Dato CSST13020 Instruction Manual
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Dato CSST13020 Instruction Manual

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SCREW AIR
COMPRESSOR
CSST13020
Instruction
Manual
Release August 2018

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  • Page 1 SCREW AIR COMPRESSOR CSST13020 Instruction Manual Release August 2018...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS 1. Safety Information…………………...………………………………………………4 Safety Alert Symbols………………………………………………………………4 Safety Precautions………………………………………………...………………...5 Pressure……………………………………..……………………………………….5 Fire and Explosion…………………………..……………………………………...6 Moving Parts………………………………………………..………………………6 Hot Surfaces…………………………….………………………….……………….6 Proper Compressed Air Applications..........6 Electrical Shock……………………………………………….…………………….7 2. General Information……………………………………………………………………8 Introduction…………………………………………………………………………8 The Compression Cycle…………………………………………………………….9 Compressor Lubrication and Cooling System…………………………..……...10 Compressor Discharge System…………………………………….……………..10 Air-end, Inlet Valve and Filtration System…………………………………….11 Control Panel Layout...…………………………………………………………..12 Technical Data……………………………………………………………..
  • Page 4 TABLE OF CONTENTS Manufacturer Parameters……………………………………………………….31 Control Principle………………………………………………….…………...39 Network Control…………………………………………………………………41 Temperature Control of Fan………………………………………….………….41 Failure Shutdown and Emergency Shutdown…………………………………..41 Early-Warning and Prompts………………………………………..…………...41 5.10 Control Protection……………………………………………………….....42 5.11 Common Failure Solving………………………………………...…………..44 5.12 Electrical Control Diagram ……………………………………………...……46 5.13 6. Servicing………………………………………………………………………………..47 Fluid Change………………………………………………………………..……..47 Air Filter……………………………………………………………………….…..47 Fluid Filter………………………………………………………………………..48 Air/Oil Separator………………………………………………………………….48 Maintenance Schedule…………………………………………………………….49...

  • Page 5: Safety Information

    Safety Information Thank you for choosing our Compressor. Please read this instruction manual carefully before using the compressor. This manual must be kept in the safe place for future reference. Our Compressor’s authorized distributors provide maintenance service for CS series rotary screw compressors. A certified technician is required to ensure compressors maintenance is safely handled.

  • Page 6: Safety Precautions

    Safety Information SAFETY PRECAUTIONS This manual describes the safety precautions, structure and functions of all systems and components, as well as the operation and maintenance methods for the GC series rotary screw air compressors. The owner and operator shall read the manual carefully. Only after thorough understanding should the machine be operated for the first time.

  • Page 7: Fire And Explosion

    Safety Information FIRE AND EXPLOSION Clean up any spills of lubricant or combustible liquid immediately. Keep sparks and flame away from the compressor. Do not permit smoking during servicing, such as checking or adding fluid. Wipe down spills immediately using industrial cleaner as required. Do not use flammable material for cleaning purposes.

  • Page 8: Electrical Shock

    Safety Information 1.8 ELECTRICAL SHOCK Never start the compressor unless it is safe to do so. Do not attempt to operate the compressor with a known unsafe condition. Tag the compressor and render it inoperative by disconnecting and locking out all power at the source or otherwise disabling its prime mover so others who may not know of the unsafe condition cannot attempt to operate it until the condition is corrected.

  • Page 9: General Information

    General Information 2.1 INTRODUCTION The GC series offer models with power ranging from 7.5 kw to 132 kw. The compressor is a single stage, positive displacement, fluid-flooded rotary screw. A complete unit of following: Screw air compressor ⚫ Dryer(optional) ⚫ Filters(optional) ⚫...

  • Page 10: The Compression Cycle

    2.2 THE COMPRESSION CYCLE The compressor housing contains of two rotors; Male and Female rotors. The male rotor has five lobes and female rotor has six flutes. They are constantly and precisely meshed, and housed in the cylinder with two parallel adjoining bores. All parts are machined to exacting tolerances.

  • Page 11: Compressor Lubrication And Cooling System

    2.3 COMPRESSOR LUBRICATION AND COOLING SYSTEM The lubrication and cooling system consists of a reservoir, centrifugal fan, fan motor, aluminum finned fluid-cooler and after-cooler, thermal valve & fluid filter. High pressure forces the lubricant through a series of direction changes in the reservoir where it is separated from the air.

  • Page 12: Airend, Inletvalve And Filtration System

    The minimum pressure check valve assures the reservoir maintains a minimum pressure between 58 psig and 72 psig (4Bar and 5Bar) during unloading conditions. This pressure is necessary for air/fluid separation and fluid circulation. 2.5 AIREND, INLETVALVE AND FILTRATION SYSTEM The compressor inlet system consists of a Kerry air filter, Kerry inlet valve.

  • Page 13: Control Panel Layout

    2.6 CONTROLLER PANEL LAYOUT Standard GC compressor is equipped with microprocessor control panel. Figure 1.1.1 ——Start Button: Press this button to start the compressor. ——Stop button：Press this button to stop the compressor. ——Set Button/ Loading / unloading Button: After modification, press this to confirm and save modified data；When the compressor is running ,press this button to load or unload under a certain pressure.
  • Page 14 ——Shift button /Enter button: This button services as shift button when data are modified and services as enter button when menu is selected. —— Back button / Reset button: This button services as back button when operate menu to come back parent menu; resetting is carried out by pressing this button for a little long time when failure shutdowns Always check power supply before you service the unit.

  • Page 15: Technical Data

    2.7 TECHNICAL DATA The specification of the models are as follow Model Pressure Capacity Weight Dimensions Main Motor Exhaust connection m3/min GC7.5-8 G3/4 800× 620× 800 GC7.5-8G G3/4 1020× 820× 1150 GC11-8 1020× 820× 1150 GC11-10 1020× 820× 1150 GC11-13 1020×...

  • Page 16: Fluid Information

    Fluid Information 3.1 FLUID GUIDE GC compressors are filled & tested with Kerry lubricant. Refer Figure 3-1 for filler port, sightglass, quarter-turn valve location on the reservoir. The compressor is filled with the manufacturer’s recommended quantity of Kerry fluid. Inspection of the reservoir fluid level during installation or operation is recommended.

  • Page 17: Installation

    Installation 4.1 COMPRESSOR MOUNTING, SUPPORT AND LOCATION Compressor should be located on a flat surface in a clean, well-lit and well ventilated area. The location must have sufficient access for maintenance equipment and lifting vehicle. Four feet (4’) of clearance around the compressor is recommended for daily inspection and easy access to all compressor components.
  • Page 18 Installation Do not install and operate compressor if the ambient temperature is below 5° C (41° F). Pre-heat option must be installed with the unit for lower ambient temperatures. NOTICE! The compressor air inlet must be located in the opposite direction to other compressors or heat generating equipment.

  • Page 19: Piping Connection

    Installation 4.3 PIPING CONNECTION Before installation, review the complete air systems layout, which includes compressor(s), receiver tank, dryer(s), line filter(s), pipe size, water drain and isolator valves. Never join pipes or fittings by soldering. Never use PVC pipe or non-genuine rubber hose in the air system.

  • Page 20: Fluid Level Inspection

    Installation Pressure relief valves are sized to protect the system. Never change the pressure setting or tamper with the valve. Only the valve manufacturer and their authorized representatives are allowed to make such changes. Pressure relief valves are used to protect system integrity in accordance with safety standards.

  • Page 21: Motor Rotation Inspection

    Our Compressor would like to emphasize the importance of providing adequate grounding for air compressors. The common practice of grounding units to a building’s structural steel may not provide adequate grounding protection, as paint and corrosion build-up may exist. All electrical supply cables must be adequately sized to prevent overheating due to current draw.

  • Page 22: Fan Rotation Inspection

    4.7 FAN ROTATION INSPECTION Fan motor rotation should be inspected. CS compressors uses an axial fan for cooling. Fan rotation is inspected through an arrow shaped observation hole above the fan motor. The fan must rotate in the direction indicated by the arrow. Always inspect fan rotation through the observation hole.

  • Page 23: Operation

    NOTICE Emergency shutdown. Press the emergency stop button or pull the circuit breaker at the main power terminal. NOTICE Operation CONTROL PANEL LAYOUT Standard compressor is equipped with microprocessor control panel. Figure 1.1.1 ——Start Button: Press this button to start the compressor. ——Stop button：Press this button to stop the compressor.

  • Page 24: Operating Procedures (Electrical Control Panel)

    ——Set Button/ Loading / unloading Button: After modification, press this to confirm and save modified data；When the compressor is running ,press this button to load or unload under a certain pressure. ——Move up button/increase button: Data at current position is increased by pressing this button when data are modified;...

  • Page 25: Display Unit Status And Operations

    After 5 seconds, the main page will show up as: PRES: 0.60MPa Main page SYS STOP C01 Operation Press shift button, the main page will show up as: TEMP: 80℃ Main page SYS STOP C01 Press “Move down button” to enter into Menu Selection Interface: RUN PARAMETER Level 1 menu screen USE PARAMETER...
  • Page 26 Continuously press “Move down button” you can see run parameters and run state parameters as follows: Fan current, Total run time, Total load time, This run time, This load time, Oil filter time, O-a filter time, Air filter time, Lube time, Grease time, Belt time……etc. Operation CUSTOMER PARAMETERS Parameter Modification...

  • Page 27: Customer Parameter And Functions

    The upper right corner with "* "prompt said the system has passed the password authentication. In as shown above interface, press “enter button” , then the data of loading pressure start to flash, users can press “increase button” or “Descending button” to modify the present data. When finished, press “Set Button”...
  • Page 28 LOAD DELAY The loading delay time after star pressure 0002S TIME descending. Load free continuous running time, the machine EMPTY DELAY 0020M will automatically stop after this time The machine will not stop until the load free STOP DELAY TIME 0010S running status lasting till this time Machine can not be restarted before this set time...
  • Page 29 Service as main or assistant air compressor during MASTER/S SEQ STATE interlocking operation. The MAIN controls the LAVE SLAVE During interlocking operation, if one air compressor continuously operates for time period more than time set here and rest time of one air TOGGLES TIME 9999 H compressor in interlocking network has reached...
  • Page 30 O/A FILTER RST 0000H Reset time for O/G Separator changing AIR FILTER RST 0000H Reset time for gas filter changing LUBE RESET 0000H Reset time for Lubricate Oil Changing GREASE RESET 0000H Reset time for Lubricate Grease Changing BELT RESET 0000H Reset time for Belt Grease Changing Set this value to “0”...

  • Page 31: Manufacturer Parameters

    Operation 5.5 Manufacturer Parameters The difference of the FACTORY PARAMETERS and the CUSTOMER PARAMETERS is that the FACTORY PARAMETERS can not be modified unless you have the initial password from the manufacturer. The modification method of the FACTORY PARAMETER is the same as that of the CUSTOMER PARAMETER. The main functions of the parameters are as the following table.
  • Page 32 Alarm and stop the machine when the air supply Stop P. 10Bar temperature reaches this set value Unload P. upper The Unload Limit Pressure in the Customer 8Bar limit Parameter must be set lower than this value. MODI LOAD The manufacturer can modify the load running ****Hours TIME time...
  • Page 33 Controller detects the voltage lower than the set value, the shutdown protection, reported voltage is too low. LOWER VOLTAGE ****V Set this value to 0000, the low voltage function is no function Controller detects the temperature is lower than this value, display LOW T PROTECT -48℃...
  • Page 34 b） Air temperature:-50～150℃；precision:± 1℃. c） Running Time: 0～999999Hours. d） Current Display Measuring Range: 0～999.9A. e） Pressure: 10～16Bar, Accuracy: 0.1Bar. 6. Phase-sequence protection: When protector inspects wrong phase, response time≤2s (optional)； 7. Protection of motor: this controller has five basic protection functions for main motor and fan’s motor ①...
  • Page 35 Time Para Action time 8. Temperature Protection: When the actual detected temperature is higher than the set temperature, the protection activates and the activate time≤2s. 9. The output relay contactor capacity: 250V 5A. The life time of the contactors: 500000 times of running.
  • Page 36 MAM970（B）（T） （V） （40） Maximum working current matching with host motor With voltage detection With RS485 communication B: pressure sensor; K: Pressure switch 970 controller Serial 2. Adopted motor Power Specification Parameter Suited main Current range motor power Remark Description (KW) Specification MAM970（20）...
  • Page 37 The installation of the mutual Inductor should be located at the places accessible for measuring the motor line current (rated current) so that the setting of the controller could be according to the nameplate of the motor. The recommended installation sizes are as below: Figure 2.
  • Page 38 specific dimensions are as follows: Figure 6 Controller structure dimensions Operation Terminal arrangement diagram...

  • Page 39: Control Principle

    △ 、 13 14 15 16 17 18 ub ua RS-485 Terminal blocks of controller： 1 is common terminal COM1；2 is input terminal for emergent stop signal； 3 is remotely controlled on/off signal input terminal；4 terminal is used to detect oil filter blocked；...
  • Page 40 （1）Local Automatic control ①press down start button for starting: (Y-△start) There is fives of self-test after controller is energized and it can not be started by pressing start button .The air compressor starts by pressing start button after self-test finished. The course of compressor’s start as followed: KM3 and KM2 are energized →...
  • Page 41 status of loading until gas supply pressure is less than loading pressure. If pressure is less than loading pressure, the unloading button do not function. ④. Normal shutdown: Press the button , the load magnetic valve will loss power and the unload magnetic will be applied with power, after a while of delay (stop delay), the motor contactor will loss power, the host and fan will stop running, after the restarting delay completed, the unload magnetic will loss power.

  • Page 42: Network Control

    ①: When communication method is set “computer”, network control between computer and controllers can be achieved ② : When communication method is set “interlocking”, network control between controllers can be achieved, but the main air compressor only can service as 1# compressor. 5.8 Temperature control of Fan When exhausting temperature is higher than fan’s starting temperature, fan operates;...

  • Page 43: Control Protection

    4, Indication of early warning for lubricating oil The Text displays “LUBE LIFE END” when the using time of the lube terminates. 5, Indication of early warning for grease The Text displays “GREASE LIFE END” when the using time of the grease terminates. 6, Indication of early warning for belt The Text displays “BELT LIFE END”...
  • Page 44 When the Air exhaust temperature is higher than the upper limit of set temperature, the controller would be stopped ,The display will show “HIGHT T”. 3, Non-reversing Protection of Air Compressor When three-phase supply phase sequence connected to the air compressor is not the same with that set for the controller, the on-site failure is displayed as “PHASE REVERSAL”, as a result, the controller cannot start up the motor.

  • Page 45: Common Failure Solving

    When a fault occurs, the controller in the main interface displays the current fault content. For example, when the pressure sensor failure, it displays the following interface: STOP: P SENSOR FAULT COMMON FAILURE AND THE CAUSES: Failure Reason Disposal method Air Exhaust Bad vent condition, Oil lacking Check the vent condition and...

  • Page 46: Electrical Control Diagram

    Voltage too low, tubes blocked, Check the set data, Voltage, Bearing Wear off or other Rotor Lock bearings, tubes and other mechanical mechanical failure or wrong set system. data etc. Wrong Wiring, Incorrect Data Checking the wiring and set the data Short Circuit setting etc.
  • Page 47 Servicing...

  • Page 48: Servicing

    The compressor requires the minimum amount of inspection and maintenance. The controller and indicator alerts the operator to perform required maintenance or repair unit problems. 6.1 FLUID CHANGE CS series compressors utilize a pressurized fluid drain. Use the following procedure to drain and replace the compressor fluid.

  • Page 49: Fluid Filter

    Intake filtration equipment supplied from the factory may not be adequate for extremely dirty applications or some forms of dust or vapors. It is the customer’s responsibility to provide adequate filtration for those NOTICE conditions. Warranty will be voided if inadequate filtration causes a failure. 6.3 FLUID FILTER The fluid filter is a spin on, full flow unit.

  • Page 50: Maintenance Schedule

    6.5 MAINTENANCE SCHEDULE This Schedule is intended to be used as a guideline only. Depending on the specific operating conditions of your compressor, maintenance requirements may vary. The instructions in this section will give more details about determining when specific service should be performed.

  • Page 51: Troubleshooting Guide

    Troubleshooting Guide Information below is a troubleshooting guideline; it describes symptoms and possible cause. Do not assume that these are the only faulty condition that may occur. Table 7-1: TROUBLE SHOOTING GUIDE Symptom Possible Cause Solution Fail to Start Power failure Check power supply to the unit Low incoming voltage Check voltage and power source, or...
  • Page 52 Troubleshooting Guide Table 7-1: TROUBLE SHOOTING GUIDE (Continued) Symptom Possible Cause Solution Compressor does not Faulty solenoid Repair or replace as necessary reload when service line Loose wiring connection Check and tighten wiring terminals pressure drops to reset Faulty proportional valve Orifice plugged.
  • Page 53 Troubleshooting Guide Table 7-1: TROUBLE SHOOTING GUIDE (Continued) Symptom Possible Cause Solution Unloading failure at Pressure loading setting Adjust as necessary working pressure, Solenoid valve failure Check and replace as necessary causing safety valve to Plugged air/oil separator Check and replace as necessary release pressure Air Intake valve stuck open Remove the intake hose and check the inlet...

  • Page 54: Standard Terms And Conditions

    Standard Terms and Conditions Standard Terms and Conditions Delivery and Title: The locations of shipment delivery will be made according to the Seller and Buyer agreement. Title and risk of loss pass to the Buyer upon delivery of the Product to the carrier.
  • Page 55 claim whether in contract, tort, warranty, or otherwise. Buyer will indemnify, defend and hold seller harmless from any claims based on (a) Seller’s compliance with buyer’s designs, specifications, or instructions, (b) Modification of any products by anyone other than Seller, or (c) use in combination with other products not supplied by seller.
  • Page 56 We reserve the right to amend on the manual. May the manual would have difference to the real products, please take the real products as standard or check with us by mail.

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