I. Maintenance of magnetic levitation bearing system
Displacement monitoring and calibration: Check the bearing displacement data in real time through the equipment control panel; the normal axial offset should be controlled within 1μm; if the fluctuation is more than 0.5μm, the sensor should be calibrated by a professional to avoid rotor wear due to the imbalance of electromagnetic force.
Cooling system maintenance: check the filter of the cooling water circuit of the bearing every month, remove impurities to prevent blockage; maintain the inlet water temperature ≤ 35℃, water pressure 0.2-0.4MPa, if the water temperature is found to be abnormally high, it is necessary to check the scaling of the water circuit or the flow rate is insufficient.
Advantage of oil-free: Compared with the traditional
Screw Air Compressor whose mechanical bearings need to be replaced with lubricating oil regularly, ZAKF's magnetic levitation bearings have no contact wear and do not require lubrication system, which reduces the maintenance cost by more than 50%.
Maintenance of High-speed Permanent Magnet Motor
Temperature Monitoring: Real-time monitoring of motor winding temperature through HMI interface (normal operation ≤120℃), quarterly scanning of stator core by infrared thermometer, if temperature difference is more than 15℃, it is necessary to check whether the winding insulation is aging or not.
Dustproof treatment: disassemble the motor cooling fan screen every month, blowing dust impurities, to avoid the accumulation of dust affecting the cooling efficiency (dusty environment can be shortened to once every half month).
Transmission efficiency maintenance: the motor directly drives the impeller, no gearbox transmission, you need to check the concentricity of the coupling every six months to ensure that the radial runout ≤ 0.05mm, to avoid long-term operation of the shaft system caused by the offset.
Three, ternary flow impeller and pneumatic system maintenance
vibration monitoring: through the PLC system to view the impeller vibration value in real time, the vibration rate under normal working conditions ≤ 2.5mm / s, if more than 4mm / s need to be immediately shut down to check the dynamic balance of the impeller, to prevent wear and tear due to dust or accumulation of dirt resulting in imbalance.
Clean air inlet system: check the pressure difference of air inlet filter every quarter, replace the filter element when the pressure difference exceeds 200Pa, and install pre-filtering device to protect the impeller from particle abrasion when conveying dusty gas (e.g., the cement industry needs to check the filter element every month).
Runner inspection: When shutting down for maintenance every year, visually inspect the impeller blades and worm shell runners for corrosion, cracks or media deposition, and carry out non-destructive testing (e.g., ray detection) if necessary.
Intelligent control system maintenance
Software upgrade and data backup: contact ZAKF manufacturer for DSP control program iteration every year to optimize the speed regulation response speed (standard response time ≤ 0.5 seconds); export operation logs (including speed, pressure, energy consumption data) every month to analyze the health status of the equipment through the cloud platform, and prejudge the failure of sensors or actuators.
Hardware maintenance: quarterly check whether the circuit boards and terminals in the control cabinet are loose, clean up the dust and test the grounding resistance (≤4Ω) to prevent electromagnetic interference from affecting the control accuracy.
V. Maintenance of frequency conversion device and energy-saving system
Frequency converter heat dissipation management: regularly check the operation status of the frequency converter cooling fan, clean up the dust of the heat sink to ensure that the ambient temperature is ≤ 40 ℃, to avoid overload protection shutdown due to poor heat dissipation.
Energy efficiency optimization debugging: adjust the frequency conversion parameters according to the actual working conditions, for example, in the sewage treatment aeration scenario, combined with the DO concentration to automatically adjust the fan speed, and every year through the manufacturer's professional software to assess the energy efficiency and optimize the operating curve.
Sixth, shutdown and standby maintenance
Long-term shutdown maintenance: If the equipment needs to be shut down for more than 1 month, it is necessary to cut off the main power supply and start the motor idling for 10 minutes on a regular basis (every week), to prevent the sensor zero drift caused by the long-term static of the magnetic levitation bearings; and at the same time, close the intake valve, to prevent the humid air from entering the flow path caused by the corrosion of the impeller.
Standby equipment linkage test: When forming a joint air supply system with standby equipment such as screw air compressors, a linkage switching test is carried out quarterly to ensure that the
Screw Compressor can be automatically put into operation when the ZAKF fails, so as to maintain the stability of air supply.
Maintenance Cycle and Professional Support
Daily Inspection: Check the sound, vibration, temperature and other parameters of the equipment daily and record the operation data;
Quarterly Maintenance: Complete the routine inspection of air intake filtration, cooling system, electrical connection, etc.;
Yearly Overhaul: Bearing system accuracy calibration, impeller dynamic balancing test and control system upgrade by the authorized team of ZAKF manufacturer.
As a high efficiency
oil free equipment, the core of ZAKF
Maglev centrifugal blower maintenance lies in the condition monitoring of the precision system, which can significantly reduce the maintenance of mechanical parts compared with traditional screw air compressors, and it is recommended to combine with the intelligent operation and maintenance platform to realize predictive maintenance and maximize the value of the equipment's life cycle and energy efficiency.
