The screw compression component in the screw air compressor is internally manufactured using a new CNC grinding machine, and is complemented by online laser technology to ensure unparalleled manufacturing tolerances. Its reliability and performance guarantee that the operating costs of the compressor remain low throughout its service life. The new products in the L/LS series compressors include the compressor adjustment, integrated compressor, and desiccant series.
Screw air compressors provide compressed air for various industries with their advantages such as high efficiency, low maintenance, and high reliability.
Advantages of Screw Air Compressors:
The screw air compressor equipment utilizes high-capacity compression components with a low peripheral speed rotor and oil injection, achieving efficiency and reliability. The new design ensures reduced system and compressed air temperatures. It guarantees cooling effects and extended service life for all components.
1. The screw air compressor boasts high stability, efficiency, minimal vibration, and low noise.
2. The yin-yang rotor and its fit with the housing are pre-set, resulting in minimal gas backflow leakage and no excess clearance volume, thus ensuring high efficiency.
3. The lubricating oil injected has the functions of sealing, cooling, noise reduction, and lubrication.
4. Compared to piston engines, there are fewer wearing parts and a lower failure rate.
5. The screw compression curve is smooth, exhibiting less vibration and lower noise compared to reciprocating engines.
6. Cooling methods generally include: water cooling and air cooling.
7. Heat Dissipation System: Utilizes a plate-fin structure and materials to ensure the cooler is pressure-resistant, has high heat dissipation efficiency, and excellent corrosion resistance.
8. Air Filter: Heavy-duty, multi-stage air inlet filter with dust removal accuracy of 1um (98% filtered out), large working surface, and relatively long service life.
9. Oil/Gas Separator: The latest separator features a brand-new filter material for higher efficiency, with an oil content in air below 2ppm.
10. Smart Controller: All operations and relevant data of the air compressor are displayed on the control panel, allowing you to have full control at your fingertips with ease and precision.
Air Compressor Equipment - Screw air compressors are driven at speeds suitable for the application by a transmission system. No maintenance is required during normal operation.
Air Compressor Equipment - The unique compressor design of the screw air compressors saves unnecessary maintenance costs. All components are designed for long life, with large-sized inlet filters, oil filters, and fine separators ensuring high-quality compressed air. All oil filters and separator components for models up to 22kW (30hp) are centrifugal shut-off, further reducing maintenance time. The "Quick Repair Points" enable repairs to be completed in minutes, minimizing downtime and maintenance costs.
Screw compressor principle:
(1) Suction Process: The motor drives the rotor, and as the main and slave rotor teeth gaps open to the intake end wall, the space becomes large, allowing external air to fill it. When the intake side face of the rotor moves away from the intake port of the housing, the air between the teeth gaps is sealed between the main and slave rotors and the housing, completing the suction process.
(2) Compression Process: At the end of the intake stroke, the enclosed volume formed by the main and auxiliary rotor teeth and the housing decreases as the rotor angle changes and moves in a helical pattern, which is referred to as the "compression process."
(3) Compression Gas and Injection Process: During the conveying process, the volume continually decreases, the gas is continuously compressed, pressure increases, and temperature rises. At the same time, due to pressure differences, the lubricant becomes mist-like and is injected into the compression chamber, achieving the effects of compression, temperature reduction, sealing, and lubrication.
(4) Exhausting Process: As the enclosed tooth peak of the rotor rotates to meet the exhaust port of the housing, the compressed air begins to be released until the mating surface of the tooth peak and the groove aligns with the exhaust face. At this point, the groove space is zero, marking the completion of the exhausting process. Simultaneously, another pair of teeth on the main and follower rotors have rotated to the intake end, creating a large space, initiating the suction process. This marks the beginning of a new compression cycle.
Principle of Screw Air Compressor
Screw air compressor displacement:
Definition
Air volume discharged by the air compressor within a unit of time, converted to the suction state.
Factors affecting the actual exhaust volume of screw air compressors
Equipment RPM:
The discharge volume of screw air compressors is proportional to the speed, which often varies with the voltage and frequency of the power grid. When the voltage or frequency decreases, the speed will drop, reducing the discharge volume of the screw air compressor.
2. Suction State:
Screw air compressors are volumetric compressors with a constant suction volume. When the suction temperature increases or the suction pipeline resistance is too high, causing a drop in suction pressure, the gas density decreases, which accordingly reduces the exhaust volume of the screw air compressor.
3. Gas Leak
The rotors do not touch each other or the casing during operation, maintaining a certain gap, which leads to gas leakage. When the pressure increases, the gas leaks through the gaps into the suction pipe and the grooves that are currently suctioning, reducing the exhaust volume. To minimize leakage, sealing teeth are designed on the top of the driven rotor's teeth, and sealing grooves are cut into the root of the driving rotor's teeth, with annular or strip-like sealing teeth also machined on the end face. If these sealing lines wear, the leakage amount will increase, so these factors should be considered during routine maintenance.
4. Cooling Effect:
Gases heat up during the compression process, and the temperature of the rotors and housing also rises accordingly. Therefore, during the intake process, the gas expands due to being heated by the rotors and housing, which consequently reduces the intake volume. Some screw air compressors use oil cooling for their rotors and water cooling for their housing, one of the purposes being to lower their temperatures. When the cooling is ineffective, temperatures rise, leading to a decrease in the discharge volume of the screw compressor.
Screw compressor operation and maintenance:
Safety Precautions
Compressor operation, maintenance, and repair must be performed by qualified personnel.
2. The compressor cannot be reversed. Before starting the compressor for the first time or after maintenance of the electrical control system, it is essential to first confirm that the motor's rotation direction matches the specified direction.
3. High-temperature components must be dismantled only after they have cooled to ambient temperature.
4. Recommend using screw compressor oil. Do not mix oils of different brands.
5. Do not make any modifications or additions that affect the safety or reliability of the compressor without the manufacturer's permission.
6. Original equipment manufacturer (OEM) compressor parts are specifically designed and manufactured. We recommend using genuine parts to ensure the reliability and safety of the compressor operation.
Do not allow any blockage at the compressor intake during operation.
8. Compressed air is not to be used for breathing unless specifically marked as safe for that purpose.
9. Compressors must not be operated beyond the specified pressure and temperature limits.
10. Upon discovering any abnormal operation of the compressor, immediately shut down the compressor and promptly address the anomaly.
11. Maintain and repair compressors with the proper tools.
12. Confirm all safety devices have been reinstalled and tools removed from the compressor before starting up.
Maintenance and service
Check oil level, exhaust temperature, and exhaust pressure daily; listen for any abnormal sounds.
2. Prior to weekly startup, open the separator drain valve to release condensate water. Check for any leaks, inspect the safety valve, and examine the belt wear (visual inspection).
3. Regularly inspect the intake control valve, low-pressure valve, electrical box connection terminals, safety valve, and cooling fan.
4. Regularly clean and sweep the cooler, test the reliability of the safety valve.
5. Regularly replace the oil filter element, oil separator filter element, intake filter element, and lubricating oil.
Common Fault Exclusion
Machine not starting: Check the main switch and power cord, inspect the motor.
2. Machine does not load after startup: Adjust the pressure switch setpoint or replace the pressure switch, check or replace the solenoid valve.
3. Compressor not unloading, safety valve releasing: Adjust the pressure switch setpoint or replace the pressure switch, inspect or replace the solenoid valve.
4. Excessive Fuel Consumption: Follow recommended oil usage, lower fuel level to normal position, remove and clean return oil lines, replace the separator element of the oil-gas separator.
5. Exhaust Pressure Below Specified Value: Reduce gas consumption or increase compressor capacity, check for system leaks, clean or replace intake air filter core, replace oil-gas separator filter core, inspect or replace solenoid valve, repair intake control valve, replace belts, adjust pressure switch setpoint.
6. Compressor High-Temperature Protection Shutdown: Improve environmental ventilation conditions, clean or wash the cooler, add oil to the designated position, replace the oil filter.
7. Compressor unload operation, exhaust pressure still slowly rising, safety valve release: inspect or replace solenoid valve, repair intake control valve, repair unload pipeline.
8. Safety valve release: Inspection or replacement of safety valves, maintenance of low-pressure valves, replacement of oil-gas separator filter elements, inspection or replacement of pressure switches, check of intake control valve or solenoid valve.
Inlet air filter maintenance
The air filter is a component that removes dust and impurities from the air, with the filtered clean air then entering the screw rotor compression chamber for compression. Since the internal clearances of the screw compressor only allow particles up to 15u to pass through, if the air filter element becomes blocked or damaged, a large number of particles larger than 15u will enter the screw compressor's circulation. This not only significantly shortens the service life of the oil filter and fine oil separation cores but also causes a large number of particles to enter the bearing cavity directly, accelerating bearing wear and increasing the rotor clearance, reducing compression efficiency, and even causing the rotor to seize.
After 500 hours of operation, the oil filter should be replaced. Use a wrench to reverse the oil filter housing and remove it. Install a new filter, apply oil with a screwdriver, and seal it by hand-tightening the filter housing. It is recommended to replace the filter every 1500-2000 hours, and to replace the oil filter at the same time as changing the oil. In harsh environments, the replacement cycle should be shortened. It is strictly prohibited to use the oil filter beyond the expiration date, as severe clogging can cause pressure differential to exceed the bypass valve's limits, resulting in the valve opening automatically and allowing large amounts of debris and particles to enter the screw main engine, causing serious consequences. The replacement of the diesel screw compressor diesel engine oil filter core and diesel filter core should follow the diesel engine maintenance requirements, with the replacement method similar to that of the screw oil filter core.
Maintenance and replacement of oil and gas separators
An oil-gas separator is a component that separates screw oil lubricant from compressed air. Under normal operation, the service life of an oil-gas separator is approximately 3,000 hours; however, the quality of the lubricant and the air filtration accuracy have a significant impact on its lifespan. It is evident that in harsh operating conditions, the maintenance and replacement cycle of the air filter core must be shortened, and even considering the installation of a pre-filter air cleaner. The oil-gas separator must be replaced when it expires or the pressure difference between the front and back exceeds 0.12 Mpa. Otherwise, it may cause motor overload and oil leakage from the oil-gas separator. Replacement method: Remove the control pipe connectors installed on the oil-gas drum cover. Remove the return oil pipe that extends into the oil-gas drum from the oil-gas drum cover, and unscrew the bolts securing the oil-gas drum cover. Remove the oil-gas drum cover and extract the oil filter. Remove the asbestos gasket and debris stuck on the top cover plate. Install the new oil-gas separator, ensuring that the upper and lower asbestos gaskets are stapled and aligned properly during tightening; otherwise, it may cause a blowout. Reinstall the top cover plate, return oil pipe, and all control pipes, and check for any leaks.
Maintenance and Replacement
The quality of screw oil has a decisive impact on the performance of injection screw machines. Good oil has excellent antioxidant stability, rapid separation, good degassing properties, high viscosity, and good corrosion resistance. Therefore, users must use genuine screw oil. The first oil change should be performed after 500 hours of磨合 on new machines, and new oil should be changed every 2000 hours thereafter. Replace the oil filter at the same time as changing the oil. Reduce the replacement cycle in harsh environments. Replacement method: Start the air compressor and run it for 5 minutes to raise the oil temperature above 50℃ and reduce the oil viscosity. Stop the operation when the oil and gas tank reaches 0.1Mpa pressure, open the bottom oil drain valve of the tank, and connect to the storage tank. Slowly open the drain valve to avoid spilling hot oil and causing injury or contamination. Close the drain valve once the oil becomes drips. Unscrew the oil filter core, drain all the lubricating oil from the pipelines at the same time, and replace the new oil filter core. Open the oil filling port bolt, add new oil to keep the oil level within the oil level scale, tighten the oil filling port bolt, and check for any leakage. Lubricating oil must be checked regularly during use. Add new oil promptly if the oil level is too low. Also, frequently drain condensate water from the oil during use, usually once a week, or every 2-3 days in hot weather. After the machine is stopped for more than 4 hours, open the oil drain valve when the oil and gas tank is pressure-free to drain the condensate water. Close the valve quickly once the oil starts to flow. It is strictly forbidden to mix lubricating oils of different brands, and avoid using lubricating oil past its expiration date. Otherwise, the quality of the lubricating oil will degrade, leading to poor lubricity, reduced flash point, causing shutdown due to high temperature, and potentially leading to spontaneous combustion of the oil.
