DENAIR DA Series Operation Manual Download Page 2 | Manualshive

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DA Series

Operation Manual

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Rear Cooler

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Exhaust Temperature Sensor

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Pressure Sensor

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Maintenance

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Inspection and Update of Belt and Pulley

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Lubrication of Motor Bearing

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Compressor Bearing

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Air Compressor Lubricating Oil

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Oil Separator

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Oil Return Pipeline

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Engine Oil Filter

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Inlet Valve

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Pressure Maintenance Valve

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Safety Valve

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Draining Solenoid Valve

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Electric Insulation

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Periodic Inspection and Cleaning

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Safety Protection and Warning Device

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Motor Overload Protection

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Protection for Over-temperature of Exhaust

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Setting and Description of Other Protection and Warning

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Failure Causes and Troubleshooting

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Annex I: Table of Cycles for Periodic Maintenance of Air Compressor

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Summary of Contents for DA Series

Page 1: ...r Air Rate of Ventilating fans 6 3 5 Warning 7 3 6 Suggestions for Pipeline 8 3 7 Electric Appliances Installation Precautions and Control System 11 4 Introduction to the System 14 4 1 Overall System 14 4 2 Composition of the Compressor Unit 14 4 3 Lubricating Oil System 15 4 4 Oil gas Separation System 15 5 Operation of Controller 16 5 1 Key Description 16 5 2 Contents of Controller 16 5 3 Conten...

Page 2: ...l Return Pipeline 30 7 8 Engine Oil Filter 30 7 9 Pipe Joint 30 7 10 Inlet Valve 30 7 11 Pressure Maintenance Valve 30 7 12 Safety Valve 31 7 13 Draining Solenoid Valve 31 7 14 Cooler 31 7 15 Electric Insulation 31 7 16 Periodic Inspection and Cleaning 31 8 Safety Protection and Warning Device 32 8 1 Motor Overload Protection 32 8 2 Protection for Over temperature of Exhaust 32 8 3 Setting and Des...

Page 3: ...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 ...

Page 4: ...ction 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 ope...

Page 5: ...s 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 compre...

Page 6: ...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 envi...

Page 7: ...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 machin...

Page 8: ...mers 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 ...

Page 9: ...reater 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 ai...

Page 10: ...rating 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 o...

Page 11: ...mprove the air quality in the air system Using two types of dryers i e refrigerated dryer and regenerative dryer can solve the problem of containing water in the outside air system of the compressor When the dew point requirement of the compressed air pressure is 1 to 4 the refrigerated dryer can be applied generally however when it is required to keep the dew point requirement of the pressure bel...

Page 12: ...ir receiver shall be installed additionally The air compression system shall be successfully isolated without exhausting the system pressure and wasting the valuable energy for later maintenance 3 The requirement on flexibility of the pipeline shall be considered during implementing piping to avoid resonance phenomenon of the pipeline as far as possible The gradient of the air pipeline shall be at...

Page 13: ...thing wire and no fuse breaker NFB for the air compressor to ensure the safety of using the electric appliances The safe current of the power line shall be set under the condition where the ambient temperature is 35 the operating temperature is lower than 55 the wire length is within 20m and shall be based on the 600V PVC wire When the power line fails to meet the settings above the specifications...

Page 14: ...0HZ 2 When the earthing wire and the power line of the movable electric appliance are both placed in the hose or cable and the wire diameter of the electric appliance shall be the same with the power line 3 7 2 Driving motor The driving motor of the air compressor shall correctly turn to the counter clockwise direction when seeing from the driving end The inching time of the motor shall be as shor...

Page 15: ... bypass pipeline and the pressure in the oil gas barrel starts to discharge meanwhile the pressure maintenance valve is quickly closed to isolate the system pressure The pressure in the oil gas barrel is consistently discharge to a certain valve i e the no load pressure to provide the pressure required by lubricating oil circulation At this time the air enters from the bypass pipeline and is exhau...

Page 16: ... can be made by the controller of the air compressor The air compressor cannot be restarted up until five minutes after shutting down the motor 3 7 5 Electrical circuit The electrical control of the air compressor consists of two systems including the internal control system and the part of the startup disk The startup disk is the Y startup control used by general machineries The control part is t...

Page 17: ...pressor can be controlled above the dew point by the heat control valve When the air compressor starts up in cold a part of the lubricating oil will flow bypass the cooler When the system temperature rises above the settings of the temperature control valve the lubricating oil will flow through the cooler When the unit is running under high temperature conditions all lubricating oil will flow thro...

Page 18: ...p key the motor can be stopped by pressing this key Reset reset key reset by pressing this key Up up arrow key page up the menu by pressing this key Down down arrow key page down the menu by pressing this key Right right arrow key page down the menu by pressing this key Set enter key 5 2 Contents of Controller 5 2 1 State and display The following interface will display when the unit is powered on...

Page 19: ...ers such as runtime runtime for this execution maintenance parameter historical fault date of production and field failure can be observed and then return to the previous menu with the movement keys and enter key set and return key reset according to the above mentioned methods 5 2 3 User parameter a Method to modify parameter The user parameters can be reviewed and modified with the above mention...

Page 20: ... or turns back to the black scrollbar while the turns back to the enter key Press the key Right when the scrollbar locates at the upper pressure limit then the flicker bit displays The and turn to page up key and page down key to modify the current bit while the Right turns to shift key to move the modified bit The flicker bit disappears upon pressing Set The or turns back to the black scrollbar w...

Page 21: ...rent for motor start up Star angle delay Time of star angle pressure reducing startup delay Load delay Delay load time after star angle pressure reducing startup No load delay Empty continuous running time where the motor will be automatic stopped when it exceeds this time Shutdown delay For shutdown only when delaying for such time after empty Startup delay Restart can be achieved only after dela...

Page 22: ...ator Air filter The service time may zero out when changing the air filter Lubricating oil The service time may zero out when changing the lubricating oil Lubricating grease The service time may zero out when changing the lubricating grease Maximum service time preset Oil filter The time warning of the oil filter does not work when set to 0 Oil ratification separator The time warning of the oil ra...

Page 23: ...troller is powered on Press key START to start the main motor after self inspection The startup process of the main motor KM3 powered on KM1 powered on Enter into Y startup state delay time out Y transfer time KM3 powered off KM2 KM3 interlocking KM2 powered on operating and startup completed All solenoid valves are powered off to achieve empty startup during startup 5 5 2 Automatic operation cont...

Page 24: ...hen the main motor and the fan motor stop running The motors can be restarted only by pressing Start 5 5 4 Frequent startup resistance control The motor cannot be immediately started up with the motor stopping running for stop by pressing Stop for a too long empty and a fault It requires some delay Under each shutdown state the time display window of the controller displays the remaining delay tim...

Page 25: ...ayed Fan overloaded The fan shut down due to overload Indicator light for overload of fan lit up Alarm and shutdown Exhaust pressure higher than limit value Shutdown for too excessive pressure Alarm and shutdown Phase sequence error default phase Shutdown for phase sequence error Indicator light for phase sequence error lit up Alarm and shutdown 5 7 Safety Protection 5 7 1 Motor Protection The con...

Page 26: ...s on the service time of the lubricating oil oil filter oil separator and body bearing In case that the air inlet filter is blocked the air intake will decrease thus affecting the air supply Denair service staff will suggest changing a new product based on the inlet dust and the service time displayed on the controller at every onsite inspection With the controller set to the longest service time ...

Page 27: ...ous increase of the pressure in the oil gas barrel When the pressure increases to the set value the safety valve on the oil gas barrel will automatically open to discharge pressure and eject the lubricating oil so as to reduce the pressure in the oil gas barrel and ensure the safe use of the unit In order to avoid accidents the set pressure of the safety valve has been adjusted before delivery and...

Page 28: ...st temperature of the compressor and send the message to the controller to maintain the normal operation of the compressor In case that the exhaust temperature is detected too high the controller may shut down the air compressor to prevent the parts from being damaged and accidents 6 11Pressure Sensor The compressor is equipped with a pressure sensor to send the message to the controller for proce...

Page 29: ... seriously damaged it can be changed by adjusting the height of the motor with the adjusting bolt until the bolt can be easily dismounted The height of the motor is supported by the bolt At the moment the belt can be replaced with a new one After then the adjusting bolt shall be removed This is convenient because there is no need to readjust the horizontal plane of the pulley 7 2 Air Filter The ai...

Page 30: ...ing is complete when the motor is delivered 2 The filling amount refers to the amount of the lubricating grease filled into the bearing at every interval Please supply timely according to the running time of the unit 3 Note more supplementary amount cannot extend the supply period Please do as the specification given in above table 4 The bearing may be overheated and the lubricating grease may be ...

Page 31: ...of special oil shall not be used mixing with other oils otherwise the air compressor may be seriously damaged otherwise specified by the Denair When changing the oil the old oil in the system shall be completely removed otherwise the service time of the new oil may be shortened The oil filter and oil separator shall also be changed when changing the lubricating oil The oil shall be changed as foll...

Page 32: ... maintenance instruction and varies with the working condition dust inlet filter efficiency and the daily clean and maintenance of the unit However the filter shall be replaced in case of a poor filtration efficiency to avoid damaging the body The filter is replaced as follows disassemble and assemble the lubricating oil filter with a special tool to avoid deforming the enclosure and affecting the...

Page 33: ...n the solenoid valve disassemble it to inspection b normal pickup of the coil rod of the energized solenoid valve touch the coil rod with a tool like electro probe c normal operation of the empty and load voice of switchover 7 14 Cooler After using for a while the heat dissipation of the flow through cooler may become poor because the dirt and dust attach to the surface thus increasing the exhaust...

Page 34: ...ased running of the motor safety valve s failure to actuate system setting failures obstruction of oil separator and etc If the motor is found overloaded in the process of running please contact maintenance supplies of Denair or specified region go for inspection and clarify the reason of overload otherwise the burnout of the motor will cause a lot of troubles for in situ air requirements and main...

Page 35: ...Draining solenoid valve unable to close Check whether the solenoid valve is excited the valve gets stuck And the controller outputs signals connection cord or relay Air pipeline obstructed the valve not full opened Check the pressure of each parts within the air compressor and remove the obstruction or open the valve Over dampness of the system Improper installation of the water drain pipe of the ...

Page 36: ...ssure setting Adjust settings Failure of pressure sensor The detection pressure of sensor is lower than the actual values Connection pipe of sensor obstructed remove Fault of controller I O fault of controller replace and repair it Fault of safety valve Replace the safety valve Short service life of lubricating oil Mixed use of different oil products Eliminate all the lubricating oil of the system...

Page 37: ...light Exhaust temperature Check temperature range 70 95 Condensate water within oil gas barrel Drain water Oil level Check transparent hose and core sleeve Check replace Inlet connection hose Check replace Pipeline rubber metal Check replace Pipeline connection Check and test leakage Cooler Clean check Cooling fan Clean Air filter Clean check replace Pre filter screen Clean Connection of solenoid ...

Page 38: ... 000 hours or one year so the oil product is recommended to be replaced whichever expires first Remark When the semi synthetic oil product is used in high temperature its usage shall be half of that in normal condition 2 The air compressor with exhaust pressure over 10 kgf cm2 shall use Denair full synthetic lubricating oil as its oil product and its recommended service hours is 4 000 hours 3 In n...

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