Operator Manual

SA/SAV Classical Series Part No.:

Oil Injected Screw Compressors 55-90kW Date: 2018.12.28 Rev. A
 Content
Chapter 1 Safety Instructions................................................................................... 1
1.1 W ARNING SIGNS ................................................................................................................... 2
1. 2 R ELEVANT WARNING AND OTHER STICKERS ....................................................................... 3
1. 3 SAFETY PRECAUTIONS ........................................................................................................ 6
Chapter 2 Screw Air Compressor General Principle and Specification ........... 13
2.1 INTRODUCTION OF O IL-INJECTED SCREW TYPE AIR COMPRESSOR ............................... 13
2.2 STAGE STRUCTURE OF O IL-INJECTED SCREW TYPE AIR COMPRESSOR ....................... 13
2.3 COMPRESSION PRINCIPLE OF SCREW AIR COMPRESSOR (REFER TO FIG.1) ............... 14
Chapter 3 Installation of Air Compressor ............................................................. 15
3.1 RECEIVING ........................................................................................................................... 15
3.2 INSTALLATION ...................................................................................................................... 15
3.3 P IPING, FOUNDATION AND COOLING SYSTEM .................................................................... 17
3.4 GENERAL SPECIFICATION AND SAFETY STANDARDS OF ELECTRICAL APPLIANCE ........ 18
Chapter 4 System Flow ........................................................................................... 20
4.1 A IR SYSTEM FLOW (REFER TO SYSTEM FLOW CHARTS OF EACH MODEL) ....................... 20
4.2 COOLANT LIQUID FLOW (REFER TO SYSTEM FLOW CHARTS OF EACH MODEL) ............... 22
4.3 COOLING SYSTEM ............................................................................................................... 23
4.4 SAFETY PROTECTION SYSTEM AND W ARNING D EVICES ................................................. 25
4.5 CONTROL SYSTEM AND E LECTRIC C IRCUIT ..................................................................... 26
Chapter 5 Operation ................................................................................................ 31
5.1 P ILOT RUNNING ................................................................................................................... 31
5.2 DAILY INSPECTION BEFORE STARTING ............................................................................... 32
5.3 CAUTIONS DURING OPERATION .......................................................................................... 33
5.4 HANDLING METHOD FOR LONG-TERM SHUT DOWN ........................................................... 33
Chapter 6 Maintenance and Inspection ................................................................ 35
6.1 COOLANT LIQUID SPECIFICATION AND USAGE ................................................................... 35
6.2 PRESSURE ADJUSTMENT ................................................................................................... 37
6.3 REPLACEMENT OF CONSUMABLE ...................................................................................... 37
6.4 MAINTENANCE AND TROUBLESHOOTING ........................................................................... 39
6.5 MOTOR MAINTENANCE ........................................................................................................ 40
6.6 TROUBLESHOOTING TABLE ................................................................................................ 41
 Chapter 1 Safety Instructions
Please read the operator’s manual before operating the air compressor:
＊＊＊＊＊＊＊＊＊＊＊＊＊＊＊＊＊＊＊＊＊＊＊＊＊＊＊＊＊＊＊＊
Precautions:
1. 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.
2. Power supply cable, fuse and air-break switch need to match the compressor
power supply requirements and must be grounded properly to ensure the safety of
all electrical components. Please install a lightning protection device if necessary.
3. New compressor initial startup must be conducted by certified technician.
4. 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.
5. Be sure that the compressor rotates in the direction of the arrow on the airend.
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. 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.
12. Use genuine parts and coolant. Do not mix with different brands or types coolant.
13. The air compressor operator must read and understand all the instructions found
in this manual before operating the compressor. The operator must employ safe
working practices.
14. Periodically check the warning labels and ensure all warning labels are not coming
off and/or fading.
15. Manually rotate the airend to ensure the airend rotates smoothly before start up
after the unit has been shut down for lengthy periods of time. If airend cannot be
rotated, please contact manufacturer.
WARNING
Violation of the safety instructions may cause serious injury.
1
1. 1 Warning Signs
Read and understand warning signs and discretions which are used to mark and
remind relevant contents to be paid attention to in this instruction manual. BE SURE
TO FOLLOW THESE PRECAUTIONS FOR THE SAFE DAY-TO-DAY OPERATION
OF YOUR COMPRESSOR.
1) Warning Sign
Warning Sign Description
Danger is used to indicate the presence of a hazard that will cause
△ !
severe personnel injury or death and /or substantial property
damage.
Danger
Warning is used to indicate the presence of a hazard that can
△ !
cause personal injury and/or property damage.
Warning
Caution is used to indicate the presence of a hazard that can
△ !
cause personal injury and/or property damage.
Caution

Notice is used to inform the user of installation, operation or
maintenance information that is important but not of a hazardous
nature.
Notice
2) Symbol Content
Describe the details with graphic or sentences in or near the symbol.
Graphic Graphic Definition
Indicate forbidden issues.
 Describe the details with graphic or sentences in or near the
graphic.
Indicate issues requiring precautions and attentions.
 Describe the details with graphic or sentences in or near the
graphic.
Follow warnings mentioned in this manual. This manual does not describe all safety
items. We, therefore, advise you to pay special attention to all items (even though they
may not be described in the manual) for your safety.
2
1. 2 Relevant warning and other stickers
Please ensure that warning stickers are firmly attached on the machine, and carefully
read and implemented. Please contact with reseller or the company when the stickers
are missing or impossible to read.
Warning and stickers description:
Before starting the machine, please read the
instruction manual carefully. Machine administrator
must forbid the operation by personnel who are not
familiar with the instruction manual.
Note that direct use of compressed air for breathing
will result in serious human injury. Please do not use
it for breathing for health and safety.
Pay attention to the voltage of control panel and
electrical parts. Turn off the compressor and cut off
the power supply before working.
3
Rotating machinery can cause human injuries;
please do not remove any protective and safety
devices.
Please stop the compressor and disconnect the
power supply before working around parts.
High pressure air and oil will result in serious human
injuries. Air outlet should not be pointed to personnel.
Touching control panel, electrical box, motors and
other electrical devices may result in electric shock
hazard. Please be sure to shut down the compressor
and disconnect the power supply before carrying out
maintenance and construction on above mentioned
devices.
Before the operation and commissioning ,please
remove the fixed bolts in compressor interior used for
delivering air end and motor firmly. Please contact
with authorized dealers or service agents for new
machine commissioning.
4
 Please use recommended lubricant for air
compressor. It is prohibited to use or mix with
lubricant of other brands; otherwise, it will cause
machine damage.
After the machine is installed in position, please
cover the forklift hole covers to prevent animal
entering the machine, resulting in machine damage.
Please regularly extrude the nozzles of air filters to
remove the dust, so as to facilitate the operation of
air compressor and maintenance of components.
Attached technical documents are in the machine;
please keep them properly for machine maintenance.
Please keep the stickers clean. When the signs and stickers fall off or
are damaged, please contact the purchase dealers or the company.
5
1. 3 Safety Precautions
1) Precautions before the operation
 Never use the unit directly or indirectly for
the following purposes:
△ !
 Never use the unit for respirator
equipment by which compressed air is
supplied for human consumption. The
Danger compressed air contains carbon
monoxide and other contaminants, and
such air may cause serious injury or even
death if used by a person for respiration.
 This compressor is not designed for air
pressurized construction method and
underwater diving jobs.
Never use compressed air for human
consumption such as pressurizing diving
air tanks. Consumption of compressed air
can cause death while diving.
 Read each instruction plate which is
displayed in the manual or on the unit
△ !


carefully, understand its content and

follow the indications thereof.
Do not modify the machine without prior
Warning
approval. The safety may be
compromised, functions may be
deteriorated, or machine life may be
shortened.
 Never use the unit for the purpose of
compression of gases other than air, or as a
vacuum pump. Otherwise, serious
accidents may occur.
 When handling machine, do not wear:
△ !  loose clothes
 clothes with unbuttoned sleeves
Warning  hanging tie or scarf
 accessories such as dangling jewelry
Such articles could be caught in the machine
or dragged in the rotating portion of the
machine, and this could cause a serious
injury.
6
△ !
 Please wear protection implements, such as
a hard hat, safety glasses, earplugs, safety
shoes, gloves, and
protection-against-dust mask, according to
a
Attention the work environment.
△
 Have first-aid boxes and fire-extinguishers
! near the unit ready for emergency
situations such as injuries and a fire.
Attention  It is advisable to have a list of phone
numbers of doctors, ambulance and the fire
department available in case of emergency.
 When the machine is operated by a person
under the affects of over-fatigue, alcohol
△ !
and other states, it may lead to injuries or
death or other accidents due to distraction
or inattention.
Warning  Please pay full attention to daily health
management.
 Be sure to carry out inspection before
operation. If there is any abnormality, it must
△
be repaired before the operation.
!  If the machine is operated ignoring
inspection before starting and without
finding abnormalities in time, it will lead to
Attention sintering, fire and other accidents. Be sure
to carry out inspection before the operating.
 Such things as unnecessary equipment
and tools, cables, hoods, covers and
pieces of wood which are a hindrance to
△
the job, have to be cleaned and removed.
! This is because operators and/or
personnel nearby may stumble on them
and may be injured.
Attention
 Place safety enclosures at the entrance of
and around working site to prevent children
or outside people from entering the site.
7
2) Precautions during the operation
△ !  It is prohibited to open the oiling cap of oil
receiver during the operation or just after
the shutdown. Internal pressure may blow
Warning oiling cap, spraying high-temperature
compressed air and oil.
 Please stop the machine when filling the oil
into the receiver . When the pressure is at
0MPa (0 kgf/cm 2) and there is no residual
pressure, slowly open oiling cap and fill in
oil .
△ !  Please do not place hands near cooling
fan during operation. If hands are caught it
may lead to serious injuries and accidents.
Warning
 Be sure to shut down the machine when
carrying out inspection and maintenance
around cooling fan.

△
Keep hands away from any rotating parts or
belts while running.
! It could cause serious injuries if hands
should be caught.
Warning  Disconnect the power supply and shut
down the machine when adjusting the
tension of conveyor belt. Hang “Under
inspection and maintenance” at the power
switch before the adjustment.
 Never blow compressed air directly at
people. Scattered impurities, dust, or
△ !
foreign objects in the compressed air may
cause skin and eyes to be seriously
injured.
Warning  Blowing compressed air on food is
prohibited.
8
  Never work near hot portions of the
△ ! 
machine while it is running.
Do not touch hot portions of the machine
while inspecting the machine when
Attention running.
 Such parts as discharge manifold,
discharge pipe, muffler, radiator, oil
cooler, air end, separator tank, and
discharging pipe are especially hot, so
never touch those parts, because it could
cause serious burns.
 Compressor oil is also very hot and
dangerous to touch. Avoid checking or
refilling them while the unit is running.
 After stopping the unit, make sure that
△
pressure gauge indicates 0MPa. Even
when the gauge shows 0MPa, open a
! service valve and further do not fail to
make sure that there is no residual
Attention pressure in the air piping. Then start such
a job as repair and maintenance.
 Residual air under pressure will blow off
and severely injure operator.
△
 Do not, under any circumstance, bring lit
cigarettes or matches near such oils as
! engine oil and compressor oil, etc.
They are extremely flammable and
Attention dangerous, so be careful when handling.
9
3) Precautions during inspection and maintenance
△ !  When cleaning dust accumulated in such
devices as the air-filter, by blowing
compressed air, wear safety glasses, etc. to
protect your eyes.
Warning
△ !  It is recommended to use a trouble light
with safety guard when the work area is
dark.
Attention Operating the machine by feel could
cause unexpected accidents.
 Any lamps without safety guard are not
recommended since they can be broken
and they could ignite flammables such as
fuel, etc.
△
 Be sure to perform the periodical check of
compressor oil and oil separator.
!
 Neglecting checks could cause overheat of
the oil, resulting in a fire.
Attention
 Waste liquid from the machine contains
harmful material. Do not discharge it onto
the ground or into the river, lake or sea.
△
Such material will contaminate the
environment.
!
 Be sure to use a container to hold the
waste liquid from the machine.
Attention
 Be sure to follow the designated regulations
when disposing of waste liquid or other
harmful materials.
10
4) Other special precautions
Please do not install the unit outside must be enclosed.
Installed in high humidity basement or places which are
△ !
accessible to rain may cause corrosion of machine or electrical
component failure.
Please install air inlet and outlet, and a ventilation fan should be
Attention
placed in discharge port if the units are installed in closed or bad
air-exchanged place.
In a dusty place, the dust will result in a short circuit of the electric
parts and damage of the mechanical components.
△
Using the compressor in conditions where corrosive gas is
! present will cause degradation of oil and corrosion of component
parts.
Attention Operating in an environment where flammable dust is present
may cause fire or explosion due to electric spark. Please make
sure to pay attention.
Electric wiring personnel must be certified
According to the power of air compressor, select the correct wire
diameter. Wires with too small diameter should not be used.
Otherwise, the wires are easily burnt by high temperature and
cause danger.
Wire cores, especially power supply wire core, cannot be
exposed.
△ ! Wires should be assembled with protective covers before entering
starter through wiring hole.
Air compressor should use a set of separate power system,
Attention
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 electrical
overload and the protective devices will shut down the machine.
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.
△ !
Air compressor must be grounded to a separate earth ground to
prevent danger due to electrical grounding.
Wire and electric circuit may send electric spark due to the
Attention following: electrical leakage, insulation degradation, over current,
short circuit, single-phase operation or failure of overload.
Please do not remove or modify protective device or change
preset value. Doing so may cause accidents.
This compressor is an air compressor; please do not use to
compress other gas.
11
 Be sure to confirm to the preset value, do not operate units under
△ !
over load state.
Be sure to inspect, clean and make maintenance regularly to
prevent from failure. Warranty period will be flexible according to
Warning
operation conditions. Please replace the components as soon as
operators find its failure.
During operation, the sound proof covers and starter cover should
be closed to prevent from electric shock.
Around the compressor, please do not place flammable articles or
do construction with spark. For example, the spark of welding may
result in fire.
Be sure to record and save daily running status to make it easy for
maintenance afterward.
Please replace with genuine parts. Using other parts may cause
damage to the machine and May void warranty.
△ !
Please make sure to check tools before and after construction. Be
sure no tools are left in machine after maintenance or cleaning.
Precaution of high pressure air or water injection：
Attention
Please release pressure between cut-off valve and machine
before maintenance or cleaning;
If the compressor is water cooled, please drain off water in the
machine after turning off the valve located in inlet/outlet of cooling
water.
Safety valve has been adjusted and tested before leaving the
factory, so do not adjust it without authorization. If there are any
malfunctions please contact the FuSheng service department.
Please turn off the air outlet ball valve after the unit power supply
△ !
is cut off.
When stopping the machine, please turn off the air outlet ball
valve and turn on the water drain valve.
Attention
The machine must run at least 10 minutes per week in order to
prevent corrosion or malfunction.
12
 Chapter 2 Screw Air Compressor General Principle and
Specification
2.1 Introduction of Oil-Injected Screw type Air Compressor
The oil-injected Screw type air compressor is the current trend of air compressor
development due to its excellent and reliable performance. The advantages
include small vibration, low noise, high efficiency and no easily damageable
parts, which the characteristics piston compressor (same discharge pressure)
does not have. The precise matching between female / male rotors, and between
rotor / compressor casing reduces air circumfluence leakage and enhances
efficiency. There is only mesh between rotors and no reciprocal movement of
cylinders, thus reducing vibration and noise sources. The unique lubrication
method brings the following advantages:
1. The oil is constantly injected into the compression chamber and bearing due to
the pressure differential generated by the compressor itself, thus simplifying the
complex machinery.
2. The injected oil can form an oil film between rotors. The male rotor can drive the
female rotor directly, without the aid of high precision synchronous gears.
3. Injected oil can increase sealing effect.
4. Lubrication oil can reduce noise generated by high frequency compression.
5. Lubrication oil can absorb large amounts of compression heat. Therefore,
discharge temperature will not become too high even if the single-stage
compression ratio is up to 16. Rotors will not rub the casing for having different
heat expansion coefficients.
2.2 Stage Structure of Oil-Injected Screw type Air Compressor
1. Basic Structure
Our inverter oil-injected air compressor is a two-shaft positive displacement
rotary compressor. The suction port is located at the upper part of c asing, and
discharge port is located at its lower part. A pair of high precision male and
female rotors is horizontally and installed parallel inside the casing. The male
rotor has five lobes and the female rotor has six flutes. The diameter of male
rotor is larger than that of the female rotor. The gear profile is made in screw
type so that two rotors can mesh with each other. The ends of male and female
rotors are positioned by bearing supports.
2. Mesh
Electrical motor directly drives male rotor through coupling. Since two rotors
can perfectly mesh with each other, the male rotor will drive the female rotor to
rotate together. From the lower portion of compressor casing, cooling coolant
liquid is directly injected into the meshed part between rotors via nozzle and
then mixed with air. It takes away the heat produced during compression
process to achieve cooling. At the same time, it forms an oil film to prevent
metal rotors from direct contact and to seal the clearance between rotors and
casing. The injected oil also reduces noise generated by high-speed
compression. Depending on different discharge pressures, the weight of
injected oil is approximately 5-10 times the air.
13
2.3 Compression Principle of Screw Air Compressor (Refer to Fig.1)
1. Suction Process
When rotors are rotating, the groove space between male and female rotors
reaches maximum when rotors rotate to the wall opening of the suction end.
At this moment, the groove space of rotors is connected with the free air at
suction port. Outside air is drawn into the enclosed chamber formed between
female, male rotors and casing. The suction end surface of rotors will rotate
away from suction port after the groove is completely filled with air, and the air
in the groove is enclosed. This is referred to as “suction process”.
2. Seal and Delivery Process
At the end of suction, the addendum of two rotors will close together with
casing to keep the air inside the groove from escaping. This is referred to as
“seal process”. As the two rotors continue rotating, the addendum and groove
will mesh at the suction end. Then the meshed surface gradually moves
toward discharge end. This is “delivery process”.
3. Compression and Oil Injection Process
During delivery process, meshed surface gradually moves toward discharge
end. The enclosed space between the teeth of the female and male rotors is
reduced gradually. The air in the groove will be compressed and the pressure
increases. This is “compression process”. Meanwhile, lubrication oil is injected
into compression chamber and mixed with air due to pressure differential.
4. Discharge process
When the enclosed space between female and male rotors rotates and
connects with discharge port of the casing (compressed air reaches the
maximum pressure at this point), compressed air begins to discharge. This will
not stop until the groove space is reduced to zero. Then the “discharge
process” is finished. Meanwhile, another pair of rotor teeth rotates to the
suction end to form maximum space, thus starting suction process and a new
compression cycle.
1. Suction Process 2. Seal and Delivery Process
3. Compression and Oil Injection Process 4. Discharge Process
14
 Chapter 3 Installation of Air Compressor
3.1 Receiving
1. Please check if you received the correct shipment as you ordered
2. Please check if the machine and any accessories received any damage
during the shipment.
3. In case of shortage or damage,please indicate the situation on the packing
list and contact the purchased distributor or the manufacturer, will be
satisfactorily resolved
4. Upon receiving this machine, please read thoroughly this manual and any
supplements related to the equipments you purchase before attempting to
install or operate the compressor.
3.2 Installation
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. Also, the higher the ambient temperature, the less the air output of
compressor will be. In addition, ambient temperature must be above 5℃, over
the solidifying point of water and lubrication oil.
4. In case of poor factory environment (such as dusty), install an additional
ventilation pipe to move suction end toward places with cleaner air. Or install
pre-filter equipment to maintain the normal service life of component in air
compressor system.
5. Reserve enough space around air compressor for parts entry during servicing
and repairing. The distance from the sides and the top of air compressor to
wall must be over 1 meter.
6. Reserve passage space and install a crane (especially for high-power air
compressor) for servicing and repairing.
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 fr 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 5~45℃.
15
 Roof fan
Discharge heat
Wall hanging fan
Suction port
Air Exhaust Example
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).
Heat air exit
Exhaust fan
Air pipe
Air Exhaust Example
If air compressor is placed in a closed
air compressor room, an exhaust fan Compressed air exit
must be installed to keep the room
temperature. Exhaust amount of
exhaust 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 The ground must be kept level, and it is
sufficient. 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.
The front and back basic maintenance space
must be more than 1m to facilitate the open and
close of maintenance door.
16
3.3 Piping, foundation and cooling system
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.
(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.
(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.
(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.
(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.
(10)The ideal piping construction is to let the main line surround the whole plant.
Thus 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.
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) 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.
(3) 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.
17
 3. Cooling System
Water-cooled compressor
(1) Cooling water in the water-cooled compressor shall conform to provisions on
industrial water in case that calcium and magnesium ions in the water might
cause chemical reaction due to high temperature, form scale in the cooler and
affect heat transfer effect of the cooler. If cooling water tower circulation
system is used, it is required to regularly add softener into the water to avoid
scaling.
(2) Automatic supply system of the cooling water circulation system must be
perfected. Otherwise, after running for some time, the cooling water will be
insufficient and exhaust temperature of the compressor will exceed the set
value and then cause shutdown.
(3) Cooling water system of the compressor had better to be used separately
instead of sharing with other systems, in case that the cooling effect is
affected due to water shortage.
(4) The cooling water tower must conform to the cooling water volume specified
by the compressor and power of the water suction pump must be correct. The
cooling water tower must be placed at a place with easy heat dissipation and
good ventilation, and must be supported and fixed in case of falling.
(5) The cooling water pressure generally shall be kept between 0.15-0.25MPa
and shall not exceed 0.5MPa at most.
(6) The cooling water outlet temperature shall be lower than 40℃.
Air-cooled compressor
(1) 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.
(2) For air-cooled type compressor, heat exchanger must be cleaned frequently
to maintain efficient heat dissipation.
3.4 General Specification and Safety Standards of Electrical Appliance
1. Select the correct wire diameter according to the rated power of the air
compressor. Do not use wire diameter that is too small, or power cord will be
easily burnt out and generate danger.
2. Air compressor should have an independent power system, especially not
connected with other different power consumption systems in parallel. If used
in parallel, it is possible to trip the overload protection device due to large
voltage reduction or imbalance of three-phase current. This is especially
18
 important for air compressors with large power.
3. Install adequate NFB according to the power of the air compressor for the
safety of power system and maintenance.
4. It is necessary to confirm the correct voltage while performing power
distribution of air compressor.
5. The grounding wire of motor or system must be reliably installed and
grounding wire cannot be connected to air delivery pipe or cooling water pipe.
6. Air compressor must be reliably grounded to prevent danger from electrical
leakage.
7. If three-phase power achieves balance, deviation between any phase of motor
three phases no-load current and average value of three phases should not be
larger than 10% of average value of three phases. If the power supply has
voltage drop, the voltage drop should not be less than 5% of rated voltage.
19
 Chapter 4 System Flow
4.1 Air system flow (refer to system flow charts of each model)
After dust particles are filtered by the air filter, air enters compression chamber
through air inlet valve and is compressed. It then mixes with coolant liquid.
Compressed oil-air mixture is discharged into air/oil separator tank, and then
passes through Air/Oil Separator, pressure maintaining valve and rear cooler.
Then it passes water separator and is sent into system for utilization.
1. Function description of parts in the air line
(1) Air filter
Air filter is a dry type paper filter. Its main function is to remove the dust in the air.
Normally it should be taken out to clean every 500 hours. The cleaning method is
to use low-pressure air to blow it outwardly. There is a pressure differential switch
installed inside the air filter. When air filter pressure differential increases and
reaches the set value of pressure differential switch, the pressure differential
switch operates. If the air filter pressure differential lamp lights up, it indicates that
the filter needs to be replaced or cleaned, although the compressor can still
operate.
(2) Air inlet valve
a. Zero and heavy loading control：
This type air inlet valve through piston’s up and down to control zero and heavy
loading of compressor. When the compressor running or stopping or zero loading,
2-way solenoid valve can control the piston up to close the air inlet valve and the
throttle valve or hole is used to keep the lowest pressure of system.
When the motor in the lowest speed, the 2-way solenoid valve on and system
stop draining, piston down because of the different pressure to keep air entrance
status .If the pressure up to the setting value of controller, 2-way solenoid valve
off and the system begin to drain, and piston up to close the valve, system
become zero loading.
b. Let adjustable control
After heavy load, inverter adjusts the motor running speed according to air needs
from system but base on steady pressure. If customer air needs reduce fewer
than supply from machine in lowest motor speed, system air pressure will up to
zero load value and system into zero loading status.
(3) Air/oil separator tank
Oil sight is installed on the tank side of air/oil separator tank. The oil level of static
coolant liquid should be between the high and low oil levels of oil sight. An oil
drain valve is installed at the bottom of the tank. Open the oil drain valve a little bit
each time before starting up to drain the condensed water deposited in the air/oil
separator tank. A 1” oil-filling port is on the tank for oil filling. Due to the wide cross
sectional area of the air/oil separator tank, the compressed air can reduce the flow
rate of screw oil and cause oil drops to separate. This is the first stage of oil
separation.
(4) Air/Oil Separator
Refer to the following sections for more detail.
20
(5) Safety valve
The safety valve will automatically open when the pressure switch is improperly
adjusted or not functioning, which leads to the internal pressure of air/oil separator
tank higher than set discharge pressure by over 0.1MPa, to reduce the pressure
so it is below the set discharge pressure. Safety valve has been adjusted before
delivery. Please do not adjust it improperly.
(6) Relief solenoid valve
Relief solenoid valve is a two-way N. O. solenoid valve. It will open when unit is
shut down or under zero load to release internal pressure of the tank. This will
ensure that compressor can start or run under zero load when it is operated again.
(7) Pressure maintaining valve
It is located at the outlet of air/Oil Separator above the air/oil separator tank. The
opening pressure is set at ~0.45MPa. The function of pressure maintaining valve
includes:
A. Give priority to the establishment of circulating pressure needed by coolant
liquid when starting, thus ensuring the lubrication of machine.
B. Open only when the pressure exceeds 0.45MPa. Reduce the airflow rate
through air/Oil Separator. Besides ensuring the effect of oil fine separation,
this can also protect the air/Oil Separator, preventing it from being damaged
by large pressure differential.
(8) Rear cooler
A. For air-cooled type cooler, cooling air is drawn in by cooler fan and passes
through cooler to cool the compressed air. Air-cooled type air compressor is
sensitive to ambient temperature condition. Pay attention to the ventilation
condition when selecting the installation location.
B. For water-cooled model, shell-and-tube cooler shall be used to cool down
compressed air with cooling water. Water-cooled compressor is not very
sensitive to the environment temperature and the exhaust temperature can be
easily controlled. If the cooling water quality is too bad, the cooler might easily
form scale and cause blockage. It is especially notable that special copper
material must be used to avoid corrosion if the water PH value is very low
(with high acidity).
(9) Water separator (optional features)
It is cyclone separation type water separator. It can remove the condensed
water, oil drop and foreign matter after the cooling of air. After passing
through water separator, the compressed air can be sent directly to any place
where it is needed.
(10) Automatic water drainer (optional features)
It can automatically drain the condensed water deposited inside the water
separator.
21
4.2 Coolant liquid flow (refer to system flow charts of each model)
1. Description of oil injection flow
The pressure in air/oil separator tank forces coolant liquid into oil cooler. After the
coolant liquid is cooled in the cooler, it passes through oil filter to remove impurity
particles. Then it is divided into two branches. One is injected into compression
chamber from the bottom of airend to cool compressed air. The other is sent to the
two ends of airend to lubricate bearing sets. Then coolant liquid from all parts is
gathered at the bottom of compression chamber to be discharged along with
compressed air. The compressed air mixed with oil enters the air/oil separator
tank where a large portion of the oil is separated. The remaining air containing oil
mist passes through air/Oil Separator to filter out the remaining oil. Then it passes
through the pressure-maintaining valve and enters the air discharge check valve,
and is cooled by rear cooler. Then it can be sent to the systems where it is used.
2. Volume control of oil injection
The injected oil in oil-injection screw type compressor is used for removing the
heat generated during the air compression process. The injection volume has a
direct influence over the performance of the compressor. The injection volume
has been set before delivery so should not be changed. If it needs adjustment due
to discharge temperature or other reasons, please contact service department in
advance to avoid damage to the compressor.
3. Description of the functions for oil line parts
(1) Oil cooler
The cooling method of oil cooler is the same as that of the air rear cooler, with
air-cooled and water-cooler types. For poor ambient conditions, the fins of
air-cooled type cooler can be easily covered by dust and this will influence the
cooling effect, causing high discharge temperature and tripping. Therefore, after a
certain period, use low-pressure compressed air to blow the dust off the fin surface.
If blowing air cannot clean it, then solvent must be used. Keep the cleanliness of
the heat-dissipation surface of cooler. If pips-shell type cooler is clogged, it must
be immersed in special reagent solution, and the scaling inside the pipe must be
cleaned with mechanical means. Be sure to completely clean it.
(2) Oil filter
The oil filter is a paper filter. Its function is to remove the impurities in the oil, such
as metal particles, oil degradation, etc. The resolution is between 10-15 microns. It
can provide complete protection to bearings and rotors. Use the pressure
differential indicator to judge whether the oil filter should be replaced. If the
indicator lights up, it means that the oil filter is clogged and must be replaced. For
the first-time operation of new compressor, oil and oil filter must be replaced after
500 hours of operation. Afterwards, it should be replaced whenever the indicator
lights up. If the oil filter is not replaced at large pressure differential, it can lead to
insufficient volume of injected oil, causing high discharge temperature and tripping.
Insufficient oil volume also affects the life of bearings.
22
(3) Air/Oil Separator
The filter element of air/Oil Separator is made of multi-layer fine glass fiber. The
misty oil air contained in compressed air will be almost completely removed (below
3 ppm) after passing through air/Oil Separator. Under normal operation, the quality
of coolant liquid and the pollution condition of surrounding environment have large
influence over its life. If the environment is heavily polluted, it is suggested to add a
pre – air filter. Special screw oil must be chosen as the coolant liquid. Safety valve,
relief valve and pressure maintaining valve are installed at the outlet of air/Oil
Separator. The compressed air exits here and is sent to rear cooler.
The oil filtered by air/Oil Separator is gathered in the small circular grove in the
center, then flows back to the bearing end of airend through oil return pipe. This
can prevent the filtered coolant liquid from being discharged along with air.
Generally, the following methods can be used to judge whether the air/Oil
Separator is damaged:
a) Increased oil content in the airline.
b) Air/Oil Separator has service life, When oil separator is blocked,the Air/Oil
Separator should be replaced immediately.
c) If the oil pressure is higher than that of the air pressure, the oil separator is
blocked seriously, and even overload protection occurs.
d) Check the oil pressure to see if it is too high.
e) Check the current to see if it is increasing.
(4) Thermal Valve
There is a thermal Valve at the front end of oil cooler. Its function is to maintain the
discharge temperature so that it is over the pressure dew point temperature. When
the compressor is just started, the temperature of coolant liquid is low. Then the
thermal Valve will automatically open the oil return loop so that the oil flows into
airend without passing through oil cooler. If the temperature of oil rises above 67℃,
the valve will open gradually and becomes fully open at 72℃. Then all the oil will
pass through oil cooler before entering airend.
4.3 Cooling system
1、Air-cooled compressor
Cool air is drawn by a circulating fan, and passes through the heat-dissipation fins
of cooler. It exchanges heat with compressed air and coolant liquid to achieve
cooling effect. The maximum allowable ambient temperature of this cooling
system is 45℃. If the ambient temperature exceeds 45℃ (e.g., located beside
boiler, etc.), the system could trip due to high temperature.
2、Water-cooled compressor
The water temperature design basis of cooling water is 32℃ and therefore it is
required to pay special attention to design of the cooling water circulation system,
especially that the cooling water quality must conform to the common industrial
water standard and above. If the water quality is poor, it is required to regularly
add softener into the cooling water tower to avoid scaling which might affect the
efficiency and service life of the cooler. Besides, water circuit of the cooler shall be
cleaned once every half a year. In winter, at regions with environment temperature
below 0℃, it is also required to discharge cooling water in the cooler after
shutdown in case of frost cracking.
23
System Flow—water-cooled compressor
System Flow—Air-cooled compressor
24
4.4 Safety Protection System and Warning Devices
1 Motor overload protection
There are two main motors within the air compressor system. One is the main motor for air
compressor, the other is the fan motor. If the motor current continuously exceeds the
upper limit set by protection device, the protection device will automatically switch off main
power supply within set time, thus stops the compressor. At this moment, find the origin of
current overload and eliminate the source. The protection device must be reset for the
compressor to be started again. The resetting method is to manually press the reset key of
setting switch. The common reasons for motor overload d include:
(1) Human error during operation: such as improper adjustment of discharge pressure and
system, etc.
(2) Mechanical failure: such as motor internal wear, motor phase loss operation, safety valve
failure, system setting failure, clogging of air/Oil Separator, etc.
(3) When motor overload occurs during operation, contact manufacturer immediately. Send
personnel to give inspection and locate the reasons. Otherwis e the motor can be
damaged, causing great loss.
2 High discharge temperature protection
The maximum discharge temperature set for the system is 95℃. If this value is exceeded,
then system will automatically switch off power supply. There are many reasons why
discharge temperature is too high, but the most common one is the failure of oil cooler.
For air-cooled type oil cooler, if the heat-dissipation fins are clogged by dust, the cool air
cannot pass through cooler freely, and then the temperature of coolant liquid will rise
gradually and cause high-temperature tripping. Therefore, use low-pressure air to blow
off the dust on heat-dissipation fins periodically. If it cannot be cleaned by air blowing,
then it is best to be cleaned by detergent or solvent.
Designed maximum ambient temperature of air compressor is 40 ℃. Therefore, it is
necessary to select a site with low ambient temperature and good ventilation to install air
compressor.When the discharge temperature is too high, the starting circuit colud be cut
off, the system can not start again, reset and restart the system.
3 Alarm devices
There are three types of alarm devices in the system: air filter clogging, oil filter clogging
and air/Oil Separator clogging. Theirs indicators are all located on the instrument panel.
When indicator illuminate, certain filter is clogged. Then the user must replace it with
spare parts in the shortest time possible. Otherwise the compressor performance and
operational safety will be jeopardized.
25
4.5 Control System and Electric Circuit
1 Control system
(1) Motor starting
During this period, the air inlet valve is fully closed and the relief valve is fully open. At this
moment, there is high vacuum on the air inlet side. Coolant liquid for compression
chamber and bearing is guaranteed by pressure difference between the vacuum in the
compression chamber and atmospheric pressure in the air/oil separator tank.
(2) Full-voltage operation of motor
The motor keep the lowest speed 10s then the relief valve is closed. At this moment, the
pressure inside the air tank gradually increases and the air inlet valve slowly opens. Thus
the pressure inside the air/oil separator tank rises rapidly, so that air inlet fully opens and
the compressor starts full-load running. When the pressure rises to 0.45MPa, the pressure
maintaining valve fully opens and the air is sent out.
(3) Heavy load /zero load operation (probably load/unload operation)
When the discharge pressure reaches the upper limit of the control system, cut off the
drain valve of the power of the control system, solenoid valve is opened, inlet valve is also
closed and the air inside the air/oil separator tank is discharged into the atmosphere, then
the compressor is running under no load condition, the system pressure maintained at
around 2 ~ 4 kg / cm2.
(4) Shut-down
Press the OFF key, the relief valve fully opens. The air inside the air/oil separator tank is
discharged into the atmosphere. After the pressure inside the air/oil separator tank is
below certain value, the motor will stop.
(5) Emergency shut-down
If the discharge temperature is over 100℃ or the current protection device acts due to
overload of motor, the power will be switched off and the motor will be stopped
immediately. Zero/heavy load solenoid valve and air inlet valve will be closed, and the
relief valve will fully open so that coolant liquid cannot enter compressor anymore. Only
when there is abnormal emergency during unit operation may the emergency key
be pressed. Otherwise it may cause system failure and oil ejection from air inlet
port.
(6) Automatic shut-down after long period of zero load operation
When the air consumption of the system reduces, the compressor will continue zero load
operation. If the time of zero load operation exceeds the set value, the c ompressor will
automatically shut down and the motor will stop. When the air consumption of the system
increases, the system pressure will decrease. Then the air compressor will automatically
start to replenish air. Time setting for zero load shut down should be that the motor
starting frequency per hour will not exceed three times. Use can decide the time setting
based on actual usage condition. Do not start motor too often as this may burn the
motor.
26
2 Electrical circuit
Electrical control of the compressor can be divided into two systems. One is the
internal control system and the other is the starter panel. Starter panel is a Y-△or
inverter control used for general machinery. The controller portion is electronic control.
Due to the complicated internal wiring and control of the electronic controller, it will not be
explained in detail in this chapter. If any damage or malfunction occurs, please contact
directly with service departments and replace the electronic circuit board.
27
 28

F
C
B

D
A
1

GND
55
CT4

M
R

U1
S

U2 V2
V1
T

S
W2
W1
CT5
3-AC Actual voltage

56
FU1
2

S01

D
实际电压
Actual voltage
PT1

25V
R11
220V
S11
Actual voltage /25V 20VA

FAN1
F
FU3
FU2
Actual voltage/220V 80VA/140VA

S
T
FIT
S2
S1

FIR
R2
R1

GND
GND
VST
T

59
57
58
S01

GND
3

ST
Fan current T

Fan current R

GND Voltage signal

Voltage detection input

REVISION RECORD ( MARK

1
JP4

)
101
DI0 1 Air filter clogged input
102
DI1 2
Oil filter clogged input/ Remote stop input
103
DI2 3

MARK Q'TY
Oil fine separator clogged input/ Remote start input
4

104
DI3 4
JP5

105 EMG Pressure switch input

DI4 5
DR.

XGD 1 100 Emergency stop/reset input

DATE

APP'D
CHK'D

S1 GND 6
CHANGE AUTH. NO. PART NO.

ACIN2 2 Control Power

S2 A 7
ACIN3 3 AC25V RS485(INV)
B 8
Crystal
2018-03-08

Bene.Y
Liang ronghong
UNIT
JP1

SCALE
MODEL
-

50
JP3

MATERIAL

PIN+ 1 Discharge pressure input

R1
R2

51 4~20mA,0~1.6MPa
HS2203-J019002-B

ACIN0 1 PIN- 2
5

52
-

ACIN1 2 TIN- 3
DF

SA15-90

17 53 Discharge temperature input

-

SV 3 TIN- 4
Relief solenoid valve Pt100，0~200℃
F

16
-

KF 4 54
TIN+ 5
15 Fan output
TITLE

RCS 5 55
I1 6
WEIGHT

The main motor current R

S

14 56
KS 6 Y Magnetic contactor output I2 7
13 The main motor current T
RCD 7 57
FIR 8
S

Fan current R
D

12 58
KD 8 FIT 9
△ Magnetic contactor output
M

11 59 Fan current T
KM 9 VST 10
M output
ST
GND Voltage signal
GND 11
SHEET
6

Released
DRAWING STATUS LEVEL

1 OF
1
REV

SIZE
A
A4
Power frequency starter electrical schematic
 29

F
C
B

D
A

Type
108
100

DELTA
PIN
XT1

Zhongchen H3000
Name

Zhongchen H6000S
M
R

U R
1

INV ALARM

X1
FWD
FWD
S

V INVERTER S

MOTOR
T
3~AC380V
T

INV START

SC
DCM

COM
0/4~20mA

INV START
FU2
FU1

42
41
S01
R01

72
70

FIC
FIC
ACI
FAN1

KA1

0/4~20mA
F1

FC
GND
ACM
S
T
PT1

FIT
FIR

GND
GND
VST

YC
YC
RC1
R11

25V
220V

T
S11

59
57
58
/25V 20VA

S01

GND
GND

INV ALARM
ST
2

YA
YB
RA1
FU4
FU3

Fan current T

Fan current R

Voltage signal
380V/220V 140(230/480/610)VA

Voltage detection input

S2
S1
R2
R1

FAN2,3
OPTION
F2,3

OL2,3

R2
R1

F1

AF
3

AC220V Fan
P1
-

50
PIN0+ 1
Discharge pressure input
51
PIN0- 2 4~20mA,0~1.6MPa
37
-

52
TIN- 3
-

53
J1

Main motor Discharge temperature input

REVISION RECORD ( MARK

TIN- 4

1
temperature switch
-

Pt100，0~200℃
+

)
54
TIN+ 5
55
I1 6
56 The main motor current R
I2 7
P5

MARK Q'TY
57 The main motor current T
4

XGD 1 FIR 8
S2 Controller power 58 Fan current R
ACIN2 2 FIT 9
DR.

S1 AC25V 59 Fan current T

DATE

APP'D

ACIN3 3
CHK'D

VST 10
ST
R2

CHANGE AUTH. NO. PART NO.

GND Voltage signal

GND 11
P3
R1 M

18 106
ACIN0 1
P6

M output Remote start input

ACIN1 2 DI5 1 Remote stop input
Crystal

Bene.Y
Bene.Y
1-30-2018

17 107
DF1

SV 3 DI6 2
Load valve
16 108 Inverter fault
J1

KF 4 DI7 3
UNIT

Fan output
SCALE

Comprehensive external fault

MODEL

60
OL2,3

RCS 5 PIN1+ 4
MATERIAL
F1,F2

HS202-J01E422-A
-
+

61 Receiver pressure input

KS 6 PIN1- 5
4~20mA,0~1.6MPa
100
5

RCD 7 GND 6
SAV22-90

KD 8 A2 7 A2
11 B2 RS485(INV)
KM 9 Inverter start B2 8
KA1 F3

TITLE

WEIGHT
P4
P2

Fan output
72 101
AO1 1 Analog output DI0 1 Air filter clogged input
71 4~20mA 102
AO0 2 DI1 2
Oil filter clogged input
70 Pressure output 103
GND 3 DI2 3
Oil fine separator clogged input
104
NC 4 DI3 4 Pressure switch input
Variable frequency

84 105 EMG
K03 5 DI4 5 Emergency stop / reset input
SHEET

Fault output
83 100
KAC 6 GND 6
6

Electrical schematic（1）

1
Released
OF
DRAWING STATUS LEVEL

82 A1
KA02 7 Run output A1 7
81 B1 RS485
KA01 8 B1 8
2

N/R control output

REV

SIZE
A
A4
 30

E
C

F
B

D
A
1
2

XT2下層
XT2上層

101 50
Air filter clogged Discharge pressure
100 51
Oil filter clogged
102 52
103 Discharge temperature 53
Oil fine separator clogged
100 54
Pressure switch
104 60
Receiver pressure
106 61
3

Remote start
100 17
Remote stop Load valve
107 R2
108 100
Comprehensive Emergency stop
external fault 100 105

REVISION RECORD ( MARK

70 R1

) 1
Emergency stop
Analog output 72 18
R1
Main motor
41 temperature switch 37
MARK Q'TY
4

Inverter start
42 AF
AC220V Fan
DR.

A2 R2
DATE

APP'D
CHK'D
CHANGE AUTH. NO. PART NO.

RS485(INV) B2 81
N/R control output
82
Run output
83 83
Crystal

Bene.Y
Bene.Y
1-30-2018

Fault output 84
UNIT

SCALE
MODEL

MATERIAL
HS202-J01E422-A
5

SAV22-90
TITLE

WEIGHT
Variable frequency

SHEET
6

Electrical schematic（1）

OF
Released
2
DRAWING STATUS LEVEL

2
REV

SIZE
A
A4
 Chapter 5 Operation
5.1 Pilot running
1. Connect power cord and grounding wire. Test main voltage and check the
balance of three-phase voltages.
2. Loosen the transport fixation bolts on the anti-vibration table of the base.
When moving the machine, fasten the transport fixation
bolts again to prevent damage of anti-vibration pads by
leaning or shock, or the displacement of anti-vibration pad.
3. Confirm that the oil level in the air/oil separator tank is between the two red
marks of the oil sight.
4. If pilot running is performed long after delivery, add ~0.5 liters of coolant liquid
from the air inlet valve. Then manually turn the air compressor several times to
avoid damage of compressor caused by oil loss during starting. In particular,
prevent any foreign matter from falling into compressor or it could be damaged.
Do not power the compressor at this moment.
5. Power the compressor control panel.
If the phases of power supply are mismatched, the electrical
malfunction indicator will light up.
6. Turning test: Press ON key, the compressor will rotate. Immediately press
Emergency Stop Key to verify the rotation direction of compressor. For correct
direction, refer to the arrow on compressor airend. If the direction is wrong,
exchange any two phases of the R, S, and T power cords. The direction of
cooling fan should also be checked.
Switch off power supply when dealing with electrical
equipment. Operation with power supply on is strictly
forbidden.
Although compressor has been tested during
manufacturing, the turning test is still an important step for
pilot running.
31
 Inverse-phase protection is for detecting the phase of
power supply. Turning test must be repeated after motor
maintenance.
7. Starting: Press ON key to start compressor.
This machine is completely automatic type,Y/∆
depressurization startup may need 15 seconds, delaying 3
seconds after switching, and inlet valve starts action.
8. Check display instruments and indicators. If there is any abnormal noise,
vibration or leakage, press Emergency Stop Key immediately to stop for
maintenance.
9. Stopping: Press OFF key, the compressor will automatically stop.
When OFF key is pressed, the relief valve of the compressor
will discharge and unload, and the timer relay will start
timing. The motor will stop after about 15 seconds.
Please do not use Emergency Stop Key for stopping the
compressor under normal circumstances.
5.2 Daily inspection before starting
The daily inspection before starting is the necessary work for the normal
operation of compressor and should be performed carefully.
1. Water drainage of air/oil separator tank: slightly open the water drainage valve
of air/oil separator tank and water separator to discharge the condensed
water formed during machine stop until there is coolant liquid in the water, then
the valve should be closed immediately.
Before opening the water drainage valve of air/oil separator
tank, be sure to confirm that there is no pressure inside the
air/oil separator tank.
2. Check the oil level: Add oil so that the level is in the middle of the upper and
lower limits of oil sight when necessary.
32
 Please use screw oil of FUSHENG. Do not mix with coolant
liquid of other brands or from other manufacturer.
Confirm that there is no pressure inside the system when
adding coolant liquid.
Observe the oil level 10 minutes after stopping the compressor. The oil level
during operation may be slightly lower than the level when the compressor is
stopped.
3. Preparation of peripheral equipments: Turn on power supply, cooling water
tower, water pump, open outlet valve of compressor, run the compressed air
drier.
4. Start the compressor.
5.3 Cautions during operation
1. Stop the compressor immediately if there is any abnormal noise or vibration.
2. There is pressure in both the piping and the containers during operation. Do not
loosen the bolt plug of pipeline. Do not unnecessarily open any valve.
3. If oil level does not show up on oil sight during long-term operation, and the oil
temperature rises gradually, immediately stop the compressor. Observe the oil
level after 10 minutes. If the oil is insufficient, wait until there is no pressure inside
the system and then add more coolant liquid.
4. The condensed water in the rear cooler and cyclone separator will be
automatically drained, but the outlet valve needs to be open, otherwise the water
will enter the system.
5. Check instrument and record voltage, current, air pressure, discharge temperature,
oil level, etc. every 2 hours during operation for future reference.
5.4 Handling method for long-term shut down
During long-term shut down, carry out the following procedures carefully,
especially for high humidity season or area.
1. Shut down for over 3 weeks
(1) Wrap the motor control panel and other electrical equipments with plastic or oil
paper to avoid moisture.
(2) Completely drain the water in the oil cooler and rear cooler.
(3) Repair any malfunction to facilitate future use.
(4) Drain the condensed water in air/oil separator tank, oil cooler and rear cooler
after several days.
2. Shut down for over 2 months
In addition to the above procedures, carry out the following treatments:
33
 (1) Seal all openings to avoid moisture and dust.
(2) Wrap safety valve, control panel, etc. with oilpaper or similar material to
prevent rusting.
(3) Replace coolant liquid before stopping usage and run for 30 minutes. Drain the
condensed water in air/oil separator tank and oil cooler after 2~3 days.
(4) Completely drain cooling water.
(5) Whenever possible, move compressor to dry and less dusty place.
3. Procedure of re-starting
a) Unwrap the plastic or oilpaper.
b) Measure the insulation of motor. It should be over 1M ohms.
c) Other procedures are the same as the pilot running.
34
 Chapter 6 Maintenance and Inspection
Please perform correct operation and maintenance according to the instruction
manual. Be sure to use genuine parts during maintenance. For malfunction and
mechanical damage due to usage of parts or oil not designated by us, our
company does not carry any warranty responsibility. For any uncertainties,
please contact our service department.
6.1 Coolant liquid specification and usage
The lubricant oil plays a vital role in the performance of oil-injected screw type air
compressor. When the air compressor is operating, the lubricant oil mixed the high
temperature and high pressure air for a long time, it will cause the cooling liquid
oxidation. At the same time, there may be water in the oil tank, which can make the
lubricant oil emulsification and reduce the service life of the lubricant oil. Therefore, in
the specified time, the customer must change the lubricant oil. When operating in
severe conditions it will be necessary to change the lubricant more frequently. If it is
improperly used, it will cause serious damage to the compressor airend, or even fire.
So，it must use the special lubricant oil of fusheng. The lubricant oil period we
specified is based on the airend discharge temperature 85℃。
1. The factors affecting coolant liquid changing time:
(1) Poor ventilation, high ambient temperature
(2) High humidity environment or rainy season.
(3) Dusty environment
(4) High content of certain chemical gas (such as O 2, O 3, Cl2, etc.) in the
environment.
2. Procedure of coolant liquid change
(1) Start the air compressor, increase the oil temperature to facilitate discharge.
Then press OFF key to stop operation.
(2) Open oil drainage valve when there is 0.1-0.2MPa pressure. The oil
discharge rate is fast so oil can be easily ejected. The valve should be
opened slowly to avoid spilling of coolant liquid.
(3) Generally, please add around 1/3 of the normal coolant liquid amount, start
and operate for 20min (the discharge temperature must be below 95℃),
stop it and fully discharge coolant liquid in the system while it is hot, which
will mainly clean old residue coolant liquid in the machine, guarantee and
prolong the performances and service life of new coolant liquid.
(4) Switch off oil drain and add new coolant liquid.
3. Precautions when using coolant liquid
(1) If the oil-injected screw type air compressor is used for the first time, the
first coolant liquid change should be performed after the 500-hour
grinding-in period of the coolant liquid. Then it should be replaced for every
3,000 hours (under normal circumstances, the discharge pressure is below
85℃.) If environment is poor and discharge temperature is higher, the
interval should be shortened.
35
(2) Do not extend the usage of coolant liquid beyond its life. Coolant
liquid should be replaced in time; otherwise, the quality of coolant
liquid will degrade and cause bad lubricity. This can easily lead to
high-temperature tripping and carbon deposition. The flammable
point of coolant liquid will also decrease, causing self-ignition and
burning of air compressor.
(3) When changing coolant liquid, it is the best to change the exclusive oil filter
and air/oil separator as well, to avoid old residue coolant liquid in them
which might affect the performances and service life of new coolant liquid.
(4) After 2 years of compressor usage, it is better to perform a “systematic
cleaning” with coolant liquid. The method is: when replacing with new
coolant liquid, run the air compressor for 6~8 hours, then change coolant
liquid immediately, so that various organic material remained in the system
can be completely cleaned. Then the newly replaced coolant liquid can last
longer.For the cleaning procedure of the upgraded special oil for screw
type air compressor, we have the following suggestions:
A: Start compressor, run for 1 hour under normal temperature. Shut down
the compressor
B: Immediately drain oil from air/oil separator tank, pipeline, oil filter, oil
cooler and water separator
C: Replace the filter element of compressor oil filter
D: Add special coolant liquid for screw air compressor till 50-60% of the
air/oil separator tank.
E: Start compressor, run for 1 hour under normal operating temperature.
During this period, open and close air discharge valve every 15 minutes,
so that the compressor works alternately under full=load and zero-load
conditions. Rising bubble will be seen inside the air tank and it will rise
until above the oil sight. The color of oil sight will change from milky
white to relatively clear.
F: Pay attention to the pressure differential across the coolant liquid filter. If
it exceeds 0.15MPa, the filter element should be replaced.
Shut down the compressor
G: As the coolant liquid is still warm, drain oil from air/oil separator tank,
pipeline, oil filter, compressor, oil cooler and water separator. Replace
oil filter element. Clean oil return filter net. Check if there is any oil
transition when the air is drawn into filter element. If yes, replace filter
element. If necessary, dismantle part of the pipeline to completely drain
the coolant liquid remaining at the lower positions (if the cleanliness of
the system is not ideal, then repeat step 4-6).
H: Add special coolant liquid for screw air compressor until specified oil
level.
I: Restart compressor. Check oil level and working temperature. When
Icompressor is functioning normally, the oil level should be above the
centerline of the oil sight.
J: After the compressor has been stopped, it may take 2 minutes for the
bubbles at the oil sight to disappear and this is considered normal.
36
6.2 Pressure Adjustment
1、System pressure adjustment
First, access the parameters of the controller screen (requires the password), then
access the control screen. access pressure setting screen by pressing up and
down button(↑↓) , then you can change the loading \ unloading pressure. First
set loading pressure and demand at unloading pressure below the set pressure
loading value,. Then set the unloading pressure value. When setting is completed,
loading / unloading pressure difference is determined (loading and unloading
pressure difference can be adjusted according to on-site condition, and minimum
pressure difference should be no less than 0.15MPa). After setting parameters,
exit the parameters screen, at this time required to enter the password again to
acesee the screen and set the value. At this point, access control query screen,
you can query the current loading / unloading pressure, but not modify.
6.3 Replacement of Consumable
1. Air filter
When compressor has operated for 500 hours, or the air filter pressure differential
indicator illuminates, remove the air filter and clean it. Normally it should be
replaced every2,000 hours, and shorter interval for poorer environment.
2. Oil filter
The first time replacement should take place after 500 hours of compressor
operation, and normally every 3,000 hours afterwards.
3. Separator element
When the air/Oil Separator pressure differential indicator illuminates, or the oil
pressure is higher than the air pressure, then inspection must be performed and
air/Oil Separator must be replaced. The normal replacement interval is 3,000
hours. Shorter interval for poorer environment.
The replacement procedure for air/Oil Separator is:
(1) After stopping the air compressor, close air outlet and open water drainage
valve, and verify that there is no pressure in the system.
(2) Dismantle the pipeline above the air/oil separator tank, and remove the
pressure-maintaining valve.
(3) Remove oil return pipe.
(4) Remove the fixation bolts on the upper cover of air/oil separator tank, and
rotate the shaft bolt at the edge of upper cover to slightly lift the upper cover.
Then rotate upper cover counter clockwise (viewed from top) to open it.
(5) Remove air/Oil Separator and replace with new one.
(6) Assemble the air/oil separator tank in reverse sequence.
Prevent unclean items from falling into air/oil separator tank
when replacing air/Oil Separator, thus maintaining the
normal operation of air compressor.
37
5. Coolant liquid
First time oil change should be performed after about 500 hours of compressor
operation. Then every 3，000 hours afterwards (discharge temperature is below
85℃). If environment is poor and discharge temperature is higher, the interval
should be shortened.
SA55-90 Classical Serial Screw Air Compressor Consumables
Type Coolant liquid（L）
SA55 55
Standard SA55 60
SA90 65
SAV55 55
VSD SAV75 60
SAV90 65
38
6.4 Maintenance and Troubleshooting
. Daily Maintenance
1. Daily or every time before starting: same as the inspection before pilot running
(refer to previous section)
2. After 500 hours of operation:
(1) Remove the air filter element for cleaning. Use low-pressure (below
0.2MPa )compressed air to blow it from inside.
(2) Replace oil filter
(3) Replace lubrication
3. After 1000 hours of operation:
(1) Check the action of air inlet valve and moveable parts, and add grease.
(2) Clean the air filter.
(3) Inspect the pipe joint fixing bolts and wire terminal fixing bolts
(4) Replace air filter element
(5) Repace oil filter
4. After 2000 hours or 6 months of operation
(1) Check all pipelines
(2) Fill electric motor grease
5. After 3000 hours or 1 year of operation
(1) Clean air inlet valve.
(2) Check all solenoid valve
(3) Check the relief valve
(4) Replace the air/Oil Separator
(5) Replace the lubrication
(6) Check pressure maintaining valve
(7) Clean cooler, and replace O-ring
(8) Replace air filter element and oil filter element
(9) Check the action of starter
6. After 6000hours
(1) Clean oil system
7. After 20000 hours or 4 years of operation
(1) Replace airend bearing and all oil seal, and adjust clearance.
(2) Measure the motor insulation, which should be above 1M ohms.
39
6.5 Motor maintenance
Maintenance:
The operating environment shall always be kept dry and the motor surface shall
be kept clean. The air inlet shall be away from the obstruction by such sundries as
dusts and fibers, etc.
In the event of continuous action of the thermal protection and short circuit
protection of motor, it is required to check if the fault lies in the motor, or overload,
or too low setting value of the protective device. After troubleshooting, it can be
put into operation.
Please guarantee good lubrication of motor bearing during operation by adding
lubricating grease regularly and quantitatively as per the period and brand
specified on the motor grease label.
Since aging of the grease will be accelerated along with the temperature rise, it is
required to reduce by half the adding interval for every temperature rise of 15℃
after 70℃, but the final temperature shall not exceed 120℃. When the
temperature is lower than 70℃, the interval can be properly prolonged, but the
interval shall not exceed 3000h even if operating at low temperature.
When greasing, it is required to inject grease into the grease cup with grease gun.
Before greasing, please take down greasy blockage on the grease drain pipe first,
then connect plastic pipe and draw grease out of the motor. After greasing, please
take down the plastic pipe and screw down the greasy blockage.
40
6.6 Troubleshooting Table
Item Malfunction Possible Causes Recommended Action
Compressor 1. Fuse burned 1. Contact electrical technician for
does not start 2. Protection relay inspection and replacement
(electrical energized 2. Contact electrical technician for
malfunction 3. Start relay inspection and replacement
indicator malfunction 3. Contact electrical technician for
illuminates) inspection and replacement
4. Poor contact of start
push-button 4. Contact electrical technician for
5. Low voltage inspection and replacement
6. Motor malfunction 5. Contact electrical technician for
（1） 7. Airend malfunction
inspection and replacement
6. Contact electrical technician for
8. Phase loss protection
inspection and replacement
relay energized
7. Manually rotate airend. If it
9. IC plate
cannot rotate, contact service
malfunction(vsd)
department
10. Inverter
8. Inspect power supply wiring and
malfunction(vsd)
each terminal
9. Replace IC plate (vsd)
10. professional check (vsd)
High operating 1. Low voltage 1.Contact electrical technician for
current, 2. Discharge pressure inspection and replacement
automatic too high 2.Check pressure gauge. If it is over
tripping of 3. Wrong coolant liquid set pressure, adjust pressure switch
compressor specification 3.Check oil code. Replace oil
(electrical
4. Clogging of air/Oil 4.Replace air/Oil Separator
malfunction
Separator (high 5.Manually rotate airend. If it cannot
indicator
illuminates) pressure of coolant rotate, contact service department
（2） liquid)
6.Inspection and repairing
5. Compressor airend
7.clean or replace
malfunction
8. Inspection and repairing
6. Poor contact of
electrical terminal 9.Contact electrical technician for
inspection
7. Clogging of cooler
(vsd)
8. Motor malfunction
9. Inverter show over
load (vsd)
Operating 1. Air consumption too 1. Check consumption rate. Add
current is below high (Operating with compressor when necessary
normal value pressure below set 2. Clean or replace
value)
3. Remove, clean and add lubricant
（3） 2. Clogging of air filter grease
3. Air inlet valve failure 4. Reset adjustment (vsd)
(stuck)
4. Inverter or controller
setting wrong (vsd)
41
Item Malfunction Possible Causes Recommended Action
Discharge 1. Cooling water quantity 1. Adjust the outlet valve of cooling
temperature is too large water. If it is air-cooled cooler,
lower than 2. Low ambient reduce the heat-dissipation area
normal value temperature of cooler
(below 70℃) 3. Incorrect discharge 2. Adjust the outlet valve of cooling
temperature gauge water. If it is air-cooled cooler,
(4) reduce the heat-dissipation area
4. Thermal Valve failure
of cooler
5. Oil flow too large
3. Replace discharge temperature
gauge
4. Replace thermal Valve
5. Add flow-limiting joint in the oil
line
High discharge 1. Insufficient amount of 1. Check oil level. If it is lower than
temperature. coolant liquid “L”, stop compressor and add
Automatic 2. Insufficient amount of coolant liquid to “H”.
tripping of cooling water 2. Check the temperature
compressor. 3. High temperature of difference between water inlet
High discharge cooling water and outlet pipes.
temperature 3. Check the temperature of
4. High ambient
indicator incoming water
temperature
illuminates (high
4. Increase air discharge volume,
than set value 5. Clogging of oil cooler
lower the room temperature
by 100℃) 6. Wrong specification of
coolant liquid 5. Check the temperature
difference between water inlet
7. Thermal Valve failure
and outlet pipes. It should be
8. Unclean air filter 5℃ normally. If it is over 9℃, the
9. Clogging of oil filter oil cooler may be clogged.
(5) 10. Cooling fan Remove and clean with reagent.
malfunction 6. Check coolant liquid code and
11. Clogging of air replace.
passage in the 7. Check if the coolant liquid is
air-cooled cooler cooled by oil cooler. If not, then
12. Temperature switch replace thermal Valve.
malfunction 8. Clean air filter with low-pressure
13. Mixing of different air.
coolant liquid 9. Replace oil filter
10. Replace cooling fan
11. Clean cooler with low-pressure
air.
12. Replace
13. Clean and replace with correct
coolant liquid
42
Item Malfunction Possible Causes Recommended Action
If there is 1. Oil level too high 1. Check oil level and drain until it is
too much 2. Oil return pipe orifice between “H” and “L”
coolant blocked 2. Remove and clean
liquid 3. Low discharge pressure 3. Raise discharge pressure (adjust
content in pressure switch to set value)
the air, the 4. Air/Oil Separator damaged
filling 5. Spring fatigue of pressure 4. Replace with new one
interval of maintaining valve 5. Replace spring
(6)
coolant
liquid will be
shortened.
The filter
generates
smoke
under zero
load
Compressor 1. Pressure switch 1. Replace with new one
current full malfunction 2. Remove and clean, then add
load 2. Air inlet valve failure lubricant grease
3. Pressure maintaining 3. Remove and check valve seat
valve failure and check valve element for any
(7) 4. Leakage from control wear, replace when necessary
pipeline 4. Check position of leakage and
5. Relief solenoid valve tighten
failure 5. Check the line and valve, replace
6. Shuttle valve failure when necessary
6. Inspect or replace
Compressor 1. Pressure switch failure 1. Inspect and replace when
cannot 2. Air inlet valve failure necessary
unload. 3. Relief solenoid valve 2. Remove and clean, then add
pressure is failure (winding damaged) lubricant grease
kept at 3. Inspect, replace when necessary
(8) 4. Air volume adjustment film
working
damaged 4. Inspect and replace
pressure or
keeps going 5. control panel failure 5. Replace the control panel
up. Safety
valve
operates
43
Item Malfunction Possible Causes Recommended Action
Air quantity 1. Air inlet filter clogged 1. Clean or replace
lower than 2. Air inlet valve failure 2. Remove, clean and add lubricant
normal 3. Pressure maintaining valve grease
failure 3. Remove and check valve seat
4. Air/Oil Separator clogged and check valve element for any
wear, replace when necessary.
5. Leakage of relief solenoid
(9) Replace when there is spring
valve
fatigue
6. Inverter setting wrong (vsd)
4. Inspect and replace when
necessary
5. Inspect and replace when
necessary
6. Reset (vsd)
Frequent 1. Pipeline leakage 1. Check leakage position and
empty and 2. Small pressure difference fasten
load setting between the upper 2. Reset (common pressure
and lower limit difference is 0.2MPa)
(10)
3. Unstable air consumption 3. Increase air tank capacity
4. Untight pressure sustaining 4. Overhaul or replace valve
valve element sealing and element or spring
spring fatigue
Coolant 1. Air inlet valve malfunction 1. Check if he air inlet valve is
liquid mist is 2. Wrong electrical wring stuck. If yes, remove, clean and
ejected from add lubricant grease
3. Leakage of pressure
air filter maintaining valve 2. Contact electrical technician for
(11) when inspection and replacement
4. Air/Oil Separator damaged
compressor 3. Inspect and replace when
is stopped necessary
4. Replace
44
Operation Record of Screw Type Air Compressor
Month
Time
Item
(1)Air/oil separator
tank level
(2) Air filter
(3) Oil filter
(4) Air/Oil Separator
(5) Operating current
(A)
(6) Operating voltage
(V)
(7) Discharge
pressure
(MPa)
(8) Discharge
temperature (℃)
(9) Coolant liquid
pressure (kg/cm2G)
(10) Running hour
(hour)
Recorder
Remark
Note:
(1) For·ark “√” if it is normal, and mark “×” if it is not (must be repaired)
(2) Record numerical value for item 5-10.
45
East China sonuth of North China northeast of South China southwest
the sales department the sales department of the sales department
ADD: No.28 ADD:15# Liye Road, ADD: 12# Torch Road
International Information Hi-Tech Development zone,
Minyi Road, Xinqiao Town,
Park ,HuiLongGuan, ChangPing ZhongShan City,
Songjiang District,
County, BeiJing GuangDong Province
Shanghai city
ZIP：201602 ZIP：102206 ZIP：528437
TEL：021-6270 4880 TEL：010-6973 2555 TEL：0760-8559 1551
FAX：021-6270 4878 FAX：010-6973 2299 FAX：0760-8559 1552
FUSHENG CO.，LTD companies to reserve end right to interpret vs the manual
A Edition