Oil-Injected Screw Compressors VMY .56 For Process Gas and Refrigeration Industry

User Manual
Installation, assembly and operating instructions
ENGLISH
for
Compressor Stage Series
VMY .56
AERZENER MASCHINENFABRIK
GMBH
V4-009 P EN
V4-009 P EN
Translation of the original instructions
176 130 000 03-2014
1
ENGLISH
Die INFO-Seite ist vor der Inbetriebnahme durchzulesen.

Dort evtl. vermerkte Hinweise und Änderungen sind durchzuführen.
Read the INFORMATION sheet prior to commissioning.

Possible notes and changes indicated herein are to be effected.
La page INFO est à lire avant la mise en route.

Y apporter éventuellement des annotations et modifications.
De INFO-Bladzijde moet voor de inbedrijfname worden doorgelezen.

Daar eventueel opgeschreven aanwijzingen en modificaties moeten worden uitgevoerd.
Prima della messa in esercizio leggere la pagina INFO, ed eseguire eventuali

istruzioni o modifiche indicate.
Antes de proceder a la puesta en marcha, leer detenidamente la página informativa y

cumplir eventuales indicaciones y modificaciones indicadas en la misma.
A página de informações deve ser lida antes da colocação em funcionamento. As eventuais indicações e alterações
aí mencionadas devem ser respeitadas.
INFO-siden skal læses igennem inden idriftsættelsen. Evt. anvisninger og ændringer der står dér skal gennemføres.
Les INFO-siden før igangsetting. Anvisninger og endringer som står oppført der, skal utføres.
Läs igenom INFO-sidan före idrifttagning. Eventuellt angivna anvisningar eller förändringar skall genomföras.
Pidätämme oikeuden painovirheisiin, erehdyksiin sekä teknisiin muutoksiin..
Druckfehler, Irrtümer sowie technische Änderungen sind vorbehalten.
We are not liable for misprints, errors, and we reserve the right to make technical changes.
Sous réserve de fautes d‘impression, d‘erreurs et de modifications techniques.
Drukfouten, vergissingen en technische wijzigingen voorbehouden.
Salvo error u omisión. Reservado el derecho a realizar modificaciones técnicas.
Salvo errori di stampa, incorrettezze e modifiche tecniche.
Reservamo-nos o direito a erros de impressão, enganos e alterações técnicas.
Der tages forbehold for trykfejl, fejl og tekniske ændringer.
Med forbehold om trykkfeil, feiltagelser og tekniske endringer.
Tryckfel, övriga fel samt tekniska förändringar förbehålles.
INFO-sivu on luettava ennen käyttöönottoa. Siellä ilmoitetut mahdolliset muutokset tai lisäykset on otettava
huomioon
2 V4-009 P EN
Aerzener Maschinenfabrik
Abteilung Technische Dokumentation
Technische Illustration & Redaktion
H.Nickel Technischer Autor
V4-009 P EN
3
ENGLISH
Title page.....................................................................................1
Notes on information page..........................................................2
Table of contents................................................................... 4 - 5
Information about spare parts.....................................................6
Service data................................................................................7
Declaration of incorporation.................................................. 8 - 9
ENGLISH
1. Suitability, general information.................................10
2. Design / information on system planning.........11 - 29

2.1 Compressor design................................................11 - 12
2.1.1 Calculated output data..................................................11
C o n t e n t s
2.1.2 Oil cooler.......................................................................11

2.1.3 Oil piping.......................................................................11
2.1.4 Differential oil pressure.................................................11
2.1.5 Oil reservoir...................................................................12
2.1.6 Oil temperature.............................................................12
2.1.7 Drive motor...................................................................12
2.1.8 Flexible coupling...........................................................12
2.2 Compressor connection........................................ 13 - 19
2.2.1 High-range displacement transducer.................... 13 - 14
2.2.2 Oil pump / pre-lubrication pump............................ 14 - 15
2.2.3 Oil piping.......................................................................16
2.2.4 Hydraulics for adjustment of the slide valve.................16
2.2.5 Oil return from oil separation........................................17
2.2.6 Monitoring of thrust bearings........................................17
2.2.7 Vibration monitoring......................................................17
2.2.8 Oil quantities......................................................... 18 - 19
2.2.9 Injection........................................................................19
/
2.3 Instrumentation..................................................... 20 - 21
2.4 Lubricating oil specifications................................. 22 - 23
2.4.1 Filling with oil / oil change.............................................24
2.5 ECO operation..............................................................25
2.6 SOC operation..............................................................26
2.7 Unit components...........................................................27
I n h a l t
2.7.1 Intake-side strainer.......................................................27

2.7.2 Oil filter..........................................................................27
2.7.3 Oil pressure control valve.............................................27
2.7.4 Coupling guard.............................................................27
2.8 Sound pressure spectrum.............................................28
2.9 Main exciter frequencies...............................................29
2.10 Torsion frequencies.......................................................29
2.11 Moments of inertia........................................................29
3. Performance data / service data........................ 30 - 33
4. Construction and function................................. 33 - 36

4.1 Principle of operation....................................................33
4.2 Bearings and lubrication...............................................33
4.3 Lubrication and cooling of rotors...................................33
4.4 Control of volumetric flow rate......................................34
4.5 Single-action hydraulics................................................34
4.6 Double-action hydraulics..............................................35
4.7 Feedback signal of slide valve position........................35
4 V4-009 P EN
4.8 Internal compression ratio, VI.......................................36
4.9 Mechanical seal (GLRD)...............................................36
5. Safety requirements before and

during operation................................................. 37 - 40
6. Inadmissible operating methods...............................41
ENGLISH
7. Transport / storage / installation / alignment... 42 - 49
7.1 Transport.......................................................................42
7.2 Storage.........................................................................42
7.3 Installation............................................................. 43 - 45
7.4 Alignment.............................................................. 46 - 49
C o n t e n t s
8. Commissioning................................................... 50 - 55
8.1 Setting the internal pressure ratio......................... 52 - 53
8.2 Automatic VI.........................................................55 - 57
8.3 Compressor with double-acting mechanical seal.........58
8.4 Refrigeration plants.......................................................58
8.5 Warming up phase, pre-lubricating phase....................58
8.6 Start-up of compressor.................................................59
8.7 Compressor operation with frequency converter..........59
9. Shutdown.....................................................................60
10. Maintenance / repairs......................................... 61 - 71

10.1 Maintenance plan, inspection schedule........................62
10.2 Fault diagnosis..............................................................63
10.3 Maintenance work.........................................................64
10.3.1 Changing the single-acting mechanical seal................64
10.3.1.1 Removal of mechanical seal, inspection of
/
driving collar and seal bushing............................ 64 - 65

10.3.1.2 Installation of driving collar,
seal bushing and mechanical seal................................66
10.3.2 Checking thrust bearing clearance....................... 66 - 67
10.3.3 Exchange and calibration of
high-range displacement transducer............................68
I n h a l t
10.3.3.1 Removal and installation of high-range

displacement transducer.............................................68
10.3.3.2 Calibration of high-range
displacement transducer..................................... 68 - 70
10.3.3.3 Calibration for operation during summer and
winter..........................................................................71
11. Recycling / disposal...................................................72
12. INFORMATION PAGE..................................................73
AM-Works Standard TN01134......................................... 74 - 75
Appendix, data sheets

1.) Oil consumption connection H.............................77
2.) Minimum speed.............................................. 78 - 83
3.) Noise data...................................................... 84 - 89
V4-009 P EN
5
Ersatzteile, spare parts, pièces dé tachée, onderdelen, repuestos, pezzi di ricambio
- VMY ... -
Ersatz- und Zubehörteile

Es wird darauf hingewiesen, dass nicht von uns gelieferte Originalteile und Zubehör auch nicht von uns
geprüft und freigegeben sind. Der Einbau oder Anbau sowie die Verwendung solcher Produkte kann daher
unter Umständen konstruktive vorgegebene Eigenschaften der Anlagen beeinflussen. Für Schäden, die
ENGLISH
durch Verwendung von nicht Originalteilen und Zubehör entstehen, ist jede Haftung des Herstellers ausge-
schlossen.
Spare parts and accessories

We draw your attention to the fact that original parts and accessories not supplied by us are also not inspec-
ted and released by us. Therefore, the installation and application of such products might influence under
certain circumstances constructively stipulated properties of the plants. Consequential damages due to
application of non-original parts and accessories release the manufacturer from any warranty and liability.
Accessoires et pièces de rechange

Nous attirons votre attention sur le fait que les accessoires et pièces d’origine n’étant pas de notre fourniture
ne peuvent être controlés et pris en considératoin lors d’une réclamation. L’intégration ou le montage ainsi
que l’utilisation de telles pièces peut influencer sous certaines conditions les caractéristiques et performances
de la machine. Pour tout dommage causé du fait de pièces n’étant pas d’origine ou de montage erroné, nous
déclinons toute responsabilité.
Reservedelen en toebehoren
Er wordt uitdrukkelijk op gewezen dat niet door ons geleverde originele delen en toebehoren ook niet door
ons getest en vrijgegeven zijn. De in of aanbouw alsmede de toepassing van zulke producten kan der-
halve onder zekere omstandigheden constructief gegeven eigenschappen van de installatie beïnvloeden.
Voor schaden, die door gebruik van niet originele delen en accessoires ontstaan, is iedere aansprakelijkheid
jegens de fabrikant uitgesloten.
Ricambi e accessori
Facciamo presente che i pezzi e ricambi originali non forniti da noi, non sono da noi controllati e accettati. Il
montaggio o l’impiego di questi prodotti può in certe circostanze provocare influenze sul cattivo funzionamento
dell’impianto. Danni causati dall’impiego di parti e ricambi non originali esonerano il fornitore da ogni garanzia.
Piezas de repuesto y accesorios

Indicamos expresamente, que aquellos repuestos y/o accesorios no suministrados por nosotros no están
comprobados ni homologados por Aerzen. Su montaje, así como su utilización pueden tener incidencia en
las características prefijadas de la instalación. Por lo tanto no asumimos garantía ni responsabilidad alguna
sobre éstas piezas y de los eventuales daños posteriores y/o alteraciones de las calidades y prestaciones
de origen. Para daños originados por la utilización de piezas y accesorios no originales, se excluye cualquier
responsabilidad por parte del fabricante.
6 V4-009 P EN
Aerzener Maschinenfabrik
Leistungsdaten VMY ...

Performance data
ENGLISH
V4-009 P EN
7
Einbauerklärung für unvollständige Maschinen gemäß Maschinenrichtlinie 2006/42/EG
Declaration of incorporation for partly completed machineries in accordance with Machine Directive 2006/42/EC
Déclaration d‘incorporation de quasi-machines selon la directive Machines 2006/42/CE
Die Einbauerklärung für diese Drehkolbenmaschine wird von den technischen Angaben im Kapitel „Leistungsdaten“ ergänzt.
Die dort erwähnten Angaben identifizieren das Produkt und sind in Verbindung mit dieser Einbauerklärung zu verwenden.
The installation declaration for the rotary piston machine is supplemented by the technical specification in the chapter „Performance data“.
The data mentioned there identify the product and must be used in association with this installation declaration.
La déclaration d‘incorporation de cette machine à pistons rotatifs est complétée par les indications techniques du chapitre « Caractéristiques de puissance ».
Les indications qui y sont données identifient le produit et sont à mettre en relation avec la présente déclaration d’incorporation.
DEUTSCH Originaleinbauerklärung
ENGLISH
Hiermit erklärt der Hersteller: Aerzener Maschinenfabrik GmbH, Reherweg 28, D-31855 Aerzen
dass folgende grundlegende Sicherheits- und Gesundheitsschutzanforderungen nach Anhang I der oben genannten Richtlinie
angewandt und eingehalten sind: Artikel 1.1.2 Grundsätze für die Integration der Sicherheit, 1.1.3 Materialien und Produkte,
1.1.5 Konstruktion der Maschine im Hinblick auf die Handhabung, 1.2.1 Sicherheit und Zuverlässigkeit von Steuerungen, 1.3.1
Risiko des Verlustes der Standsicherheit, 1.3.2 Bruchrisiko beim Betrieb, 1.3.4 Risiken durch Oberflächen, Kanten und Ecken,
1.5.6 Brand, 1.5.8 Lärm, 1.5.9 Vibrationen, 1.6.4 Eingriffe des Bedienpersonals, 1.7.1 Informationen und Warnhinweise an
der Maschine, 1.7.2. Warnung vor Restrisiken.
Die unvollständige Maschine darf erst dann in Betrieb genommen werden, wenn festgestellt wurde, ob das endgültige
Aggregat, in das die unvollständige Maschine eingebaut werden soll, den Bestimmungen der
Maschinenrichtlinie 2006/42/EG entspricht.
Bei Einbau einer unvollständigen Maschine in eine Gebrauchtmaschine ist zu prüfen, ob dieser Einbau zu einer wesentlichen
Veränderung der Gebrauchtmaschine führt und somit die Maschinenrichtlinie anzuwenden wäre.
Der Einbau unvollständiger Maschinen in Gebrauchtmaschinen fällt ansonsten nicht unter den Anwendungsbereich der
Maschinenrichtlinie.
Diese Einbauerklärung bezieht sich auf den vom Hersteller in Verkehr gebrachten originalen Maschinenzustand. Bei nachträglich
durchgeführten Veränderungen und/oder nachträglich vorgenommenen Eingriffen erlischt diese Einbauerklärung.
Der Hersteller verpflichtet sich, die speziellen Unterlagen dieser unvollständigen Maschine, einzelstaatlichen Stellen auf
begründetes Verlangen, in elektronischer Form, zu übermitteln.
Die zur Maschine gehörenden speziellen technischen Unterlagen nach Anhang VII Teil B wurden erstellt.
Dokumentationsverantwortlicher: Herr Irtel Aerzen, 18-08-2009
ENGLISH Translation of original declaration of incorporation

The manufacturer: Aerzener Maschinenfabrik GmbH, Reherweg 28, D-31855 Aerzen
hereby declares that the following safety and health protection requirements according to Appendix I of the above-mentioned
directive have been applied and complied with: Article 1.1.2 Fundamental Principles for Integrating Safety, 1.1.3 Materials
and Products, 1.1.5 Machine Design with Regard to Handling, 1.2.1 Safety and Reliability of Controllers, 1.3.1 Risk of Loss
of Stability, 1.3.2 Risk of Fracture During Operation, 1.3.4 Risks due to Surfaces, Edges and Corners, 1.5.6 Fire, 1.5.8 Noise,
1.5.9 Vibrations, 1.6.4 Intervention by Operating Personnel, 1.7.1 Information and Warnings on the Machine, 1.7.2. Warning
of Residual Risks.
Diese Einbauerklärung ist mit dem Inkrafttreten der Maschinenrichtlinie 2006/42/EG ab dem 29-12-2009 gültig.
The partly completed machinery must only be put into operation once it has been established whether the final
assembly in which the partly completed machinery is to be installed complies with the
Machine Directive 2006/42/EC.
When installing a partly completed machinery in a used machine, it is essential to check whether the installation significantly
Cette déclaration d’incorporation est valable à partir du 29/12/2009 avec l’entrée en vigueur de la directive Machines 2006/42/CE.
alters the used machine and whether the machine directive must be applied.
Otherwise, installing partly completed machineries in used machines is not covered by the area of application of the machine
directive.
This installation declaration applies when the Machine Directive 2006/42/EC comes into force on 29-12-2009.
This declaration of incorporation refers to the machine in its original state as marketed by the manufacturer. Any changes
introduced subsequently and/or interventions carried out subsequently will void this declaration of incorporation.
The manufacturer is obliged to transmit the special documents for the partly completed machinery to the national authorities
in response to a request with reasons.
The special technical documents for the machine in accordance with Appendix VII Part B have been created.
Responsible for documentation: Herr Irtel Aerzen, 18-08-2009
FRANÇAIS Traduction de la déclaration d‘incorporation d‘origine

Le fabricant : Aerzener Maschinenfabrik GmbH, Reherweg 28, D-31855 Aerzen
déclare par la présente que les exigences fondamentales relatives à la santé et à la sécurité suivantes, définies dans l’annexe
I de la directive mentionnée ci-dessus, sont appliquées et satisfaites : Article 1.1.2 Principes d’intégration de la sécurité, 1.1.3
Matériaux et produits, 1.1.5 Conception de la machine en vue de sa manutention, 1.2.1 Sécurité et fiabilité des systèmes
de commande, 1.3.1 Risque de perte de stabilité, 1.3.2 Risque de rupture en service, 1.3.4 Risques dus aux surfaces, aux
arêtes ou aux angles, 1.5.6 Incendie, 1.5.8 Bruit, 1.5.9 Vibrations, 1.6.4 Intervention de l’opérateur, 1.7.1 Informations et
avertissements sur la machine, 1.7.2. Avertissement sur les risques résiduels.
La quasi-machine ne doit pas être mise en service avant que la machine finale
dans laquelle elle doit être incorporée ait été déclarée conforme aux dispositions pertinentes de la directive
Machines 2006/42/CE.
En cas d’incorporation d’une quasi-machine dans une machine d’occasion, il convient de vérifier si cette incorporation entraîne
une modification significative de la machine d’occasion et si la directive Machines est applicable.
Sinon, l’incorporation de quasi-machines dans des machines d’occasion ne tombe pas dans le domaine d’application de la
directive Machines.
La présente déclaration d’incorporation se rapporte à l’état d’origine de la machine tel que mis en circulation par le fabricant.
Cette déclaration d’incorporation est rendue caduque par toute modification et/ou intervention ultérieure.
Le fabricant s’engage à transmettre sous forme électronique les informations pertinentes concernant la quasi-machine à la
suite d’une demande dûment motivée des autorités nationales.
La documentation technique pertinente pour la quasi-machine a été constituée conformément à l’annexe VII partie B.
Responsable de la documentation : Monsieur Irtel Aerzen, 18-08-2009
A3-045 A XT
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Leiter Techn. Abteilung
Head of the dept.
Unterschrift des Herstellers 1 von 2 08-2009
(Herr Irtel) Signature of the manufacturer
Directeur technique
V4-009 P EN
Signature du constructeur

Inbouwverklaring voor incomplete machines conform machinerichtlijn 2006/42/EG
Declaración de incorporación para cuasi máquinas, de conformidad con la Directiva de Máquinas 2006/42/CE
Dichiarazione di incorporazione per macchine incomplete secondo la Direttiva macchine 2006/42/CE
De inbouwverklaring voor deze roterende zuigercompressor wordt aangevuld door de technische informatie in het hoofdstuk „Specificaties“.
Aan de hand van de daar vermelde informatie wordt het product geïdentificeerd en de informatie moet in combinatie met deze inbouwverklaring toegepast worden.
La declaración de incorporación para esta máquina de émbolos giratorios es complementada por los datos técnicos que se encuentran en el capítulo “Datos de potencia”.
Los datos ahí indicados identifican al producto y se deberán utilizar conjuntamente con esta declaración de incorporación.
La Dichiarazione di incorporazione per la presente macchina a pistoni rotanti è integrata dai dati tecnici riportati nel capitolo „Dati di prestazione“.
Le informazioni incluse in quel capitolo identificano il prodotto e devono essere utilizzate insieme alla presente Dichiarazione di incorporazione.
NEDERLANDS Vertaling van de originele inbouwverklaring
ENGLISH
Hiermee verklaart de fabrikant: Aerzener Maschinenfabrik GmbH, Reherweg 28, D-31855 Aerzen
dat de volgende fundamentele veiligheids- en gezondheidseisen conform bijlage I van de hiervoor genoemde richtlijn toege-
past en nageleefd zijn: Artikel 1.1.2 Beginselen van geïntegreerde veiligheid, 1.1.3 Materiaal en producten, 1.1.5 Ontwerp
van de machine met het oog op het hanteren ervan, 1.2.1 Veiligheid en betrouwbaarheid van de bedieningssystemen, 1.3.1
Risico van verlies van stabiliteit, 1.3.2 Risico van breuken tijdens het gebruik, 1.3.4 Risico‘s in verband met oppervlakken,
scherpe kanten, hoeken, 1.5.6 Risico´s door brand, 1.5.8 Risico´s door geluid, 1.5.9 Risico´s door trillingen, 1.6.4 Ingrepen
door het bedieningspersoneel, 1.7.1 Informatie en waarschuwingen op de machine, 1.7.2. Waarschuwing voor restrisico‘s.
De incomplete machine mag pas in gebruik genomen worden nadat vastgesteld is of het definitieve
aggregaat waarin de incomplete machine ingebouwd wordt, aan de bepalingen van
machinerichtlijn 2006/42/EG voldoet.
Bij inbouw van een incomplete machine in een gebruikte machine moet gecontroleerd worden of deze inbouw tot een wezenlijke
verandering van de gebruiksmachine leidt en of zodoende de machinerichtlijn toegepast moet worden.
De inbouw van incomplete machines in gebruikte machines valt anders niet onder de werkingssfeer van de machinerichtlijn.
Deze inbouwverklaring heeft betrekking op de originele machinetoestand die door de fabrikant in omloop is gebracht. Bij
veranderingen en/of ingrepen die naderhand uitgevoerd zijn, komt deze inbouwverklaring te vervallen.
De fabrikant is verplicht de speciale documentatie van deze incomplete machine, op gegronde wens in elektronische vorm
aan nationale instanties door te geven.
De speciaal bij de machine horende technische documentatie conform bijlage VII deel B is opgesteld.
Verantwoordelijk voor de documentatie: de heer Irtel Aerzen, 18-08-2009
ESPAÑOL Traducción de la declaración de incorporación original

Por la presente, el fabricante: Aerzener Maschinenfabrik GmbH, Reherweg 28, D-31855 Aerzen
declara que se han aplicado y se cumplen los siguientes requisitos esenciales de seguridad y salud según el anexo I de la
directiva mencionada: Artículo 1.1.2 Principios de integración de la seguridad, 1.1.3 Materiales y productos, 1.1.5 Diseño de
la máquina con vistas a su manutención, 1.2.1 Seguridad y fiabilidad de los sistemas de mando, 1.3.1 Riesgo de pérdida de
estabilidad, 1.3.2 Riesgo de rotura en servicio, 1.3.4 Riesgos debidos a superficies, aristas o ángulos, 1.5.6 Incendio, 1.5.8
Ruido, 1.5.9 Vibraciones, 1.6.4 Intervención del operador, 1.7.1 Información y señales de advertencia sobre la máquina, 1.7.2
Advertencia de los riesgos residuales.
No está permitido poner en marcha la cuasi máquina hasta que no se haya comprobado, que el equipo
final, en el que se incorporará la cuasi máquina, cumple con las disposiciones de la
Directiva de Máquinas 2006/42/CE.
Al incorporar una cuasi máquina en una máquina usada, deberá comprobarse si esta incorporación supone una modificación
importante que implique la aplicación de la Directiva de Máquinas.
En caso contrario, la incorporación de cuasi máquinas en máquinas usadas no recae dentro del ámbito de aplicación de la
Directiva de Máquinas.
Esta declaración de incorporación se refiere al estado original de la máquina que el fabricante comercializa. En el caso de
Esta declaración de incorporación obtendrá validez con la entrada en vigor de la Directiva de Máquinas 2006/42/CE, a partir del 29.12.2009.
Con l’entrata in vigore della Direttiva macchine 2006/42/CE la presente Dichiarazione di incorporazione è valida a partire dal 29-12-2009.
realizar modificaciones y/u operaciones posteriores, la declaración perderá toda validez.
El fabricante se compromete a transmitir, en respuesta a un requerimiento debidamente motivado de las autoridades nacio-
nales, la información pertinente relativa a esta cuasi máquina, en formato electrónico.
La documentación técnica correspondiente a la máquina, de conformidad con el anexo VII, parte B ha sido elaborada.
Deze inbouwverklaring is geldig bij de inwerkingtreding van de machinerichtlijn 2006/42/EG vanaf 29-12-2009.
Responsable de la documentación: Sr. Irtel Aerzen, 18.08.2009
ITALIANO Traduzione della dichiarazione originale di incorporazione

Con la presente dichiarazione il produttore: Aerzener Maschinenfabrik GmbH, Reherweg 28, D-31855 Aerzen
dichiara di avere applicato e rispettato i seguenti requisiti essenziali di sicurezza e di tutela della salute in base all’Allegato I
della suddetta direttiva: art. 1.1.2 Principi d’integrazione della sicurezza, 1.1.3 Materiali e prodotti, 1.1.5 Progettazione della
macchina ai fini della movimentazione, 1.2.1 Sicurezza ed affidabilità dei sistemi di comando, 1.3.1 Rischio di perdita di sta-
bilità, 1.3.2 Rischio di rottura durante il funzionamento, 1.3.4 Rischi dovuti a superfici, spigoli od angoli, 1.5.6 Incendio, 1.5.8
Rumore, 1.5.9 Vibrazioni, 1.6.4 Intervento dell’operatore, 1.7.1 Informazioni e avvertenze sulla macchina, 1.7.2. Avvertenze
in merito ai rischi residui.
La quasi-macchina può essere messa in funzione soltanto una volta appurato che il
gruppo finale in cui deve essere incorporata soddisfa le disposizioni della
Direttiva macchine 2006/42/CE.
In caso di installazione di una quasi-macchina in una macchina usata, è necessario verificare se tale installazione comporta
una modifica essenziale della macchina usata e, quindi, se deve essere applicata la Direttiva macchine.
In caso contrario l’installazione di una macchina incompleta in una macchina usata non rientra nel campo applicativo della
Direttiva macchine.
Questa dichiarazione di incorporazione si riferisce allo stato della macchina originale messa in circolazione dal produttore. In caso
di modifiche eseguite successivamente e/o di interventi eseguiti in un secondo momento, decade l’obbligo della dichiarazione.
Il produttore si impegna a trasmettere la documentazione speciale in formato elettronico relativa alla quasi-macchina ad uffici
a livello nazionale dietro richiesta fondata.
È stata predisposta la documentazione tecnica speciale relativa alla macchina secondo l’Allegato VII Parte B.
Responsabile della documentazione: Sig. Irtel Aerzen, 18-08-2009
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Hoofd technische afdeling Handtekening van de fabrikant
Director Dpto, Técnico Firma del fabricante
(Herr Irtel) Responsabile reparto tecnico Firma del fornitore
V4-009 P EN
1. Suitability, general information
The German version of these instructions is the “Original instructions”.
Any version in a language other than German is a “Translation of the original instructions”.
VMY.56 screw compressors manufactured by Aerzener are intended for oil-injected,

volume controlled conveying and compressing of process gases and refrigerant gases.
These gases must not contain condensates or contaminants.
ENGLISH
Non-observance of technical limits of suitability, performance data and safety regulations

releases Aerzener Maschinenfabrik from all warranty and liability of replacement for
resultant damages. The same applies to defects arising from failure to carry out recom-
mended inspections properly and in time.
The vibration behaviour of blowers with mounted couplings is largely determined by

the balance quality of the rotors as well as the balance of the driving elements.
The use of incorrect oils and sealants as well as contaminants in gas or oil, voids all
warranty and releases Aerzener Maschinenfabrik from any liability for damages caused
by such incorrect usage.
The compressor is delivered ready to operate; also including accessories as an option.
The specifications and instructions of the suppliers of accessories and

the manufacturer of the plant must be observed.
When operating with gases containing oxygen, such as air, there is the
danger that the gas mixture could be ignited.
Special safety measures are to be provided in this case and Aerzener
Maschinenfabrik is to be contacted before the system is commissioned.
10 V4-009 P EN
2. Design / information on system planning
This chapter contains important information and instructions for the design and confi-
guration of the compressor unit.
2.1 Compressor design
ENGLISH
The compressor must be designed in accordance with the latest “compressor design
program” of Aerzener Maschinenfabrik.
The latest version is available on the Internet at www.aerzener.com or directly from
Aerzener Maschienenfabrik.
When ordering, all necessary operating data for the design of the compressor must be
specified.
When designing the compressor also special cases such as operation with extreme
pressures and temperatures during summer and winter are to be taken into consideration!
2.1.1 Calculated output data
The values specified in the program for pressure and temperature refers to the corre-
sponding inlet of the compressor, e.g. the intake-side and discharge-side flange, the
ECO-connection...
These values must be used when checking the output data.
When designing the pipes, the pressure loss in the pipes and fittings must be considered.
The oil quantity calculated by the programme is the total oil quantity fed into the compressor.
2.1.2 Oil cooler
For the design of the oil cooler a reserve of 10-20% in addition to the thermal rating
determined by the design program is to be considered. This compensates for variations
in the process data.
2.1.3 Oil piping
The injection oil system is excited with a frequency of 4/6 times of the compressor’s
driving speed and its multiples. This must be taken into consideration when designing
the pipe system.
2.1.4 Differential oil pressure
The differential oil pressure must be ensured by means of an oil pressure control valve.
Using the oil pump’s overflow valve (if there is one) is generally too imprecise a method
and can result in damage to the compressor.
2.1.5 Oil reservoir
V4-009 P EN
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The oil volume in the reservoir should be so calculated that the oil has sufficient time
to separate the gas bubbles. At the same time, the return pipe of the pressure regu-
lating valve should be positioned in the oil reservoir below the oil level, to prevent
additional agitation of the oil. The oil sucked in by the pump must be pure (free of gas
bubbles).
The maximum oil level in the reservoir must not lie above the lower end of the
compressor’s pressure flange.
ENGLISH
2.1.6 Oil temperature
The oil temperature specified in the design programme is the temperature of the oil fed
into the compressor (connections H and X1 to X3). To ensure that the oil has this tem-
perature an oil temperature control valve is to be installed in the oil circuit.
2.1.7 Drive motor
For the design of the drive motor Aerzener Maschinenfabrik makes available starting
curves corresponding to each respective operation.
Process pressures and temperatures during the starting phase are required for this.
When operating with a frequency converter observe the details stated in chapter 8.6
“Start of compressor”!
2.1.8 Flexible coupling
A flexible coupling is to be fitted between the compressor and the drive motor. This
coupling in turn must be fitted with an adapter to allow maintenance work to be carried
out; see also dimensional sheet.
When designing the protective guard for the coupling provide for adequate ventilation.
12 V4-009 P EN
2.2 Compressor connection
2.2.1 High-range displacement transducer
The high-range displacement transducer, that indicates the position of the slide valve
in the form of a 4 to 20 mA signal, is connected via a PG11 plug in accordance with
DIN 43650.
ENGLISH
As delivered, the high-range displacement transducer is calibrated to an internal
compression ratio VI in accordance with the order data. Before starting up, check the
VI-setting and the calibration of the displacement transducer. For the definition of the
VI see also chapter 4.8.
This means that the high-range displacement transducer at 100% flow volume sup-
plies a current of 20 mA and a current of 4 mA at 0%.
If the displacement transducer is not to be calibrated for the set VI, then values of the
current for the setting at 100% volume flow can be taken from the following table. The
calibration of the displacement transducer is described in chapter 10.3.3.2.
High-range displacement transducer current (mA)

VI
VMY 156 M VMY 256 M VMY 356 M
2,2 20,0 20,0 20,0
2,3 19,7 19,7 18,8
2,5 18,9 19,0 17,6
2,9 17,8 17,8 17,3
3,5 16,5 16,5 16,4
4,0 15,7 15,7 15,5
4,5 15,1 15,1 14,9
5,0 14,7 14,6 14,4
Table 1: Current output of high-range displacement transducer at 100% flow volume
dependent on the set VI .
Based on manufacturing and dimensional tolerances the actual values may deviate
from those stated in the table. For commissioning, the value at the 100% setting is to
be checked.
PIN configuration of the connecting plug

EX-free version:
Pin 1 Supply + 11 bis +32 VDC
Pin 2 Common minus pole, 0 VDC
Pin 3 4 – 20 mA output signal
Ground connected
V4-009 P EN
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EX-version
Pin 1 Supply +24 VDC
Pin 2 Common minus pole, 0 VDC
Pin 3 4 – 20 mA output signal
Ground Not connected
The power supply of the EX-free version must have the following characteristics:
ENGLISH
Supply voltage : 12 – 28 VDC

Short-circuit current : min. 50 mA
Transformer : insulated
Collection : ATEX
The installation in the EX-Zone must be made in accordance with EN 60079-14 and
IEC 79-11 intrinsic safety “i“
The position sensor can only be operated with a type “Pepperl + Fuchs” KFD2-ST4-
Ex1, number Y204 907 barrier.
Approximately 5 minutes after switching the power on the transmitter is ready for
operation.
2.2.2 Oil pump / pre-lubrication pump
Series .56 VMY compressors are equipped with a mechanical oil pump as standard. The
mechanical oil pump must be protected against impermissibly high differential pressures
by means of suitable safeguards; see Section 3.
Pre-lubrication pump
An additional pre-lubrication pump must supply the compressors with oil at connection
H prior to start-up.
When selecting the pre-lubrication pump, as well as taking into account the specified
volumetric flow rate, you will also need to consider the pressure control valve consumption
and consumption by any other consumers. We recommend adding a safety margin of 20
– 30% to the oil quantity calculated in this way to allow for fluctuations in the process data.
The pre-lubrication pump supplies connections H and Y1 with oil (moves the slide valve
to the minimum position) prior to start-up. In order for the compressor to be started up
without internal compression, the slide valve must be in the minimum position.
If there is an electric pump for supplying the compressor with oil during operation, this
same pump can be used for pre-lubrication, provided that the oil system is of a suitable
design.
CAUTION:
Connections X1-X3 must not be pre-lubricated. Pre-lubricating these connections can
result in damage to the compressor.
Operating oil pump

Standard design will be delivered without mechanically driven oil pump.
In principle, series .56 compressors can be supplied with oil in three different ways:
- By means of a complete lubricating pump 1) driven by the compressor

(consumer 2), connections H and Y1 as well as the oil injection system, connections X2
to X3, are supplied via the pump).
- By means of a dedicated lubricating pump driven by the compressor (Only the com-
pressor consumers are supplied via the mechanical oil pump, connections H and Y1.
Injection – connections X1 to X3 – is performed on the basis of discharge pressure.
or
14 V4-009 P EN
- By means of an electrically driven pump In this case, the pump can
take the form of a complete lubricating pump or a dedicated lubricating pump. The quantity
of oil specified in the design program is composed of the total consumption by the bearing,
face seal, balancing piston and the injection. When choosing the volumetric flow rate of
the lubricating pump, you also need to take the consumption by the pressure regulating
valve as well as the capacity slide valve and the quantities of oil required by other consum-
ers into consideration. Since the oil consumption of the compressor may also vary more
considerably with increasing differential pressure based on the process, the choice of
ENGLISH
the volumetric flow rate depends on the differential pressure of the compressor. You can
refer to the following diagram for arriving at the factor to increase the volumetric flow rate.
1,5
Reservefaktor / Reserve Margin
1,45
1,4
Reservefaktor
1,35
1,3
1,25
2 4 6 8 10 12 14 16 18 20
Differenzdruck / Dfferential Pressure [bar]
Differenzdruck
With certain suction and differential pressures, the compressor must be supplied with
oil via a complete lubricating pump. When ordering this must be coordinated with the
Aerzen Maschinenfabrik.
To avoid cavitation at the compressor’s flange-mounted pump, the compressor must

build up a differential pressure as quickly as possible after start-up.
1)
The total quantity of oil required by the compressor (consumers and oil injection) is
supplied via a pump.
2)
Radial and thrust bearings, mechanical seal, balance piston, slide valve lubrication
and control piston
V4-009 P EN
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Operation without a mechanical oil pump
If the compressor is operated without a mechanical oil pump, the electrically driven
pump must either be designed to supply connections H and Y1 or the total quantity of oil
required by the compressor. When selecting the volumetric flow rate for the oil, please
observe the information provided above.
If the compressor is supplied with oil by means of an external oil pump, the pump in
question must be equipped with a bypass line with non-return valve. In the event of an
oil pump failure, the discharge pressure will ensure that the compressor continues to be
ENGLISH
supplied with oil until it comes to rest.
CAUTION:
The compressor must not be operated without an oil pump!
The bypass for the external oil pump is merely intended to serve as a protective measure.
Care must be taken to ensure that the oil pump’s electrical supply is isolated from the
main motor. This safeguards the oil supply if the main motor supply should fail.
Aerzener Maschinenfabrik can assume no liability for damage caused by oil supply failures.
Operation with variable speed drive (frequency converter, turbine)

If the compressor is driven by a variable speed drive, the oil pump’s volumetric flow rate
will cease to be adequate at low speeds. In this case, the compressor should always be
supplied with oil via an external pump.
Please observe the information about operating the compressor without a mechanical
oil pump.
2.2.3 Oil piping
When connecting the compressor the recommendations given on the standard diagrams
must be observed.
2.2.4 Hydraulics for adjustment of the slide valve
The design of the valves and the pipes should be such that the full stroke of the con-
trol piston can be completed in approximately 30 seconds.
The required oil volume is specified in 2.2.8.
To control the adjusting speed of the slide valve, throttles are to be installed in the
corresponding return pipes.
This is to avoid control problems due to possible gas emission.
The hydraulic cylinder can be supplied with the lubricating oil of the compressor in
accordance with the lubricating oil specifications.
The oil filtration for the capacity slide valve must meet the specifications for solenoid
valves.
The oil leaking from the hydraulic cylinder can fed back into the compressor via con-
nection W2.
16 V4-009 P EN
2.2.5 Oil return from oil separation
The oil leaking from the oil separators can be fed back into the compressor via connec-
tion W1.
No condensates must enter the compressor since these have a negative effect on lube
oil characteristics and lead to compressor damage.
The oil which is fed back into the compressor must correspond to Aerzener’s oil purity
specification.
ENGLISH
2.2.6 Monitoring of thrust bearings
The compressors have bores for the installation of proximity sensors.

These sensors measure the axial displacement of the rotors and thus inform about the
condition of the axial bearings.
ATTENTION !
The measuring chamber of the sensors is pressurized during operation and filled with oil.
For maintenance work the compressor must be properly shut down, depressurized and
degassed.
We recommend a trend analysis, from the start of commissioning.

The measurements depend on the operating point and must therefore be carried out at
approx. identical operating points.
For evaluation purposes only similar operating points should be used.
Note: More detailed information about the dimensions of the sensors is available from
Aerzener Maschinenfabrik.
2.2.7 Vibration monitoring
Depending on their size, the compressors are standard equipped with connections for
vibration measurement.
The vibration behaviour depends on the foundation and the pipework.
The maximum permissible vibration values are fixed in the AM works standard
TN0 1151.
For compressor vibration measurement with mobile measuring units, the measuring
points indicated in the standard with Fb 009-0/0-07/03 must be observed.
Notes
We recommend a trend analysis, vibration measurement, from the start of commissioning.
The measurements depend on the operating point and must therefore be carried out at
approximately identical operating points.
For evaluation purposes only similar operating points should be used.
V4-009 P EN
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2.2.8 Oil quantities
ATTENTION !
The compressor must not be operated without oil injection!
Please refer to Table 4.
Throttle valves are to be protected against unintentional closing!
The pipes for oil injection are to be designed according to the total oil quantity calculated
by the design program.
The following flow speeds can be taken as reference value for pipe design:
ENGLISH
Pipe on the intake-side of the mechanical oil pump < 1 m/s

Pipe on the discharge side of the mechanical oil pump 2 – 3 m/s
The following table contains the volume flow of the mechanical oil pump:
VMY 156 256 356

dm3 2 4 8
Table 2: Control cylinder volume
VMY 156 256 356

dm /min
3
15 20 30
Table 3: Minimum volumetric flow of injection
(connections X1 - X3)
VMY 156 256 356

dm /min
3
15 20 30
Tabelle 4: Ölvolumenstrom Vorschmierpumpe
18 V4-009 P EN
Oil consumption at connection H
The diagrams in the appendix illustrate how oil consumption at connection H

depends on the compressor’s differential pressure (p1 – p2).
These values are based on an oil pressure of 2.5 bar, a speed of 3000 rpm and an oil
viscosity of 37.5 mm2/s.
The surplus oil that results from the difference between the pump delivery rate and
the amount of oil consumed at connection H must be fed back to the oil reservoir by
ENGLISH
means of the pressure control valve.
Please note that when the differential pressure is high, the pressure control valve may
consume so much oil that the pump delivery rate ceases to be adequate. In this case,
an external oil pump will be required.
2.2.9 Injection
If the oil is injected above the discharge pressure it must be ensured that the set VI
also matches the type of operation.
In case of low differential pressures and a high VI, the compressor’s internal pressure
could lie above the discharge pressure and oil cannot be injected.
Up to an intake pressure of 5 bar there must be a minimum differential pressure of 6
bar. If these values cannot be met, the compressor (injection and connection H) must
be supplied with oil with an external pump.
Please also observe the recommendations given in the standard diagrams.
V4-009 P EN
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2.3 Instrumentation
The following essential operating parameters are to be monitored by means of suitab-

le instruments and adhered to:
Intake pressure : according to design

Intake temperature : according to design
ENGLISH
Discharge pressure : according to design

Discharge temperature : according to design
For emergency shutdown and the alarms, the essential pressure and temperature
measurements must be designed with safe maximum values.
Definitions
p1 = Gas pressure at the compressor suction flange, intake pressure
p2 = Gas pressure at the compressor pressure flange, discharge pressure
pÖl = Oil pressure at connection P3
∆ pGas = p2-p1 Differential gas pressure
∆ pÖl = pÖl-p2 Differential oil pressure, for setting value, see chapter 3
Required minimum operating measurements

a) Alarm
- p 1 Intake pressure low / high
- p2 Discharge pressure high
- T2 Discharge temperature high
- TÖl Oil temperature high
- ∆pÖl Differential oil pressure / oil pressure low
pÖl=1.5 bar
- Strainer contamination, ∆pStrainer high
- Differential pressure (∆pGas) compressor high
20 V4-009 P EN
b) Shutdown
- p1 Suction pressure high
- p 2 Discharge pressure high
- ∆ pGas Differential gas pressure high
- T 2 Discharge pressure high
- ∆pÖl = Differential oil pressure / oil pressure low ∆ pÖl=1,0 bar
The fact that viscosity is linked to the temperature means that it may be necessary
to implement alarm and shutdown measures for oil temperature high.
ENGLISH
Attention! The maximum values in chapter ‚output data’ must not be exceeded!
Attention! The maximum values for shutdown and alarm highly depend on the
process.
Attention! The oil pressure is to be measured at the connections P2 and P3.
To control the signalled measured values, parallel installation of pressure gauge, ther-
mometer, ... is required.
The discharge pressure during operation must not exceed + / - 0.5 bar.

Sudden pressure fluctuations are to be avoided!

V4-009 P EN
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2.4 Lubricating oil specifications
The unit’s constructor and its user are responsible for adherence to and application of
the lube oil specifications.
The injection temperature for the oil ranges between 40°C - 50°C.
Variances are possible depending on operation.
ENGLISH
The maximum permissible oil flow temperature (Toil max) is 70°C.
The oil is to be tested for viscosity at 500 and 2000 operating hours after commissioning.
The results are to be documented and stored.
Based on the results, further appropriate oil checks and oil change intervals for proper
operation are to be determined.
However, the oil must be exchanged after one year at the latest.
Viscosity at compressor intake, connection H

The maximum viscosity during starting is 68 mm²/s (cST).
If the process does not permit this, Aerzener Maschinenfabrik is to be consulted.
The viscosity of the oil during operation (including dilution through the conveying medi-
um) must not fall below value 15 mm²/s (cST) at temperature T, and not exceed value
50 mm²/s (cST):
TÖl = maximum oil flow temperature during operation.
Oil with higher viscosity is to be brought up to a temperature corresponding to the vis-

cosity stated above. At the same time it is to be ensured that the oil temperature at the
feed-in to the bearing position is correct. If necessary, the pipes are to be insulated or
pre-warmed by means of flushing.
ATTENTION ! A cold compressor is to be pre-heated with warm lubricating oil, see
chapter 8.4.
Viscosity at discharge temperature

At discharge temperature of the gas (T2) the oil viscosity must not fall below 8 mm²/s (cST).
The oil must be exchanged if the viscosity falls below prescribed specifications.
Evaluation of oil usability with respect to other oil properties, such as TAN number and
contamination, will be made by the oil manufacturer and the Aerzener Maschinenfabrik
after an oil analysis. The oil analysis intervals are to be adjusted according to application.
22 V4-009 P EN
The lubricating oil must:
• be approved for each respective gas operation. The oil manufacturer’s specifications
are to be checked and observed!
• retain adequate viscosity even at
dilution through the medium and operating parameters.
The oil manufacturer’s specifications are to be checked and observed!
• show compatibility with the sealing materials of the compressor stage with regard
to gas type.
ENGLISH
Standard sealing materials = CR. Consult with Aerzener Maschinenfabrik about
the use of alternative sealing materials.
Oil and sealant manufacturer’s specifications are to be checked and observed!
• The lubricant manufacturer provides information about suitable application on the
basis of oil analysis, operating conditions and Aerzener lubrication specifications.
• When changing lubricating oil type, the compatibility with the previous-
ly used oil must be tested. Observe lubricant manufacturer’s specifications!
If necessary, the unit must be flushed or cleaned!
Mixing of different oil qualities and manufacturers is not permitted!
V4-009 P EN
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2.4.1 Filling with oil / oil change
The unit must only be filled with filtered oil with a maximum of 10µm.
Before changing the oil the machine must be depressurized, degassed and made
inert.
ATTENTION !
Gas still escapes from the oil after the compressor has been relieved! Appropriate
ENGLISH
safety measure are to be taken.
24 V4-009 P EN
2.5 ECO operation
Before the pipe is connected to the ECO connection, connection V1 and connection
V2, the bolts, position 77, with the O-ring seals, position 75 and 76, must be disas-
sembled.
• The ECO connection is used in refrigeration units only.

• In economizer operation, gaseous refrigerant under a higher pressure than intake
ENGLISH
pressure is supplied to the closed compression chamber. The mass flow of the
ECO increases the total mass flow and thus the cooling capacity and power at
coupling of the compressor.
ATTENTION ! No liquid refrigerant must enter into the compressor via the ECO
connections.
• A pressure holding valve must be installed on the ECO reservoir to control the
ECO pressure.
• ECO operation should boost the compressor’s nominal power to over 100%.
• ECO operation should be carried out at slide valve position 100% only. ECO
operation at partial load will lead to a short circuit between ECO and compressor
suction side and consequently reduce the intake volume flow.
• The short circuit depends on intake and discharge pressures and occurs at ap-
proximately 80% of the slide valve position. An precise value is to be determined
during operation, to guarantee economical operation of the system.
• If a short-circuit occurs, the compression discharge temperature and the power
consumption of the compressor increase, unless there is a pressure holding valve
installed on the ECO reservoir.
This operating condition is not critical for the compressor, as long as the maximum
compression discharge temperature of 120°C is not exceeded.
• The compressors have two ECO connections. Both connections, V1 and V2, have
the same low compression ratio.
ECO V1, V2
ECO connections V1 and V2 have the advantage that due to the lower pressure on
the connections more mass flow can enter into the compression chamber and as a
result provide a higher refrigerating capacity.
ECO connections V1 and V2 must only be operated at 100% slide valve position if the
equipment is running without a pressure holding valve on the ECO reservoir.
Depending on ECO mass flow, V1 is connected on its own or V1 and V2 are con-
nected together. The decision as to which connection to use will be taken by Aerzener
Maschinenfabrik on a case-by-case basis.
V4-009 P EN
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2.6 SOC operation
Liquid injection (refrigerant via SOC connections) can be used to lower the oil tempe-
rature as well as that of the pressure gas at the same time. SOC operation is possible
with a corresponding control group.
The compressor has two ECO connections with two different compression ratios. De-
pending on the set VI, the connection must be made according to the following table.
ENGLISH
VI = 2,2 bis 3,5 VI = 3,5 bis 5,0

S1 S2
Table 5: SOC connection dependent on the setting of VI
(VMY 156 - 356)
The SOC function depends on the suction and discharge pressure as well as the
pressure at the SOC connections.
If the SOC connection function should prove inadequate, please contact Aerzener
Maschinenfabrik.
26 V4-009 P EN
2.7 Unit components
2.7.1 Intake-side strainer
To protect the compressor against dirt and contamination, we recommend the use of a
strainer on the intake side. In practice, a mesh width of 0.5 mm has proven expedient
for the strainer.
ENGLISH
In addition we recommend installation of a commissioning strainer on the intake side
for the initial commissioning run and after repairs.
2.7.2 Oil filter
• At each oil change the filter element is to be cleaned or exchanged.

• The recommended maximum filter fineness is 0.01 mm.
• Design without bypass valve.
• The oil filter can be arranged as single or double filter.
• The filter cleanness must be monitored by means of differential “high” pressure.
• Only filter inserts with burst-protection must be used, to avoid destruction in case of
short-term reverse pressure.
• Layout of pipes for oil filter and fittings: see chapter 5 Installation.
2.7.3 Oil pressure control valve
The oil pressure control valve is to be designed for the total oil quantity of the
compressor’s mechanical pump and the oil quantity of the pre-lubrication pump.
The oil pressure is measured via a differential pressure transmitter. The measuring
points for transmitter are connection P3 (+) and P2 (-).
2.7.4 Coupling guard
In order to comply with the compressor ATEX classification, a solid coupling made
from non-sparking material such as brass must be provided and used between the
motor and compressor.
V4-009 P EN
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2.8 Sound pressure spectrum
Please refer the informations in the appendix.
Octave sound pressure spectra and average values at a distance of one metre from
the compressor.
The sound pressure relates exclusively to the compressor. Noises from the motor,
reservoir, pipes, etc. will increase this value.
ENGLISH
28 V4-009 P EN
2.9 Main exciter frequencies
The table below lists the main exciter frequencies for the compressors. If different ope-
rational speeds n are used from those given here, the formulae in the last two columns
should be applied.
ENGLISH
Speed 50 Hz 60 Hz n Hz
Drive type Main rotor Secondary Secondary Secondary Secondary Secondary
drive rotor drive rotor drive rotor drive rotor drive rotor drive
f1 (Hz) 33 50 40 60 4/6n n
f2 (Hz) 50 75 60 90 n 6/4n
f3 (Hz) 200 300 240 360 4n 6n
Table 8: Main exciter frequencies for VMY compressors with main and secondary rotor drive
2.10 Torsion frequencies
In order to determine the drive train frequencies that are critical from the point of
view of torsion, the system, consisting of the compressor, coupling and motor (driving
machine), must be considered as a whole. Aerzener Maschinenfabrik can provide you
with all the information you need to perform calculations on request.
2.11 Moments of inertia
moments of inertia kg/m2
VMY 156 M HR 0,055

VMY 156 M NR 0,123
VMY 256 M HR 0,181
VMY 256 M NR 0,406
VMY 356 M HR 0,510
VMY 356 M NR 1,150
V4-009 P EN
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3. Performance data / service data
Length of construction S H M
Suction pressure, p1 bar a min. 0,1 0,1 0,1
START bar a 40 26 26
max. with minimum slide valve
position
ENGLISH
Operation bar a 151) 91) 91)

max. with closed-loop control
Discharge pressure, p2 bar a max. 40 26 26
Static pressure, p bar a max. 40 26 26
Differential pressure bar max. 82) 82) 82)

mechanical oil pump
Intake-side pressure
drop on start-up bar max. 0,6
mechanical oil pump
Intake-side pressure
drop during operation- bar max. 0,4
mechanical oil pump
1)
The maximum suction pressure during operation depends on the VI installed. The maximum permissible
suction pressure must be clarified with Aerzener Maschinenfabrik.
2)
The maximum differential pressure of the mechanical oil pump must be safeguarded by means of a
safety relief valve or a pressure switch.
Table 9: Permissible service pressures
Minimum speed:
For details of the minimum speed, please refer to the appendix.
30 V4-009 P EN
Compressor size 156 256 356
Drive torque MA Nm 800 1750 3250
/ / / / /
The maximum peak moment (starting torque) must not exceed the 2,5-fold driving
moment.
ENGLISH
Table 10: Maximum torques
Compressor size 156 256 356

HR NR HR NR HR NR
Speed min-1 max. 4800 4600 4650 3600 4500 3000
/ / / / / / / /
6) It may be necessary to operate the compressor without a mechanical oil pump.

In this case, an electric oil pump should be used.
Table 11: Maximum speeds 6)
Caution !
Any applications involving speeds above 3600 rpm must
be clarified with Aerzener Maschinenfabrik.
V4-009 P EN
31
Oil pressure, pÖL
Total oil pressure bar p2 + 2.5 max. p2 + 3.0
Connection H
Injection bar p2 - 2.0 ≤ pÖL ≤ p2 + 2.5

X1, X2, X3
p2 Compressor discharge pressure, measured at P2

ENGLISH
Table 12: Permissible oil pressure
Temperatures
Intake temperature °C min. - 60 2) 3)
t1
Discharge temperature °C max. 120 4)

t2
2
Starting from -40°C the Aerzener Maschinenfabrik is to be contacted
3
Lower temperatures on request
4)
When regulating the discharge temperature via the injected oil volume the maximum discharge tempe-
rature must not be exceeded through overshooting even for a brief time.
Table 13: Permissible intake temperatures
VMY 156 M HR
(bar a) Balance piston
Suction pressure diameter (mm)
AKØ
/ /
/ /
Table 14: Selection of the balance piston diameter in accordance with the suction pressure
VMY 156 M NR
AKØ
/ /
/ /
VMY 256 M HR
AKØ
0-5 86
3-9 100
VMY 256 M NR
AKØ
0-6 86
4-9 100
32 V4-009 P EN
VMY 356 M HR
AKØ
0-3 100
2-9 126
ENGLISH
VMY 356 M NR
AKØ
0-2 100
1,5 - 4 110
3,5 - 9 126
4. Construction and function
4.1 Principle of operation
The screw compressor is a volumetric conveying machine with infinitely variable output
and oil injection. The compression of the sucked-in medium takes place in continuously
reducing chambers which are formed by the intermeshing of the rotors and the cylinder
walls.
The driving rotor with its gearing drives the secondary rotor. This eliminates the use of
timing gear wheels.
Oil is injected into the conveying chamber on the intake side. The oil lubricates the rotors,
seals the gaps between the rotors and the casing walls, and at the same time absorbs
a large part of the compression heat.
4.2 Bearings and lubrication
The rotors run on axial roller and radial slide bearings. To reduce the axial thrust via
the compressor’s differential pressure a balance piston has been provided.
The compressor is supplied with lubricating oil via the H connection, see dimensional
sheet.
The oil inside the compressor is fed to bearings, balance piston, slide valve and me-
chanical seal via this connection.
4.3 Lubrication and cooling of rotors
The cooling and lubricating oil for the rotors is injected directly into the compression
chamber between the rotors via connections X1 – X3. For the control of the volumetric
flow rate, solenoid valves and throttles are to be installed onsite.
V4-009 P EN
33
4.4 Control of volumetric flow rate
The volume is controlled by means of a hydraulically operated capacity slide valve

below the rotors. By varying the slide valve setting the conveyed volume is adjusted.
The compressor can reduce the volumetric flow rate via the 100% slide valve position
down to approximately 20%.
If further reduction of the volumetric flow rate is required a by-pass valve is to be in-
ENGLISH
stalled between the compressor’s discharge and intake sides.

The single-action and double-action hydraulics are described in the following. With
these two designs it may be necessary to set the adjusting speed of the slide valve via
a throttle valve. It should be observed, however, that throttling always takes place in
the oil return pipes.
4.5 Single-action hydraulics
The compressor is fitted with a single-action hydraulic cylinder for the control of the
volumetric flow rate.
Increasing the volumetric flow rate:

Connection Y1 on the compressor is connected with the intake side; with connection
W2, for example. The differential pressure presses the slide valve in the direction of
100%.
Reducing the volumetric flow rate:

The oil pressure of the compressor (pÖl) is applied to connection Y1 on the compres-
sor. The oil pressure presses the piston of the hydraulic cylinder, and with it the slide
valve, in the direction of 20% volumetric flow rate.
34 V4-009 P EN
4.6 Double-action hydraulics
As an option the compressor can also be fitted with a double-action hydraulic cylinder
for controlling the volumetric flow rate. The double-action hydraulics has the advan-
tage that a finer adjustment of the compressor can be made and, with a suitable con-
struction of the unit, the slide valve can also be driven during compressor standstill.
The double-action hydraulics are recommended for a differential pressure of up to 4
bar, since the compressor’s active differential pressure is not sufficient for pressing the
ENGLISH
slide valve to its maximum position.
Increasing the volumetric flow rate:

Connection Y1 on the compressor is connected with the intake side; with connection
W2, for example. At the same time connection Y2 is connected to the oil pressure of
the compressor. Now the oil pressure acts on the hydraulic piston in addition to the dif-
ferential pressure and moves the slide valve in the direction of 100% volumetric flow.
Reducing the volumetric flow rate:

The oil pressure of the compressor is applied to connection Y1 on the compressor. At
the same time connection Y2 is connected to the intake side of the compressor; with
connection W2, for example. The oil pressure presses the piston of the hydraulic cylin-
der, and with it the slide valve, in the direction of 20% volumetric flow rate.
4.7 Feed-back signal of slide valve position
The high-range displacement transducer supplies a 4 to 20 mA signal which indicates

the position of the slide valve. This signal can be employed in the control of the unit for
regulating the intake or the discharge pressure.
The high-range displacement transducer is fitted with a protective tube and can be
exchanged while the system is under pressure.
At delivery the transducer is calibrated. Transducers which are supplied as spare parts
are not calibrated as a rule. Installation and calibration are described in chapter 10.3.3.
V4-009 P EN
35
4.8 Internal compression ratio, VI
The ratio of the volume enclosed in the compressor at the start of compression and
the volume at the end of compression is called the internal compression ration (VI ).
The VI is dependent on the discharge pressure of the machine. The maximum inter-
nal pressure of the gas in the compressor shortly prior to opening of the compression
chamber to the discharge side is determined via the intake pressure. That is why the
compressors must be started in the minimum position of the slide valve to prevent
ENGLISH
damage due to excessive compression.

The compressor is equipped with a manual VI adjustment as standard. This makes
it possible to match the internal compression ratio to the external pressures. Here a
component, the slide valve stop, fitted to the intake side of the compressor is shifted.
This shifting alters the radial outlet of the compressor and with the internal compressi-
on ratio.
Outlet of the compressor and thus the internal pressure ratio. There is also the opti-
on of regulating the VI adjustment via a double-acting hydraulic system with its own
position transmitter.
The setting for the manual VI is described in chapter 8.1.
The VI controller with double-acting hydraulic chamber is described in Section 8.2.
4.9 Mechanical seal (GLRD)

The compressor is fitted with a single-action mechanical seal.
During continuous operation the oil leakage from the mechanical seal must be che-
cked daily.
Start-stop operation can increase the oil leakage rate.
The oil leakage quantity is to be recorded. Permanent drainage into a waste oil pipe is
therefore not recommended.
The waste oil is to be discharged via connection Z3 without danger of backing up and
must be properly collected.
Achtung ! Environmentally hazardous material.
The leakage rate from the mechanical seal is, among other things, dependent on:
- the conveying medium - the oil type - the discharge pressure
- the temperature - the rotational speed - the seal size
- ...
Therefore, only standard values can be stipulated for the leakage rate.
The standard value for the leakage rate of a seal pair can be between 2 to 10 ml/h.
36 V4-009 P EN
5. Safety before and during operation
ATTENTION! Alerts to all dangerous situations.
WARNING! Alerts to immediate danger to persons.
Upon arrival / receipt the compressor is to be checked for transport damage and com-
pleteness by means of delivery and order documents.
ENGLISH
Work safety regulations and notices as well as operating instructions must be observed.
The INFORMATION sheet must be read prior to commissioning. Any applicable notes
and changes contained therein must be carried out.
The tasks described as follows must only be carried out by qualified personnel who are
familiar with the functions of the compressor and its components and have been instructed
in the safety regulations.
The screw compressor meets European safety regulations. However, unavoidable tech-
nical risks for persons and property remain. To avoid these risks, operators must observe
the following safety instructions:

• Each person dealing with the construction, installation, operation, maintenance Read first -
and repair of this unit must have read and understood the operating manual. then operate!
• The following rules and regulations are to be observed: VBG 16 -> compressor gene-
VBG 20, DIN 8975, DIN EN 378 -> refrigerating plants, heat pumps, cooling devices.
ral,
• Responsibility for the operation must be precisely defined to avoid unclear compe-
tences.
• The warning signs and notices on the machine are to be observed. They provide
important information for safe operation.
• Next to the notes in the operating manual all legal general safety and accident-
prevention regulations are to be observed.
• Any work method interfering with the safety of the machine must be avoided.
• It is the user’s responsibility to operate the machine only in a sound condition.
• Before switching the machine on, the operator must have become familiar with the
safety, operating and monitoring elements contained in these operating instruc-
tions.
• Also the documents of the suppliers of accessories are to be observed! Observe

the safety, operating and maintenance instructions of the drive motor manufacturer!
• During operation with an acoustic hood all hood elements are to be closed before
starting operation and are only to be opened after the motor has been shut down
and the fuses removed or switched off.
• If the acoustic hood is opened while the machine is operating there is the risk of
sustaining serious injury!
• It is the operating company’s responsibility to use and operate the machine in
V4-009 P EN
37
accordance with its intended use and under consideration of local circumstances.
• The machine is to be operated only at a suitable and well-ventilated location. The

installation site must be free of excessive dust, acids, steam and explosive or
inflammable gases.
• Keep the intake area free from solid, liquid and powdery substances.
ENGLISH
• The machine must only be operated by qualified and authorized personnel. Ope-
rators must be expertly trained and instructed!
• Work on current-carrying components must only be carried out by trained, autho-

rized and qualified personnel. The machine must be disconnected from the power
supply prior to this work.
• When carrying out work on the unit the motor must be securely disconnected from
its power supply.
•
• Do not operate the unit when electrical connections are damaged, defective or not
properly connected.
• The safety devices serve to protect against injury and must not be modified or
bypassed.
• Do not operate the unit when protective devices such belt or coupling guard, acou-
stic hood elements, pressure valve, etc., are defective or missing.
• Do not carry out unprofessional repairs or modifications on the machine. In case

of problems contact Aerzener after-sales service for assistance.
• The machine must be used within its suitability range and performance limits.
• Do not remove protective guards, such as motor guard / EMERGENCY-OFF, safe-

ty devices, etc. while the machine is running. Risk of injury!
• Do not operate when electrical, mechanical or hydraulic connections, safety devi-

ces, pressure valve, etc., are defective or missing.
• Do not operate the unit with open, leaking intake or pressure collars / compressor
stage, because:
• Positive displacement machines are forced conveying machines with potential risk
of sustaining injury in the conveying chamber area. Danger from leaking gas.
• Lubrication and control pipes should only be retightened or opened while machine
is in a depressurized state.
• Bolted joints should only be retightened while the machine is in a depressurized

state. Risk of injury!
• Safety gloves must be worn on warm or cold operating temperatures of housing

surfaces!
• Conveying pipes, as well as components on intake or discharge side must not be

touched without adequate protection. Pipes and components on the discharge
side can have temperatures above 100°C; and in case of refrigerants, temperatu-
res well below 0°C.
38 V4-009 P EN
• Conveying pipes should not be disassembled until they have been relieved and
purged with neutral gas. The refrigerant must be properly disposed of. Environ-
mentally hazardous materials!
Environmentally hazardous materials!
• Use hearing protection during compressor operation!
• The installation site must be sufficiently ventilated.
ENGLISH
• There is danger of poisoning through inhalation and danger of burning through
touching when using cleaning agents and sprays.
• Do not clean the compressor with a high-pressure cleaner, steam-pressure clea-

ner, compressed air or similar. Chemical cleaning agents must only be used after
they have been tolerance tested on seals, oil and the conveying medium.
• Follow instructions by manufacturers and suppliers of component parts and obser-

ve general safety regulations!
• Before and during each starting phase the compressor is to be supplied with oil at
connection H via the pre-lubrication pump, see also dimensional sheet.
• Prior to initial operation a leak test is to be performed on the unit.
• All hand valves must be checked for proper position.
• Before operation with a refrigerant the compressor must be purged from foreign
gas.
• The measuring chamber of the axial thrust sensors is pressurized during operation
and filled with oil.
• For maintenance work the compressor must be properly shut down, depressurized
and degassed.
• Depending on the operating state the sound pressure level can vary from that sta-
ted in the operating data. A sound pressure level in excess of 80 dB(A) is therefore
possible for a short period.
• Observe oil temperature when changing the oil. The oil temperature must not
exceed 60°C. There is the risk of sustaining serious burns at an oil temperature in
excess of 60°C.
• Only suitable tools that correspond to the respective standards and design of the
bolts, nuts and fittings are to be used.
• When using diesel or petrol drive motors there is the danger of poisoning if there
is insufficient room ventilation. The installation site must be sufficiently ventilated.
Also observe the motor manufacturer’s operating instructions!
• Beware of edges and sharp contours on the compressor. Wear protective gloves
and round off the edges.
• Heavy loads during transport. There is the risk of being bruised or squashed! Life-
threatening!
For this reason, observe safety regulations when using only lifting equipment.
See dimensional sheet.
V4-009 P EN
39
• ATTENTION ! Risk of injury from flying parts during commissioning. Internal pres-
sure of conservation.
• Danger from poison and explosion as a result of escaping gases, due to defective
mechanical seal.
• Danger of destruction and from explosion due to the disintegration of the gas in
the compressor’s interior.
ENGLISH
• Danger of destruction due to excessive external forces and moments, such as

pipes, misalignment of compressor, unsuitable foundation, etc.
• Risk of injury from rotating components due to gripping, squashing or catching.
• Risk of poisoning from escaping gas as a result of leaky flange and pipe connec-
tions, etc.
• Risk of injury from inadequate or unsuitable protective clothing.
• Risk of injury due to incorrect understanding of safety symbols.
• The operator must obtain appropriate information and training.
• Working conditions that are safe and free from danger are to be guaranteed at the
installation site for commissioning, repair and maintenance work.
• When operating with gases containing oxygen, such as air, there is the danger
that the gas mixture could ignite. To prevent this, special safety measures are to
be provided and Aerzener Maschinenfabrik is to be contacted before the system is
commissioned.
40 V4-009 P EN
6. Inadmissible operating methods
• Unstable foundations, possible displacement of the compressor or the driving
motor.
• Solid or / and liquid particles entering the compressor’s intake side.
• Incorrect direction of rotation.
• Switching on - during run-down.
• - during reverse rotation.
ENGLISH
• Prolonged reverse rotation, > 3 seconds.
• Inadmissible pressure increase, pressure areas.
• Remaining under or exceeding rotational speed limits; refer to data sheets.
• Remaining under or exceeding temperature limits.
• Operation with insufficient or excessive oil pressure.
• Non-observance of operating data.
• Operating or starting the compressor with oil that does not meet the characteri-
stics prescribed in the lube oil specifications.
• Opened oil injection via connections X1, X2, X3 during pre-lubrication phase.
• Risk of flooding the compressor!
• Oil injection closed during and after the start phase.
• Lack of oil in compressor! Compressor damage!
• Oil-filled compressor, e.g. when the oil level in the oil reservoir is higher than the
discharge-sided compressor flange. (DN2).
• Risk of considerable compressor damage during starting!
• Start of compressor with slide valve outside MINIMUM position.
• Installing throttle valves in the feed pipe of the capacity slide valve.
• Maintenance work while machine is operating. Shutdown not carried out properly.
• Exceeding the maximum admissible vibration values.
• Simultaneous operation of ECO and SOC connections.
• Liquid refrigerant into the compressor via the ECO connection.
• Discharge pressure fluctuations during operation of more than + / - 0.5 bar.
• Sudden pressure fluctuations.
• Operation without a coupling guard.
“Reasonably foreseeable misuse” that can result from easily forseeable

human behaviour:
• Operating the machine without having filled the lubricant.
• Operating the machine with reduced intake performance, e.g. due to a soiled
intake strainer, starting strainer etc.
• Assembly and commissioning of the rotary piston machine with intake-side and/or
discharge-side flange sealers, protection covers or similar.
• Insufficient ventilation at the installation site.
• Open fire or sparks created by welding, separating or similar in direct proximity to
the unit. Risk of fire!
• Operating the machine without an isolated protective device, open coupling drive.
• Risk of injury from rotating components!
V4-009 P EN
41
7. Transport / storage / installation, assembly / alignment

7.1 Transport
When transporting the compressor the following points must be observed:

• Transport the machine only by means of devices intended for this purpose, see
dimensional sheet.
ENGLISH
• The machine must not be subjected to impact loads.

• The machine must be transported without oil, by means of a crane, fork lift, load
platform or similar.
• Observe total weight when selecting lifting equipment! See dimensional sheet or
the nameplate.
Notes on inspection or repair work that must be carried out at Aerzener Maschinenfa-
brik:
• The blind flanges used for conservation during delivery must be retained in order
to securely seal the compressor for transport and permit proper conservation at
AM.
• The compressor is to be transported without oil.
7.2 Storage
When storing the compressor the following points must be observed:
Intermediate storage in dry, clean and vibration-proof rooms.

The compressor must not be subjected to impact loads, vibrations and high temperature
fluctuations.
For protection from corrosion approximately 0.5 bar nitrogen should be applied to the
compressor’s interior. Protection from corrosion can only be maintained if all openings
on the compressor are tightly sealed.
The nitrogen pressure is to be checked every 4 weeks and adjusted if necessary.
For storage in excess of 6 weeks all external bare parts are to be protected.
External protection medium is to be checked every 4 weeks. “Bare components” may
need to be freshly protected or have paint damage repaired.
Disassembly of mechanical seal

When storing the compressor longer than 6 weeks the mechanical seal is to be disas-
sembled prior to commissioning. The seal rings are to be separated and cleaned. The
O-rings are to be checked before assembly and replaced if necessary.
See also 10.3.1.
42 V4-009 P EN
7.3 Installation, assembly
During installation the following points must be observed:
The following work must be carried out:
• Install compressor on the foundation, adjust the level and bolt down.
• The installation surfaces must be free from paint, burrs and contamination and be
ENGLISH
stable.
• Connect the oil and conveying pipes.
• If necessary, install accessories which are supplied separately.
• If necessary, install optional components.
• Ensure that lubricating oil supply is available.
• The installation site must offer adequate space for maintenance and repair work.
• Completely remove packing materials.
• Provide for adequate ventilation at the installation site / incoming and outgoing air.
• After removing the blind flanges and plugs, adequate protection must be provided!
Please retain the blind flanges.
• If necessary, consult Aerzener Maschinenfabrik.
• During installation protect the compressor from dust, dirt, drops of perspiration,
paint, etc.
• Provide noise protection! Sound radiation can induce natural vibration in pipes
and foundations.
• The foundation is to be designed sufficiently rigid to take up the operating forces.
The compressor must always remain in its designated position.
• The compressor must rest evenly; one or several adjusting plates may have to be
placed underneath.
Note: To compensate for manufacturing tolerances, the compressor should be
placed on alignment plates. This makes it easier to install a replacement compres-
sor.
• The housing must not be subjected to distortion when tightening the compressor
fixing bolts. Otherwise there is risk of considerable compressor damage.
• The oil level in the oil reservoir must not be higher than the discharge-sided
compressor flange. Otherwise the lube oil runs in the direction of the compressor
stage and fills it at standstill.
• Risk of considerable compressor damage during starting!
• When planning the plant yourself, additionally observe the safety instructions and
technical data of the component suppliers.
• Before commissioning ensure there is an adequate and proper lubricating oil
supply.
• Prior to initial operation provide for a strainer in the gas pipe on the intake side.
• This strainer should be fitted as far as possible in the direction of the suction fitting
of the compressor. When there is no more contaminant it can be removed.
• A permanent strainer is to be fitted to the gas pipe on the intake side.
• A bypass line with valve can be installed on the compressor to relieve the drive
motor during start-up. This valve opens during the run-up phase, thereby ensuring
pressure compensation between intake- and discharge side.
V4-009 P EN
43
Pipes / flanges
• The pipe between oil filter and compressor must be kept as short as possible.
• In addition, as many fittings as possible should be arranged between oil pump and
oil filter. This prevents the penetration of foreign particles into the compressor in
case a fitting fails.
• Discharge-side and suction-side pipes are to be fixed separately, to achieve a
stable connection.
ENGLISH
• The following table contains the maximum permissible loads on the flange.
• All pipes are to be installed stress-free at ambient conditions.

• Pipes for the intake and discharge sides may be adjusted, welded and in-
stalled only after the compressor has been aligned.
• Care should be taken that there are no straight and direct connections between
two fixed points. Thermal expansion may cause leakages or even lead to pipe
fracture.
• The pipes should always have at least one 90°-bend.
VMY compressor Intake-side flange Discharge-side flange

VMY 356 DN 200 DN 100
VMY 256 DN 150 DN 100
VMY 156 DN 100 DN 50
Nominal width of intake and discharge sided flanges
Table: 16
• CAUTION !
The flanges are realised with a groove according to DIN EN 1092-1 (shape D) and
with tapped blind holes.
44 V4-009 P EN
Maximum forces and moments
Flange Forces (N) Moments (Nm)

Axial (x) Vertical (y) Horizontal Axial (x) Vertical (y) Horizontal
(z) (z)
ENGLISH
DN 50 400 1000 250 600 600 600
DN 65 600 1500 375 900 900 900
DN 80 800 2000 500 1150 1150 1150
DN 100 1800 3000 1500 2450 1750 1750
DN 125 2100 3500 1750 2800 2000 2000
DN 150 3000 5000 2500 4200 3000 3000
DN 200 4200 7000 3500 5600 4000 4000
DN 250 5400 9000 4500 7000 5000 5000
DN 300 7800 13000 6500 10500 7500 7500
Maximum forces and moments for flange sizes of the VMY compressor
Table: 17
Y Vertical
Z Horizontal
X Axial
V4-009 P EN
45
7.4 Alignment
• A flexible drive coupling with an adapter is to be used.
• The coupling must compensate for and absorb the sum of all misalignments of the
compressor and the drive motor.
It must compensate for:
- angle error
- thermal increase
- alignment tolerances
ENGLISH
- concentric running tolerances

- displacement of rotors in the slide bearings due to gas forces
• The coupling serves for torque transmission.
• The operating data serve as a basis for maximum permissible moments and forces.
• In case of drive motors with slide bearings the flexible coupling is to be secured by
an axial stroke limiter. This prevents the coupling from sustaining damage when the
rotor of the motor moves due to variations in load.
• Due to settling and displacement behaviour a maximum of 3 shims are to be placed
under the compressor for adjustment.
• To avoid assembly stress the alignment screws must be fully screwed back before
the base screws are tightened.
• After a test run lasting approximately 2 hours the shaft alignment is to be checked
in a warm state: see also radial alignment.
Axial run-out measurement
Clean coupling halves and shaft ends.

Install coupling halves.
Fit a dial gauge according to illustration “Axial run-out measurement example” .
Turn the compressor shaft slowly and evenly.
Measure run-out.
Measure the motor shaft in the same fashion.
The run-out of the coupling surface area must not exceed the tolerance value of
0.05 mm at a distance of 50 mm to the axis of the shaft!
Tolerierter Planlauf
0,05 mm
Planlaufmessung / Messbeispiel
46 V4-009 P EN
During the axial alignment the following points are to be observed:
• The alignment of the drive coupling is to be carried out with two dial gauges or other
suitable means of measuring.
Axial measurement Example for direct coupling of compressor>coupling>motor.

• The maximum permissible axial run-out is 0.08 mm at a distance of 50 mm to the
axis of the shaft.
• The axial run-out of both coupling halves = axial angle offset, is to be measured with
ENGLISH
2 dial gauges to offset an axial deviation of the shafts.
Unit = 1/100mm 20 20 20/23

I A II III B
B A
27 25 27 25
B A
20 20 20/24
20/23 43 21,5
IV V VI
A B
27/24 25/24 51 49 25,5 24,5
20/24 44 22
Mittelwert
Axiale Messung / Messbeispiel
Measuring procedure
I  Set both gauges to a common value, e.g. 20 (1/100mm),.
II  Turn both coupling halves simultaneously. They must always remain in the
same position to each other during measurement.
III IV  The values on gauges A and B must be recorded at each quarter turn.
V
 The values obtained must be added, then halved = mean value.
VI  Result = corresponding difference.
V4-009 P EN
47
During radial alignment the following points are to be observed:
Radial measurement
• The drive shaft of the compressor changes its position with regard to radial bea-
ring clearance. This deviation needs to be taken into account on the basis of the
following drawing.
• Thermal expansion behaviour / increase is to be taken into consideration.
• When compressor and motor base are similar, a height adjustment for the axis
ENGLISH
is only of marginal importance since there is “synchronous expansion” between

compressor and motor.
• External forces such as the connection of piping and their temperature fluctuations
can appreciably alter shaft alignment.
• Such negative effect is to be avoided!
• After a trial run of approximately 2 - 3 hours the shaft alignment is to be checked
in a warm state.
• Shaft spacing “X” between compressor and motor is to be maintained in order to
have enough room for repair and maintenance work.
• A flexible drive coupling with an adapter is to be used.
• Dimension “X” is found in the dimensional sheet.
Radial measurement
Measurement example
V Motor
Compressor
Side view
X
Main rotor drive
H
V= Vertical Motor
alignment Intake connection
H= Horizontal
alignment
X= Shaft spacing
Compressor
View from top
Intake connection
Motor
Compressor
View from top
Secondary rotor drive H
48 V4-009 P EN
H-setting in V- setting
Values in 1/100 mm cold state warm state cold* / warm*
VMY 356 10 6 9
VMY 256 8 5 7
VMY 156 7 5 7
ENGLISH
* Synchronous growth of motor and compressor, see also text
Table 18: adjustment data
V4-009 P EN
49
8. Commissioning
The compressor is to be installed in accordance with all instructions stated in the

chapters of this manual.
All necessary pipes are to be connected to the compressor stage.
Ensure that the gas pipe on the intake side and the oil supply pipe are free from conta-
mination and foreign matter.
ENGLISH
Prior to initial operation:

All safety devices, control elements, ... are to be checked for function, correct direction
of flow, continuity of passage, etc. Carry out a leak-proof test on the machine.
Observe rotational direction of drive motor, see marking on the compressor, see also
dimensional sheet.
Carry out a rotational direction test in uncoupled state.
Couple motor to compressor only when rotational direction is correct.
ATTENTION ! Incorrect rotational direction destroys the compressor.
Main rotor drive Secondary rotor drive
How direction of rotation is marked on compressor
50 V4-009 P EN
The following procedure is recommended for initial commissioning:
1. Warm-up phase (when required), (oil, unit components, compressor)

2. Pre-lubricating phase
3. Start-up of compressor
After approximately one minute, switch off and monitor compressor run-down,
see chapter 9.
ENGLISH
4. Re-start the compressor
Observe instructions for drive motor
5. Check EMERGENCY-OFF button
6. Start compressor
If no faults occur the compressor can be started and brought up to operating
pressure in stages. Simultaneously check the compressor, pressures and tempe
ratures, coupling performance and noises or vibrations,
7. After a 3-hour operating period (after reaching constant pressures and tempera
tures): stop the compressor.
Inspect the compressor for leakages, bolted connections, and check alignment.
8. Labels with safety instructions must be legible and safety devices tested.
When everything functions without problems the unit is ready for operation!
The output data specified by Aerzener Maschinenfabrik must not be exceeded.
Regulations and operating instructions of the system manufacturer are to be

observed!
Adhere to the maintenance plan!
When safety elements respond the compressor is to be shut down immediately and
the cause rectified. In case of technical problems consult the Aerzener Service Dept.
V4-009 P EN
51
8.1 Setting the internal pressure ratio
This setting must only be made with the slide valve set at partial load; otherwise it
will create tension between the slide valve and the slide valve stop. If this cannot be
guaranteed, it must be assured that the slide valve can move freely. This means that
the valves which supply the slide valve’s hydraulic cylinder; connections Y1 and Y2,
must be open.
Adjustment of VI must only be carried out during machine standstill.
ENGLISH
ATTENTION ! The housing could be under pressure and gas could leak out. Appropri-
ate safety measures are to be taken.
If the safety of personnel cannot be guaranteed the compressor is to be degassed and
the pressure relieved.
The following procedure is prescribed for setting the internal compression ratio.
The following position numbers refer to the sectional drawing of the compressor.
1. Removal of the cap, position 375.

Take care when removing the cap, since the interior could be under pressure! The
gas can escape through a pressure relief hole. Use suitable safety measures!
Note:
If gas escapes when the cap (position 373) is opened, it means that the seal (posi-
tions 380, 381) is not tight.
2. Loosen hexagon nut, position 359.

By loosening the hexagon nut the guide rod fixture is lifted.
3. Loosen the cylinder screws, position 365.

First turn each screw by 45°. Then again turn all screws in turn by 45°.
ATTENTION ! Do not remove the screws under any circumstances. If the com-
pressor is internally pressurised the guide rod could shift suddenly!
4. Setting the desired VI .

By using the following table turn the adjusting ring, position 366, and set the
desired VI via dimension A, see Figure 7, Table 19.2 or diagram 1.
5. Tighten the cylinder screws, position 365.

Tighten the cylinder screws with a torque wrench crosswise. The required torque
is specified in Table 19.1.
6. Tighten the hexagon nut, position 359.
7. Install the cap, position 375.
VMY 156 256 356

Screw size M8 M8 M8
Torque 14 Nm 14 Nm 14 Nm
Table 19.1: Tightening torque for position 365
52 V4-009 P EN
ENGLISH
Fig. 7: Definition of dimensions for setting the compressor's VI
VI Dimension A Dimension B
(mm) when the slide valve is in the
maximum position (mm))
VMY 156 VMY 256 VMY 356 VMY 156 VMY 256 VMY 356
2.2 96,8 116,1 146,3 46,2 50,0 56,8
2.3 92,5 110,7 137,1 50,5 55,5 66,0
2.5 82,9 98,7 121,7 60,1 67,4 81,4
2.9 67,5 78,9 96,6 75,5 87,2 106,5
3,0 / / 90,6 / / 112,5
3.5 50,4 57,3 70,5 92,6 108,2 132,6
4.0 40,2 44,3 53,4 102,8 121,8 149,7
4.5 32,4 34,4 40,8 110,6 131,7 162,3
5.0 26,5 26,9 29,3 116,5 139,2 173,8-
Table 19.2: For other VI values, linear interpolation is possible between the values
specified in the table.
Alternative: Please use the diagram below.
Dimension B
when the slide valve is in the
minimum position (mm))
VMY 156 VMY 256 VMY 356
257,5 347,0 390,7
Table 19.2-1
V4-009 P EN
53
ENGLISH
54
Vi-Verstellung / Vi-adjustment VMY .56er Serie
150
145
140
135
130
125
120
115
110
105
100
95
90 VMY156 VMY256 VMY356
85
V4-009 P EN
80
75
Maß A / Measure A [mm]

70

65
60
55
50
45
40
35
30
25
2,2 2,3 2,4 2,5 2,6 2,7 2,8 2,9 3,0 3,1 3,2 3,3 3,4 3,5 3,6 3,7 3,8 3,9 4,0 4,1 4,2 4,3 4,4 4,5 4,6 4,7 4,8 4,9 5,0
Vi
8.2 Automatic-VI
Compressors can also be fitted with a double-acting hydraulic chamber to adjust the
VI, see the following Figure 8.
This makes it VI infinitely adjustable in the range of 2.2 to 5.0.
Since the VI of the compressor changes under partial load (opening the internal
bypass causes the volume to change at the beginning of the compression), regulation
of the VI is only effective when the capacity slider is at maximum, i.e. when the inner
ENGLISH
bypass is closed.
A pictorial schematic of the hydraulic regulator is shown in Figure 9 below.
When adjusting the VI, heed the following instructions:

• The VI-hydraulic system is not able to move the capacity slider when under load.
The VI can only be adjusted when the capacity slider is under partial load or when
it is moved simultaneously in the appropriate direction via the hydraulic system of
the capacity slide.
• The differential pressure of the compressor may produce high pressure in the VI
hydraulic system. The system must therefore be provided with appropriate safety
valves, as stated in Table 19.3.
• Since it is not practical to re-calibrate the position measurement of the capacity
slide, ZT01, during each VI adjustment, this position measurement is calibrated to
100% carriage travel (20 mA) at a VI of 2.2.
• The signal for the maximum position (100% flow) of the capacity slider is thus
dependent on the position of the VI slide. When starting up, set the VI slider to
the maximum VI of 5.0 and move the VI capacity slider to 100%. The signal of the
capacity slider position then displayed gives the maximum position of the capacity
slider for a VI of 5.0, see Table 1, Page 13.
• The position measurement of the VI-slider, ZT02, is calibrated to give 20 mA at a
VI of 2.2 and 4 mA at a VI of 5.0.
Note: With the EX versions of the high-range displacement transducer, the direc-
tion of the current rise is fixed.
VMY 156 256 356

max. pressure [bar g] 60 80 120
Table 19.3:
Maximum pressure in the hydraulic chamber of the Automatic VI
V4-009 P EN
55
8.2.1 Functional description of the VI regulator
Regulating the VI is only practical when the capacity slider is at 100%. When the capa-
city slider is at the partial load position, a gap opens between the capacity slider and
the VI carriage and moving the VI carriage has no effect on the VI of the compressor.
The regulator should only be active when there are larger changes in suction or final
pressure, since (as described below) setting the VI also affects the flow and therefore
the suction or final pressure. The VI values from the Aerzener layout can be used as
the setpoint value. At the same time, the VI regulator can be used to optimise the po-
ENGLISH
wer consumption of the compressor. In this case, the VI is adjusted until the minimum
power consumption is achieved.
When adjusting the VI, note that the hydraulic system of the compressor consists of
two hydraulic rams which can interfere with one another. As Figure 9 shows, the VI
carriage can only be adjusted in the direction of the higher VI when the capacity slider
is simultaneously moved in the direction of a smaller volume flow.
In the rest position, all solenoid valves should always be closed to prevent gas emissi-
ons from forming gas cushions (connection to T = tank, suction) which could delay the
movement of the carriage.
The oil supply pressure P is the normal oil pressure of the compressor.
We recommend using throttle valves to adjust the adjustment speeds on the system.
8.2.2 Increasing the VI

All solenoid valves are closed and the capacity slider is at 100% flow. Valves XV02,
XV03 and XV05 open at the same time. Because of the various hydraulic systems or
pressure losses, the adjustment speed of the capacity slider can be greater than that
of the VI carriage. The valves must therefore remain open until the VI carriage has re-
ached the desired position. Valves XV02, XV03 and XV05 then close again. After this,
the capacity slider must be moved back to the VI carriage by opening XV01. Once the
100% position has been reached, Valve XV01 closes again.
Table 1, Page 13 can be used here also. The capacity slider moves to a value slightly
above the desired VIs and, once the VI carriage has reached the desired position,
moves back to 100% flow.
Please note that the flow rate of the compressor changes as soon as the capacity
slider and the VI carriage have lost contact, i.e. the internal bypass is open.
8.2.3 Decreasing the VI

All solenoid valves are closed and the capacity slider is at 100% flow. Valves XV01,
XV04 and XV06 open at the same time. Because of the various hydraulic systems, the
adjustment speed of the VI slider may be greater than that of the VI carriage. The val-
ves must therefore remain open until the VI carriage has reached the desired position.
Valve XV01 must remain open until the capacity slider has reached the VI slider. XV01
then closes again.
56 V4-009 P EN
ENGLISH
Figure 8: Double-acting hydraulic system for adjusting the VI
 
 







 


 


 


Figure 9: Basic diagram of the hydraulic regulator
V4-009 P EN
57
8.3 Compressor with double-action mechanical seals
In case of compressors with double-action mechanical seals with their own oil-buffer
unit, the oil-buffer unit must be pressurised before the compressor unit is pressurised.
Please observe the operating instructions of the manufacturer of the mechanical seal
or the oil-buffer unit.
ENGLISH
8.4 Refrigeration plants

The compressor unit must be properly purged before it is filled with refrigerant. Inclu-
sion of foreign gases must be avoided. Carry out a leak-proof test on the compressor.
Leakages are to be eliminated immediately.
The unit is to be slowly filled with refrigerant from the compressor’s intake side. The
pressure must rise only very slowly. The compressor must not be operated through the
filling process.
8.5 Warming up phase, pre-lubricating phase
The characteristics of the oil in the pre-lubricating phase must correspond with those
in chapter 2.4. Take note that the compressor in a cold state can raise the oil’s viscosi-
ty through cooling.
It is therefore recommended to heat up the cold compressor with warm oil before the
pre-lubrication phase. For this the housing drainage, connection A, should be con-
nected. At the same time, care should be taken that there is sufficient height between
the compressor’s pressure-side flange, connection DN2, and the oil level in the reser-
voir.
Both during the pre-warming phase and the pre-lubrication phase, only connection H
is to be supplied with oil. The connections for injection, X1 to X3, must remain closed.
With the start of the warm-up phase the slide valve must be moved to the minimum
position via connection Y1. This prevents the oil from banking up in the compressor.
If there is no warm-up for the compressor the slide valve must be moved to minimum
position with the start of the pre-lubrication phase.
The pre-lubrication pump must be able to generate an oil pressure of 1.5 – 2.5 bar,
measured at connection P3.
The following criteria suffice for releasing the start for the compressor:
- System without error, no alarm or trip signal active
- Oil characteristics correspond to lube oil specifications, see 2.4.
- The slide valve is in minimum position.
- There is an oil pressure of at least 1.5 bar for at least 15 seconds.
- The intake pressure lies in admissible range, see chapter 3.
- Connection A, drain of the intake-side housing, is closed.
- If the unit has a bypass valve between the compressor’s intake and discharge
side, then this valve is to opened until the compressor reaches minimum rotational
speed.
It is recommended to switch the pre-lubrication pump off approximately 30 seconds

after the compressor has reached nominal speed.
58 V4-009 P EN
8.6 Start-up of compressor
With the start signal of the motor the oil must be injected via connection X1, and if
necessary X2 and X3.
The compressor must not be operated without oil injection!
The minimum injection quantity is stated in chapter 2.2.8. After failing to start three
ENGLISH
times the compressor is to be turned by hand.
8.7 Compressor operation with frequency converter
When using a frequency converter to trigger the electric motor the following instruc-
tions are to be observed.
The oil for the compressor must be supplied by an external oil pump to prevent an
insufficient supply of oil at low rotational speeds. In this case the compressor must be
designed without a mechanical oil pump.
The compressor is started with the slide valve in minimum position.
The rotational speed of the compressor is to be brought up to minimum speed as quic-
kly as possible, see chapter 3.
When the compressor’s intake pressure lies within specification, the slide valve can
be moved to maximum position. After this the compressor’s volumetric flow can be
regulated via the speed.
The same applies to the shutdown: Reduction of the compressor’s rotational speed to
minimum speed, moving of the slide valve to minimum position, shutdown of motor.
• With the addition of a frequency converter the electrical and mechanical characte-
ristics of the drive motor are to be taken into account.
• The frequency converter must be designed with a constant load moment for ope-
ration with a working machine.
• Rotational speeds must no fall below minimum nor exceed maximum.
• The maximum frequency is to be set by taking into account the maximum rotatio-
nal speed of the motor and the maximum speed of the compressor.
• Recommended rotational changeover speed: 1 Hz/s
• To prevent operational faults the function “Interception circuit” must not be para-
meterised in the control of the frequency converter. When the frequency converter
is switched off, a restart should only be possible after a complete standstill. Here
the switch interlock of the electric motor must be taken into account.
V4-009 P EN
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9. Shutdown
The unit is to be appropriately designed and must guarantee the following features.
• Switch off drive motor

• If the motor is shut down during operation, backpressure slows down the compressor
and causes it to stop quickly.
• The non-return valve built into the pipe on the intake side prevents the compressed
ENGLISH
gas from re-expanding via the rotors towards the intake side, and thereby the com-
pressor from running in reverse.
• Note: Prolonged reverse running is to be prevented by means of appropriate unit
construction.
• During prolonged shutdown, the fuses on the drive motor must be pulled, to prevent
an unintentional start-up of the compressor.
• Ensure preservative protection for the unit during shutdown of more than 2 weeks!
Please also observe storage and mothballing guidelines TN01175... .
In case of danger:
• Press EMERGENCY - OFF button. For details refer to the instructions of the supplier
of electrical components or the plant manufacturer.
60 V4-009 P EN
10. Maintenance / repairs
The service and maintenance of the compressor stage consists of the following points.
If anything is unclear consult Aerzener customer service.
During inquiries please state:

• order and serial number.
• prevailing faults / malfunctions as accurately as possible.
ENGLISH
• steps taken to rectify faults.
• process data such as intake and discharge pressure, intake and discharge tempe-
rature, oil type, oil temperature, conveyed gas.
If the compressor is sent back to the supplier, please carry out the following:
• Uninstall the compressor from the plant according to instructions.
• Dispose of conveying medium, such as refrigerant, properly.
• Completely drain oil, otherwise it is transport of hazardous goods.
• Treat bare external parts with preservation oil.
• Flush compressor with nitrogen.
• Seal compressor flange with blind flange.
• Seal open connections.
• Pressurize compressor with approximately 0.5 bar (above) nitrogen.
• Also see chapter 7, transport.
Spare parts and accessories

We expressly point out that replacement parts and accessories not supplied by us
have neither been tested nor approved by us. The installation or integration and use of
such products can under certain circumstances alter the original design characteristics
of the system. Aerzener Maschinenfabrik does not accept any liability for damages
resulting from the use of non-original parts and accessories.
V4-009 P EN
61
10.1 Maintenance plan, inspection schedule
For all maintenance and repair work the compressor must be switched off and proper-
ly shutdown.
This is to avoid the risk of injury and damage to the equipment!
ENGLISH
Period in operating Mechanics Lubrication

hours (Oh)
After the first 3 Ohh • Check all flange connections • - Check for oil leakages
and bolted connections for
proper seating
• Check for leakages
After the first 50 Oh • Check strainer on intake pipe,
remove if contamination has
ceased
Daily checks • Check compressor for unusual • Check oil supply
noises or vibrations • Check leakage quantity from
• Check intake strainer for pressu- mechanical seal
re loss and clean if necessary
• Check for leakages
After 500 Oh • Carry out oil analysis, check
viscosity, contamination and
ageing. Clean or change oil filter
when changing oil analyse
After every 2000 Oh • Check safety instruments • Carry out oil analysis, check
approx. every 3 months • Clean intake strainer viscosity, contamination and
ageing. Clean or change oil filter
when changing oil
Afterevery 8000 Oh • Check coupling alignment • Change oil
Approx. once a year • Check solenoid valves • Clean or change oil filter when
• Check thrust bearing clearance changing oil
After 3 years or 20 000 General inspection by an Aerzener service technician. A preventive overhaul
Oh of wearing parts such as bearings, seals, etc. will be carried out at this time.
Accessories will be checked.
We recommend stocking wearing parts to avoid waiting and downtime in case
of malfunction.
The maintenance dates will be repeated at the intervals stated.
Maintenance intervals for the accessories are contained in the respective instructions of the manufacturer!
Table 21: Maintenance plan, inspection schedule
62 V4-009 P EN
10.2 Fault diagnosis
Faults Possible causes / remedy

Intake pressure too low • Check fittings on the intake pipes
• Intake strainer, strainer contaminated
• Compressor output too high, incorrect position of capacity slide
valve
• Incorrect calibration of high-range displacement transducer
Intake pressure too high • Pressure change in gas feed
ENGLISH
• Incorrect position of capacity slide valve
• Conveying output of compressor too low
• Incorrect calibration of high-range displacement transducer
Discharge pressure too low • System usage too high
• Compressor does not reach 100% setting / check calibration of high-
range displacement transducer
• Unit has a bypass between intake and discharge side
Discharge pressure too high • Check fittings and strainer on the pressure pipe
• Slide valve is set too high, calibration of high-range displacement
transducer
Discharge temperature too • Injection volume too high
low • Oil temperature too low, check oil cooler and oil temperature mixing
valve
Discharge temperature too • Internal compression set too high
high • Oil injection too low
• Oil temperature too high
• Intake temperature too high
Unusual noises • Bearing damage, check axial clearance and radial bearing
• Oil injection volume too low
• Check coupling alignment
• Call Aerzener service
Unusual vibrations • Oil injection volume too low
• Check coupling alignment
Oil pressure too low • Oil pump output too low
• Discharge pressure too high
• Oil pressure control valve defective or set incorrectly
• Injection volume too high (discharge temperature)
• Internal usage too high, inform customer service, oil pressure control
valve defective or set incorrectly
Oil pressure too high • Oil pressure control valve defective or set incorrectly
Oil temperature too low • Oil temperature control valve defective
• Compression discharge temperature too low
Oil mtemperature too high • Oil temperature control valve defective
• Oil cooler water contaminated
• No cooling water
Capacity slide valve

Moves independently in • Seal of piston for adjustment of capacity slide valve defective
direction of 100% • Solenoid valve for adjusting capacity slide valve defective or incor-
rectly connected
Does not move to 100% • Incorrect calibration of high-range displacement transducer
position • Solenoid valve for adjusting capacity slide valve defective or incor-
rectly connected
• Differential pressure via compressor too small
Does not move to 0% • Incorrect calibration of high-range displacement transducer
position • Solenoid valve for adjusting capacity slide valve defective or incor-
rectly connected
Does not reachthe required • Incorrect calibration of high-range displacement transducer Mainte-
position nance work
Table 22: Faults and possible causes
V4-009 P EN
63
10.3 Maintenance work
It is absolutely necessary to use the toque settings for screws listed in the appendix.
10.3.1 It is absolutely necessary to use the toque settings for screws listed in
the appendix.
ENGLISH
The housing of the compressor must be depressurised before changing the mecha-
nical seal. Additionally, hazardous gases must be evacuated and the housing made
inert.
10.3.1.1 Removal of mechanical seal, inspection of driving collar and seal bu

shing
Remove the cylinder screws, Position 145, and carefully pull the cover, position 120,
from the housing. Remove the stationary part of the mechanical seal from the cover.
Due to the oil between the sealing rings of the mechanical seal the stationary part of
the mechanical seal can get stuck in the compressor. In this case the complete me-
chanical seal can be carefully pulled from the drive shaft. Attention: Secure both parts
of the mechanical seal together in case they separate after removal from the housing.
Check the surface of the parts of position 122 and 123 and replace if necessary. To
disassemble the driving collar (position 122), loosen the setscrews (position 147)
through the bore in the housing cover (position 16) locked with a locking screw 81 and
seal ring 91 (connection L3), see dimensional sheet, with at least three turns. Then
pull the driving collar from the shaft.
To disassemble the seal bushing (position 123) remove the circlip (position 143).
Remove the setscrew (position 148) and use a suitable pull-off device to pull the
sealing ring plus seal bushing (positions 123 / 124) out of the sealing cover. Following
disassembly, the O-ring (position 141) must be replaced.
64 V4-009 P EN
ENGLISH
V4-009 P EN
65
10.3.1.2 Installation of driving collar, seal bushing and mechanical seal
Prior to mounting the new driving collar, position 122, install the cylinder pin, position
135, so that it projects 4 mm + 0.5.
When installing the driving collar, position 122, observe the setscrews, position 147,
are secured with a screw locking device according to specifications on the sectional
drawing.
Slide the rotating part of the mechanical seal – the part with the spring – carefully onto
ENGLISH
the drive shaft and position on the cylinder pin, position 135. Pay careful attention to
cleanliness and do not touch the sliding surface of the mechanical seal. Do not coat
the sliding surface of the mechanical seal with oil or grease!
Check the cylinder pin, position 135, in the cover for correct seating. The cylinder pin
may project inside 4.0 mm + 0.5.
Coat the O-ring of the stationary part of the mechanical seal with oil and insert in the
cleaned cover. Now carefully insert the stationary part of the mechanical seal and
push over the cylinder pin. Check for correct seating.
Insert the seal bushing, position 123, into the cover and secure with the setscrew,
position 148. Attention: The seal bushing must be able to move freely. The setscrew is
to only prevent the seal bushing from rotating. The secure the setscrew with a suitable
screw locking device, see sectional drawing.
The setscrew is to be screwed in until it no longer projects out.
Install the seal ring, position 124, with a new O-ring, position 141, into the cover and
secure with the circlip, Position 143.
Push the cover with the new O-rings, position 140, and with installed parts carefully
onto the drive shaft and secure with the cylinder screws, position 145.
To prevent impacts which could result in displacement of the static part of the mecha-
nical seal, the sealing cover should be carefully pressed into the housing cover using
two threaded rods plus hexagon nuts.
10.3.2 Checking thrust bearing clearance
Fix a micrometer screw with a magnet bracket to the compressor housing and set it
on the drive shaft in axial direction on the front of the drive shaft. Press the drive shaft
into the compressor until the indicator of the micrometer screw no longer changes. Set
the micrometer screw to zero. Pull the drive shaft from the compressor with a pulling
device until the indicator of the micrometer screw no longer changes. The thread of
the drive shaft can be used.
66 V4-009 P EN
Compressor Thread to DIN 13
VMY 356 M 12
VMY 256 M 12
VMY 156 M 12
Tabelle 23: Drive shaft thread specification
ENGLISH
Compressor Axial play (mm)
VMY 356 0,03
VMY 256 0,02
VMY 156 0,01
Tabelle 24: Maximum permissible axial play
VMY 356 256 156

max. axial force 5 kN 5 kN 5 kN
CAUTION! Do not apply any unnecessarily high
forces
Table 25: Maximum permissible axial force when measuring the axial
play
V4-009 P EN
67
10.3.3 Exchange and calibration of high-range displacement transducer
The high-range displacement transducer is fitted with a protective tube and can be
exchanged while the machine is under pressure.
ATTENTION ! All work carried out while the compressor is under pressure is dan-
gerous. Appropriate protective measures are to be taken.
10.3.3.1 Removal and installation of high-range displacement transducer

ENGLISH
Remove the plug of the high-range displacement transducer and remove the screws,
position 444. Now the transducer can be carefully pulled out of the protective tube.
Before installing the new transducer, check whether the insulating plate is installed
between the control cylinder and transducer and the guide ring at the end of the pick-
up. Insert the new high-range displacement transducer into the protective tube and
secure with the screws, position 444.
Restore the electrical connection.
10.3.3.2 Calibration of high-range displacement transducer
For delivery the high-range displacement transducer is calibrated for a VI of 2.2. This
means that the pickup at the minimum position of the slide valve, the compressor
conveys the smallest possible volume flow, supplies 4 mA and at maximum position
20 mA.
By adjusting the VI the slide valve is moved and when the calibration remains unalte-
red, at maximum position of the slide valve the transducer supplies a smaller current,
see chapter 2.2.1.
When the transducer is replaced it must be newly calibrated, since a reliable calibra-
tion can only be made together with the compressor. At the same it may be required
that the transducer, during maximum load and the individually set VI, which deviates
from 2.2, supplies 20 mA. In such cases the transducer must be re-calibrated.
68 V4-009 P EN
The high-range displacement sensor is calibrated as follows:
Ex-free version
1. Connect the sensor as specified, see chapter 2.2.1 and operating manual of
sensor, supply with current and wait at least 5 minutes before calibrating.
2. Move the slide valve to minimum position.
To do this, apply oil pressure to connection Y1 via the prelubrication pump.
Under normal conditions the slide valve will reach minimum position after ap
ENGLISH
proximately 45 seconds. To check the minimum position of the slide valve,
dimension B, see chapter 8.1, Fig. 7, can be re-measured.
The slide valve is in minimum position when B corresponding the values in
table 19.2-1.
ATTENTION ! Dimension “B“ can only be re-measured in the depressuri
sed and degassed compressor. There may be residual gas in the compressor!
Use suitable safety measures! The compressor is to be closed after the mea
surement is completed.
3. Remove the screw cap from the transducer and press the calibrating button
once. The red LED will light up continuously for a brief period.
When the LED starts to blink, calibrating for the maximum position of the slide
valve can begin.
4. In case of a compressor with single-cavity hydraulic chambers the unit must
now be started and operated at a minimum differential pressure of 2 to 3 bar.
The Y1 connection is then to be connected to the compressor’s discharge
side.
The discharge pressure now presses the slide valve to maximum position.
When the power consumption of the electric motor no longer rises, the slide
valve is in maximum position. Press the calibrating button again. The red LED
will light up continuously for a brief period.
When the red LED extinguishes the calibration is finished.
To confirm that the slide valve has reached maximum position, dimension B
(see dimensional table in Section 8.1) can be checked.
ATTENTION ! Dimension “B“ can only be re-measured in the depressurised
and degassed compressor. There may be residual gas in the compressor! Use
suitable safety measures!
5. Reinstall the screw cap on the transducer.

There also is a green LED under the transducer’s screw cap. When the slide
valve is in a position higher than 95% this green LED is permanently lit. When
the slide valve is in a position of less than 5 % this green LED blinks quickly.
From 95 - 5%, the LED flashes slowly.
V4-009 P EN
69
EX displacement sensor
1. Connect the sensor as specified, see chapter 2.2.1 and operating manual of
sensor, supply with current and wait at least 5 minutes.
The red LED flash.
2. Keep the calibrating button pushed for five seconds.
The red LED will extinguish.
3. Move the slide valve in minimum position, see item 2 EX-free version. Push
ENGLISH
the calibrating button once. The red LED will light up permanently.
When the red LED extinguishes the displacement sensor is ready for 100 %
calibration.
4. Move the slide valve in maximum position and push the calibrating button
twice. The red LED will flash quickly. When the red LED flashes slowly the
calibration is completed.
The green LED indicates the final position: If the slide valve is at position smaller 1 %,
the green LED flashes. If the position is higher 99 % the LED lights up permanently.
Between 1% and 99% is the green LED off state.
In order to save energy the LEDs will extinguish after five minutes. They can be activa-
ted by means of a short actuation of the calibrating button.
70 V4-009 P EN
10.3.3.3 Calibration for operation during summer and winter
When the compressor is operated with two different VI’s it may be practical to re-cali-
brate the transducer for these VI’s. The procedure is as follows:
ENGLISH
1. Setting of the smaller of the two desired VI’s, see chapter 8.1.
2. Calibrate as described in chapter 10.3.3.2.
3. Setting of the larger VI and measuring the current of the transducer.
This current is to be used in the system control as 100% signal when the larger VI has
been set.
V4-009 P EN
71
11. Recycling / disposal
• Dispose of or process all waste products in an environmentally compatible man-
ner.
• The waste oil is to be properly disposed off.
• Ko Package and decontaminate all contaminated components and auxiliary mate-
rials.
ENGLISH
Recycling Entsorgung
72 V4-009 P EN
12. INFORMATION PAGE
The AM works standardTN0 1073 / screw torque settings is to be obser-

ved and adhered to!
ENGLISH
Gegenüber Darstellungen und Angaben dieser Betriebsanleitung sind technische Änderungen,

die zur Verbesserung der Kompressoren notwendig werden, vorbehalten.
This operating- and installation manual is subject to engineering changes necessary for the compressor advancement.
Nous nous réservons le droit dans les instructions de service procéder à toutes modifications techniques utiles visant à améliorer la qualité des compresseurs.
Wat de betrft de tekeningen en gegevens in deze bedienings- en opstellings-hanleiding verbetering van de schroefcompressor noodzakelijk worden, voorbehouden.
Nos reservamos el derecho de efectuar, frente a las representaciones e indicaciones de esta
instrucciones de montage servicio modificaciones técnicas necesarias para perfeccionar.
Rispetto all'illustrazione ed alle indicazioni di questa Istruzioni di Esercizio ci si riserva quelle modifiche tecniche che sono necessarie per migliorare i compressori.
V4-009 P EN
73
AM-Werknorm TN01134 / AM Woks Standard TN01134
Zulässige Schraubenanzugsmomente (Nm)

Admissible screw tightening torques (Nm)
Gültig für Normalschrauben. NICHT für Schaft-Dehnschrauben.

ENGLISH
Applicable for normal screws, not for reduced shaft screws.
Strength class
Thread size 3.6 4.6 4.8 5.6 5.8 8.8 10.9

M4 0.78 0.98 1.3 1.2 1.6 2.6 3.6
M5 1.7 1.9 2.6 2.5 3.3 5.3 7.5
M6 2.7 3.3 4.4 4.2 5.6 8.9 12
M8 6.8 8.2 11 10 14 22 30
M10 14 16 22 21 27 43 61
M12 24 28 38 35 47 75 108
M14 36 44 60 54 75 117 166
M16 59 72 95 89 117 186 264
M20 117 137 186 176 235 372 520
M24 196 225 314 294 392 628 883
M27 274 333 461 421 569 883 1275
M30 392 461 627 588 784 1226 1765
M33 510 618 833 775 1049 1618 2403
M36 676 804 1079 1030 1373 2109 3139
M42* - - 1353
- - 2943
4218
Tightening torque in Nm
74 V4-009 P EN
Die Tabelle gilt für 80% der Streckgrenze,* bis max. 120°C Betriebstemperatur
(AD, B7, 2,5).
Bei höheren Temperaturen müssen die Drehmomente im Verhältnis der Streckgren-
zenverminderung reduziert werden.
*Bei M42 für 70% gemäß Tabelle G71 von Reyher.
Gangreibung und Kopfreibung sind berücksichtigt (1 Nm=0,102 kpm; 1 kpm=9,81
Nm).
ENGLISH
This chart applies to 80% of the apparent yielding point,* up to max. 120°C operating
temperature
(AD, B7, 2,5).
In case of higher temperatures the torques have to be reduced in relation to the reduc-
tion of the apparent yielding point.
*In case of M42 for 70% as per chart G71 from Reyher.
Thread friction and bolt head friction were considered (1 Nm=0,102 kpm; 1 kpm=
9,81 Nm).
V4-009 P EN
75
1
ENGLISH
76 V4-009 P EN
Ölverbrauch Anschluss H, VMY 256
oil consumption connection H, VMY 256
Diagram 1.1
60
50
40
30
V4-009 P EN
20

oil volume flow [l/min]
10
Ölvolumenstrom [Liter/Minute]
0
2 4 6 8 10 12 14 16 18 20 22 24 26
Differenzdruck des Verdichters [bar]
differential pressure of compressor
1
77
ENGLISH
2 Diagram 2.1
Minimum speed
VMY 156 M NR
Min. Drehzahl VMY156M-NR

ENGLISH
Min. speed VMY156M-NR

v i = optimal ; /D=2,1; Gleitlager: D=75mm; B=78mm
L
vi = optimal; L/D=2,1; slide bearing: D=75mm; B=78mm

18
Δpmax=16
b p1abs(bar)
17
2,0 3,0 5,0 8,0
16
15
14
13
12
Differential pressure p 2 - p 1(bar)
11
Druckdifferenz p 2 - p 1(bar)
10
0
800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100
min. Motor-Drehzahl n Mot(1/min)
min. motor speed nMot(1/min)
78 V4-009 P EN
Diagram 2.2 2
Minimum speed
VMY 156 M HR
Min. Drehzahl VMY156M-HR
ENGLISH
min. speed VMY156M-HR
vi=optimal ; /D=2,1; Gleitlager: D=75mm; B=78mm
L
vi=optimal; L/D=2,1; slide bearing: D=75mm; B=78mm

18
Δpmax=16 bar
17 p1abs(bar)
1,0 2,0 3,0 5,0 8,0
16
15
14
13
12
11
10
0
1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000
V4-009 P EN
79
2 Diagram 2.3
Minimum speed
VMY 256 M NR

ENGLISH

v i = optimal ; /D=2,1; Gleitlager: D=80mm; B=70mm
L
18 vi = optimal; L/D=2,1; Slide bearing: D=80mm; B=70mm (bar a)

Δpmax=16
b p1abs(bar)
17
1,0 2,0 3,0 5,0 8,0
16
15
14
13
12
11
Differenzdruck p 2 - p 1(bar)
10
0
300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800
min. motor spped nMot(1/min)
80 V4-009 P EN
Diagram 2.4 2
Minimum speed
VMY 256 M HR
ENGLISH
Min. speed VMY256M-HR
18
p1 Saugdruck (bar a)
17 p1 suction pressure
(bar a)
1, 2, 3, 5, 8,
16
15
14
13
12
11
10
0
1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000
V4-009 P EN
81
2 Diagram 2.5
Minimum speed
VMY 356 M NR

ENGLISH

vi=optimal ; L/D=2,1; Gleitlager: D=100mm; B=90mm
18
Δpmax=16 bar
17
1,0 2,0 3,0 5,0 8,0 p1abs(bar)
16
15
14
13
12
11
10
0
300 500 700 900 1100 1300 1500
82 V4-009 P EN
Diagram 2.6 2
Minimum speed
VMY 356 M HR
ENGLISH
Min. speed VMY356M-HR
vi=optimal ; L/D=2,1; Gleitlager: D=100mm; B=90mm
18
17 Δpmax=16 bar
p1abs(bar) 1,0 2,0 3,0 5,0 8,0

16
15
14
13
12
11
10
0
500 700 900 1100 1300 1500 1700 1900 2100 2300 2500 2700 2900
V4-009 P EN
83
3 Sound specifications VMY 156
Octave sound spectra

Machine VMY 156 M NR
Speed 3000 min-1
Intake pressure 1.0 bar (abs)
ENGLISH
Discharge 9.0 bar (abs)

pressure
f (Hz) 31.5 63 125 250 500 1000 2000 4000 8000

Lp (dB) 66 69 71 84 80 78 74 76 75
dB(A) 84
linear dB 87
Measuring point: Machinery noise at 1m distance without acoustic hood / outdoor measurement
The sound specifications apply to the compressor exclusively.
Noise from motors, containers, pipes, etc. causes higher values.

Speed 3600 min-1
pressure
f (Hz) 31.5 63 125 250 500 1000 2000 4000 8000

Lp (dB) 67 70 73 86 82 80 75 77 76
dB(A) 86
linear dB 89
84 V4-009 P EN
3

Machine VMY 156 M HR
Speed 3000 min-1
ENGLISH
pressure
f (Hz) 31.5 63 125 250 500 1000 2000 4000 8000

Lp (dB) 62 64 67 80 77 76 72 74 73
dB(A) 82
linear dB 84

Speed 3600 min-1
pressure
f (Hz) 31.5 63 125 250 500 1000 2000 4000 8000

Lp (dB) 63 65 69 82 79 78 73 75 74
dB(A) 83
linear dB 86
V4-009 P EN
85
3
Sound specifications VMY 256

Speed 3000 min-1
ENGLISH

pressure
f (Hz) 31.5 63 125 250 500 1000 2000 4000 8000

Lp (dB) 69 72 74 87 82 81 77 79 78
dB(A) 87
linear dB 90

Speed 3600 min-1
pressure
f (Hz) 31.5 63 125 250 500 1000 2000 4000 8000

Lp (dB) 70 73 76 89 84 83 76 80 79
dB(A) 88
linear dB 92
86 V4-009 P EN
3

Speed 3000 min-1
ENGLISH
pressure
f (Hz) 31.5 63 125 250 500 1000 2000 4000 8000

Lp (dB) 67 70 72 85 80 79 75 77 76
dB(A) 85
linear dB 88

Speed 3600 min-1
pressure
f (Hz) 31.5 63 125 250 500 1000 2000 4000 8000

Lp (dB) 68 71 74 87 82 81 76 78 77
dB(A) 86
linear dB 90
V4-009 P EN
87
3 Sound specifications VMY 356

Speed 3000 min-1
ENGLISH

pressure
f (Hz) 31.5 63 125 250 500 1000 2000 4000 8000

Lp (dB) 72 73 76 90 86 83 79 81 80
dB(A) 89
linear dB 93

Speed 3600 min-1
pressure
f (Hz) 31.5 63 125 250 500 1000 2000 4000 8000

Lp (dB) 73 74 78 92 88 85 80 82 81
dB(A) 91
linear dB 95
88 V4-009 P EN
3

Speed 3000 min-1
ENGLISH
pressure
f (Hz) 31,5 63 125 250 500 1000 2000 4000 8000

Lp (dB) 70 71 74 88 84 81 77 79 78
dB(A) 87
linear dB 91

Speed 3600 min-1
pressure
f (Hz) 31.5 63 125 250 500 1000 2000 4000 8000

Lp (dB) 71 72 76 90 86 83 78 80 79
dB(A) 89
linear dB 93
V4-009 P EN
89
ENGLISH
Aerzener Maschinenfabrik GmbH

Reherweg 28 31855 Aer-
zen
Postfach 1163 31849 Aerzen
Telefax 0 51 54 / 81-191
e-mail info@aerzener.de
After Sales Ser-

 vice
0 51 54 / 81-7529
Aerzen on the
 Internet
www.aerzener.com
Gegenüber Darstellungen und Angaben dieser Betriebsanleitung sind technische Änderungen,

die zur Verbesserung der Kompressoren notwendig werden, vorbehalten.
This operating- and installation manual is subject to engineering changes necessary for the compressor advancement.
Nous nous réservons le droit dans les instructions de service procéder à toutes modifications techniques utiles visant à améliorer la qualité des compresseurs.
Wat de betrft de tekeningen en gegevens in deze bedienings- en opstellings-hanleiding verbetering van de schroefcompressor noodzakelijk worden, voorbehouden.
Nos reservamos el derecho de efectuar, frente a las representaciones e indicaciones de esta
instrucciones de montage servicio modificaciones técnicas necesarias para perfeccionar.
Rispetto all'illustrazione ed alle indicazioni di questa Istruzioni di Esercizio ci si riserva quelle modifiche tecniche che sono necessarie per migliorare i compressori.
90 V4-009 P EN

Oil-Injected Screw Compressors VMY .56 For Process Gas and Refrigeration Industry

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Oil-Injected Screw Compressors VMY .56 For Process Gas and Refrigeration Industry

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User Manual

Installation, assembly and operating instructions

Die INFO-Seite ist vor der Inbetriebnahme durchzulesen.

Read the INFORMATION sheet prior to commissioning.

La page INFO est à lire avant la mise en route.

De INFO-Bladzijde moet voor de inbedrijfname worden doorgelezen.

Prima della messa in esercizio leggere la pagina INFO, ed eseguire eventuali

Antes de proceder a la puesta en marcha, leer detenidamente la página informativa y

Pidätämme oikeuden painovirheisiin, erehdyksiin sekä teknisiin muutoksiin..

Druckfehler, Irrtümer sowie technische Änderungen sind vorbehalten.

Sous réserve de fautes d‘impression, d‘erreurs et de modifications techniques.

Drukfouten, vergissingen en technische wijzigingen voorbehouden.

Salvo error u omisión. Reservado el derecho a realizar modificaciones técnicas.

Salvo errori di stampa, incorrettezze e modifiche tecniche.

Reservamo-nos o direito a erros de impressão, enganos e alterações técnicas.

Der tages forbehold for trykfejl, fejl og tekniske ændringer.

Med forbehold om trykkfeil, feiltagelser og tekniske endringer.

Tryckfel, övriga fel samt tekniska förändringar förbehålles.

1. Suitability, general information.................................10

2. Design / information on system planning.........11 - 29

2.1.2 Oil cooler.......................................................................11

2.7.1 Intake-side strainer.......................................................27

3. Performance data / service data........................ 30 - 33

4. Construction and function................................. 33 - 36

5. Safety requirements before and

6. Inadmissible operating methods...............................41

10. Maintenance / repairs......................................... 61 - 71

driving collar and seal bushing............................ 64 - 65

10.3.3.1 Removal and installation of high-range

11. Recycling / disposal...................................................72

12. INFORMATION PAGE..................................................73

AM-Works Standard TN01134......................................... 74 - 75

Appendix, data sheets

Ersatz- und Zubehörteile

Spare parts and accessories

Accessoires et pièces de rechange

Piezas de repuesto y accesorios

Leistungsdaten VMY ...

ENGLISH Translation of original declaration of incorporation

FRANÇAIS Traduction de la déclaration d‘incorporation d‘origine

Translation of the original instructions

NEDERLANDS Vertaling van de originele inbouwverklaring

ESPAÑOL Traducción de la declaración de incorporación original

ITALIANO Traduzione della dichiarazione originale di incorporazione

VMY.56 screw compressors manufactured by Aerzener are intended for oil-injected,

Non-observance of technical limits of suitability, performance data and safety regulations

The vibration behaviour of blowers with mounted couplings is largely determined by

The compressor is delivered ready to operate; also including accessories as an option.

The specifications and instructions of the suppliers of accessories and

2.1 Compressor design

2.1.1 Calculated output data

2.1.2 Oil cooler

2.1.3 Oil piping

2.1.4 Differential oil pressure

2.1.5 Oil reservoir

2.1.6 Oil temperature

2.1.7 Drive motor

2.1.8 Flexible coupling

2.2.1 High-range displacement transducer

High-range displacement transducer current (mA)

PIN configuration of the connecting plug

Supply voltage : 12 – 28 VDC

2.2.2 Oil pump / pre-lubrication pump