Professional Documents
Culture Documents
Screw compressor
ALLEGRO 16 - 38
2006
All rights belong to:
ALUP Kompressoren GmbH
Adolf-Ehmann-Strae 2
73257 Kngen
2
Tel.:
0049-180-5258700
Fax:
0049-180-5258701
Table of contents
1. Safety instructions.........................................................4
1.1 Symbols in this manual.............................................4
1.2 Proper usage ............................................................5
4XDOLHGSHUVRQQHO...................................................5
1.4 General safety instructions .......................................6
2. Functional description ..................................................8
2. Functional description .................................................10
3. Storage and transport .................................................12
4. Installation ....................................................................14
4.1 Setting up ...............................................................14
4.2 Ventilation ...............................................................14
4.3 Forced ventilation(optional) ....................................15
4.4 Water cooling (optional)..........................................16
4.5 Heat recovery for heating water /
potable water (optional) ..........................................16
4.6 Connection to the compressed air net....................17
4.7 Electrical connections.............................................17
5. Displays and operating elements...............................18
5.1 Plant main switch....................................................18
5.2 Emergency OFF .....................................................18
5.3 Air Control 3 (option) ..............................................19
5.3.1 Basic display..................................................20
5.3.2 ON/OFF switching of compressed
air generation.................................................20
)XQFWLRQNH\UHVHUYDWLRQLQWKHEDVLFGLVSOD\ 21
5.3.3.1 Capacity utilization ..........................22
5.3.3.2 Service ............................................22
5.3.3.3 LLC status .......................................23
5.3.3.4 Compressor pass ............................23
5.3.3.5 Diagram net pressure......................24
'LDJUDPQDOFRPSUHVVLRQ
temperature ....................................24
5.3.3.7 Diagram compressed
DLUDPRXQWGD\SUROH....................24
5.3.3.8 Diagram compressed
DLUDPRXQWVZHHNSUROH ...............24
5.3.3.9 Modify diagram settings ..................25
5.3.4 Menu system .................................................26
5.3.4.1 Sub-menu Limit values....................27
5.3.4.2 Sub-menu Operating parameters....28
5.3.4.3 Sub-menu Service intervals ............29
5.3.4.4 Sub-menu Timer..............................30
5.3.4.5 Sub-menu Fault log ........................32
5.3.4.6 Sub-menu Display parameters........32
6XEPHQX&RQJXUDWLRQ .................33
5.3.4.8 Sub-menu Lead lag control (LLC) ...34
5.3.4.9 Sub-menu Accessories....................34
5.3.4.10 Sub-menu Diagnosis .......................35
5.3.5 Warnings / maintenance ................................36
5.3.6 Malfunctions ..................................................37
5.3.7 Adjustment of the display contrast.................38
5.4 Air Control 1............................................................39
5.4.1 Basic display..................................................40
5.4.2 ON/OFF switching of compressed
air generation.................................................41
5.4.3 Viewing additional operating data..................41
1. Safety instructions
Safety instructions
You are reading this manual in order to learn about the screw compressor.
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usage may not fall under the conditions of guarantee!
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access to it at any time.
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of-the-art technology and considering all the current safety standards.
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from the system if you comply with the stipulations of the service manual
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out according to the regulations.
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1.1
Italic text is employed when we would like to draw your attention to particular
information.
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the user.
1.2
Proper usage
The units are designed for a minimum pressure of 5 bar (operating overpressure)!
Any other utilization must be regarded as not in compliance with the design
purpose!
The manufacturer/vendor is fundamentally not liable for damage incurred if
the system is not used according to its design purpose!
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.
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7KLV PDQXDO LV GLUHFWHG WR TXDOLHG SHUVRQQHO ZKR DUH FRPPLVVLRQHG
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individuals must read the chapter relevant to their duties.
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Activities that are not described in this manual may only be carried out by
our customer service department or by authorized technical personnel.
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DI[HG WR WKH SURGXFW FDQ OHDG WR VHULRXV SHUVRQDO LQMXU\ RU GDPDJH WR
material!
5
1. Safety instructions
1.4
DANGER
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safety! The results could be serious personal, material or environmenWDOGDPDJH3RVVLEOHUHWURWWLQJRUPRGLFDWLRQVRQWKHV\VWHPZLWK
equipment components from third party manufacturers must therefore
UVWEHFOHDUHGE\XV
DANGER
The side panelings of the system are part of the contact protection
system to protect personnel from fan impellers that start up automatically, moving machine parts, hot surfaces and dangerous voltages!
Furthermore, they are required for sound insulation and cooling air
conduction. Therefore they must not be removed when the unit is in
operation.
For initial commissioning, it is required to remove the side paneling of
the system. Furthermore, in the process of the initial commissioning
of the plant, the mains switch must be turned on.
The initial commissioning, therefore, may only be carried out by qualiHGWHFKQLFDOSHUVRQQHO
DANGER
DANGER
NOTICE
For the operation of the compressor (equipment in the sense of Pressure Equipment Directive 97/23/EC) please observe national regulations
and laws. In Germany, operating equipment must be operated in accordance with the regulations laid down in the ordinance on industrial
safety and health (BetrSichV)!
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
cooling liquid may not enter the sewage system!
:HRIIHUDQDSSURSULDWHFRROLQJXLGZDWHUVHSDUDWRUIRUFRQGHQVDtion processing.
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).
7
Carry out the activities in all of the following chapters in the order given.
2. Functional description
2.1
Drive
The frequency converter supplies the electric motor with electric power.
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instructions in the control cabinet.
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coupling.
2.2
Air path
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WKH DLU OWHUV7KH DLU LV WKHQ GLUHFWHG YLD WKH VXFWLRQ UHJXODWRU LQWR WKH
FRPSUHVVRUVWDJHZKHUHLWLVFRPSUHVVHGWRWKHQDOFRPSUHVVLRQSUHVVXUH
WRJHWKHUZLWKLQMHFWHGFRROLQJXLG
,QWKHFRROLQJXLGUHVHUYRLUWKHFRPSUHVVHGDLULVVHSDUDWHGIURP
WKHFRROLQJXLGDQGWKHGRZQVWUHDPFRROLQJXLGVHSDUDWRUUHPRYHVWKH
UHPDLQLQJFRROLQJXLGIURPWKHFRPSUHVVHGDLU7KHDLUWKHQRZVYLDWKH
minimum pressure non-return valve into the compressed air aftercooler and
is cooled down to 10 - 15 C above the ambient temperature before it leaves
the compressor through the compressed air connection.
The suction regulator opens shortly after the compressor has started up for
generating compressed air. It closes when the compressor changes over
to off-load operation and/or comes to a standstill and unloads the system
via the relief valve.
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7KH FRROLQJ XLG LV VSUD\HG LQWR WKH DLU HQG DQG KDV WKH IROORZLQJ IXQFtions:
sealing lubrication of the rotors to each other and to the housing with a
FRROLQJXLGOP
bearing lubrication
noise dampening
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KRWFRROLQJXLGUHWXUQDLUPL[WXUH
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WDQNE\WKHFRROLQJXLGVHSDUDWRUDQGZKHQVHSDUDWHGLWRZVWRWKHFRROLQJXLGKHDWH[FKDQJHU7KHFRROLQJXLGWHPSHUDWXUHUHJXODWRUPL[HVWKH
FRROHGGRZQFRROLQJXLGZLWKWKHFRROLQJXLGKHDWH[FKDQJHUE\SDVVKRW
FRROLQJXLGDVGHQHGE\WKHVHWSRLQWWHPSHUDWXUH)LQDOO\WKHFRROLQJXLG
OWHUFOHDQVWKHFRROLQJXLGEHIRUHLWLVDJDLQLQMHFWHGLQWKHDLUHQG
,I GHVLUHG E\ WKH FXVWRPHU DQ DGGLWLRQDO KHDWHU FDQ EH LQVWDOOHG LQ WKH
VHSHUDWRUWDQNHLWKHURULJLQDOO\RUVXEVHTXHQWWRSXUFKDVH,WSUHYHQWVFRQGHQVDWLRQGDPDJHLQWKHFDVHRIFROGRUGDPSFRPSUHVVRUHQYLURQPHQWV
for example.
2.4
Cooling
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cooled either by
water cooling.
2. Functional description
2.5 Flow diagram
10
2.6
Components
05
01
15
02
12
19
20
10
09
19
12
20
04
01
05
07
02
2.7
Legend
01 Switching cabinet
02 Electric motor
03 Coupling
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05 Suction regulator
06 Compressor level
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08 Safety valve
09 Drain
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11 Additional heater (optional)
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13 Minimum pressure non-return
valve
14 Relief valve
15 Compressed air after-cooler
11
3OHDVHVWRUHWKHV\VWHPRQO\LQDGU\IURVWIUHHURRP
Always transport the system in its normal operating orientation in a pressure-free state. Tilting or laying the system down is not allowed.
12
13
4. Installation
4.1
Setting up
2SHQDPHRUUHDVZHOODVZHOGLQJZRUNLQWKHYLFLQLW\RIWKHV\VWHP
are forbidden!
DANGER
4.2
Ventilation
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for compressor cooling.
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6XSSO\ UHTXLUHG FRROLQJ DLU DPRXQWV DV GHQHG LQ &KDSWHUG DQG
9.3
5HPRYHH[KDXVWDLUDVGHQHGLQ&KDSWHULQRUGHUWRSUHYHQWDKHDWing up of the compressor site
7KHFRROLQJDLUPXVWEHFRROGU\DQGGXVWIUHH
The temperature of the aspired cooling air must be within the range of
+5C to +40C.
,QWKHFDVHRIDVSLUDWLRQIURPRXWVLGHSURYLGHDUHFLUFXODWLRQDS
14
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PL[WXUHVVWHDPGXVWRUDJJUHVVLYHSROOXWDQWV
0DNHFHUWDLQWKDWWKHSODFHRILQVWDOODWLRQLVGXVWIUHHDVZHOODVZLWKLQ
the prescribed operating temperature limits and as cool as possible. If
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OWHULQJURRPFRROLQJRUKHDWLQJ
NOTICE
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4.3
Forced ventilation
(optional)
15
4. Installation
4.4
)RUZDWHUFRROHGSODQWVWKHWHPSHUDWXUHRIWKHFRPSUHVVHGDLUDIWHUFRROHU
RIWKHFRROLQJXLGKHDWH[FKDQJHULVORZHUHGZLWKH[WHUQDOFRROLQJZDWHU
)RUFRROLQJZDWHUTXDQWLWLHVWHPSHUDWXUHVDQGFRQQHFWLRQV
see chapter 9.
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3UHOWUDWLRQZLWKDPHVKZLGWKRIDWOHDVWPP
3+
7RWDOKDUGQHVVP0ROO
IRUSRWDEOHZDWHUVDIHW\KHDWH[FKDQJHUZLWKEORFNLQJPHGLXP
16
:DWHUDPRXQWVWHPSHUDWXUHVDQGSUHVVXUHVVHH&KDSWHU
The heat recovery is to be connected appropriately (see drawing in Chapter
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7KHZDWHUIRUKHDWUHFRYHU\PXVWIXOOOWKHIROORZLQJFULWHULD
pressure of up to 10 bar
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4.6
DANGER
4.7
Electrical connections
During load switching in the compressed air net, the hose can move
suddenly and with great force. Therefore the hose must be adequately
DQFKRUHGRU[HG
in Chapter 9
17
DANGER
5.2
Emergency OFF
The units main switch that is installed on the control cabinet connects or
disconnects the unit to and from the power supply.
The compressor main switch must be switched off for all service or
installation work and protected from illicit or accidental switching
RQHJDI[DZDUQLQJVLJQWRWKHPDLQVZLWFKIRUELGGLQJLWVEHLQJ
turned on)!
The system may be stopped with EMERGENCY OFF in the case of a real
emergency!
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6WRSWKHPRWRULQFDVHRIGDQJHUSUHVVNH\
0DNHVXUHWKDWWKHVKXWGRZQV\VWHPLVVXIFLHQWO\SURWHFWHGDJDLQVW
recommissioning!
DANGER
Enable the system only when the cause of danger has been professionally removed and a securely operating state is achieved.
Enable system:
1. switch main switch off and on.
18
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WRDFNQRZOHGJHWKHPDOIXQFWLRQ
SUHVVNH\
5.3
7KHRSHUDWLQJGLVSOD\GHVNRIWKH$LU&RQWURO
)XQFWLRQNH\V
0RGLFDWLRQRISDUDPHWHUYDOXHV
Selection of sub-menus
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Editing modes in the sub-menus
Display additional operation data.
Switch on compressor.
Integrated green LED
%OLQNLQJ
FRPSUHVVRULVQRWUXQQLQJFDQDWDQ\WLPH
be automatically started up.
Lighted:
Compressor is running.
19
$IWHUVZLWFKLQJRQWKHPDLQVZLWFKRUGXULQJQRUPDORSHUDWLRQ$LU&RQWURO
3 will inform you about the plant condition.
Supplymentary information
Momentary
FRPSUHVVLRQQDO
temperature
Supplementary information:
Switching times are programmed
6\PERODVKHV Compressor was switched off by
the timer
Symbol ON: Compressor was switched on by the
timer
5.3.4.4
5.3.4.4
$QWLIUHH]HDFWLYHFRPSUHVVRUGRHVQRWVWDUWXS
RESTART
5.3.4.2
REMOTE
5.3.4.7
LLC MODE
5.3.4.7
AUTOMATIC
OPT.
20
)RUWKHGXUDWLRQRIWKHVWDQGVWLOOWLPHWKHFRPSUHVVRUVZLWFKHVWRWKHLGOLQJ
state and afterwards off.
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WKHIXQFWLRQNH\V
Mode 1 = reservation 1
Capacity utilization
Service
Plant pass
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and
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IXQFWLRQNH\VLQWKHEDVLFGLVSOD\FDQEHFKDQJHG
Mode 2 = reservation 2
Diagram
net pressure
21
Diagram
air amounts
GDLO\SUROH
Diagram
compression
temperature
Diagram
air amounts
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%\SUHVVLQJWKHGHQHGIXQFWLRQNH\WKHUHVSHFWLYHLQIRUPDWLRQVFUHHQLV
opened.
7KHNH\
5.3.3
7KLVGLDJUDPUHSUHVHQWVWKHUXQQLQJRIIORDGRQORDGDQGVWDQGVWLOOKRXUV
in the form of bar diagrams. The respective current hour count is also displayed in the bars.
Example:
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left and growing to the right. The sum of the on-load hours and the off-load
hours yields the total service hours.
The scaling units of this diagram are according to the service hours. If the
QXPEHURIWKHVWDQGVWLOOKRXUVLVJUHDWHUWKDQWKHVHUYLFHKRXUVWKHEDUV
of the standstill hours will be cut off. In this case note the displayed hour
count in the bars.
5.3.3.2 Service
(Mode 1 - F3)
Change of mode
The Service diagram shows the remaining time in hours until the respective
service interval is due.
5.3.3
$LUOWHU
&RROLQJXLGOWHU
&RROLQJXLGVHSDUDWRU
Motor lubrication
Compressor
22
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This display is only available if Lead lag control was activated by selecting YES in the Lead lag control menu (see Chapter 5.3.4.8).
5.3.3
This display shows the status of 4 additional compressors (K2 - K4) when
RQHDGGLWLRQDO//&PRGXOHLVXVHGRUDGGLWLRQDOFRPSUHVVRUV..
when two additional LLC modules are used.
On-load
Off-load
Ready for operation
Fault
The individual machine data stored in the compressor pass are required for
our customer service.
5.3.3
23
5.3.3
,QWKLVGLDJUDPWKHFXUUHQWSURFHVVRIWKHQDOFRPSUHVVLRQWHPSHUDWXUH
is displayed.
5.3.3
,QWKLVGLDJUDPWKHFXUUHQWSURFHVVRIWKHQHWSUHVVXUHVLVGLVSOD\HG
,QWKLVGLDJUDPWKHFXUUHQWSURFHVVRIWKHFRPSUHVVHGTXDQWLW\IRUDGD\
is displayed.
5.3.3
24
5.3.3.8 Diagram compressed air
DPRXQWVZHHNSUROH
(Mode 2 - F4)
Change of mode
5.3.3
,QWKLVGLDJUDPWKHFXUUHQWSURFHVVRIWKHFRPSUHVVHGDLUTXDQWLW\IRUD
ZHHNLVGLVSOD\HG
The scale divisions of the axis can be changed by editing the axis values.
5.3.4.6
y-axis:
x-axis:
,Q WKH GLDJUDP DLU TW\ZN WKH [D[LV YDOXHV FDQQRW EH
FKDQJHGFKDQJHVDUHSRVVLEOHLQDOORWKHUGLDJUDPV
$IWHUHGLWLQJWKH[D[LVYDOXHVWKHGLDJUDPLVQRORQJHUFRQtinually updated.
X-AUTO:
7KHNH\
,I;$87221WKHYDOXHVRIWKH[D[LVDUHDXWRPDWLFDOO\
XSGDWHG7KH;$872XVHVWKHSUHVHWGHIDXOWYDOXHVGHQHG
in the menu Display parameter diagrams (see Chapter
5.3.4.6).The manual editing x-axis values are deleted.
6HOHFWLRQRIWKHD[LVYDOXHVWREHFKDQJHGZLWKWKHNH\V
and
&RQUPDWLRQRIWKHVHOHFWLRQZLWKENTER
0RGLFDWLRQRIWKHEOLQNLQJYDOXHZLWK
Moving the cursor with
and
and
&RQUPDWLRQRIWKHPRGLFDWLRQVZLWKENTER.
7KHNH\ X/Y-Init is for resetting the scale division for the default values
preset in X-AUTO.
7KH NH\
ldeletes the recorded measurement values of the currently
displayed time diagram.
25
5.3.4.1
5.3.4.2
5.3.4.3
5.3.4.4
5.3.4.5
5.3.4.6
5.3.4.8
5.3.4.9
5.3.4.10
All basic settings of the system can be viewed in the menu system. If the
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by means of a code entry.
After pressing the INFO NH\WKHPDLQPHQXDSSHDUVUHTXHVWLQJWKHFRGH
entry.
0RGLFDWLRQRIWKHEOLQNLQJYDOXHVZLWKWKHNH\V
Moving the cursors with
and
and
&RQUPDWLRQRIWKHPRGLFDWLRQVZLWKENTER.
7KHUHDIWHUWKHPDLQPHQXDSSHDUVZLWKWKHIROORZLQJVXEPHQXV
26
7KHVXEPHQXFDQEHVHOHFWHGZLWKWKHNH\V
FRQUPHGZLWKENTER.
,QHYHU\RSHUDWLQJOHYHO
vel.
and
.The selection is
If the Code 0001 LV HQWHUHG WKH SDUDPHWHUV RI WKH VXEPHQX VKRXOG EH
changed as follows:
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and
.
7KHVHOHFWLRQLVFRQUPHGZLWKENTER.
0RGLFDWLRQRIWKHEOLQNLQJYDOXHZLWKWKHNH\V
Moving the cursor with
and
and
&RQUPDWLRQRIWKHPRGLFDWLRQVZLWKENTER.
Can be edited
Stop pressure
Can be edited
Safety pressure
Display
Display
Display
27
7KLVPHQXFRQWDLQVSDUDPHWHUVZKLFKLQXHQFHWKHWHPSRUDOUHJXODWLRQRI
the compressor:
Run-on time
Display
Off time
Run-on time of the motor for manual switching-off delay and for automatic restart
Display
Star/delta time
Star/delta time
Display
Automatic restart
Can be edited
Operating mode:
Can be edited
Display
Display
,IWKHYDOXHOLHVEHORZWKHWKUHVKROG0D[SUHVVXUHGURSWKHQWKHV\VWHP
switches off after completing the OFF time.
Max. no. of motor starts
,IWKHQXPEHURIWKHPD[LPXPSRVVLEOHPRWRUVWDUWVSHUKRXULVH[FHHGHG
then the compressor temporarily switches to the operation mode on-/offload.
,Q WKLV PHQX DOO VHUYLFH LQWHUYDOV DUH GLVSOD\HG RU DFNQRZOHGJHG DIWHU
FDUU\LQJRXWWKHVSHFLFVHUYLFHVHH&KDSWHU
5.3.4.3 Sub-menu
Service intervals
6HUYLFHZRUN
DFNQRZOHGJHG
:LWKWKHDFNQRZOHGJHPHQWWKHGLVSOD\HGUHVLGXDOWLPHIRUWKHYDOXHRIWKH
respective service intervals (see Chapter 8.1) is reset.
Service interval ASF
6HUYLFHLQWHUYDODLUOWHU
Display
6HUYLFHLQWHUYDOFRROLQJXLGOWHU
Display
6HUYLFHVLQWHUYDOFRROLQJXLGVHSDUDWRU
Display
Display
Display
Service hours
Display
Load hours
Display
Standstill hours
Display
29
7KHDGMXVWPHQWRIWKHLQWHJUDWHGUHDOWLPHFORFNDVZHOODVDOOVZLWFKLQJ
processes dependant upon it are in this menu.
Date/time
Edit
Compressor switching
times
Edit
Compressor pressure
times
Edit
Edit
Edit
7LPHUFORFNRXWSXWDFWLYH
0R7KXQWLORFORFN
)UXQWLORFORFN
30
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set to ON in the highest menu line.
If the timer channel is set to ON and
LIWKHWLPHUFORFNRXWSXWLVDFWLYDWHGDFORFNDSSHDUVLQWKHGLVSOD\
LIWKHWLPHURXWSXWLVQRWDFWLYDWHGDEOLQNLQJFORFNDSSHDUVLQWKHGLVplay
Seven switching times with the channels K1 K7 can be programmed.
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RUGHUWRFRQWLQXRXVO\DFWLYDWHWKHWLPHURXWSXWIRURQHRUDQXPEHURIGD\V
the switching time should be set to 00:00.
$GMXVWVZLWFKLQJWLPHVZHHNGD\VPDUNHGEODFN
&KDQQHOVHOHFWLRQZLWKWKHNH\V
and
&RQUPVHOHFWLRQZLWKENTER.
0RYHWKHFXUVRUWRWKHGHVLUHGZHHNGD\E\XVLQJNH\
and
RUGHUWRGHOHWHDQDOUHDG\VHOHFWHGZHHNGD\SUHVVNH\
.)
. (In
and
6WRUHWKHVHWWLQJVZLWKWKHNH\ENTER.
If the timer for switching times is activated, then the compressor only
works during the switching times entered!
NOTICE
Compressor pressure times
,QWKLVPHQXWKHSUHVVXUHWLPHVRIWKHFRPSUHVVRUVDUHGHQHGLQFUHDVLQJ
pressure / decreasing pressure).
7LPHUFORFNRXWSXWDFWLYH
6D6RXQWLORFORFN
IURP6DRFORFNXQWLO6XRFORFN
,QRUGHUWRDFWLYDWHWKHWLPHUWKHXSSHUPRVWPHQXURZRIWKHSDUDPHWHUIRU
the timer channels must be set to ON.
$FKDQQHOLVDFWLYHZKHQDWOHDVWRQHRIWKHZHHNGD\VLVPDUNHGEODFN
(For switching times adjustment: see paragraph Compressor switching
times)
The channels are searched beginning with K1 to K7 to determine whether a
FKDQQHOLVDFWLYDWHGIRUWKHFXUUHQWFORFNWLPH,IQRYDOLGFKDQQHOLVIRXQG
then the settings in the menu limit values are valid. In order to activate the
WLPHURXWSXWIRURQHRUDQXPEHURIGD\VFRQWLQXRXVO\WKHVZLWFKLQJWLPH
of 00:00 should be entered.
Switching times LLC /pressure times LLC
Switching times or pressure times can only be entered if the supplementary
module for Lead lag control (LLC) is installed in the control system.
The settings are to be carried out as described in Compressor switching
times or Compressor pressure times
31
,QWKLVPHQX\RXFDQYLHZWKHODVWVHUYLFHVZDUQLQJVDQGIDXOWVZLWK
indication of the date and time.
5.3.4.6 Sub-menu
Display parameters
,QWKLVPHQXWKHSDUDPHWHUVIRUWKHRXWSXWWRWKHGLVSOD\DUHVWRUHG
Pressure dimension
Edit
Temperature dimension
Edit
Language
Edit
Pressure offset
Display
Diagrams
Edit
Texts
Display
Diagrams
,QWKLVPHQXWKHGLVSOD\SDUDPHWHUVGHIDXOWYDOXHV;$872VHH&KDSWHU
5.3.3.8) for the diagrams can be set:
32
Saving interval
6DYLQJLQWHUYDOIRUWKHUHFRUGLQJRIWKHOLQHSUHVVXUHWKH
QDOFRPSUHVVLRQWHPSHUDWXUHRIWKHPRPHQWDU\GHOLYHU\
quanitiy. The control system always saves the most recent
8000 values. For a saving interval of 12s (basic setting) there is a logging duration of 12s x 8000 = 96000s = 26.7h
Number of
points X-auto
Line pressure
low
Line pressure
high
Temperature low
Temperature
high
Air quantity
ZHHNORZ
Air quantity
ZHHNKLJK
5.3.4.7 Sub-menu
&RQJXUDWLRQ
Selection of the menu position
0RGLFDWLRQRIWKHEOLQNLQJ
values
ENTER &RQUPVHOHFWLRQPRGLFDWLRQ
%DFNWRWKHQH[WKLJKHUOHYHO
Machine type
6HOHFWLRQRIDSUHGHQHGPDFKLQHW\SH
Display
Maximal pressure
Display
0D[LPDODLURZ
Display
Remote mode
Edit
LLC operation
Edit
Display
Frequency converter
Display
Communication
Display
Heating
Display
Remote mode
Determines how the compressor is switched on or off.
Local operation: The compressor can only be switched on or off at the opeUDWLQJGLVSOD\GHVNRI$LU&RQWURO
Remote control: The compressor can be switched on or off with an electriFDOVLJQDORUWKHNH\
,QWKHEDVLFGLVSOD\DSSHDUVDVWKHEOLQNLQJWH[W
REMOTE.
During active remote operation, the signal of the remote control must
be switched off after pressing the key
.
NOTICE
//&2.,VIRUWKHQRWLFDWLRQRIUHDGLQHVVIRURSHUDWLRQRIDVXSHULRUFRQWURO
system to the compressor. (see also LLC Operation 5.3.4.9)
33
LLC mode
The compressors are controlled by a higher-level control system. The
text LLC MODE (see also Remote Mode 5.3.4.9) appears in the basic
display
This menu contains the settings for the operation as the LLC Master.
)RUWKHXWLOL]DWLRQRIWKHIXQFWLRQ/HDGODJFRQWURO$LU&RQWUROPXVWEH
WWHGZLWK
The LLC master function may only be activated when the compressor
is actually used as master unit!
NOTICE
Display
Start pressure
Edit
Stop pressure
Edit
Cut out at
3HUFHQWDJHRIPDVWHUPDFKLQHSRZHU
below which slave compressors are
cut out
Edit
Cut in at
3HUFHQWDJHRIPDVWHUPDFKLQHSRZHU
above which slave compressors are
cut out
Edit
Start delay
Edit
Stop delay
Edit
Changeover interval
Priority 1
Edit
Changeover interval
Priority 2
Edit
Changeover interval
Priority 3
Edit
Priorities
Edit
34
Display
,QSXWFRQJXUDWLRQ
Edit
2XWSXWFRQJXUDWLRQ
Edit
6ZLWFKLQJWLPHVGHQHGIRUDFFHVVRULHV
Edit
6ZLWFKLQJWLPHVGHQHGIRUDFFHVVRULHV
Edit
6ZLWFKLQJWLPHVGHQHGIRUDFFHVVRULHV
Edit
6ZLWFKLQJWLPHVGHQHGIRUDFFHVVRULHV
Edit
Switching times
7KHVZLWFKLQJRQRIIWLPHVRIDQDFFHVVRU\UHOD\RXWSXWDUHGHQHGLQWKLV
menu.
7LPHUFORFNRXWSXWDFWLYH
0R7KXQWLORFORFN
)UXQWLORFORFN
)RUWKHDFWLYDWLRQRIWKHWLPHUWKHXSSHUPRVWPHQXURZRIWKHSDUDPHWHU
of the timer channels must be set to ON.
Seven switching times can be programmed with the channels K1 K7. One
FKDQQHOLVDFWLYHZKHQDWOHDVWRQHRIWKHZHHNGD\VLVPDUNHGEODFN
)RUDGMXVWPHQWRIWKHVZLWFKLQJWLPHVVHHSDUDJUDSK&RPSUHVVRUVZLWFKing times Chapter 5.3.4.4.
,QRUGHUWRFRQWLQXDOO\DFWLYDWHWKHWLPHURXWSXWIRURQHRUDQXPEHURIGD\V
set the switching time to 00:00.
,QSXWFRQJXUDWLRQ
The inputs 1 to 8 can be used in order to switch the compressor to malfunction or warning.
35
This menu describes the current states of digital inputs and outputs.
$ZDUQLQJLVSUHVHQWZKHQWKHUHGOLJKWLVEOLQNLQJ
The compressor is not switched off.
The display contains the additional information:
EOLQNLQJV\PEROZDUQLQJWULDQJOH
type of warning
:KDWWRGRIRUVSHFLFZDUQLQJVPDLQWHQDQFHZRUNLVGHVFULEHGLQ
Chapter 8.
$FNQRZOHGJHWKHVHZDUQLQJVRQO\ZKHQWKHGHQHGPDLQWHQDQFHZRUN
has actually been carried out!
Maintenance work not carried out degrades the service life and reliability of the system. Please note that damage because of improper
usage might invalidate the warranty!
Only original spare parts may be used.
Information on service: see Chapter 8.
6HUYLFHVZRUNDFNQRZOHGJHG
$VGHVFULEHGLQ&KDSWHUFDOOXSWKHPDLQPHQXDQGWKHQWKHVXE
menu Maintenance schedule.
36
6HOHFWWKHPDLQWHQDQFHZRUNWREHFDUULHGRXWXVLQJNH\V
3UHVVNH\
WRDFNQRZOHGJHWKHVHUYLFH
%\GRXEOHFOLFNLQJNH\
and
5.3.6 Malfunctions
EOLQNLQJV\PEROWRRONH\
type of malfunction
SUHVVNH\
37
The display contrast of the control was selected so that it ensures optimum
readability under nearly all operating conditions. If it is nevertheless required
to adjust the contrast under certain conditions (e.g. unfavourable lighting
FRQGLWLRQVGLUHFWVXQOLJKWIROORZWKHVWHSVEHORZ
Insert a small plain slot screwdriver through this opening to reach the adjustment screw for correcting the contrast.
7RLQFUHDVHWKHFRQWUDVWVOLJKWO\WXUQFORFNZLVHE\WXUQLQJFRXQWHUFORFNZLVH\RXUHGXFHWKHFRQWUDVW
5. Close the control cabinet/control box before recommissioning.
38
5.4
Air Control 1
7KHRSHUDWLQJGLVSOD\GHVNRI$LU&RQWURO
0RGLFDWLRQRISDUDPHWHUYDOXHV
&RQUPDWLRQRISDUDPHWHUFKDQJHV
FRPSUHVVRULVQRWUXQQLQJFDQDWDQ\WLPH
be automatically started up.
Lighted:
Compressor is running.
39
$IWHUVZLWFKLQJRQWKHPDLQVZLWFKRUGXULQJQRUPDORSHUDWLRQ$LU&RQWURO
1 will inform you about the compressor state.
Current pressure
Motor is running
AUTOMATIC
REMOTE
- Flashing:
- Continuous:
40
Instead of the current compressor temperature you can also have the curUHQWFRROLQJXLGWHPSHUDWXUHGLVSOD\HG3UHVVNH\
RSHUDWLQJGDWDVHH&KDSWHU
the current line pressure falls below the start pressure and
)RU WKH GXUDWLRQ RI WKH RII WLPH WKH FRPSUHVVRU VZLWFKHV WR WKH RIIORDG
state and afterwards off.
'XULQJWKHVZLWFKLQJRIISURFHVVWKHXQLWUVWFKDQJHVRYHUWRWKHRIIORDG
PRGHPRWRUUXQQLQJEXWFRPSUHVVRUGRHVQRWFRPSUHVVDLUDDVKLQJ
point appears in the display) for the duration of the off time (45 s). Only
then is the unit switched off (motor stops).
5.4.3 Viewing additional operating data
Operating data
1x
2x
3x
4x
5x
6x
7x
[
[
[
11x
12x
NOTICE
41
All basic settings of the system can be viewed in the menu system. If the
PRGLFDWLRQVKDYHQRLQXHQFHRQRSHUDWLRQDOVDIHW\WKH\PD\EHPRGLHG
by means of a code entry.
7KHXQLWFDQRQO\EHSDUDPHWHULVHGZKHQWKHJHQHUDWLRQRIFRPSUHVVHG
air is switched off. See Chapter 5.4.2.
3DUDPHWHUVDOORZWKHXQLWWREHDGMXVWHGWR\RXUVSHFLFUHTXLUHPHQWV7R
WKLVHQG$LU&RQWUROPXVWEHVZLWFKHGWRWKHSDUDPHWHULVDWLRQPRGH
The individual parameters can be selected with a code and then changed.
A description of available code numbers can be found in Chapters 5.4.4.3
to 5.4.4.13.
Paremeterisation procedure:
3UHVVNH\ until the message cod appears in the display. Air Control
1 is now at the main level of the parameterisation mode.
Code
DVKLQJ
1RZVHOHFWWKHUHTXLUHGFRGHE\PHDQVRINH\V
and
3. Press ENTERWRDFWLYDWHWKHFRGH$LU&RQWUROFKDQJHVWRWKHUVW
sub-level.
42
With some codes, several parameters can be entered one after the other.
In these cases, simply press key ENTER to select the subsequent parameter.
to leave
7KHXQLWFDQRQO\EHSDUDPHWHULVHGZKHQWKHJHQHUDWLRQRIFRPSUHVVHG
air is switched off. See Chapter 5.4.2.
3UHVVNH\
6HOHFWFRGHE\PHDQVRINH\V
and
DQGSUHVVNH\ENTER.
3UHVVNH\INFO.
&RGHDVKLQJ
Air Control 1 now shows the start pressure. The compressor compresses
air as soon as the line pressure falls below this value. Possible adjustment range: 3.5 to maximum pressure of the unit.
$GMXVWWKHUHTXLUHGVWDUWSUHVVXUHXVLQJNH\V
VHWWLQJE\SUHVVLQJNH\ENTER.
and
FRQUPWKH
3UHVVNH\INFO.
6WDUWSUHVVXUHDVKLQJ
Air Control 1 shows the stop pressure. The compressor changes over
to off-load operation as soon as the line pressure exceeds this value.
Possible adjustment range: 3.5 to maximum pressure of the unit.
The stop pressure must be higher than the start pressure!
6HOHFWWKHUHTXLUHGSDUDPHWHUYDOXHXVLQJNH\V
WKHVHWWLQJE\SUHVVLQJNH\ENTER.
3UHVVNH\
6WRSSUHVVXUHDVKLQJ
and
DQGFRQUP
43
Determines how the unit is to respond when the start or stop pressure
is reached. Both limit values are set during basic parameterisation (see
Chapter 5.4.4.2).
0: Automatic.
The symbol Automatic appears in the display.
The motor starts up and the compressor compresses air (= on-load
RSHUDWLRQDVVRRQDVWKHOLQHSUHVVXUHIDOOVEHORZWKHVWDUWSUHVVXUH
7KH XQLW FKDQJHV RYHU WR RIIORDG RSHUDWLRQ PRWRU UXQQLQJ EXW WKH
FRPSUHVVRUGRHVQRWFRPSUHVVDLUDVVRRQDVWKHOLQHSUHVVXUHH[FHHGVWKHVWRSSUHVVXUH$VVRRQDVWKHRIIORDGSKDVHVWDUWVWKHRII
WLPHHODSVHVIRUWKHSDUDPHWHULVDWLRQVHH&RGH&KDSWHU
The motor stops after the off time.
1: On-/off-load
The symbol Automatic is not shown in the display.
,QFRQWUDVWWRWKHDXWRPDWLFRSHUDWLQJPRGHWKHPRWRUQHYHUVWRSVUXQning. The compressor compresses air as soon as the line pressure falls
below the start pressure. The unit changes over to off-load operation
PRWRULVUXQQLQJEXWWKHFRPSUHVVRUGRHVQRWFRPSUHVVDLUDVVRRQ
as the line pressure rises above the stop pressure.
2: Automatic optional
The symbol Automatic and an additional dot before the temperature
are shown in the display.
6LPLODUWRWKHDXWRPDWLFPRGH+HUHWKHXVHUKDVDQLQXHQFHRQKRZ
RIWHQWKHPRWRUVWRSV7RWKLVHQGWKHSDUDPHWHUVPD[LPXPSUHVVXUH
loss (adjustment range 0.0 to 9.9 bar) and max. number of motor starts
(adjustment range 1 to 55 cycles/hour) are queried additionally.
44
Determines whether the generation of compressed air is to restart automatically after a mains power failure.
0: Automatic restart: OFF
The generation of pressure remains deactivated after a power failure.
The fault message power fail is output.
1: Automatic restart: ON
:KHQ WKLV IXQFWLRQ LV DFWLYDWHG WKH GLVSOD\ VKRZV WKH V\PERO UHstart.
If the generation of pressure was activated before the power failure
RFFXUHGWKHXQLWUHVWDUWVDXWRPDWLFDOO\DIWHUWKHRIIWLPH,QWKLVFDVH
the fault message power fail is not output. If the generation of pressure
ZDVGHDFWLYDWHGEHIRUHWKHSRZHUIDLOXUHLWUHPDLQVGHDFWLYDWHG
'HWHUPLQHVKRZWKHJHQHUDWLRQRISUHVVXUHLVWREHVZLWFKHGRQDQGRII
0: Local control
The generation of compressed air can only be switched on or off from
the control panel of Air Control 1.
1: Remote control
The generation of compressed air can be switched on only by way of a
positive edge (24 VDC) at terminal 23 and switched off only by means of
DORZOHYHO9DWWHUPLQDORUE\SUHVVLQJNH\ . This functionality
LVVLJQDOOHGRQWKHGLVSOD\RI$LU&RQWUROE\DDVKLQJWH[W5HPRWH
If the
NH\LVORFDOO\RSHUDWHGRQWKHXQLWWKHXQLWVZLWFKHVRIIDIWHU
VHFRQGVDQGIRUVDIHW\UHDVRQVFDQRQO\EHUHVWDUWHGE\UHPRWH
NH\ZDVRSHUDWHGORFDOO\DFNQRZOHGJHPHQW7KLV
control after the
also applies to a start via PLANT CONTROL V/T.
2: LLC-OK
The input at terminal 23 is used to signal the readiness for operation
of an external control. The external control can only be switch between
on-load and off-load operation when a high level (24 VDC) is applied
VHHFRGHYDOXH&KDSWHU:KHQDORZOHYHOLVDSSOLHG
LLC operation is automatically switched off and the internal pressure
sensor used.
45
5.4.4.6 Code 11: Start and stop
pressure
'HWHUPLQDWLRQRIWKHVWDUWDQGVWRSSUHVVXUHVIRUWKHSURFHGXUHVHH&KDSter 5.4.4.2
Determines whether the changeover between on-load and off-load operation is to be controlled by the internal pressure senor or by a higher-level
control.
0: Changing over between on-load/off-load operation by internal pressure sensor
1: Changing over between on-load/off-load operation by external
control (e.g. PLC)
On-load operation when a high level (24 VDC) is applied to terminal 22.
Off-load operation when a low level (0 V) is applied to terminal 22. This
functionality is signaled by the text remote that appears continuously
in the display of Air Control 1.
,VXVHGIRUDFNQRZOHGJLQJDPDLQWHQDQFHZDUQLQJFXUUHQWO\SUHVHQW)RU
WKHPHDQLQJRIPDLQWDLQHQFHQXPEHUVDQGDFNQRZOHGJHPHQWRIZDUQLQJV
see Chapter 5.4.5.
Possible damage to the unit!
Required maintenance work is signalled in the form of warnings.
NOTICE
46
0: Off-load time
Adjustment range: 10 - 1200 s. Operation in conjunction with Code
2 (operating mode). Is used in the operating modes Automatic and
Automatic optional.
1: Off time
Adjustment range: 0 - 60 s. The factory setting of 45 s should be retained.
'XULQJWKHRIIWLPHWKHPRWRULVUXQQLQJLQWKHLGOHPRGHQRFRPSUHVVHG
air is generated. The off time elapses
is pressed for switching off
ZKHQNH\
according to the Automatic optional mode
:KHQWKHIXQFWLRQ$XWRPDWLFUHVWDUWDIWHUSRZHUIDLOXUHLVVHOHFWHG
the start-up of the motor is delayed for the set time of standstill.
2: Star/delta time
Adjustment range: 3 - 30 s. Determines after which time changing over is
WRWDNHSODFHIURPVWDUWRGHOWDFLUFXLWZKHQWKHPRWRULVVZLWFKHGRQ
,VXVHGIRUDGMXVWLQJWKHLPSXOVHDQGEUHDNWLPHVRIWKHFRQGHQVDWHYDOve.
0: Impulse time
Duty cycle of the condensate valve
1: Break time
Off time of the condensat valve
47
48
$ZDUQLQJLVSUHVHQWZKHQWKHUHGOLJKWLVEOLQNLQJ
The compressor is not switched off.
Maintenence number
DVKLQJ
Symbol for warnings
DVKLQJ
([FHVVLYHQDOFRPSUHVVLRQWHPSHUDWXUH
11 5HPDLQLQJWLPHXQWLODLUOWHULVWREHVHUYLFHGK
12 5HPDLQLQJWLPHXQWLOFRROLQJXLGFRROLQJXLGOWHULVWREHVHUYLFHG
K
13 5HPDLQLQJWLPHXQWLOQHVHSDUDWRULVWREHVHUYLFHGK
14 5HPDLQLQJWLPHXQWLOPRWRULVWREHOXEULFDWHGK
15 5HPDLQLQJWLPHXQWLOFRPSUHVVRULVWREHVHUYLFHGK
Damage to the system is possible!
Necessary service work appears in the form of warnings.
NOTICE
$FNQRZOHGJHWKHVHZDUQLQJVRQO\ZKHQWKHGHQHGVHUYLFHZRUNKDV
actually been carried out!
Service work not carried out degrades the service life reliability of the
system. Please note that damage caused by improper usage is not
covered by the warranty!
Only original spare parts may be used.
Information on service: see Chapter 8.
$FNQRZOHGJHPDLQWHQDQFHZRUN
3UHVVNH\
play.
6HOHFW&RGHXVLQJNH\V
3. Press ENTERWKHQ .
and
49
Symbol of malfunction
DVKLQJ
Fault number
DVKLQJ
Fault text
DOWHUQDWHVZLWKWKHQDO
compression temperature
Par
EPROM
Lo AC
Undervoltage
No AC
Power failure
OEFEC
Emerg
Rotat
Mot t
Hi cur
Overcurrent
10
Hi P
Overpressure
11 'LI3
'LIIHUHQWLDOSUHVVXUHRIQHVHSDUDWRU
12 6HW
6HQVRUIRUQDOFRPSUHVVLRQWHPSHUDWXUH
13 6HRLO
6HQVRUIRUFRROLQJXLGWHPSHUDWXUH
14
Se P
15 +LW
50
16
Pressure sensor
([FHVVLYHQDOFRPSUHVVLRQWHPSHUDWXUH
Hi P
SUHVVNH\
The display contrast of the control was selected so that it ensures optimum
readability under nearly all operating conditions. If it is nevertheless required
to adjust the contrast under certain conditions (e.g. unfavourable lighting
FRQGLWLRQVGLUHFWVXQOLJKWIROORZWKHVWHSVEHORZ
Insert a small plain slot screwdriver through this opening to reach the adjustment screw for correcting the contrast.
7RLQFUHDVHWKHFRQWUDVWVOLJKWO\WXUQFORFNZLVHE\WXUQLQJFRXQWHUFORFNZLVH\RXUHGXFHWKHFRQWUDVW
5. Close the control cabinet/control box before recommissioning.
51
6. Correcting malfunctions
Error
Cause
Measures
Compression temperature
too high (red lamp is on)
&KHFNDQGVHFXUHVRXQGLQVXODWLRQ
hood
,QWDNHRUDPELHQWWHPSHUDWXUH
too high
&RROLQJDLULQOHWRURXWOHWEORFNHG
0DNHVXIFLHQWURRP
&RROLQJXLGOWHUIRXOHG
5HQHZFRROLQJXLGOWHU
,QVXIFLHQWFRROLQJXLG
$GGFRROLQJXLG
([WHUQDOFRROLQJXLGKHDWH[FKDQJHU
fouled!
Attention: Cooler screw should
DOZD\VEHZRUNHGZLWKDFRXQWHU
ZUHQFKNHHSIURPDSSO\LQJWRUTXHWR
the cooler
$LUOWHULVIRXOHG
5HSODFHDLUOWHU
&KHFNUHOLHIYDOYHLIQHFHVVDU\
replace seals
&KHFNVROHQRLGYDOYHUHJXODWRU
VSRRODQGLIQHFHVVDU\UHSODFH
/HDNDJHLQWKHSLSHZRUN
0DNHSLSHZRUNDLUWLJKW
&KHFNVDIHW\YDOYHLIQHFHVVDU\
exchange
0LQLPXPSUHVVXUHYDOYHEORFNHG
&RROLQJXLGVHSDUDWRUFDUWULGJH
fouled
([FKDQJHFRROLQJXLGVHSDUDWRU
cartridge
&RROLQJXLGVHSDUDWRUIRXOHG
5HSODFHFRROLQJXLGVHSDUDWRU
System pressure
released by safety valve
52
Error
Cause
Measures
&KHFNHOHFWULFFLUFXLWIRULQWHUUXSWLRQ
(only by a trained electrician)
$PELHQWWHPSHUDWXUHXQGHU&
message &RROLQJXLG
temperature too low
,QVWDOODQDGGLWLRQDOKHDWHURUNHHS
compressor room at right temperature
&KHFNVZLWFKLQJWLPHVDQGSUHVVXUH
times in Air Control
6\PEROUHPRWHLVEOLQNLQJ
&KHFNLIYROWDJHLVDSSOLHG
&KHFNVZLWFKLQJWLPHV
in the Air Control 3
Compressed air
containing large amount
RIFRROLQJXLGFRROLQJ
XLGFRQVXPSWLRQWRR
great)
&RROLQJXLGUHWXUQRZSLSLQJ
is congested
&OHDQFRROLQJXLGIHHGEDFNSLSLQJ
'HIHFWLYHFRROLQJXLGVHSDUDWRU
5HSODFHFRROLQJXLGVHSDUDWRU
Overtemperature or overpressure
&KHFNFXUUHQWORRS
(only by a trained electrician)
Switch on dryer
Condensation diverter
is not functioning
Bypass open
Close bypass
3UHVVXUHGLIIHUHQWLDOLQWKHOWHU
too great
([FKDQJHOWHU
53
Pressure decline
7. Initial commissioning
7.1
0DNHFHUWDLQWKDWZKHQWKHFRPSUHVVRUPDLQVZLWFKLVVZLWFKHGRIIQR
illicit or inadvertent switching on can occur.
Preparatory activities
&KHFNDOOWWLQJVRIWKHFRPSUHVVRU,IUHTXLUHGUHWLJKWHQWKHWWLQJV
0DNHFHUWDLQWKDWWKHV\VWHPLVFRUUHFWO\FRQQHFWHGWRWKHFRPSUHVVHG
DLUQHW0DNHFHUWDLQWKDWZKHQWKHVKXWRIIYDOYHRQWKHSUHVVXUHQHW
VLGHLVFORVHGLOOLFLWRULQDGYHUWHQWRSHQLQJFDQQRWRFFXU
&KHFNFRROLQJXLG
level
&KHFNFRROLQJXLGOHYHO
FRROLQJXLGUHOO
0DNHFHUWDLQWKDWHVFDSLQJFRROLQJXLGFDQEHFROOHFWHG
&KHFNWKHFRROLQJXLGOHYHORQWKHVLJKWJODVV7KHVLJKWJODVVPXVW
EHFRPSOHWHO\ZHWWHGZLWKFRROLQJXLG/RRVHQWKHOOLQJVFUHZ'RQRW
ORVHWKHVHDOULQJ:LWKQHZFRPSUHVVRUVWKHFRROLQJXLGOHYHOPXVW
EHDWWKHORZHUHGJHRIWKHOOHUQHFN
,I UHTXLUHG UHOO FRROLQJ XLG VHH &KDSWHU &KHFN FRROLQJ XLG
OHYHOUHOOFRROLQJXLG
7.3
$IWHU DQ H[WHQGHG VWDQGVWLOO WLPH IRU H[DPSOH EHWZHHQ IDFWRU\ GHOLYHU\
DQGFRPPLVVLRQLQJRUGXULQJDORQJHUFRPSDQ\YDFDWLRQWKHUHPLJKWQR
ORQJHUEHDQ\FRROLQJXLGLQWKHURWRUFKDPEHURIWKHDLUHQG7KLVFRROLQJ
XLGLVDEVROXWHO\QHFHVVDU\IRUEHDULQJDQGURWRUOXEULFDWLRQLQWKHVWDUWXS
phase.
%HIRUHVZLWFKLQJWKHFRPSUHVVRURQOODSSUR[OLWUHVFRROLQJXLG
into the compressor stage.
2. Rotate the air end only by hand in the correct direction of rotation until
WKHQRWLFHDEOHUHVLVWDQFHGZLQGOHVDQGWKHFRROLQJXLGSDVVHVWKURXJK
the air end.
54
,IQRH[WUDFRROLQJXLGLVDYDLODEOHRQO\FRROLQJXLGRIWKHVDPHYDULHW\PD\
EHHPSOR\HGWKHFRROLQJXLGFDQEHWDNHQIURPWKHFRROLQJXLGGUDLQ
If the system is employed only very irregularly or shut down weeks on end,
it should run an hour in the off-load mode once a week in order to avoid
corrosion damage caused by standing condensation.
7.4
7KHURWDWLRQDOGLUHFWLRQRIWKHFRPSUHVVRUYHQWLODWRUVPXVWEHFKHFNHG
The rotational direction of the main motor is determined by the frequency
FRQYHUWHUDQGPXVWFRQIRUPZLWKWKHDI[HGURWDWLRQDOGLUHFWLRQDUURZ
5HPRYHWKHFRYHUSDQHOVRIWKHV\VWHPVRWKDWWKHHOHFWULFPRWRURI
the ventilator is visible.
2. Switch the compressor main switch on.
6ZLWFKWKHV\VWHPRQZLWKNH\
Switch the system off again with the
ZKHQWKHYHQWLODWRUVWDUWVUXQQLQJ
,QRUGHUWRVXSSO\WKHV\VWHPZLWKVXIFLHQWFRROLQJDLUWKHURWDWLRQDOGLUHFWLRQ
of the ventilator motors must concur with the rotational direction arrow.
,QWKHFDVHRILQFRUUHFWURWDWLRQDOGLUHFWLRQRIWKHFRPSUHVVRUYHQWLODWRUV
a trained electrician should correct the phase sequence of the electrical
supply in the switching cabinet by exchanging the two supply phases. This
should be carried out in a switched-off state secured against accidental
switching on.
55
7. Initial commissioning
7.5
Basic settings
More precise instructions on the basic settings of the system can be found
in the following chapters :
&KDSWHU$LU&RQWURO
language
FDQEHPRGLHGDVGHVFULEHGLQSRVLWLRQ
The limit values
start pressure
stop pressure
FDQEHPRGLHGDVGHVFULEHGLQSRVLWLRQ
,I\RXU$LU&RQWUROKDVEHHQWWHGZLWKWKHVXSSOHPHQWDU\PRGXOH//&
carry out settings as in point 5.3.4.7 5.3.4.9 of the description.
,I\RXU$LU&RQWUROKDVEHHQWWHGZLWKWKHVXSSOHPHQWDU\PRGXOHDFFHVVRULHVFDUU\RXWVHWWLQJVDVLQSRLQWRIWKHGHVFULSWLRQ
56
)RUPRUHGHWDLOHGLQVWUXFWLRQVZLWKUHJDUGWRWKHEDVLFVHWWLQJVRIWKHXQLW
please refer to:
&KDSWHU$LU&RQWURO
&KDSWHU%DVLFGLVSOD\
&KDSWHU0HQXV\VWHP
3UHVVXUHXQLW&KDSWHU
7HPSHUDWXUHXQLW&KDSWHU
stop pressure
FDQEHVHWDVGHVFULEHGLQWKHVHFWLRQ%DVLFSDUDPHWHUVDWLRQ&KDSWHU
5.4.4.2.
7.6
7KHJUHHQ/('LQNH\
OLJKWVXSZKHQWKHFRPSUHVVRULVZRUNLQJ
&KHFNRQWKHRSHUDWLQJGLVSOD\GHVNIRUWKHOLQHSUHVVXUH
The line pressure will slowly rise if the compressed air consumption is less
than the quantities delivered by the compressors.
the current line pressure drops below the preset start pressure
RIWKHFRPSUHVVRULI
WKHPDFKLQHWHPSHUDWXUHULVHVDERYH&
WKHWLPHURI$LU&RQWUROLVDFWLYH
7.7
Concluding activities
&KHFNDOOSLSLQJRIFRROLQJOLTXLGVDQGSUHVVXUHDLUFRQGXLWVIRUOHDNage.
&KHFNWKHFRROLQJXLGOHYHORIWKHFRPSUHVVRUVDIWHUDQGEHIRUH
PLQXWHVRSHUDWLRQWLPH,IWKHFRROLQJXLGOHYHOLVWRRORZUHOOFRROLQJ
XLG DV GHQHG LQ &KDSWHU &KHFN FRROLQJ XLG OHYHO FRROLQJ XLG
UHOO
&KHFN WKH FRPSUHVVRU WHPSHUDWXUH 7KH FRPSUHVVRU WHPSHUDWXUH
should neither remain below approx. 75 C nor exceed 105 CDW
C a warning is outputDW&WKHFRPSUHVVRUis automatically shut
down.
We recommend:
WKHXVHRIPLQHUDORLORUV\QWKHWLFRLODWQDOFRPSUHVVLRQWHPSHUDWXUHV
between 75 and 90C
WKHXVHRIV\QWKHWLFRLODWQDOFRPSUHVVLRQWHPSHUDWXUHVKLJKHU
than 90C
5HWLJKWHQDOOHOHFWULFDOFRQQHFWLRQVDIWHUDZHHN
5. Carry out all service intervals according to Chapter 8 Overview of
maintenance intervals.
&KHFNWKHVWDQGDUGRSHUDWLRQRIWKHIXQFWLRQVFDUULHGRXWZHHNO\DFcording to Chapter 8 Overview of maintenance intervals
57
8. Service
8.1
Overview
Maintenance intervals
Preparatory activities
8.2
&KHFNFRROLQJXLGOHYHOUHOOFRROLQJXLG
&KHFNIRUOHDNDJH
&KHFNWKHFRPSUHVVRU
temperature
8.5
&KHFNWKHFRROHUIRUIRXOLQJ
&KHFNIRUFRQGHQVDWH
5HSODFHFRROLQJXLG5HSODFH
FRROLQJXLGOWHU
5HSODFHFRROLQJXLGVHSDUDWRU
5HSODFHDLUOWHU
&KHFNVDIHW\YDOYH
&KHFNGULYH
Lubrication of electric motor
8.13
Concluding activities
8.14
1HFHVVDU\VHUYLFHZRUNDSSHDUVLQWKHGLVSOD\DVZDUQLQJVVHH&KDSWHU
5.3.5 or 5.4.5)
Service activities
&KHFNFRROLQJXLGOHYHO
8.3
&KHFNIRUOHDNDJH
8.4
&KHFNFRPSUHVVRU
temperature
8.5
&KHFNFRROHU
for fouling
8.6
&KHFNIRU
condensate
8.7
5HSODFHFRROLQJXLG
DQGFRROLQJXLGOWHU
8.8
8.9
5HSODFLQJDLUOWHU
8.10
&KHFNVDIHW\YDOYH
8.11
&KHFNGULYH
8.12
Lubrication of motor
8.13
After the
UVW
operating
hours
Every
week
Every 2000
operating h.
but at least
once a year
General compressor
servicing
* The motor lubrication intervals are 20 000 hours for the entire series.
**7KHVSHFLHGUHSODFHPHQWLQWHUYDOVDUHUHOHYDQWIRU
normal industrial atmosphere
QDOFRPSUHVVLRQWHPSHUDWXUHRIDSSUR[&
:KHQ$/83V\QWKHWLFRLOLVXVHGWKHUHSODFHPHQWLQWHUYDOVIRUERWKFRRODQWDQGWKHFRRODQW
OWHULVH[WHQGHGWRKRXUV
This interval is relevant for:
normal industrial atmosphere
QDOFRPSUHVVLRQWHPSHUDWXUHRIDSSUR[&
Use of ALUB Syn S synthetic oil
Oil analysis after 2000 hours
8.2
Preparatory activities
58
3UHVVNH\
in order to switch off compressed air generation. Please
wait until the compressor has been switched off after a run-on or ventilation phase. The symbol M for the main motor is then no longer visible
in the display.
6ZLWFKWKHFRPSUHVVRUPDLQVZLWFKRIIDQGPDNHFHUWDLQWKDWLWFDQQRW
EHWXUQHGRQE\PLVWDNHRULQWHQWLRQDOO\HJZDUQLQJVLJQVSURKLELWLQJ
switching).
Use only original spare parts!
NOTICE
+RWVXUIDFHVKRWFRROLQJXLG
Make certain, with appropriate precaution, that no one can be burned
or scalded! Particularly note dangerous situations which can arise
IURPWKHUHOHDVHRIKRWFRROLQJXLGVWHDP
DANGER
&KHFNFRROLQJXLGOHYHO
UHOOFRROLQJXLG
Preparatory activities
Concluding activities
8.2
8.14
,IWKHFRPSOHWHVLJKWJODVVLVQRWIXOORIFRROLQJXLGFRROLQJXLGPXVWEH
added as follows:
8QVFUHZWKHOOHUVFUHZ'RQRWPLVSODFHWKHJDVNHWULQJ
59
'DPDJHWRWKHV\VWHPE\XVLQJGLIIHUHQWFRROLQJXLGV
NOTICE
'LIIHUHQWFRROLQJXLGVPXVWQRWEHPL[HG2QO\XVHRULJLQDOFRROLQJ
XLG
8VHDQDSSURSULDWHIXQQHOIRUOOLQJ&RROLQJXLGFDQEHOOHGXSWRWKH
OOLQJULPRIWKHWWLQJ
7DNHFDUHWKDWWKHVHDOLVFRUUHFWO\VHDWHGDQGVFUHZWKHWWLQJVFUHZ
closed.
Carry out the Concluding activities.
8. Service
8.4
&KHFNDOOSLSLQJDQGWKHERWWRPRIWKHV\VWHPIRUFRROLQJXLGUHVWV,IWKHUH
LVVWLOOFRROLQJXLGLQWKHV\VWHPWKHFDXVHVKRXOGEHIRXQGDQGWKHFRROLQJ
XLGUHPRYHG
Carry out the Concluding activities.
8.5
7KHFRPSUHVVRUWHPSHUDWXUHZKLFKFDQEHYLHZHGLQWKHGLVSOD\VKRXOG
be between 75 C and 105 C.
8.6
8.2
8.14
60
8.7
&RQGHQVDWLRQLQWKHFRROLQJXLGFLUFXODWLRQFDQOHDGWRGDPDJHVWR
the compressor. If you have determined that there is condensation in
the seperator tank, immediately get in touch with after-sales service!
NOTICE
6LQFHZDWHULVKHDYLHUWKDQFRROLQJXLGDIWHUH[WHQGHGVWDQGVWLOOWLPHVHJ
RQDZHHNHQGWKHFRQGHQVDWHFROOHFWVLQWKHERWWRPRIWKHVHSHUDWRUWDQNV
It can be simply drained off by the discharge drain.
Carry out the following activities only when the system has been turned
off at least overnight.
61
8. Service
&RROLQJXLGUHSODFHPHQW
UHSODFLQJFRROLQJXLGOWHU
Preparatory activities
Concluding activities
5HSODFHWKHFRROLQJXLGRQO\ZKHQWKHROGFRROLQJXLGLVVWLOOZDUP&ROG
FRROLQJXLGEHFDXVHRILWVKLJKHUYLVFRVLW\GRHVQRWRZVRZHOO
8.2
8.14
+RWVXUIDFHVKRWFRROLQJXLG
With appropriate precautions, make certain you are not burned or
scalded!
DANGER
Carry out the Preparatory activities.
8QVFUHZWKHOOHUVFUHZ'RQRWPLVSODFHWKHJDVNHWULQJ
%\RSHQLQJWKHGUDLQDOORZWKHFRROLQJXLGWRGUDLQLQWRDQDSSURSULDWH
vessel and then close the drain again.
'DPDJHWRWKHV\VWHPFDQEHFDXVHGE\GLIIHUHQWFRROLQJXLGV
'LIIHUHQWFRROLQJXLGVPXVWQRWEHPL[HG
62
NOTICE
8VHDQDSSURSULDWHIXQQHOIRUOOLQJ&RROLQJXLGFDQEHOOHGXSWRWKH
OOLQJULPRIWKHWWLQJ
7DNHFDUHWKDWWKHVHDOLVFRUUHFWO\VHDWHGDQGVFUHZWKHWWLQJVFUHZ
closed.
/RRVHQWKHFRROLQJXLGOWHUZLWKDVWUDSZUHQFKDQGUHPRYHSRVVLEOH
VHDOUHVWVIURPWKHFRROLQJXLGOWHUKRXVLQJ
/LJKWO\RLOWKHQHZVHDORIWKHFRROLQJXLGOWHUV
6FUHZWKHQHZFRROLQJXLGOWHUWRWKHVWRSDQGWLJKWHQWKHFRROLQJXLG
OWHUE\KDQGDQRWKHUKDOIDUHYROXWLRQ
7HVWWKHFRROLQJXLGOWHUIRUOHDNDJHDWRSHUDWLQJWHPSHUDWXUH
Carry out the Concluding activities.
63
8. Service
5HSODFLQJFRROLQJXLGVHparator
Preparatory activities
Concluding activities
8.2
8.14
/RRVHQWKHFRROLQJXLGVHSDUDWRUXVLQJDVWUDSZUHQFK5HPRYHSRVVLEOHVHDOUHVWVIURPWKHFRROLQJXLGVHSDUDWRUKRXVLQJ
2. Lightly oil the new seal(s) of the separator.
6FUHZWKHQHZFRROLQJXLGVHSDUDWRULQWRWKHVWRS7LJKWHQWKHFRROLQJ
XLGOWHUE\KDQGDQRWKHUKDOIDUHYROXWLRQ
7HVWWKHFRROLQJXLGVHSDUDWRUIRUOHDNDJHDWRSHUDWLQJWHPSHUDWXUH
64
5HSODFLQJDLUOWHU
Preparatory activities
Concluding activities
NOTICE
5HPRYHRUVFUHZRIIWKHROGDLUOWHU
,QVHUWWKHQHZDLUOWHU
Carry out the Concluding activities.
1. Remove the safety valve and remove residues at the threaded connection.
&KHFNWKHVDIHW\YDOYHLQDQDSSURSULDWHDSSDUDWXV
,ILWLVVWLOOZRUNLQJFRUUHFWO\DGGVHDOLQJWDSHWRWKHFRQQHFWLQJWKUHDG
RIWKHVDIHW\YDOYHVDQGVFUHZWKHVDIHW\YDOYHEDFNLQ
4. If the adequate functionality of the old safety valves can no longer be
JXDUDQWHHGVFUHZLQDVDIHW\YDOYH
Carry out the Concluding activities.
65
8. Service
8.12 Check drive
Preparatory activities
Concluding activities
1. Test manually whether the coupling might have some radial play.
,IVRORRVHQWKHFDPULQJRIWKHFRXSOLQJSXVKLWEDFNDQGUHSODFHWKH
coupling element.
3. Mount the cam ring again on the coupling half and test manually whether
the coupling now has no more radial play.
Carry out the Concluding activities.
8.2
8.14
66
2SHQWKHVWRSFRFNVORZO\RQWKHSUHVVXUHQHWVLGH
&KHFNDOOFRROLQJOLTXLGVDQGFRPSUHVVHGDLUSLSLQJIRUOHDNDJH
&KHFNDOOQHZFDUWULGJHVRUQHZO\PRXQWHGSUHVVXUL]HGFRPSRQHQWV
IRUOHDNDJHDWRSHUDWLQJWHPSHUDWXUH
7. Finally mount the side panels of the system.
&RQUPWKHPDLQWHQDQFHZRUNFDUULHGRXWE\\RXLQDFFRUGDQFHZLWK
Chapter 5.3.5 for Air Control 3 or 5.4.5 for Air Control 1.
8VHG OWHU FDUWULGJHV OXEULFDQWV VHDOV H[FHVV FRQGHQVDWH DQG HPployed cleaning materials should be considered hazardous waste and
disposed of in an environmently friendly way.
Services not carried out degrade the service life reliability of the
system. Please note that damages caused by improper usage are not
covered by the guarantee!
67
9. Technical Data
68
9.1
mm
&RROLQJXLG
OOLQJ
l
Compressed
air connection
G
795
1.170
1.270
795
1.170
ALLEGRO 24
1.270
795
1.170
ALLEGRO 28
1.270
795
1.170
1 1/2
ALLEGRO 32
1.540
795
1.170
17
1 1/2
ALLEGRO 38
1.540
795
1.170
17
1 1/2
Compressor
mm
mm
ALLEGRO 16
1.270
ALLEGRO 20
9.2
kg
Cooling air
amounts
m3/h
Intake air
opening
m2
Diameter exhaust
air canal
m2
ALLEGRO 16
387
3.300
ALLEGRO 20
387
3.300
ALLEGRO 24
405
3.300
ALLEGRO 28
405
3.300
ALLEGRO 32
545
3.300
ALLEGRO 38
555
6.000
9.3
Weight
Electrical data
Compressor
Motor
power
Currant at
400 V / 50 Hz
kW
IN
A
IFuse
A gL
ALLEGRO 16
16
34
50
ALLEGRO 20
20
41
50
ALLEGRO 24
24
46
63
ALLEGRO 28
28
59
80
ALLEGRO 32
32
55
80
ALLEGRO 38
38
65
100
IN = Nominal current
IFuse EDFNXSIXVHLQEXLOGLQJ
69
Compressor type:
Unit number:
3OHDVHTXRWHRQTXHULHVRUGHUVDQGFRUUHVSRQGHQFH
Motor number:
Vessel number:
Date of commissioning:
70
Coolant change
Operating
hours
Date
Filter change*
Name
Operating
hours
Date
7\SHRIOWHU
Name
71
&RRODQWOWHULQWDNHOWHUVHSHUDWRUOWHU
72
Date
Spare parts
Name
Date
Spare parts
Name
73
74
Date
Spare parts
Name
Date
Spare parts
Name
75
D
ALUP-Kompressoren GmbH
Tel.:
+49/7024/802-0
Fax:
+49/7024/802-106
Internet: www.alup.com
E-mail: info@alup.com
Adolf-Ehmann-Str. 2
73257 Kngen
DEUTSCHLAND
A
AGRE-Kompressoren GmbH
Tel.:
+43/7252/52341-0
Fax:
+43/7252/52133
Internet: www.agre.at
(PDLO RIFH#DJUHDW
Werkstrae 2
4451 Garsten-St. Ulrich
STERREICH
HU
ALUP Magyarorszg Kft.
Tel.:
+36/36/423444
Fax:
+36/36/516340
Internet: www.alup.hu
E-mail: info@alup.hu
Szlloda u. 5
3300 Eger
MAGYARORSZG
BG
ALUP-Kompressoren Bulgaria OOD.
Tel.:
+359/2/528032
Fax:
+359/2/528032
E-mail: alup@skycode.com
Tsar Asen Str. 63
1000 6RD
BULGARIA
Manual_ALL16_gb_01-2007
NL
ALUP-Kompressoren B.V.
Tel.:
+31/30/2809000
Fax:
+31/30/2895675
Internet: www.alup.nl
E-mail: info@alup.nl
Biezenwade 8-10
3439 NW Nieuwegein
NEDERLANDS