Professional Documents
Culture Documents
Quality Assurance
DIN ISO 9001 certified
Screw-type Compressors
SCK 5 - SCK 22
BAlOO/lO.Ol/04/GB
XILUP^
Kompressoren
lUlf
Quality Assurance
DIN ISO 9001 certified
Screw-type Compressors
SCK 5 - SCK 22
IMO 9274654
JLZ-020504
BA 100/10.01/04/GB
Index
General information and safety instructions
Functional description and erection
Operating
Commissioning
Maintenance
Troubleshooting
Options
Technical Data
Spare parts overviews
Plan and electric parts
Suction control and temperature control
Unit parts
Lines and gaskets
Separatorbox
Spare parts list
Services completed
Page
4
5
6
8
9
11
12
13
14
14
15
16
18
20
21
25
Type:
SCK
Machine-No.
For the perfect and troublefree operation you expect from your screw- Validity:
type compressor, we recommend to l<eep in stock one set of
maintenance and wearing parts, e.g. suction filter, oil filter, oil separator
This manual and spare parts list is valid as from maker's n
and lube oil. Our after-sales service ' S would be pleased to assist you
in the selection of these spare parts.
270.000
SCK 5 SCK 22
Date
17.07.2001
S On the reverse of this brochure you will find our adress, telephone
number and fax number
S In case of further inquiries please specify the data shown on the
compressor nameplate (electric box back side).
General information
B ^ 1. Safety instructions
Transport:
Transport is only allowed with a (fork) lift truck.
2. Functional description
2.1 The drive
The electric motor (01) drives the compressor stage (04) through the
V-belt pulleys (02) and the V-belts (03).
3. Erection
3.1 General information
C ^ The screw-type compressor is mounted on a solid frame ready
for operation. Only a level solid floor is necessary for erection.
The screw-type compressor is to be placed in a cool, dry and dust-free
room with proper ventilation and a room temperature between + 5
C and + 40 "C.
When the room temperature might fall below + 5C, an additional
compressor heating is to be Installed into the compressor system oil
tank (11) or the room is to be heated.
When the room conditions are inconvenient, it may be necessary, owing
to excess heating, to dissipate the hot exhaust air by means of exhaust
shafts or cooling fans for a sufficient supply of fresh air.
The place of installation shall be well accessible. Refer for assembly
dimensions and required quantities of fresh air to the technical data
on page 13.
Operating
4. Operating
On key
The green lamp flashes: The compressor i ready for use
and may start automatically at any time
The green lamp is lit: The compressor is running
Warning and error display
The red lamp is lit: Compressor error
The red lamp flashes: Warning
Stop key to shut down the compressor (via idling)
for input of codes
for acknowledgement of errors
INFO
4.1 Display
The display permanently displays the line pressure, final compression
temperature and operating status of the compressor.
Network
pressure
8JJ
Error number.
Warning number,
Programming level
Compressor
temperature
bar
%
Change values and parameters
Restart
Only in case of emergency the system may be shut down with the
EMERGENCY STOP switch.
"
Automatic
Remote
4.3 Warnings
i^
Symbol Error
^ \
Symbol Warning
CMJ
Kff
The red lamp and the symbol are flashing. The corresponding
warning number flashes:
2
High compressor final temperature
3
High network pressure
11
Residual service life air filter < 100 h
12
Residual service life oil/oil filter < 100 h
13
Residual service life oil separator < 100 h
14
Residual service life motor lubrication < 100 h
15
%
Restart
Symbol Heating on
Automatic restart after power failure
Operating
Code 2 Mode
c^
0=
Automatic
The red lamp shines and the symbol }> is flashing. The corresponding
("Automatic" appears in the display)
error number flashes:
Idling time according to code 51
1
Pressure rated value wrong
c^
1=
Load-idling operation
2
Parameters wrong
Unlimited idling time
3
Low voltage
C
^
2
=
Automatic
optional
4
Voltage failure
(an additional point appears in the display befor the
5
AirControl defect
temperature value)
6
Emergency stop actuated
Progr. level 1 : max. pressure drop
7
Wrong direction of rotating
Progr. level 2: max. switching frequency
8
IVIotor temperature to high
In all modes the compressor cuts in when the pressure falls below the
9
Over current
cut-in pressure level and goes into idling mode when the cut-out
10
Over pressure
pressure is reached. After the end of the idling time the motor cuts
11
Pressure drop through oil separator
off.
12
Maximum compressor temperature sensor
13
Oil temperature sensor
Code 3 Automatic Restart
14
Pressure sensor
^
0=
no automatic restart
15
IVIaximum compressor final temperature exceeded
C^
1=
with automatic restart
16
Network pressure exceeded
("Restart" appears in the display)
4.4 Errors
4.5 Programming
Codes Local/Remote/GLW
Generally the system will be controlled locally
0=
"Local" mode (standard)
r^
1=
Remote" On/Off mode ("Remote" appears flashing
in the display)
i=|> 2 =
Operation with a lead/lag control unit with automatic
switch to to "local" operation (Option)
2.
3.
Set code
Programming
level
unit
Flashing numbei
value ( ^ )
1=
Pressure in Mpa (g)
^
2=
Pressure in psi(g)
1=
Temperature in F
cO*
2=
Temperature in
Commissioning
5. Commissioning
5.6 Starting
5.1 Preservation
The 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 due
to low oil level, the compressor is to be filled up with fresh oil into the
oil filler neck (11.1).
5.7 Shutdown
Push the stop key O. The green lamp extinguishes. The compressor
shuts down after the follow-up time, the suction valve (06) doses
and the oil tank (11) is relieved. The line pressure is available up to
the non-return valve integrated in the separator box, i.e. the
compressed-air recooler (09) is admitted with line pressure. Program
changing and setting of pressure or time values can only be carried
out with the required code and the compressor at standstill.
Maintenance
The V-belt drive tensions itself due to our special unit construction.
The deflection force, however, has to be checked every 500 operating
hours with a tension force meter CBTorder n. 180.02030 ) in a right
angle, midway between the pulley contart points on one V-belt each.
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 (ret sect. 3.4).
1=- J
(
Ql1.2
T
6.8 Oil level check (mind residual pressure when
opening)
Warning > 12 - with flashing red lamp. Loosen the oil filter (15) with
Check the oil level at the oil filler neck (11.1) and refill oil, if necessary.
a strap wrench ("B" order n 180.06075) and remove it. Remove
Different kinds of oil must not be mixed. Works oil filling: SPECIAL
residues of the old sealing from the housing. Lubricate the seal of the
OIL.
new oil filter. Screw in the new oil filter (15) up to the limit stop and
manually tighten it half a turn. Check for leakage at operating 6.9 Oil change
temperature, confirm the maintenance with Code 21 and reset with
always together wiht the oil filter (15)
the key.
Warning J-15- with flashing red lamp. The oil is to be changed in
The used oil filter is to be disposed of as special waste.
accordance with the maintenance intervals on page 13 with the
required oil quantity. In case other lubricants shall be used, please
contact the after-sales service . We only grant our warranty for the
compressors when the use of equivalent lubricants is verified.
Suction filter
Oil filter
Oil change: (only in warm condition) open the filler neck (11.1) as
well 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 maintenance
with Code 21 and reset with the key
15
OS
The used oil is to be disposed of as special waste.
;^ccL
Oil filler
Warning /> 13 - with flashing red lamp. Loosen the oil separator (08)
with a strap wrench (' order n
180.06075) and remove it.
Remove the residues of the old
sealing and lubricate the seal of
(
the new oil separator. Screw in the
^Q 11.2
new oil separator (08) up to the
limit stop and manually tighten it
half a turn. Check for leakage at
6.10 Motor bearings (01)
operating temperature, confirm
Warning / 14 - with flashing red lamp. Regreasing of the electric
the maintenance with Code 21
motor (01) must strictly be carried out and is performed by means of
and reset with the key.
a grease gun with a lubrication nipple according to DIN 3404 (order
The used oil separator is to
n 180.06076 B"). If the electric motor (01 ) does not have any grease
be disposed of as special
nipples, it is equipped with long-life grease closed roller bearings.
waste.
After their lifetime these bearings are to be changed completely
^
'
'
Maintenance
^^ee
Maintenance intervals
IVlaintenance
work and compressor checks
before
erection
after
erection
after
the 1st
week
every
week
10
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 the
- 1<, 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. After
proper service, reset the warning with the - 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 display
screen. After proper maintenance, reset the trouble with the - 1< and the machine can be started up again.
Trouble
Cause
7.1 Machine switches off through - Sound absorbing bonnet not closed
- Suction/ambient temperature too high
cornpressor dis-charge
temperature; display screen - Cooling air inlet or outlet blocked
information ^
15 (red lamp - Oil filter (15) dirty
- Lack of oil
- Oil cooler (14) outside contamination
Attention : all cooler nozzles are to be
counterbacked with a sufficient key;
mind not to overturn the cooler
lights up)
connections.
7.2 Falling line pressure
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 device
Caution - danger of short circuit !
D ^ N o water jets on electric components !
10, or
16
3.1
6.5
6.8, 6.9
page 2
6.4
2
2
3.2
6.12
6.11
6.6
3.2
6.12
Circuit
diagram
3.1
4.1
4.2
Circuit
diagram
2
6.6
chapter point :
- Check the control circuit for interruption
(only by a skilled electrician)
7.1,7.4
Circuit
diagram
7.6 Machine does not start when - Line pressure above upper switch point
the start key i is pushed
- Remote control function active
- No power at the compressor
refer to
section
1.1,5.6
1.2,3.1
consumption).
7.8 Compressor switches off
before the set cut-out
pressure is reached
(red lamp lights up).
7.9 Information / \ 3 (red lamp
lights up)
Circuit
diagram
11
Options
Remote On/Off *
If the intake filter becomes soiled this is shown on the display. The
filter element must then be replaced. The filter soiling is measured by
a differential pressure sensor over the intake filter.
The direction of rotation control prevents damage resulting from the If the oil filter becomes soiled this is shown on the display. The oil
incorrect polarity of the electrical voltage (phase confusion). The filter cartridge must then be replaced.The filter soiling is measured by
direction of rotation control causes the automatic shut-down of the a differential pressure sensor over the oil filter.
compressor.
The controller shuts down the motor if the pressure switch mounted
on the compressor stage trips. Please see the attached circuit diagram for further details.
12
* The above options are not included in the standard version. These
instructions must only be observed if your compressor is fitted with
the appropriate option.
Technical Data
-+
-+
exhaust shaft
connection
1 S 3 ! |Q|
power
supply
PG36
+
j
compr. air
outlet ---^
compLair.
outlet
1.115
fresh air
MIOint
4xM5int.
ro
MIO int.
488
605
service side
General data:
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136.00185
136 00064
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176.00160
;132.00197
132.00600
132.00602
132.00600
132.00602
36.00278
132 00600
136.00120
132.00377
14
32.00196
173.02002
172 00221
165.15111
212.00213
273.02045
15
172.02549
172.07788
273.00020
273.00021
,213.0487-. \
120.00041 \
120.00151
\
278.00213 \
278.01252 \
163.00024
163.00031
163.00032
163.00033
163.00034
163.00035
163.00037
163.00065
\,
^^
213.00220
228.00850
137.00462
174.00014
226.00372
213.00427
213.00218
213.00219
16
176.00070
176.00071
278 00226
131.00039
131.00040
131.00041
131.00042
131.00058
226.O208O
226.02085
226.02090
226.02100
226.02106
226.02112
226.02118
, 226.02J32
' 226.02^50
126.91209
126.91210
126.91610
126.92012
172.51001
172.51004
176.00161
176.00164
127.00024
127.00054
127.00055
213.00217
278 00396
213.00422
213.00426
172.00221
273.01851
278.00214
278.00215
278.Q274
126.02095
126.02160
126.02180
126.02200
126.91612
126.92014
126.92518
174.00013
213.00187
17
167.01248
167.07030
173.00169
167.00072
167.00078
165.07420
165.01111
167.01249
173 00106
165.83204
165.83205
18
173.00019
173.00099
173.00064
173.00065
1.00164
165.00124
165.00370
229.00035
229.00037,
265.00057
173.00051
167.00078
165.83205
167 00078
165.83205
173.00051
167.01248
165.83209
173-00055
173.00Q57;
730"f 1
19
172.51001
172.51004
172.01013
172.01065
169.02100
169.02150
173.00412
273.0053S
273.00539
167 01425
167.01525
273 01017
165.00449
165.00443
212.00216
20
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132 00197
132 00377
132 00600 i:
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127 00024^ :i :^
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21
Article number
Description
163 00035
163 00037
163 00037
163 00065
V-belt set
V-belt set
V-belt set
V-belt set
165 00124
165 00167
165 00370
165 00443
16500449
165 01111
165 02018
165 04412
165 07420
165 15111165 83201
165 83203
165 83204
165 83205
165 83209
169 02100
169 02150
172 00221
172 01013
172 01065
172 02549
172 07788
172 07795
172 51001
172 51004
22
22-10
5
' .5
8
8
5
5
5
5
5
5
5
5'
'i. 8
' 8
8
8
8
8
8
1 8-
10
10
10
10
10
10
10
10
15
15
15
15
15
15
15
15
15
15
, 10
' 10
22 '
22
22
22
22
8
8
8
10
10
10
15
15
15
22
22
22
22
'
5
5
5
5
5
5
8
8
8
8
8
8
10
10
10
10
10
10
15
15
15
15
15
22
22
22
22
22
10
15
15
22
22
15
22
10
10
15
15
22
22
5
5
5
5
8
8
8
8
10
10
10
10
15
15
15
15
22
22
10
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10 ,
15
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22
22
22
22
5
5
5
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22
22
2 2
10
10
10
5 , 8
5''
,8
Air line
15-08
15-10
^ Oil'return line
Oil cooler line
Oil return line
Oil return.lirie . ,
Initial oil line
' Airline
';
Oil return line , ' ,
Pressure sensor line ,
Airline
' 1 .'
'
Discharge line
- '. .
Non-return valve ; ^
"_ "
Suction control connection nozzle
10-10
5-10
Elbow
Blanking end
Elbow
Stud elbow
Stud coupling
Stud adaptor
. Banjo T coupling
Stud coupling
Blanking end
Temperature control double male stud '
Single banjo bolt
Single banjo bolt Single banjo bolt "
Single banjo bolt
Doble banjo bolt
167 00071
167 00072
167 00078
167 01248
167 01249
167 01425
167 01525
167 07030
173 00019
173 00051
173 00055.
173 00057
173 00061
173 00064
173 00065
173 00099
173 00106 ,
173 00164
173 00169 '
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Services completed
Operating
hours
Date
Name/Signature
25
Services completed
Operating
hours
26
Date
Name/Signature
>1LUP
Kompressoren
ALUP-Kompressoren GmbH
Postfach 1161
Adolf-Ehmann-Str. 2
Phone.:
Fax:
E-mail:
Internet:
D-73253 Kongen
D-73257 Kongen
+49-{0)1 80-5 25 87 00
4-49-(0)1 80-5 25 87 01
service@alup.com
www.alup.com
SAUER-Gruppc
Schmierstoff-Tabelle
fr
Schraubenverdichter
Lubrication- Chart
for
Screw-Compressors
1 /97
Schmierstofftabelle fr Schraubenverdichter
This table of lubricants is valid for all air and watercooled Sauer ALUP Screw Compressors.
This table of lubricants is not valid for piston compressors or temperature ranges others than mentioned below. In such a case please ask for special
lubricant recommendations.
Die Verwendung anderer als die in unserer Schmierstofftabelle genannten le setzt die ausdrckliche
Genehmigung durch uns voraus. Nur bei der Verwendung von durch uns nachweislich zugelassenen len
bernehmen wir Gewhrleistung fr unsere Kompressoren.
Schrauben Verdichter
Screw Compressors
Weitere Information:
Further Information:
Bei Fragen wenden Sie sich bitte an unseren Kundendienst unter der Telefonnummer 0431-394087
oder per Fax 0431-394089.
(:^J.PSAUER&SOHN6^
'^CJ^ MASCHINENBAU G M B H
^CP'
Marke
Brand
Agip
ARAL
1 le fr Schraubenverdichter 1 Gruppe
1 Group
Oil for screw-compressors
1 Korrosionsschutzl
1
I Corrosion prevention oil |
Kosmol TL 46
AVIA
BP
Energol RC-R 46
Energol THB 46
Castro!
Alphasyn T 46
Aircol SR 46/68
Aircol PD 68
Chevron
DEA
Actro EP VDL 46
Trion EP 46
Astron HLP 46
Elf
Esso
Kompressor Khll 46
Compressor oil RS 46
FINA
Eolan RQ 46
Eolan SPD 46
Mobil
Shell
Compte!la S 46
Compte!la SM
SHELL Ol 4038 ( 15327)
TEXACO
Cetus S 46
Synerol 46 PA
Cetus PAO 46
TOTAL
YUKONG
nderungsstand / Revision
OELEMPFG.WDB
3.3.99
3.3.99
/fx
Seite / page 1