Oil-free compressor stations

Oil-free compressor stations
EN
0678106020L02

1411V003
Installation and Operating Instructions
Contents
Important information
1 Documentation��������������������������������������� 2
1.1 Warnings and symbols ��������������������� 2
1.2 Notes on copyright ��������������������������� 2
2 Safety ����������������������������������������������������� 3
2.1 Correct use��������������������������������������� 3
2.2 Incorrect use������������������������������������� 3
2.3 General safety notes������������������������� 3
2.4 Qualified personnel ��������������������������� 3
2.5 Protection against electrical current��� 3
2.6 Only use original parts����������������������� 3
2.7 Transportation and storage ��������������� 3
2.8 Disposal ������������������������������������������� 4
Product description
3 Overview������������������������������������������������� 5
3.1 Flexible modular system ������������������� 5
3.2 Compressor station examples ������� 10
3.3 Accessories������������������������������������� 13
3.4 Working parts and spare parts��������� 13
4 Technical data ������������������������������������� 14
8.2 Vibration damping between compressor unit and receiver����������������� 20
8.3 Installation position and fastening ��� 20
8.4 Noise reducer��������������������������������� 20
9 Operation ��������������������������������������������� 21
9.1 Remove the transport protection����� 21
9.2 Set up compressed air connection�� 21
9.3 Condensed water ��������������������������� 22
9.4 Electrical installation ����������������������� 22
9.5 Check the pressure switch ������������� 22
9.6 Check safety valve settings������������� 22
10 Setting possibilities ����������������������������� 23
10.1Pressure switch setting������������������� 23
10.2Set the motor protection switch������� 24
10.3Pressure reducer adjustment����������� 25
Usage
11 Instructions for use ����������������������������� 26
11.1Switch the unit on/off���������������������� 26
11.2Switching the unit on after a power
cut ������������������������������������������������� 26
11.3Pressure receiver test ��������������������� 26
11.4Mobile compressor station�������������� 26
5 Pressure receiver��������������������������������� 15
5.1 Overview����������������������������������������� 15
5.2 Instructions for use for the pressure
receiver (explanation by BehälterWerk Burgau GmbH)����������������������� 16
12 Maintenance����������������������������������������� 27
12.1Maintenance plan ��������������������������� 27
12.2Draining the condensate����������������� 28
12.3Change the air intake filter��������������� 28
12.4Replacing the filter of the membrane-drying unit����������������������������� 28
6 Declaration of conformity for machines in accordance with the
2006/42/EC Directive��������������������������� 17
13 Deactivation����������������������������������������� 29
13.1Shut down the unit ������������������������� 29
13.2Store the unit���������������������������������� 30
7 Function ����������������������������������������������� 18
7.1 Compressor station without membrane drying system ����������������������� 18
7.2 Compressor station with membrane drying system ����������������������� 18
Trouble-shooting
Mounting
8 Prerequisites����������������������������������������� 20
8.1 Area of installation��������������������������� 20
0678106020L02 1411V003
14 Tips for Operators and Technicians ��� 31
Addresses
1
EN
Important information
1 Documentation
EN
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
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.
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.
2
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.
0678106020L02 1411V003
Important information
2 Safety
2.4 Qualified personnel
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.
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.
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.
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.
WARNING
Serious injury and material damage
due to improper usage
•Conveying explosive mixtures in any
way other than that specified is not
permitted.
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.
0678106020L02 1411V003
3
EN
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.
EN
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.
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
Dispose of the unit properly according
to valid state and local legislation.
Packaging
Dispose of packaging material in an environmentally responsible manner.
–– Note current disposal routes.
–– Keep packaging away from children.
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.
4
0678106020L02 1411V003
Product description
3 Overview
3.1 Flexible modular system
EN
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.
0678106020L02 1411V003
5
Product description
Explanation of the product code
2
1
EN
3
T A-200 M
1 Receiver*
U
3l
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 receiver: PS = 8 bar)
2 Compressor units
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 Auxiliary modules
K
Automatic condensate drain valve
AK
Automatic condensate drain valve + starting relief
M
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)
6
0678106020L02 1411V003
Product description
Combination options of a compressor station with single-phase AC motor
l
l

l







l
l
l
l
l
l





25 l
l
l
l
l
l
l
l
l
l
l

55 l
l
l
l
l
l
l
l
l
l
l
l
90 l





l
l
l

l
l
Module M = module AK +
membrane drying unit
Marathon
25
38
60
70
65
130
105
195
90
160
230
10 l
Module AK = Modul K +
autom. starting relief
KK70
A-025
A-038
A-061
A-062
A-065
A-132
A-100
A-200
A-080
A-160
A-234
3l
Auxiliary modules
Module K = autom. condensate drain valve
KK40
Flow rate at 0 bar (l/min)
KK8
KK15
Receiver
Unit
Series
Compressor units
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
o
o
l
l
l
l
l




l
l
l
l
l
l
l
l Standard combination
o already included in the unit
 no standard
0678106020L02 1411V003
7
EN
Product description
Combination options of a compressor station with three-phase AC motor
38
73
65
130
105
195
90
160
295
590
KK40
KK70
Marathon
5l
25 l
55 l
90 l
l
l








l
l
l
l






l
l
l
l
l
l
l
l


l
l
l
l
l
l
l
l
l




l
l
l

l
l
l
Module M = module
AK + membrane drying unit
Series
KK15
3l
Module AK = Modul K
+ autom. starting relief
B-038
B-062
B-065
BG-132
B-100
B-200
B-080
B-160
B-304
2 x B-304
EN
Auxiliary modules
Module K = autom.
condensate drain
valve
Flow rate at 0 bar (l/
min)
Receiver
Unit
Compressor unit
l
l
l
l
l
l
l
l
l

l
l
o
o
l
l
l
l
l



l
l
l
l
l
l
l
l
l Standard combination
o already included in the unit
 no standard
8
0678106020L02 1411V003
Product description
Combination options of a compressor station with a DC permanent-magnet motor
Flow rate at 0 bar
(l/min)
in l
KK70
Article number
KK15
KK8
KK15
Receiver
Unit
D-040
D-030
0832-25B-01
0590 1000
40
30
10
3
D-040
0832-22B-01
40
10
D-040
0832-22B-02
40
10
D-040
D-040
D-100
0832-22B-03
ZK429T7091298
0652 0000
40
40
105
10
25
10
Comment on compressor station
EN
Design
Series
Compressor unit*
12 VDC
24 VDC
24 VDC
including interference
suppression filter
24 VDC
including interference
suppression filter
with autom. condensate drain valve
24 VDC
including interference
suppression filter
with autom. condensate drain valve and
starting relief
24 VDC
24 VDC
* Compressor units with another design are available on request
0678106020L02 1411V003
9
Product description
3.2 Compressor station examples
The item numbers designate the spare parts (see "3.4 Working parts and spare parts")
12
8
EN
1
7
3
9
13
10
2
11
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)
10
0678106020L02 1411V003
Product description
EN
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)
0678106020L02 1411V003
11
Product description
EN
8
20
3
12
9
1
11
4
10
5
2
22
21
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
12
0678106020L02 1411V003
Product description
3.3 Accessories
Item no.
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. 9000-330-09)
Accessories for compressor stations
Always specify type designation (e.g.
WA-038/0643 1000) and serial number
when ordering accessories.
Item no.
Spare parts for accessories
Pressure reducer
Quick-release coupling
(art. no. 9000-312-03)
Hose connection pieces for SW
10
(art. no. 9000-312-06)
Quick-release coupling
(art. no. 9000-312-03)
Hose connection pieces for SW 6
(art. no. 9000-311-46)
20 to 22
Seal
Operating-hour meter
Fitting unit, complete
Bracket*
(art. no. 0835-999-00)
Relay (DC only)
Power cable
Transport roller, complete
(art. no. 0643 0100)1)
Suppression filter, complete (DC
only)
*Bracket for WA-025 to WA-062
1)
optional accessory for WA -038 mobile AK,
WA-061 mobile AK, WA-062 mobile AK, WA065 mobile AK, WAG-132 mobile K
3.4 Working parts and spare parts
Spare parts for compressor station with
membrane drying system
Always specify type designation (e.g.
WA-038/0835-43B-01) and serial
number when ordering spare parts.
Carbon brushes (DC only)
End cap/screw (DC only)
Spare parts for membrane drying system
Always specify type designation (e.g.
WA-038/0835-43B-01) and serial
number when ordering spare parts.
Article no.
Spare parts for membrane
drying station
Item no.
Spare parts for compressor
station
1650-9810000
Purge air nozzle set
1
Compressor
1650-101-00
Sinter filter
2
Receiver without plug
1610-121-00
Fine filter
3
Pressure switch
Sterile filter
4
Start-up solenoid valve (not
shown)
9000-4160035ET
5
Condensate solenoid valve
7
Pressure hose
8
Suction filter, complete
Filter element (suction filter)
9
Pressure gauge
0678106020L02 1411V003
13
EN
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".
EN
14
0678106020L02 1411V003
Product description
5 Pressure receiver
5.1 Overview
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
316033 / 0834-000-010
316053 / 0654-0900
316030 / 0833-320-60
316034 / 5430-200-51
316016 / 4220-200-50
235791 / 5450-200-90
Pressure1)
PS 8 bar
PS 8 bar
PS 11 bar
PS 10 bar
PS 10 bar
PS 11 bar
Receiver2)
V3l
V3l
V 10 l
V 25 l
V 55 l
V 90 l
EB3)
A
A
A
B
A
A
c4)
c = 1.0 mm
c = 1.0 mm
c = 1.0 mm
c = 0 mm
c = 1.0 mm
c = 1.0 mm
Remark5)
2
2
4; 5
1; 6
3; 5
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
Application area
(EB)
3)
A = Pressure receiver for compressors
B = Pressure receiver for stationary systems
Corrosion supplement
c in mm
Maximum temperature
+100 °C
Minimum temperature
-10 °C
Medium
Air / nitrogen
4)
5)
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
Applied standards
0678106020L02 1411V003
EN 286-1:1998
15
EN
Product description
5.2 Instructions for use for the
pressure receiver (explanation
by Behälter-Werk Burgau
GmbH)
EN
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
16
0678106020L02 1411V003
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 30
74321 Bietigheim-BissingenGermany
EN
Reference number:
Article description:
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…
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 Machinery Directive 2006/42/EC.
The following harmonised standards and other standards have been applied:
DIN EN 1012-1:2011-02
DIN EN 60034-1: 2011-02
DIN EN 60034-5: 2007-09
DIN EN 60034-7: 2001-12
DIN EN 60034-8: 2008-04
DIN EN 60335-1:2012-10
DIN EN 61000-6-2:2006-03
DIN EN 61000-6-3:2011-09
DIN EN 60204-1:2007-06
DIN EN ISO 12100:2011-09
DIN 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
0678106020L02 1411V003
17
Product description
7 Function
7.1 Compressor station without
membrane drying system
7.2 Compressor station with
membrane drying system
EN
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.
18
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.
0678106020L02 1411V003
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.
EN
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
4
2
3
6
5
1 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.
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.
0678106020L02 1411V003
19
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).
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
30
30
The units produce vibrations. Suitable vibration
dampers must be used to damp these vibrations.
30
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.
30
EN
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).
40
20
40
0678106020L02 1411V003
Mounting
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
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.
0678106020L02 1411V003
21
EN
Mounting
9.3 Condensed water
9.5 Check the pressure switch
Condensed water is continuously separated off
in the compressor station during operation.
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").
The condensed water can be routed
through a hose to a drain.
EN
•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.
9.6 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.
22
0678106020L02 1411V003
Mounting
•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.
10 Setting possibilities
10.1Pressure 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.
0678106020L02 1411V003
23
EN
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.
EN
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.
1
1
2
•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).
24
0678106020L02 1411V003
Mounting
10.2Set 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%.
10.3Pressure 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).
0678106020L02 1411V003
25
EN
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).
EN
11.1Switch 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.
11.2Switching 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
1
2
26
3
4
Safety valve
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.
11.3Pressure receiver test
The operator must comply with the national directives.
Example for Germany: German Ordinance on
Industrial Safety and Health (BetrSichV)
11.4Mobile 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.
Start-up volume
Mechanical ventilation valve
0678106020L02 1411V003
Usage
12 Maintenance
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.
12.1Maintenance plan
EN
Units without membrane drying unit
Maintenance interval
Maintenance work
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, electrical safety inspection) according to national directives.
Observe assembly and
operating instructions
"Oil-free piston compressors KK and piston vacuum pumps
KV"
•Maintenance of compressor unit
Unit with membrane drying system
Maintenance interval
Maintenance work
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 membranedrying 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 compressors KK and piston vacuum pumps
KV"
•Maintenance of compressor unit
0678106020L02 1411V003
27
Usage
12.2Draining the condensate
EN
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.
12.4Replacing 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.
12.3Change 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.
28
0678106020L02 1411V003
Usage
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
13.1Shut down the unit
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.
0678106020L02 1411V003
29
EN
Usage
EN
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.
13.2Store 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.
30
0678106020L02 1411V003
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".
EN
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
•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 temperatures
2. Mechanical sluggishness
3. Pressure in the line
1.Allow the unit to cool down.
Ensure better ventilation.
Attention, unit restarts automatically!
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.
0678106020L02 1411V003
31
Trouble-shooting
Problem
Probable cause
Output is dropping.
Lines, hoses or connections leak- •Inform an engineer. Check/
ing
replace lines, hoses or connections.
EN
Solution
Defective membrane drying system
•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.
Unit too noisy
Water dripping from air
consumers
–– 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.
Damage to bearings
•Inform an engineer.
Vibrations are being transmitted
to the housing
•Fit suitable vibration dampers.
Defective vibration dampers
•Install new vibration dampers.
Compressor stations with membrane drying system:
Defective membrane drying system
•Inform an engineer. Replace the
membrane drying system.
Compressor stations without
membrane drying system:
Condensed water in the receiver
•Regularly drain condensed
water.
Pressure dew point is not
correct
Purge air nozzle too large or small •Inform an engineer. Replace the
purge air nozzle.
Moisture indicator on
membrane drying system
is pink
Unit has not been used for a extended period of time
•When the unit is operated, the
moisture indicator regenerates
itself and becomes blue once
more.
During operation: Membrane dry- •Inform an engineer. Replace the
ing system malfunction. Air drying
membrane drying system.
insufficient
32
0678106020L02 1411V003
Addresses
Service
Dürr Technik GmbH & Co. KG
74301 Bietigheim-Bissingen
Tel +49 (0)71 4290 2220
Fax +49 (0)71 4290 2299
E-mail: [email protected]
EN
Spare parts orders
Tel +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 / 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 30
74321 Bietigheim-Bissingen
-GermanyInternational addresses for Dürr Technik
www. duerr-technik.com
0678106020L02 1411V003
33
Dürr Technik GmbH & Co. KG
Pleidelsheimer Strasse 30
74321 Bietigheim-Bissingen
Germany
Fon: +49 7142-90 22 -0
www.duerr-technik.com
[email protected]