Operating manual

Screw compressor
GEAR 90 - 250
 © 2009

All rights belong to:

ALMiG Kompressoren GmbH

Adolf-Ehmann-Straße 2
D - 73257 Köngen

2 Tel.: +49 (0)7024 9614-0

Fax: +49 (0)7024 9614-106

No part of this manual may be duplicated by mechanical or electronic means

without the express written permission from ALMiG Kompressoren GmbH.

guarantee.
-
ware documentation at any time without previous announcement.
Table of contents
1. Safety instructions.........................................................4 6. Correcting malfunctions ............................................. 40
1.1 Symbols in this manual.............................................4 7. Initial commissioning ..................................................42
1.2 Proper usage ............................................................5 7.1 Preparatory activities .............................................. 42
...................................................5 .......................................... 42
1.4 General safety instructions .......................................6 7.3 Start-up lubrication of the compressor stage.......... 42
2. Functional description ..................................................8 7.4 Rotational direction control..................................... 43
3. Storage and transport .................................................12 7.5 Basic settings ......................................................... 44
4. Installation .................................................................... 14 7.5.1 Controlling the unit by means of Air Control 3 .. 44
4.1 Setting up ...............................................................14 7.6 Switch on compressed air generation .................... 45
4.2 Ventilation ...............................................................14 7.7 Concluding activities............................................... 45
4.3 Forced ventilation (optional) ...................................15 8. Service ..........................................................................46
4.4 Water cooling (optional).......................................... 16 8.1 Overview Maintenance intervals............................. 46
4.5 Heat recovery for heating water / 8.2 Preparatory activities .............................................. 46
potable water (optional) ..........................................17 ........... 47
4.6 Connection to the compressed air net.................... 17 ................................................... 48
4.7 Electrical connections .............................................18 ....................... 48
5. Displays and operating elements...............................19 .................................... 48
5.1 Plant main switch.................................................... 19 ............................................. 49
5.2 Emergency OFF .....................................................19
5.3 Air Control 3............................................................20 ..................................... 50
5.3.1 Basic display..................................................21 ........................... 51
5.3.2 ON/OFF switching of ................................................... 53
compressed air generation............................ 21 ................................................. 53
5.3 .. 22 ............................................................. 54
5.3.3.1 Capacity utilization .......................... 23 8.13 Relubrication of the electric motor .......................... 54
5.3.3.2 Service ............................................ 23 8.14 Concluding activities............................................... 55
5.3.3.3 LLC status .......................................24 9. Technical Data ..............................................................56
5.3.3.4 Compressor pass ............................ 24 9.1 Dimensions for connections ................................... 56
5.3.3.5 Diagram net pressure...................... 25 9.2 Data air-cooled compressors.................................. 57
5.3 9.3 Data water-cooled compressors............................. 57
compression temperature ...............25 9.4 Electrical data......................................................... 57
5.3.3.7 Diagram compressed 10. Service manual ........................................................... 58
.................... 25
5.3.3.8 Diagram compressed
...............25
5.3.3.9 Modify diagram settings .................. 26
5.3.4 Menu system .................................................27
5.3.4.1 Sub-menu Limit values.................... 28
5.3.4.2 Sub-menu Operating parameters.... 29
5.3.4.3 Sub-menu Service intervals ............ 30
5.3.4.4 Sub-menu Timer.............................. 31
5.3.4.5 Sub-menu Fault log ........................ 33
5.3.4.6 Sub-menu Display parameters........ 33 3
5.3 .................34
5.3.4.8 Sub-menu Lead lag control (LLC) ...35
5.3.4.9 Sub-menu Accessories.................... 36
5.3.4.10 Sub-menu Diagnosis .......................36
5.3.5 Warnings / maintenance................................ 37
5.3.6 Malfunctions ..................................................38
5.3.7 Adjustment of the display contrast.................39
 1. Safety instructions

Safety instructions You are reading this manual in order to learn about the screw compressor.

usage may not fall under the conditions of guarantee!

access to it at any time.

of-the-art technology and considering all the current safety standards. In

the system if you comply with the stipulations of the service manual and if

according to the regulations.

1.1 Symbols in this manual

This symbol is employed whenever personal damage can be incurred

by carelessness, or by ignoring the instructions.

DANGER

This symbol is employed when damage to property can occur through

carelessness, or by ignoring the instructions.

NOTICE

Italic text is employed when we would like to draw your attention to particular
4
information.

the user.
1.2 Proper usage The system is exclusively designed for

the generation of compressed air and

in an environment without explosion risk.

The units are designed for a minimum pressure of 5 bar (operating over-
pressure)!

Any other utilization must be regarded as not in compliance with the design
purpose!
The manufacturer/vendor is fundamentally not liable for damage incurred if
the system is not used according to its design purpose!

The generated compressed air may not be used for human respiration. In
case the compressed air is used for pharmaceutical or sanitary purposes, it
must undergo further treatment. The same is true when the compressed air
is used in production plants and comes into direct contact with foodstuffs.

individuals must read the chapter relevant to their duties.

Activities that are not described in this manual may only be carried out by
our customer service department or by authorized technical personnel.

material!
5
 1. Safety instructions
1.4 General safety instructions

Loss or decrease of compressor safety !

safety! The results could be serious personal, material or environmen-

equipment components from third party manufacturers must therefore

DANGER

Loss of contact protection!

The side panelings of the system are part of the contact protection
system to protect personnel from fan impellers that start up automati-
cally, moving machine parts, hot surfaces and dangerous voltages!
DANGER Furthermore, they are required for sound insulation and cooling air
conduction. Therefore they must not be removed when the unit is in
operation.
For initial commissioning, it is required to remove the side paneling of
the system. Furthermore, in the process of the initial commissioning
of the plant, the mains switch must be turned on.
The initial commissioning, therefore, may only be carried out by quali-

Injuries caused by fan impellers that start automatically, moving ma-

Installation, service or repair work on the components of the system

must, if not otherwise described, be categorically carried out only on
DANGER
system must be secured against an illicit or accidental switching-on.
The shut-off device for the compressed air net must be closed.
If measuring or testing work is required on the electrical components
6 while the system is in operation, they must be carried out by electri-
cians observing all the relevant safety regulations.

Damage to the sense organs!

Compressed air streams may not be directed towards persons. When
applying compressed air, dust particles can be raised by the air stream.
Therefore, when working with compressed air, protect your eyes with
DANGER safety glasses.
 Loss or decrease of compressor dependability!
Only original spare parts and lubrications may be employed!
We recommend that a set of service parts subject to wear be kept on
stock, in order to guarantee high compressor availability. Our customer
NOTICE service would be glad to help you with your selection.

Damage to the system may result in environmental damage!

Before initial commissioning, the system must have been correctly
installed according to Chapter 6!
For the operation of the compressor (equipment in the sense of Pres-
NOTICE
sure Equipment Directive 97/23/EC) please observe national regulations
and laws. In Germany, operating equipment must be operated in ac-
cordance with the regulations laid down in the ordinance on industrial
safety and health (BetrSichV)!
Dispose of all used or defective materials in a proper way!
This is especially true for components/materials containing cooling
liquid. Please note that the accumulated condensation containing
cooling liquid may not enter the sewage system!

-
tion processing.

Compressed air receivers require regular technical inspections!

Please notify the commissioning of the system at the technical inspection
authority responsible for you. They will inspect the system and provide a
receiver test book.

Document all the activities carried out (e.g. in some table format).

7
Carry out the activities in all of the following chapters in the order given.
 2. Functional description
2.1 Drive The electric motor drives the compressor stage via a perfectly adjusted
gearbox and a coupling with an elastic mounting.

2.2 Air path

minimum pressure non-return valve into the compressed air aftercooler and
is cooled down to 10 - 15 °C above the ambient temperature before it leaves
the compressor through the compressed air connection.

The suction regulator opens shortly after the compressor has started up for
generating compressed air. It closes when the compressor changes over
to off-load operation and/or comes to a standstill and unloads the system
via the relief valve.

regular intervals. Otherwise overheating will occur and the compressor

NOTICE may malfunction.
8
 -
tions:

process

for example.

2.4 Cooling The compressed air cooling and coolant cooler may be cooled by either of
the following:

The electric motor is always cooled by its own blower.A fresh air blower

dissipates the radiant heat.

9
 10

2.5

2. Functional description
Components
14

20

02

08

03
13
12 15 16

04 06
07
11 23
05
Water cooling
21

26
19 28
09
27

25
24
18

Heat recovery
17
Throughput cable not 01
required with heat
recovery system
2.6 Components
20

04
02

06 12

07
17

19
GEAR 90-110

02

06

17

07

01 GEAR 132-200

17

GEAR 201-250

2.7 Legend 01 Switching cabinet

02 Electric motor 11
03 Coupling
regulator
05 Suction regulator
06 Compressor level 20 Cooling air ventilator
21 Cooling water inlet
08 Safety valve
09 Drain air after-cooler

24 HCR water inlet

25 HCR heat exchanger
13 Minimum pressure 26 HCR thermostat
non-return valve 27 HCR water outlet
14 Relief valve 28 HCR thermostat valve
 3. Storage and transport

For measurements and weights, see Chapter 9.

Observe the local regulations and other requirements pertaining to the

professional use of tools, lifting and transport equipment, as well as
the valid standards and regulations for accident prevention.

DANGER

Always transport the system in its normal operating orientation in a pres-

sure-free state. Tilting or laying the system down is not allowed.

palette lifting trolley may be used.

12
13
 4. Installation
4.1 Setting up
Install the system in locations with the following environmental condi-
tions:

Space requirements and system weights are dependent on the compressor

type purchased. Measurements and weights: see Chapter 9.

that system service functions can be carried out without hindrance. The
minimum distance is 500 mm.
We recommend setting up the compressors in a separate compressor
room.

are forbidden!

DANGER

4.2 Ventilation
for compressor cooling.

and 9.3.
-
ing up of the compressor site.

14

the prescribed operating temperature limits and as cool as possible. If

Make certain that the place of installation is professionally ventilated.

Make certain that no circulating air short-circuit (the intake of the

NOTICE exhausted warm air) can occur.
 GEAR 90 - 110

GEAR 132 - 200

GEAR 201 - 250

4.3 Forced ventilation Forced ventilation must be dimensioned in such a way that the required
(optional)
15

Refer to the relevant installation instructions or data sheets for the nominal

supporting supplementary ventilators should be included when planning

the ducts.

The exhaust air can also be utilized for the purpose of heat recovery.
 4. Installation
4.4 Water cooling (optional)

see chapter 9.

A solenoid valve (optional) should be installed before the cooling water

inlet.
The cooling water current through the compressed air after-cooler should be
set with the throttle valve belonging to it in such a way that the compressed

resistant.

16
4.5 Heat recovery for heating Compressors can be supplied with the optional heat recovery system
water / potable water (op- or
tional)

The heat recovery is to be connected appropriately (see drawing in Chapter

4.6 Connection to the com- -

pressed air net viced compressed air net.

Install an additional shut-off valve at the input of the compressed air net.
-
pressed air net. Length of the hose employed: max.1.5 m.
17

Unpredictable movements of the compressed air hose!

During load switching in the compressed air net, the hose can move
suddenly and with great force. Therefore the hose must be adequately

DANGER
 4. Installation

4.7 Electrical connections -

protection) and a suitable main switch (to switch the supply ion and off) must
be installed in the mains supply cables.

All the relevant data for the connections can be found

Electrical voltage!
Only trained electricians may connect the system to the electrical
supply network.
DANGER

Mount the mains switch in the neighborhood of the plant. It must be easily
accessible at all times.

Connect the system according to the circuit diagram. The circuit diagram
is provided in the control cabinet of the system.

Damage to the system is possible!

Before switching on the generation of compressed air, initial commis-
sioning according to Chapter 7 must be correctly carried out!
NOTICE

protective switch etc.).

18
5. Displays and operating elements
5.1 Plant main switch The externally installed main system switch connects and disconnects the
system with/from the power supply.

The compressor main switch must be switched off for all service or
installation work and protected from illicit or accidental switching

turned on)!
DANGER

5.2 Emergency OFF The system may be stopped with EMERGENCY OFF in the case of a real
emergency!

Press the button to stop the motor in the event of danger.

recommissioning!
Enable the system only when the cause of danger has been profes-
DANGER sionally removed and a securely operating state is achieved.

Enable system:
1 pull the EMERGENCY STOP button

to switch the system on again. 19

 5. Displays and operating elements
5.3 Air Control 3 The operating / display desk of the Air Control 3

20 Integrated green LED

Blinking:

Lighted:
5.3.1 Basic display
will inform you about the plant condition.

Supplymentary information

Momentary
Momentarily available net pressure
at compressed air output temperature

Service or malfunction messages with

service telephone number

Supplementary information:

Switching times are programmed 5.3.4.4

Compressor was switched off by
the timer
Symbol ON: Compressor was switched on by the
timer
Pressure times are programmed 5.3.4.4

RESTART Automatic restart programmed 5.3.4.2

REMOTE Remote control mode programmed 5.3.4.7
Compressor OFF
Symbol ON:
LLC MODE On-load/off-load controlled by higher-level control 5.3.4.7
AUTOMATIC Meaning: Display of programmed off-load running
OPT. control
Motor running

Solenoid valve open

Additional heater switched on 21

5.3.2 ON/OFF switching of com- Switching on: .

pressed air generation The compressor is ready and can start automatically anytime.

Switching OFF: Press .

state and afterwards off.

 5. Displays and operating elements
5.3.3 Function key reservation
in the basic display

Mode 1 = reservation 1

Capacity utilization Service

Lead lag control Plant pass

and

Mode 2 = reservation 2

22
Diagram Diagram
net pressure air amounts

Diagram Diagram
compression air amounts
temperature

opened.
returns to the basic display from all information screens.
5.3.3.1 Capacity utilization
(Mode 1 - F1) in the form of bar diagrams. The respective current hour count is also dis-
Change of mode 5.3.3 played in the bars.

Example:

Total service hours

On-load oad hours

Off-load hours

Standstill hours

left and growing to the right. The sum of the on-load hours and the off-load
hours yields the total service hours.

The scaling units of this diagram are according to the service hours. If the

of the standstill hours will be cut off. In this case note the displayed hour
count in the bars.

5.3.3.2 Service The Service diagram shows the remaining time in hours until the respective
(Mode 1 - F3) service interval is due.
Change of mode 5.3.3

Motor lubrication
Compressor

23

-
 5. Displays and operating elements
5.3.3.3 LLC status
-
(mode 1 - F2)
ing “YES” in the Lead lag control menu (see Chapter 5.3.4.8).
Change of mode 5.3.3

LLC mode.

On-load
Off-load
Ready for operation
Fault

5.3.3.4 Compressor pass The individual machine data stored in the compressor pass are required for
(Mode 1 - F4) our customer service.
Change of mode 5.3.3

24
5.3.3.5 Diagram net pressure
(Mode 2 - F1)
Change of mode 5.3.3

-
sion temperature is displayed.
(Mode 2 - F2)
Change of mode 5.3.3

5.3.3.7 Diagram compressed air

is displayed.
(Mode 2 - F3)
Change of mode 5.3.3

25

5.3.3.8 Diagram compressed air

(Mode 2 - F4)
Change of mode 5.3.3
 5. Displays and operating elements
5.3.3.9 Modify diagram settings The scale divisions of the axis can be changed by editing the axis values.
X-AUTO settings 5.3.4.6

y-axis: - The values of the y-axis can be changed in every diagram.

The data in the diagram are continually updated even after
the edit function.
x-axis:

-
tinually updated.
X-AUTO: activates or deactivates X-AUTO

in the menu “Display parameter diagrams “(see Chapter

5.3.4.6).The manual editing x-axis values are deleted.

Procedure for the scale division of the axis.

Axis value y-axis (Max)

Axis value y-axis (Min)

Axis value x-axis (time point 1) Axis value x-axis (time point 2)

and
ENTER

26 and .
Moving the cursor with and .
ENTER.

„X/Y-Init“ is for resetting the scale division for the default values
preset in X-AUTO.

ldeletes the recorded measurement values of the currently

displayed time diagram.
5.3.4 Menu system All basic settings of the system can be viewed in the menu system. If the
Limit values 5.3.4.1

INFO

Diagnose 5.3.4.10

00000: View the basic settings

00001: View and change basic settings
and .
and .
ENTER.

27

and .The selection is

ENTER.
5. Displays and operating elements
00001
changed as follows:

and .
ENTER.
and .
and .
ENTER.

5.3.4.1 Sub-menu Limit values

values
ENTER

Minimum
5.3.4.2 Sub-menu
Operating parameters the compressor:
Selection of the menu position Run-on time Run-on time of the motors in automatic Display
operation
values
ENTER Off time Run-on time of the motor for manual Display
switching-off delay and for automatic
restart
Star/delta time Star/delta time Display
Automatic restart Start after voltage return Can be edited
Operating mode: Behavior on load switching Setting range: Can be edited
AUTOMATIC
ON-/OFF-LOAD
AUTOMATIC OPT.
Max. pressure loss Maximum pressure loss Display
Max. no. of motor Maximum switching cycles of the motor Display
starts per hour

Operating mode “Automatic”

The text “AUTOMATIC” is displayed in the basic display. After reaching the

time) for the duration of the run-on time and the basic display shows the
text “run-on time” with the respective residual time. At the conclusion of

automatically at any time after falling below the start pressure.

Operating mode “On-/off-load”

The text “ON-/OFF-LOAD” is displayed in the basic display. The compres-

run-on time is unlimited.

Operating mode “Automatic Optional”

The text “AUTOMATIC OPT.” is displayed in the basic display. After reaching

After 10 and after 40 seconds the net pressure is measured.

system is in the idling state for the duration of the run-on time. In the basic
29

switches off after completing the OFF time.

Max. no. of motor starts

then the compressor temporarily switches to the operation mode on-/off-

load.
 5. Displays and operating elements
5.3.4.3 Sub-menu
Service intervals

respective service intervals (see Chapter 8.1) is reset.

Service interval ASF Display

Service interval OLF Display
Service interval OLAB Display
Service interval motor Service interval for motor lubrication Display
Service interval compr. Service interval compressor Display
Service interval Nominal service interval value Display
Universal (designation is entered in the menu text)

Default setting: 0 hours

Service hours Total operating hours (motor on) Display
Load hours Accumulated load hours Display
Standstill hours Accumulated standstill hours Display
(system on motor off)
Total delivery volume Accumulated delivery volume of the Display
compressor

30
5.3.4.4 Sub-menu Timer
processes dependant upon it are in this menu.

Selection of the menu position Date/time Setting the current date and time Edit
Attention: The adjustment is entered to
values
ENTER ENTER
Compressor switching Branch to the sub-menu Edit
times
Compressor pressure Branch to the sub-menu Edit
times
Switching times LLC Branch to the sub-menu Edit
Pressure times LLC Branch to the sub-menu Edit
Switching times Branch to the sub-menu Edit
Priorities

Switching times as well as pressure times can be programmed with the

timer independently of each other.

manually switched on and off. This is to prevent the possibility that the
compressor might for instance start up automatically at night in order to
compensate for loss in the compressed air net.
-
ter 5.3.4.1) can be set for the start and stop pressure. In this way only the
minimal required operating pressure is always generated so that energy is
saved.

Switching times for compressor

31

set to “ON” in the highest menu line.

If the timer channel is set to “ON” and

display

the switching time should be set to 00:00.

 5. Displays and operating elements

and
ENTER.
and .
.)
4. Set the cursor with and and

ENTER.

If the timer for switching times is activated, then the compressor only
works during the switching times entered!
NOTICE

Compressor pressure times

pressure / decreasing pressure).

the timer channels must be set to “ON”.

(For switching times adjustment: see paragraph “Compressor switching

32 times”)
The channels are searched beginning with K1 to K7 to determine whether a

then the settings in the menu “limit values” are valid. In order to activate the

of 00:00 should be entered.

Switching times LLC / Pressure times LLC / Switching times

Priorities

Switching times or pressure times for operation in the lead lag control mode

The settings are to be carried out as described in “Compressor switching

times” or “Compressor pressure times”
5.3.4.5 Sub-menu Fault log
indication of the date and time.

5.3.4.6 Sub-menu
Display parameters

Selection of the menu position Pressure dimension Selection of the unit for the display of Edit
the line pressure
values
ENTER Temperature dimension Selection of the unit for the display of Edit

Volume unit Selection of the unit for indicating the Edit

delivery volume
Language Selection of the display language Edit
Volume unit Select the unit to display the delivery rate Edit
Setting range: m3/f
Default setting: m3
Pressure offset Readjustment possibility for the net Display
pressure sensor
Diagrams Settings for diagrams Edit
Texts Texts for the compressor pass Display

Diagrams

5.3.3.9) for the diagrams can be set:

Saving interval

quanitiy. The control system always saves the most recent

8000 values. For a saving interval of 12s (basic setting) the-
re is a logging duration of 12s x 8000 = 96000s = 26.7h
Number of Number of the recorded values for function X-Auto on the
points X-auto time axis at a saving interval of 12 s and up to 300 points for
X-Auto a time axis scaling of 12s x 300 = 3600s =1h
Line pressure Lower scale value of the x-axis of the diagram
low “line pressure” (see 5.3.3.5)
Line pressure Upper scale value of the x-axis of the diagram
high “line pressure” (see 5.3.3.5) 33
Temperature low Lower scale value of the x-axis of the diagram
“Final compression temperature” (see 5.3.3.6)
Temperature Upper scale value of the x-axis of the diagram
high “Final compression temperature” (see 5.3.3.6) (basic 120°C)
Air quantity day Lower scale value of the x-axis of the diagram “Compressed
low
Air quantity day Upper scale value of the x-axis of the diagram
high
Air quantity Lower scale value of the x-axis of the diagram “Compressed

Air quantity Upper scale value of the x-axis of the diagram “Compressed
 5. Displays and operating elements
5.3.4.7 Sub-menu Machine type Display

Maximal pressure Maximum permissible machine pressure Display

Selection of the menu position
Delivered air quantity at maximum speed in Display
values on-load operation
ENTER
Remote mode Local / Remote / Base load change mode Edit

LLC operation Operation with external base load alternate Edit

switching
Power fail Stop Switching-off when low voltage is recognized Display

Output 7 Edit

-
-

Default setting: FREE

Frequency converter Settings of the frequency converter Display

Communication Settings for serial communication Display

Heating Settings of the additional heater Display

Remote mode
Determines how the compressor is switched on or off.

Local operation: The compressor can only be switched on or off at the ope-

Remote operation: The compressor can be switched on or off with an elec-

“REMOTE”.
34

If the unit was switched off by means of key , key must be

pressed for switching the compressor on, even if remote operation
is active.
NOTICE

system to the compressor. (see also LLC Operation 5.3.4.8)

LLC mode
The compressors are controlled by a higher-level control system. The
text “LLC MODE” (see also Remote Mode 5.3.4.8) appears in the basic
display
5.3.4.8 Sub-menu This menu contains the settings for the operation as the LLC Master.
Lead lag control (LLC)

Selection of the menu position A base load sequencer composite regulates uniform distribution of the
connected compressor operating hours and thus ensures economical and
values optimal operation of the connected compressors. Implementation of the
ENTER base load sequencer is executed in a master-slave composite.

with an RS-485 interface.

The LLC master function may only be activated when the compressor
is actually used as master unit!
NOTICE

If the master system is removed from the base load sequencer

composite, e.g. for maintenance, then it must be switched off via
the button and disconnected from the mains supply with the main
NOTICE switch.

Lead lag control Parameter for the activation of the Display

LLC Master characteristics
Change immediately If YES (recommended setting) the base load Edit
change row will immediately rotate after the

whether a cut-in or cut-out threshold has been

reached or not.
If NO the base load change row will now
change until the switching threshold.
Setting range: YES / NO
Default setting: YES
Start pressure Lower pressure threshold for Edit
switching on a compressor
Stop pressure Upper pressure threshold for Edit
switching off a compressor
Start delay Minimal time between the switching on of two Edit 35
compressors (Default setting: 5 seconds)
Stop delay Minimal time between the switching off of two Edit
compressors (Default setting: 2 seconds)
Changeover interval Time between changeovers of LLC for Edit
Priority 1 compressors having priority 1
Changeover interval Time between changeovers of LLC for Edit
Priority 2 compressors having priority 2
Changeover interval Time between changeovers of LLC for Edit
Priority 3 compressors having priority 3
Priorities Assignment of sequencing priority Edit

(see also Chapter 5.3.4.7)

 5. Displays and operating elements
5.3.4.9 Sub-menu Accessories This menu contains the settings for the connection of accessories.

extension modules.

Accessories module Additional module for accessories availa- Display

ble
Function of digital inputs Edit
Function of digital outputs Edit
Switching times output 1 Edit
Switching times output 2 Edit
Switching times output 3 Edit
Switching times output 4 Edit

Please refer to the wiring diagram for information regarding electrical data.

Switching times

menu.

of the timer channels must be set to “ON”.

36 -
ing times “ Chapter 5.3.4.4.

set the switching time to 00:00.

The inputs 1 to 8 can be used in order to switch the compressor to malfunc-

tion or warning.

5.3.4.10 Sub-menu Diagnosis This menu describes the current states of digital inputs and outputs.
5.3.5 Warnings / maintenance
The compressor is not switched off.
The display contains the additional information:

Chapter 8.

Damage to the system is possible!

Necessary maintenance work appear as warnings.

NOTICE has actually been carried out!

Maintenance work not carried out degrades the service life and re-
liability of the system. Please note that damage because of improper
usage might invalidate the warranty!
Only original spare parts may be used.
Information on service: see Chapter 8.

menu Maintenance schedule.

and . 37

you will return to the basic display.

 5. Displays and operating elements
5.3.6 Malfunctions A malfunction has occurred when the red light is permanently on.

The compressor is stopped automatically.

-
sionally repaired. Troubleshooting and repair should be done exclusively

.
in order to restart the compressed air generation.

38
5.3.7 Adjustment of the display The display contrast of the control was selected so that it ensures optimum
contrast readability under nearly all operating conditions. If it is nevertheless required
to adjust the contrast under certain conditions (e.g. unfavourable lighting

1. Make sure that the compressor is disconnected from the power

supply by actuating the master switch.
DANGER

2. Open the control cabinet/control box of the compressor.

3. At the rear of the control you can see a small opening at the top.

Insert a small plain slot screwdriver through this opening to reach the ad-
justment screw for correcting the contrast.

5. Close the control cabinet/control box before recommissioning.

39
 6. Correcting malfunctions

Error Cause Measures

Compression temperature Silencing hood not closed

too high (red lamp is on) hood

Ventilate compressor room

too high

Clean with compressed air. In the

fouled! case of extensive fouling: disassemble
Attention: Cooler screw should cooler and clean with high pressure
cleaner.
Attention: Danger of short circuit!
the cooler Do not put electrical elements under
power

Line pressure falls Compressed air consumption A compressor with larger delivery
greater than delivery quantity quantity is required
of the compressor

Relief valve blows air during compres-

sion replace seals

Suction regulator does not open

System pressure Line pressure set too high Adjust line pressure anew
released by safety valve
Safety valve defective
exchange

40 Exchange solenoid valve

fouled cartridge

“Malfunction over-
pressure” or “line pressure
too high” (red lamp is on) Higher external pressure in the Equalize outside pressure or remove
compressed air net from net
Error Cause Measures

Compressor does not Net pressure set too high Adjust net pressure anew
start automatically or
does not deliver air after Interruption in the control current Check electric circuit for interruption
previous switching off circuit (only by a trained electrician)

pressure or from off-load Ambient temperature under +1 °C; Install an additional heater or keep
state. message compressor room at right temperature
temperature too low “

Switching times have been activated Check switching times and pressure
in Air Control 3 times in Air Control 3

System does not start on Line pressure greater than start Note line pressure value
pressing the start button pressure

Remote control activated Symbol “remote “ is blinking

Missing voltage at the compressor Check if voltage is applied

Electrical error in the control system Inspect (only by an trained electrician)

Switching times have been activated Check switching times

in Air Control 3 in the Air Control 3

Compressed air
containing large amount is congested

great)

System stopped before Overtemperature or overpressure Rectify error as required

(red lamp is on) Interruption in the control current loop Check current loop
(only by a trained electrician)

Water in the piping net Dryer switched off Switch on dryer

Condensation diverter Clean / exchange drain

is not functioning
41
Bypass open Close bypass

Dew point too high Demand customer service

Pressure decline
too great
 7. Initial commissioning
7.1 Preparatory activities
without permission or accidentally.

supply. Ensure that t he shut-off slide on the pressure line side is closed
and cannot be opened without authorisation or by accident.

level

7.3 Start-up lubrication of the

compressor stage

phase.

of coolant into the compressor stage.

Compressor
GEAR 90-200
42 GEAR 201-250

2. Rotate the air end only by hand in the correct direction of rotation until

the air end.

If the system is employed only very irregularly or shut down weeks on end,
it should run an hour in the off-load mode once a week in order to avoid
corrosion damage caused by standing condensation.
7.4 Rotational direction control

The unit can be damaged, if the motor rotation direction is incorrect!

Only few seconds of incorrect motor rotation direction can damage
NOTICE
rotation direction.

fol

when the fan starts.

43
 7. Initial commissioning
7.5 Basic settings
“Compressor operating elements “.

7.5.1 Controlling the unit More precise instructions on the basic settings of the system can be found
by means of Air Control 3 in the following chapters :

The display parameters

The limit values

carry out settings as in point 5.3.4.4 and 5.3.4.7 of the description.

44
7.6 Switch on compressed air 1. Before switching on the system, make certain that no one can be en-
generation dangered by doing so. The sound-insulation hood serves as a part of
the contact protection, among other things for the cooling air conduits
of the compressor plant. It must be closed during operation.
2. Carefully open the shut-off valve after the compressed air connector
and between system compressed air net (receiver). The system is now
connected to the net.
3. Switch on the main switch.
4. Make certain that no tools or loose objects are lying on or in the system.
5. Press key to switch on the compressed air generation.

The green LED in key lights up when the compressor is working.

Check on the operating display desk for the line pressure.
The line pressure will slowly rise if the compressed air consumption is less
than the quantities delivered by the compressors.

On blinking green LED, the compressor can start by itself at any

time!
DANGER
The green LED blinks when the compressor is ready for operation.
The compressor switches on automatically when

of the compressor, if

7.7 Concluding activities 1. Check all piping of cooling liquids and pressure air conduits for leakage.

3. Check the compressor temperature. The compressor temperature 45

should neither remain below approx. 75 °C
°C a warning is output is automatically shut
down.
We recommend:

4. Re-tighten all electrical connections after a week.

6. Check the standard operation of the functions carried out weekly ac-
 8. Service
8.1 Overview Necessary service work appears in the display as warnings (see Chapter
Maintenance intervals 5.3.5)
Service activities Chapter After the After the Every
week operating h.
operating operating but at least
hours hours once a year
Check the compressor

Check for leakage

Check compressor
temperature
Check cooler
for fouling
Check for
condensate

Replace cooling liquid

Check safety valve

Check drive

Lubrication of motor

General compressor
servicing

*
**
– normal industrial atmosphere

This interval is relevant for:

– normal industrial atmosphere

8.2 Preparatory activities 1. Press key in order to switch off compressed air generation. Please
46 wait until the compressor has been switched off after a run-on or venti-

in the display.
2. Switch the compressor main switch off and make certain that it cannot
be turned on by mistake or intentionally (e.g. warning signs prohibiting
switching).

Use only original spare parts!

NOTICE

DANGER
 3. Remove the side panels of the system.

cannot be opened accidentally or intentionally.

Carry out the “Preparatory activities”

Preparatory activities 8.2

Concluding activities 8.14

settled down after the running phase.

The cooling liquid level is correct if the sight glass is fully wetted by the
cooling liquid.

Top up cooling liquid if the sight glass is only half wetted by the cooling
liquid.

47

NOTICE

closed.

Carry out the “Concluding activities”.

 8. Service
8.4 Check for leakage Carry out the “Preparatory activities”.
Preparatory activities 8.2
Concluding activities 8.14

Carry out the “Concluding activities”.

8.5 Check the compressor

temperature be between 75 °C and 105 °C.

Too high or too low compressor temperature can lead to damages to

the compressor.
NOTICE

8.6 Check the cooler for Carry out the “Preparatory activities”.
fouling
Preparatory activities 8.2
Concluding activities 8.14
-

blown outside).

Carry out the “Concluding activities”.

48
8.7 Check for condensate The absorption capacity of water humidity in the air
Preparatory activities 8.2
Concluding activities 8.14

-
midity does not precipitate as condensation. Frequent switching on and off
of the compressor can result in the compressor not achieving the required
operating temperature.

the compressor. If you have determined that there is condensation in

the seperator tank, immediately get in touch with after-sales service!
NOTICE Condensation damages are not covered by the warranty!

It can be simply drained off by the discharge drain.

Carry out the following activities only when the system has been turned
off at least overnight.

Carry out the “Preparatory activities”.

1. Open the drain and carefully observe the escaping liquid. Close the

Carry out the “Concluding activities”.

49
 8. Service

Only change the coolant if the old coolant is still warm. Cold coolant will
Preparatory activities 8.2
Concluding activities 8.14

With appropriate precautions, make certain you are not burned or

scalded!
DANGER

Carry out the “Preparatory activities”.

50

NOTICE
 closed..

Carry out the “Concluding activities”.

separator
Preparatory activities 8.2 separator.
Concluding activities 8.14

Carry out the “Preparatory activities”.

51

2. Lightly oil the new seal(s) of the separator.

Carry out the “Concluding activities”.

 8. Service

Carry out the “Preparatory activities”.

separator vessel.
-

4. Mount the cover of the separator vessel and reconnect the lines.

stage.

Carry out the “Concluding activities”.

52
 Carry out the “Preparatory activities”.
Preparatory activities 8.2
Concluding activities 8.14

Damage to the system by intake dust!

NOTICE

Carry out the “Concluding activities”.

8.11 Check safety valve Carry out the “Preparatory activities”.

Preparatory activities 8.2
Concluding activities 8.14
1. Remove the safety valve and remove residues at the threaded connec-
tion.

53

4. If the adequate functionality of the old safety valves can no longer be

Carry out the “Concluding activities”.

 8. Service
8.12 Check drive Carry out the “Preparatory activities”.
Preparatory activities 8.2
Concluding activities 8.14
1. Test manually whether the coupling might have some radial play.

coupling element.
3. Mount the cam ring again on the coupling half and test manually whether
the coupling now has no more radial play.

Carry out the “Concluding activities”.

8.13 Relubrication of the Carry out the “Preparatory activities”.

electric motor
Preparatory activities 8.2
Concluding activities 8.14

2. Carry out the required relubrication with a grease gun.

capsulated permanently greased bearings. These motor bearings must be

replaced when they are worn out.

Carry out the “Concluding activities”.

54
8.14 Concluding activities
2. Switch the compressor main switch on.

system.
to switch the compressor on.

7. Finally mount the side panels of the system.

Chapter 5.3.5.

employed cleaning materials should be considered hazardous waste

and disposed of in an environmently friendly way.

Damage to the system is possible!

Only acknowledge those services actually carried out!
Services not carried out degrade the service life reliability of the
NOTICE system. Please note that damages caused by improper usage are not
covered by the guarantee!

55
 9. Technical Data

56 9.1 Dimensions for connections

Compressor L B H Cooling Compressed air Heat

connection recovery
mm mm mm l G / DN G

GEAR 90 2.300 1.400 2.025 60 2 1/2 1

GEAR 110 2.300 1.400 2.025 60 2 1/2 1
GEAR 132 2.800 1.400 2.025 60 2 1/2 1 1/2
GEAR 160 2.800 1.400 2.025 80 80 1 1/2
GEAR 200 2.800 1.400 2.025 80 80 1 1/2
GEAR 201 3.400 1.650 2.025 160 100 1 1/2
GEAR 250 3.400 1.650 2.025 160 100 1 1/2
9.2 Data air-cooled compressors

Compressor Weight Cooling air Intake air Diameter exhaust

amounts opening air canal
kg m3/h m2 m2
GEAR 90 2.650 17.100
GEAR 110 2.720 17.100
GEAR 132 3.830 18.00
GEAR 160 3.900 23.400
GEAR 200 4.150 25.200
GEAR 201 4.300 28.000
GEAR 250 4.500 33.000

9.3 Data water-cooled compressors

Compressor Weight Cooling air Cooling water currant at Connection

amounts inlet/return temperature cooling
10/40 °C 25/40 °C 35/45 °C water
kg m3/h m3/h m3/h m3/h G
GEAR 90 2.700 3.000 1
GEAR 110 2.700 3.000 1 1/2
GEAR 132 2.850 3.000 1 1/2
GEAR 160 3.400 3.000 1 1/2
GEAR 200 3.650 3.000 1 1/2
GEAR 201 4.300 6.000 1 1/2
GEAR 250 4.500 6.000 1 1/2

9.4 Electrical data

Compressor Motor Currant at Currant at Maximum switching

power 400V / 50Hz 400V / 60Hz frequency

IN IFuse IN IFuse
57
KW A AgL A AgL 1/h
GEAR 90 90 163 224 163 224 5
GEAR 110 110 199 250 199 250 4
GEAR 132 132 229 300 229 300 4
GEAR 160 160 277 315 277 315 4
GEAR 200 200 349 400 349 400 4
GEAR 201 200 349 400 349 400 4
GEAR 250 250 478 630 478 630 2

IN = Nominal currant IFuse

 10. Service manual

Compressor type:

Unit number:
Please quote on queries, orders and correspondence.

Motor number:
Vessel number:
Date of commissioning:

Your ALMiG service:

58
 Coolant change Filter change*
Operating Date Name Operating Date Name
hours hours

59
 10. Service manual

Further maintenance and repair work

Operating Date Spare parts Name
hours

60
 Further maintenance and repair work
Operating Date Spare parts Name
hours

61
 10. Service manual

Further maintenance and repair work

Operating Date Spare parts Name
hours

62
 Further maintenance and repair work
Operating Date Spare parts Name
hours

63
Manual_GEAR90-250_gb_04-2009