Operating instructions...2015/07/21 · COMBI 6 - 15 COMBI 16 - 22 COMBI 11SC / 22SC Operating...

Screw compressor

COMBI 3S - 5S COMBI 6 - 15 COMBI 16 - 22 COMBI 11SC / 22SC

Operating instructions

Read the instructions prior to performing any task!

2 2015-07-21

ALMiG Kompressoren GmbH Adolf-Ehmann-Straße 2 73257 Köngen Telephone: +49 7024 9614 240Fax: +49 7024 9614 209email: [email protected] Internet: www.almig.de Help line: Telephone: +49 1805 25 87 00Fax: +49 1805 25 87 01Item no. 195.03275

Translation of the original operating instructions Almi-13257-DE COMBI

© ALMiG Kompressoren GmbH 2015

Screw compressor COMBI 3S – 5S, 6 – 15, 16 – 22, 11SC / 22SC

Table of contents

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Table of contents

1 General information ............................................................... 7 1.1 Information about this manual ....................................... 7 1.2 Explanation of symbols .................................................. 8 1.3 Limitation of liability ...................................................... 10 1.4 Copyright ...................................................................... 10 1.5 Warranty terms ............................................................ 10 1.6 Customer service ......................................................... 10

2 Safety .................................................................................... 11 2.1 Proper use ................................................................... 11 2.2 Responsibility of the owner .......................................... 12 2.3 Staff requirements ....................................................... 13

2.3.1 Qualifications ................................................ 13 2.3.2 Unauthorised persons .................................. 14 2.3.3 Training ......................................................... 14

2.4 Personal protective equipment .................................... 15 2.5 Basic dangers .............................................................. 16

2.5.1 General dangers in the workplace ............... 16 2.5.2 Dangers due to electric energies ................. 17 2.5.3 Dangers due to mechanical elements .......... 18 2.5.4 Dangers due to hydraulic energies .............. 19 2.5.5 Dangers due to high temperatures ............... 21

2.6 Safety equipment ......................................................... 22 2.6.1 Position of the safety equipment .................. 22 2.6.2 Description of the installed safety devices ... 23

2.7 Securing to prevent restart .......................................... 25 2.8 Behaviour in case of fire or accidents .......................... 27 2.9 Environmental protection ............................................. 28 2.10 Signage ...................................................................... 29

2.10.1 Warning signs ............................................... 29 2.10.2 Instructions on the machine ......................... 30

3 Technical data ...................................................................... 32 3.1 Type plate .................................................................... 32 3.2 Emissions ..................................................................... 32 3.3 Coolant liquid ............................................................... 33 3.4 COMBI 3S – 5S ........................................................... 33

3.4.1 General details ............................................. 33 3.4.2 Connection values ........................................ 35 3.4.3 Operating conditions .................................... 36


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3.4.4 Lubricants .....................................................36 3.5 COMBI 6 – 15 ..............................................................37

3.5.1 General details..............................................37 3.5.2 Connection values ........................................41 3.5.3 Operating conditions .....................................42 3.5.4 Consumables ................................................42

3.6 COMBI 16 – 22 ............................................................43 3.6.1 General details..............................................43 3.6.2 Connection values ........................................45 3.6.3 Operating conditions .....................................46 3.6.4 Consumables ................................................46

4 Construction and function ..................................................47 4.1 Overview ......................................................................47 4.2 Brief description ...........................................................50 4.3 Assembly description ...................................................51

4.3.1 Controller ......................................................51 4.3.2 Sound insulation covers ...............................52 4.3.3 Drive unit .......................................................53 4.3.4 Intake filter ....................................................53 4.3.5 Compressor stage ........................................54 4.3.6 Coolant liquid tank ........................................54 4.3.7 Fine precipitator ............................................55 4.3.8 Minimum pressure and return valve .............55 4.3.9 Cooler ...........................................................56 4.3.10 Coolant liquid filter ........................................56 4.3.11 Cooling air fan ...............................................57 4.3.12 Refrigerant-type dryer ...................................57

4.4 Interfaces .....................................................................58

5 Transportation, packaging and storage .............................60 5.1 Safety instructions for transportation ...........................60 5.2 Transportation inspection .............................................60 5.3 Packaging ....................................................................61 5.4 Symbols on the packaging ...........................................62 5.5 Transportation ..............................................................62 5.6 Storage .........................................................................63

6 Installation, commissioning and operation .......................64 6.1 Safety instructions for the installation and

commissioning .............................................................64 6.2 Requirements in the installation location .....................66 6.3 Installation ....................................................................67


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6.3.1 Ventilation ..................................................... 67 6.3.2 Connection to the compressed air network .. 68 6.3.3 Connecting to the power supply ................... 69

6.4 Checking the coolant liquid level ................................. 70 6.5 Start-up lubrication of the compressor stage ............... 71 6.6 Switching on after the initial commissioning ................ 72 6.7 Working after the initial commissioning ....................... 73 6.8 Setting parameters ...................................................... 75 6.9 Measures in case of low compressed air

requirement .................................................................. 75

7 Operation .............................................................................. 76 7.1 Safety instructions for operation .................................. 76 7.2 Shutdown in emergency situations .............................. 76 7.3 Operating personnel and personal protective

equipment .................................................................... 77 7.4 Controllers .................................................................... 78

7.4.1 Controller COMBI 3S – 4S ........................... 78 7.4.2 Controller COMBI 5S .................................... 80 7.4.3 Air Control AC mini controller ....................... 81

8 Maintenance ....................................................................... 102 8.1 Safety instructions for maintenance .......................... 102 8.2 Spare parts ................................................................ 105 8.3 Maintenance schedule ............................................... 106 8.4 Maintenance work ...................................................... 108

8.4.1 Checking the electrical connections ........... 108 8.4.2 Checking the coolant liquid level/topping

up the coolant liquid ................................... 109 8.4.3 Checking for leaks ...................................... 111 8.4.4 Checking the compressor temperature ...... 112 8.4.5 Checking soiling of the cooler .................... 113 8.4.6 Checking the condensation accumulation .. 114 8.4.7 Changing the coolant liquid/changing the

cooling liquid filter ....................................... 115 8.4.8 Re-lubricating the electric motor................. 118 8.4.9 Change fine precipitator ............................. 119 8.4.10 Change intake filter .................................... 120 8.4.11 Checking the drive unit ............................... 121

8.5 Measures after maintenance has been performed .... 121


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9 Faults ...................................................................................122 9.1 Safety instructions for fault clearance ........................122 9.2 Fault displays .............................................................124 9.3 Fault table ..................................................................125 9.4 Work for fault clearance .............................................128 9.5 Commissioning after remedied fault ..........................128

10 Dismantling and disposal ..................................................129 10.1 Safety instructions for dismantling and disposal ........129 10.2 Dismantling ................................................................130 10.3 Disposal ....................................................................130

11 Index ....................................................................................131

12 Appendix .............................................................................135


General information

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1 General information 1.1 Information about this manual This manual enables safe and efficient handling of the machine. It is

an integral part of the machine, and must be kept in close proximity to the machine where it is permanently accessible to the personnel. Before starting any work, the personnel must have read the manual thoroughly and understood its contents. Compliance with all specified safety instructions and operating instructions is vital to ensure safe operation. In addition, local accident prevention regulations and general safety instructions must be observed for the operational area of the machine. Illustrations in this manual are intended to facilitate basic understanding, and may differ from the actual design.

The instructions for the compressor do not include the operation of the

controller. Therefore, the instructions and content of the instructions for the controller in question must also be taken into account.

Furthermore, the instructions for the installed components found in the appendices also apply.


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1.2 Explanation of symbols

Safety instructions The safety instructions provided in this manual are marked by symbols. The safety instructions are introduced by keywords used to express the extent of the danger.

Strictly adhere to all safety instructions and use caution to prevent accidents, personal injury and material damage.

DANGER! This combination of symbol and keyword points to a situation of immediate danger which may lead to serious injury or death unless avoided.

WARNING! This combination of symbol and keyword points to a situation of possible danger which may lead to serious injury or death unless avoided.

CAUTION! This combination of symbol and keyword points to a possibly dangerous situation which may lead to slight or minor injury unless avoided.

NOTICE! This combination of symbol and keyword points to a possibly dangerous situation which may lead to material and environmental damage unless avoided.

Tips and recommendations

This symbol highlights useful tips and recommendations as well as information designed to ensure efficient and smooth operation.


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Special safety instructions The following symbols are used in the safety instructions to draw attention to specific dangers:

DANGER! This combination of symbol and signal word indicates dangers posed by electric power. If the safety instructions are not observed, there is a danger of serious or fatal injuries.

WARNING! This combination of symbol and signal word indicates dangers posed by an atmosphere capable of exploding. If the safety instructions are not observed, there is a danger of serious or fatal injuries.

Signs used in this manual The following signs and highlighting is used in this manual to identify instructions, descriptions of results, numerations, references and other elements:

Sign Explanation

1., 2., 3., ... Identifies step-by-step instructions.

Identifies a state or automatic sequence as result of steps.

Identifies references to chapters in this manual and to other valid documents.

Identifies random numerations and list entries.

[Key] Indicates names of keys, buttons and other operating controls.


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1.3 Limitation of liability All specifications and instructions in this manual have been compiled

taking account of applicable standards and regulations, the current state of technology and the experience and insights we have gained over the years. The manufacturer accepts no liability for damage due to:

Failure to observe this manual

Improper use

Deployment of untrained personnel Unauthorised modifications

Technical modifications

Use of unauthorised spare parts

The actual scope of supply may differ from the explanations and depictions in this manual in the case of special designs, take-up of additional ordering options, or as a result of the latest technical modifications.

The undertakings agreed in the supply contract as well as the manufacturer's Terms and Conditions and Terms of Delivery and the legal regulations applicable at the time of conclusion of the contract shall apply.

1.4 Copyright This manual is protected by copyright and intended solely for internal use.

This manual must not be made available to third parties, duplicated in any manner or form – whether in whole or in part – and the content must not be used and/or communicated, except for internal purposes, without the written consent of the manufacturer.

Violation of the copyright will result in legal action for damages. We reserve the right to assert further claims.

1.5 Warranty terms The warranty terms are included in the manufacturer's Terms and

Conditions.

1.6 Customer service Our customer service division is available to provide technical

information. See page 2 for contact details.

In addition, our employees are always interested in acquiring new information and experience gained from practical application; such information and experience may help improve our products.


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2 Safety

This section provides an overview of all the main safety aspects involved in ensuring optimal personnel protection and safe and smooth operation. Non-compliance with the action guidelines and safety instructions contained in this manual may result in serious hazards.

2.1 Proper use The machine is designed and constructed exclusively for the proper

use described here.

The screw compressor serves exclusively to generate compressed air in an environment not subject to explosion. The screw compressor may be supplied exclusively with cool, dry and dust-free cooling air.

The proper use also includes adherence to all details in these instructions.

Any use beyond the proper use or other type of use counts as misuse.

WARNING! Danger due to misuse! Misuse of the compressor can cause dangerous situations. - The compressed air may not be used for breathing

without previous preparation. - The compressed air may not be used directly for

pharmaceutical or sanitary purposes or for the direct handling of food without appropriate after-treatment.

- The screw compressor may not be operated outdoors.

- The screw compressor or individual components may not be rebuilt, modified or re-equipped.

- The screw compressor may not be used in an atmosphere subject to explosion.

- The intake of media other than cool, dry and dust-free cooling air is forbidden.

Claims of any type for damage due to misuse are excluded.


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2.2 Responsibility of the owner

Owner The term 'owner' refers to the person who himself operates the machine for trade or commercial purposes, or who surrenders the machine to a third party for use/application, and who bears the legal product liability for protecting the user, the personnel or third parties during the operation.

Duties of the owner The machine is used in the commercial realm. Therefore, the owner of the machine is subject to legal occupational safety regulations.

In addition to the safety instructions in these instructions, the valid safety, accident prevention and environmental protection regulations for the area of application of the machine must be adhered to.

Here, the following points apply in particular:

The owner must inform himself about the applicable occupational safety provisions and also determine in a hazard assessment the dangers that arise due to the special working conditions in the machine's area of application. He must implement these in the form of operating instructions for the operation of the machine.

During the entire time the machine is used, the owner must check whether the operating instructions he has created correspond to the current state of the body of rules and regulations and adapt the operating instructions if necessary.

The owner must regulate and specify clearly the responsibilities for the installation, operation, troubleshooting, maintenance and cleaning.

The owner must ensure that all employees who handle the machine have read and understood these instructions. In addition, he must train the personnel at regular intervals and inform them about the dangers.

The owner must provide personnel with the required protective equipment and instruct them in binding fashion about how to wear the required protective equipment.

Furthermore, the owner is responsible for ensuring that the machine is always in technically-perfect condition. Therefore, the following points apply: The owner must ensure that the maintenance intervals described

in these instructions are adhered to.

The owner must have all safety equipment checked regularly to ensure that it is functional and complete.

The owner must ensure that the appropriate media connections are provided.

The owner must ensure that the supply of the required quantity of cool medium (air/water) is guaranteed.

The owner must ensure that the required heat extraction is guaranteed.


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2.3 Staff requirements 2.3.1 Qualifications

WARNING! Danger of injury if personnel are insufficiently qualified! If unqualified personnel perform work on the machine or are in the machine's danger zone, hazards may arise which can cause serious injury and substantial damage to property. - Therefore, all work must only be carried out by

appropriately qualified personnel. - Unqualified personnel must be kept away from the

danger zones.

This manual specifies the personnel qualifications required for the

different areas of work, listed below:

Forklift driver The forklift driver must be at least 18 years old and, based on his physical and intellectual attributes and character, suited to driving industrial trucks with a driver's seat or driver's platform.

Furthermore, the forklift driver has been trained to drive industrial trucks with a driver's seat or driver's platform.

The forklift driver has provided the owner with evidence of his skills in driving industrial trucks with a driver's seat or driver's platform and has therefore been authorised in writing by the owner to drive the forklift.

Manufacturer Certain tasks may only be performed by our qualified personnel. Other personnel is not authorized to perform these tasks. Contact our service department to request the execution of any necessary work. For address information, refer to page 2.

Qualified electrician Based on his technical training, knowledge, experience and knowledge of the applicable standards and regulations, the qualified electrician is able to perform work on electrical systems and recognise and avoid potential hazards himself.

The qualified electrician is specially trained for the area of responsibility he is involved with and knows the relevant standards and regulations.

The qualified electrician must comply with the requirements of the applicable legal regulations for accident prevention.


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Qualified personnel Qualified personnel is able to carry out assigned work and to recognize and prevent possible dangers self-reliantly due to its professional training, knowledge and experience as well as profound knowledge of applicable regulations.

Trained Person The trained person has been instructed in an instruction by the owner about the tasks assigned to him and possible hazards in the case of improper behaviour.

The workforce must only consist of persons who can be expected to

carry out their work reliably. Persons with impaired reactions due to, for example, the consumption of drugs, alcohol, or medication are prohibited.

When selecting personnel, the age-related and occupation-related regulations governing the usage location must be observed.

2.3.2 Unauthorised persons

WARNING! Risk to life for unauthorised persons due to hazards in the danger and working zone! Unauthorised persons who do not meet the requirements described here will not be familiar with the dangers in the working zone. Therefore, unauthorised persons face the risk of serious injury or death. - Unauthorised persons must be kept away from the

danger and working zone. - If in doubt, address the persons in question and ask

them to leave the danger and working zone. - Cease work while unauthorised persons are in the

danger and working zone.

2.3.3 Training

The personnel must be trained regularly by the customer. For better tracing, the execution of the training must be logged ( Appendix A ‘Training log’ on page 136).


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2.4 Personal protective equipment Personal protective equipment is used to protect the personnel from

dangers which could affect their safety or health while working.

The personnel must wear personal protective equipment while carrying out the different operations at and with the machine. This equipment will be indicated separately in the individual chapters of this manual. This personal protective equipment is described below:

It is mandatory to put on the personal protective equipment specified in the different chapters of this manual before starting work.

Always comply with the instructions governing personal protective equipment posted in the work area.

Description of the personal protective equipment

Ear protection Ear protection provides protection against hearing damage.

Light respiratory protection Light respiratory protection is used to protect against harmful dusts.

Protective gloves Protective gloves protect hands from friction, abrasion, puncture wounds, or deeper injuries, as well as from contact with hot surfaces.

Protective work clothing Protective clothing are tight fitting working clothes with low tear resistance, with tight sleeves and without any parts sticking out. These clothes primarily protect against getting caught by moving machine parts. Do not wear rings, chains, necklaces, and other jewellery.

Safety boots Safety boots are intended to protect against slipping hazards or foot hazards like heavy gear.

Safety goggles The protective goggles protect the eyes from flying parts and liquid splashes.


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2.5 Basic dangers The following section specifies residual risks which may result from

using the machine and have been established by means of a risk assessment.

In order to minimize health hazards and avoid dangerous situations, follow the safety instructions specified here as well as in the following chapters of this manual.

2.5.1 General dangers in the workplace

Noise

WARNING! Danger of injury from noise! The noise levels arising in the workplace may result in serious hearing damage. - Always wear ear protection while working. - Do not stay in the danger zone more than necessary.

Accumulations of liquid

CAUTION! Danger of injury from slipping in accumulations of liquid! Slipping in accumulations of liquid on the floor may result in a fall. A fall may result in injuries. - Remove accumulations of liquid immediately using

appropriate means. - Wear anti-slip safety shoes. - Post warnings and mandatory signs at or in the

vicinity of any area where liquid could accumulate on the floor.


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2.5.2 Dangers due to electric energies

Electric current

DANGER! Danger to life from electric power. There is an immediate danger to life from electric shock in the case of contact with live parts. Damage to the insulation or individual components can be fatal. - Only allow qualified electricians to work on the

electrical system. - In the case of damage to the insulation, immediately

disconnect the power supply and arrange repairs. - Establish the absence of voltage before starting work

on active parts of electrical systems and equipment and ensure this remains so for the duration of the work. Observe the 5 safety rules: - Disconnect from the power supply. - Secure against restarting. - Verify absence of voltage. - Earth and short-circuit. - Cover or shield any neighbouring live parts.

- Never bypass or disable fuses. Comply with the correct current intensity information when replacing fuses.

- Keep moisture away from live parts. This can result in short circuits.

Stored charges

DANGER! Danger to life from stored charges! Electric charges may be stored in electrical components; these charges may be maintained even after the system has been switched off and disconnected from the power supply. Contact with these components may result in serious or fatal injury. - Before working on the specified components, ensure

that they have been completely disconnected from the power supply. Allow 10 minutes to elapse in order to ensure that the internal capacitors have been fully discharged.


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2.5.3 Dangers due to mechanical elements

Moving parts

WARNING! Danger of injury from moving parts! Rotating parts and/or parts moving in linear fashion may cause serious injuries. - During operation, do not reach into or handle moving

parts. - Do not open covers during operation. - Observe the run-on time: Before opening the covers,

make sure that all parts have stopped moving. - When in the danger zone, wear close-fitting protective

work clothing with low tear strength.

Sharp edges and pointed corners

CAUTION! Danger of injury posed by sharp edges and pointed corners! Sharp edges and pointed corners may cause skin grazes and cuts. - Proceed with caution when working in the vicinity of

sharp edges and pointed corners. - If in doubt, wear safety gloves.


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2.5.4 Dangers due to hydraulic energies

Liquid stream

WARNING! Danger to life due to escaping liquid stream under high pressure! In case of defective lines or components, a stream of liquid under high pressure can escape. The stream of liquid can cause extremely severe injuries or even death. - Never hold body parts or objects in the liquid stream.

Keep people out of the danger zone. In case of accidental contact with the liquid stream, take first aid measures and consult a doctor immediately.

- Initiate emergency off immediately. If necessary, take additional measures in order to reduce the pressure and stop the stream of liquid.

- Catch and dispose of escaping liquids properly. - Have faulty components repaired immediately.

Pressure accumulator(s)

WARNING! Danger to life from improper work on the pressure accumulator! Improper handling of pressure accumulators may cause a sudden release of pressure, resulting in very serious injuries or death and in significant damage to property. - Never carry out welding or soldering work on the

pressure accumulator vessel. - Never perform any mechanical machining on the

pressure accumulator vessel. - Once it is connected to the hydraulic line, vent the

pressure accumulator vessel using the fitted vent screw.

- Only carry out work on systems with a pressure accumulator once the hydraulic pressure has been completely relieved and depressurisation has been verified.

- Do not start work on the pressure accumulator until the gas charging pressure has been completely released.


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Compressed air

WARNING! Danger of injury from compressed air! Compressed air can escape from compressed air hoses or components under pressure in case of improper handling or in case of a fault. It can injure eyes, whip up dust or cause uncontrolled movements of hoses. Components under pressure can move in uncontrolled fashion with improper handling and cause injuries. - Before removing hoses or components under

pressure, make sure the pressure is relieved. - Have faulty components that are under pressure

during operation replaced by appropriate specialist personnel immediately.

- Before all work, make sure that the compressor is not under pressure; wait at least 5 minutes.

Coolant liquid fog

CAUTION! Danger of injury from coolant liquid fog! In case of high temperatures or mechanical dust, coolant liquid fog can form. Coolant liquid fog can irritate eyes and the respiratory system. - When working on the coolant liquid system and if a

coolant liquid fog arises, wear breathing protection and protective goggles and ensure that there is a fresh air supply.


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2.5.5 Dangers due to high temperatures

Hot surfaces

WARNING! Danger of injury from hot surfaces! Surfaces of components can heat up a lot during operation. Skin contact with hot surfaces will cause severe skin burns. - During all work hear hot surfaces, wear heat-resistant

protective clothing and protective gloves. - Before all work, make sure that all surfaces have

cooled off to the ambient temperature, wait at least 30 minutes.

Hot consumables

WARNING! Danger of injury from hot consumables! Consumables may reach high temperatures during operation. Skin contact with hot consumables will cause severe skin burns. - Always wear heat-resistant protective work clothing

and protective gloves as a matter of principle when carrying out any work with consumables.

- Always check whether consumables are hot before working with them. Allow to cool down if necessary.


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2.6 Safety equipment

WARNING! Danger to life from nonfunctional safety devices! If safety devices are not functioning or are disabled, there is a danger of serious injury or death. - Check that all safety devices are fully functional and

correctly installed before starting work. - Never disable or bypass safety devices. - Ensure that all safety devices are always accessible.

2.6.1 Position of the safety equipment

The following illustration shows the position of the safety equipment.

Fig. 1: Position of the safety devices

1 Main switch with emergency stop function 2 Emergency stop button


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2.6.2 Description of the installed safety devices

Main switch with emergency off function

Fig. 2: Main switch

The main switch is also set up as an emergency stop switch. By turning the main switch to the "0" position, the machine is stopped by switching off the power immediately and an emergency stop is thus triggered.

WARNING! Danger to life from an unauthorised restart! An uncontrolled restart of the machine may cause serious injuries including death. - Before switching the machine back on, make sure the

cause of the emergency stop has been removed and all safety devices have been installed and function properly.

- Only turn the main switch to the "l" position when there is no more danger.

Emergency stop key

Fig. 3: Emergency stop key

By pressing the emergency stop key, the machine is stopped by an immediate switching off of the power supply. After an emergency stop key has been pressed, it must be unlocked by turning it so that a switching on is possible.

WARNING! Danger to life from an unauthorised restart! An uncontrolled restart of the machine may cause serious injuries including death. - Before switching the machine back on, make sure the

cause of the emergency stop has been removed and all safety devices have been installed and function properly.

- Do not unlock the EMERGENCY-STOP button until there is no more danger.


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Safety valves

Fig. 4: Safety valve

Safety valves belong to the safety taps and are unburdening equipment for the areas under pressure such as the boiler, pressure tank, pipes, transport container. In case of an impermissible pressure increase, safety valves bleed off gases, vapours or liquids into the atmosphere.


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2.7 Securing to prevent restart

WARNING! Life-threatening danger if restarted without authorisation or due to uncontrolled restart! Uncontrolled or unauthorised switching on of the machine can cause severe or fatal injuries. - Prior to restart ensure that all safety devices are

mounted and functional, and that there is no danger for personnel.

- Always adhere to the procedure described below to secure against restart.

Securing to prevent restart

Fig. 5: Securing the main switch

1. Switch off the power supply. To do this, turn the main switch to the "0" position.

2. Secure the main switch with a padlock (Fig. 5).

3. Have a responsible employee keep the key for the padlock.

4. After all work has been performed, make sure that there are no dangers to people.

5. Ensure that all safety and protective equipment is installed and functional.

WARNING! Danger to life from an unauthorised restart! If the main switch is secured with a padlock, people can be in the danger zone. These people can be fatally injured by the switching on of the power supply. - Before removing the padlock and switching the power

supply back on, make sure that there are no dangers to people.

6. Remove the padlock from the main switch.

If no main switch is installed, proceed as follows.


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WARNING! Life-threatening danger if restarted without authorisation or due to uncontrolled restart! Uncontrolled or unauthorised switching on of the machine can cause severe or fatal injuries. - Prior to restart ensure that all safety devices are


- Always adhere to the procedure described below to secure against restart.


1. Switch off the power supply.

2. Inform responsible people about work in the danger zone.

3. Mark machine with a sign that indicates the work in the danger zone and forbids switching on. Include the following details on the sign:

Switched off on: Switched off at:

Switched off by:

Note: do not switch on!

Note: Only switch on after it has been ensured that there are no dangers to people.

4. After all work has been performed, make sure that there are no dangers to people.

5. Ensure that all safety and protective equipment is installed and functional.

WARNING! Danger to life from an unauthorised restart! People in the danger zone can be fatally injured by the unauthorised or uncontrolled switching on of the power supply. - Before switching the power supply back on, ensure

that there are no dangers for people.

6. Remove the sign.


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2.8 Behaviour in case of fire or accidents

Preventive measures Be prepared for fire and accidents at all times! Keep first-aid equipment (first-aid kit, blankets, etc.) and fire

extinguishing devices operational and readily available. Make your personnel familiar with accident reporting equipment as

well as first-aid and rescue equipment. Keep access paths clear for rescue vehicles.

Steps in case of fire and accidents

Immediately trigger an Emergency Stop using EMERGENCY-STOP devices.

Provided your own health is not in danger, rescue all personnel from the danger area.

If necessary, initiate first aid measures. Alert the fire department and/or emergency medical services.

In case of fire: provided your own health is not in danger, extinguish the fire using fire extinguishing equipment and continue to do so until the fire department arrives.

Notify the person in charge at the machine's place of installation. Clear access paths for rescue vehicles.

Wave rescue vehicles into position.


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2.9 Environmental protection

NOTICE! Danger to the environment from incorrect handling of pollutants! Incorrect handling of pollutants, particularly incorrect waste disposal, may cause serious damage to the environment. - Always observe the instructions below regarding

handling and disposal of pollutants. - Take the appropriate actions immediately if pollutants

escape accidentally into the environment. If in doubt, inform the responsible municipal authorities about the damage and ask about the appropriate actions to be taken.

The following pollutants are used:

Coolant liquid Coolant liquids can contain poisonous substances and substances that are harmful to the environment. They must not be allowed to escape into the environment. Disposal must be carried out by a specialist disposal company.

Lubricants Lubricants such as greases and oils contain toxic substances. They must not be allowed to escape into the environment. Disposal must be carried out by a specialised disposal company.


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2.10 Signage The following symbols and information signs can be found in the work

area. They refer to their immediate surroundings.

WARNING! Danger of injury from illegible symbols! Stickers and signs can become dirty or otherwise obscured over time, with the result that dangers cannot be recognised and the necessary operating instructions cannot be complied with. This, in turn, poses a risk of injury. - All safety, warning and operating instructions must

always be maintained in a completely legible condition.

- Damaged signs or stickers must be replaced immediately.

2.10.1 Warning signs

Electrical voltage

Only qualified electricians are permitted to work in a work room marked by this sign. Unauthorised persons must not enter the workplaces thus marked and must not open the marked cabinet.

Automatic start-up

Maintain sufficient distance from all parts that can move; there is a danger of crushing or pulling in there.

Hot surface

Hot surfaces such as hot machine parts, containers or materials, as well as hot liquids, may not always be detected. Never touch these without protective gloves.


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2.10.2 Instructions on the machine

Direction of rotation

There is a direction of rotation sticker on the drive unit and on the cooling air ventilator. This sticker shows the appropriate direction of rotation.

Re-lubrication

The sticker for re-lubrication is on the drive unit.

Oil filling

The sticker for oil filling is on the coolant liquid pressure tank and next to the installed controller.


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Brief instructions for commissioning

This sticker is on the switch cabinet and contains brief instructions for commissioning.


Technical data

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3 Technical data 3.1 Type plate

Fig. 6: Type plate

The type plate is on the lower frame on the maintenance side and on the sound insulation cover on the Cooling air exhaust side or cooling water intake and outlet side and includes the following details:

Manufacturer

Product type Manufacturer no.

Year of construction

Direction of rotation Volume flow rate

Part number

Final pressure

Motor output

3.2 Emissions

Noise emissions

The values for noise emission are included in the enclosed data sheet.


Technical data

2015-07-21 33

3.3 Coolant liquid The following coolant liquids are tested and approved for use in

ALMiG compressors:

Designation Type Order number

Standard coolant liquid ALUB BLUE S+ 583.04055 (10 l container)

Synthetic coolant liquid ALUB Syn S 583.00004 (10 l container)

Food-compatible coolant liquid ALUB Food H1 583.04010 (10 l container)

Biodegradable coolant liquid ALUB GREEN S 583.10051 (10 l container)

3.4 COMBI 3S – 5S

3.4.1 General details

COMBI 3S

COMBI Nominal motor output

Weight Length Width Height

kW kg mm mm mm

3S

(with compressed air tank 200 l and refrigeration dryer)

3.0 215 1400 550 1250

3S

(with compressed air tank 200 l, without refrigeration dryer)

3.0 195 1400 550 1250

3S

(without pressure tank, with refrigerant-type dryer)

3.0 155 1100 550 950

3S

(without pressure tank, without refrigerant-type dryer)

3.0 130 720 550 950


Technical data

34 2015-07-21

COMBI 4S



kW kg mm mm mm

4S


4.0 220 1400 550 1250

4S


4.0 200 1400 550 1250

4S


4.0 160 1100 550 950

4S


4.0 135 720 550 950

COMBI 5S



kW kg mm mm mm

5S


5.5 225 1400 550 1250

5S


5.5 205 1400 550 1250

5S


5.5 165 1100 550 950

5S


5.5 140 720 550 950


Technical data

2015-07-21 35

3.4.2 Connection values

Electrical

COMBI 3S – 5S

COMBI Current at 400 V / 50 Hz Current at 500 V / 50 Hz Max. switching frequency

IN IFuse IN IFuse

A A gL A A gL 1/h

3S 6.6 16 5.3 10 55

4S 8.5 16 6.8 16 55

5S 11.3 16 9 16 55

IN = nominal current IFuse = building-side fuse

Air supply and cooling

COMBI 3S – 5S

COMBI Compressed air connection

Cooling air quantity (LK)

Supply air opening

Cross-section air outlet duct

G / DN m3/h m2 m2

3S ⅜ 1050 0.15 0.10

4S ⅜ 1060 0.20 0.15

5S ½ 1080 0.25 0.15


Technical data

36 2015-07-21

3.4.3 Operating conditions

Environment Data Value Unit

Temperature range +5 to +40 °C

Relative humidity, maximum 60 %

Maximum installation height above sea level

1000 m

3.4.4 Lubricants

COMBI 3S –5S

COMBI Lubricant Fill level Unit

3S Coolant liquid 3.2 l




Technical data

2015-07-21 37

3.5 COMBI 6 – 15


COMBI 6

COMBI

Nominal motor output


kW kg mm mm mm

6

(with 270 l pressure tank and refrigerant-type dryer)

5.5 455 1180 770 1680

6

(with 270 l pressure tank, without refrigerant-type dryer)

5.5 420 1180 770 1680

6


5.5 520 1900 770 1680

6


5.5 485 1900 770 1680

6


5.5 340 1180 770 1128

6


5.5 305 1180 770 1128


Technical data

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COMBI 8

COMBI



kW kg mm mm mm

8


7.5 460 1180 770 1680

8


7.5 425 1180 770 1680

8


7.5 525 1900 770 1680

8


7.5 490 1900 770 1680

8


7.5 345 1180 770 1128

8


7.5 310 1180 770 1128


Technical data

2015-07-21 39

COMBI 11 / 11SC

COMBI



kW kg mm mm mm

11 / 11SC


11.0 465 / 470 1180 770 1680

11 / 11SC


11.0 430 / 435 1180 770 1680

11 / 11SC


11.0 530 / 535 1900 770 1680

11 / 11SC


11.0 495 / 500 1900 770 1680

11 / 11SC


11.0 350 / 355 1180 770 1128

11 / 11SC


11.0 315 / 320 1180 770 1128


Technical data

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COMBI 15

COMBI



kW kg mm mm mm

15


15.0 475 1180 770 1680

15


15.0 440 1180 770 1680

15


15.0 540 1900 770 1680

15


15.0 505 1900 770 1680

15


15.0 360 1180 770 1128

15


15.0 325 1180 770 1128


Technical data

2015-07-21 41


Electrical

COMBI 6 – 15


IN IFuse IN IFuse

A A gL A A gL 1/h

6 11 25 9 16 55

8 15 32 12 25 55

11 / 11SC 22 / 22 40 / 40 17 / - 32 / - 40 / -

15 30 50 23 40 30



COMBI 6 – 15



Supply air opening


G / DN m3/h m2 m2

6 ¾ 1100 0.30 0.15

8 ¾ 1230 0.35 0.15

11 / 11SC ¾ 1800 0.50 0.20

15 ¾ 2300 0.60 0.20


Technical data

42 2015-07-21






1000 m

3.5.4 Consumables

COMBI 6 – 15


6 Coolant liquid 6.2 l


11 / 11SC Coolant liquid 6.2 l



Technical data

2015-07-21 43

3.6 COMBI 16 – 22


COMBI 16

COMBI

(on 500 l container)



kW kg mm mm mm

16

(with pressure tank and refrigerant-type dryer)

15 679 1900 780 1950

16

(with pressure tank, without refrigerant-type dryer)

15 639 1900 780 1950

16


15 494 1480 780 1375

16


15 454 1480 780 1375

COMBI 18

COMBI




kW kg mm mm mm

18


18.5 698 1900 780 1950

18


18.5 658 1900 780 1950

18


18.5 513 1480 780 1375

18


18.5 473 1480 780 1375


Technical data

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COMBI 22 / 22SC

COMBI




kW kg mm mm mm

22 / 22SC


22 744 / 750 1900 780 1950

22 / 22SC


22 704 / 710 1900 780 1950

22 / 22SC


22 559 / 565 1480 780 1375

22 / 22SC


22 519 / 525 1480 780 1375


Technical data

2015-07-21 45


Electrical

COMBI 16 – 22 / 22SC


IN IFuse IN IFuse

A A gL A A gL 1/h

16 30 50 23 40 30

18 36 63 30 50 25

22 / 22SC 41 / 41 63 / 63 34 / - 50 / - 20 / -



COMBI 16 – 22 / 22SC



Supply air opening


G / DN m3/h m2 m2

16 1 3300 0.60 0.35

18 1 3300 0.60 0.35

22 / 22SC 1 3300 0.60 0.35


Technical data

46 2015-07-21






1000 m

3.6.4 Consumables

COMBI 16 – 22 / 22SC




22 / 22SC Coolant liquid 11.5 l


Construction and function

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4 Construction and function 4.1 Overview The following presents an overview of the screw compressors

described in this manual. They differ from one another due primarily to their size. However, their basic construction is the same.

For the COMBI type, there are variants which are not built on a pressure tank. Due to their identical construction, these variants are only depicted without pressure tank and not extra as an overview figure.

Screw compressor COMBI 3S – 5S

Fig. 7: Screw compressor COMBI 3S – 5S

1 Main switch with emergency stop function 2 On and off switch 3 Refrigerant-type dryer 4 Pressure tank 5 Sound insulation covers



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Screw compressor COMBI 6 – 22

Fig. 8: Screw compressor with pressure tank

1 Controller 2 Emergency stop key / main switch with emergency stop function 3 Switch cabinet 4 Pressure tank 5 Sound insulation covers

Assemblies

The basic construction is the same for all screw compressor variants. The position of the assemblies may vary from the illustration.

Fig. 9: Assemblies COMBI 3S – 5S



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1 Minimum pressure and non-return valve 2 Fine precipitator 3 Coolant liquid filter 4 Refrigerant-type dryer 5 Compressed air connection 6 Compressor stage 7 Intake filter 8 Coolant liquid cooler 9 Fan belt 10 Cooling air fan 11 Drive unit 12 Pressure tank 13 Coolant liquid tank

Fig. 10: Assemblies COMBI 6 – 22

1 Fine precipitator 2 Refrigerant-type dryer 3 Coolant liquid filter 4 Coolant liquid cooler 5 Intake filter 6 Compressed air connection 7 Fan belt 8 Compressor stage 9 Cooling air fan 10 Drive unit 11 Pressure tank 12 Coolant liquid tank 13 Frequency converter 14 Minimum pressure and non-return valve



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4.2 Brief description The fresh air supplied by the installed cooling air ventilator is filtered

through the intake filter. The air streams over the intake regulator into the compressor stage, where it is compressed together with the injected coolant liquid to the final pressure. The compressed air is largely separated from the coolant liquid in the pressure tank. The subsequent fine precipitator removes the remaining coolant liquid from the compressed air. The compressed air then flows over the minimum pressure and return valve into the compressed air after-cooler or the pressure tank and is cooled off there. Finally, the compressed air is dried in the refrigerant-type dryer before it leaves the screw compressor via the compressed air connection. The coolant liquid is separated from the compressed air in the pressure tank and the fine precipitator and streams to the coolant liquid cooler. The coolant liquid temperature regulator adds the cooled-off coolant liquid to the hot coolant liquid via the coolant liquid cooler bypass according to the set point temperature. Finally, the coolant liquid filter cleans the coolant liquid before it is injected into the compressor stage once again.



2015-07-21 51

4.3 Assembly description 4.3.1 Controller

Controller variants

Fig. 11: COMBI 3S – 4S

The COMBI 3S – 4S is operated using the pressure switch.

Fig. 12: COMBI 5S

The COMBI 5S is operated using the two buttons for switching on and off.

Fig. 13: COMBI 6 – 22

The COMBI 6 – 22 is operated using the Air Control AC mini controller.



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Screw compressors with frequency converters

Screw compressors with frequency converters can be operated with the following controllers: AC 1, AC 3, AC B, AC P. Refer to the separately enclosed operating instructions for the controller for information.

4.3.2 Sound insulation covers

Fig. 14: Sound insulation covers

Only qualified personnel may remove the sound insulation covers (Fig. 14/1) with the included special spanner. Sound insulation covers are a part of the electric shock protection.



2015-07-21 53

4.3.3 Drive unit

Fig. 15: COMBI drive unit

With the COMBI, the drive (Fig. 15) takes place using a fan belt (Fig. 15/1).

Fig. 16: Drive unit with frequency converter

On the COMBI 11SC and COMBI 22SC screw compressors the speed of the electric motor is controlled by a frequency converter (Fig. 16/1).

4.3.4 Intake filter

Fig. 17: Standard intake filter

The standard intake filter (Fig. 17/1) sits directly above the compressor stage (Fig. 17/2).



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4.3.5 Compressor stage

Fig. 18: Compressor stage

The air taken in is compressed by the compressor stage (Fig. 18/1) and added to the coolant liquid pressure tank (Fig. 18/2) together with the injected coolant liquid.

4.3.6 Coolant liquid tank

Fig. 19: Coolant liquid pressure tank with safety valves

1 Safety valve 2 Coolant liquid pressure tank 3 Filler plugs 4 Coolant liquid drain 5 Inspection glass

The coolant liquid pressure tank consists of several components. The safety valve protects the coolant liquid pressure tank against overpressure. With the inspection glass, the level of the coolant liquid can be read. With the drain plugs, the coolant liquid is topped off and it is removed via the coolant liquid drain.

Coolant liquid heating (optional) Coolant liquid heating can be installed in the coolant liquid pressure tank at the factory or after the fact. It prevents condensate damage and the freezing of the condensate, e.g. for a screw compressor that is set up in the cold or the humidity.



2015-07-21 55

4.3.7 Fine precipitator

Fig. 20: Fine precipitator

Depending on the type of the screw compressor, several fine precipitators can be installed.

The fine precipitator (Fig. 20/1) removes the remaining coolant liquid from the compressed air.

4.3.8 Minimum pressure and return valve

Fig. 21: Minimum pressure and return valve

The minimum pressure and return valve (Fig. 21/1) only opens if the system pressure has increased to 5 bar. After the screw compressor switches off, the minimum pressure and return valve prevents the compressed air from stream back out of the network.



56 2015-07-21

4.3.9 Cooler

Fig. 22: Cooler

The compressed air is cooled off in the compressed air after-cooler (Fig. 22/2) or in the pressure tank before it leaves the screw compressor via the compressed air connection (Fig. 22/3).

The coolant liquid is cooled by the coolant liquid cooler (Fig. 22/1) and fed back into the coolant circuit.

The compressed air after-cooler and coolant liquid cooler are only present on the COMBI 16 – 22. In the COMBI 6 – 15, only a coolant liquid cooler is installed.

4.3.10 Coolant liquid filter

Fig. 23: Coolant liquid filter

The coolant liquid filter (Fig. 23/1) cleans the coolant liquid before it is injected into the compressor stage once again.



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4.3.11 Cooling air fan

Depending on the type, two different cooling air ventilators are installed.

Cooling air fan

The cooling of the compressed air after-cooler and of the coolant liquid cooler is performed by the cooling air fan. The cooling air fan also supplies the intake filter with sufficient intake air.

4.3.12 Refrigerant-type dryer

Fig. 24: Refrigerant-type dryer

The refrigerant-type dryer (Fig. 24/1) dries the compressed air using a heat exchange process. The compressed air is thus fed from the pressure tank into the refrigerant-type dryer and then via the compressed air connection (Fig. 24/3) into the compressed air network. The condensate which accumulates is discharged via the condensate drain (Fig. 24/2).

Depending on the variant, a hose for discharging the condensate is already attached to the condensate drain; otherwise, the operator must attach one.



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4.4 Interfaces

Fig. 25: Flow chart

The following interfaces are in the screw compressor:

Air supply Cooling air ventilator Intake filter

Compressed air connection



2015-07-21 59

Air supply

Fig. 26: Cooling air ventilator and intake filter

The cooling air ventilator directs the fresh air to the intake filter and also serves the purpose of process cooling. The intake filter filters the fresh air and directs it into the compressor unit for compression.

Compressed air connection

Fig. 27: Compressed air connection

The air compressed by the compressor is available to the compressed air network at the compressed air connection after it has been filtered.


Transportation, packaging and storage

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5 Transportation, packaging and storage 5.1 Safety instructions for transportation

Improper transport

NOTICE! Damage to property due to improper transport! Transport units may fall or tip over as a result of improper transport. This can cause a significant level of property damage. - Proceed carefully when unloading transport units at

delivery and during in-house transport; observe the symbols and instructions on the packaging.

- Only use the attachment points provided. - Only remove the packaging shortly before assembly.

5.2 Transportation inspection On receipt, immediately inspect the delivery for completeness and

transport damage.

Proceed as follows in the event of externally apparent transport damage:

Do not accept the delivery, or only accept it subject to reservation.

Note the extent of the damage on the transport documentation or the shipper's delivery note.

Initiate complaint procedures.

Issue a complaint in respect of each defect immediately following detection. Damage compensation claims can only be asserted within the applicable complaint deadlines.



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5.3 Packaging

About the packaging The individual screw compressors are packaged in cartons or sometimes on wooden frames and according to the anticipated transport conditions. Only environmentally-friendly materials are used for the packaging. The packaging should protect the individual components against transport damage, corrosion and other damage until assembly. Therefore, do not destroy the packaging and only remove it shortly before assembly.

Handling packaging materials Dispose of packaging material in accordance with the relevant applicable legal requirements and local regulations.

NOTICE! Danger to the environment due to incorrect disposal! Packaging materials are valuable raw materials and in many cases can continue to be used or can be properly processed and recycled. Incorrect disposal of packaging materials may pose risks to the environment. - Dispose of packaging materials in accordance with

the environmental regulations. - Observe locally applicable waste disposal

regulations. If necessary, outsource the disposal to a specialist company.



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5.4 Symbols on the packaging The following symbols are on the packaging. Always adhere to these

symbols during transportation.

Top

The arrow tips on the sign mark the top of the package. They must always point upwards; otherwise the content could be damaged.

Fragile

Marks packages with fragile or sensitive contents. Handle the package with care; do not allow to fall and do not expose to impacts.

Protect against moisture

Protect packages against moisture and keep dry.

5.5 Transportation

Transport with a fork lift Transport pieces can be transported with a fork lift under the following conditions:

The fork lift must be designed for the weight of the transport pieces.

Existing guide rails on the frame must be used.

The length of the forks must be at least 1400 mm.

Transporting Personnel: Forklift driver

Fig. 28: Transport with a fork lift

1. Drive the fork lift with the forks as shown in Fig. 28.

2. Insert the forks so that they stick out on the other side.

3. Ensure that the transport piece cannot tip with an off-centre centre of gravity.

4. Lift the transport piece and begin the transport.



2015-07-21 63

5.6 Storage

Storage of the packaging pieces Store the packaging pieces under the following conditions: Do not store outdoors.

Store dry and dust-free.

Do not expose to any aggressive media. Protect against solar radiation.

Avoid mechanical jolts.

Storage temperature: 15 to 35 °C.

Relative humidity: max. 60 %. In case of storage for longer than 3 months, check the general

condition of all parts and the packaging regularly. If necessary, refresh or replace the rust-proofing.

Under some circumstances there may be notes about storage on the packaging pieces that extend beyond the requirements named here. Adhere to these accordingly.


Installation, commissioning and operation

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6 Installation, commissioning and operation 6.1 Safety instructions for the installation and commissioning

Electrical system

DANGER! Danger to life from electric power! Contact with live parts may prove fatal. When switched on, electric components can be subject to uncontrolled movements and may cause grave injury or death. - Switch off the power supply before starting work and

make sure that it cannot be switched on again.

Improper initial commissioning

WARNING! Danger of injury due to improper initial commissioning! Improper initial commissioning can result in serious injury and significant damage to property. - Before the initial commissioning, ensure that all

installation work has been carried out and completed in accordance with the information and instructions in this manual.

- Ensure that no persons are in the danger zone before the initial commissioning.


WARNING! Danger to life from an unauthorised restart! In the event of an unauthorised restart of the power supply during installation, there is a danger of serious injuries or death for persons in the danger zone. - Switch off all power supplies before starting work and

make sure they cannot be switched on again.



2015-07-21 65

Improper installation and commissioning

WARNING! Risk of injury due to improper installation or commissioning! Improperly performed installation and commissioning may lead to serious injury and significant material damage. - Provide for sufficient mounting clearance before

starting to work. - Use caution when handling exposed components with

sharp edges. - Keep the assembly area tidy and clean! Loose

components and tools lying around or on top of each other may lead to accidents.

- Mount all components properly. Tighten all screws to the prescribed torque.

- Secure components to prevent them from falling down or tipping over.

- Observe the following prior to commissioning: - make sure that all installation work has been

performed and completed following the instructions and information provided in this manual.

- make sure that no persons are still in the danger zone of the machine.



66 2015-07-21

6.2 Requirements in the installation location Set up the screw compressor so that the following conditions are

fulfilled:

The installation location is level. The secure standing of the machine is guaranteed.

The machine is easily accessible and can be accessed from all sides.

There is sufficient lighting.

There is sufficient ventilation.

There is a power supply available. Escape paths and rescue equipment are freely accessible.

The machine is not subjected to an explosive atmosphere.

The machine is not subjected to a corrosive atmosphere.

The machine is not subjected to direct solar radiation. Outside heating from surrounding heat sources is excluded.

There is no dust accumulation.

Fire protection measures have been taken.

The machine is not subjected to vibrations. The surface is resistant to solvents, impermeable to liquids, anti-

static and easy to clean.

There are no machines in the vicinity that cause electrical or electromagnetic disturbance.



2015-07-21 67

6.3 Installation 6.3.1 Ventilation

DANGER! Danger to life from the use of explosive gas mixtures, vapours, dust or aggressive hazardous substances! The use of explosive gas mixtures, vapours, dust or aggressive hazardous substances to ventilate the screw compressor can cause severe or even fatal injuries as well as significant property damage. - Never use explosive gas mixtures, vapours, dust or

aggressive hazardous substances to ventilate the screw compressor.

- Ensure that no explosive gas mixtures, vapours, dust or aggressive hazardous substances get into the ventilation of the screw compressor.

The air supplied via the intake openings is used for compression and system cooling.

Personnel: Qualified personnel

Protective equipment: Safety boots Protective work clothing

NOTICE! Property damage due to condensation! Due to cooling air that is too hot or too humid, condensate can arise. - Only provide cool, dry and dust-free cooling air. - For the intake of outside air, use a recirculating air flap.

Fig. 29: Overview illustration of cooling air ventilator

1. Provide the required quantity of cooling air according to the technical data for the screw compressor ( Chapter 3 ‘Technical data’ on page 32).

2. Remove the exhaust air according to the technical data for the screw compressor ( Chapter 3 ‘Technical data’ on page 32).

This way, the heating of the installation room and of the screw compressor will be prevented.



68 2015-07-21

Forced ventilation and bleeding (optional)

The forced ventilation and bleeding must be dimensioned so that the required supply and exhaust air can be supplied and removed taking into account the existing residual pressure of the cooling air ventilator. The exhaust air can also be used for the purpose of heat reclamation.

6.3.2 Connection to the compressed air network


Protective equipment: Protective work clothing Safety boots

Materials: Flexible compressed air hose, max. 1.5 m

WARNING! Danger of injury due to unpredictable movement of the compressed air hose! Load switches in the compressed air network cause jerky movements of the compressed air hose with high force. - Anchor and fasten the compressed air hose

sufficiently.

The prerequisite for the correct installation is the presence of a professionally-planned, installed and maintained compressed air network and an additional cut-off valve installed at the entrance to the compressed air network.

Fig. 30: Compressed air connection

1. Connect the compressed air according to the technical data ( Chapter 3 ‘Technical data’ on page 32).

2. Ensure that the compressed air hose does not represent a stumbling hazard.

3. Anchor and fasten the flexible compressed air hose sufficiently.



2015-07-21 69

6.3.3 Connecting to the power supply

Personnel: Qualified electrician


NOTICE! Property damage to the compressor stage due to incorrect connection of the power supply! In case of incorrect connection of the power supply, there is a danger that the compressor stage will be destroyed due to a drive turning incorrectly. - Connect the power according to the wiring diagram

and check the rotating field before starting the screw compressor.

The prerequisite for the correct installation are professionally-dimensioned fuses in the network supply (person-system protection) and an appropriate main switch (for switching the supply on and off).

1. Using the data in the wiring diagram (in the switch cabinet), check whether the existing supply network is suitable. Voltage deviations of more than 10 % are not permitted.

2. Connect the power according to the included wiring diagram (in the switch cabinet) and the technical data ( Chapter 3 ‘Technical data’ on page 32).

3. Check right-rotating direction of rotation with a rotating field measurement device.

4. Ensure that the power cable does not represent a stumbling hazard.



70 2015-07-21

6.4 Checking the coolant liquid level Personnel: Qualified personnel


Protective gloves

1. Switch the machine off and secure to prevent restarting.

2. Open and remove the sound insulation covers with the special spanner.

Fig. 31: Inspection glass

3. Check the inspection glass (Fig. 31/1) to make sure it is completely moist.

4. If necessary, top up coolant liquid Chapter 8.4.7 ‘Changing the coolant liquid/changing the cooling liquid filter’ on page 115.



2015-07-21 71

6.5 Start-up lubrication of the compressor stage Personnel: Qualified personnel


NOTICE! Property damage due to lacking coolant liquid in the compressor stage! Lacking coolant liquid in the compressor stage after longer downtimes, e.g. between factory delivery and initial commissioning or after a longer downtime can cause significant property damage to the screw compressor. - Top up the coolant liquid directly in the compressor

stage before the initial commissioning or after a longer downtime.

Coolant liquid quantities for direct filling in the compressor stage

Screw compressor Coolant liquid filling

l

COMBI 3S – 5S 0.5

COMBI 6 – 15 0.5

COMBI 16 – 22 0.5

COMBI 11SC / 22SC 0.5



72 2015-07-21

Fig. 32: Screw plug intake regulator

1. Loosen 4 screws on the intake regulator (Fig. 32/1).

NOTICE! Property damage due to incorrect coolant liquid! Mixing different coolant liquids causes significant property damage to the screw compressor. - Only use the coolant liquid prescribed in the technical

data.

If there is no additional coolant liquid available, the coolant liquid will have to be removed using of the coolant liquid drain Chapter 8.4.7 ‘Changing the coolant liquid/changing the cooling liquid filter’ on page 115.

2. Remove the intake regulator and fill the coolant liquid directly into the compressor stage (Fig. 32/1).

3. Tighten 4 screws on the intake regulator (Fig. 32/1) ( Appendix B ‘Tightening torques for screws’ on page 137).

6.6 Switching on after the initial commissioning Personnel: Qualified personnel

Protective equipment: Ear protection Protective work clothing

Safety boots

1. Check the media connections for correct installation.

2. Ensure that no tools or loose objects are in or on the machine.

3. Install and check that the sound installation covers are sealed.

4. Carefully open the gate valve after the compressed air connection between the screw compressor and the compressed air network.

The screw compressor is now connected to the compressed air network.

5. Switch on the main switch.

6. Start the screw compressor Controller documentation.

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



2015-07-21 73

6.7 Working after the initial commissioning Personnel: Qualified personnel


Protective gloves

Light respiratory protection Safety goggles








74 2015-07-21



3. Wait until the components have cooled off.

4. Check all coolant liquid and compressed air lines for leaks.

5. If there is coolant liquid in the system, it must be removed.

6. The connectors of the components must be checked and the screws tightened Appendix B ‘Tightening torques for screws’ on page 137.

Fig. 33: Checking the coolant liquid level in the inspection glass

7. Check the coolant liquid level in the inspection glass (Fig. 33/1) and top up as in Chapter 8.4.2 ‘Checking the coolant liquid level/topping up the coolant liquid’ on page 109 if necessary.

8. Install and check that the sound installation covers are sealed.

NOTICE! Property damage to to compressor temperature that is too low or too high! A compressor temperature that is too low or too high can cause damage to the screw compressor. - Contact the manufacturer for more precise

information, for contact information see page 2.

A sufficiently high compressor temperature guarantees that the humidity taken in will not become condensate. Frequent switching on and off of the screw compressor can cause the compressor not to reach the required operating temperature Chapter 8.4.6 ‘Checking the condensation accumulation’ on page 114.

9. Check compressor temperature Chapter 8.4.4 ‘Checking the

compressor temperature’ on page 112.



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6.8 Setting parameters

Adjustment work for the screw compressor: Chapter 7.4 ‘Controllers’ on page 78.

6.9 Measures in case of low compressed air requirement

Measures

NOTICE! Risk of material damage in case of an excessively long downtime! Frequent operating cycles and a longer system downtime can cause increased wear.

To prevent damage in case of a low compressed air requirement, take the following measures: - Adjust the compressor to the actual compressed air

requirement. - Use a compressed air buffer tank with sufficient

dimensions. - Perform at least one hour of continuous on-load

operation in the control range every week.


Operation

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7 Operation 7.1 Safety instructions for operation

Improper operation

WARNING! Danger of injury due to improper operation! Improper operation can cause serious injury and significant material damage. - Carry out all operating steps in accordance with the

information and notices in this manual. - Pay attention to the following points before starting

work: - Ensure that all covers and safety devices are

installed and work properly. - Ensure that that no one is in the danger zone.

- Never override or bridge safety features during operation.

7.2 Shutdown in emergency situations In dangerous situations component movements must be stopped as

quickly as possible and the power supply must be switched off.

Shutdown in emergency situations

In an emergency situation proceed as follows:

1. Immediately trigger an emergency stop through the emergency stop device.

2. If there is no danger to your own health get people out of the danger zone.

3. Initiate first-aid measures if necessary.

4. Alert the fire department and/or rescue service.

5. Inform the responsible parties at the implementation site.

6. Switch off the machine and safeguard it from being switched on again.

7. Keep entry ways clear for rescue vehicles.

8. Give directions to rescue vehicles.


Operation

2015-07-21 77

After the rescue measures 9. Depending on the seriousness of the emergency situation, inform the responsible government agencies.

10. Assign specialized personal to resolve the malfunction.

WARNING! Life-threatening danger if restarted without authorization or due to uncontrolled restart! Uncontrolled or unauthorized switching on of the power supply can cause severe or fatal injuries. - Prior to restart ensure that all safety devices are


11. Prior to restarting the machine check and ensure that all safety

devices are installed and functioning.

7.3 Operating personnel and personal protective equipment The following personnel qualifications and personal protective

equipment apply for all work on all controllers:

Personnel: Trained Person

Protective equipment: Ear protection


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7.4 Controllers

Controller variants For the controller variant installed, please consult the label on the controller.

7.4.1 Controller COMBI 3S – 4S 7.4.1.1 Overview

Fig. 34: Controller COMBI 3S – 4S

No. Description of function

1 Main switch with emergency stop function

2 Operating hours counter

3 Pressure gauge


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7.4.1.2 Switching the compressor on/off

Switching the compressor on

Fig. 35: Switching the compressor on

1. Turn the twist switch to the right.

The compressor starts up automatically.

The compressor is shut off automatically by the pressure switch (automatic mode) once operating pressure is achieved. If the operating pressure drops again, the compressor is switched back on again automatically by the pressure switch.

Switching the compressor off

Fig. 36: Switching the compressor off

1. Turn the twist switch to the left.

The compressor is switched off.


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7.4.2 Controller COMBI 5S 7.4.2.1 Overview

Fig. 37: Controller COMBI 5S

No. Key/icon Description of function

1

Main switch with emergency stop function

2

Displays the hours of operation.

3

Serves to switch on the compressor.

4

Indicates the operating state.

5

Serves to switch off the compressor.



1. Press .

The operating indicator lights up, the compressor is ready and can start up automatically at any time.


1. Press .

The operating indicator no longer lights up, the compressor switches itself off.


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7.4.3 Air Control AC mini controller

7.4.3.1 Air Control Mini overview

Fig. 38: Overview of Air Control AC mini

No. Key/icon Description of function

1 Display Displays settings and operating parameters.

2

Serves to switch on the compressor. The integrated green LED indicates the operating state. Serves to scroll and increase values.

3

Serves to switch off the compressor, to acknowledge fault/warning messages and to call up the code input menu.

Serves to scroll and reduce values.

4

Serves to call up additional operating data.

5

Indicates the operating state.

6

Indicates warnings with flashing and faults with red LEDs that light up.


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7.4.3.2 Brief description

The Air Control AC mini controller serves to display operating data/the compressor state

to switch on/off the compressor/the compressed air generation

to program the compressor and the compressed air generation.

7.4.3.3 Operating modes

Overview Four operating modes can be set using the controller.

Operating mode Description

Automatic operation After reaching the switch-off pressure, the system switches to idle for the duration of the idle time (run-on). After the run-on time has elapsed, the motor switches off. The compressor can start up by itself at any time if the machine drops below the switch-on pressure.

Load/idle operation The compressor switches between "Load" and "Idle" operation; that is, there is an unlimited run-on.

Optional automatic After reaching the switch-off pressure, the compressor switches to idle. After 10 and 40 seconds, the respective network pressure is measured. If the pressure drop determined this way is above the threshold "Max. pressure drop", the compressor remains in idle for the duration of the run-on time. If the value determined is below the threshold "Max. pressure drop", the compressor switches off after the shutdown time has elapsed.

Basic load switching mode (BLS operation)

The switch on/off pressure set is not taken into account by the controller. The compressor is controlled by a superior controller, which can be connected via freely-programmable inputs (no RS485 present).

Safety pressure The safety pressure is the sum of the set maximum pressure + 0.8 bar. If the pressure exceeds the value of the safety pressure, the compressor is switched off with a fault message. If the maximum pressure is exceeded by 0.5 bar, a warning appears on the display.


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7.4.3.4 Overview of display

The display shows all operation-relevant information such as the parameters set.

Fig. 39: Overview of basic display

1 Display [Aktueller Netzdruck (Current network pressure)]: Displays the current network pressure.

2 Display [Aktuelle Verdichtertemperatur (Current compressor temperature)]: Displays the current compressor temperature.

3 [Betriebsart (Operating mode)] display: Displays the current operating mode.

By pressing the key, the current coolant liquid temperature can also be shown on the [Aktuelle Verdichtertemperatur (Current compressor temperature)] display.

Other display indicators The following symbols can also appear on the display:

Symbol Description

Warning/maintenance message present.

Fault present.

Operating mode automatic/optional automatic active.

Automatic restart after power failure is activated.

Flashing: compressed air generation on/off via remote switch. Static: compressed air generation is controlled by superior controller.

Motor is running.

Compressor is compressing air.


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1. Press .



1. Press .

When switching off, the compressor switches for the duration of the shutdown time to "idle" (motor runs, compressor does not compress any air, blinks on the display). After the shutdown time, the compressor switches off.

7.4.3.6 Calling up information

It is possible to display various information about operating states and parameter values on the display. In order to switch between the information and the parameter displays, it is only necessary to press the key. The Information menu with parameter number and the parameter value then appears on the display.

1. Press .

The next parameter value is shown on the display.

In the information menu, the parameter [Einschaltdruck (Switch-on pressure)] is always shown as the first value.

After approx. 5 seconds without pressing the key, the display switches back to the basic display.


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Key Parameter displayed Parameter number Unit of the parameter value

Switch-on pressure [1] [bar, MPa, psi]

Switch-off pressure [2] [bar, MPa, psi]

Safety pressure [3] [bar, MPa, psi]

Minimum pressure monitoring in BLS operation

[4] [bar, MPa, psi]

Minimum compressor temperature

[5] [°C, °F, Kelvin]

Maximum compressor temperature

[6] [°C, °F, Kelvin]

Hours of operation [7] [h]

Load hours [8] [h]

Remaining time intake filter [9] [kh]

Remaining time coolant liquid and coolant liquid filter

[10] [kh]

Remaining time fine precipitator

[11] [kh]

Remaining time motor lubrication

[12] [kh]

Remaining time compressor maintenance

[13] [kh]

Remaining time dryer maintenance

[14] [kh]

Hours of operation dryer [15] [h]


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7.4.3.7 Setting parameters via code input menu

The parameters for all basic settings of the compressor can be changed with code input insofar as these changes do not influence the operational stability. However, this is only possible when the compressed air generation is switched off.

7.4.3.7.1 Calling up the code input menu

1. Press and hold for three seconds.

The code input menu appears on the display.

2. Press .

A 1 appears on the display.

3. Press .

In order to exit the code input menu again, press the and keys together.

7.4.3.7.2 Inputting a code

Prerequisite: the code input menu has been called up.

1. Set the desired code with the keys.

2. To confirm the selected code, press .

The submenu for the selected code appears on the display.

For some codes, several parameters can be input one after another. By pressing the key, the next parameter is selected automatically in such cases.


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7.4.3.7.3 Select operating mode: Code 2

By entering the code 2, the operating mode can be selected.



2. Press .


3. Press .

4. Set the code 2 with the keys.


6. Press .

The submenu for setting the operating mode appears on the display.

7.

There are three values from which to choose: - 0: Automatic operation - 1: Load/idle operation - 2: Optional automatic

Set the desired value with the keys.

8. To confirm the selected value, press .

The set value is saved and the code input menu appears on the display again.

9. Press the keys at the same time to go back to the basic display.


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Value Operating mode Description

0 Automatic operation After reaching the switch-off pressure, the compressor switches to idle for the duration of the idle time (run-on). After the idle time has elapsed, the compressor then switches off, but it remains ready for operation. If the switch-on pressure is reached, the compressor starts up again automatically.

1 Load/idle operation The compressor switches between "Load" and "Idle" operation; that is, there is an unlimited run-on.

2 Optional automatic The "Automatic" symbol and an additional point are shown on the display in front of the temperature value. Here it is possible to influence how frequently the motor stops. To do this, after the confirmation, the parameters "maximum pressure drop" (input range 0.0 to 9.9 bar) and "maximum operating cycle" (input range 1 to 55 operating cycles/hour) are queried.

Maximum pressure drop If the system switches from load operation to idle, the Air Control mini saves the current network pressure after 10 and 40 seconds. If the pressure drop determined this way is above the "maximum pressure drop", the motor switches off after the idle time has elapsed; otherwise after the shutdown time.

Maximum operating cycles The motor is not switched off after the idle time (run-on) has elapsed if the number of switch-on processes of the compressor exceeds the number of the "maximum operating cycles".


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7.4.3.7.4 Switch automatic restart on/off: Code 3

By inputting the code 3, the automatic restart can be switched on/off after a power failure.



2. Press .


3. Press .



The submenu for switching the automatic restart on/off appears on the display.

6.

There are two values from which to choose: - 0: Automatic restart OFF - 1: Automatic restart ON





Value Setting Description

0 Automatic restart OFF If the automatic restart after power failure is switched off, then after a power failure, the fault "no AC" is displayed. This fault must be acknowledged manually by pressing the key. Otherwise, the compressor will not restart.

1 Automatic restart ON If the automatic restart after power failure is switched on, the time set in the "shutdown time" parameter must elapse. If the compressor was operating before the power failure, then after this time has elapsed, it will start up again. Otherwise, the compressor will then switch to STOP mode.


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7.4.3.7.5 Dryer dew-point monitoring: Code 6

The dew-point monitoring can be switched on and off by entering code 6.



2. Press .


3. Press .

4. Set code 6 using keys.


The dew-point temperature is monitored at the set limits and the temperature sensor is monitored for defects, if the function is activated. - Dew-point temperature max. 0 °C – +50 °C - Dew-point temperature min.. -10 ℃ – +50 °C (when the dew-point is set to min/max auf 0 °C the

monitoring is switched off) - Setting Warning 0 Setting Malfunction 1

6. Using key and set the desired maximum dew-point and

confirm with .

7. Using key and set the desired minimum dew-point and confirm with .

8. Using key and carry out setting Warning/Malfunction and confirm with .

The set values are saved and the code input menu appears on the display again.



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7.4.3.7.6 Set on-site operation/remote operation: Code 8

By inputting the code 8, it is possible to switch between on-site operation and remote operation.



2. Press .


3. Press .



The on-site operation/remote control submenu appears on the display.

6.

There are three values from which to choose: - 0: On-site operation - 1: Remote control - 2: BLS-OK






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Value Designation Description

0 On-site operation The compressed air generation can only be switched on or off on the control console/display of the Air Control 1.

1 Remote control The compressed air generation can only be switched on via a positive edge (24 VDC) on terminal 23 and switched off via low level (0 V) on terminal 23 or via the key. This functionality is identified by the flashing text on the display of the Air Control 1. If the key is pressed on the system on-site, the system switches off after 120 seconds and for safety reasons, it can only be started via remote control after the key has been pressed (acknowledgement) on-site. This also applies for a start via PLANT CONTROL V/T.

2 BLS-OK The input on terminal 23 serves to report the operational readiness of an external controller. Only with an existing high level (24 VDC) can the external controller switch between load operation and idle. During existing low level, the BLS operation is switched off automatically and the internal pressure sensor is used.

7.4.3.7.7 Set switch on/off pressure: Code 11

By inputting the code 11, it is possible to set the switch-on and switch-off pressure. The switch-on pressure specifies the pressure at which the switched-on compressor will begin automatically with the compression. The switch-off pressure specifies the pressure at which the compressor will be switched off automatically. Both functions are only active in automatic operation.



2. Press .


3. Press .



6. Press .

The submenu for setting the switch-on pressure appears on the display.


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7.

The adjustment range for the switch-on pressure is, with switch-off pressure set at the factory, between 3.5 and 7.9 bar. The upper limit for the switch-on pressure is 0.1 bar less than the switch-off pressure.

Set the desired switch-on pressure with the keys.

8. To confirm the setting, press the key.

The set value was saved and the submenu for setting the switch-off pressure appears on the display.

9.

The adjustment range for the switch-off pressure is, with switch-on pressure set at the factory, between 7.1 and 10 bar. The upper limit for the switch-off pressure is equal to the maximum pressure. The lower limit for the switch-off pressure is 0.1 bar higher than the switch-on pressure.

Set the desired switch-off pressure with the keys.

10. To confirm the setting, press the key.




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7.4.3.7.8 Switch Basic load switching mode on/off: Code 18

By inputting the code 18, the Basic load switching mode can be switched on/off.



2. Press .


3. Press .



The Basic load switching mode submenu appears on the display.

6.

There are two values from which to choose: - 0: Basic load switching mode is switched off - 1: Basic load switching mode is switched on






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7.4.3.7.9 Switch the pressure unit: Code 90

By entering the code 90, the pressure unit can be switched.



2. Press .


3. Press .



The submenu for setting the pressure unit appears on the display.

6.

There are three values from which to choose: - 0: bar - 1: MPa - 2: psi (pounds per square inch)





Value Pressure unit Description

0 bar All pressure displays will be in bar.

1 MPa All pressure displays will be in Megapascals.

2 psi All pressure displays will be in psi (pounds per square inch).


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7.4.3.7.10 Switch the temperature unit: Code 95

By entering the code 95, the temperature unit can be switched.



2. Press .


3. Press .



The submenu for setting the temperature unit appears on the display.

6.

There are three values from which to choose: - 0: °C - 1: °F - 2: K





Value Pressure unit Description

0 Degrees Celsius All temperature displays will be in °C.

1 Degrees Fahrenheit All temperature displays will be in °F.

2 Kelvin All temperature displays will be in Kelvin.


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7.4.3.7.11 Display the software version: Code 9999

By inputting the code 9999, the software version can be displayed.



2. Press .


3. Press .



The software version appears on the display.

6. Press the keys together to go back to the code input menu.


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7.4.3.8 Fault and warning messages 7.4.3.8.1 Fault messages

The symbol blinks and the [Aktueller Netzdruck (Current network pressure)] indicator displays the fault message and the current network pressure in alternation. The compressor stops automatically.

No. Description

E. 1 Pressure set points incorrect

E. 2 Setting parameter incorrect

E. 3 Low voltage

E. 4 Power failure

E. 5 Air Control mini faulty

E. 6 Emergency stop pressed

E. 7 Direction of rotation incorrect

E. 8 Motor temperature too high

E. 9 Overcurrent

E. 10 Overpressure

E. 11 Dryer fault

E. 12 Sensor compression temperature

E. 13 Sensor coolant liquid temperature

E. 14 Sensor pressure

E. 15 Compressor temperature too high

E. 16 Network pressure too high

E.17 Dew-point temperature too low

E.18 Dew-point temperature too high


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NOTICE! Property damage due to incorrect acknowledgement of fault messages! Faults which occur are output as fault messages. Only after the fault has been eliminated may the fault messages be acknowledged, since otherwise the service life of the compressor will be reduced. - Only have maintenance work performed by qualified

personnel. - Only acknowledge fault messages after the

appropriate work. - Only use original spare parts.

Acknowledging fault messages

Faults may only be acknowledged if the cause has been eliminated properly. Only have troubleshooting and maintenance work performed by qualified personnel.

1. Press .

2. Press .



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7.4.3.8.2 Warning messages

The symbol blinks and the [Aktueller Netzdruck (Current network pressure)] indicator displays the warning message and the current network pressure in alternation.

No. Description

E.33 Dew-point temperature

E. 34 Compressor temperature increased

E. 35 Network pressure increased

E. 36 Temperature too low

E. 39 Lower pressure threshold reached

E. 42 Maintenance dryer (remaining maintenance time < 100 h)

E. 43 Maintenance intake filter (remaining maintenance time < 100 h)

E. 44 Maintenance coolant liquid / coolant liquid filter (remaining maintenance time < 100 h)

E. 45 Maintenance fine precipitator (remaining maintenance time < 100 h)

E. 46 Maintenance motor lubrication (remaining maintenance time < 100 h)

E. 47 Maintenance compressor (remaining maintenance time < 100 h)


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Acknowledging warning messages

NOTICE! Property damage due to incorrect acknowledgement of warning messages! Maintenance which needs attention is output as warning messages. Only after the maintenance has been performed may the warning messages be acknowledged, since otherwise the service life of the compressor will be reduced. - Only have maintenance work performed by qualified

personnel. - Only acknowledge warning messages after the

appropriate work. - Only use original spare parts.



2. Press .


3. Press .



6. Press the key in order to restart the maintenance interval.



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8 Maintenance 8.1 Safety instructions for maintenance

Electrical system

DANGER! Danger to life from electric power! Contact with live parts may prove fatal. When switched on, electric components may be subject to uncontrolled movements and may cause grave injury. - Switch off the power supply before starting work and


Moving parts

WARNING! Danger of injury from moving parts! Rotating parts and/or parts moving in linear fashion may cause serious injuries. - Before carrying out any maintenance work on moving

parts, shut down the machine and take precautions to prevent restarting. Wait until all parts have stopped moving.

- When in the danger zone, wear close-fitting protective work clothing with low tear strength.


WARNING! Danger to life from an unauthorised restart! In the event of an unauthorised restart of the power supply during maintenance, there is a danger of serious injuries or death for persons in the danger zone. - Switch off all power supplies before starting work and


Hot surfaces





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Improperly performed maintenance

WARNING! Danger of injury due to improperly performed maintenance! Improperly performed maintenance may lead to serious injury and significant material damage. - Provide for sufficient mounting clearance before

starting to work. - Keep the assembly area tidy and clean! Loose

components and tools lying around or on top of each other may lead to accidents.

- When reinstalling previously removed components, make sure that the components are mounted properly, all fixing elements are reinstalled, and all screws are tightened to torque.

- Before putting the machine back into operation: - make sure that all maintenance work has been

performed and completed following the instructions and information provided in this manual.

- make sure that no persons are still in the danger zone of the machine.

- make sure that all covers and safety devices have been installed and function properly.

Compressed air






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Coolant liquid fog



Accumulations of liquid

CAUTION! Danger of injury from slipping in accumulations of liquid! Slipping in accumulations of liquid on the floor may result in a fall. A fall may result in injuries. - Remove accumulations of liquid immediately using

appropriate means. - Wear anti-slip safety shoes. - Post warnings and mandatory signs at or in the

vicinity of any area where liquid could accumulate on the floor.

Environmental protection Observe the following environmental protection instructions during maintenance work:

In respect of all lubrication points supplied manually with lubricant, remove any escaping, used or surplus grease and dispose of in accordance with applicable local regulations.

Catch replaced oils in suitable containers and dispose of in accordance with applicable local regulations.


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8.2 Spare parts

WARNING! Danger of injury due to use of incorrect spare parts! The use of incorrect or defective spare parts can lead to personal injury, material damage, malfunction or total failure. - Use only original manufacturer's spare parts or spare

parts that have been approved of by the manufacturer.

- Always contact the manufacturer if in doubt.

Loss of warranty The manufacturer's warranty will be rendered null and void if spare parts are used that are not approved.

Spare parts must be procured through an authorised dealer or directly from the manufacturer. Contact details, see page 2.

The spare parts list can be found in the Appendix.


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8.3 Maintenance schedule Maintenance tasks are described in the sections below that are

required for optimal and trouble-free machine operation.

If increased wear is detected during regular inspections, then reduce the required maintenance intervals according to the actual indications of wear. Contact the manufacturer (see the service address on page 2), if you have questions concerning maintenance tasks and intervals.

Interval Maintenance work Personnel

Daily Checking the coolant liquid level Chapter 8.4.2 ‘Checking the coolant liquid level/topping up the coolant liquid’ on page 109

Qualified personnel

Check for leaks Chapter 8.4.3 ‘Checking for leaks’ on page 111

Qualified personnel

One week after initial installation

Check all electrical connections Chapter 8.4.1 ‘Checking the electrical connections’ on page 108

Qualified electrician

Weekly Check compressor temperature Chapter 7.4 ‘Controllers’ on page 78

Trained Person

Check cooler for soiling Chapter 8.4.5 ‘Checking soiling of the cooler’ on page 113

Qualified personnel

Check for condensate formation Chapter 8.4.6 ‘Checking the condensation accumulation’ on page 114

Qualified personnel

Check the drive belt for wear Trained Person

After the first 100 hours of operation

Check for leaks Chapter 8.4.3 ‘Checking for leaks’ on page 111

Qualified personnel

Check compressor temperature Chapter 7.4 ‘Controllers’ on page 78

Trained Person

Check cooler for soiling Chapter 8.4.5 ‘Checking soiling of the cooler’ on page 113

Qualified personnel

Check for condensate formation Chapter 8.4.6 ‘Checking the condensation accumulation’ on page 114

Qualified personnel


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Interval Maintenance work Personnel

After the first 500 hours of operation

Check all electrical connections Chapter 8.4.1 ‘Checking the electrical connections’ on page 108


Change coolant liquid Chapter 8.4.7 ‘Changing the coolant liquid/changing the cooling liquid filter’ on page 115

Qualified personnel

Change coolant liquid filter* Chapter 8.4.7 ‘Changing the coolant liquid/changing the cooling liquid filter’ on page 115

Qualified personnel

Retighten the drive belt Qualified personnel

Every 2000 hours of operation, at least once a year

Re-lubricate electric motor Chapter 8.4.8 ‘Re-lubricating the electric motor’ on page 118

Qualified personnel

Change coolant liquid Chapter 8.4.7 ‘Changing the coolant liquid/changing the cooling liquid filter’ on page 115

Qualified personnel

Change coolant liquid filter* Chapter 8.4.7 ‘Changing the coolant liquid/changing the cooling liquid filter’ on page 115

Qualified personnel

Change fine precipitator* Chapter 8.4.9 ‘Change fine precipitator’ on page 119

Qualified personnel

Change intake filter* Chapter 8.4.10 ‘Change intake filter’ on page 120

Qualified personnel

Check safety valve Manufacturer

Check drive unit Chapter 8.4.11 ‘Checking the drive unit’ on page 121

Qualified personnel

Check the belt tension of the drive Qualified personnel

Perform general compressor maintenance Manufacturer

Every 4000 hours of operation

Replace the drive belt Qualified personnel

* The change intervals refer to: Ambient temperature of +40 °C

Max. humidity of 60%

Compressor temperature of approx. 85 °C


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8.4 Maintenance work

Necessary maintenance work Necessary maintenance work appears on the display of the controller as a warning Chapter 7.4 ‘Controllers’ on page 78.

8.4.1 Checking the electrical connections

Personnel: Qualified electrician


Light respiratory protection

Safety goggles Protective gloves

DANGER! Danger to life from stored charges! Electric charges may be stored in electrical components; these charges may be maintained even after the system has been switched off and disconnected from the power supply. Contact with these components may result in serious or fatal injury. - Before working on the specified components, ensure

that they have been completely disconnected from the power supply. Allow 10 minutes to elapse in order to ensure that the internal capacitors have been fully discharged.


2. Close compressed air network-side gate valve and secure against re-opening.


4. Check all electrical connections and tighten if necessary Appendix B ‘Tightening torques for screws’ on page 137.


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8.4.2 Checking the coolant liquid level/topping up the coolant liquid

Checking the coolant liquid level Personnel: Qualified personnel



Safety goggles

Protective gloves




Fig. 40: Inspection glass

4. Check the inspection glass (Fig. 40/1) to make sure it is completely moist.

5. If the whole inspection glass height is not covered with coolant liquid, the coolant liquid must be topped up.


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Topping up the coolant liquid Personnel: Qualified personnel




Materials: Collecting tray for coolant liquid Funnel with filling tool




4. With the help of a collection tray, make sure that the escaping coolant liquid is collected.

Fig. 41: Filler plug

5. Loosen the filler plug (Fig. 41/1), remove and make sure that the gasket does not get lost.


data.


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Fig. 42: Filler plugs

6. With the help of a funnel (Fig. 42/1), fill coolant liquid up to the filling edge of the filler plug (Fig. 42/3).

7. Position the gasket and check for correct fit.

8. Insert the screw plug (Fig. 42/2) and tighten Appendix B ‘Tightening torques for screws’ on page 137.

8.4.3 Checking for leaks








4. Check all lines and the base for leaks.

5. If there is coolant liquid in the system, remove it.

6. Check the connectors of the components and tighten the screws Appendix B ‘Tightening torques for screws’ on page 137.


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8.4.4 Checking the compressor temperature



NOTICE! Property damage to to compressor temperature that is too low or too high! A compressor temperature that is too low or too high can cause damage to the screw compressor. - Contact the manufacturer for more precise

information, for contact information see page 2.

- The compressor temperature should be between 70 °C and 100 °C.

- At 105 °C a warning is output. - At 110 °C the screw compressor is switched off

automatically.

1. Check compressor temperature Chapter 7.4 ‘Controllers’ on page 78.


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8.4.5 Checking soiling of the cooler


Protective equipment: Safety boots Protective work clothing Light respiratory protection

Safety goggles

Protective gloves




4. Check compressed air and coolant liquid cooler from inside and outside for soiling.

5. Remove soiling.

Soiling can be removed by blowing it out, e.g. While doing this, make sure that the soiling from the device is blown out of rather than into the machine. In case of severe soiling, consult the manufacturer.


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8.4.6 Checking the condensation accumulation

A sufficiently high compressor temperature guarantees that the humidity taken in will not become condensate. Frequent switching on and off of the screw compressor can cause the compressor not to reach the required operating temperature.




Protective gloves

NOTICE! Property damage due to condensation in the coolant liquid circuit! Condensate in the coolant liquid circuit can cause the destruction of the compressor stage. - In case of condensate in the coolant liquid pressure

tank, contact our service immediately; see page 2 for the contact data.





Condensate is heavier than the coolant liquid Since the condensate is heavier than the coolant liquid, after longer downtimes, it collects on the bottom of the coolant liquid pressure tank.


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Fig. 43: Coolant liquid drain

5. Carefully open the coolant liquid drain (Fig. 43/1) and check the liquid escaping.

6. Slowly drain condensate until coolant liquid escapes.

7. Close Appendix B ‘Tightening torques for screws’ on page 137 the coolant liquid drain (Fig. 43/1).

8. Switch on the compressor and switch off again after a maximum of one minute Controller documentation.

9. Check coolant liquid level and top up if necessary Chapter 8.4.2 ‘Checking the coolant liquid level/topping up the coolant liquid’ on page 109.

8.4.7 Changing the coolant liquid/changing the cooling liquid filter

Changing the coolant liquid Personnel: Qualified personnel




Materials: Collecting tray for coolant liquid Funnel with filling tool






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Fig. 44: Filler plug

5. Loosen the filler plug (Fig. 44/1), remove and make sure that the gasket does not get lost.

Fig. 45: Coolant liquid drain

6. Open the coolant liquid drain (Fig. 45/1).

Coolant liquid is drained.

7. Close the coolant liquid drain (Fig. 45/1).


data.

Fig. 46: Filler plugs

8. With the help of a funnel (Fig. 46/1), fill coolant liquid up to the filling edge of the filler plug (Fig. 46/3).

9. Position the gasket and check for correct fit.

10. Insert the screw plug (Fig. 46/2) and tighten Appendix B ‘Tightening torques for screws’ on page 137.

11. Switch on the compressor and switch off again after a maximum of one minute Chapter 7.4 ‘Controllers’ on page 78.



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Changing the coolant liquid filter* Personnel: Qualified personnel



Protective gloves

Materials: Collecting tray for coolant liquid Strap spanner





Fig. 47: Remove coolant liquid filter

5. Using the strap spanner, loosen and remove the old coolant liquid filter (Fig. 47/1).

6. Remove old gasket remains from the coolant liquid filter housing.

7. Moisten the new gasket with a little coolant liquid.

8. Screw in the new coolant liquid filter (Fig. 47/1) up to the stop.

9. Tighten the new coolant liquid filter (Fig. 47/1) half a turn by hand.

10. Switch on the compressor and switch off again after a maximum of one minute Chapter 7.4 ‘Controllers’ on page 78.



Maintenance

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8.4.8 Re-lubricating the electric motor

Personnel:

Protective equipment:

Materials:

Qualified personnel

Safety boots Protective work clothing Light respiratory protection

Safety goggles

Protective gloves

Lubrication grease ALMiG part number 183.00103

If there is no grease nipple on the electric motor, this has encapsulated, permanently-lubricated bearings. Replace these motor bearings when worn.


2. Close compressed air network-side gate valve and secureagainst re-opening.

3. Open and remove the sound insulation covers with the specialspanner.

4. For the quantity of lubricating grease, consult the type plate of the electric motor.

The grease nipples are always on the side of the terminal box.

Fig. 48: Grease nipples

5. Grease the grease nipples (Fig. 48/1) with a grease gun.


Maintenance

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8.4.9 Change fine precipitator



Safety goggles

Protective gloves

Materials: Strap spanner





Fig. 49: Loosen fine precipitator

5. Using the strap spanner (Fig. 49/2), loosen and remove the fine precipitator (Fig. 49/1).

6. Remove old gasket remains from the fine precipitator (Fig. 49/1).

7. Moisten the new gasket with a little coolant liquid.

Fig. 50: Fine precipitator

8. Screw in the new fine precipitator (Fig. 50/1) up to the stop.

9. Tighten the new fine precipitator (Fig. 50/1) half a turn by hand.


Maintenance

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8.4.10 Change intake filter

Standard intake filter Personnel: Qualified personnel



Safety goggles

Protective gloves




Fig. 51: Loosen the clamp of the intake filter

4. Loosen the intake filter (Fig. 51/2).

5. Remove the old intake filter (Fig. 51/1).

6. Attach the new intake filter (Fig. 51/1).

7. Tighten the clamp of the intake filter (Fig. 51/2) Appendix B ‘Tightening torques for screws’ on page 137.


Maintenance

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8.4.11 Checking the drive unit



Safety goggles

Protective gloves




4. Visually check the drive unit.

In case of visible defects, contact the manufacturer.

8.5 Measures after maintenance has been performed After completion of the maintenance work and before switching the

machine on, carry out the following steps:

1. Check all previously-loosened screw connections to make sure they are tight.

2. Check whether all previously-removed protective equipment and covers have been replaced properly.

3. Ensure that all tools, materials and other equipment used has been removed from the work area.

4. Carefully open the compressed air network-side gate valve.

5. Clean the work area and remove any substances such as liquids, processing material or similar that may have escaped.

6. Ensure that all safety equipment on the machine functions perfectly.

7. Document work on the machine in the service manual ( Appendix C ‘Service manual’ on page 138).


Faults

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9 Faults

The following section describes possible causes of faults and the work to remedy them.

In case of faults that occur more than once, abbreviate the maintenance intervals according to the actual utilisation.

In case of faults that cannot be remedied using the following instructions, contact the manufacturer, see contact data on page 2.

9.1 Safety instructions for fault clearance

Electrical system

DANGER! Danger to life from electric power! Contact with live parts may prove fatal. When switched on, electric components may be subject to uncontrolled movements and may cause grave injury. - Switch off the power supply before starting work and


Hot surfaces





WARNING! Danger to life from an unauthorised restart! In the event of an unauthorised restart of the power supply while tracking down and rectifying a fault, there is a danger of serious injuries or death for persons in the danger zone. - Switch off all power supplies before starting work and



Faults

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Improperly executed troubleshooting work

WARNING! Danger of injury from improper troubleshooting! Improperly executed troubleshooting work may result in serious injury and significant damage to property. - Ensure sufficient assembly space before starting

work. - Pay attention to orderliness and cleanliness in the

assembly location! Loosely stacked or scattered components and tools could cause accidents.

- If components have been removed, pay attention to correct assembly, refit all fixing elements and comply with bolt tightening torques.

- Before the restart, ensure that - all troubleshooting work has been carried out and

completed in accordance with the information and instructions in this manual.

- no persons are in the danger zone. - all covers and safety devices are installed and

functioning properly.

Compressed air






Faults

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Coolant liquid fog



Behaviour in the event of faults The following applies in principle:

1. Immediately initiate an emergency stop in the event of faults posing an immediate danger to people or property.

2. Ascertain the cause of the fault.

3. If fault rectification requires work in the danger zone, shut down the machine and secure to prevent restarting.

Immediately notify those responsible at the place of use about the fault.

4. Depending on the nature of the fault, have it rectified by authorised specialised personnel or rectify it yourself.

The fault table below provides information about who is authorised to rectify the fault.

9.2 Fault displays Refer to the controller documentation for information on fault

displays.


Faults

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9.3 Fault table

Fault description Cause Remedy Personnel

Compressor temperature too high (red lamp lights up)

Intake or ambient temperature too high

Ventilate compressor room

Qualified personnel

Cooling air intake or outlet blocked

Unblock cooling air intake or outlet sufficiently

Qualified personnel

Coolant liquid is soiled Change coolant liquid Chapter 8.4.7 ‘Changing the coolant liquid/changing the cooling liquid filter’ on page 115

Qualified personnel

Coolant liquid low Top up coolant liquid Chapter 8.4.2 ‘Checking the coolant liquid level/topping up the coolant liquid’ on page 109

Qualified personnel

Coolant liquid cooler soiled

Clean coolant liquid cooler Chapter 8.4.5 ‘Checking soiling of the cooler’ on page 113

Qualified personnel

Network pressure drops

Compressed air consumption higher than delivery quantity of the screw compressor

Screw compressor with greater delivery quantity necessary

Manufacturer

Intake filter soiled Replace intake filter Chapter 8.4.10 ‘Change intake filter’ on page 120

Qualified personnel

Bleeder valve blows during compression

Check bleeder valve and replace gaskets if necessary

Manufacturer

Intake regulator does not open

Check magnet valve and plunger and replace if necessary

Manufacturer

Leaks in the compressed air network

Seal up the compressed air network

Qualified personnel


Faults

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Screw compressor blows via safety valve

Minimum pressure valve blocked

Clean or replace minimum pressure valve

Manufacturer

Safety valve faulty Check safety valve and replace if necessary

Manufacturer

Fine precipitator soiled Change fine precipitator Chapter 8.4.9 ‘Change fine precipitator’ on page 119

Qualified personnel

"Overpressure fault "or "Network pressure too high" (red lamp lights up)

Fine precipitator soiled Change fine precipitator Chapter 8.4.9 ‘Change fine precipitator’ on page 119

Qualified personnel

Higher outside pressure present in compressed air network

Balance out outside pressure or disconnect from the network

Qualified personnel

Screw compressor does not start automatically or does not discharge after previous switching-off by reaching the final pressure or from idle.

Network pressure set too high

Reset network pressure Chapter 7.4 ‘Controllers’ on page 78

Trained Person

Interruption in the power circuit

Check power circuit for interruption


Ambient temperature below +1 °C, message "Coolant liquid temperature too low"

Install additional heating or temper compressor room and also contact the manufacturer

Qualified personnel

Switching times are activated in the circuitry

Check switching and pressure times in the circuitry Chapter 7.4 ‘Controllers’ on page 78

Trained Person


Faults

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System does not start up when the start key is pressed

Network pressure greater than switch-on pressure

Heed network pressure and change settings Chapter 7.4 ‘Controllers’ on page 78

Trained Person

Symbol "remote" flashes Remote control activated Chapter 7.4 ‘Controllers’ on page 78

Trained Person

Lacking voltage on the screw compressor

Check whether there is voltage


Electrical fault in the controller

Check controller Qualified electrician

Switching times are activated in the circuitry

Check switching and pressure times in the circuitry Chapter 7.4 ‘Controllers’ on page 78

Trained Person

Compressed air contains a lot of coolant liquid (coolant liquid consumption too high)

Return line for the coolant liquid is blocked

Clean or replace return line for the coolant liquid ‘Clean/change return line’ on page 128

Qualified personnel

Flawed fine precipitator Change fine precipitator Chapter 8.4.9 ‘Change fine precipitator’ on page 119

Qualified personnel

System stops before reaching the final pressure (red lamp lights up)

Overtemperature or overpressure

Eliminate fault Chapter 7.4 ‘Controllers’ on page 78

Trained Person

Interruption in the control power circuit

Check power circuit Qualified electrician

Pressure drop Pressure difference of the filter too high

Replace filter Qualified personnel


Faults

128 2015-07-21

9.4 Work for fault clearance

Clean/change return line Personnel: Qualified personnel








Fig. 52: return line

5.

Depending on the type, several fine precipitators can be installed. There is a return line for each fine precipitator.

Loosen return line (Fig. 52/2) on separator box (Fig. 52/3) and compressor stage (Fig. 52/1).

6. Clean return line (Fig. 52/2) and nozzle, if necessary replace with original spare parts ( Appendix D ‘Spare parts list’ on page 142).

7. Put nozzle and return line (Fig. 52/2) back in position and tighten screws ( Appendix B ‘Tightening torques for screws’ on page 137).

9.5 Commissioning after remedied fault After remedying the fault, carry out the following steps for re-

commissioning:

1. Reset emergency stop equipment.

2. Acknowledge fault Controller documentation.

3. no persons are in the danger zone.

4. Start the screw compressor Controller documentation.


Dismantling and disposal

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10 Dismantling and disposal

Following the end of its useful life, the machine must be dismantled and disposed of in accordance with the environmental regulations.

10.1 Safety instructions for dismantling and disposal

Electrical system

DANGER! Danger to life from electric power! Contact with live parts may prove fatal. When switched on, electric components may be subject to uncontrolled movements and may cause grave injury. - Before starting the dismantling, switch off the electric

power supply and disconnect completely.

Improper dismantling

WARNING! Danger of injury due to improper dismantling! Stored residual energy, angular components, points and edges on or in the machine or on the tools needed can cause injuries. - Ensure sufficient space before starting work. - Handle exposed, sharp-edged components with care. - Pay attention to orderliness and cleanliness in the

workplace! Loosely stacked or scattered components and tools could cause accidents.

- Dismantle the components properly. Note that some components may have a high intrinsic weight. Use hoists if necessary.

- Secure components so that they cannot fall down or topple over.

- Consult the manufacturer if in doubt.


Dismantling and disposal

130 2015-07-21

10.2 Dismantling Before starting dismantling:

Shut down the machine and secure to prevent restarting.

Physically disconnect the power supply from the machine; discharge stored residual energy.

Remove consumables, auxiliary materials and other processing materials and dispose of in accordance with the environmental regulations.

Then clean assemblies and parts properly and dismantle in compliance with applicable local occupational safety and environmental protection regulations.

10.3 Disposal If no return or disposal agreement has been made, send the

dismantled components for recycling. Scrap metals.

Send plastic elements for recycling.

Sort and dispose of other components in accordance with their material composition.

NOTICE! Danger to the environment due to incorrect disposal! Incorrect disposal may pose risks to the environment. - Electrical scrap, electronic components, lubricants

and other auxiliary materials must be disposed of by authorised specialist companies.

- If in doubt, obtain information about disposal in accordance with the environmental regulations from the local municipal authorities or specialised waste disposal companies.


Index

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11 Index

A

Accident .............................................................. 27 Air Control AC mini controller ............................. 81

Acknowledging fault messages ...................... 99

Acknowledging faults ...................................... 99

Acknowledging warning messages ............... 101 Basic display ................................................... 83

Brief description .............................................. 82

Calling up information ..................................... 84 Calling up parameter values ........................... 84

Calling up the code input menu ...................... 86

Code 11........................................................... 92

Code 18........................................................... 94 Code 2............................................................. 87

Code 3............................................................. 89

Code 6 ............................................................. 90

Code 8............................................................. 91 Code 90........................................................... 95

Code 95........................................................... 96

Code 9999 ...................................................... 97

Dew-point monitoring ....................................... 90 Display ............................................................ 83

Display the software version ........................... 97

Fault messages ............................................... 98

Faults .............................................................. 98 Inputting a code .............................................. 86

Maximum operating cycles ............................. 88

Maximum pressure drop ................................. 88

Operating modes ............................................ 82 Other display indicators .................................. 83

Overview ......................................................... 81

Safety pressure ............................................... 82

Select operating mode .................................... 87 Set Basic load switching mode ....................... 94

Set on-site operation/remote operation .......... 91

Set switch on/off pressure ............................... 92

Setting parameters .......................................... 86 Switch automatic restart on/off ........................ 89

Switch the temperature unit ............................ 96

Switching off .................................................... 84

Switching on .................................................... 84 Switching the pressure unit ............................. 95

Warning messages ....................................... 100

Warnings ....................................................... 100 Assemblies

COMBI drive unit ............................................. 53 Compressed air after-cooler ........................... 56

Controller ......................................................... 51 Coolant liquid cooler ........................................ 56

Cooler .............................................................. 56

Cooling air fan ................................................. 57

Fresh air fan .................................................... 57 Heat exchanger ............................................... 56

Water cooling .................................................. 56

B

Brief description .................................................. 50

C

Change

coolant liquid ................................................. 115

coolant liquid filter ......................................... 115

fine precipitator .............................................. 119 return line ...................................................... 128

Change intake filter ........................................... 120

Checking

the coolant liquid level ............................. 70, 109 Checking for leaks ............................................ 111

Checking soiling of the cooler ........................... 113

Checking the condensation accumulation ........ 114

Checking the temperature ................................ 112


Index

132 2015-07-21

Clean

return line ......................................................128

Components Compressor stage ...........................................54

Coolant liquid drain .........................................54

Coolant liquid filter ...........................................56

Coolant liquid pressure tank ............................54 Filler plugs .......................................................54

Fine precipitator ..............................................55

Inspection glass ..............................................54 Intake filter .......................................................53

Minimum pressure and return valve ................55

Refrigerant-type dryer .....................................57

Safety valve .....................................................54 Sound insulation covers ..................................52

Compressor stage ..............................................54

Connecting air .....................................................68

Connecting compressed air ................................68 Connecting the current .......................................69

Connecting the power supply .............................69

Connection values

COMBI 16 – 22 electric ...................................45 COMBI 16 –22 air supply ................................45

COMBI 3S – 5S air supply ..............................35

COMBI 3S – 5S electric ..................................35

COMBI 6 – 15 air supply .................................41 COMBI 6 – 15 electric .....................................41

Consumables

COMBI 16 – 22................................................46

COMBI 6 – 15..................................................42 Contact person....................................................10

Controller ............................................................51

Controller COMBI 3S – 4S

Overview .........................................................78 Switching off ....................................................79

Switching on ....................................................79

Controller COMBI 5S

Overview .........................................................80

Switching on ................................................... 80

Coolant liquid ..................................................... 33

Start-up lubrication ......................................... 71 Coolant liquid filter ............................................. 56

Coolant liquid pressure tank .............................. 54

Cooler ................................................................. 56

Cooling air fan .................................................... 57 Copyright ............................................................ 10

Customer service ............................................... 10

D

Description of function ....................................... 50

Dismantling ...................................................... 130 Disposal ........................................................... 130 Drive

COMBI ............................................................ 53

Drive unit .................................................... 53, 121

E

Electric current ................................................... 17

Emergency ......................................................... 76 Emergency stop ................................................. 76

Emergency stop key .......................................... 23

Emissions ........................................................... 32

Environmental protection Coolant liquid .................................................. 28

Lubricants ....................................................... 28

F

Fault

Return line .................................................... 128

Fault displays ................................................... 124

Fault messages .................................................. 98 Acknowledging ............................................... 99

Fault table ........................................................ 125

Fine precipitator ................................................. 55

Fire ..................................................................... 27 First aid .............................................................. 27

Forced ventilation and bleeding ......................... 68


Index

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G

General details

COMBI 16 – 22 ............................................... 43 COMBI 3S –5S ............................................... 33

COMBI 6 – 15 ................................................. 37

I Inspection at delivery .......................................... 60

Installation

Forced ventilation and bleeding ...................... 68 Ventilation ....................................................... 67

Installation conditions ......................................... 66

Installation location ............................................. 66

Intake filter .......................................................... 53 Interfaces ............................................................ 58

Air supply ........................................................ 59

Compressed air connection ............................ 59

Media .............................................................. 58

L

Liquid stream ...................................................... 19 Lubricants

COMBI 3S – 5S .............................................. 36

M

Main switch ......................................................... 23

Maintenance

Change coolant liquid filter* .......................... 115

Change fine precipitator ................................ 119 Change intake filter ....................................... 120

Checking for leaks ........................................ 111

Checking soiling of the cooler ....................... 113

Checking the compressor temperature ......... 112 Checking the condensation accumulation .... 114

Checking the coolant liquid level .................. 109

Checking the drive unit ................................. 121

Coolant liquid change ................................... 115 Re-lubricating the electric motor ................... 118

Replace coolant liquid ................................... 115

Replace coolant liquid filter ........................... 115

Top up coolant liquid ..................................... 109 Minimum pressure and return valve ................... 55

N

Noise emissions .................................................. 32

O

Operating conditions ...............................36, 42, 46 Overview

Assemblies ...................................................... 48

COMBI 3S – 5S ............................................... 47

COMBI 6 – 22 ................................................. 47 Owner ................................................................. 12

P

Packaging ........................................................... 61 Personnel ............................................................ 13

Proper use .......................................................... 11

Protective equipment .......................................... 15

R

Refrigerant-type dryer ......................................... 57

Re-lubricating the electric motor ....................... 118 Replace

coolant liquid ................................................. 115

coolant liquid filter ......................................... 115

Rescue measures ............................................... 76

S

Safety General............................................................ 11

Safety devices .................................................... 22

Safety valves ...................................................... 24

Service ................................................................ 10 Service manual ................................................. 139

Signs ................................................................... 29

Sound insulation covers...................................... 52


Index

134 2015-07-21

Spare parts .......................................................105

Starting up compressed air generation ...............72

Start-up lubrication ..............................................71 Storage ...............................................................63

Switching on after the initial commissioning .......72

Symbols

in this manual .................................................... 8 on the machine ................................................30

on the packaging .............................................62

T

Top up

coolant liquid .................................................109

Transport .............................................................62 Type plate ...........................................................32

U

Use ..................................................................... 11

V

Ventilation .......................................................... 67

W

Warning messages .......................................... 100

Acknowledging ............................................. 101

Warranty terms .................................................. 10 Working after the initial commissioning ............. 73


Appendix

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12 Appendix


Training log

136 2015-07-21

A Training log

Date Name Type of training Training conducted by

Signature


Tightening torques for screws

2015-07-21 137

B Tightening torques for screws


Service manual

138 2015-07-21

C Service manual

Compressor type:

System number: Please specify in case of inquiries, orders and correspondence.

Motor number:

Pressure tank number:

Date of commissioning:

Your ALMiG customer service:


Service manual

2015-07-21 139

Daily checks Weekly checks

Hours of operation

Coolant liquid level

Leakage Compressor temperature

Cooler soiling

Condensate accumulation

Clean intake filter mats

Date Name


Service manual

140 2015-07-21

Coolant liquid change Filter change

(coolant liquid filter / intake filter / fine precipitator)

Hours of operation

Date Name Hours of operation

Date Filter type Name


Service manual

2015-07-21 141

Additional maintenance and repair work

Hours of operation

Date Spare parts Name


Spare parts list

142 2015-07-21

D Spare parts list

Spare parts list The spare parts list is included with the documents.

ALMiG Kompressoren GmbH

Adolf-Ehmann-Straße 2

73257 Köngen

Phone +49 7024 9614 0

Email [email protected]

Internet www.almig.de

ArtNo. 195. 03276REV06_gb

mailto:[email protected]

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