Analysis of air compressor parts function and trouble shooting

First, the role of lubricating oil
Lubricating oil has the function of lubrication, cooling and sealing.
1) pay attention to the level of the oil is the unit running oil level.
2) to prevent the condensation of water in the oil, the oil temperature is about 90 degrees celsius.
3 lubrication oil temperature is low, will produce condensed water. If the temperature is low, can be turned on or off a small outlet port xiao.
4 resolutely put an end to the operation of oil temperature below 68 degrees C.
Lubricating oil composition: base oil + additive = lubricating oil. Has the following function: anti foam additive, antioxidant, anti corrosion, anti coagulation, wear-resisting, detergency (corrosion), viscosity stability (especially high temperature), dispersion. The lubricating oil can be used for a year at most, and the lubricating oil can be deteriorated too long; the oil contains impurities, water, sealing rings, etc..
Two, screw air compressor parts function
1 air filter function
The main task is to prevent the dust and other impurities in the air into the air compressor system.
Filtration accuracy: 0.001mm particle filter 98%, 0.002mm particles filter out of the, more than 0.003mm particle filter out of 99.9%.
2 oil filter function
Remove all impurities and dust from the lubricating oil, but do not separate special additives added.
The accuracy of filter media is: 0.008m m particle size 50% 0.010m filter, M filter particle size 99%, filter media fake without heating oil testing, only a few fold, greatly reduce the filtration area, and the folds of the uneven spacing.
Oil filter bypass valve role: to prevent the air pressure oil pipeline in the oil, burning air compressor parts. If the air in the inlet air is dusty and the oil is used for a period of time, the filter paper is blocked seriously, which hinders the flow of the lubricant. When the oil filter oil reaches a certain pressure difference (cold start or filter blockage), the bypass valve is opened in the filter to ensure that there is enough oil in the oil. You must open the bypass valve in the pressure difference accurately, if the pressure difference is too small, the oil filter does not work, so that each component of premature wear; if the pressure difference is too large, lack of oil in oil, lubricating oil temperature is too high, will damage the rotor.
Replace the oil filter method: turn on the oil plug to reduce the pressure of the system;
In order to avoid oil spill, prepare a oil filling device, remove the oil filter, clean the oil filter chassis, put oil on the new filter washer and screw it to the base, then tighten it by hand.
3 working principle of oil gas separator
(1) the main function of the oil and gas separator is to separate the compressor oil from the oil and gas mixture. Into the oil tank (tank by the oil and gas separator, the minimum pressure valve, safety valve and the shell of the container) composed of 3 kinds of oil and gas mixture separation: centrifugal separation, gravity separation (oil specific gravity) and fiber separation. The separation process of oil and gas mixture of oil and gas separator wall along the tangential direction into the oil tank, 80% ~ 90% of the oil separated from the oil and gas mixture (centrifugal separation), left (10% ~ 20%) of the oil viscosity in the oil and gas separator wall surface separation (gravity separation), a small amount of oil into the internal oil and gas separator (fiber separation), the return pipe pressure screw back cavity.
(2) oil and gas separator washer has conductivity due to air and oil through the glass fiber, therefore in electrostatic separation layer between the two, if the two metal layer with static electricity, there will be danger from electrostatic discharge accompanied by electric spark, it may cause an explosion of oil and gas separator. The gasket is used to seal the core of the separator and the air receiver, but this may cause the accumulation of the electrostatic field between the separator core and the receiver housing. A good oil and gas separator assembly ensures the electrical conductivity between the separator core and the air receiver housing. Air compressor metal components have good electrical conductivity, can ensure that all the static electricity can be timely export, to prevent the generation of electric sparks.
(3) oil and gas separator capable of carrying up to 0.5M P a the resistance of pressure difference of the design of adaptive differential pressure gas separator oil separator filter, if more than the maximum value, it will burst, compressor oil cannot be separated, it will affect the whole machine or cause separator completely damaged. The pressure drop of oil gas separator core increases every additional 0.1M P a differential pressure, the total energy consumption will increase 7% motor; pressure drop separator too high oil and gas separator will cause fire. There are 4 reasons for the high pressure difference: because of the dirt, the oil separator is blocked, the air is adverse, and the internal pressure fluctuates greatly.
(4) the metal of the oil and gas separator has been electroplated, so it can not be corroded according to the surrounding environment (temperature and humidity) and the working condition of the compressor. If the oil and gas separator does not undergo plating, it will form a layer of corrosion, which will have a destructive effect on the oxidation resistance of the compressor oil.
(5) measures to ensure the service life of the oil and gas separator: the accumulated dust, residual oil, air pollutants or wear will reduce the service life of the oil and gas separator. The air filter and oil filter can be replaced in time to observe the oil change time to limit the dust entering the compressor oil. Use the correct anti-aging and water free oil.
Three, screw air compressor several matters needing attention
1 screw air compressor rotor must not be reversed
The rotor is the core component of screw air compressor, male screw has 4 teeth; the female screw has 6 grooves, oil film protection and take positive and negative screw friction heat effect, Yang Yin Yang screw drive screw rotation, screw bearing axial bearings; bearing radial bearing female screw. Output air pressure is generally 0.7MPa (air inlet is 0), the gas pressure and the Yin and Yang helical gear pair of radial force to offset each other, Yang, Yin screw has a 0.02 ~ 0.04mm gap, yin and Yang screw surface does not touch. If the rotor is reversed, yin and Yang screw helical rotating radial force to push 0.7M P a; inlet pressure (outlet 0) to screw push right, move the right screw pump head, internal screw end and the pump head shell friction; not in the head of pump pressure head screw pump is established. There is no lubricating oil, lubricating oil can not makeCan not take circulation, internal friction heat pump head, the pump head in the moment to accumulate heat, high temperature, and the screw head in the pump shell deformation, yin and Yang of occlusal locking screw. Rotor end of pump head
Because of high temperature and the end surface together, rotor end wear, even parts caused by defects caused by the gear box and the rotor is damaged. Check the direction of rotation: because sometimes the factory into the line phase sequence will change
Change, reason or screw air compressor power supply changes, will cause the screw air compressor motor phase change, so it is best to use to detect and record the phase sequence tables, if no sequence tables, should be careful and do a mark in the demolition before the power line connection. If you forget to make a record, you should do the following test before the air compressor running: hand hold the cooling fan contactor to see if the wind direction is correct. If the fan power line moved, people instantly move the main motor, the motor coupling at the direction of rotation is correct.
2 screw air compressor rotor can not accumulate carbon
(1) the reasons for the use of poor quality coke, not the original manufacturers of genuine lubricants. Using false or damaged air filters. Long time high temperature operation. Lubricating oil less. Replace the lubricating oil, the old oil is not clean or new and old oil mixed use. The mixed use of different types of lubricating oil.
(2) check the carbon deposition method of the rotor and remove the intake valve to observe whether there is carbon deposition on the pump head. From the surface of the oil filter and the inner wall of the lubricating oil pipeline.
(3) check the head of the pump when the screw air compressor pump head shell is not allowed to disassemble the professional, technical personnel in the pump head, if only the professional manufacturers can maintain. Screw air compressor pump head of the Yin and Yang screw gap is very small, maintenance, pay attention to the pump head can not enter any impurities.
3 regularly add motor bearing grease
Add special gun steps: 1 in the fuel nozzle across the open vent hole. The gun nozzle and check motor. Lubricating grease is divided into high speed motor oil and low speed motor oil; the two can not be mixed, or both chemical reaction. The pressure of each oil gun oil quantity is 0.9g, each time adding 20g to 23. If the grease is added less, the grease on the oil pipe road, does not play a role in lubrication; if added more, bearing heating, grease into liquid, affecting the quality of bearing lubrication. The air compressor running every 2 000h to add a.
4 main motor coupling replacement
The coupling must be replaced by the following: 1. Coupling surface scorch. Fracture of coupling grease.
Four, screw air compressor failure analysis and exclusion
1 a North 1 40m³ /m i n running in screw air compressor, screw machine Ignition Fault scrap to produce high temperature in the compression process, the lubricating oil injection, the heat away, thereby reducing the pump head temperature. If there is no oil screw, instantly lock head. Fuel injection point is different for each pump head design, so a variety of screw air compressor manufacturers oil is different, can not be interchangeable, can not be universal. The screw air compressor in operation is on fire:
1) the flash point of lubricating oil is about 230 DEG C, the ignition temperature is about 320 degrees celsius. The use of poor quality lubricating oil, lubricating oil spray atomization, flash point, ignition point reduction.
2) the use of poor quality parts, resulting in air compressor oil, gas road impeded, gas, oil circuit components temperature is too high for a long time, easy to produce carbon deposition.
3 oil and gas separator gasket does not have conductivity, oil and gas separator can not produce static electricity.
4) there is an open flame in the machine, the oil leakage in the oil system.
5) combustible gas is inhaled at the inlet.
6) the residual oil is not released, the oil mixed.
In summary, by the relevant experts, engineering and technical personnel to confirm the machine maintenance using the vulnerability of lubricating oil inferior and inferior, electrostatic oil and gas separator produced cannot be exported, causing the machine to scrap fire.
2 when a screw air compressor is unloaded, there is a failure of oil fume
During the operation of the screw air compressor unloading pump head trembling, every 2 months air filter alarm, with high pressure air cleaning air filter does not work. Remove the air filter, the suction pipe has oil fumes, smoke and dust mixed air filter will be dead. Open the intake valve, found that the intake valve seal damage, re replacement of the intake valve maintenance package, the screw air compressor operation.
30min 3 a CompAir screw air compressor, with the required preload is replaced by a new V fault CompAir screw compressor V is set in the ex factory. In the replacement of damaged V belt in order to save labor, easy to install V belt, loosen the lock nut, reduce the tension of the automatic tensioning system. After the replacement of the V belt, the locking nut is not returned to the original running position (the corresponding color marking point), and the V belt is loose, worn, and hot, which causes the newly replaced 6 V belt to break again. In addition, the removal of the V belt, in accordance with the correct direction of rotation of the pump head pulley, pulley with each turn, the pump head of the screw has a hard point, is a screw design process, not a fault.
Five, conclusion
Screw air compressor operator maintenance should always pay attention to the maintenance of matters needing attention, understand the main components of air compressor function is very necessary. Equipment management, management department staff to purchase the original factory parts, to prevent poor quality lubricating oil, poor quality parts, to prevent unnecessary failure, the occurrence of the incident.