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Approval-Documents

STX Shipbuilding

Hull No. B5040/42/44/46/48

Sauer Order-No. 41006661

2x Main air compressor WP45L

1x Emergency air compressor H 25
1x Service air compressor SC15-8-MA60
1x Contrtol air compressor SC15-8-MA60

Note:
Please let us have your esteemed comments before 15-Apr-2009. Later comments will
effect the delivery time.
Please let us have all your comments at the same time in electronic format as word, excel
or pdf file format sent back by e-mail. Please avoid split or multiple comments. This will save
working time and reduce errors and costs on both sides.

Revision Changes Date Sign

0 initial issue 25-Feb-2009 VZ
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Sauer air-cooled piston compressor WP45L

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General hint:
Please note that the transport and installation instructions are a extract of the manual.

Transport and Installation

- Transport

Shipping The machine is packed suitable for shipping.

• Immediately on receipt of the Sauer compressor it should be
checked for completeness and damage.
• The transport company and J.P. SAUER & SOHN
must be immediately notified of any damage to the
packing or the machine.

Transportation The Sauer compressor must be transported by a forklift

truck or hoisted by crane.

Danger!

Suspended load when transported.

The forklift truck/crane must have sufficient load bearing
capacity.

• Ensure that no persons stay within the danger area

of the suspended load and the forklift truck/crane.
• Sling the unpacked compressor at the lifting eyes on the
crankcase and the motor (see illustration).
• Lift, move, and set down carefully.

- Storage before installation

If the Sauer compressor has to be stored before installation,

do not unpack and store at the following conditions:
- temperature: +5 to +40 °C;
- relative humidity 30 … 95%, not condensating;
- dry, under a roof and protected against dew;
- protected against soiling;
- protected against vibrations and shocks.

Note!
The standard factory conservation is sufficient for a maximum storage
period of 12 months.
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- Installation

Note!
In case of doubts regarding the suitability of the installation room and
place or in case of queries regarding compressor cooling contact J.P.
SAUER & SOHN in time. There you will also get help with the design of
a ventilating system, if it is required at the place of installation.

Follow the installation instructions and the following conditions during

installation.

Installation
conditions
- The place of installation must be dry and free of dust.
- The place of installation must be ventilated in such way that the
heat generated during operation is dissipated.
- Room temperature while the Sauer compressors is running: +5
… +55 °C
(deviating temperatures only if confirmed in writing
by J.P. SAUER & SOHN)

Note!
The air temperature at the installation place of the compressor must not
exceed +55 °C. Room conditions and the heat generated by the compressor
and other machines installed in the room must be taken into consideration.

- If necessary, install a ventilation or exhaust system

at the place of installation.
- Install the fresh air feed in such way that the fresh
air stream is not directed straight at the compressor. Otherwise
there is a risk of condensation of water inside the machine and
subsequent damage.
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Installation
Conditions - At a room temperature of below +5 °C the room
needs to be heated or the Sauer compressor must
be equipped with a heating system.
- Choose the location such that the Sauer compressor is
accessible and has sufficient clearance to walls and other
machinery (see installation documents).
- Do not position the motor side in a room niche, so the Sauer
compressor will not take in the warmed-up cooling air again.
- Do not position several compressors one after the other, to
prevent one compressor from taking in the warmed-up cooling
air of another compressor.

Note!
J.P. SAUER & SOHN would be glad to advise you on the installation of the
compressors.

Foundation

Note!
The resilient-mount bedding delivered as standard has a resonant frequency
of approx. 10 Hz. The excitation of the intended compressor-foundation by
vibrations from the machines installed in the vicinity must not be in the 10 Hz
range. Otherwise there is a risk that the standard delivery resilient-mount
bedding is destroyed by sympathetic vibration.

1. Check early enough if there are foundation vibrations in the 10 Hz

range.
2. If in doubt, check with J.P. SAUER & SOHN to see if a modified resilient-
mount bedding can be used.
- Connection

Danger!
The compressor should only be connected by qualified technici-
ans. Any work on the electrical installation must be carried out
by qualified electricians only.

Pipelines The compressed air outlet, as well as the and the drain outlets of the Sauer
compressors must be connected to the stationary pipelines by hose lines.

Danger!
Compressed air escapes from the drain outlets when the compressor starts
and when the condensate is drained. Do not operate compressor without the
hose lines connected.
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Hose lines have to be installed free of tension and untwisted.

Draining
Note!
Condensate that is formed contains oil. It may only be disposed
of in compliance with the applicable legal regulations.
J.P. SAUER & SOHN can supply condensate collecting pots for separating
condensate, as well as condensate treatment units for separating oil from
the condensate.

Note!
We recommend that the compressor's drain be connected separately. When
the drain lines of several compressors are to be connected to a common
pipe, observe the following:
- Choose a sufficient nominal diameter for the common drain line.
- Connect drain lines of the individual compressors at an acute
angle to the common drain line, so that no pressure can build up in
the drain line of a stopped compressor.
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Connections The illustration below shows the connections and fittings for the
operation of a standard delivery Sauer compressors.

Note!
For technical specifications of the individual items please refer
to Chapter 4 in the manual. All toggle switches are factory set.
As an option, the subsystems can be prewired on a terminal
box.
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- Filling in oil

The Sauer compressor is supplied without oil.

Danger!
Oil must be filled into the compressor's crankcase before
initial operation! Use lubricating oil (see chapter 10. “Lubricant table” in
the manual). Observe filling amount (see chapter 4. “Technical
Specifications” in the manual).

1. Unscrew oil filler plug (red).

2. Fill in oil and check level with the dipstick.

Note!
Fill only to the upper marking on the dipstick. Otherwise the oil
consumption of the compressor will increase.

3. Put dipstick back in and replace the oil filler plug.

- Checks after installation and before the first start

- Does electrical connection correspond to the type label data?

- Are all connections between compressor and the surrounding
compressed air unit correctly installed? Pay special attention to
the compressed air outlet.
- Are drain lines properly connected? (See section "Draining”.)
- Is oil filled in the crankcase?
- Have all tools and foreign objects been removed from the
compressor?
- Air filter turned from transport position to operating position?
- Is the entire unit clean?
 10/73

17522
STX 5044,5046,5048

Technical specification Sauer air-cooled compressor unit type WP45L

2 x as per attached drawing KR-WP45L

Fill-up-Capacity: 45 (max. 62,2) m³/h

Operation pressure/max operation pressure: 30 bar
Speed: 1770 rpm
Required power: 11,5 kW
Stages / Cylinders: 2/2
Cooling: air-cooled
Heat dissipation: 15 kJ/sec
Drive: direct drive
Ambient temperature up to: + 5 - + 55 ° C
Permissible inclination each direction: 22,5 °
Noise level at 1 m distance: 85 dB(A)
Lub. oil content crankcase: 5,2 ltr.
Color: Munsel 7,5BG7/2

Standard equipment:

- Sturdy rigid and weight saving design with flanged motor

- no bedplate necessary
- flexible coupling, fully covered inside compressor flange
- air intake and silencing filter
- oil- and water separator after 1st and 2nd stage, mounted
- intercoolers and final recooler
- splash oil lubrication
- crankshaft driven cooling air fan with integrated flywheel
- resilient mounts for the unit
- flex. hp-hose for drainage and air-outlet (mounted non return valve)
- all hoses type approved by class
- safety valves after each stage
- final pressure gauge, glycerine filled, with name plates (symbols)
- solenoid valve 230 V/50/60 Hz for automatic drainage
- threephase electrical motor size 160M with suitable marine cable glands,(brass)

rated output acc ISO B: 13,0 kW

speed: 1770 rpm
voltage/frequency: 440/60 V/Hz
starting current: abt. 159 A
nominal current: abt. 23,4 A
efficiency/ starting time abt. 90 %/ 1-2 sec
weight: abt. 111 kg
protection/ISO class IP 55/ F
Suitable for permanent operation under 45 ° C ambient temperature
 11/73

17522
STX 5044,5046,5048

Additional equipment for the 2 WP45L

- 2x junction box, incl. cabling from sensors (mounted)

- flange connection for all hoses (mounted)
- 2x shut off valve between non return valve and flange for air outlet (mounted)
- root valves for the pressure gauges (mounted)
- 1x temperature switch at air outlet for supervision of compressor (mounted)
cooling, “alarm + stop”

- 2x extra air filter for yards work No.: 033291 (supplied loose)
- 1x spare part set “B+A” per vessel as per regulation GL No.: 064392 (supplied loose)

- 2x pressure switch start/stop with test cock No.: 063026 (supplied loose)
- 2 x lube oil level switch

Test and certificates:

- test and certificate for the compressor as per regulation GL
- workstest for the motor
- certificate for motor
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P&I-diagram WP45L, WP65L

13/73
 14/73

Principal wiring diagram

 15/73

WP45L Reserveteilliste Sach-Nr. Ä.I

WP65L Spare parts list “B+A” 064 392

Seite/page: 1 Code-Nr.
Von/of: 3 2-0009
Pos. Stk. Benennung Sach-Nr. Bemerkungen
Item Qty. Designation Ref.-No. remarks
- - Reserveteile “B+A“ 064 392
Spare parts range B+A

1 2 Dichtung 064 048

packing

2 2 Dichtung 064 049

packing

3 2 Dichtung 064 050

packing

4 2 Dichtung 063 059

packing

5 2 Dichtring 056 235

gasket

6 2 Dichtung 064 051

packing
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WP45L Reserveteilliste Sach-Nr. Ä.I

WP65L Spare parts list “B+A” 064 392

Seite/page: 2 Code-Nr.
Von/of: 3 2-0009
Pos. Stk. Benennung Sach-Nr. Bemerkungen
Item Qty. Designation Ref.-No. remarks
8 1 Schmelzsicherung 060 342
Fusible plug

10 1 Minutenring 012 512

M-ring

11 1 Nasenring 031 901

N-ring

12 1 Gleichfasering 031 902

G-ring

13 2 Rechteckring 031 541

R-ring

14 1 Nasenring 002 548

N-ring

15 1 Ölschlitzring 031 542

S-ring
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WP45L Reserveteilliste Sach-Nr. Ä.I

WP65L Spare parts list “B+A” 064 392

Seite/page: 3 Code-Nr.
Von/of: 3 2-0009
Pos. Stk. Benennung Sach-Nr. Bemerkungen
Item Qty. Designation Ref.-No. remarks
17 1 Lamellenventil 037 157
Lammellar valve

18 1 Lamellenventil 037 158

Lammellar valve
 18/73

Ref.-no. 035222
 19/73

Receiver pressure switch

Technical drawing:

for 035221 and 035222 for 035223

4 1 2 Connection diagram:

Change over contact

Adjustment:
First set upper switching-pressure by
3 means of adjusting screw 1
Pointer 2 will indicate.
Set lower switching-pressure by means of
adjusting screw 4
The upper switching-pressure remaining
unchanged.
Pointer adjustment by manometric
comparison

G3/8

Advice for installation:

The pressure switch must be installed at the pressure vessel (to avoid pulsation)

Technical data’s:
Rated service current: 6A at 220V AC 11
Protection class: IP65

Qty. Designation Pressure range Sauer reference No.

1 Receiver pressure switch 1 - 16bar 035221
1 Receiver pressure switch 2 - 32bar 035222
1 Receiver pressure switch 3 - 60bar 035223
 20/73

Operating Manual
for Compressor Series
H25
Air-cooled hand-compressor, 2-stage

Neuenhauser Kompressoren GmbH

Ladestraße 5
D - 49828 Neuenhaus
Germany

Tel.: +49 (0) 59 41 – 6 04 - 0

Fax: +49 (0) 59 41 – 6 04 – 2 02
E-mail: nk@neuenhauser.de
Internet: www.neuenhauser.de
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Operating Manual for Compressor 09.2.2.02.01-18.2.2.02.01 Page 2

Revisions
File: H25e.doc
Status Changes Date Reviser Approved
000 1 st issue 27.04.2004 Wi Wi

Neuenhauser Kompressorenbau GmbH reserves all rights. Reproduction of the text and the illustrations
and/or drawings, even in excerpts, is prohibited.
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Operating Manual for Compressor 09.2.2.02.01-18.2.2.02.01 Page 3

Contents
1. Preface .......................................................................................................4

2. General Specifications................................................................................4
2.1. External Acceptance...................................................................................4

3. Use and Description of the Compressor .....................................................5

3.1. Construction ...............................................................................................5
3.2. Function......................................................................................................5

4. Working Place Description, Use According to the Rules, Starting, and

Control .......................................................................................................6
4.1. Warrenty .....................................................................................................6
4.2. Safety Regulations......................................................................................6
4.3. Instructions on Starting the Compressor.....................................................8
4.4. Initial and Normal Starting ..........................................................................8
4.4.1. Starting After Long Stops/ Conservation...................................................10
4.5. Safety Instructions ....................................................................................10
4.6. Duties of the Operating Authority..............................................................11
4.7. Duties of the Operating and Maintenance Personnel ...............................12
4.8. Danger Potential .......................................................................................13
4.9. Effects on Environment and Working Place..............................................13

5. Maintenance, Trouble Shooting and Maintenance....................................14

5.1. Safetey Instructions ..................................................................................14
5.2. Trouble .....................................................................................................15
5.3. Cleaning ...................................................................................................15
5.4. Maintenance Instructions..........................................................................15
5.5. Spare Parts - Aftersales Service...............................................................16
5.5.1. Ordering Spare Parts................................................................................16

6. Assembly/ Disassembly............................................................................16
6.1. Supply Check............................................................................................16
6.2. Special Assembly resources.....................................................................17
6.3. Erection at the Place of Use .....................................................................17
6.3.1. Ship Installation ........................................................................................18
6.3.2. Installation on Land and as Stationary Plants ...........................................18

Enclosure:
- List of Spare Parts
- Assembly drawing Zu_20093-a
- Drawing Ag_20063-a
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Operating Manual for Compressor 09.2.2.02.01-18.2.2.02.01 Page 4

1. Preface
Before operating the compressor, the customer must make sure that his operating and
maintenance personnel has carefully read this operating manual and that every detail of
the instructions and warnings, in particular the safety regulations, are complied with.

Furthermore, this operating manual will help you achieve optimal results when using this
compressor, ensure low-fault operation and long life of the system, and comply with
safety regulations with regard to your operating personnel.

The ”Neuenhausener Kompressorenbau GmbH” does not accept responsibility

for the contents of and individual statements in the documentation by other
manufacturers if and as far as they are included or enclosed in this operating
manual.

This operating manual applies only to the H25 hand compressor but not to the entire
compressor system in which the hand compressor is used.

2. General Specifications
Type of compressor H25
Number of strokes 50 double strokes per minute
Effective flow rate m³/h 1.8 at 50 double strokes
Working pressure bar 30
Permissible ambient °C 0 to +50
temperature
Permissible intake mbar 920-1,060
pressure
Number of cylinders 2
Number of stages 2
Diameter of piston mm 110/45
Piston stroke mm 75
Weight kg 25

The customer is responsible for erection of and air supply to the compressor.

2.1. External Acceptance

If the customer requires external acceptance procedures carried out by classification

companies or other institutions, they, or the necessary acceptance requirements, have
to be communicated in writing already when ordering from the ”Neuenhausener
Kompressorenbau GmbH”.
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Operating Manual for Compressor 09.2.2.02.01-18.2.2.02.01 Page 5

3. Use and Description of the Compressor

The type of compressor mentioned above meets today’s requirements on appropriate
classification companies and is constructed in accordance with the regulations for
prevention of accidents (UVV).

Any use other than the use the manufacturer has designed for this compressor
and any applications other than the ones described in this operating manual are
not permitted.
The manufacturer must be consulted if the operating conditions change, e.g.
different ambient conditions and connected loads, structural alterations,
modifications of the original compressor, etc.

Due to their construction, these compressors are very low-maintenance and insensitive.
Apart from the checks and tests stated in these instructions you should not dismount or
inspect the appliance unless this becomes necessary because of malfunction during
working.

3.1. Construction

The H25 hand compressor serves to fill compressed-air tanks up to 50 bar, but it is also
used where smaller amounts of air are required in batches.

The housing (part 1 of the Zu_20093 assembly drawing) is made of cast iron and has
two longitudinal bore holes lying on top of each other. The lower of these borings is
designed as high-pressure cylinder and the upper one as low-pressure cylinder. Both
pistons, L.P. stage (part 23) and H.P. stage (part 30), are equipped with cup leathers
(parts 24 and 31). Three valves ensure perfect combined action of both stages: 1 L.P.
foot valve (detail Z) with filter (part 16), 1 L.P. head valve (detail Y) which at the same
time functions as H.P. foot valve, and 1 H.P. head
valve (detail X) in the pressure joint (part 18).

3.2. Function

If the hand lever (part 4) is pushed in the direction of the compressor, the L.P. piston
takes in air through the L.P. foot valve and, during the back movement, presses the pre-
compressed air into the H.P. cylinder through the L.P. head valve which at the same
time functions as H.P. foot valve. Pushing the hand lever again in the direction of the
compressor, the air is compressed to the final pressure and pressed into the
compressed-air tank through the H.P. head valve. The H.P. head valve works at the
same time as nonreturn valve in order that the pressure built up in the tank cannot press
back into the hand compressor.
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Operating Manual for Compressor 09.2.2.02.01-18.2.2.02.01 Page 6

4. Working Place Description, Use According to the Rules,

Starting, and Control
4.1. Warranty

The compressor supplied was constructed in accordance with today’s level of

technology and the safety regulations effective at the date of delivery/completion.

No warranty is given for damage to the compressor resulting from the following causes:

• failure to observe the operating manual

• not sufficiently trained or instructed operating personnel
• normal wear and tear
• incorrect or careless treatment of the compressor
• failure to use ”Neuenhausener Kompressorenbau GmbH” genuine spare parts

Additionally, the operating authority has to take care on its own responsibility that

• the regulations for prevention of accidents are observed when transporting, erecting
and placing in running order, operating, and maintaining the appliance
• it is impossible to enter the danger area while the compressor is running
• no modifications or changes of design of the compressor, in particular of its safety
devices, are carried out inexpertly or without prior approvement by the
”Neuenhausener Kompressorenbau GmbH”
• there is no possibility of deficient starting or improper operating
• the compressor is not used inexpertly or for unsuitable uses
• use according to the rules is always guaranteed and any other than the stipulated
operating purpose cannot occur.

4.2. Safety Regulations

The latest issues of the worker’s protection rules and the regulations for prevention of
accidents (UVV) applying to both the operation of the compressor at the operating
authority’s works or at the place of erection, and to any measure described in the
operating manual, must strictly be observed. The same goes for the industrial
employer’s liability insurance association (BG).
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Operating Manual for Compressor 09.2.2.02.01-18.2.2.02.01 Page 7

They include:

• VBG - 1: "Allgemeine Vorschriften" UVV 1.0

• VBG - 5: "Kraftbetriebene Arbeitsmittel" UVV 10.0
• VBG - 121: "Lärm" UVV 1.2
• VBG - 16: "Verdichter"
• VBG - 18: "Druckluftbehälter auf Wasserfahrzeugen"
• VBG - 125: "Sicherheits- und Gesundheitsschutzkennzeichnungen am
Arbeitsplatz"

The DIN VDE regulations, among other things, apply to safety with regard to work at the
compressor’s electronic equipment. In addition to the rules and safety regulations
mentioned, the following ones have to be observed:

safety regulations in force at the place of erection of the compressor and those
required by the competent controlling authorities, and

the decrees of the German states as well as regional, local, and intercompany
regulations or directives applying to the plant and/or the place of erection.

Industrial medicine and hygiene regulations must be taken into consideration in addition
to the safety regulations.

Should any statement in this operating manual not be in accordance with local
required regulations, the stricter (national) version shall be applied.

The WHG and UVV 1.0 regulations must strictly be complied with when handling
hazardous liquids and/or liquids that can pollute ground water, such as lubricating oils
and greases, solvents, cleaning materials, or any other chemicals.

The following applies in general to all work at the compressor:

• Effectively protect the compressor from being switched on without permission and
install a sign informing that repair work is under way.
• Shut all stop valves in the pipelines.
• Prior to maintenance work, deair (depressurize) all pipelines and pressurized areas
of the compressor.
• Prior to starting, install safety devices.
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Operating Manual for Compressor 09.2.2.02.01-18.2.2.02.01 Page 8

4.3. Instructions on Starting the Compressor

The compressor supplied was constructed in accordance with today’s level of

technology and is operationally reliable.

The compressor can become dangerous to health and life of the operating personnel or
third persons, or the plant can be impaired, if operated inexpertly or put to improper use
by not sufficiently qualified or trained personnel.

The compressor must only be operated by trained personnel.

The operator/operating authority of the compressor has to ensure that no-one stays in
the danger area during operation.

Use of the compressor acc. to the rules includes manual compressing of ambient
air (no industrial gases) under normal atmospheric conditions. Any use extending
beyond this purpose is deemed improper use. Enquire first for any different uses.

”Neuenhausener Kompressorenbau GmbH” cannot be held liable for any damage

possibly resulting from such use or from inexpert manipulation and/or treatment of the
compressor; the operating authority alone bears the risk.

The compressor must only be used, maintained, or repaired by persons who have
studied it as well as the operating manual and are informed about all hazards.

4.4. Initial and Normal Starting

Important!
Prior to initial starting, make sure that the H25 hand compressor is tightly
screwed to the supporting structure by four M12 screws in the four ###14 holes on
the floor of the housing so the lever can safely be operated (bore diagram see fig.
4.4.1.). This is necessary because leverage grows as the pressure increases in
the connected tank (customer connection). The operator’s cabine must be
designed according to fig. 4.4.2. in order to ensure sufficient free space for
operation.
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Operating Manual for Compressor 09.2.2.02.01-18.2.2.02.01 Page 9

188 mm

diameter of
all bores 14
195 mm

hand lever axle

Fig. 4.4.1 pinhole plan

500 mm lenght of hand lever abt. 1.000 mm

(operation
on both
sides
900 mm)

available space over

hand compressor:
hand lever axle abt. 2.000 mm
900 mm

1.300 mm 1.100 mm

Fig. 4.4.2 providable work room

Only the genuine 1,000 mm lever lengthening (part 4) must be used. The lever
must not be lengthened.

If operation of the hand compressor is to be possible from either side, each side must
have 900 mm free space (see fig. 4.4.2.).

Any commercial motor oil can be used to lubricate the hand compressor. It should,
however, be matched to the prevailing conditions at the place of erection.
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Operating Manual for Compressor 09.2.2.02.01-18.2.2.02.01 Page 10

Prior to initial operation or after long stops, the grease fitting (part 33) and the lubricating
point for bolts (part 5) down at the hand lever (part 7) have to be greased. The four bolts
(part 26) of the rod assembly (parts 28 and 29) have to be wetted with lubricating oil.

After the charging valve at the air bottle and any possible intermediate valves have
been opened, the pumping can begin. Be sure to move the hand lever up to the
respective final positions to achieve the highest volumetric efficiency.

Always take care that the L.P. and H.P. cylinders are clean because dust and dirt on the
cylinder face can lead to leakage of the cup leathers (parts 24 and 31).

No water or splash water must leak into the compression space through the filter
discompressor (part 16).

4.4.1. Starting After Long Stops/Conservation

If the hand compressor is not or has not been used for a longer period of time, clean oil
should be filled into the grease fitting (part 33) and then the pistons should be moved
back and forth several times so the oil is distributed.
Prior to starting operation or work, the compressor has to be prepared for operation as
described. Checks and tests have to be carried out step by step. Observe the
maintenance table for daily maintenance (lubricating, etc.). In the case of new plants,
the early maintenance (acc. to machine hours) has to be performed.

4.5. Safety Instructions

The operating personnel must read the complete operating manual prior to starting
operation and take measures only according to the rules and safety regulations
described therein. On delivery and/or after initial erection of the compressor, the
operating and maintenance personnel are thoroughly instructed by the ”Neuenhausener
Kompressorenbau GmbH”. Should the amount of information received not be sufficient
or any particular problems occur during operation or maintenance that are not
sufficiently dealt with in this operating manual, the information needed can be requested
directly from ”Neuenhausener Kompressorenbau GmbH”. Safe methods of working
have to be applied and local worker’s protection rules and safety regulations be
complied with during any work. Any method of working that impairs the safety of
persons and/or of the compressor has to be prevented.

The compressor must immediately be switched off in the case of:

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Operating Manual for Compressor 09.2.2.02.01-18.2.2.02.01 Page 11

• unauthorized persons in the danger area

• abnormal working noises
• erratic running and/or vibrations

The cause of the malfunction must at any rate be determined and removed. Only
after the malfunction has been removed must the compressor be operated again!

The compressor is started and operated after placing in running order has been
completed.

The regulations, warnings, and instructions must strictly be observed when taking any
measure, operating the compressor, starting or shutting down.

Prior to initial operation of the compressor, the operating authority has to take care on
its own responsibility that

• the compressor is erected and protected in accordance with regulations

• the operating personnel are familiar with the compressor and its safety devices and
know and observe all respective instructions in this operating manual
• preparations for operation are completely finished
• no person stays within the danger area or is even working there

4.6. Duties of the Operating Authority

The operating authority is responsible for checking the compressor for safety prior to
each starting.

The operating authority has to check that all measures concerning statutory worker’s
protection rules and regulations for prevention of accidents as well as the safety
directives in this operating manual are entirely complied with.

Furthermore, the operating authority is responsible for the necessary qualification of his
staff, their trainining on the compressor, and their knowledge of the danger potential and
the operating manual. There must be no possibility of unclear competences that could
lead to dangerous situations during operation.

The operating authority has to supply the appropriate protective clothes. It must be
checked that the personnel observe the appropriate protection and waste disposal
measures.
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Operating Manual for Compressor 09.2.2.02.01-18.2.2.02.01 Page 12

4.7. Duties of the Operating and Maintenance Personnel

Any person engaged to carry out any of the measures described in this operating
manual, whether at the location where the compressor is operated or in the workshop,
must have read and understood the entire manual.

Operating and maintenance personnel must apply safe methods of working during any
work, and worker’s protection rules and regulations for prevention of accidents (UVV)
have to be observed including local supplements.

The operating authority’s operating and maintenance personnel is obliged to take care
that

• no method of working is applied that could in any way impair the safety of persons or
of the compressor
• measures at and operation of the compressors are only carried out by persons
qualified for such work
• prior to starting work, any person is informed about the devices and actuating
elements as well as about their functions and the danger area of the compressor
• it is made sure before starting the compressor, that the same is ready for work and
the safety devices are attached in accordance with regulations, and no-one can be
endangered by the starting compressor
• during operation of the compressor, no person is in the danger area, works at the
compressor, or carries out any other action, or intervenes in the operation of the
compressor, if not expressly authorized
• at least once a day the compressors are checked for visual damage and faults
• modifications of the compressors or of the operating conditions are immediately
reported to an office or person to be appointed by the operating authority
• the compressor is immediately switched off if any malfunctions occur that could
impair the safety
• maintenance is only carried out while the compressor is disconnected from the
compressed-air supply and protected against being switched on
• the operating authority has installed clearly legible safety, worker’s protection, and
danger signs
• no unauthorized modifications or alterations of the compressor take place
• environmental rules are strictly observed, e.g. when disposing of waste materials,
and
• the place of erection is always clean and open, and the hand lever lengthening (part
4) accessible.
 32/73

Operating Manual for Compressor 09.2.2.02.01-18.2.2.02.01 Page 13

4.8. Danger Potential

Placing in running order

Check the compressor for visual damage and make sure the safety devices are
completely operative.

Normal operation

It is strictly prohibited to stay in the danger area. Maintenance work must as a rule be
carried out with the compressor switched off.

In case of malfunction, such as

unusually loud noises, smoke development, erratic running or vibrations, unacceptable

deviation from the operational data, etc.,

the compressor must immediately be switched off and checked.

4.9. Effects on Environment and Working Place

The compressor has been manufactured using common machinery materials and is to a
large extent insensitive to environmental factors in the usual range. Atmospheric or
ambient temperatures above or below the operational limits may lead to a decrease of
performance and/or malfunction.
Please inform the ”Neuenhausener Kompressorenbau GmbH” about extreme ambient
conditions (temperatures, air moisture, dust) so they can check and, if necessary, install
special protections.
If properly operated, and if operational and safety measures are observed that
correspond to the respective kind of application, the compressor is not dangerous.

There are no effects on third parties.

 33/73

Operating Manual for Compressor 09.2.2.02.01-18.2.2.02.01 Page 14

5. Maintenance, Trouble Shooting, and Maintenance

5.1. Safety Instructions

As a rule, cleaning and maintenance must only be carried out with the compressor
switched off and protected against mistakenly or incorrectly being switched on. Do not
clean with solvents or cleaning agents that are aggressive, flammable, or detrimental to
health, and use no materials that contain tri-, per- or tetrachloroethylen.

Do not misadjust automatic control systems when performing maintenance work!

Immediately tighten loose screw connections using common tools and observing the
proper tightening moments. Worn or damaged components must directly be replaced
exclusively with genuine spare parts.

Welding and safety regulations must be observed when welding at the plants. Only use
faultless tools that comply with the common regulations.

Repair work must only be carried out by specially trained personnel!

IT IS STRICTLY FORBIDDEN TO STAY IN THE DANGER AREA !!!

CARRY OUT REPAIR, SET-UP, MAINTENANCE OR CLEANING WORK

ONLY WITH THE PLANT SWITCHED OFF AND PROTECTED !!!

Welding:

The operating authority is solely responsible for observance of worker’s protection rules,
UVV, and of the directives, instructions, and warnings in the ‘Safety Regulations’
chapter during inspection or maintenance work.

Note: Nonobservance of this operating manual or, among other things,

maintenance that is insufficient or not in time, shall be deemed as improper
use. The operating authority alone is liable for the consequences!

Before maintenance work begins, the operating authority has to ensure that:
 34/73

Operating Manual for Compressor 09.2.2.02.01-18.2.2.02.01 Page 15

• the compressor has been switched off and that it is impossible to switch it on by
mistake
• the operating personnel are familiar with the compressor, i.e. are sufficiently trained,
perform all work according to safety regulations, and observe this operating manual
and the manuals of the other manufacturers.

5.2. Trouble

Malfunction: Remedy:

1. Filter dirty Remove and clean filter

2. Valves leaky Remove and check valves, check valve

cone sealing properties, replace valve face

3. Piston packing leather leaky Clean packing, replace if necessary

5.3. Cleaning

Dissolved dirt is contaminated (with lubricating oil, etc.) and must therefore be collected
and disposed of in accordance with regulations.

5.4. Maintenance Instructions

To check or replace valves or seals, the cover (part 8) has to be detached. Use a new
seal (part 9) when reassembling.

If the pistons are to receive new cup leathers (parts 24 and 31), remove the cover (part
8). Replace the cup leathers after unscrewing the ring nuts (parts 25 and 32).

Necessary replacement and expendable parts are listed in the enclosed spare parts list.
Only use ”Neuenhausener Kompressorenbau GmbH” genuine spare parts!

A well-kept machine always reflects the mechanic’s care, helps limit malfunction, and
extends service life.

Any commercial motor oil can be used to lubricate the hand compressor. It should,
however, be matched to the prevailing conditions at the place of erection.
 35/73

Operating Manual for Compressor 09.2.2.02.01-18.2.2.02.01 Page 16

5.5. Spare Parts -- Aftersales Service

We always stock all spare parts in our extensive spare part stockroom. They are
delivered as soon as possible or as requested to any place in the world. In case of
emergency, spare parts are even delivered on nonbusiness days. Specialist erecting
engineers are available for repair work.

Only use ”Neuenhausener Kompressorenbau GmbH” genuine spare parts!

5.5.1. Ordering Spare Parts

Any spare parts order must include the following:

1. Type of compressor
2. Works number
3. Forwarding address
4. Requested manner of delivery

6. Assembly / Disassembly
6.1. Supply Check

Extent of supply

The extent of supply is described in the confirmation of the order received from the
”Neuenhausener Kompressorenbau GmbH”.

Check the delivery upon reception. This applies in particular to any loosely supplied
equipment parts. Immediately report to the ”Neuenhausener Kompressorenbau GmbH”
if any parts are lacking or damaged!

Damage in transit

Check the compressor for damage in transit immediately upon reception. If damage in
transit is found or even suspected, take them down or document them with Polaroid
photos and/or by free-hand sketch indicating the damage, and describe the damage in a
detailed report. Transport loss has to be reported in writing to the forwarding agent and
to the ”Neuenhausener Kompressorenbau GmbH”. As a precaution, include in your
report so-called concealed transport loss, i.e. damage that may only be discovered after
the compressor has been disassembled.
Reports/complaints that are not made in time (immediately upon reception) may lead to
the loss of insurance protection!
 36/73

Operating Manual for Compressor 09.2.2.02.01-18.2.2.02.01 Page 17

6.2. Special Assembly Resources

• Resource: Crane with suitable strikers

• Personnel: 1 fitter

6.3. Erection at the Place of Use

The generally valid regulations applying to transportation, strikers, and safety must be
observed when transporting the compressor.

The UVV in force at the operating authority’s works, and possibly the safety instructions
in force with regard to the place of use, have to be observed when erecting the
compressor.

If the air at the place of erection is extremely dusty, maintenance intervals must be
shortened, if need be halved.
Space according to the dimensions of the compressor must be provided for operation
(see drawing). Additionally, the following has to be taken into consideration:

• sufficient space for safe control

• space for maintenance and repair work all around and above the compressor

Escape routes must be kept clear.

Secure erection on firm ground prevents malfunction.

6.3.1. Ship Installation

The shipyard will install and connect the hand compressor. The only important thing is
to erect the hand compressor on a solid supporting structure.

6.3.2. Installation on Land and as Stationary Plants

The hand compressor must be erected on a firm supporting structure.

 37/73

17522
STX 5044,5046,5048

Hand Operated Compressor Typ H 25

in design as per enclosed drawing B - H 25 - E 5568

Capacity: 1,8 m3/h (50 double strokes per minute)

Pressure: 30 bar

Test of the compressor as per regulation GL

1 set of spare parts as per regulation GL

19.01.2009

Springfeld
 38/73

Operating Manual for Compressor 09.2.2.02.01-18.2.2.02.01 Page 18

FOR HAND COMPRESSOR TYPE H 25

according to drawing Zu_20093-a

Pos.-no. description order-no. number per

compressor

1 case K61000 1
2 stud K51408 12
3 hexagonal nut K51382 12
4 extension pipe K61001 1
5 bolt K61002 1
6 clamping sleeve K51505 1
7 hand lever K61003 1
8 cover K61004 1
9 gasket K61005 1
10 spring cap K61006 2
11 clamping screw K61007 1
12 valve seat K51733 3
13 valve cone K61009 3
14 valve spring K51210 2
15 retaining ring K50602 1
16 filter plate K61010 1
17 socket K61011 1
18 threaded socket K61012 1
19 cap screw K51261 1
20 clamping ring K51260 1
21 copper gasket K50810 1
22 copper gasket K50811 1
23 LP-piston K61013 1
24 sealing sleeve K51732 1
25 ring nut K61014 1
26 bolt K61015 4
27 retaining ring K50569 8
28 rod K61016 2
29 rod K61017 2
30 HP-piston K61018 1
31 sealing sleeve K51731 1
32 ring nut K61008 1
33 oiler K51730 1
34 valve spring K51213 1
35 notched nail K51620 4
36 name plate K51740 1
37 gasket K50859 3
39/73
40/73
 41/73

Sauer screw compressor SC15 to SC52

 42/73

General hint:
Please note that the transport and installation instructions are a extract of the manual.

Sauer screw compressor general informations

The drive

The electric motor (01) drives

the compressor stage (04)
through the v-belt pulleys (02)
and the v-belts

The air path

Air flows into the suction filter

(05) and the suction valve (06)
into the compressor stage
(04), which compresses the
air. The relief valve (07) closes
and the suction valve (06) opens at star delta and the reverse way at upper
pressure point into the idle running phase. The oil separator (08) decreases
the residual oil to 2-4mg/m³. In the compressed- air recooler (09) the
compressed air temperature reduces to 9-13°C above ambient temperature
and leaves the machine through the compressed air outlet (10).

The oil curcuit

Cooling and sealing lube oil

flows into the compressor
stage (04) by the produced
pressure into the oil tank
(11).The oil leaves the
compressor stage (04) mixed
with the compressed air. The –
place according the regulations
– safety valve(12) protects the
machine against excess
pressure. The oil will be
separated from the air up to
98% by our special design of
the oil tank (11), which collects
the oil. The residual separation
of the oil will be carried out by
the oil separator (08). The
working temperature of the oil is optimized by the oil temperature controller
(13). The oil passes the by-pass line or the oil controller (14) and flows
through the oil filter (15) back into the compressor stage (04).

Cooling

The compressed air after-cooler of the cooling fluid heat exchanger is

cooled either by

• a built-in cooling air ventilator or

• water cooling.

The electric motor is always cooled by its own ventilator fan. In the case
of water-cooled compressors, a fresh air ventilator additionally ensures
sufficient fresh intake air for the removal of radiated heat.
 43/73

Pneumatic connection

Screw type compressors will be delivered complete an ready for connection.

The connection from the compressed air outlet (10) to the piping system
must only take place through a tape – sealed flexible hose, so that no forces
can be transmitted between the compressed air piping system and the
compressor unit.
The pipe end of the piping system is to be roughly secured. In order to avoid
that condensate collected in the compressed air recooler (09) is fed into the
piping system or into the downstream receiver tank, a condensate trap with
automatic separator is to be installed in the discharge line, if possible in
direct vicinity of the compressed- air outlet (10).
A non return valve between piping system or receiver tank and machine is
not required, because this device is already installed in the screw type
compressor. It is, however, recommended to install a shut off valve in the
compressed air line, so that the compressor is able to be disconnected from
the piping system , if necessary.

Electric connection

Electric connection is only to be carried out by skilled electricians. Check if

current, voltage and frequency is according to the nameplate data. The
cross section of the feed line and the fuses are to be dimensioned in
accordance with the local prescriptions!

Condensate trap

The condensate collected in the condensate trap is oily and must not be fed
into the sewage system without further treat.
 44/73

17522
STX 5044,5046,5048

Technical specification Sauer - screw - compressor SC15-7-MA60

2 x as per enclosed drawing KR-CH-SC15 (1 Control- and 1 Service air)

Capacity as per ISO 1217 100 m3/h

Operation pressure: 7 bar
Required power: 12,7 kW
Cooling: aircooled
Drive: v-belt driven
Ambient temperature up to: 50 °C
Heat dissipation: 14 kJ/sec
Lub oil content crankcase : 8 ltr
Color : Munsel 7,5BG7/2
Lube oil content air outlet: less thant 4 mg/ Nm3

Standard Equipment:
- air intake filter
- compressor rotors with asymmetric profile
- final air cooler
- non-return valve mounted on the compressor
- oil separator
- oil recooler
- safety valve
- starting relief
- self induced pressure lubrication with oil filter
- sound proof canopy
- automatic control unit
ALUP AIRCONTROL AC1(microprocessor control and monitoring unit)
combined load/unload and start/stop control by integrated press-transmitter
star-delta start
indication of pressure, compressed air temperature, running hours
supervision of oil- and air temperature, pressure and maintenance intervals
potential free contact for remote alarm indication
start/ stop push button
- resilient mounts incl. flexible hose for air outlet
- threephase electrical motor size 160 M:
nominal-rating: 13,9 kW
speed: 3520 rpm
voltage: 440 V
frequency: 60 Hz
protection / insulation: IP 54 / F

Additional Equipment for the compressor unit:

- flange connection for the hose (mounted)

- 1 Spare part set seagoing GL (supplied loose)
- 2 additional cyclone separator incl. automatic
drainage of separator by BEKOMAT 230 V / 60 Hz No.: 038422 (supplied loose)

Test and certificates:

- worktest certificate
- test and certificate for the compressor as per regulation GL
- for control air compressor
 45/73

Hint: Pos 18-21 are just in use in case

of a water cooled screwcompressor version.
In case of a air cooled version these parts
can be ignored. Please refer to the technical
specification.
46/73
 47/73

Spare part set seagoing

consists of:
Ansaugfilterpatrone und
Ölabscheidepatrone
Anlagentyp Keilriemensatz Schelle Ölfilter Verschlußschraube
Oil seperator
Compressor V-Belt set Suction filter cartridge and Oil filter plug screw
cartridge
type clamp
No. No. No. No. No.
SC15-8 MA 163.00033XPA957 172.08788
SC15-10 MA 163.00033XPA957 173.08789
172.51002 172.00221
SC22-8 MA 163.00032XPA930 165.04545
SC22-10 MA 163.00032XPA930 167.01247

SC26-8 MA 163.00002XPA1215
SC26-10 MA 163.00058XPA1180
172.11105
SC31-8 MA 163.00002XPA1215
SC31-10 MA 163.00060XPA1207 172.08787
172.00222
173.08787 165.00017
SC42-8 MA 163.00128XPA1480
SC42-10 MA 163.00072XPA1429 167.01249
172.58112
SC52-8 MA 163.00006XPA1180
SC52-10 MA 163.00012XPA1207
SC51-8 MA 163.00012XPA1207 172.03291
172.58111
SC51-10 MA 163.00013XPA1232 SC51-76

SC61-8 MA 163.00019XPA1282
172.11103 167.01250
SC61-10 MA 163.00133XPA1307 172.08786
2 x 172.58111 SC61-76 ab
173.08786
SC76-8 MA F0502977
163.00127XPA1207
SC76-10 MA
 48/73

1 2 3 4 5 6 7 8

A
C over Page
A

C a b in e t: P ult
P ro te c tio n : IP 5 4
C o lo u r: RAL 7035
B B
EN 60204 T. 1

S C 15-22 M A50
S C 15-22 M A60

W ir in g

C M a in c u rre n t: b la ck C
C o n tro l vo lta g e : red

C o n tro l vo lta g e : d a rk b lu e

P ro te ctio n lin e : green-yellow

C u s to m e r:
P ot.free contacts: orange

D D

R a te d v o lta g e : 440/400 V F re q u e n z: 6 0 / 5 0 Hz

C o n tro l vo lta g e : 230 V

R a te d p o w e r: (k W ) C u s to m e rs fuses: (A )

E 60Hz 50Hz E
4 ,6 4 10

6 ,3 5 ,5 16

8 ,6 7 ,5 16

1 2 ,6 11 25

1 7 ,2 15 35
F Date 16.11.07
F
Name GKL SC 15-22 MA cover page
Check. GKL Page 0
Status Change Date Name Stand. Orig. from From
238.00204MA-00 of 10 Ps.
1 2 3 4 5 6 7 8
 49/73

1 2 3 4 5 6 7 8
L1
/2.1
L2
/2.1
L3
A /2.1
-option-
A
current transformer and
amperemeter optional 2
4mm

K k
-1T1 -1P1
A
50/5A 50/5A
B L l Ameter B

2 up to 4mm 2
up to 4mm

up to 4mm 2
1 3 5 1 3 5 1 3 5

2 -3K1 -3K3 -3K2

4mm /3.3 /3.4 /3.3
2 4 6 2 4 6 2 4 6

C C
1 3 5
-1Q1
2 4 6
Option

PE
/2.1
-W001
1 2 3 gr/ge 4 5 6
D D
-X1
U V W PE PE
W1 W2
3x440V/PE 60Hz MA60
3x400V/PE 50Hz MA50 M U2
V1
option with mainswitch 3
without supply terminal U1 V2
PTC

E -1M1 E

line relay Compressor motor delta relay star relay

F Date 16.11.07
F
Name GKL SC 15-22 MA m a in current

Check. GKL Page 1

Status Change Date Name Stand. Orig. from from
238.00204MA-00 of 10 Ps.
1 2 3 4 5 6 7 8
 50/73

1 2 3 4 5 6 7 8
/1.8 L1 L1
/2.1
/1.8 L2 L2
/2.1
L3 L3
A /1.8 /2.1
A

-2F1 -2F5 -2F2 -2F4

4A 4A 1A 1A
control trafo
primer 440V bei MA60
400V bei MA50
B B
4 4 0 V + /- 5 %
4 0 0 V + /- 5 %

1 3 5 -2T2
-3K4 230V 18 V 10 V
/3.6 2 4 6 0V
N5
-2F3 -2F6 /3.1
10V
1A 1A L5
/3.1
0V N6
C /3.1 C
-2S1 11
18V
L6
/3.1
0V N4
12 /3.1
/4.6
230V
L4
/3.1
PE PE
/1.8 /3.1

D D
-X1
1 PE 1.1
-W002
1 gr/ge 2

-2R1
T
E E
KTY
/4.3
in case of mainswitch
without emmergency button

heater 440V/600W
Emergency stop
F Date 16.11.07
F
c o n tro l v o lta g e
Name GKL SC 15-22 MA h e a ter
Check. GKL Page 2
Status Change Date Name Stand. Orig. from from
238.00204MA-00 of 10 Ps.
1 2 3 4 5 6 7 8
 51/73

1 2 3 4 5 6 7 8
/2.8 L5 /3.1
/2.8 N5 /3.1
L6
A /2.8 /3.1
/2.8
N6
/3.1
A
PE
/2.8

-3F5 -3F6
1A 1A

B 1 2 3 4 5 B

-A3.5

C C
6 7 8 9 10 11 12 13 14 15

/2.8 L4 L4
/6.1

21 21
-3K3 -3K2
D /3.4 22 /3.3 22 D
PE PE
/2.8 /6.1

-3K1 A1
-3K2 A1
-3K3 A1 A1
-3K4

A2 A2 A2 4kW A2
E E
N4 N4 /6.1
/2.8
1.3 1
2
/1.6 1
2
/1.5 1
2
/2.2 1
2
-X1 -X1
1.3 3
4 /1.6 3 4 /1.5 3 4 2 3 PE
/2.2 3
4
-W003 4 5 6
1.3 5
6
/1.6 5
6
/1.5 5
6
/2.2 5
1 2 gr/ge 6
/1.3
A1
6.7 13
14 13 14 13 14 7 8
-3Y1
7.3 21
22
/3.4 21
22
/3.3 21
22 13 14
A2
line relay star relay delta relay solenoid valve Heater collective error
F Date 16.11.07
F
Name GKL SC 15-22 MA A ir C o n tro l

Check. GKL Blatt 3

Status Change Date Name Stand. Orig. from from
238.00204MA-00 von 10 Bl.
1 2 3 4 5 6 7 8
 52/73

1 2 3 4 5 6 7 8
Compr.temp. temp.sensor Pressure sensor lead-lag load local Emergency stop Diff. Press.
in heater no load remote

option: external
A pressure switch A
bridge in case mainswitcher
-Option- -Option-
+24
/5.1

-X1
7 9

-4R2 -4R3 2
B -4U1 21 13 21 B
P
-2S1
KTY T KTY T 22 14
P 22
/2.4
1

-X1
8 10

C C
-W004 -W005
Schirm br we Schirm br we

16 17 18 19 20 21 22 23 24 25
- + +24V
KTY 4-20m A
D D
-A3.5

E E

F Date 16.11.07
F
Name GKL SC 15-22 MA A ir C o n tro l
Check. GKL Page 4
Status Change Date Name Stand. Orig. from from
238.00204MA-00 of 10 Ps.
1 2 3 4 5 6 7 8
 53/73

1 2 3 4 5 6 7 8
se n se o f o v e rp re s s u r e o v e r lo a d PTC M1 RS485-interface - Option -
r o t a t io n
- o p t io n -

A connection to PC or to next compressor A

+24

Schirm
RXD

TXD
/4.8

M
M
-X1 27
RxD (B-)
TxD (A+)
B -5R3 B
Schirm
2 4 PTC T
P
-W006 -X1
-5B1 1 2 32 33 34 PE
0-4bar 1
0,8bar

-W007
-X1
C 11 12 C
SST
-X1 ge gr rs
PE 22

26 27 28 29 30 31 32 33 34 35
+12V +24V

D D
-A3.5

E E

F Date 16.11.07
F
Name GKL SC 15-22 MA A ir C o n tro l

Check. GKL Page 5

Status Change Date Name Stand. orig. from from
238.00204MA-00 of 10 Ps.
1 2 3 4 5 6 7 8
 54/73

1 2 3 4 5 6 7 8

L4 L4 /7.1
/3.8

A O p tio n : L o ca l R e m o te sw itch
A
R e m o te S tart S top +24

13 -X1
7 9
-6S2
14 Remote Start/Stop
13 43 Param. 008 = 2
B -6K7 -6K6 Param. 018 = 1 B
/6.7 6.2
14 44

-X1
8 10

22 23

C C

21 13
-6K7 A1
13
-6K6 -3K1
D A1 A2 /3.3 D
/7.2 22 14 14
-6K6
A2
N4 N4 /7.1
/3.8
PE PE /7.1
/3.8

6.1 13 14

6.1 21
22 -X2 1 2 3 4 5 6 7 8
31 32
E 21 E
6.7 43
44
P
IM C S 22

13 14
6.6

Remote
start/stop
Remote on Local Remote Running
F Date 16.11.07
F
re m o te
Name GKL SC 15-22 MA s ta rt/sto p
Check. GKL Page 6
Status Change Date Name Stand. orig. from from
238.00204MA-00 of 10 Ps.
1 2 3 4 5 6 7 8
 55/73

1 2 3 4 5 6 7 8
L4
/6.8

A option: option:
terminals for terminals for A
drier condensate drain

13
Option:
space heater -7S3
on/off 14

B B

21
-3K1
/3.3
3.3 22

C C

Option:
lamp space
heater on
-7H1

D D

/6.8 N4

/6.8 PE

-X1 -X1
15 16 PE 17 18 PE 19 20 PE
-W008
1 2 gr/ye
E E
1
L1 PE L N PE
N
-7R2
(-1M1) 2

option: space heater -1M1 Drier condensate drain

F Date 16.11.07
F
s p a ce h e a te r
Name GKL SC 15-22 MA d rie r
c o n d . d r a in
Check. GKL Page 7
Status Change Date Name Stand. orig. from from
238.00204MA-00 of 10 Ps.
1 2 3 4 5 6 7 8
 56/73

1 2 3 4 5 6 7 8

A
A
in terface
R S -232/R S -485
c a b le : L iY C Y 3 x 0 ,5 m m ²

to Compressor 3-6
A
B
B B

C C
32 33 34 PE 32 33 34 PE 32 33 34 PE
R S -2 32-
in terface R S485- R S485- R S485-
in terface in terface in terface

b o th ca b le s b o th ca b le s
p arallel p arallel
D lead-lag D
PC com pressor 1 c o m pressor 2
s e le cto r sw .

adress 1 adress 2

E w irin g o f R S 4 8 5 -in te rfa c e s to P C E

(ref. to page 5)

F Date 16.11.07
F
Name GKL SC 15-22 MA s e r . in te rfa ce
Check. GKL Page 8
Status Change Date Name Stand. orig. from from
238.00204MA-00 of 10 Ps.
1 2 3 4 5 6 7 8
 57/73

1 2 3 4 5 6 7 8

A
A

530

+ 0 ,1 + 0 ,1
6,5 6,5

B 9 512 9 B

C C

K le m m le is te

2F2

2F4

2F5

2F6

3F5

3F6
2F1
3K1 3K3 3K2 3K4 2T1 4U 1 1T 1
X1

D 1,75 1,75 D

PE

PE
PE

PE
L1
L2
L3
160

E D I1 6
2F3

15
E E

536

F Date 16.11.07
F
Name GKL SC 15-22 MA c o n s t r u c tio n

Check. GKL Page 9

Status Change Date Name Stand. Orig. from from
238.00204MA-00 of 10 Ps.
1 2 3 4 5 6 7 8
 58/73

1 2 3 4 5 6 7 8

A
A

90

B 6K7 6K6
B
X2

45
C C

b a c k p la n e c a b in e t

D D

E E

F Date 16.11.07
F
Name GKL SC 15-22 MA c o n s t r u c tio n
Check. GKL Page 10
Status Change Date Name Stand. Orig. from from
238.00204MA-00 of 10 Ps.
1 2 3 4 5 6 7 8
 external cable
Page

Status
description c o n n e c tio n line: -X 1
1

external function internal function

Change
page/line

bridges

conn. no.

Date
connection
connection

description
description

-W006 Ölfl. 3x1,5

functional text
-W003 Ölflex 3x1,5
-W002 SINF-JB 3x1,5

Name
heater 1 -2R1 1 -3K4 2 2.2

Name
Date
heater gr/ge PE -A3.5 1 2.2

Stand.
Check.
heater 2 -2R1 1.1 -3K4 6 2.2
solenoid valve 1 -3Y1 A2 2 -3K3 A2 3.4
solenoid valve 2 -3Y1 A1 3 -A3.5 10 3.5

GKL
GKL
solenoid valve gr/ge PE 3.5

16.11.07
collect error 4 -A3.5 13 3.6
collect error 5 -A3.5 14 3.7
collect error 6 -A3.5 15 3.7

Orig.
remote start/stop -lead-lag -6K7 13 7 -A3.5 31 4.5
remote start/stop -lead-lag -6K7 14 8 -A3.5 22 4.5
local/remote -6K6 31 9 -A3.5 31 4.6
local/remote -6K6 32 10 -A3.5 23 4.6
PTC 1 11 -A3.5 29 5.3
PTC 2 12 -A3.5 30 5.4
space heater 15 22 7.3

from
-3K1

SC 15-22 MA
space heater 16 N4 7.3
space heater PE 7.3
drier 17 L4 7.5
drier 18 N4 7.5
drier PE 7.5
cond. drain 19 L4 7.6

from
cond. drain 20 N4 7.6
cond. drain PE 7.6
pressure switch -5B1 gr/ge -5B1 PE 5.2

te rm in a l
pressure switch -5B1 1 -5B1 1 21 -A3.5 26 5.2
pressure switch -5B1 2 -5B1 2 27 5.2

s trip
RS-485 M 32 -A3.5 5.5
RS-485 RXD 33 -A3.5 5.6
RS-485 TXD 34 -A3.5 5.6
RS-485 shield PE shield 5.7
supply U -3K1 1 1.1
supply V -3K1 3 1.1
supply W -3K1 5 1.2
supply PE 1.2
supply PE 1.4
238.00204MA-00
59/73

Page
fr. 2
1
Ps.
 external cable
Page

Status
description c o n n e c tio n line: - X 2
1

external function internal function

Change
page/line

bridges

conn. no.

Date
connection
connection

description
description

functional text

Name
Local 1 -6K6 22 /6.4

Name
Date
Local 2 -6K6 21 /6.4

Stand.
Check.
Remote 3 -6K6 14 /6.5
Remote 4 -6K6 13 /6.5
remote start/stop 5 -6K7 A1 /6.6

GKL
GKL
remote start/stop 6 -6K7 A2 /6.6

16.11.07
Running 7 -3K1 14 /6.7
Running 8 -3K1 13 /6.8

Orig.
from
SC 15-22 MA

from
te rm in a l
s trip

238.00204MA-00
60/73

Page
fr. 2
2
Ps.
 61/73

No. Quant. Art.No.

Material list
Name Maker
Page 1

Part. No. Ref.

1 1 13600185 Air Control 1 el. compressor control AC1 Sauer -A3.5

2 4 13700401 3005507 fuse connection f. Fuse 6,3x32mm UK10-Drehsi Phoenix -2F5, -2F1
-2F2, -2F4
3 2 132.00196 fuse 4A 6,3x32mm Siemens -2F5, -2F1
4 2 132.00197 fuse 1A 6,3x32mm Siemens -2F2, -2F4
5 1 137.08940 8WA2 011-1SG20 fuseconnection for 5x20mm Siemens -2F6
6 4 132.00173 8WA1822-7EF76 fuse 1A 5x20mm Siemens -2F3,-2F6, -3F5 -3F6
7 3 132.01205 3RT1015-2AP02-1AA0 relay type S00 3KW, AC230V50/60HZ cage-clamp; Siemens SC 5-8 -3K1, -3K2, - 3K3
1 132.01205 3RT1015-2AP02-1AA0 relay type S00 3KW, AC230V50/60HZ cage-clamp; Siemens SC 10 -3K2
2 132.01206 3RT1017-2AP02-1AA0 relay type S00 5,5KW, AC230V50/60HZ cage-clamp; Siemens SC 10 -3K1, -3K3
3 132.00600 3RT1024-3AL20-1AA0 relay type S0 5,5KW, AC230V50/60HZ cage-clamp; Siemens SC15 -3K1, -3K2, - 3K3
1 132.00602 3RT1024-3AL20-1AA0 relay type S0 5,5KW, AC230V50/60HZ cage-clamp; Siemens SC 22 -3K2
2 132.00600 3RT1026-3AL20-1AA0 relay type S0 11KW, AC230V50/60HZ cage-clamp; Siemens SC 22 -3K1, -3K3
8 3 132.00601 3RH1921-2DA11 auxiliary switch block 1NC1NO cage-clamp Siemens SC15-22 -3K1 - 3K3
9 1 132.00604 3RT1015-2AP01-1AA0 contactor type S00, 3-ph. AC230V 50/60Hz 1NO Siemens MA60 -3K4
1 132.00377 3TG1010-0AL2 relay 4- pol. 50/60Hz Siemens MA50

10 1 137.00461 heater 440V, 600W KTY-sensor Sauer -2R1

11 1 136.00103 90.820-F06-4Mf temp. sensor KTY G1/4 Jumo -4R2
12 1 136.01250 3SB12031AC01 em. stop button 40mm,1 NC rd,22mm Siemens -2S1
13 1 136.01251 3SB1400-0C switch element 1NC Siemens -2S1
14 1 136.01216 STV 0,1 control transformer 440/230/18/10V 112VA EMB MA 60 -2T2
1 136.00278 STV 0,1 control transformer 400/230/18/10V 112VA EMB MA 50
15 1 13600120 EDI16 pressure sensor 0-16bar 4-20mA Condor -4U1
16 3 137.00664 8WA2011-1DH20 terminal 6mm² cage-clamp Siemens -X1
17 1 132.00278 3RH11222AP01 auxiliary relay 230V 50/60Hz 2NO 2NC Siemens Option Loc/Rem -6K6
18 1 136.05009 3TX7002-2AF00 coupling relay AC/DC230V 1S Siemens Option Loc/Rem -6K7
19 1 136.00090 3SB12024LB01 key operated switch 1S 22mm Siemens Option Loc/Rem -6S2
20 2 137.08665 8WA2011-1PH20 PE-terminal 6mm² cage-clamp Siemens -X1

21 8 137.08666 8WA2011-2DG20 two-tier terminal 4mm² cage-clamp Siemens -X1

22 2 137.08667 8WA2011-1PG20 PE-terminal 4mm² cage-clamp Siemens -X1
23 1 137.08668 8WA2011-1PG30 PE-terminal 4mm² 3 connections cage-clamp Siemens -X1
24 1 136.08313 current transformer 50/5A 1,25VA Peterreins Option Ameter -1T1
25 1 136.08327 EC48 ameter 50/5A 48x48mm Microtherm Option Ameter -1P1
26 1 135.06339 1229 solenoid valve 230V AC 50/60Hz Bürkert -3Y1
27 1 134.00220 MC1,5/4ST/3,81 Mini-Combicon fem. connector 4-pol. Phoenix -A3.5
28 1 134.00221 MC1,5/5-ST/3,81 Mini-Combicon fem. connector 5-pol. Phoenix -A3.5
29 1 134.00054 MC1,5/6-ST/3,81 Mini-Combicon fem. connector 6-pol. Phoenix -A3.5

Date 16.11.07
Name GKL SC 15-22 MA60 material list
Check. GKL Page 1
Stat. Change Date Name Stand. Orig. from from
238.00204MA-00 of 2 Ps.
 62/73

No. Quant. Art.No.

Material list
Name Maker
Page 1

Part. No. Ref.

30 1 134.00223 MC1,5/10-ST/3,81 Mini-Combicon fem. connector 10-pol. Phoenix -A3.5

31 1 134.00224 MSTB2,5/3-ST Combicon fem. connector 3-pol. Phoenix -A3.5
33 1 134.00225 MSTB2,5/7-ST Combicon fem. connector 7-pol. Phoenix -A3.5
34 1 3SB1202-2AB01 knob-operated switch 1S Siemens Option -7S3
35 1 3SB1212-6BG06 signalling light 230V white Siemens Option -7H1
36 1 136.00399 3LD2202-0TK53 mains switch 11,5 kW 32A Siemens opt. mains sw. -1Q1
SC 5-15
1 136.00378 3LD2504-0TK53 mains switch 22 kW 63A Siemens opt. mains sw.
SC 22
37 1 137.09130 mounting rail 35mm 530mm

Date 16.11.07
Name GKL SC 15-22 MA60 material list
Check. GKL Page 2
Stat. Change Date Name Stand. Orig. from from
238.00204MA-00 of 2 Ps.
 63/73

Lubrication oil recommendation

for Sauer piston and screw compressors
 64/73

Introduction for lubricating oils for Sauer compressors

The following lubricating oil recommendations for Sauer piston and

screw type compressors include:

- Mineral oils
- Synthetic oils
- Preservation oils
- Lubricating oils for Sauer screw type compressors.

Note!
The approved oils in these lists are based upon
proven operational experience with Sauer piston
compressors. Lubricants ’bold’ referred to in the
lubricant table may only be used after approval by
J.P. SAUER & SOHN. Otherwise the warranty is
void. Please contact our Customer Service when
selecting oils not listed, or if operating conditions
differ from those recommended.

Scope The lubricant table applies to all Sauer

compressors. The lubricant table does not apply to
temperature ranges outside of +5 … +55°C.In general,
we recommend mineral oils of the viscosity class in
accordance with ISO VG 100 for the temperature range
5 … 55°C for air compressors. The lubricating oils
should at least con-form to the group VCL in accordance
with DIN 51506.

Changing lubricating When changing lubricating oil types from mineral oil to
oil types from mineral synthetic oil, or vice versa, we recommend to drain
to synthetic oil completely the existing oil and to flush three times before
refilling with the new oil type.
 65/73

Lubricating oils for Sauer piston type compressors

- Mineral oils
Mineral-base oils are used for a wide range of applications providing
exceptional equipment protection and reliability for compressors by:

Mineral-base oil - Mineral oils have good lubricating qualities.

general properties - Mineral oils are available with differing viscosity’s.
- Mineral oils can adsorb water.
- Mineral oils do not affect standard seals (NBR).
- Mineral oils are readily available, worldwide.
- Mineral oils are inexpensive in comparison to “special“ oil types.
- Different mineral oils can be mixed together.
- The disposal of mineral oil is simpler compared to the disposal
needed for synthetic oils.

The range of application for mineral oils is limited by:

Application limitations - Mineral oils are limited by operating temperature.

- Mineral oil viscosity changes with temperature.
- Use of mineral oils may be restricted with high ambient
temperatures.

Standard mineral oil As a standard for industrial applications, Shell Corena P100
is used in Sauer compressors.

Note!
Unless otherwise ordered, Sauer piston compressors are
delivered without oil.
 66/73

Admitted mineral oils The approved list of mineral oils can be used in Sauer compressors:
 67/73

Mineral oils for The following alternative mineral oils can be used without
naval applications restriction for Naval applications:

- Synthetic oils
Synthetic oils are used in applications for which special
properties are needed:

’Special’ properties - Synthetic oils offer good oxidation resistance.

- Synthetic oils have improved viscosity-temperature behavior.
- Synthetic oils are suitable for high and low temperature
operation:

• they have a better flow behavior at low

temperatures;
• they have a slight tendency to vaporize at
high temperatures.

- Synthetic oils have a greater life span owing to lower aging.

- Synthetic oils have a lower combustibility tendency.
- Synthetic oils have an improved chemical compatibility.

The range of application for synthetic oils is limited by the fact as:

Application limitations - Synthetic oils display solubility of additives.

- Synthetic oils have hydrolytic properties
(separation when water is added).
- Synthetic oils have limited anti-corrosion properties.
- Synthetic oils have limited compatibility with elastomers.
- Synthetic oils are not always readily available.
- Synthetic oils are more costly compared to a mineral oil.
- Synthetic oils cannot be mixed with mineral oils.

Note!
We recommend for initial starting to use mineral
oils. Please consult our Customer Service, if you wish to
use synthetic oils.
 68/73

The synthetic oils listed below can be used in Sauer compressors:

Synthetic oils for The NATO classified synthetic oil OY 1230 can be used
naval applications for Naval applications.
 69/73

Compression of The favorable properties of synthetic oil make this oil type
“dry“ gases the re commended choice for Sauer ’dry’ gas
compressors. The absence of water, or oxygen, content in
the ’dry’ gas can result in poor oil film adhesion and rapid
internal wear. To prevent premature wear, Sauer standard is
Mobil Rarus 829 for all ’dry’ gas applications, such as
Nitrogen, Helium, Argon, etc.

Standard synthetic oil As a standard synthetic oil, Mobil Rarus 829 is

recommended for the compression of ’dry’ gases in
Sauer compressors.

Note!
As a standard, compressors for Helium- and Argon
compression are supplied by Sauer with a first filling of
Mobil Rarus 829, while compressors made for the
compression of other gases are supplied without first oil
filling; for special requests, please contact our Service.
 70/73

- Preservation oils
Sauer standard is to use preservation oil Mobilarma 524. Alternatively,
the following preservation or, flushing, oils can be used:

Sauer standard is to deliver all compressors preserved with

Mobilarma 524 to guard against internal corrosion. To avoid any
possibility of downstream contamination on initial start-up, it is
recommended the compressor is run for 15 minutes “unloaded“ with drain
valves open.
 71/73

Lubricating oils for Sauer screw type compressors

The following lubricating oils are recommended for screw
type compressors:

Mineral oils

As a standard mineral lubricating oil Energol RC-R 46 is

used and required for screw-type compressors. The use of other mineral
oils for screw-type compressors is subject to special approval by J.P.
SAUER & SOHN.

Note!
Unless otherwise ordered, screw-type compressors are delivered with oil.
 72/73

Synthetic oils

As a standard synthetic lubricating oil Enersyn RC-S 46 is used and

required for screw-type compressors. The use of other synthetic oils for
screw-type compressors is subject to special approval by J.P. SAUER &
SOHN.

Note!
Unless otherwise ordered, screw-type compressors are delivered with oil.
 73/73

Oil filling amount for Sauer piston and screw type compressors
- Application for Sauer piston type compressors

- Compressor will be supplied without oil

- Oil must be filled into the compressor’s crankcase before
running
- Application point: crank case
- Oil change interval: 50 hour after initial operation
(more detail: please refer to the compressor manual)

Crank case oil volume for Sauer water cooled compressors

(liter/set)

WP100: 9 WP200: 11,5 WP240: 11,5 WP400: 13,5

Crank case oil volume for Sauer air cooled

compressors (liter/set)

WP15L: 1,5 WP22L: 1,5 WP33L: 1,5 WP45L: 5,2

WP65L: 5,2 WP81L: 10,5 WP101L: 10,5 WP121L: 13,6

WP151L: 13,6 WP271L: 21,5 WP311L: 21,5

WP146L: 13,0 WP226L: 21,5

- Application for Sauer screw type compressors

- Compressor will be supplied with oil

- Ensure that the screw compressor is filled with oil before
running. If not please refill the compressor with oil before
running.
- Application point: Oil tank
- Oil change interval: 50 hour after initial operation
(more detail: please refer to the compressor manual and/or to
the maintenance list)

Crank case oil volume for Sauer screw

compressors (liter/set)

SC15: 6 SC22: 6 SC26: 8 SC31: 8

SC42: 17 SC52: 17

SC51: 25 SC61: 25 SC76: 25