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SA220-400 Operator manual 20170204

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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
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