HDSD - Almig-Varibale 35 - 355
HDSD - Almig-Varibale 35 - 355
HDSD - Almig-Varibale 35 - 355
Screw compressor
VARIABLE 35 - 355
© 2009
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 .............................................. 42
...................................................5 .......................................... 42
1.4 General safety instructions .......................................6 7.3 Start-up lubrication of the compressor stage .......... 42
2. Functional description ..................................................8 ..................................... 43
3. Storage and transport .................................................12 7.5 Basic settings ......................................................... 44
4. Installation .................................................................... 14 7.5.1 Controlling the unit
4.1 Setting up ...............................................................14 by means of Air Control 3 .............................. 44
4.2 Ventilation ...............................................................14 .................... 45
...................................15 ............................................... 45
.......................................... 16 8. Service ..........................................................................46
............................. 46
..........................................16 .............................................. 46
.................... 17 ........... 47
4.7 Electrical connections .............................................17 8.4 Check for leakage................................................... 48
5. Displays and operating elements...............................18 8.5 Check the compressor temperature ....................... 48
.................................................... 18 8.6 Check the cooler for fouling .................................... 48
5.2 Emergency OFF .....................................................18 ............................................. 49
5.3 Air Control 3............................................................19
..................................................20 ..................................... 50
........................... 52
air generation.................................................20 ................................................... 53
................................................. 53
........................................ 21 ............................................................. 54
5.3.3.1 Capacity utilization .......................... 22 8.13 Relubrication of the electric motor .......................... 54
............................................ 22 ............................................... 55
5.3.3.3 LLC status .......................................23 9. Technical Data ..............................................................56
5.3.3.4 Compressor pass ............................ 23 9.1 Dimensions for connections ................................... 56
5.3.3.5 Diagram net pressure...................... 24 .................................. 57
............................. 57
compression temperature ...............24 ......................................................... 57
10. Service manual ........................................................... 58
.................... 24
...............24
.................. 25
5.3.4 Menu system .................................................26
.................... 27
5.3.4.2 Sub-menu Operating parameters.... 28
............ 29
5.3.4.4 Sub-menu Timer.............................. 30
5.3.4.5 Sub-menu Fault log ........................ 32 3
5.3.4.6 Sub-menu Display parameters........ 32
.................33
...34
5.3.4.9 Sub-menu Accessories.................... 34
5.3.4.10 Sub-menu Diagnosis .......................35
................................ 36
5.3.6 Malfunctions ..................................................37
.................38
1. Safety instructions
Safety instructions You are reading this manual in order to learn about the screw compressor.
from the system if you comply with the stipulations of the service manual
DANGER
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 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.
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
-
tion processing.
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 frequency converter in the switching cabinet supplies the electric motor
coupling.
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.
8
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tions:
• heat removal of the temperature increase caused by the compression
process
• sealing lubrication of the rotors to each other and to the housing with a
• bearing lubrication
• noise dampening
for example.
2.4 Cooling
cooled either by
• a built-in cooling air ventilator or
• water cooling.
9
2. Functional description
2.5 Flow diagram
10
2.6 Components
20 01
02
04
19 03
01 06
18
17
07
04
15
07
19 01
17 06 02
20
DANGER
12
13
4. Installation
4.1 Setting up
Install the system in locations with the following environmental condi-
tions:
DANGER
4.2 Ventilation
14
VARIABLE 150-210
15
4.3 Forced ventilation and
venting duct (optional)
4. Installation
4.4 Water cooling (optional)
inlet.
16
4.5 Heat recovery for heating Compressors can be supplied with the optional heat recovery system
water / potable water (op- • for heating water or
tional)
• pressure of up to 10 bar
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.
Electrical voltage!
Only trained electricians may connect the system to the electrical
supply network.
DANGER
18
Test the correct functioning of all safety facilities (protective grounding,
protective switch etc.).
Carefully lock the control cabinet after the connection work is completed.
5. Displays and operating elements
5.1 Plant main switch The unit‘s main switch that is installed on the control cabinet connects or
disconnects the unit to and 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!
recommissioning!
Enable the system only when the cause of danger has been profes-
sionally removed and a securely operating state is achieved.
DANGER
Enable system:
1. switch main switch off and on.
Lighted:
5.3.1 Basic display
3 will inform you about the plant condition.
Supplymentary information
Momentary
Momentarily available net pressure
at compressed air output temperature
Supplementary information:
Mode 1 = reservation 1
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:
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 In this diagram, the current process of the net pressures is displayed.
(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 In this diagram, the current process of the compressed quantity for a day
is displayed.
(Mode 2 - F3)
Change of mode 5.3.3
25
5.3.3.8 Diagram compressed air In this diagram, the current process of the compressed air quantity for a
week is displayed.
(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
-
tinually updated.
X-AUTO: activates or deactivates X-AUTO
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.
INFO
Diagnose 5.3.4.10
27
vel.
5. Displays and operating elements
00001
changed as follows:
and .
ENTER.
and .
and .
ENTER.
values
ENTER
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 swit- Display
ching-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
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
system is in the idling state for the duration of the run-on time. In the basic
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
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.
31
-
play
and
ENTER.
and . (In
.)
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
then the settings in the menu “limit values” are valid. In order to activate the
Switching times or pressure times for operation in the lead lag control mode
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
Diagrams
Saving interval
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
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”.
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)
The LLC master function may only be activated when the compressor
is actually used as master unit!
5.3.4.9 Sub-menu Accessories This menu contains the settings for the connection of accessories. 35
extension modules.
menu.
Seven switching times can be programmed with the channels K1 –K7. One
-
ing times “ Chapter 5.3.4.4.
36
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:
• type of warning
• telephone number of the service hotline
Chapter 8.
• type of malfunction
• telephone number of the service hotline
-
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
Insert a small plain slot screwdriver through this opening to reach the ad-
justment screw for correcting the contrast.
39
6. Correcting malfunctions
Line pressure falls Compressed air consumption A compressor with larger delivery
greater than delivery quantity quantity is required
of the compressor
System pressure Line pressure set too high Adjust line pressure anew
released by safety valve
Safety valve defective
exchange
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
previous switching off circuit (only by a trained electrician)
System does not start on Line pressure greater than start Note line pressure value
pressing the start button pressure
Compressed air
containing large amount is congested
great)
Pressure decline
too great
7. Initial commissioning
7.1 Preparatory activities 1. Make certain that when the compressor main switch is switched off, no
illicit or inadvertent switching on can occur.
level
phase.
Compressor
42
2. Rotate the air end only by hand in the correct direction of rotation until
1. Remove the cover panels of the system, so that the electric motor of
the ventilator is visible.
2. Switch the compressor main switch on.
3. Switch the system on with key Switch the system off again with the
, when the ventilator starts running.
of the ventilator motors must concur with the rotational direction arrow.
In the case of incorrect rotational direction of the compressor ventilators,
a trained electrician should correct the phase sequence of the electrical
supply in the switching cabinet by exchanging the two supply phases. This
should be carried out in a switched-off state secured against accidental
switching on.
43
7. Initial commissioning
7.5 Basic settings -
pressor 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 :
• language
44
7.6 Switch on compressed air -
generation dangered by doing so. The sound-insulation hood serves as a part of
The line pressure will slowly rise if the compressed air consumption is less
than the quantities delivered by the compressors.
45
than 90°C
Check compressor
temperature 8.5
Check cooler
Check safety valve 8.11 8.6
Check drive 8.12 for fouling
Lubrication of electric motor 8.13 Check for
8.7
Concluding activities 8.14 condensate
8.8
General compressor
servicing
*
**
– normal industrial atmosphere
When ALMiG synthetic oil is used, the replacement intervals for both coolant and the
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-
lation phase. The symbol “M” for the main motor is then no longer visible
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).
DANGER
3. Remove the side panels of the system.
added as follows:
47
NOTICE
closed.
8.6 Check the cooler for fou- Carry out the “Preparatory activities”.
ling
Preparatory activities 8.2
Concluding activities 8.14
-
blown outside).
48
8.7 Check for condensate The absorption capacity of water humidity in the air
Preparatory activities 8.2 • falls with increasing pressure
Concluding activities 8.14
• rises with increasing temperature.
-
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.
Carry out the following activities only when the system has been turned
off at least overnight.
1. Open the drain and carefully observe the escaping liquid. Close the
49
8. Service
NOTICE
50
closed.
51
8. Service
-
parator
Preparatory activities 8.2 separator.
Concluding activities 8.14
-
tor:
Carry out the “Preparatory activities”.
52
separator vessel.
-
4. Mount the cover of the separator vessel and reconnect the lines.
stage.
NOTICE
53
coupling element.
3. Mount the cam ring again on the coupling half and test manually whether
the coupling now has no more radial play.
54
8.14 Concluding activities
2. Switch the compressor main switch on.
-
tem.
to switch the compressor on.
55
9. Technical Data
H
L
B
56
9.1 Dimensions for connections
* Only water-cooled
* Only water-cooled
Compressor Motor
power 400 V / 50 Hz
IN I
kW A A gL
VARIABLE 35 40 61 80
VARIABLE 37 50 71 100
VARIABLE 55 60 95 125
VARIABLE 65 80 126 160
VARIABLE 70 85 145 200
VARIABLE 90 100 159 200
VARIABLE 115 115 190 250
58
VARIABLE 130 130 207 250
VARIABLE 150 150 262 315
VARIABLE 210 210 330 400
VARIABLE 260 260 480 630
VARIABLE 315* 315 570 630
VARIABLE 355* 355 600 2 x 355
* Only water-cooled
IN = Nominal Current
IFuse = backup fuse in building
Compressor type:
Date of commissioning:
59
Coolant change Filter change*
Operating Date Name Operating Date Name
60
Further maintenance and repair work
Operating Date Spare parts Name
hours
61
10. Service manual
62
Further maintenance and repair work
Operating Date Spare parts Name
hours
63
Manual_VARIABLE35_gb_09-2009