Huong Dan Su Dung May Nen Khi AIR CONTROL 3 PDF

Operating manual
ALLEGRO 30 - 210
2001
All rights belong to:
Alup Kompressoren GmbH
Adolf-Ehmann-Strae 2
73257 Kngen
Tel.: ++49 (0) 7024 / 8020
Fax: ++49 (0) 7024 / 8050
No part of this manual may be duplicated by mechanical or electronic means
without the express written permission from Alup Compressors GmbH.
All particulars in this manual are specified to our best knowledge, but without
guarantee.
We reserve the right to make changes to information on hardware and
firmware documentation at any time without previous announcement.
We are thankful for any criticism and suggestions.
Table of contents
1. Safety instructions .............................................. 4
1.1
1.3
1.4
5.3.4.10 Sub-menu Accessories ............ 30

5.3.5 Warnings / service work ................... 32
5.3.6 Malfunctions .................................... 33
Symbols in this manual ................................ 4

Qualified personnel ...................................... 5
General safety instructions ........................... 6
6. Correcting malfunctions ................................... 34
2. Functional description ........................................ 8
7. Initial commissioning ....................................... 36
3. Storage and transport ....................................... 10

4. Installation ......................................................... 12
4.1
4.2
4.3
4.4
4.5
4.6
4.7
Setting up ................................................... 12
Ventilation .................................................. 12
Forced ventilation (optional) ....................... 13
Water cooling (optional) .............................. 14
Heat recovery for heating water / potable
water (optional) .......................................... 14
Connection to the compressed air grid ....... 15
Electrical connections ................................. 15
5. Displays and operating elements .................... 16

5.1
5.2
5.3
Plant main switch ....................................... 16

Emergency OFF ......................................... 16
Air Control 3 ............................................... 17
5.3.1 Basic display ................................... 18
5.3.2 ON/OFF switching of compressed air
generation ....................................... 18
5.3.3 Function key reservation in the basic
display ............................................. 18
5.3.3.1 Capacity utilization .................. 19
5.3.3.2 Service .................................... 20
5.3.3.3 Plant pass ............................... 20
5.3.3.4 Diagram grid pressure ............. 21
5.3.3.5 Diagram compression end
temperature ............................. 21
5.3.3.6 Diagram compressed air amount /
day profile ............................... 21
5.3.3.7 Diagram compressed air amounts
/ week profile ........................... 21
5.3.3.8 Modify diagram settings ........... 22
5.3.4 Menu system ................................... 23
5.3.4.1 Sub-menu Limit values ............ 24
5.3.4.2 Sub-menu
Operating parameters.............. 24
5.3.4.3 Sub-menu
Service intervals ...................... 25
5.3.4.4 Sub-menu Timer ...................... 26
5.3.4.5 Sub-menu Malfunction storage 28
5.3.4.6 Sub-menu
Display parameter ................... 28
5.3.4.7 Sub-menu
Configuration ........................... 29
5.3.4.8 Sub-menu
Communication ....................... 30
5.3.4.9 Sub-menu
Base Load Switching (BLS) ..... 30
7.1
7.2
7.3
7.4
7.5
7.6
7.7
Preparatory activities .................................. 36

Check coolant
level ........................................................... 36
Start-up lubrication of the compressor stage 36
Rotational direction control ......................... 37
Basic settings ............................................. 38
7.5.1 Control system of the system with Air
Control 3 ......................................... 38
Switch on compressed air generation ......... 39
Concluding activities ................................... 39
8. Service ............................................................... 40
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11
8.12
8.13
8.14
Overview
Service intervals ......................................... 40
Preparatory activities .................................. 40
Check coolant level / refill coolant ............... 41
Check for leakage ...................................... 41
Check the compressor temperature ............ 41
Check the cooler for fouling ........................ 42
Check for condensate development ........... 42
Coolant replacement / replacing coolant filter
43
Replacing coolant separator ....................... 44
Replacing air filter ....................................... 44
Check safety valve ..................................... 44
Check clutch element ................................. 45
Relubrication of the electric motor ............... 45
Concluding activities ................................... 45
9. Technical Data ................................................... 46

9.1
9.2
9.3
9.4
Dimensions for connections ....................... 46

Data air-cooled compressors ...................... 47
Data water-cooled compressors ................. 47
Electrical data ............................................ 47
1. Safety instructions
Safety instructions
You are reading this manual in order to learn about the screw compressor.
It contains information that is required for safe, malfunction-free operation
of the system. Please keep in mind that damages incurred due to improper
usage may not fall under the conditions of guarantee!
For this reason, please keep this manual where all users can have free
access to it at any time.
The system was developed, manufactured, tested, and documented in stateof-the-art technology and considering all the current safety norms.
In normal circumstances, no danger for personnel or property can result
from the system if you comply with the stipulations of the service manual
and if the transport, assembly, service and the described handling is carried out according to the regulations.
1.1
Symbols in this manual
Nevertheless certain risks remain!
This symbol is employed whenever personal damage can be incurred

by carelessness, or by ignoring the instructions.
DANGER
This symbol is employed when damage to property can occur through

carelessness, or by ignoring the instructions.
NOTICE
Italic text is employed when we would like to draw your attention to particular information.
4
Text in a frame signifies the description of an activity to be carried out by

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

the generation of compressed air and
for operation in a non-explosion-endangered environment.
Any other utilization must be regarded as not in compliance with the design
purpose!
The manufacturer/vendor is fundamentally not liable for damages incurred
if the system is not used according to its design purpose!
The generated compressed air may not be used for human respiration. In
case the compressed air is used for pharmaceutical or sanitary purposes, it
must undergo further treatment. The same is true when the compressed air
is used in production plants and comes into direct contact with foodstuffs.
1.3
Qualified personnel
This manual is directed to qualified personnel, who are commissioned

with the transport, installation, operation or service of the system. These
individuals must read the chapter relevant to their duties.
Qualified personnel are individuals who:
upon the basis of their professional training, knowledge and experience

as well as their understanding of the relevant norms can assess the
work to be carried out with regard to all possible dangers, or
based on many years of activity in a comparable field, have the same

state of knowledge as someone with professional training.
Activities that are not described in this manual may only be carried out by
our customer service department or by authorized technical personnel.
Unqualified actions or disregarding the warnings in this manual or those

affixed to the product can lead to serious damage to persons and to material!
5
1. Safety instructions
1.4
General safety instructions
Loss or decrease of plant safety !
DANGER
Retrofitting or modifications on the system can reduce its level of safety! The results could be serious personal, material or environmental
damage. Possible retrofitting or modifications on the system with
equipment components from third party manufacturers must therefore first be cleared by us.
Loss of protection from contact to hazardous zones!
DANGER
The side panelings of the system are a part of the contact protection
system to protect personnel from ventilator wheels that start up automatically, moving machine parts, hot surfaces and dangerous voltages! Furthermore, they are required for sound insulation for the cooling air conduction. Therefore they may not be removed in the normal
operating mode of the system.
Injuries caused by ventilator wheels that start automatically, moving

machine parts, hot surfaces or escaping coolant mist!
DANGER
Installation, service or repair work on the components of the system

must, if not otherwise described, be categorically carried out only on
a switched-off, sufficiently cooled-off and pressure-free system! The
system must be secured against an illicit or accidental switching-on.
The shut-off device for the compressed air grid must be closed.
If measuring or testing work is required on the electrical components
while the system is in operation, they must be carried out by electricians observing all the relevant safety regulations.
Damage to the sense organs!
DANGER
Compressed air streams may not be directed towards persons. When

applying compressed air, dust particles can be raised by the air stream. Therefore, when working with compressed air, protect your eyes
with safety glasses.
Loss or decrease of plant dependability!

Only original spare parts and lubrications may be employed!
NOTICE
We recommend that a set of service parts subject to wear be kept on

stock, in order to guarantee high plant availability. Our customer service would be glad to help you with your selection. Tel: (+49) 0180
5258700.
Damage to the system may result in environmental damage!

Before the initial commissioning, the system must have been correctly installed according to Chapter 6!
NOTICE
Plants greater than 100 kW may be taken into operation by qualified

personnel.
Dispose of all used or defective materials in a proper way!
This is especially true for components/materials containing cooling
liquid. Please note that the accumulated condensation containing cooling liquid may not enter the sewerage system!
We offer an appropriate coolant/water separator for condensation processing.
Compressed air receivers require regular technical inspections!

Please notify the commissioning of the system at the technical inspection
authority responsible for you. They will inspect the system and provide a
receiver test book.
Document all the activities carried out (e.g. in some table format).
7
Carry out the activities in all of the following chapters in the order given.
2. Functional description
2.1
Drive
The frequency converter in the switching cabinet supplies the electric motor with power. For the operating principle of the frequency converter, please
refer to the instructions in the switching cabinet.
The electric motor drives the compressor stage via a flexibly supported
coupling.
2.2
Air path
Fresh air supplied by the integrated cooling air ventilator is filtered through
the intake filter(s). The air is then directed via the intake regulator into the
compressor stage, where it is compressed to the final compression pressure together with injected coolant.
In the coolant reservoir, the compressed air is separated 98 % from the
cooland and the downstream coolant separator removes the remaining
coolant from the compressed air. The air then flows via the minimum pressure one way valve into the compressed air aftercooler and is cooled down
to 10 - 15 C above the ambient temperature before it leaves the compressor through the compressed air port.
The intake regulator opens shortly after the compressor has started up for
generating compressed air. It closes when the compressor changes over
to off-load operation and/or comes to a standstill and unloads the system
via the relief valve.
2.3
Coolant circulation
The coolant is sprayed into the compression stage and has the following
functions:
heat removal of the temperature increase caused by the compression

process
sealing lubrication of the rotors to each other and to the housing with a
coolant film
bearing lubrication
noise dampening
The coolant leaves the compression stage together with the compressed
air as a hot coolant return air mixture.
The coolant is separated from the compressed air into the coolant container by the coolant separator and when separated, it streams to the coolant heat exchanger. The coolant temperature regulator mixes the cooled
down coolant with the coolant heat exchanger-bypass hot coolant as defined by the setpoint temperature. Lastly, the coolant filter cleans the coolant, before it is again injected in the compression stage.
If desired by the customer, an additional heater can be installed in the

coolant container either originally or subsequent to purchase. It prevents
condensation damages in the case ofcold or damp compressor plant environments, for example.
2.4
Cooling
The compressed air after-cooler of the coolant heat exchanger is cooled

either by
a built-in cooling air ventilator or
water cooling.
The electric motor is always cooled by its own ventilator fan.

In the case of water-cooled compressors, a fresh air ventilator additionally
ensures sufficient fresh intake air for the removal of radiated heat.
2.5 Flow diagram
14
02
20
M
03
PD 1
08
PS
13
12
04
06
07
05
11
PI
15
16
22
PD2
23
21
19
26
09
28
27
24
25
18
17
2.6
01
Components
20
02
04
05
15
06
01
12
07
08
10
19
2.7
Legend
01 Switching cabinet
02 Electric motor
03 Clutch
04 Intake filter
05 Intake regulator
06 Compressor level
07 Coolant container
08 Safety valve
09 Drain
10 Inlet fitting
11 Additional heater (optional)
12 Coolant separator
13 Minimum pressure one-way
valve
14 Relief valve
15 Compressed air after-cooler

16 Compressed air connection
17 Coolant cooler
18 Coolant temperature regulator
19 Coolant filter
20 Cooling air ventilator
21 Cooling water inlet
22 Throttle valve compressed air
after-cooler
23 Magnet valve
24 HCR water inlet
25 HCR heat exchanger
26 HCR thermostat
27 HCR water outlet
28 HCR thermostat valve
3. Storage and transport
For measurements and weights, see Chapter 9.
Please store the system only in a dry, frost-free room.
Observe the local regulations and other requirements pertaining to

the professional use of tools, lifting and transport equipment, as well
as the valid norms and the regulations for accident prevention.
DANGER
Always transport the system in its normal operating orientation in a pressure-free state. Tilting or laying the system down is not allowed.
Use a fork-lift truck for transport. For short transportation distances, a

palette lifting trolley may be used.
10
11
4. Installation
4.1
Setting up
Install the system in locations with the following environmental conditions:

max. height above sea level:
1000 m
ambient temperature:
+5 to +40 C
ambient temperature for Version T:
+5 to +45 C
ambient conditions:
cool, dry, dust free
Space requirements and system weights are dependent on the plant type
purchased. Measurements and weights: see Chapter 9.
Always maintain the minimal clearances to the walls or other objects, so
that system service functions can be carried out without hindrance.
We recommend setting up the compressors in a separate compressor room.
Open flame or fire as well as welding work in the vicinity of the system
are forbidden!
DANGER
4.2
Ventilation
The air entering the intake opening is used for the compression as well as
for plant cooling.
The ventilation must fulfill at least the following criteria:
Supply required cooling air amounts as defined in Chapterd 9.2 and 9.3
Remove exhaust air as defined in Chapter 9 in order to prevent a heating up of the plant site
The cooling air must be cool, dry and dust-free

Make certain that the supply air contains no dangerous explosive gas
mixtures, steam, dust or aggressive pollutants.
12
Make certain that the setup site is dust-free as well as within the prescribed operating temperature limits and as cool as possible. If necessary,
ensure the professional installation of forced air ventilation, filtering, room
cooling or heating.
Make certain that the setup site is professionally ventilated.
NOTICE
Make certain that no circulating air short circuit (the intake of the
exhausted warm air) can occur.
Cooling air volume currents: see Chapter 9.
4.3
Forced ventilation (optional)
Forced ventilation must be dimensioned in such a way that the required

fresh and exhaust air, considering the available residual pressure of the
compressor ventilator, can be supplied and expelled.
Nominal diameters of the channel connections and information on the residual pressure : see Chapter 9.
If ventilation channels are to be connected to the system, then the required
supporting supplementary ventilators should be included when planning
the channels.
The exhaust air can also be utilized for the purpose of heat recovery.
13
4. Installation
4.4
Water cooling (optional)
For water-cooled plants, the temperature of the compressed air after-cooler

of the coolant heat exchanger is lowered with external cooling water.
12
13
PI
15
16
22
PD2
23
21
17
Cooling water amounts, temperatures and pressures: see Chapter 9.
The cooling water is to be connected to the defined connections (see drawing Chapter 9).
The cooling water must satisfy the following criteria:
inlet temperature less than +35 C
pressure 2.5 bar(o) to 10 bar(o)
pre-filtering with a mesh size of at least 0.1 mm
An electromagnetic valve (optional) should be installed before the cooling

water input.
The cooling water volume current through the compressed air after-cooler
should be set with the throttle valve belonging to it in such a way that the
compressed air outlet temperature is 15 C greater than the output air.
4.5
Heat recovery for heating

water / potable water (optional)
Plants can be supplied with the optional heat recovery system
for heating water or
for potable water (safety heat exchanger with blocking medium)
26
14
28
27
24
25
01
Water amounts, temperatures and pressures: see Chapter 9.

The heat recovery is to be connected appropriately (see drawing in Chapter
9) as defined.
The water for heat recovery must fill the following criteria:
pressure of up to 10 bar (over)
pre-filtering with a mesh size of at least 0.1 mm
4.6
Connection to the
compressed air grid
We assume the existence of a professionally designed, installed and serviced compressed air grid.
Install an additional shut-off valve at the input of the compressed
air grid.
Attach the system only with a flexible compressed air hose to the
compressed air grid. The length of the hose employed: max.1.5 m.
Unpredictable movements of the compressed air hose!
DANGER
4.7
Electrical connections
During load switching in the compressed air grid, the hose can move
suddenly and with great force. Therefore the hose must be adequately anchored or fixed.
The system is designed for connections to a three-phase supply network

(clockwise phase sequence). The mains supply contains professionally
dimensioned fuse protection devices (for human and plant system
protection), an appropriate mains switch (switching on/off of the supply
current) is required.
All the relevant data for the connections can be found
in Chapter 9
on the nameplate of the system.
Electrical voltage!
Only trained electricians may connect the system to the electrical supply network.
DANGER
Before making the connections based on the plant nameplate, determine
if the available supply network is adequate. Voltage deviations of larger
than 10 % are not allowed.
Mount the mains switch in the neighborhood of the plant. It must be easily
accessible at all times.
Lay the supply cables professionally. Make certain that the installation
cannot endanger individuals or property. Take into account the necessary
cable diameters, strain relief, and max. allowed cable lengths.
Connect the system according to the switching plan. The switching plan
is located in the control cabinet of the system.
Damage to the system is possible!

NOTICE
Before switching on compressed air generation, initial commissioning according to Chapter 6 must be correctly carried out!
Test the correct functioning of all safety facilities (protective grounding,

protective switch etc.).
Carefully lock the control cabinet after the connection work is completed.
15
5. Displays and operating elements

5.1
Plant main switch
The plant main switch connects or separates the system with the current
supply.
The plant main switch must be switched off for all service or installation work and protected from illicit or accidental switching on (e.g.
affix a warning sign to the main switch forbidding its being turned on)!
DANGER
5.2
Emergency OFF
The system may be stopped with EMERGENCY OFF in the case of a real
emergency!
Stop the motor in case of danger: press key.
Make sure that the shut-down system is sufficiently protected against
recommissioning!
DANGER
Enable the system only when the cause of danger has been professionally removed and a securely operating plant state is achieved.
Enable system:
1. pull key
2. switch main switch off and on.
16
3. press key
for the malfunction receipt.
4. press key
to switch the system on again.
5.3
Air Control 3
The operating / display desk of the Air Control 3
displays the plant states / operating data
switches on and off compressed air generation
is used for plant parameterizing.
F1 F2 F3 F4
Function keys
Modification of parameter values

Selection of sub-menus
Confirmation of parameter changes
Editing modes in the sub-menus
Display additional operation data.
Switch on compressor.
Integrated green LED
Blinking:
compressor is not running, can at any time

be automatically started up.
Lighted:
Compressor is running.
Compressor shut down.

Signals a current warning/malfunction with the integrated red
LED.
17
5. Displays and control elements

5.3.1 Basic display
After switching on the main switch or during normal operation, the Air Control
3 will inform you about the plant condition.
Momentary com-
Momentarily available grid pressure at com-
pression final tem-
pressed air output
perature
Service or malfunction messages with

service telephone number
Current reservation of the function keys
5.3.2 ON/OFF switching of

compressed air generation
Service type
Switching ON: press key
The compressor is ready and can start up automatically at any time.

Switching OFF: press key
For the duration of the standstill time, the compressor switches to the idling
state and afterwards off.
5.3.3 Function key reservation

in the basic display
In the basic display, the following informative pictures can be accessed

with the function keys:
Mode 1 = reservation 1
18
F1
Capacity
utilization
F2
F3
F4
Service
Plant pass
With the key

and
, the mode and therefore the reservation of the
function keys in the basic display can be changed.
Mode 2 = reservation 2
F1
F2
Diagram
grid pressure
F3
F4
Diagram
air amounts
daily profile
Diagram
compression
temperature
Diagram
air amounts
weekly profile
By pressing the defined function key, the respective information screen is

opened.
The key
5.3.3.1 Capacity utilization

(Mode 1 - F1)
Change of mode
5.3.3
F4
returns to the basic display from all information screens.
This diagram represents the operating run, full load run, idling run, and
standstill hours in the form of bar diagrams. The respective current hour
count is also displayed in the bars.
Example:
Total service hours

Load hours
Idling time hours
Standstill hours
With the exception of the idling time hours, all bars are represented from
the left and growing to the right. The sum of the load hours and the idling
time hours yields the total service hours.
The scaling units of this diagram are according to the service hours. If the
number of the standstill hours is larger than the service hours, the bars of
the standstill hours will be cut off. In this case note the displayed hour
count in the bars.
19

5.3.3.2 Service
(Mode 1 - F3)
Change of mode
The Service diagram shows the remaining residual time in hours until the
respective service interval is due.
5.3.3
Intake filter
Coolant filter
Coolant separator
Motor lubrication
Compressor
If the remaining residual time is less than 100 hours until the next service,
the respective bar begins to blink and a defined warning appears on the
display.
5.3.3.3 Plant pass

(Mode 1 - F4)
Change of mode
20
The individual machine data stored in the plant pass are required for our
customer service.
5.3.3
5.3.3.4 Diagram grid pressure

(Mode 2 - F1)
Change of mode
5.3.3
5.3.3.5 Diagram compression

end temperature
(Mode 2 - F2)
Change of mode
In this diagram, the current process of the compression end temperature is

displayed.
5.3.3
5.3.3.6 Diagram compressed air

amount / day profile
(Mode 2 - F3)
Change of mode
In this diagram, the current process of the grid pressures is displayed.
In this diagram, the current process of the compressed air-delivery amounts

for a day are displayed.
5.3.3
21
5.3.3.7 Diagram compressed air
amounts / week profile
(Mode 2 - F4)
Change of mode
5.3.3
In this diagram, the current process of the compressed air-delivery amounts

for a week are displayed.

5.3.3.8 Modify diagram settings
X-AUTO settings
The scale divisions of the axis can be changed by editing the axis values.
5.3.4.6
y-axis:
- The values of the y-axis can be changed in every diagram.

The data in the diagram are continually updated even after
the edit function.
x-axis:
- In the diagram air qty.wk., the x-axis values cannot be

changed, changes are possible in all other diagrams
- Editing the x-axis is only possible when the text X-AUTO
ON does not appear on the display. After editing the x-axis
values, the diagram is no longer continually updated.
X-AUTO:
- The key
F1
activates or deactivates X-AUTO
- If X-AUTO ON, the values of the x-axis are automatically

updated. The X-AUTO uses the preset default values defined in the menu Display parameter diagrams (see Chapter 5.3.4.6).The manual editing x-axis values are deleted.
Procedure for the scale division of the axis.

Axis value y-axis (Max)
Axis value y-axis (Min)
Axis value x-axis (time point 1)
Axis value x-axis (time point 2)
1. Selection of the axis values to be changed with the keys
and
2. Confirmation of the selection with ENTER

22
3. Modification of the blinking value with

Moving the cursor with
F1
and
F2
and
4. Confirmation of the modifications with ENTER.
The key F2 X/Y-Init is for resetting the scale division for the default values
preset in X-AUTO.
The key F3 ldeletes the recorded measurement values of the currently
displayed time diagram.
5.3.4 Menu system

Limit values
Operating parameters
Service intervals
Timer
Malfunction storage
Display parameter
Configuration
Communication
Base load switching
Accessories
5.3.4.1
5.3.4.2
5.3.4.3
5.3.4.4
5.3.4.5
5.3.4.6
5.3.4.7
5.3.4.8
5.3.4.9
5.3.4.10
All basic settings of the system can be viewed in the menu system. If the
modifications have no influence on operation safety, they may be modified
by means of a code entry.
After pressing the INFO key, the main menu appears requesting the code
entry.
Code 0000: View the basic settings
Code 0001: View and change basic settings
1. Modification of the blinking values with the keys

Moving the cursors with
F1
and
F2
and

Thereafter, the main menu appears with the following sub-menus:
The sub-menu can be selected with the keys

confirmed with ENTER.
In every operating level,
F4
and
.The selection is
will lead you to the next higher operating level.
If the Code 0001 is entered, the parameters of the sub-menu should be

changed as follows:
1. The selection of the desired menu position is carried out with the keys
and
.
2. The selection is confirmed with ENTER.
3. Modification of the blinking value with the keys
Moving the cursor with
F1
and
F2
and
23

5.3.4.1 Sub-menu Limit values
Selection of the menu position
Modification of the blinking values
ENTER Confirm selection/modification
F4
This menu contains the pressure / temperature limit values:

Switch-on pressure
Lower value for the pressure regulation
Can be edited
Switch-off pressure
Upper value for the pressure regulation
Can be edited
Safety pressure
Maximum permissible pressure for

malfunction triggering (always 0.8 bar
greater than switch-off pressure)
Display
Compression end
temperature min
Minimum permissible compression

end temperature
Display
Compression end
temperature max
Maximum permissible compression

end temperature
Display
Back to the next higher level
5.3.4.2 Sub-menu
Operating parameters
This menu contains parameters which influence the temporal regulation of

the compressor:

After-run time
After-run time of the motors in

automatic operation
Display
Standstill time
After-run time of the motor for manual

switching-off delay and for automatic
restart
Display
Run-up time
Run-up time
Display
Automatic
restart
Start after voltage return
Can be
edited
Operation mode:
Setting range:
Behavior on load switching

AUTOMATIC
LOAD/IDLING
AUTOMATIK OPT.
Can be
edited
Max. pressure drop
Maximum pressure drop
Display
Max. switching cycles

per hour
Maximum switching cycles of the motor Display

per hour
F4
Operation mode Automatic
24
The text AUTOMATIC is displayed in the basic display. After reaching the
switch-off pressure, the system goes into idling mode (after-run time) for
the duration of the after-run time and in the basic display; the text afterrun time appears with the respective residual time. At the conclusion of
the after-run time, the motor switches off. The compressor can be started
up automatically at any time after falling below the switch-on pressure.
Operation mode Load/Idling
The text LOAD/IDLING is displayed in the basic display. The compressor
switches between full load run and idling, which means that its after-run
time is unlimited.
Operation mode Automatic Optional

The text AUTOMATIC OPT. is displayed in the basic display. After reaching the switch-off pressure, the system goes into idling.
After 10 and after 40 seconds the grid pressure is measured.
If the pressure drops above the threshold Max. pressure drop, then the
system is in the idling state for the duration of the after-run time. In the
basic display, the text After run appears with the residual time as defined.
If the value lies below the threshold Max. pressure drop, then the system
switches off after completing the standstill time.
Max. switching cycles
If the number of the maximum possible switching cycles per hour for the
motors is exceeded, then the compressor temporarily switches to the operation mode load/idling.
5.3.4.3 Sub-menu
Service intervals
Service work acknowledged
5.3.5
In this menu, all service intervals are displayed, or acknowledged after

carrying out the specific service (see Chapter 5.3.5).
With the acknowledgement, the displayed residual time for the value of the
respective service intervals (see Chapter 8.1) is reset.
Service interval ASF
Service interval intake filter
Display
Service interval OLF
Service interval coolant filter
Display
Service interval OLAB
Services interval coolant

separator
Display
Service interval motor
Service interval for motor lubrication
Display
Service interval compr.
Service interval compressor
Display
Service hours
Total operating hours

(motor on)
Display
Load hours
Accumulated load hours
Display
Standstill hours
Accumulated standstill hours

(system on motor off)
Display
25

5.3.4.4 Sub-menu Timer
The adjustment of the integrated real-time clock, as well as all switching

processes dependant upon it are in this menu.
Date/time
Setting the current date

and time
Attention: The adjustment is entered
to the real-time clock when the
seconds are confirmed with ENTER
Edit
Compressor switching
times
Branch to the sub-menu
Edit
Compressor pressure
times
Edit
Switching times BLS
Edit
Pressure times BLS
Edit

F4
Switching times as well as pressure times can be programmed with the

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

In this menu, the switching on/off times of the compressors are defined.
Timer clock output active:

Mo - Th 6:00 until 20:00 oclock
Fr 6:00 until16:00 oclock
26
For the activation of the timer, the parameter of the timer channels must be
set to ON in the highest menu line.
If the timer channel is set to ON and
if the timer clock output is activated, a clock appears in the display
if the timer output is not activated, a blinking clock appears in the display
Seven switching times with the channels K1 K7 can be programmed.

A channel is active when at least one of the weekdays is marked black. In
order to continuously activate the timer output for one or a number of days,
the switching time should be set to 00:00.
Adjust switching times (weekdays marked black):

1. Channel selection with the keys
and
2. Confirm selection with ENTER.

3. Move the cursor to the desired weekday by selecting the key F1 and
F2 . (In order to delete an already selected weekday, press the key
.)
4. Set the cursor with F1 and F2 onto the clock time with the keys
to modify the blinking value.
and
5. Store the settings with the key ENTER.
If the timer for switching times is activated, then the compressor only
works during the switching times entered!
NOTICE
Compressor pressure times
In this menu, the pressure times of the compressors are defined (increasing
pressure / decreasing pressure).

Sa - So 0:00 until 24:00 oclock
(= from Sa 0:00 oclock until So
24:00 oclock)
In order to activate the timer, the uppermost menu row of the parameter for
the timer channels must be set to ON.
A channel is active when at least one of the weekdays is marked black.
(For switching times adjustment: see paragraph Compressor switching
times)
The channels are searched beginning with K1 to K7 to determine whetherr
a channel is activated for the current clock time. If no valid channel is found,
then the settings in the menu limit values are valid. In order to activate
the timer output for one or a number of days continuously, the switching
time of 00:00 should be entered.
Sw
witching times BLS /pressure times BLS
Switching times or pressure times can only be entered if the supplementary
module for Base Load Selective switching (BLS) is installed in the control
system.
The settings are to be carried out as described in Compressor switching
times or Compressor pressure times
27

5.3.4.5 Sub-menu Malfunction
storage
In this menu, the last 20 malfunctions are listed in order.
5.3.4.6 Sub-menu
Display parameter
In this menu, the parameters for the output to thedisplay are stored.

F4
Pressure unit
Selection of the unit for the display

of the grid pressure
Edit
Temperature unit
Selection of the unit for the display

of the compression final temperature
Edit
Language
Selection of the display language
Edit
Pressure offset
Readjustment possibility for the

grid pressure sensor
Display
Diagrams
Settings for diagrams
Edit
Texts
Texts for the plant pass
Display
Diagrams
In this menu, the display parameters (default values X-AUTO - see Chapter
5.3.3.8) for the diagrams can be set:
28
Storage interval
Storage interval for the recording of the grid pressure, the

compression final temperature of the momentary delivery
amounts. The control system always stores the most recent
8000 values. For a storage interval of 12s (basic setting)
there is a logging duration of 12s x 8000 = 96000s = 26.7h
Number of points
for X-Auto
Number of the recorded values for function X-Auto

On the time axis at a storage interval of 12 s amd up to 300
points for X-Auto a time axis scaling of 12s x 300 =3600s
=1h
Grid pressure
lower limit
Lower scale value of the x-axis of the diagram

Grid pressure (see 5.3.3.4)
Grid pressure
upper limit
Upper scale value of the x-axis of the diagram

Grid pressure (see 5.3.3.4)
Temperature
lower limit
Lower scale value of the x-axis of the diagram

Compression final temperature (see 5.3.3.5)
Temperature
upper limit
Upper scale value of the x-axis of the diagram

Compression final temperature (see 5.3.3.5) (basic setting
120 C)
Compressed air amt. day Lower scale value of the x-axis of the diagram
lower limit
Compressed air amounts daily profile (see 5.3.3.6)
Compressed air amt. day Upper scale value of the x-axis of the diagram
upper limit
Compressed air amounts daily profile (see 5.3.3.6)
Compressed air amt. week Lower scale value of the x-axis of the diagram
lower limit
Compressed air amounts weekly profile (see 5.3.3.7)
Compressed air amt. week Upper scale value of the x-axis of the diagram
upper limit
Compressed air amounts weekly profile (see 5.3.3.7)
5.3.4.7 Sub-menu
Configuration
F4
Plant type
Selection of a pre-defined
machine type.
Display
Maximum pressure
Maximum permissible machine pressure Display
Max. delivery amounts
Delivery amounts at maximum speed

in full load run
Display
Remote mode
Switching on/off of the system
Edit
BLS-operation
Operation with external base load

alternate switching
Edit
Low voltage Stop
Switching-off when low voltage

is recognized
Display
Analog output
Output module for the control module

of a frequency converter (if present)
Display
Heating/Ventilation
Temperature values for additional

heater or plant ventilator
Display
Remote mode
Determines how the compressor is switched on or switched off.
Local operation: The compressor can only be switched on or switched off
at the operating/display desk of the Air Control 3.
Remote control: The compressor can be switched on or switched off with
an electrical signal or the key 0. In the basic display appears as the blinking
text REMOTE.
During active remote operation, the signal of the remote control must
be switched off after pressing the key 0.
NOTICE
BLS OK: Is for the notification of the operation ready state of a superior
control system to the compressor. (see also BLS Operation 5.3.4.9)
BLS Operation
The control system of the compressors is carried out by a superior control
system. The text BLS OPER. (see also Remote Mode 5.3.4.9) appears in
the basic display
29

5.3.4.8 Sub-menu
Communication
5.3.4.9 Sub-menu
Base Load Switching
(BLS)
F4
This menu contains parameters for serial communication

RS485 Address
Participant address for RS484

communication
Display
RS485 Mode
Data exchange on the serial

interface
Display
This menu contains the settings for the operation as the BLS Master.
For the utilization of the function base load switching, the Air Control 3
must be fitted with
a supplementary module for up to 4 additional compressors
two supplementary modules for up to 8 additional compressors.
Base load switching
Parameter for the activation of the

BLS Master characteristics
(basic setting: NO)
Display
Switched-on pressure
Lower pressure threshold for

switching on a compressor
Edit
Switched-off pressure
Upper pressure threshold for

switching off a compressor
Edit
Switched-on dampening
Minimal time between the

switching on of two compressors
(basic setting:5 s)
Edit
Switched-off dampening
Minimal time between the

switching off of two compressors
(basic setting:2 s)
Edit
Replacing interval
Time between the additional

switching of the BLS (basic setting: 24 h)
Edit
Number of main
compressors
Number of compressors in the

main group
Edit
Number of reserve
compressors
Number of compressors in the

reserve group
Edit
(see also Chapter 5.3.4.7)

30
5.3.4.10 Sub-menu Accessories
This menu contains the settings for the connection of accessories. The Air
Control 3 must be fitted with the supplementary module accessories for
the utilization of these functions.
Accessory module
Supplementary module for accessories Display

available
Switching times output 1
Switching times defined for accessories 1
Edit
Edit
Edit
Edit
Input configuration
Configuration of the
accessories digital inputs
Edit
Switching times
The switching on/off times of an accessory relay output are defined in this
menu.

Mo - Th 8:00
until 18:00 oclock

Fr. 8:00 until 14:00 oclock
For the activation of the timer, the uppermost menu row of the parameter
of the timer channels must be set to ON.
Seven switching times can be programmed with the channels K1 K7.
One channel is active when at least one of the weekdays is marked black.
For adjustment of the switching times, see paragraph Compressor switching times Chapter 5.3.4.4.
In order to continually activate the timer output for one or a number of
days, set the switching time to 00:00.
Input configuration
The inputs 1 to 8 can be used in order to switch the compressor to malfunction or warning.
31

5.3.5 Warnings / service work
A warning is current when the red light is blinking.

The compressor is not switched off.
The display contains the additional information:
blinking symbol warning triangle
type of warning
telephone number of the service hotline
What to do for specific warnings/service work is described in Chapter 8.
Damage of the system is possible!

Necessary service work appear as warnings.
NOTICE
Acknowledge these warnings only when the defined service work has
actually been carried out!
Service work not carried out degrades the service life reliability of the
system. Please note that damages because of improper usage might
cancel the guarantee!
Only original spare parts may be used.
Information on service: see Chapter 8.
Services work acknowledged:
1. As described in Chapter 5.3.4, call up the main menu and then the submenu Service Interval.
32
2. Select the service work to be carried out with the keys
3. Press key
F3
and
to acknowledge the service.
4. By double clicking the key
F4
you will return to the basic display.
5.3.6 Malfunctions
A malfunction has occurred when the red light is permanently on.

The compressor is stopped automatically.
In addition, the display also shows:
blinking symbol tool key
type of malfunction
telephone number of the service hotline
Malfunctions can only be acknowledged when the cause has been professionally repaired. Error searches and repair should be done exclusively by
qualified personnel!
Malfunction messages acknowledged:
1. press key
2. press key
.
in order to restart the compressed air generation.
33
6. Correcting malfunctions
Error
Cause
Measures
Compression temperature
too high (red lamp is on)
- Silencing hood not closed
- Check and secure soundinsulation hood
- Intake or environmental
temperature too high
- Ventilate compressor room
- Cooling air inlet or outlet blocked

- Coolant filter fouled
- Coolant deficiency
- Outside coolant heat exchanger
fouled! A t t e n t i o n : Cooler
screw should always be
worked with a counter wrench;
keep from applying torque to
the cooler
Grid pressure falls
System pressure released on

safety valve
- Make sufficient room

- Renew coolant filter
- Add coolant
- Clean with compressed air. In the
case of extensive fouling:
disassemble cooler and clean
with high pressure cleaner.
Attention: Danger of short
circuit! Do not put electrical
elements under power
- Compressed air consumption

greater than delivery amounts of
the compressor
- A compressor with larger delivery

amounts is required
- Air filter is fouled
- Replace air filter
- Relief valve blows air during

compression
- Check relief valve; if necessary,

replace seals
- Intake regulator does not open
- Check magnet valve regulator

piston and if necessary, replace
- Leakage in the piping grid
- Make piping grid airtight
- Grid pressure set too high
- Adjust grid pressure anew
- Safety valve defective
- Check safety valve; if necessary,

exchange
- Minimum pressure valve blocked
- Exchange magnet valve
- Coolant separator cartridge

fouled
- Exchange coolant separator

cartridge
- Coolant separator fouled
- Replace coolant separator
34
Malfunction overpressure or Grid
pressure too high (red
lamp is on)
- Higher outside pressure in the

compressed air grid
- Equalize outside pressure or

remove from grid
Error
Cause
Measures
Compressor does not start

automatically or does not
deliver after previous
switching off upon reaching
the final pressure or from
idling state.
- Grid pressure set too high
- Adjust grid pressure anew
- Interruption in the control current

circuit
- Check current loop for interruption (only by an trained electrician)
- Ambient temperature under +1

C; message Coolant temperature too low
- Build in an additional heater or

keep compressor room at right
temperature
- Switching times have been

activated in the Air Control 3
- Check switching times and

pressure times in the Air Control
- Grid pressure greater than

switch-on pressure
- Note grid pressure value
- Remote control activated
- Symbol remote is blinking
- Missing voltage at the

compressor
- Check if voltage is available
System does not start on

pressing the start button
- Electrical error in the control

system
- Switching times have been
activated in the Air Control 3
- Review (only by an trained

electrician)
- Check switching times in the Air
Control 3
Compressed air containing

large amount of coolant
(coolant consumption too
great)
- Coolant return flow piping is

congested
- Clean coolant feedback piping
- Defective coolant separator
- Replace coolant separator
System stopped before

reaching the final pressure
(red lamp is on)
- Overtemperature or overpressure
- Rectify error as required
- Interruption in the control current

loop
- Check current loop (only by a

trained electrician)
35
Water in the piping grid
Pressure decline
- Dryer switched off
- Switch on dryer
- Condensation diverter is not

functioning
- Clean / exchange drain
- Bypass open
- Close bypass
- Dew point too high
- Demand customer service
- Pressure difference in the filter

too great
- Exchange filter
7. Initial commissioning
7.1
Preparatory activities
1. Make certain that when the plant mains switch is switched off, no illicit
or inadvertent switching on cannot occur.
2. Make certain that the system is correctly connected to the compressed
air grid.Make certain that when the shut-off valve on the pressure grid
side is closed, illicit or inadvertent opening cannot occur.
7.2
Check coolant
level
Check coolant level/
coolant refill
1. Make certain that escaping coolant can be collected.
8.3
2. Check the coolant level at the sight glass which is located on the front
side of the coolant container: the sight glass must be totally filled with
coolant. Unscrew the the filling screw. Do not misplace the seal. For
new compressors, the coolant level must reach up to the lower level of
the inlet fitting.
3. If required, refill the coolant (see Chapter 8 Check coolant level / refill
coolant)
7.3
Start-up lubrication of the

compressor stage
After an extended standstill time, for example between factory delivery

and commissioning or during a longer company vacation, there might no
longer be any coolant in the rotor chamber of the compression stage. This
coolant is absolutely necessary for bearing and rotor lubrication in the startup phase.
1. Before switching on the compressor plant, fill approx. 0.2 liter coolant
into the filler screw of the intake regulators.
2. Rotate the compression stage only by hand in rotational direction until
the noticeable resistance dwindles and the coolant passes through the
compression stage.
3. Finally, tighten the filler screw of the intake regulators (05).
36
If no extra coolant is available (only coolant of the same variety may be
employed!), the coolant can be taken from the coolant drain.
If the system is employed only very irregularly or shut down weeks on end,
it should run an hour in idling mode once a week in order to avoid corrosion
damage caused by standing condensation.
7.4
Rotational direction control
The rotational direction of the plant ventilators must be checked.

The rotational direction of the main motor is determined by the frequency
converter and must conform with the affixed rotational direction arrow.
1. Remove the cover panels of the system, so that the electric motor of the
ventilator is visible.
2. Switch the plant main switch on.
3. Switch the system on with the key
Switch the system off again with
, when the ventilator starts running.
the key
In order to supply the system with sufficient cooling air, the rotational direction of the ventilator motors must concur with the rotational direction arrow.
In the case of incorrect rotational direction of the plant ventilators, a trained
electrician should correct the phase sequence of the electrical supply in
the switching cabinet by exchanging the two supply phases. This should
be carried out in a switched-off state secured against accidental switching
on.
37
7. Initial commissioning
7.5
Basic settings
7.5.1 Control system of the

system with Air Control 3
In order to understand plant basics, please read the chapter 5 Plant

operating elements .
More precise instructions on the basic settings of the system can be found
in the following chapters :
Chapter 5.3 Operating screen,
Chapter 5.3.1 Basic display
Chapter 5.3.4 Menu system
The display parameters
pressure unit,
temperature unit
language
can be modified as described in position 5.3.4.6.

The limit values
switch-on pressure
switch-off pressure
can be modified as described in position 5.3.4.1.

If your Air Control 3 has been fitted with the supplementary module BLS,
carry out settings as in point 5.3.4.7 5.3.4.9 of the description.
If your Air Control 3 has been fitted with the supplementary module accessories, carry out settings as in point 5.3.4.10 of the description.
38
7.6
Switch on compressed air

generation
1. Before switching on the system, make certain that no one can be endangered by doing so. The sound-insulation hood serves as a part of
the contact protection, among other things for the cooling air conduits
of the compressor plant. It must be closed during operation.
2. Carefully open the shut-off slide valve after the compressed air connector and between system compressed air grid (container). The system is
now connected to the grid.
3. Switch on the main switch.
4. Make certain that no tools or loose objects are lying on or in the system.
5. Press key
to switch on the compressed air generation.
The green LED in the key
lights up when the compressor is working.
Check on the operating display desk for the grid pressure.

The grid pressure will slowly rise if the compressed air consumption is less
than the delivery amounts of the compressors.
On blinking green LED, the compressor can start by itself at any time!
DANGER
The green LED blinks when the compressor is in operational readiness.
The compressor switches on automatically when the current grid pressure
drops below the preset switch-on pressure of the compressor plant, if
7.7
Concluding activities
the machine temperature rises above +1 C,
the timer of the Air Control 3 is active,
or the base load selective switching setting (BLS) is activated.
1. Check all piping of cooling liquids and pressure air conduits for leakage.
2. Check the coolant level of the compressors after 10 and until 20 minutes operation time. If the coolant level is too low, refill coolant as defined in Chapter 8
Check coolant level /coolant refill.
3. Check the compressor temperature. The compressor temperature should
not fall under approx. 75 C and not rise above 105 C; at 105 C a
warning is issued, at 110 C the compressor plant automatically shuts
down.
4. Tighten all electrical connections after a week.
5. Carry out all service intervals according to Chapter 8 Overview service
intervals.
6. Check the standard operation of the functions carried out weekly according to Chapter 8 Overview of service intervals
39
8. Service
8.1
Overview
Service intervals
8.2
Check coolant level / refill coolant
8.3
Check for leakage
8.4
Check the compressor
temperature
8.5
Check the cooler for fouling
8.6
Check for condensation
8.7
Replace coolant / Replace
coolant filter
8.8
Replace coolant separator
8.9
Replace air filter
8.10
Check safety valve
8.11
Check drive
8.12
Lubrication of electric motor
8.13
8.14
Necessary service work appears in the display as warnings (see Chapter

7.1)
Service activities
Chapter After the first After the first Every

100 operating 500 operatweek
hours
ing hours
Check coolant level
8.3
Check for leakage
8.4
Check compressor
temperature
8.5
Check of the cooler

for fouling
8.6
Check for
condensation
Coolant replacement
and replacing coolant
filter
Every 4000
operating h.
but at least
once a year
8.7
8.8
Replacing cooling liquid

separator
8.9
Replacing air filter
8.10
Check safety valve
8.11
Check clutch element
8.12
Lubrication of motor
8.13
General compressor
servicing
8.2
1. Press key
in order to switch off compressed air generation. Please
wait until the compressor has been switched off after an idling or ventilation phase. The symbol M for the main motor is then no longer visible in the display.
2. Switch the plant main switch off and make certain that it cannot be turned
on by mistake or intentionally (e.g. warning signs prohibiting switching).
40
Use only original spare parts!

NOTICE
Hot surfaces hot coolant!!
Make certain, with appropriate precaution, that no one can be burned
or scalded! Particularly note dangerous situations which can arise
from the release of hot coolant steam!
DANGER
3. Remove the side panels of the system.
4. Make certain that the pressure grid side shut-off valve is closed and
cannot be opened accidentally or intentionally.
5. Make certain that when working on the coolant circulation, escaping
coolant is collected.
8.3
Check coolant level / refill

coolant
8.2
8.14
Carry out the Preparatory activities

Only check the coolant level when the system has been turned off for a
minimum of 30 minutes. This is to ensure that the coolant has settled
down after the running phase.
The coolant level is in order if the complete sight glass is full of coolant.
If the complete sight glass is not full of coolant, coolant must be added as
follows:
1. Unscrew the filler screw. Do not misplace the gasket ring.
Damage of the system by using different coolants!

Different coolants may not be mixed. Only use original coolant!
NOTICE
2. Use an appropriate funnel for filling. Coolant can be filled up to the filling
rim of the fitting.
3. Take care that the seal is correctly seated and screw the fitting screw
closed.
Carry out the Concluding activities.
8.4
Check for leakage

Carry out the Preparatory activities.

8.2
8.14
Check all piping and the bottom of the system for coolant rests. If there is
still coolant in the system, the cause should be found and the coolant
removed.
8.5
Check the compressor

temperature
The compressor temperature, which can be viewed in the display, should

be between 75 C and 105 C.
Too high or too low compressor temperature can lead to damages to

the compressor.
NOTICE
41
8. Service
8.6
Check the cooler for

fouling

8.2
8.14
Check the compressed air after-cooler and the coolant heat exchanger
from the inside and outside. If you determine any fouling, it should be removed (e.g. by compressed air blowing, where the dirt particles should be
blown outside).
8.7
Check for condensate

development
The absorption capacity of water humidity in the air

8.2
8.14
falls with increasing pressure
rises with increasing temperature.
Sufficiently high compressor temperature guarantees that the intake air

humidity does not precipitate as condensation. The frequent switching on
and off of the compressor can result in the compressor not achieving the
required operating temperature.
Condensation in the coolant circulation can lead to damages to the

compressor. If you have determined that there is condensation in the
coolant container, immediately get in touch with customer service!
NOTICE
Condensation damages lead to the loss of the guarantee!
Since water is heavier than coolant, after extended standstill times (e.g. on
a weekend) the condensation collects in the bottom of the coolant containers. It can be simply drained off by the discharge drain.
Carry out the following activities only when the system has been turned
off at least overnight.

42
1. Open the discharge drain and carefully observe the escaping liquid.
Close the discharge drain again as soon as coolant appears.
2. Check the coolant level according to Chapter 8.3.
8.8
Coolant replacement /
replacing coolant filter
Carry out a coolant replacement only when the old coolant is still warm.
Cold coolant, because of its higher viscosity, does not flow so well.
8.2
8.14
Hot Surfaces - hot coolant!
DANGER
With appropriate precautions, make certain you are not burned or

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

2. By opening the discharge drain, allow the coolant to drain into an appropriate vessel and then close the discharge drain again.
Damage of the system can be caused by different coolants!

Different coolants may not be mixed.
NOTICE
3. Use an appropriate funnel for filling. Coolant can be filled up to the filling
rim of the fitting.
4. Take care that the seal is correctly seated and screw the fitting screw
closed.
5. Loosen the coolant filter with a strap wrench and remove possible seal
rests from the coolant filter housing.
6. Lightly oil the new seal of the coolant filters.
7. Screw the new coolant filter to the stop and tighten the coolant filter by
hand another half a revolution.
8. Test the coolant filter for leakage at operating temperature .
43
8. Service
8.9
Replacing coolant
separator

8.2
8.14
1. Loosen the coolant separator with a strap wrench. Remove possible

seal rests from the coolant separator housing.
2. Lightly oil the new seal(s) of the separator.
3. Screw the new coolant separator to the stop. Tighten the coolant filter
by hand another half a revolution.
4. Test the coolant separator for leakage at operating temperature.

8.10 Replacing air filter

8.2
8.14
Damage of the system by intake dust!

The system may not be operated without an air filter.
NOTICE
1. Remove the covering of the air filter (04)

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

8.11 Check safety valve

8.2
8.14
1. Remove the safety valve and remove residues at the threaded connection.
2. Check the safety valve in an appropriate apparatus.
3. If it is still working correctly, add sealing tape to the connecting threading of the safety valves and screw the safety valve back in.
4. If the adequate functionality of the old safety valves can no longer be
guaranteed, screw in a safety valve.
8.12 Check clutch element


8.2
8.14
1. Test manually whether the clutch might have some radial play.
2. If so, loosen the cam ring of the clutch, push it back, and replace the
clutch element.
3. Mount the cam ring again on the clutch half and test manually whether
the clutch now has no more radial play.
8.13 Relubrication of the

electric motor

8.2
8.14
1. The bearing lubrication periods for the electric motor, which appear on
the operating display desk, must be observed.
2. Carry out the required relubrication with a grease gun.
If there are no grease nipples on the electric motor, then it is equipped with
capsulated permanently greased bearings. These motor bearings must be
replaced when they are worn out.
8.14 Concluding activities

Service work acknowledged
1. Open the stopcock slowly on the pressure grid side.

7.1
2. Switch the plant main switch on.

3. Make certain that no tools or loose objects are lying on or in the system.
4. Press the key I to switch the compressor on.
5. Check all cooling liquids and compressed air piping for leakage
6. Check all new cartridges or newly mounted pressurized components
for leakage at operating temperature.
7. Finally mount the side panels of the system.
8. Confirm that the services carried out by you work according to Chapter
5.3.5.
9. Used filter cartridges, lubricants, seals, surplus condensation and employed cleaning materials should be considered hazardous waste and
disposed of in an environmently friendly way.
Damage of the system is possible!

Only acknowledge those services actually carried out!
NOTICE
Services not carried out degrade the service life reliability of the system. Please note that damages caused by improper usage are not covered by the guarantee!
45
9. Technical Data
46
9.1
Dimensions for connections

Compressor
ALLEGRO 30
ALLEGRO 40
ALLEGRO 60
mm
mm
mm
1,520
850
2,020
2,020
850
850
Coolant
filling
l
Compressed
air connection
G
Heat
recovery
G
1,600
1 1/2
1,600
1 /2
1,600
1 /2
ALLEGRO 80
2,020
850
1,600
1 /2
ALLEGRO100
2,300
1,400
1,800
2 1/2
ALLEGRO115
2,300
1,400
1,800
2 /2
1 1/2
ALLEGRO130
2,300
1,400
1,800
2 1/2
1 1/2
9.2
Data air-cooled compressors

Compressor
Weight
kg
9.3
ALLEGRO 30
1,095
ALLEGRO 40
1,165
ALLEGRO 60
1,265
Cooling air
amounts
m3/h
Room
ventilation
m3/h
Intake air
opening
m2
Diameter exhaust
air canal
m2
ALLEGRO 80
1,350
ALLEGRO100
1,675
16,500
17,000
1.50
0.84
ALLEGRO115
1,820
16,800
21,000
1.80
1.00
ALLEGRO130
1,820
16,800
21,000
1.80
1.00
Data water-cooled compressors

Compressor
Weight Cooling air
kg
Cooling water current at Cooling water Connection
amountsinlet/return temperature pressure

10/40 C 25/40 C 35/45 C
m3/h
m3/h
m3/h
m3/h
pressure
min - max
bar
cooling
water
G
ALLEGRO 30
ALLEGRO 40
ALLEGRO 60
ALLEGRO 80
9.4
ALLEGRO100
1,800
2,400
2.44
4.87
7.31
2.5 - 10
ALLEGRO115
1,950
2,400
2.80
5.60
8.41
2.5 - 10
1 1/2
ALLEGRO130
1,950
2,400
3.05
6.09
9.14
2.5 - 10
1 1/2
Electrical data
Compressor
Motor
power
kW
Current at
220V/60Hz
IN
IV
A
A gL
Current at
400V/50Hz
IN
IV
A
A gL
Current at
550V/50Hz
IN
IV
A
A gL
Maximum
motor switching
frequency
1/h
ALLEGRO 30
30
ALLEGRO 40
40
ALLEGRO 60
60
ALLEGRO 80
80
ALLEGRO100
100
295
325
148
194
129
142
ALLEGRO115
115
369
406
185
693
161
178
ALLEGRO130
130
461
508
231
1083
202
222
IN = Nominal current
IV = backup fuse in building
47
D
ALUP-Kompressoren GmbH
Tel.:
+49/7024/802-0
Fax:
+49/7024/802-106
Internet: www.alup.com
E-mail:
info@alup.com
Adolf-Ehmann-Str. 2
73257 Kngen
DEUTSCHLAND
A
AGRE-Kompressoren GmbH
Tel.:
+43/7252/52341-0
Fax:
+43/7252/52133
Internet: www.agre.at
E-mail:
office@agre.at
Werkstrae 2
4451 Garsten-St. Ulrich
STERREICH
NL
ALUP-Kompressoren B.V.
Tel.:
+31/30/2809000
Fax:
+31/30/2895675
Internet: www.alup.nl
E-mail:
info@alup.nl
Biezenwade 8-10
3439 Nieuwegein
NEDERLANDS
HU
ALUP Magyarorszg Kft.
Tel.:
+36/36/423444
Fax:
+36/36/516340
Internet: www.alup.hu
E-mail:
info@alup.hu
Szlloda u. 5
3300 Eger
MAGYARORSZG
BG
ALUP-Kompressoren Bulgaria OOD.
Tel.:
+359/2/528032
Fax:
+359/2/528032
E-mail:
alup@skycode.com
Tsar Asen Str. 63
1000 Sofia
BULGARIA

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Operating manual

5.3.4.10 Sub-menu Accessories ............ 30

Symbols in this manual ................................ 4

6. Correcting malfunctions ................................... 34

2. Functional description ........................................ 8

7. Initial commissioning ....................................... 36

3. Storage and transport ....................................... 10

5. Displays and operating elements .................... 16

Plant main switch ....................................... 16

Preparatory activities .................................. 36

9. Technical Data ................................................... 46

Dimensions for connections ....................... 46

Symbols in this manual

Nevertheless certain risks remain!

This symbol is employed whenever personal damage can be incurred

This symbol is employed when damage to property can occur through

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

The system is exclusively designed for

This manual is directed to qualified personnel, who are commissioned

Qualified personnel are individuals who:

upon the basis of their professional training, knowledge and experience

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

Unqualified actions or disregarding the warnings in this manual or those

General safety instructions

Loss or decrease of plant safety !

Loss of protection from contact to hazardous zones!

Injuries caused by ventilator wheels that start automatically, moving

Installation, service or repair work on the components of the system

Damage to the sense organs!

Compressed air streams may not be directed towards persons. When

Loss or decrease of plant dependability!

We recommend that a set of service parts subject to wear be kept on

Damage to the system may result in environmental damage!

Plants greater than 100 kW may be taken into operation by qualified

Compressed air receivers require regular technical inspections!

heat removal of the temperature increase caused by the compression

If desired by the customer, an additional heater can be installed in the

The compressed air after-cooler of the coolant heat exchanger is cooled

a built-in cooling air ventilator or

The electric motor is always cooled by its own ventilator fan.

2.5 Flow diagram

15 Compressed air after-cooler

3. Storage and transport

For measurements and weights, see Chapter 9.

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

Observe the local regulations and other requirements pertaining to

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

Install the system in locations with the following environmental conditions:

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

Make certain that the setup site is professionally ventilated.

Cooling air volume currents: see Chapter 9.

Forced ventilation (optional)

Forced ventilation must be dimensioned in such a way that the required

Water cooling (optional)

For water-cooled plants, the temperature of the compressed air after-cooler

inlet temperature less than +35 C

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

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

An electromagnetic valve (optional) should be installed before the cooling

Heat recovery for heating

Plants can be supplied with the optional heat recovery system

for heating water or