Servicing and operating manual

Reciprocating compressors
HL series
General information
Table of contents Page
Safety instructions 3
Function description 4
Installation 5
Operating 6
Commissioning 7
Servicing 8
Troubleshooting 10
Servicing intervals 11
Technical data for the units 12
Technical data for the tank systems 13
Completed servicing work 14
To maintain the high availability of your reciprocating compressor we
recommend that you keep a set of servicing and wear parts in stock.
Our after-sales team p will be delighted to help you selecting your
spare parts.
p On the reverse of this brochure you will find our address, telephone
number and fax number.
p If you have any questions, particularly for ordering spare parts, please
quote the data shown on the system model plate (on the bottom of
the casing).
F Symbol for instructions that must be obeyed.
Transport information:
Only transport the compressor with a hand truck or forklift truck.
2
Individual machine data:
Model: HL
Machine No.:
System with the following design/options
that differ from the standard:
General information
This servicing and operating manual contains information that
you will require to ensure the perfect, trouble-free operation of
your reciprocating compressor. Read this manual carefully before
commissioning the compressor because damage caused by incorrect
handling of the compressor is not covered by the warranty.
F Directives, use and safety instructions
This compressor complies with the EC Machine Directive
89/392 EEC. All the details for noise emissions comply with
the Third Directive for the Equipment Safety Law dated 18
January 1991 and the EC Machine Directive, Appendix I,
Section 1.7.4.ff. The system is designed to be state of the
art and complies with the acknowledged safety regulations.
Nevertheless its use may result in risks for users or third
parties and damage to the system and other property.
The system is designed exclusively for the compression of air.
No other use is permitted. The manufacturer cannot accept
liability for damage resulting from other uses.
THESE BRIEF SAFETY INSTRUCTIONS DO NOT RELEASE USERS
FROM THEIR OBLIGATION TO COMPLY PRECISELY WITH THE
FOLLOWING DETAILED INSTRUCTIONS!
 Safety instructions

F1. Safety instructions 1.2 Safety instructions before commissioning

1.1 Safety instructions and compressor function
Only trained personnel who have been authorised by the operator
may be commissioned with the installation, operation and servicing of
the compressor system and they must have read and understood the
complete servicing and operating manual. Unauthorised modifications
and changes that affect the safety level of the reciprocating compressor
are not permitted.
All work on the compressor is only to be completed when the
compressor is at a standstill, has been disconnected from the mains
supply and depressurised. The compressor system is to be secured to
prevent its being switched on again without authorisation.
F The permitted compressor chamber temperature is +5°C to
+35°C. The electrical connection of the system may only be made by
an authorised electrician. Check the conformity of the current type,
voltage and frequency with the system data. The power supply lead
must be designed and fused to suit the electrical connection data on
pages 12, 13.
1.3 Safety instructions during commissioning
F Check the oil level on the oil window or using a dipstick (see 5.1).
Check that the electric motor is turning in the correct direction (see
the arrow on the belt safety grille) when it starts. For this purpose the
compressor system should be switched on and off again briefly.

Danger!
The belt safety grille and noise reduction hood on the
compressor system are designed to prevent contact and
may not be removed until the above measures have been
completed.
1.4 Safety action for servicing and operating the
system
All work must be completed with the machine at a standstill and
depressurised. Switch off the main switch and secure it to prevent its
being switched on again. Close the shut-off valve to the compressed air
line (tank). Check the oil level when the compressor has warmed up.

Important. Do not drain compressed air condensate into the

sewer without prior treatment (see 3.4).

3 5 8 15
2 stage unit

9 14

2
10 10
28 18
7 10 19
1 24
4 20
23
13 21
25
22
26

11 12
27 6 27

1 Motor 12 Oil dipstick and oil filler cap 21 Non-return valve

2 Belt pulley 13 Intermediate cooler / cooling pipe 22 Start-up relief and condensate
3 V-belt (from four cylinder block cooler) drain valve SMV
4 Compressor 14 Thermometer for first stage 23 Drain valve SMV (final cooler)
5 Safety valve (from 20 kW) 24 Final cooler / cooling pipe
6 Thermometer for second stage 15 Crank casing for ventilation line (from four cylinder block cooler)
(from 20 kW) 16 Safety valve – first stage 25 Oil drain cock
7 Second compression stage 18 Start-up relief and condensate drain 26 Compressor system model plate
8 Compressed air manifold valve OMV 27 Vibration dampers (accessories)
9 Air filter 19 Thermometer for compressed air outlet 28 Control cabinet with star-delta switch
10 First compression stage (from 20 kW) and hour counter
11 Compressor model plate 20 Final pressure gauge (standard from 7.5 kW)

3
Function description

2. Function description 2.2b The airway (two-stage, 10 – 35 bar)

2.1 The drive
The electric motor drives the compressor via the belt pulleys and the
V-belt.
2.2a The airway (single stage, 10 bar)
The ambient air gets into the compression chamber through the air
filter(s). The air inlet and outlet is controlled by the inlet/outlet valve in
the cylinder head. After the compression process the hot compressed air
flows into the air manifold and into the final cooler (cooling pipe). The
compressed air leaves the compressor through the non-return valve.
The ambient air gets into the compression chamber through the
air filter(s). The air inlet and outlet is controlled by the inlet/outlet
valve in the cylinder head. After the first compression process the hot
compressed air flows into the air manifold and into the intermediate
cooler (cooling pipe). From there the compressed air flows into the
high pressure cylinder where it is compressed to the final pressure. The
compressed air leaves the compressor through the non-return valve.
2.3 Safety valves
The reciprocating compressor is protected against excess pressure
by a safety valve. On two-stage systems there is another safety valve

1-stage tank system

15
2 8
5
3
9
10 11
28 10 24

18
4 12
1
25
20 21
26

33

30

31 32

27

1 Motor 12 Oil dipstick and oil filler cap 27 Vibration dampers (accessories)
2 Belt pulley 15 Crank casing for ventilation line 28 Control cabinet with star-delta switch
3 V-belt 18 Start-up relief and condensate drain and hour counter
4 Compressor valve OMV (standard from 7.5 kW)
5 Safety valve 20 Final pressure gauge 30 Compressed air tank
8 Compressed air manifold 21 Non-return valve 31 Tank hand hole
9 Air filter 24 Final cooler / cooling pipe 32 Tank condensate drain
10 First compression stage 25 Oil drain cock 33 Pressure switch
11 Compressor model plate 26 Compressor system model plate

4
 Installation

between the first and second stage to protect the intermediate pressure.
This is calibrated to the appropriate maximum pressure and sealed to
prevent its being adjusted unintentionally.
The seal must not be removed. The manufacturer cannot accept any
liability for damage caused by removing the seal.
2.4 Pressurised tank (tank systems only)
Pressurised tanks are subject to the Pressurised Tank Directive and
must be registered with the local monitoring authorities (for example
TÜV) using the test certificates provided.
Keep these test certificates safely.
3.2 Pneumatic connection
Reciprocating compressors are supplied ready for connection. The
connection to the pipework may only be made using flexible hose
so that the compressor can be installed without casing stress in the
pipework. The end of the pipe on the compressed air system must be
properly secured.
A non-return valve between the compressed air line or compressed air
tank and the compressor is already integrated in your reciprocating
compressor. A shut-off device must be fitted in the compressed air line
so that the reciprocating compressor can be disconnected from the
compressed air system.

3.3 Electrical connection

3. Installation
3.1 General information
F The compressor is mounted on a sturdy frame. A flat, solid floor is
required for its installation. Vibration dampers must be used to reduce
vibration. The reciprocating compressor is to be placed in a cool, dry,
dust-free room with good ventilation. The room temperature must not
fall below 5°C and should not exceed +35°C. If the room temperature
is below 5°C the compressor room is to be fitted with a temperature
control system. In adverse conditions, the warm flue air is to be removed
through flue air ducts or blowers and an adequate fresh air supply is
to be provided. The installation site should offer easy access.
F The electrical connection of the system may only be made by an
authorised electrician who must check the conformity of the current
type, voltage and frequency with the data on the model plate. In
particular the technical connection conditions of the local electricity
supply company must be complied with.
The size of the power supply lead and the fuse must comply with IEC
60 364. See pages 12, 13.
For power units the supplied pressure switch must be connected to
the compressed air tank.

Important – Compressors without noise reduction hoods

must be installed in a separate room. Ear protection is to
be worn.

1-stage unit 10 bar 2-stage unit 10 - 35 bar

1 4
5

4 3 2
2
6
1

7
8 11 12 7

8 11 12
9 13
10 9 13
10
14
14

1 Inlet filter 6 Safety valve for second stage 10 Compressed air tank
2 First compressor stage 7 Final cooler 11 Pressure gauge
3 Second compressor stage 8 Pressure relief valve and 12 Safety valve
4 Safety valve for first stage condensate drain 13 Compressed air outlet with shut-off cock
5 Intermediate cooler 9 Non-return valve 14 Condensate drain on compressed air tank

5
Operation

3.4 Condensate disposal 4. Operation

Cooling the compressed air in the cooler produces condensate that is
drained automatically when the line pressure is released after it cuts 4.1 Control elements
out automatically when it reaches the final pressure. Compressors with a star-delta control cabinet (optional) have the
following control elements:
Important: After it reaches the final pressure the system will
release the pressure automatically. During this pressure relief
process the condensate line will be pressurised briefly.
Main switch
Hour counter Operating lamp
In addition the condensate that forms in the tank must be Start-Stop button
drained at regular intervals. This condensate contains oil and
must not be drained straight into the sewer without first
undergoing treatment (oil – water separation p).

Connection of units to a separate compressed air tank

Line pressure switch 35 bar compressors that are equipped with a control cabinet without
a star-delta switch have an On-Off switch on the control cabinet with
Control line
a switch contactor.
The control elements on 10 and 15 bar compressors without a star-
Outlet line delta switch (machines that can be switched on direct) are on the
actual pressure switch.
If the control cabinet has not been sourced from us, the compressor
will be controlled by the site control cabinet.

CAUTION: IF THE COMPRESSOR HAS BEEN SWITCHED ON IT

MAY START AUTOMATICALLY.

4.2 Shut-down
The compressor cuts out when it reaches the final pressure set on the
pressure switch and cuts in again automatically when the pressure falls
below the line pressure set on the pressure switch.

6

5. Commissioning
5.0 General instructions
Before you commission the system check the following points.
5.1 Check the oil level
The oil level must be checked every day at the oil window or oil dipstick
(see illustration on page 8). The minimum oil level must always be
above the bottom of the red circle / bottom mark on the oil dipstick.
You must top up the system with fresh oil before the oil level reaches
this mark.
Error lamp RESET button
We recommend that you use the OIL LEVEL CONTROL (optional as from
4 kW and in conjunction with a control cabinet with a star-delta switch)
to monitor the oil level and prevent the compressor being damaged
due to a lack of oil. A sensor that uses the calorific principle is screwed
into the crank casing instead of the oil dipstick and is immersed in the
oil. As soon as this sensor is no longer covered by oil a signal is sent to
the electronic evaluation system that triggers an error signal (the red
lamp is lit) and shuts down the compressor. After eliminating the error
by topping up the oil and pressure the Reset button, the compressor
can be restarted.
Commissioning
5.2 Oil quality
F Do not mix different types of oil. If you use different types of
lubricant, contact our after-sales team p.
Only if you use verifiably equivalent lubricants can we offer a warranty
for our compressors.
Our special oil has been specially developed for heavily used compressors
and is suitable for all reciprocating compressors. This special oil has a
viscosity of 60 mm+/s at a temperature of 50°C. It is suitable for high
temperatures and ideal for permanent operation.
Our special oil quality 3 is a synthetic oil for heavy use single-stage
compressors with very high thermal stresses. Before use the compressor
must be flushed out with this oil and the oil window must be replaced
with a version that is resistant to synthetic oil. Precise instructions are
available from our after-sales team p.
5.3 Direction of rotation of the motor (see 1.3)
F The direction of rotation must comply with the arrows on the belt
safety grille and the electric motor. To check the direction of rotation
the system must be switched on and off again briefly to ensure that
the compressor does not suffer any damage. The direction of rotation
can be changed by swapping two supply cables.
5.4 Starting
Before switching on the system ensure that nobody is in danger. The
belt safety grille and noise reduction hood act as contact guards and
may only be removed when the compressor is at a standstill, has been
disconnected from the power supply and depressurised. Open the
shut-off slide valve between the system and the compressed air line
(tank). Connect the system to the line.
Switch on the main switch and press the green Start button.
IMPORTANT. THE COMPRESSOR MAY START AUTOMATICALLY
AT ANY TIME ONCE THE START BUTTON HAS BEEN PRESSED.
Pressurised lines are to be checked for leaks. When it reaches the final
pressure the system will cut out.
5.5 Stopping
Press the red Stop button.
The white operating lamp will go out and the compressor cuts
out.F Only press the EMERGENCY STOP main switch in an
emergency.
The system may otherwise only be switched off using the red Stop
button.
5.6 Air filters
When the air filters are soiled, depending the type of use, they must
be replaced. If the compressor is fitted with wet air filters, these must
be immersed in oil before they are used for the first time.
7
Servicing

6. Servicing the system
6.1 General information
All servicing work must be completed in compliance with the local
health and safety regulations.
In addition servicing work may only be completed by trained perso-
nnel (ask our after-sales team about training courses p) when the
compressor system has been switched off, has reached a standstill and
has also been depressurised.
The compressor must be secured to prevent its being switched on again
without authorisation.
6.2 Cleaning and checking
The valves must be checked after 2,000 to 5,000 hours and replaced
if they are defective. When you install them ensure that you do not
correctly. If heavy oil carbon deposits are found when the compressor
is exposed to normal loads, check the oil and, if necessary, replace
it with a more suitable oil. Information on this is available from our
after-sales team p.
The cooling ribs on the cylinder heads and cooling system are to be
checked at regular intervals and any deposits are to be removed from
them if necessary.
6.5 Changing the oil and cleaning the cooling
pipe / cooler
The oil is to be changed and the cooling pipe / cooler cleaned (when
dirty) as set out in the servicing interval table (page 11). The oil volumes
required are listed on pages 12, 13. If you use different lubricants please
contact our after-sales team p.
Only if you use verifiably equivalent lubricants can we offer a warranty
for our compressors.
6.6 Changing the oil when the compressor is
warm
Change the oil by draining the oil through the oil drain cock / oil drain
screw into a suitable vessel. After this close the oil cock / oil drain
screw again and pour oil of a suitable quality into the oil filler neck up
to the top mark on the oil window (see illustration) or up to the top
mark on the oil dipstick. When the compressor has reached operating
temperature check for leaks. Dispose of the old oil as special waste.
Oil window

6.3 Belt drive

When you replace the V-belts you must replace all the belts at the same
time. To do this, push the electric motor towards the compressor after Max.
released the motor tensioning device. Place the new V-belts over the
V-belt pulley in sequence and tensioned by pulling back the electric Min.
motor with the tensioning device.

6.4 Condensate
Cooling the compressed air results in the formation of condensate in
the cooler. The condensate is drained during the drainage phase when
the compressor is at a standstill through the SMV solenoid valve. The Oil dipstick
condensate must be collected and disposed of as described in 3.4.

IMPORTANT: On two-stage systems that are not operated at

full load condensate is also formed in the crank casing. If the
oil level rises and the compressor only runs briefly, switch it
off and take a specimen of the oil. If there is condensate in the
oil contact our after-sales team p to select a more suitable Max.
oil. Remove the condensate by cover the cooler in stages, or
by wrapping spiral rib cooling pipes. Until the problem has Min.
been remedied, change the oil after every 30 hours.

8
 Servicing

6.7 Safety valves 6.9 Air filter servicing

The function of the safety valves must be checked at regular intervals.
This check is to be conducted at a line pressure of at least 85% of the
trip pressure of the safety valve. To do this the safety valve is to be
turned anti-clockwise several turns until the valve blows off and then
turned clockwise again until the valve is sealed again.
If the valve is obviously dirty or the seal is damaged the safety valve
must be replaced. To do this clean the screw-in thread and screw in
the new safety valve with sealing tape or sealing compound. When it
has reached operating temperature check for leaks.
6.9.1 To clean a wet air filter
(standard up to 11 kW)
The filter requires servicing if there is a visible build-up of dust on the
surface of the filter. Remove the filter and take off the cap. Wash out
the filter in a suitable fluid and dry it. (Caution: do not use petrol – risk
of explosion). Immerse the filter insert in fresh oil and leave to drip for
20 to 30 minutes before installing it.

Wet air filter

Safety valve

6.9.2 To clean a dry air filter

(standard as from 15 kW)
Check the filter every 100 hours for signs of damage and dirt. If it is
damaged the filter insert must be replaced immediately, otherwise,
depending on how dirty it becomes, replace it every 500 to 2,000
hours since otherwise it will reduce the delivery rate.

Dry air filter

6.8 Line pressure switch

The line pressure switch setting depends on the compressor type. A
precise description is provided with the relevant pressure switches.
The pressure is to be read off the pressure gauge to achieve a precise
adjustment. To do this build up pressure slowly at the air outlet by
throttling until the cut-out pressure is reached (read off the gauge) and
then release the pressure slowly until the cut-in pressure is reached.

IMPORTANT. Only make this adjustment when the system is

pressurised.

Line pressure switch 10 – 15 bar Line pressure switch 35 bar

9
Troubleshooting
Error Cause
7.1 System does not start when - Line pressure still too high
you press the green Start - Line pressure set too high
button - Line pressure switch defective
- Control power circuit broken
- No voltage at the compressor
- Electrical error in the controller
- Control fuse defective
7.2 Line pressure drops - Air filter (cartridge) dirty
- Cylinder head seal defective
- Valve fault
- Pistons, piston rings or cylinders defecti- - Send in the compressor to be repaired
ve
- Compressed air consumption higher
- Leaks in the line
- Solenoid valve does not close
7.3 Compressor safety valve or - Flow to the tank defective
tank safety valve blows off
- Line pressure set too high
- Safety valve defective
7.4 Strange noises - V-belts loose
- Belt safety grille loose
- Piston striking valve head
- Piston rod out of its mountings
- Bearing defective
- Non-return valve defective
7.5 Compressed air escapes - Non-return valve (seat) defective
when the compressor is at a
standstill
7.6 Compressed air escapes - Pressure release valve seat defective
whilst the compressor is
operating
7.7 Electric motor (7) becomes - Too frequent switch cycles
hot
- Inadequate air supply
10
Action Section
- Watch line pressure indicator
- Reset line pressure switch 6.8
- Replace line pressure switch 6.8
- Check with the circuit diagram
- Check with the circuit diagram
- Check with the circuit diagram
- Check with the circuit diagram
- Wash wet air filter 6.9.1
- Replace dry air filter cartridge 6.9.2
- Fit a new seal
- Replace the valve plate 6.2
- You require a compressor with a higher
delivery rate p
- Seal the line
- Clean or replace
- Check for blocked cooler / pipe 6.5
- Check non-return valve
- Reset line pressure switch 6.8
- Replace safety valve 6.7
- Retension V-belts 6.3
- Secure belt safety grille
- Remove foreign bodies
- Send the compressor for repair
- Send the compressor for repair
- Replace non-return valve
- Clean valve seat or replace the valve
- Replace the valve
- Reduce switch cycles, increase tank
volume with a larger or additional
tank p
- Improve ventilation and venting
 Servicing intervals

Servicing and inspection of the compressor Before Every Every After After Every ... hours
commissining day week 50 hours 150 hours
100 500 2,000 10,000
Check direction of rotation
Oil level
Condensate formation
Tighten electrical connections
Check for condensate in the oil
Tighten screw connections
First oil change
Second oil change
Further oil changes
Check air filter
Clean or replace air filter
Check valves/pistons/cylinders/safety valves
Check and, if required, change V-belt
Overhaul compressor

11
Technical data for the units

Model Motor- Number Dimensions Weight Oil tank Currents at 400V/50Hz Maximum Compressed
rating of switch cycle air
capacity Overcurrent Site back-up
cylinders relay setting fuse connection

Direct Star Direct Star

L B H I(nenn)
start-up Delta start-up Delta

kW mm mm mm kg l A A A AgL AgL 1/h G

10 bar,
1-stage
HL 081012 4,0 2 1110 480 720 130 1,4 8,5 9,4 5,4 20 16 55 1
/2
HL 091012 5,5 2 1110 480 720 160 1,4 11,4 12,5 7,3 25 16 55 1
/2
HL 131013 7,5 3 1360 500 720 210 1,9 16,0 – 10,2 – 20 55 3
/4
HL 181013 11,0 3 1360 590 720 230 1,9 22,0 – 14,0 – 35 40 3
/4
HL 211014 11,0 4 1560 640 740 320 2,2 22,0 – 14,0 – 35 40 1
HL 221014 15,0 4 1615 640 740 330 2,2 28,5 – 18,2 – 50 30 1

15 bar,
2-stage
HL 051522 4,0 2 1110 480 720 135 1,4 8,5 9,4 5,4 20 16 55 1
/2
HL 081523 5,5 3 1110 480 720 165 1,9 11,4 12,5 7,3 25 16 55 3
/4
HL 101523 7,5 3 1360 500 720 168 1,9 16,0 – 10,2 – 20 55 3
/4
HL 131523 11,0 3 1360 590 720 185 2,2 22,0 – 14,0 – 35 40 3
/4
HL 151524 11,0 4 1560 640 740 320 2,2 22,0 – 14,0 – 35 40 1
HL 201524 15,0 4 1615 640 740 340 2,2 28,5 – 18,2 – 50 30 1
HL 221524 15,0 4 1865 650 800 410 3,4 28,5 – 18,2 – 50 30 1 1/2
35 bar,
2-stage
HL 023522 2,2 2 1110 480 720 90 0,5 4,8 5,3 – 16 – 55 1
/2
HL 033522 3,0 2 1110 480 720 95 0,5 6,8 7,5 – 16 – 55 1
/2
HL 043522 4,0 2 1110 480 720 145 1,4 8,5 9,4 5,4 20 16 55 1
/2
HL 053522 5,5 2 1110 480 720 155 1,4 11,4 12,5 7,3 25 16 55 1
/2
HL 083523 7,5 3 1360 500 720 220 1,9 16,0 – 10,2 – 20 55 3
/4
HL 103523 11,0 3 1360 590 720 220 1,9 22,0 – 14,0 – 35 40 3
/4

L B

12
 Technical data for the tank systems

Model Motor- Number Dimensions Weight Oil tank Currents at 400V/50Hz Maximum Compressed
rating of switch cycle air
capacity Overcurrent Site back-up
cylinders relay setting fuse connection

Direct Star Direct Star

L B H I(nenn)
start-up Delta start-up Delta

kW mm mm mm kg l A A A AgL AgL 1/h G

10 bar,
1-stage
HL 081012-270 4,0 2 1210 530 1380 250 1,4 8,5 9,4 5,4 20 16 55 1
/2
HL 091012-270 5,5 2 1210 530 1380 270 1,4 11,4 12,5 7,3 25 16 55 1
/2
HL 131013-500 7,5 3 2005 530 1375 350 1,9 16,0 – 10,2 – 20 55 3
/4
HL 181013-500 11,0 3 2005 530 1375 370 1,9 22,0 – 14,0 – 35 40 3
/4

15 bar,
2-stage
HL 051522-270 4,0 2 1210 530 1380 260 1,4 8,5 9,4 5,4 20 16 55 1
/2
HL 081523-500 5,5 3 2005 530 1375 350 1,9 11,4 12,5 7,3 25 16 55 3
/4
HL 101523-500 7,5 3 2005 530 1375 360 1,9 16,0 – 10,2 – 20 55 3
/4
HL 131523-500 11,0 3 2005 530 1375 380 2,2 22,0 – 14,0 – 35 40 3
/4
35 bar,
2-stage
HL 023522-250 2,2 2 1140 670 1390 310 0,5 4,8 5,3 – 16 – 55 1
/2
HL 043522-500 4,0 2 2005 670 1390 445 1,4 8,5 9,4 5,4 20 16 55 3
/4
HL 053522-500 5,5 2 2005 670 1390 455 1,4 11,4 12,5 7,3 25 16 55 3
/4
HL 083523-500 7,5 3 2005 670 1390 520 1,9 16,0 – 10,2 – 20 55 3
/4
HL 103523-500 11,0 3 2005 670 1390 545 1,9 22,0 – 14,0 – 35 40 3
/4

min. min.
400 400

B L

13
Completed servicing work

Operating Date Servicing work completed Name/Signature

hours

14
 Completed servicing work

Operating Date Servicing work completed Name/Signature

hours

15
 Manual_HL_gb_08-2009

D
ALMiG Kompressoren GmbH
Tel.: +49 (0)7024 9614-0
Fax: +49 (0)7024 9614-106
Internet: www.almig.de
E-mail: info@almig.de
Adolf-Ehmann-Str. 2
73257 Köngen
DEUTSCHLAND