Caution

Please read the operate manual carefully before start the compressor working

— Don’t dismantle any connector or equipment when machine is

running. Otherwise, the high-pressure gas and high temperature will
hurt you seriously.

— Please pay more attention to parts such as pump, oil tank and
pipelines, because they are high temperature when machine is running.

— Don’t try to change the working pressure rated . Because change

working pressure exceeding the rated range will cause machines to
overload and stop to work.

——
— Provide proper grounding connection for electric parts according
to electric security regulations. Use suitable wires matching the
working power, otherwise they will burnt out due to high temperature
or some other dangerous events occur.

— The compressed air for breathe use is prohibit.

Page 2 of 26
 Regular maintenance interval schedule
Every 50 hours or weekly
--- Check oil level.
--- Check intake filter, if necessary clean it.
--- Drain condensation water from oil tank.
Every 500 hours
--- Check and adjust belt tension if necessary (belt driven only)
Every 2000 hours
--- Replace lubricants (for mineral lubricants oil)
--- Replace oil filter.
--- Replace intake filter
Every 4000 hours
--- Replace lubricants (for synthetic lubricants oil)
--- Replace oil separator
--- Clean cooler for dirt

Attention:
1、Replace filter element and lubricant after first 500 hours of operation.
2、Use incorrect lubricant oil and spare parts will cause compressor damage, only use original
manufacture oil and parts.
3、The service life of compressor depends on the environment conditions such as dust, vent
etc.

Guarantee period

DMC products enjoy 1-year guarantee calculated from the buying date for complete machine.
we will not offer free of charge service to repair damaged machine due to installation error, using
error, bad oil, maintenance error and use of not original manufacturer parts.
For routine maintenance note that DMC technical service team are able to provide you with
assistance and spare parts, please contact us via email or phone call in [Link]

Page 3 of 26
 CONTENT
1、General
1.1 Working principal
1.2 System control
1.3 Manipulation Temperature
1.4 Lubricant features

2、Installation requirements and inspection before running

2.1 Hoist and transportation
2.2 Field requirements
2.3 Requirements for quality of cooling water
2.4 Connection requirements for air pipe
2.5 Electric installation requirements
2.6 Machine inspection

3、Daily operation
3.1 Preparations before running
3.2 Start-up procedure for the first time
3.3 Start-up procedure for the daily time
3.4 Turn-off procedure

4、Control panel operation

4.1 PLC Controller
4.2 VSD Mode
4.3 Fixed Speed Mode

5、 Regular Maintenance

6、 Troubleshooting

Page 4 of 26
1、General
DMC screw air compressor adapts up-to-date structure design from Italy technology. Its key parts such as
screw air end, control valves are origin Europe design. It which falls into the category of products of
intellect-type and environments-protecting-type is microcomputer -controlled feathering compact structure,
high efficiency, low noise, long life period and so on. And it is the ideal air source equipment popularly
applied to textile, machinery, chemicals, electric, mining and other industrial areas. It runs intelligently, and
realizes long-range control and chain control.

1.1Working principle

Compression: the screw air end sucks air through air intake filter and intake control valve. Then the rotary
double shafts compress the air . At the same time, oil is put into the air compressing cavity making the screw
and bearing cool and lubricant.

Separation: The mixed gas of air and oil generated by compressing is exhausted into air and oil separation
cartridge. Most of oil is separated from the mixed gas under the influence of gravity and mechanical
centrifugal force. Almost all oil mist is separated out after the gas of air and oil is through separation cartridge
core. So then the oil amount of the mixed gas is below 3PPM. The oil separated through separation cartridge
core is back to screw principal machine through oil return tube. A throttle is mounted on the oil return tube in
order to keep the loss of compressed air in the lowest extent. The clean oil flows into air end internal cavity
after being filtered.

Cooling: After oil is separated, compressed air flows out of separation element through minimum pressure
valve then into after-cooler. Then cool the compressed air into a temperature towering above environmental
temperature by 7-10 degrees centigrade before it is discharged. Minimum pressure valve guarantees the
minimum pressure needed to keep up circulation of oil when the screw air compressor is started or when it is
running normally. Due to the check valve on minimum pressure valve, the compressed air can’t flow
backwards into separation element.

1.2 System control

The aim of having a control system is how to control the intake valve correctly to let air in normally. The
system is comprised of intake valve, work piston, magnet valve and pressure gauge.

Start-up: the intake valve shuts up under the influence of spring force. Hence only little air is sucked through
single-direct valve of intake valve to generate cartridge pressure to keep up circulation of oil when screw air
compressor is started up from no-load state.
Load: when compressor is running to a load state, it’s vacuum within compressor. And there is pressure in
intake filter. So, due to the difference of pressure, which makes the piston of intake valve work, intake valve
opens. Vacuum of one side lets air in then be compressed, which makes intake valve open fully. After that,
system pressure increases.
Full load: when the pressure of oil separation cartridge reaches 0.4MPa, minimum valve opens to let
compressed air flow out. (When the system pressure is lower than the rated pressure, intake valve will be open
all the time.)

Page 5 of 26
No-load: when the pressure of empty pipeline reaches the maximum pressure rated by pressure switch, the
switch turns off the magnet valve’s power. Then there is no pressure difference. Intake valve shuts up under
the influence of spring force. Discharge magnet valve releases pressure and the pressure of separation element
goes down. All these make back pressure of frame end of screw air compressor low down. When compressor
is in the no-load condition, a little air goes in to keep certain pressure. It is needed as working pressure of
lubricant system to make rotors and bearing lubricant. When the pressure of pipeline goes down to the rated
load pressure, compressor is back to load state. Then magnet valve gets power. Intake valve opens.
Accordingly, the system pressure goes up. As per requirement to compressed air, make the process be in a
cycle.

Stop: when the compressor is stopped, all magnet valves’ power will be turned off. Then intake valve will
close up. Last the discharge magnet valve will release the cartridge pressure.

1.3Manipulation temperature

Screw air compressor’s environment temperature ranges from 5 degrees centigrade to 40 degrees centigrade.
Intake point is the measure point.

Condensation---low temperature

When the manipulation temperature is lower, water would concentrate in oil on the location of higher degree
of moisture. Compressor is equipped with a thermostatic valve. And the temperature is set to 70℃. (Upon
reaching the temperature, water vapors.) Oil won’t pass through the oil cooler until it reaches the rated
temperature.
In the area of temperature below 5 ℃, anti-condensation apparatus should be mounted. And a heater should be
installed under the separation element too.

Overheat---high temperature

The air sucked under this condition (environmental temperature is above 40℃ or the compressor is installed in
a house where there is a boiler) when the compressor is in full load state may be excessively hot and above the
cooling requirement. The air for cooling use had better be input from outdoors. When the load rate is below
100% load, a higher environmental temperature can also meet the cooling requirements. The maximum of
working temperature of compressor is 105℃. If the temperature is above 105℃, the compressor will be
overheat and cease to work.

Discharge temperature

The measure point of discharge temperature is located in the vent of frame end of compressor. Discharge
would vary according to environmental temperature, load percentage, cleanliness of cooler, cleanliness of
intake filter and the cleanliness of oil filter. The normal manipulation temperature is between 70℃ and
90℃.When the compressor is started up from a cool condition, the discharge temperature will go up quickly to
85℃. Then thermostatic valve open fully. (it sets to open when the temperature is 70℃)If it is with down

Page 6 of 26
 loads, oil temperature will be back to 70℃. At this time a little oil will pass through thermostatic valve in case
the oil temperature be too low. With the increase of load, thermostatic valve adjusts discharge temperature by
control the oil amount through oil cooler.

1.4 Lubricant features

The feathers of DMC screw air compressor is as follow:

 Low degree of blister, not easy to volatilize
 High degree of anti-emulsification, high degree of anti-oxidation
 Motion viscosity (40℃) ㎟/s 46
 Pour point temperature -35℃ anti-solidification, low energy-consumption
 Flash temperature 230℃, anti-carbon-deposit, and low-energy-consumption

Oil for bearing of motor:

Commended: Shell Alvania RL 3

2. Installation requirements and inspection before running machine

Examine in details whether there is damage due to transportation or not before accepting the compressor. If
any, please request the shipping company to confirm it by signing and contact us immediately.

2.1Hoist and transportation

 Guide rope should be used when compressor is being hoisted lest it be damaged. Check if welding crack and
bolt become loose after it is lifted [Link] figure shows, a supporting board is needed when compressor is being
hoisted.
 If use a platform trailer to transport the compressor, make sure the trailer has enough driving-power.
 If use a forklift to transport the compressor, also make sure it has enough driving-power. Specific requirement
is subject to the local regulation.
The length of fork should not be less than the length of the base of compressor.

2.2Field requirements

 Compressor should be located in a clean, no-dust, well-ventilated place (discharge the heat wind from upside,
input air from bottom) with air excluding toxic gas, inflammable gas and explosive gas. Where it is easy to
maintain the compressor.
 Compressor mustn’t be used outdoors. Because there is a bad condition. That is, there is a great quantity of
dust. A filter screen should be mounted in the air intake of house in order to reduce the quantity of dust.
 Environmental temperature should be above 5℃ to guarantee lubricant a normal cycle.
 Some space (1m between compressor and wall is perfect) must be set aside in order to make daily maintenance
work convenient. See figure3.
 Compressor should be placed in a solid level surface. There is no using nut to fasten it.

Tip: Don’t put it in a place where the hot wind can be sucked circularly. (Put it in a well-ventilated place)

2.3 Requirement for cooling water and water-cooling set

Page 7 of 26
 General hardness expressed by CaCo3 should be less than 100PPM (100 milligram/liter)
 PH value varies from 6-8
 Suspended material should be less than 50PPM (50 milligram/liter)

Tip: the temperature of cooling water is set to 32℃.And the water quality must be in conformity with general
industrial water. Avoid using ground water. If the water quality is not good, use purifying agent to clean depositing
dirt periodically. If the compressor comes into disuse for a long time, drain out all cooling water.

2.4 Connection requirements for air pipe

 The diameter of discharge pipe should be at least the same as that of compressor. All pipes and connectors
should be able to bear the rated pressure. The configuration should meet the requirements for flowing velocity of
compressed air. And the pressure drop of pipeline mustn’t exceed the set pressure by 5% or more. Try to use
elements with a bent or high drag coefficient as little as may be. If the pipeline is relatively long, adopt pipes with
a diameter bigger than rated one.
 Don’t let this matter occur. That is, don’t let condensation water flow into working machine or elements driven
by air along the pipeline. An oil/water separation apparatus and a dirt-draining apparatus should be mounted on
front end of pipeline. Install the main pipe with a slope of 1-2 degrees, and then the condensate water can be
easily drained out.
 One-way valve, stop valve are mounted at the exit of compressor. And a sample connection of pressure and a
stop valve for maintenance and pipe-connecting use are mounted after them.
 Because there is an anti-vibration mat and not supporting things for fixing, all external pipelines should have its
individual supporting things. In order not to let condensate water flow back into compressor when it stops, make
pipeline lower than the air gate of compressor.
 When compressor is used with drier, an air reservoir should be installed in between compressor and drier. In this
case, it can low down the temperature of discharged air and separate a part of condensate water. At the same time,
compressed air of lower temperature and less amount of water is transported into the drier through air reservoir. In
such way, it can lessen the load of drier and save energy.
 Main pipeline going around the whole air-use house is the ideal plan. In this case, compressed air from direction
can be got anywhere. If there is a sudden increase of air-use quantity on some branch pipe, it can reduce pressure
drop. Moreover, mounting proper valves on main pipeline can insure convenience for maintenance. Because we
can cut it off, if necessary.

2.5 Electric installation requirements

All internal wires of compressor are through test by factory. All external wires linked to compressor must be
manufactured by qualified factory. According to the input working power required by compressor set, choose right
wire specification. If the wire is too long, line loss should be taken into consideration. Under this circumstance,
diameter of wire should be made bigger so as to meet the requirements for starting-up and running.
Compressor of a big quantity of discharging air needs an individual power-supply system; otherwise it will have
bad influence on normal working of other equipment.
Make sure that power voltage meets rated working voltage of compressor before running it.
Reliable grounding of compressor set is needed to avoid dangers resulted in by power leaking.
Power supply

Page 8 of 26
Standard requirements:
230V, 3 phase, 60Hz grounding 460V, 3 phase, 60Hz grounding
380V, 3 phase, 50Hz grounding 415V, 3 phase, 50Hz grounding
Other
Make special requirements on placing the order

Turning of motors

Power must be linked to compressor correctly to guarantee the right turning of motor. DMC screw air compressor
is equipped with a special apparatus to avoid backward rotation of motor. (If the sequence of 3 phases is not
correct, motor stops automatically to protect the motor.)
Particularized methods as follow: First, switch on power. Second, unloose the scram button. Third, press the stop
button. Then the machine will check itself. Finally, press the start button. If the machine is running normally, that
means the sequence of 3 phases is correct.
If the motor stops automatically, that means the sequence of 3 phases is not. Then exchange the two phases of
power input. (Instead of exchanging the wire ring of motor or the wire ring of starter, all these wire rings are set to
optimize the performance of motor.) Men with electrician certification should finish wire-linking work.

2.6 Machine inspection

Inspection for screw air end
 Revolve the belt pulley or shaft coupling of gear end by hands from two different directions. Check if the screw
end is not locked.
 When compressor is not in use for more than two months or stored for a period of time, intake valve should be
opened. Then fill half litre of oil into compressor through it. Revolve the belt pulley or shaft coupling of air end by
hands from two different directions. Make sure all oil enters air end.
 When reconnect inlet pipe, make sure nozzle is sealed.

Inspection for oil level

When open the side door, you can see the oil inspection mirror. The maximum oil level must not be higher than
the upper part of oil inspection mirror and the minimum oil level must not be lower than the bottom of oil
inspection mirror. The requirements also holds true when compressor is running.
Charge the rated amount of oil. Make sure the lid to the nozzle is screwed on well and seal ring is in good
condition.
Tips: Charge oil according to the amount stipulated. Too much oil will make the compressed air contain too much
oil. And too little oil will lead to high temperature of compressor.

Inspection for transmission system

 Inspection for belt
Check if all belts are in the groove. Adjust the tightness of belts through the adjusting bolt on motor.
 Inspection for flexible shaft coupling
Check if the bolt of the flexible shaft coupling is in fixed state.

Inspection for all valves of system

Check if stop valve is open.

Page 9 of 26
3、Daily operation
The procedure below is for starting up for the first time or compressor being not in use for more than two months.

3.1 Preparations before running

Delay-start: This function is to avoid starting up continuously after power cut or emergency shut down. During
this period, compressor can’t be started up. Make sure the pressure is cut down to avoid starting up the compressor
when there is back pressure. Press the start button. And this signal will be put down automatically by system.
When the delaying time has elapsed, compressor will start up automatically.

Delay-stop: This is a soft stop function. This function makes compressor unload and cease to work. First, press
the stop button to unload compressor. Then it will be running for a while until the preset time and stop. (This will
contribute to reducing the pressure of oil separation cartridge.) During the delaying time, if press the start button,
the delaying time will be finished automatically. If the system pressure needs loading, the compressor will load or
unload normally.

3.2 Start-up procedure for the first time

 Check if the stop valve on outlet is open. (If the stop valve is open, this pressure is the pressure of compressor
system)
 Turn on power, and then power indicator light will be on. Compressor begins its delay-start. Starting instantly is
forbidden.
 Press start button to run the compressor, and then compressor is in the normal delay-start condition. Once it
reaches the preset time, compressor will start up automatically. (During the delaying time, press the stop button,
and then compressor will stop)
 Watch the manipulating temperature and system pressure on control pane to manipulate the compressor
correctly.
 When it reaches the pressure stipulated, Compressor goes on running. But it is running in a un-load state.
 Compressor supplies compressed air through loading and unloading. Pay attention to pressure, temperature and
power flux when manipulating it. Make sure there is no accidental vibration and compressor is running smoothly.

3.3Start-up procedure for the daily time

 Check if oil level is correct. The oil level must be in the center of oil gage.
 Drain out the condensate water in the air-storing tank.
 Confirm that stop valve is open.
 Press start button. (Compressor does not start up automatically. But run light is flashing, it means compressor is
in a delay-start state.)

3.4Turn-off procedure
Press the stop button, and then the compressor will be in delay-stop state. Meanwhile, the stand-by indicator light
is flashing. After some time, the compressor stops.
If the compressor is start stopping, press the stop button to make it stop thoroughly.
Attention: when compressor is in stand-by state, it may stop and may start up at some time. So don’t take it for
granted that compressor has been stopped when the motor is not in motion. Check if the stand-by light is on.
Tip: emergency shut down button is generally pressed on emergency.

Page 10 of 26
4. Control Panel Operation ( VSD )

4.1 PLC Control Panel (VSD)

—Start Button: Press this button to start the compressor.

—Stop button：Press this button to stop the compressor.

—Set Button/ Loading / unloading Button: After modification, press this to confirm and save modified
data；When the compressor is running ,press this button to load or unload under a certain pressure.

— Move up button/increase button: Data at current position is increased by pressing this button when
data are modified; Menu is moved upwards when menu is selected.

— Move down button / Descending button: Data at current position is descended by pressing this
button when data are modified; menu is moved downwards when menu is selected.

— Shift button /Enter button: This button services as shift button when data are modified and services
as enter button when menu is selected.

—Back button / Reset button: This button services as back button when operate menu to come back
Parent menu; resetting is carried out by pressing this button for a little long time when failure
shutdowns

Page 11 of 26
4.2 Operate for VSD (variable speed driven) mode
The display interface is as following when power on:

DMC SCREW
COMPRESSOR

After 5 seconds, the main page will show up as:

T：150F 0.0Hz
P: 90PSI 0RPM
STOP
230V 7.5KW

Press to move black bar and enter sub-menu:

RUN PARA.
USER PARA.
FACTORY PARA.

RUN PARAMETER

FREQUENCY PARA
TOTAL RUN TIME
CURRENT RUN TIME
MAINTAIN PARA

HISTORY FAULT
PRODUCT NO. DATE
CURRENT FAULT
ABOUT COMPRESSOR

TOTAL RUN TIME：

20HR 05MIN 12SEC
TOTAL LOAD TIME：
15HR 08MIN 10SEC

Page 12 of 26
 USER PARAMETER:

PRESSURE SET
ON/OFF DELAY SET
OPERATE MODE SET
BLOCK PARA SET

MAINTAINPARA RESET
USE TIME SET
USER PASSWORD:****
LANGUAGE：ENGLISH

LOAD PRESSURE：90PSI
UNLOAD PRESSURE：115PSI
FREQUENCY PRESSURE：110PSI
FAN START T：178F

FAN STOP T：158F

MOTOR POWER：7.5KW
ROTARY SPEED：3000RPM

if you want change parameter setting, password is required:

PASSWORD
****

显示此界面后，出现闪烁位，

after modification, press to confirm and save.

Attention: All setting parameter must be when the compressor in stop

USER PARAMETER LIST:

INITIAL
FIRST MENU SECOND MENU FUNCTION
VALUE
LOAD PRESSURE 90PSI
PRESSURE
UNLOAD PRESSURE 115PSI

Page 13 of 26
 FREQUENCY STABLE DISCHARGE PRESSURE,
110PSI
PRESSURE SPEED WILL BEGIN TO SLOW DOWN
FAN START TEMP 178F
FAN STOP TEMP 158F
MOTOR POWER 7.5KW
ROTARY SPEED 3000RPM
MOTOR START
0010S
DELAY
LOADING DELAY 0005S
MAX NO LOAD RUN
900S
TIME
DELAY TIME
STOP DELAY 0003S
RESTAT DELAY 0005S
HZ RISE UP 0010

HZ DROP DOWN 0010

LOCAL/
OF/OFF MODE
REMOTE
AUTOMATI
OPERATE LOADING MODE
MANUAL
MODE
COMPUTER PROHABIT/
MODBUS PROTOCOL
COMMUNICATE ALLOWED
CODE 001-016
ONE HOST COMPRESSOR CONTROL
HOST/SLA
STATE MORE THAN ONE SLAVE
VE
COMPRESSOR
VSD-FIXED
CASCADE WAY
/VSD-VSD
CASCADE
CASCADE NO. 0000
ALTERNATE TIME 9999HR
MAX PRESSURE 115PSI
MIN PRESSURE 90PSI
DELAY TIME 0000SEC
RESET TIME TO 0000 WHEN REPALCE
OIL FILTER 0000HR
NEW FILTER
OIL SEPARATOR 0000HR
MAINTAIN AIR FILTER 0000HR
TIME RESET RESET TIME TO 0000 WHEN REPALCE
LUBRICATE OIL 0000HR
NEW OIL
LUBRICATE GREASE 0000HR
BELT/COUPLING KIT 0000HR
ALARM WHEN LIFE TIME EXCEED
MAX LIFE OIL FILTER 2000HR MAX, IF SET 0000 ALARM UNABLE
TIME FOR WORK

Page 14 of 26
 OIL SEPARATOR 2000HR
AIR FILTER 2000HR
LUBRICATE OIL 0000HR
LUBRICATE GREASE 0000HR
BELT/COUPLING KIT 0000HR
USER Ask USER PASSWORD IS REQUIRED
****
PASSWORD WHEN CHANGE PARAMETER

LANGUAGE ENGLISH/CHINESE ENGLISH RUSSIA VERSION IS OPTIONAL

FACTORY PARAMETER LIST:

PARAMETER
INITIAL VALUE FUNCTION

IF MOTOR CURRENCY MORE THAN

MAIN MOTOR
MAX /1.2 1.2 TIMES OF SETTING VALUE,
CURRENCY
COMPRESSOR WILL SHUT DOWN
ALARM TEMP 105℃ LUBRICATE OIL TEMP
SHUT DOWN
110℃
TEMP
RUN TIME 000000HR
LOADING
000000HR
TIME
ALL PRESSURE SETTING VALUE IN
MAX LOAD
0.80MPa USER PARAMETER MUST BE LOWER
PRESSURE
THAN THIS VALUE
IF DISCHARGE PRESSURE IS
SHUT DOWN
BASIC 1.00MPa HIGHER THAN IT THE COMPRESSOR
PRESSURE
PARAMETE WILL SHUT DOWN
R HISTORY
0000
FAULT RESET
CODE ******** RANG:0-9,A,B,C,D,E,F
DATE ****-**-** PRODUCTION DATE
POWER
60HZ/50HZ NEED SUPER PASSWORD
SUPPLY
PHASE
OF/OFF NEED SUPER PASSWORD
PROTECT
MAX RUN
0000H NEED SUPER PASSWORD
TIME
MAX ALARM IF LONG TIME ALARM THE
0010H
TIME COMPRESSOR WILL SHUT DOWN
BACKUP 0001
LOW TEMP -005℃ IF DISCHARGE TEMP IS LOWER

Page 15 of 26
 PROTECT THAN IT THE COMPRESSOR WILL
SHUT DOWN
FOR CHANGE ALL USER PARA
ANDFACTORY PARA EXCLUDE
TOTAL RUN TIME,LOAD
PASSWORD-2 **** TIME,MAX TIME,LONG ALARM
TIME,HZ,PHASE
PROTECT,PASSWORD-2,PASSWOR
D-TIME
FOR CHANGE ALL USER PARA
ANDFACTORY PARA INCLUDE
PASSWORD-TI TOTAL RUN TIME,LOAD TIME,MAX
****
ME TIME,LONG ALARM TIME,HZ,PHASE
PROTECT,PASSWORD-2,PASSWORD-
TIME
COMMUNICA
OF/OFF
TE
INTEGRAL
00.20 MPa
RANGE
INTEGRAL
0020
INITIAL
RATIO PLUS 0010
INTEGRAL
0012
PLUS
DIFFERENCE
0000
PLUS
MAX HZ 060.0Hz
FREQUENC MIN HZ 020.0Hz
Y PARA NO LOAD HZ 010.0Hz
PRESSURE OF
REDUCE 00.72MPa
FREQUENCY
REDUCE HZ 005.0Hz
FREQUENCY
INVERTER **** COMMUNICATE TO PLC
CODE
REDUCE SPEED/FREE
STOP WAY
SPEED
PID 000.5SEC

NO.3 SWITCH SIGNALS

HARDWAR
NORMAL ON/OFF
D SET NO.4
NO.17 RUN/REMOTE/ALARM

Page 16 of 26
Page 17 of 26
5. Maintenance

Inside drawing ( main parts list)

Page 18 of 26
5.1Maintenance items and maintenance period
Compressor will not be in a good motion, unless it gets adequate maintenance. Right maintenance can prolong its
service life and greatly cut down the time of stopping due to failure.

Daily manipulation
Before starting up: drain out the condensate water in the bottom of oil separation until some oil flows out. And
check if the oil level is in correct position.
Attention: Don’t open oil-discharging ball valve until five minutes later after stopping
After starting up: Watch the pressure on the control panel. Check manipulating temperature and the general
conditions inside compressor. Check if there is leakage on the outer surface of cooler or on bolts.

Maintenance plan
Check the running temperature and working pressure. (Every day)
Put down the current, voltage, temperature and pressure. (Every day)
Clean compressor. (Only after stopping). (Every week)
Blew wash the ail filter. (Every week)
Check oil level. (Every month) Check the bolts on the belt pulley (shaft coupling)
Blow wash cooler. (Every month)

Make maintenance every 500 hours

Check the quality of oil. If it is qualified, it can be used again after be filtered cleanly. Otherwise, replace it.
Replace the core of oil filter
Replace the core of intake filter
Replace the core of oil separation
Replace the filtering net of oil return pipe
Check the fatness of belt pulley or the labiality of the shaft coupling.

Every 2000 hours

Replace the core of oil filter
Replace the core of intake filter or intake filter
Check and adjust the fatness of belt pulley or the liberality of shaft coupling.
Check intake-controlling valve

Every 4000 hours

Replace lubricant
Replace the core of oil separation or oil separation
Replace the minimum-pressure control valve
Check thermostatic valve
Check if the electronic lead is tight
Check if main bolts, main nuts and connectors are tight.
Check the security apparatus
Guard for maintenance
Don’t repair and maintain compressor if compressor is in motion or there is pressure in it. First, stop it, and then
maintain it after inner pressure is released.

Page 19 of 26
Lubricate Oil

HRI-1043 is an ISO 32 grade synthetic based Compressor lubricant specifically designed to provide long term
lubrication in rotary screw air Compressor
Oil Capacity:
5– 10 HP – 6 liters (2 gal)
15 – 20 HP – 9 liters (2.5 gal)
25 – 30 HP – 15 liters (4 gal)
40 – 60 HP – 25 liters (7 gal)
75 – 100 HP – 35 liters (10 gal)
125 – 150 HP – 70 liters (20 gal)
175 – 200 HP – 90 liters (25 gal)
Note: mixed difference brand / ISO grade lube oil is serious forbitten

Replacement of air filter, oil filter, oil separator

Page 20 of 26
 Maintenance method for intake filter
1. Open the end cover
2. Take out the filter core
3. Check the condition of intake filter (if it is not good, replace it)
4. Clean out the dust accumulating on the bottom cover
5. Replace it with a new filter core

Maintenance method for oil filter

1. Screw out the old filter with pliers
2. Clean the touching surface
3. Lay a thin film of oil on the seal ring of new filter
4. Press the filter with handle until the washer is sealed
5. Check if there is leakage after starting up

Maintenance method for cartridge of oil separator

1. Open the service wicket door
2. Loosen the connector between pipe and minimum-pressure valve
3. Loosen the pipeline on the cover of oil separation. Make sure it can be reinstalled.
4. Loosen the fixing bolts on the oil separation
5. Lift up the cover board slightly, and then clean the oil return pipe
6. Take out the oil separation cartridge
7. Replace the oil separation cartridge and washer
8. Install it according the reverse procedure. Check the length of oil return pipe

Features of intake valve, solenoids valve and its maintenance method

Intake-controlling valve is mainly composed of valve body, valve gate, piston, cylinder, spring and seal ring and
so on. And there is a controlling plate and an electromagnetic control valve on its side. They are with the functions
such as load shedding, noise elimination, depressurizing, stopping to release thoroughly, adjustment of on or off,
and so on. A small part of air is output through the vintage of intake-controlling valve to balance the amount of
sucked air through the vintage. This can keep the pressure in the separation element in the range of 0.2-0.3 Mpa.
So that lubricant can be in a normal cycle. The pressure sensor and the electromagnetic valve of adjusting system
control the action of on or off of intake-controlling valve automatically. The agility of the action of on or off is
very important for the reliability of compressor.

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Maintenance method for minimum-pressure valve and temperature control valve
1. Screw out the lid, pay attention to the spring force of the valve.
2. Take down the lid,
3. Check if there is abrasion on the O-type ring of the piston. If so, replace the ring.
4. Check if there is abrasion on the seal ring. If so, replace it.
5. Lubricate them with high temperature grease. Reinstall them according the revere direction.

Exchanging method for lubricant

1. Stop compressor
2. Connect up oil-discharging pipe, then open the ball valve, and then drain the oil into the oil-recycling can.
3. Close the oil-discharging ball valve, then open the oil filling cover, and then refill new oil until the oil
level is in the center of oil gauge.
4. Fix the oil filling cover, and then check if the O-type ring is in the correct position.
5. Start up the compressor. Check the oil level after compressor running for a while. If oil lever is lower,
properly fill oil again.
Attention: short down replacing period when there is too much dust or the manipulating temperature high.

Oil level:
Maximum oil level: oil level is in the center of oil gauge, after compressor stopping for 30 minutes.
Minimum oil level: oil level is in the lower part of oil gauge when compressor is running.
Adjusting method for tightness of belt
1. Stop
2. Shift out wicket door
3. Loosen the fixing bolt for security under motor base. (Three-fourths ring tightness is always kept)
4. Rotate the adjusting bolt, then adjust the tightness of belt until getting the right tightness
5. Screw down the fixing bolt of gear end
Method for replacing belt
The method is the same as the method of the adjusting method for tightness of belt. First, adjust the belt loose
enough, then replace it with a new one, and then adjust the tightness.
Attention: After replacing it, adjust the new belt once 5 minutes later after starting up, and then adjust it once
again 10 minutes later after starting up again
Tip: full group of belts should be replaced at one time. It is not allowed that replace one or some belts of them
at one time.

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 Adjustment of belt pulley
Poor parallelism of belt pulley will cause belts be abraded quickly, thus reduce the service life of belts and belt
pulley. Insure the two belt pulleys in the same plane. First, fix the belt pulley of gear end in the right position,
and then adjust the belt pulley of motor to let them be in the same plane.
Centering of flexible shaft coupling
The flexible shaft coupling must be centered when the motor or gear end is moved or reinstalled. And
parallelism and axiality must fall into the range of 0-0.05mm

Maintenance method for motor

A lubricant should be applied on the motor bearing every 1500 hours. (Use shell Alvania RL3, if not specified.)
Clean up the grease with a clean duster cloth. Run the motor in a unload state after belt pulley being
dismantled. Don’t stop applying new lubricant when motor is running, until all original oil is drained out
through the oil-discharging ventage (Oil-discharging ventage is under the bearing cavity).

6. Troubleshooting

FAULT POSSIBLE REASON SOLUTION

1、no electric power to compressor, Check electrical connection

switch or emergency stop button does
not closed
2、sequence of phases is not correct or Check or interchange two phases
Compressor does phase lacking (L1,L2 or L3) in the power cable
not start 3、overload protection relay does not Reset it with hand
reset
4、fuses or electrical contactor are Check it, replace if necessary
defective
1、under- voltage or three phase voltage Ensure constant voltage in accordance
is not balance with IEC Standard
2、electrical connection is flexible Check and tighten connection
Compressor is
difficult to start 3、compressor can not vented perfectly Check intake valve and replace if
and stop necessary
automatically in
4、compressor oil is very viscous due to Heat up the compressor before startup
start process due
low ambient temperature
to high current
5、minimum pressure valve does not Check the valve spring and replace if
closed perfectly necessary
1、exhaust pressure is exceed rated Check and adjust unloading pressure
value value
Compressor stop 2、setting value of overload protection Check and adjust setting current value
automatically in current is not correct of main motor or fan motor
working process 3、oil/air separator is jam Check it, replace if necessary
due to over load
4、pressure control or sensor Check pressure sensor, switch or
computer controller

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 5 、 screw air end or main motor is Simple examine through rotate it with
defective hand, repair or replace if necessary
1 、 insufficient oil quantity or use Fill oil and ensure oil level is not below
incorrect type oil than “minimum level” mark, use original
manufacture oil only
Compressor stop 2、cooling unit soiled or internal jam Clean cooling unit
automatically in 3 、 ambient temperature too high （ ≥ Improve air ventilation of compressor
working process
45℃） room
due to over heat
4、insufficient vent cooling air Clean and keep air inlet vent opening
5 、 oil filter or thermostatic valve Clean it , replace if necessary
cartridge jam
6、cooling fan fault Check and replace if necessary
7、temperature sensor PT100 defective Check and replace if necessary
or wire break
8、oil pipe leakage Fasten and seal oil pipe coupling
1、oil/air separator element is defective Check and replace if necessary
2、excessive oil filling Drain off some oil, ensure oil level is not
Excessive oil higher than “maximum level” mark
consumption 3、oil-return line jam Check and replace one-way valve if
necessary
4、working pressure is too low for long User should reduce compressed air
time（≤0.6MPA） consume to let pressure increase
5、use incorrect oil, more foam and low Use original manufacture oil only
viscous
6、too many condense water in internal Drain condensation water from oil tank
system due to high humidity climate promptly
1、intake valve does not open Intake controller or solenoid valve is
defective, or air pipe connected to
controller is leakage, check and replace
if necessary
No compressed 2、discharge solenoid valve is defective Check electric supply and clean valve
air exhaust, no holes, replace if need
pressure build up 3 、 minimum pressure valve does not Check minimum pressure valve spring ,
open replace if necessary
4 、 components in compressor are Check oil and air lines in compressor,
leaking tighten and reseal screw coupling
connections
5、V-belts are slipped or torn Check and replace if necessary
1、intake valve does not close Intake controller or solenoid valve is
defective, or air pipe connected to
System pressure controller is leakage, check and replace if
does not decrease necessary
when reach rated 2、discharge solenoid valve is defective Check electric supply and clean valve

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pressure value holes, replace if necessary
3、system pressure control fault Check pressure sensor, pressure switch or
computer controller, replace if necessary
1、intake valve is leaking Check and replace if necessary

2、press Emergency Stop Button when Switch off compressor using OFF Button,
Oil or oil smoking compressor is in loading only use the Emergency Stop Button in
in intake filter emergencies
when stop
3、minimum pressure non-return valve is Check and replace if necessary
leaking
4、Excessive oil in air See the reasons of excessive oil
consumption

1 、 air vent, intake filter or oil/air Clean and replace if necessary

Discharge flow separator jam
volume decrease 2、intake valve does not move perfectly Check and replace if necessary

3 、 components in compressor are Check air lines in compressor, tighten and

leaking reseal screw coupling connections if
necessary
1、pressure difference value incorrectly Adjust pressure difference value, not
set smaller than 0.15MPA usually
Compressor load/
2、air consumptions is not steady Use a bigger volume receiver tank
unload very
frequently
3、external units of the compressed air Clean external air pipeline ,air dryer or air
treatment jam filter , replace if necessary

4、ball valve at compressor outlet closed Open ball valve

1、fixed screw on the base is released Tighten screw

2、V-belts are slipped Adjust v-belts tension, replace if

Abnormally noise necessary
and vibration in 3、friction with fan vane and edge Adjust fan vane
compressor
4、compressor install improperly Mounted compressor in flat ground

5、screw air end or motor is defective Check air end or main motor and fan
motor, repair if necessary
1 、 operating pressure has been Set operating pressure to the maximum
misadjusted permissible pressure range of compressor
Safety valve (see value in nameplate)
blows 2、safety valve is defective Replace safety valve

3. System internal pressure has exceed Check and replace air/oil separator if
over setting pressure of safety valve necessary

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