V6977-Z-MA-001 - Compressors & Standby APVs - QGOG 2 (HN 1908) Drillship - User Manual - Rev 0 PDF

Document number V6977-Z-MA-001 TOC
TABLE OF CONTENTS Revision: 0

Page: 1
Vol. Section Title Add. code Rev. Document number

Other document number
1 Introduction
User Manual, Introduction for User Manual 2 74309174
2 Data sheet
Remarks: Data sheet is not applicable. Please check drawings or Standard Documentation for
relevant information.
3 Technical Description
Technical Description, Standby APV's and Compressors 1 V6977-Z-SA-001A
QGOG 2 (HN 1908)
4 Operating Instructions
Remarks: Included in Standard Documentation
5 Maintenance Instructions
6 Spare Parts List

Spare Parts List for 1 year operation, Standby APV's and 0 V6977-Z-MC-001
Compressors
QGOG 2 (HN 1908)
7 Drawings & Parts Lists
7.1 General Arrangement Drawing

General Arrangement Drawing, Standby APV's 1 V6977-D1157-G0145
QGOG 2 (HN 1908)
General Arrangement Drawing, Selector Panel & Pressure switch 0 V6977-D1157-G0305
QGOG 2 (HN 1908)
General Arrangement Drawing, APV's COMPRESSOR SKID 1 V6977-D1157-G0313
QGOG 2 (HN1908)
General Arrangement Drawing, Standby APV's and Compressors 0 V6977-D1157-G2100
QGOG 2 (HN 1908)
7.2 Flow Diagram

Flow Diagram, Standby APV's and Compressors 0 V6977-D1157-H0001
QGOG 2 (HN 1908)
Flow Diagram, Compressors 1 V6977-D1157-H0002
QGOG 2 (HN1908)
7.3 Block Diagram

Electrical Block Diagram, Standby APV's and Compressors 1 V6977-D1157-E0001
QGOG 2 (HN 1908)
7.4 Termination Drawing

Termination Drawing, Standby APV's and Compressors 1 V6977-D1157-E0100
QGOG 2 (HN 1908)
QGOG 2 (HN 1908)
7.5 Loop Diagram

Loop Diagram, Standby APV's and Compressors 1 V6977-D1157-E0200
QGOG 2 (HN 1908)
QGOG 2 (HN 1908)
7.6 Layout Drawing
www.nov.com
Document number V6977-Z-MA-001 TOC
Page: 2

7.6 Layout Drawing

Layout Drawing, DUMMY 3D14121, Standby APV's and 0 V6977-D1157-E0300
Compressors
QGOG 2 (HN 1908)
8 Standard Documentation
Remarks: Includes Operating and Maintenance Instructions
Standard Documentation, Compressors & Standby APVs 0 V6977-Z-MA-010
QGOG 2, H1908 Drillship
R5461 QGOG 2 (HN 1908)

V6977 Standby APV's and Compressors
www.nov.com
Document number V6977-Z-MA-001 TOC section 1.d1
Page: 1

1 Introduction
User Manual, Introduction for User Manual 2 74309174
R5461 QGOG 2 (HN 1908)

www.nov.com
Document number V6977-Z-MA-001 TOC section 2
Page: 1
Vol. Section Title
2 Data sheet
Remarks: Data sheet is not applicable. Please check drawings or Standard Documentation for
relevant information.
R5461 QGOG 2 (HN 1908)

www.nov.com
Page: 1

3 Technical Description
Technical Description, Standby APV's and Compressors 1 V6977-Z-SA-001A
QGOG 2 (HN 1908)
R5461 QGOG 2 (HN 1908)

www.nov.com
Technical Description
Standby APV's and Compressors
QGOG 2 (HN 1908)
RIG/PLANT REFERENCE REFERENCE DESCRIPTION

QGOG 2 (HN 1908) V6977 Standby APV's and Compressors
ADDITIONAL CODE SDRL CODE TOTAL PGS
11 This document contains proprietary and confidential Postboks 401, Lundsiden
information which belongs to National Oilwell Varco; it is N-4604 Kristiansand
REMARKS loaned for limited purposes only and remains the property
of National Oilwell Varco. Reproduction, in whole or in Norway
MAIN TAG NUMBER DISCIPLINE part; or use of this design or distribution of this information Phone +47 38 19 20 00
to others is not permitted without the express written Fax +47 38 19 26 04
consent of National Oilwell Varco. This document is to be
CLIENT PO NUMBER returned to National Oilwell Varco upon request and in
any event upon completion of the use for which it was
loaned.
© Copyright National Oilwell Varco - 2012
CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV
V6977-Z-SA-001A 1
Document number V6977-Z-SA-001A
Revision 1
Page 3 of 11
TABLE OF CONTENTS
1 INTRODUCTION. .............................................................................................................. 4
2 TECHNICAL SPECIFICATION ......................................................................................... 5
3 DELIVERY SCOPE OF COMPRESSOR SKID PARTS & FUNCTIONS: ......................... 6
3.1 Electrical Control Panel ........................................................................................... 7
3.1.1 Operation, Monitoring and Indication ........................................................... 7
3.2 HP Air Dryer ............................................................................................................ 7
3.3 Test and certificates: ............................................................................................... 8
4 DESCRIPTION OF COMPRESSOR SKID FUNCTIONS .................................................. 9
4.1 Air Compression System......................................................................................... 9
4.2 Water Cooling System. ........................................................................................... 9
4.3 Oil/Water Removal. ................................................................................................. 9
4.4 Air Intake Filtration/Silencing................................................................................... 9
4.5 Lubrication. ............................................................................................................. 9
4.6 Electric Motor ........................................................................................................ 10
4.7 Compressor Control Panel. ................................................................................... 10
4.8 Compressed Air Dryer .......................................................................................... 11
Revision 1
Page 4 of 11
1 INTRODUCTION.
The compressor package is a purpose designed and manufactured unit producing dry, filtered,
high pressure air for Riser Tensioning applications in offshore conditions world-wide. Its
principal components are listed as follows:
1. A Compact four stage direct drive high-pressure compressor

2. An IEC class marine motor.
3. A fully automatic desiccant dryer.
4. Water cooled.
5. High efficient separators.
6. PLC based starter/controller mounted and wired on a frame adjacent to the compressor.
7. Common alarm, Running and Enable/Stop signals are wired to Drillers Cabin
The unit is provided fully piped and wired with all connections being brought to the base edge
and identified for ease of installation. Provided with lifting points and all services are fully
integrated.
Revision 1
Page 5 of 11
2 TECHNICAL SPECIFICATION
Classification: DNV Class II

Capacity at 300 bar: 140 m^3/h *
Working pressure: 207 bar
Max. Design pressure: 350 bar
Speed: 1770 rpm
Required power: 55 kW
Stages/Cylinder: 4/4
Cooling: water-cooled / Fresh water
Cooling water flow-rate: 80 l/min @ 3.5-8 bars
Cooling Water temperature range: 0 - 37 °C
o For lower temperatures glycol-water required
Heat dissipation to atmosphere: 6 kJ/s
Air-outlet temperature/deltaT: 10 °C
Air Outlet quality of compressor Acc. to ISO 8573-1 class 3.3.3
Residual oil content at air-outlet from Compressor: < 5 mg/m³ (before filtration)
Drive: direct drive via flexible coupling
Max. ambient temperature: + 5 up to + 50 ° C
Noise level at 1 m distance: 85 dB (A)
Total Unit weight: 2450 kgs (approx.)
* Capacity data with +/- 5 % tolerance related to 20°C ambient and 1013 mbar.
Revision 1
Page 6 of 11
3 DELIVERY SCOPE OF COMPRESSOR SKID PARTS & FUNCTIONS:
Standard Compressor only includes:

o Air intake and silencing filter
o Intercooler(s) between each stage
o Final after cooler
o Flywheel
o Pressure oil lubrication inc. low oil pressure (LOP) trip
o Oil-level dipstick
o High Air Temperature (HAT) trip protection switch
o Gauge panel for all stage pressure(s), oil pressure, 3rd stage air temperature and
cooling water outlet temperature
o Hour meter is mounted on control cabinet.
o Safety valve at each stage
o Oil/Water separator after 1st,2nd , 3rd and 4th (final) stage
o Auto-drain system
 1st and 2nd stage Solenoid drain valve 230 V/60 Hz
 Pneumatic 3rd and 4th stage drain valve
 Collection manifold to „Demister‟ for air and oil/water
drainage for drainage
 Starting relief integrated within the oil/water auto-drain system
o Flexible hose connection for oil/water drain to „demister'
o Flexible drive coupling
o Resilient AV mounts
Controlling Pressure switch(s) installed at Unit base
„Crankcase heater to cater for -20°C ambient air temperature; note min. cooling water
temperature
Three phase IEC E-motor size 225M 4 pole Continuous (S1):

o Rated output: 55 kW
o Speed: 1770 rpm
o Voltage/frequency: 440/60 V/Hz
o Protection/ Insulation class IP 55 / Class F / B temperature rise
Revision 1
Page 7 of 11
3.1 Electrical Control Panel
Supply: 440V/ 60 Hz / 3Ph

Protection: IP 54
Control voltage: 230 V
Indication voltage: 24 V AC
Contactor Star Delta
Disconnect mains supply Red handle, yellow collar
Wiring: Numbered wiring terminals
3.1.1 Operation, Monitoring and Indication
Door mounted
Operation: HAND - OFF/ RESET– AUTO (remote) Start-Stop
Solenoid drain valve (current-less Open)
Unloaded Start
Periodic drainage („normal‟ 15 min / 15 sec)
Solenoid water inlet valve (current-less Open)
Emergency STOP (latched)
Potential free signals: Running, Off, collective alarm/trip(s)

Indication Running
Hours run
Trip (shutdown): E-Motor over-current
Low oil pressure
High air temperature
Motor Over Current
Motor Over Temperature
3.2 HP Air Dryer
Operation Fully automatically continuous operation,

Regenerative, heatless
Volume flow rate at outlet 120 m^3/h (1013 mbar 20° C)
Inlet temperature 45 ° C
Relative humidity 100 %
Pressure dew point -40 ° C
Design Pressure 350 bar
Test Pressure 525 bar
Control Voltage 230/60 v/Hz
Protection IP54
Type of Desiccant 20% WS / 80% MS
Pre-filter G 5-350ZPXP
After-filter G 5-350ZP
Revision 1
Page 8 of 11
3.3 Test and certificates:
Works test for the compressor and motor

CE marked
Certification compliant with DNV–OS-E101
Operator Manual
Revision 1
Page 9 of 11
4 DESCRIPTION OF COMPRESSOR SKID FUNCTIONS
4.1 Air Compression System.
During normal operation, ambient air is drawn into the compressor, which compresses the air
within a range 150 to 350 barg four single acting stages. The compressed air then exits to a
high-pressure air dryer before being discharged to the high-pressure (HP) air system. The four
compressor stages are arranged radially in four horizontal cylinders around the vertical
crankshaft.
4.2 Water Cooling System.
The air is heated up during compression and is cooled by sea or freshwater. The air passes
through the tubes of a single pass shell and tube cooler. The freshwater passes over the tubes
through the shell side of the cooler to remove heat from the compressed air. One of these
coolers follows each compression stage (all 4 stages). Water is also used to remove the heat
generated in the cylinder by flowing through a water jacket surrounding each cylinder.
A solenoid valve is used to stop the cooling water flow when the compressor is idle.
4.3 Oil/Water Removal.
The air coming out each cooler flows through an oil/water separator, in which oil and water are
separated from the air. At regular intervals, the four separators are drained by an automatic
drain system, into an oil/water „demister‟ vessel, which separates the oil/water collected from
the air. The air, free from bulk oil/water, is exhausted from the „demister‟ vessel to atmosphere.
4.4 Air Intake Filtration/Silencing.
Air is filtered at the inlet to the compressor.

The air enters the compressor through a suction filter to remove large debris, which might
damage the compressor and then passes to a second filtration stage, which acts as a silencer.
4.5 Lubrication.
Lubrication of the compressor internal parts is achieved by the use of a gear-type oil pump. A
gear attached to the bottom of the crankshaft drives the pump, which mates with a gear on the
drive shaft of the lubricating oil pump. The lubricating oil is pumped through the drilled oil-
passages in the crankshaft to provide lubrication for the crankshaft main-end bushings and
crankpin big-end connecting rod bearings. The final stage cylinder also receives oil from the oil
pump via a check valve to provide a small additional quantity of lubricating oil.
Revision 1
Page 10 of 11
Oil splash provides lubrication for the remaining cylinder components as it discharges from the
connecting rod bearings and crankshaft bearings.
4.6 Electric Motor
A four-pole AC 55KW motor drives the compressor at the motor speed via a flexible coupling.
4.7 Compressor Control Panel.
The self contained Control Panel (LCP = Local Control Panel) mounted beside the vertical
motor is used for the control of the Motor, to monitor the compressor and „enable‟ remote
automatic Stop/Start control from a controlling pressure switch.
The Control Panel is designed to „start‟ the compressor in an unloaded condition with to relieve
the compressor of air pressure to ease starting and open cooling water inlet solenoid valve.
Potential free contacts are available for remote “Running”, “Off” and “Summary Alarm” signals.
The compressor can be operated either locally from the LCP at the compressor in „HAND‟
mode to manually Stop/Start for servicing or in „AUTO‟ mode.
The compressor will „stop‟ in AUTO mode, as above, or by depressing the „Stop‟ pushbutton.
Either „stop‟ method above will cause the drain valve solenoids to de-energize and close the
cooling water inlet solenoid.
If the E-Stop is depressed or the compressor receives an alarm signal, the compressor will
immediately „stop‟.
The two compressors, each with an individual Controller, are arranged for lead/lag operation.
The lead compressor will „start‟ when the pressure in the common air discharge main falls
below a pre-set value, and the lag compressor will „start‟ when the air pressure falls below a
lower pre-set value. Both compressors will „stop‟ when the air pressure returns to maximum
operating pressure.
When initiated by selecting AUTO from the front panel, the „start‟ pushbutton will remain
illuminated causing the compressor to run. When the air main pressure reaches the high-
pressure level the compressor will automatically „stop‟ and de-energize the two compressors
mounted drain valve solenoids will open to unload the compressor.
The compressor will re-start automatically when the pressure falls again to the lower specified
level(s).
Revision 1
Page 11 of 11
4.8 Compressed Air Dryer
The LCP supplies the compressed HP Air Dryer for continuous operation to dry, and filter, the
compressed air.
The high-pressure heatless Air Dryer employs the pressure swing or change method to
maintain the outlet air dryness. Two adsorption towers, each filled with desiccant, work in
parallel. When the air is being dried in one tower the other vessel desiccant is regenerated with
a percentage of dry (purge) air. Periodically to maintain a consistent dew-point, the Air Dryer
automatically switches from the newly dried tower to dry the exit air, and the wet desiccant in
the other tower is regenerated with purge air.
The Air Dryer is fully automatic. When the compressor is started, a contact in the LCP closes
and the dryer starts operation. When the compressor is switched off, the contact opens and
the dryer stops operation.
Page: 1
Vol. Section Title
4 Operating Instructions
R5461 QGOG 2 (HN 1908)

www.nov.com
Page: 1
Vol. Section Title
5 Maintenance Instructions
R5461 QGOG 2 (HN 1908)

www.nov.com
Page: 1

6 Spare Parts List

Spare Parts List for 1 year operation, Standby APV's and 0 V6977-Z-MC-001
Compressors
QGOG 2 (HN 1908)
R5461 QGOG 2 (HN 1908)

www.nov.com
Document number V6977-Z-MA-001 TOC section 7.3
Page: 1
Vol. Section Title
7 Drawings & Parts Lists

7.2 Flow Diagram
7.3 Block Diagram
7.5 Loop Diagram
7.6 Layout Drawing
R5461 QGOG 2 (HN 1908)

www.nov.com
Document number V6977-Z-MA-001 TOC section 7.1.d
Page: 1


General Arrangement Drawing, Standby APV's 1 V6977-D1157-G0145
QGOG 2 (HN 1908)
General Arrangement Drawing, Selector Panel & Pressure switch 0 V6977-D1157-G0305
QGOG 2 (HN 1908)
General Arrangement Drawing, APV's COMPRESSOR SKID 1 V6977-D1157-G0313
QGOG 2 (HN1908)
General Arrangement Drawing, Standby APV's and Compressors 0 V6977-D1157-G2100
QGOG 2 (HN 1908)
R5461 QGOG 2 (HN 1908)

www.nov.com
12 11 10 9 8 7 6 5 4 3 2 1
H H
G G
V6977-D1157-G0313
Compressor skid
QGOG 2 (HN 1908)
F F
E E
V6977-D1157-G0145
Standby APV's
QCOG 2 (HN 1908)
D D
C C
Notes:
1. Hyd. Flow diagram: V6977-D1157-H0001, V6977-D1157-H0002
2. El. diagram: V6977-D1157-E0001
3. Selector Panel & Pressure Switch: V6977-D1157-G0305
4. For detail information see separate reference list.

B B
0 24.04.2012 For Information TOVI THRO MORA

Rev. Date Description Made Checked Appr.
This doc ument contains proprietary and confidential information w hich
belongs to National Oilw ell Varco Norw ay AS. It is loaned for lim ited
purposes only and rem ains the property of N ational Oilwell Varco N orw ay
AS. R eproduc tion, in w hole or in part, or use of this des ign or distribution
of this information to others is not perm itted without the expres s written
consent of National Oilw ell Varco Norw ay AS. T his document is to be
National Oilwell Varco Norway AS
returned to National O ilw ell Varco Norw ay A S upon request and in any Servicebox 401, Lundsiden
event upon com pletion of the use for w hich it w as loaned. N-4604 Kristiansand, Norway
Title:
General Arrangement Drawing

Standby APV's and Compressors
QGOG 2 (HN 1908)
A Scale: Projection: Size: Main Part: A
1:10 A1
Drawing Number: Sheet: Revision:
V6977-D1157-G2100 1/1 0
12 11 10 9 8 7 6 5 4 3 2 1
Page: 1

7.2 Flow Diagram

Flow Diagram, Standby APV's and Compressors 0 V6977-D1157-H0001
QGOG 2 (HN 1908)
Flow Diagram, Compressors 1 V6977-D1157-H0002
QGOG 2 (HN1908)
R5461 QGOG 2 (HN 1908)

www.nov.com
National Oilwell Norway AS
Customer Parts List
Drawing No.: V6977-D1157-H0001 Drawing Name: Remarks:
Revision: 0 Standby APV's and Compressors
Item No: XV6977D1157H0001 QGOG 2 (HN 1908)
Updated 01.01.1900 FLOW DIAGRAM
Other Doc No:
Project:
Customer:
Qty Item No. Drawing Reference / Remarks

Pos
Unit Wgt. Item Name Tag No.
6 198805 V6977-D1157-G0111
H60/1-6
2000,00 APV, 1600L,WP207 BAR, COMPLETE ASSY
6 65472
H61/1-6
15,00 BALL VALVE 2", H27serie, SS316,3000-13
6 32826
H63/1-6
3,14 SAFETY RELIEF VALVE, AIR,RHPS 1" BSPP M
6 27407
H64/1-6
0,40 BALL VALVE, FOR AIR, 400 BAR
6 152930
H65/1-6
0,90 BLOCK AND BLEED VALVE
6 152937
H66/1-6
0,10 PRESSURE GAUGE 0-400 BAR + PSI
6 11993
H67/1-6
0,10 MINIMESS, 1/4" BSP
Total weight 12117,83
www.nov.com PDFPartslist.exe (1.29.4059.25834) (XAL) 17.02.2011 15:07:37 Page: 1 of 1

Customer Parts List
Drawing No.: V6977-D1157-H0002 Drawing Name: Remarks:
Revision: 1 Compressors
Item No: XV6977D1157H0002 QGOG 1 (HN1907)
Updated 25.03.2011 FLOW DIAGRAM
Other Doc No:
Project:
Customer:

Pos
3 198598 V6977-D1157-G0313
H01/1-3
2500,00 COMPRESSOR HIGH PRESSURE, 207 BAR
1 173003 V6977-D1157-G0305
H03
15,00 SEQUENCE SELECTOR for 3compressor system
Total weight 7515,00

Page: 1

7.3 Block Diagram

Electrical Block Diagram, Standby APV's and Compressors 1 V6977-D1157-E0001
QGOG 2 (HN 1908)
R5461 QGOG 2 (HN 1908)

www.nov.com
Customer Parts List
Drawing No.: V6977-D1157-E0001 Drawing Name: Remarks:
Item No: XV6977D1157E0001 QGOG 2 (HN 1908)
Updated 26.01.2011 ELECTRICAL BLOCK DIAGRAM
Other Doc No:
Project:
Customer:

Pos
1 XV6977D1157E0100 V6977-D1157-E0100
Standby APV's and Compressors;QGOG 2 (HN
0,00
1908);TERMINATION DRAWING
1 XV6977D1157E0101 V6977-D1157-E0101
0,00
1908);TERMINATION DRAWING
1 XV6977D1157E0300 V6977-D1157-E0300
0,00
1908);LAYOUT DRAWING, DUMMY 3D14121
0 REF
E01
0,00 BY MECHANIC 3D152
0 REF
E02
0,00 BY MECHANIC 3D152A
0 REF
E03
0,00 BY MECHANIC 3D152B
0 REF
E04
0,00 BY MECHANIC 3D152C
5 REF
E05
0,00 PART OF 3D151A-PS-001 3D152-PS-001-C01
4 157437
E06
0,01 EL. CONTROL NAME PLATE, TextHeights=10mm
4 157441
E07
0,00 EL. CONTROL NAME PLATE, TextHeights=5mm
Total weight 0,03

Page: 1


QGOG 2 (HN 1908)
QGOG 2 (HN 1908)
R5461 QGOG 2 (HN 1908)

www.nov.com
Page: 1

7.5 Loop Diagram

QGOG 2 (HN 1908)
QGOG 2 (HN 1908)
R5461 QGOG 2 (HN 1908)

www.nov.com
Customer Parts List
Updated 27.01.2011 LOOP DIAGRAM
Other Doc No:
Project:
Customer:

Pos
1 50197
E01
0,02 RELAY MINIATURE 10A/16A 1 POL -K1
1 50198
E02
0,02 SOCKET FOR MINIATURE RELAY 1 POL -K1.1
1 50197
E03
1 50198
E04
1 50197
E05
1 50198
E06
1 50197
E07
1 50198
E08
1 50197
E09
1 50198
E10
1 50197
E11
1 50198
E12
Total weight 0,21

Customer Parts List
Updated 27.01.2011 LOOP DIAGRAM
Other Doc No:
Project:
Customer:

Pos
1 50197
E01
1 50198
E02
1 50197
E03
1 50198
E04
1 50197
E05
1 50198
E06
Total weight 0,11

Page: 1

7.6 Layout Drawing

Layout Drawing, DUMMY 3D14121, Standby APV's and 0 V6977-D1157-E0300
Compressors
QGOG 2 (HN 1908)
R5461 QGOG 2 (HN 1908)

www.nov.com
Customer Parts List
Drawing No.: V6977-D1157-E0300 Drawing Name: Drawing Revision: 0
Item No.: XV6977D1157E0300 Standby APV's and Compressors Updated: 01.01.1900
Item Group: DRAW QGOG 2 (HN 1908)
DRAWING LAYOUT DRAWING, DUMMY 3D14121
Project: V6977 - Standby APV's and Compressors Machine Number:

Customer: Samsung Heavy Industries Co, Ltd.
Qty Item No. Drawing Reference

Pos
1 XV6977D1157E0200 V6977-D1157-E0200
0,00
1908);LOOP DIAGRAM
1 XV6977D1157E0201 V6977-D1157-E0201
0,00
1908);LOOP DIAGRAM
Total weight 0,00

Page: 1

8 Standard Documentation
Remarks: Includes Operating and Maintenance Instructions
Standard Documentation, Compressors & Standby APVs 0 V6977-Z-MA-010
R5461 QGOG 2 (HN 1908)

www.nov.com
Standard Documentation
Compressors & Standby APVs
RIG/PLANT REFERENCE REFERENCE DESCRIPTION

QGOG 2 (HN 1908) V6977 Standby APV's and Compressors
ADDITIONAL CODE SDRL CODE TOTAL PGS
4.3 11 + This document contains proprietary and confidential National Oilwell Varco Norway AS
information which belongs to National Oilwell Varco; it is Postboks 401, Lundsiden
Attach. loaned for limited purposes only and remains the property
REMARKS of National Oilwell Varco. Reproduction, in whole or in N-4604 Kristiansand
part; or use of this design or distribution of this information Norway
MAIN TAG NUMBER DISCIPLINE to others is not permitted without the express written
consent of National Oilwell Varco. This document is to be
returned to National Oilwell Varco upon request and in Phone +47 38 19 20 00
CLIENT PO NUMBER any event upon completion of the use for which it was Fax +47 38 19 26 04
loaned.
© Copyright National Oilwell Varco - 2011
CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV
V6977-Z-MA-010 0
Document number V6977-Z-MA-010
Revision 0
Page 3 of 11
TABLE OF CONTENTS
1 STANDARD DOCUMENTATION...................................................................................... 4
1.1 Sub-vendor Literature ............................................................................................. 4
1.2 Compressor Photos (V6977)................................................................................... 5
1.3 Addition: Typical Compressor Photos ................................................................... 10
Revision 0
Page 4 of 11
1 STANDARD DOCUMENTATION
1.1 Sub-vendor Literature
The sub-vendor literature in this document replaces the ordinary Operating Instructions
and Maintenance Instructions documents for the compressors and standby APVs
supplied by National Oilwell Varco Norway (NOV) for the QGOG 2 (HN 1908).
The literature is for the three parallel air compressors and the standby APVs they are
filling. From the standby APVs the air is supplied to the working APVs of the CMC-E
(Crown Mounted Compensator of E-type) and the WRTS (Wireline Riser Tension
System) as required. Each compressor includes an on-skid starter control panel and an
air dryer. In addition there is a common sequence selector panel for selecting lead,
follow and standby compressor. The lead compressor will be running most, and over
time different compressors should be selected as lead compressor, so that the wear is
distributed evenly. All compressor control is strictly local. During normal operation the
compressors are set to automatically keep the pressure in the standby APVs at
207 barg.
The six standby APVs are conventional steel type APVs, and each is equipped with a
manual isolating valve and a pressure relief valve set to open at 230 barg.
The following literature is attached at the end of the document:
Literature title: RHPS Pressure Relief Valves

Literature no.: Pamphlet 27-10-2009 and PRV6 user manual 19-01-2005
Total pages: 9
NOV item no.: 32826
Literature title: Sauer Compressor WP 5000

Literature no.: Drawings-Diagrams-Manuals Edition 09/2011,
for NOV V6977.
Total pages: 492
NOV item no.: 198598
Revision 0
Page 5 of 11
1.2 Compressor Photos (V6977)

Revision 0
Page 6 of 11
Electrical motor
Automatic drainage system

Revision 0
Page 7 of 11
High-pressure filter
Compressor control panel

Revision 0
Page 8 of 11
Gauge panel
Dryer control panel

Revision 0
Page 9 of 11
Bentley Air Dryer

Revision 0
Page 10 of 11
1.3 Addition: Typical Compressor Photos

Revision 0
Page 11 of 11
Common sequence selector panel & skid

Sauer
Compressor
WP 5000 System
Drawings - Diagrams - Manuals
NOV-No.: V6977
001_41007852_WP5000_System_cover_en_1109.fm
001_41007852_WP5000_System_cover_en
Edition: 09 / 2011
Edited by: J.P. Sauer & Sohn Maschinenbau – Technical Documentation
Overview
Overview
– „As built“ drawing
general arrangement B 5000 - A6676
– P&I Diagram
of compressor module AUT - C 22478
– Sauer compressor system 090 646,

manual and spare parts list
– Sauer compressor WP 5000,

manual and spare parts list
– HPS compressor control 043 461 E,

manual and wiring diagrams
– Sequence Panel 068018,

manual
– HP Filters
operating instructions
– Bentley air dryer BD90-EP350

manual, spare parts list and wiring diagram
001_41007852_WP5000_System_cover_en
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Sauer
Compressor
Air Compression System
with HP Air Compressor WP5000
Operation and maintenance instructions
NOV-No.: V6977
004_41007852_WP5000_System_BA_Titel_en_1109.fm
004_41007852_WP5000_System_BA_Titel_en_1109.f
Edition: 09 / 2011
Table of Content
1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Description of the Compressor Module . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.1 Compressed air, cooling water and condensate piping . . . . . . . . . . . . . . . . 6
2.2 Electrical devices and cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Conditions of Use/Use restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Unauthorised modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6 Safety Information - Warning and Caution . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7 Safety Warnings on the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.8 Safety and protection devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.9 Noise protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.10 Waste disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.11 Safety requirements for personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.12 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Technical Specification Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6 Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
004a_41007852_WP5000_System_BA_IVZ_en_
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005_41007852_WP5000_System_BA_en_0810.fm
1 Safety
Specific Only authorised and well trained personnel should operate and
precautions service the compressor module. Such responsible personnel
must be thoroughly familar with, and frequently review, the
Operating Manual.
These instructions should always be readily available at the
compressor installation.
The whole compresssor module must be relieved of any

pressure, electrically isolated and secured with locking devices.
Strictly follow the safety instructions in the Manual before starting
operation.
Observing operating instructions, the installation requirements

detailed in the instructions, and keeping maintenance records,
are all part of the specified conditions of use.
Most accidents which occur during operation and maintenance of
machinery result from failure to observe basic safety rules or
precautions.
When handling, operating or carrying out maintenance,
personnel must observe safe engineering working practices and
local regulations.
Transport Transport and handling must be done by trained personnel using

only certigied lifting equipment, such as forklifts, cranes lifting
gears, slings, shackles etc. with sufficient load bearing capacity.
Use personal protection wear, such as safety boots, helmet,
gloves, safety googles.
Please refer to the general arrangement drawing for advice.
Lift the entire system only by using the hoisting lugs at the
baseframe and keep the module in an upright position.
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4
Description of the Compressor Module
2 Description of the Compressor Module

Please refer to drawing.
The compressor module consists of a watercooled 4-stage
compresssor system type WP5000 with a 3-phase AC-motor.
The compressor is fitted with integrated coolers and condensate
separators, fittings, instruments and pipes. The module is
equipped with a high pressure Air Dryer, with condensate
demister vessel and a local Control Panel to control and monitor
the compressor operation. The Control Panel is pre-wired with all
electrical module components.
During normal operation, ambient air is taken into the
compressor. The air is compressed within a range of 170 to 207
bar.
The compressed air is passed to a high pressure air dryer and
downstream pressure maintaining valve before being discharged
to the high pressure (HP) air system.
The four compressor stages are arranged radially in four
horizontal cylinders around the vertical crankshaft. This
equipment is mounted on a commom baseframe.
All termination points for air, condensate and cooling water are on
one side of the module. A dual pressure switch for starting and
stopping the compressor, according to the pressure level in the
compressed air receivers, is supplied loose for on-site installation
and cabling.
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2.1 Compressed air, cooling water and condensate
piping
Please refer to P&I-diagramm.
The compressor draws in atmospheric air at ambient conditions

and compresses the air in 4 stages up to final pressure. Each
stage is equipped with a safety relief valve, integrated air/water
coolers and condensate separators that are drained by solenoid
or pneumatic drain valves. The compressed air is dried by a HP
desiccant dryer to a termination point with on the baseframe.
The compressor condensate drained is separated in a demister
vessel for disposal. The condensate is piped to a termination
point via a flexible hose with a pipe connection.
The cooling water is fed from the central fresh cooling water
circuit. The cooling water enters the compressor at the cooler of
the 1st / 4th stages, flows through coolers and cylinder jackets
and leaves the compressor after the jacket of the 4th stage
cylinder.
2.2 Electrical devices and cabling

Please refer to the wiring diagram.
The electrical devices of the compressor such as valves,
AC motor, dryer and switches are wired to the mounted
compressor Control Panel. This panel forms the central electrical
termination point for customer’s wiring such as power supply and
signal interfaces.
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2.3 Commissioning
Note!
Installation and commissioning of the compressor is described in
Chapter 5 and 6 of the Compressor Manual and in Chapter
“Operation“ of the Dryer Manual. The safety instructions within
the Manuals must be strictly adhered to.
This section “Commissioning“ only gives a quick step-by-step

guide.
1. Check installation and fill with lubrication oil following the

instructions in Chapter 5.5 and 5.6 of the Compressor Manual
2. Follow Chapter 6.3 of the Compressor Manual up to “Test
run“, point 3.
3. Wash preservation oil from the compressor:
The compressor module is conserved prior to delivery with
about 1/2 liter of preservation oil that is sprayed into all
compressor air spaces. This preservation oil can contaminate
the downstream dryer of the compressor, if the compressor is
not purged at initial operation.
To wash the compressor of preservation oil, please proceed
as follows:
– Disconnect the power supply from the compresor Control
Panel to the drain valves. Please refer to wiring diagram,
terminals X1:41 to 44.
– After disconnection, open the Dryer bypass valve A14 and
close A13 (see P&I diagram) and let the compressor run for
about 5 minutes. The drain lines will remain open and wash
the oil from the compressor condensate line. A loud “sizzling“
noise indicates the drains are open.
– Then stop the compressor and reconnect the power supply to
the drain valves.
– Open A13 and close A14.
4. Continue with commissioning as per “Test run“, point 4.
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5. Please note:
The desiccant needs to be dried. In order to eliminate the
remaining moisture from the hygroscopic desiccant medium,
run the Compressor and Dryer for about 4 hours with open air
discharge A01 (see P&I diagram) at the air outlet of the
module.
After this period, connect the air discharge to the downstream
pipeline at site.
6. The compresor module is now ready for operation.
7
Check the settings of the pressure switch(s) for automatic
operation and adjust, as neccessary.
2.4 Conditions of Use/Use restrictions

The compressor system may only be used for compressing
the specified gas (air or nitrogen).
The Sauer compressor must not be used at ambient
temperatures below +5 °C and higher +45 °C. Any other
unauthorised use requires the express written approval of
J.P. SAUER & SOHN.
In addition, specified conditions of use also include observing the
Operator Manual and the installation requirements and
maintenance intervals described there.
precautions.
local regulations.
Note!
The compressor system must not be operated intermittently.
– The system must run for at least 30 minutes after each start-
up.
– Repeatedly using the system for shorter operating periods
leads to reduced gas quality and/or damage to the
compressor system.
– The compressor control limits the number of start-ups to a
maximum of 6 per hour. This start-up frequency must only be
used for commissioning and maintenance purposes.
2.5 Unauthorised modification

Unauthorised modification of the Sauer compressor is not
005_41007852_WP5000_System_BA_en_0810.fm
permitted. Modifications may lead to an accident that can be life-

threatening, cause personal injury or result in damage to the
equipment.
Contact J.P. SAUER & SOHN when planning any modification to
obtain written approval.
8
2.6 Safety Information - Warning and Caution

The safety information in these instructions is presented as ‘high’
risk and ‘lower’ risk, as follows:
Warning - Danger!
High risk.
Ignoring these safety instructions can cause personal injury, or
death, and significant equipment damage.
Caution - Note!
Less risk.
Disregarding this safety note may cause damage to the
equipment.
2.7 Safety Warnings on the Machine

Danger!
Safety labelling affixed to the machine must not be altered or
removed. Replace damaged or lost safety labels immediately
with an approved replacement.
The Sauer compressor with an EC Manufacturer's Declaration or

EC Declaration of Conformity is marked with the following safety
labelling.
Safety label Meaning Safety label Meaning

High voltage! Danger to Read Operator
life! Manual!
Compressor starts Wear hearing

automatically without protection!
warning!
005_41007852_WP5000_System_BA_en_0810.fm
Hot surface! Rotational direction of

crankshaft
9
2.8 Safety and protection devices
Danger!
Safety devices must not be adjusted, tampered with or removed.
The safety devices must be periodically tested and checked.
Safety valves must only be installed with a lock-seal and
replaced, adjusted and re-sealed by authorised personnel.
2.9 Noise protection

Sound pressure level details are found in the Technical
Specification (see Chapter 4).
The Sauer compressor can be equipped with a sound-
dampening enclosure to reduce noise, available as an accessory
from J.P. SAUER & SOHN.
Danger!
When the compressor is operated without sound-dampening
enclosure, hearing protection should be worn when working
near the compressor.
2.10 Waste disposal

Note!
The following materials which accumulate during operation of
the compressor must be disposed of in an environmentally
sound manner in accordance with applicable laws:
– Condensate (oil/water) arising from inter-cooling in the
compression process
005_41007852_WP5000_System_BA_en_0810.fm
– Used oil and grease, and used oil and grease and materials
soiled by such lubricants
– Cleaning agents and rags soiled by such agents
10
2.11 Safety requirements for personnel

Only personnel authorised by J.P. SAUER & SOHN are
permitted to service the Sauer compressor! Before commencing
work they must have read and understood the instructions in the
Operator Manual, and must be familiar with all safety devices and
safety regulations.
In addition to the instructions in this Operator Manual and
supplier documentation, accepted engineering standards must
be observed as well as all local laws, standards and regulations
such as
– The Equipment and Product Safety Act,
– The regulations for industrial safety,
– The regulations for accident prevention pertaining to
compressors,
– Provision of the Verband Deutscher Elektrotechniker (VDE/
German electrical engineering industry association)
– Regulations on environmental protection.
Additionally, where appropriate classification society and
operational regulations must be observed.
Only those trained and thoroughly familiar with the compressor
operation should be authorised to operate the compressor.
Personnel authorised to service the compressor must be trained
technical specialists of the owner and manufacturer.
2.12 Personal protective equipment

The owner should provide personal protection equipment (e.g.
hearing protection, safety boots, etc.) for personnel carrying out
any work on the Sauer compressor.
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3 Technical Specification Data
Description Data
Air flow: see factory acceptance test certificate
Operation pressure: 207 bar
Speed: 1780 rpm (nominal)
Power intake: see wiring diagram
Power supply, voltage: 690 V
Power supply, frequency: 60 Hz
Control voltage: 220 - 240 V internally transformed and supplied
to valves and sensors
Ambient temperature: min +5 °C to max 45 °C
Sensors and intruments settings

Oil pressure: 1 bar falling: alarm and trip,
NO-contact switch
Air temperature: 80 °C and rising: alarm and trip,
NO-contact switch
Solenoid drain valves: 220 V AC, NO
Safety valves 1st stage: 6 bar
2nd stage: 20 bar
3rd stage: 95 bar
4th stage 5 % above final pressure

cooling water: 10 bar (burst disc)
005_41007852_WP5000_System_BA_en_0810.fm
Note!
Actual technical data may vary from this overview and are given
in the Inspection Certificate of the compressor
12
Troubleshooting
4 Troubleshooting
Compressor Place
Operating instructions
WP 5000
Chapter “Troubleshooting”
Dryer Place
Operating manual
BD90 - EP350
Chapter “Troubleshooting”
HP Filter Place
High-pressure filter Operating instructions
G3/100 - G14/350 Chapter “Correcting faults”
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13
5 Maintenance
Compressor Place
WP 5000
Chapter “Maintenance”
Dryer Place
BD90 - EP350 Operating manual
Chapter “Maintenance”
HP Filter Place
High-pressure filter
Chapter “Maintenance
G3/100 - G14/350
intervals”
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Annex
6 Annex
This annex to the operating instructions contains
– the format for the start-up journal;
– the format for notification of claim and return of goods;
– drawings and spare part lists.
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J.P. SAUER & SOHN
Start-up journal for compressors Maschinenbau GmbH
Brauner Berg 15 - 24159 Kiel
Phone: +49 - 431- 39 40 - 0
Fax: +49 - 431- 39 40 - 89
e-mail: service@sauersohn.de
Purchaser Operating company Place of installation
Company Company
Street Street
Postcode Postcode
Contact person Contact person
Telephone number Telephone number
Customer number
Order number
Compressor type Serial number
Delivery date Hour of operation
Start-up date
Sauer service engineer Company/Name
Company/Name
Company/Name
Company/Name
Installation of compressor / Complete system Rotating direction check
 good  failings Compression temp. °C
Ventilation Suction temperature °C
 good  failings Switch on/off pressure
Environment conditions Oil level check
 good  failings Control check
Voltage? Test run
 good  failings
Vibration behaviour of the compressor
 good  failings
Accessories Installation of complete system carried out by:
Compressed air vessel
Refrigerant type dryer
Adsorption dryer  good  failings
Filter
Condensate removal
The operational personnel has been instructed and familarised with the safety and maintenance instructions.
005_41007852_WP5000_System_BA_en_0810.fm
The maintenance instructions are on hand of the operating company.

The operating company has been adverted only to use genuine SAUER & SOHN spare parts.
Notes / Failings:
The system has been accepted by the operating Place: Date:

company.
Purchaser Operating company Authorised SAUER service partner
16
Annex
J.P. SAUER & SOHN

 Return of goods Maschinenbau GmbH
 Notification of claim Brauner Berg 15 - 24159 Kiel
Phone: +49 - 431- 39 40 - 0
Date: Fax: +49 - 431- 39 40 - 89
e-mail: service@sauersohn.de
Applicant: Please complete always:
Company Compressor type:
Street
Postcode / Place
Customer-No. Serial No.:
Station
End customer: Working hours:
Company
Street Date of fault:
Postcode / Place
Customer-No. Ambient temperature:
Station
Spare parts Reason for return
Description Quantity Part-No. Report on fault 
To be completed by applicant
Repair 
Checking by matter of 
goodwill

Goods returnd against credit 
note
Short description of fault

005_41007852_WP5000_System_BA_en_0810.fm
Report
To be completed
by manufacturer
17
18
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S a u e r
C o m p r e s s o r
Type: WP 5000
Operator Manual
High-pressure Compressor
4-stage
Water-cooled
008_41007852_WP5000_BA_Titel_en_1109.fm
008_41007852_WP5000_BA_Titel_en_1109.
Edition: 12 / 2010
Sauer-CompressorsType Approvals
010_41007852_Zertifikate_en_0.fm
Note!
On this page only a few examples are shown. FurtherType Ap-
provals are available on request.
Genuine Sauer spare parts –
certified safety
M E N
CI
SPE 010_41007852_Zertifikate_en_0.fm
Table of Content
1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 Type approval and genuine Sauer spare parts . . . . . . . . . . . . . . . . . . . . . 10
1.5 J.P. SAUER & SOHN Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.6 Text conventions used in this Operator Manual . . . . . . . . . . . . . . . . . . . . . 12
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Conditions of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Unauthorised modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 Safety information - warning and caution . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4 Safety warnings on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.5 Safety and protection devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.6 Noise protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.7 Waste disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.8 Safety requirements for personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.9 Personnel protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3 Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2 Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Displays on the Sauer compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.4 Indicators and operation at the compressor electrical control panel . . . . . . 29
4 Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.1 Specification data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.2 P&I diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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5
5 Transport and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.2 Storage before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.4 Connecting the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.5 Filling with oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.6 Checks to be carried out after installation and before first start-up . . . . . . 47
6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.1 Safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.2 Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.3 Initial operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.4 Routine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7 Troubleshooting guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.1 J.P. SAUER & SOHN Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.2 Maintenance safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.3 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.4 Table of tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.5 Changing the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8.6 Checking screwed connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.7 Changing the air filter insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.8 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.9 Checking piston rings and connecting rods . . . . . . . . . . . . . . . . . . . . . . . . 79
8.10 Replacing the gudgeon pins/gudgeon pin bearings (small-end bearing) . . 92
8.11 Replacing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
8.12 Checking pistons and cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
8.13 Checking the drive bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
8.14 Replacing the connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
8.15 Checking the separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
8.16 Checking safety valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
8.17 Cleaning the particle trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
8.18 Checking the zinc protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
8.19 Checking the burst disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
8.20 Checking the cooler tube bundles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
009_41007852_WP5000_BA_IVZ_e
6
9 Storage, Preservation – “Lay-up” Procedure . . . . . . . . . . . . . . . . . . . 110
9.1 Safety when storing and removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
9.2 Temporary preservation and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
9.3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
10 Lubricant table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

10.1 Lubricating oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
10.2 Preservation oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
11 Spare parts and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
12 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
12.1 Commissioning certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
12.2 Return of goods and notification of a claim . . . . . . . . . . . . . . . . . . . . . . . 122
009_41007852_WP5000_BA_IVZ_en_09.fm
7
011_WP5000_BA_en_0111.fm
1 General
1.1 Foreword
This Operator Manual provides installation guidance, safe
operation, maintenance and repair instructions with illustrated
parts breakdown.
The following unique specification for the Sauer compressor can
be found on the nameplate affixed to the compressor:
– Compressor type
– Serial number
– Year of construction:
We recommend you record this information in Chapter 11 “Spare
Parts and Accessories” and always provide this data when
requesting parts and any repair instructions.
1.2 Precautions
Specific We recommend that only authorised and trained personnel
precautions operate and service the Sauer compressor. Such responsible
personnel must be thoroughly familiar with, and frequently
review, the Operator Manual.
These instructions must always be readily available at the
compressor installation.
Copyright The copyright for this Operator Manual remains with

J.P. SAUER & SOHN. These instructions, or parts thereof, shall
not be copied, distributed or made available to third parties.
Contravention will result in prosecution.
011_WP5000_BA_en_0111.fm
8
General
1.3 Warranty and Liability

Sauer can no longer continue the Warranty, be liable for any
Claims, if a failure is attributed to any of the following:
– Use of the machine not as specified
– Substitution of parts not manufactured or approved by Sauer
– Use of spare parts that are not genuine Sauer spare parts
– Operation of the machine with faulty or improperly installed
safety and/or protection devices
– Failure to observe Operator Manual
– Unauthorised modification to the machine or its control system
– Inadequate monitoring of machine parts subject to wear
– Failure to maintain/repair in accordance with Sauer
instructions
– Force majeure
011_WP5000_BA_en_0111.fm
9
1.4 Type Approval and Genuine Sauer Spare Parts
• Type Approval for the Sauer compressor is valid under the
condition that parts and components specified and qualified by
J.P. SAUER & SOHN are used. Type Approval is provided by
the Classification Society and the EC Declaration of
Conformity or EC Manufacturer's Declaration. Failure to
observe these requirements may void Type Approval.
• Only the use of genuine Sauer spare parts will ensure
compliance with the above and, therefore, reliable and safe
operation of the Sauer compressors.
• If non-genuine Sauer spare parts are used, we reserve the
right of exclusion from liability for personal injury and material
damage.
• Genuine Sauer spare parts are supplied with a Certificate of
Conformity and a Certificate of Authenticity. An example of this
document is shown just before the Table of Contents in these
instructions. If spare parts are received without this certificate,
there is a risk that these are not genuine Sauer spare parts. In
such an instance please contact our Customer Service.
Note!
Be aware this is a high-pressure compressor, for your own
safety and for reliable compressor operation, only use genuine
Sauer parts.
Correct Incorrect
Only use genuine Sauer spare parts Do not use parts from the
with a certificate! “grey market”!
011_WP5000_BA_en_0111.fm
10
General
1.5 J.P. SAUER & SOHN Customer Service

Should you have any technical questions relating to maintenance
or repair, please contact our Customer Service:
J.P. SAUER & SOHN Maschinenbau GmbH

Customer Service
P.O. Box 92 13
24157 Kiel, Germany
Phone (international):
Technical information +49 431 39 40 -87
Spare parts orders +49 431 39 40 -86/886
Fax (international): +49 431 39 40 -89
Emergency service (international): +49 172 4 14 63 94
E-mail: service@sauersohn.de
Web: www.sauercompressors.de
Note!
If you have questions regarding your Sauer compressor, please
specify the compressor model and serial number (see Chapter
11 “Spare Parts and Accessories” or nameplate on the
compressor).
011_WP5000_BA_en_0111.fm
11
1.6 Text Conventions Used in This Operator Manual
Lists General lists are marked using a dash.
Example:
Compressor cooling consists of
– Cooler assembly
– Cooling water lines
Instructions Individual instructions or multiple instructions requiring action but

where the sequence is of no importance are normally denoted by
a bullet-point.
Example:
• Check oil level.
Instructions to be carried out in a certain sequence are

numbered.
Example:
1. Turn the main switch ON.
2. Choose the operating mode.
3. Turn the control ON.
Results of actions carried out are denoted by a tick mark.

Example:
The control light is on.
Safety Safety and warning instructions are presented pictorially with

instructions clear instructions. The safety instructions are described in detail
in Chapter 2 “Safety”. 011_WP5000_BA_en_0111.fm
12
Safety
2 Safety
2.1 Conditions of Use
This Sauer compressor is designed for the compression of air
only. Operational limits, maintenance repair and servicing, and
proper installation instructions are provided in the OPERATOR
MANUAL. Written approval must be sought from J.P. SAUER &
SOHN if the compressor is to be used outside of limits within the
MANUAL.
Additionally, specified conditions of use also include following the
installation requirementinstructions and maintenance intervals
described within the MANUAL.
precautions.
local regulations.
2.2 Unauthorised modification

Unauthorised modification to the Sauer compressor is not
permitted. Modifications may lead to an accident that can be life-
threatening, cause personal injury or result in damage to the
equipment.
Contact J.P. SAUER & SOHN when planning any modification to
obtain written approval.
011_WP5000_BA_en_0111.fm
13
2.3 Safety Information - Warning and Caution
The safety information in these instructions is presented as ‘high’
risk and ‘lower’ risk, as follows:
Warning - Danger!
High risk.
Ignoring these safety instructions can cause personal injury, or
death, and significant equipment damage.
Caution - Note!
Less risk.
Disregarding this safety note may cause damage to the
equipment.
011_WP5000_BA_en_0111.fm
14
Safety
2.4 Safety Warnings on the Machine

Danger!
Safety labelling affixed to the machine must not be altered or
removed. Replace damaged or lost safety labels immediately
with an approved replacement.
The Sauer compressor with an EC Manufacturer's Declaration or

EC Declaration of Conformity is marked with the following safety
labelling:
Safety label Meaning Safety label Meaning

High voltage! Danger Read Operator
to life! Manual!
Compressor starts Wear hearing

automatically without protection!
warning!
Hot surface! Rotational direction of

crankshaft
Location of safety markings

011_WP5000_BA_en_0111.fm
15
2.5 Safety and protection devices
Danger!
Safety devices must not be adjusted, tampered with or removed.
The safety devices must be periodically tested and checked:
Safety valves must only be
installed with a lock-seal and
replaced, adjusted and re-sealed by authorised personnel.
Safety valves Each compression stage of the Sauer compressor is equipped

with a safety valve, which will fully discharge air when the blow-
off pressure is reached.
Safety valves are installed at the following locations:
– 1st compression stage: directly after the 1st cooler;
– 2nd Compression stage: directly after the 2nd stage cooler;
– 3rd Compression stage: directly after the 3rd stage cooler;
– 4th compression stage: directly after the 4th stage cooler.
Burst discs The water system is protected against excess pressure by burst
discs fitted to each cooler housing for protection against com-
pressed air leakage into the water system. The burst discs are lo-
cated behind each burst disc flange on the cooler housing of the
3rd and the 4th stage. Pressure peaks in the cooling water circuit
cause the burst disc to rupture, relieve internal pressure and al-
low the water to discharge. With a loss of cooling water, the pro-
tective high air temperature switch activates.
Optionally, a combined burst disc plus water relief valve can be
installed. The valve reacts in response to minor water pressure
peaks without rupturing the disc.
High air tempera- The Sauer compressor is equipped with a high air temperature
ture switch switch. The high air temperature switch shuts down the
compressor if the compressed air temperature exceeds a preset
limit. This protects the Compressor against loss of cooling water
flow.
Low oil pressure The Sauer compressor comes supplied with a low oil pressure
switch switch which trips if the lubricating oil pressure drops below poil <
1 bar.
011_WP5000_BA_en_0111.fm
16
Safety
2.6 Noise protection

Sound pressure level details are found in the Technical
Specification (see Chapter 4).
Danger!
Hearing protection must be worn when working near the
compressor.
2.7 Waste disposal

Note!
The following materials are considered hazardous and must be
disposed of safety in accordance with Ships‘ instructions.
– Condensate (oil/water) arising from inter-cooling in the
compression process
– Used oil and grease, and used oil and grease and materials
soiled by such lubricants
– Cleaning agents and rags soiled by such agents
011_WP5000_BA_en_0111.fm
17
2.8 Safety requirements for personnel
Only personnel authorised by J.P. SAUER & SOHN are permitted
to service the Sauer compressor! Before commencing work they
must have read and understood the instructions in the Operator
Manual, and must be familiar with all safety devices and safety
regulations.
In addition to the instructions in this Operator Manual and
supplier documentation, accepted engineering standards must
be observed as well as ships regulations.
Additionally, where appropriate classification society and
operational regulations must be observed.
Only those trained and thoroughly familiar with the compressor
operation should be authorised to operate the compressor.
Personnel authorised to service the compressor must be trained
technical specialists of the owner and manufacturer.
011_WP5000_BA_en_0111.fm
18
Safety
2.9 Personnel protective equipment

Ships‘ engineers should observe personal protection equipment
(e.g. hearing protection, safety boots, etc.) for personnel carrying
out any work on the Sauer compressor.
011_WP5000_BA_en_0111.fm
19
3 Design and Function
3.1 Overview
25
20
23 10
6
5 12 11
8
13 14
3
4
2 1
17
18
19 22
16 1st stage 24
7
21
11, 14
12, 13
3rd stage 4th stage
2nd stage
011_WP5000_BA_en_0111.fm
15
20
Design and Function
Item Designation
1 Cylinder 1st stage
2 Cylinder 2nd stage
3 Cylinder 3rd stage
4 Cylinder 4th stage
5 Safety valve 1st stage
6 Safety valve 2nd stage
7 Safety valve 3rd stage
8 Safety valve 4th stage
9 Compressed air temperature switch
10 Low oil pressure switch
11 Cooler 1st stage
12 Cooler 2nd stage
13 Cooler 3rd stage
14 Cooler 4th stage
15 Separator 1st stage
16 Separator 2nd stage
17 Separator 3rd stage
18 Separator 4th stage
19 Automatic drainage system
20 Air filter
21 Crankcase vent
22 Sump oil drain
23 Gauge panel
011_WP5000_BA_en_0111.fm
24 Cooling water pump

25 Motor
21
4 5 3 1 2 7
10
12 15
11 17
30
1st stage 16
29 2nd stage
13
18
14
39
5 8
37 35 33
36
34
24
25
26 21
32 22
31
27
20
28
4th stage
3rd stage 23
011_WP5000_BA_en_0111.fm
6
38
22
Design and Function
Item Designation Item Designation

1 Coupling 20 Piston 3rd stage
2 Flywheel 21 Liner 3rd stage
3 Crankshaft 22 Concentric valve 3rd stage
4 Bearing bracket 23 Cylinder 3rd stage
5 Bearing bush 24 Connecting rod 4th stage
6 Lubrication oil system 25 Piston 4th stage
7 Crankcase 26 Liner 4th stage
8 Oil sump 27 Concentric valve 4th stage
9 Connecting rod 1st stage 28 Cylinder 4th stage
10 Piston 1st stage 29 Valve cover 1st stage
11 Liner 1st stage 30 Valve cover 2nd stage
12 Concentric valve 1st stage 31 Valve cover 3rd stage
13 Cylinder 1st stage 32 Valve cover 4th stage
14 Connecting rod 2nd stage 33 Cooler 1std stage
15 Piston 2nd stage 34 Cooler 2nd stage
16 Liner 2nd stage 35 Cooler 3rd stage
17 Lamellar valve 2nd stage 36 Cooler 4th stage
18 Cylinder 2nd stage 37 Zinc protection
19 Connecting rod 3rd stage 38 Pressure relief valve
39 Dipstick
011_WP5000_BA_en_0111.fm
23
3.2 Functional description
Drive The Sauer Compressor is driven by an electric motor which is
directly connected to the crankcase via a flange and bell housing.
The power is transmitted by means of a flexible coupling.
Compressor Driven by an AC motor drive, the Sauer compressor is controlled

control and monitored by an electrical compressor control. This control
system must comply with legal regulations. Optionally, J.P.
SAUER & SOHN supplies a suitable compressor control.
Compression The compressor takes in the ambient air via a suction air filter and
compresses it in four single stage compression stages to the final
pressure. The air inafter each compression stage is inter-cooled
using cooling water. A replaceable liner is installed in each
cylinder.
The cylinders arranged in a flat-four configuration are equipped
with concentric valves and lamellar valves which are easy to
maintain and have a long service life.
Cooling The compressor can be cooled with either fresh water or sea
water. Cooling water is used to cool the compressed air in the
cooling tubes of the cooler , and to cool the cylinder jackets of the
four compression stages as well.
When at a complete standstill, the cooling water supply is shut-
off by a solenoid valve at the cooling water inlet. The compressor
cooling is protected by a high air temperature switch. The
compressor is immediately stopped if the compressed air
temperature exceeds the upper limit value.
Inter-cooling takes place in tubular coolers installed above the
cylinders. Within each stage the compressed air flows through
straight tubes and the cooling water passes over the tube
bundles in the opposite direction i. e. counter-flow. Burst discs on
the cooler housing protect the cooling water system against over-
pressure; the burst disc is ruptured if the cooling water pressure
exceeds the upper limit value and cooling water is discharged.
The tubular cooler bundle consists of a number of straight length
cooling tubes between cooler end covers. One tube-end is fixed,
and the other is allowed to ‘float‘ to allow for thermal expansion
during operation.
011_WP5000_BA_en_0111.fm
24
Design and Function
Tubular cooler
Tube bundle
O-ring Cooling tube O-ring

Burst disc Zinc protection
flange
Optionally, the compressor can be fitted with a cooling water

pump driven by its own electric motor.
Cooling water is fed into the cooler of the 4th stages, flows
through it and enters the 1st stage cooler. From here the cooling
water water flows around the outer cylinder jacket of the 1st stage
cylinder and then passes through the 3rd stage cylinder housing.
Then the cooling water passes through the 3rd stage tubular coo-
ler, then through the 2nd stage tubular cooler and finally cools the
4th stage cylinder housing wall. The cooling water temperature is
controlled after the 4th stage cylinder before passing through a
cooling water thermostatic control valve.
Cooling water circuit
M 1 4 3 2
011_WP5000_BA_en_0111.fm
Condensate Following each stage of cooling an oil/water separator collects

separation the oil/water while operating. At regular intervals, the oil/water is
25
drained automatically to the condensate collection via the
automatic drainage system.
Oil/water The oil/water collected from each separator is automatically

draining and drained using solenoid valves for the 1st and 2nd stages and a
pneumatic valve for the 3rd and 4th stage. These drain valves
pressure relief
have a dual function. They are normally open to de-pressurise
the Sauer Compressor (i. e. unload) to allow starting and also
opened periodically to drain oil/water (condensate). A few
seconds after starting, the drain valves close and the compressor
will come on-load against system pressure. The drain valves also
drain the system during operation at preset intervals. The control
of the drain valves is carried out by the compressor control.
Both the 1st and 2nd stage solenoid drain valves open at the same
time. Then sequentially, as the 2nd stage solenoid valve opens,
the pressure drops in the 2nd stage solenoid inlet line. The 3rd
stage pneumatic valve senses the pressure drop in the 2nd stage
inlet and opens. The 4th stage pneumatic valve, sensing the
pressure drop in the 3rd stage pneumatic valve inlet, opens,
allowing the 4th stage oil/water to drain. After 15 seconds the 1st
and 2nd stage solenoid valves will shut. The increased pressure
in the 2nd stage solenoid valve inlet line will shut the 3rd stage
pneumatic valve. The increased pressure in the 3rd stage
pneumatic valve will force the 4th stage pneumatic valve shut.
Lubrication / Oil from the sump is drawn through an oil strainer assembly to the
Oil Pressure gear driven oil pump driven by the crankshaft. The oil pump
pressurises to the lower main-end bearing. At this point a portion
of oil is pumped through drilled passages in the crankshaft,
providing lubrication for the crankshaft bearings, to the
connecting rod bearings and to the cylinder components. The
remaining oil is pumped through drilled passages in the
crankcase to piping, external to the crankcase. The oil pump
provides oil to the oil pressure gauge, low oil pressure switch and
the 4th compressor stage. Gudgeon pin needle bearings and the
pistons (final stage also receives a small amount of injected oil)
are lubricated by oil splash or mist present in the crankcase.
Passing throug an oil passage in the crankcase splash oil flows
back into the oil sump.
The crankcase drilled-passage is fitted with a pressure relief
valve. An oil level dipstick is provided to allow personnel to
periodically monitor compressor sump oil level. An oil fill pipe and
cap are provided to allow personnel to add oil to the compressor
011_WP5000_BA_en_0111.fm
sump as required. A drain plug is located at the bottom of the

compressor sump to allow personnel to drain the lubricating oil
for periodic maintenance.
A low lubricating oil pressure switch is installed, set at 1 bar
falling, to activate an alarm and shutdown the compressor should
the lubricating oil pressure decrease to the set point.
26
Design and Function
7
1
Oil 4
passage
6
3 2
8
Item Designation
1 Crankshaft
2 Oil pump
3 Drilled-passage
4 Pressure relief valve
5 Drain plug
6 Oil level dipstick
7 Crankcase
8 Oil sump
011_WP5000_BA_en_0111.fm
27
3.3 Displays on the Sauer compressor
1 2 3 4 5
1 2 3 4 5 6 7
Item Designation Display

1 Pressure gauge 1st stage Compressed air pressure after 1st stage
2 Pressure gauge 2nd stage Compressed air pressure after 2nd stage
3 Pressure gauge 3rd stage Compressed air pressure after 3rd stage
4 Pressure gauge 4th stage Compressed air pressure after 4th stage
5 Oil pressure gauge Oil pressure of oil pump
6 Thermometer 3rd stage Compressed air temperature after 3rd stage
7 Cooling water thermometer Temperature of cooling water outlet 011_WP5000_BA_en_0111.fm
28
Design and Function
3.4 Indicators and operation at the compressor

control
Note!
If the compressor control is supplied by J.P. SAUER & SOHN,
read the documentation supplied.
On the front of the compressor control, the following indicators

and control features can be found:
Display/operating
Explanation
element
Signal lamp
Illuminates when the compressor is running.
“Operation”
Fault indicator lamp Illuminates if the compressor has shut down because of low oil
“Oil pressure” pressure.
Fault indicator lamp Illuminates if the compressor has shut down because of high
“Air temperature” outlet gas temperature.
Fault indicator lamp Illuminates if the compressor has shut down because of excess
“Overcurrent” motor current.
Run time counter Indicates the hours the compressor has run.
“Manual” mode:
Starts the compressor manually. The compressor starts up and
continues to run until it is manually turned off again.
Selector position “0”:
Operation mode Turn the compressor off manually. Any pending fault messages
selector are reset.
“Auto” mode:
The compressor starts and stops with the opening and closing of
a remote contact (e.g. pressure switch at a compressed air
vessel).
Disconnects the power supply from the compressor control to the
compressor.
Main switch
A main isolator switch should be installed if required by local law
and regulations.
011_WP5000_BA_en_0111.fm
29
4 Technical Specification
4.1 Specification data
Designation Data
Compressor type WP 5000
Number of cylinders 4
Number of compression stages 4
Cylinder diameter 1st stage 195 mm
Cylinder diameter 2nd stage 100 mm
Cylinder diameter 3rd stage 50 mm
Cylinder diameter 4th stage 24 mm
Piston stroke 70 mm
Maximum speed 1800 rpm
Direction of rotation (when looking toward Clockwise
flywheel)
Working pressure 207 bar

Maximum working pressure 350 bar
Set pressures for safety valves:

1st stage 6 bar
2nd stage 20 bar
3rd stage 95 bar
4th stage 5% above final pressure
Oil sump capacity 27.5 l

011_WP5000_BA_en_0111.fm
Oil refill quantity – dipstick MAX/MIN 7.5 l

Oil type See Chapter 10 “Lubricant Table”
Oil pressure switch:
30
Technical Specification
Designation Data
Maximum switching current 6 A/220 V
Setting Opens at 1 bar falling
approximately 15 s delay on start
instruction
Switch function Change-over contact
Drain valves
Pickup and holding power 18 VA/14 W
Setting Currentless open
Relief starting: approx. 15 sec
Periodic automatic drainage: every 15
min for 15 s
Final pressure sensor (option):

Setting As required by customer
High air temperature switch:

Setting Opens at 80 °C rising
Maximum permissible entry pressure at 5 bar without cooling water pump

the cooling water inlet 2.5 bar with cooling water pump
Bursting pressure of the burst disc in the >10 bar
cooling water system:
Cooling water temperature at the outlet 40 to 50 °C
Cooling water stop valve Holding power: 36 W
Valve is currentless closed
011_WP5000_BA_en_0111.fm
Cooling water pump (option):

Electrical connection 440 V/60 Hz 1.1 kW or 400 V/50 Hz 1 kW
Setting Not self-priming,
should start and stop in synchronisation
with the compressor
31
Designation Data
Sound pressure level max. 90 dB(A)

free field at 1 m
Weight and dimensions See installation drawing
Note!
Please refer to the order-specific documentation of your
compressor for data such as final pressure, speed, power
requirements, etc.
011_WP5000_BA_en_0111.fm
32
011_WP5000_BA_en_0111.fm
33
4.2 P&I Diagram
17 13
19 21
Cooling water
inlet 15
18 14
38 20 16
37 7
43
5 8 34 33
M 6
42 41
32
M 1 4 3 2
29 31
36 4 3 2 35
1 30
40
39
27
Cooling water
9
28 outlet
10
Air intake 11 12
atm 24 25 Compressed air
outlet
22 23
26
Condensate
011_WP5000_BA_en_0111.fm
34

Solenoid valve
1 1st compression stage 22
(drainage) 1st stage
Solenoid valve
2 2nd compression stage 23
(drainage) 2nd stage
3 3rd compression stage 24 Manual drain valve 1st stage
4 4th compression stage 25 Manual drain valve 2nd stage
Pneumatic relief valve
5 Cooler 1st stage 26
(drainage) 3rd and 4th stage
6 Cooler 2nd stage 27 Intake air filter
7 Cooler 3rd stage 28 Non-return valve
8 Cooler 4th stage 29 Pressure relief valve
9 Separator 1st stage 30 Drive lubrication
10 Separator 2nd stage 31 Oil filter
11 Separator 3rd stage 32 Oil pump
12 Separator 4th stage 33 Oil pressure gauge
13 Safety valve 1st stage 34 Oil pressure switch / trip
14 Safety valve 2nd stage 35 Oil level indicator
15 Safety valve 3rd stage 36 Drive motor
16 Safety valve 4th stage 37 Cooling water particle trap
17 Pressure gauge 1st stage 38 Cooling water stop valve
18 Pressure gauge 2nd stage 39 Cooling water thermometer
19 Pressure gauge 3rd stage 40 Cooling water control valve
20 Pressure gauge 4th stage 41 Cooling water pump
21 Thermometer 3rd stage 42 Motor cooling water pump
43 Cooling water manual valve
011_WP5000_BA_en_0111.fm
35
5 Transport and Installation
5.1 Transport
Shipping The machine is packed ready for shipping.
• The Sauer compressor must be checked for completeness
and any damage immediately upon receipt.
• Damage to the packaging or the machine should be reported
to the transport firm and J.P. SAUER & SOHN immediately.
Transport The Sauer compressor must be transported using a forklift truck

or be hoisted by a crane.
Danger!
Suspended load during transport.
The forklift truck/crane must have sufficient load-bearing
capacity.
Ensure that no personnel are within the danger area of the
suspended load and the forklift truck/crane.
Sling the unpacked compressor using the four lifting eye bolts
(see illustration).
Raise, move into position and set down with care.
Danger!
The oil sump is not designed to carry the weight of the whole
compressor, therefore the compressor may not be posed on the
oil sump.
For transport, supports with drillings are fixed under the anti-vib-
ration resilient mounts. For transport by crane, shakles shall be
attached to these drillings. There are drillings for Transport in the
base frame as well.
011_WP5000_BA_en_0111.fm
36
Transport and Installation
Support
Anti-vibration
resilient mount
Oil sump
Base frame,
drilled for transport
011_WP5000_BA_en_0111.fm
37
5.2 Storage before Installation
If the Sauer compressor has to be stored before installation, do
not unpack, and store under the following conditions:
– Temperature: +5 to +40 °C;
– Relative humidity 30 to 95%, non-condensing
– In a dry area, under a roof and protected from the weather
– Protected from being soiled
– Protected against vibration and shock
Note!
The standard factory protective packing is sufficient for a
maximum storage period of 12 months.
Note!
High pressure hoses can be stored for up to five years after
delivery.
011_WP5000_BA_en_0111.fm
38
5.3 Installation
Note!
If in doubt regarding the suitability of the intended installation
area, please contact J.P. SAUER & SOHN. If required for the
installation area, Sauer can provide help with the design of a
ventilation system.
For proper installation follow the installation instructions and

observe the following.
Installation re- – The installation area must be dry and free from dust.
quirements – Ensure that the installation is ventilated in such a way that the
heat generated during operation is removed.
– Room temperature during operation of the Sauer compressor:
max. 45 °C
+5 °C to +45 °C
(Please contact J.P. SAUER & SOHN for operation outside
this temperature range).
min. 5 °C – For proper installation, follow the installation instructions and
observe the following conditions.
Note!
The air temperature at the location where the compressor is
installed must not exceed +45 °C. Conditions in the area of
installation as well as the heat generated by the compressor and
any other machines installed in the same area must be kept in
mind.
If necessary, install a ventilation or air extraction system in the
area.
Install the fresh air feed in such a way that the cooling air stream
is never directed at the compressor. Otherwise, there is a danger
that condensation will occur within the machine, with
corresponding consequential damage.
– At room temperatures below +5 °C the room must be heated

or a heater must be installed on the Sauer compressor.
011_WP5000_BA_en_0111.fm
– The installation location must be selected in such a way that

the Sauer compressor is easily accessible.
The cooling water spaces are automatically kept vented through

the arrangement of the cooling water inlet and outlet.
39
The quantity of cooling water must be set at a level such that the
cooling water outlet temperature is between 40 °C and 50 °C. A
maximum cooling water outlet temperature of 50 °C must not be
exceeded.
Note!
The Sauer compressor is cooled with fresh water or with
seawater.
Seawater can be used for cooling if desired, but according to its
temperature and chemical composition seawater can be very
corrosive.
Note!
J.P. SAUER & SOHN would be pleased to advise you on
installation of the compressors.
Foundation
Note!
The standard delivery anti-vibration mount has a resonant
frequency of approx. 7 Hz.
Excitation of the compressor foundation by vibrations from other
machines installed in the vicinity must not be in the 7 Hz range.
Otherwise there is a danger that the standard anti-vibration
mount could be destroyed by resonating vibration.
1. Check whether there are vibrations of the machine
foundation in the 7 Hz range.
2. If in doubt, contact J.P. SAUER & SOHN in order to clarify
whether a different anti-vibration mount can be used.
011_WP5000_BA_en_0111.fm
40
5.4 Connecting the compressor
Danger!
The compressor should only be connected by a qualified
technician. Any work on the electrical installation must be carried
out by qualified electricians only.
Pipelines Compressed air outlet, cooling water inlet and outlet, and
drainage connections of the Sauer compressor must be
connected by hose connections to any of the system owner’s
permanent piping.
Compressed air outlet
Condensate
Drainage Cooling water Cooling water

intake outlet
Danger!
At the compressor start-up and during drainage compressed air
escapes from the drainage connections. Consequently, do not
operate the compressor without hose lines connected.
011_WP5000_BA_en_0111.fm
41
The hose lines must be installed free of tension and not twisted.
Correct installation Incorrect installation
Drainage
Note!
Accumulated condensate contains oil. It may only be disposed
of in compliance with applicable legal regulations.
J.P. SAUER & SOHN offers condensate collection containers for
separating air from condensate as well as condensate
processing systems for separating oil from condensate.
Note!
We recommend connecting up the compressor drainage
separately.
If you wish to combine the drainage of several compressors,
please observe the following:
Choose a sufficient nominal diameter for the common drainage
line;
Connect the drainage lines of the individual compressors at a
sharp angle to the common drainage line, so that no pressure
can build up in the drainage line of a compressor that is not in
operation.
011_WP5000_BA_en_0111.fm
42
Non-return valve The non-return valve in the compressed air outlet must be ins-
talled in the air line least 750 mm away from the compressor out-
let. Ensure that the arrow markings embossed on the valve point
in flow direction.
Non-return valve
Flow direction
011_WP5000_BA_en_0111.fm
43
Connections The illustration below shows the connections and the fittings for
the operation of a typical Sauer compressor.
1 2 3 4
9 8 6
011_WP5000_BA_en_0111.fm
44
Item Designation Type Function

1 Drive motor AC motor Compressor drive
2 Non-return valve Plate valve Prevent air flowing back
3 Final pressure Change-over Start/stop control for the compressor
switch switch
4 Safety valve Spring-loaded To limit excessive pressure on the
safety valve parts subjected to pressure
5 Drainage valve Solenoid valve Start relief and drainage
6 High air tempera- Change-over Switch off compressor if temperature
ture switch switch is too high
7 Low oil pressure Change-over Switch off the compressor if oil
switch switch pressure is too low
8 Cooling water Solenoid valve Prevent flow of cooling water when
stop valve machine is not operating
9 Cooling water Centrifugal pump, Circulate cooling water
pump not self-priming
Note!
For technical specifications of the individual items, please refer
to Chapter 4.
All change-over switches are factory adjusted.
If desired, the components are supplied pre-wired to a terminal
box.
011_WP5000_BA_en_0111.fm
45
5.5 Filling with oil
The Sauer compressor is delivered without oil.
1st stage
Oil fill cap
3rd stage
4th stage
Dipstick
2nd stage
Danger!
Make sure to fill the crankcase of the compressor with oil before
initial operation!
Use an appropriate lubricating oil (see Chapter 10 “Lubricant
Table”).
Note the amount of oil needed (see Chapter 4 “Technical
Specification”).
1. Unscrew the oil fill cover.

2. Pour in oil and check the filling level with the dipstick.
Note!
Only fill with oil up to the upper level gauge mark on dipstick.
Overfilling increases the oil consumption of the compressor.
3. Replace the dipstick and screw the oil fill cap back in.
011_WP5000_BA_en_0111.fm
46
5.6 Checks to be carried out after installation and

before the first start-up.
– Check that the electricity connection matches the data on the
nameplate.
– Check that all connections between the compressor and the
compressed air equipment are properly installed.
Pay particular attention to the compressed air connection.
– Are the drainage lines properly connected?
– Are the cooling water lines open?
– Has the crankcase been filled with oil?
– Have all tools and foreign objects been removed from the
compressor?
– Is the entire unit clean?
011_WP5000_BA_en_0111.fm
47
6 Operation
6.1 Safe operation
Danger!
Only authorised persons are permitted to put the Sauer
compressor into operation and operate it!
Danger!
Only switch on and start the compressor when
it has been checked that it is in perfect condition;
all tools and foreign objects have been removed from the
machine.
Danger!
Immediately turn compressor off if personnel and property are
endangered. Only re-start compressor when there is no more
danger or possible damage.
Danger!
In Automatic mode the compressor starts automatically without
warning.
Danger!
Risk of burns from touching hot surfaces of the compressor
during operation. Wear protective gloves.
Danger!
Risk of hearing damage because of the sound pressure level
while the compressor is running! Wear hearing protection near
the compressor.
Note!
Switch compressor off in the event of any abnormal/fault
conditions or unexpected events. Eliminate the cause of the
problem with the help of Chapter 7 “Troubleshooting.”
011_WP5000_BA_en_0111.fm
48
Operation
6.2 Operating modes

After you have turned on the power supply to the Sauer
compressor, it can be started with one of the following two
operating modes using the mode selector switch:
– “Manual” operating mode:
The compressor starts and continues to run until it is stopped
or turned off either by using the mode selector switch or the
main switch.
– “Automatic” operating mode:
Starting and stopping the compressor is controlled by external
devices (for example using the pressure switch of the pressure
vessel).
When the Sauer compressor starts, it starts without load with the
drainage valves open. After a few seconds the valves close and
the compressor powers up against system pressure.
011_WP5000_BA_en_0111.fm
49
6.3 Initial operation
Check the Allow the Sauer compressor to run only for a few seconds to
direction of check the direction of rotation.
rotation 1. Switch the power supply on.
2. Set the mode selector switch to “Manual” to start the
compressor in manual mode.
3. In case of incorrect direction of rotation no oil pressure is
indicated. The compressor is shut-down after 15 seconds.
4. Set the mode selector switch to “0” to stop the compressor.
5. Switch off the power supply.
6. If the direction of rotation is incorrect, the polarity of the
electric motor should be changed by a qualified electrician.
Danger!
If the crank shaft rotates in the wrong direction, no oil pressure
builds up. Risk of subsequent damage.
7. Checking the direction of rotation of the cooling water

pump (option):
Switch on the pump motor.
The motor must not be allowed to reach its operating speed.
The direction of rotation must agree with the rotation direction
arrow on the pump. If the direction of rotation is incorrect, the
polarity of the electric motor should be changed by a qualified
electrician.
Pump and suction pipe must be completely filled with cooling
water.
Danger!
The cooling water pump must not be allowed to run dry.
011_WP5000_BA_en_0111.fm
50
Operation
Test run 1. Switch the power supply on.

2. Set the mode selector switch to “Manual” to start the
compressor in manual mode.
If correctly adjusted, the drain valves close after about 15
seconds and the compressor should power up against
system pressure.
3. Check the pressure gauges of each stage as well as the oil
pressure gauge and compare readings with the nominal
values (see Chapter 6.4 “Routine Operation”).
4. Check the function of the automatic periodic drainage.
It must drain for about 15 - 20 seconds every 15 minutes. This
is indicated by a drop in pressure on the pressure gauge.
5. Check that cooling water is flowing.
The temperature of the cooling water at the outlet must stay
within the range given in the “Specification data table” in
Chapter 4.1. The temperature can be read from the cooling
water thermometer at the cooling water outlet. If these
temperatures are exceeded or not reached the flow of cooling
water must be increased or decreased accordingly.
In the case of machines with an integrated cooling water
pump, the flow rate can be regulated with the slide on the
pump.
6. Set the mode selector switch to “0” to stop the compressor.
7. Switch off the power supply.
8. If necessary eliminate the cause of deviations from nominal
values and malfunctions. See also Chapter 7
“Troubleshooting”.
9. Complete the commissioning certificate and send it to J.P.
SAUER & SOHN Customer Service. The commissioning
certificate is in the Appendix.
011_WP5000_BA_en_0111.fm
51
6.4 Routine operation
Cleaning • Keep compressor area clean.
• Keep indicators and control elements clean.
Checks • Inspect connections, pipes and electric cables for damage.

• Check the oil level once a week before starting, top up, if
necessary. Do not overfill with oil beyond the maximum mark.
Operation 1. Switch the power supply on.

2. Open the cooling water lines.
3. Set mode selector switch to “Auto“ to operate the compressor
in Automatic mode.
Watch out for • Abnormal operating noise.

• Pay attention to leaks (compressed air, oil, condensate). The
temperature of the cooling water at the outlet must stay within
the range given in the “Specification data table” in Chapter 4.1.
• The pressure indicated on the pressure gauge must remain
within the grey zone in the stage pressure diagram (see
below).
• The oil pressure should be between 1.8 bar and 4 bar.
In the event of deviations, see Chapter 7 “Troubleshooting”.
011_WP5000_BA_en_0111.fm
52
Operation
Stage pressure diagram
4th stage [bar]
400
300
200
100
0
1 3 5 13 15 17 40 60 80
1st stage [bar] 2nd stage [bar] 3rd stage [bar]
Note!
Depending on the desired final pressure in the 4th stage, the
allowable pressure for the 1st, 2nd and 3rd stages can be read
from the above diagram.
011_WP5000_BA_en_0111.fm
53
Emergency ope-
ration
Note!
If faults occur in the compressor control or the auxialiary electri-
cal supply fails, the compressor can be operated manually.
1. Open manual drain valves for 1st and 2nd stage.

2. Turn power supply on.
3. Start cooling water supply.
4. Start the compressor.
5. After approx.1 minute, close the manual drain valves for 1st
and 2nd stage.
6. Every 20 minutes, open manual drain valves for 1st and 2nd
stage for approx. 15 seconds.
Danger!
The monitor and control devices in the compressor do not work
in manual mode.
The compressor must be continuously observed and switched off

if the following measured values on the gauge panel are excee-
ded:
• Air pressure of 1st stage above 3.5 bar;
• Air pressure of 2nd stage above 17 bar;
• Air pressure of 3rd stage above 80 bar;
• Air pressure of 4th stage above 320 bar
(safety valve activates);
• Compressed air temperature downstream of 3rd stage above
80°C;
• Cooling water outlet temperature above 40°C;
• Lubricating oil pressure below 1 bar.
7. If the maximum set value for the ultimate pressure is reached,

cease operations;
if the values fall below the minimum set value for the ultimate
pressure switch, start operations again in maunal mode.
011_WP5000_BA_en_0111.fm
54
Operation
Ceasing operati- 1. Let the compressor run for approx. 3 minutes with the manual
on valves for the 1st and 2nd stages open.
2. Stop the compressor.
3. Turn the power supply off.
4. Shut down the cooling water supply.
Note!
If inactive for more than one week, behave as for temporary de-
commissioning.
011_WP5000_BA_en_0111.fm
55
7 Troubleshooting guide
Note!
Should a malfunction occur, first check the indicators on the
compressor control panel and on the compressor.
Try to correct the fault with the help of the table below.
If the fault cannot be corrected, please contact J.P. SAUER &
SOHN Customer Service. The fault description journal is in the
Appendix of this Operator Manual.
Probable
Fault Remedy
cause
Compressor does not start No input power supply/no Check the fuses. Replace blown fuses.
or switches off. control voltage.
Compressor was switched Oil level too low. Check oil level and top up if necessary.
off because the oil pressure Check for leaks.
cutout switch tripped.
Oil too viscous. Fill with recommended oil.
Check that room temperature is
> + 5 °C.
Oil filter blocked. Clean the oil filter.
Oil pipe blocked. Clean oil pipe.
Oil pump faulty or leaking. Check oil pump. If necessary eliminate

leak or replace oil pump.
Compressor was switched Excessive current drawn. Check supply voltage and electrical
off by overcurrent relay. connections. The compressor can be
started again after a cooling down
period.
Check whether the crankshaft can

easily be turned by hand. If not,
011_WP5000_BA_en_0111.fm
disconnect and ascertain whether the

problem has to do with the motor or the
compressor.
Piston seizure Check cylinders and pistons for any

score marks, replace as necessary.
56
Troubleshooting guide
Probable
Fault Remedy
cause
Safety valve of 1st stage
blows off:
Pressure exceeds blow- 2nd stage valve is not working Check the valve of the 2nd stage and
off pressure (6 bar) properly. replace if necessary.
Gasket between suction and Replace gasket.

pressure side of the 2nd stage
is faulty.
Pressure below blow-off Safety valve is faulty. Replace safety valve.

pressure (6 bar)
Safety valve of 2nd stage

blows off:
Pressure exceeds blow- 3rd stage valve is not working Check the valve of the 3rd stage and

pressure side of the 3rd stage
is faulty.

pressure (20 bar)
Safety valve of 3rd stage

blows off:
Pressure exceeds blow- 4th stage valve is not working Check the valve of the 3rd stage and

pressure side of the 4th stage
is faulty.

pressure (95 bar)
Safety valve of 4th stage

blows off:
Pressure above blow-off Valve in the air line to the Open valve.
pressure (final pressure compressed air vessel is
+ 5%) closed.
Pressure switch is set too Lower the pressure setting.

high.
Excessively high pressure Reduce the pressure losses.

011_WP5000_BA_en_0111.fm
losses in the air line to the

compressed air vessel.
Pressure below blow-off Safety valve is set too low or is Replace safety valve.
pressure (final pressure faulty.
+5%).
57
Probable
Fault Remedy
cause
Safety valve of 1st stage
blows off:
Pressure exceeds blow- 2nd stage valve is not working Check the valve of the 2nd stage and

pressure side of the 2nd stage
is faulty.

pressure (6 bar)
Safety valve of 2nd stage

blows off:
Pressure exceeds blow- 3rd stage valve is not working Check the valve of the 3rd stage and

pressure side of the 3rd stage
is faulty.

pressure (20 bar)
Safety valve of 3rd stage

blows off:
Pressure exceeds blow- 4th stage valve is not working Check the valve of the 3rd stage and

pressure side of the 4th stage
is faulty.

pressure (95 bar)
Safety valve of 4th stage

blows off:
Pressure above blow-off Valve in the air line to the Open valve.
pressure (final pressure compressed air vessel is
+ 5%) closed.
Pressure switch is set too Lower the pressure setting.

high.
Excessively high pressure Reduce the pressure losses.

011_WP5000_BA_en_0111.fm
losses in the air line to the

compressed air vessel.
Pressure below blow-off Safety valve is set too low or is Replace safety valve.
pressure (final pressure faulty.
+5%).
58
Probable
Fault Remedy
cause
Pressure gauge of the 1st Valve of the 2nd stage is Check the valve of the 2nd stage and
stage is showing excessive leaking. replace if necessary. Replace gaskets.
pressure.
Pressure gauge of the 2nd Valve of the 3rd stage is Check the valve of the 3rd stage and
pressure.
Pressure gauge of the 3rd Valve of the 4th stage is Check the valve of the 4th stage and
pressure.
Pressure gauge of the 1st Valve of the 1st stage is Check the valve of the 1st stage and
stage is showing insufficient leaking. replace if necessary.
pressure.
Air filter very dirty. Clean the air filter insert or replace it.
The pressure gauges of all No power at solenoid drainage Check solenoid valve power supply.
stages show no pressure. valve.
Solenoid valve of the drainage Check the solenoid valve and replace it
is faulty. if necessary.
Air escaping from the Connection gaskets or seals Replace faulty gasket or seal.
compressed air lines. leaking.
Cutting rings leaking. Switch compressor off. Wait until all

parts are no longer under pressure;
check the pressure gauge for this.
Tighten all fittings.
Compressor was switched Compressed air temperature Increase flow of cooling water
off, high air temperature at the outlet too high as a (in the case of a cooling water pump
switch has tripped. result of shortage of cooling only: Open the slide at the rear of the
water. pump further);
Check the temperature of the cooling
water at the outlet and the functioning
of the cooling water stop valve;
Clean the particle trap
Compressed air temperature Clean the cooling water containers

at the outlet too high because with a descaling agent.
of poor thermal transition in
the cooler as a result of
scaling in the chamber.
011_WP5000_BA_en_0111.fm
59
Probable
Fault Remedy
cause
Cooling water outlet Cooling water intake is blo- Check cooling water supply.
temperature too high. cked.
Cooling water pressure is too Check cooling water flow.

low.
Lack of cooling water. Clean particle trap.
Excessive cooling water intake Check cooling water intake tempera-

temperature: ture
temperature > 32 °C check the quantity of intaken cooling
water.
Thermostatic valve defective, Check setting, replace defective ther-

incorrectly set or installed for mostatic valve.
wrong area.
Cooling water line is blocked. Check cooling water flow.
Cooling water housing or coo- Repair or remove leaking components,

ling water line is leaking. replace gaskets.
Scaling in the cooler. Clean the cooling water containers

with a descaling agent.
Cooling water outlet tempe- Cooling water flow too high. Check thermostatic valve, replace
rature too low. defective thermostatic valve.
Thermostatic valve defective, Check setting, replace defective ther-

incorrectly set or installed for mostatic valve.
wrong area.
Solenoid valve (drainage) No power supply. Check fuses, replace blown fuses.
does not close.
Solenoid faulty. Replace solenoid.
Foreign matter in solenoid Clean solenoid valve.

valve.
Pneumatic relief valve does Foreign matter in pneumatic Clean pneumatic relief valve.
not close. relief valve.
Gaskets worn. Replace gaskets.
Cooling water stop valve No power supply. Check fuses, replace blown fuses.
does not open.
Solenoid faulty. Replace solenoid.
Foreign matter in solenoid Replace solenoid valve.

valve.
011_WP5000_BA_en_0111.fm
60
Probable
Fault Remedy
cause
Abnormal compressor Connecting rod bearing faulty. Check connecting rod bearing, replace
noise. if necessary.
Check oil supply.
Gudgeon pin bearing faulty. Check gudgeon pin bearing, replace if

necessary.
Crankshaft bearing faulty. Check crank shaft bearing, replace if

necessary.
Motor bearing faulty. Check motor bearing, replace if

necessary.
Oil leaking from crankcase. Gasket or shaft Tighten all screws.

seal faulty. Screws not tight. If there is significant leakage check to
see which gasket is faulty, then replace
it.
Minor traces of oil on the crankcase
or oil drops below the compressor are
harmless. Wipe off with a lint-free rag.
Water escaping at the relief O-ring of the liner is faulty Replace O-ring.
groove of the cylinder flange above the relief groove.
surface.
Oil escaping at the relief O-ring of the liner is faulty Replace O-ring.
groove of the cylinder flange below the relief groove.
surface.
Water in the oil Excessive cooling of Reduce flow of cooling water. Change
compressor due to room ventilation so that air stream is
- Flow of cooling water too not blown directly against compressor.
high Extend compressor running time
- Unfavourable room
ventilation
- Very short compressor
running time
Poor drainage. Check drainage lines and drainage

intervals.
Burst disc in the cooling Leaks in cooler. Replace cooler bundle.

water circuit triggers
OR Pressure peaks in the cooling Determine the cause of the pressure
Cooling water safety valve water circuit cause the burst peaks and eliminate these causes
triggers. disc bursting pressure or the (startup of additional pumps, actuation
safety valve preset pressure to of electromagnetic stop valves or
be exceeded. shuttle valves, or similar causes)
Premature fracture of valve Poor drainage. Check drainage lines and drainage
plates or valve springs intervals.
011_WP5000_BA_en_0111.fm
Note:Indentations in the gasket

contact surface of the valve plate are
normal.
61
8 Maintenance
8.1 J.P. SAUER & SOHN Customer Service
The J.P. SAUER & SOHN Customer Service offers various
maintenance services – e.g. full maintenance or valve
replacement service. Please contact our Customer Service:
J.P. SAUER & SOHN Maschinenbau GmbH

Customer Service
P.O. Box 92 13
24157 Kiel, Germany
Phone (international):
Technical information +49 431 39 40 -87
Spare parts orders +49 431 39 40 -86/886
Fax (international): +49 431 39 40 -89
Emergency service (international): +49 172 4 14 63 94
Web: www.sauercompressors.de
or contact an authorised J.P. SAUER & SOHN service partner in

your area.
011_WP5000_BA_en_0111.fm
62
Maintenance
8.2 Maintenance safety

Before mainte- 1. Disconnect the power supply to the compressor.
nance work 2. Put up “Attention! Maintenance work!” sign on the power
supply.
Danger!
Only authorised persons are permitted to service and make
adjustments to the Sauer compressor!
Danger!
Risk of injury from hot surfaces!
Allow compressor to cool down after shutting OFF.
Danger!
Risk of injury from pressurised compressor components!
Check the pressure gauges before servicing to ensure the
compressor is completely relieved of pressure.
Danger!
High voltage! Danger to life!
Never assume that a circuit is de-energised – Always check for
your own safety!
– The main switch is energised, even when it is turned off.
– Components being worked on must only be energised if this
is explicitly specified.
Danger!
Danger of death from missing safety devices and missing
isolating protection devices!
Reinstall all safety devices and isolating protection devices after
servicing. This also applies to electrical protection devices (e.g.
earth wires).
011_WP5000_BA_en_0111.fm
63
8.3 Maintenance schedule
Danger!
For all maintenance work Chapter 8.4 “Table of Tightening
Torques” must be observed for certain screws/bolts.
Note!
The maintenance intervals specified in the maintenance
schedule must be adhered to. Shortening maintenance intervals
is of no advantage with regard to operating performance or
service life of the Sauer compressor.
Note!
After a major overhaul (=8,000 operating hours) the
maintenance schedule begins all over again.
Instructions for • Use the maintenance schedule as a master template or copy

the maintenance the respective page from the document and save it as a
separate file under a suitable name. Use the maintenance
schedule
schedule as a guide and as a record of work completed.
• Regularly check the maintenance schedule to see which
maintenance intervals, must be kept, depending upon the
number of operation hours. The intervals are shown in the
table’s column headers.
• Check the column of each maintenance interval to see what
maintenance work is to be carried out at the end of each
maintenance interval. The required tasks are indicated by
check boxes. The description and chapter number for tasks
are shown in the first column.
• Carry out all maintenance work for an interval and tick the
appropriate check boxes of the maintenance schedule. Then
enter operation hours count, date and your signature.
• When beginning a new maintenance schedule
– Enter: main specifications, date of commissioning, number
of maintenance schedule, current date and operation hours
count.
– Mark with an “X”: beginning after commissioning/after
major overhaul
011_WP5000_BA_en_0111.fm
64
Maintenance
Maintenance schedule No.: Compressor type:

Maintenance schedule Type series WP5000
beginning:
 After commissioning Compressor number:
 After major overhaul Factory No.:
Date: Year of construction:
Operation hours count: Date of commissioning:
Interval
At least annually if < 1000

50 h after commissioning
50 h after major overhaul
operation hours per year

[Operation hours]
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
Maintenance routine
Checking screw connections           
Changing air filter insert 1 (small)         
Changing air filter insert 2 (big)         
Changing oil           
Cleaning oil filter           
Checking, cleaning valve 1st stage  
Checking, cleaning valve 2nd stage  
Checking, cleaning valve 3nd stage    
Checking, cleaning valve 4th stage    
Changing valve 1st stage  
Changing valve 2nd stage  
Changing valve 3nd stage    
Changing valve 4th stage    
Changing piston rings and gudgeon pins 
Changing gudgeon pin bearings 
Changing connecting rod bearings 
Changing gaskets of pneumatic relieve valve  
Changing gaskets, o-rings and spring of
 
solenoid valve 1st stage
 
solenoid valve 2nd stage
011_WP5000_BA_en_0111.fm

 
solenoid valve cooling water circuit
 
pressure maintaining valve
Checking / changing zinc protection  
Cleaning coolers    
65
Intervall
At least annually if < 1000

50 h after commissioning
50 h after major overhaul
operation hours per year

[Operation hours]
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
Maintenance routine
Changing burst discs        
Cleaning separators        
Changing savety valves yearly / 1000 h        
Changing final air filter annually or a differential
       
pressure of 0.6- 0.8 bar
Changing pistons and cylinders  
Check liners  
Checking drive bearings 
Checking the coupling  
Replace coupling flexible insert 
Replace shaft seal 
Check cooling water pump  
Major overhaul by Sauer service 
Operation hours count

Date
Signature
(initials)
Note!
There are maintenance lists containing the work procedures and
materials lists of the required spare parts which go with the
individual maintenance routines.
Note!
Carry out a check 50 h after commissionin
Check all screws as described in Chapter 8.6(Checking screwed
connections)
011_WP5000_BA_en_0111.fm
Note!
Carry out a check 50 h after completing a maintenance
routine.
Check all screws affected by maintenance to see if they are tight.
66
011_WP5000_BA_en_0111.fm
67
Maintenance
8.4 Table of tightening torques
Bolts/screws Tightening torque

Connecting rod screws 90 Nm
Flywheel retaining nut Tighten 90° above
clearly noticeable
increasing power
Cylinder base nut 350 Nm
Cylinder head screws 1st, 2nd and 175 Nm

3rd stage
Cylinder head screws 4th stage 275 Nm
Burst disc flange screws 75 Nm

Coupling half screw 30 Nm
Fixing screw for cooler 110 Nm
Fixing screw for bearing bracket 54 Nm
011_WP5000_BA_en_0111.fm
68
Maintenance
8.5 Changing the oil

Note!
Only use oil as recommended in the lubricant table (see
Chapter 10).
Note!
Independent of maintenance schedule, in case of water inleaka-
ge or contamination of lubrating oil the oil has to be changed im-
mediately.
To change the oil completely, the oil sump has to be removed
and the used oil from the sump must be disposed of in an envi-
ronmentally sound manner.
Oil level check /

filling with oil
Z Z
Oil fill cap
1st stage
3rd stage
4th stage
2nd stage
Oil drain Dipstick
1. Place oil catchpan (of a size sufficient for the oil sump
capacity, see Chapter 4 “Technical Specification”) beneath
the oil drain.
011_WP5000_BA_en_0111.fm
2. Open the oil drain.

3. Wait until all the oil has drained.
4. Close the oil drain.
5. If necessary:
Loosen cap screws and remove the oil sump from the
69
crankcase.
6. Remove the used oil from the oil sump and dispose it in an
environmentally sound manner.
7. Mount the crankcase on the oil sump, use new gasket.
8. Unscrew the oil fill cover.
9. Fill in oil and at intervals check the filling level with the
dipstick.
The filling level must be between the upper and lower gauge
mark on the dipstick.
10. Slide the dipstick in and screw the oil fill cover shut.
011_WP5000_BA_en_0111.fm
70
Maintenance
Clean oil filter

Note!
Cleaning the oil filter should be done together with an oil change.
To clean the oil filter the crankcase must be removed from the oil
sump.
Z 11 9
Z
1st stage
10
2
rd th
3 stage 4 stage
8
1 14
2nd stage 13
12
3 5 4 6 7

1 Inspection hole cover 8 Oil pipe
2 Crankcase 9 Socket
3 Oil sump 10 O-ring
4 Oil filter pipe (Oil filter insert) 11 Cap screw
5 Oil filter plate (Oil filter insert) 12 Dipstick
6 Pipe 13 Cap screw
7 Threaded socket 14 Gasket
1. Unscrew cap screws and remove oil sump from the the rank-
case.
2. Remove the inspection hole covers between the 2nd and 4th
011_WP5000_BA_en_0111.fm
stage.
3. Unscrew the cap screws on the socket.
4. The socket is fitted with two jacking threads M8. Two jacking
screws size M8 have to be screwed into these threads to
withdraw the socket out of the crankcase. Then take it out
through the open inspection hole.
71
Socket
Jacking thread M8
5. Pull down the oil pipe with the socket out of the crankcase.
Socket
Oil pipe
Crankcase Oil filter
6. Unscrew the oil filter from the oil pipe.

7. Dismantle oil filter and filter base and wash in an oil-dissol-
ving fluid (e. g. kerosine or petrol).
8. Blow kerosine out of the oil filter with compressed air fron in-
side to outside.
Danger!
Compressed air must never be pointed at persons!
9. Soak oil filter in new oil according to the lubricant table and let
it drain for 20 to 30 minutes.
Note!
Collect draining oil anddispose it in an environmentally safe
011_WP5000_BA_en_0111.fm
manner.
10. Attach the oil filter to the oil pipe and put it back into the crank-
case.
11. Put the socket into the crankcase, use new o-rings.
72
Maintenance
12. Connect oil pipe with oil filter with the socket using cap
screws.
13. Apply inspection hole covers.
14. Mount the the oil sump to the crankcase, use new gaskets.
011_WP5000_BA_en_0111.fm
73
8.6 Checking screwed connections
Check all fittings and screw connections for tightness, re-tighten
as necessary. This includes:
– Coolers and air lines
– Fittings for pipe lines and flexible hose lines
– Cylinder heads
– Cylinders
– Electric motor and bell-housing flange
– Monitoring systems and switchgear
– Baseframe/foundation
– Accessories and ancillary equipment
011_WP5000_BA_en_0111.fm
74
Maintenance
8.7 Changing the air filter insert
Cover
Air filter with

insert
1. Remove air filter cover.

2. Take out the spent air filter insert.
3. Clean housing with a lint-free rag.
4. Insert new air filter insert.
5. Insert cover.
011_WP5000_BA_en_0111.fm
75
8.8 Checking valves
Note!
Plate valves (concentric valves), and reed (lamellar) valves in
particular, are subjected to the most stress in a reciprocating
compressor. In order to achieve the guaranteed maintenance
intervals, these valves are high-quality precision parts, specially
matched to the individual compression stages and their function
carefully checked before delivery. Repair by maintenance and
operating personnel requires specialist knowledge, which may
not be readily available. Please contact Sauer Customer Service
for assistance.
Note!
Install all valves with new gaskets and seals. Do not reuse the
used seals under any circumstances. Doing so leads to leakage
within a short time.
Only use genuine Sauer spare parts. They are precision parts
specially designed for these installation applications with defined
and tested dimensions and material characteristics. Installation
of other gaskets may lead to leakage and may cause substantial
damage to the compressor.
Removing valves 1. Disassemble compressed air pipes and remove hoses.

2. 1st stage: Loosen the valve cover screws and remove the
valve cover.
3. Loosen socket and carefully remove the 1st stage plate valve.
Socket
1st stage valve
4. 2nd stage: Loosen the valve cover screws and remove the
valve cover.
5. Remove the 2nd stage lamellar valve from the valve cover by
loosening the valve retaining screw, carefully remove the
valve.
6. 3rd stage: Loosen the valve cover screws and remove the
011_WP5000_BA_en_0111.fm
valve cover.
7. Carefully remove the 3rd stage plate valve.
8. 4th stage: Loosen the valve cover screws and remove the
valve cover.
9. Carefully remove the 4th stage plate valve.
76
Maintenance
Check plate
valves (1st, 3rd,
4th stage)
Note!
Ensure that no valve parts are damaged while removing,
cleaning and installing the plate valves. This particularly applies
to the mating surfaces and the valve springs.
Plate valves
1st stage 3rd stage 4th stage
10. Use a pin with rounded tip to check the valve plates are
moving freely against the spring pressure.
Checking the 11. Inspect the 2nd stage lamellar valve.

lamellar valve If there is heavy coking or damage, replace the complete
lamellar valve.
(2nd stage)
Lamellar valve 2nd stage

011_WP5000_BA_en_0111.fm
77
Note!
Lamellar valves require very little maintenance and, in contrast
to plate valves, function even when there are small quantities of
dirt present. Normally the plates have the same service life as
the valve body which, due to its geometry, cannot be re-faced or
lapped.
We therefore advise against replacing individual lamellar ele-
ments. Should a lamellar element be broken prematurely (e.g.
by foreign objects), please contact Sauer Customer Service.
011_WP5000_BA_en_0111.fm
78
Maintenance
Valve installation
Note!
Do not reuse used seals under any circumstances. Doing so
leads to leakage within a short time.
12. Install the 1st stage plate valve with socket and valve cover.
Use new seals in the valve cover when doing this. Observe
the tightening torque of 160 Nm.
1st stage O-ring

Socket
160 Nm
Valve cover
Plate valve
13. Mount crankcase ventilation hose.

14. Install the 2nd stage lamellar valve and valve cover. Use new
O-rings for this. Observe the tightening torque of 160 Nm of
the cylinder head screws.
2nd stage
160 Nm Valve cover
O-ring
O-ring
Lamellar valve
15. Install the 3rd stage plate valve and valve cover.
011_WP5000_BA_en_0111.fm
Use new gasket and new o-rings in the valve cover when
doing this. Observe the tightening torque of 160 Nm of the
cylinder head screws.
79
3rd stage
160 Nm
Valve cover
O-ring
Gasket
Plate valve
16. Install the 4th stage plate valve and valve cover.
Use new gasket and new o-rings in the valve cover when
doing this. Observe the tightening torque of 250 Nm of the
cylinder head screws.
4th stage
250 Nm
Valve cover
O-ring
Gasket
Plate valve
17. Reinstall the pipe fittings and hose lines.

011_WP5000_BA_en_0111.fm
80
Maintenance
8.9 Checking piston rings and connecting rods
Note!
Remove the pistons in order stage 1 - 4 - 3 - 2.
1. Remove valve covers and valves as described in Chapter 8.8

“Checking valves”.
2. Drain cooling water out of the cylinders via drain plugs.
Drain plug
Eye bolt
1st stage 2nd stage 3rd stage 4th stage
Note!
For removal, lift the cylinders by the crane using the eye bolts.
1st stage 3. Unfasten clamp on intake manifold and intake filter clamp and
remove air intake filter.
4. Unscrew fittings of the pressure channel and of the cooling
water lines on the cylinder.
5. Remove air intake filter clamp.
011_WP5000_BA_en_0111.fm
81
Cooling water lines
Air intake filter Clamp
Pressure channel
6. Loosen cylinder base nuts and pull off cylinder.

7. Remove both crankcase inspection covers opposite to the 1st
stage cylinder.
Cylinder base nut

4th stage
Inspection hole cover
1st stage 2nd stage

350 Nm
3rd stage
8. Loosen connecting rod bolts and, together with the bearing

cover, remove the lower half of the connecting rod from the
crankcase.
The half of the connecting rod must be held securely from the
other side during disassembly!
9. Pull the upper half of the connecting rod and piston out of the
crankcase.
10. Check connecting rod bearing for scoring marks, replace if
are signs of excessive wear.
011_WP5000_BA_en_0111.fm
11. Replace the gudgeon pin and the gudgeon pin bearing
(small-end bearing) if necessary:
– Remove the criclips of the gudgeon pin and press gudgeon pin
bearing (Small-end bearing) out of the connecting rod‘s small
end with a proper tool.
82
Maintenance
– Remove piston.
– Replace gudgeon pin and gudgeon pin bearing (small-end be-
aring).
– Press gudgeon pin bearing (small-end bearing) into the con-
necting rod‘s small end with a proper tool.
12. Remove the set of piston rings from its piston by piston ring
expander.
13. Insert the piston rings in the respective cylinder and measure
the gap clearance and the ring groove clearance with a feeler
gauge.
14. Replace all piston rings if the clearance of one ring exceeds
the limit value.
Note!
For mesurement, the piston rings must be placed outside of the
working area in the liner.
Piston rings 1st stage Min clearance Max clearance

Plain ring 0.70 mm 0.90 mm
Nose ring 0.70 mm 0.90 mm
Oil scraper ring 0.70 mm 0.90 mm
Ring groove clearance

Piston rings 1st stage Min clearance Max clearance
Nose ring
Note!
Always replace all pistons rings of a piston when one of the
piston rings exceeds the limit value.
15. piston rings in the piston.

011_WP5000_BA_en_0111.fm
Make sure they are in the correct position: piston rings having
an asymmetric cross section are marked with “TOP” on one
of the surfaces. The marked face must be at the top when the
piston ring is installed (see illustration).
83
Piston rings TOP
1st stage TOP
16. The piston ring gaps should be staggered around the piston
circumference.
17. Check cylinder liner for scores. Replace in case of excessive
wear.
18. Use a tightening strap of diameter 195 to slide the piston into
the cylinder.
19. Put the cylinder on the cylinder flange surface. Use new
cylinder gasket. During assembly, grab through the
inspection holes to pass the connecting rod.
20. Install connecting rod as described in Chapter 8.14
“Replacing the connecting rod”.
21. Tighten the cylinder base nuts, observe the tightening torque
of 350 Nm.
22. Install the crankcase inspection covers, the pressure
channels, the air intake filter and the cooling water lines.
2nd stage 1. Remove the protection from the 2nd stage cylinder.
Protection
3rd stage 4th stage
2nd stage
2. Unscrew fittings of the pressure channels and of the cooling

3. Unscrew fittings of the manifold and remove the manifold.
011_WP5000_BA_en_0111.fm
84
Maintenance
3rd stage 4th stage
2nd stage Manifold

5. Remove both crankcase inspection covers opposite to the
2nd stage cylinder.
Cylinder base nut

4th stage
350 Nm
1st stage
2nd stage
3rd stage
6. Loosen connecting rod bolts.

crankcase.
Note!
If the big-end bearing shall not be checked, the lower section of
the connecting rod can be left in position. A spacer is not nee-
ded.
8. Checking the big-end bearing:

– Mark the position of the connecting rod and put a spacer
(thickness 37.5 mm) to the crankshaft to prevent the other con-
011_WP5000_BA_en_0111.fm
necting rods from sagging.

– Remove thrust washer.
– Together with the thrust washer, remove the lower half of the
connecting rod from the crankcase.
– Check connecting rod bearing for scoring marks, replace if are
signs of excessive wear.
85
– Attach the thrust washer again.
Thrust washer Connecting rod

– Remove piston.
aring).
expander.
gauge.
12. Replace all piston rings if the gap clearance of one ring
exceeds the limit value.
Piston rings 2nd stage Min clearance Max clearance


Piston rings 2nd stage Min clearance Max clearance
Nose ring 0.02 0.11 mm
011_WP5000_BA_en_0111.fm
86
Maintenance
Note!
Always replace all pistons rings of a piston when one of the pis-
ton rings exceeds the limit value.
13. Install piston rings in the piston.

Piston rings
2nd stage TOP
TOP
circumference.
wear.
16. Use a tightening strap of diameter 100 to slide the piston into
the cylinder.
The thrust washer of the connecting rod must be at the
bottom!
of 350 Nm.
20. Fit air lines, manifold, cooling lines as well as inspection hole
covers and protection. Use new gaskets.
3rd stage 1. Unscrew fittings of the pressure channels and of the cooling
3. Remove both crankcase inspection covers opposite to the 3rd
stage cylinder.
011_WP5000_BA_en_0111.fm
87
4th stage
1st stage
2nd stage
Cylinder base nut
350 Nm
3rd stage

crankcase.
Note!
ded.

(thickness 32 mm) to the crankshaft to prevent the connecting
rods above from sagging.
– Remove the lower half of the connecting rod from the crank-
case.
– Remove piston.
aring).
011_WP5000_BA_en_0111.fm
expander.
gauge.
88
Maintenance
10. Replace all piston rings if the clearance of one ring exceeds
the limit value.
Piston rings 3rd stage Min clearance Max clearance


Piston rings 3rd stage Min clearance Max clearance
Note!
11. Install piston rings in the piston.

Piston rings
3rd stage TOP
circumference.
wear.
14. Turn the cylinder with liner collar downwards and push the
piston into the cylinder. Ensure that the piston does not cant.
In case of obstacle the position of the piston rings must be
011_WP5000_BA_en_0111.fm
checked.
89
3rd stage
Piston
Cylinder
Liner
of 350 Nm.
18. Fit air lines, cooling lines and inspection hole covers . Use
new gaskets.
4th stage 1. Unscrew fittings of the pressure channels, of the cooling

water lines and of the lubrication line on the cylinder.
4th stage Lubrication line

011_WP5000_BA_en_0111.fm

3. Remove both crankcase inspection covers opposite to the
4thstage cylinder.
90
Maintenance
Cylinder base nut th

4 stage
350 Nm
1st stage
2nd stage
Inspection hole cover 3rd stage

crankcase.
Note!
ded.
(thickness 32 mm) to the crankshaft to prevent the connecting
rods above from sagging.
– Remove the lower half of the connecting rod from the crank-
case.
– Remove piston.
aring).
011_WP5000_BA_en_0111.fm
expander.
the gap clearance with a feeler gauge.
10. Replace all piston rings if the gap clearance of one ring
91
exceeds the limit value.
Piston rings 4th stage Min clearance Max clearance


Piston rings 4th stage Min clearance Max clearance
Plain ring (pair) 0.01 mm 0.12 mm
Note!
11. Install piston rings two by two and staggered against each
other in the piston.
circumference.
wear.
14. Turn the cylinder with liner collar downwards and push the
piston into the cylinder. Ensure that the piston does not cant.
In case of obstacle the position of the piston rings must be
checked.
4th stage
Piston
Cylinder
Liner
011_WP5000_BA_en_0111.fm
92
Maintenance

of 350 Nm.
18. Fit air lines, cooling lines and inspection hole covers . Use
new gaskets.
011_WP5000_BA_en_0111.fm
93
8.10 Replacing the gudgeon pins/gudgeon pin
bearings (small-end bearing)
1. Remove valve heads and valves as described in Chapter 8.8
2. Remove the cylinder and piston as described in Chapter 8.9
“Checking piston rings and connecting rods”.
3. Remove crankcase inspection cover and remove connecting
rods.
4. Press gudgeon pin bearing (small-end bearing) out of the
connecting rods' small ends with a proper tool.
5. Replace gudgeon pins and gudgeon pin bearings (small-end
bearing).
6. Press gudgeon pin bearing (small-end bearing) into the
connecting rod's small end with a proper tool.
8. Install inspection hole cover.
9. Install the cylinder and piston as described in Chapter 8.9
“Checking piston rings and connecting rods”.
10. Install valves and cylinder heads as described in Chapter 8.8
011_WP5000_BA_en_0111.fm
94
Maintenance
8.11 Replacing valves

Remove and install valves as described in Chapter 8.8 “Checking
valves”. Make sure to completely replace the valves when doing
this.
8.12 Checking pistons and cylinders

1. Remove valve heads and valves as described in Chapter 8.8
2. Remove the cylinder and piston as described in Chapter 8.9
“Checking piston rings”.
3. Check cylinders and pistons for scoring marks and excessive
wear. Replace parts as required.
4. Measure cylinders and replace if the following wear limits are
exceeded:
Cylinder Cylinder diametral wear limit
1st stage 195.15 mm
2nd stage 100.15 mm

Upper part: 50.10 mm
3rd stage
Guide part: 88.10 mm
5. Install the cylinder and piston as described in Chapter 8.9

“Checking piston rings”.
6. Install valves and cylinder heads as described in Chapter 8.8
011_WP5000_BA_en_0111.fm
95
8.13 Checking the drive bearings
1. Remove cylinders, pisrons and connectiong rods of all stages
as described in Chapter 8.9 “Checking piston rings and
connecting rods”.
Motor
Air intake filter

Clamp Gauge panel
Fixing
screw
Protection
Bell
housing
2. Remove protection between motor and bell housing.

3. Remove air intake filter clamp.
4. Loosen the fixing screws of the motor on bell housing and lift
off the motor.
5. Loosen fixing screws of the gauge panel on intermediate
flange.
6. Loosen fixing screws of the coolers on intermediate flange.
Cooler
Fixing screw
110 Nm
011_WP5000_BA_en_0111.fm
7. Loosen fixing screws of the bell housing on the crankcase

and lift off the bell housing.
96
Maintenance
Flywheel nut Coupling

Flywheel Fixing screw
30 Nm
Fixing screw
4x Forcing thread 54 Nm
M10 Bearing bracket
8. Loosen the fixing screws of the coupling on the flywheel and

take off the coupling.
9. Loosen the fixing screws of flywheel nut and take off the fly-
wheel.
10. Loosen the fixing screws of the bearing bracket. Use screws
M10 to screw into the four forcing threads to lift off the bearing
bracket.
11. Check shaft seal in the bearing bracket and replace if there
are signs of extreme wear. Replace o-ring.
O-ring Shaft seal
Bearing bracket
12. Drain the oil, remove the oil sump as described in Chapter 8.5
“Oil sump“.
13. Loosen fixing screws of the driving gear wheel of the oil pump
011_WP5000_BA_en_0111.fm
and remove the gear wheel from the crankshaft.

14. Draw the crankshaft with the bearings out of the crankcase.
97
Gear wheel
oil pump
Fixing
screw
Oil sump Bearing
Crankshaft
Oil pipe
Oil drain
15. Check the crankshaft bearings for scores and excessive wear
and replace if there are signs of extreme wear.
Bearing Crankshaft
16. Assembly follows the steps in reverse order.

– Use new gaskets and o-rings.
– Tighten flywheel nut 90° above the point when an increase in
force can be clearly felt.
– Install connecting rods “from bottom to top“ in order of 2nd sta-
ge, 3rd stage, 4th stage, 1st stage.
– Check the tightening torques 90 Nm.
011_WP5000_BA_en_0111.fm
98
Maintenance
8.14 Replacing the connecting rods

1. Remove the crankcase inspection covers and remove the
connecting rods as described in Chapter 8.9 “Checking the
Piston Rings and Connecting Rods”.
Note!
When replacing a connection rod, the gudgeon pin of the
corresponding stage must also be replaced.
2. Place the well oiled connecting rods onto the crankshaft.

Make sure the connecting rods are in the correct position on
the crankshaft (see illustration).
The connecting rod bolts must be completely screwed in by
hand. This is the only way to ensure proper seating of the
crankshaft. After tightening, the connecting rod should rotate
easily on the crankshaft. Observe torque of 90 Nm (see
Chapter 8.4).
1st stage
4th stage
3rd stage
2nd stage
Gudgeon pin
Note!
Numbers are punched on the upper and lower halves of the
connecting rod. These numbers must match. See illustration.
011_WP5000_BA_en_0111.fm
14
14
99
3. Install inspection hole covers.
011_WP5000_BA_en_0111.fm
100
Maintenance
8.15 Checking the separator

1. Shut down the compressor and secure it against restarting.
2. Disconnect installed air lines and hoses.
3. Remove the separator housing from the crankcase.
Separator
1st and 2nd stage
Gasket Fixing screw
O-ring Separator housing
Separator insert
Baffle cone
Fixing screw
Drain line
Condensate
4. Unfasten the fixing screws and take off the separator

housing.
5. Pull out the separator insert.
6. Unfasten the fixing screw and take off the baffle cone.
7. Check the separator inside for residues and check for dam-
age.
8. Clean the separator housing with kerosene.
9. Blow out kerosene with air.
Use new gasket and new o-ring.
011_WP5000_BA_en_0111.fm
101
Separator
3rd stage
Separator head
O-ring
Plug, gasket Separator housing
Drain line
Condensate
1. Unscrew and remove separator housing.

2. Take off separator head.
3. Unscrew plugs.
age.
011_WP5000_BA_en_0111.fm
102
Maintenance
Separator
4th stage
Separator head
O-ring
Plug, gasket
Separator housing
Drain line
Condensate
1. Unscrew and remove separator housing.

2. Take off separator head.
3. Unscrew plugs.
age.
011_WP5000_BA_en_0111.fm
103
8.16 Checking safety valves
Danger!
There is risk of injury from escaping air.
Therefore keep your head away from the safety valve.
Note!
The testing operation must take place quickly and must not be
repeated.
1. Turn on the system and start up the compressor unit until it
has reached final pressure.
Safety valve
Lifting device
2. Turn the lifting device on the safety valve to the left until the
safety valve blows.
3. After the valve actuates, turn the lifting device back to the
right as far as possible. The valve must closely tightly after
doing this.
Note!
The pressure setting must only be changed at the manufacturer
factory. Each time the pressure setting is changed, the safety
valve is lock sealed again and, if necessary, the punched
pressure value corrected.
011_WP5000_BA_en_0111.fm
104
Maintenance
8.17 Cleaning the particle trap

The particle trap is located in front of the cooling water stop valve
at the cooling water intake of the 4th stage cooler.
Pump
Cooling water
Cooling water stop valve

Cooling water stop valve
1. Shut off the cooling water inflow.

2. Loosen the particle trap cap in front of the cooling water stop
valve and take out the screen.
3. Clean the screen.
4. Insert screen and screw cap back on.
5. Connect the cooling water line.
011_WP5000_BA_en_0111.fm
105
8.18 Checking the zinc protection
All cylinders and coolers have zinc protection in the water circuit
against corrosion. The zinc protection with a copper gasket is
located along the long side of the coolers and along the side of
the cylinder jacket.
Zinc protection
Zinc cartridge
Cylinders
st nd 3rd stage 4th stage
1 stage 2 stage
Zinc protection,
gasket
Cooler
1st / 2nd stage
3rd / 4th stage
1. Unscrew the zinc protection with copper gasket

2. Ensure copper gasket is removed and destroyed.
3. Check the zinc cartridge.
The minimum diameter is 24 mm.
If consumption is too high, replace the zinc protection.
4. Install the zinc protection using a new gasket.
011_WP5000_BA_en_0111.fm
106
Maintenance
8.19 Checking the burst disc

The burst disc which prevents overpressure from the water-
cooling system is a thin, circular disc located behind the burst
disc flange on the long side of the 3rd stage as well as 4th stage
cooler housing.
.
Cooler
3rd / 4th stage
Gasket Impringement screw

Burst disc Flange screw
Burst disc flange 75 Nm
1. Drain water from the compressor cooler by removing the

drain plugs and discard gaskets at the cooler housing.
2. Allow water to drain into a bucket. Reinstall drain plugs to
stop seawater flow if bucket must be emptied. Repeat
process until cooler is completely drained of water.
3. Unscrew flange screws to release burst disc flange
completely with burst disc.
4. Discard gasket.
5. Clean sealing faces with lint free cloth.
6. Check surface of burst disc flange and mating cooler
housings are smooth and free from burrs and corrosion.
7. Insert new gasket and new burst disc.
Note!
Gasket is placed first then burst disc.
8. Install burst disc flange by screwing the four flange screws to

75 Nm.
Caution!
011_WP5000_BA_en_0111.fm
Do not adjust impringement screw.

This is pre-set to burst disc pressure.
9. Renew drain plug gaskets.

10. Replace drain plugs.
107
108
011_WP5000_BA_en_0111.fm
Maintenance
8.20 Checking the cooler tube bundles

The compressed air is cooled in tube cooler, arranged in cooler
housings for the 1st and 4th stage and for the 2nd and 3rd stage.
3 10 9 4 1 8 2 3
1st / 2nd stage

Compressed
Compressed air
air
3rd / 4th stage
Cooling water
6 7

1 Cooling housing 6 Burst disc flange
2 Supporting ring 7 Zinc protection
3 Cooler connection 8 O-ring
4 Cooler tube (pipe bundle) 9 Gasket
5 Cooler insert 10 Screw
Note!
Depending on installation, the cooler bundles must be drawn out
of their cooling housings towards the gauge panel (2nd stage cy-
linder ) or towards the air intake filter (1st stage cylinder ).
011_WP5000_BA_en_0111.fm
109
Air intake filter 1st stage
Cooler
2nd / 3rd stage
Cooler
1st / 4th stage
Gauge panel
2nd stage
1. Shut off the cooling water intake, drain the cooling water and
remove the cooling water lines.
2. Disconnect the compressed air lines and drain lines to the
cooler by loosening the pipe fittings.
3. Remove the separator and safety valves if necessary.
4. Remove the protection under the gauge panel.
Note!
For assembly of the protection, use a spacer sleeve and an in-
sulating disc for each cap screw.
Gauge panel
Safety valve
Protection
Cooler 2nd stage
Cooler 1st stage
Separator
3rd stage Separator
1st stage
5. Loosen the supporting ring screws M12.

011_WP5000_BA_en_0111.fm
110
Maintenance
M12 Supporting ring

Cooler
1st / 2nd stage M10
Cooler bundle
Cooler
3rd / 4th stage
6. Screw in the M12 screws into the threaded holes in the sup-
porting ring perimeter and pull the supporting ring together
with the cooler bundle out of the cooler housing.
7. Discard gaskets.
8. Pull the cooler insert out of the supporting ring by slight ro-
cking motion using screws M10.
Note!
Always turn cooler bundle clockwise during removal and instal-
lation.
9. Discard all O-rings.

10. Clean the inside and outside of the pipe bundle with a wire
brush.
11. Use a long turnscrew to scrape the dirt off inside the cooler
housing. After this, flush with water and a cleaning agent.
12. Reassemble the tubular cooler and replace the O-rings and
gaskets by new ones.
Assembly follows the steps in reverse order.
Note!
Install all parts with new gaskets and with new o-rings. Do not
reuse the used seals under any circumstances. Doing so leads
to leakage within a short time.
011_WP5000_BA_en_0111.fm
111
9 Storage, Preservation – “Lay-up”
Procedure
9.1 Safety when storing and
removing
Danger!
The compressor shall only be removed and “laid up” by trained
specialists of the owner. These specialists must be familiar with
the protection devices and regulations before starting the work.
Any work on the electrical installation must be carried out by
qualified electricians only.
In addition, information contained in suppliers’ documentation
must be observed.
011_WP5000_BA_en_0111.fm
112
Storage, Preservation – “Lay-up” Procedure
9.2 Temporary preservation and storage

Test run once a It is recommended a test run to be completed for a minimum of
week 30 minutes if the compressor has remained idle.. For the test run,
the manual drain valves are open until the cooling water outlet
temperature is within the green range of the thermometer.
Additional corrosion prevention measures are not required.
Preservation When the Sauer compressor is to be laid up for more than 12

weeks, preservation with a preservation oil is recommended.
When preservation is completed, periodic test runs are not
needed.
Note!
Use one of the preservation oils recommended in Chapter 10
“Lubricant Table” for corrosion protection.
The preservation oil has satisfactory running properties. In an
emergency the machine can be started for a short duration when
filled with preservation oil.
The compressor must be filled with preservation oil as follows:
Stage Quantity
Cylinder 1st stage 120 cm3
Cylinder 2nd stage 30 cm3
Cylinder 3rd stage 20 cm3
Cylinder 4th stage 10 cm3
Danger!
Do not exceed oil volumes to prevent oil impact.
To inject preservation oil into the cylinders, the intake air filter at
the 1st stage cylinder and the compressed air intake lines at the
2nd, 3rd and 4th stage cylinders have to be removed.
011_WP5000_BA_en_0111.fm
113
Air intake filter (removed)
1st stage
Compressed air Z
3rd stage 4th stage
3rd stage
Compressed air
Z 4th
stage
2nd stage
Compressed air 2nd stage
1. Run compressor for approx. 5 minutes with drain valves and

final pressure line open.
Any existing oil/water is removed.
2. Stop the compressor.
Danger!
Check on the pressure gauges that the compressor is at normal
pressure and that the oil pressure is within normal range.
3. Blow out compressor oil and dispose of in an environmentally

safe manner.
4. Fill with about 12 litres of preservation oil
5. Remove air filter on the 1st stage cylinder head.
6. Fill with about 120 cm3 of preservation oil.
7. Remove fixing screw of compressed air line to 2nd stage
cylinder (intake side).
8. Inject about 30 cm3 of preservation oil.
9. Screw fixing screw again.
10. Remove compressed air line connection to 3rd stage cylinder
(intake side).
12. Connect compressed air line again.
13. Remove compressed air line connection to 4th stage cylinder
(intake side).
011_WP5000_BA_en_0111.fm
15. Connect compressed air line again.

16. Start compressor and run for approx. 5 second with drain
valves and final pressure line open.
17. Wait until oil mist comes out of the final pressure line.
18. Stop compressor.
114
Storage, Preservation – “Lay-up” Procedure
19. Close drain valves.

20. Close cooling water intake and outlet valves.
21. Drain cooling water out of the cylinders and coolers via drain
plugs.
22. Reattach air filter on the 1st stage cylinder head.
23. If necessary, put up a sign that the compressor was
preserved and taken out of service.
24. If necessary, disconnect mains supply cables.
Putting back into 1. If necessary, connect the mains supply cables.

service 2. Drain preservation oil and put in compressor oil as described
in Chapter 5.6 “Filling with Oil”.
3. Follow the instructions given in Chapter 6.3 “Initial
Operation”.
011_WP5000_BA_en_0111.fm
115
9.3 Disassembly
Follow these 1. Turn compressor off and disconnect from power supply.
steps for 2. Read the gas pressure display to ensure that the compressor
disassembly: is completely depressurised.
3. Disconnect the mains supply cables.
4. Remove oil and lubricants and dispose of in an
environmentally safe manner.
5. Drain any remaining condensate and dispose of in an
environmentally safe manner.
Disposal
Material/system component Disposal method

Lubricants As hazardous waste
Steel/iron As metal scrap
Electric cables As hazardous waste
Electronic components As scrap electronic waste
Plastics As hazardous waste
011_WP5000_BA_en_0111.fm
116
Lubricant table
10 Lubricant table
Scope The lubricant table applies to all Sauer compressors which are
designed to compress air.
The lubricant table does not apply to
– Sauer compressors designed to compress neutral gasses
– Temperatures outside the 5 to 55 °C range
Note!
The recommended types of oil reduce the level of coking in the
compressor valves and the upstream pipe lines and fittings to a
minimum.
Lubricants which are not listed in the lubricant table may only be
used after approval has been given by J.P. SAUER & SOHN.
Otherwise the guarantee is made void.
Please contact our Customer Service when selecting oils not
listed, or if operating conditions differ from those recommended.
Note!
Unless otherwise ordered, Sauer compressors
are delivered without oil.
011_WP5000_BA_en_0111.fm
117
10.1 Lubricating oils
The following synthetic oilsmay be used in Sauer compressors;
Brand Product name Group

Agip Dicrea 100 VDL-100
AVIA Avilub Verdichteröl VDL-100 VDL-100
BP Energol RC 100 VDL-100
Tribol 890/100 VDL-100
CHEVRON HD Compressor Oil 100 VDL-100
DEA Xenic EP VDL 100 VDL-100
Synstar DE 100 VDL-100
ESSO Compressor Oil RS 100 VDL-100
MOBIL Rarus 427 VDL-100
Shell Corena P 100 VDL-100
Statoil COMPWAY 100 VDL-100
YUKONG Super Compressor Oil S 100 VDL-100
Synthetic oils for The NATO classified synthetic oil OY 1230 can be used for Naval
Naval aplications.
applications
Brand Product name Group
NATO classified O -1230 VDL-120
011_WP5000_BA_en_0111.fm
118
Lubricant table
10.2 Preservation oils

The standard oil used by Sauer for compressor preservation is
Mobilarma 524.
Alternatively, the following preservation oils can be used:
Brand Product name

Agip Rustica C SAE 30
ARAL Konit Motoröl SAE 30
AVIA MK 1540 S
BP MEK 20 W-20
DEA Deamot EKM 642 SAE 30
Mobil Mobilarma 524
Shell Ensis Motor Oil 30
Note!
The product name may vary by country.
011_WP5000_BA_en_0111.fm
119
11 Spare Parts and Accessories
Note!
Please note the information in Chapter 1 “General” regarding our
genuine Sauer spare parts.
J.P. SAUER & SOHN guarantee the complete spare parts supply
over the entire service life of the Sauer compressor.
Our genuine Sauer spare parts are subject to constant quality
control and further development. They conform to the latest
technical developments.
In addition to genuine Sauer spare parts, our range of supply
includes many accessories for your Sauer compressor as well as
special equipment for your entire compressed air system,
including:
– Fully automatic controls
– Adsorption dryers
– Refrigerant type dryers
– Filters
– Sound-dampening enclosures
– Compressed air vessels and
– fittings
We supply instructions and a maintenance manual for each
accessory.
011_WP5000_BA_en_0111.fm
120
Spare Parts and Accessories
Spare parts The spare parts catalogue is in the Appendix to this Operator
catalogue Manual.
– The required parts can be quickly found with the help of
diagrams, illustrations and lists.
– The spare parts catalogue and Operator Manual are also
available on CD-ROM. This makes it easy to fill out an order
form, print it out and send it in immediately.
To do so, you need the main specifications of your Sauer
compressor from the table below. If the data has not yet been
entered, it can be found on the nameplate affixed to the
crankcase.
Compressor type:
Factory No.:
Year of construction:
You should additionally indicate the number of operating

hours.
011_WP5000_BA_en_0111.fm
121
12 Appendix
This Appendix to the Operator Manual contains
– Form for commissioning certificate
– Form for Return of Goods/Notification of a Claim
– Supplier documentation
– Data sheets
011_WP5000_BA_en_0111.fm
122
Appendix
Commissioning certificate for compressors J.P. SAUER & SOHN
Maschinenbau GmbH
Brauner Berg 15 - 24159 Kiel
Phone: +49 - 431- 39 40 - 0
Fax: +49 - 431- 39 40 - 89
E-mail:service@sauersohn.de
Purchaser Owner Installation site
Company Company
Street Street
Postcode Postcode
Contact Contact
Phone number Phone number
Customer number
Order number
Compressor type Serial No.
Delivery date Operation hours
Date commissioned
Sauer service engineer Company/name
Company/name
Company/name
Company/name
Installation of compressor/complete system Check of rotational
direction
 Good  Faults Compression °C
temperature
Ventilation Suction temperature °C
 Good  Faults Start/stop pressure
Ambient conditions Oil level check
 Good  Faults Control system check
Voltage? Test run
 Good  Faults
Vibration behaviour of compressor
 Good  Faults
Accessories Installation of complete system carried out by:
Compressed air vessel
Refrigerant type dryer
Adsorption dryer  Good  Faults
Filter
Condensate removal
Operating personnel have received instruction and are familiar with the safety and maintenance requirements.
The maintenance instructions are available to the owner.
The operating company has been advised to use only genuine SAUER & SOHN spare parts.
Notes/faults:
011_WP5000_BA_en_0111.fm
The system has been accepted by the owner. City: Date:
Purchaser Owner Authorised Sauer Service Partner
123
J.P. SAUER & SOHN
 Return of goods Maschinenbau GmbH
 Notification of a claim Brauner Berg 15 - 24159 Kiel, Germany
Phone: +49 - 431- 39 40 - 0
Date: Fax: +49 - 431- 39 40 - 89
Manufacturer: Please always complete.
Company Compressor type:
Street
Postcode/City
Customer No. Serial No.:
Location
End customer: Operation hours:
Company
Street Date of fault:
Postcode/City
Customer No. Ambient temperature:
Location
Spare parts Reason for return
Designation Quantity Part No. Report on fault 
To be completed by manufacturer
Repair 
Checking as customer 
service
Goods taken back against 
credit note
Short description of fault:
Report
by manufacturer only
To be completed
011_WP5000_BA_en_0111.fm
124
011_WP5000_BA_en_0111.fm
125
Appendix
S a u e r
C o m p r e s s o r
Type: WP 5000
Spare parts list
NOV-No.: V6977
012_41007852_WP5000_ET_Titel_en_1109.fm
012_41007852_WP5000_ET_Titel_en_1109.
Edition: 09 / 2011
Spare Parts List
090 648 Sauer Compressor-Unit WP 5000
Page
Ref. No. Assembly
E-
090 648 Sauer Compressor-Unit WP 5000 ....................................... 6
067 340 Compressor WP 5000 ......................................................... 10

067 697 Crankcase ........................................................................... 14
067 692 Dipstick complete ................................................................ 18
065 870 Dipstick ................................................................................ 20
061 848 Crankshaft ........................................................................... 22
062 177 Connecting rod 1st stage ..................................................... 24
061 662 Connecting rod 2nd stage .................................................... 26
061 660 Connecting rod 3rd and 4th stage ........................................ 28
062 495 Piston 1st stage.................................................................... 30

061 768 Piston 2. Stufe ..................................................................... 32
061 758 Piston 3rd stage ................................................................... 34
062 234 Piston 4th stage ................................................................... 36
064 937 Cylinder with head and valve 1st stage................................ 38

061 822 Zinc protection ..................................................................... 40
061 872 Cylinder with head and valve 2nd stage............................... 42
061 828 Cylinder with head and valve 3rd stage ............................... 44
062 232 Cylinder with head and valve 4th stage ............................... 46
062 654 Cooler 1st and 4th stage....................................................... 48

013_41007852_WP5000_ET_en_0511.fm
061 750 Cooler insert 4th stage ......................................................... 50
062 655 Cooler 2nd and 3rd stage ..................................................... 52

061 940 Cooler insert ........................................................................ 54
067 346 Air pressure piping............................................................... 56
061 958 Separator 1st and 2nd stage................................................. 62
E-3
Page
Ref. No. Assembly
E-
064 817 Separator 3rd stage.............................................................. 64
064 869 Separator 4th stage.............................................................. 66

067 513 Cooling water piping ............................................................ 68
061 933 Lubricating line..................................................................... 70
061 902 Lubrication oil pump drive.................................................... 72
062 930 Lubrication oil pump............................................................. 74
061 913 Oil pipe................................................................................. 76
057 916 Pressure relief valve ............................................................ 78
062 637 Crankcase vent.................................................................... 80
067 408 Oil / water drainage piping ................................................... 82
067 409 Automatic drainage system ................................................. 84
061 078 Pneumatic relief valve............................................................ 88
067 416 Compressor monitoring and protection.................................. 90
068 193 Protection grid........................................................................ 92
067 066 Gauge panel .......................................................................... 94
068 617 Cooling water piping with pump............................................. 96
038 387 Cooling water pump for sea water (option)............................ 100
Note:
Explaination of the assemblies in Chapter 3 “Design and Func-
tion“ of the Operator Manual.
013_41007852_WP5000_ET_en_0511.fm
E-4
013_41007852_WP5000_ET_en_0511.fm
E-5
Spare Parts List
25, 26, 31, 36, 37
12, 15,19, 32
1 2
28,30
39 7
13, 20, 21
5
013_41007852_WP5000_ET_en_0511.fm
E-6
Spare Parts List
38
35
013_41007852_WP5000_ET_en_0511.fm
E-7
Item Ref. No. Description Qty.

1 067 340 Compressor WP 5000 1
21) 036 394 Intake air filter 1

3 067 408 Oil / water drainage piping 1
4 067 416 Compressor monitoring and protection 1
5 068 193 Protection grid 1
6 067 066 Gauge panel 1
7 067 412 Cooling water piping with pump 1
12 068 124 Bell housing 1
13 062 201 Kompressor foot 4
15 063 600 Spacer ring 1
19 000 585 Socket head cap screw 8
25 039 985 Stud 8
26 002 057 Hexagon nut 8
28 032 361 Union 1
30 005 090 Gasket 1
036 649/
31 AC-Motor 1
41007852
32 036 606 Hub 1
35 066 032 Label 1
36 037 727 Washer 8
37 039 686 Nut 8
013_41007852_WP5000_ET_en_0511.fm
38 057 285 Retainer 2

39 050 232 Savety valve 120 - 250 bar 1
1) The order number for the filter insert is 036 395.
E-8
013_41007852_WP5000_ET_en_0511.fm
E-9
Spare Parts List
067 340 Compressor WP 5000
2nd stage A 11
12
3rd stage
4th stage
B B
15
13
14
A
16 10 17 19
1st stage
013_41007852_WP5000_ET_en_0511.fm
E - 10
Spare Parts List
A–A
1st stage 2nd stage
5
4
2, 13
B–B
20 20
9
8
4th stage
3rd stage
1
013_41007852_WP5000_ET_en_0511.fm
18
E - 11
E - 12
013_41007852_WP5000_ET_en_0511.fm
Spare Parts List

1 067 697 Crankcase 1
2 061 848 Crankshaft 1
3 062 177 Connecting rod 1st stage 1
4 061 662 Connecting rod 2nd stage 1
5 061 660 Connecting rod 3rd and 4th stage 2
6 062 495 Piston 1st stage 1
7 061 768 Piston 2nd stage 1
8 061 758 Piston 3rd stage 1
9 062 234 Piston 4th stage 1
10 064 937 Cylinder with head and valve 1st stage 1
11 061 872 Cylinder with head and valve 2nd stage 1
12 061 828 Cylinder with head and valve 3rd stage 1
13 062 232 Cylinder with head and valve 4th stage 1
14 062 654 Cooler 1st and 4th stage 1
15 062 655 Cooler 2nd and 3rd stage 1

16 067 346 Air pressure piping 1
17 067 513 Cooling water piping 1
18 061 933 Lubrication 1
19 062 637 Crankcase vent 1
20 061 916 Hexagon head screw 6
013_41007852_WP5000_ET_en_0511.fm
E - 13
067 697 Crankcase
A–A
20 8 9 6 1
14
27
15
13
21
30
31 6 31 3
013_41007852_WP5000_ET_en_0511.fm
E - 14
Spare Parts List
067 697 Crankcase
B–B
4th stage
17 16 11 10 24, 29
10
2 2
15 15
2nd stage
1st stage 12
12
17 A
16
16
17
10
A
2 15 16 17 11 15 10 2
3rd stage
013_41007852_WP5000_ET_en_0511.fm
E - 15
E - 16
067 697 Crankcase
013_41007852_WP5000_ET_en_0511.fm
Spare Parts List
067 697 Crankcase

1 061 886 Crankcase 1
2 065 808 Inspection hole cover 4
3 067 692 Dipstick complete 1
6 061 860 Bearing bush 2
7 061 772 Oil sump 1
8 061 729 Bearing bracket 1
9 030 743 Shaft seal 1
10 051 885 Gasket 4
11 061 889 Gasket 2
12 061 890 Gasket 2
13 061 891 Gasket 1
14 035 842 O-ring 1
16 035 825 Stud 16
20 000 505 Cap screw 8
21 000 499 Cap screw 16
24 030 744 Plug 1
27 062 205 Baffle 1
29 005 009 Gasket 1
30 030 509 Plug 1
31 005 016 Gasket 2
013_41007852_WP5000_ET_en_0511.fm
E - 17
067 692 Dipstick complete
1
4
15
13
2, 8
7, 18
19, 20 5 12, 17
013_41007852_WP5000_ET_en_0511.fm
E - 18
Spare Parts List
067 692 Dipstick complete

1 065 870 Dipstick 1
2 067 693 Retainer 1
4 064 833 Adaptor 1
5 064 365 Adaptor 1
6 067 725 Pipe 1
7 000 428 Cap screw 1
12 005 547 Fitting 1
13 037 276 Fitting 1
15 032 360 Reducing fitting 1
17 005 016 Gasket 1
18 035 845 Clamp 1
19 030 744 Plug 1
20 005 009 Gasket 1
013_41007852_WP5000_ET_en_0511.fm
E - 19
E - 20
065 870 Dipstick
3
5
013_41007852_WP5000_ET_en_0511.fm
Spare Parts List
065 870 Dipstick

1 066 286 Holder 1
3 066 127 Bar 1
5 035 520 O-ring 2
013_41007852_WP5000_ET_en_0511.fm
E - 21
061 848 Crankshaft
8 6 11
10
013_41007852_WP5000_ET_en_0511.fm
E - 22
Spare Parts List
061 848 Crankshaft

1 061 849 Crankshaft 1
2 061 850 Balance weight 2
4 061 851 Flywheel 1
6 035 828 Flexible coupling 1
10 000 565 Cap screw 4
11 000 463 Cap screw 8
013_41007852_WP5000_ET_en_0511.fm
E - 23
062 177 Connecting rod 1st stage
3
013_41007852_WP5000_ET_en_0511.fm
E - 24
Spare Parts List
062 177 Connecting rod 1st stage

1 061 661 Connecting rod 1
2 035 823 Small-end bearing 1
3 061 857 Big-end bearing 1
61) 061 676 Connecting rod bolt 2
72) 036 078 Gudgeon pin 1
1)
Item 6, Connecting rod bolt 061 676 is part of raw part Connecting rod.
2)
Item 7, Gudgeon pin 036 078 is part of assembly 062 495.
013_41007852_WP5000_ET_en_0511.fm
E - 25
061 662 Connecting rod 2nd stage
5
3
4
013_41007852_WP5000_ET_en_0511.fm
E - 26
Spare Parts List
061 662 Connecting rod 2nd stage

4 061 947 Thrust washer 1
5 003 152 Cylinder pin 2
1)
Item 6, Connecting rod bolt 061 676 is part of raw part Connecting rod.
2)
Item 7, Gudgeon pin 061 742 is part of assembly 061 768.
013_41007852_WP5000_ET_en_0511.fm
E - 27
061 660 Connecting rod 3rd and 4th stage
7, 8
013_41007852_WP5000_ET_en_0511.fm
E - 28
Spare Parts List
061 660 Connecting rod 3rd and 4th stage

1) Item 6, Connecting rod bolt 061 676 is part of raw part Connecting rod.
2) Item 7, Gudgeon pin 061 742 is part of assembly 065 090.
3) Item 8, Gudgeon pin 061 742 is part of assembly 062 234.
013_41007852_WP5000_ET_en_0511.fm
E - 29
062 495 Piston 1st stage
1
4
013_41007852_WP5000_ET_en_0511.fm
E - 30
Spare Parts List
062 495 Piston 1st stage

1 035 785 Piston 1
2 002 716 Plain ring 1
3 037 520 Nose ring 1
4 035 962 Oil scraper ring 1
5 002 985 Circlip 2
6 036 078 Gudgeon pin 1
71) 035 823 Small-end bearing 1
1)
Item 7, Small-end bearing 035 823 is part of assembly 062 177.
013_41007852_WP5000_ET_en_0511.fm
E - 31
061 768 Piston 2nd stage
1 6
013_41007852_WP5000_ET_en_0511.fm
E - 32
Spare Parts List
061 768 Piston 2nd stage

1 061 767 Piston 1
3 002 985 Circlip 2
5 002 563 Nose ring 1
6 035 965 Oil scraper ring 1
1)
013_41007852_WP5000_ET_en_0511.fm
E - 33
061 758 Piston 3rd stage
7
013_41007852_WP5000_ET_en_0511.fm
E - 34
Spare Parts List
061 758 Piston 3rd stage

1 065 091 Piston 1
3 002 985 Circlip 2
5 002 544 Nose ring 1
1)
013_41007852_WP5000_ET_en_0511.fm
E - 35
062 234 Piston 4th stage
7
013_41007852_WP5000_ET_en_0511.fm
E - 36
Spare Parts List
062 234 Piston 4th stage

1 062 229 Piston 1
3 002 985 Circlip 2
4 037 634 Plain ring 16
1)
013_41007852_WP5000_ET_en_0511.fm
E - 37
064 937 Cylinder with head and valve 1st stage
6 11 10 13
3
8
7 9
14
4
12
15
1
14
5, 9 5, 9
013_41007852_WP5000_ET_en_0511.fm
E - 38
Spare Parts List
064 937 Cylinder with head and valve 1st stage

1 061 813 Cylinder 1
3 064 820 Valve cover 1
4 037 508 Concentric valve 1st stage 1
5 061 822 Zinc protection 2
7 035 837 O-ring 1
8 030 912 O-ring 1
9 005 023 Washer 4
10 064 628 Threaded connection 1
11 003 099 Lock washer 1
12 000 267 Eye bolt 1
14 000 977 Plug 2
151) 061 858 Liner 1st stage 1
1) Item 15 Liner 1st stage is part of assembly 061 813.

013_41007852_WP5000_ET_en_0511.fm
E - 39
E - 40
2
061 822 Zinc protection
3
1
013_41007852_WP5000_ET_en_0511.fm
Spare Parts List
061 822 Zinc protection

1 061 820 Plug 1
2 061 821 Zinc cartridge 1
3 001 463 Stud screw 1
061 822 Zinc protection is ordered as a complete spare part.

013_41007852_WP5000_ET_en_0511.fm
E - 41
061 872 Cylinder with head and valve 2nd stage
13 3
9 10
14
7 1
4
12
15
14
10
5, 10 5, 10
013_41007852_WP5000_ET_en_0511.fm
E - 42
Spare Parts List
061 872 Cylinder with head and valve 2nd stage

4 035 787 Lamellar valve 2nd stage 1
7 035 970 O-ring 1
9 035 837 O-ring 2
10 005 023 Washer 4
12 000 267 Eye bolt 1
14 000 977 Plug 2
151) 061 859 Liner 2nd stage 1
1)
Item 15 Liner 2nd stage is part of assembly 061 871.
013_41007852_WP5000_ET_en_0511.fm
E - 43
061 828 Cylinder with head and valve 3rd stage
6 2
10
14
4, 9
15
1
13
7
17
16
15
14
3, 14 3, 14
013_41007852_WP5000_ET_en_0511.fm
E - 44
Spare Parts List
061 828 Cylinder with head and valve 3rd stage

4 035 788 Concentric valve 3rd stage 1
7 000 267 Eye bolt 1
9 035 893 O-ring 1
10 035 818 O-ring 2
13 053 398 Gasket 1
14 005 023 Washer 4
15 000 977 Plug 2
161) 061 825 Liner 3rd stage 1
172) 061 842 Packing 1
1) Item 16 Liner 3rd stage is part of assembly 061 827.

2)
Item 17 Packing is part of assembly 061 827.
013_41007852_WP5000_ET_en_0511.fm
E - 45
062 232 Cylinder with head and valve 4th stage
6 3
10
11
4, 9
13 1
7 17
16
14, 15 14, 15
2, 14 2, 14
013_41007852_WP5000_ET_en_0511.fm
E - 46
Spare Parts List
062 232 Cylinder with head and valve 4th stage

4 035 793 Concentric valve 4th stage 1
7 000 267 Eye bolt 1
9 035 893 O-ring 1
10 035 819 O-ring 2
11 035 820 Back-up ring 1
13 035 826 Gasket 1
14 005 023 Washer 4
15 000 977 Plug 2
161) 062 230 Liner 4th stage 1
172) 061 844 Packing 1
1) Item 16 Liner 4th stage is part of assembly 062 231.

2) Item 17 Packing is part of assembly 062 231.
013_41007852_WP5000_ET_en_0511.fm
E - 47
062 654 Cooler 1st and 4th stage
18 14 1 14 5, 28, 29 22
22 18
2
5 Z
3
24
7 19 15 15 19 6 23
1st stage
9, 20
9, 20
13, 26
25 4th stage
11 12 16 013_41007852_WP5000_ET_en_0511.fm
E - 48
Spare Parts List
062 654 Cooler 1st and 4th stage

1 062 653 Cooler housing 1
2 061 801 Cooler insert 1st stage 1
3 061 750 Cooler insert 4th stage 1

5 061 793 Supporting ring 2
11 065 985 Burst disc flange 1
12 062 3841) Burst disc 1
13 065 989 Spacing screw 1
14 061 794 Gasket 2
15 061 878 Gasket 2
16 061 944 Gasket 1
18 031 130 O-ring 3
19 031 109 O-ring 2
20 005 023 Washer 2
22 000 559 Cap screw 10
23 000 516 Cap screw 4
24 000 504 Cap screw 6
28 033 806 Plug 1
013_41007852_WP5000_ET_en_0511.fm
29 005 001 Gasket 1
1) The order number for the burst disc is order-specific.
E - 49
061 750 Cooler insert 4th stage
5 3 8 4
013_41007852_WP5000_ET_en_0511.fm
E - 50
Spare Parts List
061 750 Cooler insert 4th stage

3 061 936 Tube plate 1
4 061 753 Cooler connection 1
5 058 110 Cooler tube 12
8 035 857 O-ring 1
013_41007852_WP5000_ET_en_0511.fm
E - 51
062 655 Cooler 2nd and 3rd stage
18 14 1 14 5, 28, 29 22
22 18
2
5 Z
3
24
7 19 15 15 19 6 23
2nd stage
9, 20
9, 20
13, 26
25 3rd stage
11 12 16 013_41007852_WP5000_ET_en_0511.fm
E - 52
Spare Parts List
062 655 Cooler 2nd and 3rd stage

1 062 653 Cooler housing 1
2 061 801 Cooler insert 2nd stage 1
3 061 940 Cooler insert 3rd stage 1

11 065 985 Burst disc flange 1
12 062 3841) Burst disc 1
13 065 989 Spacing screw 1

14 061 794 Gasket 2
15 061 878 Gasket 2
16 061 944 Gasket 1
18 031 130 O-ring 3
19 031 109 O-ring 2
20 005 023 Washer 2
22 000 559 Cap screw 10
23 000 516 Cap screw 4
24 000 504 Cap screw 6
28 033 806 Plug 1
013_41007852_WP5000_ET_en_0511.fm
29 005 001 Gasket 1
1) The order number for the burst disc is order-specific.
E - 53
E - 54
061 940 Cooler insert
4
6
5
3
013_41007852_WP5000_ET_en_0511.fm
Spare Parts List
061 940 Cooler insert

3 061 883 Cooler connection 1
4 058 107 Cooler tube 16
5 035 858 O-ring 1
6 062 174 Tube plate 1
013_41007852_WP5000_ET_en_0511.fm
E - 55
067 346 Air pressure piping
1st stage
6, 7, 24, 34, 44, 46

20, 32, 48 25 36 18, 21 22, 25, 37 8 32, 45
1,
40
32
12
4th stage
11
26,
42
32 3rd stage
17
21
20, 32, 48 41 5, 2 1, 40
013_41007852_WP5000_ET_en_0511.fm
2nd stage
E - 56
Spare Parts List
10 43 25 37 9 25
39
35
38
29 4st stage
3rd stage
13
2nd stage
33 23, 40 32 14
013_41007852_WP5000_ET_en_0511.fm
E - 57
20, 32, 48
15, 33 27 19 16, 32
28
30, 31
41
1. Stufe
2nd stage
4th stage
013_41007852_WP5000_ET_en_0511.fm
E - 58
013_41007852_WP5000_ET_en_0511.fm
E - 59
Spare Parts List

1 061 958 Separator 1st and 2nd stage 2
2 062 322 Gasket 1
3 064 817 Separator 3rd stage 1
4 064 829 Separator 4th stage 1

6 062 001 Intake manifold 1
7 062 002 Filter flange 1
8 061 954 Pressure channel 1
9 064 761 Intake channel 1
10 061 956 Pressure channel 1
11 061 960 Intake line 1
12 061 961 Pressure line 1
15 062 335 Pressure line 1
16 032 939 Safety valve 1st stage 1
17 035 862 Safety valve 2nd stage 1
18 062 090 Safety valve 3rd stage 1
19 050 233 Safety valve 4th stage 1

20 034 842 Fitting 3
21 038 394 Fitting 3
22 002 160 Washer 4
013_41007852_WP5000_ET_en_0511.fm
23 067 343 Manifold 1

24 031 109 O-ring 1
25 061 966 Washer 5
26 053 166 Washer 1
27 031 153 O-ring 2
E - 60
Spare Parts List

28 004 349 O-ring 2
29 004 340 O-ring 2
30 012 455 O-ring 2
31 035 863 Back-up ring 2
32 005 016 Gasket 9
33 005 009 Gasket 3
34 000 500 Cap screw 4
35 037 022 Cap screw 8
36 037 628 Cap screw 4
37 037 629 Cap screw 8
38 037 630 Cap screw 4
39 000 539 Cap screw 8
40 037 631 Cap screw 10
41 002 004 Cap screw 2
42 000 545 Cap screw 2
43 037 632 Cap screw 8
44 037 879 Cap screw 3
45 012 770 Fitting 1
46 065 444 Gasket 1
48 038 393 Adaptor 3
013_41007852_WP5000_ET_en_0511.fm
E - 61
061 958 Separator 1st and 2nd stage
10
1
9
2 7
5
3
013_41007852_WP5000_ET_en_0511.fm
13 12
E - 62
Spare Parts List
061 958 Separator 1st and 2nd stage

1 061 746 Separator head 1
2 061 884 Separator insert 1
3 062 189 Separator housing 1
5 053 208 Baffle cone 1
7 012 711 Cap screw 4
9 030 152 O-ring 1
10 061 959 Joint 1
12 005 016 Gasket 1
13 037 596 Plug 1
013_41007852_WP5000_ET_en_0511.fm
E - 63
064 817 Separator 3rd stage
5, 6

Test pressure145 bar
013_41007852_WP5000_ET_en_0511.fm
E - 64
Spare Parts List
064 817 Separator 3rd stage

5 001 008 Plug 2
6 003 496 Washer 2
7 030 639 O-ring 1
81) 065 766 End cover 1
92) 012 438 O-ring 1
1)
Item 8 End cover 065 766 is part of Separator housing 065 656.
2)
Item 9 O-ring 012 438 is part of Separator housing 065 656.
013_41007852_WP5000_ET_en_0511.fm
E - 65
064 869 Separator 4th stage
5, 6

013_41007852_WP5000_ET_en_0511.fm
Test pressure 550 bar
E - 66
Spare Parts List
064 869 Separator 4th stage

5 001 010 Plug 1
6 005 001 Gasket 1
7 030 639 O-ring 1
81) 065 775 End cover 1
92) 030 639 O-ring 1
1)
Item 8 End cover 065 775 is part of Separator housing 065 657.
2)
Item 9 O-ring 030 639 is part of Separator housing 065 657.
013_41007852_WP5000_ET_en_0511.fm
E - 67
067 513 Cooling water piping
2 1
1st stage
Cooler
2nd / 3rd stage
Cooler
1st /4th stage
8, 9
3rd stage
3 4th stage
2nd stage
4 5
013_41007852_WP5000_ET_en_0511.fm
E - 68
Spare Parts List
067 513 Cooling water piping

1 061 949 Cooling water pipe 1
8 053 165 Gasket 10
9 045 942 Cap screw 20
013_41007852_WP5000_ET_en_0511.fm
E - 69
061 933 Lubricating line
11, 12 9 4 7, 18 1
3 17 8
5 13
013_41007852_WP5000_ET_en_0511.fm
E - 70
Spare Parts List
061 933 Lubricating line

1 061 902 Lubrication oil pump drive 1
2 056 452 Oil filter insert 1
3 061 913 Oil pipe 1
4 057 916 Pressure relief valve 1
5 008 633 Pipe 1
7 003 496 Washer 1
8 032 621 O-ring 2
9 005 001 Gasket 1
11 034 132 Fitting 1
12 004 598 Fitting 1
13 031 193 Non-return valve 1
17 000 456 Cap screw 2
18 001 007 Plug 1
013_41007852_WP5000_ET_en_0511.fm
E - 71
061 902 Lubrication oil pump drive
3 2
7 9 8 1
013_41007852_WP5000_ET_en_0511.fm
E - 72
Spare Parts List
061 902 Lubrication oil pump drive

1 062 930 Oil pump 1
2 061 904 Cover 1
3 030 544 Gasket 1
4 035 853 O-ring 2
5 000 466 Cap screw 4
6 001 291 Grub screw 2
7 061 903 Pinion 1
8 035 850 Seal ring 1
9 000 497 Cap screw 2
013_41007852_WP5000_ET_en_0511.fm
E - 73
062 930 Lubrication oil pump
8 4 7 6
013_41007852_WP5000_ET_en_0511.fm
E - 74
Spare Parts List
062 930 Lubrication oil pump

1 062 929 Oil pump housing 1
2 062 908 Oil pump gear wheel 1
3 036 359 Oil pump gear wheel 1
4 057 890 Pinion 1
7 001 672 Locking plate 1
8 001 925 Key 1
013_41007852_WP5000_ET_en_0511.fm
E - 75
061 913 Oil pipe
1st stage
2nd stage
013_41007852_WP5000_ET_en_0511.fm
E - 76
Spare Parts List
061 913 Oil pipe

1 061 911 Socket 1
2 061 912 Pipe 1
3 061 914 Threaded socket 1
4 061 917 Pipe 1
013_41007852_WP5000_ET_en_0511.fm
E - 77
057 916 Pressure relief valve
4th stage
3rd stage
013_41007852_WP5000_ET_en_0511.fm
061 902
057 916
E - 78
Spare Parts List
057 916 Pressure relief valve

3 054 164 Spring 1
5 002 962 Circlip 1
013_41007852_WP5000_ET_en_0511.fm
E - 79
062 637 Crankcase vent
8 3 17 18
13
6
17 3 7 16
11
12 2
9
4 10
10
2nd stage
4th stage 3rd stage

013_41007852_WP5000_ET_en_0511.fm
062 637
1st stage
E - 80
Spare Parts List
062 637 Crankcase vent

1 062 638 Pipe 1
2 062 584 Pipe 1
3 008 663 Pipe 1
4 008 702 Pipe 1
5 036 156 Mesh 1
6 035 824 Filler 1
7 036 000 Fitting 1
8 006 216 Fitting 1
9 036 157 Fitting 1
10 006 193 Fitting 2
11 012 865 Reducer 1
12 011 448 Reducer 1
13 005 390 Reducer 1
16 005 006 Washer 1
17 036 109 Clamp 2
18 035 997 Low pressure hose 1
013_41007852_WP5000_ET_en_0511.fm
E - 81
067 408 Oil / water drainage piping
6, 12, 14 5, 16 19 9
1st stage
21
4th stage
3rd stage
1
4
2nd stage
8 15, 22 20 10, 11, 14

013_41007852_WP5000_ET_en_0511.fm
E - 82
Spare Parts List
067 408 Oil / water drainage piping

1 067 409 Automatic drainage system 1
4 037 022 Cap screw 4
5 000 435 Cap screw 2
6 034 803 Fitting 1
8 032 997 Fitting 1
9 032 414 Fitting 1
10 037 720 Fitting 1
11 037 694 Stub 1
12 032 360 Reducing fitting 1
14 005 016 Gasket 2
15 033 975 Pipe clamp 1
16 033 120 Pipe clamp 1
19 008 661 Pipe 1
20 008 650 Pipe 1
21 012 915 Pipe 1
22 000 433 Cap screw 2
013_41007852_WP5000_ET_en_0511.fm
E - 83
067 409 Automatic drainage system
31 8 5 9 39 41 6
28
4 38
Separator 1
1st stage
2 23, 32
14, 16 16, 19 26 16, 29 23

26 15, 16 21 14, 16
19
28
22
25
34
28
013_41007852_WP5000_ET_en_0511.fm
40 7
3rd stage 16, 19 4th stage 11
E - 84
Spare Parts List
19, 20, 27
17, 18
24, 30
013_41007852_WP5000_ET_en_0511.fm
E - 85

1 066 945 Support 1
2 067 420 Condensate collecting vessel 1
3 031 623 Low pressure ball valve, drainage 2nd stage 1
4 038 167 Low pressure ball valve, drainage 1st stage 1
51) 038 8062) Solenoid valve, drainage 1st stage 1
61) 037 6812) Solenoid valve, drainage 2nd stage 1

7 061 078 Pneumatic drain valve 3rd and 4th stage 1
8 037 694 Stub 1
9 037 716 Fitting 1
11 037 653 Stub 1
14 034 802 Fitting 2
15 036 911 Reducing union 1
16 005 001 Gasket 8
18 002 152 Washer 2
19 038 178 Fitting 6
20 037 752 Fitting 1
21 032 414 Fitting 1
22 036 301 Fitting 1
23 035 544 Fitting 2
24 037 592 Fitting 1
25 037 721 Fitting 1
26 012 915 Pipe 3
013_41007852_WP5000_ET_en_0511.fm
27 037 722 Fitting 1

28 037 723 Fitting 5
29 061 577 Cone 1
30 005 016 Gasket 1
31 037 720 Fitting 1
E - 86
Spare Parts List

32 005 009 Gasket 1
34 037 525 Fitting 1
38 008 661 Pipe 1
39 013 439 Pipe 1
40 000 539 Cap screw 4
41 012 915 Pipe 1
1) Specify voltage and frequency for order!

2) The order number for the solenoid valve is order-specific.
013_41007852_WP5000_ET_en_0511.fm
E - 87
061 078 Pneumatic relief valve
3 10
8 8
7 7
2 2
1 1
11 11
12 12
9 9
4 4
10
013_41007852_WP5000_ET_en_0511.fm
E - 88
Spare Parts List
061 078 Pneumatic relief valve

1 054 871 Valve piston 2
2 056 719 Valve body 2
3 056 721 Housing cover 1
4 056 927 Valve seat 2
7 030 149 Lip seal 2
8 004 083 O-ring 2
9 004 045 O-ring 2
10 000 466 Cap screw 16
11 030 340 O-ring 2
12 039 791 Spring 2
013_41007852_WP5000_ET_en_0511.fm
E - 89
067 416 Compressor monitoring and protection
Temperature
Stages 19 8
1 2 3 4 Oil
5, 6
3rd stage 4th stage
3, 11
2, 4
1st stage
7, 10
7, 10
16
14
5, 6
5, 6
3rd stage 4th stage
17
013_41007852_WP5000_ET_en_0511.fm
5, 6
7, 10
nd
2 stage
7, 10 15 1, 12 4, 9 18 13
E - 90
Spare Parts List
067 416 Compressor monitoring and protection

1 030 082 Control switch oil pressure 1
2 035 468 Temperature sensor 1
3 038 745 Protective sleeve for sensor 1
6 030 478 Clamp 4
7 030 510 Fitting 4
8 033 375 Fitting 1
9 067 417 Platte 1
10 005 001 Gasket 4
11 005 009 Gasket 1
13 008 633 Pipe 1
14 008 633 Pipe 1
15 008 633 Pipe 1
16 008 633 Pipe 1
17 008 633 Pipe 1
18 008 633 Pipe 1
19 006 382 Reducing union 1
013_41007852_WP5000_ET_en_0511.fm
E - 91
068 193 Protection grid
1 8, 9 2
A-A
A 7
10
3rd stage 4th stage
2 8, 9
013_41007852_WP5000_ET_en_0511.fm
E - 92
Spare Parts List
068 193 Protection grid

1 062 346 Covering plate 1
2 062 361 Covering plate 2
5 062 347 Spacer bushing 4
6 062 348 Insulating washer 4
7 002 151 Washer 4
8 002 146 Washer 8
013_41007852_WP5000_ET_en_0511.fm
E - 93
067 066 Gauge panel
14, 15, 20
13, 16 13, 18 13, 19 13, 17 21 22
23 24 25 26 27 31 28
30 9, 10, 11 1
013_41007852_WP5000_ET_en_0511.fm
E - 94
Spare Parts List
067 066 Gauge panel

1 067 774 Gauge panel 1
9 002 151 Washer 2
10 005 247 Hexagon head cap screw 2
11 062 348 Insulating washer 2
13 006 266 Fitting 4
14 035 438 Fitting 1
15 035 906 Socket fitting 1
16 030 548 Pressure gauge 1st stage 1
17 035 559 Pressure gauge oil 1
18 007 048 Pressure gauge 2nd stage 1
19 032 626 Pressure gauge 3rd stage 1
20 030 451 Pressure gauge 4th stage 1
21 038 615 Thermometer air inlet 1
22 038 616 Thermometer cooling water outlet 1
23 051 536 Label 1st stage 1
24 051 537 Label 2nd stage 1
25 051 538 Label 3rd stage 1
26 051 540 Label 4th stage 1
27 051 539 Label oil 1
28 062 537 Label cooling water outlet 1
30 004 404 Groove pin 14
31 062 536 Label air temperature inlet 1
013_41007852_WP5000_ET_en_0511.fm
E - 95
068 617 Cooling water piping with pump
21
5, 13, 14, 40 20
19
22
17 19 1, 38 23
18 37
1st stage 3rd stage
23
28 37
19
4th stage 2nd stage
013_41007852_WP5000_ET_en_0511.fm
24
25 39 27 26 25 35
E - 96
Spare Parts List
2, 4, 29 22 19 18
3, 4, 29 23 27 30 19
35
34
33
22
7 8
6
20, 32 20, 31 36 33
17 17
10
12
10
013_41007852_WP5000_ET_en_0511.fm
9 11 16 11 15 6
E - 97

1 067 411 Support 1
2 053 108 Angle flange 1
3 053 156 Flange 1
4 053 165 Gasket 2
5 038 387 Cooling water pump for seawater 1
6 038 908 Screwed flange 3
7 032 725 Double nipple 1
8 038 201 Reducer 1
9 038 907 Screwed flange 1
12 037 727 Washer 8
15 030 658 Gasket 1
16 037 441 Gasket 1
17 037 267 Reducing nipple 3
18 037 144 Elbow 4
19 036 898 Hose nipple 6
20 037 143 Clip 6
21 036 968 Cooling water hose 1
22 038 930 Transition sleeve 4
23 013 380 Pipe 3
013_41007852_WP5000_ET_en_0511.fm
24 013 380 Pipe 1

25 036 624 Fitting 2
26 034 469 Particle trap 1
27 034 470 Double nipple 2
28 013 380 Pipe 1
E - 98
Spare Parts List

29 045 942 Cap screw 4
30 038 958 Temperature controller 1
33 037 305 Double reducing nipple 2
34 013 380 Pipe 1
35 035 361 Pipe clamp 2
36 037 566 Tee branch 1
37 035 749 Elbow 2
391) 037 9442) Solenoid valve for cooling water 1

40 002 161 Washer 2
1)
Specify voltage and frequency for order!
2)
The order number for the solenoid valve is order-specific.
013_41007852_WP5000_ET_en_0511.fm
E - 99
038 387 Cooling water pump for sea water
1, 2
DN 32
DN 40
Motor terminal box
Cable entry
013_41007852_WP5000_ET_en_0511.fm
E - 100
Spare Parts List
038 387 Cooling water pump for sea water
Item No. Ref. No. Designation Quantity

1 038 387 Cooling water pump 1
21) 038 257 Repair kit for cooling water pump 1
1)
Repair kit 038 257 can be supplied.
Technical specification
Pump:
Max. working pressure: 10 bar
67 l/min against 19 m water column
Pump capacity:
100 l/min against 18 m water column
Medium: sea water
Max. working pressure: 30 °C
AC motor:
Capacity: 1.1 kW, IP 55
Voltage and frequency: 400/440 V, 50/60 Hz
Max. ambient temperature: 50 °C
013_41007852_WP5000_ET_en_0511.fm
E - 101
E - 102
013_41007852_WP5000_ET_en_0511.fm
Index
Parts List by Ref. No.
Page
Ref. No. Designation Assembly Item
E-
000 010 Hexagon cap head screw 067 692 18 8
000 072 Hexagon head cap screw 068 617 96 10
000 267 Eye bolt 061 828 44 7
000 267 Eye bolt 061 872 42 12
000 267 Eye bolt 062 232 46 7
000 267 Eye bolt 064 937 38 12
000 428 Socket head cap screw 067 692 18 7
014_41007852_WP5000_ET_Index_en_0511.f

E - 111
Page
E-
000 977 Plug 061 828 44 15
000 977 Plug 061 872 42 14
000 977 Plug 062 232 46 15
000 977 Plug 064 937 38 14
001 007 Plug 061 933 70 18
001 008 Plug 064 817 64 5
001 010 Plug 064 869 66 5
001 064 Hexagon nut 062 930 74 6
001 291 Grub screw 061 902 72 6
001 463 Stud screw 061 822 40 3
001 620 Hexagon nut 068 617 96 14
001 672 Locking plate 062 930 74 7
001 925 Key 062 930 74 8
014_41007852_WP5000_ET_Index_en_0511.f
002 004 Hexagon nut 067 346 56 41

002 027 Hexagon nut 062 654 48 26
002 027 Hexagon nut 062 655 52 26
002 057 Hexagon nut 068 617 96 11
002 057 Hexagon nut 090 648 6 26
E - 112
Index
Page
E-
002 063 Hexagon nut 067 697 14 17
002 146 Washer 068 193 92 8
002 151 Washer 067 066 94 9
002 151 Washer 068 193 92 7
002 152 Washer 067 409 84 18
002 160 Washer 067 346 56 22
002 161 Washer 068 617 96 40
002 544 Nose ring 061 758 34 5
002 563 Nose ring 061 768 32 5
002 663 Plain ring 061 758 34 4
002 716 Plain ring 062 495 30 2
002 755 Plain ring 061 768 32 4
002 962 Circlip 057 916 78 5
002 985 Circlip 061 758 34 3
002 985 Circlip 061 768 32 3
002 985 Circlip 062 234 36 3
002 985 Circlip 062 495 30 5
003 099 Lock washer 064 937 38 11
003 152 Cylinder pin 061 662 26 5
003 496 Gasket 061 933 70 7
003 496 Gasket 064 817 64 6
004 045 O-ring 061 078 88 9
004 083 O-ring 061 078 88 8
004 340 O-ring 067 346 56 29
014_41007852_WP5000_ET_Index_en_0511.f
004 349 O-ring 067 346 56 28

004 404 Groove pin 067 066 94 30
004 598 Fitting 061 933 70 12
005 001 Gasket 061 933 70 9
005 001 Gasket 062 654 48 29
E - 113
Page
E-
005 001 Gasket 062 655 52 29
005 001 Gasket 064 869 66 6
005 001 Gasket 067 409 84 16
005 001 Gasket 067 416 90 10
005 006 Gasket 062 637 80 16
005 009 Gasket 067 692 18 20
005 009 Gasket 067 346 56 33
005 009 Gasket 067 409 84 32
005 009 Gasket 067 416 90 11
005 009 Gasket 067 697 14 29
005 016 Gasket 061 958 62 12
005 016 Gasket 067 346 56 32
005 016 Gasket 067 408 82 14
005 016 Gasket 067 409 84 30
005 016 Gasket 067 692 18 17
005 016 Gasket 067 697 14 31
005 023 Gasket 061 828 44 14
005 023 Gasket 061 872 42 10
005 023 Gasket 062 232 46 14
005 023 Gasket 062 654 48 20
005 023 Gasket 062 655 52 20
005 023 Gasket 064 937 38 9
005 090 Gasket 090 648 6 30
014_41007852_WP5000_ET_Index_en_0511.f

005 390 Reducer 062 637 80 13
005 547 Fitting 067 692 18 12
006 193 Fitting 062 637 80 10
E - 114
Index
Page
E-
006 216 Fitting 062 637 80 8
006 266 Fitting 067 066 94 13
006 382 Reducing union 067 416 90 19
007 048 Pressure gauge 2nd stage 067 066 94 18
008 633 Pipe 061 933 70 5
008 633 Pipe 067 416 90 13
008 633 Pipe 067 416 90 14
008 633 Pipe 067 416 90 15
008 633 Pipe 067 416 90 16
008 633 Pipe 067 416 90 17
008 633 Pipe 067 416 90 18
008 650 Pipe 067 408 82 20
008 661 Pipe 067 408 82 19
008 661 Pipe 067 409 84 38
008 663 Pipe 062 637 80 3
008 702 Pipe 062 637 80 4
011 448 Reducer 062 637 80 12
012 455 O-ring 067 346 56 30
012 711 Cap screw 061 958 62 7
012 770 Fitting 067 346 56 45
012 865 Reducer 062 637 80 11
012 915 Pipe 067 408 82 21
012 915 Pipe 067 409 84 26
012 915 Pipe 067 409 84 41
014_41007852_WP5000_ET_Index_en_0511.f
013 380 Pipe 068 617 96 23

013 380 Pipe 068 617 96 24
013 380 Pipe 068 617 96 28
013 380 Pipe 068 617 96 34
013 439 Pipe 067 409 84 39
E - 115
Page
E-
030 082 Control switch oil pressure 067 416 90 1
030 149 Lip seal 061 078 88 7
030 152 O-ring 061 958 62 9
030 340 O-ring 061 078 88 11
030 451 Pressure gauge 4th stage 067 066 94 20
030 478 Clamp 067 416 90 6
030 509 Plug 067 697 14 30
030 510 Fitting 067 416 90 7
030 544 Gasket 061 902 72 3
030 548 Pressure gauge 1st stage 067 066 94 16
030 639 O-ring 064 817 64 7
030 639 O-ring 064 869 66 7
030 658 Gasket 068 617 96 15
030 743 Shaft seal 067 697 14 9
030 744 Plug 067 692 18 19
030 744 Plug 067 697 14 24
030 912 O-ring 064 937 38 8
031 109 O-ring 062 654 48 19
031 109 O-ring 062 655 52 19
031 109 O-ring 067 346 56 24
031 130 O-ring 062 654 48 18
031 130 O-ring 062 655 52 18
031 153 O-ring 067 346 56 27
031 193 Non-return valve 061 933 70 13
014_41007852_WP5000_ET_Index_en_0511.f
Low pressure ball valve, drainage 2nd sta-

031 623 067 409 84 3
ge
032 360 Reducing fitting 067 408 82 12
032 360 Reducing fitting 067 692 18 15
032 361 Union 090 648 6 28
032 414 Fitting 067 408 82 9
E - 116
Index
Page
E-
032 414 Fitting 067 409 84 21
032 621 O-ring 061 933 70 8
032 626 Pressure gauge 3rd stage 067 066 94 19
032 725 Double nipple 068 617 96 7
032 939 Safety valve 1st stage 067 346 56 16
032 997 Fitting 067 408 82 8
033 120 Pipe clamp 067 408 82 16
033 375 Fitting 067 416 90 8
033 806 Plug 062 654 48 28
033 806 Plug 062 655 52 28
033 975 Pipe clamp 067 408 82 15
034 132 Fitting 061 933 70 11
034 469 Particle trap 068 617 96 26
034 470 Double nipple 068 617 96 27
034 802 Fitting 067 409 84 14
034 803 Fitting 067 408 82 6
034 842 Fitting 067 346 56 20
035 361 Pipe clamp 068 617 96 35
035 438 Fitting 067 066 94 14
035 468 Temperature sensor 067 416 90 2
035 520 O-ring 065 870 20 5
035 544 Fitting 067 409 84 23
035 559 Pressure gauge oil 067 066 94 17
014_41007852_WP5000_ET_Index_en_0511.f
035 749 Elbow 068 617 96 37

035 785 Piston 062 495 30 1
035 787 Lamellar valve 2nd stage 061 872 42 4
035 788 Concentric valve 3rd stage 061 828 44 4
035 793 Concentric valve 4th stage 062 232 46 4

035 818 O-ring 061 828 44 10
E - 117
Page
E-
035 819 O-ring 062 232 46 10
035 820 Back-up ring 062 232 46 11
035 823 Small-end bearing 061 660 28 2
035 824 Filler 062 637 80 6
035 825 Stud 067 697 14 16
035 826 Gasket 062 232 46 13
035 828 Flexible coupling 061 848 22 6
035 837 O-ring 061 872 42 9
035 837 O-ring 064 937 38 7
035 842 O-ring 067 697 14 14
035 845 Clamp 067 692 18 18
035 850 Seal ring 061 902 72 8
035 853 O-ring 061 902 72 4
035 857 O-ring 061 750 50 8
035 858 O-ring 061 940 54 5
035 862 Safety valve 2nd stage 067 346 56 17
035 863 Back-up ring 067 346 56 31
035 893 O-ring 061 828 44 9
035 893 O-ring 062 232 46 9
035 906 Socket fitting 067 066 94 15
035 962 Oil scraper ring 062 495 30 4
014_41007852_WP5000_ET_Index_en_0511.f
035 965 Oil scraper ring 061 768 32 6

035 970 O-ring 061 872 42 7
035 997 Low pressure hose 062 637 80 18
036 000 Fitting 062 637 80 7
036 078 Gudgeon pin 062 495 30 6
E - 118
Index
Page
E-
036 109 Clamp 062 637 80 17
036 156 Mesh 062 637 80 5
036 157 Fitting 062 637 80 9
036 301 Fitting 067 409 84 22
036 359 Oil pump gear wheel 062 930 74 3
036 394 Intake air filter 090 648 6 2
036 606 Hub 090 648 6 32
036 624 Fitting 068 617 96 25
036 649/
AC-Motor 090 648 6 31
41007852
036 898 Hose nipple 068 617 96 19
036 911 Reducing union 067 409 84 15
036 968 Cooling water hose 068 617 96 21
037 681 Solenoid valve, drainage 2nd stage 067 409 84 6
037 143 Clip 068 617 96 20
037 144 Elbow 068 617 96 18
037 267 Reducing nipple 068 617 96 17
037 276 Fitting 067 692 18 13
037 305 Double reducing nipple 068 617 96 33
037 441 Gasket 068 617 96 16
014_41007852_WP5000_ET_Index_en_0511.f
037 508 Concentric valve 1st stage 064 937 38 4

037 520 Nose ring 062 495 30 3
037 525 Fitting 067 409 84 34
037 566 Tee branch 068 617 96 36
037 592 Fitting 067 409 84 24
037 596 Plug 061 958 62 13
E - 119
Page
E-
037 634 Plain ring 062 234 36 4
037 653 Stub 067 409 84 11
037 694 Stub 067 408 82 11
037 694 Stub 067 409 84 8
037 716 Fitting 067 409 84 9
037 720 Fitting 067 408 82 10
037 720 Fitting 067 409 84 31
037 721 Fitting 067 409 84 25
037 722 Fitting 067 409 84 27
037 723 Fitting 067 409 84 28
037 727 Washer 068 617 96 12
037 727 Washer 090 648 6 36
037 752 Fitting 067 409 84 20
037 944 Solenoid valve for cooling water 068 617 96 39
Low pressure ball valve, drainage 1st sta-
038 167 067 409 84 4
ge
038 178 Fitting 067 409 84 19
014_41007852_WP5000_ET_Index_en_0511.f

038 201 Reducer 068 617 96 8
038 257 Repair kit for cooling water pump 038 387 100 2
038 387 Cooling water pump 038 387 100 1
038 387 Cooling water pump 068 617 96 5
038 393 Adaptor 067 346 56 48
E - 120
Index
Page
E-
038 394 Fitting 067 346 56 21
038 615 Thermometer air inlet 067 066 94 21
038 616 Thermometer cooling water outlet 067 066 94 22
038 745 Protective sleeve for sensor 067 416 90 3
038 806 Solenoid valve, drainage 1st stage 067 409 84 5
038 907 Screwed flange 068 617 96 9
038 908 Screwed flange 068 617 96 6
038 930 Transition sleeve 068 617 96 22
038 958 Temperature controller 068 617 96 30
039 686 Nut 090 648 6 37
039 791 Spring 061 078 88 12
039 985 Stud 090 648 6 25
050 232 Savety valve 120 - 250 bar 090 648 6 39
050 233 Safety valve 4th stage 067 346 56 19
051 536 Label 1st stage 067 066 94 23
051 537 Label 2nd stage 067 066 94 24
051 538 Label 3rd stage 067 066 94 25
051 539 Label oil 067 066 94 27
051 540 Label 4th stage 067 066 94 26
014_41007852_WP5000_ET_Index_en_0511.f
051 885 Gasket 067 697 14 10

053 108 Angle flange 068 617 96 2
053 156 Flange 068 617 96 3
053 165 Gasket 067 513 68 8
053 165 Gasket 068 617 96 4
053 166 Gasket 067 346 56 26
E - 121
Page
E-
053 208 Baffle cone 061 958 62 5
053 398 Gasket 061 828 44 13
054 164 Spring 057 916 78 3
054 871 Valve piston 061 078 88 1
056 452 Filter insert 061 933 70 2
056 719 Valve body 061 078 88 2
056 721 Housing cover 061 078 88 3
056 927 Valve seat 061 078 88 4
057 285 Retainer 090 648 6 38
057 890 Pinion 062 930 74 4
057 916 Pressure relief valve 061 933 70 4
058 107 Cooler tube 061 940 54 4
058 110 Cooler tube 061 750 50 5
061 078 Pneumatic drain valve 3rd and 4th stage 067 409 84 7
061 883 Cooler connection 061 940 54 3
061 577 Cone 067 409 84 29
061 659 Connecting rod 061 660 28 1
061 660 Connecting rod 3rd and 4th stage 067 340 10 5
061 661 Connecting rod 062 177 24 1
061 662 Connecting rod 2nd stage 067 340 10 4
061 729 Bearing bracket 067 697 14 8
061 732 Valve cover 061 872 42 3
061 734 Valve cover 061 828 44 2
014_41007852_WP5000_ET_Index_en_0511.f
061 742 Gudgeon pin 061 758 34 2

061 742 Gudgeon pin 061 768 32 2
061 742 Gudgeon pin 062 234 36 2
061 746 Separator head 061 958 62 1
061 750 Cooler insert 4th stage 062 654 48 3
061 753 Cooler connection 061 750 50 4
E - 122
Index
Page
E-
061 758 Piston 3rd stage 067 340 10 8
061 767 Piston 061 768 32 1
061 768 Piston 2nd stage 067 340 10 7
061 772 Oil sump 067 697 14 7
061 793 Supporting ring 062 654 48 5
061 793 Supporting ring 062 655 52 5
061 794 Gasket 062 654 48 14
061 794 Gasket 062 655 52 14
061 801 Cooler insert 1st stage 062 654 48 2
061 801 Cooler insert 2nd stage 062 655 52 2
061 813 Cylinder 064 937 38 1

061 820 Plug 061 822 40 1
061 821 Zinc cartridge 061 822 40 2
061 822 Zinc protection 061 828 44 3
061 822 Zinc protection 061 872 42 5
061 822 Zinc protection 062 232 46 2
061 822 Zinc protection 062 654 48 9
061 822 Zinc protection 062 655 52 9
061 822 Zinc protection 064 937 38 5
061 827 Cylinder 061 828 44 1
061 828 Cylinder with head and valve 3rd stage 067 340 10 12
061 848 Crankshaft 067 340 10 2
061 849 Crankshaft 061 848 22 1
014_41007852_WP5000_ET_Index_en_0511.f
061 850 Balance weight 061 848 22 2

061 851 Flywheel 061 848 22 4
061 857 Big-end bearing 061 660 28 3
061 857 Big-end bearing 061 662 26 3
061 857 Big-end bearing 062 177 24 3
061 860 Bearing bush 067 697 14 6
E - 123
Page
E-
061 871 Cylinder 061 872 42 1
061 872 Cylinder with head and valve 2nd stage 067 340 10 11
061 878 Gasket 062 654 48 15
061 878 Gasket 062 655 52 15
061 879 Supporting ring 062 654 48 7
061 879 Supporting ring 062 655 52 7
061 880 Supporting ring 062 654 48 6
061 880 Supporting ring 062 655 52 6
061 884 Separator insert 061 958 62 2
061 886 Crankcase 067 697 14 1
061 889 Gasket 067 697 14 11
061 890 Gasket 067 697 14 12
061 891 Gasket 067 697 14 13
061 902 Lubrication oil pump drive 061 933 70 1
061 903 Pinion 061 902 72 7
061 904 Cover 061 902 72 2
061 911 Socket 061 913 76 1
061 912 Pipe 061 913 76 2
061 913 Oil pipe 061 933 70 3
061 914 Threaded socket 061 913 76 3
061 917 Pipe 061 913 76 4
061 933 Lubrication 067 340 10 18
014_41007852_WP5000_ET_Index_en_0511.f
061 936 Tube plate 061 750 50 3

061 940 Cooler insert 3rd stage 062 655 52 3
061 944 Gasket 062 654 48 16

061 944 Gasket 062 655 52 16
061 946 Connecting rod 061 662 26 1
061 947 Thrust washer 061 662 26 4
E - 124
Index
Page
E-
061 949 Cooling water pipe 067 513 68 1
061 954 Pressure channel 067 346 56 8
061 956 Pressure channel 067 346 56 10
061 958 Separator 1st and 2nd stage 067 346 56 1
061 959 Gasket 061 958 62 10
061 960 Intake line 067 346 56 11
061 961 Pressure line 067 346 56 12
061 966 Gasket 067 346 56 25
062 001 Intake manifold 067 346 56 6
062 002 Filter flange 067 346 56 7
062 090 Safety valve 3rd stage 067 346 56 18
062 093 Hexagon nut 061 848 22 8
062 174 Tube plate 061 940 54 6
062 177 Connecting rod 1st stage 067 340 10 3
062 185 Valve cover 062 232 46 3
062 189 Separator housing 061 958 62 3
062 201 Kompressor foot 090 648 6 13
062 205 Baffle 067 697 14 27
062 229 Piston 062 234 36 1
062 231 Cylinder 062 232 46 1
014_41007852_WP5000_ET_Index_en_0511.f
062 232 Cylinder with head and valve 4th stage 067 340 10 13
062 234 Piston 4th stage 067 340 10 9
062 322 Gasket 067 346 56 2
062 335 Pressure line 067 346 56 15
062 346 Covering plate 068 193 92 1
E - 125
Page
E-
062 347 Spacer bushing 068 193 92 5
062 348 Insulating washer 067 066 94 11
062 348 Insulating washer 068 193 92 6
062 361 Covering plate 068 193 92 2
062 384 Burst disc 062 654 48 12
062 384 Burst disc 062 655 52 12
062 495 Piston 1st stage 067 340 10 6
062 536 Label air temperature inlet 067 066 94 31
062 537 Label cooling water outlet 067 066 94 28
062 584 Pipe 062 637 80 2
062 637 Crankcase vent 067 340 10 19
062 638 Pipe 062 637 80 1
062 653 Cooler housing 062 654 48 1
062 653 Cooler housing 062 655 52 1
062 654 Cooler 1st and 4th stage 067 340 10 14
062 655 Cooler 2nd and 3rd stage 067 340 10 15

062 908 Oil pump gear wheel 062 930 74 2
062 929 Oil pump housing 062 930 74 1
062 930 Oil pump 061 902 72 1
063 600 Spacer ring 090 648 6 15
064 365 Adaptor 067 692 18 5
064 628 Threaded connection 064 937 38 10
064 629 Retainer 064 937 38 6
014_41007852_WP5000_ET_Index_en_0511.f
064 761 Intake channel 067 346 56 9

064 764 Intake line 067 346 56 13
064 765 Intake line 067 346 56 14
064 811 Retainer 067 346 56 5
064 817 Separator 3rd stage 067 346 56 3
064 818 Separator head 064 817 64 2
E - 126
Index
Page
E-
064 820 Valve cover 064 937 38 3
064 829 Separator 4th stage 067 346 56 4
064 833 Adaptor 067 692 18 4
064 870 Separator head 064 869 66 2
064 937 Cylinder with head and valve 1st stage 067 340 10 10
065 091 Piston 061 758 34 1
065 444 Gasket 067 346 56 46
065 808 Inspection hole cover 067 697 14 2
065 870 Dipstick 067 692 18 1
065 985 Burst disc flange 062 654 48 11
065 985 Burst disc flange 062 655 52 11
065 989 Spacing screw 062 654 48 13
065 989 Spacing screw 062 655 52 13
066 032 Label 090 648 6 35
066 127 Bar 065 870 20 3
066 286 Holder 065 870 20 1
066 945 Support 067 409 84 1
067 066 Gauge panel 090 648 6 6
067 340 Compressor WP 5000 090 648 6 1
067 343 Manifold 067 346 56 23
067 346 Air pressure piping 067 340 10 16
014_41007852_WP5000_ET_Index_en_0511.f
067 408 Oil / water drainage piping 090 648 6 3

067 409 Automatic drainage system 067 408 82 1
067 411 Support 068 617 96 1
067 411 Support 068 617 96 1
067 412 Cooling water piping with pump 090 648 6 7
067 416 Compressor monitoring and protection 090 648 6 4
E - 127
Page
E-
067 417 Platte 067 416 90 9
067 420 Condensate collecting vessel 067 409 84 2
067 513 Cooling water piping 067 340 10 17
067 692 Dipstick complete 067 697 14 3
067 693 Retainer 067 692 18 2
067 697 Crankcase 067 340 10 1
067 725 Pipe 067 692 18 6
067 774 Gauge panel 067 066 94 1
068 124 Bell housing 090 648 6 12
068 193 Protection grid 090 648 6 5
014_41007852_WP5000_ET_Index_en_0511.f
E - 128
Compressor control
for Sauer Compressor WP 5000
Manual and wiring diagrams
Type: 043 461 E

015_41007852_WP5000_control_Titel_en_1012.fm
015_41007852_WP5000_control_Titel_en_1
Edition: 12 / 2010
OPERATING INSTRUCTION
SYSTEM DESCRIPTION
Customer-No 41 00
Order-No /
Drawing-No. /
Type-No. 043 461 E + 043 462 E
Compressor-Switchboard
Nominal Power 55 kW
Nominal Current see drawings
Nominal Voltage see drawings
Frequency see drawings
Control Voltage 230 / 24 V
043461_043462_norge.doc- DOH/HAU – 21-01.2009 0

LIST OF CONTENTS
1 General Information
1.1 Introduction
1.2 Maintenance and Service
1.3 Installation Setup
2 Operation Modes Compressor 1-3
3 Operating Elements Compressor 1-3
4 Indication Compressor 1-3
5 Eliminating of Operation Defaults Compressor 1-3
6 Operating Modes Central Control
7 Operating Elements Central Control
043461_043462_norge.doc- DOH/HAU – 21-01.2009 1

1 General Information
1.1 Introduction
The switchgear is designed to supply the consumers. Please follow the maintenance and service
instructions and check the unit in regular intervals.
The unit must only be operated by experienced and trained persons.
The regulations for prevention of accidents have to be observed.
Also the VDE, IEC and technical regulations.
Keep an operation log of the installation, where the following points are regularly protocoled:
♦ last general maintenance
♦ last repair etc..

In the course of maintenance and service work, all automatic operations, switch operations and
functions have to be shut down and locked and to be protected against inadvertent restart.
The regulations for prevention of accidents have to be observed.
We would recommend to conclude a maintenance and service contract for the annual maintenance
of the switch gear system.
1.3 Installation Setup

The compressor switchboard consists the control of three compressors and an automatic switch
gear assembly.
The main components of the compressor unit are:

♦ Compressor with monitoring equipment and
♦ E-motor.
The automatic switch gear assembly contains:

♦ main and control contactors
♦ the fault control.
The start-stop control contains all functions that are important for the operation of the installation:
♦ Operational control of the units
♦ Shut-down in case of a failure.
043461_043462_norge.doc- DOH/HAU – 21-01.2009 2

2 Operation Modes Compressor 1-3
Supply voltage release (switchboard emergency stop button) has to be present for operation.
Following operation modes of the compressor can be selected at selector switch

S1102,2102,3102.
1 = MANUAL
0 = OFF
2 = REMOTE / AUTO
MANUAL
Choose the switch in position “1”
Start of the compressor. Acceleration of the engine via contactor while the drain valves are open.
After acceleration the drain valves will be energized and the compressor starts to build up
pressure.
Stopping the compressor switching S102 in position OFF. The drain valves will open and the
compressor shuts down automatically.
! Manual running is only a service position. Don’t leave your position!

! The compressors may operate against the stage safety valves!
OFF
Shut down of the compressor.
REMOTE / AUTO
Choose the switch in position “2”
If the system pressure is too low, the compressors receive their start demands from the central
control. Acceleration of the engine via contactor while the drain valves are open. After acceleration
the drain valves will be energized and the compressor starts to build up pressure. After reaching
the final pressure, the drain valves open and the compressor shuts down automatically.
3 Operating Elements Compressor 1-3

Q51 / "MAIN SWITCH"
The main switch cuts the main power from the motor. For opening the switchboard the main switch
has to be in position OFF.
! Caution! Even if the main switch is opened there may be high voltage at some terminals.
! Before opening the switchboard doors the main switch has to be in position off !
Caution: Even if the main switch is opened there may be high voltage at some terminals.
S102 / "SELECTOR SWITCH 1-0-2"

See item 2.1.
S103 / "FAULT RESET"

If the compressor has stopped by a fault you have to ascertain the reason before resetting and
restart the compressor.
! Caution! In case of a failure you have to ascertain the reason before restart the engine.
An exact observation after clearing the fault and restart is an absolutely requirement.
S71 / "EMERGENCY STOP"

Pushing the emergency stop button all compressors will stop immediately. The tripping is shown at
the panel. (see indication compressor 1-3)
043461_043462_norge.doc- DOH/HAU – 21-01.2009 3

4 Indication Compressor 1-3
H142 / "VOLTAGE PRESENT"
Indication that the control voltage is in range.
H143 / "OPERATION"
Indication of compressor operation.
H145 / "OVER CURRENT"

Automatically shut down in case of overload. Reset by quitting the over current relay, waiting for
cooling down from the motor and reset by S103.
The motor and contactors are dimensioned for four starts within one hour. In case of more starts
the logic blogs starting and the lamp is flashing. After one hour the compressor can be started
again, look for the reason. The pressure switches might be damaged.
H146 / "OIL PRESSURE"

If the compressor oil pressure is too low the compressor stops immediately. After checking and
refilling reset by S103.
If the oil pressure switch doesn’t open after stopping the indication lamp is flashing.
H147 / "AIR PRESSURE TEMPERATURE"

If the air temperature is too high the compressor stops immediately. After checking (see
compressor manual) and cooling down reset by S103.
H148 / "MOTOR TEMPERATURE"

Automatically shut down in case of high motor temperature check the reason and reset by S103
after cooling down.
H149 / "EMERGENCY STOP"

If an installed compressor emergency stop button is activated clear the reason before resetting by
S103.
! Caution! In case of a failure you have to ascertain the reason before restart the engine.
An exact observation after clearing the fault and restart is demand.
H152 / "ENGINE HEATER"

Indication of motor heater operation. Heating while still stand.
P141 / "WORKING HOUR COUNTER"

Indication of the operation time of the compressor.
5 Eliminating of Operation Defaults Compressor 1-3

z If it is not possible to start the compressor for operating, please check the following:
z No fault indication at the switchboard?
z The compressor starts up in position "MANUAL"?
z The supply voltage is available?
z The fuses Q61 and F62 and F64 are o.k.
z External start release setted?
z The pressure switch is in operation?
043461_043462_norge.doc- DOH/HAU – 21-01.2009 4

6 Operating Modes Central Control
S121 / "SELECTOR SWITCH 1-2-3"
Position 1 = manual start sequence dependent to pressure switches compressor 1-2-3

043461_043462_norge.doc- DOH/HAU – 21-01.2009 5

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0 1 2 3 4 5 6 7 8 9
Hanseatic Power Solutions GmbH

Oststraße 67
D-22844 Norderstedt
Phone: + 49 (0)40 5303479 - 0
Fax: + 49 (0)40 5303479 - 90
Internet: www.hps-power.com
Firma / Kunde J.P. Sauer & Sohn Maschinenbau GmbH Zeichnungsnummer 12001513 / 1
Company / customer Job number
Kommission 41007852 // 1/1 Speise // Steuerspannung 440V // 230V AC / 24V 60Hz
Commission Supply // Control
Kundenauftragsnummer 112787 Leistung // Strom 55kW // 107A
Customer order number Power // Current
Anlagentyp 043 461E Schutzart IP 54
Plant Type Degree of protection
Vorschrift Maritim Farbe RAL 7035
Regulation Color
=C1
+EN100
Erstellt am 22.02.2011
Created on
Bearbeitet am 24.03.2011 Anzahl der Seiten 37
Edit date Number of pages
2
Date 23.02.2011 Kompressorsteuerung Deckblatt = C1
12001513 / 1
Ed. DOH / COMPRESSOR CONTROL CENTER COVER SHEET + EN100
Appr 112787 Page 1
Revision Date Name 41007852 // 1/1 Page 502
0 1 2 3 4 5 6 7 8 9
Inhaltsverzeichnis
Table of contents
Seite Seitenbeschreibung Datum
Page Page description Date
Deckblatt
=C1+EN100/1 23.02.2011
COVER SHEET
Inhaltsverzeichnis
=C1+EN100/2 24.03.2011
TABLE OF CONTENTS
Inhaltsverzeichnis
=C1+EN100/2.A 24.03.2011
TABLE OF CONTENTS
Frontansicht
=C1+EN100/3 23.02.2011
FRONT VIEW
Maßbild / Befestigung Rittal AE
=C1+EN100/4 23.02.2011
DIMENSION DIAGRAM / FIXING RITTAL AE
Einspeisung / Antrieb
=C1+EN100/111 24.03.2011
POWER SUPPLY / DRIVE
Steuerspannung 230 / 24V / 1000VA
=C1+EN100/114 24.03.2011
CONTROL VOLTAGE 230 / 24V / 1000VA
Übersicht Steuerspannungstrafos BLO
=C1+EN100/114.A 24.03.2011
OVERVIEW TRANSFORMER BLO
Not-Halt
=C1+EN100/117 24.03.2011
EMERGENCY STOP
Steuerung
=C1+EN100/119 23.02.2011
CONTROL
Steuerung
=C1+EN100/120 23.02.2011
CONTROL
Ventile
=C1+EN100/122 23.02.2011
SOLENOID
Anforderungen
=C1+EN100/124 23.02.2011
REQUIREMENTS
Motortemperatur
=C1+EN100/126 23.02.2011
MOTOR TEMPERATURE
Störmeldungen
=C1+EN100/128 23.02.2011
COMMON FAULT
Störmeldungen
=C1+EN100/129 23.02.2011
COMMON FAULT
Meldungen
=C1+EN100/131 23.02.2011
SIGNALS
Meldungen
=C1+EN100/132 23.02.2011
SIGNALS
Stillstandsheizung
=C1+EN100/135 23.02.2011
ANTI-CONDENSATION HEATER
Heizung ECC Watlow
=C1+EN100/136 24.03.2011
HEATING ECC WATLOW
Trockner
=C1+EN100/140 23.02.2011
DRYER
Schaltschranklüfter
=C1+EN100/145 24.03.2011
PANEL FAN
Fernmeldungen
=C1+EN100/150 23.02.2011
POT. FREE SIGNALS
1 2.A
Date 24.03.2011 Kompressorsteuerung Inhaltsverzeichnis = C1
12001513 / 1
Ed. DOH / BAC COMPRESSOR CONTROL CENTER TABLE OF CONTENTS + EN100
Appr 112787 Page 2
0 1 2 3 4 5 6 7 8 9
Inhaltsverzeichnis
Table of contents
Fernmeldungen
=C1+EN100/151 23.02.2011
POT. FREE SIGNALS
LOGO Übersicht
=C1+EN100/180 23.02.2011
LOGO OVERVIEW
LOGO Übersicht
=C1+EN100/181 23.02.2011
LOGO OVERVIEW
LOGO Übersicht
=C1+EN100/182 23.02.2011
LOGO OVERVIEW
LOGO Übersicht
=C1+EN100/183 23.02.2011
LOGO OVERVIEW
Klemmenanschlussplan =C1+EN100-X1
=C1+EN100/200 24.03.2011
TERMINAL-CONNECTION DIAGRAM =C1+EN100-X1
Klemmenanschlussplan =C1+EN100-X1-POT.FREE
=C1+EN100/201 24.03.2011
TERMINAL-CONNECTION DIAGRAM =C1+EN100-X1-POT.FREE
Klemmenanschlussplan =C1+EN100-X1-230VAC
=C1+EN100/202 24.03.2011
TERMINAL-CONNECTION DIAGRAM =C1+EN100-X1-230VAC
=C1+EN100/203 24.03.2011
Klemmenanschlussplan =C1+EN100-X38/24VDC
=C1+EN100/204 24.03.2011
TERMINAL-CONNECTION DIAGRAM =C1+EN100-X38/24VDC
Klemmenanschlussplan =C1+EN100-XTHERM
=C1+EN100/205 24.03.2011
TERMINAL-CONNECTION DIAGRAM =C1+EN100-XTHERM
Artikelstückliste
=C1+EN100/500 24.03.2011
PARTS LIST
Artikelstückliste
=C1+EN100/501 24.03.2011
PARTS LIST
Artikelstückliste
=C1+EN100/502 22.03.2011
PARTS LIST
2 3
12001513 / 1
Appr 112787 Page 2.A
0 1 2 3 4 5 6 7 8 9
Kompressor 1
COMPRESSOR 1 315 - EN100
2000 -E1455 Schaltschranklüfter PANEL FAN
-P1311 Spannung vorhanden VOLTAGE PRESENT
-P1313 Betrieb OPERATION
1900
Nach Bau Innenansicht -P1314 Überstrom OVERCURRENT
1800
Schraubklemmen -P1315 Kompressor Öldruck
Potentiale Trennen -P1316 Kompressortemperatur COMPRESSOR TEMPERATURE
1700 Doppelte Bezeichnung -P1317 Motortemperatur MOTOR TEMPERATURE
Warnschilder -P1318 Not-Halt EMERGENCY STOP
-P1322 Trockner Fehler - Filter Differenzdruck Option
1600
GROUND BOLT HIGH-GRADE STEEL OUTSIDE DRYER FAILURE - FILTER DIFF. PRESSURE OPTION
1500 -P1323 Motorheizung ein MOTOR HEATER ON
-P1312 Betriebsstundenzähler OPERATING HOURS COUNTER
1400 -S1175 Not-Halt EMERGENCY STOP
-S1243 Hand--Aus / Reset--Fern Start-Stop
LOCAL--OFF / RESET--REMOTE START-STOP
1300
-S1247 Reset RESET
1200 -Q1112 Hauptschalter MAIN SWITCH
-X1 Austrittsfilter OUTLET FILTER
1100
1000
900 760 mm
300 mm
800
700 -P1311 -P1313 -P1318 -P1312
-X1 -P1314 -P1317 -P1315 -P1316

600
500 -P1322 -P1323

760 mm
-S1175
-S1243 -S1247
400
-Q1112
300
200 -E1455
100
0
M50 M63 17xM20 3xM25 Erdungsbolzen Edelstahl Schaltschrank: Rittal
EARTHING BOLT STAINLESS STEEL SWITCHBOARD: RITTAL
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
2.A 4
Date 23.02.2011 Kompressorsteuerung Frontansicht = C1
12001513 / 1
Ed. DOH / COMPRESSOR CONTROL CENTER FRONT VIEW + EN100
Appr 112787 Page 3
0 1 2 3 4 5 6 7 8 9
Lieferung
DELIVERY
A C
Durchmesser: 10,2mm
Durchmesser: 8mm DIAMETER: 10,2mm
DIAMETER: 8mm
15 mm
20 mm
D
B
20 mm
15 mm
20 mm 20 mm
29 mm 29 mm
A B C D
Breite Höhe Breite Höhe Breite Höhe
WIDTH HEIGHT WIDTH HEIGHT WIDTH HEIGHT
200mm 300mm 160mm 260mm 142mm 330mm
300mm 300mm 260mm 260mm 242mm 330mm
400mm 500mm 360mm 460mm 342mm 530mm
600mm 600mm 560mm 560mm 542mm 630mm
600mm 800mm 560mm 760mm 542mm 830mm
760mm 760mm 720mm 720mm 602mm 790mm
800mm 1000mm 760mm 960mm 742mm 1030mm
1000mm 760mm 960mm 720mm 942mm 790mm
1000mm 1000mm 960mm 960mm 942mm 1030mm
1200mm 1200mm 1160mm 1160mm 1142mm 1230mm
3 111
Date 23.02.2011 Kompressorsteuerung Maßbild / Befestigung Rittal AE = C1
12001513 / 1
Ed. DOH / COMPRESSOR CONTROL CENTER DIMENSION DIAGRAM / FIXING RITTAL AE + EN100
Appr 112787 Page 4
0 1 2 3 4 5 6 7 8 9
95mm²
-L1 / 114.0
95mm²
95mm²
-L3 / 114.0
2 4 6
-Q1112
N2-200A 1 3 5
1 3 5
-Q1205
/120.3 2 4 6
1 3 5 95 97
-B1113
95-125A 2 4 6 96 98
107A /120.3 /128.1
Direktanschluss Direktanschluss
DIRECT CONNECTION DIRECT CONNECTION
-T1 / 126.1
-T2 / 126.2
-PE / 114.0
-X1 PE Klemme: 150mm² PE Klemme: 95mm² -XTHERM 7 8 PE

TERMINAL: 150mm² TERMINAL: 95mm²
-X L1 L2 L3 PE -X 1U 1V 1W
M
-M01 3~
Θ
=MCCROOM -T02
+MCC873-EN-101B =COM
440V, 3PH, 60Hz +
Einspeisung 440V AC Kompressorantrieb Thermistor
POWER SUPPLY 440V AC COMPRESSOR DRIVE THERMISTOR
vorgesichert 200A gG / gL
PREFUSED 200A gG / gL
M63 M50 M20
4 114
Date 24.03.2011 Kompressorsteuerung Einspeisung / Antrieb = C1
12001513 / 1
Ed. DOH / BAC COMPRESSOR CONTROL CENTER POWER SUPPLY / DRIVE + EN100
Appr 112787 Page 111
0 1 2 3 4 5 6 7 8 9
111.9 / -L1
111.9 / -L3
-B1145
1 3 5 SIRIUS
3UG4633
-Q1142 12 14
2,50-4,00A
2,50A
I> I> I> A1 A2
11
2 4 6 /124.8
24V DC
-L51+ / 131.0
-T1147 -L50- / 132.0
520V 460V 400V 230V -20V 0 +20V
+ -
24V DC
-T1148 1,3A
STU 1000/2x115V
1000/2650VA 0 115V 0 115V PE
230V AC
L N (85-264V)
-XT 1 1 1 1
-F1144
2 C1A 2
-F1143
C2A 1
-XT PE 0 0 0 0 -XT 2 2 2
-L11 / 119.0
-L10 / 117.0
-LT11 / 117.0
NOT FUSED 230V AC
-L110 / 135.0
-L100 / 135.0
111.9 / -PE -PE / 122.0
Steuertrafo Spannungswächter 24V DC Spannungsversorgung

CONTROL TRANSFORMER VOLTAGE MONITOR 24V DC POWER SUPPLY
111 114.A
Date 24.03.2011 Kompressorsteuerung Steuerspannung 230 / 24V / 1000VA = C1
12001513 / 1
Ed. DOH / BAC COMPRESSOR CONTROL CENTER CONTROL VOLTAGE 230 / 24V / 1000VA + EN100
0 1 2 3 4 5 6 7 8 9
STUX 180 STUX 320
T1151 - 180VA / 490VA T1151 - 320VA / 1120VA

2x115V / 24V 2x115V / 24V
BLOCK BLOCK
Q1151 Q1151
Uin link max Uin link max
600V 34-35 0,34A 600V 34-35 0,60A
575V 33-35 0,35A 575V 33-35 0,62A
560V 32-35 0,36A 560V 32-35 0,65A
525V 31-35 0,38A 525V 31-35 0,67A
500V 34-36 0,40A 500V 34-36 0,71A
480V 33-36 0,42A 480V 33-36 0,74A
460V 32-36 0,44A 460V 32-36 0,77A
440V 32-37 0,46A 440V 32-37 0,81A
420V 31-37 0,48A 420V 31-37 0,85A
400V 32-38 0,50A 400V 32-38 0,89A
380V 31-38 0,53A 380V 31-38 0,94A
230V 1-36 / 2-32 0,88A 230V 1-36 / 2-32 1,55A
208V 1-37 / 2-31 0,96A 208V 1-37 / 2-31 1,69A
STU 1000
T1148 - 1000VA / 2650VA

2x115V
BLOCK
Q1141
Uin max
540V 1,90A
520V 2,00A
500V 2,10A
480V 2,20A
460V 2,30A
440V 2,40A
420V 2,50A
400V 2,60A
380V 2,70A
250V 4,20A
230V 4,60A
210V 5,00A
114 117
Date 24.03.2011 Kompressorsteuerung Übersicht Steuerspannungstrafos BLO = C1
12001513 / 1
Ed. DOH / BAC COMPRESSOR CONTROL CENTER OVERVIEW TRANSFORMER BLO + EN100
0 1 2 3 4 5 6 7 8 9
114.9 / -LT11 -LT11 / 124.0
21
-X1-230VAC 98 98 -S1175
22
*
11 23 15 13
-K1515 -S1247 -K1247 -K1175
/151.7 14 12 /124.7 24 /124.8 18 16 /117.5 14
-X1-230VAC 99
A1
-K1175
A2
114.9 / -L10 -L10 / 119.0

* Brücke bei Anschluss entfernen
* REMOVE LINK IF REQUIRED
DILER-40(230V50/60HZ)
04DILE
-X1-230VAC 100 101
13 14 /117.7
23 24 /120.3
33 34
43 44
51 52 /128.8
61 62
71 72
-ES1 -ES2 81 82
=EXT
+
Not-Halt Steuerfeld Reset Not-Halt
EMERGENCY STOP CONTROL PANEL RESET EMERGENCY STOP
M20
114.A 119
Date 24.03.2011 Kompressorsteuerung Not-Halt = C1
12001513 / 1
Ed. DOH / BAC COMPRESSOR CONTROL CENTER EMERGENCY STOP + EN100
0 1 2 3 4 5 6 7 8 9
114.9 / -L11 -L11 / 120.0
-A1191 -K1192 -K1193 -K1194

/180.4 /181.4 /182.4 /183.4
L L L L
8DI 4DI 4DI 4DI
Siemens - Display
6ED1052-1FB00-0BA6
4DO 4DO 4DO 4DO
N N N N
117.9 / -L10 -L10 / 120.0
117 120
Date 23.02.2011 Kompressorsteuerung Steuerung = C1
12001513 / 1
Ed. DOH / COMPRESSOR CONTROL CENTER CONTROL + EN100
0 1 2 3 4 5 6 7 8 9
119.9 / -L11 -L11 / 122.0
Betriebsbereit READY FOR

OPERATION Antrieb ein DRIVE ON
-K1194:L -A1191:1
Q1 Q2
/180.5 /180.5
-A1191 -A1191
1 2 1 2
23
-K1175
/117.5 24
95
-B1113
/111.4 96
13
-Q1205
/120.3 14
I4
-A1191
/180.5
I4
-Q1205:A2
Kompressor läuft
COMPRESSOR RUNNING
A1 A1 A1
-K1204 -Q1205 -K1207
A2 A2 A2
119.9 / -L10 -L10 / 122.0
DILM150(RAC240)
48.52.8.230.0060 DILM1000-XHI11-SI REL-IR/LDP-230VAC/4X21
14 1 2 /111.4 14
3 4 /111.4
12 11 /151.2 12 11 /151.3
5 6 /111.4
24 24
13 14 /120.4
22 21 /150.4 21 22 /136.7 22 21 /150.2
34
32 31 /131.2
44
42 41 /135.7
Betriebsbereit Antrieb ein Kompressor läuft

READY FOR OPERATION DRIVE ON COMPRESSOR RUNNING
119 122
12001513 / 1
0 1 2 3 4 5 6 7 8 9
120.9 / -L11 -L11 / 124.0
Kühlwassermagnetventil
Entwässerung Magnetventil COOLING WATER SOLENOID
DRAINAGE SOLENOID VALVE VALVE
-A1191:1 -A1191:1
Q3 Q11 (Q3)
/180.5 /182.5
-A1191 -K1193
1 2 1 2
Magnetventil:
SOLENOID VALVE:
Startverzögert 10 sek.
Entwässerung 15 min. / 15 sek.
START DELAY 10 SEC
DRAINAGE 15 MIN / 15 SEC
120.9 / -L10 -L10 / 124.0

114.9 / -PE -PE / 124.0
-X1-230VAC 41 42 PE 43 44 PE 47 48 PE 49 50 PE
x1 x1 x1 x1
PE PE PE PE
-D03 -D05 -C03 -Y12
x2 x2 x2 x2
=COM =COM =COM =COM

+ + + +
Stufe 1 Stufe 2 Kühlwassermagnetventil Taupunktventil
STAGE 1 STAGE 2 COOLING WATER SOLENOID VALVE DEW POINT VALVE
Entwässerung Magnetventil
DRAINAGE SOLENOID VALVE
M20 M20 M20 M20
120 124
Date 23.02.2011 Kompressorsteuerung Ventile = C1
12001513 / 1
Ed. DOH / COMPRESSOR CONTROL CENTER SOLENOID + EN100
0 1 2 3 4 5 6 7 8 9
117.9 / -LT11
122.9 / -L11 -L11 / 126.0
2 4 13 11
-S1243 -S1247 -B1145
/150.3 1 3 /117.5 14 /114.5 14 12
1-0-2 Reset
1=Hand ein
0=Aus
2=Fern Start-Stop
1=man run
0=off / reset
2=remote start-stop
I1 I1 I2 I2 I3 I5
-A1191 -K1192 -A1191 -K1192 -A1191 -A1191

/180.5 /181.5 /180.5 /181.5 /180.5 /180.5
I1 I9 (I1) I2 I10 (I2) I3 I5
-S1243:1 -A1191:I1 =EXT-MAX =EXT-MIN -S1247:14 -B1145:14
Ort Hand Start REMOTE ein ON Auto Stop AUTOMATIC STOP Auto Start AUTOMATIC START Reset RESET Spannung vorhanden
MANUAL START VOLTAGE PRESENT
A1 B1
-K1247 M
DI A2
1,5 SEC
122.9 / -L10 -L10 / 126.0

122.9 / -PE -PE / 128.0
82.01.0.240
-X1-230VAC 21 22 PE 23 24 PE 110 111 51 52 PE
315-EC100-P01 1 2 GN/YE 3 4 5 18
16 15 /117.6
-C1-X1/230VAC 21 22 PE 23 PE 110 111 -X x x PE
-MAX P -MIN P
=EXT =EXT
+ +
Ort Hand Start ein Auto Stop Auto Start Reserve Fernstart Reset Spannung vorhanden
REMOTE MANUAL START ON AUTOMATIC STOP AUTOMATIC START SPARE REMOTE START RESET VOLTAGE PRESENT
M25 M20
122 126
Date 23.02.2011 Kompressorsteuerung Anforderungen = C1
12001513 / 1
Ed. DOH / COMPRESSOR CONTROL CENTER REQUIREMENTS + EN100
0 1 2 3 4 5 6 7 8 9
124.9 / -L11 -L11 / 128.0
-B1261
A1
95 97
/128.6
96 98
A2 T1 T2
111.6 / -T1
111.6 / -T2
124.9 / -L10 -L10 / 136.0
Motortemperatur
ENGINE TEMPERATURE
124 128
Date 23.02.2011 Kompressorsteuerung Motortemperatur = C1
12001513 / 1
Ed. DOH / COMPRESSOR CONTROL CENTER MOTOR TEMPERATURE + EN100
0 1 2 3 4 5 6 7 8 9
126.9 / -L11 -L11 / 129.0
97 95 51
-B1113 -B1261 -K1175
/111.4 98 /126.2 96 /117.5 52
I6 I7 I8 I3 I4
-A1191 -A1191 -A1191 -K1192 -K1192

/180.5 /180.5 /180.5 /181.5 /181.5
I6 I7 I8 I11 (I3) I12 (I4)
-B1113:98 =EXT-D04 =EXT-A08 -B1261:96 -K1175:52
Überstrom OVERCURRENT Öldruck OIL PRESSURE Drucklufttemperatur AIR Motortemperatur ENGINE Not-Halt EMERGENCY STOP
PRESSURE TEMPERATURE TEMPERATURE
124.9 / -PE -PE / 129.0
-X1-230VAC 25 26 PE 27 28 PE
-X x x PE -X x x PE
-D04 P -A08
=EXT =EXT
+ +
Überstrom Öldruck Drucklufttemperatur Motortemperatur Not-Halt
OVERCURRENT OIL PRESSURE AIR PRESSURE TEMPERATURE ENGINE TEMPERATURE EMERGENCY STOP
M20 M20
126 129
Date 23.02.2011 Kompressorsteuerung Störmeldungen = C1
12001513 / 1
Ed. DOH / COMPRESSOR CONTROL CENTER COMMON FAULT + EN100
0 1 2 3 4 5 6 7 8 9
128.9 / -L11 -L11 / 136.0
-X1-230VAC 29
-A -A1 -X2:1 2 6
24V DC
DRYER
CONTROL
8 7
=
=Y12 +DIFF_PRESSURE
-X PE
DRYER ASSEM. LV.G
-X1-230VAC 30 PE

I1 * REMOVE LINK IF REQUIRED
-K1193
/182.5
I13 (I1)
=Y12DRYER ASSEM.LV.G-A1:7
Taupunkt DEW POINT
128.9 / -PE -PE / 135.0
Taupunkt
DEW POINT
Option
OPTION
M20
128 131
12001513 / 1
0 1 2 3 4 5 6 7 8 9
24V DC
114.9 / -L51+ -L51+ / 132.0
Spannung vorhanden Drucklufttemperatur AIR Motortemperatur ENGINE

VOLTAGE PRESENT Überstrom OVERCURRENT Öldruck OIL PRESSURE PRESSURE TEMPERATURE TEMPERATURE Not-Halt EMERGENCY STOP
-T1147:+ -K1207:31 -A1191:1 -K1192:1 -K1192:1 -K1192:1
Q12 (Q4) Q4 Q5 (Q1) Q6 (Q2) Q7 (Q3) Q8 (Q4)
/182.5 /180.5 /181.5 /181.5 /181.5 /181.5
31
-K1193 -A1191 -K1192 -K1192 -K1192 -K1192
-K1207
/120.4 34 32
1 2 1 2 1 2 1 2 1 2 1 2
x1
X1 X1 X1 X1 X1 X1 X1 A1
-P1311 -P1312 -P1313 -P1314 -P1315 -P1316 -P1317 -P1318 -K1318
BU X2 24V DC h GN X2 RD X2 RD X2 RD X2 RD X2 RD X2 A2
x2
-LT50 / 132.0
IB-2-024-D-G
14
12 11 /150.5
24
22 21
Spannung vorhanden Betriebsstundenzähler Betrieb Überstrom Öldruck Drucklufttemperatur Motortemperatur Not-Halt

VOLTAGE PRESENT OPERATING HOURS COUNTER OPERATION OVERCURRENT OIL PRESSURE AIR PRESSURE TEMPERATURE ENGINE TEMPERATURE EMERGENCY STOP
129 132
Date 23.02.2011 Kompressorsteuerung Meldungen = C1
12001513 / 1
Ed. DOH / COMPRESSOR CONTROL CENTER SIGNALS + EN100
0 1 2 3 4 5 6 7 8 9
24V DC
131.9 / -L51+
Trockner fehler - Filter

Differenzdruck DRYER
FAILURE -FILTER DIFF.
PRESSURE
-K1192:1
Q9 (Q1)
/182.5
13
-K1193
-K1352
/135.7 14
1 2
X1 X1
-P1322 -P1323
RD X2 BU X2
131.9 / -LT50
114.9 / -L50-
Trockner fehler - Motor Heizung ein

Filter Differenzdruck MOTOR HEATING ON
DRYER FAILURE -
FILTER DIFF. PRESSURE
Option
OPTION
131 135
12001513 / 1
0 1 2 3 4 5 6 7 8 9
114.9 / -L110 -L110 / 136.0

114.9 / -L100 -L100 / 136.0
2 4
-F1351
C2A 1 3
1 3 41
-K1352 -K1207
/135.7 2 4 /120.4 44 42
A1
-K1352
A2
129.9 / -PE -PE / 136.0
DILEM-10(230V50/60HZ)
22DILEM
-X1-230VAC 14 15 PE
1 2 /135.1
3 4 /135.1
5 6
-X x x PE 13 14 /132.3
53 54
61 62
-H01 71 72
83 84
=COM
+E
Stillstandsheizung Stillstandsheizung
STANDSTILL HEATING STANDSTILL HEATING
Max. 100 Watt
M20
132 136
Date 23.02.2011 Kompressorsteuerung Stillstandsheizung = C1
12001513 / 1
Ed. DOH / COMPRESSOR CONTROL CENTER ANTI-CONDENSATION HEATER + EN100
0 1 2 3 4 5 6 7 8 9
129.9 / -L11
135.9 / -L110 -L110 / 140.0
135.9 / -L100 -L100 / 140.0
1 3 -B1365
-F1361
C2A 2 4 Watlow 0-66°C
103E-2K4C-1100 L1/10
7
TC+ TC- 6 8 DC+ DC-

4 3 5 L2/9 1 2
33 43 21
-K1366 -Q1205
/136.7 34 44 /120.3 22
Direktanschluss
DIRECT CONNECTION
A1
-K1366
A2
126.9 / -L10
135.9 / -PE -PE / 140.0

DILER-40(230V50/60HZ)
-X1-230VAC 16 17 PE 18 19 PE 9 10
13 14
23 24
33 34 /136.3
x x PE x x PE 43 44 /136.3
+ - + -
-B1361
-H01 -H01
=NICRNI =NICRNI
=OSH1 =OSH2 + +
+ +
Heizung 1 Ölwanne Heizung 2 Ölwanne Thermostat Thermostat
HEATER 1 OIL SUMP HEATER 2 OIL SUMP Reserve THERMOSTAT
THERMOSTAT
100W 100W SPARE
M20 M20 M20 M20

135 140
Date 24.03.2011 Kompressorsteuerung Heizung ECC Watlow = C1
12001513 / 1
Ed. DOH / BAC COMPRESSOR CONTROL CENTER HEATING ECC WATLOW + EN100
0 1 2 3 4 5 6 7 8 9
136.9 / -L110 -L110 / 145.1

136.9 / -L100 -L100 / 145.1
2 4
-F1402
C2A 1 3
Trockner Betrieb DRYER

OPERATION
Q10 (Q2)
/182.5
-K1193
1 2
136.9 / -PE -PE / 145.1
-X1-230VAC 61 62 PE 63 64 PE
-X1 L1 N PE -X1 L1 N PE
-Y10 -Y11
=COM
+E
Trockner Trockner Betrieb
DRYER DRYER OPERATION
230V 50/60Hz
60VA
M20 M20
136 145
Date 23.02.2011 Kompressorsteuerung Trockner = C1
12001513 / 1
Ed. DOH / COMPRESSOR CONTROL CENTER DRYER + EN100
1 2 3 4 5 6 7 8 9 10
140.9 / -L110
2
-F1455
C2A 1
-B1455
Θ=30°C
3
1 2
-XF 5
-E1455
L PE
M
1~
N
-XF 4
140.9 / -L100
140.9 / -PE -PE / 150.0
SWITCHBOARD FAN
250V AC
140 150
Date 24.03.2011 Kompressorsteuerung Schaltschranklüfter = C1
12001513 / 1
Ed. DOH / BAC COMPRESSOR CONTROL CENTER PANEL FAN + EN100
0 1 2 3 4 5 6 7 8 9
Achtung: Gefährliche Spannung, auch wenn der Hauptschalter ausgeschaltet ist!

CAUTION: HAZARDOUS VOLTAGE EVEN MAIN SUPPLY TURNED OFF
21 6 8 21 11
-K1207 -S1243 -K1204 -K1318
/120.4 24 22 /124.1 5 7 /120.2 24 22 /131.8 14 12
145.10 / -PE -PE / 151.0
-X1-POT.FREE 81 82 83 PE 84 85 86 PE 87 88 89 PE 90 91 92 PE
-X x x x x x x x x x x x x x x
=ECR
+
Versorgung 82-83 ein aus Versorgung 85-86 Hand Auto Sammelstörung Not-Halt
COM 82-83 ON OFF COM 85-86 MANUAL AUTOMATIC COLLECTIVE FAULT EMERGENCY STOP
M25
145 151
Date 23.02.2011 Kompressorsteuerung Fernmeldungen = C1
12001513 / 1
Ed. DOH / COMPRESSOR CONTROL CENTER POT. FREE SIGNALS + EN100
0 1 2 3 4 5 6 7 8 9
11 11
-K1204 -K1207
/120.2 14 12 /120.4 14 12
A1 s.S. 117
SEE PAGE 117
-K1515
A2
1X 2X 3X 5X 17X 18X
150.9 / -PE
-X38/24VDC 1 2 PE 3 4 PE 5 6 7 8 PE
IB-2-024-D-G
14
1BK 1BU PE 2BK 2BU 3BK 3BU 4BK 4BU 12 11 /117.1
-315-EN100-C01 24
-X38 1 2 PE 3 4 PE 5 6 7 8 22 21
+
24V DC
=315_IB100
+ gebrückt und geerdet
RISER TENSIONER SYSTEM CONTROL CABINET LINKED AND EARTHED
Sammelstörung Betrieb 0=Stop Not-Halt
COLLECTIVE FAULT OPERATION 1=Aktivieren EMERGENCY STOP
COLLECTIVE FAULT
M25
150 180
12001513 / 1
0 1 2 3 4 5 6 7 8 9
-A1191
/119.4
LOGO! SIEMENS
I1 Ort Hand Start

I1 /124.1
REMOTE MANUAL START
I2 Auto Stop
I2 /124.5
AUTOMATIC STOP
I3 Reset
I3 /124.7
RESET
I4 Kompressor läuft
I4 /120.5
COMPRESSOR RUNNING
I5 Spannung vorhanden
I5 /124.8
VOLTAGE PRESENT
I6 Überstrom
I6 /128.1
OVERCURRENT
I7 Öldruck
I7 /128.3
OIL PRESSURE
I8 Drucklufttemperatur
I8 /128.5
AIR PRESSURE TEMPERATURE
1 Betriebsbereit
Q1 /120.1
READY FOR OPERATION
2 Betriebsbereit
Q1 /120.2
READY FOR OPERATION
1 Antrieb ein
Q2 /120.3
DRIVE ON
2 Antrieb ein
Q2 /120.3
DRIVE ON
1 Entwässerung Magnetventil
Q3 /122.1
2 Stufe 1
Q3 /122.2
STAGE 1
1 Überstrom
Q4 /131.3
OVERCURRENT
2 Überstrom
Q4 /131.4
OVERCURRENT
6ED1055-1FB00-0BA1
151 181
Date 23.02.2011 Kompressorsteuerung LOGO Übersicht = C1
12001513 / 1
Ed. DOH / COMPRESSOR CONTROL CENTER LOGO OVERVIEW + EN100
0 1 2 3 4 5 6 7 8 9
-K1192
/119.5
LOGO! SIEMENS
I1 ein
I9 (I1) /124.2
ON
I2 Auto Start
I10 (I2) /124.6
AUTOMATIC START
I3 Motortemperatur
I11 (I3) /128.6
ENGINE TEMPERATURE
I4 Not-Halt
I12 (I4) /128.8
EMERGENCY STOP
1 Öldruck
Q5 (Q1) /131.4
OIL PRESSURE
2 Öldruck
Q5 (Q1) /131.5
OIL PRESSURE
1 Drucklufttemperatur
Q6 (Q2) /131.6
Q6 (Q2) /131.6
1 Motortemperatur
Q7 (Q3) /131.7
ENGINE TEMPERATURE
2 Motortemperatur
Q7 (Q3) /131.8
ENGINE TEMPERATURE
1 Not-Halt
Q8 (Q4) /131.8
EMERGENCY STOP
2 Not-Halt
Q8 (Q4) /131.9
EMERGENCY STOP
6ED1052-1FB00-0BA6
180 182
12001513 / 1
0 1 2 3 4 5 6 7 8 9
-K1193
/119.6
LOGO! SIEMENS
I1 Taupunkt
I13 (I1) /129.3
DEW POINT
I2
I14 (I2)
I3
I15 (I3)
I4
I16 (I4)
1 Trockner fehler - Filter Differenzdruck

Q9 (Q1) /132.1
DRYER FAILURE -FILTER DIFF. PRESSURE
Q9 (Q1) /132.2
1 Trockner Betrieb
Q10 (Q2) /140.3
DRYER OPERATION
2 Trockner Betrieb
Q10 (Q2) /140.3
DRYER OPERATION
1 /122.4 Kühlwassermagnetventil
Q11 (Q3)
/140.9 COOLING WATER SOLENOID VALVE
2 Kühlwassermagnetventil
Q11 (Q3) /122.5
COOLING WATER SOLENOID VALVE
1 Spannung vorhanden
Q12 (Q4) /131.1
VOLTAGE PRESENT
Q12 (Q4) /131.2
VOLTAGE PRESENT
6ED1052-1FB00-0BA6
181 183
12001513 / 1
0 1 2 3 4 5 6 7 8 9
-K1194
/119.6
LOGO! SIEMENS
I1
I17 (I1)
I2
I18 (I2)
I3
I19 (I3)
I4
I20 (I4)
1
Q13 (Q1)
2
Q13 (Q1)
1
Q14 (Q2)
2
Q14 (Q2)
1
Q15 (Q3)
2
Q15 (Q3)
1
Q16 (Q4)
2
Q16 (Q4)
6ED1052-1FB00-0BA6
182 200
12001513 / 1
0 1 2 3 4 5 6 7 8 9
Terminal-connection diagram
=MCCROOM+MCC873-X
=COM-M01
X1
PE
PE
PE
M
PE 3~
Θ
=MCCROOM+MCC873-X =COM-M01
COMPRESSOR DRIVE
Kompressorantrieb
183 201
Date 24.03.2011 Kompressorsteuerung Klemmenanschlussplan =C1+EN100-X1 = C1
12001513 / 1
Ed. DOH / BAC COMPRESSOR CONTROL CENTER TERMINAL-CONNECTION DIAGRAM + EN100
Appr =C1+EN100-X1 112787 Page 200
0 1 2 3 4 5 6 7 8 9
=ECR-X
=ECR-X
=ECR-X
-K1207
-K1207
-K1207
-K1204
-K1204
-K1318
-K1318
-E1455
-S1243
-S1243
-S1243
X1-POT.FREE
PE
PE
PE
PE
81
82
83
84
85
86
87
88
89
90
91
92
x x x x x x x x x x x x x x
=ECR-X
COLLECTIVE FAULT
EMERGENCY STOP
Versorgung 82-83
Versorgung 85-86
Sammelstörung
AUTOMATIC
COM 82-83
COM 85-86
MANUAL
Not-Halt
Hand
Auto
OFF
aus
ON
ein
200 202
Date 24.03.2011 Kompressorsteuerung Klemmenanschlussplan = C1
12001513 / 1
Ed. DOH / BAC COMPRESSOR CONTROL CENTER =C1+EN100-X1-POT.FREE + EN100
Appr TERMINAL-CONNECTION DIAGRAM 112787 Page 201
Revision Date Name =C1+EN100-X1-POT.FREE 41007852 // 1/1 Page 502
201
Revision
0
Date
X1-230VAC
Name
Auto Stop
21
21 -S1243
1
1
AUTOMATIC STOP -315-EC100-P01
22
= 22 -A1191
1
Ed.
Date
Appr
PE
= PE =COM-Y12
Auto Start
23
23 -K1192
GN/YE 3
GN/YE 3
DOH
AUTOMATIC START
21
= 24
24.03.2011
/
PE
= PE =EXT-C1-X1/230VAC
=EXT-C1-X1/230VAC
-315-EC100-P01
BAC
Auto Start
110
110
4
4
AUTOMATIC START
2
= 111
111
5
5
Fernstart
x
51
REMOTE START
Der Inhalt des Dokuments ist urheberrechtlich geschützt. Weitergabe und Vervielfältigung sind nicht gestattet.
x
= 52
Kompressorsteuerung
=EXT-X
Fernstart
PE
PE =EXT-C1-X1/230VAC
REMOTE START
3
Stillstandsheizung
COMPRESSOR CONTROL CENTER

14 -K1352
STANDSTILL HEATING
x
= 15 -K1352
=COM+E-X
PE
= PE =Y12DRYER ASSEM.LV.G-X
Heizung 1 Ölwanne
x
4
16 -K1366
HEATER 1 OIL SUMP
x
100W 17
PE
= PE
x
Heizung 2 Ölwanne
x
18 -K1366
HEATER 2 OIL SUMP
x
100W 19 -F1361
PE
= PE
5
Thermostat Reserve
+
9
THERMOSTAT SPARE
+
-
-
= 10
Öldruck
Klemmenanschlussplan
x
25 -B1113
=C1+EN100-X1-230VAC
=C1+EN100-X1-230VAC
OIL PRESSURE
x
= 26 -A1191
6
PE
= PE =EXT-X
TERMINAL-CONNECTION DIAGRAM
x
Drucklufttemperatur
x
=EXT-X
27 -B1261
x
= 28 -A1191
PE
= PE =EXT-X
112787
7
29 -K1175
41007852 // 1/1
6
12001513 / 1
Taupunkt
7
30 -K1193
DEW POINT
7
=Y12DRYER ASSEM.LV.G-A1
Taupunkt
PE
8
PE =EXT-X
PE
DEW POINT
Stufe 1
x1
41 -A1191
=Y12DRYER ASSEM.LV.G-X
STAGE 1
= C1
x2
x1
x2
= 42 -K1207
+ EN100
=COM-D03
PE
The content of the document is our copyright property. Passing on and copying is not permitted.
Page
Page
502
202
203
0 1 2 3 4 5 6 7 8 9
=COM+E-X1
=COM+E-X1
=COM-D03
=COM-D05
=COM-C03
-K1193
-K1247
-K1193
-K1193
-K1515
-T1148
-S1243
-S1175
-F1402
-F1402
X1-230VAC
100
101
PE
PE
PE
PE
PE
PE
43
44
47
48
49
50
61
62
63
64
98
98
99
PE x1 x2 PE x1 x2 PE x1 x2 PE L1 N PE L1 N PE 11 12 14
x1
x1 x1 x1 12 14
PE PE PE PE
L1
x2
x2 x2 x2 11
=COM-D03 =COM-D05 =COM-C03 =COM-Y12 =COM+E-X1 EMERGENCY STOP CONTROL PANEL -K1515 =EXT-ES1
DRYER OPERATION
DEW POINT VALVE
Not-Halt Steuerfeld
Trockner Betrieb
Taupunktventil
Trockner
STAGE 1
STAGE 2
Stufe 1
Stufe 2
DRYER
=
202 204
12001513 / 1
Ed. DOH / BAC COMPRESSOR CONTROL CENTER =C1+EN100-X1-230VAC + EN100
Revision Date Name =C1+EN100-X1-230VAC 41007852 // 1/1 Page 502
0 1 2 3 4 5 6 7 8 9
=315_IB100-X38
=315_IB100-X38
=ECR-X
-K1204
-K1204
-K1207
-K1207
-K1515
-K1515
X38/24VDC
PE
PE
PE
1
1BK 1BU PE 2BK 2BU 3BK 3BU 4BK 4BU

-315-EN100-C01
-315-EN100-C01

1 2 PE 3 4 PE 5 6 7 8
=315_IB100-X38
0=Stop 1=Aktivieren
COLLECTIVE FAULT
COLLECTIVE FAULT
Sammelstörung
OPERATION
Betrieb
=
203 205
12001513 / 1
Ed. DOH / BAC COMPRESSOR CONTROL CENTER =C1+EN100-X38/24VDC + EN100
Revision Date Name =C1+EN100-X38/24VDC 41007852 // 1/1 Page 502
0 1 2 3 4 5 6 7 8 9
=COM-M01
-B1261
-B1261
XTHERM
PE
7
M
3~
Θ
=COM-M01
THERMISTOR
Thermistor
204 500
12001513 / 1
Ed. DOH / BAC COMPRESSOR CONTROL CENTER =C1+EN100-XTHERM + EN100
Revision Date Name =C1+EN100-XTHERM 41007852 // 1/1 Page 502
0 1 2 3 4 5 6 7 8 9
Artikelstückliste
Parts list
Betriebsmittelkennzeichen Menge Bezeichnung Typnummer Hersteller Artikelnummer
Device tag Quantity Designation Type number Manufacturer Part number
Logikmodul
-A1191 1 Uh: 115/230V AC/DC, Display 6ED1052-1FB00-0BA6 Siemens K-SL-SIE-052-230-020
Logic module
Speicherkarte
-A1191 1 Memorycard,Logo Know-Howschutz 6ED1056-7DA00-0BA0 Siemens K-SL-SIE-056-000-020
Memory card
Überlastrelais
-B1113 1 3-POL. 1xS 1xÖ Ir: 95-125A X-START ZB150-125 Eaton Electric B-IA-MOE-125-A11-040
Overload relay
Spannungsrelais
-B1145 1 22,5mm, 1-Phasenspannungsüberw 3UG4633-1AL30 Siemens B-RU-SIE-UG4-275-010
Voltage relay
Temperaturrelais
-B1261 1 1S/1Ö, Thermistor 230VAC 3RN1010-1CM00 Siemens B-RT-SIE-3RN-230-010
Temperature relay
Temperaturanzeige
-B1365 1 Zulieferung P-GT-ZUL-000-000-010
Temperature indication
Thermostat
-B1455 1 10-60°C 250V 50/60Hz,1Wechsler TRW60 Rübsamen & Herr B-ST-RUB-TRW-000-010
Thermostat
Filterlüfter
-E1455 1 230V,50/60Hz, LV250 Rübsamen & Herr G-LF-RUB-LV2-050-010
Fan
Austrittsfilter
-E1455 1 für LV250,RAL7035 GV250 Rübsamen & Herr G-LA-RUB-GV2-050-010
Outlet filter
Leitungsschutzschalter
-F1143 1 Typ C 1 Pol.,2A FAZ-C2/1 Eaton Electric F-F1-MOE-C00-002-010
Miniature circuit-breaker
-F1351 1 Typ-C 2Pol. 2A FAZ-C2/2 Eaton Electric F-F2-MOE-C00-002-010
Hilfsschütz
-K1175 1 4S 230V 50/60Hz DILER-40(230V50/60HZ) Eaton Electric K-HA-MOE-230-W40-010
Auxiliary contactor
Hilfsschalterblock
-K1175 1 für DIL-ER 4Ö 04DILE Eaton Electric K-HZ-MOE-H04-000-010
Auxiliary contact block
Erweiterungsmodul
-K1192 1 230V/230V Logo! 4xDE /4xDA 6ED1055-1FB00-0BA1 Siemens K-SL-SIE-055-230-010
Extension module
Erweiterungsmodul
Extension module
Erweiterungsmodul
Extension module
Relais
-K1204 1 2U / 10A+Sockel 230VAC-Ed, Us: 230VAC 48.52.8.230.0060 Finder K-RK-FIN-230-W2U-010
Relay
Relais
-K1207 1 Us:230VAC REL-IR/LDP-230VAC/4X21 Phoenix Contact K-RK-PHX-230-W4U-020
Relay
Multifunktionsrelais
-K1247 1 1U 24-240V 0,05S-10H ,Zeitrelais 82.01.0.240 Finder K-TM-FIN-MUL-U1U-010
Multi-function relay
Relais
-K1318 1 Koppelrelais, Us:24V DC,2X Wechsler:8A IB-2-024-D-G IDEC K-RK-IDE-024-G2U-010
Relay
Leistungsschütz
-K1352 1 3Pol. 4kW/AC3 16A/Ith Us: 230V 50/60Hz 1S DILEM-10(230V50/60HZ) Eaton Electric Q-AC-MOE-013-W10-010
Contactor
Hilfsschalterblock
-K1352 1 4-Pol. 2S,2Ö Schraubklemmen X-Start 22DILEM Eaton Electric Q-AZ-MOE-H22-0EM-010
Hilfsschütz
Auxiliary contactor
Relais
Relay
205 501
Date 24.03.2011 Kompressorsteuerung Artikelstückliste = C1
12001513 / 1
Ed. DOH / BAC COMPRESSOR CONTROL CENTER PARTS LIST + EN100
0 1 2 3 4 5 6 7 8 9
Artikelstückliste
Parts list
Leuchtmelder
-P1311 1 22mm,blau,komplett, Adapter, Karlotte, LED Moeller Eaton Electric P-LB-MOE-M22-030-010
Indicator light
Betriebsstundenzähler
-P1312 1 24VDC, mit Gummidichtung BG 40.X7 Müller P-WH-MUL-024-VDC-010
Operating hours counter
Leuchtmelder
-P1313 1 22mm,grün, Adapter, Karl, LED komplett Eaton Electric P-LG-MOE-M22-030-010
Indicator light
Leuchtmelder
-P1314 1 22mm,rot, Adapter, Karl, LED komplett Eaton Electric P-LR-MOE-M22-030-010
Indicator light
Leuchtmelder
Indicator light
Leuchtmelder
Indicator light
Leuchtmelder
Indicator light
Leuchtmelder
Indicator light
Leuchtmelder
Indicator light
Leuchtmelder
Indicator light
Leistungstrennschalter
-Q1112 1 3pol, 200A, Festeinbau N2-200-BT Eaton Electric Q-L0-MOE-200-F3H-015
Disconnector
Berührungsschutz
-Q1112 1 für NZM2-, N2 NZM2-XKSA Eaton Electric Q-ZZ-MOE-NZM-2XK-010
Protection against contact
Türkupplungsdrehgriff
-Q1112 1 für N2 und NZM2 NZM2-XHBR Eaton Electric Q-ZD-MOE-HBR-0N2-010
Door interlocked external handle
Motorschutzschalter
-Q1142 1 2,50...4,00A, BG:PKZM0 PKZM0-4 Eaton Electric Q-LM-MOE-ZM0-004-010
Motor overload switch
Leistungsschütz
-Q1205 1 3Pol. 75kW, 190-240V, 50/60Hz, DILM150(RAC240) Eaton Electric Q-AO-MOE-150-W00-010
Contactor
Hilfsschalterblock
-Q1205 1 2-Pol. 1S, 1Ö Schraubklemmen X-Start DILM1000-XHI11-SI Eaton Electric Q-AZ-MOE-H11-P02-010
Pilzdrucktaster
-S1175 1 verrastend rot M22 M22-PV Eaton Electric S-NR-MOE-M22-000-010
Mushroom pushbutton
Schutzkragen
-S1175 1 gelb M22 M22-XGPV Eaton Electric S-NR-MOE-M22-000-025
Protective shroud
Schaltelement
-S1175 1 Steck: CC 1Ö M22-CK01 Eaton Electric S-SH-MOE-M22-H01-010
Contact block
Umschalter
-S1243 1 2-pol, 1-0-2 U2/8ZM/X70A/NS Sontheimer S-WU-SON-0U2-102-010
Change-over switch
Drucktaster schwarz
-S1247 1 M22-D-S Eaton Electric S-TS-MOE-M22-H00-010
Pushbutton black
Schaltelement
-S1247 1 Steck: CC 1S M22-CK10 Eaton Electric S-SH-MOE-M22-H10-010
Contact block
Netzgerät
-T1147 1 Input: 120-230VAC, Out: 24VDC 6EP1331-1SH03 Siemens T-NA-SIE-331-1_3-010
Power supply unit
Universaltrafo
-T1148 1 210-540/115+115V 1000VA STU1000/2x115 Block T-TU-BLO-540-230-H10
Universal transformer
Wandgehäuse
-1U 1 B/H/T 760/ 760/ 300 AE1073.500 Rittal U-WG-RIT-AE1-073-010
Wall-mounting case
Wandbefestigungshalter
-1U 1 für AE, Wandabstand 10mm SZ2508.010 Rittal U-GZ-RIT-SZ2-508-010
Wall mount
Marineverschraubung
-1U 1 M63 x 1,5, Messing vernickelt EMSKV 63 EMV-Z Wiska U-ZV-WIS-M63-1_5-020
Marine gland
Marineverschraubung
Marine gland
500 502
12001513 / 1
0 1 2 3 4 5 6 7 8 9
Artikelstückliste
Parts list
Marineverschraubung
Marine gland
Verschraubung
Gland
Gegenmutter
-1U 1 M63 x 1,5,Messing vernickelt EMMU-EMV 63 Wiska U-ZM-WIS-M63-1_5-010
Nut
Marinemutter
-1U 1 M50 x 1,5, Messing vernickelt EMMU-EMV 50 Wiska U-ZM-WIS-M50-1_5-010
Marine nut
Marinemutter
Marine nut
Marinemutter
Marine nut
Erdungsbolzen
-1U 1 Erdungsbolzen im Gehäuse, M8- ERD-M8-VA Hanseatic Power Solutions X-KP-XYZ-ERD-008-0VA
Earthing bolt
501
12001513 / 1
0 1 2 3 4 5 6 7 8 9

Oststraße 67
D-22844 Norderstedt
Phone: + 49 (0)40 5303479 - 0
Fax: + 49 (0)40 5303479 - 90
Regulation Color
=C2
+EN200
Created on
2
12001513 / 2
Appr 112787 Page 1
0 1 2 3 4 5 6 7 8 9
Inhaltsverzeichnis
Table of contents
Deckblatt
=C2+EN200/1 23.02.2011
COVER SHEET
Inhaltsverzeichnis
=C2+EN200/2 24.03.2011
TABLE OF CONTENTS
Inhaltsverzeichnis
=C2+EN200/2.A 24.03.2011
TABLE OF CONTENTS
Frontansicht
=C2+EN200/3 23.02.2011
FRONT VIEW
=C2+EN200/4 23.02.2011
=C2+EN200/111 24.03.2011
=C2+EN200/114 24.03.2011
=C2+EN200/114.A 24.03.2011
Not-Halt
=C2+EN200/117 24.03.2011
EMERGENCY STOP
Steuerung
=C2+EN200/119 23.02.2011
CONTROL
Steuerung
=C2+EN200/120 23.02.2011
CONTROL
Ventile
=C2+EN200/122 23.02.2011
SOLENOID
Anforderungen
=C2+EN200/124 23.02.2011
REQUIREMENTS
Motortemperatur
=C2+EN200/126 23.02.2011
MOTOR TEMPERATURE
Störmeldungen
=C2+EN200/128 23.02.2011
COMMON FAULT
Störmeldungen
=C2+EN200/129 23.02.2011
COMMON FAULT
Meldungen
=C2+EN200/131 23.02.2011
SIGNALS
Meldungen
=C2+EN200/132 23.02.2011
SIGNALS
Stillstandsheizung
=C2+EN200/135 23.02.2011
Heizung ECC Watlow
=C2+EN200/136 24.03.2011
HEATING ECC WATLOW
Trockner
=C2+EN200/140 23.02.2011
DRYER
=C2+EN200/145 24.03.2011
PANEL FAN
Fernmeldungen
=C2+EN200/150 23.02.2011
POT. FREE SIGNALS
1 2.A
12001513 / 2
Appr 112787 Page 2
0 1 2 3 4 5 6 7 8 9
Inhaltsverzeichnis
Table of contents
Fernmeldungen
=C2+EN200/151 23.02.2011
POT. FREE SIGNALS
LOGO Übersicht
=C2+EN200/180 23.02.2011
LOGO OVERVIEW
LOGO Übersicht
=C2+EN200/181 23.02.2011
LOGO OVERVIEW
LOGO Übersicht
=C2+EN200/182 23.02.2011
LOGO OVERVIEW
LOGO Übersicht
=C2+EN200/183 23.02.2011
LOGO OVERVIEW
=C2+EN200/200 24.03.2011
=C2+EN200/201 24.03.2011
=C2+EN200/202 24.03.2011
=C2+EN200/203 24.03.2011
=C2+EN200/204 24.03.2011
=C2+EN200/205 24.03.2011
Artikelstückliste
=C2+EN200/500 24.03.2011
PARTS LIST
Artikelstückliste
=C2+EN200/501 24.03.2011
PARTS LIST
Artikelstückliste
=C2+EN200/502 22.03.2011
PARTS LIST
2 3
12001513 / 2
0 1 2 3 4 5 6 7 8 9
Kompressor 1
1900
1800
1600
1300
-S1247 Reset RESET
1100
1000
900 760 mm
300 mm
800
700 -P1311 -P1313 -P1318 -P1312
-X1 -P1314 -P1317 -P1315 -P1316

600
500 -P1322 -P1323

760 mm
-S1175
-S1243 -S1247
400
-Q1112
300
200 -E1455
100
0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
2.A 4
12001513 / 2
Appr 112787 Page 3
0 1 2 3 4 5 6 7 8 9
Lieferung
DELIVERY
A C
Durchmesser: 10,2mm
DIAMETER: 8mm
15 mm
20 mm
D
B
20 mm
15 mm
20 mm 20 mm
29 mm 29 mm
A B C D
200mm 300mm 160mm 260mm 142mm 330mm
300mm 300mm 260mm 260mm 242mm 330mm
400mm 500mm 360mm 460mm 342mm 530mm
600mm 600mm 560mm 560mm 542mm 630mm
600mm 800mm 560mm 760mm 542mm 830mm
760mm 760mm 720mm 720mm 602mm 790mm
800mm 1000mm 760mm 960mm 742mm 1030mm
1000mm 760mm 960mm 720mm 942mm 790mm
1000mm 1000mm 960mm 960mm 942mm 1030mm
1200mm 1200mm 1160mm 1160mm 1142mm 1230mm
3 111
12001513 / 2
Appr 112787 Page 4
0 1 2 3 4 5 6 7 8 9
95mm²
-L1 / 114.0
95mm²
95mm²
-L3 / 114.0
2 4 6
-Q1112
N2-200A 1 3 5
1 3 5
-Q1205
/120.3 2 4 6
1 3 5 95 97
-B1113
95-125A 2 4 6 96 98
107A /120.3 /128.1
-T1 / 126.1
-T2 / 126.2
-PE / 114.0

-X L1 L2 L3 PE -X 1U 1V 1W
M
-M01 3~
Θ
=MCCROOM -T02
440V, 3PH, 60Hz +
M63 M50 M20
4 114
12001513 / 2
0 1 2 3 4 5 6 7 8 9
111.9 / -L1
111.9 / -L3
-B1145
1 3 5 SIRIUS
3UG4633
-Q1142 12 14
2,50-4,00A
2,50A
I> I> I> A1 A2
11
2 4 6 /124.8
24V DC
-L51+ / 131.0
-T1147 -L50- / 132.0
520V 460V 400V 230V -20V 0 +20V
+ -
24V DC
-T1148 1,3A
STU 1000/2x115V
1000/2650VA 0 115V 0 115V PE
230V AC
L N (85-264V)
-XT 1 1 1 1
-F1144
2 C1A 2
-F1143
C2A 1
-XT PE 0 0 0 0 -XT 2 2 2
-L11 / 119.0
-L10 / 117.0
-LT11 / 117.0
NOT FUSED 230V AC
-L110 / 135.0
-L100 / 135.0
111.9 / -PE -PE / 122.0

111 114.A
12001513 / 2
0 1 2 3 4 5 6 7 8 9
STUX 180 STUX 320
T1151 - 180VA / 490VA T1151 - 320VA / 1120VA

2x115V / 24V 2x115V / 24V
BLOCK BLOCK
Q1151 Q1151
600V 34-35 0,34A 600V 34-35 0,60A
575V 33-35 0,35A 575V 33-35 0,62A
560V 32-35 0,36A 560V 32-35 0,65A
525V 31-35 0,38A 525V 31-35 0,67A
500V 34-36 0,40A 500V 34-36 0,71A
480V 33-36 0,42A 480V 33-36 0,74A
460V 32-36 0,44A 460V 32-36 0,77A
440V 32-37 0,46A 440V 32-37 0,81A
420V 31-37 0,48A 420V 31-37 0,85A
400V 32-38 0,50A 400V 32-38 0,89A
380V 31-38 0,53A 380V 31-38 0,94A
230V 1-36 / 2-32 0,88A 230V 1-36 / 2-32 1,55A
208V 1-37 / 2-31 0,96A 208V 1-37 / 2-31 1,69A
STU 1000
T1148 - 1000VA / 2650VA

2x115V
BLOCK
Q1141
Uin max
540V 1,90A
520V 2,00A
500V 2,10A
480V 2,20A
460V 2,30A
440V 2,40A
420V 2,50A
400V 2,60A
380V 2,70A
250V 4,20A
230V 4,60A
210V 5,00A
114 117
12001513 / 2
0 1 2 3 4 5 6 7 8 9
114.9 / -LT11 -LT11 / 124.0
21
-X1-230VAC 98 98 -S1175
22
*
11 23 15 13
-K1515 -S1247 -K1247 -K1175
/151.7 14 12 /124.7 24 /124.8 18 16 /117.5 14
-X1-230VAC 99
A1
-K1175
A2
114.9 / -L10 -L10 / 119.0

DILER-40(230V50/60HZ)
04DILE
-X1-230VAC 100 101
13 14 /117.7
23 24 /120.3
33 34
43 44
51 52 /128.8
61 62
71 72
-ES1 -ES2 81 82
=EXT
+
M20
114.A 119
12001513 / 2
0 1 2 3 4 5 6 7 8 9
114.9 / -L11 -L11 / 120.0
-A1191 -K1192 -K1193 -K1194

/180.4 /181.4 /182.4 /183.4
L L L L
8DI 4DI 4DI 4DI
Siemens - Display
6ED1052-1FB00-0BA6
4DO 4DO 4DO 4DO
N N N N
117.9 / -L10 -L10 / 120.0
117 120
12001513 / 2
0 1 2 3 4 5 6 7 8 9
119.9 / -L11 -L11 / 122.0

-K1194:L -A1191:1
Q1 Q2
/180.5 /180.5
-A1191 -A1191
1 2 1 2
23
-K1175
/117.5 24
95
-B1113
/111.4 96
13
-Q1205
/120.3 14
I4
-A1191
/180.5
I4
-B1113:96
Kompressor läuft
COMPRESSOR RUNNING
A1 A1 A1
-K1204 -Q1205 -K1207
A2 A2 A2
119.9 / -L10 -L10 / 122.0
DILM150(RAC240)
14 1 2 /111.4 14
3 4 /111.4
12 11 /151.2 12 11 /151.3
5 6 /111.4
24 24
13 14 /120.4
22 21 /150.4 21 22 /136.7 22 21 /150.2
34
32 31 /131.2
44
42 41 /135.7

119 122
12001513 / 2
0 1 2 3 4 5 6 7 8 9
120.9 / -L11 -L11 / 124.0
-A1191:1 -A1191:1
Q3 Q11 (Q3)
/180.5 /182.5
-A1191 -K1193
1 2 1 2
Magnetventil:
SOLENOID VALVE:
START DELAY 10 SEC
120.9 / -L10 -L10 / 124.0

114.9 / -PE -PE / 124.0
-X1-230VAC 41 42 PE 43 44 PE 47 48 PE 49 50 PE
x1 x1 x1 x1
PE PE PE PE
-D03 -D05 -C03 -Y12
x2 x2 x2 x2
=COM =COM =COM =COM

+ + + +
M20 M20 M20 M20
120 124
12001513 / 2
0 1 2 3 4 5 6 7 8 9
117.9 / -LT11
122.9 / -L11 -L11 / 126.0
2 4 13 11
-S1243 -S1247 -B1145
/150.3 1 3 /117.5 14 /114.5 14 12
1-0-2 Reset
1=Hand ein
0=Aus
2=Fern Start-Stop
1=man run
0=off / reset
2=remote start-stop
I1 I1 I2 I2 I3 I5
-A1191 -K1192 -A1191 -K1192 -A1191 -A1191

/180.5 /181.5 /180.5 /181.5 /180.5 /180.5
I1 I9 (I1) I2 I10 (I2) I3 I5
A1 B1
-K1247 M
DI A2
1,5 SEC
122.9 / -L10 -L10 / 126.0

122.9 / -PE -PE / 128.0
82.01.0.240
-X1-230VAC 21 22 PE 23 24 PE 110 111 51 52 PE
315-EC100-P02 1 2 GN/YE 3 4 5 18
16 15 /117.6
-C2-X1/230VAC 21 22 PE 23 PE 110 111 -X x x PE
-MAX P -MIN P
=EXT =EXT
+ +
M25 M20
122 126
12001513 / 2
0 1 2 3 4 5 6 7 8 9
124.9 / -L11 -L11 / 128.0
-B1261
A1
95 97
/128.6
96 98
A2 T1 T2
111.6 / -T1
111.6 / -T2
124.9 / -L10 -L10 / 136.0
Motortemperatur
ENGINE TEMPERATURE
124 128
12001513 / 2
0 1 2 3 4 5 6 7 8 9
126.9 / -L11 -L11 / 129.0
97 95 51
-B1113 -B1261 -K1175
/111.4 98 /126.2 96 /117.5 52
I6 I7 I8 I3 I4
-A1191 -A1191 -A1191 -K1192 -K1192

/180.5 /180.5 /180.5 /181.5 /181.5
I6 I7 I8 I11 (I3) I12 (I4)
-B1113:98 =EXT-D04 =EXT-A08 -B1261:96 -K1175:52
124.9 / -PE -PE / 129.0
-X1-230VAC 25 26 PE 27 28 PE
-X x x PE -X x x PE
-D04 P -A08
=EXT =EXT
+ +
M20 M20
126 129
12001513 / 2
0 1 2 3 4 5 6 7 8 9
128.9 / -L11 -L11 / 136.0
-X1-230VAC 29
-A -A1 -X2:1 2 6
24V DC
DRYER
CONTROL
8 7
=
=Y12 +DIFF_PRESSURE
-X PE
DRYER ASSEM. LV.G
-X1-230VAC 30 PE

-K1193
/182.5
I13 (I1)
Taupunkt DEW POINT
128.9 / -PE -PE / 135.0
Taupunkt
DEW POINT
Option
OPTION
M20
128 131
12001513 / 2
0 1 2 3 4 5 6 7 8 9
24V DC
114.9 / -L51+ -L51+ / 132.0

-T1147:+ -K1207:31 -A1191:1 -K1192:1 -K1192:1 -K1192:1
Q12 (Q4) Q4 Q5 (Q1) Q6 (Q2) Q7 (Q3) Q8 (Q4)
/182.5 /180.5 /181.5 /181.5 /181.5 /181.5
31
-K1193 -A1191 -K1192 -K1192 -K1192 -K1192
-K1207
/120.4 34 32
1 2 1 2 1 2 1 2 1 2 1 2
x1
X1 X1 X1 X1 X1 X1 X1 A1
-P1311 -P1312 -P1313 -P1314 -P1315 -P1316 -P1317 -P1318 -K1318
x2
-LT50 / 132.0
IB-2-024-D-G
14
12 11 /150.5
24
22 21

129 132
12001513 / 2
0 1 2 3 4 5 6 7 8 9
24V DC
131.9 / -L51+

PRESSURE
-K1192:1
Q9 (Q1)
/182.5
13
-K1193
-K1352
/135.7 14
1 2
X1 X1
-P1322 -P1323
RD X2 BU X2
131.9 / -LT50
114.9 / -L50-

DRYER FAILURE -
Option
OPTION
131 135
12001513 / 2
0 1 2 3 4 5 6 7 8 9
114.9 / -L110 -L110 / 136.0

114.9 / -L100 -L100 / 136.0
2 4
-F1351
C2A 1 3
1 3 41
-K1352 -K1207
/135.7 2 4 /120.4 44 42
A1
-K1352
A2
129.9 / -PE -PE / 136.0
DILEM-10(230V50/60HZ)
22DILEM
-X1-230VAC 14 15 PE
1 2 /135.1
3 4 /135.1
5 6
-X x x PE 13 14 /132.3
53 54
61 62
-H01 71 72
83 84
=COM
+E
Max. 100 Watt
M20
132 136
12001513 / 2
0 1 2 3 4 5 6 7 8 9
129.9 / -L11
135.9 / -L110 -L110 / 140.0
135.9 / -L100 -L100 / 140.0
1 3 -B1365
-F1361
103E-2K4C-1100 L1/10
7
TC+ TC- 6 8 DC+ DC-

4 3 5 L2/9 1 2
33 43 21
-K1366 -Q1205
/136.7 34 44 /120.3 22
Direktanschluss
DIRECT CONNECTION
A1
-K1366
A2
126.9 / -L10
135.9 / -PE -PE / 140.0

DILER-40(230V50/60HZ)
-X1-230VAC 16 17 PE 18 19 PE 9 10
13 14
23 24
33 34 /136.3
x x PE x x PE 43 44 /136.3
+ - + -
-B1361
-H01 -H01
=NICRNI =NICRNI
=OSH1 =OSH2 + +
+ +
THERMOSTAT
100W 100W SPARE
M20 M20 M20 M20

135 140
12001513 / 2
0 1 2 3 4 5 6 7 8 9
136.9 / -L110 -L110 / 145.1

136.9 / -L100 -L100 / 145.1
2 4
-F1402
C2A 1 3

OPERATION
Q10 (Q2)
/182.5
-K1193
1 2
136.9 / -PE -PE / 145.1
-X1-230VAC 61 62 PE 63 64 PE
-Y10 -Y11
=COM
+E
230V 50/60Hz
60VA
M20 M20
136 145
12001513 / 2
1 2 3 4 5 6 7 8 9 10
140.9 / -L110
2
-F1455
C2A 1
-B1455
Θ=30°C
3
1 2
-XF 5
-E1455
L PE
M
1~
N
-XF 4
140.9 / -L100
140.9 / -PE -PE / 150.0
SWITCHBOARD FAN
250V AC
140 150
12001513 / 2
0 1 2 3 4 5 6 7 8 9

21 6 8 21 11
-K1207 -S1243 -K1204 -K1318
/120.4 24 22 /124.1 5 7 /120.2 24 22 /131.8 14 12
145.10 / -PE -PE / 151.0
=ECR
+
M25
145 151
12001513 / 2
0 1 2 3 4 5 6 7 8 9
11 11
-K1204 -K1207
/120.2 14 12 /120.4 14 12
A1 s.S. 117
SEE PAGE 117
-K1515
A2
1X 2X 3X 5X 17X 18X
150.9 / -PE
-X38/24VDC 9 10 PE 11 12 PE 13 14 15 16 PE
IB-2-024-D-G
14
-315-EN200-C01 24
-X38 9 10 PE 11 12 PE 13 14 15 16 22 21
+
24V DC
=315_IB100
COLLECTIVE FAULT
M25
150 180
12001513 / 2
0 1 2 3 4 5 6 7 8 9
-A1191
/119.4
LOGO! SIEMENS
I1 Ort Hand Start

I1 /124.1
REMOTE MANUAL START
I2 Auto Stop
I2 /124.5
AUTOMATIC STOP
I3 Reset
I3 /124.7
RESET
I4 /120.5
COMPRESSOR RUNNING
I5 /124.8
VOLTAGE PRESENT
I6 Überstrom
I6 /128.1
OVERCURRENT
I7 Öldruck
I7 /128.3
OIL PRESSURE
I8 /128.5
1 Betriebsbereit
Q1 /120.1
READY FOR OPERATION
2 Betriebsbereit
Q1 /120.2
READY FOR OPERATION
1 Antrieb ein
Q2 /120.3
DRIVE ON
2 Antrieb ein
Q2 /120.3
DRIVE ON
Q3 /122.1
2 Stufe 1
Q3 /122.2
STAGE 1
1 Überstrom
Q4 /131.3
OVERCURRENT
2 Überstrom
Q4 /131.4
OVERCURRENT
6ED1055-1FB00-0BA1
151 181
12001513 / 2
0 1 2 3 4 5 6 7 8 9
-K1192
/119.5
LOGO! SIEMENS
I1 ein
I9 (I1) /124.2
ON
I2 Auto Start
I10 (I2) /124.6
AUTOMATIC START
I3 Motortemperatur
I11 (I3) /128.6
ENGINE TEMPERATURE
I4 Not-Halt
I12 (I4) /128.8
EMERGENCY STOP
1 Öldruck
Q5 (Q1) /131.4
OIL PRESSURE
2 Öldruck
Q5 (Q1) /131.5
OIL PRESSURE
Q6 (Q2) /131.6
Q6 (Q2) /131.6
1 Motortemperatur
Q7 (Q3) /131.7
ENGINE TEMPERATURE
2 Motortemperatur
Q7 (Q3) /131.8
ENGINE TEMPERATURE
1 Not-Halt
Q8 (Q4) /131.8
EMERGENCY STOP
2 Not-Halt
Q8 (Q4) /131.9
EMERGENCY STOP
6ED1052-1FB00-0BA6
180 182
12001513 / 2
0 1 2 3 4 5 6 7 8 9
-K1193
/119.6
LOGO! SIEMENS
I1 Taupunkt
I13 (I1) /129.3
DEW POINT
I2
I14 (I2)
I3
I15 (I3)
I4
I16 (I4)

Q9 (Q1) /132.1
Q9 (Q1) /132.2
1 Trockner Betrieb
Q10 (Q2) /140.3
DRYER OPERATION
2 Trockner Betrieb
Q10 (Q2) /140.3
DRYER OPERATION
Q11 (Q3)
Q11 (Q3) /122.5
Q12 (Q4) /131.1
VOLTAGE PRESENT
Q12 (Q4) /131.2
VOLTAGE PRESENT
6ED1052-1FB00-0BA6
181 183
12001513 / 2
0 1 2 3 4 5 6 7 8 9
-K1194
/119.6
LOGO! SIEMENS
I1
I17 (I1)
I2
I18 (I2)
I3
I19 (I3)
I4
I20 (I4)
1
Q13 (Q1)
2
Q13 (Q1)
1
Q14 (Q2)
2
Q14 (Q2)
1
Q15 (Q3)
2
Q15 (Q3)
1
Q16 (Q4)
2
Q16 (Q4)
6ED1052-1FB00-0BA6
182 200
12001513 / 2
0 1 2 3 4 5 6 7 8 9
=MCCROOM+MCC873-X
=COM-M01
X1
PE
PE
PE
M
PE 3~
Θ
COMPRESSOR DRIVE
Kompressorantrieb
183 201
12001513 / 2
Appr =C2+EN200-X1 112787 Page 200
0 1 2 3 4 5 6 7 8 9
=ECR-X
=ECR-X
=ECR-X
-K1207
-K1207
-K1207
-K1204
-K1204
-K1318
-K1318
-E1455
-S1243
-S1243
-S1243
X1-POT.FREE
PE
PE
PE
PE
81
82
83
84
85
86
87
88
89
90
91
92
=ECR-X
COLLECTIVE FAULT
EMERGENCY STOP
Versorgung 82-83
Versorgung 85-86
Sammelstörung
AUTOMATIC
COM 82-83
COM 85-86
MANUAL
Not-Halt
Hand
Auto
OFF
aus
ON
ein
200 202
12001513 / 2
201
Revision
0
Date
X1-230VAC
Name
Auto Stop
21
21 -S1243
1
1
22
= 22 -A1191
1
Ed.
Date
Appr
PE
= PE =COM-Y12
Auto Start
23
23 -K1192
GN/YE 3
GN/YE 3
DOH
AUTOMATIC START
21
= 24
24.03.2011
/
PE
=EXT-C2-X1/230VAC
-315-EC100-P02
BAC
Auto Start
110
110
4
4
AUTOMATIC START
2
= 111
111
5
5
Fernstart
x
51
REMOTE START
x
= 52
Kompressorsteuerung
=EXT-X
Fernstart
PE
REMOTE START
3
Stillstandsheizung

14 -K1352
STANDSTILL HEATING
x
= 15 -K1352
=COM+E-X
PE
Heizung 1 Ölwanne
x
4
16 -K1366
HEATER 1 OIL SUMP
x
100W 17
PE
= PE
x
Heizung 2 Ölwanne
x
18 -K1366
HEATER 2 OIL SUMP
x
100W 19 -F1361
PE
= PE
5
Thermostat Reserve
+
9
THERMOSTAT SPARE
+
-
-
= 10
Öldruck
x
25 -B1113
=C2+EN200-X1-230VAC
=C2+EN200-X1-230VAC
OIL PRESSURE
x
= 26 -A1191
6
PE
= PE =EXT-X
x
Drucklufttemperatur
x
=EXT-X
27 -B1261
x
= 28 -A1191
PE
= PE =EXT-X
112787
7
29 -K1175
41007852 // 1/1
6
12001513 / 2
Taupunkt
7
30 -K1193
DEW POINT
7
Taupunkt
PE
8
PE =EXT-X
PE
DEW POINT
Stufe 1
x1
41 -A1191
STAGE 1
= C2
x2
x1
x2
= 42 -K1207
+ EN200
=COM-D03
PE
Page
Page
502
202
203
0 1 2 3 4 5 6 7 8 9
=COM+E-X1
=COM+E-X1
=COM-D03
=COM-D05
=COM-C03
-K1193
-K1247
-K1193
-K1193
-K1515
-T1148
-S1243
-S1175
-F1402
-F1402
X1-230VAC
100
101
PE
PE
PE
PE
PE
PE
43
44
47
48
49
50
61
62
63
64
98
98
99
x1
x1 x1 x1 12 14
PE PE PE PE
L1
x2
x2 x2 x2 11
DRYER OPERATION
DEW POINT VALVE
Not-Halt Steuerfeld
Trockner Betrieb
Taupunktventil
Trockner
STAGE 1
STAGE 2
Stufe 1
Stufe 2
DRYER
=
202 204
12001513 / 2
0 1 2 3 4 5 6 7 8 9
=315_IB100-X38
=315_IB100-X38
=ECR-X
-K1204
-K1204
-K1207
-K1207
-K1515
-K1515
X38/24VDC
PE
PE
PE
10
11
12
13
14
15
16
9

-315-EN200-C01
-315-EN200-C01

9 10 PE 11 12 PE 13 14 15 16
=315_IB100-X38
0=Stop 1=Aktivieren
COLLECTIVE FAULT
COLLECTIVE FAULT
Sammelstörung
OPERATION
Betrieb
=
203 205
12001513 / 2
0 1 2 3 4 5 6 7 8 9
=COM-M01
-B1261
-B1261
XTHERM
PE
7
M
3~
Θ
=COM-M01
THERMISTOR
Thermistor
204 500
12001513 / 2
0 1 2 3 4 5 6 7 8 9
Artikelstückliste
Parts list
Logikmodul
Logic module
Speicherkarte
Memory card
Überlastrelais
Overload relay
Spannungsrelais
Voltage relay
Temperaturrelais
Temperature relay
Temperaturanzeige
Thermostat
Thermostat
Filterlüfter
Fan
Austrittsfilter
Outlet filter
Hilfsschütz
Auxiliary contactor
Hilfsschalterblock
Erweiterungsmodul
Extension module
Erweiterungsmodul
Extension module
Erweiterungsmodul
Extension module
Relais
Relay
Relais
Relay
Relais
Relay
Leistungsschütz
Contactor
Hilfsschalterblock
Hilfsschütz
Auxiliary contactor
Relais
Relay
205 501
12001513 / 2
0 1 2 3 4 5 6 7 8 9
Artikelstückliste
Parts list
Leuchtmelder
Indicator light
Leuchtmelder
Indicator light
Leuchtmelder
Indicator light
Leuchtmelder
Indicator light
Leuchtmelder
Indicator light
Leuchtmelder
Indicator light
Leuchtmelder
Indicator light
Leuchtmelder
Indicator light
Leuchtmelder
Indicator light
Disconnector
Berührungsschutz
Motorschutzschalter
Leistungsschütz
Contactor
Hilfsschalterblock
Pilzdrucktaster
Mushroom pushbutton
Schutzkragen
Protective shroud
Schaltelement
Contact block
Umschalter
Change-over switch
Drucktaster schwarz
Pushbutton black
Schaltelement
Contact block
Netzgerät
Power supply unit
Universaltrafo
Wandgehäuse
Wall-mounting case
Wall mount
Marineverschraubung
Marine gland
Marineverschraubung
Marine gland
500 502
12001513 / 2
0 1 2 3 4 5 6 7 8 9
Artikelstückliste
Parts list
Marineverschraubung
Marine gland
Verschraubung
Gland
Gegenmutter
Nut
Marinemutter
Marine nut
Marinemutter
Marine nut
Marinemutter
Marine nut
Erdungsbolzen
Earthing bolt
501
12001513 / 2
0 1 2 3 4 5 6 7 8 9

Oststraße 67
D-22844 Norderstedt
Phone: + 49 (0)40 5303479 - 0
Fax: + 49 (0)40 5303479 - 90
Regulation Color
=C3
+EN300
Created on
2
12001513 / 3
Appr 112787 Page 1
0 1 2 3 4 5 6 7 8 9
Inhaltsverzeichnis
Table of contents
Deckblatt
=C3+EN300/1 23.02.2011
COVER SHEET
Inhaltsverzeichnis
=C3+EN300/2 22.03.2011
TABLE OF CONTENTS
Inhaltsverzeichnis
=C3+EN300/2.A 22.03.2011
TABLE OF CONTENTS
Frontansicht
=C3+EN300/3 23.02.2011
FRONT VIEW
=C3+EN300/4 23.02.2011
=C3+EN300/111 24.03.2011
=C3+EN300/114 24.03.2011
=C3+EN300/114.A 24.03.2011
Not-Halt
=C3+EN300/117 24.03.2011
EMERGENCY STOP
Steuerung
=C3+EN300/119 23.02.2011
CONTROL
Steuerung
=C3+EN300/120 23.02.2011
CONTROL
Ventile
=C3+EN300/122 23.02.2011
SOLENOID
Anforderungen
=C3+EN300/124 23.02.2011
REQUIREMENTS
Motortemperatur
=C3+EN300/126 23.02.2011
MOTOR TEMPERATURE
Störmeldungen
=C3+EN300/128 23.02.2011
COMMON FAULT
Störmeldungen
=C3+EN300/129 23.02.2011
COMMON FAULT
Meldungen
=C3+EN300/131 23.02.2011
SIGNALS
Meldungen
=C3+EN300/132 23.02.2011
SIGNALS
Stillstandsheizung
=C3+EN300/135 23.02.2011
Heizung ECC Watlow
=C3+EN300/136 24.03.2011
HEATING ECC WATLOW
Trockner
=C3+EN300/140 23.02.2011
DRYER
=C3+EN300/145 24.03.2011
PANEL FAN
Fernmeldungen
=C3+EN300/150 23.02.2011
POT. FREE SIGNALS
1 2.A
12001513 / 3
Appr 112787 Page 2
0 1 2 3 4 5 6 7 8 9
Inhaltsverzeichnis
Table of contents
Fernmeldungen
=C3+EN300/151 23.02.2011
POT. FREE SIGNALS
LOGO Übersicht
=C3+EN300/180 23.02.2011
LOGO OVERVIEW
LOGO Übersicht
=C3+EN300/181 23.02.2011
LOGO OVERVIEW
LOGO Übersicht
=C3+EN300/182 23.02.2011
LOGO OVERVIEW
LOGO Übersicht
=C3+EN300/183 23.02.2011
LOGO OVERVIEW
=C3+EN300/200 24.03.2011
=C3+EN300/201 24.03.2011
=C3+EN300/202 24.03.2011
=C3+EN300/203 24.03.2011
=C3+EN300/204 24.03.2011
=C3+EN300/205 24.03.2011
Artikelstückliste
=C3+EN300/500 24.03.2011
PARTS LIST
Artikelstückliste
=C3+EN300/501 24.03.2011
PARTS LIST
Artikelstückliste
=C3+EN300/502 22.03.2011
PARTS LIST
2 3
12001513 / 3
0 1 2 3 4 5 6 7 8 9
Kompressor 1
1900
1800
1600
1300
-S1247 Reset RESET
1100
1000
900 760 mm
300 mm
800
700 -P1311 -P1313 -P1318 -P1312
-X1 -P1314 -P1317 -P1315 -P1316

600
500 -P1322 -P1323

760 mm
-S1175
-S1243 -S1247
400
-Q1112
300
200 -E1455
100
0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
2.A 4
12001513 / 3
Appr 112787 Page 3
0 1 2 3 4 5 6 7 8 9
Lieferung
DELIVERY
A C
Durchmesser: 10,2mm
DIAMETER: 8mm
15 mm
20 mm
D
B
20 mm
15 mm
20 mm 20 mm
29 mm 29 mm
A B C D
200mm 300mm 160mm 260mm 142mm 330mm
300mm 300mm 260mm 260mm 242mm 330mm
400mm 500mm 360mm 460mm 342mm 530mm
600mm 600mm 560mm 560mm 542mm 630mm
600mm 800mm 560mm 760mm 542mm 830mm
760mm 760mm 720mm 720mm 602mm 790mm
800mm 1000mm 760mm 960mm 742mm 1030mm
1000mm 760mm 960mm 720mm 942mm 790mm
1000mm 1000mm 960mm 960mm 942mm 1030mm
1200mm 1200mm 1160mm 1160mm 1142mm 1230mm
3 111
12001513 / 3
Appr 112787 Page 4
0 1 2 3 4 5 6 7 8 9
95mm²
-L1 / 114.0
95mm²
95mm²
-L3 / 114.0
2 4 6
-Q1112
N2-200A 1 3 5
1 3 5
-Q1205
/120.3 2 4 6
1 3 5 95 97
-B1113
95-125A 2 4 6 96 98
107A /120.3 /128.1
-T1 / 126.1
-T2 / 126.2
-PE / 114.0

-X L1 L2 L3 PE -X 1U 1V 1W
M
-M01 3~
Θ
=MCCROOM -T02
440V, 3PH, 60Hz +
M63 M50 M20
4 114
12001513 / 3
0 1 2 3 4 5 6 7 8 9
111.9 / -L1
111.9 / -L3
-B1145
1 3 5 SIRIUS
3UG4633
-Q1142 12 14
2,50-4,00A
2,50A
I> I> I> A1 A2
11
2 4 6 /124.8
24V DC
-L51+ / 131.0
-T1147 -L50- / 132.0
520V 460V 400V 230V -20V 0 +20V
+ -
24V DC
-T1148 1,3A
STU 1000/2x115V
1000/2650VA 0 115V 0 115V PE
230V AC
L N (85-264V)
-XT 1 1 1 1
-F1144
2 C1A 2
-F1143
C2A 1
-XT PE 0 0 0 0 -XT 2 2 2
-L11 / 119.0
-L10 / 117.0
-LT11 / 117.0
NOT FUSED 230V AC
-L110 / 135.0
-L100 / 135.0
111.9 / -PE -PE / 122.0

111 114.A
12001513 / 3
0 1 2 3 4 5 6 7 8 9
STUX 180 STUX 320
T1151 - 180VA / 490VA T1151 - 320VA / 1120VA

2x115V / 24V 2x115V / 24V
BLOCK BLOCK
Q1151 Q1151
600V 34-35 0,34A 600V 34-35 0,60A
575V 33-35 0,35A 575V 33-35 0,62A
560V 32-35 0,36A 560V 32-35 0,65A
525V 31-35 0,38A 525V 31-35 0,67A
500V 34-36 0,40A 500V 34-36 0,71A
480V 33-36 0,42A 480V 33-36 0,74A
460V 32-36 0,44A 460V 32-36 0,77A
440V 32-37 0,46A 440V 32-37 0,81A
420V 31-37 0,48A 420V 31-37 0,85A
400V 32-38 0,50A 400V 32-38 0,89A
380V 31-38 0,53A 380V 31-38 0,94A
230V 1-36 / 2-32 0,88A 230V 1-36 / 2-32 1,55A
208V 1-37 / 2-31 0,96A 208V 1-37 / 2-31 1,69A
STU 1000
T1148 - 1000VA / 2650VA

2x115V
BLOCK
Q1141
Uin max
540V 1,90A
520V 2,00A
500V 2,10A
480V 2,20A
460V 2,30A
440V 2,40A
420V 2,50A
400V 2,60A
380V 2,70A
250V 4,20A
230V 4,60A
210V 5,00A
114 117
12001513 / 3
0 1 2 3 4 5 6 7 8 9
114.9 / -LT11 -LT11 / 124.0
21
-X1-230VAC 98 98 -S1175
22
*
11 23 15 13
-K1515 -S1247 -K1247 -K1175
/151.7 14 12 /124.7 24 /124.8 18 16 /117.5 14
-X1-230VAC 99
A1
-K1175
A2
114.9 / -L10 -L10 / 119.0

DILER-40(230V50/60HZ)
04DILE
-X1-230VAC 100 101
13 14 /117.7
23 24 /120.3
33 34
43 44
51 52 /128.8
61 62
71 72
-ES1 -ES2 81 82
=EXT
+
M20
114.A 119
12001513 / 3
0 1 2 3 4 5 6 7 8 9
114.9 / -L11 -L11 / 120.0
-A1191 -K1192 -K1193 -K1194

/180.4 /181.4 /182.4 /183.4
L L L L
8DI 4DI 4DI 4DI
Siemens - Display
6ED1052-1FB00-0BA6
4DO 4DO 4DO 4DO
N N N N
117.9 / -L10 -L10 / 120.0
117 120
12001513 / 3
0 1 2 3 4 5 6 7 8 9
119.9 / -L11 -L11 / 122.0

-K1194:L -A1191:1
Q1 Q2
/180.5 /180.5
-A1191 -A1191
1 2 1 2
23
-K1175
/117.5 24
95
-B1113
/111.4 96
13
-Q1205
/120.3 14
I4
-A1191
/180.5
I4
-B1113:96
Kompressor läuft
COMPRESSOR RUNNING
A1 A1 A1
-K1204 -Q1205 -K1207
A2 A2 A2
119.9 / -L10 -L10 / 122.0
DILM150(RAC240)
14 1 2 /111.4 14
3 4 /111.4
12 11 /151.2 12 11 /151.3
5 6 /111.4
24 24
13 14 /120.4
22 21 /150.4 21 22 /136.7 22 21 /150.2
34
32 31 /131.2
44
42 41 /135.7

119 122
12001513 / 3
0 1 2 3 4 5 6 7 8 9
120.9 / -L11 -L11 / 124.0
-A1191:1 -A1191:1
Q3 Q11 (Q3)
/180.5 /182.5
-A1191 -K1193
1 2 1 2
Magnetventil:
SOLENOID VALVE:
START DELAY 10 SEC
120.9 / -L10 -L10 / 124.0

114.9 / -PE -PE / 124.0
-X1-230VAC 41 42 PE 43 44 PE 47 48 PE 49 50 PE
x1 x1 x1 x1
PE PE PE PE
-D03 -D05 -C03 -Y12
x2 x2 x2 x2
=COM =COM =COM =COM

+ + + +
M20 M20 M20 M20
120 124
12001513 / 3
0 1 2 3 4 5 6 7 8 9
117.9 / -LT11
122.9 / -L11 -L11 / 126.0
2 4 13 11
-S1243 -S1247 -B1145
/150.3 1 3 /117.5 14 /114.5 14 12
1-0-2 Reset
1=Hand ein
0=Aus
2=Fern Start-Stop
1=man run
0=off / reset
2=remote start-stop
I1 I1 I2 I2 I3 I5
-A1191 -K1192 -A1191 -K1192 -A1191 -A1191

/180.5 /181.5 /180.5 /181.5 /180.5 /180.5
I1 I9 (I1) I2 I10 (I2) I3 I5
A1 B1
-K1247 M
DI A2
1,5 SEC
122.9 / -L10 -L10 / 126.0

122.9 / -PE -PE / 128.0
82.01.0.240
-X1-230VAC 21 22 PE 23 24 PE 110 111 51 52 PE
315-EC100-P03 1 2 GN/YE 3 4 5 18
16 15 /117.6
-C3-X1/230VAC 21 22 PE 23 PE 110 111 -X x x PE
-MAX P -MIN P
=EXT =EXT
+ +
M25 M20
122 126
12001513 / 3
0 1 2 3 4 5 6 7 8 9
124.9 / -L11 -L11 / 128.0
-B1261
A1
95 97
/128.6
96 98
A2 T1 T2
111.6 / -T1
111.6 / -T2
124.9 / -L10 -L10 / 136.0
Motortemperatur
ENGINE TEMPERATURE
124 128
12001513 / 3
0 1 2 3 4 5 6 7 8 9
126.9 / -L11 -L11 / 129.0
97 95 51
-B1113 -B1261 -K1175
/111.4 98 /126.2 96 /117.5 52
I6 I7 I8 I3 I4
-A1191 -A1191 -A1191 -K1192 -K1192

/180.5 /180.5 /180.5 /181.5 /181.5
I6 I7 I8 I11 (I3) I12 (I4)
-B1113:98 =EXT-D04 =EXT-A08 -B1261:96 -K1175:52
124.9 / -PE -PE / 129.0
-X1-230VAC 25 26 PE 27 28 PE
-X x x PE -X x x PE
-D04 P -A08
=EXT =EXT
+ +
M20 M20
126 129
12001513 / 3
0 1 2 3 4 5 6 7 8 9
128.9 / -L11 -L11 / 136.0
-X1-230VAC 29
-A -A1 -X2:1 2 6
24V DC
DRYER
CONTROL
8 7
=
=Y12 +DIFF_PRESSURE
-X PE
DRYER ASSEM. LV.G
-X1-230VAC 30 PE

-K1193
/182.5
I13 (I1)
Taupunkt DEW POINT
128.9 / -PE -PE / 135.0
Taupunkt
DEW POINT
Option
OPTION
M20
128 131
12001513 / 3
0 1 2 3 4 5 6 7 8 9
24V DC
114.9 / -L51+ -L51+ / 132.0

-T1147:+ -K1207:31 -A1191:1 -K1192:1 -K1192:1 -K1192:1
Q12 (Q4) Q4 Q5 (Q1) Q6 (Q2) Q7 (Q3) Q8 (Q4)
/182.5 /180.5 /181.5 /181.5 /181.5 /181.5
31
-K1193 -A1191 -K1192 -K1192 -K1192 -K1192
-K1207
/120.4 34 32
1 2 1 2 1 2 1 2 1 2 1 2
x1
X1 X1 X1 X1 X1 X1 X1 A1
-P1311 -P1312 -P1313 -P1314 -P1315 -P1316 -P1317 -P1318 -K1318
x2
-LT50 / 132.0
IB-2-024-D-G
14
12 11 /150.5
24
22 21

129 132
12001513 / 3
0 1 2 3 4 5 6 7 8 9
24V DC
131.9 / -L51+

PRESSURE
-K1192:1
Q9 (Q1)
/182.5
13
-K1193
-K1352
/135.7 14
1 2
X1 X1
-P1322 -P1323
RD X2 BU X2
131.9 / -LT50
114.9 / -L50-

DRYER FAILURE -
Option
OPTION
131 135
12001513 / 3
0 1 2 3 4 5 6 7 8 9
114.9 / -L110 -L110 / 136.0

114.9 / -L100 -L100 / 136.0
2 4
-F1351
C2A 1 3
1 3 41
-K1352 -K1207
/135.7 2 4 /120.4 44 42
A1
-K1352
A2
129.9 / -PE -PE / 136.0
DILEM-10(230V50/60HZ)
22DILEM
-X1-230VAC 14 15 PE
1 2 /135.1
3 4 /135.1
5 6
-X x x PE 13 14 /132.3
53 54
61 62
-H01 71 72
83 84
=COM
+E
Max. 100 Watt
M20
132 136
12001513 / 3
0 1 2 3 4 5 6 7 8 9
129.9 / -L11
135.9 / -L110 -L110 / 140.0
135.9 / -L100 -L100 / 140.0
1 3 -B1365
-F1361
103E-2K4C-1100 L1/10
7
TC+ TC- 6 8 DC+ DC-

4 3 5 L2/9 1 2
33 43 21
-K1366 -Q1205
/136.7 34 44 /120.3 22
Direktanschluss
DIRECT CONNECTION
A1
-K1366
A2
126.9 / -L10
135.9 / -PE -PE / 140.0

DILER-40(230V50/60HZ)
-X1-230VAC 16 17 PE 18 19 PE 9 10
13 14
23 24
33 34 /136.3
x x PE x x PE 43 44 /136.3
+ - + -
-B1361
-H01 -H01
=NICRNI =NICRNI
=OSH1 =OSH2 + +
+ +
THERMOSTAT
100W 100W SPARE
M20 M20 M20 M20

135 140
12001513 / 3
0 1 2 3 4 5 6 7 8 9
136.9 / -L110 -L110 / 145.1

136.9 / -L100 -L100 / 145.1
2 4
-F1402
C2A 1 3

OPERATION
Q10 (Q2)
/182.5
-K1193
1 2
136.9 / -PE -PE / 145.1
-X1-230VAC 61 62 PE 63 64 PE
-Y10 -Y11
=COM
+E
230V 50/60Hz
60VA
M20 M20
136 145
12001513 / 3
1 2 3 4 5 6 7 8 9 10
140.9 / -L110
2
-F1455
C2A 1
-B1455
Θ=30°C
3
1 2
-XF 5
-E1455
L PE
M
1~
N
-XF 4
140.9 / -L100
140.9 / -PE -PE / 150.0
SWITCHBOARD FAN
250V AC
140 150
12001513 / 3
0 1 2 3 4 5 6 7 8 9

21 6 8 21 11
-K1207 -S1243 -K1204 -K1318
/120.4 24 22 /124.1 5 7 /120.2 24 22 /131.8 14 12
145.10 / -PE -PE / 151.0
=ECR
+
M25
145 151
12001513 / 3
0 1 2 3 4 5 6 7 8 9
11 11
-K1204 -K1207
/120.2 14 12 /120.4 14 12
A1 s.S. 117
SEE PAGE 117
-K1515
A2
1X 2X 3X 5X 17X 18X
150.9 / -PE
-X38/24VDC 17 18 PE 19 20 PE 21 22 23 24 PE
IB-2-024-D-G
14
-315-EN300-C01 24
-X38 17 18 PE 19 20 PE 21 22 23 24 22 21
+
24V DC
=315_IB100
COLLECTIVE FAULT
M25
150 180
12001513 / 3
0 1 2 3 4 5 6 7 8 9
-A1191
/119.4
LOGO! SIEMENS
I1 Ort Hand Start

I1 /124.1
REMOTE MANUAL START
I2 Auto Stop
I2 /124.5
AUTOMATIC STOP
I3 Reset
I3 /124.7
RESET
I4 /120.5
COMPRESSOR RUNNING
I5 /124.8
VOLTAGE PRESENT
I6 Überstrom
I6 /128.1
OVERCURRENT
I7 Öldruck
I7 /128.3
OIL PRESSURE
I8 /128.5
1 Betriebsbereit
Q1 /120.1
READY FOR OPERATION
2 Betriebsbereit
Q1 /120.2
READY FOR OPERATION
1 Antrieb ein
Q2 /120.3
DRIVE ON
2 Antrieb ein
Q2 /120.3
DRIVE ON
Q3 /122.1
2 Stufe 1
Q3 /122.2
STAGE 1
1 Überstrom
Q4 /131.3
OVERCURRENT
2 Überstrom
Q4 /131.4
OVERCURRENT
6ED1055-1FB00-0BA1
151 181
12001513 / 3
0 1 2 3 4 5 6 7 8 9
-K1192
/119.5
LOGO! SIEMENS
I1 ein
I9 (I1) /124.2
ON
I2 Auto Start
I10 (I2) /124.6
AUTOMATIC START
I3 Motortemperatur
I11 (I3) /128.6
ENGINE TEMPERATURE
I4 Not-Halt
I12 (I4) /128.8
EMERGENCY STOP
1 Öldruck
Q5 (Q1) /131.4
OIL PRESSURE
2 Öldruck
Q5 (Q1) /131.5
OIL PRESSURE
Q6 (Q2) /131.6
Q6 (Q2) /131.6
1 Motortemperatur
Q7 (Q3) /131.7
ENGINE TEMPERATURE
2 Motortemperatur
Q7 (Q3) /131.8
ENGINE TEMPERATURE
1 Not-Halt
Q8 (Q4) /131.8
EMERGENCY STOP
2 Not-Halt
Q8 (Q4) /131.9
EMERGENCY STOP
6ED1052-1FB00-0BA6
180 182
12001513 / 3
0 1 2 3 4 5 6 7 8 9
-K1193
/119.6
LOGO! SIEMENS
I1 Taupunkt
I13 (I1) /129.3
DEW POINT
I2
I14 (I2)
I3
I15 (I3)
I4
I16 (I4)

Q9 (Q1) /132.1
Q9 (Q1) /132.2
1 Trockner Betrieb
Q10 (Q2) /140.3
DRYER OPERATION
2 Trockner Betrieb
Q10 (Q2) /140.3
DRYER OPERATION
Q11 (Q3)
Q11 (Q3) /122.5
Q12 (Q4) /131.1
VOLTAGE PRESENT
Q12 (Q4) /131.2
VOLTAGE PRESENT
6ED1052-1FB00-0BA6
181 183
12001513 / 3
0 1 2 3 4 5 6 7 8 9
-K1194
/119.6
LOGO! SIEMENS
I1
I17 (I1)
I2
I18 (I2)
I3
I19 (I3)
I4
I20 (I4)
1
Q13 (Q1)
2
Q13 (Q1)
1
Q14 (Q2)
2
Q14 (Q2)
1
Q15 (Q3)
2
Q15 (Q3)
1
Q16 (Q4)
2
Q16 (Q4)
6ED1052-1FB00-0BA6
182 200
12001513 / 3
0 1 2 3 4 5 6 7 8 9
=MCCROOM+MCC873-X
=COM-M01
X1
PE
PE
PE
M
PE 3~
Θ
COMPRESSOR DRIVE
Kompressorantrieb
183 201
12001513 / 3
Appr =C3+EN300-X1 112787 Page 200
0 1 2 3 4 5 6 7 8 9
=ECR-X
=ECR-X
=ECR-X
-K1207
-K1207
-K1207
-K1204
-K1204
-K1318
-K1318
-E1455
-S1243
-S1243
-S1243
X1-POT.FREE
PE
PE
PE
PE
81
82
83
84
85
86
87
88
89
90
91
92
=ECR-X
COLLECTIVE FAULT
EMERGENCY STOP
Versorgung 82-83
Versorgung 85-86
Sammelstörung
AUTOMATIC
COM 82-83
COM 85-86
MANUAL
Not-Halt
Hand
Auto
OFF
aus
ON
ein
200 202
12001513 / 3
201
Revision
0
Date
X1-230VAC
Name
Auto Stop
21
21 -S1243
1
1
22
= 22 -A1191
1
Ed.
Date
Appr
PE
= PE =COM-Y12
Auto Start
23
23 -K1192
GN/YE 3
GN/YE 3
DOH
AUTOMATIC START
21
= 24
24.03.2011
/
PE
=EXT-C3-X1/230VAC
-315-EC100-P03
BAC
Auto Start
110
110
4
4
AUTOMATIC START
2
= 111
111
5
5
Fernstart
x
51
REMOTE START
x
= 52
Kompressorsteuerung
=EXT-X
Fernstart
PE
REMOTE START
3
Stillstandsheizung

14 -K1352
STANDSTILL HEATING
x
= 15 -K1352
=COM+E-X
PE
Heizung 1 Ölwanne
x
4
16 -K1366
HEATER 1 OIL SUMP
x
100W 17
PE
= PE
x
Heizung 2 Ölwanne
x
18 -K1366
HEATER 2 OIL SUMP
x
100W 19 -F1361
PE
= PE
5
Thermostat Reserve
+
9
THERMOSTAT SPARE
+
-
-
= 10
Öldruck
x
25 -B1113
=C3+EN300-X1-230VAC
=C3+EN300-X1-230VAC
OIL PRESSURE
x
= 26 -A1191
6
PE
= PE =EXT-X
x
Drucklufttemperatur
x
=EXT-X
27 -B1261
x
= 28 -A1191
PE
= PE =EXT-X
112787
7
29 -K1175
41007852 // 1/1
6
12001513 / 3
Taupunkt
7
30 -K1193
DEW POINT
7
Taupunkt
PE
8
PE =EXT-X
PE
DEW POINT
Stufe 1
x1
41 -A1191
STAGE 1
= C3
x2
x1
x2
= 42 -K1207
+ EN300
=COM-D03
PE
Page
Page
502
202
203
0 1 2 3 4 5 6 7 8 9
=COM+E-X1
=COM+E-X1
=COM-D03
=COM-D05
=COM-C03
-K1193
-K1247
-K1193
-K1193
-K1515
-T1148
-S1243
-S1175
-F1402
-F1402
X1-230VAC
100
101
PE
PE
PE
PE
PE
PE
43
44
47
48
49
50
61
62
63
64
98
98
99
x1
x1 x1 x1 12 14
PE PE PE PE
L1
x2
x2 x2 x2 11
DRYER OPERATION
DEW POINT VALVE
Not-Halt Steuerfeld
Trockner Betrieb
Taupunktventil
Trockner
STAGE 1
STAGE 2
Stufe 1
Stufe 2
DRYER
=
202 204
12001513 / 3
0 1 2 3 4 5 6 7 8 9
=315_IB100-X38
=315_IB100-X38
=ECR-X
-K1204
-K1204
-K1207
-K1207
-K1515
-K1515
X38/24VDC
PE
PE
PE
17
18
19
20
21
22
23
24

-315-EN300-C01
-315-EN300-C01

17 18 PE 19 20 PE 21 22 23 24
17
=315_IB100-X38
0=Stop 1=Aktivieren
COLLECTIVE FAULT
COLLECTIVE FAULT
Sammelstörung
OPERATION
Betrieb
=
203 205
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0 1 2 3 4 5 6 7 8 9
=COM-M01
-B1261
-B1261
XTHERM
PE
7
M
3~
Θ
=COM-M01
THERMISTOR
Thermistor
204 500
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0 1 2 3 4 5 6 7 8 9
Artikelstückliste
Parts list
Logikmodul
Logic module
Speicherkarte
Memory card
Überlastrelais
Overload relay
Spannungsrelais
Voltage relay
Temperaturrelais
Temperature relay
Temperaturanzeige
Thermostat
Thermostat
Filterlüfter
Fan
Austrittsfilter
Outlet filter
Hilfsschütz
Auxiliary contactor
Hilfsschalterblock
Erweiterungsmodul
Extension module
Erweiterungsmodul
Extension module
Erweiterungsmodul
Extension module
Relais
Relay
Relais
Relay
Relais
Relay
Leistungsschütz
Contactor
Hilfsschalterblock
Hilfsschütz
Auxiliary contactor
Relais
Relay
205 501
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0 1 2 3 4 5 6 7 8 9
Artikelstückliste
Parts list
Leuchtmelder
Indicator light
Leuchtmelder
Indicator light
Leuchtmelder
Indicator light
Leuchtmelder
Indicator light
Leuchtmelder
Indicator light
Leuchtmelder
Indicator light
Leuchtmelder
Indicator light
Leuchtmelder
Indicator light
Leuchtmelder
Indicator light
Disconnector
Berührungsschutz
Motorschutzschalter
Leistungsschütz
Contactor
Hilfsschalterblock
Pilzdrucktaster
Mushroom pushbutton
Schutzkragen
Protective shroud
Schaltelement
Contact block
Umschalter
Change-over switch
Drucktaster schwarz
Pushbutton black
Schaltelement
Contact block
Netzgerät
Power supply unit
Universaltrafo
Wandgehäuse
Wall-mounting case
Wall mount
Marineverschraubung
Marine gland
Marineverschraubung
Marine gland
500 502
12001513 / 3
0 1 2 3 4 5 6 7 8 9
Artikelstückliste
Parts list
Marineverschraubung
Marine gland
Verschraubung
Gland
Gegenmutter
Nut
Marinemutter
Marine nut
Marinemutter
Marine nut
Marinemutter
Marine nut
Erdungsbolzen
Earthing bolt
501
12001513 / 3
0 1 2 3 4 5 6 7 8 9

Oststraße 67
D-22844 Norderstedt
Phone: + 49 (0)40 5303479 - 0
Fax: + 49 (0)40 5303479 - 90
Kommission 41007852 // 1/1 Speise // Steuerspannung - // 230V AC
Kundenauftragsnummer 112787 Leistung // Strom - // -
Anlagentyp 043 502E DPS Schutzart IP 54
Regulation Color
Created on
2
Date 24.03.2011 Wahlschalter Deckblatt =
12001513 / 4
Ed. DOH / BAC SELECTOR SWITCH COVER SHEET +
Appr 112787 Page 1
0 1 2 3 4 5 6 7 8 9
Inhaltsverzeichnis
Table of contents
Deckblatt
=+/1 24.03.2011
COVER SHEET
Inhaltsverzeichnis
=+/2 24.03.2011
TABLE OF CONTENTS
Frontansicht
=+/5 24.03.2011
FRONT VIEW
=+/5.A 24.03.2011
Wahlschalter
=+/10 24.03.2011
SELECTOR SWITCH
Druckschalter
=+/11 24.03.2011
PRESSURE SWITCH
Klemmenanschlussplan =+-C1-X1/230VAC
=+/200 24.03.2011
TERMINAL-CONNECTION DIAGRAM =+-C1-X1/230VAC
=+/201 24.03.2011
=+/202 24.03.2011
Klemmenanschlussplan =+-X0
=+/203 24.03.2011
TERMINAL-CONNECTION DIAGRAM =+-X0
Artikelstückliste
=+/500 24.03.2011
PARTS LIST
1 5
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Ed. DOH / BAC SELECTOR SWITCH TABLE OF CONTENTS +
Appr 112787 Page 2
0 1 2 3 4 5 6 7 8 9
2000 -S102 Wahlschalter 1-2-3 SELECTOR SWITCH 1-2-3

1=C1 Führung - C2 Nachlauf - C3 Nachlauf 1=C1 LEAD - C2 LAG - C3 LAG
1900 2=C2 Führung - C3 Nachlauf - C1 Nachlauf 2=C2 LEAD - C3 LAG - C1 LAG
3=C3 Führung - C1 Nachlauf - C2 Nachlauf 2=C3 LEAD - C1 LAG - C2 LAG
1800
1700
1600
1500
1400
1300
1200
1100
1000
900
800
700
600
500
300 mm
400 210 mm
300
-S102
300 mm
200
100
0
6xM25 Schaltschrank: Rittal
SWITCHBOARD: RITTAL
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
2 5.A
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Appr 112787 Page 5
0 1 2 3 4 5 6 7 8 9
Lieferung
DELIVERY
A C
Durchmesser: 10,2mm
DIAMETER: 8mm
15 mm
20 mm
D
B
20 mm
15 mm
20 mm 20 mm
29 mm 29 mm
A B C D
200mm 300mm 160mm 260mm 142mm 330mm
300mm 300mm 260mm 260mm 242mm 330mm
400mm 500mm 360mm 460mm 342mm 530mm
600mm 600mm 560mm 560mm 542mm 630mm
600mm 800mm 560mm 760mm 542mm 830mm
760mm 760mm 720mm 720mm 602mm 790mm
800mm 1000mm 760mm 960mm 742mm 1030mm
1000mm 760mm 960mm 720mm 942mm 790mm
1000mm 1000mm 960mm 960mm 942mm 1030mm
1200mm 1200mm 1160mm 1160mm 1142mm 1230mm
5 10
Date 24.03.2011 Wahlschalter Maßbild / Befestigung Rittal AE =
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Ed. DOH / BAC SELECTOR SWITCH DIMENSION DIAGRAM / +
Appr FIXING RITTAL AE 112787 Page 5.A
0 1 2 3 4 5 6 7 8 9
-101 / 11.0
-102 / 11.0
-103 / 11.0
-201 / 11.0
-202 / 11.0
-203 / 11.0
-301 / 11.0
-302 / 11.0
-303 / 11.0
1 3 5 21 23 19 37 39 41 9 11 7 25 27 29 45 47 43 13 15 17 33 35 31 49 51 53
-S102
1-2-3 2 4 6 22 24 20 38 40 42 10 12 8 26 28 30 46 48 44 14 16 18 34 36 32 50 52 54
1=Kompressor 1-2-3
2=Kompressor 2-3-1
3=Kompressor 3-1-2
1=COMPRESSOR 1-2-3
2=COMPRESSOR 2-3-1
3=COMPRESSOR 3-1-2
X92 / D0
X84 / D0 = 60°
OG OG OG OG OG OG OG OG OG
1,5mm² 1,5mm² 1,5mm² 1,5mm² 1,5mm² 1,5mm² 1,5mm² 1,5mm² 1,5mm²
-PE / 11.0
-X0 1 2 PE 3 4 PE 5 6 PE 7 8 PE 9 10 PE 11 12 PE
-X x x PE x x PE -X x x PE x x PE -X x x PE x x PE
-B1 P -B2 P -B3 P -B4 P -B5 P -B6 P

MAX MIN MAX MIN MAX MIN
=EXT =EXT =EXT

+ + +
Druckschalter p< Druckschalter p<< Druckschalter p<<<
PRESSURE SWITCH P< PRESSURE SWITCH P<< PRESSURE SWITCH P <<<
Betrieb / aus Start Betrieb / aus Start Betrieb / aus Start
OPERATION / OFF START OPERATION / OFF START OPERATION / OFF START
M25 M25 M25
5.A 11
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Ed. DOH / BAC SELECTOR SWITCH SELECTOR SWITCH +
Appr 112787 Page 10
0 1 2 3 4 5 6 7 8 9
10.9 / -101
10.9 / -102
10.9 / -103
10.9 / -201
10.9 / -202
10.9 / -203
10.9 / -301
10.9 / -302
10.9 / -303
OG OG OG OG OG OG OG OG OG
1,5mm² 1,5mm² 1,5mm² 1,5mm² 1,5mm² 1,5mm² 1,5mm² 1,5mm² 1,5mm²
10.9 / -PE
-C1-X1/230VAC 21 22 23 110 111 PE -C2-X1/230VAC 21 22 23 110 111 PE -C3-X1/230VAC 21 22 23 110 111 PE

1 2 3 PE
315-EC100-P01 315-EC100-P02 315-EC100-P03

-X1 21 22 23 110 111 PE -X1 21 22 23 110 111 PE -X1 21 22 23 110 111 PE
=COM1 =COM2 =COM3

+ + +
Kompressor 1 Kompressor 2 Kompressor 3
COMPRESSOR 1 COMPRESSOR 2 COMPRESSOR 3
M25 M25 M25

10 200
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Ed. DOH / BAC SELECTOR SWITCH PRESSURE SWITCH +
Appr 112787 Page 11
0 1 2 3 4 5 6 7 8 9
=EXT-X
-S102
-S102
-S102
C1-X1/230VAC
110
111
PE
21
22
23
1 2 3 PE
-315-EC100-P01
-315-EC100-P01
1 2 3 PE
21 22 23 110 111 PE
21
=COM1-X1
COMPRESSOR 1
Kompressor 1
11 201
Date 24.03.2011 Wahlschalter Klemmenanschlussplan =
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Ed. DOH / BAC SELECTOR SWITCH =+-C1-X1/230VAC +
Revision Date Name =+-C1-X1/230VAC 41007852 // 1/1 Page 500
0 1 2 3 4 5 6 7 8 9
=COM1-X1
-S102
-S102
-S102
C2-X1/230VAC
110
111
PE
21
22
23
-315-EC100-P02
21 22 23 110 111 PE
21
=COM2-X1
COMPRESSOR 2
Kompressor 2
200 202
12001513 / 4
0 1 2 3 4 5 6 7 8 9
=COM2-X1
-S102
-S102
-S102
C3-X1/230VAC
110
111
PE
21
22
23
-315-EC100-P03
21 22 23 110 111 PE
21
=COM3-X1
COMPRESSOR 3
Kompressor 3
201 203
12001513 / 4
0 1 2 3 4 5 6 7 8 9
=EXT-X
=EXT-X
=EXT-X
=EXT-X
=EXT-X
=EXT-X
-S102
-S102
-S102
-S102
-S102
-S102
-S102
-S102
-S102
X0
PE
PE
PE
PE
PE
PE
10
11
12
1
x x PE x x PE x x PE x x PE x x PE x x PE
=EXT-X
PRESSURE SWITCH P <<<
PRESSURE SWITCH P<<
PRESSURE SWITCH P<
Druckschalter p<<<
Druckschalter p<<
OPERATION / OFF
OPERATION / OFF
OPERATION / OFF
Druckschalter p<
Betrieb / aus
Betrieb / aus
Betrieb / aus
START
START
START
Start
Start
Start
=
202 500
Date 24.03.2011 Wahlschalter Klemmenanschlussplan =+-X0 =
12001513 / 4
Ed. DOH / BAC SELECTOR SWITCH TERMINAL-CONNECTION DIAGRAM =+-X0 +
0 1 2 3 4 5 6 7 8 9
Artikelstückliste
Parts list
Stufenschalter
-S102 1 9-pol, 1-2-3, Zentraleinbau ST39/8E/X70A/NS/X92/X84 Sontheimer S-WS-SON-T39-1_3-010
Step switch
Wandgehäuse
Wall-mounting case
Marineverschraubung
Marine gland
Marinemutter
Marine nut
203
Date 24.03.2011 Wahlschalter Artikelstückliste =
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Ed. DOH / BAC SELECTOR SWITCH PARTS LIST +
Sequence Panel
for Sauer Compressors WP 5000
Type: 068 018
Operation Instructions
021_41007852_WP5000_Sequence_Panel_Titel_en_1012.fm
021_41007852_WP5000_Sequence_Panel_Titel_e
Edition: 12 / 2010
Table of Contents
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Maintenance and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Installation Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Selection of starting sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

022_41007852_WP5000_Sequence_Panel_en_10
3
023_41007852_WP5000_Sequence_Panel_K1_3_en_1012.fm
1 General information
1.1 Introduction
The Sequence Panel is designated to to change the starting se-
quence of the compressors in order to reach a constant running
time of all compressors.
The Sequence Panel is designed to be connected to the com-
pressor control panels. Please observe the maintenance and
service instructions and check the Panel at regular intervals.
The Panel should only be operated by experienced and trained
personnel.
Regulations must be observed to avoid an accident.
Note also Classification, VDE, IEC, national and local regulations
where applicable.
Maintain an Operation Log for the installation, where the following
should be regularly recorded:
– last general maintenance
– last repair

During maintenance and service work, the compressor must not
be operational, and all electrical devices must be switched off. All
connected Control Panels must be locked and protected against
an inadvertent restart. 023_41007852_WP5000_Sequence_Panel_K1_3_en_1012.f
4
Installation Setup
2 Installation Setup
The main components of the Sequence Panel are:
– selector for starting sequence

– terminals for connection to control panels
– pressure switches
to customer‘s air receiver
1
2
3
Sequence Panel Pressure switch
Compressor control panels and sequence panel must be connec-

ted as per sequence panel wiring diagram.
023_41007852_WP5000_Sequence_Panel_K1_3_en_1012.fm
The pressure switches must be connected to the customer‘s air

receivers by a common pipe.
5
3 Selection of starting sequence
Selector
switch position
1 Compressor 1: Start at 180 bar Stop at 207 bar
Compressor 2: Start at 170 bar Stop at 207 bar


023_41007852_WP5000_Sequence_Panel_K1_3_en_1012.f
6
HP Filters
024_41007852_WP5000_HP Filters_Titel_de_en_0111.fm
024_41007852_WP5000_HP
Edition: 12 / 2010
Hochdruckfilter
High Pressure Filters
G 3/100–G 14/350
100/250/350 bar
für Fluide Gruppe 2

for Fluid Group 2
Betriebsanleitung
inklusive
including
Ausgabe 06/2008-DE
Issue 06/2008-EN
HERSTELLERERKLÄRUNG
Wir,
Parker Hannifin GmbH
Hiross Zander Division,
Im Teelbruch 118, D-45219 Essen, Germany,
erklären hiermit in alleiniger Verantwortung, dass für die Produkte
Fluide Gruppe 2
Filtertyp max. Betriebsüberdruck [bar]
G03/100–G07/100 100
G03/250–G07/250 250
G03/350–G07/350 350
die folgenden Normen und technischen Spezifikationen angewandt wurden:
EN 1050
97/23/EG
Die Überwachung des Qualitätssicherungs-Systems erfolgt durch die benannte

Stelle Lloyd’s Register Quality Assurance GmbH, Hamburg (Kennnummer 0525).
Essen,
04.01.2010
Datum / Date i. V. Dr. Jürgen Timmler

Leiter Technik und Entwicklung /
Manager Engineering and Development
KONFORMITÄTSERKLÄRUNG
Wir,
erklären hiermit in alleiniger Verantwortung, dass die Produkte
Fluide Gruppe 2
max. Betriebs-
Filtertyp überdruck [bar] Modul
G9 – G12 100 A
G13–G14 100 A1
G9 – G12 250 A1
G13–G14 250 H
G9 – G12 350 H
G13–G14 350 H
auf die sich diese Erklärung bezieht,

mit der Richtlinie 97/23/EG übereinstimmen und
der Konformitätsbewertung nach dem Modul entsprechend der obigen
Tabelle unterzogen wurden.
Die Überwachung des Qualitätssicherungs-Systems erfolgt durch die benannte

Stelle Lloyd’s Register Quality Assurance GmbH, Hamburg (Kennnummer 0525).
Die folgenden Normen und technischen Spezifikationen wurden angewandt:

harmonisierte Normen:
— EN 1050.
Essen,
04.01.2010

Deutsch/English
Inhaltsverzeichnis Contents
Deutsch
Allgemeine Informationen .................................................................................. 5
Zu Ihrer Sicherheit ............................................................................................... 6
Filter montieren.................................................................................................... 9
Technische Informationen................................................................................ 11
Ersatzteilliste für G 3/100–G 14/350 ................................................................. 12
Wartungsintervalle und –arbeiten.................................................................... 13
Störungen beseitigen ........................................................................................ 14
Verfügbares Zubehör ........................................................................................ 14
Deutsch English
Übersichtszeichnung G 3/100–G 14/350 Assembly Drawing ...................... 15
English
General information........................................................................................... 16
For your own safety........................................................................................... 17
Filter Installation ................................................................................................ 20
Technical information ....................................................................................... 22
Spare parts list for G 3/100–G 14/350 .............................................................. 23
Maintenance intervals ....................................................................................... 24
Correcting faults ................................................................................................ 25
Accessories........................................................................................................ 25
Deutsch
Allgemeine Informationen
Hochdruckfilter der Serie G (mit Gewindeanschluss) dienen zum Filtern von
Feststoffen, Öl und Wasser aus unkritischen und inerten Gasen der Fluidgruppe
2. Sie können als Einzelfilter oder als Filterkombination eingesetzt werden.
Hinweise zu dieser Betriebsanleitung

Diese Betriebsanleitung enthält alle Informationen zum sicheren und
wirtschaftlichen Umgang mit G-Filtern der Serien V, ZP, XP, XP4, A und KT.
Zielgruppe dieser Betriebsanleitung sind Fachleute wie z. B. Schlosser, bei
denen wir grundsätzliche Kenntnisse über den Umgang mit Druckgeräten
voraussetzen.
Verwendete Zeichen und Symbole

► Arbeitsschritte, die Sie nacheinander durchführen sollen, sind mit einem
Dreieck gekennzeichnet.
Mit einem Kästchen werden Aufzählungen gekennzeichnet.
Achtung!
Diese Sicherheitshinweise warnen Sie vor Schäden an Maschinen oder
Einrichtungen und helfen Ihnen, diese zu vermeiden.
Gefahr!
Diese grau hervorgehobenen Gefahrenhinweise warnen Sie vor
Verletzungen und/oder Lebensgefahren; Gefahrenhinweise helfen Ihnen,
gefährliche oder lebensbedrohliche Situationen für Sie oder Dritte zu
vermeiden.
Hinweise zur Gewährleistung

Unter folgenden Bedingungen erlischt der Anspruch auf Gewährleistung:
Wenn der Filter nicht bestimmungsgemäß eingesetzt wird.
Wenn der Filter nicht so gewartet wird, wie in dieser Betriebsanleitung
genannt.
Wenn andere als die Original-Ersatzteile verwendet werden.
Hinweise zur europäischen Richtlinie für Druckgeräte 97/23/EG

Gemäß der europäischen Richtlinie 97/23/EG werden druckgeführte Fluide nach
ihrem Gefährdungspotential in zwei Fluidgruppen eingeordnet: Fluidgruppe 1
umfasst vor allem brennbare, explosive oder giftige Fluide; Fluidgruppe 2
unkritische und inerte Fluide wie Druckluft, Helium oder Stickstoff. Folgend eine
Übersicht zur Kennzeichnungspflicht nach 97/23/EG:
G3/100-G14/350_DE-EN_1 5
Deutsch
Filter Vol./[L] Kategorie Kennzeichnung

100 bar, Fluidgruppe 2
G3/100 0,35 — —
G5/100 0,35 — —
G7/100 0,53 — —
G9/100 1,43 I CE
G11/100 1,96 I CE
G12/100 3,00 I CE
G13/100 4,30 II CE0525
G14/100 6,90 II CE0525
G3/250 0,35 — —
G5/250 0,35 — —
G7/250 0,53 — —
G9/250 1,38 II CE
G11/250 1,91 II CE
G12/250 3,00 II CE0525
G13/250 4,20 III CE0525
G14/250 6,80 III CE0525
G3/350 0,35 — —
G5/350 0,35 — —
G7/350 0,53 — —
G9/350 1,35 II CE0525
G11/350 1,88 II CE0525
G12/350 3,00 II CE0525
G13/350 4,20 III CE0525
G14/350 6,70 III CE0525
Zu Ihrer Sicherheit
Bestimmungsgemäße Verwendung
Die technischen Angaben auf dem Typenschild sind zu beachten und einzuhal-
ten. Ein anderer Einsatz, als unter den auf dem Typenschild vermerkten Daten,
gilt als nicht bestimmungsgemäß. Im Rahmen dieser Grenzwerte sind die hier
beschriebenen Filter uneingeschränkt nutzbar für die Filtration von Druckluft und
Stickstoff. Für die Anwendung mit anderen Gasen der Fluidgruppe 2 ist eine
Rücksprache mit dem Hersteller bzgl. der Auslegung und der spezifischen
Kennwerte (z. B. Materialverträglichkeiten) erforderlich.
6 G3/100-G14/350_DE-EN_1
Deutsch
Naheliegender Missbrauch
Explosionsgefahr durch Filtration von Sauerstoff!
Die hier beschriebenen Filter keinesfalls zur Filtration von Sauerstoff
einsetzen! Die Materialien des Filters und die verwendeten Schmiermittel
sind nicht sauerstoffbeständig. Der Filter könnte explodieren oder sich
selbst entzünden. Wenn Sie beabsichtigen Sauerstoff zu filtrieren,
benötigen Sie einen speziellen Filter. Setzen Sie sich dazu bitte mit dem
Hersteller in Verbindung.
Gefahr durch Filtration von kritischen Fluiden!

Filter, die für unkritische Gase der Fluidgruppe 2 ausgelegt sind, dürfen
nicht zur Filtration von explosiven, brennbaren oder giftigen Gasen der
Fluidgruppe 1 eingesetzt werden.
Sicherheitshinweise
Gefahr durch plötzlich entweichenden Druck!

Niemals Teile des Filters entfernen oder sonstige Manipulationen
vornehmen, solange der Filter unter Druck steht! Plötzlich entweichender
Druck kann schwere Verletzungen verursachen.
Vor Arbeiten am Filter zuerst den Filter drucklos machen.
Gefahr durch heiße Oberflächen!

Die Fluide, die den Filter durchströmen, können bis zu 80 °C heiß sein.
Heiße Oberflächen nicht berühren. Betriebsanweisungen des Betreibers
beachten.
Hinweis:
Beachten Sie bei allen Tätigkeiten an den Filtern die gültigen
nationalen Vorschriften zur Unfallverhütung!
Die in dieser Anleitung genannten Tätigkeiten an den Filtern dürfen
nur von autorisiertem und qualifiziertem Fachpersonal durchgeführt
werden.
Hinweise zu lackverträglichen Filtern

Lackverträgliche Druckluftanlagen und -filter dienen dazu, Lack zu fördern und
auf die zu lackierenden Teile aufzubringen. Dabei bestehen besonders hohe
Anforderungen an die Reinheit der Druckluft, denn bereits kleinste Verunreini-
gungen können zu Kratern im Lack, Verfärbungen, Aufquellungen und anderen
Unregelmäßigkeiten führen. Auch geringste Mengen öl- und fetthaltiger Fremd-
stoffe oder Lösemittel — vor allem Silikone — vermindern die Qualität der
Lackierung. Lackverträgliche Anlagen und Filter müssen unbedingt silikon- und
fettfrei gehalten werden. Berücksichtigen Sie dies bitte bei allen Arbeiten am
Filter!
G3/100-G14/350_DE-EN_1 7
Deutsch
Hinweise zu Transport und Installation

Der Transport — besonders von Filtern größerer Bauart — darf nur von
Fachpersonal durchgeführt werden.
Einen durch den Transport beschädigten Filter nicht in Betrieb nehmen.
Berücksichtigen Sie bei der Montage auch das Eigengewicht des Filters und
montieren Sie ggf. eine Stützvorrichtung. Führen Sie die Befestigung des
Filters so aus, dass auch das Gewicht eines vollständig mit Flüssigkeit
befüllten Filters gehalten wird.
Es muss stets eine direkte Verbindung zu einer Sicherheitseinrichtung für die
Einhaltung des maximalen Betriebsdrucks und der zulässigen
Fluidtemperatur vorhanden sein.
Hinweise zum Betrieb des Filters

Setzen Sie den Filter nur gemäß den auf dem Typenschild genannten
minimalen und maximalen Betriebsbedingungen ein.
An den Filtern dürfen keine Umbauten und Veränderungen vorgenommen
werden, die nicht vom Hersteller genehmigt wurden. Ungenehmigte
Änderungen gefährden die Betriebssicherheit und können Schäden oder
Verletzungen zur Folge haben.
Schlagartigen Druckaufbau bzw. -abfall vermeiden. Wenn sich der Druck zu
schnell aufbaut oder abfällt, kann dies zu Schäden am Filter führen.
Während des Betriebes können die Oberflächen des Filters sehr heiß
werden. Berücksichtigen Sie dies stets bei Arbeiten an dem Filter.
Bei der Verwendung von Zubehör mit externer Spannungsversorgung
besteht Gefahr durch die elektrische Spannung. Arbeiten an elektrischen
Teilen daher nur stromlos durchführen.
Hinweise zur Wartung

Filter stets langsam drucklos machen. Bei Arbeiten an dem Filter Augen-
schutz tragen.
Halten Sie stets die vorgeschriebenen Wartungsintervalle ein. Bei
Nichtbeachtung ist die einwandfreie Funktion des Filters nicht gewährleistet
und der Hersteller übernimmt für mögliche Folgen keine Haftung.
Reparaturen und Wartungen nur von Fachpersonal durchführen lassen.
Zum Öffnen der Filter nur geeignetes Werkzeug, z. B. einen Filterschlüssel,
verwenden.
Bei Arbeiten an lackverträgllichen Filtern unbedingt silikon- und fettfreie
Handschuhe aus Baumwolle oder Kunststoff tragen.
Hinweis zur Demontage und Entsorgung

Filtergehäuse und –elemente sind unter Umständen durch gefilterte Substanzen
kontaminiert. Daher unbedingt das Sicherheitsdatenblatt des verwendeten
Fluides beachten und alle Teile des Filters entsprechend den gültigen
Entsorgungsbestimmungen entsorgen.
8 G3/100-G14/350_DE-EN_1
Deutsch
Filter montieren
Die Filter werden betriebsfertig geliefert und können direkt in das
Rohrleitungssystem installiert werden. Falls Optionen wie z. B. ein elektronischer
Kondensatableiter bestellt wurden, so liegen diese zur Vermeidung von
Transportschäden ggf. in eigener Verpackung separat bei. Dieses Zubehör muß
entsprechend den jeweils beiliegenden Anleitungen vor der Inbetriebnahme an
den Filter montiert werden.
Voraussetzungen und vorbereitende Tätigkeiten

Die Filter sollten im Rohrleitungssystem grundsätzlich an der Stelle mit der
niedrigsten Temperatur eingesetzt werden.
Für den Filterelementwechsel ausreichend freien Platz unterhalb des Filters
vorsehen (siehe Maß D in den Technischen Informationen).
Es muß eine Sicherheitseinrichtung für die Einhaltung des maximalen
Betriebsdrucks und der zulässigen Fluidtemperatur vorhanden sein.
Zusätzliche Voraussetzungen wenn eine Kartusche installiert ist:
Aus der Kartusche kann evtl. Staub austreten. Schützen Sie das
nachfolgende Druckluftnetz, indem Sie einen geeigneten Nachfilter
installieren.
Filter montieren
Vorsicht bei lackverträglichen Filtern!

Bei Arbeiten an lackverträgllichen Filtern unbedingt silikon- und fettfreie
Handschuhe aus Baumwolle oder Kunststoff tragen!
► Rohrleitungssystem drucklos zu machen.

► Filter auf mögliche Transportschäden kontrollieren. Einen beschädigten Filter
nicht montieren.
► Falls notwendig, Stützvorrichtung montieren. Führen Sie die Befestigung des
Filters so aus, dass auch das Gewicht eines vollständig mit Flüssigkeit
befüllten Filters gehalten wird.
► Filter grundsätzlich senkrecht einbauen. Die Strömungsrichtung ist durch
einen Pfeil am Gehäuseoberteil gekennzeichnet.
► Filter im Rohrleitungssystem montieren.
► Rohrleitungsabschnitt wieder unter Druck setzen und Dichtigkeit prüfen.
G3/100-G14/350_DE-EN_1 9
Deutsch
Bei Montage eines Filters mit Kartusche

Warnung vor Beschädigung durch falsche Strömungsrichtung!
Beim Einbau des Filters in die Rohrleitung die Strömungsrichtung beachten!
Der Filter darf nur in der Richtung durchströmt werden, die der Pfeil am
Gehäuseoberteil vorgibt. Bei einer Kartusche ist die vorgesehene
Strömungsrichtung von unten nach oben.
Die Durchströmung der Kartusche in falscher Richtung kann zu Beschädi-
gungen an der Kartusche führen.
► Berücksichtigen Sie auch die allgemeinen Informationen zur Montage von

Filtern im vorhergehenden Abschnitt.
► Einen Filter mit Kartusche so montieren, dass die Kartusche von unten nach
oben durchströmt wird.
Aus der Kartusche kann u. U. Abrieb austreten und das nachfolgende Gasnetz
verunreinigen oder die Qualität des Gases mindern.
► Vermeiden Sie Verunreinigungen des nachfolgenden Gasnetzes, indem Sie
einen geeigneten Partikelfilter installieren.
10 G3/100-G14/350_DE-EN_1
Deutsch
Technische Informationen
Abmessungen Filter-
Typ Leistung* Anschluss [mm] Gewicht element
m³/h G A B C D kg Anzahl x
Typ
100 bar
G 3/100 120 G¼ 85 330 25 100 3,3 1 x 1050
G 5/100 180 G⅜ 85 330 25 115 3,4 1 x 1070
G 7/100 300 G½ 85 395 25 185 3,9 1 x 1140
G 9/100 550 G¾ 116 445 25 170 11,0 1 x 2010
G 11/100 850 G1 116 530 25 270 12,4 1 x 2020
G 12/100 1175 G1½ 125 640 33 365 16,5 1 x 2030
G 13/100 1750 G1½ 125 900 33 560 21,0 1 x 2050
G 14/100 2700 G2 155 925 45 565 31,0 1 x 3050
* bezogen auf 1 bar abs. und 20 °C bei 100 bar Betriebsüberdruck
250 bar
G 3/250 125 G¼ 85 330 25 100 3,3 1 x 1050
G 5/250 220 G⅜ 85 330 25 115 3,4 1 x 1070
G 7/250 400 G½ 85 395 25 185 3,9 1 x 1140
G 9/250 900 G¾ 116 445 25 170 14,0 1 x 2010
G 11/250 1400 G1 116 530 25 270 17,4 1 x 2020
G 12/250 1750 G1½ 125 640 33 365 21,5 1 x 2030
G 13/250 2900 G1½ 125 900 33 560 30,0 1 x 2050
G 14/250 4500 G2 155 925 45 565 47,0 1 x 3050
* bezogen auf 1 bar abs. und 20 °C und 250 bar Betriebsüberdruck
350 bar
G 3/350 130 G¼ 85 330 25 100 3,3 1 x 1050
G 5/350 250 G⅜ 85 330 25 115 3,4 1 x 1070
G 7/350 450 G½ 85 395 25 185 3,9 1 x 1140
G 9/350 1020 G¾ 116 445 25 170 19,0 1 x 2010
G 11/350 1500 G1 116 530 25 270 21,6 1 x 2020
G 12/350 1950 G1½ 125 640 33 365 28,0 1 x 2030
G 13/350 3200 G1½ 125 900 33 560 40,0 1 x 2050
G 14/350 5000 G2 155 925 45 565 62,0 1 x 3050
* bezogen auf 1 bar abs. und 20 °C und 350 bar Betriebsüberdruck
Filterelement Differenzdruck* Abscheidegrad Restölgehalt

[Werte im Neuzustand, trocken,
Filtrationsgrad [Bezogen auf 1 bar absolut und 20 °C.]
bei nominaler Leistung.]
V 0,02 bar 99,99 % (3,0 µ)
0,5 mg/m³ * *1)
ZP 0,03 bar 99,9999 % (1,0 µ) ≤
0,01 mg/m³ * *1)
XP 0,06 bar 99,99999% (0,01 µ) ≤
*1)
XP4 0,12 bar ≥99,99999 % (0,01 µ) ≤ 0,001 mg/m³
*2)
A 0,03 bar – ≤ 0,003 mg/m³
KT… abhängig von der Bauart
* gemessen bei 7 bar *1) Restölaerosolgehalt nach ISO8573-2
*2) Restölgehalt (Dampf und Flüssigkeit) nach ISO8573-1
G3/100-G14/350_DE-EN_1 11
Deutsch
Ersatzteilliste für G 3/100–G 14/350

Ersatzteil
Pos.* Bezeichnung nach Filtergröße Art.-Nr.
3 O-Ring Gehäuse (FPM, Viton) G3 – G 7 671 091 005 630
G9 – G13 671 090 008 835
G14 671 090 011 053
4 Gewindestange G3 701 160 001 002
G5 701 160 002 002
G7 701 160 003 002
G9 701 030 004 002
G11 701 030 005 002
G12 701 030 006 002
G13 701 160 007 003
G14 701 160 008 002
6 Filterelement G3 Baugröße 1050
G5 Baugröße 1070
G7 Baugröße 1140
G9 Baugröße 2010
G11 Baugröße 2020
G12 Baugröße 2030
G13 Baugröße 2050
G14 Baugröße 3050
A Handablass EV05, komplett G3 – G14 631120008001
B Differenzdruckmanometer HZD80/350,
komplett (ab G3 verfügbar) G3 – G14 104 000 008 004
C elektronischer Kondensatableiter G3 – G 14/100/250 104100000016
G3 – G 14/350 104100000018
* Positions-Zuordnung siehe Kapitel Übersichtszeichnungen.

Geben Sie bei der Ersatzteilbestellung bitte hinter dem Filtertyp die Baugröße und den
Filtrationsgrad an: z. B.: G 11 mit der Elementbaugröße 2020 und dem Filtrationsgrad V.
12 G3/100-G14/350_DE-EN_1
Deutsch
Wartungsintervalle und –arbeiten
Gefahr durch plötzlich entweichenden Druck!

Niemals Teile des Filters entfernen oder sonstige Manipulationen
vornehmen, solange der Filter unter Druck steht! Plötzlich entweichender
Druck kann schwere Verletzungen verursachen.
Vor Arbeiten am Filter zuerst den Filter drucklos machen.
Wartungsintervalle
Wartungsintervall
vierteljährlich, jährlich*, spätestens bei einem

Bauteil/Serie Tätigkeit
spätestens alle 1500 Bh Differenzdruck von 0,6–0,8 bar
Elektronischer
Manuell kontrollieren gemäß Angaben im Handbuch des Kondensatableiters
Kondensatableiter
A Filterelement erneuern
V, ZP, XP, XP4 Filterelement erneuern
KT… Katusche erneuern abhängig von der Beladung und durch Messung zu bestimmen
* unabhängig von Betriebsstunden (Bh)
Funktion des elektronischen Kondensatableiters prüfen

Den elektronischen Kondensatableiter gemäß den Angaben im Handbuch des
Kondensatableiters prüfen.
Kondensat regelmäßig ablassen

Entleeren Sie das angesammelte Kondensat regelmäßig durch Öffnen des
Handablasses oder mittels eines Kondensatableiters. Je nach der anfallenden
Kondensatmenge kann das Entleeren mehrmals täglich erforderlich sein.
Filterelement erneuern
Lagern Sie die Filterelemente bis zu ihrer Verwendung in der Originalverpackung
an einem sauberen und trockenen Ort.
Vorsicht bei lackverträglichen Filtern!

Falls kleinste Silikon- oder Fettpartikel in das Gehäuse gelangen und das
Element verunreinigen, kann das zu Fehlern im Lack führen.
Daher bei Arbeiten an lackverträglichen Filtern unbedingt silikon- und
fettfreie Handschuhe aus Baumwolle oder Kunststoff tragen.
G3/100-G14/350_DE-EN_1 13
Deutsch
► Fluidzufuhr zum Filter sperren und Filtergehäuse

drucklos machen.
► Mit Hilfe eines geeigneten Werkzeugs (z. B. eines
Filterschlüssels) das Gehäuse öffnen. Das Gehäuse-
unterteil (1) herausdrehen und abnehmen.
► Filterelement (2) herausdrehen und entfernen.
► Neues Filterelement mit O-Ring einsetzen.
Filterelement handfest anziehen, dabei auf den
einwandfreien Sitz des O-Rings achten.
► Vor dem Zusammenbau die Gewinde der Gehäuseteile
mit Molykote oder vergleichbarem Schmierstoff leicht
fetten.
► Gehäuseunter- und -oberteil wieder miteinander
verbinden und handfest anziehen.
► Gehäuseunterteil um 30° zurückdrehen. Dadurch läßt sich das

Gehäuseunterteil auch nach längerem Betrieb und häufigem Druckwechsel
leicht öffnen.
► Entleerungsventil wieder schließen.
► Dichtigkeit des Gehäuses prüfen.
Kartusche erneuern
Die Einsatzbedingungen von Kartuschen mit ihren jeweiligen Füllungen sind sehr
spezifisch und je nach Anwendung unterschiedlich. Daher können keine
einheitlichen Wechselintervalle empfohlen werden.
Der Zeitpunkt des Wechsels ist am sichersten durch Messung zu bestimmen.
Wenden Sie sich dazu bitte an ein authorisiertes Labor bzw. an den Hersteller.
Störungen beseitigen
Falls die Filtrationsleistung nur ungenügend ist, obwohl das Filterelement ord-
nungsgemäß erneuert wurde, so sind möglicherweise Einsatzbedingungen oder
Durchsatzraten nicht auf den eingesetzten Filter abgestimmt. Kontaktieren Sie
bitte den Hersteller.
Verfügbares Zubehör
Für die Microfilter sind verschiedene Optionen verfügbar:
Differenzdruckmanometer
Handablass
Elektronischer Kondensatableiter
14 G3/100-G14/350_DE-EN_1
English
Übersichtszeichnung G 3/100–G 14/350 Assembly Drawing

Pos. Bezeichnung
1 Verschlussschraube
2 Gehäuse-Oberteil
3 O-Ring Gehäuse
4 Gewindestange
5 O-Ring Filterelement
6 Filterelement
7 Gehäuse-Unterteil
8 Handablass EV05
Optional
A Differenzdruckmanometer
HZD80, 350 bar
B Elektron. Kondensatableiter
Traptronic
Item Description
1 Locking srew
2 Filter head
3 O-ring
4 Tie rod
5 O-ring
6 Filter element
7 Filter bowl
8 Manual drain EV05
Optional
A Differential pressure gauge
HZD80, 350 bar
B Electronic condensate drain
Traptronic
G3/100-G14/350_DE-EN_1 15
English
General information
High pressure filters G Series (with threaded connection) are used for separating
solids, oil and water from uncritical and inert gases of fluid group 2. They can be
used as single filters or as a filter combination.
Notes on these operating instructions

These operating instructions contain all necessary information for the safe and
economic use of the G filters of series V, ZP, XP, XP4, A and KT.
These instructions are compiled for competent installers and fitters. It is assumed
that they have an adequate knowledge of good practice in installing components
in a compressed and inert gas system.
Characters and symbols used

► Work steps that you have to carry out one after the other are marked with a
triangle.
Lists are marked by a small box.
Warning!
These safety notes warn against damage to machines or equipment and
help you to avoid such damage.
Danger!
These danger notes with a grey background warn against personal injury
and/or danger to life and limb; danger notes help you to avoid dangerous
or life-threatening situations for yourself and/or third parties.
Warranty notes
In the following cases, the warranty shall be void:
If the filter is not used in accordance with its intended use.
If the filter is not serviced as specified in these operating instructions.
If other than original spare parts are used.
Notes on the European Pressure Equipment Directive (PED) 97/23/EC

In accordance with the European directive 97/23/EC, pressure-controlled media
are classified into two fluid groups depending on their hazard potential: Fluid
group 1 comprises primarily flammable, explosive, or toxic media; fluid group 2
comprises non-critical and inert media such as compressed air, helium, or nitro-
gen. Below you will find a summary description of the marking and identification
requirement according to 97/23/EC:
16 G3/100-G14/350_DE-EN_1
English
Filter Vol [m3/h] Category Designation

100 bar, Fluid group 2
G3/100 0,35 — —
G5/100 0,35 — —
G7/100 0,53 — —
G9/100 1,43 I CE
G11/100 1,96 I CE
G12/100 3,00 I CE
G13/100 4,30 II CE0525
G14/100 6,90 II CE0525
G3/250 0,35 — —
G5/250 0,35 — —
G7/250 0,53 — —
G9/250 1,38 II CE
G11/250 1,91 II CE
G12/250 3,00 II CE
G13/250 4,20 III CE0525
G14/250 6,80 III CE0525
G3/350 0,35 — —
G5/350 0,35 — —
G7/350 0,53 — —
G9/350 1,35 II CE0525
G11/350 1,88 II CE0525
G12/350 3,00 II CE0525
G13/350 4,20 III CE0525
G14/350 6,70 III CE0525
For your own safety
Intended use
The technical data on the type plate should be noted and complied with. Any
other use than with the data shown on the type plate shall be deemed to be not
within the intended use. Within these limits, the filters described herein can be
used for filtering compressed air and nitrogen without restrictions. Contact the
manufacturer with regard to design and specific characteristics (such as compati-
bility of material) if you intend to use them with other gases of fluid group 2.
G3/100-G14/350_DE-EN_1 17
English
Common improper use

Risk of explosion due to filtration of oxygen!
Never use the filters described here to filter oxygen! The filter materials
and lubricants are not resistant to oxygen. There is a serious risk of
spontaneous ignition or explosion. If you wish to filter oxygen, you must
install a special filter. For more information, please contact the
manufacturer.
Hazard from filtration of critical media!

Filters that have been designed for non-critical media (fluid group 2) must
not be used for the filtration of explosive, flammable, or toxic gases of fluid
group 1.
Safety notes
Hazard due to a sudden release of pressure!

Never remove any parts of the filter, or manipulate the same in any way, for
as long as the filter is still pressurised! A sudden escape of pressure may
cause serious injuries. Before carrying out any work on the filter, first
depressurise the filter.
Hazard caused by hot surfaces!

The media that flow through the filter can have a temperature of up to 80 °C.
Do not touch hot surfaces. Note the operating instructions issued by the
operator.
Note:
When carrying out any work on the filters comply with all applicable
national safety regulations!
The activities on the filters described in these operating instructions
may be carried out only by authorized, qualified and trained personnel.
Notes on filters suitable for paint

Compressed air systems and filters suitable for paint are used to apply paint onto
surfaces. Such equipment must meet extremely high standards as regards the
purity of the compressed air, as even minute particles contained in the air might
lead to scratches, uneven coating, bubbles, etc. Also tiny quantities of contamin-
ants or solvents containing oil or grease, and in particular silicone, might have a
negative effect on the quality of the paintwork. Units and filters that are suitable
for paint must therefore be protected against any contamination from silicone or
grease. Please take this into account when working at the filters!
18 G3/100-G14/350_DE-EN_1
English
Notes on transportation and installation

The transportation — in particular of larger build type filters — may be carried
out by specialist personnel only.
Filters damaged during transportation must not be installed.
Take into account the weight of the filter during assembly, and, if necessary,
fit a support device. The filter mounting must be designed such that the
weight of a filter completely filled with fluid is safely supported.
There must always be a direct connection to a safety device for maintaining
the maximum working pressure and the permissible fluid temperature.
Notes on filter operation

Only use the filter in accordance with the minimum and maximum operating
conditions specified on the type plate.
Without prior approval by the manufacturer, no conversions and modifica-
tions must be made to the filters! Any non-approved modifications endanger
the operational safety and may cause damage or personal injury.
Avoid sudden pressure fluctuations on pressure build-up and de-
pressurization. If the pressure builds up or drops, too quickly, this may cause
damage to the filter.
Whilst the filter is in operation, the filter surfaces can become extremely hot.
Always remember this when working on the filter.
When using accessories with an external power supply, there is a hazard
from electrical voltage. Therefore, work on electrical components must be
carried out in a voltage-free condition.
Notes on maintenance
Depressurise filter slowly, avoiding sudden drops in pressure. When working
at the filter, always wear protective goggles.
Always maintain the prescribed service intervals. If these are not complied
with, the filter may not function correctly and the manufacturer does not ac-
cept any liability whatever for any possible consequences.
Repairs and maintenance should be carried out by specialist personnel only.
To open the filter, always use a suitable tool, such as a filter spanner.
When working with paint-compatible filters, always wear gloves made in cot-
ton or synthetic fibre that are free of silicone and grease.
Notes on disassembly and disposal

The filter housing and elements might be contaminated by substances held back
in the filter. Therefore always read the material safety data sheet of the
respective fluid. Dispose of all components of the filter according to the applicable
statutory regulations.
G3/100-G14/350_DE-EN_1 19
English
Filter Installation
The filters are supplied in a ready to operate condition and can be installed di-
rectly into the pipe system. Optional devices might be packed separately in order
to ensure that the equipment is not damaged during transport. These accessories
must be fitted to the filter before commissioning and in accordance with the re-
spective instructions supplied.
Requirements and preparatory activities

As a rule, the filters should always be used in the pipe system at the point
with the lowest temperature.
For changing filter elements, sufficient free space underneath the filter must
be provided (see dimension D in the Technical Information).
A safety device for maintaining the maximum working pressure and the per-
missible fluid temperature must be available.
Additional requirements and preparatory activities for filters with cartridge
installed:
Dust may escape from the cartridge. Protect the downstream compressed air
network by installing a suitable downstream filter.
Fit filter
Filters that are suitable for paint must be handled with special care!
Minute particles of silicone or grease penetrating the housing and the filter
element might have a negative effect on the quality of the paintwork.
Therefore, always wear protective gloves made of cotton or plastic that are
free of silicone or grease when handling such filters.
► Before fitting the filter the relevant section in the pipe system must be de-
pressurised.
► Check filter for possible transport damage. Do not fit a damaged filter.
► If necessary, fit a bracket or pipe support. When selecting the mounting, take
into account the weight of the filter and the weight of the possible water con-
densate.
► The filter must always be fitted vertically. The flow direction is marked by an
arrow on the housing top section.
► Fit filter in the pipe system.
► Re-pressurize pipe section and check for leaks.
20 G3/100-G14/350_DE-EN_1
English
When installing a filter with cartridge

Beware of damage due to wrong flow direction!
Heed the flow direction when installing the filter in the pipeline! The gas
must flow through the filter in the direction of the arrow on the upper
housing only. The intended flow direction for a cartridge is from bottom to
top.
A reversed air flow through the cartridge can damage the cartridge.
► Also heed the general information on filter installation in the previous section.
► Install a filter with cartridge so that the gas flow is from bottom to top.
Wear debris can exit from the cartridge, contaminate the downstream gas net-
work or degrade the gas quality.
► Prevent any contamination of the downstream gas network by installing a
suitable particle filter.
G3/100-G14/350_DE-EN_1 21
English
Technical information
Filter
Type Capacity* Connection Dimensions [mm] Weight element
m³/h G A B C D kg type
100 bar
G 3/100 120 G¼ 85 330 25 100 3,3 1 x 1050
G 5/100 180 G⅜ 85 330 25 115 3,4 1 x 1070
G 7/100 300 G½ 85 395 25 185 3,9 1 x 1140
G 9/100 550 G¾ 116 445 25 170 11,0 1 x 2010
G 11/100 850 G1 116 530 25 270 12,4 1 x 2020
G 12/100 1175 G1½ 125 640 33 365 16,5 1 x 2030
G 13/100 1750 G1½ 125 900 33 560 21,0 1 x 2050
G 14/100 2700 G2 155 925 45 565 31,0 1 x 3050
* per 1 bar abs. at 20 °C, 100 bar operating pressure
250 bar
G 3/250 125 G¼ 85 330 25 100 3,3 1 x 1050
G 5/250 220 G⅜ 85 330 25 115 3,4 1 x 1070
G 7/250 400 G½ 85 395 25 185 3,9 1 x 1140
G 9/250 900 G¾ 116 445 25 170 14,0 1 x 2010
G 11/250 1400 G1 116 530 25 270 17,4 1 x 2020
G 12/250 1750 G1½ 125 640 33 365 21,5 1 x 2030
G 13/250 2900 G1½ 125 900 33 560 30,0 1 x 2050
G 14/250 4500 G2 155 925 45 565 47,0 1 x 3050
350 bar
G 3/350 130 G¼ 85 330 25 100 3,3 1 x 1050
G 5/350 250 G⅜ 85 330 25 115 3,4 1 x 1070
G 7/350 450 G½ 85 395 25 185 3,9 1 x 1140
G 9/350 1020 G¾ 116 445 25 170 19,0 1 x 2010
G 11/350 1500 G1 116 530 25 270 21,6 1 x 2020
G 12/350 1950 G1½ 125 640 33 365 28,0 1 x 2030
G 13/350 3200 G1½ 125 900 33 560 40,0 1 x 2050
G 14/350 5000 G2 155 925 45 565 62,0 1 x 3050
Filter element Differential pressure* Filtration efficiency Residual oil content

Degree of filtration [Values in a condition as new,
[In relation to 1 bar absolute and 20°C.]
dry, at nominal capacity.]
V 0.02 bar 99.99 % (3,0 µ) –
*1)
ZP 0.03 bar 99.9999 % (1,0 µ) ≤ 0.5 mg/m³
*1)
XP 0.06 bar 99.99999 % (0,01 µ) ≤ 0.01 mg/m³
*1)
XP4 0,12 bar ≥99,99999 % (0,01 µ) ≤ 0,001 mg/m³
*2)
A 0.03 bar – ≤ 0.003 mg/m³
KT… according to type
* at 7 bar *1) Residual oil spray content according to ISO8573-2
*2) Residual oil content (steam and liquid) according to ISO8573-1
22 G3/100-G14/350_DE-EN_1
English
Spare parts list for G 3/100–G 14/350

Replacement part
Item* Designation acc. to filter size Item no.
3 O ring housing (FPM, Viton) G3 – G 7 671 091 005 630
G9 – G13 671 090 008 835
G14 671 090 011 053
4 Threaded rod G3 701 160 001 002
G5 701 160 002 002
G7 701 160 003 002
G9 701 030 004 002
G11 701 030 005 002
G12 701 030 006 002
G13 701 160 007 003
G14 701 160 008 002
6 Filter element G3 model 1050
G5 model 1070
G7 model 1140
G9 model 2010
G11 model 2020
G12 model 2030
G13 model 2050
G14 model 3050
8 Manual drain valve EV05, G3 – G14 631120008001
complete
A Differential pressure gauge
HZD80/350, complete G3 – G14 104 000 008 004
(available from G3)
B Electronic condensate trap G3 – G 14/100/250 104100000016
G3 – G 14/350 104100000018
* Please refer to the Assembly Drawing to identify these parts.

When ordering replacement parts, always state the build size and degree of filtra-
tion after the filter type: e.g.: G 11 with the element build size 2020 and the de-
gree of filtration V.
G3/100-G14/350_DE-EN_1 23
English
Maintenance intervals
Hazard due to a sudden release of pressure!

Never remove any parts of the filter, or manipulate the same in any way, for
as long as the filter is still pressurised! A sudden escape of pressure may
cause serious injuries.
Before carrying out any work on the filter, first depressurise the filter.
Maintenance intervals
Maintenance interval
quarterly, at the latest annually*, at the latest at a differential

Component/Series Activity every 1500 op. hrs pressure of 0.6–0.8 bar
Electronic
Check manually according to instructions in condensate drain manual
condensate drain
A Renew filter element
V, ZP, XP, XP4 Renew filter element
KT… Renew cartridge Determine in dependence of the load and by measuring
* irrespective of operating hours
Check the function of the electronic condensate trap

Check the electronic condensate trap, following the instructions in the manual
supplied with the trap.
Regularly drain condensate

Regularly drain the collected condensate by opening the manual drain valve, or
by using a condensate drain pipe. Depending on the operation, condensate might
have to be drained several times a day.
Replacing the filter element

Store the filter elements in their original packaging in a clean and dry location un-
til they are used.
Special caution is required when handling of filters that are suitable for
paint!
Minute particles of silicone or grease penetrating the housing and the filter
element might have a negative effect on the quality of the paintwork.
Therefore, always wear protective gloves made of cotton or plastic that are
free of silicone or grease when handling such filters.
24 G3/100-G14/350_DE-EN_1
English
► Shut off compressed air or gas supply to the filter and depressurise filter
housing. The filter is depressurised when no flow noise can be heard any
more.
► Open the filter housing, using a suitable tool
(e.g. filter spanner). Unscrew the filter bowl
section (1) and remove.
► Unscrew filter element (2) and remove.
► Insert new filter element and O-ring. Tighten
filter element until it is hand tight, ensure that
the O ring is seated correctly.
► Before assembly lightly grease the threads of
the housing sections with Molykote or a
comparable lubricant.
► Reconnect the filter bowl to the head and
tighten until hand tight.
► Unscrew the filter bowl by 30 °. This allows
the filter bowl to be opened easily even after
an extended period of operation and frequent
pressure changes.
► Close the manual or automatic drain.
► Check the housing for leaks.
Replacing the cartridge

The operating conditions of cartridges with their respective fillings are very
specific and differ with regard to application. It is therefore impossible to
recommend any fixed intervals.
It is safest to determine the necessary exchange by measuring. Please contact
an authorised laboratory or the manufacturer for this purpose.
Correcting faults
If the filtration capacity is insufficient, although the filter element was replaced at
the correct intervals, then the ambient conditions of use or throughput rates may
not have been matched to the filter used. Contact the manufacturer.
Accessories
Various options are available for the micro filter:
Differential pressure gauges
Manual drain valve.
Electronic condensate drains
G3/100-G14/350_DE-EN_1 25
English
MANUFACTURER'S DECLARATION

herewith declares that to products
Fluid group 2
max. operating
Filter type pressure [bar]
G03/100–G07/100 100
G03/250–G07/250 250
G03/350–G07/350 350
the following standards and technical specifications apply:
EN 1050
97/23/EC
The quality control system is monitored by Lloyd’s Register Quality Assurance

GmbH, Hamburg (code no. 0525).
Essen,
30.09.2009

26 G3/100-G14/350_DE-EN_1
English
DECLARATION OF CONFORMITY
herewith declares that products
hereby declares with sole responsibility, that the products
Fluid group 2
max. operating
Filter type pressure [bar] Module
G9 – G12 100 A
G13–G14 100 A1
G9 – G12 250 A1
G13–G14 250 H
G9 – G12 350 H
G13–G14 350 H
to which this declaration applies,

comply with Directive 97/23/EC and
that conformity has been verified for the modules according to the above ta-
ble.
The quality control system is monitored by Lloyd’s Register Quality Assurance

GmbH, Hamburg (code no. 0525).
The following standards and technical specifications apply:

harmonised standards:
— EN 1050.
Essen,
30.09.2009

G3/100-G14/350_DE-EN_1 27
Hiross Zander Division
Im Teelbruch 118 Telefon: 0049 (0)2054/934-0

D-45219 Essen Fax: 0049 (0)2054/934-164
Internet: www.parker.com/hzd
Bentley air dreyer
Installation and maintenance instructions

026_41007852_WP5000_Dryer_Titel_en_0111.fm
026_41007852_WP5000_Dryer_Titel_en
Edition: 12 / 2010
BENTLEY
Manufacturers of Specialist Filters,
Dryers and Valves
H.P. AIR DRYER PACKAGE BD90-EP350

AS DRAWING LBB 33030
INSTALLATION AND MAINTENANCE

INSTRUCTIONS
OM 33030
L. B. BENTLEY LTD.
KINGFISHER BUSINESS PARK,
LONDON ROAD,
STROUD,
GLOUCESTERSHIRE
GL5 2BY.
TEL: 01453 733060

FAX: 01453 733064
www.lb-bentley.com
LB BENTLEY LTD 1
OM33030
INDEX
PAGE
1. Contents 2
2. Specification 4
3. Principles of Operation 5
4. Main Air Circuit 6
5. Electrical Circuit 9
6. Pneumatic Control System 10
7. Installation 11
8. Checking and Starting the Plant 12
9. Trouble Shooting 14
10. Maintenance and Routine Checks 15
11. Changing the Desiccant 22
12. Back Pressure Maintaining Valve (PMV) Type H15 23
13. Recommended Spares 24
LB BENTLEY LTD 2
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Drawing index.
G. A. of Air Dryer - LBB 33030
P + ID - LBB 33030-1
Timing Chart - LBB 33030
Control Panel - LBB 33071
Dryer Vessel Left Hand - LBB 33034
Dryer Vessel Right Hand - LBB 33034
Wiring Diagram - LBB 33071-1
Pre-Filter Separator MSHP-13N-PF737 - LBB 33061
Coalescer Filter MSHP-13-C534 - LBB 33037
Dust Filter MSHP-13-D534 - LBB 33036
Air Operated Valves - LBB 06074
Manual Stop valves - LBB 05532
NRV/Orifice Assembly - LBB 05955
Regulator Assembly - LBB 32244
Pressure Maintaining Valve H15 - LBB 01463
Stop Valve Cartridge - LBB 05801
Stop Valve Cartridge - LBB 05797
LB BENTLEY LTD 3
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Specification:
Maximum flow rate of compressed air - 165M³/HR
Max. Working Pressure - 350.BAR
Maximum temperature of incoming air - 45ºC
Activation bleed volume (inst.) - 12 m³hr@207-300.Bar
Nominal activation pressure - < 25 psi
Dust particles - 1 micron
Control Instrument Compressed Air.
Pressure -valve actuators PRV1 (PG1) - 10 bar

FPRV2(PG2) - 7 bar.
Control Panel.
Power supply - 220v 1Ph – 50/60HZ
Operating cycle: Electronic Step Timer - 20 minutes/cycle

Adsorption period - 10 minutes
Regeneration period - 2 minutes 40 seconds
Pressurisation - 7 minutes
Automatic Drains.
Pre-Filter - 2 x 5 seconds/20 minutes

Coaleser Filter - 5 seconds/20 minutes
Back Pressure Maintaining Valve - Min. set pressure 180- 270.bar
Relief Valves.
RV1 - 15 bar
RV2 - 10 bar
LB BENTLEY LTD 4
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1. Principles of Operation.
1.01. Pre-Filter MSHP-13N-PF737 as Drawing LBB 33061. Removes large

liquid loads and solid contaminants 1 micron and larger.
1.02. Coalescer Filter MSHP-13N-C534 as Drawing LBB 33037. Removes the

liquid oil content in the air down to 0.1micron, whilst removing all free
moisture and dirt particles.
1.03. The Pre-Filter and Coalescer Filters are each piped to an auto/Manual
drain manifold.
1.04. The heatless Compressed Air Dryer comprises of two adsorption

vessels, which are connected together such that during normal
operation one vessel is on stream and pressurized, and the second
vessel is bypassed.
1.05. Before the first vessel becomes saturated with water vapour the dryer
will automatically change to the second adsorption vessel.
1.06. This changeover occurs after 10 minutes uninterrupted operation.
1.07. Once changeover has occurred the saturated tower is depressurized

and purged with dry air to regenerate the desiccant.
1.08. The dryer is now ready to repeat the cycle of operation.
1.9. The dryer is fully automatic under the control of a 220v AC electronic
Step Timer which in turn controls the sequence operation of the
compressed air inlet valves, reactivation purge valves and filter auto-
drain valves.
1.10. 0-600 Bar Pressure Gauges are fitted to indicate air pressure in each
Adsorber vessel.
1.11. A Dust Filter MSHP-13-D534 as Drawing LBB 33036 is fitted

downstream of the air dryer vessels and non-return valves. Fitted
with a replaceable Element D534 for the removal of desiccant
dust/dirt particles of 1 micron size and larger.
Fitted with manual drain valve. LBB 5532
1.12. A Back Pressure Maintaining Valve H15 LBB 01463 is fitted to

maintain a system pressure within 10% of normal working pressure
LB BENTLEY LTD 5
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when discharging into a low downstream line pressure.
NOTE:
When depressurizing the air dryer package, the drain valves should be
opened carefully to ensure that the air pressure falls gradually in the
plant thus avoiding high air velocities, which could damage the filter
inserts and fluidise the desiccant bed.
2. Main Air Circuit: (See Flow Diagram LBB 33030-1)
2.01. For the purpose of description, assume that the left hand Adsorber
AD1 of the Drying Plant is on drying duties and the desiccant in the
right hand Adsorber AD2 is being reactivated.
2.02. The wet compressed air enters through the Pre-Filter and Coalescer
Filter as mounted on the Dryer Package.
2.03. The compressed air then passes through the air operated inlet Valve
V1 and up through Adsorber AD1 where water vapour will be
removed and retained in the pores of the desiccant. The dry air will
leave the adsorber through the left hand non-return valve at the top
of the Plant.
2.04. A small volume of the dry compressed air leaving Adsorber AD1
passes through the activation flow control orifices. The dry air passes
through the combined filter and orifices which regulates the flow of
activation air and expands it to approximately 25 psi. It then passes
into the top section of Adsorber AD2.
Adsorber AD1 Pressure Gauge PG3 reading high.

Adsorber AD2 Pressure Gauge PG4 reading low.
2.05. The dry expanded air entering the top part of Adsorber AD2 will pass
down through the desiccant and pick up the water vapor adsorbed
during the previous drying cycle. The moisture-laden air leaves the
adsorber through the bottom connection and passes through
activation purge Valve V4 and out of the Plant via the activation air
Silencer S1.
LB BENTLEY LTD 6
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2.06. The reactivation air passes down through Adsorber AD2 for 3 minutes
of the period. The activation purge Valve V4 then closes and the
reactivation air continues to flow and increase the pressure in
Adsorber AD2. During the remaining 5.1/2 minutes the pressure
increases until both Adsorber Vessels are at line pressure.
Adsorber AD2 Pressure Gauge PG4 rising to full pressure.
2.07. At the end of the cycle, inlet valve V2 will open and Valve V1 will
close 20 seconds later and the changeover of the airflow will be
completed.
Adsorber Pressure Gauges PG3 and PG4 both reading high.
2.08. Activation purge Valve V3 now opens and the pressure in Adsorber
AD1 will reduce and activation of the desiccant will proceed.

Adsorber AD2 Pressure Gauge PG4 reading high.
2.09. The activation air flow is maintained by the "fixed" flow restrictor
orifice "FO" and pressure at which activation takes place is controlled
by the purge orifice "PO" in the outlet pipework coupling from the
activation purge valve.
2.10. Air then leaves the Drying Plant through the Dust Filter and Back
Pressure Maintaining Valve.
LB BENTLEY LTD 7
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Automatic Condensate Drain:
(Refer to P+ID DIAGRAM FOR LBB33030-01)
2.11. The Pre-Filter and Coalescer Filters are each fitted with:-
1) Manual Drain Valve
2) Automatic air operated Drain Valve sequenced from control panel.
2.12. Liquid condensate collected in the sump of the Pre and Coalescer
Filters drain to the timer controlled Drain Valves V5 and V6 (located
inside control panel).
Rate of discharge is controlled by an "orifice" restrictor coupling which

is fitted into the outlet of each automatic Drain Valve.
The outlet of the manual and automatic drain valves manifold

will need to be connected with high-pressure pipework to a
suitable drain tank.
2.13. The air operated Drain Valves V5 and V6 are sequenced from Timer
outputs through air solenoid valves SV5 and SV6.Condensate
discharge time is set at 5 seconds.
2.14. Manual override test button on each solenoid SV5 and SV6 allows
operation and checking of each drain valve and that condensate or air
discharges freely from each filter.
2.15. Manual drain valves are fitted for manual draining of the filters. This
also allows depressurisation of the Plant .
The system pressure should not be reduced quickly, to avoid damage

to filter inserts and fluidising of the desiccant bed.
LB BENTLEY LTD 8
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3. Electrical Circuit:
SEE: Control Panel Layout LBB 33071

Wiring Diagram LBB 33071-1
Timing Chart LBB 33030 TIMING CHART
Supply Voltage 220V AC 50/60HZ
3.01. The operation of the Dryer is under the control of an Electronic Step
Timer through a pneumatic micro-solenoid valve set. Instrument
Status LED’s indicates valve condition, pressure "on" valve "open".
3.02. Once the control panel is switched on the Electronic Timer is running.
Its 6 outputs energise the electro-pneumatic solenoid control valves
SV1 – SV6 which operates the main air valves sequenced as Timing
Chart.
Solenoids SV1 and SV2: Controls the air supply to the main inlet
valves V1 and V2 and instrument pressure gauges PG1 and PG2.
Solenoids SV3 and SV4: Controls the air supply to the reactivation
purge Valves V3 and V4 and instrument pressure gauges PG3 and
PG4.
Solenoids SV5 and SV6: Controls the air supply to the auto drain
purge Valves V5 (pre filter) and V6 (coalescer).
3.03. A panel alive light is fitted in the control panel and is illuminated when
the electric power is switched on and the Dryer is running.
3.04. Compressor Inlet Contacts are wired to terminals 2 and 3.
3.05. Hour Counter HC totals the hour’s run.
3.06. Panel is protected by a 1 amp fuse and has its own isolator switch.
LB BENTLEY LTD 9
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4. Pneumatic Control System.
See Flow Diagram LBB 33030-1
4.01. 7 bar compressed control air required for instrumentation purposes is

taken from the dryer inlet via the pressure reducing Valves PRV1 and
FPRV2.
4.02. Pressure Regulator PRV1 accepts the air at inlet pressure, and by
manipulation of the hand wheel the outlet supply pressure is
controlled between zero and 300 PSIG maximum pressure indicated
on PG1.
Relief Valve RV1 is set to relieve supply pressure above 15 bar.
4.03. A second stage Filter/Regulator FPRV2 further reduces and stabilises

the supply pressure for implementation to 7 bar, as indicated on
Pressure Gauge PG2. The integral filter with efficient cyclone
separator and 40 micron element ensures a clean air supply free of
water and particles.
This regulated air pressure at 7 bar is supplied direct to the Control

Panel 33071.
4.04. The 6 output electro-pneumatic solenoid valve set passes air to the
main inlet Valves V1 and V2, reactivation purge Valves V3 and V4 and
auto drain valves V5 and V6. Manual override test buttons allow
selective operation and checking of each valve.
4.05. Sequence operation of the electro-pneumatic solenoid valves are

shown on Timing Chart.
4.06. Pneumatic arrangement is shown on Flow Diagram Drawing LBB

33030-1.
LB BENTLEY LTD 10
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5. Installation: (Refer to G. A. Drawing LBB 33030)
IT IS ESSENTIAL THAT A RELIEF VALVE IS FITTED TO THE

INCOMING GAS SUPPLY TO ENSURE THE EQUIPMENT IS NOT
OVER PRESSURISED.
INLET PRESSURES ABOVE THE MWP OF THE EQUIPMENT ARE
NOT RECOMMENDED.
MOREOVER, MAY RESULT IN INJURY TO PERSONNEL AND
FAILURE OF THE EQUIPMENT.
5.01. The Drying Plant should be placed in position and secured with 12mm
diameter bolts through the 14mm diameter holes provided in the mild
steel frame. Install in a dry environment, ideally where the ambient
temperature is between 5ºC and 35ºC.
CAUTION:
Do not lift by pipework, move by means of a forklift truck and, if

necessary, Sling from Lifting Points Provided.
5.02. Connect compressed air lines to the Dryer 1/2" BSP.PL inlet, 3/8"
BSP.PL outlet. The 1/4” BSP.PL blow down connection will need to be
connected with high-pressure pipework to a suitable drain tank.
Piping arrangement may include suitable air bypass system.
Inlet pipework should not form bends, which may trap water.
5.03. Connect a 220V AC single phase electric supply to the inlet terminals
of the control panel. These terminals are marked "L" for the live
connection and "N" for the neutral connection. Control panel is fitted
with an ON/OFF isolator switch and 1 AMP line fuses F1 and F2.
5.04. Wire from control relay contact terminals 2 and 3 to Compressor

Switching Circuit Relays.
5.05. A mains isolator should be incorporated in the electric supply so that

the Plant can be switched off from the electric supply for servicing
and maintenance.
LB BENTLEY LTD 11
OM33030
6. Checking and Starting the Plant:
6.01. Ensure the electric supply to the control panel is switched on and that
power on light is illuminated.
6.02. The dryer Electronic Step Timer and purge flow orifices have been
factory set and should not require adjustment.
6.03. Check the hand wheel of the Pressure Regulator Valve PRV1 is wound
2 or 3 turns in a clockwise position.
6.04. Close the manual drain valves of each filter.

Open outlet isolation valve.
6.05. Open inlet valve slowly and immediately adjust the Pressure Regulator
PRV1 so that the reduced pressure at PG1 reads approximately 10
bar.
6.06. Adjust the second stage Filter/Regulator FPRV2 so that the reduced
pressure at PG2 reads 7 bar.
6.07. When full Dryer System pressure has been reached adjust Pressure
Regulator PRV1 so that Gauge PG1 reads 10 bar.
6.08. Check entire system for air leaks. Depressurise and make good if
necessary.
6.09. Flow from the dryer will not commence until the Dryer System
pressure is above the setting of the Back Pressure Maintaining Valve
BPMV.
6.10. Check the program of the Electronic Step Timer against the Timing
Chart, one complete cycle in 20 minutes. LED display indicates Step
program and instrument Status LED’s mounted on the front of the
control box show which air valves are being operated.
LB BENTLEY LTD 12
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6.11. Manual Override test buttons on each solenoid valve with pneumatic
indicator allows individual operation of the main inlet, reactivation
purge and auto-drain valves.
Override test buttons to purge valve V3,V4,V5 and V6 can be used to
depressurise the air dryer. Air is discharged through silencer muffler
S1.
6.12. Every 8 hours crack open the filter manual drain valves, blow clear
and close.
If excess water comes from either of the Pre or Coalescer Filters the
step time period of the auto drain valves should be increased.
(Consult factory)
6.13. Although the Plant leaves the works in a fully active condition it is
quite possible that due to the length of storage before commissioning,
dry air will not be obtained from the dryer until at least two complete
changeovers have taken place.
LB BENTLEY LTD 13
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7 Trouble shooting
FAULT CAUSE MEASURE
Air blasting from 1: inlet valve stuck open Strip & inspect valve.
Purge valve. with dirt.
2: Check valve failed to Strip & inspect valve.

close (dirt).
High pressure drop 1: Filter element blocked. Replace filter elements.

through dryer.
(i.e. restriction 2: Inlet valve blocked or Strip & inspect valve.
to flow) failed to open.
3: Desiccant diffuser pipe Strip, remove desiccant,

blocked. Check for blockages.
High dew point. 1: The dryer has excessive Monitor & adjust inlet
volume being put through volume.
it.
Monitor & adjust inlet
2: High inlet temperature. temperature.
3: Aged or oil Strip, examine desiccant &

contaminated desiccant. Replace if necessary.
Dryer not cycling Timer/control panel Check dryer cycles against

Correctly Malfunction. Timing chart.
LB BENTLEY LTD 14
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8 Maintenance and Routine Checks:
The following routine maintenance and checks should be carried out

at six monthly intervals. When routine maintenance and servicing is
carried out, the Plant should be isolated by closing main airline inlet
and outlet Stop Valves.
Switch off the electrical supply and mains isolator.
All pipework and vessels should be at atmospheric pressure before

any of the following maintenance checks are carried out.
EACH FILTER AND DRYER ADSORBER VESSEL IS

A PRESSURE CONTAINING DEVICE: ALWAYS
DEPRESSURISE COMPLETE SYSTEM BEFORE
SERVICING.
****************************
OPEN ALL DRAIN VALVES SLOWLY SO THAT THE

PRESSURE CAN SAFELY BE REDUCED BEFORE
WORKING ON ANY OF FILTERS OR DRYER.
Override test buttons SV3, SV4,SV5 & SV6
(in control box) which operate reactivation
purge valves can be used to depressurise the air
dryer provided electrical power is switched on.
air will discharge through the silencer muffler s1
****************************
DO NOT OVERTIGHTEN COUPLING NUTS -

MAXIMUM TORQUE 90 LBS. FT.
*****************************
ENSURE CORRECT ALIGNMENT OF PIPEWORK

AND IF NECESSARY LOOSEN FILTER FIXING
BOLTS, ADJUST
ALIGNMENT, TIGHTEN JOINT AND THEN MAKE
GOOD
FIXING BOLTS.
LB BENTLEY LTD 15
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8.01 3000 Hour Maintenance Instructions For:
Pre-Filter.
Type MSHP-13N-PF737
As DRG. LBB 33061
1. Unscrew Filter Head by hand or with strap wrench.
2. Remove and replace Element PF737 - LBB 30737-1
3. Remove 'O' Ring and anti-extrusion rings (Items 6 and 7) from Filter
Head and fit new, which has been rubbed with silicone grease.
Pt. No's LBB 1288 and LBB 1641.
4. Spray Filter base threads with an inorganic anti-scuffing paste

AS.MT or equivalent.
5. Reassemble filter body and do not over tighten.
LB BENTLEY LTD 16
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8.02 3000 Hour Maintenance Instructions For:
Coalescer Filter.
Type MSHP-13-C534
Constructed As Drawing LBB 33037
.
1. Unscrew Filter Head by hand or with strap wrench.
2. Remove and replace Element C534 - LBB 00534C
3. Remove 'O' Ring and anti-extrusion rings (Items 4 and 6) from Filter
Head and fit new which has been rubbed with silicone grease.
Pt. No's LBB 01405 and LBB 01834.
4. Spray Filter base threads with an inorganic anti-scuffing paste

AS.MT or equivalent.
6. Reassemble filter body and do not over tighten.
LB BENTLEY LTD 17
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8.03. 3000 Hour Maintenance Instructions For:
Dust Filter
Type MSHP-13-D534
Constructed As Drawing LBB 33036
1. Remove outlet pipework and unscrew Filter body by hand or with

strap wrench.
2. Remove and replace Filter Element LBB 00534D.
3. Remove 'O' Ring and anti-extrusion ring (Items 4 and 6) from Filter
Head and fit new which has been rubbed with silicone grease.
Pt. No's. LBB 1405 and LBB 1834.
4. Spray Filter head thread with an inorganic anti-scuffing paste

AS.MT or equivalent. Reassemble to vessel and do not over tighten.
5. Check operation of Drain Valve LBB 5532, if necessary use Service Kit
LBB 6334
LB BENTLEY LTD 18
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8.04. Maintenance Instructions For:
Fully Automatic Heatless Air Dryer BD90-EP350
A Every 3000 hours -

Procedure for Air Operated Valve Seat Replacement:
When servicing valves or removing any parts of the dryer always

replace 'O' rings and bonded seals with new.
A1. Inlet/Purge and Drain Valves LBB 6074-01(V1-V4)+LBB

5797-01 (V5 – V6)
The Bentley Air Operated Stop Valve has a service interval well above
the recommended service interval of the dryer. It is recommended
however, that the valve be inspected / serviced, as a precaution, at
the same time as the dryer.
1. Ensure system is at atmospheric pressure and remove valve from

Adsorber Base to a suitable clean working area.
2. Unscrew actuator body (2) using a suitable wrench on the flats

provided.
This should not require undue force as these items should only be
tightened with
moderate force ( less than 25 Nm ). The sub assembly body (2) and
cap (5) will now come away.
3. Hold body (2) by the flats in the vice and using a strap wrench
unscrew cap(5).
Care must be taken when drawing cap (5) to ensure indicator pin (9)
disengages from the cap (5).
4. Remove disc springs (8) but leave all 'O' rings, unscrew indicator pin
(9) and
place in a suitable receptacle for keeping along with disc springs.
5. Using a small diameter drift, carefully tap out roll pin (7) from piston
(4) and
peek seal (6). This will allow the piston assembly (4) to be drawn out
from the body.
LB BENTLEY LTD 19
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6. Inspect all items for damage and wear and replace all seals and 'O'
rings using service kit.
7 Re-assemble in reverse order taking care not to scratch or damage

sealing
items.
Coat all 'O' rings with silicone grease before assembling.

Spray internals
particularly disc springs lightly with silicone spray on assembly.
A2. Function Test
After completion of service/maintenance check and start plant as

detailed under Paragraph 6.
NOTE:
When reassembling Valves use D.F.S.M inorganic anti-scuffing spray

on all threads. lightly smear all moving parts and 'O' ring seals with
silicone grease.
8.05B Every 2000 Hours/12 Months _- Complete Service Of Dryer.
B1. Air Operated Stop Valves LBB 6074 (V1 – V4).
See Page 19 for procedure.
B2. Non Return Valve/Orifice Assy LBB 5955.
Remove the Non-Return Valve/Purge Orifice Assemblies from the

Adsorber Heads, clean all parts, replace Seals and reassemble.
Ensure that they seal and reassemble to Plant the correct way round.
Use Spares Kit LBB 6389
After completion of service/maintenance check, start plant as detailed

under Paragraph 6.
NOTE:

on all threads. Slightly smear all moving parts and 'O' ring seals with
silicone grease.
LB BENTLEY LTD 20
OM33030
8.05B Every 3000 Hours _- Complete Service Of Dryer.
B1. Air Operated Stop Valves LBB 6074 (V1 – V4).
See Page 19 for procedure.
B2. Non Return Valve/Orifice Assy LBB 5955.
Remove the Non-Return Valve/Purge Orifice Assemblies from the

Dryer Vessel Heads, clean all parts, replace Seals and reassemble.
Ensure that they seal and reassemble to Plant the correct way round.
Use Spares Kit LBB 6389
After completion of service/maintenance check, start plant as detailed

in Paragraph 6.
NOTE:

on all threads. Smear all moving parts and 'O' ring seals with silicone
grease.
LB BENTLEY LTD 21
OM33030
9. Changing The Desiccant.
9.01 The desiccant used in each Dryer Vessel is 3.5KG of Activated

Alumina. Desiccant can, in the absence of contamination, remain
active for 2 to 3 years. Ageing, however, does occur and the
desiccant will slowly deteriorate from the moment it is put into
operation. Where very low dewpoints are required it may be prudent
to change the desiccant at more frequent intervals.
9.02 To change the desiccant adopt the following procedure:-
1. Depressurise the Dryer.
2. Remove the top filler plug.
3. Remove the bottom filler plug. The desiccant should now pour out of
the vessel, collect in a polythene bag.
4. Ensure all desiccant is removed, inspect dryer vessel interior and

check that entry port inserts are not damaged.
5. Replace the bottom filler plug.
6. Using the correct desiccant fill the vessel with Activated Alumina. Tap
vessel with soft face mallet to ensure complete fill.
NOTE: DESICCANT SHOULD BE FREE OF DUST, SIEVE IF NECESSARY
7. Replace the top filler plug.
8. Pressurise the dryer and check for leaks.
9. Run the dryer on purge only (no outlet flow) for several cycles to dry
out the desiccant.
LB BENTLEY LTD 22
OM33030
10. Back Pressure Maintaining Valve - Type H15 (Ref LBB 01463)
A Back Pressure Maintaining Valve (PMV) is fitted to ensure that flow

does not commence until the set pressure has been reached, within
10% of normal working pressure.
Functionally the Valve is a sensitive Relief Valve which will commence

to open at the 'set' pressure and any further increase in pressure will
cause the Valve to fully open and give free flow between inlet and
outlet.
Set Pressure: 180 - 270.Bar.G. (10% below Working Pressure)
Should it be necessary to’re-set' the Valve, remove the top cap, two
peg holes provided. Adjust spring loading plate to required setting.
Clockwise rotation to increase and anti-clockwise to decrease.
Replace top cap.
LB BENTLEY LTD 23
OM33030
11. RECOMMENDED SPARES:
11.01. PRE-FILTER MSHP-13N-PF737
i. 1 - Filter Element PF737. LBB 30737-1

ii. 1 - 'O' Ring. LBB 01288
iii. 1 - PTFE Anti Extrusion Ring LBB 01641
iv. 1 - C.N.A.F Washer LBB 00591-8
v 1 - C.N.A.F Washer LBB 01711
11.02. COALESCER FILTER MSHP-13-C534.
i. 1 - Coalescer Element C534 . LBB 00534C

ii. 1 - 'O' Ring. LBB 01405
iii. 1 - PTFE Anti Extrusion Ring. LBB 01834
11.03. DUST FILTER MSHP-13-D534.
i. 1 - Filter Elements. LBB 00534D

ii. 1 - 'O' Ring. LBB 01405
iii. 1 - PTFE Anti Extrusion Ring. LBB 01834
11.04. DRAIN VALVE LBB 5532.
i. 1 - Spares Kit. LBB 06334
11.05. AIR DRYER
i. 4 - Spares Kit K6074. LBB 05476

ii 2 - Non Return Valve/Orifice Service Kit. LBB 06389
iii. 4 - Dryer Vessel 'O' Rings. LBB 01603
iv. 4 - Dryer Vessel Anti Extrusion Rings. LBB 03079
v. 1 - NRV Service Kit LBB 31053
vi. 16 - Bonded Seal LBB 01627
vii. 2 - Spares kit K5797. LBB 04528
viii. 2 - Spares kit K5801. LBB 06334
10Kg Activated Alumina LBB 06059
11.06. PMV TYPE H15 - LBB 1463.
i. 1 - Spares Kit H15. LBB 1445
LB BENTLEY LTD 24
OM33030
C OF G 9.4
786.0
686.0 (Ø14.0 LIFTING HOLES)
(HEIGHT TO 1/2" BSPP INLET)

1608.0
1120.0 (HIGHT TO 3/8" BSPP OUTLET)
1425.0
1346.0
(HEIGHT TO 1/4" BSPP AUTO/MANUAL DRAIN)
C OF G 770.0
661.0
C OF G 394.4
C OF G
455.0 208.0
546.0 (MOUNTING HOLES)
Ø14.0 THRO TYP 4 PLACES
(MOUNTING HOLES)
405.0
UNLESS OTHERWISE STATED: MATERIAL DRAWN DATE

DO NOT SCALE DRAWING ALL DIMENSIONS IN MM. SEE BOM NJO 17/05/10
X.X ±0.5
IF IN DOUBT ASK !!! X.XX ±0.25
SPEC CHKD DATE
X.XXX ±0.13 SEE BOM JCD 25/05/10

ANG. ±0.5° TREATMENT PROD ENG DATE
NJO
0 FIRST ISSUE 25/05/10
CONCENTRICITY WITHIN 0.25 TIR
CHAMFER FIRST THREADS AT 45°
PAINT TO QA PLAN
SIGNATURE SIGNATURE BURRS AND SHARP CORNERS REMOVED WEIGHT SCALE
THIRD ANGLE PROJECTION REV DESCRIPTION OF CHANGE
DATE
REV DESCRIPTION OF CHANGE
DATE TO 0.1 - 0.4 RADIUS OR CHAMFER. 320 KG 0.15:1
WORKING PRESSURE HYD TEST PRESSURE
L.B. BENTLEY LIMITED TITLE : 350 BAR 578 BAR

THIS DRAWING IS THE PROPERTY OF DRYER PACKAGE
L.B. BENTLEY LTD AND IS NOT TO BE
COPIED OR COMMUNICATED TO ANY OTHER BD90-EP350 DRG No. (SHT 1 OF 3)
LONDON ROAD, STROUD, GLOS GL5 2BY MODEL REF:
TELEPHONE: 01453 733060 FAX: 01453 733061 PERSON WITHOUT WRITTEN PERMISSION
LBB33030.iam LBB 33030
26 27 41 60 27 41
38 36 36 38
13
13
36 38
2 1
25
8
41 27 60 6
4
43 3
5
40 22 51
35 42 47
46 35 42
23 39 42 49 35
11
48 35 42 42 68 35
23 39
39 10 24 33
9 14
15 32
39 23
40 61 16
63
38 34 40 22 60
12
31
41 64 65
20 7 32
43
21 41
35 59 42
19 18 29 30 39 27 26 27
70
66
17

20 X.X ±0.5
SPEC CHKD DATE

37 38 37 38 NJO
PAINT TO QA PLAN
DATE

THIS DRAWING IS THE PROPERTY OF
KINGFISHER BUSINESS PARK, L.B. BENTLEY LTD AND IS NOT TO BE
DRYER PACKAGE DRG No. (SHT 2 OF 3)
LONDON ROAD, STROUD, GLOS GL5 2BY COPIED OR COMMUNICATED TO ANY OTHER
MODEL REF:
TELEPHONE: 01453 733060 FAX: 01453 733061 PERSON WITHOUT WRITTEN PERMISSION BD90-EP350 LBB 33030
LBB33030.iam
X.X ±0.5
SPEC CHKD DATE

NJO
PAINT TO QA PLAN
DATE

THIS DRAWING IS THE PROPERTY OF DRYER PACKAGE (SHT 3 OF 3)
COPIED OR COMMUNICATED TO ANY OTHER BD90-EP350 DRG No.
LONDON ROAD, STROUD, GLOS GL5 2BY MODEL REF:
IF IN DOUBT ASK !!! DO NOT SCALE
THIRD ANGLE PROJECTION
A/F
NRV NRV
PG 3 PG4
FO FO
PG2
BDV
control panel MAN PMV1
SET @
180-270 BAR
AD1 PRV 2 AD2
P/F C/F PG1 outlet

inlet
RV 1
SET @ 15BAR
PRV1
V1 V2
7 BAR 7 BAR
SOV
SOV
MAN
MAN V6
V5
PO PO
V3 V4
7 BAR 7 BAR
S1 RV 2
SET @ 10BAR
UNLESS OTHERWISE STATED :- MATERIAL DRAWN DATE

ALL DIMENSIONS IN MM N/A NJO 06/06/10
MACHINED DIMS 0.25 FABRICATED DIMS 3.0 SPEC CHKD DATE
CONCENTRICITY WITHIN 0.25 TIR N/A
NJO JCD 08/06/10
BURRS AND SHARP CORNERS REMOVED TO 0.1 - 0.4 TREATMENT SCALE
SIGNATURE SIGNATURE RADIUS OR CHAMFER N/A
REV DESCRIPTION OF CHANGE DATE REV DESCRIPTION OF CHANGE
DATE # = PART NUMBER AND OTHER IDENTIFICATION HERE N/A
L.B. BENTLEY LIMITED

WEIGHT: TITLE : 350 BAR N/A
N/A DRG No.
KINGFISHER BUSINESS PARK, L.B. BENTLEY LTD AND IS NOT TO BE
P+ID DIAGRAM FOR LBB 33030
MODEL REF:
TELEPHONE: 01453 733060 FAX: 01453 733086
PERSON WITHOUT WRITTEN PERMISSION
LBB33030-1
DRYER TIMING CHART
Dryer LBB 33030

Control Panel LBB 33071
STEP TIME VALVE OUTPUT

V1 V2 V3 V4 V5 V6 7 8
0 10 secs # #
1 10 secs #
2 1 mins 30 secs # #
3 5 secs # # #
4 1 min # #
5 5 secs # # #
6 7 mins #
7 10 secs # #
8 10 secs #
9 1 mins 30 secs # #
10 5 secs # # #
11 1 min 5 secs # #
12 7 mins #
13
14
15
J P Sauer
J30159
Purchase Order – P87387
SSL 08737
20 Minute cycle time
LBB 33030 DRYER PACKAGE BD90-EP350 Page 1 of 3
Drawing No LBB 33030 Drg Revision No 0 Print Date 30/06/2010
Eng Master Revision No 0
Item Description Material Part Qty Units
No Id
001 90.00 mm BORE DRYER VESSEL CARBON STEEL LBB 33034 1.00 ea
(RH)
002 90.00 mm BORE DRYER VESSEL CARBON STEEL LBB 33035 1.00 ea
(LH)
003 MSHP-13N-PF737 PRE-FILTER ALLOY STEEL AISI 4130 LBB 33061 1.00 ea
004 MSHP-13-C534 COALESCER ALLOY STEEL AISI 4130 LBB 33037 1.00 ea
005 MSHP-13-D534 DUST FILTER ALLOY STEEL AISI 4130 LBB 33036 1.00 ea
006 DRYER SUPPORT FRAME BS 4360 GRADE 43A LBB 33031 1.00 ea
007 AIR OP STOP VALVE CARTRIDGE 303 STAINLESS STEEL LBB 06074 4.00 ea
008 DRYER CONTROL PANEL LBB 33071 1.00 ea
009 REGULATOR ASSEMBLY LBB 32244 1.00 ea
010 STOP VALVE (SHUT-OFF TYPE) 316 STAINLESS STEEL LBB 05664 1.00 ea
011 PRESS MAINT VALVE H15 STAINLESS STEEL LBB 01463 1.00 ea
012 RELIEF VALVE TYPE NABIC 542L GUNMETAL LBB 30956 1.00 ea
(CE MARKED)
013 CHECK VALVE (BENTLEY ALUMINIUM BRONZE LBB 05955 2.00 ea
DESIGN)
014 STOP VALVE (CARTRIDGE) 316 STAINLESS STEEL LBB 05801 2.00 ea
015 AIR OP STOP VALVE CARTRIDGE 303 STAINLESS STEEL LBB 05797 2.00 ea
016 AUTO DRAIN MANIFOLD BLOCK 316 STAINLESS STEEL LBB 32625 1.00 ea
017 SILENCER 2" BSPT STEEL / FIBRE LBB 03741 1.00 ea
018 ADAPTOR FEMALE X FEMALE CARBON STEEL LBB 05270 1.00 ea
019 ELBOW FEM X FEM 90° MILD CARBON STEEL LBB 02528 2.00 ea
020 BARREL NIPPLE MILD CARBON STEEL LBB 01846 4.00 ea
021 CONNECTOR TUBE X MALE 316 STAINLESS STEEL LBB 31570 6.00 ea
024 ADAPTOR MALE X MALE ALUMINIUM BRONZE CA123 LBB 04274 1.00 ea
025 ELBOW TUBE X MALE POSN 316 STAINLESS STEEL LBB 32033 1.00 ea
No Id
026 TEE EQUAL TUBE 316 STAINLESS STEEL LBB 31564 2.00 ea
027 TUBE ADAPTER 316 STAINLESS STEEL LBB 33068 4.00 ea
029 ELBOW FEM X FEM 90° STAINLESS STEEL LBB 33066 2.00 ea
030 HEXAGON NIPPLE 316 STAINLESS STEEL LBB 32255 2.00 ea
031 PRESSURE GAUGE 0 - 600 BAR STAINLESS STEEL LBB 31872 2.00 ea
032 ELBOW TUBE X MALE SWIVEL NI PLATED BRASS LBB 05106 6.00 ea
033 TEE EQUAL FEMALE THRD BRASS CZ121 LBB 03961 1.00 ea
034 CAP SCREW M10 A4-70 STAINLESS STEEL LBB 05298 4.00 ea
035 WASHER M8 NOM PLAIN STAINLESS STEEL LBB 04719 24.00 ea
036 HEXAGON SCREW M10 A2 STAINLESS STEEL LBB 06335 7.00 ea
037 HEXAGON BOLT M10 A4 STAINLESS STEEL LBB 04937 4.00 ea
038 WASHER M10 NOM PLAIN A4 STAINLESS STEEL LBB 01692 11.00 ea
039 BONDED WASHER 1/4" BSP NITRILE RUBBER LBB 01625 8.00 ea
042 M8 HEXAGON NUT A2 STAINLESS STEEL LBB 04934 12.00 ea
042 12.00 mm OD x 2.0 mm W TUBE 316 STAINLESS STEEL LBB 76002 72.00 in
316 ST/ST
044 6.00 mm OD x 1 mm W TUBE 316 STAINLESS STEEL LBB 07684 2.00 ft
316 ST/ST
045 LOOSE ACTIVATED ALUMINA ACTIVATED ALUMINA LBB 06059 10.00 kg
046 DRYER 'U' BOLT CLAMP AISI 321 STAINLESS LBB 06266 2.00 ea
047 FILTER 'U' BOLT CLAMP AISI 321 STAINLESS LBB 30928 1.00 ea
049 FILTER U BOLT CLAMP AISI 321 STAINLESS LBB 31016 2.00 ea
050 SILENCER 1/4" BSP SINTERED BRONZE LBB 01887 1.00 ea
051 LABEL (AIR DRYER PACKAGE) 16 SWG STAINLESS STEEL 316 LBB 31218 1.00 ea
052 LABEL WARNING 1.5 MM TRAFFOLITE LBB 05136 1.00 ea
053 CAP SCREW M5 A4-70 STAINLESS STEEL LBB 04248 2.00 ea
054 HEXAGON SCREW M5 A2 STAINLESS STEEL LBB 05656 2.00 ea
056 HEXAGON SCREW M4 316 STAINLESS STEEL LBB 32184 2.00 ea

No Id
057 M4 HEXAGON NUT ALLOY STEEL LBB 04898 2.00 ea
058 WASHER M4 NOM PLAIN ALLOY STEEL LBB 04891 2.00 ea
059 DRYER U BOLT CLAMP AISI 321 STAINLESS LBB 33072 1.00 ea
060 ELBOW UNION TYPE 316 STAINLESS STEEL LBB 31915 3.00 ea
062 REGULATOR MTG BRACKET MILD STEEL LBB 32242-30 1.00 ea
063 ELBOW TUBE X MALE NPT 316 STAINLESS STEEL LBB 05101 1.00 ea
(ORIFICE)
065 GRUB SCREW M12 WITH 316 STAINLESS STEEL LBB 33080 2.00 ea
ORIFICE
066 ELBOW FEM X MALE 90° GALVANISED MILD CARBON STEEL LBB 31533 1.00 ea
067 ORIFICE PLATE BS 970-303 STAINLESS LBB 06312 2.00 ea
069 4.00 mm OD TUBE NYLON YELLOW NYLON LBB 33094 5.00 m
070 BLANKING PLUG 3/4"BSPT 316 STAINLESS STELL LBB 33095 1.00 ea
071 BUTTON HEAD SCREW M5 A2 STAINLESS STEEL LBB 33096 6.00 ea
072 TRUNKING 20MM PLASTIC LBB 33097 1.50 m
073 P CLIP PLASTIC LBB 33098 6.00 ea

A
7 8
SECTION A-A B
CHECK VALVE C
PORT
1/2" BSPP
OUTLET
5 4 6 1 6 4 5 2 7 8
B
A 1265.0
R
80
.0
1/2" BSPP
BLOW DOWN
1/4" BSPP
GAUGE PORT 2 MOUNTING HOLES
M10 EQUI SP
AS SHOWN.
116.0
1/2" BSPP
INLET
V3
VIEW ON ARROW C
V1 UNLESS OTHERWISE STATED: MATERIAL DRAWN DATE
X.X ±0.5
SPEC CHKD DATE

NJO
SECTION B-B SIGNATURE
SIGNATURE BURRS AND SHARP CORNERS REMOVED
PAINT TO QA PLAN
WEIGHT
DW 20/05/10
SCALE
THIRD ANGLE PROJECTION REV DESCRIPTION OF CHANGE REV DESCRIPTION OF CHANGE
(SHOWING PORT POSITIONS) DATE DATE TO 0.1 - 0.4 RADIUS OR CHAMFER. 75.0 KG
WORKING PRESSURE
1:1.5
HYD TEST PRESSURE

KINGFISHER BUSINESS PARK, L.B. BENTLEY LTD AND IS NOT TO BE DRG No.
MODEL REF:
RIGHT HAND BD90 VESSEL
LBB 33034 90.00 mm BORE DRYER VESSEL (RH) Page 1 of 1
No Id
002 DRYER VESSEL BASE (LH) STAINLESS STEEL BS970 303 LBB 31007 1.00 ea
003 DRYER VESSEL HEAD CARBON STEEL 4130 LBB 31005 1.00 ea
004 ANTI-EXTRUSION RING VIRGIN PTFE LBB 03571 2.00 ea
005 O-RING MEDIUM NITRILE LBB 01372 2.00 ea
006 DRYER DIFFUSION PIPE BRASS CZ121 LBB 03554 2.00 ea
007 DRYER VESSEL PLUG 1/2" BRASS CZ121 LBB 03570-3 2.00 ea
A
SECTION A-A B
8
CHECK VALVE C
PORT
1/2" BSPP
OUTLET
4 5 6 1 6 4 5 2 7 8
B
A
1265.0
R
80
. 0
1/2" BSPP
BLOW DOWN
1/4" BSPP
GAUGE PORT 2 MOUNTING HOLES
M10 EQUI SP
AS SHOWN.
116.0
1/2" BSPP V4
INLET
VIEW ON ARROW C
V2 DO NOT SCALE DRAWING ALL DIMENSIONS IN MM. SEE BOM NJO 09/05/10
X.X ±0.5
SPEC CHKD DATE

NJO
SECTION B-B SIGNATURE
SIGNATURE BURRS AND SHARP CORNERS REMOVED
PAINT TO QA PLAN
WEIGHT
DW 20/05/10
SCALE
THIRD ANGLE PROJECTION REV DESCRIPTION OF CHANGE REV DESCRIPTION OF CHANGE
(SHOWING PORT POSITIONS) DATE DATE TO 0.1 - 0.4 RADIUS OR CHAMFER. 75.0 KG
WORKING PRESSURE
1:1.5
HYD TEST PRESSURE

MODEL REF:
LEFT HAND BD90 VESSEL
LBB 33035 90.00 mm BORE DRYER VESSEL (LH) Page 1 of 1
No Id
002 DRYER VESSEL BASE (RH) STAINLESS STEEL BS970 303 LBB 31008 1.00 ea
003 DRYER VESSEL HEAD CARBON STEEL 4130 LBB 31005 1.00 ea
006 DRYER DIFFUSION PIPE BRASS CZ121 LBB 03554 2.00 ea
007 DRYER VESSEL PLUG 1/2" BRASS CZ121 LBB 03570-3 2.00 ea
3 M10 MOUNTING HOLES 340.0
EQUI SP ON A 76.0 PCD
1/2" BSPP
INLET 23.0
TYP
SECTION B-B
1/4" BSPP
DRAIN
Ø116.5
30° B
1/2" BSPP
B OUTLET
1 9 10 11 3 4 8 5 6 7 2

X.X ±0.5
SPEC CHKD DATE

NJO
CONCENTRICITY WITHIN 0.25 TIR PAINT TO QA PLAN DW 12/05/10
STAMP BODY TO P7002 THIRD ANGLE PROJECTION REV DESCRIPTION OF CHANGE
SIGNATURE
SIGNATURE BURRS AND SHARP CORNERS REMOVED WEIGHT SCALE
DATE DATE TO 0.1 - 0.4 RADIUS OR CHAMFER. 18.3 KG 1:1

MODEL REF:
MSHP-13N-PF737 PRE FILTER
LBB33061.iam 83MM NOM BORE LBB 33061
LBB 33061 MSHP-13N-PF737 PRE-FILTER Page 1 of 1
No Id
001 FILTER BODY MSHP ALLOY STEEL AISI 4130 LBB 33063 1.00 ea
002 FILTER HEAD MSHP ALLOY STEEL AISI 4130 LBB 33062 1.00 ea
003 FILTER ELEMENT - PF737 BOROUS SILICATE LBB 30737-1 1.00 ea

(MODIFIED)
004 FILTER ELEMENT SPACER GREY PVC LBB 32239 1.00 ea
005 ELEMENT ROD AISI 321 STAINLESS LBB 06113 1.00 ea
008 WASHER 38.00 mm OD C.N.A.F BS 2815 GR B LBB 00591-8 1.00 ea
009 M8 WING NUT STAINLESS STEEL LBB 02049 1.00 ea
011 WASHER 16.00 mm OD C.N.A.F BS 2815 GR B LBB 01711 1.00 ea

422.0
2 OFF M10
MOUNTING HOLES
ON A 76.0 PCD 23.0 1/2" BSPP
TYP INLET
Ø104.0
1/4" BSPP
DRAIN
A
1/2" BSPP
A OUTLET
1 5 4 6 3 2 SECTION A-A

X.X ±0.5
SPEC CHKD DATE

NJO
0 FIRST ISSUE CONCENTRICITY WITHIN 0.25 TIR PAINT TO QA PLAN DW 12/05/10
SIGNATURE
12/05/10
DATE DATE TO 0.1 - 0.4 RADIUS OR CHAMFER. 19.5 KG 1:1.3

MODEL REF:
COALESCER FILTER
LBB33037.iam (MSHP-13-C534) LBB 33037
LBB 33037 MSHP-13-C534 COALESCER Page 1 of 1
No Id
001 FILTER HEAD MSHP-13 ALLOY STEEL AISI 4130 LBB 33039 1.00 ea
003 FILTER ELEMENT C534 BOROUS SILICATE LBB 00534C 1.00 ea

2 OFF M10
MOUNTING HOLES
ON A 76.0 PCD
422.0
B 23.0 TYP
1/2" BSPP OUTLET
Ø104.0
1/4" BSPP
DRAIN
1 5 4 6 3 2 SECTION B-B
B
1/2" BSPP INLET

X.X ±0.5
SPEC CHKD DATE

NJO
CONCENTRICITY WITHIN 0.25 TIR PAINT TO QA PLAN DW 12/05/10
SIGNATURE
DATE DATE TO 0.1 - 0.4 RADIUS OR CHAMFER. 19.5 KG 1:1.3

MODEL REF:
DUST FILTER
LBB33036.iam (MSHP-13-D534) LBB 33036
LBB 33036 MSHP-13-D534 DUST FILTER Page 1 of 1
No Id
001 FILTER HEAD MSHP-13 ALLOY STEEL AISI 4130 LBB 33038 1.00 ea
003 FILTER ELEMENT D534 BOROUS SILICATE LBB 00534D 1.00 ea

LBB 06074 AIR OP STOP VALVE CARTRIDGE Page 1 of 1
No Id
002 ACTUATOR BODY BS 970-303 STAINLESS LBB 05449 1.00 ea
003 STEM AIR OP PILOT VALVE BS 970-303 STAINLESS LBB 05445 1.00 ea
004 PISTON AIR OP PILOT VALVE BS 970-303 STAINLESS LBB 05446 1.00 ea
005 ACTUATOR CAP BS 970-303 STAINLESS LBB 04415 1.00 ea
006 ACTUATOR SEAL PEEK 450G LBB 04416 1.00 ea
007 ROLL PIN 304 STAINLESS STEEL LBB 04337 1.00 ea
008 DISC SPRING STAINLESS STEEL LBB 04339 8.00 ea
009 ACTUATOR INDICATOR PIN BS 970-303 STAINLESS LBB 04425 1.00 ea
010 GRUB SCREW M4 316 STAINLESS STEEL LBB 04374 1.00 ea
011 O-RING VITON A LBB 04841 4.00 ea
014 O-RING NBR 70 BS 2751 LBB 04426 1.00 ea
016 CIRCLIP EXTERNAL STAINLESS STEEL LBB 05153 1.00 ea

LBB 32119 REGULATOR ASSEMBLY Page 1 of 1
No Id
001 PRESSURE GAUGE 0 - 10 BAR BLACK FINISH STEEL LBB 03198 1.00 ea
002 PRESSURE GAUGE 0 - 20 BAR BLACK FINISH STEEL LBB 03509 1.00 ea
003 PRESSURE REGULATOR 316 STAINLESS STEEL LBB 32094 1.00 ea
004 RELIEF VALVE (CE MARKED) BRASS LBB 30850 1.00 ea
006 ADAPTOR TUBE X MALE 316 STAINLESS STEEL LBB 31132 1.00 ea
008 ELBOW TUBE X MALE 90° NI PLATED BRASS LBB 06394 1.00 ea
009 INLINE FILTER STAINLESS STEEL LBB 31131 1.00 ea
010 END PLUG 1/4" NPT 316 STAINLESS STEEL LBB 04277 1.00 ea
011 1/4" OD x 16 SWG TUBE 316 316 STAINLESS STEEL LBB 07673 0.50 ft
ST/ST
012 TEE UNEQUAL 316 STAINLESS STEEL LBB 32120 1.00 ea
2
11 5
5
7 BAR OUTLET
12
MAX 400 BAR INLET
3 10
MATERIAL DRAWN DATE
UNLESS OTHERWISE STATED :-
ALL DIMENSIONS IN MM SEE BOM MH 17/02/06
NJO MACHINED DIMS 0.25 FABRICATED DIMS 3.0
1 400 BAR WAS 450 BAR 11/06/10 CONCENTRICITY WITHIN 0.25 TIR
SPEC CHKD DATE
MH JCD 22/02/06
BURRS AND SHARP CORNERS REMOVED TO 0.1 - 0.4 TREATMENT SCALE
SIGNATURE
DESCRIPTION OF CHANGE SIGNATURE RADIUS OR CHAMFER 1:1
REV DESCRIPTION OF CHANGE REV
DATE DATE # = PART NUMBER AND OTHER IDENTIFICATION HERE
L.B. BENTLEY LIMITED TITLE : 400 BAR MAX N/A
FROMEHALL WORKS, STROUD, GLOUCESTERSHIRE, THIS DRAWING IS THE PROPERTY OF
L.B. BENTLEY LTD AND IS NOT TO BE Model LBB32119.ipt HIGH PRESSURE REGULATOR ASSY DRG No.
GL5 3EH COPIED OR COMMUNICATED TO ANY OTHER
LBB 32244
NOTES:
1). TIGHTEN ITEM2 INTO ITEM 1 TO 80lbs/FT

(MIN) TORQUE, SEAL ITEM 2 TO ITEM 1
USING LOCTITE "STUD LOC" 270, PRE 2 HOLES
M6 x 10 DEEP
SPRAY ITEMS 1 AND 2 WITH ACTIVATOR 7471.
2). FIT ITEM 4 TO ITEM 2 WITH LOCTITE 243,
6
PRE-SPRAY WITH ACTIVATOR 7471.
3). ASSEMBLE ITEMS 4, 7 AND 9 TO ITEM 3
PRIOR TO ASSEMBLING ITEMS 6 AND 10 TO
ITEM 3.
HOLE
n2.50
SEE NOTE 3
4). VIBRO-ETCH PART No LBB 5664 ON OPPOSITE 10
=
19.00
FACE TO FLOW DIRECTION ARROW AND
PRESSURE RATING, SEE NOTE BELOW.
=
5.00
5). PRESSURE TEST VALVE TO Q3075.
4
6). PANEL MOUNT HOLE n21.00.

8
7
9
= =
2 19.00
3
MOUNTING HOLE DETAILS

(Scale 2:1)
1/4" BSPT 1/4" BSPT

OUTLET INLET
5 1
MWP 400 BARG

65.00
ENGRAVING DETAILS UNLESS OTHERWISE STATED :-

MATERIAL
STAINLESS STEEL
DRAWN DATE
MH 24/04/07
4 REDRAWN MH
24/04/07
ALL DIMENSIONS IN MM
MACHINED DIMS `0.25 FABRICATED DIMS`3.0
SPEC CHKD DATE
CONCENTRICITY WITHIN O.25 TIR
MFW 24/04/07
0 FIRST ISSUE SNT
22/04/98
BURRS AND SHARP CORNERS REMOVED TO 0.1-0.4
RADIUS OR CHAMFER TREATMENT SCALE
=PART NUMBER AND OTHER IDENTIFICTION HERE
SIGNATURE
DATE
SIGNATURE
DATE
3:1
WORKING PRESURE HYD TEST PRESSURE
TITLE SEE ABOVE SEE ABOVE
FROMEHALL WORKS, STROUD, GLOUCESTERSHIRE,
ASSEMBLY OF 1/4" BSPT STOP VALVE DRG No.
LBB 5664
LBB 05664 STOP VALVE (SHUT-OFF TYPE) Page 1 of 1
No Id
001 VALVE BODY SHUT-OFF VAL BS 970-316-S11-AV STAINLESS LBB 05665 1.00 ea
002 THREADED INSERT STOP VAL 22% CR DUPLEX M3010/01 LBB 05883 1.00 ea
003 VALVE STEM SHUT-OFF VAL BS 970-316-S11-AV STAINLESS LBB 05535 1.00 ea
004 VALVE BONNET SHUT-OFF VAL BS 970-316-S11-AV STAINLESS LBB 05536 1.00 ea
005 VALVE SEAT SHUT-OFF VAL PEEK LBB 05537 1.00 ea
006 ADJUSTER KNOB STOP VAL BLACK THERMOPLASTIC LBB 05538 1.00 ea
007 THRUST BEARING NEEDLE VAL DELRIN ACETAL LBB 02441 1.00 ea

4
2
B 6
SECTION A-A
A
JCD MATERIAL DRAWN DATE
9 2 RE-DRAWN 2/12/03
UNLESS OTHERWISE STATED :-
ALL DIMENSIONS IN MM SEE BOM SNT 4/1/99
AC
1 PICTORIAL CHANGE 30/7/99
MACHINED DIMS `0.25 FABRICATED DIMS `3.0 SPEC CHKD DATE
DETAIL B (Scale 2:1) 0 FIRST ISSUE SNT

CHAMFER FIRST THREADS AT 45° SNT 4/1/99
11/1/99 BURRS AND SHARP CORNERS REMOVED TO 0.1 - 0.4 TREATMENT SCALE
REV SIGNATURE
SIGNATURE RADIUS OR CHAMFER 1:1
DESCRIPTION OF CHANGE DATE
DATE # = PART NUMBER AND OTHER IDENTIFICATION HERE
WORKING PRESURE HYD TEST PRESSURE
TITLE 400 BarG 600 BarG
FROMEHALL WORKS, STROUD, GLOUCESTERSHIRE,
NON RETURN VALVE / PURGE ORIFICE DRG No.
LBB 5955
LBB 05955 CHECK VALVE (BENTLEY DESIGN) Page 1 of 1
No Id
001 SPRING HOUSING CHECK VALVE ALUMINIUM BRONZE CA129 LBB 05956 1.00 ea
002 SPOOL HOUSING CHECK VALVE BRASS CZ121 LBB 05957 1.00 ea
003 ORIFICE PLATE BS 970-316-S31 STAINLESS LBB 04058 0.00 ea
004 FILTER ELEMENT H.D. POLYETHELENE LBB 05874 1.00 ea
005 SPRING STAINLESS STEEL LBB 06221 1.00 ea
006 ORIFICE NUT STAINLESS STEEL LBB 02724 1.00 ea
008 BONDED WASHER 1.1/4" BSP NITRILE RUBBER LBB 01630 1.00 ea
009 WASHER 8.00 mm OD COPPER LBB 02725 2.00 ea

LBB 05797 AIR OP STOP VALVE CARTRIDGE Page 1 of 1
No Id
002 ACTUATOR BODY BS 970-303 STAINLESS LBB 04422 1.00 ea
003 STEM AIR OP PILOT VALVE BS 970-303 STAINLESS LBB 05613 1.00 ea
004 PISTON AIR OP PILOT VALVE BS 970-303 STAINLESS LBB 05614 1.00 ea
005 ACTUATOR CAP BS 970-303 STAINLESS LBB 04424 1.00 ea
006 ACTUATOR SEAL PEEK 450G LBB 04336 1.00 ea
008 DISC SPRING STAINLESS STEEL LBB 04339 8.00 ea
009 ACTUATOR INDICATOR PIN BS 970-303 STAINLESS LBB 04425 1.00 ea
010 GRUB SCREW M4 316 STAINLESS STEEL LBB 04374 1.00 ea
016 CIRCLIP EXTERNAL STAINLESS STEEL LBB 05153 1.00 ea

LBB 05801 STOP VALVE (CARTRIDGE) Page 1 of 1
No Id
002 THREADED INSERT STOP VALVE BS 970-316-S11-AV STAINLESS LBB 05534 1.00 ea
003 VALVE STEM SHUT-OFF VALVE BS 970-316-S11-AV STAINLESS LBB 05535 1.00 ea
004 VALVE BONNET SHUT-OFF BS 970-316-S11-AV STAINLESS LBB 05536 1.00 ea

VALVE
005 VALVE SEAT SHUT-OFF VALVE PEEK LBB 05537 1.00 ea
006 ADJUSTER KNOB STOP VALVE BLACK THERMOPLASTIC LBB 05538 1.00 ea
007 THRUST BEARING NEEDLE DELRIN ACETAL LBB 02441 1.00 ea

VALVE
011 PANEL LOCKNUT BRASS LBB 05541 1.00 ea

PARTS LIST: LBB 05801
MANUAL STOP VALVE CARTRIDGE
ITEM 6
ADJUSTER KNOB
LBB 05538
ITEM 4
VALVE BONNET
LBB 05536
ITEM 8
O-RING SPARES KIT LBB 06334
LBB 05152
CONTENTS:
ITEM 10
ROLL PIN ITEM 5 - LBB 05537
LBB 05540
ITEM 7 - LBB 02441
ITEM 11 ITEM 8 - LBB 05152
PANEL LOCKNUT ITEM 9 - LBB 02443
LBB 05541
ITEM 10 - LBB 05540
ITEM 2
THREADED INSERT
LBB 05883
ITEM 9
O-RING
LBB 02443
ITEM 7
THRUST BEARING
LBB 02441
ITEM 3
VALVE STEM
LBB 05535
ITEM 5
VALVE SEAT
LBB 05537

V6977-Z-MA-001 - Compressors & Standby APVs - QGOG 2 (HN 1908) Drillship - User Manual - Rev 0 PDF

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Document number V6977-Z-MA-001 TOC

TABLE OF CONTENTS Revision: 0

Vol. Section Title Add. code Rev. Document number

6 Spare Parts List

7 Drawings & Parts Lists

7.1 General Arrangement Drawing

7.2 Flow Diagram

7.3 Block Diagram

7.4 Termination Drawing

7.5 Loop Diagram

7.6 Layout Drawing

Vol. Section Title Add. code Rev. Document number

7.6 Layout Drawing

R5461 QGOG 2 (HN 1908)

Vol. Section Title Add. code Rev. Document number

R5461 QGOG 2 (HN 1908)

Vol. Section Title

R5461 QGOG 2 (HN 1908)

Vol. Section Title Add. code Rev. Document number

R5461 QGOG 2 (HN 1908)

RIG/PLANT REFERENCE REFERENCE DESCRIPTION

CLIENT DOCUMENT NUMBER DOCUMENT NUMBER REV

1. A Compact four stage direct drive high-pressure compressor

Classification: DNV Class II

3 DELIVERY SCOPE OF COMPRESSOR SKID PARTS & FUNCTIONS:

Standard Compressor only includes:

Three phase IEC E-motor size 225M 4 pole Continuous (S1):

3.1 Electrical Control Panel

Supply: 440V/ 60 Hz / 3Ph

3.1.1 Operation, Monitoring and Indication

Potential free signals: Running, Off, collective alarm/trip(s)

3.2 HP Air Dryer

Operation Fully automatically continuous operation,

3.3 Test and certificates:

Works test for the compressor and motor

4 DESCRIPTION OF COMPRESSOR SKID FUNCTIONS

4.1 Air Compression System.

4.2 Water Cooling System.

4.3 Oil/Water Removal.

4.4 Air Intake Filtration/Silencing.

Air is filtered at the inlet to the compressor.

4.6 Electric Motor

4.7 Compressor Control Panel.

4.8 Compressed Air Dryer

Vol. Section Title

R5461 QGOG 2 (HN 1908)

Vol. Section Title

R5461 QGOG 2 (HN 1908)

Vol. Section Title Add. code Rev. Document number

6 Spare Parts List

R5461 QGOG 2 (HN 1908)

Vol. Section Title

7 Drawings & Parts Lists

R5461 QGOG 2 (HN 1908)

Vol. Section Title Add. code Rev. Document number

7.1 General Arrangement Drawing

R5461 QGOG 2 (HN 1908)

1. Hyd. Flow diagram: V6977-D1157-H0001, V6977-D1157-H0002

2. El. diagram: V6977-D1157-E0001

3. Selector Panel & Pressure Switch: V6977-D1157-G0305

4. For detail information see separate reference list.

0 24.04.2012 For Information TOVI THRO MORA

General Arrangement Drawing