user manual KB-10Hp-100Hp 1 - Air Compress · the air compressor or air compressor station, or installing unauthorized air compressor parts. Safety Instructions Danger The safety

S C R E W A I R

C O M P R E S S O R MODELS KB－10A，KB－15A，KB－20A，

KB-25A, KB-30A, KB-40A,

KB-50A, KB-60A， KB－75A，KB－100A

I N S T R U C T I O N M A N U A L

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1.Foreword 1.1 Introduction to Air Compressors

The Rotary Screw Air Compressors are the achievements of many years’ study and investigation into the air compressor industry. Combined with high quality standards, these models ensure longevity, high reliability and high efficiency. These models are green products, which meet all relevant standards of environmental protection.

1.2 Application Scope

Our series of air compressors is a proven mature technology produced in compliance with public safety regulations. However, due to the nature of the equipment, it is important to understand the dangers of equipment misuse.. Serious personnel injury, damage to equipment or other working materials can be caused by the following factors:

l Improper application scope l Operation of machinery by unqualified or

untrained users l Unreasonable modification or changing

of machinery l Disregarding safety instructions

Therefore, all personnel required to operate,

maintain or repair machinery must strictly follow all instructions. If necessary, the relevant personnel should be required to acknowledge compliance with all instructions by signature..

In addition. the below must be followed: l Appropriate accident prevention

requirements or regulations l Public safety requirements or

regulations l National regulations and laws This series of The company Air Compressors

must be operated under proper technical conditions. The operators must operate the machinery in accordance with the manual’s application scope and instructions. Operators must be fully conscious of safety, understanding the dangers associated with the machinery’s operation. Any functional breakdown, particularly related to safety, must be immediately repaired by a professional.

The definition of operating the machinery in the application scope includes following all instructions in the manual, regular inspection of the machinery and carrying out maintenance as appropriate.

1.3 Maintenance

The air compressor must be well-maintained for optimal performance. Maintenance must be carried out thoroughly in accordance with the manual, particularly during adverse environmental conditions. Service

If assistance is required with troubleshooting or replacing parts, please contact the equipment dealer. If the machinery experiences problems, our well-trained technicians will provide prompt service with genuine authorized parts. These parts are built to the highest standards with the latest techniques, and consequently only genuine authorized parts should be used for replacement.

Warranty

Read through the entire manual and fully understand the air compressor’s instruction information before using the machinery.

The company does not take any responsibility for the machinery’s safety if the actual application scope does is not in accordance with the machinery’s application scope, or theapplication purpose is out of the scope mentioned in this manual.

The company’s warranty does not cover any of the following conditions:

l misuse or abuse of machineryr l improper maintenance of machinery l improper use of accessories l use of non-genuine, unauthorized parts l changing or modifying machinery

For the statements mentioned above, The

company does not increase general warranty and liability provisions.

The company is not liable for and does not warrant any unauthorized changing or modifying of the air compressor or air compressor station, or installing unauthorized air compressor parts.

Safety Instructions

Danger

The safety regulations in the third chapter of this manual must be strictly followed.

Technical Improvement

Owing to The company’s policy of continuous improvement, The company reserves the right to make changes, without obligation of notification.

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2. Table of Contents

1. Foreword …………………………………………………………………………………………… 2 1.1 Introduction to Air Compressor …………………………………………… 2 1.2 Application Scope …………………………………………………………………… 2 1.3 Maintenance……………………………………………………………………………… 2

2.Table of Contents ………………………………………………………………………………… 3 3. Safety Regulation……………………………………………………………………………… 5

3.1 Define Safety Regulation ……………………………………………………… 5 3.2 Safety Regulation in General ……………………………………………………… 5 3.3 Change and Modify Machinery…………………………………………… 6 3.4 Installation and Normal Operating…………………………………………… 6 3.5 Special Operation / Maintenance ……………………………………………… 8 3.6 Special Danger Warning …………………………………………………… 9 3.7 Air Compressor Storage …………………………………………………………… 10

4. Design and Functions ……………………………………………………………………… 11

4.1 Technical Functional Parameter …………………………………………………………… 11 4.2 Layout of Machinery………………………………………………………… 13 4.3 Bodywork of Machinery…………………………………………………… 14 4.4 System Flow Diagram of Machinery………… 22 4.5 Oil System……………………………………………………………………………… 23 4.6 Air Flow………………………………………………………………………………… 23 4.7 Start / Stop / Voltage Failure………………………………………… 23

5. Transportation and Installation ………………………………………………………… 24

5.1 Transportation ……………………………………………………………………………… 24 5.2 Installation ………………………………………………………………………………… 24

6. Adjusting Preparation ………………………………………………………………………… 25

6.1 Refrigerating Air Inlet/Outlet ……………………………………………………………… 25 6.2 Compressed Air Connections…………………………………………………… 25 6.3 Electrical System Connection………………………………………………………… 26 6.4 Check Oil Level ………………………………………………………………… 27

7. Adjustments………………………………………………………………………………………… 28

7.1 Initial Adjustment…………………………………………………………………… 28 7.2 Adjustment after Fault ………………………………………………………… 28 7.3 Running Method ……………………………………………………………………… 28 7.4 Monitor …………………………………………………………………………………… 28

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2. Table of Contents 8. Maintenance ……………………………………………………………………………………… 30

8.1 Maintenance and Suggested Lubrication………………………………………………………… 30 8.2 Motor Maintenance ………………………………………………………………… 30 8.3 Maintenance Schedule…………………………………………………………… 30 8.4 Changing Oil ………………………………………………………… 32 8.5 Replacement of Oil Filter…………………………………………… 33 8.6 Replacement of Oil Separator………………………………………… 33 8.7 Changing/ Checking Air Filter………………………………………… 35 8.8 V Type Strap Tension System………………………………………………… 37 8.9 Normal Maintenance and Cleaning ………………………………………… 38

9. Troubleshooting ……………………………………………………………………………… 39

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3. Safety Regulations

3.1 Define Safety Regulations

The company is in no event liable for any damages or injuries arising from neglecting to follow the safety regulations, or non-observance of the normal caution and care required for transportation, installation, operation, maintenance and repairs, even if not expressly stated in this manual.

If any of the statements in this manual do not

comply with local legislation, especially the instructions relating to safety, the stricter of the two shall apply.

These safety regulations are applicable to many

types of machinery and equipment. Hence, some statements may not apply to these models in this manual.

Danger

Indicating a hazardous situation which, if not avoided, WILL result in death or serious injury.

Important Note

Indicating a hazardous situation which, if not avoided, COULD result in damages to machinery or its parts.

Description

This symbol is used to provide technical information on how to optimally use the machinery.

3.2 Safety Regulation in General

Instruction

This Instruction Manual must be put in the

machinery’s working environment, such as put in the tool room or in the box of manuals for reference.

Apart from the Instruction Manual, the operators

must observe any other related requirements and regulations of accident prevention and environment protection, and request other personnel observing. These regulations may relate to the transportation of dangerous material, or labor protection articles granted or taken, or transportation regulations.

The instructions in this manual shall also include

supervising responsibility and notice responsibility. Different factors inside the factory must be considered, such as working organization, operating flow, labor allocation, etc.

Repairman must read through the instruction

manual before starting repairing the machinery, especially related safety. It is too late to read the instruction manual after starting working. It is very important the users operating machinery occasionally read the instructions in advance, such as persons who do settings and maintenance.

The operators must be checked frequently

whether their operating procedures are followed the

regulations, and they observe the safety requirement. Due to safety consideration, DO NOT wear

loose clothing, gloves, neckties, rings, or jewelry which may get caught in moving parts, resulting in damages or injuries to body. Wear protective hair covering to container long hair and wear non-slip footwear. Protective articles must be provided to the users in accordance with the regulations or requirements.

All the safety notice and warning symbols on the

machine must be observed strictly. All the safety notice and warning symbols on the

machine must be kept clearly, obviously and completely.

Always stop and shut off the machinery

immediately when machine or running status is changed relating to safety. Always report the problem to the supervising department or person in charge.

Spare parts must be in accordance with the

technical requirements of the manufacturer. Make sure using genuine spare parts.

The oil hose needs to be replaced periodically,

even if there is no safety problem. Check periodically according to the interval or

requirements of the instructions Related personnel must know the fire

extinguisher’s position and its usage method. All fire alarm reporting and extinguishing methods must be followed

Limit ratings must be indicated clearly, such as

pressure, time setting etc.

Personnel Selection and Qualification; Basic Responsibility

Any work to machine and machinery must be

performed by proper personnel. The regulation of youngest lawful age must be strictly followed.

Only allow trained personnel to operate

machinery. Ensure different personnel are allocated responsibilities in operation, setting, maintenance and repairs.

Only employ authorized personnel to operate

and repair machinery. Ensure operator responsibility, and inform them

not to implement any requests of third parties against safety regulations.

Without experienced personnel supervision,

personnel awaiting training or still in the process of training ARE NOT allowed to operate the machinery.

The machine’s electronic devices must be

checked and repaired by a qualified electrician according to electrical regulations.

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The machine’s hoses must be checked and repaired by experienced personnel with professional hydraulic pressure knowledge.

3. Safety Regulations

3.3 Change and Modify Machinery

It is prohibited to do any change or add any

accessories to machinery without the manufacturer’s permission. It may influence the safety of the machinery

For the sake of safety, any change to machinery

without any authorized permission is prohibited Original spare parts are specially designed for

the machinery. We will not provide spare parts or special accessories that are not provided by us. Hence, installing or using other branded spare parts will influence our machine’s safety.

The manufacturer will not be liable for any

damages due to non-use of original genuine spare parts or accessories. This also apply to installation and setting of safety equipment and valves, as well as the structure’s welding. 3.4 Installation and Normal Operation Installation

Apart from complying with local regulations of normal operation, we specially state the following regulations.

The machine must only be lifted using suitable

equipment in accordance with local safety regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to dwell or stay in the risk zone under a lifted load.

Proper lifting methods must be used in

accordance with the lifting equipment’s instruction manual.

Any blanking flanges, plugs, caps and desiccant

bags must be removed before connecting the pipes. Air hoses must be of correct size and suitable for the working pressure.

Machines must be installed in such a way that an

adequate space is available for the operator, and that there is adequate air cooling. Never obstruct the air inlet. Care must be taken to minimize the entry of moisture at the air inlet.

The aspirated air must be free of dangerous

ingredients, such as solvent vapors, dust, and other dangerous material. This also applies to sparks.

Arrange the air intake so that loose clothing

worn by people cannot be sucked in.

Ensure that the discharge pipe from the compressor to the after-cooler or air net is free to expand under heat and that it is not in contact with or close to flammable materials.

No external force may be exerted on the air outlet valve; the connected pipe must be free to strain.

If remote control is installed, the machine must

bear a clear sign stating: DANGER: This machine is remotely controlled and may start without warning.

As another safeguard, persons switching on

remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machine. Therefore, a suitable notice shall be affixed to the start equipment.

Compressed air and water cooling flow must be

stated clearly corresponding to the local regulations. In multiple compressor systems, manual valves

must be installed to isolate each compressor. Non-return valves (check valves) must not be relied upon for isolating pressure systems.

Never remove or tamper with the safety devices,

guards or insulation fitted on the machine. Every pressure vessel or auxiliary installed outside the machine containing air above atmospheric pressure, together with two or more air-supplying pipes must be protected by a pressure-relieving device or devices as required. These devices can automatically prevent intake working pressure above 10%.

The special safety valve of the air compressor

only bears current pressure protection function in accordance with current standards and regulations.

The pressure device and system installed on the

connected flange at the pressure end of the air compressor must have pressure protection parts correspondingly, such as safety valves or parts. The weakest force bearing part should be taken into consideration.

Pipe work or other parts with a temperature in

excess of 80oC (176oF) and which may be accidentally touched by personnel in normal operation must be guarded or insulated. Other high-temperature pipe work must be clearly marked.

The electrical connections must correspond to the local codes. The machines must be earthed and protected against short circuits by fuses in all phases. Maintenance and repairs must be done with due care. Removed pipes must be checked before re-installation. If there is any damage to pipes, a new pipe must replace them.

New sealed material must be used in the process of assembly and installation.

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3. Safety Regulations

Normal Operation The machine must be only used in reliable

safety conditions with necessary safeguards. The machine may be operated only when all

protective devices, emergency stop devices, sound-damping device and recovering device are installed in place and working with normal functions.

Periodically check that:

l All protective devices are in place and securely fastened.

l All hoses and pipes inside the machine are in good conditions, secure and not rubbing.

l There are no leaks. (fuel, oil or refrigerant). l All fasteners are tight. l All electrical leads are secure and in good

order. l All safety valves and other pressure-relief

devices are not obstructed by dirt or paint. l Safety devices are in good conditions.

Use only the correct type and size of hose in accordance with related working pressure. Never use frayed, damaged, or low quality hoses.

Use only the correct type and size of hoses

fittings and connections. When blowing through a hose or air line,

ensure that the open end is held securely. A free end will whip and may cause injury.

Make sure that a hose is fully depressurized

before disconnecting it. DO NOT use unreliable working methods from

the angle of safety.

3.5 Special Operation / Maintenance

Caution Issue

Machine adjusting, maintenance and checking must be performed according to the statement and interval of instruction manual, including related spare parts’ replacement and equipment’s information. All this work must be done by skillful specialized personnel.

Before starting special operation or

maintenance, information must be introduced to the operators. Authorized personnel must be assigned to supervise the operation at the same time.

Maintenance must be undertaken and

supervised by the qualified specialized personnel. Oil leaks may make the floor slippery. Clean

the floor and the surface of the machine before any maintenance.

Checking, maintenance and repair must be

done only after the screw air compressor is shut off

and the pressure is relived. Protective devices must be taken off after work is completed. It is prohibited to operate machinery without protective devices. Personnel who are checking and maintaining machinery must wear close-fitting clothes.

Before any maintenance or repair work, stop

the machine and lock the compressor to ensure that the machinery will not start accidentally:

l Lock power switch and take key away; and/or l A warning sign shall be attached to the power

switch.

Use only the correct tools for maintenance and repair work.

Never use flammable solvents or carbon

tetrachloride for cleaning parts. Take safety precautions against toxic vapors of cleaning liquids.

Observe the statements related to start and shut

off system and maintenance in this manual when the machinery and safety devices are operated, converted and adjusted, or related maintenance, checking or repair work is carried out

Maintain the machine where the safety is

adequate. To prevent an accident, every spare part or

accessory disassembled must be hanged and fixed to the lifting equipment. It is essential that suitable proper technical lifting equipment is used. Lifting equipment must be capable of lifting loads with safe limits. It is strictly forbidden to work or stand in the area of overhead or lifting equipment.

Scrupulously observe cleanliness during

maintenance and repair. Keep dirt away by covering the parts and exposed openings with a clean cloth, paper or tape.

Make sure that no tools, loose parts or rags are

left in or on the machine, motor or driving device after maintenance or repair work.

Scrupulously operate the screw air compressor

system.

Maintenance and Troubleshooting

Employer must notify the employee of

potential dangers and danger preventing methods during maintenance and repair; employee must observe all safety precautions and safeguards. To prevent danger or eliminate danger, safety devices must be maintained periodically and safety functions must be checked at least once a year. Any problem noticed must be solved immediately and / or the supervising personnel notified.

Use genuine spare parts and accessories.

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3. Safety Regulations

Make sure maintenance and repair is performed before the machine is working, and the power is switched off. Make sure that the electrical power is not connected with negligence.

Before dismantling or opening pressurized components, effectively shut off the machine from all sources of pressure and relieve the entire system of pressure.

Never weld or perform any operation involving heat near the oil system. Pressure vessels or parts and pipes with oil must be completely purged, e.g. by steam-cleaning, before carrying out such operations.

Never weld on or modify pressure vessels.

If repairs work will cause heat, flame or sparks, nonflammable material must be used to protect the surrounding parts.

Before clearing the machine for use after maintenance or repair, check that operating pressures, temperatures and time settings are correct. Check that all control and shut-down devices are fitted and that they function correctly. After above checking, connect the electric power and operate the machinery.

Protective precautions must be noticed when using steam-cleaning to protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from entering them.

Never dismantle or change sound damping material.

Never use caustic solvents which can damage materials of the air net

Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the machine shall be stopped.

Periodically check and clean the surface of the discharge device, e.g. radiator blind, inter cooler, water-cooled jacket to prevent increasing operating temperature. The best cleaning schedule must be made for every machinery accordingly.

Avoid damages to safety valves or any other pressure relieving parts. Make sure that these devices are not obstructed by paint, carbon or dust to ensure that they function properly.

Make sure that part weight over 15kg shall not move or roll when removing or repairing an air compressor, motor or other machines.

Make sure that no tools, loose parts or clothes are left in or on the machine, motor or driving device after repair work. Reciprocal machine must be moved with return at least once. Rotating machine must be rotated several times to make sure that there is no mechanical problem with machine or driving system. Check motor’s rotating direction for the initially machine adjustment and every time after modifying the electrical connections to prevent

air compressor damaged.

Skillful specialized personnel must be responsible for fixing the loading parts and directing lifting equipment.

When operating a vehicle, the operators must see or hear the supervisor’s directions.

Before maintenance, the machine must be cleaned and wiped clearly, especially the oil, fuel, and cosmoline on the connector or screw threads. Never use caustic detergent. All the exposed openings must be covered when clean machinery with non-winceyette cloth with a little water or steam-cleaning (high pressure cleaning), or any other detergent. Prevent the previously mentioned detergent from entering the machine, especially the exposed openings of motor and power switch.

Take all coverings after cleaning.

All oil pipes must be checked after cleaning to prevent leaks, loose accessories, parts fray or damaged etc. Any issues must be solved immediately.

Unfastened parts during maintenance and repair must be re-fastened tightly.

If a safety device is dismantled during settings, maintenance or repairs, this safety device must be re-fixed in place immediately and checked after such operations are performed.

The methods of disposing consumable parts and replacements must be safe and not in an environmentally-hazardous manner.

3.6 Special Dangerous Warning

Electricity

All fuses of electrical connections must be in accordance with the rated current. The machinery must be shut down immediately when the electrical system fails.

Repairing electrical system or devices must be done by skillful specialized electrician or personnel supervised and directed by such electrician in accordance with related electrical regulations.

If there is any statement in the local code, the electric power supply of awaiting parts during checking, maintenance, and repairs work and that of workshop area must be shut off. Ensure that the electrical parts are not live before doing such performance. Make sure not only that the electrical parts and units nearby are insulated, but also these must be earthed and in short circuits.

Periodically checking electronic devices. Any problems such as loose connections or burned wires must be solved immediately.

When operating with electrical machinery or parts, a second person must oversee. Once danger occurs, they can use emergency stop equipment or switch off the voltage. Working area must be used red and white safety chains and warning symbol

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enclosure. Only use insulated tools.

3. Safety Regulations

Gas, Dirt, Vapor and Fume

Only with definite authorization, such operations as welding, flame cutting, and polishing shall be performed. These operations may cause explosion and fire.

Before welding, flame cutting, and polishing operations, the machine, its environment around and other flammable materials must be cleaned clearly, and the room must be ventilated, due to the potential danger of explosion.

Comply with the operating area’s regulations.

If the operation is performed in a small room, the national regulations and laws must be complied with.

Hydraulic Pressure Devices, Pneumatic Devices

Hydraulic pressure devices must be operated by personnel who have professional hydraulic knowledge and experience.

Periodically check all pipes, hoses and connections’ threads to ensure no leaks or obvious damage. Damaged parts must be repaired immediately. High-pressure injection of oil may cause injury or fire.

Before repair work, make sure that all system’s parts and pressure hoses are dismantled, e.g. hydraulic pressure system, compressed air system, are fully depressurized in accordance with the related special instructions.

Hydraulic pressure hoses and compressed air hoses must be placed properly and installed suitably. Connections cannot be changed to use. Hoses’ connections, lengths and quality must be in accordance with the technical requirements.

3.7 Air Compressor Storage

All air compressors stored temporary must be cosmoline protected before distribution in the factory and adjusting.

Other storage preventive precautions must be taken if the storage time is over six months.

Cosmoline protection must be taken if the machine needs to be shut off for a long time.

The machine will be more easily caustic at a moisturized atmosphere than at a dry atmosphere. It is difficult to define the longest non-operating time that is suitable under all conditions.

Description

Air compressor’s storage must take consideration of the following aspects:

Air compressor must be stored in a dry warehouse; if possible, the warehouse has to be warmed by increasing the room temperature. This is necessary in winter.

Before adjusting the air compressor, make sure that all electrical parts and components are not exposed to water or condensation.

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4. Design and Functions

4.1 Technical Functional Parameter

Model KB-10A KB-15A KB-20A KB-25A KB-30A

Air outlet volume/ pressure (m3/min)/MPA

1.20/0.7 1.65/0.7 2.25/0.7 3.22/0.7 3.60/0.7

1.10/0.8 1.53/0.8 2.03/0.8 3.01/0.8 3.56/0.8

0.95/1.0 1.32/1.0 1.82/1.0 2.52/1.0 3.07/1.0

0.80/1.2 1.10/1.2 1.55/1.2 2.30/1.2 2.84/1.2

Environment temperature ℃ -5～+45

Cooling method Air cooling

Air outlet temperature ℃ ≤ environment temperature +15℃

Lubricant oil volume L 6 8 8 12 12

Driving method Belt-driving

Noise dB (A) 62±2 63±2 63±2 63±2 65±2

Power 380V/ 3 phase /50HZ,220V/3 phase/50HZ

Power (KW) 7.5 11 15 18.5 22

Starting Y- starting△

Specification

L mm 890 1066 1066 1216 1216

W mm 630 856 856 966 966

H mm 920 1125 1125 1295 1295

Weight (KG) 240 450 470 620 650

Air outlet hose diameter G3/4 G1” G1” G1 1/4” G1 1/4”

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4. Design and Functions

Model KB-40A KB-50A KB-60A KB-75A KB-100A

Air outlet volume/ pressure (m3/min)/MPA

5.20/0.7 6.58/0.7 7.36/0.7 10.8/0.7 13.5/0.7

5.06/0.8 6.26/0.8 7.10/0.8 10.1/0.8 12.7/0.8

4.53/1.0 5.80/1.0 6.47/1.0 8.50/1.0 11.3/1.0

3.90/1.2 5.06/1.2 5.80/1.2 7.69/1.2 10.0/1.2

Environment temperature ℃ -5～+45

Cooling method Air cooling

Air outlet temperature ℃

≤ environment temperature +15℃

Lubricant oil volume L 12 20 20 35 35

Driving method Belt-driving

Noise dB (A) 65±2 65±2 68±2 68±2 72±2

Power 380V/ 3 phase /50HZ,220V/3 phase/50HZ

Power (KW) 30 37 45 55 75

Starting Y- starting△

Specification

L mm 1266 1486 1552 1766 1766

W mm 1016 1046 1100 1336 1376

H mm 1335 1455 1500 1695 1710

Weight (KG) 750 1060 1200 1750 1820

Air outlet hose diameter G1 1/4” G1 1/2” G1 1/2” G2” G2”

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4. Design and Functions

4.2 Layout of Machinery

1: Monitor 2: Emergency stop button 3: Motor 4:Shock proof rack 5: Base 6: Minimum pressure valve 7: Safety valve 8: Oil separator 9: Oil tank 10: Oil level glass 11: Oil outlet valve 12:Airend belt pulley 13: Belt 14: Motor belt pulley 15: Fan 16: Air Filter

17: Cooler 18: Oil filter 19: Air inlet valve 20:airend

21:Electric box

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4. Design and Functions

4.3 Bodywork of Machinery

1) KB-10A

4. Design and Functions

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2) KB-15A,20A

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3) KB-25A,30A

4. Design and Functions

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4) KB-40A

4. Design and Functions

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5) KB-50A

4. Design and Functions

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6) KB-60A

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4. Design and Functions

7) KB-75A

4. Design and Functions

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8) KB-100A

4. Design and Functions

4.4 System Flow Diagram of Machinery

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1.Air inlet filter 2.Air inlet valve 3.Drive motor 4.Compressor

element 5.Temperature

sensor 6.Oil tank 7.Oil separator 8.Oil outlet ball

valve 9.Safety valve

10.Oil filter 11.Oil cooler 12.One direction valve 13.Minimun pressure valve

14.Post-cooler 15.Pressure

sensor 16.Solenoid

valve

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4. Design and Functions

4.5 Oil System

All oil is removed from oil tank (6), flowing through oil cooler and filter (10) to compressor element (4).

Oil removed by oil separator (6) was forced to compressor element (4) through oil pipe. The entire circulation is driven through the system’s natural pressure differences. The pressure in oil system is around 0.15MPa, and oil can inject into the compressor element (4) at pressure 0.55MPa, when air outlet pressure is, for instance, 0.7MPa.

When the screw air compressor runs unloaded, air inlet valve (2) is closed, and a vacuum status is generated at the air receiving area or oil injection area to ensure adequate pressure difference and oil-injection volume required.

4.6 Air Flow

Air drawn through air inlet valve (1), going

through air inlet valve (2) to enter compressor element (4). During the course of air compressing, air received is cooled by the injected oil, and compressed air and oil flow into oil tank (6). After pre-separating and refined separating through oil separator (7), compressed air with little oil flows through minimum pressure valve (13), post-cooler (14) and to flow into the user’s general pipe.

4.7 Start / Stop / Voltage Failure

l Compressor （3）starts with Star (Y).

l When solenoid valve （ 16 ） de-energized, regulating electrical system is connected. When oil tank is more than a certain pressure, the plunger of air inlet valve (2) is closed with the function of air force, and the compressor runs unloaded.

l Due to the vacuum pressure at the oil injected area, oil supply to compressor element (4) is started.

l After switching to triangle （ △ ） starting, solenoid valve （ 16 ） is energized, disconnecting regulating electrical system.

l The plunger of air inlet is open with the function of vacuum force, air compressor receives air and runs fully loaded.

l When system’s pressure is around 0.45MPa，the minimum pressure valve（13）opens.

l Air compressed starting entering user’s consumption pipes.

Running automatically (Start/ Switching off ) l When the consumption pipe’s pressure reaches

the maximum value of pressure sensor (15), solenoid valve （16）is shut off.

l Compressor element（4）runs unloaded.

l Oil tank （6）depressurizing.

l The system is de-energized if the pressure of consumption pipe does not decrease to pressure sensor （15）within 6 minutes.

l The solenoid valve (16) is re-energized if the pressure of consumption pipe does not decrease to pressure sensor （15）within 6 minutes.

l Machine is switched to run loaded.

Stopping System l Press OFF button on the control panel to make

solenoid valve (15) de-energized to connect the regulating electrical system.

l The plunger of air inlet valve （2）closes with the function of air, spontaneously reliving air and the system is depressurized.

l Driving motor (3) is shut off after around 30 seconds.

System’s Pause l When system does not run, the compressed

spring in driving tank will close air inlet valve (2).

l Solenoid valve (15) is de-energized.

Oil tank (6) relieves air to air inlet valve depressurized direction via solenoid valve (15).

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5. Transportation and Installation 5．1 Transportation

1,2: Forklift’s fork holes, please see the sizes on page 11. Danger

The machine must only be lifted using suitable equipment in accordance with local safety regulations.

All loose or pivoting parts must be securely

fastened before lifting.

It is strictly forbidden to work or stand in the risk zone under a lifted load.

Proper lifting method must be used in accordance with lifting equipment’s instruction manual. Important Note

Never lift binding the bodywork of air compressor to lift air compressor.

Screw air compressor must be lifted by forklift. The distance between forks and fork length must be considered in the transportation conditions.

Lifting point must be clearly marked. Machine on the floor must not be dragged to move.

Weight

The approximate weights shown below indicate the weight of air compressor added oil:

Model KB-10A Approximate 240 KG KB-15A Approximate 450 KG KB-20A Approximate 470 KG KB-25A Approximate 620 KG KB-30A Approximate 650 KG KB-40A Approximate 750 KG KB-50A Approximate 1060 KG KB-60A Approximate 1200 KG KB-75A Approximate 1750 KG KB-100A Approximate 1820 KG

5．2 Installation

Danger

l The ground base’s loading capacity must be considered.

l The ground base must be solid and level.

l Arrange air inlet in the place where the aspirated air must be free of dangerous ingredients, such as solvent vapors, dust and other dangerous material. This applies to sputtering sparks.

Important Note

The operator must provide ventilated conditions for air compressor.

Screw air compressor must be kept level.

Air compressor must be kept at a distance from other machinery to ensure adequate space for maintenance and repair work.

When screw air compressor is running, driving motor and compressing process will generate heat. Screw air compressor shall relieve part of heat to the surrounding atmosphere.

Proper ventilation has a great effect on the air compressor’s working life and its functions.

6. Adjusting Preparation

23

6．1 Refrigerating Air Inlet/Outlet

Statement： 1．Refrigerating air inlet 2．Refrigerating air outlet

The Screw Air Compressor’s rating

environment temperature and refrigerating air temperature is -5°C ~ +45°C. Please enquire with The company if the actual environment temperature is in excess of above rated values.

Description

To ensure good cooling conditions, the rated value of air volume dealt by auxiliary fan shall be 15% to 20% higher than total air volume required by air compressor station installed all air compressors.

6．2 Compressed Air Connections

Please see the diameter of air outlet opening on Page 11.

The connections of air compressor must be connected with the consumption devices by the user. Air outlet pipe must not add any additional weight to prevent air compressor post-cooler damage.

- 24 -

6. Adjusting Preparation

6．3 Electrical System Connection

Rated Power

of Key Motor [KW]

Copper Conductor Section [mm2]

Air Cooling KB-15A 11 3×16/PE 16 KB-20A 15 3×16/PE 16 KB-25A 18.5 3×16/PE 16 KB-30A 22 3×16/PE 16 KB-40A 30 3×25/PE 16 KB-50A 37 3×35/PE 16 KB-60A 45 3×50/PE 16 KB-75A 55 3×90/PE 16

KB-100A 75 3×90/PE 16 Table statement：

As we do not know your specific usage conditions, such as cable type, length and installation conditions, this table is only for your reference.

Fan-driven motor switch protective value must be set in accordance with the environment and installation on spot. For the sake of safety, the exact setting values shall be obtained from the manufacturer.

I setting value=I rated value×1.15× Pressure coefficient of correction

If necessary, I setting value may be checked from the label of fan motor.

Danger

User must connect a switch control on the electric wire. Suitable spared fuses must be fixed if the switch control cannot protect against short-circuit and over-loading. (Please see the table.)

Starting machine after connecting electric system / Checking rotating direction

After the machine is connected with the

electric system, initial starting may be performed. Make sure air compressor’s air hoses are connected completely before starting, and follow below statements: Important Note

The motor’s proper rotating direction must be checked when the air compressor is connected with the electric system for the first time. (Please see the arrow direction)

Shut off using emergency stop button if the motor’s rotating direction is incorrect. If stopping the machine at normal stopping process, the machine will shut down after a few seconds.

Any wrong direction rotation of motor, even if only very short time (about 2 seconds), will make air compressor seriously damaged or indirectly

damaged.

6.3 Adjusting Preparation

17

Symbol Description: 1 Oil level glass

Important Note

DO NOT mix different types or brands of oil.

Check oil level l Check oil level through oil level glass attached

to oil tank when the machine is stopped every time and at intervals.

l Oil must be deposited before check, and the air

in the oil must be relieved. This process may take some time, and the exact timing is attributed to different conditions.

l The highest oil level is at the top of oil level

glass, and the lowest level is at the bottom of oil level glass. Oil must be refilled fully.

Please read “Maintenance” in the 8th chapter.

- 26 -

7. Adjustments 7．1 Initial adjustment

Danger

Before adjustment, make sure that there is

no-one in the risk zone around the motor or air

compressor.

Working door and panels must be closed

before the screw air compressor is running.

Safety valve may be still at the heating status

because of previous running. Functional checks must

be performed under the working pressure. Be careful

of air leakage (possible injury danger of burning).

Important Note

Air compressor must be inspected strictly

before the product’s shipment. Though each The

company screw air compressor is tested in the

factory, we do not guarantee non-damage during

the transportation. Hence, before the adjustments,

every air compressor must be checked to make

sure that there is no damage. Apart from this,

during the initial several hours, the machinery’s

working conditions must be observed. Screw air

compressor is equipped completely before

shipment. Soft connectors may be used to connect

the machine and the air compressor’s main pipe

directly.

Motor’s rotating direction must be checked if

screw air compressor is connected with electric

power for the first time.

Emergency stop button must be pressed

immediately if the motor’s rotating direction is

incorrect. Otherwise, the air compressor may be

seriously damaged.

Machinery’s door may be opened temporarily

to check the rotating direction.

Additionally, the following points must be

noticed.

l All connectors of electric control box must be

re-fastened to do the adjustments.

l Check oil level before adjustment every time.

l Open the isolated valve between air

compressor, air tank and pipes.

l Connect the entire power switch.

Statement: Safety valve is installed to the

upper position of inner system. When the air

compressor is working under nominal pressure,

the maximum working pressure is more than 20%

than nominal pressure, and the exhaust volume of

safety is selected in such a way.

After connecting the main electric switch, all

LED and display section on Liquid Crystal

Display are lit, and then the displaying test can

proceeded.

7.2 Adjustment after Fault Important Note

Never start the screw air compressor

repeatedly before the failure is solved. Otherwise there is a risk of seriously damaging the machine.

Automatically restart the compressor after its

failure and shut down: l Read the instructions of failure l Switch off the main electric power l Troubleshoot l Re-store voltage. l Start screw air compressor. 7.3 Running Method Running Automatically

When working pressure reaches the maximum

set, the machine shall not generate any compressed

air. Motor stops after a period of running, which

relies on electrical system net. When working

pressure decreases to the minimum pressure set, the

motor is connected and the machine starts generating

compressed air. 7.4 Monitor

Working pressure and air compressor’s

temperature may be read from the text of control

panel.

During running oil-injected air compressor,

avoid the temperature inside the compressor being in

excess of the preset final compressed temperature.

Screw air compressor is equipped with

automatic monitoring system, thus the machine shall

be shut down for any failure.

- 27 -

8. Maintenance

8.1 Maintenance and Suggested Lubricant Description

Screw air compressor shall run at a best

performance which makes you satisfied as long as the machine is maintained with due care according to the stated time interval.

The running timing is indicating the suggested

normal running conditions and maintenance interval. Running interval shall be changed adapting to the air conditions.

User may invite our well-trained technicians to

perform maintenance. With regards to the lubricant problem, The

company’s lubricant is suitable for relevant running conditions, especially the oil’s ingredients, viscidity, burning point and anti-aging. Never use any other lubricant. 8.2 Motor Maintenance

Grease must be added to motor periodically

according to the marked label on the motor, and the grease type is indicated on the motor’s label.

8.3 Maintenance Schedule Danger

When controlling, adjusting and maintaining

the machine, take notice of the heated surface of the machine’s parts.

When checking and maintenance is carried

out, the following must be noticed:

l Press [O] button on the control panel to stop the machine, and wait until the air compressor stops running.

l Relieve pressure of screw air compressor. l System may have a little remaining pressure

after the screw air compressor is shut down shortly.

l Hence, the oil refilling plunger (refilling oil

opening) must be slowly relieved to depressurize the screw air compressor.

l Switch the main switch installed by user to

“O”（Shut down）position； l Warning: Voltage: After the power is

switched off, the air compressor may be checked and maintained.

28

8. Maintenance Maintenance Item W 1 Change oil

New machine must be changed after running first 500 hours, see the functional parameter on page 9. Under the normal working environment, the oil changing interval is 4000 hours.

W5 V-type strap.. Adjusting strap’s tension for a new machine after running first 50 hours.

W 2 Replacement of oil filter Oil filter must be replaced for a new machine after running 500 hours. Under the normal working environment, the oil filter’s replacement interval is 4000 hours.

W6 Adding motor’s grease. Grease must be added to motor

periodically according to the marked label on the motor, and the grease type is indicated on the motor’s label. (not necessary to add grease no bigger than 7.5kKw) 。

W 3 Replacement of oil separator. Under the normal working environment, the oil separator’s replacement interval is 4000 hours.

W7 Normal maintenance and cleaning. Shorten the cleaning interval in a dusty atmosphere accordingly.

W 4 Replacement of air inlet filter. air inlet filter must be replaced for a new machine after running 500 hours. Under the normal working environment, the oil separator’s replacement interval is 4000 hours. Periodically clean air inlet filter according to the working conditions.

- 29 -

8. Maintenance 8.4 Changing Oil

1: Place oil ball valve. Danger

Oil must be changed only after the screw air compressor stops running and is depressurized！

Relieving hot oil must be in a caution: Scalded

danger! Important Note

Clean the remaining oil stain and other

deposits on the machine’s parts and cooler according to the instruction manual, as they are exposed in the heated compressed air. Description

Collect used oil; do not let it soak into the earth

Dispose of used oil accordingly. Never splash the used oil. Make sure that there are no oil leakages.

The oil-changing interval and recirculation

oil’s contamination have a very big relationship with the air compressors. Never allow contaminant materials (dirt, vapor and gas) via air filter to enter air compressor’s oil recirculation.

At the same time, high moisture of the air

intake shall generate condensation inside the

machine, which influences the lubricant’s working

age. Therefore, in this case, the oil-changing

interval may be shortened. Oil changing interval set

is based on the normal environment conditions.

There must be no exotic materials (dirt, vapor and

gas). If under very good environmental conditions,

oil sample must be inspected to maximize oil’s

working age. Analyze the result to ensure longevity. Caution

Used oil must be drained completely when

changing oil. Used oil will shorten new oil’s

working life age.

Never mix oils of different brands or types.

The previous oil must be drained fully and

replaced by another type of oil.

Please see oil changing interval schedule in the

instruction manual.

Follow below procedures when changing oil:

l Open air tank’s oil outlet valve, taking use of

the remaining pressure to drain the oil.

l Drain oil at the running temperature.

l Open the oil filler opening.

l Close the oil outlet valve of oil tank.

l Fill oil, and the oil volume, see functional

parameter on page 9.

l Close the oil filler with screw plunger.

l Make the screw air compressor run for about 2

minutes.

l Check for possible leakage. l Shut down the air compressor. l Check oil level: before checking oil, oil must

be settled, i.e. air intake in the oil must be vaporized.

l Oil level must reach the top-most position in the middle of oil level glass.

l Fill oil fully if necessary. Lubricant Changing Interval

Running conditions (such as cooling

intermediate’s temperature), running methods, and

air inlet quality, e.g. dirt volume, other air such as

SO2, solvent vapor volume etc., have a very

important effect on oil changing interval.

See functional parameter of oil changing volume

on page 9.

- 30 -

8. Maintenance

8.5 Replacement of Oil Filter

1:Oil filter

Danger

Oil filter must be replaced only after the air

compressor stops running and depressurizes! Be

careful of hot oil: scalding danger! Never splash

oil out!

Description

Dispose of oil filter according to the regulations of relevant special scrapped material. Check for possible leakage!

Please refer to the maintenance schedule, relating to the replacement interval.

The screw air compressor’s pressure must be

relieved, and below procedures must be followed to replace oil filter:

l Unscrew the oil filter with suitable tool.

l Deal with oil filter in accordance with the

instructions.

l Apply a little oil to the new oil filter.

l Oil the gasket of the new filter and screw it into

place. Tighten firmly by hand.

l Check for possible leakage

l Check oil level.

l Refill the oil fully if necessary.

Interval of Change Oil Filter

Running conditions (such as cooling intermediate’s temperature), running methods, and air inlet quality, e.g. dirt volume, other air such as SO2, solvent vapor volume etc, have a very important effect on oil filter changing interval.

Oil filter must be replaced for a new machine after running 500 hours. Thereafter, under the normal working environment, the oil filter’s replacement

interval is 4000 hours.

8.6 Replacement of Oil Separator

1: Oil tank panel

2: Connecting bolt

3: Oil separator

Danger

Oil tank is below the pressure! The

replacement of oil separator may be performed

only after screw air compressor stops running and

relieving pressure.！

Be caution of hot oil: scalded danger!

Never splash the oil out！

Description

Disposing oil separator according to the regulations of relevant special scrapped material. Check for possible leakage!

Oil separator must be replaced. Under the

normal working environment, the oil filter’s replacement interval is 4000 hours.

The screw air compressor’s pressure must be

relieved, and below procedures must be followed to replace oil separator:

l Open all bodywork panels, dismantle connecting

pipes of oil tank. l Unscrew the connecting bolts of oil tank, move

forward oil tank panel. Notice: there is a recirculation oil pipe inserted oil separator in the middle of oil tank panel. This copper pipe must not be contacted/bent when removing and placing oil tank panel.

l Draw upward to take oil separator, and dispose oil separator in accordance with the regulations.

l Install a new oil separator, re-fix the oil tank panel connected with bolts according to original positions. Re-installing all pipes in accordance with original positions.

l Check for possible leakage.

- 31 -

8. Maintenance Interval of Changing Oil Separator

Running conditions (such as cooling intermediate’s temperature), running methods, and air inlet quality, e.g. dirt volume, other air such as SO2, solvent vapor volume etc, have a very important effect on oil separator changing interval. 8.7 Changing / Checking Air Filter

1. Air filter 2. Air inlet valve Danger

Checking and operations may be performed

only after the screw air compressor stops

running and pressure is relieved! Important Note

Never run the screw air compressor without

installing an air filter. The machine can be

seriously damaged even if running without one

for a short time.

Obstructed air filter must be replaced or

cleaned during maintenance.

Air filter must be check at least one time for

accumulated dust. Check everyday if necessary.

During the maintenance, prevent dust entering

the air filter’s clean side.

Air Filter’s Maintenance

Air filter must be cleaned or new air filter must

be replaced; refer to the cleaning instruction in the

instruction manual.

Air Filter’s Cleaning

Description

Air filter’s cleaning must not be more than 5

times.

If air filter is damaged or cleaned over 5 times,

a new air filter must be replaced. Clean the filter

with due care, not damaging it to prevent the

contaminated materials from entering air filter’s

clean end.

Air filter must be changed after a new

machine runs 500 hours; thereafter, air filter must

be replaced with an interval of 4000 hours under

the normal industrial environment.

Cleaning Air Filter by Blowing Through Air

Compressor

Danger

The following points must be followed during

cleaning air filter by blowing through the air

compressor:

l Wear eye protector and respirator.

l Air compressor’s pressure must be not more

than 5 bar.

l Blow towards outside of air filter to ensure

that the dust decreases clearly.

Cleaning by Washing

Danger

Never use gasoline, alkali solvents or hot

liquids to clean the air filter.

Please clean the air filter through the following

procedures.

l Stir the air filter inside the warm water with

non-foam cleaning detergent.

l Cool the air filter.

l Moisturized air filter must not be installed.

Check for air filter’s damage.

Before installation after cleaning, air filter

must be checked in front of light source (portable

light) to ensure that air filter has no cracks, holes or

any other damage. Sealing conditions must be

checked at the same time.

Air filter and separator’s replacement interval

Running conditions (such as cooling intermediate’s temperature), running methods, and air inlet quality, e.g. dirt volume, other air such as SO2, solvent vapor volume etc, have a very important effect on the working lives of filters, e.g. air filter, oil filter and oil separator.

32

8. Maintenance 8.8 V Type Strap Tension System Danger

V type belt tension system must be checked

only after the air compressor stops running and pressure is relieved！

Important Note

All the entire V-type belt system must be changed instead of only one V-type belt.

1：Motor 2：Motor’s fixing bolts, total 4 pieces 3：Tension bolts，total 2 pieces 4：Sliding drive bolts，total 2 pieces 5: Sliding drive nuts，total 2 pieces 6: Sliding board，total 2 pieces

Strap Tension Method ● Suitably loosening bolts 2 and 3. Take precaution

of not dismantling the bolts to prevent sliding board dropping.

● Rotating clockwise 2 pieces of bolts 5 with a

wrench. As bolts 4 are screwed into sliding board, sliding board is driven by bolts 4. The belt is tensioned through bolts 2 driving motor.

● Adjusting strap wheel’s parallel through

observing a leveling ruler touched the surfaces of the strap wheel. Any one of bolts 5 is adjusted if the surface is not level.

● When the surfaces of two strap wheels are

paralleled and strap is tensioned to a suitable degree, wrench 4 pieces of bolts 2.

- 33 -

8. Maintenance

8.9 Normal Maintenance and Cleaning

Important Note

Cleaning the exposed machine’s parts of air

compressor and the remained oil and other

deposits in accordance with the instruction

manual.

Periodically clean screw air compressor with

compressed air, not allowed to blow to personnel,

especially to the following parts:

l Adjusting components

l Pipe connectors

l Motor

l Cooler

l Motor

Motor Two bearings of the motor must be re-

lubricated periodically. The interval relies on the type of motor.

8.13 Fixed Air Compressor’s Maintenance and

Suggested Lubricant

Suggested Lubricant

Please note that good lubricant can maximize

the air compressor’s working life.

The company’s special screw air compressor

oil ensures the machinery’s reliability. Never mix

different types of lubricants.

- 34 -

9. Troubleshooting

Condition Possible Fault Remedy

1. Air compressor

cannot be started.

1． Fuses burnt 2． Protect relay 3． Starting button is of loose

connection 4． Voltage too low 5． Motor out of order 6． Machinery malfunctioning

1． Consult technician to check and replace 2． Consult technician to check and replace 3． Consult technician to check and replace 4． Consult technician to check and replace 5． Consult technician to check and replace. 6． Manual start machine, if cannot be moved,

consult the company service department.

2. Air outlet

temperature too high

(Machine stops

above 105°C)

7． Environment temperature too

high

8． Temperature control valve out

of order

9． Oil level too low

10． Oil cooler too dirty

11． Oil filter choked

12． Cooling fan out of order

13． Heat resistance out of order

7． Improve ventilation of the compressor room.

8． Check/replace

9． Check/ adjusting oil level

10． Clean cooler

11． Have oil filter replaced

12． Have cooling fan replaced

13． Check / replace heat resistance.

3. Air output below

normal

14． Air consumption exceeds air

delivery of compressor.

15． Air filter choked

16． Inlet valve not fully open

17． Oil separator choked

14． Check for equipment leakage conditions

15． Clean or replace a new filter

16． Have valve checked

17． Check oil separator pressure meter before and

after and pressure value displayed on LCD;

have separator replaced if necessary.

4. Air compressor

does not unload, or

unload with working

pressure holding or

going upward.

18． Inlet valve does not perform

well.

19． Pressure sensor out of order

20． Outlet valve does not perform

well.

18． Have valve checked.

19． Check and replace if necessary.

20． Check and replace if necessary.

5. Air compressor

frequent unloads or

overloads

21． Leak in pipes

22． The setting pressures’

difference of unloading and

loading too low

23． Air consumption unstable.

21． Have pipes checked.

22． Reset the value.

23． Enlarge the air tank’s volume.

6. Too much oil in

the air, excessive oil

consumption.

24． Oil level too high

25． Oil filter or throttle choked

26． Oil separator or washer

defective

27． Leak in oil system pipes

28． Air outlet pressure too low

24． Check oil level, and drain oil to correct level.

25． Clean filter and throttle; replace if necessary

26． Check separator or washer, replace if

necessary

27． Have pipes checked

28． Increase air outlet pressure.

40

29． Too much foam caused by oil 29． Change oil

40

10.Easily Damaged Parts

No Product Name

1 Air Fillter

2 Oil Fillter

3 Oil Seperater

4 Temperature Sensor

5 Pressure Sensor

6 lubricating Oil

7 Belt

8 Solenoid Valve

9 Temperature Controler Insert

10 Oil Outlet Ball Valve

11 Pressure Gage