UD110A UD132A UD160A UD180A

UD110W UD132W UD160W UD180W

OPERATIOAN AND MAINTENANCE MANUAL

Stationary Screw Air Compressor

The unit was purchased

From:

On:

Customer Order/Contract No:

Model Number： UD160W-8

Serial Number on Units： 161671152

Shanghai United Compressor reserves the right to make changes

and improvements to products without notice and without incurring any
obligation to make such changes or add such improvements to products
sold previously. This manual contains important safety information and
must be available to personnel who operate this machine.

File No.：1161412001
2016/A
1 CONTENT

CONTENT
1 CONTENT -------------------------------------------------------------------------------1

2 FOREWORD ----------------------------------------------------------------2

3 DECALS ------------------------------------------------------------------4

4 SAFTY -------------------------------------------------------------------7

5 INSTALLATION INSTRUCTION -------------------------------------9

6 GENERAL INFORMATION --------------------------------------------12

7 OPERATING ORDERS ---------------------------------------------------18

8 MAINTENANCE ---------------------------------------------------------25

ATTACHED TABLES:

PERIODIC MAINTENANCE TABLE ---------------------------------------45

TROUBLE SHOOTING TABLE ----------------------------------------------46

COMMON ELECTRIC FAILURE AND CAUSES ------------------------47

RECORDS OF MAINTENANCE --------------------------------------------48

9 COMPRESSED AIR DEW POINT TEMPERATURE TABLE-------------49

ATTACHED DRAWING ：

COMPRESSED AIR DEW POINT TEMPERATURE TABLE--------------50

 FOREWORD 2
The contents of this manual are considered to be proprietary and confidential to Shanghai United
Compressor and should not be reproduced without the prior written permission of Shanghai United
Compressor.

This manual contains instructions and technical data to cover routine operation and scheduled
maintenance tasks by operation and maintenance staff.
IF IN DOUBT CONSULT SUPERVISION.

Shanghai United Compressor reserves the right to make changes and improvements to products
without notice and without incurring any obligation to make such changes or add such improvements
to products sold previously. This manual contains important safety information and must be available
to personnel who operate this machine.

Customers should know about and abide by local applicable codes and regulations on machines.

Operator should be responsible for safety running of the machines and overhaul for potential unsafely
hidden trouble.

Shanghai United Compressor cannot anticipate every application or work situation that may arise.

All components, accessories, pipes and connectors added to the compressed air system should
be:

„ of good quality, procured from a reputable manufacturer and；

„ wherever possible, be of a type approved Shanghai United Compressor；
„ clearly rated for a pressure at least equal to the machine maximum allowable working pressure；
„ Compatible with the compressor lubricant/coolant.

Details of approved equipment are available from Shanghai United Compressor Service departments.

The use of non–genuine spare repair parts other than those included within the Shanghai United
Compressor approved parts list may create hazardous conditions over which Shanghai United
Compressor has no control. Therefore Shanghai United Compressor does not accept any liability for
losses caused by equipment in which non–approved repair parts are installed. Standard warranty
conditions may be affected.

This machine has been designed and supplied for use only in the following specified conditions and
applications:

„ Compression of normal ambient air containing no known or detectable additional gases, vapors,
or particles；
„ Operation within the ambient temperature range specified in the GENERAL INFORMATION
section of this manual.
3 FOREWORD

Shanghai United Compressor will approve and accept no claims on the following applications.：

„ direct human consumption and indirect human consumption, without suitable filtration and purity
checks；
„ Use of the machine where there is any actual or foreseeable risk of hazardous levels of
flammable gases or vapors；
„ Use of the machine with safety or control components missing or disabled.

Note that content mentioned here does not render any warranty or guarantee on the machine. Any
warranty in force at the time of purchase of the compressor or negotiated as part of the purchase order
may take precedence over this warranty.

For applications listed below, UNITED OSD will not accept any liability
arising

The production license NO. of air compressor is XK06-010-00287

UNITED OSD air compressor manufacturing and testing in accordance with

standard as follows:

1、GB/T 3853-1998 Displacement compressors Acceptance Test

2、GB19153-2009Displacement compressors energy efficiency limits and rating

3、GB 22207-2008 Safety requirements for displacement air compressors

4、GB/T 4980-2003 Displacement compressor noise measurement

5、 GB/T 7777-2003 Displacement compressors mechanical vibration

measurement and evaluation

6、JB/T 6430-2014 Injected screw air compressor for general use

 DECALS 4

RAPHIC FORM AND MEANING OF THE SYMBOLS:

5 DECALS

GRAPHIC FORM AND MEANING OF THE SYMBOLS:

 DECALS 6

GRAPHIC FORM AND MEANING OF THE SYMBOLS:

7 SAFETY

GENERAL INFORMATION:

Ensure that the operator understands the decals and consults the manuals before maintenance or
operation.

Ensure that operation and maintenance personnel are adequately trained, competent and have read the
Manuals.

Make sure that all protective covers are in place and that the canopy/doors are closed during operation.

Compressed air and electricity can be dangerous. Before undertaking any work on the compressor,
ensure that the electrical supply has been isolated and the compressor has been released of all
pressure.

Installation of this compressor must be in accordance with recognized electrical codes and any local
Health and Safety Codes.

Compressed air can be dangerous if incorrectly handled. Doing any work on the unit, ensure that all
pressure is vented from the system and that the machine cannot be started accidentally.

Cooling air is drawn in at the end of the machine package passing through the filter and cooler before
being discharged from the top of the machine. Care should be taken to avoid blocking the airflow, or
causing any restriction in excess of the maximum backpressure allowed for ducting.

Avoid bodily contact with compressed air.

COMPRESSED AIR

Ensure that the machine is operating at the rated pressure and that the rated pressure is known to all
relevant personnel.

All air pressure equipment installed in or connected to the machine must have safe working pressure
ratings of at least the machine rated pressure.

All pressure containing parts, especially flexible hoses and their couplings, must be regularly
inspected, be free from defects and be replaced according to the Manual instructions.

When using compressed air always use appropriate personal protective equipment.

Safety valves mounted on the air/oil tank must be regularly inspected

If the discharged air is to be ultimately released into a confined space, adequate ventilation must be
provided.
 SAFETY 8

TRANSPORT
When loading or transporting machines ensure that the specified lifting and tie down points are used.

Ensure nobody and tools are left in the machine.

Do not work on or walk under the compressor while it is suspended.

ELECTRICAL
Close and lock all access doors when the compressor is left unattended.

Any electrical connections or adjustments should only be made by a suitably qualified electrician

Keep all parts of the body and any hand–held tools or other conductive objects away from exposed
live parts of the compressor electrical system.

Attempt repairs only in clean, dry, well lighted and ventilated areas.

Connect the compressor only to electrical systems that are compatible with its electrical characteristics
and that are within it’s rated capacity.

Do not use extinguishers intended for Class A or Class B fires on electrical fires. Use only
extinguishers suitable for class BC or class ABC fires.

Maintain dry footing, stand on insulating surfaces and do not contact any other portion of the
compressor when making adjustments or repairs to exposed live parts of the compressor electrical
system.

MATERIALS
The following substances are used in the manufacture of this machine and may be hazardous to health
if used incorrectly:
„ UNITED OSD compressor coolant；
„ rust preventative；
„ Motor grease.

AVOID INGESTION, SKIN CONTACT AND INHALATION OF FUMES

„ Skin contact, clean water rinsing immediately；
„ Eye contact，clean water rinsing for at least 5 minutes；
„ Ingestion and inhalation largely, consult with doctor.

COOLANT DISPOSAL
Sip up spillage of coolant with proper material, then save them into plastic bag for disposal by.

DISPOSAL WAY
Burn off in approved incineration furnace or handle in a way prescribed by local codes.
9 INSTALLATION INSTRUCTION

CONDENSATE DISPOSAL
Ensure that condensate disposal are discarded in a manner prescribed by local codes.

LOCATION
A wide, well-lighted indoor location for adequate service access and ventilation.
The compressor can be installed on any level floor capable of supporting it. A rubber pad between the
floor and the machine is recommended
A dry, well ventilated area where the atmosphere is clean is recommended. Normal ambient
temperature should be lower than 46℃.
A minimum of 1.2m should be left between wall and machine and at least 1.5m at the sides of the
machines and at least 2m away from the top of house for adequate service access and ventilation.
Adequate clearance needs to be allowed around and above the machine to permit safe access for
specified maintenance tasks.

COMPRESSED AIR STATION

Near to the compressed air loading center；With reasonable power and water supply；
Possibility of expanding construction；

The use age of all PVC hosepie and nylon hose in siede the
machine is 2 years and hoses must be replaced within these 2
years,which otherwise would cause severe accidents. When
replace, please use UNITED OSD original spare parts.
Compressor use Elastic joint, the service life time for seal ring is
Half a year, it should be changed after Half a year, please use
United OSD original spare part to change.

This machine is not intended and must not be used in or near potentially explosive atmospheres ,
including situations where flammable or caustic or toxic gases or vapors may be present；
Spaces required to proof noise and vibration should conform to local regulation.

DISCHARGE PIPING
Ensure discharge piping is correctly calibrated and supported. Do not use the machine support piping.
The main pipeline shouldn’t be narrowed at random. If users must narrow or widen the pipeline,
please use gradual narrow pipe.
Sub-pipeline must be connected from the top of the main pipeline.

All PVC hose and nylon tube inside of compressor must be replaced within two years.
Otherwise, it will cause serious accident. please choose UNITED OSD genius spare part
s for better operating result
Install the ball valve or stop valve on the air discharge pipe of the compressor. Cannot mount check
valve.
The pressure loss of sub-pipeline couldn’t exceed the rated pressure more than 5%, so user should
select wider pipe.
To decrease pressure loss, sub-pipeline connections should meet design limits and less tie-in
connections and valves should be used.
 INSTALLATION INSTRUCTION 10
Compressed air pipeline in cold and chilliness areas should be built on laying stilts and prevent
frostbite.
Compressed air pipeline mounted in chilliness areas should be laid with thermal pipeline or under the
ground.
— If air receiver and dryer behind the compressor, the ideal layout of pipeline is: Screw Air
Compressor + Air Receiver + Pre-Filter + Dryer + After-Filter + Fine-Filter.
Fine-Filter

Dryer

Pre-Filter After-Filter

Compressor Air Receiver

COOLING SYSTEM
COOLING SYSTEM
The site should be wide and well-light for easy operation and overhaul. Do not place the machine at
vicinity of high temperature.

Mount exhaust or venting equipment at the setting place of machine. And install extra fan hood.

The concrete base to mount the machine should block up 50mm in order to install pipeline. The size of
the base should be 50mm wider than external dimension of the machine both in length and width for

adequate service access and ventilation.

For air cooling machine, mounting exhaust tube to lead hot cooling air out of the house is
recommended. The loss of exhaust pressure should be less than 6 mm water column，otherwise install
extra exhausting fan. Air exhaust should be higher than the following data.

AIR EXHAUST
MODEL
m3/min
UD110A—UD132A 490
UD160A—UD180A 650
11 INSTALLATION INSTRUCTION

CONVEY

After unpacking, convey of the machine should be followed precisely to transit instructions to avoid
injury or death.

When use fork lift truck to convey the machine, place padding as shown below to avoid any breakage
of the machine.

Ensure that the correct fork lift truck slots or marked lifting points are used whenever the machine is
lifted or transported. Use rails to support sling can counteract side pressure. Note: Do not use
safeguard material between sling and sound isolation cover, this will damage side doors of the
machine.
吊绳
吊装支撑架

UNPACKING
The compressor will normally be delivered with a polythene cover. If a knife has to be used to remove
this cover ensure that the exterior Paint work of the compressor is not damaged. If there is any doubt,
please refer to Shanghai United Compressor authorized service department.

Ensure that all transport and packing materials are discarded in a manner prescribed by local codes.

If the machine are not put into service for a long time，properly greasing
s the air end at three-month interval. Rotating the air end by hand at
the same time.

Area with inferior power supply, suggest monitor circuit and install AC
regulator.
 GENERAL INFORMATION 12

WORKING PRINCIPLE

The machine is an electric motor driven, single stage screw compressor.

Compression in the screw type air compressor is created by the meshing of two (male & female)
helical rotor. The machine consists of air end, motor, driven parts, cooling system,
controlling system and enclosure, etc.

WORKING PROCESS OF COMPRESSOR

Continuous cycle air flow between the two rotors running in the rotor housing makes the
air among the meshing flow from the inlet side to the outlet ends, completing the three air
working steps from suction to compressing to discharge.

WORKING CONDITION

The standard compressor is designed to operate in an ambient range of 30.26°F to 104°F (1.7
~46℃).The maximum temperature is applicable to either version up to a maximum elevation of
3280ft (1000m) above sea level. Above this altitude significant reduction in maximum allowable
ambient temperature is required.

MERITS OF THE MACHINE

Reliable performance, easy operation and high efficiency together with light weight, low vibration and
little noise.

The air/coolant mixture discharges from the compressor into the separation system. This system
removes all but a few PPM of the coolant from the discharge air. The coolant is returned to the cooling
system and the air passes through the after cooler and out of the compressor.

Cooling air is moved through the coolers by the cooling fan and discharged from the machine.

Guaranteed safety function. Safety of operation is provided as the compressor will shut down if
excessive temperatures or electrical overload conditions should occur. Note: examine and repair the
machine in time.
 13 GENERAL INFORMATION

UD110A-UD180A SCREW AIR COMPRESSOR ELECTRICAL SCHEMATIC

FLOW CHART

14 17

15
18
1 16 7
20
21 8
2
5
6
3 4

9
13 11
12
10
22
air

oil
19

control

1、air filter 7、minimum pressure valve 13、oil filter 19、sewer valve

2、suntion pilot valve 8、pressure gage 14、regulator valve 20、pressure differential switch
3、air end 9、cooler 15.air release valve (kaeser)
4、temperature sensor 10、air-water separator 16.check valve 21、pressure differential switch
5、air/oil tank 11、thermostatic valve 17.solenoid valve (air filter)
6、safety valve 12、drain valve 18、pressure sensor 22、pressure differential switch
(oil filter)
 GENERAL INFORMATION 14

UD110W-U180W SCREW AIR COMPRESSOR ELECTRICAL SCHEMATIC

FLOW CHART

15 18

16
19
1
17 7

21 8 20
2
5
6
3 4
9 10

water

air
14
12
13

water
22
air pipeline
11
oil pipeline
control line

1.air filter 7.minimum pressure valve 13.drain valve 19、pressure sensor

2.suction pilot valve 8.pressure gage 14.oil filter 20、pressure differential switch
3.air end 9.oil cooler 15.regulator valve (kaeser)
4.temperature sensor 10.after cooler 16.air release valve 21、pressure differential switch
5.air/oil tank 11.air-water separator 17.check valve (air filter)
6.safety valve 12.thermostatic valve 18.solenoid valve 22、pressure differential switch
(oil filter)
15 GENERAL INFORMATION

UD110W-UD180W EXTERIOR DEMENSION

 GENERAL INFORMATION 16

UD110A- UD180A EXTERIOR DEMENSION

 17 GENERAL INFORMATION

SPECIFICATION
POWER PRESSURE AIR FLOW OUTLET WEIGHT DIMENSION
MODEL
kW MPa m3 /min CONNECTION Kg L×W×Hmm

UD110A/W-7 0.7 20.8

UD110A/W-8 0.8 20.6

110 3300
UD110A/W-10 1.0 17.5

UD110A/W-12.5 1.25 14.2

UD132A/W-7 0.7 24.0

UD132A/W-8 0.8 23.0

2850X1850X2120(W)
132 3400

3050X1850X2120(A)
UD132A/W-10 1.0 20.6

UD132A/W-12.5 1.25 17.0 Rp3

UD160A/W-7 0.7 28.5

UD160A/W-8 0.8 27.0

160 3750
UD160A/W-10 1.0 25.0

UD160A/W-12.5 1.25 19.7

UD180A/W-7 0.7 32.0

UD180A/W-8 180 0.8 30.5 3790

UD180A/W-12.5 1.25 22.5

Discharge of stream
MODEL Water quality standard
t/h
water pressure： 0.25-0.5 MPa
UD110W
10 Water temperature： ≤32 ℃
UD132W Organic content： ≤25mg/l
Suspension solids content： ≤100mg/l
UD160W Oil content: ≤5mg/l
15 PH： 6.5～9
UD180W Ca+： ≤140mg/l
Note:
Selection of model
UD 110 A-XXX

Pressure(bar): □7 □8 □10 □13

Cooling model: □A: air cooling □W: water cooling
Power(kw): □110 □132 □160 □180
 OPERATING ORDERS 18

Please read this manual carefully before operation

Preparation Prior to Start-up

Check various components connections. Transportation and installation may loosen these
connections, such as pipe ling joints, metering interface, circuit connections, etc.

Dismantle and remove fixed frames and bolts used for transportation, save them for the future use.

Correctly furnishing, mounting and wiring circuit, grounding of the ground terminals of the
machine as shown in the electric scheme.

The applied voltage must be compatible with the motor and compressor data nameplate ratings.

Check coolant level through the observing mirror

Oiling air end of new machine or heavy repaired machine or stopped machine for a long period.
Rotate the air end by hand till it can easily running.

When restarting the machine stopped for a long time,

dismantle suction valve, fill in same type coolant of our
company from air end suction inlet. Rotate air end by hand.

When dismantling the suction valve, avoid any impurity into

the air end chamber.

Safety valve’s unlock pressure is compressor rated pressure

plus 0.2MPa.

Ensure that the motor rotates in the correct direction as

indicated by direction arrows.
19 OPERATING ORDERS

The Machine’s Initial Start-up：

Enter three-phase power source. Checking carefully for the wiring of the input/output before
power applying. Test whether voltage and three-phase power entry is in order.( Ensure
that the motor rotates in the correct direction as indicated by direction arrows.)

Open the valve on the air discharge.

Turn on the emergency stop button clockwise by 90°to be in the condition of startup,
and press the start button to start up the compressor instantaneously. Check carefully
whether the machine rotates in the correct direction as indicated by direction arrows. When it is
reverse arrowhead, exchange any two phases position of the three-phase cable.
Recheck to restart the compressor when there is no error, then go into the next
operation step.

Avoid the frequent start / stop. Do avoid the machine from start / stop frequently in
the process of debugging and service, unless it is for special occasion, instant start
under high pressure in particular. Each start / stop interval should not be less than 3
minutes.

Push stop button to stop the running of the machine.

After the compressor is put into use, regularly check the

controller’s parameter and record of history running for future
service.
 OPERATING ORDERS 20

EPC Intellectual Controller

——Start Button: Press this button to start the machine

——Stop Button: Press this button to stop the machine

——Load/ Releasing Button: Load/ Releasing at certain range of pressure when the state is
“Manual”.

——Up button: Press this button to move upward during modification data. Press this button to
select menu during the menu selection

——Down Button: Press this button to move downward during modification data. Press this
button to select menu during the menu selection

——Cursor / Confirm Button: This button can be used as cursor during the data modification and
as confirm button during the menu selection

——Return/Preset Button: Press this button to return to upper menu during the menu operation.
Press this button to reset the machine when the unit is stopped in failure.

——Mode Button: Press this button to confirm the input data to be saved after modification of the
data.
21 OPERATING ORDERS

Status Display and Operation

The display interface is as following when the units are POWERED ON：
Welcome to use
UNITED OSD
Screw Air Compressor

The main display after 5 seconds will be the following:

GAS T：20℃
GAS P：0.60Mpa
STATE：NORMAL STOP
NEAR

Press “v” Enter the following Menu Selection Interface:

RUN PARAMETER
CALENDAR
CUSTOMER PARAMETER
FACTORY PRAMETER

Run the Parameter Review

Press ‘v’or ‘u’ to move the black cursor over the menu ‘RUN PARAMETER’and then
press ‘t’ to pop up the submenu:

HOST、FAN CURRENT
TOTAL RUN TIME
CURRENT RUN TIME
MAINTENANCE PARAMETER

Press ‘t’ to pop up another menu:

CUR(A)：R S T
HOST： 56.1 56.2 56.0
FAN： 4.1 4.1 4.1

If the menu pop up is the last menu level, the black cursor will disappeared, press the RETURN
button “ ” and return to the upper menu or the main interface. If the operation is stopped in
a certain interface, it will automatically return to the main interface after several seconds.
 OPERATING ORDERS 22

Using the moving buttons ‘v’ , ‘u’ ,CONFIRM button ‘t’ return button“ ”to view the RUN
PARAMETERS such as the RUN TIME, CURRENT RUN TIME MAINTENANCE
PARAMETER, HISTORY FAILURE, PRODUCING DATE and CURRENT FAILURES and
then return to the upper menu with the similar method of the above.

Calendar and Time

Press ‘v’ or ‘u’ to move the black cursor to the menu ‘CALENDAR’ and then press ‘t’ , the
following menu will be pop up:

DATE AND TIME

2004 Y 2 M 22 D
SUNDAY
12 H 46 M 59 S

At the stop status of the unit, the date and time could be adjusted according to the following steps:
Press ‘v’ or ‘u’ to move the black cursor to the parameters you want to modify and then press ‘t’
to reach the blinking position. Now the button ‘v’ and ‘u’ are changed to ‘Page up’ and ‘Page
down’ button. Press ‘S’ button to confirm and save the data after finish the modification. The
buttons ‘v’ or ‘u’ return to black cursor move button and the button ’t’ change back to its Return
function.

CUSTOMER PARAMETERS
The Customer Parameters and the Factory Preset Parameters
can not be modified during the Running State and Stop
Delaying period

The Customer Parameters could be read and modified with the same method of running the
Parameter Review mentioned above. For example, to modify the parameter BLOCK UNLOAD
PRESSURE, the steps will be as the following:

Press ‘v’ or ‘u’ to move the black cursor to ‘CUSTOMER PARAMETER’ menu and then press
the CONFIRM button ‘t’ to pop up the following menu:

SET P、T
ON/OFF DELAY PRESET
OP. MODE PRESET
BLCK PARA PRESET

Press the CONFIRM button ‘t’ again to reach the following menu:

LOADING P 0.8MPa
UNLOADING P 0.6MPa
FAN START T 80℃
FAN STOP T： 70℃
23 OPERATING ORDERS
The CUSTOMER PARAMETERS can be read now when the CONFIRM button ‘t’ is not
pressed now. Press the CONFIRM button ‘t’ again to pop up the following interface where the
password input is needed:

ENTER PASSWORD
****

Attention: The Customer Password can me modified in the CUSTOMER PARAMETER, the
DEFAULT PASSWORD is: 1688

The Blinking Position will appear after this interface displayed. The button ‘v’ and ‘u’ have been
changed to Pg Up and Pg Down button that could be used to change the current value. The button
‘t’ is changed to move button to move the position where the modification is needed, Press ‘S’ to
confirm and the following interface will be displayed:

BLOCK LOAD P 0.8MPa *

BLOCK UNLOAD P: 0.6MPa
FAN START T: 80℃
FAN STOP T: 70℃

When there is a ‘*’ displayed at the up right corner, it means it is at the CUSTOMER
PARAMETER set status.

CONFIRM button ‘t’ when the cursor is over the menu ‘ BLOCK UNLOAD PRESSURE’, now
the blinking position appears and the button ‘v’ and ‘u’ have been changed to PgUp and PgDwn
button that could be used to change the current value. The button ‘t’ is changed to move button to
move the position where the modification is needed, Press ‘S’ to confirm and the blinking position
will disappear. The ‘v’ or ‘u’ return to black cursor move button and the button ’t’ change back
to its CONFIRM button to continue to modify the other CUSTOMER PARAMETERS. If there are
no other parameters needed to be modified, press the button ‘↳’ to return to the upper menu or the
main menu. The other CUSTOMER PARAMETERS could be modified with the same method
above.
 OPERATING ORDERS 24

EPC PARAMETERS AND ITS FUNCTION

Preset
First Submenu Second submenu Functions
Value
UNLOAD P. *.**Mpa UNLOADING PRESSURE VALUE
LOAD P. *.**MPa LOADING PRESSURE VALUE
Control the fan starting. This value will be set to
SET P. T.
FAN START T. ***℃ ‘120℃' if there is no fan present or the fan is not
required to be protected.”
FAN STOP T. ***℃ Control the stopping of the fan
When using the controller to protect the motor, it
is required that the time here defined will not
HOST START TIME 0008s meet the impulse starting current of the motor,
the value here must be longer than the STAR
DELAY TIME plus LOAD DELAY TIME
When using the controller to protect the motor, it
FAN START TIME 0006s is required that the time here defined will not
meet the impulse starting current of the motor.
STAR DELAY TIME 0006S Star pressure release starting delay time.
The loading delay time after star pressure
LOAD DELAY TIME 0002S
ON/OFF releasing.
DELAY TIME Load free continuous running time, the machine
EMPTY DELAY 0020M
PRESET will automatically stop after this time
The machine will not stop until this time passed
STOP DELAY TIME 0010S
the load free state when stop the machine
Machine can not be restarted before this set time
START DELAY TIME 0100S after stopped or over time operation at load free
state
STANDBY DELAY TIME 0000S Additional functions
The continuous draining time during the
DRAIN OPEN TIME 0002S
automatic draining control.
The Draining Gap duration during the automatic
DRAIN CLOSE TIME 0010M
Draining control
When the remote mode is set, both the buttons at
Machine
ON/OFF MODE machine side and the remote control button can
side
turn on and off the machines
When the manual mode is set, the Load/Unload
OPERATION
LOAD MODE Auto function can only be executed by pressing
MODE PRESET
buttons
When this is set to ‘PROHIBIT’ the
COM MODE Prohibited
communication function is not available
COM CODE 0255 Communication address
 25 OPERATING ORDERS
Continued

Act as Host or Secondary Machine when there

Blocking mode HOST are more than one machines running in blocking
mode. The HOST controls the SECONDARY
BLOCKING BLOCKING ON/OFF Sequence
PARAMETERS Switching Time 9999 Hours
PRESET Block Number 0016
BLOCK LOAD P *.**MPa
BLOCK UNLOAD P *.**MPa
BLOCK DELAY TIME 0000S
O/ F RESET 0000 Hours Reset time for the duration of oil filter changing
O/G RESET 0000Hours Reset time for O/G Separator changing
Maintenance
G/F FILTER RESET 0000Hours Reset time for gas filter changing
Parameter Preset
LUB OIL RESET 0000Hours Reset time for Lubricate Oil Changing
LUB GREASE RESET 0000Hours Reset time for Lubricate Grease Changing
Set this value to ‘0’ will make the oil filter alarm
OIL FILTER 9999Hours
not available
Set this value to ‘0’ to disable the O/G separator
O/G SEPARATOR 9999Hours
alarm function
MAX LIFE Set this value to ‘0’ to disable the alarm function
GAS FILTER 9999Hours
TIME PRESET of gas filter
Set this value to ‘0’ to disable the time alarm of
LUB. OIL 9999Hours
lub. oil
Set this value to ‘0’ to disable the time alarm of
LUB GREASE 9999Hours
Lub. Grease
Language
Set to ‘CHINESE’ will change the interface to
Select(Chinese/E English
be English display.
nglish)
NEW USER
**** Customer could modify the user password
PASSWORD
 OPERATING ORDERS 26

The Basic Wiring diagram of the electronic Installation.

Text Display Connector Terminals:

There are five connect terminals and one D type display cabal connector which are relatively used
for the display connector, Rs—485 communication interface and 24V Power input

Diagram 8. The array of the connector terminals

Electric details refer to ELECTRICAL SCHEMATIC FLOW CHART enclosed with the
delivered machine.

Controller Connect Terminals:

The display panel is connected with the controller using communication cabals. 23, 24 and 25 are
the phase sequence input terminals; 7 and 9 are the Air Exhaust Temperature Input terminals; CT1
is the host mutual inductor; CT2 is the fan mutual Inductor. 32 is the common port COM1 of the
relay output; 27 controls the main contactor; 28 controls the star contactor; 29 controls the angel
contactor; 30 is the loading magnetic valve; 31 controls the Fan; 34 controls the Load release
valve: 37 is the running indicator; 38 is the Failure indicator; 39 is the Alarm indicator; 40 is
COM2; 42 is the simulated ground (Earth); 43 and 44 are the 220V power source.

The magnetic coil must be connected to the surging absorber when

wiring
27 OPERATING ORDERS
Local Automatic control(ON/OFF mode: Beside Machine; Loading method: Automatic)

Press ‘I’ to start:（Y—△ Starting）

When the controller is powered on, it will perform a 3S self-checking. Press the ‘I’ button cannot
start the machine until the self-checking is completed. The starting process of the host will be as
the following: KM3 is powered on, KM2 is Powered on Æ Y type Starting Status Æ Time Delay
finish（Y—△ converting time）, KM3 loss power (KM1 and KM3 interlocked)，KM1 is powered
on Æ Motor runs in △ type and the Starting is completed. All the magnetic Valves are without
power during the whole starting process to ensure the load free starting.

Running Control

Switch Working status

When the motor is started to △ status and after a certain period of delaying, the power applies to
the electromagnetic valve switch and then the air compressor starts to load thus the pressure of the
air container is increased. When the air pressure is get high enough to be over the preset limited
high value(Unload Value), the electromagnetic valve switch losses the power to allow the air
compressor running without load. If the air pressure is running low enough to be under the preset
limited low value(the Loading Pressure Value) within the time of the load free running of the air
compressor，the electromagnetic valve switch will be applied with power again to allow the air
compressor to work at the normal state to increase the air pressure in the air container. If in the
period of the load free running time of the air compressor, the air pressure in the air container does
not reach the preset limited low value, the controller will stop the running of the motor to enter the
status of overtime load free running stop. The restarting of the motor can only be performed when
the pressure reaches the preset limited low value and it will repeat with the same mode
continuously.

Manual Loading/Unloading when the Loading state is ‘AUTOMATIC’

The machine is at the unloading status in the automatic mode. Press ‘M’ once to load. If the
pressure is higher than the unloading pressure, the electromagnetic Valve will inch and then return
to the unload state; if the pressure is lower than the unload pressure, the electromagnetic valve will
be applied with power will not return to unload status until the air pressure is higher than the
unload pressure. When the machine is at the loading status, press ‘M’once. If the pressure is higher
than the load pressure, the electromagnetic valve will lose the power and it will not return to the
loading state until the pressure is lower than the load pressure. If the pressure is less than load
pressure , the unload function is disabled.

Normally Stop
Press ‘O’ button and the Switch Electromagnetic Valve will lose power and after a certain period of
delay (Stop Delay), the motor connector will lose power so that the Main motor and the fan motor
will stop rotating. The system can only be restarted by pressing ‘I’ button.
 OPERATING ORDERS 28
Frequently starting protection control

The motor could not be restarted immediately after stopped by pressing ‘O’ button, Overtime free
loading stop, failure stop. There must be a certain time of delay, the controller screen will display
the delay count down time(such as 90 seconds) , the motor could only be restarted after the count
down time.
Remote Automatic Control (ON/OFF mode: Remote; Load mode: Automatic)

The remote automatic control is almost the same as the local automatic control, the only difference
is that the start and stop of the unit is controlled by remote control.

Local Manual Control (On/Off mode: beside machine; Load mode: Manual)

The Starting and stopping control is the same as the automatic control, the only difference is that
when the starting procedure finished in this mode, the machine is at the load free state and will be
loaded by pressing the button “M” . When the air supply pressure is higher than the unload
pressure, the unit will load automatically, if the button“M” is not pressed to load, the unit will be
running at the load free state till load free stop. During the unload process, press the button “M”
to load and during the process of loading, press the button “M” to unload.

Remote Manual Control (On/Off Mode: Remote; Load mode: Manual)

The remote automatic control is almost the same as the local manual control, the only difference is
that the start and stop of the unit is controlled by remote control.

Network Control

When the control network is set to ‘COMPUTER’, it could perform the computer network control
of the units

I. Computer Network Control System Instructions

The Computer Network Control System is a set of computer network management software which
is designed for our UNITED OSD air compressor controller. The system mainly uses
multi-document interface. Different settings are for different customer requirements. The system
consists of several functional parts including Data Gathering, Automatic Control, Network Control,
Data Storage, Data Search, Report Creating, and System Parameter Settings. The computer is the
Host, air compressor controllers are the Slaves in the system. The system applies “Host Turn
Check”, “Slave Respond” communication code. The Host uses RS232, externally connecting a
communication converter to realize the transformation from RS232 to RS485. (See the following
figure).
 29 OPERATING ORDERS

Computer Network Controlling System is comprised of the following interfaces:

User Login Interface Running Parameter Interface (each

Slave has its corresponding interface

System Parameter setting

Interface Review History Running Parameter
Network control system

Interface

Main Interface
Review History Running Failure
Interface
Block Control Setting
Interface
History Running Parameter Report
Interface
System Password
Setting Interface
History Failure Parameter Report
Interface
System Password
Verification Interface

II. Program Installation

The system provides the program package for user to install. User needs to open the folder which
contains the package and then execute the corresponding Setup.exe file according to user’s
operational system. Follow the instructions to finish the installation. Please be aware that the
program needs to be installed in the disk which has comparatively larger space in order to store
more record data. When user begins the installation, the sketch map is as the following figure.
When the installation is finished, the program would automatically generate a shortcut icon on the
desktop. Hit the icon to run the program.
 OPERATING ORDERS 30

III. Program Initialization

User needs to initialize the program when first use. Enter into System Parameter Set interface
through Parameter Setting menu or System Set short cut icon to set each parameter. After
finishing the settings, hit the confirm button, the program would automatically detects and checks
the input data and then record the correct user input data. Corresponding forms will be generated
for the system to monitor and control the slave compressors. (System Parameter Set interface is as
following figure):
31 OPERATING ORDERS
IV. Running the program

After the user has correctly set the system parameters, the program will automatically generate
corresponding windows to monitor and control each slave compressor. User is able to view the
running status of each slave compressor and send different kinds of control demand to slave
compressors. The operational interface is as following figure (4 slave compressors are given):

Attention: after the system settings have been finished, user can arrange the windows freely and
then hit System Control Menu→Save Window Parameter Menu, or hit the Save Window button
when exiting the system. Next time when starting the program, the system will automatically
arrange the windows following the previous arrangement.

When the program starts running, there will be an icon be generated at the toolbar. User can hit the
icon by pressing the right key of the mouse to activate the menu to execute Display Window
demand or Exit demand; or double click the left key of the mouse to activate the program. On a
computer, only one case is running in the program at a time. If user wishes to rerun the program,
should exit the previous program first. After the user has exited the system, the icon will be
deleted automatically. (See the following figure)
 OPERATING ORDERS 32
V. Remote Control

The computer is the Host. Air compressor controllers are the Slaves. The computer inspects each
air compressor’s running data in turn and then analyzes the data. The analyzed results (current Air
Feed Pressure, Air Exhaust Temperature, Phase current and current running status) will be
displayed in the corresponding columns on the computer. User can send corresponding control
commands to air compressor controllers according to the displayed data on the computer thus
realizing remote control. User can also view and modify Slave Parameters on the in the Slave
Setting Interface on the computer.

VI. Network Parameter Settings

When multi-compressors comprise an Air Feed Network supplying the same gasholder, the
computer collects every compressor’s Air feed pressure data and compares the data with the data
set by the user in the system. According to the comparison result, the computer selects suitable
compressors to send corresponding control commands to control the activities (Start/Stop,
Loading/Unloading) of air compressors in order to maintain the pressure balance in the gasholder.
Through proper settings, the system can balance each compressor’s running time. Network
groupings can be liberally set by the user. The computer only sends commands to those air
compressors which are in the network. In the network setting, Block pressure can be Block
Loading Pressure and Block Unload Pressure. User needs to preset the Block Parameters first
and save the data and then than click the start button to start the network. Under Block Running
Mode, the program collects the Air Feed Pressure values of the slave compressors and then
compares them with the User Set values. If the Air Feed Pressure value in the network is lower
than the Block Loading Pressure set by the user, the program will automatically search an air
compressor which is at stop or no-load status to send Start or Loading command. If the Air Feed
Pressure value is higher than the set Block Unloading Pressure, the program will search a
compressor which is currently loading in the network and send the Unload command. The system
maintains the balance of the Air Feed Pressure in the network through the Block Control. The
system will automatically save the correct Block Parameters (The following figure is Block
Control Parameter Setting interface).
33 OPERATING ORDERS

Block Control

Set the controller communication to ‘BLOCKING’ could perform the network control between the
controllers but the host must be 1# controller.

I. Air Compressor Block Control Instruction

Air Compressor Block Control is one of the important functions of our EPC Air Compressor
Controllers. The system is applied for an air feed network by uniting multiple compressors to
supply one air tank. The address code of the controllers starts from 001. Up to 16 controllers can
be operated in the network. The controller which’s address code is 001 is the Host Controller,
others are Slave Controllers. Loading Pressure, Unloading Pressure, Block Number and Block
Control Delay Time are set in the host compressor. After the manual start of the host compressor,
Block Control Mode activates automatically. The host set the Block Control Pressure; compare air
feed pressure, chooses specific compressor in the network to send control command; control the
start / stop of the compressors in the network; stabilize air feed pressure, set the running time.
Applying Block Control can avoid the damage of device by compressors’ frequent start / stop;
save energy.

II. System Settings.

1. Host Setting: when the device is at stop status, press ‘↓’ to enter into the following interface
and select ‘Customer Parameter’. Press‘→’to ‘Operation Mode’ and set the communication
mode as ‘Block’. Communication Code: 0001. Go back to ‘Customer Parameter’ and then
select ‘Blocking Mode’, and press ‘→’ to go in. Set Block Status as ‘Host’; Block On / Off as
‘Sequence’. Users can set ‘Switching Time’, ‘Block Number’, ‘Block Unload Pressure’, and
‘Block Loading Pressure’ by their own according to the actual situation. Attention: (The
values of Block Loading Pressure and Block Unload Press should be set between the
values of Air feed Loading Pressure and Air feed Unload Pressure).

RUN PARAMETER
CALENDAR
CUSTOMER PARAMETER
FACTORY PARAMETER

2. Slave Setting: when the device is at stop status, press ‘↓’ to enter into the above interface
and select ‘Customer Parameter’. Press‘ → ’to ‘Operation Mode Preset’ and set the
communication mode as ‘Block’. Communication Code: from 0002 to 0016, (Attention:
devices using the same code are not allowed in the network). Return to ‘Customer
Parameter’ interface, select ‘Block Parameter Preset’, then press ‘→’ to go in. Set Block
Status as Slave’. Don't need to set Block On / Off, Switching Time, Block Number, Block
Unload Pressure, Block Loading Pressure and Block Delay Time
 OPERATING ORDERS 34
III. Network Connection.

In the block control network, the communication line is needed for shielding. The communication
lines are used for parallel connecting the Air Compressor Controllers’ communication terminal A
and B. During the wiring, please avoid high voltage interference. Communication wires and
power lines should go through different pipes. The network construction is as follow:

............

A B A B A B A B A B

NO.1 NO.2 NO.3 NO.4 NO.N

Host Slave Slave Slave Slave

IV. Running the system

After the user has set the Air Compressors’ Block Control Parameters in the network and
connected the communication lines, start the host compressor, the slaves will automatically
operate in Block Control System. According to the Block Control Parameters which set by the user,
the Host sends control commands in order to control Slaves by their Start / Stop, Load / unload
Rotation and etc. in the network. To stop the system, the user needs to press the Stop Button which
is on the Host. After the network has been cut off, users need to press the Stop Buttons to stop the
slaves.

V. Cases and Explanations

Case1.
A user now has 4 Air Compressors to supply a gasholder. To maintain the pressure value of the
gasholder between 0.6MPa and 0.85MPa, the Block Settings are as follows:

(1). Test each compressor to make sure they work in good order independently. When “Normal
Stop” is shown on the screen of the Air Compressor Controller, enter into “User Parameter”, select
“Set P.T.” to set Unload Pressure and Load Pressure. In this case, we set the Unload Pressure as
0.85MPa, Load Pressure as 0.6MPa. In the actual circumstances, model types, air consumption
volume need to be taken into considerations when setting the pressures.
35 OPERATING ORDERS
(2). Enter into “User Parameter”, select “Operation Mode Preset”, and set “Communication
Mode” as “Block”, “Communication Code” as 001, 002, 003, 004. Select the compressor which’s
communication code is 001 and set to be the Host. Set “Block Unload Pressure” to be 0.82MPa,
“Block Load Pressure” to be 0.63MPa, “Rotate Time” as 2 hours, “Block Number” as 004, “Block
Delay Time” as 0040 seconds. After finishing the settings of the Host, enter into the operation
interfaces of the compressors which’s communication code is 002, 003, and 004, set these
compressors as Slave. After finishing all the settings, cut off the powers supply of all the
controllers for a few seconds and then reconnect the power supply.

(3). According to the locations of the compressors, prepare 4 communication lines for shielding.
These communication lines are used for parallel connecting the marked terminals A and B which
are located behind the display panels of the controllers. Then the network connection is finished.

(4). Manual start the compressor which’s communication code is 001; compressors operate
automatically in the Block Control System. The host sends control commands to the compressors
in the network according to its Supply Pressure, Block Unload Pressure and Block Load Pressure
in order to maintain the Pressure Balance in the gasholder.

(5). Stop the system: the user press the Stop Button on the host will stop the host. The host will not
send any control commands to the slave compressors in the network.

Case 2.

Now a user has 2 compressors supplying air to 1 gasholder. The preferred pressure of the
gasholder is between 0.6MPa and 0.8MPa. Usually only one compressor is needed for operation,
another one for spare, depending on the air consumption volume. When a compressor has been
working for 5 hours, the other one will start operating. When one breaks down in failure, the other
one starts working. Steps for setting Block Control:

(1). Test each compressor to make sure they work in good order independently. When “Normal
Stop” is shown on the screen of the Air Compressor Controller, enter into “User Parameter”, select
“Set P.T.” to set Unload Pressure and Load Pressure. In this case, we set the Unload Pressure as
0.8MPa, Load Pressure as 0.6MPa. In the actual circumstances, compressor model types, air
consumption volume need to be taken into considerations when setting the pressures.

(2). Enter into “User Parameter” interface, select “Operation Mode Preset”, and set
“Communication Mode” as “Block”, “Communication Code” as “001, 002”. Select the
compressor which’s communication code is 001 and set to be the Host. Set “Block Unload
Pressure” to be 0.78MPa, “Block Load Pressure” to be 0.62MPa, “Rotate Time” as 5 hours,
“Block Number” as 0002, “Block Delay Time” as 0040 seconds. After finishing the settings of the
Host, enter into the operation interface of the compressors which’s communication code is 002, set
this compressor as the Slave. After finishing all the settings, cut off the powers supply of all the
controllers for a few seconds and then reconnect the power supply.
 OPERATING ORDERS 36

(3). According to the locations of the compressors, prepare 2 communication lines for shielding.
The lines are used for parallel connecting the marked terminals A and B which are located behind
the display panels of the controllers. Then the network connection is finished.

(4). Start the compressor which’s communication code is 001; compressors operate automatically
in the Block Control System. After the host has start operating for 40 seconds, the host sends
commands to the compressors in the network according to its Supply Pressure, Block Unload
Pressure and Block Load Pressure in order to maintain the Pressure Balance in the gasholder. If
the pressure level is lower than the Block Load Pressure in the Block Control (here is 0.62MPa),
the host will send Start command to the compressor which’s address code is 0002. When Air feed
Pressure level is higher than the Block Unload Pressure (here is 0.78MPa), the Host will compare
its own running time with the running time of the compressors in the network, then pick the one
who has the longest running time for unloading (in this case, the host compares its running time
with the running time of No.0002 compressor). When the Host or any one of the Slaves has been
working for 5 hours, if there’s one compressor is at stop status, the Host will send it a Start
command and then send the compressor which has been working for 5 hours a Stop command to
realize the rotation. When the running compressor in the network stops in failure, meanwhile
there’s a compressor is at stop status. However the Host’s Air feed Pressure level is higher then the
Host’s Block Load Pressure which is set in the Block Control Parameters, the compressor will not
start operating until the Host’s Air feed Pressure level is lower then the set level in the Host Block
Control Parameter. The Host will send it (compressor at stop status) a start command to maintain
the pressure balance within the value extent which is set by the user.

(5). Stop the network: the user press the stop button on the Host, host will stop. The Host will not
send any commands to the Slaves in the network.

VI. Attention.

(1). In order to avoid the incident that the slave compressors not controlled by Block Control
System in the network, each Slave’s Unload Pressure value set in the User Parameter needs to be
higher then the Host (which’s communication code is 001)’s Block Unload Pressure set in the
Block Parameters; Loading Pressure value needs to be lower then Block Load Pressure.

(2). The Host’s communication code is 001. Only one Host is allowed in the network. Other
compressors’ communication codes are set in commands. Slaves using the same communication
codes are not allowed in the network.

(3). Every time after resetting the Communication Mode, power off reset is needed.

(4). When user want to start the Block Control System, what he need is selecting the Host,
pressing the Start button so that the network will enter into Block Control State immediately. The
host will control the slave compressors’ Start / Stop, loading / Unloading.
 37 OPERATING ORDERS
(5). When user wants to stop the network, press the Stop button on the Host to stop the Host. The
host stops and will not send any commands to the slave compressors in the network. After the host
stops operating, the user may control the Slaves’ Start / Stop, loading / unloading independently.

(6). When the network is at the Block Control Status, the Host power off, Block Control stops.
When power on again, the network will not enter the Block Control System automatically, the user
needs to press the Start button on the Host so that the system will start. If it is the Slave power off
and power on again, but the Host never power off and at the Block Control Status, the Slave will
automatically enter into the system. The Host will control the Slave according to the pressure
value.

(7). When the compressor breaks down in failure in the network, there will be alarm rang from the
display panel. After the user has solved the problem, he needs to press the Reset button on the
display panel. Keep pressing until the alarm stop.

VII. Term explanation.

Block Number: Block Number is set in the Host (which’s communication code is 001)’s Block
Parameter. The Maximum value is 016. That is 16 compressors are allowed in the network
including the Host.

Block Delay Time: In the Block Control System, after the Host has sent a command, it needs to
wait a while to send another command. For example, if the Host has send Start or Loading
command, the pressure level of the gasholder will not go up immediately. The Host needs a short
delay time (which is the Block Delay Time set here) to compare the Air feed Pressure and Block
Load Pressure. If the Air feed Pressure level is lower then Block Load Pressure, then the Host will
send command to the next compressor in order to avoid the frequent start / stop in the network.

Host: which’s Communication Code is 001. In the Block Parameter, such compressor’s Block
State is set to be the HOST. Only one compressor is allowed to be the host in the network. Block
Number, Block Unload Pressure and Block Load Pressure and Block Delay Time and etc. need to
be set in the Host.

Slave: Communication Code is 002-016. In the Block Parameter, these compressors’ Block State
is set to be the SLAVE. Slaves using the same communication codes are not allowed in the
network.

Block Load Pressure: set in the Host’s Block Parameter. In the Block Control System, when
Host’s Air feed Pressure level is lower than this set level, if there’s compressor at stop or unload
status, the Host will pick one and sends loading or start command to it.

Block Unload Pressure: set in the Host’s Block Parameter. In the Block Control System, when
Host’s Air feed Pressure level is higher than this set level, if there’re compressors still loading
running, the Host will pick one and sends unload command to it.
 OPERATING ORDERS 38
Attention: Every time after resetting the Communication Mode, power off reset is needed. To
initiate the network, the user needs to start the Host. Slave’s start / stop are controlled by the Host.
The Host power off, Block Control stops. When power on again, the network will not enter the
Block Control System automatically, the user needs to press the Start button on the Host so that
the system will start. If it is the Slave power off and power on again, but the Host never power off
and at the Block Control Status, the Slave will automatically enter into the system. The Host will
control the Slave according to the pressure value.

Fan Temperature control

When the air Exhausting temperature is higher than the fan starting temperature, the Fan motor
will run; when the air exhausting temperature is lower than the fan stop temperature, the fan motor
will stop running. If there is no fan or the fan is not necessary to be protected, set the starting
temperature of the fan to ‘120℃’ and the stop temperature to be ‘70℃’.

Failure stop and Emergency stop

When there is any electronic failure or high air temperature failures occurred during the running
process, the controller would stop the motor immediately. The motor can only be restarted after
the failures are cleared. Any emergency situation occurred, please press down the emergency stop
button to cut off the power supply of the controller and contactor power.

Alarm and Notices

Text Display tips

Air filter Alarm tips

Set the running time alarm of the air filter

The Text displays ‘Air filter life terminated’ when the using time of the air filter terminates.

Oil Filter alarm tips

Set the running time alarm of the oil filter

The Text displays ‘Oil filter life terminated’ when the using time of the oil filter terminates.

Oil separator alarm tips

Set the running time alarm of the oil separator

The Text displays ‘Oil separator life terminated’ when the using time of the oil separator
terminates.

Lubricate Oil alarm tips

The Text displays ‘Lubricate Oil life terminated’ when the using time of the lubricate oil
terminates.
39 OPERATING ORDERS
Lubricate Grease alarm tips

The Text displays ‘Lubricate Grease life terminated’ when the using time of the lubricate grease
terminates.

Main Controller Tips

Item Meaning and Functions Lights Status

POWER Controller Power on PWR Lights

RUN Controller run RUN Lights
Failure Detect failure and Stop the unit ERR Blinking
Input Switching Terminal 20～12 Input switching IN00~08 lights, but if there is no
Value value activate function at the input point, no light
Terminals
Output Switching
27,28,29,30,31,35,36,37,38 and OUT00~09 lights
Value
39 output switching value

Data Save Set Data and save time PWR blinking once

SAFETY PROTECTION

Motor Protection

EPC air compressor controller can perform the short-circuit protection, rotor lock protection,
overload protection, Phase Lacking Protection and Unbalance Protections to the motor.

Air Exhaust overheat protection

When the air exhaust temperature is higher than the set limited unload temperature, the controller
will alarm and stop the machine. Local Failure display ‘Air Exhaust High Temperature’.

Reverse running protection of the air compressor

When the phase sequence of the power connected to the air compressor is not conform to the set
of the controller, the local failure displays ‘ Wrong phase sequence’ and as a result the controller
can not start the motor. It is needed to check and alternate any two of the phase sequence and
investigate the motor rotation direction.

Over Pressure protection

When the pressure of the air exhaust is higher than the set unload pressure of the controller, the
controller will alarm and stop the machine, the local failure displays ‘Pressure too high’.
 OPERATING ORDERS 40
Sensor Failure Protection
When the cable of the pressure sensor or the temperature sensor is broken, the controller will
alarm and stop the machine and the local failure displays ‘** sensor failure’.

Interlock Protection
The Host is running and the air exhaust temperature reaches the Fan starting temperature but the
Fan does not run, the controller alarm, the local failure displays ‘ Fan is stopped’

Common Failure Solving

The failures caused by the peripheral equipments of the controller could be investigated by
queering from the local failure record or the history failure record to find out the failure causes
and solves the relative problem.

Temperature sensor Failure

170℃

Check the Temperature sensor to confirm if there are any line broken or damage of this equipment.

The detailed method for inquiry of history failure is as the following：

Press the button ‘v’ or ‘u’ to move the black cursor over the menu ‘ Run Parameter’ and then press
the confirm button ‘t’ to popup the submenu as the following:

MOTORS CURRENT
TOTAL RUN TIME:
CURRENT RUN TIME
MAINTENANCE

Press the button ‘v’ repeat to popup the following menu:

HISTORY FAULT
PROD. DATE/NUM
CURRENT FAULT

Press ‘t‘ to reach the history failure cause:

41 OPERATING ORDERS

HAZARDOUS VOLTAGE.
Disconnect main power supply before servicing.
Lockout/Tag out machine.

HIGH PRESSURE AIR.

Ensure the machine come to a full stop.
Release all pressure before performing maintenance.

ROUTINE MAINTENANCE

This section refers to the various components which require periodic maintenance and
replacement.

It should be indicated that t components’ descriptions and the intervals when maintenance has to
take place.

Ensure that maintenance personnel are adequately trained, competent and have read the
Maintenance Manuals.

CAUTIONS PRIOR TO MAINTENANCE：

„ Ensure that the compressor is FULLY SHUT– DOWN, power isolated and all air pressure
Released from the system..
„ Ensure that the machine cannot be started accidentally or otherwise；
„ Tag warning or caution signs, and install extra anti-start device.
„ All residual electrical power sources (mains and battery) are isolated.

Prior to opening or removing panels or covers to work inside a machine:

„ Notice hot surfaces and intermittently moving parts；
„ Tag warning or caution signs, and install extra anti-start device；
„ Attention to anti-slippery.

PRIOR TO MAINTENANCE ON THE RUNNING MACHINE:

„ Limit to operations of the running machine；
„ Understand the existing danger（electrified components, high temperature, in/out air flow,
safety valve discharge, pressurized components）；
„ Warning signs posted in a position that can be clearly see，indicating Maintenance Work is in
Progress；
„ Individual safety protection should be worn.
 MAINTENANCE 42

Upon completion of maintenance tasks and prior to returning the machine into
service, ensure that:

„ All guards and safety protection devices are refitted and correctly working；
„ All panels are replaced, canopy and doors closed；
„ The machine is suitably tested；
„ Hazardous materials are effectively contained and disposed of in a manner compliant with
local or National environmental protection codes.

DO NOT operate the compressor when discharge pressures exceeding the maximum operating
pressure.

CLEAN COOLER

Fully inspect all external surfaces, and fittings every month. Record and clean up any trapped oil
dirt.
Blow compressed air in a reverse direction from cooler’s air discharge side to keep the cooling
pipeline ventilate.

REPLACE OIL FILTER

„ Unscrew oil filter；

„ Mount new oil filter/element on the position；
„ Check coolant level；
„ Start the machine and ensure no leakage；
„ Put old oil filter into plastic bag, handle them in accordance with local regulation.

Please use specialized UNITED OSD oil filter/element

CHECK COOLANT LEVEL

Check coolant level regularly, recommending once per day. Refill when the oil level lower than
designed limits.
43 MAINTENANCE

REPLACE COOLANT

High temperature occurs when release hot oil.

„ Stop the machine, release hot oil；

„ There is drain valve at the bottom of air/oil tank drain bowl. Please directly discharge into the
container；
„ Open the drain valve and drain coolant into container；
„ Close the drain valve and refill coolant；
„ Dispose waste oil in accordance with local regulation.

NOTE:
Coolant level is correct when a unit is showing coolant in bottom half of sight glass when up to
operating temperature (ten minutes running loaded).
Please use original UNITED OSD coolant. Mixture with other
lubricants or replacement is forbidden due to incompatibility.
Otherwise UNITED OSD will not obligate for the problems such as
deterioration of oil, coking, which cause the air-end lock.

Shorten replacement interval of coolant when the ambient environment is

bad.

Stop the machine, electrically isolate and vent all trapped pressure.

REPLACE AIR FILTER ELEMENT

„ Remove fill cap and plug from drain valve, then demount the air filter element；
„ Install new air filter element，Rebuild in reverse order；
„ Remove the element from the housing; place it in a sealed bag and dispose of it in accordance
with local safety regulation.

If the working ambient environment is inferior, please shorten element

replacement interval.

Please use specialized UNITED OSD air filter element.

 MAINTENANCE 44

REPLACE AIR/OIL SEPARATOR

„ Loosen separator element with the correct tool；

„ Remove the element from the housing; place it in a sealed bag and dispose of it safely；
„ Clean the mating face of the housing;
„ Apply a small amount of lubricant to the element seal;
„ Screw the new element down until the seal makes contact with the housing, then hand tighten

This unit is not designed or intended to operate when contaminated with

silicone. Lubricants, greases or other items containing silicone should not
be used on this unit.

Please use specialized UNITED OSD separator element

AIREND BEARING

Air end bearing lubricated by coolant , Maintenance is Unnecessary.

 45 MAINTENANCE
Attached: PERIODIC MAINTENANCE TABLE
Replacing intervals（ｈ）hours Remark
Item Content
500 1000 2000 4000 8000 16000 24000
Prolong or shorten
Clean external dusts 〇
Air Filter replacing interval
Replace element of filter ● according to dust volume

Quality coolant ◎ ● sample once every week，check

Specialized coolant
Super coolant ◎ ● oil. replace when necessary
Suction Valve Check 〇 replace when need
Prolong or shorten replacing
◎ ●
Oil Filter Replace new filter interval according to working
condition
Prolong or shorten replacing
●
Oil-air Separator Replace new separator interval according to working
condition
MIN. Pressure Valve Check 〇 ●
Clean external dusts 〇 Air cooled. Prolong or shorten
De-Dust Cooler
Decaled Cooler 〇 according to the working condition

Clean internal scale 〇 Water cooled. Prolong or

Decaled Cooler shorten according to the
Decaled Cooler 〇 working condition
Safety Valve check sensitive or not 〇 Check start pressure
Check 〇
Thermostatic valve Check performance
Replace new one ●
Solenoid valve Check 〇 ●
Pressure gauge check 〇
Drain Valve Check whether blocked * 〇
discharge condensate in
Condensate drain 〇 Discharge every week
oil tank 〇
Add grease ● The period of four-poles grease
Motor filling is once longer than the
Insulation Test normal one.
check main connection Check when first start the
Electric 〇
and poles compressor
Replace a new one when
Belt check and adjust n 〇
necessary
It can be prolonged according to
Air end bearing Replace a new one ●
the performance
Air end bearing Replace a new one ●
Motor bearing Replace a new one ●
elastomer Replace 〇 ● Replace when necessary
Clamp ring Replace 〇 ● Replace when necessary
 MAINTENANCE 46
Remarks:*--- Regular Maintenance in clean working environment according to above intervals. Shorten
Maintenance interval for belt, coolant, oil filter, air filter element and oil fine separator in curviness working
condition.
*+---replacement interval of quality coolant is 4000hours or one year,whichever comes first
*++---replacement interval of super coolant is 8000hours or two year, whichever comes first
When carrying out regular maintenance, please check air/oil tank, airdischargepipeline, cooler as well as
components conducting and bearing heat, clean oil scale and accumulated carbon subjects.
◎first time replace〇check、clean ●replace
Attached: TROUBLE SHOOTING TABLE

Malfunction Possible Causes Solution

1. The fuse is burnt.

Compressor cannot start.
Running current is high. The
compressor stops by itself.
(Alarm due to excessive hot
of Air end )
Discharge temperature is
lower than normal level.
Discharge too much oil in
compressed air
Air flow is blow normal
level.
Oil return from the air filter
after stop.
Safety valve puff away.
2. Malfunction of start-up of electrical equipment.
3. Ill connection of start-up of button.
4. Ill connection of circuit.
5. Voltage is too low. Ask qualified electrician for overhaul and
6. Malfunction of motor. replacement.
7. Malfunction of air end. (Abnormal noise and feel part
of the air end too hot.)
8. Lack phases of power supply.
9. Overload of fan motor.
1. Voltage is too low. 1. Ask electrician for overhaul.
2. Discharge pressure is too high. 2. Check/regulate pressure parameters.
3. Jam of oil-air separator core. 3. Replace with new pats.
4. Malfunction of air end. 4. Disassembly, examine and repair.
5. Malfunction of circuit. 5. Ask electrician for overhaul.
1. Invalidation of thermostatic valve. 1. Examine, repair and clean or replace
2. A long time in vacancy of ON. valve core.
3. Invalidation of discharge temperature sensor. 2. Increase air consumption.
4. Invalidation of suction valve, suction inlet does not 3. Examine and replace.
open fully. 4. Clean and replace.
1. Core of oil-air separator broken. 1. Use new subassemblies.
2. Jam of valve. 2. Clean the valve.
3. Too much lubricating condensate. 3. Discharge part of oil.
1. Remove impurities or use new
1. Jam of air filter.
subassemblies.
2. Jam of oil-air separator core.
2. Use new subassemblies.
3. Blowy of electromagnetic valve.
3. Clean out or use new subassemblies.
4. Leakage of pipeline.
4. Examine and repair.
5. Suction valve cannot be open fully.
5. Clean out or use new subassemblies.
Invalidation of spring or sealed ring is broken. Replace broken subassemblies.
1. Safety valve runs too long. 1. Use new subassemblies or regulate
2. Invalidation of pressure control and working pressure again.
is too high. 2. Examine or regulate it again.
 47 MAINTENANCE

Attached: COMMON ELECTRIC FAILURE AND CAUSES

CAUSES MEASUREMENT TO TAKE

FAILURE
Air Exhaust Temperature too
Bad vent condition, Oil lacking etc. Check the vent condition and lubricant amount etc.
high

Temperature Sensor Failure Cable off or PT1OO damaged Checking the wiring and PT100

The pressure too high or the pressure

Over Pressure Check the pressure and the pressure sensor
sensor failure
Cable off, Sensor damaged or the cable
Pressure Sensor Failure Check the wiring and sensor transformer
connected reversed

Water Lacking Water Pressure switch damaged Check the water pressure switch

Power phase lacking or the Contactor

Phase Lacking Check the power and contactors
terminal damaged
Voltage too low, tubes blocked, Bearing
Check the set data, Voltage, bearings, tubes and other
Overloaded Wear off or other mechanical failure or
mechanical system.
wrong set data etc.
Power unbalance, Contactor damaged
Unbalance Check the power, contactors and the motor
or the internal open of the motor
Voltage too low, tubes blocked, Bearing
Check the set data, Voltage, bearings, tubes and other
Rotor Lock Wear off or other mechanical failure or
mechanical system.
wrong set data etc.
Wrong Wiring, Incorrect Data setting
Short Circuit Checking the wiring and set the data correctly
etc.

Wrong Phase Sequence Reversed Phase sequence or phase off Check the wiring

Fan damaged, Contactor damaged, no

Fan stopped Check the wiring and control output
control output
Overload or Rotor locking Host start time set to a valueless than Reset the host starting time to be longer than star
during starting process the star angel time delay angel delay + Load delay time
Main Contactor activate
The emergency button loose Check the wiring
time to time
 MAINTENANCE 48

Attached: RECORDS OF MAINTENANCE

Accumulated Oil-air
Air Filter Oil Filter Replace Greasing
Running time Separator Date Signature
(Element) (Element) Coolant motor
（h） (Element)
 49 Compressed air dew point temperature table
To make the compressor run more stable, water does not condensate in the oil. According to

the ambient temperature, relative humidity, the discharge pressure of the compressor, the lowest

discharge temperature which compressor required when load can be look up from table. Attach a

profile table for reference.

Suction
Temper- Discharge
Dew ature pressure
（℃）
point 0.7 0.8 1.0 1.3
temp
Relative
（℃）
humidity

20 44.5 46.8 50.8 55.8

50 30 56.6 59.1 63.4 68.8

35 62.6 65.2 69.8 75.4

20 48.1 50.4 54.6 59.7

60 30 60.4 63 67.5 73.1

35 66.7 69.3 74 79.8

20 51.2 53.6 57.8 63

70 30 63.8 66.4 71 76.7
35 70.2 72.9 77.7 83.7

20 53.9 56.4 60.7 66

80 30 66.8 69.5 74.2 80

35 73.3 76.1 81 87.1

20 56.4 58.9 63.2 68.6

90 30 69.5 72.2 77 82.9

35 76.1 78.9 83.9 90.1

Remark: 1) When the discharge temperature higher than dew point temperature, water does not
condensate in the oil.

2) Other data please check the table. JB/T6430-2014 General oil-flood screw air
compressor Page8 Curve table, attached table is in next page.
Minimum exhaust temperature of the machine should be higher than
the dew point temperature, otherwise the water in compressed air will
condenses. It will affect the oil life when the water content of the oil
accumulates, resulting in oil emulsion and bearing damage.
 Compressed air dew point temperature table 50

Attached: Compressed air dew point temperature table