SWT/SWTV Series

Oil-free Screw Air Compressor System

Operation & Maintenance

Manual

Fusheng
Thank you for choosing the FushengTM oil-free screw air
compressor!

Fusheng Group has the right to change the product design, and is not responsible
for the modification or improvement of any product released from the factory. The
specifications or parts of some products are subject to change without notice.
************************************************************************

Notes: 1. All pressures in this manual are gauge pressures unless otherwise
specified;
2. When the user contacts us about maintenance, service or any other
matter about the compressor, please specify the model and pressure
value, which are indicated on the nameplate and warranty card of the
unit.
************************************************************************

Model number ______________________________

Number of main unit _________________________

Date of starting and adjustment ________________

-1-
 Safety Notice

Please read the following carefully before operating the unit safely.
*********************************************

Safety precautions:

1 When pipes are being mounted and welded, flammable materials nearby should be removed, and
sparks should be prevented from falling into the unit in order not to burn out certain parts of the unit;

2 The power cord of the unit must match its power and be provided with an air switch, fuse and other
safety devices. To ensure the reliability and safety of the unit, it must be grounded and if necessary,
provided with a lightning arrester;

3 A new unit must be adjusted by someone appointed or accepted by us;

4 Before starting the unit, make sure that no one is inside, check for any object or tool left in it, and close
the door of the unit; remind the personnel around the unit of safety before starting the unit;

5 When the unit is started for the first time or the power cord is varied, make sure the unit turns in the
direction indicated by the arrow;

6 The unit cannot operate at any exhaust pressure higher than that specified on the nameplate,
otherwise the motor will burn out due to overloading;

7 Do not start the unit forcibly when the unit is malfunctioning or exists any unsafe factor; in this case,
cut off the power supply and make a visible sign;

8 Both the compressed air and the electric appliance are hazardous; during repair or maintenance,
make sure the power supply has been cut off, and hung a warning sign of “being repaired” or “Do not
switch on” at the power supply to prevent anyone else from switching on the unit to cause any injury;

9 When the unit is shut down for maintenance, the maintenance personnel should not enter the unit until
the whole unit has cooled down and the compressed air has been released safely, and the
maintenance personnel should avoid any exhaust port in the unit and close the relevant isolation
valves;

10 The parts of the unit should be cleaned with a non-corrosive safe solvent other than any flammable,
explosive or volatile detergent;

11 After the unit has run for a certain period, the safety valves and other protective devices should be
checked regularly (usually once a year) to ensure that they are sensitive and reliable;

12 The parts of the unit must be original Fusheng products, and the lubricant must be the FushengTM
special lubricant for air compressors designated by us; never use two different brands of lubricant,
otherwise coking may cause damages to the unit; in this case, the user will be liable for such

-2-
 damages;

13 The unit should be operated by regular personnel, who should read and understand this manual, and
observe the operating procedures, safety precautions and maintenance provisions in this manual.

Warning:

Any violation of the above safety precautions may lead to serious

consequences.

-3-
 Warning Signs

The following warning signs indicate important rules that must be observed to avoid
any potential personal injury or property damage.

◎ Warning signs

Definitions of signs

△
Indicating hazards that are likely to occur when the unit is operated
! improperly, such as death or serious injury, and refers to the most
urgent (or dangerous) circumstances only
Danger

△ !
Warning
Indicating hazards that are likely to occur when the unit is operated
improperly, such as death or serious injury

△ !
Caution
Indicating hazards that are likely to occur when the unit is operated
improperly, such as slight injury or equipment damage

_ ____
_ ____
_ ____
Indicating auxiliary materials on operation and maintenance

Reference

Definitions of icons
The details of an icon are indicated graphically or textually inside or near it.
Icon Definition
Indicating prohibited matters
Its details are indicated graphically or textually inside or near the icon.
Indicating matters that should be highly cautioned
Its details are indicated graphically or textually inside or near the icon.

◎ Make sure that warning signs have been affixed firmly on the unit.
Make sure that warning signs have been affixed firmly on the unit. Contact your dealer if any sign is
missing or becomes illegible.
◎ Description of stickers
Before touching any electric device, such as distributing board,
electric box or motor, or working on any such device, make
sure the unit has been shut down and the power supply has
been cut off.

-4-
 Rotating parts can cause personal injuries, so no guard or
safety device should be removed. Before working beside any
rotating part, be sure to shut down the unit and cut off the
power supply.

High-pressure air can cause serious personal injuries. Do not

point the compressed air outlet to anyone.

When the unit is running, the surface temperature of the parts

is very high. Do not touch any part by hand in order to avoid
any personal injury.

The unit is running

Please read the operation manual carefully before starting the

unit. Anyone who is not familiar with the operation manual must
be prohibited from operating the unit.

Staying in the noise of a running machine for a prolonged

period of time is likely to damage one’s physical and mental
health. Noise protection devices should be provided in work.

※ Do not remove any warning sign from the unit.

-5-
 Foreword

Thank you very much for choosing the FushengTM oil-free screw air
compressor! Our products have been inspected and tested strictly at
the factory. However, to ensure the safe, reliable and proper operation
of the unit over time, please read this manual carefully before
operating it to fully master the operating practices and skills of the
unit.
In order to protect your rights and interests, please mail the warranty
card of the unit back to our service department, so that you will
receive the best service within the shortest possible time.

Thank you!

-6-
 Contents
==================================

Technical Specifications of Oil-free Screw Air Compressor 1

External Views of the SWT110-450W and the SWTV110-3750W 7

Introduction to the Oil-free Screw Air Compressor 10

Operating Principle of the Oil-free Screw Air Compressor 11

System Flowchart 14

Installation Instructions for the Unit 20

Schematic Installation Diagram 21

Safety Protection System and Warning Devices 24

Control System 25

Control Wiring Diagram of the SWT (Standard Model) 26

Operating Procedures of the FushengTM oil-free screw air compressor 30

Maintenance and Inspection of the FushengTM oil-free screw air

compressor 32

Maintenance and Troubleshooting 35

Attached Table 1 Troubleshooting Table 36

Attached Table 2 Replacement Schedule of Spare Parts 39

General Lubricant Replacement Procedure of the FushengTM Oil-free

Screw Air Compressor 42

-7-
 Technical Specifications of Oil-free Screw Air Compressor
Model SWT110W SWT132W SWT150W
Type - Non-inverter Non-inverter Non-inverter
Number of
stages of - 2 2 2
Type

compressor
Operation Continuous Continuous Continuous
-
mode operation operation operation
Suction gas - Air Air Air
Suction state

Suction
℃ ≤46° ≤46° ≤46°
temperature
Suction
MPa Unlimited Unlimited Unlimited
pressure
Relative
% Unlimited Unlimited Unlimited
humidity
Operating
MPa 0.75/0.85/10.0 0.75/0.85/10.0 0.75/0.85/10.0
pressure
Compressor performance

Displacement m3/min 18.7 20.8 24.0

Exhaust Normal Normal Normal
℃
temperature temperature +8 temperature +8 temperature +8
Driving mode - Coupling Coupling Coupling
Speed rpm 2975 2975 2975
Lubrication
- Forced lubrication Forced lubrication Forced lubrication
mode
Lubricant
MPa 0.15-0.18 0.15-0.18 0.15-0.18
pressure
Cooling
- Water cooling Water cooling Water cooling
mode
Motor type - 3-phase, SF1.20 3-phase, SF1.20 3-phase, SF1.20
Motor power KW 110-128 123-141 141-161
Number of
electrodes of - 2 2 2
motor
Motor

Input voltage V 380 380 380

Frequency HZ 50 50 50
Starting
- Y-△ Y-△ Y-△
mode
Insulation
- F F F
class
Length mm 3400 3400 3400
specifications

Width mm 1600 1600 1600

Other

Height mm 1800 1800 1800

Weight kg 3300 3500 3700
Power of
KW 1.5 1.5 1.5
exhaust fan

Model SWT200W SWT220W SWT250W

Type - Non-inverter Non-inverter Non-inverter
Number of
stages of - 2 2 2
Type

compressor
Operation Continuous Continuous Continuous
-
mode operation operation operation
Suction gas - Air Air Air
Suction
Suction

≤46° ≤46° ≤46°

state

℃
temperature
Suction
MPa Unlimited Unlimited Unlimited
pressure

-1-
 Relative
% Unlimited Unlimited Unlimited
humidity
Operating
MPa 0.75/0.85/10.0 0.75/0.85/10.0 0.75/0.85/10.0
pressure
Compressor performance

Displacement m3/min 33.6 40.0 43.6

Exhaust Normal temperature Normal temperature Normal temperature
℃
temperature +8 +8 +8
Driving mode - Coupling Coupling Coupling
Speed rpm 1490 1490 1490
Lubrication
- Forced lubrication Forced lubrication Forced lubrication
mode
Amount of
MPa 0.15-0.18 0.15-0.18 0.15-0.18
lubricant
Cooling mode - Water cooling Water cooling Water cooling
Motor type - 3-phase, SF1.20 3-phase, SF1.20 3-phase, SF1.20
Motor power KW 192-223 228-263 251-288
Number of
electrodes of - 4 4 4
Motor

motor
Input voltage V 380 380 380
Frequency HZ 50 50 50
Starting mode - Y-△ Y-△ Y-△
Insulation
- F F F
class
Length mm 3600 3600 3600
specifications

Width mm 1900 1900 1900

Height mm 2000 2000 2000
Other

Weight kg 5000 5200 5400

Power of
KW 2.2 2.2 2.2
exhaust fan

Model SWT315W SWT375W SWT450W

Type - Non-inverter Non-inverter Non-inverter
Number of
stages of - 2 2 2
Type

compressor
Operation Continuous Continuous Continuous
-
mode operation operation operation
Suction gas - Air Air Air
Suction state

Suction
℃ ≤46° ≤46° ≤46°
temperature
Suction
MPa Unlimited Unlimited Unlimited
pressure
Relative
% Unlimited Unlimited Unlimited
humidity of air
Operating
MPa 0.75/0.85/10.0 0.75/0.85/10.0 0.75/0.85/10.0
pressure
Compressor performance

Displacement m3/min 50.8 60.1 71.2

Exhaust Normal temperature Normal temperature Normal temperature
℃
temperature +8 +8 +8
Driving mode - Coupling Coupling Coupling
Speed rpm 1475 1475 1475
Lubrication
mode of - Forced lubrication Forced lubrication Forced lubrication
bearing
Lubricant
MPa 0.15-0.18 0.15-0.18 0.15-0.18
pressure

-2-
 Cooling mode - Water cooling Water cooling Water cooling
Motor type - 3-phase, SF1.20 3-phase, SF1.20 3-phase, SF1.20
Motor power KW 308-360 364-421 426-487
Number of
electrodes of - 4 4 4
motor
Motor

Input voltage V 10000 10000 10000

Frequency HZ 50 50 50
Impedance or direct Impedance or direct Impedance or direct
Starting mode -
starting starting starting
Insulation
- F F F
class
Length mm 4500 4500 4500
specifications

Width mm 2250 2250 2250

Other

Height mm 2250 2250 2250

Weight kg 800 8300 8800
Power of
KW 3 3 3
exhaust fan
SWTV18
Model SWTV110W SWTV132W SWTV150W
5W
Type - Inverter Inverter Inverter Inverter
Number of
stages of - 2 2 2 2
Type

compressor
Operation Continuous Continuous Continuous Continuous
-
mode operation operation operation operation
Suction gas - Air Air Air Air
Suction state

Suction
℃ ≤46° ≤46° ≤46° ≤46°
temperature
Suction
MPa Unlimited Unlimited Unlimited Unlimited
pressure
Relative
% Unlimited Unlimited Unlimited Unlimited
humidity
Operating
MPa 0.75/0.85/10.0 0.75/0.85/10.0 0.75/0.85/10.0 0.75/0.85/10.0
pressure
Displacement m3/min 13.2-18.7 13.2-20,8 13.2-24.0 13.2-28.8
Compressor performance

Normal Normal Normal Normal

Exhaust
℃ temperature temperature temperature temperature
temperature
+8 +8 +8 +8
Driving mode - Coupling Coupling Coupling Coupling
Inverter Inverter Inverter Inverter
Speed rpm
variable variable variable variable
Lubrication Forced Forced Forced Forced
-
mode lubrication lubrication lubrication lubrication
Lubricant
MPa 0.15-0.18 0.15-0.18 0.15-0.18 0.15-0.18
pressure
Cooling mode - Water cooling Water cooling Water cooling Water cooling
3-phase, 3-phase, 3-phase, 3-phase,
Motor type -
SF1.20 SF1.20 SF1.20 SF1.20
Motor power KW 110-128 123-141 141-161 176-198
Number of
electrodes of - 2 2 2 2
Motor

motor
Input voltage V 380 380 380 380
Frequency HZ 50 50 50 60
Inverter Inverter Inverter Inverter
Starting mode -
starting starting starting starting
Insulation - F F F F

-3-
 class
Length mm 3400 3400 3400 3400
specifications Width mm 1600 1600 1600 1600
Other

Height mm 1800 1800 1800 1800

Weight kg 3500 3700 3900 4000
Power of
KW 1.5 1.5 1.5 1.5
exhaust fan
Model SWTV200W SWTV220W SWTV250W SWTV300W
Type - Inverter Inverter Inverter Inverter
Number of
stages of - 2 2 2 2
Type

compressor
Operation Continuous Continuous Continuous Continuous
-
mode operation operation operation operation
Suction gas - Air Air Air Air
Suction state

Suction
℃ ≤46° ≤46° ≤46° ≤46°
temperature
Suction
MPa Unlimited Unlimited Unlimited Unlimited
pressure
Relative
% Unlimited Unlimited Unlimited Unlimited
humidity
Operating
MPa 0.75/0.85/10.0 0.75/0.85/10.0 0.75/0.85/10.0 0.75/0.85/10.0
pressure
Displacement m3/min 23.2-33.6 23.2-40.0 23.2-43.6 23.2-48.3
Compressor performance

Normal Normal Normal Normal

Exhaust
℃ temperature temperature temperature temperature
temperature
+8 +8 +8 +8
Driving mode - Coupling Coupling Coupling Coupling
Inverter Inverter Inverter Inverter
Speed rpm
variable variable variable variable
Lubrication Forced Forced Forced Forced
-
mode lubrication lubrication lubrication lubrication
Lubricant
MPa 0.15-0.18 0.15-0.18 0.15-0.18 0.15-0.18
pressure
Cooling mode - Water cooling Water cooling Water cooling Water cooling
3-phase, 3-phase, 3-phase, 3-phase,
Motor type -
SF1.20 SF1.20 SF1.20 SF1.20
Motor power KW 192-223 228-263 251-288 284-324
Number of
electrodes of - 4 4 4 4
Motor

motor
Input voltage V 380 380 380 380
Frequency HZ 50 50 50 60
Inverter Inverter Inverter Inverter
Starting mode -
starting starting starting starting
Insulation
- F F F F
class
Length mm 3600 3600 3600 3600
specifications

Width mm 1900 1900 1900 1900

Other

Height mm 2000 2000 2000 2000

Weight kg 5100 5300 5500 5800
Power of
KW 2.2 2.2 2.2 2.2
exhaust fan
Model SWTV315W SWTV375W
Type - Inverter Inverter
Type

Number of
stages of - 2 2
compressor

-4-
 Operation
- Continuous operation Continuous operation
mode
Suction state Suction gas - Air Air
Suction
℃ ≤46° ≤46°
temperature
Suction
MPa Unlimited Unlimited
pressure
Relative
% Unlimited Unlimited
humidity
Operating
MPa 0.75/0.85/10.0 0.75/0.85
pressure
Compressor performance

m3/mi
Displacement 36.4-50.8 36.4-60,1
n
Exhaust
℃ Normal temperature +8 Normal temperature +8
temperature
Driving mode - Coupling Coupling
Speed rpm Inverter variable Inverter variable
Lubrication
- Forced lubrication Forced lubrication
mode
Lubricant
MPa 0.15-0.18 0.15-0.18
pressure
Cooling mode - Water cooling Water cooling
Motor type - 3-phase, SF1.20 3-phase, SF1.20
Motor power KW 308-360 364-387
Number of
electrodes of - 4 4
Motor

motor
Input voltage V 380 380
Frequency HZ 50 50
Starting mode - Inverter starting Inverter starting
Insulation
- F F
class
Length mm 4500 4500
specifications

Width mm 2250 2250

Other

Height mm 2250 2250

Weight kg 8500 8800
Power of
KW 2.2 2.2
exhaust fan

-5-
 External Views of the SWT110-150W and the SWTV110-185W

No.
编号 Item
项目名称 name
11 Drain valve of intercooler ¼”
中冷洩水阀 1/4"
2 Drain valve of after-cooler ¼”
2 后冷洩水阀 1/4"
3 Oil outlet of oil tank ¾”
3 油箱泄油口 3/4"
4 Cooling water outlet 2”
4 冷却水出水口 2"
5 Cooling water inlet 2”
5 冷却水入水口 2"
6 Exhaust port flange DN80
6 排气口法兰 DN80
7 Fan air vent
87 风扇排气口
Control panel
98 Service entrance ○100
控制面板

10
9 Air inlet
进线口 ofOair
100 compressor

7 10 空压机进气门
11 Air inlet for motor heat radiation
11 马达散热进气门
Air inlet ○100 (with protective
12
12 进风口 O100（有护盖）
cover)
408

6
8
10 11
1800

562
1115

1 2 3 4 5 9 12
1600 3140

-6-
 External Views of the SWT200-250W and SWTV200-300W
No.编号 Item name
项目名称
1 1
Drain 中冷洩水阀
valve of intercooler
1/4"
¼”
2 2
Drain 后冷洩水阀
valve of after-cooler
1/2"
½”
3 3
Oil outlet of oil tank ¾”
油箱泄油口 3/4"
4 Cooling water outlet 2-12”
4 冷却水出水口 2-1/2"
5 Cooling water inlet 2-12”
5 冷却水入水口 2-1/2"
6 Exhaust port flange DN100
7 6 Fan air vent DN100
排气口法兰

7
8 7 Control panel
风扇排气口
9 8 Service entrance
控制面板
○120
10 Air inlet of air compressor
9 进线口 O120
Air inlet for motor heat
11 10 空压机进气门
radiation
11 马达散热进气门
Air inlet ○120 (with protective
12
12 cover)
进风口 O120（有护盖）

637

6 8
2322
2000

10
1223

11

9 12
1 2 3 4 5
3600 1900
1980

-7-
External Views of the SWT315-450W and the
SWTV315-375W

Exhaust port flange

1
DN125
Water outlet of
2
intercooler ¼”
Water outlet of
3
after-cooler ¼”
4 Oil drain ¾”
Outlet pipe of
5
cooling water 3”
Inlet pipe of cooling
6
water 3”
Service entrance
7
Ф120
Air inlet window
8
640×638×2
9 Air exit
10 Display screen

-8-
 Introduction to the Oil-free Screw Air Compressor
I. Introduction to the FushengTM oil-free screw air compressor
The FushengTM oil-free screw air compressor features novel structure, a small number of
wearing parts, low vibration, noise and energy consumption, high efficiency, long useful life,
and reliable operating performance.
1. The overall structure is compact, and the air pipeline is made of stainless steel pipes; the integrated
electric control box and control system saves design space, and makes the unit look artistic and
novel.
2. This two-stage compressor is absolutely free from oil; the precise engagement of rotors ensures
efficient output; the super coating and the antirust materials used in the unit provide you with
high-quality compressed air.
3. The precise engagement of rotors meets the air consumption of the user at minimum costs; the
inverter translates into maximum energy savings.
4. The unit is provided with a sophisticated electronic monitoring system, and all data is displayed on
the control panel for the convenience of setting, operation and monitoring.
5. In the outer fin type coolers, air flows through the casing and water flows through the pipeline,
featuring uniform water flow rate and high heat exchange efficiency, keeping impurity deposits at a
minimum. The cores of the coolers can be removed for easy cleaning.
6. The unit has reliable operating performance and long useful life. All parts of the unit are made of and
connected with stainless steel, and are therefore durable; the rotors of the unit are protected with a
super coating for higher impact resistance; the dew point control system reduces the impact of
water beads on the rotors, and prolong the useful life of the unit.
7. The unit is easy to maintain. All door plates are removable, so that every service point is visible to
you for quick maintenance; the air filter box is provided with an additional filter element gate; when
the filter element gate is opened, the filter element can be replaced or cleaned.

II. Operating Principle of the FushengTM Oil-free Screw Air Compressor (refer to the figure
below)
1. Operating principle of the body

Figure 1: Schematic diagram of the body

Zone A is the intake zone of the body, and Zone B is the exhaust zone of the body; “1” denotes the

-9-
 male rotor of the body, and “2” denotes the female rotor of the body. When air enters Zone A via the
air cleaner and the intake valve, the negative pressure produced by the engagement and
high-speed rotation of the male and female rotors will suck the air in Zone A into the gap of the
engagement zone of the male and female rotors. With the rotation of the rotors, the rotor
engagement zone will progress to Zone B until it enters Zone B and then the cooler. With this cycle
repeating, air will be compressed from Zone A into Zone B continuously to produce compressed air.

2. Intake and release process

Heavy load Air inlet

Compre
ssed air

Building up oil
pressure
No load
Release port Air inlet

Compress
ed air

Relieving oil pressure

Figure 2: Structural and schematic diagram of intake valve

When the unit is under heavy load, the oil pump will start, an oil pressure will build up in the oil
hydraulic cylinder, and the oil pressure rod will drive the link to swing. When the air inlet opens, the
“release port” will close and the unit will be loaded. When the unit is under no load or stops, the
loading/unloading T-joint solenoid valve will operate to release the oil pressure, the oil pressure rod
will reset, the link will open the T-joint “release port” while driving the intake valve to close, and the
unit will run under no load; in case of shutdown, the unit will begin to release the oil pressure
thoroughly.

III. Other structural features

1. Unique cooler design

Since the unit compresses air only, it will generate a lot of heat, so it is critical to radiate heat from
compressed air effectively. We employ a large-capacity shell and tube cooler, whose casing is
made of stainless steel. Compressed air flows through the casing side, and cooling water flows
through the pipeline. The cooling water pipeline is wrapped by copper fins uniformly, so that
compressed air and cooling water can conduct heat exchange to the greatest extent, ensuring the

- 10 -
 high quality of compressed air; the cooling core can be removed easily for cleaning and
maintenance.

2. Low vibration and noise

Through the precise fitting of gears and bearings, the body of the unit features low vibration and
stable operation. The unit has been dynamically balanced before installation to ensure stable
operation and minimum vibration. An exhaust muffler duct (as shown in the figure below) is provided
at the exhaust end of each stage of the body, reducing the noise at the exhaust end greatly.

The special design of the acoustic hood and the muffler reduce noise at the sound source.

Figure 3: Structural diagram of muffler duct

- 11 -
System Flowchart of the Oil-free Screw Air Compressor

PDS
TI
PI PT
Air loop
气路(AIR)

油路(OIL)
Oil loop

水路(WATER)
Water loop
泄水(WATER)
Water drainage
TI

PDS

M TO OILPUMP
PT TI

PT TI

TO GEARBOX

PT TI

LI
压缩空气
Compressed
出 口
air

冷却水
Cooling water
进 口

冷却水
Cooling
出 口 water

System Flowchart

- 12 -
List of components
Code Name of component Code Name of component Code Name of component
1 First body stage 15 Oil tank 29 Release muffler
2 Second body stage 16 Oil level gauge 30 Puff port
Loading/unloading
3 Gear box 17 Oil pump 31
solenoid valve
4 Motor 18 Oil cooler 32 Dew point control valve
5 Coupling 19 Thermal valve 33 Flow switch
6 Air cleaner 20 Oil filter 34 One-way valve
Oil hydraulic cylinder of
7 21 Release valve 35 One-way valve
intake valve
First stage exhaust
8 22 Ball valve 36 Y filter
muffler pipe
Second stage exhaust
9 23 Ball valve 37 Y filter
muffler pipe
10 Safety valve 24 Ball valve PT Pressure transmitter
11 Safety valve 25 Ball valve TI Temperature sensor
Mechanical automatic
12 Intercooler 26 PI Pressure indicator
drain valve
Electronic automatic Differential pressure
13 After cooler 27 PDS
drain valve switch
14 One-way valve 28 Primary oil filter

I. Air flow (refer to the system flowchart)

First stage
Atmosphere Air filter Intake First body Intercooler
exhaust
valve stage duct

Differential Loading To temperature sensor,

pressure switch /unloading Release pressure transmitter and
(PDG) of air filter solenoid valve muffler safety valve

Air Second
consumption After cooler One-way stage Second
system valve exhaust body stage

To temperature sensor, To
pressure transmitter and temperature
safety valve sensor

- 13 -
A. Air will enter the first body stage for compressor via the intake valve after being filtered of
dust by the air cleaner. The compressed air will be cooled in the intercooler and further
compressed in the second body stage, and the air compressed in the second stage will be
cooled by the after cooler and delivered to the consumption system.

B. Functional description of components in the main air source passage

1. Air filter
The air filter is a dry paper filter, and should be removed for surface cleaning every 1,000 hours of
operation by blowing dust off outwards with low-pressure air. If the differential pressure switch of the
air cleaner on the display panel gives an alarm, the air filter must be cleaned or replaced. The
cleaning or replacement interval of the air filter is closely related to ambient cleanliness.

2. Differential pressure switch

When the differential pressure reaches the set value, the system will give an alarm that the oil filter
should be replaced.

3. Intake valve
The intake valve is controlled by an oil hydraulic cylinder. When it starts, the oil pump will operate
and produce an oil pressure that forces oil into the oil hydraulic cylinder, which will drive the link to
swing, open the intake valve and close the release T-joint to create the intake condition. When the
unit stops, the solenoid valve will release the oil pressure, and the oil pressure rod will reset, driving
the link to close the intake valve and open the drain valve for release.

4. Intercooler and after cooler

Compressed air flows through the casing side of the coolers; cooling water flows through the pipe
side of the coolers, and this pipe is wrapped by copper fins (see the cooler cleaning section for the
detailed structure). Compressed air will enter the fin layer from the upper part of the coolers and be
discharged from the lower part to create a cooling effect. A drain valve is provided below the cooler
and should be opened at each startup. The cooler core should be cleaned regularly at the
maintenance interval of the unit.

5. Mechanical automatic drain valve

The prolonged operation of a cooler will generate condensate. When the condensate level is
sufficient to make the ball of the mechanical drain valve float, the automatic drain valve will open
automatically to drain water, and the water level will drop; when the ball resets, the automatic drain
valve will close. This cycle will ensure that a cooler is free from condensate.

6. Electronic automatic drain valve

The operation of a cooler will generate condensate. The electronic automatic drain valve will open
regularly to drain water (the interval is the optimum interval obtained from long-term experiments) to
ensure that no condensate will build up in a cooler.

7. Safety valve
When the pressure switch is maladjusted or fails so that the pressure in the air loop is higher than
the set exhaust pressure by over 10%, the safety valve will open automatically to let the pressure
drop below the set exhaust pressure. The safety valve has been adjusted before factory release
and should not be adjusted without authorization.

8. Exhaust muffler duct

Reducing the exhaust noise by rectifying the air flow

- 14 -
9. One-way valve
Preventing compressed air from reflux

10. Release muffler

Reducing the release noise

11. Temperature sensor

Detecting temperature and monitoring the operating status of the unit in real time

12. Pressure transmitter

Detecting pressure and monitoring the operating status of the unit in real time

13. Puff port

Ensuring that the atmospheric pressure is maintained in the oil tank and out of the oil seals, and
preventing oil from entering the body due to any differential pressure

II. Lubricant flow (refer to the system flowchart)

A. Oil flow
inverter
models to be
added
Oil

solenoid valve
/unloading
Auxiliary release
oil pump ball valve Oil cooler Loading Intake Oil tank
valve

Oil pump Safety Thermal Release

release valve Oil filter
of oil pressure valve valve

Differential
pressure Pressure
switch of oil
filter gauge

Primary oil
filter L/R gear
boxes
Manifold block

Puff port Oil tank Oil seal

Front/ rear
Oil release
bearings
ball valve

To temperature sensor and

pressure transmitter

When the lubricant in the oil tank has no pressure, the lubricant will be extracted from the oil pump
at the shaft end and enter the thermal valve via the primary oil filter. When the lubricant temperature
is below the set value of the thermal valve, the thermal valve will close, and the lubricant will flow
through the thermal valve and the oil filter (when the lubircant temperature reaches the set value of
the thermal valve, the thermal valve will open slowly, and the lubricant will flow through the thermal
valve and then through the oil filter after being cooled by the oil cooler). Afterwards, the lubricant will
flow in two ways: In one way, the lubricant will enter the oil hydraulic cylinder of the intake valve at

- 15 -
 the original pressure, and be controlled by loading/unloading solenoid valve so that when the unit is
being loaded, the intake valve will open to take in air and the release T-joint on the intake valve will
close, and when the unit is being unloaded, the intake valve will open and then close, and the
release T-joint on the intake valve will open for release. In the other way, when the pressure of the
release valve drops to 0.15-0.18MPa, the lubricant will enter the gear box and the front/rear
bearings for lubrication and cooling, and finally return to the oil tank.

B. Functional description of components in oil loop

1 Oil pump
Increase the lubricant pressure in the oil tank to above 0.3MPa

2 Primary oil filter

Filtering off impurities in the oil loop preliminarily

3 Oil cooler
A water cooling oil cooler (water flow side) that cools the lubricant with cooling water

The cooling effect of a water cooling cooler is directly related to the temperature and flow rate of
cooling water; the water pressure should be within 0.2-0.4MPa.

4 Thermal valve
It is used to keep the lubricant temperature within a certain range. When the unit has just started,
the lubricant temperature is low, when the thermal valve will open the reflux circuit, and the lubricant
will enter the body without going through the oil cooler. If the lubricant temperature rises to over
40℃, the thermal valve will open slowly and be fully open at 48℃, when the lubricant will enter the
body after being cooled by the oil cooler.

5 Oil filter
The oil filter is a paper filter, used to remove impurities from the lubricant, such as metal particles
and deterioration products of the lubricant, with filter fineness of below 10μ, playing a good
protective role for bearings and rotors. If the oil filter should be replaced may be judged from its
differential pressure indicator. If the differential pressure indicator is illuminated, the filter is blocked
and must be replaced. For a new unit, the lubricant and the oil filter should be replaced after the first
500 hours of operation, and then replaced as indicated by the differential pressure indicator or
according to the maintenance schedule. If the oil filter has not been replaced while the differential
pressure is high, the unit may trip due to insufficient lubricant and high exhaust temperature, and the
useful life of the unit may be shortened.

6 Release valve
The direct pressure of the oil pump is over 0.3MPa, and can be reduced to 0.15-0.18MPa through
the release valve; the latter is the best pressure for oil injection.

7 Pressure indicator
Displaying and monitoring the lubricant pressure

8 Differential pressure switch

When the differential pressure reaches the set value, the system will give an alarm that the oil filter
should be replaced.

9 Temperature sensor
Detecting temperature and monitoring the operating status of the unit in real time

- 16 -
10 Pressure transmitter
Detecting pressure and monitoring the operating status of the unit in real time

11 Oil level gauge

Monitoring the oil level of the oil tank

III. Cooling water system

Y filter One-w Mechanical

ay drain Ball
valve valve valve

Water flow Main inlet

Main inlet pipe of cooling water

Intercooler pipe of
Main inlet pipe of cooling water

regulating
valve cooling
water

Cooling water
Flow switch circulation
Oil cooler
system

After
cooler

Electronic
One-way drain Ball
Y filter valve valve valve

Ball
valve

The main cooling water pipeline leads to the intercooler, the after cooler and the oil cooler in three
ways for cooling.

1. Dew point control valve

It is mounted on the cooling water loop of the intercooler. When the intake temperature of the
second stage (after cooling by the intercooler) is lower than the set dew point, the dew point
controller will make the motor valve close slowly until the intake temperature of the second stage
reaches the set dew point, and vice versa.
2. Flow switch (user-installed)
Detecting the flow rate of the main water pipeline and giving an alarm if the flow rate is insufficient.

- 17 -
 Installation Instructions for the Unit

I. Handling
Take care during transport and handling. Handle the unit with care. When carrying the
unit with a forklift or hoisting it with lifting ropes, protective pads should be added at
appropriate positions (as shown).

Support
with a soft
object.

Use the hoisting

method shown in the
figure, and support
with a soft object.

II. Installation
The choice of the installation site is the most likely to be neglected by the staff. The unit
is often piped and operated immediately at a random site after purchase without any
prior planning. Such recklessness may become the cause of difficulty in repair of the

- 18 -
 unit or bad quality of compressed air. Therefore, selecting a good installation site is a
prerequisite to the proper operation of the unit.
1. An open and well-day-lit site should be selected for the convenience of operation, examination
and repair.
2. The air around the installation site should have a relatively low humidity and be clean, and the
site should be well ventilated.
3. The ambient temperature should be lower than 46℃. The higher the ambient temperature is,
the less the air output of the unit will be. If the unit is placed in an enclosed compressor room,
an exhaust blower must be provided to maintain the temperature of the room, and the air output
of the exhaust blower must be higher than that of the cooling fan of the unit.
4. If the environment of the plant is poor and dusty, a prefilter should be installed.
5. An access road should be reserved and an overhead crane installed (especially necessary for
high-power compressors) for the convenience of repair and maintenance.
6. The unit should be kept away from walls by at least 1m for the purpose of maintenance.
7. The unit should have a headspace of at least 1m.

Note: 1. The floor of the installation site of

If the unit is placed in an
enclosed compressor room, the unit must be kept level, and a soft
an air duct must be provided cushion or absorbing pad should be
to maintain the temperature of preferably put under the bottom of the
the room, the air output of the unit to reduce vibration and noise.
exhaust blower must be higher 2. A space of at least 900-1,100mm
than that of the cooling fan, should be kept around the unit
and the entrance area of cool (depending on the model) for the
air must be sufficient. convenience of air suction, piping,
maintenance and repair.
3.A distance of at least 1,500mm
should be kept above the unit to
facilitate the proper circulation of the
heat radiation system of the unit.

A distance of at least
1,000mm should be
kept in this direction
for the purpose of
maintenance and
repair.

A distance of at
least 1,100mm
should be kept in
this direction for the
purpose of pipe
connection.

There is a suction port here. A space of at least 1,000mm

A distance of at least 1,000 should be kept in the front for
mm should be kept in this the convenience of
direction for the purpose of maintenance and repair of the
ventilation. access door.

Schematic Installation Diagram

III. Precautions for piping, foundation and cooling system

1. Precautions for piping of air pipeline

- 19 -
 1) The main pipeline should have an inclination of 1°-2° to facilitate the drainage of
condensate.
2) The pressure drop of any pipeline should not exceed 5% of the set pressure of the unit,
and a larger pipe diameter is preferred.
3) A branch pipeline must be led out from the top of the main pipeline to prevent condensate
therein from flowing down into the unit, and a one-way valve should be provided for the air
outlet pipeline.
4) The tools to be lubricated should be a triple combination (air water filter, pressure regulator
and oil supplier) in order to maintain the useful life of such tools.
5) The main pipeline should not be changed in size arbitrarily. If it has to be diminished or
expanded, a reducing pipe must be used, otherwise a mixed flow may occur at the joint,
resulting in a high pressure loss and affecting the useful life of the pipeline greatly.
6) If there are purifying and buffering devices, such as air storage tank and drier, after the unit,
the ideal configuration should be the unit + air storage tank + drier. Thus, the air storage
tank may filter off part of condensate, and the air storage tank can also reduce the exhaust
temperature of the air. When cooler and dryer air enters into the drier again, the load of the
drier can be reduced.
7) If the air consumption of the system is very high for a short period, an air storage tank
should be preferably installed for buffering so as to reduce the frequency of starting the unit,
which is very useful for the unit.
8) For compressed air with a system pressure of below 1.5MPa, the flow rate in the delivery
pipeline must be lower than 15m/sec so as to avoid any excessively high pressure drop.
9) Elbows and valves used in the pipeline should be kept at a minimum to reduce the
pressure loss.
10) Ideally, the main pipeline should surround the whole plant building, so that compressed air
is available in two directions at any position. If the air consumption of any branch pipeline
increases suddenly, the pressure drop can be reduced. Appropriate valves should be
provided on the circular main pipeline for the convenience of cutoff for examination and
repair.
2. Foundation
1) The foundation should be built on hard soil; before installation, the foundation plane must
be leveled to avoid high noise due to the vibration of the unit.
2) If the unit is installed on an upper floor of a building, proper anti-vibration treatment should
be made to prevent vibration from being transferred to lower floors or causing resonance,
which is a potential safety hazard for the unit and the building itself.
3) The ground on which the unit is placed should be flat and should not be composed of soft
soil.
3. Cooling system
The compressors in this series are of the water cooling type, where particular attention should
be paid to the pressure, amount and temperature of cooling water. In addition, the unit should
not be placed near any high-temperature machinery or in a poorly ventilated enclosed room so
as to avoid low air consumption or even tripping of the unit due to excessively high intake
temperatures. If the unit is operated in an ordinary enclosed system, an exhaust device should
be installed to facilitate air flow. Generally speaking, the exhaust air flow should be greater than

- 20 -
 the air flow for heat radiation of the unit.

IV. General electric rules and safety specifications

1 A proper power route should be selected based on the power of the unit. No excessively
small wire size should be used, otherwise the power cord may be burnt out due to high
temperatures.
2 The unit should preferably be serviced by a separate power system. In particular,
operating it in parallel with any other system with different power consumption should be
avoided. In case of parallel operation, an excessively voltage drop or the imbalance of the three
phase currents may overload the unit, thereby causing the guards to trip.
3 An NFB (no-fuse breaker) suited to the power of the unit should be installed to ensure the
safety of the power-consuming system and maintenance.
4 The unit must be wired under proper voltages.
5 The ground wire of the motor or the unit should be provided practically to avoid the risk of
current leakage. The ground wire should not be connected directly to the air delivery pipeline or
the cooling water pipeline.
6 Generally, the imbalance of a three-phase power supply should not exceed 3%.
7 The power supply must be cut off before any electric repair work is carried out.

- 21 -
 Safety Protection System and Warning Devices

1 Motor overload protection

Usually, when the operating current of the motor exceeds the upper limit of the over-current
protector, the over-current protector will cut off heavy current control automatically and the unit
will stop running. At this point, the unit cannot start unless it is reset. The unit should be reset by
holding down to reset the setting switch and enter the corresponding alarm reset password (this
is used to ensure that the user knows about the condition of the unit). The over-current protector
has been set before factory release, and is particularly important for protecting the proper
operation of the motor, so its settings should not be modified without authorization.
1) Manmade operating error: such as increasing the exhaust pressure without authorization
and improper system adjustment
2) Mechanical failure: such as internal wear of the motor, phase failure of the motor,
non-operation of the safety valve, failure of system settings, and loaded starting due to the
incomplete closing of the intake valve, etc.
If the motor is found to be overloaded during operation, please contact the manufacturer
immediately, which should assign a technician to find out the cause, otherwise the
motor may burn out.
2 Exhaust over-temperature protection
The design maximum exhaust temperature of the system is 210℃. If the exhaust
temperature exceeds 210℃, the control panel will give an alarm by flashing. If the exhaust
temperature exceeds 220℃, the system will cut off the power supply automatically. There
are many causes of exhaust over-temperature, but the most common cause is the failure
of the cooler, which may be attributed to the insufficiency or over-temperature of cooling water
(failure of the cooling water tower), the blocking of the water pipeline or the blocking of the fins of
the air loop (resulting in increased load of the unit).
The design maximum ambient temperature of the unit is 40℃, so it is necessary to select a cool
and ventilated site to place the unit.
When protective tripping occurs due to exhaust over-temperature, the starting circuit of
the system will be cut off, and it is impossible to start the system again. The system can
only be started after the reset button has been pressed and the alarm has been released.
3 Alarm system
The unit is provided with alarms, and an alarm signal will be displayed on the control panel when
the air cleaner or the oil filter is blocked. When an indicator is illuminated, a filter has been
blocked and must be replaced as soon as possible, otherwise the performance and safe
operation of the unit will be affected.

- 22 -
 Control System

1. Control system
1) Starting
Before starting, make sure everything is okay, and then press the “ON” button to start the motor,
open the intake valve and operate the unit.
2) Shutdown
Press the “OFF” button to close the intake valve and discharge air. The exhaust fan will run
continuously for 3-5 minutes to ensure that the internal temperature of the unit will not be too
high.
3) Emergency stop
When the exhaust temperature exceeds 220℃ or the over-current protector starts due to the
overload of the motor, the over-current protector will cut off heavy current control automatically,
the control panel will give an overload alarm, the motor will stop running, and the intake valve
will be closed to discharge air. The exhaust fan will run continuously for several minutes to
ensure that the internal temperature of the unit will not be too high. Only if any emergency
arises during the operation of the unit can the emergency stop button be pressed.
Never start the motor too frequently, otherwise the motor may burn out.

2. Electric wirings
The unit is electrically controlled by two systems – the internal control system and the
starting board. The starting board controls starting through the Y-△ structure commonly used
in machines or through an inverter. The control section is controlled by a microcontroller.
Microcontroller control will not be discussed in more detail here due to complex internal wirings
and principles. If the starting board is damaged or fails, please contact the Fusheng service
center directly for replacement.

- 23 -
Control Wiring Diagram of the SWT110-250W Oil-free Screw Air Compressor (Standard Model)

Note: This control wiring diagram is for reference only; please refer to the diagram attached to the unit.

- 24 -
Control Wiring Diagram of the SWT315-375W Oil-free Screw Air Compressor (Standard Model)

Switchin
g power
l

Power indicator

Start indicator

Stop indicator

control output

control output
Close/remote

Close/remote
Serious fault
high-voltage

high-voltage

Slight fault
Starting of

Operation

Backup

Backup
Stop of

output

output

output
motor

Note: motor
1. This schematic diagram applies to the dry-type screw starting board.
2. The controller employs the Mitsubishi FI2N series PLC,3.8” touch screen.
3. The voltage of the control power supply is 3-AE380V, 50HZ.
4. The model of the control transformer PTL is JBK3-1KVA (380V/220V
(950VA/35V (50VA)).
5. The specification of the fuses FU1-FU2 is 6A, and that of FU3 2A.
Note: This control wiring diagram is for reference only; the diagram attached to the unit shall prevail.

- 25 -
 Control Wiring Diagram of the SWTV110-375W Oil-free Screw Air
Compressor (Standard Model)

 No-fuse breaker (NFB) and leakage circuit breaker

 Select an NFB of an appropriate rated current by referring to
Power supply Table 3.
 Do not use the NFB to start/stop the inverter.
 If a leakage circuit breaker is installed for current leakage
No-fuse breaker NFB
(and leakage circuit
protection, please select one with an induction current of over
breaker) 200mA and an actuation time of over 0.1 second to prevent
mis-operation at high frequencies.
 Electromagnetic contactor
 An electromagnetic contactor is not necessary during ordinary
operation; however, when the unit is to restart automatically
Electromagnetic
after external sequential control or power cut, for example, an
contactor
electromagnetic contactor should be provided.
 Try to avoid using the electromagnetic contactor to start/stop
the inverter.
 AC reactor

AC reactor  Models of 30HP or more come standard with a DC reactor.

Generally, it is not necessary to install an external AC reactor.
However, to further improve the power or inhibit external
surges, an AC reactor may be provided (300-400HP as
standard).
* 300-400HP models must be provided with an external AC
reactor.
Input noise filter  Input noise filter
 A special filter is provided to meet the EN55011A standard.
 See the Technical Manual for the selection of the input noise
filter.
Inverter SVC  Inverter
 Terminals R, S and T on the input side do not distinguish
between phase sequence, and may be changed randomly.
 Make sure the earth terminal has been grounded
Output noise filter
practically.
 Output noise filter
 If a noise filter is installed on the input side of the inverter, the
radiated interference and the induced noise may be reduced.
3-phase  Refer to Section 1.9.2 on the selection of the noise filter.
induction
motor  Motor
 If one inverter drives multiple motors, the rated current of the
inverter must be greater than the total current of the motors
running concurrently.
 The motors and the inverter should be grounded separately.
Mutual wiring

- 26 -
 Example of standard wiring diagram of special inverter for SVC compressor (◎ denotes a terminal
on the main circuit and ○ denotes a terminal on the control circuit.)
See Tables 1 and 2 for a description of the terminals of the main and control circuits.
Brake resistor
(optional)

P B

MCCB ○- B2
B1/P
L1(R) L1(R) T1(U) Motor
3-phase
power L2(S) L2(S) T2(V) IM
supply
200-230V L3(T)
50/60Hz
L3(T) SVC T3(W)
E
Forward run/stop (Continuous input Grounding (Type 3, resistance <100Ω)
1 FWD forward)
Backward run/stop (Continuous input
2 REV
External abnormity backward)
3 Eb 21
Abnormity reset Multifunctional analog
Multi-stage speed 4 RESET
instruction 1 Analog output output (factory setting:
(Main/aux. switching) 5 22 output frequency)
Standard Multi-stage speed FM
- +
instruction 2
functions at 6 Multifunctional (12)
factory Inching instruction contact terminal Pointer frequency meter
7 (Spec.: DC 3V 1mA)
release
External BB Common terminal of
8
11 input signal (0V) 18
Abnormal contact output
Shielded wire terminal 19 <250V AC 1A
2kΩ 12
Power supply for <30V DC 1A
speed setting 20
15
+15V 20mA
External 0-+10V
13 Main speed instruction 0-10V(20kΩ) Multifunctional contact output
frequency Main speed instruction <250V AC 1A
instruction 4~20mA 14 4-20mA(250Ω) 9
P <30V DC 1A
0~+10V 10 (Factory setting: operating signal)
16 Multifunctional analog
0V P P 17 input 0-10V(20kΩ)

0V 25

Multifunctional open connector

output 1 (factory setting: zero
speed signal)
26 <48V 50mA

Multifunctional open connector output 2

(factory setting: speed consistency signal)
27

Notes: 1. is a shielded wire, is a shielded twisted wire.

2. The output of Terminal 15 is +15V and up to 20mA.
3. Terminals 13 and 14 cannot be used concurrently (when they are used concurrently, the frequency
instructions should be added.)
4. Terminal symbols: ◎ denotes a terminal on the main circuit and ○ denotes a terminal on the control
circuit.
5. The multifunctional analog output is an analog output specially for such meters as the frequency
meter. Do not use it for the feedback control of the control system. If a feedback signal is to be
used, a selective adapter card may be selected (AO-12 card).

Note: This control wiring diagram is for reference only; the diagram attached to the unit shall prevail.

- 27 -
 Operation of the FushengTM Oil-free Screw Air Compressor

I. Trial run, starting and shutdown

1. Connect the power cord and the ground wire, and check if the power voltage is correct and
the three-phase power supply is properly connected.
2. Check if the oil level in the oil tank is within the normal range.
3. Check the cooling water system, the intake system and the exhaust system.
4. Check the cooling system.
5. Press the Emergency Stop button within several seconds of pressing the “ON” button to see if
the unit runs in the proper direction (as indicated by the arrow); if not, exchange any of two of
the three wires.
6. Press the “ON” button again to start the unit.
7. See the meters and indicators for any abnormal indication.
8. 10-15 seconds after the “OFF” button is pressed, the controller will stop the motor to prevent
the unit from being damaged by shutdown under heavy load.

II. Pre-starting inspection

An inspection should be performed before starting to prevent any major fault of the unit and
improve operating efficiency.
1. Check the lubricant level, which should not be excessively high or low. The lubricant should be
replenished when it is insufficient. Do not use any lubricant not supplied by Fusheng. The
lubricant level should be observed 10 minutes after shutdown.
2. Check if the pressure of the cooling water is 2-4kg and if the cooling water tower runs
properly.

III. Precautions during operation

1. The unit should be stopped immediately when there is noise or abnormal vibration during
operation.
2. All pipelines and containers are pressurized during operation. Do not loosen the plug of any
pipeline or open any valve unnecessarily.
3. During prolonged operation, if the lubricant level indicated by the oil level gauge is found to be
insufficient and the lubricant temperature is rising gradually, stop the unit immediately and
observe the lubricant level 10 minutes later. The lubricant should be replenished when it is
insufficient.
4. The intercooler and the after cooler are provided with an automatic drain valve, otherwise water
will be taken into the system. Check if the automatic drain valves operate properly. If any valve
is blocked or damaged, it should be repaired or replaced timely.
5. Check the voltage, current, air pressure, exhaust temperature, lubricant level, oil pressure and
other parameters indicated by the meters every two hours of operation for future reference.
6. Rotating parts may cause personal injuries. Do not open the door or the protective cover when
the unit is running.

IV. Measures for prolonged shutdown

- 28 -
 If the unit is not to be operated for a long time, the following measures should be taken carefully,
especially in high humidity seasons or areas.
1. If the unit is not to be operated for 3 weeks or more
1) Wrap the motor control panel and other electric devices with plastic or oilpaper to prevent the
entry of moisture.
2) Any existing fault should be removed in advance for the sake of future operation.
3) After the unit has been shut down for several days, drain condensate from the coolers.
2. If the unit is not to be operated for 2 months or more, the following measures should be
taken in addition to the above measures:
1) Close all openings to prevent the entry of moisture and dust.
2) Wrap the safety valve and the control panel with oilpaper or other similar paper to prevent
rusting.
3) Before the unit is shut down, replace the lubricant and run the unit for 30 minutes; remove
condensate from the coolers 2 or 3 days later.
4) Move the unit to a clean and dry place where possible.
3. Restart procedure
1) Remove the plastic or oilpaper from the unit.
2) Measure the insulation resistance of the motor, which should be over 1MΩ.
3) The other steps are the same as those of trial run.
4. Introduction to control panel (see the description of the control system for details)

- 29 -
 Maintenance and Inspection of the FushengTM Oil-free Screw Air
Compressor

I. Specifications and maintenance of special lubricant for the FushengTM oil-free screw air
compressor
1. The lubricant can be critical to the performance of the unit; if it is improperly used, the
unit may be seriously damaged or even a fire may occur. Therefore, the FushengTM
lubricant must be used.
2. Factors affecting the lubricant replacement interval
1) Poor ventilation or excessively high ambient temperature;
2) High humidity or high dust level;
3) The recommended lubricant replacement interval is one year.
When the operating conditions are very harsh (very dirty or very humid, etc.), it is necessary to
increase the frequency of lubricant replacement. The interval of lubricant replacement should be
based on the operating conditions and an analysis of the appearance of used lubricant.
3. Replacement of lubricant (see the attached General Lubricant Replacement
Procedure of the FushengTM Oil-free Screw Air Compressor)
1) Operate the unit to increase the lubricant temperature and facilitate discharge. Then press the
“OFF” button to stop the unit.
2) Open the oil drain slowly to prevent the lubricant from splashing.
3) After the lubricant has been fully drained, close the oil drain and open the oil filler cap to inject
fresh lubricant. Be sure to drain up all lubricant in the system, including that in the pipelines and
coolers. If the lubricant is replaced when its temperature is high, be careful of scald.
4. Precautions for the use of lubricant
1) If the unit is operated for the first time, it is advised to replace the lubricant at about 2,000 hours
of operation, and this interval may be extended to 4,000 hours if the lubricant has no abnormity.
Afterwards, the lubricant should usually be replaced every 4,000 hours of operation. However, if
the operating environment of the unit is poor, such as high temperature and much dust, the
lubricant replacement interval should be shortened appropriately.
2) Never use the lubricant beyond its useful life. The lubricant should be replaced timely, otherwise
the quality and performance of the lubricant will deteriorate, and the unit is likely to burn out.
3) After the unit has been operated for two years, it is advisably to clean the oil loop systematically
with lubricant. The method is to replace the lubricant with fresh FushengTM lubricant immediately
after the unit has run for 6-8 hours, so that organic compounds remaining in the system can be
rinsed out, so that the new lubricant will have a longer useful life.

II. Adjustment of safety valve

The discharge pressure of the safety valve is usually set as 10% higher than the maximum
exhaust pressure, and has been set before factory release and needs no further adjustment. If
the discharge pressure of the safety valve has to be adjusted for any other reason, loosen the
locknut above the safety valve and adjust the adjusting screw. Turn it clockwise to increase the
discharge pressure or anticlockwise to decrease the discharge pressure. After the discharge
pressure has been set, tighten the locknut. Setting the safety valve improperly may damage the

- 30 -
 unit and may even result in a safety accident, so please not change the setting arbitrarily

III. Replacement of oil filter

1. Shut down the unit.
2. Ensure that the oil pipeline is free from pressure to prevent oil jetting.
3. Replace the oil filter with a new one using a special tool.

IV. Cleaning of air cleaner

Remove the gate of the air filter, screw off the butterfly nut
and remove the filter element.
Blow dust off the filter element with low-pressure
compressed air (0.2MPa) (as shown in the figure).
Blow dust off the air filter box and the air duct with an air
gun.
After cleaning, fit the filter element into the air filter box and
replace the air filter gate.

V. Cleaning of cooler

If the water pipeline is cleaned only, remove the end cap of the
cooler only, and clean the water pipeline with a detergent.
To clean the fins: As shown in the figure, remove the bolts, and
then pull out the cooler core slowly with a traveling crane or
electric hoist until the cooler is pulled out;
Then clean the cooler casing and the cooler core. Note that the
cooler core should be cleaned in a way that does not damage the
cooler fins;
After cleaning, replace the cooler fins, and replace the cooler core
into the casing with a traveling crane or electric hoist.
Note: An antirust agent should be applied on the screws so as not
to hinder the next cleaning operation.

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VI. Cleaning of filter screen

Remove the filter screen;

Blow dust off the filter screen with low-pressure compressed air
(0.2MPa) (as shown in the figure, do not remove the filter
screen);
After cleaning, replace the filter screen.

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 Maintenance and Troubleshooting

I. Routine maintenance
1. Before each day or each run: the same as the pre-starting inspection (Refer to the
previous section.)
2. 500 hours of operation
1) Remove the air filter element for cleaning by blowing it outwardly with low-pressure
compressed air of lower than 0.2MPa (G).
2) When the oil filter of a new unit is replaced for the first time
3. 2,000 hours of operation or 6 months
1) Check all pipelines for any oil leak or air leak, and if the pipe joints, retaining bolts and wire
terminals are tightened securely.
2) Replace the filter element of the air filter and the oil filter.
4. 4,000 hours of operation or 1 year
1) Clean the intake valve.
2) Replace the lubricant.
3) Check and clean the thermal valve.
4) Clean the cooler core and replace the seal ring.
5) Replace the air filter element and the oil filter.
6) Check the operation of the starter.
7) Check all protective differential pressure switches for proper operation.
5. Every 20,000 hours of operation or 5 years
1) Replace the body bearings and oil seals, and adjust clearances.
2) Maintain or replace the second body stage as the case may be.
3) Measure the insulation resistance of the motor, which should be over 1MΩ.
Please observe Attached Table 1 “Replacement Schedule of Spare Parts”.

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 Troubleshooting Table
No. Fault symptom Possible cause Measure

1. Blowing of the fuse 1. Have a maintainer check/replace it.

2. Operation of the protective relay 2. Have a maintainer check/replace it.
3. Failure of the starting relay 3. Have a maintainer check/replace it.
4. Bad contact of the start button 4. Have a maintainer check/replace it.
Failure of starting 5. Under voltage 5. Have a maintainer check/repair the
(The electric 6. Failure of the motor electric system.
1
failure indicator is 7. Failure of the body 6. Have a maintainer check/replace it.
illuminated) 8. The controller detects a phase 7. If no other cause can be found, contact
sequence error. the Fusheng service center.
9. Disconnection of the pressure 8. Check the power cord and its contacts.
transmitter / temperature sensor 9. Have a maintainer check/replace it.
10. Failure of inverter (for inverter models) 10. Have a maintainer check it.
1. Have an electrician check the power
The unit trips
grid.
automatically due 1. Under voltage
2. Adjust the pressure setting of the
to high operating 2. High exhaust pressure
controller.
2 current. 3. Driving system
3. Check and adjust it.
(The electric 4. Blocking of the cooler
4. Clean the cooler.
failure indicator is 5. Failure of the body
5. If no other cause can be found, contact
illuminated)
the Fusheng service center.
1. Excessively high air consumption
1. Check the air consumption; check the
(pressure below set value)
The operating pipelines for any leak.
2. Blocking of the air filter
current is lower 2. Clean or replace it.
3 3. Poor operation of the intake valve
than the normal 3. Remove it for cleaning.
4. Improper parameter setting of the
value. 4. Contact the Fusheng service center.
inverter or controller
5. Clean the cooler.
5. Blocking of the cooler
The intake
temperature of the 1. Failure of the dew point control system 1. Check the dew point control system
4 second stage is 2. Failure of the temperature sensor 2. Replace the temperature sensor
lower than the set 3. Damage of the dew point control valve 3. Replace the dew point control valve
value.
The unit trips
1. Failure of the dew point control system 1. Check the dew point control system.
automatically due
2. Excessively high ambient temperature 2. Increase the exhaust capacity and
to high exhaust
3. Unclean air cleaner reduce the room temperature.
temperature, and
4. Insufficient cooling water pressure 3. Clean the air cleaner with
5 an over-
5. Excessively high cooling water low-pressure air.
temperature alarm
temperature 4. Check the water loop.
is given (beyond
6. Blocking of the heat radiation system 5. Check the cooling water tower.
the upper limit of
of the acoustic hood 6. Check the heat radiation system.
protection)
6 Oil in air 1. Failure of the body 1. Contact the Fusheng service center.
1. Failure of the pressure transmitter
1. Replace it.
2. Poor operation of the intake valve
The unit is unable 2. Remove it for cleaning.
3. Leak of the control pipeline
7 to operate under 3. Check the leak position and lock it up.
4. Improper setting of the controller
full load. 4. Contact the Fusheng service center.
5. Improper setting of the inverter (for
5. Contact the Fusheng service center.
inverter models)
1. Clean or replace it.
1. Blocking of the air cleaner
The air output of 2. Remove it for cleaning, and then refill
2. Poor operation of the intake valve
the unit is lower lubricant.
8 3. Blocking of the cooler
than the normal 3. Clean the cooler.
4. Leak of the loading/unloading solenoid
value. 4. Examine and repair it; replace it when
valve
necessary.

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 1. Check the leak position and lock it up.
1. Leak of the pipeline
2. Reset (the differential pressure is
Frequent reset 2. The loading and unloading differential
9 usually 0.1Mpa)
and standby pressures are too low
3. Increase the capacity of the air storage
3. Unstable air consumption
tank.

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Attached Table 1
Replacement Schedule of Spare Parts
2,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000
4,000
500 hours/ hours/ hours/ hours/ hours/ hours/ hours/ hours/ hours/
No. Part name hours/
hours 0.5 1.5 2 2.5 3 3.5 4 4.5 5
1 year
year years years years years years years years years

1 Lubricant

2 Oil Filter.

Air filter
3
element

4 Filter screen

5 Seal ring

6 Release valve

Shaft seal kit

7 (including shaft
bushing)

8 Controller

AC contactor
9
assembly

Thermal relay
10
assembly

11 Transformer

Emergency
12
stop switch

Temperature
13
sensor

14 Check valve

- 36 -
 Replacement Schedule of Spare Parts
2,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000
4,000
500 hours/ hours/ hours/ hours/ hours/ hours/ hours/ hours/ hours/
No. Part name hours/
hours 0.5 1.5 2 2.5 3 3.5 4 4.5 5
1 year
year years years years years years years years years

15 Intake valve kit

16 Intake pipe

High-pressure
17
hose

18 Solenoid Valve

19 Y filter

20 Drain valve

Water flow
21
regulating valve

Element of
22
thermal valve

23 Coupling

24 Absorbing pad

Pressure
25
transmitter

Body
maintenance
26 (replacement of
bearings and
shaft seal kit)

27 Oil cooler

Maintenance of
28
air cooler

- 37 -
 Replacement Schedule of Spare Parts
2,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000
4,000
500 hours/ hours/ hours/ hours/ hours/ hours/ hours/ hours/ hours/
No. Part name hours/
hours 0.5 1.5 2 2.5 3 3.5 4 4.5 5
1 year
year years years years years years years years years

Cooling fan
29
motor

Motor
maintenance
30 (replacement of
bearings and
windings)

31 Safety valve

Note: The data in the above table is for reference only. Due to the operating environment and
condition at the user site, the number of replacement hours of some wearing parts may vary.
Fusheng’s professional sales service personnel will perform maintenance work based on the
user’s practical conditions in a user-friendly manner.

- 38 -
 General Lubricant Replacement Procedure of the FushengTM Oil-free
Screw Air Compressor
Although the FushengTM lubricant is highly resistant to oxidation, it would be oxidized
over time because it is working under high temperatures when the unit is running. Therefore,
the user should replace the lubricant in the unit at the specified interval.
Before the lubricant is replaced, if the main performance indicators of the lubricant in
the unit do not exceed the limits, the following procedure should be followed: 1) Start the
unit, shut it down after about one hour of normal operation, and drain up the lubricant in the
system while the unit is still hot (drain up the lubricant in the oil cooler, oil filter, body and
pipelines as much as possible). 2) Add lubricant at 2/3 of the normal refilling amount, run the
unit for 20 minutes (note that the lubricant temperature should be below 60℃), shut down
the unit, and drain up the lubricant in the system while the unit is still hot (drain up the
lubricant in the oil cooler, oil filter, body head and pipelines as much as possible). 3) Replace
the oil filter. 4) Add the FushengTM lubricant at the normal amount. The lubricant replacement
operation is completed.

Fusheng Group

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主 速 指 令
0-10V(20kΩ)

Eastern China Sales Office

Address: 4/F, 6868 Gubei Road, Shanghai
zip code : 200336
Tel: 021-62704880
Fax: 021-62704878

Northern China Sales Office

Address: International Information Park, Siding Road (Qiliqu), Huilongguan, Changping
District, Beijing
zip code :102206
Tel: 010-69732555
Fax: 010-69732299

Southern China Sales Office

Address: Torch Avenue, Torch Development Zone, Zhongshan, Guangdong
zip code :528437
Tel: 0760-5591551
Fax: 0760-5591552