Ziqi User Manual 2021
Ziqi User Manual 2021
Dear user:
Thank you very much for choosing Ziqi Compressor (Shanghai) Co., Ltd. screw air
compressor (hereinafter referred to as air compressor or compressor).
In order to ensure the safety and reliability when operating the machine, please read this
manual carefully before using the machine.
The terms stipulated in this instruction manual are applicable to the company's air compressor
products, and the accompanying instructions for accessory parts (such as motors, controllers, etc.)
are also applicable to the accessory products.
The user should be aware of local laws and regulations regarding the installation and use of air
compressors, and abide by them
When the provisions in this manual are different from the relevant local laws and
regulations (especially in terms of safety), they should be implemented in favor of safer
provisions.
The operator is responsible for ensuring that the machine runs under safe conditions. If
the machine is considered to be unsafe, it should be overhauled in time.
From the day you purchase our products, you will get our company's best after-sales
service. In order to facilitate contact, we provide our company's address and telephone number
as follows:
Address:280 Wangwei West Road, Fengjing Industrial Zone, Jinshan District, Shanghai
Postcode:201502
telephone:400-016-1099
Fax:021-68148280
Web:www.ziqi-group.com
Service email:ziqi@ziqi-group.com
Safety
Precautions
1>.Installation
The installation of the air compressor should follow the relevant local laws and regulations,
and strictly abide by the following regulations:
1. The air compressor should be hoisted by lifting equipment which load-bearing capacity
greater than the weight of the unit, and the hoisting speed and acceleration should be limited within
the permitted range.
2. Try to install the air compressor in a cool, clean, and well-ventilated place to ensure that the
air flow into the air compressor is clean and the moisture content is minimal.
3. The air sucked by the air compressor is not allowed to contain flammable gas and corrosive gas,
in order not to cause explosion or internal rust
4. The discharge of air compressor sewage and waste oil shall comply with the regulations of
the local environmental protection department
5. The cooling water quality for water-cooling type compressor should meet the following
requirements:
⑴. The total hardness expressed by CaCO3 should be less than 100PPM (100 mg/L)
⑵. PH value is between 6.0~8.0
⑶. Suspended matter does not exceed 50PPM (50 mg/L)
Inferior cooling water will reduce the cooling effect of the cooler, and in severe cases will cause
the entire cooler to fail and be unusable.
6. This series of machines use three-phase AC power supply of 380V, 50Hz. If there is a special
voltage, it is determined by the user when placing the order. There are 110V, 220V, 400V, 415V, 440V,
660V, 690V, etc., and the frequency is 60Hz, etc., and reliable grounding is required.
7. Read this manual "Operation and Use" carefully before starting the compressor. The
compressor and cooling fan must run in the specified direction (the direction of the cooling fan
should refer to the logo on the motor), otherwise it may cause the air compressor to run out of oil or
increase the temperature. , Seriously damage the air compressor.
8. When the air compressor is under remote control, the machine may start at any time and
should be listed as a reminder.
2>.Maintenance
1. The repair and maintenance of the air compressor must be carried out by trained and
qualified engineers or under their guidance.
2. Please use our company's special screw compressor lubricating fluid and original genuine
parts. Any damage or malfunction caused by the use of counterfeit substitute parts is not within the
scope of product warranty or product liability.
3. The correct tools must be used for repairs and maintenance work.
4. When the air compressor is working, its exhaust temperature reaches about 100℃, and some
parts become very hot. Please do not touch these parts with your hands to avoid being burned.
5. When the machine needs to be repaired, the main power supply must be cut off, the
connection to the external air circuit must be shut off, and the system must be pressure-free and
high-temperature-free before proceeding.
CATALOG
Chapter 1 Introduction to Screw Compressor·····························································5
1.1 Overview of screw compressors··································································5
1.2 Screw compressor inner structure································································ 5
1.2.1 Basic structure·············································································· 5
1.2.2 Meshing······················································································5
1.3 Screw compression principle····································································· 5
1.3.1 Inspiratory process········································································· 5
1.3.2 Compression and injection process······················································6
1.3.3 Exhaust process·············································································6
Chapter 2 Outline Drawing of Screw Compressor·····················································7
Chapter 3 Installation of Air Compressor································································ 25
3.1 The location of the air compressor room······················································ 25
3.2 The layout of the air compressor room and the placement of the air compressor······· 25
3.3 Piping connection of air compressor··························································· 25
3.3.1 Air compressor exhaust pipe connection·············································· 25
3.3.2 Water-cooled air compressor cooling water pipe connection······················ 27
3.4 Cooling water for water-cooled air compressor·············································· 27
3.5 Ventilation of air compressor····································································27
3.6 Compressor technical parameters·······························································28
3.6.1 Installation and connection technical parameter····································· 28
3.6.2 Cooling water parameters······························································· 29
3.6.3 Cooling wind parameters································································ 30
3.6.4 Electrical technical parameters (380V)················································31
Chapter 4 Compressor system process and functions of various parts······························ 32
4.1 Overview ··························································································32
4.2 Transmission system··········································································· 32
4.3 Intake and exhaust system······································································· 32
4.4 Function description of main parts····························································· 32
4.4.1 Air Filter··················································································· 32
4.4.2 Intake valve················································································32
4.4.3 Compressor Air End······································································32
4.4.4 Oil and gas tank··········································································· 32
4.4.5 Safety valve················································································33
4.4.6 Oil and gas separation core······························································33
4.4.7 Minimum pressure valve································································ 33
4.5 Cooling and lubricating system································································· 33
4.5.1 System flow··············································································· 33
4.5.2 Function description of main parts····················································· 33
4.6 control system and electric circuit······························································ 35
4.6.2 Electrical wiring and cables····························································· 35
Chapter 5 Operation and Use·············································································· 37
5.1 Safe operation regulations······································································· 37
5.2 Compressor steering check······································································ 37
5.3 Start································································································· 37
5.4 Running·····························································································37
5.5 Shutdown···························································································37
5.6 Precautions during running······································································ 37
1.2.2 Meshing
As the rotors mesh with each other, the male rotor directly drives the female rotor to rotate together.
The cooling lubricating oil is directly sprayed into the meshing part between the rotors through the nozzle
from the lower part of the compressor casing, and is mixed with the air to take away the heat generated by
compression to achieve the cooling effect. At the same time, an oil film is formed to prevent direct contact
between the rotors and close the gap between the rotor and the casing. The injected lubricating oil can also
reduce the noise caused by high-speed compression.
3.2 The layout of the air compressor room and the placement of the air
compressor
1)A gas storage tank should be installed behind the air compressor. The volume of the gas
storage tank should be more than 20% of the air compressor's exhaust per minute, and personnel
should be arranged to drain water regularly.
2)If the air compressor has a dryer, the air storage tank must be installed before the dryer so that
the compressed air discharged from the air compressor has proper buffering and cooling before
entering the dryer. The dryer needs a bypass valve for future Overhaul. (see. Figure1)
3) The air compressor should be placed directly on a level concrete floor that can bear the
weight of the air compressor.
4)Without special requirements, the air compressor does not need to be heightened or installed
with shock absorbers.
5) Keep a distance of more than 1.5 meters between the air compressor and surrounding walls
or other equipment, in order to facilitate the inspection and maintenance of the air compressor.
Figure 2:
Figure 3:
2)wiring
Wiring according to the control principle diagram of Ziqi compressor and the wire
specifications in the above table:
1.In the electrical cabinet of Ziqi Compressor, a wiring terminal is reserved for the user's
incoming line. The user can easily find this terminal. The user only needs to connect the incoming
line to this terminal and connect the protective ground wire in accordance with local requirements.
2. After checking that the wiring is correct, turn on the power and check, the motor rotation
should be the same as the steering sign on the compressor head, otherwise, please switch off the
power to change the position of any two phases in the incoming line, and reconnect the incoming
line.
Note:
a) Please note that wiring and maintenance work must be carried out in the case of power
failure,
b) There should be no too much stress during the installation of the cable, so as to avoid the
loosening of the cable in the future and cause a short circuit.
c) The cable should not be in contact with the metal port, so as to prevent the cable from being
cut and causing a short circuit in the future.
5.3 Start
1.Confirm that all preparations and inspections described in the installation chapter have been
completed,
2.Check whether the wiring is correct,
3.Check for leaks in the pipeline,
4.Check whether the oil level in the oil tank is between the upper oil level and the lower oil
level,
5.If the machine is shut down for a long time and then restarted (more than two months),
approximately 1 liter of lubricating oil should be added to the intake valve to rotate the air
compressor for several revolutions to prevent the compressor from losing oil and burning during
startup. Please pay special attention not to let foreign objects fall into the compressor body to avoid
damage to the compressor,
6. Press the compressor start button
5.4 Running
After the unit is turned on, it will enter normal operation. Check the operating parameters
during operation.
5.5 Shutdown
Press the compressor stop button and the compressor will stop after about 10-30 seconds.
5.6 Precautions during running
1.When there is abnormal noise or abnormal vibration during running, the machine should be
www.ziqi-group.com 37 Superior Quality ,Best After Sales Service
USER MANUAL
shut down immediately.
2.The pipeline and container are under pressure during running. Do not loosen the bolts or
joints of the pipeline.
3.During long-term operation, if the oil level on the oil level gauge is invisible and the
exhaust temperature gradually rises, shut down immediately. Observe the oil level after 10 minutes
of shutdown. If it is insufficient, replenish lubricating oil when there is no pressure inside the
system.
4.The pressure, temperature, oil level and other parameters must be recorded every day during
operation for reference for future maintenance.
Figure 1
︱——Start key: press this key to start the motor running
○——Stop key: press this key to stop the motor running
S——Setting key: After modifying the data, press this key to confirm the data storage input
▲——Move up key: When data is being modified, press this key to scroll up and modify the
digit; it is used as a selection key when selecting a menu
▼——Down key: When data is being modified, press this key to scroll down to modify the
digit; it is used as a selection key when selecting a menu
▶ — — Shift key/Confirm key: When modifying data, this key is used as a shift key; when
selecting a menu, it is used as a confirm key
C——Return key/Reset key: When the menu is operated, it is used as the return key to return
to the previous menu; when the fault stops, press this key to reset
After the unit is powered on, the following interface will be displayed:
Welcome to use
Screw Compressor
Outlet temperature:20℃
Exhaust pressure:0.6Mpa
Status:Stop
local
RUN PARA.
USER PARA.
FACTORY PARA.
CALBR PARA.
MOTOR(A) FAN(A)
A 0.0 0.0
B 0.0 0.0
C 0.0 0.0
If it is the last level of the menu, the interface will not appear black scroll bar, press the return
key "C" to return to the previous menu or main interface. If you stop operating on a certain
interface, it will automatically return to the main interface after a few seconds.
Use the "▲" and "▼" movement keys, the confirmation key "S" and the return key "C" to
fully observe the running time, current running time, maintenance parameters, historical faults,
factory date, field faults, etc. according to the above methods. Parameters and return to the
previous menu.
b. User parameters
1)Parameter modification method
P.T. SET
TIMER SET
OPERATION MODE
SEQ PARA. SET
MAX. P. 0.8MPa
MIN. P. 0.6MPa
FAN START : 0085℃
FAN STOP: 0075℃
If you do not continue to press the OK key "▶", you can view the user parameters. Then
press the OK key "▶" and the following interface will pop up to ask for the user password:
INPUT CODE
****
Note: The user password can be modified in the user parameters, and the factory password is
fixed at: 1688
After this interface pops up, a flashing bit appears. At this time, the "▲" and "▼" keys
become the up and down keys to modify the current position, and the "▶" becomes the shift key to
move the modified position, and finally press "S" to confirm the input . Pop-up interface:
LOAD P: 0.8MPa
UNLOAD P:0.6MPa
FAN START : 0085℃
FAN STOP: 0075℃
There is a "*" prompt in the upper right corner, indicating that the user parameter setting state
has been entered.
"▲" or "▼" changes back to move the black scroll bar, and "▶" changes back to the OK
button. Press the confirm key "▶" on the scroll bar at the "upper limit of pressure", a flashing digit
appears at this time, the "▲" and "▼" keys become the up and down keys to modify the current
position, and the "▶" becomes the shift key to move Modify the digit, press "S" to confirm after
inputting, the flashing digit disappears. The "▲" or "▼" changes back to move the black scroll bar,
and the "▶" key changes back to the OK key to continue to modify other user parameters. If you
do not need to modify other parameters, press the "C" key to return to the previous menu or main
menu. Use the same method to modify other user parameters.
E.g:
Maintenance plan Time
Maintenance A Every 500 operating hours or half a year, whichever comes first
Maintenance B Every 2000 operating hours or one year, whichever comes first
Maintenance C Every 4000 operating hours or two years, whichever comes first
Maintenance D Every 6000 operating hours or three years, whichever comes first
Maintenance E Every 8000 operating hours or four years, whichever comes first
Maintenance F Every 18,000 operating hours or six years, whichever comes first
Maintenance timer
Total running time 5971
Next maintenance time 6000 ABC
Last maintenance time 3000 AB
"Running time" means that the current total running time of the compressor is 5971 hours.
"Next maintenance time" means that the next maintenance schedule will be schedules A, B and C and
these schedules will be carried out after every 6000 operating hours.
"Last maintenance time" means that the maintenance schedules A and B were carried out after 3000
hours of operation of the unit.
Stop the compressor, cut off the power supply, and implement the maintenance measures related to
plans A, B and C; refer to the preventive maintenance plan.
After the maintenance is completed, turn on the power, find the "Maintenance Timer Reset" menu under
the "User Menu", and the maintenance time reset appears prompt.
Confirm the reset problem displayed on the screen.
The maintenance timer reset function is only effective when the next
maintenance time is approaching
Chapter 7 Maintenance
7.1 Preventive maintenance plan
Control Panel:
Before performing any maintenance, repair work or adjustment work, please follow
the steps below:
·Stop the compressor.
·Close the compressor outlet exhaust valve and completely relieve the pressure of the
compressor air system.
·Press the emergency stop button.
·Turn off the power.
·Depressurize the compressor.
For a detailed introduction, please refer to the common faults and troubleshooting
methods.
The operator must do the relevant safety protection。
Warranty-Product Liability
Please ensure that you use genuine parts. Any damage or malfunction caused by the use of counterfeit
substitute parts is not within the scope of product warranty or product liability!
Preventive maintenance kit
Excellent maintenance is the guarantee for the normal operation of the unit, and it is also a
prerequisite for reducing the wear of parts and extending the life of the compressor unit. Therefore, it is
very important to carry out preventive maintenance of the air compressor on a regular basis.
For preventive maintenance or overhaul of the machine, Ziqi Compressor provides a dedicated
maintenance package, which contains all the vulnerable parts required for machine maintenance, making
your maintenance easier and more convenient, and improving equipment reliability.
Maintenance contract
Ziqi Compressor provides services such as main engine replacement and overhaul, so as to relieve
or alleviate the user’s inability to carry out all preventive maintenance
Worry about work. For details, please contact the after-sales service department of Ziqi Compressor.
Overview
During maintenance, all removed seals, such as gaskets, O-rings and gaskets, must be replaced at
the same time。
Cycle
For compressors with different working environments and different working conditions, the
maintenance period is different. If necessary, please contact the after-sales service department of Ziqi
Compressor.
Except for the daily and monthly inspections, all maintenance operation
requirements have been compiled into plans, called maintenance plans A, B, C...
as determined in the following maintenance schedule.
Each maintenance plan has a set time interval. When the maintenance
interval is reached, the maintenance measures belonging to the maintenance plan
must be implemented. When the maintenance period is reached, a prompt
message will be displayed on the display of the computer controller, prompting
the operator which maintenance plan to execute.
cycle Operating
every day Check the oil level
″ Check the display reading
3 months Check the cooler,clean the cooler if necessary
Remove the air filter core, clean it with compressed air and inspect it.
If the compressor is running in a dusty environment, the number of cleanings should be
″ more.
If the air filter element is damaged or severely contaminated, please replace the air filter
element.
Check whether the electrical components are operating normally, and tighten the main
″
power supply terminals
8.1 Overview
Warning
The operator must do the relevant safety protection. When the compressor is
running or there is pressure in the system, please do not remove the nuts, end caps
and other parts. Maintenance and maintenance can only be carried out after
shutting down and releasing the stored internal pressure.
1. Make the unit always work at the ideal working temperature (below 95℃), which is good for
the performance and life of the machine.
2. The dirt can be removed by using a cleaning fluid, otherwise when the dirt is thick, the
cleaning work is quite troublesome, and the cooler needs to be disassembled and the cleaning work
can be completed by mechanical methods.
3. For specific cleaning of the cooler, please contact the after-sales service department of ZIQI
Compress
Maintenance content: the air filter element can be filled in: clean, replace; lubricating oil can be
filled in: add xx liters, replace xx brand; other items can be filled in: replace.
Electrical
On-site fault display Cause
failure
"Air end or fan short There is a short circuit or the rated current
Short circuit
circuit" setting is wrong
“Air end or fan Excessive load, bearing wear, other mechanical
Locked-rotor
locked-rotor” failures
"Air end or fan Excessive load, bearing wear, other mechanical
Overload
overload" failures, voltage imbalance
"Air end or fan
Default phase Power supply, contactor, motor phase loss, fuse
default phase"
"Air end or fa current Bad contactor, open loop inside the motor,
Imbalance
is unbalanced" unstable voltage
The inverter compressor adopts a compressor controlled by a frequency converter, and its
control system can change the motor speed according to the change of the user's air consumption, so
as to achieve the purpose of saving electric energy and stabilizing the air supply pressure.
When the user's gas consumption is relatively large, the control system makes the motor run at
full load; when the user's gas consumption is relatively small, the control system adjusts the working
frequency of the main motor through the inverter, thereby reducing the motor speed and exhaust
volume, which greatly saves energy Consumption, and can make the pressure of compressed air
stabilize at the set value, to ensure the stability of the air supply pressure.