Operator Manual SA SERIES Oil Injected Screw Compressors 220-400kW Part No.: Date: 2017.02.04 Rev. A Information on these operating instructions Limitation of liability These instructions enable you to use the machine safely and efficiently. The instructions are a component part of the machine and must be kept in the direct vicinity of the device and be accessible for staff at all times. All information and instructions in this manual have been compiled taking account of the applicable standards and regulations, state-of-the-art technology and our years of knowledge and experience. Staff must have carefully read and understood these instructions before starting all work. The basic prerequisite for safe working is compliance with all the safety instructions and instruction for actions included in these operating instructions. The manufacturer assumes no liability for damages caused by: The local occupational health and safety regulations and general safety rules for operational area of the machine also apply. The instructions for the machine do not cover operation of the controller. Therefore, the instructions and content of the instructions for the controller in question must also be taken into account. Furthermore, the instructions for the installed components found in the appendices also apply. Copyright These instructions are protected by copyright and for internal purposes only. These instructions must not be made available to third parties, reproduced in any way - even excerpts - and the content must not be utilised and/or communicated, except for internal purposes, without the written permission of the manufacturer. Any infringement shall be subject to compensation for damages. We reserve the right to assert further claims. failure to adhere to these instructions improper use use of unqualified staff unauthorised conversions technical modifications use of non-approved spare parts The actual scope of supply may differ from the descriptions and illustrations in these instructions in the case of special designs, the inclusion of additional ordering options or as a result of the latest technical modifications. The obligations agreed in the contract of supply, the manufacturer's general terms and conditions of business and delivery and the legal regulations valid at the time of completion of the contract apply. Customer service Our Customer Service department is available to provide technical information. In addition, our employees are always interested in receiving new information and hearing of your experiences from usage which could be valuable for the improvement of our products. Screw compressor 220-400kW 1 Safety ....................................................................................................................................................... 3 1.1 Precautions .................................................................................................................................... 3 1.2 Symbols in these instructions ......................................................................................................... 4 1.3 Proper use ...................................................................................................................................... 5 1.4 General safety ................................................................................................................................ 6 Safety devices .......................................................................................................................................... 6 1.4.1 Position of the safety devices ................................................................................................... 6 1.4.2 Description of the installed safety devices ................................................................................ 7 1.5 1.5.1 2 3 4 5 6 Environmental protection ............................................................................................................... 7 Instructions on the machine ...................................................................................................... 8 Technical data......................................................................................................................................... 9 2.1 Name plate ..................................................................................................................................... 9 2.2 Emissions ....................................................................................................................................... 9 2.3 General specifications ..................................................................................................................10 2.3.1 Operating conditions ...............................................................................................................10 2.3.2 Coolant ....................................................................................................................................10 2.3.3 Consumables ..........................................................................................................................10 2.3.4 Inlet air and cooling .................................................................................................................11 Transportation,packaging and storage ..............................................................................................12 3.1 Safety instructions for transportation ...........................................................................................12 3.2 Inspection on receipt of delivery...................................................................................................12 3.3 Packaging.....................................................................................................................................12 3.4 Symbols on the packaging ...........................................................................................................13 3.5 Transportation ..............................................................................................................................13 3.6 Storage .........................................................................................................................................13 Installation and commissioning ..........................................................................................................14 4.1 Requirements in the installation location .....................................................................................14 4.2 Piping,foundation and cooling system .........................................................................................16 4.3 Electrical appliance general specifications and safety standards ................................................17 System flow ...........................................................................................................................................19 5.1 Air system flow .............................................................................................................................19 5.2 Lubricating fiow ............................................................................................................................20 5.3 Cooling system .............................................................................................................................21 Compressor control system ................................................................................................................24 6.1 Operating mode ...........................................................................................................................24 6.2 Start-up of the main motor ...........................................................................................................24 6.3 Stop ..............................................................................................................................................25 6.4 Emergency stop ...........................................................................................................................25 6.5 Calculation of air/oil separator pressure difference......................................................................25 6.6 Fan control ...................................................................................................................................25 6.7 Calibration of discharge pressure transmitter ..............................................................................25 Screw compressor 220-400kW 1 6.8 Key functions description .............................................................................................................25 6.9 Safety protection and alarm system .............................................................................................27 6.10 Common fault description ............................................................................................................28 7 8 9 10 Control system operation instructions ..............................................................................................30 7.1 Brief description ...........................................................................................................................30 7.2 Interface .......................................................................................................................................30 7.3 Data query interface .....................................................................................................................31 7.4 Parameter setup interface ............................................................................................................32 7.5 Operating instructions ..................................................................................................................35 7.5.1 Start of air compressor ............................................................................................................35 7.5.2 Stop of air compressor ............................................................................................................35 7.5.3 Switching of operation mode ...................................................................................................35 7.5.4 Switching of remote and local control .....................................................................................36 7.5.5 Remote start and stop .............................................................................................................36 7.5.6 Fault resetting .........................................................................................................................36 Precaution during compressor start or sotp .....................................................................................37 8.1 Commissioning .............................................................................................................................37 8.2 Routine inspection before starting ...............................................................................................38 8.3 Precautions during operation .......................................................................................................38 8.4 Treatment for long-term shut down ..............................................................................................38 8.5 Special safety warning(adopting the compressor with power supply of 3-10kV high-voltage) ....39 Maintenance ..........................................................................................................................................40 9.1 Coolant(lubricationg oil)specifications and use maintenance .................................................40 9.2 Motor maintenance ......................................................................................................................40 9.3 Pressure adjustment ....................................................................................................................40 9.4 Consumables replacement ..........................................................................................................41 9.5 List of consumable and vulnerable (SA220-280) .........................................................................43 9.6 List of consumable and vulnerable(SA315-400) .....................................................................44 Equipment warranty provisions ..........................................................................................................45 Appendix .........................................................................................................................................................46 Fault shooting table ........................................................................................................................................47 A Training log ...........................................................................................................................................50 B Bolt tightening torque requirements ..................................................................................................51 C Service log ............................................................................................................................................52 D Maintenance schedule .........................................................................................................................56 2 Screw compressor 220-400kW operation after commissioning of the compressor and the wiring of high-voltage power supply inlet is changed, detailed observation to the start-up of the compressor has to be made, mainly focusing on the direction of rotation at instant start-up of the motor. If the motor rotates in the opposite direction, the compressor has to be stopped immediately! 1 Safety This section is a summary of important safety aspects to ensure optimum protection of the personnel and safe and trouble-free operation. The owner, lessor or operator of this compressor is hereby notified and forewarned that failure to observe these safety precautions may result in injury and/or property damage. Fusheng does not mean to imply that the following safety precautions are all inclusive or that the observance of these precautions will prevent all injury or property damage. Fusheng expressly disclaims responsibility or liability for any injury or property damage caused by failure to follow these specified precautions or by failure to exercise ordinary caution and due care required in operating or handling this equipment even though not expressly specified. 1.1 Precautions 1. 2. 3. 4. 5. While welding pipes during installation please be sure that there are no flammable materials in the work area and pay attention to prevent welding sparks from falling onto the compressor. The power wire is connected to the air compressor, and the wire diameter has to match the compressor power (taking into account the pressure drop caused by the wire length), with safety devices such as air switch and fuse installed. New compressor initial startup must be conducted by certified technician. Be sure that no tools, rags or loose parts are left on compressor or drive parts before locking the panel and starting up compressor. Inform people in the vicinity of the compressor before starting up. In case of first start-up or change of the power wire, it has to be noticed whether the direction of rotation of the air end and fan is the same as the indicated arrow tip. If the compressor is provided with a compatible high-voltage motor, the low-voltage control system of the compressor is unable to detect the phase sequence of the motor as the controller of the motor locates at the high-voltage cabinet side. In order to prevent the motor from reverse rotation, during the first start-up or normal 6. Do not operate the compressor in excess of its rated pressure and speeds indicated on the compressor nameplate. 7. Do not attempt to start up compressor when the compressor has failed or shut down on fault, until condition has been addressed or repaired. 8. Disconnect the main power source before working on or performing any maintenance procedures on this unit, and put “Under Maintenance” or “Do Not Connect Power” warning sign in front of the power source. 9. 10. Release air pressure in the system and wait till the compressor cools down before starting maintenance. Service engineer should avoid any discharge ports. 10. Do not use caustic or flammable solvents for cleaning parts. 11. Periodically check all safety and relief devices for proper operation.(Check once a year generally) 12. Use genuine parts and coolant. Do not mix with different brands or types coolant,Otherwise it will cause a major accident caused by coke deposition system; 13. When the compressor comes to rest in winter, the coolant inside the oil cooler and rear cooler must be discharged completely to avoid corrosion and frost crack. 14. The compressor unit shall be operated by permanent personnel, who shall read and understand the content of this manual and follow the working procedures and safety precautions and maintenance specifications in this manual. Screw compressor 220-400kW 3 1.2 Symbols in these instructions Safety instructions The safety instructions and safety information in these instructions are denoted by symbols. The safety instructions are prefaced by signal words which express the extent of the risk. DANGER! Example: 1. Unfasten the screw. 2. CAUTION! Risk of entrapment on the cover! Close the cover carefully. This combination of symbol and signal word indicates a directly hazardous situation which will lead to serious or even fatal injuries if not avoided. 3. Tighten the screw. Special safety instructions The following symbols are used in conjunction with the safety instructions in order to draw attention to particular hazards: Warning – high-voltage. WARNING! This combination of symbol and signal word indicates a possibly hazardous situation which may lead serious or even fatal injuries if not avoided. CAUTION! Warning – explosive substances. Warning – danger zone. Tips and recommendations This combination of symbol and signal word indicates a possibly hazardous situation which may cause minor or light injuries if not avoided. This symbol indicates tips and recommendations and information for efficient and trouble-free operation. NOTICE! This combination of symbol and signal word indicates a possibly hazardous situation which may cause material damage if not avoided or possible hazards for the environment. Safety instructions in action sequences Safety instructions may relate to certain, individual instructions for actions. These safety instructions are embedded in the instruction for action so that they do not interrupt the flow of reading when performing the action. The signal words described above are used. 4 Screw compressor 220-400kW Further markings The following markings are used in these instructions for emphasising instructions for actions, results, lists, cross references and other elements: Marking sanitary purposes or for the direct handling of food without appropriate after-treatment. - The screw compressor may not be operated outdoors. - The screw compressor or individual components may not be rebuilt, modified or re-equipped. - The screw compressor may not be used in an atmosphere subject to explosion. - The intake of media other than cool, dry and dust-free cooling air is forbidden. Explanation Step-by-step instructions for actions Results of actions References to sections of these instructions and other applicable documents Lists without a set order [Button] Operating controls (e.g. buttons, switches), display elements (e.g. indicator lamps) "Display" Screen elements (e.g. buttons, assignment of function keys) Claims of any type for damage due to misuse are excluded. 1.3 Proper use The machine is designed and constructed exclusively for the proper use described here. The screw compressor serves exclusively to generate compressed air in an environment not subject to explosion. The screw compressor may be supplied exclusively with cool, dry and dust-free cooling air. Do not operate the compressor in excess of its rated pressures and speeds indicated on the compressor nameplate. The proper use also includes adherence to all details in this manual. Any use beyond the proper use or other type of use counts as misuse. WARNING! Danger due to misuse! - The compressed air may not be used for breathing without appropriate after-treatment. - The compressed air may not be used directly for pharmaceutical or Screw compressor 220-400kW 5 1.4 General safety Safety devices 1. Read and understand all the instructions found in this manual before operating your compressor. WARNING! Danger to life from nonfunctional safety devices! 2. Disconnect the main power source before working on or performing any maintenance procedures on this unit. Use a lock out and tag out process. If safety devices are not functioning or are disabled, there is a danger of grave injury or death. 3. Do not attempt to remove any parts, break any connection, loosen oil fill plug or drain plug until the unit has been shut down and air pressure has been relieved. 4. Do not operate the compressor in excess of its rated pressures and speeds indicated on the compressor nameplate. 5. Do not remove guards, shields, or screens while the compressor is in operation. If removed for maintenance replace before resuming operation. 6. Observe the delivery pressure gauge daily to be sure the automatic control system is operating within proper limits. 1.4.1 - Check that all safety devices are fully functional and correctly installed before starting work. - Never disable or bypass safety devices. - Ensure that all safety devices are always accessible. Position of the safety devices The following illustrations show the position of the safety devices. 7. Periodically check all safety and relief devices for proper operation. 1 8. Use compressed air properly. Pressurized air can cause serious injury to personnel. 9. Be sure that no tools, rags or loose parts are left in or on the compressor or drive parts. 10. Do not use flammable solvents for cleaning parts. 11. Exercise cleanliness during maintenance and when making repairs. Keep dirt away from parts and exposed openings by covering with clean cloth or Kraft paper. Fig. 1 Emergency stop (1) on the screw compressor 220–400 kW 12. Do not install a shut-off valve in the discharge line without installing a pressure relief valve between the shut-off and the compressor package. 13. Do not operate the compressor in areas where there is a possibility of flammable or toxic substances entering the system. 14. Never disconnect (or jump) the air discharge temperature switch or any other safety device and attempt to operate the compressor. 15. Know what mode of operation the compressor is in before working around the unit. The power may be on but the machine not running if it is in the auto restart mode. Adhere to note #2 above. 6 Screw compressor 220-400kW 1.4.2 Description of the installed safety devices Relief valves Emergency stop button Fig. 2 Emergency stop button By pressing the emergency stop key, the machine is stopped by an immediate switching off of the power supply. After an emergency stop key has been pressed, it must be unlocked by turning it so that a switching on is possible. WARNING! Danger to life from an unauthorised restart! An uncontrolled restart of the machine may cause serious injuries including death. - - Before switching the machine back on, make sure the cause of the emergency stop has been removed and all safety devices have been installed and function properly. Do not unlock the EMERGENCY-STOP button until there is no more danger. Fig. 3 Relief valve Relief valves are unburdening equipment for areas under pressure such as boilers, pressure vessels and pipes. In case of an impermissible pressure increase, relief valves bleed off gases, vapors or liquids into the atmosphere. Do not change the pressure setting of the pressure relief valve, restrict the function of the relief valve or replace the relief valve with a plug. 1.5 Environmental protection NOTICE! Danger to the environment from incorrect handling of pollutants! Incorrect handling of pollutants, particularly incorrect waste disposal, may cause serious damage to the environment. - Always observe the instructions below regarding handling and disposal of pollutants. - Take the appropriate actions immediately if pollutants escape accidentally into the environment. If in doubt, inform the responsible municipal authorities about the damage and ask about the appropriate actions to be taken. Screw compressor 220-400kW 7 The following pollutants are used: Brief instructions for commissioning Coolant This sticker is on the switch cabinet and contains brief instructions for operation. Coolant can contain poisonous substances and substances that are harmful to the environment. They must not be allowed to escape into the environment. Disposal must be carried out by a specialist disposal company. Lubricants Lubricants such as greases and oils contain toxic substances. They must not be allowed to escape into the environment. Disposal of lubriants in accordance with applicable government regulations 1.5.1 Instructions on the machine Direction of rotation There is a direction of rotation sticker on the drive unit and on the cooling air ventilator. This sticker shows the appropriate direction of rotation. 8 Screw compressor 220-400kW 2 Technical data 2.1 Name plate 2.2 Emissions Noise emissions For the values for noise emission refer to the technical data sheet. Fig 1:Name plate The name plate is on the lower frame on the maintenance side and on the sound insulation cover on the cooling air exhaust side or cooling water intake and outlet side and includes the following details: Manufacturing Licence Model Model No. Air Flow Working Pressure Power Net Weight Fingure Dim Serial No. Manufacturing Date Screw compressor 220-400kW 9 2.3 General specifications 2.3.1 Operating conditions Environment Data Value Temperature range +3 to +45°C Relative humidity, maximum 60% Maximum installation altitude above sea level 2.3.2 1000m Coolant The following coolants have been tested and approved for use in these compressors: Designation Type Coolant FS600 Super Coolant FS800 2.3.3 2100050232 (20L) 2100050233 (205L) 2100050210 (20L) 2100050211 (205L) Consumables Screw compressor S 10 Part number 220– 400KW Type Consumable Fill level (L) SA220 Coolant 140 SA250 Coolant 140 SA280 Coolant 140 SA315 Coolant 230 SA350 Coolant 230 SA400 Coolant 230 Screw compressor 220-400kW 2.3.4 Inlet air and cooling Air-cooled screw compressor 220-400 KW Type Discharge Port SA220 DN100 SA250 DN100 SA280 DN100 SA315 DN100 SA350 DN100 SA400 DN100 Water-cooled screw compressor 220 –400KW Type Discharge Port Cooling water inlet / outlet SA220 DN100 2“ SA250 DN100 2“ SA280 DN100 2“ SA315 DN100 Oil cooler DN65,Air cooler DN40 SA350 DN100 Oil cooler DN65,Air cooler DN40 SA400 DN100 Oil cooler DN65,Air cooler DN40 Screw compressor 220-400kW 11 3 Transportation,packaging and storage 3.1 Safety instructions for transportation 3.3 Packaging Improper transport The individual screw compressors are packaged in cartons or sometimes on wooden frames and according to the anticipated transport conditions. Only environmentally-friendly materials are used for the packaging. About the packaging NOTICE! Damage to property due to improper transport! Units may fall or tip over as a result of improper transport. This can cause a significant level of property damage. - Proceed carefully when unloading transport units at delivery and during in-house transport; observe the symbols and instructions on the packaging. - Only use the attachment points provided. - Only remove the packaging shortly before assembly. The packaging should protect the individual components against transport damage, corrosion and other damage until assembly. Therefore, do not destroy the packaging and only remove it shortly before assembly. Handling packaging materials Dispose of packaging material in accordance with the relevant applicable legal requirements and government regulations. 3.2 Inspection on receipt of delivery NOTICE! Danger to the environment due to incorrect disposal! On receipt, immediately inspect the delivery for completeness and transport damage. Packaging materials are valuable raw materials and in many cases can continue to be used or can be properly processed and recycled. Incorrect disposal of packaging materials may pose risks to the environment. Proceed as follows in the event of externally apparent transport damage: Do not accept the delivery, or only accept it subject to reservation. Note the extent of the damage on the transport documentation or the shipper's delivery note. - Dispose of packaging materials in accordance with the environmental regulations. - Observe locally applicable waste disposal regulations. If necessary, outsource the disposal to a specialist company. Initiate complaint procedures. Issue a complaint in respect of each defect immediately following detection. Damage compensation claims can only be asserted within the applicable complaint deadlines. 12 Screw compressor 220-400kW 3.4 Symbols on the packaging Transporting The following symbols are on the packaging. Always heed these symbols during transport. Top The arrow tips on the sign mark the top of the package. They must always point upwards; otherwise the content could be damaged. Fragile Fig. 5 Transportation with a fork lift 1. Drive the fork lift with the forks as shown in Fig. 20. 2. Insert the forks so that they stick out on the other side. 3. Ensure that the package cannot tip if the centre of gravity if off-centre. 4. Lift the package and begin transportation. Marks packages with fragile or sensitive contents. Handle the package with care; do not allow to fall and do not expose to impacts. 3.6 Storage Storage of the packaging pieces Protect against moisture Store the packaging pieces under the following conditions: Do not store outdoors. Store dry and dust-free. Do not expose to any aggressive media. Protect packages against moisture and keep dry. Protect against solar radiation. Avoid mechanical jolts. Storage temperature: 15 to 35 °C. 3.5 Transportation Relative humidity: max. 60 %. Transportation with a fork lift In case of storage for longer than 3 months, check the general condition of all parts and the packaging regularly. If necessary, refresh or replace the rust-proofing. Packages can be transported with a fork lift under the following conditions: The fork lift must be engineered for the weight of the packages. Existing guide rails on the frame must be used. The length of the forks must be at least 2400 mm. Under some circumstances there may be notes about storage on the packaging pieces that extend beyond the requirements named here. Adhere to these accordingly. Screw compressor 220-400kW 13 4 Installation and commissioning entrance of cooling air. It is also possible to install a wind guide at the discharge fan outlet on top of air compressor, to draw hot air discharged by air compressor away from air pipe, thus maintaining a room temperature of 3~45℃. The air director shall be designed based on the size of the compressor outlet opening, without reduction of the area. 4.1 Requirements in the installation location Users typically ignore the selection of installation site for air compressor. An air compressor is often erected at a convenient place after procurement and then used immediately after finishing piping work. Such a careless installation will result in air compressor failure, service difficulties and bad quality of compressed air. Therefore, a good installation site is the prerequisite for correct air compressor system application. Select a site that has: 1. A spacious and illuminated place for easy operation and maintenance. 2. Low relative humidity, low dust, clean air and good ventilation. 3. Ambient temperature below 45℃ to avoid unnecessary high-temperature tripping. Higher ambient temperature, less output air of air compressor. In addition, ambient temperature must be higher than 3℃, and be controlled above the freezing point of water. 4. In case of poor factory environment (such as dusty),install pre-filter equipment to maintain the normal service life of component in air compressor system. 5. Reserve space and install a crane (especially for high-power air compressor) for servicing and repairing. 6. Reserve enough space around air compressor for parts entry during servicing and repairing. The distance from the sides of air compressor to wall must be over 1000mm. 7. Air compressor is heat-generating equipment (especially air-cooled type), so plant ventilation is very important. It is necessary to install air suction/discharge equipment based on direction of outside wind. Its air suction quantity must be larger than the air quantity of compressor circulating fan or cooling fan. There should be enough area for 14 8. When using air discharge pipe, reserve space for adjustable canvas joint used for maintenance (e.g., there will be enough space to dismount cover and other parts from compressor when cleaning the cooler). 9. In order to keep the compressor room temperature above 3°C during winter, a movable door can be mounted on the exhaust duct to lead a proper amount of hot air into the room. 10. The exhaust duct outlet shall be designed with necessary facilities to prevent the cold air after stop from feeding back to the compressor during winter, resulting in that the heat exchanger temperature is identical to the ambient temperature and the lubricant viscosity is increasing to cause the compressor difficult to start. Screw compressor 220-400kW If air compressor is placed in a closed air compressor room, an exhuast fan must be installed to keep the room temperature. Discharge amount of discharge fan must be higher than the air volume of circulating fan or cooling fan of air compressor, and the area at cooling air inlet must be sufficient. Compressed air outlet The ground must be kept level, and it is better that the bottom of air compressor lays soft cushion or anti-vibration cushion to prevent vibration and noise. Basic maintenance space must be more than 1m. Screw compressor 220-400kW 15 compressed air in two directions can be obtained at any location. This can decrease the pressure drop when air consumption goes up abruptly in certain branch lines. Also install suitable valves in circular main line for service and repairing. 4.2 Piping,foundation and cooling system 4.2.1 Air line piping 1. During main line piping construction, the line should have 1-2 degree of slope to drain the condensed water in the pipe. 4.2.2 Foundation 1. Foundation should be built on solid ground. The foundation surface must be ground leveled before installation to prevent air compressor from vibration and thus large noise. 2. The pressure drop in piping line should not exceed 5% of designed pressure of compressor. Therefore, it is better to select a pipe with a larger diameter. 3. Branch line must be connected to the top of main line to prevent condensed water inside the piping from flowing down to operating machine or back to the compressor. Check valve should be installed in the air outlet line of compressor. 2. Should the air compressor be installed upstairs, oscillation prevention must be implemented to prevent vibration from transmitting to downstairs or creating resonance that could lead to safety hazards for the compressor and building. 4. When installing several air compressors in parallel, install ball valve or automatic water discharge valve at the end of main line for the automatic discharge of condensed water. 3. 5. Do not arbitrarily reduce the size of the main line. Use pipe reducer when it is necessary to reduce or enlarge line size. Otherwise turbulent flow will occur at joints and cause significant pressure loss, as well as have a serious influence over the life of the line. Vibration generated by screw air compressor is small, so there is no foundation need. But the installation place must be flat and the underground should not be soft oil. It would be better if 5mm-15mm rubber anti-vibration pad is padded. 6. If there are purification and buffer facilities such as drier or air tank after the compressor, the ideal piping arrangement is: air compressor + air tank + drier. In this way, the air tank can filter out part of the condensed water and decrease the air discharge temperature. Air with lower temperature and less moisture enters the drier and thus lessens the load of drier. 7. If the system consumes large amounts of air in a short period, it is recommended to add an air tank as buffer to reduce the changeover frequency of compressor’s idle and heavy duty. It is very beneficial for the compressor. 8. If the system air pressure is under 1.5Mpa, the flow rate in the delivery pipe should not exceed 15m/s to avoid large pressure drop. 9. Try not to use elbows and various valves in the line to minimize pressure loss. 4.2.3 Cooling system 1. Air-cooled compressor For air-cooled compressor, it is particularly important to maintain a good ventilation environment. Do not place air compressor near high-temperature machinery or inside enclosed space with poor ventilation, in order to prevent tripping caused by a high temperature of discharged air. If the compressor is used in an enclosed system, air suction and discharge equipments must be installed to facilitate air circulation. Generally speaking, the individual air quantity ventilated must be larger than the discharged air volume of compressor fan for heat dissipation. For air-cooled type compressor, heat exchanger must be cleaned frequently to maintain efficient heat dissipation(expecially at the high temperature ambient ). 10. The ideal piping construction is to let the main line surround the whole plant. Thus 16 Screw compressor 220-400kW 2. Water-cooled compressor a) Cooling water circulation system requirements Automatic replenishment system of cooling water circulation system should be improved. Otherwise, after a long time of operation, cooling water will be in shortage, and discharge temperature of air compressor will exceed the set value, resulting in protective shutdown.( Cooling water would better supply independently) water pressure and flow are both lower than the values given in the above table; the energy consumption of the cooling water circulation system is reduced through the use of the variable frequency pump. Site placing cooling water tower should dissipate heat easily and well ventilated, with support to prevent dumping. Cooling water tower should conform to cooling water volume specified by air compressor, and at the same time water pump power must be properly selected. It is preferred to use variable frequency pump as the inlet water temperature has a significant seasonal difference. When the inlet water temperature decreases, the required cooling b) Cooling water requirements Water-cooled compressor Type 220-400kW SA220W SA250W SA280W SA315W SA350W SA400W Cooling water capacity-max(m3/h) 21 23 25 28 30 35 Hydraulic-inlet(MPa) 0.18 0.20 0.22 0.12 0.15 0.2 ≤35℃ Temperature-inlet Water quality requirements Fouling coefficient reguarly) (m2*h*℃/kcal) ≤0.0006 industrial water(need add softener Note: the inlet water pressure refers to the water pressure at the compressor inlet, with the maximal pressure not more than 0.5MPa and minimal pressure not less than 0.12MPa. It is beyond the bearing capacity of the cooler when the maximal pressure is exceeded. The cooling water flow is insufficient when the minimal pressure is not reached. 4.3 Electrical appliance general specifications and safety standards 1. Based on the compressor power and local application environment and soil property, the power wire diameter, grounding wire diameter and air switch capacity of the compressor shall be selected properly (in case of smaller power wire diameter, there will be danger as it is easy to burn due to high temperature; in case of bigger diameter, there will be a certain waste).The total loads of different models of compressor are listed as below: a) The load table of the compressor main motor Power(kW) 220 250 280 315 355 400 380V 464 528 591 665 745 —— 6kV 32.0 36.2 40.1 45.2 50.9 57.2 10kV 19.3 22.2 24.2 27.4 31.9 34.3 Item Current (Max.A) Screw compressor 220-400kW 17 b) The fan motor of the compressor + load capacity of auxiliary control circuit, taking the power wire voltage of 380V as an example, the current of the water-cooled compressor is less than 5A, while the current of the air-cooled compressor is less than 33A. c) The power wire diameter of low-voltage 380V compressor shall be selected as follows: main motor load + fan motor + generated total load of auxiliary control circuit. The three-phase four-wire power wire shall be selected properly. d) As for high-voltage(3~10kV) compressor, based on the main motor load, the user shall select the main motor high-voltage cable properly; and based on the load capacity of low-voltage control system of the compressor(mainly consisting of fan motor + auxiliary control circuit), the user shall select its three-phase four-wire power wire properly. 2. Air compressor should use a set of separate power system, especially avoiding use with other system with different power consumption in parallel. If it is used in parallel, excessive voltage drop or three-phase current unbalance will result in air compressor overload and the protective devices will shut down the machine, especially air compressor with big power. 3. Configure corresponding NFB (No Fuse Breaker) in accordance with air compressor power, to maintain electricity application system and maintenance safety. 4. Confirm the voltage correctness during power distribution of air compressor. 5. Grounding wire of motor or system should be erected, and the grounding wire should not be directly connected with air supply pipe or cooling water pipe. 6. Air compressor must be grounded reliably, to prevent danger due to electrical leakage. 7. Before performing any electrical maintenance work, be sure to cut off the power supply. 18 Screw compressor 220-400kW 5 System flow block of intake valve connected with valve rod is also under semi-open state, and the intake volume is reduced and balanced with system air consumption. This is capacity adjustment process. 5.1 Air system flow 1. Air flow The air dust is removed through air filter (1), and the air passes through intake valve (3) to main compression chamber for compressing, and is mixed with coolant. Compressed air mixed with oil is drained to air/oil separator tank (8), and then passes through air/oil separator, pressure remaining valve (13), rear cooler (18) and water separator (21), finally into application system. 2. Air circuit components function description: 1) Air filter 1 Air filter is a dry paper filter, and its main function is to filter the dust in the air. Generally, air filter should be removed to clear surface dust every 1000h. The clear method is to blow the dust from air filter internal with low-pressure air. Air filter is equipped with a differential pressure switch (2), when pressure difference of air filter increases to the set value of pressure difference switch, differential pressure switch acts; air filter ∆P indicating light on control panel system flow chart is on. At the same time, controller displays air filter block alarming menu, indicating that the air filter must be cleaned or changed, but air compressor can still continue to operate. 2) Intake valve 3 Butterfly intake control valve is used, with single pendulum type check valve. When starting the compressor, valve block of intake valve is closed to ensure no-load start. When air compressor is operated with heavy-duty, solenoid valve is opened; air from solenoid valve path enters servo cylinder of intake valve through inverse proportion valve to drive valve rod of servo cylinder, completely opening intake butterfly valve to achieve heavy-duty operation. When system pressure increases to set pressure of inverse proportion valve due to reduced air consumption, inverse proportion valve acts and reduces controlled air output volume. So servo cylinder valve rod thrust of intake valve is reduced. Valve rod retracts by spring force. When spring force is balanced with cylinder gas thrust, valve rod is under semi-open state. At this time, valve If system air consumption is significantly reduced, pressure rise rate is faster than respond ability of capacity adjustment, controller sends out unloading command to deenergize and close solenoid valve. Valve rod returns back to cylinder bottom by spring force, and valve block of intake valve is under full-close state. At the same time, pressure in air compressor system is released by discharge valve, and main machine is under no-load operation. When system pressure drops to set value, controller sends out loading command to energize the solenoid valve and recover heavy-duty operation. Press OFF button to turn off the machine, the machine will delay about 15-30 second and shut down after unloading. 3) Temperature sensor Under the circumstances of water loss, oil loss and water shortage, discharge temperature may be too high. Temperature sensor will transfer the temperature change amount to controller on start disk. When discharge temperature reaches to temperature set value (107℃), controller sends out shutdown command and compressor stop operation.Controller displays discharge high temperature alarming information. At the same time, discharge high temperature indicating light on system flow chart is on. 4) Expansion joint 7 Expansion joint is used to eliminate the internal stress and unit vibration of pipes due to thermal expansion. 5) Air/oil separator tank 8 Air/oil separator tank side has sight glass (10). Heavy vehicle coolant level should between high level line and low level line of sight glass. Air/oil separator tank lower part has drainage valve (15), which should be slightly opened to drain deposited condensation water in air/oil separator tank before each start. Barrel side has 1‘‘ oil hole for oil injection. Large cross-sectional area of air/oil separator tank can reduce compressed air flow rate and separate the oil in air/oil separator tank, and this is the first stage oil separation. Screw compressor 220-400kW 19 6) attention should be paid to that problem. In addition, special copper materials should be used to avoid corrosion if PH value in water is relatively low (i.e., high acidity). Air/oil separator The details can refer to next section description. 7) Safety valve 9 If pressure in air/oil separator tank is above 0.1MPa higher than set discharge pressure due to improper pressure control or failure of control system, safety valve will automatically open and reduce the pressure to be lower than set discharge pressure, so as to protect air/oil separator tank and system. Safety valve has been adjusted before leaving the factory, so do not adjust it without authorization. 8) Minimum pressure and non-return valve 13 Located at air/oil separator outlet above air/oil separator tank, minimum pressure and non-return valve(13) start pressure is set at about 0.45MPa. The functions of minimum pressure and non-return valve include: a) When starting, establish circulation pressure for coolant preferably to ensure the machine lubrication. b) It can only be started when pressure is higher than 0.45MPa, to control maximum air flow rate passing through air/oil separator (volume flow rate is inversely proportional to pressure). In addition to ensure oil separation effects, it can protect air/oil separator from damage due to big pressure difference. 10) Rear cooler a) b) 20 21 Water separator is cyclone-type centrifugal separator which can remove the condensation water, oil and impurities after air cooling. Compressed air after water separator can be directly delivered to application departments which have no particularly high requirements on compressed air quality. 12) Floattype drain valve ( water separator attachment) Discharge solenoid valve (included intake valve) Discharge solenoid valves are two normally opened solenoid valve, which will open and discharge pressure in air/oil separator tank during shutdown or no-load, so as to ensure that the air compressor can restart without load or operate with no load. 9) 11) Water separator 18 For air-cooled cooler, pump the cool air with cooling fan and cool down compressed air with cooler. Air-cooled air compressor is more sensitive to ambient conditions, so it is better to pay attention to ambient ventilation conditions before selecting the installation site. For water-cooled machine, shell and tube cooler is used which uses cooling water to cool down the compressed air. Water-cooled air compressor is not so sensitive to ambient conditions, so it is easier to control discharge temperature. Bad cooling water quality may deposit and block the cooler, so special This compressor adopts mechanical float type drain valve (mounted at the bottom of water separator) to drain the condensation water collected inside the water separator automatically. 5.2 Lubricating fiow 1. Oil injection description Pressure in air/oil separator tank (8) pumps coolant into oil cooler (19) where coolant is cooled; oil filter (16) removes the impurities and particles of coolant; coolant is divided into two paths: one is injected into compression chamber through machine (4) lower part to cool down compressed air; while the other is injected into machine two ends to lubricate bearings and gears; then all coolant (coolant of all parts) is gathered at the bottom of compression chamber and dischargeed together with compressed air. Compressed air mixed with coolant enters air/oil separator tank (8) to separate a large part of oil, and the remaining mist air with oil passes through air/oil separator to remove remaining oil, then enters rear cooler (18) for cooling after minimum pressure and non-return valve(13). After the water separator, the coolant can be sent to application systems. 2. Oil circuit component funciton description 1) Oil filter 19 The cooling method of oil cooler is identical with air rear cooler, including air-cooled and water-cooled two methods. Under severe environment conditions, air-cooled cooler fins are easily covered by dust and affects cooling effects, too high discharge temperature will trip the machine. Therefore, low-pressure compressed air should be used to remove the dust on fins surface after some operation time (depending on working Screw compressor 220-400kW conditions). If the dust could not be removed completely by air, it must be cleaned with solvents. Be sure to keep the cleanness of cooler heat dissipation surface. When shell and tube cooler is plugged, it must be soaked in special lotion, and the deposition plugged in pipes must be removed mechanically. Be sure to clean completely. 2) Oil filter 16 Oil filter is a paper filter, and its function is to remove the oil impurities such as metal particles and oil deterioration, with the filtration precision in 10µ. It has perfect protection function for bearings and rotors. Whether the oil filter should be replaced can be judged by oil filter ∆P alarming indicating light on control panel system flow chart and oil filter block alarming menu on controller. If differential pressure indicating light is on and controller displays alarming menu simultaneously, it indicates that oil filter is blocked and must be replaced. When new machine runs 500 hours for the first time, oil and oil filter must be replaced. Then it should be replaced according to the differential pressure indicating light on and alarming menu displaying in controller.If it is promptly replaced, it may lead to high discharge temperature and machine tripping due to insufficient oil-taking. At the same time, insufficient oil may affect the bearing service life. 3) pressure retaining valve. Pressure difference between these two pressure transmitters is set at 0.12MPa. When the pressure difference between these two pressure transmitters exceeds set value, air/oil separator ∆P indicating light on control panel system flow chart is on, at the same time, LCD displays air/oil separator plugging alarming menu, indicating that the air/oil separator is blocked and should be replaced immediately. c. Check whether the oil pressure is too high. d. Check whether the current increases. e. Check the oil return sight glass (11). If oil return flow is obviously increased, oil has been under failure state. 4) Thermal valve 17 There is a thermal valve in the front of oil cooler. Its function is to maintain the discharge temperature is above pressure dew point temperature. When the compressor is just started, coolant temperature is low. At this time, bypass oil path of thermal valve is opened, and oil flows in the machine without passing through oil cooler. When oil temperature increases to the set temperature of thermal valve core, the valve slowly opens. It completely opens at set temperature upper limit, and then oil passes through oil cooler and flows to machine. Air/oil separator The filter of air/oil separator is made of multiple layers of compact glass fibers. Mist oil in compressed air can be almost completely filtered by air/oil separator, lower than 3ppm. Under normal operation, coolant quality and surrounding environmental pollution degree have significant influences on its service life. Pre-filter can be installed if the environment pollution is serious. As to the coolant, it must be super coolant fluids dedicated for FUSHENG screw air compressor of our company. Minimum pressure and non-return valveis installed at air/oil separator outlet where compressor air is introduced to rear cooler. Air/oil separator is also connected with discharge valve. Oil filtered by air/oil separator is collected in small circular groove in the central of its bottom, and then flows to machine bearing end through a return pipe, avoiding the filtered coolant is drained together with air. Generally speaking, the following methods can be used to determine whether air/oil separator is damaged: a. Oil content in the air pipe increases. b. Pressure transmitters are installed between air/oil separator tank and air/oil separator and after 5.3 Cooling system 1. Air-cooled compressor Cooled air is pumped by a centrifugal fan, passes through cooler fins where exchanges heat with compressed air and coolant to achieve cooling effect; then centrifugal fan exhausts heat air. Maximum allowable ambient temperature of this cooling system is 45℃, if ambient temperature is higher than 45℃, the system may suffer from high temperature and machine shutdown. 2. Water-cooled compressor Designed cooling water temperature is 32℃, so special attention should be paid to cooling water circulation system design. Especially that cooling water quality must conform to standards higher than general industrial water. If water quality is not so good, softener should be regularly added to prevent cooler scaling, avoiding affecting cooler efficiency and service life. In winter, for regions with ambient temperature below 0℃, cooling water in cooler must be drained after the machine is shut down to avoid cooler frost crack. Screw compressor 220-400kW 21 22 Screw compressor 220-400kW Screw compressor 220-400kW 23 6 Compressor control system 6.1 Operating mode 1) 2) General operation: under this mode, when the discharge pressure is higher than the given upper limit of the pressure parameter, the control system will cut off the power to the electromagnetic valve, and servo cylinder will exhaust air, causing that the intake valve closes and the relief block path fully opens simultaneously, enabling the air in the air/oil separator tank to exhaust into the atmosphere through the air filter (which is effective in cleaning of the air filter). At this moment, the compressor is running without load (with decreased power consumption). The required coolant pressure is ensured during pressure relief; when the discharge pressure is lower than the given lower limit of the pressure parameter, the electromagnetic valve powers on, the intake valve opens and the relief block path closes, enabling the compressor to run with full load. Automatic operation: on the basis of general operation mode, this mode is provided with functions such as stop after long idle running and automatic start-up; when the compressor comes into idle running state due to higher discharge pressure, the system will start timing. If the timing reaches the stop time of automatic operation, the motor stops running (but the control system remains running); when the system equipment begins to discharge the air, the system pressure drops, causing the compressor to start automatically and top up the air. Note: the time setting of stop after long idle running shall follow the guideline that the number of motor starts per hour is not more than twice (otherwise the motor will damage due to frequent starts). As for starts more than twice, the soft start is recommended. 1) 24 Integrated control operation: this mode can enable the required most economical operation mode through the communication and control between compressors.This function works best under sufficient storage capacity and different loads. The compressor will operate on the remote instructions of integrated control cabinet, and the auxiliary machine will operate automatically in order (up to 7 sets). The messages between controllers will be transferred via twisted shielded pair cables on the controller circuit board.Under this mode, the display will show that this compressor locates at remote position (please refer to related integrated control cabinet information for the integrated control functions). 6.2 Start-up of the main motor Y/△ Reduce voltage start (the common start method for the motor with voltage not more than 660V): Y connects to the operation initially, after reaching the Y/△ switch time set by the control system (at this moment, the motor reaches the rated rotational speed), the motor switches to △, enabling the compressor to start operating at full load. Advantages: low cost and small control disk. Disadvantages: the Y/△ switch procedures between coils will generate secondary impact to the power grid. The maximal starting current is about 5 times the rated motor current, and the number of motor starts is strictly limited. Soft start (the start method of low start current motor for the compressor with voltage not more than 660V): the motor △ connects to soft start operation in cooperation with the soft starter. Advantages: it is designed with smooth start and free from impact current, and the maximal start current is about 3~4 times the rated motor current, with minimal impact to the grid; in addition, it reduces damage to the motor at start and applies to situations where there are frequent starts or smaller transformer capacity is provided by the customer. Disadvantages: the soft starter is required, with higher cost compared to “Y/△ reduce voltage start”. Immediate start (the common motor start method for the compressor with voltage not less than 3000V): the motor Y connects to the full voltage start operation in cooperation with the high-voltage cabinet. Advantages: simple control disk and small size. 2) Disadvantages: the high-voltage cabinet is required, with higher cost of high-voltage motor compared to the low-voltage motor; the max. start current is about 6 times the rated motor current, with strict limit on the number of motor starts. The high-voltage motor can start 2 times continuously Screw compressor 220-400kW under cold state and only 1 time under thermal state, and will restart again after the high-voltage motor is cooling off. The cooling time shall be not less than 30 minutes. Attention: As for high-voltage motor with 3~10kV, as the compressor operation and control locate at “low-voltage side”, location at high-voltage cabinet side is never allowed, the high-voltage cabinet only controls the high-voltage motor configured on the compressor, adopting on site method. The high-voltage motor starts separately by manipulating high-voltage cabinet closing switch; when high-voltage motor starts separately at high-voltage cabinet side, the control system at compressor low-voltage side fails to act. The compressor head will operate without oil, thus causing it to lock and even more serious accidents to occur. The working status of the control system when the motor starts: after pressing the compressor start button, the intake valve (3) closes fully and electromagnetic valve is disconnected, causing the intake side to become high vacuum. The lubricant required by the compressor room and bearing is ensured by the atmosphere pressure difference between the vacuum of the compressor room and air/oil separator tank; the motor runs with light load; when the start time set by control system is exceeded (at this moment, rated motor rotational speed and moment are reached), as the electromagnetic valve is connected, the pressure inside the air/oil separator tank is increasing and the intake valve opens gradually, thus the pressure inside the air/oil separator tank keeps increasing, causing the intake valve to open fully and the compressor to operate at full load. When the pressure is up to 0.45MPa, the pressure sustaining valve opens to deliver compressed air. 6.3 Stop After pressing the stop button STOP, the electromagnetic valve is disconnected and relief block path opens fully. The air inside the air/oil separator tank is discharged into the atmosphere. When the pressure inside the air/oil separator tank falls to a certain value, the motor will stop running. power supply will be cut off and the motor will stop immediately, causing the electromagnetic valve to be disconnected and the intake valve to close and relief block path to open fully. At this moment, the compressed air inside the air/oil separator tank is discharged to the atmosphere through the air filter until the pressure drops to zero. Only when unusual emergencies arise during the unit operation, the emergency stop button is allowed to use, otherwise it will be harmful to the system. 6.5 Calculation of air/oil separator pressure difference The air/oil separator pressure difference value is calculated with discharge pressure and air/oil separator tank pressure after the compressor is loaded. But when the air/oil separator tank pressure is lower than discharge pressure or 0.55MPa, this value will not be calculated and will be displayed as zero. 6.6 Fan control Fan control methods are divided into water-cooled and air-cooled modes. Under water-cooled mode, the fan will start with start-up of the unit; under air-cooled mode, if the unit discharge temperature or air/oil separator tank temperature is higher than the given fan start temperature, the fan will start and stop running automatically until both temperatures are lower than the stop temperature. 6.7 Calibration of discharge pressure transmitter The gains and zero point of discharge pressure transmitter can be calibrated. When there is no pressure imposed on the discharge duct, the transmitter is calibrated. The current measured value of the transmitter can be set to zero point forcibly. In case there is pressure in the discharge duct, when the pressure deviation exists, the transmitter can be calibrated by increasing or decreasing the gains. 6.8 Key functions description 6.4 Emergency stop 1) In case the discharge temperature is higher than 107°C or the over-current protection device acts due to motor overload, the system performs emergency stop automatically; at this moment, the Mandatory unloading function: when the motor current exceeds the set current, the controller will carry out mandatory unloading to reduce the main motor operating current.In case the current fails to be reduced effectively, Screw compressor 220-400kW 25 the unit will stop running and deliver failure alarm.In case of effective running, but over-current arising again after loading, the mandatory unloading process will apply again.In this way, if this process keeps arising 10 times within 5 minutes, the unit is running under overload, causing the unit to stop running and deliver failure alarm information of “main motor over-current”; the current overload reason shall be tracked down to troubleshoot in time.The compressor is unable to start if the protection device is not reset.The reset method is to press the reset button of the switch manually. 1) The high discharge temperature protection function: the maximal discharge temperature set by the system is 107°C. in case of higher temperature, the compressor will stop automatically and cut off the power supply (generally, there are many reasons for high discharge temperature, but the most common one is the failure of oil cooling system; or insufficient cooling oil due to the low pressure of oil supply system). 2) High start pressure and automatic standby function: when the unit starts by selecting the “automatic operation” mode, if the discharge pressure is higher than the unloading pressure, the unit will switch to standby state directly and will officially start when the discharge pressure drops to loaded pressure value.During this process, a prompt message of “high discharge pressure, the unit will start automatically when the pressure is lower than the loaded pressure value” will be displayed. 3) Heavy load start prevention protection function: when the air/oil separator tank pressure is higher than 0.04MPa, the unit will switch to “standby” state and start officially until this pressure is lower than 0.04MPa.During this process, a prompt message of “high air/oil separator tank pressure, the unit will start automatically when the pressure is lower than 0.04MPa” will be displayed. 4) Compressor anti-reversal protection function (this function is available when the motor △ connects to the compressor with voltage not more than 660V): in case the three-phase power wire phase sequence that is connected to the compressor is not identical to the compressor settings, the electrical failure will arise and the compressor will not start. At this moment, only exchange of any two-phase power wire is required (in spite of this function, it has to be noticed whether the rotation direction of the motor is correct after every wir- 26 ing to prevent the compressor head from being locked). 5) Low temperature protection function: when the compressor room ambient temperature is lower than 0°C, due to increased coolant viscosity with decreased temperature and long service time of the cooler, the oil duct is cloggedand the coolant circulation is also compromised. This function effectively prevents the compressor from being locked due to lack of oil caused by poor coolant circulation at low temperature. Screw compressor 220-400kW 6.9 Safety protection and alarm system The control system provides the following functions, such as detection display and alarm protection (failure alarm information is shown and scrolled at the bottom of the display, which can keep latest 20 failure records. In case of more failures, the first occurred failure information will be overwritten): Main motor protection function Compressor head protection function Detection display function Overloaded main motor High temperature of front bearing High temperature of motor winding High discharge pressure, the unit will start automatically when the pressure is below the lower limit High air/oil separator tank pressure, the unit will start automatically when the pressure is lower than 0.4 bar Over-current of main motor and mandatory unloading Over-current of motor No current alert Y start failure High discharge temperature Low oil sure(alert) Low temperature protection Wrong phase sequence (compressor anti-reversal protection) Discharge Discharge pressure Air/oil pressure difference Air/oil separator tank pressure Motor winding temperature Oil injection pressure Motor current 4AD module failure Main contactor failure Overloaded fan 4PT module failure Discharge temperature sensor failure Pressing of stop button Discharge pressure transmitter failure Air/oil separator tank temperature transmitter failure Fan contactor failure Air/oil separator tank pressure transmitter failure Front bearing temperature transmitter failure Current transmitter failure Oil injection pressure transmitter failure Winding temperature transmitter failure High air/oil separator tank temperature Abnormal pressure Abnormal air/oil tank pressure temperature Air/oil separator temperature Motor front temperature Electrical and system failure alarm function High-voltage unit, high-voltage tank bearing discharge Remote operation is not allowed to high-voltage cabinet injection pres- feedback Low air/oil separator tank pressure emergency feedback separator High-voltage cabinet failure Screw compressor 220-400kW High-voltage cabinet feedback failure 27 cabinet tection alarm proand Compressor maintenance tips function High-voltage fails to operate cabinet Air filter is clogged Service time of air filter is due Service time of lubricant is due Oil filter is clogged Service time of oil filter is due Machine maintenance time is due Air/oil separator clogged is Service time of air/oil separator is due 6.10 Common fault description No. 1 Description 4AD module fault , 4PT module fault This control system has 4AD, 4PT two modules. When any module has fault or disconnects with main PLC system, it will send out signal of “4AD module fault” or “4PT module fault”. Pressure transmitter fault The control system has two sets of pressure transmitters which will send out corresponding pressure transmitter fault signal when detecting that current signal is lower than 3.2mA or higher than 20mA due to transmitter broken wire or short circuit. Oil pressure transmitter is allowed to emerge negative pressure at the beginning of startup, that is, the current signal is allowed to be lower than 3.2mA. 3 Current transmitter fault As the same as pressure transmitter, the system will send out “current transmitter fault” when detecting the current signal of current transmitter is lower than 3.2mA or higher than 20mA. However, at the beginning of startup, especially for star delta starting machine, it may exceed the range of current transmitter due to high starting and switching current. Therefore, fault signal detection is not carried out at the beginning of machine startup. 4 Temperature transmitter fault When temperature sensor broken wire or short circuit is detected, it will send out temperature transmitter fault alarming information. 5 Dischange temperature high Air/oil separator tank temperature high When the detected airend discharge temperature or air/oil separator tank temperature exceeds the set temperature upper limit, it will send out fault alarming signal of “discharge temperature is too high” or “air/oil separator tank temperature is too high”. 6 Motor bearing high temperature Motor winding high temperature To the compressor,It have the functions of detecting the temperature of motor front bearing and winding. When the detected temperature of front bearing or motor winding is higher than set alarming temperature value, it will indicate “front bearing temperature is too high” or “ winding temperature is too high” and send out fault signals 7 Pressure over-limit air/oil separator tank pressure abnormal When the machine discharge pressure or air/oil separator tank pressure is higher than set limit value, the system will send out corresponding pressure over-limit fault alarming signal and stop the compressor. motor over-current no current alarm The system has motor current detection function. When the detected main motor current exceeds set service coefficient current, the machine will be shut down and sends out motor over-current signal. If current signal could not be detected during starting process, it will send out “no current” fault signal. Low pressure machine is also equipped with thermal overload protector in addition to current detection. When this protector acts, it will 2 8 28 Fault type Screw compressor 220-400kW send out motor overload fault signal. Fan motor only has overload protection function. During the operation process, when the machine pressure is too low, it will send out “air/oil separator tank pressure is too low” fault signal and stop the compressor. 9 air/oil separator tank pressure too low 10 Phase sequence protection(function of preventing motor reversion) 11 Contactor feedback fault After machine operation, it will detect corresponding contactor feedback signal. If not detected, it will send out contactor feedback or “star startup failure” fault signal. High-voltage cabinet signal “allow remote switching on” When high-voltage unit connects with high-voltage starting cabinet, high-voltage cabinet should provide “allow remote switching on”. If allowed signal is not received, the unit could not be started and send out alarming signal “not allowed”.When operating, the signal “allow remote switching on” disappeared , control system will send out high-voltage cabinet “not allowed”alarming signal. 13 High-voltage cabinet fault alarm Control system will send low-voltage control system “High-voltage cabinet fault”alarming signal,if high-voltage cabinet detected the high-voltage motor over-load, over-current or other fault alarm, When received the alarming signal send out“High-voltage cabinet fault”alarming signal and stop the compressor. 14 High-voltage cabinet feedback signal If high pressure unit sends out switching on command but does not receive switching on feedback signal, the system will send out “high pressure cabinet feedback fault” . 15 high pressure cabinet tripping If high pressure unit sends out switching off command but does not receive switching off feedback signal, the system will send out “high pressure cabinet tripping” fault alarming signal. 12 Low pressure machine is equipped with phase sequence protector. When power phase sequence is inconsistent with requirements, it will update to prevent motor reversion. Screw compressor 220-400kW 29 7 Control system operation instructions 7.1 Brief description The intelligent controller of Fusheng air compressor, combining the stable PLC and LCD touch screen, has the intelligent control function, simple operation mode and friendly information interface. The operation mode is humanized while multi-protection is provided for the air compressor. 7.2 Interface 30 Screw compressor 220-400kW Seven state data query interfaces are available, with details as follows. 7.3 Data query interface 1. Air/oil separator tank state data interface The current state of the unit can be observed by the indicator on the panel and directly read from the display screen. The default interface of the display screen is as follows. Intelligent Control System of Fusheng Air Compressor Discharge port pressure: Query Discharge port temperature: Setting Operating state: High discharge temperature Pressure of Air/oil separator tank: Temperature of Air/oil separator tank: Differential pressure of oil separator: Local control Serious unit fault High discharge temperature Back Oil injection pressure: Hour Total operating time: State of Air/oil separator tank High discharge temperature The default interface shows the current discharge pressure, discharge temperature, operating time and state of the unit. The fault alarm information scroll bar is provided at the bottom of the interface, in which relevant information will roll in case of fault alarm. Query the current pressure and temperature of the Air/oil separator tank , differential pressure of the fine oil separator and the current oil injection pressure in this interface. 2. Operating time interface: query the current total operating and loading time of the unit. Back Time data query Click “Query” to enter the query menu to view other operation data of the unit, as shown in the figure below. Data query State of Air/oil separator tank Pressure and temperature setting query Unit maintena nce query Back Time query Main motor state Alarm record query Bearing and winding temperature query Operating time: Hour Load time: Hour Current system date: 03/15/2014 Time: 3. Main motor state interface: Main motor state Back Main motor current: Rated current: Service factor: CT rate: This interface shows the current and related current test parameters (for query only) of the current main motor. Screw compressor 220-400kW 31 4. Pressure and temperature limit query Pressure and temperature limit query Back This interface shows the temperature of the front bearing and winding of the current main motor, and the upper limit of temperature. 7. Historical fault alarm query interface Unloading pressure: Historical fault records 12/20 Back Load pressure: Feb. 10, 2014 12:15 Upper limit of temperature High discharge temperature Previous This interface shows the pressure and temperature parameters of the current unit, including the loading pressure, unloading pressure and allowable upper limit of temperature. 5. Unit maintenance time query Unit maintenance time query Operating time of air filter: Operating time of oil filter: Operating time of oil separator: Operating time of coolant: Operation after previous maintenance: Back Hour Current system date:05/06/2014 Time:13:30:02 The controller is able to record the latest 20 faults. This interface shows the temperature of front bearing and winding of the current main motor, and the upper limit of temperature. The latest fault record is displayed in the default mode. Click “Next” or “Previous” to query the previous or following fault record. Hour Hour Hour Hour 7.4 Parameter setup interface Click “Setup” in the main interface to enter the menu interface. The operator should verify the password to avoid artificial errors. Parameters cannot be modified until the correct password is entered. The password verification interface is as follows: This interface shows the operating time of filters and oil (coolant) of the current air compressor, and the time after previous maintenance. 6. 12th fault record Next Motor bearing and winding temperature interface (optional for the low-voltage unit) Back Enter the password, at least 5 digits… Password input Main motor state query Back Parameter setup Front bearing temperature: Winding temperature: Bearing alarm value: Winding alarm value: 32 1. Enter the operator password. 2. Click this button after the correct password prompt appears. If the password is not correct, the prompt “Password error” will appear, and “Parameter setup” will be unavailable, that is, the parameter setup interface will not appear, as shown in the figure below. Screw compressor 220-400kW Back Password input error… the loading pressure must not exceed the unloading pressure. 2. Password input Main motor parameter setup interface Main motor parameter setup Back Rated current: Parameter setup Service factor: CT rate: After entering the correct password, click “Parameter setup” to enter the parameter setup menu option interface. Back Parameter setup Pressure and temperature limit Main motor parameter Delay time parameter Fan control setup Unit maintenance time Overload delay: Click “Main Motor Parameters” to enter this interface, where the rated current, service factor, CT rate and overload delay time can be set. 3. Motor temperature limit Unit maintenance time interface Unit maintenance time setup (hour) Operating time Change password Air filter Factory parameter setup Oil filter Eight menus are provided in total. Click the buttons to enter relevant interfaces, with details as follows. 1. Pressure and temperature limit setup interface Pressure and temperature limit setup Back Unloading pressure: Back Set time Clear Clear Air/oil separator Clear Coolant Clear Maintenan ce time Clear Click “Unit Maintenance Time” to enter this interface, in which the filters, oil and maintenance time can be set. Click “Clear” on the right side to clear the current operating time of the corresponding item. Load pressure: Limit pressure: Upper limit of temperature: Click “Pressure & Temperature Limit” to enter this interface, in which the loading pressure, unloading pressure, limit pressure and upper limit of temperature of the unit can be set. The unloading pressure must not exceed the limit pressure, and Screw compressor 220-400kW 33 4. 6. Delay time parameter Delay time parameter setup Back Main motor temperature setup 5. Current value: Winding temperature: Stop delay of auto running: Minute Delay between normal stop and restart: Minute High bearing temperature alarm value: Delay between breakdown and restart: Minute High winding temperature alarm value: Click “Delay Time Parameters” to enter this interface, in which the parameters related to delay time of the unit can be set, including the start delay time (delta start time of the low-voltage unit), stop delay of auto running (no-load operation delay), delay between normal stop and restart, and delay between breakdown and restart. Fan control setup Back Water-cooled mode Water-cooled Air-cooled Click “Motor Temperature Limit” to enter the motor temperature setup interface. Set the upper limits of the front bearing and winding temperature of the motor, with reference to the actual temperature. 7. Password change interface Change user password Fan control setup interface Back Front bearing temperature: Second Start delay: Motor temperature protection setup interface (optional for low-voltage unit) Back Enter new password, at least 4 digits Password input Water-cooled + motor valve OK Cancel Air-cooled+ VDT Upper limit of temperature Click “Password Setup” to enter the user password change interface. Enter new password between 1 and 9999 in the password input box. Lower limit of temperature Enter the fan control setup interface, and set the fan control mode of the current unit, including water-cooling, air-cooling, water-cooled + motor valve, and fan VDT control. In the air-cooling or VDT control mode, set the upper and lower limits of temperature to start and stop the fan of the unit based on the current temperature. Change user password Back Change password success Password input OK Cancel Click this button Click “OK”. Thus the password is changed. 34 Screw compressor 220-400kW 7.5 Operating instructions 7.5.1 Intelligent Control System of Fusheng Air Compressor Start of air compressor Observe fault indicators of the air compressor in the OFF state, and check whether any fault occurs. At the same time, observe the display screen and check whether the unit is “Ready for Operation” and in the “Local Control” mode. Then press “General Run” or “Auto Run” on the panel. The unit will immediately start running and enter the corresponding operation mode. If the air compressor is powered up by the high-voltage power supply of 3-10kV, the closing switch of the high-voltage cabinet must not be operated in a local manner to separately start the high-voltage motor. Attention If the high-voltage motor is separately started on the high-voltage cabinet side, but the control system on the low-voltage side of the air compressor does not work, the head part will be short of oil in a short time, resulting in high temperature. If the high-voltage motor is not stopped promptly, the head part will be locked under high temperature caused by shortage of oil! Intelligent Control System of Fusheng Air Compressor Discharge port pressure: Discharge port temperature: 1. Confirm that the Total unit operating is “Ready time: for Operation”. Operating state: Query 2. Confirm that the Setting control mode Hour Ready for Operation is “Local control”. Discharge port pressure: Query Discharge port temperature: Setting Total operating time: Operating state: Hour General Run, Started Local contro l Smooth start state 7.5.2 Stop of air compressor Intelligent Control System of Fusheng Air Compressor Discharge port pressure: Query Discharge port temperature: Total operating time: Operating state: Setting Hour General Run, Loaded Local contro l Confirm that the air compressor in operation is in the “Local control” control mode. Press “Stop” on the panel to stop the air compressor. 7.5.3 Switching of operation mode Select the operation mode of the unit in the startup process or switch it in the running process. 1) Local control If the air compressor is not started, press “General Run” to enter the general running mode, and “Auto Run” to enter the auto running mode. Intelligent Control System of Fusheng Air Compressor Discharge port pressure: 3. Confirm that there is no fault alarm. After startup, the unit will be in the “General Run, Started” (“Auto Run, Started” in the Auto mode), indicating that the current unit has been normally started. Query Discharge port temperature: Total operating time: Operating state: 2) Setting Hour Auto Run, Loaded Local control If the air compressor is running, regardless of the Screw compressor 220-400kW 35 operation mode, press “General Run” to enable the general running mode and “Auto Run” to enable the auto running mode. Intelligent Control System of Fusheng Air Compressor Discharge port pressure: Query Intelligent Control System of Fusheng Air Compressor Discharge port temperature: Discharge port pressure: Query Discharge port temperature: Setting Total operating time: Operating state: Total operating time: Hour General Run, Started Operating state: 1) Hour General Run, Loaded Local control Local control 7.5.5 7.5.4 Setting Switching of remote and local control Switching to remote control: press “Sequence” on the panel of the air compressor to enable the “Remote” control mode, as shown in the figure below: Intelligent Control System of Fusheng Air Compressor Remote start and stop In the “Remote” control mode, the air compressor can be controlled remotely by operating the remote start and remote stop contacts in the electrical cabinet or by means of communication. Consult the After-sales Service Department of Fusheng for technical support of specific operations. 7.5.6 Fault resetting Intelligent Control System of Fusheng Air Compressor Discharge port pressure: Query Discharge port pressure: Discharge port temperature: Total operating time: Operating state: Setting Hour General Run, Loaded Remote control Discharge port temperature: Total operating time: Operating state: High discharge temperature 2) Switching to local control: press “Reset” on the panel of the air compressor to enable the “Local control” control mode, as shown in the figure below: Query Fault information scroll bar Setting Hour Serious unit fault High discharge temperature Local control High discharge temperature Indicating that the fault signal is detected by the unit If the air compressor is faulty, the fault information scroll bar will appear at the bottom of the display screen, reminding the operator to carry out troubleshooting and maintenance. After troubleshooting, confirm that the fault signal has been canceled. Press “Reset” on the panel. The fault information will disappear, and the unit will be “Ready for Operation”. In this case, the air compressor will run normally. 36 Screw compressor 220-400kW 8 Precaution during compressor start or sotp tection function. 8.1 Commissioning 1. Connect power wire and grounding wire to test whether the voltage is correct and whether three-phase voltage is balanced. 2. Remove the long bolts which fixed the anti-displace frame and expansion joint(it will reduce the vibration of the compressor after remove them) Attention During machine transportation, re-tighten transportation long bolts which fixed red anti-displace frame and expansion joint to prevent tilt, vibration and damage to anti-vibration pad or displacement of anti-vibration pad, leading to rupture of expansion joint. 3. Check whether air/oil separator tank level is between two lines of the sight glass. 4. If the commissioning is long time after delivery, first add about 2 liters of coolant from intake valve and rotate air compressor with hands to prevent burning air compressor lack of oil during starting process. Pay attention not to allow foreign items to fall in compressor to avoid damage. 1) Rotation direction commissioning: press “Start” button and the compressor rotates; immediately press “emergency stop button” to confirm rotation direction of compressor. There is a direction of rotation sticker on the drive unit and on the cooling air fan. This sticker shows the appropriate direction of rotation. Exchange any two-phase wiring of power wires R, S and T if the rotation direction is incorrect. Also pay attention to rotation direction of cooling air fan. Cut off the power supply for electrical equipment repair, no live working. Attention Attention It is prohibited to energize compressor. Energize compressor control panel. Attention Attention If power phase sequence is inconsistent, phase sequence abnormal indicating light will be on. High-voltage model and high-voltage motor are controlled by the high-voltage start-up cabinet. The compressor low-voltage control system is unable to detect the high-voltage motor phase sequence, hence the low-voltage control system of high-voltage model is not provided with phase sequence pro- Even though the compressor has been tested during production process, rotation direction test is still the key procedure for new machine commissioning. Anti-reverse protection is to detect power phase, and rotation direction must be re-tested after motor repair. Attention 5. To the high-voltage compressor , must cut off the relevant power supply , preventing power from supplying to high-voltage cabinet and preventing low-voltage power from supplying to the compressor Attention 6. Startup: Start the compressor by pressing button “START Attention Screw compressor 220-400kW This compressor is completely automatic type, Y/ ∆ depressurization startup may need 12 seconds, delaying 3 seconds after switching, and intake valve starts action.The common motor start method for compressor with voltage not more than 660V, the high-voltage model mainly uses direct start method. 37 7. Observe whether controller and indicating lights are normal. If there is any abnormal noise, vibration and blinking, immediately press “emergency stop button” to shut down the machine for repair. 8. Stop: Stop the compressor automatically after press the button“STOP” After pressing “OFF” button, discharge valve of compressor discharges; discharge delays shutdown start timing; motor is stopped after about 15 second. Attention Attention In case the air/oil separator tank pressure drops lower than 0.15MPa, the motor will stop. In case the air/oil separator tank pressure rises higher than 0.15MPa, the motor will be stop forcibly after 60 seconds. Be sure the system internal has no pressure when injecting coolant. 3. Peripheral devices preparation: power transmission, cooling tower, pump, opening compressor drainage valve and operating compressed air dryer. 4. Start the compressor. 8.3 Precautions during operation 1. The machine should be shut down if there is any noise or abnormality during operation. 2. Pipes and containers have pressure during operation, so please do not unscrew pipe plug screws and do not open unnecessary valves. 3. If oil on oil level gauge is invisible during long term operation and oil temperature increases gradually, the machine should be shut down immediately. Observe the oil level ten minutes after shutdown. If oil is insufficient, add coolant when system internal has no pressure. 4. During the operation, check the instrument and record voltage, current, discharge pressure, discharge temperature and oil level every 2 hours as the reference of future maintenance. Never use “emergency stop button” to shut down the machine under normal condition. 8.2 Routine inspection before starting Routine inspection before starting is necessary for normal operation of compressor, so be sure to implement the inspection. 1. Air/oil separator tank water drain: slowly open oil drainage valve of air/oil separator tank to drain condensation water during shutdown until flowing out coolant, immediately close the valve. Attention 2. Check oil level: add to the middle of oil upper and lower limit of sight glass if necessary. Attention 38 Be sure that air/oil separator tank has no pressure before opening drainage valve of air/oil separator tank. Please use super coolant fluids dedicated for FUSHENG screw air compressor. It is prohibited to mix with coolant of other brands or different designations. 8.4 Treatment for long-term shut down After long-term shutdown, please handle the machine in accordance with following methods, especially in high humidity seasons or regions. 1. The compressor is idle for more than 3 weeks. 1) Motor, control panel and other electrical equipment should be wrapped with plastic paper or oiled paper to prevent moisture intrusion. 2) Drain the water in oil cooler and rear cooler. 3) Troubleshooting before future use. 4) Drain condensation water in air/oil separator tank, oil cooler and rear cooler after a few days. 2. The compressor is idle for more than 2 months. Screw compressor 220-400kW 1) Close all openings to prevent moisture and dust. 2) Safety valve and control panel should be wrapped with oiled paper or similar paper to prevent corrosion. 3) Replace the coolant before idle and operate for 30 minutes. Drain condensation water in air/oil separator tank and oil cooler after two or three days. 4) Completely drain cooling water. 5) Move the machine to the less dusty and dry place as far as possible. 3. Restart procedure 1) Remove the plastic paper or oiled paper on machine. 2) Measure the motor insulation which should be more than 1 MΩ. 3) Other procedures can refer to commissioning procedures. the wiring of high-voltage power supply inlet is changed, detailed observation to the start-up of the compressor has to be made, mainly focusing on the direction of rotation at instant start-up of the motor. If the motor rotates in the opposite direction, the compressor has to be stopped immediately. 4. The high-voltage switch cabinet operation and maintenance personnel must have certified qualification and document. Improper manipulation will cause personal injury and major equipment failure. 8.5 Special safety warning(adopting the compressor with power supply of 3-10kV high-voltage) 1. The compressor can start only by pressing “start-up” button on its low-voltage control system, location at high-voltage cabinet side is never allowed, adopting on site method. The high-voltage motor starts separately by manipulating high-voltage cabinet closing switch; when high-voltage motor starts separately at high-voltage cabinet side, the control system at compressor low-voltage side fails to act. After a short running of the high-voltage motor, the compressor head will be lack of oil, causing a high temperature. If it fails to stop in time, the compressor head will be in high temperature and locked due to lack of oil. 2. After the compressor stops due to heavy failure during operation, as the high-voltage motor stops under thermal state, it will restart until the high-voltage motor is cooled off after troubleshooting, with cooling time no less than 30 minutes! 3. As the high-voltage motor control locates at high-voltage cabinet side, the low-voltage control system is unable to detect the phase sequence of the high-voltage motor. In order to prevent the motor from reverse rotation, during the first start-up or normal operation after commissioning of the compressor and Screw compressor 220-400kW 39 9 Maintenance Proper operation and maintenance should be carried out in accordance with provisions in instruction manual. Be sure to use genuine parts for maintenance. The company will not bear the reliability for faults and mechanical damages caused by using non-genuine parts or oil not dedicated by the company. If there is any doubt, please contact with service agency. time. Otherwise, the coolant quality and lubrication performance will be deteriorated, easily resulting in high temperature shutdown and carbon deposition phenomenon. At the same time, decrease of coolant burning point may easily cause coolant spontaneous combustion, thus burning air compressor. 3) 9.1 Coolant(lubricationg oil) specifications and use maintenance 1. Coolant has a decisive influence on the performance of screw air compressor. Improper or wrong use will lead to serious compressor damage or even fire. Therefore, it must be super coolant fluids dedicated for FUSHENG screw air compressor. 2. Factors affecting coolant change 1) Bad ventilation, too high ambient temperature. 2) High humidity environment or rainy season. 3) Dusty environment. 3. Coolant repalcing procedures 1) The compressor operates to raise the coolant temperature, facilitating the discharge. Then press “STOP” button to stop running. 2) When the pressure in air/oil separator tank is at 0.1-0.2MPa, open the drainage valve. Due to the pressure presence, coolant is drained quickly, but coolant is easily sprayed; slowly open the valve to avoid coolant splashing. 3) When the coolant is released, the coolant drain valve closes and the refilling opening is opened to top up new coolant.Note that all coolant inside the system, including duct, cooler and air/oil separator tank, etc., must be drained completely. 4) Topping up the new coolant 4. Coolant use precautions 1) If screw air compressor is used for the first time, the first coolant replacement time should be 500 hours after using the coolant. Then the coolant should be replaced every 4000 hours under normal conditions. 2) 40 It is prohibited to allow the coolant to exceed its service life. Coolant should be replaced in After the air compressor is used for two years, coolant “system cleaning” should be carried out with coolant. The method is: operate the air compressor for 6-8 hours after replacing new coolant, and then replace the coolant immediately, so that various organic ingredients left in original system can be cleaned. Replacing coolant is beneficial for its service life. 9.2 Motor maintenance The use environment should be kept dry, and the motor surface should be kept clean. Air suction port should not be blocked with dust, fibers and other debris. When motor thermal protection and short circuit protection act in succession, check whether the fault is caused by motor or over-load, or set value of protection device is too low. Motor can be launched into operation after troubleshooting. Ensure the good lubrication of motor bearing during operation. Lubrication grease should be supplemented on time, and the amount is determined by the following formula. With the increase of temperature, grease aging is accelerated. Therefore, when the temperature is higher than 70℃, supplementary interval must be halved with the temperature increasing every 15℃, but the terminal temperature should not be more than 120℃. When injecting the coolant, oiling gun should be used to inject the coolant into oil cup. Before adding, remove the oil plug in drainage pipe and connect outside of machine with plastic pipe. After topping up, remove plastic pipe and tighten the oil plug. 9.3 Pressure adjustment 1. System pressure adjustment (refers to the parameter setting screen description in Chapter 5 for details) Screw compressor 220-400kW First of all, the compressor is required to stop, press the setting key on the main screen to go to the password setting screen. With input and confirmation of the password, the alert screen is displayed. Press ENTER key to enter the parameter setting screen, the pressure setting screen is displayed by pressing PAGE UP/DOWN key. Press increment/decrement key or number keys to change the pressure loading/unloading setting value. When the setting of the parameter is finish, press confirm key, then the pressure difference between loading/unloading is determined (the pressure difference between loading and unloading can be adjusted based on the site application, with minimal pressure difference no less than 0.15MPa). When the parameter setting is finish, the main screen is displayed. The normal start-up and operation are available. 2. Capacity adjustment (inverse proportional valve) The capacity adjustment system is used to regulate the air intake capacity of the compressor identical to the airflow required by the field device, enabling the most economical and energy-saving operation efficiency. If the pressure is set to 0.7MPa without load, 0.5MPa with heavy load, and the field device working pressure is set to 0.5~0.65MPa, the inverse proportional valve capacity adjustment pressure shall be set to >0.65~0.68MPa, namely >0.65MPa, the compressor begins to adjust the capacity and reduces the airflow output. The counterclockwise direction will reduce the pressure setting. 9.4 Consumables replacement 1. 4. Pre-filter Air/oil separator When the air/oil separator pressure difference alarm is displayed on the control panel (at this moment, the air/oil separator tank pressure is 0.12MPa higher than the discharge pressure), the air/oil separator must be replaced, with general replacement time of 4000 hours. The replacement time shall be reduced in case of poor environment. Observation of the oil return sight glass: the sight glass is mounted on the sub sleeve of the air/oil return duct, which is proximity to the machine body end. Normally, the returned oil is barely visible in the oil return sight glass of the air/oil separator, which means the returned oil is little. If obvious large flow of returned oil is visible in the sight glass, the air/oil separator has been in abnormal running condition. The returned oil amount in the oil return sight glass is considered as another reference to judge the air/oil service condition. Replacement procedures of air/oil separator 1) Shut down the compressor and close air outlet; open the drainage valve and ensure there is no pressure in the system. 2) Dismantle pipes above air/oil separator tank. 3) Remove oil return pipe, sub-set and main-set oil return pipes are placed separately or marked to prevent confusion. 4) Unscrew fixed bolts on upper cover of air/oil separator tank. 5) Lift the upper cover uniformly with M20 long bolts. 6) Lock spindle bolts. Rotate upper cover of air/oil separator tank after upper cover of air/oil separator tank is completely removed from the barrel. 7) Remove the air/oil separator and replace with a new air/oil separator. At the same time, replace new gasket on sub-set and main-set air/oil separators. 8) Assembly air/oil separator tank in reverse sequence of dismantling. Air filter When the compressor is operated for 1000 hours and air filter differential pressure indicating light is on, remove the air filter and clean. Generally replace the air filter every 2000 hours, and the replacement time should be shorten under bad environment conditions. 2. hours or when oil filter differential pressure indicating light is on. Remove and clean the pre-filter every 1-2 weeks without replacement. Clean time should be shortened under bad environment conditions. 3. Oil filter The first time replacement should be conducted after the compressor is operated for 500 hours, and then usually replace the oil filter every 2000 Attention 5. During air/oil separator replacement, prevent impurities falling into air/oil separator tank, so as not to affect air compressor operation. Coolant Screw compressor 220-400kW 41 Initial oil replacement is about 500 hours after compressor operation, and then every 4000 hours (discharge temperature is at 80-90℃). Under bad environment conditions, the discharge temperature is higher and the coolant replacement period should be shortened. WARNING! Risk of injury due to using wrong spare parts! Using incorrect or faulty spare parts brings dangers to the personnel and can cause damages, malfunctions or complete failure. 42 - Only use genuine spare parts supplied by the manufacturer or manufacturer-approved spare parts. - If in doubt, always contact the manufacturer. Screw compressor 220-400kW 9.5 List of consumable and vulnerable (SA220-280) Screw compressor Name 220-280kW Part No. Consumptio n Per unit Replaceing time(h) Air filter element 2116040201 1 2000 Oil filter 2116020074 2 2000 Motor grease 2100050185 1 2000 2116010085 1 Remarks The first time replacement should be conducted after the compressor is operated for 500 hours(when the compressor is idle over 2000 hours ,then operat again,suggest to replace air filter element and oil filter in 500hours ) Specific situation shall be subject to the time marked on the motor nameplate 2116010086 1 Coolant 2100050232 7 4000 The first time replacement should be conducted after the compressor is operated for 500 hours(when the compressor is idle over 2000 hours ,then operat again,suggest to replace coolant and air/oil separator in 500hours ) Cleaning agent 2100100059 4 4000 It only applies to water-cooled compressor Coolant flush 2100100100 4 4000 The circulatory system for cleaning Cleaning of the entire cooling and lubrication system Air/oil separator 4000 Compressor flush One time 8000 Intake valve cylinder 2605697780 1 8000* Intake valve coil 2605697770 1 16000* Minimum pressure and non-return valve pak(maintenance kit) 2605697760 1 16000* The vulnerable parts on minimum pressure and non-return valve (130-STF) maintenance kit for thermal valve 2606690760 (150-STF) maintenance kit for thermal valve 1 16000* 2605697530 The vulnerable parts on thermal valve(There are two kinds of thermal valve , and the valve cores are different.) Flexible couping 2605220901 1 16000* Start and stop the compressor too frequently, the replacement time is shortened Intake duck 2101460147 1 16000* The black rubber hose between the inlet valve and the air filter Intake duck -10KV 2101460152 1 16000* The black rubber hose between the inlet valve and the air filter,and it is dedicated for motor with 10KV-IP23 and motor with 6KV-10KV-IP54 2605467440 1 2606463510 1 2606463520 1 16000* 2606463530 1 2606463460 1 The hose between air-cooled oil cooler and machine base oil-drain outlet The hose between air/oil separator tank and machine base oil-drain outlet The hose between water-cooled oil cooler and machine base oil-drain outlet The hose between water separator and machine base water-drain outlet The hose between air/oil separator tank and intake valve O-ring 2111010113 1 16000* O-ring for tank filler cap of air/oil separator tank O-ring 2111010508 4 16000* O-ring for oil sight glass The vulnerable parts on the intake valve Rubber Note 1. The time of the replacement frequency is the time for carrying out the operation, maintenance and maintenance completely in accordance with the requirements of this manual when the customer's operating environment is in accordance with the environment required in this manual. If not, the replacement time should be shortened. 2. 16000 * indicates that the failure probability of this part after operation for 16000h is higher than before, but the replacement is not forced. (The customer who has high stability requirements of the air compressor operation is suggested to make replacement). Screw compressor 220-400kW 43 9.6 List of consumable and vulnerable(SA315-400) Screw compressor Name 315-400kW Part No. Consumption Per unit Replaceing time(h) Remarks The first time replacement should be conducted after the compressor is operated for 500 hours(when the compressor is idle over 2000 hours ,then operat again,suggest to replace air filter element and oil filter in 500hours ) Air filter element 2116040087 1 2000 Oil filter 2116020051 4 2000 蜂窝空滤芯 2116040235 1 4000 二级高精度空滤芯 Motor grease 2100050185 1 1000 Specific situation shall be subject to the time marked on the motor nameplate 2116010126 1 2116010127 1 Coolant 2100050232 13 4000 Cleaning agent 2100100059 4 4000 It only applies to water-cooled compressor Coolant flush 2100100100 4 4000 The circulatory system for cleaning 1 8000 Cleaning of the entire cooling and lubrication system Air/oil separator 4000 Compressor flush The first time replacement should be conducted after the compressor is operated for 500 hours(when the compressor is idle over 2000 hours ,then operat again,suggest to replace coolant and air/oil separator in 500hours ) Intake valve cylinder 2605697780 2 8000 Intake valve coil 2605697770 1 16000* Minimum pressure and non-return valve pak(maintenance kit) 2605697760 1 16000* (130-STF) maintenance kit for thermal valve 2606690760 1 16000* (150-STF) maintenance kit for thermal valve 2605697530 1 16000* Flexible couping 2605221020 1 16000* Start and stop the compressor too frequently, the replacement time is shortened O-ring 2111010113 1 16000* O-ring for tank filler cap of air/oil separator tank O-ring 2111010508 4 16000* O-ring for oil sight glass Main injection tube for water-cooled compressor 2606463670 1 16000* Main injection tube for air-cooled compressor 260537S15110101 The vulnerable parts on the intake valve Note 44 The vulnerable parts on minimum pressure and non-return valve The vulnerable parts on thermal valve (There are two kinds of thermal valve , and the valve cores are different.) Stainless steel hose between oil filter and airend 1 16000* 1. The time of the replacement frequency is the time for carrying out the operation, maintenance and maintenance completely in accordance with the requirements of this manual when the customer's operating environment is in accordance with the environment required in this manual. If not, the replacement time should be shortened. 2. 16000 * indicates that the failure probability of this part after operation for 16000h is higher than before, but the replacement is not forced. (The customer who has high stability requirements of the air compressor operation is suggested to make replacement). Screw compressor 220-400kW 10 Equipment warranty provisions FUSHENG Company guarantees the users that: if the air compressor has faults due to manufacturing or material failures in 18 months or 12 months after commissioning and operation or 3000 hours of accumulated operation (limited to the first due) from the date of delivery, the company provides free service and replaces the damaged parts strictly in accordance with the following warranty provisions. 1. Equipment warranty obligation is only effective under the following conditions: 1) Users must strictly follow the specifications in <Installation, Maintenance and Use Instruction Manual> attached in the company machine to operate, repair and maintain the company equipment, and conform to normal industry practices. 2) The equipment faults are not caused by improper installation, operation, repair or negligence of users, as well as irresistible natural disasters, war or violence. 3) Manufacturing number is not removed, worn or counterfeit changed. 4) Used parts and coolant must be FUSHENG genuine parts and FUSHENG super coolant fluids dedicated for screw air compressor. Warning Any behavior using non-genuine FUSHENG parts will affect human safety and machine operation safety 2. Normally used consumables (such as air filter, oil filter, air/oil separator, super coolant fluids dedicated for FUSHENG screw air compressor) are not covered by the warranty. 3. The company does not bear any liability on indirect losses caused by the machine or any other losses. 4. Users should properly keep “Warranty Card” to guarantee the warranty right. Screw compressor 220-400kW 45 Appendix 46 Screw compressor 220-400kW Fault shooting table Item Fault description Unable to start (electrical fault light is on) Possible causes Troubleshooting 1. Fuse burning 1. Troubleshooting and replace by electrician 2. Protection relay action 2. Troubleshooting and replace by electrician 3. Starter relay failure 3. Troubleshooting and replace by electrician 4. Starter button contact is bad 4. Troubleshooting and replace by electrician 5. Too low voltage 5. Troubleshooting supply system by electrician 6. Motor fault 6. Troubleshooting and replace by electrician 7. Machine fault 7. Rotate the machine by hands, if impossible, contact FUSHENG Company service agency (I) (II) (III) (IV) (V) Operation current is high, automatic compressor shutdown (electrical fault light is on) Operation current is lower than normal value 8. Under-phase protection relay action 8. Check power wire and joints 1. Voltage is too low 1. Troubleshooting supply system by electrician 2. Discharge pressure is too high 2. Check pressure display value, if over set pressure, adjust pressure setting parameter 3. Incorrect coolant specifications 4. Air/oil separator plugging (high coolant pressure) 3. Check coolant number and replace coolant quality 4. Replace air/oil separator 5. Compressor fault 5. Rotate the machine by hands, if impossible, contact FUSHENG Company service agency 6. Bad circuit contact 6. Troubleshooting 1. Huge air consumption amount (operated with pressure under set value) 1. Check consumption volume and increase compressor if necessary 2. Air filter plugging 2. Clean or replace 3. Intake valve bad action (butterfly valve is blocked without action) 3. Check adjustment 4. Volume adjusting valve is adjusted improperly 4. Re-adjust set pressure 5. Improper pressure setting 5. Re-adjust set value Discharge temperature is lower than normal value (lower than 70℃) 1. Huge cooling water amount 1. Adjust cooling water outlet valve 2. Low ambient temperature 2. Adjust cooling water outlet valve, heat air of air-cooled cooler can be vented outdoor 3. Temperature sensor fault 3. Replace temperature sensor 4. Thermal control valve fault 4. Replace thermal control valve High discharge temperature, air compressor automatic shutdown, 1. Insufficient coolant 1. Check if coolant level is lower than “L”, shut down and inject coolant between “L-H” 3. 2. Check water inlet and outlet pipe temperature Insufficient cooling water Screw compressor 220-400kW 47 discharge high temperature indicating light on (over set value 107℃) 3. High cooling water temperature 4. High ambient temperature 3. Check inlet water temperature 4. Increase air discharge and reduce ambient temperature 5. Oil cooler plugging 5. Check water inlet and outlet pipe temperature difference; normal temperature difference is about 5-8℃; if higher than 9℃, the oil cooler may be blocked, remove and clean with lotion 6. Incorrect coolant specification 6. Check coolant number and change coolant quality 7. Thermal control valve fault 8. Air filter is not clean 9. Oil filter plugging 10. Cooling fan fault 11. Air-cooled cooler air duct plugging 12. Temperature sensor fault 7. Check whether the coolant is cooled by oil cooler, if not, replace thermal control valve 8. Clean air filter with low-pressure air 9. Replace oil filter 10. Replace cooling fan 11. Clean cooler with low-pressure air 12. Replace (VI) (VII) (VIII) 48 1. Check coolant level and drain to between “H” and “L” High oil content in air, supplementary period of coolant is shortened, air filter smoking without loading 1. Coolant level is too high 5. Minimum pressure and non-return valvespring fatigue 4. Replace with new air/oil separator Unable to full-load operation 1. Pressure transmitter fault 1. Replace with new product 2. Three-way solenoid valve fault 2. Replace with new product 3. Controller internal fault 3. Troubleshooting and replace by electrician 4. Intake valve bad action 4. Inspection and adjustment 5. Minimum pressure and non-return valvebad action 5. After removal, check valve seat and check valve block are worn, if so, replace 6. Control pipe leakage 6. Check leakage position and lock 7. Drainage solenoid valve fault 7. Replace with new product 1. Pressure transmitter fault 1. Troubleshooting, replace if necessary 2. Intake valve bad action 2. Inspection and adjustment 3. Drainage solenoid valve failure (coil burnt) 3. Troubleshooting, replace if necessary 4. Air volume adjusting diaphragm is damaged 4. Troubleshooting and replace Unable to no-load. Gauge pressure is retained under no load, working pressure increases gradually, safety valve acts 2. Oil return pipe flow limiting hole plugging 3. Low discharge pressure 4. Air/oil separator is damaged 5. Controller internal fault 2. Remove and clean 3. Increase discharge pressure (adjust upper and lower pressure limit to set value) 5. Update the spring 5. Troubleshooting and replace by electrician Screw compressor 220-400kW (IX) Compressor air volume is lower than normal value 1. Intake filter plugging 1. Clean or replace 2. Intake valve bad action 2. Open and inspect 3. Minimum pressure and non-return valvebad action 3. After removal, check whether valve seat and check valve block is worn, if so, replace, replace fatigue spring 4. Air/oil separator plugging (X) (XI) Frequent empty heavy vehicle During shutdown, oil mist is emitted from air filter 5. Drainage solenoid valve leakage 4. Troubleshooting, replace if necessary 6. Volume adjusting valve improper adjustment 6. Re-adjust volume adjusting pressure 1. Pipe leakage 1. Check leakage position and lock 2. Pressure upper and lower limit is set at low value 2. Reset (general pressure difference is 0.2MPa) 3. Instable air consumption volume 3. Increase air tank capacity 4. Minimum pressure and non-return valvecore is not sealed completely, spring fatigue 4. Repair or replace valve core, spring 1. Intake check valve is not sealed completely 1. Inspection 5. Troubleshooting, replace if necessary 2. Heavy vehicle shutdown 2. Check whether intake valve is closed completely 3. Electrical wire fault 3.Troubleshooting and replace by electrician 4. Minimum pressure and non-return valveleakage 4. Troubleshooting, replace if necessary 5. Replace 5. Air/oil separator is damaged Screw compressor 220-400kW 49 A Training log Date 50 Name Type of training Screw compressor 220-400kW Conducted by Signature B Bolt tightening torque requirements Lock bolts/nuts B 158/193/196/251 design or similar Thread Thread Thread Thread Thread M5 M5 M5 M5 M5 M6 M6 M6 M6 M6 M8 M8 M8 M8 M8 M 10 M 10 M 10 M 10 M 10 M 12 M 12 M 12 M 12 M 12 M 16 M 16 M 16 M 16 M 16 Lock bolts/nuts DIN 912/931/933/934/982 design or similar Thread Thread Thread Thread Thread M5 M5 M5 M5 M5 M6 M6 M6 M6 M6 M8 M8 M8 M8 M8 M 10 M 10 M 10 M 10 M 10 M 12 M 12 M 12 M 12 M 12 M 16 M 16 M 16 M 16 M 16 Screw compressor 220-400kW 51 C Service log Compressor type: Plant number: Please specify for all enquiries, orders and correspondence. Motor number: Air/oil separator tank number: Date of commissioning: Your Customer Service department: 52 Screw compressor 220-400kW Daily checks Runnin g hours Coolant level Weekly checks Leakag e Compres sor temperat ure Runnin g hours Coolant level Leakag e Screw compressor 220-400kW Compre ssor tempera ture Running hours 53 Filter change Coolant replaceing (Oil filter / intake filter/ air/oil separator) Running hours 54 Date Running hours Date Runni ng hours Screw compressor 220-400kW Date Running hours Other Maintenance Running hours Running hours Running hours Screw compressor 220-400kW Running hours 55 D Maintenance schedule Maintenance schedule The maintenance schedule is included with the documents 56 Screw compressor 220-400kW FUSHENG INDUSTRIAL CO., LTD. www.fusheng.com