DA Series Operation Manual

Contents
1.Safety Precautions .............................................................................................................................. 1
1.1 Electrical Safety.............................................................................................................................. 1
1.2Driving Components............................................................................................................................ 1
1.3High Temperature and High Pressure............................................................................................. 1
1.4 Unit Drainage.............................................................................................................................. 2
2.Inspection and Handling ................................................................................................................... 2
2.1Product Warranty of Compressors................................................................................................... 2
2.2Check of Specifications and Model.................................................................................................. 2
2.3Inspection of Accessories and Appearance................................................................................... 3
2.4Handling Precautions.......................................................................................................................... 3
3. Installation ..................................................................................................................................... 4
3.1Environment Requirements............................................................................................................... 4
3.2Installation Location Requirements.................................................................................................. 5
3.3Ventilation and Cooling Requirements............................................................................................ 5
3.4Selection Requirements for Air Rate of Ventilating fans............................................................. 6
3.5 Warning.............................................................................................................................. 7
3.6Suggestions for Pipeline..................................................................................................................... 8
3.7Electric Appliances Installation Precautions and Control System.......................................... 11
4.Introduction to the System ............................................................................................................. 14
4.1 Overall System............................................................................................................................ 14
4.2Composition of the Compressor Unit............................................................................................ 14
4.3Lubricating Oil System...................................................................................................................... 15
4.4Oil-gas Separation System.............................................................................................................. 15
5 Controller Operation ......................................................................................................................... 16
5.1 Key Description............................................................................................................................ 16
5.2Schematic Wiring Diagram.............................................................................................................. 17
6.Function Description of System Components ........................................................................18
6.1 Air Filter............................................................................................................................ 18
6.2 Inlet Valve............................................................................................................................ 18
6.3 Oil-gas Barrel............................................................................................................................ 18
6.4 Oil Separator............................................................................................................................ 18
6.5 Safety Valve............................................................................................................................ 18
6.6Pressure Maintenance Valve........................................................................................................... 19
6.7 Rear Cooler............................................................................................................................ 19
6.8 Oil Cooler............................................................................................................................ 19
6.9 Oil Filter............................................................................................................................ 19
6.10Exhaust Temperature Sensor....................................................................................................... 19
6.11 Pressure Sensor............................................................................................................................ 20

1
DA Series Operation Manual

7. Maintenance ................................................................................................................................... 20
7.1Inspection and Update of Belt and Pulley.................................................................................... 20
7.2 Air Filter............................................................................................................................ 21
7.3Lubrication of Motor Bearing........................................................................................................... 21
7.4Compressor Bearing..........................................................................................................................22
7.5Air Compressor Lubricating Oil....................................................................................................... 23
7.6 Oil Separator............................................................................................................................ 23
7.7 Oil Return Pipeline............................................................................................................................ 23
7.8 Engine Oil Filter............................................................................................................................ 23
7.9 Pipe Joint............................................................................................................................ 24
7.10 Inlet Valve............................................................................................................................ 24
7.11 Pressure Maintenance Valve.......................................................................................................24
7.12 Safety Valve............................................................................................................................ 24
7.13 Draining Solenoid Valve............................................................................................................... 24
7.14 Cooler............................................................................................................................ 25
7.15 Electric Insulation........................................................................................................................... 25
7.16 Periodic Inspection and Cleaning.............................................................................................. 25
8.Safety Protection and Warning Device ..................................................................................... 25
8.1Motor Overload Protection............................................................................................................... 25
8.2Protection for Over-temperature of Exhaust................................................................................26
8.3Setting and Description of Other Protection and Warning....................................................... 26
8.4Failure Causes and Troubleshooting.............................................................................................26
Annex I: Table of Cycles for Periodic Maintenance of Air Compressor ...........................28

2
DA Series Operation Manual

1. Safety Precautions
Please carefully read this manual and operate based on the detailed instructions given in the
manual before installing and using the air compressor of the Company to avoid hazardous
events and prevent machines being damaged.

1.1 Electrical Safety

(1) Once power up the air compressor, the voltage generated will be very dangerous, therefore
only electricians and electrical engineers who are certified through national examinations
are allowed to perform the installation. The operators shall perform the safety operations in
strict accordance with the operating mode specified in this manual and national regulations
and safety code.

(2) Users and installation personnel shall provide earthing and installation protective circuit for
compressor units in accordance with national electrical standards.

(3) Each standalone compressor shall be installed with an exclusive breaker, which shall be
used with NFB with corresponding capacity, and see detailed configuration in the
instructions of Fig. 3.7.

(4) Make sure the power switch is turned off before any maintenance to avoid accidents. There
shall be a warning saying “No switching on” hanging on the power switch.

1.2 Driving Components

(1) Do not open soundproof enclosure before the air compressor is completely shut down so
as to avoid ganger.

(2) Any dismounting shall not be implemented until the motor and the fan have been
completely shut down and it is ensured that the power is cut off.

(3) Do not wear excessively loose clothes during maintenance to avoid accidents.

1.3 High Temperature and High Pressure

(1) For part of pipelines and components whose temperature may increase (a warning sign is
significantly affixed on the air compressor), touching is not allowed to avoid scald
accidents until it is confirmed to be completely cooled.

(2) There may be high pressure fluid in each component and pipeline of the air compressor, so
it shall be confirmed that the pressure of the unit has been completely discharged before
dismounting. The high pressure fluid shall be prevented from pointing to any person to
protect the person from been injured by the high pressure fluid.

(3) The compressed air provided by the air compressor is only for industrial purpose. Do not
breathe the air before it has been processed appropriately, or it will result in bodily injury,

1
DA Series Operation Manual

disease or death.

1.4 Unit Drainage

(1) The drain valves of oil-gas barrels of the unit and the system shall be open to drain
condensate water completely before starting up the air compressor, to ensure that the oil
products of the unit will not be emulsified and the compressor will not be stuck due to
deterioration of oil products.

(2) The post treatment device and the drainage function of devices shall be regularly
inspected to ensure the normal operation of the system.

2. Inspection and Handling

Please carefully read this chapter to ensure the rights of the customers. Handling shall be
implemented as per the manner mentioned in section 2.4 to avoid accidents and damage to the
unit.

2.1 Product Warranty of Compressors

The Denair Screw Air Compressors shall be delivered after conducting the strict quality management and
performance test. Except as otherwise noted (according to the terms of the product warranties), the
warranty period of the compressor shall be 18 months from the date of production of the compressor or
12 months from the date of formal commissioning of the compressor (which is due earlier).For any poor
quality or fault and damage caused by manufacturing reasons during the product warranty period, the
Company will provide free service for the products after confirmation. Any fault caused by, such
incontrollable factors as moving, striking, natural disasters and wars, or the operation and maintenance
not in conformity with instructions or without use of the consumables and oil products marked with Denair,
or the maintenance conduct by other person other than personnel of our company and servicemen of
service agency appointed by Denair, shall be excluded from the product warranty.

It is recommended that customers using Denair products should immediately inform the original Denair or
appointed service agency to troubleshoot the factors but not modify the system by yourself and force the
compressor to work, which may result in damages to the compressor, if there is abnormity of the
compressor caused by unusual condition of the unit

2.2 Check of Specifications and Model

Please check whether the nameplate specifications (see Fig. 2.1) of this air compressor conform to the
requirements of your order.

2
DA Series Operation Manual

Fig. 2.1

Note:

Model: prepared as per Denair ’s in-plant model

Model specifications: prepared as per national standard JB/T2589-86

2.3 Inspection of Accessories and Appearance

Please check whether spare and accessory parts are all in readiness after receiving the air
compressor. If there is any quality problem, please contact us immediately. All Denair air
compressors shall be attached with the followings:

(1) One copy of operation manual;

(2) One copy of Warranty;

(3) Two keys to the door.

2.4 Handling Precautions

Please choose proper forklift or crane for handling based on the weight of the air compressor.
Please do not stand below the air compressor and keep at a safe distance as far as possible
during hoisting.

3
DA Series Operation Manual

Fig. 2.2

Notice: it is not allowable to place any items on the cooler over the metal plate, and the cooler
shall not covered to avoid tripping resulting from high temperature of the unit.

3. Installation
Please carefully read this chapter before installation to ensure the proper installation and
reliable operation of the air compressor.

3.1 Environment Requirements

(1) The air compressor shall be installed indoors where it is well ventilated and lit other than
the places with high dust, high humidity, etchant gas, metallic dust, direct radiation of
sunlight or direct rainwater.;

(2) The range of ambient temperature is 0℃~45℃.

(3) The air compressor shall be kept away from boilers and equipment which may emit heat,
and shall be equipped with awnings with favorable ventilation environment while being
installed outdoors.

(4) The ventilating fans around and over the air compressor shall set apart at least 900 mm
maintenance space (see Fig. 3.1).

(5) The altitude shall be less than 1000 m.

4
DA Series Operation Manual

(6) The relative humidity shall be less than 95%.

Fig. 3.1

3.2 Installation Location Requirements

The screw air compressor can be installed on any floor slab which may withstand the weight of the air
compressor without any special foundation, where the floor is smooth and horizontal. The air
compressor shall be fixed with foundation bolts; meanwhile rubber blanket shall be equipped to slow
down the vibration of the unit while being installed on the steel frame and mobile ships or vehicles.

3.3 Ventilation and Cooling Requirements

When installing the air compressor indoors or outdoors, good ventilation shall be ensure to
avoid heat short cycle or interaction effect from heat extraction of the machines, so the locations
of vent pipes, ventilating fans and compressors must be considered (there are typically three
ways, see Fig. 3.2).

5
DA Series Operation Manual

Fig. 3.2

Note:

(1) Fig. A: when the exhaust duct is not used for ventilation, refer to Table 3.1 Ventilation Rate (1) for the
recommended exhaust air rate of ventilating fans, and please install the ventilating fans as high as
possible.

(2) Fig. B: While using exhaust duct without installing the ventilating fans, the exhaust air rate of
the compressor and the pressure loss in the exhaust duct shall be calculated. When the pressure
loss is less than 20Pa, there is no need to install ventilating fans and the dismountable exhaust air
hose shall be directly installed at the air outlet of the compressor.(It is recommended that
customers should use the ventilation design of Fig. A and Fig. C best).

(3) Fig. C: When the pressure loss in the exhaust duct is greater than 20Pa, ventilating fans
shall be installed additionally where the distance between the exhaust duct and the air
outlet of the compressor shall be 200-300mm. Refer to Table 3.1 Ventilation Rate (2) for the
recommended exhaust air rate of ventilating fans. Pay attention to the exhaust air rate and
such conditions as the pressure loss in the exhaust duct and exhaust temperature increase
while choosing ventilating fans.

3.4 Selection Requirements for Air Rate of Ventilating fans

Table 3.1

Cooling method of the unit Air cooling

Motor power of the unit

5.5 7.5 11 15 18 22 30 37 45 55 75
(KW)

Exhaust air rate (1)

95 95 140 180 225 270 360 450 540 540 900
(m3/min)

Exhaust air rate (2)

50 50 50 90 90 170 170 170 240 240 340
(m3/min)

6
DA Series Operation Manual

3.5 Warning

The compressed air and electricity are dangerous.

Prior to any operation on the air compressor, it shall be ensured that:

1 The power has been cut off with the switch locked and the notice plate hung;

2 All the pressure within the entire air compressor system shall be relieved.

(1) It is prohibited to dismount all kinds of caps and mounting and dismounting any joint or device while
the air compressor is running since the high temperature fluid and the compressed air in the air
compressor may cause severe personal injury and even death.

(2) It will bring voltage danger in the electric cabinet when starting up the motor of the air compressor,
therefore all installations shall be implemented in accordance with the accepted laws and
regulations. It shall be ensured that the system voltage can be cut off by disconnecting the switch
manually and the no-fuse switch shall be installed on the power supply line leaded to the air
compressor before running the electrical system. The personnel responsible for equipment
installation shall provide proper found connection, maintenance space and lightning arrester for all
electrical parts.

(3) The air compressor cannot be operated under the exhaust pressure which is greater than that
specified by the nameplate of the air compressor, otherwise the motor will overload which may
result in the tripping of the motor of the air compressor.

(4) The air compressor and auxiliary equipment shall be only cleaned with safe solvent.

(5) The manual stop valve (separate-type) shall be installed in the exhaust pipeline. If the safety valve
is installed between the stop valve and the air compressor, the safety valve shall provide adequate
capacity to release the maximum continuous air flow of the air compressor.

(6) Once any pressure is released through the safety valve due to over-high pressure in the system,
the reason for over-high pressure shall be promptly found out.

(7) If the lubricating oil of the air compressor flows into the air system of the plant, it may bring about
adverse impact. Such post treatment equipment as air dryer and secondary filter (oil-gas separator)
shall be chosen and installed properly to minimize any liquid additions in the air. It may be risky to
use plastic casing without metal cover for the filtration of pipelines. From a safety point of view,
metal casing shall be applied to all the pressure systems. For this purpose, it is recommended that
the air circuit system of the plant shall be re-inspected.

(8) The air tank of post treatment equipment of the air compressor shall be installed and maintained in
accordance with the regulations of Monitoring Specification for Pressure Vessel issued by Ministry

7
DA Series Operation Manual

of Labor of the People’s Republic of China.

(9) The indication stickers on the control panel and this operation manual shall be carefully read
according to each standard operation before starting up the air compressor.

(10) Various cover plates and casings shall be re-installed after completing daily maintenance.

Notice: when the shield plate of the unit is open, the air compressor shall not be started up.

Warning

Not taking such safety advice abovementioned may result in mechanical faults, property damages,
severe personal injuries and even death. Such factors as vibration, pulse, temperature, maximum
pressure, corrosion resistance and chemical resistance shall be considered for any air inlet pipe and
exhaust pipeline connected to inlet/outlet joints, and it should also be noted that there may be a little
lubricating oil in the compressed air generated by the oil air compressor, therefore reasonable allocation
and compatibility shall be ensured between exhaust pipeline and system post treatment device and filed
air demand.

3.6 Suggestions for Pipeline

3.6.1 Pipeline

The air cooler in the unit may sharply reduce the exhaust temperature below the dew point temperature
(under most environmental conditions), so there will be a large amount of condensate separating out. The
condensate valve (drainage device) shall be installed near the exhaust outlet of the air compressor and a
length of exhaust pipe shall be connected to the drainage device of condensate water.

Key point: The drainage device shall be inclined downward in order to work normally.

Notice: A length of drain pipe (transparent hose) shall be placed in the drain pipeline for ease of
inspecting the operation of the automatic drain valve. If the posterior pipeline further cools
the air, it may regenerate the condensate water. Therefore, the release valve and the
drainer of condensate water shall be installed at the lower place of the piping system.

Key point: The diameter of the exhaust pipeline shall be kept at least the same big with that of exhaust
connection pipeline in the casing of the air compressor. All pipelines and joints shall apply to
the maximum operating temperature of the unit, and the nominal pressure shall be kept at
least the same high with that of the oil-gas separator of the air compressor. It is important to
check over each joint dimension of the air compressor, and proper length and dimension of
the pipe, the number and category of the joints and valves shall be considered to reach the
maximum efficiency of the air compressor. It is important to comprehensively consider the
air system of the whole plant to ensure the safety of the entire system while installing new
air compressors. Condensate water will be necessarily produced in the air pipeline during

8
DA Series Operation Manual

air compression. Since vapor in the environment will be concentrated during inflating, it will
be cooled in the posterior air pipeline and become condensate water. The water in the
compressed air shall be drained in the whole pipeline system of nearly all the air
compressors, therefore every customer shall pay more attention to the above issues during
the use of the air compressor, the design of the pipeline system and daily maintenance. The
common problems caused by water are as follows:

(1) The water of the internal system of the air compressor may emulsify the lubricating oil and the air
compressor will be scaled and stuck.

(2) The water in the pipeline of the internal system of the air compressor will contribute to such poor
conditions as corrosion and scale formation and even worse situations.

(3) The instrument is obstructed,

(4) The control valve is stuck,

(5) There is a risk for air pipeline outdoors to freeze under low temperature environment,

Any problem above may lead to suspending production of part of or the whole plant. The compressed-air
dryers of post treatment equipment may reduce the concentration of vapor to prevent the air pipeline
forming liquid water. The combined use of the dryer and the filter, the after-cooler and the automatic drain
valve can effectively improve the air quality in the air system. Using two types of dryers, i.e. refrigerated
dryer and regenerative dryer can solve the problem of containing water in the outside air system of the
compressor. When the dew point requirement of the compressed air pressure is 1 ℃ to 4 ℃ , the
refrigerated dryer can be applied generally, however when it is required to keep the dew point
requirement of the pressure below 1℃, the regenerative dryer shall be used. Please contact local branch
or appointed distributor of Denair, which may help you choose the proper dryer.

Note: the rotary air compressor cannot be connected to a reciprocating air compressor system without
pulsation isolation device (e.g. sharable air tank).It is recommended that two different types of air
compressors should be connected to a common air tank via individual air pipeline.

A shut-off valve and a drain valve shall be provided for each air compressor in front of the sharable air
tank during parallel (selective assembly) installation of several air compressors in the plant.Notice:

(1) The drainage device shall be installed at backend of the air outlet of the compressor during
parallel connection.

(2) The drain valves of oil-gas barrels in the air compressor and air reservoirs of the
external system of the air compressor shall be opened to drain condensate water
completely before starting up the air compressor, to make sure that the oil products
of the unit will not be emulsified and the compressor will not be stuck due to
deterioration of oil products.

9
DA Series Operation Manual

(3) The drainage function of drainage devices of each post treatment device (equipment)
in the external system of the air compressor shall be inspected regularly to make
sure that the external system in the whole air compressor can operate normally.

3.6.2 Suggestions for Piping of Air Pipeline

(1) Based on the diameter of the air outlet pipe of the compressor, the air compression pipe with the
same or larger diameter shall be selected for the connection between the air outlet of the air
compressor and the air reservoir to reduce pressure drop.

(2) For ease of daily maintenance in the future, the outlet of the air compressor and air barrel shall be
connected with flange and one shut-off valve (close to the side of the air receiver) shall be installed
additionally. The air compression system shall be successfully isolated without exhausting the
system pressure and wasting the valuable energy for later maintenance.

(3) The requirement on flexibility of the pipeline shall be considered during implementing piping to avoid
resonance phenomenon of the pipeline as far as possible. The gradient of the air pipeline shall be
at least 1/100 so that the water in the air pipeline can be drained successfully.

(4) To prevent overmuch water in the pipeline being condensed and affecting the function of the
equipment, the dryer which can process blowing rate appropriately shall be usually installed behind
the air barrel to remove the water and produce the dry air as required.

See standard configuration of the general air system in the architecture of Fig. below.

Please contact Denair for different air qualities and their respective detailed configuration.

1 2 3 4 5 6 7 8

Fig. 3.7

10
DA Series Operation Manual

The numbers in the Fig. respectively indicate the following meanings:

1. Air receiver 5. Oil filter
2. Pre-filter 6. Adsorption drier
3. Refrigerated dryer 7. Ultra-filter
4. Ultra-filter 8. Air receiver

3.7 Electric Appliances Installation Precautions and Control System

3.7.1 Regulations on electric appliances installation preparatory measures

Before installing the electric appliances, it is recommended that you should review those safety
precautions abovementioned in this manual and find the nameplates of the air compressor and the motor
on the casing. The working pressure, the maximum exhaust pressure and characteristics and power of
the motor are listed on the nameplate. Make sure that the voltage of the circuit is consistent with that
specified on the nameplate of the air compressor. Open the electric cabinet and make sure that all the
electric appliances are properly and securely connected. Make sure voltage supplied by the control
transformer is proper. It shall be inspected for the secure connection of the motor and the control circuit.
Then reclose the electric cabinet.

Please refer to JB6213.5-92 national standard and the specifications in the table below to choose proper
specifications of the main power line, earthing wire and no-fuse breaker (NFB) for the air compressor to
ensure the safety of using the electric appliances. The safe current of the power line shall be set
under the condition where the ambient temperature is 35 ℃ , the operating temperature is lower
than 55 ℃ , the wire length is within 20m and shall be based on the 600V PVC wire. When the
power line fails to meet the settings above, the specifications of the power line shall be
increased to avoid failing to start up the air compressor due to over-limit of the voltage drop and
even bringing electrical hazards.

(1) It shall be better to separately apply one set of electric power system to the air compressor
but the parallel connection with other different power consumption system shall be
particularly avoided. If not, the air compressor will be overloaded, resulting in tripping of
the protective devices due to large voltage drop or imbalance of three-phase current,
therefore please pay more attention to the requirement for the air compressor with high
power.

(2) The correctness of the voltage shall be confirmed during the distribution of the air
compressor. The earthing wire of the air compressor shall be securely set up but not on the
air delivery pipe or the cooling water pipe directly.

(3) The air compressor shall connect an earthing wire to the ground to avoid danger caused by
electric leakage.

(4) The single cable shall not be too thick with the limitation of the dimension of the electric cabinet. If

11
DA Series Operation Manual

the sectional area of the power line is too large, it can be replaced with two or more power lines.
Each power line shall be three-phase balanced while using multiple power lines; otherwise it may
result in overheating cable and unbalanced synthesized voltage. The input supply voltage shall be
kept within ±10 ％ of the nominal voltage and the three-phase voltage difference shall be within
3%.There must be proper earthing wire connected with the air compressor, otherwise noise may be
connected to any control system in series and cause interference. If the earthing connection cannot
be improved, the values of temperature, current and voltage of the controller may fluctuate.

KW
5.5 7.5 11 15 18.5 22 30 37 45 55 75
Specifications

Full-load current (A) 15 18 25 35 41 49 66 81 98 119 167

Sectional area of the

2.5 2.5 4.0 8 10 10 16 25 35 50 70
power line (m m2)

Sectional area of the

2.5 2.5 4.0 8 10 10 16 25 25 25 35
earthing wire (m m2)

Breaker (NFB) 50 50 50 70 100 125 125 125 175 225 300

Note:

(1) The voltage specifications are 380V and 50/60HZ.

(2) When the earthing wire and the power line of the movable electric appliance are both
placed in the hose or cable, and the wire diameter of the electric appliance shall be the
same with the power line.

3.7.2 Driving motor

The driving motor of the air compressor shall correctly turn to the counter-clockwise direction when
seeing from the driving end. The inching time of the motor shall be as short as possible while inspecting
the turning of the motor of the air compressor. The button of “emergency shutdown” shall be pressed
promptly after pressing the startup button. If the turning direction of the motor is not correct, the master
switch shall be disconnected and the warning saying “No switching on” shall be locked and hung. Open
the electric cabinet, exchange any two joints (R, S, and T) on the starter, close and screw the electric
cabinet and re-inspect the turning direction of the motor.

3.7.3 Fan motor

Observe whether the fan exhausts air to the external unit, if the turning direction is not correct, the master
switch shall be disconnected and the warning saying “No switching on” shall be locked and hung. Please
exchange any two terminals on the contactor of the fan, close and lock the electric cabinet and inspect
the turning direction.

3.7.4 Control system

12
DA Series Operation Manual

(1) Start-up of the electromotor (pressure drop or Y running)

The inlet valve is fully cut off, the release valve is fully opened and the release solenoid valve is
closed during this period, meanwhile the inlet side is of high vacuum and the lubricating oil required
by the compression chamber and bearings is ensured by the difference between the vacuum in the
compression chamber and the atmospheric pressure in oil-gas barrel.

(2) Full pressure running of the electromotor (full pressure or △ running)

The release solenoid valve is opened with power on after the control system switches to full pressure
running. When the release solenoid valve is closed, the pressure in the oil-gas barrel will gradually
rise. When the inlet valve is opened little by little, the pressure in the oil-gas barrel will rapidly rise so
that the inlet valve is fully opened and the compressor starts the heavy-load running. When the
pressure rises to a certain value, the pressure maintenance valve is fully opened and the air is
output.

(3) Heavy-load/no-load compressor

When the pressure persistently rises to the unload pressure settings, the release solenoid
valve starts to exhaust air. The inlet valve is closed so that the air enters from the bypass pipeline
and the pressure in the oil-gas barrel starts to discharge, meanwhile the pressure maintenance valve
is quickly closed to isolate the system pressure. The pressure in the oil-gas barrel is consistently
discharge to a certain valve, i.e. the no-load pressure to provide the pressure required by
lubricating oil circulation. At this time, the air enters from the bypass pipeline and is exhausted
by the release solenoid valve after being compressed by the compressor and this circulation shows
the no-load running. When the system pressure drops to the settings of the loading pressure,
the release solenoid valve will stop discharging, the inlet valve will be fully opened and the
compressor will be running with load for a second time.

(4) Shutdown

After pressing the STOP button, the release solenoid valve starts to exhaust air. When the
inlet valve is closed, the pressure maintenance valve will be closed, the pressure in the
oil-gas barrel will start to discharge and be isolated with the system pressure. The motor
shall stop running after the pressure in the barrel is exhausted to the no-load pressure and
the motor will be shut down after 20s.The pressure in the oil-gas barrel is consistently
exhausted to zero.

(5) High temperature tripping or motor overloading

When the exhaust temperature is greater than 105 o C or the motor results in current
protective device actions due to overload, the power supply will be cut off which will

13
DA Series Operation Manual

immediately shut down the motor. Meanwhile the inlet valve is closed, the release valve will
be fully opened and the pressure maintenance valve will be closed and the pressure in the oil-gas
barrel will be exhausted to zero. Only when there are abnormalities during the running of the unit, it is
allowed to press the emergency shutdown, otherwise it may easily cause the system failure.

(6) Automatic stop system for overtime idling and reboot time setting

If the air used by the system reduces, the compressor keeps running at no-load conditions.
If the no-load running time exceeds the set time, the compressor will be automatically shut
down and the motor will stop running. When the air used by the system increases, the
system pressure will be reduced and the air compressor will automatically start to
supplement the air amount. For the time setting of shutdown caused by long-time no-load
running, another setting can be made by the controller of the air compressor. The air
compressor cannot be restarted up until five minutes after shutting down the motor.

3.7.5 Electrical circuit

The electrical control of the air compressor consists of two systems, including the internal

control system and the part of the startup disk. The startup disk is the Y-△startup control

used by general machineries. The control part is the electronic control. The electronic
control part will not be presented thoroughly in this chapter due to the complicated internal
circuit and control. If there is any loss or fault, please contact the customer service center of
Denair.

4. Introduction to the System

4.1 Overall System

The air compressor is driven by motor and the complete internal and external systems of the air
compressor are composed of the screw air compressor unit compressed by single stage and post
treatment device (air reservoir, dryer and filter) of the external system.

4.2 Composition of the Compressor Unit

The internal system of the air compressor unit is composed of the following main parts:

(1) Air filter

(2) Compressor

(3) Oil separator

(4) Pressure maintenance valve

14
DA Series Operation Manual

(5) After-cooler assembly

(6) Oil-gas barrel

The air enters the air compressor and flows through the inlet filter and the inlet valve. The compression of
the screw air compressor is generated by the meshing of a pair of helical rotors (one is male and the other
is female), which are respectively installed on two parallel shafts and in the high-strength cast iron casing.
The inlet and the outlet are located at either ends of the shell respectively. The slot of the female rotor is
meshed with and driven by the male rotor, and the exhaust end employs the bearing to prevent the rotor
axial floating. The oil-gas mixture is exhausted from the outlet of the main engine and enters the oil-gas
separation system which removes the most lubricating oil in the oil-gas separator. The lubricating oil will
flow back this system and enter the cooling system with the compressed air leaving a little PPM oil
content. The after-cooling system consists of a heat exchanger and drain device. The exhausted air after
cooling will condense much vapor contained in the air which can be removed in the posterior pipeline and
equipment terminal of the unit. The inlet valve is closed, the release valve is opened and the compressed
air enters in the inlet valve from the bypass pipeline during unload running.

4.3 Lubricating Oil System

The lubricating oil flows from the oil-gas separator and the oil-gas barrel to the inlet of the cooler and the
bypass port of the heat control valve under the pressure. The exhaust temperature of the compressor can
be controlled above the dew point by the heat control valve. When the air compressor starts up in cold, a
part of the lubricating oil will flow bypass the cooler. When the system temperature rises above the
settings of the temperature control valve, the lubricating oil will flow through the cooler. When the unit is
running under high temperature conditions, all lubricating oil will flow through the cooler. The outlet
temperature of the oil cooler of the air compressor can be controlled to eliminate the possibility of the
condensation of the vapor in the oil-gas separator. The temperature of the oil-gas mixture exhausted from
the unit can be kept above the dew point by maintaining high oil temperature. The lubricating oil with
controllable temperature enters the engine body through the oil filter under the constant pressure.

4.4 Oil-gas Separation System

The oil-gas separation system is composed of the oil-gas barrel with specially designed internal structure,
two-level gathered separator element and cooling oil recovery device. Basic operation principle of the
oil-gas barrel: The oil-gas enters from the inlet and impact the head of the oil-gas barrel to separate the
oil drops from the oil-gas mixture based on the state. The machinery impact can be applied to the oil-gas
barrel, which can separate oil drops with large diameter relying on its own gravity of the oil drop, which is
suitable for the oil drops with diameter greater than 1um.

When using the method of machinery impact, impacting the head by the oil-gas mixture may control the
oil molecules with a certain flow rate so that the oil drops can fall to the bottom of the oil-gas barrel during
discharging and the oil content discharged from the air can be reduced.

15
DA Series Operation Manual

Notice:

When the air compressor adopts water cooling type, please install a Y filter in front of the water
inlet of the air compressor additionally, otherwise the water cooling system of the air compressor
will fail to work.

5 Controller Operation

Fig. 5.1

5.1 Key Description

BUTTON FUNCTION REMARKS

START the motor can be started by pressing this key.

STOP the motor can be stopped by pressing this key

RESET reset by pressing this key

SET enter button

UP page up by pressing this key

DOWN page down by pressing this key

EXIT exit from current interface by pressing this key

16
DA Series Operation Manual

5.2 Schematic Wiring Diagram

17
DA Series Operation Manual

6. Function Description of System Components

6.1 Air Filter

The air filter is a kind of dry paper filter to filtrate the air entering the compressor. The filtration efficiency
has direct effects on the service time of the lubricating oil, oil filter, oil separator and body bearing. In case
that the air inlet filter is blocked, the air intake will decrease, thus affecting the air supply. Denair service
staff will suggest changing a new product based on the inlet dust and the service time displayed on the
controller at every onsite inspection. With the controller set to the longest service time, when the
controller displays a warning message, the air inlet filter of the air compressor unit shall be replaced with
a new one.

6.2 Inlet Valve

The inlet valve is a kind of piston valve which facilitates the movement of the piston with the air source
entering through the bottom of the piston，thus controlling the air intake. The piston moves farther with
more controlled air source to make the air inlet smaller and reduce the air intake, otherwise the air intake
increases.

6.3 Oil-gas Barrel

In addition to store lubricating oil, the oil-gas separator can primarily separate the air-fuel mixture with
mechanical collision method. The separating effect has an effect on that of the oil separator, thus affecting
the oil content in the air. The oil level indicator on the side of the barrel is used to view the oil level. The oil
drain valve on the bottom is used for draining the condensate water in the oil-gas barrel before starting up
the air compressor and for changing the lubricating oil for periodic maintenance.

6.4 Oil Separator

The oil separator, composed of two fine glass fibers, can be used to filter the oil spill in the compressed air.
The filtered oil gathers in the central flute and flows back to the compressor to prevent the oil draining with
the air. The oil content in the air can be controlled under 3PPM for normal operation under the nominal
pressure. The dust pollution in the working environment, the quality of the lubricating oil, the filtration
efficiency of the oil filter and the decision whether to drain the water in the oil-gas barrel prior to start up
have a great effect on the service time of the oil separator and the filtration efficiency. The compressed air
will contain more oil to lead to “oil throwing” phenomenon in case of blocking or poor filtration efficiency.
Denair service staff will suggest changing a new product based on the working environment, inlet dust,
quality of lubricating oil and the total time used displayed on the controller at every onsite inspection. With
the controller set to the longest service time, when the controller displays a warning message, the oil
separator of the air compressor unit shall be replaced with a new one.

6.5 Safety Valve

An air compressor in abnormal operation or pressure sensor failure may result in a continuous
increase of the pressure in the oil-gas barrel. When the pressure increases to the set value, the
safety valve on the oil-gas barrel will automatically open to discharge pressure and eject the

18
DA Series Operation Manual

lubricating oil so as to reduce the pressure in the oil-gas barrel and ensure the safe use of the
unit. In order to avoid accidents, the set pressure of the safety valve has been adjusted before
delivery and nobody shall adjust it at will.

6.6 Pressure Maintenance Valve

The functions are as follows:

A When it starts, the pressure maintenance valve facilitates the establishment of the
pressure required by the lubricating oil circulation to ensure the lubrication of the parts.

B The pressure maintenance valve helps to keep the pressure in the oil-gas barrel at a
minimum valve, protect the oil separator from being damaged by large differential pressure,
maintain the best separation of oil and gas, and reduce the oil content of exhaust.

C The pressure maintenance valve can be used to separate the system and the oil-gas
separator and prevent the condensate water from reflowing in the compressed air and
pipelines for empty or stop.

6.7 Rear Cooler

The rear cooler can be used to cool the compressed air, control the exhaust outlet temperature
and prevent dryer of the external system from being damaged or poor effect caused by excess
temperature. The efficiency of the cooler may be reduced for blocking or scales. So it shall be
maintained clean during daily maintenance to ensure cooling effect.

6.8 Oil Cooler

The cooler is used to cool the lubricating oil. When the efficiency of the cooler is reduced for
blocking or scales, the system may be halted for high exhaust temperature. So it shall be
maintained clean during daily maintenance to ensure cooling effect.

6.9 Oil Filter

As a paper filter, the oil filter is used to remove the impurities in the oil to improve the lubrication
effect and reduce its damage to the compressor bearing and some parts. The Denair service
staff will measure the pressure valve in front and at the back of the oil filter, observe the quality
of the lubricating oil at every onsite inspection. The staff may suggest changing a new product
based on the synthetic judgment. With the controller set to the longest service time, when the
controller displays a warning message, the oil filter of the air compressor unit shall be replaced
with a new one. If the blocked parts are not replaced, the lack of oil in the lubricating oil pipeline
system may cause the exhaust temperature to be too high, or shorten the service time of the key
parts, components or bearing. In even severe cases, the compressor may be burned out.

6.10Exhaust Temperature Sensor

The sensor is used to detect the exhaust temperature of the compressor and send the message

19
DA Series Operation Manual

to the controller to maintain the normal operation of the compressor. In case that the exhaust
temperature is detected too high, the controller may shut down the air compressor to prevent
the parts from being damaged and accidents.

6.11Pressure Sensor

The compressor is equipped with a pressure sensor to send the message to the controller for
process and judgment to ensure the normal operation of the air compressor in a perfect
protection.

7. Maintenance
Any dismounting shall be implemented after the motor and the fan have stopped working
completely and make sure the power is cut off. A signboard shall be set on the starter at the
maintenance of the air compressor with the words of “warning: under overhaul, no driving”. The
maintenance of pressure parts shall be started after the internal compressed air is exhausted
completely.

7.1 Inspection and Update of Belt and Pulley

(1) Adjustment of belt and pulley

The tension of the belt can be automatically adjusted with the self-weight of the motor and the
equilibrium principle to produce the torque, thus there is no need for tension adjustment and
calibration for changing the belt. The belt has a long service time, the working pressure and air
volume can be easily changed as required. The pulley can be verified by placing a ruler or
vertical bar closely at the end of the pulley and measuring the distance “A” between the outer
edge of the other pulley and the ruler, the “A” shall be less than 1mm.In case that the horizontal
plane between the side pulleys of the motor and the body fails to meet the standard
requirements, the horizontal plane can be adjusted by adjusting the position of the fixing bolt.
The fixing bolt shall be fastened after adjustment.

20
DA Series Operation Manual

(2) Update of belt

In case that it requires changing the belt because the belt reaches the end of its service life, or
the belt is cracked and seriously damaged, it can be changed by adjusting the height of the
motor with the adjusting bolt until the bolt can be easily dismounted. The height of the motor is
supported by the bolt. At the moment, the belt can be replaced with a new one. After then the
adjusting bolt shall be removed. This is convenient because there is no need to readjust the
horizontal plane of the pulley.

7.2 Air Filter

The air filter shall be replaced when the maintenance indicator light is lit up. The service time is
determined by the quality of the ambient air, usually 3000 hours. The air inlet filter has a direct
effect on the service life of the lubricating oil filter and oil separator. The air filter is replaced as
follows: dismount the fixing bolt of the air inlet filter and replace with a new product. Note that
the sealing gasket of the inlet filter shall stick close to the permanent seat.

7.3 Lubrication of Motor Bearing

The oil filling bearing shall be periodically filled with lubricating oil according to the Instructions
for use of the motor or the following table.

(a) Supplementary amount and interval table of lubricating grease

Initial filling amount (g) Supplementary amount (g) Supply interval for operating
Power (kw)
Note (1) Note (2) for 24h per day (h)

18.5 50 30 1500
22 100 30 1500
30 100 30 1500
37 100 30 1500
45 200 30 1500
55 200 30 1500
75 200 30 1500

Table 7.2

21
DA Series Operation Manual

Note:

(1) The initial filling amount refers to the new filling amount after the bearing is dismounted
and cleaned. The bearing is 1/3 filled while the others are filled into the bearing cap (the
filling is complete when the motor is delivered).

(2) The filling amount refers to the amount of the lubricating grease filled into the bearing at
every interval. Please supply timely according to the running time of the unit.

(3) Note: more supplementary amount cannot extend the supply period. Please do as the
specification given in above table.

(4) The bearing may be overheated and the lubricating grease may be leaked for the stirring
resistance when the lubricating grease deposits at the outlet to exhaust the lubricating
grease stored. Please open the cap to clean the lubricating grease (once after filling
2-3times).

(5) The fuel quantity shall conform to the standard value. The motor may be damaged in case
of excess.

(6) The grease shall be changed according to the size of the motor, the operation condition
and working condition. The change interval and filling amount shall comply with the filling
label on the motor.

(b) The lubricating greases in the following specification have been filled when delivering.
Please use the lubricating grease with the same quality and specification to ensure the
service time of the bearing.

Marketability Biggest lubricating grease manufacturer, easy to buy

Generally, the lubricating grease is –20℃～120℃, the others out of this range shall use low
Allowable temperature
or high temperature grease.
For high-speed and major For good resistance to pressure (oil film strength).The hard ones are better. For better voice,
diameter bearing vibration and exhaust effect, the soft ones are better.(avoid using Silicon grease)〕
For belt and gear with high load, the one with good resistance to pressure is better.
Load resistance
(avoid using Silicon grease)
Water resistance Avoid using Na or Ca grease under high humidity condition.
The soft ones are better in terms of the temperature increase which is determined by the
Consistency lubricity and exhaust effect when filling under creak, abnormal vibration and cold
environment for the similar hardness.
Please use the grease with good lubricity and select the grease based on its
Lubricity
strengths and weaknesses.

7.4 Compressor Bearing

The compressor bearing is a consumable (change once per 30,000 working hours). The noise
and vibration may be high when operating because the service time is shortened for a
combination of normal or abnormal wear, the inlet quality, lubricating oil quality and oil filtration
effect. The Denair service staff will decide whether to change the bearing in case of this
condition.

22
DA Series Operation Manual

7.5 Air Compressor Lubricating Oil

The lubricating oil of the rotary screw air compressor, as a kind of special oil, shall not be used
mixing with other oils; otherwise the air compressor may be seriously damaged otherwise
specified by the Denair. When changing the oil, the old oil in the system shall be completely
removed, otherwise the service time of the new oil may be shortened. The oil filter and oil
separator shall also be changed when changing the lubricating oil. The oil shall be changed as
follows: confirm to close the power switch of the compressor, relieve the pressure in the oil-gas
separator, open the oil drain valve of the oil-gas barrel and cooler under pressure-free condition
and place it on the oil receiver, completely drain the old oil in the oil-gas barrel and cooler, close
the oil drain valve before turning on the power, restart the air compressor for operating 3
seconds and stop it, turn off the power, and open the oil drain valve to drain the remaining oil
provided that there is no pressure in the oil-gas barrel. When filling oil, the oil drain valve of the
oil-gas barrel and cooler shall be fastened and placed on the oil receiver. The oil-gas barrel
shall be filled with the lubricating oil for the first time through observing the oil gauge pipe.
Restart the compressor to view whether the oil reaches the half of the oil gauge pipe after the
oil-gas barrel is fully filled. Shut it down to add appropriate lubricating oil in case of lowering
than the half. Do not add too much oil.

7.6 Oil Separator

The filter screen will be gradually blocked after using for a while, thus reducing the pressure.
The cleanliness of the oil separator has an effect on the quality of the filtered oil. Too much
blocking may increase the oil content of the outlet air and the normal supplementary amount of
the lubricating oil and the power consumption. Generally, the service time of the oil separator
ranges between 3000-6000h and varies with the environmental quality (dust), periodic clean
and change of the inlet filter and the use of the lubricating oil filter and lubricating oil.

The oil separator is changed as follows: the spin- on oil separator is a kind of thread screw-in
separator and unscrewed with a special tool. Check whether the O-ring and sealing gasket are
right when dismounting and changing. The sealing gasket shall be applied with lubricating oil
before lock-in.

7.7 Oil Return Pipeline

The smoothness of the oil return pipeline into the body shall be periodically inspected. The high
temperature in the oil return pipeline when operating is normal. The pipeline is blocked in case
that the surface of the pipeline is not warm or there is too much oil in the drained condensate
water and shall be cleaned.

Inspection method: inspect the smoothness of the oil separator, oil return pipeline, connector,
check valve, oil return orifice of body and clean.

7.8 Engine Oil Filter

23
DA Series Operation Manual

The service time of the filter is 2000-3000 h based on the maintenance instruction and varies
with the working condition, dust, inlet filter efficiency and the daily clean and maintenance of the
unit. However, the filter shall be replaced in case of a poor filtration efficiency to avoid damaging
the body.

The filter is replaced as follows: disassemble and assemble the lubricating oil filter with a
special tool to avoid deforming the enclosure and affecting the function. The oil receiver shall be
placed under the filter to receive the spilled lubricating oil when dismounting. The lubricating oil
filter shall be cleaned before installation. The sealing gasket shall be applied with the lubricating
oil before lock-in.

7.9 Pipe Joint

The linkage of all pipe joints of the compressor shall be regularly inspected as well as the aging
and crack of the hose. The gasket, O-ring or hose shall be replaced according to the problem, or
applied with sealant. When maintaining or dismounting the parts, the parts shall be relocked in
case of any loose ones and resealed if necessary. The Denair service staff will suggest whether
to buy a repair kit as appropriate to replace the necessary accessories and hose.

7.10 Inlet Valve

Regularly dismount the piston of the inlet valve to remove deposits and apply to grease or
change the piston ring to ensure the sensitivity of the piston to control the air volume.

7.11 Pressure Maintenance Valve

The pressure maintenance valve shall be regularly dismounted to remove deposits and applied
with grease. The O-ring or sealing ring of the valve block shall be changed in case of any
damage. A regular test of the valve block sealing helps to reduce leakage loss.

7.12 Safety Valve

(1) The safety valve has been adjusted. Do not adjust it anymore.

(2) The effectiveness of the safety valve shall be regularly tested by applying the air
compressor pressure to the corresponding safety valve opening pressure and verifying no
blocking.

7.13 Draining Solenoid Valve

(1) In case of a frequent operation of the empty and load of the air compressor, please set an
appropriate load/unloading pressure according to the air consumption, otherwise the
service time of the draining solenoid valve will be reduced by half.

(2) The abnormal movement of the draining solenoid valve has a direct effect on the normal
use. Therefore, a periodic inspection is very necessary.

(3) The draining solenoid valve shall be regularly inspected for:

24
DA Series Operation Manual

a particulate matters in the solenoid valve (disassemble it to inspection);

b normal pickup of the coil rod of the energized solenoid valve (touch the coil rod with a
tool like electro-probe);

c normal operation of the empty and load (voice of switchover).

7.14 Cooler

After using for a while, the heat dissipation of the flow through cooler may become poor
because the dirt and dust attach to the surface, thus increasing the exhaust temperature. So it
shall be regularly cleaned to blow the dust with the high pressure gas. It is important to
strengthen the cooling capacity. The ambient air quality may affect the maintenance period.

7.15 Electric Insulation

The insulation value of the compressor motor and fan motor shall be regularly tested to prevent
the motor burning out without any warning. The lowest safe insulation value is 500VDCk, 5MΩ.
The reason for insulation degradation shall be identified and handled as soon as possible.

7.16 Periodic Inspection and Cleaning

The air compressor shall be periodically tested and cleaned as per the parts in the Air
Compressor Periodic Maintenance Table after running for a while. The Denair service staff and
the qualified service staff of the specified regional maintainer will provide periodic inspection
and cleaning services for above working.

8. Safety Protection and Warning Device

8.1 Motor Overload Protection

There are two main motors in air compressor system, including air compressor main driving
motor and cooling and circulating fan motor. For main motors, in the normal condition, the
running current shall not exceed the setting of micro-computerized controller due to voltage
drop, three-phase imbalance and etc. When the running current of the more exceeds the upper
limit defined by electrical protection device, the micro-computerized controller will automatically
cut off the power and shut down the motor where the air compressor will be unable to start up
unless reconnected to power supply. For reset, just press down the set switch with your hand.

Warning: Voltage fluctuation shall be controlled ≤(-10%～ +10%) and imbalance between phases
shall not exceed 3%, otherwise the temperature within the motor will sharply increase. For
example, when the imbalance of voltage reaches 3.5%, the temperature of the motor will
increase approximately 25%.

Reasons for general motor overload:

(1) Manual misoperation: voluntarily adjust exhaust pressure, inappropriate system

25
DA Series Operation Manual

adjustment and etc.

(2) Mechanical failures: internal wear and tear of the motor, under-phased running of the
motor, safety valve’s failure to actuate, system setting failures, obstruction of oil separator
and etc.

If the motor is found overloaded in the process of running, please contact maintenance supplies
of Denair or specified region, go for inspection and clarify the reason of overload, otherwise the
burnout of the motor will cause a lot of troubles for in-situ air requirements and maintenance
fees.

8.2 Protection for Over-temperature of Exhaust

The highest exhaust temperature set by the system is 105oC, where the system will
automatically cut off the power when it exceeds 105oC.Generally, many reasons can result in
over-temperature of exhaust, among which the most common one is the failure of oil cooler. For
air cooled oil cooler, if the fins are obstructed by dust which makes the cooling air fail to pass
through the cooler freely, the temperature of lubricating oil will gradually increase and result in
shutdown due to the high temperature. Therefore, it is necessary to utilize the low pressure air
to remove the dust on the fins every once in a while. For failure to blow off the obstruction on the
fins, cleansing solution or solvent is recommended. The designed highest temperature of the air
compressor is 45 ℃ where the exhaust temperature will increase with the increase of ambient
temperature, so it’s important to select a region of low ambient temperature and good ventilation
to place the air compressor.

8.3 Setting and Description of Other Protection and Warning

See the introduction given in Section 5.6 and 5.7 of this manual.

8.4 Failure Causes and Troubleshooting

Failure Cause Troubleshooting

Check the specification of the control voltage, fuse and
Fault of control voltage
connection cord
Check whether the emergency actuates or the contact is
Actuation of emergency switch
disconnected
Failure of the power supply to Check whether the power supply is turned on
Startup failure
turn on Check the power supplies of the motor and controller
The diameter of the wiring is too small / change the
specification of the wiring diameter
Low voltage
The voltage of power supply is too low/ adjust it to the right
voltage
The requirement of the system
for air exceeding the capacity of Add air compressor
the compressor
Poor actuation of inlet valve Check and maintenance
Under-pressure Leakage of system air Check and maintain the pipeline
of the system Belt slipping Adjust the tension of the belt

Inlet filter too dirty Replace the inlet filter

Controller pressure too low Check the accuracy of the settings and pressure detector

26
DA Series Operation Manual

Check whether the solenoid valve is excited, the valve gets

Draining solenoid valve unable
stuck
to close
And the controller outputs signals (connection cord or relay)
Failure Cause Troubleshooting

Belt slipping/ readjust tension or replace the belt

Drive anomalies
Poor alignment of pulley/ recalibrate the alignment
Bearing of compressor body Reasons for damage shall be identified while return to
damaged factory for change.
Reasons for damage shall be identified while return to
Bearing of main motor damaged
Excessive factory for change.
vibration and Loose parts Lock and fix the parts
noise Improper installation of air The support of the installation surface is unstable.
compressor Improper installation of water or air pipe causes vibration.
The compressor is running under low oil pressure and loss
Abnormal running of
of oil or at over-temperature/ eliminate the causes of loss of
compressor resulting in Bearing
oil, over-temperature and low oil pressure and replace new
seal wearing
oil product
Wrong controller pressure
Adjust settings
setting
The detection pressure of sensor is lower than the actual
Actuation of
Failure of pressure sensor values
safety valve
Connection pipe of sensor obstructed/ remove
Fault of controller I/O fault of controller/ replace and repair it
Fault of safety valve Replace the safety valve
Mixed use of different oil Eliminate all the lubricating oil of the system and refill with
products new lubricating oil
It is necessary to eliminate all the residual oil when
Incomplete removal of old oil
replacing the lubricating and refill with new lubricating oil.
Since over-temperature may reduce the service life of the oil
Excessive running temperature
Short service life products, the exhaust temperature shall be adjusted to
of compressor
of lubricating oil normal temperature.
The compressor runs under the pressure dew point and
Insufficient running
there is too much condensate water within oil-gas barrel
temperature of compressor
which cause the lubricating oil emulsified.
Difference level of air compressor oils have different service
Insufficient oil level
lives and oil product with proper service life shall be chosen.
Air pipeline obstructed, the Check the pressure of each parts within the air compressor
valve not full opened and remove the obstruction or open the valve
Improper installation of the
water drain pipe of the air Modify the improper arrangement of water drain pipe
compressor pipeline
Over-dampness
Poor heat dissipation of the
of the system The cooler is too dirty and requires cleaning
cooler
Air dryer not installed
Install and open the air dryer
Air dryer not opened
Air requirements fluctuating Increase the capacity of air reservoir
sharply
Great pressure
fluctuation
The scope of set pressure of
Change the pressure settings
empty/ loaded car too large
Leakage of lubricating oil Check whether the oil lines and oil seals leak or replace the
System parts
Excess of oil Oil separator obstructed Replace the oil separator
content in the Leakage of oil separator Check the oil separator
exhaust and Check all the parts of the oil return pipeline and remove any
Oil return pipeline obstructed
great oil foreign matter
consumption Reduce the air consumption or add air compressor and
The compressor running under
adjust the compressor to operate under the nominal
the set pressure
pressure

27
DA Series Operation Manual

28
DA Series Operation Manual

Annex I: Table of Cycles for Periodic Maintenance of Air Compressor

○ Clean ◎ Adjust and check ● Replace
6000 Re
500 1500 3000 12000 18000 30000
hour mar
We hours hours hours hours hours hours
Dai s ks
Item Work content ekl
ly Every Every Every Every
y Month Quarte Ann
half two three five
ly rly ually
year years years years

Visually inspect the

Indicator light of
abnormity of indicator ◎
instrument board
light

Exhaust Check (temperature

◎
temperature (℃ ) range: 70~95 ℃ )

Condensate water
Drain water ◎
within oil-gas barrel

Oil level Check ◎

transparent hose
Check/ replace ◎ ●
and core sleeve

Inlet connection
Check/ replace ◎ ●
hose

Pipeline (rubber/
Check/ replace ◎ ●
metal)

Pipeline connection Check and test leakage ◎

Cooler Clean/ check ○ ◎
Cooling fan Clean ○
Air filter Clean/ check/ replace ○ ◎ ●
Pre-filter screen Clean ○
Connection of
Clean/ check/ replace ○ ◎ ●
solenoid switch

Belt/ pulley Replace ●

Oil filter Replace ●
Motor Fill with bearing grease ◎
Bearing seal of
Check/ replace ◎ ●
compressor

Lubricating oil of Add/ replace lubricating

air compressor oil

Semi-synthetic
●
lubricating oil

29
DA Series Operation Manual

Full-synthetic
●
lubricating oil

Oil Separator Check/ replace ◎ ●

Check all the electric
Electric insulation ◎
inter-phase and earthing

Heat control valve Check/ replace ◎ ●

Inlet valve Check/ replace ◎ ●
Pressure Check/ replace ◎
●
maintenance valve

Proportioning valve Check/ replace ◎ ●

Safety valve Check/ replace ◎ ●
Draining solenoid Check/ replace
◎ ●
valve

Pressure sensor Verify and check/ replace ◎ ●

Temperature ◎ ●
Verify and check/ replace
sensor

Compressor
Check/ replace ◎ ●
bearing

Note: this maintenance cycle is a recommended period and shall be modified according to
different actual environments and working conditions.

Please pay attention to the following precautions:

(1) Denair semi-synthetic lubricating can be used for 3,000 hours or half a year, Denair
full-synthetic lubricating oil for 6,000 hours or one year, so the oil product is recommended
to be replaced whichever expires first. Remark: When the semi-synthetic oil product is
used in high temperature, its usage shall be half of that in normal condition.

(2) The air compressor with exhaust pressure over 10 kgf/ cm 2 shall use Denair full-synthetic
lubricating oil as its oil product and its recommended service hours is 4,000 hours.

(3) In normal working condition, when original Denair oil products is used away from dust with
ambient temperature lower than 45 ℃ , the normal service time of oil filter and inlet filter is
3,000 hours and that of oil separator is 3,000~6,000 hours.

(4) In case that the environment is severe and non-Denair original lubricating oil is used, the
service hour of the above three filters can only reach the 60% of normal service hours.

(5) In case that the environment is severe and non-Denair original lubricating oil is used,
Denair will be exempt from warranty of the Unit and subsequent maintenance service.

30