarm of air filter will be deactivated

Lubricating oil

9999

hours

When setting 0. The alarm of lubrication oil will be deactivated

Grease

9999

hours

When setting 0. The alarm of grease will be deactivated

English and

 

Chinese

If setting is English. English

Window will display in

Chinese

selection

 

Change

 

****

Customer can change the password.

customer

password

D. Maker setting Maker data is different with customer data. It cannot be monitored by customer. Reset maker setting only can be done by maker with maker password. The operation of changing maker setting is same as changing customer setting. Major function as following:

Setting item

 

Initial setting

Function

Main

compressor

Permitting motor maximum over current / 1.2

After start relay, if working current exceed 120% of initial setting and less four times initial setting. The compressor will trip as over loading program.

rating current

Fan motor rating current

Permitting motor maximum over current / 1.2

As above

Discharging

air

105

When discharging air temperature get this setting. Alarm will sound

temperature alarm

 

Discharging

air

110

When discharging air temperature get this setting. Alarm will sound. Compressor stop

temperature alarm

 

Pressure

for

1.00Mpa

When air pressure get this setting value, alarm will sound. the compressor will automatically stop

stopping

Up pressure limit for unloading

0.80Mpa

In customer setting menu, the up pressure limit setting should be less this setting.

Change working hours with loading

**** hours

Maker can change this number

Change

total

**** hours

Maker can change this number

running hours

Trouble

history

****

Enter password for trouble history will clear all trouble history.

reset

14

Setting

of

0006

If maximum phase current / minimum is more than (1+ setting value/10), the unbalance current protection will act and trip compressor.

Unbalance current

Relay

time

for

0005

If the setting is more than 20 seconds, this protection will not act. The unbalance protection will act.

phase

loss

protection

Relay

time

of

0000 minutes

If the compressor trip due to over load. To avoid frequent start to damage motor, the compressor can be restart only after this relay setting.

restart

after

over

load trip

Date of delivery

** day ** months **** year

Maker enters the date of delivery.

Serial number

 

******

Maker enter the serial number

Section three: Function and specification 1.Switch Quantity: input : 9 ; relay output switch : 10

2.Simulated Quantity : Pt100 3.Three phases 380 V

4.Power of controller : 220v , 50 HZ 20VA 5.Display information:

input : 2 ; 4-20mA Transmit

a) Oil temperature : -20-150 °C

precision : ±1 °C

b) Air temperature : -20-150 °C

precision : ±1 °C

input : 2 ; three-phases current input : 2 sets .

c) Running time: 0-999999 hours

d) Current: 0-999.9A

e) Pressure: 0-1.60 Mpa precision: 0.01 Mpa

6.Phase order protection : when examine the wrong order the action time

7.Motor protection : there are five kinds of protect function Blocked : When the running current is 4- 8 times of setting current , the action time will 0.2s

Short circuit :When the current is more than 8 times of setting current , the action time will 0.2s Lack of phase : when lack of phase the action time will 2s Overload : showed as following table ( time of unit is second)

Ir

will 2s

Real Running current; Is: Setting current; Times = Ir/Is

when the motor running current over or same the action time is indicated in following table

as

1.2- 3.0 times of the setting current

Ir/Is Time parameter
Ir/Is
Time parameter

Action time

1.2

1.3

1.5

1.6

2.0

3.0

60

48

24

8

5

1

Motor protection

15

8.Temperature protection: When examining the real temperature is over setting temperature, the action time will equal or less than 2 s 9. Relay output voltage and current: 250 V 5A, The life of contact: 5000000times

10. error probability

11. RS-485 communication

of current display : 1%

Section Four: Controller

1. Frame of controller showed in fig.5

a. Input indicating light (IN) The corresponding input switch terminal' No. :of 0001020304050607 is 20191817

16151413

b. Input indicating light (OUT)

The corresponding output switch terminal' No. :of 0001020304272829303135

36373839

c. Power light: PWR

d. Running light: RUN

e. Error light: ERR

Power light: PWR d. Running light: RUN e. Error light: ERR Fig .5 2.Electric installation (Fig.6)

Fig .5

2.Electric installation (Fig.6) The display panel:

There are 5 connecting terminals and a cable display joint, used for displaying connecting, RS-485 communication, 24V power input Controller connecting terminals:

The controller and the display panel connected by cable and a cable joint , 232425 is phase order input terminals; 79 is discharge

temperature input terminals. CT1: main mother mutual inductor, CT2: fan motor mutual inductor. 32: output relay common terminal COM 1 ; 27 : controlling main contactor ; 28 :controlling star-contactor ; 29:controlling angle-shape contactor ; 30 load solenoid valve ; 31 : controlling fan motor ; 34 :controlling relief valve ; 37: Running indicator ; 38 :

Error indicator ; 38- precaution indicator ; 40 :COM2 ; 42

16

LCD Longdistance P re ss u re Therm al Dz-7 s w itch se n
LCD
Longdistance
P
re ss u re
Therm al
Dz-7
s w itch
se n s o r
se n s o r
Dz-13
Emergency
stop
CT 2
Ct 1
DzDzDzDz
Dz
Dz
-8
-9
-4
-3
-6
-5
Dz-13
Dz-2
5
B
A
4
-
+
-
+
3
Dz-1
22 21
20
19
16 15 14
13
11 10
9
8
7
4
12
2
2
18 17
6
5
-
3
1
+
1
24V 0V
c
b
a
C
B
A
P LC
PE C OM
23
25 44 43 42 32
28
31
29
30
24
34 35 36 37 38 39 40
27
F U 1(0.5A)
L1
Dz-10
L2
F U1(0.5A)
L3
Q
KM1
KM4
KM3
KM2
FU 2 ( 1A)
05
06
T
Dz-11
KM2
KM3
FU2 1A( )
Y
Dz-15D2-14
S o le n oid F a n m o to r
JB K5-100
E m e rg e nc y s to p
Fig.6

17

S e ctio n five : C on tro lling p rin ciple (F ig .7)

L1 L2 L3 a b a CT1 c b C T2 d c d KM4
L1
L2
L3
a
b
a
CT1
c
b
C T2
d
c
d
KM4
KM1
U
V
W
.
.
.
M2
M1
FAN
COMP
KM2
.
.
.
v2
w2
u2
KM3

Lo ng distance sw itch(D Z )

22 21 10 12 7 9 22 14 13 30 04 22 20 01 03
22 21
10
12
7
9
22
14
13
30
04
22
20
01
03
1 2
3
4
5
6
7
8
9
10
11
12
13
14
15
+
-
+
-
+
-
- 2 4V
~ 2 2 0 V
S o le no id valve
E m e rg en cy stop
ON
Lo ng distan ce sw itch
Fig.7
OFF
Commonswitch-terminal
T he rm a lse nso r
P ressu re sen sor
LC D

18

1. Independent control (1) Local auto controlling (start/stop type: Local , auto loading ) Press ONbutton start, Connect the power, after the three-second-self -examination; press the “ON” button to start the main machine. Auto running controlling:

When the motor start to state, the load solenoid valve will be electrified after a few seconds and the air compressor begin loading, the pressure in the oil & air chamber rise up. When the pressure over the setting value (unloading pressure), the load solenoid valve loses power, the relief valve begins to work and the air compressor enters no load running. In the certain time (unloading) if the pressure falls to the setting unloading pressure, the load solenoid valve will be electrified again, the relief valve will lose power, the compressor will work normally and increase the pressure of the air tank; if the pressure don't fall down to the setting value, the motor will be stopped by the controller and the air compressor will shut down after long time unload. So, when the pressure falls to the lower limit the motor will start automatically and this is a beginning of a new circle. Load / unload manually under auto running state Under auto running state, the equipments are under unloading state, press the “M” to load, if the pressure over the unloading pressure, the load solenoid valve back to the unloading state after inching; if the pressure lower than the unloading pressure, the load solenoid valve will be electrified and only back to the unloading state when the supply pressure over the unloading pressure. When the equipments under the loading state, press the“M”to unload, if the pressure over the loading pressure, the load solenoid valve will lose power and back to the loading state after the supply pressure lower than the loading pressure ; The unloading will can't work if the pressure lower the loading pressure . Normal shut down Press“OFF”button,the loading solenoid valve lose power the relief solenoid will be electrified , after a few time, the motor conductor will lower power , the air end and fan motor stop working, finally, after a few time again, the relief solenoid valve will lose power. Only start the machine by press the“ON”button. Anti-frequent start controlling PressOFFto stop, the air compressor stop after long time loading or error stop, the motor can't be started again at once but some time later. The controller can display the rest time of start again eg. 90 seconds it means that the motor can only be started after 90 seconds) The motor only can be start when the rest time is 0

Long-distance auto controlling (start/ stop method: Long distance control ,auto loading )

All most the same like near controlling, only the start/ stop is controlled by distance switch. (3)Local manually controlling (start/stop method: Local, manually loading) The start and stop method is the same as the auto controlling, only after the start the machine is under unloading running state, press the“M”button to load, when the supply pressure is over the unloading pressure, the machine will unload automatically, if don't press the “M”button the machine will unload till stop without load . In the course of unloading,“M”is loading button, but in the course of loading the“M”is the unloading button. (4) Long-distance manually controlling (start/ stop method: Long distance control, manually loading) All most the same like local controlling, only the start/ stop is controlled by distance switch. 2.Net working control (1)When the communication type of controller set to “Computer”, the machine can be controlled by computer. (2)When the communication type of controller set to “Linkage”, the controllers can link with each other but the main machine should be the NO.1 machine. 3.Fan motor temperature control When the discharge pressure over the fan motor start pressure, the fan motor will begin to work, when the discharge pressure lower than the fan motor stop pressure, the fan motor will stop running. 4.Auto drainage For the machine equipped with drainer, there is the“time drainage“function, it can drainage according setting time. 5.Error stop and emergency stop If error or some emergency happens stop the motor immediately, press the“Emergency Stop”button to cut the power off, only start again after eliminating the problems.

19

Section six: Precautions system 1.Text display precaution

1) Precaution of air filter a. Examine the action of air filter pressure gap switch if there is problem then give the precaution that “the air filter blocked”

b. Service time precaution

If the air filter's service time reaches the setting time, the display will remind that the air filter is out of use. 2) Precaution of oil filter

a. Examine the action of oil filter pressure gap switch if there is problem then give the precaution that “the oil filter blocked”

b. Service time precaution

If the oil filter's using time reaches the setting time, the display will remind that the oil filter is out of use.

3)Precaution of oil & air separator

a. Examine the action of oil filter pressure gap switch if there is problem then give the precaution that “the oil & air separator blocked”

b. Service time precaution

If the oil & air separator's service time reaches the setting time, the display will remind that the oil & air separator is out of use. 4) Lubrication oil precaution If the lubrication oil's service time reaches the setting time, the display will remind that the lubrication oil is out of use. 5) Lubrication grease precaution

Item

Description

Signal light state

Power

Power on of the controller

PWR light on

Running

Controller Running

RUN light on

Error

Error examined out

ERR light twinkling

Input switch

No.20-12 input switch terminals act

IN00-08 corresponding indicating lights on

Quantity

Output switch

No.2728293031353637

OUT00-09 corresponding indicating lights on

Quantity

3839 output switch terminals act

Data storage

Set the data and the storing time

A flash of PWR light

Section seven: Safe guard 1)Safe guard for motor

Error

Error display

Cause

Short circuit

Error display:short circuit of main machine or fan motor

Short circuit or setting wrong circuit

Blocked

Error display: main machine or fan motor blocked

Overload , bearing wearing other errors

Over load

Error display:main machine or fan motor overload

Overload , bearing wearingother errors

Lack of phase

Error display:main machine or fan motor lack of phases

Powercontactormotor lack phase

Unbalance

Error display unbalance circuit of main machine or fan motor

The contactor lose contact, the motor open loop inside

2Discharge temperature safeguard Discharge temperature higher than the setting value, the controller will warning and stop, the error display:

over high discharge temperature 3Anti reverse rotating safeguard

20

When the Three-phase order is not in line with the setting order, the error display“wrong phase order”the controller can not start the motor. At this time exchange any two of the three power lines will eliminate the error. 4Over high discharge pressure safeguard When the discharge pressure is higher than the pressure limit, the controller will warning and stop, the error display“High discharge pressure" 5Sensor safeguard When the pressure sensor and thermal sensor out of use, the controller will warning and stop, the error display“ transformer out of use” 6Linkage safeguard The main machine running, the discharge temperature has fallen to the fan starting temperature, but the fan don't work, the controller will warning and stop , the error display :“fan starting error” Section eight: Common error eliminating The errors that caused by the outer equipments can be eliminated by checking the error record. push or to shift the highlight black scroll on Running Parametermenu, then push the enter button “→”. Following window will be displayed

Totalrunning tim e This tim e running M aintenance param eter

Totalrunning tim e

This tim e running

M aintenance param eter

P ush the e nter button enter button “→”. Follow in g w indow w illbe d ispla yed

H

P

istory e rror

roduct N O .

Last erro r

P u sh the e nte r b utto n en ter b utto n “→”Fo llo w ing w in d ow w ill be disp laye d

The therm als ensor ou tofuse

1 70

A t this tim e che ck th e tem pe rature tran sform er w heth er broken or d am a ged .

21

Charter V

Section one: Testing 1)Connect air pipeline correctly by following the setting instructions to make sure that air pipeline is clear and avoid air pressure in the pipeline quickly expanded as soon as turn on the power. 2)Double check all the joints are fixed on the machine. Such as: pipeline joints Input and output joints, extension cord. If there's any damage or joints' come off which caused by the transporting, installation so on, please fix the joints immediately. 3)Make sure that oil level in the oil container is above the upper threshold scale in order that machine has sufficient oil to run. If not, please refill oil immediately. 4)Before operating the machine please add about half liter lubricating oil into air valve and use hand to twist ( ) many rounds in case that () is burnt by lacking of oil while operating. Please be aware of do not let any solid waste drop into the air compression room which will damage the head of machine. 5)Check that power sources are correctly connected. If the three-phase power point is set in a wrong order, the warning signal will be on. Then, you must retry by changing any of two-phase lines. 6)Check the machine main head rotation direction after following instruction: press start button and hold for 2 seconds, release and press emergency stop button, make sure that main head is: Rotating along the indicated arrow. 7)Press start button and begin to run the machine. 8)Watch for pressure and temperature raising normally, check that if there are any warning signals. If there are, press "emergency stop" then check the machine. 9)Watch out for regularly loading, if any irregular noise, vibration, oil leaking or so on, press "emergency stop”, then check the machine. 10)Check that if unloading setting's functioning well. Section two: Daily operation instruction 1) Before turning on the main switch everyday, turn on the waste dischargingball valve which is located under the oil & air chamber first, in order to discharge condensation water created inside the oil & air chamber , close the valve immediately when there is oil flow out. For the continue running air compressor in hot and wet circumstance10-hour-stop time a week is necessary, so that the condensation water can be discharged out. For the continue running air compressor in cold circumstance please make sure that the lubricating oil not freezing. 2)Check the oil level and supply oil if not sufficient. (The running oil-level is a little lower than stop oil level) Before supplying oil making sure that there is no pressure and it's forbidden to use different brand of lubricating oil. 3)Running the air compressor several circles by hand to check whether the air compressor running smoothly, if not, please check. 4)Press the start button, the compressor start to run. 5)Connect the power source and open the retaining valve. 6)In order to make sure safe running, during running the air compressor running state should be checked and recorded regularly such as the discharge pressure, the circumstance temperature, the discharge temperature, the oil-level and etc. 7)In the course of running, the oil pipe full of high temperature & high-pressure liquid any action of relax the oil pipe or other dangerous operation is forbidden. Press the “emergency stop “button to stop if there is some abnormal. 8)After the work finished, press the “stop “ button to stop, the machine will enter normal stop process: stop some time later than discharge, please make sure that only adopt “Emergency stop “process when it is emergent. Section three:Instruction of storing Instruction of long time stop, please follow the below instructions strictly when the air compressor need long time stop especially in the low temperature and wet areas 1.Stop more than one month 1)Pack the controller, switch box and other electric equipments with plastic paper or oilpaper. 2)Discharge the water in the oil cooler and back cooler completely. 3)Eliminate any trouble of the machine 4)Discharge out the condensation water in the oil & air chamber, the oil cooler, the back cooler two or three

22

days after stop. 2. Stop more than three months Besides the above the below instruction should be followed too. 1) Close all the ports. 2)Replace the lubricating oil before stop, then running for 30 minutes, discharge out the condensation water in the oil & air chamber, the oil cooler, the back cooler two or three days later. 3) Discharge condensation water completely 4) Locate the air compressor in the little dust, dry circumstance 5) Restart process 6) Remove the plastic paper or oilpaper.

23

Charter VI

Section one: Lubricating oil 1.Instruction of lubricating oil Lubricating oil determines the performance of the screw air compressor, wrong or false operation may damage the air compressor. For our screw air compressor we suggest that the users adopt the lubricating oil with the following characters: stable anti oxidation performance, easy to separate the oil out; good anti-rust performance, high viscosity degree. The requirement of lubricating oil:

Viscosity degree ISO VG32 Flash limit 200

Flowing limit

Lubricating oil recommended

5

or more lower than the environmental temperature

Brand

Code

viscosity

degree at

viscosity

degree at

Viscosity

Index

Flash

limit

Flowing

limit

Lowest working

environment

40

100

at 40

at 40

temperature

 

Corena

           

SHEEL

RS 32

32.1

6.16

144

242

-35

-25

 

Madrela

           

SHEEL

AS46

46

7.93

134

254

-54

-40

2.The factors that affect oil-replace period 1)Bad ventilation and high environment temperature 2)High humidity

3)Dusty

3.The steps of replacing oil 1)Run the air compressor for whiles to raise the oil temperature and the oil will be easy to be discharged 2)Press“stop“ button stop the machine 3)When the pressure in the oil & air chamber at 0.1 Mpa. Open the oil relief valve, the oil will flow out quickly and even splash out by the force of pressure, so the relief valve must be opened gradually. Close the oil relief valve after the discharge finished. Note: All the lubricating oil in the system must be discharged completely including the oil in the pipes, cooler and oil & air chamber. 4)Open the oil feeding screw, feed new lubricating oil. 4.The operation instruction of lubricating oil 1)Generally, for the new machine, for the first time replace the oil after 500 running hours, for the second time, after 1000 running hours, for the third time the oil can be replaced at normal period, 2000 hours. For the non-continuous running machine, the oil should be replaced on time. 2)Make sure that not use the lubricating oil out of its service life, the oil should be replaced on time or low quality oil may damage the air end and the bearing, at the same time the quality of oil decreases and the flash point decreases accordingly, this may cause self-ignition and burn the machine. 3)It's better clean the air compressor completely with lubricating oil after it running two years. The method is: replace with the new oil then let the air compressor run for 6-8 hours, replace the oil again immediately, remove all the sundries completely. This is can prolong the lubricating oil 's service life. 4)Only replace with the same brand and code lubricating oil, it's forbidden to mix different lubricating oil. Section two: Maintenance of air filter 1)Clean the air filter after running 500 hours or warning information display on the controller. Get the filter core out of the filter blow out the dust with low-pressure compressed air. 2)Change the filter core every 2000 running hours Note: In poor condition the period should be shortening accordingly. Note: Make sure no sundries dropped into the air inlet valve in case of block the air end even damage. Section three: Maintenance the oil filter 1)For the new machine, replace the old one with a new after running the first 500 hours 2)Later, the replacing every 2000 hours 3)When replacing the lubricating oil replace the oil filter too

24

Note: In poor condition the period should be shortening accordingly. Note: Replacing the oil filter only after stop and unload, rotating out the oil filter core from the filter anticlockwise carefully don't drop lubricating oil to the seat. When install the filter core, turn the core tightly by hand. After finished, start the machine to check whether there is leakage of oil or not . Section four: Replacing fine oil separator 1)In normal running state , the fine oil separator can work about 3000 hours , but the lubricating oil's quality and the pollution of the environment may short its life . If the pollution is serious , a front set air separator can be fixed. Generally speaking , the users can judge the fine oil filter whether damaged through following information The oil content in the air pipe increases The pressure gap of the fine oil separator exceeds 0.12 Mpa Whether the current increases 2)Note: replace only after stop the system is in no-pressure state. 3)The method of replacing external-set fine oil separator is the same as the replacing of oil filter. 4)The method of replacing internal-set fine oil separator Dissemble all the pipes on the cover of oil & air chamber (including the pipe from the exit hole of minimum pressure valve to the oil filter ) Dissemble all the tighten screws on the cover of oil & air chamber Replace the fine oil separator Assemble the oil & air chamber again 3)Note: There are two asbestos washers on and under the flange of the separator. Some metal pieces like stapling nail or something else has been fixed on it, when replacing the nail must be stapled again at its original place this can prevent damage from static electricity. 4) Note: when assembling keep that the distance between oil-return pipe and the bottom of the fine oil at 2-3

mm

5) Note: don't drop dirt to the oil & air chamber when replacing the separator

Period

Maintenance detail

Every day / every starting

Discharge the condensed water in the oil & air chamber

Clean the air filter

Every 3 month / 500 hours

Replace oil filter after running 500 hours ( new machine )

Replace lubricating oil filter after running 500 hours (new machine )

Check whether the oil, air, electric pipes joint relax or not

Tight the belt

Check the release function of safety valve

Every 6 month / 2000 hours

Replace the lubricating oil

Replace the air filters core

Replace the oil filter

Replace the fine oil filters core

Clean the oil and air cooler

Every 12 month / 4000 hours

Feed the lubricating grease to the motor

Check the electric circuit system

25

Charter VII

Trouble shooting

Symptom

Reason

Remedy

 

1. Fuse burnt

Change

Start trouble

2. Voltage is too low

Examine and change

3. Wrong power phase order

Examine and adjust

4. Loose contact of start button

Examine and change

5.The emergency-stop button not reset

Reset it

6.

Trouble of the motor

Examine and change

7.Trouble of the air circuit

Examine the power wire and every joint

8.Trouble of the air end

Turn round the rotor manually, if the rotor cant not rotate, please contact us

Running current is too big The machine stop automatically

1.

Voltage is too low

Examine and change

2.The discharge pressure is too high

Check the set unload pressure, and adjust

3.

Wrong lubricating oil

Examine and change

 

4.Fine oil separator blocked, the pressure inside is too high

Change fine oil filter

5.Trouble of the air end

Turn round the rotor manually, if the rotor cant not rotate, please contact us

The running current lower than the normal value

1.Too much air consumption

Examine the air consumption, increase air compressor if necessary

2.The air separator blocked

Clean or change

3.The air inlet valve not work normally

Check the cylinder and piston whether work normally

4.Wrong with the reverse proportion valve

Adjust the set valve

The discharge temperature of air end is lower than the normal value

1.low environment temperature

Increase the fan starting temperature

2.Long unload running time

Increase air consumption or install a side relief valve

 

3.

The temperature transducer out

Change

of use

The discharge temperature of air end is too high, the air compressor out of work

1. Not enough lubricating oil

Check the oil level

2. Wrong oil brand

Check and change

3.High environment temperature

Keep good ventilation and decrease the working temperature

 

4.Oil separator blocked

Change

5.Oil cooler blocked inside

Get it out and clean with medicament

6.The surface of the cooler dusty

Clean the fins of the cooler

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7.Hihg motor fan starting temperature

Adjust

8.The thermal sensor out of use

Change

9.The wires may loose contact

Examine

Oil content is too high ,the period of replace oil shortened .

1.The oil level is too high

Check the oil level

2.The oil-return single direction valves throttle hole blocked

Dissemble and clean

 

3.Low discharge pressure

Increase the set value of unload pressure

4.

The fine oil separator damaged

Change

5.The minimum pressure valves spring out of use

Change

Cant run with load

1.

Trouble of load solenoid valve

Change

2.Pipeline leakage

Examine

3.Porpartion valve trouble

Change

4.Air inlet valve, cylinder not work normally

Examine

5.Minimum pressure valve not work normally

Examine

Cant not unload, the pressure increases constantly until discharged from the safety valve .

1.The set unload pressure is too high

Adjust

2.Load solenoid valve out of work

Change

3.The limit of discharge too small

Adjust

4.The pressure sensor out of use

Change

5.The film of air inlet valve cylinder broken

Examine

 

6.

Trouble of CPU controller

Examine or change

Discharge volume lower than the normal value

1.Air filter blocked

Clean or change

2.Air inlet valve not work normally

Examine and clean

3.Fine oil separator blocked

Examine

 

4.

Reverse proportion valve trouble

Adjust

5.Trouble of load solenoid valve

Examine

6.Leakage of safety valve or other pipelines

Examine

Load and unload exchange too frequent

1.

Leakage of pipelines

Examine

2.The gap between load and unload pressure too small

Reset(Generally,above0.1Mpa)

 

3.Air consumption is not stable

Increase the air tank capacity

Oil fog belch out when stop

1. Leakage of air valve

Check the valve parts is wear or not, change if necessary

2. Stop with heavy load

Check whether the air inlet valve blocked

3.Leakage of minimum pressure valve

Examine and change if necessary

4.Discharge valve not work

Check the discharge valve, change if necessary

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