MechMaxx M50AC460 Rotary Screw Air Compressor 50HP 220 CFM User Manual

Operator’s Manual

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WARRANTY

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TRADEMARKS AND COPYRIGHTS

Compressor User's Manual 2024. No part of this manual

may be reproduced, adapted, or disseminated without

permission.

The trademarks on the products belong to their regis-

trants.

PRODUCT DESCRIPTION

The manufacturer has the right to design changes of

products and is not responsible for obligation to modify

and improve the products that have been shippied. We

may make modifications to the specifications or compo-

nents of certain products in the future without prior

notice.

MATTERS NEEDING ATTENTION

Before using the equipment, be sure to read this manual

and understand various contents, so as to correctly

install, debug, operate, and maintain the equipment. This

manual should be kept in the hands of the actual end user.

Be sure to keep this manual and the supporting docu-

ments with the air compressor together until the equip-

ment is scrapped.

SCOPE OF APPLICATION OF THIS MANUAL

This manual is applicable to the installation, commission-

ing, operation, maintenance, and repair of screw air

compressors. This manual does not include the operating

instructions for the permanent magnet motor drive

frequency converter. For its operating instructions and

maintenance, please refer to the user manual for the

frequency converter supplied with the air compressor.

If you have specialized knowledge in mechanical and

electrical aspects, you can better understand the

contents of this manual.

KNOWLEDGE REQUIRED TO READ THIS

MANUAL

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Welcome to purchase and use our company's products,

we will wholeheartedly serve you, and please carefully

read and understand the various contents of this opera-

tion manual to be able to use it correctly!

1.1Description of the compressor

1.2The compressor of our company is the result of years

of research and development. These prerequisites,

combined with high quality standards, can ensure that

the manufactured screw compressor has a long service

life, high reliability, and high operating efficiency, and the

product can meet all environmental requirements.

1.2 Scope of use

This series of machines are manufactured according to

mature technology and recognized safety rules. However,

if the following situations occur, they may still pose a

threat to the lives and limbs of users or third parties, or

cause damage to machines and other property:

▪ Incorrect range of use

▪ Operated by unqualified personnel

▪ Unreasonably modify parameters or mofify the machine

▪ Failure to comply with safe rules

Therefore, any person authorized to operate, maintain, or

repair the machine must read and comply with safety

regulations. If necessary, you can request a signature to

confirm this.

In addition, it is also necessary to comply with:

▪ Relevant accident prevention rules

▪ Recognized safety regulations

▪ National regulations

This series of machines and units must be used under

perfect technical conditions, must be used in accordance

with the scope of use specified in the operation manual,

and the users must have safety awareness and be able to

fully understand the dangers in the operating machine. If

any functional failure occurs, especially a failure that

affects safety, it must be repaired in time (or contact our

after-sales service for repair)!

The meaning of operating the machine within the scope of

use also includes complying with various requirements in

the operating manual, and conducting inspections and

maintenance as required.

1.3 Maintenance, service, and warranty

This machine must be carefully maintained to enable

screw compressors or compressor units to meet various

requirements. Therefore, it is necessary to carefully main-

tain the machine according to the specified maintenance

period, especially in harsh working conditions.

PREFACE

MAINTENANCE

Please contact the manufacturer in case of failure or need

for spare parts. If the equipment is damaged, our compa-

ny's trained maintenance personnel will definitely provide

prompt and good maintenance services using original

accessories. Genuine original spare parts are manufac-

tured using the most mature technology, thereby ensuring

the reliable operation of the machine.

SERVICE

Before operating this machine, it is necessary to accu-

rately understand the machine and relevant instructions,

and carefully read the operating instructions.

If the use of this machine does not conform to the appli-

cable scope or the purpose of use exceeds the scope

mentioned in this instruction, the company will not be

responsible for the safety of operation. Our company will

not accept warranty claims under the following circum-

stances:

▪ Operational errors

▪ Improper maintenance

▪ Misuse of excipients

▪ Our original accessories are not used

▪ Modify or modify this device

The company will not expand the warranty and indemnity

conditions of the general terms due to the above descrip-

tion.

The manufacturer will not accept claims or warranty

requirements for any unauthorized modifications to the

compressor or compressor station, or the installation of

components not approved by the manufacturer.

WARRANTY

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TABLE OF CONTENTS

PREFACE

TABLE OF CONTENTS

SAFETY INSTRUCTIONS

CHECK AND TEST RUN BEFORE STARTING

THE MACHINE FOR THE FIRST TIME

CHECK BEFORE STARTING THE MACHINE FOR

THE FIRST TIME

TEST RUN

HANDLING METHODS FOR LONG-TERM SHUTDOWN

AND STORAGE

REBOOT PROGRAM

SAFETY PRECAUTIONS

REPLACEMENT AND MAINTENANCE OF AIR

FILTER ELEMENT

OIL GAS SEPARATION FILTER ELEMENT

REPLACEMENT

OIL FILTER REPLACEMENT

LUBRICATING OIL REPLACEMENT

MOTOR MAINTENANCE

MAINTENANCE OF FREQUENCY CONVERTERS

TROUBLESHOOTING TABLE (CONTINUED)

MAINTENANCE AND REPAIR ITEMS AND

MAINTENANCE CYCLE TABLE

EQUIPMENT ARRIVAL ACCEPTANCE

HANDLING OF AIR COMPRESSOR

INSTALLATION OF AIR COMPRESSOR

ELECTRICAL INSTALLATION

ELECTRICAL CONNECTIONS

INSPECTION BEFORE STARTUP

STARTING OPERATION

SHUTDOWN

WORKING PRINCIPLE OF AIR COMPRESSOR

PERMANENT MAGNET SYNCHRONOUS

MOTOR(INVERTER SCREW AIR COMPRESSOR)

ADVANTAGES OF PERMANENT MAGNET

VARIABLE FREQUENCY AIR COMPRESSOR

(INVERTER SCREW AIR COMPRESSOR)

INVERTER OVERVIEW(INVERTER SCREW AIR

COMPRESSOR)

OVERVIEW OF AIR COMPRESSOR

INSTALLATION OF AIR COMPRESSOR

AIR COMPRESSOR SYSTEM

OPERATION OF THE AIR COMPRESSOR

MAINTENANCE AND TROUBLESHOOTING

TROUBLESHOOTING TABLE

AIR FILTER

INTAKE VALVE

OIL GAS SEPARATOR

AFTERCOOLER

SAFETY AND RELIEF VALVES

LUBRICATING OIL SYSTEM

OIL FILTER

OIL COOLER

TEMPERATURE CONTROL VALVE

OIL GAS SEPARATOR

REMINDER LABEL

SECURITY PROTECTION SYSTEM AND ALARM

DEVICE

AIR COMPRESSOR ANTI REVERSE PROTECTION

PROTECTION AGAINST EXCESSIVE EXHAUST

TEMPERATURE

PROTECTION AGAINST LOW AMBIENT

TEMPERATURE

HIGH EXHAUST PRESSURE PROTECTION

LIGHT FAULT PROMPT FUNCTION

LUBRICATING OIL AND WEAR PARTS SERVICE LIFE

ALARM PROMPT

MECHANICAL PROTECTION OF THE MACHINE

SAFETY WARNINGS AND TIPS

SAFETY WARNING LABEL

SYSTEM FLOW DIAGRAM

AIR CIRCUIT SYSTEM

SECURITY PROTECTION AND ALARM SYSTEM 17

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SAFETY INSTRUCTIONS

FOR "CAUTION", "WARNING", AND "DANGER"

ABOUT OPERATIONS

ABOUT USES

ABOUT INSTALLATION

BE CAREFUL

Before installing, debugging, operating, and maintaining

the air compressor, please carefully read the "Safety

Instructions" and use the screw air compressor in the

correct way. This "Safety Instructions" contains import-

ant information that can enable you to use this product

safely, correctly, and efficiently, and prevent personal

injury and property damage to you or others. Please keep

this user manual properly after reading it so that the

operator of this product can consult it at any time If the

provisions in these instructions, especially those related

to safety, do not comply with local regulations, the strict-

er of the two shall prevail.

Sometimes, even if matters such as "attention" are

handled improperly or not observed, significant accidents

may occur depending on the situation. It is recommended

that the important contents proposed in this manual

must be observed.

Indicates that failure to follow this

instruction or improper handling can

cause hazardous conditions, such as

minor personal injury, and equipment

malfunction.

BE CAREFUL

Operating instructions must always be

available at the operating site of the

machine (such as in a tool room or storage

guide box for reference)! In addition to the

operating instructions, you must also

comply with all other applicable laws and

regulations on accident prevention and

environmental protection, and require

others to also comply.

BE CAREFUL

Frequently check whether the work of the

operators conforms to the operating

procedures and whether they pay atten-

tion to safety requirements.

BE CAREFUL

All safety notices and warning signs on

the machine must be observed The safety

instructions and warning signs posted on

the machine must always be complete and

clearly visible.

WARNING

Indicates that failure to follow this

instruction or improper handling can

result in hazardous conditions such as

moderate personal injury, minor injury,

and equipment failure.

WARNING

The air compressor room must be well

ventilated to allow the compressor to

absorb fresh and clean air. Avoid install-

ing the machine in places full of micropar-

ticles and toxic and corrosive.

DANGER

Indicates that failure to comply with this

instruction or improper handling can

cause hazardous conditions such as

serious personal injury, even death, and

equipment damage.

DANGER

Do not use compressed air in closed

rooms or tunnels.

It is prohibited to use compressed air for

respiratory purposes without professional

equipment processing.

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SAFETY INSTRUCTIONS

ABOUT OPERATIONS

WARNING

The incoming power line of the air com-

pressor must match the rated power of its

equipment, and safety devices such as

circuit breakers or fuses must be installed

to ensure the safety and reliability of elec-

trical equipment.

WARNING

The power supply of the air compressor

should be isolated from other precision

equipment. If necessary, a line filter

should be added to the front end of the

frequency converter to prevent the inter-

ference of higher harmonics generated by

the frequency converter on precision

equipment.

WARNING

When the air compressor is stopped from

use when the ambient temperature may be

lower than 0 ℉, drain the water in the oil

gas separator and pipeline to avoid freez-

ing and cracking the pipeline or damaging

the compressor.

WARNING

During machine operation, ensure smooth

ventilation of the compressor room.

During the operation of the frequency

converter, the parameters of the frequen-

cy converter shall not be modified without

permission.

WARNING

Before starting the machine, confirm that

there is no one in the machine, check

whether there are any remaining items

and tools, and close the air compression

chassis. When turning on, the personnel

around the machine should be notified to

pay attention to safety.

DANGER

The body and motor housing of the air

compressor must be reliably grounded,

and reliable lightning protection devices

must be installed if necessary. Unreliable

grounding can cause fire or personal

injury.

DANGER

When starting the machine for the first

time or changing the power cord, it is

necessary to pay attention to whether the

motor rotates in the direction indicated by

the arrow. If the rotation direction of the

motor is inconsistent with the arrow direc-

tion, any two phases of the motor intput

terminal wiring should be changed.

Note: Changing the incoming power

supply of the frequency converter cannot

change the rotation direction of the

motor.

DANGER

Do not operate above the exhaust pres-

sure specified on the nameplate of the air

compressor, otherwise it may cause the

motor or frequency converter to overload

and burn out.

DANGER

When the air compressor fails or unsafe

factors exist, do not forcibly start it. At

this time, cut off the power supply and

make a prominent mark.

DANGER

Keep your fingers and clothes away from

rotating motors, belts, and heating com-

ponents such as oil gas separators, pipe-

lines, and compressor housings. Do not

touch any exposed electrical parts with

your hands to avoid electric shock.

DANGER

Do not remove various protective cover

and components when the machine is

running. High temperature liquid and

pressurized air in the machine may cause

personal injury. Do not open the front

cover of the inverter or disassemble the

power supply or inverter output terminal

ground wiring.

Failure to heed the above warnings may

result in serious personal injury or even

death.

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SAFETY INSTRUCTIONS

REGARDING MAINTENANCE

ABOUT MODIFICATIONS

ABOUT LUBRICATING OIL

WARNING

When maintaining and overhauling the

machine, attention must be paid to sharp

parts of the machine to avoid scratching

the body.

WARNING

It is prohibited to use the compressor

host, frequency converter, and pipelines

as support points for the human body.

Failure to pay attention to this warning

may damage the equipment.

WARNING

After the maintenance and repair of the

machine, be sure to clean the garbage and

dust inside and around the machine to

avoid affecting the air quality or causing

clogging of the inverter air inlet.

Please regularly clean the heat dissipa-

tion components according to the user

manual of the general inverter to ensure

smooth ventilation.

DANGER

During maintenance or repair, it is neces-

sary to confirm that the power supply has

been cut off and hang warning signs such

as "Repair" or "Do Not Switch On" at the

power supply, otherwise incorrect opera-

tion by others may cause disability or

death of the maintenance personnel.

When performing maintenance or repair

on the main circuit, make sure all electri-

cal parts of the machine are fully

discharged.

DANGER

During shutdown and maintenance, it is

necessary to confirm that the compressed

air in the machine has been released, that

the machine has been isolated from other

air sources, and that the machine has

cooled down.

DANGER

The assembly of the compressor host and

the maintenance of the controller and

frequency converter require highly skilled

personnel and special tools. Users are not

allowed to disassemble and maintain the

main engine, controller, and frequency

converter of the air compressor by them-

selves.

The installation of a permanent magnet

synchronous motor is completed in a

dust-free workshop. Users should not

attempt to disassemble the permanent

magnet synchronous motor, otherwise the

motor will be damaged.

The complete air compressor has been

strictly tested before leaving the factory,

and any form of modification may affect

the performance and service life of the

machine. Without the permission of the

manufacturer, the machine shall not be

modified in any form.

Users' self modification of the air com-

pressor may cause machine failure and

even personal injury! Without the permis-

sion of the manufacturer, users can

modify the air compressor by themselves,

which will lead to the early end of the

warranty period of the machine.

WARNING

Be sure to use the special lubricating oil

for the air compressor of our company,

otherwise the efficiency of the compres-

sor will be reduced, and even the main

engine of the compressor will be dam-

aged.

WARNING

Please dispose of lubricating oil in accor-

dance with relevant national or local laws

and regulations. Incorrect handling of

lubricating oil may cause serious environ-

mental pollution.

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OVERVIEW OF AIR COMPRESSOR

The main engine of this compressor is a screw type air

compressor, which filters the dust from the air filter at

atmospheric pressure and then enters the screw engine

through the intake valve for compression. The

compressed gas mixed with oil enters the oil-gas separa-

tor through the exhaust pipe for rotational separation.

After separation, the compressed air is filtered through

the oil-gas separator filter element and cooled by the

minimum pressure valve and aftercooler before being

discharged for use by the user terminal.

After using the frequency converter, it is possible to

change the rotation speed of the motor according to the

air supply pressure of the machine to achieve a balance

between the air compressor production and the end user

gas consumption, achieving maximum energy saving.

Its working principle:

(1)Preset the required variable frequency pressure value

in the operation screen. When the air supply pressure of

the machine fluctuates around the set of variable

frequency pressure value, the controller adjusts the

output frequency of the frequency converter, thereby

adjusting the rotational speed of the motor, making the

air supply pressure of the machine close to the variable

frequency pressure value, achieving the effect of

constant pressure air supply.

(2)The end user's gas consumption continues to

decrease, and the motor speed continues to decrease.

When the motor frequency drops to the lower limit

frequency, the motor maintains the lower limit frequency

operation. If the gas consumption continues to decrease

and the unit supply pressure increases, the machine

adjusts the supply and demand balance through loading

and unloading.

(3)Starting, loading, variable frequency speed regulation,

unloading, stopping when the vehicle is empty for a long

time, and automatically restarting and stopping are the

operating states of variable frequency compressors.

1.1.1 Working principle of oil-injected screw air compres-

sor (power frequency machine)

Starting, loading, unloading, stopping empty for too long

and automatically restarting, and stopping are the operat-

ing states of the oil-injected screw air compressor.

1.1.2 Working principle of frequency conversion fuel injec-

tion screw air compressor (frequency conversion

machine)

After using the inverter, the motor speed can be changed

according to the air supply pressure of the machine, so as

to achieve the balance between the air compressor gas

production and the end user's gas consumption, and

achieve maximum energy saving.

The air compressor is equipped with a permanent magnet

synchronous motor. The permanent magnet synchronous

motor adopts high-performance neodymium iron boron

permanent magnets, which do not lose excitation at 302

℉. The stator structure and working principle of the

permanent magnet synchronous motor are the same as

those of the AC asynchronous motor. The difference

between the permanent magnet synchronous motor and

the AC asynchronous motor is the rotor structure, on

which permanent magnet poles are installed.

Advantages of permanent magnet synchronous motors:

• High power density;

• Compared to three-phase asynchronous motors, it has

high efficiency and small size;

• The rotational inertia of the rotor is small.

（1）Constant pressure air supply

The gas supply pressure of the stabilized unit is near the

frequency conversion pressure value, extending the

service life of the terminal customer equipment. Setting

an appropriate frequency conversion pressure can maxi-

mize energy saving.

（2）Low load, low current startup

The frequency converter adopts a soft start method to

start the unit, with large starting torque and small start-

ing current, reducing the impact of air compressor startup

on the power grid.

WORKING PRINCIPLE OF AIR COMPRESSOR

PERMANENT MAGNET SYNCHRONOUS

MOTOR(INVERTER SCREW AIR COMPRESSOR)

ADVANTAGES OF PERMANENT MAGNET

VARIABLE FREQUENCY AIR COMPRESSOR

(INVERTER SCREW AIR COMPRESSOR)

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OVERVIEW OF AIR COMPRESSOR

（3）Energy Saving

The unloading process of non variable frequency units is a

process of energy consumption. Variable frequency units

reduce the unloading process of units through frequency

conversion and speed reduction, thereby achieving the

effect of energy conservation and consumption reduction;

According to the principle of constant pressure gas

supply by frequency converters, set appropriate frequency

conversion pressure values (just enough to meet the

pressure values used by terminal equipment), reduce high

pressure losses, and achieve further energy conservation.

The universal frequency converter is mainly used to

control and adjust the rotational speed of the motor. It

has user programmable functions, background software

monitoring, and communication bus functions. Its combi-

nation functions are rich and powerful, and its perfor-

mance is stable. For details, please refer to the operating

instructions of the matching frequency converter.

（1）Before performing maintenance operations on the

frequency converter, please carefully read the supporting

operating instructions of the frequency converter and

operate in strict accordance with the requirements of the

instructions.

（2）After the inverter cuts off the power supply, there

is still residual voltage in the internal capacitor. Residual

voltage can cause injury to operators. When operating the

frequency converter, wait for more than 10 minutes and

confirm that the charging indicator light is off.

INVERTER OVERVIEW(INVERTER SCREW AIR

COMPRESSOR)

DANGER

During the wiring operation of the

frequency converter, the incoming power

supply of the air compressor should be

cut off. Even if the power supply is turned

off, there is still residual voltage in the

internal capacitor. After switching off the

power, please wait at least 10 minutes.

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INSTALLATION OF AIR COMPRESSOR

When you receive the equipment, you should carefully

inspect the air compressor. If you do not immediately

unpack and inspect, you should check for any signs of

improper shipping. If any defects are found, it is necessary

to obtain the carrier's signature for recognition, which will

facilitate your future insurance claims.

When checking the air compressor, please check the

following items:

（1）The nameplate of the machine should be checked

to confirm the specifications of the product you ordered.

Product Model: Please refer to the technical parameters

in Item 1.6 of this user manual to confirm that it is

consistent with the product you need.

Motor power: Convenient for you to choose power cables

and circuit breakers.

Weight and overall dimensions: It is convenient for you to

design the foundation of the air compressor. For the

design drawing of the air compressor station, please refer

to the outline dimension drawing in item 1.5 of this user

manual.

（2）Visually inspect for any damage that occurred

during transportation, such as pipe breakage, shell defor-

mation, and component damage or detachment.

（3）In addition to the machine body, there should also

be attached user manuals and other accompanying

accessories. Please check whether the attached acces-

sories are complete according to the packing list

attached to the machine.

2.2.1 Lift the air compressor with a crane

Pass the lead through the forklift hole of the equipment,

and support the air compressor with the top frame (if any)

or support frame of the packaging box to prevent the rope

from crushing the equipment shell.

2.2.2 Handling the air compressor with a forklift

Forklift holes are reserved for the air compressor for

users to transport the air compressor with a forklift.

During transportation, soft pads should be used to

protect the air compressor from bumps.

2.2.3 Handling the air compressor by rolling wood

The air compressor can also be transported in place with

load-bearing rollers.

2.3.1 Requirements for installation site of air compressor

The air compressor should be installed in a clean, well-lit,

well ventilated place with sufficient maintenance space

around it. A good computer room is a prerequisite for the

correct use of the air compressor system.

2.3.1.1 Ventilation, lighting, ambient temperature, main-

tenance space.

（1）Air compressor operation can generate a large

amount of heat, therefore, the air compressor must be

placed in a well ventilated room, and the cooling air inlet

area must be sufficient.

（2）The installation site should have good lighting, and

each side of the air compressor machine should be more

than 1.5 meters away from the wall, with a top space

distance of more than 1.5 meters, and the top of the

air-cooled machine should be more than 2.5 meters away

for easy operation and maintenance.

EQUIPMENT ARRIVAL ACCEPTANCE HANDLING OF AIR COMPRESSOR

INSTALLATION OF AIR COMPRESSOR

BE CAREFUL

• After unpacking, please properly store

the user manual and other accompany-

ing accessories.

• The top frame of the packaging box (if

any) can be used to lift the air compres-

sor. Do not discard it randomly.

BE CAREFUL

The crane and rope used for lifting should

meet the load bearing requirements,

otherwise it may cause equipment

damage or casualties.

INSTALLATION OF AIR COMPRESSOR

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（3）The ambient temperature should be lower than 104

℉ to avoid unnecessary high-temperature tripping. The

higher the ambient temperature, the less air output from

the air compressor. In addition, the ambient temperature

must be higher than 0 ℉, controlled above the condensa-

tion point temperature of water and lubricating oil.

（4）The environment around or near the air compressor

must be considered. The selected air compressor room

should have a low relative humidity and be free of dust,

chemicals, paint odor, and painting operations. If the

working environment is harsh, pre filtration equipment

should be installed in front of the intake port, and a venti-

lation duct should be installed to guide the intake end to

a place where the air is relatively clean.

2.3.1.2 Foundation requirements

A flat foundation can reduce the vibration of the machine

and extend the service life of the machine.

（1）The air compressor should be placed on a concrete

floor that can support its weight, and the floor should be

horizontal and flat. The air compressor should be installed

horizontally. If there is vibration from outside, vibration

isolation slots should be provided on the floor.

（2）It is recommended to use anchor bolts to fix the air

compressor.

（3）To connect the inlet and outlet pipelines, the

length and width of the cement platform are 100mm

larger than the overall size of the machine. The height of

the cement platform shall be 150 mm, and grooves shall

be opened around the platform to facilitate the shutdown

of the machine. During oil change and maintenance, oil

and water can flow away from the grooves and be collect-

ed for disposal by relevant departments.

2.3.2.2 The diameter of the pipeline should be greater

than or equal to the diameter of the compressor exhaust

pipe. The use of elbows and various valves in pipelines

should be minimized to reduce pressure losses. The

pressure drop of the pipeline should not be greater than

5% of the set pressure.Excessive pressure loss is not

conducive to energy conservation.

2.3.2.3 The main pipe should not be arbitrarily reduced. If

it is necessary to reduce or enlarge the pipe, use a

tapered pipe, otherwise there will be turbulence at the

joint, resulting in significant pressure loss and a signifi-

cant impact on the life of the pipe.

2.3.2.4 If the air consumption is large and the time is

short, it is best to install a buffer tank, which can reduce

the loading and unloading times of the air compressor and

extend the service life of the air compressor.

2.3.2.5 When multiple screw machines share a common

exhaust pipeline, each machine should install a stop valve

on its own exhaust pipeline to isolate each other. If a

screw unit and a reciprocating compressor are brought

together, an air storage tank must be installed between

the two machines. When installing an air storage tank, a

stop valve and a maintenance evacuation valve must be

installed between the air storage tank and the machine

(during shutdown, the compressed air between the

minimum pressure valve in the system and the stop valve

must be discharged).

2.3.2.6 The branch pipeline should be led out from the top

of the main pipeline to prevent the condensed water in

the pipeline from flowing down to the working machine.

An overflow valve should be installed on the compressor

pipeline.

2.3.2.7 If there are air storage tanks and dryers after the

air compressor machine, the best piping order is air

compressor+air storage tank+dryer.

2.3.2 Pipe installation

2.3.2.1 When piping the main pipeline, the pipeline must

have an inclination of 1 ° to 2 °. It is conducive to the

discharge of condensed water in the pipeline.

WARNING

The oil and water leaked from the machine

should be collected and submitted to the

environmental protection department for

treatment to prevent environmental pollu-

tion.

INSTALLATION OF AIR COMPRESSOR

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2.3.3 Cooling system installation

2.3.3.1Installation of air-cooled cooling system

（1）The air-cooled screw air compressor should be installed in a well ventilated machine room, and installed with an

air guide hood to guide the heat generated by the air-cooled cooler to the outside.

（2）Install an air source near the air compressor to regularly clean the cooling fins of the air-cooled cooler.Regularly

clean the air-cooled cooler to prevent the machine from shutting down at high temperatures.

2.3.3.2 Water-cooled cooling system

(1) The cooling water of the air compressor should comply with the provisions of industrial water to avoid the calcium and

magnesium plasma in the water from causing chemical reactions due to high temperature, in the cooler

Scale builds, affecting the efficiency of the cooler. The cooling water quality should comply with the following regulations:

• The content of suspended solids should not be greater than 100mg/L;

• The PH value shall not be less than 6.5, and should not be greater than 9;

• Thermally stable

(2)The cooling water system of the air compressor should be used separately, if the cooling water tower circulation

system is used, the cooling water tower should comply with the cooling water specified by the air compressor volume,

while the selection of pump power should be correct.

(3) The water pressure of cooling but water must generally be maintained between 21.7~65 PSI; The cooling water outlet

temperature should be kept below 104℉.

(4) Cooling water consumption of water-cooled air compressor:

Figure 2-1 Air compressor+air storage tank+dryer system

BE CAREFUL

The installation of the wind guide cover should prevent outdoor dust and rain from pouring back

into the cooler of the air compressor.

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INSTALLATION OF AIR COMPRESSOR

(5) Regularly clean the scale in the radiator copper tube

to maintain efficient heat dissipation.

2.4.1 Selection and installation of circuit breakers

（1）The circuit breaker is mainly used to cut off the

main power supply of the air compressor and protect the

motor.

Select an appropriate circuit breaker based on the rated

current of the host motor. The circuit breaker must have a

motor overcurrent protection function.

（2）The circuit breaker must be a motor protected

circuit breaker with an instantaneous action setting of

8-15 times the rated current of the motor. Please avoid

using a power distribution type circuit breaker, and

choose a power distribution type circuit breaker. The

circuit breaker may malfunction when the motor is start-

ed.For inverter screw air compressors, avoid using circuit

breakers with leakage protection.

（3）The circuit breaker should be installed next to the

air compressor machine to facilitate maintenance of the

air compressor. The installation of circuit breakers should

comply with corresponding safety regulations.

2.4.2 Selection and installation of cables

Select the appropriate cable based on the rated voltage

and current of the air compressor, and determine it based

on factors such as environmental conditions, laying meth-

ods, and product technical data. The type selection and

installation shall generally be considered according to the

following principles:

（1）Cables should be laid underground or through

buried pipes as much as possible to reduce the damage

caused by external pressure on the cables. Plastic

sheathed cables shall be laid in pipes.

（2）The low-voltage power cable shall be a four-core

power cable, and the sheath method of the cable shall be

selected according to the laying method.

（3）The cable cross-section should be appropriately

increased when the ambient temperature is high, and the

cross-section must also be increased to reduce voltage

drop when the laying distance is long.

2.4.3 Power Requirements

The user's incoming power supply should be consistent

with the rated voltage and frequency of the air compres-

sor.

Power supply voltage requirements:

（1）The voltage fluctuation should not be too large, and

the voltage fluctuation should be between - 10%

and+10% of the rated voltage of the motor.

（2）The voltage imbalance should meet the standard,

and the three-phase imbalance of the three-phase power

supply voltage should not exceed 5%. If the fluctuation is

too large, a voltage stabilizer must be installed or the

power grid must be rectified.

（3）The capacity of the power grid meets the starting

requirements of the motor, otherwise it will be difficult to

start the motor, and even cause the circuit breaker to trip.

（4）It is best to use a separate power system for the

air compressor to facilitate maintenance.

2.4.4 Grounding requirements

The body and motor housing of the air compressor should

be reliably grounded to prevent static electricity from

causing a fire in the oil gas separator and causing hazards

due to electrical leakage.

The body and motor housing of the air compressor are

connected to the grounding body through yellow and

green dual color PE grounding wires or galvanized round

steel (flat steel), with a cross-section meeting relevant

requirements.

ELECTRICAL INSTALLATION

DANGER

Do not use cables with too small cross

sections, otherwise the cables are prone

to danger due to high temperatures;

Do not use cables with voltage that does

not meet the requirements, otherwise

serious accidents such as fire and electric

shock may occur.

DANGER

Do not use high-voltage power supplies

on low-voltage equipment, otherwise the

equipment may burn down and cause

personal injury.

Horse

Power

100

120

150

175

200

250

300

350

380

420

100 140 180 220 260

2.5.1 Cable connection from user power supply to air

compressor control cabinet

Air compressor control cabinet uses three-phase AC

power supply AC230V/460V (~3 × L+PE), see Table 1-1

for connecting cables. The user power supply is connect-

ed to the R, S, and T terminals of the frequency converter

via a circuit breaker.

2.5.2 Ground wire connection

Connect the grounding terminal of the air compressor to

the grounding body with yellow and green dual color PE

wire. After grounding, use a grounding resistance measur-

ing instrument to measure the grounding resistance,

which should be less than 4 ohms.

ELECTRICAL CONNECTIONS

BE CAREFUL

The wiring work shall be completed by

electricians with electrician certificates.

Failure to heed warnings may result in

electric shock accidents or damage to

equipment.

BE CAREFUL

The cable connection must be firm and

not loose, otherwise it may cause the

cable to heat up, burn components, or

even cause a fire.

DANGER

Unreliable grounding or non grounding

may cause serious accidents such as fire

and electric shock.

It is strictly prohibited to use gas pipe-

lines and water pipelines as grounding

bodies. Otherwise, accidents may occur.

It is prohibited to connect the three-phase

power supply zero line to the air compres-

sor casing or grounding body, otherwise

causing equipment failure.

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INSTALLATION OF AIR COMPRESSOR

The system flow diagram of the air compressor is shown in Figure 3-1

Figure 3-1 System Flow Chart

3.2 Water-cooled air compressor system flow chart

SYSTEM FLOW DIAGRAM

AIR COMPRESSOR SYSTEM

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AIR COMPRESSOR SYSTEM

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The air circuit system consists of an air filter, an intake

valve, a main engine, an oil gas separator, a minimum

pressure valve, an aftercooler, and a gas pipe.

After dust removal by the air filter, the air flows through

the intake valve and enters the intake port of the host

machine. The air is compressed inside the host machine

and discharged from the exhaust port of the host

machine, and then enters the oil gas separator through

the exhaust pipe. Oily compressed air is separated by

rotary centrifugation in the upper part of the oil gas

separator, and the lubricating oil is gathered on the cylin-

der wall under the action of centrifugal force to condense

into droplets, which fall into the oil tank. After centrifugal

separation, compressed air enters the filter element in

the oil gas separator for fine separation. The finely sepa-

rated oil accumulates at the bottom of the filter element.

Due to the installation of a return pipe inside the filter

element, the oil at the bottom of the filter element enters

the intake pipe of the host machine through the return

pipe under pressure. The compressed air after two sepa-

rations is very clean. The compressed air flowing from the

oil gas separator is supplied to the user through the

minimum pressure valve and the aftercooler.

The main function of the air filter is to remove dust from

the air, to avoid premature wear of the compressor host

engagement pair, and to prevent clogging of the oil filter

and oil gas separation filter element.。

Generally, the dust on the surface should be removed and

removed every 500 hours by using low-pressure air to

blow the dust away from the inside out. In dusty areas,

the cleaning time should be shortened.

Figure 3-2 Air Path Flow Chart

AIR CIRCUIT SYSTEM

AIR FILTER

The intake valve has two main functions:

（1）When starting and unloading the compressor,

close the intake valve plate to keep the compressor in an

unloaded state, achieving low current starting and

unloading time and load operation;

（2）When the gas consumption changes, balance the

intake air of the compressor with the actual gas

consumption.

The minimum pressure valve is located at the outlet

above the oil gas separator and has the following

functions:

（1）When starting, priority should be given to estab-

lishing the circulation pressure required for lubricating oil

to ensure machine lubrication.

（2）When the pressure exceeds the opening pressure,

the valve opens, which can reduce the air flow rate

through the oil gas separator. In addition to ensuring the

oil gas separation effect, it can also protect the oil gas

separator filter element from damage due to excessive

pressure difference.

（3）Prevent system pressure backflow during empty

vehicle discharge (unloading).

An air-cooled cooler uses a cooling fan to draw in cold air

and cool compressed air through the cooler. Air cooled air

compressors are sensitive to ambient temperature condi-

tions, so it is best to pay attention to the ventilation

conditions of the environment when selecting a place to

place them.

（1）Safety valve:

When the pressure switch is improperly adjusted or fails,

resulting in the pressure at the outlet of the oil-gas

separator exceeding the rated exhaust pressure to a

certain value (for products with a working pressure of

145 PSI or less, the opening pressure of the safety valve

is the rated working pressure+14.5 PSI, and for products

with a working pressure of 145 PSI or more, the opening

pressure of the safety valve is the rated working pressure

× 1.1), the safety valve will jump open to relieve pressure.

INTAKE VALVE

OIL GAS SEPARATOR

AFTERCOOLER

SAFETY AND RELIEF VALVES

AIR COMPRESSOR SYSTEM

（2）Relief valve:

When the oil gas separator filter element has reached its

service life or is clogged, resulting in a large pressure

difference, and the pressure in the oil gas separator has

exceeded a certain value of the rated exhaust pressure

before the safety valve is activated (the opening pressure

of the relief valve is the rated working pressure × 1.2),

the relief valve will jump open to relieve pressure. When

the relief valve operates, the oil gas separation filter

element must be replaced.

The lubricating oil for screw compressors has four main

functions: lubricating the contact surface between the

bearing and the screw, sealing the gap between the

meshing pairs, cooling the compressed gas, and reducing

noise. The lubricating oil in the oil gas separation filter

element is compressed into the oil cooler by high-pres-

sure gas for cooling, and then enters the compressor

after being cleaned of dirt and impurities through the oil

filter. (Machines 75 kW and below are not equipped with

temperature control valves)

The oil filter is a paper-based filter whose function is to

remove impurities in the oil, such as worn metal particles,

dust, oil compounds, etc. The filtering accuracy is

between 10u and 15u, providing perfect protection for

bearings and screws. The first time the new machine runs

for about 500 hours, the oil and oil filter need to be

replaced. Afterwards, they will be replaced according to

the oil filter timing or pressure difference fault alarm

indication. If the oil filter has a large differential pressure

and is not replaced, it may lead to insufficient oil intake,

causing a high temperature trip, and at the same time,

insufficient oil may affect the bearing life.

The fins of the air-cooled air compressor oil cooler are

covered with dust, which affects the cooling effect. The

exhaust temperature may be too high, resulting in a trip.

Therefore, it is necessary to regularly blow off the dust on

the surface of the fins with compressed air.

The function of the temperature control valve is to main-

tain the exhaust temperature above the pressure dew

point temperature. When starting up, the lubricating oil

temperature is low, and at this time, the bypass ports of

the temperature control valve are all open, and the oil

enters the engine body without passing through the oil

cooler. If the oil temperature rises above 140℉, the valve

slowly closes the bypass port. When the temperature

reaches 158℉, the bypass port is fully closed, and at this

time, all the oil passes through the oil cooler before enter-

ing the engine.

The oil gas separator has two functions: oil storage and

oil gas separation. An oil level gauge is installed on the

side, and the lubricating oil pointer should be located in

the middle of the upper and lower scale lines of the oil

level gauge during operation. The lower part of the tank

has an oil filler for refueling. An oil drain valve is installed

at the bottom of the oil gas separator. In wet seasons,

slightly open the oil drain valve before starting every day

to drain condensed water from the bottom of the oil gas

separator. The mist like oil and gas contained in the

compressed air can be almost completely filtered out

through the oil gas separator filter element, with an oil

content of less than 3 ppm. The oil filtered by the oil-gas

separation filter element is concentrated at the bottom

of the filter element. Then, it flows back to the engine

body through the filter, orifice, and oil mirror through the

oil return pipe.

Figure 3-3 Lubricating Oil Circuit Flow

LUBRICATING OIL SYSTEM

OIL FILTER

OIL COOLER

TEMPERATURE CONTROL VALVE

OIL GAS SEPARATOR

BE CAREFUL

In winter, in areas where the normal

temperature is below the freezing point,

the cooling water in the cooler must be

drained after the machine is shut down。

WARNING

The safety valve and relief valve have

been adjusted before leaving the factory.

Please do not adjust them randomly and

send them for regular inspection.

WARNING

The company does not recommend users

to choose other brands of lubricating oil,

as using unqualified oil will damage the

air compressor.

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AIR COMPRESSOR SYSTEM

This equipment is equipped with safety warning prompts,

safety protection systems, and alarm devices to prevent

machine damage or personal injury due to human opera-

tions, mechanical failures, and electrical failures. For your

safety, please be sure to follow any safety instructions on

the machine and in the user manual.

Safety warning labels and usage reminder labels are

posted on the body or components of the air compressor

to guide the operation and maintenance of the equipment.

Please strictly follow the precautions on the label when

operating or maintaining the air compressor to ensure

safe and reliable operation.

This user manual also contains safety instructions and

safety warnings. Please carefully read and understand

them, and strictly abide by them during the use of the

equipment.

1）Remove the transportation fixing label: Paste it next

to the main engine and motor transportation fixing bolts

to be removed, with the arrow pointing towards the trans-

portation fixing bolt. When the unit is started up and

running, the transportation fixing bolts and transportation

fixing seats (racks) here should be removed and properly

stored. During the next transportation, the bolts and

transportation fixing seats (racks) should be installed

and locked tightly.Failure to heed this warning may result

in compressor host and pipeline failures.

（2）Warning and Maintenance Plan Label: Please

carefully read and strictly implement the corresponding

contents and operations to ensure that the machine

operates in the optimal state.

（3）Determine the steering label (warning level):

Please refer to Section 4.1.2.

（4）Do not use it as a respiratory label (hazard level): It

is strictly prohibited to use compressed air directly for

breathing. Compressed air should be treated with

dedicated aftertreatment equipment before being used

for breathing. Otherwise, serious personal injury will

result.

（5）Label (Hazard Level): It is strictly prohibited to use

this machine in flammable and explosive environments.

Electric arcs generated during machine operation can

cause major accidents. Please use an air compressor

with corresponding explosion-proof grade in flammable

and explosive environments. Please consult our company

for sales information.

（6）Use caution label (warning level): The operation

and maintenance of the air compressor requires fixed

professional personnel. Before using the air compressor,

it is necessary to carefully read the operating instruc-

tions, strictly follow the instructions for operation and

maintenance, and use original spare parts. Otherwise, the

company cannot fulfill the originally agreed commitment

of free warranty and after-sales service.

（7）Air filter maintenance label (warning level): Regu-

larly clean the air filter to keep the machine running in the

best energy efficient state. During cleaning, the pressure

of compressed air used to clean the filter element should

not exceed 72.5 PSI. Excessive blowing pressure may

damage the filter element.

Figure 4-1 Safety Warning Label

SAFETY WARNINGS AND TIPS

SAFETY WARNING LABEL

SECURITY PROTECTION AND ALARM SYSTEM

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Before loosening or

removing the oil plug,

make sure that the oil

and gas separator

pressure gauge reads

0 Mpa.

It is forbidden to use this

machine in places where

flammable or explosive

gases are present.

Otherwise, the arc

generated by the unit will

cause a fire, resulting in

personal injury or property

damage!

Directly using compressed

air for breathing may result

in serious personal injury.

It is strictly forbidden to use

compressed air in a

confined space under

construction.

When running for the first

time or when the power cord

is changed, make sure that

the rotation of the compressor

motor and the cooling fan is in

the direction indicated by the

arrow.

Compressor reversal will

cause severe head failure.

HIGH TEMPERATURE

CAUTION

MECHANICAL INJURY

DANGER! ELECTRIC

GROUNDING

Be sure to remove

the red shipping

anchor bolt and

anchor frame

before starting up.

SECURITY PROTECTION AND ALARM SYSTEM

（8）Full pressure relief warning label (hazard level):

When disassembling pressure bearing components, the

residual pressure inside the machine may eject the

pressure bearing components, causing personal injury.

When disassembling pressure bearing components, it is

necessary to confirm that the pressure in the oil gas

separator is zero.

（9）Pay attention to the high temperature label (warn-

ing level): the temperature of the exhaust outlet pipeline

of the host and the surface of the oil-gas separator is

high. Please do not touch the corresponding parts to

avoid scalding.

（10）Beware of hand clamping (danger level): paste it

near the rotating parts (host motor coupling, fan rotating

parts). Do not touch the corresponding parts or prohibit

operation nearby. Be careful not to get involved, which

may lead to machine failure or serious personal injury.

（11）Electrical hazard label (hazard level): Posted on

the electrical box door and electrical insulation partition.

When opening the electrical box door or removing the

electrical insulation partition, please cut off the incoming

power supply to prevent electric shock.

（12）Be sure to place a grounding label (warning level)

near the grounding point. Please connect the air compres-

sor to a reliable grounding body in accordance with the

relevant electrical specifications. Do not use gas

pipelines or water pipelines as grounding devices, as this

may cause serious accidents.Unreliable grounding may

cause electrostatic ignition or electric shock accidents in

the oil gas separator filter element.

Figure 4-2 Reminder Label

（1）Motor steering label: used to determine whether

the motor's steering is consistent with this label.

（2）Oil inlet label: posted near the oil inlet of the oil gas

separator, indicating that this is the compressor oil inlet.

（3）Sewage outlet label: posted at the outlet position

of the air compressor water distributor, indicating that

the outlet is a sewage outlet. (Applicable to some

models)

（4）Power supply inlet label: posted at the external

inlet of the air compressor, indicating that the inlet is

power supply inlet.

（5）Oil outlet label: posted at the position of the oil

outlet at the lower end of the oil gas separator, indicating

that the outlet is an oil outlet. When not using this oil

outlet, please plug it with a plug.

（6）Air outlet label: posted at the exhaust port of the

air compressor, indicating that the port is an air outlet.

The electrical control system of the air compressor is

equipped with fault and alarm self-diagnosis functions.

When an abnormality occurs in the air compressor, the

electrical control system of the air compressor will

promptly diagnose and safely protect the shutdown or

issue an alarm signal.

The fault and alarm self-diagnosis function of the air

compressor is divided into heavy faults and light faults.

Any fault that causes the machine to shut down becomes

a serious fault. When a serious fault occurs, the machine

stops and locks, and the control panel displays fault

information or codes.

Reverse rotation of the air compressor can cause serious

damage to the compressor. In order to prevent the

compressor from reversing, the controller has a phase

sequence protection function. When the controller

displays a phase sequence error, switch any two phases

of the motor feed line.

REMINDER LABEL

SECURITY PROTECTION SYSTEM AND

ALARM DEVICE

AIR COMPRESSOR ANTI REVERSE

PROTECTION

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Direction of Rotation

6. 7.

SECURITY PROTECTION AND ALARM SYSTEM

The reasons for motor protection shutdown include:

（1）Due to human operation reasons, such as self

adjustment of loading and unloading pressure, incorrect

adjustment of system parameters, frequent use of emer-

gency shutdowns, unstable wiring, and untimely mainte-

nance.

（2）Mechanical faults, such as internal loss of the

motor, stuck motor bearings, non action of the safety

valve, unclosed intake valve, excessive lubricating oil in

the main engine, etc.

（3）Electrical faults, such as low power supply voltage,

high current caused by loose cable joints, motor out of

phase operation, motor winding faults, etc.

The set temperature for overtemperature warning of

compressors with a rated pressure of 43.5 PSI~145PSI is

221℉. When the exhaust temperature exceeds this set

value, the alarm will not stop; When the exhaust tempera-

ture exceeds 230℉, an over temperature alarm will be

triggered and the machine will shut down.

The set temperature for overtemperature warning of

compressors with a rated pressure of 181 PSI to 232 PSI

is 239℉. When the exhaust temperature exceeds this

set value, the alarm will not stop; When the exhaust

temperature exceeds 248℉, an over temperature alarm

will be triggered and the machine will shut down.

There are many reasons for high exhaust temperature,

mainly:

（1）The fins of the air-cooled cooler are covered with

dust.

（2）The oil filter is blocked.

（3）The ambient temperature in the air compressor

room is too high and the ventilation is not smooth.

（4）The lubricating oil level of the oil gas separator is

too low.

The ambient temperature is too low, the lubricating oil

thickens, and it is difficult to start the machine; The

phenomenon of "ice blockage" is prone to occur in the oil

and gas separator, and forcibly starting the machine can

easily cause serious faults. When the ambient tempera-

ture is below 0 ℉, the unit cannot start.

After installing the minimum pressure valve, the air

compressor is equipped with a pressure transmitter that

displays the exhaust pressure of the machine. In addition,

the microcomputer controller is equipped with an

overpressure protection function. When the exhaust

pressure exceeds the rated pressure of the machine

by+7.2 PSI, the machine will report an exhaust overpres-

sure shutdown. This action occurs before the action of

the safety valve and relief valve.

PROTECTION AGAINST EXCESSIVE

EXHAUST TEMPERATURE

PROTECTION AGAINST LOW AMBIENT

TEMPERATURE

HIGH EXHAUST PRESSURE PROTECTION

WARNING

When debugging a new machine or chang-

ing the incoming power supply, even if the

controller does not display a phase

sequence error, it is necessary to jog the

air compressor to determine whether the

motor direction is consistent with the

marked direction.

WARNING

The air compressor must be started at an

ambient temperature above 0 ℉. In areas

with ambient temperatures below 0 ℉,

the oil drain valve should be opened

before each cold start of the machine to

confirm that there is no "ice blockage" in

the oil gas separator.

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BE CAREFUL

For machines equipped with frequency

converters, the rotation of the motor is not

affected by the phase sequence of the

incoming power supply.For frequency

converters, changes in the phase

sequence of the three-phase incoming

power supply cannot change the direction

of the motor's rotation.To change the

direction of the motor, it is necessary to

exchange any two phases of the

three-phase wires at the output end of the

frequency converter (connected to the

motor).

SECURITY PROTECTION AND ALARM SYSTEM

After an alarm occurs, an alarm that does not affect the

normal operation of the unit in the short term becomes a

minor fault. When a minor fault occurs, the unit does not

shut down.

When the service life of lubricating oil, motor lubricating

grease, air filter, oil filter, and oil gas separation filter

element reaches the prompt, the user should replace the

three filters and lubricating oil, and add motor lubricating

grease.

The air compressor oil gas separator filter element is

equipped with a relief valve in front of it, and the oil gas

separator cover is equipped with a safety valve.

LIGHT FAULT PROMPT FUNCTION

LUBRICATING OIL AND WEAR PARTS

SERVICE LIFE ALARM PROMPT

MECHANICAL PROTECTION OF THE

MACHINE

WARNING

After a minor malfunction occurs, please

promptly notify maintenance personnel to

maintain the air compressor. Long term

failure to handle may affect the perfor-

mance of the unit and even lead to the

occurrence of serious faults.

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SECURITY PROTECTION AND ALARM SYSTEM

OPERATION OF THE AIR COMPRESSOR

Although each screw compressor has undergone testing

before leaving the factory and strict inspection before

shipment, it cannot be guaranteed that there will be no

damage during transportation. Therefore, before debug-

ging, each compressor should be rechecked for damage,

and the transportation fixing bolts and transportation

fixing seats (frames) should be removed to check wheth-

er the red lines of the moving component bolts are consis-

tent. In addition, during the first few hours of operation,

attention should be paid to observing the operation of the

machine. The screw compressor is fully assembled before

leaving the factory and can be directly connected to the

compressed air main using a flexible joint.

（1）Check whether the pipeline joints, instruments,

circuit connection joints, etc. are loose or detached due

to transportation, installation, etc. If any, please tighten

it in a timely manner. Confirm that the exhaust valve is

open.

（2）Check if the air filter element and oil filter are

loose, and if so, tighten them in a timely manner.

（3）Please make sure that the power supply voltage

fluctuation range is within ±10% of the rated voltage

(230V/460V).

（4）Confirm that an independent circuit breaker is

installed for the air compressor, and the capacity of the

circuit breaker should be selected according to the

requirements of this manual.

（5）Check whether all wiring in the electrical box is

loose, and if so, please tighten it in time.Use a screw-

driver or wrench to check and tighten the wiring of the

main circuit and the control circuit of the AC contactor.

（1）Within 1-2 seconds after pressing the start button

on the touch screen, immediately press the "Emergency

Stop" button to check if the steering is correct (as

indicated by the arrow direction). If the steering is incor-

rect, please switch any two phases of the three-phase

wire at the output end of the frequency converter

(connected to the motor) to check if the fan steering is

correct.

（6）Check if the components inside the electrical box

are damaged and if the wires are damaged. If available,

please contact our company's after-sales service.

（7）Check whether the oil level in the oil and gas

separator is within the safety line. If not, please add the

appropriate amount of lubricating oil. If the oil level is very

low, please check whether the blowdown valve is open, or

the pipeline is loose and leaking oil.（8）Check the

cooling system for damage or damage.

（8）Check the safety valve and relief valve for damage.

（9）If the trial operation is only carried out after a long

time of delivery or if the shutdown time exceeds three

months before use, approximate lubricating oil should be

added to the intake valve and the air compressor should

be turned several times by hand to prevent oil shortage

and burning in the compressor host during start-up.

（10）According to the safety warning label (1) shown

in item 4.1.1 (this warning label is posted on the base

near the motor and the host in a prominent position),

remove the host and the motor transportation fixed

column (frame). It is recommended to retain the removed

main engine, motor transportation fixed frame, and

fasteners for use during long-distance transportation

（11）Check the cooling system.

CHECK AND TEST RUN BEFORE STARTING

THE MACHINE FOR THE FIRST TIME

CHECK BEFORE STARTING THE MACHINE

FOR THE FIRST TIME

TEST RUN

WARNING

（1）Before operating the machine, the

main engine support seat and motor

transportation fixing bracket must be

removed, otherwise it may damage the

compressor main engine.

（2）Before long-distance transporta-

tion, it is necessary to install the main

engine support seat and motor transpor-

tation fixing frame to protect the main

engine and compressor system.

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BE CAREFUL

The first start-up of a new air compressor

after installation, or the first start-up after

transportation to another location, must

undergo pre start-up inspection and trial

operation.

OPERATION OF THE AIR COMPRESSOR

（2）After resetting the emergency stop button, press

the start button and the air compressor will start running.

（3）Observe if there are any abnormal indications on

the display screen; Can the machine load normally; Is

there any abnormal vibration in the air compressor. If

there is any abnormal sound, vibration, water leakage, oil

leakage or other abnormal phenomena, immediately press

the stop button, and check after stopping the machine.

（4）Observe whether the motor speed changes when

the exhaust pressure rises to the variable frequency

pressure setting. When the pressure reaches the sleep

pressure, can the machine sleep normally. When the

pressure drops to the sleep start pressure, can the

machine start and operate normally.

（5）Press the stop button to check if the machine

stops normally.

（2）Observe the oil level to ensure that the lubricating

oil level should be in the middle of the upper and lower

scale lines of the oil level gauge when the machine is

running. If the lubricating oil is too much, the machine

should be closed first, and then the oil drain valve can be

opened to discharge a part of the oil; If the lubricating oil

is insufficient, stop and press the emergency stop button

first, and then open the upper oil cap to refuel.The method

of injecting lubricating oil into the air compressor (as

shown in Figure 5-2):：

Figure 5-1

（1）Slightly open the drain valve at the bottom of the

oil gas separator to drain the condensate inside, and then

tighten it again. Condensate discharge method: as shown

in Figure 5-1.

INSPECTION BEFORE STARTUP

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BE CAREFUL

For machines equipped with frequency

converters, the rotation of the motor is not

affected by the phase sequence of the

incoming power supply.The change in

phase sequence of the variable frequency

machine, i.e. the three-phase incoming

power supply, cannot change the direction

of the motor.To change the direction of

the motor, it is necessary to exchange any

two phases of the three-phase wires at the

output end of the frequency converter

(connected to the motor).

BE CAREFUL

Before discharging condensate, it is

necessary to ensure that the pressure

inside the system is zero before proceed-

ing.

OPERATION OF THE AIR COMPRESSOR

（3）Rotate the coupling between the host and the

motor by hand, and it should move freely. If there is any

jamming, it should be checked before starting.

（4）Turn on the main power supply, open the shut-off

valve, and confirm that the pressure in the system is zero.

5.3.1 This compressor has a high degree of automation

and complete safety protection functions, generally

without the need for personnel to take care of it.

5.3.2 When there is abnormal sound, vibration, air

leakage, oil leakage, etc. during operation, the machine

should be immediately shut down.

5.3.3 Check every two hours during operation, record

voltage, current, air pressure, exhaust temperature, oil

level, etc. for future maintenance reference.

5.4.1 Press the stop button to automatically complete

the entire shutdown program for the compressor

machine. The time for complete shutdown will vary

depending on the state of the compressor unit at that

time, but the maximum time will not exceed half a minute.

5.4.2 Turn off the shut-off valve and the main power

supply.

5.4.3 In case of emergency, the emergency stop button

can be pressed to stop the machine, but it should not be

used under normal circumstances.

STARTING OPERATION

SHUTDOWN

WARNING

During operation, there is high pressure in

both the pipeline and the container. Some

components have high temperatures, and

electrical circuits have high pressure.

Therefore, the machine door should be

tightly closed and the pipeline should not

be loosened or other dangerous opera-

tions should be carried out.

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BE CAREFUL

Before discharging or refueling, it is

necessary to ensure that the pressure

inside the system is zero before entering.

BE CAREFUL

Before starting up, the oil drain valve must

be opened to drain the condensed water

inside the machine. If there is condensed

water inside the machine, it can cause

pollution to the unit. Customers can

determine the appropriate interval for

discharging condensate water based on

local usage.

BE CAREFUL

When the temperature in the area is below

zero degrees Celsius, it is necessary to

ensure that there is no "ice blockage" in

the oil and gas separator before starting

it, otherwise it may cause serious acci-

dents; For these cold regions, the conden-

sate should generally be discharged after

the last shutdown before the temperature

of the oil gas separator has dropped to

zero.

OPERATION OF THE AIR COMPRESSOR

Long term shutdown refers to a shutdown and storage

period of more than three months, including long-term

storage of new machines for more than three months and

long-term storage after operation for more than three

months. To ensure that the machine does not damage the

air compressor during long-term shutdown and can

operate normally and safely when resuming operation.

（1）To prevent the influence of humid gases, strict

packaging should be carried out and desiccants should be

added to keep the relative humidity inside the packaging

below 75%.

（2）If the shutdown does not exceed one year, the

condensate at the bottom of the oil gas separator should

be discharged after a few days of shutdown. If the

shutdown time exceeds one year or more, the lubricating

oil in the machine should be drained completely.

（3）Electrical equipment such as electric motors,

electronic control panels, solenoid valves, etc. should be

wrapped in plastic paper and placed with moisture-proof

agents in high and humid areas to prevent moisture intru-

sion.

（4）The machine should be stored in an environment

free from direct sunlight, dust, corrosive gases, flamma-

ble gases, steam, dripping water, and vibrations.

（1）Remove plastic paper from the machine or electri-

cal equipment.

（2）Measure the insulation resistance of the motor

with a 500V megohmmeter, and each data item should be

greater than or equal to 1 megohm.

（3）For machines with a shutdown time of no more

than one year, the color or amount of lubricating oil should

be checked to see if it meets the start-up requirements.

Machines that have been shut down for more than a year

should be injected with new lubricating oil.

（4）Perform the pre startup inspection and trial run

according to item 5.1 of this manual.

HANDLING METHODS FOR LONG-TERM

SHUTDOWN

HANDLING METHODS FOR LONG-TERM

SHUTDOWN AND STORAGE

REBOOT PROGRAM

WARNING

When using emergency shutdown or

sudden power outage, a large amount of

lubricating oil may flow into the main

engine. If starting again, first jog 2-3

times to allow the lubricating oil to flow

out of the main engine before normal

operation. If the inching method cannot

start the compressor, first turn the engine

for a few turns and feel that the engine

can be easily cranked before starting. If

the engine still cannot be started, open

the side cover of the engine, drain most of

the lubricating oil and add it to the oil gas

separator before running.2. When the

water-cooled air compressor is shut down

in winter, the accumulated water in the

cooler must be drained, otherwise it may

cause the cooler to freeze and crack!

WARNING

Disposal of waste oil: The waste oil

discharged from the air compressor

should be disposed of in accordance with

Chinese or local laws and regulations.

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OPERATION OF THE AIR COMPRESSOR

Maintenance personnel must have a certain level of

knowledge and operational skills in mechatronics, have a

certain understanding of air compressors, and carefully

read all the contents of this manual before maintenance.

6.1.1 Maintenance work must be carried out when the

machine is shut down, the shut-off valve is closed, and

the power supply is cut off.

6.1.2 Before disassembling any pressurized components,

it must be ensured that the pressure inside the system

has decreased to zero.

6.1.3 Some components in the system have high

temperatures during initial shutdown, so be careful to

avoid burns during operation.

6.1.4 After maintenance and repair, it must be confirmed

that there are no tools, parts, rags, etc. left inside the

compressor.

6.3.1 The oil filter should be replaced after the first 500

hours of operation and every 2000 hours of operation or

when changing the lubricating oil thereafter. The replace-

ment cycle should be shortened in dirty environments.

6.3.2 The oil filter alarm indicates that the oil filter is

blocked and should be replaced in a timely manner. The

replacement of the oil filter should be carried out after

shutdown and pressure relief. When replacing, use a

wrench to rotate the oil filter counterclockwise. To

prevent oil from splashing down, prepare a plate to catch

the lubricating oil flowing out. Reinstall the new oil filter,

do not use a wrench during installation, tighten by hand

until the components are in close contact, and then tight-

en by 1/5 turn with the wrench.

6.3.3 Turn on the machine to check for oil leakage. If there

is no oil leakage, it indicates that the replacement is

complete.

6.3.4 An example of oil filter replacement is shown in

Figure 6-2:

The operating conditions determine the maintenance

cycle. The air filter element should be replaced after about

500 hours of use for a new machine. The second replace-

ment time should be set at 2000 hours, and the replace-

ment cycle should be shortened in dusty environments. If

the air filter alarm message is displayed, the air filter

element needs maintenance or replacement.

SAFETY PRECAUTIONS

REPLACEMENT AND MAINTENANCE OF

AIR FILTER ELEMENT

OIL FILTER REPLACEMENT

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MAINTENANCE AND TROUBLESHOOTING

BE CAREFUL

When installing the return oil pipe, the

distance from the bottom of the oil pipe

should not exceed 3mm, otherwise it may

cause excessive oil content in the

exhaust.

The operating conditions determine the maintenance

cycle, and if the environment is poor, the replacement

time should be shortened. The first replacement time of

the new machine is 1500 hours; The second replacement

time is set to 2000 hours. If the timing alarm message of

the oil gas separation filter element is displayed, the filter

element must be replaced.

The replacement steps for the oil gas separation filter

element are as follows:

1. After the air compressor is stopped, close the air outlet

to confirm that the system is not pressurized.

2. Disassemble the pipeline above the oil and gas separa-

tor and at the same time put the outlet of the minimum

pressure valve

The flange bolt is removed.

3. The big machine should be disassembled back into the

oil pipe, and the small machine should directly remove the

cover, without dismantling.

4. Remove the fixing bolt on the upper cover of the oil and

gas separator.

5. Turn the lid bolt to move the upper cover up for a

distance and turn the upper cover (Figure

6-3)。

6. Remove the return tubing. (According to the actual

situation, some machines can be removed directly

without dismantling.)

7. Remove the filter element and replace it with a new

one.

8. Install the oil and gas separator in reverse order of

disassembly.

Figure 6-2

Figure 6-3

OIL GAS SEPARATION FILTER ELEMENT

REPLACEMENT

WARNING

The sealing gasket equipped with the oil

gas separation filter element method has

sealing and anti-static functions. If the

flange surface is replaced, a metal soft

gasket must be installed. If this regulation

is violated, it may cause serious conse-

quences and even burn the entire air com-

pressor.

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MAINTENANCE AND TROUBLESHOOTING

After 500 hours of operation of the new machine, the

lubricating oil alarms in a timed alarm state. The lubricat-

ing oil should be replaced. The second lubricating oil set

life timer alarm time is 2000 hours.

If the air compressor operates in dusty or high tempera-

ture environments, the oil change interval should be

shortened.

6.5.1 The oil change steps are as follows:

6.5.1.1 Confirm that the machine is completely shut

down and confirm that there is no air pressure inside the

oil gas separator. Disconnect the main circuit, mark it,

and disconnect the power supply of the starter.

6.5.1.2 Thoroughly drain the lubricating oil from the

system:

a.Disconnect the low point connection and drain oil from

the pipeline;

b. Drain oil from the oil gas separator drain valve;

c. Pour out the oil from the filter; And reinstall the used oil

filter.

6.5.1.3 Inject 50% new oil into the system:

a. Start the compressor and observe its operation.

b. Run for 5 minutes or until the exhaust temperature

stabilizes, then stop the machine.

6.5.1.4 Thoroughly drain the oil in the air compressor.

6.5.1.5 Replace with a new oil filter.

6.5.1.6 Fill the system with new oil and then reinstall the

fuel filler plug.

To ensure the safe and good operation of the air compres-

sor, please regularly maintain the motor. Please refer to

the motor manual for specific maintenance methods.

Blocking the air inlet of the frequency converter can easily

cause poor heat dissipation, and the frequency converter

is prone to heating, resulting in failure or reduced lifespan

of the frequency converter. To ensure the good operation

of the frequency converter, please regularly maintain the

frequency converter. Please refer to the inverter manual

for specific maintenance methods.

LUBRICATING OIL REPLACEMENT

MOTOR MAINTENANCE

MAINTENANCE OF FREQUENCY CONVERTERS

WARNING

Pressurized air and oil can cause serious

personal injury or death. Before removing

valves, nuts, plugs, installing screws, and

filters, turn off the compressor and

release all pressure in the system, discon-

nect the main circuit, mark it, and discon-

nect the power supply to the starter.

WARNING

Our company does not recommend users

to choose other brands of lubricating oil,

as using unqualified oil will damage the

air compressor.

WARNING

Excessive or insufficient lubricating

grease can cause damage to the motor, so

it is necessary to strictly follow the motor

manual and the motor's greasing name-

plate for greasing.

WARNING

When maintaining the frequency convert-

er, please cut off the incoming power

supply and wait for the charging indicator

light of the frequency converter to turn off

before operating the frequency converter.

Please dispose of lubricating oil in accor-

dance with relevant national or local laws

and regulations. Improper handling of

lubricating oil may cause serious environ-

mental pollution.

DANGER

The compressor, oil gas separator, and all

pipelines during and after operation may

be in a high-temperature state.

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MAINTENANCE AND TROUBLESHOOTING

MAINTENANCE AND REPAIR ITEMS AND MAINTENANCE CYCLE TABLE

WARNING

The content of this table is for users' reference. Customers should change the maintenance cycle

appropriately based on the actual operating environment and performance of the machine.

WARNING

When the air filter element and oil gas separation element are blocked and alarm occurs, they should

be replaced.

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MAINTENANCE AND TROUBLESHOOTING

Everyday

Weekly

Everythree months

Annually

Drain the condensate in the oil gas separator before start-

ing up every day

Check whether the unloading and loading pressure, return

oil sight glass, and return oil are normal

Check the cooler and clean it if necessary

Clean the air filter and frequency converter cooling air duct

Check for oil leaks

Check the oil level before startup and during operation

Check the exhaust temperature of the air compressor

Check if the electrical wiring is securely connected

The first 500 hours of operation of the new machine,

replace the oil filter and lubricating oil

Check the tightness of the oil and gas pipeline connection

Replace lubricating oil

Manual inspection of safety valves (annual inspection)

Replace the air filter element and clean the cooling air duct

of the frequency converter

Replace the oil filter

Check the motor and electrical system

Replace the oil-air separator core, clean the radiator,

Clean the intake valve

Maintenance content

Maintenance intervals

Operating hours

500

2000

1000-2000

2000

4000

TROUBLESHOOTING TABLE

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1. Unable to

start

2. The

operating

current is

too high,

causing the

motor to

overload

and stop

3.The

exhaust

temperature

is often too

high

1.Electrical personnel inspect the control circuit and

switch it on or replace it.

2.Increase the ambient temperature.

3.Electrical personnel adjust the phase sequence.

4.Electrical personnel maintenance and replacement.

5.Reset the emergency stop button.

6.Electrical personnel maintenance and replacement.

7.Electrical personnel shall maintain and connect firmly.

8.Refer to the instructions and take appropriate

measures.

9.Replace the switch or jumper.

10.Manually rotate the host. If it cannot be rotated,

please contact our customer service center.

11.Electrical personnel maintenance

1. Check the pressure gauge and adjust the pressure

setting.

2. Check the oil number and replace the oil.

3. Replace the oil gas separation filter element.

4. Electrical personnel adjust the power system.

5. Stay away from vibration sources or take vibration

reduction measures.

6. Manually rotate the host. If it cannot be rotated,

please contact our customer service center.

7. Electrical personnel maintenance

1.The small circuit breaker trips or the fuse

blows.

2.The ambient temperature is too low.

3.The phase sequence of the power supply is

reversed.

4.Poor contact of the operation button.

5.The emergency stop button has not been

reset.

6.Motor malfunction.

7.Loose electrical wiring.

8.Read error messages from the touch

screen and frequency converter.

9.Remote contact virtual connection.

10.Host failure.

11.Loose communication line

1. The exhaust pressure is too high.

2. The lubricating oil specification is incor-

rect.

3. The oil gas separation filter element is

blocked and the system pressure is high.

4. Abnormal power supply voltage.

5. There is strong impact vibration nearby.

6. Host failure.

7. Poor contact of circuit contacts.

1. Insufficient or overdue use of lubricating

oil.

2. Insufficient cooling water volume.

3. The ambient temperature is high.

4. The dust filter is blocked.

5. The lubricating oil specification is incor-

rect.

6. The oil filter is blocked.

7. The temperature control valve is faulty.

8. Fan fault

9. The temperature sensor connection wire is

loose.

10. The oil cooler is blocked.

1.Check the pointer of the oil level gauge. During opera-

tion, the lubricating oil pointer should be located in the

middle of the upper and lower scale lines of the oil level

gauge.

2.Check the temperature of the inlet and outlet water

pipes and increase the cooling water flow rate.

3.Check the ventilation of the air compressor room and

increase the air circulation.

4.Cleaning and dust removal.

5.Check the oil number and replace the oil.

6.Replace the oil filter.

7.Repair the temperature control valve core.

8.Electrical personnel repair and replace the fan.

9.Electrical personnel repair or replace corresponding

components.

10.Repair or clean the oil cooler.

Exclusion method

Fault

Cause of occurrence

TROUBLESHOOTING TABLE

TROUBLESHOOTING TABLE (CONTINUED)

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6.Unable to

load

normally

under low

pressure

7. Unable to

automati-

cally unload

and operate

under high

pressure

8. High fuel

consump-

tion

9. High oil

content in

the air

10. The

exhaust

volume of

the

compressor

machine is

lower than

the normal

value

1.Adjust the loading pressure value.

2.Clean the control pipeline.

3.Adjust the discharge flow rate.

4.Repair, adjust, and replace with new products.

5.Replace solenoid valve.

6.Check the leak location and lock it tightly.

7.Replace the intake valve

1.Adjust the unloading pressure value.

2.Replace the intake valve.

3.Clean the control pipeline.

4.Adjust the discharge flow rate.

5.Replace the sealing gasket.

1.The loading pressure value is not set

correctly.

2.The control pipeline is blocked.

3.Leakage pipeline failure.

4.The minimum pressure valve is not

functioning properly.

5.The solenoid valve is faulty.

6.Severe leakage in the control pipeline.

7.The intake valve is faulty.

1.The unloading pressure value is not set

correctly.

2.The intake valve is not functioning properly.

3.The control pipeline is blocked.

4.Leakage pipeline failure.

5.The sealing gasket under the intake valve

is damaged.

1.The oil in the oil gas separator is too full.

2.The return pipe is blocked, damaged, or

loose.

3.The oil gas separation filter element is

broken.

4.Loose components

5.The minimum pressure valve is not

functioning.

6.Operate at high exhaust temperatures.

7.Using incorrect engine oil

1.The air filter element is blocked.

2.The intake valve is not functioning properly.

3.The oil gas separation filter element is

blocked.

4.Improper pressure control setting.

5.There is leakage in the system, safety

valve, or other pipelines.

6.Host failure.

7.The minimum pressure valve is faulty.

1.Clean or replace.

2.Disassemble, disassemble, and clean the

intake valve.

3.Repair and replacement

4.Adjust the settings.

5.Check and repair.

6.Manually rotate the main engine. If it

cannot be rotated, please contact our

company's after-sales service center.

7.overhaul

1.Drain excess oil from the system.

2.Replace damaged pipes

3.Replace.

4.Tighten all devices and gaskets.

5.Clean and replace

6.Reduce the exhaust temperature.

7.Replace with 'Special lubricating oil for

screw compressors'.

1.The oil content of gas is high.

2.Device and gasket oil leakage

1. Refer to "High Oil Content" below.

2.Lock or replace the device and gasket.

Exclusion method

Fault

Cause of occurrence

TROUBLESHOOTING TABLE

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11.

Frequent

conversion

times for

loading and

unloading

1.Check the leak location and lock it tightly.

2.Reset (usually with a pressure difference of 0.1MPa or

above).

3.Increase the capacity of the gas storage tank

1.Pipeline leakage

2.The set pressure difference for loading and

unloading is too small.

3.The air consumption is unstable.

Exclusion method

Fault

Cause of occurrence

TROUBLESHOOTING TABLE

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MechMaxx M50AC460 Rotary Screw Air Compressor 50HP 220 CFM

Product's Documents

Air Compressor Product manual 1.0.

Specifications

MechMaxx M50AC460 Questions and Answers