(SH LP SAUER & SOHN EOS ~ MASCHINENBAU GMBH S) Ein Mitglied der SAUER-Gruppe Final-Documentation Hyundai Heavy Industries Samho SY H1517/18 Sauer Order-No. 412806 Z 2. x HP-Compressor WP 240 Main Air without ew-pump. 1x HP-Compressor WP 100 Topping up air with cw-pump x Screwcompressor SCK42-8MAG60WK service air without cw-pump SEC. NO. [SHIP DESIGN OFFICE SHIP TYPE 386 SHIP OUTFITTING DESIGN DEPTT No.1 74,999 DWT PRODUCT OIL CARRIER TEL. NO. | SHIP NO. SHIP NAME 3778 A517, RUDOLF SCHULTE pees = JOH NAME OF DRAWING J.D. Yoo FINAL DRAWING FOR AIR COMPRESSORS CHECKED INCL. OPERATING MANUAL FOR SERVICE AIR COMPRESSC AND ELEC. AUTOMATIC DRAIN VALVE DRAWN 2004. 06. 21 3A - Perel. SCALE’ | DRAWING NO. 6U-2844-172 pen 1 HYUNDAI HEAVY INDUSTRIES CO.,LTD [CONSOLIDATED NO. ULSAN SHIPYARD, KOREA M-16-A, 8,Order No. 412806 Tech ion Sauer HP water-cool ressor-unit WP. in design according attached drawing 412806A Fill up capacity (0 - 30 bar) 160.0 main Working pressure: 30 bar Speed: 4170 rpm Required power: 310 KW Stages / Cylinders: 212 Cooling: fresh water ‘Min. cooling water required for delta T 10K: 40.0 min Heat dissipation: 28.0 kdisec Air outlet temperature/delta t 25 “c Residual oil content at air-outlet <5 mgim3 Drive: direct drive Max. ambient temperature: +5°C up to + 55°C Unit weight 850 kgs Noise level at 1 m distance: 84 dB(A) Allcapacity data with 5 % tolerance related to 20 °C and 1013 mbar Regular Equipment: = air intake and silencing filter = _ intercooler and final recooter - cil and water separators after 1" and 2™ stage - safety vaives after each stage + air thermometer after each stage = cooling water thermometer ~ stage pressure and final pressure gauge = solenoid valves 230 Vi50160 Hz for automatic and periodic drainage of the separators = starting relief integrated in condensate drain automation = _ pressure oil lubrication = oil pressure control switch and oil-pressure gauge + contaetthermometer for supervision of compressor cooling ~ flywheel + flexible coupling + resilient mounts for the unit = flex. hp-hose for air-outlet 1000 mm, 28x1,5 solderless, incl. non return valve = flex. hp-hoses for drainage 500 mm, “and 2 ,15x1.5 solderiess = flex. hp-hose for cooling water inlet 1000 mm, G 1" male = flex. hp-hose for cooling water outlet 1000 mm, G 1” male + pressure switch startistop, loose = threephase motor size 225 M. rated output 360 kW speed 1170 pm voltage/frequency: 4a0i60 Viz rated current: cagd A starting current: ca 360A protection! insulation: IP 551 F For 45° C ambient temperature as per regulation LR Additional Equipment for the 2 compressor units: = 2junction boxes: = 2 automatic cooling water solenoid valve = 2 cooling water safety valves = cooling water sight glassesOrder No. 412806 = 1 set spare parts "B+A" as per regulation LR = hoses with flanges + counterfianges = pressure gauges with root valve = pressure switches with 3-way test cock Test and certificates: - test and certificate for the compressor as per regulation LR = workstest for the motori 228 | —. ss | = E- [EF = } th r aie ce ae f We | f Hiwe200/ Reserveteilliste Sach-Nr, [Aq eee Spare parts list 064007 | 4 simage 2 Code-Nr, vonlot 3 Reserveteile "B+A" 2- 0009 Pos. [Stekz, Benennung Sach-Nr. | Bemerkungen Item | Qty. [Designation RefNo. 8 1 Lamellenventil 036 959 lamellar valve 9 L RD-Ring 035.970 oving 10 1 Brechplatte 061 942 bursting plate t WY] 2] Petcog TY 003 493 gasket 1 y | 1 2 2 Dichtring 005 001 gasket i | 13 | 10 | Dichtring | 005 009 gasket | mW ' + | Ww w4 | 15 | Dichtring i 005 023, gasket tReserveteilliste Sach-Nr, A spare parts list 064007 | d Code-Ne Reserveteile "B+A" 2- 0009 Benennung Sach-Nr. | Bemerkungen [Designation RefNo__| remarks Dichtung 063 748 packing cH 6 f Dichtung, 051 530 packing | 8 wv | RD-Ring 030 131, | o-ring, Cr) , os? 18, RD-Ring, 036 962 | o-ring 19 RD-Ring i | 036 963 orring 20 RD-Ring 030912 d o-ring | C+) " { os ww) { ot aoe 2 RD-Ring 037 151 o-ring NZ~ ~ SH J.P SAUER « SOHN Sy MASCHINENBAU GMBit INSTRUCTIONS OF INSTALLATION AUT-E 22078 WATER-COOLED HIGH-PRESSURE-COMPRESSORS 1. Setting-up_ If the compressor-unit is cesiliently mountea, sufficient space for movement is to be provided. All wunnections ro the compressor-unit are to be provided with flevible intermediate connecting links. The frequency af vibrations that might be transmitted to the compressor-unit due to near vibrators (diese! mo~ tors, shie propellers. etc.), must not coincide vith the natu.al Frequency of the resilient mounts. The standard mounts have got a natural frequency of 7-10 Hz. IF the compressor-unit is mounted without resilient mounts, a suffi- ciently stiff basement must be provided. Unevenness of the basement is to be belenced by shins, Accurate elignnent between compressor end driving motor must be essured for installation of 3 single compressor. 2. Drainage The Crain pipe lines of the particuler stages and of different conpressors must not be combined in one pipe conduit because othervise there is the dan- ger that condensate is blown into the compressor valves. The easiest vay is tc guide rhe particular pipe lines into an open funnel from vhere the o4l/ weter mixture is lead to the collecting tenk. 3,_Lipling Stopouge of the comressor requires interruption of the cooling veter supply. Adjust the quantity of cooling veter flov for a caaling vater ourlet temperature of approx. 30° ¢ - 40° Cc, 4. Pressure Switch Adjustment Pressure losses between compressor and air battle must be considered by an ecjustment of the pressure switch at the sir bottle being lower compared to the compressor operation pressure. Otnervise it is risked thet the compressor safety valve reacts befure the pressure switch. 5. Nor eturn Valves Wher installing non-return valves, a minimum distance of 1 m to the compressed air outlet on the compressor should be observed . On normal compressor operation conditions, the valves may not make any noises: “utting Into Operation Putting into operation of the compressor is to be dune eccording to the di- rections of the instruction book. The compressur is despatched without 21) Filling, J.P Sauer & Sohn Maschinenbau GmoH ~» Brauner Berg 15, D-24159 Kiel Service-Department: Telefon + 49 (0) 431/39 40 86/97, Fax + 49 (0) 431/39 40 8910. Lubricant Table eS Area of validity General recom- mendat Note! Lubricants not mentioned in the lubricant table may only be used after approval by J.P. SAUER & SOHN. Otherwise the warranty will expire. Contact our service in case of need. Take note of all information about the lubricants given in this sec- tion. The lubricant table applies to all Sauer compressors intended for the compression of air. The lubricant table does not apply to ~ Sauer compressors for the compression of neutral gases; — temperature ranges outside of 5 ... 55 °C. The following recommendations apply to the 5 ... 55 °C temper- ature range: ~ Use mineral oils of viscosity class ISO VG 100 or SAE 30. — Asa minimum, lubricating oils should conform to group VCL acording to DIN 51506. Notet Only for 2-stage 30 bar compressors the use of synthetic lu- bricating oils may be of advantage. In case of need we will name the synthetic lubricating oils approved by us. In general we do not permit the use of synthetic lubricating oils for the following reasons: — The good water separation ability of these oils causes con- densation of moisture in the crankcase. Risk of corrosion damage and drive damage. — Because of their design, 3-stage air-cooled compressors have low compression end temperatures, rendering the high temperature stability of these oils useless. 62 cooraAzinLubricant Table rrr 10.1 Lubricating oils Brand Description Group | Agip Diesel Gamma 30 | VOL-100, | Dierea 100, VOL-100 Acer 100 VEL-i00 [Maotor O1 HD 60 SAESO | Cladium 50 SAE 30 ARAL Motanol HE 100, VOL-100, | [Kowal 80099 [Discla M30 pag Wik ‘Aulub Compressor OU VBL-100 VoL-100 ‘vic Compressor O1VBI-160 Vei-100 Motorol HDG 30 SAE | Motorei HD 80 SAE 80 cS Energo! RO 100 EnergoliC-G 30 |[Energol DUMP 30 [Energol OE-HT 30 [ Vanellus Ca SAE 30 Casiol Airco! PD 100 VoL-100 Marine CDX30 Chevron HD Compressor 0 100 VDL-100 Delo 1000 Marine 30 SAE 90 Veritas 800 Marine 20 SAE 30 i PM Heavy Duty Motor 30 SAE 30 DEA ‘Actro EP VDL-100 VDL-100 i} Trion EP VDL-100 VOL-100, Regis SAE 30, SAE 30 [eur Dacnis P 100 at VOL-100 | Polytelis 100 VOL-100 Performance XA 30 eee ‘SAE 30 | | Allanta Marine 3005 ‘SAE 50 sins Disola M3075 ‘SAE 20 Esso 7 Exxoolub 77 VoL | Exxcolub 100 VDU-100 H Compressor O11 3021 N VDL-100 | Examar 12 TP 30 #1 SAE 30 Bomar XA SAE 30 Essolube HDX Plus +30 SAE 30 corns, 6310. Lubricant Table Se Area of validity General recom- mendation & = Note! Lubricants not mentioned in the lubricant table may only be used after approval by J.P. SAUER & SOHN. Otherwise the warranty will expire, Contact our service in case of need. Take note of all information about the lubricants given in this sec- tion. The lubricant table applies to all Sauer compressors intended for the compression of air. The lubricant table does not apply to - Sauer compressors for the compression of neutral gases; — temperature ranges outside of 5... 55 °C. The following recommendations apply to the 5 ... 55 °C temper- ature range: — Use mineral oils of viscosity class ISO VG 100 or SAE 30. — As a minimum, lubricating oils should conform to group VEL. acording to DIN 51506. Note! Only for 2-stage 30 bar compressors the use of synthetic lu- bricating oils may be of advantage. In case of need we will name the synthetic lubricating oils approved by us. In general we do not permit the use of synthetic lubricating oils for the following reasons: — The good water separation ability of these oils causes con- densation of moisture in the crankcase. Risk of corrosion damage and drive damage. — Because of their design, 3-stage air-cooled compressors have low compression end temperatures, rendering the high temperature stability of these oils useless.Lubricant Table comakzin as 10.1 Lubricating oils Brand Description t Group [Aa Diesel Gamma 20 VEL-700 Dicrea 100 VDL-100 [Acer 100 VOL-100 Motor OW HO 50 SAE 30 | Ciadiom 60 SAEO Ee ARAL Motani HE 100 VOL-100 ] Kowal M30) | Vot-100 [DisolaM 30 ‘SAE 30 AVIA Avllub Compressor Oil VBL-700 VOL-100 ‘Avilub Compressor Of VOL-100 VGL-100 Motoroii HDG 30 [SaESOSS™~«* Motorait HD 30 SAE 30 BP Energol RC 100 A VOL-100. Energol 1C-DG 30 VEL-100 Energol LMP 30 SAE 30 Energol OE-HT 30 SAE 30 [Vanellus C3 SAE 30, SAE 30, Fz Castrol Tireol PD 100 Vau-100 [ Marine COX 30 [ SAE 30 ee Chevron HD Compressor OF 100 | WOL-100 Delo 1000 Marine 30 SAE 80 Veritas 800 Marine 30, ‘SAE 30 RPM Heavy Duty Motor 30 | SAE 30. | DEA ‘Actro EP VDL-100 VDL-100 Trion EP VDL-100 VOL-100 E Regis SAE 50 ‘SAE 3 ELF Dacnis P 100 VDL-100, | Palyielis 100 VCL-100) Performance XR 30 | SAE 30 Rilanita Marine © 3005 SAE 30 [[Disoia wia018 ['SAé 30 Esso Beicohub 77 vou | I"Exxcolud 100 VoL-100 | Compressor Oil 3021 N VDL-100 | Exxmar 12 TP 30 | SAE 30, Exxmar XA : SAE 30 Essolube HOX Plus +50 SAE 30 | 63Brand Description Group FINA Bolan AC 100 VOL-100 Eolan D-CL 100 Veu-700 l | | eoave Wolo SESS OC i | Alcano: 308 T y ob Rarus 427 VoU-700 OTE Ol Heavy vou Wobiigard 300 SAE 80 Set Corena O1P 100 VOL-100 Rimula X 30 SAE 30 [MeinaS0m50~SSSCSC~*~S~S~C~*SCSAE SO Melina 0130 SAE 80 et Gadinia 0130, SAE 30 ] [rex Compresioe OF EP VBL 100 VOL-100 | | | Regal R&O 100 __ | VeL-100 Ursaiex 30 ~__ [SAE 80 [DOROARSO | SAE 30 PEE ToL | Cortusa 100 VDL-100 “Cortis 100 VCL-100 Goris MD SO ie SAE 30 YUKONG See ‘Compressor Oi! P 100 Ht VDL-100 HD SD 30_ SAESO oa coo nazOrder No, 412806 ‘Technical Specification Sauer HP water-cooled compressor-unit WP 100 in design according attached drawing 412806D Fillup capacity (0 ~ 30 bar) 80 m3ih Working pressure: 30 bar Speed: 4470 rpm Required power: 170 kW Stages / Cylinders: 212 Cooling: fresh water Min. cooling water required 230 min Heat dissipation: 18,0 —_kJ/sec Residual cil content at air-cutlet <5 mgim3 Drive: direct drive Max. ambient temperature: +5°C upto+ 55°C Unit weight appr. 550 kgs Noise level in 1 m distance: 87 dB(A) All capacity data with 5 % tolerance related to 20° C and 1013 mbar Regular Equipment: = ait intake and silencing fier = intercooler and final recooler ~ oil and water separator after 2” stage - safety valves after each stage - air thermometer after each stage ~ stage pressure and final pressure gauge = solenoid valves 230 W/S0/60 Hz ‘sr and 2” stage for automatic and periodic drainage starting relief integrated in condensate drain automation = splash oil lubrication = contactthermometer for supervision of compressor cooling - flywheel = flexible coupling = resilient mounts for the unit = flex. hp-hose for air-outiet 1000 mm, 22x1,5 solderless, incl, non return valve = flex. hp-hoses for drainage 500 mm, 1°and 2" .16x1.5 solderless = flex, hp-hose for cooling water inlet 500 mm, G 3/4” male = flex. hp-hose for cooling water outlet 500 mm, G 3/4" male - pressure switch start/stop, loose ~ threephase motor size 180 L: rated output! 174 KW speed 1200 rpm voltage/trequency. 440/60. Viz protection’ insulation IP 58) F For 45° C ambient temperature as per regulation LR Additional Equipment for the_ compressor unit: = 4 junction boxes = 1 automatic cooling water solenoid valve = 1 cooling water safety valves = 1 cooling water sight glasses = toillevel suprvision + 1 set spare parts "B+A" as per regulation LR = hoses with flanges + counterflanges = pressure gauges with root valve + pressure switches with 3-way test cockOrder No. 412808 Test and certificates: = test and certificate for the compressor as per regulation LR = workstest for the motor1 | vn = [see fet (mans lr alae Sac teh | Scketecen ae f a | “TERRING UP AUR COMPRESSOR 1 oat ji cra ms C.00007007 commana E — E : rWP 100 Reserveteilliste Sach-Nr. | Al spare parts list 066 221 [Setepage Code-Nr. a! Reserveteile "B+A" 2-009 Pos. [Stckz. Benennung Sach-Nr. | Bemerkungen Item _| Quy. Designation RefNo. | remarks ~ | = | Reserveteite BEA" 066 221 spare parts list "A+B" 1 | 1 | Mimutenring 012512 Maing 2 1 ‘Nasenring a 031 901 N-ring 3 1 Gleichfasenring 031 902 G-ring 4 2 Rechteckring 031541 Rering 5 1 ‘Nasenring 002 548 N-ring, 6 1 | Olschlitzring 031 542 Seing 8 J.P SAUER & SOHN MASCHINENBAU GMBHWP 100 Reserveteilliste SachNr. [A spare parts list 066 221 seterpage 2 Code-Nr, wot 4 Reserveteile "BEA" 2-009 Pos. |Stckz ‘Benennung Sach-Nr. | Bemerkungen Item | Quy. Designation RefNo. | remarks 8 1 Lamellenventil 037 157 lamellar valve 9 1 Konzentrisches Ventil 038 157 concentric valve W 3 RD-Ring 031 136 o-ring 12 1 RD-Ring 030 638 oxing 13 1 RD-Ring 038 158 o-ring 14 2 | RD-Ring 004 181 oving 15 1 | RD-Ring 004 175 o-ring ® J.P SAUER & SOHN MASCHINENBAU GMBHWP 100 Reserveteilliste | sens. [Ar spare parts list 066 224 IScicpage 3 Code-Ne, von 4 Reserveteile "BYA" 2-0009 Pos. ]Stckz. ‘Benennung Sach-Nr. | Bemerkungen Item | Quy. Designation Ref.No. 16 1 RD-Ring 031 024 o-ring 17 1 RD-Ring 036 162 o-ring 19 1 | Dichtung 066 072 350 packing eI 5) 20 | 1 | Dichting 063 748 Bho. | packing 2 1 | Dichtung 051530 packing 22 1 Brechplaite 061 942 bursting plate 24 1 | Dichtring 056 235 a tez5| gasket 90 S J.P SAUER & SOHN MASCHINENBAU GMBHReserveteilliste we 100 Sach-Nr. [AT spare parts list 066 221 [Seite/page = 4 ‘Code-Nr. vonof 4 Reserveteile "B+A" 2-0009 Pos. |Stokz. Benennung Sach-Nr. | Bemerkungen Item | Qy. Designation RefNo. | remarks 25 1 Dichtring 053 398 7 gasket a 26 | 5 | Dichting 005.016 em ben gasket i \\ 27 | 10 | Dichtring 005 009 tet! gasket at 28 10 Dichtring 005 023 = a Be JP SAUER & SOHN ® MASCHINENBAU GMBHQuotation No. Mw.2754 ‘Technical Specification Sauer - ALUP Screwcompressor SCK42-8 MAGOwk as per enclosed drawing 412806C Capacity as per 1S01217 270 mah Operation pressure’ 7 bar (max 8 bar Required power: 343 kW Cooling aircooled Drive: v-belt driven ‘Ambient temperature up to: 50 °C Cooling water requirement ca26 mh Compressor weight: 600 kgs. Al capacity data with 5 % tolerance related to ambient conditions (of 20°C and 1013 mbar as per DIN 1945, ‘Standard Equipment: = airintake fiter = compressor rotors with asymmetric profile = final air cooler = non-return vaive mounted on the compressor = oll separator = ail ecooler - safety valve = starting relief ~ _ self induced pressure lubrication with oi fiter = sound proof canopy ~ automatic control unit ALUP AIRCONTROL (microprocessor control and monitoring unit) combined load/unload and startistop control by integrated press. transmitter star-delta start indication of pressure, compressed air temperature, running hours supervision of oil- and air temperature. pressure and maintenance intervals, potentialfree contact for remote alarm indication start/stop push button = resilient mounts incl. flexible hose for airoutlet - threephase electrical motor size 200 L: nominab-rating 36 kw speed: 3545 pm nominal current 7 OA Pre fuse 8 A Staring current ca170 star delta start voltage: 44000 OV frequency: 60 Hz protection / insulation IPs4sF Adgitional Equipment for the compressor uni = spare parts set "seagoing’ as per regulation LR = pressure switch, loose with text cock for external operation + color Munsell 7.5 BG7/2 Test and certificates: - worktest certificate = test and certificate for the compressor as per regulation LRSpareparts “seagoing” for SCK 42 gas set Suction Fitter Oil separator inserts Oil fiter Sealing V-belts 172.0787 172.5811 172.0022 167.01249 163,00128‘edttinung (use erie : 1200 cooing a ping “8 —__» a a 1 (hit shter rest) | el “A | KKZEXYs Armature Ange -— dashboard ® e Kitiveserintt . cong wrinek ‘Stromeufu PG Kitaserastit Westnet power PG36 cooky verte sence board if —— hit cong Amatrer-Anage Schwingnete dastbcert ‘esfien! mount ‘Anschiisse Flansch ‘Schlauch fr Deuckuaustit ‘Schlauch fir Kahiwascerein-u austrit ‘connections fame ‘enle he or air ott ‘exible hse for ocolng water in- and cutet ee 500mm langong 500mm anglong " Drude (110) Wn sic erg PKK @) ie . g vasseranschlsse cts eee ae ora 240 mm comocions C:00008193 - Tl a {am _| mt | om | oe JP.SAUER SOHN 8 | Datum 1008, MASCHINENBAU GMBH Name | Romeyte oo ce oe : ate a SERVICE AIR COMPREUOR ALUP-Schraubenverdichteranlage [iam cree eer | Peete Typ SCK42MA wassergekdtit ____412806C Bite [a eee ALUP-sorew compressor plant [eat [ant [fee EEE ees ESP CePr ‘pe SOK 2A waco [oe Hee 14MALUP Kompressoren Operating manual Screw compressor SCK 5 - 52©2001 All rights belong to: ALUP Kompressoren GmbH Adolf-Ehmann-Strate 2 73257 Kéngen Tel: 0049-180-5258700 Fax: 0049-180-5258701 No part ofthis manual may be duplicated by mechanical or electronic means: without the express written permission from ALUP Compressors GmbH. Allparticulars in this manual are specified to our best knowledge, but without guarantee. We reserve the right to make changes to information on hardware and firmware documentation at any time without previous announcement. ‘We are thankful for any criticism and suggestions,Table of contents 1. Safety instructions.. 4.1. Symbols in this manual 4.2 Proper usage 4.3. Qualified personne! 1.4 General safety instructions 2. Funetional descri 3, Storage and transport, 4, Installation 4.1 Seting up 4.2. Ventilation 4.3 Forced ventilation (optional). 44 Water cooing (optional). 4.5 Heat recovery for heating water/ potable water (optiona) 4.8. Connection tothe compressed air net 4.7. Electncal connections. 5. Displays and operating elements 5.1. Plant main switch 5.2 Emergency 0 5.3. Air Control 3 (option) 531 Basi cispiay 5.32 ONIOFF switching of ‘cornpressed sir generation. 5.33. Function key reservation in the base display 5.3.1 Capaciy ubization 5332 Service 53.33 ULC status 53.3.4 Compressor pace 5.3.3.5 Diagram net pressure 5.236 Diagram final compression temperature Diagram comoreased air amount! day profile Diagram compressed air amounts / week profile 5.3.3.9 Modiy diagram setings 534 Manu system 5.34.1. Subsmenu Limit valves 5.342 Subsmenu Operating parameters 5.34.3. Subsmenu Senice intervals 5344 Suomen hmer 5.34.5. Submenu Fault log 5.348 Subsmonu Display parameters 53.4.7. Submenu Configuration 534.8. Submenu Lead lag contol (LLC) 5348. Submenu Accessories 5.34.10 Sub-menu Diagnosis 53.5. Warnings! mainienance 5.3.6 Mailunctions 54 AirContolt 54.1 Basic display... 542 ON/OFF swiching of comaressed air generation 543 Viewing addtional operating data 5337 5338 24 5.4.4 Menu system enn $4 6.4.4.1 Unit parameterisation 4 54.42 Basic parameterisation 42 5.4.4.3, Code 2: Operating mode 43 5.4.44 Code 3: Automatic restart after power FaiLUTE anew 44 5.4.46 Code 11: Start and stop pressure. 44 5.4.4.5 Code 8: Local control, remote control, LLC-CK 44 5.4.4.7 Code 18: Lead leg control (LLC) ... 45 5.4.48 Code 21: Maintenance acknowledgement 48 5.4.49 Code 51: Oft-load, off, staridelta time soon 4B 5.44.10 Code 85: Condensate vave 46 5.4.4.1 Code 90: Unit for pressure indication 7 46 9.4.4.12Code 95: Unit for temperature indication .. 46 5.44.13 Code 999: Software version 46 5.4.5 Warnings / maintenance WOFK nnn 48 5.4.6. Malfunctions 6. Correcting matfunctions.... 7. Initial commissioning ... 7.4 Preparatory activities 7.2. Check cooiing fluid level 52. 7.3. Start-up lubrication of the compressor stage .. 52 7.4 Rotational direction contro! 53 7.8 Basic settings... . 54 75.4 Controling the unit bby means of Air Control 3 (OptiON) es 54 7.5.2 Controting the unit by means of Air Control 1... 54 7.6 Switch on. compressed air generation 55. 77 Concluding activities. : 8. Service. : 8.1. Overview Maintenance intervals 8.2 Preparatory activites .. 83. Check cooling uid level refi cooling Fuld... 57 84 Check for leakage 58 85. Check the compressor temperature 58 86 Check the cooler for fouling 58 8.7 Check for condensate 59. 8.8 Cooling fd replacement / replacing cooling fuid filter. 60 8.9. Replacing cooling Nuid Separator a eninnne 82 8.10 Replacing ait fier 7 63 8.11 Check safety valve a 63 8.12Check drive 64 8.13 Relubrication of the electric MOIOF eo nenusnenas 64 8.14 Concluding activities. 9. Technical Data... 9.1 Dimensions for connections. ow 88 9.2 Data air-cooled compressors 7 9.3 Data water-cooled compressors « onuscwne 87 94 Electrical data: 671. Safety instructions Safety instructions 14 ‘Symbols in this manual DANGER NOTICE You are reading this manual in order to learn about the screw compressor, contains information that is required for safe, malfunction-tree operation of the system. Please keep in mind that damage incurred due to improper usage may not fall under the conditions of guarantee! For this reason, please keep this manual where all users can have free access to it at any time. The system was developed, manufactured, tasted, and documented in state- of-the-art technology and considering all the current safety standards. In normal circumstances, no danger for personnel or property can result from the system if you comply with the stipulations of the service manual and ifthe transport, assembly, service and the described handling is car- ried out according to the regulations, Nevertheless certain risks remain! This symbol is employed whenever personal damage can be incurred by carelessness, or by ignoring the instructions. This symbol is employed when damage to property can occur through carelessness, or by ignoring the instructions. Italic text is employed when we would like to draw your attention to particu- Jar information. Text in a frame signifies the description of an activity to be carried out by the user.1.2. Proper usage 1.3. Qualified personnel The system is exclusively designed for + the generation of compressed air and + for operation in an environment without explosion risk. Any other utlization must be regarded as not in compliance with the design purpose! ‘The manufacturervendor is fundamentally not liable for damage incurred if the system is not used according to its design purpose! The generated compressed air may ot be used for human respiration. In caso the compressed air is used for pharmaceutical or sanitary purposes, it ‘must undergo further treatment. The same is true when the compressed air is used in production plants and comes into direct contact with foodstuffs. This manual is directed to “qualified personnel", who are commissioned with the transport, installation, operation or service of the system. These individuals must read the chapter relevant to their cuties, “Qualified personne” are individuals who: * upon the basis oftheir professional training, knowledge and experience as well as their understanding of the relevant norms can assess the work to be carried out with regard to all possible dangers, or + based on many years of activity in a comparable field, have the same state of knowledge as someone with professional training, Activites that are not described in this manual may only be carried out by our customer service depariment or by authorized technical personnel Unqualified actions or ofsregarding the wamings in this marwal or those affixed to the product can lead to serious personal injury or clamage fo ma- terial!1. Safety instructions 1.4 General safety instructions DANGER DANGER DANGER DANGER Loss or decrease of compressor safety ! Retrofitting or modifications on the system can reduce its level of safe- ty! The results could bo serious personal, material or environmental damage. Possible retrofitting or modifications on the system with equipment components from third party manufacturers must there- fore first be cleared by us. Loss of contact protection! Tho side panelings of the system are part of the contact protection system to protect personnel from fan impellers that start up automat ‘cally, moving machine parts, hot surfaces and dangerous voltages! Furthermore, they are required for sound insulation and cooling ai conduction. Therefore they must not be removed when the unit is in operation. For initial commissioning, itis required to remove the side paneling of the system. Furthermore, in the process ofthe initial commissioning of the plant, the mains switch must be turned on. The initia! commissioning, therefore, may only be carried out by qualified technical personnel! Injuries caused by fan impellers that start automatically, moving ma- chine parts, hot surfaces or escaping cooling fluid mist! Installation, service or repair work on the components of the system must, if not otherwise described, be categorically carried out only on a switched-off, sufficiently cooled-off and pressure-free system! The system must be secured against an illicit or accidental switching-on. The shut-off device for the compressed air net must be closed. If measuring or testing work is required on the electrical components while the system is in operation, they must be carried out by electr- cians observing aif the relevant safety regulations. Damage to the sense organs! Compressed air streams may not be directed towards persons, When applying compressed air, dust particles can be raised by the air stream. Therefore, when working with compressed air, protect your eyes with safety glasses.NOTICE NOTICE Loss or decrease of compressor dependability! Only original spare parts and lubrications may be employed! We recommend that a set of service parts subject to wear be kept on stock, in order to guarantee high compressor availability. Our cus- tomer service would be glad to help you with your selection. Damage to the system may result in environmental damage! Before initial commissioning, the system must have been correctly installed according to Chapter 6! Compressor greater than 100 kW must be taken into operation by qual- ified personnel, Dispose of all used or defective materials in a proper way! This is especially true for components/materials containing cooling liquid. Please note that the accumulated condensation containing cool- ing liquid may not enter the sewage system! We offer an appropriate cooling fluidiwater separator for condensation processing. Compressed air receivers require regular tochnical inspections! Please notify the commissioning of the system at the technical inspection authority responsible for you, They wil inspect the system and provide a receiver test book. Document all the activi 5 carried oul (@.g. in Some table formal), Carry out the activities in all of the following chapters in the order given.2. Functional description 24° Drive 22 Alrpath The electric motor drives the compression stage via a V-belt. Fresh air supplied by the integrated cooling air ventilator is filtered through the air filter(s). The air is then directed via the suction regulator into the ‘compressor stage, where it is compressed to the final compression pres- sure together with injected cooling fui In the cooling fluid reservoir, the compressed air is separated 98 % from the cooling fluid and the downstream cooling fluid separator removes the remaining cooling fluid from the compressed air. The ar then flows via the minimum pressure non-retum valve into the compressed sir aftercooler and is cooled down to 10 - 15 °C above the ambient temperature before it leaves the compressor through the compressed air connection ‘The suction regulator opens shortly after the compressor has started up for generating compressed air. It closes when the compressor changes over to off-load operation and/or comes to a standstill and unloads the system via the relief valve,23 Cooling fluid circulation 2.4 Cooling ‘The cooling fluid is sprayed into the air end and has the following functions: + heat removal of the temperature increase caused by the compression process, + sealing lubrication of the rotors to each other and to the housing with a cooling fluid film + bearing lubrication + noise dampening The cooling fluid leaves the air end together with the compressed air as a hot cooling fluid return air mixture, ‘The cooling fluid is separated from the compressed air inio the seperator tank by the cooling fluid separator and when separated, it flows to the cooling fuid heat exchanger. The cooling fuuid temperature regulator mixes the cooled down cosiing fiuid wth the cooling fluid nest exchanger-bypass hot cooling fluid as defined by the setpoint temperature, Finally, the cooling fluid fiter cleans the cooling fluid, before it is again injected in the air end, If desired by the customer, an additional heater can be installed in the seperator tank either criginally or subsequent to purchase. It prevents condensation damage in the case of cold or damp compressor environ- ments, for example. The compressed air after-cooler of the cooling fluid heal exchanger is coo- led either by + a built-in cooling air ventitator or + water cooling, ‘The electric motor is always cooled by its own ventilator fan, In the case of water-cooled compressors, a fresh air ventilator additionally ensures sufficient fresh intake air for the removal of radiated heat.2. Functional description 2.8 Flow diagram2.6 Components 27 Legend on 02 03 05, or 08, 10 1 12 3 Switching cabinet Electric motor Vebett Air filter Suction regulator Compressor ievel Cooling fuid reservcir Safely valve Drain Inlet fitting Additional heater (optional) Gooling fluid separator Minimum pressure non-return valve Relief valve Gontpressed air atter-cooler 7 18 19 20 21 22 23 24 25 26 2 28 Compressed air connection Cooling fluid cooler Cooling fluid temperature regulator Cooling fluid titer Cooling air ventilator Cooling water inlet Thrattle valve compressed air after-cooler Solenoid valve HICR water iniet HGR heat exchanger HER thermostat HER water outlet HCR thermostat valve3. Storage and transport For measurements and weights, see Chapter 9. Please store the system only in a dry, frost-free room Observe the local regulations and other requirements pertaining to the professional use of tools, lifting and transport equipment, aswell = _y as the valid standards and regulations for accident prevention. DANGER Always transport the system in its normal operating orientation in a pres- sure-free state, Tiling or laying the system down is nat allowed. Use a forkift truck for transport. For short transporation distances, 6 palette ling trolley may be used.4. Installation 44 Setting up DANGER 4.2 Ventilation NOTICE Install the system in locations with the following environmental condi + max. height above sea level: 1000 m + ambient temperature: +510 +40°C. + ambient temperature for Version T: +510 445°C + ambient concitions: cool, dry, dust free Space requirements and system weights are dependent on the compressor type purchased. Measurements and weights: see Chapter 9, ‘Always maintain the minimal clearances to the walls or other objects, 50 that system service functions can be carried out without hingrance. We recommend setting up the compressors in a separate compressor room. Open flame or fire as well as welding work in the vicinity of the system are forbidden! ‘The air entering the intake opening is used for the compression as well as, for compressor cooling The ventilation must full at least the following enteria: + Supply required cooling air amounts as defined in Chapterd 9.2 and 9.3, + Remove exhaust air as definad in Chapter 9 in order to prevent 2 heat- ing up of the compressor site + The cooling air must be cool, dry and dust-free ‘Make cartain that the supply air contains no dangerous explosive gas mixtures, steam, dust or aggressive pollutants. Make certain that the place of installation is dustfree as well as within the prescribed operating temperature limits and as cool as possible. If neces- sary, ensure the professional installation of forced air ventilation, fitering, room cooling or heating. ‘Make certain that the place of installation is professionally ventilated. ‘Make certain that no circulating air short-circult (the intake of the ex- hausted warm air) can occur.4.3 Forced ventilation (op- tional) =) Be ‘: Cooling air volume flows: see Chapter 9. Forced ventilation must be dimensioned in such a way that the required fresh and exhaust air, considering the available residual pressure of the ‘compressor ventilator, can be supplied and expelied. Nominal diameters of the channel connections and information on the re- sidual pressure : see Chapter 9 IF ventilation ducts are to be connected to the system, then the required supporting suppiementary ventilators should be included when planning the ducts, ‘The exhaust air can also be utlized for the purpose of heat recovery.4. Installation 4.4 Water cooling (optional) For water-cooled plants, the temperature of the compressed air after-cooler of the cooling fluid heat exchanger is lowered with external cooling water. For cooling water quantities, temperatures, pressures and connections, see chapter 9, The cooling water must fulfill he following criteria: + Inlet temperature less than +35 °C + Pre-pressure 4 bar to10 bar + Prevfiltration with a mesh width of at least 0.1: mm. A solenoid valve (optional) shou'd be installed before the cooling water inet ‘The cooling water current through the compressed air after-cooler should be set with the throttle valve belonging to it in such a way that the com- pressed air outlet temperature is 15 °C higher than the output air. 4.5 Heat recovery for heating Compressors can be supplied with the optional heat recovery system water /potable water (op- —. for heating water or tional) + for potable water (safety heat exchanger with blocking medium) ‘Water amounts, temperatures and pressures: see Chapter 9. The heat recovery is to be connected appropriately (soe drawing in Chapter 9) as defined. The water for heat recovery must fulfil the folowing eriter + pressure of up to 10 bar + presfitering with a mesh width of at least 0.1 mm46 47 Connection to the compressed air net DANGER Electrical connections DANGER NOTICE We assume the existence of a professionally designed, installed and ser- viced compressed air net install an additional shut-off valve at the input of the compressed | air net. Connect the system only with a flexible compressed air hose to the | compressed air net. Length of the hose employed: max.1.5 m. Unpredictable movements of the compressed air hose! During load switching in the compressed air net, the hose can move suddenly and with great force. Therefore the hose must be adequate- Jy anchored or fixed. The system is designed for connections to a three-phase supply network (clockwise phase sequence). The mains supply contains professionally dimensioned fuse protection devices (for human and plant system protection). an appropriate mains switch (switching anf of the supply currant) is required. All the relevant data for the connections can be found + InChapter 9 + onthe nameplate of the system. Electrical voltage! Only trained electricians may connect the system to the electrical sup- ply network. | Before making the connections according to the compressor nameplate, determine if the available supply network is adequate. Voltage deviations. ‘greater than 10% are not allowed, Mount the mains switch in the neighborhood of the plant. It must be easily accessible at all mes, Lay the supply cables professionally. Make certain that the installation cannot endanger individuals or property. Take info accaunt the necessary ble diameters, strain relief, and max. allowed cable lengths. Connect the system according to the circuit diagram, The cireult diagram is provided in the control cabinet of the system. Damage to the system is possible! Before switching on the generation of compressed air, initial commis- sioning according to Chapter 6 must be correctly carried out! Test the correct functioning of all safety facilities (protective grounding, protective switch etc.) Carefully lock the control cabinet after the connaction work is completed,5. Displays and operating elements 5.4 Plant main switch The unit is connected to and disconnected from the power supply by a main switch, which is to be installed externally. The compressor main switch must be switched off for all service or Installation work and protected from ilicit or accidental switching on (e.g. affix a warning sign to the main switch forbidding its being turned DANGER ont 5.2 Emergency OFF The system may be stopped with EMERGENCY OFF in the case of a real emergency! Stop the motor in case of danger: press key. Make sure that the shut-down system is sufficiently protected against recommissioning! Enable the system only when the cause of danger has been profes DANGER sionally removed and a securely operating state is achieved. Enable system: 1. Pull the EMERGENCY OFF pushbutton 2. press key @ to acknowledge the malfunction, 3._ press key €D to switch the system on again5.3 Air Control 3 (option) The operating / display desk of the Air Control 3 + displays the plant states / operating data + switches on and off compressed air generation + Is used for plant parameterizing DOODE © saccionsoys Moaification of parameter values Selection of sub-menus Confirmation of parametar changes Editing modes in the sub-menus Display additional operation data, Switch on compressor, Integrated green LED. Blinking: compressor isnot running, can at any time be automatically started up. Lighted: Compressor is running ® Ooo § Compressor shut down. Signals a current warningimalfunction with the integrated red LED.5. Displays and control elements 5.3.1 Basic display 3 will inform you about the plant condition. Service oF malfunction messages with service tslephone number Current reservation of the funtion keys After switching on the main switch or during normal operation, Air Control Ee Momentary aveitable net prescure at com- 3, ome enpratary}— Momentary cor rssed ai ouput if PeBre| ie ead _P Bal] meeson ta er surowme or. [late/Tine= | non aes @ og SS Beater | Higeesteae ete] cenves pending : = } = atall Supplementary information: ‘Switching times are progranmed Ba4a © ‘Symbol flashes: Compressor was switches off by thetimer ‘Symbol ON: Comprossor was switched on by the timer ¥ a Pressure tines are programmed Anttreeze active, compressor does nol start up. 3384 RESTART _ | Automatic restart programmed 8342 REMOTE | Remote control mode programmed 5347 ‘Symbol flashes: Compressor OFF | Symbol ON: In remote made, Compressor ON | LLC MODE | Onoadiotiicac controled by higher-level contol | 53.47 ‘AUTOMATIC | ‘Meaning: Display of programmed oftload runcing PT. contrat ‘Motor running 2X Solenoid valve open J © S ‘Acditional heater switched on 5.3.2 ON/OFF switching of compressed air generation Switching ON: press key ‘The compressor is ready and can start up automatically at any time. Switching OFF: press key. For the duration of the standstil time, the compressor switchas tothe idling state and afterwards off,5.33 Function key reservation In the basic display, the folowing informative pictures can be accessed inthe basie display with the function keys Mode 1 = reservation 1 cnc i | Capacity Service | vitiization Lead lag Plant pass control With the key @ and @, the mode and therefore the reservation of the: {unction keys in the basie display can be changed ® ® ® dally profie | Diagram Diagram compression air amounts temperature weekly profile By pressing the defined function key, the respective information screen is opened. The key @ returns to the basic display trom al information screens.5. Displays and operating elements 53.3.4 Capacity utilization This diagram represents the running, off-ioad, on-load, and standstill hours (Mode 1 - F1) in the form of bar diagrams. The respective current hour count is also Change ofmede «6.83 displayed in the bars. Example: ‘aa verconure —) Ontoad cad hours —»| Lose Cftload hours —e ort] sunésitnoun —e) ovr IL i With the exception ofthe oftioad hours, all bars are represented from the left and grosving to the right. The sum of the on-load hours and the oftload hours yields tne total service hours. ‘The scaling units ofthis diagram are according tothe service hours. Ifthe ‘numberof the standstill hours is greater than the service hours, the bars of the standstil hours wil be cut off In this case note the displayed hour count in the bars. 5332 Service ‘The Service diagram shows the remaining time in hours until the respective (Mode 1 - F3) service interval is due. Change ofmode 5.3, eter Coating fu er Coating ta soparater ~ Motor lubrication compressor If the remaining time is less than 100 hours until the next service, the respective bar begins to bink and a defined warning appears on the display.5.3.3.3 LLC status (mode 1 - F3) Change ofmede «5.83 This display s only available if"Lead lag control” was activated by selecting “YES” in the Lead lag controi menu (see Chapter 4.8) ‘This display shows the status of 4 additional compressors (KZ - K4) when one additional LLC module is used, or 8 additional compressors (K2 - K9) when two additional LLC modules are used, Omtoud ——eftod Base Leed Chanveover ottveat —- | oF easy ror operation ——e | Ready + “Fault” and "Offload!" are displayed for compressors K2 - KS (or K2- K9) only, if the corresponding feedback (fault and motor running) is wired to the additional module 5.3.3.4 Compressor pass The individual machine data stored in the compressor pass are required (Mode 1 - Fa) for our customer service, Change otmade 53.3, = hte Contre | esen: PLLEsRO 108 | Factores 21e2a0 EDP Brant | Censtarmantatio.t Sehanavie“No,? 1S7.e09a8 6 son ont 25-08, 2001 a5. Displays and operating elements 5.3.3.5 Diagramnet pressure —_ in this diagram, the current process of the net pressures is displayed. (Mode 2 - F1) Change ofmode 533, ( | | a ae a | a a Be et 5.3.3.6 Diagram final In this diagram, the current process of the final compression temperature compression is displayed temperature : 7 (Mode 2 - F2) Final-Tenperature-Diastam Change otmose 533 5.3.3.7 Diagram compressed air _ In this diagram, the current process of the compressed quantity for a dayis amount /day profile displayed. (Mode 2 -F3) Change ofmode 5:33 1 pgp Be Guan as = By ) (ay | | ! i i : 1 1 i i | tetas wee aaa oe i; I 5.3.3.8 Diagram compressed air in this diagram, the current process of the compressed air quantity for a amounts /week profile week is displayed. (Mode 2 - Fa) Change ofmeco 5.33 fan RiP Quantaty ~ Meek Diseran3.3.9 Modify diagram settings The scale divisions of the axis can be changed by editing the axis values. XAUTO sullings 53.46 y-axis: - The values of the y-axis can be changed in every diagram, ‘The data in the diagram are continually updated even after the edit function. x-axis: In the diagram “air qty.wk.", the x-axis values cannot be changed, changes are possible in all other diagrams. + Aller editing the x-axis values, the diagram is no longer continually undated. X-AUTO: — - The key © activates or deactivates X-AUTO = If"X-AUTO ON’, the values of the x-axis are automatically updated. The X-AUTO uses the preset default values de- fined in the menu "Display parameter diagrams "(see Chap- ter 5.3.8.6), The manual eciting x-axis values are deleted. Procedure for the scale civision of the axis, fis value yas (Max) ——e | fis value yan Min) —e |e rt Baia ss ‘As value wane (ine point °) As value x-ans (lime point 2) 1, Selection of the axis values to be changed with the keys @ and @ 2. Confirmation of the selection with ENTER 3. Modification of the biinking vatue with @ and ©) Moving the cursor with @ and ©. 4, Confirmation of the modifications with ENTER. ‘The key @ ,X/V-Anit’is for resetting the scale division for the default values preset in X-AUTO, Tho key @ Ideletes the recorded measurement values of the currently displayed time diagram,5. Displays and operating elements 5.3.4 Menu system All basie settings of the system can be viewad in the menu system. If the Limit valves 5341 modifications have no influence on operational safety, they may be modi- Goering premsies $342 fied by means of a code ent. Timer E344 Aer pressing the INFO key, the main menu appears requesting the code Mattinction storage 6345 entry. Display parometer 5.3.48, Configuration 5347 7 — Leediagconto 53.48 ( ‘Accossories 5348 Diagnose 534.10 | | eee 3004 | i 1] — + Code 0000: View the basic settings + Code 0001: View and change basic settings 1. Modification of the blinking values with the keys @ and @. Moving the cursors with @ and ®. 2. Confirmation of the modifications with ENTER. ‘Thereafter, the main menu appears with the following sub-menus: Pontiguration => Kea tag sonteal ~ Diegnoetise => ‘The sub-menu can be selected with the keys @ and @ The selection is confirmed with ENTER. In every operating level, () will lead you to the next higher operating level.5.3.4.1 Sub-menu Limit values j@o!s Mosticaton B® [Bacriome ction ofthe menu poston inking values ENTER] Confirm salacio If the Code 0001 is entered, the parameters of the sub-menu should be changed as follows: 1 The selection of the desired menu position is carried out with the keys. @ans®. “The selection is confirmed with ENTER, Modification of the blinking value with the keys @ and @. Moving the cursor with @ and @. Confirmation of the modifications with ENTER. This menu contains the pressure / temperature limit values: [Start pressure Lower value for ine pressure regulation | Can be edie] Stop pressure vbe edited) Salely pressure | Maximum permissible pressure for ‘| Display Final compression" Minimum permissible final compression | Display temperature min _ temperature Final compression] Maxum permissible final temperature max | temperature malfunction triggering (aiways 0 8 bar slop pressure) Display5. Displays and operating elements 5.342 Submenu This menu contains parameters which influence the temporal regulation of Operating parameters the compressor: DO [seectencrivemenssosion | [Rurcontne Funon time ofthe motors in Dispay Meatcatonctneeiningveues| |__| automatic operation ENTER] Confim seecionneditcaton | [Gr time Runon time ofthe motor for manual | Display @ __[Backto torent higher loved switching-off deay and for automate | restart Siaridetia tine Stari ine Display [Automata Start ait voltage return ‘Can be estat edited ‘Behevior on bad switching ‘Can be Setting range AUTOMATIC) edited ONJ/OFF-LOAD AUTOMATICOPT. eee] vax. pressure oss | Maximum pressure ose Display ax. no. of motor starts | Maximum switching eyes ofthe motor Display per hour Operating mode “Automatic” ‘The text "AUTOMATIC" is displayed in the basic display. After reaching the stop pressure, the system changes over to the off-load mode (after running time) for the duration of the run-on time and the basic display shows the text “run-on time” with the respective residual time. At the conclusion of the run-on time, the motor switches off, The compressor can be started up automatically at any time after falling beiow the start pressure. Operating mode “On-/off-load” ‘The text *ON-IOFF-LOAD" is displayed in the basic display. The compres- sor switches between on-load and off-load operation, which means that its run-on time is unlimited, Operating mode “Automatic Optional” ‘The text “AUTOMATIC OPT." Is displayed in the basic display. After ceach+ ing the stop pressure, the system goes inte the off-load mode. ‘After 10 and after 40 seconds the net pressure is measured, If the pressure drops above the threshold “Max. pressure drop”. then the system is in the idling state for the duration of the run-on fime. In the basic display, the text “Run-on" appears with the residual time as defined, If the value lies below the threshold "Max. pressure drop’, then the system switches off after completing the OFF time, Max. no. of motor starts If the number of the maximum possible motor starts per houris exceeded, then the compressor temporarily switches to the operation mode on-/off- load.8.3.4.3 Sub-menu Service intervals Service work cknowiedged 52, In this menu, all service intervals are displayed, or acknowledged after carrying out the specific service (see Chapter 5.3.5) With the acknowiedgemont, the displayed residual time for the value of the respective service intervals (see Chapter 8.1) is reset, [Sonice iteratASF 'Senice mienalanrfiter Display] Service interval OLF | Service interval ccoling fuid filter Display Service interval OLAB | Services interval cooing fd [Display | separator Senge iervai motor | Sendee nierval for motortwbricaton _[oisplay | Senge inerval comoc | SeniceInerval compressor isola service hous J otal operating nous Display ie | (rotor on Toad hours Taccumulled load nous [bisa ‘Standstill hours: ] Accumulated standstill hours: [Display5. Displays and operating elements $3.44 Subsmenu Timer ‘The agjustment of the integrated real-ime clock, as well as all switching processes dependant upon it are in this menu. Sandi oo new pn BO ee crueticintaues| [Pstatine Setng tho Covent date Eat andre JENTER | Confirm selector/modiication . Attention: The adjustment is entered @ — [oack ote nen nate ve toto reaktme clock wnon te seconde are confmed wth ENTER _ Somerossor ewig | Branch othe sub-ment Eat times [Compressor pressure | Branch othe aub-menu Eat ives Swichig lines LO” Bianchi he eubmen en Pressure tes LLG | Sranch ote bens Te ‘Switching times as well as pressure times can be programmed with the timer independently of each other. ‘When programming switching times, the compressor needs no fonger be manually switched on and off. This is to prevent the possibility that the compressor might for instance start up automatically at night in order to compensate for loss in the compressed air net. For a limited time, values deviating from the preset limit values (see Chap- ter 5.3.4.1) can be set for the start and stop pressure. In this way only the ‘minimal required operating pressure is always generated so thal energy is, saved. ‘Switching times for compressor In this menu, the ewitching on/off times of the compressors are defined. “Timor lock output activ: Mo - Th 6:00 uni 20:00 o' Fr 6:00 untl16-00 etock —P te ju ue ter Sa Sx Fe Ta ke Ta Fe For the activation of the timer, the parameter ofthe timer channels mustbe set fo ON" in the highest menu tine. I the timer channel is set to “ON* and + ifthe timer clock output is activated, a clock appears in the display + ifthe timer output is not activated, a blinking ciock appears in the di lay ‘Seven switching times with the channels K1 -K7 can be programmed. A channel is active when at least one of the weekdays is marked black. In ‘order to continuously activate the timer output for one ora number of days, the switching time should be set t0 09:00.Acjust switching times (weekdays marked black): 1. Channel selection with the keys @) and @ 2. Confirm selection with ENTER, Move the cursor to the desired weekday by using key @ and ®. (in order to delete an already selected weekday, press key @).) 4, Satthe cursor with ® and @ onto the clock time and use keys @ and to modify the blinking value. Stove the seitings with the key ENTER, If the timer for switching times is activated, then the compressor only works during the switching times entered! NOTICE Compressor prossure times In this menu, the pressure times of the compressors are defined (increasing pressure / decreasing pressure) Timer clack outpul active Sa So 0:00 until 24:00 o'elock (¢ from Sa 0:00 o'clock until Su 24:00 o'clack) Cit fo Take Th FREER 1:06:60 0 In order to activate the timer, the uppermost menu row of the parameter for the timer channels must be set to "ON", A channel is active when at least one of the weekdays is marked black (For switching times adjustment: see paragraph "Compressor switching times) The channels are searched beginning with Kt to K7 to determine whether a channel is activated for the current clock time, Ifno valid channel is found, then the settings in the menu “limit values” are valid, in order to activate the timer output for one or 2 number of days continuously, the switching time of 00:00 should be entered, Switel 1g times LLC pressure times LLC ‘Switching times or pressure times can only be enteredif the supplementary module for Lead lag control (LLC) is installed in the control system, ‘The settings are to be carried out as described in “Compressor switching times” or “Compressor pressure times”5. Displays and operating elements 5.3.4.5 Sub-menu Fault log 3.4.6 Sub-menu Display parameters. In this menu you can view the last 20 services, warnings and faults with indication of the date and time. In this menu, the p yarameters for the output to the display are stored. Seleton of fe mera poston | Medication of he bring values Pressure dimension Selection ofthe unitfor the display | Edt ofthe line pressure I ENTER] Conti selacion/odeation Temperature dimension | Selection of tho unit for the display | Edit @ [back oe nex note: et _| of the final compression temperature | Language ___| Selection of the display language | Edit Pressure offset Readjustment possiblity for the Display et prassure sansor [Diagrams Settings for diagrams Eat [Texts “Texis for the compressor pass Display Diagrams Inthis menu, the display parameters ( PEEP EEE Changuover interval | Tie between changoovers ofLLG | Edt Prony 3 for compressors having roy 3 Proves ‘Assignment of sequencing proriy | Edit (see also Chapter 5.3.4.7) ‘This menu contains the settings for the connection of accessories. ‘Tobe able to utlize this function, Air Control 3 must be fitted with accessories modules ‘Accessories module Input configuration. ‘Output configuration ‘Switcring times ovtput 1 Switching times output 2 | Additional module for accessories | availa Function of digital inputs 2 Function of tigi! o puts ‘Switching times defined for acces _ Switching times defined for accessories 1 | Eait ss 2 | Edit Display ee leat Ea ‘Switching times output 3 ‘Suiching timas defines for accessories 3 | Edit ‘Switching times output 4 Switching limes defined for accessories 4 | EditSwitching times The switching on/off times of an accessory rolay output are defined in this menu. Timer clock output aaive Yo- 1h 8:00 until 18:00 o'clock ——» | PHS" geet sa su Fr. #:00 until 14:00 o'clock || C2 Tu He Trams 54 ' & ho Tule th Fo 63 Su i fo Tue Te Ee sa su 1208100 i 1 1S Tu le Th E> € Su ineorga Sreee 08 et Ha Tu lle them €3 Sa For the activation of the timer, the uppermost menu row of the parameter of the timer channels must be set to “ON’ Seven switching times cen be programmed with the channels K1 -K7, ‘One channel is active when at least one of the weekdays is matked black. For adjustment of the switching times, see paragraph "Compressor switch- ing times * Chapter 5.3.4.4 In order to continually activate the timer output for one or @ number of days, set the switching time to 00:00, Input configuration The inputs 1 to 8 can be used in order to switch the compressor fo mal- function or warning ‘This menu describes the current states of digital Inputs and outputs.5. Displays and operating elements 5.3.5 Warnings / maintenance NOTICE ‘A warning is present when the red light is blinking The compressor is not switched off The display contains the additional information: + blinking symbol warning triangle + type of warning + telephone number of the service hotiine [Yn taintenanoet 011 Filter (Arcireiser'e ea 6 What to do for specific warnings/maintenance work is described in Chapter 8, Damage to the system is possible! Necessary maintenance work appear as warning: Acknowledge these warnings only when the defined maintenance work has actually been carried out! Maintenance work not carried out degrades the service life and relia: bility of the system, Please note that damage because of improper usage might invalidate the warranty! Only original spare parts may be used. Information on service: see Chapter 8. Services work acknowledged: 1. As daseribed in Chapter 6.3.4, call up the main menu and then the sub- menu Maintenance schedule. 2. Select the maintenance work to be carried out using keys @) and ©) 3, Press key © to acknowledge the service. 4, By double clicking key @ you will return to the basic display.5.3.6 Malfunctions ‘A malfunction has occurred when the red light is permanently on. ‘The compressor is stopped automatically. In addition, the display aiso shows: + blinking symbol tool key + type of matfunction + telephone number of the service hotline ‘Malfunctions can only be acknowledged when the cause has been profes- sionally repaired. Troubleshooting and repair should be done exclusively by qualified personnel! Fault messages acknowledged: +. press key ®. 2. press key @ in order to restart the compressed air generation.5. Displays and operating elements 5.4 Air Gontrol 1 ‘The operating / display desk of Air Control 3 + displays the compressor states / operating data + Switches on and off compressed air generation + is used for compressor parameterizing, Confirmation of parameter changes: Display additional operating data. ‘Switch on compressor. Integrated green LED Blinking: compressor is not running, can at any time be automatically started up. Lighted: Compressor is running. Compressor shut down. Signals a current warning/malfunction with the integrated rad LED.5.4.1 Basic display ‘After switching on the main switch or during normal aperation, Air Control 1 will inform you about the compressor stale, Remote | le by Current pressure LX Waring present (see chapter .4.5) Motor is sunning ee tee aang aaerteseaaaeee F Fault is present (see Chapter 5.4.6) Restart Automatic restart after power supply is activated Automatic Operating mode Automatic or Automatic optional Remote - Flashing: Generation of compressed air ON/OFF by remote switch Continuous: Generation of compressed air controlled by higher-level control Current compressor temperature Instead ofthe curent compressor ernperaure you can also have he curent cooling fid temperature displayed: Press key (®). For viewing further operating cata, see Chapter 5.4.5. Displays and operating elements 5.4.2 ONIOFF switching of compressed air generation Viewing additional operating data NOTICE, ‘Switching ON: press key D ‘The compressor is ready and can start up automatically at anytime. The compressor starts up only when + the current line pressure falls below the start pressure and + the compressor temperature is at least 1 °C. Switching OFF: pross key For the duration of the off time, the compressor switches to the off-load state and afterwards off. During the switching-off process, the unit first changes over to the ‘off toad’ mode (mator running, but compressor does not compress ar; afiash- ing point appears in the display) for the duration of the “off time” (46 s). Only then Is the unit switched off (motor stops). ie EAL te | t ! | “7 | ‘Operating data + — t 7 I Automatic aH 2x Stop pressure in bar, The unit changes over to the off-load mode. a ‘as soon as the line pressure increases above this value, 3x. Safety pressure in bar (= stop pressure + 0.8 bar}. When this safety pressure is reached, the compressor shuts down and an error mes sage is output, 4x min, permissible compressor temperature 5x _ max. permissible compressor temperature: 6x Total running hours 7x Ondoad hours 8x Remaining service life of air fiter 9x Remaining service life of cooling fluid and cooiing fluid fiter 10x Remaining service life of fine separator 11x Remaining service life of motor lubrication. 12x Time remaining until compressor must be serviced Display of faultsiwarnings is deactivated! As long as the operating data above are viewed, no fault messages or ‘warning can be output. This screen should therefore be exited as soon as possible.5.44 Menu system Unit prameterisatlon 5.4.4.1, Basic patametersaton 54.42 ‘Available code numbers 5443 b8 54413 5.4.4.4 Unit parameterisation Al basic settings of the system can be viewed in the menu system. If the modifications have no influerice on operational safely, they may be modi- fied by means of a code entry. ‘The unit can only be parameterised, when the generation of compressed air is switched off. See Chapter 5.4.2. Parameters allow the unit to be adjusted to your specific requirements, To this end, Air Control 1 must be swiiched to the parameterisation mode. The incividual parameters can be selected with a code and then changed. A description of available code numbers can be found in Chapiers 5.4.4.3 105.4.4.13. Paremeterisation procedure: 1. Press key @ unt the message “cod” appears in the display. Air Cone trol 1 is now at the main level ofthe parameterisation mode, ae eed et : | / rn Le i {flashing Automatic 2. Now select the required code by means of keys ®) and ©. 3. Press ENTER to activate the code. Air Control 1 changes io the first sub-level With some codes, several paramotors can be entored one afer the other, In these cases, simply press key ENTER to solect the subsequent parame- ter 4, Use keys @® and © to change the current sotting of he selected code according fo your requirements. 5. Press key ENTER to take over the new settings or press key @ to ‘eave the setting unchanged and return to the next higher level5. Displays and operating elements 544.2 Basic parameterisation The unit can only be parameterised, when the generation of compressed air is switched off. See Chapter 5.4.2. “The basic parameterisalion prepares the unit for operation, 1. Press key © until the message “cod” appears in the aispiay. Seiect code 11 by means of keys @) and @ and press key ENTER. Press key INFO. Air Control 1 now shows the start pressure. The compressor compress~ {88 air as soon as the line pressure falls below this value. Possible ad~ jusiment range: 3.5 to maximum pressure of the unit. 4. Adjust the required start pressure using keys @ and @ confirm the setting by pressing key ENTER i 8. Press key INFO. 1 Air Control 1 shows the slop pressure. The compressor changes over if (coftioad operation as soon the ine pressure exceeds ths value, 4 Possible adjustment range: 3.5 to maximum pressure of the unit ‘The stop pressure must be higher than the start pressure! Select the required parameter valve using keys @ and @ and confirm Vv Start pressure (flashing) the setting by pressing key ENTER, Press key © to complete the basic parameterisation, Slop pressure (ashing)5.44.3 Code 2: Operating mode Determines how the unit is to respond when the start or stop pressure is reached. Both limit values are set during basic parameterisation (see Chap- ter 5.4.8.2), 0: Automatic. ‘The symbol ‘Automatic" appears in the disolay. ‘The motor starts up and the compressor compresses air (= on-load. operation), as soon as the line pressure falls below the start pressure. Tho unit changes over to of-oad operation (motor running, but the com pressor does not compress ir), a5 soon as the line pressure exceeds the stop pressure, As soon as the off-ioad phase starts, the off time lapses (for the parameterisation, see Code 51 Chapter. 5.4.4.9). The motor stops after the off time, 4: On-off-load The symbol ‘Automatic” is not shown in the dispiay. In contrast to the automatic operating mode, the motor never stops run- ning. The compressor compresses air as soon as the line pressure falls below the start pressure. The unit changes over to off-load operation (motor is running, but the compressor does not compress air), as soon as the line pressure rises above the stop pressure. 2: Automatic optional The symbol “Automatic are showin in the cisplay. Similar to the automatic mode, Here, the user has an influence on how often the motor stops. To this end, the parameters “maximum pressure Joss" (adjustment range 0.0 to 9.8 bar) and “max. number of motor siarts™ (adjustment range 1 to 55 cycles/hour) are queried additionally and an additional dot before the temperature Function “Max. pressure loss" ‘When the unit changes over from on-load to off-load operation, Air Con- trol 1 saves the current line pressure after 10 and after 40 seconds. If the pressure loss thus established is higher than the “Max. pressure loss", the motor shuts dovin alter the off time has elapsed (parameteri sation with code 51, see Chapter 5.4.4.9), otherwise after the “off” time (45 si. Function ‘Max. number of motor starts" The motor is not switched off after the “off" ime elapsed, when the number of starting cycles of the compressor exceeds the "Max. number of motor staris”,5. Displays and operating elements 5.444 Code 3: Automatic Determines whether the generation of compressed air is to restart auto- restart after power matically after a mains power failure. failure 0: Automatic restart: OFF ‘The generation of pressure remains deactivated after @ power failure. ‘The fault message “power fail” is output. 1: Automatic restart: ON ‘When this function is activated, the display shows the symbol ‘restart’ If the generation of pressure was activated before the power failure occured, the unit restarts automatically after the “off time, In this case, the fault message “power fail is not output. If the generation of pres- sure was deactivated before the power failure, it remains deactivated, 5.44.5 Code 8: Local control, Determines, how the generation of pressure is to be switched on and off. remote control, LLC-OK 0: Local contro! The generation of compressed air can only be switched on or off from the control panel of Air Control 1 4: Remote contro! ‘The generation of compressed air can be switched an only by way of a positive edge (24 VDC) at terminal 23 and switched off only by means (of a low level (0 V) at terminal 23 or by pressing key @). This function- ality is signalled on the display of Air Control 1 by a flashing tex! “Re- mote’ 2: LLC-OK ‘The input at terminal 23 is used to signal the readiness for operation of an external control. The external control can only be switch between on-load and of-load operation when a high lavel (24 VDC) is applied (see code 18, value 1, Chapter 5.44.7). When a low level is applies, LLC operation is automatically switched off and the internal pressure sensor used. 5.4.46 Code 11: Start and stop Determination of the start and stop pressures; for the procedure, see pressure Chapter 5.4.4.25.4.4.7 Code 18: Lead leg control (LLC) 5.44.8 Code 21: Maintenance acknowledgement NOTICE Determines whether the changeover between on-load and off-load opera- tion is to be controlled by the internal pressure senor or by a higher-level control ‘Changing over between on-load/off-load operation by internal pres- sure sensor Changing over botween on-loadioff-load operation by external con- trol (e.g. PLC) (On-load operation when a high level (24 VDC) is applied to terminal 22. Off-load operation whan a iow level (0 V) is applied to terminal 22. This functionality is signaled by the text “remote” that appears continuously in the display of Air Control 4 Is used for acknowledging 2 maintenance warning currently present: For the meaning of maintainence numbers and acknowledgement of warnings, see Chapter 5.4.6. Possible damage to the unit! Required maintenance work is signalled in the form of warnings. ‘Acknowledge these warning only, when the required maintenance has actually been carried out! If the unit is not serviced, its service life and reliability are reduced. Please note that damage resulting from improper handling is not cov- ered by the warranty! Use only genuine spare parts, More information about servicing can be found in Chapter 8,5. Displays and operating elements 5.44.9 Code 51: Offload, off, The relevant times can be entered successively at operating levels 0 to 2. staridelta time 0: Off-load time Adjustment range: 10 - 1200 s. Operation in conjunction with Code 2 {operating mode). Is used in the operating modes “Automatic” and “AL tomatic opiona’. 4: Offtime ‘Adjustment range: 0 - 60 s. The factory seting of 45 s should be re- tained. During the off time, the motor is running in the idle mode; no compressed aris generated. The of time elapses = when key © is pressed for switching off ~ during automatic restart = according tothe Automatic optional mode 2: Staridelta time ‘Adjustment range: 3-30 s. Determines after which time changing over isto take place from star to delta circuit when the motors switched on, 5.44.10 Code 65: Condensate _Is used for adjusting the impulse and break times of the condensate valve valve 0: Impulse time Duly cycle of the condensate valve 4: Break time Off time of the condensat valve5.4.4.11 Code 90: Unit for pressure indication 5.4.4.12 Code 95: Unit for temperature indication 5.4.4.13 Code 999: Software version Determines the unit for the pressure indication: 0: bar 4: MPa 2: psi Determines the unit for the temperature indication: 0: Degree Celsius (°C) 4: Degree Fahrenheit (°F) 2: Kelvin (Kk) Indicates the software version of Air Control 15. Displays and operating elements 5.4.5 Warnings / maintenance A warning is present when the red light is blinking work The compressor is not switched off. ‘The following is displayed: Maintenence umber (tashing) ‘symbol far warnings: —~ (ashing) Automatic Meaning of maintenance numbers: 2 Excessive final compression temperature 3 Excessive line pressure 41 Remaining time unti ar fiter is to be serviced < 100 h 412. Remaining time untii cooling fuid / cooling fluid fitar is to be serviced < 100 413. Remaining time unti fine separator is to be serviced < 100 h 44. Remaining time until motor is to be lubricated < 100 h 415. Remaining time until compressor is to be serviced < 100 h Damage to the system is possible! Necessary service work appears in the form of warnings. Acknowledge these warnings only when the defined service work has NOTICE actually been carried out! Service work not carried out degrades the service life reliability of the system. Please note that damage caused by improper usage Is not covered by the warranty! ‘Only original spare parts may be used. Information on service: seo Chapter 8. ‘Acknowledge maintenance work: 1. Press key @ (ca. 3 sec.) until the message “cod” appears in the dis- play. 2. Select Code 21 using keys @ and @. 3. Press ENTER, then D>5.4.6 Malfunctions Malfunction has occurred when the red light is permanently on. The compressor is stopped automaticaly, The following is shown in the displa Symbel.ot maruretion — (Mashing) Faut number (ashing) aut ———_1e alternates with he final compression temperature Automatic Meaning of ‘fault numbers and texts: 1 Par Incorrect pressure setpoints 2 EPROM Incorrect setting parameters 3° Loac Undervoltage 4 NoAC Power failure 5 OEFEC Air Control 1 defective 6 Emerg EMERGENCY OFF actuated 7 Rotat Wrong direction of rotation 8 Mott Excessive motor temperature 9 Hicur Overcurrent 10 HIP, Overpressure 14 DIP Differential pressure of fine separator 12 Set ‘Sensor for fina! compression temperature 13. Seoil Sensor for cooling fluid temperature 14 Sep Pressure sensor 15 Hit Excessive final compression temperature 16 HiP Excessive line pressure Malfunctions can only be acknowledged when the cause has been profes- sionally repaired. Troubleshooting and repair should be done exclusively by qualified personnel! Acknowledge fault messages: 1. press key @. 2. press key GD in order to restart the compressed alr generation6. Correcting malfunctions Error Compression teriperature too high (red lamp is on) Line pressure falls ‘System pressure released by safety valve “Matfunction over pressure” or “line pressure to9 high’ (red iamp is on) Cause + Silencing hood not closed ~ Intake or ambient temperature too high = Cooling air inlet or outlet blocked + Coating fuid filter fouled = Insufficient cooting fluid + External cooling fuid heat exchanger fouled! Attention: Cooler sorew should always be worked with a counter vwrench; keep from applying torque tothe cooler ~ Compressed air consumption greeter than delivery quantity of the compressor ~ Air fiteris fouled = Relief valve blows alr during compression = Suction regulator does not open + Leakage in the pipework = Line pressure set too high + Safety valve defective = Minimum pressure valve blocked ~ Cooling fluid separator cartridge fouled Cooling fluid separator fouled Higher external pressure in the compressed air net Measures + Check and secure sound insulation hood = Ventilate compressor room + Make sufficient room + Renew cooling fluid fiter + Add cooling fluid ~ Clean with compressed ai. In the case of extensive fouling: disassemble cooler and clean with high pressure cleaner. Attention: Danger of short circuitt Do not put electrical elements under power - Acompressor with larger delivery quantity is required ~ Replace air filter + Check relief vaive: if necessary, replace seals, + Check solenoid valve regulator spo! and if necessary, replace + Make pipework airtight = Adjust line pressure anew + Check safety valve; if necessary, exchange - Exchange solenoid valve ~ Exchange cooling fluid separator cartridge = Replace cooling fluid separator + Equalize outside pressure or remove from natError ‘Compressor does not start ‘automatically or does not oliver air after previous switching off upon reaching the final pressure or from off- load state System does net ster on pressing the start outton C1) Compressed air containing large amount of cooling fluie (cooling fluid consumption too great) System stopped before reaching the final pressure (ed lamp is on) Water in the piping net Pressure decline Cause Net pressure set too high Interruption in the control current circuit Ambient temperature under +1 °C; message “Cooling fh temperature too low * ‘Switching times have been activated in Air Control 3 Line pressure greater than start pressure Remote control activated Missing voltage at the compressor Electrical error in the contro! system Switching times have bean activated in Air Control 3 Cooling fiuid return flow piping is congested Defective cooling fluid separator ‘Overtemperature or overpressure Interruption in the control current loop Dryer switched off Condensation diverter is not functioning Bypass open Dew point too high Pressure differential in the filler too great Measures = Adjust net pressure anew + Check electric circuit for intarrup- tion (only by a trained electrician) + Install an additional heater or keep compressor room at right temperature ~ Check switching times and pressure times in Air Contral + Note line pressure value + Symbol “remote “is blinking + Check if voltage is applied = Inspect (only by an trained electrician) + Check switching times in the Air Control 3 ~ Clean cooling fluid feedback piping ~ Replace cooling fluid separator ~ Rectify error as required + Check current loop (only by a trained electrician) = Switch on dryer + Clean / exchange drain - Close bypass + Demand customer service + Exchange filter7. Initial commissioning 7A Preparatory activities 7.2 Check cooling fluid level Check cooing fue evel paling fui roi 83 7.3. Start-up lubrication of the compressor stage 1. Make certain that when the compressor main switch is switched off, no cit or inadvertent switching on can ocour. 2. Make certain that the system Is correctly connected to the compressed air nel. Make certain that when the shut-off valve on the pressure net side is closed, ilict or inadvertent opening cannot occur. 41. Make certain that escaping cooiing fuid can be collected 2. Check the cooling fu level onthe sight-giass: The sight-glass must be completely wetted with cooling fluid. Loosen the filing screw. Do not lose the seal ring. With new compressors, the cooling fuid level must be at the lower edge ofthe filer nack 3. If required, refl cooling fluid (see Chapter 8 “Check oo refll cooking tui") 1 fluid tevel/ After an extended standstill ime, for example between factory delivery ‘and commissioning or during a longer company vacation, there might no longer be any cooling fluid in the rotor chamber of the air end. This cooling fluid is absolutely necessary for bearing and rotor lubrication in the start-up phase. 1. Before switching on the compressor, fil approx. 0.2 liter cooling fluid into the filer screw of the suction regulators, 2. Rotate the air end only by hand in the correct direction of rotation until the noticeable resistance dwindles and the cooling fluid passes through the alr end, 3. Finally, tighten the filler sorew of the suction regulators (05). if no extra cooling fluid is available (only cooling fluid of the same variely may be employed), the cooling fluid can be taken from the cooling fluid drain. If the system is employed only vary irregularly or shut down weeks on end, it should run an hour in the off-load mode once a week in orcier to avoid corrosion damage caused by standing condensation.7.4 Rotational direction control NOTICE 3. Observe the motor shaft and press keys CD and The rotational direction of the main motor must be checked. 1. Remove the panel from the unit so that a part of the V-belt is visible, 2. Switch the compressor main switch on. Operating the motor in the incorrect direction of rotation may cause damage to the system! Turning just a few seconds in the wrong direc tion of rotation is sufficient to damage the compressor! To check the direction of rotation you may start up the motor only briefly! in short succes- sion. The V-belt must turn in the direction of the arrow shown on the ‘main motor. In the case of the wrong direction of rotation, have the phase sequence corrected by a qualified electrician by interchanging the two supply phas. es while the compressor is switched off and protected against unwant-7. Initial commissioning 7.8 Basic settings 7.5.1 Control system of the system with Air Control 3 (option) 7.8.2 Controlling the unit by means of Air Control 4 In order to understand compressor basics, please read the chapter 5 “Compressor operating elements *. More precise instructions on the basic settings of the system can be found in the following chapters, + Chapter §.3 Air Control 3 (option), + Chapter 5.3.1 Basic display + Chapter 5.3.4 Menu system ‘The display parameters + pressure dimension, + temperature dimension, + language can be modified as described in position 5.3.4.6. The limit values + start pressure + stop pressure can be modified as described in position 5.3.4.1. 1 your Air Control 3 has been fitted with the supplementary module LLC, carry out settings as in point 5.3.4.7 5.9.4.9 of the description I your Air Control 3 has been fitted with the supplementary module “acces- sories”, carry out settings as in point 5.3.4.10 of the description. For more detailed instructions with regard to the basic settings of the unit, please refer to: + Chapter 6.4, Air Control 4 + Chapter 5.4.1, Basic display + Chapter 5.4.4, Menu system Please set the display parameters as described in the following chapters: + Pressure unit, Chapter 5.4.4.11 + Temperature unit, Chapter 5.4.4.12 “The limit values for + start pressure and + stop pressure can be set as described in the section "Basic parametersation’, Chapter 5442.7.6 Switch on compressed ai generation DANGER 7.7 Concluding activities 1. Before switching on the system, make certain that no one can be en- angered by doing so. The sound-insulation hood serves as a part of the contact protection, among other things for the cooing air conduits ‘of the compressor piant. It must be closed during operation, 2. Carefully open the shut-off valve after the compressed air connector and between system compressed air net (receiver). The system is now connected to the net, 3, Switch on the main switch, ‘Make certain that no tools or Isose objects are lying on or in the system. 5. Press key D to switch on the compressed air generatios ‘The green LED in key © lights up when the compressor is working, Check on the operating cisplay desk for the line pressure. ‘The fine pressure will slowly rise if the compressed air consumption is less than the quantities do ivored by the compressors. ©n blinking green LED, the compressor can start by itself at any time! ‘The green LED biinks when the compressor is ready for operation ‘The compressor switches on automatically when + the current line pressure drops below the preset start pressure of the compressor, if + the machine temperature rises above +1 % + the timer of Air Control 3 is active, + orthe Lead lag controt (LLC) is activated 1. Check all piping of cosling liquids and pressure air conduits for leak- age 2. Check the cooling fluid level of the compressors after 10 and before 20 minutes operation timo, If the cooling fluid level is too low, refill cooling fluid a8 defined in Chapter 8 *Check cooling Muid level /cooling fluid refi, Check the compressor temperature. The compressor temperature should Not fal! uncer approx. 75 °C and not rise above 105 °C; at 105 °C a warning is issued, al 110 °C the campressor automatically sauts down, Re-tighten al electrical connections after 4 week. Carry out all service intervals according to Chapter 8 “Overview of main- tenance interva's” 8. Check tne standard operation of the functions carried out weekly ac- cording to Chapier 8 "Overview of maintenance intervals”8. Service 81 Overview Maintenance intervals Preparatory actives 82 ‘Check coating fis vel / ref cooling tid aa Check ‘or leakage Ba Check the compressor tomperature 85 Ghavk the cootor for fouling 88 (Check for condensate, a7 Replace cooling fuid Replace cooing ful itor ag Replace cocting #uld separator8 9 Roplace ari 810 Chock satety vale an Check deve. 8.2 Lubrication ofelectic motor 8.19 Goncleding activities axa 8.2 Preparatory activities % NOTICE rN DANGER Necessary service work appears in the display as warnings (see Chapter 5.3.5 0r 5.4.5) first 100 ‘operating operating hours ours Chock sing id © '83" |G ° inet Checklorleskege 84 O ° check cameressor temperature, 85 ° ° check coor for foulng as (OO ° Check te condensate ar 0 OF Replace cooing Mid bn cooing ° ° fee as Replae cooing auld separator 29 ° Roping setter 8.10 ° Check sly vale ett ° Check ve en ° Lubrication ot notor 8.18 o Gonstal compressor es ° servicing * The mot lubcication latarvals vary elwean 3100 and 20 000 hours depsniding onthe ype af unit. Awaming an the contol ndiates when the motor nas tobe lubricated 1. Press key ® in order to switch off compressed air generation. Please wait until the compressor has been switched off after a run-on or venti- lation phase. The symbot "Mi for the main motor is then no longer visi- ble in the display. 2. Switch the compressor main switch olf and make cerlain thet it cannot bbe turned on by mistake or intentionally (¢.g, waming signs prohibiting switching}. Use only original spare parts! Hot surfaces ~ hot cooling fluid! Make certain, with appropriate precaution, that no one can be burned or scalded! Particularly note dangerous situations which can arise from the release of hot cooling fluid steam! 3. Remove the side panels of the system. 4, Make certain that the pressure net side shutoff valve is closed and cannot be opened accidentally or intentionally. 5. Make certain that when working on the cooling fuid circulation, escaping cooling fluid is collected,83 Check cooling fluid level / refill cooling fluid Presaralery activites a2 Bonckuing activities ata NOTICE Carry out the "Preparatory activities* Only check the cooling uid level whan the sysiem has been turned off for a minimum of 30 minutes. This is to ensure that the cooling fluid has settled down after the running phase. ‘The cooling fluid level is in order if the complete sight glass is full of cooling fluid It the complete sight glass is not full of cooting fluid, cooling fluid must be added as follows: 1. Unscrew the filer screw. Do not misplace the gasket ring, Damage to the system by using different cooling fluids: Different cooling fluids must not be mixed, Only use original cooling ‘iuiat 2. Use an appropriate funnel for filing, Cooling fluid can be filled up to the {iling rim of the fiting, 3. Take care that the seal is correct'y seated and screw the fitting screw closed Carry out the “Concluding activities”,8. Service 84 Check for leakage Preparatory actvtios Gonchuding eciies 85 Check the compressor temperature NOTICE 86 Check the cooler for fouling Progaratory actives Concluding activites 64 a2 ai Carry out the "Preparatory activities”. Check all piping and the bottom of the system for cooling fluid rests. If there is st cooling uid in the system, the cause should be found and tho cooling fluid removed. Carry aut the "Conciuding activities" ‘The compressor temperature, which can be viewed in the display, should be between 75°C and 105 °C. ‘Too high or too low compressor temperature can lead to damages to the compressor. Carry out the “Preparatory activities". Check the compressed air after-cooler and the cooling fluid heat exchanger ‘rom the inside and outside. If you determine any fouling, it should be re- moved (e.g. by compressed air blowing, where the dirt particles should be blown outside). Carry out the "Concluding activities” ~8.7 Check for condensate Preparatory ates Concluding activities NOTICE 82 Bie ‘The absorption capacity of water humidity in the air + falls with increasing pressure + rises with increasing temperature. Suficiently high compressor temperature guarantees that the intake alr humidity does not precipitate as condensation, Frequen! switching on and off of the compressor can result in the compressor not achieving the re- quired operating terperature. Condensation in the cooling fluid circulation can load to damages to the compressor. If you have determined that there is condensation in the seperator tank, immediately get in touch with after-sales servi Condensation damages are not covered by the warranty! Since water is heavier than cooling fluid, after extended standstil times (e.g. n'a weekend) the condensate collects in the bottom of the seperator tanks. It can be simply drained off by the discharge drain, Carry out the following activities only when the system has been turned off at least overnight. Carty out the “Preparatory activities” 1. Open the drain and carefully observe the escaping liquid. Close the drain again as soon as cooiing fluid appears. 2. Check the cooling fluid level according to Chapter 8 3. Carry out the "Concluding activities”8. Service 88 Cooling fluid replacement / replacing cooling fluid fitter Preparatory actviios 82 Concluding activities Bi DANGER NOTICE Replace the cooling fluid only when the old cooling fluid is stil warm. Cold cooling fluid, because ofits higher viscosity, does not flow so well Hot surfaces - hot cooling fluid! With appropriate precautions, make certain you ere not burned or scalded! Carry out the "Preparatory activities”. +. Unscrew the filer screw. Do not misplace the gasket ring. 2. By opening the drain, allow the cooling Rud to drain nto an appropriate vessel and then close the drain again, Damage to the system can be caused by different cooling fluids! Different cooling fluids must not be mixed.3. Use an appropriate funnel for filing. Cooling fluid can be fled up to the filing rim of the ftuiag, 4, Take care that the seal is correctly seated and screw the fitting screw closed. 5. Loosen the cooling fluid fter with a strap wrench and remove possible seal rests irom the cooling fluid fiter housing Lightly oil the new seal of the cooling fluid filters. 7. Sorew the new cooling fluid fitar to the stop and tighten the cooling fluid filter by hand another hall @ revolution. 8. Test the cooling Muid fer for leakage at operating temporature Carry cut the “Concluding activities”,8. Service 8.9 Replacing cooling fluid Carry out the "Preparatory activities’ separator Preparatory actives 82 Concluding ecivtes ane 4. Loosen the cooling fluid separator using a strap wrench. Remove pos- sible seal rests from the cooling fiuid separator housing. 2. Lightly oil the new seal(s) of the separator. 3. Screw the new cooling fluid separator in to the stop. Tighten the cooling uid fier by hand another half a revolution. 4, Test the cooling fluid separator for leakage at operating temperature. Carry out the “Concluding activities”8.10 Replacing air filter Carry out the “Preparatory activities” Preparatory actviies a2 Geneluting autivns et Damage to the system by intake dust! The system must not be operated without an air filter. NOTICE 1, Remove or screw off the old air filter 2. Insert the new air fiter Carry oul the “Concluding activites” 8.11 Check safety valve Carry out the “Preparatory activities”, Preparatory sctvties a2 Conelusing e14 Remove the safety valve and remove residues at the threaded connec- tion, Check the safety valve in an appropriate apparatus. Ifitis stl working correctly, add sealing tape to the connecting thread of the safety valves and screw the safety valve back in 4. Ifthe adequate functionality of the old safety valves can no longer be guaranteed, screw in a safely valve, Carry out the “Concluding activites’8. Service 8.12 Check drive Preparatory activites CConctuding activites 8.13 Relubrication of the electric motor Preparatory atvtios CConclosing aeivios 82 aie a2 ana Carry out the “Preparatory activities’. The V-belt tension can be measured with the help of a belt tension tester: 1. Apply the tension tester al right angles in the centre of the free V-bett span, 2. Apply the V-bell test force according to Chapter 9.1 3. Read off the V-belt deflection from the tension tester. If these values do not correspond to the values given in chapter 9.1, the V- belts have to be changed by a service technician. Carry out the “Concluding activities". Carry out the ‘Preparatory activities" Carry out the required relubrication with a grease gun. Ii there are no grease nipples on the electric motor, then itis equipped with capsulated permanently greased bearings. These motor bearings must be replaced when they are worn out Carry out the “Concluding activities",