Air compressor operating procedures and precautions

Air compressor operation specification

i. Purpose

make the operators master the use, maintenance and maintenance of the air compressor, ensure the normal operation of the air compressor, and meet the test requirements of the salt spray corrosion test chamber.

II. Scope of application

suitable for our factory air compressor equipment.

III. Duties

1.IQC is responsible for basic use and maintenance and maintenance records.

2.IQC team leader is responsible for the inspection of air compressor.

IV. Operation

please check the following items before 4.1 operation:

4.1.1 Check whether the screws or nuts of each part are loose.

4.1.2 Whether the tightness of the belt is moderate.

4.1.3 Whether the pipeline is normal.

4.1.4 Whether the lubricating oil level is appropriate.

4.1.5 Whether the wires and electrical switches meet the requirements and whether the wiring is correct.

4.1.6 Whether the voltage of the power supply is correct.

4.1.7 Whether the compressor pulley can be easily rotated by hand (shut down for safety during inspection).

4.1.8 Check whether all the valves are in the proper position and the correct opening and closing state.

4.1.9 Check the system and remove foreign objects.

4.1.10 Open and close the drain valve at the lower part of the air tank again.

4.1.11 If the system equipment is restarted after maintenance, all maintenance accessories and maintenance signs installed on the safety maintenance surface shall be removed.

Notes for 4.2 operation:

4.2.1 After checking the above points, fully open the air valve, and then press the start button or start the diesel engine to make the machine start operation under no load condition, which can prolong the life of the air compressor and the prime mover.

4.2.2 Check whether the running direction is the same as that indicated by the arrow on the belt protective cover. If not, please turn off the power and inform the electrician to repair.

4.2.3 If there is no abnormal sound about three minutes after starting, close the valve to gradually increase the pressure in the air tank to reach the predetermined pressure. After reaching the set pressure, the pressure switch automatically cuts off the power supply and the motor stops running. (At this time, the release valve at the pressure switch will release air for a few seconds to discharge the compressed air in the exhaust copper pipe, which is a normal phenomenon. The purpose is to reduce the load and make it easier to start when the motor runs again, without air leakage).

Adjustment of 4.3 pressure control system:

special attention: it shall be adjusted by the mechanic electrician of the factory, and shall not be adjusted by himself.

1) Rotate the pressure adjustment screw clockwise to increase the use pressure, otherwise the set pressure is reduced.

2) Rotate the differential pressure adjustment screw clockwise to increase the differential pressure, otherwise the differential pressure will decrease.

Adjustment of 4.4 safety valve:

special attention: the operating pressure of the compressor shall not be higher than the rated working pressure of the compressor. If it needs to be adjusted, it must be adjusted by the mechani electrician of the factory, and shall not be adjusted by itself.

The relief pressure of the safety valve is generally set to be 0.1Mpa higher than the exhaust pressure, so there is no need to adjust it by itself. If the discharge pressure of the safety valve must be adjusted for other reasons, the lock nut on the safety valve can be loosened, and then the adjustment screw can be adjusted. If the discharge pressure is increased by rotating the time value, and if it is rotated counterclockwise, the pressure setting will be decreased. After setting the discharge pressure, tighten the lock nut.

Five. Maintenance and inspection

regular inspection and maintenance of 5.1:

5.1.1 Please keep the machine clean.

5.1.2 Open the drain valve of the gas tank once a day to drain the oil and water.

5.1.3 Please check the lubricating oil level once a day to ensure the lubrication of the air compressor.

5.1.4 Empty

the air filter should be cleaned or replaced every 15 days (the filter element is a consumable).

5.1.5 Check the tightness of the belt and screws at various parts from time to time.

5.1.6 The lubricating oil should be replaced with new oil after 50 hours or one week of operation at first, and then replaced with new oil every 300 hours and refueled every 36 hours of operation.

5.1.7 Please remove the air valve for cleaning after 500 hours (or half a year) of use.

5.1.8 Please clean the parts of the machine once a year.

5.1.9 Check all the protective covers, warning signs and other safety protection devices every day.

5.1.10 Regularly check the pressure release device, parking protection device and pressure gauge of the air compressor (once a month), and the sensitivity of the safety valve to ensure that the air compressor is in normal working condition.

5.1.11 Regularly check the parts subject to high temperature, such as valves, cylinder heads and exhaust pipes, and remove the grease and carbon deposits on the inner wall (once every six months). It is strictly forbidden to touch these high-temperature parts during operation.

5.2 use and maintenance

5.2.1 The steering direction of the air compressor shall be the same as that indicated by the arrow on the belt protective cover.

5.2.2 All maintenance work should be stopped and cut off the power supply.

5.2.3 Before removing the pressure parts of the air compressor, the air compressor shall be separated from all pressure sources, and the compressed air in the air compressor shall be completely exhausted.

5.2.4 When repairing the air compressor, measures should be taken to avoid starting the air compressor due to negligence, the starting power should be disconnected, and a sign "Warning: under maintenance, no driving" should be hung on the starting device ".

5.2.5 When the complete set is used, all safety devices should be maintained to maintain their normal functions. The safety devices should not fail and can only be replaced with other devices that can provide the same safety. The pressure gauge, safety valve and automatic air pressure switch should be checked regularly. (once a half month)

5.2.6 The air valve, filter, cylinder head, air pipe and parts in contact with compressed air under normal conditions shall be cleaned regularly. Under no circumstances shall volatile, flammable or harmful cleaning agents be used for cleaning. After cleaning, all parts shall be rinsed and dried. (once a month)

5.2.7 Pressure vessel shall be subject to pressure resistance test regularly, and the test period shall be at least once every 10 years. (Check the internal and external surfaces at least once every 6 years)

5.2.8 The air tank shall be decompressed before the air compressor runs (before moving), and measures shall be taken to prevent the displacement of the machine during operation before starting up.

5.3 failure causes and countermeasures: (the following troubleshooting should be carried out by the factory electrician operation, other personnel can not move)

when the air compressor can rotate:

motor wiring error ---- change wiring

voltage reduction-please check with power company

the connecting wire is too thin or too long --- use thicker and shorter wires instead

belt too loose-adjust belt

motor failure, sent to motor factory for repair

exhaust pressure too high --- reduce exhaust pressure

speed too high-reduce speed

v-belt is not correct or flywheel is loose-readjust

crankshaft deformation-sent to special factory for repair

loose seat --- lock seat

piston impact cylinder head --- thickening gasket

belt too loose-adjust belt

motor failure-sent to motor factory for repair

poor valve action

leakage of valve plate

valve seat spring failure-replace with new one

foreign matters such as carbon or paint attached to the valve plate --- Remove and clean

safety valve or automatic release air leakage --- Disassemble, clean, repair or replace with new ones

air leakage of air valve, drain valve, pipe joint and screw

tighten or replace with new ones

excessive Oil-Adjust Oil Level

wear of piston ring

piston cylinder wear

overload operation due to excessive pressure adjustment --- reduce operating pressure

the voltage is too high or the connecting wire is too long --- please ask the power company to repair or replace the shorter wire.

Exhaust valve fault

burned bearing

piston Burned-Replacement

demand air volume is greater than the amount of the amount --- replace the larger horsepower air compressor.

The output pressure is greater than the rated pressure --- reduce the operating pressure

the intake pipe is too small and too long --- replace the larger and shorter pipe.

Air filter clogged-remove and clean

broken or not tightly positioned valve group --- send it to special factory for repair

GASKET WEAR-REPLACE NEW

wear of piston ring or cylinder --- Replace with new one

loose V-belt-readjustment

the release piston has not been completely separated --- adjusted.

Exhaust pipe leakage --- Replace with new one

the pressure rod end of the release valve is worn or damaged by other parts-replace and repair

blocked or Leaky Load Release Line --- Disassemble, clean or replace

the release piston is stuck-disassemble it for maintenance or replace it with a new one.

The output pressure is greater than the rated pressure --- reduce the operating pressure

damage and failure of the release system --- replacement

release pressure set too high --- reduce set pressure

pressure gauge damaged-replace and repair

air Leakage of Release Air Duct-Repair and replace it with a new one

the set pressure of the safety valve is too low or damaged --- increase the pressure of the safety valve or replace it with a new one.

Valve group dirt removal cleaning

pressure is too high-reduce the use of pressure

valve seat overheating-check whether the exhaust pipe is smooth and cleaned

seat loose-re-lock

dirt and rust enter valve seat --- remove and clean

broken valve plate-new product

power failure --- contact power company for maintenance

the wiring or fuse is broken-replace it with a new one for repair.

Motor failure-sent to motor factory for repair

broken wiring or fuse --- Replace with new one

voltage reduction-power company maintenance

exhaust Valve Leakage-Repair Exhaust Valve

wiring error-replace wiring

motor failure-sent to motor factory for repair

motor overload-reduce load

crankshaft too tight --- Dismantling and repairing