Product Information
XF SERIES CNG COMPRESSOR—MODEL XF01-SM
Description
XF Series CNG Compressor
Model XF01-SM
OPERATION MANUAL
INDEX
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1.
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GENERAL DESCRIPTION…………………………………………
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2.
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MAIN TECHNICAL PARAMETERS…………………………………
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3.
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STRUCTURAL PRINCIPLE…………………………………………
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3.1 MAIN STRUCTURE………………………………………
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3.2 COMPRESSOR SET……………………………………
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3.3 PRESSURE GAUGE AND SAFETY VALVE……………
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4.
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INSTALLATION AND OPERATION…………………………………
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4.1 INSTALLATION……………………………………………
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4.2 PREPARATION BRFORE STARTUP…………………
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4.3 TRIAL RUN…………………………………………………
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4.4 BOTTLE-FILLING OPERATION…………………………
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5.
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DAILY MAINTENANCE AND SERVICE……………………………
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5.1 OIL LEVEL INSPECTION AND OIL CHANGE…………
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5.2 DISCHARGE FILTRATION………………………………
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5.3 DRAIANGE…………………………………………………
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6.
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TROUBLE SHOOTING………………………………………………
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7.
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ELECTRICAL WIRING DIAGAM……………………………………
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8.
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OPERATING INSTRUCTIONS………………………………………
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1. GENERAL DESCRIPTION
The CNG Compressor Model XF-2/(0.017-0.035)-200 is a natural gas pressuring device and is mainly used to compress and fill the family-use natural gas to cars, i.e. pressuring the family-use micro-pressured natural gas to 20MPa with the gas-filling time of 3-6 hours every time. It is small in dimensions, light in weight, superior in performance, safe and reliable in operation, durable and economic in application.
Model Explanation:
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Compressor model
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X, star-type
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Cooling mode
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F, air
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Volumetric displacement
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2, Nm3/h
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Intake pressure
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0.017-0.035 MPa
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Discharge pressure
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20 MPar
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2. MAIN TECHNICAL PARAMETERS
1) Nominal Volumetric Displacement: 2 Nm3 / h
2) Intake Pressure: 0.0017-0.0035MPa
3) Discharge Pressure: 20 MPa
4) Compression Medium: Natural gas
(No containing sulfur, water and solid particles of more than 20um)
5) Stroke 14mm
6) Rotating Speed: 1100
7) Compression Stage No.: four
8) Gas Feeding Temperature: ambient temperature +10?)
9) 1st Stage Discharge Pressure: 0.38-0.48 MPa
10) 2nd Stage Discharge Pressure: 1.8-2.5 MPa
11) 3rd Stage Discharge Pressure: 7.0-8.2MPa
12) Cooling Mode: air-cooled
13) Motor Power: 1.1 KW
14) Voltage: 110V?240V?220V
15) Frequency: 60HZ?60HZ?50 HZ
16) Noise Level: 55 dBA
17) Weight: 65kg
18) Recommend Oil: FS-1265 Silicofluo-based Compressor Oil
(Made in America Dow Corning Company)
19) Overall Dimensions: 650 x 450 x 450
3. STRUCTURAL PRINCIPLE
3.1 MAIN STRUCTURE
The compressor is mainly composed of compressor set, explosion-proof motor, controlling box, cooling fan, oil/gas separator, pipeline, safety components and frame, etc. At first the gas passes through the gas intake pipe to the 1st stage cylinder, and then, after the 1st stage compression, to the 1st stage cooler and then to the 2nd stage cylinder after cooling, thus, after passing through the 3rd stage cylinder and 4th stage cylinder, the pressure of natural gas will be raised to 20-25MPa. Finally, the compressed natural gas is discharged through the high pressure de-oil filter where the excessive residual oil will be filtered out and fed through the high-pressure hose to fill cars. The compressor is integrally explosion-proof and is of discharge pressure protection. If filling to the set pressure value, the compressor will be stopped automatically the filling. In addition, the safety valve is fitted to prevent overpressure.
3.2 COMPRESSOR SET (HOST)
The compressor set (host) is mainly composed of crankcase, crankshaft, cylinder, piston, gas intake and discharge valves, etc. The crankcase is made of Al-alloy material, and the needle bearings are installed on the front and rear end covers of the crankcase to support the rotation of the crankshaft, meanwhile, the front and rear end covers of the crankcase are sealed with the O-rings. The movement of the crankshaft and connecting rod depend fully on the operation of the needle bearing with the protective support. All the connecting rods are installed on the crankshaft with the special angles. The 1st stage and 2nd stage pistons are all made of aluminium material and equipped with piston rings. The 3rd stage piston is made of Al-alloy material and with the special piston rings. The 4th stage piston is made of reliable neutral steel without elastic rings. The cylinder with radiator plates is provided in every stage.
3.3 PRESSURE GAUGE AND SAFETY VALVE
The pressure gauge is installed in every stage of the compressor. Check whether the readings on every pressure are in conformity with the set values or not in order to find whether there is a trouble in the compressor. The safety valve is installed at the rear of the 4th stage cylinder to take the overpressure protection on the final discharge pressure. The preset opening pressure of safety valve is 1.1times to rated pressure. The safety valve should be installed on the compressor in advance to avoid overpressure due to any compressor troubles. As soon as the safety valve’s pressure reaches to the preset value, the valve will be opened automatically Don’t adjust the safety valve, otherwise, the serious damage or danger will be resulted from, and if so, our warranty for maintenance will be cancelled. Caution: the opening pressure of the safety valve can’t be adjusted higher at random).
4. INSTALLATION AND OPERATION
4.1 INSTALLATION
The compressor should be placed at the site where the qualified power supply and clean and good ventilation are all provided. The bevel between the compressor and ground shouldn’t less than 50. To make thermal radiation and operation easy, there should be enough space around the compressor.
4.2 PREPARATION BRFORE STARTUP
Fill the crankcase with the recommend compressor oil and check that the oil level should be above the upper line of the oil leveler. Note that too high or lower oil level isn’t good. If the oil level is too high, the oil consumption will be larger and the carbon will be accumulated in the gas valve. If too lower, the lubrication will be poor or no, the compressor will be damaged. In accordance with the requirements in the electrical wiring diagram, the power supply wire should be connected correctly with reliable grounding. Check the tension of the delta belt and the connection of all parts. Rotate the fan manually to check whether it is normal or not. Start the compressor to check the rotating direction. If the cooling airflow from the fan blows toward the cylinder, it means the rotating direction is right.
4.3 TRIAL RUN
Before starting the compressor, the drainage valve should be opened to carry out the idle startup. After startup, the idle running should be carried for short time, at the same time, the gas-filling bottle and compressor should be connected by the high-pressure hose. As soon as the operation is stable, the drainage valve should be closed and the compressor will begin to pressure. When the rated pressure value is reached, the pressure controller will activate so that the compressor will be stopped automatically. The compressor can also be stopped manually. When the compressor is stopped manually, the drainage valve should be opened at first, Press the red button to cut off the power supply. The gas-filling time of every time should be controlled within 3-6 hours. If such time is too long, the compressor maybe shutdown due to high temperature. After the gas-filling operation is carried out every time, all the drainage valves should be opened to keep all the readings on the every stage’s pressure gauge at zero.
4.4 BOTTLE-FILLING OPERATION
The verified and qualified high-pressure steel bottles should be selected and their max gas-filling pressure shouldn’t be more than the safety working pressure of the steel bottle. Check and make sure that there is no scratch or damage in the high-pressure gas-filling hose. The high-pressure gas-filing hose should be installed on the bottle required to be filled gas. Open the drainage valve and start the compressor at idle load. After the running is stable, close the drainage valve and begin to fill the bottle. When the gas-filling pressure reaches the preset value, the drainage valve should be opened to keep the compressor at an unloading run. The pressure within all the pipelines should be also relieved. (After the bottle is filled well every time, the drainage valve should be opened once to discharge high pressure gas and water in the pipeline)
5. DAILY MAINTENANCE AND SERVICE
5.1 OIL LEVEL INSPECTION AND OIL-CHANGING
Before starting the compressor every time, the oil level in the crankcase should be checked to make sure that the oil level should be between the two marks of the oil leveler, and the oil in the compressor should be renewed once every 2000 running hours. If the compressor is stopped for 6 months and restarted, the oil should be also renewed in time. The recommend oil for the compressor is FS-1265 Silicofluo-based compressor oil (made in America Dow Corning Company) and it is forbidden that the various lube oils are mixed to use.
5.2 DISCHARGE FILTRATION
In order to remove out the oil content in natural gas resulted from the lubrication, the de-oil filter is equipped in the 4th stage and the filter element should be replaced after 8000 working hours or after 12 working months.
5.3 DRAIANGE
After the compressor is stopped, the drainage valve should be opened in time to relief the high-pressure gas and exhaust the oily dirty filtered out.
6. TROUBLE SHOOTING
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Trouble
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Possible Cause
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Solution
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The compressor can not be started
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Power cutoff
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1.Check the power supply;
2. the fuse in circuit-breaker should be replaced
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The motor works but the compressor doesn’t work
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Too high load or the belt loose
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1. Make sure that the discharge gas should be emptied in starting without pressure.
2. Tight the belt
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Too high 1st stage discharge pressure
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The 2nd stage gas valve damaged
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Check the 2nd stage gas valve
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Too low 1st stage discharge pressure
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No natural gas enters
The 1st stage gas valve damaged
The 1st stage discharge pipe leaked
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1. Without any intake pressure
2. Check the 1st stage gas valve
3. Check and fasten it
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Too high 2nd stage discharge pressure
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The 3rd stage gas valve damaged
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Check the 3rd stage gas valve
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Too Low 2nd stage discharge pressure
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Low in the 1st stage discharge pressure
The 2nd stage gas valve damaged
The 2nd stage discharge pipe leaked
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1. Check and find the reason that the 1st stage discharge pressure is low
2. Check the 2nd stage gas valve
3. Check and fasten it
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Too high 3rd stage discharge pressure
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The 4th stage gas valve damaged
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Check the 4th stage gas valve
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Too low 3rd stage discharge pressure
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Low in the 2nd stage discharge pressure
The 3rd stage gas valve damaged
The 3rd stage discharge pipe leaked
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1. Check and find the reason that the 2nd stage discharge pressure is low
2. Check the 3rd stage gas valve
3. Check and fasten it
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Too high 4th stage discharge pressure
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Too high set value in pressure controller
The safety valve doesn’t work
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Reset it
Check the safety valve
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The shutdown pressure is reached but the compressor can not be stopped automatically.
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Failure in the circuit of pressure controller
The pressure controller damaged
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1. Check the controlling circuit
2. Replace the pressure controller
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The compressor overheated
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High in ambient temperature
Too much dust on the surface of compressor
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Improve the environment
2. Clean and remove the dust
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Descent in discharge capacity
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The pipeline leaked
Low in the gas intake pressure
The gas valve damaged
The piston ring abraded
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1. Check and find the leakage point
2. Increase the gas intake pressure
3. Replace the gas valve
4. Replace the piston ring
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Too much oil in discharge
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Too much oil in CNG gas
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Drain it in time
Replace the filter element
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Abnormal noise is found in the compressor
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The gas valve damaged
The moving parts abraded
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1. Check and replace the gas valve if necessary
2. Replace the damaged moving arts
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He piston doesn’t move in the cylinder
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The crankcase is short of oil
The selected compressor oil is wrong in brand
High ambient temperature
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Fill the oil
Change the oil
Improve the environment
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7. ELECTRICAL WIRING DIAGAM
8. OPERATING INSTRUCTIONS
8.1 Before starting, the oil level in the crankcase should be checked to make sure that the oil level is between the upper and lower marks of the oil leveler.
8.2 The power wire should be connected correctly.
8.3 Before starting the compressor, the drainage valve should be opened to empty the high-pressure gas to start the compressor at light load.
8.4 Connect the gas-filling hose.
8.5 Press the green button to start the compressor.
8.6 When the gas-filling operation is stopped automatically, press down the red button and rotate it clockwise to cut off the power supply.
8.7 Open the drainage valve to empty the high pressure gas in the system to keep the readings in every stage pressure gauge at zero.
8.8 Dismantle the gas-filling hose.
8.9 When stopping the compressor manually: press down the red button to cut off the power supply. Open the drainage valve to empty the high pressure gas in the system to keep the readings in every stage pressure gauge at zero.
Notes:
A. when dismantling the hose, it is necessary to keep the readings in every stage pressure gauge at zero.
B. When the compressor is stopped, the user’s intake valve should be closed.
C. The electrical voltage is 110V.
D. The grounding should be fixed tightly.
E. When carrying the operation and maintenance, make sure that there isn’t any possible spark or high temperature on the site.
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Home CNG refueling Unit |
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4 stage compressor meter |
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Inside |
compressor |
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Profile |
Profile |
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Explosion Proof Component |
Oil Filling Port |
Keywords
Home CNG refuelling unit, CNG Compressor
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