Maintenance of main components is carried out with reference to the following table:
note:
A. When maintaining and replacing various components according to the above table, it must be confirmed that the pressure in the air compressor system has been released, isolated from other pressure sources, and the switch on the main circuit has been turned off, and a safety sign prohibiting closing is made.
B The replacement time of compressor cooling lubricating oil depends on the use environment, humidity, dust and whether there is acid-base gas in the air. The newly purchased air compressor must be replaced with new oil after the first operation of 500 hours, and then every 4000 hours according to the normal oil change cycle, and the machine with an annual operation of less than 4000 hours should be replaced once a year.
C. The oil filter must be replaced after 300-500 hours for the first use, and every 2000 hours according to the normal time after 2000 hours for the second use.
D when repairing and replacing the air filter or air inlet valve, remember not to let any sundries fall into the main cavity of the compressor. When operating, close the host entrance. After the operation, turn it by hand several times according to the rotation direction of the main engine, and then turn it on after confirming that there are no obstacles.
E. When the machine is running, check the belt tension every 2000 hours. If the belt is loose, adjust it until the belt is tight; In order to protect the belt, it is necessary to prevent the belt from being scrapped due to oil pollution in the whole process.
F every time the oil is changed, the oil filter must be changed at the same time.
G try to replace the parts with the original parts of the company, otherwise the supplier will not be responsible for the matching problem.
Clean the cooler
When the air compressor runs for about 2000 hours, in order to remove the dust on the cooling surface, it is necessary to open the cover of the cooler purge hole on the fan bracket and purge the cooler with a dust-blowing air gun until the dust on the cooling surface is completely purged. Shang Ruo's radiating surface is seriously polluted and difficult to clean. You can unload the cooler, pour out the oil in the cooler, seal the four entrances and exits to prevent dirt from entering, then blow off the dust on both sides with compressed air or rinse with water, and finally dry the water stains on the surface. Put it back in place.
Remember! Don't scrape off dirt with hard objects such as iron brush to avoid damaging the surface of radiator.
Drain condensed water
The moisture in the air may condense in the oil-gas separation tank, especially in wet weather, when the exhaust temperature is lower than the pressure dew point of the air or when the machine is stopped for cooling, more condensed water will be precipitated. Too much water in the oil will cause emulsification of lubricating oil, which will affect the safe operation of the machine, such as:
1. The compressor main engine is poorly lubricated.
2. The effect of oil-gas separation becomes worse, and the pressure difference of oil-gas separator becomes larger.
3. Causes the parts to rust.
Therefore, the condensed water discharge plan should be made according to the humidity.
Discharge method of condensed water
It should be carried out after the machine stops, there is no pressure in the oil-gas separation tank, it is fully cooled, and the condensed water is fully precipitated, such as before starting the machine in the morning.
① Unscrew the front plug of the ball valve at the bottom of the oil-gas separation tank.
② Slowly open the ball valve to drain water until the oil flows out, and then close the ball valve.
③ Screw on the front plug of the ball valve.
safety valve
The safety valve has been set before the whole machine leaves the factory, and the supplier does not encourage users to adjust the safety valve privately. If adjustment is really necessary, it should be carried out under the guidance of the local labor safety department or the supplier's maintenance personnel to avoid adverse consequences.
Maintenance work suggestion
For general users, some compressor maintenance suggestions are provided for users' reference.
① Every week:
A. check the device for abnormal sound and leakage.
Check whether the meter reading is correct.
C. check whether the temperature display is normal.
② Every month:
A. check whether the machine is rusty or loose. If there is rust, remove rust, oil or paint, and tighten it loosely.
B. drain the condensed water.
(3) Every three months:
A clean the dust on the outer surface of the cooler, fan cover and blades.
B. fill the motor bearing with lubricating oil.
C. check whether the hose is aged and cracked.
D. check the electrical components and clean the electrical cabinet.
When the compressor is replenished with oil, the oil level of the compressor should be kept between the lowest and highest oil levels. Too much oil will affect the separation effect, and too little oil will affect the lubrication and cooling performance of the machine. During the oil change cycle, if the oil level is lower than the minimum oil level, the lubricating oil should be replenished in time. The method is as follows:
(1) Stop the machine and wait for the internal pressure to be released (confirm that there is no pressure in the system), and then pull down the main power switch.
(2) Open the oil filler on the oil-gas separation tank and replenish proper amount of cooling lubricating oil.
③ Please refer to the regular maintenance table for the oil change time after the normal operation of the air compressor. For technical questions and answers about the operation and maintenance of screw air compressor, please refer to the book China Electric Power Press.
Cleaning of air compressor
Long-term operation of air compressor will cause equipment to be blocked by scale, reduce efficiency, increase energy consumption and shorten service life. If the scale can not be removed in time, it will be in danger of equipment maintenance, shutdown or scrap replacement. For a long time, traditional cleaning methods, such as mechanical methods (scraping, brushing), high-pressure water and chemical cleaning (pickling), have caused many problems when cleaning air compressors: deposits such as scale cannot be completely removed, equipment is corroded, and residual acid causes secondary corrosion or under-scale corrosion to materials, which eventually leads to equipment replacement. In addition, the cleaning waste liquid is toxic, and wastewater treatment needs a lot of money. Enterprises can avoid the above situation by using efficient and environmentally friendly cleaning agents, which are efficient, environmentally friendly, safe and non-corrosive. Not only the cleaning effect is good, but also the equipment is not corroded, which can ensure the long-term use of the air compressor. Fujita cleaning agent (specially added with wetting agent and penetrant) can effectively remove the most stubborn deposits such as calcium carbonate, rust scale, oil dirt and sticky mud generated in water-using equipment, and at the same time, it will not cause harm to human body, and will not cause other harmful reactions such as corrosion, pitting and oxidation to steel, copper, nickel, titanium, rubber, plastic, fiber, glass and ceramics, and can greatly prolong the service life of the equipment.
Case description: Atlas Copco air compressor model is GA3 15W-8.5, shaft power is 3 15KW, rotating speed is 1492 r/min, displacement is 864L/S, head temperature before cleaning is about 97℃, oil content temperature is about 86℃, and the head temperature of this compressor exceeds/kloc-. The working temperature before cleaning is close to the alarm temperature of the equipment, so it is urgent to clean the heat exchange system. After four hours of cleaning, the equipment was put into operation immediately. After cleaning, the head temperature is about 83℃, and the oil-bearing temperature is about 72℃, and the temperature drops obviously, which meets the requirements of enterprises.
Control noise pollution
Noise pollution is also an important factor of environmental pollution. People living in factories or near expressway are more or less troubled by machinery and car noise. Taking noise pollution index as an index to assess factories and living environment has long been included in the national environmental protection standards. Then, equipment manufacturers and suppliers should also have the responsibility and obligation to reduce the noise pollution during the operation of mechanical equipment through technical means and better create a low-decibel working and living environment.
Noise control of air compressor mainly adopts muffler, anechoic tunnel and sound insulation technology;
1, install the air compressor muffler:
The main noise sources are the air intake and exhaust ports, and appropriate air intake and exhaust silencers should be selected. The intake noise spectrum of air compressor presents low frequency characteristics, and the intake muffler should adopt resistance structure or impedance composite structure with individual resistance as the main factor. The air compressor has high exhaust pressure and fast airflow speed, so a small hole muffler should be used at the outlet of the air compressor.
2, set up the air compressor muffler tunnel:
An underground or semi-underground tunnel, the wall of which is made of bricks with good sound absorption performance. Connect the air inlet pipe of the air compressor with the silencing tunnel, so that air can enter the air compressor through the silencing tunnel. The use of muffler tunnel can greatly reduce the intake noise of air compressor and prolong the service life of muffler.
3, the establishment of sound insulation cover:
After installing silencers or silencing tunnels at the air inlet and outlet of the air compressor, the airflow noise can be reduced to below 80db(a), but the mechanical noise and motor noise of the air compressor are still high, so a sound insulation cover should be installed on the air compressor unit. 4. Suspended spatial sound absorber: In Foshan Linggefeng air compressor station, the reverberation of the tall and empty factory building is very heavy. If the sound absorber is hung on the ceiling of the workshop, the noise of the workshop can be reduced by 3- 10db(a), and the reverberation time can be reduced by 5- 10s.