DT SERIES USER MANUAL - Detroit Air Detroit Air

DT SERIES USER MANUAL - Detroit Air Detroit Air

DETROIT AIR SCREW COMPRESSOR

DT SERIES

PARTS AND SPECIFICATION SUBJECT TO CHANGE WITHOUT PRIOR NOTICE. PICTURES AND DRAWINGS ARE FOR

ILLUSTRATION PURPOSES ONLY.

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DETROIT AIR SCREW COMPRESSOR

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DT SERIES – Creating affordable and reliable compressed air.

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DETROIT AIR SCREW COMPRESSOR

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—— Do not dismantle any part of the machine while in operation, risk of death or personal injury is very probable.

——

—— Pay attention to hot surfaces, risk of burns.

—— Do not exceed the machines rated pressure, this may lead to machine failure or shut-down. Only use the machine at the factory-set pressure.

—— Ensure proper cable connection and grounding. Use of under-rated power cable will result in damage to the cables and machine. and is toxic.

—— Do not breathe compressed air, it contains oil and other contaminants

Caution

*****Please read the maintenance manual carefully before maintaining or using the machine*****

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Regular maintenance interval schedule

Every 50 hours or weekly

--- Check oil level.

--- Check intake filter, if necessary clean it.

--- Drain condensation water from oil reservoir.

Every 500 hours

--- Check and adjust belt tension if necessary (belt driven only)

Every 1000 hours

--- Replace lubricants (for mineral oil)

--- Replace oil filter.

--- Replace intake filter.

Every 2000 hours

--- Replace lubricants (for synthetic oil)

--- Replace oil separator.

--- Clean the after cooler.

Attention:

1. Replace oil filter element and lubricant after the first 500 hours of operation.

2. Use of incorrect lubricant and spare parts will cause compressor damage, only use original manufacturer oil and parts. Use of non-original parts will void your warranty.

3. The service life of the compressor depends on the environmental conditions such as dust, heat, frequency of service, quality of service parts and lubricant.

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Warranty card

Product name

Customer name

Address

Maintenance

date

Reference

Contact

person

Maintenance content

Maintenance

man signature

Purchase date

Telephone

Customer signature

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Warranty period

Our products enjoy 1-year warranty calculated from the purchase date for the complete machine and two-year warrantee on the air-end.

The warrantee covers only parts. Labor, transport and any other cost of repair incurred will not be covered by the warrantee. Our company will not offer free of charge service or parts to repair damages due to installation errors, incorrect usage, maintenance errors and use of non- original manufacturer parts. Use of non-original service parts will void all warranties as will late or skipped servicing.

For routine or unscheduled maintenance note that Detroit Technical Service is able to provide you with assistance and spare parts as and when required.

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CONTENTS

1. General

7

1.1 Operating principals 7

1.2 System control 7

1.3 Operation temperature 8

1.4 Lubricant features 9

2. Installation requirements and inspection before running

11

2.1 Hoist and transportation 11

2.2 Field requirements

11

2.4 Connection requirements for air pipe 12

2.5 Electric installation requirements 13

2.6 Machine inspection 14

3. Daily operation

15

3.1 Preparations before running 15

3.2 Start-up procedure for the first time 16

3.3 Start-up procedure for the daily time 16

3.4 Turn-off procedure 16

4. Control panel

17

5. Control panel operation

18

5.1 Basic operation 18

5.2 PLC functions and technical parameters 25

5.2.1 Wiring diagram split type controller 27

5.2.2 Wiring diagram integrated type controller 28

5.3 Control principle 29

5.4 Alarm and notices 30

5.5 Safety protection 32

5.6 History failure record check 32

6. Maintenance

33

6.1 Maintenance items and maintenance interval 35

6.2 Maintenance of air intake filter 35

6.3 Maintenance of oil filter 35

6.4 Maintenance of oil separator 35

6.5 Maintenance of minimum-pressure valve and temperature control valve 36

7. Explored diagram/parts lists

39

8. Troubleshooting

47

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1. General

DETROIT screw air compressors adopt up-to-date European design and technology . All key parts such as screw air-end, electric motor, cabinet and pressure vessels are manufactured in house by Detroit

Air. Compressors are built to European standards with focus on high-efficiency, low cost, long service life and low power consumption. Detroit air-screws are computer controlled, monitored and protected to ensure best performance, efficiency and service life.

1.1 Operating principles

Compression: The air end sucks air through air intake filter and intake control valve, dual rotary shafts compress the air. Oil is injected into the air compressing cavity providing lubrication and cooling for the air-end.

Separation: The mixture of air and oil generated in the compression stage is exhausted into an air and oil separation cartridge. Most of the oil is separated from the air under the influence of gravity and mechanical centrifugal force. Almost all oil mist is separated out of the air in this stage by means of the separator cartridge core. Remaining oil content is below 3PPM. The oil separated through the separation cartridge core is fed back to the screw through an oil return tube. A valve is mounted on the oil return tube in order to keep the loss of compressed air to a minimum. The clean oil flows into the air end internal cavity after being filtered.

Cooling: After oil is separated, compressed air flows out of the separation element through a minimum pressure valve then into the after-cooler. The cooler cools the compressed air into a temperature range

7-10 degrees Celsius higher than ambient before it is discharged through the discharge pipe. The minimum pressure valve guarantees the minimum pressure needed to keep circulation of oil on start-up or when running normally. Due to the check valve on minimum pressure valve, the compressed air cannot flow back into the separation element.

1.2 System control

The aim of having a control system is to control the intake valve correctly to control air intake. The system is comprised of the intake valve, loading piston, solenoid valve and pressure gauge.

Start-up: the intake valve shuts under the influence of spring force. Hence only a little air is sucked through a single-direct valve on the intake valve to generate cartridge pressure to keep up circulation of oil when the screw air compressor is started up from no-load state.

Load: when the compressor is running in a load state, it creates a vacuum within the compressor. This creates a difference of pressure between the intake filter and the air end. A solenoid controlling the loading-head piston opens the intake valve and allows air to be drawn in and compressed. The air pressure on the compression side thus increases.

Full load: when the pressure of the oil separation cartridge reaches 0.4MPa, the minimum pressure valve opens to let compressed air flow out. (When the system pressure is lower than the rated pressure, intake valve will stay open.)

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No-load: when the discharge pipe’s pressure reaches the maximum pressure rated by the pressure switch, the switch cuts the solenoid valve’s power. As there is no pressure difference, the Intake valve shuts and the discharge solenoid valve releases pressure, thus reducing pressure in the separation cartridge. When the discharge pressure drops below the rated operating pressure, the cycle will repeat.

A minimum pressure is maintained in the system to ensure lubrication of the system.

Stop: when the compressor is shut down, all solenoid valves will be powered off. The intake valve will close and the discharge solenoid will release any remaining pressure in the machine.

1.3 Operating temperature

DETROIT Screw air compressors can operate in ambient temperatures ranging from 5 degrees centigrade to 40 degrees centigrade. Intake point is the measurement point.

Condensation---low temperature

When the ambient temperature is low water will condense in oil at a higher rate. This screw compressor is equipped with a thermostatic valve set to open at 70℃. Water vaporizes at 70℃. Oil will not pass through the oil cooler until the rated temperature is reached, thus preventing water condensation in the oil.

In areas of temperatures below 5℃ anti-condensation apparatus should be mounted and a heater should be installed under the separation element.

Overheating---high temperature

In environments with high ambient temperatures, air intake should be via ducting directly from outside the compressor room/location. For example: compressors installed in boiler rooms or high temperature environments must get their air intake for outside the room where normal ambient temperatures exist.

Discharge temperature

The measure point of discharge temperature is located in the vent/air-outlet of the compressor.

Discharge temperature would vary according to environmental temperatures, load percentage, cleanliness of cooler, cleanliness of intake filter and the cleanliness of oil filter. The normal operating temperature is between 70℃ and 90℃. When the compressor is started up from a cool condition the discharge temperature will increase to 85℃ quickly. The thermostatic valve will open fully at 70℃. The thermostatic valve controls the temperature accurately by constantly varying the oil-flow through the oil-cooler. Detroit compressors can safely run up to 109℃ after which the automatic overheat protection function will shut the machine down.

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1.4 Lubricant features

Properties of Detroit Airs crew oil:

Low degree of blister, non- volatile.

High degree of anti-emulsification. High degree of anti-oxidation.

Motion viscosity (40℃) ㎟/s 46.

Pour point temperature -35℃ anti-solidification, low energy-consumption.

Flash temperature 230℃, anti-carbon-deposit, and low-energy-consumption.

Oil for electric motor bearings:

Recommended: Shell Alvania RL 3

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S.N.

1

Name

Safety in electricity utilization

Symbol Description

Make sure the working supply voltage is off during operation

2

3

Danger! Electricity !

Danger warning

Watch out charged body ,leakage body and other electrical parts

Pay attention to and be careful about relevant warning information

4

Reading instruction the

Read the instruction before operation

5

6

7

8

Ignition hazard

Explosion hazard

Electric shock hazard

No air leakage

Inflammable and explosive materials must kept be away from the machine

Please don't weld or repair the air storage tank

Please don't place the equipment in wet places or outdoors to avoid electricity leakage due to reduction in electrical insulation resistance

No air leakage here

9

10

Caution, hand injury

Rotational direction of the motor

11 Danger, hot!

11

Don't touch transmission part

Check rotational direction of the motor during the process of first starting up or changing wire to avoid serious breakdown to the machine

Hot surface, avoid burns

DETROIT AIR SCREW COMPRESSOR

DT SERIES

Installation information

2. Installation requirements and inspection before running machine

Examine the machine for any damage whatsoever cause by installation or transport. Do not run this machine if it has been damaged. Please report damage to your agent before commissioning.

2.1 Hoist and transportation

Guide ropes should be used when compressor is being hoisted to avoid damage. Check for welding cracks and loose bolts after it is lifted. As the below figure shows a supporting board is needed when the compressor is being hoisted.

When using a forklift to move the compressor, ensure the forks can cover the entire base length of the compressor. Never use under-rated lifting or towing equipment to move machinery. Ensure the machine is secure when being lifted or towed on a trailer.

The length of fork should not be less than the length of the base of compressor.

2.2 Installation requirements

The compressor should be located in a clean, dust-free, well-ventilated location. Air should not contain toxic or flammable gasses.

The compressor should not be placed outside unless well protected from the elements. Should the environment be dusty, dust filters should be placed on the intake vents.

Environmental temperature should be above 5℃ to guarantee normal lubricant cycle.

Some space (1m between the wall and compressor) must be set aside in order to make daily maintenance work convenient and allow for sufficient airflow. See figure3.

Compressor should be placed on a solid level surface. Do not bolt it down.

If compressor is mounted in an enclosed room, an exhaust fan must be mounted in this room to keep the room cool. The extractor fan should be able to cope with a higher volume of air than the air compressor after-cooler system can produce.

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WARNING:

In order to avoid damage caused by transportation safety bolts have been installed. The user must lock in the bolt before transportation and loosen it before usage, shown below.

S t a b i l i z e r b o l t f a s t e n e r s

2.4 Discharge pipe connection requirements

The diameter of discharge pipe should be at least the same as that of the compressors outlet. All pipes and connectors should be able to bear the rated pressure. The configuration should meet the requirements for flowing velocity of the produced compressed air and the pressure drop of pipeline must not exceed the set pressure by 5%. Try to avoid using restrictive bends of small diameter piping. If the pipeline is relatively long, use pipes with a diameter exceeding the discharge pipe diameter on the compressor.

Never let condensate flow into a working machine from the air compressor. Always put a water filter and separator system that removes water, oil and solid particles before it reaches production line machinery.

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Install the pipeline leading to the pre-filter system at a 1 to 2 degree down slope. This will make water drainage more efficient.

A one-way stop valve should be mounted at the air outlet of the compressor to allow for simple shut-off and maintenance of the system.

Due to the anti-vibration design and rubber mounted after-cooler, all external pipelines should be supported externally. In order to prevent water condensate from flowing back into the machine after shut-down, configure the out-going pipe suitably.

When compressor is used with an air dryer an air reservoir should be installed in between compressor and drier. This allows the air to cool and water to condensate inside the pressure vessel. This configuration greatly reduces load on the drying system thus saving energy.

Installation of a ring-main system is recommended as it reduces pressure drop when load increases. Ring

–mains also allow for easy maintenance of the distribution system without the need to shut-down air supply.

2.5 Electric installation requirements

All internal electrical systems of the compressor are thoroughly tested during the manufacturing process.

All external power connections should be to proper specification for the electric motor power requirements.

Ensure the electrical systems are installed by competent persons only and that the length and gauge of power cable have been taken into consideration. No warranty will be given for electrical damage of any kind.

Each compressor should be on its own circuit breaker system. Make sure that power supply voltage meets the rated working voltage of the compressor before running it. Reliable grounding of the compressor set is needed to avoid earth leakage.

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Power supply

Minimum cross area of power cable (Copper wire mm

2

)

Model

DT-30

DT-50

DT-75

DT-100

DT-10

Motor power

(Kw)

22

37

55

75

7.5

16

35

50

70

6

Cross-section

(mm

2

)

DT-15 11 10

DT-20 15 16

Rotational direction of the motor

Power must be linked to the compressor correctly to guarantee the correct rotation of the electric motor.

DETROIT screw air compressors are equipped with a rotation monitoring system. The electric motor will not start-up unless the phases are in the correct order.

Commission as follows: First - switch on power. Second - loosen the emergency button. Third - press the stop button. The machine will then run a self-test. Press the start button. If the machine runs normally the 3 phases are correct. Should the motor stop automatically swap any 2 phases. Do not change any wiring on the machine to force a start. This may damage your machine.

2.6 Machine inspection

Inspection of screw air end

Revolve the belt pulley (belt drive) or shaft coupling (direct drive) of gear end by hand. Rotate the drive shaft by hand in both directions back and forth to ensure the rotors are free.

Should the compressor be out of use for more than 2 months open the intake valve and pour about half a litre of oil into the loading-head. Rotate the drive shaft back and forth and ensure the oil enters the air-end.

When reconnecting the inlet pipe make sure the nozzle is sealed.

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Inspecting oil level

When opening the side door, you will see the oil inspection tube. The maximum oil level must not be above the upper part of oil inspection tube, the minimum oil level must not be lower than the bottom of the oil inspection tube. The oil level will differ when the machine is running. Check oil level only 30 minutes after the machine has been turned off.

Add the rated amount of oil. Make sure the lid to the nozzle is screwed on well and the seal ring is in good condition.

Tip: Too much oil will cause compressed air to contain excess oil, too little oil will lead to high operating temperatures.

O il inspe ct ion tub e

Inspection of transmission system

Inspect belts

Check if all belts are in the pulley grooves. Adjust the tightness of belts through the adjusting bolt on motor.

Inspect the flexible coupling on the drive shaft.

Check the bolt of the flexible shaft coupling is properly tightened.

Inspection for all valves in the system

Check valves for leaks and proper operation.

3. Daily operation

The procedure below is for starting up for the first time or for the start-up procedure for the compressor after not being in use for more than two months.

3.1 Preparation before running

DETROIT screw air compressors have an advanced delay-start/delay-stop function. This function protects the motor, air-end and electromagnetic starter so as to optimize operating performance.

Delay-start: This function is to avoid starting up continuously after power cuts or emergency shut downs.

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During this period, the compressor cannot be started-up. Make sure there is no pressure in the system to avoid start-up when there is backpressure. Press the start button and wait for the delay-time to elapse, then the machine will start automatically.

Delay-stop: This is a soft stop function. This function makes the compressor unload and shut-down. Press the stop button, the shut-down procedure will begin and the compressor will unload. The machine will continue to run for a few moments and then turn-off once the system pressure has been reduced. If the start button is pressed during the unload procedure, the system will cancel the shut-down and continue to operate normally.

3.2 Start-up procedure for the first start

Check if the stop valve on the outlet is open. (If the stop valve is open, this pressure is the pressure of the compressor system)

Turn power on, the power indicator light will illuminate. The compressor begins the delay-start procedure.

Starting instantly is not possible.

Press start button to run the compressor, the delay-start procedure will complete and the compressor will load.

Check the operating temperature and pressure are stable and correct.

Once the compressor has reached the operating pressure it will continue to run but will unload.

Check that the output pressure is correct, ensure the machine is running as it should, without vibration.

3.3 Daily start-up procedure

Check if oil level is correct. The oil level must be in the center of the oil gauge.

Drain the water condensate from the external pressure vessel.

Confirm the stop valve is open.

Press start button. (If the compressor does not start up automatically and the run light is flashing, it means compressor is in a delay-start state.)

Attention: Do not start up within 60 seconds of shut-down. The system must not start up under pressure.

3.4 Shut-down procedure

Press the stop button, the compressor will commence the shut-down procedure, the stand-by indicator light will be flashing. After some time, the compressor stops.

If the compressor is start stopping, press the stop button to make it stop properly.

Attention: when compressor is in stand-by, it may stop and may start up at random. Do not take it for granted that the compressor has been stopped when the motor is not in motion. Check if the stand-by light is on to confirm.

Tip: emergency shut-down button is only to be pressed in case of an emergency.

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T Y P E : M A M - K Y 0 2 S ( B ) - ( Ⅷ )

Attention

Please read this manual carefully before operation.

Only Authorized technicians are may install MAM.

Please take into consideration the installation environment during the installation to ensure good ventilation and to minimize electromagnetic interference.

During the wiring procedure, please separate the high current and light current lines to reduce electromagnetic interference.

A surging protector must be installed to the inductive load systems such as AC contactors of the relay outputs

Check carefully when wiring the input/output before applying power.

Correct grounding of the ground terminals of the unit (Third grounding) can improve the anti-noise capability of the unit.

The pre-setting of the rating current of the motor is set to the rated current on the name plate X

Motor overload factor/1.2.

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Features:

● LCD display

● Full protection function for the motor against short circuit, ceased rotor, phase drop, overload or unbalance.

● Start/Stop and operating control of the motor.

5. Control Panel (for 18.5-250kw)

● Rotation protection of the air compressor.

● Measuring, protecting and controlling temperature vital systems.

● Automatic adjustment of load rating to balance pressure.

● High Integrity, stable reliability and excellent performance.

● Optional remote / machine side control.

● Optional interactive/ independent operation.

● RS-485 communication interface function.

5.1 Basic Operation

ON

GAS T:80℃

GAS P:0.8MPa

STATE NORMAL STOP

0S

M

REMOTE

Button Description Figure 1

ON——Start Button: Press this button to start the motor.

OFF——Stop Button: Press this button to stop the motor.

M——Set Button: Press this button to confirm the input data to be saved after modification of data.

——Up button: Press this button to move upward during modification of data. Press this button to select menu during the menu selection.

——Down Button: Press this button to move downward during modification of data. Press this button to select menu during the menu selection.

——Cursor / Confirm Button: This button can be used as cursor during data modification and as a confirm button during menu selection.

RT——Return/reset Button: Press this button to return to upper-level menu during the menu operation. Press this button to reset the machine when the unit has stopped in failure.

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Status Display and Operation

The display interface is as following when POWERED ON:

Welcome to

**Screw Air Compressor**

The main display after 5 seconds will be the following:

GAS T:20℃

GAS P:0.60Mpa

STATE:NORMAL STOP

NEAR

Press “” Enter the following Menu Selection Interface:

RUN PARAMETER

CALENDAR

CUSTOMER PARAMETER

FACTORY PRAMETER

Run the Parameter Review

Press ‘’or ‘’ to move the black cursor over the menu ‘RUN PARAMETER’and then press ‘’ into the submenu:

HOST、FAN CURRENT

TOTAL RUN TIME

CURRENT RUN TIME

MAINTENANCE PARAMETER

Press ‘’ to into the next menu:

CUR(A):R S T

HOST: 56.1 56.2 56.0

FAN: 4.1 4.1 4.1

If the display menu is the last menu level, the black cursor will disappear, press the RETURN button ‘RT’ and return to the upper menu or the main interface. If the operation is stopped in a certain interface, it will automatically return to the main interface after several seconds.

Using the moving buttons ‘’ ‘‘, confirm button ‘’ return button ‘ RT’ to view the RUN

PARAMETERS such as: CURRENT, RUN TIME, MAINTENANCE PARAMETER, HISTORIC FAILURE,

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PRODUCTION DATE and CURRENT FAILURES and then return to the upper menu with the similar method of the above.

Calendar and Time

Press ‘’ or ‘’ to move the black cursor to the menu ‘CALENDAR’ and then press ‘’ , the following menu will pop up:

DATE AND TIME

2004 Y 2 M 22 D

SUNDAY

12 H 46 M 59 S

2

At the stop status of the unit, the date and time can be adjusted by the following steps: Press ‘’ or ‘’

0 to move the black cursor to the parameters you want to modify and then press ‘’ to reach the

0 blinking position. Now the button ‘’ and ‘’ change to ‘Page-up’ and ‘Page-down’ button. Press ‘M’

4

button to confirm and save the data after finishing the modification. The buttons ‘’ or ‘’ return to

年 black cursor move button and the button ’’ changes back to its Return function.

2

2

CUSTOMER PARAMETERS

2

Tips: The Customer Parameters and the Factory Parameters cannot be modified during operation

星期日

The Customer Parameters could be read and modified by the same method of running the

Parameter Review mentioned above. For example, to modify the parameter BLOCK UNLOAD

PRESSURE, the steps will be as follows:

Press ‘’ or ‘‘ to move the black cursor to ‘CUSTOMER PARAMETER’ menu and then press the

CONFIRM button ‘’ to pop up the menu:

SET P、T

ON/OFF DELAY PRESET

OP. MODE PRESET

BLOCK PARA PRESET

Press the CONFIRM button ‘’ again to reach the following menu:

LOADING P 0.8MPa

UNLOADING P 0.6MPa

FAN START T 80℃

FAN STOP T: 70℃

星期日

21

2

2

2

2

0

0

4

2

2

2

2

0

4

星期日

DETROIT AIR SCREW COMPRESSOR

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The CUSTOMER PARAMETERS can be read now when the CONFIRM button ‘’ is not pressed now.

Press the CONFIRM button ‘’ again to pop up the following interface where the password input is required:

ENTER

PASSWORD

Note: The Customer Password can be modified in the CUSTOMER PARAMETER, the FACTORY

****

PASSWORD is only available from your Detroit Authorized agent.

The Blinking Position will appear after this interface is displayed. The button ‘’ and ‘’ have been changed to PgUp and PgDown button that can be used to change the current value. The button ‘’ is changed to a move button to move to the position where the modification is needed, Press ‘M’ to confirm and the following interface will be displayed:

BLOCK LOAD P

:

0.8MPa *

When there is a ‘*’

BLOCK UNLOAD P: 0.6MPa displayed at the top right

FAN START T: 80℃ corner, it means it is at

FAN STOP T: 70℃

星期日 the CUSTOMER

2

0

0

2

2

2

2

0

0

4

The ‘’ or ‘’ button returns to black cursor function and the button ‘’ returns to be the CONFIRM

年 button function. Press the CONFIRM button ‘’ when the cursor is over the menu ‘ BLOCK UNLOAD

PRESSURE’, now blinking, appears and the button ‘’ and ‘’ have been changed to PgUp and PgDwn

2 button function, move to the position where the modification is needed, Press ‘M’ to confirm and the blinking position will disappear. The ‘’ or ‘’ return to black cursor function, the move button

日 and the button ’’ change back to the CONFIRM function to continue to modify the other

CUSTOMER PARAMETERS. If there are no other parameters needed to be modified, press the button

RT’ to return to the upper menu or the main menu. The other CUSTOMER PARAMETERS could be modified with the same method above.

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CUSTOMER PARAMETERS

First Submenu

SET P. T.

ON/OFF DELAY

TIME PRESET

OPERATION

MODE PRESET

Second submenu

UNLOAD P.

LOAD P.

FAN START T.

FAN STOP T.

HOST START TIME

FAN START TIME

STAR DELAY TIME

LOAD DELAY TIME

EMPTY DELAY

STOP DELAY TIME

START DELAY TIME

STANDBY DELAY TIME

DRAIN OPEN TIME

DRAIN CLOSE TIME

ON/OFF MODE

LOAD MODE

COM MODE

Preset

Value

*.**Mpa

*.**MPa

***℃

***℃

0008s

0006s

0006S

0002S

0020M

0010S

0100S

0000S

0002S

0010M

Machine side

Auto

Prohibited

Functions

Unload pressure value

Load pressure value

Control fan starting. This value will be set to ‘120℃' if there is no fan present or the fan is not required.

Control the stopping temperature of the fan

When using the controller to protect the motor, it is required that the time here defined will not meet the impulse starting current of the motor, the value here must be longer than the STAR DELAY TIME plus

LOAD DELAY TIME

When using the controller to protect the motor, it is required that the time here defined will not meet the impulse starting current of the motor.

Star contactor release starting delay time.

The loading delay time after the star contactor released.

The machine will automatically stop after this time of being unloaded.

The machine will not stop until this time elapses on shut-down.

Machine can not be restarted before this set time after stopped or over time operation at a load free state.

Additional function.

The continuous draining time during the automatic drain function.

The duration the automatic drain will stay shut between opening.

When the remote mode is set, both the buttons at machine side and the remote control button can turn the machine on and off.

When the manual mode is set, the

Load/Unload function can only be executed by pressing buttons.

When this is set to ‘PROHIBIT’ the communication function is not available.

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COM CODE

BLOCKING

PARAMETERS

PRESET

MAINTENANCE

O/A RESET

PARAMETER

AIR FILTER RESET

PRESET

MAX LIFE TIME

PRESET

LANGUAGE

SELECT

NEW USER

PASSWORD

BLOCKING MODE

BLOCKING ON/OFF

SWITCHING TIME

BLOCK NUMBER

BLOCK LOAD P

BLOCK UNLOAD P

BLOCK DELAY TIME

OIL FILTER RESET

LUB OIL RESET

LUB GREASE RESET

OIL FILTER

O/G SEPARATOR

GAS FILTER

LUB. OIL

LUB GREASE

0255 Communication address.

HOST

Sequence controls the SECONDARY.

9999 Hours

Act as Host or Secondary Machine when there are more than one machines running in blocking mode. The HOST

0016

*.**MPa

*.**MPa

0000S

0000

HOURS

Reset time for the duration of oil filter changes.

0000Hours Reset time for O/G Separator changes.

0000Hours Reset time for air filter changes.

0000Hours Reset time for Oil Changes.

0000Hours Reset time for Greasing bearings.

9999Hours

9999Hours

Setting this value to ‘0’ will make the oil filter alarm null.

Set this value to ‘0’ to disable the O/G separator alarm function.

9999Hours

9999Hours

9999Hours

English

Set this value to ‘0’ to disable the alarm for the air filter.

Set this value to ‘0’ to disable the alarm for lubricant change.

Set this value to ‘0’ to disable the time alarm of lubricating grease .

Set to ‘ENGLISH’ will change the interface to English.

Customer can modify the user password.

****

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FACTORY PARAMETERS

The difference of the FACTORY PARAMETERS to the CUSTOMER PARAMETERS is that the FACTORY

PARAMETERS cannot be modified unless you have the initial password from the factory. The modification method of the FACTORY PARAMETER is the same as that of the CUSTOMER PARAMETER.

The main functions of the parameters are as follows:

PARAMETER Initial Value

HOST RATED CURR.

Maximum overload value of the motor /1.2

Functions

After the start- delay time, if the motor current is greater than 1.2 times of the set value or less than 4 times the set value, the unit will activate the overload feature.

FAN RATED CURR.

Maximum overload value of the fan motor

/1.2

Same as above

PRE-ALARM T

MODI LOAD TIME

MODI TOTAL TIME

HISTORY FAULT

RESET

STOP T.

STOP P.

UNLOAD LIM P

UNBALANCE SCOPE

LACK PHASE STOP

105℃

110℃

1.00MPa

0.80MPa

****Hours

****Hours

****

0006

0005

0000 M

****Y**M**D

******

Alarm sounds when the temperature reaches this set value.

Alarm sounds when the air exhaust temperature reaches this set value.

Alarm and stop when the air supply pressure reaches this set value.

The Unload Limit Pressure in the Customer Parameter must be set lower than this value.

The factory can modify the load running time.

The factory can modify the total running time.

Input the history failure password to clear all the history failures.

When (the max. phase current/min. phase current) is greater than (1+set value), the unbalance protection will stop the machine. If the set value is greater than

15, the unbalance protection will be disabled.

Set the LACK PHASE TIME ≥20S, the Lack phase protection will be disabled.

The factory inputs the product date of the unit.

The factory inputs the product No. of the unit

PROD. DATE

PROD. NO.

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5.2. PLC Functions and Technical Parameters

Switching value: 8 ways of switching the value input. 10 ways of relay switching the value input.

Analog quantity:2 Pt100 temperature input; 2 ways of 4~20mA transferred input; 2 groups of 3 phase current input (Match with CT)

Input voltage of phase sequence: 3 phase 460V/230V.

Working power of controller: 100V-220V, 50Hz/60Hz, 20VA.

Display measuring Range:

Oil Temperature: —20~150℃; Accuracy: ±1℃.

Air Temperature: —20~150℃ Accuracy: ±1℃.

Running time: 0~999999 hours.

Current Display Measuring Range: 0~999.9A.

Pressure: 0~1.60Mpa, Accuracy: 0.01Mpa.

Phase sequence Protection: When the protector detects the wrong phase sequence, it activates for

≤2s.

Motor Protection: This control unit has the following 5 basic protection functions.

-Rotor Lock protection: After the starting of the motor, if the working current reaches 4 or 8 times

the set value, the protection activates. The activation time is less than 0.2s.

-Short-Circuit Protection: if the detected current reaches 8 times or more above the set value,

the protection activates in less than 0.2s.

-Drop phase protection: Any of the phases drop the protection activates as per the set time.

-Unbalance Protection: Current difference between any of the two phases reaches the percentage

of the setting value, the protection activates in less than 5s.

-Overload anti-time limitation protection (time unit: s): See the following table. The multiple=I

Actual value/I Set Value.

When the running current of the motor is in 1.2 ~3.0 times of the set value, the overload multiple and action delay time will be accordance with the following table.

Iact/I set

Time Para

≥1.2 ≥1.3 ≥1.5 ≥1.6 ≥2.0 ≥3.0

Action time 60 48 24 8 5 1

-Temperature Protection: When the actual detected temperature is higher than the set temperature,

the protection activates, the activation time ≤2s.

-The output relay contactor capacity: 250V 5A. The life time of the contactors: 500000 contacts.

-The current display tolerance <1.0%.

-RS—485 communications.

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Controller installation

The Controller will be installed in the control cabinet.

There must be enough space around the controller for accessibility when wiring. The recommended sizes are as below:

04, 05, 06 and 07 relatively correspond to the input switching value terminals of 20,

19, 18, 17, 16, 15, 14 and 13.

2. Output LCD(OUT)

00, 01, 02, 03, 04, 05, 06, 07, 08 and 09 relatively corresponded to the output switching value terminals of 27, 28, 29, 30, 31,

35, 36, 37, 38 and 39.

Diagram 6: Main Control

Unit Structure Size

3. Power LCD:PWR

4. Running LCD: RUN LCD

5. FAILURE LCD: ERR LCD

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5.2.1 Basic wiring diagram of the split type electronic Installation.

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5.2.2 Basic wiring diagram of the integrated type electronic Installation.

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Text Display connector terminals:

There are five connection terminals and one D type display cable connector which are used for the display connector, Rs—485 communication interface and 24V Power input

Controller Connection Terminals:

The display panel is connected to the controller using communication cables. 23, 24 and 25, are the phase sequence input terminals; 7 and 9 are the Air Exhaust Temperature Input terminals; CT1 is the host motor contactor; CT2 is the fan motor contactor. 32 is the common port COM1 of the relay output; 27 controls the main contactor; 28 controls the star contactor; 29 controls the angel contactor; 30 is the loading solenoid valve; 31 controls the Fan; 34 controls the Load release valve: 37 is the running indicator;

38 is the Failure indicator; 39 is the Alarm indicator; 40 is COM2; 42 is the simulated ground (Earth); 43 and 44 are the 220V power source.

Attention: the transformer must be connected to a surge protector when wiring

5.3 Control Principle

Individual Control

-Local Automatic control (ON/OFF mode: User operated; Loading method: Automatic)

Press ‘I’ to start: (Y—△ Starting)

When the controller is powered on, it will perform a 3S self-check. Press the ‘I’ button, the machine will not start until self-checking is completed. The starting process of the host will be as follows:

KM3 is powered on, KM2 is Powered on  Y type Starting Status  Time Delay finish(Y—△ converting time), KM3 loses power (KM1 and KM3 interlocked) ,KM1 is powered on  Motor runs in △ type and starting is completed. The load solenoid valves are without power during the whole starting process to ensure load free starting.

Automatic Run Control:

When the motor is started in △ state and loads, the solenoid valves will be activated. The air compressor will load and compress air until the pressure in the discharge reaches the pre-set unload pressure value. The compressor will then unload as the solenoid valve loses power, the loading head valve closes. Should the compressor be unloaded for extended periods the control system will shut the motor off until such time as the pressure in the system drops below the LOAD PRESSURE VALUE.

At this time the control system will restart the machine.

Manual Load/unload in automatic status function

At the automatic status function, the unit will stay in the unload state, press the button ‘’ to load, if the pressure is higher than the unload pressure, the loading solenoid valve will close once and then return to the unloaded status; if the pressure is lower than the unload pressure, the loading solenoid valve will be activated. The unit will not unload until the air supply pressure becomes higher than the unload pressure. When the unit is in the load state, press the button ‘’ to unload.

If the pressure is higher than the load pressure, the loading solenoid valve will lose power and return to the unload state until the air discharge pressure becomes lower than the load pressure. If the pressure is lower than the load pressure, unloading is disabled.

Normal Stopping:

Press the button ‘O’, the loading solenoid will lose power and the unloading solenoid activate, after

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Frequency starting prevents control

The motor cannot be started immediately after shutdown. Should the system be started up again a time delay countdown will begin. The system will restart once the timer reaches “0”.

-Remote Automatic Control (ON/OFF mode: Remote; Load mode: Automatic)

The remote automatic control is almost the same as the local automatic control, the only difference is that the start and stop of the unit is controlled by remote control.

-Local Manual Control (On/Off mode: User operated; Load mode: Manual)

This starting and stopping control is the same as the automatic control, the only difference is that when the starting procedure completes in this mode, the machine is at the load free state and will be loaded by pressing the button ‘’. When the air supply pressure is higher than the unload pressure, the unit will load automatically, if the button ‘’ is not pressed to load, the unit will be running at the load free state until the load free stop is activated by the PLC. During the unloaded stage, press the button ‘’ to load and during the loaded stage, press the button ‘’ to unload.

-Remote Manual Control (On/Off Mode: Remote; Load mode: Manual)

The remote automatic control is almost the same as the local manual control, the only difference is that the start and stop of the unit is controlled by remote control.

-Network control

When the control network is set to ‘COMPUTER’, it can be controlled by a computer network.

Set the controller communication to ‘BLOCKING’ to enable network control between the machines.

The master control machine to which all other compressors are linked must be #1 controller.

-Fan Temperature control

When the air exhaust temperature is higher than the fan starting temperature, the fan motor will run; when the air exhaust temperature is lower than the fan stop temperature, the fan motor will stop running. If there is no fan or the fan is not necessary, set the starting temperature of the fan to ‘120℃’ and the stop temperature to ‘70℃’.

Failure stop and Emergency stop

When there is any electronic failure or high temperature alarm during the running process, the controller will stop the motor immediately. The motor can only be restarted after the failures are cleared. Should any emergency situation occur, please press the emergency stop button to cut off the power supply to the controller and motor contactors.

5.4 Alarm and Notices

Text Display tips

Air-filter Alarm tips:

Check the alarm using the switch signal

The controller can display the message on the LCD display to show the operator ‘ the air filter is blocked’ by checking the air pressure state.

Set the running time alarm of the air filter

The LCD displays ‘Air filter life end’ when the usage time of the air filter expires.

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Oil Filter alarm tips:

Check the alarm using the switch signal

The controller can display a message on the LCD display to show the operator that ‘the oil filter is blocked’ by checking the oil pressure state.

Set the running time alarm of the oil filter

The LCD displays ‘Oil filter life end’ when the usage time of the oil filter expires.

Oil separator alarm tips:

Check the alarm using the switch signal

The controller can display the message on the LCD display to show the operator that ‘the oil separator is blocked’ by checking the pressure state.

Set the running time alarm of the oil separator

The LCD displays ‘Oil separator life end’ when the usage of the oil separator expires.

Lubricant oil alarm tips:

The LCD displays ‘Lubricant Oil life end’ when the usage time of the lubricant oil expires.

Lubricant grease alarm tips:

The LCD displays ‘Lubricant grease life end’ when the usage time of the grease expires.

Main Controller Tips

Item Meaning and Functions Lights Status

POWER

RUN

Failure

Input Switching

Value

Output Switching

Value

Controller Power on

Controller run

Detect failure and stop

Terminal 20~12 Input switching value activated

Terminals 27,28,29,30,31,35,36,37,38 and 39 output switching value activated

PWR Light

RUN Light

ERR Blinking

IN00~08 lights, but if there is no function at the input point, no light illumination

OUT00~09 lights

Data Save Set data and save time PWR blinking once

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5.5 SYSTEM SAFETY PROTECTION

Motor Protection

MAM air compressor controller can perform short-circuit protection, rotor-lock protection, overload protection, phase-drop protection and unbalanced voltage protection for the motor.

Electronic failure

Failure Display Possible Causes

Short-Circuit

Rotor lock

OVERLOAD

Phase Lack

Local Failure display ‘Host or Fan short-circuited’

Local Failure display ‘Host or Fan Rotor

Locked’

Local Failure display ‘Host or Fan

Overloaded’

Local Failure display ‘ Host or Fan Phase

Lacking’

Short-circuited or the rated current is incorrectly set

Overloaded, bearing wear or other mechanic failures

Overloaded, bearing wear or other mechanic failures

Phase drop occurred to power or the contactors

Unbalance

Local Failure display ‘Host or Fan current unbalance’.

Contactors are not contacting correctly or the motor core is damaged.

Air Exhaust overheat protection

When the air exhaust temperature is higher than the set limited unload temperature, the controller will alarm and stop the machine. LCD displays ‘Air Exhaust High Temperature’.

Reverse rotation running protection

Attention: When the phase sequence of the power connected to the air compressor is not conforming to the input of the controller, the LCD displays ‘Wrong phase sequence’ and as a result the controller will not start the motor. Check and alternate any two of the phase inputs and check rotation direction.

Over Pressure protection

When the pressure of the air exhaust is higher than the set stop pressure of the controller, the controller will alarm and stop the machine, the LCD displays ‘Pressure too high’.

Sensor Failure Protection

When the cable of the pressure or the temperature sensor is broken, the controller will alarm and stop the machine. LCD displays ‘** sensor failure’.

5.6 History failure record

The failures caused by the peripheral equipments of the controller can be investigated by querying the failure record or the history failure records to find the failure causes and solve the problem.

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6. Maintenance

6.1 Maintenance items and maintenance intervals

Without proper maintenance the service life of the machine will be greatly reduced. Any high performance equipment requires regular maintenance to ensure perfect operation.

Daily maintenance

Before start-up: drain out water in the bottom of oil tank until some oil flows out, check the oil level is correct.

Water /O i l d rai nage va l ve

Attention: Don’t open the oil-discharging ball valve for five minutes after shutdown.

After start-up: Watch the pressure on the control panel. Check temperature and the general condition inside the compressor. Check if there is leakage on the outer surface of the cooler.

Maintenance plan

DAILY

Check the running temperature and working pressure.

Write down the current, voltage, temperature and pressure.

WEEKLY

Clean compressor after shut-down.

Blow the air filter clean.

Air fi lter el em ent

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MONTHLY

Check oil level.

Check the bolts on the belt pulley / shaft coupling.

Blow the cooler clean.

Maintenance - 500 hours

Check the quality of oil. If it is clean, it can be re-used after being re-filtered. Otherwise, replace it.

Replace the oil filter.

Replace the intake filter.

Replace the filter net of the oil return pipe.

Check the belts / shaft coupling for wear or damage.

Attention: Reduce maintenance interval if the environment is harsh.

O il fi lt er

Every 2000 hours

Replace the intake filter.

Replace the separator.

Replace lubricant.

Check intake-control valve.

Every 4000 hours

O il -g as separa to r

Replace the minimum-pressure control valve.

Check thermostatic valve.

Check the electronic connections are secure.

Check if main bolts, main nuts and connectors are tight.

Check the security apparatus.

CAUTION

Don’t repair / maintain the machine if the compressor is in motion or there is pressure in the system.

Always shut the machine down and ensure no pressure remains in the system.

On completion of repairs or maintenance work, check compressor is properly assembled before restarting.

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6.2 Maintenance of air intake filter

1. Open the end cover.

2. Take out the filter core.

3. Check the condition of intake filter (if it is not good, replace it).

4. Clean out the dust accumulation on the bottom cover.

5. Replace it with a new filter core if needed.

6. Replace the end cover.

6.3 Maintenance of oil filter

1. Unscrew the old filter with filter removal pliers.

2. Clean the contact surface.

3. Lay a thin film of oil on the seal ring of the new filter.

4. Tighten the filter by hand until it is tight and the contact surfaces are sealed.

5. Check if there is leakage after starting up.

6.4 Maintenance of oil separator

The method for the external type is the same as the oil filter.

The method for the built-in type is as follow:

1. Open the service door.

2. Loosen the connector between pipe and minimum-pressure valve

3. Loosen the pipeline on the cover of oil separator. Make sure it can be reinstalled.

4. Loosen the fixing bolts on the oil separator.

5. Lift up the cover board slightly, and then clean the oil return pipe.

6. Take out the oil separator cartridge.

7. Replace the oil separator cartridge.

8. Install the new separator in reverse procedure. Check the length of oil return pipe (Refer to the maintenance method for the oil return pipe)

9. Tighten bolts with a torque wrench to ensure uniform tightening.

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10. Restart the compressor and let it reach operating temperature, shut down the machine. Re-tighten the bolts of the cover plate of the oil separation cartridge.

The intake valve, solenoid valve and maintenance thereof

The Intake-control valve is comprised of a valve body, valve gate, piston, cylinder, spring and seal ring. A solenoid valve is mounted on the side of the unit. The system performs the functions of unloading the system, noise elimination, depressurizing the system etc… A small amount of air is output through an outlet in the intake-control valve. This keeps pressure in the separation element in the range of 0.2-0.3 Mpa and allows for normal cycling of the oil system. The pressure sensor and the solenoid valve automatically adjust and control the system loading and unloading as required by air demand. To increase the service life of the loading system and its components it is recommended that a pressure vessel be used for storage.

This will reduce the loading and unloading frequency. Periodic maintenance is required to ensure smooth operation of the intake system. When maintenance is done, parts should be dismantled and checked for wear on friction surfaces. Special attention should be given to the surface of the intake seal ring located on the piston in the intake tube. If there is damage it must be replaced. Lubricate all friction surfaces to prolong service life.

6.5 Maintenance of minimum-pressure valve and temperature control valve

1. Unscrew the lid, pay attention to the spring force of the valve.

2. Remove the lid.

3. Check if there is abrasion on the O-ring of the piston. If so replace the ring.

4. Check if there is abrasion on the seal ring. If so replace it.

5. Lubricate with high temperature grease. Reinstall.

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Replacing lubricant

1. Stop compressor. Power off.

2. Connect up the oil-discharging pipe, open the ball valve and then drain the oil into an oil-recycling can.

3. Close the oil-discharging ball valve, then open the oil filling cap and refill with new oil. Ensure the oil level is in the center of oil gauge.

4. Close the oil filling cap and then check the O-ring is in the correct position.

5. Start up the compressor. Check the oil level after running for a while. If oil level is low properly fill it to the correct level.

Attention: If the environment is dusty or hot replace oil more frequently.

Oil level:

Maximum oil level: oil level is in the center of the oil gauge after the compressor has stopped for 30 minutes.

Minimum oil level: oil level is in the lower part of oil gauge when the compressor is running.

Adjusting belt tension

1. Stop the machine, power off.

2. Open service door.

3. Loosen the bolt under the motor base. Three-quarter turn tightness is correct once under tension.

4. Rotate the adjusting bolt adjust the tightness of the belt until getting the correct tension.

5. Re-torque the bolt on the base.

Method for replacing belts

Follow the same method as tension adjusting.

After installing the new belts run the machine for 5 minutes then shut down and re-tension the belt.

Repeat this process 3 times. The belts are now tensioned correctly.

Tip: Replace all belts, never run old belts with new ones.

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Adjustment of belt pulley

It is essential that the motor pulley and the air-end pulley stay perfectly aligned. After moving any of these parts relocate the motor and air-end and ensure the pulleys run on the same plane. This will ensure that belt abrasion does not occur. Properly set belts run quieter, cooler and last much longer.

Centering of flexible shaft coupling on direct drive systems

The flexible shaft coupling must be centered when the motor or gear end is moved or reinstalled. Both shafts must be completely axial with a tolerance of 0-0.05mm.

Maintenance for the electric motor

A high quality lubricant should be applied on the motor bearings every 1500 hours. (Use shell Alvania

RL3, if not specified.) Run the motor in a unload state after removing the pulley and belts. Continue to pump lubricant while the motor is running until all original old grease has been purged from the bearing cavity. Do not add grease while the motor is shut down, bearing damage may occur. Wipe away the excess grease. Excess grease causes damage to the bearings.

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7. Flow diagram

DT- SERIES (18.5-250KW direct drive)

40

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Flow diagram

DT- SERIES (18.5-250KW belt drive)

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Parts list

DT- SERIES (90-250KW direct drive)

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19

20

21

22

23

11

12

13

9

10

7

8

14

15

16

17

S.N. Name

1 Right panel

2

3

4

5

6

Cabinet frame leg

Front and back right shutters

Motor

Coupling

Back-central gatepost

Anti-vibration pad

Back-left gatepost

Main baseplate

Center bracket

Screw air end

Air inlet valve

Air end exhaust

Bend

Oil level indicator

Left shutter

Relief valve

18 Oil-gas separator tank

Refill cap of the oil-gas tank

Electrical control panel

Front-left shutter

Emergency "stop" button

Controller

1

1

1

1

1

Quantity S.N. Name

1 24 Control shutter

1 25 Bend

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

26

34

35

36

30

31

32

33

27

28

29

37

38

39

40

41

Adjustable pipe joint

Minimum pressure valve

Air outlet pipe

Head oil inlet

Cooler oil inlet joint

Oil filter assembly

Oil filter joint

Removable service panel

After-cooler cover

Air outlet

Ball valve

After-cooler

Fan cowl

Fan

Removable side panel

Separator tank pressure gauge

Oil return pipe 42

43

44

Unloading pipe

Air filter assembly

Quantity

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

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Parts list

DT- SERIES (18.5-250KW belt drive)

44

S.N. Name

1 Left shutter

2 Digital display panel

5

6

3

4

Emergency "stop" button

Motor pulley

Motor

Electrical control panel

7

8

Cabinet frame leg

Automatic belt tension spring

9 Front shutter

10 Anti-vibration platform

11 Main base-plate

12 Anti-vibration pad

13 Cabinet frame leg

14 Shutter on the right side

15 Transportation fixing bolt

16 Air end mounting frame

17 Exhaust header pipe for air end

18 Oil-gas separator tank

19 Bend

20 Cabinet frame leg

21 Separator cartridge

22 Back shutter panel

23 Removable panel

24 Separator tank exhaust

25 Cabinet frame leg

26 Minimum pressure valve

DETROIT AIR SCREW COMPRESSOR

DT SERIES

Quantity

1

1

1

1

1

1

1

1

1

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

S.N. Name

27

28

Oil return pipe from separator

Main return pipe for air end

29 Air filter assembly

30 Oil filter

31 Oil filter joint

32 Oil filter housing

33 Oil filter exhausting pipe

34 Oil inlet bend

35 Oil return bend

36 After-cooler cover

37 After-cooler cover panel

38 After-cooler

39 Exhaust bend

40 Cooling fan cage

41 Cooling fan

42 Control panel

43 Belt

44 Air end

45 Air end pulley

46 Oil Return pipe

47 Unloading pipe

48 Air intake valve

49

Oil-gas separator tank pressure gauge

50 Oil refill cap of separator

51 Air intake pipe joint

Quantity

1

1

3

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

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Parts list

DT- SERIES (7.5-75KW direct drive)

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S.N.

1

Name

Front side panel

Quantity S.N.

1 25

Name

Oil level indicator

Quantity

1

14

15

16

10

11

12

13

8

9

6

7

4

5

2

3

17

18

19

20

21

22

23

24

Cabinet frame leg

Left side panel

Electrical control panel

Motor frame

Motor vent grid

Motor end-plate

Oil filter

Oil filter mount

Adjustable connector

Cooling fan

Cooling fan cage

After cooler

After-cooler cover

Fan cover plate

Discharge pipe connector

Oil-gas separator discharge pipe

Minimum pressure valve

Separator lid

Separator cartridge

Oil return pipe connector

Pressure gauge

Separator tank oil return pipe

Safety valve

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

41

42

43

44

45

46

38

39

40

34

35

36

37

30

31

32

33

26

27

28

29

47

Separator tank oil filler cap

Ball valve

Air filter element

Air filter cover

Back side panel

Cabinet frame leg

Right side panel

Cabinet frame leg

Plastic panel mount

LCD control panel

Emergency stop switch

90° adjustable connector

Main air end return pipe

Air inlet valve

Air end

Oil inlet connector

Air end support

Anti-vibration pad

Oil return valve

Temperature sensor

Air end discharge pipe

Main base plate

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

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8. Troubleshooting

FAULT POSSIBLE REASON

No electric power to compressor.

Emergency stop is activated.

Sequence of phases is not correct or phase lacking

Compressor does

not start

Overload protection relay does not reset

Fuses or electrical contactors are defective

Under- voltage or phase voltage unbalanced

Electrical connection is loose

Compressor fails to start and stop automatically

Compressor cannot vent pressure

due to high current

Compressor oil is very viscous due to low ambient temperature

Minimum pressure valve fails to close

Exhaust pressure exceeds rated value

Compressor stops automatically due to over

Set value of overload protection is incorrect

Oil/air separator is blocked

Pressure control or sensor faulty

load

Air end or main rotor jammed

Insufficient or incorrect type oil

Cooling unit soiled or internal blockage

Compressor stops automatically due to

overheating

Ambient temperature too high (≥40℃)

Insufficient cooling air intake

Oil filter or thermostatic valve jam

Cooling fan faulty broken

Oil pipe leakage

Ensure constant voltage in accordance with IEC

Standard

Check and tighten connection

Check intake valve and replace if necessary

Heat up the compressor before startup

Check the valve spring and replace if necessary

Check and adjust unloading pressure value

Check and adjust setting current value of main motor or fan motor

Check it, replace if necessary

Check pressure sensor or replace

Rotate by with hand, repair or replace if necessary

Fill oil and ensure oil level is not below the

“minimum level” mark

Clean cooling unit

Improve ventilation of compressor room

Clean and keep air inlet vents open

Clean it , replace if necessary

SOLUTION

Check electrical connection

Check or interchange two phases

(L1,L2 or L3) in the power cable

Reset it by hand

Check , replace if necessary

Check and replace if necessary

Fasten and seal oil pipe couplings

48

DETROIT AIR SCREW COMPRESSOR

DT SERIES

No compressed air exhaust,

no pressure build up

Separator element Is defective

Excessive oil level

Oil-return line blockage

Working pressure is too low for

Excessive oil consumption extended periods(≤0.6MPA)

Incorrect oil, more foam and low viscosity

Excess water in internal system due to high humidity climate

Intake valve does not open

Discharge solenoid valve defective

Minimum pressure valve does not open

Components in compressor are leaking

V-belts are torn or slip

Intake valve does not close

Check and replace if necessary

Drain some oil, ensure oil level is not higher than

“maximum level” mark

Check and replace one-way valve if necessary

User should reduce compressed air consumption to let pressure build-up

Use original manufacture oil only

Drain condensate water from oil tank frequently

Intake controller or solenoid valve is defective, or air pipe connected to controller is leaking, check and replace if necessary

Check electric supply and clean valve , replace if need

Check minimum pressure valve spring , replace if necessary

Check oil and air lines in compressor, tighten and reseal coupling connections.

Check and replace if necessary

System pressure does not decrease when reaching

Discharge solenoid valve is

rated pressure value defective

System pressure control fault

Intake controller or solenoid valve is defective, or air pipe connected to controller is leaking, check and replace if necessary

Check electric supply and clean valve, replace if necessary

Check pressure sensor, pressure switch or computer controller, replace if necessary

Oil or oil smoking in intake filter

Intake valve is leaking. Pressing

Emergency Stop when compressor is in load can cause this

Check and replace if necessary

Switch off compressor using OFF Button, only use the

Emergency Stop Button in emergencies

when stopping

Minimum pressure non-return valve is leaking

Excessive oil in air

Air vent, intake filter or oil/air

Check and replace if necessary

See the reasons of excessive oil consumption

Clean and replace if necessary

Exhaust volume decreases

separator blockage

Intake valve does not function correctly

Components in compressor are leaking

Pressure differential incorrectly set

Check and replace if necessary

Check air lines in compressor, tighten and reseal screw coupling connections if necessary

Adjust pressure differential, not smaller than 0.15MPA

Air consumptions is not steady

Compressor loads/ unloads

External units of the compressed

very frequently

air treatment block

Ball valve at compressor outlet closed usually

Use a bigger volume receiver tank

Clean external air pipeline ,air dryer or air filter , replace if necessary

Open ball valve

49

DETROIT AIR SCREW COMPRESSOR

DT SERIES

Abnormal noise and vibration of the compressor

Safety valve blows

Fixing bolts on the base are loose

V-belts are slipping

Friction with fan vane and edge

Compressor installed improperly

Screw air end or motor is defective

Operating pressure has been misadjusted

Safety valve is defective

System internal pressure has exceeded pressure of safety valve

Tighten

Adjust v-belt tension, replace if necessary

Adjust fan vane

Mounted compressor on flat ground

Check air end or main motor and fan motor, repair if necessary

Set operating pressure to the maximum permissible pressure range of compressor (see value in nameplate)

Replace safety valve

Check and replace air/oil separator if necessary

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50

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