Operating manual

ALLEGRO 30 - 210
 2001

All rights belong to:

Alup Kompressoren GmbH

Adolf-Ehmann-Strae 2
73257 Kngen

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

Fax: ++49 (0) 7024 / 8050

No part of this manual may be duplicated by mechanical or electronic means

without the express written permission from Alup Compressors GmbH.

All particulars in this manual are specified to our best knowledge, but without
guarantee.
We reserve the right to make changes to information on hardware and
firmware documentation at any time without previous announcement.

We are thankful for any criticism and suggestions.

Table of contents
1. Safety instructions .............................................. 4
1.1 Symbols in this manual ................................ 4
1.3 Qualified personnel ...................................... 5
1.4 General safety instructions ........................... 6
2. Functional description ........................................ 8
3. Storage and transport ....................................... 10
4. Installation ......................................................... 12
4.1 Setting up ................................................... 12
4.2 Ventilation .................................................. 12
4.3 Forced ventilation (optional) ....................... 13
4.4 Water cooling (optional) .............................. 14
4.5 Heat recovery for heating water / potable
water (optional) .......................................... 14
4.6 Connection to the compressed air grid ....... 15
4.7 Electrical connections ................................. 15
5. Displays and operating elements .................... 16
5.1 Plant main switch ....................................... 16
5.2 Emergency OFF ......................................... 16
5.3 Air Control 3 ............................................... 17
5.3.1 Basic display ................................... 18
5.3.2 ON/OFF switching of compressed air
generation ....................................... 18
5.3.3 Function key reservation in the basic
display ............................................. 18
5.3.3.1 Capacity utilization .................. 19
5.3.3.2 Service .................................... 20
5.3.3.3 Plant pass ............................... 20
5.3.3.4 Diagram grid pressure ............. 21
5.3.3.5 Diagram compression end
temperature ............................. 21
5.3.3.6 Diagram compressed air amount /
day profile ............................... 21
5.3.3.7 Diagram compressed air amounts
/ week profile ........................... 21
5.3.3.8 Modify diagram settings ........... 22
5.3.4 Menu system ................................... 23
5.3.4.1 Sub-menu Limit values ............ 24
5.3.4.2 Sub-menu
Operating parameters.............. 24
5.3.4.3 Sub-menu
Service intervals ...................... 25
5.3.4.4 Sub-menu Timer ...................... 26
5.3.4.5 Sub-menu Malfunction storage 28
5.3.4.6 Sub-menu
Display parameter ................... 28
5.3.4.7 Sub-menu
Configuration ........................... 29
5.3.4.8 Sub-menu
Communication ....................... 30
5.3.4.9 Sub-menu
Base Load Switching (BLS) ..... 30
5.3.4.10 Sub-menu Accessories ............ 30
5.3.5 Warnings / service work ................... 32
5.3.6 Malfunctions .................................... 33
6. Correcting malfunctions ................................... 34
7. Initial commissioning ....................................... 36
7.1 Preparatory activities .................................. 36
7.2 Check coolant
level ........................................................... 36
7.3 Start-up lubrication of the compressor stage 36
7.4 Rotational direction control ......................... 37
7.5 Basic settings ............................................. 38
7.5.1 Control system of the system with Air
Control 3 ......................................... 38
7.6 Switch on compressed air generation ......... 39
7.7 Concluding activities ................................... 39
8. Service ............................................................... 40
8.1 Overview
Service intervals ......................................... 40
8.2 Preparatory activities .................................. 40
8.3 Check coolant level / refill coolant ............... 41
8.4 Check for leakage ...................................... 41
8.5 Check the compressor temperature ............ 41
8.6 Check the cooler for fouling ........................ 42
8.7 Check for condensate development ........... 42
8.8 Coolant replacement / replacing coolant filter
43
8.9 Replacing coolant separator ....................... 44
8.10 Replacing air filter ....................................... 44
8.11 Check safety valve ..................................... 44
8.12 Check clutch element ................................. 45
8.13 Relubrication of the electric motor ............... 45
8.14 Concluding activities ................................... 45
9. Technical Data ................................................... 46
9.1 Dimensions for connections ....................... 46
9.2 Data air-cooled compressors ...................... 47
9.3 Data water-cooled compressors ................. 47
9.4 Electrical data ............................................ 47
 1. Safety instructions

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

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

The system was developed, manufactured, tested, and documented in state-

of-the-art technology and considering all the current safety norms.
In normal circumstances, no danger for personnel or property can result
from the system if you comply with the stipulations of the service manual
and if the transport, assembly, service and the described handling is car-
ried out according to the regulations.
Nevertheless certain risks remain!
1.1 Symbols in this manual

This symbol is employed whenever personal damage can be incurred

by carelessness, or by ignoring the instructions.

DANGER

This symbol is employed when damage to property can occur through

carelessness, or by ignoring the instructions.

NOTICE

Italic text is employed when we would like to draw your attention to particu-
lar information.

Text in a frame signifies the description of an activity to be carried out by

the user.
1.2 Proper usage The system is exclusively designed for

the generation of compressed air and

for operation in a non-explosion-endangered environment.

Any other utilization must be regarded as not in compliance with the design
purpose!
The manufacturer/vendor is fundamentally not liable for damages incurred
if the system is not used according to its design purpose!

The generated compressed air may not be used for human respiration. In
case the compressed air is used for pharmaceutical or sanitary purposes, it
must undergo further treatment. The same is true when the compressed air
is used in production plants and comes into direct contact with foodstuffs.

1.3 Qualified personnel This manual is directed to qualified personnel, who are commissioned
with the transport, installation, operation or service of the system. These
individuals must read the chapter relevant to their duties.

Qualified personnel are individuals who:

upon the basis of their professional training, knowledge and experience

as well as their understanding of the relevant norms can assess the
work to be carried out with regard to all possible dangers, or

based on many years of activity in a comparable field, have the same

state of knowledge as someone with professional training.

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

Unqualified actions or disregarding the warnings in this manual or those

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

5
 1. Safety instructions
1.4 General safety instructions

Loss or decrease of plant safety !

Retrofitting or modifications on the system can reduce its level of safe-
ty! The results could be serious personal, material or environmental
damage. Possible retrofitting or modifications on the system with
equipment components from third party manufacturers must there-
DANGER
fore first be cleared by us.

Loss of protection from contact to hazardous zones!

The side panelings of the system are a part of the contact protection
system to protect personnel from ventilator wheels that start up auto-
matically, moving machine parts, hot surfaces and dangerous voltag-
DANGER es! Furthermore, they are required for sound insulation for the cool-
ing air conduction. Therefore they may not be removed in the normal
operating mode of the system.

Injuries caused by ventilator wheels that start automatically, moving

machine parts, hot surfaces or escaping coolant mist!
Installation, service or repair work on the components of the system
must, if not otherwise described, be categorically carried out only on
DANGER a switched-off, sufficiently cooled-off and pressure-free system! The
system must be secured against an illicit or accidental switching-on.
The shut-off device for the compressed air grid must be closed.
If measuring or testing work is required on the electrical components
while the system is in operation, they must be carried out by electri-
6 cians observing all the relevant safety regulations.

Damage to the sense organs!

Compressed air streams may not be directed towards persons. When
applying compressed air, dust particles can be raised by the air st-
ream. Therefore, when working with compressed air, protect your eyes
DANGER with safety glasses.
 Loss or decrease of plant dependability!
Only original spare parts and lubrications may be employed!
We recommend that a set of service parts subject to wear be kept on
stock, in order to guarantee high plant availability. Our customer ser-
NOTICE vice would be glad to help you with your selection. Tel: (+49) 0180
5258700.

Damage to the system may result in environmental damage!

Before the initial commissioning, the system must have been correct-
ly installed according to Chapter 6!
Plants greater than 100 kW may be taken into operation by qualified
NOTICE
personnel.
Dispose of all used or defective materials in a proper way!
This is especially true for components/materials containing cooling
liquid. Please note that the accumulated condensation containing cool-
ing liquid may not enter the sewerage system!

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

cessing.

Compressed air receivers require regular technical inspections!

Please notify the commissioning of the system at the technical inspection
authority responsible for you. They will inspect the system and provide a
receiver test book.

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

7
Carry out the activities in all of the following chapters in the order given.
 2. Functional description
2.1 Drive The frequency converter in the switching cabinet supplies the electric mo-
tor with power. For the operating principle of the frequency converter, please
refer to the instructions in the switching cabinet.
The electric motor drives the compressor stage via a flexibly supported
coupling.

2.2 Air path Fresh air supplied by the integrated cooling air ventilator is filtered through
the intake filter(s). The air is then directed via the intake regulator into the
compressor stage, where it is compressed to the final compression pres-
sure together with injected coolant.
In the coolant reservoir, the compressed air is separated 98 % from the
cooland and the downstream coolant separator removes the remaining
coolant from the compressed air. The air then flows via the minimum pres-
sure one way valve into the compressed air aftercooler and is cooled down
to 10 - 15 C above the ambient temperature before it leaves the compres-
sor through the compressed air port.

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

2.3 Coolant circulation The coolant is sprayed into the compression stage and has the following
functions:

heat removal of the temperature increase caused by the compression

process

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

bearing lubrication

noise dampening
The coolant leaves the compression stage together with the compressed
air as a hot coolant return air mixture.
The coolant is separated from the compressed air into the coolant con-
tainer by the coolant separator and when separated, it streams to the cool-
ant heat exchanger. The coolant temperature regulator mixes the cooled
down coolant with the coolant heat exchanger-bypass hot coolant as de-
8 fined by the setpoint temperature. Lastly, the coolant filter cleans the cool-
ant, before it is again injected in the compression stage.
If desired by the customer, an additional heater can be installed in the
coolant container either originally or subsequent to purchase. It prevents
condensation damages in the case ofcold or damp compressor plant envi-
ronments, for example.

2.4 Cooling The compressed air after-cooler of the coolant heat exchanger is cooled
either by

a built-in cooling air ventilator or

water cooling.
The electric motor is always cooled by its own ventilator fan.
In the case of water-cooled compressors, a fresh air ventilator additionally
ensures sufficient fresh intake air for the removal of radiated heat.
2.5 Flow diagram 14

20
02 M
08
PD 1 03 PS

12 13 PI
15 16
04 06 22
07 11 PD2
23
05
21
19 26 28
09 27

25 24
18

17
01

2.6 Components
20

04 02

05
15
06

12 01

07
08

10

19

2.7 Legend 01 Switching cabinet 15 Compressed air after-cooler 9

02 Electric motor 16 Compressed air connection
03 Clutch 17 Coolant cooler
04 Intake filter 18 Coolant temperature regulator
05 Intake regulator 19 Coolant filter
06 Compressor level 20 Cooling air ventilator
07 Coolant container 21 Cooling water inlet
08 Safety valve 22 Throttle valve compressed air
09 Drain after-cooler
10 Inlet fitting 23 Magnet valve
11 Additional heater (optional) 24 HCR water inlet
12 Coolant separator 25 HCR heat exchanger
13 Minimum pressure one-way 26 HCR thermostat
valve 27 HCR water outlet
14 Relief valve 28 HCR thermostat valve
 3. Storage and transport

For measurements and weights, see Chapter 9.

Please store the system only in a dry, frost-free room.

Observe the local regulations and other requirements pertaining to

the professional use of tools, lifting and transport equipment, as well
as the valid norms and the regulations for accident prevention.

DANGER

Always transport the system in its normal operating orientation in a pres-

sure-free state. Tilting or laying the system down is not allowed.

Use a fork-lift truck for transport. For short transportation distances, a

palette lifting trolley may be used.

10
11
 4. Installation
4.1 Setting up
Install the system in locations with the following environmental conditions:
max. height above sea level: 1000 m
ambient temperature: +5 to +40 C
ambient temperature for Version T: +5 to +45 C
ambient conditions: cool, dry, dust free

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

Always maintain the minimal clearances to the walls or other objects, so

that system service functions can be carried out without hindrance.

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

Open flame or fire as well as welding work in the vicinity of the system
are forbidden!
DANGER

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

The ventilation must fulfill at least the following criteria:

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

Remove exhaust air as defined in Chapter 9 in order to prevent a heat-

ing up of the plant site

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

Make certain that the supply air contains no dangerous explosive gas
12 mixtures, steam, dust or aggressive pollutants.
Make certain that the setup site is dust-free as well as within the prescri-
bed operating temperature limits and as cool as possible. If necessary,
ensure the professional installation of forced air ventilation, filtering, room
cooling or heating.

Make certain that the setup site is professionally ventilated.

Make certain that no circulating air short circuit (the intake of the
NOTICE exhausted warm air) can occur.
 Cooling air volume currents: see Chapter 9.

4.3 Forced ventilation (op- Forced ventilation must be dimensioned in such a way that the required
tional) fresh and exhaust air, considering the available residual pressure of the
compressor ventilator, can be supplied and expelled.

Nominal diameters of the channel connections and information on the re- 13

sidual pressure : see Chapter 9.

If ventilation channels are to be connected to the system, then the required

supporting supplementary ventilators should be included when planning
the channels.

The exhaust air can also be utilized for the purpose of heat recovery.
 4. Installation
4.4 Water cooling (optional) For water-cooled plants, the temperature of the compressed air after-cooler
of the coolant heat exchanger is lowered with external cooling water.

12 13 PI
15 16
22
PD2
23
21

17

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

The cooling water is to be connected to the defined connections (see draw-

ing Chapter 9).
The cooling water must satisfy the following criteria:

inlet temperature less than +35 C

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

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

An electromagnetic valve (optional) should be installed before the cooling
water input.
The cooling water volume current through the compressed air after-cooler
should be set with the throttle valve belonging to it in such a way that the
compressed air outlet temperature is 15 C greater than the output air.
4.5 Heat recovery for heating Plants can be supplied with the optional heat recovery system
water / potable water (op-
tional) for heating water or

for potable water (safety heat exchanger with blocking medium)

26 28
14 27

25 24

01

Water amounts, temperatures and pressures: see Chapter 9.

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

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

pressure of up to 10 bar (over)

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

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

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

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

Unpredictable movements of the compressed air hose!

During load switching in the compressed air grid, the hose can move
suddenly and with great force. Therefore the hose must be adequate-
ly anchored or fixed.
DANGER

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

All the relevant data for the connections can be found

in Chapter 9
on the nameplate of the system.

Electrical voltage!
Only trained electricians may connect the system to the electrical sup-
ply network.
DANGER

Before making the connections based on the plant nameplate, determine

if the available supply network is adequate. Voltage deviations of larger
than 10 % are not allowed.
Mount the mains switch in the neighborhood of the plant. It must be easily
accessible at all times.
Lay the supply cables professionally. Make certain that the installation
cannot endanger individuals or property. Take into account the necessary
cable diameters, strain relief, and max. allowed cable lengths.
Connect the system according to the switching plan. The switching plan 15
is located in the control cabinet of the system.

Damage to the system is possible!

Before switching on compressed air generation, initial commission-
NOTICE ing according to Chapter 6 must be correctly carried out!

Test the correct functioning of all safety facilities (protective grounding,

protective switch etc.).
Carefully lock the control cabinet after the connection work is completed.
 5. Displays and operating elements
5.1 Plant main switch The plant main switch connects or separates the system with the current
supply.

The plant main switch must be switched off for all service or installa-
tion work and protected from illicit or accidental switching on (e.g.
affix a warning sign to the main switch forbidding its being turned on)!
DANGER

5.2 Emergency OFF The system may be stopped with EMERGENCY OFF in the case of a real
emergency!

Stop the motor in case of danger: press key.

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

recommissioning!
Enable the system only when the cause of danger has been profes-
sionally removed and a securely operating plant state is achieved.
DANGER

Enable system:

1. pull key

2. switch main switch off and on.

3. press key for the malfunction receipt.

4. press key to switch the system on again.

16
5.3 Air Control 3 The operating / display desk of the Air Control 3

displays the plant states / operating data

switches on and off compressed air generation

is used for plant parameterizing.

F1 F2 F3 F4 Function keys

Modification of parameter values

Selection of sub-menus

Confirmation of parameter changes

Editing modes in the sub-menus

Display additional operation data.

Switch on compressor.
Integrated green LED
Blinking: compressor is not running, can at any time 17
be automatically started up.
Lighted: Compressor is running.

Compressor shut down.

Signals a current warning/malfunction with the integrated red

LED.
 5. Displays and control elements
5.3.1 Basic display After switching on the main switch or during normal operation, the Air Control
3 will inform you about the plant condition.

Momentary com-
Momentarily available grid pressure at com-
pression final tem-
pressed air output
perature

Service or malfunction messages with

service telephone number

Current reservation of the function keys Service type

5.3.2 ON/OFF switching of Switching ON: press key .

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

Switching OFF: press key .

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

5.3.3 Function key reservation In the basic display, the following informative pictures can be accessed
in the basic display with the function keys:

Mode 1 = reservation 1

18

F1 F2 F3 F4

Capacity Service
utilization Plant pass

With the key and , the mode and therefore the reservation of the
function keys in the basic display can be changed.
 Mode 2 = reservation 2

F1 F2 F3 F4

Diagram Diagram
grid pressure air amounts
daily profile

Diagram Diagram
compression air amounts
temperature weekly profile

By pressing the defined function key, the respective information screen is

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

5.3.3.1 Capacity utilization This diagram represents the operating run, full load run, idling run, and
(Mode 1 - F1) standstill hours in the form of bar diagrams. The respective current hour
Change of mode 5.3.3 count is also displayed in the bars.

Example:

Total service hours

Load hours

Idling time hours 19

Standstill hours

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

The scaling units of this diagram are according to the service hours. If the
number of the standstill hours is larger than the service hours, the bars of
the standstill hours will be cut off. In this case note the displayed hour
count in the bars.
 5. Displays and operating elements
5.3.3.2 Service The Service diagram shows the remaining residual time in hours until the
(Mode 1 - F3) respective service interval is due.
Change of mode 5.3.3

Intake filter
Coolant filter
Coolant separator
Motor lubrication
Compressor

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

5.3.3.3 Plant pass The individual machine data stored in the plant pass are required for our
(Mode 1 - F4) customer service.
Change of mode 5.3.3

20
5.3.3.4 Diagram grid pressure In this diagram, the current process of the grid pressures is displayed.
(Mode 2 - F1)
Change of mode 5.3.3

5.3.3.5 Diagram compression In this diagram, the current process of the compression end temperature is
end temperature displayed.
(Mode 2 - F2)

Change of mode 5.3.3

5.3.3.6 Diagram compressed air In this diagram, the current process of the compressed air-delivery amounts
amount / day profile for a day are displayed.
(Mode 2 - F3)
Change of mode 5.3.3

21

5.3.3.7 Diagram compressed air In this diagram, the current process of the compressed air-delivery amounts
amounts / week profile for a week are displayed.
(Mode 2 - F4)
Change of mode 5.3.3
 5. Displays and operating elements
5.3.3.8 Modify diagram settings The scale divisions of the axis can be changed by editing the axis values.

X-AUTO settings 5.3.4.6

y-axis: - The values of the y-axis can be changed in every diagram.

The data in the diagram are continually updated even after
the edit function.
x-axis: - In the diagram air qty.wk., the x-axis values cannot be
changed, changes are possible in all other diagrams
- Editing the x-axis is only possible when the text X-AUTO
ON does not appear on the display. After editing the x-axis
values, the diagram is no longer continually updated.
X-AUTO: - The key F1 activates or deactivates X-AUTO
- If X-AUTO ON, the values of the x-axis are automatically
updated. The X-AUTO uses the preset default values de-
fined in the menu Display parameter diagrams (see Chap-
ter 5.3.4.6).The manual editing x-axis values are deleted.

Procedure for the scale division of the axis.

Axis value y-axis (Max)

Axis value y-axis (Min)

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

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

2. Confirmation of the selection with ENTER

22 3. Modification of the blinking value with and .

Moving the cursor with F1 and F2 .
4. Confirmation of the modifications with ENTER.

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

The key F3 ldeletes the recorded measurement values of the currently

displayed time diagram.
5.3.4 Menu system All basic settings of the system can be viewed in the menu system. If the
Limit values 5.3.4.1 modifications have no influence on operation safety, they may be modified
Operating parameters 5.3.4.2 by means of a code entry.
Service intervals 5.3.4.3
Timer 5.3.4.4 After pressing the INFO key, the main menu appears requesting the code
Malfunction storage 5.3.4.5 entry.
Display parameter 5.3.4.6
Configuration 5.3.4.7
Communication 5.3.4.8
Base load switching 5.3.4.9
Accessories 5.3.4.10

Code 0000: View the basic settings

Code 0001: View and change basic settings

1. Modification of the blinking values with the keys and .

Moving the cursors with F1 and F2 .

2. Confirmation of the modifications with ENTER.

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

The sub-menu can be selected with the keys and .The selection is
confirmed with ENTER.
In every operating level, F4 will lead you to the next higher operating level.
23

If the Code 0001 is entered, the parameters of the sub-menu should be

changed as follows:

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

2. The selection is confirmed with ENTER.

3. Modification of the blinking value with the keys and .

Moving the cursor with F1 and F2 .

4. Confirmation of the modifications with ENTER.

 5. Displays and operating elements
5.3.4.1 Sub-menu Limit values This menu contains the pressure / temperature limit values:

Selection of the menu position Switch-on pressure Lower value for the pressure regulation Can be edited
Modification of the blinking values
Switch-off pressure Upper value for the pressure regulation Can be edited
ENTER Confirm selection/modification
Safety pressure Maximum permissible pressure for Display
F4 Back to the next higher level malfunction triggering (always 0.8 bar
greater than switch-off pressure)
Compression end Minimum permissible compression Display
temperature min end temperature
Compression end Maximum permissible compression Display
temperature max end temperature

5.3.4.2 Sub-menu This menu contains parameters which influence the temporal regulation of
Operating parameters the compressor:

Selection of the menu position After-run time After-run time of the motors in Display
Modification of the blinking values automatic operation
ENTER Confirm selection/modification Standstill time After-run time of the motor for manual Display
F4 Back to the next higher level switching-off delay and for automatic
restart
Run-up time Run-up time Display
Automatic Start after voltage return Can be
restart edited
Operation mode: Behavior on load switching Can be
Setting range: AUTOMATIC edited
LOAD/IDLING
AUTOMATIK OPT.
Max. pressure drop Maximum pressure drop Display
Max. switching cycles Maximum switching cycles of the motor Display
per hour per hour

Operation mode Automatic

The text AUTOMATIC is displayed in the basic display. After reaching the
switch-off pressure, the system goes into idling mode (after-run time) for
the duration of the after-run time and in the basic display; the text after-
24 run time appears with the respective residual time. At the conclusion of
the after-run time, the motor switches off. The compressor can be started
up automatically at any time after falling below the switch-on pressure.

Operation mode Load/Idling

The text LOAD/IDLING is displayed in the basic display. The compressor
switches between full load run and idling, which means that its after-run
time is unlimited.

5.3.4.3 Sub-menu
Service intervals
Service work acknowledged
5.3.5
Operation mode Automatic Optional
The text AUTOMATIC OPT. is displayed in the basic display. After reach-
ing the switch-off pressure, the system goes into idling.
After 10 and after 40 seconds the grid pressure is measured.
If the pressure drops above the threshold Max. pressure drop, then the
system is in the idling state for the duration of the after-run time. In the
basic display, the text After run appears with the residual time as defined.
If the value lies below the threshold Max. pressure drop, then the system
switches off after completing the standstill time.
Max. switching cycles
If the number of the maximum possible switching cycles per hour for the
motors is exceeded, then the compressor temporarily switches to the op-
eration mode load/idling.
In this menu, all service intervals are displayed, or acknowledged after
carrying out the specific service (see Chapter 5.3.5).
With the acknowledgement, the displayed residual time for the value of the
respective service intervals (see Chapter 8.1) is reset.
Service interval ASF Service interval intake filter Display
Service interval OLF Service interval coolant filter Display
Service interval OLAB Services interval coolant Display
separator
Service interval motor Service interval for motor lubrication Display
Service interval compr. Service interval compressor Display
Service hours Total operating hours Display
(motor on)
Load hours Accumulated load hours Display
Standstill hours Accumulated standstill hours Display
(system on motor off)
25
 5. Displays and operating elements
5.3.4.4 Sub-menu Timer The adjustment of the integrated real-time clock, as well as all switching
processes dependant upon it are in this menu.
Selection of the menu position
Modification of the blinking values Date/time Setting the current date Edit
and time
ENTER Confirm selection/modification
Attention: The adjustment is entered
F4 Back to the next higher level to the real-time clock when the
seconds are confirmed with ENTER
Compressor switching Branch to the sub-menu Edit
times
Compressor pressure Branch to the sub-menu Edit
times
Switching times BLS Branch to the sub-menu Edit
Pressure times BLS Branch to the sub-menu Edit

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

timer independently of each other.
When programming switching times, the compressor need no longer be
manually switched on and off. This is to prevent the possibility that the
compressor might for instance start up itself at night in order to compen-
sate for loss in the compressed air grid.
For a limited time, deviating values from the preset limit values (see Chap-
ter 5.3.4.1) can be set for the switch-on and the switch-off pressure. In this
way only the minimal required operating pressure is always generated so
that energy is saved.

Switching times for compressor

In this menu, the switching on/off times of the compressors are defined.

Timer clock output active:

Mo - Th 6:00 until 20:00 oclock
Fr 6:00 until16:00 oclock

26

For the activation of the timer, the parameter of the timer channels must be
set to ON in the highest menu line.
If the timer channel is set to ON and

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

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

Seven switching times with the channels K1 K7 can be programmed.

A channel is active when at least one of the weekdays is marked black. In
order to continuously activate the timer output for one or a number of days,
the switching time should be set to 00:00.
 Adjust switching times (weekdays marked black):
1. Channel selection with the keys and
2. Confirm selection with ENTER.
3. Move the cursor to the desired weekday by selecting the key F1 and
F2 . (In order to delete an already selected weekday, press the key
.)
4. Set the cursor with F1 and F2 onto the clock time with the keys and
to modify the blinking value.
5. Store the settings with the key ENTER.

If the timer for switching times is activated, then the compressor only
works during the switching times entered!
NOTICE

Compressor pressure times

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

Timer clock output active:

Sa - So 0:00 until 24:00 oclock
(= from Sa 0:00 oclock until So
24:00 oclock)

In order to activate the timer, the uppermost menu row of the parameter for
the timer channels must be set to ON.

A channel is active when at least one of the weekdays is marked black.

(For switching times adjustment: see paragraph Compressor switching
times) 27
The channels are searched beginning with K1 to K7 to determine whetherr
a channel is activated for the current clock time. If no valid channel is found,
then the settings in the menu limit values are valid. In order to activate
the timer output for one or a number of days continuously, the switching
time of 00:00 should be entered.

witching times BLS /pressure times BLS

Sw

Switching times or pressure times can only be entered if the supplementary

module for Base Load Selective switching (BLS) is installed in the control
system.

The settings are to be carried out as described in Compressor switching

times or Compressor pressure times
 5. Displays and operating elements
5.3.4.5 Sub-menu Malfunction In this menu, the last 20 malfunctions are listed in order.
storage

5.3.4.6 Sub-menu In this menu, the parameters for the output to thedisplay are stored.
Display parameter

Selection of the menu position Pressure unit Selection of the unit for the display Edit
Modification of the blinking values of the grid pressure
ENTER Confirm selection/modification Temperature unit Selection of the unit for the display Edit
F4 Back to the next higher level of the compression final temperature
Language Selection of the display language Edit
Pressure offset Readjustment possibility for the Display
grid pressure sensor
Diagrams Settings for diagrams Edit
Texts Texts for the plant pass Display

Diagrams

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

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

Number of points Number of the recorded values for function X-Auto

for X-Auto On the time axis at a storage interval of 12 s amd up to 300
points for X-Auto a time axis scaling of 12s x 300 =3600s
=1h
Grid pressure Lower scale value of the x-axis of the diagram
lower limit Grid pressure (see 5.3.3.4)
Grid pressure Upper scale value of the x-axis of the diagram
upper limit Grid pressure (see 5.3.3.4)
Temperature Lower scale value of the x-axis of the diagram
28 lower limit Compression final temperature (see 5.3.3.5)
Temperature Upper scale value of the x-axis of the diagram
upper limit Compression final temperature (see 5.3.3.5) (basic setting
120 C)
Compressed air amt. day Lower scale value of the x-axis of the diagram
lower limit Compressed air amounts daily profile (see 5.3.3.6)
Compressed air amt. day Upper scale value of the x-axis of the diagram
upper limit Compressed air amounts daily profile (see 5.3.3.6)
Compressed air amt. week Lower scale value of the x-axis of the diagram
lower limit Compressed air amounts weekly profile (see 5.3.3.7)
Compressed air amt. week Upper scale value of the x-axis of the diagram
upper limit Compressed air amounts weekly profile (see 5.3.3.7)
5.3.4.7 Sub-menu Plant type Selection of a pre-defined Display
Configuration machine type.
Maximum pressure Maximum permissible machine pressure Display
Selection of the menu position
Max. delivery amounts Delivery amounts at maximum speed Display
Modification of the blinking values
in full load run
ENTER Confirm selection/modification
Remote mode Switching on/off of the system Edit
F4 Back to the next higher level
BLS-operation Operation with external base load Edit
alternate switching
Low voltage Stop Switching-off when low voltage Display
is recognized
Analog output Output module for the control module Display
of a frequency converter (if present)
Heating/Ventilation Temperature values for additional Display
heater or plant ventilator

Remote mode
Determines how the compressor is switched on or switched off.

Local operation: The compressor can only be switched on or switched off

at the operating/display desk of the Air Control 3.

Remote control: The compressor can be switched on or switched off with

an electrical signal or the key 0. In the basic display appears as the blinking
text REMOTE.

During active remote operation, the signal of the remote control must
be switched off after pressing the key 0.
NOTICE

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

BLS Operation
29
The control system of the compressors is carried out by a superior control
system. The text BLS OPER. (see also Remote Mode 5.3.4.9) appears in
the basic display
 5. Displays and operating elements
5.3.4.8 Sub-menu This menu contains parameters for serial communication
Communication
RS485 Address Participant address for RS484 Display
communication
RS485 Mode Data exchange on the serial Display
interface

5.3.4.9 Sub-menu This menu contains the settings for the operation as the BLS Master.
Base Load Switching
(BLS)
For the utilization of the function base load switching, the Air Control 3
Selection of the menu position
must be fitted with
Modification of the blinking values
ENTER Confirm selection/modification a supplementary module for up to 4 additional compressors
F4 Back to the next higher level
two supplementary modules for up to 8 additional compressors.

Base load switching Parameter for the activation of the Display

Switched-on pressure
Switched-off pressure
Switched-on dampening
Switched-off dampening
Replacing interval
Number of main
compressors
Number of reserve
compressors
BLS Master characteristics
(basic setting: NO)
Lower pressure threshold for Edit
switching on a compressor
Upper pressure threshold for Edit
switching off a compressor
Minimal time between the Edit
switching on of two compressors
(basic setting:5 s)
Minimal time between the Edit
switching off of two compressors
(basic setting:2 s)
Time between the additional Edit
switching of the BLS (basic setting: 24 h)
Number of compressors in the Edit
main group
Number of compressors in the Edit
reserve group

(see also Chapter 5.3.4.7)

30

5.3.4.10 Sub-menu Accessories This menu contains the settings for the connection of accessories. The Air
Control 3 must be fitted with the supplementary module accessories for
the utilization of these functions.

Accessory module Supplementary module for accessories Display

available
Switching times output 1 Switching times defined for accessories 1 Edit
Switching times output 2 Switching times defined for accessories 2 Edit
Switching times output 3 Switching times defined for accessories 3 Edit
Switching times output 4 Switching times defined for accessories 4 Edit
Input configuration Configuration of the Edit
accessories digital inputs
 Switching times

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

Timer clock output active:

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

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

Seven switching times can be programmed with the channels K1 K7.

One channel is active when at least one of the weekdays is marked black.

For adjustment of the switching times, see paragraph Compressor switch-

ing times Chapter 5.3.4.4.

In order to continually activate the timer output for one or a number of

days, set the switching time to 00:00.

Input configuration

The inputs 1 to 8 can be used in order to switch the compressor to mal-

function or warning.

31
 5. Displays and operating elements
5.3.5 Warnings / service work A warning is current when the red light is blinking.
The compressor is not switched off.
The display contains the additional information:
blinking symbol warning triangle
type of warning
telephone number of the service hotline

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

Damage of the system is possible!

Necessary service work appear as warnings.
Acknowledge these warnings only when the defined service work has
NOTICE actually been carried out!
Service work not carried out degrades the service life reliability of the
system. Please note that damages because of improper usage might
cancel the guarantee!
Only original spare parts may be used.
Information on service: see Chapter 8.

Services work acknowledged:

1. As described in Chapter 5.3.4, call up the main menu and then the sub-
menu Service Interval.
32
2. Select the service work to be carried out with the keys and .

3. Press key F3 to acknowledge the service.

4. By double clicking the key F4 you will return to the basic display.
5.3.6 Malfunctions A malfunction has occurred when the red light is permanently on.

The compressor is stopped automatically.

In addition, the display also shows:

blinking symbol tool key
type of malfunction
telephone number of the service hotline

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

Malfunction messages acknowledged:

1. press key .

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

33
 6. Correcting malfunctions
Error
Compression temperature
too high (red lamp is on)
Grid pressure falls
System pressure released on
safety valve
34
Malfunction over- - Coolant separator fouled
pressure or Grid
pressure too high (red
lamp is on)
Cause
- Silencing hood not closed
- Intake or environmental
temperature too high
- Cooling air inlet or outlet blocked
- Coolant filter fouled
- Coolant deficiency
- Outside coolant heat exchanger
fouled! A t t e n t i o n : Cooler
screw should always be
worked with a counter wrench;
keep from applying torque to
the cooler
- Compressed air consumption
greater than delivery amounts of
the compressor
- Air filter is fouled
- Relief valve blows air during
compression
- Intake regulator does not open
- Leakage in the piping grid
- Grid pressure set too high
- Safety valve defective
- Minimum pressure valve blocked
- Coolant separator cartridge
fouled
- Higher outside pressure in the
compressed air grid
Measures
- Check and secure sound-
insulation hood
- Ventilate compressor room
- Make sufficient room
- Renew coolant filter
- Add coolant
- Clean with compressed air. In the
case of extensive fouling:
disassemble cooler and clean
with high pressure cleaner.
Attention: Danger of short
circuit! Do not put electrical
elements under power
- A compressor with larger delivery
amounts is required
- Replace air filter
- Check relief valve; if necessary,
replace seals
- Check magnet valve regulator
piston and if necessary, replace
- Make piping grid airtight
- Adjust grid pressure anew
- Check safety valve; if necessary,
exchange
- Exchange magnet valve
- Exchange coolant separator
cartridge
- Replace coolant separator
- Equalize outside pressure or
remove from grid
Error
Compressor does not start
automatically or does not
deliver after previous
switching off upon reaching
the final pressure or from
idling state.
System does not start on
pressing the start button
Compressed air containing
large amount of coolant
(coolant consumption too
great)
System stopped before
reaching the final pressure
(red lamp is on)
Water in the piping grid
Pressure decline
Cause
- Grid pressure set too high
- Interruption in the control current
circuit
- Ambient temperature under +1
C; message Coolant tempera-
ture too low
- Switching times have been
activated in the Air Control 3
- Grid pressure greater than
switch-on pressure
- Remote control activated
- Missing voltage at the
compressor
- Electrical error in the control
system
- Switching times have been
activated in the Air Control 3
- Coolant return flow piping is
congested
- Defective coolant separator
- Overtemperature or overpressure
- Interruption in the control current
loop
- Dryer switched off
- Condensation diverter is not
functioning
- Bypass open
- Dew point too high
- Pressure difference in the filter
too great
Measures
- Adjust grid pressure anew
- Check current loop for interrup-
tion (only by an trained electri-
cian)
- Build in an additional heater or
keep compressor room at right
temperature
- Check switching times and
pressure times in the Air Control
- Note grid pressure value
- Symbol remote is blinking
- Check if voltage is available
- Review (only by an trained
electrician)
- Check switching times in the Air
Control 3
- Clean coolant feedback piping
- Replace coolant separator
- Rectify error as required
- Check current loop (only by a
trained electrician)
35
- Switch on dryer
- Clean / exchange drain
- Close bypass
- Demand customer service
- Exchange filter
 7. Initial commissioning
7.1 Preparatory activities 1. Make certain that when the plant mains switch is switched off, no illicit
or inadvertent switching on cannot occur.

2. Make certain that the system is correctly connected to the compressed

air grid.Make certain that when the shut-off valve on the pressure grid
side is closed, illicit or inadvertent opening cannot occur.

7.2 Check coolant 1. Make certain that escaping coolant can be collected.
level
Check coolant level/ 2. Check the coolant level at the sight glass which is located on the front
coolant refill 8.3 side of the coolant container: the sight glass must be totally filled with
coolant. Unscrew the the filling screw. Do not misplace the seal. For
new compressors, the coolant level must reach up to the lower level of
the inlet fitting.

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

7.3 Start-up lubrication of the
compressor stage
After an extended standstill time, for example between factory delivery
and commissioning or during a longer company vacation, there might no
longer be any coolant in the rotor chamber of the compression stage. This
coolant is absolutely necessary for bearing and rotor lubrication in the start-
up phase.

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

2. Rotate the compression stage only by hand in rotational direction until

the noticeable resistance dwindles and the coolant passes through the
compression stage.

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

36
If no extra coolant is available (only coolant of the same variety may be
employed!), the coolant can be taken from the coolant drain.
If the system is employed only very irregularly or shut down weeks on end,
it should run an hour in idling mode once a week in order to avoid corrosion
damage caused by standing condensation.
7.4 Rotational direction control The rotational direction of the plant ventilators must be checked.
The rotational direction of the main motor is determined by the frequency
converter and must conform with the affixed rotational direction arrow.

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

2. Switch the plant main switch on.

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

In order to supply the system with sufficient cooling air, the rotational direc-
tion of the ventilator motors must concur with the rotational direction arrow.
In the case of incorrect rotational direction of the plant ventilators, a trained
electrician should correct the phase sequence of the electrical supply in
the switching cabinet by exchanging the two supply phases. This should
be carried out in a switched-off state secured against accidental switching
on.

37
 7. Initial commissioning
7.5 Basic settings
7.5.1 Control system of the
system with Air Control 3
38
In order to understand plant basics, please read the chapter 5 Plant
operating elements .
More precise instructions on the basic settings of the system can be found
in the following chapters :
Chapter 5.3 Operating screen,
Chapter 5.3.1 Basic display
Chapter 5.3.4 Menu system
The display parameters
pressure unit,
temperature unit
language
can be modified as described in position 5.3.4.6.
The limit values
switch-on pressure
switch-off pressure
can be modified as described in position 5.3.4.1.
If your Air Control 3 has been fitted with the supplementary module BLS,
carry out settings as in point 5.3.4.7 5.3.4.9 of the description.
If your Air Control 3 has been fitted with the supplementary module acces-
sories, carry out settings as in point 5.3.4.10 of the description.
7.6 Switch on compressed air 1. Before switching on the system, make certain that no one can be en-
generation dangered by doing so. The sound-insulation hood serves as a part of
the contact protection, among other things for the cooling air conduits
of the compressor plant. It must be closed during operation.

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

3. Switch on the main switch.

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

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

The green LED in the key lights up when the compressor is working.
Check on the operating display desk for the grid pressure.
The grid pressure will slowly rise if the compressed air consumption is less
than the delivery amounts of the compressors.

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

DANGER

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

The compressor switches on automatically when the current grid pressure
drops below the preset switch-on pressure of the compressor plant, if
the machine temperature rises above +1 C,
the timer of the Air Control 3 is active,
or the base load selective switching setting (BLS) is activated.

7.7 Concluding activities 1. Check all piping of cooling liquids and pressure air conduits for leak-
age.
39
2. Check the coolant level of the compressors after 10 and until 20 min-
utes operation time. If the coolant level is too low, refill coolant as de-
fined in Chapter 8 Check coolant level /coolant refill.

3. Check the compressor temperature. The compressor temperature should

not fall under approx. 75 C and not rise above 105 C; at 105 C a
warning is issued, at 110 C the compressor plant automatically shuts
down.

4. Tighten all electrical connections after a week.

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

intervals.

6. Check the standard operation of the functions carried out weekly ac-
cording to Chapter 8 Overview of service intervals
 8. Service
8.1 Overview Necessary service work appears in the display as warnings (see Chapter
Service intervals 7.1)
Preparatory activities 8.2
Check coolant level / refill coolant Service activities Chapter After the first After the first Every Every 4000
8.3 100 operating 500 operat- week operating h.
Check for leakage 8.4 hours ing hours but at least
Check the compressor once a year
temperature 8.5
Check the cooler for fouling 8.6 Check coolant level 8.3
Check for condensation 8.7
Replace coolant / Replace Check for leakage 8.4
coolant filter 8.8
Replace coolant separator 8.9 Check compressor
Replace air filter 8.10 temperature 8.5
Check safety valve 8.11 Check of the cooler
Check drive 8.12 for fouling 8.6
Lubrication of electric motor 8.13
Concluding activities 8.14 Check for
condensation 8.7
Coolant replacement 8.8
and replacing coolant
filter
Replacing cooling liquid
separator 8.9
Replacing air filter 8.10
Check safety valve 8.11

Check clutch element 8.12

Lubrication of motor 8.13

General compressor
servicing

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

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

40 Use only original spare parts!

NOTICE

Hot surfaces hot coolant!!

Make certain, with appropriate precaution, that no one can be burned
or scalded! Particularly note dangerous situations which can arise
from the release of hot coolant steam!
DANGER

3. Remove the side panels of the system.

4. Make certain that the pressure grid side shut-off valve is closed and
cannot be opened accidentally or intentionally.

5. Make certain that when working on the coolant circulation, escaping

coolant is collected.
8.3 Check coolant level / refill Carry out the Preparatory activities
coolant
Only check the coolant level when the system has been turned off for a
Preparatory activities 8.2
Concluding activities 8.14 minimum of 30 minutes. This is to ensure that the coolant has settled
down after the running phase.
The coolant level is in order if the complete sight glass is full of coolant.

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

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

Damage of the system by using different coolants!

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

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

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

Carry out the Concluding activities.

8.4 Check for leakage Carry out the Preparatory activities. 41

Preparatory activities 8.2
Concluding activities 8.14
Check all piping and the bottom of the system for coolant rests. If there is
still coolant in the system, the cause should be found and the coolant
removed.

Carry out the Concluding activities.

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

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

the compressor.
NOTICE
 8. Service
8.6 Check the cooler for Carry out the Preparatory activities.
fouling
Preparatory activities 8.2
Concluding activities 8.14 Check the compressed air after-cooler and the coolant heat exchanger
from the inside and outside. If you determine any fouling, it should be re-
moved (e.g. by compressed air blowing, where the dirt particles should be
blown outside).

Carry out the Concluding activities.

8.7 Check for condensate The absorption capacity of water humidity in the air
development falls with increasing pressure
Preparatory activities 8.2
Concluding activities 8.14 rises with increasing temperature.
Sufficiently high compressor temperature guarantees that the intake air
humidity does not precipitate as condensation. The frequent switching on
and off of the compressor can result in the compressor not achieving the
required operating temperature.

Condensation in the coolant circulation can lead to damages to the

compressor. If you have determined that there is condensation in the
coolant container, immediately get in touch with customer service!
NOTICE Condensation damages lead to the loss of the guarantee!

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

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

Carry out the Preparatory activities.

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

2. Check the coolant level according to Chapter 8.3.

Carry out the Concluding activities.

8.8 Coolant replacement /
replacing coolant filter Carry out a coolant replacement only when the old coolant is still warm.
Cold coolant, because of its higher viscosity, does not flow so well.
Preparatory activities 8.2
Concluding activities 8.14

Hot Surfaces - hot coolant!

With appropriate precautions, make certain you are not burned or
scalded!
DANGER

Carry out the Preparatory activities.

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

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

Damage of the system can be caused by different coolants!

Different coolants may not be mixed.
NOTICE

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

4. Take care that the seal is correctly seated and screw the fitting screw 43
closed.

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

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

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

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

Carry out the Concluding activities.

 8. Service
8.9 Replacing coolant Carry out the Preparatory activities.
separator
Preparatory activities 8.2
Concluding activities 8.14

1. Loosen the coolant separator with a strap wrench. Remove possible

seal rests from the coolant separator housing.

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

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

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

Carry out the Concluding activities.

8.10 Replacing air filter Carry out the Preparatory activities.

Preparatory activities 8.2
Concluding activities 8.14

Damage of the system by intake dust!

The system may not be operated without an air filter.
NOTICE

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

2. Remove or screw off the old air filter
3. Insert the new air filter
44
4. Reinstall the covering of the air filter
Carry out the Concluding activities.

8.11 Check safety valve Carry out the Preparatory activities.

Preparatory activities 8.2
Concluding activities 8.14 1. Remove the safety valve and remove residues at the threaded connec-
tion.

2. Check the safety valve in an appropriate apparatus.

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

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

4. If the adequate functionality of the old safety valves can no longer be

guaranteed, screw in a safety valve.
Carry out the Concluding activities.
8.12 Check clutch element Carry out the Preparatory activities.

Preparatory activities 8.2 1. Test manually whether the clutch might have some radial play.
Concluding activities 8.14
2. If so, loosen the cam ring of the clutch, push it back, and replace the
clutch element.

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

Carry out the Concluding activities.

8.13 Relubrication of the Carry out the Preparatory activities.

electric motor
Preparatory activities 8.2 1. The bearing lubrication periods for the electric motor, which appear on
Concluding activities 8.14 the operating display desk, must be observed.

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

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

Carry out the Concluding activities.

8.14 Concluding activities 1. Open the stopcock slowly on the pressure grid side.
Service work acknowledged 7.1
2. Switch the plant main switch on.

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

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

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

6. Check all new cartridges or newly mounted pressurized components

for leakage at operating temperature.

7. Finally mount the side panels of the system. 45

8. Confirm that the services carried out by you work according to Chapter
5.3.5.

9. Used filter cartridges, lubricants, seals, surplus condensation and em-

ployed cleaning materials should be considered hazardous waste and
disposed of in an environmently friendly way.

Damage of the system is possible!

Only acknowledge those services actually carried out!
Services not carried out degrade the service life reliability of the sys-
NOTICE tem. Please note that damages caused by improper usage are not cov-
ered by the guarantee!
 9. Technical Data

9.1 Dimensions for connections

46

Compressor L W H Coolant Compressed Heat

filling air connection recovery
mm mm mm l G G

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

1
ALLEGRO 40 2,020 850 1,600 1 /2 1
1
ALLEGRO 60 2,020 850 1,600 1 /2 1
1
ALLEGRO 80 2,020 850 1,600 1 /2 1
ALLEGRO100 2,300 1,400 1,800 2 1/2 1
1
ALLEGRO115 2,300 1,400 1,800 2 /2 1 1/2
ALLEGRO130 2,300 1,400 1,800 2 1/2 1 1/2
9.2 Data air-cooled compressors

Compressor Weight Cooling air Room Intake air Diameter exhaust

amounts ventilation opening air canal
kg m3/h m3/h m2 m2

ALLEGRO 30 1,095
ALLEGRO 40 1,165
ALLEGRO 60 1,265
ALLEGRO 80 1,350
ALLEGRO100 1,675 16,500 17,000 1.50 0.84
ALLEGRO115 1,820 16,800 21,000 1.80 1.00
ALLEGRO130 1,820 16,800 21,000 1.80 1.00

9.3 Data water-cooled compressors

Compressor Weight Cooling air Cooling water current at Cooling water Connection
amountsinlet/return temperature pressure pressure cooling
10/40 C 25/40 C 35/45 C min - max water
kg m3/h m3/h m3/h m3/h bar G

ALLEGRO 30
ALLEGRO 40
ALLEGRO 60
ALLEGRO 80
ALLEGRO100 1,800 2,400 2.44 4.87 7.31 2.5 - 10 1
ALLEGRO115 1,950 2,400 2.80 5.60 8.41 2.5 - 10 1 1/2
ALLEGRO130 1,950 2,400 3.05 6.09 9.14 2.5 - 10 1 1/2

9.4 Electrical data

Compressor Motor Current at Current at Current at Maximum 47

power 220V/60Hz 400V/50Hz 550V/50Hz motor switching
IN IV IN IV IN IV frequency
kW A A gL A A gL A A gL 1/h

ALLEGRO 30 30
ALLEGRO 40 40
ALLEGRO 60 60
ALLEGRO 80 80
ALLEGRO100 100 295 325 148 194 129 142 5
ALLEGRO115 115 369 406 185 693 161 178 4
ALLEGRO130 130 461 508 231 1083 202 222 4

IN = Nominal current IV = backup fuse in building

D
ALUP-Kompressoren GmbH
Tel.: +49/7024/802-0
Fax: +49/7024/802-106
Internet: www.alup.com
E-mail: info@alup.com
Adolf-Ehmann-Str. 2
73257 Kngen
DEUTSCHLAND

A
AGRE-Kompressoren GmbH
Tel.: +43/7252/52341-0
Fax: +43/7252/52133
Internet: www.agre.at
E-mail: office@agre.at
Werkstrae 2
4451 Garsten-St. Ulrich
STERREICH

NL
ALUP-Kompressoren B.V.
Tel.: +31/30/2809000
Fax: +31/30/2895675
Internet: www.alup.nl
E-mail: info@alup.nl
Biezenwade 8-10
3439 Nieuwegein
NEDERLANDS

HU
ALUP Magyarorszg Kft.
Tel.: +36/36/423444
Fax: +36/36/516340
Internet: www.alup.hu
E-mail: info@alup.hu
Szlloda u. 5
3300 Eger
MAGYARORSZG

BG
ALUP-Kompressoren Bulgaria OOD.
Tel.: +359/2/528032
Fax: +359/2/528032
E-mail: alup@skycode.com
Tsar Asen Str. 63
1000 Sofia
BULGARIA