The efficient operation of an
air compressor depends on a scientific maintenance system. As a
ZAKF screw air compressor manufacturer with 20 years of experience and 60,000 square meters of production base, our single-phase screw models have a monthly production capacity of 2,500 units, and our oil-less scroll models support global certifications such as CE/ASME, etc., and are shipped within 15 days in Southeast Asia/Middle East by relying on 7 overseas warehouses. The following is a detailed explanation of ZAKF's specialized maintenance program from the technical characteristics of the two types of models.
1. Core items of daily inspection (ZAKF recommends daily implementation)
Motor status monitoring: real-time view of permanent magnet synchronous motor winding temperature (normal operation ≤120℃) through ZAKF's self-developed HMI interface, customized models are equipped with PT100 temperature sensors with an accuracy of ±1℃, and automatically triggered sound and light alarms when over temperature.
Rotor operation monitoring: listen to the equipment running noise (ZAKF 5:6 asymmetric toothed rotor design noise ≤ 75dB), abnormal vibration need to check the bearing clearance (ZAKF control at 0.03-0.05mm, through the five-axis machining center to ensure accuracy).
Frequency conversion system check: Observe the inverter display parameters to ensure that the output frequency matches the load, and the response time of ZAKF customized inverter algorithm is ≤0.3 seconds to avoid efficiency loss during low frequency operation.
2. Regular Maintenance Cycle and ZAKF Technical Advantages
2000 hours of in-depth maintenance: Replacement of food-grade synthetic lubricating oil (for CE certified models), which extends the service life by 50% compared with traditional mineral oil.
3000 hours of consumables replacement: Disassembly of the air filter element (ISO 16890 certified, with a filtration precision of ≤1μm), and sealing test of each filter element by ZAKF's digital production line. ZAKF digital production line conducts a sealing test on each filter element, with a passing rate of 100%.
Annual system maintenance: Test the capacitance capacity of the inverter (Japanese brand, life expectancy ≥80,000 hours), ZAKF global after-sales center provides remote data diagnosis, response time ≤2 hours.
3. Customized Scenario Maintenance Program
High Altitude Working Condition: The model customized for Tibet customers is equipped with a booster fan, which needs to be calibrated with altitude adaptive parameters (ZAKF's unique algorithm) every quarter to ensure the accuracy of air intake compensation.
Humid environment: models in Southeast Asia are equipped with moisture-proof heating tape (power 50-80W/m) as standard, and the working condition of the heating tape needs to be tested during maintenance to avoid electrical failures caused by condensation.
1. Maintenance of oil-free core components (ZAKF patented technology application)
Scroll disk gap management: real-time monitoring of dynamic and static scroll disk gap through PLC (normal 0.02-0.05mm), ZAKF 5-axis machining center to ensure the precision of the scroll disk ±0.003mm, and automatic early warning when the amount of wear exceeds 0.01mm (in the case of a German automobile factory, the warning accuracy is 100 percent). (A German automobile factory case warning accuracy rate of 100%).
Intelligent condensate treatment: ZAKF's self-developed electronic drain valve (zero air consumption design) is equipped as standard, and the drain cycle (5-10 minutes) is checked during maintenance. 316L stainless steel pipes are adopted in ASME certified models, with corrosion-resistant service life up to 10 years.
2. Heat dissipation and refrigerant system maintenance
condenser deep cleaning: quarterly compressed air blowing fins (ZAKF fin spacing 5mm design, compared with the traditional 3mm to reduce the accumulation of dust), desert area models are equipped with an automatic blowback device, a project in the United Arab Emirates after the application of heat dissipation efficiency increased by 20%.
Precise management of refrigerant: monitoring the system pressure through high and low pressure sensors (normal high pressure 1.2-1.6MPa), adopting the following methods
3. Special maintenance points for certified models
FDA-certified food-grade models: Monthly inspection of the FDA-compliant epoxy resin coating on the surface of the scroll disk, and NSF-certified maintenance tools to ensure that there is no risk of oil contamination.
ATEX explosion-proof certified models: Customized models for European chemical zones need to be regularly tested for explosion-proof junction box sealing (IP66 rating). ZAKF's overseas operating companies provide localized explosion-proof certification services to ensure compliance with the 2014/34/EU standard.
ZAKF Factory Advantage: Full Chain Guarantee from Maintenance Program to Global Service
Customized Maintenance Manual Development
provides personalized maintenance guidelines according to customer's working conditions (temperature, humidity, gas medium). In the case of an electronics factory in Vietnam, ZAKF set up “one policy for one machine” for 15 oil-free scroll machines, and the accuracy of failure warning was increased to 95%.
Extremely fast spare parts supply system
7 warehousing bases reserve more than 500 kinds of core spare parts (scroll discs, screw rotors, etc.), and realize 15-day extremely fast shipment in Southeast Asia / Middle East. When a Thai pharmaceutical factory urgently replaced its scroll discs, ZAKF completed the delivery of the spare parts in 72 hours through the local warehouses, which is 60% faster than the average in the industry.
Intelligent Operation and Maintenance System Empowerment
is equipped with ZAKF's self-developed intelligent monitoring system as standard, which supports remote reading of motor current, exhaust temperature and other data. An automobile factory in Germany reduced unplanned shutdowns by 85% through the system, and increased maintenance efficiency by 40%.
Industry Application Cases: Practical Value of ZAKF Maintenance Solutions
Single-phase Screw Machine Energy Saving Maintenance: A textile factory in Suzhou adopts ZAKF inverter single-phase screw machine, and through quarterly optimization of inverter parameters, annual power saving is 150,000 kWh, with a payback period of 1.2 years, and with the ZAKF annual energy-efficiency assessment service, the operation curve is continuously optimized.
Clean maintenance of oil-free scroll machine: A semiconductor factory in Taiwan uses ZAKF Class 0 oil-free scroll machine, following the “three-stage maintenance standard” (daily inspection + quarterly maintenance + annual overhaul), for three consecutive years
oil content of the air source is <0.01mg/m³, which meets the requirements of ISO 14644-1 Class 5 clean room. The oil content of the air source is <0.01mg/m³ for 3 consecutive years.
As a manufacturer of
screw air compressors with an annual output value of 500 million RMB, ZAKF has always taken “Technology + Global Service” as its core competitiveness. Whether it is the precision maintenance of the lubrication system of single-phase
Screw Compressor or the oil-free precision control of oil-free scroll compressor, ZAKF provides global customers with full-cycle solutions from daily inspection to the exclusive maintenance of certified models based on the 60,000 square meters of manufacturing strength and CE/ASME certification system. For a customized maintenance solution based on your working conditions, please contact ZAKF team, and let our 2500 units/month production capacity and 7 warehouses respond quickly to your equipment's efficient operation.
