Doc. No.

:
OPERATOR MANUAL
Date: 2011/10/18 Rev. A

SA220A/W～280A/W Serial
Screw Air Compressor

OPERATOR MANUAL
Thank you for purchasing Fusheng screw air compressor!

FU SHENG Company enjoys the right to modification of the design.

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Note: 1 ． If not specially indicated, all the pressures mentioned in this

instruction manual refer to gauge pressure;
2 ． When the user contacts the company regarding compressor
problems such as maintenance, service, etc, please indicate the
machine model and pressure level stated in the name- plate of the
machine and in the warranty card.

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Machine set model ___________________

Mainframe NO.__________________
Debugging date __________

2
 Introduction

Thank you for purchasing Fusheng screw air compressor.

Our products have been strictly checked and tested before leaving factory.
To ensure that the machines are used in safe, credible and durable conditions,
please read the instruction manual carefully before using our machines. In
order to ensure the longevity of the machine, please read and understand the
operation regulations and techniques of the air compressor unit before use.
In order to activate the warranty and be eligible for after-sale service,
please mail the quality assurance card to the service department of Fu Sheng.

Thanks!

3
 Safety warning
Please read the following items carefully before operating the air compressor:
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Safety warning:

1. While installing tube welding, make sure no flammable articles are in the
vicinity. Be careful not to allow any sparks to fall into the compressor.

2. The diameter of the power supply wire should comply with the voltage that
the machine is designed to receive. The safety devices such as the air
switch and electrical fuse should be installed to ensure the safety of the
electric appliance. Ground protection installation and lightening protection
can be installed if necessary.

3. Debugging of the new machine must be conducted under the supervision of

a debugging technician appointed or qualified by our company.

4. Confirm that no articles, tools, or people are inside the unit before closing
the unit’s door and starting. Inform the surrounding personnel before starting
the engine.

5. When starting the compressor for the first time or altering the power line,
ensure that the host engine and fan rotate in the same direction as the arrow
points (normal direction).

6. Pressure should not exceed exhaust pressure stated on compressor name

plate.

7. Forced starting of the compressor is prohibited when the air compressor has
problems or any other unsafe factors exist. The power supply should be cut
off immediately with a warning signal.

8. Compressed air and electric appliances are dangerous. Power should be

cut off while checking or maintaining, and a warning notice, such as
‘inspection’ or ‘do not switch on’ should be placed next to the control
switches in order to prevent injury to operators.

9. The corresponding outgoing separating valve of the air compressor should

be closed while maintaining, and maintainers should avoid any exhaust
outlet in the compressor system. Maintenance should be conducted only
after the machine has cooled down completely.

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10. While cleaning the spare parts, a non-corrosive safety solvent should be
used. Using any flammable, explosive, and/or volatile washing agents is
strictly forbidden.

11. The protection system, such as the safety valve of air compressor should
be inspected after use to ensure sensitivity. The safety valve should be
checked periodically (one time per year).

12. It is highly recommended that spare parts of the air compressor be

provided by our factory. Screw oil should be the super coolant produced
by Fusheng Company. The mixing of oil and oil brands is strongly
prohibited. Doing so may cause serious accidents and or system coking.

13. If shut down in winter, the oil cooler and the cooling water from the rear
cooler of air compressor must be discharged completely to prevent
corrosion and frost.

14. The air compressor should be operated by personnel who have read and
understand the instruction book, and follow the operational and
maintenance procedures and regulations in the book.

Warning：
Any action violating the safety precautions may result in serious
injury.

5
 Directory
General Rules for using the Screw Type Air Compressor................................... 7
Installation Details of Air Compressor................................................................. 10
System flowchart of SA220A~SA280A............................................................... 15
System flowchart of SA220W~SA280W............................................................. 16
System Flowchart..................................................................................................17
Safety Protection System and Alarm Device......................................................22
Control System and Electric Circuit.....................................................................24
Schematic Drawing of the Electric Control(SA220A～SA280A)................. 30-33
Schematic Drawing of the Electric Control(SA220W～SA280W)............... 34-37
Operations............................................................................................................. 38
Warranty.................................................................................................................41
Maintenance and Inspection................................................................................ 42
Daily maintenance and troubleshooting..............................................................45
Motor Maintenance............................................................................................... 46
Failure Handling List............................................................................................. 47
Screw Type Air Compressor Running Records..................................................51

6
 General Rules for using the Screw Type Air
Compressor
Ⅰ. Introduction to the oil injection screw compressor:
The oil injection screw air compressor is fast becoming dominant in the
world of compressors, known for its reliable performance including low
vibration, low noise, high efficiency, and durable components, thus
possessing a large advantage over piston type compressors of the same
discharge pressure. The precise matching between Yin and Yang rotors as
well as between the rotor and the casing reduces the gas reflux leakage,
greatly improving the efficiency. Features, such as the intermeshing
engagement of the rotors reduce the vibration source and noise source.
The unique lubricating system holds the following advantages:
1、By relying on the pressure difference generated on its own, lubricating oil
is continuously injected into compression chamber and bearings, thus
simplifying the complex mechanical structure of the machine.
2 、 The injected lubricating oil forms an oil film between the two rotors,
allowing the main rotor’s power to drive the auxiliary rotor, eliminating
the need for a secondary motor and precision timing gear.
3、The injected lubricating oil forms a seal between the rotors, decreasing
air loss, thus increasing efficiency.
4、The lubricating oil also reduces noise generated by rotor rotations and
motor vibrations associated with high frequency compression.
5、The lubricating oil absorbs a large quantity of compression heat, allowing
for the single stage compression ratio, which builds to 16, to continue
function efficiently, under carbonizing and the deteriorating of
temperature occurring inside the compressor. It also reduces friction to
a negligible amount between the rotor and the casing.

Ⅱ. The construction of oil injection screw compressor

1、Body construction:
The oil injection screw type air compressor produced by FuSheng is a
rotary type compressor of twin shaft positive displacement. The air inlet is
located at the top of casing, and the air outlet is located at the bottom of the
casing. A highly precise main rotor and auxiliary rotor are horizontally
installed in the casing. The main rotor holds five teeth, and the auxiliary
rotor holds six teeth, which are the twisted shape of the rotors. The two
rotors mesh to each other, and are supported by bearing at each end of the
casing. The machine set adopts what is known as “direct drive type”,
namely relying on one clutch to connect the motor and main machine body
together, and then through a group of high accurate, high speed increasing
gears to drive the rotation of main rotor.
2、Mesh:
The motor drives the main rotor through the coupling and the increasing
gears. From the lower portion of compression casing, lubricating oil can be
straightly injected into the meshed part of rotors via nozzles and mixed with
air. It can take away the heat produced during compression procedure. At

7
 the same time, it can form an oil film to prevent metal rotors from direct
contact and to seal the clearance between yin and yang rotors, and the gap
between the rotors and casing. The injected oil can also reduce the noise
generated by high-speed compression. According to different discharge
pressure, the weight of injected oil is approximately 5-10 times of the air
discharged.
Ⅲ. Compression principle
1、Aspirating:
The rotor apparatus has no air inlet or exhaust valves. Rotation of the
rotors creates a de-meshing of the male and female teeth, forming a
vacuum, into which, air flows due to pressure difference, as shown in figure
(a). After that, the tooth of Yang rotor will increasingly deviate from the tooth
space of Yin rotor, and the space containment expands continuously. When
the space containment reaches a maximum state, the inter-tooth space
containment will depart from the stomata aperture and the aspirating
course ends.

2、Compressing and oil injecting:

When the aspirating course ends, the air is enclosed in a close space by
the rotor tooth and casing. With the rotating of rotor, the space
containment will be continuously reduced due to intermeshing of rotors,
and the air pressure enclosed in the said space will raise the desired
compression pressure, as shown in figure (c). The compressing course will
continue until the space between teeth meets the exhaust vent. In the initial
stage of the compression course, the lubricating oil is injected into the
compression chamber, due to pressure difference, in which it is mixed with
air.

3、Exhaust process:
After the containment space connects with the exhaust vent, the exhaust
process begins. As the rotors turn, the compressed air in the containment
space will discharge, or exhaust as seen in figure (d). At the exhaust vent,
the male and female Teeth mesh, completely closing the containment
space. The air that had been in the containment space has continued
through the compressor, effectively ending the exhaust process.

Aspirating Process Seal and Delivery Process

Fig a Fig b

8
Compressing and Oil-injecting Process Exhaust Process

Fig c Fig d

9
 Installation Details of Air Compressor
1. Installation
Site selection:
When selecting the installation site of air compressor, make sure that the
machine is placed in a location that allows it to run normally and is
accessible for repairs. An optimal position is vital for proper use of air
compressors.
1) The air compressor must be installed indoors. There should be
adequate lighting for the safe operation and repair of the compressor.
2) Low relative humidity, little dust, clear air, and good ventilation are
needed at the installation location.
3) To avoid unnecessary shut down, the ambient temperature should be
lower than 40*C. The higher the temperature is, the less air the
machine can output. The ambient temperature however, can not be too
low. It is recommended that the temperature of the environment in
which the compressor is working, should be higher than 5*C in order to
keep the lubricating oil from solidifying and the water cooler from
possibly cracking.
4) If the factory is located in a dusty environment, install ventilation pipes
on the machine allowing air intake from a dust-free place, or a
preposition filter facility in order to keep the parts durable.
5) Leave enough maintenance space; at least 1000mm is needed
between the air compressor and the wall.
6) Install a crane which is used for reservation.
7) If the compressor is an air cooling type, the ventilation is very important.
Please concern to install extractor equipments. The area of the air inlet
should be enough. Please install the air guide cover to let the hot air out
from the air guide pipe, and the room temperature will maintain 5~40℃.

Roof fan

Heat outlet
Fan

Air inlet

Wind flow sample

User must install canvas active junction on the air outlet pipe in favor of
reservation. (Keep enough area to uninstall the components on the
compressor cover when cleaning the cooler.)

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 Hot wind outlet
Ventilation fan

Wind guide pipe

Wind flow sample

If the compressor is installed in a closed room,

the extra ventilation fan should be installed to
keep the room temperature suitable. The air
volume of the ventilation fan must be larger
.
than the compressor’s. The area of air inlet Compressed air
should be enough. outlet

The ground must be flat. Place soft pad

or anti-vibration pad in order to keep
from vibration and noise. Leave
1000mm for maintenance.

Leave 1000mm to open the maintenance door.

2. Notes for Piping, Foundation and Cooling System

1) Piping
(1) During pipeline construction, the pipeline should have 1-2 degree
slope in order for the pipe to drain condensation easily.
(2) The pressure drop in the pipeline should not exceed 5% of the
preset pressure of the air compressor. It’s better to select pipes
with diameters larger than the designed value.
(3) The branch pipelines must be connected to the top take-off of the

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 main pipeline to avoid condensation from flowing down into the
operating system or back to into the air compressor. The check
valve should be installed in the air outlet of the compressor.
(4) The drainage valve and globe valve should be installed at the end
of the main pipeline in order to drain condensation when one more
compressors connected together.
(5) Do not reduce or increase the size of the main pipeline arbitrarily.
Doing so may cause turbulent flow to occur at the machine's joints.
The turbulent flow will cause pressure loss, and thus reduce the life
of the pipeline because of the impact force of the airflow.
(6) If there are purification and buffer facilities such as a drier after the
compressor, the ideal piping arrangement is air compressor + air
tank + drier. In this arrangement, the air tank can trap a portion of
condensation and decrease the air discharge temperature. Air with
a lower temperature and less moisture content can lessen the load
of a drier.
(7) If the system consumes a large volume of air over a short period, it
is recommended that the user should add an air tank as buffer to
reduce the changeover frequency of compressor’s idle and
heavy-load modes. This will increase the compressor’s life.
(8) If the system air pressure is under 1.5Mpa, the flow speed in the
delivery pipe should not exceed 15m/sec in order to avoid a drop in
pressure.
(9) Try not to use elbows and valves in the pipeline in order to reduce
pressure loss.
(10) The ideal piping construction is to let the main pipeline revolve
around the whole plant. Thus any location can get mutual
compressed air. This can decrease a chance of a drop in pressure
when air consumption goes up abruptly at certain branch pipeline.
We can also install suitable valve sets in the main pipeline for
service purposes.
2) Foundation
(1) The foundation should be built on solid ground or cement ground
and the ground must be flat in order to keep the air compressor
from vibration and noise.
(2) If the air compressor is installed on a high building, ensure
avoidance of vibrations reverberating downstairs, creating
resonance.
(3) There is no need to make foundation because the screw
compressor has less vibration, but the ground must be flat and
there is no soft soil underground. It’s better to fix 5~15mm damping
cushion under the machine.
3) Cooling System

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 (1) The cooling water had better be soft water in order to avoid the
chemical reaction caused by Ca2+ and Mg2+ due to high
temperature, which will form a crust in the cooler and thus influence
the heat exchange effectiveness. Add softening agents in the water
if required.
(2) Install an auto-supply system for the cooling water circulating
system. Otherwise the cooling water flow will become insufficient
after a period and thus the air compressor will shut down due to
high temperature.
(3) The machine’s cooling water system is suitable to be used
separately in case of a water shortage, and thus influence cooling
effectiveness.
(4) The capacity of the cooling water tower should meet the water
amount needed by the air compressor. The power of the suction
pump should also be suitable. The location of the cooling water
tower must have good ventilation and heat elimination. The tower
should be supported to prevent overturning.
(5) The pressure of the cooling water should be maintained at
0.15~0.25Mpa and should not exceed 0.5Mpa.
(6) The outlet temperature of the cooling water should be lower than
40℃.
(7) Please notice the environment temperature if the machine is an
air-cooling compressor. If the environment is a closed system, it
should use ventilation and make sure it’s capacity for wind is more
than the compressor’s.
(8) The air compressor’s heat exchanger need to be cleaned often to
ensure the cooling efficiency.
3. General Safety Specification for Electrical Components
1) Select the correct wire diameter according to the rated power of the air
compressor. Don’t use wires with smaller diameters. Doing so may
cause the power supply wire to burn out, leading to malfunction and
danger.
2) The Air compressor should have an independent power system. Do not
connect the compressor to a power source supplying power to another
source, known as a parallel connection. Parallel connections possibly
cause the wire to trip out causing the overload protection device to
have a three-phase current imbalance. This is especially true with
larger compressors that require high voltage.
3) Install adequate NFB according to the power of the air compressor for
power appliance protection and service.
4) It’s necessary to confirm the correct voltage before plugging in the
compressor.
5) The ground wire of the motor or system must be installed and the
ground wire cannot be connected to the air delivery pipeline or cooling

13
 water pipe.
6) The installation of the ground wire must be confirmed to keep people
away from the electric leakage
7) As a rule, when three-phase power is in balance, the difference of the
motor idling current between any phase and the three-phase average
value will not exceed 10%; If voltage reduction occurs at this time, the
voltage reduction cannot be lower than the rated voltage by 5%.

System flowchart of SA110A~SA200A

System flowchart of SA110W~SA200W

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SA220A
～SA280ASystemFlowChart

15
SA220W
～SA280WSystemFlowChart

16
 System Flowchart
1. Air system flowchart (please refer to system flowchart)
1) The air enters main compression chamber through air inlet valve (3) after
passing through the air filter (1) and the dust particles removed; the air will
be compressed. The air mixes with lubricating oil and then enters oil& air
tank (8) through discharge check-valve. Finally, the oil-mixed air will flow out
of the system through fine oil separator, minimum pressure valve (13), after
cooler (18) and water separator (14).
2) Descriptions of the components’ function on the main air source circuit
a. Air filter (1)
The air filter is a dry paper filter. The function of the filter is to remove dust
in the air. Pull out the filter and clean it by blowing low-pressure air on it
every 1000 hours to remove the dust on its surface. There is a pressure
difference switch (2) in the air filter. When its pressure difference rises to
reach the set value, the switch acts, and then in the instrument panel the
filter △ Plight will flash, in the meantime the alarm menu of air filter
jammed will show up, it means that the operator should clean or change
the filter, however the compressor can still run ahead.

――――Warning――――
Pressuredifferenceincreasingmaycausedecreasingoftheair-inlet
volume.It’srecommendedtocleanorchangetheairfilter.

b. Air inlet valve (3)

The air inlet valve is a butterfly type suction valve of Hoergiber with
pendulum check valve.
The valve plate is closed to make sure the unloading start. Then the
solenoid valve acts and the air go into the servo cylinder (SC) through the
inverse proportion valve. The air can drive the guide-bar of the SC to
open the butterfly suction valve fully, and the machine will load in the
same time.
The inverse proportion valve will act and reduce the quantity of the control
air source when the system pressure rise to reach the set value of the
inverse proportion valve, then the force on the guide bar reduced until it
equals the spring force of its own, and the valve plate is half-opened, the
air consumption will be kept in balance.
When the system pressure continues to go up and its speed is over
the adjust ability of the Capacity regulating valve, the controller will send
the unloading order and the solenoid valve will be closed. The guide bar
will return to the bottom of the cylinder and the valve plate will be fully
closed, and the system air will be exhausted from the Solenoid blowout
valve, the main machine is unloading at the same time. The machine will

17
 load and the solenoid valve acts when the system pressure comes down
below the system set value.
The machine will unload and then stop after 15-30 seconds when button
“OFF” is pressed.
c. Temp. Sensor
The compressor may trip due to high discharge temperature caused by
water loss, oil loss, insufficient water flow or insufficient oil, etc. As
discharge temperature reaches the preset point of the temperature
Controller, the Controller will shut the unit down. Usually the preset
value of the temperature value is 107℃. There is also a temperature
gauge in instrument board, from which you can read the discharge
temperature.
d. Expansion joint 7
Remove the internal stress caused by heat expansion, and vibration of
the unit.
e. Oil& Air tank 8
There is an oil level indicator (10) installed on the tank. The static oil
level should be between H and L. An oil drain valve (15) is equipped on
the bottom of the tank. Open the oil drain valve a little before starting
the machine up every time, which will remove the condensed water in
the tank. If oil flows out, shut the valve immediately. There is a filling
aperture (1”) on the tank. The operator can add oil through the aperture.
The wide sectional area of the oil gas tank can decrease the flow speed
of compressed air and separate it from the oil drops. This is the initial
stage of oil separation.
f. Fine Oil separator
Please read the section “Lubricating Oil Flowchart” for detailed
descriptions.
g. Safety valve (9)
The safety valve will purge when the pressure switch is improperly
adjusted or doesn’t work at all, which leads to the internal pressure of oil
tank to be higher than designed discharge pressure by 0.1Mpa. The
safety valve will purge till the system pressure is lower than the
pressure preset level. The safety valve has been adjusted before
delivery, so please don’t change it arbitrarily.
h. Solenoid blowout valve (included in the air inlet valve)
This is a two way N.O. magnetic valve. The valve will open and
discharge the compressed air in the tank in case of shutting down or
unloading. So the air compressor can start or run in low-load mode.
i. Minimum pressure valve (13)
This valve is located on the top of the oil gas tank. Its preset pressure is
around 0.45MPa. The minimum pressure valve has the following
functions:
a) It takes the priority to build up the circulation pressure the lubricating oil

18
needed when starting the machine, which assures lubrication for this stage.
b) The minimum pressure valve only opens when the pressure is over the
preset value (0.45MPa). It can reduce the airflow velocity entering the
fine oil separator, which can protect the fine oil separator form being
damaged.
j. After cooler (18)
a) The compressed air can be cooled down by the cooling fan in the
air-cooling mode. The air-cooling compressor requires a well ventilation
environment.
b) If it’s a water-cooling compressor, the compressed air can be cooled
down by cooling water through the pipe-type cooler. Please keep the
cooling pipes away from jam and corroded.
k. Water separator (14)
The rotate-type water separator can remove water, oil and other
impurities from compressed air, and the separated air can be used by
the departments which has not high quality demand of compressed air.
l. Y-type filter
The Y-type filter can remove the impurities from cooling water to make
sure the water drained pipes of the ball float trap (13) clear.
m. Ball float trap
The ball float trap can drain the water condensed in the water separator,
it has two modes, one is Machinery control and the other is electric
control.
2. Lubricating Oil Flowchart (please refer to system flowchart)
1) Description of oil injection flowchart
The pressure in the oil& Air tank (8) forces lubricating oil into the oil
cooler (19). Oil is cooled in the oil cooler and then flows through oil
filter (16) where foreign particles are removed. Afterwards it is divided
into two channels. One channel of oil is injected into compression
chamber from the bottom trim of stage and the other channel of oil
flows to both ends of the stage to lubricate bearing sets. Lubricating oil
from each section will be collected at the bottom of compressed
chamber and discharge from exhaust port. After mixed with oil, the
compressed air will go directly into oil tank (8) to be separate from the
oil. The air, which still contains oil mist, will pass through oil fine
separator, where the residual oil will be removed. Then the air flows
through pressure maintenance valve (13) to after cooler (18), where
the air will be cool down. Then the air is ready to be used in the
system.
2) Descriptions of parts functions in lubricating system
a. Oil cooler (19)
The system has two type cooling method, which include air
cooling and water cooling. If the environment situation is not well,
the air-cooling cooler will be covered by ash, and the system

19
 temperature will be higher than normal. Please make sure the
surface of the cooler to be cleaned by blowing the ash away from
it periodically. Please make sure the cleanness of the water-
cooling cooler by special chemicals.
b. Oil filter (16)
The oil filter is a paper filter that eliminates foreign substances in
the oil, such as metal particles, deteriorated, or burnt oil, etc, with
the filtering accuracy being not more than 10μ. The oil filter
protects the bearings, rotors, and gears from the above
mentioned undesirables. The oil and oil filter should be changed
within the first five hundred hours of running, even sooner if it is
working in an exceptionally dusty environment. Whether the filter
needs replacing or not, which will be shown in the instrument
panel. If the pressure difference light flashes and the alarm menu
show up, the filter might be jammed, and need to be cleaned or
changed. The compressor may trip due to high discharge
temperature caused by the oil filter jam, so the filter must be
replaced in time.
c. Fine oil separator
The oil-gas separator is made from multiple layers of fine fabric.
This fabric filters take almost all the vaporous oil particles out of
the compressed air. The oil frog is separated from compressed
air through the oil-gas separator completely, and the oil content
in the air lower than 3PPM, if the machine is working properly.
Provided environmental conditions around the compressor are
normal, the lubricating oil life is greatly affected by the
environment. Fu Sheng prefers customers use the oil that our
company recommends; using other brands at your own risk. The
pressure maintenance valve is installed in the outlet of oil-gas
separator. The oil filtered out by the oil-gas separator is collected
in the small central flute for re-flowing to the machine body
through the return pipe, which prevents re-exhausting of the
filtered lubricating oil with the air. Generally speaking, whether an
oil fine separator has been damaged or not can be decided by
the following methods:
a) The oil content in the air pipeline increase.
b) There are two pressure transmitters, one is at the place
between oil& air tank and oil fine separator and the other is
after the Minimum pressure valve. The set pressure difference
is 0.12MPa between the two pressure transmitters. Once the
pressure difference of the oil fine separator exceeds the set
value, the pressure difference indicator will illuminate. The oil
fine separator then should be replaced immediately.
c) Check whether the oil pressure is too high.
d) Check whether the current increase.
e) Check the oil-return level gauge (11), if the oil-return flow

20
 increase, it means that the separator is failure.
d. Heat control valve (17)
A thermo valve is installed in the front of cooler with the function
of maintaining the exhaust temperature to be above the pressure
dew-point temperature. When starting the machine, the
lubricating oil temperature is low, so the thermo valve will
automatically open the circuit for back flow, with the oil entering
directly into the machine body without passing through the oil
cooler. If the oil temperature rises to reach the lower limit of the
valve set value, the thermo valve will begin slowly opening,
becoming fully opened when the machine reaches the upper limit
of the set value. At this moment all the oil that enters into the
machine body will first pass through the oil cooler.
3. Cooling System
(a) Air-cooling compressors
The cool air flows into the system through a centrifugal fan, blows the
cooler, where it makes a heat exchange with lubricating oil, in turn
reducing the temperature. The highest permitted temperature of the
environment should be below 40℃, and the system will be protected if
the temperature is higher than it.
(b) Water-cooling compressors
The standard temperature of the cooling water is 32℃, so the design of
the cooling water circulation system must be paid attention to.
Especially the cooling water quality must meet the requirements of the
ordinary industrial regulations. If the quality is bad, softener should be
added into the water tower to avoid cooler scaling. During winter time in
the areas where the ambient temperature is below 0℃, the cooling
water must be drained out from the cooler completely after the
compressors shut down to prevent from frost cracking.

21
 Safety Protection System and Alarm Device
1. Motor Protection
There are two major motors in air compressor system. One is main
driving motor of the air compressor; the other is circulation fan motor.
The protection relay will automatically cut off primary power source to
shut down the unit when motor running current exceeds upper-limit of
preset point of protection relay. If Manual reset is required, press down
the reset button.
Common causes for motor overload:
1) Operator’s mistake: improper adjustment to the system, working
pressure too high, etc.
2) Mechanical failures: motor interior wear, loss phase of motor
operation, safety valve failure, system setting failure, and fine oil
separator plugged, etc.
3) Electrical failures: low power voltage, over-current caused by bad
connection.
2. Anti-reverse-rotation Protection for Air Compressor
When the phase orders of the three-phase power wires don’t comply
with the air compressor settings, there may be electrical failures and the
motor will not start. Please exchange any two of the three power supply
wires.

――――NOTICE――――
Although there is anti-reverse-rotation protection, the operator
should still check whether the rotation direction of the motor is
correct.

3. High Discharge Temperature Protection

The highest designed discharge temperature of the machine is 107℃.
The system will cut off power supply if the temperature exceeds 107℃.
There are many possible causes for high discharge temperature, but
the most common one is failure of the oil cooler. When the air-cooling
oil cooler is jammed by ashes, the oil temperature will increase due to
insufficient cooling. As a result the machine will shut down due to the
high discharge temperature. It’s necessary to clean the oil cooler plates
in a period by low pressure compressed air or cleaner at best.
For water-cooling compressors, the cooling cope pipes scaling is the
common cause for high discharge temperature.
The highest permitted temperature of the environment should be not
exceeding 40℃. It’s quite important to select a suitable site for the air
compressor.
Once the discharge temperature rise to reach 100℃, the control
system will send alarm, and once the temperature reach 107℃, the

22
 system starting circuit will be cut off. The system cannot be started at
this point. The operator must solve the problem before pressing the
emergency stop button and reset the machine.
4.Alarm Device
There are three alarm devices in system, including the air filter plugged,
oil filter plugged and oil fine separator blocked alarms. Indicating lights
are all on the instrument panel. When an indicating light illuminates, a
certain filter has been blocked but the machine will not stop. The
plugged filter must be changed as soon as possible to prevent the
compressor from damage.

23
 Control System and Electric Circuit
1．Control System
1） Motor Staring Up (voltage reduction or “Y” starting)
In this step, the air inlet valve (3) is fully closed and the solenoid
valve is closed. The suction side lies in vacuum status. The needed
lubricating oil for compression chamber and bearings is supplied
due to the pressure difference between vacuum of the compression
chamber and atmospheric pressure of oil tank.
2） Full Voltage Running (full voltage or “△” running)
After the control system switches into full voltage operation, the
solenoid valve is energized to open. The pressure inside the air
tank increases gradually and the suction valve opens slowly. As the
pressure inside oil gas tank increases to 0.45MPa, the minimum
pressure valve will open and compressed air will flow out.
3） Load/unload
When the discharge pressure reaches the upper limit of the preset
pressure, the power supply of the solenoid valve is cut off. At the
same time, the air inlet valve closes and the solenoid blowout valve
opens fully. Then the air in the oil gas tank will be discharged out
through the air filter. The air compressor then runs in unloaded
(idling) state. There is a pressure difference between inlet low
pressure and the pressure in the oil gas tank, which provides the
pressure for air compressor to keep lubricating oil in supply.
4） Shut Down
Press the OFF button. The solenoid valve is de-energized (closed)
and the solenoid blowout valve opens fully. Then the air in the oil
gas tank will be discharged out. The motor will stop running when
the pressure in the oil gas tank reduces to a certain value.
5） Emergency Stop
When discharge temperature of the machine is over 107℃ or the
thermal protection device acts because of overloading, the power
supply will be disconnected and the motor will stop immediately.
Meanwhile, the solenoid valve and the air inlet valve (3) will close.
At the same time, the solenoid blowout valve will open fully. Then
the air in the oil gas tank will be discharged out through the air filter
completely. Only when the emergency situation happens to the
system running, the emergency stop button permitted to be
pressed to prevent the machine from damage.
6） Automatic Stop System Because of Long Time Unloaded Running
When the air consumption of the system reduces to zero,
compressor will run under unloaded state. If this period exceeds
preset time, the compressor will stop automatically. When air
consumption increases again, the air compressor will automatically

24
 start up to compensate the discharge volume. When setting the
time limit for unloaded operation, note the starting times of the
motor. It should not exceed 3 times per hour. Don’t restart motor
too often. Doing so may cause the motor burn-out.

2. Electric Circuit
Electric control of air compressor can be divided into two parts. One is
internal control panel and the other is starting plate.
The starting plate is a general Y-△ starter, while the control part is an
electronic control. Since electronic control part is complicated in internal
wiring and control, we will not give a detailed introduction. If there is any
wiring failure, please contact the service department of FuSheng
Machinery CO.,LTD.

3. Control Running
1) Running mode of the compressor set
a. Common running mode
When the discharge pressure reaches the value of unloaded
pressure, the compressor set will run under unloaded state. Once the
discharge pressure becomes lower than loaded pressure value, the
compressor set will load again.
b. Automatic running
When the compressor set runs under unloaded state due to high
discharge pressure, the system will begin to count time. Once the
unloaded running time exceeds the set value, the compressor will
stop automatically and be under the state of shut-down because of
long time unloaded running.

Failures checkout and protection

This control system contains many kinds of failures protection functions,
which are mainly divided into two types—serious failures and slight failures.
When serious failures happen, the compressor set will shut down; in the
mean time indicate alarm information. However the compressor set can run
normally if slight failures happen. Only alarm message will be indicated at
this situation.

c. Serious failures
NO. FailureType Introduction
1 Failuresof There are two modules -- FX2N-4AD and
Analog FX2N-4AD-PTinthiscontrolsystem.Whenany
quantity ofthetwomodulesgetfailureordisconnected
module with the main PLC system, the alarm
information,suchas“4ADmodulefailure”
or“4PTmodulefailure” willbeindicated.

25
2 Pressure Therearethreepressuretransmittersinthis
transmitter control system. When the transmitters are
failure disconnected or short circuit, the failure
alarm will be indicated. Except for oil
pressuretransmitter(Thecurrentispermitted
tobelowerthan3.2mAatthebeginningofthe
compressorstarting.),thefailurealarmwill
be indicated once the current become below
3.2mAorabove20mA.
3 Current Same as the pressure transmitters, when the
transmitter currentgetlowerthan3.2mAorhigherthan
failure 20mA, the failure alarm will be indicated.
However at the beginning of starting, the
currentvaluemayquitehighduetostarting
andtransforming,soitisnotafailure.
4 Temp.sensor Whenthetemp.Sensorisdisconnectedorshort
failure circuit;thefailurealarmwillbeindicated.
5 Highdischarge When discharge temperature or the oil tank
temperature temperature exceeds the set value, the high
temperaturealarmwillbeindicated.
6 High Whenthetemperatureofthemotorfrontbearing
temperatureof orbacksidebearingexceedsthesetvalue,the
bearings hightemperaturealarmwillbeindicated.
7 Highpressure Whendischargepressureortheoiltankpressure
exceedsthesetvalue,thehighpressurealarm
willbeindicated.
8 Motor Whenthemainmotorcurrentexceedsthepreset
protection S.F value, the alarm will be indicated and
meanwhile the machine will shut down. “No
current” alarm will be indicated if the
currentcannotcheckedduringstarting.In
low-voltage compressor sets, motors’
overloadingcanalsobechecked,iffailures
happen,thealarmwillbeindicated.Motorsfor
fans only have the protection function of
overloading.
9 Lowpressureof Whenthepressureofoiltankgetstoolowduring
oiltank running,thefailurealarmwillbeindicated.
10 Phase-sequence Phase-sequence protector is installed in
protection low-voltage compressor set. When the power
phasesequenceisdifferentfromrequirement,
therelevantalarmwillbeindicatedtoprotect
theairendfrominversion.

26
 11 Contactor Ifthefeed-backinformationofthecontactor
feed-back cannotbecheckedduringrunning,thefailure
failure of “contactor feed-back” or “Y start
failure” willbeindicated.
12 High-voltage High-voltageboardshouldsendtheinformation
board of “start” or “failure” to the
failure high-voltage compressor set before the set
start. If the set can not receive the
information of “start”, it will not be
started and meantime an alarm will be
indicated.Ifthesetreceivetheinformation
of“failure”,thealarmof“high-voltage
boardfailure” willbeindicated.
13 High-voltage When operators start or shut down the
boardstart high-voltage compressor set, a relevant
feed-back feed-back information from the high-voltage
board can not be received, the system will
indicatealarmof“high-voltageboardstart
feed-back failure” or “high-voltage board
rejectsstarting”.

d.Slightfailures
1 Airfilter When the acting of the pressure difference
jam switchoftheairfilterischecked,thealarm
of“airfilterjam” willbeindicated.
2 Oil When the pressure difference between the
separator dischargeandtheoiltankexceedsthepreset
jam value,thesystemwillindicatethealarm“oil
separatorjam”.
3 Maintenance Whenthemaintenancetimeofthethreefilters,
time lubricatingoilorthecompressorsetexceeds
indication thepresetvalue,therelevantalarmwillbe
ofthree indicated.
filters
and
lubricatin
goil
4 Lowoil Whentheoilpressurebecomeslowerthanthe
pressure preset value, the system will indicate the
alarm“lowoilpressure”.

2)Auxiliaryprotectionfunction
e.Load-startingprotection

27
 Thecompressorsetwillstartonlywhenthepressureofoiltank
isbelow0.04MPawhilethesetwillbeunderthestateof“Wait
forstarting” oncetheoiltankpressureexceeds0.04MPa,inthe
sametimetheinformationof“theoiltankpressureishigh,and
thesetwillstartautomaticallyoncethepressuredecreasesto
bebelow0.04MPa” willbeindicated.
f.Functionof“waitforstarting” automaticallyduetohigh
startingpressure
Whentheoperatorselectsthemodeof“runningautomatically”,
thecompressorsetwillbeunderthestateof“waitforstarting”
ifthedischargepressureishigherthantheunloadedpressure.The
machinewillnotstartuntilthedischargepressurebecomeslower
thanloadedpressure.Inthemeantimetheinformationof“high
dischargepressure,thesystemwillstartautomaticallyoncethe
pressuregetslowerthanloadedpressure” willbeindicated.
g.Functionofforceunload
When the main motor current exceeds the S.F value, the
controllerwillunloadforcedlyinordertodecreasethemotor
current.Ifthecurrentcannotbedecreased,thecompressorset
willstopandindicatefailurealarmatonetime.Ifthecurrent
rises to exceed the set value once more after decreasing
successfully,thecompressorwillbeunderthestateof“force
unload” again.Ifthisprocedureshowsuptentimeswithinfive
minutes,itmeansthatthecompressorsetisrunningunderthe
loadedstate.Thesetwillshutdownaccordinglyandindicatethe
failureinformationof“mainmotorcurrentexceeding”.

h.Pressuredifferencecalculationofoilfineseparator
The pressure difference value of oil fine separator is
calculatedbythevalueofdischargepressureandoiltankpressure.
Whenthepressureofoiltankislowerthanthedischargepressure
or0.55MPa,thepressuredifferenceofoilfineseparatorwillbe
indicatedaszero.
i.Controloffan
Therearethreecontroltypesforfan:watercooling,air
coolingandVDTcontrolling
a) Thefanwillstartassoonasthecompressorset
startswhenwatercoolingmethodisselected.
b) Whenaircoolingmethodisselected,thefanwill
start if the discharge temperature or oil tank
temperature is higher than the preset starting
temperatureoffan,andthenthefanwillstoponce
the discharge temperature and the oil tank
temperaturearebothlowerthanthesetstopping

28
 temperaturevalue.
c) Thefanwillstartassoonasthecompressorset
startswhenVDTmethodisselected.Therotating
speedoffaniscontrolledbyVDT.
j.Calibrationofdischargepressuretransmitter
Operatorscancalibratethegainandzeropointofthedischarge
pressuretransmitter.Whenthereisnopressureindischargepipes,
thetransmitterispermittedtoadjusttozero.Ifdifference
happenswhenthereispressureindischargepipes,operatorscan
calibratethetransmitterbyincreasingordecreasinggain.
k.Failuresrecord
Thesystemwillrecordthelatesttwentynotesoffailures.When
thequantityofrecordsexceedstwenty,theearliestrecordwill
bereplaced.

AttachedList： Reference Value of The Diameters of Power Supply Wires

Power 120 132 138 160 185 220 250 280
（KW）
Items
Rated 234 239.7 259.3 289 335 398 443 497
current
（A）
Largest 269 287.6 298 346.8 402 477.6 531 596.4
current
Wire 95 95 120 120 120 150 185 185
diameter
（mm2）
Note: If the multi-core cable is dissimilar, please refer to in order to
fix the problem

29
 SA220A
～SA280ASchematicDrawingof
ElectricControlforAirCompressor

30
31
32
33
 SA220W
～SA280WSchematicDrawingof
ElectricControlforAirCompressor

34
35
36
37
 Operations
Ⅰ、Trial run for new machine
1、Connect the machine to a power and ground wire source, and then ensure
that the primary voltage and the three-phase power cables are correct.
2、Release the conveyance fixing screw on the base of the shockproof-desk.
――――NOTICE――――
When the machine is transported, the conveyance fixing screw must be
tightened in order to avoid damage to the isolator-vibrator by inclination
and vibration, or movement of the isolator-vibrator causing breakage of
the expansion joint.
3、Check whether the oil level in oil reservoir is between two lines of oil level
gauge.
4 、 If the trial running of the machine takes place long after delivery, you
should add about 2 liters of lubricating oil to the suction valve before
starting, as well as manually rotate the compressor several times. This
can prevent the compressor from being burnt out due to by oil loss during
start up. Avoid dropping any foreign objects or materials into compressor.
Doing so may cause serious damage.
――――NOTICE――――
At this moment it is prohibited to connect the compressor to power.
5、Starter power on
――――NOTICE――――
In case the power supply phase is erroneous, the indicator light of Phase.
SEG ERROR will illuminate.
6、Rotation debugging: Press the “ON” button for a few seconds, and then
press the” EMERGENCY STOP” button immediately. Check whether the
direction of rotation is the same as the direction indicated by the arrow on
the end of the stage. If the direction of rotation is incorrect, change any
two of the three power supply cables (R, S,T).
――――NOTICE――――
Disconnect the compressor unit from its power source before repairing
electric equipment. Live-line work is strictly prohibited.
Although the compressor has been tested in its production course, the
rotation test is still tan important procedure for new machines during
trial running.
――――NOTICE――――
The phase protector detects the power phase. A rotation test must be
carried out after repairing the motor.

7、Start : Press the “ON” key to start running the compressor.

――――NOTICE――――
This machine includes automatic operation technology. The starting up

38
 time for Y/△ reduced-voltage is around 15 seconds, with a 3 second
delay until the air inlet valve will begin to operate.
8 、 Observe whether the instruments and indicating lights are in normal
condition and whether the pre-warning indication lights give out
abnormal signals. Press “EMERGENCY STOP” button to stop and
check the machine in case of abnormal sounds, vibrations and shut
down the machine for repair.
9 、 Stop: Press the “OFF” key make to the compressor stop running
automatically.
――――NOTICE――――
After the “OFF” key is pressed, the blow-down valve of the compressor
will unload exhaust. The delayed stop discharging and unloading begins
after 15 seconds. After this time, the motor will stop.
――――NOTICE――――
In normal conditions, please don’t use the “emergency stop” button to
stop the machine.

Ⅱ、Daily Check before starting

A daily check of the machine, before starting, is necessary for the normal
and safe operation of the compressor.
1、Open the oil drain valve on the bottom of oil reservoir and drain out the
condensation accumulated during shutdown. Close the valve as soon
as the oil flows out.
――――NOTICE――――
Before opening the oil drain valve of oil reservoir please confirm that no
air pressure is in the oil reservoir.
2 、 Check the oil level: The oil level should be between minimum and
maximum levels of oil level gauge.
――――NOTICE――――
Please use FU SHENG Screw Compressor Superior Lubricants only. Do
not mix different types of lubricants in the machine.
Ensure that there is no air pressure in system when supplementing
lubricant
Observation of the oil level should be 10 minutes after the machine is
shut down. During operation, the oil level observed may be lower than
the oil level observed at shut down.
3、Preparation of periphery equipment: Prepare the Power supply, cooling
tower, and water pump of the machine. Open the outlet valve of the
compressor and operate the air compression drier.
4、Start up the compressor.

Ⅲ.Notes for Running

1) In the case of abnormal noise or vibration, stop the machine

39
 immediately.
2) Because the pressure in the pipe and container is higher than outside
pressure, don’t loosen the pipeline, plug, or open valves.
3) If the oil position in the oil level gauge is invisible during a long period of
operation, stop the unit immediately. Check the oil level after shutting
the machine down for 10 minutes. If the oil is insufficient, add oil when
the system is in a zero-pressure state.
4) If there is condensation in the after cooler, drain it timely or install an
automatic trap. Otherwise moisture will be carried into system.
5) Please clean the Y-Type filter core regularly to avoid water being taken
into the system.
6) During operation, check instruments every 2 hours and record voltage,
current, pressure, discharge temperature and oil level for future use.
Ⅳ.Handling Method for Long Period Shut Down
If the machine is not going to be used for a long period, carry on the
following procedures, especially when the temperature is lower than 10℃
or the machine is installed in a high humid place.
1) Unused for more than 3 weeks
(1) Wrap the electric equipment such as the motor control panel with
plastic or oiled paper in order to keep them protected from
moisture.
(2) Drain water out thoroughly from oil cooler and after cooler.
(3) If there is any failure, remove it before operation.
(4) Drain the condensation in the oil gas tank, oil cooler and after
cooler several days later.
2) Shut down for more than 2 months
In addition to the necessary measures mentioned in section 1), the
following procedures are also necessary:
(1) Seal all the ports to seal out moisture and dust.
(2) Wrap the safety valve and control panel with plastic or oiled paper
in order to keep them from being rusted.
(3) Change the lubricating oil before suspension the machine. The
process is running the machine for 30 minutes. Remove the
condensate inside oil gas tank and oil cooler several days later.
(4) Discharge the cooling water completely.
(5) Store the machine in a dry place with little dust.
3) Procedures for restarting
(1) Remove all the plastic or oiled papers wrapped on the machine.
(2) Measure the insulation resistance of the motor, which should be
more than 1MΩ.
(3) Other procedures are the same as those in trial running section.

40
 Warranty
The warranty is valid for 12 months (1 year) after first trial run of the product
or 18 moths after delivery or 3000 hours after running, whichever period
expires first. While the warranty is valid, if any failure occurs due to
improper manufacturing, our company will be fully responsible for repair,
free of charge. The owner shall properly provide maintenance for the
machine according to management and rules of use for the machine. If the
warranty has expired, the expenses for the parts, components, and the
labor need to fix the machine shall be paid by owner.
During the period that the warranty is valid, we will actively appoint the
technical personnel to your mine for inspection and explanation, and
technical support.
1. The warranty is valid under the situations as follow:
a. The user obeys the items of the compressor criterion seriously to
operate and maintain the machine.
b. The faults are caused by wrong installation, operation, repairing or
natural disaster, war and violence.
c. The machine’s factory number is destroyed, removed and artificially
changed.
d. The accessory and lubricated oil must be from Fusheng.
It is not safe for user to use the fake accessory and lubricated oil.
2. The warranty does not include normal expandable as air filter, oil filter,
oil separator, Fusheng lubricating oil and so on.
3. Fusheng company do not respond for the indirect losses or other losses
caused by compressor.
4. Please reserve the warranty card to make sure your benefits.

41
 Maintenance and Inspection
Please do maintenance of compressor with user’s menu, and make sure the
parts and lubricating oil is from Fusheng. If there are some faults on the
compressor because of the fake parts and lubricating oil, Fusheng will not
respond. Please contact us if you have any question.

Specifications for lubricating oil and directions for use

1. Specifications for lubricating oil
The lubricating oil plays a critical role in the performance of the screw
compressor. If improperly or wrongly used, the compressor may be
seriously damaged and/ or fire and injury may occur. Therefore the Fu
Sheng brand screw compressor high-quality cooling fluid must be used.

2. Factors affecting oil replacement time:

a. improper ventilation, high external environmental temperature
b. High humidity environmental issues i.e. the rainy season
c. Dusty environment
Under the above mentioned environment, the oil replacing time mentioned in
section shall be shortened accordingly.
3. Oil replacing procedures
a. Start compressor and allow the oil temperature rise to facilitate
discharging, and then press the “stop” button to make the compressor
stop.
b. Turn on the blow off valve at the bottom of oil gas barrel. If it is turned
on too quickly, and residue pressure exists in the barrel, the oil
discharging speed will be very fast and spurt out, causing injury, so it
should be turned on slowly. Furthermore please ensure that all the
lubricating oil in the system is empty, including that in the pipeline,
cooler, and oil gas barrel.
c. After emptying the lubricating oil, please turn off the blow off valve,
then open the filler cap to fill in the new oil. Note: After starting up,
partial oil will remain in the pipeline, so the oil shall be filled to the
compressor till, reaching the fastening screw above the oil watching
42
 mirror. In other words, the entire oil watching mirror should be full of
the oil. After starting up the oil level will fall greatly, so the operator
must ensure that when the compressor is running normally, the oil
level is between the red lines (rectangle) of the oil watching mirror.
When the oil is insufficient the machine must be stopped for the
addition of more oil.
d. Inject new oil.
4. Notice for the using of lubricating oil:
a. The first time to change the lubricating oil for compressor is 500 hours
running, and then it will be 6000 hours every time.
b. Precautions for the use of lubricating oil
Be sure not to use lubricating oil that has passed the expiration date. Old
oil most likely has deteriorated over time, causing improper lubrication
performance, thus causing overheating, blockage of the oil passage and
possible damage to the machine’s parts and components.
c. Please clean the oil system after two years running. The method is running
the compressors for 6~8 hours after changing the lubricating oil and then
changing the lubricating oil again, which can clean the organic components
enough and make sure the machine’s life.
Pressure System Adjustment
1. System Pressure Adjustment
The compressor must in stop status, and then the user can press the
“setting” button of the controller and enter the password setting fig. ,
input and confirm the passwords and then enter the warning fig. , enter
the parameter fig. by pressing the “ENTER” button and then increase
or decrease the pressure parameter to adjust the system pressure.
Confirm the parameter after setting in the end and the difference
between the loading and unloading pressure. (the minimum valve can
not be over 0.15MPa)
2. Air Regulating System (Capacity Regulating System)
The air regulating system is used for adjusting the air inlet value to
equal what the user needs, and amplify the efficiency. If the unloading
pressure setting is 0.7MPa and the loading pressure is 0.5MPa, and
the local system’s pressure scale is 0.5~0.65MPa, the
capacity-regulating valve’s pressure setting should be over the scale of
0.5~0.65MPa. It means the compressor’s capacity-regulating system
will act when the system’s pressure is over 0.65MPa.

The Change of Expendable Parts

1. Air filter: Clean the air filter once every 1000 hours. Change the air filter
approximately every 2000 hours.
2. Fore-filter net: There is no need to replace the fore-filter net. Clean and
wash the fore-filter net once every 1-2 weeks.
3. Oil filter: Change the oil filter the first time after 500 running hours; after

43
 that, change it once every 2000 hours or when the indicator illuminates.
4. Fine Oil separator: When fine oil separator ΔP indicator illuminates or
oil pressure surpasses air pressure, the oil fine separator must be
changed. Usually change it every 3000hours, though.
The Changing Procedures of the Fine Oil Separator
1. Shut down the air compressor. Close the air outlet valve and open
water draining valve. Make sure there is no pressure in the system.
2. Dismantle the pipe line at the top of the oil& air tank, and the ones
between the pressure maintaining valve and after cooler.
3. Dismantle the oil return pipe.
4. Dismantle the belt on the upper cover of the oil& air tank.
5. Use M20 belt push the upper cover up evenly.
6. Tighten the shaft belt, and wait for the upper cover leaving from the
oil& air tank, then rotate the cover.
7. Take out and change the fine oil separator. Replace the sealed gaskets
of the two separators.
8. Reassemble the oil gas tank in the reverse order of the procedures
mentioned above.
Notice: Avoid to drop some Impurities in the oil& air tank when change the
fine oil separator.
The changing of lubricating oil:
The initial changing should be at 500 hours for witch the machine has run, and
then change the oil every 6000 hours. The time can be shortened if the
environment is not good.

44
 Daily maintenance and troubleshooting
Daily maintenance
1. Check the machine daily or every time before starting up (please refer
to pervious sections).
2. 500 hours running
(1) Change oil filter cartridge.
(2) Remove the air filter cartridge to clean. Blow it with compressed air
pressurized at 0.2MPa.
(3) Change lubricating oil.
3. 1,000 hours running
(1) Check all pipe joints and screws.
(2) Clean the air filter cartridge.
4. 2,000 hours or 6 months running
(1) Inspect each pipeline.
(2) Change oil filter cartridge and air filer cartridge
5. 3,000 hours or one year running
(1) Check suction valve
(2) Check 3-way solenoid valve.
(3) Check blow-down valve.
(4) Change the fine oil separator
(5) Check minimum pressure valve.
(6) Clean the cooler and change the O ring.
(7) Change the air filter cartridge and the oil filter cartridge。
(8) Add lubricating grease for motor.
(9) Check the motion of the contactors on the starting plate.
(10) Check whether the motion of the protection pressure
difference switch is normal.
6. 6000 hours
Change Fusheng super lubricating oil.
7. 20,000 hours or 4 years running
(1) Change the bearing and oil seals of the machine and adjust their
spaces.
(2) Measure the motor’s insulation resistance, which should be over
1MΩ.

45
 Motor Maintenance

a. Please keep the motor from ash or fiber to make sure clean and dry.
b. Please check and handle the problem of the motor when the
protection for it acts.
Check the lubrication of the motor to make sure its steady running,
operator should add the lubrication to the motor when it has run for
2000h. Please use the lubrication of Polyrex EM, the quantity is as Gp
＝0.005DB
Gp= the quantity of the lubrication
D= outer diameter, mm
B= the width of the bearing, mm
c. The user should shorten the time of injecting lubrication to motor when
rising every 15℃ after over 70℃, because the lubrication’s aging with
the rising of the temperature. The limit temperature is 120℃. The
interval can be prolonged if the temperature is below 70℃, but the
maximum time is not over 3000 hours.
Please inject the motor lubricating oil into the oil cup with the oil gun.
Take out of the oil plug on the oil drainage pipe before injecting the oil,
and connect the plastic guide pipe to educe the oil out of the machine.
Please tighten the oil plug after injecting the lubricating oil.

46
 Failure Handling List
Item Failure Possible Causes Handling Methods
1. Fuse burned. 1. Contact qualified electrician
to check and change.
2. Protection relay 2. Contact qualified electrician
energized. to check and change.
3. Contact qualified electrician
3. Start relay failure. to check and change.
4. Contact qualified electrician
Cannot start 4. Bad connection of start to check and change.
(electrical button. 5. Contact qualified electrician
1
failure light to check and change.
turns on). 5. Low voltage. 6. Contact qualified electrician
to check and change.
6. Motor failure. 7. Turn the rotor of the stage.
Contact Fu Sheng service
7. Stage failure. department if it cannot
move.
8. Phase lose protection 8. Check power wires and
relay energized. terminals.
1. Low voltage. 1. Contact qualified electrician
to check and change.
2. Discharge pressure is too 2. Check pressure gauge,
Working current
high. adjust pressure switch if
is too high and
over set pressure.
the air
3. Incorrect lubricating oil. 3. Check oil code and change
compressor
2 4. Oil fine separator plugged oil; refer to section 6-1.
shut down by
(high oil pressure). 4. Change oil fine separator.
itself (electrical
5. Turn the rotor of the stage.
failure light
5. Stage failure. Contact Fu Sheng service
turns on).
department if it cannot
6. Bad connection of the move.
electric circuit. 6. Check and repair.
1. Too much air consumption 1. Check air consumption. Add
(pressure is below the set air compressor if necessary.
value). 2. Clean or replace.
2. Air filter is clogged. 3. Remove, clean and add
Working current 3. Suction valve failure, such grease.
3
is below normal. as being jammed.
4. Capacity control valve is 4. Reset the valve.
adjusted improperly.
5. The pressure setting is not 5. Readjust the pressure
suitable. parameter.

47
Item Failure Possible Causes Handling Methods
1. Adjust the valve of the
1. Too much cooling water. cooling water.
Discharge 2. Adjust the valve of the
temperature is 2. Low ambient temperature. cooling water. Exhaust the
4 lower than 3. The gauge shows the heat air in room if it’s
normal value wrong discharge air-cooling cooler.
(below 70℃). temperature. 3. Change discharge
4. Heat control valve failure. temperature gauge.
4. Change heat control valve.

1. The oil level should be

1. Insufficient lubricating oil.
between H and L. Stop the
machine and add oil if oil
level is below L.
2. Check the temperature
2. Insufficient cooling water.
difference between inlet and
outlet water.
3. Check the temperature of
3. High water temperature.
inlet water.
4. Increase the ventilation and
Discharge 4. High ambient temperature.
reduce the room
temperature is
temperature.
too high causing 5. Oil cooler is jammed.
5. Check whether the
the compressor
temperature difference
to shut down by
between inlet and outlet pipe
itself. High
5 is between 5-8℃. Clean the
discharge
oil cooler if the temperature
temperature
difference is above 9℃.
light turns on 6. Wrong lubricating oil.
6. Check oil grade and change
(when temp.
oil.
exceeds preset 7. Heat control valve failure.
7. Check whether the oil has
value of 107℃).
been cooled down. Change
the heat control valve if not.
8. Air cleaner is not clear.
8. Clear the air cleaner with
low-pressure air.
9. Oil filter is plugged.
9. Change the oil filter.
10. Cooling fans have faults
10. Change the cooling fans
11. Wind pipes of cooling fans
11. Clean the cooler by low
are jammed
pressure air.
12. Temperature sensor has
12. Change the temperature
faults.
sensor.

48
Item Failure Possible Causes Handling Methods
1. Oil level too high.

Oil content in 1. Check whether the oil level

2. Back Oil pipe plugged.
the air is too is between H and L.
much. 2. Disassemble and clear.
3. Discharge pressure too
Lubricating oil
low.
6 refueling period 3. Increase discharge pressure
is becoming (adjust the pressure switch
shorter. Filter to preset value).
4. Fine Oil separator
belches smoke 4. Change.
damaged.
during off-load. 5. Change the spring.
5. Minimum pressure valve
spring failure.
1. Pressure switch failure.
2. 3-way solenoid valve 1. Change.
failure. 2. Change.
3. Blow-down valve failure. 3. Change.
4. Suction valve failure. 4. Repair and add lubricating
oil after clearing.
Compressor
5. Minimum pressure valve 5. Check whether the valve
7 cannot run
failure. base or check-valve is
under full load.
damaged and change them
6. Leakage in control if necessary.
pipeline. 6. Check leakage position and
screw it up.
7. Capacity regulating valve 7. Reset.
is adjusted improperly.

1. Pressure switch failure. 1. Repair, change if necessary.

Compressor
2. Suction valve failure. 2. Add lubricating oil after
can’t unload.
cleaning.
Gauge pressure
3. Blow-down valve failure 3. Repair; change if necessary.
keep at working
8 (coin burnt out).
pressure or
4. Air volume adjusting 4. Repair and change.
going up till
diaphragm is damaged.
safety valve
5. Discharge orifice is too 5. Enlarge the orifice diameter
energizes.
small. properly.

49
Item Failure Possible Causes Handling Methods

1. Clean or change.
1. Air filter blocked.
2. Add lubricating oil after
2. Suction valve failure.
cleaning.
3. Check whether the valve
Discharge air 3. Minimum pressure valve
base or check-valve is
volume is lower failure.
9 damaged and change them
than normal
if necessary.
value. 4. Oil fine separator plugged.
4. Repair; change if necessary.
5. Blow-down valve leakage.
5. Repair; change if necessary.
6. Capacity-regulating valve
6. Readjust the
do not be adjusted well
capacity-regulating valve.

1. Pipe leakage.
2. Pressure difference of the
1. Repair; change if necessary.
pressure switch is too
2. Reset (the normal pressure
Often changes small.
difference value is 0.2MPa).
10 from loaded to 3. Unstable air consumption.
3. Increase capacity of air tank.
unloaded. 4. The core of the Minimum
4. Check and change the valve
pressure valve is not
core and spring
sealed well or the spring is
fatigue

1. Oil stop valve leakage.

1. Repair; change if necessary.
2. Check-valve leakage.
2. Check whether the valve or
the valve base is damaged
and change them if
3. Loaded running shut
Oil mist is necessary.
down.
belching from 3. Check whether the suction
11
air filter during valve is jammed. Clean it
shut down. and change if blocked.
4. Electric circuit failure.
4. Call qualified electrician to
repair.
5. Minimum pressure valve
5. Repair; change if necessary.
leakage.

50
 Screw Type Air Compressor Running Records
Year Month
Date
Items Time

1. Oil level of oil gas tank

2. Air cleaner △P indicator

3.Oil filter △P indicator

4.Fine Oil separator △P indicator

5.Working current (A)

6.Working voltage (V)

7.Discharge air pressure (MPa)(G)

8.Head discharge air temperature
(℃)
9.Lubricating oil pressure (MPa)(G)

10.Working time (Hours)

Recorders

Remarks

Notes:
1 For item 1-4, mark √ for normal condition and × for abnormal condition
(the abnormal condition should be handled).
2 For item 5-10, please fill numbers in the blanks.

51