DENAIR DA Series Manuel utilisateur

DA Series Operation Manual
1
Contents
Safety Precautions.............................................................................................................. 1
1 Electrical Safety...................................................................................................................... 1
2 Driving Components..............................................................................................................1
3 High Temperature and High Pressure.............................................................................. 1
4 Unit Drainage........................................................................................................................... 2
Inspection and Handling...................................................................................................2
1 Product Warranty of Compressors....................................................................................2
2 Check of Specifications and Model................................................................................... 2
3 Inspection of Accessories and Appearance................................................................... 3
4 Handling Precautions............................................................................................................3
Installation..............................................................................................................................4
1 Environment Requirements.................................................................................................4
2 Installation Location Requirements.................................................................................. 5
3 Ventilation and Cooling Requirements.............................................................................5
4 Selection Requirements for Air Rate of Ventilating fans............................................. 6
5 Warning..................................................................................................................................... 7
6 Suggestions for Pipeline...................................................................................................... 8
7 Electric Appliances Installation Precautions and Control System......................... 11
Introduction to the System............................................................................................14
1 Overall System......................................................................................................................14
2 Composition of the Compressor Unit.............................................................................14
3 Lubricating Oil System....................................................................................................... 15
4 Oil-gas Separation System................................................................................................ 15
Operation of Controller.................................................................................................. 16
1 Key Description.................................................................................................................... 16
2 Contents of Controller........................................................................................................ 16
3 Contents of User Parameter..............................................................................................19
4 Schematic Wiring Diagram................................................................................................ 20
5 Control Operation................................................................................................................ 21
6 Warnings and Prompts....................................................................................................... 22
7 Safety Protection..................................................................................................................23
Function Description of System Components...................................................... 24
1 Air Filter.................................................................................................................................. 24
2 Inlet Valve............................................................................................................................... 24
3 Oil-gas Barrel........................................................................................................................ 24
4 Oil Separator..........................................................................................................................25
5 Safety Valve........................................................................................................................... 25
6 Pressure Maintenance Valve.............................................................................................25

DA Series Operation Manual
2
7 Rear Cooler............................................................................................................................ 25
8 Oil Cooler................................................................................................................................25
9 Oil Filter.................................................................................................................................. 26
10 Exhaust Temperature Sensor........................................................................................ 26
11 Pressure Sensor............................................................................................................... 26
Maintenance.........................................................................................................................26
1 Inspection and Update of Belt and Pulley..................................................................... 26
2 Air Filter.................................................................................................................................. 27
3 Lubrication of Motor Bearing............................................................................................28
4 Compressor Bearing........................................................................................................... 29
5 Air Compressor Lubricating Oil....................................................................................... 29
6 Oil Separator..........................................................................................................................29
7 Oil Return Pipeline............................................................................................................... 30
8 Engine Oil Filter.................................................................................................................... 30
9 Pipe Joint................................................................................................................................30
10 Inlet Valve..........................................................................................................................30
11 Pressure Maintenance Valve....................................................................................... 30
12 Safety Valve......................................................................................................................31
13 Draining Solenoid Valve................................................................................................31
14 Cooler................................................................................................................................ 31
15 Electric Insulation...........................................................................................................31
16 Periodic Inspection and Cleaning.............................................................................. 31
Safety Protection and Warning Device.....................................................................32
1 Motor Overload Protection................................................................................................ 32
2 Protection for Over-temperature of Exhaust................................................................ 32
3 Setting and Description of Other Protection and Warning....................................... 33
4 Failure Causes and Troubleshooting..............................................................................33
Annex I: Table of Cycles for Periodic Maintenance of Air Compressor............... 35

DA Series Operation Manual

1. Safety Precautions

Please carefully read this manual and operate based on the detailed instructions given in the

manual before installing and using the air compressor of the Company to avoid hazardous

events and prevent machines being damaged.

1.1 Electrical Safety

(1) Once power up the air compressor, the voltage generated will be very dangerous, therefore

only electricians and electrical engineers who are certified through national examinations

are allowed to perform the installation. The operators shall perform the safety operations in

strict accordance with the operating mode specified in this manual and national regulations

and safety code.

(2) Users and installation personnel shall provide earthing and installation protective circuit for

compressor units in accordance with national electrical standards.

(3) Each standalone compressor shall be installed with an exclusive breaker, which shall be

used with NFB with corresponding capacity, and see detailed configuration in the

instructions of Fig. 3.7.

(4) Make sure the power switch is turned off before any maintenance to avoid accidents. There

shall be a warning saying “No switching on” hanging on the power switch.

1.2 Driving Components

(1) Do not open soundproof enclosure before the air compressor is completely shut down so

as to avoid ganger.

(2) Any dismounting shall not be implemented until the motor and the fan have been

completely shut down and it is ensured that the power is cut off.

(3) Do not wear excessively loose clothes during maintenance to avoid accidents.

1.3 High Temperature and High Pressure

(1) For part of pipelines and components whose temperature may increase (a warning sign is

significantly affixed on the air compressor), touching is not allowed to avoid scald

accidents until it is confirmed to be completely cooled.

(2) There may be high pressure fluid in each component and pipeline of the air compressor, so

it shall be confirmed that the pressure of the unit has been completely discharged before

dismounting. The high pressure fluid shall be prevented from pointing to any person to

protect the person from been injured by the high pressure fluid.

(3) The compressed air provided by the air compressor is only for industrial purpose. Do not

breathe the air before it has been processed appropriately, or it will result in bodily injury,

DA Series Operation Manual

disease or death.

1.4 Unit Drainage

(1) The drain valves of oil-gas barrels of the unit and the system shall be open to drain

condensate water completely before starting up the air compressor, to ensure that the oil

products of the unit will not be emulsified and the compressor will not be stuck due to

deterioration of oil products.

(2) The post treatment device and the drainage function of devices shall be regularly

inspected to ensure the normal operation of the system.

2. Inspection and Handling

Please carefully read this chapter to ensure the rights of the customers. Handling shall be

implemented as per the manner mentioned in section 2.4 to avoid accidents and damage to the

unit.

2.1 Product Warranty of Compressors

The Denair Screw Air Compressors shall be delivered after conducting the strict quality management and

performance test. Except as otherwise noted (according to the terms of the product warranties), the

warranty period of the compressor shall be 18 months from the date of production of the compressor or

12 months from the date of formal commissioning of the compressor (which is due earlier).For any poor

quality or fault and damage caused by manufacturing reasons during the product warranty period, the

Company will provide free service for the products after confirmation. Any fault caused by, such

incontrollable factors as moving, striking, natural disasters and wars, or the operation and maintenance

not in conformity with instructions or without use of the consumables and oil products marked with Denair,

or the maintenance conduct by other person other than personnel of our company and servicemen of

service agency appointed by Denair, shall be excluded from the product warranty.

It is recommended that customers using Denair products should immediately inform the original Denair or

appointed service agency to troubleshoot the factors but not modify the system by yourself and force the

compressor to work, which may result in damages to the compressor, if there is abnormity of the

compressor caused by unusual condition of the unit

2.2 Check of Specifications and Model

Please check whether the nameplate specifications (see Fig. 2.1) of this air compressor conform to the

requirements of your order.

DA Series Operation Manual

Fig. 2.1

Note:

Model: prepared as per Denair’s in-plant model

Model specifications: prepared as per national standard JB/T2589-86

2.3 Inspection of Accessories and Appearance

Please check whether spare and accessory parts are all in readiness after receiving the air

compressor. If there is any quality problem, please contact us immediately. All Denair air

compressors shall be attached with the followings:

(1) One copy of operation manual;

(2) One copy of Warranty;

(3) Two keys to the door.

2.4 Handling Precautions

Please choose proper forklift or crane for handling based on the weight of the air compressor.

Please do not stand below the air compressor and keep at a safe distance as far as possible

during hoisting.

DA Series Operation Manual

Fig. 2.2

Notice: it is not allowable to place any items on the cooler over the metal plate, and the cooler

shall not covered to avoid tripping resulting from high temperature of the unit.

3. Installation

Please carefully read this chapter before installation to ensure the proper installation and

reliable operation of the air compressor.

3.1 Environment Requirements

(1) The air compressor shall be installed indoors where it is well ventilated and lit other than

the places with high dust, high humidity, etchant gas, metallic dust, direct radiation of

sunlight or direct rainwater.;

(2) The range of ambient temperature is 0℃~45℃.

(3) The air compressor shall be kept away from boilers and equipment which may emit heat,

and shall be equipped with awnings with favorable ventilation environment while being

installed outdoors.

(4) The ventilating fans around and over the air compressor shall set apart at least 900 mm

maintenance space (see Fig. 3.1).

(5) The altitude shall be less than 1000 m.

DA Series Operation Manual

(6) The relative humidity shall be less than 95%.

Fig. 3.1

3.2 Installation Location Requirements

The screw air compressor can be installed on any floor slab which may withstand the weight of the air

compressor without any special foundation, where the floor is smooth and horizontal. The air

compressor shall be fixed with foundation bolts; meanwhile rubber blanket shall be equipped to slow

down the vibration of the unit while being installed on the steel frame and mobile ships or vehicles.

3.3 Ventilation and Cooling Requirements

When installing the air compressor indoors or outdoors, good ventilation shall be ensure to

avoid heat short cycle or interaction effect from heat extraction of the machines, so the locations

of vent pipes, ventilating fans and compressors must be considered (there are typically three

ways, see Fig. 3.2).

DA Series Operation Manual

Fig. 3.2

Note:

(1) Fig. A: when the exhaust duct is not used for ventilation, refer to Table 3.1 Ventilation Rate (1) for the

recommended exhaust air rate of ventilating fans, and please install the ventilating fans as high as

possible.

(2) Fig. B: While using exhaust duct without installing the ventilating fans, the exhaust air rate of

the compressor and the pressure loss in the exhaust duct shall be calculated. When the pressure

loss is less than 20Pa, there is no need to install ventilating fans and the dismountable exhaust air

hose shall be directly installed at the air outlet of the compressor.(It is recommended that

customers should use the ventilation design of Fig. A and Fig. C best).

(3) Fig. C: When the pressure loss in the exhaust duct is greater than 20Pa, ventilating fans

shall be installed additionally where the distance between the exhaust duct and the air

outlet of the compressor shall be 200-300mm. Refer to Table 3.1 Ventilation Rate (2) for the

recommended exhaust air rate of ventilating fans. Pay attention to the exhaust air rate and

such conditions as the pressure loss in the exhaust duct and exhaust temperature increase

while choosing ventilating fans.

3.4 Selection Requirements for Air Rate of Ventilating fans

Table 3.1

Cooling method of the unit

Air cooling

Motor power of the unit

(KW)

5.5

7.5

Exhaust air rate (1)

(m3/min)

140

180

225

270

360

450

540

900

Exhaust air rate (2)

(m3/min)

170

240

340

DA Series Operation Manual

3.5 Warning

The compressed air and electricity are dangerous.

Prior to any operation on the air compressor, it shall be ensured that:

1 The power has been cut off with the switch locked and the notice plate hung;

2 All the pressure within the entire air compressor system shall be relieved.

(1) It is prohibited to dismount all kinds of caps and mounting and dismounting any joint or device while

the air compressor is running since the high temperature fluid and the compressed air in the air

compressor may cause severe personal injury and even death.

(2) It will bring voltage danger in the electric cabinet when starting up the motor of the air compressor,

therefore all installations shall be implemented in accordance with the accepted laws and

regulations. It shall be ensured that the system voltage can be cut off by disconnecting the switch

manually and the no-fuse switch shall be installed on the power supply line leaded to the air

compressor before running the electrical system. The personnel responsible for equipment

installation shall provide proper found connection, maintenance space and lightning arrester for all

electrical parts.

(3) The air compressor cannot be operated under the exhaust pressure which is greater than that

specified by the nameplate of the air compressor, otherwise the motor will overload which may

result in the tripping of the motor of the air compressor.

(4) The air compressor and auxiliary equipment shall be only cleaned with safe solvent.

(5) The manual stop valve (separate-type) shall be installed in the exhaust pipeline. If the safety valve

is installed between the stop valve and the air compressor, the safety valve shall provide adequate

capacity to release the maximum continuous air flow of the air compressor.

(6) Once any pressure is released through the safety valve due to over-high pressure in the system,

the reason for over-high pressure shall be promptly found out.

(7) If the lubricating oil of the air compressor flows into the air system of the plant, it may bring about

adverse impact. Such post treatment equipment as air dryer and secondary filter (oil-gas separator)

shall be chosen and installed properly to minimize any liquid additions in the air. It may be risky to

use plastic casing without metal cover for the filtration of pipelines. From a safety point of view,

metal casing shall be applied to all the pressure systems. For this purpose, it is recommended that

the air circuit system of the plant shall be re-inspected.

(8) The air tank of post treatment equipment of the air compressor shall be installed and maintained in

accordance with the regulations of Monitoring Specification for Pressure Vessel issued by Ministry

DA Series Operation Manual

of Labor of the People’s Republic of China.

(9) The indication stickers on the control panel and this operation manual shall be carefully read

according to each standard operation before starting up the air compressor.

(10) Various cover plates and casings shall be re-installed after completing daily maintenance.

Notice: when the shield plate of the unit is open, the air compressor shall not be started up.

Warning

Not taking such safety advice abovementioned may result in mechanical faults, property damages,

severe personal injuries and even death. Such factors as vibration, pulse, temperature, maximum

pressure, corrosion resistance and chemical resistance shall be considered for any air inlet pipe and

exhaust pipeline connected to inlet/outlet joints, and it should also be noted that there may be a little

lubricating oil in the compressed air generated by the oil air compressor, therefore reasonable allocation

and compatibility shall be ensured between exhaust pipeline and system post treatment device and filed

air demand.

3.6 Suggestions for Pipeline

3.6.1 Pipeline

The air cooler in the unit may sharply reduce the exhaust temperature below the dew point temperature

(under most environmental conditions), so there will be a large amount of condensate separating out. The

condensate valve (drainage device) shall be installed near the exhaust outlet of the air compressor and a

length of exhaust pipe shall be connected to the drainage device of condensate water.

Key point: The drainage device shall be inclined downward in order to work normally.

Notice: A length of drain pipe (transparent hose) shall be placed in the drain pipeline for ease of

inspecting the operation of the automatic drain valve. If the posterior pipeline further cools

the air, it may regenerate the condensate water. Therefore, the release valve and the

drainer of condensate water shall be installed at the lower place of the piping system.

Key point: The diameter of the exhaust pipeline shall be kept at least the same big with that of exhaust

connection pipeline in the casing of the air compressor. All pipelines and joints shall apply to

the maximum operating temperature of the unit, and the nominal pressure shall be kept at

least the same high with that of the oil-gas separator of the air compressor. It is important to

check over each joint dimension of the air compressor, and proper length and dimension of

the pipe, the number and category of the joints and valves shall be considered to reach the

maximum efficiency of the air compressor. It is important to comprehensively consider the

air system of the whole plant to ensure the safety of the entire system while installing new

air compressors. Condensate water will be necessarily produced in the air pipeline during

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