SCREW AIR COMPRESSOR

Installation, Operation and Maintenance Manual

Shanghai Screw Compressor Co.,Ltd

Thank you for choosing SCR for the supply of your air compressor. This manual

will help your better understand the use of your industrial air compressor. Your

feedback and suggestions are welcome.

We have tried to ensure the integrity and accuracy of this manual; however we

reserve the right for continuous research and improvement on our products and

assume no responsibility for any modifications or improvements on previously

delivered products. The design of products is subject to the change without notice.

Production license:
Model number of compressor:
Serial number of compressor:
Model number of motor:
Serial number of motor:

1
 Preface
This operation manual describes the safety precautions, structure and functions of all systems
and components, as well as the operation and maintenance methods for the SCR series screw
air compressors.
The operators should read the operation manual carefully. Only after thorough understanding of
the structure and functions of all systems and components as well as the safety precautions, can
they start operating and maintaining the unit. In addition to the descriptions in the manual, if the
user fails to follow the operation and maintenance procedures in the manual for the operation
and maintenance, or dismantles and modifies the machine by itself, or uses parts not specified
by SCR, the user shall forfeit the right for any warranty claims.
There is no catalogue for the illustrations of parts and components given in the manual. If you
want to order parts from our company, please consult the parts manual for relevant units. It is
noted that SCR is continuously researching and improving its products and the contents of part
manual may vary from the actual products. Before you order the parts, please confirm with the
service (parts) department of our company in advance.
This operation manual gives a general description of the motor, electrical system and
maintenance. However, if you have any questions before operating and maintaining the unit,
please contact your local dealer or SCR service department.

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 Standard Warranty Clause
SCR provides the following warranty on the manufacturing process and material defects for the screw air
compressor manufactured by itself in the conditions of normal operation, maintenance, repair and service.
Compressor unit: within 16 months after the ex-factory date of delivery,or within 12 months after
commissioning, the earlier shall prevail;
Compressor airend returned for repair: within 6 months after the ex-factory date of delivery;
Spare parts (except for filters and oil): within 9 months after the ex-factory date of delivery,or within 3
months after commissioning, the earlier shall prevail.

For products not manufactured by SCR, the warranty clause of the original manufacturer shall be directly
applied in feasible conditions. Within the warranty period, SCR or the agent should be informed in writing
within 3 days after the defects are discovered, and the details shall be attached for identification, including
the ex-factory serial number, model, purchasing date, etc.

The single responsibility assumed by SCR in the warranty clause is to repair or replace the products or
parts which are proven defective according to the evidence. If necessary, SCR can ask the users to return
the defective products or parts to the factory for inspection with freight prepaid.

SCR holds the warranty period of 3 months or the remaining warranty period for the repaired products,
parts or replaced parts in the conditions of normal operation, maintenance, repair and service.

The warranty clause is not applicable to the following responsibilities and SCR assumes no responsibility
or obligation:
A. Indirectly caused, incidental or special losses or damages.
B. Damages caused due to the normal wear, abnormal operating conditions, neglect or wrong
operation of equipment, poor storage or transport.
C. Failure to follow the stipulations in operation instructions, regulations or other special sales
conditions.
D. Labor cost, losses or damages caused due to wrong operation (running), maintenance and repairs
performed by the maintenance personnel authorized or not authorised by the Buyer.
E. Improper use of products.

In any cases, the compensation obligation of the Seller shall be limited to the scope of the selling price,
regardless of the claims caused due to the termination of the contract or the warranty against product
neglect.

The warranty clause is the sole warranty clause for the Buyer. Any other warranty clauses,
whether clearly stated or implied in the law, or are implied in the factors, including any
commercial warranty clauses and the ones applied to some special purposes, are excluded and
shall not be accepted.

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 Safety Warning Signs
In this manual, the operations and items related to the safety are identified for their risks, and they are
classified based on the severity of machine damages and the level of injuries caused due to the operations.
They are represented and described in boldface with the following signs respectively.

“Caution” is meant to indicate unsafe factors which may cause general damage to the machines or
injuries.

“Warning” is meant to indicate unsafe factors which may cause property loss or injuries.

“Danger” is meant to indicate unsafe factors which will cause severe accidents or injuries.

“Danger” is meant to indicate an unsafe factor which has voltages exceeding safe levels enough to
cause severe injuries. All electrical operations shall be performed by qualified electricians.

“Caution” is meant to indicate unsafe factors which have hot surfaces enough to cause property loss or
injuries.

“Caution” is meant to indicate important installation, operation and maintenance information.

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 Safety Tips
Please read the following information carefully before operating and using the compressors

Warning
There are risks that are present in compressed air and the compressed air system!
If you fail to follow the operating procedures and safety precautions in the operation
manual, there may be accidents and injuries to yourself or other persons!
Before operating and maintaining the compressors, you must read carefully and
understand the operating manual!

The detailed instructions are given to indicate safety precautions which should be followed whilst operating the
machines and the places with risks in the Chapter 1. ”Safety Rules”. Before operating the machine, ensure the
clear warning labels have been attached to all relevant areas with risks and the areas requiring careful
operations.

1. Before any operation or maintenance on the unit, you must read and understand the operation manual.
2. Do not operate the unit above the rated air discharge capacity pressure of the unit. Otherwise, an overload
will occur to the motor and it will be damaged.
3. Before the unit is delivered, individual protection controls will be preset. Do not modify or remove the
control components of the unit. Otherwise, severe equipment damage may occur and personal injuries
may be caused.
4. When the unit is operating, Do not remove or loosen any pipeline elements, joints and connectors or
remove the safety valve.
5. The unit is full of the pressurized thermal working medium, which can cause severe injuries.
6. Prior to any maintenance on the unit, you must confirm that:
 The unit is stopped;
 The internal pressure in the unit has been discharged;
 The power supply is shut off.
7. Only a safe solution is to be used to clean the compressors and the auxiliary equipment of the unit.
8. Once any parts have failed, they must be replaced immediately. Otherwise, further damage may be
caused.

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Contents
Chapter 1. Safety Rules
1. G e n e r a l r u l e s …………………………………………………………………………. 8
2. C o m m o n p r e c a u t i o n s … … … … … … … … … … … … … … … … … … … … … … … … … … … … 8
3. P r e s s u r e r e l e a s i n g …………………………………………………………………………9
4. O p e r a t i n g c o m p o n e n t s … … … … … … … … … … … … … … … … … … … … … … … … … … … … . 9
5. High-temperature surface, sharp corner and sharp edge ……………………………………….9
6. To xic and irritant s u bsta nces ……… … ……… …… ……… …… ……… …… ……… ….. ……. 10
7. L i f t i n g … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … . 1 0
Chapter 2. Introduction to System Functions
1. I n t r o d u c t i o n … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … . . 11
2. Compressor airend and compression cycle ……………………………………………………..12
3. A i r i n l e t s y s t e m … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … 1 2
4. Air discharge system of compressor…………………………………………………………….13
5. Cooling and lubricating system of compressor …………………………………………………14
6. Air flow adjustment and control system of compressor …………………………………..…….16
7. Electrical system and automatic protection ……………………………………………………..18
8. C o n t r o l i n d i c a t i o n p a n e l … … … … … … … … … … … … … … … … … … … … … … … … … … … 2 0
9. E x t e r n a l c o v e r a s s e m b l y … … … … … … … … … … … … … … … … … … … … … … … … … … … 2 1
Chapter 3. Installation and Acceptance
1 Installation, acceptance and storage …………………………………………………………….22
2 Installing and locating ……………………………………………………………………….…23
3 Storage and maintenance of the unit ……………………………………………………………24
4 Pipe connection …………………………………………………………………………….…24
5 Installation of safety facilities …………………………………………………………………. 26
6 Electrical installation ……………………………………………………………………….…..27
7 Water supply and drainage (water cooling type)…………………………………………….… 27
8 Adjustment and c alibration of belt ………………………………………………………….….27
9 Adjustment the coupling ……………………………………………………………...…....29
Chapter 4. Operating Procedures
1. O v e r v i e w … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … . … . 3 2
2. Preparation for the starting ………………………………………..………………………….....32
3. R e g u l a r s ta r t i n g s t e ps … … … … … . . … … … … … … … … … … … … … … … … … . . … … … . . … . . 3 2
4. S h u t d o w n p r o c e d u r e … … … … . . … … … … … … … … … … … … … … … … … … … . . … … … … … . 3 3
5. E m e r g e n c y s h u t d o w n … … … … … … … … … … … … … … … … … … … … … … … … … … … … 3 3
Chapter 5. Parameter Setting and Adjustment of Working Conditions
1. Introduction to the operations and parameters of the intelligent controller………………………. ..34
2. Sta t u s D i s p l a y A n d O p e r a t i o n ……………………………………………………………....34
3. Functions and technical parameters ………………………………..……………………... .40
4. Controller Connect Terminals Instruction. ……………………..………………………….....40
5. Control Principle (Refer to the attached for the Electric schematic circuit) ………………... 41
6. A l a r m a n d N o t i c e s …………………………………………………………….…………... 43
7. S a f e t y P r o t e c t i o n … … … … … … … … … … … … … … … … … … … … … … … . … … … … … … … . . 4 3
8. H a n d l i n g o f c o m m o n f a i l u r e s … … … … … … … … … … … … … … . … … … … … … … … … . 4 4
9. Parameter setting of intelligent controller in the standard unit. ……….……………………... 45
10. Settings of capacity adjusting valve ……….…………………………….………………………47

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Chapter 6. Maintenance and Service
1. Preparations before maintenance and service ……….……………………….………………….. 48
2. Maintenance and service of screw compressor ….……………………..……..…….………...….. 48
2.1Lubricating oil of compressor ………………………………………………………………….48
2.2 O i l f i l t e r ……………………………………………………………………………………...51
2.3 S a f e t y v a l v e … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … . 5 1
2.4 S e c o n d a r y o i l r e t u r n p i p e … … … … … … … … … … … … … … … … … … … … … … … … … … … . 5 1
2.5 O i l c o o l e r … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … . … . 5 2
2.6 A i r f i l t e r … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … . . . . 5 2
2.7 A i r - o i l s e p a r a t o r … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … 5 3
2.8 A i r i n l e t a d j u s t i n g v a l v e … … … … … … … … … … … … … … … … … … … … … … … … … … . … . . . 5 4
2.9 Control pipeline filter (water filter cup) ……………………………………………………………….….….55
2.10 Maintenance of pressure regulator (capacity adjusting valve) ………………………….….…..57
2.11 Maintenance of minimum pressure valve …………………….….…………………………….57
2.12 B el ts a n d b e lt p ul l ey s … ……… … … …. … … … ……… . …… …… … …… …… … …… …… …. 5 7
2.13 Maintenance and replacement of thermostatic valve ….…………………………….………….58
2.14 H o s e … … … … … … . … … … … … … . … … … … … … … … … … … … … … … … … … . … … … . … . 5 8
2.15 Installation of shaft seal ………….……………………………………………….…… ..….….58
3.Maintenance and service of the motor …………………….………………………….…… ..…....60
4.Service plan ….………………….……….….………………….………………….……….......63

Chapter 7. Troubleshooting
Failure 1: Over-High discharge air temperature ….………………….…………………………...65
Failure 2: Oil over-consumption ….……….….………………….………………….…….….…..66
Failure 3: Overload or blockage of main motor ….….………………….………………..….…......67
Failure 4: Abnormal shutdown during operation …………….…………………………..….……..68
Failure 5: Air generation without loading ….……….….………………….…………………..…...69
Failure 6: No unloading when pressure reaches high limit ……………….………………………..70
Fail ure 7: Low air out put ………….……….….………………….…………………. ….…….....71
Failure 8: No indication on display screen ….……….….………………….……………..…..…...72
Failure 9: Indicating the data without starting (failing to start) ……………….……………..….....73
Failure 10: Too low pressure in air tank ….……….….………………….…………….…………...74
Failure 11: Too high pressure in air tank….……….….………………….…………….……….…..74
Failure 12: Frequent blockages in oil/gas separator.….………………….…………….………......75
Failure 13: Frequent blockages in oil filter.….………………….…………….…………………...76
Failure 14: Frequent blockages in air filter ………………….…………….……….…………..…..76
Failure 15: Frequent switching between loading and unloading ……….…………….……..….…..77
Failure 16: Excessive water content in compressed air at discharge end….……………..……....77
Failure 17: Abnormal opening of safety valve …………….……….……………….….…….…...78
Failure 18: Abnormal noises in the air compressor …………………………………………………………….79
Failure 19: Oil injection in suction valve during shutdown…………………………………………………….. 79

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Chapter 1. Safety Rules

1. General rules

The following listed safety measures and safety precautions are only a part of the measures which has to be
followed for operating the compressors and compressed air system, but are not complete.

Warning
If you fail to follow the following safety measures, injuries, property loss or compressor
damages will be caused.

Only trained and authorized persons are allowed to operate the compressor. Prior to any operations, the
operation manual should be carefully read and its contents should be comprehensively understood. If you fail
to follow the operation and maintenance procedures and safety rules in the operation manual, then accidents
and injuries are possible.
It is never allowed to start the unit in an unsafe condition; if a problem occurs to the unit, do not attempt to
start the unit. The power supply should be shut off and a sign/tag should be attached to prevent the persons
not knowing the condition from wrongly operating.
Compressed air is hazardous. Only when the compressed air is totally discharged in the whole
compressor system, can maintenance and service can be performed on the unit.
Do not change the internal structure and control mode of the unit, unless the written permission from SCR is
given.
The daily service and maintenance should be performed diligently. The unit should be carefully inspected
every day to check for conditions such as leakage, loose, damaged and poorly adjusted parts. If a problem is
discovered, it shall be rectified prior to start up.

2. Common precautions

1) Before repairing the machine, all power supplies and any possible long distance control devices should be
shut off, locked and identified.
2) If the unit is stopped, do not assume that it is safe. The unit has automatic starting and stopping devices
and starting is possible at any time.
3) The compressor is designed to compress only general air. Other gases or steams are not to drawn into the
inlet of the compressor or to flow through the compressor.
4) Only safety relief valves with proper size should be installed in the system and shall be located before the
suction valve, heat exchanger, restriction orifice or any potential blockage points. If no safety relief valve is
installed, then damage of compressor or compressor parts or an explosion may be caused.
5) Do not change the pressure setting of safety relief valve, or limit its function, or replace it with a plug.
Otherwise an over-pressure will be caused to the compressor parts or system, consequently resulting in
injuries and property loss.
6) Do not use plastic pipe, rubber pipe or brazed connecting pieces in the compressed air system. If the safe
connection between the compressor pipes and system pipes cannot be guaranteed, then joint damage
may be caused.
7) Do not use combustible or toxic solvents to clean the air filter or any other components.
8) When the compressor is operating, don’t remove any protection cover or cabinet doors. It is prohibited to
service or repair any parts in the unit when the machine is operating.

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9) When the compressor is operating, it is suggested to observe the meters and record, ensuring the normal
operation of compressor.
10) Follow the stipulations in the maintenance and repair procedures and periodically inspect all safety
devices, ensuring that they are in a good condition.
11) Do not allow the high-temperature protection switch (probe) to short circuit, become blocked or be
removed.
12) It is prohibited to play with compressed air, always minimise risks.
13) Follow the maintenance and repair procedures and only use the proper lubricating oil.
14) When the unit is operating, don’t open the cover, to avoid personal injury.
15) Before installing the cabinet, ensure that the area is clean, safe and secure.

3. Pressure releasing

1) Operate the safety valve at least once every week and inspect whether there is a blockage or other
damage present. Do not pull the handle of safety valve when the unit is pressurized.
2) Confirm that the installed pneumatic equipment, air hose, pipe fittings, valves, filters and other
accessories are in a good condition and the operating pressure is not above the rated pressure.
3) Before opening the oil filling cap of Air-oil separator tank, the machine should be stopped and you should
ensure that the unit is not pressurized.
4) When removing any pipe fittings, valves, and oil drain plugs as well as the parts and components such as
oil filters and Air-oil separator, you should ensure that no pressure is present inside the system.
5) Do not vent the compressor whilst running.
6) Only compressed air with a pressure below 30 psi (2.1 bars) can be used for dust removal. During the
actual operation, the protection equipment such as dust protection cover should be installed. It is
permitted to use compressed air with a pressure above 3 bars for maintaining the air filter element; but
you shall ensure that the compressed air is used safely. The service person should perform the operation
using the necessary personal safety protection equipment.

4. Operating components
1) Hands, arms and other body parts as well as clothes should not touch the operating components, such as
coupling, fans, etc.
2) After removal of protection covers at the fan, coupling or other components do not operate the
compressor.
3) During operation, especially in areas of high-temperatures or rotating components, the tight fitting clothes
should be worn and the long hair shall be tied back.
4) The door on the unit should always be closed unless it is for maintenance.
5) It should be ensured that the area is clear before starting.
6) The lubricating oil shall be filled only after the machine is stopped.
7) It maybe required that adjustments to the capacity regulating valve or pressure maybe required whilst the
unit is operating. During the adjustment, do not touch other operating components and electrical
components. Other adjustments should be made only after the machine is stopped.
8) Oil and water leakage around the unit should be cleaned immediately to prevent slipping and personal
injuries.
5. High-temperature surface, sharp corners and sharp edges
1) Do not touch hot oil, lubricating fluid and high-temperature surfaces or sharp edges and corners.
2) No part of body should face the air vents of compressors and cooling fans.
3) When operating or maintenance tasks are being performed inside the unit or surrounding the unit,
protection equipment such as gloves, safety glasses should be worn.
4) A first aid box should be equipped and readily available. Medical treatment should be made immediately
after a person is injured. Report all injuries.

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6. Toxic and irritant substances
1) If the compressed air produced by the compressor is directly applied for respiration or food processing,
then severe injuries or death may be caused. The compressed air supplied for the above purposes should
meet the stipulations in OSHA 29 CFR1910.134 or FDA 21XDE178.3570 standards.
2) Avoid the skin contact and swallowing the lubricating oil (fluid). If skin contact is made inadvertently, then it
should be washed immediately with the soapy water. If swallowed inadvertently, you should see a doctor
immediately.
7. Lifting
 Prior to lifting, please carefully inspect lifting lugs to insure that they are free from cracks, deformation
or corrosion. Please also insure that all lifting straps are secure.
 You should ensure that the selected lifting equipment, hangers and riggings are in safe condition and
are able to withstand the weight of the unit. If the weight of the unit is not clear, you can weigh the unit
or consult the local agent before hoisting.
 The lifting hook should have a safety detent which can securely catch the lug or lifting chain.
 The unit should be guided with a rope to prevent the hoisted unit from turning or swinging.
 Do not lift the unit when a strong wind is present.
 After the compressor unit is lifted, do not stand under it.
 After it is has been lifted, the lifting operator should not leave the controls.
 Only lift the unit to a sufficient height to clear obstacles.

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Chapter 2. Introduction to System Functions

1. Introduction

The SCR I series screw compressor unit, designed and manufactured by SCR, is a positive displacement type,
single-stage and oil-injected double-screw compressor. The motor is connected to the male rotor of
compressor airend via a belt or elastic coupling to drive the compressor. The compressor airend is originally
imported from a quality assured German manufacturer, and therefore the unit has good dynamics, economical
efficiency and reliability.

The unit has a logical layout, complete functions, simple operation and maintenance, and modern design. The
unit consists of the compressor airend, air inlet system, air discharge system of compressor, cooling and
lubricating system, air flow adjustment and control system of compressor, instrument control panel, electrical
and automatic protection system etc. In addition to the excellent acoustic absorbing material, the unit has a
fully enclosed silent type design which can reduce the noise of the unit to a minimum level. All instruments,
indicators and control devices are centralized on the control panel for convenient operation; all components
are installed on a high-strength steel frame for a long-term stable and reliable operation.

An illustration of a model is quoted in the manual for the description of the system. For the structure of other
models, please refer to the quoted illustrations in the manual, as the structures and functions of individual
systems are similar or alike. To maintain the best operating status of your purchase, please read the details in
Chapter 5 Maintenance and Service Procedures in the operation manual. If you have any difficulties which are
not mentioned in the operation manual, please contact the local agent of SCR or the After-Sales Service
Department of SCR.

Control
panel Air inlet system

Driving system

Cooling and
lubricating system

External cover

Air discharge system

Electrical Air-oil separator Compressor airend

cabinet

11
2. Compressor airend and compression cycle

The compressor airend (main machine) is a very important component in the screw compressor unit. The
carefully designed single-stage oil-injected cooling and lubricated screw compressor can provide a stable
compressed air flow without air flow ripple. Compared with other types of compressor airends, the unique
property of the airend selected by SCR has extremely high mechanical reliability and durability, and the
working component achieves requirements of the “inspection-free” process. In addition, no frequent
maintenance and internal inspections are required during operation.

In the housing of the compressor airend, there is a pair of parallel rotors (male rotor and female rotor) with
spiral slots, which are finely processed. The air inlet and outlet are provided in the diagonal positions of the
outside box at both ends of the rotors. The threaded slot of female rotor engages with the threaded teeth of
male rotor, and it is driven by the male rotor. During operation, the air flows into the housing via the air inlet at
the power input end. When the rotor turns through the edge of suction hole in the housing, part of suctioned air
is trapped into the enclosed volume which is formed by the female and male rotors and the housing. The
closed volume of threaded slot changes with the engaging movement of the female and male rotors, and
consequently the continuous operation cycle for suction, closing, compression and discharge will be realized.
The compressed air will be discharged via the air vent and then enter into the Air-oil separator.

3. Air inlet system

See Fig. 2-2, the function of air inlet system in the compressor unit is to provide clean air to the compressor. It
includes an air filter, a suction valve and connecting pipeline. At the outlet of the air filter, a vacuum
pressure switch or vacuum indicator is installed.
The air filter adopted in the unit is the dry heavy duty filter, which can be used in the extremely severe
operating environment to handle very dirty air, ensuring the normal operation of the compressor. In addition to
the main filter core, there is a cyclone separating blade ring outside the main filter core in the outside box. It
can pre-filter the relative coarse dust particles. The operators shall frequently remove the dust particles
accumulating in the dust bag at the rear cover of air filter. When the vacuum pressure switch in the air filter acts
or the vacuum indicator turns to red, it indicates that the flow resistance in the air filter is too high and the main
filter core shall be maintained or replaced in time. In addition, some models have a safety filter core, which has
the function for temporary protection in a short-term in the case that the main filter core is damaged. The safety
filter core usually requires no maintenance and shall be replaced only while the main filter core is replaced.

Caution
The aperture of the safety filter core is larger than that of the main filter core. It only
has temporary protection for a short time (4-6 hours) after the main filter core has
failed. Therefore, once the main filter core has failed, it should be replaced immediately.
Otherwise, it may cause premature failure of the compressor rotors, damaged
bearings etc.

The connecting elbow of the air inlet system adopts a high-quality moulded rubber pipe fitting, which has the
properties of relatively good cold resistance, heat resistance and aging resistance. To ensure reliable sealing,
all the joints in the air inlet system of the unit should have stainless steel T-type bolt clamp for connections.

12
 Warning
Always use the correct clamps and correct rubber fittings.

1. Air filter core

2. Clamp

3. Air filter assembly

4. Air inlet guide pipe

5. Suction valve

Fig. 2-2 Air inlet system

4. Air discharge system of compressor

The air discharge system of compressor unit mostly consists of air discharge pipe, Air-oil separator,
minimum pressure valve, safety valve, after-cooler and etc. See Fig. 2-3.
When the compressor is operating, the air inside the closed volume of threaded slot is continuously
compressed and the heat generated in the air during the compression is absorbed at the same time by the
lubricating oil which is continuously injected into the closed volume of threaded slot. When the closed volume
of threaded slot is reduced to a certain value (designed value), the closed volume of threaded slot is connected
to the specially designed air vent, and the mixture of oil and air is discharged out of the air vent. As the pair of
rotors in the screw compressor has several threaded slots and the rotating speeds of rotors are very high, the
air discharge of the unit is continuous.
The mixture of oil and air discharged from the compressor airend enters into the Air-oil separator. Most oil is
separated from the air by the catching, collision and direction change in the separator. The formed oil drops
accumulate to the relative large particles which will fall into the lower part of the tank by the gravity. Only some
very fine oil mist is left. When the air flows through the filter core of Air-oil separator, the oil mist will congeal to
the fine oil drops on the fibers of filter core by the collision, dispersion and catching. The oil drops congealing
on the outer fibers of filter core will fall to the oil level in the lower part of the cylinder by the gravity, while the oil
drops congealing on the inner fibers will finally be collected in the bottom of filter core. A secondary oil return
pipe is led from the bottom of filter core and connected to the suction chamber of compressor. The oil
accumulating in the bottom of filter core will flow back to the suction chamber of compressor under the action
of pressure differential. The throttle orifice is installed in the oil return pipe. The throttle orifice is confirmed by
test and will ensure both the stable oil return and the minimum air loss. Therefore, modification is not allowed
unless it is permitted by SCR.

13
A minimum pressure valve is installed in the downstream of the outlet of Air-oil separator tank and its function
is to ensure that a minimum tank pressure will be established in the tank when the compressor is normally
operating, ensuring the normal operation of the lubricating oil circuit. When the unit is stopped or unloaded, the
minimum pressure valve acts as a check valve to prevent the return flow of compressed air. The unsealing
pressure of minimum pressure valve is 4.0±0.34bars (60±5psi), which has been pre-set before leaving factory.
The compressed air after Air-oil separating only contains several PPM (usually below 3PPM) lubricating oil.
After the separated compressed air flows through the minimum pressure valve, it will enter into the after-cooler
for cooling down and then can be used.

The after-cooler is used to reduce the discharge temperature of compressed air and consequently make most
of the water in the compressed air condense and separate, reducing the water content in the compressed air
and avoiding the problems caused by water content in the downstream air.

Due to the different cooling method, the after-cooler is classified into two types: air cooling and water cooling.
The air cooling after-cooler is connected to the oil cooler to form an integral component. The fan drives the
cooling air flow through the surface of cooler for cooling.

The water cooling type after-cooler and oil cooler usually are connected in series. The cooling water flows
through the after-cooler at first and then enters into the oil cooler.

A safety valve is installed on the cylinder of the Air-oil separator tank. When the pressure inside the tank
exceeds the setting pressure of safety valve, the safety valve will automatically open. The sealed pressure
safety valve is set before the delivery. Please do not tamper with settings. A temperature sensor is additionally
installed in the air discharge pipe. When the discharge temperature of compressor exceeds 105C (221°F), the
unit will automatically stop.

The screw-plug in the oil filling port of the Air-oil separator is designed to release the remaining pressure in the
tank when it is removed. The oil sight glass on the cylinder is installed to inspect the level of lubricating oil in
the tank. When the machine is not operating, the normal oil level should be located between the center of the
oil sight glass and its top position.

Warning
When the compressor is operating or pressurised, do not remove the nuts, oil filling cap
and other parts. Before maintenance, the machine should be stopped and all internal
pressure should be released.
It is not recommended to replace or use a safety valve with other than genuine SCR.
5. Cooling and lubricating system of compressor

The lubricating oil in the system has the following three main functions:
A) It acts as the coolant. The injected lubricating oil can absorb a large amount of the heat generated
during the compression, and consequently control the temperature rise of compressed air.
B) It fills the leakage clearances between the rotor and housing which reduces the internal leakage of
the compressed air and increases the efficiency of the compressor.
C) The lubricating oil film is formed between rotors. It allows the male rotor to directly drive the female
rotor and can absorb some mechanical noises at the same time.
See the flow chart in 2-4. Generally, the cooling and lubricating system of compressor consists of Air-oil
separator, oil cooler, oil filter and oil pipes, etc. For the air cooling model, the assemblies such as the
thermostatic valve, cooling fan and etc. will be added.
14
 The thermostatic valve is a direction valve with temperature sensing device. The lubricating oil leaving the
Air-oil separator will flow through the thermostatic valve before it enters into the cooler. The valve will sense the
temperature of lubricating oil discharged by the Air-oil separator and automatically control the flow of
lubricating oil through the oil cooler, to keep the compressor to operate normally in the temperature between
80~95 C (176~200°F).

Safety valve

Minimum pressure valve

Air-oil separator

Air discharge pipe

Fig. 2-3 Air discharge system

Fig. 2-4 Cooling and lubricating system of compressor

15
The oil filter consists of filter base and replaceable spin-on filter core (depending on the size of model, there
may be two or three filter cores) with built-in by-pass valve which will ensure an open oil circuit and normal
operation of compressor in the case that the filter core is dirty or the viscosity of oil is too high.

The oil cooler is an important part in the cooling and lubricating system. Due to different cooling methods, it
can be classified into two types: air cooling and water cooling. The brief description is given below.

Air cooling type oil cooler: the cooler has the aluminium plate-fin type structure. The cooling fan forces the
air to flow through the fins of the cooler and cool down the lubricating oil in the pipes of cooler. To maintain the
normal operation of compressor, the radiating fins of cooler should be kept clean and the maximum operating
ambient temperature of compressor shall not exceed 43C. During the daily maintenance, the surface of cooler
should be periodically cleaned. If necessary, high-temperature pressurized water not above 3.5 bars can be
applied to wash it.

Water cooling type oil cooler: the water cooling type oil cooler has the shell and tube type structure. The
lubricating oil flowing in the shell transfers most heat via the pipe wall to the cooling water flowing through the
pipes. Similar to the air cooling model, the lubricating oil flows through the thermostatic valve first and then
enters into the cooler for cooling down, ensuring that the unit operates in the normal temperature between
80~95C (176~200°F).

6. Air flow adjustment and control system of compressor

The (I series) of compressors are equipped with standard automatic (double) control system, providing two
control modes: continuous operation and automatic (double) control. In the continuous operation mode, the
compressor continuously operates and controls the actions of suction valve via differential pressure regulating
valves, to match the air demand. When the system reaches the unloading pressure (usually it is the rated
pressure plus 0.6Bar (9psi)), the controller (pressure switch) will act to force the suction valve to be closed.
The compressed air in the Air-oil separator will be discharged. In this point, the compressor is still operating,
but no compressed air is generated.

When the automatic (double) control mode is selected for the unit, the compressor will operate as the above
description. However, while the controller (pressure switch) acts, the (solid-state) timer will be triggered and the
machine will come into the unloading/timing status. After the timing period expires, the compressor will stop
automatically and turn into the “waiting” status. When the system pressure lowers to the loading pressure
(usually it is lower than the rated pressure by 0.7Bar (10psi)), the controller (the contact of pressure switch is
closed) will send out the command and then the timer will be reset. The unit will be automatically restarted.
When the unit is started, the time delay period of timer can be set. Generally, it can be set from 15 minutes to
minimum.

See Fig. 2-5 for the air flow adjustment and control system of compressor unit. Different models have different
configurations. It mostly can be classified into the following two cases: 1. Simple loading-unloading control
(On-Off); 2. Depending on the actually air consumption capacity, the air inlet capacity can be automatically
adjusted, and the air supply pressure of compressor is kept to be constant. The system mostly consists of the
following elements:

Air inlet control valve, pressure regulating valve, pressure switch, relief valve, throttle orifice, silencer,
solenoid valve, pressure relief valve, as well as the pipe fittings and joints for elements connection.
For the model with simple configuration, the operation of the machine mainly has three states: A. working
conditions of starting; B. working conditions of loading operation; C. working conditions of unloading and stop.
See the following descriptions for the detailed meanings.
16
Generally the air flow adjustment and control system of the compressor unit has been set before leaving the
factory, so the user does not have to adjust it. If an adjustment is necessary, refer to the contents of Section 7
Setting Procedure in Rated Working Conditions, Chapter 4 in the operation manual.

The unit adopts air inlet throttling for the air flow adjustment. That is to say that the air input capacity of
compressor is controlled by controlling the opening of suction valve, consequently achieving the purpose of
adjusting the air flow. The unit has four operating states: A. working conditions of starting; B. working
conditions of loading operation; C. working conditions of adjustment operation; D. working conditions of
unloading. The model with the rated pressure of 8bars (116psi) will be taken as the example for introducing
their operating principles respectively, and the units with other rated pressures can be analogized based on it.

Warning
Do not think that if the compressor is not operating, then the maintenance operation on it
will be safe, as the compressor may be in the “waiting” status and can start at any time.
Please strictly follow all related stipulations in “Maintenance and Service Procedures”.
6.1. Working conditions of starting

Push the starting button. Then star starting is applied to the motor. The suction valve of compressor is open to
draw a little air under the action of instantaneous vacuum. At this point, the capacity adjusting valve is closed.
Unload the port 1 and 3 of solenoid valve to maintain the connection and open the vent valve at the same time
to allow the Air-oil separator tank to be in the vented status. A small amount of air is drawn instantaneously
during the starting and will enter into the suction valve via the above-mentioned solenoid valve to force it to be
closed. The small holes on the suction valve plate (or the small clearance between the valve plate and valve
body) allows a small amount of air to enter into the compressor to basically keep its starting pressure to be
within 1.5-3.5 bar (22-51psi). Compressors with different specifications have different values. The compressor
senses it is starting at light load. After the setting period (usually 6-10 seconds) expires, the motor is switched
to the delta operation. At this point, the solenoid valve is unloaded as well as the vent valve. The suction valve
will be fully open under the action of suction vacuum. The compressor is loaded for operation. The system
pressure quickly rises to 4.0bars (60psi).

6.2. Working conditions of loading operation

If the system pressure exceeds 4.0bars (60psi), the minimum pressure valve will be open and the unit will
bleed the air to outside. At this point, we keep the ports 1 and 2 of unloading solenoid valve always open. The
suction valve is in the full open status and the unit operates under load. Then the system pressure quickly rises
to the rated pressure and the unit turns into normal operating conditions. Unless the air consumption capacity
of customer is changed, the unit will continuously operate in this status.

6.3. Working conditions of adjustment operation

If the air consumption capacity of customer is below the rated air discharge capacity, the pressure in the
system will rise. If the pressure exceeds the rated pressure by 0.06-0.13 bar (1-2psi) (i.e. air discharge
pressure reaching to 8.06-8.13 bars (117-118psi) for the 8Bar unit), the capacity adjusting valve will act to
control gas entering into the suction valve and reduce its opening, consequently reducing the air inlet capacity
of compressor. The restriction effect of suction valve is proportional to the pressure in the pipeline. The higher
pressure in the pipeline will lead to the smaller opening of suction valve and the more significant throttling
effect. The adjustable range of air flow by the capacity adjusting valve is 100%~20%, and the corresponding
pressure in the pipeline is 8.07~8.6bar (117~125psi) in this point.

17
If the demand of compressed air increases in this point, then the pressure in the Air-oil separator will decrease.
If the pressure lowers to below the pressure setting of capacity adjusting valve, the capacity adjusting valve will
be closed and consequently it will control the suction valve to be fully open. Then the unit will operate at full
load again.

6.4. Working conditions of unloading and stop

If the air consumption capacity of customer continuously decreases to below the 20% of the rated air discharge
capacity of compressor, the pressure in the system will exceed the setting of controller (pressure switch) which
is 8.6bar (125psi). In this point, the contact normally closed of controller (pressure switch) will be disconnected
to shut off the power supply for the unloading and discharging solenoid valves. The solenoid valve will be open
(port 1 and 3 connected), and the control gas will enter into the suction valve to close it. The vent valve will be
open to discharge the compressed air in the Air-oil separator. Relying on a little air input from the by-pass pipe
of suction valve, the pressure of unit is kept within 1.5~3.5bar (22-51psi), ensuring the circulation of lubricating
oil in the oil circuit system. In this pressure range, the minimum pressure valve is closed to disconnect the
pipeline of user from the unit. The unit will operate with no load at a relatively low back pressure to reduce the
energy consumption.

If the air consumption capacity increases, then the pressure in pipeline will decrease. If the pressure is below
7.3bar (106psi), the contact of pressure switch will be closed to turn on the power supply of unloading solenoid
valve and disconnect the port 1 and 3. The discharging solenoid valve will be disconnected and discharge of
compressed air in the Air-oil separator will stop. The control gas in the piston chamber of suction valve will be
discharged into the atmosphere via the throttle orifice, and then the suction valve is open under the action of
suction vacuum. The unit will come into the loading operation state again.
For the models with simple configuration, if the air consumption capacity of customer is below the rated air
discharge capacity, the pressure in the system will rise. However, the unit has no adjustment function. When
the pressure quickly rises to the unloading pressure (8.6Bar), the controller (pressure switch) will act and the
unit will come into unloading operation until the machine stops.

7. Electrical system and automatic protection

See Fig. 2-6. The electrical system is the control system for the starting, stop, parameter display and automatic
protection on the unit. The system includes motor, starting cabinet, instrument cabinet, contactor, mutual
inductor, terminal block, and cables as well as various protection switches.

Caution
The related documents are attached when the unit leaves factory. To avoid incorrect
connection, please refer to the electrical schematic diagrams attached to the machine
for the maintenance and service of electrical system.

The standard drive motor is the IEC closed type with a protection level of IP54/IP55, and the maximum
ambient temperature for operation is 43C (110F). The standard motor is not suitable for saline, corrosive, moist
or explosive environments.

18
 Filter cup

Capacity adjusting valve Two-position

three-way
normally
open valve

Throttle orifice Vent valve

Shuttle valve

Pressure sensor
After-cooler

Check Minimum
Pressure differential switch in air valve Oil pressure valve
sight
filter glass
Lift valve
Throttle
orifice Air-oil Pressure gauge Moisture separator
separator
Motor
Main
machine

Discharge

Oil filter
Oil cooler Thermostatic valve

Pressure differential switch in oil

filter

Fig. 2-5 Control process

The standard series of compressors are equipped with 380V/50Hz star-delta starter. The transformer in the
control box reduces the voltage of power supply to 220V for the operation of secondary control circuit. The
controller mostly includes the switch, over-heat (-current) relay, timer, high-temperature switch, solenoid valve,
indicator light, mutual inductor, etc.

For the air cooling type compressor unit, the specialized contactor is applied to start the drive motor of cooling
fan. The starter receives the command from the controller and controls the starting and stop of fan as per the
setting in the procedure.

The automatic protection is an important part in the unit. Its function is to ensure that the unit can’t be started or
can automatically stop timely when it is abnormal, consequently protecting the safety of the main machine of
compressor and motor. The function mostly includes: shutdown protection against discharge temperature
of compressor, current overload protection (thermal relay), voltage relay, safety valve and etc. When the
unit is under operating conditions, other automatic protection equipment can stop the unit, except the safety
valve. The detailed introductions to individual control equipment are given respectively as follow.
 Protection against discharge temperature of compressor – If the discharge temperature of main machine
reaches to 105C (221°F), the controller will send out the command to cut off the power supply of motor to
stop it.
 Current overload protection – If the compressor unit operates at overload due to some reason and the
operating current of motor exceeds the setting, the controller will send out the command to cut off the
power supply of motor to stop it.

19
 Overload relay – If the compressor unit operates at over load due to some reason and the current flowing
through the relay exceeds the setting (see Section 1 Setting of Rated Working Conditions and Equipment
Adjustment of Chapter 6), the contact in the relay will be disengaged due to the electrical heat energy to
cut off the power supply to the motor.
 Phase sequence protector – The machines of this series are equipped with phase sequence protector.
When the machine leaves the factory, the wiring of motor has been configured in good condition. If the
wrong phase sequence, phase loss and over-/under-voltage occur in the wiring for power supply by user,
then the unit can’t be started to ensure the safety of compressor unit.
 Safety valve - See Section 5 of Chapter 3.

Warning
High voltage will cause severe injury and death. Please shut down the power supply
before maintaining the electrical apparatus or opening the electrical control box.

Warning
Do not remove, bridge, or damage the high-temperature safety switch. If these safety
functions are not provided, severe injuries, death and property loss may be caused. If the
machine is shut off due to the over-high temperature, please contact the qualified service
persons immediately.

8. Control indication panel

Display area
排气温度:80C
Discharge temperature: 80℃

供压：0.60MPa
Supply valve: 0.60MPa
Button operating
Operating status: the equipment has stopped.
运行状态:设备已停止 area
0秒
0 second 机旁
Local

ON M

Fig. 2-7 Display panel

The I Series compressors are equipped with an intelligent controller, the display panel of which is shown as Fig.
2-7. The names and meanings of the buttons are shown as follows. To ensure the normal operation of unit, the
operators are required to be familiar with the functions and usages of display instruments and operating
elements for the correct judgment based on the displayed values.

20
 Display area – Indicate the machine parameters and information in total four lines.
The first line shows the discharge temperature of the machine, i.e. showing the temperature of the mixture
of oil and air at the outlet of compressor airend. The normal range of discharge temperature is within
80-95C (176-200F) when the compressor is operating. If the indicated temperature exceeds 105C (221F),
the high-temperature shut-down alarm will be triggered and the unit will stop;
The second line shows the system pressure of the machine. If the system pressure reaches the maximum
shut-down pressure (the pressure setting is 9.3Bar (135psi) for the 8Bar unit) when the unit is operating,
the unit will send an alarm and it will stop due to the high pressure;
The third line shows the status of the unit: stop, automatic loading operation or manual unloading, etc;
The fourth line is the indication for operating the soft keys.

Caution
The indicator light for power supply may have failed. It is necessary to inspect whether
the power supply is disconnected using a metering device.
9. External cover assembly

The external cover of the unit is designed to have good high ventilation and good sealing performance to
efficiently prevent the infiltration of rain-water. The model number and warning labels are attached to the
external cover. The heat-resistant and fire-retardant acoustic absorbing materials are adopted in the
construction of the cabinet, which significantly reduces the noise of the unit.

21
Chapter 3. Installation and Acceptance

1. Installation, acceptance and keeping

In the process of delivery of the machine to site, the correct shutdown maintenance and service of the unit
contribute to the completion and normal operation of equipment. Therefore, the machine should be inspected
immediately for damage caused during transportation when it is received. If damages are found, the carrier
should be required to make a note on the shipping document and give a damage report. If the damages are not
found at the time and then hidden damages are found afterwards, please inform the carrier within 2 days after
receiving the goods and request the carrier give a damage report. The detailed report is very critical for
handling any damage claims.

Check the nameplate of compressor to ensure that it has the model number and specifications you ordered
and check whether optional parts are included. In addition, inspect the Air-oil separator and safety valve to
confirm whether the design or pressure setting is correct.

The handling and installation of the unit should strictly follow the precautions related to handling after the
packaging is opened. Two holes for fork lift are set under the base of unit. When it is lifted, a supporting block
should be placed to prevent the fork lift from crushing the door plate of unit (shown as the figure). If a lifting
rope is used, a cross bar must be used, which can counteract the lateral pressure against the cabinet caused
by the lifting rope. Note: It is not acceptable to place protection materials between the lifting rope and the
outside cabinet of the unit. It will not prevent damages to the unit.

22
2. Installation and location

The (I series) compressor units are only suitable for an indoor environment. Please install the compressor in a
clean environment with good lighting and ventilation, and the foundation shall be solid and level. The whole
base shall tightly fit the horizontal level of foundation. If necessary, a hard rubber cushion can be used. For
safety and easier maintenance and daily inspections, sufficient space should be provided around the machine
(At least 1.2m space shall be left around and above the compressor).

The operating ambient temperature of compressor can’t exceed 43C (110F). Otherwise, the compressor could
shut down due to over-heating. The spatial dimensions and shape of compressor room should be carefully
considered, to prevent the hot air discharged by the cooling fan from circulating in the machine room and
consequently causing the rising of operating ambient temperature. In principle, all stationary type screw
compressors from SCR are designed for indoor installation and application.

Warning
The compressor cannot operate in an environment with the temperature below 0C (32F) or
above the maximum operating temperature limit.

Do not place the compressor in an environment where it may draw in high-temperature waste gas discharged
by other compressors or thermal load equipment. Do not block the cooling air discharge capacity of the air
cooling compressor, and it should be vented outside the compressor room, avoiding the excessive ambient
temperature in the compressor room. If the ventilation in compressor room is poor, a high-temperature
shut-down of the machine may be caused. Moreover, don’t place the compressor in a basement or places with
poor ventilation. If there is a possibility of oil contamination caused to the water is considered an issue, the
operating temperature and the lubricating oil of the compressor should be monitored.

Caution
The normal operation of compressor requires sufficient clean air.

Caution
Removing or modifying the outside cabinet will cause excessive noise to escape and
consequently be harmful to human health.

The screw compressor has a stable operation and basically no vibration. It can be naturally placed without
anchor connection. However, if it is necessary for the user, the compressor can be fixed with bolts to prevent
the pipes from breaking or prevent the electrical connection from being damaged due to the displacement of
machine caused by a collision. In this point, it is noted that the bolts shall not be tightened excessively to
prevent the oil cooler, pipes and air tank from cracking and being damaged due to the distortion and
deformation of machine base caused by the excessively tightened bolts.

23
 Warning
Do not install or expose the compressor to toxic, volatile or corrosive gases. It is also not
recommended to store any substances with similar properties around it otherwise severe
injuries and property losses may be caused.

If the working conditions for operation are relatively poor and in a high dust area, then the specially configured
heavy duty air filter should be fitted to maintain the service life of the air compressor system and parts.

Please refer to Codes for Design of Compressed Air Stations, for the design, installation and operation related
to compressor rooms.

3. Storage and maintenance of the unit

The screw compressor unit is highly engineered; especially the airend of the machine, which is precisely
machined and formed. The operating procedure and requirements from the manufacturer should be strictly
followed for maintenance and service procedures. Otherwise, property losses or personal injuries may occur. If
the unit is stored for a long time or will be out of service for a long period, then you should ensure at first that it
is placed in a clean and dry environment. The accumulated water in the bottom of the parts and components
such as Air-oil tank, cooler (especially the water cooler), steam-water separator, pipeline water filter should be
drained out. Individual major parts and components of unit and joints should be inspected periodically and
cleaned to ensure no leakage and rust signs. It should start and operate for at least 60 minutes every month to
ensure the safe lubrication in the airend of main machine. Secondly, careful inspection is required before it is
started. If necessary, the lubricating oil should be replaced in the unit. In addition, 2-hour operation test should
be performed at full load on the unit and the data shall be recorded. A qualified service engineer should be
present for instruction.

4. Pipe connection

No lead/tin solder is allowed in the connection of pipes or connecting pieces. The lead/tin solder materials
have the characteristics of low strength and cannot resist the high temperatures. Their melting point is only
182C (360F). Therefore, please do not mistake them for braze welding such as silver solder and copper solder.
In addition, please note that no plastics, PVC, ABS pipes or rubber hoses are allowed in the piping system for
compressed air.

It has to be noted that no contaminated piping should be installed on the compressor. The pipes should be
connected in the proper position without bending and distortion. To avoid the effect of heat expansion of the
pipes on the system, some flexible expansion joints or hoses can be installed in the system, if necessary. The
pipes shall be independently supported and fixed to reduce the vibration and prevent the expansion and
deformation. In any case, the size of pipes shall be no less than the connection size of discharge pipes in the
compressor.

For the compressor, clean air is critical. The air filter is indispensable. The air supply which can supply clean air
shall be selected. If outdoor air supply is used, then it shall ensure that all pipes are short and straight. The
pipes shall be properly laid out and vibration shall be avoided. The diameter of pipes shall be no less than the
dimensions of suction valve. For excessively long pipes, the diameter of pipes should be increased. In addition,
the pipes should be free from leaks and should be absolutely clean after they have been installed.

24
4.1. Points for attention in piping, base and cooling system

4.1.1 Points for attention in piping of air pipeline

1） For piping of mainline, a 1 to 2 degree inclination is required to facilitate the discharge of condensation
water in the pipeline.
2） The pressure drop of the pipeline should not exceed 5 percent of the setting pressure of the air
compressor. It is recommended oversized piping be selected for air systems.
3） The branch pipeline must be connected to the top of the main pipeline to prevent the condensation
water in the pipeline from flowing down to the machine or flowing back to the air compressor.
4） A combination of three devices including water filter, pressure regulator and oil feeder shall be installed
on the tools that require lubrication to maintain their service life.
5） Do not reduce the size of the main pipeline. If the reduction or enlargement of the pipe is required, a
reducing pipe must be adopted or the mixed flow may occur at the connection which will lead to a
bigger pressure loss and also exert a great influence on the service life of the pipeline.
6） If a buffer is required facilities such as receiver and dryers are available, the ideal piping shall be air
compressor + receiver + dryer. In this way, the receiver may reduce part of the condensation in the
system and also have the function of decreasing the exhaust temperature. Air with lower
temperatures and less moisture will ease the load of the dryer.
7） If the system requires both a large volume of air and a short time, it’s recommended to install an air
receiver for a buffer to reduce the times of transition from no-load to working load, which will lessen
the load on the air compressor.
8） For the compressed air whose system pressure below 1.5MPa, the speed in the transmission pipes
must be less than 15m/s to avoid excessive pressure drop.
9） The number of bends and valves used in the pipeline should be kept to a minimum to reduce loss..
10） The ideal system is to have the main pipeline go around the whole plant so the bilateral compressed
air is available at any position. The main pipeline should be equipped with appropriate valves to cut
off during servicing.

11) When banks of air compressors are parallel connected, we suggest a pipe check valve for each
compressor to avoid back pressure.

4.1.2 Base
1） The base should be a solid level area at least 150mm larger than the footprint of the air compressor.
2） If the air compressor is installed upstairs, vibration protection should be installed to prevent the
vibration from transmitting downwards and to prevent resonance. It’s crucial to the security of the air
compressor and the building itself.

4.1.3 Cooling system

1） For those water-cooled air compressors, soft water shall be used as the cooling water to avoid
chemical reactions due to such ions as calcium and magnesium in high temperature. The reaction
may form scale on the cooler, which jeopardises the heat exchange of the cooler. If the cooling water
tower system is adopted, a softening agent must be added regularly to maintain the clean water
25
 quality.
2） The self-feeding system of the cooling water circulation system shall be improved or after a certain
period of operation, the cooling water quantity may be insufficient which will cause the tripping of the
air compressor due to the high temperature.
3） The cooling water system of the air compressor shall run independently to avoid any influence on
cooling effect due to insufficient water quantity.
4） The cooling water tower must meet the cooling water quantity specified by the air compressor and the
power of the pump must be selected correctly. The tower should be installed in an area that is good
for heat dissipation and ventilation. The cooling water tower must be installed securely to prevent
collapse.
5） The pressure of cooling water is maintained usually at 0.15 to 0.25MPa.
6） Special attention should be paid to the ventilation environment if the air compressor is air-cooled. The
air compressor should not be placed near high-temperature machines or in an air-tight space with
poor ventilation to avoid tripping due to over temperature. If the compressor runs in an air-tight
system, exaction and exhaust equipment must be added. Generally speaking, the single air rate of
exaction and exhaust must exceed the exhaust rate for heat dissipation of the air compressor.

5. Installation of safety facilities

a) Safety valve (relief valve)

The safety valve is a pressure relief device sized correctly to protect the system. It has been set before delivery.
You are not permitted to change its pressure setting or remove the valve. Only the manufacturer of the safety
valve or qualified agent can perform such an operation.

The safety valve should be located before potential blockage points, including (but not limited to) the check
valve, heat exchanger and discharge silencer. In theory, the safety valve shall be directly connected to the
pipes or vessels which bear the pressure, instead of being connected via the pipes. The discharged gas from
safety valve shall be led to a safety place away from the people.

Warning
Do not modify, weld, repair or reprocess the pressure vessel with GB (or ASME)
specifications. No operation exceeding the ratings on the nameplate is allowed.
Otherwise, the warranty will be affected and severe injuries and property losses may be
caused.
b) Protection cover

All mechanical movement has risks at differing levels. Therefore, the protection covers should always be
installed. All SCR units follow national, international and industrial standards and have the necessary
protection facilities. The user should periodically inspect and maintain them and no modification or removal is
permitted.

c) Manual vent valve and shutoff valve

26
It is recommended to install a manual vent valve in the air system of customers. The purpose of installing the
manual vent valve is to discharge the air in the compressor and its air discharge capacity pipes to the
atmosphere. If the air tank in the system is used with a single compressor only, then the vent valve can be
installed on the air tank. If the shutoff valve is installed in the system, the manual vent valve shall be installed in
the upstream side of shutoff valve. However, the safety valve should be installed in the upstream side of
manual shutoff valve. Such a configuration can ensure that the persons and equipment are in a safe
environment during maintenance and service.

If the compressor is isolated from the system only for the maintenance, please note not to replace the shutoff
valve with the check valve.

Warning
Before maintaining the machine, the manual vent valve has to be opened to release the
pressure in the compressor and system. The neglect in the pressure reduction of system
may cause the severe injuries, death and property losses.

6. Electrical installation

Before installation, check that adequate power supply is available. The proper fuse or breaker should be
configured in the installation. The unbalance between the voltage phases should be limited to be within 5%, to
prevent over-current due to low voltage. For installation of the motor, cables and all electrical elements, the
related national electrical standards and local regulations must be followed. Only qualified electricians can
perform the above-mentioned operations. The grounding of compressor should be in a good condition. Refer
to the electrical wiring diagrams.

7. Water supply and drainage (water cooling type)

Ensure the unblocked connection of water supply and drainage pipes. The water path and pipeline configured
by the user shall have at least the same diameter as the water path in compressor unit. The drainage
equipment should have minimal joints. The local drainage standard and the requirements from the compressor
shall be met. It shall be absolutely ensured that the connection of water supply and drainage pipes are correct.

Caution
The water temperature regulating valve is located in the water discharge pipe.

Warning
Removing or covering the safety signs is dangerous. It may cause injuries or property
losses. The warning signs should be highly visible and placed in a prominent position
with good lighting. In addition, the text should be clear and do not remove the warning
signs and other attached indications.
8. Adjustment and calibration of belt

d) Use the leveling rod (with the accuracy ≤0.5mm) to measure the verticality between two belt pulleys
27
 and the identical base level. The allowable error is ≤ 0.5mm.

e) If the error in verticality exceeds 0.5mm, then the shims can be applied to adjust the mounting anchor
of the airend or Air-oil tank, to ensure that the error in the verticality with the identical base level
doesn’t exceed 0.5mm.

f) Tighten the mounting bolts of the airend or Air-oil tank.

g) Install the belts on the belt pulleys with the rule that the same trademark code shall be in the same
position.

h) Based on the small belt pulley, use the straight ruler or laser measuring instrument to measure the
plane straightness between two belt pulleys. The allowable error is ≤0.5mm.

i) Use the motor adjusting screw to tension the belts. See the attached table for the tension
requirement.

j) And also, based on the large belt pulley, check the plane straightness between two belt pulleys. The
allowable error is ≤0.5mm.

k) Lock the adjusting screw and nut.

Attached table: Belt tension

Model Tension (N)

Machine Center
number of Remark
model distance Preliminary After starting
belt

SCR10I 3VX 380~480 250~310 200~250

SCR15I
3VX 480~580 310~370 250~300
SCR20I
SCR25, 30,
5VX 500~600 830~960 700~810
40, 50, 60
SCR75, 90,
5VX 800~900 1000~1050 800~840
100
SCR75I,
5VX 900~950 1050~1070 840~860
100I

Notes:
1. The center distance in the table is calculated from the diameters of two belt pulleys and the
28
 circumference of the belt as per the formula, and it is basically consistent with the actual
measurement.
2. The preliminary tension in the table is calculated from the documents provided by the Martin
Corp. and it is modified.
3. The tension after starting is selected to be 80% preliminary tension, referring to the documents
provided by the Optibelt.

9. Adjusting the coupling

The alignment of coupling should be inspected and corrected after the placement of machine is completed by
the user for this series of compressors. This task is essential. Any misalignment of the coupling should be
corrected to be within the allowable range before the machine is started. Each time the machine is moved,
then the task should be performed again, ensuring that failures such as efficiency reduction, shortening the
service life and increasing the noise will not be caused due to an alignment problem with the coupling. The
calibration methods for the coupling are as follows:

a) Required tools: micrometer gauge, vernier calipers, measuring tape, steel-plate straight ruler, small
mirror, several clean shims with the thickness of 0.025mm-0.5mm, recording sheets, crowbar, etc.

b) Preliminary calibration: See Fig. 4. The preliminary calibration has two functions: one of them is the
rough calibration to allow the micrometer gauge to achieve the measurement (because the measured
value can not exceed the range of micrometer gauge; otherwise the micrometer gauge will be
damaged); the other is to adjust the motor shaft to be slightly lower than the compressor shaft, so that
the final calibration requires to add the shims only. As shown in the figure, place the straight ruler on
the coupling flange edge of compressor shaft. The vertical distance between the straight ruler and the
coupling flange edge of motor shaft is adjusted to be within the range of micrometer gauge. Adjust the
shims on the support legs of motor or directly lower the motor to a certain position, to adjust the above
distance to be within 1mm.

Turn the motor shaft and adjust it again to allow the above distance to be within 1mm. Repeat the adjustment
as above several times.

Armor plate ruler

Put feeler gauge

Compressor
Motor

View from level

distance

Fig. 4 Preliminary calibration

29
c) Fine calibration: As shown in Fig. 5, use a small vice or loop chain to fix two micrometer gauges on a
half-coupling, or use the magnetic micrometer gauge base. Move a probe to the slight upper position
on the end face of the other half-coupling, to measure the angular deviation; move the other probe to
the center of external circumference of the coupling, to measure the coaxially deviation. It needs to
ensure that the measuring surface is clean and has no coating; adjust the micrometer gauge and
press down the probe in a midway to allow it to be able to move in two directions.

d) Reset the micrometer gauge to zero at the N point in Fig. 5.

e) Turn the compressor shaft with the motor shaft for 360 degrees (one turn). During the turning, it
should be ensured that the probe is fixed on the flange. After one week, the micrometer gauge should
return to the zero position. If the micrometer gauge doesn’t return to the zero position, then inspect
the installation conditions of micrometer gauge, and inspect the tightening condition of small vice or
loop chain or the adhesion condition of magnetic block. Afterwards, try again. During the turning, it is
best to allow the coupling to be connected or partially connected, which will be helpful for turning the
compressor shaft with the motor shaft, as shown in Fig. 6.

f) At first adjust the parallel and then adjust the coaxially (Please note: for the positive and negative
values of the number of micrometer gauge, the symbols shall be given in the calculation). Reset the
micrometer gauge to zero (0.000mm) at the N point in Fig. 5. Turn the compressor shaft with the
motor shaft, and record the readings of two micrometer gauges every 90 degrees (1/4 turn). A group
of readings are shown in Fig. 5. As two shafts turn together, the position of micrometer gauge relative
to the shafts is not changed and then it will eliminate the deviation caused due to the irregular rim or
end face. The mirror can be used for easily getting the readings. Generally, a single reading is
insufficient. Several readings are necessary to confirm whether the readings are consistent.

g) In the example shown in Fig. 5, the deviation from the micrometer gauge for angular measurement is
0.000mm at N point and becomes -0.152mm at S point; it indicates that the tail end of motor is higher
(relative to the compressor). The total angular deviation (T.I.R) is 0.152mm. The calculation of the
distance required for the motor adjustment is described as follows:

1) Measure the revolving diameter D of the probe of “angle” micrometer gauge (relatively smaller
than the diameter of half-coupling). It is assumed to be 152mm in that example.
2) Measure the distance L between two mounting bolts in the front and rear of motor. It is assumed
to be 750mm.
3) In this example, the angular deviation (T.I.R.) M in the vertical direction was just now measured
to be 0.152mm.
4) It assumes that the thickness of shim to be inserted or removed is S.
5) The thickness of shim can be calculated as per the following formula: S＝LM/D. Then
S=750X0.152/152=0.75mm

30
 Coaxial micrometer gauge
Angle micrometer gauge

Small vice
MOTOR

AIREND

Fig. 5 Fig. 6

Fig. 7 Fig. 8

h) According to the above calculation, it is necessary to remove the shim with the thickness of 0.75mm
from the support leg in the tail end of motor. For operation, the motor is lifted by the crowbar or
hoisting equipment, as shown in Fig. 7. After the adjustment is completed, tighten the mounting bolts
as per the order shown in Fig. 8. After the mounting bolts are tightened, use the micrometer gauge to
inspect whether the error is within the controlled range.

31
Chapter 4. Operating Procedures

1. Overview

The I Series compressors are equipped with a series of control elements and display/indicating elements. To
ensure the normal operation of the unit, it requires the operators to properly operate the machine. In addition, it
requires that the operators can have a proper judgment against the operating status or failure conditions of the
unit according to the displayed/indicated values or states. Before the unit is started, the operators should be
familiar with the positions, functions and usages of the control/operating elements and display/indicating
elements. See Section 8 Control Indication Panel in Chapter 2 for details.

2. Preparation for the starting

1) Remove any foreign materials and tools around the compressor.

2) Inspect the oil level to ensure that it is in the normal position (See the sections for lubricating oil).
3) If necessary, inspect the alignment of belts or coupling.
4) Inspect the fan to ensure that it is mounted firmly.
5) Manually turn the machine to ensure that no mechanical interference occurs.
6) Inspect whether all joints for pressure pipes are secure and not loose.
7) Open the suction valve.
8) Inspect and ensure that the safety valve is installed in position.
9) Inspect whether all covers and protection devices are safe and secure.
10) Inspect whether the specifications or control current setting of the fuse, breaker and thermal overload
protection device is proper and the settings are correct.
11) For the water cooling unit, inspect the water inlet and discharge pipes and ensure that their connections
are correct and secure and that the cooling water is turned on.
12) Inspect whether the air filter is securely installed.
13) Turn on power supply switch, and the indicator light for power supply will be lit. Inch the starting button and
inspect the rotational direction of compressor to ensure that it is consistent with the specified rotational
direction.

3. Regular starting steps

1) Open the shutoff value going to the air supply system.

2) Pre-set the control parameters and then push the starting button.
3) Observe whether the started compressor has the abnormal vibration, noise and air/oil leakage. If the
problem is found, please immediately shut down the machine and correct it.
4) Close all external cover doors to control the noises of the unit and ensure the normal flow of cooling air.
5) Slowly close the air supply shutoff valve. Inspect whether the unit is unloaded as per the setting. See the
Section 1 Setting Procedure in Rated Working Conditions in Chapter 6.
6) Inspect whether the indicating values of status parameters are normal.
7) For the water cooling unit, please inspect the inflowing water pressure. Adjust the ball valve in the water
circuit to allow the discharge temperature of unit to be kept in the normal range.
8) In the first hour that the compressor operates, please carefully observe the operating conditions. In the
following seven hours, observe it regularly. If any abnormality occurs, please shut down the machine and
call the SCR service department.
9) After the primary operation, shut down the machine as per the shutdown procedures. Inspect whether it is
necessary to add any lubricating oil into the oil tank; inspect whether the joints are loose.

32
 Caution
 To prevent the lubricating oil from foaming and consequently reducing the oil
filtering efficiency of the system, and to protect the motor, the interval between
two starts of unit should be no less than 5 minutes.
 It is necessary to discharge the condensate water in the bottom of Air-oil
separator periodically. The operation for discharging the condensate water
should be performed before starting the unit.
 It is necessary to discharge the condensate water in the bottom of filter in the
control pipes periodically (every week). The operation for discharging the
condensate water should be performed before starting the unit.

4. Shutdown procedure

4.1. Push the stop button.

4.2. Close the shutoff value connecting to the air supply system.
4.3. Disconnect the power supply switch.

Caution
Closing the shutoff valve for service can avoid compressed air returning to
the compressor and damaging the check valve and other internal parts of the machine.

5. Emergency shutdown: In emergency situations, push the emergency stop/resetting switch to shut down
the machine, and disconnect the power supply.

33
Chapter 5. Parameter Setting and Adjustment of Working Conditions

1. Introduction to the operations and parameters of intelligent controller

The screw compressor units in this series are equipped with the specialized controller specially designed by
SCR. It can not only locally monitor the whole unit and perform the operations and protection, but also realize
the functions such as long distance control, interconnection between several machines, etc. The details of its
functions and operations are introduced in the below:

2. Status Display and Operation

The display interface is as following when the units are POWERED ON:

Welcome to use

SCR Air Compressor

The main display after 5 seconds will be the following:

T1：20℃ T2：20℃
P1：0.60Mpa P2：0.60Mpa
STATE：NORMAL STOP
LOCAL

Remarks: T1 is system temperature; P1 is system pressure.T2 and P2 only use for Oil-free compressor

Press “” Enter the following Menu Selection Interface:

RUN PARAMETER
CALENDAR
CUSTOMER PARAMETER
FACTORY PARAMETER

a) Run the Parameter Review

Press ‘’or ‘’ to move the black cursor over the menu ‘RUN PARAMETER’ and then press ‘’ to
popup the submenu:
MOTORS CURRENT
SYS PARAMETER
TOTAL RUN TIME
THIS RUN TIME

MAINTENANCE PRRAMETER
HISTORY FAULT
PROD TIME、SERIAL NO.
THIS FAULT

34
 Press ‘’ 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 pops up is the last menu level, the black cursor will disappeared, press the RETURN
button ‘RT’ 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.

Using the moving buttons ‘’ , ‘’ ,CONFIRM button ‘’ return button ‘ RT’ to view the RUN
PARAMETERS such as the ‘SYS PARAMETER’,’TOTAL RUN TIME’,’THIS RUN
TIME’,’MAINTENANCE PARAMETER’,’HISTORY FAULT’,’PROD TIME’ AND ‘THIS FAULT’ ETC
RUN PARAMETER and then return to the upper menu with the similar method of the above.

b) Calendar and Time

Press ‘’ or ‘’ to move the black cursor to the menu ‘CALENDAR’
RUN PARAMETER
CALENDAR
CUSTOMER PARAMETER
FACTORY PARAMETER

and then press ‘’, the following menu will be pop up:

DATE AND TIME

2004 Y 2 M 22 D
W1
12 H 46 M 59 S

Caution
Only at the stop status of the unit, the date and time could be adjusted according
to the following steps:

Press ‘’ or ‘’ to move the black cursor to the parameters you want to modify and then press ‘’ to
reach the blinking position. Now the button ‘’ and ‘’ are changed to ‘Page up’ and ‘Page down’
button. Press the ‘S’ button to confirm and save the data after finishing the modification. The buttons
‘’ or ‘’ return to black cursor move button and the button ’’ change back to its Return function.

35
c) Customer Parameters
1） Parameter Modification

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

The Customer Parameters can be read and modify settings using the same method as running the
Parameter Review mentioned above. For example, to modify the parameter BLOCK UNLOAD
PRESSURE, the steps will be as the follows:

Press ‘’ or ‘’ to move the black cursor to ‘CUSTOMER PARAMETER’ menu
RUN PARAMETER
CALENDAR
CUSTOMER PARAMETER
FACTORY PARAMETER

and then press the CONFIRM button ‘’ to pop up the following menu:

SET P、TEMP
SET DELAY TIME
OPERATION MODE
BLOCKING MODE

CLR LIFE TIME

SET MAX LIFE TIME
LANGUAGE SET: ENGLISH/CHINESE
NEW USER PASSWORD: ****

Press the CONFIRM button ‘’ again to reach the following menu:

LOADING P 0.8MPa
UNLOADING P 0.6MPa
FAN START T 80℃
FAN STOP T： 70℃

36
 The CUSTOMER PARAMETERS can be read now when the CONFIRM button ‘’ is not pressed.
Press the CONFIRM button ‘’ again to pop up the following interface where the password input is
needed:

ENTER PASSWORD

****

Caution
The Customer Password can be modified in the CUSTOMER PARAMETER, the
DEFAULT PASSWORD is

The Blinking Position will appear after this interface displayed. The button ‘’ and ‘’ have been
changed to Pg Up and Pg Dwn button that could be used to change the current value. The button
‘’ 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:

LOADING P: 0.8MPa *
UNLOADING P: 0.6MPa
FAN START T: 80℃
FAN STOP T: 70℃

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

The ‘’ or ‘’ button return to black cursor and the button ‘’ return to be the CONFIRM button. Press
the CONFIRM button ‘’ when the cursor is over the menu ‘ BLOCK UNLOAD PRESSURE’, now the
blinking position appears and the button ‘’ and ‘’ have been changed to Pg Up and Pg Dwn button that
could be used to change the current value. The button ‘’ 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 ‘’ or ‘’ return to black cursor move button and the button ’’ change back to it’s CONFIRM button
to continue to modify the other CUSTOMER PARAMETERS. If there are no other parameters needed to
be modified, press the button ‘RT’ to return to the upper menu or the main menu. The other CUSTOMER
PARAMETERS could be modified with the same method above.

2）The CUSTOMER PARAMETERS and its function

Preset
First Submenu Second submenu Functions
Value
UNLOADING P1. ***Mpa UNLOADING PRESSURE VALUE
LOADING P1. ***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
37
 When using the controller to protect the motor, it
is required that the time here defined will not
MAIN START TIME ***s 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 ***s is required that the time here defined will not
meet the impulse starting current of the motor.
STAR/DELTA TIME ***S Star pressure release starting delay time.
The loading delay time after star pressure
LOAD DELAY TIME ***S
releasing.
SET DELAY
UNLOAD DELAY Load free continuous running time, the machine
TIME ***M
TIME will automatically stop after this time
The machine will not stop until this time passed
STOP DELAY TIME ***S
the load free state when stop the machine
Machine can not be restarted before this set time
START DELAY TIME ***S after stopped or over time operation at load free
state
OTHER ***S Additional functions
The continuous draining time during the
DRAIN OPEN TIME ***S
automatic draining control.
The Draining Gap duration during the automatic
DRAIN CLOSE TIME ***M
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
buttons
When this is set to ‘PROHIBIT’ the
COM MODE Prohibited
communication function is not available
COM ADDRESS 0255 Communication address

Continued
Act as Host or Secondary Machine when
there are more than one machines running in
BLOCK STATE MAIN
blocking mode. The HOST controls the
SECONDARY
BLOCKING BLOCK ON/OFF ORDER
MODE TURN TIME ***H
BLOCK NUMBER ***
BLOCK LOAD P ***MPa
BLOCK UNLOAD P ***MPa
BLOCK DELAY TIME ***S
Reset time for the duration of oil filter
CLR OIL FILTER 0000 HOURS
CLR LIFE changing
TIME CLR O/A SEPARATOR 0000Hours Reset time for O/G Separator changing
CLR AIR FILTER 0000Hours Reset time for gas filter changing
38
 CLR LUBE 0000Hours Reset time for Lubricate Oil Changing
GLR GREASE 0000Hours Reset time for Lubricate Grease Changing
Set this value to ‘0’ will make the oil filter
OIL FILTER ***Hours
alarm not available
Set this value to ‘0’ to disable the O/G
O/A SEPARATOR ***Hours
separator alarm function
MAX LIFE Set this value to ‘0’ to disable the alarm
AIR FILTER ***Hours
TIME function of gas filter
Set this value to ‘0’ to disable the time alarm
LUBE ***Hours
of lube. oil
Set this value to ‘0’ to disable the time alarm
GREASE ***Hours
of Lube. Grease
Language Set to ‘ENGLISH’ will change the interface
***
Select(English) to be English display.
NEW USER Customer could modify the user password
***
PASSWORD

d) FACTORY PARAMETERS
The difference of the FACTORY PARAMETERS and the CUSTOMER PARAMETERS is that the
FACTORY PARAMETERS can not be modified unless you have the initial password from the factory. The
modification method of the FACTORY PARAMETER is the same as that of the CUSTOMER PARAMETER.
The main functions of the parameters are as the following table.

PARAMETER Initial Value Functions

After the starting delay time, when the motor current is

MAXIMUM
greater than 1.2 times of the set value and less than 4
MAIN MOTOR CUR OVERLOAD VAULE
times of the set value, the unit will jump as per overload
OF THE MOTOR /1.2
feature.
Maximum allowable
FAN MOTOR CUR Same as above
motor overload value/1.2
PRE-ALARM T 102℃ Alarm when the temperature reaches this set value
Alarm when the air exhausting temperature reaches this
STOP T1 105℃
set value.
Alarm and stop machine when the air supply temperature
STOP P1 ****MPa
reaches this set value
The Unload Limit Pressure in the Customer Parameter
MAX UNLOAD P1 ****MPa
must be set lower than this value.
CLR LOAD TIME ****Hours The factory can modify the load running time
CLR TOTAL TIME ****Hours The factory can modify the total running time
CLR FAULT Input the history failure password to clear al the history
****
RECORD failures.
When (the max. phase current/min. phase current) is not
UNBALANCE greater than (1+set value), the unbalance protection will
****
SCOPE stop the machine. If the set value is greater than 15, the
unbalance protection will be disabled.
Set the LACK PHASE TIME ≥20S, the Lack phase
LACK PHASE STOP ****
protection will be disabled, if the unbalance protection is

39
 active, it will be started.
P1 ZERO.COR. ****
PROD.TIME ****Y**M**D The factory input the product date of the unit.
SERIAL. NO. ****** The factory input the Serial No. of the unit
O/A ALM P DOWN ****MPa
CONDUIT P DOWN ****MPa
STOP P2 ****MPa Alarm when the system pressure reaches this set value
P2 ZERO COR. ****MPa
Alarm when the system temperature reaches this set
PRE-ALARM T2 102℃
value
Alarm when the system air exhausting temperature
STOP T2 105℃
reaches this set value.
POWER
****HZ 50Hz or 60Hz
FREQUENCY
PHASE PROTECT **** ON/OFF
HIGH/LOW V SEL **** High voltage or Low voltage
T2 **** ON/OFF
P2 **** ON/OFF

3. Functions and technical parameters

1） System over-temperature protection

If the temperature of the system is above the high limit of set temperature, the controller will send out
the alarm to shut down the machine and the field failure is indicated to be “system over-temperature”.
2） Anti-reverse protection of air compressor
If the phase sequence of the 3-phase power supply connected to the air compressor has a setting
different from that of controller, the field failure is indicated to be “wrong phase sequence” and the
controller cannot start the motor. In this point, it is only needed to exchange the power supply wires of
any two phases and look over the rotational direction of motor.
3） System over-pressure protection
If the system pressure is above the high limit of set pressure, the controller will send out the alarm to
shut down the machine and the field failure is indicated to be “system over-pressure”.
4） Sensor failure protection
If the pressure sensor or temperature sensor is disconnected, the controller will send out the alarm to
shut down the machine. The field failure is indicated to be “** sensor failure”.
5） Interlocking protection
When the main machine is operating and the system temperature reaches the starting temperature of
fan, if the fan fails to operate, then the controller will send out the alarm to shut down the machine.
The field failure is indicated to be “fan failing to operate”.

4. Controller Connect Terminals Instruction

1) 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

2) Controller Connect Terminals

The display panel is connected with the controller using communication cabals. 23, 24 and 25 are the phase

40
 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.

Attention: the magnetic coil must be connected to the surging absorber when
wiring

5. Control Principle (Refer to the attached for the Electric schematic circuit)

1）Individual Control
(1) Local Automatic control (ON/OFF mode: Beside Machine; Loading method: Automatic)
▲ Press ‘ON’ to start: （Y— Starting）
When the controller is powered on, it will perform a 3S self-checking. Press the ‘ON’ 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  Y type Starting Status  Time Delay finish（Y—▲
converting time）, KM3 loss power (KM1 and KM3 interlocked) ，KM1 is powered on  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.
② Automatic Running Control:
When the motor is running in ▲ status and the magnetic valve has power applied after a certain period
of delay. Then the air compressor will be applied with air pressure to increase the pressure in the air
tank. When the air pressure reaches the value over the set unload pressure (unload pressure value),
the loading magnetic valve will loss power and the release magnetic valve is applied with power to run
the air compressor with load free. If in the specified time (load free running period) the air pressure turns
to be lower than the set load pressure (LOAD PRESSURE VALUE), the load magnetic valve obtains
power and the unload magnetic valve loses power, the air compressor will apply normal pressure to
increase the pressure in the air tank. If the pressure in the air tank does not drop down to the load
pressure limit within the load free running time, the controller will automatically stop the machine for
over time load free running. Only when the pressure drops to the load pressure limit, the motor will
restart according to the normal starting process and it will continually run repeatedly in this way.
③ Manual Load/unload at the automatic status
At the automatic status, the unit will stay in the unload state, press the button ‘’ to load, if the pressure
is higher than the unload pressure, the load magnetic valve will inch once and then return to the unload
status; if the pressure is lower than the unload pressure, the load magnetic valve will be applied with
power and will not stop running and return to the unload state until the air supply pressure becomes
higher than the unload pressure. When the unit is in the load state, press the ‘’ button to unload. If the
pressure is higher than the load pressure, the load magnetic valve will loss the power and return to the
load state till the air supply pressure becomes lower than the load pressure. If the pressure is lower than
the load pressure, the unload function is disable.

④ Normal Stopping:

Press the button ‘O’, the load magnetic valve will lose power and the unloaded magnetic valve will be
applied with power, after a delay (stop delay), the motor contactor will lose power, the host and fan will
stop running, after the restarting delay has been completed, the unloaded magnetic valve will lose
power. Only pressing the button ‘I’ will restart the motor.
41
⑤ Frequency starting prevent control

The motor can not be started immediately unless there has been a time delay after stopping pressing
‘O’ button or stopped due to failure. Whatever the situation is, this controller will display the remaining
count down of the time delaying (such as 90s).
The motor can only be started when the time display is 0.

(2) 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.

(3) 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 ‘’. When the air supply pressure is higher than the unload pressure, the unit will
load automatically, if the button ‘’ 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 ‘’ to load and during the process of
loading, press the button ‘’ to unload

(4) 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.

(5) Network control

(1) When the control network is set to ‘COMPUTER’, it can perform the computer network control of
the units
(2) Set the controller communication to ‘BLOCKING’ can perform the network control between the
controllers but the host must be 1# controller.
(3)
(6) Fan Temperature control
When the air Exhausting temperature is higher than the fan starting temperature, the Fan motor will
run; when the air exhaust 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 required, set the starting temperature of the fan
to ‘120C’ and the stop temperature to be ‘70C’.

(7) Failure stop and Emergency stop

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

42
6. Alarm and Notices

(1) Text Display tips

① Air filter Alarm tips
a. Check the alarm using the switch signal
The controller can display the message on the text display to remind the operator that ‘the air filter
is blocked’ by checking the pressure difference switch operating state.
b. 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.
② Oil Filter alarm tips
a. Check the alarm using the switch signal
The controller can display the message on the text display to remind the operator that ‘the oil filter
is blocked’ by checking the pressure difference switch operating state.
b. 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.
③ Oil separator alarm tips
a. Check the alarm using the switch signal
The controller can display the message on the text display to remind the operator that ‘the oil
separator is blocked’ by checking the pressure difference switch operating state.
b. 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.
④ Lubricate Oil alarm tips
The Text displays ‘Lubricate Oil life terminated’ when the using time of the lubricate oil terminates.
⑤ Lubricate Grease alarm tips
The Text displays ‘Lubricate Grease life terminated’ when the using time of the lubricate grease
terminates.

(2) 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 function at the
Value value activate input point, no light lighting

Output Switching Terminals 27,28,29,30,31,35,36,37,38

OUT00~09 lights
Value and 39 output switching value activate

Data Save Set Data and save time PWR blinking once

7. Safety Protection
① Motor Protection
MAM—KY02S air compressor controller controls short-circuit protection, rotor lock protection,
overload protection, Phase Lacking Protection and Unbalance Protections to the motor.

43
 Electronic
Failure Display Possible Causes
failure
Local Failure display ‘Host or Fan Short-circuited or the rated current is
Short-Circuit
short-circuited’ wrongly set
Local Failure display ‘Host or Fan Rotor Overloaded, Bearing failure or other
Rotor lock
Locked’ mechanic Failures
Local Failure display ‘Host or Fan Overloaded, Bearing failure or other
OVERLOAD
Overloaded’ mechanic Failures
Local Failure display ‘ Host or Fan Phase Phase lacking occurred to the Power or the
Phase Lack
Lacking’ connectors
Local Failure display ‘Host or Fan current Contactors are not contacted correctly or the
Unbalance
unbalance’. motor inner parts open.

② 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’.
③ Reverse running protection of the air compressor
When the phase sequence of the power connected to the air compressor is not conforming to the
setting of the controller, the local failure displays ‘Wrong phase sequence’ and as a result the controller
can not start the motor. It is required to check and alternate any two of the phase sequence and
investigate the motor rotation direction.
④ 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’.
Sensor Failure Protection
If the cable of the pressure sensor or the temperature sensor is damaged, the controller will alarm and
stop the machine and the local failure displays ‘** sensor failure’.

⑤ 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’

8. Handling of common failures

As the failure causes can be located by reviewing the field failures or history failures for the failure shutdown
caused by the external devices of controller, then the peripheral failures can be eliminated. See the “Reviewing
operating parameters” for detailed methods.

CAUSES MEASUREMENT TO TAKE

FAULT
Air Exhaust Bad vent condition, Oil lacking Check the vent condition and lubricant
Temperature too high etc. amount etc.
Temperature Sensor
Cable off or PT1OO damaged Checking the wiring and PT100
Failure
The pressure too high or the Check the pressure and the pressure
Over Pressure
pressure sensor failure sensor
Pressure Sensor Cable off, Sensor damaged or
Check the wiring and sensor transformer
Failure the cable connected reversed
Water Pressure switch
Water Lacking Check the water pressure switch
damaged
44
 Power phase lacking or the
Phase Lacking Check the power and contactors
Contactor terminal damaged
Voltage too low, tubes blocked,
Bearing Wear off or other Check the set data, Voltage, bearings,
Overloaded
mechanical failure or wrong set tubes and other mechanical system.
data etc.
Power unbalance, Contactor
Unbalance damaged or the internal open Check the power, contactors and the motor
of the motor
Voltage too low, tubes blocked,
Bearing Wear off or other Check the set data, Voltage, bearings,
Block
mechanical failure or wrong set tubes and other mechanical system.
data etc.
Wrong Wiring, Incorrect Data Checking the wiring and set the data
Short Circuit
setting etc. correctly
Reversed Phase sequence or
Phase Reversal Check the wiring
phase off
Fan damaged, Contactor
Fan won’t rotate Check the wiring and control output
damaged, no control output
Over Carry or block Host start time set to a
Reset the host starting time to be longer
during starting valueless than the star angel
than star angel delay + Load delay time
process time delay
Main Contactor
The emergency button loose Check the wiring
activate time to time

9. Parameter setting of intelligent controller in the standard unit

System unloading pressure Rated operating pressure + 0.6 bar (9psi)

System loading pressure Rated operating pressure - 0.7 bar (10psi)
Fan starting temperature 85C
Fan shutdown temperature 75C
Below 15HP: 9 seconds;20HP-100HP:11 seconds; Above 125HP:
Starting time of main machine 15 seconds
Starting time of fan 6 seconds
Below 15HP: 6 seconds;20HP-100HP:6 seconds; Above 125HP:
Star-delta delay time 10 seconds
Loading delay time Below 15HP: 2 seconds; Above 20HP: 4 seconds
No-load delay time 15 minutes
Shutdown delay time 15 seconds
Starting delay time Below 100HP:200 seconds; Above 100HP:600 seconds
Starting and shutdown mode Local
Loading mode Automatic
Communication mode Prohibited
Resetting of oil filter 0 hour
Resetting of fine oil separator 0 hour
Resetting of air filter 0 hour
Resetting of lubricating oil 0 hour
Resetting of lubricating grease 0 hour
45
Oil filter 600 hours; 1000 hours after the first maintenance
Fine oil separator 4000 hours
Air filter 2000 hours,
Lubricating oil 2000 hours,
Below 20HP: 2000 hours; 25HP-125HP:2000 hours; Above 150HP:
Lubricating grease 1000 hours
Selection of English/Chinese English
Changing the user password Please contact the service engineer.
System pre-warning temperature 102C
System alarm temperature 105C
System shutdown pressure High limit of pressure + 0.7 bar (10psi)
High limit of unloading pressure Rated operating pressure + 0.6 bar (9psi)
Resetting of history failure 8888
Current unbalance tolerance 15
Phase lack protection time 2 seconds
Zero point correction of system
00.00MPa
pressure
Pre-warning pressure differential
00.07MPa
of oil separator
Pressure resistance of pipeline 00.00MPa
System shutdown pressure High limit of pressure + 0.69 bar (10psi)
Zero point correction of system
00.00MPa
pressure
Backup pre-warning temperature 102C
Backup shutdown temperature 105C
Selection of power frequency 50HZ
Phase sequence protection Enabled
Selection of high or low voltage Low voltage
Motor temperature Prohibited
System pressure Prohibited

46
10. Settings of capacity adjusting valve

Except for the units with simple configurations, all units of this series are equipped with the pressure
capacity adjusting valve to adjust the air discharge of compressor to match the demand of users. The
adjusting valve has been set when the unit leaves the factory. The user is not allowed to change its
setting. In special cases, the adjustment can be made as per the following method with the instruction
of qualified service persons:

1) Ensure that the unloading pressure of unit is set correctly and the operation is effective (refer to the
above mentioned parameter settings);

2) Start the machine and allow it to operate at full load. Slowly adjust the suction valve to increase the
system pressure in the unit to rise to rated pressure +0.07-0.13bar (1-2psi);

3) Adjust the adjusting screw under the capacity adjusting valve to allow the control gas to flow out of the
small hole in the capacity adjusting valve. The air flow can be felt by the hand;

4) Slowly close the suction valve and observe the changes of the pressure in the unit. If the pressure
slightly rises and then quickly returns to the original position, then the setting is successful. Otherwise,
go back to the above step to continue;

5) Lock the fastening nut of capacity adjusting valve.

47
Chapter 6. Maintenance and Service
1. Preparations before maintenance and service

To ensure normal operation and long service life of the unit, good maintenance and service are critical.
Therefore, the maintenance and service procedures for the screw compressor unit should be carefully
performed. Before proceeding with maintenance, please carefully read Chapter 1 Safety Rules in this manual.
The following preparations are required at least:

1) Shut off the power supply of main machine and hang the sign at the power supply switch.
2) Close the shutoff valve going to the air supply system to prevent the compressed air from returning to
the maintained parts.
3) Open the manual vent valve to release the pressure in the system. Keep the vent valve in the open
status.
4) For the water cooling machine, the water supply system has to be shut off and the pressure in the
water pipes be released.
5) Ensure that the compressor unit has been cooled down to prevent from scald and burning.
6) Clean any spilt oil and water on the ground to prevent personal injury.

Warning
Do not think that the maintenance and service operations can be performed when
only the machine is shut down. The automatic control system of machine will start
the compressor at any time.
 Poor maintenance and service will influence not only the normal operation of unit,
but also the safety of operators.
 When the compressor is operating or pressurized, do not remove the nut, oil filling
plug or other parts.
 It is not recommended to use combustible solvents, such as the gasoline or
kerosene oil, to wash the air filter or other parts and components. Only safe
solvents shall be applied as per the instructions.

2. Maintenance and service of screw compressor

Caution
Only trained and qualified maintenance persons have the qualification to perform
the maintenance and service on these machines.
2.1 Lubricating oil for the compressor

The screw air compressor uses specially formulated and manufactured lubricants for SCR. We use only the
synthetic lubricating oil listed in the below table. Every delivered compressor unit has a lubricating oil tag to
indicate the type of lubricating oil filled in the unit. The lubricating oils are adaptive to the different ambient
temperature and load conditions and the oil-change intervals also vary according to working environment. Only
when the specialized synthetic lubricating oil from SCR is used, will the corresponding warranty service be
obtained.

48
 Type of lubricating oil Oil-changed interval Ambient temperature C
(hour)
SCR SLT 2000 ≤43C

For compressor units with standard configuration, the SCR lubricating oil is generally added prior to delivery.
The lubricating oil is specialized oil for the screw compressor, which is blended specifically by the manufacturer
for SCR. It will provide reliable operation and long intervals between changes.

Do not mix the oils with different types or trademarks for application. Otherwise, failures such as the lubricating
oil foaming, filter blockages, orifice or pipe blockages may be caused, reducing the designed service life of the
compressor and lubricating oil.

When the machine is operating, please inspect the level of lubricating oil periodically. The oil sight glass is
installed in the Air-oil separator in each unit. The normal oil level is located in the green area of oil sight glass. If
the oil level of Air-oil separator lowers to the red area of oil sight glass after the machine is shut down, then
adding oil will be required. However, only when the machine is shut down and thoroughly drained out, that oil
can be added.

2.1.1 Factors influencing the service life of lubricating oil

1) Abnormal high operating temperature

2) Contamination:
a) Other types or brands of lubricating oils
b) Strong oxidizing substances, such as
 Acid
 Sulphur
 Chloride
 Nitrogen oxide
 Welding waste-gas
 Ozone
c) Ammonia water
d) Solution type fume
e) Airborne dust
Place the compressor in a well ventilated and cool place as far as possible, ensuring that it can operate within
the normal temperature range. Otherwise, the oil consumption of the compressor and oil content in the air will
be increased. In addition, if the operating temperature exceeds 95C (203F), the service life of lubricating oil will
be halved every time the discharge temperature increases by 10C (18F). Therefore, it is preferred that the
operating temperature of the above lubricating oil doesn’t exceed 95C (203F).

2.1.2 Lubricating oil analysis plan

SCR provides all customers with an oil analysis service. The oil analysis inspects the total acid value (TAN),
viscosity and other indices of lubricating oil in the compressor and provides the users with the best oil-changed
interval, protecting the compressor equipment. A general oil analysis plan is recommended. Consult your
agent or the service department of SCR for the related details.

49
Caution: Oil sampling should only be taken when the compressor is stopped. It is best to take the sample from
the interface of oil filter. It will better reflect the current quality of lubricating oil.
 After new machine is started and operated for 600 hours;
 After operation for 2000 hours;
 When abnormal conditions such as the high oil consumption, oil leakage at shaft seal, or airend locking
has occurred.
 If necessary.

Danger
The high-temperature and high-pressure lubricating oil can cause severe scalding and
even the injuries. During the operation or when the pressure is present in the compressor,
it is prohibited to open the oil filling plug. If oil addition is required, then confirm at first
that the equipment is in the shutdown state and the power supply of system is shut off so
that the equipment can not automatically start.

2.1.3 Water discharge and replacement of lubricating oil

The condensate in the bottom of Air-oil separator tank shall be removed periodically. If the water content in the
lubricating oil exceeds 200PPM, the lubricating oil will be severely emulsified and consequently it will damage
the airend and bearings will fail. Therefore, it is necessary to replace the lubricating oil. It is prohibited to mix
the lubricating oils with different types or brands for replacement. Otherwise, the warranty clause for the
compressor unit will be invalid. If it is necessary to use other types of lubricating oils due to the special
operating conditions, please contact SCR.

SCR SLT lubricating oil should be replaced after every 2000 hours of operation or one year, whichever comes
first, under the normal maintenance and service and operating conditions; for other lubricating oils, please
contact SCR.

Caution
In cold conditions, the pressure differential switch on the filter may send out an alarm
after the air compressor starts. This is due to the high pressure differential caused by the
low fluidity of the lubricating oil. Please monitor the pressure differential switch after the
operating temperature of compressor has reached normal conditions.
When the signs present show insoluble deposits have formed on the oil filter element,
this indicates that the lubricating oil in the compressor can not operate normally and it
should be replaced immediately.

50
2.2 Oil filter

After a new machine operates for 600 hours, the oil filter element should be replaced. Thereafter, it is required
to be replaced when the following conditions occur. For replacing the filter core, the machine should be shut
down. Clean off any dirt and contaminates from the outside carefully and prevent any foreign matter from
entering into the lubricating system.
 Under normal operating temperatures, if the (pressure differential) at the filter has exceeded a
pressure differential of 1.7 bars (25 psi) an alarm will sound.
 Every time it operates for 2000 hours.
 When the lubricating oil is replaced.
 When the oil sample is assessed to be disqualified.

Caution
In cold conditions, the indicating light may be lit after the air compressor starts, due to
the high pressure differential caused by the low fluidity of lubricating oil. Please monitor
the indicator after the operating temperature of compressor is normal.
When the signs are present to show that the insoluble deposits are formed on the element
of oil filter, it indicates that the lubricating oil in the compressor can’t operate normally
and it should be replaced immediately.
The replacement and adjustment steps for the element of oil filter are as follows:

① Use the band type wrench to remove the old filter core and shim.
② Clean the mounting surface of shim.
③ Apply a thin layer of lubricating oil on the surface of new shim.
④ Tighten the filter core by hand for 1/2 - 3/4 turn.
⑤ Start the machine again and inspect whether the leakage occurs.

Warning
 To reduce the possibility of the damage to the filter core to a minimum, only the
products provided by SCR can be used, substitutes may not match the pressure in
the unit.
2.3 Safety valve

If a blockage occurs in the safety valve, it will cause the safety valve not to operate as designed. If a safety
valve fails to open, then its function to protect the pressure system will be lost and safety will be compromised.
If the safety valve fails to close, then the lubricating oil in the Air-oil separator may be ejected in volume. The
machine should be shut down every week for a safety valve inspection.

2.4 Secondary oil return pipe

The function of secondary oil return pipe is to guide the oil accumulating inside the filter core of Air-oil
separator to return to the low-pressure chamber of compressor. Its orifice is sized to ensure stable oil return. If
a severe blockage occurs in the secondary oil return pipe (mostly in the orifice and filter), then the oil content in
the discharged air will be excessive. The secondary oil return pipe should be inspected at the specified time.
Clean the orifice and filter (if equipped).

51
In the daily maintenance, if the following conditions occur, then the orifice shall be cleaned:
 Fail to see the lubricating oil to flow through the oil sight glass.
 It is found that the oil content in the discharged air is too high.
 Every time the lubricating oil is replaced.
 Once every half a year.

2.5 Oil cooler

When oil, grease, dust and dirt accumulate onto the surface of cooler, the hear transfer effect of cooler will be
reduced and finally it will lead to the excessive discharge temperature. For the air cooling cooler, the external
surface of cooler should be cleaned every two months with, cleaning fluid or low-pressure (usually not above
3.5 bars) compressed air. For the water cooling cooler, the discharge temperature shall be monitored in real
time. In the general operating conditions, the interior of cooler should be cleaned every 8,000 hours or 1 year,
whichever comes first.

2.6 Air filter

The air filter should be inspected every day.

Every day, the dust-collecting bag should be cleared (for heavy duty air filter), and the dust cap or air inlet
silencing chamber should be cleaned. In dusty environments, the cleaning operations should be more frequent.
If it is being operated in an extreme environment, it is recommended to arrange the air inlet of compressor to
the placed to draw clean air supply from outdoors.

Every time the vacuum switch of air filter acts, or when the pressure loss reaches 25” water column, or when
the indicator is lit, the filter core should be maintained. After operating every 500 hours or 3 months, the air filter
should be inspected for any damage and the air inlet system should be inspected for the sealing; in normal
operating conditions, the element of air filter should be replaced every 2000 hours or 1 year. If the
environmental conditions are poor or dusty (such as ceramic, cement industries etc), the maintenance and
replacement intervals should be adjusted accordingly. For the heavy duty filter, when the main filter core is
replaced, the safety filter core shall be also replaced. The safety filter core requires no maintenance during the
operation.

Every time the air filter is maintained, it should be inspected whether the downstream side of filter core is
contaminated. If so, the causes should be located and eliminated. It is necessary to ensure the air tightness of
sealing elements; thread connection, flange connection and hose connection between the air filter and the air
inlet of compressor are absolutely secure.

The maintenance and replacement steps for the filter core:

 Remove the rear cover and clear off the dust in the dust pan.
 Carefully take off the main filter core. Visually inspect whether the filter paper is damaged, the
adhesion of rubber sealing pad is secure, the adhesion between metal end cover and filter paper
is secure and the crack occurs to the metal end cover.
 Use the clean wet cloth to clean the inner side of outside box. Please note that no compressed air
is allowed.
 After Slightly tapping the end face of filter core on a flat surface, use dry compressed air not
exceeding 5.88 bars (85 psi) to blow off the dust in the main filter core from inside to outside along
the direction 45 degrees to the longitudinal direction of filter core.

52
  Re-install the cleaned filter core or new filter core in position. Please note not to forget the sealing
ring under the retaining nut of filter core. The nut shall be properly tightened. If it is too loose, then
it can’t ensure that the sealing washer fits tightly the end face of outside box. If is too tight, then it
will easily cause the deformation and disengagement of end cover of filter core.
 Install the dust pan and rear cover. Please note that the opening direction must be re –installed
correctly.

Caution
When the compressor is operating, do not remove and replace the air filter.
Do not use oil, water or compressed air containing water to clean the filter core.
A filter core with damaged filter paper or sealing ring should be replaced
immediately.
Every time the filter core is installed, the whole circumference of end face of the
sealing ring in the filter core should be applied with a little grease, to prevent the
adhesion between the sealing ring and the outside box of air filter.

2.7 Air-oil separator

The element has an overall structure and can congeal the oil mist on its surface to become the oil drops which
will fall into the bottom of separator and then be recovered by the oil return pipe to return to the compression
chamber. The separator has to be carefully handled to avoid the damage. Once the element of separator is
damaged or deformed, even an indentation will influence the separating efficiency, consequently resulting in
the excessive oil content in the discharged air of compressor. Even the slightest imperfection on the
component will lead to very high oil content.

In normal circumstances, if the air filter and oil filter are maintained in a good condition, then the periodic
replacement of filter core in the Air-oil separator will not be required.

If the following conditions occur to the machine, then it will be required to replace the element of Air-oil
separator:
 The pressure differential switch of separator acts and the pressure differential between the front and
rear sides exceeds 1.0kg.
 In the case that the oil level, loading and unloading, and the oil return system are identified to be
normal, the oil content in compressed air is still too high.
 Every other 4,000 hours

The detailed replacement and adjustment steps are as follows:

If the supplied air contains a high oil concentration and the filter, check valve, orifice and the diaphragm of vent
valve in the oil return pipe are inspected and are in normal condition, then it will be necessary to replace the
filter core of Air-oil separator.

53
  Remove all pipes (oil return pipe, air supply pipe and etc.) connected to the flat cover.
 Remove the oil return pipe (stainless steel pipe) from the joint on the flat cover.
 Remove the bolts and washers on the flat cover, and take off the flat cover.
 Remove the filter core.
 Clean the sealing surface between the flat cover and cylinder. It is noted not to allow the chips and dust
to fall into the cylinder.
 Replace the new filter core. Please note do not remove the staples from the shim.
 Install the flat cover and tighten the bolts by hand. Then diagonally tighten the bolts in 4-5 steps. The
tightening torque is referred to the standards of SCR.
 Re-connect all pipes. The stainless steel oil return pipe shall extend to the position 1.5mm away from
the bottom of filter core of Air-oil separator to maintain the unblocked oil return.
 Before restarting the machine, clean the filter, orifice and check valve in the oil return pipe.
 After operating for 24 hours again, tighten the bolts on the flat cover as per the requirements in Step 7.

2.8 Air inlet adjusting valve

See Fig. 6-1. The maintenance of suction valve usually requires the replacement of piston spring, piston
O-ring, sealing ring and check valve spring. During the maintenance, the following steps should be
followed:

Warning
 Do not remove the screws, screw-plug and other components when the
compressor is operating or pressurized.
 Before the removal, shut down the machine and release the internal pressure
completely.

1. Remove all pipes connected to the suction valve;

2. Remove 4 bolts and spring washers connecting the suction valve body and the compressor. Move the
suction valve away from the compressor;
3. Remove the retaining ring and O-ring in the suction valve body;
4. Remove the check valve assembly and spring in the valve body;
5. Remove the piston spring and piston assembly;
6. Clean the valve body. Ensure that the internal path is clean. Clear the old sealing ring on the flange of
suction valve;
7. Replace the old parts with the new parts provided in the spare parts and install them into the suction
valve;

Caution
To ensure the sealing, apply a little oil on the parts.

8. Insert the fluoride O-ring onto the piston. Apply a little on its exterior and install it into the valve body;
9. Install the new piston spring;
10. Place the new check valve spring into the piston. Then install the check valve assembly.

54
 11. Place the new Teflon O-ring into the valve body and lock the nut. In this point, it requires to remove
the bolt. Tap it on the airend. Please note the sequence of individual components for removal;
12. Before installing the new flange sealing pad, clean the inlet flange face of compressor;
13. Tighten 4 bolts and lock the locking washer.

Caution
Apply the compressor oil with the same model number on the flange
sealing ring to strengthen the sealing effect.

*Piston spring
Retaining ring
*Piston
*O-ring
(polytetrafluoroethylene)
*O-ring (fluororubber)

Valve body Check valve

Bolt
Retaining ring

Washer Cover

Shim *Check valve spring

*Service spare parts No. 250029-249

Fig. 6-1 Suction valve

Periodically inspect the suction valve (usually 600 hours or two months), vent valve and loading solenoid valve
and ensure that they are sealed without any leakage and act normally.

2.9 Control pipeline filter (water filter cup)

Refer to Fig. 6-2. The maintenance of the control line filter (part number: 25750020-051) usually includes the
replacement of filtering elements, float component and sealing elements.

Warning
 Do not remove the screws, plug or other parts when the compressor is
operating or pressurized. Before removal, shut down the machine and release
the internal pressure completely.

55
 1. Screw off the bottom case;
2. Loosen and remove the filtering elements from the valve body;
3. Discard the filtering elements;
4. Replace it with the new filtering elements in the spare parts package. Re-install it and tighten the
guiding disc;
5. Loosen and screw off the nuts on the bottom case;
6. Remove the float component and sealing element;
7. Replace it with the new sealing element in the spare parts package. It is noted to apply the
compressor oil on its surface to strengthen the sealing before the installation;
8. Replace with the new float component in the spare parts package;
9. Re-install the float component. Place it into the bottom case. Tighten the nuts;
10. Re-connect the valve body and bottom case. Rotate them for 2-1/2 turns.

Valve
body

*Filter core

Baffle board
Valve
Cap body Valve bolt*

Check
Float
ring* Diaphragm*
component*
Float Valve disc*
Lock shim*
Seal ring Valve disc nut*
Sealing
*Seal ring shim*

Spring chamber
Adjusting spring

Locking nut Spring seat

Adjusting screw

Bottom
cabinet

Bolt
Fig. 6-2 Fig. 6-3

56
2.10 Maintenance of pressure regulator (capacity adjusting valve)

Refer to Fig. 6-3. The maintenance of the valve usually requires the replacement of diaphragm only. The
steps are as follows:
1. Loosen the locking nut. Turn the adjusting screw counter clockwise until the spring is loose. In this
point, the spring screw has no pressure;
2. Screw off the spring chamber;
3. Remove the spring seat and spring diaphragm assembly;
4. Remove the sealing pad;
5. Loosen the valve disc nut and remove the valve disc and diaphragm;
6. Remove the retaining ring and discard it;
7. Replace with the maintenance components and re-install it;

8. Replace with a new retaining ring;

9. Replace with a new sealing pad;
10. If the spring is damaged, replace it;
11. Place the spring seat;
12. Install other components in position. Install the spring chamber;
13. Tighten the adjusting screw until it bears the spring pressure;
14. Refer to the adjusting steps for control system and re-adjust the pressure regulator.

2.11 Maintenance of minimum pressure valve

See Fig. 6-4. Only after the pressure in the machine is released, is maintenance permitted. Refer to Fig.
19.
1. Remove the valve from the top of Air-oil separator tank;
2. Screw off the top cover and remove the main spring;
3. Reverse the valve. Use the screwdriver to tap the check valve assembly until the piston and check
valve assembly disengages;
4. Clean the valve body and undamaged components;
5. Apply a layer of oil on the new check valve. Gently place it into the valve body. Install a new
non-return spring;
6. Apply a layer of oil on a new O-ring. Install the piston and a new piston spring. Re-install the top cover
in position.

2.12 Belts and belt pulleys

During normal operation, good alignment should be ensured between the drive pulley and driven pulley. The
efficiency of belt transmission, service life of the belts and the safe operation of the airend can be ensured only
with proper belt tension. If the following conditions occur to the machine, then it requires inspection and
adjustment to the alignment of belt pulleys and the belt tension, or to replace the belts:
 600 hours after commissioning;
 Every 2000 hours operation after the first inspection;

57
  Every time the maintenance is performed and the shaft seal is replaced;
 When abnormal belt wear or belt damage occurs;
 When any abnormal noises and vibrations occur at the airend;
Alignment requirement of belt pulleys: Place the machine on a level and solid foundation. The circular run out
of external end faces on two belt pulleys shall not exceed 0.5mm relative to the horizontal base level. It can be
inspected with a levelling rod.

2.13 Maintenance and replacement of thermostatic valve

Spring
Top
cover

Check
valve
assembly
Washer Spring

Locking washer

Hexagonal set *O-ring

screw

Piston

Valve
body

Fig. 6-4 Minimum pressure valve

2.14 Hose

After operating 600 hours or 6 months, it will be necessary to inspect the air supply hose, lubricating oil
pipeline and the flexible hose in the control pipeline. If required, replace them.

2.15 Installation of shaft seal

The shaft seal of compressor is a wearing part and will be replaced. The shaft seal can be successfully
replaced when the specialized tools are available and the installation process and operating procedure are
thoroughly understood.

58
 Caution
When a suspected shaft seal is removed, do not damage it. The damaged part of the
sealing element should be noted and observed to obtain the causes for the
damages of the sealing element.
The Screw compressor from SCR is equipped with an oil return pipeline to match the shaft seal assembly, so
that the whole shaft seal has the triple-sealing function. The oil return pipeline should be inspected for the
maintenance and replacement of shaft seal. The following points shall be ensured:

A. Inspect for the unblocked connection between the oil return pipe and sealing chamber of shaft seal.
B. Ensure that no blockage is present in the oil return pipe (insides).

The wearing level or service life of shaft seal varies depending on the operating status and mode of screw air
compressor, such as the rotational speed, final pressure, oil pressure, and operating temperature. Therefore
the customer should operate the machine strictly following the requirements in the instructions for the
operation and application, ensuring the normal service life of shaft seal. The installation steps for the shaft
seal:
1. Shut down the compressor. Ensure that no restarting will occur and it must be unloaded;
2. Remove the drive components (such as belt pulleys, coupling and etc.);
3. Remove the keys firstly from the keyway and then from the main shaft;
4. Remove the socket screw and front cover;
5. Remove the inner ring from the main shaft with the dismantling tools or thermal removal tools;
6. Clean the main shaft of compressor. Clear off the grease;
7. Apply a layer of silicon gel on the main shaft at the circumference tightly fitting the inner ring of
bearing;
8. Heat the new inner ring to 100C. And then tightly slide it onto the main shaft until it contacts the
limited edge;
9. Before installing the shaft seal, thoroughly clean the main shaft and inner ring. Press the old shaft
seal out of the front cover. Clean the front cover and apply a layer of silicon gel on it;
10. Press the shaft seal into the front cover in a proper angle. Clean the silicon gel inside the shaft seal
and replace with a new O-ring;
11. Slide the mounting guide ring of shaft seal into the main shaft until it contacts the limited edge;
12. Carefully press the prepared whole set of front cover including the shaft seal and O-ring into the
mounting guide ring of shaft seal on the main shaft, and keep it with the compressor housing to be
concentric. It should be always noted not to damage the lip of the shaft seal. Tighten the socket
screw to fix the front cover.
13. Press the key into the keyway;
14. Wait for the solidification of silicon gel (for about 30 minutes). And then re-install the drive
components. Inspect the oil level in the oil tank. Test the compressor in a short period;
15. Perform the leakage test and inspect the functions of components;
16. Fill in the replacement recording sheet.

59
3. Maintenance and service of the motor

3.1. The operating conditions of Screw compressor from SCR:

Ambient temperature ≤45C

Frequency 50Hz
Voltage 380V
Operating mode S1
Protection level /Insulation level IP54/IP55/F

3.2. Operation of the specialized motor in Screw compressor

3.2.1. The motor should be securely grounded to earth. The grounding wire of the specialized motor of the
compressor is usually connected to the inside of electrical cabinet and connected to the cabinet body.
It is only required to securely connect the grounding wire of user to that point.
3.2.2. The specialized motor in Screw compressor shall be connected as per the wiring and connecting signs
on the nameplate or instruction. Its lead-out line has the specified signs.
3.2.3. The specialized motor in the compressor can continuously operate at the rated power multiplying the
application coefficient, when the voltage and frequency are kept to be the values specified on the
nameplate. When the frequency deviation of power supply exceeds the value on the nameplate by 1%
or the voltage deviation exceeds its value by 5%, the motor can’t ensure that it outputs continuously the
power.
3.2.4. When the 3-phase unbalance in the power supply doesn’t exceed 1%, the specialized motor in Screw
compressor can operate in a good condition.
3.2.5. When the motor operates at no load or at load, no intermittent or abnormal noise or vibration should
occur.

3.3. Maintenance, service and repair of the specialized motor in Screw compressor

3.3.1. The operating environment should be kept dry at all times. The surface of the motor should be kept
clean at all times. The air inlet should not be obstructed by dust, fibers and etc.
3.3.2. If the operating environment is moist or the machine is out of service for a long term, then it should be
heated for restarting to eliminate the moisture.
3.3.3. When the controller or thermal relay acts, the failure source should be inspected. After the failure is
eliminated, then it can be put into operation.
3.3.4. If a failure occurs to the motor, please contact the service department of SCR or the nearest agent.
3.3.5. The motor should be maintained periodically. If a fault is found it should be attended to immediately.
Generally, a light maintenance operation should be performed once a month and comprehensive
maintenance should be performed once a year.

3.3.5.1. The items in the light maintenance include:

A. Clear off the dust on the surface of motor;

B. Measure the insulation resistance of motor;
C. Tighten the mounting bolts and grounding bolts as well as various connecting bolts;
D. Clean the starting device and insulation terminal;
E. Clear off the dust, carbon deposits and etc. on the slip-ring and electric brush in the winding rotor
(YP series) motor;
F. Clean the mesh of air screen in the motor, ensuring there are no blockages of either the air inlet
or outlet.

60
3.3.5.2. The items in the comprehensive maintenance include:

G. 2.2.1 All items in the light maintenance;

H. 2.2.2 Clean the inside of motor to keep the stator winding in the motor to be clean without oil dirt
and copper exposure;
I. 2.2.3 Inspect whether the bearing in the motor is in a good condition. If it is damaged, replace it
immediately;
J. 2.2.4 If it is not necessary to replace the bearing, then clean it and replace with the lubricating
grease;
K. 2.2.5 Clean or replace other components in the motor.

3.3.6. Lubricating the motor

The proper lubrication of motor will have a direct effect on the service life of bearing as well as the service
life of motor. It is critical to add lubricating oil (grease) into the bearings in the motor correctly and
periodically.
A. SCR has used dual-seal bearings comprehensively to all small motors (the suffix in the model
number of bearing is “ZZ”). This type of bearing is pre-lubricated and requires no lubricating.
B. The larger motors (usually H180 and above) and specially required motors have oil filling and
drainage features. They have been lubricated before delivery. However, the periodic replacement
of grease is required. The interval of grease replacement depends on the size and application
condition of motor.
The recommended values for lubricating the motor are as follows (excessive or infrequent lubrication may
damage the motor)

Rated power Rotational Recommended value of lubrication interval

(KW) speed of motor Normal working Rigorous Bad working

(rpm) conditions working conditions

conditions

<18.5 1500 5 years 3 years 1 year

18.5～90 1500 1 year 6 months 3 months

90～200 1500 3 months 3 months 1 month

200～630 1500 3 months 1 month 15 days

<18.5 3000 5 years 3 years 1 year

18.5～90 3000 1 year 6 months 3 months

90～200 3000 3 months 1 month 1 month

200～630 3000 3 months 1 month 15 days

Note:

61
 Normal working conditions: Motor operates at rated power or less power in a clean environment for 8
hours per days.
Rigorous working conditions: Motor operates at rated power in a relatively dirty and dusty environment
for 24 hours per days.
Bad working conditions: Motor operates in a very dirty and dusty environment, or there is heavy impact
duty and high vibrations are present.

C. Oil filling method

A. Open the dust cap for the lubricating nipple and oil outlet. Confirm that the lubricating nipple is clean.
Use the manual grease gun or pneumatic grease gun to connect to the lubricating nipple and add the
grease until the new grease is discharged from the oil outlet.
B. Remove the grease gun. Run the motor for 10～20 minutes. Confirm that the excessive grease has
not been discharged. Re-install the dust cap for the lubricating nipple and oil outlet. The lubrication is
completed.
C. See the lubrication nameplate on the motor or instructions for the grade of lubricating grease.

62
4. Service plan

1) Every day

a) Record the operating status of machine every day. See Table 6-2 for the detailed contents of record.
b) Clean the dust-collecting bag of air filter or the inlet silencing chamber. It is not recommended to start
the machine without an air filter. If the pressure differential switch of air filter activates, it will be
necessary to service the filter core.
c) Observe whether the oil level is within the specified range.
d) Inspect the pressure differential switch of oil filter.
e) If the intelligent controller sends out an alarm for a blockage in the oil filter, please replace the oil filter.

2) Every week (50 hours)

a) Inspect whether the safety valve is blocked or other damage is present.

b) Inspect the oil filter in the first 50 hours from installation of a new machine. If necessary, replace the
filter core.
c) Clean the orifice and screen (if equipped) in the secondary oil return pipeline in the first 50 hours since
the new machine operates.
d) Inspect the control line filter and drain out the water in the cup (water filter cup).

3) 3 months (600 hours)

a) Clear off the dust at the air inlet of machine.

b) Remove the air filter and inspect the filter core. Keep the maintenance of filter core in a good
condition.
c) Remove the breathing pipeline. Clean and dry it.
d) Replace the oil filter for the initial operation.
e) An oil sample should be taken and sent to SCR service department for analysis after the initial
operation.
f) Inspect the belt tension. If necessary, adjust it.

4) Half a year (1000 hours)

a) Inspect belt tension; if necessary, adjust.

b) Inspect and clean the orifice and screen (if equipped) in the secondary oil return pipeline.
c) Service air filter

5) One year (2000 hours)

a) Replace the air filter core.

b) Change oil.
c) Inspect whether the spring and pin inside the check valve can normally operate. If necessary, replace
them.
d) An oil sample should be taken and sent to SCR service department for analysis.
e) Inspect and calibrate the pressure meter and sensor.
f) Inspect the capacity adjusting (loading) solenoid valve (two-position, three-way and normally closed
solenoid valve). If necessary, replace the internal sealing ring.
g) Review the record of operating status of machine. Identify whether it is necessary to clean the interior
of cooler. If necessary, it may be better to use a chemical agent to clean it.
h) Inspect the quality of cooling water

63
 Table 6-2 Daily inspection record sheet
Reference
Items
value
Discharge
xxx bar
pressure
Ambient (inlet)
≤45C
temperature
Discharge
≤95C
temperature
Oil level Green area
Drainage period
of electronic
1-2 seconds
water discharge
valve

6) Preparations for long-term shutdown

If the interval between shutdown and restart is relatively long, please turn on the manual switch of the
(electronic) water (waste-water) discharge valve before the shutdown, and allow the draining period
not to be less than 5 minutes, ensuring that the water in the system is completely drained out. The
accumulated water in the components such as the cooler, air tank and etc. should be discharged after
the shutdown.
a) Shutdown period less than 1 month
 It is necessary to start the machine once every week and allow the machine to operate in
unloading mode for 10 minutes.
 Manually turn the coupling once every week.
b) Shutdown period exceeding 1 month
(A) Shutdown preparation
 Continuously load it for 10 minutes to discharge the air in the pipe.
Remember: Drain out the water inside two gas-water separators
 Manually turn the coupling after the shutdown.
 Discharge the water in the components such as the cooler, air tank and etc.
(B) During the shutdown
 Repeat (A) once every other three months
(C) Before the restarting
 Replace the oil inside the oil tank
 Open the water discharge valve in the gas-water separator
 Manually turn the connecting component (coupling) between the motor and main machine,
ensuring that the rotation is easy.

64
Chapter 7. Troubleshooting
Failure 1: Over-High discharge air temperature
---The discharge air temperature is equal to or above 110C.
Inspect whether oil level is Add lubricating oil
relatively low
Yes

Oil Emulsified
Poor oil
Replace lubricating oil

Wrong oil application

No
High discharge Adjust the operating pressure to below the specified value
pressure
Purging or cleaning
Air-cooling

Cooler Blocked

Water-cooling
Remove the dirt
Contactor failure
Air-cooling
Fan fails to rotate
Cooling system failure Failure of fan motor
and reverses.

Water-cooling ■Low water pressure < 0.25Mpa

■Water flow becomes lower
■High water temperature >32℃

Air filter Blocked Purging or replacing

Ambient temperature > 40C Improve the ventilation

Temperature sensor failure ■Connecting wire loose ■Locking

■Damage ■Replace

Maintain thermostatic Replace the valve core

Thermostatic valve failure
valve

Aged and blocked parts and

Replace
components in oil pipe

Oil filter blocked Replace the filter

Blocked cooling air and reduced flow

Wrong indication of temperature gauge

or controls Inspect motor current

Damaged main machine Whether the sound is normal

Maintain main machine

Vibration is larger than that of

other parts

65
Failure 2: Oil over-consumption
The air compressor requires
lubricating frequently

Replace leaked
Leakage of lubricating oil
pieces
pipe

Whether oil content in discharged air is

very high or not Replace it as needed. If necessary,
No Failure of sealing
replace all sealing elements.
elements

Yes Clean, inspect the check valve and throttle

orifice
Inspect whether oil return pipe is
unblocked
Purge oil return pipe

No
Too high oil level Oil level shall not exceed high limit of oil sight glass
for the shutdown.

Drain out part of oil

Low-pressure operation for Increase the air supply Adjust the air pressure
a long-term pressure

Oil leakage in pressure differential Inspect the sealing ring of pressure Replace
switch of oil separator differential switch

Yes
Too short oil return pipe Replace
Failure in oil return
pipe
The 30°~45° inclined plane shall Machine the oil
be present in bottom of oil return return pipe
pipe

Pressure differential in oil Replace

separator > 0.7Bar
Oil separator failure

Breakage of oil Replace

separator
Emulsified oil or wrong
application of lubricating oil Replace with the recommended
lubricating oil

Failure of filter Replace filter core

Too high discharge See Failure 1

temperature

Too frequent cycles of loading and See Failure 15

unloading

66
Failure 3: Overload or blockage of main motor

Relatively low 3-phase Adjust and improve

voltage

Whether electrical part acts normal or Yes Unstable 3-phase voltage Adjust or improve

not

Poor contact of contactor Replace

No
No air release Inspect drainage
pipeline

Whether air compressor is Failed relief valve Replace

started with loading or not

Wrongly connected Reconnect

relief pipe

Poor insulation Repair

Motor failure Poor lubrication Add lubricating oil

Burned motor Repair or replace

Failed lubricating oil, damaged Replace bearing

bearing

Airend failure Repair the airend

67
Failure 4: Abnormal shutdown during operation

High-temperature See Failure 1

caused shutdown

Sudden shutdown No
during operation Overload Power supply Inspect power supply
shutdown failure

Loose connecting Inspect all lines including

Yes wire power supply

Failure of relay or fuse in Inspect and repair

control circuit

Inspect whether circuit part is normal No ■ Voltage is relatively low and less than rating by 10%

■ Voltage is unstable/unbalanced

Yes
Adjust pressure
Too high discharge pressure

Failure of installation and connection

Inspect and repair
of thermal relay

Higher viscosity of lubricating oil Replace lubricating oil

Failure of motor Maintain or repair

Loose connecting wire in motor or Inspect all wires and repair

contactor

Relatively low setting value Resetting the protection value

68
Failure 5: Air generation without loading

Damaged propelling rod of suction Replace

valve

Too low setting or failure of capacity Reset or replace

Suction valve failure adjusting valve

Damaged diaphragm of suction valve Replace

Damaged loading solenoid valve Replace

Solenoid valve failure Wrong connecting wire of the Modify the wiring
solenoid valve

Blocked solenoid valve Clean

Severe air leakage in control air pipe Repair or replace

or filter cup

Blocked control pipeline Clean

Other failures
Loose control connecting wires Reconnect

Failed controller (keys) Repair or replace

Failure of pressure switch Repair or replace

69
Failure 6: No unloading when pressure reaches high limit

Failed action of suction Repair or replace

valve
Failure of suction
valve
Damaged capacity Repair or replace
adjusting valve

Damaged solenoid Repair or replace

valve

Wrong set of the controller Reset controller (pressure switch) to

(pressure switch) proper valve

Controller failure

Damaged controller (pressure switch) Replace controller (pressure switch)

Leakage in control pipeline Inspect, maintain the joints in control

system

Leakage in compressed air supply Inspect all compressed air pipes

pipe

70
Failure 7: Low air output

No ■Damaged air valve diaphragm ■Replace

Whether suction valve is fully opened ■Poor adjustment of capacity adjusting valve ■Re-adjust
■Blocked suction valve ■Repair or replace

Yes
Blocked air filter Replace

Belt slip Adjust belt tension or replace belt and pulleys

Wrong type oil Poor sealing effect

Replace
oil

Air leakage of rear pipeline (operating Inspect leakage and

pipeline) repair it

Blocked oil separator Replace

■Clearance between rotors becomes larger Repair or replace

Airend failure
■Damaged rotor

Minimum pressure valve fails to

open fully Replace valve core of minimum
pressure valve

Insufficient oil supply Inspect oil circuit, especially oil filter

71
Failure 8: No indication on display screen

Damaged fuse Replace

No power supply for display

Damaged transformer Replace

No
Whether power supply is present for No 3-phase power supply or not Inspect
main controller correct rating

Damaged AC contactor Replace

Yes
Inspect whether there is power supply
No. 21 and 22 output indicator light are
not lit
Poor connection Reconnect

Yes No

Replace display screen Replace main controller

72
Failure 9: Indicating the data without starting (failing to start)

Yes
Inspect whether field Eliminate field failure and restart
failure occurs on the
display screen

Key malfunction Replace controller

No Controller failure

Loose connecting wire

between display and main Connect the wire well
controller

Inspect input voltage, and compare it

Too low voltage
with voltage at motor terminal to inspect
the causes of too low voltage

Failure of circuit part Damaged control relay Replace relay

Inspect whether AC contactor engages Replace

normally

Transformer failure Inspect secondary voltage of

transformer

Inspect for the burning signs on the Repair or replace

motor

Other failures
Loose connecting wires Reconnect

Airend failure Repair or replace

Failure of starting switch Inspect switch to identify

whether loose or damaged
contact occurs

73
 Failure 10: Too low pressure in air tank

Suction valve is not fully open Repair air suction valve

In the machine

Wrong set of capacity adjusting

valve Re-adjust capacity adjusting valve
to obtain required adjusting range

See Failure 7

Too many leakages in operating Inspect the leakages in operating

pipes pipes with soap water

External Inspect for causes. If it is

inspection Damaged pressure gauge in air damaged, replace it
tank

Too high air demand Inspect the air consumption

capacity of user. If necessary,
increase air supply

Failure 11: Too high pressure in air tank

Wrong setting of controller Adjust controller (pressure switch) to allow

(pressure switch) the unloading pressure to be less than rated

maximum operating pressure

No unloading when
Suction valve is not closed
control pressure Inspect suction valve and repair it
reaches high limit

See Failure 6

74
 Failure 12: Frequent blockages in oil/gas separator

Air filter is damaged or not Replace damaged air filter core. If it is not applicable to the
applicable to the operating operating environment, then select the heavy duty air filter or
environment lead the air inlet of compressor to the place with cleaning air

Failure of oil filter

Replace oil filter core. Use the genuine filter from SCR
Frequent indications
for blockages in oil
separator
Damaged or improper element of
Replace the core of separator. Use the genuine filter core from SCR
Air-oil separator

Deteriorated lubricating oil Clean and replace the system

Operate in the extreme environment such

as high-temperature, high-humidity or
high-pressure; Operate compressor at
rated air tank pressure and oil temperature.
In the oil Contaminated lubricating Shorten the change interval of lubricating
oil oil or filter. Replace lubricating oil. As per
daily maintenance sheet, repair and
maintain elements of air filter and oil filter

Mixed the lubricating oil with different

Application of improper grades or types;
lubricating oil Do not mix the lubricating oil with different
grades or types. Do not use the lubricating
oil from different manufacturers

Failed pressure differential Replace pressure differential

switch switch

75
 Failure 13: Frequent blockages in oil filter

Indicator failure
Replace indicator

Frequent
indications of
Use the genuine spare parts from SCR
blockages in oil Improper oil filter
filter

Failure of air filter Replace air filter. Use the genuine spare

parts from SCR only.

Deteriorated lubricating oil Clean the system and replace

The system is contaminated; inspect and clear off the dust, corrosive

substances, painting film and oil mud in the system

Failure 14: Frequent blockages in air filter

Failure of pressure Replace pressure differential switch

differential switch

Frequent indications for Compressor operates in a Make the air inlet far away from
blockages in air filter highly contaminated air contamination

Air filter is not applicable Use heavy duty air filter. Please
to the environmental contact SCR
conditions

76
 Failure 15: Frequent switching between loading and unloading

Too low capacity of operating pipe Increase the size of system air tank

The setting of controller (pressure Reset the value of pressure differential between
switch) is close to that of capacity controller (pressure switch) and capacity adjusting
adjusting valve valve

Leakage of pipeline Inspect and repair

Frequent loading and
unloading on air
compressor

Accumulated water or freezing of Drain out control pipeline. Repair filter.

control pipeline Inspect throttle orifice of capacity adjusting
valve

Damaged controller (pressure switch) Repair or replace if necessary

There is check valve installed

between air compressor and air tank Remove check valve

Failure 16: Excessive water content in compressed air at discharge end

Failure of refrigerated dryer Eliminate the failure. See the

or adsorption dryer below for handling the failure

High water content Blocked water/gas separator Clean or replace

at discharge end

Installation/application failure Inspect other compressors in the

same system

Leakage in water cooler; Replace water cooler

(only for water cooling type)

77
Failure 17: Abnormal opening of safety valve

Wrong set of pressure Re-adjust the range of pressure differential to

differential adjusting valve get the correct range

Abnormal opening
Wrong setting in air controller Reset controller (pressure switch) to unload
of safety valve
(pressure switch) compressor at schedule pressure

Suction valve is not closed as

Inspect and repair suction valve
per requirements

Blocked separator Replace element of oil/gas separator

Failure of pressure gauge or Inspect the pressure gauge. If necessary,

sensor replace it. Lower the control setting

Inspect whether safety valve is in the proper

Defective safety valve
pressure setting position. If the leakage occurs,
replace it

Failure of minimum pressure Repair or replace

valve

Other failures See the failure of air compressor unloading

78
Failure 18: Abnormal noises in the air compressor

----Pressure sensor can’t detect the pressure in 2 seconds after starting

Inspect whether belt is slipped or not ■Adjust belt

■Replace belts or belt pulleys

Deteriorated and emulsified oil; rusty signs occur Replace the oil
on the airend

Scratched or damaged rotor Inspect or repair the airend

Damaged airend bearing Replace

Insufficient oil return Blocked oil filter

Failure 19: Oil injection in suction valve during shutdown

Damaged suction valve and check valve Replace

Sudden shutdown at heavy load Avoid emergency stop

The discharged air due to the blockage in

Inspect or replace oil return pipe
return pipe returns to the suction valve

Relatively high oil level in Air-oil tank Drain out part of oil

Too fast air drainage speed in Air-oil Inspect whether the size of vent

separator valve is accurate

79