Operating instructions

Screw compressor
L22S - 37

Issue December 2000 Ident. no.: 100 00 2311 / 00

2
 1. Foreword

1.1 Notes on the compressor The machine/unit must only be used in technically
perfect condition and in accordance with its intended
CompAir screw compressors are the result of many use and the instructions set out in the operating manu-
years of research and development. These prerequi- al, and only by safety-conscious persons who are fully
sites combined with high quality standards guarantee aware of the risks involved in operating the machine/
the manufacture of screw compressors providing a long unit! Any functional defects, especially those affecting
service life, high reliability and cost-effective operation. the safety, have to be rectified immediately (or rectified
It stands to reason that all requirements concerning by others)!
environmental protection are met.
The machine/unit is designed exclusively for the
generation of compressed air to power air-driven de-
Certificate of conformity vices. Using the machine/unit for purposes other than
those mentioned above is considered contrary to its
The compressor and its accessories as supplied by intended use. The manufacturer/supplier cannot be
CompAir conform to the basic safety and health requi- held responsible for damage resulting from such use.
rements included in the EC Machinery Directive 98/37/ The risk of such misuse lies solely with the user.
EC. The compliance with the currently valid directives
is demonstrated by the "CE mark" (Fig. 1). Operating the machine within the limits of its intend-
ed use also involves observing the instructions set out
in the operating manual and complying with the in-
spection and maintenance directives.

1.3 Maintenance
Carefully performed maintenance is imperative, this
ensures that your screw compressor can meet all the
requirements placed upon it. It is, therefore, indispen-
sable to adhere to prescribed servicing and mainte-
nance intervals and to carry out servicing and upkeep
thoroughly, especially in the case of harsh operating
conditions.

Fig. 1
Servicing
Please contact your authorized CompAir dealer in
the case of malfunctions or when spare parts are re-
quired. In the case of damage, our fully trained per-
1.2 Intended use sonnel will ensure that a quick and proper repair is
The machine/unit has been constructed in accord- carried out using original CompAir spare parts. Origi-
ance with state-of-the-art technology and the recog- nal CompAir spare parts are manufactured utilizing
nized safety regulations. Nevertheless, its use may state-of-the-art technology, thus guaranteeing the fur-
constitute a risk to life and limb of the user or third per- ther reliable operation of the unit.
sons or cause damage to the machine or to other ma-
terial property, if In case of queries
• it is not used as intended,
Please enter the data on the nameplate of your com-
• it is operated by unqualified personnel,
pressor into the nameplate shown below (fig. 2). In the
• it is improperly modified or changed, case of queries or spare parts orders, please refer to
• the safety regulations are not observed. the compressor type indicated on the nameplate, the
Therefore, any person entrusted with the operation, identification no. and the year of construction. With this
maintenance or repair of the machine must read and information at hand it can be guaranteed that you will
follow the safety regulations. If required, this has to be receive the right information or required spare parts.
acknowledged by signature.
In addition,
• relevant accident prevention regulations,
• generally recognized safety regulations and
• national regulations
have to be observed.

3
 1. Foreword

Guarantee
CompAir Operate this compressor only if you have an exact
knowledge of the machine taking into respect these in-
structions.
CompAir Drucklufttechnik cannot be held responsi-
ble for the safe operation of the machine/unit if it is
used in a manner, which does not correspond to the
intended use, or for other applications, which are not
mentioned in these instructions.
Warranty claims will not be accepted in the case of
• Operating errors
• Incorrect maintenance
• Wrong auxiliary materials
• Use of spare parts other than CompAir original
spare parts
• Modifications and changes to the installation
The warranty and liability conditions of the general
terms and conditions of CompAir Drucklufttechnik will
not be extended by the notes above.
Any unauthorized change to the compressor unit/sta-
tion, or the installation of components not accepted by
the manufacturer (e.g. fine separator) will result in the
withdrawal of the CE mark. As a consequence, any lia-
Fig. 2
bility and warranty claims will not be accepted by the
manufacturer.
1.4 Notes
General
These operating instructions are intended to familiar- Safety regulations
ize the user with the machine/unit and its intended use.
The instructions contain important notes on how to Danger.
operate the compressor safely, properly and cost-effec-
tively. Observing these instructions helps to avoid risks, The safety regulations in chapter 3 of the operating
to reduce repair costs and downtimes and to increase instructions have to be strictly observed.
the reliability and service life of the machine/unit.
The operating instructions have to be supplemented
by the respective national rules and regulations re- Technical changes
garding the prevention of accidents and environmen-
In the course of technical development we reserve the
tal protection. They must always be available at the lo-
right to modify the units without further notice.
cation of the machine/unit. The operating instructions
must be read and followed by any person carrying out
work in connection with the machine/unit, e.g. opera-
tion, including setting up, trouble-shooting in the oper-
ation cycles, disposal of production waste, care, serv-
ice, and disposal of waste fuels and consumables, up-
keep (maintenance, inspection, repair), transport.
Besides the operating instructions and the binding
regulations for the prevention of accidents, which are
valid in the country and place of operation of the ma-
chine/unit, the generally recognized technical regula-
tions for safe and proper working have also to be ob-
served.

4
 2. Table of contents

1. Foreword .................................................................................................................................................................. 3

1.1 Notes on the compressor ............................................................................................................................... 3

1.2 Intended use ................................................................................................................................................... 3
1.3 Maintenance ................................................................................................................................................... 3
1.4 Notes ............................................................................................................................................................... 4

2. Table of contents ..................................................................................................................................................... 5

3. Safety regulations ................................................................................................................................................... 7

3.1 Identification of safety guidelines ................................................................................................................... 7

3.2 General safety instructions ............................................................................................................................. 7
3.3 Changes and modifications to the machine .................................................................................................. 8
3.4 Installation and normal operation .................................................................................................................. 8
3.5 Special work/maintenance ........................................................................................................................... 10
3.6 Warning of special dangers ......................................................................................................................... 11
3.7 Storage of compressors ............................................................................................................................... 13
3.8 Symbols and explanations ........................................................................................................................... 14

4. Design and functioning ......................................................................................................................................... 19

4.1 Design of the unit .......................................................................................................................................... 19

4.2 Schematic diagram ....................................................................................................................................... 20
4.3 Oil circuit ....................................................................................................................................................... 21
4.4 Air circuit ....................................................................................................................................................... 21
4.5 Start/stop/shutdown ...................................................................................................................................... 21

5. Transport and installation ..................................................................................................................................... 22

5.1 Transport ....................................................................................................................................................... 22

5.2 Installation ..................................................................................................................................................... 22

6. Preparations for commissioning ......................................................................................................................... 23

6.1 Cooling air volume/minimum cross-sections .............................................................................................. 23

6.2 Compressed air connection ......................................................................................................................... 23
6.3 Electrical connection .................................................................................................................................... 24
6.4 Oil level check ............................................................................................................................................... 26
6.5 Sound pressure level ................................................................................................................................... 26

7. Commissioning ..................................................................................................................................................... 27

7.1 First commissioning ...................................................................................................................................... 27

7.2 Routine commissioning ................................................................................................................................ 27
7.3 Commissioning after malfunction ................................................................................................................ 28
7.4 Operating modes .......................................................................................................................................... 28
7.5 Setting of the operating pressure ................................................................................................................. 28
7.6 Monitoring ..................................................................................................................................................... 29

5
 2. Table of contents

8. DELCOS 1000 electronics ................................................................................................................................... 30

8.1 Operating elements ...................................................................................................................................... 31

8.1.1 Keyboard ......................................................................................................................................... 31
8.1.2 Light emitting diodes ....................................................................................................................... 32
8.1.3 Final compression pressure display (bar) ...................................................................................... 33
8.1.5 Menu structure DELCOS 1000 ........................................................................................................ 33
8.1.4 Final compression temperature display (°C) .................................................................................. 33
8.2.1 Start of the unit ................................................................................................................................. 34
8.2.2 Operation under load/idle running .................................................................................................. 34
8.2 Commissioning ............................................................................................................................................. 34
8.2.3 Stopping of the unit .......................................................................................................................... 34
8.2.4 Malfunctions/shutdowns/power failures ......................................................................................... 34
8.2.5 Warnings/maintenance ................................................................................................................... 34
8.2.6 Collective fault relay ........................................................................................................................ 34
8.2.7 Operating/load hours counter ......................................................................................................... 35
8.2.8 Fault log ............................................................................................................................................ 35
8.2.9 Fault log table ................................................................................................................................... 36
8.3 Menu Additional functions ............................................................................................................................ 38
8.3.1 Navigating in the menu ................................................................................................................... 38
8.3.2 Changing the settings ..................................................................................................................... 38
8.3.3 Maintenance intervals ..................................................................................................................... 39
8.3.4 Operating modes ............................................................................................................................. 40
8.3.4.1 Automatic operation ...................................................................................................... 40
8.3.4.2 Continuous operation ................................................................................................... 40
8.3.4.3 Remote control (Remote ON/OFF) ............................................................................... 40
8.3.4.4 Automatic restart after power failure ............................................................................. 41
8.3.4.5 Extended automatic restart after power failure ............................................................ 41
8.3.5 Factory settings ................................................................................................................................ 41
8.3.5.1 Changing the run-on time ............................................................................................. 42
8.4 Controlling the unit via a terminal strip ........................................................................................................ 42
8.4.1 Remote control (remote ON/OFF) ................................................................................................... 42
8.4.2 Input External fault ........................................................................................................................... 42
8.5 Installation of a new DELCOS 1000 ............................................................................................................ 43
8.6 Brief instructions for DELCOS 1000 ............................................................................................................ 44

9. Servicing and maintenance ................................................................................................................................. 46

9.1 Maintenance and lubricant recommendations ............................................................................................ 46

9.2 Maintenance electric motor .......................................................................................................................... 46
9.3 Servicing and maintenance schedule ......................................................................................................... 46
9.4 Oil change ..................................................................................................................................................... 48
9.5 Change of the oil filter cartridge ................................................................................................................... 49
9.6 Change of the fine separator ....................................................................................................................... 49
9.7 Air filter change/check .................................................................................................................................. 50
9.8 Safety valve ................................................................................................................................................... 51
9.9 V-belts - automatic tensioning system ......................................................................................................... 51
9.10 Connecting terminals in the switch cabinet ................................................................................................. 52
9.11 Fittings ........................................................................................................................................................... 52
9.12 General maintenance and cleaning ............................................................................................................ 53
9.13 Maintenance instructions and lubricant recommendations for stationary compressors ........................... 53

10. Trouble-shooting ................................................................................................................................................... 54

6
 3. Safety regulations

3.1 Identification of safety guidelines 3.2 General safety instructions

CompAir is not liable for any damage or injury result- Organizational measures
ing from the non-observance of these safety instruc-
The operating instructions must always be at hand at
tions or negligence of the usual care and attention
the place of operation of the machine/unit (in the tool
required during handling, operation, maintenance or
compartment or box provided for such a purpose) !
repair, even if this is not explicitly mentioned in these
operating instructions. In addition to the operating instructions, all other ge-
nerally applicable legal and other mandatory regulati-
If any of the regulations contained in these instruc-
ons relevant to accident prevention and environmental
tions - especially with regard to safety - does not corre-
protection must be adhered to and passed on to
spond to the local legal provisions, the stricter of both
others ! These compulsory regulations may also deal
shall prevail.
with the handling of hazardous materials or the is-
These safety regulations are general and valid for suing/wearing of personal protective equipment, or
various types of machines and equipment. It is there- traffic regulations.
fore possible that some references do not apply to the
Instructions, including supervisory responsibility and
unit(s) described in these instructions.
duty of notification for taking into account in-plant fac-
tors, for example regarding work organization, se-
quences of operations, personnel assigned to certain
tasks, are to be added to the operating manual.
Danger.
The personnel entrusted with working on the ma-
Passages marked with this sign indicate a possible chine must have read the operating instructions and in
danger to persons. particular the chapter on safety regulations before
starting work. Reading the instructions after work has
begun is too late. This applies especially to persons
Important working only occasionally on the machine, e.g. for
setting up or maintenance.
Passages marked with this sign indicate a possible
danger to machines or part of machines. Check on a regular basis that the personnel are
carrying out the work in compliance with the operating
instructions and that they are paying attention to the
Note safety requirements !

Passages marked with this sign provide technical For safety reasons, long hair must be tied back or
information on an optimal cost-effective use of the ma- otherwise secured, garments must be close-fitting and
chine. no jewellery - such as rings - may be worn. Injury may
result from being caught up in the machinery or from
rings catching on moving parts ! As necessary or as
required by regulations, personal protective equip-
ment should be used.
Observe all safety and warning notices attached to
the machine/unit !
See to it that safety instructions and warnings at-
tached to the machine are always complete and per-
fectly legible.
In the case of safety-relevant changes to the ma-
chine/unit or its operating behaviour, stop the ma-
chine/unit immediately and report the fault to the re-
sponsible department/person !
Spare parts have to comply with the technical re-
quirements specified by the manufacturer. This can
always be ensured by using original spare parts.
Hydraulic hoses have to be changed within stipulat-
ed and periodic intervals, even if no safety-relevant
faults have been detected !
Adhere to prescribed intervals or those specified in
the operating instructions for routine checks and in-
spections !
For the execution of maintenance work, tools and
workshop equipment adapted to the task on hand are
absolutely indispensable.

7
 3. Safety regulations

The personnel must be made familiar with the locati- we would like to refer in particular to the following re-
on and operation instructions of fire extinguishers ! gulations.
Observe all fire-warning and fire-fighting procedures ! For the lifting of a compressor, a suitable lifting me-
Limit values (pressures, time settings, etc.) have to chanism is to be used, which meets the local safety re-
be permanently identified ! gulations. All loose or slewable parts must be safely fi-
xed before the machine can be lifted. It is strictly prohi-
bited to stay in the danger zone of a lifted load.
Selection and qualification of personnel; The correct method of lifting (according to the opera-
basic responsibilities ting instructions of the load suspension device) has to
Work on/with the machine/unit must be carried out by be ensured.
reliable personnel only. Statutory minimum age limits All blind flanges, plugs, caps and bags with drying
must be observed! agent have to be removed prior to the installation of
Employ only trained or instructed personnel and the pipes. Distributing pipes and pipe connections
clearly set out the individual responsibilities of the per- have to be of the proper size and suitable for the rele-
sonnel for operation, set-up, maintenance and repair ! vant operating pressure.

Ensure that only authorized personnel work on or The system has to be installed in such a way that it is
with the machine ! adequately accessible and the required cooling is
guaranteed. Never block the air intake. Make sure that
Define the machine operator's responsibilities giving the ingress of humidity via the intake air is kept to a mi-
the operator the authority to refuse instructions by third nimum.
persons that are contrary to safety regulations.
The air intake is to be located so that no hazardous
Do not allow persons to be trained or instructed or constituent (solvent vapour, etc., but also dusts and
persons taking part in a general training course to other hazardous material) can be sucked in. This app-
work on or with the machine/unit without being perma- lies also to flying sparks.
nently supervised by an experienced person !
The air intake is to be positioned so that no loose
Work on the electrical equipment of the machine/unit clothing of persons can be sucked in.
must be carried out only by a skilled electrician in ac-
cordance with electrical engineering rules and regula- Make sure that the pressure line from the compres-
tions. sor to the aftercooler or the air circuit can expand un-
der heat and does not come into contact with in-
Work on system elements such as hoses may only flammable material.
be carried out by personnel with special knowledge
and experience of hydraulics ! The pressure line connected to the air outlet of the
system must be fitted stress-free.
If a remote control is used, the system must carry a
3.3 Changes and modifications to the clearly visible sign with the following note : Attention !
machine This installation is operated by remote control and can
start up without prior warning !
Do not make any changes, modifications or attach-
ments to the machine/unit, which could affect safety, As an additional safety measure, persons, who start
without the supplier's prior permission ! remotely controlled systems, have to take sufficient
safety precautions in order to ensure that nobody is
Unauthorized changes to the machine are not per- checking the system or working on it. For this, a label
mitted for safety reasons. with a corresponding warning notice has to be atta-
Original parts were especially designed for this ma- ched to the remote control equipment.
chine. We would like to point out that we have not re- Compressed air and cooling water lines have to be
leased and will not release parts and special accesso- clearly marked in line with the local regulations.
ries which have not been supplied by us. The installa-
tion and/or use of such products can therefore affect If a system comprises several compressors, hand-
the active and/or passive safety. operated isolator valves have to be installed in order
to be able to shut off each machine individually. When
The manufacturer is not liable for damage resulting operating pressure systems, do not rely on the effecti-
from the use of non-original parts or special accesso- veness of check valves alone to isolate these systems.
ries. This applies also to the installation and setting of
safety equipment and valves as well as to welding on Safety equipment, protective covers or insulation
structural or pressurized parts. must not be removed or modified. Any pressure reser-
voir, which is located outside the system, the permissi-
ble operating pressure of which is higher than the at-
3.4 Installation and normal operation mospheric pressure and which is fitted with two or
more pressure supply lines, has to be equipped with
Installation additional safety equipment, which will automatically
prevent the admissible operating pressure from rising
In addition to the general technical operation in ac- by more than 10 %.
cordance with the stipulations of the local authorities,

8
 3. Safety regulations

The system-specific safety valves used in these com- • Cooling water must not be discharged in an
pressors only assume the pressure safeguarding uncotrolled manner to the public drainage systems.
functions that are prescribed according to currently va- Uncontrolled overflowing of the oil separator reser-
lid standards and regulations. voir to the public drainage systems must be
For the pressure devices/systems installed at the avoided.
pressure side connection flange of the compressor, a Strictly observe the relevant waste water regula-
corresponding pressure safeguarding feature (safety tions.
valve or similar) must be provided taking into account • Maintenance and repair work has to be carried out
the weakest pressurized component. carefully. Dismantled bundles of pipes have to be
The min. and max. temperatures of +1 °C and +40 °C checked for damage prior to being reinstalled. In
are also valid for the intake air. the case of even the slightest damage, the pipes
have to be replaced.
Pipes and/or other parts with a surface temperature Always use new seals when carrying out assembly
higher than 70 °C have to be suitably identified and and mounting work.
shielded against touching.
Electrical connections must meet the local regulati- Normal operation
ons. Power units must be connected to earth and pro-
tected from short-circuits by means of fuses. Take the necessary precautions to ensure that the ma-
chine is used only when in a safe and reliable state !
Operate the machine only when all protective equip-
Cold dryer ment, emergency shut-off equipment, sound-proofing
Wherever possible, the cold dryer should be instal- elements and extraction devices are in place and fully
led in a place where the ambient air is as clean as functional !
possible and where the temperatures never rise abo- Check regularly that
ve or fall below the respective limit values as indicated
• all means of protection are correctly fitted and fixed,
in the operating instructions. If required, the cooling air
is to be taken from a cleaner, cooler or warmer area • all hoses and/or pipes within the system are in
via an intake channel; depending on the size of the good condition, firmly fixed and do not chafe,
machine, an additional ventilator could turn out to be • there are no leakages (fuel, oil or coolant),
necessary. • all fittings are firmly tightened,
If the room temperature can fall below zero, the con- • all wires are connected correctly and are in good
densation drain system must be protected from free- condition,
zing, e.g. by means of a steam heater. • all safety valves and other pressure relief mecha-
nisms are in good order and not blocked by e.g. dirt
If it is possible that the intake temperature of the air or paint,
will exceed, from time to time, the admissible maxi-
• the safety mechanisms are fully functional.
mum specified in the operating instructions, a pre-coo-
ler with condensate drain is to be installed before the If compressed air hoses are used, they must be of
dryer. the proper size and suitable for the relevant operating
pressure. Do not use chafed, damaged or poor-quality
Tests or repair work on the coolant circuit may only
hoses.
be carried out in a well vented room. Never breath in
cool-ant vapour; if necessary, wear a breathing mask. Only use hose couplings and fittings of the right type
Always wear protective goggles and gloves. If skin and the correct size.
comes into contact with coolants, rinse well with water. Before blowing through a hose or an air pipe ensure
Never take off or tear up clothes but rinse them well that the open end is positively held. A free end whips
with water until the coolant is washed off; then see a and can cause injuries.
doctor.
Before decoupling a hose ensure that it is pressure-
less.
Condensate drain
Refrain from any working method which is doubtful in
The drain hose for condensate discharge is to be terms of safety.
connected to the drains or to a collecting reservoir, if
local regulations prohibit direct discharge to the Never play around with compressed air !
drains. In connection with this, it must be taken into ac- Never aim compressed air at your skin or at other
count that the condensate from compressors with oil- persons !
lubricated pressure chambers can contain oil.
Never use compressed air to clean your clothing.
When using compressed air to clean equipment take
Note the utmost care and always wear protective goggles.
When operating water-cooled screw compressor units, The compressed air generated by these compres-
the following points must strictly be adhered to : sors must never be used for breathing unless it has
been conditioned for those applications in line with the
• As a result of leakage in oil/water coolers some oil "safety requirements for respiratory air“.
can get into the cooling water circuit.

9
 3. Safety regulations

Before starting up or setting the machine in motion, • attach a warning sign to the main switch.
ensure that nobody is at risk. Always use the correct tools for maintenance and repair
Do not cut off or remove extraction or venting faci- work.
lities while the machine is running. Never use inflammable solvents or carbon tetrachloride
Never use the machine in an environment, where in- to clean parts. Take precautions against poisonous va-
flammable or poisonous vapour can be sucked in. pours from cleaning agents.
Never operate the system at pressures and tempera- In any work concerning the operation, conversion or
tures below or above the values indicated in the tech- adjustment of the machine and its safety-oriented de-
nical data sheet. vices or any work related to maintenance, inspection and
The access panels, etc. have to be closed during repair, always observe the start-up and shutdown proce-
operation. dures set out in the operating instructions and the infor-
mation on maintenance work.
Persons who stay in an environment or rooms, in
which the sound pressure is 85 dB(A) or higher, have Ensure that the maintenance area is adequately secu-
to wear ear protectors. red.

Check the machine/unit at least once per shift for vi- To lower the risk of accidents, individual parts and large
sible damage and faults ! Report any changes (inclu- assemblies being moved for replacement purposes
ding changes in the machine’s operating behaviour) should be carefully attached to lifting tackle and secured.
to the responsible department/person immediately. If Use only suitable and technically correct lifting gear and
necessary, stop and lock the machine immediately ! only utilize suspension systems with adequate lifting ca-
pacity. Never work or stand under suspended loads !
In the case of malfunction, stop the machine/unit im-
mediately and lock it ! Have any defects rectified im- During maintenance and when carrying out repair
mediately ! work, cleanliness is very important. Avoid the ingress of
dirt by covering parts and free openings with a clean
Observe the start-up and stopping procedures and cloth, paper or adhesive tape.
the control displays according to the operating instruc
After the completion of each repair, check that tooling or
loose parts have not been left in the machine, drive mo-
tor or drive equipment and ensure that no cloth has been
left inside these units.

3.5 Special work/maintenance Be careful when the screw compressor system is in

operation.
Carefulness
Observe the adjusting, maintenance and inspection Maintenance/rectification of faults
activities and intervals set out in the operating instruc- The employer has to inform the employee of the dan-
tions, including information on the replacement of gers possibly arising during the repair and maintenance
parts and equipment. These activities may be carried of the machine/unit as well as on how to avoid them; the
out by skilled personnel only. employee has to observe all measures for safety at work.
Brief the operating personnel prior to starting special Safety equipment for the prevention or elimination of
operations or maintenance work ! Appoint a person to danger has to be maintained regularly and functionally
supervise the activities ! checked at least once a year. Faults observed have to be
immediately rectified and/or reported to the responsible
Maintenance and repair work may only be carried out person.
under the supervision of a person who is qualified for this
work. Use only original spare parts.
Oil losses result in a slippery floor. Therefore, always Only carry out maintenance and repair work when the
clean the floor and the outside of the machine prior to system is not in operation and the power supply discon-
starting the maintenance work. nected. Ensure that the power unit cannot be switched
on inadvertently.
Checks, maintenance and repair work may only be
carried out with the screw compressor being at rest and Before removing or opening pressurized components,
depressurized. Protective equipment to be removed for positively isolate any source of pressure and depressuri-
this work, has to be refitted after completion of these ze the entire system.
activities. Operation of the machine without protective Never weld near oil systems or carry out any other work
equipment is not permitted. When working on a running requiring heat. Pressure reservoirs or components and
screw compressor system, working clothes have to be pipes containing oil have to be drained completely and
close-fitting. cleaned, for example by means of a steam jet, before be-
If the machine/unit is completely shut down for mainte- ginning such work.
nance and repair work, it must be secured against inad- Never weld any pressure reservoir or change it in any
vertent restarting : way.
• Lock the main command elements and remove the
key and/or

10
 3. Safety regulations

If work which produces heat, flames or sparks has to be For carrying out overhead assembly work always use
carried out on a machine, the adjacent components have specially designed or otherwise safety-orientated lad-
to be protected by means of non inflammable material. ders and working platforms. Never use machine parts as
Before releasing the power unit for operation after a climbing aid. Wear a safety harness when carrying out
maintenance or overhaul, check that the operating pres- maintenance work at greater heights.
sures, temperatures and time settings are correct and Keep all steps, handles, handrails, platforms, landings
that the regulating and shut-down equipment function and ladders free from dirt, snow and ice !
properly. Clean the machine, especially connections and
Examine the pressure tube and the pressure vibration threaded unions, of any traces of oil, fuel or preservatives
dampers for carbon deposits every six months. Excessi- before carrying out maintenance or repair work ! Never
ve deposits have to be removed. use aggressive detergents ! Use lint-free cleaning rags !
Motor, air filter, electrical components and regulating Before cleaning the machine with water or steam jet
equipment have to protected from the ingress of humidi- (high pressure cleaner) or other cleaning agents, cover/
ty, e.g. when cleaning the system by means of a steam mask all openings which have to be protected from the
jet. ingress of water, steam or detergents for safety and/or
Under no circumstance must the sound-proofing mate- functional reasons, in particular electric motors and
rial be removed or modified. switch cabinets.

Never use etching solvents which could attack the ma- After cleaning, remove the covers/masking completely !
terials used. Check all hydraulic oil lines for leakage, loose fittings,
If indicated or if there is any suspicion that an internal abrasion and damage after cleaning. Any defect must be
part of the machine has run hot, the machine has to be rectified immediately !
shut down. Always re-tighten screwed connections which have
In order to avoid an increase in the operating tempera- been loosened for maintenance and repair work.
ture, check and clean the heat transfer surfaces (cooling If the set-up, maintenance or repair require the de-
fins, intermediate cooler, water cooling jackets, etc.) at re- mounting of safety equipment, this equipment has to be
gular intervals. Prepare a plan of the most favourable remounted and checked immediately after these activi-
cleaning intervals for each machine. ties.
Avoid damage to the safety valves and other pressure Ensure that consumables and replacement parts are
reducing components. Check in particular for clogging disposed of in a safe and environmentally friendly man-
caused by paint, oil carbon or the accumulation of dust, ner.
which could deteriorate the effectiveness of these com-
ponents.
Insulation or protective shielding, the temperature of 3.6 Warning of special dangers
which may exceed 70 °C and which could be erroneous-
ly touched by the personnel, must not be removed before Electric energy
these parts have cooled down to room temperature. Use only original fuses with the specified current rating.
Check the accuracy of pressure and temperature indi- Switch off the machine/unit immediately if trouble occurs
cators at regular intervals. If the admissible tolerance li- in the electric system.
mits have been exceeded, these devices have to be re- Work on the electrical system or equipment may only
placed. be carried out by a skilled electrician or by specially
Before removing or overhauling a compressor, a motor instructed personnel under the control and supervision of
or another machine, ensure that all moveable parts of a such an electrician and in line with the relevant electrical
mass of more than 15 kg cannot move or roll away. engineering rules.
After completion of repair work, always verify that no If regulations require, the power supply to parts of ma-
tools, loose parts or cloths have been left in or on the ma- chines and plants, on which inspection, maintenance
chine, drive motor or drive equipment. Machines perfor- and repair work is to be carried out, must be cut off. Be-
ming a back and forward main movement have to be cy- fore starting any work, check the de-energized parts for
cled at least once, rotating machines have to be cycled the presence of power and ground or short-circuit them
several times in order to ensure that there are no mecha- in addition to insulating adjacent live parts and elements.
nical faults in the machine or the drive member. Check The electrical equipment of the machines/units is to be
the direction of rotation of the electric motors during first inspected and checked at regular intervals. Defects such
commissioning and after each modification of the electri- as loose connections or scorched cables must be recti-
cal connections in order to prevent the compressor from fied immediately.
being damaged.
Necessary work on live parts and elements must be
The fastening of loads and the instructing of crane ope- carried out in the presence of a second person who can
rators should be entrusted to experienced persons only. cut off the power supply in case of danger by operating
The person giving the instructions must be within sight or the emergency shutdown or main power switch. Secure
voice contact with the operator. the working area with a red-and-white safety chain and a
warning sign. Use insulated tools only.

11
 3. Safety regulations

Before starting work on high-voltage assemblies and • Above 70 dB(A)

after having cut out the power supply, the feeder cable Persons who stay permanently in this room have to
must be grounded, and components, such as capacitors, wear ear protectors
short-circuited with a grounding rod. • Below 85 dB(A)
In the case of occasional visitors who stay in this
Gas, dust, steam and smoke room only for a short while, no special precautions
Carry out welding, flame-cutting and grinding work on are to be taken
the machine/unit only if this has been expressly authori- • Above 85 dB(A)
zed, as there may be a risk of explosion and fire. Hazardous noise zone ! A warning sign has to be
attached to each entrance indicating that everybody
Before carrying out welding, flame-cutting and grinding
who enters the room - even for a short time only -
operations, clean the machine/unit and its surroundings
has to wear ear protectors.
from dust and other inflammable substances and make
sure that the premises are adequately ventilated (risk of • Above 95 dB(A)
explosion) ! The warning signs have to contain the recommen-
dation that occasional visitors also have to wear ear
Adhere to the regulations valid for the place of opera- protectors.
tion !
• Above 105 dB(A)
Observe any existing national regulations if work is Special ear protectors, which are suitable for the
to be carried out in small rooms. noise level and the spectral composition of the noi-
se must be available. A corresponding warning
Hydraulics, pneumatics sign must be fixed to each entrance door.
Take care that the noise transmission through walls
Work on hydraulic equipment may only be carried
and frames does not result in too high a noise level in
out by persons with special knowledge and experi-
the surrounding areas.
ence of hydraulics.
Check all lines, hoses and screwed connections
regularly for leaks and obvious damage. Repair dam- Oils, greases and other chemical sub-
age immediately. High pressure jets of oil may cause
injury and fire.
stances
Depressurize all system sections and pressure pipes When handling oils, greases and other chemical
(hydraulic system, compressed-air system) which are substances, observe the safety regulations for this pro-
to be removed in accordance with the specific instruc- duct!
tions for the assemblies concerned before carrying out Be careful when handling hot fuels and consuma-
any repair work. bles (danger of burning or scalding)!
Hydraulic and compressed-air lines must be laid and
fitted properly. Ensure that no connections are ex-
changed. The fittings, lengths and quality of the hoses Rooms subject to explosion hazards
must comply with the technical requirements.
Danger.
Noise
Compressor units must never be operated in areas
Sound-proofing elements on the machine/unit have subject to explosion hazards!
to be active during operation (i.e. sound-proofing pa-
nels closed, etc.). (Exception: Special units with the corresponding
technical modifications)
Wear personal ear protection as prescribed.
Noise, even at a low level, can cause nervousness
and annoyance; over a longer period of time, our nerv-
ous system can suffer serious damage. We therefore
recommend a separate machine room in order to keep
the noise of the machine away from the workshop.
Depending on the number of machines in a machine
room, the noise can be quite loud. In accordance with
the sound pressure level at manned posts, the follo-
wing precautions have to be taken :
• Below 70 dB(A) :
No special measures

12
 3. Safety regulations

3.7 Storage of compressors Note

All compressors are protected against corrosion at the The following aspects must be taken into account for
factory for transport and for brlef storage before storage of storing compressors.
commissioning.
The compressor should be stored in a dry building
If the compressors are to be stored for period which should be heated if possible.
exceeding six months, additional precautions must be
taken. This is particularly true during the months of winter.

Compressors which are to be shut down for a lengthy If there is a risk that the temperature will fall or rise
period must also be protected from corrosion. above the limits of -10 °C to +65 °C , the electrical
controller must be removed and stored in ambient
Since corrosion occurs more quickly in damp temperatures of +5 °C to +30 °C.
atmospheres than in dry conditions, it is not possible to
specify a maximum permissible standstill time which Before commissioning the compressor all the
will apply in all cases. electrical and electronic components and units should
be checked for the ingress of water or condensation.

13
 3. Safety regulations

3.8 Symbols and explanations

Carefully read the operating manual before commis-

sioning or servicing this compressor.

Never operate the machine without protective equip-

ment fitted.

Never breath in compressed air from this system.

14
3. Safety regulations

Warning: Never operate the unit with open doors or

loose access panels.

Warning: Hot surface

Warning: Pressurized part or system

15
3. Safety regulations

Warning: This system can start up by means of a

remote control or automatically after a
power failure.

Warning: The system continues to run for 30 sec-

onds after pressing the O-key.

Warning: Danger of electric shock

16
3. Safety regulations

Lifting point

Warning: Change the running-in oil filter cartridge

after approx. 100 operating hours. For
further recommendations, see the operat-
ing instructions.

Warning: Check connecting terminals and

retighten, if required. For further recom-
mendations, see the operating instruc-
tions.

17
3. Safety regulations

Attention: Only lubricate the system while the motor

is running. For further details, see the
operating instructions

18
 4. Design and functioning

4.1 Design of the unit

Fig. 3

1 Pressure reservoir 9 Air filter

2 Oil filter 10 Cooling air ventilator
3 Oil cooler 11 Support frame
4 Pressure holding and check valve 12 Panel
5 Operating panel control 13 Switch cabinet
6 Screw compressor 14 Intake regulator
7 Air cooler 15 Fine separator
8 El. motor

19
 4. Design and functioning

4.2 Schematic diagram

23 1
26 R4
U
B1
17 S3 P

M R6
S7 25
2.2 2.1
16
2

15
20

S6
Y4 7
S10
19 B2 24
Y1
U
P
13
18
F1 4 6 9
3 14 S12 22
M

8
5 R2

S8

10 S5
R3
12

11
21 L22-37

Fig. 5

1. Intake filter Pressure holding + F1 Motor temperature* S3 Pressure monitor

2. Intake regulator check valve R2 Compressor temperature S5 Differential pressure
2.1 Actuating cylinder 16. Air cooler R3 Oil injection temp.* oil filter*
2.2 Pressure control valve 17. Pressure monitor R4 Ventilator motor temp.* S6 Differential pressure
18. Pressure monitor + R6 After-cooler temperature* fine separator*
3. Electric motor
display S7 Differential pressure
4. Screw compressor
19. 3/2-way solenoid B1 Sensor mains pressure* air filter*
5. Thermo-sensor +
valve B2 Sensor compression end S8 Oil injection pres-
indicator
20. 2/2-way solenoid pressure sure*
6. Pressure reservoir
valve B3 Sensor outlet of the fine S10 Direction of rotation
7. Fine separator cartridge monitor*
21. Oil temperature separator*
8. Oil drain ball valve S12 Oil level*
regulator
9. Safety valve
22. Oil level indicator
10. Switch of oil filter Y1 Regulating valve
23. Switch of intake filter
(maintenance)*
(maintenance)* Y4 Blow-off valve
11. Oil filter
24. Switch of fine separator
12. Oil cooler
(maintenance)* * option
13. Throttle
25. Ventilator
14. Check valve
26. Clogging indicator of air
15. Valve combination: filter

20
 4. Design and functioning

4.3 Oil circuit Automatic operation (open/close operation)

• When the mains pressure reaches the maximum
The required oil is drawn from the pressure reservoir -6-
value set at pressure monitor -17-, the solenoid val-
, passes through the oil thermostat -21- (closes the by-
ves -19 + 20- de-energize.
pass line of the oil cooler -12- and opens the passage to
the oil cooler at an oil temperature > 45 °C), through the • The screw compressor -4- is running in the idle
oil filter -11- and is fed to the screw compressor -4-. mode.
• The pressure vessel -6- is unloaded into the intake
The oil separated in the fine separator -7- is fed through channel via solenoid valve -20-.
an oil line to the screw compressor -4-. The entire oil cir-
• If the mains pressure does not fall to the minimum
culation is based on a natural differential pressure in the
value set at pressure monitor -17- or at the sensor
system. Considering the pressure difference of approx.
of the mains pressure B1 within 6 minutes, the sy-
1.5 bar within the oil circuit, the oil is then injected into the
stem shuts down.
compressor -4- with approx. 5.5 bar at a reservoir pressu-
re of e.g. 7 bar. • If the minimum value preset at pressure monitor
-17- or at the sensor of the mains pressure B1 is re-
During idle running of the screw compressor, the re- ached in less than 6 minutes, the solenoids -19 +
quired oil injection quantity is achieved owing to the fact 20- are again energized.
that a sufficiently high pressure drop occurs and thus, • The unit changes over to load operation.
with the inlet controller -2- being closed, a vacuum pres-
sure develops at the inlet connection (place of injection). Throttling operation (option)
• The upper switching point is set to the maximum
operating pressure at pressure monitor -17- or, de-
4.4 Air circuit pending on the machine version, at the sensor of
the mains pressure B1 (0.3 bar higher than the set-
The intake air passes through the suction filter -1- and
ting of the proportional regulator). The standard
the intake regulator -2- into the screw compressor -4-.
proportional regulator can only be used for a pres-
During the compression process, the intake air is cooled
sure range of between 7 bar and the nominal pres-
via the injected oil, and the developed air/oil mixture
sure.
flows tangentially into the pressure reservoir (oil reser-
voir) -6-. After the pre-separation and the subsequent • The regulation range can be set lower by adjusting
fine separation in the fine separator -7-, the compressed the proportional regulator accordingly.
air with a low oil content passes through the valve combi- • With an increasing input pressure (increasing pressure in
nation -15-, the air cooler -16- and the condensate sepa- the pressure reservoir -6-), the proportional regulator pro-
rator (option) into the consumer network. vides a decreasing output pressure within the regulating
range (corresponds to a decreasing pilot pressure in the
The condensate separated in the condensate separa- lower control chamber of the actuator -2.1-).
tor (option) is carried to the outside via a solenoid valve
• As a result of the pressure drop in the lower control
(option) which is to be installed by the customer and con-
chamber, the compression spring in the upper con-
trolled by a "Kondensomat“ (option).
trol chamber partly closes the pressure control val-
ve -2.2- and thus causes throttling of the intake flow.

4.5 Start/stop/shutdown Note

The throttling operation provides only a restricted
Start of the unit throttling function, the task of which is to reduce the
supply flow to 70 %. When this value is reached, the
• The electric motor -3- starts up in the Y-mode. pressure monitor -17- or the mains pressure sensor B1
• The intake regulator -2- is closed. (depending on the machine version) switches the
• The oil supply of the screw compressor -4- is provi- screw compressor unit over to automatic operation.
ded by the vacuum pressure where the injection
takes place. Stopping of the system
• When changing over to ∆-operation, the solenoid • After pressing the OFF-key on the operating panel,
valves -19 + 20- switch due to being energized. the solenoid valves -19 + 20- are de-energized.
• The pressure control valve -2.2- is closed by a • The pressure control valve -2.2- in the intake regu-
spring in the actuator of the intake regulator -2.1-. lator -2- closes and the system is relieved.
The control air is bled into the intake channel via • After approximately 30 seconds, the electric motors
the de-energized solenoid valve -19-. -3 + 25- shut down.
• The pressure control valve -2.2- in the intake regu-
lator -2- opens. Standstill of the system
• The valve combination (pressure holding and • When the system is at rest the intake controller -2-
check valve) -15- opens at a system pressure of ap- is closed by the compression spring in the actuating
prox. 4,5 bar. cylinder -2.1-.
• The delivery of compressed air into the consumer • The solenoid valves -19 + 20- are de-energized.
network starts. • The pressure reservoir -6- is bled via the solenoid
valve -20- into the intake channel.

21
 5. Transport and installation

5.1 Transport 5.2 Installation

CompAir
A A A

B B B

AA=1,20
= 0,9m
m
BB=1,20
= 0,9m
m

Fig. 5 Fig. 6

Danger. Danger.
The screw compressor unit must be lifted using a • The foundation weight carrying capacity has to
suitable fork lift truck, which complies with the local be taken into account.
safety regulations. • Provide for a solid and plane base.
Before lifting, all loose or slewable parts of the • The intakes are to be located so that no hazar-
machine have to be firmly secured. dous constituent (solvent vapour, etc., but also
dusts and other hazardous material) can be suk-
It is strictly prohibited to work or stand in the ked in. This applies also to flying sparks.
danger zone of a lifted load. • Pipes and/or other parts with a surface tempera-
The proper lifting of the load (according to the ture higher than 70 °C have to be suitably identi-
operating instructions of the load suspension fied and secured against touching. See also the
device) has to be ensured. safety regulations in chapter 3 of the operating
instructions.
Important
Important
Never lift or lash the compressor via its enclosure.
The operator has to provide adequate ventilation
The screw compressor is lifted with the help of a for the compressor station.
fork lift truck (fig. 5). The separation of the forks and
their length must be taken into account for transpor-
tation. The screw compressor unit has to be levelled.
Only use the identified lifting points. Do not slide A minimum distance from walls, other machines, etc.
the unit when it is standing on the floor. should be maintained so that there is sufficient clear-
ance for maintenance and repair work (fig. 6).
During operation of the screw compressor unit, heat
Weights (with electric motor IP 55) is generated by the electric motor and the compres-
The values listed below are approximate values, they sion process. The screw compressor radiates a part of
refer to a screw compressor unit including oil fill : this heat into the surroundings.

Version: Proper ventilation has a considerable effect on the

service life and the performance of a compressor.
L22S approx. 765 kg
L30 approx. 825 kg
L37 approx. 850 kg

22
 6. Preparations for commissioning

6.1 Cooling air volume/minimum cross- 6.2 Compressed air connection

sections

CompAir 1 1

Fig. 7 Fig. 8

1 Cooling air intake 1 Compressed air outlet DN 40, PN 16

2 Cooling air outlet
The compressed air mains is connected to the tap-
The cooling air volume required by air-cooled screw ping flange of the screw compressor (DN 40). The com-
compressors is as follows : pensator is available as optional extra.
L30 : approx. 90 m3 min,
L37 : approx. 106 m3/min. Note
Under unfavourable local conditions, we recommend After-coolers, separators, collecting reservoirs and
the installation of venting ducts. However, the velocity the compressed air lines must be equipped with drain
of the cooling air should not exceed 5 m/s. We recom- facilities at their lowest points to drain collected liquids.
mend a minimum cross-section of approx. 0.4 m2. These facilities have to be fitted to allow the
observance of the draining of such liquids.
Important Hand-operated drain facilities have to be actuated in
The stated minimum cross-section refers to a ma- accordance with the operating instructions.
ximum duct length of 5 m and a maximum of one Automatic drain facilities have to be checked for pro-
bend. In case of differing values (over 5 m, more per function at regular intervals. When draining
than one bend, filter cartridges, screens, etc.) please condensates into a collecting line, which also collects
contact your technical adviser. CompAir screw com- the condensate from other machines, make sure that
pressors are rated for ambient temperatures and the collecting line is free from counterpressure.
cooling air temperatures of +1 °C to +40 °C. In the Therefore, measures have to be taken to ensure that
case of temperatures other than the above limiting counterpressure cannot build up.
values, please consult your technical adviser.
Condensate may contain oil ! When draining
condensate, observe the corresponding regulations for
Note waste water disposal.
In order to ensure a good heat dissipation, auxiliary
fans should be rated to process approximately 15 to
20 % more air volume than the total cooling air volume
required by the compressors installed in the
compressed air station.

23
 6. Preparations for commissioning

6.3 Electrical connection

Recommended supply line cross-sections and fuses

Installed Nominal Fuse protection Cable-
380 V/50 Hz nominal motor power (slow-blow cross-section
motor power ventilator fuse) at 30 °C
2
[kW] [kW] [A] [mm ]
L22S 22 0,75 63 3 x 16 /PE 16
L30 30 0,75 80 3 x 25 /PE 16
L37 37 1,1 100 3 x 35 /PE 16
Installed Nominal Fuse protection Cable-
400 V/50 Hz nominal motor power (slow-blow cross-section
motor power ventilator fuse) at 30 °C
2
[kW] [kW] [A] [mm ]
L22S 22 0,75 50 3 x 10 /PE 10
L30 30 0,75 80 3 x 25 /PE 16
L37 37 1,1 80 3 x 25 /PE 16

Installed Nominal Fuse protection Cable-

415 V/50 Hz nominal motor power (slow-blow cross-section
motor power ventilator fuse) at 30 °C
2
[kW] [kW] [A] [mm ]
L22S 22 0,75 50 3 x 10 /PE 10
L30 30 0,75 63 3 x 16 /PE 16
L37 37 1,1 80 3 x 25 /PE 16

Notes on the table: Danger.

We do not know the cable type used by you, its
length and the installation conditions (tempera- The customer has to connect a main switch in the
tures, grouping). The table above can therefore incoming line of the screw compressor unit (unless
only be regarded as a guideline. factory-mounted as special accessories) (DIN EN
The supply line cross-sections given in the table 1012 - 1). If this switch does not assume short-circuit
correspond to VDE 0100, part 523 - group 2 (multi- and overload protection functions for the system,
wire cables or grouped, individual wires at 30 °C suitable back-up fuses must be installed (see table)
and a max. line length of 50 m). In the case of diffe- The main switch must meet the requirements of
ring conditions (cable length, temperature and safety standard EN 60 204-1/Art. 5.3 (electrical
grouping), the cable cross-sections have to be sel- equipment of machinery).
ected in line with DIN VDE 0298, part 4, which also The electrical connections and the protective
refers to the cable type. measures have to be carried out in line with VDE
The setting values of the motor protective switch for regulations or the national stipulations in your
the fan drive and the bimetal relay for the main drive country. Generally, additional rules of the respective
are determined as follows: electrical power supplier have to be observed.
Bimetal relays: The connections must be made by an authorized
I = x 1.15 / √ 3 x voltage correction, if required specialist.
setting Inom
Attention: Interference voltage! If external electric
Motor protective switch circuits, which cannot be cut out via the main switch,
are connected to the control, these have to be
I =I x 1.15 x voltage correction, if required identified according to EN60204. Warning signs have
setting nom
to be fixed near the main switch and near these
Compressed air stations are finished in the factory electric circuits. In addition, these conductors have
according to standard EN60204 (industrial machin- to be laid separately and/or identified by colours.
ery). Please observe the following notes:
Work on control cabinets may only be carried out
by electrotechnical specialists.
Important If the erection conditions of the system deviate
A poor energy quality jeopardizes the trouble-free from the conditions described in EN60204, please
operation of the compressor unit. contact your technical consultant.

Once the installation work is completed, the supply

line openings have to be closed using suitable fittings.

24
 6. Preparations for commissioning

Checking the setting of the control-power Start-up of the unit after connection to the
transformer electric network/Checking the direction of
The control-power transformer is factory-preset to the rotation
rated voltage. However, practice has shown that the After connection to the electric network the unit can
actual supply voltage often differs from this value. In be started up for the first time. Make sure that the com-
order to adjust the unit to the local conditions, the set- pressed air lines are connected and observe the follo-
ting of the control-power transformer must be checked wing notes:
by measuring the control-power transformer supply
voltage under load and, if required, re-set. Several Important
tapping points are provided for this purpose (see cir-
cuit diagram). When connecting a compressor unit to the electric
network for the first time, it is necessary to check
the drive motor for the correct direction of rotation
(see arrow).
In the case of a wrong direction of rotation stop the
Serie
unit immediately by actuating the emergency OFF
push-button. The normal stop push-button stops the
drive only after the soft stop time (several seconds).
Even a short operation of the drive in the wrong di-
435V 415V 400V 380V 360V rection of rotation (approx. 2 seconds) results in se-
Option vere damage or consequential damage.

Connecting terminals for heater (option)

For L22S-37 with 380/400/415 V:
• Connecting terminals for heater 230 V ±10 %
Fig. 9 • 2.0 kW, 1P/N/PE
• with ventilator
Danger.
• Integrated thermostat
When carrying out adjustment work on the control- • Supply of the unit : 3P/PE
power transformer, the unit must be off circuit.
Work on the control cabinet may only be carried
out by electrotechnical specialist personnel.

Important
A wrong setting of the control-power transformer
jeopardizes the trouble-free operation of compres-
sor units and can result in malfunction or damage.
The verification of the control-power transformer
setting is a must during commissioning and periodic
inspection/maintenance, as the voltage supply con-
ditions may vary.
The correct setting should be checked in on-load
operation of the unit by measuring the control-power
transformer output voltage.

25
 6. Preparations for commissioning

6.4 Oil level check Important

Do not mix oils of different specifications.
Danger.
Only check the oil level when the screw Check oil level
compressor unit is out of operation and
• The oil level is to be checked with the help of the oil
depressurized ! The pressure reservoir can be
dipstick at the pressure vessel (Fig. 10) after each
under pressure and the oil hot. Warning : Danger of
stop and at regular intervals.
scalding ! Do not spill oil ! Check for leakage !
• The oil should have settled and the air entrapped
should have been dispersed. This procedure may
take up to one hour (depending on the conditions).
• The max. oil level is in the middle of the upper oil
level sight-glass, the min. oil level in the middle of
the lower oil sight glass (fig. 10). If required, top up
oil.
See also chapter 9 "Maintenance“.

1
6.5 Sound pressure level
Sound pressure level measured to DIN 45 635 under
full load at a distance of 1 m dB(A):
2
Anlage dB(A)

L22S 72

3 L30 74

L37 74

4 Subject to technical revision.

Fig. 10

1 Oil filling point 1"

2 Oil dipstick
3 Max. oil level
4. Min. oil level

26
 7. Commissioning

7.1 First commissioning • Press the OFF-key for unlocking.

• Press the ON-key,
the ON-key lights up >>green<< in order to show
Danger. that the screw compressor unit is in the auto-
Make sure before commissioning that nobody is in matic operating mode.
the danger zone of the motor/screw compressor.
Note
Only operate the screw compressor with closed
access panels. Before first commissioning or when re-commissioning
after maintenance of the water-cooled units, the air
The safety valve can be hot as a result of
cooler must be bled via the bleed screw.
preceding operation. A functional check must only
be carried out at operating pressure. Be careful with
escaping air (danger of burning and scalding).

7.2 Routine commissioning

Important
Although every CompAir screw compressor has
been subjected to a test run at the factory and has 1
again been thoroughly inspected before shipment,
damage during shipment cannot be excluded. For
this reason, every screw compressor should be
checked once again for damage before being com-
missioned. In addition, it should be observed during
the first operating hours. The screw compressor unit 2
is completely factory-assembled. It can be directly
connected to the compressed air mains by means of
a flexible connection.
If the screw compressor is newly connected to a
power supply, check the direction of rotation of the
drive motor !
With a wrong direction of rotation, shut down the
Fig. 11
unit immediately by actuating the emergency shut-
down, otherwise the compressor might suffer se-
1 Knurled cap
rious damage.
2 Outlet
The access panels may temporarily be opened for
checking the direction of rotation (wear ear protec-
tors). Danger.
Moreover, the following points must be taken into ac- Make sure before commissioning that nobody is in
count : the danger zone of the motor/screw compressor.
• Fasteners used for securing the unit during After completion of work : Verify that all safety
transportation have to be removed prior to com- devices have been refitted and that all tools have
missioning. been removed.
• Before commissioning, panels and doors should Only operate the screw compressor unit with
be realigned, if required. closed access panels.
• Check and, if necessary, correct the pre-set val-
ues at the Kondensomat (option). Before each commissioning, check the safety
• Re-tighten all connecting terminals of the electri- valve (fig. 11) for function by turning the knurled cap
cal control before commissioning. at the safety valve (at operating pressure). The
• Check the oil levels in the pressure reservoir safety valve can be hot as a result of preceding
before each commissioning. operation. A functional check must only be carried
• Open the isolator valves between the screw com- out at operating pressure. Be careful with escaping
pressor, reservoir and pipe, air (danger of burning and scalding).
• Operate main switch.
• Before each commissioning, check the safety
valve (fig. 11) for function by turning the knurled
cap at the safety valve (at operating pressure).
• When switching the power supply on, all of the
LEDs and all segments of the LCD displays will
light up for a display test.
• For testing purposes, all LEDs and segments on
the operating panel light up.

27
 7. Commissioning

Note 7.4 Operating modes

The condensate separator (option) and the Automatic operation
condensate drain (option) have to be installed by the
customer. The generation of compressed air is stopped when
the set maximum operating pressure has been achie-
ved, and the electric motor stops after a corresponding
Before each commissioning of the screw compressor coasting time (dependent upon the electrical network).
follow the steps below : The generation of compressed air commences and
• Check the oil levels in the pressure reservoir. the electric motor cuts in, when the operating pressure
has decreased to the set minimum value.
• Open the isolator valves between the screw com-
pressor, reservoir and pipework.
• Actuate main switch. Throttling operation
• Check the safety valve at operating pressure. The delivery of compressed air is throttled as soon
as the pressure range set at the proportional regulator
Start-up protection of the electric motor has been reached.

The screw compressor unit does not start up, if the

system pressure is higher than 0.8 bar.

7.5 Setting of the operating pressure

Temperature start-up protection
The screw compressor unit does not start up, if the Danger.
ambient temperature is lower than +1 °C. The operating pressure must be set by a specialist
only.
The operating pressure must not be set higher.

7.3 Commissioning after malfunction

Important
Do not switch the screw compressor on repeatedly
without having rectified the malfunction, since this
may cause considerable damage to the machine.

Re-start after an automatic shutdown due to malfunc-

tion:
• Read off error code (see chapter 8.2.8)
• Turn main switch off
• Rectify malfunction
• Turn main switch on
• Press acknowledgement key [ Θ ] Fig. 13
• Start the screw compressor unit by pressing the
ON key [ I ]. The operating pressure is set at the pressure monitor-
ing device (fig. 13) :
• Remove protective cap
• The cut-in and cut-out pressure is set via the setting
screws
• The (approximate) values are indicated on the cor-
responding scales
• Attach the protective cap.

Fig. 12

28
 7. Commissioning

Important 7.6 Monitoring

The operating pressure is indicated on the name- The operating pressure and the compressor tempe-
plated (Fig. 2). Higher pressure settings are not per- rature can be read from the text field on the control pa-
mitted. nel (Fig. 12).

Higher pressures are not permitted. Compressors with oil-lubricated pressure chambers
are to be operated in a manner that avoids exceeding
Re-check the settings of the switching points of the pre-set final compression temperature.
(pressure range) using a pressure gauge.
The screw compressor is equipped with an automa-
The operating pressure can be set to a value of tic operation monitoring system, which shuts the unit
between 5 and 13 bar. Higher pressures are not per- down in the case of the following malfunctions.
missible.
The pressure difference (∆ ∆p) must not be smaller
than 0.5 bar. Generally, it should be 10 % of the ope- Important
rating pressure.
Warning : Electric voltage !
It is possible to reduce the operating pressure to a
minimum of 5 bar. Encoders for automatic operation monitoring must
not be bridged !
The admissible maximum number of motor cycles
The screw compressor unit must not be operated
is controlled by the DELCOS electronics.
with bridged encoders !
On units with electrical controls type DELCOS 3000,
the operating pressure is set at the electronics.

29
 8. DELCOS 1000 electronics

Table of contents re DELCOS 1000

8. DELCOS 1000 electronics ................................................................................................................................... 30

8.1 Operating elements ...................................................................................................................................... 31

8.1.1 Keyboard ......................................................................................................................................... 31
8.1.2 Light emitting diodes ....................................................................................................................... 32
8.1.3 Final compression pressure display (bar) ...................................................................................... 33
8.1.5 Menu structure DELCOS 1000 ........................................................................................................ 33
8.1.4 Final compression temperature display (°C) .................................................................................. 33
8.2 Commissioning ............................................................................................................................................. 34
8.2.1 Start of the unit ................................................................................................................................. 34
8.2.2 Operation under load/idle running .................................................................................................. 34
8.2.3 Stopping of the unit .......................................................................................................................... 34
8.2.4 Malfunctions/shutdowns/power failures ......................................................................................... 34
8.2.5 Warnings/maintenance ................................................................................................................... 34
8.2.6 Collective fault relay ........................................................................................................................ 34
8.2.7 Operating/load hours counter ......................................................................................................... 35
8.2.8 Fault log ............................................................................................................................................ 35
8.2.9 Fault log table ................................................................................................................................... 36
8.3 Menu Additional functions ............................................................................................................................ 38
8.3.1 Navigating in the menu ................................................................................................................... 38
8.3.2 Changing the settings ..................................................................................................................... 38
8.3.3 Maintenance intervals ..................................................................................................................... 39
8.3.4 Operating modes ............................................................................................................................. 40
8.3.4.1 Automatic operation ...................................................................................................... 40
8.3.4.2 Continuous operation ................................................................................................... 40
8.3.4.3 Remote control (Remote ON/OFF) ............................................................................... 40
8.3.4.4 Automatic restart after power failure ............................................................................. 41
8.3.4.5 Extended automatic restart after power failure ............................................................ 41
8.3.5 Factory settings ................................................................................................................................ 41
8.3.5.1 Changing the run-on time ............................................................................................. 42
8.4 Controlling the unit via a terminal strip ........................................................................................................ 42
8.4.1 Remote control (remote ON/OFF) ................................................................................................... 42
8.4.2 Input External fault ........................................................................................................................... 42
8.5 Installation of a new DELCOS 1000 ............................................................................................................ 43
8.6 Brief instructions for DELCOS 1000 ............................................................................................................ 44

30
 8. DELCOS 1000 electronics

8.1 Operating elements

Fig. 14

8.1.1 Keyboard

Key I ⇒ Switch the system on

Key O ⇒ Switch the system off
Key Θ ⇒ Acknowledgement and return to
pressure and temperature display

Key ∆ ⇒ Scroll upwards in the menu

Key ∇ ⇒ Scroll downwards in the menu
Key − ⇒ Scroll to the left in the menu and
change parameters
Key + ⇒ Scroll to the right in the menu and
change parameters
Key ↵ ⇒ Change settings

31
 8. DELCOS 1000 electronics

(a) (e)
bar °C
(b) (f)
(c) (g)

(d) (h)

Fig. 15

8.1.2 Light emitting diodes

Operating messages Fault messages

LED a ⇒ flashing: The system is in the stand-by LED e ⇒ Malfunction / compressor temperature
mode, i.e. the motor can start
up automatically at any time. LED f ⇒ Malfunction / motor monitoring

on: The drive motor is running LED g ⇒ Warning / maintenance

LED b ⇒ Unit is in operation under load LED h ⇒ Collective fault

LED c ⇒ flashing: Remote control, remote OFF

If LED g or LED h light up, determine the cause of
failure, warning or service message in the fault stor-
on: Remote control, remote ON age as described in the following chapter 8.2 "Com-
missioning".
LED d ⇒ Automatic restart ON

32
 8. DELCOS 1000 electronics

8.1.3 Final compression pressure dis- 8.1.4 Final compression temperature

play (bar) display (°C)
Under normal operating conditions, the pressure dis- Under normal operating conditions, the temperature
play indicates the operating pressure of the unit. display indicates the final compression temperature of
If the reservoir pressure is exceeded by more than the compressor.
1 bar, the control outputs a warning message by me- The display flashes in order to indicate excessive
ans of a flashing pressure display. The warning is temperatures. In the case of overheating, the compres-
stored in the fault storage; LED g lights up. sor shuts down automatically. In the case of too low
In the case of an incorrect transfer from the pressure temperatures, the unit does not enable a start.
sensor, the actual reservoir pressure cannot be deter- In the case of an incorrect transfer from the pressure
mined or displayed. The display shows : - - -. sensor, the actual reservoir pressure cannot be deter-
mined or displayed. The display therefore shows : - - -.

8.1.5 Menu structure DELCOS 1000

2 3 4 5
Fig. 16

1 Operating/load hours 4 Operating modes

2 Fault storage 5 Factory pre-settings
3 Maintenance intervals 6 See chapter 8.3 "Additional functions"

33
 8. DELCOS 1000 electronics

8.2 Commissioning 8.2.3 Stopping of the unit

After pressing of the [ O ] key, the unit searches for an
8.2.1 Start of the unit off load and stable working point before the motor is
When switching the power supply on, the display test switched off. Depending on the preceding utilization,
appears, which must be acknowledged before starting the unit stops immediately or after some seconds.
the unit by pressing key [ Θ ]. Prior to setting the unit
into operation by pressing the [ I ] key, faults must have 8.2.4 Malfunctions/shutdowns/power
been rectified and acknowledged.
failures
The compressor cannot be started at temperatures -
1 °C. In order to protect the unit, all recognized faults will
result in the immediate shutdown of the system or will
If the compressed air mains does not report a requi- prevent a start-up.
rement at the time of start, the unit will go into the
stand-by mode - LED a flashes (only in the automatic These faults are transferred to the fault log with a cor-
operating mode). responding error message and then signalled to the
collective fault relay.
Moreover, a safety circuit (start-up protection) pre-
vents the drive motor from starting against an internal The faults have to be acknowledged (after rectificati-
residual pressure. In this case, the compressor also on of the fault) by pressing key [ Θ ].
goes into the stand-by mode. The compressor starts In the case of a fault [Power failure] the display test is
automatically, if the pressure falls below a factory-pre- run when voltage is again applied. This must be ack-
set value (start-up protection). nowledged by pressing key [ Θ ]. In the remote control
operating mode, however, a REMOTE ON edge is suf-
Danger. ficient since it is also used to acknowledge a power
failure in the fault log.
If the unit is in the stand-by mode, i.e. LED a
flashes, the compressor can start up automatically
at any time ! 8.2.5 Warnings/maintenance
Warning or maintenance messages will be signalled
via LED g, but will not result in the shutdown of the
8.2.2 Operation under load/idle running compressor.
The operating mode is factory-set to automatic opera- Ignoring warnings/service messages can result in
tion. This means that the compressor changes over to malfunction !
stand-by mode after a pre-set run-on time, when no
more pressure is required.
When the compressor is in the stand-by mode, it is au- 8.2.6 Collective fault relay
tomatically restarted when the pressure demand in- A potential-free contact in the control (see electrical
creases. circuit diagram) reports malfunction of the unit. The
The run-on time is determined by the value set for the contact opens in the case of a fault.
max. number of motor starts per hour. How to extend The contact of the collective fault relay must not be
the run-on time is described in chapter 8.3.5.1 loaded with more than 250 V/8 A.
"Changing the run-on time“.

Danger.
When the system is in the stand-by operating
mode, i.e. LED a flashes, the compressor can start
up at any time !

34
 8. DELCOS 1000 electronics

8.2.7 Operating/load hours counter 8.2.8 Fault log

Fig. 17

The operating and load hours of the unit can be called

at any time.
To this end, press key [ ∆ ] for the operating hours
(rhr: Running hours) and press key [ ∆ ] again to have
the load hours of the system displayed (Lhr: Loaded
hours).
Press key [ ∇ ] to return step by step to the normal
display or simply press key [ Θ ].
The 3-digit temperature display shows the operating
and load hours. To allow the representation of counter
readings above 999 hours, the following representa- Fig. 18
tion is provided.
The fault log contains the last 5 fault or warning mes-
A dot in the display identifies the representation of
sages sorted in chronological order.
operating hours in the range of thousands.
Press key [∇] to get to the fault log.
Examples:
Starting with the latest entry (Er1) you can use key
Operating time 0 - 999 h Display 0 - 999
[∇] to scroll through to the earliest entry (Er5). The
Operating time 1000 - 9999 h Display 1.00 - 9.99 right-hand display shows the relevant error code. For
Operating time 10000 - 99999 h Display 10.0 - 99.9 the error codes, please refer to the fault log table.
Flashing error codes indicate that the faults have not
yet been acknowledged. You cannot acknowledge
faults by pressing key [Θ] before the fault has been
rectified.
The example above shows that the latest fault (Er1)
resulted in a shutdown due to excessive motor tem-
perature (error code 3). Before that, (Er2), the system
shut down as a result of a power failure (error code 1).

35
 8. DELCOS 1000 electronics

8.2.9 Fault log table

Error Description Possible cause Remedy
code

1 Fault power failure Power failure Search for the reason

Cabling defective Check, if required, repair

2 Fault emergency stop Emergency stop is/was Unlock

activated
Emergency shutdown switch Check, if required, replace
defective
Cabling to the emergency Check, if required, replace
shutdown defective

3 Fault motor monitoring Motor started too frequently (*) Limit number of manual starts/stops
Motor protection set wrongly Set correctly
Motor defective Check, if required, replace
Power requirement too high Check, search for cause
Defective power supply Check, search for cause
Star/delta starter defective Check

4 Fault compressor Excessive intake temperature Improve

excessive temperature (*)
Insufficient venting Improve
Unit operated with access Close access panels
panels open
Oil injection quantity/ Check, search for cause
temperature too small/high
Temperature sensor defective Check, if required, replace
(wrong indication)
Cabling of the temperature Check, if required, repair
sensor defective

5 Fault, start tried at Internal temperature of the unit Heat compressor room
low temperature (*) too low
Temperature sensor defective Check, if required, replace
(wrong indication)
Cabling of the temperature Check, if required, repair
sensor defective

6 Warning compressor see point 4 see point 4

temperature (*)

7 Fault overpressure Final compression pressure

shutdown exceeded by 1.5 bar (*)
- System pressure loss too high Check, search for cause
- Mains pressure switch defective Check, if required, replace
- Intake regulator does not close Check, search for cause
- Pressure sensor defective Check, if required, replace
(wrong indication)

36
 8. DELCOS 1000 electronics

Error Description Possible cause Remedy

code

8 Warning overpressure Final compression pressure

exceeded by 1 bar (*)
- see point 7 see point 7

9 Fault pressure sensor Wrong pressure measurement

(indication : - - - bar)
- Pressure sensor defective Check, if required, replace
- Cabling of the pressure Check, if required, repair
sensor defective

10 Fault temperature sensor Wrong temperature measure-

ment (indication : - - -°C)
- Temperature sensor defective Check, if required, replace
- Cabling of the temperature Check, if required, repair
sensor defective

11 Fault, wrong direction of Vacuum pressure at the pres- Connect correct phase grouping
rotation sure connection caused by L1 L2 L3,
wrong direction of rotation of Isolate unit from power source
the motor to acknowledge
(acknowledgement in the fault
storage not possible)

12 Warning ∆p fine separator Only, if optionally installed

13 Warning ∆p air filter Only, if optionally installed

14 Warning ∆p oil filter Only, if optionally installed

15 External fault Only, if optionally installed

16 Warning maintenance Programmed maintenance Carry out maintenance, re- program

interval(s) exceeded interval(s) have reached or new maintenance interval(s)
exceeded 0 hours

17 Fault shutdown maintenance Programmed maintenance Carry out maintenance, re- program
limit interval(s) interval(s) have reached 100 new maintenance interval(s)
have been reached hours, shutdown is thus active

18 Fault of mains pressure sensor - Incorrect pressure measurement

(Option) (display --- nEt)
- Pressure sensor defective Check and replace, if required
- Cabling of the mains pressure Check and replace, if required
sensor defective

19 Fault of start-up against A defect causes a high Check output regulator and, if required,
great resistance pressure build-up (approx replace it
2-3 bar) during the start-up
phase
(*) For settings, see chapter 8.3.4 "Factory pre-settings"

37
 8. DELCOS 1000 electronics

*
+
2 3

4
Fig. 19

8.3 Menu Additional functions 8.3.1 Navigating in the menu

The control provides different menus (Fig. 19), which Key [-] to the left
allow the user to change, for example, the compressor Key [+] to the right
control, query information or program maintenance in-
Key [∇] down
tervals.
Key [∆] up
Starting from the normal display 1 you can go to this
menu block by pressing the [ + ] key for 5 seconds. Key [Θ ] return to the normal display
To have the maintenance interval for oil changes dis-
This menu block comprises the following menus. played (see *), you have to press the following keys in
the normal display (1):
2 Maintenance intervals
3 Operating modes • Hold key [+] depressed for 5 seconds and then
• press key [∇] 3 times
4 Factory settings
You can return to the normal display in the reverse
order using the keys shown above. It is, however,
much easier to use key [ Θ ] .
Note
The menu item for extended automatic restart after a 8.3.2 Changing the settings
power failure (PFt, see +) only appears when you have
activated this function. See chapter 8.3.4.5 "Extended If you wish to change settings, you have to select the
automatic restart after power failure" relevant menu item and press key [ ↵ ]. The setting
starts to flash and can be changed with the help of
keys [ + ] or [ - ]. This is not valid for factory settings, ex-
cept for the run-on time setting.
All the other settings can be changed at any time.

38
 8. DELCOS 1000 electronics

8.3.3 Maintenance intervals You can set the maintenance intervals for air filters,
oil filters, fine separators and oil change by yourself,
thus partly substituting your maintenance book.
The programming has to be adjusted to your specific
application conditions, because for example the
clogging degree of the air filter depends on the intake
conditions.
The settings of the maintenance intervals can be
programmed from 0 to 6000 hours. If no maintenance
intervals are requested, program a value above 6000
hours. The display shows - - -. Thus, this maintenance
interval is blocked.
The indication of times of more than 999 hours is as
with the operating and load hours (see 8.2.7).
The factory pre-set "maintenance“ values are
blocked (the display shows : - - -), i.e. no programming
has been made.
The individual setting values are programmed by
pressing the [ ↵ ] key. The setting value will flash and
can then be changed.
If the setting value has counted down to 0 hours, a
corresponding error code entry is made and LED g
Fig. 20
(maintenance) flashes.

Annotations re fig. 20 It is possible to display negative, i.e. overdue mainte-

nance intervals.
Moreover, a shutdown can be activated/deactivated
Field "bar" = pressure display (Stt = oFF/on) for maintenance intervals, if a mainte-
nance interval has counted down to -100 hours. If one
AFI = Remaining time air filter of the intervals has reached this shutdown threshold,
the shutdown is triggered off by the collective fault
oFI = Remaining time oil filter LED h, which acts in addition to LED g. The fault
storage contains the message "shutdown limit of
SEP = Remaining time fine separator
maintenance interval(s) exceeded“.
oIL = Remaining time oil change You will then have to carry out the planned mainte-
nance work, newly program the maintenance intervals
Stt = Shutdown at -100 hours (service and then acknowledge the fault by means of key [ Θ ]
timer trip) for a restart.

Field "°C" = Temperature display

--- = Maintenance interval blocked

24 = 24 hours

1.04 = Display multiplied by 1000 = 1040 hours

-87 = Maintenance interval has been over-

due for 87 hours

oFF = OFF = no shutdown

on = ON = activates shutdown

39
 8. DELCOS 1000 electronics

8.3.4 Operating modes Settings for start-up delay (SdL))

1..30 = Start delayed by 1..30 sec
Possible settings for power fail time (PFt)
Ltd = Limited to max. 1.5 sec

uLt = Unlimited automatic restart

8.3.4.1 Automatic operation

The operating mode "automatic operation" is the
most economic, because the control stops the com-
pressor, when no compressed air is required, and re-
starts the unit automatically as necessary.

Note
Before the unit can be switched between automatic
and continuous operation, it must be stopped.

+ 8.3.4.2 Continuous operation

This operating mode is required in special applicati-
Fig. 21 ons only. Continuous operation prevents the drive mo-
tor from being stopped, when no compressed air is re-
Annotations re fig. 21 quired. The compressor continues to operate in the
off-load mode for an unlimited time.
Field "bar" = pressure display
In contrast to the automatic operating mode, the unit
ctL = Operating mode (control) can be started, even if no mains pressure request is
present.
oPr = Local/remote control (operator)
rSt = Automatic restart Note
SdL = Start delay for progressive startup in Before the unit can be switched between automatic
conjunction with automatic restart and continuous operation, it must be stopped.
PFt = Power fail time for automatic restart

8.3.4.3 Remote control (Remote ON/OFF)

Important
Note
In this operating mode the compressor can start
The menu item for the extended automatic restart af- automatically at any time!
ter a power failure (PFt, see +) is only displayed if you
have activated this funciton. See chapter 8.3.4.5 "Ex- In the operating mode "Remote control" the unit can
tended automatic restart after power failure“. be switched on and off using a coupling relay (with
contacts suitable for small currents) in the input "Re-
mote ON" (see circuit diagram).
Field "°C" = Temperature display When remote operation is activated, LED c lights up
and keys [ I ] and [ Θ ] of the compressor are blocked.
Possible settings for the operating mode (ctL) For starting the unit the control expects an ON com-
Aut = Automatic operation (automatic) mand (contact is made) on the terminal strip. The unit
is switched on as long as the contact is made and is
cnt = Continuous operation (continue) switched off when the contact is broken.
Possible settings for remote ON/OFF (oPr) For further information on the electrical connection,
please refer to the chapter "Controlling the unit via a
Loc = Local control (local) terminal strip".
Etn = Remote control (external) Since the display test after a power failure is not run
in this operating mode, the compressor can be restar-
Possible settings for automatic restart (rSt) ted using the remote switch without requiring local
oFF = OFF acknowledgement beforehand. The acknowledgement
is given with the start command (Remote ON).
on = ON

40
 8. DELCOS 1000 electronics

8.3.4.4 Automatic restart after power 8.3.5 Factory settings

failure With this menu you can verify the factory settings of
your unit, but not change them. *)
Important
In this operating mode the compressor can start
automatically at any time!
After a power failure, which has not taken longer
than 1.5 seconds, the compressor restarts automati-
cally, provided it was switched on, i.e. it was in opera-
tion or in the stand-by mode, before the power failure
occurred.
Failures longer than 1.5 seconds trigger off the mes-
sage "power failure"; automatic restart is not executed.
In addition, you can program a start delay (1-30 sec.)
in order to ensure that with stations comprising several
compressors the compressors do not start up simulta-
neously (to relieve the power supply mains).

8.3.4.5 Extended automatic restart after

power failure
The control can execute an automatic restart after a
power failure of any duration. For this purpose, you
have to activate menu item PFt and set the power fail
time to unlimited restart (uLt).

Danger.
In this operating mode the compressor can start
automatically at any time and after an unlimited du-
ration of a power failure.
Please refer to your national safety regulations
(e.g. EN1012-1, EN60204) and verify whether you are
allowed to program an unlimited automatic restart
Fig. 22
and which precautions must be taken.
In any case, attach warning signs to the compres- Legend of Fig. 22:
sor, restrict the access to the compressor room and
Field "bar" = Pressure display
instruct your personnel accordingly.
Install the mains switch prescribed according to tyP = Max. operating pressure (type)
EN60204 and attach corresponding warning signs. SPL = Start-up pressure limitation
How to activate menu item PFt (Power Fail Time)
htt = Shutdown - final compression tempera-
1. Disconnect the power supply to the compressor,
ture (high-temperature trip)
2. hold the four keys [∆] [∇] [-] [+] depressed simulta-
neously and htA = Early warning - final compression tem-
3. reconnect the power supply while holding these perature (high-temperature alarm)
keys depressed.
Ltt = Start blocked - low temperature (low-
4. You can release the four keys when the display test
temperature trip)
appears.
Sdt = Y/∆ changeover time (Y/∆-time)
Shr = Max. number of starts per hour
SSt = Soft stop time)

*) Except for the setting of Shr = Starts per hour (^=

run-on time); see chapter 8.3.5.1 "Changing the
run-on time"

41
 8. DELCOS 1000 electronics

The illustration on the left (Fig. 22) shows 8.4.1 Remote control (remote ON/OFF)
the following settings as an example: The control offers the possibility of switching the
compressor ON and OFF when a floating contact is
tyP = 10.0 bar pressure variant
connected.
SPL = 0.8 bar start-up pressure limitation To activate the input Remote ON, you have to enable
htt = 120 °C shutdown - final compression Remote control in the Operating modes menu (see
temperature chapter 8.3.4.3).

htA = 110 °C early warning - final compres- Important

sion temperature
You must only connect floating contacts to the ter-
Ltt = 0 °C start blocked - low temperature minal strip. Externally supplied voltages can destroy
Delcos 1000.
Sdt = 6 seconds Y/∆ changeover time
The distance between floating contacts and the ter-
Shr = 40 starts per hour (=^ 90 s run-on time minal strip must not exceed 20 metres. If required,
install coupling relays in the control cabinet.
SSt = 30 seconds soft stop time

8.4.2 Input External fault

8.3.5.1 Changing the run-on time The control offers the possibility of shutting down the
compressor via a floating contact and outputting a cor-
The run-on time of the unit determines, how long the responding fault message when an external event oc-
compressor continues to run off load in the automatic curs. An example of this would be the shutdown of the
mode, before the unit changes over to the stand-by compressor as a result of a fault of the downstream
mode. The setting of max. starts per hour (Shr) deter- compressed air dryer.
mines the run-on time.
As a standard, this input of Delcos 1000 is enabled. If
Example: you break the contact via a floating switch, the com-
Shr = 40 starts per hour pressor shuts down immediately with error code 15.
Run-on time = 90 seconds
Important
Shr = 10 starts per hour
You must only connect floating contacts to the ter-
Run-on time = 360 seconds
minal strip. Externally supplied voltages can destroy
You can only extend the run-on time in order to pre- Delcos 1000.
vent the maximum starts per hour of the electric motor
from being exceeded. The distance between floating contacts and the ter-
minal strip must not exceed 20 metres. If required,
install coupling relays in the control cabinet.

8.4 Controlling the unit via a terminal

strip
Please have the circuit diagram of your unit at hand
when you read this chapter. The circuit diagram can
be found in the control cabinet of your compressor.

Important
When the unit is controlled via the terminal strip,
the compressor can start automatically at any time!

Note
The floating contacts for controlling the unit via the
terminal strip must be suitable for small currents (24
VDC, 5 mA).

42
 8. DELCOS 1000 electronics

8.5 Installation of a new DELCOS 1000

With the following display

Fig. 23

the new Delcos 1000 prompts you to enter the maximum

operating pressure of the unit.
Select the max. operating pressure according to the va-
lue stamped in the field "stages pressure" on the unit's
nameplate (Fig. 2) with the help of key or .

Confirm your entry by pressing key .

For safety reasons, you have to enter the operating

pressure twice.

Important
The operating pressure entered is firmly stored af-
ter the second acknowledgement and can no longer
be changed!
Entering an incorrect operating pressure can re-
sult in severe damage to the machine, and liability
and warranty claims become void !

When the entries are made, the controller is program-

med with the basic settings.
Verify wether these presettings meet your operating
requirements !

43
 8. DELCOS 1000 electronics

8.6 Brief instructions for DELCOS 1000

Control elements LEDs

→ Switches the system on

→ Switches the system off

Automatic restart ON
Flashing: Remotecontrol,remoteOFF
ON: Remote control, remote ON
Unit is in on-load operation
→ Acknowledgement and Flashing: System is in the stand-by mode, i.e. the mo-
return to the pressure tor can start automatically at any time.
and temperature ON: Drive motor is running
display.

Scrolls upwards in the menu Scrolls downwards

in the menu

Scrolls to the left in the menu Scrolls to the left in the menu
and adjusts parameters and adjusts parameters
Collective fault
Warning/maintenance
Fault Motor monitoring
Fault Compressor temperature
Change of settings

44
 Operating hours How to change settings
8.

If you wish to change settings, select the relevant menu item and press key ↵ . The set value flashes and can now be changed
using the keys + and – . This does not apply to factory settings, except for the setting of Shr = Starts per hour (see chapter "chang-
Load hours ing the run-on time).

* Press key for 5 seconds

Operating hours

Pressure and temperature display Maintenance Operating mode Factory settings

*
Remaining time air filter Operating mode Max. operating pressure
Aut = Automatic operation
DELCOS 1000 electronics

cnt = Continuousoperation

Start-up pressure limitation

Fault log Remaining time oil filter
Local/remote control
Loc = Local control
Etn = Remote control Shutdown - high compr. temp.
Remaining time fine separator

Automatic restart Early warning - high compr. temp.

Remaining time oil change

Start blocked - low temp.

Start delay for pro-
gressive start-up
Shutdown after
-100 hours
Star/delta changeover time

Power fail time

Ltd = Limited (max. 1.5 s)
Fault order (Er1=latest entry). uLt = Unlimited Max. starts pper hour
Note
The error codes shown in the right-
hand display can be found in the The menu item for extended automatic restart after po-
fault log table. wer failure (PFt) is only displayed, when this function has
been activated. See chapter "Extended automatic restart
Soft stop time
after power failure“.

45
 9. Servicing and maintenance

9.1 Maintenance and lubricant 9.3 Servicing and maintenance

recommendations schedule

Note Danger.
The screw compressor unit can only operate to your When carrying out control, adjusting and mainte-
complete satisfaction, when the maintenance work is nance work, be careful with hot surfaces of machine
carefully carried out at the specified intervals. parts.
In order to facilitate this task, the scope of supply of Checking and maintenance work may only be car-
the screw compressor unit comprises the "Mainte- ried out when :
nance and inspection manual for CompAir compres- • Press the OFF-key on the control panel and wait
sors, in which you can list your performed mainte- until the screw compressor unit has come to
nance work at the specified intervals. rest;
The operating hours stated herein are recommended • the screw compressor unit is depressurized,
maintenance intervals for average operating conditi- • the pressure display does no longer indicate
ons. Depending on the intake conditions, the opera- pressures < 0.3 bar.
ting times may differ. • Shortly after switching the screw compressor off,
the system can contain a low residual pressure.
You can also have this maintenance work performed • The screw compressor unit must therefore be
by our trained technicians. Please ask your technical unloaded prior to any maintenance work by
adviser for a maintenance contract. slowly opening the plug (oil fill port) with integral
For lubricant recommendations, see 9.13. venting bore.
• The customer-installed main switch is set to "O"
(OFF);
• Warning : Electrical voltage:
9.2 Maintenance electric motor Only work on the screw compressor unit when it
is disconnected.
The maintenance of the electric motor is to be perfor-
med in line with the motor operating instructions.

46
 9. Servicing and maintenance

Service kits
C-kit Spare oil filter cartridge
Spare air filter cartridge
D-kit Spare oil fine separator
E-kit Spare wear parts
V-kit Spare V-belt (recommended)

These intervals are valid for normal industrial atmos-

pheres and operating conditions.
For order numbers, see spare parts list.

Maintenance schedule
W1 Oil change (CompAir - 4000-hour oil) 1)
W 5 Safety valve / functional test
Valid for normal industrial atmosphere! (In case
of doubt with regard to the oil change intervals,
have oil analyses carried out). W 6 V-belt
Minimum oil change = 1 x year (visual inspection only)
1) Oil change when the CompAir special oil "Blue

Energy" (option) is used, W 7 Check / retighten connecting terminals in the

1st oil change after 5000 h, later in accordance switch cabinet / electric motor and check the
with oil analyses, however, every two years at setting of the "control-power transformer"
the latest!

W 8 Check / retighten bolted connections

W 2 Replacement of oil filter cartridge
Valid for normal industrial atmosphere! W 9 General maintenance / cleaning
(in the case of a very dirty atmosphere, short-
W 3 Replacement of oil fine separator en the cleaning intervals as required)
Valid for normal industrial atmosphere!
W10 Replacement of V-belt / recommendation
W 4 Replacement of air filter cartridge (complete kits only)
Valid for normal industrial atmosphere!

Servicing and maintenance intervals

After OH Commis- 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000
or months sioning 3M 6M 9M 12 M 15 M 18 M 21 M 24 M 27 M 30 M 33 M 36 M
C-kit ● ● ● ● ● ●
D-kit ● ● ●
E-kit ●
V-kit ●
W1 ● ● ●
W2 ● ● ● ● ● ●
W3 ● ● ●
W4 ● ● ● ● ● ●
W5 ● ● ● ● ● ● ● ● ● ● ● ● ●
W6 ● ● ● ●
W7 ● ● ● ●
W8 ● ● ● ●
W9 ● ● ●
W10 ●

These maintenance intervals have to be observed!

47
 9. Servicing and maintenance

9.4 Oil change

Fig. 25

Note
When changing the oil, the waste oil is to be drained
completely, if possible, since used oil reduces the
service life of the new oil fill considerably.
Fig. 24 Lubricants of different types should not be mixed.
When changing over to a new oil type, the oil in the oil
circuit must be drained completely.
Danger.
The oil must only be changed, when the screw
For the oil change intervals, see the maintenance
compressor is out of operation and depressurized
schedule.
!Be careful when draining hot oil :
Danger of scalding ! When changing the oil, proceed as follows :
• Carefully open the oil drain (fig. 24) of the pressure
Important reservoir and the oil cooler, utilize the residual
pressure in the unit for draining.
Remove oil residues and other deposits from unit • Drain the oil at operating temperature
parts and from the coolers of compressors, which
• Open oil filling point
are exposed to hot compressed air, according to the
operating instructions. • Close the oil drain,
• Fill in oil (approx. 25 L)
• Close the oil filling hole with the plug screw
Note • Let the screw compressor unit run for approx. 2 mi-
Collect the waste oil, let not seep away into the soil ! nutes
Disposal in accordance with the regulations ! Do not • Check for leakages
spill oil ! Check for leakage ! • Switch the screw compressor unit off
With these compressors, the oil change intervals • Check oil level :
strongly depend on the degree of contamination of the For this, the oil should have settled, i.e. the entrap-
circulating oil. It must therefore be taken care that no ped air should have been dispersed
oil-deteriorating matter (dusts, vapours, gases) are • The oil level must reach the maximum marking on
transported through the air intake filter into the oil circuit the oil dipstick.
of the compressor unit. Also a high content of humidity • If required, top up oil.
in the intake air and the formation of condensate within
the machine affect the service life of the lubricant oil so Changing intervals for lubricants
that a reduction in the oil change intervals may become
The operating conditions (e.g. coolant temperatures),
necessary. The specified oil change intervals refer to
the operating modes and the quality of the intake air
an intake air from a normal environment without a high
(e.g. content of dust, content of gaseous foreign matter
content of foreign matter (dusts, vapours, gases). If,
such as SO2, solvent vapours, etc.) have a strong in-
under favourable conditions, it is intended that the oil
fluence on the oil change intervals. We therefore re-
service life be extended, oil samples have to be
commend to have your mineral oil supplier work out
examined, and the extension of the operating time is to
oil analyses in the starting time. This is required in any
be determined on the basis of these analysis results.
case, if the specified oil change intervals are to be ex-
tended. For these applications, the permissible time of
use of the oil must be verified on the basis of an oil
analysis.

48
 9. Servicing and maintenance

9.5 Change of the oil filter cartridge 9.6 Change of the fine separator

Fig. 26 Fig. 27

Danger.
Danger.
Only replace the oil filter cartridge, when the screw
The pressure reservoir is under pressure ! Only
compressor unit is out of operation and depressurized
work on the screw compressor unit, when it is out of
! Be careful with hot oil : Danger of scalding !
operation and depressurized !
Do not spill oil !
Be careful with hot oil : Danger of scalding !
Do not spill oil !
Note
Dispose of the oil filter cartridge in line with the
regulations - special waste - ! Check for leakage !
Note
Dispose of the fine separator cartridge in line with the
For the changing intervals, see the maintenance regulations - special waste - !
schedule.
Check for leakage !
If the oil filter cartridge is monitored (option), a high
differential pressure is indicated at the operating panel. If
the corresponding LED lights up, change the oil filter
For the changing intervals, see the maintenance
cartridge.
schedule.
Make sure that the screw compressor unit is depressu- If the fine separator cartridge is monitored (option), a
rized. Change the oil filter cartridge as follows : high differential pressure is indicated at the operating
• Unscrew the oil filter cartridge using an appropriate panel. If the corresponding LED lights up, change the
tool fine separator cartridge.
• Dispose of the oil filter cartridge according to the re- Make sure that the screw compressor unit is depressu-
gulations rized. Change the fine separator cartridge as follows:
• Oil the gasket of the new oil filter cartridge slightly
• Unscrew the fine separator cartridge using an ap-
• Screw on the new oil filter cartridge and tighten ma- propriate tool
nually (take notice of the instructions on the oil filter
• Dispose of the fine separator cartridge according to
cartridge)
the regulations
• Check for leakage
• Oil the gasket of the new fine separator cartridge
• Check oil level
slightly
• If required, top up oil. • Screw on the new oil filter cartridge and tighten ma-
nually (take notice of the instructions on the fine se-
Changing intervals for oil filter cartridges parator cartridge)
The operating conditions (e.g. coolant temperatures), • Check for leakage
the operating modes and the quality of the intake air
(e.g. content of dust, content of gaseous foreign matter
such as SO2, solvent vapours, etc.) have a strong influ-
ence on the oil change intervals. In such applications,
the required changing intervals may be shorter.

49
 9. Servicing and maintenance

Changing intervals of fine separators A clogged air filter must be cleaned or replaced when
the maintenance point has been reached.
The operating conditions (e.g. coolant temperatures),
the operating modes and the quality of the intake air If the air filter cartridge is monitored (option), a high
(e.g. content of dust, content of gaseous foreign matter differential pressure is indicated on the operating pan-
such as SO2, solvent vapours, etc.) have a strong influ- el. When the corresponding LED lights up, the air filter
ence on the oil change intervals. In such applications, cartridge is to be replaced.
the required changing intervals may be shorter. Check the air filter for accumulated dust at least once
a week or, if required, daily.
During maintenance work, take care that no dirt en-
ters the clean air side of the air filter.
9.7 Air filter change/check
Maintenance of the air filter
The air filter must be cleaned intermediately or be re-
placed by a new one (refer to the instructions on inter-
mediate cleaning).

Intermediate cleaning of the air filter

Note
Intermediate cleaning can be done no more than five
times.
The air filter must be replaced when damaged, after
five intermediate cleaning procedures or after two
years at the latest.
Clean the filter carefully in order to avoid damage to
the filter material and ensure that no dust enters the
clean air side of the filter.

Intermediate cleaning of the air filter by

Fig. 28
blowing through with compressed air
1 Safety valve
2 Fine separator Danger.
When blowing through an air filter, observe the
following :
Danger.
• Wear protective goggles and a breathing mask
Only perform checks and carry out work on the • The pressure of the compressed air must not ex-
screw compressor when the unit is out of operation ceed 5 bar
and depressurized !
• Blow through the air filter from the inside to the
outside until the formation of dust has consi-
Important derably decreased.

Never operate the screw compressor unit without

air filter (even a short operating time without this fil-
ter can result in considerable damage to the machi-
ne) !

50
 9. Servicing and maintenance

Intermediate cleaning of the air filter by rins- 9.8 Safety valve

ing

Danger.
Never use gasoline, alkaline solutions or hot liquids
for cleaning !
Rinse the filter as follows :
• Swirl the air filter cartridge in luke-warm water
which contains a special non-foaming rinsing agent
• Let the air filter dry
• Never install wet or damp air filters.

Check the air filter for damage

Before reinstalling the cleaned air filter, it must be
thoroughly checked for cracks, holes or other damage
by examining it against the light using a bright light
source (portable lamp). Check also the seals.

Changing intervals for filter and

separator cartridges
The operating conditions (e.g. coolant temperatures), Fig. 29
the operating modes and the quality of the intake air
(e.g. content of dust, content of gaseous foreign matter 1 Safety valve
such as SO2, solvent vapours, etc.) have a strong influ- 2 Fine separator
ence on the service life of the filters (air filters, oil fil-
ters, fine separators). In such applications, the requi-
red changing intervals may be shorter.
Danger.
Never operate a screw compressor unit with a
defective safety valve !
Before each commissioning, check the safety
valve for function by turning the knurled cap at the
safety valve at operating pressure.
If the safety valve does not function properly, it
must be immediately replaced by a new safety valve
with the corresponding pressure rating.
The safety valve can be hot as a result of previous
operation !
Escaping air can be hot and contain oil (danger of
burning/scalding) !

9.9 V-belts - automatic tensioning

system

Danger.
Only perform checks and carry out work when the
screw compressor unit is out of operation and
depressurized !
Any safety equipment which had to be removed for
the replacement of the V-belt set must be remounted
after completion of this work.

51
 9. Servicing and maintenance

Important
The replacement of a single V-belt is not permitted,
always replace a complete V-belt set.
During the entire service life of the V-belt set, no
readjustment of the automatic V-belt tensioning sys-
tem will be necessary.

operating position

Fig. 31

When replacing the V-belt set, the automatic tension-

ing system can be stressrelieved by means of the nut
(14) (fig. 31). After the replacement of the V-belts, the
nut (14) has to be returned to the "operation" position
Fig. 30 (mechanical stop of the fork and clevis combination
(13)).
1 Main frame of the drive
2 Compressor The compression spring has to be set to the corre-
3 V-belt pulley - compressor sponding colour marking on the threaded rod using
4 V-belt set the clamping nut (10).
5 Electric motor
6 V-belt pulley - electric motor
7 Bearing flange
8 Threaded rod 9.10 Connecting terminals in the switch
9 Distance sleeve cabinet
10 Clamping nut (self-locking)
11 Guide ring Danger.
12 Compression spring In the case of electric voltage :
13 Adjustment support
14 Nut • Actuate OFF-key at the operating panel
• Set the customer-fitted main power switch to "O"
(OFF)
It is not permissible to loosen the bearing flange
screws (anti-vibration mount of the electric motor). The connecting terminals in the switch cabinet have
to be checked and, if required, retightened during first
Any changes to the anti-vibration mount of the elec- commissioning and later on in line with the mainte-
tric motor can result in a drastic reduction in the ser- nance schedule.
vice life of the drive system.
The required pre-tensioning rate of the V-belt for
each screw compressor type is set in the factory.
For the adjustment after the first installation or a re- 9.11 Fittings
placement of the V-belt set, the compression spring
has be pretensioned. For this purpose, a blue marking The fittings of the air and oil circuits have to be chek-
is provided on the threaded rod. ked and, if required, retightened according to the
maintenance schedule.

52
 9. Servicing and maintenance

9.12 General maintenance and cleaning 9.13 Maintenance instructions and lubri-
cant recommendations for
Important stationary compressors
Remove oil residues and other deposits from unit
parts and from the coolers of compressors, which Lubricant recommendation
are exposed to hot compressed air, according to the
Please note that proper lubrication significantly ex-
operating instructions.
tends the service life of your compressor system.
Blow off the screw compressor unit with compressed According to the regulations for the prevention of ac-
air at the specified intervals (never aim compressed cidents in connection with compressors (issed by the
air at persons) paying particular attention to : German social insurance against occupational acci-
dents VBG 16) lubricants must be used, whose prop-
• Regulating elements
erties comply with the operating conditions provided.
• Fittings
Do not mix different lubricants. This means also that
• Compressor block
in the case of an oil change, the old oil type should be
• Cooler
completely drained from the circuit.
• Electric motor
In the case of final compressing temperatures perma-
nently above 90 °C, the oil change intervals given in par-
agraph 9.3 (maintenance schedule) shorten by 50 %.
Electric motor The oil change intervals should be determined ac-
cording to actual operating conditions and with the
The electric motors are permanently lubricated
help of oil analyses.

You should use the following oil types:

a) CompAir "4000“
b) CompAir "Blue Energy“

53
 10. Trouble-shooting

Malfunction Possible cause Remedy

Unit cannot be started 1. No operating or control voltage 1. Check fuses, main switch and supply line

2. Malfunction not acknowledged 2. Acknowledge fault message

3. Pressure reservoir not depressurized 3. Wait until depressurized, the reservoir

pressure must be <0.8 bar for a start

4. Electric motor defective 4. Check connections, winding, etc.

5. Compressor defective 5. Turn the compressor manually; if required,

replace

6. Ambient temperature less than +1 °C 6. Make sure that the ambient temperature is
not than +1 °C; install an auxiliary heater, if
required.

Unit stops during the 1. The intake regulator closes only partly 1. Repair or, if required, replace the intake
start-up phase regulator; check solenoid valve - 19 -

2. Short-circuit in the unit 2. Determine and eliminate cause; replace

defective fuses

3. Connecting terminals in the switch 3. Check and re-tighten

cabinet are loose

4. No or insufficient pressure builds up 4. Check the pressure holding valve and the
in the pressure reservoir during the opening function of the intake regulator
∆ phase

5. Oil too viscous 5. Select the type of oil according to the

ambient conditions or install an auxiliary
heater

6. Maximum motor switching cycles 6. Avoid frequent manual on and off-switching,

exceeded due to too frequent manual let electric motor cool down
on and off-switching

Unit does not reach the 1. Pressure monitoring device set too low 1. Check, re-set
final pressure
2. Intake regulator opens only partly 2. Repair or, if necessary, replace intake
regulator; check solenoid valves -19 + 20-

3. Excessive air consumption 3. Reduce consumption or cut in a further

compressor

4. V-belt slips 4. Replace the V-belt set

5. Fine separator clogged 5. Replace oil fine separator

6. Air filter clogged 6. Carry out intermediate cleaning or replace

54
 10. Trouble-shooting

Malfunction Possible cause Remedy

Unit switches off 1. Ambient temperature too high 1. Ventilate compressor room

2. Ventilator defective 2. Check el. motor and protective motor switch

3. Appears on the pressure or 3. Check sensors, connections and lines

temperature displays

4. Cross-section of the electric supply 4. Measure power requirement, if necessary,

lines too small replace lines

5. Power requirement too high 5. Fine separator or air filter cartridge

clogged; replace, if necessary

6. Oil level too low 6. Top up oil in the pressure reservoir

7. Oil injection pressure too low 7. Replace oil filter cartridge, clean oil system

8. Excessive oil temperature 8. Check oil cooler and ventilator

Excessive idling pressure 1. Intake regulator does not close 1. Check intake regulator and solenoid valves
correctly -19 + 20-

2. System not unloaded 2. Check solenoid valve (19) and lines

Oil in the compressed air 1. Oil fine separator defective 1. Replace

2. Oil foams 2. Change oil, blow-off time too short

3. Oil level too high 3. Drain off oil

4. Opening pressure of the pressure 4. Check pressure holding valve

control valve too low

5. Check valve 14 defective 4. Replace check valve

Oil in the air filter 1. Packing spool in the intake regulator 1. Check sliding fit and sealing surface and
defective replace, if necessary

2. Intake regulator does not close correctly 2. Check intake regulator and solenoid valves
-19 + 20-

3. Blow-off time too short 3. Extend time (nozzle)

4. Check valve defective 4. Remove check valve

Displayanzeige 1. Electronics defective, fault in 1. Replace electronics. Temporary commissioning

DELCOS 1000 possible by entering the initial parameters
(see BA, point 8.4)

Safety valve opens 1. Safety valve defective 1. Replace

2. Oil fine separator clogged 2. Replace

3. Intake regulator closes too slowly 3. Check intake regulator and solenoid valves
-19 + 20-

4. Pressure monitoring device defective 4. Replace

5. Electronics defective 5. Replace

6. Solenoid valves -19 + 20- defective 6. Replace

The screw compressor must not be operated with defective safety valve!

55
CompAir UK Ltd. High Wycombe
Hughenden Avenue
High Wycombe
Buckinghamshire
HP13 5SF
United Kingdom

Tel. +44 (0) 1494 605-0

CompAir Drucklufttechnik GmbH

Argenthaler Str. 11
55469 Simmern
Deutschland

Tel. +49 (0) 6761 832-0

www.compair.com
e-mail: sales@compair.com