This is compact industrial air compressor machine. And it is 4 in 1 integrated type. That is, it has 4 parts. Firstly, this compressor is screw compressor with refrigerated dryer. In addition, it has air tank and compressed air filters. This compact compressor has wide application for laser cutting. The max air pressure is 16 bar.
We are the rotary screw compressor with dryer manufacturer. And the available power is as follows: 10 HP, 15 HP, 20 HP, 30 HP, etc. It’s usually 380V. But we can also customize 220V, 240V, 415V, 440V, 460V and 480V.
1. Technical parameters of 10 HP rotary screw air compressor with dryer
|1||Air Capacity/Air Pressure||（m3/min）/ MPa||0.9/1.0|
|2||Max Air Pressure||Bar||16|
|5||Discharge Temp.||℃||≤Ambient Temp.+15|
|6||Lubricant Oil Quantity||L/kg||3.8L|
|8||Air Volume Adjustment Type||Variable frequency|
|9||Air Oil Content (after air-treatment)||ppm||≤0.003|
|10||Compact Compressor Noise||dB(A)||68±2|
|11||Lubricant Oil Brand||S2|
|12||Safety Valve Set Pressure||MPa||Rated Work Pressurex1.1=1.1|
|13||Motor Power of Screw Compressor with Dryer||kW||7.5|
|15||Motor Starting Method||PM VSD|
|17||Motor protection class/insulation class||IP23 or IP54/F|
|20||Fan Rotating Speed||rpm||1440|
|21||Fan Air Volume||m3/h||2800|
|22||Refrigerated Dryer Model||TR01-HD|
|23||Refrigerant Dryer Power||kW||0.37|
|24||Refrigeration Dryer Air Capacity||M3/min||1.2|
|26||Dryer Inlet Air Temp.||℃||≤65℃|
|27||Dimension of Industrial Air Compressor Machine||mm||1430*710*1470|
|28||Air Tank Volume||L||250|
|29||Whole Compact Compressor Weight||kg||380|
|30||Air Port Connection Size||Rp3/4|
This is the techinical specifications of PM VSD type screw compressor with dryer. If you need fixed speed type, contact us.
2. Why choose our 4 in 1 compact compressor?
(1) Output high quality compressed air
Firstly, this integrated air compressor is with a 4-stage high-precision filters. Besides, it’s also with a high-performance refrigerated dryer. Therefore, the water removal efficiency is far more than 99%. The particle content is ≤0.01um. Oil content as low as 0.003ppm. Moreover, the pressure dew point is as low as 2-10℃.
So it can remove tiny oil and water molecules. Then output high-quality dry and clean air. This is essential for our laser cutting production.
(2) Compact structure, saving space
Secondly, the compact compressor adopts an integrated design. It brings all the parts together. That is, screw compressor, refrigerated dryer, air tank and filters.
It’s compact design. Thus, this industrial air compressor machine can save space cost. Besides, there is no need to install pipes. It realizes plug and play.
(3) 2 years warranty high quality compressor airend
Our 4 in 1 air compressor uses the famous Hanbell brand airend. The airend is with Sweden original SKF bearings. Moreover, there is nternal temperature control system. With copper pipes, so it has high pressure and corrosion resistance.
In addition, we use the permanent magnet motor. High-performance RuFeB permanent magnets do not lose magnetism at 200°C. Besides, energy saving of our screw compressor with dryer can be up to 30%.
(4) Intelligent computer control system
Easy to use. It realizes one-button control for the compact compressor. Fully automatic operation control. In addition, it’s with alarm display.
Moreover, we can switch Chinese/English freely. And it can intelligently monitor the usage time of filters and lubricating oil. Besides, there is a remote control function.
(5) With air tank, it can ensure stable pressure
Air receiver reduces pressure fluctuations. So reduce the start and stop of industrial air compressor machine. In addition, it can also removal a part of water. So it can reduce the load of refrigerated dryer.
(6) Use high efficiency oil filter, air filter and separator
The air filter has a large filtration area. Besies has higher precision. and longer life. In addition, it can pressure loss of screw compressor with dryer.
The oil separator adopts a special design. It composes of a gathering separation core and an oil return device. The service life is up to 6000 hours.
The oil filter is designed with a low pressure drop. The service life can reach 4000 hours.
High filtration precision can effectively protect the bearings and rotors of airend.
3. Why does the laser industry use the integrated compact compressor?
Auxiliary gas is an indispensable substance for laser cutting. Compressed air is the most commonly used. Because compressed air is much cheaper than oxygen and nitrogen.
In addition, it can blow away metal slag. And it also prevents dust from clogging the laser nozzle.
At first, the laser cutting used low power. But it keeps developing to high power. Likewise, the pressure of compact compressor is constantly increasing. At first, it was 8bar. Later it increased to 13bar. And now we usually use 16 bar. Of course, it is still developing towards 20~30bar.
The quality of compressed air has a direct impact on laser cutting. So we need to use rotary screw compressor with dryer.
Laser cutting generally require multi-stage filtration. In order to better protect the service life of the laser cutter. If don’t clean water mist and oil, they will be sprayed on the protective mirror surface.
As a result, it will severely affect the transmission of the laser beam. So it will scatter focus. Finally, the cutting efficiency is reduced. Besides, it is also possible to burn out the laser head.
Our 4-in-1 air compressor can effectively remove water and oil. Because the refrigerated dryer can remove 99% of the moisture. Moreover, the filters can also remove water, dust and oil. So compact compressor ensures high quality compressed air.
4. How does rotary screw compressor with dryer work?
The rotor of PM motor directly drives compact compressor. It is mounted on the output shaft. Firstly, the air goes through the air filter. After filtering, it passes via the intake control valve. And then enter the compressor intake chamber.
The airend screw groove compresses air. Afterwards, it is discharged from the air outlet. Next, it enters the oil separator. Oil and air separation takes place here. After separation, the oil content is very small.
Then compressed air passes via the minimum pressure valve and the aftercooler. Finally goes into the air tank. The air receiver can stabilize pressure. Besides, it can reduce temperature. Also remove some moisture.
Hereafter, the air enters the air-water separator. It will separate out many water. Then air goes to the evaporator of refrigerated dryer. Deep cooling takes place here. It can turn gaseous water into liquid water. Besides, liquid water will be drained. Finally, the air goes back to the heat exchanger of of dryer. It will heat up here.
In addition, the precision filters can remove dust, oil and water. The separated lubricating oil will settle to the bottom of the oil-air separator. It is cooled by oil cooler. Finally, it will return to the working chamber of screw compressor with dryer. So it starts recycling.
5. Screw compressor with dryer use manual
(1) Integrated air compressor wiring
① The power supply is AC three-phase 380V 50Hz.
② The voltage drop should not exceed ±5% of the rated voltage. The voltage difference of each phase is within ±3%. And there needs to be phase sequence protection line.
③ The screw compressor with dryer must have an isolation switch. In order to prevent short-circuit.
④ Check the secondary circuit fuse. Select safety switch according to the power of 4 in 1 air compressor.
⑤ The specifications of power lines are as follows:
|Compact Compressor Power||Regular Voltage||Max Current||Wire Specification|
(2) Initial start-up procedure of 4 in 1 compact compressor
① Firstly, place the 4 in 1 air compressor on a flat ground. Then connect it to the backend equipments.
② Secondly, check the oil level of the oil separator. Normally it should be in the lower center of the sight glass.
③ Thirdly, close all air supply valves of compact compressor.
④ Next, turn on the power. And check whether the display of each instrument is normal.
⑤ Press the start button of refrigerated dryer. Wait for the evaporation temperature to drop to about 5°C.
⑥ Afterwards, press the start button on the controller. The screw compressor with dryer starts up.
⑦ Warm up at the lowest frequency. Then industrial air compressor machine transitions to the loading state. At this time, the motor rises to the rated speed and runs. The exhaust pressure also rises slowly.
⑧ Close all maintenance doors. In order to control the noise of integrated compressor. Ensure proper flow of cooling air.
⑨ Check whether the value of each gauge is normal.
⑩ After the initial operation, stop according to the procedure. Check if need to add oil. In addition, check whether there is any looseness in the joints.
(3) Shutdown procedure of 4 in 1 industrial air compressor machine
① Close all air supply valves. Then press the stop button. The compact compressor starts unloading delay. After completion, it will automatically stop.
② Sometimes emergencies occur. At this time, we can pressure the emergency stop button. The screw compressor with dryer will be shut down quickly.
But under normal circumstances, prohibit direct emergency shutdown. Otherwise, it will cause great damage to industrial air compressor machine.
Sometimes, the 4 in 1 compressor runs for longer than the set time due to no-load. They will stop automatically. In this case, please don’t carry out inspection and repair work. Because the integrated air compressor will recover operation at any time. It must turn off the power firstly.
6. Compact screw compressor with dryer maintenance
Good maintenance is the key to the best condition of our industrial air compressor machine. The following is the detailed maintenance plan of the 4 in 1 air compressor.
(1) Each day maintenance
① Air filter —— clean the dust valve;
② Oil-air separator —— release the condensate before starting screw compressor with dryer;
③ Lubricating oil —— check the oil level before starting and during operation;
④ Air storage tank —— release the condensed water before starting compact compressor;
⑤ Secondary oil return pipeline —— if any blockage, clean in time;
(2) Weekly maintenance
① Safety valve —— check for blockage or other damage;
② Secondary oil return line —— clean orifice;
③ Oil-air cooler and dryer condenser —— clean the dust on the outer surface;
(3) 500 hours maintenance (first time)
① Oil filter —— replace the filter element;
② Integrated compressor lubricating oil —— replace the lubricant oil;
(4) Six-month maintenance (working time 2000~3000 hours)
① Air filter —— replace the filter element;
② Oil separator —— replace the oil-air separation filter;
③ Precision compressed air filters —— replace the filter element;
④ Oil filter —— replace the oil filter element;
⑤ Compressor lubricating oil —— replace the compact compressor lubricant oil;
(5) Annual maintenance (3000~6000 hours)
① Intake valve —— exchange the seal ring;
② Pressure-retaining valve —— internal cleaning and replacement of sealing ring;
③ Air-water separator —— clean the bottom spherical drain valve;
(6) Maintenance every two years (6000~9000 hours)
① Oil pipeline —— clean impurities and carbon deposits;
② Oil and gas cooler —— clean internal passages;
(7) Maintenance every four years (9000~18000 hours)
① Motor of screw compressor with dryer —— motor maintenance;
② Electrical components —— replace aging parts;
③ Compressor airend —— replace bearings, shaft seals, etc.;
④ Seals —— replace the seals of various parts;
7. Why water removal is important for laser cutting 4 in 1 integrated compact compressor?
Water removal has a great impact on the quality of laser cutting. Why? Firstly, let’s see how much liquid water is produced by 1m³/min compressed air at 16bar.
For example, the temperature in summer is 35°C. Relative humidity 80%. Then at atmospheric pressure, the air moisture content is 0.0279KG/KG (dry air).
Compress the air to 16bar. If the exhaust temperature is 80°C, the moisture content is 0.0178KG/KG (dry air).
Therefore, liquid water = 0.0279-0.0178 = 0.0119KG/KG (dry air). Air capacity of screw compressor with dryer is 1m³/min. Work for 10 hours a day. Then one day’s liquid water=0.01196010*1.29=9.21KG.
These liquid water is mixed in the lubricating oil. So it will degrade the lubricant oil. Make it generate many air bubbles. And they surround the oil separator filter. So it will lose the interception filtering function. Finally, purification function of dryer and filters can be very difficult.
(1) How much water will appear in the air tank?
Compact compressor and dryer are above the air tank. Firstly, the compressed air will go through the aftercooler. And then enter the air receiver. The aftercooler will produce condensate. So this part of the water will also enter the air tank.
In addition, there will convective heat exchange with the tank wall. This also cools the compressed air. So it will result in more condensed water.
Exhaust air temperature is generally about 15°C higher than the ambient temperature. After entering the air tank, the temperature will drop by 5~8℃. Assume the ambient temperature is 35℃. So the air temperature in the air tank does not exceed 35+15-5=45℃.
Under 16bar pressure, the moisture content of saturated air at 45℃ is 0.0035KG/KG (dry air). Therefore, the liquid water in the tank=0.0297-0.0035=0.0262KG/KG (dry air).
Similarly, assume that air flow of screw compressor with dryer is 1m³/min. Work 10 hours a day. Then the condensed water in the tank for one day=0.02626010*1.29=20.28KG.
(2) What are the consequences of this water?
Tank volume of compact compressor is generally 300L~400L. It generates 20.28KG of condensed water per day. Assume that there has been no drainage all the time. It only takes 2 weeks. The entire air tank will be full of water.
As a result, compressed air can carry many liquid water into the dryer and filters. These devices cannot handle it. Therefore, a lot of oil and water will enter the laser cutter. It quickly fogs up the lenses. This makes the laser cutting machine unable to work. In severe cases, the optical lens will be burned out.
So we must have good maintenance habits. Drain the condensed water from the air receiver daily.
(3) How much water will appear before the refrigerated dryer?
Compressed air leaves the air tank. Then it will enter the dryer through the pipeline. In the pipeline, there is also heat exchange. The temperature will also drop. So it will produce condensation.
Assuming a 5°C drop. The moisture content at 40°C is 0.0027KG/KG (dry air). So this part of the condensed water = 0.0035-0.0027 = 0.0008KG/KG (dry air). Also assume that the air capacity of screw compressor with dryer is 1m³/min. Work 10 hours a day. So condensed water one day=0.00086010*1.29=0.6192KG.
This is why install the air-water separator before the refrigerated dryer. We can install an automatic drain below the separator. And can set to drain water every 45 minutes.
(4) How much water does the refrigerated dryer produce?
Compressed air enters the dryer. Assume a pressure dew point of 5°C. Then the condensed water produced by dryer is 0.0024KG/KG (dry air). Also assume that the air flow of compact compressor is 1m³/min. Condensed water each day=0.00246010*1.29=1.858KG.
Therefore, we need to drain these water in time. Otherwise, subsequent filters will lose their function. So our dryer has a built-in water separator. There is an electronic drain valve. It drains automatically.
Besides, the refrigerated dryer has a temperature recovery function. It can prevent the outlet temperature from being too low. So can avoid water mist from forming on the lenses.
In addition, the precision filter can remove oil. The oil removal effect can reach 0.001ppm. So it can prevent oil mist from forming on the lens.
In summary, the water removal of screw compressor with dryer is very important. We need to do maintenance well.
8. Compact compressor troubleshooting
There are various reasons for air compressor failure. We list some frequently asked questions. And below also include some solutions.
(1) Compact screw compressor with dryer not working
① The fuse is burnt —— check and replace;
② Lack of phase or poor contact of the start button —— overhaul and replace;
③ Wrong setting of exhaust pressure —— reset;
④ Motor overload protection trip/damage —— motor overhaul/waiting for cooling;
⑤ AC contactor failure —— check, handle with it and replace;
⑥ Airend failure of industrial air compressor machine —— check the airend. It should be able to rotate the airend;
(2) Compact screw compressor with dryer not building pressure
① Air leakage from the minimum pressure valve —— check and adjust;
② The intake valve is stuck in the closed position. Or the small hole is blocked —— check and replace;
③ Solenoid valve failure of industrial air compressor machine—— check and replace;
④ The air filter element blockage —— clean/replace the filter element;
(3) Compact rotary screw compressor with dryer not drying
① The power cord of dryer is not connected —— connect it;
② Or the wiring of the dryer power supply is incorrect —— check the wiring;
③ The amount of refrigerant is insufficient or leaked —— supplement the refrigerant;
④ The refrigerant bypass volume is too large —— adjust and reduce the bypass volume;
⑤ The starting pressure of the condenser fan is too high —— lower the pressure switch value;
(4) Industrial air compressor machine has abnormal noise
① Main motor bearing wear —— check and replace motor bearing;
② Fan motor bearing wear —— check and replace the bearing;
③ The bearing of the main engine is worn —— check and replace the airend bearing;
④ The fan collides with the windshield —— adjust the gap;
⑤ Belt loose —— adjustment;
Q1. What is the air tank volume of 4 in 1 compact compressor?
A1: If 10 HP 7.5 KW screw compressor with dryer, the tank volume is 250L. And if 15 HP, 20 HP and 30 HP industrial air compressor machine, the tank volume is 400L.
Q2. What’s the max pressure of your screw compressor with dryer?
A2: The max pressure of our 4 in 1 integrated air compressor is 16 bar.