Operation- and installation manual

for belt driven

VM-, VML-compressors

DELTA SCREW

english

AERZENER MASCHINENFABRIK
GMBH

V4-003 L EN
168 404 001 09-2006
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.
 Konformitäts-Erklärung
Declaration of Conformity
Certificat de conformité
EG-Verklaring van over-

english
eenstemming voor machines
C o n t e n t s

Declaración de conformidad
Dichiarazione di conformità

Ersatzteil-Bestellung Leistungsdaten
Ordering spare parts Performance data
Commande de pièces dé tachée Performances
Bestellen van onderdelen Capaciteitsgegevens
Pedido de repuestos Datos de servicio
Ordinazione di pezzi di ricambio Dati di esercizio

Verschleißteilzeichnungen
Wearing parts drawings
Plans des pièces d'usure
Tekening waarop aangegeven
Disegno parti soggette ad usura
Dibujo de pieza de desgaste

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/

34
I n h a l t

INFO - Seite
Information sheet 35
Page infos
Info bladzijde
Pagina
Informativa
Informazioni
Abteilung Technische Dokumentation
Technische Illustration & Redaktion
Aerzener Maschinenfabrik

H.Nickel Technischer Autor

english
 Konformitäts-Erklärung EG-Verklaring van overeen-
Declaration of Conformity stemming voor machines
Certificat de conformité Declaración de conformidad
Dichiarazione di conformità

deutsch english
français
Hiermit bestätigen wir, dass diese We herewith confirm that this
Nous déclarons par la présente que
Maschine den folgenden machine is in accordance with the
cette machine est conforme aux
EG-Richtlinien entspricht: following EC directives:
EG-Maschinen- EC machine directive 98/37 EG directives CE suivantes :
Richtlinie 98/37 EG Appendix II A Directive machine CE 98/37 CE

english
Anhang II A for machines to be installed Annexe II A
EMV-Richtlinie 89/336 EG EMV directive 89/336 EG Directive CEM 89/336 CE
Druckgeräte-Richtlinie 97/23 EG pressure device Directive équipements sous pression
Niederspannungs- directive 97/23 EG
97/23 CE
Richtlinie 73/23 EG low-voltage
Directive basse tension 73/23 CE
Die Maschine wurde konstruiert, gefertigt directive 73/23 EG
und dokumentiert, in Übereinstimmung mit The machine was designed, manufactured La machine a été conçue, fabriquée et
den harmonisierten Normen der genann- and documented in accordance with the documentée en accord avec les normes
ten EG-Richtlinien, von Firma: harmonized standards of the stated EC- d’harmonisation des directives CE
Aerzener Maschinenfabrik GmbH guidelines of: indiquées, par la société :
D-31855 Aerzen Aerzener Maschinenfabrik GmbH Aerzener Maschinenfabrik GmbH D-
Eine technische Dokumentation ist vollstän- D-31855 Aerzen 31855 Aerzen
dig vorhanden. A copy of all relevant technical information Une documentation technique complète
Die zur Maschine gehörende Betriebsan- is provided and available. est disponible.
leitung liegt vor. The operating manual pertaining to the
Le présent document comprend la notice
machine is provided and available.
d’instructions de la machine.

nederlands español italiano

Hiermee bevestigen we, dat deze Nos aseguramos de esta forma, que Con la presente si conferma che la
machine aan de volgende EG- la máquina cumple con las siguientes presente macchina è conforme alle
richtlijnen voldoet: Directivas de la CE: seguenti direttive CEE:
EG-Machinerichtlijn 98/37 EG Directiva de máquinas CE 98/37 CE Direttiva macchine
Bijlage II A Anexo II A
EMC-richtlijn 89/336 EG Directiva EMV 89/336 CE CEE 98/37 EG
Drukapparatuurrichtijn 97/23 EG Directiva de dispositivos Anhang II A
Laagspanningsrichtlijn 73/23 EG de impresión 97/23 CE Direttiva EMV 89/336 EG
De machine werd geconstrueerd, Directiva de baja Direttiva per apparecchi
vervaardigd en gedocumenteerd in tensión 73/23 CE ed impianti a pressione 97/23 EG
overeenstemming met de La máquina fue construida, concluida y Direttiva bassa
geharmoniseerde normen van de documentada en conformidad con las tensione 73/23 EG
genoemde EG-richtlijnen door de: normativas harmonizadas de las Directivas La macchina è stata costruita, prodotta e
Aerzener Maschinenfabrik GmbH de la CE mencionadas, por la empresa: documentata, in conformità alle norme
D-31855 Aerzen Aerzener Maschinenfabrik GmbH armonizzate delle succitate direttive
Een technische documentatie is D-31855 Aerzen CEEdalla ditta:
compleet aanwezig. Se encuentra disponible una Aerzener Maschinenfabrik GmbH
De bij de machine behorende documentación técnica completa. D-31855 Aerzen
bedieningshandleiding ligt ter inzage. É disponibile la documentazione tecnica
Existe un manual de instrucciones de la
completa.
máquina.
Le istruzioni per l'uso necessarie alla
macchina sono allegate.

Leiter Techn. Abteilung Unterschrift des Herstellers

Head of the dept. Signature of the manufacturer
Directeur technique Signature du constructeur
Hoofd technische afdeling Handtekening van de fabrikant
(Herr Seidel) Director Dpto, Técnico Firma del fabricante
Responsabile reparto tecnico Firma del fornitore
 Ersatzteile, spare parts, pièces dé tachée, onderdelen, repuestos, pezzi di ricambio

- DELTA SCREW -

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 durch
Verwendung von nicht Originalteilen und Zubehör entstehen, ist jede Haftung des Herstellers ausgeschlossen.

Spare parts and accessories

We draw your attention to the fact that original parts and accessories not supplied by us are also not
inspected 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
english

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
derhalve 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.
 Leistungsdaten / performance data
- Ersatzteilbestellung / ordering spare parts -

l Bitte richten Sie Ihre Bestellung, an die für Sie zuständige Aerzener Vertretung / -Gesellschaft.
Abruf unter (++49) 0 51 54 81 192
l Please send your ordering to the Aerzener representation / -company responsible for your country.

Rechnungsanschrift --------------------------------------------------------------------------------
--------------------------------------------------------------------------------
Invoice address ------------------------------------------------------------------------------------------------------ Ersatzteil-
------------------------------------------------------------------------------------------------------
anfrage
Inquiry spare
Lieferanschrift --------------------------------------------------------------------------------
-------------------------------------------------------------------------------- parts
Dispatch address ------------------------------------------------------------------------------------------------------
------------------------------------------------------------------------------------------------------ Ersatzteil-
bestellung

english
Kunden-Bestell-Nr.N° --------------------------------------------------------------------------------
Ordering spare
Customer's order n° ------------------------------------------------------------------------------------------------------
parts
performance data

Alvorens in te vullen dit formulier s.v.p. kopiëren !

Por favor copiar este listado de cumplimentario !
Si prega di copiare questo formulario prima di compilarlo !
/ Leistungsdaten

Ø
Ø
Ø
Avant de remplir ce formulaire, veuillez copier !
Dieses Formular bitte vor dem Ausfüllen kopieren !
Prior to filling-in this form, please copy !
/ spare parts
Ersatzteile

Gültig für die folgende Verschleißteilzeichnung. Applicable for the following wear part drawing.

!
010 ð ... 100 ð ... 190 ð ...
020 ð ... 110 ð ... 200 ð ...
030 ð ... 120 ð ... 210 ð ...
040 ð ... 130 ð ... 220 ð ...
050 ð ... 140 ð ... 230 ð ...
Ø
Ø
Ø

060 ð ... 150 ð ... 240 ð ...

070 ð ... 160 ð ... 250 ð ...
080 ð ... 170 ð ...
090 ð ... 180 ð ...

Ersatzteile markieren / Stückzahl eintragen. Mark the spare parts / fill in the quantity.

Dieses Ersatzteilformular ist ein fester Bestandteil der Betriebsanleitung
und darf nicht enfernt werden !
This spare part form is an essential part of the operating manual and must not be removed !
Ce formulaire de pièce détachée est un élément essentiel de l'instruction de service
et ne doit pas écarter !
Dit reservedelenformulier is een vast bestanddeel van het bedrijfsvoorschrift en mag
niet worden verwijderd !
Este listado de repuestos forma parte integrante de las Instrucciones de Servicio y
no puede per eliminado !
Questo formulario dei ricambi è parte integrante delle istruzioni di esercizio e non
deve essere staccato !
 DELTA SCREW
Verschleißteilzeichnung / Wearing parts drawing
english

Diese Abbildung ist eine Beispiel-Darstellung und zeigt umfangreiches Zubehör.

Sie verdeutlicht die Zubehörbauteile und dient der Ersatzteilbestellung.
Abweichungen zu dem ausgelieferten Aggregat sind möglich.
Detaillierte Informationen enthält die, der Auftrags-Nummer entsprechende Aufbauzeichnung.
This figure is an example-presentation and shows extensive accessories. It shows clearly the
accessories and serves for spare part order. Deviations to the unit supplied are possible.
The installation drawing gives detail information according to the order number.
 DELTA SCREW
Verschleißteilzeichnung / Wearing parts drawing

english

Diese Abbildung ist eine Beispiel-Darstellung und zeigt umfangreiches Zubehör.

Sie verdeutlicht die Zubehörbauteile und dient der Ersatzteilbestellung.
Abweichungen zu dem ausgelieferten Aggregat sind möglich.
Detaillierte Informationen enthält die, der Auftrags-Nummer entsprechende Aufbauzeichnung.
This figure is an example-presentation and shows extensive accessories. It shows clearly the
accessories and serves for spare part order. Deviations to the unit supplied are possible.
The installation drawing gives detail information according to the order number.
 Contents
page page
1. Suitability, general advice 1 10.6 V-belt pulleys 14
2. Construction, function 2 10.7 Oil demister 14
3. Care to be taken before and 10.8 Oil cooler / Oil temperature
during operation 3-4 regulator 15
4. Inadmissible operation 10.9 Oil pressure regulating valve 15
methods 5 10.10 High lift-spring safety
5. Transport / Installation 5-6 relief valve 16
6. Commissioning 7-8 11. Acoustic hood 17
7. Admissible connecting 12. Special accessories 17 - 19
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frequency of drive motors 9 12.1 Start-up unloading device 17 - 18

8. Compressor shutdown 9 12.2 Constant speed unloading
9. Operation of device 18 - 19
compressor units 13.1 Instrumentation 20 - 21
9.1 - with frequency converter 10 13.2 Aerzen control 22 - 24
9.2 - with pole-changing motor 10 14. V-belts - installation / exchange 25
9.3 - operated with nitrogen 11 15. Lube oil regulations 26 - 28
10. Accessories- / Maintenance / 16. Exchange of lubricants 29 - 30
Attendance 11 - 14 17. Lube oil quantities 31
10.1 Maintenance schedule 12 18. Operation of compressors
10.2 Inspection / -dates 13 with housing jacket cooling 31
10.3 Intake filter 13 19. Failure analysis 32 - 33
10.4 Starting strainer in case of 20. Recycling / disposal 34
pipeline suction 13 21. Information sheet 35
10.5 Oil filter 14

1. Suitability, general advice

The useful suitability of screw compressors made by Aerzen is the oil-free conveying and
compressing of air, even of other gases in modified design.

In order to ensure an optimum operation, the technical suitability limits have to be observed.

Intake temperature t1 stated in the order confirmation applies as ambient temperature

at place of installation.

Non-observance of the technical application limits and safety regulations releases

the Aerzener Maschinenfabrik from warranty and liability regarding replacement for
consequential damages. The same applies to defects caused by inspections carried
out not in time or not properly.

1
2. Construction, function
Unit:
The unit is delivered with mounted accessories ready to operate.
The following steps are to be effected in addition:
Ü Connect the conveying piping.
Ü Check lube oil level, adjust if necessary.
Ü Install the electrical connection.
Ü Mount the special accessories delivered separately - if there are any.
Drive:
The unit is driven by an electric motor by means of V-belts. Also with I.C. engine drive

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possible.
Motor connection:
The electrical installation has to be effected by an authorized electrical fitter.
The terminal diagram for the motor can be found in the cover of the terminal box
as well as in the accompanying documentation.
The motor- and control voltage is to be connected to a common network,
where the sealing-in of the power contactor is cancelled in case of an interruption
of circuit.
Alternative: Parallel to the driving motor an electronic monitoring relay is to be
installed which cancels the sealing-in of the power contactor in case of an
interruption of circuit.
Base frame:
The base frame provides the basis for the installation of the compressor and the
motor, incl. accessories. It consists of a welded, stable steel construction or a
cast construction.
Bearings and lubrication:
The rotors are equipped with roller bearings. Timing gears and roller bearings are
lubricated by a common forced oil-lubrication by circulation.
The oil pump is flanged to the compressor, sucks in from the oil chamber and conveys
the oil via a cooler up to the places where the oil is needed.
Intake side:
The compressor sucks in via a filter element, fixed directly to the base support.
For a possible installation of a constant speed unloading device an additional
throttle flap is available. In case of nitrogen design the compressor sucks in via a
suction silencer and a starting strainer with intermediate ring.
Discharge side:
On the discharge side the following items are flanged directly:
A silencer, a non-return flap, an axial compensator and a fitting piece.
The discharge side pipe is to be connected there. Pipes are to be fixed separately.
A safety relief valve is mounted at a flange at the silencer and consequently
protects the pipes, the reservoir and the accessories.
Due to the high compressed discharge temperatures, -> high surface heat emission in the
range of the discharge side can lead to stripping or bubble formation of the varnish.
This process does not impair the compressor operation and is not considered as defect of
fabrication.
If included in scope of supply the instruments necessary for monitoring are combined in
a panel.The entire unit is installed on flexible machinery mountings and is available with
or without acoustic hood.

Compressor with housing jacket cooling

Compressors of this series supplement the former types.
Thanks to the housing jacket cooling an additional operation optimization is offered.
A jacket filled with oil covers the compressor housing, so that a sufficient heat
elimination during operation is ensured by the oil system.
For further operating advice, please refer to chapter 18.

2
 3. Care to be taken before and during operation
ATTENTION ! Draws the attention to all dangerous situations.

WARNING! Points to direct risks of persons.

Read first - Upon receipt the compressor is to be checked for damages during transport and
then operate! completeness by means of delivery note and order.

Work safety rules, safety regulations as well as the operating instructions are to
be observed. Read the Information sheet prior to commissioning. Possible notes and
english

changes indicated herein are to be effected. The following described tasks are only to be
carried out by experts who are familiar with the functions of the compressor unit and its
components as well as with the safety regulations to be kept.
This screw compressor meets the European regulations for accident prevention.
Nevertheless, residual technical risks remain, with a possibility of endangering persons
and property. To avoid this, operators have to comply with the following safety
regulations:

Ü Any person dealing with the installation, operation, maintenance and repair of the unit
must have read and understood the operating manual.

Ü The unit must be operated by trained and authorized staff only. Operators must be
skilled, introduced to their job and instructed !

Ü Work on current-carrying components is to be carried out by authorized specialized

staff introduced to their job. For this work the machine is to be currentless.

Ü The responsibility for the operation is to be defined exactly, so that there are no
unclear competences.

Ü Any method of working interfering with the safety at the machine has to be refrained
from.

Ü The user is obliged to operate the machine in proper condition only.

Ü Do not carry out any improper repair or modification work at the compressor. In case
of problems contact the Aerzener after-sales service!

Ü Prior to switching-on, operators must be familiar with the protection-, operating- and
monitoring elements by means of these instructions.

Ü Use the machine in accordance with its suitability, keep its performance limits.

Ü Remove solids, liquids and powdery substances from the intake range.

Ü Safety appliances, such as belt guard, fan protection, hood element,

motor protection/EMERGENCY-OFF, safety instruments, pressure valve etc. must
not be removed when machine is operated. Safety appliances must also not
be defective. Operation safety must always be ensured. Risk of injury!

Ü Do not operate when electrical, mechanical, or hydraulical connections, belt guard,

fan protection, safety instruments, pressure valve etc. are defective or missing.

3
Ü No operation with open intake- or pressure socket / compressor stage, as:
positive displacement machines are forced conveying machines with risk of injury in
the range of conveying chamber.

Ü Lube- and control oil pipes are to be retightened or opened in unpressurized

condition of the machine only.

Ü Screwings are to be retightened in unpressurized condition of the machine only.

Risk of burns!

Ü In case of open or non-existing acoustic hood wear safety gloves when the housing

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surface is at operation temperature!

Ü Do not touch conveying pipes and discharge side components without corresponding
protection. Pipes and components may be more than 70 °C hot.

Ü Do not disassemble conveying pipes, before they are released from tension. In case
of technical gases the conveying pipes are to be flushed with neutral gas before.

Ü Never touch or look into the discharge opening /-side of pressure valve!
Risk of injury as upon pressure valve blow-off hot gas is released and emerges
with high speed. Entrain such as dirt /-dust particles etc. may occur.

Ü Use ear protection in case of compressor operation !

Due to the respective operating condition, the sound pressure level can deviate from
the mentioned operating data. Therefore a sound pressure level higher than 85 dB(A)
can be possible at short notice.

Ü If the machine is driven by Diesel- or petrol motors, with missing or too low room
ventilation there is danger of poisoning. The place of installation is to be aerated or
deaerated sufficiently. In addition pay close attention to the operating instructions of
motor manufacturer!

Ü Danger of poisoning by inhalation and risk of causticization by touching

when using cleaning agents and sprays.

Ü Upon oil change pay attention to the oil temperature.The oil temperature must not exceed
60 °C. Risk of combustion at oil temperature exceeding 60 °C!

Ü Follow manufacturers’ instructions as well as applicable regulations !

Ü Only tools that correspond to the standard and design of the bolts, nuts and fittings must
be used.

Notes regarding operation / protection

of compressor stage and the pressurized piping elements
Ü The compressor stage is protected by oil pressure-, discharge temperature- and
discharge pressure sensors. At site the sensors are switched with a fault alarm
device / control. Upon exceeding of resp. falling below the admissible operation
parameters the fault alarm device / control switches off the drive motor. In case
of units without fault alarm device resp. control a corresponding operationally
reliable control is to be provided by the customer.
Ü For proper operation the fault alarm device / control is to be included in the safety
chain of the drive motor according to circuit diagram. Pay close attention to the fact
that the fault alarm device / control and drive motor are being fed by the common
circuit, in order to exclude motor operation without compressor protection.

4
 4. Inadmissible operation methods
Ü Wrong direction of rotation.
Ü Switching-on - during run-down.
- upon rotating in reverse direction.
Ü Inadmissible pressure increase.
Ü Remaining under or exceeding the limit speed.
Ü Exceeding the limit-discharge temperature.
Ü Pole-changing to lower speed prior to standstill of the motor.
Ü Transport of the unit by means of the lifting screws to be found in the hood roof.
Ü Non-observance of the operating data.
english

Ü Non-observance of maintenance intervals.

Ü Operation without oil filling.
Ü Compressor operation without properly connected fault alarm device / control.
Risk of total damage!
wrong

5. Transport / installation
During transport of the compressor unit the following points must be always observed:
Ü Protect the unit from impacts.
Ü The unit is to be transported by means of crane, high-lift truck. elevating truck or
similar, without oil filling.
Ü Lift the unit only according to sketch. Pay attention to corresponding cross pieces
between the ropes.
Ü Concerning units without acoustic hood transport is effected by application of the
transport devices, such as shackles, at the base frame or by lifting jacks below the
transport lugs.
correct Ü Lay the centre of gravity of the machine centric to the transport forks.

During installation the following points must be observed:

Ü Upon dispatch Positive Displacement machines are preserved for 12 months and packed
accordingly. Upon a storage for more than 12 months, the preservation is to be repeated,
observe TN0 1175.
Ü During storage pay atttention to proper preservation, packing and if necessary
nitrogen filling, according to TN0 1175. Test interval every 6 weeks.
Negative influences are to be removed immediately to guarantee a continuous preservation.
Ü Intermediate storage in dry, clean and vibrationless chambers.
Ü The installation site must have enough space for maintenance and repair, min 800 mm.
Ü When installed outside the weather cowls (supplied separately) must be installed
at site by means of the screws, washers and sealant (silicon) supplied.
Ü In case of shut down for more than 6 weeks, the conveying chamber, rotors
and polished parts must coated with a preservative.
Ü The oil chambers are preserved sufficiently for one year.
Ü Place unit on even, vibrationless and slope-free ground. If necessarry - there is the
possibility to dowel the units. In this case, only one anchor bolt per machine foot
is sufficient.
Ü Remove all packaging. If using an acoustic hood it is important to ensure free air
access to the inlet and outlet silencers.
Ü Regarding units without acoustic hood the instrument panel incl. installation panel
is to be removed from machine base support. Instrumentation is to be mounted
separately onto appropriate underground, to be bored and drilled accordingly.
Pay close attention to cable- and hose lengths! Bended or / and damaged hoses
and cables are to be avoided!

5
Ü The following standard installation conditions have to be adhered to:
l Temperature limits
VM compressors VML compressors
-10°C £ t1 £ + 50°C -10°C £ t1 £ + 50°C
-10°C £ t0 £ + 50°C -10°C £ t0 £ + 50°C
(t 1-t 0) £ 20 K (t 1-t 0) £ 20 K
delta (t) £ 230 K delta (t) £ 180 K
t2 £ 280 °C t2 £ 230 °C
t0 = ambient temperature /compressor housing temperature / t1 = intake temperature
t2 = discharge temperature / delta (t) = t - t
2 1
lower,equal £
- In the above mentioned temperature range, the intake temperature
must not be 20 K higher than ambient temperature.
- If this limit is not observed, the compressor housing must be heated up by suitable

english
measures.
- Vice versa a warm compressor, can suck in cold gas within the temperature
limits without limits.
Rel. air humidity : 0% to 80%
Chemical-free atmosphere
Ü Rotate the compressor by hand and check for smooth running. If the unit shows signs of
being "tight" it may be due to distortion (nozzle loading, uneven base, etc.) or foreign
particles in the conveying chamber.
Ü In order to avoid an electrostatic charge building up, the unit, motor, acoustic hood and
base frame must be earthed via the earthing straps and lugs provided.
Ü Connect the discharge side pipework and suction-side pipework if applicable, so
that the unit is connected to the system. In both cases connection must be via a
flexible joint or axial compensator .
Ü Connect the electric motor. For technical details of the motor, refer to the nameplate or
the instructions on the internal side of the terminal box.
Ü Please read the operating manual for the motor enclosed separately!
Ü An authorised electrician must only carry out electrical connections and wiring.
Ü The transmission of noise should be taken into consideration. Pipe work and foundations
can transmit vibrations from sound emissions.
Ü The installation must be planned with safety in mind and the safety guidelines in the
technical documents of each component supplied must be observed.

Ü Prior to commissioning check oil level!

Alignment
Ü The unit must be level. The maximum deviation from the horizontal is
0.2 mm per meter.
Ü When the motor is already installed, check the pulley alignment. To do this it is
necessary to remove the belt guard.
Ü ATTENTION! When doing this, the unit must be isolated electrically.
(Remove the fuses)
Ü After checking the alignment the belt guard must be re-installed before running.
Ü When the motor is installed later, alignment has to be effected by means of shims.
Ü ATTENTION! Excessive alignment error affects the life of the driving components.
Ü Following initial commissioning the pulley alignment, the lube oil pipes and the
security of all nuts bolts should be checked and retightened after 3 hours running
time.

A taut length of string or a straight edge must touch points A, B, C and D as shown in
the sketch.

6
 Preparation
6. Commissioning
The compressor is installed in accordance with chapter 5 of this manual.

In case of initial commissioning

Check oil level, if necessary adjust.
Check oil filling screw and drain valve for tight fit and impermeability.
Pay close attention to commissioning remarks and lubrication intervals of
drive motor manufacturer !
english

Depending on design, cut off rubber nipple on top of the pressure gauges (if existing) or
turn deaeration bracket to OPEN.

Check direction of rotation.

See also red direction of rotation shield on the compressor.
No V-belts must be on the motor disc.
Remove locking screw between pulley and motor casing.
Start driving motor for a short time / approx. 1 or 2 seconds
Please also refer to the instructions of the supplier of electric components
resp. of the plant manufacturer.
with interm.
gear also see
ATTENTION! Incorrect direction of rotation during operation will destroy compressor.
chapt.16
Compressors without intermediate gear rotate when looking at drive shaft:
Position of drive shaft "left" "clockwise".
Position of drive shaft "right" "anti-clockwise".
without interm. gear,
also see chapt. 16 Compressors with intermediate gear rotate when looking at the drive shaft:
Position of drive shaft "anti-clockwise" "anti-clockwise".
Starting The directions of rotation of drive motor and compressor must be equal.

In case of correct direction of rotation the following tasks are to be effected:

The correct function of fault alarm device / control is to be checked.
The security- and control instruments are to be checked.
The shutdown of the motor is to be checked via every switch,
in case of running motor.
ATTENTION! Pay attention to number of switching actuations of the driving motor.
E.g. set timing relay for bridging of oil pressure to approx. 10-15 seconds, test
shutdown, afterwards set into initial position again.
Remove transport locking screw of the hinged motor plate / refer to 14.
Check alignment of the pulleys. Lift hinged motor plate by means of hydraulic jack.
Put on V-belts (refer to chapter 14). The hinged motor plate is to be released/
remove hydraulic jack. The V-belts are tensioned by the motor weight.
Close openings for motor driving shaft in belt guard with pre-mounted, movable protection
covers. Slide protection covers up to max. 2 cm to motor driving shaft and secure.

7
Connect pipings with unit ready to operate, stickers concerning safety instructions must
be legible and safety devices must have been inspected.
Open slide valves available at the unit. Operation can start.

Switch on driving motor!

Switch off after approx. 20 seconds and verify the smooth run-down of the
compressor. Should one protection element react remove the cause immediately.

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Þ

After three hours of initial commissioning the following items are to be checked again:
Pulley alignment, all the screws on pipes and on the unit.
All the screwings on lube oil pipes and on the unit.

Then, switch on again and check EMERGENCY-OFF switch!

Now the unit is ready to operate!
Operation

8
 7. Admissible connecting frequencies of the
drive motors
To 160 kW = 6 starts per hour
From 200 kW = 3 cold starts or 2 warm starts

Ü For further indications and advice, please refer to the documentation of the
motor manufacturer.
Ü Please also refer to chapter 2, motor connection.
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8. Compressor shutdown
Switching-off driving motor.

Switching-off Compressor-shutdown with gas cooler and control

Ü Prior to shutdown of the compressor a “dry-running phase” of approx.
2 minutes is to be scheduled. During this “slow-down period” the compressor
is tobe operated with suction-sided closed throttle flap and discharge sided
open regulator to avoid condensate accumulations.

Compressor-shutdown with gas cooler without control

Ü To avoid a condensate return the gas cooler is to be arranged deeper than
the compressor unit.

Ü If the motor is shutdown during conveying at counterpressure, the pressure brakes the
compressor and stops it quickly.
Ü The non-return flap installed downstream of the compressor closes
immediately and avoids, that the compressed medium releases through the
compressor and prevents the compressor from running in reverse.
Ü A possible condensate return from the pressure pipe is to be avoided.
Ü If a bypass is installed around the compressor, this is opened before shutdown, to
have the compressor run down unloaded, e.g. in case of VM-compressors a constant
speed unloading device.
Ü At standstill of the compressor the suction- and discharge side slide valves are to be
closed.
Ü In case of longer standstill of the compressor the fuses of the driving motor are to be
withdrawn to avoid an unintentional starting of the compressor.
Ü Preserve the conveying chamber if standstill lasts longer than 6 weeks. Rotate the
compressor regularly by hand, in order to prevent damages which may arise from
standstill.
Ü If water-oil coolers or water-aftercoolers are installed, the water valves in the supply
are to be closed. If there is danger of frost drain off water, or do not interrupt water
flow.

In case of danger:
Press EMERGENCY-OFF button. For details please refer to the instructions of the
supplier of electric components resp. of the plant manufacturer.

9
9. Operation of compressor units
9.1 with frequency converter

The following has to be taken into consideration:

Ü In case the frequency converter is provided by others the electrical and
mechanical characteristics of the driving motor are to be taken into account.
Ü The minimum frequency must always be set in a fixed manner.
Upon operation this frequency must not be remained under.
Ü The maximum frequency must be set under consideration of the maximum
motor speed and the maximum blower- / compressor speed.

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Ü The run-up time of driving motor from standstill up to minimum speed may be 3 to 6
seconds.
Ü The frequency converter must be designed for operation of a work machine with
constant load moment.
Min.- or max. speeds are not to be remained under or exceeded.

Ü In case of speeds below 50% the oil pressure drops to approx. 0,6 bar (g). In order to
ensure operation of the machine up to 25% within speed range, the main oil pressure
switch, l set value 1,8 bar (g) is bypassed by a trigger.
For the oil pressure protection an additional switch is installed, l set value 0,5 bar (g).

Ü The highest admissible voltage increase speed of the motor converter is

1200 V/ms. When exceeding the value, e.g. due to too long cables, frequency
converter make etc. a motor throttle / motor filter coil corresponding to the frequency
converter is to be applied. A renunciation of these component parts may lead to a
damage of the motor isolation and to a motor breakdown.
Ü The max. speed regulation speed on Positive Displacement blowers /Screw
compressors after run-up to min. speed for regulation time upward and downward is
1 Hz per second.
Min.-frequency = 20 Hz // Max.-frequency = 50 Hz results in a regulation time from
min. to max. of 30 seconds.
Ü The max. current limit of the motor must not be exceeded.
Observe the details on the motor name plate.

Ü In order to avoid operational failures the function "flying restart circuit" must not be
parameterized in the control of the frequency converter. Upon shutdown of the
frequency converter a re-start is only permitted following complete standstill of
blower resp. compressor.

9.2 with pole-changing motor

The following has to be taken into consideration:

Ü Between a change of motor speed
- from high to low speed the motor must have reached each time
speed zero.
- from low to high speed switching can be effected directly, undelayed.

10
 9.3 Operated with nitrogen

Ü In order to keep the leakage losses at the seal as low as possible, the discharge side
seal is to be released, if possible, to the suction side of the compressor at the first
lantern ring via a pipe, with valve and pressure gauge.
At compressor standstill it is possible that nitrogen penetrates into the atmosphere
e.g. by opened neutral rooms, oil demister or similar. Attention: In closed chambers
hoods, a gas mixture can develop in the hood.
Ü In case of machines with admission pressure the valve in the relief pipe is completely
open.
Ü On machines sucking in without admission pressure, the valve is slightly throttled.
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In the relief pipe there has to be a slight overpressure of approx. 50 mbar. This is to
avoid that a vacuum arises in the pipe and that oxygen is sucked into the machine via
the seal.

In nitrogen operation is dropped is to be used

the following
- maintenance indicator
- suction pressure switch
- intake filter
- special accessories,
page 15 - 17
- pressure gauge
- suction pressure switch /
type DG 150 U / switch
setting, see standard
instruments
- suction from the pipe via
silencer / starting strainer

10. Accessories- / Maintenance / Attendance

The attendance and maintenance of the accessories and the unit consists of the
following items: 10.1 - 10.10 / 14. - 17

In case of questions please refer to the Aerzen after-sales service.

In your queries please state the following:

Ü Order- and serial number.
Ü Describe arisen failures / malfunctions as detailed as possible.
Ü Steps taken so far to remove the failures.

If the compressor is sent back to the supplier, the following measures are to be carried
out:
Ü Drain-off the oil, otherwise it is a transport of hazardous goods.
Ü Provide polished parts with a preservation oil.
Ü Close compressor flanges by means of blind covers.

Spare parts and accessories

We expressly draw your attention to the fact that replacement parts and accessories
not supplied by us are neither tested nor approved by us. The integration or installation,
as well as the use of such products can, under certain circumstances, alter the original
design characteristics of the equipment. The manufacturer is exempted from any liability
for damages resulting from the use of parts and accessories not supplied by him.

11
 10.1 Maintenance plan
Whenever it is being worked on the compressor, it must be ensured that the compressor is
switched off, otherwise there is risk of injury and damage!
In order to achieve long lifetime and optimized operation conditions, the below mentioned
maintenance work is to be carried out within the stated intervals. urs

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Fixing bolts and
screwings
l

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- retighten after
cooling down of
machine
Starting strainer
if necessary
- check,
if no more
l
contamination
it can be dismantled
Intake filter
- check filter contamination,
if necessary replace filter l
insert, max. -45 mbar
- replace
filter insert
l
Ventilation slots
- of acoustic hood l
to be cleaned
Condition of V-belts
- to be checked and l l l l
replaced if necessary
Pulley alignment
- to be checked,
adjust if necessary l l l l l
Control,
fault indicator,
pressure- and
temperature sensors
l l l l
- check functioning
Pressure valve
- check functioning l l l l
Oil level, -pressure
- to be checked l l
Oil filter
- to be replaced l l
*upon difficult operation l*
Lube oil
- to be replaced l l
*upon difficult operation l*
Cooler lamellar,
wired mesh, oil
demister l l
- to be cleaned

Non-return flap
- to be checked for
wear and leakage
l
Drive motor
- Adhere to maintenance intervals and maintenance indications of motor
- to be maintained
- pre-lubrication periods manufacturer !
to be considered - Additional indications for Aerzen motors are to be kept !
Main inspection / maintenance
- Replacement of wear parts l
- Inspection of complete machine

12
 10.2 Inspection / - dates
After 3 years or 20.000 operating hours we recommend a general inspection at
site by an Aerzen technician. On this occasion a preventive overhauling of wearing
parts, such as bearings, sealings or similar is effected. We recommend to keep wearing
parts on stock, in order to avoid waiting times and non-productive times in case of
failures. The maintenance dates repeat at the intervals mentioned.
The maintenance intervals for accessories, such as e.g. driving motor etc., can be taken
from the corresponding instructions from the manufacturers.

10.3 Intake filter

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Ü The cleaning intervals depend on the degree of contamination in

the intake air. Observe the maintenance plan!
Ü The contamination of the filter is displayed by means of the
red trailing indicator of the maintenance unit.
Ü A zero point adjustment is to be carried out on the unit prior
to the initial operation. Pull out the front plug and turn the set
screw by means of a screwdriver.
Observe “+ and -” designations!
Ü The red trailing indicator is to be re-positioned between 0 to
Maintain
-10mbar prior to initial operation and after every filter change.
intake filter Ü As contamination increases, the red trailing indicator is pulled
along by the black indicator and remains on the maximum
prevailing intake pressure.
Ü The filter element is to be replaced when the trailing indicator
reaches the red sector of the scale.
Ü The trailing indicator is to be re-positioned between 0 to
-10mbar after the filter has been replaced.
Ü Replace element by removing the retaining nut.
Remove the filter element from the guide rods.

10.4 Intake from piping

Ü Upon intake from a closed piping system a starting strainer resp. a filter housing
is to be installed upstream of the compressor intake side. Depending on order it is
included in scope of supply. Therefore the machine is protected against contamination
and torn foreign particles in intake flow.
Ü The resistance of starting strainer / filter element, max. 45-50 mbar, is to be monitored
and not to be exceeded.
Ü If the strainer stays clean after approx. 500 operating hours, it can be dismantled and
replaced by the supplied adjusting ring.
Ü The filter element is to be checked resp. replaced according to corresponding indications
'intake filter' of maintenance plan.

starting
strainer
DN Øf m g
—————————————————————
50 105 112 15 filter housing
80 140 112 15
100 158 142 15
125 188 162 15
150 212 182 15
200 268 227 15
250 325 243 15
300 375 200 15
350 435 460 15

13
400 485 342 15
10.5 Oil filter
Ü The oil filter is to be exchanged on occasion of every
change of lubricating oil.
Ü The filter fineness is 10 µm and the filter resistance at clean
condition is approx. 0,2 bar.
Ü The max. resistance must not exceed 2,0 bar.
Ü The compressor switches off at an oil pressure of approx. 1,8 bar.
Upon frequency converter operation it switches off at approx. 0,5 bar (g),
a further switch becomes necessary.
Ü Disassembly is effected e.g. by means of an oil filter tape assembly device or similar.

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Ü For assembly of the new oil filter slightly lubricate the sealing ring and hand-screw the
filter.

10.6 V-belt pulleys

Ü Assembly: All polished surfaces of the bores and the jacket of cone of the tension
sleeve are to be degreased.
Ü Insert Taperlock bushing into hub and turn bushing in such a way, that half threaded
bores each are opposite half even bores.
Ü Slightly grease set screw (size 1008-3030) or pan head screw (size 3535-5050) and
screw them in but do not yet tighten them.
Ü Clean and degrease shaft. Put pulley with Taperlock bushing onto the shaft up to the
required position.
Ü Between fitting key and the bore slot there must be a gap.
Ü The fixing screws are to be tightened by means of a torque wrench by the values
indicated in the chart.
Ü After a running time of 30 - 60 minutes the screws are to be checked for tight fit and if
necessary to be retightened.
Ü In order to prevent foreign particles from penetrating, fill up the screw heads with
grease.
Disassembly: Loosen and unscrew all screws. Depending on the size of the bushing
one or two screws are to be greased and screwed into the bore of the pulling-off thread.
The screws are to be tightened steadily until the bushing moves away from the cone.
Pulley and bushing are now to be taken off the shaft.

l Pulling-off thread

10.7 Oil demister

Ü The oil demister is joined with the gearbox casing and
sucks-off oil vapours. Standard operating data
Ü The oil condensed through centrifugal action flows back 4 AP 71-2 B14A
to the oil reservoir via the suction pipe. 230 / 400 V 50 Hz
Ü The oil demister is switched with the driving motor. 254 / 440 V 60 Hz
IP 55
Ü Checking the operation can be integrated into the 0,37 kW
safety chain.
Ü The direction of rotation can be selected freely.
After each 4000 operating hours or half a year the wire mesh is to be cleaned.

14
 10.8 Oil cooler / oil temperature regulator
Ü The oil cooler maintains the oil temperature within the required limits.
Ü The fan driven directly by the compressor presses the cooling air through the cooler.
Ü The oil flow is lead through the cooler depending on the temperature via a thermostat.
The regulating temperature of the thermostat is approx. 55 °C.
Ü The oil temperature is up to 95 °C.
Ü The cooler lamellas are to be cleaned after 4000 operating hours or half a year.
.
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Beispiel / Example

Oil cooler Oil temperature regulator

10.9 Oil pressure regulating valve

Ü An oil pressure regulating valve is to be set between 2,0 and 3,0 bar (g). lt.
At factory it is preset.

Ü Changing of the oil pressure:

- Removal of the protection cap
- Adjustment of the threaded spindle (1), which is fixed by a locknut.

Example Oil pressure regulating valve

15
10.10 High-lift spring safety relief valve
Ü The safety relief valve serves as overload protection of discharge-sided piping
components within Aerzen scope of supply.
The safety relief valve is not a overload protection for the compressor!
Ü The valve only serves for the protection of our delivery share.
If the subsequent unit shall be protected at a lower level, a further safety
relief valve needs to be installed downstream of the non-return flap.
Ü No shut-off organ may be placed between valve and compressor.
Ü The valve is not a regulating organ and must also not be applied as such.

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The valve is set to the following values by the manufacturer and is leaded depending
on the design:
- VM-compressors pe = 4,2 bar
- VML-compressors pe = 2,8 bar
Ü An adjustment is only possible after consultation with AM.

Ü The function of the valve is to be checked acc. to the periods of time

stipulated in the maintenance plan by means of manual lifting.

ATTENTION ! Upon lifting hot air escapes.

Example
High-lift spring safety relief valve

16
 11. Acoustic hood for unit
Ü The acoustic hood is made of galvanized steel plate.
Ü Aeration is effected via a fan wheel installed directly on the compressor shaft, specific
to the type separately driven fans are used.
Ü The fan wheel presses the air out of the hood and consequently provides sufficient
aeration and heat dissipation.
Ü The temperature in the acoustic hood is approx. 10 °C higher than the ambient ---
temperature.
Ü The hinges are to be re-lubricated periodically acc. to the installation conditions.
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12. Special accessories

12.1 Start-up unloading device / AEROMAT
Ü The start-up unloading device is installed in units which are driven by electric motors
with star/delta drive. Therefore, blowers resp. compressors can start in an unloaded
condition against the consisting supply pressure.
Ü Concerning drives with pole-changing motors a start-up unloading device with solenoid
valve can be applied, in order to start also in higher speed in unloaded condition.
Ü For frequency converter drives a start-up unloading device is not necessary.
Ü Following the setting the start-up unloading device works maintenance-free.
Ü Should the start-up unloading device not close after correct adjustment, the nozzle (5)
is to be cleaned by compressed air, please also refer to sectional drawing, page 16.

Attention!
Ü If the start-up unloading device is within the acoustic hood, in case of machine stand-
still an adjustment is to be effected step by step. Furthermore, the drive motor is to
be started paying attention to the starting frequency, also control the closing time.
Due to safety reasons all adjusting work within the acoustic hood must only
be effected when the motor is switched off!

l The necessary closing time is to be set as follows:

Ü In view to acoustic hoods the outlet silencer is to be disassembled depending on
the unit design.
Ü Upon delivery the maximum closing time is adjusted.
Adjustment Ü The start-up unloading device may only completely close directly after change-over
at star/delta from star to delta.
Ü The closing process can be noticed by hearing and can also be seen due to the
starting discharge pressure gauge.
Ü If necessary change adjustment, in order to receive optimum closing time:
The closing time is to be set by loosening the counternut (10) and moving the
spindle (8):
- spindle (8) clockwise closing time is decreased
- spindle (8) anticlockwise closing time is increased
Following the adjustment, tighten counternut (10).
Ü Following the adjustment, all loosened and disassembled component parts are to be
fastened properly.

17
 Pole-changing
Ü The start-up unloading device is to be set to operation with „lower speed“ and acc. Adjustment at
to steps 1 - 5 in case of star/delta-drive.
Ü Closing time: pole-changing
Regarding pole-changing motors the closing time is to be set in the lower speed
range as long as possible, so that in case of higher speed an acceptably long
closing period can be still obtained.
Ü If this is not possible due to too high conveying quantity deviations, a solenoid valve
will be applied in addition.
Ü The solenoid valve (9) keeps the start-up unloading device open at „high speed“ in
case of direct run-up.
Ü The solenoid valve is switched via a time relay, so that it is opened prior to

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switching-on of the high speed and it is closed after run-up.

10

1 spring
2 blow-off opening
3 valve housing
4 protection grid
5 hollow spindle with
nozzle
6 diaphragm
7 valve
8 spindle,
9 solenoid valve
10 counternut

12.2 Constant speed unloading device

This facility renders it possible to start the compressor against existing line pressure.
It can be used for VM-compressors.

Relief valve Throttle flap with control cylinder

Ü There is a throttle flap in the suction line. Control is effected via a solenoid valve
by means of oil pressure.
Ü The throttle flap is provided with a bore adapted to the conveying quantity through
which the compressor sucks in at idle running mode and during starting.
Ü In the pressure line there is a relief valve in a bypass line. Control is effected via a
solenoid valve by means of air pressure.

18
 Ü Starting takes place in idle running mode, with closed throttle flap and open
relief valve.
Ü A pressure sensor with a Min.-Max. contact is installed downstream of the non-return
flap in system pressure and controls the solenoid valves by pulses.
Ü When starting the unit the pressure sensor is bridged for approx. 10 seconds.
Ü During this time the compressor starts working in idle-running mode, the driving motor
can reach nominal speed.
Ü The compressor sucks-in via the bore in the throttle flap and blows off the air to
atmosphere via the relief valve.
ATTENTION! Hot air is escaping!
Ü Following the 10 seconds the throttle flap starts opening and closing the relief valve.
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The compressor is now working in full-load mode.

Ü If the system pressure is reached a pulse is given via the max.-contact of the pressure
sensor, the relief valve opens, the non-return flap to the system and the throttle flap close.
Ü The changes of switching idle-running/full-load mode, must not repeat more than 20 times
per hour.
Ü The switch-contacts, Min.-Max. are to be set as far as possible, at least 0,5 bar.
Ü If the run-up time of the motor is longer than 10 seconds, the solenoid valves have to be
controlled externally directly, e.g. by delta contactor, after switching from star to delta.
Ü In case of a control for released starting and released run-down no pressure sensor
is existing. Apart from that the control is identical.

Example
Scheme for constant speed-unloading device

1 intake filter 8 blow-off silencer (not always installed)

2 throttle flap 9 3-way solenoid valve
3 compressor 10 pressure sensor
4 discharge silencer 11 3-way solenoid valve
5 safety relief valve 12 motor
6 non-return valve 13 coupling
7 relief valve 14 pressure selector relay

19
13.1 / 13.2 Instrumentation / Aerzen control
A control- and protection function is taken over by an instrument cabinet with
accessories, such as pressure gauge etc. or an instrument cabinet with electronic
control.
13.1 Instrumentation

Example

Fault indicator l

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Operating hour meter l

Discharge-, oil temperature l l

Discharge-, oil pressure gauge l l

Maintenance indicator l

Instrumentations
Maintenance indicator for intake filter
The intake filter is to be changed, when the
pointer reaches the red zone at -45 mbar.
The pointer is reset to initial position by
pushing the reset button.
Intake pressure switch
l Switch setting: 0,94 bar (abs.)
The compressor is switched off at
decreasing intake pressure (e.g. suction
strainer contamination).
After shutdown the switch is promptly
released again.
Discharge pressure switch and
pressure gauge
l Switch setting:
0,15 bar above operating pressure
The switch is automatically released again
above operating pressure after response at
decreasing pressure, approx. 1 bar
below response pressure.
Discharge temperature switch
l Switch setting: 15 °C above operating
temperature. The compressor switches off
when the set temperature is exceeded. It
can be started again after the discharge
temperature has sunk. The discharge
temperature depends on the discharge
pressure, intake pressure, intake
temperature as well as the compressor
speed.
20
 Instrumentations

Oil pressure switch and pressure

gauge
l switch setting: 1,8 bar (g).
The switch cuts off at decreasing oil
pressure and is operative again in case
of increasing pressure at approx. 10 %
above the set point. The oil pressure is
to be set between 2,0 and 3,0 bar(g).
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Oil temperature switch

l switch setting: 100°C
when using SAE 5W-40
The compressor switches off when
the set temperature is exceeded.
The switch releases again when
the temperature sinks.
The oil temperature is between
60 °C and 95 °C.

Fault indicator relay

Here all faults, which have led
to a shutdown, are optically
displayed. The compressor can only
be started after pushing the release
button.

Timing relay for oil pressure

monitoring
l Time delay setting: 10-15 seconds.
When starting the compressor an oil
pressure slowly builds up. It is bridged
for the time stipulated, so that the oil
pressure switch does not respond and
the compressor can be started.

Special oil pressure switch

l Switch setting: 0,5 bar.
The switch is only required in case of
speed controlled drives and speeds
below 50 %. The function is the same as
described under “Oil pressure switch and
pressure gauge”.
Note:
Ü Before commissioning the pressure gauges are to be deaerated (if available) by
cutting off the rubber nipples on the upper side of the pressure gauge.
Ü Compressor restart following switch actuation must be independent of switch reset,
i.e. the compressor must not restart by itself following switch reset, but rather must
be restarted manually once the cause of failure has been determined and corrected.
Ü The monitoring devices are factory set prior to delivery.
Ü The set points of the intake- and oil pressure switches are adjusted in a fixed
condition and cannot be changed.
Ü Should the discharge pressure switch be reset, use a pressure gauge, as the scale
provided on the switch is intended for us as a guide only.
21
13.2 Control / standard:

1 2 3 4 6

bar °C

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psi °F

Example

5 12 13 9 10 11 8 7

Item Display Indication Description

(example)

1 3-digit segmental display 16.0 discharge pressure

... sensor error
2 indicated unit item 1 bar reversible (code 12)
LED display psi parameter P. unit
3 3-digit segmental display 150 discharge temperature
... sensor error
4 indicated unit item 3 °C reversible (code 12)
LED indication °F parameter T. unit
5 alphanumeric display ready to start status-/operation indication
2 rows with each 16 symbols 08 Mar thurs 10:39 fault indication/measur. values
6 green rectangle
START compressor at site "START"

7 red rectangle
STOP compressor at site "STOP"
back to base menue
8 reset acceptance of an alarm-or
maintenance signal
9 minus back to base menue or to
former menue point
indication of software version
10 plus selection from main-or sub-
menue
11 enter, acknowledgement select "Change values" and
confirmation of change
12 arrow to top select sub-menue point

13 arrow to bottom select next sub-menue point

22
 Control / standard:
The control can be applied completely with an additional power panel or as
indication- and monitoring device.

Basic functions:
Ü Control of a star/delta starter.
Ü Control of a direct drive, e.g. frequency converter operation.
Ü Oil pressure suppression.
Ü Operating hours counter.
Ü Load hours counter.
Ü No-load hours counter.
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Ü Changeover remote-/local operation.

Ü Password protected alarm- and shutdown limit values.
Ü Intermittent periodic duty.
Ü Reclosing lockout.

Additional functions:
Ü Service- and maintenance indication.
Ü PID controller for the discharge pressure control.
Ü Manual control for a frequency converter or a bypass control valve.
Ü Suppression of the intake pressure for max. 30 seconds.
Ü Suppression of the discharge pressure for max. 30 seconds.
Ü Selection of four different control types.
Ü Error memory with max. ten entries.
Stored will be the reason, date and time.
Ü Changeover between BAR and PSI, °C and °F.
Ü Meter for starts per hour.
Ü Different languages may be selected.

Remark:
Further information and options are included in the user information ...

Password protection
without password protection with password
Ü Selection of the parameter protection
in one menue
Ü Press Enter button (value flashing) ( (code number flashing)

Ü Adjustment of code numbers /

+
Ü Confirmation of code numbers / (paramet. value flashing)
Ü Change of value + +
Ü Confirmation of value

Code numbers:
Control data / operating parameters / -types : 11
Machine parameters : 12
Access to the works adjustment, service data, diagnosis, configuration entries
is only possible by Aerzen experts.

Attention !
A parameter modification in case of emergency stop button is not stored in the
device.

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Indication in basic menue:
Ready to start = The compressor can be started
Starting active = Starting procedure of compressor
Unloaded = Compressor operates with nominal speed in no-load operation
Loaded = Compressor operates with nominal speed in load operation
Stopping active = No-load operation active, compressor switches off after time x
Starting lockout = Reclosing lockout of compressor active
Standby = The compressor starts automatically upon reaching of the
lower system pressure
26.03.2001 07:28 = day.month.year time
Failure = present alarm flashing

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Technical data Description
Input voltage 4460 VAC
440 VAC
400 VAC
230 VAC
120 VAC
Input current 1,0 A ac max.
Frequency 50 – 60 c/s
Control voltage AC 24V 2,6A, 2 miniature fuse 2,5 AT, 5x 20mm;
Note: The control voltage must not be
earthed.
Control voltage DC 24V 1,5A, miniature fuse 1,5 AT; 5x 20mm;
Note: The control voltage must not be earthed.
Type of protection IP 55, control device front IP 65
Ambient temperature -5 °C - +40 °C
Storage temperature -25 °C - +55 °C
Potentialfree contacts max. switching voltage 250 VAC
min. switching voltage 12 VAC/ DC
limit. continuous current 6 A
max. breaking power,
ohmic load: 24VDC 140W
48VDC 20W
60VDC 18 W
110VDC 23W
230VDC 40W
250VAC 1500VA
min. switch. capacity 120mW
Input connecting relay input voltage 24 VAC/DC
typ. input current 11/ 8,5 mA
typ. response time 6 ms
typ. release time 15 ms
with operat. display and
bridge-connected rectifier

24
 14. V-belts - installation / - replacement
For all work necessary at belt drive, the machine is to be taken out of operation and
disconnected properly from the supply.
A starting / operation of the machine must be excluded.
Attention: At belt drive and hinged motor plate risk of shearing and squeezing!

Ü Open belt protection housing and / or acoustic hood.

Ü Dismount protection cover of compressor- resp. blower belt pulley, only in case of
design with acoustic hood.
Ü Protection cover / plastic plate of motor belt pulley to be dismantled, only in case of
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design with acoustic hood.

Ü At first placement of belts the transport locking screws resp. the transport locking angle
are to be removed.
Ü Depending on machine size the hinged motor plate is to be lifted by hand or by
means of the supplied hydraulic jack kit until the belts can be placed upon resp.
exchanged.
Ü During lifting the hinged motor plate is to be supported step-by-step, in order to avoid
possible accidents.
Ü The V-belts are to be replaced set by set.
Ü Regarding the acoustic hood design the V-belts are to be turned via a fan blade omitting
the fan channel. Mount V-belts.
Ü The hinged motor plate is to be completely lowered.
Ü The tension of the belt drive is effected automatically by the motor weight.
Ü Belt protection housing and protection covers to be mounted properly and / or acoustic
hood to be closed.
Ü Upon design with belt protection housing the distance between motor drive shaft
and plastic cover is 10 mm maximum.

Disassembly of various transport safety devices

Lifting of various hinged motor plates

ATTENTION! Support hinged motor plate upon lifting.

Motor shaft cover Fan cover Fan cover

25
15. Lube oil instructions for
VM / VML Screw Compressors

For the selection of the lubricating oil brand, additivity and viscosity class are
determinant.
Under consideration of the application conditions the following oils with corresponding
viscosity and additivity are to be used.

General requirements to the lube oil properties at operating oil temperature

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Kinematic viscosity : ³ 13 cSt (mm²/s)
Kinematic viscosity at –10 °C : £ 3500 cSt (mm²/s)

Minimum properties of oil additivity

· EP-wearing protection additives for the application in roller bearing gearboxes
· Oxidation stability up to 110 °C
· Foam suppressor
· Detergencies for solution of deposits
· Neutrality compared with sealing materials made of Fluor-Propylene-Methyl (Viton)
· Neutrality compared with single-component synthetic resin primers.

1. Single- or double shifted operation / intermittent operation

Intake temperature up to 60 °C
Discharge temperature up to 280 °C
Ambient temperatures £ 10 °C

SAE 5W-40 / Fully synthetic high-capacity smooth running motor oil

API CF or higher
ACEA B3 / E3 or higher
Example Special rotary piston oil made by Aerzener,
Order No.: 160 754 or 160 755

ISO VG 68 / Fully synthetic (PAO) Poly-Alpha Olefin, gearbox – or compressor oil

Use of oil only in connection with an oil heating.
The lube oil is to be heated up to at least + 10 °C prior to starting.
Example MOBIL SHC 626

2. Continuous operation / 24 hours per day

Intake temperature up to 60 °C
Discharge temperature up to 280 °C
Ambient temperatures non-seasonal > + 10 °C

SAE 5W-40 / Fully synthetic high-capacity smooth running motor oil

API CF or higher
ACEA B3 / E3 or higher
Example Special rotary piston oil made by Aerzener,
Order No.: 160 754 or 160 755

ISO VG 68 / Fully synthetic (PAO) Poly-Alpha Olefin, gearbox – or compressor oil

Example MOBIL SHC 626

26
 3. Lubricating oils in the foodstuff- and pharmaceutical industry
Example KLÜBER Hy Syn FG 68

4. Lube oils for VM compressors, upon application of certain differential

pressures and speeds

If one of the items 4.1 to 4.3 corresponds to operating data, paragraphs 1, 2 and 3
are inapplicable!
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4.1
Differential pressure Dp = p2 – p1 1,5 up to 2 bar
pressure ratio used Pi_i = 3

ISO VG 46 / Fully synthetic (PAO) Poly-Alpha Olefin, gearbox – or compressor oil

Example BP Enersyn RC-S46

4.2
Differential pressure Dp = p2 – p1 1,0 up to 1,5 bar
Pressure ratio used Pi_i = 3
Max. circumferential speed of main rotor £ 90 m/s

The max. circumferential speed is achieved at the following speeds

Type n (1/min)
VM 8 19 000
VM 15/21 15 000
VM 37 12 000
VM 45 9 500
VM 75 7 500
VM 85 6 000
VM 140 4 800

ISO VG 46 / Fully synthetic (PAO) Poly-Alpha Olefin, gearbox – or compressor oil

Example BP Enersyn RC-S46

4.3
VM compressors with Pi_i = 4 are not approved for differential pressures £ 2 bar.

27
Notes concerning miscibility / exchange of lubricants
High-capacity smooth running motor oils and PAO-oils are completely consolute.
Upon changing-over from one of the above oil brands to another, special measures are
not to be considered.

In order to maintain the application properties of the new oil, after an operating period of
24 hours the oil to be changed should be completely drained and exchanged against
new oil.

For possible refilling only the same oil brand should be used.

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28
 17. Exchange of lubricants
VML 18R / VML 25R / VML 40R
VM 8R / VM 15R / VM 21R / VM 37R / Gehäusemantelkühlung
Refill oil
Refill oil
ÜÜ Oil drain must be sealed / pay attention to tight fit.
ÜÜ Open oil filling.
ÜÜ Fill up oil until center of sight glass / Attention! Oil runs down the internal walls.
ÜÜ Close oil filling.
ÜÜ Take compressor into operation for some seconds until oil pressure is reached.
ÜÜ Switch off compressor and wait for oil level regulation in oil reservoir.
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Ü Adjust oil level until center of sight glass is reached.

Ü Repeat start- and filling procedure.
>>>Pay attention to switch-on frequencies of drive motors.<<<
Ü If necessary - fill in oil. Adjust oil level at sight glass center.
Ü Ü Close oil filling.
Ü Ü Especially after initial oil filling the oil level is to be watched carefully and
if necessary - to be adjusted after short operation time.

Drain oil

Drain oil
Ü Ü Screw off cap (1) of drain valve (A).
In case of tight fit the valve (A) and/or (B) is to be held by means of a
fork wrench and the cap is to be released with a further wrench.
Ü Ü Screw supplied hose onto drain valve (A), whereas hose end leads into collecting
reservoir.
Ü Ü Upon fixing of hose, drain valve opens automatically.
Ü Ü Drain oil completely.
Ü Ü Remove hose from drain valve and close with cap by hand.
Ü Ü Waste oil is completely disposed of.
Ü Ü If the drain valve works loose in the fixing thread, it needs to be replaced
by a new valve with new sealing.

Ü Disassemble locking screw (B), collect used oil and lead it into a reservoir.
Ü Dispose off used oil properly and environmentally friendly.
Ü Assemble locking screw properly with new sealing ring.
Ü Pay attention to tightness.

Ü Upon oil change pay close attention to the oil temperature. The oil temperature must
not exceed 60 °C due to thermal load of "drain hose".
Risk of combustion with oil temperature exceeding 60°C !

29
 english
B
oil drain
in addition to compressor
with housing jacket
cooling

oil filling
oil level
oil level too high,
center of sight oil in the conveying
glass chamber

oil level too low,

mechanical
damage bearings
and gear wheels

The lower second sight glass

has been omitted dependent
on the type !

A
oil drain

Beispiel / example
A/B

oil
drain
valve

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 16. Lube oil quantities
Total oil fillings in approx. litres (up to center of upper sight glass)
VM 8 R* 18 l VM 37 R* 50 l VML 18 R 8l
VM 15 R* 26 l VML 25 R* 21 l
VM 21 R* 26 l VML 40 R 32 l
* with intermediate gear
The oil level is to be checked when the machine is at standstill and must be at the center
of the upper sight glass.
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18. Operation of compressors with

housing jacket cooling
VM 8R, VM 15R, VM 21R, VM 37R

A compressor housing jacket cooling makes possible a.o. improved start conditions as
well as a continuous cooling during operation and consequently arranges for
improvement of efficiency.

Compressor in operation
Ü In case of an operation-oil temperature below 10 °C the lube oil is warmed up by
means of oil heating.
Upon achieving of minimum temperature of 10 °C the oil heating switches off.

Ü The temperature measurement is effected in the oil reservoir depending on design of

the control system, by a resistance thermometer or a temperature measuring switch.

Ü The corresponding circuit diagram for the energy supply is to be observed !

Beispiel /
Example

oil heating

Standard operating data

Voltage 230 V
Amperage 16 A
Rating 870 W
Frequency 50 Hz
Type of protection IP 65

Compressor with housing jacket cooling

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 19. Failure analysis
Malfunctions Possible causes Remedy

- Abnormal running - Bearing damage - Exchange

noise - Rotary pistons contact each
other or in the conveying
chamber
- Foreign particles in gear wheels
- Shaft deflection
- Check clearance adjustment /
if necessary exchange
- Clean wheels
- Measure shaft deflection / if
necessary exchange shafts

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- Failure due to intake - Intake filter or starting strainer - Clean, exchange
pressure contaminated
- Closed valve in intake line - Open valve
- Gate installed - Draw gate

- Failure due to - Compressor overload due to - Observe performance limits

compression discharge excessive discharge pressure
pressure - Closed valve in discharge line - Open valve
- Gate installed - Draw gate

- Failure due to - Intake pressure sunk - Check suction line

excessive discharge - Discharge pressure increased
temperature - Lower volumetric efficiency due
to increased clearances
- Intake temperature increased
- Missing exhaust air
- Outlet silencer of acoustic hood
contaminated
- Check pressure line
- Check adjustments of
clearances and if necessary
exchange individual
components
- Provide sufficient intake air
- Provide sufficient exhaust air
- Clean

- Failure due to - Oil cooler contaminated - Clean

increased oil - Fan defective - Exchange
temperature - Defective oil temp. control valve - Exchange

- Failure due to lack of - Oil filter contaminated - Replace

oil - Defective oil pump
- Oil pump draws in air
- Oil regulating valve defective or
blocked
- Oil level too low
- Exchange
- Check suction lines
- Move spindle, knock slightly
on housing, exchange
- Refill, find cause of lack of oil

- Compressor leaks oil - Oil demister has failed - Check motor electrics and
-mechanics
- Defective oil seal - Replace seals
- Screwings in oil line loose or - Retighten, seal
leaky

- Oil in conveyed air - Oil chambers overfilled with oil - Drain, clean conveying
chamber

32
 Malfunctions Possible causes
- Compressor too hot - Intake filter contaminated
- Ambient temp. too high
- Hood ventilator defective
- Oil level or viscosity too high
- Overload
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- Intake volume too low - Leaky piping
- Incorrect dimensioning of
compressor
- Piston wear
- Compressor runs in - Non-return flap defective resp.
reverse direction after leaky
switching-off
- Failure due to motor - Excessive discharge pressure
overload - Mechanical damage within the
compressor or motor
- Voltage drop in motor
- Operating data deviate from
order data
- Abnormal noise - Pulley alignment
- End of the belt vibrates - V-belts worn
- Machine damaged, - Motor and control system are
due to incorrect connected to two different
power supply networks
After each interference at the compressor due to malfunction, the following is to be
checked:
Ü Smooth running.
Ü Contactless rotation.
Ü Proper functioning.
In case of resistances, do not start compressor!
After starting observe the compressor thoroughly!
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Remedy
- Exchange
- Ensure sufficient room
ventilation / inlet- /
exhaust air
- Replace
- Adjust / drain
- Keep operating data
- Seal
- Compare with performance
diagram
- Replace pistons, if necessary
- Replace it
- Check pressure pipe
- Repair, consult manufacturer
- Check electrical lines, adjust
capacity, refer to instructions
of motor manufacturer
- Compare performance data
with measured values
- Measure again, correct if
necessary
- Examine V-belts, replace if
necessary
- Motor and control voltage are
to be connected to one
supply network
- Alternatively: installation of a
power monitoring
20. Recycling / Disposal
Ü All waste products are to be disposed of or treated not harmful to the environment.
Ü Used lubricants are to be disposed of properly.
Ü Contaminated components and auxiliary material are to be packed and decontaminated.

Recycling Disposal

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34
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21. Information sheet

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35
english

Aerzener Maschinenfabrik GmbH

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

Aerzener International Rental B.V.

www.airental.nl
phone +31 (0) 26 44 64 723
Telefax +31 (0) 26 44 63 570
e-mail info@airental.nl

Kundenservice
( 0 51 54 / 81-529

Aerzen im
8 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.