compressor manual 2009

DMC SCREW COMPRESSOR SHANGHAI DAVEY MACHINERY CO., LTD

CONTENT

1、General ………………………………………………………… 2

1.1 Working principal ……………..……………………………………… 2

1.2 System control ………….…………………………………………… 2

1.3 Manipulation Temperature ……………. …………………………………… 3

1.4 Lubricant features …………………………………………………… 4

2、Installation requirements and inspection before running …………. 4

2.1 Hoist and transportation … ……………………………………… 4

2.2 Field requirements ……………………………………………… 5

2.3 Requirements for quality of cooling water …………….…………………… 6

2.4 Connection requirements for air pipe …………………………………… 6

2.5 Electric installation requirements .…………………………………… 7

2.6 Machine inspection ……………………………………………… 8

3、Daily operation ………………………………………………… 8

3.1 Preparations before running ………………………………………… 8

3.2 Start-up procedure for the first time …………………………………… 9

3.3 Start-up procedure for the daily time .……………………………………… 9

3.4 Turn-off procedure …………………………………………… 9

4、 Control panel operation（for pack series 4-15kw）…….……….… 10

4.1 Basic operation ……………………………………………… 11

4.2 Customer parameters …………………….…………………………. 12

4.3 Factory parameters ………………………………………… 15

4.4 Pressure Switch (for pa ck series with pressure gauge)……………………………… 16

4.5 Circuit diagram ………………………………………………… 17

5、 Control panel operation（for sc series 18-250kw）…………… 19

5.1 Basic operation …………………………………………………… 20

5.2 PLC functions and technical parameters ……………………………… 26

5.3 Control principle ………………………………………… 28

5.4 Alarm and notices …………………………………… 30

5.5 Safety protection ………………………………………………… 31

5.6 Histroy failure record check ……………………………………………… 32

5.7 Circuit diagram ………………………………………………… 33

6、 Maintenance ………………………………………………... 34

7、 Explored drawing ……………………………………… 39

8、 Troubleshooting ……………………………………………… 42

- 1 -


1、General

DMC screw air compressor adapts up-to-date structure design from Italy. Its key parts such as screw

air end, control valves are of European origin. It which falls into the category of products of

intellect-type and environments-protecting-type is microcomputer -controlled feathering compact

structure, high efficiency, low noise, long life period and so on. And it is the ideal air source equipment

popularly applied to textile, machinery, chemicals, electric, mining and other industrial areas. It runs

intelligently, and realizes long-range control and chain control.

1.1Working principle

Compression: the screw air end sucks air through air intake filter and intake control valve. Then the

rotary double shafts compress the air . At the same time, oil is put into the air compressing cavity making

the screw and bearing cool and lubricant.

Separation: The mixed gas of air and oil generated by compressing is exhausted into air and oil

separation cartridge. Most of oil is separated from the mixed gas under the influence of gravity and

mechanical centrifugal force. Almost all oil mist is separated out after the gas of air and oil is through

separation cartridge core. So then the oil amount of the mixed gas is below 3PPM. The oil separated

through separation cartridge core is back to screw principal machine through oil return tube. A throttle is

mounted on the oil return tube in order to keep the loss of compressed air in the lowest extent. The clean

oil flows into air end internal cavity after being filtered.

Cooling: After oil is separated, compressed air flows out of separation element through minimum

pressure valve then into after-cooler. Then cool the compressed air into a temperature towering above

environmental temperature by 7-10 degrees centigrade before it is discharged. Minimum pressure valve

guarantees the minimum pressure needed to keep up circulation of oil when the screw air compressor is

started or when it is running normally. Due to the check valve on minimum pressure valve, the

compressed air can’t flow backwards into separation element.

1.2 System control

The aim of having a control system is how to control the intake valve correctly to let air in normally. The

system is comprised of intake valve, work piston, magnet valve and pressure gauge.

Start-up: the intake valve shuts up under the influence of spring force. Hence only little air is sucked

through single-direct valve of intake valve to generate cartridge pressure to keep up circulation of oil

when screw air compressor is started up from no-load state.

Load: when compressor is running to a load state, it’s vacuum within compressor. And there is pressure

in intake filter. So, due to the difference of pressure, which makes the piston of intake valve work, intake

valve opens. Vacuum of one side lets air in then be compressed, which makes intake valve open fully.

After that, system pressure increases.

Full load: when the pressure of oil separation cartridge reaches 0.4MPa, minimum valve opens to let

- 2 -


compressed air flow out. (When the system pressure is lower than the rated pressure, intake valve will be

open all the time.)

No-load: when the pressure of empty pipeline reaches the maximum pressure rated by pressure switch,

the switch turns off the magnet valve’s power. Then there is no pressure difference. Intake valve shuts up

under the influence of spring force. Discharge magnet valve releases pressure and the pressure of

separation element goes down. All these make backpressure of frame end of screw air compressor low

down. When compressor is in the no-load condition, a little air goes in to keep certain pressure. It is

needed as working pressure of lubricant system to make rotors and bearing lubricant. When the pressure

of pipeline goes down to the rated load pressure, compressor is back to load state. Then magnet valve

gets power. Intake valve opens. Accordingly, the system pressure goes up. As per requirement to

compressed air, make the process be in a cycle.

Stop: when the compressor is stopped, all magnet valves’ power will be turned off. Then intake valve

will close up. Last the discharge magnet valve will release the cartridge pressure.

1.3Manipulation temperature

Screw air compressor’s environment temperature ranges from 5 degrees centigrade to 40 degrees

centigrade. Intake point is the measure point.

Condensation---low temperature

When the manipulation temperature is lower, water would concentrate in oil on the location of higher

degree of moisture. Compressor is equipped with a thermostatic valve. And the temperature is set to 70℃.

(Upon reaching the temperature, water vapors.) Oil won’t pass through the oil cooler until it reaches the

rated temperature.In the area of temperature below 5 ℃, anti-condensation apparatus should be mounted. And a heater should be installed under the separation element too.

Overheat---high temperature

The air sucked under this condition (environmental temperature is above 40℃ or the compressor is

installed in a house where there is a boiler) when the compressor is in full load state may be excessively

hot and above the cooling requirement. The air for cooling use had better be input from outdoors. When

the load rate is below 100% load, a higher environmental temperature can also meet the cooling

requirements. The maximum of working temperature of compressor is 105℃. If the temperature is above105℃, the compressor will be overheat and cease to work.

Discharge temperature

The measure point of discharge temperature is located in the vent of frame end of compressor. Discharge

would vary according to environmental temperature, load percentage, cleanliness of cooler, cleanliness

of intake filter and the cleanliness of oil filter. The normal manipulation temperature is between 70℃ and90℃.When the compressor is started up from a cool condition, the discharge temperature will go up

- 3 -


quickly to 85℃. Then thermostatic valve open fully. (it sets to open when the temperature is 70℃)If it is with down loads, oil temperature will be back to 70℃. At this time a little oil will pass through thermostatic valve in case the oil temperature be too low. With the increase of load, thermostatic valve

adjusts discharge temperature by control the oil amount through oil cooler.

1.4 Lubricant features

The feathers of DMC screw air compressor is as follow:

• Low degree of blister, not easy to volatilize

• High degree of anti-emulsification, high degree of anti-oxidation

• Motion viscosity (40℃) ㎟/s 32

• Pour point temperature -35℃ anti-solidification, low energy-consumption

• Flash temperature 230℃, anti-carbon-deposit, and low-energy-

consumption

Oil for bearing of motor:

Commended: Shell Alvania RL 3

2. Installation requirements and inspection before running machine

Examine in details whether there is damage due to transportation or not before accepting the compressor.

If any, please request the shipping company to confirm it by signing and contact us immediately.

2.1Hoist and transportation

• Guide rope should be used when compressor is being hoisted lest it be damaged. Check if welding

crack and bolt become loose after it is lifted up.As figure shows, a supporting board is needed when

compressor is being hoisted.

• If use a platform trailer to transport the compressor, make sure the trailer has enough driving-power.

• If use a forklift to transport the compressor, also make sure it has enough driving-power. Specific

requirement is subject to the local regulation.

The length of fork should not be less than the length of the base of compressor.


2.2Field requirements

• Compressor should be located in a clean, no-dust, well-ventilated place (discharge the heat wind from

upside, input air from bottom) with air excluding toxic gas, inflammable gas and explosive gas. Where it is

easy to maintain the compressor.

• Compressor mustn’t be used outdoors. Because there is a bad condition. That is, there is a great quantity

of dust. A filter screen should be mounted in the air intake of house in order to reduce the quantity of dust.

• Environmental temperature should be above 5℃ to guarantee lubricant a normal cycle.

• Some space (1m between compressor and wall is perfect) must be set aside in order to make daily

maintenance work convenient. See figure3.

• Compressor should be placed in a solid level surface. There is no using nut to fasten it.

Tip: D on’t put it in a place where the hot wind can be sucked circularly. (P ut it in a well-ventilated place)

If compressor is mounted in an enclosed room, an exhaust fan must be mounted in this room with a view to

keep the room temperature. The exhausting quantity must be more than air volume of circulating fan or

cooling fan. There should be enough area of entrance of cool air. The minimum of maintenance space should

be 500mm or above. If air entrance for cooling is in this direction, the minimum of maintenance space

should be 1000mm and above.

- 5 -


2.3 Requirement for cooling water and water-cooling set

• General hardness expressed by CaCo3 should be less than 100PPM (100 milligram/liter)

• PH value varies from 6-8

• Suspended material should be less than 50PPM (50 milligram/liter)

T i p: t he t e m pe r a t u r e of c o o li ng w a t er i s s et t o 32 ℃ . A nd t he w a t er qua lit y m u s t be i n con f o r m i t y w i t h

gene r al i ndu stri al w a t e r . A vo i d u si ng g r ound w a t e r . I f t he w a t er qua li t y i s not good, u s e pu ri f y i ng agent t o

c l ean depo siti ng d ir t pe ri od i ca l l y . I f t he co m p r e ss or co m es i n t o d is u s e f or a l ong tim e, d r a i n out a l l coo li ng

w a t e r .

2.4 Connection requirements for air pipe

• The diameter of discharge pipe should be at least the same as that of compressor. All pipes and connectors

should be able to bear the rated pressure. The configuration should meet the requirements for flowing

velocity of compressed air. And the pressure drop of pipeline mustn’t exceed the set pressure by 5% or more.

Try to use elements with a bent or high drag coefficient as little as may be. If the pipeline is relatively long,

adopt pipes with a diameter bigger than rated one.

• Don’t let this matter occur. That is, don’t let condensation water flow into working machine or elements

driven by air along the pipeline. An oil/water separation apparatus and a dirt-draining apparatus should be

mounted on front end of pipeline. Install the main pipe with a slope of 1-2 degrees, and then the condensate

water can be easily drained out.

• One-way valve, stop valve are mounted at the exit of compressor. And a sample connection of pressure and

a stop valve for maintenance and pipe-connecting use are mounted after them.

• Because there is an anti-vibration mat and not supporting things for fixing, all external pipelines should

have its individual supporting things. In order not to let condensate water flow back into compressor when it

stops, make pipeline lower than the air gate of compressor.

• When compressor is used with drier, an air reservoir should be installed in between compressor and drier.

In this case, it can low down the temperature of discharged air and separate a part of condensate water. At the

same time, compressed air of lower temperature and less amount of water is transported into the drier

through air reservoir. In such way, it can lessen the load of drier and save energy.

- 6 -


• Main pipeline going around the whole air-use house is the ideal plan. In this case, compressed air from

direction can be got anywhere. If there is a sudden increase of air-use quantity on some branch pipe, it can

reduce pressure drop. Moreover, mounting proper valves on main pipeline can insure convenience for

maintenance. Because we can cut it off, if necessary.

2.5 Electric installation requirements

All internal wires of compressor are through test by factory. All external wires linked to compressor must be

manufactured by qualified factory. According to the input working power required by compressor set, choose

right wire specification. If the wire is too long, line loss should be taken into consideration. Under this

circumstance, diameter of wire should be made bigger so as to meet the requirements for starting-up and

running.

Compressor of a big quantity of discharging air needs an individual power-supply system; otherwise it will

have bad influence on normal working of other equipment.

Make sure that power voltage meets rated working voltage of compressor before running it.

Reliable grounding of compressor set is needed to avoid dangers resulted in by power leaking.

Power supply

Standard requirements:

230V, 3 phase, 60Hz grounding




Other

Make special requirements on placing the order

Turning of motors

Power must be linked to compressor correctly to guarantee the right turning of motor. DMC screw air

compressor is equipped with a special apparatus to avoid contra-rotation of motor. (If the sequence of 3

phases is not correct, motor stops automatically to protect the motor.)

Particularized methods as follow: First, switch on power. Second, unloose the scram button. Third, press the

stop button. Then the machine will check itself. Finally, press the start button. If the machine is running

normally, that means the sequence of 3 phases is correct.

If the motor stops automatically, that means the sequence of 3 phases is not. Then exchange the two phases

of power input. (Instead of exchanging the wire ring of motor or the wire ring of starter, all these wire rings

are set to optimize the performance of motor.) Men with electrician certification should finish wire-linking

work.

- 7 -


2.6 Machine inspection

Inspection for screw air end

• Revolve the belt pulley or shaft coupling of gear end by hands from two different directions. Check if the

screw end is not locked.

• When compressor is not in use for more than two months or stored for a period of time, intake valve should

be opened. Then fill half-kilolitre of oil into compressor through it. Revolve the belt pulley or shaft coupling

of air end by hands from two different directions. Make sure all oil enters airr end.

• When reconnect inlet pipe, make sure nozzle is sealed.

Inspection for oil level

When open the side door, you can see the oil inspection mirror. The maximum oil level must not be higher

than the upper part of oil inspection mirror and the minimum oil level must not be lower than the bottom of

oil inspection mirror. The requirements also holds true when compressor is running.

Charge the rated amount of oil. Make sure the lid to the nozzle is screwed on well and seal ring is in good

condition.

T i p s : C ha r ge o i l acco r d i ng t o t he a m ount sti pu l a t ed. T o o m uch o i l wil l m ake t he co m p r e ss ed a i r con t a i n t oo

much oil. A nd too little oil will lead to high temperature of compressor.

Inspection for transmission system

• Inspection for belt

Check if all belts are in the groove. Adjust the tightness of belts through the adjusting bolt on motor.

• Inspection for flexible shaft coupling

Check if the bolt of the flexible shaft coupling is in fixed state.

Inspection for all valves of system

Check if stop valve is open.

3、Daily operation

The procedure below is for starting up for the first time or compressor being not in use for more than two

months.

3.1 Preparations before runningDMC screw air compressor is with an advanced delay-start/delay-stop function. This function can protect

motor, air end and electromagnetic starter so as to optimize operating performance.

Delay-start: This function is to avoid starting up continuously after power cut or emergency shut down.

During this period, compressor can’t be started up. Make sure the pressure is cut down to avoid starting up

the compressor when there is backpressure. Press the start button. And this signal will be put down

- 8 -


automatically by system. When the delaying time has elapsed, compressor will start up automatically.

Delay-stop: This is a soft stop function. This function makes compressor unload and cease to work. First,

press the stop button to unload compressor. Then it will be running for a while until the preset time and stop.

(This will contribute to reducing the pressure of oil separation cartridge.) During the delaying time, if press

the start button, the delaying time will be finished automatically. If the system pressure needs loading, the

compressor will load or unload normally.

3.2 Start-up procedure for the first time

• Check if the stop valve on outlet is open. (If the stop valve is open, this pressure is the pressure of

compressor system)

• Turn on power, and then power indicator light will be on. Compressor begins its delay-start. Starting

instantly is forbidden.

• Press start button to run the compressor, and then compressor is in the normal delay-start condition. Once it

reaches the preset time, compressor will start up automatically. (During the delaying time, press the stop

button, and then compressor will stop)

• Watch the manipulating temperature and system pressure on control pane to manipulate the compressor

correctly.

• When it reaches the pressure stipulated, Compressor goes on running. But it is running in a un-load state.

• Compressor supplies compressed air through loading and unloading. Pay attention to pressure, temperature

and power flux when manipulating it. Make sure there is no accidental vibration and compressor is running

smoothly.

3.3Start-up procedure for the daily time

• Check if oil level is correct. The oil level must be in the center of oil gage.

• Drain out the condensate water in the air-storing tank.

• Confirm that stop valve is open.

• Press start button. (Compressor does not start up automatically. But run light is flashing, it means

compressor is in a delay-start state.)

A tt en ti on: D o not st a r t up i t wit h i n 60 s econds a ft er co m p r e ss or i s st opped. R e l ea s e a l l p r e ss u r e wit h i n

s epa r a ti on e l e m en t . ( A v o i d t hat co m p r e ss or i s st a r t ed up w hen t he r e i s backp r e ss u r e.)

3.4Turn-off procedure

Press the stop button, and then the compressor will be in delay-stop state. Meanwhile, the stand-by indicator

light is flashing. After some time, the compressor stops.

If the compressor is start stopping, press the stop button to make it stop thoroughly.

Attention: when compressor is in stand-by state, it may stop and may start up at some time. So don’t take it

for granted that compressor has been stopped when the motor is not in motion. Check if the stand-by light is

on.

Tip: emergency shut down button is generally pressed on emergency.

- 9 -


4、 Control Panel (for PACK series 4-15kw without pressure gauge)

Type: M A M - 2 2 0 （ B ） - T

Attention

Please read this manual carefully before operation.

Only Authorized technicians are allowed to install MAM—KY.

Please take into fully consideration of the installation position during the mechanical installation to

ensure good vent condition and to minimize the electromagnetic interference.

During the wiring procedure, please separate the Strong current and light current lines to reduce the

electromagnetic interference.

A surging absorber must be applied to the inductive load such as the AC contactor of the relay output.

Check carefully for the wiring of the input/output before power applying.

Correctly grounding of the ground terminals of the unit (Third grounding) can improve the anti-noise

capability of the unit.

The presetting of the rating current of the motor (skip current) is set to Rated Current on the name plate

X Motor overload factor/1.2.

- 10

-


Features:

LCD English display

• Full protections for motor in terms of short-circuit, locked rotor, lack of phase, overload and unbalance.

• Start/Stop and operation control of the Motor

• Anti- reverse protection for Air Compressor

• Measuring, protecting and controlling multi-points temperatures

• Automatic adjust load rating to balance pressure

• Stable, reliable, competitive price with high value

• Remote / nearby control

• Block / independent operation

• RS-485 communication

4.1. Basic OperationButtons Description

MAM-220

GAS T:80℃STATE NORMAL STOP

POWER RUN

FALT

S RT ON

Figure 1

ON——Start Button: Press this button to start the compressor

OFF——Stop Button: Press this button to stop the compressor

S—— Set Button: users press this button to confirm the data inputted and save it after modification.

When compressor is running press this button will switch to load run / unload run.

▲——Up button: Press this button to move upward during data modification. Press this button to

select menu during the menu selection

▼——Down Button: Press this button to move downward during data modification. Press this button

to select menu during the menu selection

►——Cursor / Confirm Button: This button can be used as cursor during the data modification and as

confirm button during the menu selection

RT——Return / reset Button: Press this button to return to upper menu during the menu operation.

Press this button for 5 seconds to reset the machine when the unit is stopped in failure.

- 11

THIS RUNNING TIME FAILURE 1 CUSTOMER PARAMETER

THIS LOADING TIME FAILURE 2 FACTORY PARAMETER

OIL FILTER FAILURE 3

AIR FILTER FAILURE 4

O-A SEPERATOR FAILURE 5


Status Display and Operation

The display interface is as follow when the units are POWER ON:

SCREW

COMPRESSOR

The main display after 5 seconds will be the following:

P：0.8Mpa

S: NORMAL STOP

Attention: press“►” the position of “P:0.8 Mpa” change to display “T:080‡” .

Press “▼” Enter the following Menu Selection Interface:

TOTAL RUN TIME：******H*

*M

Run the Parameter Review

Press ‘▼’button, parameters and status are as follows

LOADING TIME LUBE TIME PRODUCE DATE

MAIN MOTOR CURRENT LUBE GREASE PRODUCE NO.

4.2 Customer Parameters

T ip : T h e C us t o m e r P a r a m e t e r s a nd t h e F a c t o r y P r e s e t P a r a m e t e r s c a nn o t b e m od i f i e d du r i n g t h e R unn i ng S t a t e a nd S t op D e l a y i ng p er i od

Press the ‘▼’ button, the last page is the ‘CUSTOMER SET’ and ‘FACTORY SET’. Or on the main menu,

your can press the ‘▲’button, immediacy turn to the ‘CUSTOMER SET’ and ‘FACTORY SET’. Interface.

CUSTOMER SET

FACTORY SET

- 12


At this time, press “▼” button or “▲”button, the black cursor will move to select “CUSTOMER SET” Or “FACTORY SET”，when the black cursor is on the “CUSTOMER SET ”, press “►” button ,

the following interface will appeared

LOADING P： 00.65MPa

The CUSTOMER PARAMETER is being showed now without press the CONFIRM button ‘ ’.

Press the CONFIRM button ‘ ’ again to pop up the following interface where the password input

is needed:

PASSWORD

****

A tte n t i o n : The C us t o m e r P a sswo r d ca n m e m od i f i e d i n t he C U S T OMER P A R AM ETE R , t he F AC T O R Y P A SS W O R D i s ****

The ‘▼’ or ‘▲’ button return to be black cursor and the button ‘►’ return to be the CONFIRM

button. Press the CONFIRM button ‘►’ when the cursor is over the menu ‘LOADING P’, now the

blinking appears and the button ‘▼’ and ‘▲’ are Page-Up and Page-Down button for changing the

current value. The button ‘►’ is now the move button to move the position where the modification

is needed; Press ‘S’ to confirm and the blinking will disappear. The ‘▼’ or ‘▲’ return to be black

cursor move button and the button ’ ►’ change back to be CONFIRM button to continue to modify

the other CUSTOMER SET. If there are no other parameters needed to be modified, press the button

‘RT’ to return to the upper menu or the main menu. The other CUSTOMER Set could be modified

with the same method as above.

Customer Parameters Fuctions

Parameter Preset Value Functions

LOADING P *.**MPa Loading pressure value

UNLOADING P. *.**Mpa Unload pressure value

FAN START T ***℃Control the fan starting. This value will be set to‘120℃' if there is no fan present or the fan is not required to be protected.”

FAN STOP T ***℃ Control the stopping of the fan

MOT START TIME 0008s

When using the controller to protect the motor, it

is required that the time here defined will not

meet the impulse starting current of the motor, the

value here must be longer than the STAR DELAY

TIME plus LOAD DELAY TIME

- 13

-


STAR DELAY TIME 0006S Star pressure release starting delay time.

LOAD DELAY TIME 0002SThe loading delay time after star contactor

releasing.

EMPTY RUN TIME 0020MLoad free continuous running time, the machine

will automatically stop after this time

STOP DELAY TIME 0010SThe machine will not stop until this time passed

the load free state when stop the machine

BLOWDOWN TIME 0100SMachine can not be restarted before this set time

after stopped or over time operation

ON/OFF MODE Machine side

When the remote mode is set, both the buttons at

machine side and the remote control button can

turn on and off the machines

LOAD MODE AutoWhen the manual mode is set, the Load/Unload

function can only be executed by pressing buttons

CLR OIL FILTER 0000 HOURS Reset time for the duration of oil filter changing

CLR O/A SEP 0000Hours Reset time for O/A Separator changing

CLR AIR FILTER 0000Hours Reset time for air filter changing

CLR LUBE 0000Hours Reset time for Lubricate Oil Changing

CLR GREASE 0000Hours Reset time for Lubricate Grease Changing

MAX OIL FILTER 9999HoursSet this value to ‘0’ will make the oil filter alarm

not available

MAX O/A SEP 9999HoursSet this value to ‘0’ to disable the O/G separator

alarm function

MAX AIR FILTER 9999HoursSet this value to ‘0’ to disable the alarm function

of gas filter

MAX LUBE 9999HoursSet this value to ‘0’ to disable the time alarm of

lub. oil

MAX GREASE 9999HoursSet this value to ‘0’ to disable the time alarm of

Lub. Grease

COM MODECOMPUTER/BLOCK

/PROHIBITSelect communications mode

COM ADD 0001-0255

BLOCK STATEMAIN

Act as Host or Secondary Machine

when there are more than one machines

The HOSTcontrols the others

BLOCK NUMBER 0016

BLOCK LOAD P*.**MPa

BLOCK UNLOAD P *.**MPa

- 14

-


BLOCK DELAY 0000S Blocking delay time

LANGUAGE SEL ENGLISH/CHINESE Select language

POWER FREQ 50Hz/60Hz Select power frequency

PHASE PROT INACTIVE/ACTIVE Active or inactive phase sequence protect

4.3 Factory ParametersThe difference between the ‘CUSTOMER SET’ and the ‘FACTORY SET’ is that the ‘FACTORY SET’

can not be modified unless you have the factory password from the manufacturer. The main functions of

the

‘FACTORY SET’ are as the following table.

Factory Parameter Initial Value Functions

MANI MOTOR

CURR.

MAXIMUM

OVERLOAD VAULE

OF THE MOTOR /1.2

After the starting delay time, when the motor

current is greater than 1.2 times of the set value

and less than 4 times of the set value, the unit will

jump as per overload feature.

PRE-ALARM T 105℃ Alarm when the temperature reaches this set value

STOP T. 110℃ Alarm when the air exhausting temperature

reaches this set value.

STOP P. 1.00MPaAlarm and stop machine when the air supply

pressure reaches this set value

MAX UNLOAP 0.80MPaThe Unload Limit Pressure in the Customer

Parameter must be set lower than this value.

CLR LOAD TIME ****Hours The factory can modify the load running time

CLR TOTAL TIME ****Hours The factory can modify the total running time

CLR ALM RECORD **** Input password to clear all the history failures.

UNBALANCE

SCOPE0006

When unbalance is not greater than (1+set value),

the unbalance protection will stop the machine. If

the set value is greater than 15, the unbalance

protection will be disabled.

LACK PHASE

STOP0005S

Set the LACK PHASE TIME ≥20S, the Lack

phase protection will be disabled, if the unbalance

protection is active, it will be started.

PROD. DATE ****Y**M**D The factory input the product date of the unit.

PROD. NO. ****** The factory input the product No.

- 15

-


4.4 Pressure Switch (for PACK series with pressure gauge)

T i p s : wo r k i ng p r e ssu r e ca n b e a d j us t e d on l y b y p r e ssu r e sw it c h a nd i nd i c a t e d i n p re ssu r e

g a u g e f or t h i s m od e l

Pressure switch is used to controls compressor operation within the set switching limits. If the supply pressure drops to the Switch-on pressure( Pmin), the compressor will switches on, if the supply pressure increases to the switch–off pressure (Pmax),the compressor will switches off.There are two adjusting screws on the top of pressure switch.

1(DIFF)—is to adjust difference of Pmax / Pmin.2(RANGE)—is to adjust Pmax .In normal, Diff value is between 1.0-1.5bar, Max Pressure value is 7-10bar.

W ARNI N G : Do n ot a d j u st P m ax u p t h an s ett in g va lu e o f c o m p r e sso r p r e ss u r e o p t i o n a ll y .

- 16

-


4.5 Circuit diagram

- 17

-


- 18

-


5、 Control Panel (for SC series 18.5-250kw)

T Y P E : M A M - K Y 0 2 S（ B

）-（ Ⅷ ）

Attention

Please read this manual carefully before operation.

Only Authorized technicians are allowed to install MAM—KY.

Please take into fully consideration of the installation position during the mechanical installation to

ensure good vent condition and to minimize the electromagnetic interference.

During the wiring procedure, please separate the Strong current and light current lines to reduce the

electromagnetic interference.

A surging absorber must be applied to the inductive load such as the AC contactor of the relay output.

Checking carefully for the wiring of the input/output before power applying.

Correctly grounding of the ground terminals of the unit (Third grounding) can improve the anti-noise

capability of the unit.

The presetting of the rating current of the motor (skip current) is set to Rated Current on the name plate

X Motor overload factor/1.2.

- 19


Features:● LCD English display

● Full protection function for the motor in short circuit, locked rotor, phase lost, overload or unbalance.

● StartIStop and operating control of the Motor

● Anti- reversing protection of Air Compressor

● Measuring and protection controlling to multi-points temperatures

● Automatic adjusting load rating to balance pressure

● High Integrity, Stable reliability and excellent value-ability

● Optional remote I machine side control

● Optional interactiveI independent operation

● RS-485 communication interface function

5.1 Basic Operation

Buttons Description

GAS T:80℃ GAS P:0.8MPaSTATE NORMAL STOP

0S REMOTE

ON M

Figure 1

ON——Start Button: Press this button to start the motor

OFF——Stop Button: Press this button to stop the motor

M——Set Button: Press this button to confirm the input data to be saved after modification of the data.

——Up button: Press this button to move upward during modification data. Press this button to select

menu during the menu selection

——Down Button: Press this button to move downward during modification data. Press this button to

select menu during the menu selection

——Cursor I Confirm Button: This button can be used as cursor during the data modification and as

confirm button during the menu selection

RT——ReturnIPreset Button: Press this button to return to upper menu during the menu operation.

Press this button to reset the machine when the unit is stopped in failure.

- 20

-


Status Display and Operation

The display interface is as following when POWER ON:

Welcome to use

***Screw Air Compressor

The main display after 5 seconds will be the following:

GAS T：20℃

GAS P：0.60Mpa

STATE：NORMAL STOP

NEAR

Press “1” Enter the following Menu Selection Interface:

RUN PARAMETER

CALENDAR

CUSTOMER PARAMETER

FACTORY PRAMETER

Run the Parameter Review

Press ‘1’or ‘f’ to move the black cursor over the menu ‘RUN

PARAMETER’and then press ‘ W to popup the submenu:

HOST、FAN CURRENT

TOTAL RUN TIME

CURRENT RUN TIME

MAINTENANCE PARAMETER

Press ‘ W to pop up another menu:

CUR(A)：R S T

HOST： 56.1 56.2 56.0

FAN： 4.1 4.1 4.1

If the menu pop up is the last menu level, the black cursor will disappeared, press the RETURN button ‘ RT’ and return to the upper menu or the main interface. If the operation is stopped in a certain interface, it will automatically return to the main interface after several seconds.

Using the moving buttons ‘1W , ‘fW ,CONFIRM button ‘ W return button ‘ RT’ to view the

RUN PARAMETERS such as the CURRENT RUN TIME MAINTENANCE

PARAMETER,

- 21

-


HISTORY FAILURE, PRODUCING DATE and CURRENT FAILURES and then return to the

upper menu with the similar method of the above.

Calendar and Time

Press ‘1’ or ‘f’ to move the black cursor to the menu ‘CALENDAR’ and then press ‘ ’ , the following

menu will be pop up:

DATE AND TIME

2004 Y 2 M 22 D

SUNDAY

12 H 46 M 59 S

At the stop status of the unit, the date and time could be adjusted according to the following steps: Press

‘1’ or ‘f’ to move the black cursor to the parameters you want to modify and then press ‘ ’ to reach the

blinking position. Now the button ‘1’ and ‘f’ are changed to ‘Pageup’ and ‘Pagedown’ button. Press

‘M’ button to confirm and save the data after finish the modification. The buttons ‘1’ or ‘f’ return

to black cursor move button and the button ’ ’ change back to its Return function.

CUSTOMER PARAMETERS

T ip s: T h e C us t o m e r P a r a m e t er s a nd t he F a c t o r y P ara m e t e r s ca nnot b e m od i f i e d du r i ng t he R unn i ng S t a t e a nd S t op D e l a y i ng p er i od

The Customer Parameters could be read and modified with the same method of running the

Parameter Review mentioned above. For example, to modify the parameter BLOCK UNLOAD

PRESSURE, the steps will be as the following:

Press ‘1’ or ‘f‘ to move the black cursor to ‘CUSTOMER PARAMETER’ menu and then press

the CONFIRM button ‘ ’ to pop up the following menu:

SET P、T

ONIOFF DELAY PRESET

OP. MODE PRESET

BLOCK PARA PRESET

Press the CONFIRM button ‘ ’ again to reach the following menu:

LOADING P 0.8MPa

UNLOADING P 0.6MPa

FAN START T

80℃

FAN STOP T：

70℃

The CUSTOMER PARAMETERS can be read now when the CONFIRM button ‘ ’ is not

pressed now. Press the CONFIRM button ‘ ’ again to pop up the following interface where the

password input is needed:

- 22

-


ENTER

A tte n t i o n : The C us t o m e r P a sswo r d ca n be m od i f i e d i n t he C U S T OMER P A R AM ETE R , t he F A C T O R Y P A SS W O R D i s ****

The Blinking Position will appear after this interface displayed. The button ‘1’ and ‘f’ have been

changed to PgUp and PgDown button that could be used to change the current value. The button

‘ ’ is changed to move button to move the position where the modification is needed, Press ‘M’

to confirm and the following interface will be displayed:

BLOCK LOAD P: 0.8MPa *

BLOCK UNLOAD P: 0.6MPa

FAN START T:

80℃ FAN

STOP T:

70℃

When there is a ‘*’

displayed at the up right

corner, it means it is at the

CUSTOMER

PARAMETER set status.

The ‘1’ or ‘f’ button return to black cursor and the button ‘ ’ return to be the CONFIRM button.

Press the CONFIRM button ‘ ’ when the cursor is over the menu ‘ BLOCK UNLOAD PRESSURE’,

now the blinking position appears and the button ‘1’ and ‘f’ have been changed to PgUp and PgDwn

button that could be used to change the current value. The button ‘ ’ is changed to move button to move

the position where the modification is needed, Press ‘M’ to confirm and the blinking position will

disappear. The ‘1’ or

‘f’ return to black cursor move button and the button ’ ’ change back to its CONFIRM button

to continue to modify the other CUSTOMER PARAMETERS. If there are no other parameters needed to

be modified, press the button ‘RT’ to return to the upper menu or the main menu. The other CUSTOMER

PARAMETERS could be modified with the same method above.

The CUSTOMER PARAMETERS menu list

First Submenu Second submenu Preset Value Functions

SET P. T.

UNLOAD P. *.**Mpa Unload pressure value

LOAD P. *.**MPa Load pressure value

FAN START T. ***℃

Control the fan starting. This value will be set to ‘120℃' if there is no fan present or the fan is not required to be protected.‛

FAN STOP T. ***℃

Control the stopping of the fan

- 23

-


HOST START TIME 0008s

FAN START TIME 0006s

When using the controller to protect the motor,

it is required that the time here defined will not

meet the impulse starting current of the motor,

the value here must be longer than the STAR

DELAY TIME plus LOAD DELAY TIME

When using the controller to protect the motor,

it is required that the time here defined will not

meet the impulse starting current of the motor.

STAR DELAY TIME 0006S Star contactor release starting delay time.

The loading delay time after star contactor

ONIOFF DELAY

TIME PRESET

LOAD DELAY TIME 0002S

EMPTY DELAY 0020M

STOP DELAY TIME 0010S

START DELAY TIME 0100S

releasing.

Load free continuous running time, the machine

will automatically stop after this time

The machine will not stop until this time passed

the load free state when stop the machine

Machine can not be restarted before this set time

after stopped or over time operation at load free

state

STANDBY DELAY TIME 0000S Additional functions

The continuous draining time during the

OPERATION

MODE PRESET

DRAIN OPEN TIME 0002S

DRAIN CLOSE TIME 0010M

MachineONIOFF MODE

side

LOAD MODE Auto

COM MODE Prohibited

automatic draining control.

The Draining Gap duration during the

automatic Draining control

When the remote mode is set, both the buttons

at machine side and the remote control button

can turn on and off the machines

When the manual mode is set, the LoadIUnload

function can only be executed by pressing

buttons

When this is set to ‘PROHIBIT’ the

communication function is not available

COM CODE 0255 Communication address

Act as Host or Secondary Machine when there

are more than one machines running in

BLOCKING

PARAMETERS

PRESET

MAINTENANCE

PARAMETER

BLOCKING MODE HOST

BLOCKING ONIOFF Sequence

SWITCHING TIME 9999 Hours

BLOCK NUMBER 0016

BLOCK LOAD P *.**MPa

BLOCK UNLOAD P *.**MPa

BLOCK DELAY TIME 0000S

0000OIL FILTER RESET

HOURS

blocking mode. The HOST controls the

SECONDARY

Reset time for the duration of oil filter changing

- 24

-


PRESET OIA RESET 0000Hours Reset time for OIG Separator changing

AIR FILTER RESET 0000Hours Reset time for gas filter changing

LUB OIL RESET 0000Hours Reset time for Lubricate Oil Changing

LUB GREASE RESET 0000Hours Reset time for Lubricate Grease Changing

Set this value to ‘0’ will make the oil filter

MAX LIFE

TIME PRESET

LANGUAGE

SELECT

NEW USER

PASSWORD

OIL FILTER 9999Hours

OIG SEPARATOR 9999Hours

GAS FILTER 9999Hours

LUB. OIL 9999Hours

LUB GREASE 9999Hours

English

****

alarm not available

Set this value to ‘0’ to disable the OIG separator

alarm function

Set this value to ‘0’ to disable the alarm

function of gas filter

Set this value to ‘0’ to disable the time alarm of

lub. oil

Set this value to ‘0’ to disable the time alarm of

Lub. Grease

Set to ‘ENGLISH’ will change the interface to

be English display.

Customer could modify the user password

FACTORY PARAMETERS

The difference of the FACTORY PARAMETERS and the CUSTOMER PARAMETERS is that

the FACTORY PARAMETERS cannot be modified unless you have the initial password from the

factory. The modification method of the FACTORY PARAMETER is the same as that of the

CUSTOMER PARAMETER. The main functions of the parameters are as the following table.

PARAMETER Initial Value Functions

HOST RATED

CURR.

MAXIMUM

OVERLOAD VALUE

OF THE MOTOR I1.2

After the starting delay time, when the motor current

is greater than 1.2 times of the set value and less than

4 times of the set value, the unit will jump as per

overload feature.

FAN RATED CURR.

MAXIMUM

OVERLOAD VALUE

OF FAN MOTOR I1.2

Same as above

PRE-ALARM T 105℃

Alarm when the temperature reaches this set value

STOP T. 110℃

Alarm when the air exhausting temperature reaches

this set value.

STOP P. 1.00MPaAlarm and stop machine when the air supply

temperature reaches this set value

UNLOAD LIM P 0.80MPaThe Unload Limit Pressure in the Customer

Parameter must be set lower than this value.

MODI LOAD TIME ****Hours The factory can modify the load running time

MODI TOTAL TIME ****Hours The factory can modify the total running time

- 25

-


HISTORY FAULT

RESET****

Input the history failure password to clear all the

history failures.

UNBALANCE

SCOPE0006

When (the max. phase currentImin. phase current) is

greater than (1+set value), the unbalance protection

will stop the machine. If the set value is greater than

15, the unbalance protection will be disabled.

LACK PHASE

STOP0005

Set the LACK PHASE TIME ≥20S, the Lack phase

protection will be disabled.

0000 M

PROD. DATE ****Y**M**D The factory input the product date of the unit.

PROD. NO. ****** The factory input the product No. of the unit

5.2. PLC Functions and Technical Parameters• Switching value：8 ways of switching value input; 10 ways of relay switching value input.

• Analog quantity：2 Pt100 temperature input; 2 ways of 4～20mA transferred input; 2 groups of 3

phase current input (Match with CT)

• Input voltage of phase sequence: 3 phase 460VI230V.

• Working Power of the controller: 100V-220V, 50HzI60Hz, 20VA.

• Display measuring Range:

Oil Temperature of Oil: —20～150℃;

Accuracy: ±1℃. Air Temperature: —20～150℃ Accuracy: ±1℃. Running

Time: 0～999999Hours.

Current Display Measuring Range: 0～999.9A.

Pressure: 0～1.60Mpa, Accuracy: 0.01Mpa.

• Phase sequence Protection: When the protector detects the wrong phase sequence, it activate for the

time≤2s.

• Motor Protection: This control unit has the following 5 basic protection functions.

-Rotor Lock protection: After the starting of the motor, if the working current reaches 4 or 8 times

of the set value, the protection activates. The activate time is less than 0.2s.

-Short-Circuit Protection: if the detected current reaches 8 times or more above the set value,

the protection activates, the activate time is less than 0.2s.

-Lack phase protection: Any of the phase lack, the protection activates and the activate time is

the setting time.

-Unbalance Protection: the current difference between any of the two phases reaches the percentage

of the setting value, the protection activates and the activate time is less than 5s.

-Overload anti-time limitation protection (time unit: s): See the following table. The multiple=I Actual value／I Set Value.

When the running current of the motor is in 1.2 ~3.0 times of the set value, the overload multiple and

action delay time will be accordance with the following table.

IactII set

Time Para≥1.2 ≥1.3 ≥1.5 ≥1.6 ≥2.0 ≥3.0

Action time 60 48 24 8 5 1

-Temperature Protection: When the actual detected temperature is higher than the set temperature,

- 26


the protection activates and the activate time≤2s.

-The output relay contactor capacity:250V5A. The life time of the contactors: 500000 times of running.

-The current display tolerance <1.0%.

-RS—485 communications.

Controller installation

The Controller will be installed in the control cabinet. There must be enough spaces around

the controller for the accessibility when making the wiring. The recommended sizes are as below:

1. Input LCD （ IN）：00, 01, 02, 03, 04, 05, 06 and 07 is relatively

correspond to the input switching value

terminals of 20, 19, 18, 17, 16, 15, 14 and 13.

2. Output LCD（OUT）00, 01, 02, 03, 04, 05, 06, 07, 08 and 09 is

relatively corresponded to the output

switching value terminals of 27, 28, 29, 30,

31, 35, 36, 37, 38 and 39.

3. Power LCD：PWR 灯4. Running LCD: RUN LCD

5. FAILURE LCD: ERR LCD

Diagram 6:

Main Control Unit

Structure Size

2. The Basic

Wiring diagram of

the

electronic

Installation.

- 27

-


Text Display connector terminals:

There are five connect terminals and one D type display cabal connector which are relatively used for the

display connector, Rs—485 communication interface and 24V Power input

Controller Connect Terminals:

The display panel is connected with the controller using communication cabals. 23, 24 and 25 are the

phase sequence input terminals; 7 and 9 are the Air Exhaust Temperature Input terminals; CT1 is the host

mutual inductor; CT2 is the fan mutual Inductor. 32 is the common port COM1 of the relay output; 27

controls the main contactor; 28 controls the star contactor; 29 controls the angel contactor; 30 is the

loading magnetic valve; 31 controls the Fan; 34 controls the Load release valve: 37 is the running

indicator; 38 is the Failure indicator; 39 is the Alarm indicator; 40 is COM2; 42 is the simulated ground

(Earth); 43 and 44 are the 220V power source.

A tte n t i o n : t h e m a g n e ti c c o i l m us t b e c onn ec t e d t o t h e su r g i ng a bso r b e r wh e n w i r i ng

5.3 Control Principle

Individual Control-Local Automatic control (ONIOFF mode: Beside Machine; Loading method: Automatic)

• Press ‘I’ to start:˄Y— Starting When the controller is powered on, it will perform a 3S self-checking. Press the ‘I’ button cannot

start the machine until the self-checking is completed. The starting process of the host will be as the

following: KM3 is powered on, KM2 is Powered on - Y type Starting Status - Time Delay

finish

˄Y— converting time , KM3 loss power (KM1 and KM3 interlocked) ，KM1 is powered on -

Motor runs in type and the Starting is completed. The load magnetic Valves are without

power during the whole starting process to ensure the load free starting.

• Automatic Running Control:

When the motor is started to running in state and load the magnetic valve with power applied

after a certain period of delay. Then the air compressor will be applied with air pressure to increase

- 28

-


the pressure in the air tank. When the air pressure reaches the value over the set unload pressure

(unload pressure value), the loading magnetic valve will loss power and the release magnetic valve is

applied with power to run the air compressor with load free. If in the specified time (load free

running period) the air pressure turns to be lower than the set load pressure (LOAD PRESSURE

VALUE), the load magnetic valve obtains power and the release magnetic valve losses power, the air

compressor will apply normal pressure to increase the pressure in the air tank. If the pressure in the

air tank is not drop down to the load pressure limit within the empty free running time, the controller

will automatically stop the running of the motor to perform the automatic stop of machine for over

time empty free running. Only when the pressure drops to the load pressure limit, the motor could

restart according to the normal starting process and it runs repeat in this way.

• Manual LoadIunload at the automatic status

At the automatic status, the unit will stay in the unload state, press the button ‘1f’ to load, if the

pressure is higher than the unload pressure, the load magnetic valve will inch once and then return to

the unload status; if the pressure is lower than the unload pressure, the load magnetic valve will be

applied with power and will not stop running and return to the unload state until the air supply

pressure becomes higher than the unload pressure. When the unit is at the load state, press the button

‘1f’ to unload. If the pressure is higher than the load pressure, the load magnetic valve will loss the

power and return to the load state till the air supply pressure becomes lower than the load pressure. If

the pressure is lower than the load pressure, the unload function is disable.

• Normal Stopping:

Press the button ‘O’, the load magnetic valve will loss power and the unload magnetic will be

applied with power, after a while of delay (stop delay), the motor contactor will loss power, the host

and fan will stop running, after the restarting delay completed, the unload magnetic will loss power.

Only pressing the button ‘I’ could restart the motor.

• Frequency starting prevents control

The motor can not be started immediately unless after a while of time delay after stopped by pressing

‘O’ button or stopped due to failure. Whenever the situation is, this controller will display the

remaining count down of the time delaying (such as 90s). The motor can only be started when the

time display is 0.

-Remote Automatic Control (ONIOFF mode: Remote; Load mode: Automatic)The remote automatic control is almost the same as the local automatic control, the only difference is

that the start and stop of the unit is controlled by remote control.

-Local Manual Control (OnIOff mode: beside machine; Load mode: Manual)The Starting and stopping control is the same as the automatic control, the only difference is that

when the starting procedure finished in this mode, the machine is at the load free state and will be

loaded by pressing the button ‘1f’. When the air supply pressure is higher than the unload pressure,

the unit will load automatically, if the button ‘1f’ is not pressed to load, the unit will be running at

the load free state till load free stop. During the unload process, press the button ‘1f’ to load and

during the process of loading, press the button ‘1f’ to unload

-Remote Manual Control (OnIOff Mode: Remote; Load mode: Manual)The remote automatic control is almost the same as the local manual control, the only difference is

that the start and stop of the unit is controlled by remote control.

- 29

-


Network controlWhen the control network is set to ‘COMPUTER’, it could perform the computer network control

of the units

Set the controller communication to ‘BLOCKING’ could perform the network control between the

controllers but the host must be 1# controller.

Fan Temperature controlWhen the air Exhausting temperature is higher than the fan starting temperature, the Fan motor will

run; when the air exhausting temperature is lower than the fan stop temperature, the fan motor will

stop running. If there is no fan or the fan is not necessary to be protected, set the starting

temperature of the fan to ‘120℃’ and the stop temperature to be ‘70℃’.

Failure stop and Emergency stopWhen there is any electronic failure or high air temperature failures occurred during the running

process, the controller would stop the motor immediately. The motor can only be restarted after the

failures are cleared. Any emergency situation occurred, please press down the emergency stop

button to cut off the power supply of the controller and contactor power.

5.4 Alarm and Notices

Text Display tipsAir filter Alarm tips

• Check the alarm using the switch signal

The controller can display the message on the text display to remind the operator that ‘ the air

filter is blocked’ by checking the pressure difference switch operating state.

• Set the running time alarm of the air filter

The Text displays ‘Air filter life terminated’ when the using time of the air filter terminates.

Oil Filter alarm tips


The controller can display the message on the text display to remind the operator that ‘ the oil

filter is blocked’ by checking the pressure difference switch operating state.

• Set the running time alarm of the oil filter

The Text displays ‘Oil filter life terminated’ when the using time of the oil filter terminates.

Oil separator alarm tips


The controller can display the message on the text display to remind the operator that ‘ the oil

separator is blocked’ by checking the pressure difference switch operating state.

• Set the running time alarm of the oil separator

The Text displays ‘Oil separator life terminated’ when the reach using time of the oil separator.

Lubricate Oil alarm tips

• The Text displays ‘Lubricate Oil life terminated’ when reach the using time of the lubricate oil .

- 30


Lubricate Grease alarm tips

• The Text displays ‘Lubricate Grease life terminated’ when reach the using time of the lubricate.

Main Controller Tips

Item Meaning and Functions Lights Status

POWER Controller Power on PWR Lights

RUN Controller run RUN Lights

Failure Detect failure and Stop the unit ERR Blinking

Input Switching

Value

Terminal 20～12 Input switching

value activate

IN00~08 lights, but if there is no function at the

input point, no light lighting

Output Switching

Value

Terminals 27,28,29,30,31,35,36,37,38

and 39 output switching value activateOUT00~09 lights

Data Save Set Data and save time PWR blinking once

5.5 SAFETY PROTECTION

Motor Protection

• MAM — KY02S air compressor controller can perform the short-circuit protection, rotor

lock protection, overload protection, Phase Lacking Protection and Unbalance Protections to the motor.

Electronic

failureFailure Display Possible Causes

Short-CircuitLocal Failure display ‘Host or Fan

short-circuited’

Short-circuited or the rated current is

wrongly set

Rotor lockLocal Failure display ‘Host or Fan Rotor

Locked’

Overloaded, Bearing wear off or other

mechanic Failures

OVERLOADLocal Failure display ‘Host or Fan

Overloaded’

Overloaded, Bearing wear off or other

mechanic Failures

Phase LackLocal Failure display ‘ Host or Fan

Phase Lacking’

Phase lacking occurred to the Power or the

connectors

UnbalanceLocal Failure display ‘ Host or Fan

current unbalance’.

Contactors are not contacted correctly or

the motor inner parts open.

Air Exhaust overheat protection

• When the air exhaust temperature is higher than the set limited unload temperature, the controller will

alarm and stop the machine. Local Failure display ‘Air Exhaust High Temperature’.

• Reverse running protection of the air compressor

- 31

-


A t t e n t i o n : W h e n t h e ph a s e s e qu e n c e of t h e p ow e r c onn e c t e d t o t h e a i r c o m p r e ssor i s not c on f o r m t o t h e s e t of t he c on t r o ll e r , t h e l o ca l f a i l u r e d i sp l a y s ‘ W r o n g ph a s e s e qu e n c e ’ a nd

a s a r e su l t t h e c on t r o ll e r ca n no t s t a r t t h e m o t o r . I t i s n ee d e d t o c h e c k a nd a lt e r n a t e a n y t wo of

t he phase sequence and i nvesti gat e t he m ot or rot at ion di recti on.

Over Pressure protection

When the pressure of the air exhaust is higher than the set stop pressure of the controller, the controller

will alarm and stop the machine, the local failure displays ‘Pressure too high’.

Sensor Failure Protection

When the cable of the pressure sensor or the temperature sensor is broken, the controller will alarm and

stop the machine and the local failure displays ‘** sensor failure’.

5.6 History failure record check

The failures caused by the peripheral equipments of the controller could be investigated by

queering from the local failure record or the history failure record to find out the failure causes and

solves the relative problem.

- 32

-


5.7 Circuit diagram

- 33

-


6. Maintenance

6.1Maintenance items and maintenance periodCompressor will not be in a good motion, unless it gets adequate maintenance. Right maintenance can

prolong its service life and greatly cut down the time of stopping due to failure.

Daily manipulation

Before starting up: drain out the condensate water in the bottom of oil separation until some oil flows out.

And check if the oil level is in correct position.

Attention: Don’t open oil-discharging ball valve until five minutes later after stopping

After starting up: Watch the pressure on the control panel. Check manipulating temperature and the general

conditions inside compressor. Check if there is leakage on the outer surface of cooler or on bolts.

Maintenance plan

Check the running temperature and working pressure. (Every day)

Put down the current, voltage, temperature and pressure. (Every day)

Clean compressor. (Only after stopping). (Every week)

Blew wash the ail filter. (Every week)

Check oil level. (Every month) Check the bolts on the belt pulley (shaft coupling). (Only after compressor

stopping)

Blew wash cooler. (Every month)

Make maintenance every 500 hours

Check the quality of oil. If it is qualified, it can be used again after be filtered cleanly. Otherwise, replace it.

Replace the core of oil filter

Replace the core of intake filter

Replace the core of oil separation

Replace the filtering net of oil return pipe

Check the fatness of belt pulley or the labiality of the shaft coupling.

Attention: Reduce the replacing time, if the environment is spoiled excessively.

Every 2000 hours

Replace the core of oil filter

Replace the core of intake filter or intake filter

Check and adjust the fatness of belt pulley or the labiality of shaft coupling.

Check intake-controlling valve

Every 4000 hours

Replace lubricant

Replace the core of oil separation or oil separation

Replace the minimum-pressure control valve

Check thermostatic valve

Check if the electronic lead is tight

Check if main bolts, main nuts and connectors are tight.

Check the security apparatus

- 34

-


G u a r d f o r m a i n t e n a n ce

D on ’ t r epa i r and m a i n t a i n co m p r e ss or i f co m p r e ss or i s i n m o ti on or t he r e i s p r e ss u r e i n it . F irst , st op it , and

t hen m a i n t a i n i t a ft er i nner p r e ss u r e i s r e l ea s ed.

A ft er fi n is h i ng t he r epa i r and m a i n t enance w o r k, check f u l l y i f c o m p r e ss or i s a ss e m b l ed and s et w e l l and i f

all fixing parts and sealing parts are installed well.

Maintenance method for intake filter

1. Open the end cover

2. Take out the filter core

3. Check the condition of intake filter (if it is not good, replace it)

4. Clean out the dust accumulating on the bottom cover

5. Replace it with a new filter core

6. Fix the end cover well.

Maintenance method for oil filter

1. Screw out the old filter with pliers

2. Clean the touching surface

3. Lay a thin film of oil on the seal ring of new filter

4. Press the filter with handle until the washer is sealed

5. Check if there is leakage after starting up

- 35

-


Maintenance method for cartridge of oil separator

The method of external type is the same as the oil filter

The method of built-in type is as follow:

1. Open the service wicket door

2. Loosen the connector between pipe and minimum-pressure valve

3. Loosen the pipeline on the cover of oil separation. Make sure it can be reinstalled.

4. Loosen the fixing bolts on the oil separation

5. Lift up the cover board slightly, and then clean the oil return pipe

6. Take out the oil separation cartridge

7. Replace the oil separation cartridge and washer

8. Install it according the reverse procedure. Check the length of oil return pipe (Refer to the maintenance

method for oil return pipe)

9. Screw down every bolt with torque spanner.

10. When compressor is started up and reaches the manipulating temperature, screw down the bolts of cover

board of oil separation cartridge

- 36 -


Features of intake valve, solenoids valve and its maintenance method

Intake-controlling valve is mainly composed of valve body, valve gate, piston, cylinder, spring and seal ring

and so on. And there is a controlling plate and an electromagnetic control valve on its side. They are with the

functions such as load shedding, noise elimination, depressurizing, stopping to release thoroughly,

adjustment of on or off, and so on. A small part of air is output through the vintage of intake-controlling

valve to balance the amount of sucked air through the vintage. This can keep the pressure in the separation

element in the range of 0.2-0.3 Mpa. So that lubricant can be in a normal cycle. The pressure sensor and the

electromagnetic valve of adjusting system control the action of on or off of intake-controlling valve

automatically. The agility of the action of on or off is very important for the reliability of compressor. So

compressor must be maintained periodically, and then it will be in a good motion. When maintaining is being

done, parts should be dismantled to check the worn condition on every friction surface. Special attention

should be paid to the surface of rubber seal ring. If there is damage or crack on it, it must be replaced. On

reinstalling then, every part should be cleaned up and lubricant should be laid on the friction surface of every

metal part.

Maintenance method for minimum-pressure valve and temperature control valve

1. Screw out the lid, pay attention to the spring force of the valve.

2. Take down the lid,

3. Check if there is abrasion on the O-type ring of the piston. If so, replace the ring.

4. Check if there is abrasion on the seal ring. If so, replace it.

5. Lubricate them with high temperature grease. Reinstall them according the revere direction.

- 37

-


Exchanging method for lubricant

1. Stop compressor

2. Connect up oil-discharging pipe, then open the ball valve, and then drain the oil into the oil-recycling

can.

3. Close the oil-discharging ball valve, then open the oil filling cover, and then refill new oil until the

oil level is in the center of oil gauge.

4. Fix the oil filling cover, and then check if the O-type ring is in the correct position.

5. Start up the compressor. Check the oil level after compressor running for a while. If oil lever is lower,

properly fill oil again.

A tt en ti on: s ho r t d o w n t he r e p l ac i ng pe ri od w h e n t he r e i s t oo m uch du s t or t he m an i pu l a ti ng t e m pe r a t u r e

is too high.

Oil level:

Maximum oil level: oil level is in the center of oil gauge, after compressor stopping for 30 minutes.

Minimum oil level: oil level is in the lower part of oil gauge when compressor is running.

Adjusting method for tightness of belt

1. Stop

2. Shift out wicket door

3. Loosen the fixing bolt for security under motor base. (Three-fourths ring tightness is always kept)

4. Rotate the adjusting bolt, then adjust the tightness of belt until getting the right tightness

5. Screw down the fixing bolt of gear end

Method for replacing belt

The method is the same as the method of the adjusting method for tightness of belt. First, adjust the belt

loose enough, then replace it with a new one, and then adjust the tightness.

Attention: After replacing it, adjust the new belt once 5 minutes later after starting up, and then adjust it

once again 10 minutes later after starting up again

T i p : f u l l g r oup of be lt s s hou l d be r ep l aced at one ti m e. I t i s not a ll o w ed t hat r ep l ace one or s o m e be lt s of

them at one time.

Adjustment of belt pulley

The parallelism of belt pulley should be adjusted again when the motor or air end is moved or reinstalled.

Poor parallelism of belt pulley will cause belts be abraded quickly, thus reduce the service life of belts

and belt pulley. Insure the two belt pulleys in the same plane. First, fix the belt pulley of gear end in the

right position, and then adjust the belt pulley of motor to let them be in the same plane.

Centering of flexible shaft coupling

The flexible shaft coupling must be centered when the motor or gear end is moved or reinstalled. And

parallelism and axiality must fall into the range of 0-0.05mm

Maintenance method for motor

A lubricant should be applied on the motor bearing every 1500 hours. (Use shell Alvania RL3, if not

specified.) Clean up the grease with a clean duster cloth. Run the motor in a unload state after belt pulley

being dismantled. Don’t stop applying new lubricant when motor is running, until all original oil is

drained out through the oil-discharging ventage (Oil-discharging ventage is under the bearing cavity).

Finally, Wipe away the excessive grease. (Excessive grease does harm to bearing)

- 38

-


7. Explored drawing

PACK SERIES (4-15kw)

- 39 -


- 40


SC SERIES (18.5-250KW)

- 41 -


8. Troubleshooting:

FAULT POSSIBLE REASON SOLUTION

Compressor does not start

1、 no electric power to

compressor, switch or emergency stop button does not closed

2、sequence of phases is not correct or phase lacking

3、overload protection relay does not reset

4、fuses or electrical contactor are defective

check electrical connection

check or interchange two phases

(L1,L2 or L3) in the power cable

reset it with hand

check it, replace if necessary

Compressor is difficult to start and stop automatically in

start process due to high current

1、under- voltage or three phasevoltage is not balance

2、electrical connection is flexible

ensure constant voltage in accordance with IEC Standard

check and tighten connection

3、compressor can not vented perfectly

check intake valve and replace if necessary

4、compressor oil is very

viscous due to low ambient temperature

5、minimum pressure valve does not closed perfectly

heat up the compressor before startup

check the valve spring and replace if necessary

Compressor stop automatically in working process due to over load

1、exhaust pressure is exceed

rated valuecheck and adjust unloading pressure value

2、setting value of overload

protection current is not correct

3、oilIair separator is jam

check and adjust setting current value of main motor or fan motor

check it, replace if necessary

4、pressure control or sensorfault

check pressure sensor, switch or computer controller

- 42

-


5、screw air end or main motor is defective

simple examine through rotate it with hand, repair or replace if necessary

Compressor stop automatically in working process due to over heat

1、insufficient oil quantity or use

incorrect type oil

2、cooling unit soiled or internal jam

3、ambient temperature too high˄≥40

fill oil and ensure oil level is not below than “minimum level” mark, use original manufacture oil only

clean cooling unit

improve air ventilation of compressor room

4、insufficient vent cooling air clean and keep air inlet vent opening

5、oil filter or thermostatic valve cartridge jam

clean it , replace if necessary

6、cooling fan fault check and replace if necessary

7、temperature sensor PT100 defective or wire break

check and replace if necessary

8、oil pipe leakage fasten and seal oil pipe coupling

Excessive oil consumption

1、oilIair separator element is

defective

2、excessive oil filling

3、oil-return line jam


drain off some oil, ensure oil level is not higher than “maximum level” mark

check and replace one-way valve if necessary

4、working pressure is too low for long time˄≤0.6MPA

5、use incorrect oil, more foam and low viscous

user should reduce compressed air consume to let pressure increase

use original manufacture oil only

- 43

-


6、too many condense water in

internal system due to high humidity climate

drain condensation water from oil tank promptly

No compressed air exhaust , no pressure build up

1、intake valve does not open intake controller or solenoid valve is defective, or air pipe connected to controller is leakage, check and replace if necessary

2、discharge solenoid valve is defective

check electric supply and clean valve holes, replace if need

3、minimum pressure valve does not open

check minimum pressure valve spring , replace if necessary

4、components in compressor are leaking

check oil and air lines in compressor, tighten and reseal screw coupling connections

5、V-belts are slipped or torn check and replace if necessary

System pressure does not decrease when reach rated pressure value

1、intake valve does not closeintake controller or solenoid valve is defective, or air pipe connected to controller is leakage, check and replace if necessary

2、discharge solenoid valve is defective

check electric supply and clean valve holes, replace if necessary

3、system pressure control faultcheck pressure sensor, pressure switch or computer controller, replace if necessary

Oil or oil smoking in intake filter when sto

Exhause volume decrease

1、intake valve is leaking check and replace if necessary

2、press Emergency Stop

p Button when compressor is in loading

switch off compressor using OFF Button, only use the Emergency Stop Button in emergencies

3、minimum pressure non-return valve is leaking


4、Excessive oil in air

1、air vent, intake filter or oilIair separator jam

see the reasons of excessive oil consumption

clean and replace if necessary

2、intake valve does not move perfectly


- 44

-


Compressor load/ unload very frequently

Abnormally noise and vibration in compressor

3、components in compressor are leaking

1、pressure difference value incorrectly set

2、air consumptions is not steady

3、external units of the

compressed air treatment jam

4、ball valve at compressor outlet closed

1、fixed screw on the base is released

2、V-belts are slipped

3、friction with fan vane and edge

4、compressor install improperly

5、screw air end or motor is defective

check air lines in compressor, tighten and reseal screw coupling connections if necessary

adjust pressure difference value, not smaller than 0.15MPA usually

use a bigger volume receiver tank

clean external air pipeline ,air dryer or air filter , replace if necessary

open ball valve

tighten screw

adjust v-belts tension, replace if necessary

adjust fan vane

mounted compressor in flat ground

check air end or main motor and fan

motor, repair if necessary

Safety valve blows

1、operating pressure has been misadjusted

2、safety valve is defective

3. System internal pressure has exceed over setting pressure of safety valve

set operating pressure to the maximum permissible pressure range of compressor(see value in nameplate)

replace safety valve

Check and replace airIoil separator if necessary

- 45

-

compressor manual 2009

Documents