Operating manual Screw compressor
ALLEGRO 16 - 38
© 2006 All rights belong to: ALUP Kompressoren GmbH Adolf-Ehmann-Straße 2 73257 Köngen 2 Tel.:
0049-180-5258700
Fax:
0049-180-5258701
No part of this manual may be duplicated by mechanical or electronic means without the express written permission from ALUP Compressors GmbH. $OOSDUWLFXODUVLQWKLVPDQXDODUHVSHFL¿HGWRRXUEHVWNQRZOHGJHEXWZLWKRXW guarantee. :HUHVHUYHWKHULJKWWRPDNHFKDQJHVWRLQIRUPDWLRQRQKDUGZDUHDQG¿UPware documentation at any time without previous announcement. :HDUHWKDQNIXOIRUDQ\FULWLFLVPDQGVXJJHVWLRQV
Table of contents 1. Safety instructions.........................................................4 1.1 Symbols in this manual.............................................4 1.2 Proper usage ............................................................5 4XDOL¿HGSHUVRQQHO...................................................5 1.4 General safety instructions .......................................6 2. Functional description ..................................................8 2. Functional description .................................................10 3. Storage and transport .................................................12 4. Installation ....................................................................14 4.1 Setting up ...............................................................14 4.2 Ventilation ...............................................................14 4.3 Forced ventilation(optional) ....................................15 4.4 Water cooling (optional)..........................................16 4.5 Heat recovery for heating water / potable water (optional) ..........................................16 4.6 Connection to the compressed air net....................17 4.7 Electrical connections.............................................17 5. Displays and operating elements...............................18 5.1 Plant main switch....................................................18 5.2 Emergency OFF .....................................................18 5.3 Air Control 3 (option) ..............................................19 5.3.1 Basic display..................................................20 5.3.2 ON/OFF switching of compressed air generation.................................................20 )XQFWLRQNH\UHVHUYDWLRQLQWKHEDVLFGLVSOD\ 21 5.3.3.1 Capacity utilization ..........................22 5.3.3.2 Service ............................................22 5.3.3.3 LLC status .......................................23 5.3.3.4 Compressor pass ............................23 5.3.3.5 Diagram net pressure......................24 'LDJUDP¿QDOFRPSUHVVLRQ temperature ....................................24 5.3.3.7 Diagram compressed DLUDPRXQWGD\SUR¿OH....................24 5.3.3.8 Diagram compressed DLUDPRXQWVZHHNSUR¿OH ...............24 5.3.3.9 Modify diagram settings ..................25 5.3.4 Menu system .................................................26 5.3.4.1 Sub-menu Limit values....................27 5.3.4.2 Sub-menu Operating parameters....28 5.3.4.3 Sub-menu Service intervals ............29 5.3.4.4 Sub-menu Timer..............................30 5.3.4.5 Sub-menu Fault log ........................32 5.3.4.6 Sub-menu Display parameters........32 6XEPHQX&RQ¿JXUDWLRQ .................33 5.3.4.8 Sub-menu Lead lag control (LLC) ...34 5.3.4.9 Sub-menu Accessories....................34 5.3.4.10 Sub-menu Diagnosis .......................35 5.3.5 Warnings / maintenance ................................36 5.3.6 Malfunctions ..................................................37 5.3.7 Adjustment of the display contrast.................38 5.4 Air Control 1............................................................39 5.4.1 Basic display..................................................40 5.4.2 ON/OFF switching of compressed air generation.................................................41 5.4.3 Viewing additional operating data..................41
5.4.4 Menu system .................................................42 5.4.4.1 Unit parameterisation ......................42 5.4.4.2 Basic parameterisation....................43 5.4.4.3 Code 2: Operating mode .................44 5.4.4.4 Code 3: Automatic restart after power failure............................45 &RGH /RFDOFRQWURO UHPRWHFRQWURO//&2. ..................45 5.4.4.6 Code 11: Start and stop pressure ...45 5.4.4.7 Code 18: Lead leg control (LLC) ....46 5.4.4.8 Code 21: Maintenance DFNQRZOHGJHPHQW ...........................46 &RGH 2IIORDGRII star/delta time..................................47 5.4.4.10 Code 65: Condensate valve ............47 5.4.4.11 Code 90: Unit for pressure indication ........................................48 5.4.4.12 Code 95: Unit for temperature indication .........................................48 5.4.4.13 Code 9999: Software version ..........48 :DUQLQJVPDLQWHQDQFHZRUN .......................49 5.4.6 Malfunctions ..................................................50 5.4.7 Adjustment of the display contrast.................51 6. Correcting malfunctions .............................................52 7. Initial commissioning ..................................................54 7.1 Preparatory activities ..............................................54 &KHFNFRROLQJÀXLGOHYHO ..........................................54 7.3 Start-up lubrication of the compressor stage..........54 7.4 Rotational direction control .....................................55 7.5 Basic settings .........................................................56 7.5.1 Controlling the unitby means of Air Control 3 56 7.5.2 Controlling the unitby means of Air Control 1 56 7.6 Switch on compressed air generation ....................57 7.7 Concluding activities...............................................57 8. Service ..........................................................................58 8.1 Overview Maintenance intervals.............................58 8.2 Preparatory activities ..............................................58 &KHFNFRROLQJÀXLGOHYHOUH¿OOFRROLQJÀXLG ...........59 &KHFNIRUOHDNDJH...................................................60 &KHFNWKHFRPSUHVVRUWHPSHUDWXUH .......................60 &KHFNWKHFRROHUIRUIRXOLQJ....................................60 &KHFNIRUFRQGHQVDWH.............................................61 &RROLQJÀXLGUHSODFHPHQW UHSODFLQJFRROLQJÀXLG¿OWHU .....................................62 5HSODFLQJFRROLQJÀXLGVHSDUDWRU ...........................64 5HSODFLQJDLU¿OWHU...................................................65 &KHFNVDIHW\YDOYH .................................................65 &KHFNGULYH.............................................................66 8.13 Relubrication of the electric motor ..........................66 8.14 Concluding activities...............................................67 9. Technical Data..............................................................68 9.1 Dimensions for connections ...................................69 9.2 Data air-cooled compressors..................................69 9.3 Electrical data .........................................................69 10. Service manual ...........................................................70
3
1. Safety instructions Safety instructions
You are reading this manual in order to learn about the screw compressor. ,WFRQWDLQVLQIRUPDWLRQWKDWLVUHTXLUHGIRUVDIHPDOIXQFWLRQIUHHRSHUDWLRQ RIWKHV\VWHP3OHDVHNHHSLQPLQGWKDWGDPDJHLQFXUUHGGXHWRLPSURSHU usage may not fall under the conditions of guarantee! )RU WKLV UHDVRQ SOHDVH NHHS WKLV PDQXDO ZKHUH DOO XVHUV FDQ KDYH IUHH access to it at any time. 7KHV\VWHPZDVGHYHORSHGPDQXIDFWXUHGWHVWHGDQGGRFXPHQWHGLQVWDWH of-the-art technology and considering all the current safety standards. ,QQRUPDOFLUFXPVWDQFHVQRGDQJHUIRUSHUVRQQHORUSURSHUW\FDQUHVXOW from the system if you comply with the stipulations of the service manual DQGLIWKHWUDQVSRUWDVVHPEO\VHUYLFHDQGWKHGHVFULEHGKDQGOLQJLVFDUULHG out according to the regulations. 1HYHUWKHOHVVFHUWDLQULVNVUHPDLQ
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
4
Italic text is employed when we would like to draw your attention to particular information.
7H[WLQDIUDPHVLJQL¿HVWKHGHVFULSWLRQRIDQDFWLYLW\WREHFDUULHGRXWE\ the user.
1.2
Proper usage
The system is exclusively designed for •
the generation of compressed air and
•
for operation in an environment without explosion risk.
The units are designed for a minimum pressure of 5 bar (operating overpressure)! Any other utilization must be regarded as not in compliance with the design purpose! The manufacturer/vendor is fundamentally not liable for damage incurred if the system is not used according to its design purpose! The generated compressed air may not be used for human respiration. In case the compressed air is used for pharmaceutical or sanitary purposes, it must undergo further treatment. The same is true when the compressed air is used in production plants and comes into direct contact with foodstuffs.
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1. Safety instructions 1.4
General safety instructions
Loss or decrease of compressor safety !
DANGER
5HWUR¿WWLQJ RU PRGL¿FDWLRQV RQ WKH V\VWHP FDQ UHGXFH LWV OHYHO RI safety! The results could be serious personal, material or environmenWDOGDPDJH3RVVLEOHUHWUR¿WWLQJRUPRGL¿FDWLRQVRQWKHV\VWHPZLWK equipment components from third party manufacturers must therefore ¿UVWEHFOHDUHGE\XV
Loss of contact protection!
DANGER
The side panelings of the system are part of the contact protection system to protect personnel from fan impellers that start up automatically, moving machine parts, hot surfaces and dangerous voltages! Furthermore, they are required for sound insulation and cooling air conduction. Therefore they must not be removed when the unit is in operation. For initial commissioning, it is required to remove the side paneling of the system. Furthermore, in the process of the initial commissioning of the plant, the mains switch must be turned on. The initial commissioning, therefore, may only be carried out by quali¿HGWHFKQLFDOSHUVRQQHO
Injuries caused by fan impellers that start automatically, moving maFKLQHSDUWVKRWVXUIDFHVRUHVFDSLQJFRROLQJÀXLGPLVW
DANGER
Installation, service or repair work on the components of the system must, if not otherwise described, be categorically carried out only on DVZLWFKHGRIIVXI¿FLHQWO\FRROHGRIIDQGSUHVVXUHIUHHV\VWHP7KH system must be secured against an illicit or accidental switching-on. The shut-off device for the compressed air net 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 electricians observing all the relevant safety regulations.
6
Damage to the sense organs!
DANGER
Compressed air streams may not be directed towards persons. When applying compressed air, dust particles can be raised by the air stream. Therefore, when working with compressed air, protect your eyes with safety glasses.
Loss or decrease of compressor dependability! Only original spare parts and lubrications may be employed!
NOTICE
We recommend that a set of service parts subject to wear be kept on stock, in order to guarantee high compressor availability. Our customer service would be glad to help you with your selection.
Damage to the system may result in environmental damage! Before initial commissioning, the system must have been correctly installed according to Chapter 6! NOTICE
For the operation of the compressor (equipment in the sense of Pressure Equipment Directive 97/23/EC) please observe national regulations and laws. In Germany, operating equipment must be operated in accordance with the regulations laid down in the ordinance on industrial safety and health (BetrSichV)! Dispose of all used or defective materials in a proper way! This is especially true for components/materials containing cooling liquid. Please note that the accumulated condensation containing cooling liquid may not enter the sewage system! :HRIIHUDQDSSURSULDWHFRROLQJÀXLGZDWHUVHSDUDWRUIRUFRQGHQVDtion processing. Compressed air receivers require regular technical inspections! Please notify the commissioning of the system at the technical inspection authority responsible for you. They will inspect the system and provide a receiver test book.
Document all the activities carried out (e.g. in some table format). 7 Carry out the activities in all of the following chapters in the order given.
2. Functional description 2.1
Drive
The frequency converter supplies the electric motor with electric power. )RUWKHRSHUDWLQJSULQFLSOHRIWKHIUHTXHQF\FRQYHUWHUSOHDVHUHIHUWRWKH instructions in the control cabinet. 7KH HOHFWULF PRWRU GULYHV WKH FRPSUHVVRU VWDJH YLD D ÀH[LEO\ VXSSRUWHG coupling.
2.2
Air path
)UHVKDLUVXSSOLHGE\WKHLQWHJUDWHGFRROLQJDLUYHQWLODWRULV¿OWHUHGWKURXJK WKH DLU ¿OWHU V 7KH DLU LV WKHQ GLUHFWHG YLD WKH VXFWLRQ UHJXODWRU LQWR WKH FRPSUHVVRUVWDJHZKHUHLWLVFRPSUHVVHGWRWKH¿QDOFRPSUHVVLRQSUHVVXUH WRJHWKHUZLWKLQMHFWHGFRROLQJÀXLG ,QWKHFRROLQJÀXLGUHVHUYRLUWKHFRPSUHVVHGDLULVVHSDUDWHG IURP WKHFRROLQJÀXLGDQGWKHGRZQVWUHDPFRROLQJÀXLGVHSDUDWRUUHPRYHVWKH UHPDLQLQJFRROLQJÀXLGIURPWKHFRPSUHVVHGDLU7KHDLUWKHQÀRZVYLDWKH minimum pressure non-return valve into the compressed air aftercooler and is cooled down to 10 - 15 °C above the ambient temperature before it leaves the compressor through the compressed air connection. The suction regulator opens shortly after the compressor has started up for generating compressed air. It closes when the compressor changes over to off-load operation and/or comes to a standstill and unloads the system via the relief valve.
8
&RROLQJÀXLGFLUFXODWLRQ
7KH FRROLQJ ÀXLG LV VSUD\HG LQWR WKH DLU HQG DQG KDV WKH IROORZLQJ IXQFtions: •
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 FRROLQJÀXLG¿OP
•
bearing lubrication
•
noise dampening
7KHFRROLQJÀXLGOHDYHVWKHDLUHQGWRJHWKHUZLWKWKHFRPSUHVVHGDLUDVD KRWFRROLQJÀXLGUHWXUQDLUPL[WXUH 7KHFRROLQJÀXLGLVVHSDUDWHGIURPWKHFRPSUHVVHGDLULQWRWKHVHSHUDWRU WDQNE\WKHFRROLQJÀXLGVHSDUDWRUDQGZKHQVHSDUDWHGLWÀRZVWRWKHFRROLQJÀXLGKHDWH[FKDQJHU7KHFRROLQJÀXLGWHPSHUDWXUHUHJXODWRUPL[HVWKH FRROHGGRZQFRROLQJÀXLGZLWKWKHFRROLQJÀXLGKHDWH[FKDQJHUE\SDVVKRW FRROLQJÀXLGDVGH¿QHGE\WKHVHWSRLQWWHPSHUDWXUH)LQDOO\WKHFRROLQJÀXLG ¿OWHUFOHDQVWKHFRROLQJÀXLGEHIRUHLWLVDJDLQLQMHFWHGLQWKHDLUHQG ,I GHVLUHG E\ WKH FXVWRPHU DQ DGGLWLRQDO KHDWHU FDQ EH LQVWDOOHG LQ WKH VHSHUDWRUWDQNHLWKHURULJLQDOO\RUVXEVHTXHQWWRSXUFKDVH,WSUHYHQWVFRQGHQVDWLRQGDPDJHLQWKHFDVHRIFROGRUGDPSFRPSUHVVRUHQYLURQPHQWV for example.
2.4
Cooling
7KH FRPSUHVVHG DLU DIWHUFRROHU RI WKH FRROLQJ ÀXLG KHDW H[FKDQJHU LV cooled either by •
a built-in cooling air ventilator or
•
water cooling.
The electric motor is always cooled by its own ventilator fan. ,QWKHFDVHRIZDWHUFRROHGFRPSUHVVRUVDIUHVKDLUYHQWLODWRUDGGLWLRQDOO\ HQVXUHVVXI¿FLHQWIUHVKLQWDNHDLUIRUWKHUHPRYDORIUDGLDWHGKHDW
9
2. Functional description 2.5 Flow diagram
10
2.6
Components
05 01 15
02
12
19 20
10 09
19
12 20 04
01 05
07 02
2.7
Legend
01 Switching cabinet 02 Electric motor 03 Coupling $LU¿OWHU 05 Suction regulator 06 Compressor level &RROLQJÀXLGUHVHUYRLU 08 Safety valve 09 Drain ,QOHW¿WWLQJ 11 Additional heater (optional) &RROLQJÀXLGVHSDUDWRU 13 Minimum pressure non-return valve 14 Relief valve 15 Compressed air after-cooler
16 Compressed air connection &RROLQJÀXLGFRROHU &RROLQJÀXLGWHPSHUDWXUHUHJXlator &RROLQJÀXLG¿OWHU 20 Cooling air ventilator 21 Cooling water inlet 22 Throttle valve compressed air after-cooler 23 Solenoid valve 24 HCR water inlet 25 HCR heat exchanger 26 HCR thermostat 27 HCR water outlet 28 HCR thermostat valve
11
3. Storage and transport
For measurements and weights, see Chapter 9.
3OHDVHVWRUHWKHV\VWHPRQO\LQDGU\IURVWIUHHURRP
Observe the local regulations and other requirements pertaining to the professional use of tools, lifting and transport equipment, as well as the valid standards and regulations for accident prevention. DANGER
Always transport the system in its normal operating orientation in a pressure-free state. Tilting or laying the system down is not allowed.
8VH D IRUNOLIW WUXFN IRU WUDQVSRUW )RU VKRUW WUDQVSRUWDWLRQ GLVWDQFHV D palette lifting trolley may be used.
12
13
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 DPELHQWFRQGLWLRQV FRROGU\GXVWIUHH
Space requirements and system weights are dependent on the compressor type purchased. Measurements and weights: see Chapter 9. $OZD\VPDLQWDLQWKHPLQLPDOFOHDUDQFHVWRWKHZDOOVRURWKHUREMHFWVVR that system service functions can be carried out without hindrance. For the HQWLUHVHULHVWKHPLQLPXPFOHDUDQFHLVPP We recommend setting up the compressors in a separate compressor room.
2SHQÀDPHRU¿UHDVZHOODVZHOGLQJZRUNLQWKHYLFLQLW\RIWKHV\VWHP are forbidden! DANGER
4.2
Ventilation
7KHDLUHQWHULQJWKHLQWDNHRSHQLQJLVXVHGIRUWKHFRPSUHVVLRQDVZHOODV for compressor cooling. 7KHYHQWLODWLRQPXVWIXO¿OODWOHDVWWKHIROORZLQJFULWHULD 6XSSO\ UHTXLUHG FRROLQJ DLU DPRXQWV DV GH¿QHG LQ &KDSWHUG DQG 9.3 5HPRYHH[KDXVWDLUDVGH¿QHGLQ&KDSWHU LQRUGHUWRSUHYHQWDKHDWing up of the compressor site 7KHFRROLQJDLUPXVWEHFRROGU\DQGGXVWIUHH •
The temperature of the aspired cooling air must be within the range of +5°C to +40°C.
,QWKHFDVHRIDVSLUDWLRQIURPRXWVLGHSURYLGHDUHFLUFXODWLRQÀDS 14 0DNH FHUWDLQ WKDW WKH VXSSO\ DLU FRQWDLQV QR GDQJHURXV H[SORVLYH JDV PL[WXUHVVWHDPGXVWRUDJJUHVVLYHSROOXWDQWV 0DNHFHUWDLQWKDWWKHSODFHRILQVWDOODWLRQLVGXVWIUHHDVZHOODVZLWKLQ the prescribed operating temperature limits and as cool as possible. If QHFHVVDU\HQVXUHWKHSURIHVVLRQDOLQVWDOODWLRQRIIRUFHGDLUYHQWLODWLRQ ¿OWHULQJURRPFRROLQJRUKHDWLQJ
Make certain that the place of installation is professionally ventilated.
NOTICE
Make certain that no circulating air short-circuit (the intake of the exhausted warm air) can occur.
&RROLQJDLUYROXPHÀRZV VHH&KDSWHU
4.3
Forced ventilation (optional)
Forced ventilation must be dimensioned in such a way that the required IUHVK DQG H[KDXVW DLU FRQVLGHULQJ WKH DYDLODEOH UHVLGXDO SUHVVXUH RI WKH FRPSUHVVRUYHQWLODWRUFDQEHVXSSOLHGDQGH[SHOOHG Nominal diameters of the channel connections and information on the residual pressure : see Chapter 9. ,I YHQWLODWLRQ GXFWV DUH WR EH FRQQHFWHG WR WKH V\VWHP WKHQ WKH UHTXLUHG supporting supplementary ventilators should be included when planning the ducts. The exhaust air can also be utilized for the purpose of heat recovery.
15
4. Installation 4.4
Water cooling (optional)
)RUZDWHUFRROHGSODQWVWKHWHPSHUDWXUHRIWKHFRPSUHVVHGDLUDIWHUFRROHU RIWKHFRROLQJÀXLGKHDWH[FKDQJHULVORZHUHGZLWKH[WHUQDOFRROLQJZDWHU
)RUFRROLQJZDWHUTXDQWLWLHVWHPSHUDWXUHVDQGFRQQHFWLRQV see chapter 9. 7KHFRROLQJZDWHUPXVWIXO¿OOWKHIROORZLQJFULWHULD •
Inlet temperature less than + 35 °C
•
Pre-pressure 4 bar to10 bar
3UH¿OWUDWLRQZLWKDPHVKZLGWKRIDWOHDVWPP
•
Electrical conductivity: 10 - 500 µS/cm
3+
7RWDOKDUGQHVV P0ROO
A solenoid valve (optional) should be installed before the cooling water inlet. The cooling water current through the compressed air after-cooler should be set with the throttle valve belonging to it in such a way that the compressed DLURXWOHWWHPSHUDWXUHLV&KLJKHUWKDQWKHLQWDNHDLU 7KHFRQQHFWLRQVWRWKHFRROLQJZDWHUVXSSO\PXVWEHÀH[LEOHDQGZDWHU resistant. 4.5
Heat recovery for heating water / potable water (optional)
Compressors can be supplied with the optional heat recovery system •
for heating water or
IRUSRWDEOHZDWHU VDIHW\KHDWH[FKDQJHUZLWKEORFNLQJPHGLXP
16
:DWHUDPRXQWVWHPSHUDWXUHVDQGSUHVVXUHV VHH&KDSWHU The heat recovery is to be connected appropriately (see drawing in Chapter DVGH¿QHG 7KHZDWHUIRUKHDWUHFRYHU\PXVWIXO¿OOWKHIROORZLQJFULWHULD •
pressure of up to 10 bar
SUH¿OWHULQJZLWKDPHVKZLGWKRIDWOHDVWPP
4.6
Connection to the compressed air net
:HDVVXPHWKHH[LVWHQFHRIDSURIHVVLRQDOO\GHVLJQHGLQVWDOOHGDQGVHUviced compressed air net. Install an additional shut-off valve at the input of the compressed air net. &RQQHFWWKHV\VWHPRQO\ZLWKDÀH[LEOHFRPSUHVVHGDLUKRVHWRWKHFRPpressed air net. Length of the hose employed: max.1.5 m.
Unpredictable movements of the compressed air hose!
DANGER
4.7
Electrical connections
During load switching in the compressed air net, the hose can move suddenly and with great force. Therefore the hose must be adequately DQFKRUHGRU¿[HG
7KHXQLWLVSURYLGHGIRUFRQQHFWLRQWRDWKUHHSKDVHVXSSO\V\VWHP FORFNwise). Properly dimensioned safety equipment (to protect personnel/the unit) must be installed in the power supply lines. All the relevant data for the connections can be found •
in Chapter 9
•
on the nameplate of the system.
When using residual-current-operated circuit-breakers in conjunction with a speed-controlled machine, install exclusively residual-currentoperated circuit-breakers that are suitable for this application! NOTICE Electrical voltage! Only trained electricians may connect the system to the electrical supply network. DANGER %HIRUHPDNLQJWKHFRQQHFWLRQVDFFRUGLQJWRWKHFRPSUHVVRUQDPHSODWH GHWHUPLQHLIWKHDYDLODEOHVXSSO\QHWZRUNLVDGHTXDWH9ROWDJHGHYLDWLRQV JUHDWHUWKDQDUHQRWDOORZHG /D\ WKH VXSSO\ FDEOHV SURIHVVLRQDOO\ 0DNH FHUWDLQ WKDW WKH LQVWDOODWLRQ FDQQRWHQGDQJHULQGLYLGXDOVRUSURSHUW\7DNHLQWRDFFRXQWWKHQHFHVVDU\ FDEOHGLDPHWHUVVWUDLQUHOLHIDQGPD[DOORZHGFDEOHOHQJWKV Connect the system according to the circuit diagram. The circuit diagram is provided in the control cabinet of the system.
Damage to the system is possible! Before switching on the generation of compressed air, initial commissioning according to Chapter 6 must be correctly carried out! NOTICE 7HVWWKHFRUUHFWIXQFWLRQLQJRIDOOVDIHW\IDFLOLWLHV SURWHFWLYHJURXQGLQJ protective switch etc.). &DUHIXOO\ORFNWKHFRQWUROFDELQHWDIWHUWKHFRQQHFWLRQZRUNLVFRPSOHted.
17
5. Displays and operating elements 5.1
Plant main switch
DANGER
5.2
Emergency OFF
The unit‘s main switch that is installed on the control cabinet connects or disconnects the unit to and from the power supply.
The compressor main switch must be switched off for all service or installation work and protected from illicit or accidental switching RQ HJDI¿[DZDUQLQJVLJQWRWKHPDLQVZLWFKIRUELGGLQJLWVEHLQJ turned on)!
The system may be stopped with EMERGENCY OFF in the case of a real emergency! 7KHPDLQVZLWFKIXO¿OOVWKHIXQFWLRQRIWKHHPHUJHQF\VWRS 6WRSWKHPRWRULQFDVHRIGDQJHU SUHVVNH\ 0DNHVXUHWKDWWKHVKXWGRZQV\VWHPLVVXI¿FLHQWO\SURWHFWHGDJDLQVW recommissioning!
DANGER
Enable the system only when the cause of danger has been professionally removed and a securely operating state is achieved.
Enable system: 1. switch main switch off and on.
18
SUHVVNH\
WRDFNQRZOHGJHWKHPDOIXQFWLRQ
SUHVVNH\
to switch the system on again.
5.3
Air Control 3 (option)
7KHRSHUDWLQJGLVSOD\GHVNRIWKH$LU&RQWURO •
displays the plant states / operating data
•
switches on and off compressed air generation
•
is used for plant parameterizing.
)XQFWLRQNH\V
0RGL¿FDWLRQRISDUDPHWHUYDOXHV Selection of sub-menus &RQ¿UPDWLRQRISDUDPHWHUFKDQJHV Editing modes in the sub-menus Display additional operation data. Switch on compressor. Integrated green LED %OLQNLQJ
FRPSUHVVRULVQRWUXQQLQJFDQDWDQ\WLPH be automatically started up.
Lighted:
Compressor is running.
Compressor shut down. Signals a current warning/malfunction with the integrated red LED.
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5. Displays and operating elements 5.3.1 Basic display
$IWHUVZLWFKLQJRQWKHPDLQVZLWFKRUGXULQJQRUPDORSHUDWLRQ$LU&RQWURO 3 will inform you about the plant condition. Supplymentary information Momentary FRPSUHVVLRQ¿QDO temperature
Momentarily available net pressure at compressed air output
Service or malfunction messages with service telephone number &XUUHQWUHVHUYDWLRQRIWKHIXQFWLRQNH\V
Supplementary information: Switching times are programmed 6\PEROÀDVKHV Compressor was switched off by the timer Symbol ON: Compressor was switched on by the timer
5.3.4.4
Pressure times are programmed
5.3.4.4
$QWLIUHH]HDFWLYHFRPSUHVVRUGRHVQRWVWDUWXS
6
RESTART
Automatic restart programmed
5.3.4.2
REMOTE
Remote control mode programmed 6\PEROÀDVKHV Compressor OFF Symbol ON:,QUHPRWHPRGH&RPSUHVVRU21
5.3.4.7
LLC MODE
On-load/off-load controlled by higher-level control
5.3.4.7
AUTOMATIC OPT.
Meaning: Display of programmed off-load running control Motor running
Solenoid valve open
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Additional heater switched on
5.3.2 ON/OFF switching of compressed air generation
Switching ON: press NH\
.
The compressor is ready and can start up automatically at any time. Switching OFF: press NH\
.
)RUWKHGXUDWLRQRIWKHVWDQGVWLOOWLPHWKHFRPSUHVVRUVZLWFKHVWRWKHLGOLQJ state and afterwards off.
5.3.3 Function key reservation in the basic display
,QWKHEDVLFGLVSOD\WKHIROORZLQJLQIRUPDWLYHSLFWXUHVFDQEHDFFHVVHGZLWK WKHIXQFWLRQNH\V Mode 1 = reservation 1
Capacity utilization
Service
Lead lag control
Plant pass
:LWKWKHNH\ and WKHPRGHDQGWKHUHIRUHWKHUHVHUYDWLRQRIWKH IXQFWLRQNH\VLQWKHEDVLFGLVSOD\FDQEHFKDQJHG
Mode 2 = reservation 2
Diagram net pressure
21
Diagram air amounts GDLO\SUR¿OH
Diagram compression temperature
Diagram air amounts ZHHNO\SUR¿OH
%\SUHVVLQJWKHGH¿QHGIXQFWLRQNH\WKHUHVSHFWLYHLQIRUPDWLRQVFUHHQLV opened. 7KHNH\
returns to the basic display from all information screens.
5. Displays and operating elements 5.3.3.1 Capacity utilization (Mode 1 - F1) Change of mode
5.3.3
7KLVGLDJUDPUHSUHVHQWVWKHUXQQLQJRIIORDGRQORDGDQGVWDQGVWLOOKRXUV in the form of bar diagrams. The respective current hour count is also displayed in the bars. Example:
Total service hours On-load oad hours Off-load hours Standstill hours
:LWKWKHH[FHSWLRQRIWKHRIIORDGKRXUVDOOEDUVDUHUHSUHVHQWHGIURPWKH left and growing to the right. The sum of the on-load hours and the off-load hours yields the total service hours. The scaling units of this diagram are according to the service hours. If the QXPEHURIWKHVWDQGVWLOOKRXUVLVJUHDWHUWKDQWKHVHUYLFHKRXUVWKHEDUV of the standstill hours will be cut off. In this case note the displayed hour count in the bars.
5.3.3.2 Service (Mode 1 - F3) Change of mode
The Service diagram shows the remaining time in hours until the respective service interval is due. 5.3.3
$LU¿OWHU &RROLQJÀXLG¿OWHU &RROLQJÀXLGVHSDUDWRU Motor lubrication Compressor
22 ,IWKHUHPDLQLQJWLPHLVOHVVWKDQKRXUVXQWLOWKHQH[WVHUYLFHWKHUHVSHFWLYHEDUEHJLQVWREOLQNDQGDGH¿QHGZDUQLQJDSSHDUVRQWKHGLVSOD\
5.3.3.3 LLC status (mode 1 - F3) Change of mode
This display is only available if “Lead lag control” was activated by selecting “YES” in the Lead lag control menu (see Chapter 5.3.4.8). 5.3.3
This display shows the status of 4 additional compressors (K2 - K4) when RQHDGGLWLRQDO//&PRGXOHLVXVHGRUDGGLWLRQDOFRPSUHVVRUV .. when two additional LLC modules are used.
On-load Off-load Ready for operation Fault
“Fault” and “Off-load” are displayed for compressors K2 - K5 (or K2 - K9) RQO\LIWKHFRUUHVSRQGLQJIHHGEDFN IDXOWDQGPRWRUUXQQLQJ LVZLUHGWRWKH additional module.
5.3.3.4 Compressor pass (Mode 1 - F4) Change of mode
The individual machine data stored in the compressor pass are required for our customer service. 5.3.3
23
5. Displays and operating elements 5.3.3.5 Diagram net pressure (Mode 2 - F1) Change of mode
5.3.3
'LDJUDP¿QDOFRPSUHVsion temperature (Mode 2 - F2) Change of mode
,QWKLVGLDJUDPWKHFXUUHQWSURFHVVRIWKH¿QDOFRPSUHVVLRQWHPSHUDWXUH is displayed.
5.3.3
5.3.3.7 Diagram compressed air DPRXQWGD\SUR¿OH (Mode 2 - F3) Change of mode
,QWKLVGLDJUDPWKHFXUUHQWSURFHVVRIWKHQHWSUHVVXUHVLVGLVSOD\HG
,QWKLVGLDJUDPWKHFXUUHQWSURFHVVRIWKHFRPSUHVVHGTXDQWLW\IRUDGD\ is displayed.
5.3.3
24 5.3.3.8 Diagram compressed air DPRXQWVZHHNSUR¿OH (Mode 2 - F4) Change of mode
5.3.3
,QWKLVGLDJUDPWKHFXUUHQWSURFHVVRIWKHFRPSUHVVHGDLUTXDQWLW\IRUD ZHHNLVGLVSOD\HG
5.3.3.9 Modify diagram settings X-AUTO settings
The scale divisions of the axis can be changed by editing the axis values.
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:
,Q WKH GLDJUDP ³DLU TW\ZN´ WKH [D[LV YDOXHV FDQQRW EH FKDQJHGFKDQJHVDUHSRVVLEOHLQDOORWKHUGLDJUDPV
$IWHUHGLWLQJWKH[D[LVYDOXHVWKHGLDJUDPLVQRORQJHUFRQtinually updated.
X-AUTO:
7KHNH\
,I³;$87221´WKHYDOXHVRIWKH[D[LVDUHDXWRPDWLFDOO\ XSGDWHG7KH;$872XVHVWKHSUHVHWGHIDXOWYDOXHVGH¿QHG in the menu “Display parameter diagrams “(see Chapter 5.3.4.6).The manual editing x-axis values are deleted.
activates or deactivates X-AUTO
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)
6HOHFWLRQRIWKHD[LVYDOXHVWREHFKDQJHGZLWKWKHNH\V
and
&RQ¿UPDWLRQRIWKHVHOHFWLRQZLWKENTER 0RGL¿FDWLRQRIWKHEOLQNLQJYDOXHZLWK Moving the cursor with
and
and
.
.
&RQ¿UPDWLRQRIWKHPRGL¿FDWLRQVZLWKENTER.
7KHNH\ „X/Y-Init“ is for resetting the scale division for the default values preset in X-AUTO. 7KH NH\ ldeletes the recorded measurement values of the currently displayed time diagram.
25
5. Displays and operating elements 5.3.4 Menu system Limit values Operating parameters Service intervals Timer Malfunction storage Display parameter &RQ¿JXUDWLRQ Lead lag control Accessories Diagnose
5.3.4.1 5.3.4.2 5.3.4.3 5.3.4.4 5.3.4.5 5.3.4.6 5.3.4.8 5.3.4.9 5.3.4.10
All basic settings of the system can be viewed in the menu system. If the PRGL¿FDWLRQVKDYHQRLQÀXHQFHRQRSHUDWLRQDOVDIHW\WKH\PD\EHPRGL¿HG by means of a code entry. After pressing the INFO NH\WKHPDLQPHQXDSSHDUVUHTXHVWLQJWKHFRGH entry.
•
Code 0000: View the basic settings
•
Code 0001: View and change basic settings
0RGL¿FDWLRQRIWKHEOLQNLQJYDOXHVZLWKWKHNH\V Moving the cursors with
and
and
.
.
&RQ¿UPDWLRQRIWKHPRGL¿FDWLRQVZLWKENTER. 7KHUHDIWHUWKHPDLQPHQXDSSHDUVZLWKWKHIROORZLQJVXEPHQXV
26
7KHVXEPHQXFDQEHVHOHFWHGZLWKWKHNH\V FRQ¿UPHGZLWKENTER. ,QHYHU\RSHUDWLQJOHYHO vel.
and
.The selection is
will lead you to the next higher operating le-
If the Code 0001 LV HQWHUHG WKH SDUDPHWHUV RI WKH VXEPHQX VKRXOG EH changed as follows: 7KHVHOHFWLRQRIWKHGHVLUHGPHQXSRVLWLRQLVFDUULHGRXWZLWKWKHNH\V and . 7KHVHOHFWLRQLVFRQ¿UPHGZLWKENTER. 0RGL¿FDWLRQRIWKHEOLQNLQJYDOXHZLWKWKHNH\V Moving the cursor with
and
and
.
.
&RQ¿UPDWLRQRIWKHPRGL¿FDWLRQVZLWKENTER.
5.3.4.1 Sub-menu Limit values Selection of the menu position 0RGL¿FDWLRQRIWKHEOLQNLQJ values ENTER &RQ¿UPVHOHFWLRQPRGL¿FDWLRQ %DFNWRWKHQH[WKLJKHUOHYHO
This menu contains the pressure / temperature limit values: Start pressure
Lower value for the pressure regulation
Can be edited
Stop pressure
Upper value for the pressure regulation
Can be edited
Safety pressure
Maximum permissible pressure for malfunction triggering (always 0.8 bar greater than stop pressure)
Display
Final compression 0LQLPXPSHUPLVVLEOH¿QDOFRPSUHVVLRQ temperature min temperature
Display
Final compression 0D[LPXPSHUPLVVLEOH¿QDOFRPSUHVVLRQ temperature max temperature
Display
27
5. Displays and operating elements 5.3.4.2 Sub-menu Operating parameters Selection of the menu position 0RGL¿FDWLRQRIWKHEOLQNLQJ values ENTER &RQ¿UPVHOHFWLRQPRGL¿FDWLRQ %DFNWRWKHQH[WKLJKHUOHYHO
7KLVPHQXFRQWDLQVSDUDPHWHUVZKLFKLQÀXHQFHWKHWHPSRUDOUHJXODWLRQRI the compressor: Run-on time
Run-on time of the motors in automatic operation
Display
Off time
Run-on time of the motor for manual switching-off delay and for automatic restart
Display
Star/delta time
Star/delta time
Display
Automatic restart
Start after voltage return
Can be edited
Operating mode:
Behavior on load switching Setting range: AUTOMATIC ON-/OFF-LOAD AUTOMATIC OPT.
Can be edited
Max. pressure loss
Maximum pressure loss
Display
Max. no. of motor starts
Maximum switching cycles of the motor per hour
Display
Operating mode “Automatic” The text “AUTOMATIC” is displayed in the basic display. After reaching the VWRSSUHVVXUHWKHV\VWHPFKDQJHVRYHUWRWKHRIIORDGPRGH DIWHUUXQQLQJ time) for the duration of the run-on time and the basic display shows the text “run-on time” with the respective residual time. At the conclusion of WKHUXQRQWLPHWKHPRWRUVZLWFKHVRII7KHFRPSUHVVRUFDQEHVWDUWHGXS automatically at any time after falling below the start pressure. Operating mode “On-/off-load” The text “ON-/OFF-LOAD” is displayed in the basic display. The compresVRUVZLWFKHVEHWZHHQRQORDGDQGRIIORDGRSHUDWLRQZKLFKPHDQVWKDWLWV run-on time is unlimited. Operating mode “Automatic Optional” The text “AUTOMATIC OPT.” is displayed in the basic display. After reaching WKHVWRSSUHVVXUHWKHV\VWHPJRHVLQWRWKHRIIORDGPRGH After 10 and after 40 seconds the net pressure is measured. ,IWKHSUHVVXUHGURSVDERYHWKHWKUHVKROG³0D[SUHVVXUHGURS´WKHQWKH system is in the idling state for the duration of the run-on time. In the basic GLVSOD\WKHWH[W³5XQRQ´DSSHDUVZLWKWKHUHVLGXDOWLPHDVGH¿QHG 28
,IWKHYDOXHOLHVEHORZWKHWKUHVKROG³0D[SUHVVXUHGURS´WKHQWKHV\VWHP switches off after completing the OFF time. Max. no. of motor starts ,IWKHQXPEHURIWKHPD[LPXPSRVVLEOHPRWRUVWDUWVSHUKRXULVH[FHHGHG then the compressor temporarily switches to the operation mode on-/offload.
,Q WKLV PHQX DOO VHUYLFH LQWHUYDOV DUH GLVSOD\HG RU DFNQRZOHGJHG DIWHU FDUU\LQJRXWWKHVSHFL¿FVHUYLFH VHH&KDSWHU
5.3.4.3 Sub-menu Service intervals 6HUYLFHZRUN DFNQRZOHGJHG
:LWKWKHDFNQRZOHGJHPHQWWKHGLVSOD\HGUHVLGXDOWLPHIRUWKHYDOXHRIWKH respective service intervals (see Chapter 8.1) is reset. Service interval ASF
6HUYLFHLQWHUYDODLU¿OWHU
Display
Service interval OLF
6HUYLFHLQWHUYDOFRROLQJÀXLG¿OWHU
Display
Service interval OLAB
6HUYLFHVLQWHUYDOFRROLQJÀXLGVHSDUDWRU
Display
Service interval motor
Service interval for motor lubrication
Display
Service interval compr.
Service interval compressor
Display
Service hours
Total operating hours (motor on)
Display
Load hours
Accumulated load hours
Display
Standstill hours
Accumulated standstill hours (system on motor off)
Display
29
5. Displays and operating elements 5.3.4.4 Sub-menu Timer
Selection of the menu position 0RGL¿FDWLRQRIWKHEOLQNLQJ values ENTER &RQ¿UPVHOHFWLRQPRGL¿FDWLRQ %DFNWRWKHQH[WKLJKHUOHYHO
7KHDGMXVWPHQWRIWKHLQWHJUDWHGUHDOWLPHFORFNDVZHOODVDOOVZLWFKLQJ processes dependant upon it are in this menu. Date/time
Setting the current date and time Attention: The adjustment is entered to WKHUHDOWLPHFORFNZKHQWKHVHFRQGVDUH FRQ¿UPHGZLWKENTER
Edit
Compressor switching times
Branch to the sub-menu
Edit
Compressor pressure times
Branch to the sub-menu
Edit
Switching times LLC
Branch to the sub-menu
Edit
Pressure times LLC
Branch to the sub-menu
Edit
Switching times as well as pressure times can be programmed with the timer independently of each other. :KHQSURJUDPPLQJVZLWFKLQJWLPHVWKHFRPSUHVVRUQHHGVQRORQJHUEH manually switched on and off. This is to prevent the possibility that the compressor might for instance start up automatically at night in order to compensate for loss in the compressed air net. )RUDOLPLWHGWLPHYDOXHVGHYLDWLQJIURPWKHSUHVHWOLPLWYDOXHV VHH&KDSter 5.3.4.1) can be set for the start and stop pressure. In this way only the minimal required operating pressure is always generated so that energy is saved.
Switching times for compressor ,QWKLVPHQXWKHVZLWFKLQJRQRIIWLPHVRIWKHFRPSUHVVRUVDUHGH¿QHG
7LPHUFORFNRXWSXWDFWLYH 0R7K XQWLO RµFORFN )U XQWLO RµFORFN
30 )RUWKHDFWLYDWLRQRIWKHWLPHUWKHSDUDPHWHURIWKHWLPHUFKDQQHOVPXVWEH set to “ON” in the highest menu line. If the timer channel is set to “ON” and LIWKHWLPHUFORFNRXWSXWLVDFWLYDWHGDFORFNDSSHDUVLQWKHGLVSOD\ LIWKHWLPHURXWSXWLVQRWDFWLYDWHGDEOLQNLQJFORFNDSSHDUVLQWKHGLVplay Seven switching times with the channels K1 –K7 can be programmed. $FKDQQHOLVDFWLYHZKHQDWOHDVWRQHRIWKHZHHNGD\VLVPDUNHGEODFN,Q RUGHUWRFRQWLQXRXVO\DFWLYDWHWKHWLPHURXWSXWIRURQHRUDQXPEHURIGD\V the switching time should be set to 00:00.
$GMXVWVZLWFKLQJWLPHV ZHHNGD\VPDUNHGEODFN &KDQQHOVHOHFWLRQZLWKWKHNH\V
and
&RQ¿UPVHOHFWLRQZLWKENTER. 0RYHWKHFXUVRUWRWKHGHVLUHGZHHNGD\E\XVLQJNH\ and RUGHUWRGHOHWHDQDOUHDG\VHOHFWHGZHHNGD\SUHVVNH\ .)
. (In
4. Set the cursor with and RQWRWKHFORFNWLPHDQGXVHNH\V WRPRGLI\WKHEOLQNLQJYDOXH
and
6WRUHWKHVHWWLQJVZLWKWKHNH\ENTER.
If the timer for switching times is activated, then the compressor only works during the switching times entered! NOTICE Compressor pressure times ,QWKLVPHQXWKHSUHVVXUHWLPHVRIWKHFRPSUHVVRUVDUHGH¿QHG LQFUHDVLQJ pressure / decreasing pressure).
7LPHUFORFNRXWSXWDFWLYH 6D6R XQWLO R¶FORFN IURP6D R¶FORFNXQWLO6X R¶FORFN
,QRUGHUWRDFWLYDWHWKHWLPHUWKHXSSHUPRVWPHQXURZRIWKHSDUDPHWHUIRU the timer channels must be set to “ON”. $FKDQQHOLVDFWLYHZKHQDWOHDVWRQHRIWKHZHHNGD\VLVPDUNHGEODFN (For switching times adjustment: see paragraph “Compressor switching times”) The channels are searched beginning with K1 to K7 to determine whether a FKDQQHOLVDFWLYDWHGIRUWKHFXUUHQWFORFNWLPH,IQRYDOLGFKDQQHOLVIRXQG then the settings in the menu “limit values” are valid. In order to activate the WLPHURXWSXWIRURQHRUDQXPEHURIGD\VFRQWLQXRXVO\WKHVZLWFKLQJWLPH of 00:00 should be entered. Switching times LLC /pressure times LLC Switching times or pressure times can only be entered if the supplementary module for Lead lag control (LLC) is installed in the control system. The settings are to be carried out as described in “Compressor switching times” or “Compressor pressure times”
31
5. Displays and operating elements 5.3.4.5 Sub-menu Fault log
,QWKLVPHQX\RXFDQYLHZWKHODVWVHUYLFHVZDUQLQJVDQGIDXOWVZLWK indication of the date and time.
5.3.4.6 Sub-menu Display parameters
,QWKLVPHQXWKHSDUDPHWHUVIRUWKHRXWSXWWRWKHGLVSOD\DUHVWRUHG
Selection of the menu position 0RGL¿FDWLRQRIWKHEOLQNLQJ values ENTER &RQ¿UPVHOHFWLRQPRGL¿FDWLRQ %DFNWRWKHQH[WKLJKHUOHYHO
Pressure dimension
Selection of the unit for the display of the line pressure
Edit
Temperature dimension
Selection of the unit for the display of WKH¿QDOFRPSUHVVLRQWHPSHUDWXUH
Edit
Language
Selection of the display language
Edit
Pressure offset
Readjustment possibility for the net pressure sensor
Display
Diagrams
Settings for diagrams
Edit
Texts
Texts for the compressor pass
Display
Diagrams ,QWKLVPHQXWKHGLVSOD\SDUDPHWHUV GHIDXOWYDOXHV;$872VHH&KDSWHU 5.3.3.8) for the diagrams can be set:
32
Saving interval
6DYLQJLQWHUYDOIRUWKHUHFRUGLQJRIWKHOLQHSUHVVXUHWKH ¿QDOFRPSUHVVLRQWHPSHUDWXUHRIWKHPRPHQWDU\GHOLYHU\ quanitiy. The control system always saves the most recent 8000 values. For a saving interval of 12s (basic setting) there is a logging duration of 12s x 8000 = 96000s = 26.7h
Number of points X-auto
Number of the recorded values for function X-Auto on the time axis at a saving interval of 12 s and up to 300 points for X-Auto a time axis scaling of 12s x 300 = 3600s =1h
Line pressure low
Lower scale value of the x-axis of the diagram “line pressure” (see 5.3.3.4)
Line pressure high
Upper scale value of the x-axis of the diagram “line pressure” (see 5.3.3.4)
Temperature low
Lower scale value of the x-axis of the diagram “Final compression temperature” (see 5.3.3.5)
Temperature high
Upper scale value of the x-axis of the diagram “Final compression temperature” (see 5.3.3.5) (basic 120°C)
Air quantity day low
Lower scale value of the x-axis of the diagram “Compressed DLUTXDQWLW\GDLO\SUR¿OH´ VHH
Air quantity day high
Upper scale value of the x-axis of the diagram ³&RPSUHVVHGDLUTXDQWLW\GDLO\SUR¿OH´ VHH
Air quantity ZHHNORZ
Lower scale value of the x-axis of the diagram “Compressed DLUTXDQWLW\ZHHNO\SUR¿OH´ VHH
Air quantity ZHHNKLJK
Upper scale value of the x-axis of the diagram “Compressed DLUTXDQWLW\ZHHNO\SUR¿OH´ VHH
5.3.4.7 Sub-menu &RQ¿JXUDWLRQ Selection of the menu position 0RGL¿FDWLRQRIWKHEOLQNLQJ values ENTER &RQ¿UPVHOHFWLRQPRGL¿FDWLRQ %DFNWRWKHQH[WKLJKHUOHYHO
Machine type
6HOHFWLRQRIDSUHGH¿QHGPDFKLQHW\SH
Display
Maximal pressure
Maximum permissible machine pressure
Display
0D[LPDODLUÀRZ
Delivered air quantity at maximum speed in on-load operation
Display
Remote mode
Switching on/off of the system
Edit
LLC operation
Operation with external base load alternate switching
Edit
Power fail Stop
Switching-off when low voltage is recognized
Display
Frequency converter
Settings of the frequency converter
Display
Communication
Settings for serial communication
Display
Heating
Settings of the additional heater
Display
Remote mode Determines how the compressor is switched on or off. Local operation: The compressor can only be switched on or off at the opeUDWLQJGLVSOD\GHVNRI$LU&RQWURO Remote control: The compressor can be switched on or off with an electriFDOVLJQDORUWKHNH\ ,QWKHEDVLFGLVSOD\DSSHDUVDVWKHEOLQNLQJWH[W “REMOTE”.
During active remote operation, the signal of the remote control must be switched off after pressing the key . NOTICE
//&2. ,VIRUWKHQRWL¿FDWLRQRIUHDGLQHVVIRURSHUDWLRQRIDVXSHULRUFRQWURO system to the compressor. (see also LLC Operation 5.3.4.9) 33 LLC mode The compressors are controlled by a higher-level control system. The text “LLC MODE” (see also Remote Mode 5.3.4.9) appears in the basic display
5. Displays and operating elements 5.3.4.8 Sub-menu Lead lag control (LLC) Selection of the menu position 0RGL¿FDWLRQRIWKHEOLQNLQJ values ENTER &RQ¿UPVHOHFWLRQPRGL¿FDWLRQ %DFNWRWKHQH[WKLJKHUOHYHO
This menu contains the settings for the operation as the LLC Master. )RUWKHXWLOL]DWLRQRIWKHIXQFWLRQ³/HDGODJFRQWURO´$LU&RQWUROPXVWEH ¿WWHGZLWK •
a supplementary module for up to 4 additional compressors
•
two supplementary modules for up to 8 additional compressors.
The LLC master function may only be activated when the compressor is actually used as master unit! NOTICE
Lead lag control
Parameter for the activation of the LLC Master characteristics (basic setting: NO)
Display
Start pressure
Lower pressure threshold for switching on a compressor
Edit
Stop pressure
Upper pressure threshold for switching off a compressor
Edit
Cut out at
3HUFHQWDJHRIPDVWHUPDFKLQHSRZHU below which slave compressors are cut out
Edit
Cut in at
3HUFHQWDJHRIPDVWHUPDFKLQHSRZHU above which slave compressors are cut out
Edit
Start delay
Minimal time between the switching on of two compressors
Edit
Stop delay
Minimal time between the switching off of two compressors
Edit
Changeover interval Priority 1
Time between changeovers of LLC for compressors having priority 1
Edit
Changeover interval Priority 2
Time between changeovers of LLC for compressors having priority 2
Edit
Changeover interval Priority 3
Time between changeovers of LLC for compressors having priority 3
Edit
Priorities
Assignment of sequencing priority
Edit
(see also Chapter 5.3.4.7)
34
5.3.4.9 Sub-menu Accessories
This menu contains the settings for the connection of accessories. 7REHDEOHWRXWLOL]HWKLVIXQFWLRQ$LU&RQWUROPXVWEH¿WWHGZLWKDFFHVVRries modules. Accessories module
Additional module for accessories available
Display
,QSXWFRQ¿JXUDWLRQ
Function of digital inputs
Edit
2XWSXWFRQ¿JXUDWLRQ
Function of digital outputs
Edit
Switching times output 1
6ZLWFKLQJWLPHVGH¿QHGIRUDFFHVVRULHV
Edit
Switching times output 2
6ZLWFKLQJWLPHVGH¿QHGIRUDFFHVVRULHV
Edit
Switching times output 3
6ZLWFKLQJWLPHVGH¿QHGIRUDFFHVVRULHV
Edit
Switching times output 4
6ZLWFKLQJWLPHVGH¿QHGIRUDFFHVVRULHV
Edit
Switching times 7KHVZLWFKLQJRQRIIWLPHVRIDQDFFHVVRU\UHOD\RXWSXWDUHGH¿QHGLQWKLV menu.
7LPHUFORFNRXWSXWDFWLYH 0R7K XQWLO R¶FORFN )U XQWLO R¶FORFN
)RUWKHDFWLYDWLRQRIWKHWLPHUWKHXSSHUPRVWPHQXURZRIWKHSDUDPHWHU of the timer channels must be set to “ON”. Seven switching times can be programmed with the channels K1 –K7. One FKDQQHOLVDFWLYHZKHQDWOHDVWRQHRIWKHZHHNGD\VLVPDUNHGEODFN )RUDGMXVWPHQWRIWKHVZLWFKLQJWLPHVVHHSDUDJUDSK³&RPSUHVVRUVZLWFKing times “ Chapter 5.3.4.4. ,QRUGHUWRFRQWLQXDOO\DFWLYDWHWKHWLPHURXWSXWIRURQHRUDQXPEHURIGD\V set the switching time to 00:00.
,QSXWFRQ¿JXUDWLRQ The inputs 1 to 8 can be used in order to switch the compressor to malfunction or warning. 35
5.3.4.10 Sub-menu Diagnosis
This menu describes the current states of digital inputs and outputs.
5. Displays and operating elements 5.3.5 Warnings / maintenance
$ZDUQLQJLVSUHVHQWZKHQWKHUHGOLJKWLVEOLQNLQJ The compressor is not switched off. The display contains the additional information:
EOLQNLQJV\PEROZDUQLQJWULDQJOH
•
type of warning
•
telephone number of the service hotline
:KDWWRGRIRUVSHFL¿FZDUQLQJVPDLQWHQDQFHZRUNLVGHVFULEHGLQ Chapter 8.
Damage to the system is possible! Necessary maintenance work appear as warnings. NOTICE
$FNQRZOHGJHWKHVHZDUQLQJVRQO\ZKHQWKHGH¿QHGPDLQWHQDQFHZRUN has actually been carried out! Maintenance work not carried out degrades the service life and reliability of the system. Please note that damage because of improper usage might invalidate the warranty! Only original spare parts may be used. Information on service: see Chapter 8. 6HUYLFHVZRUNDFNQRZOHGJHG $VGHVFULEHGLQ&KDSWHUFDOOXSWKHPDLQPHQXDQGWKHQWKHVXE menu Maintenance schedule.
36
6HOHFWWKHPDLQWHQDQFHZRUNWREHFDUULHGRXWXVLQJNH\V 3UHVVNH\
WRDFNQRZOHGJHWKHVHUYLFH
%\GRXEOHFOLFNLQJNH\
you will return to the basic display.
and
.
5.3.6 Malfunctions
A malfunction has occurred when the red light is permanently on. The compressor is stopped automatically. ,QDGGLWLRQWKHGLVSOD\DOVRVKRZV
EOLQNLQJV\PEROWRRONH\
•
type of malfunction
•
telephone number of the service hotline
0DOIXQFWLRQVFDQRQO\EHDFNQRZOHGJHGZKHQWKHFDXVHKDVEHHQSURIHVsionally repaired. Troubleshooting and repair should be done exclusively E\TXDOL¿HGSHUVRQQHO )DXOWPHVVDJHVDFNQRZOHGJHG SUHVVNH\
.
SUHVVNH\
in order to restart the compressed air generation.
37
5. Displays and operating elements 5.3.7 Adjustment of the display contrast
The display contrast of the control was selected so that it ensures optimum readability under nearly all operating conditions. If it is nevertheless required to adjust the contrast under certain conditions (e.g. unfavourable lighting FRQGLWLRQVGLUHFWVXQOLJKW IROORZWKHVWHSVEHORZ
1. Make sure that the compressor is disconnected from the power supply by actuating the master switch. DANGER
2. Open the control cabinet/control box of the compressor. 3. At the rear of the control you can see a small opening at the top.
Insert a small plain slot screwdriver through this opening to reach the adjustment screw for correcting the contrast. 7RLQFUHDVHWKHFRQWUDVWVOLJKWO\WXUQFORFNZLVH E\WXUQLQJFRXQWHUFORFNZLVH\RXUHGXFHWKHFRQWUDVW 5. Close the control cabinet/control box before recommissioning.
38
5.4
Air Control 1
7KHRSHUDWLQJGLVSOD\GHVNRI$LU&RQWURO •
displays the compressor states / operating data
•
switches on and off compressed air generation
•
is used for compressor parameterizing.
0RGL¿FDWLRQRISDUDPHWHUYDOXHV
&RQ¿UPDWLRQRISDUDPHWHUFKDQJHV
Display additional operating data. Switch on compressor. Integrated green LED %OLQNLQJ
FRPSUHVVRULVQRWUXQQLQJFDQDWDQ\WLPH be automatically started up.
Lighted:
Compressor is running. 39
Compressor shut down. Signals a current warning/malfunction with the integrated red LED.
5. Displays and operating elements 5.4.1 Basic display
$IWHUVZLWFKLQJRQWKHPDLQVZLWFKRUGXULQJQRUPDORSHUDWLRQ$LU&RQWURO 1 will inform you about the compressor state.
Current pressure
Warning present (see Chapter 5.4.5)
Motor is running
Compressor compresses air
Fault is present (see Chapter 5.4.6) RESTART
Automatic restart after power supply is activated
AUTOMATIC
Operating mode Automatic or Automatic optional
REMOTE
- Flashing:
Generation of compressed air ON/ OFF by remote switch
- Continuous:
Generation of compressed air controlled by higher-level control
40
Current compressor temperature
Instead of the current compressor temperature you can also have the curUHQWFRROLQJÀXLGWHPSHUDWXUHGLVSOD\HG 3UHVVNH\ RSHUDWLQJGDWDVHH&KDSWHU
. For viewing further
5.4.2 ON/OFF switching of compressed air generation
Switching ON: press NH\
.
The compressor is ready and can start up automatically at any time. The compressor starts up only when •
the current line pressure falls below the start pressure and
•
the compressor temperature is at least 1 °C.
Switching OFF: press NH\
.
)RU WKH GXUDWLRQ RI WKH RII WLPH WKH FRPSUHVVRU VZLWFKHV WR WKH RIIORDG state and afterwards off. 'XULQJWKHVZLWFKLQJRIISURFHVVWKHXQLW¿UVWFKDQJHVRYHUWRWKH³RIIORDG´ PRGH PRWRUUXQQLQJEXWFRPSUHVVRUGRHVQRWFRPSUHVVDLU DÀDVKLQJ point appears in the display) for the duration of the “off time” (45 s). Only then is the unit switched off (motor stops). 5.4.3 Viewing additional operating data
Press the INFONH\UHSHDWHGO\WRYLHZWKHIROORZLQJRSHUDWLQJGDWDLQWKH order below.
Operating data
1x 2x 3x
4x 5x 6x 7x [ [ [ 11x 12x
Start pressure in bar. The compressor starts up as soon as the line pressure falls below this value. Stop pressure in bar. The unit changes over to the off-load mode as soon as the line pressure increases above this value. Safety pressure in bar (= stop pressure + 0.8 bar). When this safety SUHVVXUHLVUHDFKHGWKHFRPSUHVVRUVKXWVGRZQDQGDQHUURUPHVsage is output. min. permissible compressor temperature max. permissible compressor temperature Total running hours On-load hours 5HPDLQLQJVHUYLFHOLIHRIDLU¿OWHU 5HPDLQLQJVHUYLFHOLIHRIFRROLQJÀXLGDQGFRROLQJÀXLG¿OWHU 5HPDLQLQJVHUYLFHOLIHRI¿QHVHSDUDWRU Remaining service life of motor lubrication Time remaining until compressor must be serviced
Display of faults/warnings is deactivated!
NOTICE
As long as the operating data above are viewed, no fault messages or warning can be output. This screen should therefore be exited as soon as possible.
41
5. Displays and operating elements 5.4.4 Menu system Unit parameterisation 5.4.4.1 Basic parameterisation 5.4.4.2 Available code numbers 5.4.4.3 bis 5.4.4.13
5.4.4.1 Unit parameterisation
All basic settings of the system can be viewed in the menu system. If the PRGL¿FDWLRQVKDYHQRLQÀXHQFHRQRSHUDWLRQDOVDIHW\WKH\PD\EHPRGL¿HG by means of a code entry.
7KHXQLWFDQRQO\EHSDUDPHWHULVHGZKHQWKHJHQHUDWLRQRIFRPSUHVVHG air is switched off. See Chapter 5.4.2. 3DUDPHWHUVDOORZWKHXQLWWREHDGMXVWHGWR\RXUVSHFL¿FUHTXLUHPHQWV7R WKLVHQG$LU&RQWUROPXVWEHVZLWFKHGWRWKHSDUDPHWHULVDWLRQPRGH The individual parameters can be selected with a code and then changed. A description of available code numbers can be found in Chapters 5.4.4.3 to 5.4.4.13.
Paremeterisation procedure: 3UHVVNH\ until the message “cod” appears in the display. Air Control 1 is now at the main level of the parameterisation mode.
Code ÀDVKLQJ
1RZVHOHFWWKHUHTXLUHGFRGHE\PHDQVRINH\V
and
.
3. Press ENTERWRDFWLYDWHWKHFRGH$LU&RQWUROFKDQJHVWRWKH¿UVW sub-level. 42 With some codes, several parameters can be entered one after the other. In these cases, simply press key ENTER to select the subsequent parameter.
8VHNH\V and to change the current setting of the selected code according to your requirements. 3UHVVNH\ENTERWRWDNHRYHUWKHQHZVHWWLQJVRUSUHVVNH\ the setting unchanged and return to the next higher level.
to leave
5.4.4.2 Basic parameterisation
7KHXQLWFDQRQO\EHSDUDPHWHULVHGZKHQWKHJHQHUDWLRQRIFRPSUHVVHG air is switched off. See Chapter 5.4.2.
The basic parameterisation prepares the unit for operation.
3UHVVNH\
until the message “cod” appears in the display.
6HOHFWFRGHE\PHDQVRINH\V
and
DQGSUHVVNH\ENTER.
3UHVVNH\INFO.
&RGH ÀDVKLQJ
Air Control 1 now shows the start pressure. The compressor compresses air as soon as the line pressure falls below this value. Possible adjustment range: 3.5 to maximum pressure of the unit. $GMXVWWKHUHTXLUHGVWDUWSUHVVXUHXVLQJNH\V VHWWLQJE\SUHVVLQJNH\ENTER.
and
FRQ¿UPWKH
3UHVVNH\INFO.
6WDUWSUHVVXUH ÀDVKLQJ
Air Control 1 shows the stop pressure. The compressor changes over to off-load operation as soon as the line pressure exceeds this value. Possible adjustment range: 3.5 to maximum pressure of the unit. The stop pressure must be higher than the start pressure! 6HOHFWWKHUHTXLUHGSDUDPHWHUYDOXHXVLQJNH\V WKHVHWWLQJE\SUHVVLQJNH\ENTER. 3UHVVNH\ 6WRSSUHVVXUH ÀDVKLQJ
and
to complete the basic parameterisation.
DQGFRQ¿UP
43
5. Displays and operating elements 5.4.4.3 Code 2: Operating mode
Determines how the unit is to respond when the start or stop pressure is reached. Both limit values are set during basic parameterisation (see Chapter 5.4.4.2). 0: Automatic. The symbol “Automatic“ appears in the display. The motor starts up and the compressor compresses air (= on-load RSHUDWLRQ DVVRRQDVWKHOLQHSUHVVXUHIDOOVEHORZWKHVWDUWSUHVVXUH 7KH XQLW FKDQJHV RYHU WR RIIORDG RSHUDWLRQ PRWRU UXQQLQJ EXW WKH FRPSUHVVRUGRHVQRWFRPSUHVVDLU DVVRRQDVWKHOLQHSUHVVXUHH[FHHGVWKHVWRSSUHVVXUH$VVRRQDVWKHRIIORDGSKDVHVWDUWVWKHRII WLPHHODSVHV IRUWKHSDUDPHWHULVDWLRQVHH&RGH&KDSWHU The motor stops after the off time. 1: On-/off-load The symbol “Automatic“ is not shown in the display. ,QFRQWUDVWWRWKHDXWRPDWLFRSHUDWLQJPRGHWKHPRWRUQHYHUVWRSVUXQning. The compressor compresses air as soon as the line pressure falls below the start pressure. The unit changes over to off-load operation PRWRULVUXQQLQJEXWWKHFRPSUHVVRUGRHVQRWFRPSUHVVDLU DVVRRQ as the line pressure rises above the stop pressure. 2: Automatic optional The symbol “Automatic“ and an additional dot before the temperature are shown in the display. 6LPLODUWRWKHDXWRPDWLFPRGH+HUHWKHXVHUKDVDQLQÀXHQFHRQKRZ RIWHQWKHPRWRUVWRSV7RWKLVHQGWKHSDUDPHWHUV³PD[LPXPSUHVVXUH loss” (adjustment range 0.0 to 9.9 bar) and “max. number of motor starts” (adjustment range 1 to 55 cycles/hour) are queried additionally.
44
Function “Max. pressure loss“: :KHQ WKH XQLW FKDQJHV RYHU IURP RQORDG WR RIIORDG RSHUDWLRQ$LU Control 1 saves the current line pressure after 10 and after 40 seconds. If the pressure loss thus established is higher than the “Max. pressure ORVV´WKHPRWRUVKXWVGRZQDIWHUWKHRIIWLPHKDVHODSVHG SDUDPHWHULVDWLRQZLWKFRGHVHH&KDSWHU RWKHUZLVHDIWHUWKH³RII´WLPH (45 s). Function “Max. number of motor starts“: 7KH PRWRU LV QRW VZLWFKHG RII DIWHU WKH ³RII´ WLPH HODSVHG ZKHQ WKH number of starting cycles of the compressor exceeds the “Max. number of motor starts”.
5.4.4.4 Code 3: Automatic restart after power failure
Determines whether the generation of compressed air is to restart automatically after a mains power failure. 0: Automatic restart: OFF The generation of pressure remains deactivated after a power failure. The fault message “power fail” is output. 1: Automatic restart: ON :KHQ WKLV IXQFWLRQ LV DFWLYDWHG WKH GLVSOD\ VKRZV WKH V\PERO ³UHstart“. If the generation of pressure was activated before the power failure RFFXUHGWKHXQLWUHVWDUWVDXWRPDWLFDOO\DIWHUWKH³RII´WLPH,QWKLVFDVH the fault message “power fail” is not output. If the generation of pressure ZDVGHDFWLYDWHGEHIRUHWKHSRZHUIDLOXUHLWUHPDLQVGHDFWLYDWHG
5.4.4.5 Code 8: Local control, remote control, LLC-OK
'HWHUPLQHVKRZWKHJHQHUDWLRQRISUHVVXUHLVWREHVZLWFKHGRQDQGRII 0: Local control The generation of compressed air can only be switched on or off from the control panel of Air Control 1. 1: Remote control The generation of compressed air can be switched on only by way of a positive edge (24 VDC) at terminal 23 and switched off only by means of DORZOHYHO 9 DWWHUPLQDORUE\SUHVVLQJNH\ . This functionality LVVLJQDOOHGRQWKHGLVSOD\RI$LU&RQWUROE\DÀDVKLQJWH[W³5HPRWH³ If the NH\LVORFDOO\RSHUDWHGRQWKHXQLWWKHXQLWVZLWFKHVRIIDIWHU VHFRQGVDQGIRUVDIHW\UHDVRQVFDQRQO\EHUHVWDUWHGE\UHPRWH NH\ZDVRSHUDWHGORFDOO\ DFNQRZOHGJHPHQW 7KLV control after the also applies to a start via PLANT CONTROL V/T. 2: LLC-OK The input at terminal 23 is used to signal the readiness for operation of an external control. The external control can only be switch between on-load and off-load operation when a high level (24 VDC) is applied VHHFRGHYDOXH&KDSWHU :KHQDORZOHYHOLVDSSOLHG LLC operation is automatically switched off and the internal pressure sensor used.
45 5.4.4.6 Code 11: Start and stop pressure
'HWHUPLQDWLRQRIWKHVWDUWDQGVWRSSUHVVXUHV IRUWKHSURFHGXUHVHH&KDSter 5.4.4.2
5. Displays and operating elements 5.4.4.7 Code 18: Lead leg control (LLC)
Determines whether the changeover between on-load and off-load operation is to be controlled by the internal pressure senor or by a higher-level control. 0: Changing over between on-load/off-load operation by internal pressure sensor 1: Changing over between on-load/off-load operation by external control (e.g. PLC) On-load operation when a high level (24 VDC) is applied to terminal 22. Off-load operation when a low level (0 V) is applied to terminal 22. This functionality is signaled by the text “remote” that appears continuously in the display of Air Control 1.
5.4.4.8 Code 21: Maintenance acknowledgement
,VXVHGIRUDFNQRZOHGJLQJDPDLQWHQDQFHZDUQLQJFXUUHQWO\SUHVHQW )RU WKHPHDQLQJRIPDLQWDLQHQFHQXPEHUVDQGDFNQRZOHGJHPHQWRIZDUQLQJV see Chapter 5.4.5. Possible damage to the unit! Required maintenance work is signalled in the form of warnings.
NOTICE
Acknowledge these warning only, when the required maintenance has actually been carried out! If the unit is not serviced, its service life and reliability are reduced. Please note that damage resulting from improper handling is not covered by the warranty! Use only genuine spare parts. More information about servicing can be found in Chapter 8.
46
5.4.4.9 Code 51: Off-load, off, star/delta time
The relevant times can be entered successively at operating levels 0 to 2.
0: Off-load time Adjustment range: 10 - 1200 s. Operation in conjunction with Code 2 (operating mode). Is used in the operating modes “Automatic” and “Automatic optional”. 1: Off time Adjustment range: 0 - 60 s. The factory setting of 45 s should be retained. 'XULQJWKHRIIWLPHWKHPRWRULVUXQQLQJLQWKHLGOHPRGH QRFRPSUHVVHG air is generated. The off time elapses is pressed for switching off ZKHQNH\ according to the Automatic optional mode :KHQWKHIXQFWLRQ³$XWRPDWLFUHVWDUWDIWHUSRZHUIDLOXUH´LVVHOHFWHG the start-up of the motor is delayed for the set time of standstill. 2: Star/delta time Adjustment range: 3 - 30 s. Determines after which time changing over is WRWDNHSODFHIURPVWDUWRGHOWDFLUFXLWZKHQWKHPRWRULVVZLWFKHGRQ
5.4.4.10 Code 65: Condensate valve
,VXVHGIRUDGMXVWLQJWKHLPSXOVHDQGEUHDNWLPHVRIWKHFRQGHQVDWHYDOve. 0: Impulse time Duty cycle of the condensate valve 1: Break time Off time of the condensat valve
47
5. Displays and operating elements 5.4.4.11 Code 90: Unit for pressure indication
Determines the unit for the pressure indication: 0: bar 1: MPa 2: psi
5.4.4.12 Code 95: Unit for temperature indication
Determines the unit for the temperature indication: 0: Degree Celsius (°C) 1: Degree Fahrenheit (°F) 2: Kelvin (K)
5.4.4.13 Code 9999: Software version
48
Indicates the software version of Air Control 1.
5.4.5 Warnings / maintenance work
$ZDUQLQJLVSUHVHQWZKHQWKHUHGOLJKWLVEOLQNLQJ The compressor is not switched off.
The following is displayed:
Maintenence number ÀDVKLQJ Symbol for warnings ÀDVKLQJ
Meaning of maintenance numbers: 2
([FHVVLYH¿QDOFRPSUHVVLRQWHPSHUDWXUH
3
Excessive line pressure
11 5HPDLQLQJWLPHXQWLODLU¿OWHULVWREHVHUYLFHG K 12 5HPDLQLQJWLPHXQWLOFRROLQJÀXLGFRROLQJÀXLG¿OWHULVWREHVHUYLFHG K 13 5HPDLQLQJWLPHXQWLO¿QHVHSDUDWRULVWREHVHUYLFHG K 14 5HPDLQLQJWLPHXQWLOPRWRULVWREHOXEULFDWHG K 15 5HPDLQLQJWLPHXQWLOFRPSUHVVRULVWREHVHUYLFHG K Damage to the system is possible! Necessary service work appears in the form of warnings. NOTICE
$FNQRZOHGJHWKHVHZDUQLQJVRQO\ZKHQWKHGH¿QHGVHUYLFHZRUNKDV actually been carried out! Service work not carried out degrades the service life reliability of the system. Please note that damage caused by improper usage is not covered by the warranty! Only original spare parts may be used. Information on service: see Chapter 8.
$FNQRZOHGJHPDLQWHQDQFHZRUN 3UHVVNH\ play.
(ca. 3 sec.) until the message “cod“ appears in the dis-
6HOHFW&RGHXVLQJNH\V 3. Press ENTERWKHQ .
and
.
49
5. Displays and operating elements 5.4.6 Malfunctions
Malfunction has occurred when the red light is permanently on. The compressor is stopped automatically. The following is shown in the display:
Symbol of malfunction ÀDVKLQJ Fault number ÀDVKLQJ Fault text DOWHUQDWHVZLWKWKH¿QDO compression temperature
Meaning of fault numbers and texts: 1
Par
Incorrect pressure setpoints
2
EPROM
Incorrect setting parameters
3
Lo AC
Undervoltage
4
No AC
Power failure
5
OEFEC
Air Control 1 defective
6
Emerg
EMERGENCY OFF actuated
7
Rotat
Wrong direction of rotation
8
Mot t
Excessive motor temperature
9
Hi cur
Overcurrent
10
Hi P
Overpressure
11 'LI3
'LIIHUHQWLDOSUHVVXUHRI¿QHVHSDUDWRU
12 6HW
6HQVRUIRU¿QDOFRPSUHVVLRQWHPSHUDWXUH
13 6HRLO
6HQVRUIRUFRROLQJÀXLGWHPSHUDWXUH
14
Se P
15 +LW 50
16
Pressure sensor
([FHVVLYH¿QDOFRPSUHVVLRQWHPSHUDWXUH
Hi P
Excessive line pressure
0DOIXQFWLRQVFDQRQO\EHDFNQRZOHGJHGZKHQWKHFDXVHKDVEHHQSURIHVsionally repaired. Troubleshooting and repair should be done exclusively E\TXDOL¿HGSHUVRQQHO $FNQRZOHGJHIDXOWPHVVDJHV SUHVVNH\
.
SUHVVNH\
in order to restart the compressed air generation.
5.4.7 Adjustment of the display contrast
The display contrast of the control was selected so that it ensures optimum readability under nearly all operating conditions. If it is nevertheless required to adjust the contrast under certain conditions (e.g. unfavourable lighting FRQGLWLRQVGLUHFWVXQOLJKW IROORZWKHVWHSVEHORZ
1. Make sure that the compressor is disconnected from the power supply by actuating the master switch. DANGER
2. Open the control cabinet/control box of the compressor. 3. At the rear of the control you can see a small opening at the top.
Insert a small plain slot screwdriver through this opening to reach the adjustment screw for correcting the contrast. 7RLQFUHDVHWKHFRQWUDVWVOLJKWO\WXUQFORFNZLVH E\WXUQLQJFRXQWHUFORFNZLVH\RXUHGXFHWKHFRQWUDVW 5. Close the control cabinet/control box before recommissioning.
51
6. Correcting malfunctions Error
Cause
Measures
Compression temperature too high (red lamp is on)
Silencing hood not closed
&KHFNDQGVHFXUHVRXQGLQVXODWLRQ hood
,QWDNHRUDPELHQWWHPSHUDWXUH too high
Ventilate compressor room
&RROLQJDLULQOHWRURXWOHWEORFNHG
0DNHVXI¿FLHQWURRP
&RROLQJÀXLG¿OWHUIRXOHG
5HQHZFRROLQJÀXLG¿OWHU
,QVXI¿FLHQWFRROLQJÀXLG
$GGFRROLQJÀXLG
([WHUQDOFRROLQJÀXLGKHDWH[FKDQJHU fouled! Attention: Cooler screw should DOZD\VEHZRUNHGZLWKDFRXQWHU ZUHQFK NHHSIURPDSSO\LQJWRUTXHWR the cooler
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
Compressed air consumption greater than delivery quantity of the compressor
A compressor with larger delivery quantity is required
$LU¿OWHULVIRXOHG
5HSODFHDLU¿OWHU
Relief valve blows air during compression
&KHFNUHOLHIYDOYH LIQHFHVVDU\ replace seals
Suction regulator does not open
&KHFNVROHQRLGYDOYHUHJXODWRU VSRRODQGLIQHFHVVDU\UHSODFH
/HDNDJHLQWKHSLSHZRUN
0DNHSLSHZRUNDLUWLJKW
Line pressure set too high
Adjust line pressure anew
Safety valve defective
&KHFNVDIHW\YDOYH LIQHFHVVDU\ exchange
0LQLPXPSUHVVXUHYDOYHEORFNHG
Exchange solenoid valve
&RROLQJÀXLGVHSDUDWRUFDUWULGJH fouled
([FKDQJHFRROLQJÀXLGVHSDUDWRU cartridge
&RROLQJÀXLGVHSDUDWRUIRXOHG
5HSODFHFRROLQJÀXLGVHSDUDWRU
Higher external pressure in the compressed air net
Equalize outside pressure or remove from net
Line pressure falls
System pressure released by safety valve
52
“Malfunction overpressure” or “line pressure too high” (red lamp is on)
Error
Cause
Measures
Compressor does not start automatically or does not deliver air after previous switching off XSRQUHDFKLQJWKH¿QDO pressure or from off-load state.
Net pressure set too high
Adjust net pressure anew
Interruption in the control current circuit
&KHFNHOHFWULFFLUFXLWIRULQWHUUXSWLRQ (only by a trained electrician)
$PELHQWWHPSHUDWXUHXQGHU& message ³&RROLQJÀXLG temperature too low “
,QVWDOODQDGGLWLRQDOKHDWHURUNHHS compressor room at right temperature
Switching times have been activated in Air Control 3
&KHFNVZLWFKLQJWLPHVDQGSUHVVXUH times in Air Control
Line pressure greater than start pressure
Note line pressure value
Remote control activated
6\PERO³UHPRWH³LVEOLQNLQJ
Missing voltage at the compressor
&KHFNLIYROWDJHLVDSSOLHG
Electrical error in the control system
Inspect (only by an trained electrician)
Switching times have been activated in Air Control 3
&KHFNVZLWFKLQJWLPHV in the Air Control 3
Compressed air containing large amount RIFRROLQJÀXLG FRROLQJ ÀXLGFRQVXPSWLRQWRR great)
&RROLQJÀXLGUHWXUQÀRZSLSLQJ is congested
&OHDQFRROLQJÀXLGIHHGEDFNSLSLQJ
'HIHFWLYHFRROLQJÀXLGVHSDUDWRU
5HSODFHFRROLQJÀXLGVHSDUDWRU
System stopped before UHDFKLQJWKH¿QDOSUHVVXUH (red lamp is on)
Overtemperature or overpressure
Rectify error as required
Interruption in the control current loop
&KHFNFXUUHQWORRS (only by a trained electrician)
Water in the piping net
Dryer switched off
Switch on dryer
Condensation diverter is not functioning
Clean / exchange drain
Bypass open
Close bypass
Dew point too high
Demand customer service
3UHVVXUHGLIIHUHQWLDOLQWKH¿OWHU too great
([FKDQJH¿OWHU
System does not start on pressing the start button
53
Pressure decline
7. Initial commissioning 7.1
0DNHFHUWDLQWKDWZKHQWKHFRPSUHVVRUPDLQVZLWFKLVVZLWFKHGRIIQR illicit or inadvertent switching on can occur.
Preparatory activities
&KHFNDOO¿WWLQJVRIWKHFRPSUHVVRU,IUHTXLUHGUHWLJKWHQWKH¿WWLQJV 0DNHFHUWDLQWKDWWKHV\VWHPLVFRUUHFWO\FRQQHFWHGWRWKHFRPSUHVVHG DLUQHW0DNHFHUWDLQWKDWZKHQWKHVKXWRIIYDOYHRQWKHSUHVVXUHQHW VLGHLVFORVHGLOOLFLWRULQDGYHUWHQWRSHQLQJFDQQRWRFFXU
&KHFNFRROLQJÀXLG level &KHFNFRROLQJÀXLGOHYHO FRROLQJÀXLGUH¿OO
0DNHFHUWDLQWKDWHVFDSLQJFRROLQJÀXLGFDQEHFROOHFWHG
&KHFNWKHFRROLQJÀXLGOHYHORQWKHVLJKWJODVV 7KHVLJKWJODVVPXVW EHFRPSOHWHO\ZHWWHGZLWKFRROLQJÀXLG/RRVHQWKH¿OOLQJVFUHZ'RQRW ORVHWKHVHDOULQJ:LWKQHZFRPSUHVVRUVWKHFRROLQJÀXLGOHYHOPXVW EHDWWKHORZHUHGJHRIWKH¿OOHUQHFN ,I UHTXLUHG UH¿OO FRROLQJ ÀXLG VHH &KDSWHU ³&KHFN FRROLQJ ÀXLG OHYHOUH¿OOFRROLQJÀXLG´
7.3
Start-up lubrication of the compressor stage
$IWHU DQ H[WHQGHG VWDQGVWLOO WLPH IRU H[DPSOH EHWZHHQ IDFWRU\ GHOLYHU\ DQGFRPPLVVLRQLQJRUGXULQJDORQJHUFRPSDQ\YDFDWLRQWKHUHPLJKWQR ORQJHUEHDQ\FRROLQJÀXLGLQWKHURWRUFKDPEHURIWKHDLUHQG7KLVFRROLQJ ÀXLGLVDEVROXWHO\QHFHVVDU\IRUEHDULQJDQGURWRUOXEULFDWLRQLQWKHVWDUWXS phase.
%HIRUHVZLWFKLQJWKHFRPSUHVVRURQ¿OODSSUR[OLWUHVFRROLQJÀXLG into the compressor stage. 2. Rotate the air end only by hand in the correct direction of rotation until WKHQRWLFHDEOHUHVLVWDQFHGZLQGOHVDQGWKHFRROLQJÀXLGSDVVHVWKURXJK the air end. 54 ,IQRH[WUDFRROLQJÀXLGLVDYDLODEOH RQO\FRROLQJÀXLGRIWKHVDPHYDULHW\PD\ EHHPSOR\HG WKHFRROLQJÀXLGFDQEHWDNHQIURPWKHFRROLQJÀXLGGUDLQ If the system is employed only very irregularly or shut down weeks on end, it should run an hour in the off-load mode once a week in order to avoid corrosion damage caused by standing condensation.
7.4
Rotational direction control
7KHURWDWLRQDOGLUHFWLRQRIWKHFRPSUHVVRUYHQWLODWRUVPXVWEHFKHFNHG The rotational direction of the main motor is determined by the frequency FRQYHUWHUDQGPXVWFRQIRUPZLWKWKHDI¿[HGURWDWLRQDOGLUHFWLRQDUURZ
5HPRYHWKHFRYHUSDQHOVRIWKHV\VWHPVRWKDWWKHHOHFWULFPRWRURI the ventilator is visible. 2. Switch the compressor main switch on.
6ZLWFKWKHV\VWHPRQZLWKNH\ Switch the system off again with the ZKHQWKHYHQWLODWRUVWDUWVUXQQLQJ ,QRUGHUWRVXSSO\WKHV\VWHPZLWKVXI¿FLHQWFRROLQJDLUWKHURWDWLRQDOGLUHFWLRQ of the ventilator motors must concur with the rotational direction arrow. ,QWKHFDVHRILQFRUUHFWURWDWLRQDOGLUHFWLRQRIWKHFRPSUHVVRUYHQWLODWRUV a trained electrician should correct the phase sequence of the electrical supply in the switching cabinet by exchanging the two supply phases. This should be carried out in a switched-off state secured against accidental switching on.
55
7. Initial commissioning 7.5
Basic settings
7.5.1 Controlling the unit by means of Air Control 3
,QRUGHUWRXQGHUVWDQGFRPSUHVVRUEDVLFVSOHDVHUHDGWKHFKDSWHU³&RPpressor operating elements “.
More precise instructions on the basic settings of the system can be found in the following chapters :
&KDSWHU$LU&RQWURO
•
Chapter 5.3.1 Basic display
•
Chapter 5.3.4 Menu system
The display parameters SUHVVXUHGLPHQVLRQ WHPSHUDWXUHGLPHQVLRQ •
language
FDQEHPRGL¿HGDVGHVFULEHGLQSRVLWLRQ The limit values •
start pressure
•
stop pressure
FDQEHPRGL¿HGDVGHVFULEHGLQSRVLWLRQ ,I\RXU$LU&RQWUROKDVEHHQ¿WWHGZLWKWKHVXSSOHPHQWDU\PRGXOH//& carry out settings as in point 5.3.4.7 5.3.4.9 of the description. ,I\RXU$LU&RQWUROKDVEHHQ¿WWHGZLWKWKHVXSSOHPHQWDU\PRGXOH³DFFHVVRULHV´FDUU\RXWVHWWLQJVDVLQSRLQWRIWKHGHVFULSWLRQ
7.5.2 Controlling the unit by means of Air Control 1
56
)RUPRUHGHWDLOHGLQVWUXFWLRQVZLWKUHJDUGWRWKHEDVLFVHWWLQJVRIWKHXQLW please refer to:
&KDSWHU$LU&RQWURO
&KDSWHU%DVLFGLVSOD\
&KDSWHU0HQXV\VWHP
Please set the display parameters as described in the following chapters:
3UHVVXUHXQLW&KDSWHU
7HPSHUDWXUHXQLW&KDSWHU
The limit values for •
start pressure and
•
stop pressure
FDQEHVHWDVGHVFULEHGLQWKHVHFWLRQ³%DVLFSDUDPHWHUVDWLRQ´&KDSWHU 5.4.4.2.
7.6
Switch on compressed air generation
%HIRUHVZLWFKLQJRQWKHV\VWHPPDNHFHUWDLQWKDWQRRQHFDQEHHQdangered by doing so. The sound-insulation hood serves as a part of WKHFRQWDFWSURWHFWLRQDPRQJRWKHUWKLQJVIRUWKHFRROLQJDLUFRQGXLWV of the compressor plant. It must be closed during operation. 2. Carefully open the shut-off valve after the compressed air connector and between system compressed air net (receiver). The system is now connected to the net. 3. Switch on the main switch. 0DNHFHUWDLQWKDWQRWRROVRUORRVHREMHFWVDUHO\LQJRQRULQWKHV\Vtem. 3UHVVNH\
to switch on the compressed air generation.
7KHJUHHQ/('LQNH\
OLJKWVXSZKHQWKHFRPSUHVVRULVZRUNLQJ
&KHFNRQWKHRSHUDWLQJGLVSOD\GHVNIRUWKHOLQHSUHVVXUH The line pressure will slowly rise if the compressed air consumption is less than the quantities delivered by the compressors.
On blinking green LED, the compressor can start by itself at any time! DANGER 7KHJUHHQ/('EOLQNVZKHQWKHFRPSUHVVRULVUHDG\IRURSHUDWLRQ The compressor switches on automatically when •
the current line pressure drops below the preset start pressure RIWKHFRPSUHVVRULI
WKHPDFKLQHWHPSHUDWXUHULVHVDERYH& WKHWLPHURI$LU&RQWUROLVDFWLYH •
7.7
Concluding activities
or the Lead lag control (LLC) is activated.
&KHFNDOOSLSLQJRIFRROLQJOLTXLGVDQGSUHVVXUHDLUFRQGXLWVIRUOHDNage. &KHFNWKHFRROLQJÀXLGOHYHORIWKHFRPSUHVVRUVDIWHUDQGEHIRUH PLQXWHVRSHUDWLRQWLPH,IWKHFRROLQJÀXLGOHYHOLVWRRORZUH¿OOFRROLQJ ÀXLG DV GH¿QHG LQ &KDSWHU ³&KHFN FRROLQJ ÀXLG OHYHO FRROLQJ ÀXLG UH¿OO´ &KHFN WKH FRPSUHVVRU WHPSHUDWXUH 7KH FRPSUHVVRU WHPSHUDWXUH should neither remain below approx. 75 °C nor exceed 105 °C DW °C a warning is outputDW&WKHFRPSUHVVRUis automatically shut down. We recommend: ± WKHXVHRIPLQHUDORLORUV\QWKHWLFRLODW¿QDOFRPSUHVVLRQWHPSHUDWXUHV between 75 and 90°C ± WKHXVHRIV\QWKHWLFRLODW¿QDOFRPSUHVVLRQWHPSHUDWXUHVKLJKHU than 90°C 5HWLJKWHQDOOHOHFWULFDOFRQQHFWLRQVDIWHUDZHHN 5. Carry out all service intervals according to Chapter 8 “Overview of maintenance intervals”. &KHFNWKHVWDQGDUGRSHUDWLRQRIWKHIXQFWLRQVFDUULHGRXWZHHNO\DFcording to Chapter 8 “Overview of maintenance intervals”
57
8. Service 8.1
Overview Maintenance intervals Preparatory activities 8.2 &KHFNFRROLQJÀXLGOHYHOUH¿OOFRROLQJÀXLG &KHFNIRUOHDNDJH &KHFNWKHFRPSUHVVRU temperature 8.5 &KHFNWKHFRROHUIRUIRXOLQJ &KHFNIRUFRQGHQVDWH 5HSODFHFRROLQJÀXLG5HSODFH FRROLQJÀXLG¿OWHU 5HSODFHFRROLQJÀXLGVHSDUDWRU 5HSODFHDLU¿OWHU &KHFNVDIHW\YDOYH &KHFNGULYH Lubrication of electric motor 8.13 Concluding activities 8.14
1HFHVVDU\VHUYLFHZRUNDSSHDUVLQWKHGLVSOD\DVZDUQLQJV VHH&KDSWHU 5.3.5 or 5.4.5) Service activities
Chapter After the ¿UVW operating hours
&KHFNFRROLQJÀXLGOHYHO
8.3
&KHFNIRUOHDNDJH
8.4
&KHFNFRPSUHVVRU temperature
8.5
&KHFNFRROHU for fouling
8.6
&KHFNIRU condensate
8.7
5HSODFHFRROLQJÀXLG DQGFRROLQJÀXLG¿OWHU
8.8
Replace cooling liquid VHSDUDWRU
8.9
5HSODFLQJDLU¿OWHU
8.10
&KHFNVDIHW\YDOYH
8.11
&KHFNGULYH
8.12
Lubrication of motor
8.13
After the ¿UVW operating hours
Every week
Every 2000 operating h. but at least once a year
General compressor servicing * The motor lubrication intervals are 20 000 hours for the entire series. **7KHVSHFL¿HGUHSODFHPHQWLQWHUYDOVDUHUHOHYDQWIRU – normal industrial atmosphere ±¿QDOFRPSUHVVLRQWHPSHUDWXUHRIDSSUR[& :KHQ$/83V\QWKHWLFRLOLVXVHGWKHUHSODFHPHQWLQWHUYDOVIRUERWKFRRODQWDQGWKHFRRODQW ¿OWHULVH[WHQGHGWRKRXUV This interval is relevant for: – normal industrial atmosphere ± ¿QDOFRPSUHVVLRQWHPSHUDWXUHRIDSSUR[& – Use of ALUB Syn S synthetic oil – Oil analysis after 2000 hours
8.2
Preparatory activities
58
3UHVVNH\ in order to switch off compressed air generation. Please wait until the compressor has been switched off after a run-on or ventilation phase. The symbol “M” for the main motor is then no longer visible in the display. 6ZLWFKWKHFRPSUHVVRUPDLQVZLWFKRIIDQGPDNHFHUWDLQWKDWLWFDQQRW EHWXUQHGRQE\PLVWDNHRULQWHQWLRQDOO\ HJZDUQLQJVLJQVSURKLELWLQJ switching). Use only original spare parts!
NOTICE +RWVXUIDFHV±KRWFRROLQJÀXLG Make certain, with appropriate precaution, that no one can be burned or scalded! Particularly note dangerous situations which can arise IURPWKHUHOHDVHRIKRWFRROLQJÀXLGVWHDP DANGER
3. Remove the side panels of the system. 0DNH FHUWDLQ WKDW WKH SUHVVXUH QHW VLGH VKXWRII YDOYH LV FORVHG DQG cannot be opened accidentally or intentionally. 0DNHFHUWDLQWKDWZKHQZRUNLQJRQWKHFRROLQJÀXLGFLUFXODWLRQHVFDSLQJ FRROLQJÀXLGLVFROOHFWHG
&KHFNFRROLQJÀXLGOHYHO UH¿OOFRROLQJÀXLG Preparatory activities Concluding activities
8.2 8.14
Carry out the “Preparatory activities” 2QO\FKHFNWKHFRROLQJÀXLGOHYHOZKHQWKHV\VWHPKDVEHHQWXUQHGRII IRUDPLQLPXPRIPLQXWHV7KLVLVWRHQVXUHWKDWWKHFRROLQJÀXLGKDV settled down after the running phase. 7KH FRROLQJ ÀXLG OHYHO LV LQ RUGHU LI WKH FRPSOHWH VLJKW JODVV LV IXOO RI FRROLQJÀXLG
,IWKHFRPSOHWHVLJKWJODVVLVQRWIXOORIFRROLQJÀXLGFRROLQJÀXLGPXVWEH added as follows: 8QVFUHZWKH¿OOHUVFUHZ'RQRWPLVSODFHWKHJDVNHWULQJ
59
'DPDJHWRWKHV\VWHPE\XVLQJGLIIHUHQWFRROLQJÀXLGV NOTICE
'LIIHUHQWFRROLQJÀXLGVPXVWQRWEHPL[HG2QO\XVHRULJLQDOFRROLQJ ÀXLG
8VHDQDSSURSULDWHIXQQHOIRU¿OOLQJ&RROLQJÀXLGFDQEH¿OOHGXSWRWKH ¿OOLQJULPRIWKH¿WWLQJ 7DNHFDUHWKDWWKHVHDOLVFRUUHFWO\VHDWHGDQGVFUHZWKH¿WWLQJVFUHZ closed. Carry out the “Concluding activities”.
8. Service 8.4
Check for leakage Preparatory activities Concluding activities
Carry out the “Preparatory activities”. 8.2 8.14
&KHFNDOOSLSLQJDQGWKHERWWRPRIWKHV\VWHPIRUFRROLQJÀXLGUHVWV,IWKHUH LVVWLOOFRROLQJÀXLGLQWKHV\VWHPWKHFDXVHVKRXOGEHIRXQGDQGWKHFRROLQJ ÀXLGUHPRYHG Carry out the “Concluding activities”.
8.5
7KHFRPSUHVVRUWHPSHUDWXUHZKLFKFDQEHYLHZHGLQWKHGLVSOD\VKRXOG be between 75 °C and 105 °C.
Check the compressor temperature
Too high or too low compressor temperature can lead to damages to the compressor. NOTICE
8.6
Check the cooler for fouling Preparatory activities Concluding activities
8.2 8.14
Carry out the “Preparatory activities”. &KHFNWKHFRPSUHVVHGDLUDIWHUFRROHUDQGWKHFRROLQJÀXLGKHDWH[FKDQJHU IURPWKHLQVLGHDQGRXWVLGH,I\RXGHWHUPLQHDQ\IRXOLQJLWVKRXOGEHUHPRYHG HJE\FRPSUHVVHGDLUEORZLQJZKHUHWKHGLUWSDUWLFOHVVKRXOGEH blown outside). Carry out the “Concluding activities”.
60
8.7
Check for condensate Preparatory activities Concluding activities
The absorption capacity of water humidity in the air 8.2 8.14
•
falls with increasing pressure
•
rises with increasing temperature.
6XI¿FLHQWO\KLJKFRPSUHVVRUWHPSHUDWXUHJXDUDQWHHVWKDWWKHLQWDNHDLUKXmidity does not precipitate as condensation. Frequent switching on and off of the compressor can result in the compressor not achieving the required operating temperature.
&RQGHQVDWLRQLQWKHFRROLQJÀXLGFLUFXODWLRQFDQOHDGWRGDPDJHVWR the compressor. If you have determined that there is condensation in the seperator tank, immediately get in touch with after-sales service! NOTICE
Condensation damages are not covered by the warranty!
6LQFHZDWHULVKHDYLHUWKDQFRROLQJÀXLGDIWHUH[WHQGHGVWDQGVWLOOWLPHV HJ RQDZHHNHQG WKHFRQGHQVDWHFROOHFWVLQWKHERWWRPRIWKHVHSHUDWRUWDQNV 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”. 1. Open the drain and carefully observe the escaping liquid. Close the GUDLQDJDLQDVVRRQDVFRROLQJÀXLGDSSHDUV &KHFNWKHFRROLQJÀXLGOHYHODFFRUGLQJWR&KDSWHU Carry out the “Concluding activities”.
61
8. Service &RROLQJÀXLGUHSODFHPHQW UHSODFLQJFRROLQJÀXLG¿OWHU Preparatory activities Concluding activities
5HSODFHWKHFRROLQJÀXLGRQO\ZKHQWKHROGFRROLQJÀXLGLVVWLOOZDUP&ROG FRROLQJÀXLGEHFDXVHRILWVKLJKHUYLVFRVLW\GRHVQRWÀRZVRZHOO
8.2 8.14
+RWVXUIDFHVKRWFRROLQJÀXLG With appropriate precautions, make certain you are not burned or scalded! DANGER Carry out the “Preparatory activities”.
8QVFUHZWKH¿OOHUVFUHZ'RQRWPLVSODFHWKHJDVNHWULQJ %\RSHQLQJWKHGUDLQDOORZWKHFRROLQJÀXLGWRGUDLQLQWRDQDSSURSULDWH vessel and then close the drain again.
'DPDJHWRWKHV\VWHPFDQEHFDXVHGE\GLIIHUHQWFRROLQJÀXLGV 'LIIHUHQWFRROLQJÀXLGVPXVWQRWEHPL[HG 62
NOTICE
8VHDQDSSURSULDWHIXQQHOIRU¿OOLQJ&RROLQJÀXLGFDQEH¿OOHGXSWRWKH ¿OOLQJULPRIWKH¿WWLQJ 7DNHFDUHWKDWWKHVHDOLVFRUUHFWO\VHDWHGDQGVFUHZWKH¿WWLQJVFUHZ closed. /RRVHQWKHFRROLQJÀXLG¿OWHUZLWKDVWUDSZUHQFKDQGUHPRYHSRVVLEOH VHDOUHVWVIURPWKHFRROLQJÀXLG¿OWHUKRXVLQJ /LJKWO\RLOWKHQHZVHDORIWKHFRROLQJÀXLG¿OWHUV 6FUHZWKHQHZFRROLQJÀXLG¿OWHUWRWKHVWRSDQGWLJKWHQWKHFRROLQJÀXLG ¿OWHUE\KDQGDQRWKHUKDOIDUHYROXWLRQ 7HVWWKHFRROLQJÀXLG¿OWHUIRUOHDNDJHDWRSHUDWLQJWHPSHUDWXUH Carry out the “Concluding activities”.
63
8. Service 5HSODFLQJFRROLQJÀXLGVHparator Preparatory activities Concluding activities
Carry out the “Preparatory activities”.
8.2 8.14
/RRVHQWKHFRROLQJÀXLGVHSDUDWRUXVLQJDVWUDSZUHQFK5HPRYHSRVVLEOHVHDOUHVWVIURPWKHFRROLQJÀXLGVHSDUDWRUKRXVLQJ 2. Lightly oil the new seal(s) of the separator. 6FUHZWKHQHZFRROLQJÀXLGVHSDUDWRULQWRWKHVWRS7LJKWHQWKHFRROLQJ ÀXLG¿OWHUE\KDQGDQRWKHUKDOIDUHYROXWLRQ 7HVWWKHFRROLQJÀXLGVHSDUDWRUIRUOHDNDJHDWRSHUDWLQJWHPSHUDWXUH
Carry out the “Concluding activities”.
64
5HSODFLQJDLU¿OWHU Preparatory activities Concluding activities
Carry out the “Preparatory activities”. 8.2 8.14
Damage to the system by intake dust! 7KHV\VWHPPXVWQRWEHRSHUDWHGZLWKRXWDQDLU¿OWHU
NOTICE
5HPRYHRUVFUHZRIIWKHROGDLU¿OWHU ,QVHUWWKHQHZDLU¿OWHU Carry out the “Concluding activities”.
8.11 Check safety valve Preparatory activities Concluding activities
Carry out the “Preparatory activities”. 8.2 8.14
1. Remove the safety valve and remove residues at the threaded connection. &KHFNWKHVDIHW\YDOYHLQDQDSSURSULDWHDSSDUDWXV ,ILWLVVWLOOZRUNLQJFRUUHFWO\DGGVHDOLQJWDSHWRWKHFRQQHFWLQJWKUHDG RIWKHVDIHW\YDOYHVDQGVFUHZWKHVDIHW\YDOYHEDFNLQ 4. If the adequate functionality of the old safety valves can no longer be JXDUDQWHHGVFUHZLQDVDIHW\YDOYH Carry out the “Concluding activities”.
65
8. Service 8.12 Check drive Preparatory activities Concluding activities
Carry out the “Preparatory activities”. 8.2 8.14
1. Test manually whether the coupling might have some radial play. ,IVRORRVHQWKHFDPULQJRIWKHFRXSOLQJSXVKLWEDFNDQGUHSODFHWKH coupling element. 3. Mount the cam ring again on the coupling half and test manually whether the coupling now has no more radial play. Carry out the “Concluding activities”.
8.13 Relubrication of the electric motor Preparatory activities Concluding activities
8.2 8.14
Carry out the “Preparatory activities”. 7KHEHDULQJOXEULFDWLRQSHULRGVIRUWKHHOHFWULFPRWRUZKLFKDSSHDURQ WKHRSHUDWLQJGLVSOD\GHVNPXVWEHREVHUYHG 2. Carry out the required relubrication with a grease gun. ,IWKHUHDUHQRJUHDVHQLSSOHVRQWKHHOHFWULFPRWRUWKHQLWLVHTXLSSHGZLWK capsulated permanently greased bearings. These motor bearings must be replaced when they are worn out. Carry out the “Concluding activities”.
66
2SHQWKHVWRSFRFNVORZO\RQWKHSUHVVXUHQHWVLGH
8.14 Concluding activities 6HUYLFHZRUNDFNQRZOHGJHG
2. Switch the compressor main switch on. 0DNHFHUWDLQWKDWQRWRROVRUORRVHREMHFWVDUHO\LQJRQRULQWKHV\Vtem. 3UHVVNH\
to switch the compressor on.
&KHFNDOOFRROLQJOLTXLGVDQGFRPSUHVVHGDLUSLSLQJIRUOHDNDJH &KHFNDOOQHZFDUWULGJHVRUQHZO\PRXQWHGSUHVVXUL]HGFRPSRQHQWV IRUOHDNDJHDWRSHUDWLQJWHPSHUDWXUH 7. Finally mount the side panels of the system. &RQ¿UPWKHPDLQWHQDQFHZRUNFDUULHGRXWE\\RXLQDFFRUGDQFHZLWK Chapter 5.3.5 for Air Control 3 or 5.4.5 for Air Control 1. 8VHG ¿OWHU FDUWULGJHV OXEULFDQWV VHDOV H[FHVV FRQGHQVDWH DQG HPployed cleaning materials should be considered hazardous waste and disposed of in an environmently friendly way.
Damage to the system is possible! Only acknowledge those services actually carried out! NOTICE
Services not carried out degrade the service life reliability of the system. Please note that damages caused by improper usage are not covered by the guarantee!
67
9. Technical Data
68
9.1
Dimensions for connections
mm
&RROLQJÀXLG ¿OOLQJ l
Compressed air connection G
795
1.170
8
1
1.270
795
1.170
8
1
ALLEGRO 24
1.270
795
1.170
8
1
ALLEGRO 28
1.270
795
1.170
8
1 1/2
ALLEGRO 32
1.540
795
1.170
17
1 1/2
ALLEGRO 38
1.540
795
1.170
17
1 1/2
Compressor
L
B
H
mm
mm
ALLEGRO 16
1.270
ALLEGRO 20
9.2
Data air-cooled compressors Compressor
kg
Cooling air amounts m3/h
Intake air opening m2
Diameter exhaust air canal m2
ALLEGRO 16
387
3.300
ALLEGRO 20
387
3.300
ALLEGRO 24
405
3.300
ALLEGRO 28
405
3.300
ALLEGRO 32
545
3.300
ALLEGRO 38
555
6.000
9.3
Weight
Electrical data Compressor
Motor power
Currant at 400 V / 50 Hz
kW
IN A
IFuse A gL
ALLEGRO 16
16
34
50
ALLEGRO 20
20
41
50
ALLEGRO 24
24
46
63
ALLEGRO 28
28
59
80
ALLEGRO 32
32
55
80
ALLEGRO 38
38
65
100
IN = Nominal current
IFuse EDFNXSIXVHLQEXLOGLQJ
69
10. Service manual
Compressor type: Unit number: 3OHDVHTXRWHRQTXHULHVRUGHUVDQGFRUUHVSRQGHQFH
Motor number: Vessel number: Date of commissioning:
Your ALUP service:
70
Coolant change Operating hours
Date
Filter change* Name
Operating hours
Date
7\SHRI¿OWHU
Name
71
&RRODQW¿OWHULQWDNH¿OWHUVHSHUDWRU¿OWHU
10. Service manual Further maintenance and repair work Operating hours
72
Date
Spare parts
Name
Further maintenance and repair work Operating hours
Date
Spare parts
Name
73
10. Service manual Further maintenance and repair work Operating hours
74
Date
Spare parts
Name
Further maintenance and repair work Operating hours
Date
Spare parts
Name
75
D ALUP-Kompressoren GmbH Tel.: +49/7024/802-0 Fax: +49/7024/802-106 Internet: www.alup.com E-mail:
[email protected] Adolf-Ehmann-Str. 2 73257 Köngen DEUTSCHLAND A AGRE-Kompressoren GmbH Tel.: +43/7252/52341-0 Fax: +43/7252/52133 Internet: www.agre.at (PDLO RI¿FH#DJUHDW Werkstraße 2 4451 Garsten-St. Ulrich ÖSTERREICH
HU ALUP Magyarország Kft. Tel.: +36/36/423444 Fax: +36/36/516340 Internet: www.alup.hu E-mail:
[email protected] Szálloda u. 5 3300 Eger MAGYARORSZÁG BG ALUP-Kompressoren Bulgaria OOD. Tel.: +359/2/528032 Fax: +359/2/528032 E-mail:
[email protected] Tsar Asen Str. 63 1000 6R¿D BULGARIA
Manual_ALL16_gb_01-2007
NL ALUP-Kompressoren B.V. Tel.: +31/30/2809000 Fax: +31/30/2895675 Internet: www.alup.nl E-mail:
[email protected] Biezenwade 8-10 3439 NW Nieuwegein NEDERLANDS
