Functional Description and Maintenance Method of Components on Main Air Supply

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 goods 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 maintained 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. 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.