Screw air compressor maintenance

Screw air compressor maintenance 1. Air intake filter The air filter is a component that filters out air dust and dirt. The filtered clean air enters the screw rotor compression chamber to be compressed. Because the internal clearance of the screw machine only allows particles within 15µ to be filtered out. If the air filter is clogged and damaged, a large amount of particles larger than 15µ will enter the screw machine to circulate, which not only greatly shortens the service life of the oil filter and oil-gas separation filter, but also causes a large amount of particles to directly enter the bearing cavity, accelerating bearing wear, increasing the rotor gap and compressing The efficiency is reduced, and even the rotor is boring and dead. Second, the oil filter The oil filter element should be replaced after the first 500 hours of operation of the new machine, and the oil filter element should be removed with a special wrench. It is best to add screw oil before installing the new filter element. The filter element seal should be screwed back into the oil filter seat with both hands and tightened firmly. It is recommended to replace the new filter element every 1500-2000 hours. When changing the oil, the oil filter element must be replaced at the same time. When the environment is harsh, the replacement period should be shortened. It is strictly forbidden to use the oil filter element beyond the time limit, otherwise, due to the serious blockage of the filter element, the pressure difference exceeds the limit of the bypass valve, the bypass valve opens automatically, and a large amount of stolen goods and particles will directly enter the screw host with random oil, causing serious consequences. The replacement of diesel engine oil filter core and diesel filter core of diesel-driven screw engine should follow the maintenance requirements of diesel engine, and the replacement method is similar to that of screw engine oil core. 3. Oil fine separator The oil separator is a component that separates the screw lubricating oil from the compressed air. Under normal operation, the service life of the oil separator is about 3000 hours, but the quality of the lubricant and the air filtration accuracy have a huge impact on its life. It can be seen that the maintenance and replacement cycle of the air filter element must be shortened in the use environment of 2022, and even consider installing a front air filter. The oil fine separator must be replaced after the expiration or the pressure difference before and after exceeds 0.12Mpa. Otherwise, the motor will be overloaded and the oil separator will be damaged and run away. Replacement method: Remove the control pipe joints installed on the oil and gas barrel cover. Take out the oil return pipe that extends into the oil and gas barrel on the oil and gas barrel cover, and remove the fastening bolt of the oil and gas barrel upper cover. Remove the upper lid of the oil and gas barrel and remove the oil. Remove asbestos pads and dirt stuck to the upper cover. Install a new oil fine separator. Note that the upper and lower asbestos pads must be stapled, and the asbestos pads must be neatly arranged when pressed, otherwise it will cause flushing pads. Reinstall the upper cover, oil return pipe, and control pipes as they are, and check for leaks. 4. Oil replacement 5. The quality of the screw machine oil has a decisive influence on the performance of the oil-injected screw machine. Good oil products have good anti-oxidation stability, rapid separation, good defoaming performance, high viscosity, and good anti-corrosion performance, so the user must use pure The company's special screw oil. The new oil is replaced for the first time after 500 hours of running-in period of the new machine, and the new oil is replaced every 2000 hours after operation. It is best to change the oil filter at the same time when changing the oil. Used in places with harsh environment to shorten the replacement cycle. Replacement method: start the air compressor and run for 5 minutes to increase the oil temperature to above 50℃, and the oil product will fall annually. Stop running, when the pressure of 0.1Mpa in the oil and gas barrel, open the oil drain valve at the bottom of the oil and gas barrel, and connect to the oil storage tank. The oil drain valve should be opened slowly to avoid splashing of warm lubricating oil under pressure and hurting people and dirt. Close the drain valve after the lubricant drops. Unscrew the oil filter element, drain all the lubricating oil in each pipeline at the same time, and replace it with a new oil filter element. Open the filler plug and fill with new oil so that the oil level is within the scale of the oil scale. Tighten the filler plug and check for leaks. The lubricating oil must be checked frequently during use. When the oil level line is found to be too low, new oil should be added in time. Condensate must also be discharged frequently during the use of lubricating oil. Generally, it is discharged once a week, and it should be 2-3 days in high temperature climate Discharge once. Shut down for more than 4 hours, open the drain valve when there is no pressure in the oil and gas barrel, drain the condensate, and close the valve quickly when you see the organic oil flowing out. It is strictly forbidden to mix and use different brands of lubricants. Remember to use the lubricants over time, otherwise the quality of the lubricants will deteriorate, the lubricity will be poor, and the flash point will be reduced. It is easy to cause high temperature shutdown and spontaneous combustion of the oil. 5. Failure phenomenon of screw air compressor: the exhaust temperature of the unit is high (more than 100℃) The coolant level of the unit is too low: the oil cooler is dirty, how to determine whether the cooler is dirty, mainly depends on the temperature difference between the oil inlet temperature and the oil outlet temperature, the normal temperature difference is between 20-30 degrees, if The external dust is clogged, and the cooling air can be blown clean with compressed air. If it cannot be blown off, the interior of the radiator needs to be cleaned with professional cleaning agents. If the radiator is clogged badly, it needs to be cleaned and cleaned with a clean water pump. Time depends on the situation: if the water-cooled radiator is clogged, the best way is to remove the front and rear end covers and clean the inside of the copper tube with sticking strips; the clogging of the oil filter core will also cause the failure of the screw air compressor; Oil solenoid valves generally appear in old models; cooling fan motor failure; exhaust pipe is not smooth or exhaust resistance (back pressure) is large; ambient temperature exceeds the specified range (38 ℃ or 46 ℃). 6. Failure phenomenon of screw air compressor: the exhaust pressure of the unit is too high Intake valve failure; hydraulic cylinder failure; load solenoid valve (1SV) failure; pressure setting is too high; pressure sensor failure (Intellisys control unit); pressure gauge failure (relay control unit); pressure switch failure (relay control unit). 7. Failure phenomenon of screw air compressor: the unit cannot start Broken fuse; bad temperature switch; loose wiring; main motor thermal relay action; fan motor thermal relay action; transformer fault; Intellisys no power input (Intellisys control unit); Intellisys controller failure. 8. Failure phenomenon of screw air compressor: when the unit starts, the current is large or trips User air switch problem; input voltage is too low; star-delta conversion interval time is too short (should be 10--20 seconds); hydraulic cylinder failure (no reset); intake valve failure (open too much or stuck) wiring Loose; the failure of the main motor and the host will cause the failure of the entire screw air compressor; the 1TR time relay is broken (the relay controls the unit).