Quality Assurance DIN ISO 9001 certified

Maintenance and Operating Instructions Spare Parts List

Screw-type Compressors SCK 21 - SCK 52

Ident number: 195.02022

BA 101/04.01/03/GB

Index General information and safety instructions Functional description Erection Operating Commissioning Maintenance Troubleshooting Options Technical Data Spare parts overviews Plan and electric parts Unit parts Lines and gaskets Suction control and temperature control Separatorbox Spare parts list Service completed

Page 4 5 6 7 9 10 12 13 14 15 15 16 18 20 21 22 26

Individual machine data:

Type:

SCK

Machine-No.

System with the following design/options that differ from the standard version:

For the perfect and troublefree operation you expect from your screwtype compressor, we recommend to keep in stock one set of maintenance and wearing parts, e.g. suction filter, oil filter, oil separator and lube oil. Our after-sales service p would be pleased to assist you in the selection of these spare parts. p On the reverse of this brochure you will find our address, telephone number and fax number. p In case of further inquiries please specify the data shown on the compressor nameplate (electric box back side).

Validity:
This manual and spare parts list is valid as from makers n SCK 51 - SCK 151 Date : : 260.607 02.04.2001

General information and safety instructions

General information
These maintenance and operating instructions contain information necessary for the perfect and troublefree operation of your screwtype compressor. Thoroughly read these instructions before commission, because damage caused by improper handling is not covered by our warranty.

F 1. Safety instructions
1.1 Safety instructions for personnel and compressor function
F The compressor system must only be erected, operated and maintained by trained p and from the user authorized personnel. Each authorized person must have read and understood the complete manual. Unauthorized conversions and modifications which influence the safety of the compressor are not allowed. F In any case all work to be carried out on the compressor is to be done in cut-off and pressure-relieved condition. The compressor system is to be protected against unauthorized reconnection. Attention - caution! The sound absorbing bonnet of the compressor is part of the protection against accidental contact and may only be opened upon completion of the above mentioned measures.

F Regulations, laws and important information This compressor has been built in accordance with the EG machine regulations 98/37/EG. All our specifications about the noise emission are in accordance with EN ISO 3746 and the EG machine regulation, chapter I, section 1.5.8 etc., this manual in according to section 1.7.4, etc. The machine has been built in accordance with the general technical rules. Operation can still mean danger for user or others, or even result in damage to the machine and other values. The machine may only be used to produce compressed air. Other use is strictly not allowed. Neither the manufacturer nor the supplier take the responsibility for damage caused by other use as to produce compressed air.
THESE BRIEF SAFETY INSTRUCTIONS DO NOT RELIEVE YOU FROM OBSERVING THE FURTHER DETAILED INSTRUCTIONS! F Sign for instructions which have to be strictly observed

1.2 Safety measures to be taken before commissioning

F The allowable compressor room temperature is : +5 C to +40 C. The electric connection must only be carried out by an authorized specialist. Check the correctness of current, voltage and frequency. The correct supply line is to be dimensioned and protected in compliance with the electrical data mentioned on page 13.

1.3 Safety measures to be taken during commissioning

F Check the maximum oil level at the lower edge of the oil filler neck (11.1). Fill about 0.2 l. oil into the oil prefill plug of the suction unit (06). Check the correct direction of rotation (see arrow on the electric motor). Switch on (and immediately off) for only a very short (max. 0.5 sec.) time.

Transport:
Transport is only allowed with a (fork) lift truck.

1.4 Safety measures for maintenance and operation

F All work is to be carried out with the machine at standstill and pressure-relieved. Switch off the power supply and protect it against reconnection. Close the shut-off valve to the compressed-air piping system (or compressed-air receiver tank). Damaging condensate water in the oil tank (11) should only be checked out in cold condition and must be drained. Check the oil level only with the compressor in warm condition. Attention: all cooler nozzles are to be counterbacked with a sufficient key; mind not to overturn the cooler connections. Caution! The compressor system oil tank (11) can be under residual pressure! Hot and oily compressed air penetrates when the safety valve (12) is operated! Do not discharge the compressed-air condensate into the sewage system (refer to section 3.4).

Functional description

2. Functional description
2.1 The drive
The electric motor (01) drives the compressor stage (04) through the V-belt pulleys (02) and the V-belts (03).

Flow diagram

14

13 15

09 10

08

11 04

06

05

2.2 The air path

Air flows into the suction filter (05) and the suction valve (06) into the compressor stage (04), which compresses the air. The relief valve (07) closes and the suction valve (06) opens at star delta and the revers way at the upper pressure point into the idle running phase. The oil separator (08) decreases the residual oil to 2 - 4 mg/m3. In the compressed-air recooler (09) the compressed-air temperature reduces to 9-13C above ambient temperature and leaves the machine through the compressed-air outlet (10).

12

01

07

2.3 The oil circuit

Cooling and sealing lube oil flows into the compressor stage (04) by the produced pressure in the oil tank (11). The oil leaves the compressor stage (04) mixed with the compressed air. The - placed according to the regulations - safety valve (12) protects the machine against excess pressure. The oil will be separated from the air up to 98% by our special design of the oil tank (11), which collects the oil. The residual separation of the oil will be carried out by the oil separator (08). The working temperature of the oil is optimized by the oil temperature controller (13). The oil passes the by-pass line or the oil cooler (14) and flows through the oil filter (15) back into the compressor stage (04).

18 05 14 02 03 17 10 09 11 01 13 15 06 04 08

12 16

2.4 The air cooling

The cooling air fan (16) on the rear motor shaft (17) takes in cooling air and leads it over the electric motor (01), passing the oil cooler (14) and the compressed-air recooler (09) and leads it through the for exhaust shaft connection prepared exhaust air grid (18) out of the machine.

Erection

3. Erection
3.1 General information
F The screw-type compressor is mounted on a solid frame ready for operation. Only a level solid floor is necessary for erection. The screw-type compressor is to be placed in a cool, dry and dust-free room with proper ventilation and a room temperature between + 5 C and + 40 C. When the room temperature might fall below + 5C, an additional compressor heating is to be installed into the compressor system oil tank (11) or the room is to be heated. When the room conditions are inconvenient, it may be necessary, owing to excess heating, to dissipate the hot exhaust air by means of exhaust shafts or cooling fans for a sufficient supply of fresh air. The place of installation shall be well accessible. Refer for assembly dimensions and required quantities of fresh air to the technical data on page 13.

3.3 Electric connection

F Electric connection is only to be carried out by skilled electricians. Check if current, voltage and frequency is according to the nameplate data. The cross section of the feed line and the fuses are to be dimensioned in accordance with the local prescriptions ! Refer to the data on page 13.

3.4 Condensate trap

F The condensate collected in the condensate trap (refer 3.2) is oily and must not be fed into the sewage system without further treat (Our after-sales service would be pleased to assist you in the selection of sufficient air-oil separation systems p).

3.2 Pneumatic connection

F Screw-type compressors will be delivered complete and ready for connection. The connection from the compressed-air outlet (10) to the piping system must only take place through a tape-sealed flexible hose, so that no forces can be transmitted between the compressed air piping system and the compressor unit. The pipe end of the piping system is to be thoroughly secured. In order to avoid that the condensate collected in the compressed-air recooler (09) is fed into the piping system or into the downstream receiver tank, a condensate trap with automatic separator is to be installed in the discharge line, if possible in direct vicinity of the compressed-air outlet (10). Refer page 13 for the outlet dimensions. A non-return valve between piping system or receiver tank and machine is not required, because this device is already installed in the screw-type compressor. It is, however, recommended to install a shutoff valve in the compressed-air line, so that the compressor is able to be disconnected from the piping system, if necessary.

Operating

4. Operating
The Air-Control is the central control element of the Compressors.

4.2 Key assignment

I On key The green lamp flashes: The compressor i ready for use and may start automatically at any time The green lamp is lit: The compressor is running Warning and error display The red lamp is lit: Compressor error The red lamp flashes: Warning O
INFO

___

A LUP
Kompressoren
bar

AIR CONTROL 1

M
o

Automatik

ENTER

Stop key to shut down the compressor (via idling) for input of codes for acknowledgement of errors Information can be obtained on the set values by pressing several times: 1x Cut-in pressure (bar) 2x Cut-out pressure (bar) 3x Safety pressure (bar) 4x Min. start temperature (5.0 C) 5x Max. compressor temperature (110 C) 6x Total operating hours (h) 7x Load hours (h) 8x Residual service life air filter (h) 9x Residual service life oil and oil filter (h) 10x Residual service life oil separator (h) 11x Residual service life lubricant (h) 12x Residual service life to service (h)

INFO

4.1 Display
The display permanently displays the line pressure, final compression temperature and operating status of the compressor.

Network pressure

bar
Error number, Warning number, Programming level

ENTER Confirm entered values and parameters Change values and parameters Only in case of emergency the system may be shut down with the EMERGENCY STOP switch.

M
Automatic

Compressor temperature

Restart

C Remote

4.3 Warnings
Symbol Error The red lamp and the symbol ! are flashing. The corresponding warning number flashes: 2 High compressor final temperature 3 High network pressure 11 Residual service life air filter < 100 h 12 Residual service life oil/oil filter < 100 h 13 Residual service life oil separator < 100 h 14 Residual service life motor lubrication < 100 h 15 Residual service life to maintenance < 100 h Realised maintenance have to be acknowledged with Code 21.

Symbol Warning Symbol Motor operates Symbol Compressor compresses Symbol Heating on

Restart

Automatic restart after power failure

Automatic Operation mode Automatic Remote

Flashing: Operation in Remote On/Off mode Constant: Operation through lead / lag control

Operating

4.4 Errors
The red lamp shines and the symbol is flashing. The corresponding error number flashes: 1 Pressure rated value wrong 2 Parameters wrong 3 Low voltage 4 Voltage failure 5 AirControl defect 6 Emergency stop actuated 7 Wrong direction of rotating 8 Motor temperature to high 9 Over current 10 Over pressure 11 Pressure drop through oil separator 12 Maximum compressor temperature sensor 13 Oil temperature sensor 14 Pressure sensor 15 Maximum compressor final temperature exceeded 16 Network pressure exceeded Errors have to be acknowledged by pressing the O-key.

Code 2 Mode 0 = Automatic (Automatic appears in the display) Idling time according to code 51 1 = Load-idling operation Unlimited idling time 2 = Automatic optional (an additional point appears in the display befor the temperature value) Progr. level 1: max. pressure drop Progr. level 2: max. switching frequency In all modes the compressor cuts in when the pressure falls below the cut-in pressure level and goes into idling mode when the cut-out pressure is reached. After the end of the idling time the motor cuts off. Code 3 Automatic Restart 0 = no automatic restart 1 = with automatic restart (Restart appears in the display) In the event of a power failure, which is shorter than the programmable restart time, the compressor will restart automatically Code 8 Local / Remote / GLW Generally the system will be controlled locally. 0 = Local mode (standard) 1 = Remote On/Off mode (Remote appears flashing in the display) 2 = Operation with a lead / lag control unit with automatic switch to to local operation (Option) Code 11 Cut-in and cut-out pressure When pressing the INFO key once the current cut-in pressure (bar) appears in the display and can then be changed. After pressing the INFO key a second time the current cut-out pressure appears (bar) in the display. The cut-out pressure can be changed and must always be at least 0.1 bar higher than the cut-in pressure. Code 18 Lead / lag operation 0 = Standard without lead / lag control unit 1 = Operation with a lead / lag control unit (Remote appears in the display) Code 21 Maintenance acknowledgement Relaised maintenance can be acknowledged by immediately pressing the ENTER key and after that the O key. Code 51 Idling, standstill and ru-up time Progr. level 1: Idling time (10 - 1200 s) Progr. level 2: Standstill time (0 60 s) Progr. level 3: run-up time (3 - 30 s) Code 90 Change of pressure unit 0 = Pressure in bar (g) 1 = Pressure in Mpa (g) 2 = Pressure in psi (g) Code 95 Change of temperature unit 0 = Temperature in C 1 = Temperature in F 2 = Temperature in K

4.5 Programming
The factory settings may be changed by programming 1. Press the O-key until the message cod appears 2. Select the codes described below using the keys; confirm your selection using ENTER 3. The code appears with 3 digits in the display. Change of the flashing value ( ) with the keys; confirm your selection with ENTER

Set code

Programming level

Flashing number value ( )

4. 5.

Certain codes allow settings in the second and third programming level after pressing of the ENTER key Press the O-key to return to the main menue

Commissioning

5. Commissioning
5.1 Preservation
Machines which are standing still after delivery ex works or are to be stored for a longer period before commissioning, will be filled up with preservative oil. This preservative oil has to be drained and disposed together with the flushing oil (appr. 1/3 of the normal oil supply, which will be flushed through the operating unit for about 30 min.). Please mind the initial lubrication of section 5.4 before commissioning!

5.6 Starting
Before starting the machine, verify that no persons can be endangered. The sound cover hood is part of the protection against accidental contact and leads the cooling air of the machine. It must be closed during operation. Open the shut-off valve between compressor and compressed-air system. Switch on the power supply. Push the start key I. The green lamp lights up and indicates operation or, if the line pressure is above the set cut-in pressure, the start temperature is below + 5C or with activated remote control, only flashes stand-by. CAUTION! A FLASHING GREEN LAMP MEANS THE COMPRESSOR CAN ALWAYS START UP AUTOMATICALLY The lines carrying oil and compressed air are to be checked for leakages. After the cut-out pressure is achieved the machine shuts down after the set follow-up time (automatic) or changes over to idle running (load-idle mode).

5.2 Oil level check

The maximum oil level is the lower edge of the oil filler neck (11.1). During operation the oil level will slightly fall by internal distribution. With rising machine temperature or even a temperature cut-off due to low oil level, the compressor is to be filled up with fresh oil into the oil filler neck (11.1).

5.3 Oil quality

With regard to the high load of the lube oil in oil injection cooled screw-type compressors, we recommend to use very non-aging, waterrepellent, non-foaming, anti-corrosion oils, e.g. our SPECIAL OIL. This oil is filled in by the works (refer to the oil tank (11) sticker). F Different kinds of oils must not be mixed. In case other lubricants are used, you should contact the after-sales service p. We only grant our warranty for the compressors when the use of equivalent lubricants is verified.

5.7 Shutdown
Push the stop key O. The green lamp extinguishes. The compressor shuts down after the follow-up time, the suction valve (06) closes and the oil tank (11) is relieved. The line pressure is available up to the non-return valve integrated in the separator box, i.e. the compressed-air recooler (09) is admitted with line pressure. Program changing and setting of pressure or time values can only be carried out with the required code and the compressor at standstill.

5.4 Initial lubrication of the compressor stage (04) (refer to section 1.3)
F After a longer standstill period, e.g. between initial commissioning and delivery ex works or after a longer works holiday, it may happen that there is no oil in the rotor compartment of the compressor stage (04). This oil, however, is absolutely necessary for lubricating rotors and bearings in the starting phase. Therefore it is necessary to fill about 0.2 l. oil into the prelube plug of the suction valve (06). Manually rotate the compressor stage (04) in the right direction of rotation until the sensible resistance disappears and the oil is passed through the stage (04). Mount the prelube plug again into the suction valve (06). If no additional oil is available (only use the same kind of oil) the oil can be drained from the system by means of the oil drain (11.2). Irregular operating machines and those which are standing still for several weeks should run for one hour every week, in idle mode, to prevent corrosion damage.

6. Compressor maintenance
6.1 General information
F All maintenance work is to be carried out by trained specialists with the machine switched off, at standstill, pressure-relieved and protected against reconnection.

6.2 Pressure relief

Before any maintenance work is carried out, the pressure relief is to be checked as follows : disconnect the compressor from the compressed-air system by closing the shut-off valve. The pressure relief is to be checked by venting the safety valve (12). F The temperature of the oil tank (11) may not be more than +40 C! F Attention - caution! It is absolutely necessary to wear face and body protection because hot oil mist can penetrate.

5.5 Direction of rotating (refer to section 1.3)

F The direction of rotation must comply with the arrow on the electric motor (01). When checking, the machine must only be switched on (and immediately off) for a very short time (max. 0.5 sec.) in order not to damage the compressor stage (04). The direction of rotation can be changed when two external conductors are exchanged.

Maintenance

6.3 V-belt drive

Our constructions keeps the V-belts (03) at the required tension; nevertheless they must be checked every 500 hours and retensioned if necessary. Place the test pin (p Order No. 180.02030) at right-angles to a V-belt (03) in the middle of the section between the rollers and press it down. Deflection at 50 N testing force: SCK 21 - 31 = 11 - 9 mm SCK 42, 52 = 8 mm If you have to replace one V-belt, you must replace all the V-belts (03) at the same time. To do this release the motor rocker arm upwards using the adjustment screws. Place the new V-belts (03) individually around the V-belt pulleys (02) and lower the motor rocker arm using the adjustment screws until the test force is achieved. Then lock the adjustment screws again.

manually tighten it half a turn. Check for leakage at operating temperature, confirm the main-tenance with Code 21 and reset with the O key. The used oil separator is to be disposed of as special waste.

6.7 Condensate water

When the full capacity of the compressor is not utilized, condensate water may deposit at the lowest point (heavier than oil) of the oil tank (11). This condensate water should be drained through the oil drain (11.2) regularly, when the compressor is at standstill for a longer period, e.g. at the weekend (ref. sect. 3.4). If any condensate water is observed, please contact immediately the after-sales service p, otherwise your warranty might be endangered.
Condensate and oil drain

6.4.1 Replacement of the suction filter (05) SCK 21-42

Warning 11 - with flashing red lamp. Replace the suction filter (05), confirm the maintenance with Code 21 and reset with the O key. The used suction filter is to be disposed of as special waste.

11.2

6.4.2 Replacement of the suction filter (05) SCK 52

Warning 11 - with flashing red lamp. Loosen the filter cap with the butterfly nut. Replace the suction filter (05) and secure the filter cap with the butterfly nut again. Confirm the maintenance with Code 21 and reset with the O key. The used suction filter is to be disposed of as special waste.
Suction filter SCK 21-42 Suction filter SCK 52

6.8 Oil level check (mind residual pressure when opening)

Check the oil level at the oil filler neck (11.1) and refill oil, if necessary. Different kinds of oil must not be mixed. Works oil filling: SPECIAL OIL.

6.9 Oil change always together wiht the oil filter (15)
Warning 15 - with flashing red lamp. The oil is to be changed in accordance with the maintenance intervals on page 13 with the required oil quantity. In case other lubricants shall be used, please contact the after-sales service p. We only grant our warranty for the compressors when the use of equivalent lubricants is verified. Oil change: (only in warm condition) open the filler neck (11.1) as well as the oil drain (11.2) and drain the used oil. Close the oil drain (11.2) and fill in fresh oil up to the lower edge of the filler neck (11.1). Check for leakage at operating temperature. Confirm the maintenance with Code 21 and reset with the O key. The used oil is to be disposed of as special waste.
Oil filler
11.1

05

05

6.5 Replacement of the oil filter (15)

Oil filter

15

Warning 12 - with flashing red lamp. Loosen the oil filter (15) with a strap wrench (p order n 180.06075) and remove it. Remove residues of the old sealing from the housing. Lubricate the seal of the new oil filter. Screw in the new oil filter (15) up to the limit stop and manually tighten it half a turn. Check for leakage at operating temperature, confirm the maintenance with Code 21 and reset with the O key. The used oil filter is to be disposed of as special waste.

6.6 Replacement of the oil separator (08)

Warning 13 - with flashing red lamp. Loosen the oil separator (08) with a strap wrench (p order n 180.06075) and remove it. Remove the residues of the old sealing and lubricate the seal of the new oil separator. Screw in the new oil separator (08) up to the limit stop and 10

11.2

Oil separator

6.10 Motor bearings (01)

Warning 14 - with flashing red lamp. Regreasing of the electric motor (01) must strictly be carried out and is performed by means of a grease gun with a lubrication nipple according to DIN 3404 (order n 180.06076 p). If the electric motor (01) does not have any grease nipples, it is equipped with long-life grease closed roller bearings. After their lifetime these bearings are to be changed completely.

08

Maintenance

6.11 Safety valve (12)

In order to maintain the proper function of the safety valve (12), Safety valve it is necessary to check the valve (12) every 2,000 operating hours or at least once a year. Checking: dismount the safety valve (12) from the unit and check it in a suitable device. If no device is available, the safety valve (12) can be checked by us p. Remove the residues from the thread connection. Wrap the thread of the safety valve (12) with sealing tape and screw the safety valve in. Check for leakage at operating temperature.

6.12 Set pressure switch points with Code 11

After 3 seconds continuous pushing the O-key, CODE 11 can be called with the keys followed by ENTER. Call the lower pressure switch point with the INFO key. Set the required value with the keys and save it with ENTER. After pushing the INFO key again, the upper pressure switch point can be called and set with the keys and saved the same way with ENTER.

6.13 General compressor maintenance

Warning 15 - with flashing red lamp - to carry out a general compressor maintenance. This general compressor maintenance includes all maintenance work which is to be done, with the unit in normal condition and normal ambient. Our after-sales service p would be pleased to assist you.

Maintenance intervals
Maintenance work and compressor checks Direktion of rotation (01) Oil level check (11) Leak check, discharge temperatur Reteighten electric connections Condensate collection (11) cooler contamination (09,14) First oil (11) + oil filter (15) change, V-belts check (03) Suction filter (05), l (11) + oil filter (15) change, oil separator (08), safety valve (12) at least once a year Regreasing of motor bearings (01) - maintenance intervals depending on compressor type (refer section 6.10) General compressor maintenance, at least once a year before erection after erection after the 1st week

#) Warning 100 h before run out service time

every week

each ... operating hours #) #) #) 500 2000 4000

11

Troubleshooting

A reminding information due to a run out service time or a run out service interval must be confirmed with Code 21 and reset with the O - key, after proper service. A warning has occured when the red lamp flashes with the machine still operating. The warning cause is shown in the display screen. After proper service, reset the warning with the O - key. A trouble has occured when the red lamp lights up continuously and the machine is at standstill. The trouble cause is shown in the display screen. After proper maintenance, reset the trouble with the O - key and the machine can be started up again. Trouble Cause Sound absorbing bonnet not closed Suction/ambient temperature too high Cooling air inlet or outlet blocked Oil filter (15) dirty Lack of oil Oil cooler (14) outside contamination Attention : all cooler nozzles are to be counterbacked with a sufficient key; mind not to overturn the cooler connections. Oil temperature controller (13) defective Air consumption exceeds air supply quantity Suction filter (05) dirty Relief valve (07) blows off when loading Measures to be taken Close the sound absorbing bonnet Vent the compressor compartment Clear the cooling air inlet/outlet Change the oil filter (15) Refill with fresh compressor oil Clean with compressed air. At severe contamination, remove the cooler (09, 14) unit and clean it with a water jet device Caution - danger of short circuit! FNo water jets on electric components! - Replace the controller (13) insert - Compressor with higher discharge quantity required p - Change the suction filter (05). - Check the relief valve (07) and replace the seals, if necessary - Check the solenoid valve and the suction valve piston (06) and replace, if necessary - Check and seal the line system - Adjust the upper pressure switch point - Replace the safety valve (12) - Change the oil separator (08) - Lower the high pressure source or eliminate it from the line - Adjust the upper pressure switch point - Check the control circuit for interruption (only by a skilled electrician) - Install a standstill heating device or heat the compressor compartment properly Observe the line pressure at the display. Check flashing display "remote" symbol. Check whether power is applied. Check the control (only by a skilled el.) refer to section 1.1, 5.6 1.2, 3.1 3.1 6.5 6.8, 6.9 2

7.1 Machine switches off through compressor dis-charge temperature; display screen information ! 15 (red lamp lights up) -

7.2 Falling line pressure

2 page 2 6.4 2 2 3.2 6.12 6.11 6.6 3.2

- Suction valve (06) does not open - Leakages in the line system 7.3 Machine blows off through the safety valve (12). 7.4 10, or ! 16 (red lamp lights up)
!

- Upper pressure switch point too high - Safety valve (12) defective - means oil separator (08) dirty - means external high pressure source

7.5 No automatic start or - Upper pressure switch point too high switching to load after - Interruption in the control circuit previous shutdown when the set cut-out pressure is - Ambient temperature below +1C; the reached or from idling symbol for temperature flashes 7.6 Machine does not start when - Line pressure above upper switch point the start key I is pushed - Remote control function active - No power at the compressor - Electric defect in the control 7.7 High oil content in the compressed air (excess oil consumption). 7.8 Compressor switches off before the set cut-out pressure is reached (red lamp lights up). 7.9 Information lights up) 12
!

6.12 Circuit diagram 3.1

4.1 4.2 Circuit diagram 2 6.6

- Oil return line clogged - Oil separator (08) defective

- Clean the oil return line. - Change the oil separator (08)

- Excess temperature or pressure - Interruption in the control circuit

- Eliminate the defect in compliance with chapter point : - Check the control circuit for interruption (only by a skilled electrician) - Check the power supply (only by a skilled electrician)

7.1, 7.4 Circuit diagram

3 (red lamp - Power voltage below appr. 180 Vac

Circuit diagram

Options

Tropical version (T) *

The tropical version is suitable for installation in ambient temperatures of up to 45 C. Please refer to the separate attached sheet

Remote On/Off *
The compressed can be switched on and off using a floating contact. Please refer to the attached circuit diagram for further details.

Special voltage / Frequency 60 Hz *

If your compressor is operated with a non-standard 400 V or with a frequency of 60 Hz, please refer to the separate, attached description.

Proportional controller *
The proportional controller makes it possible to adjust the delivery rate to the actual consumption of compressed air. To achieve this the air delivery rate is throttle in the intake controller by narrowing the cross-section.

Direction of rotation control *

The direction of rotation control prevents damage resulting from the incorrect polarity of the electrical voltage (phase confusion). The direction of rotation control causes the automatic shut-down of the compressor. The controller shuts down the motor if the pressure switch mounted on the compressor stage trips. Please see the attached circuit diagram for further details.

Soiling indicator, intake filter *

If the intake filter becomes soiled this is shown on the display. The filter element must then be replaced. The filter soiling is measured by a differential pressure sensor over the intake filter.

Soiling indicator, oil filter *

If the oil filter becomes soiled this is shown on the display. The oil filter cartridge must then be replaced. The filter soiling is measured by a differential pressure sensor over the oil filter.

Additional heating system *

The additional electric heating system is housed in the compressors oil tank. The oil heating system cuts in automatically as soon as the temperature falls below the factory set nominal temperature in the oil tank, which is measured by a temperature sensor. This prevents the condensation of the airs humidity in the compressed air. The additional heating system is required on systems that cut in and out frequently and temporarily and therefore do not reach the required operating temperature.

Soiling indicator, oil separator cartridge *

If the oil separator becomes soiled, this is shown by the controller on the display. The oil separator cartridge must then be replaced. The fine separator soiling is measured by a differential pressure sensor over the oil filter.

Floating error signal *

An error on the compressor can be forwarded by means of a floating contact. For example the error message can be connected to a central controller or a contactor. Please see the attached circuit diagram for details of the connection terminals.

Heat recovery system *

If you system is fitted with a heat recovery system or is prepared for a heat recovery system, please refer to the separate attached description.

Floating operating signal *

An operating signal showing whether the main compressor motor is running, can be connected to the central controller, for example, using a floating contact or can also be used, for example, to control blowers of refrigeration driers. Please refer to the attached circuit diagram for connection details.

* The above options are not included in the standard version. These instructions must only be observed if your compressor is fitted with the appropriate option.

13

Technical Data

Performance and erection data:

dashboard 219

669 4 x M5 int.

1270 waste air

exhaust shaft connection

compr. air outlet fresh air M10 int. 973 M10 int.

compr. air outlet

412

65

677 795

service side

dashboard

cooling air opening without shutter or mash

min. wall distance 50 cm

General data:
Compressor Weight Cooling air volume m3/h 3300 3300 3500 5300 5700 Supply air opening m2 0,40 0,40 0,40 0,60 0,65 Flue air duct cross section m2 0,37 0,37 0,39 0,60 0,65 Oil tank capacity l 8,0 8,0 8,0 17,0 17,0 3 3 3 3 4 XPA XPA XPA XPA XPA Number of V belts Type of V belts Compressed air connection G 1 1 1 1 1/2 1 1/2

kg SCK 21 SCK 26 SCK 31 SCK 42 SCK 52 435 450 485 580 595

Electrical data:
Compressor Motor rating kw SCK 21 SCK 26 SCK 31 SCK 42 SCK 52 15,0 18,5 22,0 30,0 37,0 Currents at 220V/60Hz
I(rated) A I(max) A Site back-up fuse A gL

Currents at 400V/50Hz
I(rated) A I(max) A Site back-up fuse A gL

Currents at 550V/50Hz
I(rated) A I(max) A Site back-up fuse A gL

1070 Maximum switching frequency 1/h 30 25 20 15 12 22 25 29 42 48 24 27 32 46 53 35 35 50 50 80

power supply PG 36

48 58 70 90 119

52 64 77 99 131

63 80 80 125 160

30 34 40 57 67

32 38 45 63 73

50 50 63 80 100

14

Spare parts: Plan and electric parts

136.00185

136.00064

176.00163

The serial number of the screw compressor (on the name plate) is to be indicated in any spare parts order. The required part number can be defined by the following views.

132.00602 132.00603 132.00607 132.00602 132.00603 132.00607 132.00600 132.00602 132.00603 132.05001

K1 137.00009 K3 137.08744 K2 136.00272 136.00278

136.00120

15

Spare parts: Unit parts

213.00490 172.02550 172.07787 213.00489 273.01852 273.01853 120.00110 273.00040 273.00041

172.11102 172.58111

172.00222 278.00224 273.01578 273.01579 154.00150 154.00154 136.00103 228.00851 228.00852 278.00222 278.00230 278.00246 278.00519 137.00462 174.00007

213.00456

226.00376 226.00377 176.00369 176.00381 176.00384

16

Spare parts: Unit parts

226.03112 226.03118 226.03125 226.03132 226.03140 278.00277

226.03150 226.03180 226.04095 226.04106 226.04126

163.00009 163.00026 163.00029 163.00044 163.00051

163.00066 163.00068 136.00128 163.00129 136.00131 163.00168 276.00440

213.00457 278.00338 278.00339 127.00066 127.00177 278.00366 278.00377

173.00003

126.03180 126.03224 126.03280 126.04280

172.07800 176.00095 131.00301 131.00302 131.00303 131.00304 131.00305 260.00047 278.00237 174.00013 213.00489

17

Spare parts: Lines and gaskets

165.04418 165.00168 165.01332 173.00199 173.00039

173.00286

167.00077 173.00011 167.00544

173.00107

165.00246 165.83202 167.08026 167.01249 173.00290 173.00292 165.00017

167.00077

165.83202

18

Spare parts: Lines and gaskets

173.00286

165.00331

165.00330 173.00291 165.00120

167.00077 173.08176 229.00038 229.00039

167.00077 165.83202

165.03416 165.83202 165.83202 173.00288 173.00289

19

Spare parts: Suction control and temperature control

212.00211

173.04003

173.04001

212.00210

212.00211

212.00213

172.00222

165.15101 273.02055

20

Spare parts: Separator box

172.01017 172.01036

273.00552 273.01529 167.02228 167.03036 169.02110 169.02250

172.11102 172.58111

165.00449 165.00015 273.02513 212.00215

165.00247

273.00578 273.00579

165.00329

273.04018

21

Spare parts list

Article number
120 00110 126 126 126 126 03180 03224 03280 04280

Description
Compressor stage Motor pulley Motor pulley Motor pulley Motor pulley Oil / air cooler Oil / air cooler Electric motor Electric motor Electric motor Electric motor Electric motor Fuses (optional heating) Relais (optional heating) Power relais Power relais Power relais Power relais Power relais Power relais Relais (option) Emergency button Temperature sensor Pressure sensor Air Control 1 system Transformator Transformator Primer fuses Heating (option) Transformer fuse Security valve Security valve V-belt set V-belt set V-belt set V-belt set V-belt set V-belt set V-belt set V-belt set V-belt set V-belt set V-belt set 21 21

SCK model
26 26 31 42 52 21 26 31 42 42 26 21 31 52 21 21 21 21 26 26 26 26 31 31 42 42 52 52 52 52 52 52 52 52 31 31 42 42 52 52 52 31 42 52

127 00066 127 00177 131 131 131 131 131 00301 00302 00303 00304 00305

132 00196 132 00377 132 132 132 132 132 132 132 136 136 136 136 136 136 00600 00602 00602 00603 00603 00607 05001 00064 00103 00120 00185 00272 00278

21 21 21 21 21 21 21 21 21 21

26 26 26 26 26 26 26 26 26 26

31 31 31 31 31 31 31 31 31 31

42 42 42 42 42 42 42 42 42

137 00009 137 00462 137 08744 154 00150 154 00154 163 163 163 163 163 163 163 163 00009 00026 00029 00044 00051 00066 00068 00128

52 52 52

42 26-08 26-13 31-13 31-10 26-10 31-08 42-13 42-08 42-10 21-10

52

21-08 21-13

163 00129 163 00131 163 00168 22

52-08 52-10 52-13

Spare parts list

Article number
165 165 165 165 165 165 165 165 165 165 165 165 165 165 165 165 00015 00017 00120 00168 00246 00247 00278 00329 00330 00331 00449 01332 03416 04418 15101 83202

Description
Stud coupling Blanking end Compressed-air elbow Blanking end Stud adaptor Stud elbow Stud elbow Stud elbow Stud coupling Stud elbow Stud coupling Banjo T coupling T coupling adjustable Stud adaptor Temp. control double male stud Banjo screw Bajo screw sealing edge ring Oil tank o-ring Bolt joint Variseal oil separator Variseal oil separator Oil separator Injection nozzle Injection nozzle Oil filter cartridge Oil separator double stud Oil separator double stud Heavy duty air filter cartridge (option) Air filter cartridge Dust filter (option) Oil separator Oil separator Oil return line clamp Oil return line Non-return valve Pressure sensor line Discharge line Compressed air line Initial oil line Initial oil line Bypass oil line Oil return line Bypass oil line Suction control connection nozzle Suction control housing Oil drain valve 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21 21

SCK model
26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 26 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 31 42 21 21 21 21 21 21 26 26 26 26 26 26 31 31 31 31 31 31 42 42 42 42 42 42 21 21 21 21 21 21 21 26 26 26 26 26 26 26 31 31 31 31 31 31 31 42 42 42 42 42 42 42 42 42 42 42 42 52 52 52 52 52 -52 52 52 52 52 52 52 52 52 52 52 52 52 42 42 42 42 42 42 42 42 42 42 42 42 42 42 42 42 42 42 42 52 52 52 52 52 52 52 52 52 52 52 52 52 52 52 52 52 52 52

167 00077 167 167 167 167 167 00544 01249 02228 03036 08026

169 02110 169 02250 172 172 172 172 172 172 172 172 173 173 173 173 173 173 173 173 173 173 173 173 173 173 00222 01017 01036 02550 07787 07800 11102 58111 00003 00011 00039 00107 00199 00286 00288 00289 00290 00291 00292 04001 04003 08176

21 21 21 21 21

26 26 26 26 26

31 31 31 31 31

23

Spare parts list

Article number
174 00007 174 00013 176 176 176 176 176 176 00095 00163 00369 00381 00384 09038

Description
Oil tank support Elastic supports Fresh air grid Operation panel Ventilator with hub Ventilator Ventilator with hub Key Special oil 8 ltr. Special oil 14 ltr. Operating instructions D Operating instructions GB Operating instructions NL Operating instructions F Operating instructions I Operating instructions E Line kit Discharge valve service kit Suction control service kit Temperature control service kit Minimum pressure valve service kit Joint kit Service kit Filter kit Filter kit Front side board Rear side board Sound cover hood Service board Ventilator hub Ventilator hub Compressor pulley Compressor pulley Compressor pulley Compressor pulley Compressor pulley Compressor pulley Compressor pulley Compressor pulley Compressor pulley Compressor pulley Oil tank Oil tank 21 21 21 21 21 21 21

SCK model
26 26 26 26 26 26 26 31 31 31 31 31 31 31 42 21 21 21 21 21 21 21 21 21 21 21 21 21 21 26 26 26 26 26 26 26 26 26 26 26 26 26 26 31 31 31 31 31 31 31 31 31 31 31 31 31 31 42 42 42 42 42 42 42 42 42 42 42 42 42 42 21 21 21 21 21 26 26 26 26 26 31 26-08 31-08 26-10 21-08 26-13 21-10 21-13 31-13 52-08 52-10 52-13 21 26 31 42 52 31-10 42-13 42-08 42-10 31 31 31 31 42 42 42 42 52 52 52 52 52 52 52 52 52 52 52 52 52 52 52 52 52 52 52 42 52 52 42 42 42 42 42 52 52 52 52

183 04050 183 04050 195 195 195 195 195 195 212 212 212 212 212 212 212 212 212 213 213 213 213 226 226 226 226 226 226 226 226 226 226 226 226 02021 02022 02023 02024 02025 02026 00165 00210 00211 00213 00215 01130 01131 02160 02162 00456 00457 00458 00459 00376 00377 03112 03118 03125 03132 03140 03150 03180 04095 04106 04126

228 00851 228 00852

24

Spare parts list

Article number
229 00038 229 00039 260 00047 273 273 273 273 273 273 273 273 273 273 273 273 00040 00041 00552 00578 00579 01529 01578 01579 01852 02055 02513 04018

Description
Compressed air connection socket Compressed air connection socket Support distance Suction control Proportional suction control (option) Separator bush Separator housing Separator housing Separator bush Separator box Separator box Temperature control unit Temperature control housing Non-return valve set Minimum pressure valve cover Exhaust air grid Air intake plate Electric box Air intake plate Frame with oil protection carter Air intake plate Compressor flange Front plate Front plate Cooler side board Cooler side board Air intake plate 21

SCK model
26 31 42 21 21 21 21 21 26 26 26 26 26 31 31 31 31 31 42 42 42 52 52 52 52

42 42 21 21 21 21 21 21 26 26 26 26 26 26 31 31 31 31 31 31 31 31 31 31 31 31 42 42 42 42 42 42 42

52 52 52 52 52 52 52 52

276 00440 278 278 278 278 278 278 278 278 278 278 278 00222 00224 00230 00237 00246 00277 00338 00339 00366 00377 00519

21 21 21 21 21 21

26 26 26 26 26 26

42 42 42 42 42

52 52 52 52 52 52

25

Services completed

Operating hours

Date

Servicing work completed

Name/Signature

26

ALUP-Kompressoren GmbH Postfach 1161 Adolf-Ehmann-Str. 2 Phone.: Fax: E-mail: Internet: D-73253 Kngen D-73257 Kngen

+49-(0)1 80-5 25 87 00 +49-(0)1 80-5 25 87 01 service@alup.com www.alup.com

28