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Screw compressor
COMBI 3S - 5S COMBI 6 - 15 COMBI 16 - 22 COMBI 11SC / 22SC
Operating instructions
Read the instructions prior to performing any task!
2 2015-07-21
ALMiG Kompressoren GmbH Adolf-Ehmann-Straße 2 73257 Köngen Telephone: +49 7024 9614 240Fax: +49 7024 9614 209email: info@almig.de Internet: www.almig.de Help line: Telephone: +49 1805 25 87 00Fax: +49 1805 25 87 01Item no. 195.03275
Translation of the original operating instructions Almi-13257-DE COMBI
© ALMiG Kompressoren GmbH 2015
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Table of contents
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Table of contents
1 General information ............................................................... 7 1.1 Information about this manual ....................................... 7 1.2 Explanation of symbols .................................................. 8 1.3 Limitation of liability ...................................................... 10 1.4 Copyright ...................................................................... 10 1.5 Warranty terms ............................................................ 10 1.6 Customer service ......................................................... 10
2 Safety .................................................................................... 11 2.1 Proper use ................................................................... 11 2.2 Responsibility of the owner .......................................... 12 2.3 Staff requirements ....................................................... 13
2.3.1 Qualifications ................................................ 13 2.3.2 Unauthorised persons .................................. 14 2.3.3 Training ......................................................... 14
2.4 Personal protective equipment .................................... 15 2.5 Basic dangers .............................................................. 16
2.5.1 General dangers in the workplace ............... 16 2.5.2 Dangers due to electric energies ................. 17 2.5.3 Dangers due to mechanical elements .......... 18 2.5.4 Dangers due to hydraulic energies .............. 19 2.5.5 Dangers due to high temperatures ............... 21
2.6 Safety equipment ......................................................... 22 2.6.1 Position of the safety equipment .................. 22 2.6.2 Description of the installed safety devices ... 23
2.7 Securing to prevent restart .......................................... 25 2.8 Behaviour in case of fire or accidents .......................... 27 2.9 Environmental protection ............................................. 28 2.10 Signage ...................................................................... 29
2.10.1 Warning signs ............................................... 29 2.10.2 Instructions on the machine ......................... 30
3 Technical data ...................................................................... 32 3.1 Type plate .................................................................... 32 3.2 Emissions ..................................................................... 32 3.3 Coolant liquid ............................................................... 33 3.4 COMBI 3S – 5S ........................................................... 33
3.4.1 General details ............................................. 33 3.4.2 Connection values ........................................ 35 3.4.3 Operating conditions .................................... 36
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3.4.4 Lubricants .....................................................36 3.5 COMBI 6 – 15 ..............................................................37
3.5.1 General details..............................................37 3.5.2 Connection values ........................................41 3.5.3 Operating conditions .....................................42 3.5.4 Consumables ................................................42
3.6 COMBI 16 – 22 ............................................................43 3.6.1 General details..............................................43 3.6.2 Connection values ........................................45 3.6.3 Operating conditions .....................................46 3.6.4 Consumables ................................................46
4 Construction and function ..................................................47 4.1 Overview ......................................................................47 4.2 Brief description ...........................................................50 4.3 Assembly description ...................................................51
4.3.1 Controller ......................................................51 4.3.2 Sound insulation covers ...............................52 4.3.3 Drive unit .......................................................53 4.3.4 Intake filter ....................................................53 4.3.5 Compressor stage ........................................54 4.3.6 Coolant liquid tank ........................................54 4.3.7 Fine precipitator ............................................55 4.3.8 Minimum pressure and return valve .............55 4.3.9 Cooler ...........................................................56 4.3.10 Coolant liquid filter ........................................56 4.3.11 Cooling air fan ...............................................57 4.3.12 Refrigerant-type dryer ...................................57
4.4 Interfaces .....................................................................58
5 Transportation, packaging and storage .............................60 5.1 Safety instructions for transportation ...........................60 5.2 Transportation inspection .............................................60 5.3 Packaging ....................................................................61 5.4 Symbols on the packaging ...........................................62 5.5 Transportation ..............................................................62 5.6 Storage .........................................................................63
6 Installation, commissioning and operation .......................64 6.1 Safety instructions for the installation and
commissioning .............................................................64 6.2 Requirements in the installation location .....................66 6.3 Installation ....................................................................67
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6.3.1 Ventilation ..................................................... 67 6.3.2 Connection to the compressed air network .. 68 6.3.3 Connecting to the power supply ................... 69
6.4 Checking the coolant liquid level ................................. 70 6.5 Start-up lubrication of the compressor stage ............... 71 6.6 Switching on after the initial commissioning ................ 72 6.7 Working after the initial commissioning ....................... 73 6.8 Setting parameters ...................................................... 75 6.9 Measures in case of low compressed air
requirement .................................................................. 75
7 Operation .............................................................................. 76 7.1 Safety instructions for operation .................................. 76 7.2 Shutdown in emergency situations .............................. 76 7.3 Operating personnel and personal protective
equipment .................................................................... 77 7.4 Controllers .................................................................... 78
7.4.1 Controller COMBI 3S – 4S ........................... 78 7.4.2 Controller COMBI 5S .................................... 80 7.4.3 Air Control AC mini controller ....................... 81
8 Maintenance ....................................................................... 102 8.1 Safety instructions for maintenance .......................... 102 8.2 Spare parts ................................................................ 105 8.3 Maintenance schedule ............................................... 106 8.4 Maintenance work ...................................................... 108
8.4.1 Checking the electrical connections ........... 108 8.4.2 Checking the coolant liquid level/topping
up the coolant liquid ................................... 109 8.4.3 Checking for leaks ...................................... 111 8.4.4 Checking the compressor temperature ...... 112 8.4.5 Checking soiling of the cooler .................... 113 8.4.6 Checking the condensation accumulation .. 114 8.4.7 Changing the coolant liquid/changing the
cooling liquid filter ....................................... 115 8.4.8 Re-lubricating the electric motor................. 118 8.4.9 Change fine precipitator ............................. 119 8.4.10 Change intake filter .................................... 120 8.4.11 Checking the drive unit ............................... 121
8.5 Measures after maintenance has been performed .... 121
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
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9 Faults ...................................................................................122 9.1 Safety instructions for fault clearance ........................122 9.2 Fault displays .............................................................124 9.3 Fault table ..................................................................125 9.4 Work for fault clearance .............................................128 9.5 Commissioning after remedied fault ..........................128
10 Dismantling and disposal ..................................................129 10.1 Safety instructions for dismantling and disposal ........129 10.2 Dismantling ................................................................130 10.3 Disposal ....................................................................130
11 Index ....................................................................................131
12 Appendix .............................................................................135
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General information
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1 General information 1.1 Information about this manual This manual enables safe and efficient handling of the machine. It is
an integral part of the machine, and must be kept in close proximity to the machine where it is permanently accessible to the personnel. Before starting any work, the personnel must have read the manual thoroughly and understood its contents. Compliance with all specified safety instructions and operating instructions is vital to ensure safe operation. In addition, local accident prevention regulations and general safety instructions must be observed for the operational area of the machine. Illustrations in this manual are intended to facilitate basic understanding, and may differ from the actual design.
The instructions for the compressor do not include the operation of the
controller. Therefore, the instructions and content of the instructions for the controller in question must also be taken into account.
Furthermore, the instructions for the installed components found in the appendices also apply.
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1.2 Explanation of symbols
Safety instructions The safety instructions provided in this manual are marked by symbols. The safety instructions are introduced by keywords used to express the extent of the danger.
Strictly adhere to all safety instructions and use caution to prevent accidents, personal injury and material damage.
DANGER! This combination of symbol and keyword points to a situation of immediate danger which may lead to serious injury or death unless avoided.
WARNING! This combination of symbol and keyword points to a situation of possible danger which may lead to serious injury or death unless avoided.
CAUTION! This combination of symbol and keyword points to a possibly dangerous situation which may lead to slight or minor injury unless avoided.
NOTICE! This combination of symbol and keyword points to a possibly dangerous situation which may lead to material and environmental damage unless avoided.
Tips and recommendations
This symbol highlights useful tips and recommendations as well as information designed to ensure efficient and smooth operation.
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Special safety instructions The following symbols are used in the safety instructions to draw attention to specific dangers:
DANGER! This combination of symbol and signal word indicates dangers posed by electric power. If the safety instructions are not observed, there is a danger of serious or fatal injuries.
WARNING! This combination of symbol and signal word indicates dangers posed by an atmosphere capable of exploding. If the safety instructions are not observed, there is a danger of serious or fatal injuries.
Signs used in this manual The following signs and highlighting is used in this manual to identify instructions, descriptions of results, numerations, references and other elements:
Sign Explanation
1., 2., 3., ... Identifies step-by-step instructions.
Identifies a state or automatic sequence as result of steps.
Identifies references to chapters in this manual and to other valid documents.
Identifies random numerations and list entries.
[Key] Indicates names of keys, buttons and other operating controls.
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1.3 Limitation of liability All specifications and instructions in this manual have been compiled
taking account of applicable standards and regulations, the current state of technology and the experience and insights we have gained over the years. The manufacturer accepts no liability for damage due to:
Failure to observe this manual
Improper use
Deployment of untrained personnel Unauthorised modifications
Technical modifications
Use of unauthorised spare parts
The actual scope of supply may differ from the explanations and depictions in this manual in the case of special designs, take-up of additional ordering options, or as a result of the latest technical modifications.
The undertakings agreed in the supply contract as well as the manufacturer's Terms and Conditions and Terms of Delivery and the legal regulations applicable at the time of conclusion of the contract shall apply.
1.4 Copyright This manual is protected by copyright and intended solely for internal use.
This manual must not be made available to third parties, duplicated in any manner or form – whether in whole or in part – and the content must not be used and/or communicated, except for internal purposes, without the written consent of the manufacturer.
Violation of the copyright will result in legal action for damages. We reserve the right to assert further claims.
1.5 Warranty terms The warranty terms are included in the manufacturer's Terms and
Conditions.
1.6 Customer service Our customer service division is available to provide technical
information. See page 2 for contact details.
In addition, our employees are always interested in acquiring new information and experience gained from practical application; such information and experience may help improve our products.
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2 Safety
This section provides an overview of all the main safety aspects involved in ensuring optimal personnel protection and safe and smooth operation. Non-compliance with the action guidelines and safety instructions contained in this manual may result in serious hazards.
2.1 Proper use The machine is designed and constructed exclusively for the proper
use described here.
The screw compressor serves exclusively to generate compressed air in an environment not subject to explosion. The screw compressor may be supplied exclusively with cool, dry and dust-free cooling air.
The proper use also includes adherence to all details in these instructions.
Any use beyond the proper use or other type of use counts as misuse.
WARNING! Danger due to misuse! Misuse of the compressor can cause dangerous situations. - The compressed air may not be used for breathing
without previous preparation. - The compressed air may not be used directly for
pharmaceutical or sanitary purposes or for the direct handling of food without appropriate after-treatment.
- The screw compressor may not be operated outdoors.
- The screw compressor or individual components may not be rebuilt, modified or re-equipped.
- The screw compressor may not be used in an atmosphere subject to explosion.
- The intake of media other than cool, dry and dust-free cooling air is forbidden.
Claims of any type for damage due to misuse are excluded.
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2.2 Responsibility of the owner
Owner The term 'owner' refers to the person who himself operates the machine for trade or commercial purposes, or who surrenders the machine to a third party for use/application, and who bears the legal product liability for protecting the user, the personnel or third parties during the operation.
Duties of the owner The machine is used in the commercial realm. Therefore, the owner of the machine is subject to legal occupational safety regulations.
In addition to the safety instructions in these instructions, the valid safety, accident prevention and environmental protection regulations for the area of application of the machine must be adhered to.
Here, the following points apply in particular:
The owner must inform himself about the applicable occupational safety provisions and also determine in a hazard assessment the dangers that arise due to the special working conditions in the machine's area of application. He must implement these in the form of operating instructions for the operation of the machine.
During the entire time the machine is used, the owner must check whether the operating instructions he has created correspond to the current state of the body of rules and regulations and adapt the operating instructions if necessary.
The owner must regulate and specify clearly the responsibilities for the installation, operation, troubleshooting, maintenance and cleaning.
The owner must ensure that all employees who handle the machine have read and understood these instructions. In addition, he must train the personnel at regular intervals and inform them about the dangers.
The owner must provide personnel with the required protective equipment and instruct them in binding fashion about how to wear the required protective equipment.
Furthermore, the owner is responsible for ensuring that the machine is always in technically-perfect condition. Therefore, the following points apply: The owner must ensure that the maintenance intervals described
in these instructions are adhered to.
The owner must have all safety equipment checked regularly to ensure that it is functional and complete.
The owner must ensure that the appropriate media connections are provided.
The owner must ensure that the supply of the required quantity of cool medium (air/water) is guaranteed.
The owner must ensure that the required heat extraction is guaranteed.
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2.3 Staff requirements 2.3.1 Qualifications
WARNING! Danger of injury if personnel are insufficiently qualified! If unqualified personnel perform work on the machine or are in the machine's danger zone, hazards may arise which can cause serious injury and substantial damage to property. - Therefore, all work must only be carried out by
appropriately qualified personnel. - Unqualified personnel must be kept away from the
danger zones.
This manual specifies the personnel qualifications required for the
different areas of work, listed below:
Forklift driver The forklift driver must be at least 18 years old and, based on his physical and intellectual attributes and character, suited to driving industrial trucks with a driver's seat or driver's platform.
Furthermore, the forklift driver has been trained to drive industrial trucks with a driver's seat or driver's platform.
The forklift driver has provided the owner with evidence of his skills in driving industrial trucks with a driver's seat or driver's platform and has therefore been authorised in writing by the owner to drive the forklift.
Manufacturer Certain tasks may only be performed by our qualified personnel. Other personnel is not authorized to perform these tasks. Contact our service department to request the execution of any necessary work. For address information, refer to page 2.
Qualified electrician Based on his technical training, knowledge, experience and knowledge of the applicable standards and regulations, the qualified electrician is able to perform work on electrical systems and recognise and avoid potential hazards himself.
The qualified electrician is specially trained for the area of responsibility he is involved with and knows the relevant standards and regulations.
The qualified electrician must comply with the requirements of the applicable legal regulations for accident prevention.
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Qualified personnel Qualified personnel is able to carry out assigned work and to recognize and prevent possible dangers self-reliantly due to its professional training, knowledge and experience as well as profound knowledge of applicable regulations.
Trained Person The trained person has been instructed in an instruction by the owner about the tasks assigned to him and possible hazards in the case of improper behaviour.
The workforce must only consist of persons who can be expected to
carry out their work reliably. Persons with impaired reactions due to, for example, the consumption of drugs, alcohol, or medication are prohibited.
When selecting personnel, the age-related and occupation-related regulations governing the usage location must be observed.
2.3.2 Unauthorised persons
WARNING! Risk to life for unauthorised persons due to hazards in the danger and working zone! Unauthorised persons who do not meet the requirements described here will not be familiar with the dangers in the working zone. Therefore, unauthorised persons face the risk of serious injury or death. - Unauthorised persons must be kept away from the
danger and working zone. - If in doubt, address the persons in question and ask
them to leave the danger and working zone. - Cease work while unauthorised persons are in the
danger and working zone.
2.3.3 Training
The personnel must be trained regularly by the customer. For better tracing, the execution of the training must be logged ( Appendix A ‘Training log’ on page 136).
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2.4 Personal protective equipment Personal protective equipment is used to protect the personnel from
dangers which could affect their safety or health while working.
The personnel must wear personal protective equipment while carrying out the different operations at and with the machine. This equipment will be indicated separately in the individual chapters of this manual. This personal protective equipment is described below:
It is mandatory to put on the personal protective equipment specified in the different chapters of this manual before starting work.
Always comply with the instructions governing personal protective equipment posted in the work area.
Description of the personal protective equipment
Ear protection Ear protection provides protection against hearing damage.
Light respiratory protection Light respiratory protection is used to protect against harmful dusts.
Protective gloves Protective gloves protect hands from friction, abrasion, puncture wounds, or deeper injuries, as well as from contact with hot surfaces.
Protective work clothing Protective clothing are tight fitting working clothes with low tear resistance, with tight sleeves and without any parts sticking out. These clothes primarily protect against getting caught by moving machine parts. Do not wear rings, chains, necklaces, and other jewellery.
Safety boots Safety boots are intended to protect against slipping hazards or foot hazards like heavy gear.
Safety goggles The protective goggles protect the eyes from flying parts and liquid splashes.
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2.5 Basic dangers The following section specifies residual risks which may result from
using the machine and have been established by means of a risk assessment.
In order to minimize health hazards and avoid dangerous situations, follow the safety instructions specified here as well as in the following chapters of this manual.
2.5.1 General dangers in the workplace
Noise
WARNING! Danger of injury from noise! The noise levels arising in the workplace may result in serious hearing damage. - Always wear ear protection while working. - Do not stay in the danger zone more than necessary.
Accumulations of liquid
CAUTION! Danger of injury from slipping in accumulations of liquid! Slipping in accumulations of liquid on the floor may result in a fall. A fall may result in injuries. - Remove accumulations of liquid immediately using
appropriate means. - Wear anti-slip safety shoes. - Post warnings and mandatory signs at or in the
vicinity of any area where liquid could accumulate on the floor.
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2.5.2 Dangers due to electric energies
Electric current
DANGER! Danger to life from electric power. There is an immediate danger to life from electric shock in the case of contact with live parts. Damage to the insulation or individual components can be fatal. - Only allow qualified electricians to work on the
electrical system. - In the case of damage to the insulation, immediately
disconnect the power supply and arrange repairs. - Establish the absence of voltage before starting work
on active parts of electrical systems and equipment and ensure this remains so for the duration of the work. Observe the 5 safety rules: - Disconnect from the power supply. - Secure against restarting. - Verify absence of voltage. - Earth and short-circuit. - Cover or shield any neighbouring live parts.
- Never bypass or disable fuses. Comply with the correct current intensity information when replacing fuses.
- Keep moisture away from live parts. This can result in short circuits.
Stored charges
DANGER! Danger to life from stored charges! Electric charges may be stored in electrical components; these charges may be maintained even after the system has been switched off and disconnected from the power supply. Contact with these components may result in serious or fatal injury. - Before working on the specified components, ensure
that they have been completely disconnected from the power supply. Allow 10 minutes to elapse in order to ensure that the internal capacitors have been fully discharged.
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2.5.3 Dangers due to mechanical elements
Moving parts
WARNING! Danger of injury from moving parts! Rotating parts and/or parts moving in linear fashion may cause serious injuries. - During operation, do not reach into or handle moving
parts. - Do not open covers during operation. - Observe the run-on time: Before opening the covers,
make sure that all parts have stopped moving. - When in the danger zone, wear close-fitting protective
work clothing with low tear strength.
Sharp edges and pointed corners
CAUTION! Danger of injury posed by sharp edges and pointed corners! Sharp edges and pointed corners may cause skin grazes and cuts. - Proceed with caution when working in the vicinity of
sharp edges and pointed corners. - If in doubt, wear safety gloves.
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2.5.4 Dangers due to hydraulic energies
Liquid stream
WARNING! Danger to life due to escaping liquid stream under high pressure! In case of defective lines or components, a stream of liquid under high pressure can escape. The stream of liquid can cause extremely severe injuries or even death. - Never hold body parts or objects in the liquid stream.
Keep people out of the danger zone. In case of accidental contact with the liquid stream, take first aid measures and consult a doctor immediately.
- Initiate emergency off immediately. If necessary, take additional measures in order to reduce the pressure and stop the stream of liquid.
- Catch and dispose of escaping liquids properly. - Have faulty components repaired immediately.
Pressure accumulator(s)
WARNING! Danger to life from improper work on the pressure accumulator! Improper handling of pressure accumulators may cause a sudden release of pressure, resulting in very serious injuries or death and in significant damage to property. - Never carry out welding or soldering work on the
pressure accumulator vessel. - Never perform any mechanical machining on the
pressure accumulator vessel. - Once it is connected to the hydraulic line, vent the
pressure accumulator vessel using the fitted vent screw.
- Only carry out work on systems with a pressure accumulator once the hydraulic pressure has been completely relieved and depressurisation has been verified.
- Do not start work on the pressure accumulator until the gas charging pressure has been completely released.
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Compressed air
WARNING! Danger of injury from compressed air! Compressed air can escape from compressed air hoses or components under pressure in case of improper handling or in case of a fault. It can injure eyes, whip up dust or cause uncontrolled movements of hoses. Components under pressure can move in uncontrolled fashion with improper handling and cause injuries. - Before removing hoses or components under
pressure, make sure the pressure is relieved. - Have faulty components that are under pressure
during operation replaced by appropriate specialist personnel immediately.
- Before all work, make sure that the compressor is not under pressure; wait at least 5 minutes.
Coolant liquid fog
CAUTION! Danger of injury from coolant liquid fog! In case of high temperatures or mechanical dust, coolant liquid fog can form. Coolant liquid fog can irritate eyes and the respiratory system. - When working on the coolant liquid system and if a
coolant liquid fog arises, wear breathing protection and protective goggles and ensure that there is a fresh air supply.
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2.5.5 Dangers due to high temperatures
Hot surfaces
WARNING! Danger of injury from hot surfaces! Surfaces of components can heat up a lot during operation. Skin contact with hot surfaces will cause severe skin burns. - During all work hear hot surfaces, wear heat-resistant
protective clothing and protective gloves. - Before all work, make sure that all surfaces have
cooled off to the ambient temperature, wait at least 30 minutes.
Hot consumables
WARNING! Danger of injury from hot consumables! Consumables may reach high temperatures during operation. Skin contact with hot consumables will cause severe skin burns. - Always wear heat-resistant protective work clothing
and protective gloves as a matter of principle when carrying out any work with consumables.
- Always check whether consumables are hot before working with them. Allow to cool down if necessary.
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2.6 Safety equipment
WARNING! Danger to life from nonfunctional safety devices! If safety devices are not functioning or are disabled, there is a danger of serious injury or death. - Check that all safety devices are fully functional and
correctly installed before starting work. - Never disable or bypass safety devices. - Ensure that all safety devices are always accessible.
2.6.1 Position of the safety equipment
The following illustration shows the position of the safety equipment.
Fig. 1: Position of the safety devices
1 Main switch with emergency stop function 2 Emergency stop button
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2.6.2 Description of the installed safety devices
Main switch with emergency off function
Fig. 2: Main switch
The main switch is also set up as an emergency stop switch. By turning the main switch to the "0" position, the machine is stopped by switching off the power immediately and an emergency stop is thus triggered.
WARNING! Danger to life from an unauthorised restart! An uncontrolled restart of the machine may cause serious injuries including death. - Before switching the machine back on, make sure the
cause of the emergency stop has been removed and all safety devices have been installed and function properly.
- Only turn the main switch to the "l" position when there is no more danger.
Emergency stop key
Fig. 3: Emergency stop key
By pressing the emergency stop key, the machine is stopped by an immediate switching off of the power supply. After an emergency stop key has been pressed, it must be unlocked by turning it so that a switching on is possible.
WARNING! Danger to life from an unauthorised restart! An uncontrolled restart of the machine may cause serious injuries including death. - Before switching the machine back on, make sure the
cause of the emergency stop has been removed and all safety devices have been installed and function properly.
- Do not unlock the EMERGENCY-STOP button until there is no more danger.
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Safety valves
Fig. 4: Safety valve
Safety valves belong to the safety taps and are unburdening equipment for the areas under pressure such as the boiler, pressure tank, pipes, transport container. In case of an impermissible pressure increase, safety valves bleed off gases, vapours or liquids into the atmosphere.
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2.7 Securing to prevent restart
WARNING! Life-threatening danger if restarted without authorisation or due to uncontrolled restart! Uncontrolled or unauthorised switching on of the machine can cause severe or fatal injuries. - Prior to restart ensure that all safety devices are
mounted and functional, and that there is no danger for personnel.
- Always adhere to the procedure described below to secure against restart.
Securing to prevent restart
Fig. 5: Securing the main switch
1. Switch off the power supply. To do this, turn the main switch to the "0" position.
2. Secure the main switch with a padlock (Fig. 5).
3. Have a responsible employee keep the key for the padlock.
4. After all work has been performed, make sure that there are no dangers to people.
5. Ensure that all safety and protective equipment is installed and functional.
WARNING! Danger to life from an unauthorised restart! If the main switch is secured with a padlock, people can be in the danger zone. These people can be fatally injured by the switching on of the power supply. - Before removing the padlock and switching the power
supply back on, make sure that there are no dangers to people.
6. Remove the padlock from the main switch.
If no main switch is installed, proceed as follows.
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WARNING! Life-threatening danger if restarted without authorisation or due to uncontrolled restart! Uncontrolled or unauthorised switching on of the machine can cause severe or fatal injuries. - Prior to restart ensure that all safety devices are
mounted and functional, and that there is no danger for personnel.
- Always adhere to the procedure described below to secure against restart.
Securing to prevent restart
1. Switch off the power supply.
2. Inform responsible people about work in the danger zone.
3. Mark machine with a sign that indicates the work in the danger zone and forbids switching on. Include the following details on the sign:
Switched off on: Switched off at:
Switched off by:
Note: do not switch on!
Note: Only switch on after it has been ensured that there are no dangers to people.
4. After all work has been performed, make sure that there are no dangers to people.
5. Ensure that all safety and protective equipment is installed and functional.
WARNING! Danger to life from an unauthorised restart! People in the danger zone can be fatally injured by the unauthorised or uncontrolled switching on of the power supply. - Before switching the power supply back on, ensure
that there are no dangers for people.
6. Remove the sign.
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2.8 Behaviour in case of fire or accidents
Preventive measures Be prepared for fire and accidents at all times! Keep first-aid equipment (first-aid kit, blankets, etc.) and fire
extinguishing devices operational and readily available. Make your personnel familiar with accident reporting equipment as
well as first-aid and rescue equipment. Keep access paths clear for rescue vehicles.
Steps in case of fire and accidents
Immediately trigger an Emergency Stop using EMERGENCY-STOP devices.
Provided your own health is not in danger, rescue all personnel from the danger area.
If necessary, initiate first aid measures. Alert the fire department and/or emergency medical services.
In case of fire: provided your own health is not in danger, extinguish the fire using fire extinguishing equipment and continue to do so until the fire department arrives.
Notify the person in charge at the machine's place of installation. Clear access paths for rescue vehicles.
Wave rescue vehicles into position.
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Safety
28 2015-07-21
2.9 Environmental protection
NOTICE! Danger to the environment from incorrect handling of pollutants! Incorrect handling of pollutants, particularly incorrect waste disposal, may cause serious damage to the environment. - Always observe the instructions below regarding
handling and disposal of pollutants. - Take the appropriate actions immediately if pollutants
escape accidentally into the environment. If in doubt, inform the responsible municipal authorities about the damage and ask about the appropriate actions to be taken.
The following pollutants are used:
Coolant liquid Coolant liquids can contain poisonous substances and substances that are harmful to the environment. They must not be allowed to escape into the environment. Disposal must be carried out by a specialist disposal company.
Lubricants Lubricants such as greases and oils contain toxic substances. They must not be allowed to escape into the environment. Disposal must be carried out by a specialised disposal company.
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Safety
2015-07-21 29
2.10 Signage The following symbols and information signs can be found in the work
area. They refer to their immediate surroundings.
WARNING! Danger of injury from illegible symbols! Stickers and signs can become dirty or otherwise obscured over time, with the result that dangers cannot be recognised and the necessary operating instructions cannot be complied with. This, in turn, poses a risk of injury. - All safety, warning and operating instructions must
always be maintained in a completely legible condition.
- Damaged signs or stickers must be replaced immediately.
2.10.1 Warning signs
Electrical voltage
Only qualified electricians are permitted to work in a work room marked by this sign. Unauthorised persons must not enter the workplaces thus marked and must not open the marked cabinet.
Automatic start-up
Maintain sufficient distance from all parts that can move; there is a danger of crushing or pulling in there.
Hot surface
Hot surfaces such as hot machine parts, containers or materials, as well as hot liquids, may not always be detected. Never touch these without protective gloves.
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Safety
30 2015-07-21
2.10.2 Instructions on the machine
Direction of rotation
There is a direction of rotation sticker on the drive unit and on the cooling air ventilator. This sticker shows the appropriate direction of rotation.
Re-lubrication
The sticker for re-lubrication is on the drive unit.
Oil filling
The sticker for oil filling is on the coolant liquid pressure tank and next to the installed controller.
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Safety
2015-07-21 31
Brief instructions for commissioning
This sticker is on the switch cabinet and contains brief instructions for commissioning.
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Technical data
32 2015-07-21
3 Technical data 3.1 Type plate
Fig. 6: Type plate
The type plate is on the lower frame on the maintenance side and on the sound insulation cover on the Cooling air exhaust side or cooling water intake and outlet side and includes the following details:
Manufacturer
Product type Manufacturer no.
Year of construction
Direction of rotation Volume flow rate
Part number
Final pressure
Motor output
3.2 Emissions
Noise emissions
The values for noise emission are included in the enclosed data sheet.
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Technical data
2015-07-21 33
3.3 Coolant liquid The following coolant liquids are tested and approved for use in
ALMiG compressors:
Designation Type Order number
Standard coolant liquid ALUB BLUE S+ 583.04055 (10 l container)
Synthetic coolant liquid ALUB Syn S 583.00004 (10 l container)
Food-compatible coolant liquid ALUB Food H1 583.04010 (10 l container)
Biodegradable coolant liquid ALUB GREEN S 583.10051 (10 l container)
3.4 COMBI 3S – 5S
3.4.1 General details
COMBI 3S
COMBI Nominal motor output
Weight Length Width Height
kW kg mm mm mm
3S
(with compressed air tank 200 l and refrigeration dryer)
3.0 215 1400 550 1250
3S
(with compressed air tank 200 l, without refrigeration dryer)
3.0 195 1400 550 1250
3S
(without pressure tank, with refrigerant-type dryer)
3.0 155 1100 550 950
3S
(without pressure tank, without refrigerant-type dryer)
3.0 130 720 550 950
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Technical data
34 2015-07-21
COMBI 4S
COMBI Nominal motor output
Weight Length Width Height
kW kg mm mm mm
4S
(with compressed air tank 200 l and refrigeration dryer)
4.0 220 1400 550 1250
4S
(with compressed air tank 200 l, without refrigeration dryer)
4.0 200 1400 550 1250
4S
(without pressure tank, with refrigerant-type dryer)
4.0 160 1100 550 950
4S
(without pressure tank, without refrigerant-type dryer)
4.0 135 720 550 950
COMBI 5S
COMBI Nominal motor output
Weight Length Width Height
kW kg mm mm mm
5S
(with compressed air tank 200 l and refrigeration dryer)
5.5 225 1400 550 1250
5S
(with compressed air tank 200 l, without refrigeration dryer)
5.5 205 1400 550 1250
5S
(without pressure tank, with refrigerant-type dryer)
5.5 165 1100 550 950
5S
(without pressure tank, without refrigerant-type dryer)
5.5 140 720 550 950
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Technical data
2015-07-21 35
3.4.2 Connection values
Electrical
COMBI 3S – 5S
COMBI Current at 400 V / 50 Hz Current at 500 V / 50 Hz Max. switching frequency
IN IFuse IN IFuse
A A gL A A gL 1/h
3S 6.6 16 5.3 10 55
4S 8.5 16 6.8 16 55
5S 11.3 16 9 16 55
IN = nominal current IFuse = building-side fuse
Air supply and cooling
COMBI 3S – 5S
COMBI Compressed air connection
Cooling air quantity (LK)
Supply air opening
Cross-section air outlet duct
G / DN m3/h m2 m2
3S ⅜ 1050 0.15 0.10
4S ⅜ 1060 0.20 0.15
5S ½ 1080 0.25 0.15
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Technical data
36 2015-07-21
3.4.3 Operating conditions
Environment Data Value Unit
Temperature range +5 to +40 °C
Relative humidity, maximum 60 %
Maximum installation height above sea level
1000 m
3.4.4 Lubricants
COMBI 3S –5S
COMBI Lubricant Fill level Unit
3S Coolant liquid 3.2 l
4S Coolant liquid 3.2 l
5S Coolant liquid 3.2 l
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Technical data
2015-07-21 37
3.5 COMBI 6 – 15
3.5.1 General details
COMBI 6
COMBI
Nominal motor output
Weight Length Width Height
kW kg mm mm mm
6
(with 270 l pressure tank and refrigerant-type dryer)
5.5 455 1180 770 1680
6
(with 270 l pressure tank, without refrigerant-type dryer)
5.5 420 1180 770 1680
6
(with 500 l pressure tank and refrigerant-type dryer)
5.5 520 1900 770 1680
6
(with 500 l pressure tank, without refrigerant-type dryer)
5.5 485 1900 770 1680
6
(without pressure tank, with refrigerant-type dryer)
5.5 340 1180 770 1128
6
(without pressure tank, without refrigerant-type dryer)
5.5 305 1180 770 1128
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Technical data
38 2015-07-21
COMBI 8
COMBI
Nominal motor output
Weight Length Width Height
kW kg mm mm mm
8
(with 270 l pressure tank and refrigerant-type dryer)
7.5 460 1180 770 1680
8
(with 270 l pressure tank, without refrigerant-type dryer)
7.5 425 1180 770 1680
8
(with 500 l pressure tank and refrigerant-type dryer)
7.5 525 1900 770 1680
8
(with 500 l pressure tank, without refrigerant-type dryer)
7.5 490 1900 770 1680
8
(without pressure tank, with refrigerant-type dryer)
7.5 345 1180 770 1128
8
(without pressure tank, without refrigerant-type dryer)
7.5 310 1180 770 1128
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Technical data
2015-07-21 39
COMBI 11 / 11SC
COMBI
Nominal motor output
Weight Length Width Height
kW kg mm mm mm
11 / 11SC
(with 270 l pressure tank and refrigerant-type dryer)
11.0 465 / 470 1180 770 1680
11 / 11SC
(with 270 l pressure tank, without refrigerant-type dryer)
11.0 430 / 435 1180 770 1680
11 / 11SC
(with 500 l pressure tank and refrigerant-type dryer)
11.0 530 / 535 1900 770 1680
11 / 11SC
(with 500 l pressure tank, without refrigerant-type dryer)
11.0 495 / 500 1900 770 1680
11 / 11SC
(without pressure tank, with refrigerant-type dryer)
11.0 350 / 355 1180 770 1128
11 / 11SC
(without pressure tank, without refrigerant-type dryer)
11.0 315 / 320 1180 770 1128
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Technical data
40 2015-07-21
COMBI 15
COMBI
Nominal motor output
Weight Length Width Height
kW kg mm mm mm
15
(with 270 l pressure tank and refrigerant-type dryer)
15.0 475 1180 770 1680
15
(with 270 l pressure tank, without refrigerant-type dryer)
15.0 440 1180 770 1680
15
(with 500 l pressure tank and refrigerant-type dryer)
15.0 540 1900 770 1680
15
(with 500 l pressure tank, without refrigerant-type dryer)
15.0 505 1900 770 1680
15
(without pressure tank, with refrigerant-type dryer)
15.0 360 1180 770 1128
15
(without pressure tank, without refrigerant-type dryer)
15.0 325 1180 770 1128
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Technical data
2015-07-21 41
3.5.2 Connection values
Electrical
COMBI 6 – 15
COMBI Current at 400 V / 50 Hz Current at 500 V / 50 Hz Max. switching frequency
IN IFuse IN IFuse
A A gL A A gL 1/h
6 11 25 9 16 55
8 15 32 12 25 55
11 / 11SC 22 / 22 40 / 40 17 / - 32 / - 40 / -
15 30 50 23 40 30
IN = nominal current IFuse = building-side fuse
Air supply and cooling
COMBI 6 – 15
COMBI Compressed air connection
Cooling air quantity (LK)
Supply air opening
Cross-section air outlet duct
G / DN m3/h m2 m2
6 ¾ 1100 0.30 0.15
8 ¾ 1230 0.35 0.15
11 / 11SC ¾ 1800 0.50 0.20
15 ¾ 2300 0.60 0.20
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Technical data
42 2015-07-21
3.5.3 Operating conditions
Environment Data Value Unit
Temperature range +5 to +40 °C
Relative humidity, maximum 60 %
Maximum installation height above sea level
1000 m
3.5.4 Consumables
COMBI 6 – 15
COMBI Lubricant Fill level Unit
6 Coolant liquid 6.2 l
8 Coolant liquid 6.2 l
11 / 11SC Coolant liquid 6.2 l
15 Coolant liquid 6.2 l
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Technical data
2015-07-21 43
3.6 COMBI 16 – 22
3.6.1 General details
COMBI 16
COMBI
(on 500 l container)
Nominal motor output
Weight Length Width Height
kW kg mm mm mm
16
(with pressure tank and refrigerant-type dryer)
15 679 1900 780 1950
16
(with pressure tank, without refrigerant-type dryer)
15 639 1900 780 1950
16
(without pressure tank, with refrigerant-type dryer)
15 494 1480 780 1375
16
(without pressure tank, without refrigerant-type dryer)
15 454 1480 780 1375
COMBI 18
COMBI
(on 500 l container)
Nominal motor output
Weight Length Width Height
kW kg mm mm mm
18
(with pressure tank and refrigerant-type dryer)
18.5 698 1900 780 1950
18
(with pressure tank, without refrigerant-type dryer)
18.5 658 1900 780 1950
18
(without pressure tank, with refrigerant-type dryer)
18.5 513 1480 780 1375
18
(without pressure tank, without refrigerant-type dryer)
18.5 473 1480 780 1375
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Technical data
44 2015-07-21
COMBI 22 / 22SC
COMBI
(on 500 l container)
Nominal motor output
Weight Length Width Height
kW kg mm mm mm
22 / 22SC
(with pressure tank and refrigerant-type dryer)
22 744 / 750 1900 780 1950
22 / 22SC
(with pressure tank, without refrigerant-type dryer)
22 704 / 710 1900 780 1950
22 / 22SC
(without pressure tank, with refrigerant-type dryer)
22 559 / 565 1480 780 1375
22 / 22SC
(without pressure tank, without refrigerant-type dryer)
22 519 / 525 1480 780 1375
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Technical data
2015-07-21 45
3.6.2 Connection values
Electrical
COMBI 16 – 22 / 22SC
COMBI Current at 400 V / 50 Hz Current at 500 V / 50 Hz Max. switching frequency
IN IFuse IN IFuse
A A gL A A gL 1/h
16 30 50 23 40 30
18 36 63 30 50 25
22 / 22SC 41 / 41 63 / 63 34 / - 50 / - 20 / -
IN = nominal current IFuse = building-side fuse
Air supply and cooling
COMBI 16 – 22 / 22SC
COMBI Compressed air connection
Cooling air quantity (LK)
Supply air opening
Cross-section air outlet duct
G / DN m3/h m2 m2
16 1 3300 0.60 0.35
18 1 3300 0.60 0.35
22 / 22SC 1 3300 0.60 0.35
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Technical data
46 2015-07-21
3.6.3 Operating conditions
Environment Data Value Unit
Temperature range +5 to +40 °C
Relative humidity, maximum 60 %
Maximum installation height above sea level
1000 m
3.6.4 Consumables
COMBI 16 – 22 / 22SC
COMBI Lubricant Fill level Unit
16 Coolant liquid 11.5 l
18 Coolant liquid 11.5 l
22 / 22SC Coolant liquid 11.5 l
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Construction and function
2015-07-21 47
4 Construction and function 4.1 Overview The following presents an overview of the screw compressors
described in this manual. They differ from one another due primarily to their size. However, their basic construction is the same.
For the COMBI type, there are variants which are not built on a pressure tank. Due to their identical construction, these variants are only depicted without pressure tank and not extra as an overview figure.
Screw compressor COMBI 3S – 5S
Fig. 7: Screw compressor COMBI 3S – 5S
1 Main switch with emergency stop function 2 On and off switch 3 Refrigerant-type dryer 4 Pressure tank 5 Sound insulation covers
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Construction and function
48 2015-07-21
Screw compressor COMBI 6 – 22
Fig. 8: Screw compressor with pressure tank
1 Controller 2 Emergency stop key / main switch with emergency stop function 3 Switch cabinet 4 Pressure tank 5 Sound insulation covers
Assemblies
The basic construction is the same for all screw compressor variants. The position of the assemblies may vary from the illustration.
Fig. 9: Assemblies COMBI 3S – 5S
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Construction and function
2015-07-21 49
1 Minimum pressure and non-return valve 2 Fine precipitator 3 Coolant liquid filter 4 Refrigerant-type dryer 5 Compressed air connection 6 Compressor stage 7 Intake filter 8 Coolant liquid cooler 9 Fan belt 10 Cooling air fan 11 Drive unit 12 Pressure tank 13 Coolant liquid tank
Fig. 10: Assemblies COMBI 6 – 22
1 Fine precipitator 2 Refrigerant-type dryer 3 Coolant liquid filter 4 Coolant liquid cooler 5 Intake filter 6 Compressed air connection 7 Fan belt 8 Compressor stage 9 Cooling air fan 10 Drive unit 11 Pressure tank 12 Coolant liquid tank 13 Frequency converter 14 Minimum pressure and non-return valve
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Construction and function
50 2015-07-21
4.2 Brief description The fresh air supplied by the installed cooling air ventilator is filtered
through the intake filter. The air streams over the intake regulator into the compressor stage, where it is compressed together with the injected coolant liquid to the final pressure. The compressed air is largely separated from the coolant liquid in the pressure tank. The subsequent fine precipitator removes the remaining coolant liquid from the compressed air. The compressed air then flows over the minimum pressure and return valve into the compressed air after-cooler or the pressure tank and is cooled off there. Finally, the compressed air is dried in the refrigerant-type dryer before it leaves the screw compressor via the compressed air connection. The coolant liquid is separated from the compressed air in the pressure tank and the fine precipitator and streams to the coolant liquid cooler. The coolant liquid temperature regulator adds the cooled-off coolant liquid to the hot coolant liquid via the coolant liquid cooler bypass according to the set point temperature. Finally, the coolant liquid filter cleans the coolant liquid before it is injected into the compressor stage once again.
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Construction and function
2015-07-21 51
4.3 Assembly description 4.3.1 Controller
Controller variants
Fig. 11: COMBI 3S – 4S
The COMBI 3S – 4S is operated using the pressure switch.
Fig. 12: COMBI 5S
The COMBI 5S is operated using the two buttons for switching on and off.
Fig. 13: COMBI 6 – 22
The COMBI 6 – 22 is operated using the Air Control AC mini controller.
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Construction and function
52 2015-07-21
Screw compressors with frequency converters
Screw compressors with frequency converters can be operated with the following controllers: AC 1, AC 3, AC B, AC P. Refer to the separately enclosed operating instructions for the controller for information.
4.3.2 Sound insulation covers
Fig. 14: Sound insulation covers
Only qualified personnel may remove the sound insulation covers (Fig. 14/1) with the included special spanner. Sound insulation covers are a part of the electric shock protection.
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Construction and function
2015-07-21 53
4.3.3 Drive unit
Fig. 15: COMBI drive unit
With the COMBI, the drive (Fig. 15) takes place using a fan belt (Fig. 15/1).
Fig. 16: Drive unit with frequency converter
On the COMBI 11SC and COMBI 22SC screw compressors the speed of the electric motor is controlled by a frequency converter (Fig. 16/1).
4.3.4 Intake filter
Fig. 17: Standard intake filter
The standard intake filter (Fig. 17/1) sits directly above the compressor stage (Fig. 17/2).
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Construction and function
54 2015-07-21
4.3.5 Compressor stage
Fig. 18: Compressor stage
The air taken in is compressed by the compressor stage (Fig. 18/1) and added to the coolant liquid pressure tank (Fig. 18/2) together with the injected coolant liquid.
4.3.6 Coolant liquid tank
Fig. 19: Coolant liquid pressure tank with safety valves
1 Safety valve 2 Coolant liquid pressure tank 3 Filler plugs 4 Coolant liquid drain 5 Inspection glass
The coolant liquid pressure tank consists of several components. The safety valve protects the coolant liquid pressure tank against overpressure. With the inspection glass, the level of the coolant liquid can be read. With the drain plugs, the coolant liquid is topped off and it is removed via the coolant liquid drain.
Coolant liquid heating (optional) Coolant liquid heating can be installed in the coolant liquid pressure tank at the factory or after the fact. It prevents condensate damage and the freezing of the condensate, e.g. for a screw compressor that is set up in the cold or the humidity.
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Construction and function
2015-07-21 55
4.3.7 Fine precipitator
Fig. 20: Fine precipitator
Depending on the type of the screw compressor, several fine precipitators can be installed.
The fine precipitator (Fig. 20/1) removes the remaining coolant liquid from the compressed air.
4.3.8 Minimum pressure and return valve
Fig. 21: Minimum pressure and return valve
The minimum pressure and return valve (Fig. 21/1) only opens if the system pressure has increased to 5 bar. After the screw compressor switches off, the minimum pressure and return valve prevents the compressed air from stream back out of the network.
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Construction and function
56 2015-07-21
4.3.9 Cooler
Fig. 22: Cooler
The compressed air is cooled off in the compressed air after-cooler (Fig. 22/2) or in the pressure tank before it leaves the screw compressor via the compressed air connection (Fig. 22/3).
The coolant liquid is cooled by the coolant liquid cooler (Fig. 22/1) and fed back into the coolant circuit.
The compressed air after-cooler and coolant liquid cooler are only present on the COMBI 16 – 22. In the COMBI 6 – 15, only a coolant liquid cooler is installed.
4.3.10 Coolant liquid filter
Fig. 23: Coolant liquid filter
The coolant liquid filter (Fig. 23/1) cleans the coolant liquid before it is injected into the compressor stage once again.
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Construction and function
2015-07-21 57
4.3.11 Cooling air fan
Depending on the type, two different cooling air ventilators are installed.
Cooling air fan
The cooling of the compressed air after-cooler and of the coolant liquid cooler is performed by the cooling air fan. The cooling air fan also supplies the intake filter with sufficient intake air.
4.3.12 Refrigerant-type dryer
Fig. 24: Refrigerant-type dryer
The refrigerant-type dryer (Fig. 24/1) dries the compressed air using a heat exchange process. The compressed air is thus fed from the pressure tank into the refrigerant-type dryer and then via the compressed air connection (Fig. 24/3) into the compressed air network. The condensate which accumulates is discharged via the condensate drain (Fig. 24/2).
Depending on the variant, a hose for discharging the condensate is already attached to the condensate drain; otherwise, the operator must attach one.
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Construction and function
58 2015-07-21
4.4 Interfaces
Fig. 25: Flow chart
The following interfaces are in the screw compressor:
Air supply Cooling air ventilator Intake filter
Compressed air connection
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Construction and function
2015-07-21 59
Air supply
Fig. 26: Cooling air ventilator and intake filter
The cooling air ventilator directs the fresh air to the intake filter and also serves the purpose of process cooling. The intake filter filters the fresh air and directs it into the compressor unit for compression.
Compressed air connection
Fig. 27: Compressed air connection
The air compressed by the compressor is available to the compressed air network at the compressed air connection after it has been filtered.
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Transportation, packaging and storage
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5 Transportation, packaging and storage 5.1 Safety instructions for transportation
Improper transport
NOTICE! Damage to property due to improper transport! Transport units may fall or tip over as a result of improper transport. This can cause a significant level of property damage. - Proceed carefully when unloading transport units at
delivery and during in-house transport; observe the symbols and instructions on the packaging.
- Only use the attachment points provided. - Only remove the packaging shortly before assembly.
5.2 Transportation inspection On receipt, immediately inspect the delivery for completeness and
transport damage.
Proceed as follows in the event of externally apparent transport damage:
Do not accept the delivery, or only accept it subject to reservation.
Note the extent of the damage on the transport documentation or the shipper's delivery note.
Initiate complaint procedures.
Issue a complaint in respect of each defect immediately following detection. Damage compensation claims can only be asserted within the applicable complaint deadlines.
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Transportation, packaging and storage
2015-07-21 61
5.3 Packaging
About the packaging The individual screw compressors are packaged in cartons or sometimes on wooden frames and according to the anticipated transport conditions. Only environmentally-friendly materials are used for the packaging. The packaging should protect the individual components against transport damage, corrosion and other damage until assembly. Therefore, do not destroy the packaging and only remove it shortly before assembly.
Handling packaging materials Dispose of packaging material in accordance with the relevant applicable legal requirements and local regulations.
NOTICE! Danger to the environment due to incorrect disposal! Packaging materials are valuable raw materials and in many cases can continue to be used or can be properly processed and recycled. Incorrect disposal of packaging materials may pose risks to the environment. - Dispose of packaging materials in accordance with
the environmental regulations. - Observe locally applicable waste disposal
regulations. If necessary, outsource the disposal to a specialist company.
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Transportation, packaging and storage
62 2015-07-21
5.4 Symbols on the packaging The following symbols are on the packaging. Always adhere to these
symbols during transportation.
Top
The arrow tips on the sign mark the top of the package. They must always point upwards; otherwise the content could be damaged.
Fragile
Marks packages with fragile or sensitive contents. Handle the package with care; do not allow to fall and do not expose to impacts.
Protect against moisture
Protect packages against moisture and keep dry.
5.5 Transportation
Transport with a fork lift Transport pieces can be transported with a fork lift under the following conditions:
The fork lift must be designed for the weight of the transport pieces.
Existing guide rails on the frame must be used.
The length of the forks must be at least 1400 mm.
Transporting Personnel: Forklift driver
Fig. 28: Transport with a fork lift
1. Drive the fork lift with the forks as shown in Fig. 28.
2. Insert the forks so that they stick out on the other side.
3. Ensure that the transport piece cannot tip with an off-centre centre of gravity.
4. Lift the transport piece and begin the transport.
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Transportation, packaging and storage
2015-07-21 63
5.6 Storage
Storage of the packaging pieces Store the packaging pieces under the following conditions: Do not store outdoors.
Store dry and dust-free.
Do not expose to any aggressive media. Protect against solar radiation.
Avoid mechanical jolts.
Storage temperature: 15 to 35 °C.
Relative humidity: max. 60 %. In case of storage for longer than 3 months, check the general
condition of all parts and the packaging regularly. If necessary, refresh or replace the rust-proofing.
Under some circumstances there may be notes about storage on the packaging pieces that extend beyond the requirements named here. Adhere to these accordingly.
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Installation, commissioning and operation
64 2015-07-21
6 Installation, commissioning and operation 6.1 Safety instructions for the installation and commissioning
Electrical system
DANGER! Danger to life from electric power! Contact with live parts may prove fatal. When switched on, electric components can be subject to uncontrolled movements and may cause grave injury or death. - Switch off the power supply before starting work and
make sure that it cannot be switched on again.
Improper initial commissioning
WARNING! Danger of injury due to improper initial commissioning! Improper initial commissioning can result in serious injury and significant damage to property. - Before the initial commissioning, ensure that all
installation work has been carried out and completed in accordance with the information and instructions in this manual.
- Ensure that no persons are in the danger zone before the initial commissioning.
Securing to prevent restart
WARNING! Danger to life from an unauthorised restart! In the event of an unauthorised restart of the power supply during installation, there is a danger of serious injuries or death for persons in the danger zone. - Switch off all power supplies before starting work and
make sure they cannot be switched on again.
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
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Improper installation and commissioning
WARNING! Risk of injury due to improper installation or commissioning! Improperly performed installation and commissioning may lead to serious injury and significant material damage. - Provide for sufficient mounting clearance before
starting to work. - Use caution when handling exposed components with
sharp edges. - Keep the assembly area tidy and clean! Loose
components and tools lying around or on top of each other may lead to accidents.
- Mount all components properly. Tighten all screws to the prescribed torque.
- Secure components to prevent them from falling down or tipping over.
- Observe the following prior to commissioning: - make sure that all installation work has been
performed and completed following the instructions and information provided in this manual.
- make sure that no persons are still in the danger zone of the machine.
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6.2 Requirements in the installation location Set up the screw compressor so that the following conditions are
fulfilled:
The installation location is level. The secure standing of the machine is guaranteed.
The machine is easily accessible and can be accessed from all sides.
There is sufficient lighting.
There is sufficient ventilation.
There is a power supply available. Escape paths and rescue equipment are freely accessible.
The machine is not subjected to an explosive atmosphere.
The machine is not subjected to a corrosive atmosphere.
The machine is not subjected to direct solar radiation. Outside heating from surrounding heat sources is excluded.
There is no dust accumulation.
Fire protection measures have been taken.
The machine is not subjected to vibrations. The surface is resistant to solvents, impermeable to liquids, anti-
static and easy to clean.
There are no machines in the vicinity that cause electrical or electromagnetic disturbance.
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6.3 Installation 6.3.1 Ventilation
DANGER! Danger to life from the use of explosive gas mixtures, vapours, dust or aggressive hazardous substances! The use of explosive gas mixtures, vapours, dust or aggressive hazardous substances to ventilate the screw compressor can cause severe or even fatal injuries as well as significant property damage. - Never use explosive gas mixtures, vapours, dust or
aggressive hazardous substances to ventilate the screw compressor.
- Ensure that no explosive gas mixtures, vapours, dust or aggressive hazardous substances get into the ventilation of the screw compressor.
The air supplied via the intake openings is used for compression and system cooling.
Personnel: Qualified personnel
Protective equipment: Safety boots Protective work clothing
NOTICE! Property damage due to condensation! Due to cooling air that is too hot or too humid, condensate can arise. - Only provide cool, dry and dust-free cooling air. - For the intake of outside air, use a recirculating air flap.
Fig. 29: Overview illustration of cooling air ventilator
1. Provide the required quantity of cooling air according to the technical data for the screw compressor ( Chapter 3 ‘Technical data’ on page 32).
2. Remove the exhaust air according to the technical data for the screw compressor ( Chapter 3 ‘Technical data’ on page 32).
This way, the heating of the installation room and of the screw compressor will be prevented.
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Forced ventilation and bleeding (optional)
The forced ventilation and bleeding must be dimensioned so that the required supply and exhaust air can be supplied and removed taking into account the existing residual pressure of the cooling air ventilator. The exhaust air can also be used for the purpose of heat reclamation.
6.3.2 Connection to the compressed air network
Personnel: Qualified personnel
Protective equipment: Protective work clothing Safety boots
Materials: Flexible compressed air hose, max. 1.5 m
WARNING! Danger of injury due to unpredictable movement of the compressed air hose! Load switches in the compressed air network cause jerky movements of the compressed air hose with high force. - Anchor and fasten the compressed air hose
sufficiently.
The prerequisite for the correct installation is the presence of a professionally-planned, installed and maintained compressed air network and an additional cut-off valve installed at the entrance to the compressed air network.
Fig. 30: Compressed air connection
1. Connect the compressed air according to the technical data ( Chapter 3 ‘Technical data’ on page 32).
2. Ensure that the compressed air hose does not represent a stumbling hazard.
3. Anchor and fasten the flexible compressed air hose sufficiently.
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6.3.3 Connecting to the power supply
Personnel: Qualified electrician
Protective equipment: Protective work clothing Safety boots
NOTICE! Property damage to the compressor stage due to incorrect connection of the power supply! In case of incorrect connection of the power supply, there is a danger that the compressor stage will be destroyed due to a drive turning incorrectly. - Connect the power according to the wiring diagram
and check the rotating field before starting the screw compressor.
The prerequisite for the correct installation are professionally-dimensioned fuses in the network supply (person-system protection) and an appropriate main switch (for switching the supply on and off).
1. Using the data in the wiring diagram (in the switch cabinet), check whether the existing supply network is suitable. Voltage deviations of more than 10 % are not permitted.
2. Connect the power according to the included wiring diagram (in the switch cabinet) and the technical data ( Chapter 3 ‘Technical data’ on page 32).
3. Check right-rotating direction of rotation with a rotating field measurement device.
4. Ensure that the power cable does not represent a stumbling hazard.
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6.4 Checking the coolant liquid level Personnel: Qualified personnel
Protective equipment: Protective work clothing Safety boots
Protective gloves
1. Switch the machine off and secure to prevent restarting.
2. Open and remove the sound insulation covers with the special spanner.
Fig. 31: Inspection glass
3. Check the inspection glass (Fig. 31/1) to make sure it is completely moist.
4. If necessary, top up coolant liquid Chapter 8.4.7 ‘Changing the coolant liquid/changing the cooling liquid filter’ on page 115.
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6.5 Start-up lubrication of the compressor stage Personnel: Qualified personnel
Protective equipment: Protective work clothing Safety boots
NOTICE! Property damage due to lacking coolant liquid in the compressor stage! Lacking coolant liquid in the compressor stage after longer downtimes, e.g. between factory delivery and initial commissioning or after a longer downtime can cause significant property damage to the screw compressor. - Top up the coolant liquid directly in the compressor
stage before the initial commissioning or after a longer downtime.
Coolant liquid quantities for direct filling in the compressor stage
Screw compressor Coolant liquid filling
l
COMBI 3S – 5S 0.5
COMBI 6 – 15 0.5
COMBI 16 – 22 0.5
COMBI 11SC / 22SC 0.5
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Fig. 32: Screw plug intake regulator
1. Loosen 4 screws on the intake regulator (Fig. 32/1).
NOTICE! Property damage due to incorrect coolant liquid! Mixing different coolant liquids causes significant property damage to the screw compressor. - Only use the coolant liquid prescribed in the technical
data.
If there is no additional coolant liquid available, the coolant liquid will have to be removed using of the coolant liquid drain Chapter 8.4.7 ‘Changing the coolant liquid/changing the cooling liquid filter’ on page 115.
2. Remove the intake regulator and fill the coolant liquid directly into the compressor stage (Fig. 32/1).
3. Tighten 4 screws on the intake regulator (Fig. 32/1) ( Appendix B ‘Tightening torques for screws’ on page 137).
6.6 Switching on after the initial commissioning Personnel: Qualified personnel
Protective equipment: Ear protection Protective work clothing
Safety boots
1. Check the media connections for correct installation.
2. Ensure that no tools or loose objects are in or on the machine.
3. Install and check that the sound installation covers are sealed.
4. Carefully open the gate valve after the compressed air connection between the screw compressor and the compressed air network.
The screw compressor is now connected to the compressed air network.
5. Switch on the main switch.
6. Start the screw compressor Controller documentation.
The compressor is ready and can start up automatically at any time.
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6.7 Working after the initial commissioning Personnel: Qualified personnel
Protective equipment: Protective work clothing Safety boots
Protective gloves
Light respiratory protection Safety goggles
WARNING! Danger of injury from hot surfaces! Surfaces of components can heat up a lot during operation. Skin contact with hot surfaces will cause severe skin burns. - During all work hear hot surfaces, wear heat-resistant
protective clothing and protective gloves. - Before all work, make sure that all surfaces have
cooled off to the ambient temperature, wait at least 30 minutes.
CAUTION! Danger of injury from coolant liquid fog! In case of high temperatures or mechanical dust, coolant liquid fog can form. Coolant liquid fog can irritate eyes and the respiratory system. - When working on the coolant liquid system and if a
coolant liquid fog arises, wear breathing protection and protective goggles and ensure that there is a fresh air supply.
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1. Switch the machine off and secure to prevent restarting.
2. Open and remove the sound insulation covers with the special spanner.
3. Wait until the components have cooled off.
4. Check all coolant liquid and compressed air lines for leaks.
5. If there is coolant liquid in the system, it must be removed.
6. The connectors of the components must be checked and the screws tightened Appendix B ‘Tightening torques for screws’ on page 137.
Fig. 33: Checking the coolant liquid level in the inspection glass
7. Check the coolant liquid level in the inspection glass (Fig. 33/1) and top up as in Chapter 8.4.2 ‘Checking the coolant liquid level/topping up the coolant liquid’ on page 109 if necessary.
8. Install and check that the sound installation covers are sealed.
NOTICE! Property damage to to compressor temperature that is too low or too high! A compressor temperature that is too low or too high can cause damage to the screw compressor. - Contact the manufacturer for more precise
information, for contact information see page 2.
A sufficiently high compressor temperature guarantees that the humidity taken in will not become condensate. Frequent switching on and off of the screw compressor can cause the compressor not to reach the required operating temperature Chapter 8.4.6 ‘Checking the condensation accumulation’ on page 114.
9. Check compressor temperature Chapter 8.4.4 ‘Checking the
compressor temperature’ on page 112.
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6.8 Setting parameters
Adjustment work for the screw compressor: Chapter 7.4 ‘Controllers’ on page 78.
6.9 Measures in case of low compressed air requirement
Measures
NOTICE! Risk of material damage in case of an excessively long downtime! Frequent operating cycles and a longer system downtime can cause increased wear.
To prevent damage in case of a low compressed air requirement, take the following measures: - Adjust the compressor to the actual compressed air
requirement. - Use a compressed air buffer tank with sufficient
dimensions. - Perform at least one hour of continuous on-load
operation in the control range every week.
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7 Operation 7.1 Safety instructions for operation
Improper operation
WARNING! Danger of injury due to improper operation! Improper operation can cause serious injury and significant material damage. - Carry out all operating steps in accordance with the
information and notices in this manual. - Pay attention to the following points before starting
work: - Ensure that all covers and safety devices are
installed and work properly. - Ensure that that no one is in the danger zone.
- Never override or bridge safety features during operation.
7.2 Shutdown in emergency situations In dangerous situations component movements must be stopped as
quickly as possible and the power supply must be switched off.
Shutdown in emergency situations
In an emergency situation proceed as follows:
1. Immediately trigger an emergency stop through the emergency stop device.
2. If there is no danger to your own health get people out of the danger zone.
3. Initiate first-aid measures if necessary.
4. Alert the fire department and/or rescue service.
5. Inform the responsible parties at the implementation site.
6. Switch off the machine and safeguard it from being switched on again.
7. Keep entry ways clear for rescue vehicles.
8. Give directions to rescue vehicles.
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After the rescue measures 9. Depending on the seriousness of the emergency situation, inform the responsible government agencies.
10. Assign specialized personal to resolve the malfunction.
WARNING! Life-threatening danger if restarted without authorization or due to uncontrolled restart! Uncontrolled or unauthorized switching on of the power supply can cause severe or fatal injuries. - Prior to restart ensure that all safety devices are
mounted and functional, and that there is no danger for personnel.
11. Prior to restarting the machine check and ensure that all safety
devices are installed and functioning.
7.3 Operating personnel and personal protective equipment The following personnel qualifications and personal protective
equipment apply for all work on all controllers:
Personnel: Trained Person
Protective equipment: Ear protection
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7.4 Controllers
Controller variants For the controller variant installed, please consult the label on the controller.
7.4.1 Controller COMBI 3S – 4S 7.4.1.1 Overview
Fig. 34: Controller COMBI 3S – 4S
No. Description of function
1 Main switch with emergency stop function
2 Operating hours counter
3 Pressure gauge
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7.4.1.2 Switching the compressor on/off
Switching the compressor on
Fig. 35: Switching the compressor on
1. Turn the twist switch to the right.
The compressor starts up automatically.
The compressor is shut off automatically by the pressure switch (automatic mode) once operating pressure is achieved. If the operating pressure drops again, the compressor is switched back on again automatically by the pressure switch.
Switching the compressor off
Fig. 36: Switching the compressor off
1. Turn the twist switch to the left.
The compressor is switched off.
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7.4.2 Controller COMBI 5S 7.4.2.1 Overview
Fig. 37: Controller COMBI 5S
No. Key/icon Description of function
1
Main switch with emergency stop function
2
Displays the hours of operation.
3
Serves to switch on the compressor.
4
Indicates the operating state.
5
Serves to switch off the compressor.
7.4.2.2 Switching the compressor on/off
Switching the compressor on
1. Press .
The operating indicator lights up, the compressor is ready and can start up automatically at any time.
Switching the compressor off
1. Press .
The operating indicator no longer lights up, the compressor switches itself off.
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7.4.3 Air Control AC mini controller
7.4.3.1 Air Control Mini overview
Fig. 38: Overview of Air Control AC mini
No. Key/icon Description of function
1 Display Displays settings and operating parameters.
2
Serves to switch on the compressor. The integrated green LED indicates the operating state. Serves to scroll and increase values.
3
Serves to switch off the compressor, to acknowledge fault/warning messages and to call up the code input menu.
Serves to scroll and reduce values.
4
Serves to call up additional operating data.
5
Indicates the operating state.
6
Indicates warnings with flashing and faults with red LEDs that light up.
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7.4.3.2 Brief description
The Air Control AC mini controller serves to display operating data/the compressor state
to switch on/off the compressor/the compressed air generation
to program the compressor and the compressed air generation.
7.4.3.3 Operating modes
Overview Four operating modes can be set using the controller.
Operating mode Description
Automatic operation After reaching the switch-off pressure, the system switches to idle for the duration of the idle time (run-on). After the run-on time has elapsed, the motor switches off. The compressor can start up by itself at any time if the machine drops below the switch-on pressure.
Load/idle operation The compressor switches between "Load" and "Idle" operation; that is, there is an unlimited run-on.
Optional automatic After reaching the switch-off pressure, the compressor switches to idle. After 10 and 40 seconds, the respective network pressure is measured. If the pressure drop determined this way is above the threshold "Max. pressure drop", the compressor remains in idle for the duration of the run-on time. If the value determined is below the threshold "Max. pressure drop", the compressor switches off after the shutdown time has elapsed.
Basic load switching mode (BLS operation)
The switch on/off pressure set is not taken into account by the controller. The compressor is controlled by a superior controller, which can be connected via freely-programmable inputs (no RS485 present).
Safety pressure The safety pressure is the sum of the set maximum pressure + 0.8 bar. If the pressure exceeds the value of the safety pressure, the compressor is switched off with a fault message. If the maximum pressure is exceeded by 0.5 bar, a warning appears on the display.
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7.4.3.4 Overview of display
The display shows all operation-relevant information such as the parameters set.
Fig. 39: Overview of basic display
1 Display [Aktueller Netzdruck (Current network pressure)]: Displays the current network pressure.
2 Display [Aktuelle Verdichtertemperatur (Current compressor temperature)]: Displays the current compressor temperature.
3 [Betriebsart (Operating mode)] display: Displays the current operating mode.
By pressing the key, the current coolant liquid temperature can also be shown on the [Aktuelle Verdichtertemperatur (Current compressor temperature)] display.
Other display indicators The following symbols can also appear on the display:
Symbol Description
Warning/maintenance message present.
Fault present.
Operating mode automatic/optional automatic active.
Automatic restart after power failure is activated.
Flashing: compressed air generation on/off via remote switch. Static: compressed air generation is controlled by superior controller.
Motor is running.
Compressor is compressing air.
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7.4.3.5 Switching the compressor on/off
Switching the compressor on
1. Press .
The compressor is ready and can start up automatically at any time.
Switching the compressor off
1. Press .
When switching off, the compressor switches for the duration of the shutdown time to "idle" (motor runs, compressor does not compress any air, blinks on the display). After the shutdown time, the compressor switches off.
7.4.3.6 Calling up information
It is possible to display various information about operating states and parameter values on the display. In order to switch between the information and the parameter displays, it is only necessary to press the key. The Information menu with parameter number and the parameter value then appears on the display.
1. Press .
The next parameter value is shown on the display.
In the information menu, the parameter [Einschaltdruck (Switch-on pressure)] is always shown as the first value.
After approx. 5 seconds without pressing the key, the display switches back to the basic display.
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Key Parameter displayed Parameter number Unit of the parameter value
Switch-on pressure [1] [bar, MPa, psi]
Switch-off pressure [2] [bar, MPa, psi]
Safety pressure [3] [bar, MPa, psi]
Minimum pressure monitoring in BLS operation
[4] [bar, MPa, psi]
Minimum compressor temperature
[5] [°C, °F, Kelvin]
Maximum compressor temperature
[6] [°C, °F, Kelvin]
Hours of operation [7] [h]
Load hours [8] [h]
Remaining time intake filter [9] [kh]
Remaining time coolant liquid and coolant liquid filter
[10] [kh]
Remaining time fine precipitator
[11] [kh]
Remaining time motor lubrication
[12] [kh]
Remaining time compressor maintenance
[13] [kh]
Remaining time dryer maintenance
[14] [kh]
Hours of operation dryer [15] [h]
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7.4.3.7 Setting parameters via code input menu
The parameters for all basic settings of the compressor can be changed with code input insofar as these changes do not influence the operational stability. However, this is only possible when the compressed air generation is switched off.
7.4.3.7.1 Calling up the code input menu
1. Press and hold for three seconds.
The code input menu appears on the display.
2. Press .
A 1 appears on the display.
3. Press .
In order to exit the code input menu again, press the and keys together.
7.4.3.7.2 Inputting a code
Prerequisite: the code input menu has been called up.
1. Set the desired code with the keys.
2. To confirm the selected code, press .
The submenu for the selected code appears on the display.
For some codes, several parameters can be input one after another. By pressing the key, the next parameter is selected automatically in such cases.
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7.4.3.7.3 Select operating mode: Code 2
By entering the code 2, the operating mode can be selected.
1. Press and hold for three seconds.
The code input menu appears on the display.
2. Press .
A 1 appears on the display.
3. Press .
4. Set the code 2 with the keys.
5. To confirm the selected code, press .
6. Press .
The submenu for setting the operating mode appears on the display.
7.
There are three values from which to choose: - 0: Automatic operation - 1: Load/idle operation - 2: Optional automatic
Set the desired value with the keys.
8. To confirm the selected value, press .
The set value is saved and the code input menu appears on the display again.
9. Press the keys at the same time to go back to the basic display.
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Value Operating mode Description
0 Automatic operation After reaching the switch-off pressure, the compressor switches to idle for the duration of the idle time (run-on). After the idle time has elapsed, the compressor then switches off, but it remains ready for operation. If the switch-on pressure is reached, the compressor starts up again automatically.
1 Load/idle operation The compressor switches between "Load" and "Idle" operation; that is, there is an unlimited run-on.
2 Optional automatic The "Automatic" symbol and an additional point are shown on the display in front of the temperature value. Here it is possible to influence how frequently the motor stops. To do this, after the confirmation, the parameters "maximum pressure drop" (input range 0.0 to 9.9 bar) and "maximum operating cycle" (input range 1 to 55 operating cycles/hour) are queried.
Maximum pressure drop If the system switches from load operation to idle, the Air Control mini saves the current network pressure after 10 and 40 seconds. If the pressure drop determined this way is above the "maximum pressure drop", the motor switches off after the idle time has elapsed; otherwise after the shutdown time.
Maximum operating cycles The motor is not switched off after the idle time (run-on) has elapsed if the number of switch-on processes of the compressor exceeds the number of the "maximum operating cycles".
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7.4.3.7.4 Switch automatic restart on/off: Code 3
By inputting the code 3, the automatic restart can be switched on/off after a power failure.
1. Press and hold for three seconds.
The code input menu appears on the display.
2. Press .
A 1 appears on the display.
3. Press .
4. Set the code 3 with the keys.
5. To confirm the selected code, press .
The submenu for switching the automatic restart on/off appears on the display.
6.
There are two values from which to choose: - 0: Automatic restart OFF - 1: Automatic restart ON
Set the desired value with the keys.
7. To confirm the selected value, press .
The set value is saved and the code input menu appears on the display again.
8. Press the keys at the same time to go back to the basic display.
Value Setting Description
0 Automatic restart OFF If the automatic restart after power failure is switched off, then after a power failure, the fault "no AC" is displayed. This fault must be acknowledged manually by pressing the key. Otherwise, the compressor will not restart.
1 Automatic restart ON If the automatic restart after power failure is switched on, the time set in the "shutdown time" parameter must elapse. If the compressor was operating before the power failure, then after this time has elapsed, it will start up again. Otherwise, the compressor will then switch to STOP mode.
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7.4.3.7.5 Dryer dew-point monitoring: Code 6
The dew-point monitoring can be switched on and off by entering code 6.
1. Press and hold for three seconds.
The code input menu appears on the display.
2. Press .
A 1 appears on the display.
3. Press .
4. Set code 6 using keys.
5. To confirm the selected code, press .
The dew-point temperature is monitored at the set limits and the temperature sensor is monitored for defects, if the function is activated. - Dew-point temperature max. 0 °C – +50 °C - Dew-point temperature min.. -10 ℃ – +50 °C (when the dew-point is set to min/max auf 0 °C the
monitoring is switched off) - Setting Warning 0 Setting Malfunction 1
6. Using key and set the desired maximum dew-point and
confirm with .
7. Using key and set the desired minimum dew-point and confirm with .
8. Using key and carry out setting Warning/Malfunction and confirm with .
The set values are saved and the code input menu appears on the display again.
9. Press the keys at the same time to go back to the basic display.
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7.4.3.7.6 Set on-site operation/remote operation: Code 8
By inputting the code 8, it is possible to switch between on-site operation and remote operation.
1. Press and hold for three seconds.
The code input menu appears on the display.
2. Press .
A 1 appears on the display.
3. Press .
4. Set the code 8 with the keys.
5. To confirm the selected code, press .
The on-site operation/remote control submenu appears on the display.
6.
There are three values from which to choose: - 0: On-site operation - 1: Remote control - 2: BLS-OK
Set the desired value with the keys.
7. To confirm the selected value, press .
The set value is saved and the code input menu appears on the display again.
8. Press the keys at the same time to go back to the basic display.
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Value Designation Description
0 On-site operation The compressed air generation can only be switched on or off on the control console/display of the Air Control 1.
1 Remote control The compressed air generation can only be switched on via a positive edge (24 VDC) on terminal 23 and switched off via low level (0 V) on terminal 23 or via the key. This functionality is identified by the flashing text on the display of the Air Control 1. If the key is pressed on the system on-site, the system switches off after 120 seconds and for safety reasons, it can only be started via remote control after the key has been pressed (acknowledgement) on-site. This also applies for a start via PLANT CONTROL V/T.
2 BLS-OK The input on terminal 23 serves to report the operational readiness of an external controller. Only with an existing high level (24 VDC) can the external controller switch between load operation and idle. During existing low level, the BLS operation is switched off automatically and the internal pressure sensor is used.
7.4.3.7.7 Set switch on/off pressure: Code 11
By inputting the code 11, it is possible to set the switch-on and switch-off pressure. The switch-on pressure specifies the pressure at which the switched-on compressor will begin automatically with the compression. The switch-off pressure specifies the pressure at which the compressor will be switched off automatically. Both functions are only active in automatic operation.
1. Press and hold for three seconds.
The code input menu appears on the display.
2. Press .
A 1 appears on the display.
3. Press .
4. Set the code 11 with the keys.
5. To confirm the selected code, press .
6. Press .
The submenu for setting the switch-on pressure appears on the display.
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7.
The adjustment range for the switch-on pressure is, with switch-off pressure set at the factory, between 3.5 and 7.9 bar. The upper limit for the switch-on pressure is 0.1 bar less than the switch-off pressure.
Set the desired switch-on pressure with the keys.
8. To confirm the setting, press the key.
The set value was saved and the submenu for setting the switch-off pressure appears on the display.
9.
The adjustment range for the switch-off pressure is, with switch-on pressure set at the factory, between 7.1 and 10 bar. The upper limit for the switch-off pressure is equal to the maximum pressure. The lower limit for the switch-off pressure is 0.1 bar higher than the switch-on pressure.
Set the desired switch-off pressure with the keys.
10. To confirm the setting, press the key.
The set value is saved and the code input menu appears on the display again.
11. Press the keys at the same time to go back to the basic display.
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7.4.3.7.8 Switch Basic load switching mode on/off: Code 18
By inputting the code 18, the Basic load switching mode can be switched on/off.
1. Press and hold for three seconds.
The code input menu appears on the display.
2. Press .
A 1 appears on the display.
3. Press .
4. Set the code 18 with the keys.
5. To confirm the selected code, press .
The Basic load switching mode submenu appears on the display.
6.
There are two values from which to choose: - 0: Basic load switching mode is switched off - 1: Basic load switching mode is switched on
Set the desired value with the keys.
7. To confirm the selected value, press .
The set value is saved and the code input menu appears on the display again.
8. Press the keys at the same time to go back to the basic display.
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7.4.3.7.9 Switch the pressure unit: Code 90
By entering the code 90, the pressure unit can be switched.
1. Press and hold for three seconds.
The code input menu appears on the display.
2. Press .
A 1 appears on the display.
3. Press .
4. Set the code 90 with the keys.
5. To confirm the selected code, press .
The submenu for setting the pressure unit appears on the display.
6.
There are three values from which to choose: - 0: bar - 1: MPa - 2: psi (pounds per square inch)
Set the desired value with the keys.
7. To confirm the selected value, press .
The set value is saved and the code input menu appears on the display again.
8. Press the keys at the same time to go back to the basic display.
Value Pressure unit Description
0 bar All pressure displays will be in bar.
1 MPa All pressure displays will be in Megapascals.
2 psi All pressure displays will be in psi (pounds per square inch).
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7.4.3.7.10 Switch the temperature unit: Code 95
By entering the code 95, the temperature unit can be switched.
1. Press and hold for three seconds.
The code input menu appears on the display.
2. Press .
A 1 appears on the display.
3. Press .
4. Set the code 95 with the keys.
5. To confirm the selected code, press .
The submenu for setting the temperature unit appears on the display.
6.
There are three values from which to choose: - 0: °C - 1: °F - 2: K
Set the desired value with the keys.
7. To confirm the selected value, press .
The set value is saved and the code input menu appears on the display again.
8. Press the keys at the same time to go back to the basic display.
Value Pressure unit Description
0 Degrees Celsius All temperature displays will be in °C.
1 Degrees Fahrenheit All temperature displays will be in °F.
2 Kelvin All temperature displays will be in Kelvin.
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7.4.3.7.11 Display the software version: Code 9999
By inputting the code 9999, the software version can be displayed.
1. Press and hold for three seconds.
The code input menu appears on the display.
2. Press .
A 1 appears on the display.
3. Press .
4. Set the code 9999 with the keys.
5. To confirm the selected code, press .
The software version appears on the display.
6. Press the keys together to go back to the code input menu.
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7.4.3.8 Fault and warning messages 7.4.3.8.1 Fault messages
The symbol blinks and the [Aktueller Netzdruck (Current network pressure)] indicator displays the fault message and the current network pressure in alternation. The compressor stops automatically.
No. Description
E. 1 Pressure set points incorrect
E. 2 Setting parameter incorrect
E. 3 Low voltage
E. 4 Power failure
E. 5 Air Control mini faulty
E. 6 Emergency stop pressed
E. 7 Direction of rotation incorrect
E. 8 Motor temperature too high
E. 9 Overcurrent
E. 10 Overpressure
E. 11 Dryer fault
E. 12 Sensor compression temperature
E. 13 Sensor coolant liquid temperature
E. 14 Sensor pressure
E. 15 Compressor temperature too high
E. 16 Network pressure too high
E.17 Dew-point temperature too low
E.18 Dew-point temperature too high
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NOTICE! Property damage due to incorrect acknowledgement of fault messages! Faults which occur are output as fault messages. Only after the fault has been eliminated may the fault messages be acknowledged, since otherwise the service life of the compressor will be reduced. - Only have maintenance work performed by qualified
personnel. - Only acknowledge fault messages after the
appropriate work. - Only use original spare parts.
Acknowledging fault messages
Faults may only be acknowledged if the cause has been eliminated properly. Only have troubleshooting and maintenance work performed by qualified personnel.
1. Press .
2. Press .
The compressor is ready and can start up automatically at any time.
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7.4.3.8.2 Warning messages
The symbol blinks and the [Aktueller Netzdruck (Current network pressure)] indicator displays the warning message and the current network pressure in alternation.
No. Description
E.33 Dew-point temperature
E. 34 Compressor temperature increased
E. 35 Network pressure increased
E. 36 Temperature too low
E. 39 Lower pressure threshold reached
E. 42 Maintenance dryer (remaining maintenance time < 100 h)
E. 43 Maintenance intake filter (remaining maintenance time < 100 h)
E. 44 Maintenance coolant liquid / coolant liquid filter (remaining maintenance time < 100 h)
E. 45 Maintenance fine precipitator (remaining maintenance time < 100 h)
E. 46 Maintenance motor lubrication (remaining maintenance time < 100 h)
E. 47 Maintenance compressor (remaining maintenance time < 100 h)
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Acknowledging warning messages
NOTICE! Property damage due to incorrect acknowledgement of warning messages! Maintenance which needs attention is output as warning messages. Only after the maintenance has been performed may the warning messages be acknowledged, since otherwise the service life of the compressor will be reduced. - Only have maintenance work performed by qualified
personnel. - Only acknowledge warning messages after the
appropriate work. - Only use original spare parts.
1. Press and hold for three seconds.
The code input menu appears on the display.
2. Press .
A 1 appears on the display.
3. Press .
4. Set the code 21 with the keys.
5. To confirm the selected code, press .
6. Press the key in order to restart the maintenance interval.
7. Press the keys at the same time to go back to the basic display.
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8 Maintenance 8.1 Safety instructions for maintenance
Electrical system
DANGER! Danger to life from electric power! Contact with live parts may prove fatal. When switched on, electric components may be subject to uncontrolled movements and may cause grave injury. - Switch off the power supply before starting work and
make sure that it cannot be switched on again.
Moving parts
WARNING! Danger of injury from moving parts! Rotating parts and/or parts moving in linear fashion may cause serious injuries. - Before carrying out any maintenance work on moving
parts, shut down the machine and take precautions to prevent restarting. Wait until all parts have stopped moving.
- When in the danger zone, wear close-fitting protective work clothing with low tear strength.
Securing to prevent restart
WARNING! Danger to life from an unauthorised restart! In the event of an unauthorised restart of the power supply during maintenance, there is a danger of serious injuries or death for persons in the danger zone. - Switch off all power supplies before starting work and
make sure they cannot be switched on again.
Hot surfaces
WARNING! Danger of injury from hot surfaces! Surfaces of components can heat up a lot during operation. Skin contact with hot surfaces will cause severe skin burns. - During all work hear hot surfaces, wear heat-resistant
protective clothing and protective gloves. - Before all work, make sure that all surfaces have
cooled off to the ambient temperature, wait at least 30 minutes.
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Improperly performed maintenance
WARNING! Danger of injury due to improperly performed maintenance! Improperly performed maintenance may lead to serious injury and significant material damage. - Provide for sufficient mounting clearance before
starting to work. - Keep the assembly area tidy and clean! Loose
components and tools lying around or on top of each other may lead to accidents.
- When reinstalling previously removed components, make sure that the components are mounted properly, all fixing elements are reinstalled, and all screws are tightened to torque.
- Before putting the machine back into operation: - make sure that all maintenance work has been
performed and completed following the instructions and information provided in this manual.
- make sure that no persons are still in the danger zone of the machine.
- make sure that all covers and safety devices have been installed and function properly.
Compressed air
WARNING! Danger of injury from compressed air! Compressed air can escape from compressed air hoses or components under pressure in case of improper handling or in case of a fault. It can injure eyes, whip up dust or cause uncontrolled movements of hoses. Components under pressure can move in uncontrolled fashion with improper handling and cause injuries. - Before removing hoses or components under
pressure, make sure the pressure is relieved. - Have faulty components that are under pressure
during operation replaced by appropriate specialist personnel immediately.
- Before all work, make sure that the compressor is not under pressure; wait at least 5 minutes.
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Coolant liquid fog
CAUTION! Danger of injury from coolant liquid fog! In case of high temperatures or mechanical dust, coolant liquid fog can form. Coolant liquid fog can irritate eyes and the respiratory system. - When working on the coolant liquid system and if a
coolant liquid fog arises, wear breathing protection and protective goggles and ensure that there is a fresh air supply.
Accumulations of liquid
CAUTION! Danger of injury from slipping in accumulations of liquid! Slipping in accumulations of liquid on the floor may result in a fall. A fall may result in injuries. - Remove accumulations of liquid immediately using
appropriate means. - Wear anti-slip safety shoes. - Post warnings and mandatory signs at or in the
vicinity of any area where liquid could accumulate on the floor.
Environmental protection Observe the following environmental protection instructions during maintenance work:
In respect of all lubrication points supplied manually with lubricant, remove any escaping, used or surplus grease and dispose of in accordance with applicable local regulations.
Catch replaced oils in suitable containers and dispose of in accordance with applicable local regulations.
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8.2 Spare parts
WARNING! Danger of injury due to use of incorrect spare parts! The use of incorrect or defective spare parts can lead to personal injury, material damage, malfunction or total failure. - Use only original manufacturer's spare parts or spare
parts that have been approved of by the manufacturer.
- Always contact the manufacturer if in doubt.
Loss of warranty The manufacturer's warranty will be rendered null and void if spare parts are used that are not approved.
Spare parts must be procured through an authorised dealer or directly from the manufacturer. Contact details, see page 2.
The spare parts list can be found in the Appendix.
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8.3 Maintenance schedule Maintenance tasks are described in the sections below that are
required for optimal and trouble-free machine operation.
If increased wear is detected during regular inspections, then reduce the required maintenance intervals according to the actual indications of wear. Contact the manufacturer (see the service address on page 2), if you have questions concerning maintenance tasks and intervals.
Interval Maintenance work Personnel
Daily Checking the coolant liquid level Chapter 8.4.2 ‘Checking the coolant liquid level/topping up the coolant liquid’ on page 109
Qualified personnel
Check for leaks Chapter 8.4.3 ‘Checking for leaks’ on page 111
Qualified personnel
One week after initial installation
Check all electrical connections Chapter 8.4.1 ‘Checking the electrical connections’ on page 108
Qualified electrician
Weekly Check compressor temperature Chapter 7.4 ‘Controllers’ on page 78
Trained Person
Check cooler for soiling Chapter 8.4.5 ‘Checking soiling of the cooler’ on page 113
Qualified personnel
Check for condensate formation Chapter 8.4.6 ‘Checking the condensation accumulation’ on page 114
Qualified personnel
Check the drive belt for wear Trained Person
After the first 100 hours of operation
Check for leaks Chapter 8.4.3 ‘Checking for leaks’ on page 111
Qualified personnel
Check compressor temperature Chapter 7.4 ‘Controllers’ on page 78
Trained Person
Check cooler for soiling Chapter 8.4.5 ‘Checking soiling of the cooler’ on page 113
Qualified personnel
Check for condensate formation Chapter 8.4.6 ‘Checking the condensation accumulation’ on page 114
Qualified personnel
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Interval Maintenance work Personnel
After the first 500 hours of operation
Check all electrical connections Chapter 8.4.1 ‘Checking the electrical connections’ on page 108
Qualified electrician
Change coolant liquid Chapter 8.4.7 ‘Changing the coolant liquid/changing the cooling liquid filter’ on page 115
Qualified personnel
Change coolant liquid filter* Chapter 8.4.7 ‘Changing the coolant liquid/changing the cooling liquid filter’ on page 115
Qualified personnel
Retighten the drive belt Qualified personnel
Every 2000 hours of operation, at least once a year
Re-lubricate electric motor Chapter 8.4.8 ‘Re-lubricating the electric motor’ on page 118
Qualified personnel
Change coolant liquid Chapter 8.4.7 ‘Changing the coolant liquid/changing the cooling liquid filter’ on page 115
Qualified personnel
Change coolant liquid filter* Chapter 8.4.7 ‘Changing the coolant liquid/changing the cooling liquid filter’ on page 115
Qualified personnel
Change fine precipitator* Chapter 8.4.9 ‘Change fine precipitator’ on page 119
Qualified personnel
Change intake filter* Chapter 8.4.10 ‘Change intake filter’ on page 120
Qualified personnel
Check safety valve Manufacturer
Check drive unit Chapter 8.4.11 ‘Checking the drive unit’ on page 121
Qualified personnel
Check the belt tension of the drive Qualified personnel
Perform general compressor maintenance Manufacturer
Every 4000 hours of operation
Replace the drive belt Qualified personnel
* The change intervals refer to: Ambient temperature of +40 °C
Max. humidity of 60%
Compressor temperature of approx. 85 °C
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8.4 Maintenance work
Necessary maintenance work Necessary maintenance work appears on the display of the controller as a warning Chapter 7.4 ‘Controllers’ on page 78.
8.4.1 Checking the electrical connections
Personnel: Qualified electrician
Protective equipment: Safety boots Protective work clothing
Light respiratory protection
Safety goggles Protective gloves
DANGER! Danger to life from stored charges! Electric charges may be stored in electrical components; these charges may be maintained even after the system has been switched off and disconnected from the power supply. Contact with these components may result in serious or fatal injury. - Before working on the specified components, ensure
that they have been completely disconnected from the power supply. Allow 10 minutes to elapse in order to ensure that the internal capacitors have been fully discharged.
1. Switch the machine off and secure to prevent restarting.
2. Close compressed air network-side gate valve and secure against re-opening.
3. Open and remove the sound insulation covers with the special spanner.
4. Check all electrical connections and tighten if necessary Appendix B ‘Tightening torques for screws’ on page 137.
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8.4.2 Checking the coolant liquid level/topping up the coolant liquid
Checking the coolant liquid level Personnel: Qualified personnel
Protective equipment: Safety boots Protective work clothing
Light respiratory protection
Safety goggles
Protective gloves
1. Switch the machine off and secure to prevent restarting.
2. Close compressed air network-side gate valve and secure against re-opening.
3. Open and remove the sound insulation covers with the special spanner.
Fig. 40: Inspection glass
4. Check the inspection glass (Fig. 40/1) to make sure it is completely moist.
5. If the whole inspection glass height is not covered with coolant liquid, the coolant liquid must be topped up.
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Topping up the coolant liquid Personnel: Qualified personnel
Protective equipment: Safety boots Protective work clothing
Light respiratory protection
Safety goggles Protective gloves
Materials: Collecting tray for coolant liquid Funnel with filling tool
1. Switch the machine off and secure to prevent restarting.
2. Close compressed air network-side gate valve and secure against re-opening.
3. Open and remove the sound insulation covers with the special spanner.
4. With the help of a collection tray, make sure that the escaping coolant liquid is collected.
Fig. 41: Filler plug
5. Loosen the filler plug (Fig. 41/1), remove and make sure that the gasket does not get lost.
NOTICE! Property damage due to incorrect coolant liquid! Mixing different coolant liquids causes significant property damage to the screw compressor. - Only use the coolant liquid prescribed in the technical
data.
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Fig. 42: Filler plugs
6. With the help of a funnel (Fig. 42/1), fill coolant liquid up to the filling edge of the filler plug (Fig. 42/3).
7. Position the gasket and check for correct fit.
8. Insert the screw plug (Fig. 42/2) and tighten Appendix B ‘Tightening torques for screws’ on page 137.
8.4.3 Checking for leaks
Personnel: Qualified personnel
Protective equipment: Safety boots Protective work clothing
Light respiratory protection
Safety goggles Protective gloves
1. Switch the machine off and secure to prevent restarting.
2. Close compressed air network-side gate valve and secure against re-opening.
3. Open and remove the sound insulation covers with the special spanner.
4. Check all lines and the base for leaks.
5. If there is coolant liquid in the system, remove it.
6. Check the connectors of the components and tighten the screws Appendix B ‘Tightening torques for screws’ on page 137.
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8.4.4 Checking the compressor temperature
Personnel: Qualified personnel
Protective equipment: Safety boots Protective work clothing
NOTICE! Property damage to to compressor temperature that is too low or too high! A compressor temperature that is too low or too high can cause damage to the screw compressor. - Contact the manufacturer for more precise
information, for contact information see page 2.
- The compressor temperature should be between 70 °C and 100 °C.
- At 105 °C a warning is output. - At 110 °C the screw compressor is switched off
automatically.
1. Check compressor temperature Chapter 7.4 ‘Controllers’ on page 78.
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8.4.5 Checking soiling of the cooler
Personnel: Qualified personnel
Protective equipment: Safety boots Protective work clothing Light respiratory protection
Safety goggles
Protective gloves
1. Switch the machine off and secure to prevent restarting.
2. Close compressed air network-side gate valve and secure against re-opening.
3. Open and remove the sound insulation covers with the special spanner.
4. Check compressed air and coolant liquid cooler from inside and outside for soiling.
5. Remove soiling.
Soiling can be removed by blowing it out, e.g. While doing this, make sure that the soiling from the device is blown out of rather than into the machine. In case of severe soiling, consult the manufacturer.
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8.4.6 Checking the condensation accumulation
A sufficiently high compressor temperature guarantees that the humidity taken in will not become condensate. Frequent switching on and off of the screw compressor can cause the compressor not to reach the required operating temperature.
Personnel: Qualified personnel
Protective equipment: Safety boots Protective work clothing
Light respiratory protection Safety goggles
Protective gloves
NOTICE! Property damage due to condensation in the coolant liquid circuit! Condensate in the coolant liquid circuit can cause the destruction of the compressor stage. - In case of condensate in the coolant liquid pressure
tank, contact our service immediately; see page 2 for the contact data.
1. Switch the machine off and secure to prevent restarting.
2. Close compressed air network-side gate valve and secure against re-opening.
3. Open and remove the sound insulation covers with the special spanner.
4. With the help of a collection tray, make sure that the escaping coolant liquid is collected.
Condensate is heavier than the coolant liquid Since the condensate is heavier than the coolant liquid, after longer downtimes, it collects on the bottom of the coolant liquid pressure tank.
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Fig. 43: Coolant liquid drain
5. Carefully open the coolant liquid drain (Fig. 43/1) and check the liquid escaping.
6. Slowly drain condensate until coolant liquid escapes.
7. Close Appendix B ‘Tightening torques for screws’ on page 137 the coolant liquid drain (Fig. 43/1).
8. Switch on the compressor and switch off again after a maximum of one minute Controller documentation.
9. Check coolant liquid level and top up if necessary Chapter 8.4.2 ‘Checking the coolant liquid level/topping up the coolant liquid’ on page 109.
8.4.7 Changing the coolant liquid/changing the cooling liquid filter
Changing the coolant liquid Personnel: Qualified personnel
Protective equipment: Safety boots Protective work clothing
Light respiratory protection
Safety goggles Protective gloves
Materials: Collecting tray for coolant liquid Funnel with filling tool
1. Switch the machine off and secure to prevent restarting.
2. Close compressed air network-side gate valve and secure against re-opening.
3. Open and remove the sound insulation covers with the special spanner.
4. With the help of a collection tray, make sure that the escaping coolant liquid is collected.
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Fig. 44: Filler plug
5. Loosen the filler plug (Fig. 44/1), remove and make sure that the gasket does not get lost.
Fig. 45: Coolant liquid drain
6. Open the coolant liquid drain (Fig. 45/1).
Coolant liquid is drained.
7. Close the coolant liquid drain (Fig. 45/1).
NOTICE! Property damage due to incorrect coolant liquid! Mixing different coolant liquids causes significant property damage to the screw compressor. - Only use the coolant liquid prescribed in the technical
data.
Fig. 46: Filler plugs
8. With the help of a funnel (Fig. 46/1), fill coolant liquid up to the filling edge of the filler plug (Fig. 46/3).
9. Position the gasket and check for correct fit.
10. Insert the screw plug (Fig. 46/2) and tighten Appendix B ‘Tightening torques for screws’ on page 137.
11. Switch on the compressor and switch off again after a maximum of one minute Chapter 7.4 ‘Controllers’ on page 78.
12. Check coolant liquid level and top up if necessary Chapter 8.4.2 ‘Checking the coolant liquid level/topping up the coolant liquid’ on page 109.
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Changing the coolant liquid filter* Personnel: Qualified personnel
Protective equipment: Safety boots Protective work clothing
Light respiratory protection Safety goggles
Protective gloves
Materials: Collecting tray for coolant liquid Strap spanner
1. Switch the machine off and secure to prevent restarting.
2. Close compressed air network-side gate valve and secure against re-opening.
3. Open and remove the sound insulation covers with the special spanner.
4. With the help of a collection tray, make sure that the escaping coolant liquid is collected.
Fig. 47: Remove coolant liquid filter
5. Using the strap spanner, loosen and remove the old coolant liquid filter (Fig. 47/1).
6. Remove old gasket remains from the coolant liquid filter housing.
7. Moisten the new gasket with a little coolant liquid.
8. Screw in the new coolant liquid filter (Fig. 47/1) up to the stop.
9. Tighten the new coolant liquid filter (Fig. 47/1) half a turn by hand.
10. Switch on the compressor and switch off again after a maximum of one minute Chapter 7.4 ‘Controllers’ on page 78.
11. Check coolant liquid level and top up if necessary Chapter 8.4.2 ‘Checking the coolant liquid level/topping up the coolant liquid’ on page 109.
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8.4.8 Re-lubricating the electric motor
Personnel:
Protective equipment:
Materials:
Qualified personnel
Safety boots Protective work clothing Light respiratory protection
Safety goggles
Protective gloves
Lubrication grease ALMiG part number 183.00103
If there is no grease nipple on the electric motor, this has encapsulated, permanently-lubricated bearings. Replace these motor bearings when worn.
1. Switch the machine off and secure to prevent restarting.
2. Close compressed air network-side gate valve and secureagainst re-opening.
3. Open and remove the sound insulation covers with the specialspanner.
4. For the quantity of lubricating grease, consult the type plate of the electric motor.
The grease nipples are always on the side of the terminal box.
Fig. 48: Grease nipples
5. Grease the grease nipples (Fig. 48/1) with a grease gun.
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8.4.9 Change fine precipitator
Personnel: Qualified personnel
Protective equipment: Safety boots Protective work clothing Light respiratory protection
Safety goggles
Protective gloves
Materials: Strap spanner
1. Switch the machine off and secure to prevent restarting.
2. Close compressed air network-side gate valve and secure against re-opening.
3. Open and remove the sound insulation covers with the special spanner.
4. With the help of a collection tray, make sure that the escaping coolant liquid is collected.
Fig. 49: Loosen fine precipitator
5. Using the strap spanner (Fig. 49/2), loosen and remove the fine precipitator (Fig. 49/1).
6. Remove old gasket remains from the fine precipitator (Fig. 49/1).
7. Moisten the new gasket with a little coolant liquid.
Fig. 50: Fine precipitator
8. Screw in the new fine precipitator (Fig. 50/1) up to the stop.
9. Tighten the new fine precipitator (Fig. 50/1) half a turn by hand.
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8.4.10 Change intake filter
Standard intake filter Personnel: Qualified personnel
Protective equipment: Safety boots Protective work clothing
Light respiratory protection
Safety goggles
Protective gloves
1. Switch the machine off and secure to prevent restarting.
2. Close compressed air network-side gate valve and secure against re-opening.
3. Open and remove the sound insulation covers with the special spanner.
Fig. 51: Loosen the clamp of the intake filter
4. Loosen the intake filter (Fig. 51/2).
5. Remove the old intake filter (Fig. 51/1).
6. Attach the new intake filter (Fig. 51/1).
7. Tighten the clamp of the intake filter (Fig. 51/2) Appendix B ‘Tightening torques for screws’ on page 137.
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8.4.11 Checking the drive unit
Personnel: Qualified personnel
Protective equipment: Safety boots Protective work clothing Light respiratory protection
Safety goggles
Protective gloves
1. Switch the machine off and secure to prevent restarting.
2. Close compressed air network-side gate valve and secure against re-opening.
3. Open and remove the sound insulation covers with the special spanner.
4. Visually check the drive unit.
In case of visible defects, contact the manufacturer.
8.5 Measures after maintenance has been performed After completion of the maintenance work and before switching the
machine on, carry out the following steps:
1. Check all previously-loosened screw connections to make sure they are tight.
2. Check whether all previously-removed protective equipment and covers have been replaced properly.
3. Ensure that all tools, materials and other equipment used has been removed from the work area.
4. Carefully open the compressed air network-side gate valve.
5. Clean the work area and remove any substances such as liquids, processing material or similar that may have escaped.
6. Ensure that all safety equipment on the machine functions perfectly.
7. Document work on the machine in the service manual ( Appendix C ‘Service manual’ on page 138).
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9 Faults
The following section describes possible causes of faults and the work to remedy them.
In case of faults that occur more than once, abbreviate the maintenance intervals according to the actual utilisation.
In case of faults that cannot be remedied using the following instructions, contact the manufacturer, see contact data on page 2.
9.1 Safety instructions for fault clearance
Electrical system
DANGER! Danger to life from electric power! Contact with live parts may prove fatal. When switched on, electric components may be subject to uncontrolled movements and may cause grave injury. - Switch off the power supply before starting work and
make sure that it cannot be switched on again.
Hot surfaces
WARNING! Danger of injury from hot surfaces! Surfaces of components can heat up a lot during operation. Skin contact with hot surfaces will cause severe skin burns. - During all work hear hot surfaces, wear heat-resistant
protective clothing and protective gloves. - Before all work, make sure that all surfaces have
cooled off to the ambient temperature, wait at least 30 minutes.
Securing to prevent restart
WARNING! Danger to life from an unauthorised restart! In the event of an unauthorised restart of the power supply while tracking down and rectifying a fault, there is a danger of serious injuries or death for persons in the danger zone. - Switch off all power supplies before starting work and
make sure they cannot be switched on again.
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Improperly executed troubleshooting work
WARNING! Danger of injury from improper troubleshooting! Improperly executed troubleshooting work may result in serious injury and significant damage to property. - Ensure sufficient assembly space before starting
work. - Pay attention to orderliness and cleanliness in the
assembly location! Loosely stacked or scattered components and tools could cause accidents.
- If components have been removed, pay attention to correct assembly, refit all fixing elements and comply with bolt tightening torques.
- Before the restart, ensure that - all troubleshooting work has been carried out and
completed in accordance with the information and instructions in this manual.
- no persons are in the danger zone. - all covers and safety devices are installed and
functioning properly.
Compressed air
WARNING! Danger of injury from compressed air! Compressed air can escape from compressed air hoses or components under pressure in case of improper handling or in case of a fault. It can injure eyes, whip up dust or cause uncontrolled movements of hoses. Components under pressure can move in uncontrolled fashion with improper handling and cause injuries. - Before removing hoses or components under
pressure, make sure the pressure is relieved. - Have faulty components that are under pressure
during operation replaced by appropriate specialist personnel immediately.
- Before all work, make sure that the compressor is not under pressure; wait at least 5 minutes.
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Coolant liquid fog
CAUTION! Danger of injury from coolant liquid fog! In case of high temperatures or mechanical dust, coolant liquid fog can form. Coolant liquid fog can irritate eyes and the respiratory system. - When working on the coolant liquid system and if a
coolant liquid fog arises, wear breathing protection and protective goggles and ensure that there is a fresh air supply.
Behaviour in the event of faults The following applies in principle:
1. Immediately initiate an emergency stop in the event of faults posing an immediate danger to people or property.
2. Ascertain the cause of the fault.
3. If fault rectification requires work in the danger zone, shut down the machine and secure to prevent restarting.
Immediately notify those responsible at the place of use about the fault.
4. Depending on the nature of the fault, have it rectified by authorised specialised personnel or rectify it yourself.
The fault table below provides information about who is authorised to rectify the fault.
9.2 Fault displays Refer to the controller documentation for information on fault
displays.
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Faults
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9.3 Fault table
Fault description Cause Remedy Personnel
Compressor temperature too high (red lamp lights up)
Intake or ambient temperature too high
Ventilate compressor room
Qualified personnel
Cooling air intake or outlet blocked
Unblock cooling air intake or outlet sufficiently
Qualified personnel
Coolant liquid is soiled Change coolant liquid Chapter 8.4.7 ‘Changing the coolant liquid/changing the cooling liquid filter’ on page 115
Qualified personnel
Coolant liquid low Top up coolant liquid Chapter 8.4.2 ‘Checking the coolant liquid level/topping up the coolant liquid’ on page 109
Qualified personnel
Coolant liquid cooler soiled
Clean coolant liquid cooler Chapter 8.4.5 ‘Checking soiling of the cooler’ on page 113
Qualified personnel
Network pressure drops
Compressed air consumption higher than delivery quantity of the screw compressor
Screw compressor with greater delivery quantity necessary
Manufacturer
Intake filter soiled Replace intake filter Chapter 8.4.10 ‘Change intake filter’ on page 120
Qualified personnel
Bleeder valve blows during compression
Check bleeder valve and replace gaskets if necessary
Manufacturer
Intake regulator does not open
Check magnet valve and plunger and replace if necessary
Manufacturer
Leaks in the compressed air network
Seal up the compressed air network
Qualified personnel
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Fault description Cause Remedy Personnel
Screw compressor blows via safety valve
Minimum pressure valve blocked
Clean or replace minimum pressure valve
Manufacturer
Safety valve faulty Check safety valve and replace if necessary
Manufacturer
Fine precipitator soiled Change fine precipitator Chapter 8.4.9 ‘Change fine precipitator’ on page 119
Qualified personnel
"Overpressure fault "or "Network pressure too high" (red lamp lights up)
Fine precipitator soiled Change fine precipitator Chapter 8.4.9 ‘Change fine precipitator’ on page 119
Qualified personnel
Higher outside pressure present in compressed air network
Balance out outside pressure or disconnect from the network
Qualified personnel
Screw compressor does not start automatically or does not discharge after previous switching-off by reaching the final pressure or from idle.
Network pressure set too high
Reset network pressure Chapter 7.4 ‘Controllers’ on page 78
Trained Person
Interruption in the power circuit
Check power circuit for interruption
Qualified electrician
Ambient temperature below +1 °C, message "Coolant liquid temperature too low"
Install additional heating or temper compressor room and also contact the manufacturer
Qualified personnel
Switching times are activated in the circuitry
Check switching and pressure times in the circuitry Chapter 7.4 ‘Controllers’ on page 78
Trained Person
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Fault description Cause Remedy Personnel
System does not start up when the start key is pressed
Network pressure greater than switch-on pressure
Heed network pressure and change settings Chapter 7.4 ‘Controllers’ on page 78
Trained Person
Symbol "remote" flashes Remote control activated Chapter 7.4 ‘Controllers’ on page 78
Trained Person
Lacking voltage on the screw compressor
Check whether there is voltage
Qualified electrician
Electrical fault in the controller
Check controller Qualified electrician
Switching times are activated in the circuitry
Check switching and pressure times in the circuitry Chapter 7.4 ‘Controllers’ on page 78
Trained Person
Compressed air contains a lot of coolant liquid (coolant liquid consumption too high)
Return line for the coolant liquid is blocked
Clean or replace return line for the coolant liquid ‘Clean/change return line’ on page 128
Qualified personnel
Flawed fine precipitator Change fine precipitator Chapter 8.4.9 ‘Change fine precipitator’ on page 119
Qualified personnel
System stops before reaching the final pressure (red lamp lights up)
Overtemperature or overpressure
Eliminate fault Chapter 7.4 ‘Controllers’ on page 78
Trained Person
Interruption in the control power circuit
Check power circuit Qualified electrician
Pressure drop Pressure difference of the filter too high
Replace filter Qualified personnel
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9.4 Work for fault clearance
Clean/change return line Personnel: Qualified personnel
Protective equipment: Safety boots Protective work clothing
Light respiratory protection
Safety goggles Protective gloves
1. Switch the machine off and secure to prevent restarting.
2. Close compressed air network-side gate valve and secure against re-opening.
3. Open and remove the sound insulation covers with the special spanner.
4. With the help of a collection tray, make sure that the escaping coolant liquid is collected.
Fig. 52: return line
5.
Depending on the type, several fine precipitators can be installed. There is a return line for each fine precipitator.
Loosen return line (Fig. 52/2) on separator box (Fig. 52/3) and compressor stage (Fig. 52/1).
6. Clean return line (Fig. 52/2) and nozzle, if necessary replace with original spare parts ( Appendix D ‘Spare parts list’ on page 142).
7. Put nozzle and return line (Fig. 52/2) back in position and tighten screws ( Appendix B ‘Tightening torques for screws’ on page 137).
9.5 Commissioning after remedied fault After remedying the fault, carry out the following steps for re-
commissioning:
1. Reset emergency stop equipment.
2. Acknowledge fault Controller documentation.
3. no persons are in the danger zone.
4. Start the screw compressor Controller documentation.
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Dismantling and disposal
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10 Dismantling and disposal
Following the end of its useful life, the machine must be dismantled and disposed of in accordance with the environmental regulations.
10.1 Safety instructions for dismantling and disposal
Electrical system
DANGER! Danger to life from electric power! Contact with live parts may prove fatal. When switched on, electric components may be subject to uncontrolled movements and may cause grave injury. - Before starting the dismantling, switch off the electric
power supply and disconnect completely.
Improper dismantling
WARNING! Danger of injury due to improper dismantling! Stored residual energy, angular components, points and edges on or in the machine or on the tools needed can cause injuries. - Ensure sufficient space before starting work. - Handle exposed, sharp-edged components with care. - Pay attention to orderliness and cleanliness in the
workplace! Loosely stacked or scattered components and tools could cause accidents.
- Dismantle the components properly. Note that some components may have a high intrinsic weight. Use hoists if necessary.
- Secure components so that they cannot fall down or topple over.
- Consult the manufacturer if in doubt.
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Dismantling and disposal
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10.2 Dismantling Before starting dismantling:
Shut down the machine and secure to prevent restarting.
Physically disconnect the power supply from the machine; discharge stored residual energy.
Remove consumables, auxiliary materials and other processing materials and dispose of in accordance with the environmental regulations.
Then clean assemblies and parts properly and dismantle in compliance with applicable local occupational safety and environmental protection regulations.
10.3 Disposal If no return or disposal agreement has been made, send the
dismantled components for recycling. Scrap metals.
Send plastic elements for recycling.
Sort and dispose of other components in accordance with their material composition.
NOTICE! Danger to the environment due to incorrect disposal! Incorrect disposal may pose risks to the environment. - Electrical scrap, electronic components, lubricants
and other auxiliary materials must be disposed of by authorised specialist companies.
- If in doubt, obtain information about disposal in accordance with the environmental regulations from the local municipal authorities or specialised waste disposal companies.
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Index
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11 Index
A
Accident .............................................................. 27 Air Control AC mini controller ............................. 81
Acknowledging fault messages ...................... 99
Acknowledging faults ...................................... 99
Acknowledging warning messages ............... 101 Basic display ................................................... 83
Brief description .............................................. 82
Calling up information ..................................... 84 Calling up parameter values ........................... 84
Calling up the code input menu ...................... 86
Code 11........................................................... 92
Code 18........................................................... 94 Code 2............................................................. 87
Code 3............................................................. 89
Code 6 ............................................................. 90
Code 8............................................................. 91 Code 90........................................................... 95
Code 95........................................................... 96
Code 9999 ...................................................... 97
Dew-point monitoring ....................................... 90 Display ............................................................ 83
Display the software version ........................... 97
Fault messages ............................................... 98
Faults .............................................................. 98 Inputting a code .............................................. 86
Maximum operating cycles ............................. 88
Maximum pressure drop ................................. 88
Operating modes ............................................ 82 Other display indicators .................................. 83
Overview ......................................................... 81
Safety pressure ............................................... 82
Select operating mode .................................... 87 Set Basic load switching mode ....................... 94
Set on-site operation/remote operation .......... 91
Set switch on/off pressure ............................... 92
Setting parameters .......................................... 86 Switch automatic restart on/off ........................ 89
Switch the temperature unit ............................ 96
Switching off .................................................... 84
Switching on .................................................... 84 Switching the pressure unit ............................. 95
Warning messages ....................................... 100
Warnings ....................................................... 100 Assemblies
COMBI drive unit ............................................. 53 Compressed air after-cooler ........................... 56
Controller ......................................................... 51 Coolant liquid cooler ........................................ 56
Cooler .............................................................. 56
Cooling air fan ................................................. 57
Fresh air fan .................................................... 57 Heat exchanger ............................................... 56
Water cooling .................................................. 56
B
Brief description .................................................. 50
C
Change
coolant liquid ................................................. 115
coolant liquid filter ......................................... 115
fine precipitator .............................................. 119 return line ...................................................... 128
Change intake filter ........................................... 120
Checking
the coolant liquid level ............................. 70, 109 Checking for leaks ............................................ 111
Checking soiling of the cooler ........................... 113
Checking the condensation accumulation ........ 114
Checking the temperature ................................ 112
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Index
132 2015-07-21
Clean
return line ......................................................128
Components Compressor stage ...........................................54
Coolant liquid drain .........................................54
Coolant liquid filter ...........................................56
Coolant liquid pressure tank ............................54 Filler plugs .......................................................54
Fine precipitator ..............................................55
Inspection glass ..............................................54 Intake filter .......................................................53
Minimum pressure and return valve ................55
Refrigerant-type dryer .....................................57
Safety valve .....................................................54 Sound insulation covers ..................................52
Compressor stage ..............................................54
Connecting air .....................................................68
Connecting compressed air ................................68 Connecting the current .......................................69
Connecting the power supply .............................69
Connection values
COMBI 16 – 22 electric ...................................45 COMBI 16 –22 air supply ................................45
COMBI 3S – 5S air supply ..............................35
COMBI 3S – 5S electric ..................................35
COMBI 6 – 15 air supply .................................41 COMBI 6 – 15 electric .....................................41
Consumables
COMBI 16 – 22................................................46
COMBI 6 – 15..................................................42 Contact person....................................................10
Controller ............................................................51
Controller COMBI 3S – 4S
Overview .........................................................78 Switching off ....................................................79
Switching on ....................................................79
Controller COMBI 5S
Overview .........................................................80
Switching on ................................................... 80
Coolant liquid ..................................................... 33
Start-up lubrication ......................................... 71 Coolant liquid filter ............................................. 56
Coolant liquid pressure tank .............................. 54
Cooler ................................................................. 56
Cooling air fan .................................................... 57 Copyright ............................................................ 10
Customer service ............................................... 10
D
Description of function ....................................... 50
Dismantling ...................................................... 130 Disposal ........................................................... 130 Drive
COMBI ............................................................ 53
Drive unit .................................................... 53, 121
E
Electric current ................................................... 17
Emergency ......................................................... 76 Emergency stop ................................................. 76
Emergency stop key .......................................... 23
Emissions ........................................................... 32
Environmental protection Coolant liquid .................................................. 28
Lubricants ....................................................... 28
F
Fault
Return line .................................................... 128
Fault displays ................................................... 124
Fault messages .................................................. 98 Acknowledging ............................................... 99
Fault table ........................................................ 125
Fine precipitator ................................................. 55
Fire ..................................................................... 27 First aid .............................................................. 27
Forced ventilation and bleeding ......................... 68
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
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G
General details
COMBI 16 – 22 ............................................... 43 COMBI 3S –5S ............................................... 33
COMBI 6 – 15 ................................................. 37
I Inspection at delivery .......................................... 60
Installation
Forced ventilation and bleeding ...................... 68 Ventilation ....................................................... 67
Installation conditions ......................................... 66
Installation location ............................................. 66
Intake filter .......................................................... 53 Interfaces ............................................................ 58
Air supply ........................................................ 59
Compressed air connection ............................ 59
Media .............................................................. 58
L
Liquid stream ...................................................... 19 Lubricants
COMBI 3S – 5S .............................................. 36
M
Main switch ......................................................... 23
Maintenance
Change coolant liquid filter* .......................... 115
Change fine precipitator ................................ 119 Change intake filter ....................................... 120
Checking for leaks ........................................ 111
Checking soiling of the cooler ....................... 113
Checking the compressor temperature ......... 112 Checking the condensation accumulation .... 114
Checking the coolant liquid level .................. 109
Checking the drive unit ................................. 121
Coolant liquid change ................................... 115 Re-lubricating the electric motor ................... 118
Replace coolant liquid ................................... 115
Replace coolant liquid filter ........................... 115
Top up coolant liquid ..................................... 109 Minimum pressure and return valve ................... 55
N
Noise emissions .................................................. 32
O
Operating conditions ...............................36, 42, 46 Overview
Assemblies ...................................................... 48
COMBI 3S – 5S ............................................... 47
COMBI 6 – 22 ................................................. 47 Owner ................................................................. 12
P
Packaging ........................................................... 61 Personnel ............................................................ 13
Proper use .......................................................... 11
Protective equipment .......................................... 15
R
Refrigerant-type dryer ......................................... 57
Re-lubricating the electric motor ....................... 118 Replace
coolant liquid ................................................. 115
coolant liquid filter ......................................... 115
Rescue measures ............................................... 76
S
Safety General............................................................ 11
Safety devices .................................................... 22
Safety valves ...................................................... 24
Service ................................................................ 10 Service manual ................................................. 139
Signs ................................................................... 29
Sound insulation covers...................................... 52
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Index
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Spare parts .......................................................105
Starting up compressed air generation ...............72
Start-up lubrication ..............................................71 Storage ...............................................................63
Switching on after the initial commissioning .......72
Symbols
in this manual .................................................... 8 on the machine ................................................30
on the packaging .............................................62
T
Top up
coolant liquid .................................................109
Transport .............................................................62 Type plate ...........................................................32
U
Use ..................................................................... 11
V
Ventilation .......................................................... 67
W
Warning messages .......................................... 100
Acknowledging ............................................. 101
Warranty terms .................................................. 10 Working after the initial commissioning ............. 73
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Appendix
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12 Appendix
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Training log
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A Training log
Date Name Type of training Training conducted by
Signature
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Tightening torques for screws
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B Tightening torques for screws
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Service manual
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C Service manual
Compressor type:
System number: Please specify in case of inquiries, orders and correspondence.
Motor number:
Pressure tank number:
Date of commissioning:
Your ALMiG customer service:
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Service manual
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Daily checks Weekly checks
Hours of operation
Coolant liquid level
Leakage Compressor temperature
Cooler soiling
Condensate accumulation
Clean intake filter mats
Date Name
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Service manual
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Coolant liquid change Filter change
(coolant liquid filter / intake filter / fine precipitator)
Hours of operation
Date Name Hours of operation
Date Filter type Name
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Service manual
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Additional maintenance and repair work
Hours of operation
Date Spare parts Name
Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC
Spare parts list
142 2015-07-21
D Spare parts list
Spare parts list The spare parts list is included with the documents.
ALMiG Kompressoren GmbH
Adolf-Ehmann-Straße 2
73257 Köngen
Phone +49 7024 9614 0
Email info@almig.de
Internet www.almig.de
ArtNo. 195. 03276REV06_gb
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