Oil-free compressor stations

Transcription

1 Oil-free compressor stations Installation and Operating Instructions L V003

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3 Contents Important information 1 Documentation Warnings and symbols Notes on copyright Safety Correct use Incorrect use General safety notes Qualified personnel Protection against electrical current Only use original parts Transportation and storage Disposal Vibration damping between compressor unit and receiver Installation position and fastening Noise reducer Operation Remove the transport protection Set up compressed air connection Condensed water Electrical installation Check the pressure switch Check safety valve settings Setting possibilities Pressure switch setting Set the motor protection switch Pressure reducer adjustment Product description 3 Overview Flexible modular system Compressor station examples Accessories Working parts and spare parts Technical data Pressure receiver Overview Instructions for use for the pressure receiver (explanation by Behälter- Werk Burgau GmbH) Declaration of conformity for machines in accordance with the 2006/42/EC Directive Function Compressor station without membrane drying system Compressor station with membrane drying system Usage 11 Instructions for use Switch the unit on/off Switching the unit on after a power cut Pressure receiver test Mobile compressor station Maintenance Maintenance plan Draining the condensate Change the air intake filter Replacing the filter of the membrane-drying unit Deactivation Shut down the unit Store the unit Trouble-shooting 14 Tips for Operators and Technicians.. 31 Mounting 8 Prerequisites Area of installation Addresses L V003 1

4 Important information 1 Documentation These assembly and operating instructions form an integral part of the unit. They correspond to the particular model of the unit and to the technical standards applicable at the time it was brought to market. In the event that the instructions and information in these assembly and operating instructions are not observed, Dürr Technik undertakes to provide no warranty and accepts no liability of any kind for the safe and reliable operation of the unit. This translation has been produced to the best of our knowledge. The original German language version of the manual is definitive. Dürr Technik will not be held liable for translation errors. 1.1 Warnings and symbols Warnings The warnings in this document are there to point out possible injury to persons or damage to machinery. The following warning symbols are used: General warning symbol Warning - dangerous electrical voltage Warning - the unit starts up automatically The warnings are structured as follows: SIGNAL WORD Description of type and source of danger Possible consequences of ignoring the safety warning here Measures to be taken to avoid any possible danger. The signal word differentiates between different levels of danger: DANGER High risk of danger of serious injury or death WARNING Possible risk of danger of serious injury or death CAUTION Risk of danger of minor injuries NOTICE Risk of serious damage Further symbols These symbols are used within the documentation and on the unit itself: Notes, e.g. special instructions concerning economical use of the unit. CE-labeling Switch off the unit (i. e. unplug and disconnect from mains). Observe the accompanying documentation. Dispose of the unit properly according to valid state and local legislation. Dispose of the packing material in an environmentally friendly way. 1.2 Notes on copyright All circuits, processes, names, software programs and units specified are protected under industrial property rights. The reprinting of the assembly and operating instructions, even in extracts, is only permitted with the written permission of Dürr Technik L V003

5 2 Safety Dürr Technik has designed and developed the unit in such a way that danger is to a large extent excluded if the unit is used as intended. However, residual risks may be present. Therefore, please observe the following information. 2.1 Correct use The unit is designed for compressing atmospheric air. This unit is designed to be operated in dry, ventilated rooms. The unit must not be operated in wet or damp environments. Use of the unit in the proximity of gases or combustible liquids is prohibited. Ensure that mobile units are stationary before operation. 2.2 Incorrect use Any use of this unit above and beyond that specifically described in these instructions will be deemed to be as not according to the intended use. The manufacturer cannot be held liable for any damage resulting from incorrect usage. The user bears all risks. WARNING Serious injury and material damage due to improper usage Conveying explosive mixtures in any way other than that specified is not permitted. 2.4 Qualified personnel Important information Instructions for use Persons who operate the unit must, on the basis of their training and knowledge, ensure safe and correct handling of the unit. Ensure personnel are trained in the correct usage of the unit. Installation and repair Assembly and installation work, readjustments, modifications, upgrades and repairs must be carried out by Dürr Technik or personnel authorised and trained by Dürr Technik, who are familiar with the technology used in the unit and are aware of the risks involved when working on or operating the unit. 2.5 Protection against electrical current Observe all electrical safety regulations when working on the unit. Replace any damaged lines and plug and socket outlets immediately. 2.3 General safety notes Before using the unit observe any and all guidelines, laws, regulations and other restrictions which may apply to the unit. Before each use check the function and condition of the unit. Do not convert or change the unit in any way. Observe the Installation and Operating Instructions precisely. Keep the Installation and Operating Instructions in an accessible place so that the operator has instant access to them L V003 3

6 Important information 2.6 Only use original parts Only use accessories known to or approved by Dürr Technik. Only use original wear parts and spare parts. Result: Dürr Technik accepts no liability for damage resulting from the use of nonapproved accessories or any wear parts or spare parts other than genuine parts. 2.7 Transportation and storage The unit is shipped in a cardboard box filled with packaging padding. This packaging ensures that the unit is optimally protected in transit. As far as possible, always use the original packaging for transporting or storing the unit. Keep packaging away from children. WARNING Explosion of the pressure receiver and pressure hoses Ensure that the air has been evacuated from the pressure receiver and pressure hoses when they are stored and transported. Protect the unit against moisture during transit. Always transport the unit in an upright position. Only transport the unit using the transport handles provided. Do not transport the unit by the suction filter. The unit may be stored in its original packaging: in warm, dry and dust-free rooms; protected from contaminants. If possible, retain the packaging material. Ambient conditions during storage and transport Ambient conditions during storage and transport Temperature C -25 to +55 Rel. atmospheric humidity % 10% to 90% Please note here the label on the packaging padding. 2.8 Disposal Unit Packaging Dispose of the unit properly according to valid state and local legislation. Dispose of packaging material in an environmentally responsible manner. Note current disposal routes. Keep packaging away from children L V003

7 Product description 3 Overview 3.1 Flexible modular system The compressor stations can be assembled individually from various components according to requirements. The following components are available for selection: Oil-free compressor units with outputs from 25 l/min to 600 l/min. Fitted with single-phase AC motors or three-phase AC motors or special designs with DC permanent-magnet motors. Different pressure vessels with a volume of 3 l, 10 l, 25 l, 55 l or 90 l. Different designs of fittings with the necessary safety valve, pressure gauge and power cable as well as automatic condensate drainage (optional) or starting relief by means of solenoid valve (optional). A wide range of accessories such as suction filters, quick-release couplings, pressure hoses (optional), pressure reducers (optional) etc. Membrane drying system (optional) as separate component L V003 5

8 Product description Explanation of the product code T A-200 M 1 Receiver* U W T H P 3 l 10 l 25 l 55 l 90 l * Receivers with a maximum pressure (PS) of 10 bar (exception: compressor stations with 25-l receiver: PS = 8 bar) 2 Compressor units A B D Compressor units with single-phase AC motors Compressor units with three-phase AC motors Compressor units with DC permanent-magnet motors 3 Auxiliary modules K AK M Automatic condensate drain valve Automatic condensate drain valve + starting relief Membrane drying unit (also performs the function of module AK) The compressor station TA-200M used as an example comprises: 25-l receiver (T) Compressor unit: A-200 (with single-phase AC motor) Membrane drying system (M) L V003

9 Combination options of a compressor station with single-phase AC motor Product description Compressor units Receiver Auxiliary modules Series Unit Flow rate at 0 bar (l/min) 3 l 10 l 25 l 55 l 90 l Module K = autom. condensate drain valve Module AK = Modul K + autom. starting relief KK8 A KK15 A Module M = module AK + membrane drying unit A A KK40 A o A o KK70 A A Marathon A A A Standard combination o already included in the unit no standard L V003 7

10 Product description Combination options of a compressor station with three-phase AC motor Compressor unit Receiver Auxiliary modules Series Unit Flow rate at 0 bar (l/ min) 3 l 5 l 25 l 55 l 90 l Module K = autom. condensate drain valve Module AK = Modul K + autom. starting relief Module M = module AK + membrane drying unit KK15 B B KK40 B o BG o KK70 B B Marathon B B B x B Standard combination o already included in the unit no standard L V003

11 Product description Combination options of a compressor station with a DC permanent-magnet motor Compressor unit* Receiver Comment on compressor station Series Unit Article number Flow rate at 0 bar (l/min) in l Design KK15 D B VDC KK8 D VDC KK15 24 VDC D B including interference suppression filter D B VDC including interference suppression filter with autom. condensate drain valve D B VDC including interference suppression filter with autom. condensate drain valve and starting relief D-040 ZK429T VDC KK70 D VDC * Compressor units with another design are available on request L V003 9

12 Product description 3.2 Compressor station examples The item numbers designate the spare parts (see "3.4 Working parts and spare parts") Figure 1: TA-200M combination: A-200 compressor unit with 25 l receiver (T) and auxiliary module M (membrane drying system) Figure 2: UA-025 combination: A-025 compressor unit with 3 l receiver (U) L V003

13 Product description Figure 3: WA-062AK configuration: A-062 compressor unit with 10-l receiver (W) and auxiliary module AK (autom. condensate drain valve + autom. starting relief) Figure 4: TA-100K combination: A-100 compressor unit with 25 l receiver (T) and auxiliary module K (autom. condensate drainage system) L V003 11

14 Product description Figure 5: WA-062AK configuration: mobile AK: A-062 compressor unit with 10-l receiver (W), auxiliary module AK (autom. condensate drain valve + autom. starting relief) and transport rollers Figure 6: HA-160M combination: A-160 compressor unit with 55 l receiver (H) and auxiliary module M (membrane drying system) and pressure reducer L V003

15 3.3 Accessories Accessories for compressor stations Item no. Always specify type designation (e.g. WA-038/ ) and serial number when ordering accessories. Spare parts for accessories Pressure reducer Quick-release coupling (art. no ) Hose connection pieces for SW 10 (art. no ) Hose connection pieces for SW 6 (art. no ) Operating-hour meter Bracket* (art. no ) 20 to 22 Transport roller, complete (art. no ) 1) *Bracket for WA-025 to WA-062 1) optional accessory for WA -038 mobile AK, WA-061 mobile AK, WA-062 mobile AK, WA- 065 mobile AK, WAG-132 mobile K 3.4 Working parts and spare parts Spare parts for compressor station with membrane drying system Item no. Always specify type designation (e.g. WA-038/ B-01) and serial number when ordering spare parts. Spare parts for compressor station 1 Compressor 2 Receiver without plug 3 Pressure switch 4 Start-up solenoid valve (not shown) 5 Condensate solenoid valve 7 Pressure hose 8 Suction filter, complete Filter element (suction filter) 9 Pressure gauge Item no. Product description Spare parts for compressor station 10 Safety valve 11 Vibration dampers 12 Capacitor 13 Manual condensate drain (partially not shown) 14 Relief valve 15 Ventilation hose 16 Surge tank (art. no ) Quick-release coupling (art. no ) Seal Fitting unit, complete Relay (DC only) Power cable Suppression filter, complete (DC only) Carbon brushes (DC only) End cap/screw (DC only) Spare parts for membrane drying system Article no Always specify type designation (e.g. WA-038/ B-01) and serial number when ordering spare parts. Spare parts for membrane drying station Purge air nozzle set Sinter filter Fine filter ET Sterile filter L V003 13

16 Product description 4 Technical data For detailed information on the technical data of the compressor units refer to the assembly and operating instructions "Oil-free piston compressors KK and piston vacuum pumps KV" L V003

17 5 Pressure receiver 5.1 Overview Product description The units are fitted with pressure receivers of Behälter-Werk Burgau GmbH. The operating instructions provided below apply to the following pressure receiver types: Type Pressure 1) Receiver 2) EB 3) c 4) Remark 5) / PS 8 bar V 3 l A c = 1.0 mm / PS 8 bar V 3 l A c = 1.0 mm / PS 11 bar V 10 l A c = 1.0 mm 4; / PS 10 bar V 25 l B c = 0 mm 1; / PS 10 bar V 55 l A c = 1.0 mm 3; / PS 11 bar V 90 l A c = 1.0 mm 4 For serial number and build year see receiver identification 1) Pressure maximum operating pressure PS in bar 2) Receiver Receiver volume V in litres 3) Application area (EB) 4) Corrosion supplement Maximum temperature Minimum temperature Medium A = Pressure receiver for compressors B = Pressure receiver for stationary systems c in mm +100 C -10 C Air / nitrogen 5) Remark 1: The receiver is fatigue-resistant within a pressure fluctuation range of 1.6 bar (10% PS) Applied standards 286-1:1998 2: The receiver is fatigue-resistant within a pressure fluctuation range of 1.6 bar (20% PS) 3: The receiver is fatigue-resistant within a pressure fluctuation range of 2.0 bar (20% PS) 4: The receiver is fatigue-resistant within a pressure fluctuation range of 2.2 bar (20% PS) 5: The wall thicknesses must not fall below 2 mm 6: Condensate must be drained at the internal pressure specified in the operating instructions L V003 15

18 Product description 5.2 Instructions for use for the pressure receiver (explanation by Behälter-Werk Burgau GmbH) The pressure receiver may only be within the limits of the purpose of use and technical data described above. Any use other than as indicated is not permitted for reasons of safety. The pressure receiver was constructed in accordance with Directive 2009/105/ EG and was manufactured as a single component without safety-related equipment for the field of application indicated. The unit was designed for internal compressive stress. The supplier must additionally determine whether the pressure receiver, when equipped ready for use, must undergo an inspection test before commissioning. The supplier/operator is required to comply with applicable laws and regulations relating to the operation of the pressure receiver in the country of use. The receiver is capable of sustained operation within a pressure fluctuation range of D p 20% of the maximum operating pressure PS. Remarks: See "5.1 Overview". Before commissioning, the receiver must be provided with the required safety equipment, such as a pressure gauge, safety equipment to prevent overpressure, etc. These parts are not included in the scope of our delivery. No welding work or heat treatment may be carried out on the pressure-retaining walls of the receiver. It must be ensured that the internal pressure does not exceed the operating pressure PS under normal operating conditions indicated in the receiver marking. For a short time, however, this pressure may be exceeded by up to 10%. Vibration stress which would be damaging for the pressure receiver, as well as corrosion on the receiver, must be prevented using appropriate measures. The pressure receiver must be assembled and installed such that it is safe to use (e.g. no rigid connection to the floor or machine base frame without vibration dampers). Taking the equipment parts into consideration, the operating instructions to be drawn up by the supplier must contain the following: a) Instructions on draining the condensate b) Instructions and information on maintenance to ensure safety of use L V003

19 Product description 6 Declaration of conformity for machines in accordance with the 2006/42/EC Directive The manufacturer hereby declares that the machine complies with the requirements of the directive cited above and the requirements of the following additional directives: Electromagnetic Compatibility (EMC) Directive 2004/108/EC Simple pressure vessel directive 2009/105/EC in its current version RoHS directive 2011/65/EU Name of manufacturer: Dürr Technik GmbH & Co. KG Manufacturer's address: Pleidelsheimer Straße Bietigheim-BissingenGermany Reference number: Article description: From serial number: A Compressor stations and drying stations Validity: All units that are ready to connect and have a compressor, pressure receiver, and possibly membrane dryer and cooler and control elements, such as a pressure switch, condensate drain, etc. Can normally be identified from the following code (first figure) under the ref. no. on the type plate of the complete unit: UA-025K, WA-038, TA-100, HB-200, XB-304, ZK, AATA-100, BBTAG-132, CCHA-234, DDHB-304, SAS We hereby declare that the machine must not be commissioned until it has been established that the machine into which this machine is to be installed complies with the provisions as set out in Machinery Directive 2006/42/EC. The following harmonised standards and other standards have been applied: DIN : DIN : DIN : DIN : DIN : DIN : DIN : DIN : DIN : DIN ISO 12100: DIN ISO : Bietigheim-Bissingen, Andreas Ripsam General manager at Dürr Technik Proof of signature in the original document in the Dürr Technik archive L V003 17

20 Product description 7 Function 7.1 Compressor station without membrane drying system 7.2 Compressor station with membrane drying system 1 Compressor unit 2 Pressure receiver 3 Pressure switch 4 Start-up solenoid valve* 5 Condensate solenoid valve* 6 Operating-hour counter* 7 Pressure hose 8 Suction filter 9 Pressure gauge 10 Safety valve 11 Vibration damper 12 Condensor* *If included in the scope of delivery The atmospheric air is induced via the suction filter. This air is compressed in the cylinder by the piston. The inlet or the outlet valve cuts off the respective flow direction. The compressed air flows through the pressure hose into the pressure receiver via the integrated non-return valve. The compressor unit supplies compressed air until the set cut-off pressure is reached. The unit switches off. The pressure is indicated by the pressure gauge. The pressure hose is made pressureless by the integrated relief valve (on AK stations possibly with a starting solenoid valve only when starting the compressor).if compressed air is drained by a consumer, the pressure in the receiver drops. On reaching the cutin pressure, the compressor is switched on automatically by the pressure switch. A safety valve prevents the maximum permissible receiver pressure from being exceeded. 1 Compressor unit 2 Pressure receiver 3 Pressure switch 4 Cooler 5 Membrane dryer 6-7 Pressure hose 8 Suction filter (quick-release coupling) 9 Pressure gauge 10 Safety valve 11 Vibration damper 12 Condensor* *If included in the scope of delivery The atmospheric air is induced via the suction filter. This air is compressed in the cylinder by the piston. The inlet or the outlet valve cuts off the respective flow direction. The hot and moist compressed air flows from the compressor into the cooler. In the cooler, the compressed air is cooled down. Water condenses. 100% saturated compressed air and condensate leave the cooler and flow into the water separator. The condensate is separated by the sinter filter and accumulates in the water collecting container. The automatic condensate solenoid valve discharges the water in intervals. The air then flows to the membrane element. It then flows through the membrane fibres. The water molecules contained in the air diffuse through the membrane wall and accumulate on the outside of the fibre. The dried air flows via the fine filter, pressure relief valve and non-return valve to the receiver L V003

21 Product description A small partial current of dried air flows via the purge air nozzle to the outside of the membrane fibre for regeneration. This absorbs the accumulated moisture and is dissipates it to the environment. This regeneration takes place continuously during operation. Standstill periods are not required. The pressure relief valve in the upper part of the membrane ensures that the membrane drying unit reaches its rated operating pressure within the shortest time possible. A moisture indicator installed in the upper part of the membrane is visible through the transparent upper part. If the air is not dried sufficiently, the colour changes from blue to pink Warm air 2 Cooler with fan 3 Cold air 4 Membrane dryer 5 Condensate drain 6 Dry air The compressor unit supplies compressed air until the set cut-off pressure is reached. The unit switches off. The pressure is indicated by the pressure gauge. The pressure hose is made pressureless by the relief valve.if compressed air is drained by a user, the pressure in the receiver drops. 5 On reaching the cut-in pressure, the compressor is switched on automatically by the pressure switch. A safety valve prevents the maximum permissible receiver pressure from being exceeded L V003 19

22 Mounting 8 Prerequisites 8.1 Area of installation The installation area must meet the following requirements: Dry, well-ventilated room Not a purpose-built room (e. g. heating or wet room) Set up the unit on a clean, level and sufficiently stable surface (observe the weight of the unit). A socket outlet must be easily accessible. The type plate of the unit must be easily readable (also when installed). The unit must be easily accessible for operation and maintenance. Once the units are installed, the connecting terminals must be easily accessible when removing/opening the housing access. Maintain a sufficient distance from the wall (min. 30 to 40 mm) The air is filtered during induction. This does not alter the composition of the air. The air induced should therefore be kept free of harmful substances (e.g. do not draw in air from a basement garage or directly next to a suction machine). NOTICE Risk of overheating due to insufficient ventilation The unit produces heat. This can lead to heat damage and/or to a reduction in the service life of the unit. Do not cover the unit. Air must be able to flow in and out unobstructed. Ventilation openings must be sufficiently large. For installed units, an independent ventilation system may be required in unfavourable cases. 8.2 Vibration damping between compressor unit and receiver The units produce vibrations. Suitable vibration dampers must be used to damp these vibrations. CAUTION The use of rigid connections may damage the units or the system in which the units have been installed. Do not use rigid connection lines between the units and the system. 8.3 Installation position and fastening Install the units such that they are as level as possible. Other installation positions must be agreed in advance with Dürr Technik L V003

23 8.4 Noise reducer Elevated noise levels occur in pressure and vacuum mode at both the suction nozzle and the exhaust air nozzle. A suitable silencer must therefore be used. Suction filters and exhaust air filters (silencers) can be found in our spare parts list. Silencers act simultaneously as air filters. 9 Operation Mounting 9.1 Remove the transport protection For safe transportation, the unit is securely protected with packaging material. Remove the packaging material. Remove the protective film. Check the unit for damage in transit. 9.2 Set up compressed air connection The units are designed for a nominal pressure of 7 bar as standard. The service life of the unit will be reduced if the nominal pressure is regularly exceeded. The unit is equipped as standard with a control gear, which consists of a pressure switch, pressure gauge, safety valve, non-return valve and condensate drain. In order to avoid the transfer of vibrations, we recommend installing a flexible pressure hose between the pressure switch and the consumer. A pressure reducer can be connected as an additional accessory. The compressed-air supply is connected to the quick-release coupling (incl. hose connection piece) or to the pressure switch by means of a G 1/4" internal thread. Secure the pressure hose to the hose connection piece using a hose clamp. Connect the hose connection piece to the quick-release coupling L V003 21

24 Mounting 9.3 Condensed water Condensed water is continuously separated off in the compressor station during operation. The condensed water can be routed through a hose to a drain. Fasten the condensed-water hose to the unit and secure it against slipping out. Secure the condensed-water hose by guiding it or fastening it to the drain. 9.4 Electrical installation For detailed information on electrical installations refer to the assembly and operating instructions "Oil-free piston compressors KK and piston vacuum pumps KV". Electrical connection using a mains plug The unit must only be connected to a correctly installed socket outlet. When routing the lines to the unit, make sure that they are not subject to any mechanical tension. The socket must be easily accessible. Before commissioning, compare the mains voltage to the voltage information on the type plate. DANGER Electric shock due to defective mains cable Mains cables must not come into contact with the hot surfaces of the unit. Route mains cables without mechanical tension. Plug the mains plug into an earthed socket. The unit starts immediately after the mains plug is inserted. 9.5 Check the pressure switch The cut-off pressure is generally set to 7 bar (0.7 MPa). Switch on the unit by turning the pressure switch to the "I" position. Read the cut-off pressure indicated on the pressure gauge. Result: If the value read from the pressure gauge differs from the factory setting, the pressure switch can be adjusted (see "10.1 Pressure switch setting"). 9.6 Check safety valve settings The safety valve must be checked to establish that it is functioning correctly when the unit is started up for the first time. The safety valve is set to 10 bar (1 MPa) or 8 bar (0.8 MPa) (depending on the maximum pressure), inspected and stamped at the factory (see also "5.1 Overview"). DANGER Explosion of the pressure receiver and pressure hoses Do not change the safety valve setting. WARNING Damage to the safety valve Explosion of pressure receiver and pressure hoses due to defective safety valve Do not use the safety valve to evacuate air from the pressure receiver. Electrical connection without a mains plug DANGER Connection to the power supply may only be performed by a qualified electrician L V003

25 Switch on the unit at the pressure switch and fill the pressure receiver to the cut-off pressure. Turn the cap on the safety valve a few turns anti-clockwise until the valve begins to blow off. Allow the safety valve to blow off for a short time only. Turn the cap clockwise as far as it will go. Mounting 10 Setting possibilities 10.1 Pressure switch setting DANGER Bare live parts Electric shock due to live parts Unplug the unit from the socket outlet. Use an insulated tool. Do not touch live parts. The cut-off pressure must be at least 0.5 bar (0.05 MPa) below the maximum pressure of 10 bar (1 MPa) or 8 bar (0.8 MPa) (depending on the maximum pressure) of the safety valve. Otherwise, the safety valve may open early, and the cut-off pressure will not be reached by the compressor unit and it will therefore run continuously. The maximum pressure is indicated by a red line on the pressure gauge that is fitted. The valve is closed. The pressure switch must be set under pressure. The code for the pressure switch (MDR3 or MDR2) can be found on the pressure switch cover. Setting the MDR3 If the values read from the pressure gauge differ from the factory settings or if other settings are required, the compressor cut-off pressure can be altered by adjusting the setting screw on the pressure switch. The cut-in pressure can then be adjusted using the pressure differential Δp. Lift off the pressure switch cover L V003 23

26 Mounting Adjust the cut-off pressure p using the setting screw. The cut-off pressure increases in the "+" arrow direction and decreases in the "-" arrow direction. The pressure differential p will also be altered when this adjustment is made. Setting the MDR2 If the read-off values differ from the factory settings or if other settings are required, the cut-off pressure of the compressor can be adjusted at the adjusting screw on the pressure switch. The cut-in pressure can then be adjusted via the pressure differential Δp. Loosen the fastening screws of the pressure switch cover. Remove the pressure switch cover. Set the cut-off pressure p at the two adjustment screws (1). Turning the screws in arrow direction "+" increased the cut-off pressure, turning them in arrow direction "-" decreases the cut-off pressure Use the setting screw to readjust the pressure differential p between the cut-in pressure and the cut-off pressure. The pressure differential increases in the "+" arrow direction and decreases in the "-" arrow direction. The pressure differential p between cut-in pressure and cut-off pressure is adjusted at the adjustment screw (2). Turning the screw in arrow direction "+" increases the pressure differential (lower cut-in pressure), turning it in arrow direction "-" decreases the pressure differential (higher cut-in pressure) L V003

27 10.2 Set the motor protection switch The motor protection circuit breaker is not present in all units. The motor protection circuit breaker is adjusted and marked at the factory. Remove the pressure switch cover. Adjust the motor protection circuit breaker with the adjustment screw according to the motor current (note the range between min. permissible setting and max. permissible setting of the motor protection circuit breaker). The max. permissible motor current is the current rating on the type plate + 10%. Mounting 10.3 Pressure reducer adjustment The pressure reducer (available as an option) regulates the receiver pressure (inlet pressure) to the required operating pressure (secondary pressure). An additional secondary air evacuation system prevents the pressure from rising while the consumer is switched off. The pressure reducer is fitted to the pressure switch (G1/4"). Setting the pressure reducer: 1 Adjuster knob 2 Pressure gauge Pull up the adjuster knob (1). To increase the supply pressure: Turn the adjuster knob (1) clockwise towards "+". To decrease the supply pressure: Turn the adjuster knob (1) anti-clockwise towards "-". Once you have reached the required supply pressure (this can be read from the pressure gauge (2)), push the adjuster knob (1) down until it clicks into place. Check the supply pressure on the pressure gauge (2) L V003 25

28 Usage 11 Instructions for use Prior to working on the unit or in case of danger, disconnect it from the mains (e. g. pull the plug) Switch the unit on/off Switch on the unit by turning the pressure switch to the "I" position. The compressor unit will start up automatically and the pressure receiver will begin to fill. Once the cut-off pressure has been reached, the compressor unit automatically switches off again. Switch off the unit, if necessary, by turning the pressure switch to the "0" position Switching the unit on after a power cut Some units do not necessarily have to start up under pressure. These units can optionally be equipped either with a start-up volume (1) and a mechanical ventilation valve (2) or with an automatic start-up valve. Units with an automatic start-up valve: If the unit is fitted with an automatic start-up valve, the valve allows the unit to start up without being pressurised. Units with a start-up volume and mechanical ventilation valve and units with a membrane drying system 3 Safety valve 4 Condensate drain (manual) Switch off the unit using the pressure switch. Switch the unit back on using the pressure switch once the air has escaped from the start-up volume (duration: Approximately 5 seconds) or via the membrane drying system Pressure receiver test The operator must comply with the national directives. Example for Germany: German Ordinance on Industrial Safety and Health (BetrSichV) 11.4 Mobile compressor station NOTICE Risk of crushing when operating the articulated joints If the angle and height of the sliding handle are adjusted, keep fingers away from the area around the articulated joints in which crushing may occur. If both of the black knobs on the articulated joints are pressed at the same time, the height and angle of the sliding handle can be adjusted. 1 Start-up volume 2 Mechanical ventilation valve L V003

29 12 Maintenance Usage De-energise the unit prior to working on it or in the event of potential hazards (e. g. pull the mains plug) and prevent it from being switched back on again Maintenance plan Units without membrane drying unit Maintenance interval Weekly Every six months Yearly Every 4 years According to national directives Observe assembly and operating instructions "Oil-free piston compressors KK and piston vacuum pumps KV" Maintenance work Necessary for units without K-module: drain condensate - if humidity is high, daily (see "12.2 Draining the condensate"). Check safety valve (see "9.6 Check safety valve settings"). Change suction filter - every six months if dust concentration is high (see "12.3 Change the air intake filter"). Replace vibration dampers. Carry out recurring safety checks (e.g. pressure vessel inspection, electrical safety inspection) according to national directives. Maintenance of compressor unit Unit with membrane drying system Maintenance interval Every six months Yearly Every 4 years According to national directives Observe assembly and operating instructions "Oil-free piston compressors KK and piston vacuum pumps KV" Maintenance work Drain condensate (see "12.2 Draining the condensate"). Check safety valve (see "9.6 Check safety valve settings"). Change suction filter - every six months if dust concentration is high (see "12.3 Change the air intake filter"). Change fine or sterile filter (see "12.4 Replacing the filter of the membrane-drying unit"). Change sterile filter (see "12.4 Replacing the filter of the membranedrying unit"). Replace vibration dampers. Carry out recurring technical safety inspections (e.g. pressure vessel inspection, electrical safety inspection) according to national guidelines. Maintenance of compressor unit L V003 27

30 Usage 12.2 Draining the condensate Units with an automatic condensate solenoid valve and/or with membrane drying systems do not have a manual drainage system. Condensed water collects in the pressure receiver during operation. When the receiver is at maximum pressure, open the condensate drain Replacing the filter of the membrane-drying unit Fine/Sterile filter Switch off the unit. Pull out the plug. Unscrew and remove the filter cover. Remove the fine/sterile filter. Insert the new fine/sterile filter. Replace the filter cover and close. 4 Condensate drain (manual) Close the condensate drain once all the accumulated condensed water has been drained off Change the air intake filter Open the cover of the suction filter by turning it clockwise. Remove the filter element (white/green). Insert a new filter element. Close the cover of the suction filter by turning it anti-clockwise L V003

31 Sinter filter Unscrew and remove the filter housing. Remove the sinter filter. Insert a new sinter filter. Replace the filter housing and close. 13 Deactivation 13.1 Shut down the unit Usage If the unit is not to be used for a prolonged period of time, it is recommended to decommission it. To do so, the condensate accumulating from the unit must be drained. Switch on the unit and wait until the cut off pressure is reached. Unit with condensate separator At maximum tank pressure, unscrew the bottom screw fitting on the condensate separator. Close the screw fitting as soon as all of the compressed air and condensate have been blown out. Membrane drying unit Open the condensate drain valve on the membrane drying unit as long as the compressor unit is running. When no more condensate emerges, close the condensate drain valve. Switch off the unit L V003 29

32 Usage Pressure receiver Switch off the unit. Pull the mains plug. Relieve the pressure from the air receiver (e.g. using a blow-off gun connected to the quickrelease coupling or using the condensate drain valve (if present)). Disconnect the compressed-air supply at the quick-release coupling Store the unit WARNING Explosion of pressure tank and pressure hoses Only store and transport the pressure tank and pressure hoses in a completely vented condition. Protect unit against moisture, soiling and extreme temperatures during storage (see ambient conditions). Only store the unit when it is completely emptied L V003

33 Trouble-shooting 14 Tips for Operators and Technicians For further information on trouble-shooting refer to the assembly and operating instructions "Oil-free piston compressors KK and piston vacuum pumps KV". Repairs above and beyond simple maintenance may only be carried out by a qualified technician or one of our service technicians. De-energise the unit prior to working on it or in the event of potential hazards (e. g. pull the mains plug) and prevent it from being switched back on again. Problem Probable cause Solution Unit does not start No mains voltage Contact an electrician. Check mains fuse, switch on unit again, if possible. Replace the thermal fuse if defective. Undervoltage or overvoltage Capacitor defective Pressure switch in position "0" Motor defective Temperature switch in motor is tripped (not present in all units) 1. High ambient temperatures 2. Mechanical sluggishness 3. Pressure in the line Over-current switch is tripped Suction filter is clogged Contact an electrician. Measure mains voltage. Contact a technician. Check the capacitor and replace it, if necessary. Set to "I". Replace the unit. 1. Allow the unit to cool down. Ensure better ventilation. Attention, unit restarts automatically! 2. Factory repair. 3. Vent the intake plenum. Contact an electrician. Check the motor protection circuit breaker setting. Determine the cause. Insert a new filter L V003 31

34 Trouble-shooting Problem Probable cause Solution Output is dropping. Lines, hoses or connections leaking Defective membrane drying system Suction filter dirty Defective seals Cup seal leaking as a result of wear and/or for one or more of the following reasons: Dirt Inform an engineer. Check/ replace lines, hoses or connections. Inform an engineer. Replace the membrane drying system. Replace the suction filter at least once a year. The suction filter must never be cleaned. Inform an engineer. Replace the seals. Inform an engineer. Replace the cup seal, cylinder and seals (spare part kit). If necessary/appropriate: Install the filter upstream or replace the filter. Excessive ambient temperature Ensure that cooling is more effective. Unsuitable materials drawn in Only convey approved materials. Defective lamellar valves Inform an engineer. Replace lamellar valves and, if necessary, the valve plate and seals. Unit too noisy Damage to bearings Inform an engineer. Water dripping from air consumers Pressure dew point is not correct Moisture indicator on membrane drying system is pink Vibrations are being transmitted to the housing Defective vibration dampers Compressor stations with membrane drying system: Defective membrane drying system Compressor stations without membrane drying system: Condensed water in the receiver Fit suitable vibration dampers. Install new vibration dampers. Inform an engineer. Replace the membrane drying system. Regularly drain condensed water. Purge air nozzle too large or small Inform an engineer. Replace the purge air nozzle. Unit has not been used for a extended period of time During operation: Membrane drying system malfunction. Air drying insufficient When the unit is operated, the moisture indicator regenerates itself and becomes blue once more. Inform an engineer. Replace the membrane drying system L V003

35 Addresses Service Dürr Technik GmbH & Co. KG Bietigheim-Bissingen Tel +49 (0) Fax +49 (0) Spare parts orders Tel +49 (0) Fax +49 (0) office@duerr-technik.de Please provide the following information when ordering spare parts: Type code and article number Order number as appears on the spare parts list Quantity required Exact shipping address Shipping information Repairs / returns Please depressurise the unit before transporting it. If possible, please use the original packaging when returning units. Always pack the units in a plastic bag. Please use recyclable packing material. Return address Dürr Technik GmbH & Co. KG Pleidelsheimer Straße Bietigheim-Bissingen -Germany- International addresses for Dürr Technik www. duerr-technik.com L V003 33

36 Dürr Technik GmbH & Co. KG Pleidelsheimer Strasse Bietigheim-Bissingen Germany Fon: