Oil-free compressor stations
36
Oil-free compressor stations Installation and Operating Instructions 0678106020L02 1411V003 EN
Transcript of Oil-free compressor stations
Oil-free compressor stations
Installation and Operating Instructions
0678106020L02
1411
V00
3
EN
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8.2 Vibration damping between com-pressor unit and receiver . . . . . . . . . 20
8.3 Installation position and fastening . . 208.4 Noise reducer . . . . . . . . . . . . . . . . . 20
9 Operation . . . . . . . . . . . . . . . . . . . . . . . 219.1 Remove the transport protection . . . 219.2 Set up compressed air connection. . 219.3 Condensed water . . . . . . . . . . . . . . 229.4 Electrical installation . . . . . . . . . . . . 229.5 Check the pressure switch . . . . . . . 229.6 Check safety valve settings . . . . . . . 22
10 Settingpossibilities . . . . . . . . . . . . . . . 2310.1 Pressure switch setting . . . . . . . . . . 2310.2 Set the motor protection switch . . . . 2410.3 Pressure reducer adjustment . . . . . . 25
Usage11 Instructionsforuse . . . . . . . . . . . . . . . 26
11.1 Switch the unit on/off. . . . . . . . . . . . 2611.2 Switching the unit on after a power
cut . . . . . . . . . . . . . . . . . . . . . . . . . 2611.3 Pressure receiver test . . . . . . . . . . . 2611.4 Mobile compressor station. . . . . . . . 26
12 Maintenance . . . . . . . . . . . . . . . . . . . . 2712.1 Maintenance plan . . . . . . . . . . . . . . 2712.2 Draining the condensate . . . . . . . . . 2812.3 Change the air intake filter . . . . . . . . 2812.4 Replacing the filter of the mem-
brane-drying unit . . . . . . . . . . . . . . . 28
13 Deactivation. . . . . . . . . . . . . . . . . . . . . 2913.1 Shut down the unit . . . . . . . . . . . . . 2913.2 Store the unit. . . . . . . . . . . . . . . . . . 30
Trouble-shooting14 TipsforOperatorsandTechnicians . . 31
Addresses
EN
Contents
Importantinformation1 Documentation . . . . . . . . . . . . . . . . . . . 2
1.1 Warnings and symbols . . . . . . . . . . . 21.2 Notes on copyright . . . . . . . . . . . . . . 2
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.1 Correct use . . . . . . . . . . . . . . . . . . . . 32.2 Incorrect use . . . . . . . . . . . . . . . . . . . 32.3 General safety notes . . . . . . . . . . . . . 32.4 Qualified personnel . . . . . . . . . . . . . . 32.5 Protection against electrical current . . 32.6 Only use original parts . . . . . . . . . . . . 32.7 Transportation and storage . . . . . . . . 32.8 Disposal . . . . . . . . . . . . . . . . . . . . . . 4
Productdescription3 Overview . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Flexible modular system . . . . . . . . . . 53.2 Compressor station examples . . . . 103.3 Accessories . . . . . . . . . . . . . . . . . . . 133.4 Working parts and spare parts . . . . . 13
4 Technicaldata . . . . . . . . . . . . . . . . . . . 14
5 Pressurereceiver . . . . . . . . . . . . . . . . 155.1 Overview . . . . . . . . . . . . . . . . . . . . . 155.2 Instructions for use for the pressure
receiver (explanation by Behälter-Werk Burgau GmbH) . . . . . . . . . . . . 16
6 Declarationofconformityforma-chinesinaccordancewiththe2006/42/ECDirective. . . . . . . . . . . . . . 17
7 Function . . . . . . . . . . . . . . . . . . . . . . . . 187.1 Compressor station without mem-
brane drying system . . . . . . . . . . . . 187.2 Compressor station with mem-
brane drying system . . . . . . . . . . . . 18
Mounting8 Prerequisites . . . . . . . . . . . . . . . . . . . . 20
8.1 Area of installation . . . . . . . . . . . . . . 20
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The signal word differentiates between different levels of danger:
– DANGERHigh risk of danger of serious injury or death
– WARNINGPossible risk of danger of serious injury or death
– CAUTIONRisk of danger of minor injuries
– NOTICERisk of serious damage
FurthersymbolsThese symbols are used within the documenta-tion and on the unit itself:
Notes, e.g. special instructions con-cerning economical use of the unit.
CE-labeling
Switch off the unit (i. e. unplug and dis-connect from mains).
Observe the accompanying documenta-tion.
Dispose of the unit properly according to valid state and local legislation.
Dispose of the packing material in an environmentally friendly way.
1.2 NotesoncopyrightAll circuits, processes, names, software pro-grams and units specified are protected under industrial property rights. The reprinting of the assembly and operating in-structions, even in extracts, is only permitted with the written permission of Dürr Technik.
1 DocumentationThese assembly and operating instructions form an integral part of the unit. They correspond to the particular model of the unit and to the tech-nical standards applicable at the time it was brought to market.
In the event that the instructions and in-formation in these assembly and oper-ating instructions are not observed, Dürr Technik undertakes to provide no war-ranty 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 lan-guage version of the manual is definitive. Dürr Technik will not be held liable for translation er-rors.
1.1 Warningsandsymbols
WarningsThe 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 automatical-ly
The warnings are structured as follows:
SIGNALWORDDescriptionoftypeandsourceofdangerPossible consequences of ignoring the safety warning here• Measures to be taken to avoid any
possible danger.
Importantinformation
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Important information
2.4 Qualifiedpersonnel
InstructionsforusePersons who operate the unit must, on the ba-sis of their training and knowledge, ensure safe and correct handling of the unit. • Ensure personnel are trained in the correct us-
age of the unit.
Installationandrepair• Assembly and installation work, readjust-
ments, modifications, upgrades and repairs must be carried out by Dürr Technik or per-sonnel authorised and trained by Dürr Tech-nik, 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 Protectionagainstelectricalcurrent
• Observe all electrical safety regulations when working on the unit.
• Replace any damaged lines and plug and socket outlets immediately.
2 SafetyDürr Technik has designed and developed the unit in such a way that danger is to a large ex-tent excluded if the unit is used as intended. However, residual risks may be present. There-fore, please observe the following information.
2.1 CorrectuseThe unit is designed for compressing atmos-pheric 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 IncorrectuseAny use of this unit above and beyond that spe-cifically 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.
WARNINGSeriousinjuryandmaterialdamageduetoimproperusage• Conveying explosive mixtures in any
way other than that specified is not permitted.
2.3 Generalsafetynotes• Before using the unit observe any and all
guidelines, laws, regulations and other restric-tions which may apply to the unit.
• Before each use check the function and con-dition of the unit.
• Do not convert or change the unit in any way. • Observe the Installation and Operating In-
structions precisely. • Keep the Installation and Operating Instruc-
tions in an accessible place so that the opera-tor has instant access to them.
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Important information
Ambientconditionsduringstorageandtransport
AmbientconditionsduringstorageandtransportTemperature °C -25 to +55Rel. atmospheric hu-midity % 10% to 90%
Please note here the label on the packaging padding.
2.8 Disposal
Unit
Dispose of the unit properly according to valid state and local legislation.
Packaging
Dispose of packaging material in an en-vironmentally responsible manner.
– Note current disposal routes. – Keep packaging away from children.
2.6 Onlyuseoriginalparts• 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 non-approved accessories or any wear parts or spare parts other than genuine parts.
2.7 TransportationandstorageThe 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 packag-ing for transporting or storing the unit. – Keep packaging away from children.
WARNINGExplosionofthepressurereceiverandpressurehoses• Ensure that the air has been evacuat-
ed from the pressure receiver and pressure hoses when they are stored and transported.
• Protect the unit against moisture dur-ing 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 suc-tion 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 materi-al.
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3 Overview3.1 FlexiblemodularsystemThe compressor stations can be assembled individually from various components according to re-quirements.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 mo-tors 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 (op-tional), pressure reducers (optional) etc.
– Membrane drying system (optional) as separate component.
Productdescription
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Product description
Explanationoftheproductcode
T A-200 M11 32
11 Receiver*
U 3 l
W 10 l
T 25 l
H 55 l
P 90 l
* Receivers with a maximum pressure (PS) of 10 bar (exception: compressor stations with 25-l receiv-er: PS = 8 bar)
2 Compressorunits
A Compressor units with single-phase AC motors
B Compressor units with three-phase AC motors
D Compressor units with DC permanent-magnet motors
3 Auxiliarymodules
K Automatic condensate drain valve
AK Automatic condensate drain valve + starting relief
M Membrane drying unit (also performs the function of module AK)
ThecompressorstationTA-200Musedasanexamplecomprises: – 25-l receiver (T) – Compressor unit: A-200 (with single-phase AC motor) – Membrane drying system (M)
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Product description
Combinationoptionsofacompressorstationwithsingle-phaseACmotor
Compressorunits Receiver Auxiliarymodules
Ser
ies
Un
it
Flo
wr
ate
at0
bar
(l/m
in)
3l 10l 25l 55l 90l
Mo
du
leK
=a
uto
m.c
on
-d
ensa
ted
rain
val
ve
Mo
du
leA
K=
Mo
du
lK+
au
tom
.sta
rtin
gr
elie
f
Mo
du
leM
=m
od
ule
AK
+
mem
bra
ne
dry
ing
un
it
KK8 A-025 25 l l l l l l KK15 A-038 38 l l l l l l
A-061 60 l l l l l A-062 70 l l l l l l
KK40 A-065 65 l l l l o l
A-132 130 l l l l l o l
KK70 A-100 105 l l l l l l
A-200 195 l l l l l l
Marathon A-080 90 l l l l l
A-160 160 l l l l l l
A-234 230 l l l l l
l Standard combination o already included in the unit no standard
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Product description
Combinationoptionsofacompressorstationwiththree-phaseACmotor
Compressorunit Receiver AuxiliarymodulesS
erie
s
Un
it
Flo
wr
ate
at0
bar
(l/
min
)
3l 5l 25l 55l 90l
Mo
du
leK
=a
uto
m.
con
den
sate
dra
in
valv
e
Mo
du
leA
K=
Mo
du
lK
+a
uto
m.s
tart
ing
rel
ief
Mo
du
leM
=m
od
ule
A
K+
mem
bra
ne
dry
-in
gu
nit
KK15 B-038 38 l l l l l l B-062 73 l l l l l l
KK40 B-065 65 l l l l o l
BG-132 130 l l l l l o l
KK70 B-100 105 l l l l l l
B-200 195 l l l l l l
Marathon B-080 90 l l l l l
B-160 160 l l l l l l
B-304 295 l l l l l
2 x B-304 590 l l
l Standard combinationo already included in the unit no standard
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Product description
CombinationoptionsofacompressorstationwithaDCpermanent-magnetmotor
Compressorunit* Receiver Commentoncom-pressorstation
Ser
ies
Un
it
Art
icle
nu
mb
er
Flo
wr
ate
at0
bar
(l/
min
)
inl
Des
ign
KK15 D-040 0832-25B-01 40 10 12 VDCKK8 D-030 0590 1000 30 3 24 VDC
KK15
D-040 0832-22B-01 40 10
24 VDC including interference
suppression filter
D-040 0832-22B-02 40 10
24 VDC including interference
suppression filter with autom. conden-
sate drain valve
D-040 0832-22B-03 40 10
24 VDC including interference
suppression filter with autom. conden-sate drain valve and
starting reliefD-040 ZK429T7091298 40 25 24 VDC
KK70 D-100 0652 0000 105 10 24 VDC
* Compressor units with another design are available on request
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Product description
3.2 Compressorstationexamples
The item numbers designate the spare parts (see "3.4 Working parts and spare parts")
11
71
3
9
1310
2
812
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)
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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)
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Product description
20
21
22
2
11112
8
39
4105
Figure 5: WA-062AK configuration: mobile AK: A-062 compressor unit with 10-l receiver (W), aux-iliary 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 mod-ule M (membrane drying system) and pressure reducer
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Product description
Itemno. Sparepartsforcompressorstation
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. 9000-330-09)
Quick-release coupling (art. no. 9000-312-03)
Seal
Fitting unit, complete
Relay (DC only)
Power cable
Suppression filter, complete (DC only)
Carbon brushes (DC only)
End cap/screw (DC only)
Sparepartsformembranedryingsystem
Always specify type designation (e.g. WA-038/0835-43B-01) and serial number when ordering spare parts.
Articleno. Sparepartsformembranedryingstation
1650-981-0000
Purge air nozzle set
1650-101-00 Sinter filter
1610-121-00 Fine filter
9000-416-0035ET
Sterile filter
3.3 Accessories
Accessoriesforcompressorstations
Always specify type designation (e.g. WA-038/0643 1000) and serial number when ordering accessories.
Itemno. Sparepartsforaccessories
Pressure reducer
Quick-release coupling (art. no. 9000-312-03)
Hose connection pieces for SW 10 (art. no. 9000-312-06)
Hose connection pieces for SW 6 (art. no. 9000-311-46)
Operating-hour meter
Bracket* (art. no. 0835-999-00)
20 to 22 Transport roller, complete (art. no. 0643 0100)1)
*Bracket for WA-025 to WA-0621) 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 Workingpartsandspareparts
Sparepartsforcompressorstationwithmembranedryingsystem
Always specify type designation (e.g. WA-038/0835-43B-01) and serial number when ordering spare parts.
Itemno. Sparepartsforcompressorstation
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
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Product description
4 Technicaldata
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".EN
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Product description
5 Pressurereceiver5.1 OverviewThe units are fitted with pressure receivers of Behälter-Werk Burgau GmbH.The operating instructions provided below apply to the following pressure receiver types:
Type Pressure1) Receiver2) EB3) c4) Remark5)
316033 / 0834-000-010 PS 8 bar V 3 l A c = 1.0 mm 2316053 / 0654-0900 PS 8 bar V 3 l A c = 1.0 mm 2316030 / 0833-320-60 PS 11 bar V 10 l A c = 1.0 mm 4; 5316034 / 5430-200-51 PS 10 bar V 25 l B c = 0 mm 1; 6316016 / 4220-200-50 PS 10 bar V 55 l A c = 1.0 mm 3; 5235791 / 5450-200-90 PS 11 bar V 90 l A c = 1.0 mm 4
Forserialnumberandbuildyearseereceiveridentification
1)Pressure maximum operating pressure PS in bar2)Receiver Receiver volume V in litres3)Applicationarea(EB)
A = Pressure receiver for compressors
B = Pressure receiver for stationary systems
4)Corrosionsupple-ment
c in mm
Maximumtempera-ture
+100 °C
Minimumtempera-ture
-10 °C
Medium Air / nitrogen5)Remark 1: The receiver is fatigue-resistant within a pressure fluctuation range of
1.6 bar (10% PS)
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
Appliedstandards EN 286-1:1998
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Product description
The supplier must additionally determine wheth-er the pressure receiver, when equipped ready for use, must undergo an inspection test before commissioning. The supplier/operator is re-quired to comply with applicable laws and regu-lations 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".
5.2 Instructionsforuseforthepressurereceiver(explanationbyBehälter-WerkBurgauGmbH)
The pressure receiver may only be within the limits of the purpose of use and technical data described above. Any use other than as indicat-ed is not permitted for reasons of safety. The pressure receiver was constructed in accord-ance with Directive 2009/105/ EG and was manufactured as a single component without safety-related equipment for the field of applica-tion indicated. The unit was designed for inter-nal compressive stress.
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 car-ried out on the pressure-retaining walls of the receiver. It must be ensured that the internal pressure does not exceed the operating pres-sure PS “under normal operating conditions” in-dicated in the receiver marking. For a short time, however, this pressure may be exceeded by up to 10%. Vibration stress which would be dam-aging for the pressure receiver, as well as corro-sion 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 mainte-nance to ensure safety of use
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Product description
6 Declarationofconformityformachinesinaccordancewiththe2006/42/ECDirective
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 3074321 Bietigheim-BissingenGermany
Reference number:
Article description: Compressor stations and drying stations Validity: All units that are ready to connect and have a compres-sor, 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…
From serial number: A 000100
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 Machin-ery Directive 2006/42/EC.
Thefollowingharmonisedstandardsandotherstandardshavebeenapplied:DIN EN 1012-1:2011-02DIN EN 60034-1: 2011-02DIN EN 60034-5: 2007-09DIN EN 60034-7: 2001-12DIN EN 60034-8: 2008-04DIN EN 60335-1:2012-10DIN EN 61000-6-2:2006-03DIN EN 61000-6-3:2011-09DIN EN 60204-1:2007-06DIN EN ISO 12100:2011-09DIN EN ISO 12100-2:2004-04
Bietigheim-Bissingen, 12.01.2012
Andreas Ripsam Proof of signature in the
General manager at Dürr Technik original document in the Dürr Technik archive
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Product description
7.2 Compressorstationwithmembranedryingsystem
1 Compressor unit2 Pressure receiver3 Pressure switch4 Cooler5 Membrane dryer6 -7 Pressure hose8 Suction filter (quick-release coupling)9 Pressure gauge10 Safety valve11 Vibration damper12 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% saturat-ed 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 con-tainer. 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.
7 Function7.1 Compressorstationwithout
membranedryingsystem
1 Compressor unit2 Pressure receiver3 Pressure switch4 Start-up solenoid valve*5 Condensate solenoid valve*6 Operating-hour counter*7 Pressure hose8 Suction filter9 Pressure gauge10 Safety valve11 Vibration damper12 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 com-pressed air is drained by a consumer, the pres-sure in the receiver drops. On reaching the cut-in pressure, the compressor is switched on au-tomatically by the pressure switch. A safety valve prevents the maximum permissible receiv-er pressure from being exceeded.
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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 accumu-lated moisture and is dissipates it to the environ-ment. This regeneration takes place continuous-ly during operation. Standstill periods are not re-quired.
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.
1
2
3
4
5
6
1 Warm air2 Cooler with fan3 Cold air4 Membrane dryer5 Condensate drain6 Dry airThe 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.
On reaching the cut-in pressure, the compres-sor is switched on automatically by the pressure switch. A safety valve prevents the maximum permissible receiver pressure from being ex-ceeded.
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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).
NOTICERiskofoverheatingduetoinsuffi-cientventilationThe 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 un-
obstructed.• Ventilation openings must be suffi-
ciently large.• For installed units, an independent
ventilation system may be required in unfavourable cases.
8.2 Vibrationdampingbetweencompressorunitandreceiver
The units produce vibrations. Suitable vibration dampers must be used to damp these vibra-tions.
CAUTIONTheuseofrigidconnectionsmaydamagetheunitsorthesysteminwhichtheunitshavebeeninstalled.• Do not use rigid connection lines be-
tween the units and the system.
8.3 Installationpositionandfas-tening
Install the units such that they are as level as possible. Other installation positions must be agreed in advance with Dürr Technik.
8 Prerequisites8.1 AreaofinstallationThe 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 suf-ficiently stable surface (observe the weight of the unit).
– A socket outlet must be easily accessible. – The type plate of the unit must be easily read-able (also when installed).
– The unit must be easily accessible for opera-tion 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).
30 30
30
40 40
30
Mounting
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Mounting
9 Operation9.1 Removethetransportprotec-
tionFor safe transportation, the unit is securely pro-tected with packaging material.• Remove the packaging material.• Remove the protective film.• Check the unit for damage in transit.
9.2 Setupcompressedaircon-nection
The units are designed for a nominal pressure of 7 bar as standard. The serv-ice 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, pres-sure 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 ad-ditional accessory.
• The compressed-air supply is connected to the quick-release coupling (incl. hose connec-tion piece) or to the pressure switch by means of a G 1/4" internal thread.
• Secure the pressure hose to the hose con-nection piece using a hose clamp.
• Connect the hose connection piece to the quick-release coupling.
8.4 NoisereducerElevated noise levels occur in pressure and vac-uum 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 fil-ters.
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9.5 CheckthepressureswitchThe 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 ChecksafetyvalvesettingsThe 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").
DANGERExplosionofthepressurereceiverandpressurehoses• Do not change the safety valve set-
ting.
WARNINGDamagetothesafetyvalveExplosion of pressure receiver and pres-sure hoses due to defective safety valve• Do not use the safety valve to evacu-
ate air from the pressure receiver.
9.3 CondensedwaterCondensed 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 Electricalinstallation
For detailed information on electrical in-stallations refer to the assembly and op-erating instructions "Oil-free piston compressors KK and piston vacuum pumps KV".
Electricalconnectionusingamainsplug• The unit must only be connected to a correct-
ly 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.
DANGERElectricshockduetodefectivemainscable• Mains cables must not come into
contact with the hot surfaces of the unit.
• Route mains cables without mechani-cal tension.
• Plug the mains plug into an earthed socket.
• The unit starts immediately after the mains plug is inserted.
Electricalconnectionwithoutamainsplug
DANGERConnectiontothepowersupplymayonlybeperformedbyaquali-fiedelectrician.
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10 Settingpossibilities10.1Pressureswitchsetting
DANGERBarelivepartsElectric shock due to live parts• Unplug the unit from the socket out-
let.• 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 pres-sure is indicated by a red line on the pressure gauge that is fitted.
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.
SettingtheMDR3If 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.
• Switch on the unit at the pressure switch and fill the pressure receiver to the cut-off pres-sure.
• 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.
The valve is closed.
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SettingtheMDR2If the read-off values differ from the factory set-tings 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 adjust-
ment screws (1).Turning the screws in arrow direction "+" increased the cut-off pressure, turning them in arrow direction "-" decreases the cut-off pressure.
1 1
2
• 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).
• Adjust the cut-off pressure p using the setting screw.The cut-off pressure increases in the "+" ar-row direction and decreases in the "-" arrow direction. The pressure differential ∆p will also be altered when this adjustment is made.
• 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.
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10.3PressurereduceradjustmentThe pressure reducer (available as an option) regulates the receiver pressure (inlet pressure) to the required operating pressure (secondary pressure). An additional secondary air evacua-tion system prevents the pressure from rising while the consumer is switched off. The pres-sure reducer is fitted to the pressure switch (G1/4").Settingthepressurereducer:
1 Adjuster knob2 Pressure gauge• Pull up the adjuster knob (1).• Toincreasethesupplypressure:Turn the
adjuster knob (1) clockwise towards "+".• Todecreasethesupplypressure: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).
10.2Setthemotorprotectionswitch
The motor protection circuit breaker is not present in all units.
• The motor protection circuit breaker is adjust-ed 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 set-ting of the motor protection circuit breaker). The max. permissible motor current is the current rating on the type plate + 10%.
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3 Safety valve4 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.
11.3Pressurereceivertest
The operator must comply with the na-tional directives.
ExampleforGermany: German Ordinance on Industrial Safety and Health (BetrSichV)
11.4Mobilecompressorstation
NOTICERiskofcrushingwhenoperatingthearticulatedjoints
• If the angle and height of the sliding handle are adjusted, keep fingers away from the area around the articu-lated joints in which crushing may oc-cur.
• 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 adjust-ed.
11 InstructionsforusePrior to working on the unit or in case of danger, disconnect it from the mains (e. g. pull the plug).
11.1Switchtheuniton/off• Switch on the unit by turning the pressure
switch to the "I" position.
The compressor unit will start up automati-cally 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.
11.2Switchingtheunitonafterapowercut
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.
Unitswithanautomaticstart-upvalve:If the unit is fitted with an automatic start-up valve, the valve allows the unit to start up with-out being pressurised.
Unitswithastart-upvolumeandmechani-calventilationvalveandunitswithamem-branedryingsystem
1 Start-up volume2 Mechanical ventilation valve
Usage
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Usage
12 MaintenanceDe-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.
12.1Maintenanceplan
Unitswithoutmembranedryingunit
Maintenanceinterval Maintenancework
Weekly • Necessary for units without K-module: drain condensate - if humidity is high, daily (see "12.2 Draining the condensate").
Every six months • Check safety valve (see "9.6 Check safety valve settings").
Yearly • Change suction filter - every six months if dust concentration is high (see "12.3 Change the air intake filter").
Every 4 years • Replace vibration dampers.
According to national directives
• Carry out recurring safety checks (e.g. pressure vessel inspection, elec-trical safety inspection) according to national directives.
Observe assembly and operating instructions "Oil-free piston com-pressors KK and pis-ton vacuum pumps KV"
• Maintenance of compressor unit
Unitwithmembranedryingsystem
Maintenanceinterval Maintenancework
Every six months • Drain condensate (see "12.2 Draining the condensate").• Check safety valve (see "9.6 Check safety valve settings").
Yearly • 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 membrane-drying unit").
Every 4 years • Replace vibration dampers.
According to national directives
• Carry out recurring technical safety inspections (e.g. pressure vessel inspection, electrical safety inspection) according to national guidelines.
Observe assembly and operating instructions "Oil-free piston com-pressors KK and pis-ton vacuum pumps KV"
• Maintenance of compressor unit
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12.4Replacingthefilterofthemembrane-dryingunit
Fine/Sterilefilter• 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.
12.2DrainingthecondensateUnitswithanautomaticcondensatesole-noidvalveand/orwithmembranedryingsystemsdonothaveamanualdrainagesystem.Condensed water collects in the pressure re-ceiver during operation. • When the receiver is at maximum pressure,
open the condensate drain.
4 Condensate drain (manual)• Close the condensate drain once all the accu-
mulated condensed water has been drained off.
12.3Changetheairintakefilter
• 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.
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Usage
13 Deactivation13.1ShutdowntheunitIf the unit is not to be used for a prolonged peri-od 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.
Unitwithcondensateseparator• At maximum tank pressure, unscrew the bot-
tom screw fitting on the condensate separa-tor.
• Close the screw fitting as soon as all of the compressed air and condensate have been blown out.
Membranedryingunit• Open the condensate drain valve on the
membrane drying unit as long as the com-pressor unit is running. When no more con-densate emerges, close the condensate drain valve.
• Switch off the unit.
Sinterfilter• Unscrew and remove the filter housing.• Remove the sinter filter.• Insert a new sinter filter.• Replace the filter housing and close.
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Pressurereceiver• 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 quick-release coupling or using the condensate drain valve (if present)).
• Disconnect the compressed-air supply at the quick-release coupling.
13.2Storetheunit
WARNINGExplosionofpressuretankandpressurehoses• Only store and transport the pressure
tank and pressure hoses in a com-pletely vented condition.
• Protect unit against moisture, soiling and ex-treme temperatures during storage (see ambi-ent conditions).
• Only store the unit when it is completely emp-tied.
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14 TipsforOperatorsandTechnicians
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 techni-cian 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 Probablecause Solution
Unitdoesnotstart No mains voltage • Contact an electrician. Check mains fuse, switch on unit again, if possible. Replace the thermal fuse if defective.
Undervoltage or overvoltage • Contact an electrician. Measure mains voltage.
Capacitor defective • Contact a technician. Check the capacitor and replace it, if necessary.
Pressure switch in position "0" • Set to "I".
Motor defective • Replace the unit.
Temperature switch in motor is tripped (not present in all units)1. High ambient temperatures2. Mechanical sluggishness3. Pressure in the line
1. Allow the unit to cool down. Ensure better ventilation. Attention, unit restarts automati-cally!
2. Factory repair.3. Vent the intake plenum.
Over-current switch is tripped • Contact an electrician. • Check the motor protection
circuit breaker setting.• Determine the cause.
Suction filter is clogged • Insert a new filter.
Trouble-shooting
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Trouble-shooting
Problem Probablecause Solution
Outputisdropping. Lines, hoses or connections leak-ing
• Inform an engineer. Check/replace lines, hoses or connec-tions.
Defective membrane drying sys-tem
• Inform an engineer. Replace the membrane drying system.
Suction filter dirty • Replace the suction filter at least once a year. The suction filter must never be cleaned.
Defective seals • Inform an engineer. Replace the seals.
Cup seal leaking as a result of wear and/or for one or more of the following reasons:
Inform an engineer. Replace the cup seal, cylinder and seals (spare part kit) . If necessary/appropriate:
– Dirt – 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.
Unittoonoisy Damage to bearings • Inform an engineer.
Vibrations are being transmitted to the housing
• Fit suitable vibration dampers.
Defective vibration dampers • Install new vibration dampers.
Waterdrippingfromairconsumers
Compressor stations with mem-brane drying system: Defective membrane drying sys-tem
• Inform an engineer. Replace the membrane drying system.
Compressor stations without membrane drying system: Condensed water in the receiver
• Regularly drain condensed water.
Pressuredewpointisnotcorrect
Purge air nozzle too large or small • Inform an engineer. Replace the purge air nozzle.
Moistureindicatoronmembranedryingsystemispink
Unit has not been used for a ex-tended period of time
• When the unit is operated, the moisture indicator regenerates itself and becomes blue once more.
During operation: Membrane dry-ing system malfunction. Air drying insufficient
• Inform an engineer. Replace the membrane drying system.
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ServiceDürr Technik GmbH & Co. KG 74301 Bietigheim-Bissingen Tel +49 (0)71 4290 2220 Fax +49 (0)71 4290 2299 E-mail: [email protected]
SparepartsordersTel +49 (0)71 4290 0 Fax +49 (0)71 4290 99 E-mail: [email protected]
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/returnsPlease depressurise the unit before transport-ing it. If possible, please use the original pack-aging when returning units. Always pack the units in a plastic bag. Please use recyclable packing material.
ReturnaddressDürr Technik GmbH & Co. KG Pleidelsheimer Straße 30 74321 Bietigheim-Bissingen -Germany-
InternationaladdressesforDürrTechnikwww. duerr-technik.com
Addresses
EN
Dürr Technik GmbH & Co. KGPleidelsheimer Strasse 30 74321 Bietigheim-BissingenGermanyFon: +49 7142-90 22 [email protected]
