Dato CSST13020 Manual de usuario

SCREW AIR

COMPRESSOR

CSST13020

Instruction

Manual

Release August 2018

TABLE OF CONTENTS

1. Safety Information…………………...………………………………………………4

1.1 Safety Alert Symbols………………………………………………………………4

1.2 Safety Precautions………………………………………………...………………...5

1.3 Pressure……………………………………..……………………………………….5

1.4 Fire and Explosion…………………………..……………………………………...6

1.5 Moving Parts………………………………………………..………………………6

1.6 Hot Surfaces…………………………….………………………….……………….6

1.7 Proper Compressed Air Applications.................................................6

1.8 Electrical Shock……………………………………………….…………………….7

2. General Information……………………………………………………………………8

2.1 Introduction…………………………………………………………………………8

2.2 The Compression Cycle…………………………………………………………….9

2.3 Compressor Lubrication and Cooling System…………………………..……...10

2.4 Compressor Discharge System…………………………………….……………..10

2.5 Air-end, Inlet Valve and Filtration System…………………………………….11

2.6 Control Panel Layout...…………………………………………………………..12

2.7 Technical Data…………………………………………………………….. 14

3. Fluid Information……………………………………………………………………..15

3.1 Fluid Guide………………………………………………………………….……..15

3.2 Fluid Change and Recommendations……………………………………....……15

4. Installation……………………………………………………………………………..16

4.1 Compressor Mounting, Support and Location…………………………………16

4.2 Ventilation and Cooling……………………………………….…………………16

4.3 Piping Connection………………………………………………………..............18

4.4 Fluid Level Inspection………………………………………….…………………19

4.5 Electrical………………………………………..…………………………………19

4.6 Motor Rotation Inspection…………………………………………...…………...20

4.7 Fan Rotation Inspection …………………………………………….……………21

5. Operation…………………………………………………………………….………...22

5.1 Routine Operation…………………………………………….…………………..22

5.2 Operating Procedures (Electrical Control Panel)………………………………24

5.3 Display Unit Status and Operations……………………………………………24

5.4 Customer Parameter and Functions………………………………….…………27

TABLE OF CONTENTS

5.5 Manufacturer Parameters……………………………………………………….31

5.6 Control Principle………………………………………………….…………...39

5.7 Network Control…………………………………………………………………41

5.8 Temperature Control of Fan………………………………………….………….41

5.9 Failure Shutdown and Emergency Shutdown…………………………………..41

5.10 Early-Warning and Prompts………………………………………..…………...41

5.11 Control Protection……………………………………………………….............42

5.12 Common Failure Solving………………………………………...…………..44

5.13 Electrical Control Diagram ……………………………………………...……46

6. Servicing………………………………………………………………………………..47

6.1 Fluid Change………………………………………………………………..……..47

6.2 Air Filter……………………………………………………………………….…..47

6.3 Fluid Filter………………………………………………………………………....48

6.4 Air/Oil Separator………………………………………………………………….48

6.5 Maintenance Schedule…………………………………………………………….49

7. Troubleshooting Guide.………………………………………………………………50

8. Standard Terms and Conditions ……………………………………………….…..53

Safety Information

Thank you for choosing our Compressor. Please read this instruction manual carefully

before using the compressor. This manual must be kept in the safe place for future

reference. Our Compressor’s authorized distributors provide maintenance service for CS

series rotary screw compressors. A certified technician is required to ensure compressors

maintenance is safely handled. By following the instructions in this manual, the user will

minimize possibility of an accident throughout the useful life of this equipment.

1.1 SAFETY ALERT SYMBOLS

Key hazards are used throughout this manual. The level of hazards seriousness is

symbolized as follows:

This symbol identifies immediate

hazards which will result in severe

personal injury, death or substantial

properly damage.

This symbol identifies hazards or

unsafe practices which could

result in personal injury, death or

substantial property damage.

This symbol identifies immediate

electrical hazards which will result

in severe personal injury, death or

substantial properly damage.

This symbol identifies hazards or

unsafe practices which could

result in personal injury or

substantial property damage.

This symbol identifies immediate

hot surface hazards which will

result in severe personal injury.

NOTICE

Identifies important installation,

operation or maintenance

information which is not hazard

related.

Safety Information

1.2 SAFETY PRECAUTIONS

This manual describes the safety precautions, structure and functions of all systems and

components, as well as the operation and maintenance methods for the GC series rotary

screw air compressors. The owner and operator shall read the manual carefully. Only after

thorough understanding should the machine be operated for the first time. This manual

gives you a general description of the, mechanical and electrical systems and maintenance.

However, if you have any questions about operating and maintenance of the compressor;

please contact your authorized distributor or our service department personnel.

Do not modify the compressor and/or controls in any way except with written factory

approval. While not specifically applicable to all types of compressors with all types of

prime movers, most of the precautionary statements contained herein are applicable to most

compressors and the concepts behind these statements are generally applicable to all

compressors.

Failure to follow any of these precautions may results in severe personal injury,

death, property damage and/or compressor damage

1.3 PRESSURE

A properly sized pressure relief valve must be installed in the discharge piping ahead

(upstream) of any shutoff valve (block valve), heat exchanger, orifice or any potential

blockage point. Failure to install a pressure relief valve could result in the rupturing or

explosion of some system component. Relieve all pressure internally to the compressor

prior to servicing. Do not depend on check valves to hold system pressure. Do not change

the pressure setting of the pressure relief valve, restrict the function of the pressure relief

valve, or replace the pressure relief valve with a plug. Over pressurization of system or

compressor components can occur, resulting in death, severe personal injury or property

damage. Do not operate the compressor at pressures in excess of its rating. Never use

plastic pipe, rubber hose, or soldered joints in any part of the compressed air system.

Failure to ensure system compatibility with compressor piping is dangerous.

Safety Information

1.4 FIRE AND EXPLOSION

Clean up any spills of lubricant or combustible liquid immediately. Keep sparks and flame

away from the compressor. Do not permit smoking during servicing, such as checking or

adding fluid. Wipe down spills immediately using industrial cleaner as required. Do not use

flammable material for cleaning purposes. Do not operate the compressor in a hazardous

environment unless the compressor has been specially designed for that environment. Wear

personal protective equipment including safety goggles and clothing during servicing the

compressor. Never use a flammable or toxic solvent for cleaning the air filter or any parts.

1.5 MOVING PARTS

Keep hands, arms and cloths away from the coupling and fans of the compressor. Do not

remove any guards or cabinet panels or attempt to service any compressor part while the

compressor is operating.

1.6 HOT SURFACES

Do not touch any hot surface and parts during the compressor’s operation. Keep all body

parts away from air/oil receiver tank, steel tubing, air end and after-cooler. Wear personal

protective equipment including gloves while servicing the compressor.

1.7 PROPER COMPRESSED AIR APPLICATIONS

Air from this compressor will cause severe injury or death if used for breathing or food

processing. Air used for those processes must meet OSHA and applicable industry

regulations. This compressor is designed for use in the compression of normal atmospheric

air only. No other gases, vapors or fumes should be exposed to the compressor intake, nor

processed through the compressor. Keep personnel away from the compressed air discharge.

Use compressed air for cleaning purpose, only with effective chip guarding and personal

protective equipment which meet OSHA standard and/or any federal, state, local codes,

standard and regulation.

Safety Information

1.8 ELECTRICAL SHOCK

Never start the compressor unless it is safe to do so. Do not attempt to operate the

compressor with a known unsafe condition. Tag the compressor and render it inoperative

by disconnecting and locking out all power at the source or otherwise disabling its prime

mover so others who may not know of the unsafe condition cannot attempt to operate it

until the condition is corrected. Install, use and operate the compressor only in full

compliance with all pertinent OSHA regulations and/or any applicable Federal, State, and

Local codes, standards and regulations. Never assume it is safe to work on the compressor

because it is not operating. Many installations have automatic start/stop controls and the

compressor may start at any time.

NOTICE

- Follow all maintenance procedures and check all safety devices on schedule.

- Use the correct compressor fluid at all time

- Do not rely on the discharge check valve to isolate the compressed air service line

- Keep panels closed at all times and stay away from hot surfaces to prevent hazards

NOTICE

These instructions, precautions and descriptions cover GC series air compressors.

As a service to our customers, we often modify or construct packages to the

customer’s specifications. This manual may not be appropriate in those cases.

Every effort has been taken to ensure complete and correct instructions have been included

in this manual. However, possible product updates and changes may have occurred since

printing this manual. Compressor reserves the right to change specifications without

incurring any obligation for equipment previously or subsequently sold.

General Information

2.1 INTRODUCTION

The GC series offer models with power ranging from 7.5 kw to 132 kw. The compressor is

a single stage, positive displacement, fluid-flooded rotary screw. A complete unit of

following:

⚫Screw air compressor

⚫Dryer(optional)

⚫Filters(optional)

⚫Air tank(optional)

All components are assembled on a structural steel base with enclosure. The control panel

is located in the front of the enclosure door panel. Acoustical enclosure is one of the

standard features for all compressors.

NOTICE!

Dismantling the compressor’s enclosure may void its warranty.

General Information

2.2 THE COMPRESSION CYCLE

The compressor housing contains of two rotors; Male and

Female rotors. The male rotor has five lobes and female rotor

has six flutes. They are constantly and precisely meshed, and

housed in the cylinder with two parallel adjoining bores. All

parts are machined to exacting tolerances. The rotors provide

positive-displacement internal compression smoothly and

without surging. As the rotors rotate, air is drawn into the

cylinder through the inlet port. A volume of air is filled and

trapped as the rotor lobes pass the inlet port in the cylinders.

Compression occurs as the male rotor rolls into the female

flute, progressively reducing the space thereby raising the

pressure. Compression continues until the lobe and flute pass

the discharge port. The compressed air is then discharged into the air/oil separator tank.

There are five complete compression cycles for each complete rotation of the male rotor.

When the compressor is operating, a partial vacuum is produced at the compressor inlet.

Fluid is injected into the compressor unit and mixed with the air. The fluid has three basic

functions:

•As a coolant, it controls the rise in air temperature normally associated with the heat

of compression.

•It seals the leakage paths between the rotors and stator and also between the rotors

themselves.

•It acts as a lubricating film between the rotors allowing one rotor to directly drive

the other, which is an idler.

After air/fluid mixture is discharged from compressor to the reservoir, fluid is separated

from the air in the separator tank. Compressed air then flows through the after-cooler for

moisture removal while the lubricant is being cooled by the fluid-cooler for re-injectio

General Information

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