Operating instructions

Screw compressor
VARIO 5 - 22
 © 2005

All rights reserved by:

2 ALUP Kompressoren GmbH

Adolf-Ehmann-Strasse 2
73257 Köngen

Tel.: ++49-180-5258700
Fax: ++49-180-5258701

No part of this manual may be reproduced by mechanical or electronic

means without the written consent of ALUP Kompressoren GmbH.

All data in this manual are given to the best of our knowledge, but no
responsibility is taken for the correctness of this information.
We reserve the right to improve and correct the hardware, firmware and
documentation at any time without prior notice.

We appreciate your suggestions and criticism.

Table of contents
1. Foreword.........................................................................4 7.2.3.5 Warnings / maintenance work ....................28
2. Explanation of symbols.................................................5 7.2.3.6 Faults ..........................................................29
2.1 Symbols used in this manual ....................................5 7.2.3.7 Type selection .............................................30
2.2 Symbols on the compressor .....................................5 7.2.3.8 Oil heater ....................................................30
3. Warranty conditions ......................................................6 7.2.3.9 Dryer control ...............................................31
4. Performance and technical data...................................7 7.2.3.10 Maintenance interval for dryer ..................31
4.1 General data .............................................................7 8. Troubleshooting ...........................................................32
4.2 Technical data of the compressor .............................8 9. Maintenance .................................................................34
4.3 Air tank .....................................................................8 9.1 Function cycle.........................................................34
4.4 Compressor ..............................................................8 9.2 Table of normal maintenance activities...................35
4.5 Electric motors and gearboxes .................................8 9.3 Replacing the intake pre-filter .................................36
4.6 Power supply data ....................................................9 9.4 Cleaning or replacing the air filter ...........................37
4.7 Cooling lubricant .......................................................9 9.5 Replacing the oil filter and the deoiling filter ...........38
4.8 Dryer .........................................................................9 9.6 Replacing the oil filter and the oil separator filter....41
4.9 Drawings of installation dimensions 9.7 Draining condensation water ..................................42
and layout plans .......................................................9 9.8 Changing the fuse ..................................................43
5. Safety regulations ........................................................10 10. Spare parts and after-sales centres .........................44
5.1 General regulations ................................................10 11. Diagrams .....................................................................45
5.2 Safety regulations for maintenance work ...............10 11.1 Schematic diagram of the hydraulic-pneumatic
6. Transport and installation ...........................................12 system ...................................................................45
6.1 Instructions for transport .........................................12 11.2 Electrical diagram of main power supply circuits
6.2 Space required for the installation ..........................12 - machines without dryer ........................................46
6.3 Pneumatic connection ............................................15 11.3 Electrical diagram of main power supply circuits
6.4 Electrical connection...............................................15 - machines with dryer .............................................47
11.4 Electrical diagram of secondary power supply circuits
7. Commissioning and operating principle ...................16
- machines without dryer ........................................48
7.1 Checks before commissioning................................16
11.5 Electrical diagram of secondary power supply circuits
7.2 Operating elements ................................................17 - machines with dryer .............................................49
7.2.1 Machine master switch ..................................17
11.6 Electrical-topographic circuit diagram
7.2.2 Emergency stop.............................................17
- machines without dryer ........................................50
7.2.3 Air Control 1 ...................................................18
7.2.3.1 Basic display...........................................19 11.7 Electrical-topographic circuit diagram
7.2.3.2 Switching the generation - machines with dryer .............................................51
of compressed air on/off .........................20
7.2.3.3 Displaying of further operating data........20
7.2.3.4 Menu system ..........................................21
7.2.3.4.1 Parameterising the compressor ...21
7.2.3.4.2 Basic parameterisation .................22
7.2.3.4.3 Code 2: Operating mode ..............23
7.2.3.4.4 Code 3: Automatic restart after
power failure .................................24
7.2.3.4.5 Code 8: Local operation, remote
control, BLS-OK ...........................24
7.2.3.4.6 Code 11: Cut-in and cut-off 3
pressure .......................................24
7.2.3.4.7 Code 18: Base Load Selection
operation (BLS) ............................25
7.2.3.4.8 Code 21: Maintenance
acknowledgement ........................25
7.2.3.4.9 Code 51: Off-load, standstill,
start-up time .................................26
7.2.3.4.10 Code 65: Condensate valve .........26
7.2.3.4.11 Code 90: Unit for pressure
indication ......................................27
7.2.3.4.12 Code 95: Unit for temperature
indication ......................................27
7.2.3.4.13 Code 999: Indication of the
software version ...........................27
 1 Foreword
Dear customer,
Thank you for having bought this compressor and for the confidence you placed in our company.

The machine in your possession is a rotary screw compressor with lubrication - a concentration of
advanced technology for the generation of compressed air.
The screw compressor of series VARIO 5 - 22 is characterised by high efficiency and low-noise ope-
ration.
The primary objectives behind its development were versatile application options, reliability, low ope-
rating and maintenance cost as well as compact design in conjunction with an excellent performance
level. Like all products manufactured in our factories, this series of compressors was developed and
manufactured in accordance with strictest quality control standards.

The product is EC-approved and complies with current European Directives as is demonstrated by
the declaration of conformity that is included in the Annex to this manual.

We urgently ask you to have the compressor installed by the specialists of our authorised
after-sales centres.

Before you commission this machine, we kindly ask you to read all chapters of this
manual with attention and to strictly observe all instructions included therein. In this
way you will be able to get familiar with the methods of correct operation and proper
maintenance of the compressor and the precautions to be taken for operator safety.

This manual must always be available in the vicinity of the compressor in order to have it at
hand when needed.

As far as general maintenance work is concerned, we recommend that you conclude a maintenance
contract for regular servicing with authorised after-sales centres.

4
 Explanation of symbols 2
Symbols used in this manual 2.1
This symbol refers to the necessity of reading the manual attentively and thoroughly before
any work is carried out on the machine.

This symbol is used for describing working steps or behaviour that can result in danger to
life or risk of accident for the operator. All the required preventive and precautionary measu-
res have to be taken and the personnel working on the machine must be instructed accor-
dingly.
Moreover, this symbol refers to activities that require particular attention on the part
of the user.

This symbol refers to activities that may be carried out exclusively by personnel of authori-
sed after-sales centres.

This symbol points out that waste oil, condensation water and all filters of the machine must
be disposed of in accordance with local regulations, since these substances are harmful to
the environment.

Symbols on the compressor 2.2

This symbol stands for the prohibition of reaching with the hands into the machine while it is
in operation.

This symbol indicates that the compressor includes rotary machine parts and that it is conse-
quently prohibited to carry out maintenance or repair work while the machine is in operation.

This symbol indicates that electric voltage is applied inside the machine.

This symbol indicates the direction of rotation of the primary electric motor and the ven-
tilator.

This symbol refers to the oil filling connection.

5

These symbols indicate the direction of rotation of the key, which is included in the scope
of supply, for opening and closing the machine housing and the control panel.

These symbols indicate the nominal voltage of the compressor.

This symbol indicates that the compressor contains hot components.

 Warranty conditions 3
The product is properly tested before it leaves the factory and is subject to a warranty that starts on
the invoice date.

This warranty is applied only, if the buyer observes the contractual and administrative standards and
the compressor is installed and operated in accordance with the instructions given in this manual.

The warranty, which excludes any responsibility for direct and indirect personal injury and damage to
property, is limited to pure design and manufacturing defects on machine parts.
Excluded from the warranty are all parts, which, due to their specific use, are subject to strong wear
such as seals, transmission belts, etc., as well as all consumables such as air filters, oil filters, oil se-
parator filters, etc. Moreover, the warranty does not cover repairs required as a result of damage that
can be traced back to poor servicing or improper use.

The non-observance of the instructions included in this manual, the use of non-genuine spare parts
and maintenance, which is carried out by the customer, but for which no invoices of genuine spare
parts can be presented, render the warranty void.

The entire information included in this manual must be regarded as purely informative and non-bin-
ding. The manufacturer reserves the right to make changes to the product, which he deems necessa-
ry, without prior notice.

6
 Performance and
4 technical data
Gernal data 4.1
Dimensions and Weights:
Compressor L B H Weight
mm mm mm kg*
VARIO 5 1030 615 1045 270
VARIO 7 1030 615 1045 275
VARIO 11 1030 615 1045 280
VARIO 15 1030 615 1045 285
VARIO 16 1030 615 1045 295
VARIO 18 1800 710 1170 480
VARIO 22 1800 710 1170 480 * VARIO_T + 35 kg

Dimensions and Weights (unit mounted on 270 l tank):

Compressor L B H Weight
mm mm mm kg
VARIO 5 TR/270 1180 615 1645 385
VARIO 7 TR/270 1180 615 1645 390
VARIO 11 TR/270 1180 615 1645 395
VARIO 15 TR/270 1180 615 1645 400
VARIO 16 TR/270 1180 615 1645 410

Dimensions and Weights (unit mounted on 500 l tank):

Compressor L B H Weight
mm mm mm kg
VARIO 5 TR/500 1960 615 1645 450
VARIO 7 TR/500 1960 615 1645 455
VARIO 11 TR/500 1960 615 1645 460
VARIO 15 TR/500 1960 615 1645 465
VARIO 16 TR/500 1960 615 1645 475
VARIO 18 TR/500 1960 710 1800 720
7
VARIO 22 TR/500 1960 710 1800 720

General Data
Compressor Coolant Compressed Cooling air
quantitiy air connection quantitiy
l G m³/h
VARIO 5 / T / TR 7 3/4 1000
VARIO 7 / T / TR 7 3/4 1000
VARIO 11 / T / TR 7 3/4 2200
VARIO 15 / T / TR 7 3/4 2200
VARIO 16 / T / TR 7 3/4 2200
VARIO 18 / T / TR 11 1 2600
VARIO 22 / T / TR 11 1 2600
 Performance and
4 technical data
Technical data of the compressor 4.2
The unit is provided with a TM label, which specifies the
technical data of the compressor. The location of this label
is shown on Fig. 25.

TM
PF

Fig. 25

Air tank 4.3

Capacity 270 or 500 litres depending on model; approval for 11 or 17 bar, depending on model.

Compressor 4.4
Patented, single-stage pump unit series VT, model BA69,
lubrication by oil injection.
RM
Main rotor drive RM with 5 teeth and asymmetric profile

Auxiliary rotor drive RF with 6 teeth and

asymmetric profile
RF

Electric motors and gearboxes 4.5

Compressor drive
Encapsulated three-phase asynchronous motor with two poles, nominal speed 3000 rev/min at 50 Hz,
3600 rev/min at 60 Hz, type of protection IP56, insulation class F, operating class S1

Electric ventilator
Ventilator coaxial to the electric motor

Transmission
Motor - compressor: via pulleys with detachable tapered sleeve and V-belt with open flanks.

Electric ventilator: coaxial direct drive

 Performance and
4 technical data
Power supply data 4.6
Three-phase current supply: voltage and frequency according to technical data; supply cables made
of copper braid with minimum cross-section according to table; mains fuses and magneto-thermal
protection according to table.
Electrical data
ompressor Motor- Current at 400 V / 50 Hz Cable
power IN Ifuse cross-section
kW A A gL mm
VARIO 5 / T / TR 5,5 10,7 16 2,5
VARIO 7 / T / TR 7,5 14,5 20 4
VARIO 11 / T / TR 11 20,1 25 6
VARIO 15 / T / TR 15 27,0 40 10
VARIO 16 / T / TR 15 27,0 40 10
VARIO 18 / T / TR 18,5 33,7 50 16
VARIO 22 / T / TR 22 37,0 50 16

Cooling lubricant 4.7

The compressor comes with AGIC DICREA 46 oil.

Total oil quantity according to table

Should it be required to top up cooling lubricant, use the same type of cooling lubricant that was alrea-
dy filled in.

If you wish to use another, non-recommended cooling lubricant type, please contact the tech-
nical department of the manufacturer.

Dryer 4.8
Equipment with temperature-controlled cooling cycle, with direct expansion of the cooling fluid Freon
R134a; average temperature of air cooling for drying: 3 °C;
9
Filtration rating of the conditioned air: 1 micron
Oily residue after filtration: 0.1 mg/m3

The dew temperature can be viewed on the display.

Time-controlled condensate drain, controlled by AirControl1

Drawings of installation dimensions and layout plans 4.9

The drawings of installation dimensions of the compressors are shown on Fig. 1-12. The hydraulic,
pneumatic and electric circuit diagrams (schematic diagram and terminal diagram) are shown in chap-
ter 11.
 5 Safety regulations

General regulations 5.1

Inexperienced personnel may operate the machine only under adequate supervision.
Children and animals must be kept away from the working area.
Never direct compressed air at persons or at your own body.

Wearing goggles is indispensable to protect eyes from foreign bodies that may be swirled around by
the air jet.

Never operate the machines barefoot or with wet hands.

The compressor was developed exclusively for the generation of compressed air and must
therefore not be used for any type of other gas.

The compressed air generated by the machine must not be used for breathing purpo-
ses, for pharmaceutical or sanitary purposes or for production plant, in which the air
gets into direct contact with foodstuffs, unless the air is additionally and adequately
treated.

The air aspired by the compressor must be completely free from dust, vapours of any nature, explosi-
ve or inflammable gases, solvents or sprayed lacquers and poisonous smoke of whatever nature.

Compressed air may only be used for various intended purposes (inflating, pneumatic tools, painting
work, washing with cleaning agents on a watery basis only, etc.) when the standards provided for the
individual applications are known and observed.

Switch the machine not on before having made sure that all protective guards are properly fit and that
nobody can be hit directly or indirectly by air jets, which may escape from pressurised lines without
prior warning.

It must be noted that the machine is completely automated and, depending on the settings and re-
quirements of the operator, performs various working cycles independently.
When the machine is put out of operation after a normal stoppage, it is advisable to disconnect the
voltage on the main control panel.
10 A change in the intended purpose of the machine is to be regarded as improper use: The manufactu-
rer will not be liable for any resulting personal injury or damage to property.

Safety regulations for maintenance work 5.2

The activities of proper maintenance can be carried out by the user according to the instructions given
in this manual.
The safe and reliable long-term operation can only be ensured through the use of genuine
spare parts.
With regard to work that can be carried out by the user, please refer to Chapter 9.
 5 Safety regulations
Extraordinary maintenance work must be carried out by specialists of authorised
after-sales centres.

Before any work is carried out or the protective guards are removed, the power sup-
ply of the machine must be disconnected, the pneumatic system depressurised and
the machine cooled down.

After having disconnected the supply voltage, secure the master switch in order to
prevent undesirable restarting while work is carried out on the compressor. Moreover,
take care that the shut-off valve between the compressor and the distributing line is
closed.

The machine can only be regarded as depressurised when the MPI pressure gauge
inside the machine indicates a pressure equal to zero.

It is not permitted to make any changes to the electrical, pneumatic or oil-dynamic circuits within the
machine and/or to the settings. In particular the peak values of the working pressure and the settings
of any valves on the machine, especially those of the safety valves, must in no case be changed.

The individual components must never be cleaned with solvents, inflammable or poisonous fluids.
Use only alkali cleaning agents - but never for the motor or electrical and electronic components.

Never carry out any welding or mechanical work on tanks: In the case of damage or corrosion, tanks
must always be replaced, since they are subject to specific safety regulations.

At the end of any work, re-fit all protective equipment and guards and take the same precautions as
are required for initial commissioning.

Please remember that waste oil, condensation water and all filters must be disposed
of in accordance with local regulations, since these substances are harmful to the
environment.
11
Thorough and regular maintenance contributes to maintaining the efficiency of the machine and to the
safety of operators.
 6 Transport and installation
Instructions for transport 6.1
For transporting the compressor we re-
commend the use of a forklift truck, with
the forks having to be inserted between the
supporting feed of the machine base frame
(Fig. 27).

Lift the machine exclusively from the front.

This is valid for both, the basic version and
the version with tank.

For the machine with 270-litre tank, the

width of the forks must not exceed 540
mm, whereas there are no restrictions for
the machine with 500-litre tank. Fig 27

Make sure that the load is balanced.

For short distances a hand pallet truck can

be used alternatively. In this case, care
must be taken to prevent excessive stress
on the metal structure (Fig. 28).

If the compressor is to be relocated with

the help of lifting gear, the introduction of
forces onto the lateral parts of the machine
is to be prevented in order not to damage
the housing or the control unit; moreover,
ensure that the load is balanced.
Fig. 28

Tanks under pressure, even of low capacity, must not be transported!

12

Space required for the installation 6.2

General remarks
For the purpose of a correct assessment of the suitability of the place of installation for the com-
pressor, we advise you to have the compressor installed by specialists of our authorised after-sales
centres.

The machines are prepared for direct installation and need no foundations. Erect the compressor hori-
zontally at a stable position, with the weight having to be distributed evenly on the supports.
 6 Transport and installation
The ambient temperature conditions that are listed in the following represent operating limits of the
compressor:

- Maximum height above sea level of the place of installation : 1000 m

- Min. ambient temperature : +5 °C
- Max. ambient temperature : +40 °C
Please note that the machine performance given in this manual is guaranteed only for places, where
the specified limit values are not exceeded.

In the case of special ambient conditions, please consult the technical department of the manufactu-
rer.

Outdoor installation

Fig. 29 shows an example of installation in

the open air.

The compressor must not be exposed

max. 5000
to influences of weather: In the case of
installation in the open air, provide suitable
protection. Observe the minimum clearan-
ce of 0.6 m from walls of buildings.
min. 3000

600

Fig. 29

Indoor installation

The machine is not suitable for operation in environments that are classified as „po-
tentially explosive“.
13
The air aspired by the compressor must be completely free from dust, vapours of any
kind, explosive or inflammable gases, solvents or sprayed lacquers and poisonous
smoke of whatever kind. In the case of critical environments (presence of ceramic,
marble, cement dust, etc.), replace filters more frequently and place special attention
to the air filter.
 6 Transport and installation
The size of the installation room and ven-
ting facilities must allow that the ambient
temperature can be maintained during
normal operating conditions.

If no suitable opening is available for

carrying away warm air, provide the
installation of one or several venting
points. These venting points should be
located at the highest possible point in
the room.

Air ducts possibly installed for using the

cooling air of the machine for heating the Fig. 30
room must be dimensioned so that the air
flow velocity does not exceed 3 m/s and
that the ducts are not longer than 6 m; if
these limits cannot be adhered to, install
an auxiliary ventilator into the warm air
duct system.

In any case, backpressure that might occur as a result of the installation of warm air ducts
must not exceed 5-6 mm of the water column, measured at the warm air outlet of the compres-
sor.

As a guideline, a cross-section of the air duct may be assumed that corresponds to the outlet grid for
warm air on the compressor.
If the necessary minimum temperature cannot be guaranteed, heat the surroundings.

The minimum clearances from walls of

a room as specified on Fig. 31 must be
adhered to. 600
600
The compressor must be arranged in the
room so that ease of inspection is ensured.
If the compressor is installed within the
working area, an adequate safety distance
must be provided that depends on the type
14 of machining carried out and is to avert 600
risks or damage to the machine by the
products used.

Fig. 31
 6 Transport and installation
In no case may the compressor be in-
stalled in a niche that will not guarantee
sufficient venting; the warm airflow must
not be hindered and no re-flowing may
occur (Fig. 32).

Fig. 32

Pneumatic connection 6.3

When connecting the compressor to a tank or to a distributing line, it is recommended that a hose of
suitable size and with suitable properties (pressure and temperature) be installed in between and con-
nected to connection MA. All air carrying lines must be in perfect condition and adequately mounted.

Especially hoses can cause severe damage due to uncontrolled movements, if they are not firmly
connected. Before pressurising hoses, make sure that the ends are firmly anchored.
The condensation water drain must be connected via a suitable line to a collecting system, which
complies with local regulations with regard to the disposal of environmentally harmful substances.

Electrical connection 6.4

The electrical system for the power supply must be provided with a lockable master switch with circuit
breaking function, fuses or a magnetothermal protective switch with a disconnecting capacity, which is
suitable for the characteristics of the machine, and means of protecting the personnel from unintentio-
nal contacts.
The protective equipment must be set and the rating of the circuit breaker selected according to the
15
instructions given in the table of chapter 4.6.
The switch must be located in the direct vicinity of the machine, with the specific local regulations for
the prevention of accidents having to be strictly observed.
The supply cables must have a cross-section that is suitable for the current consumption values (refer
to the table in chapter 4.6).
The electrical systems must be properly installed by a qualified electrician who must verify the effi-
ciency of the grounding system.
The supply cable must be mounted using the cable binders provided for this purpose, and the control
panel must be positively closed in order that the specified type of protection IP44 is achieved.
The machine must never be connected to non-approved sockets or sockets, which are not provided
with a suitable grounding cable of proven efficiency.
Have the correct mounting of the electrical cabling of the individual components checked periodically
by qualified personnel.
The block diagrams and circuit diagrams of the auxiliary and power circuits are shown in chapter 11.
The same diagrams are also provided inside the control panel of the machine.
 Commissioning and
7 operating principle
Checks before commissioning 7.1
REMARK: The erection, electrical connections and pneumatic connections are carried out to the
buyer‘s account.

It is indispensable that initial commissioning of the system is carried out by trained

personnel, who carry out various checks and observe the associated information.

Each machine was thoroughly inspected before it left the company.

Nevertheless, we recommend that the compressor be checked, in particular during the first
operating hours, in order to detect possible faults.

• For the installation, all requirements specified in chapters 5 and 6 must be met.
• All the materials and devices used for packing the machine must be stowed away
• The compressor must be connected to the air supply system as described in chapters 6.2 and 6.3
• Check the oil level in the tank: For more details, see chapter 9.5. In the case of a low oil level,
top up with lubricating oil with the correct properties.
• Compare the data on the nameplate of the compressor with those of the existing electrical system
for compliance; a difference in voltage of +/-10 % from the nominal intensity is permitted.
• Connect the machine to the electrical system in accordance with the information given in section 6.4.

For the electrical connection, it is crucial

that the phase sequence of the voltage is
observed, since this determines the direc-
tion of rotation, which must correspond to
the data specified on the label on the screw
compressor group (Fig. 33).
We expressly point out that rotation in the
wrong direction, even for a few seconds
only, can lead to serious damage.
The electronic control panel includes a fea-
ture for checking the phase sequence and
hence prevents possible mistakes.
16
Fig. 33

The machine is now ready for operation.

Nevertheless, we recommend our customer to read chapter 9 that refers to mainte-

nance in order to get familiar with this topic before the machine is started up.
 Operating elements 7.2
7.2.1 Machine master switch The externally installed machine master switch connects and dis-
connects the machine from the power supply.

The machine master switch must be switched off, when any

maintenance and installation work is to be carried out, and
must be secured against unauthorised or unintentional swit-
ching on (e.g. install warning sign or sign that prohibits swit-
DANGER
ching on)!

7.2.2 Emergency Stop The machine may only be shut down with the emergency stop in
an emergency!

To shut the motor down in the event of danger, press pushbutton.

Make sure that the shut down machine is sufficiently secured

against unauthorised restarting!
Unlock the machine only when the cause of risk is properly
eliminated and an operationally safe condition of the machine
DANGER is restored.

To unlock the machine:

1 Pull emergency stop pushbutton
2. Press the key to acknowledge the fault.
3. Press the key to restart the machine.

17
 AirControl 1 7.2
7.2.3 Air Control 1 The operating/display panel of Air Control 1 serves for
• displaying the machine state/operating data
• switching the generation of compressed air on/off
• parameterising the machine.

Changing of parameter values

Acknowledgement of changes to parameters

Displaying of additional operating data

Switching the compressor on.

Integrated green LED
flashes: The compressor is not running, but
can start up automatically at any
18
time
is on: The compressor is running.

Switching the compressor off.

Signalling of a present warning/fault by the integrated

red LED.
 AirControl 1 7.2
7.2.3.1 Basic display After operation of the master switch or during normal operation, Air Control
1 informs you about the state of the compressor.

Current line pressure

Warning present (see chapter 7.2.3.5)

Motor running

Compressor compresses air

Fault present (see chapter 7.2.3.6)

Restart Automatic restart after power failure is activated

Automatic Automatic or Automatic optional operating mode

Remote - flashing: Generation of compressed air on/off by 19

means of remote switch
- static: Generation of compressed air is controlled by
higher-level control

Current compressor temperature

Instead of the current compressor temperature, the current cooling fluid

temperature can be displayed: Press key. For viewing further operating
data, see chapter 7.2.3.3.
 AirControl 1 7.2
7.2.3.2 Switching the generation ON: Press key.
of compressed air on/off The compressor is ready and can start up automatically at any time.

The compressor starts up only when

• the current line pressure falls below the cut-in pressure and
• the compressor temperature is at least 1 °C.

OFF: Press key.

The compressor changes over to the on-load mode for the duration of the
standstill time and then switches off.

During the cut-off procedure, the compressor first changes to the „off-
load“ mode (motor running, but compressor does not compress air; a
flashing dot is shown on the display) for the duration of the standstill time
(45); only then switches the compressor off (motor stops).

7.2.3.3 Displaying of further By pressing the INFO key repeatedly you can successively view the follo-
operating data wing operating data:

Operating data

1x Cut-in pressure in bar. The compressor starts up as soon as the

mains pressure falls below this value.
2x Cut-off pressure in bar. The compressor switches to the off-load
mode as soon as the mains pressure rises above this value
3x Safety pressure in bar (= cut-off pressure + 0.8 bar). When the
safety pressure is reached, the compressor is shut down and a fault
20 message is output.
4x Min. permitted compressor temperature
5x Max. permitted compressor temperature
6x Total operating hours
7x On-load hours
8x Remaining service life of air filter
9x Remaining service life of cooling fluid and cooling fluid filter
10x Remaining service life of fine separator
11x Remaining service life of motor lubrication
12x Remaining time until compressor maintenance

The display of faults/warnings is deactivated!

As long as the operating data above are displayed, faults or war-

nings are not shown. For this reason, exit this display as soon as
CAUTION possible.
 AirControl 1 7.2
7.2.3.4 Menu system All basic settings of the compressor can be viewed in the menu system.
As far as changes have no influence on the operational safety, these can
be made by entering codes.

7.2.3.4.1 Parameterising the The compressor can only be parameterised, when the generation of com-
compressor pressed air is switched off. See chapter 7.2.3.2

Parameter changes allow the adjustment of the compressor to your

specific requirements. To this end, Air Control 1 must be switched to the
parameterisation mode.

The individual parameters can then be selected and changed by means

of code numbers. A description of the available code numbers can be
found in chapters 7.2.3.4.3 to 7.2.3.4.13.

Proceeding for parameterising:

1. Press key until the message „cod“ appears on the display. Air Control
1 is now at the main level of the parameterisation mode.

Code
(flashing)

2. Use keys and to set the required code.

3. Press the ENTER key to select the code. Air Control 1 now changes to
21
the first sub-level.

With some codes, several parameters can be entered successively. In

such cases, pressing of the ENTER key automatically selects the subse-
quent parameter.

4. Change the current setting of the selected code according to your re-
quirements by means of keys and .
5. Press the ENTER key in order to accept the new settings or press key
(0) to leave the old settings unchanged and return to the next higher
level.
 AirControl 1 7.2
7.2.3.4.2 Basic parameterisation The compressor can only be parameterised while the generation of com-
pressed air is switched off. See chapter 7.2.3.2.

Before carrying out basic parameterisation, prepare the compressor for

operation.
1. Press key until the message „cod“ appears on the display.

2. Use keys and to set code 11 and then press the ENTER key.
3. Press INFO key
Air Control 1 now shows the cut-in pressure. The compressor compres-
ses air as soon as the mains pressure falls below this value. Possible
adjustment range: 3.5 to maximum pressure of the compressor.Einstell-
bereich: 3,5 bis Maximaldruck der Anlage.

Code (flashing)

4. Set the required cut-in pressure using keys and and acknowledge
the setting by pressing ENTER.
5. Press INFO key.
The Air Control 1 now shows the cut-off pressure. The compressor
changes over to the off-load mode as soon as the mains pressure rises
above this value. Possible adjustment range: 3.5 to maximum pressure
of the compressor.

Cut-in pressure (flashing)

The cut-off pressure must be higher than the cut-in pressure!

6. Set the required parameter value with the help of keys and and
confirm the selection by pressing ENTER.
22
7. Press key to terminate basic parameterisation.

Cut-off pressure (flashing)

 AirControl 1 7.2
7.2.3.4.3 Code 2: Determines, how the compressor responds upon reaching the cut-in or
Operating mode cut-off pressure. Both limit values are set in the course of the basic para-
meterisation (see chapter 7.2.3.4.2).

0: Automatic
The symbol „Automatic“ is shown on the display.
The motor starts up and the compressor compresses air (= on-load
operation) as soon as the mains pressure falls below the cut-in pressure.
The compressor changes over to the off-load mode (motor running, but
compressor does not compress air) as soon as the mains pressure rises
above the cut-off pressure. The off-load time starts to elapse as the off-
load phase is entered (for the parameterisation, see code 51, chapter
7.2.3.4.9). When the off-load time has elapsed, the motor stops.
1: On-load/off-load
The symbol „Automatic“ is not shown on the display.
In contrast to automatic operation, the motor never stops. The compres-
sor compresses air as soon as the mains pressure falls below the cut-in
pressure. The compressor changes over to the off-load mode (motor
running, but compressor does not compress air) as soon as the mains
pressure rises above the cut-off pressure.
2: Automatic optional
The display shows the symbol „Automatic“ and an additional dot in front
of the temperature value.
Similar to the automatic mode. However, in this mode, it is possible to
determine how often the motor stops. To this end, your are prompted
to set the parameters „maximum pressure drop“ (input range 0.0 to
9.9 bar) and „maximum no. of cycles“ (input range 1 to 55 cycles/
hour).

„Maximum pressure drop“ function:

When the compressor changes from on-load operation to off-load
operation, Air Control 1 saves the current mains pressure after 10 and
45 seconds. If the pressure drop such established is higher than the
„maximum pressure drop“, the motor shuts down after the off-load
time has elapsed (parameterisation by means of code 51, see chapter
7.2.3.4.9), otherwise after the standstill time (45 s).

„Maximum no. of switching cycles“ function:

The motor is not shut down after the off-load time has elapsed, if the
number of cut-in cycles of the compressor exceeds the „maximum no. 23
of switching cycles“
 AirControl 1 7.2
7.2.3.4.4 Code 3: Automatic Determines, whether the generation of compressed air is to be reassu-
restart after power med automatically after a power failure.
failure
0: Automatic restart OFF
After a power failure that generation of compressed air remains switched
off. The fault message „Power failure“ is output.
1: Automatic restart ON
When this function is activated, the symbol „Restart“ appears on the
display. When the generation of compressed air was switched on before
the power supply failed, the system starts up automatically after the
standstill time elapsed. In this case, the fault message „Power failure“
will not appear. When the generation of compressed air was switched
off before the power failure occurred, it will remain switched off.

7.2.4.4.5 Code 8: Local operati- Determines, how the generation of compressed air is switched on or off.
on, remote control,
BLS-OK 0: Local operation
The generation of compressed air can only be switched on and off on
the operating/display panel of Air Control 1.
1: Remote control
The generation of compressed air can only be switched off via a posi-
tive edge (24 VDC) at terminal 23 and by means of a low level (0 V) at
terminal 23 or by pressing key (0). This functionality is signalled on the
display of Air Control 1 by the flashing text „Remote“. When the (0) key
is operated locally on the compressor, the compressor shuts down after
45 seconds and can, for safety reasons, only be restarted by remote
control after the (I) key was operated locally (acknowledgement). This
is also valid for a start by means of PLANT CONTROL V/T.
2: BLS-OK
The input at terminal 23 is used for signalling an external control‘s rea-
diness for operation. Only when a high level (24 VDC) is present can
the external control switch between on-load and off-load operation (see
code 18, value 1, chapter 7.2.4.4.7). While the low level is present, BLS
operation is automatically switched off and the internal pressure sensor
used.

24

7.2.3.4.6 Code 11: Cut-in and Determines the cut-in and cut-off pressure. For the proceeding, see chap-
cut-off pressure ter 7.2.3.4.2.
 AirControl 1 7.2
7.2.3.4.7 Code 18: Base Load Determines, whether the changeover between on-load and off-load ope-
Selection operation ration is to be assumed by the internal pressure sensor or by a higher-le-
(BLS) vel control.

0: Changeover between on-load/off-load operation via internal pres-

sure sensor
1: Changeover between on-load/off-load operation by external control
(e.g. PLC).
On-load operation, when high level (24 VDC) is present at terminal 22.
Off-load operation, when low level (0 V) is present at terminal 22. This
functionality is signalled by the static text „Remote“ on the display of Air
Control 1.

7.2.3.4.8 Code 21: Maintenance Serves for acknowledging a momentarily present maintenance warning:
acknowledgement For the meaning of maintenance numbers and the acknowledgement of
warnings, see chapter 7.2.3.5.

Damage to the system is possible!

Required maintenance work is signalled in the form of warnings.
Acknowledge such warnings only when the corresponding mainte-
nance was in fact carried out!
CAUTION No maintenance results in the reduction of the service life and reli-
ability of the system. Please note that damage caused by improper
treatment will not be covered by the warranty!
Use only genuine spare parts.
For information about maintenance, see chapter 9.

25
 AirControl 1 7.2
7.2.3.4.9 Code 51: Off-load, Associated times can be entered successively in operator control levels 0
standstill, start-up time to 2:

0: Off-load time
Input range: 10 - 1200 s. Function in conjunction with code 2 (operating
mode). Is used in the operating modes „Automatic“ and „Automatic
optional“.
1: Standstill time
Input range: 0 - 60 s. The factory setting of 45 s should be left unchan-
ged. During the standstill time, the motor is idling; no compressed air is
generated. The standstill time starts to elapse:
- when the compressor is switched off using key (0)
- with automatic restart
- in the operating mode „Automatic optional“
2: Start-up time
Input range: 3 - 30 s. Determines after which period of time changing
over from star to delta connection is to take place when the motor is
switched on.

7.2.3.4.10 Code 65: Is used for adjusting the impulse and break times of the condensate valve
Condensate valve

0: Impulse time
Operating time of the condensate valve
1: Break time
Turn-off time of the condensate valve

26
 AirControl 1 7.2
7.2.3.4.11 Code 90: Unit for Determines the unit for the indication of pressure:
pressure indication
0: bar
1: MPa
2: psi

7.2.3.4.12 Code 95: Unit for
temperature indication
Determines the unit for the indication of temperature:
0: Degree Celsius (°C)
1: Degree Fahrenheit (°F)
2: Kelvin (K)

7.2.3.4.13 Code 999: Indication Shows the software version of Air Control 1.
of the software
version

27
 AirControl 1 7.2
7.2.3.5 Warnings / maintenance A warning is present, when the red lamp is flashing.
work
The compressor is not shut down.

The following is shown on the display

Maintenance number
(flashing)

Symbol for warnings

(flashing)

Meaning of maintenance numbers:

2 Final compressing temperature too high
3 Mains pressure too high
11 Remaining time until maintenance of intake filter < 100 h
12 Remaining time until maintenance of cooling fluid / cooling fluid filter
< 100 h
13 Remaining time until maintenance of fine separator < 100 h
14 Remaining time until maintenance of motor lubrication < 100 h
15 Remaining time until maintenance of compressor < 100 h

Damage to the system is possible!

Required maintenance work is signalled in the form of warnings.
Acknowledge such warnings only when the corresponding mainte-
nance was in fact carried out!
28 CAUTION No maintenance results in the reduction of the service life and reli-
ability of the system. Please note that damage caused by improper
treatment will not be covered by the warranty!
Use only genuine spare parts.
For information about maintenance, see chapter 9.

Acknowledging maintenance work:

1. Press key (approx. 3 sec.) until the message „cod“ appears on the
display.
2. Select code 21 using keys and .
3. Press ENTER and successively.
 AirControl 1 7.2
7.2.3.6 Faults A fault is present, when the red lamp is permanently on.

The compressor stops automatically.

The following is shown on the display:

Fault symbol (flashing)

Fault number
(flashing)

Fault text
alternating with compression
temperature

Meaning of the fault numbers and texts:

1 Par Incorrect pressure setpoint values

2 EMPROM Incorrect parameter setting
3 Lo AC Undervoltage
4 No AC Power failure
5 OEFEC Air Control 1 defective
6 Emerg Emergency stop actuated
7 Rotat Wrong direction of rotation
8 Mot t Motor temperature high
9 Hi cur Overcurrent
10 Hi P Overpressure
11 Dif P Differential pressure of fine separator
12 Se t Final compression temperature sensor
13 Se oil Cooling fluid temperature sensor
14 Se P Pressure sensor
15 Hi t Final compression temperature high
16 Hi P Line pressure high
29

Faults can only be acknowledged, if their cause was properly rectified

before. Troubleshooting and repair must be carried out exclusively by
qualified personnel!

Acknowledging fault messages:

1. Press key.
2. Press key in order to restart the generation of compressed air.
 AirControl 1 7.2
7.2.3.7 Type selection Input „Code 0060“
060
1
##### new types „C-rS“ and „C-rSE“

7.2.3.8 Oil heater Input „Code 0005“

005
1
# 1 = Oil heater = present
0 = Oil heater = not present

0: Oil heater = not present

If the temperature is in the range „+1°C ... +5°C“, the display shows
„warning low temperature“, but the machine is still allowed to start.
If the temperature is equal or below „0°C“ the compressor is not allowed
to start (the green LED and the symbol „°C“ are blinking).

1: Oil heater = present

If the external oil heater is activated (input 25+31 of AC-1 is open), then
the compressor is not allowed to start (green LED and the symbol „°C“
are blinking). If the oil heater is activated for more then 10 minutes, the
compressor is allowed to start.
When the oil heater is activated, in the display the decimal point right
beside the temperature is turned on (for examble „25°C“).

30
 AirControl 1 7.2
7.2.3.9 Dryer control Input „Code 0060“
080
1
# Dryer off / on (0 / 1)

ENTER
080
2
# Dryer off temp. (0°C ... 6°C)

ENTER
080
3
## Dryer diff. temp. (0°C ... 6°C)

ENTER
080
4
### Min. time dryer off (30 ... 180s)

ENTER
080
5
## Dewpoint temp. offs. (-10 ... +10°C)

When the dryer is activated, the symbol is shown on the display.

The dewpoint temperature will bei displayed when the key is pressed
(the symbol „T2“ is also displayed => „2nd temperature“).

When the keys and ENTER are pressed at the same time, the dryer
can be turned ON/OFF manually. If the dryer is turned off, the symbol
ist blinking.
31

7.2.3.10 Maintenance interval Input „Code 0040“

for dryer 040
1
##### maint. interval (0 ... 20000h)
 8 Troubleshooting
Fault
Excessive compression tem-
perature (red lamp on)
Mains pressure falls
System blows off via safety
valve
32
„Fault overpressure“ or „Line
pressure high“ (red lamp on)
Cause
- Sound insulation hood not closed
- Intake/ambient temperature too
high
- Cooling inlet or outlet blocked
- Cooling fluid filter clogged
- Cooling fluid shortage
- Cooling fluid cooler externally
contaminated! Caution: Always
secure cooler fitting by means of
a spanner; avoid torque on the
cooler
- Compressed air consumption
higher then delivery volume of the
compressor
- Air filter clogged
- Unloading valve blows off during
compressing
- Intake regulator does not open
- Leakage in the mains
- Mains pressure set too high
- Safety valve defective
- Minimum pressure valve blocked
- Fine separator cartridge clogged
- Fine separator clogged
- Higher external pressure in the
compressed air mains
Remedy
- Check and close sound insulation
hood
- Vent compressor room
- Clear sufficiently
- Change cooling fluid filter
- Top up cooling fluid
- Clean with compressed air. In the
case of severe contamination:
Remove cooler and clean it with a
water-jet cleaner. Caution: Risk
of short-circuit! Do not wet elec-
trical components
- Compressor with greater delivery
volume required
- Replace air filter
- Check unloading valve and, if
required, replace seals
- Check and, if required, replace
solenoid valve and regulator pis-
ton
- Seal mains
- Re-adjust mains pressure
- Check and, if required, replace
safety valve
- Replace solenoid valve
- Replace fine separator cartridge
- Change fine separator
- Adjust external pressure or dis-
connect it from the mains
8 Troubleshooting
Fault
Compressor does not start
up automatically, or does not
deliver air after preceding
shutdown due to having
achieved final pressure, or
from off-load mode
System does not start up
when the start key is
pressed
Compressed air contains
great amount of cooling fluid
(cooling fluid consumption
too high)
System stops before rea-
ching final pressure (red lamp
lights up)
Water in the mains
Pressure drop
Cause
- Mains pressure set too high
- Interruption in the control current
circuit
- Ambient temperature below +1
°C, message „Coolant flow temp.
too low“
- Mains pressure higher than cut-in
pressure
- Remote circuit activated
- No voltage applied to the com-
pressor
- Electrical fault in the control
- Cooling fluid return line blocked
- Defective fine separator
- Overtemperature or overpressure
- Interruption in the control current
circuit
- Dryer switched off
- Condensate drain not operable
- By-pass open
- Dewpoint too high
- Pressure differential across filter
too high
Remedy
- Re-adjust mains pressure
- Check control current circuit for
interruption (by an electrician
only)
- Install auxiliary heater or heat
compressor room
- Observe line pressure value
- Symbol „remote“ flashes
- Check, whether voltage is applied
- Check (by an electrician only)
- Clean cooling fluid return line
- Replace fine separator
- Rectify fault as required
- Check control current circuit for
interruption (by an electrician
only)
- Switch dryer on
- Clean/replace drain 33
- Close by-pass
- Call after-sales service
- Replace filter
 9 Maintenance
To maintain the performance of the compressor over a long period of time it is necessary to carry out
regular maintenance.
The manufacturer authorises the user to carry out some of the regular maintenance activities, provi-
ded that trained personnel is assigned to these tasks.
We expressly point out that only genuine spare parts may be used.
For the instructions, please read the following paragraphs.

Before starting any maintenance work, please read chapter 5 attentively, which deals
with the safety regulations for workers. It is indispensable to strictly observe these
regulations for all kinds of maintenance work.

Function cycle 9.1

The compressor group consists of two rotors (main and auxiliary rotor) with special, asymmetric pro-
file, patent series VT, which are mounted onto rolling bearings that withstand axial and radial pressu-
res. The main rotor is the drive motor, whereas the auxiliary rotor is the driven rotor. The main rotor
takes the secondary rotor along when rotating. The two rotors are nevertheless not in direct contact
with each other, since they run on an oil film that protects the contact surfaces.
The oil therefore assumes several functions: Lubrication of the bearings and the rotors, dissipation of
the heat generated by the air compression process, provision of a „fluidic seal“, reduction of detrimen-
tal clearances in the interior of the pump group, noise reduction.
With compressors with fixed speed, the machines start up in a start-delta circuit. During the phase of
star connection, inlet valve VA is closed: This procedure allows starting up in the off-load mode with
low forces and low energy consumption.
After a pre-determined period of time of some seconds, control unit PC initiates the transition to the
delta connection, and after a short transient state, motor MP reaches its nominal speed. This causes
the inlet valve to open, and the normal working cycle starts.

The air aspired through filter FA is directed to the pump group and mixes with the injected oil. It is gra-
dually compressed and pressed into the separator vessel, where the oil is separated for the first time
under gravity. This oil settles at the bottom.
The air, which is still mixed with small oil droplets, flows through oil separator filter FD as a result of
the specific design of the vessel. Due to the coalescence effect, the oil drops combine and settle at
the bottom of the filter, from where they are fed back to the pump group through a line.
The cleaned air is directed to check and pressure reducing valve VT, which opens only when the limit
value of approx. 4 bar is exceeded, thus guaranteeing the correct lubrication of the system under all
34 operating conditions.

The oil settled at the bottom of tank SS is fed by pressure to oil cooler RO, where it is cooled down. If
the oil temperature falls below the value set on thermostat valve VT, the flow through the oil cooler is
by-passed and the oil flows through filter FO back to the injection point in the pump group. Temperatu-
re sensor STO, which is integrated in the outlet and connected to a microprocessor, allows continuous
temperature monitoring of the pump group.

The control of the delivery volume differs for machines with fixed speed and those with variable
speed. On compressors with fixed speed, the piston of the inlet valve closes when the nominal opera-
ting pressure is reached. The internal pressure in the tank is reduced to a value of approx. 2 bar.
This value is maintained by a minimum amount of air aspired by the inlet valve, which ensures that
the pressure required for correct lubrication of the system is maintained. For this reason, the machine
can continue to run in the off-load mode with low energy consumption.
After a pre-determined operating time in the off-load mode, the machine comes to a standstill and is
ready to restart automatically as soon as the pressure falls below the minimum limit value.
 9 Maintenance

Table of normal maintenance activities 9.2

The following table lists the entire maintenance work that is to be carried out on the machine.

Activities that must be carried out by specialists of the after-sales centre are marked
with the symbol shown on the left.

After the After the

To be carried Every Every Every Every
first 100 first 1000
Intervention Reference out by after- 500 1000 2000 4000
operating operating
sales service hours hours hours hours
hours hours

Check of intake
pre-filter
9.3
• • •
Replacement of intake
pre-filter
9.3
• •
Check of air filter 9.4
• • •
Replacement of air
filter
9.4
• •
Overhaul of minimum
pressure valve •
Overhaul of intake
valve •
Replacement
of oil filter
9.6
• • •
Oil level check / top-
ping up oil
9.5
• • •
Oil change 9.5
•
Replacement of
deoiling filter
9.6
•
Check of oil return
• •
Check of couplings
for jamming • • •
Check of electrical
terminals • • •
Condensate drain of
air/oil tank
9.7
• • • 35

Cleaning of cooler
• •
Cleaning of
condensate dryer • •
Replacement
of dryer filter • •
Check of voltage and
wear of belts • • •
Replacement
of drive belts •
Check of settings and
calibrations •
Function check of
protective equipment •
 9 Maintenance
* This period of time is valid for normal environmental dust conditions. In the case of critical dust con-
ditions, the display may signal the necessity of maintenance or replacement of the air filter before the
stated period of time has elapsed. In this case, replace the filter as soon as possible. Our specialists
are pleased to establish the dust conditions prevailing at the place of installation when they install the
compressor.

Replacing the intake pre-filter 9.3

Before starting any maintenance work, please read chapter 5 attentively, which deals
with the safety regulations for workers. It is indispensable to strictly observe these
regulations for all kinds of maintenance work.

From the outside of the compressor:

PA
loosen the screws that are used for fixing
cover PPA of the intake pre-filter
From the inside of the compressor:
remove the grid of the intake pre-filter
and take filter insert PA out (Fig. 37).

Replace filter insert PA

Re-fit the grid of the intake pre-filter.

PPA

Fig. 37

With regard to zeroing the hours counter for the activities of regular maintenance (only acces-
sible to authorised users), please refer to section 7.2.3.5.

Cleaning or replacing the air filter 9.4

36 Before starting any maintenance work, please read chapter 5 attentively, which deals
with the safety regulations for workers. It is indispensable to strictly observe these
regulations for all kinds of maintenance work.

VARIO 5-16

Open the upper panel PS of the com-

pressor housing by loosening the fixing
screws.

Open the front panel PF of the compres-

sor using the spanner that is included in
the scope of supply.
 9 Maintenance

Loosen fixing clamp FFA shown on Fig. FA

38 and take air filter FA out.

Blow through the filter by directing the

air jet to the inside or replace the filter as
indicated on the maintenance schedule:
never use fluids or cleaning agents for
cleaning the filter.

Shove the filter up to the limit stop on FFA

the inlet valve

Completely tighten the fixing clamp. Fig. 38

Die Abdeckungen PS und PF des

Gehäuses montieren

With regard to zeroing the hours counter for the activities of regular maintenance (only acces-
sible to authorised users), please refer to section 7.2.3.5.

VARIO 18-22

Open filter flap SF of the compressor

housing with the spanner that is included
in the scope of supply.

Unlatch the front part of filter housing CF

by opening the two latches (Fig. 39).
Take air filter FA out of its fixture (Fig.
40).

Blow through the filter by directing the

air jet to the inside or replace the filter as
indicated on the maintenance schedule:
never use fluids or cleaning agents for 37
cleaning the filter.
CF
Fig. 39
 9 Maintenance

Insert filter FA to the limit stop.

Snap in the front part of filter housing

CF by closing the two latches.

Refit filter flap SF of the compressor

housing

FA

Fig. 40

With regard to zeroing the hours counter for the activities of regular maintenance (only accessible to
authorised users), please refer to section 7.2.3.5.

Replacing the oil filter and the deoiling filter 9.5

Before starting any maintenance work, please read chapter 5 attentively, which deals
with the safety regulations for workers. It is indispensable to strictly observe these
regulations for all kinds of maintenance work.

Oil level check and topping up oil

We recommend that the oil level be frequently checked after the machine was switched off for
at least 30 minutes.

For inspection, simply remove front panel PF and check the oil level on oil level indicator tube TRL
38 (Fig. 41).

The oil level must be visible, but must not exceed the reference marking for the maximum level RL-
MAX.
When the oil level comes close to the lower limit of oil level indicator tube TRL, top up oil.

The oil level must never fall so far that no oil at all is visible in oil level indicator tube
TRL.

The maximum oil level is reached when the oil reaches the edge of the reference marking for max.
level RLMAX.

If it is required to top up oil, proceed as follows:

 9 Maintenance
Remove front panel PF with the help of
the spanner that is included in the scope
of supply.

Remove plug TO and take care not to TRL

lose the seal (Fig. 42).

It is advisable to use a funnel for filling, RLMAX

which is to be inserted in the oil fill con-
nection (Fig. 42).
RLMIN
Fill in oil and observe the information
given in chapter 4.7.

Do not fill in too much oil!!! The oil Fig. 41

level must not exceed the reference
marking max. level RLM (Fig. 33)

Check whether the seal of the plug fits

properly and tighten plug lightly.

Re-fit front panel PF with the help of the

spanner that is included in the scope of
supply.

TO
Fig. 42

Oil change
Change the oil at regular intervals as specified in the table of regular maintenance in chapter 10.2 or
when another oil than that existing in the machine is to be used.

This process must be carried out while the oil is still warm in order that it features a
low viscosity and high flowability; however, the oil temperature must not be so hot
that it can cause burns! 39

Proceed as follows:

Remove front panel PF with the help of

the spanner that is included in the scope
of supply.

Remove plug TO and take care not to

lose the seal (Fig. 43).

Connect adapter R, which is included in

the scope of supply and connected to a
suitable collecting container on one end,
to connecting piece DO after the safety
plug was removed (Fig. 44).
 9 Maintenance

Open valve RSO to let the oil drain (Fig.

44).

When the oil has drained completely,

close valve RSO again.

Fill in oil and follow the steps described

in „Oil level check and topping up oil“
(Fig. 43).

Lightly screw on plug TO, after having

checked the seal for correct fit.

Re-fit front panel PF with the help of the

spanner that is included in the scope of
supply.

Open the isolator valve between the

compressor and the distributing line,
switch on the master switch and perform TO
a test run. After some minutes of opera- Fig. 43
tion, carry out a visual inspection of the
machine in order to detect any potential
leaks of lubricants.

Re-check the oil level as described in

the chapter „Oil level check and topping
up oil“ and, if required, top up oil.
RSO

40 DO

Fig. 44

Please remember that waste oil, condensation water and all filters of the machine
must be disposed of in accordance with local regulations, since these are environ-
mentally harmful substances.

With regard to zeroing the hours counter for the activities of regular maintenance (only acces-
sible to authorised users), please refer to section 7.2.3.5.
 9 Maintenance

Replacing the oil filter and the oil seperator filter 9.6

Before starting any maintenance work, please read chapter 5 attentively, which deals
with the safety regulations for workers. It is indispensable to strictly observe these
regulations for all kinds of maintenance works.

Remove front panel PF with the help of

the spanner that is included in the scope
of supply.
FO
Remove top panel PS with the help of
the spanner that is included in the scope
of supply.
Remove the insert of oil filter FO using
an appropriate spanner (Fig. 45)

Before installing the new filter insert,

lubricate its seal (Fig. 46)

Screw the filter on and tighten it by hand:

Do not use any tools for tightening the
filter insert in order not to damage its
Fig. 45
structure!

Open the isolator valve between the

compressor and the distributing line,
switch on the master switch and carry
out a test run.

After some minutes of operation, carry

out a visual inspection of the machine
in order to detect potential lubricant
leaks.

Check the oil level again as described in

the section „Oil level check and topping
up oil“ and, if required, top up oil

Re-fit top panel PS and front panel PF. 41

Fig. 46

Please remember that waste oil, condensation water and all filters of the machine
must be disposed of in accordance with local regulations, since these are environ-
mentally harmful substances

With regard to zeroing the hours counter for the activities of regular maintenance (only accessible to
authorised users), please refer to section 7.2.3.5.
 9 Maintenance

Draining condensation water 9.7

Before starting any maintenance work, please read chapter 5 attentively, which deals
with the safety regulations for workers. It is indispensable to strictly observe these
regulations for all kinds of maintenance works.

If the machine is provided with a dryer and/or air tank, Air Control 1 controls the electrical valve of the
condensation water drain in relation to time and in a programmable manner.

In the case of machines that are provided with a dryer with or without air tank, the condensation water
is drained via the connection located at rear panel PP.

In the case of machines that are provided with an air tank, the condensation water is drained via the
electrical valve located on air tank SA.

Air tank
Drain the condensation water collected in the air tank as follows:

Place a suitable container under drain

plug screw RSC below air tank SA
RSC
Make sure that the isolator valve bet-
ween the compressor and the air supply
line is closed.
SA
Open drain screw RSC (Fig. 47), if
required, with the help of water pump
pliers

Drain the condensation tank until the

tank is completely empty.
Fig. 47
Re-fit drain plug screw RSC.

42 Please remember that waste oil, condensation water and all filters of the machine
must be disposed of in accordance with local regulations, since these are environ-
mentally harmful substances.

Tank of the oil/air separator

The condensation water that accumulates in the deoiling tank must be drained from time to time utili-
sing the principle of the formation of layers of resting fluids.
This process must be repeated the more frequently, the more critical the ambient conditions are (low
temperature, high humidity) and the more frequently the compressor starts up under cold conditions.

When carrying out this operation, make sure that the compressor has been at rest for
at least one hour.
 9 Maintenance
Remove front panel PF with the help of
the spanner that is included in the scope
of supply RSC

Connect connecting piece R, which is

connected to a suitable collecting con-
tainer on one end, to connecting piece SA
RSO
DO after having removed the safety plug
(Fig. 48)

Open drain valve RSO (Fig. 48).

Observe draining of the fluid and close

drain valve RSO immediately as soon
as lubricant starts to flow out.

Check the oil level again as described in

the chapter „Oil level check and topping
up oil“.

Remove the safety cover and the PF

panel. DO

Fig. 48

Please remember that the user must regularly drain the condensation water manually from the
air tank and the deoiling tank once a week.

Changing the fuse 9.8

Please remember that waste oil, condensation water and all filters of the machine
must be disposed of in accordance with local regulations, since these are environ-
mentally harmful substances.

Open the electric control box (panel

SCE) with the spanner provided for this
purpose.
43
Replace damaged fuses observing the
fuse values specified in chapters 12.8
and 12.9.

Close the electric control box (panel

SCE).

Fig. 49
 10 Spare parts and
after-sales centres
The manufacturer guarantees optimum after-sales service through its closely meshed after-sales ser-
vice network and its technical office that will provide solutions in the event of problems.
When contacting the authorised after-sales centres or the manufacturer, you have to indicate the mo-
del and its serial number.

To learn, which after-sales centre is close to the place of installation of the compressor, or to
obtain any other information, please contact us by phone or fax at the following numbers:

(+49) 01805-258 700 Fax: (+49) 01805-258 701

E-mail: service@alup.com

44
 11 Diagrams
Schematic diagram of the hydraulic-pneumatic system 11.1

45

Legend
1 Air filter 8 Oil filter 16 Air tank group (only with
2 Intake unit 9 Air/oil exchanger versions equipped accordingly)
2.1 Air filter clogging sensor 10 Oil return 16.1 Air tank
3 Drive 11 Oil separator filter 16.2 Safety valve
4 Motor 12 Pressure reducing and check 16.3 Drain valve
5 Pump group valve 16.4 Condensate drain (only
6 Separator tank 13 Air/air exchanger on version with tank
6.1 Safety valve 14 Line pressure encoder without dryer)
6.2 Oil level indicator 15 Dryer unit (only with versions
6.3 Air-oil mixture temperature equipped accordingly)
sensor 15.1 Dryer
6.4 Oil drain valve 15.2 Temperature sensor
7 Thermostat valve 15.3 Automatic condensation
water drain
 11 Diagrams
Electrical diagram of main power supply circuits
- machines without dryer 11.2

46
11 Diagrams
Electrical diagram of main power supply circuits
- machines with dryer 11.3

47
 11 Diagrams
Electrical diagram of auxiliary circuits
- machines without dryer 11.4

48
11 Diagrams
Electrical diagram of auxiliary circuits
- machines with dryer 11.5

49
 11 Diagrams
Electrical-topographic circuit diagram
- machines without dryer 11.6

50
11 Diagrams
Electrical-topographic circuit diagram
- machines with dryer 11.7

51
D
ALUP-Kompressoren GmbH
Tel.: +49/7024/802-0
Fax: +49/7024/802-106
Internet: www.alup.com
E-mail: info@alup.com
Adolf-Ehmann-Str. 2
73257 Köngen
DEUTSCHLAND

A
AGRE-Kompressoren GmbH
Tel.: +43/7252/52341-0
Fax: +43/7252/52133
Internet: www.agre.at
E-mail: office@agre.at
Werkstraße 2
4451 Garsten-St. Ulrich
ÖSTERREICH

NL
ALUP-Kompressoren B.V.
Tel.: +31/30/2809000
Fax: +31/30/2895675
Internet: www.alup.nl
E-mail: info@alup.nl
Biezenwade 8-10
3439 NW Nieuwegein
NEDERLANDS

HU
ALUP Magyarország Kft.
Tel.: +36/36/423444
Fax: +36/36/516340
Internet: www.alup.hu
E-mail: info@alup.hu
Szálloda u. 5
3300 Eger
MAGYARORSZÁG
Manual_VAR_gb_03-2005

BG
ALUP-Kompressoren Bulgaria OOD.
Tel.: +359/2/528032
Fax: +359/2/528032
E-mail: alup@skycode.com
Tsar Asen Str. 63
1000 Sofia
BULGARIA