huong dan su dung may nen khi air control 3 .pdf

8/9/2019 Huong dan su dung may nen khi AIR CONTROL 3 .pdf

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Operating manual

ALLEGRO 30 - 210


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2001

All rights belong to:

Alup Kompressoren GmbH

Adolf-Ehmann-Strae 2

73257 Kngen

Tel.: ++49 (0) 7024 / 8020

Fax: ++49 (0) 7024 / 8050

No part of this manual may be duplicated by mechanical or electronic meanswithout the express written permission from Alup Compressors GmbH.

All particulars in this manual are specified to our best knowledge, but withoutguarantee.

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.


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Table of contents

1. Safety instructions.............................................. 4

1.1 Symbols in this manual ................................ 41.3 Qualified personnel ...................................... 51.4 General safety instructions ........................... 6

2. Functional description........................................ 8

3. Storage and transport....................................... 10

4. Installation......................................................... 12

4.1 Setting up................................................... 124.2 Ventilation .................................................. 124.3 Forced ventilation (optional) ....................... 134.4 Water cooling (optional) .............................. 144.5 Heat recovery for heating water / potable

water (optional) .......................................... 14

4.6 Connection to the compressed air grid ....... 154.7 Electrical connections ................................. 15

5. Displays and operating elements .................... 16

5.1 Plant main switch ....................................... 165.2 Emergency OFF......................................... 165.3 Air Control 3 ............................................... 17

5.3.1 Basic display ................................... 185.3.2 ON/OFF switching of compressed air

generation ....................................... 185.3.3 Function key reservation in the basic

display ............................................. 18

5.3.3.1 Capacity utilization .................. 195.3.3.2 Service .................................... 205.3.3.3 Plant pass ............................... 205.3.3.4 Diagram grid pressure ............. 215.3.3.5 Diagram compression end

temperature............................. 215.3.3.6 Diagram compressed air amount /

day profile ............................... 215.3.3.7 Diagram compressed air amounts

/ week profile ........................... 215.3.3.8 Modify diagram settings........... 22

5.3.4 Menu system ................................... 235.3.4.1 Sub-menu Limit values ............ 245.3.4.2 Sub-menu

Operating parameters.............. 245.3.4.3 Sub-menu

Service intervals ...................... 255.3.4.4 Sub-menu Timer...................... 265.3.4.5 Sub-menu Malfunction storage 285.3.4.6 Sub-menu

Display parameter ................... 285.3.4.7 Sub-menu

Configuration ........................... 29

5.3.4.8 Sub-menuCommunication ....................... 30

5.3.4.9 Sub-menuBase Load Switching (BLS) ..... 30

5.3.4.10 Sub-menu Accessories ............ 305.3.5 Warnings / service work ................... 325.3.6 Malfunctions .................................... 33

6. Correcting malfunctions................................... 34

7. Initial commissioning ....................................... 36

7.1 Preparatory activities .................................. 367.2 Check coolant

level ........................................................... 367.3 Start-up lubrication of the compressor stage367.4 Rotational direction control ......................... 377.5 Basic settings ............................................. 38

7.5.1 Control system of the system with AirControl 3 ......................................... 38

7.6 Switch on compressed air generation ......... 39

7.7 Concluding activities ................................... 398. Service............................................................... 40

8.1 OverviewService intervals ......................................... 40

8.2 Preparatory activities .................................. 408.3 Check coolant level / refill coolant ............... 418.4 Check for leakage ...................................... 418.5 Check the compressor temperature............ 418.6 Check the cooler for fouling ........................ 428.7 Check for condensate development ........... 428.8 Coolant replacement / replacing coolant filter

438.9 Replacing coolant separator ....................... 448.10 Replacing air filter....................................... 448.11 Check safety valve ..................................... 448.12 Check clutch element ................................. 458.13 Relubrication of the electric motor ............... 458.14 Concluding activities ................................... 45

9. Technical Data................................................... 46

9.1 Dimensions for connections ....................... 469.2 Data air-cooled compressors ...................... 479.3 Data water-cooled compressors ................. 479.4 Electrical data ............................................ 47


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1. Safety instructions

You are reading this manual in order to learn about the screw compressor.It contains information that is required for safe, malfunction-free operationof the system. Please keep in mind that damages incurred due to improperusage may not fall under the conditions of guarantee!

For this reason, please keep this manual where all users can have freeaccess to it at any time.

The system was developed, manufactured, tested, and documented in state-of-the-art technology and considering all the current safety norms.

In normal circumstances, no danger for personnel or property can resultfrom the system if you comply with the stipulations of the service manualand if the transport, assembly, service and the described handling is car-ried out according to the regulations.

Nevertheless certain risks remain!

Safety instructions

This symbol is employed whenever personal damage can be incurred

by carelessness, or by ignoring the instructions.

1.1 Symbols in this manual

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-

lar information.

Text in a frame signifies the description of an activity to be carried out bythe user.

DANGER

NOTICE


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The system is exclusively designed for

the generation of compressed air and

for operation in a non-explosion-endangered environment.

Any other utilization must be regarded as not in compliance with the designpurpose!

The manufacturer/vendor is fundamentally not liable for damages incurredif the system is not used according to its design purpose!

1.2 Proper usage

The generated compressed air may not be used for human respiration. In

case 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 commissionedwith the transport, installation, operation or service of the system. Theseindividuals must read the chapter relevant to their duties.

Qualified personnel are individuals who:

upon the basis of their professional training, knowledge and experienceas well as their understanding of the relevant norms can assess thework to be carried out with regard to all possible dangers, or

based on many years of activity in a comparable field, have the samestate of knowledge as someone with professional training.

Activities that are not described in this manual may only be carried out byour customer service department or by authorized technical personnel.

1.3 Qualified personnel

Unqualified actions or disregarding the warnings in this manual or those

affixed to the product can lead to serious damage to persons and to mate-

rial!


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6

1. Safety instructions

1.4 General safety instructions

DANGER

DANGER

DANGER

DANGER

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 st-

ream. Therefore, when working with compressed air, protect your eyes

with safety glasses.

Loss or decrease of plant safety !

Retrofitting or modifications on the system can reduce its level of safe-

ty! The results could be 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 protection from contact to hazardous zones!

The side panelings of the system are a part of the contact protection

system to protect personnel from ventilator wheels that start up auto-matically, moving machine parts, hot surfaces and dangerous voltag-

es! Furthermore, they are required for sound insulation for the cool-

ing air conduction. Therefore they may not be removed in the normal

operating mode of the system.

Injuries caused by ventilator wheels that start automatically, moving

machine parts, hot surfaces or escaping coolant 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 grid 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 electri-

cians observing all the relevant safety regulations.


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Loss or decrease of plant 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 plant availability. Our customer ser-

vice would be glad to help you with your selection. Tel: (+49) 0180

5258700.

NOTICE

NOTICE

Carry out the activities in all of the following chapters in the order given.

Damage to the system may result in environmental damage!

Before the initial commissioning, the system must have been correct-

ly installed according to Chapter 6!Plants greater than 100 kW may be taken into operation by qualified

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 sewerage system!

We offer an appropriate coolant/water separator for condensation pro-

cessing.

Compressed air receivers require regular technical inspections!

Please notify the commissioning of the system at the technical inspection

authority responsible for you. They will inspect the system and provide a

receiver test book.

Document all the activities carried out (e.g. in some table format).


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2. Functional description

2.1 Drive

2.2 Air path

2.3 Coolant circulation

2.4 Cooling

The frequency converter in the switching cabinet supplies the electric mo-tor with power. For the operating principle of the frequency converter, pleaserefer to the instructions in the switching cabinet.

The electric motor drives the compressor stage via a flexibly supported

coupling.

Fresh air supplied by the integrated cooling air ventilator is filtered throughthe intake filter(s). The air is then directed via the intake regulator into thecompressor stage, where it is compressed to the final compression pres-sure together with injected coolant.

In the coolant reservoir, the compressed air is separated 98 % from thecooland and the downstream coolant separator removes the remainingcoolant from the compressed air. The air then flows via the minimum pres-sure one way valve into the compressed air aftercooler and is cooled downto 10 - 15 C above the ambient temperature before it leaves the compres-sor through the compressed air port.

The intake regulator opens shortly after the compressor has started up forgenerating compressed air. It closes when the compressor changes overto off-load operation and/or comes to a standstill and unloads the systemvia the relief valve.

The coolant is sprayed into the compression stage and has the followingfunctions:

heat removal of the temperature increase caused by the compressionprocess

sealing lubrication of the rotors to each other and to the housing with acoolant film

bearing lubrication

noise dampening

The coolant leaves the compression stage together with the compressedair as a hot coolant return air mixture.

The coolant is separated from the compressed air into the coolant con-tainer by the coolant separator and when separated, it streams to the cool-ant heat exchanger. The coolant temperature regulator mixes the cooled

down coolant with the coolant heat exchanger-bypass hot coolant as de-fined by the setpoint temperature. Lastly, the coolant filter cleans the cool-ant, before it is again injected in the compression stage.

If desired by the customer, an additional heater can be installed in thecoolant container either originally or subsequent to purchase. It preventscondensation damages in the case ofcold or damp compressor plant envi-ronments, for example.

The compressed air after-cooler of the coolant heat exchanger is cooledeither by

a built-in cooling air ventilator 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 additionallyensures sufficient fresh intake air for the removal of radiated heat.


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901 Switching cabinet02 Electric motor03 Clutch04 Intake filter05 Intake regulator06 Compressor level07 Coolant container08 Safety valve09 Drain10 Inlet fitting11 Additional heater (optional)12 Coolant separator13 Minimum pressure one-way valve14 Relief valve

15 Compressed air after-cooler16 Compressed air connection17 Coolant cooler18 Coolant temperature regulator19 Coolant filter20 Cooling air ventilator21 Cooling water inlet22 Throttle valve compressed air after-cooler23 Magnet valve24 HCR water inlet

25 HCR heat exchanger26 HCR thermostat27 HCR water outlet28 HCR thermostat valve

M

PI

PSPD 1

PD204

05

06

19

07

03

02

18

09

11

08

12

17

14

13

22

15

20

16

23

21

24

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2.5 Flow diagram

2.6 Components

2.7 Legend

01

20

19

05

02

1206

08

07

15

10

04


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4.2 Ventilation

4. Installation

4.1 Setting up Install the system in locations with the following environmental conditions: max. height above sea level: 1000 m ambient temperature: +5 to +40 C ambient temperature for Version T: +5 to +45 C

ambient conditions: cool, dry, dust free

DANGER

Open flame or fire as well as welding work in the vicinity of the system

are forbidden!

Space requirements and system weights are dependent on the plant typepurchased. Measurements and weights: see Chapter 9.

Always maintain the minimal clearances to the walls or other objects, sothat system service functions can be carried out without hindrance.

We recommend setting up the compressors in a separate compressor room.

NOTICE

The air entering the intake opening is used for the compression as well asfor plant cooling.

The ventilation must fulfill at least the following criteria:

Supply required cooling air amounts as defined in Chapterd 9.2 and 9.3

Remove exhaust air as defined in Chapter 9 in order to prevent a heat-ing up of the plant site

The cooling air must be cool, dry and dust-free

Make certain that the supply air contains no dangerous explosive gasmixtures, steam, dust or aggressive pollutants.

Make certain that the setup site is dust-free as well as within the prescri-bed operating temperature limits and as cool as possible. If necessary,ensure the professional installation of forced air ventilation, filtering, roomcooling or heating.

Make certain that the setup site is professionally ventilated.

Make certain that no circulating air short circuit (the intake of theexhausted warm air) can occur.


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4.3 Forced ventilation (op-

tional)

Cooling air volume currents: see Chapter 9.

Forced ventilation must be dimensioned in such a way that the requiredfresh and exhaust air, considering the available residual pressure of thecompressor ventilator, can be supplied and expelled.

Nominal diameters of the channel connections and information on the re-sidual pressure : see Chapter 9.

If ventilation channels are to be connected to the system, then the requiredsupporting supplementary ventilators should be included when planningthe channels.

The exhaust air can also be utilized for the purpose of heat recovery.


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4. Installation

4.4 Water cooling (optional)

4.5 Heat recovery for heatingwater / potable water (op-tional)

Cooling water amounts, temperatures and pressures: see Chapter 9.

The cooling water is to be connected to the defined connections (see draw-ing Chapter 9).

The cooling water must satisfy the following criteria:

inlet temperature less than +35 C

pressure 2.5 bar(o) to 10 bar(o)

pre-filtering with a mesh size of at least 0.1 mm

An electromagnetic valve (optional) should be installed before the cooling

water input.The cooling water volume current through the compressed air after-coolershould be set with the throttle valve belonging to it in such a way that thecompressed air outlet temperature is 15 C greater than the output air.

Water amounts, temperatures and pressures: see Chapter 9.

The heat recovery is to be connected appropriately (see drawing in Chapter

9) as defined.The water for heat recovery must fill the following criteria:

pressure of up to 10 bar (over)

pre-filtering with a mesh size of at least 0.1 mm

For water-cooled plants, the temperature of the compressed air after-coolerof the coolant heat exchanger is lowered with external cooling water.

Plants can be supplied with the optional heat recovery system

for heating water or

for potable water (safety heat exchanger with blocking medium)

PI

PD2

12

17

13

22

15 16

23

21

24

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01


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4.7 Electrical connections

Test the correct functioning of all safety facilities (protective grounding,protective switch etc.).

Carefully lock the control cabinet after the connection work is completed.

NOTICE

DANGER

4.6 Connection to the

compressed air grid

Unpredictable movements of the compressed air hose!

During load switching in the compressed air grid, the hose can move

suddenly and with great force. Therefore the hose must be adequate-

ly anchored or fixed.DANGER

We assume the existence of a professionally designed, installed and ser-viced compressed air grid.

Install an additional shut-off valve at the input of the compressed

air grid.

Attach the system only with a flexible compressed air hose to thecompressed air grid. The length of the hose employed: max.1.5 m.

The system is designed for connections to a three-phase supply network(clockwise phase sequence). The mains supply contains professionallydimensioned fuse protection devices (for human and plant systemprotection), an appropriate mains switch (switching on/off of the supplycurrent) is required.

All the relevant data for the connections can be found

in Chapter 9

on the nameplate of the system.

Electrical voltage!

Only trained electricians may connect the system to the electrical sup-

ply network.

Before making the connections based on the plant nameplate, determineif the available supply network is adequate. Voltage deviations of largerthan 10 % are not allowed.

Mount the mains switch in the neighborhood of the plant. It must be easilyaccessible at all times.

Lay the supply cables professionally. Make certain that the installationcannot endanger individuals or property. Take into account the necessarycable diameters, strain relief, and max. allowed cable lengths.

Connect the system according to the switching plan. The switching planis located in the control cabinet of the system.

Damage to the system is possible!

Before switching on compressed air generation, initial commission-

ing according to Chapter 6 must be correctly carried out!


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5. Displays and operating elements

5.1 Plant main switch

DANGER

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.

The plant main switch must be switched off for all service or installa-

tion work and protected from illicit or accidental switching on (e.g.

affix a warning sign to the main switch forbidding its being turned on)!

Enable system:

1. pull key

2. switch main switch off and on.

3. press key for the malfunction receipt.

4. press key to switch the system on again.

The plant main switch connects or separates the system with the currentsupply.

Make sure that the shut-down system is sufficiently protected against

recommissioning!

Enable the system only when the cause of danger has been profes-

sionally removed and a securely operating plant state is achieved.DANGER


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5.3 Air Control 3 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.

Function keys

Modification of parameter values

Selection of sub-menus

Confirmation of parameter changes

Editing modes in the sub-menus

Display additional operation data.

Switch on compressor.

Integrated green LEDBlinking: compressor is not running, can at any timebe automatically started up.

Lighted: Compressor is running.

Compressor shut down.

Signals a current warning/malfunction with the integrated redLED.

F1 F2 F3 F4


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5. Displays and control elements

5.3.1 Basic display

5.3.2 ON/OFF switching of

compressed air generation

5.3.3 Function key reservation

in the basic display

After switching on the main switch or during normal operation, the Air Control3 will inform you about the plant condition.

Switching ON: presskey .

The compressor is ready and can start up automatically at any time.

Switching OFF: presskey .

For the duration of the standstill time, the compressor switches to the idlingstate and afterwards off.

In the basic display, the following informative pictures can be accessedwith the function keys:

With the key and , the mode and therefore the reservation of thefunction keys in the basic display can be changed.

Mode 1 = reservation 1

Momentarily available grid pressure at com-

pressed air output

Momentary com-

pression final tem-

perature

Service type

Service or malfunction messages with

service telephone number

Current reservation of the function keys

Plant passServiceCapacity

utilization

F1 F2 F3 F4


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5.3.3.1 Capacity utilization

(Mode 1 - F1)

This diagram represents the operating run, full load run, idling run, andstandstill hours in the form of bar diagrams. The respective current hourcount is also displayed in the bars.

Example:

By pressing the defined function key, the respective information screen isopened.

The key F4 returns to the basic display from all information screens.

Mode 2 = reservation 2

Diagramair amounts

weekly profile

Diagramair amounts

daily profile

Diagramgrid pressure

Diagramcompressiontemperature

Change of mode 5.3.3

With the exception of the idling time hours, all bars are represented fromthe left and growing to the right. The sum of the load hours and the idlingtime hours yields the total service hours.

The scaling units of this diagram are according to the service hours. If thenumber of the standstill hours is larger than the service hours, the bars ofthe standstill hours will be cut off. In this case note the displayed hourcount in the bars.

Total service hours

Load hours

Idling time hours

Standstill hours

F1 F2 F3 F4


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5.3.3.2 Service

(Mode 1 - F3)

5.3.3.3 Plant pass

(Mode 1 - F4)

The Service diagram shows the remaining residual time in hours until therespective service interval is due.

If the remaining residual time is less than 100 hours until the next service,the respective bar begins to blink and a defined warning appears on thedisplay.

The individual machine data stored in the plant pass are required for ourcustomer service.




Intake filter

Coolant filter

Coolant separator

Motor lubrication

Compressor


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5.3.3.7 Diagram compressed air

amounts / week profile

(Mode 2 - F4)

In this diagram, the current process of the compressed air-delivery amountsfor a week are displayed.

5.3.3.6 Diagram compressed air

amount / day profile

(Mode 2 - F3)

In this diagram, the current process of the compressed air-delivery amountsfor a day are displayed.

5.3.3.5 Diagram compression

end temperature

(Mode 2 - F2)

In this diagram, the current process of the compression end temperature isdisplayed.

5.3.3.4 Diagram grid pressure

(Mode 2 - F1)In this diagram, the current process of the grid pressures is displayed.






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5.3.3.8 Modify diagram settings

The key F2 X/Y-Init is for resetting the scale division for the default valuespreset in X-AUTO.

The keyF3

ldeletes the recorded measurement values of the currentlydisplayed time diagram.

X-AUTO settings 5.3.4.6

The scale divisions of the axis can be changed by editing the axis values.

y-axis: - The values of the y-axis can be changed in every diagram.The data in the diagram are continually updated even afterthe edit function.

x-axis: - In the diagram air qty.wk., the x-axis values cannot bechanged, changes are possible in all other diagrams

- Editing the x-axis is only possible when the text X-AUTOON does not appear on the display. After editing the x-axisvalues, the diagram is no longer continually updated.

X-AUTO: - The key F1 activates or deactivates X-AUTO

- If X-AUTO ON, the values of the x-axis are automaticallyupdated. The X-AUTO uses the preset default values de-

fined in the menu Display parameter diagrams (see Chap-ter 5.3.4.6).The manual editing x-axis values are deleted.

1. Selection of the axis values to be changed with the keys and

2. Confirmation of the selection with ENTER

3. Modification of the blinking value with and .

Moving the cursor with F1 and F2 .

4. Confirmation of the modifications with ENTER.

Axis value y-axis (Max)

Axis value y-axis (Min)

Axis value x-axis (time point 1) Axis value x-axis (time point 2)

Procedure for the scale division of the axis.


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5.3.4 Menu system All basic settings of the system can be viewed in the menu system. If themodifications have no influence on operation safety, they may be modifiedby means of a code entry.

After pressing the INFO key, the main menu appears requesting the code

entry.

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 F1 and F2 .


Thereafter, the main menu appears with the following sub-menus:

If the Code 0001 is entered, the parameters of the sub-menu should bechanged as follows:

1. The selection of the desired menu position is carried out with the keysand .

2. The selection is confirmed with ENTER.

3. Modification of the blinking value with the keys and .Moving the cursor with F1 and F2 .


The sub-menu can be selected with the keys and .The selection isconfirmed with ENTER.

In every operating level, F4 will lead you to the next higher operating level.

Limit values 5.3.4.1Operating parameters 5.3.4.2Service intervals 5.3.4.3Timer 5.3.4.4

Malfunction storage 5.3.4.5Display parameter 5.3.4.6Configuration 5.3.4.7Communication 5.3.4.8Base load switching 5.3.4.9Accessories 5.3.4.10


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5.3.4.1 Sub-menu Limit values

5.3.4.2 Sub-menuOperating parameters

This menu contains the pressure / temperature limit values:

This menu contains parameters which influence the temporal regulation ofthe compressor:

Switch-on pressure Lower value for the pressure regulation Can be edited

Switch-off pressure Upper value for the pressure regulation Can be edited

Safety pressure Maximum permissible pressure for Displaymalfunction triggering (always 0.8 bargreater than switch-off pressure)

Compression end Minimum permissible compression Displaytemperature min end temperature

Compression end Maximum permissible compression Displaytemperature max end temperature

After-run time After-run time of the motors in Displayautomatic operation

Standstill time After-run time of the motor for manual Displayswitching-off delay and for automaticrestart

Run-up time Run-up time Display

Automatic Start after voltage return Can berestart edited

Operation mode: Behavior on load switching Can be

Setting range: AUTOMATIC editedLOAD/IDLINGAUTOMATIK OPT.

Max. pressure drop Maximum pressure drop Display

Max. switching cycles Maximum switching cycles of the motor Displayper hour per hour

Selection of the menu positionModification of the blinking values

ENTER Confirm selection/modificationF4 Back to the next higher level


ENTER Confirm selection/modification

F4 Back to the next higher level

Operation mode Automatic

The text AUTOMATIC is displayed in the basic display. After reaching theswitch-off pressure, the system goes into idling mode (after-run time) for

the duration of the after-run time and in the basic display; the text after-run time appears with the respective residual time. At the conclusion ofthe after-run time, the motor switches off. The compressor can be startedup automatically at any time after falling below the switch-on pressure.

Operation mode Load/Idling

The text LOAD/IDLING is displayed in the basic display. The compressorswitches between full load run and idling, which means that its after-runtime is unlimited.


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Operation mode Automatic Optional

The text AUTOMATIC OPT. is displayed in the basic display. After reach-ing the switch-off pressure, the system goes into idling.

After 10 and after 40 seconds the grid pressure is measured.

If the pressure drops above the threshold Max. pressure drop, then thesystem is in the idling state for the duration of the after-run time. In thebasic display, the text After run appears with the residual time as defined.

If the value lies below the threshold Max. pressure drop, then the systemswitches off after completing the standstill time.

Max. switching cycles

If the number of the maximum possible switching cycles per hour for themotors is exceeded, then the compressor temporarily switches to the op-eration mode load/idling.

5.3.4.3 Sub-menu

Service intervalsIn this menu, all service intervals are displayed, or acknowledged aftercarrying out the specific service (see Chapter 5.3.5).

With the acknowledgement, the displayed residual time for the value of therespective service intervals (see Chapter 8.1) is reset.

Service interval ASF Service interval intake filter Display

Service interval OLF Service interval coolant filter Display

Service interval OLAB Services interval coolant Displayseparator

Service interval motor Service interval for motor lubrication DisplayService interval compr. Service interval compressor Display

Service hours Total operating hours Display(motor on)

Load hours Accumulated load hours Display

Standstill hours Accumulated standstill hours Display(system on motor off)

Service work acknowledged5.3.5


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5.3.4.4 Sub-menu Timer The adjustment of the integrated real-time clock, as well as all switchingprocesses dependant upon it are in this menu.

Switching times for compressorIn this menu, the switching on/off times of the compressors are defined.

Date/time Setting the current date Editand timeAttention: The adjustment is enteredto the real-time clock when theseconds are confirmed with ENTER

Compressor switching Branch to the sub-menu Edittimes

Compressor pressure Branch to the sub-menu Edittimes

Switching times BLS Branch to the sub-menu Edit

Pressure times BLS Branch to the sub-menu Edit

For the activation of the timer, the parameter of the timer channels must beset to ON in the highest menu line.

If the timer channel is set to ON and

if the timer clock output is activated, a clock appears in the display

if the timer output is not activated, a blinking clock appears in the dis-play

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. Inorder to continuously activate the timer output for one or a number of days,the switching time should be set to 00:00.


ENTER Confirm selection/modificationF4 Back to the next higher level

Timer clock output active:

Mo - Th 6:00 until 20:00 oclock

Fr 6:00 until16:00 oclock

Switching times as well as pressure times can be programmed with the

timer independently of each other.When programming switching times, the compressor need no longer bemanually switched on and off. This is to prevent the possibility that thecompressor might for instance start up itself at night in order to compen-sate for loss in the compressed air grid.

For a limited time, deviating values from the preset limit values (see Chap-ter 5.3.4.1) can be set for the switch-on and the switch-off pressure. In thisway only the minimal required operating pressure is always generated sothat energy is saved.


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If the timer for switching times is activated, then the compressor only

works during the switching times entered!

Adjust switching times (weekdays marked black):

1. Channel selection with the keys and

2. Confirm selection with ENTER.

3. Move the cursor to the desired weekday by selecting the key F1 andF2 . (In order to delete an already selected weekday, press the key

.)

4. Set the cursor with F1 and F2 onto the clock time with the keys andto modify the blinking value.

5. Store the settings with the key ENTER.

Compressor pressure times

In this menu, the pressure times of the compressors are defined (increasingpressure / decreasing pressure).

In order to activate the timer, the uppermost menu row of the parameter forthe 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 switchingtimes)

The channels are searched beginning with K1 to K7 to determine whetherra channel is activated for the current clock time. If no valid channel is found,then the settings in the menu limit values are valid. In order to activatethe timer output for one or a number of days continuously, the switchingtime of 00:00 should be entered.

Switching t imes BLS /pressure t imes BLSwitching t imes BLS /pressure t imes BLSwitching t imes BLS /pressure t imes BLSwitching t imes BLS /pressure t imes BLSwitching t imes BLS /pressure t imes BLS

Switching times or pressure times can only be entered if the supplementarymodule for Base Load Selective switching (BLS) is installed in the controlsystem.

The settings are to be carried out as described in Compressor switchingtimes or Compressor pressure times

NOTICE


Sa - So 0:00 until 24:00 oclock

(= from Sa 0:00 oclock until So

24:00 oclock)


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Pressure unit Selection of the unit for the display Editof the grid pressure

Temperature unit Selection of the unit for the display Editof the compression final temperature

Language Selection of the display language Edit

Pressure offset Readjustment possibility for the Displaygrid pressure sensor

Diagrams Settings for diagrams Edit

Texts Texts for the plant pass Display


5.3.4.5 Sub-menu Malfunction

storage

5.3.4.6 Sub-menuDisplay parameter

In this menu, the last 20 malfunctions are listed in order.

In this menu, the parameters for the output to thedisplay are stored.

Diagrams

In this menu, the display parameters (default values X-AUTO - see Chapter5.3.3.8) for the diagrams can be set:




Storage interval Storage interval for the recording of the grid pressure, thecompression final temperature of the momentary deliveryamounts. The control system always stores the most recent8000 values. For a storage interval of 12s (basic setting)there is a logging duration of 12s x 8000 = 96000s = 26.7h

Number of points Number of the recorded values for function X-Autofor X-Auto On the time axis at a storage interval of 12 s amd up to 300

points for X-Auto a time axis scaling of 12s x 300 =3600s=1h

Grid pressure Lower scale value of the x-axis of the diagramlower limit Grid pressure (see 5.3.3.4)

Grid pressure Upper scale value of the x-axis of the diagramupper limit Grid pressure (see 5.3.3.4)

Temperature Lower scale value of the x-axis of the diagramlower limit Compression final temperature (see 5.3.3.5)

Temperature Upper scale value of the x-axis of the diagramupper limit Compression final temperature (see 5.3.3.5) (basic setting

120 C)

Compressed air amt. day Lower scale value of the x-axis of the diagramlower limit Compressed air amounts daily profile (see 5.3.3.6)

Compressed air amt. day Upper scale value of the x-axis of the diagramupper limit Compressed air amounts daily profile (see 5.3.3.6)

Compressed air amt. week Lower scale value of the x-axis of the diagramlower limit Compressed air amounts weekly profile (see 5.3.3.7)

Compressed air amt. week Upper scale value of the x-axis of the diagramupper limit Compressed air amounts weekly profile (see 5.3.3.7)


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5.3.4.7 Sub-menu

Configuration

Remote mode

Determines how the compressor is switched on or switched off.

Local operation: The compressor can only be switched on or switched offat the operating/display desk of the Air Control 3.

Remote control: The compressor can be switched on or switched off withan electrical signal or the key 0. In the basic display appears as the blinkingtext REMOTE.

Plant type Selection of a pre-defined Displaymachine type.

Maximum pressure Maximum permissible machine pressure Display

Max. delivery amounts Delivery amounts at maximum speed Display

in full load runRemote mode Switching on/off of the system Edit

BLS-operation Operation with external base load Editalternate switching

Low voltage Stop Switching-off when low voltage Displayis recognized

Analog output Output module for the control module Displayof a frequency converter (if present)

Heating/Ventilation Temperature values for additional Displayheater or plant ventilator




During active remote operation, the signal of the remote control must

be switched off after pressing the key 0.NOTICE

BLS OK: Is for the notification of the operation ready state of a superiorcontrol system to the compressor. (see also BLS Operation 5.3.4.9)

BLS Operation

The control system of the compressors is carried out by a superior controlsystem. The text BLS OPER. (see also Remote Mode 5.3.4.9) appears inthe basic display


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5.3.4.8 Sub-menu

Communication

5.3.4.9 Sub-menu

Base Load Switching

(BLS)

5.3.4.10 Sub-menu Accessories

This menu contains parameters for serial communication

This menu contains the settings for the operation as the BLS Master.

For the utilization of the function base load switching, the Air Control 3must be fitted with

a supplementary module for up to 4 additional compressors

two supplementary modules for up to 8 additional compressors.

(see also Chapter 5.3.4.7)

This menu contains the settings for the connection of accessories. The AirControl 3 must be fitted with the supplementary module accessories forthe utilization of these functions.

RS485 Address Participant address for RS484 Displaycommunication

RS485 Mode Data exchange on the serial Displayinterface

Base load switching Parameter for the activation of the DisplayBLS Master characteristics(basic setting: NO)

Switched-on pressure Lower pressure threshold for Editswitching on a compressor

Switched-off pressure Upper pressure threshold for Editswitching off a compressor

Switched-on dampening Minimal time between the Editswitching on of two compressors(basic setting:5 s)

Switched-off dampening Minimal time between the Editswitching off of two compressors(basic setting:2 s)

Replacing interval Time between the additional Editswitching of the BLS (basic setting: 24 h)

Number of main Number of compressors in the Editcompressors main group

Number of reserve Number of compressors in the Editcompressors reserve group

Accessory module Supplementary module for accessories Displayavailable

Switching times output 1 Switching times defined for accessories 1 Edit

Switching times output 2 Switching times defined for accessories 2 Edit

Switching times output 3 Switching times defined for accessories 3 EditSwitching times output 4 Switching times defined for accessories 4 Edit

Input configuration Configuration of the Editaccessories digital inputs





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Switching times

The switching on/off times of an accessory relay output are defined in thismenu.

For the activation of the timer, the uppermost menu row of the parameterof the timer channels must be set to ON.

Seven switching times can be programmed with the channels K1 K7.One channel is active when at least one of the weekdays is marked 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 a number ofdays, set the switching time to 00:00.

Input configuration

The inputs 1 to 8 can be used in order to switch the compressor to mal-function or warning.


Mo - Th 8:00 until 18:00 oclockFr. 8:00 until 14:00 oclock


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A warning is current 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 hotline

5.3.5 Warnings / service work

NOTICE

Damage of the system is possible!

Necessary service work appear as warnings.

Acknowledge these warnings only when the defined service work hasactually been carried out!

Service work not carried out degrades the service life reliability of the

system. Please note that damages because of improper usage might

cancel the guarantee!

Only original spare parts may be used.

Information on service: see Chapter 8.

Services work acknowledged:

1. As described in Chapter 5.3.4, call up the main menu and then the sub-

menu Service Interval.

2. Select the service work to be carried out with the keys and .

3. Press key F3 to acknowledge the service.

4. By double clicking the key F4 you will return to the basic display.

What to do for specific warnings/service work is described in Chapter 8.



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5.3.6 Malfunctions A malfunction has occurred when the red light is permanently on.

The compressor is stopped automatically.

In addition, the display also shows:

blinking symbol tool key

type of malfunction

telephone number of the service hotline

Malfunctions can only be acknowledged when the cause has been profes-sionally repaired. Error searches and repair should be done exclusively byqualified personnel!

Malfunction messages acknowledged:

1. press key .

2. press key in order to restart the compressed air generation.


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6. Correcting malfunctions

Compression temperaturetoo high (red lamp is on)

Error

Grid pressure falls

System pressure released onsafety valve

Malfunction over-

pressure or Gridpressure too high (redlamp is on)

- Silencing hood not closed

- Intake or environmentaltemperature too high

- Cooling air inlet or outlet blocked

- Coolant filter fouled

- Coolant deficiency

- Outside coolant heat exchangerfouled! Attention:Attention:Attention:Attention:Att ent ion: Coolerscrew should always be

worked with a counter wrench;keep from applying torque tothe cooler

- Check and secure sound-insulation hood

- Ventilate compressor room

- Make sufficient room

- Renew coolant filter

- Add coolant

- Clean with compressed air. In thecase of extensive fouling:disassemble cooler and cleanwith high pressure cleaner.

Attention: Danger of short

circuit! Do not put electricalelements under power

Cause Measures

- Compressed air consumptiongreater than delivery amounts ofthe compressor

- Air filter is fouled

- Relief valve blows air duringcompression

- Intake regulator does not open

- Leakage in the piping grid

- A compressor with larger deliveryamounts is required

- Replace air filter

- Check relief valve; if necessary,replace seals

- Check magnet valve regulator

piston and if necessary, replace

- Make piping grid airtight

- Grid pressure set too high

- Safety valve defective

- Minimum pressure valve blocked

- Coolant separator cartridgefouled

- Adjust grid pressure anew

- Check safety valve; if necessary,exchange

- Exchange magnet valve

- Exchange coolant separatorcartridge

- Coolant separator fouled

- Higher outside pressure in thecompressed air grid

- Replace coolant separator

- Equalize outside pressure orremove from grid


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System does not start onpressing the start button

Error

- Grid pressure greater thanswitch-on pressure

- Remote control activated

- Missing voltage at thecompressor

- Electrical error in the controlsystem

- Switching times have been

activated in the Air Control 3

- Note grid pressure value

- Symbol remote is blinking

- Check if voltage is available

- Review (only by an trainedelectrician)

- Check switching times in the AirControl 3

Cause Measures

Compressor does not startautomatically or does notdeliver after previousswitching off upon reachingthe final pressure or fromidling state.

- Grid pressure set too high- Interruption in the control current

circuit

- Ambient temperature under +1C; message Coolant tempera-ture too low

- Switching times have beenactivated in the Air Control 3

- Adjust grid pressure anew- Check current loop for interrup-

tion (only by an trained electri-cian)

- Build in an additional heater orkeep compressor room at righttemperature

- Check switching times andpressure times in the Air Control

Compressed air containinglarge amount of coolant(coolant consumption toogreat)

- Coolant return flow piping iscongested

- Defective coolant separator

- Clean coolant feedback piping

- Replace coolant separator

System stopped beforereaching the final pressure(red lamp is on)

- Overtemperature or overpressure

- Interruption in the control currentloop

- Rectify error as required

- Check current loop (only by atrained electrician)

Water in the piping grid - Dryer switched off

- Condensation diverter is notfunctioning

- Bypass open

- Dew point too high

- Switch on dryer

- Clean / exchange drain

- Close bypass

- Demand customer service

Pressure decline - Pressure difference in the filter

too great

- Exchange filter


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7. Initial commissioning

7.2 Check coolant

level

7.1 Preparatory activities 1. Make certain that when the plant mains switch is switched off, no illicitor inadvertent switching on cannot occur.

2. Make certain that the system is correctly connected to the compressedair grid.Make certain that when the shut-off valve on the pressure gridside is closed, illicit or inadvertent opening cannot occur.

7.3 Start-up lubrication of the

compressor stage

After an extended standstill time, for example between factory deliveryand commissioning or during a longer company vacation, there might nolonger be any coolant in the rotor chamber of the compression stage. Thiscoolant is absolutely necessary for bearing and rotor lubrication in the start-up phase.

Check coolant level/coolant refill 8.3

If no extra coolant is available (only coolant of the same variety may be

employed!), the coolant can be taken from the coolant drain.

If the system is employed only very irregularly or shut down weeks on end,

it should run an hour in idling mode once a week in order to avoid corrosion

damage caused by standing condensation.

1. Before switching on the compressor plant, fill approx. 0.2 liter coolantinto the filler screw of the intake regulators.

2. Rotate the compression stage only by hand in rotational direction untilthe noticeable resistance dwindles and the coolant passes through thecompression stage.

3. Finally, tighten the filler screw of the intake regulators (05).

3. If required, refill the coolant (see Chapter 8 Check coolant level / refillcoolant)

1. Make certain that escaping coolant can be collected.

2. Check the coolant level at the sight glass which is located on the frontside of the coolant container: the sight glass must be totally filled withcoolant. Unscrew the the filling screw. Do not misplace the seal. Fornew compressors, the coolant level must reach up to the lower level ofthe inlet fitting.


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7.4 Rotational direction control

3. Switch the system on with the key Switch the system off again withthe key , when the ventilator starts running.

In order to supply the system with sufficient cooling air, the rotational direc-tion of the ventilator motors must concur with the rotational direction arrow.

In the case of incorrect rotational direction of the plant ventilators, a trainedelectrician should correct the phase sequence of the electrical supply inthe switching cabinet by exchanging the two supply phases. This shouldbe carried out in a switched-off state secured against accidental switchingon.

The rotational direction of the plant ventilators must be checked.

The rotational direction of the main motor is determined by the frequencyconverter and must conform with the affixed rotational direction arrow.

1. Remove the cover panels of the system, so that the electric motor of theventilator is visible.

2. Switch the plant main switch on.


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7.5 Basic settings In order to understand plant basics, please read the chapter 5 Plantoperating elements .

7.5.1 Control system of the

system with Air Control 3

More precise instructions on the basic settings of the system can be foundin the following chapters :

Chapter 5.3 Operating screen,

Chapter 5.3.1 Basic display

Chapter 5.3.4 Menu system

The display parameters

pressure unit,

temperature unit

languagecan be modified as described in position 5.3.4.6.

The limit values

switch-on pressure

switch-off pressure

can be modified as described in position 5.3.4.1.

If your Air Control 3 has been fitted with the supplementary module BLS,carry out settings as in point 5.3.4.7 5.3.4.9 of the description.

If 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.

7. Initial commissioning


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1. Before switching on the system, make certain that no one can be en-dangered by doing so. The sound-insulation hood serves as a part ofthe contact protection, among other things for the cooling air conduitsof the compressor plant. It must be closed during operation.

2. Carefully open the shut-off slide valve after the compressed air connec-tor and between system compressed air grid (container). The system isnow connected to the grid.

3. Switch on the main switch.

4. Make certain that no tools or loose objects are lying on or in the system.

5. Press key to switch on the compressed air generation.

The green LED in the key lights up when the compressor is working.

Check on the operating display desk for the grid pressure.The grid pressure will slowly rise if the compressed air consumption is lessthan the delivery amounts of the compressors.

7.6 Switch on compressed air

generation

1. Check all piping of cooling liquids and pressure air conduits for leak-age.

2. Check the coolant level of the compressors after 10 and until 20 min-utes operation time. If the coolant level is too low, refill coolant as de-fined in Chapter 8 Check coolant level /coolant refill.

3. Check the compressor temperature. The compressor temperature shouldnot fall under approx. 75 C and not rise above 105 C; at 105 C awarning is issued, at 110 C the compressor plant automatically shutsdown.

4. Tighten all electrical connections after a week.

5. Carry out all service intervals according to Chapter 8 Overview service

intervals.

6. Check the standard operation of the functions carried out weekly ac-cording to Chapter 8 Overview of service intervals

7.7 Concluding activities

The green LED blinks when the compressor is in operational readiness.

The compressor switches on automatically when the current grid pressure

drops below the preset switch-on pressure of the compressor plant, if

the machine temperature rises above +1 C,

the timer of the Air Control 3 is active,

or the base load selective switching setting (BLS) is activated.

On blinking green LED, the compressor can start by itself at any time!

DANGER


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8.2 Preparatory activities

3. Remove the side panels of the system.

4. Make certain that the pressure grid side shut-off valve is closed andcannot be opened accidentally or intentionally.

5. Make certain that when working on the coolant circulation, escapingcoolant is collected.

8. Service

8.1 Overview

Service intervalsNecessary service work appears in the display as warnings (see Chapter7.1)

Preparatory activities 8.2Check coolant level / refill coolant8.3Check for leakage 8.4Check the compressortemperature 8.5Check the cooler for fouling 8.6Check for condensation 8.7Replace coolant / Replacecoolant filter 8.8Replace coolant separator 8.9Replace air filter 8.10Check safety valve 8.11Check drive 8.12Lubrication of electric motor 8.13Concluding activities 8.14

1. Press key in order to switch off compressed air generation. Pleasewait until the compressor has been switched off after an idling or venti-lation phase. The symbol M for the main motor is then no longer visi-ble in the display.

2. Switch the plant main switch off and make certain that it cannot be turnedon by mistake or intentionally (e.g. warning signs prohibiting switching).

Hot surfaces hot coolant!!

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 coolant steam!

DANGER

Check coolant level 8.3

Check for leakage 8.4

Check compressortemperature 8.5

Check of the coolerfor fouling 8.6

Check forcondensation 8.7

Coolant replacement 8.8and replacing coolantfilter

Replacing cooling liquidseparator 8.9

Replacing air filter 8.10

Check safety valve 8.11

Check clutch element 8.12

Lubrication of motor 8.13

General compressorservicing

Service activities Chapter After the first After the first Every Every 4000

100 operating 500 operat- week operating h.

hours ing hours but at leastonce a year

NOTICE

Use only original spare parts!


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8.3 Check coolant level / refill

coolant

Only check the coolant level when the system has been turned off for aminimum of 30 minutes. This is to ensure that the coolant has settled

down after the running phase.

The coolant level is in order if the complete sight glass is full of coolant.

Carry out the Preparatory activities

If the complete sight glass is not full of coolant, coolant must be added asfollows:

1. Unscrew the filler screw. Do not misplace the gasket ring.

2. Use an appropriate funnel for filling. Coolant can be filled up to the fillingrim of the fitting.

3. Take care that the seal is correctly seated and screw the fitting screwclosed.

Carry out the Concluding activities.

Damage of the system by using different coolants!

Different coolants may not be mixed. Only use original coolant!

Carry out the Preparatory activities.

Check all piping and the bottom of the system for coolant rests. If there isstill coolant in the system, the cause should be found and the coolantremoved.


The compressor temperature, which can be viewed in the display, shouldbe between 75 C and 105 C.

8.4 Check for leakage

8.5 Check the compressor

temperature

Too high or too low compressor temperature can lead to damages to

the compressor.

Preparatory activities 8.2Concluding activities 8.14


NOTICE

NOTICE


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8. Service

8.6 Check the cooler for

fouling

8.7 Check for condensate

development


Check the compressed air after-cooler and the coolant heat exchangerfrom 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 beblown outside).


The absorption capacity of water humidity in the air

falls with increasing pressure

rises with increasing temperature.

Sufficiently high compressor temperature guarantees that the intake air

humidity does not precipitate as condensation. The frequent switching onand off of the compressor can result in the compressor not achieving therequired operating temperature.

Condensation in the coolant circulation can lead to damages to the

compressor. If you have determined that there is condensation in the

coolant container, immediately get in touch with customer service!

Condensation damages lead to the loss of the guarantee!

Since water is heavier than coolant, after extended standstill times (e.g. ona weekend) the condensation collects in the bottom of the coolant contain-ers. It can be simply drained off by the discharge drain.

Carry out the following activities only when the system has been turnedoff at least overnight.

1. Open the discharge drain and carefully observe the escaping liquid.Close the discharge drain again as soon as coolant appears.

2. Check the coolant level according to Chapter 8.3.





NOTICE


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Hot Surfaces - hot coolant!

With appropriate precautions, make certain you are not burned or

scalded!

8.8 Coolant replacement /

replacing coolant filterCarry out a coolant replacement only when the old coolant is still warm.Cold coolant, because of its higher viscosity, does not flow so well.


1. Unscrew the filler screw. Do not misplace the gasket ring.

2. By opening the discharge drain, allow the coolant to drain into an ap-propriate vessel and then close the discharge drain again.

3. Use an appropriate funnel for filling. Coolant can be filled up to the fillingrim of the fitting.

4. Take care that the seal is correctly seated and screw the fitting screwclosed.

5. Loosen the coolant filter with a strap wrench and remove possible sealrests from the coolant filter housing.

6. Lightly oil the new seal of the coolant filters.

7. Screw the new coolant filter to the stop and tighten the coolant filter byhand another half a revolution.

8. Test the coolant filter for leakage at operating temperature .


Damage of the system can be caused by different coolants!

Different coolants may not be mixed.


DANGER

NOTICE


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8. Service

8.10 Replacing air filter

Damage of the system by intake dust!

The system may not be operated without an air filter.

8.9 Replacing coolant

separatorCarry out the Preparatory activities.



1. Remove the covering of the air filter (04)

2. Remove or screw off the old air filter

3. Insert the new air filter4. Reinstall the covering of the air filter


8.11 Check safety valve Carry out the Preparatory activities.

1. Remove the safety valve and remove residues at the threaded connec-tion.

2. Check the safety valve in an appropriate apparatus.

3. If it is still working correctly, add sealing tape to the connecting threa-

ding of the safety valves and screw the safety valve back in.

4. If the adequate functionality of the old safety valves can no longer beguaranteed, screw in a safety valve.


1. Loosen the coolant separator with a strap wrench. Remove possibleseal rests from the coolant separator housing.

2. Lightly oil the new seal(s) of the separator.

3. Screw the new coolant separator to the stop. Tighten the coolant filterby hand another half a revolution.

4. Test the coolant separator for leakage at operating temperature.




NOTICE


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8.12 Check clutch element

8.13 Relubrication of the

electric motor

8.14 Concluding activities


1. Test manually whether the clutch might have some radial play.

2. If so, loosen the cam ring of the clutch, push it back, and replace the

clutch element.

3. Mount the cam ring again on the clutch half and test manually whetherthe clutch now has no more radial play.



1. The bearing lubrication periods for the electric motor, which appear onthe operating display desk, must be observed.

2. Carry out the required relubrication with a grease gun.

If there are no grease nipples on the electric motor, then it is equipped withcapsulated permanently greased bearings. These motor bearings must bereplaced when they are worn out.


1. Open the stopcock slowly on the pressure grid side.

2. Switch the plant main switch on.

3. Make certain that no tools or loose objects are lying on or in the system.

4. Press the key I to switch the compressor on.

5. Check all cooling liquids and compressed air piping for leakage

6. Check all new cartridges or newly mounted pressurized componentsfor leakage at operating temperature.

7. Finally mount the side panels of the system.

8. Confirm that the services carried out by you work according to Chapter5.3.5.

9. Used filter cartridges, lubricants, seals, surplus condensation and em-ployed cleaning materials should be considered hazardous waste anddisposed of in an environmently friendly way.

Damage of the system is possible!

Only acknowledge those services actually carried out!Services not carried out degrade the service life reliability of the sys-

tem. Please note that damages caused by improper usage are not cov-

ered by the guarantee!

Service work acknowledged 7.1



NOTICE


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9. Technical Data

9.1 Dimensions for connections

Compressor L W H Coolant Compressed Heat

filling air connection recovery

mm mm mm l G G

ALLEGRO 30 1,520 850 1,600 1 1/2

1

ALLEGRO 40 2,020 850 1,600 1 1/2

1

ALLEGRO 60 2,020 850 1,600 1 1/2

1

ALLEGRO 80 2,020 850 1,600 1 1/2

1

ALLEGRO100 2,300 1,400 1,800 2 1/2

1

ALLEGRO115 2,300 1,400 1,800 2 1/2 11/2

ALLEGRO130 2,300 1,400 1,800 2 1/2

1 1/2


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9.2 Data air-cooled compressors

9.3 Data water-cooled compressors

9.4 Electrical data

Compressor Motor Current at Current at Current at Maximum

power 220V/60Hz 400V/50Hz 550V/50Hz motor switching

IN IV IN IV IN IV frequency

kW A A gL A A gL A A gL 1/h

ALLEGRO 30 30

ALLEGRO 40 40

ALLEGRO 60 60

ALLEGRO 80 80

ALLEGRO100 100 295 325 148 194 129 142 5

ALLEGRO115 115 369 406 185 693 161 178 4ALLEGRO130 130 461 508 231 1083 202 222 4

Compressor Weight Cooling air Cooling water current at Cooling water Connection

amountsinlet/return temperature pressure pressure cooling

10/40 C 25/40 C 35/45 C min - max water

kg m3/h m3/h m3/h m3/h bar G

ALLEGRO 30

ALLEGRO 40

ALLEGRO 60

ALLEGRO 80

ALLEGRO100 1,800 2,400 2.44 4.87 7.31 2.5 - 10 1

ALLEGRO115 1,950 2,400 2.80 5.60 8.41 2.5 - 10 1 1/2

ALLEGRO130 1,950 2,400 3.05 6.09 9.14 2.5 - 10 1 1/2

Compressor Weight Cooling air Room Intake air Diameter exhaust

amounts ventilation opening air canal

kg m3/h m3/h m2 m2

ALLEGRO 30 1,095

ALLEGRO 40 1,165

ALLEGRO 60 1,265

ALLEGRO 80 1,350

ALLEGRO100 1,675 16,500 17,000 1.50 0.84

ALLEGRO115 1,820 16,800 21,000 1.80 1.00

ALLEGRO130 1,820 16,800 21,000 1.80 1.00

IN = Nominal current IV = backup fuse in building


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DALUP-Kompressoren GmbH

Tel.: +49/7024/802-0Fax: +49/7024/802-106Internet: www.alup.comE-mail: [email protected]. 273257 KngenDEUTSCHLAND

A

AGRE-Kompressoren GmbHTel.: +43/7252/52341-0Fax: +43/7252/52133

Internet: www.agre.atE-mail: off [email protected] 24451 Garsten-St. UlrichSTERREICH

NL

ALUP-Kompressoren B.V.

Tel.: +31/30/2809000Fax: +31/30/2895675Internet: www.alup.nlE-mail: [email protected] 8-103439 Nieuwegein

NEDERLANDS

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