Machine cleaning
Close the air press, wait for the internal pressure to leak, open the fuel cap, pour into the air compressor cleaning agent, and tighten the fuel cap;
Let go of the old oil and add new oil.
First run the air compressor for a few minutes, and the oil reaches the normal temperature;
Open the air compressor for 30 minutes;
Generally, the air compressor temperature after cleaning will drop by about 10 degrees.
Cooler cleaning
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In China, air compressor coolers are generally divided into air-cooled and water-cooled, so there are different cleaning methods for different coolers.
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Air cooled cooler
1 Open the air hood to clear the cover, or remove the cooling fan;
2 Use compressed air to blow back the dirt, and then take the dirt out of the air hood; if it is dirty, spray some degreaser and then blow. When the screw air compressor cannot be cleaned by the above method, the cooler needs to be removed, soaked or sprayed with a cleaning solution and cleaned with a brush (no wire brush is strictly prohibited).
3 Install the cover or cooling fan
Water-cooled cooler
1 Disassemble the cooling water inlet and outlet pipes.
2Injection into the cleaning solution or scouring with the pump cycle (reverse kickback effect is better)
3 rinse with water
4 Install the cooling water inlet and outlet pipes
Oil cooler fouling is more serious
When the above method is not ideally cleaned, the oil cooler can be removed separately, the end caps can be opened, and the scale can be removed with a special cleaning steel brush or other tools. When cleaning the cooler media side can not effectively reduce the temperature, the screw air compressor needs to clean the oil side, as follows:
1 Unpack the inlet and outlet pipes
2Injection into the cleaning solution or scouring with the pump cycle (reverse kickback effect is better)
3 rinse with water
4 Dry with dry air or remove water with dehydrated oil
5 installed in and out of the tubing
Steam separator cleaning
The structure of the screw air compressor water gas separator is similar to that of oil and gas tanks. The air inlet is designed to be walled and solidified into centrifugal force. Because of the weight of water and gas, it can effectively separate the moisture in the compressed air.
Cleaning of the water gas separator: Disassemble the water gas separator cover and wash it with a cleaning agent.
Reduced load valve (intake valve) cleaning
The unloading valve is composed of a valve body, a valve core (piston), a gas manifold block, a solenoid valve and a proportional valve (capacity regulating valve). The unloading valve mainly controls the loading of the air compressor (the screw air compressor heavy truck), the unloading (empty vehicle), and the proportional (tolerance) control function. In addition, the lubricating oil can be prevented from being ejected from the main engine when the air compressor is stopped.
Unloading valve disassembly
Remove the hose connecting the unloading valve to the air filter;
Remove all other parts of the air line connected to the relief valve;
Remove the solenoid valve coil;
Remove the nut assembled from the unloading valve and the main unit and remove it;
Move the relief valve to the floor with a clean paper or related clean floor.
Cleaning and reducing valve
Screw air compressor cleaning agent should use soapy water, diesel oil, clean gasoline, Tianna water, etc. The cleaning agent should be selected according to the degree of dirt. It is generally recommended to use soapy water or diesel for cleaning.
Disconnect solenoid valve
Remove the solenoid valve and check if the O-ring and seal in the solenoid valve need to be replaced. (Reminder: If you are not familiar with the intake valve, please write down the position of the removed component to avoid error when reinstalling). If there is no need to replace, put the disassembled screws, O-rings, sealing sheets, magnetic rods, cores and other components into the prepared container and put them in the appropriate cleaning agent. (Note: Use gasoline and Tianna water for cleaning. Do not soak the rubber products such as O-rings for too long to avoid corrosion.
Split proportional valve
Remove the proportional valve from the valve body, and then unscrew the adjusting nut (it is best to make a mark on the nut before screwing to avoid too much deviation of the ratio when reinstalling), take out the valve core, O-ring, U-ring, Spring and check if the O and U ring need to be replaced, and put the removed components into the cleaning agent to soak.
Demolition road manifold
The integrated block is removed from the valve body, and there are air holes on the four sides of the integrated block (the screw air compressor is used to clear the air when the integrated air circuit is blocked), and the sealing nut on the air hole is screwed out and The integrated blocks are immersed together in a cleaning agent.
Demolition of the valve spool
Use a circlip pliers to remove the circlip at the connection between the valve core and the valve body, then use the pipe wrench to unscrew the valve core, take out the cylinder, valve plate, O-ring, U-ring, spring and put it into the cleaning agent. Soak, remove the air inlet on the valve body, and put the whole valve body into the soaking. At this time, the disassembly process of the relief valve has been completed.
Cleaning
If the dirt of the intake valve is serious, replace it with a new one. When cleaning, clean the parts and wash the dirt. Wash the parts again with clean water to avoid corrosion. Shorten the service life of components. Parts cleaned with water should be placed in a clean place to dry to prevent rusting of iron-containing parts.
When cleaning the valve plate and the valve body and the valve plate, pay attention to the flatness of the surface, and clean it, if necessary, replace it, otherwise it will cause the air compressor to start with load (screw air compressor large unit with load start) It will not start when it is).
Installation component
The assembly is carried out in the reverse step of disassembly. It should be noted that when installing the components, the position of the sealing ring and the moving components should be coated with an appropriate amount of oil to make the sealing ring better installed and the moving parts more flexible.
Since there are many parts of the relief valve, if you are not sure to remember the position of each part, you can install the part after cleaning one part, but the parts should not be attached to the valve body until all parts are cleaned and then together. Assembled to the valve body. After the entire cleaning process of the relief valve is completed, it is placed next to the air compressor.
Minimum pressure valve (pressure maintenance valve) cleaning
Although the minimum pressure valve in the screw air compressor seems to be relatively small, but it is small, it controls the entire machine. In order to allow it to operate normally under normal work, the following provides a maintenance method for the minimum pressure valve of the screw air compressor.
The minimum pressure valve consists of a minimum pressure valve consisting of a valve body, a valve core, an adjusting nut, a spring, a sealing element, and the like. The minimum pressure valve mainly establishes the internal pressure of the unit, promotes the circulation of the lubricating oil, and satisfies the working pressure of the unloading valve. In addition, the minimum pressure valve also functions as a check valve to prevent the compression of the unit in the gas storage tank during unloading operation. The air flows back to the air compressor.
The structure of the minimum pressure valve is very simple. Unscrew the nut of the screw air compressor between the valve core and the valve body, and the inner component can be taken out. The minimum pressure valve spool of the small unit is built in the valve body, and the valve body cover is disassembled. All internal components can be removed.
The minimum pressure valve cleans the minimum pressure valve by cleaning the relief valve.
Since the structure of the minimum pressure valve is very simple, the assembly process is not described one by one, but it should be noted that if there is a U-ring inside, pay attention to the direction of the U-ring. The minimum pressure valve of the screw air compressor is placed on the side of the air compressor after the entire cleaning process is completed.
Oil return check valve cleaning
The one-way valve is composed of a valve body, a steel ball, a steel ball seat, a spring and the like. The oil and gas mixture compressed by the air compressor main engine is firstly separated by the centrifugal force in the oil and gas tank. Because the weight of the oil is greater than the air, most of the oil in the solid oil and gas mixture falls to the oil tank by centrifugal force, and the screw air compressor is again Under the action of internal pressure, return to the host for a lubrication cycle, and the compressed air containing a small amount of oil is separated again by the oil separator. At this time, the oil separated by the oil separator will fall to the bottom of the oil separator. This part of the oil is not taken away with the compressed air. The unit is designed to be inserted into the bottom of the oil separator with a tubing. By means of internal pressure, this part of the oil is directly introduced into the main engine for lubrication. The oil pipe has a check valve and a screw. The air compressor is called a return single oil valve.
Its function is to smoothly recycle the oil from the oil separator to the main unit without returning the oil from the main unit to the oil separator. The returning oil single valve has a joint at the valve body, from which it is unscrewed, and the spring, the steel ball and the steel ball seat are taken out.
Clean the oil return check valve: clean the valve body, spring, steel ball, steel ball seat with cleaning agent, and some filter valves inside the check valve, if any, clean together.
Cleaning the temperature control valve
The temperature control valve is composed of a valve body, a valve core, a temperature sensing element, a spring, and the like. The temperature control valve functions as a constant temperature control. When the oil temperature measured by the temperature sensing component of the temperature control valve is lower than the action value (the operating value of the temperature sensing element is generally 71 degrees), the lubricating oil is directly returned from the oil and gas barrel to the host, when the temperature is When the oil temperature measured by the temperature sensing component of the control valve is higher than the action value, the temperature control valve sensible component ejector action, pushing the valve core to open the bypass valve of its own equipment, so that the lubricating oil enters the cooler to cool (if the temperature sensing component measures The higher the temperature, the larger the bypass valve opens, and the cooled lubricant returns to the main unit.
The screw air compressor temperature control valve has a cover on the surface, and the cover has a screw hole. Find a suitable nut and screw it into the cover. Then use a circlip plier to remove the circlip that fixes the cover, and then pull the clamp with the clamp. Screw in the nut to remove the cover and all internal parts. Clean all parts of the temperature control valve by cleaning the relief valve.
After all the above parts have been cleaned and dried, they will be installed in the air compressor. After all the components are installed in the air compressor, check the leaks and clean the tools and tools used in the installation.
Correct all parameters
Preparation before starting up
Belt (coupling) correction: If the air compressor is driven by belt, the tightness of the belt should be between 10 and 20 mm. For example, if the air compressor is a coupling drive, after installation, the motor and the main unit should be moved and the balance of the coupling should be checked. Screw air compressor couplings basically use elastic couplings, which can be ignored when the solid balance deviation is small.
Screw air compressor main engine steering correction: If the main power supply is removed during maintenance, the motor should be reversed after the power is connected. The steering of the motor should be based on the steering of the main engine. Please check the correct indication of the main unit. Turn to the icon.
Correction method
Exchange any two of the three-phase power cables.
Load, unload, proportional value
When setting these three parameters, the unloading value should be determined first. The unloading value should be determined according to the rated pressure of the air compressor and the pressure required by the air end. After determining the unloading value, set the loading value, the pressure of the two. The difference should be between 0.1 and 0.2 MPa. After the unloading and loading values are set, the ratio value should be set last. The proportional value should be set between the unloading value and the loading value. The screw air compressor is an example: if a factory needs an air compressor The gas supply pressure is 0.8 MPa, and the gas supply requirement is relatively stable. Three parameters should be set as follows: the unloading pressure is set to 0.8 MPa, the loading pressure is set to 0.65 MPa, and the proportional control pressure is set between 0.73 and 0.75 MPa.
Correction method
Set this parameter in the microcomputer controller (if the control of the air compressor is controlled by button, the loading and unloading parameters should be adjusted from the pressure switch, and the proportional value should be adjusted at the adjusting nut of the proportional valve on the unloading valve) .
The internal pressure effect of the unit is positive
The internal pressure of the unit should be between 0.2 and 0.45 MPa.
Correction method
The pressure value should be carried out during the unloading operation of the unit. The value is adjusted on the adjustment nut of the minimum pressure valve. In order to facilitate reading the set value, the pressure detection point should be taken before the minimum pressure valve and the pressure gauge should be installed (partially The microcomputer controller has an internal pressure parameter display function. If there is no such function, the pressure gauge should be installed before the minimum pressure valve).
High temperature protection value
When the screw air compressor works normally, its temperature should be between 65 and 98 °C. The automatic shutdown temperature for over-temperature protection must not exceed 105 °C.
Correction method
Adjust the high temperature automatic shutdown temperature value in the controller, which is preferably 1.2 (ie, enlarge the 20% margin).
Correct maintenance and maintenance plays a vital role in the service life and operational reliability of the screw air compressor. Air compressor cleaning is a skill that must be mastered by after-sales service personnel and even equipment operators.
