SCR PM Series Air Compressor

(5.5KW~15 KW)

Installation, maintenance and operation manual

Shanghai Screw Compressor Co.,Ltd

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 Vote of Thanks

Thank you for purchase of SCR PM Screw air compressor. This manual will help your
better use of our strong air compressor system. And you are welcome to make suggestions
and advice.

We try our best to ensure the completeness and correctness of the manual, but SCR
Company shall reserve the rights for continuous research and improvement on its products
and assume no obligation for the modification and improvement on the previously
delivered products. The design of products is subject to the change without notice.

Production license：
Model of compressor：
Serial number of compressor：
Model of motor：
Serial number of motor：____________________

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 Preface

This manual describes the safety precautions, structure and functions of all systems and
components, as well as the operation and maintenance methods for the SCR series screw
air compressors designed by SCR Company.

The operators shall read this manual carefully. Only after thorough understanding the
structure and functions of all systems and components as well as the safety precautions, can
they start operating and maintaining the unit. In addition to the descriptions in the manual,
if the user fails to follow the operation and maintenance procedures in the manual for the
operation and maintenance, or dismantles and modifies the machine by itself, or uses the
parts not specified by SCR Company, the user shall loss the right for claims.

There is no catalogue for the illustrations of parts and components given in the manual. If
you want to order the parts from our company, please consult the part manual for related
units. It is noted that SCR Company is continuously researching and improving its products
and the contents of part manual may vary from the actual products after a certain period.
Before you order the parts, please confirm it with the service (parts) department of our
company in advance.
This manual gives a general description of the motor, electrical system and maintenance.
However, if you have any questions before operating and maintaining the unit, please
contact the local dealer or the service department of SCR Company

—— Editor

October, 2015

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 Standard Warranty Clause
SCR Company provides the following warranties on the manufacturing process and material
defects for the SCR air compressor manufactured by itself in the conditions of normal operation,
maintenance, repair and service.
SCR series screw compressor unit: within 14 months after the ex-factory date of delivery, or
within 12 months after commissioning, the earlier shall prevail.
Compressor airend returned for repair: within 6 months after the ex-factory date of delivery.
Spare parts (except for filters and oil): within 9 months after the ex-factory date of delivery, or
within 3 months after commissioning, the earlier shall prevail;
For the products not manufactured by SCR Company, the warranty clause of the original
manufacturer shall be directly applied in feasible conditions. Within the warranty period, SCR
Company or the agent shall be informed in writing in 30 days after the defects are found, and the
details shall be attached for identification, including the ex-factory serial number, model,
purchasing date and etc.

The single responsibility assumed by SCR Company in the warranty clause is to repair or replace
the products or parts which are proven defective according to the evidence. If necessary, SCR
Company can ask the users to return the defective products or parts to the factory for inspection
with freight prepaid.
SCR Company holds the warranty period of 3 months or the remaining warranty period for the
repaired products, parts or replaced parts in the conditions of normal operation, maintenance, repair
and service.
The warranty clause is not applicable to the following responsibilities and SCR Company assumes
no responsibility or obligation.
A. Indirectly caused, incidental or special losses or damages.
B. Damages caused due to the normal wearing, abnormal operating conditions, neglects or
wrong operation of equipment, poor storage or transport.
C. Fail to follow the stipulations in operation instructions, regulations or other special sales
conditions.
D. Labor cost, losses or damages caused due to wrong operation (running), maintenance and
the repair performed by the maintenance personnel authorized or not authorized by the
Buyer.
E. Improper use of products.
In any cases, the compensation obligation of the Seller shall be limited to the scope of the selling
price, regardless of the claims caused due to the termination of the contract or the warranty against
the production neglect.

The warranty clause is the sole warranty clause for the Buyer. Any other warranty clauses,
whether clearly stated or implied in the law, or are implied in the factors, including any
commercial warranty clauses and the ones applied to some special purposes, are excluded and
shall not be accepted.

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 Content

Chapter 1 Safety Rules......................................................................6

Chapter 2 Introduction to System Functions................................. 8

Chapter 3 Installation and Acceptance............................................ 15

Chapter 4 Operating Procedures......................................................19

Chapter 5 Maintenance and Service................................................ 21

Chapter 6Troubleshooting................................................................27

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 Chapter 1 Safety Rules

Safety Warning Signs

In this manual, the operations and items related to the safety are identified for their risks,
and they are classified based on the severity of machine damages and the level of injuries
caused due to the operations. They are represented and described in boldface with the
following signs respectively.

“Caution” is meant to the unsafe factors which may cause the general damages to
the machines or injuries.

“Warning” is meant to the unsafe factors which may cause property loss or the
injuries.

“Danger” is meant to the unsafe factors which will cause the severe accidents or
injuries.

“Danger” is meant to the unsafe factor which has the voltage exceeding the safety
level to cause severe injuries. All electrical operations shall be performed
by the qualified electricians.

“Caution” is meant to the unsafe factor which has the hot surface to cause the
property loss or the injuries.

“Caution” is meant to the important installation, operation and maintenance

information.

The following listed safety measures and safety precautions are only a part of the items which have to be
followed for operating the compressors and compressed air system, but are not complete.

Warning
If you fail to follow the following safety measures, the injuries, property loss or compressor
damages will be caused.

Only the trained and authorized persons are allowed to operate the compressor. Prior to any
operations, the operation manual shall be carefully read and its contents shall be comprehensively
understood. If you fail to follow the operation and maintenance procedures and safety rules in the
operation manual, the accidents and injuries are possible.
It is never allowed to start the compressor in an unsafe condition; if the problems occur to the unit,
don’t attempt to start the unit. The power supply shall be shut off and the significant sign shall be given
to prevent the person not knowing the condition from wrongly operating.

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The compressed air is hazardous. Only when the compressed air is totally discharged in the whole
compressor system, the maintenance and service can be performed on the unit.
Don’t change the internal structure and control mode of the unit, unless the written permission from
Screw Company is given.
The daily service and maintenance shall be performed well. The unit shall be carefully inspected every
day to check if the conditions such as leakage, loose, damaged and poorly adjusted parts, or missed parts
and components are present. If the problem is discovered, it shall be handled in time.

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 Chapter 2 Introduction to System Functions
1. Introduction
SCR7.5-20PM permanent magnetic screw air compressor unit designed and manufactured by SCR
Company is a kind of displacement, oil-injection twin-screw compressor unit. The motor and the male
rotor of compressor head are integrated together to drive the compressor to rotate. The compressor head
is imported, so the unit has good power performance, economical efficiency, and reliability.
The unit features reasonable layout, complete functionality, easy operation and maintenance,
beautiful and generous appearance. All the instruments, indicators, and control devices are concentrated
in the control panel, providing easy operation and long-term, stable, reliable running. See Figure 2-2. To
maintain the best operating conditions of the screw compressor unit you bought or use, please carefully
read Chapter 6 "Maintenance and Service" of this Operation Manual.

① Compressor head ② Driving system ③Air intake system ④ Exhaust system ⑤ Control piping
system ⑥ Oil-gas tank ⑦ Noise enclosure ⑧ Electrical control system ⑨ Cooling system ⑩ Oil
piping system
Figure 2-1 Introduction of compressor system

2. Compressor head and compression cycle

Compressor head (main unit). See Figure 2-2. During operation, the air enters the casing through
the air inlet at the power input end. When the rotor passes by the edge of the air intake in the casing, Part
of the intake air is enclosed in the spiral groove closed volume form by the female, male rotors and the
casing. The spiral groove closed volume varies constantly with the engaging movement of the female
and male rotors, to achieve the work cycle of air suction, enclosing, compression, and exhaust. The
compressed air is discharged into the oil-air tank via the air outlet.

1. Air suction process 2. Enclosing and delivery 3. Compression and oil-injection stroke 4.
Exhaust process

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 Figure 2-2 Compression cycle
3. Air intake system
See Figure 2-3. The function of the air intake system of the compressor unit provides clean air to
the compressor. It includes an air filter and an intake valve.

① Air filter assembly ② Clamp ③ Intake valve

Figure 2-3 Air intake system

4. Compressor exhaust system

The exhaust system of the compressor unit mainly consists of integral tank (oil-air tank and air
storage tank), combination valve, oil separator, safety valve, etc., see figure 2-4.

① Integral tank (oil-air tank and air storage tank) ② combination valve ③ Fine oil separator ④ Oil
filter ⑤ Inlet pipe ⑥ Safety valve ⑦ Pressure gauge ⑧ Air supply ball valve
Figure 2-4 Exhaust system

The integral tank integrates oil-air tank and air storage tank. The right chamber of it is the oil-air
tank in which oil-air mixture is separated. A fine oil separator is installed over the oil-air tank. The
compressed air after oil-air separation contains only a few PPM (usually below 3PPM) of the lubricating
oil. The left part of it is the air storage tank. It has buffer function and can protect the compressor very
well. It can filter out part of the condensate water and also has the function of reducing the exhaust

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temperature, and thus to reduce the load of the dryer.
The combination valve integrates the fine oil separator base, oil filter base, pressure-maintaining
valve, and safety valve interfaces. The function of the pressure-maintaining valve is to ensure that a
minimum tank pressure is established in the system in normal operation of the compressor, so as to
ensure normal operation of the oil path. When the unit stops, the pressure-maintaining valve also
functions as a check valve to prevent reflowing of the compressed air. The opening pressure of the
pressure-maintaining valve is 4.0±0.34bar (60±5psi). It has been preset in the factory.

Figure 2-5 Safety valve

On the parts of the tank body where the oil-air tank and air storage tank are installed separately, a
safety valve is fitted respectively. When the air pressure in the tank exceeds the set pressure of the safety
valve, the valve will open automatically. The opening pressure of the safety valves has been set in the
factory. Do not change without permission!

Warning
Do not remove any nut, oil filler plug, or other parts when the compressor is running or under pressure.
Stop the unit and relieve all pressure inside it before any maintenance work.
Do not change and use safety valve of other types.

5. Compressor cooling and lubricating system

The compressor cooling and lubricating system consists of the integral tank (oil-air tank and air
storage tank), oil cooler, combination valve, oil filter and oil pipeline, etc., see Figure 2-6.

① oil filter ② combination valve ③ oil cooler ④ oil inlet, outlet, return pipes

Figure 2-6 Compressor cooling and lubricating system

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 The oil filter consists of a filter base and a replaceable filter cartridge, with built-in bypass valve to
ensure smooth flow of oil and normal operation of the compressor when the cartridge is blocked by dirt
or the oil viscosity is too high.
Oil cooler: The cooler has a fin structure of aluminum plate. The cooling fan forces the air to flow
through the cooling fins to cool the lubricating oil in the cooling pipeline. In daily maintenance, clean
the cooler surface regularly, and wash with hot pressure water not more than 3.5Bar if necessary.

6. Compressor air amount regulation and control system

SCR7.5-20PM series compressor unit is equipped with standard automatic control system.
The compressor enters the loading state directly after startup and regulates motor frequency
according to the pressure in the back-end pipe network When the system reaches the unloading/stopping
pressure (generally rated pressure + 0.6Bar (9psi)), the intake valve is forced to close, the compressed
air in the oil/air separator is emptied, and the compressor stops directly. At the moment, however, the
controller acts, the timer triggers, the compressor enters unloading/timing state. At end of the timing
cycle, the compressor enters "Waiting" state. When the system pressure falls to loading pressure
(generally 0.7Bar (10psi) below rated pressure), the controller sends an order, the timer is reset, and the
unit restarts automatically.
The air amount regulation and control system of the compressor unit consists of the following
elements:
Air intake control valve, pressure control valve, release valve, throttle orifice, solenoid valve, as
well as fittings and connectors for connecting various elements.
There are 3 main operation states: A. Starting and operation with load; B. Stop; C. Stand-by.
In general, the air amount regulation and control system of the compressor unit has been set in the
factory and needs no adjustment by the user. Refer to the User Instructions of the controller in the case
it really needs to be adjusted.
The unit adopts the air amount regulation mode of air intake throttle, i.e. regulates the air intake
flow rate and thus realizes air amount regulation by controlling the intake valve opening. The unit has 4
operation states: A. Starting; B. Operation with load; C. Operation under frequency converter control; D.
Stand-by. Hereunder we will describe the operation principle taking the model of 8bar (116psi) rated
pressure as an example, and the operation of units of other rated pressure can be followed by analogy.

Warning
Do not consider it is safe to perform maintenance work on the compressor when it is not running. The
compressor may in "Waiting" state, and may start at any moment. Strictly follow relevant provisions in
"Maintenance and Service Regulations".

6.1. Starting

Press “Start” button, the motor starts under the control of the frequency converter, the compressor
intake valve opens under the action of instantaneous vacuum, and the compressor enters loading state.

6.2. Operation with load

When the system pressure exceeds 40.bar (60psi), the pressure-maintaining valve opens, and the
unit starts to supply air. When the intake valve is in fully open state, the unit operates with load. After
that, the system pressure will reach the rated pressure very quickly, and then the unit enters normal

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operation state. The unit will operate continuously in this state unless the air consumption of the
consumer changes.

6.3. Operation under frequency converter control

When the air consumption of the consumer is less than the rated air output, the pressure in the
system will rise. When the pressure exceeds the rated pressure by 0.01 to 0.02bar, the frequency
converter actuates to reduce motor speed. If the demand of compressed air increases at this time, the
pressure in the oil/air separator will decrease. When the pressure falls below the setting of the rated
pressure, the frequency of the converter will increase, and then the unit will operate with full load again.

6.4. Unloading, stopping

At that moment, the pipeline pressure will exceed the controller (pressure switch) setting 8.6bar
(125psi), the controller sends an order directly, and the compressor stops operation and enters stand-by
state.
When the pipeline pressure is below 7.3bar (106psi), the controller controls the frequency converter
to start.

7. Electrical system and automatic protection

The electrical system is the control system for realizing start, stop, parameter display and automatic
protection of the unit. The system mainly consists of motor, starting cabinet, instrument cabinet,
contactor, mutual inductor, terminals and cables, as well as all kinds of protective switches, etc.

NOTE: The unit is delivered with related documents. To avoid mis-operation, please refer to the
electrical diagram provided with the unit when performing repair and maintenance works on the electrical system.

The standard driving motor is oil cooled closed type, with a protection grade of IP54/IP65 and a
highest environmental temperature of 40℃（ 107 ℉）. This standard motor is not suitable for saline,
corrosive, damp, dirty, and explosive situations.
This series of standard compressor units are equipped with 380V/50Hz frequency converter. The
transformer in the control cabinet reduces the power voltage to 220V to power the secondary control
circuit. The controller mainly consists of switch, overheat (current) relay, timer, high temperature switch,
solenoid valve, indicator light, mutual inductor, etc.
Special contactor is used to start the driving motor of the cooling fan. This starter receives order
from the controller, and controls starting and stopping of the fan according to the program setting.
Automatic protection is an important part of the unit. Its function is to ensure that the unit cannot
start or stops automatically in abnormal cases, and thus to protect the main unit and motor of the
compressor. This function mainly includes: compressor exhaust temperature shutdown protection,
current overload protection (thermal relay), voltage relay, safety valve, etc. In the unit operation, in
addition to the safety valve, all the other automatic protection equipment can also make the unit to stop.
The following are the detailed introduction of each control equipment.
 Compressor exhaust temperature protection – when the exhaust temperature of the main unit
reaches 98℃, the controller sends an order to cut off its power supply to stop it.
 Overcurrent protection - when the compressor unit is overloaded for some reason, the operating
current of the motor exceeds the set value, the controller sends an order to cut off the motor's power
supply to stop it.

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 Overload relay – when the compressor unit is overloaded for some reason, the current through this
relay exceeds the set value, the contacts in the relay trip due to electrothermal energy, cutting off the
motor's power supply to stop it.
 Phase sequence protector – this series of machines are equipped with a phase sequence protector.
The motor wirings have been properly configured in the factory. If the consumer's power
connection has wrong phase sequence, lack of phase/under-voltage, it is impossible to start the unit
and ensure safety of the compressor unit.
 Safety valve – see Section 5 of Chapter 3.

Warning:

High voltage may cause series personal injury or death. Please cut off the power supply before making
maintenance on electrical components or opening the control cabinet.

: Warning
Do not remove, bridge, or damage the high temperature safety switch. Serious personal injury, death, and
property damage may be caused without this safe function. If the compressor has stopped due to too high
temperature, please immediately contact a qualified service person.

8. Control and indication panel

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 Figure 2-8 Control panel

This series of compressor units are equipped with a smart controller. The display panel of the
controller is as shown in Figure 2-8. To ensure the normal operation of the unit, the operators should be
familiar with the functions and usage of each indication instrument and control element.

Installation illustration
A: The control panel is mounted on the HCU front cover
To connect the control panel:
1. Place its bottom into the bottom of the slot in the drive (A).
2. Rotate the control panel around A and push its upper part (B) until a click is heard.
To remove the control panel:
1. Press and hold the clip (B) with your index finger and middle finger to release the control panel.
2. Pull the upper end of the control panel out from the slot of the drive.
B: The control panel is mounted on the cabinet door.

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 Chapter 3 Installation and Acceptance
1 Installation, acceptance and keeping:

All the processes from shipment, transportation to on-site installation, shutdown maintenance and
service have effects on the integrity and normal operation of the equipment, so upon receiving the
compressor, it shall be immediately inspected for damaged caused by transportation. If any damage is
found, please ask the carrier to sign on the shipment bill and make a damage report. If any hidden
damage was not discovered at the time of inspection and was found later, please inform the carrier
within 15 days after the goods are received and ask the make a damage report. A detailed report is very
important for processing (claim) of the loss.
Check against the name plate of the compressor to determine if it is of correct model and size, and
if all the options are included. Also check that the design or pressure setting of the oil-air tank and safety
valve are correct. For the unit that will not installed at the moment or not operate for a long period of
time, a protection and maintenance program must established to ensure normal operation of the unit,
especially the compressor head.
After unpacking, the handling and installation of the unit shall be performed strictly according to
related handling precautions. There are 2 forklift holes under the base of the unit. When handling with a
forklift, wooden pads shall be placed to prevent the forklift to damage the door panel of the unit (see
Figure 3-1).

Figure 3-1 Handling with a forklift

2 Installation and positioning

This series of compressor units are used indoor. Position the compressor in a clean, well-ventilated
place. The foundation shall be firm. For safety and ease of maintenance and daily inspections, there must
be enough space around the compressor (at least 1.2 meters around and on top of the compressor), see
Figure 3-2.

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 Maintenance space ○
C
Exhaust fan
Install an exhaust fan in
case the setting place is
narrow
Foundation

Maintenance space ○
D
Maintenance space ○
B

Maintenance space ○
A

Figure 3-2 Installation space

The operation environment temperature of the compressor operates shall not exceed 45℃ . Avoid
environment temperature rise due to circulation of hot air from the cooling fan in the machine room. All
the stationary screw compressors from SCR are in principle for indoor use. They can also be installed in
some outdoor locations after being modified. In this case, they should be protected against rain, snow,
and ice.

: "Warning"
The compressor cannot be used in an environment below 0℃ (32℉) or higher than the upper temperature
limit.

: "Note"
The normal operation of the compressor requires enough clean air.

: "Note"
Removal or alteration of noise enclosure will produce high noise and cause harm to human health.

: "Warning"
Do not install or expose the compressor in locations with toxic, volatile or corrosive gases. Do not store
materials of the similar nature in the vicinity of it. Otherwise, it will cause serious personal injury, death and
property damage.
For compressor room design, installation and use, refer to GBJ29-90 "Design code of compressed
air station".

3 Storage and service of the complete unit

When the unit is stored or shut down for a long period of time, firstly, ensure clean, dry placing
environment. Empty the water at the bottom the oil-air tank and air storage tank, cooler (especially water
cooler), water filter in the pipeline and other parts and components. Check and clean all the main parts
and components, connectors of the unit regularly to ensure they are free from leakage, rust. Start the
compressor and operate it for not less than 60 minutes every month at least to ensure safe lubrication of
the compressor head. Secondly, carefully check before starting, change the lubrication oil of the unit if

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necessary, and make a 2-hour test run at full load on the unit. Record data and ask a qualified
professional service engineer to direct the work.

4 Installation of safety facilities

4.1. Safety valve (relief valve)

The safety valve is used to protect the pressure release device of the system. It has been set in the
factory. Do not change its pressure setting or block it. This work can only be down by the safety valve
manufacturer or qualified agent. The gas vented from the safety valve shall be induced to a safe place far
away from the crowd.

: "Warning"
The pressure vessels covered in GB (or ASME) specifications cannot be changed, welded, repaired or
reworked, nor are they allowed to be used under the conditions beyond the rating values on the nameplate,
otherwise it will affect the insurance clauses, and cause serious personal injury, death and property damage.

4.2. Protective cover

All mechanical movements have different levels of potential for danger, so protective covers shall
be provided. This series of compressor units are provided with necessary protective facilities completely
according to national and industry standards. The user shall check and maintain them regularly and is
not allowed change or remove them at will.

4.3. Manual air release valve and cut off valve

It is recommended to install a manual air release valve in the customer's air system. The purpose
of this is to vent the air in the compressor and its exhaust pipe to the atmosphere. In the case where the
air storage tank of the system works together with only one set of compressor, if a cut off valve is
installed in the system, the manual air release valve should be installed at the upstream of the cut off
valve. Such configuration can ensure safety of person and equipment during repair and maintenance.
If only the compressor is isolated from the system for repair, never use check valve instead of cut
off valve.

: "Warning"
Be sure to open the manual air release valve to release the pressure in the compressor and the system before
repairing. Negligence on pressure release of the system may lead to serious personal injury, death, and property
damage.

5 Electrical installation

Prior to installation, check if the power supply, the power lines, and the transformer have consistent
capacity. Appropriate fuses or circuit breakers shall be provided in the installation. The unbalance
between the voltage phases must be limited to less than 5% in order to prevent overcurrent caused by
low voltage. See Table 3-3 for selection of consumer power lines and air switches. The current
specification of the consumer air switches is selected based on 1.5-2 times of the total current. The
compressor must be properly earthed, see the electrical connection diagram.

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 Table 3-6: Selection of consumer power lines and air switches
Diameter of consumer Current specification
Service
Model Rated power Line power lines of the consumer air
Factor
(HP) (kW) current (A) Calculation of current switches
Current (A)
capacity at 40℃ Not less than (A)
7.5 5.5 11.0 12.7 4*6m² 19
10 7.5 14.7 17.6 4*6m² 26
15 11 21.0 25.2 4*6m² 38
20 15 28.4 34.1 4*6m² 51

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 Chapter 4 Operating Procedures
1. General

This series of screw compressor units are equipped with a series of control elements and
display/indication elements. To ensure normal operation of the unit, the operator is required not only to
properly operate the compressor, but also to make correct judgment on the operation state or faults of the
unit according to the displayed/indicated values or state. Prior to starting the unit, the operator should be
familiar with the position, function, and usage of the control elements and display/ indication elements.
Refer to the user manual of the controller for details.

2. Preparation for startup

1) Take off debris and tools around the compressor.

2) Remove bolts or devices for transportation fixing.
3) Check that the oil level is okay (see section "Lubrication oil").
4) Check centering of the belt or coupler if necessary.
5) Check that the fan is installed firmly.
6) Drive the machine by hand to ensure that there is no mechanical interference.
7) Check if all pressure pipefittings are tightened firmly.
8) Open the air supply valve.
9) Check that the safety valve is installed in place.
10) Check if all cover plates and guards are safe and firm.
11) Check if the specifications of the fuses, circuit breakers, and thermal overload protection device or
the current setting of the controller are correct.
12) For water cooled units, check that the water inlet and outlet pipes are connected correctly, firmly,
and that the cooling water is turned on.
13) Check if the air filter is fitted reliably.
14) Turn on the “Power” switch, the power indicator will light up. Touch the “Start” button briefly to
check the compressor rotation direction, ensure it is the same as specified.

3. Normal startup procedures

1) Open the cut off valve to the air supply system.

2) Preset the control parameters and then press “Start” button.
3) Observe the started compressor for abnormal vibration, noise, air/oil leakage. If any problem is
found, immediately stop the compressor for correction.
4) Close all noise enclosure doors to control noise of the unit and ensure normal flow of the cooling
air.
5) Slowly close the air supply cut off valve, and check if the unit is unloading as set. Refer to Chapter
6 for setting and adjustment of the operation parameters.
6) Check if the indication values of various state parameters are okay.
7) For water-cooled units, check the pressure of the inlet water, adjust the ball valve in the water
circuit to keep the exhaust temperature of the unit in normal range.
8) Please carefully observe the operation in the first hour of operation and frequently in the next 7
hours. If any abnormality is found, please stop the compressor for repair.

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9) After initial running, stop according to the stop procedure. Check if it is necessary to refill oil in the
oil tank, and if any connections get loose.

"Note":

① The interval between startups of the unit shall not be less than 5 minutes in order to prevent reduction
of oil filtration efficiency due to oil foaming and to protect the motor.
② Discharge condensate water at the bottom of the oil and gas tank regularly. This shall be done prior to startup of the
unit.
③ Discharge condensate water at the bottom of the filters in the control piping regularly (weekly).
This shall be done prior to startup of the unit.

4. Stop procedures

4.1. Press “Stop” button.

4.2. Close the cut off valve to the air supply system.
4.3. Turn off the power switch.

"Note": closing the cut off valve when stopping can prevent the compressed air of the air
supply system reflowing to the compressor in case that the check valve is damaged,
and thus avoid leakage and damage to components.

5. Emergency stop: Under abnormal conditions, press the emergency stop / reset switch to stop, and
turn off the power switch.

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 Chapter 5 Maintenance and Service
1. Preparations before maintenance and service

Good maintenance and service are essential to normal operation and long service life of the unit.
Therefore, the maintenance and service regulations of the screw compressor unit must be followed
carefully. Before starting maintenance, please carefully read Chapter 1 of this manual "Safety Rules"
and make at least the following preparations:

1) Switch off the power supply of the main unit and tag the power switch.
2) Close the cut off valve to the air supply system to prevent the compressed air reflowing to the
part being repaired.
3) Open the manual air release valve to release the pressure in the system, and keep the air
release valve open.
4) For water-cooled unit, turn off the water supply system, and release the pressure in the water
pipeline.
5) Make sure the compressor unit has been cooled down, avoid scald, burn.
6) Wipe off oil spots and water splash on the ground to avoid slip.

"Warning"

Do not think it is safe to carry out maintenance and service on the machine when it is stop, the
automatic control system will start the compressor at any time.
Poor maintenance and service affect not only the unit's normal operation, but also the operator's safety.
Do not remove any nut, oil filler plug or other parts when the compressor is running or under pressure.
Do not use flammable solvents such as gasoline or kerosene to clean the air filter or other parts. Use safe
solvents according to the instructions.

2. Maintenance and service of the screw compressor

"Note": trained, qualified persons can only perform maintenance and service.

2.1 Compressor lubricating oil

The synthetic lubricating oils listed in the table below can be used in the screw air compressor
designed and manufactured by SCR Company. Each compressor unit is delivered with a lubricating oil
label, indicating the types of the lubricating oil added in the unit. Different types of lubricating oils adapt
to different environment temperature and load conditions, and the change interval is also different.
Relevant warranty service can be enjoyed only when special synthetic lubricating oil from SCR
Company is used.

Type of lubricating oil Oil change interval (h) Environment temperature ℃

SCR SKR 4000 ≤40℃
SCR SLS 6000 ≤40℃

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 For the compressor units with standard configuration, generally SCR lubricating oil is filled before
shipment. It is special screw compressor oil specially supplied by the manufacturer, which features
reliable operation and long change interval.
Do not mix oils of different types or different brand as this may cause
operation faults such as foaming of lubricating oil, blockage of filter, throttle
orifice, or pipelines, and shorten the designed service life of the compressor
and the lubricating oil.
Check the oil level regularly when the compressor is running. See Figure
6-1. There is a sight glass in the oil-air tank of each unit of SCR. Normal oil
level shall be between the upper limit and lower limit of the sight glass. The unit needs oil refilling, but
it can be done only when the unit is stop and after the air in it is completely released.
Figure 6-1 Sight

2.1.1. Water discharge and change of lubricating oil

The condensate water in the bottom of the oil-air tank shall be discharged regularly. Never mix
lubricating oils of different types or brands when changing oil. Otherwise, the guarantee of the
compressor unit will expire. If other type of lubricating oil needs to be used for particular reason, please
contact your SCR representative or SCR service department.
For SCR SKR lubricating oil, under normal maintenance, service, and operation conditions, the oil
must be changed every 4000 operating hours or every year, whichever comes first.

2.2. Oil filter

Fir new compressor, the oil filter element shall be replaced after first 600 operating hours and
whenever one of the following situations occurs after that. It is necessary to stop the compressor to
replace the filter element. Carefully wipe off dirt and oil came in from the outside. Prevent impurities
into the lubrication system as far as possible.
Filter (voltage difference) alarm at normal operation temperature. At this time the filter
pressure difference exceeds 1.7Bar (25psi).
Every 1000 operating hours.
When lubricating oil is changed.
Each time the oil sample is analyzed as unqualified.

"Note": In cold morning after the compressor is started, the indicator of the filter may light
up. This is because the high-pressure difference caused by low fluidity of
lubricating oil. Please observe the indicator after the operation temperature of the
compressor has become normal.

If there is any indication that insoluble sediments formed on the oil filter element, it indicates
that the compressor lubricating oil must be replaced immediately.

The change and adjustment procedures of the oil filter are as below, see Figure 6-2:

① Remove the old filter element using a spanner.

② Clean the mounting surface of the gasket.
③ Apply a thin film of lubricating oil on the new sealing ring.
④ Screw on the filter element by hand, and then tighten 1/2 - 3/4 turn using the spanner.

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 ⑤ Restart the compressor to check for leakage.

Unscrew
旋松Screw旋紧
Oil filter element
油滤芯

Figure 6-2 Replacing the oil filter

2.3. Fine oil separator

Under normal circumstances, if the air filter and oil filter are properly maintained, the oil/air
separator does not require periodic replacement.
The oil/air separator needs to be replaced when one of the following situations appears:
The differential pressure switch of the separator actuates, which indicates the pressure
difference across it exceeds 0.1MPa.
The oil content in the compressed air is still too high when it has been determined that the oil
level, loading, and unloading, oil return systems are all okay.
Every 2000 hours
The specific change and adjustment procedures are as below, see Figure 6-3:
If the supplied air contains oil obviously, but the oil return pipe filter, check valve, throttle orifice,
and air release valve diaphragms are checked
as normal, then it's necessary to replace the oil/air separator.
① Remove the old filter element using a spanner.
② Clean the mounting surface of the gasket.
③ Apply a thin film of lubricating oil on the new sealing ring.
④ Screw on the filter element by hand, and then tighten 1/2 - 3/4 turn using the spanner.
⑤ Restart the compressor to check for leakage.

旋松
Unscrew 旋紧
Screw

油分
Oil separator

Figure 6-3 Replacing the fine oil separator.

Warning

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 To minimize the possibility for filter element breakage, only use product provided by SCR Company as
products from other manufacturers may have an unmatched pressure with the unit.

2.4. Safety valve

A safety valve blocked by dirt is unable to open or unable to close automatically after opened. This
will make the safety of the unit is not guaranteed. In case the safety valve is unable to close
automatically, the lubricating oil in the oil-air tank may eject out in large quantity, resulting in property
damage. Check the condition of the safety valve each week, see Figure 6-3.
Pull up
Pulling ring

Safety valve

Figure 6-3 Check the safety valve

2.5. Oil cooler

For air-cooled unit, clean the outer surface of the cooler using vacuum cleaner, cleaning liquid or
low-pressure (generally not higher than 3.5bar) compressed air each 2 months. For water-cooled unit,
monitor the exhaust temperature of the cooler. Generally, under normal operating conditions, clean the
internal of the filter every 8000 operating hour or one year, whichever comes first.

2.6. Air filter

Check the air filter every day.

Service the filter element when the vacuum switch of the air filter actuates, the pressure loss
reaches 25" water column, the indicator lights up. Check the air filter for breakage and the air
intake system for loose sealing every 500 operating hours or three months. Under normal operating
conditions, replace the filter element every 2000 operating hours or one year.
Service or replacement procedures of the air filter:
① Remove the filter cover.
② Take out the filter element.
③ Clean the inside of the housing with a piece of clean, wet cloth. Do not use compressed air.
④ Tap the end face of the filter element on a flat plate, and then use dry compressed air not more
than 5.88bar (85psi) to blow out the dust in each wrinkle of the filter element from inside in a
direction 45 degrees to the longitudinal direction of the filter element.
⑤ Install the cleaned filter element or a new one.
⑥ Install the filter cover.

"Note": Never remove and replace air filter element while the compressor is running.
Never use oil, water, or compressed air containing water to clean the filter
element.

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 The filter element with damaged filter paper or sealing ring must be replaced
immediately.

3. Service plan

1) Daily

a， Record daily operation state of the compressor. See Table 6-2 for specific contents to be
recorded.
b， Clean the air filter dust collection bag or intake muffling cavity. Never start the compressor
without the air filter. Maintain the air filter when the filter's differential pressure switch
actuates to alarm.
c， Check if the oil level is in the specified range.
d， Check the differential pressure switch of the oil filter.
e， Replace the oil filter when the smart controller alarms that the oil filter is blocked.

2) Weekly (50 operating hours)

a， Check the safety valve for blockage or other damage.

b， Replace the filter elements after the first 50 operating hours of a new compressor.
c， Clean the throttle orifice, strainer (if equipped) in the secondary oil return pipe after the first
50 operating hours of a new compressor.
d， Check the filter in the control piping, empty water in the filter cup.

3) Every 3 months (600 operating hours)

a) Remove the dust in the air inlet.

b) Remove the air filter, check, and maintain the filter element.
c) Remove the breathing pipeline, wash, and dry in the air.
d) For initial use, replace the oil filter.
e) For initial use, take oil sample and send it to SCR service department to be analyzed.
f) Check the belt tension, adjust if necessary.

4) Every 6 months (1000 operating hours)

a) Maintain and service. Replace the oil filter.

b) Check and clean the throttle orifice, strainer (if equipped) in the secondary oil return pipe.

5) Yearly (2000 operating hours)

a) Replace the air filter.

b) Disassemble the air/water separator, clean the inside.
c) Check if the spring valve plate in the check valve operates normally, replace if necessary.
d) Take oil sample and send it to the manufacturer for routine analysis.
e) Check and calibrate the pressure gauges and sensors.
f) Check the capacity control (load) solenoid valve (2-position 3-way N.C. solenoid valve),
replace the sealing ring in it if necessary.
g) View the operation state record of the compressor, judge if the inside of the cooler needs

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 cleaning. If so, it is preferable to clean with a chemical reagent.
h) Check the quality of the cooling water.
Table 6-2 Daily inspection record
Item Reference value
Exhaust pressure xxxbar
Environment
(intake air) ≤45℃
temperature
Exhaust
≤95℃
temperature
Oil level Green region
Draining time of
the electronic drain 3-5 s
valve

6) Preparations before long-term shutdown

In case that the interval from stop to restart is relatively long, before stop, turn on the manual
switch of the electronic drain valve, keep draining water for at least 5 minutes. Be sure the water in the
system is completely drained. After stop, drain the water accumulated in the cooler, air storage tank, etc.
a， Less than 1 month shutdown
 Start the compressor every week and run it for 10 minutes without load.
 Rotate the coupler by hand every week.
b， More than 1 month shutdown
(A) Preparation for shutdown
 Load continuously for 10 minutes to vent the air in the pipeline.
Remember: drain the water inside the two air/ water separator.
 Rotate the coupler by hand after stop.
 Drain the water accumulated in the cooler, air storage tank, etc.
(B) During shutdown
 Repeat (A) every 3 months.
(C) Before restarting
 Change the oil in the oil tank.
 Open the drain valve of the air/water separator.
 Rotate connection components (coupler) between the motor and the main unit to make
sure that it is easy to rotate.

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 Chapter 6 Troubleshooting
Failure 1: Over-High discharge air temperature
---The discharge air temperature is equal to or above 110℃.
Inspect whether oil level is Add lubricating oil
relatively low

Oil Emulsified
Poor oil
Replace lubricating oil

Yes Wrong oil application

High discharge Adjust the operating pressure to below the specified value
pressure
Purging or cleaning
Air-cooling
No
Cooler Blocked

Water-cooling
Remove the dirt
Contactor failure
Air-cooling
Fan fails to rotate
Cooling system failure Failure of fan motor
and reverses.

Water-cooling ■Low water pressure < 0.25Mpa

■Water flow becomes lower
■High water temperature >32℃

Air filter Blocked Purging or replacing

Ambient temperature > 40℃ Improve the ventilation

Temperature sensor failure ■Connecting wire loose ■Locking

■Damage ■Replace

Maintain thermostatic Replace the valve core

Thermostatic valve failure
valve

Aged and blocked parts and

Replace
components in oil pipe

Oil filter blocked Replace the filter

Blocked cooling air and reduced flow

Wrong indication of temperature gauge

or controls Inspect motor current

Damaged main machine Whether the sound is normal

Maintain main machine

Vibration is larger than that of

other parts

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Failure 2: Oil over-consumption
The air compressor requires
lubricating frequently

Replace leaked
Leakage of lubricating oil
pieces
pipe

Whether oil content in discharged air is

very high or not Replace it as needed. If necessary,
No Failure of sealing
replace all sealing elements.
elements

Yes Clean, inspect the check valve and throttle

orifice
Inspect whether oil return pipe is
unblocked
Purge oil return pipe

No
Too high oil level Oil level shall not exceed high limit of oil sight glass
for the shutdown.

Drain out part of oil

Low-pressure operation Increase the air supply Adjust the air pressure
for a long-term pressure

Oil leakage in pressure differential Inspect the sealing ring of pressure Replace
switch of oil separator differential switch

Yes
Too short oil return pipe Replace
Failure in oil return
pipe
The 30°~45° inclined plane shall Machine the oil
be present in bottom of oil return return pipe
pipe

Pressure differential in oil Replace

separator > 0.7Bar
Oil separator failure

Breakage of oil Replace

separator
Emulsified oil or wrong
application of lubricating oil Replace with the recommended
lubricating oil

Failure of filter Replace filter core

Too high discharge See Failure 1

temperature

Too frequent cycles of loading and See Failure 15

unloading

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Failure 3: Abnormal shutdown during operation

High-temperature See Failure 1

caused shutdown

Sudden shutdown No
during operation Overload Power supply Inspect power supply
shutdown failure

Loose connecting Inspect all lines including

Yes wire power supply

Failure of relay or fuse in Inspect and repair

control circuit

Inspect whether circuit part is normal No ■ Voltage is relatively low and less than rating by 10%

■ Voltage is unstable/unbalanced

Yes
Adjust pressure
Too high discharge pressure

Failure of installation and connection

Inspect and repair
of thermal relay

Higher viscosity of lubricating oil Replace lubricating oil

Failure of motor Maintain or repair

Loose connecting wire in motor or Inspect all wires and repair

contactor

Relatively low seting value Reseting the protection value

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Failure 4: Low air output

No ■Damaged air valve diaphragm ■Replace

Whether suction valve is fully opened ■Poor adjustment of capacity adjusting valve ■Re-adjust
■Blocked suction valve ■Repair or replace

Yes
Blocked air filter Replace

Belt slip Adjust belt tension or replace belt and gears

No good sealing
Wrong type oil effect achieved Replace

Air leakage of rear pipeline (operating Inspect leakage and

pipeline) repair it

Blocked oil separator Replace

■Clearance between rotors becomes larger Repair or replace

Airend failure
■Damaged rotor

Minimum pressure valve fails to

open fully Replace valve core of minimum
pressure valve

Insufficient oil supply Inspect oil circuit, especially oil filter

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 Failure 5: Too low pressure in air tank

Suction valve is not fully open Repair air suction valve

In the machine

Wrong set of capacity adjusting

valve Re-adjust capacity adjusting valve
to obtain required adjusting range

See Failure 7

Too many leakages in operating Inspect the leakages in operating

pipes pipes with soap water

External Inspect for causes. If it is

inspection Damaged pressure gauge in air damaged, replace it
tank

Too high air demand Inspect the air consumption

capacity of user. If necessary,
increase air supply

Failure 6: Too high pressure in air tank

Wrong set of controller Adjust controller (pressure switch) to allow

(pressure switch) the unloading pressure to be less than rated

maximum operating pressure

No unloading when
Suction valve is not closed
control pressure Inspect suction valve and repair it
reaches high limit

See Failure 6

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 Failure 7: Frequent blockages in oil/air separator

Air filter is damaged or not Replace damaged air filter core. If it is not applicable to the
applicable to the operating operating environment, then select the heavy duty air filter or
environment lead the air inlet of compressor to the place with cleaning air

Failure of oil filter Replace oil filter core. Use the genuine filter from Screw
Company
Frequent indications
for blockages in oil
separator
Damaged or improper element of Replace the core of separator. Use the genuine filter core from
oil-gas separator Screw Company

Deteriorated lubricating oil Clean and replace the system

Operate in the extreme environment such

as high-temperature, high-humidity or
high-pressure; Operate compressor at
rated air tank pressure and oil temperature.
In the oil Contaminated lubricating Shorten the change interval of lubricating
oil oil or filter. Replace lubricating oil. As per
daily maintenance sheet, repair and
maintain elements of air filter and oil filter

Mix the lubricating oil with different grades

Application of improper or model numbers;
lubricating oil Do not mix the lubricating oil with different
grades or model numbers. Do not use the
lubricating oil from different manufacturer

Failed pressure differential Replace pressure differential

switch switch

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 Failure 8: Frequent blockages in oil filter

Indicator failure
Replace indicator

Frequent
indications of
Use the genuine spare parts from Screw
blockages in oil Improper oil filter
filter

Failure of air filter Replace air filter. Use the genuine spare

parts from Screw only.

Deteriorated lubricating oil Clean the system and replace

The system is contaminated; inspect and clear off the dust, corrosive

substances, painting film and oil mud in the system

Failure 9: Frequent blockages in air filter

Failure of pressure Replace pressure differential switch

differential switch

Frequent indications for Compressor operates in a Make the air inlet far away from
blockages in air filter highly contaminated air contamination

Air filter is not applicable Use heavy duty air filter. Please
to the environmental contact the agent of Screw Company
conditions

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Failure 10: Excessive water content in compressed air at discharge end
Failure of refrigerated dryer Eliminate the failure. See the
or adsorption dryer below for handling the failure

High water content Blocked water/gas separator Clean or replace

at discharge end

Installation/application failure Inspect other compressors in the

same system

Leakage in water cooler; Replace water cooler

(only for water cooling type)

Failure 11: Abnormal opening of safety valve

Wrong set of pressure Re-adjust the range of pressure differential to

differential adjusting valve get the correct range

Abnormal opening
Wrong setting in air controller Reset controller (pressure switch) to unload
of safety valve
(pressure switch) compressor at schedule pressure

Suction valve is not closed as

Inspect and repair suction valve
per requirements

Blocked separator Replace element of oil/gas separator

Failure of pressure gauge or Inspect the pressure gauge. If necessary,

sensor replace it. Lower the control setting

Inspect whether safety valve is in the proper

Defective safety valve
pressure setting position. If the leakage occurs,
replace it

Failure of minimum pressure Repair or replace

valve

Other failures See the failure of air compressor unloading

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Failure 12: Abnormal noises in the air compressor

----Pressure sensor can’t detect the pressure in 2 seconds after starting

Inspect whether belt is slipped or not ■Adjust belt

■Replace belts or belt pulleys

Deteriorated and emulsified oil; rusty signs occur Replace the oil
on the airend

Scratched or damaged rotor Inspect or repair the airend

Damaged airend bearing Replace

Insufficient oil return Blocked oil filter

Failure 13: Oil injection in suction valve during shutdown

Damaged suction valve and check valve Replace

Sudden shutdown at heavy load Avoid emergency stop

The discharged air due to the blockage in

Inspect or replace oil return pipe
return pipe returns to the suction valve

Relatively high oil level in oil-gas tank Drain out part of oil

Too fast air drainage speed in oil-gas Inspect whether the size of vent

separator valve is proper

35
SHANGHAI SCREW COMPRESSOR CO.,LTD.
Address: No. 1555, Tingfeng Road, North Jinshan Industrial Zone, Shanghai
Postcode: 201504
Tel: 86-21-57383073
Fax: 86-21-57382222
Service Hotline: 400-820-5059
Website: en.screw.sh.cn

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