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Instruction Manual ZS100T, ZS150T & ZS200T Series II (MAM-870) Senator Industrial Air Compressors

4.8

Preventative Maintenance Program ................................................................ 23

Chapter 5 Fault Diagnosis and Repair ....................................................................... 24

5.1

Compressor Fault Analysis ......................................................................... 24

5.2

Troubleshooting Chart ................................................................................ 25

Chapter 6 Warranty ................................................................................................... 27

6.1

Proof of Purchase ........................................................................................ 27

6.2

Warranty Conditions ................................................................................... 27

Maintenance and Repair Log ....................................................................................... 29

Summary of Contents for MAM-870

Page 1: ...manufactured to provide many years of safe and reliable service if installed operated and maintained in accordance with these instructions Please read and understand this manual before operating the c...

Page 2: ......

Page 3: ...stallation 11 2 1 Outline Dimensions 11 2 2 Installation Site of Compressor 11 2 3 Electrical Safety Requirements 12 Chapter 3 Operation 13 3 1 Initial Start Up 13 3 2 Daily Operation 14 3 2 1 Start U...

Page 4: ...ustrial Air Compressors 4 8 Preventative Maintenance Program 23 Chapter 5 Fault Diagnosis and Repair 24 5 1 Compressor Fault Analysis 24 5 2 Troubleshooting Chart 25 Chapter 6 Warranty 27 6 1 Proof of...

Page 5: ...rated above the discharge pressure specified on the nameplate Otherwise it will result in shutdown due to motor overload f For service and maintenance the power supply should be switched off and the c...

Page 6: ...emperature 45 at atmospheric pressure and relative humidity 80 Driving Mode Belt Drive Cooling Mode Air Cooling Motor Starting Mode Direct On Line Y Y Temperature Control Mode Control by Thermostatic...

Page 7: ...o computer controller with an LCD display It can efficiently reduce the power consumption and provide the operators with convenient operation and monitoring The typical outside view of ZST Series II s...

Page 8: ...Instruction Manual ZS100T ZS150T ZS200T Series II MAM 870 Senator Industrial Air Compressors 4...

Page 9: ...ine oil separator After the oil air separation the compressed air flows through the minimum pressure valve and air tank and then it will be discharged out of the compressor and into the pipeline netwo...

Page 10: ...he compressor if the temperature of the lubricating oil is below 71 C the thermostatic valve will automatically open the bypass circuit and the circulating oil from the oil air tank will be directly i...

Page 11: ...gainst damage A safety valve is installed in the oil air tank If the pressure inside the oil air tank exceeds the setting the safety valve will automatically open to quickly discharge the air and rele...

Page 12: ...tion control and protection temperature indication and protection phase sequence protection motor protection pressure control operation record and so on To ensure normal operation of the unit the user...

Page 13: ...Instruction Manual ZS100T ZS150T ZS200T Series II MAM 870 Senator Industrial Air Compressors 9 Fig 1 5 Electrical Schematic Diagram of ZS100T Series II...

Page 14: ...Instruction Manual ZS100T ZS150T ZS200T Series II MAM 870 Senator Industrial Air Compressors 10 Fig 1 6 Electrical Schematic Diagram of ZS150T and ZS200T Series II...

Page 15: ...ements a It is essential to install the compressor in an area with good lighting and sufficient free space for unhindered operation and maintenance The compressor should have a distance no less than 1...

Page 16: ...s recommended for the compressor to avoid motor current overload due to excessive voltage drop or unbalanced 3 phase caused by other electrical equipment operating in parallel b The power supply cable...

Page 17: ...perature will be shown on the panel Caution If the phase of power supply is inconsistent the LCD window will indicate wrong phase sequence At this point any two phases of power supply cable should be...

Page 18: ...ating oil flows out Caution Before opening the water drainage and oil discharge outlet in the oil separation tank always check that there is no air pressure inside it b Open the ball valve underneath...

Page 19: ...ill be kept Unload If the air consumption is continuously below the air discharge the discharge pressure of the unit will reach or exceed the setting of unloading pressure At this point the micro comp...

Page 20: ...inlet valve should be closed at first The vent valve should be opened to release the pressure in the oil separation tank After 30 50 seconds the unit will be shut down at a lower system pressure After...

Page 21: ...lso be recorded 3 3 Long Term Shutdown 3 3 1 Preparation If long term shutdown is required for the compressor the following steps should be performed a Any faults should be rectified in preparation fo...

Page 22: ...commended oil types Do not use a mixture of mineral and synthetic oils 4 1 1 Oil Change Interval a The initial oil change should be performed after the compressor operates for about 500 running hours...

Page 23: ...Restart the compressor and allow it to operate in loading state for 5 minutes and then check the oil level If the oil level is low then the unit should be shut down After the system pressure in the oi...

Page 24: ...mm away from the inner surface of the filter element After the air filter element is cleaned 3 4 times it should be replaced b It is not permitted to hit the air filter element or to clean it with wa...

Page 25: ...lter b Clean the sealing washer of new lubricating oil filter and apply a layer of clean lubricating oil on the sealing washer c Install the new filter onto the lubricating oil filter base until the s...

Page 26: ...oil cooler s fins should be blown off with clean compressed air If it can t be cleaned in this manner then wash it with a proper cleaning agent Never use a metal wire brush or metal scraper to remove...

Page 27: ...ace air inlet screen if fitted Clean air filter element Replace air filter element Clean fittings of inlet valve Replace maintenance kit of inlet valve Replace maintenance kit of minimum pressure valv...

Page 28: ...acing any components various factors causing failures should be analyzed in detail to find the exact reason Don t disassemble or move the compressor unit in a disorderly way otherwise unnecessary dama...

Page 29: ...replace temperature sensing element Too low air discharge temperature 75 C 1 Very low ambient temperature 2 Thermostatic valve is faulty 3 Temperature sensor is incorrect 1 Reduce radiating area of c...

Page 30: ...g washer in oil air separator is damaged 4 Oil return pipe in oil separator element is damaged 5 Leakage in oil piping system 6 Oil grade is poor causing excessive foaming 1 Check oil level and drain...

Page 31: ...rformed according to the Company s normal work flow and availability of replacement parts The Company shall not be obligated however to repair or replace Goods which have been repaired by others abuse...

Page 32: ...g and whether caused by breach of statute breach of contract negligence or other tort The Company s liability will be limited to in the case of products the replacement of the products the supply of e...

Page 33: ...Instruction Manual ZS100T ZS150T ZS200T Series II MAM 870 Senator Industrial Air Compressors 29 Maintenance and Repair Log Date Maintenance or Repair Activity...

Page 34: ...Instruction Manual ZS100T ZS150T ZS200T Series II MAM 870 Senator Industrial Air Compressors 30 Date Maintenance or Repair Activity...

Page 35: ...Instruction Manual ZS100T ZS150T ZS200T Series II MAM 870 Senator Industrial Air Compressors 31 Date Maintenance or Repair Activity...

Page 36: ...Instruction Manual ZS100T ZS150T ZS200T Series II MAM 870 Senator Industrial Air Compressors 32 Date Maintenance or Repair Activity...

Page 37: ...Instruction Manual ZS100T ZS150T ZS200T Series II MAM 870 Senator Industrial Air Compressors 33 Date Maintenance or Repair Activity...

Page 38: ...Instruction Manual ZS100T ZS150T ZS200T Series II MAM 870 Senator Industrial Air Compressors 34 Date Maintenance or Repair Activity...

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Page 41: ...INSTRUCTION MANUAL MAM 870 COMPRESSOR CONTROLLER...

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Page 43: ...load unload operation Up Button Press this button to move upward during data modification Press this button to select menu during the menu selection Down Button Press this button to move downward duri...

Page 44: ...display the Menu Selection Interface Press again twice to display 1 3 Parameter Review Pressing in the RUN PARAMETER menu will display the following parameters and status MAIN MOTOR CURRENT PER PHASE...

Page 45: ...anual M A M 8 7 0 Senator Industrial Air Compressors 3 BELT TIME ALARM 1 TIME AND TYPE ALARM 2 TIME AND TYPE ALARM 3 TIME AND TYPE ALARM 4 TIME AND TYPE ALARM 5 TIME AND TYPE PRODUCTION DATE SERIAL NU...

Page 46: ...required The USER PASSWORD is 9999 Enter it using button to move the blinking cursor from left to right and use or buttons to change the numerical value Then press S button and the previous screen wil...

Page 47: ...or below this air end discharge temperature MOTOR DELAY T 0010 S When using the controller to protect the motor it is required that the time here defined will not meet the impulse starting current of...

Page 48: ...the selection or value shown in the SET VALUE column Sequencing function is not available on this model TOGGLES TIME 0000 H Enter only the selection or value shown in the SET VALUE column Sequencing...

Page 49: ...NGUAGE SEL ENGLISH Set this value to the required display language USER PASSWORD 9999 For access to the User Set Parameters 2 3 Factory Set Parameters The factory set parameters can be reviewed in a s...

Page 50: ...S Set this value 20 S to disable the lack of phase shutdown protection function PRODUCT DATE Y M D The factory inputs the production date of the unit Do not change it SERIAL NUMBER The factory inputs...

Page 51: ...will divide the target current value by the sample input current value to work out the coefficient The target value is for calculation only will not be saved COEF 1 000 Controller displays the current...

Page 52: ...UR 000 0A Enter the target current value when the compressor is running the controller will divide the target current value by the sample input current value to work out the coefficient The target val...

Page 53: ...activates within a time of 2 S Motor protection This control unit has the following 6 basic protection functions for the motor 1 Locked rotor After the starting of the motor if the working current re...

Page 54: ...l Air Compressors 12 6 Temperature When the actual detected temperature is higher than the set temperature the protection activates in less than 2 S The output relay contactor capacity is 250V 5A The...

Page 55: ...Instruction Manual M A M 8 7 0 Senator Industrial Air Compressors 13 4 0 SPECIFICATIONS 4 1 Connections Terminal Arrangement Diagram of ZS100T...

Page 56: ...Instruction Manual M A M 8 7 0 Senator Industrial Air Compressors 14 Terminal Arrangement Diagram of ZS150T and ZS200T...

Page 57: ...ver Pressure The pressure setting is too high or the pressure sensor is faulty Check pressure and pressure sensor Pressure Sensor Failure Wire disconnected or reversed or the pressure sensor is faulty...

Page 58: ...NOTES...

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