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 ensure 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, maintenance-free, 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. Screw air compressors feature high stability, efficiency, low vibration, and low noise.
2. The yin-yang rotor and its mating with the housing are pre-set, resulting in minimal gas backflow and leakage, and no excess clearance volume, thus ensuring high efficiency.
3. The injected lubricant provides sealing, cooling, noise reduction, and lubrication functions.
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 compressors.
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 Filters: Heavy-duty, multi-stage air inlet filters with dust removal accuracy of 1um (98% filtered), large working surface, and relatively long service life.
9. Oil/Gas Separator: The latest separator features a new filter material, offering higher efficiency and 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 a speed suitable for their application by the drive system. No maintenance is required during normal operation.
Air Compressor Equipment - The innovative 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 the quality of compressed air. All oil filters and separator components for models 22kW (30hp) and below are centrifugal shut-off, further reducing maintenance time. The "Quick Repair Point" allows for repair work to be completed in minutes, minimizing downtime and maintenance costs.
Screw air compressor principle:
(1) Suction Process: The motor drives the rotor, and as the main and auxiliary rotors turn to the intake end wall opening, the space between the teeth is large, allowing external air to fill it. When the intake side face of the rotor moves away from the housing intake port, the air between the teeth is sealed between the main and auxiliary 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 casing decreases as the rotor angle changes and moves in a spiral manner, which is referred to as the "compression process."
(3) Compression Gas and Spray Process: During transportation, the volume decreases continuously, causing the gas to be compressed, increasing pressure and temperature. At the same time, due to pressure difference, the lubricant in a mist-like state is sprayed into the compression chamber, achieving the effects of compression, temperature reduction, sealing, and lubrication.
(4) Exhausting Process: As the rotor's enclosed tooth crest rotates to meet the housing exhaust port, the compressed air begins to be released until the tooth crest and groove mating surface reaches the exhaust face. At this point, the groove space is zero, indicating the completion of the exhausting process. Concurrently, another pair of teeth on the main and auxiliary rotors have rotated to the intake end, forming a large space, initiating the suction process. This marks the beginning of a new compression cycle.
Screw air compressor principle
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 Discharge Volume of Screw Air Compressors
Equipment RPM:
The exhaust 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 drops or the frequency decreases, the speed will decrease, leading to a reduction in the exhaust volume of the screw air compressor.
2. Suction state:
Screw air compressors are volumetric compressors, with a constant intake volume. When the intake temperature rises or the intake pipe has excessive resistance, causing a drop in intake pressure, the gas density decreases, which in turn reduces the exhaust volume of the screw air compressor.
3. Gas Leak
The rotors do not touch each other or the housing during operation, maintaining a certain gap, which causes gas leakage. When the pressure-increased gas leaks through the gap into the intake pipeline and the slots that are currently drawing in, it reduces the exhaust volume. To minimize leakage, sealing teeth are provided at the top of the driven rotor's teeth, the driven rotor's root has sealing grooves, and the end face is machined with annular or strip-shaped sealing teeth. If these sealing lines wear, the leakage will increase, so these factors should be considered during routine maintenance.
4. Cooling Effect:
Gases heat up during compression, and the temperature of the rotor and casing also rises accordingly. Thus, during the intake process, the gas expands due to the heating from the rotor and casing, resulting in a reduced intake volume. Some screw air compressors incorporate oil cooling in their rotors, while the casings are cooled with water; one of the objectives is to lower the temperature. If the cooling is not effective, the temperature increases, leading to a decrease in the discharge volume of the screw air compressor.
Screw Air Compressor Operation and Maintenance:
Safety Precautions
Operation, maintenance, and service of compressors must be performed by qualified personnel.
2. The compressor is not reversible. Prior to starting the compressor, it must first be confirmed that the motor's rotation direction is consistent with the specified direction, especially after the initial startup or after maintenance of the electrical control system.
3. High-temperature components must cool to ambient temperature before disassembly.
4. Recommend using screw compressor oil. Do not mix lubricants of different brands.
5. Do not make any modifications or additions to the compressor that affect its safety or reliability without the manufacturer's permission.
6. Original equipment manufacturer (OEM) compressor parts are specifically designed and manufactured. It is recommended to use genuine spare parts to ensure the reliability and safety of the compressor's 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 operate beyond the specified pressure and temperature limits.
10. Upon detecting any abnormal operation of the compressor, immediately shut down the compressor and promptly rectify the anomaly.
11. Maintain and repair compressors with the proper tools.
12. Confirm all safety devices are reinstalled and tools are removed from the compressor before powering on.
Maintenance and care
Check oil levels, exhaust temperatures, and pressures daily; listen for any unusual sounds.
2. Before starting up weekly, open the separator drain valve to discharge 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 control box wiring 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 does not start: Check the main switch and power cord, inspect the motor.
2. Machine fails to load after startup: Adjust the pressure switch's setpoint or replace the pressure switch, check or replace the solenoid valve.
3. Compressor not unloading, safety valve discharge: 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 oil level to normal position, remove and clean the return oil line, replace the fuel/air separator filter element.
5. Exhaust pressure below the specified value: Reduce gas consumption, increase compressor capacity, check system leaks, clean or replace intake filter core, replace oil-gas separator filter core, inspect or replace solenoid valves, repair intake control valve, replace belts, adjust pressure switch setpoints.
6. Compressor High-Temperature Protection Shutdown: Improve environmental ventilation, clean or wash the cooler, add oil to the specified level, replace the oil filter.
7. Compressor unload operation, exhaust pressure still slowly rising, safety valve release: inspect or replace solenoid valve, overhaul intake control valve, overhaul unload pipeline.
8. Safety Valve Discharge: 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.
Air Intake Filter Core Maintenance
The air filter is a component that removes dust and impurities from the air, with the filtered clean air entering the screw rotor compression chamber for compression. Since the internal clearance of the screw machine only allows particles of 15u or less to pass through, if the air filter element becomes clogged or damaged, a large number of particles larger than 15u will enter the screw machine's circulation. This not only significantly shortens the service life of the oil filter element and the oil fine separator element but also causes a large number of particles to enter the bearing cavity directly, accelerating bearing wear, increasing the rotor clearance, reducing compression efficiency, and even causing the rotor to seize up.
After 500 hours of operation, the oil filter should be replaced. Use a wrench to unscrew the oil filter element, install a new filter element, apply oil with a screwdriver, and tighten the filter element seal by hand, ensuring it is securely fastened. It is recommended to replace the filter element every 1500-2000 hours, and to replace the oil filter element at the same time as changing the oil. In harsh environments, the replacement cycle should be shortened. Absolutely do not exceed the service life of the oil filter element, as severe clogging can cause pressure differential to exceed the bypass valve's limits, triggering the valve to open automatically. This allows a large amount of debris and particles to enter the screw main unit with the oil, resulting in serious consequences. The replacement of the diesel screw compressor's diesel engine oil filter element and diesel filter element should follow the diesel engine maintenance requirements, and the replacement method is similar to that of the screw oil filter element.
Oil and gas separator maintenance and replacement
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 consider adding a pre-filter air cleaner. The oil-gas separator must be replaced when it expires or the pressure difference between the inlet and outlet exceeds 0.12 Mpa. Otherwise, it may cause motor overload and oil leakage from the oil-gas separator. Replacement method: Remove the control pipe fittings 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 asbestosis pad and debris stuck to the top cover plate. Install a new oil-gas separator, ensuring that the upper and lower asbestosis pads are stapled and arranged neatly to prevent blowouts. Reinstall the top cover plate, return oil pipe, and control pipes as originally, and check for leaks.
Maintenance and Replacement
The quality of the screw oil has a decisive impact on the performance of the screw injection compressor. Good oil products have good antioxidant stability, quick separation, excellent degassing properties, high viscosity, and good corrosion resistance. Therefore, users must use genuine screw oil. The first oil change should be done after 500 hours of磨合 in new machines, and then replace the oil every 2000 hours of operation. Replace the oil filter at the same time as changing the oil. Reduce the replacement cycle in harsh environments. The oil change procedure is as follows: Start the air compressor and run it for 5 minutes to raise the oil temperature to above 50℃ and reduce the oil viscosity. Stop the operation when the pressure in the oil-gas drum reaches 0.1 Mpa, open the drain valve at the bottom of the drum, and connect the storage tank. Open the drain valve slowly to prevent hot, pressurized lubricant from splashing and causing injury or contamination. Close the drain valve when the lubricant starts to drip. Unscrew the oil filter core, drain all the lubricant from the pipelines at the same time, and replace it with a new filter core. Open the filling port bolt, add new oil to keep the oil level within the marking line, tighten the filling port bolt, and check for any leakage. The lubricant must be frequently checked during use; if the oil level is too low, add new oil promptly. It is also necessary to regularly drain condensate from the lubricant; typically, this should be done once a week, and in hot weather, every 2-3 days. After shutting down for over 4 hours, open the drain valve with the oil-gas drum pressure-free to expel condensate, and close the valve quickly when the oil starts to flow. It is strictly forbidden to mix lubricants of different brands, and avoid using lubricants beyond their expiration date. Otherwise, the quality of the lubricant may deteriorate, leading to poor lubricity, reduced flash point, causing shutdowns due to high temperatures, and potentially leading to spontaneous combustion of the oil.
