installation and operation instructions dÜrr...

INSTALLATION AND OPERATION INSTRUCTIONSDÜRR COMPRESSORS

Tornado • Primo • Duo • Trio • Quattro • Duo-Tandem • Quattro Tandem

Duo

Tornado

2003/06

2

CONTENTImportant Information

1. Note ........................................................... 31.1 CE-Marking ........................................ 31.2 Guidelines and Directives ................. 31.3 General Information ........................... 31.4 General Information Concerning Safety

31.5 Safety Instructions on Protection from

Electric Current .................................. 41.6 Warning Information and Symbols .... 4

2. Product Information ................................ 52.1 Use for the Intended Purpose ........... 52.2 Use other than that for the Intended

Purpose ............................................. 52.3 Product Description ........................... 5

3. Scope of delivery ..................................... 53.1 Special Accessories .......................... 53.2 Consumables .................................... 5

4. Technical Data ......................................... 65. Overview of functions of compressors . 8

5.1 Compressor with Dry-air System ....... 85.2 Compressor without Dry-air System .. 8

6. Functional description ............................ 96.1 Compressor with

Dry-air System ................................... 96.2 Compressor without

Dry-air System ................................... 9

Assembly

7. Storage and transport conditions ....... 108. Installation and placing in initial service

108.1 Environmental Conditions ................ 108.2 Compressed-air Connection ........... 118.3 Electrical Connection ....................... 118.4 Placing in Initial Service ................... 128.5 Setting the Motor Protection Switch . 128.6 Checking the Safety Valve ............... 128.7 Checking and Adjusting the Pressure

Switch .............................................. 138.8 Draining off Condensation Water .... 13

9. Circuit Diagrams .................................... 149.1 Version 1/N/PE AC230 V .................. 149.2 Version 3/N/PE AC 400 V ................. 149.3 Version 3/N/PE AC 400 V, 2 Aggrega-

tes, Duo Tandem .............................. 159.4 Version 3/N/PE AC 400V, 2 Aggrega-

tes, Quattro Tandem ........................ 15* For spare parts list please see the end of

this manual.

Use

10. Operation ............................................... 1610.1 Switching on the Compressor ......... 16

11. Maintenance Intervals – User /Technician .............................................. 17

12. Maintenance ........................................... 1712.1 Pressure Reducer ............................ 1712.2 Setting the Pressure Reducer .......... 1812.3 Draining off Condensation Water .... 1812.4 Checking the Safety Valve ............... 1812.5 Filter Replacement ........................... 19

13. Shutting down the unit ......................... 20

Disposal

14. Disposal of the machine ....................... 20

Trouble Shooting

15. Tips for Users ........................................ 2116. Tips for Technicians .............................. 22

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IMPORTANT INFORMATION

1. NOTE1.1 CE-MarkingAll products bear the CE Conformity Marking.This marking denotes that the productsconform to the safety guidelines and directiveslaid down by the European Union.

1.2 Guidelines and DirectivesThe products comply with the followingguidelines and directives:• Machinery Directive 98/37EC

including amendments.• Electromagnetic Compatibility 89/336/EEC

including amendments.• Low-Voltage Directive 73/23/EEC,

including amendments.• Pressure Vessel Regulation 87/404/EEC.

1.3 General Information• The Instructions for Assembly and Use form

an integral part of the machine. They mustbe kept close to the machine and inreadiness whenever required. Preciseobservance of these instructions is a priorcondition for use of the machine for theintended purpose and for its correctoperation.These Instructions for assembly and useshould be passed on to future users ifnecessary.

• Safety for the operator as well as trouble-free operation of the machine are onlyensured if use is made of original equipmentparts. Moreover, use may only be made ofthose accessories that are specified in thetechnical documentation or that have beenexpressly approved and released by DürrDental for the intended purpose.If and where use is made of accessories orconsumer supplies from outside sources,Dürr Dental are unable to assume anyguarantee for safe operation or safefunctioning.

• No warranty claims are accepted in respectof damage arising from the use ofaccessories or consumer supplies fromoutside sources.

• Dürr Dental only regard themselves as beingresponsible for the unit from the angle ofsafety, reliability and proper functioning ifassembly, resettings, changes ormodifications, extensions and repairs havebeen carried out by Dürr Dental or anagency authorised by Dürr Dental and if themachine is used in conformity with theInstructions for Assembly and Use.

• The Instructions for Assembly and Useconform to the relevant version of themachine and the underlying safety standardsvalid at the time of going to press. Allproprietary rights are reserved in respect ofthe specified circuitry, methods, names,software programs and equipment.

• Any reprinting of the technical documentation,in whole or in part, is subject to prior writtenapproval of Dürr Dental.

1.4 General Information ConcerningSafety

The compressor has been designed andconstructed by Dürr Dental in such a way thathazards occurring when using the machine forthe intended purpose are ruled out to thefullest extent possible. Even so, we feelobliged to draw attention to the safetyprecautions described below as a means ofruling out any remaining hazards.• When operating the compressor the laws

and regulations in force in the place of usemust be observed! In the interest of safeoperation, the operator and user areresponsible for observing such regulations.

• The original packaging has to be kept in asafe place in case of having to return theunit.Ensure that the packaging is kept out of thereach of children. Only the original packagingwarrants optimum protection of the unitduring transport.In the event of the unit having to be returnedduring the period of guarantee Dürr Dentaldoes not assume any liability for damage intransit due to faulty or improper packing!

• Each time prior to using the machine theuser must check to ensure that it isfunctionally safe and in proper condition.

• The user must be familiar with how tooperate the machine.

• The product is not intended for use in areas

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of rooms that are exposed to risk ofexplosion. Explosion hazards may resultfrom the use of inflammable anaesthetics,skin cleansing agents, oxygen and skindisinfectants.

• The machine is not suitable for operation in acombustion-stimulating atmosphere.

1.5 Safety Instructions on Protectionfrom Electric Current

• The compressor may only be connected to aproperly installed earthing contact-typesocket or CEE-power socket.

• Prior to connecting up the machine a checkmust be carried out to see whether themains voltage and mains frequencyspecified on the machine conform to thedata applicable to the supply mains.

• Prior to being put into operation, themachine and the lines need to be inspectedfor damage. Damaged lines, socket outletsand plugs must be replaced immediately.

• In hazardous situations or in the event oftechnical faults occurring, disconnect themachine from the mains immediately(disconnect plug from mains).

• When carrying out repair or maintenancework of any kind, the mains plug mustalways be disconnected from the socket. Inaddition, air must be removed from allpressure lines and the pressure tankdepressurised.

• All installation work must be carried out by asuitably qualified engineer.

1.6 Warning Information and SymbolsIn the Instructions for Assembly and Use, aswell as on the packaging and the productitself, use is made of the following terms orsymbols to denote data or information ofspecial importance:

Information and/or mandatoryregulations or prohibitions for theprevention of personal injury orsubstantial property damage.

Warning of dangerous electricalvoltage.

Special information regarding theeconomical use of the machine andother information.

CE-Marking

Disconnect mains plug.

Caution! Hot surface.

Caution! Compressor can start upautomatically!

Make due allowance for environmentaleffects. Do not operate the machine ina damp or wet environment!

Recycling

Observe Instructions for Assembly andUse!

Date of manufacture

5

2. PRODUCT INFORMATION2.1 Use for the Intended PurposeThe compressor is intended to be used forgenerating compressed air required foroperating dental units of equipment or forsimilar applications.Installation in medical care facilities:In designing and constructing thecompressor, allowance has been made for therequirements of medical products whereapplicable. Accordingly, the unit can be usedfor installation in medical care facilities.If the unit is installed in medical care facilities,the requirements stipulated in Directive 93/42EEC IEC 601-1 as well as the relevant normsmust be observed as applied to installationand assembly.

2.2 Use other than that for theIntended Purpose

The compressed air produced bythe compressor is unsuitable foroperating breathing equipment orsimilar facilities without additionalfilters required for the operatingarea.

• The compressors are designed to beoperated in dry, ventilated rooms, ambienttemperature +10 to +40 °C.

• Do not expose the compressor to rain. Themachine must not be operated in a damp orwet environment. Use is also prohibited inproximity to gases or combustible liquids.

• Prior to installing the compressor in medicalfacilities, it must be ensured that the avail-able medium complies with the requirementsstipulated for the relevant purpose in eachindividual case. Observe the particularsgiven in Chapter 4. "Technical Data".When installing, classification andconformity rating must be carried out by themanufacturer of the ultimate product.

• Any other use or use beyond what isspecified is deemed to be not for theintended purpose. The manufactureraccepts no liability for damage resultingtherefrom. All risk is borne solely by theoperator/user.

2.3 Product DescriptionThe compressor generates an oil-free, dry andfiltered compressed air required for operatingunits of dental equipment.

3. SCOPE OF DELIVERYCompressor with / withoutdry-air systemInstructions for assemblyand use .................................... 9000-610-38/30Accessories incl. pressure hoseø 8x3x14, length 1 m .................... 5410-002-00Only for compressors with dry-air system:Collecting trough .......................... 3413-001-00

3.1 Special AccessoriesThe parts listed below are not included in thescope of delivery.Please order as required!5150, 5151, 5170, 5171,5250, 5251, 5270, 5271 ............... 5110-500-004151, 4251, 5351, 5451 ............... 4251-500-00Pressure reducer ......................... 6040-992-00

3.2 ConsumablesFilter cartridge suitable for compressor model:Primo, Duo, Duo-Tandem,Trio, Quattro, Quattro Tandem ..... 0832-982-00Tornado ........................................ 5430-982-00

Fine-mesh filter fordry-air system............................... 1610-121-00Sterilisation filter fordry-air System .............................. 1640-981-00

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Voltage V 230 230 400 230 400

Frequency Hz 50 – 60 50 – 60 50 – 60 50 50 – 60Current Consumptionat 8 bar A 4,3c – 4,4c 6,3c – 7,0c 3,1c – 2,5c 8,6 4,4c – 4,8c

Motor Protection Switch Amax. permissible setting 6,3 8,5 3,5 10,0 6,3recommended setting 5,6c – 4,4c 6,5c – 7,6c 3,2c – 2,5c 8,6 4,4c – 5,0c

Rated Output kW 0,80c – 0,98c 1,30c – 1,60c 1,40c – 1,42c 1,90 2,20c – 3,00c

Speed min–1 1440c – 1710c 1360c – 1600c 1410c – 1690c 1350 1440c – 1700c

Mains Fuse LS-10Ad LS-10Ad LS-10Ad LS-10Ad LS-10Ad

Protection System IP 54 IP 54 IP 54 IP 54 IP 54

Noise Level dB(A) 67c – 72c 71c – 75c 72c– 76c 77 75c – 77c

Number of Cylinders Zyl. 1 2 2 3 4

Delivery at 5 bar l/min

w. DASb 60c – 70c 110c – 120c 110c – 120c 165 230 – 260

w/o. DASa 60c – 70c 115c – 130c 115c– 130c – 235 – 270

Switch-on/off Pressure bar 5,5 / 7,5 5,5 / 7,5 5,5 / 7,5 5,5 / 7,5 5,5 / 7,5Safety Valve - AdmissibleOperating Pressure bar 10 10 10 10 10

Volume of Pressure Tank l 20 20 20 50 50

Duty cycle %

w. DASb 50 50 50 50 50

w/o. DASa 100 100 100 _ _

Grade of Filtration, Cartridgefor compressor µm 10 10 10 10 10Grade of Filtr., Fine-mesh Filterfor DAS µm 1 1 1 1 1Grade of Filtr., Sterilised Filter

for DAS µm 0,01 0,01 0,01 0,01 0,01

Weight w. DASb kg 56 57 57 90

w/o. DASa 47 49 49 87 –

Dimensions (H x W x D) cm

w. DASb 64 x 49 x 46 64 x 49 x 47 64 x 49 x 47 86 x 74 x 51 86 x 74 x 51

w/o. DASa 64 x 49 x 44 64 x 49 x 45 64 x 49 x 45 – 70 x 74 x 50

Charging Time 0 – 7.5 bar s

w. DASb 135c – 120c 75c – 65c 75c – 65c 130 95c – 80c

w/o. DASa 125c – 105c 65c – 55c 65c – 55c – –

a w/o. DAS (without dry-air system)b w. DAS (with dry-air system)c depending on mains frequencyd mains fuse: 10 A LS-switch, characteristics B, C, and D according to DIN EN 60898

4. TECHNICAL DATAModel Primo Duo Trio Quattro

5150-01a 5250-01a 5250-51a 5450-51a5151-01b 5251-01b 5251-51b 5351-01b 5451-51b

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230 / 400 400 400 400 230 230 22050 – 60 50 – 60 50 – 60 50 – 60 50 – 60 50 60

3,1c– 2,5c 6,2c– 5,0c 4,4c– 4,8c 8,8c– 9,6c 4,9c – 4,3c 6,7 7,9

- / 3,5 3,5 6,3 6,3 6,3 8,5 10,06,5c–7,6c/3,2c–2,5c 3,2c – 2,5c 4,4c – 5,0c 4,4c – 5,0c 5,1c – 4,3c 7 8,0

1,40c – 1,42c 2,80c – 2,84c 2,2c – 3,0c 4,4c – 5,9c 0,92c – 0,97c 1,42 1,70

1410c – 1690c 1410c – 1690c 1440c – 1700c 1440c – 1700c 1420c – 1700c 1380 1660

LS-10Ad LS-10Ad LS-10Ad LS-10Ad LS-10Ad LS-10Ad LS-10Ad

IP 54 IP 54 IP 54 IP 54 IP 54 IP 44 IP 44

72c – 76c 75c – 77c 74c – 76c 76c – 79c 67c – 70c 70b – 72a 72b – 75a

2 x 2 / 2 2 x 2 4 2 x 4 1 2 2

215c – 240c / 220c – 240c 230c – 260c 460c – 520c 67c – 69c 115 125

110c – 120c – – 470c – 540c 70c – 80c 130 150

5,5 / 7,5 5,5 / 7,5 6,5 / 8,5 6,5 / 8,5 5,5 / 7,5 5,5 / 7,5 5,5 / 7,5

10 10 10 10 10 10 10

50 50 90 90 20 20 20

50 50 50 50 50 50 50

– – – – 100 100 100

10 10 10 10 10 10 10

1 1 1 1 1 1 1

0,01 0,01 0,01 0,01 0,01 0,01 0,01

87 97 114 175 52 67 67

71 – – – 44 59 59

86 x 76 x 51 86 x 76 x 51 86 x 103 x63 86 x 103 x 63 64 x 49 x 46 64 x 49 x 46 64 x 49 x 46

– – – 75 x 103 x 63 64 x 49 x 44 64 x 49 x 44 64 x 49 x 44

171c – 147c 86c – 76c 165c – 135c 76c – 66c 130c –115c 65 55

– – – – 100c – 85c 45 40

Climatic Conditions for Storage and TransportTemperature –25 °C to +55 °C, 24h to +70 °CRelative Atmospheric Humidity 10 % to 90 % (without condensation)Climatic Conditions for OperationTemperature +10 °C to 40 °CRelative Atmospheric Humidity up to +70 %

4251-01b / 4680-51a 5170-01a 5270-01a 5270-02a4151-51b 4251-51b 4641-51b 4681-51b 5171-01b 5271-01b 5271-02b

2 Aggregate 2 Aggregates 1 Aggregate 2 Aggregates

Duo Tandem Quattro Tandem Tornado 70 Tornado 130

1 Aggregate

12,2c– 14,3c

2,7c – 3,3c /

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5. OVERVIEW OF FUNCTIONS OF COMPRESSORS5.1 Compressor with Dry-air System

5.2 Compressor without Dry-air System

13

11

17

15b

8

10b

1

2

4

2

3

1

10a

9

11

76

15a

14

16

5

12

13

8

9

6. FUNCTIONAL DESCRIPTION6.1 Compressor with

Dry-air SystemConcise Functional Description:The compressor aggregat (10a) draws inatmospheric air which is then compressedwithout any contamination by oil.The compressor feeds the compressed oil-free air to the dry-air system (2).The dry-air system removes moisture from thecompressed air.Now in an dry state, the clean, oil-free air ismade available in the pressure tank (8) to theconsumers (e.g., turbine).

Detailed Functional Description:• • • • • Compressor SetAtmospheric air is drawn in via the intakefilter (13). The cylinder piston (12) of thecompressor set (10a) then compresses theair. The inlet valve/outlet valve blocks thedirection of flow so that the compressed airis forced to the dry-air system (2).

• Dry-air SystemThe compressed air is conducted round thedry-air system via the spiral-shaped coolingtube (3).Inside the cooling tube, the compressed,heated air cools down and a large percentageof the moisture present in the air is extractedin the form of condensation water.This pre-dried air then passes into thepressure tank (8) via the drier (14), sinteredmetal filter (4), fine-mesh or sterilisation filter(1) and non-return valve (15a).The non-return valve (15)a serves to preventany backflow of the compressed air emergingfrom the pressure tank.Each time the compressor is switched off,the condensation water is blown into thewater collecting (5) through by means of thedry-air system and the pressure hoses arevented on the compressor.

• • • • • Regeneration of the Dry-air SystemThe polyamide band (16) fitted inside thehygrostat expands due to the presence ofhumidity. If the permissible relative humidityinside the pressure tank (8) is exceeded, thevalve on the hygrostat responds by open-ing, causing air to flow out of the pressuretank in the opposite direction. This can beheard blowing out underneath the dry-air

system (2). In this phase, the system under-goes a process of regeneration, for whichpurpose the compressor must be at astandstill. This process of regeneration willcontinue to repeat itself until the relativehumidity originally set on the hygrostat (16)is attained.

• • • • • Valve Unit with Pressure SwitchWhenever compressed air is withdrawn for acertain consumer (e. g., turbine), the pressureinside the tank is reduced. When the minimumtank pressure set on the pressure switch (11)is attained, the compressor will be switchedon again via the pressure switch. As soon asthe maximum tank pressure (7.5 bar) set onthe pressure switch is attained (5,5), thecompressor will switch itself off. The maxi-mum permissible tank pressure of 10 bar ismarked in red on the pressure gauge (7).The safety relief valve (6) serves to prevent themaximum permissible tank pressure of10 bar from being exceeded.The drain cock (9) is used for draining offcondensation water from the pressure tank,this being done by opening the valve.Also refer to Section 12.3 "Draining OffCondensation Water".

6.2 Compressor withoutDry-air System

• • • • • Compressor setThe compressor set (10b) draws in atmos-pheric air via the suction filter (13) which isthen compressed without any contaminationby oil by means of the cylinder piston. Theinlet valve/outlet valve blocks the direction offlow so that the compressed air is forcedthrough the non-return valve (15b) into thepressure tank (8).

• Pressure SwitchThe compressor set (10b) continues to feedcompressed air until the maximum pressurepreset on the pressure switch (11) is attainedinside the pressure tank (8) and thecompressor set switches itself off.After the compressor set has switched itselfoff, the pressure hoses are vented via ventvalve (17).

• • • • • Valve Unit with Pressure SwitchRefer to previous section, "Detailed Functional

10

Description".ASSEMBLY

7. STORAGE AND TRANSPORTCONDITIONS

The compressor leaves the factorypacked in a transport carton whichserves to prevent damage to the unit intransit.For transportation, always use theoriginal packing materials of thecompressor where possible. Alwaystransport the compressor upright.When transporting the compressorprotect against damp, dirt and extremetemperatures.Compressors packed in original cartonscan be stored in warm and dry roomsnot exposed to dust.As far as possible store the packingmaterials in a safe place.If storage of the packing materials is notpossible, ensure that they are disposedof in a manner serving to protect theenvironment. The transport carton canbe disposed of in the paper recyclingbin.The compressor must always betransported in the depressurisedstate.Prior to transport evacuate all airfrom the pressure tank and pressurehoses and definitely drain offcondensation water that is present(refer to Section 8.8 "Draining OffCondensation Water").

8. INSTALLATION AND PLACINGIN INITIAL SERVICE

On compressors assigned to TestGroup 3 according to German Pres-sure-tank Regulations, e.g., modelsTrio 5351-01 or Quattro 5451-51,installation and initial placing inservice must only be carried out by asuitably qualified engineer who isrequired to provide an appropriaterecord documenting such installationin the form of an InstallationCertificate and to enclose thisdocument along with the other

compressor records.

Prior to placing in service for thefirst time, all transport securitydevices must be removed.

8.1 Environmental Conditions• The unit may only be installed and operated

in dry rooms that are well ventilated and freeof dust.

• The compressor must be installed in such away that ease of access is warranted foroperation and maintenance as well as for therating plate.

• The unit must be mounted on a level floorbase revealing adequate stability. Observeweight of compressor (refer to Chapter 4."Technical Data").

The suction side of the air filter aswell as the ventilation slats must bekept unobstructed and reveal ad-equate spacing distance away fromwalls (approx. 20 cm).The mains connection line and theair hoses must not reveal any bendsor kinks.

The room temperature must not be allowed tofall below +10 °C as otherwise properfunctioning of the compressor will not bewarranted on account of the possibility ofundesirable condensation.The room temperature must not be allowed toexceed +40 °C. If room temperatures exceed+40 °C provision must be made for additionalmeans of ventilation by a fan (see Fig. 3).The ideal room temperature is from +10°C to+25 °C.

Due to technical reasons, approx.70 % of the electricity consumed bythe compressor set is converted toheat and released into the environment.

The motor fan caters for effective ductedcooling of the unit. To ensure this, the air mustbe allowed to flow in and away withoutobstruction of any kind. In unfavorable casesor circumstances a forced ventilation systemwill need to be installed (see Fig. 3).

No objects of any kind must beallowed to come into contact withthe compressor since, at a roomtemperature of, e.g., +40 °C, thecylinders and cylinder heads areliable to heat up to temperaturesexceeding +110 °C.

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Fire Hazards!

8.2 Compressed-air ConnectionA standard feature of the compressor is acontrol unit comprising the following:pressure switch (11), safety valve (6),compressed-air connection coupling (20) andpressure gauge (7).• Slip flexible pressure hose (ø 8x3x14) onto

connecting socket of pressure reducer andsecure with hose clip (21) to preventslipping off.

A flexible pressure hose fitted betweenthe firmly installed compressed-airtube and the compressor serves toprevent transmission of vibration andthus reduces noise.

8.3 Electrical ConnectionConnection up to the voltage supplysystem may only be carried out by asuitably qualified electrician(with exception of those stationssupplied ready for plugging into anearthing-contact type socket or CEEsocket, depending on the version ofthe compressor).

The 400 V version of the compressor issupplied fitted with a CEE connector, and the230 V version with an earthing-contact typeplug. The regulations of local power supplycompanies must definitely be observed.The mains voltage and frequency must conformto the data specified on the rating plate.

No connecting cable must beallowed to run across the unit. Thehot surfaces of the compressormight otherwise cause damage tothe cable insulation.

• If the unit is permanently connected up tothe voltage supply system, provision mustbe made for a power disconnecting devicewith a contact opening width of at least3 mm (e.g., a power circuit breaker).

• If the unit is connected up to the voltagesupply system by means of a plug-typeconnector, ease of access must be providedto the socket for safety reasons, enablingthe unit to be disconnected safely from themains in cases where danger situationsarise.

• The corresponding circuit must be protectedby a fuse consisting of an LS-switch10 A(characteristics B, C, and D) supplied and

20

21

11

7

6

4

3

5

12

fitted by the client.

8.4 Placing in Initial Service• Check to ensure that all transport security

devices have been removed from thecompressor.

• Check to ensure proper connection of thecompressed-air lines.

• The compressor must be properlyconnected up to the voltage supply system.

• Check air filter for proper assembly.• Switch on the compressor at the pressure

switch (11) by turning the rotary switch toposition "I AUTO" (refer to Fig. 6).

During the initial running hours, thecompressor may continue to switchitself on again after shorter periods ofdisuse – even if no air has beenwithdrawn from the pressure tank.During this phase, drying of thepressure tank takes place while itreveals excessive moisture content.A blow-off noise can be perceived onthe silencer (dry-air system), fromwhich the absorbed moisture emergesin the form of water vapor.

8.5 Setting the Motor ProtectionSwitch

In all compressor models except Duo-,Quattro Tandem, motor protection switch andpressure switch are combined into onecomponent (see Fig. 7). The motor protectionswitch can be set by adjusting the setscrew

(31). Model Duo-, Quattro Tandem featurestwo separate motor protection switches whichare built into the control box of thecompressor set. These switches each havea setscrew (35) as well as a start and stopbutton (36 and 37).All motor protection switches have been set atthe factory to certain values. These values areequal to the recommended values given inChapter 4. "Technical Data" for a frequency of50 Hz. The factory settings need to bechecked during installation. They should onlybe changed if necessary.

When changing the settings, themaximum values given in Chapter 4."Technical Data" must not beexceeded.

For checking or resetting the motor protectionswitch please proceed as follows:• Remove protective housing of the pressure

switch (11) or, respectively, of the controlbox of model Duo-, Quattro Tandem.

• Measure the maximum current (value shortlybefore switch-off pressure is attained).

Measurements and adjustments canonly be carried out with thecompressor in the live state.

• Set the motor protection switch by adjustingthe setscrew (31 or 35, depending onmodel) to the measured value.

8.6 Checking the Safety ValveThe safety valve has been set at thefactory to 10 bar, tested and con-firmed by an endorsement stamp.The valve must not be altered.When placing the compressor inservice for the first time, the safetyvalve must be checked for properfunctioning.

Give screw (6) a couple of turns in thecounter-clockwise direction until blow-offoccurs on the safety valve (refer to Fig. 9).The safety valve should only be allowed toblow freely for a short time.Turn screw (8-2) in clockwise direction to fullextent; the valve should now be in the fullyclosed state once more (refer to Fig. 8).

During this check, the pressure tankshould be under pressure (maximum7.5 bar).The safety valve should never beused for venting the pressure tank.

6

11

13

7

31

32

33

9

96

8

35

36

37

8.7 Checking and Adjusting thePressure Switch

The pressure switch has been set at the factory.At 5.5 bar tank pressure the unit switches itselfon.At 7.5 bar the unit switches itself off.

If required, the working pressure of thecompressor can be modified at thepressure switch.

To do this, it is necessary to first set the switch-offpressure and afterwards the switch-on pressurevia pressure-difference (∆p).

When carrying out this work, theprotective housing of the pressureswitch (11) needs to be removed.Settings can only be carried out withthe compressor in the live state.

Proceed to set the switch-off pressure p onthe adjusting screw (32, refer to Fig. 7): plus (+)direction of arrow = higher and minus (–)direction of arrow = lower. When making thisadjustment, the pressure difference alsoundergoes modification (readjust if necessary).Observe maximum pressure(10 bar) on safety valve. The switch-off pressuremust be at least 0.5 bar below the value of thesafety valve as otherwise the safety valve wouldopen and the compressor set would then fail toattain the switch-off pressure, thus continuing torun all the time.The pressure difference ∆p betweenswitch-on and switch-off pressure can bemodified. This is done by turning the adjustingscrew (33) in the plus (+) or minus (–) direction.When carrying out this adjustment, the pressuretank must be under pressure.

8.8 Draining off Condensation WaterDuring transportation, condensation water mayform inside the pressure tank due to differencesin temperature. Each time a compressor isinstalled, always drain off the condensation waterfirst; this also applies to compressorsincorporating a dry-air system.When doing this, proceed as follows:• With the compressor in the switched-on

state and at tank pressure, proceed to screwopen the condensation-water drain cock (9).

• Wait until the condensation water hascompletely drained off from the pressure tank.

• Close drain cock (9) again.

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This may otherwise impair properfunctioning of the safety valve.

9. CIRCUIT DIAGRAMS9.1 Version 1/N/PE AC230 VList of EquipmentQ1 Pressure switch/motor

protection switch

X1 Mains connection 1/N/PE AC 230 VM1 Compressor motor

M2 Proposed fan connection(can be allocated if required)

9.2 Version 3/N/PE AC 400 VList of EquipmentQ1 Pressure switch/motor

protection switchX1 Mains connection 3/N/PE AC 400 V

10

11

15

9.3 Version 3/N/PE AC 400 V, 2 Aggregates, Duo Tandem

12

List of equipmentQ1 Pressure switchQ2,Q3 Motor protection switchX1 Mains connection 3/N/PE AC 400 V

P>2 4 6

1 3 5X2 3 3 3 2 2 2 1 1 1 7 7 7 PE PE PE

3 3 3 2 2 2 1 1 1 7 7 7 PE PE PE

A1

44

66

PEPE

11

22

33

X3 33

44

66

PEPE

11

22

3MM1 3

MM2L1L2L3 N PE

Q22 4 6

1 3 5

22

21

14

13Q32 4 6

1 3 5

22

21

14

13

X4

X1

Q1

X2 Connection to A1X3, X4 Connection A1 to MM1,M2 Compressor motors 1 and 2A1 Control

9.4 Version 3/N/PE AC 400V, 2 Aggregates, Quattro TandemList of equipmentA1 ControlK1 Time lag relais

13L1L2L3 N PE

6 4 2

135P>

4 44 5 5 5

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16

M1 Compressor motorM2 Proposed fan connection

(can be allocated if required)USE

10. OPERATIONIn dangerous situations alwaysunplug the unit from the mains(disconnect plug from mains).

The surfaces of the compressor arehot. There is a risk of burns beingsustained if these surfaces aretouched.

Automatic start-up. Whenever thepressure inside the pressure tankdrops, this will result in thecompressor being switched onautomatically and remaining on untilthe maximum operating pressure of7.5 bar is attained once more.

10.1 Switching on the Compressor• Switch on the compressor at the pressure

switch (11) by turning the switch (25) toposition "I AUTO".

This starts up the compressor set and thepressure tank is filled. As soon as the switch-off pressure is attained, the compressor setwill switch itself off automatically.The maximum permissible operating pressuremust not be exceeded. The permissibleoperating pressure is marked by a red strokeon the mounted pressure gauge (7).

In the event of the maximum oper-ating pressure (10 bar) being ex-ceeded, the compressor set mustbe switched off and disconnectedfrom the mains (disconnect mains

14

25

11

7

17

plug). Inform the technician responsible.11. MAINTENANCE INTERVALS – USER / TECHNICIANMaintenance due to be carried out Chapter Interval

• Setting the pressure reducer 12.2 Once a year

• Draining off condensation water 12.3

Compressors without dry-air system Once a monthAt a high degree of humidity Once a day

Compressors with dry-air system Check every six months,draining if necessary

• Safety-valve check 12.4 Every six months

• Filter replacement 12.5 Once a year

12. MAINTENANCERepair work exceeding normalmaintenance operations may only becarried out by a suitably qualifiedengineer or our customer servicestaff.Only use spare parts licensed by themanufacturer as well as accessoriesdestined for the purpose.

Prior to performing any maintenanceor repair work, be absolutely sure toswitch off the compressor first anddisconnect from mains (pull outmains plug).

To ensure proper functioning of the com-pressor, be sure to regularly carry out main-tenance as described in Sections 12.1 to 12.5.

12.1 Pressure ReducerThis part is sold as a special accessoryitem and is therefore not included in thescope of delivery.

The pressure reducer (40) serves to control theflow pressure in alignment with the desiredworking pressure. The pressure reducer isconnected to the pressure switch via anexpress coupling (20).

40

15

20

18

12.2 Setting the Pressure ReducerTo set the flow pressure, place the syringe,turbine, etc. in operation. Lift the rotaryadjusting knob (41) and continue to turn in thedirection of the + arrow (to increase flowpressure) or in the direction of the – arrow (toreduce pressure) until the required flowpressure is indicated on the pressure gauge(42). Afterwards push the adjusting knobback in position making sure that it firmlyengages in place so as to preventdisplacement of the pressure reducer. Theset pressure is now fixed.For flow pressure refer to data specified by themanufacturer of the consumers (e.g., turbine).

12.3 Draining off Condensation WaterOn compressor versions fitted with a dry-airsystem, the condensation water is dischargedautomatically through the dry-air system.On compressor versions without a dry-airsystem it is necessary to drain off thecondensation water at least once a month!In countries having a high degree ofatmospheric humidity, the condensation waterneeds to be drained off every day!Procedure:• With the compressor in the switched-on state

and maximum tank pressure, proceed toscrew open the condensation-water draincock (9) as far as possible.

• Wait until the condensation water hascompletely drained off from the tank.

• Close drain cock (9).

12.4 Checking the Safety ValveThe safety valve (6) has been set atthe factory to 10 bar, tested andconfirmed by an endorsement stamp.The valve must not be altered.

Give screw (26) a couple of turns in thecounter-clockwise direction until blow-offoccurs on the safety valve.The safety valve should only be allowed toblow off for a short time.Turn screw (26) in clockwise direction to fullextent; the valve should now be in the fullyclosed state once more.

During this check, the pressure tankshould be under max. pressure (7.5 bar).The safety valve should never beused for venting the pressure tank.This may otherwise impair properfunctioning of the safety valve.

16

40

41

42

9

17

18

26

6

19

12.5 Filter ReplacementUsed filters must not be cleanedbut must be replaced by new ones.Attempting to clean destroys filters.

The intervals in which the filtercartridges need replacing will dependessentially on the amount of dustcontained in the air.Regular filter replacement serves topreserve the high quality of thecompressed air over a longer periodof time apart from enhancing theservice life of the compressor.Subject to proper installation (refer toSection 8.1 "EnvironmentalConditions"), we recommend that allfilters on the compressor and the dry-air system be replaced once a year.

Order numbers for filter cartridges:

Compressor types 5170, 5171, 5270, 5271Suction filter (13a) ........................ 5430-982-00Compressor types4151, 4251, 4641, 4681, 5150,5151, 5250, 5251, 5351, 5451Suction filter (13b) ........................ 0832-982-00Compressors with dry-air system types4151, 4251, 4641, 4681, 5151,5171, 5251, 5271, 5351, 5451Fine-mesh filter (1) ....................... 1610-121-00orSterilisation filter* (1) .................... 1640-981-00

When replacing filters, the suppliedsticker and documentation recordingthe last filter replacement should befilled out with the appropriateinformation and stuck in a visible place.Also refer to the information enclosedin the pack containing the new filters.

* A sterilisation filter serves to eliminate anyadditional contamination caused by micro-organisms such as bacteria, fungus sporesand viruses which may be present in theambient atmoshere.

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20

21

13a

13b

1

20

13. SHUTTING DOWN THE UNITIf the compressor is not used for a longerperiod of time, it is recommended that thecondensation water be drained off from thepressure tank. Afterwards put the compressorinto operation for approximately 10 minuteswith the condensation-water drain cock (9) inthe open state. Then switch off the unit on thepressure switch (25), close the condensation-water drain cock and disconnect the mainsplug.

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25

9

DISPOSAL

14. DISPOSAL OF THE MACHINE• Disconnect mains plug.• Let off air pressure in compressed-air tank

by opening the condensation-water draincock (9).

• Dispose of the compressor in accordancewith local valid regulations.

21

TROUBLE SHOOTING

15. TIPS FOR USERS

• Check mains fuse, if necessary,switch unit back on again(if fuse is defective, replace).

• Switch on pressure switch.

• Notify technician.

1. Compressor failsto start up.

• Absence of mains power.

• Pressure switch notswitched on.

Possible CauseFault Removal of Fault

2. Compressor failsto switch off.

• Compressor under-dimensioned,excessive air withdrawal(per treatment site approximately50 ltr/min)

• Leakage in compressed-air linesystem.

• Ascertain air requirements,using a larger compressor ifnecessary.

• Detect leak and seal.


3. Compressorswitches on fromtime to time with-out air being with-drawn for anyconsumer.

• Dry-air system is in regenerationphase, humidity being reduced intank.



• Air escaping downwards via thedry-air system (regenerationphase).


• Notify technician.4. Sound of knock-ing or loud noisescoming fromcompressor.

• Bearing damage.

• Suction filter contaminated. • Replace suction filter once ayear at least. Never clean thesuction filter.

5. Decline in feedperformance,compressor runslonger to chargetank. Forcharging timesrefer to Chapter 4"Technical Data".

6. Water is drippingout of the air con-sumers (e.g.,turbine).

• Condensation water in pressuretank.

• Drain off condensation water fromtank at least once a month. Thisshould be done once a day inareas where a high degree ofhumidity prevails or in tropicalcountries. Carefully observeambient temperature ofcompressor (refer to Section 8.1"Environmental Conditions").

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16. TIPS FOR TECHNICIANSThe following trouble shooting guide is intended solely for technical staff. Repairsmay only be carried out by technicians.

Possible Cause• Absence of mains power.

• Pressure switch notswitched on.

• Under voltage/Over voltage.

• Motor protection switch settoo low.

• Motor protection switchdefective.

• Air-relief valve defective,compressor set starting upagainst pressure (onlycompressors withoutdry-air system).

• Set reveals mechanicalsluggishness, piston stuck(motor protection switchtrips)

Fault1. Compressor fails

to start up.

Removal of Fault• Check mains fuse, switch unit

back on again if necessary (if fuseis defective, replace). Check mainsvoltage.

• Switch on pressure switch.If the pressure switch remainsswitched on for a brief durationand does not switch the motor offuntil afterwards, the currentconsumption on the 3-phasecurrent needs to be checked in allthree phases or in one phase onAC current.

• Measure voltage, notifying theelectrician if necessary.

For a detailed descriptionrefer to Section 8.5 "Settingthe Motor Protection Switch".

• Measure current. Set motorprotection switch accordingly (referto Chapter 4. "Technical Data").

• Check motor protection switch,replacing if necessary.

• Check to see whether the air-reliefvalve produces blowoff after theset is switched off. Renderoperable or replace.

• Disconnect mains plug, removecrankcase cover on compressorthat has heated and turn fanwheel; if this is not possible,replace piston and cylinder orcomplete set.

Users of model Duo-,Quattro Tandem maytemporarily utilize only oneaggregate.

23

Possible CauseFault Removal of FaultTo do this, please proceed as follows:

– Remove mains connection.When one of the aggregates of modelDuo-, Quattro Tandem is mal-functioning, the button "I" of its motorprotection switch is released. Inaddition, the rotary switch of thepressure switch jumps into position "0OFF". To disconnect the defectiveaggregate, please pull one the mainsplug on top of the control box whichis directly above the released switch(see Fig. 23). In order to temporarilyoperate the remaining aggregate set,set the rotary switch of the pressureswitch back to position "I AUTO".

– Disconnect defective aggregatepneumatically.

Remove pressure hose (54), T-connector (53) and connector (52).Connect functioning aggregate anddry-air system by directly joiningpressure hose (51) and the elbow(50) fitted to this aggregate.

• Substitute for defective aggregate.

Unplug the unit from themains.

– Turn rotary switch of the pressureswitch to position "0 OFF".

– Depressurize tank via condensa-tion-water drain cock. Afterwardsclose cock again.

– Replace defective aggregate by anew one.

– Replug unplugged plug on top of thecontrol box.

– Remove cover of the control box. Todo this, turn the two screws(55)counterclockwise to the stop.

– Press button "I" of the releasedmotor protection switch.

– Put cover back on and screw tight.– Plug in mains plug.– Turn rotary switch of the pressure

switch to position "I AUTO".– Test run the system.

23

24

50

51

525354

50

24

Possible Cause• Lamellar valve (inlet / outlet

valve) between cylinder andcylinder head defective.

• Air escaping on air-relief valve(only on compressors withoutdry-air system).

• Air blowing through dry-airsystem into collecting trough.


• Compressor under-dimensioned;excessive air withdrawal,

• Compression collar worn onpiston.

• Air escaping downwards via thedry-air system.

• Non-return valve defective.Air escaping via the dry-airsystem.

Air escaping at relief valve oncompressors not incorporating adry-air system.


• Bearing damage.

• Suction filter contaminated.

• Lamellar valve (inlet/outlet valve)defective.

• Compression collar worn onpiston.

Fault2. Compressor fails

to switch off.

3. Compressorswitches on fromtime to timewithout air beingwithdrawn for anyconsumer.

4. Sound of knockingor loud noisescoming fromcompressor.

5. Decline in feedperformance,compressor runslonger to chargetank. (For chargingtimes refer toChapter4. "TechnicalData").

Removal of Fault• Dismantle cylinder head and

install new lamellar valve.

• Replace air-relief valve.

• Check control head on dry-airsystem.

• Bring pressure to act upon lines.Seal leak, if necessary.

• Ascertain air requirements (pertreatment site approx. 50 ltr/min).Use a larger compressor, ifnecessary.

• Replace piston and cylinder orcomplete set.

• Dry-air system is in regenerationphase; atmospheric humiditybeing reduced in tank.

• Check non-return valve to seewhether air is escaping. Clean orreplace non-return valve.


• Check motor shaft bearings andcrankshaft bearings, replacing ifnecessary.

• Replace suction filter once a yearat least. Never clean suctionfilter.

• Replace cylinder head and valveplate.

• Replace piston and cylinder orcomplete set.

25

• Drain off condensation waterfrom tank at least once a month.This should be done once a dayin areas where a high degree ofhumidity prevails or in tropicalcountries.

Refer to Section 12.3"Draining off CondensationWater".

Carefully observe ambienttemperature of compressor.Refer to Section 8.1"Environmental Conditions".

• Remove screws (63) from controlunit and clean control nozzlesusing cleaning pin (60).

• Replace control unit.For maintenance work or in theevent of defects occurring, thecontrol unit (64) can bedismantled on the dry-air system.

– Dismantle dry-air system oncompressor.

– Remove three hexagon socketscrews (65) from base of dry-airsystem.

– Remove control unit (64).– Remove O-rings (62) from base

of water collecting chamber andreplace by new ones.

– Remove valve together withsealing washer and compressionspring (61) and substitute bysupplied parts.

6. Water is drippingout of the airconsumers(e.g., turbine).

7. Compressor isrunning andcompressed air isbeing blown offvia the dry-airsystem.

• Condensation water in tank.

• Congestion of control nozzle ondry-air system.

• Control unit defective.

Possible CauseFault Removal of Fault

25

60

6360

63

64

65

6162

26

Possible Cause• Control unit defective.

Fault8. Failure on dry-air

system.

Removal of Fault• Replacement of control unit;

alternatively and temporarily:• Bridge over the dry-air system.

In the event of failure occurring onthe dry-air system, this can bebridged over so to enable work tocontinue with the compressor.If the dry-air system is bridged over,action should be taken to ensure itsspeedy repair. Meanwhilecondensation water should bedrained off at least once a day.

Draining off condensation water:– Switch on compressor and wait for a short

time until switch-off pressure is attained.– Open drain cock (9) by turning in the

counter-clockwise direction until escapingair is able to entrain water from thepressure tank.

Refer to Section 12.3 "Draining offCondensation Water".

– Wait until no further water is blown out ofthe drain cock.

– Close drain cock again.

Bridging over the dry-air system:– Disconnect compressor from mains so as

to prevent it from starting up whilerebuilding operations are in progress.For this:

Unplug the unit from the mains.

– Drain compressed air from pressure tank(open drain cock (9), refer to Fig. 16).

– Remove screw (74). Remove washer andsave for later use (needed again afterrepair). Fit screw (74) again, screwingback in to full extent.

By removing the washer, the screwpresses against a metal plate andthus closes the duct governingregeneration.

– Screw off cap nut (70) and remove conicalnipple (71) from threaded joint (73).

To prevent loss of cap nut andconical nipple, these parts shouldbe attached to the threaded joint ofthe cooling tube during bridge-over.

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26

70

71

75

72

72

76

73

7374

27

– Screw off pressure hose (72) fromcompressor set on dry-air system andscrew onto threaded joint (73).

– Remove screw plug (75) along with filter(76), turn 180° and insert. Tighten screwplug (75).

This action serves to seal off theduct to the dry-air system, and thecontrol head on the dry-air isvented during stoppage through asmall borehole drilled into the plugscrew (75).

Fault Possible Cause Removal of Fault

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