JAGUAR Compressor Operating Instruction

Operating Instruction for JAGUAR permanent Magnet
Variable-frequency Screw Compressor
XS 7.5-150
2020.5
1
Contents
Chapter 1. Safety precautions..............................................................................5
Chapter 2. Installation standards & requirements...........................................7
1. Precautions in hauling .........................................................................................................................7
2. Layout requirements on installations environments............................................................................7
3. Installation recommendations..............................................................................................................7
4. Installation requirements.....................................................................................................................8
5. Determination of air supply scheme...................................................................................................9
6. Determination of design capacity................................................................................................... .10
Chapter 3. Compressor unit system structure, process and function......12
1.Main engine structure and working principle......................................................................................12
2.System flow diagram...........................................................................................................................13
Chapter 4. Electrical control system and Circuit....................................16
1.Low-voltage power supply and peripheral wiring requirements........................................................ 16
2. Electrical (schematic diagram appendix)..........................................................................................18
Chapter 5. Pipeline configurations and installations.............................18
1. Pipeline installation and requirements..............................................................................................18
2. General principles to determine pipe system....................................................................................18
3. Selection to piping dimension............................................................................................................19
4. Connection and layout of air pipeline.................................................................................................21
Chapter 6.Instructions..............................................................................................22
1.JAGUAR system directions...................................................................................................................22
2.Machine starting.................................................................................................................................24
3.spection before the first starting.........................................................................................................26
4.The first starting...................................................................................................................................26
5.Descripition on control........................................................................................................................28
6.IOT directions......................................................................................................................................36
Chapter 7. Routine maintenance and servicing..........................................................46
1.Maintenance cycle content compressor..............................................................................................46
2.Specification and use of lubricant/cooling liquid...........................................................................................................47
3.Adjustment of control device........................................................................................................................................48
2
4.Maintenance of consumable parts for unit....................................................................................................................49
5. Maintenance of screw compressor..............................................................................................................................51
Chapter 8.Common fault and troubleshooting.................................................................................51
3
Thanks for choosing Jaguar permanent
magnet variable-frequency screw air
compressor
Xiamen East Asia Machinery Industrial Co., Ltd has the right of
design alteration over the products and takes no responsibility
for making corresponding modification and improvement. The
specification and parts of one product may be changed
afterwards without prior notice.
This product has gone through the strict inspection and test
before leaving the factory. For the purpose of ensuring the
machine to be used safely for a long time and in good working
state, the operator shall read this operating instruction carefully
prior to the operation of unit. Do not regulate the parameters set
at the ex-factory day at will.
copyright statement
Need permission for JAGUAR company otherwise prohibited use
or copy for all the content of manual
4
Chapter 1 Safety Precautions
Please read carefully prior to safe operation of air compressor
1. When installation, piping and welding, remove the peripheral flammables, and
pay attention to avoid the welding spark from dropping into the air compressor.
2. The supply lines led to the air compressor must be installed with the power
matching air switch, fuse wire and safety devices, as well as the grounding devices.
The lightning arrester shall be added if necessary.
3. The new product debugging must be carried out by our company technical staff or
our accepted personnel.
4. Attention must be paid to the rotation direction of unit upon startup for the first
time or alteration of power lines.
5. The air compressor cannot work under the discharge pressure as stated in name
plate. Without consent of Technology Department of Xiamen East Asia Machinery
Industrial Co., Ltd, do not modify the pressure setting value arbitrarily.
6. In case the air compressor breaks down or has any unsafe factors, do not start up
forcibly, but shut off the power supply and make significant mark.
7. As the compressed air and electric appliances are of risk, upon the repair or
maintenance, determine that the power supply is shut off, and hang the “repair” or
“no switching on” mark at the power supply.
8. Upon downtime maintenance, the repair or maintenance can be made on the unit
only after the complete air compressor cools down and compressed air of system is
safely released (pressure in unit is equal to the atmosphere pressure).
5
9. When washing the unit parts, the non-corrosive safe flux shall be applied, and no
inflammable and volatile cleaning agents shall be used.
10. After a period time of air compressor operation, check the safety valve and other
protection system in regular to ensure its sensitivity and reliability, normally once
every year.
11. The parts and components of air compressor must be provided by the original
factory. Its oil must be the specialized oil for screw air compressor assigned by us,
and it is prohibited to mix two brands of oil, otherwise it may cause the tar
accumulation resulting in material accidents.
12. The air compressor unit shall be operated by the fixed operating personnel who
shall read through and understand this instruction content and abide by the working
procedures and safety cautions of the instruction as well as maintenance
specification.
13. The compressor cannot be directly used as the equipment producing breathing
air. To reach the breath standard, the corresponding treatment shall be made for
the compressor.
14. Upon the operation of unit, the cabinet door shall be closed, which can be
opened for a while only at the time of inspection. However, attention shall be paid
to the damage of moving parts and high temperature parts to the human body.
15. Do not repair the pressure container by welding, or check the machine or
pressure container interior by open fire light source.
16. The frequency convertor must be used according to the safety and notes in the
user manual of frequency convertor. All behaviors contrary to the safety cautions
6
may incur severe consequences.
Chapter 2 Installation Standards &
Requirements
A. Precautions in hauling
1. In order to ensure the safe hauling, please pay attention to the overall weight of
the unit.
2. In order to ensure the balance during the hauling by crane, please pay attention
to the placement location of steel wire rope, prepare the lifting appliance and avoid
the steel wire rope from extruding the cabinet, for fear of damage to cabinet.
3. When hauling by forklift, to prevent the surface damage of compressor, please
protect with soft gasket, and the forklift fork shall be completely inserted into the
compressor pedestal.
B. Layout requirements on installation environment
1. The machine room shall be as close as possible to the load center, so as to
shorten the pipe length, decrease the pressure damage, lower the power
consumption and guarantee the supply air pressure.
2. Upon machine room location planning, the reasonability of power and water
supply shall be taken into consideration.
3. For adaption to the development demand, the room for expansion of machine
room shall be left around.
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4. As the air compressor inhales the atmosphere directly, for the purpose of
decreasing the unit abrasion, corrosion and exploration, the machine room must be
at certain distance from the place emitting explosive, corrosive, poisonous gas, dust
and other hazardous substances and shall be located at the downside of the
minimum frequency one in the annual wind directions of above places, to lower the
influence of hazardous substances on machine room to the minimum extent. See
the Table 2-1 for the interval between the machine room and emission source of
hazardous substances. Table 2-1 Interval between Machine Room and Emission
Source of Hazardous.
Table 2-1 Interval between Machine Room and Emission Source of Hazardous
Name of emission source
of
hazardous substances
Places emitting
combustible gas
(acetylene and coal gas)
Chimneys and discharge
pipes emitting dust
Places emitting dust
Relationship with wind
direction
Horizontal
distance
(m)
Any wind direction
≥20
Downwind side of minimum
frequency of local wind
direction
≥50
Adverse wind direction
Beneficial wind direction
≥50
≥20
5. Because of large heat release of compressor, especially of which the machine is in
high temperature in summer, the orientation of machine room shall be to the
benefit of good ventilation in the machine room, and reduce the sunshine as far as
8
possible.
6. Although there is cabinet for the compressor, the rainwater sprinkling is
prohibited, so that the compressor shall not be installed in the open air.
7. The compressor room shall be the independent building. See Table 2-2 for the
minimum interval from it to other buildings and structures:
C. Installation recommendations
Recommended minimum installation space of air compressor (unit: mm)
9
D. Installation requirements
1. Enough room shall be left for repair and maintenance.
2. The ground shall be the smooth cement ground. The compressor pedestal shall be
placed on the concrete platform about 150mm from the ground, and the platform
levelness shall not be more than 0.5/1000 (mm). There shall be a groove between
the periphery and platform, so that the oil and water can flow away from the groove
upon unit shutdown for oil change and overhaul or ground scouring and cleaning,
and the groove size shall be determined by the user.
3. The compressor unit shall be placed on the platform in good fitting of cabinet
bottom and ground, to reduce the vibration and noise.
4. For the conditional users, the machine room wall shall be pasted with acoustic
panel absorber, to further lower the noise, while the hard surface materials like
ceramic veneer shall not be used to decorate the wall surface.
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5. As the air-cooled compressor is largely influenced by the environment
temperature, the machine room shall be in good and dry ventilation, with exhaust
fan set inside, and the environment temperature of compressor shall be within
5
40 .
6. Inside the machine room, there shall be little dust and clean air, free from
hazardous gas and other corrosive medium like sulphurous acid.
As the air compressor is heat-producing device, especially the air-cooled type, the
factory ventilation is of great significance. It is necessary to consider the installation
of air exhaust equipment as per the outside wind. Its air volume exhausted must be
more than the air volume of the circulating fan and cooling fan of air compressor,
and the area of cooling air inlet shall be large enough. A wind scooper can be added
at the exhaust fan outlet in the top of air compressor, to exhaust the hot air vented
by the air compressor from the air hose, to maintain the room temperature at
5~40°C.
When using the exhaust duct, the room shall be left for adding the moving joint of
canvas for maintenance (for example, only when cleaning the air cooler, there can
be enough activity space to dismantle the upper cover and other parts of
compressor).
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E. Determination of air supply scheme
1. Air supply of overall air compression station
Namely, build a compressed air supply station to supply all compressed air users of
whole factory. Such scheme is mostly used for the small and middle-size factories
and large-scale factories with rather concentrated users.
2. Air supply of regional air compression station
In case of large factory scale, large consumption of compressed air and relatively
scattered users, in order to reduce the pressure drop caused by too long pipe
network and guarantee the air supply of main user, such air supply scheme is usually
applied. The regional station rooms shall be connected by the pipes, to achieve the
purpose of mutual load adjustment and mutual backup. At the time, the reserve
capacity or standby unit in the design of every station room shall be taken into
uniform consideration.
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3. Local air supply scheme
In case of small total air consumption of the factory, as well as few and scattered
users, the local air supply by small-scale compressor shall be considered, and the
unit can be put at one end of factory or into the slope room, or also can be put near
to the air utilization point.
4. Air supply scheme combined with concentration and decentralization
In some large and middle-size factories, as its main compressed air users are
relatively concentrated, and second users are scattered or every group of users are
in unbalanced load, especially in case of little air utilization of the third team, this
scheme shall be applied.
F. Determination of design capacity
1. Calculation method solving the design capacity Q2 based on average
consumption sum
Q2 = Q0 K (1 +  1+  2+  3)m 3 / h
Q2 : Design capacity m3 / h
 Q : Sum of average consumption of gas appliance or workshop m / h
3
0
K : Consumption inequality (maximum) coefficient 1.2 – 1.4
1 : Pipeline leakage coefficient. When the total pipe length is less than 1km, 0.1 is taken; when it is
less than 0.5km, 0.15 is taken; when it is more than 2km, 0.2 is taken.
 2 : Wear consumption coefficient of gas appliances 0.15 – 0.2
 3 : Unforeseen consumption coefficient is 0.1
2. Calculation method solving design capacity based on maximum consumption
Qmax
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= Q max K 2 (1 +  1+  2+  3)m 3 / h
Q2
Q
max : Maximum consumption of gas appliance or workshop
m3 / h
K 2 : Coefficient used simultaneously (determined by empirical data according every industry
condition, or chosen in reference to the K 2 value of similar engineering).
1 ,
 2 and
 3 are the same as above. In case this calculation method is selected, it is
suggested to use variable-frequency screw compressor.
3. Calculation method for solving design capacity in comprehensive condition
Q 2= (Q1+  Q0)(1 + 1+  2+  3) m / h
3
Q1 : Maximum air consumption of main gas appliances
 Q : Average consumption of residual gas appliances
0
This method can be used for the design capacity calculation of air compression
station with individual devices of large air consumption and greatly different 1 Q and
0 Q .Above three kinds of calculation methods shall be chosen according to the
industry characteristics, traditional customs and experiences for every industry.
When the heat or heatless regeneration absorption dryer is applied in the
purification system, the regenerative air consumption shall be added in its design
capacity.
At the plateau areas, its design capacity shall multiply the plateau correction factors
in Table 2-3 according to the altitude of the area.
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Chapter 3 Unit system structure & process
function
I. The Structure and Working Principle of the Host
1. Structure diagram of the host of the screw machine
Stator
electronic rotor
Male rotor
Bearing
Motor Casing
Female rotor
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Main engine
casing
2. Working principle
The working cycle can be divided into three processes: suction, compression and
exhaust.
2.1 Suction
process
2.2 Compression
process
2.3Discharge
process
2.1 The Process of Inhaling
As shown in Figure a, the suction process of the screw compressor is marked with
arrows for the pair of teeth studied. In the figure, the male rotor rotates in a clockwise
direction, and the female rotor rotates in a counterclockwise direction. The end face
of the rotor in the picture is the exhaust end face. The meshing teeth are gradually
separated at the inlet end as the rotor rotates. And the volume between the teeth
formed by it gradually increases, and communicates start to inhale with the inlet；
The rotor continues to rotate, and the volume between the teeth continues to
increase. When the volume between the teeth reaches the maximum value, the pair
of teeth is disconnected from the suction port, and the suction process ends.
2.2 The Process of Compression
Figure b shows the process of compression in the screw compressor. The female
and male rotor teeth mesh with each other to form a complete sealed contact line.
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The gas is surrounded by the rotor teeth and the casing in a closed volume. As the
rotor rotates, the contact line between the teeth moves toward the exhaust end, the
enclosed volume between the teeth gradually decreases, and the gas pressure inside
gradually increases. The internal compression of gas ends when the inter-tooth
volume is in communication with the exhaust port.
2.3 The Process of Exhaust
As shown in Figure c, the volume between the teeth is divided into a low pressure
side and a high pressure side by the contact line between the rotors. When the
volume on the high-pressure side is connected to the exhaust port, the exhaust
process begins, and the volume on the low-pressure side is in the process of
inhalation. The volume of the high-pressure side is reduced to zero as the rotor
continues to rotate, and all the gas inside is discharged. At the same time, the lowpressure side volume reaches the maximum, and the inhalation process is completed.
So that the inhalation, compression, and exhaust are repeated in a cycle.
B. System process diagram
1.system process
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1.Air filter
6.Minimum
12.One
pressure valve
10.Discharge pipe
way valve
7.Air
2.Intake valve
cooler
5.Oil separator lamp
pith
11.Return
tube
3.Main engine
8.Oil
cooler
4.Oil separator tank
1.Air filter
2.Intake
valve
3.Main
engine
7.Air cooler
8.Oil cooler
9.Oil filter
4.Oil
separator
tank
9.Oil filter
5.Oil
separator
lamp pith
6.Minimum
pressure
valve
10.Discharge 11.Return
pipe
tube
12.One way
valve
The process of the unit includes air system, lubricating oil system and cooling
system.
When the air compressor is running, the air in the atmosphere is filtered through
1 air filter assembly, and the filtered clean air is sucked by the main engine through
2 intake valves and compressed. Then drain into 4 oil drums through the exhaust
port. The oil-gas mixture is separated from the lubricating oil by the cyclone
separation of the oil barrel and the interception and separation of the 5 oil-gas
separation core. The clean gas is cooled and discharged through the 6 minimum
pressure valve through the 7 gas cooler to the customer gas end. The separated
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lubricating oil enters the 8 oil cooler through the oil return pipe for heat dissipation
（There must be a heat dissipation system because the compression process will
generate a lot of heat）The high-temperature lubricating oil is controlled at a certain
temperature, and then returned to the host through 9 oil filters to provide lubrication,
sealing and cooling for the host. There are also two pipes on the oil drum cover, one
is the 11 oil return pipe, which returns the oil separated by the oil-gas separation
core to the main engine through the oil return pipe. One is a 10 relief pipe. When the
air compressor is shut down, the high-pressure gas in the oil drum is discharged
through the relief pipe, which can avoid starting with load when it is turned on next
time.
The process of the unit includes air system, lubricating oil system and cooling system.
1. The process of the air system
After the air is dedusting by the air filter, it enters the main engine through the
intake control valve and is compressed. The two-stage compression air compressor
is divided into two main engines to compress the gas successively according to the
equal compression ratio. The compressed oil and gas mixture enters the oil and gas
separator, and the gas is separated by the oil and gas separator, and then discharged
through the minimum pressure valve, after cooler, gas and water separator, and
finally valve by the gas supply.（The gas-water separator is configured according to
the needs of users and it can be installed behind the gas supply valve）. The separated
oil stays in the oil-gas separator tank and enters the lubricating oil circulation system.
2.The process of the lubricating oil system
19
The lubricating oil system consists of an oil-air separator, a temperature control
valve, an oil cooler, an oil filter, etc. The lubricating oil in the oil-gas separator is
driven by gas pressure and enters the oil pipeline, then through the oil cooler and
filtered by the oil filter, and it is divided into two paths. A route is sprayed into the
rotor of the main engine at the lower part of the body. The other way is introduced
into the front and rear bearing housing of the main engine to lubricate the bearing,
and then gathered in the main engine rotor, mixed with the gas, discharged into
the oil-gas separator, separated by the oil-gas separator ,left in the oil-gas
separator, and finally entered the next cycle.
3.The process of the cooling system
The screw compressor is air-cooled and water-cooled, which is forced to be
cooled by fan or water pump.
The air-cooled system is mainly composed of cooling fan, oil cooler and air
cooler. The cooling air is pumped in by the fan and passes through the oil cooler
and the air cooler while cooling the compressed lubricating oil and air. Attention
should be paid to the cleaning and maintenance of the surface of the cooler.
The water-cooled system is mainly composed of water cooler, which includes
oil water cooler and air water cooler. At the same time, the compressed air and
lubricating oil are cooled, and the water supply system is installed by the customer.
Attention should be paid to the treatment of cooling water.
Water quality standard of cooling water
20
Cooling water quality standard
Supplement water
Item
Unit of measure
Cooling water
PH(25℃)
uS/cm
6.5~8.0
6.0~8.0
Conductivity(25℃)
mg/l
<800
<200
Total
mg/l
<200
<50
mg/l
<100
<50
Chloride ion(CI-)
mg/l
<200
<50
Sulfate ion(SO42-)
mg/l
<200
<50
Iron(Fe)
mg/l
<1.0
<0.3
Ionic silica(SiO2)
mg/l
<50
<30
Sulfide ion(S2-)
mg/l
0
0
Ammonia(NH4+)
mg/l
<1.0
<0.2
hardness(CaCo3)
Acid
consumption(CaCO3)
Chapter 4 Electric Control System &
Circuit
A. Low-voltage power supply and peripheral wiring requirement
1. The low-voltage power supply is AC (380V/50Hz) ,or base on customer to
requirements.
2. The voltage drop shall not be more than 5% of rated voltage, and every phase of
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voltage pressure shall be within 3%, together with phase-sequence guard wire.
3. The compressor power supply must be equipped with breaker, to avoid the
phase-deficient operation incurred from short circuit.
4. Check the secondary loop fuse, and select the proper wireless safety switch
according to the compressor power.
5. The dimensions of incoming power lines of our compressor user are as shown in
following table:
Dimension of Incoming Lines and Breaker
Rated voltage（kW)
380/220V
3.0/1.5
3.7/2.2
5.5/3.7
7.5/11/5.5
15/7.5
18.5/22/11
30/15
37/18.5
45/22
55/30
75/37
90/45
110/55
132/160/-75
200/220/250/280/-
Recommended cable
specifications（mm²）
3*1
3*1.5
3*2.5
3*4
3*6
3*10
3*10
3*16
3*16
3*25
3*35
3*50
3*70
3*95
3*120
3*150
3*185
2*(3*95)
2*(3*120)
2*(3*120)
2*(3*150)
Recommended ground
wire specifications
（mm²）
1
1.5
2.5
4
6
10
10
16
16
16
16
25
35
50
70
95
95
95
120
120
150
22
Recommended broker
specifications
Rated electronic
current（A）
13
16
25
32
50
63
63
80
80
100
160
160
250
250
250
400
400
500
630
630
800
315/355/400/450/-
2*(3*185)
2*(3*185)
2*(3*240)
2*(3*240)
185
185
240
240
800
800
1000
1000
Note: The power line in the table is armor cable (Cu). When it is more than 10m,the
armor of armor cable must be grounded independently.
6. It is best to use a set of electric system for the compressor, to avoid the parallel
use with other different electric consumption systems, especially when the
compressor power is large, the compressor may be overloaded due to the oversize
voltage drop or unbalance three-phase current, making the protective device act
and trip.
7. The grounding wire must be connected to avoid from the electric leakage causing
the danger, which must not be connected to the air delivery pipe or cooling water
pipe!!!(Where the local regulations are stricter than the above, the local regulations
shall be prevailing.)
Chapter 5 Pipeline Configuration and Installation
A. Pipeline installation requirements
1. Air supply port of unit has a threaded pipe, which can be connected with the air
supply line. Refer to appearance dimension of product for installation dimension.
2. To avoid affecting operation of the whole station or other units during
maintenance, and to prevent backflow of compressed air reliably during
maintenance, cut-off valve must be installed between unit and air storage tank, and
a safety valve shall be installed on air storage tank.
3. Branch pipeline must be connected from top of main road to avoid condensate in
23
pipeline to flow down to compressor unit.
4. The pipeline shall be shortened as much as possible to surround the whole plant
in straight-line mode, and elbow and various valves shall be reduced to reduce
pressure loss.
B. General principles to determine pipe system
Compressed air pipe system shall meet requirements of users to compressed air
flow, pressure and air quality, and shall be comprehensively determined from
reliable air supply, energy saving, investment reduction and convenient
maintenance etc., which can be considered from following aspects specifically:
1. Considering from pressure requirement
1-1. Pipeline system is designed according to requirements of user with the highest
pressure, while dropping equipment shall be locally installed for other users
requiring relatively low pressure. Pressure frequently used by general machine plant
includes 0.6MPa and 0.3MPa, pressure of pipe can be selected in accordance with
0.6MPa, and pressure relief (valve) hole plate can be installed behind branch pipe
valve of users requiring 0.3MPa pressure to meet air supply requirement of lowpressure users.
1-2. Pipeline system can be divided into several pressure grades according to size of
pressure required by users with combination of workshop or equipment layout
condition etc., to realize air supply with pipeline system of several kinds of pressure.
2. Considering from air quality requirement
2-1. An untreated compressed air pipe system is adopted. Small degreasing, drying
24
and purification device can be locally installed for few users having special
requirements on air quality.
2-2.Two pipe systems shall be designed at the whole plant or some areas, of which
one system is untreated compressed air transport system, while the other one is
dry, or oil-free compressed air transport system.
3. Considering from load characteristic
Instantaneous maximum gas consumption of some gas consumption equipment is
quite different (such as pneumatic sand transport, air pump and large modeling etc.
of hammering and foundering workshop powered by compressor), and to avoid
affecting other gas consumption equipment, air supply by special pipe is generally
adopted or air storage tank is installed around gas consumption equipment to buffer
load and stabilize pressure.
C. Selection to piping dimension
When air flows in pipe, friction resistance is produced at straight-line section; local
resistance is produced at valve, tee joint, elbow and adapter bonnet etc., thus
causing loss of air pressure. Pressure drop within length of pipe of a section can be
calculated based on checking in following table:
C.Table 7-1 Air Flow - Pressure Drop of Piping Kg/ cm2 – (100m)
Description:
25
26
Descriptions
1. Actual pressure drop of straight-line section = tabular value× pipe
length(100×compression ratio) (compression ratio= tabular pressure +1)
2. Total pressure drop of pipeline part shall include local pressure loss generated by
elbow, pipe reducer, T-junction and valve etc., and these values can be searched in
related manual.
27
D. Connection and layout of air pipeline
1. Compressed air pipe is generally connected through welding, but at connection
with equipment and valve etc., the flange or thread connection corresponding to it
shall be used. For pipe section frequently disassembled, when pipe diameter is
lower than or equal to DN25, thread connection shall be used; when pipe diameter
is greater than DN25, flange connection shall be used.
2. For undried and uncleaned compressed air transport pipe, for the convenience of
discharge to oil and water in pipe, pipe generally shall have gradient exceeding
2/1000,blow-down valve (plug screw) is set at low side, and pipe shall be rarely
turned and short and straight, and valve shall be as little as possible.
3. The top burial depth of underground pipe shall not be lower than 0.7m, but dry
and clean compressed air pipe is not restricted by it.
4. Installation location and surface size of pressure and flow meters shall enable
operators to see indication pressure clearly. Pressure scale shall make working
pressure at 1/2 to 2/3 position of the dial.
5. Air pressure strength and tightness test shall be made instead of hydrostatic test
after completion of system installation. Test shall be made under 1.05 to 1.5 times
of pressure of the same gas, and no leakage is conforming.
6. Selection to drying and purification degree of compressed gas is also different
because of difference of permissible degree required by customers. Post-processing
device, such as air storage tank, dryer, precision filter and so on, can be selected
according to use conditions of equipment. Ideal configuration shall be: gas water
28
separator + air storage tank + prefilter + dryer + precision filter.
7. Because air storage tank belongs to pressure vessel, its safety accessories, such as
safety valves, pressure gauges and blow-down valves etc., shall be complete, and
shall be filed at local labor department, with routine inspection made annually.
Chapter 6. Instructions
JAGUAR+ System description
◆
Jaguar + Intelligent control system：
◆
JAGUAR+ The control system has the following functions
Automatic compressor control
Compressor protection
Maintenance reminder
Low temperature automatic preheating (enabled)
Jaguar Smart Network (standard configuration for 90kW and above)
1、Automatic Compressor Control
The controller can load and unload the compressor automatically, and adjust the speed
according to the gas end pressure automatically, and use the gas end pressure to maintain within
a set range.
The controller controls the speed of the motor to keep the pressure consistent with the target
pressure in the adjustable speed range of the motor. When the air volume is less than the
29
minimum output volume of the air compressor, the controller switches the state to unload when
the pressure reaches the set unloading pressure, and stops running within a certain period of
time to save power consumption.
If the air compressor stops automatically and the pressure on the air end drops, the controller
will automatically start the air compressor when the pressure on the air end drops and the loading
pressure. To prevent the pressure of the air end from falling below the minimum standard, please
stop the compressor manually, and the controller will perform unloading operation on the air
compressor for a period of time. Then stop the compressor and wait for the pressure in the
system to decrease.
2、Protection of Compressor
Several sensors equipped with the compressor are used to detect the state parameters of the
air compressor. If the value of one of the sensors exceeds the alarm level, the control system will
give priority to reminding on the display / smart network (if any) in order to initiate a reminder
to the relevant responsible person. When the value of the sensor exceeds the stop level, the
controller will immediately stop the operation of the compressor in order to prevent accidents.
When the fault information is contacted, the alarm information can be eliminated by the
reset button and the machine can be turned on again.
3、Maintenance Reminder
According to the set time plan, the controller lists the maintenance cycle and
service time of a series of consumables. When the use time of a consumable material
arrives, an alarm will be displayed on the controller to remind the responsible person
30
to implement the required maintenance measures in accordance with the
maintenance plan.
4、Automatic Preheating of Low Temperature (enabled)
If the control system finds that the ambient temperature of the compressor is too
low before starting, in order to prevent the compressor from being worn or stuck
due to lack of oil, the control system will automatically perform the preheating
operation of the compressor according to the current ambient temperature to
protect the compressor. The control system immediately enters the normal working
mode when the temperature rises to a suitable temperature.
The low temperature automatic preheating function can effectively prevent the
compressor from being damaged. Please do not disable this function unless
necessary
5、Jaguar Smart Network (standard configuration for 90kW and above)
Smart networking is an extended function of the JAGUAR+ control system. It can
communicate through the relevant network to transfer the controller parameters to
the cloud, and then present it to you through mobile phones and computers. Smart
networking is conducive to compressor data collection, remote operation, remote
reminder, etc
B. Star-up of the unit
1. The process of starting
31
Check the circuit first and reinforce it before turning on the power to prevent it
from loosening during transportation. Turn on the power supply, and observe
whether the power supply is in reverse phase firstly. The machine is equipped with
reverse phase protection. If it is reverse phase, the controller will alarm and lock, and
the unit cannot be started. It can start after adjusting the phase sequence. After
pressing the "ON" key or "RUN" on the control panel, the motor will run from a low
speed to the rated speed during the acceleration time to achieve a soft start of the
motor.
The unit is strictly prohibited to start with load (the exhaust pressure
gauge has pressure). Otherwise, electrical components will be damaged due to
excessive starting current!
2. Load Regulation During Operation
The control system has PID automatic adjustment function. When the gas
consumption decreases and the gas pressure rises; the inverter adjusts its output
frequency; changes the compressor gas supply; and ensures that the gas supply
pressure is output stably at the working pressure. When the gas consumption is low,
the whole machine will run at the lowest frequency and start delay. And when the
delay time reaches the set time, the gas supply is still greater than the gas
consumption, the whole machine will automatically stop and enter sleep until the gas
consumption increases. The system will be awakened when the wakeup threshold is
reached. The control valves in the system are automatically reset, and the unit reruns and seeks a balance point.
32
Maintenance and inspection are strictly prohibited during the sleep period
of the unit, and the unit may start at any time. Otherwise, accidents may occur.
.
3 Downtime
3.1 Normal downtime
When it needs to stop, please press the "OFF (O)" key or "STOP (stop)" key on the
control panel, the unit will delay for a period of time and the motor will stop running.
If it is expected to take a long time to use after shutdown, please turn off the
air switch in the control cabinet and cut off the power supply.
After cutting off the power supply, wait for the indicator light of the
inverter to go out before checking the circuit, otherwise an electric shock
accident may occur.
It is permissible to press the emergency stop button only when the unit has an abnormal situation,
otherwise it may cause oil to spit from the air inlet of the main engine!
Do not use to the emergency stop button frequently, otherwise it will affect the service
life of the machine.
The unit will automatically stop when the compressor has abnormal conditions
(such as over temperature, over pressure, etc.).
3.2 Emergency shutdown
3.2.1 Emergency stop when the following situations occur:
(1) When abnormal sound or vibration occurs；
(2) The exhaust pressure exceeds the set pressure of the safety valve and the
safety valve is not opened；
(3) No automatic shutdown when exhaust temperature exceeds 110℃；
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(4) When there is an emergency around；
3.2.2 During emergency stop, there is no need to decelerate to stop, just press
the "emergency stop" button directly.
4. The Function of Exception Protection
4.1
Phase sequence protection
Cannot start when the power connection is out of phase, any two incoming wires
should be replaced.
4.2
Protection against excessive exhaust temperature
The unit stops automatically and gives an alarm when the exhaust temperature
reaches the set value of the temperature switch (usually 105 ℃). An overheated
shutdown will be displayed on the panel. There are many reasons why the exhaust
temperature is too high, the most common reason is that the surface of the oil cooler
is covered by dirt and other dirt, which makes the oil cooling failure.
4.3
Protection against excessive exhaust pressure
When the exhaust pressure exceeds the maximum set due to some reason, the
unit will automatically stop and give an alarm, and the overpressure stop will be
displayed on the panel. The cause should be checked and dealt with accordingly.
4.4
Overload protection
The unit stops automatically and gives an alarm when the motor is overloaded
for some reason. The overload shutdown will be displayed on the panel, so you
should check the cause and deal with it accordingly.
4.5 Fault of frequency converter
The unit stops automatically and gives an alarm when the frequency converter is
34
overheated and under voltage due to some reason. You should check the fault record
of the frequency converter, find out the cause and deal with it accordingly.
C. Check before the first starting
Check the capacity of the lubricating oil in the oil-air separator. After normal
operation, make sure that the oil level in the oil level gauge is above the middle of
the upper limit and the lower limit.
1、 The electrical wiring and grounding wire have been completed and meet
safety standards.
2、 The air supply pipeline is dredged, and all bolts and joints are tightened.
3、 Check whether the motor power supply, voltage and instrument panel
indication are correct, and ensure that the compressor starts without load.
4、 If it takes a long time for the test run, you should add about 0.5 liters of
lubricating oil from the air inlet to prevent the compressor from losing oil
and burning when starting. Please pay special attention not to let foreign
matter fall into the body to avoid damage to the compressor.
5、 Operate the valve according to the requirements of the process pipeline,
and the compressor exhaust valve is in the open position.
6、 Check whether the operator is in a safe position when preparing to start, .
7、 Close the manual drain valve.
8、 Before turning on the power, make all the switches off to ensure that the
inverter will not start and no abnormal actions will occur when the power
is turned on.
35
D. The First start
1、 Turn on the power first, observe whether there is an abnormal display on the panel and
whether the phase sequence is correct. If there is an abnormal display, remove the abnormal
situation before turning on the power. The machine has reverse phase protection, and the
host cannot be started in reverse. After starting, please be sure to check the
rotation of the motor for safety reasons, as the marked rotation has been,
the phase sequence is correct. Otherwise, the phase sequence is wrong, the power
supply should be cut off and any two of the three wires can be exchanged. Remember:
the motor is strictly prohibited to reverse.
2、 Press the "Start" button to start the operation, and the compressor can run in
the set mode. At this time, observe whether the display panel is normal, whether
the pressure and temperature are normal, whether there is abnormal sound,
whether there is oil leakage. If any, stop and check immediately.
3、 Press the "Stop" button, the unit will stop only after a delay. It is normal not to
stop immediately.
Notice
Emergency stopping button can only be special aberrant situations
can press emergency shutdown button if u want to restarting can only be made
after 2 minutes.
Normal operation
36
1. Preparations before starting: Check the oil level in the oil-air separator, slightly
open the drain valve under the oil-air separator to remove possible condensate
in it, and tighten the valve after confirming that there is no condensed water.
Open the valve of the compressor air supply port.
2.Turn on: Turn on the power switch and press the "ON (I)" button on the
panel to start the compressor.
3. Stop: Press the "OFF (O)" button on the dashboard, the compressor will
automatically stop after a delay. When it is determined that the machine
is not in use, the power supply should be cut off and the valve of the
compressor air supply port should be closed.
When the compressor runs for more than the set time due to low frequency,
it will go to sleep or automatically stop. At this time, inspection or maintenance
work is absolutely not allowed because the compressor will resume operation at
any time. For the unit with a separate fan, the operation and stop of the fan is
automatically controlled, and the fan must not be touched to avoid personal
injury. The power must be cut off for mechanical inspection!
The operation of the compressor will suddenly stop after a power failure. At this time,
remember to cut off the power supply to avoid burning the electronic control part when the
power is suddenly supplied.
E. Description on controller panel
1.After the unit is powered on, the controller will display the following screen. In this interface,
you can view the real-time running status and information, or start and stop the air compressor
37
through the corresponding button to enter more functional interfaces.
Main
Signal-source:
Condition
operation
net work signal
display
parameter
indication.
compressor.
of
air
A Mode: current
air supply mode.
display area of
air compressor.
Menu key: press
the key to enter
into menu.
Resetting
key:
when
Starting key: press
air
compressor breaks
down and failure is
removed, press the
key
to
the key to start air
Stopping
compressor under
press the key to
stopping condition of
stop air compressor
air compressor.
under
eliminate
key:
operation
condition
alarm.
compressor.
38
of
air
Return
key:
press the key to
return
to last
menu.
1.3 Menu and function introduction
Home
page
key:
press the key to
return
to
main
interface under any
interface.
39
Press the blue menu key under the main interface to enter this interface, which contains 8
program buttons, as follows:
a、Monitoring data: Real-time display of all operating information and pressure, temperature,
and frequency curves of the air compressor. If you want to view current, power, and motor
temperature information, you need to click on more parameters to view after password
verification.
b、Maintenance parameters: Display the cumulative use time of each consumable of the air
compressor and the remaining time for maintenance. The relevant person in charge can prepare
the air compressor for maintenance in advance based on this information.
c、Air supply mode: The control system has 4 built-in operating modes (parameters), namely
A, B, C, and P. After verification, the user can enter this interface for mode switching or click
"parameter modification" to enter the parameter modification interface. To fine-tune the
operating parameters. The mode description is as follows:
A：Mode A is the standard mode, and the air compressor runs under rated load to
achieve the most energy saving in this mode.
B：Mode B is a low air consumption mode, and the air compressor will shorten the
sleep delay time and wait in this mode.
C：Mode C is a large air consumption mode, and the air compressor will increase the
speed to supply air in this mode.
P：Mode P is a performance mode, the air compressor will give full play to its
performance and supply air in this mode.
d、Factory parameters: including factory number, production date, password change, record
40
clearing, early warning, sensor range and calibration, PID parameter preset, switch input and
output function settings and other parameter settings.
f、Inverter parameters: motor parameter setting and motor parameter self-learning of the
main motor and cooling fan.
Fault list: When the air compressor fails, the fault information will be displayed here. If you want
to query historical faults, please click the historical fault button at the bottom right to switch to
the historical fault interface. Press the reset button to clear the fault after confirming the
troubleshooting. And Start the air compressor again.
g、Timing start and stop: Built-in 7 days, 2 groups per day, a total of 14 groups of air compressor
timing switch time settings. After setting the air compressor start/stop time, turn on the on/off
permission switch. And the timer start and stop function of the current group is effective. After
the timer start and stop function takes effect, a small clock icon will appear in the upper right
corner of the homepage. If there is this icon, please note that the unit may start at any time. To
prevent accidents, be sure to cut off the power during maintenance.
1.4 Operation guide
The control system uses a 7-inch LCD resistive touch screen. The resistive touch screen is used to
input information by pressing. Therefore, when the user is performing related operations or
parameter input, use fingernails as much as possible to input, so as to avoid missing or wrong
input.
5.5 Parameter set up explanation：
permanent magnet parameter set up (V2.2.1)
41
Menu
Maintenance
parameter
Automatic
Extension menu
Air filter maintenance cycle
Oil separator maintenance cycle
Oil filter maintenance cycle
Replace lubricating oil
Low temperature protection
Allow start temperature
Parameter explanation
Alarm reminder after running time
reaches set time
Base on air-end and male rotor
profile speed to set up
Warm-up frequency
（<3.5m/s），
Low temperature automatic warmup
Main engine jog frequency
Main engine frequency upper limit
Air supply
mode A
The maximum frequency output by
the main frequency inverter
The minimum frequency output by
the main frequency inverter
Main engine frequency lower limit
Pre-run time
Main engine speed up time
Main engine deceleration time
Run time before loading
Time required for the main motor
from 0 to the upper limit frequency
The time required for the main
electric motor from the upper limit
frequency to 0
Target exhaust temperature
Frequency temperature
Air supply
mode A
If the temperature is higher than this
value, the fan will start
Fan start temperature
When the temperature is lower than
this value, the fan will stops
Fan stop temperature
42
Air supply
mode A
Loading pressure
In the running status, after the pre-run
time, the exhaust pressure is lower
than this set value, the control system
actively opens the intake valve to
perform the loading operation
Constant frequency pressure
In order to achieve the target output
pressure, the PID algorithm is
calculated according to this set
pressure, and the corresponding
running speed is output to achieve a
constant pressure effect
Unloading pressure
In the running status, when the
pressure is higher than this set value,
the control system actively closes the
intake valve to perform the unloading
operation
Dormancy judgment time
When the running frequency is in the
lower limit frequency status, after
some time, the air compressor will
entering the dormancy status
Air supply
mode A
Air supply
mode A
When compressor out of serving then
un-loading in set up time to stop
The second start needs interval setting
time
Turn off delay
Restart delay
Dormancy and wake up delay
43
Air supply
mode A
Manufacturing NO.,
Manufacturing date
Manufacturer
parameters
The exhaust temperature is more than
the set value, the touch screen will
alarm but do not stop air compressor
The exhaust temperature is more than
the set value then air compressor
malfunction and stop operating.
Turn on this switch, the low
temperature protection takes effect
Air compressor control-end cutover
Warning temperature
Out of serving temperature
Low temperature reminder
Remote/local
Advance warning pressure
Exhaust pressure is higher than the set
value, the alarm sound but don't stop
air compressor
Stop after exceeding the advance
warning setting time
Sounds alarm and stop to machine
after working exceeds set time
Advance warning overtime
Manufacturer
parameters
Maximum use time
Out of serving pressure
Sounds alarm and stop to machine
after exceeding set pressure
DI1(X1)
DI2(X2)
PLC model to key in terminal can be
customized functions, according to
specific model (actual wiring) to site.
DI3(X3)
DI4(X4)
Manufacturer
parameters
DI5(X5)
DI6(X6)
44
The pressure sensor maximum
allowable pressure of exhaust gauge
Pressure sensor range
Pressure KP
pressure PID proportional
coefficient ,large value can be able to
more adjustment range
Pressure TI
Pressure PID TI coefficient
Temperature PID proportional
coefficient，large value can be able to
more adjustment range
Temperature PID proportion coefficient
Electric current calibrations
coefficient，acquiescence100%
Temperature KP
Temperature TI
Electric current (Ampere）
calibrations
Power calibrations
Pressure calibrations
Temperature calibrations
CT2 transformation ratio
Password
Power calibrations coefficient
Pressure calibrations coefficient
Temperature calibrations coefficient
Fan convertor transformation ratio
Frequency convertor input maximum
frequency
Maximum frequency
Main Electric motor Opposing
electromotive force rate
Opposing electromotive force
Frequency
parameter
Fan machine
frequency
convertor
parameter
Electric motor output power of under rated
Electric motor rated power
Electric motor rated frequency
Electric motor rated voltage
Electric motor rated electric current
Electric motor rated revolving speed
Out of serving method
Maximum frequency
Electric motor rated power
Electric motor rated voltage
Electric motor rated frequency
Electric motor rated electric current
Electric motor rated revolving speed
Fan machine lower limit frequency
Speed up time
Deceleration time
Electric motor cooling fan machine
rated electric current
Fan machine overload judgment time
45
load
Electric motor rated frequency
Electric motor rated voltage
Electric motor rated electric current
Electric motor rated revolving speed
Free/Deceleration out of serving
Maximum frequency
Electric motor rated power
Electric motor rated voltage
Electric motor rated frequency
Electric motor rated electric current
Electric motor rated revolving speed
Fan machine lower limit frequency
Speed up time
Deceleration time
Electric motor cooling fan machine
rated electric current
When exceeds rated loading then
the actual time reaches the set time, at
this time the screen will show fan
overload fault
Main engine jog frequency
When use jog operation working frequency
Timed
starting and
Automatically switch on and off
according to the set time
stopping
6.Operation and explanation of Internet of things
6.1 Login
Open the browser;
Enter the URL in the browser address box and confirm;
Click the login button in the upper right corner after opening the webpage, ;
46
Enter your account password and verification code in the login dialog box that pops up,
and click to Login after making sure that it is correct.
47
Different account levels have different permissions. Common functions include remote
monitoring, remote assistance, and permission management.
6.2 Remote monitoring
48
Click the "remote Monitoring" icon on the left workbench to enter the monitoring page.
The remote monitoring page will display all air compressors belonging to the current
49
account
6.3 Filter
In order to find the air compressor you want faster when the number of air compressors is
large, you can filter by the bar above.
The choice of mechanism
Check the corresponding organization，
Click to search filter
out the air compressors of the non-checked institutions.
Factory number/name/hardware registration code search
Enter the part number or name of the air compressor in the search box and click to search,
you can filter out all air compressors that contain keywords.
Search for the status of air compressor
Select the running state of the air compressor
Such as: running, shutdown, offline, etc. The system will filter according to the status of the
air compressor
50
Region screening
According to the positioning area of the air compressor
To perform area screening.
Combinatorial screening
Combination screening is carried out through four screening/searching methods, and air
compressors that meet multiple screening conditions at the same time will be screened out.
For example: I want to filter 150HP permanent magnet air compressors under A organization.
51
The screening method is: select institution A, and enter 150HP in the search box, then click
search. The system will search for 150HP machines belonging to A organization.
6.4Choose an air compressor
Click on any air compressor to enter the data monitoring interface of the air compressor
Under this interface, you can view all the data uploaded to the IoT platform of the air
compressor, including real-time data, fault information, operating parameters, protection
parameters, manufacturer parameters, historical data, and historical faults.
52
6.5 Running Data
Real-time data: display the current operating parameters and curves of the air compressor,
current, voltage, exhaust pressure, temperature, etc.
Fault information: display the current air compressor fault information.
Operating parameters: Display the operating parameters set by the current air compressor,
such as motor rated parameters, air compressor loading and unloading pressure, etc.
Protection parameters: display the current protection parameters set by the air compressor,
such as pre-alarm pressure, shutdown pressure, etc.
Historical data: the historical faults of previous air compressors can be retrieved and filtered
by date.
Factory parameters: display the factory parameters set by the current air compressor, such
as the maximum use time, etc.
53
Historical data: the running data of the past date can be called out, and the running curve
can be filtered by date.
Maintenance parameters: display the current maintenance parameters set by the air
compressor and the usage time of consumables.
Curve view: Under the real-time data column, the supply pressure and exhaust temperature
curves are displayed by default. The curve parameters that can be viewed currently are:
supply pressure, exhaust temperature, host output voltage, host power, host output
frequency, and host output current.
54
If you want to view other data curves, you can click the "View Curve" button on the right to
check the curve parameters you want to view and confirm.
6.6 Historical data column
Select the date you want to view the data, you can display the data list by time of the day,
and select a certain time period data table and click the detailed data, you can view other
running data of the current time period.
6.7 Remote Assistance
55
Click the left remote assistance icon on the workbench on the left side of the main interface,
you can enter the remote assistance interface to select the air compressor to be operated,
and click the parameter setting or start/stop according to your needs. After the icon is
verified, you can send it directly to start Or an order to stop.
56
please click the blue setting button to modify the parameter, and enter the parameter value
to be modified, then click OK.
6.8 Creation of subordinate accounts
When each air compressor uses the Internet of things for the first time, it needs to create a
customer account and assign the air compressor to the corresponding created account.
57
Click on left permission
dealer list entering dealer list creating interface,
select on the left side permission
and click create subordinate organization.
58
Enter the required information in turn and click Save to complete the creation.
59
Select the left equipment list column, and then check the air compressor to be assigned and
click the distribution mechanism.
Select the corresponding customer account, confirm it and click OK to complete the
allocation of the air compressor.
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Chapter 7 Routine Maintenance and
Servicing
1. Maintenance cycle and content of screw compressor
Maintenan
Service
ce cycle
hours(h)
Maintenance content
Check the oil level before starting and during operation
(water-cooled motors need to check the level of cooling
Daliy
8
water), the display status on the display panel, and the
pressure setting. Drain the oil drum, check temperature,
noise, etc.
Check and clean the vacuum indexer of the air filter, and
Each 3
months
replace the oil filter with the new one. Change
500
compressor oil than replace the motor coolant for new
water-cooled motors.
Replace the air filter element, replace the oil filter, and
Every years
change the oil. If it exceeds the adjustment range, it
3000
should be replaced in time, and the tightening bolts of
the moving parts should be checked. Clean the cooler.
61
Check whether the temperature control valve works
normally. When the differential pressure indicator of the
oil and gas separator is on, or when the oil pressure is
higher than the air pressure, check it. The oil and gas
separator must be replaced. If the environment is poor,
its time will be shortened. Clean the cooler. Add grease
to motor bearings.
10000
Nylon tube, belt, oil level gauge, solenoid valve, O-ring
replacement.
Replacement of bearings, shaft seals, soundproof
20000
sponges and rubber tubes (dispose according to specific
circumstances).
Note: The above maintenance cycle shall be subject to the first time to be
achieved.
2. Specification and use of lubricant
Lubricant has decisive influence on performance of oil injection screw
compressor; if it is not used properly or wrongly, it will lead to serious damage to
compressor; therefore, it shall observe the following.
specifications:
1. Please use dedicated oil of Jaguar screw compressor.
2. Precautions for use of lubricant
62
2.1 Oils shall conform to requirements. Do not mix and use lubricants of different
factories and models and do not use fake oil and reclaimed oil.
2.2 Performance requirement of oil is as follows: anti-oxidation, anti-foam, anticorrosion and abrasion resistance, water separation, viscosity, high flash point, low
pour point.
2.3 Do not let lubricant exceed use life of oils; otherwise, oil quality will be poor and
its flash point will decrease with it and oils will burn automatically and easily, which
will burn unit.
2.4 Observe oil change period. To confirm oil change period according to actual
condition, it is suggested to analyze main indexes relevant to lubricants, such as
viscosity, acid value, moisture, ash, flash point, mechanical impurities, etc to
conducting analysis, ensure lubricants real need to change cycle no waste.
2.5 After compressor is used for two years, it is better to make “system cleaning”
with lubricant; the method is to change oil twice; implement for the second time
after operating for 6 hours after the first time.
2.6 Change oil filter during oil change.
3. Factors that influence oil change time
3.1 Unfavorable ventilation and too high environment temperature
3.2 High-humidity environment or rainy season.
3.3 Dusty environment
3.4 Mix lubricants of different marks
4. Oil change steps
4.1 Make compressor operate firstly and shut down by pressing “OFF (O)” key after
63
oil temperature rises.
4.2 After discharge pressure decreases to zero, close stop valve on air supply of
compressor and open oil relief valve under oil storage bucket slowly to discharge
wasted oil and move main engine along marked steering wheel and add few new oil
from oil filler to clean completely.
4.3 Discharge all lubricant in oil cooler and oil pipeline system.
4.4 Screw oil discharge valve under oil gas separator and inject new oil from oil filler.
Because there is no oil in oil cooler and oil pipeline system, new oil can be added.
4.5 Start up and check oil level; if oil level is insufficient, add lubricant properly after
halt.
3. Adjustment of control device
Adjustment of safety valve
Discharge pressure of safety valve is set as 1.1 times of rated discharge pressure,
which has been set before ex-factory and shall not be adjusted automatically. When
discharge pressure shall be discharged for other reasons and locking nut on safety
valve shall be loosened, so, screw shall be rotated clockwise to improve discharge
pressure; it will decrease if rotated anticlockwise and do not forget to lock nut
tightly.
Notice
Discharge pressure of safety valve has been set before ex-factory and
shall not be adjusted automatically. If there is special condition, consult to
relevant professional personnel and operate under its supervision and guidance;
64
otherwise, you shall bear all consequences.
4. Maintenance of consumable parts for unit
1 Change of oil-gas separator filter element
When lubricating oil consumption of compressor increases largely, check to see
whether oil cleaner and oil return tube are blocked and cleaned; when oil
consumption is very large, oil-gas separator has been poor and shall be changed
promptly; when both-end pressure difference of oil-gas separator filter element
reaches 0.15MPa, it shall be changed; when pressure difference is 0, it shows that
filter core has fault or there is short circuit in airflow; at that time, filter element
shall be changed promptly. Changing step is as follows:
Generally, changing time is 3000～4000 hours, if environment is relatively poor,
time will be shortened. Its change steps are as follows:
(1) External type
a. After shutting down compressor halts, closing air outlet and opening water
escape valve, confirm there is no pressure in system.
b. Change new product after disassembling oil-gas separator.
(2) Built-in type
a. After shutting down compressor halts, closing air outlet and opening water
escape valve, confirm there is no pressure in system.
b. Disassemble pipelines on oil storage bucket and at the same time and
disassemble pipelines from pressure maintenance valve outlet to after-cooler.
65
c. Disassemble oil return pipe.
d. Disassemble fixed bolt covered on oil storage bucket and move cover on oil
storage bucket.
e. Take off oil-gas separator and change for new oil-gas separator.
f. Assemble according to reverse order of disassembly.
Notice
When changing oil-gas separator, pay attention to electrostatic discharge, connect
inner metal net and oil bucket shell to prevent explosion caused by statistic
accumulation. At the same time, prevent any dirt from falling into oil bucket to
prevent from influencing operation of compressor.
2 Change of oil filter
When oil filter shall be maintained or blocking light of oil filter is on or
contract exceeds 1.5Kg, it shall be changed promptly. If it is not changed promptly,
machine halt may be caused by too high discharge temperature; furthermore, it will
lead to serious abrasion of main engine bearing, so that service life of main engine
bearing will be shortened. Engine oil shall be coated on washer when new oil filter is
installed; after being rotated in place, screw for 3/4 cycles manually. When it
operates after changing, check to see whether it leaks oil.
3 Cleaning of air filter
Generally, after operating for 1500 to 2000 hours or when negative pressure is
larger than 0.63Kg and air filter is blocked and filter element shall be changed and
66
change time shall be shortened for dusty use site and cleaning and maintenance foe
filter core shall be strengthened usually. Shut down when disassembling filter
element and it is suggested to change for a new or cleaned reserved filter element
to reduce shut down time. During cleaning filter element, dab both end faces of
filter element to remove most dust and blow internally with 0.2Mpa compression air
and it shall be noticed that nozzle shall be nearly 25mm from fold line; if there is
many grease on filter paper, it cannot be reused. When there is damage in filter
element (even if there is fine hole), it shall not be used again and shall be changed
promptly.
4 Cleaning of cooler
(1) Air cooler can be blown with compression air reversely. If it cannot be blown for
serious blocking, it shall be cleaned. If cleaning is not prompt, machine halt may be
caused by too high main engine temperature for poor cooling effect.
(2) Disassembly of water cooler: I. Close inlet and outlet of two kinds of
liquid completely to prevent it from flowing; II. discharge two kinds of fluids in
cooler and its connection pipeline; III. disassemble externally-connected part, so
that it will be in decomposition condition; IV. Make mark before decomposition
(specially in direction of fixing tube sheet) to facilitate use during assembly;
disassemble backwater cover and take off “O” ring; disassemble backwater cover
and take out gasket; V. pull tube bundle frompipe barrel wholly lightly. Then,
decomposition work is completed.
(3) Assembly of water cooler. Assembly order of cooler shall be reverse to
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decomposition order. It shall be specially noticed that: moving tube sheet will touch
step of pipe barrel flange and pipe bunch shall be raised to be installed to pipe
barrel lightly; “O” ring shall be changed with gasket; connection screw of water
cover and flange shall be screwed tightly symmetrically and uniformly.
5. Maintenance of screw compressor
(1) Please implement the following events if compressor is not used temporarily:
A. Storage site shall be dry, ventilated with proper temperature
B. Change position of rotor if exceeding three months so that contact point of
bearing will be changed. (Otherwise, grease loss will lead to bearing rust.
(2)Pipelines and circuits shall be tidy, regular, clean, smooth and well insulated.
(3) Reliable keeping for safety device (such as safety valve, insurance device,
automatic or protective device) and explosion-proof lightning protection device and
grounding device shall conform to safety requirement.
(4) Equipment and working site shall be tidy, clean without oil stain and marks shall
be ready; connection of pipeline and circuit shall be reliable.
Chapter 8 Common Fault and Troubleshooting
Fault
Compressor
fails to start
Possible causes
Troubleshooting methods
Fuse is burnt
Check and change
Default phase or bad contact of start
button
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Check and change
Wrong setting for discharge pressure
Setting again
Tripping of overload protection of
Motor overhaul/waiting for
motor/damage
cooling of motor
AC contactor fault
Check、handling and change
Wait for 2 minutes if it fails to restore
Restore by pressing urgent stop
after breakdown
button
Check main engine and move
Main engine fault
main engine
The minimal pressure valve leaks air
Check and adjustment
Compressor
Inlet valve is stuck in close position and
cannot
small hole is blocked
generate
Magnetic valve does not work
Check magnetic valve/circuit
pressure
Filter element of air cleaner is blocked
Clean/change filter element of
seriously
air cleaner
No idling or
keeping
pressure valve
or safety
valve operate
during idling
Discharge
Unfavorable inlet valve operation
Invalid magnetic valve
Filter element of oil-gas separator is
blocked
Adjustment value of safety valve
changes or safety valve breaks down
Air cleaner element is blocked
Check and change
Check and repair inlet control
valve
Overhaul or change
Change
Adjust or change again
Clean/change air cleaner
element
quantity and
Oil leakage and gas leakage in system
Check and eliminate
discharge
Gas consumption exceeds compressor
Check connection condition of
pressure are
discharge quantity
equipment
lower than
normal valus
Unfavorable inlet valve operation
Magnetic valve breaks down or leaks
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Check and repair inlet control
valve
Check, repair or change
Discharge
pressure
stops for
excessive
Pressure transmitter fails or there is
abnormal interference signal
Eliminate or change
pressure
Too low oil level
Refuel
Increase environment
Too high environment temperature
ventilation and reduce
environment temperature
Too high
discharge
Too dirty oil cooler surface
Clean oil cooler
temperature
Fan or fan motor fault
Check, repair and change fan
or thermal
Oil cleaner is blocked
Change oil cleaner
protection
Thermostat valve fault
Temperature display control fault
Lack of water
Cooling water pressure too low
No unloading process for emergent halt
Inlet of main
engine leaks
oil during halt
Invalid inlet control valve
Invalid magnetic valve
The minimal pressure valve breaks
down without return
discharge and
large oil
consumption
in compressor
thermostat valve
Brand new restoration of
display panel
Check cooling water and water
pump
Avoid urgent halt
Check and repair inlet control
valve
Check, repair or change
Check, repair or change
Discharge part of oil and
Too high oil level
A lot of oil in
Check, repair and change
reduce oil level
Oil return pipe/Oil return nozzle is
blocked
Oil-gas separation filter element is
damaged
The minimal pressure valve spring is
loose
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Disassemble，clean
Change filter element
Adjust or change new spring
Unit oil pipeline/oil seal oil leakage
Environment
Low ambient temperature
temperature
too low
Check leakage part and
eliminate leakage
Enhance the ambient
temperature
Defective temperature sensor
Check and replace
Low electric current
Transformer circuit
Motor
High exhaust pressure
Readjust the pressure control
temperature
Main engine malfunction
Inspection main engine
too high
Main engine bearing abrasion
Check and replace
主电机热保护器故障
检查电机热敏电阻
Main motor bearing is worn
Check and change
Abnormal
Fan motor bearing is worn
Check and change
sound in unit
Main engine bearing is worn
Check and change
Fan and wind shield crash
Adjust interval
Machinery seal ring is aged
Change
O ring is aged in oil gas seat
Change
Main
O ring is aged in discharge
engine
end gland
part
Unfavorable sealing of main
engine oil injector flange
Change
Replace the seal
connector
Oil leakage
Oil gas
O ring of exhaust pipe and
pipeline
splice is aged
part
Splice is loose
Oil gas
Sealing of flange cover and
separato
bucket plane is not tight
r part
O ring of oil level is aged
sealing face of inspiration
Change
Screw tightly
Change asbestos gasket
Change
Glue and reinstall after cleaning
Other
control valve leaks oil
part
Sealing face of oil filter leaks
reinstall after replace and
oil
cleaning
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Common fault
Possible causes
Troubleshooting method
①Whether output cable leaks ①Change
Wiring fault
electricity
cable
or
improve
environment
②Whether there is short-circuit ②Change motor
in motor
③Change frequency converter
③Frequency converter breaks
down
①Whether
Motor overload
carrier
frequency ①Adjust carrier frequency
setting is proper
②Check main engine and motor
②Whether load is too large
③Change fan blade
③Whether there is problem in ④Improve environment problems
motor heat dissipation
④Whether
environment
temperature is too high
①Whether communication wire ①Check circuit and lock
Communication
fault
is loose
②Whether
②Change
communication
communication parameters
parameter is changed
③Eliminate external fault
③whether frequency converter
works
①Whether acceleration time is ①Lengthen acceleration time
Acceleration
current
over too short
②Adjust to normal range
②Input voltage is too low
③Whether
outlet
side
③Eliminate external fault
is
grounded
①Deceleration time is too short
Deceleration over ②Whether voltage is too low
current
③Whether outlet side
grounded
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①Lengthen deceleration time
②Adjust to normal scope
is ③Eliminate external fault
①Whether motor is adjusted ①Implement motor parameter
Constant
speed automatically
over current
automatically)
(learned identification
②Reduce load
②Whether load is too large
③Eliminate external fault
③Whether there is grounding in ④Change frequency converter
output side
④Whether it is problem of
frequency converter itself
Input phase loss
①Check the three-phase input is ①Check the input side circuit: such
normal
as MCB
②Frequency convertor itself fault ②Replace frequency convertor
Note:
for complete machine not used for long term, start the complete machine after preheating for 10
minutes by powering on to prevent electrical apparatus element from being burnt.
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厦门东亚机械工业股份有限公司
XIAMEN EAST ASIA MACHINERY INDUSTRIAL CO.，LTD
If you need to help, please call 400-6113080 ext. 3
JAGUAR WeChat APP public account
www.jaguar-compressor.com
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