DENAIR DA-100A, Installation, Maintenance And Operation Manual

Page 1: ...ssor net 1 48 Double Screw Air Compressor Installation Maintenance and Operation Manual Shanghai Denair Compressor Co Ltd Add Room301 No 18 Baosheng Road Songjiang District Shanghai PRC Tel 86 21 37831829 Fax 86 21 37831829 Web www denaircompressor net ...

Page 2: ...rrect grounding connection the third one of the machine body s earth terminal can improve its noise proof capability 8 The setting of the motor rated current machine tripping current is as per that the motor nameplate rated current the motor overload multiple 1 2 Features LCD display in Chinese and English All round protection of the motor against the short circuit blocked rotor phase lacking over...

Page 3: ...f Variable Frequency Electrical Appliance 21 Seven Early Warning and Prompt 25 Eight Safeguard 27 Chapter Three System Flow and Functions of all kinds of Parts 28 35 One System Flow and Parts Name 28 Two System Flow 31 Three Lubricating Oil 33 Chapter Four Compressor Acceptance and Installation 35 38 One Acceptance and Installation 35 Two Compressor Installation 36 Three Cautions for Air Supplying...

Page 4: ...ricating Oil and Using Maintenance 41 Two Belt Adjustment 41 Three Pressure System Adjustment 42 Four Safety Valve Adjustment 43 Five Replacing Steps of Oil gas Separator 43 Chapter Seven Maintenance and Faults Removal 43 48 One Common Faults Disposal 43 Two Faults Removal Form 44 Three Screw Air Compressor Operation Log Sheet 48 ...

Page 5: ...bearing at the air inlet and a four point bearing and a pin roller bearing at the air outlet Rolling bearing bears radial force and four point bearing is responsible for axial thrust B meshing The male rotor is driven by the motor through coupling overdrive gear or belts Because of the two rotors meshed together the male rotor directly drives the female rotor to rotate together The cooling lubrica...

Page 6: ...ge that is to say the alveolus volume between the active line and air outlet gradually decreases and the inner air is compressed to increase the pressure meanwhile lubricating oil infuse the compressing chamber and mix the air D Exhaust Process When the meshing end face of rotors rotates communicates with the air outlet of the main case the pressure of the compressing air reach the highest and the...

Page 7: ...8 40 0 8 14 0 10 17 5 10 20 0 10 22 5 10 26 0 10 28 0 10 31 0 10 37 0 10 Air delivery working pressure m 3 min bar 11 5 13 15 8 14 18 0 13 20 1 13 25 1 13 26 0 13 28 5 13 33 0 13 Power KW 22 37 55 75 90 110 132 160 180 200 220 250 Speed r min 1480 2980 Start way Y start Noise dB A 72 5dB Content of oil discharge 1 3ppm Air outlet temp Environmental temperature 15 Cooling air volume m3 min 145 255 ...

Page 8: ...3 10 5 5 10 7 0 10 8 7 10 9 5 10 11 6 10 Air delivery working pressure m 3 min bar 0 6 13 1 2 13 1 7 13 2 2 13 2 7 13 3 7 14 4 8 13 5 8 13 7 5 13 8 4 13 10 0 13 Power KW 7 5 11 15 18 5 22 30 37 45 55 65 75 Speed r min 1480 2980 Voltage power V HZ 380V 50HZ Start way Direct drive Y start Noise dB A 72 5dB Content of oil discharge 1 3ppm Air outlet temp Environmental temperature 15 Cooling air volum...

Page 9: ...to do upturning a selection key when doing menu option down key when revising data change it by pressing the key to do down turning a selection key when doing menu option shift key and confirm key when revising data it is shift key and confirm key when menu selection backspace key or reset key when menu operation it is the backspace key by pressing which to return the previous page when orderly cl...

Page 10: ...on in a certain interface it will automatically get back to the main interface after several seconds We can absolutely observe operating parameters such as the operating time operating time for this time maintenance parameter historical breakdown production date on site stoppage and so on and return to the top level menu by the same method with the help of using the shift key confirm key and backs...

Page 11: ...the backspace key c User Parameter A Parameter modification method unallowable to change the user parameter and manufacturer parameter in the process of operating status and delayed stop The user parameter can be checked and changed by applying the above checking method of operating parameter for example altering the pressure upper limit and the operation methods are as follows Press the shift key...

Page 12: ...on place After inputting press S to do confirmation and the flicker bit disappears The or changes into the moving black scroll bar and the back to be the confirm key which can continue to revise other user parameter If it is unnecessary to change other parameter press the key to return to the top level menu or the main menu Using the same methods can revise other user parameter B The user paramete...

Page 13: ...tically stop Stop delay time 0010 Second When shut down don t stop the machine until delay the time after the deadhead Start delay time 0100 Second Restart after delaying the time when the deadhead s overlong stop Alternating delay time 0000 Second Additional function Dewatering on delay time 0002 Second Continue the drainage time when controlling automatic dewatering Dewatering off delay time 001...

Page 14: ...ease 9999 hour Set as 0 the time early warning of lubricating grease is useless Chinese English choice Chinese Set as English the interface turns into English operation Alter user password User can alter password C Manufacturer Parameter The difference between manufacturer parameter and user parameter is that manufacturer parameter can t be checked and should be altered just according to the manuf...

Page 15: ...op only start the machine by time delay no matter power down or reset to avoid the motor frequent starting date of production year month day The production date of the manufacturer input device Factory number The factory number of the manufacturer input device Two Function and technical parameters A Switching value nine way switching value input and ten way switching value of the relay switch outp...

Page 16: ...re protection when detecting the actual temperature greater than the set temperature the acting time 2s I Output relay switch contactor capacity 250V5A contactor life is 500000 times J Current display error is less than1 0 K RS 485communication Three Type and specification A Model Instruction MAM KY02S 40 B T Ⅷ Ⅷ Ⅷ Ⅷ VIII Control mode Ⅷ Ⅷ Ⅷ Ⅷ T with RS 485 communication B transmitter K pressure sw...

Page 17: ...Figure 2 CT1 structure size ф36 perforation Figure 3 CT1 structure size Figure 4 CT2 structure size ф10 perforation Figure 5 CT2 installation size b Controller installation The controller should be installed in the control cabinet and there should have some space around the controller to make the wiring easy The detailed dimension is as follows a input indicator light IN 00 01 02 03 04 05 06 07 Th...

Page 18: ...ator PWR lamp d Operation indicator RUN lamp e failure indicator ERR lamp c Display panel function and installation Model 200 display panel is fixed on the control cabinet panel Figure 6 Plate size and the size of opening holes 运行状态 设备已停止 0秒 排气温度 80C O S 本地 250 150 138 50 22 14 3 油 后 却 冷 冷 却 器 器 供压 0 80MPa I ...

Page 19: ...iring terminals Display panel and controller are connected with communication cable 23 24 and 25 are phase sequence input terminal 7 and 9 are exhaust temperature input terminal CT1 is the main motor mutual inductor CT2 is fan motor mutual inductor 32 is output relay public terminal COM1 27 controls the main contactor 28 controls star contactor 29 controls angular contactor 30 uploads solenoid val...

Page 20: ...d automatic stop Only if the pressure reduces to the lower limit pressure the motor will automatically operates according to its starting process then reciprocating and cycling in this way c Manually uploading or unloading at the automatic status At the automatic status the equipment is unloading so press the key to load If the pressure higher that the unloading pressure load the electromagnetic v...

Page 21: ...machine C Fan temperature control When exhaust temperature is more than the fan start temperature fan motor operates when exhaust Temperature less than fan temperature the fan motor will stop operation D Automatic drainage The controller is equipped with automatic drainage function and dewater on time as per the setting drainage continuing time and interval time E Malfunction shut down and emergen...

Page 22: ...tar angle delay time 0006 Second Star triangle decompression start delay time Upload delay time 002 Second Delay uploading time after star triangle decompression start unload delay time 0005 Minute The deadhead continuing runtime over which time the machine will automatically stop Stop delay time 0010 Second When shut down don t stop the machine until delay the time after the deadhead Start delay ...

Page 23: ...e Olein differentiator reset 0000 hour Replacing olein differentiator to clear service time Air filter reset 0000 hour Replacing air filter to clear service time Lubricating oil reset 0000 hour Replacing lubrication oil to clear service time Maintenance parameter reset Lubricating grease reset 0000 hour Replacing lubricating grease to clear service time Oil filter 9999 hour Set as 0 the time early...

Page 24: ... modify loading operation time Alter running time hour Manufacturers can modify the total operating time History fault reset After Inputting history fault password the faults will be completely cleared out Current imbalance degrees 0006 When the maximum phase current minimum phase current 1 S et value 10 the imbalance protection action stops When set value 15 the imbalance protection is useless Co...

Page 25: ...e The system totally has four kinds of warning devices Air filer blocking indicator lamp oil filter blocking indicator lamp oil gas filer blocking indicator lamp and oil level over low indicator lamp are all displayed on the dashboard When indicators are on it shows that some filter has been blocked or we need add lubricating oil and users must replace spare parts or adding oil in the shortest tim...

Page 26: ...rning by switch signal The controller indicates oil gas separator on the text indicator to the operator by inspecting the pressure difference switch action of the oil gas separator b Set the pre warning of oil gas separator service time When the oil gas separator service time is out the text display indicates the operator oil gas separator service time is out D Lubricating oil pre warning indicati...

Page 27: ...ch as voluntary adjusting discharge pressure improper system adjustment and so on b Machinery failures Such as inner consumption of motors motor phase lacking operation inaction of safe valve system set failure oil gas separator blocking and so on Please stop the machine when find the motor overload during its operation and contact our company and so we will dispatch our service team to repair it ...

Page 28: ...vironmental temperature of the air compressor is designed at 40 if the environmental temperature is higher the discharge temperature will be higher so it is necessary to choose a place with low environmental temperature and good ventilation After the discharge temperature switch action the system return circuit is cut off during which moment it can not be restart again unless reset again C Protect...

Page 29: ...Shanghai Denair Compressor Co Ltd www denaircompressor net 29 48 Chapter Three System flow and all parts functions One System flow and part name ...

Page 30: ...Shanghai Denair Compressor Co Ltd www denaircompressor net 30 48 ...

Page 31: ...t pressure of the volume adjusting valve and a little air pass through to push the air inlet valve piston upwards and then the air inflow will decrease gradually during which time the system has begun to adjust the volume If the pressure continues to rise the air inlet piston will go up and close down and on the contrary if the system pressure lowers down the air inflow will be more when starting ...

Page 32: ... the oil level of static lubricating oil should be between high oil level line and low oil level line of oil level indicator Meanwhile the inner of air gas tank could be installed an oil level indicator optional part and if the oil level lower than the lower limit of oil level indicator the oil level on the plate will be over low and the warning lamp powers on Oil discharge valve is installed at t...

Page 33: ...bove methods and it is not necessary to use the automatic drainer Three Lubricating oil flow A Oil injection flow instruction Because of the pressure in the oil gas tank it compresses the lubricating oil into oil cooler After cooling the lubricating oil in the cooler and through the oil filter to remove impurities the pressure separates into two ways and one way injects into the compressed chamber...

Page 34: ...tilayer fine glass fiber The fog style oil gas in the compressed air almost can be filtered away through the oil gas separator and the oil particle size can be controlled below 0 1m and oil content below 5PPM The lubricating oil quality and its surrounding environment pollution degree will have a great influence on the service life of oil gas separator If the environment is severely polluted front...

Page 35: ...pressor Acceptance and Installation One Acceptance and Installation A Acceptance a When you get the air compressor please check its quantity model size and attached documents b Visually check the air compressor and its attachment to clear whether it is damaged during transportation c If there is any shortage or damage of the air compressor please mark out the condition and inform the business pers...

Page 36: ...age to keep the temperature Two Compressor Installation a Compressor unit installation The unit should be placed horizontally and tightly close to the foundation surface Foundation surface should be horizontal to avoid the big vibration of air compressor and loud noise b Compressor unit ventilation To keep the working temperature of the compressor unit stable the air should freely be in and out of...

Page 37: ... the delivering pipe should be less than 15m s to avoid the overlarge pressure drop g Try to reduce the usage of elbow and various valves in the pipeline to avoid the pressure loss h Ideal piping is that the main pipe line surrounds the whole factory so that we can get the compressed air in all aspects at any position If the air usage amount of certain branch suddenly increases a lot the pressure ...

Page 38: ...ing water determines the inflow temperature 3 120W 90 140 Allocated with necessary management category 4 150W 110 170 Water supply pump 5 175W 132 200 Seven Ordinary regulation of electrical equipment and safety rules a According to the using power of air compressor we choose the right power wire and can not use too small line if not the power line will burn out for high temperature and occur dang...

Page 39: ...t stop to check whether the rotating direction is right like the direction of arrow if the rotating direction is wrong please exchange any two lines among the tree power lines f Press again the button ON to start the air compressor g Observe whether the meter and indicating lamp is normal if appearing abnormal sounds vibration and oil leaking immediately press the button urgent stop to stop the ma...

Page 40: ...e carefully refer to the following disposal methods especially in high humidity seasons or districts A Stopping for over 3 weeks a Well wrap up the electric devices for example the motor control plate in plastic paper or oil paper to avoid the moisture entering b Totally discharge the water in the oil cooler and after cooler c First remove any failures in favor of the future usage d Discharge the ...

Page 41: ...on air compressor the time of replacing oil is more difficult to be confirmed we can send oil sample to our company for oil quality test after using the oil quality for 500 hours to assure the lubricating oil quality Repeat the above steps every 1000 hours and after several times we can make sure the oil change period of the air compressor and don t waste oil quality b Don t let the lubricating oi...

Page 42: ...st replace one belt or the tension will be imbalance d When do adjusting and replacing belts please note that don t make the lubricating oil splash on the belt or pulley e After adjustment the motor wheel and air end wheel must be on the same straight line if not the belt will be easy to be damaged and produce abnormal sounds Three System pressure adjustment A System pressure adjustment a Pressure...

Page 43: ...tting the discharge pressure tighten the locking nut then Five Oil gas separator replacing steps A 37 250KW Style a After stopping the air compressor open the water discharge valve at the air outlet and confirm there is no pressure in the system b Take apart the pipeline on the oil tank at the same time remove the pipeline from the pressure maintenance valve to the after cooler c Remove the set sc...

Page 44: ... replace g Machine malfuntion Operate th g Operate the machine by hand if unable to operate it please contact our service department One Unable start electrical failure lamp on f Phase lacking protect replay action Examine f Check power line and connecting point a Too low voltage a Ask electric worker to inspect and replace b Too high discharge pressure b Check the pressure meter if exceeding the ...

Page 45: ...eat dissipating area c Too long zero load c Increase the air consumption d Wrong air delivery temperature form d Replace the air delivery temperature form Four Exhaust temperature lower than normal value 75 e Heat control valve failure e Replace the heat control valve a Insufficient lubricating oil a Check the oil level if it is lower than L please stop the compressor and fill oil to H b Insuffici...

Page 46: ...re b Replace it with the new one c Time delay replay failure c Ask electric worker to inspect and replace it e Bad action of air inlet valve e Dismantle and clean the air intake valve and fill lubricating grease f Bad action of pressure maintenance valve f After dismantle check the valve seat and the non return flap valve block to find whether it is damaged if so replace them Seven Unable operatio...

Page 47: ...ce it a Pipeline leaking a Check the leaking position and lock it b Small set pressure value of empty and over load b Reset it the common differential pressure value is 0 1MPa Ten Frequent empty and over load c Unstable air consumption c Increase the air receiver volume a Oil stop valve leakage a Check it and if necessary replace it b Non return flap valve leakage b After dismantling it please che...

Page 48: ...bnormal one is which should be managed to remove away B Record the item from 5 to 10 in the form of number Our company ceaselessly reform and innovate our products while the instruction book revise always slow a pace so when you have any questions about the contents in the book or need detailed information please contact each service department of us We keep the right of reforming and improving ou...