Ident number: 195.02022 BA 101/04.01/03/GB

Screw-type CompressorsSCK 21 - SCK 52

Maintenance and Operating InstructionsSpare Parts List

Quality AssuranceDIN ISO 9001 certified

3

Index Page Individual machine data:

Type: SCK

Machine-No.

System with the following design/optionsthat differ from the standard version:

For the perfect and troublefree operation you expect from your screw-type compressor, we recommend to keep in stock one set ofmaintenance and wearing parts, e.g. suction filter, oil filter, oil separatorand lube oil. Our after-sales service p would be pleased to assist youin the selection of these spare parts.

p On the reverse of this brochure you will find our address, telephonenumber and fax number.

p In case of further inquiries please specify the data shown on thecompressor nameplate (electric box back side).

Validity:

This manual and spare parts list is valid as from maker’s n°

SCK 51 - SCK 151 : 260.607Date : 02.04.2001

General information and safety instructions 4Functional description 5Erection 6Operating 7Commissioning 9Maintenance 10Troubleshooting 12Options 13Technical Data 14Spare parts overviews 15

Plan and electric parts 15Unit parts 16Lines and gaskets 18Suction control and temperature control 20Separatorbox 21

Spare parts list 22Service completed 26

4

Transport:Transport is only allowed with a (fork) lift truck.

General information and safety instructions

General information

These maintenance and operating instructions contain informationnecessary for the perfect and troublefree operation of your screw-type compressor. Thoroughly read these instructions beforecommission, because damage caused by improper handling is notcovered by our warranty.

F Regulations, laws and important informationThis compressor has been built in accordance with the EG machineregulations 98/37/EG. All our specifications about the noise emissionare in accordance with EN ISO 3746 and the EG machine regulation,chapter I, section 1.5.8 etc., this manual in according to section 1.7.4,etc.

The machine has been built in accordance with the general technicalrules. Operation can still mean danger for user or others, or evenresult in damage to the machine and other values.The machine may only be used to produce compressed air. Other useis strictly not allowed.

Neither the manufacturer nor the supplier take the responsibility fordamage caused by other use as to produce compressed air.

THESE BRIEF SAFETY INSTRUCTIONS DO NOT RELIEVE YOUFROM OBSERVING THE FURTHER DETAILED INSTRUCTIONS!

FFFFF Sign for instructions which have to bestrictly observed

F 1. Safety instructions

1.1 Safety instructions for personnel andcompressor function

F The compressor system must only be erected, operated andmaintained by trained p and from the user authorized personnel.Each authorized person must have read and understood the completemanual. Unauthorized conversions and modifications which influencethe safety of the compressor are not allowed.

F In any case all work to be carried out on the compressor is to bedone in cut-off and pressure-relieved condition. The compressor systemis to be protected against unauthorized reconnection.

Attention - caution! The sound absorbing bonnet of thecompressor is part of the protection against accidentalcontact and may only be opened upon completion of theabove mentioned measures.

1.2 Safety measures to be taken beforecommissioning

F The allowable compressor room temperature is : +5 °C to +40°C. The electric connection must only be carried out by an authorizedspecialist. Check the correctness of current, voltage and frequency.The correct supply line is to be dimensioned and protected incompliance with the electrical data mentioned on page 13.

1.3 Safety measures to be taken duringcommissioning

F Check the maximum oil level at the lower edge of the oil fillerneck (11.1). Fill about 0.2 l. oil into the oil prefill plug of the suctionunit (06). Check the correct direction of rotation (see arrow on theelectric motor). Switch on (and immediately off) for only a very short(max. 0.5 sec.) time.

1.4 Safety measures for maintenance andoperation

F All work is to be carried out with the machine at standstill andpressure-relieved. Switch off the power supply and protect it againstreconnection. Close the shut-off valve to the compressed-air pipingsystem (or compressed-air receiver tank). Damaging condensate waterin the oil tank (11) should only be checked out in cold condition andmust be drained. Check the oil level only with the compressor in warmcondition.

Attention: all cooler nozzles are to be counterbacked with asufficient key; mind not to overturn the cooler connections.

Caution! The compressor system oil tank (11) can be underresidual pressure! Hot and oily compressed air penetrateswhen the safety valve (12) is operated! Do not dischargethe compressed-air condensate into the sewage system (referto section 3.4).

5

Functional description

2. Functional description

2.1 The driveThe electric motor (01) drives the compressor stage (04) through theV-belt pulleys (02) and the V-belts (03).

2.2 The air pathAir flows into the suction filter (05) and the suction valve (06) intothe compressor stage (04), which compresses the air. The relief valve(07) closes and the suction valve (06) opens at star delta and therevers way at the upper pressure point into the idle running phase.The oil separator (08) decreases the residual oil to 2 - 4 mg/m3. In thecompressed-air recooler (09) the compressed-air temperature reducesto 9-13°C above ambient temperature and leaves the machine throughthe compressed-air outlet (10).

2.3 The oil circuitCooling and sealing lube oil flows into the compressor stage (04) bythe produced pressure in the oil tank (11). The oil leaves the compressorstage (04) mixed with the compressed air. The - placed according tothe regulations - safety valve (12) protects the machine against excesspressure. The oil will be separated from the air up to 98% by ourspecial design of the oil tank (11), which collects the oil. The residualseparation of the oil will be carried out by the oil separator (08). Theworking temperature of the oil is optimized by the oil temperaturecontroller (13). The oil passes the by-pass line or the oil cooler (14)and flows through the oil filter (15) back into the compressor stage(04).

2.4 The air coolingThe cooling air fan (16) on the rear motor shaft (17) takes in coolingair and leads it over the electric motor (01), passing the oil cooler(14) and the compressed-air recooler (09) and leads it through thefor exhaust shaft connection prepared exhaust air grid (18) out of themachine.

Flow diagram 1314

15

06 05

01

0411

12

07

0809

10

18

05

061514

02

091011

04

08

17

12

16

1301

03

6

3. Erection

3.1 General informationF The screw-type compressor is mounted on a solid frame readyfor operation. Only a level solid floor is necessary for erection.

The screw-type compressor is to be placed in a cool, dry and dust-freeroom with proper ventilation and a room temperature between + 5°C and + 40 °C.

When the room temperature might fall below + 5°C, an additionalcompressor heating is to be installed into the compressor system oiltank (11) or the room is to be heated.

When the room conditions are inconvenient, it may be necessary, owingto excess heating, to dissipate the hot exhaust air by means of exhaustshafts or cooling fans for a sufficient supply of fresh air.

The place of installation shall be well accessible. Refer for assemblydimensions and required quantities of fresh air to the technical dataon page 13.

3.2 Pneumatic connectionF Screw-type compressors will be delivered complete and readyfor connection. The connection from the compressed-air outlet (10)to the piping system must only take place through a tape-sealed fle-xible hose, so that no forces can be transmitted between thecompressed air piping system and the compressor unit.

The pipe end of the piping system is to be thoroughly secured.

In order to avoid that the condensate collected in the compressed-airrecooler (09) is fed into the piping system or into the downstreamreceiver tank, a condensate trap with automatic separator is to beinstalled in the discharge line, if possible in direct vicinity of thecompressed-air outlet (10). Refer page 13 for the outlet dimensions.

A non-return valve between piping system or receiver tank andmachine is not required, because this device is already installed in thescrew-type compressor. It is, however, recommended to install a shut-off valve in the compressed-air line, so that the compressor is able tobe disconnected from the piping system, if necessary.

3.3 Electric connectionF Electric connection is only to be carried out by skilled electricians.

Check if current, voltage and frequency is according to the nameplatedata. The cross section of the feed line and the fuses are to bedimensioned in accordance with the local prescriptions ! Refer to thedata on page 13.

3.4 Condensate trapF The condensate collected in the condensate trap (refer 3.2) isoily and must not be fed into the sewage system without further treat(Our after-sales service would be pleased to assist you in the selectionof sufficient air-oil separation systems p).

Erection

7

Operating

4. Operating

The Air-Control is the central control element of the Compressors.

ENTER INFO

AIR CONTROL 1

Kompressoren ALUP___

Automatik

bar

o

C

M

4.1 DisplayThe display permanently displays the line pressure, final compressiontemperature and operating status of the compressor.

Restart Automatic Remote

bar

o

C

! M

Networkpressure

Compressortemperature

Error number,Warning number,Programming level

Symbol Error

Symbol Warning!

Symbol Motor operates

Symbol Compressor compresses

Symbol Heating on

Automatic restart after power failure

M

Restart

Operation mode „Automatic“Automatic

Flashing: Operation in „Remote On/Off mode“Constant: Operation through lead / lag control

Remote

4.2 Key assignment

I On keyThe green lamp flashes: The compressor i ready for useand may start automatically at any timeThe green lamp is lit: The compressor is running

Warning and error displayThe red lamp is lit: Compressor errorThe red lamp flashes: Warning

O Stop key to shut down the compressor (via idling)for input of codesfor acknowledgement of errors

INFO Information can be obtained on the set values bypressing several times:1x Cut-in pressure (bar)2x Cut-out pressure (bar)3x Safety pressure (bar)4x Min. start temperature (5.0 °C)5x Max. compressor temperature (110 °C)6x Total operating hours (h)7x Load hours (h)8x Residual service life air filter (h)9x Residual service life oil and oil filter (h)10x Residual service life oil separator (h)11x Residual service life lubricant (h)12x Residual service life to service (h)

ENTER Confirm entered values and parameters

Change values and parameters

Only in case of emergency the system may be shut down with theEMERGENCY STOP switch.

4.3 WarningsThe red lamp and the symbol ! are flashing. The correspondingwarning number flashes:

2 High compressor final temperature3 High network pressure11 Residual service life air filter < 100 h12 Residual service life oil/oil filter < 100 h13 Residual service life oil separator < 100 h14 Residual service life motor lubrication < 100 h15 Residual service life to maintenance < 100 h

Realised maintenance have to be acknowledged with Code 21.

8

Operating

Code 2 Mode0 = Automatic

(“Automatic” appears in the display)Idling time according to code 51

1 = Load-idling operationUnlimited idling time

2 = Automatic optional(an additional point appears in the display befor thetemperature value)Progr. level 1: max. pressure dropProgr. level 2: max. switching frequency

In all modes the compressor cuts in when the pressure falls below thecut-in pressure level and goes into idling mode when the cut-outpressure is reached. After the end of the idling time the motor cutsoff.

Code 3 Automatic Restart0 = no automatic restart1 = with automatic restart

(“Restart” appears in the display)

In the event of a power failure, which is shorter than the programmablerestart time, the compressor will restart automatically

Code 8 Local / Remote / GLWGenerally the system will be controlled locally.

0 = “Local” mode (standard)1 = Remote” On/Off mode (“Remote” appears flashing

in the display)2 = Operation with a lead / lag control unit with automatic

switch to to ”local” operation (Option)

Code 11 Cut-in and cut-out pressure

When pressing the INFO key once the current cut-in pressure (bar)appears in the display and can then be changed.

After pressing the INFO key a second time the current cut-out pressureappears (bar) in the display. The cut-out pressure can be changed andmust always be at least 0.1 bar higher than the cut-in pressure.

Code 18 Lead / lag operation0 = Standard without lead / lag control unit1 = Operation with a lead / lag control unit

(“Remote” appears in the display)

Code 21 Maintenance acknowledgementRelaised maintenance can be acknowledged by immediately pressingthe ENTER key and after that the O key.

Code 51 Idling, standstill and ru-up timeProgr. level 1: Idling time (10 - 1200 s)Progr. level 2: Standstill time (0 – 60 s)Progr. level 3: run-up time (3 - 30 s)

Code 90 Change of pressure unit0 = Pressure in bar (g)1 = Pressure in Mpa (g)2 = Pressure in psi (g)

Code 95 Change of temperature unit0 = Temperature in °C1 = Temperature in °F2 = Temperature in K

4.4 ErrorsThe red lamp shines and the symbol is flashing. The correspondingerror number flashes:

1 Pressure rated value wrong2 Parameters wrong3 Low voltage4 Voltage failure5 AirControl defect6 Emergency stop actuated7 Wrong direction of rotating8 Motor temperature to high9 Over current10 Over pressure11 Pressure drop through oil separator12 Maximum compressor temperature sensor13 Oil temperature sensor14 Pressure sensor15 Maximum compressor final temperature exceeded16 Network pressure exceeded

Errors have to be acknowledged by pressing the O-key.

4.5 ProgrammingThe factory settings may be changed by programming

1. Press the O-key until the message cod appears

2. Select the codes described below using the

keys; confirm your selection using ENTER

3. The code appears with 3 digits in the display. Changeof the flashing value ( ) with the keys;confirm your selection with ENTER

4. Certain codes allow settings in the second and thirdprogramming level after pressing of the ENTER key

5. Press the O-key to return to the main menue

Programminglevel

Set code

Flashing numbervalue ( )

9

Commissioning

5. Commissioning

5.1 PreservationMachines which are standing still after delivery ex works or are to bestored for a longer period before commissioning, will be filled up withpreservative oil. This preservative oil has to be drained and disposedtogether with the flushing oil (appr. 1/3 of the normal oil supply, whichwill be flushed through the operating unit for about 30 min.).

Please mind the initial lubrication of section 5.4 before commissioning!

5.2 Oil level checkThe maximum oil level is the lower edge of the oil filler neck (11.1).During operation the oil level will slightly fall by internal distribution.With rising machine temperature or even a temperature cut-off dueto low oil level, the compressor is to be filled up with fresh oil into theoil filler neck (11.1).

5.3 Oil qualityWith regard to the high load of the lube oil in oil injection cooledscrew-type compressors, we recommend to use very non-aging, water-repellent, non-foaming, anti-corrosion oils, e.g. our SPECIAL OIL. Thisoil is filled in by the works (refer to the oil tank (11) sticker).

F Different kinds of oils must not be mixed. In case other lubricantsare used, you should contact the after-sales service p. We only grantour warranty for the compressors when the use of equivalent lubricantsis verified.

5.4 Initial lubrication of the compressor stage(04) (refer to section 1.3)

F After a longer standstill period, e.g. between initialcommissioning and delivery ex works or after a longer works holiday,it may happen that there is no oil in the rotor compartment of thecompressor stage (04). This oil, however, is absolutely necessary forlubricating rotors and bearings in the starting phase. Therefore it isnecessary to fill about 0.2 l. oil into the prelube plug of the suctionvalve (06). Manually rotate the compressor stage (04) in the rightdirection of rotation until the sensible resistance disappears and theoil is passed through the stage (04). Mount the prelube plug againinto the suction valve (06).

If no additional oil is available (only use the same kind of oil) the oilcan be drained from the system by means of the oil drain (11.2).

Irregular operating machines and those which are standing still forseveral weeks should run for one hour every week, in idle mode, toprevent corrosion damage.

5.5 Direction of rotating (refer to section 1.3)F The direction of rotation must comply with the arrow on theelectric motor (01). When checking, the machine must only be switchedon (and immediately off) for a very short time (max. 0.5 sec.) in ordernot to damage the compressor stage (04). The direction of rotationcan be changed when two external conductors are exchanged.

5.6 StartingBefore starting the machine, verify that no persons can be endangered.The sound cover hood is part of the protection against accidentalcontact and leads the cooling air of the machine. It must be closedduring operation. Open the shut-off valve between compressor andcompressed-air system. Switch on the power supply.

Push the start key I. The green lamp lights up and indicates operationor, if the line pressure is above the set cut-in pressure, the starttemperature is below + 5°C or with activated remote control, onlyflashes stand-by.

CAUTION! A FLASHING GREEN LAMP MEANS THECOMPRESSOR CAN ALWAYS START UP AUTOMATICALLY

The lines carrying oil and compressed air are to be checked for leakages.

After the cut-out pressure is achieved the machine shuts down afterthe set follow-up time (automatic) or changes over to idle running(load-idle mode).

5.7 ShutdownPush the stop key O. The green lamp extinguishes. The compressorshuts down after the follow-up time, the suction valve (06) closesand the oil tank (11) is relieved. The line pressure is available up tothe non-return valve integrated in the separator box, i.e. thecompressed-air recooler (09) is admitted with line pressure. Programchanging and setting of pressure or time values can only be carriedout with the required code and the compressor at standstill.

6. Compressor maintenance

6.1 General informationF All maintenance work is to be carried out by trained specialistswith the machine switched off, at standstill, pressure-relieved andprotected against reconnection.

6.2 Pressure reliefBefore any maintenance work is carried out, the pressure relief is tobe checked as follows : disconnect the compressor from thecompressed-air system by closing the shut-off valve. The pressure reliefis to be checked by venting the safety valve (12).

F The temperature of the oil tank (11) may not be more than+40 °C!

F Attention - caution!It is absolutely necessary to wear face and body protectionbecause hot oil mist can penetrate.

10

Suction filter SCK 21-42

Oil filter

Maintenance

6.3 V-belt driveOur constructions keeps the V-belts (03) at the required tension;nevertheless they must be checked every 500 hours and retensioned ifnecessary.

Place the test pin (p Order No. 180.02030) at right-angles to a V-belt(03) in the middle of the section between the rollers and press it down.

Deflection at 50 N testing force: SCK 21 - 31 = 11 - 9 mm

SCK 42, 52 = 8 mmIf you have to replace one V-belt, you must replace all the V-belts (03)at the same time. To do this release the motor rocker arm upwardsusing the adjustment screws. Place the new V-belts (03) individuallyaround the V-belt pulleys (02) and lower the motor rocker arm usingthe adjustment screws until the test force is achieved. Then lock theadjustment screws again.

6.4.1 Replacement of the suction filter (05) SCK 21-42Warning 11 - with flashing red lamp. Replace the suction filter (05),confirm the maintenance with Code 21 and reset with the O key.

The used suction filter is to be disposed of as special waste.

6.4.2 Replacement of the suction filter (05) SCK 52Warning 11 - with flashing red lamp. Loosen the filter cap with thebutterfly nut. Replace the suction filter (05) and secure the filter capwith the butterfly nut again. Confirm the maintenance with Code 21and reset with the O key.

The used suction filter is to be disposed of as special waste.

manually tighten it half a turn. Check for leakage at operatingtemperature, confirm the main-tenance with Code 21 and reset withthe O key.

The used oil separator is to be disposed of as special waste.

6.7 Condensate waterWhen the full capacity of the compressor is not utilized, condensatewater may deposit at the lowest point (heavier than oil) of the oiltank (11).

This condensate water should be drained through the oil drain (11.2)regularly, when the compressor is at standstill for a longer period,e.g. at the weekend (ref. sect. 3.4).

If any condensate water is observed, please contact immediately theafter-sales service p, otherwise your warranty might be endangered.

6.5 Replacement of the oilfilter (15)

Warning 12 - with flashing red lamp.Loosen the oil filter (15) with a strapwrench (p order n° 180.06075) andremove it. Remove residues of the oldsealing from the housing. Lubricate the seal of the new oil filter. Screwin the new oil filter (15) up to the limit stop and manually tighten ithalf a turn. Check for leakage at operating temperature, confirm themaintenance with Code 21 and reset with the O key.

The used oil filter is to be disposed of as special waste.

6.6 Replacement of the oilseparator (08)

Warning 13 - with flashing red lamp.Loosen the oil separator (08) with a strapwrench (p order n° 180.06075) andremove it. Remove the residues of theold sealing and lubricate the seal of thenew oil separator. Screw in the new oilseparator (08) up to the limit stop and

Oilseparator

6.8 Oil level check (mind residual pressure whenopening)

Check the oil level at the oil filler neck (11.1) and refill oil, if necessary.Different kinds of oil must not be mixed. Works oil filling: SPECIAL OIL.

6.9 Oil changealways together wiht the oil filter (15)

Warning 15 - with flashing red lamp. The oil is to be changed inaccordance with the maintenance intervals on page 13 with therequired oil quantity. In case other lubricants shall be used, pleasecontact the after-sales service p. We only grant our warranty for thecompressors when the use of equivalent lubricants is verified.

Oil change: (only in warm condition) open the filler neck (11.1) aswell as the oil drain (11.2) and drain the used oil. Close the oil drain(11.2) and fill in fresh oil up to the lower edge of the filler neck (11.1).Check for leakage at operating temperature. Confirm the maintenancewith Code 21 and reset with the O key.

The used oil is to be disposed of as special waste.

Oil filler

05 05

15

Suction filter SCK 52

08

11.2

Condensate andoil drain

11.1

11.2

6.10 Motor bearings (01)Warning 14 - with flashing red lamp. Regreasing of the electricmotor (01) must strictly be carried out and is performed by means ofa grease gun with a lubrication nipple according to DIN 3404 (ordern° 180.06076 p). If the electric motor (01) does not have any greasenipples, it is equipped with long-life grease closed roller bearings.After their lifetime these bearings are to be changed completely.

11

After 3 seconds continuous pushing the O-key, CODE 11 can be calledwith the keys followed by ENTER. Call the lower pressureswitch point with the INFO key. Set the required value with thekeys and save it with ENTER. After pushing the INFO key again, theupper pressure switch point can be called and set with the keysand saved the same way with ENTER.

6.13 General compressor maintenanceWarning 15 - with flashing red lamp - to carry out a generalcompressor maintenance. This general compressor maintenanceincludes all maintenance work which is to be done, with the unit innormal condition and normal ambient. Our after-sales service p wouldbe pleased to assist you.

Maintenance

Safety valve

6.11 Safety valve (12)In order to maintain the properfunction of the safety valve (12),it is necessary to check the valve(12) every 2,000 operating hoursor at least once a year.

Checking: dismount the safetyvalve (12) from the unit and checkit in a suitable device.

If no device is available, the safetyvalve (12) can be checked by usp.

Remove the residues from thethread connection. Wrap thethread of the safety valve (12) withsealing tape and screw the safety valve in. Check for leakage atoperating temperature.

6.12 Set pressure switch points with Code 11

Maintenance work before after after every each ... operating hoursand compressor erection erection the 1st week #) #) #)checks week 500 2000 4000

Direktion of rotation (01)

Oil level check (11)

Leak check, discharge temperatur

Reteighten electric connections

Condensate collection (11)cooler contamination (09,14)

First oil (11) + oil filter (15) change,V-belts check (03)

Suction filter (05), Öl (11) + oil filter (15)change, oil separator (08), safety valve (12)at least once a year

Regreasing of motor bearings (01)- maintenance intervals depending oncompressor type (refer section 6.10)

General compressor maintenance,at least once a year

Maintenance intervals #) Warning 100 h before run out service time

12

Troubleshooting

A reminding information due to a run out service time or a run out service interval must be confirmed with Code 21 and reset with theO - key, after proper service.A warning has occured when the red lamp flashes with the machine still operating. The warning cause is shown in the display screen. Afterproper service, reset the warning with the O - key.A trouble has occured when the red lamp lights up continuously and the machine is at standstill. The trouble cause is shown in the displayscreen. After proper maintenance, reset the trouble with the O - key and the machine can be started up again.

Trouble

7.1 Machine switches off throughcompressor dis-chargetemperature; display screeninformation ! 15 (red lamplights up)

7.2 Falling line pressure

7.3 Machine blows off throughthe safety valve (12).

7.4 ! 10, or ! 16(red lamp lights up)

7.5 No automatic start orswitching to load afterprevious shutdown when theset cut-out pressure isreached or from idling

7.6 Machine does not start whenthe start key I is pushed

7.7 High oil content in thecompressed air (excess oilconsumption).

7.8 Compressor switches offbefore the set cut-outpressure is reached(red lamp lights up).

7.9 Information ! 3 (red lamplights up)

Cause

- Sound absorbing bonnet not closed- Suction/ambient temperature too high- Cooling air inlet or outlet blocked- Oil filter (15) dirty- Lack of oil- Oil cooler (14) outside contamination

Attention : all cooler nozzles are to becounterbacked with a sufficient key;mind not to overturn the coolerconnections.

- Oil temperature controller (13) defective

- Air consumption exceeds air supplyquantity

- Suction filter (05) dirty- Relief valve (07) blows off when loading

- Suction valve (06) does not open

- Leakages in the line system

- Upper pressure switch point too high- Safety valve (12) defective

- means oil separator (08) dirty- means external high pressure source

- Upper pressure switch point too high- Interruption in the control circuit

- Ambient temperature below +1°C; thesymbol for temperature flashes

- Line pressure above upper switch point- Remote control function active- No power at the compressor- Electric defect in the control

- Oil return line clogged- Oil separator (08) defective

- Excess temperature or pressure

- Interruption in the control circuit

- Power voltage below appr. 180 Vac

Measures to be taken

- Close the sound absorbing bonnet- Vent the compressor compartment- Clear the cooling air inlet/outlet- Change the oil filter (15)- Refill with fresh compressor oil- Clean with compressed air. At severe

contamination, remove the cooler (09, 14)unit and clean it with a water jet deviceCaution - danger of short circuit!

FNo water jets on electric components!- Replace the controller (13) insert

- Compressor with higher discharge quantityrequired p

- Change the suction filter (05).- Check the relief valve (07) and replace the

seals, if necessary- Check the solenoid valve and the suction

valve piston (06) and replace, if necessary- Check and seal the line system

- Adjust the upper pressure switch point- Replace the safety valve (12)

- Change the oil separator (08)- Lower the high pressure source or

eliminate it from the line

- Adjust the upper pressure switch point- Check the control circuit for interruption

(only by a skilled electrician)- Install a standstill heating device or heat

the compressor compartment properly

- Observe the line pressure at the display.- Check flashing display "remote" symbol.- Check whether power is applied.- Check the control (only by a skilled el.)

- Clean the oil return line.- Change the oil separator (08)

- Eliminate the defect in compliance withchapter point :

- Check the control circuit for interruption(only by a skilled electrician)

- Check the power supply (only by a skilledelectrician)

refer tosection1.1, 5.61.2, 3.13.16.56.8, 6.92

2page 2

6.42

2

3.2

6.126.11

6.63.2

6.12Circuitdiagram3.1

4.14.2Circuitdiagram

26.6

7.1, 7.4Circuitdiagram

Circuitdiagram

13

Options

Tropical version (T) *The tropical version is suitable for installation in ambient temperaturesof up to 45 °C. Please refer to the separate attached sheet

Special voltage / Frequency 60 Hz *If your compressor is operated with a non-standard 400 V or with afrequency of 60 Hz, please refer to the separate, attached description.

Direction of rotation control *The direction of rotation control prevents damage resulting from theincorrect polarity of the electrical voltage (phase confusion). Thedirection of rotation control causes the automatic shut-down of thecompressor.

The controller shuts down the motor if the pressure switch mountedon the compressor stage trips. Please see the attached circuit dia-gram for further details.

Additional heating system *The additional electric heating system is housed in the compressor’soil tank. The oil heating system cuts in automatically as soon as thetemperature falls below the factory set nominal temperature in theoil tank, which is measured by a temperature sensor.

This prevents the condensation of the air’s humidity in the compressedair. The additional heating system is required on systems that cut inand out frequently and temporarily and therefore do not reach therequired operating temperature.

Floating error signal *An error on the compressor can be forwarded by means of a floatingcontact. For example the error message can be connected to a centralcontroller or a contactor. Please see the attached circuit diagram fordetails of the connection terminals.

Floating operating signal *An operating signal showing whether the main compressor motor isrunning, can be connected to the central controller, for example, usinga floating contact or can also be used, for example, to control blowersof refrigeration driers. Please refer to the attached circuit diagram forconnection details.

Remote On/Off *The compressed can be switched on and off using a floating contact.Please refer to the attached circuit diagram for further details.

Proportional controller *The proportional controller makes it possible to adjust the deliveryrate to the actual consumption of compressed air. To achieve this theair delivery rate is throttle in the intake controller by narrowing thecross-section.

Soiling indicator, intake filter *If the intake filter becomes soiled this is shown on the display. Thefilter element must then be replaced. The filter soiling is measured bya differential pressure sensor over the intake filter.

Soiling indicator, oil filter *If the oil filter becomes soiled this is shown on the display. The oilfilter cartridge must then be replaced. The filter soiling is measured bya differential pressure sensor over the oil filter.

Soiling indicator, oil separator cartridge *If the oil separator becomes soiled, this is shown by the controller onthe display. The oil separator cartridge must then be replaced. Thefine separator soiling is measured by a differential pressure sensorover the oil filter.

Heat recovery system *If you system is fitted with a heat recovery system or is prepared for aheat recovery system, please refer to the separate attached description.

* The above options are not included in the standard version. Theseinstructions must only be observed if your compressor is fitted withthe appropriate option.

14

Technical Data

Performance and erection data:

General data:

Electrical data:

Com- Weight Cooling Supply Flue air Oil tank Number of Type of Compressedpressor air air duct cross capacity V belts V belts air

volume opening section connectionkg m3/h m2 m2 l G

Com- Motor Currents at 220V/60Hz Currents at 400V/50Hz Currents at 550V/50Hz Maximumpressor rating switching

frequencykw 1/h

Site Site Siteback-up back-up back-up

I(rated) I(max) fuse I(rated) I(max) fuse I(rated) I(max) fuseA A A gL A A A gL A A A gL

973

1270

waste airdash

boar

d

powersupplyPG 36

M10 int. M10 int.

compr. airoutlet

fresh air

compr. airoutlet

412 65

677

795

1070

exhaust shaftconnection

669

219

4 x M5 int.

cooling air openingwithout shutter or mash

min. wall distance 50 cm

dash

boar

d

service side

SCK 21 15,0 48 52 63 30 32 50 22 24 35 30SCK 26 18,5 58 64 80 34 38 50 25 27 35 25SCK 31 22,0 70 77 80 40 45 63 29 32 50 20SCK 42 30,0 90 99 125 57 63 80 42 46 50 15SCK 52 37,0 119 131 160 67 73 100 48 53 80 12

SCK 21 435 3300 0,40 0,37 8,0 3 XPA 1SCK 26 450 3300 0,40 0,37 8,0 3 XPA 1SCK 31 485 3500 0,40 0,39 8,0 3 XPA 1SCK 42 580 5300 0,60 0,60 17,0 3 XPA 1 1/2SCK 52 595 5700 0,65 0,65 17,0 4 XPA 1 1/2

15

Spare parts: Plan and electric parts

The serial number of the screwcompressor (on the name plate) is tobe indicated in any spare parts order.The required part number can bedefined by the following views.

136.00185136.00064

176.00163

K1

132.00602

132.00603

132.00607

K3

132.00600

132.00602

132.00603

K2

132.05001

136.00272

136.00278

137.08744

137.00009

132.00602

132.00603

132.00607

136.00120

16

Spare parts: Unit parts

213.00489 273.01852

273.01853

172.02550

172.07787

273.00040

273.00041

213.00490

226.00376

226.00377

120.00110

172.00222

136.00103

137.00462

174.00007

228.00851

228.00852

154.00150

154.00154

172.11102

172.58111

273.01578

273.01579

278.00222

278.00230

278.00246

278.00519

213.00456

278.00224

176.00369

176.00381

176.00384

17

Spare parts: Unit parts

276.00440

213.00457

127.00066

127.00177

278.00366

278.00377

126.03180

126.03224

126.03280

126.04280

213.00489

172.07800

176.00095

131.00301

131.00302

131.00303

131.00304

131.00305

260.00047

174.00013278.00237

173.00003

278.00277

278.00338

278.00339

163.00009

163.00026

163.00029

163.00044

163.00051

163.00066

163.00068

163.00129

136.00128

136.00131

163.00168

226.03112

226.03118

226.03125

226.03132

226.03140

226.03150

226.03180

226.04095

226.04106

226.04126

18

Spare parts: Lines and gaskets

173.00199

165.01332

165.04418

167.00077

173.00011

173.00286

173.00039

165.00168

165.00246

167.00077

167.01249

165.83202

165.00017

173.00290

173.00292

173.00107

165.83202

167.08026

167.00544

19

Spare parts: Lines and gaskets

173.00286 165.00331 165.00330

173.08176

173.00291

165.00120

167.00077

165.83202

165.03416

229.00038

229.00039

167.00077

165.83202

173.00288

173.00289

165.83202

20

Spare parts: Suction control and temperature control

173.04001

173.04003

165.15101

172.00222

273.02055

212.00211

212.00210

212.00211

212.00213

21

Spare parts: Separator box

172.01017

172.01036

273.00552

273.01529

167.02228

167.03036

169.02110

169.02250

165.00015

165.00247

165.00329

273.00578

273.00579

165.00449

273.02513

273.04018

172.11102

172.58111

212.00215

22

Spare parts list

Article number Description SCK model

120 00110 Compressor stage 21 26 31 42 52

126 03180 Motor pulley 21 26126 03224 Motor pulley 31126 03280 Motor pulley 42126 04280 Motor pulley 52

127 00066 Oil / air cooler 21 26 31127 00177 Oil / air cooler 42 52

131 00301 Electric motor 42131 00302 Electric motor 26131 00303 Electric motor 21131 00304 Electric motor 31131 00305 Electric motor 52

132 00196 Fuses 21 26 31 42 52(optional heating)

132 00377 Relais 21 26 31 42 52(optional heating)

132 00600 Power relais 21 26132 00602 Power relais 21 26132 00602 Power relais 31 42132 00603 Power relais 31 42132 00603 Power relais 52132 00607 Power relais 52132 05001 Relais (option) 21 26 31 42 52

136 00064 Emergency button 21 26 31 42 52136 00103 Temperature sensor 21 26 31 42 52136 00120 Pressure sensor 21 26 31 42 52136 00185 Air Control 1 system 21 26 31 42 52136 00272 Transformator 52136 00278 Transformator 21 26 31 42

137 00009 Primer fuses 21 26 31 42 52137 00462 Heating (option) 21 26 31 42 52137 08744 Transformer fuse 21 26 31 42 52

154 00150 Security valve 21 26 31154 00154 Security valve 42 52

163 00009 V-belt set 26-08163 00026 V-belt set 21-08 26-13163 00029 V-belt set 21-13 31-13163 00044 V-belt set 31-10163 00051 V-belt set 26-10163 00066 V-belt set 31-08163 00068 V-belt set 42-13163 00128 V-belt set 42-08

42-10163 00129 V-belt set 21-10163 00131 V-belt set 52-08

52-10163 00168 V-belt set 52-13

23

Article number Description SCK model

Spare parts list

165 00015 Stud coupling 21 26 31 42 52165 00017 Blanking end 21 26 31 42 52165 00120 Compressed-air elbow 21 26 31165 00168 Blanking end 21 26 31 42 52165 00246 Stud adaptor 21 26 31 42 52165 00247 Stud elbow 21 26 31 42 52165 00278 Stud elbow 21 26 31 42 52165 00329 Stud elbow 21 26 31 42 52165 00330 Stud coupling 42 52165 00331 Stud elbow 21 26 31165 00449 Stud coupling 21 26 31 42 52165 01332 Banjo T coupling 21 26 31 42 52165 03416 T coupling adjustable 21 26 31 42 52165 04418 Stud adaptor 21 26 31 42 52165 15101 Temp. control double male stud 21 26 31 42 52165 83202 Banjo screw 21 26 31 42 52

167 00077 Bajo screw sealing 21 26 31 42 52edge ring

167 00544 Oil tank o-ring 21 26 31 42 52167 01249 Bolt joint 21 26 31 42 52167 02228 Variseal oil separator 21 26 31167 03036 Variseal oil separator 42 52167 08026 Oil separator 21 26 31 42 52

169 02110 Injection nozzle 21 26 31169 02250 Injection nozzle 42 52

172 00222 Oil filter cartridge 21 26 31 42 52172 01017 Oil separator double stud 42 52172 01036 Oil separator double stud 21 26 31172 02550 Heavy duty air filter cartridge (option) 21 26 31 42 52172 07787 Air filter cartridge 21 26 31 42 52172 07800 Dust filter (option) 21 26 31 42 - -172 11102 Oil separator 21 26 31172 58111 Oil separator 42 52

173 00003 Oil return line clamp 21 26 31 42 52173 00011 Oil return line 21 26 31 42 52173 00039 Non-return valve 21 26 31 42 52173 00107 Pressure sensor line 21 26 31 42 52173 00199 Discharge line 21 26 31 42 52173 00286 Compressed air line 21 26 31 42 52173 00288 Initial oil line 21 26 31173 00289 Initial oil line 42 52173 00290 Bypass oil line 42 52173 00291 Oil return line 21 26 31 42 52173 00292 Bypass oil line 21 26 31173 04001 Suction control connection nozzle 21 26 31 42 52173 04003 Suction control housing 21 26 31 42 52173 08176 Oil drain valve 21 26 31 42 52

24

Article number Description SCK model

Spare parts list

174 00007 Oil tank support 21 26 31 42 52174 00013 Elastic supports 21 26 31 42 52

176 00095 Fresh air grid 21 26 31 42 52176 00163 Operation panel 21 26 31 42 52176 00369 Ventilator with hub 42176 00381 Ventilator 21 26 31176 00384 Ventilator with hub 52176 09038 Key 21 26 31 42 52

183 04050 Special oil 8 ltr. 21 26 31183 04050 Special oil 14 ltr. 42 52

195 02021 Operating instructions D 21 26 31 42 52195 02022 Operating instructions GB 21 26 31 42 52195 02023 Operating instructions NL 21 26 31 42 52195 02024 Operating instructions F 21 26 31 42 52195 02025 Operating instructions I 21 26 31 42 52195 02026 Operating instructions E 21 26 31 42 52

212 00165 Line kit 21 26 31 42 52212 00210 Discharge valve service kit 21 26 31 42 52212 00211 Suction control service kit 21 26 31 42 52212 00213 Temperature control service kit 21 26 31 42 52212 00215 Minimum pressure valve service kit 21 26 31 42 52212 01130 Joint kit 21 26 31 42 52212 01131 Service kit 21 26 31 42 52212 02160 Filter kit 21 26 31212 02162 Filter kit 42 52

213 00456 Front side board 21 26 31 42 52213 00457 Rear side board 21 26 31 42 52213 00458 Sound cover hood 21 26 31 42 52213 00459 Service board 21 26 31 42 52

226 00376 Ventilator hub 21 26226 00377 Ventilator hub 31226 03112 Compressor pulley 26-08226 03118 Compressor pulley 31-08 42-08226 03125 Compressor pulley 26-10 42-10226 03132 Compressor pulley 21-08 31-10226 03140 Compressor pulley 26-13 42-13226 03150 Compressor pulley 21-10 31-13226 03180 Compressor pulley 21-13226 04095 Compressor pulley 52-08226 04106 Compressor pulley 52-10226 04126 Compressor pulley 52-13

228 00851 Oil tank 21 26 31228 00852 Oil tank 42 52

25

Article number Description SCK model

Spare parts list

229 00038 Compressed air connection socket 21 26 31229 00039 Compressed air connection socket 42 52

260 00047 Support distance 21 26 31 42 52

273 00040 Suction control 21 26 31 42 52273 00041 Proportional suction control (option) 21 26 31 42 52273 00552 Separator bush 21 26 31273 00578 Separator housing 21 26 31273 00579 Separator housing 42 52273 01529 Separator bush 42 52273 01578 Separator box 21 26 31273 01579 Separator box 42 52273 01852 Temperature control unit 21 26 31 42 52273 02055 Temperature control housing 21 26 31 42 52273 02513 Non-return valve set 21 26 31 42 52273 04018 Minimum pressure valve cover 21 26 31 42 52

276 00440 Exhaust air grid 21 26 31 42 52

278 00222 Air intake plate 31278 00224 Electric box 21 26 31 42 52278 00230 Air intake plate 42278 00237 Frame with oil protection carter 21 26 31 42 52278 00246 Air intake plate 21 26278 00277 Compressor flange 21 26 31 42 52278 00338 Front plate 21 26 31278 00339 Front plate 42 52278 00366 Cooler side board 21 26 31278 00377 Cooler side board 42 52278 00519 Air intake plate 52

26

Operating Date Servicing work completed Name/Signaturehours

Services completed

28

ALUP-Kompressoren GmbH

Postfach 1161 D-73253 KöngenAdolf-Ehmann-Str. 2 D-73257 Köngen

Phone.: +49-(0)1 80-5 25 87 00Fax: +49-(0)1 80-5 25 87 01

E-mail: service@alup.comInternet: www.alup.com