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The most complete functional description of the internal components of the air compressor in history (with maintenance methods)
Classification: News dynamics
Time：2017-12-21 14:51
1. Function description and maintenance method of each component on the main air source channel 1. Air filter The air filter is a dry paper filter with a fine pore size of about 5μm. Its main function is to filter out dust in the air to avoid premature wear of the screw rotor, premature blockage of the oil filter and the oil separator. Usually every 500 hours of work, should be removed to clear the surface of the dust. The method of removal is to use low-pressure air to blow the dust from the inside out. Maintenance method of air filter: It is best to maintain the air filter once a week. Unscrew the gland nut, take out the air filter element, and use 0.2-0.4
Functional Description and Maintenance Method of Components on Main Air Source
1. Air filter
The air filter is a dry paper filter with a fine pore size of about 5μm. Its main function is to filter out dust in the air to avoid premature wear of the screw rotor, premature blockage of the oil filter and the oil separator. Usually every 500 hours of work, should be removed to clear the surface of the dust. The method of removal is to use low-pressure air to blow the dust from the inside out.
air filter maintenance methods:
The air filter is best maintained once a week. Unscrew the gland nut, take out the air filter element, use 0.2-0.4Mpa compressed air, blow out the dust particles on the outer surface of the air filter element from the inner cavity of the air filter element, and use a clean cloth to clean the air filter. Wipe off the dirt on the inner wall of the housing, and reinstall the air filter element. Pay attention to the tight fit between the sealing ring at the front end of the air filter element and the inner end of the air filter housing. The heavy-duty air filter can directly open the shell, and the maintenance method is the same as above.
Under normal circumstances, the air filter is replaced every 1500-2000 hours. In places where the environment is particularly harsh, such as mines, ceramic factories, cotton mills, etc., it is recommended to replace the air filter element every 500 hours. Please be sure to use genuine filter when replacing.
When cleaning or replacing the air filter, the parts must be matched one by one to prevent foreign matter from falling into the intake valve.
At ordinary times, it is necessary to check whether the intake telescopic tube is damaged or flat, and whether the connection port between the telescopic tube and the air filter intake valve is loose or leaking. If found, it must be repaired and replaced in time.
2. Intake valve
The intake valve is a disc-type intake valve, which is mainly controlled by opening and closing the disc in the intake valve to carry out empty and heavy load control; there are two control methods, one is on-off type, when the pressure reaches the high limit set value, Close the air inlet, the pressure drops to the low limit set value, and reopen the air inlet to work at full load. Another kind of capacity adjustment control, the disc of the intake valve is slightly closed and the proportional valve is used for capacity adjustment control to adapt to the external air consumption, so that the pressure is stable within a certain range, the pressure does not reach the capacity adjustment pressure, and the disc of the intake valve is fully open, At this time, the compressor is running at full load.
maintenance method of intake valve:
The failure of the valve is generally that the screw machine does not unload and the intake valve is not closed. Does not load, intake valve solenoid valve is damaged. Screw machine oil injection, valve body control block failure. The screw machine is overloaded and the intake valve opens in advance when starting. Therefore, the intake control valve should be replaced regularly to maintain a good working condition. During each maintenance, the parts must be removed to check the wear of each friction surface. Special attention should be paid to checking the surface of the rubber sealing ring. If there is damage or cracks, new parts must be replaced. When the repair kit is replaced, all parts should be Clean, and the friction surface of metal parts should be coated with lubricating oil.
3. Oil and gas barrel
Oil and gas barrel has two functions of oil and gas separation and oil storage. The compressed oil and gas mixture is discharged to the oil and gas barrel, and most of the lubricating oil can be separated by rotating in the oil and gas barrel; the oil and gas barrel has more lubricating oil to prevent the hot oil just separated from immediately participating in the next cycle, which is beneficial to reduce Exhaust temperature. Oil level indicator is installed on the side of oil and gas barrel. There is a refueling hole on the barrel for refueling. The oil level of static lubricating oil should be between the upper limit and the lower limit of the oil level gauge. The oil (water) ball valve is installed under the oil and gas barrel. The ball valve should be slightly opened before each operation to drain the condensed water in the oil and gas barrel (because the water is heavier than the oil, it settles in the lower part). Once there is oil outflow, quickly shut down. Due to the wide cross-sectional area of the oil and gas barrel, the compressed air flow rate can be reduced, which is conducive to the separation of oil droplets and plays the role of preliminary oil removal.
4. Safety valve
When the gas pressure in the oil and gas barrel is 1.1 times higher than the rated exhaust pressure, the safety valve will automatically take off and relieve the pressure, so that the pressure drops below the rated exhaust pressure. Check the safety valve method is in the compressor full load work, gently pull the safety valve on the vent rod, if the safety valve can exhaust, it is considered normal.
maintenance method of safety valve:
In order to ensure that the performance of the air compressor safety valve does not change, the air compressor safety valve must be regularly protected and cleaned to prevent ash, water vapor, stains, etc. from entering the valve body and affecting the performance of the valve body.
Monthly maintenance items
It is necessary to maintain the safety valve of the air compressor every month, and the maintenance personnel must be professional personnel, otherwise the valve body will have problems during the maintenance process. Monthly maintenance content Organic oil filter and oil and gas separator cleaning, air filter also need to be cleaned. There are also cooling equipment that needs to be lubricated, and various parts of the pump body are checked to eliminate potential safety hazards, and the valve body is cleaned.
Annual maintenance items
The annual maintenance item is the most important maintenance of the air compressor safety valve, which is different from the monthly, and the inspection is more extensive. Regarding the annual maintenance project, it is necessary to clean the oil circuit and water vapor circuit for stains, etc., and adjust the various parts of the valve body to check whether there are problems. If there are problems, they need to be replaced in time.
5. Minimum pressure valve
Located at the outlet of the fine oil separator above the oil and gas poke, the opening pressure is set to about 0.45MPa. The minimum pressure valve mainly has the following functions:
When starting, the circulating pressure required for the lubricating oil is established as a priority to ensure the lubrication of the machine.
After the gas pressure of the oil and gas barrel exceeds 0.4MPa, the air flow rate flowing through the fine oil separator can be reduced, and in addition to ensuring the fine oil separation effect, the fine oil separator can be protected from damage due to too large pressure difference.
Return function: when the pressure in the oil and gas barrel drops after shutdown, it prevents the pipeline compressed air from flowing back.
Maintenance method of minimum pressure valve:
The temperature detection of the valve cover shall check and record the surface temperature of the minimum pressure valve cover on a regular basis and make an icon record. Combined with the operation parameters (such as temperature and pressure) of the instrument detection equipment, the operation condition of the minimum pressure valve shall be analyzed according to the recorded temperature change, the service life shall be predicted, and the maintenance time shall be reasonably arranged.
The minimum pressure valve running sound detection uses auscultation stick and other tools to monitor the movement sound of the minimum pressure valve plate and compare it with the valve of the same level. It is easy to distinguish the abnormal minimum pressure valve, and the maintenance can be arranged accordingly.
Analysis of changes in process parameters Once the minimum pressure valve leaks, it will cause changes in temperature, pressure or flow. Through the change of these parameters, which level of minimum pressure valve or even which minimum pressure valve fails can be analyzed.
6. After cooler
The compressed air from the minimum pressure valve is passed to the aftercooler. The after-cooler and the oil cooler are made into one body, and their structures are the same, and they are all plate-type. The cooling fan draws cool air in and over the after-cooler rocker. The temperature of the cooled compressed air is generally below the ambient temperature of 15°C.
After cooler maintenance methods:
The cooler should be cleaned regularly according to the environmental conditions to make the compressor work at normal temperature to ensure that the machine has a long service life. When the cooler is dirty, the compressor exhaust temperature will rise. Generally, the outside of the air-cooled cooler should be cleaned every 1500 hours, and the water side of the water-cooled cooler should be cleaned every 1500 hours. Regular cleaning of the cooler has the following advantages:
The unit always works at the ideal working temperature (below 95 ℃), which is good for the performance and life of the machine.
The dirt can be removed by using a cleaning fluid, otherwise when the dirt is thick, the cleaning work is quite troublesome, and the cooler needs to be disassembled and the cleaning work can be completed by mechanical methods.

Function Description of Main Components of Second Oil Circuit
1. Temperature control valve
The main function of the temperature control valve is to control the exhaust temperature of the compressor by controlling the humidity of the lubricating oil injected into the head to avoid the condensation of water vapor in the air in the oil and gas barrel and emulsified lubricating oil. Just boot, the lubricating oil temperature is low, the temperature control valve is closed, cold oil is not through the cooler and directly injected into the body. If the oil temperature rises above 70 ℃, the temperature control valve gradually opens to the passage of the oil cooler, and fully opens at 76 ℃. At this time, all the oil will be cooled by the oil cooler and then injected into the body. Some models do not have a temperature control valve, but by controlling the fan motor stop to control the oil temperature. When the exhaust temperature rises to 85 ℃, the fan starts to run; when the exhaust temperature is lower than 75 ℃, the fan stops automatically to keep the temperature within a certain range.
Maintenance method of temperature control valve
Disassembly of temperature control valve: there is a cover on the surface of the temperature control valve of the screw air compressor, and there is a screw hole on the cover. find a suitable nut to screw into the cover, then take out the circlip fixing the cover with circlip pliers, and then pull the nut just screwed in with pliers to remove the cover and all internal parts.
Cleaning temperature control valve: cleaning agent should be selected soapy water, diesel oil, clean gasoline, Tianna water, etc., should be selected according to the degree of dirt cleaning agent, generally recommended the use of soapy water or diesel cleaning. Such as the temperature control valve of the more serious dirt, when cleaning for a new cleaning agent.
2. Oil cooler
The oil cooler is integrated with the aftercooler.
3. Oil filter
The oil filter is a paper filter with a filtering accuracy of 10μ ~ 15μ. Its function is to remove impurities from the oil. Such as metal particles, dust, oil deterioration, etc., to protect the normal operation of the bearing and rotor. If the oil filter is blocked, it may cause insufficient fuel injection to affect the service life of the main engine bearing, and the exhaust temperature of the head will rise (even shutdown).
Maintenance method of oil filter
Every 100h or drilling rig work within a week: must clean the oil filter level filter screen and the oil tank on the coarse filter screen, cleaning the filter element with a wire brush to remove dirt on the net, because the air compressor works in a dusty environment, it is very important to clean the air filter and the oil filter frequently, ignoring this point will cause a series of failures.
Every 300h: clean the filter core, blow dry after cleaning, and then soak the same oil in the oil tank. If the dust is very serious, determine the cleaning cycle according to the actual situation. When the red line of the air pollution indicator on the relief valve can be seen, it means that the air filter is seriously polluted and the air filter should be cleaned. Clean or inspect parts such as relief valve, minimum pressure valve and automatic vent valve. Thoroughly clean the oil filter to clean the dirt deposited on the bottom of the oil filter.
Every 1000h: The oil filter paper filter element must be replaced. Check whether the safety valve, temperature control valve, pressure regulator and pressure regulating valve work normally.
Every 3000h: check the oil pump, check or replace the sealing ring. According to the emulsification degree of the base oil, the amount of impurities, and the change of viscosity, replace the new oil as appropriate. Oil separator filter components, generally can be used for 2000~4000h. No special maintenance is required during this time. If found a significant increase in compressor oil consumption should be checked or replaced the core, unscrew the exhaust seat on the two M24 × 1.5 bolts, check the exhaust valve clearance, as appropriate to adjust. When used in a dusty environment, dust is easy to gather on the oil cooler, and the cooling effect deteriorates. It should be cleaned according to the specific situation. Generally, it is required to be cleaned once every 4 months to ensure the heat dissipation effect.
4. Fine oil separator
The filter element of the fine oil separator is made of multi-layer fine special fibers. The mist lubricating oil contained in the compressed air can be almost completely filtered out after passing through the fine oil separator. The oil particle size can be controlled below 0.1μm, and the oil content can be less than 3PPM.
Maintenance method of oil fine separator
Oil and gas separator will generally produce blockage fault. If the oil and gas filter is blocked, it may be caused by the following reasons:
Check the environment around the press. Whether there are corrosive gases, such as some occasions there will be sulfide, water, cleaning chemicals such as volatile in the air. Or whether the air compressor temperature is too high.
Use qualified air filter, oil filter and engine oil. Replace the oil and filter element in time.
Check for leaks on the piping between the air filter and the air inlet of the main engine. The common causes of leakage are: the air filter is not installed properly; the contact area of the air filter assembly is uneven; dirt is attached to the contact surface of the air filter and the assembly, causing leakage; the elastic contact pad on the surface of the air filter is tilted; The air filter or air filter assembly is broken, etc.
Check whether there is too much water on the oil filter material to prevent the increase of oil resistance and blockage in advance.
5. Return check valve
The residual oil filtered by the fine oil separator is concentrated in the small circular groove in the center of the filter element and is led to the main engine through the oil return pipe to prevent the separated lubricating oil from being discharged with the air. In order to prevent the oil in the compression chamber of the main engine from flowing back, a check valve is set after the oil return pipe. If the oil consumption increases suddenly during the operation of the machine, check whether the throttle hole of the check valve is blocked.
Maintenance method of return check valve:
Disassembly of oil return single valve: there is a connection in the valve body, unscrew it from there, and take out the spring, steel ball and steel ball seat.
Clean the oil return check valve: clean the valve body, spring, steel ball and steel ball seat with cleaning agent. There is also a filter screen inside some check valves. If there is one, clean it together.
Three gas path control components
1. Loading solenoid valve
For two normally closed solenoid valve. The on-off state of the gas circuit is controlled by the power-on and power-off of the solenoid valve to realize the loading and unloading functions.
2. Vent valve
When unloading operation or shutdown, the valve is opened to release the pressure in the oil and gas drum, so that the compressor low load operation, or to ensure that no load in the case of restart.
3. Inverse proportional valve
It only works when the set adjustment pressure is exceeded. At this time, the higher the proportional valve (that is, the exhaust pressure of the system), the lower the output control pressure. The lower the control pressure, the smaller the opening of the intake and unloading valve disc controlled by the expansion and contraction of the cylinder, and the smaller the intake air volume of the compressor, so that the air supply and air consumption of the compressor are balanced to achieve Stepless air volume adjustment function. The method of setting the adjustment pressure is: lift up the black cap of the anti-proportional valve and rotate it. Rotate clockwise to increase the pressure, and rotate counterclockwise to decrease it. After setting, press down the cap to prevent it from rotating on its own due to vibration. The set value should generally be less than the rated exhaust pressure. If it is higher than the unloading pressure set by the microcomputer controller, there will be only empty and heavy vehicles without capacity adjustment.
4. Sensor
The pressure and temperature sensors realize the measurement of various parameters to realize the screw air compressor loading, load shedding, various fault prompts, and automatic shutdown when necessary.