Original operating manual - SCC Compressors

Original operating manual - SCC Compressors

Version 1.0 E• 28.05.2017

Imprint

Tolpec GmbH

Wertstrasse 44

73240 Wendlingen

Tel.: +49 (0)7022-789 6040

[email protected] http://www.tolpec.com

Copyright protection

Tolpec GmbH is the owner of the copyright for this document.

Disposal, multiplication and recording of this document, remaking and sharing of its content are forbidden, if not confirmed by Tolpec GmbH in written form.

Non-compliance shall result in the recovery of losses.

All rights in the case of patent issue or registration of design are reserved.

All the mentioned in this guide below, product labelling are trademarks of corresponding firms.

Technical changes reserved. SCC is a registered trade name and all rights in the case of patent issue or registration of design are reserved.

Operation Manual SCC-Compressors / Page 2

1. Description of the product ................................................................................................................................. 6

1.1. Operating Instructions .................................................................................................................................. 6

1.2. Storage of the Manual / keep it accessible ................................................................................................... 7

1.3. Used Symbols and definitions ..................................................................................................................... 7

1.3.1. Safety instructions ................................................................................................................................... 7

1.3.2. Warning signs ......................................................................................................................................... 9

1.3.3. Mandatory signs ..................................................................................................................................... 10

1.3.4. Additional symbols in the manual .......................................................................................................... 11

1.3.5. Directional indications ............................................................................................................................ 11

1.4. Change history ........................................................................................................................................... 12

1.5. Applicable documents ................................................................................................................................. 12

1.6. Warranty and liabilities .............................................................................................................................. 12

1.7. Contact information of Tolpec GmbH and the SCC-Sales- and Service partner ....................................... 13

2. Description of the product ............................................................................................................................... 15

2.1. Construction of the Equipment / Controllers .............................................................................................. 15

2.1.1. Areas of work and maintenance. ........................................................................................................... 23

2.2. Identification of the Equipment .................................................................................................................. 23

2.3. General descriptions .................................................................................................................................. 24

2.4. Use of the machine ................................................................................................................................... 25

2.4.1. Intended use ......................................................................................................................................... 25

2.4.2. Incorrect Use .......................................................................................................................................... 25

2.5. Safety equipment’s...................................................................................................................................... 26

2.5.1. Overview ............................................................................................................................................... 26

2.5.2. Protection/safety devices ....................................................................................................................... 26

2.5.3. Emergency stop system ......................................................................................................................... 30

2.5.4. Symbols and signs on the machine. ...................................................................................................... 30

2.6. Operating of the Equipment ....................................................................................................................... 32

2.7. Operating and installation conditions .......................................................................................................... 32

3. Safety ................................................................................................................................................................. 33

3.1. General safety instructions ......................................................................................................................... 33

3.1.1. Avoiding of dangerous situations .......................................................................................................... 33

3.1.2. Operation instructions ........................................................................................................................... 34

3.1.3. Notes for trouble shooting and repairing ............................................................................................... 34

3.1.4. Notes on electrical equipment ............................................................................................................... 35

3.1.5. Electromagnetic compatibility (EMC) .................................................................................................... 35

3.1.6. Information for environmental protection ............................................................................................... 36

3.2. Unacceptable operating conditions ........................................................................................................... 36

3.3. Responsibility of the operator .................................................................................................................... 37

3.3.1. Minimize the risk of injuries ................................................................................................................... 37


3.3.2. Determine the operator ......................................................................................................................... 38

3.3.3. Operator training ................................................................................................................................... 38

3.3.4. Protective equipment ............................................................................................................................ 39

3.4. Requirements of an operator ..................................................................................................................... 40

3.4.1. Qualification .......................................................................................................................................... 40

3.4.2 Operator groups ................................................................................................................................... 42

3.4.3 Specialised knowledge ......................................................................................................................... 42

3.5. Personal protective equipment .................................................................................................................. 43

3.6. Residual risk .............................................................................................................................................. 44

3.7. Procedure in case of an accident ................................................................................................................ 44

4 Transport und installation ................................................................................................................................ 45

4.1 Required tools .............................................................................................................................................. 46

4.2 Transport ....................................................................................................................................................... 46

4.3 Unpacking and removing of package ........................................................................................................... 49

4.4 Installation .................................................................................................................................................... 49

4.4.1 Place of installation and infrastructure ................................................................................................... 49

4.4.2 Installation and connection ................................................................................................................... 50

4.4.3 Installation of the mechanical components ............................................................................................. 51

4.4.4 Installation of the electrical components ................................................................................................. 52

4.4.5 Final Check .............................................................................................................................. 52

5 Commissioning ................................................................................................................................................. 53

5.1 Check of safety devices ............................................................................................................................... 55

5.2 First Commissioning ..................................................................................................................................... 56

5.3 Daily commissioning ..................................................................................................................................... 60

5.4 Commissioning after storage ........................................................................................................................ 61

6 Operation ........................................................................................................................................................... 61

6.1 Description of the working area .................................................................................................................... 63

6.2 On and Off sequences ................................................................................................................................. 63

6.2.1 Switch on .............................................................................................................................................. 63

6.2.2 Switch off .............................................................................................................................................. 64

6.3 Operating modes .......................................................................................................................................... 64

6.4 Parameter list ............................................................................................................................................... 65

7 Faults ................................................................................................................................................................. 65

7.1 Faults during operation ................................................................................................................................. 67

7.1.1 Troubleshooting table ........................................................................................................................... 67

7.1.2 Commissioning after troubleshooting ..................................................................................................... 70

8 Maintenance and testing during operation ...................................................................................................... 70

8.1 Secure the machine against restarting ......................................................................................................... 76

8.2 Maintenance schedule ................................................................................................................................. 77


8.2.1 Daily ...................................................................................................................................................... 77

8.2.2 Weekly .................................................................................................................................................. 78

8.2.2.1 After 100 operation hours ....................................................................................................... 78

8.2.3 After 500 operation hours ..................................................................................................................... 78

8.2.4 Each 2000 operating hours ................................................................................................................... 79

8.2.5 Each 3000 operation hours or 1 / year .................................................................................................. 79

8.2.6 Each 4000 operation hours or 1 / year ................................................................................................... 80

8.3 Maintenance works ...................................................................................................................................... 81

8.3.1 Visual inspection ................................................................................................................................... 81

8.3.2 Cleaning ................................................................................................................................................ 82

8.3.3 Checking and servicing the mechanics .................................................................................................. 82

8.3.3.1 Maintenance and cleaning of Air filters .............................................................................. 84

8.3.3.2 Maintenance and cleaning oil filter ..................................................................................... 84

8.3.3.3 Maintenance oil separator ................................................................................................. 84

8.3.3.4 Maintenance of motors and bearings .................................................................................. 85

8.3.3.5 Checking belt and tension ................................................................................................. 85

8.3.3.6 Replacing belts ................................................................................................................... 85

8.3.3.7 Adjust belt pulley ................................................................................................................ 85

8.3.3.8 Adjusting axes ................................................................................................................... 86

8.3.3.9 Maintenance of minimum pressure and non-return valve .................................................. 86

8.3.3.10 Maintenance of Intake valve ............................................................................................. 86

8.3.4 Check and maintenance of electrical parts .............................................................................................. 86

8.3.3.1 Maintenance of safety devices ............................................................................................... 87

8.3.5 Check pneumatic System and service ..................................................................................................... 88

8.3.5.1 Maintenance of air receiver ............................................................................................... 88

8.3.5.2 Check for condensation ..................................................................................................... 89

8.3.6 Oil level and oil change ......................................................................................................................... 91

8.3.7 Replacement of worn parts ..................................................................................................................... 92

8.4 Compressor oil and lubricant ......................................................................................................................... 93

8.5 Wear and tear and spare parts ...................................................................................................................... 94

8.6 Customer service through the Manufacturer ................................................................................................ 94

9 Repair .................................................................................................................................................................. 95

10 Decommissioning, storage, disposal .............................................................................................................. 95

10.1 Temporary decommissioning ....................................................................................................................... 97

10.2 Final removal from operation ........................................................................................................................ 98

10.3 Dismantlement .............................................................................................................................................. 98

10.4 Re-packaging of the machine ....................................................................................................................... 98

10.5 Storage of the Equipment .............................................................................................................................. 98


10.6 Disposal ....................................................................................................................................................... 98

11 Technical Documents / Annex list

................................................................................................................. 99

11.1 Plan of maintenance and repair works ......................................................................................................... 99

List of Pictures .......................................................................................................................................................... 100

List of Tables ............................................................................................................................................................ 101

Glossary ................................................................................................................................................................... 101

Index of subjects ...................................................................................................................................................... 102

1. Description of the product

This operating manual (hereafter - Manual) allows the User to work on SSC-compressors (hereafter

Equipment or Compressor) safely, with optimum efficiency which ensures a long service life of the compressor. It describes the equipment, manufactured by the company Tolpec GmbH (hereafter –

Tolpec).

– Read the Manual thoroughly.

– Follow all the safety instructions .

1.1. Operating instructions

The Manual serves as a guide for the User and technical staff in relation to questions of maintenance. All the technical aspects of the Equipment are included.

The technical data relating to settings and upkeep as well as the maintenance and the safe operation of the equipment is included in the manual. The maintenance and operation of the equipment referred to in this manual should only be done by qualified persons (see requirements of the operator, [p. 40]).

Before proceeding with the operation of this equipment the operator/s should read and fully understand the manual. Compliance with all items indicated in the Manual and the explanations provided are the basis of the safe operation of this equipment.

All local Health and safety regulations need to be adhered to. Work safety orders and common safety rules for the field of use of the Equipment remain in force.

The Equipment Manual does not contain information about compressed air management control systems. When working with them, compliance with the relevant manual for such management systems is required.

In the event of using such management control systems, additional instructions for installed components are to be followed. Supplied by the manufacturers of such management systems.


Copyright protection

This Manual is protected by copyright and issued for internal use only.

Sharing of this Manual with third parties, their multiplication in any way and form – also selective – as well as copy/reproduce and/or distribution of its content without written permission, except for internal use, is forbidden. Non-compliance may lead to a claim for damages. The other possible claims are defined by the contract.

1.2. Storage of the Manual / keep it accessible

The Manual is an integral part of the Equipment and must be kept with the Equipment, so that the operator/s can have access to it at any time. The User must make the Manual available for technical staff and all operators during the whole working lifespan of the Equipment.

1.3. Used symbols and definitions

In this chapter, the symbols used in this Manual are explained.

1.3.1. Safety instructions

The safety instructions in this manual contain the following elements.


DANGER

Warning of an immediate danger to the user.

This safety instruction warns about immediate danger, that can lead to hard injuries or death.

WARNING

Warning of an immediate danger to the user.

This safety instruction warns about an immediate dangerous situation, that can lead to hard injuries or death.

CAUTION

Warning of potential danger to the user.

This safety instruction warns of a potentially hazardous situation that can result in minor or moderate injury .

ATTENTION

Warning of possible property damage.

This Safety instruction warns of possible property damage.

A security note exists next to the symbol and the signal word:

– Signal word

– Type and source of danger

– Consequences

Escape (= measures to avoid danger)

Example:


DANGER

Electric shock caused by high voltage ( type and source of danger )

Death caused by high voltage! ( aftermaths) a) Wait 3-10 minutes before starting work with electrical motor connections.

1.3.2. Warning signs

The following warning signs are used in the manual. These signs are intended to draw the reader’s attention primarily to the text of the accompanying warning or safety instructions.

Symbol Meaning

Warning of high voltage

Warning of hand injury

Warning of hot surfaces around air end, motor, oil receiver and tubing.

Warning of overhead load


Symbol Meaning

Warning of poisonous substances

Warning of combustible and flammable materials

Warning of a slip hazard

Table 1: Warning signs

1.3.3 Mandatory signs

In the Manual, the following mandatory signs are used.

Symbol Meaning

Read the operating manual

Wear protective gloves

Wear eye protection glasses


Symbol Meaning

Wear protective clothes

Wear light respiratory protection for protection from dust

Wear ear protection

Wear protective boots

Table 2: mandatory signs

1.3.4

Additional symbols in the manual

2 Important or helpful notices as well as, information and tips appear as follows:

NOTE

Note

With this symbol, you will get application tips and information that will help you make the most of all the functions on your machine .

1.3.5 Directional indications

Directional indications, are clearly marked and refer to the respective position from the control station, the direction of rotation of electric motors, viewed from the end wall of the driving side,


i.e. from the side where machine / system is coupled. They are either clockwise or anti clockwise.

1.4 Change history

No. of version Date From serial No.

Table 3: Change of history of this document

1.5. Applicable documents

Document

Operation and working manual

Spare parts list

Technical data sheet

Dimensional drawing of the equipment

Table 4: Table of applicable documents

1.6. Warranty and liabilities

The General Terms and Conditions of Sale and Delivery (GTC) of Tolpec GmbH are applicable. The User shall be notified thereof by the latest at the time of signing the contact as to the correct use of the equipment to make use of the legal liability for defects.

Limitation of liability

All information and instructions in this manual have been compiled in accordance with the applicable standards and regulations, as well as our many years of experience

Non-compliance with the notices and guidance of this manual will render the warranty void.

The Manufacturer shall not take responsibility for damages because of:

– non-compliance with the manual

– improper use

– use of non-trained personnel

– unauthorized conversions


– technical changes

– use of non-approved spare parts

There may be a slight variance from your delivered machine to this manual/ instruction and schemes described here in relation to construction, and additional options of later /current edition machines or because of the latest technical changes without prior notice.

The obligations stipulated in the delivery contract, the general terms and conditions as well as the conditions of delivery of the manufacturer and the statutory regulations valid at the time of conclusion of the contract apply.

1.7 Contact information of Tolpec GmbH and the SCC Sales- and

Service partner

For technical information, please contact customer service.

In addition, our employees are constantly interested in additional information and experience that can arise from the use of the equipment and can be valuable for the improvement of our products.

If you have any questions or suggestions regarding the equipment, please contact us on the details below or visit our website, stating the following information:

– Your name and address,

–

–

Contact person on site, data of name plate: type, serial No. and production year, Address:

Address:

Tolpec GmbH

SCC-Compressors Wertstrasse 44

73240 Wendlingen

Telephone: +49 (0)7022-789 6041

E-mail: [email protected]

Internet: http://www.tolpec.com

Table 5: Central contacts


SCC Sales- and Service partner

Address

Phone:

Email:

Operation manual received at: _____________________

Table 6: Your SCC sale and service partner


2 Description of the product

The compressors are available in the Smart, Flexi, Focus and Strong series. The technical design of the different series is identical except for the type of drive. The Smart series and Flexi series are driven by a belt. The Focus, Strong and Flexi series are direct drive.

The dimensions of the individual machines vary. The following section describes the machine, and the use of its main components.

The dimensions of certain Equipment are different.

In the following chapter the main components of the Equipment are described.

2.1 Construction of the Equipment/Controllers

Picture 1: Front view of the Equipment (example picture, Focus series)

1 Oil tank 2 Motor frame

3 Electrical Control box (open) 4 Operation panel/ control


Picture 2: Front view of the Compressor (example picture, Focus series)

1 Oil filter 2 Suction filter

3

5

7

Suction controller

Oil-level gauge

Minimal pressure and backswing valve

4 Air end

6 Oil tank

Not showed: drive behind the air end

Picture 3: Example picture: drive side of the Compressor with belt-drive (Smart series)

1 Electrical Control box 2 Motor


3

5

7

Belts

Air end

Oil tank

4 Oil filter

6 Suction controller: displaying without suction filter

All compressors consist essentially of :

– Air end,

–

–

–

–

–

–

–

–

–

– motor, suction filter, oil tank, pressure gauge, safety valve, oil fine filter, oil filter, ventilator, cooler, operation panel, control box.

Safety-relevant operating components

– 1x emergency stop button next to the control panel,

– 1 x Pressure display by the pressure sensor on the control panel

The emergency stop button is linked to the control panel / control of the machine.

Picture 4: Safety-relevant operating components and indicator elements of the Compressor


1

3

Safety valve of the oil tank

Operating panel

2

4

Pressure gauge

Emergency button

Picture 5: Safety valve

1 Safety valve for pressure tank 2 Pressure gauge


Operating panel MAM – 890

Picture 6:

1

3

5

Operating panel MAM - 890

ON – Start button for starting of motor

Indication Power – Voltage available

7

Alarm

1. Notification of warning through blinking diodes, when the warning value is reached.

2. Notification of error, when the diode shines constantly and the

Compressor switches off.

Switch to submenu / enter

Works as enter button, when the menu is chosen. (in various levels a password is needed)

9

11

2

4

OFF – Button for switching off the motor

6 C-

1 – Reset of error messages

2 – Switching to the previous menu level

Indication Run – Compressor in operation

1. Switching from main display to main menu levels.

2. Main menu – choose downwards

3. Decreasing of numeric data.

4. Submenu – choose downwards

Display indications

8 1. Switching from main display to main menu levels.

2. Main menu – choose upwards

3. Increasing of numeric data.


10 SET

1. Confirm changed parameters

2. Function of switch to charge to idle run



Picture 7:

1


ON

1. Switching on the Compressor

2. If the Compressor is used as master in

Block mode control, the Block mode control switches on.

3

OFF

1. Switching off the Compressor

2. If the Compressor is used as mode in block mode control, the block mode control switches off.

3. For reading of software. Press for a few seconds

5 Switch to submenu / enter

Works as enter button, when the menu is chosen

2 Display indications

4 C

1. Reset of error messages

2. Switching to the previous menu level


2. Choose in the main menu – upwards




2.

3.

4.

Choose in the main menu – downwards

Decreasing of numeric data.

Submenu – choose downwards

9 Alarm

1.

2.

Notification of warning through blinking diodes, when the warning value is reached.

Notification of trouble, when the diode shines constantly and the Compressor switches off.

11 Indication Power – Voltage available

8 SET



10 Indication Run – Compressor in operation



Picture 8: Operating panel MAM - 200

1 START

1. S witching on the compressor

2.

If the Compressor is used as master in Block mode control, the

Block mode control switches on.

3

5

STOP

1. Switching off the compressor

2. If the Compressor is used as master in block mode control, the block mode control switches off.

3.

For reading of software. Press for a few seconds

RESET

1. Reset of error messages

2. Switch to the previous menu level

7

9

1. Switching from main display to main menu levels.

2. Choose in the main menu – upwards

3. Increasing of numeric data


SET



2 Display indications

4 LOAD / UNLOAD

When the Compressor is in operation, it can be switched to charge or idle run

6 Switch to submenu / enter

Works as enter button, when the menu is chosen. (in various levels a password is needed).


2. Choose in the main menu – downwards

3. Decreasing of numeric data.



Operating panel MAM 6080

Picture 9:

1 Indication Power – Voltage available

3 Alarm

1.

2.


Notification of warning through blinking diodes, when the warning value is reached.

Notification of trouble, when the diode shines constantly and the Compressor switches off.

5

1. Switching the cursor on the icon to next icon

2. Switch to the next page of working parameters.

3. D ecreasing of numeric data.

7

1. Check the data in the text fields.

2. Switching in data editing mode, switching of numbers from right to left.

3. While changing the data or switching of icons on the display. Press the button for editing and changing.

4. For switching of the icon indication to the previous icon.

9 SET



2 Indication Run – Compressor in operation

4

1. Check the data in the text field.

2. Switching in data editing mode, switching of numbers from left to right.

3. While changing the data or switching of icons on the display. Press the button for editing and changing.

4. For switching of the icon indication to next icon

6 1.Switching the cursor on the icon to the previous icon

2. Switch to the previous page of working parameters.


8 C

1. Reset of error messages. (Press the button for

5 seconds)

2. Switch to previous menu level

10 OFF

1. Switching off the Compressor

2.

If the Compressor is used as mode in block mode control, the block mode control switches off.


11

ON

1. Switching the Compressor on

2. If the Compressor is used as master in Block mode control, the Block mode control switches on.

2.1.1. Areas of work and maintenance

Picture 10: Areas of work and maintenance

1 Screw compressor 2 Area of maintenance

3 Area of work

The working area during automatic operation is in front of the machine. The area for set-up, maintenance and maintenance work is the area in front, on the side and behind the machine.

POSITIONING After unpacking the equipment and preparing the compressor room, put the machine into position, checking the following items: Ensure that there is sufficient space around the machine to allow for maintenance. Check that the compressor is standing on a perfectly flat floor. Ideally the compressor must have a metre space around the compressor in all directions

2.2. Identification of the Equipment

The Equipment can be identified on basis of the name plate on the outer side of the Equipment.

Picture 11: Name plate of the Equipment


1

3

Name plate on the oil tank

Name plate of the Equipment

2 Name plate on the air receiver

Data on the name plate of the Equipment

The name plate contains following data:

–

– model marking power input in kW

–

–

–

–

–

– pneumatic capability/output in m3/min maximum possible air pressure in bar (g) weight of the Equipment in kg dimensions in mm serial No. production date

2.3. General descriptions

The Equipment produces compressed air.

The Equipment must be used only:

– for the intended use

– and in a safe environment.

Situations, that can affect the safety, must be immediately rectified. While the error remains, the

Equipment cannot be used.

Operation mode

Compressed Air is produced by drawing air in from the environment

or through an air supply channel (from outside of the building). The air is drawn in by the air end and the air filter as well as by the suction controller/suction valve. In the air end the air will be compressed by two interdependent screw-shaped rotors. The oil is injected into the compressor chamber. The oil is used for cooling, lubricating, protection of metal contacts of the rotors and for sealing of the rotors in the air end. The compressed air, after the air end will be mixed with oil and flow through the outlet in the oil tank. Large quantities of the oil are immediately removed in the lower part of the oil tank located directly in the oil circuit. The compressed-air oil mixture in the upper part of the oil tank passes through the separator vessel into the oil filter in which the oil is removed from the compressed air by filtration. The compressed air is led through a cooler to the compressed air outlet and the residual oil is returned from the filtration back through the scavenge line into the oil circuit.


A compressed air connection must be provided by the user.

Also refer to Appropriate use [ 25 ]

2.4. Use of the machine

In this chapter, the intended use of the Equipment is described.

2.4.1. Intended use

The Compressor is designed to produce compressed air through the compressing of air from the environment. The users technical staff shall always be on hand to ensure the safe operation of the equipment.

Operation of the machine in potentially explosive environments is prohibited.

A prerequisite for the intended use is that the operators read, understand and follow these instructions. The intended use includes the compliance of all instructions in this operating manual.

The machine must be checked regularly and maintained.

The machine is intended exclusively for industrial and commercial use.

Any other use not previously stated is forbidden

Also refer to Technical data page 32

2.4.2. Incorrect use

The following are examples of incorrect use that may occur if the guidelines and instructions outlined in this manual are not adhered too.

- Suction of media and the use of power with a specification that does not meet the requested operating specifications.

- Operation without protective cover

- An unauthorized use, for example, when unauthorized access/tampering/modification is made to relevant safety components.

- A failure may also occur if the specified operating parameters (i.e. temperature, overrun of maintenance intervals) are not observed.

- An unlawful use is to place or use the machine in areas where explosive environments may occur as defined by Zone 1

- Any use other than the intended.


2.5. Safety equipment

2.5.1. Overview

The Equipment is equipped with safeguards in the dangerous areas.

Without the intended mounted and adjusted safety devices, the Equipment can cause serious injuries to persons. The safety devices can't be changed or removed from operation. All the safety devices must always be accessible.

The user should be familiar with all the safety devices that may prevent and minimize injuries and/or machine failures. The controller with the operational panel is in front of the Equipment.

Automatic operation is carried out from outside the hazardous area.

Protective devices ensure safety from dangerous areas on the system. They have no influence on the movements of the plant.

Also refer to: Installation of the Equipment [ 49 ]

2.5.2. Protection/Safety devices

Protection devices protect the dangerous parts of the machine. They have no effect on the movement of the machine.

Removal of safety equipment:

The following are part of the safety equipment on this machine:

– motor frame

– protection covers

Separate protective devices prevent or hinder direct access to rotating or moving parts of the installation. They may only be removed for set-up, maintenance or repair work and must be reinstalled before restarting .


Motor frame with protection covers

Picture 12: Compressor frame with panels

1 Protection cover / panels 2 Motor frame

T he machine is completely enclosed in a machine frame with a protective covering. The machine frame contains the air end, the motor, the oil tank with the oil fine separator, the multiblock with the screwed oil filter, oil filter cartridge, the safety valve, the pressure sensor, the electrical control cabinet and the fan. As a separate protective device, the protective covering offers a comprehensive protection for the personnel working on the machine from the dangerous moving parts of the machine.

The protective cover is lockable or secured by a snap mechanism and is manually mounted or disassembled. The protective covering must be closed during the operation of the machine.

Non - Contact safety devices

The non – contact safety devices are as follows:

– safety valve

– pressure sensor

– temperature sensor

Non-contact safety devices cause the machine to stop. The direct access to rotating or moving parts of the system is thus prevented. The protective devices may only be switched off for maintenance or repair work and must be switched on again before restarting.


Pressure sensor at the minimum pressure and non-return valve or at the multi-block

Picture 13: Pressure sensor (example picture)

1 Pressure sensor

The pressure sensor is mounted on the minimum pressure check valve or on the multiblock. It controls the operation of the compressor. The compressor compresses (load operation) until the max. operating pressure is reached. The compressor then switches to idle mode. When switching to idle mode, a run-on time begins, in which the compressor is switched on either when reaching the min. operating pressure or after the time has elapsed, the motor switches off and goes into the standby mode.

As soon as the set min. operating pressure is reached, the system starts and operates on load .

Safety valve on the oil receiver

Picture 14: Safety valve on the oil receiver

1 Safety valve

A safety valve on the oil tank opens, when the maximum safety pressure exceeds the design pressure of the oil tank against over pressurisation.


Safety valve on the air receiver of the Equipment

Picture 15: Safety valve of the air receiver

1 Safety valve on the air receiver 2 Pressure gauge

A safety valve at the compressed air receiver is installed on the console between the compressor and the dryer at the compressed air inlet. The safety valve opens when the set safety pressure is exceeded and secures the compressed air receiver against high pressurisation.

Oil temperature sensor on the discharge/outlet of the air end

Picture 16: Oil temperature sensor

1 Oil temperature sensor

A temperature sensor monitors the oil temperature of the machine. If the permissible oil temperature programmed at the control unit is exceeded, a fault message is generated which leads to the shutdown of the machine.


2.5.3. Emergency stop system

Pressing the emergency stop button triggers the emergency stop function. The machine is safely stopped by immediate interruption of the control voltage. The emergency stop button is unlocked by turning the button.

Picture 17:

1

Emergency stop button

Emergency stop button

The Equipment has following emergency stop devices:

– Emergency stop button at the operator station.

2.5.4. Symbols and Signs on the Machine

Warning signs

Dangerous areas on the machine are marked with warning signs.

Warning labels and other instructions on the machine must always be clearly readable. Unreadable safety signs must be replaced immediately.

Symbol Meaning

Warning high voltage


Warning of hot surfaces around air end, motor, oil receiver and tubing.

Warning of hand injury

Warning of machine automatically starting

Table 7: Overview of the warning signs

Mandatory signs

Mandatory signs

Meaning

Read the operating manual

Wear eye protection


Wear ear protection

Wear protective clothes

Wear light respiratory protection for protection from dust

Wear protective boots

Table 8: Overview of the mandatory signs

2.6. Operating the Equipment

The Equipment works in automatic mode. The machine is operated by an operator in front of the compressor.

2.7 Operating and installation conditions

General data

Manufacturer Tolpec GmbH

Designation: Screw compressor

Production year

From 2016

Operation conditions Usage at the 3-shifts-factory

Location Roofed production plant or separate compressor room


Environment temperature During operating

Environment temperature during storage [°C]

+5 to +40

+5 to +40

Air quality for the

Equipment

The air in the production plant or in the compressor room must be as clean as possible and must contain the least amount of dust, aerosols or soot as possible

3. Safety

The machine is built according to state of the art and recognized safety regulations.

Nevertheless, dangers to the life and limb of the operator or third parties may arise if not used appropriately. Likewise, the machine or other property may be damaged. The Equipment should be used only:

–

– for the intended use and in safety-perfect conditions for the appropriate usage

The machine must not be put into operation again, after failures that can impair safety, until they have been remedied/repaired.

3.1 General safety instructions

3.1.1 Avoiding of dangerous situations

Dangerous situations while operating can be avoided through diligent and cautious behaviour of the staff. The following rules are obligatory for everybody who works with or on the Equipment:

– Keep the operating instructions in a readable form for everyone at the machine location.

–

–

–

–

Only use the machine as intended.

The machine must be functional and clean. Check the condition of the machine before starting work and at regular intervals.

Wear close-fitting work clothes during all work on the machine.

Make sure that nobody is injured by the parts of the machine.


–

–

Report faults or recognizable changes to the machine immediately to the person responsible.

Observe accident prevention regulations and local Health and Safety regulations.

3.1.2 Operation Instructions

The following ground rules are applicable while operating:

– Only one operator may operate the machine.

–

–

–

–

The machine must run continuously in automatic mode.

Safety devices must not be altered, disassembled or taken out of service. Safety devices must be checked at regular intervals.

All panels, covers and hoods must be fitted as intended .

Constructional modifications to the machine are not permitted.

– Any modification to the machine must be reported immediately to the person responsible.

– The danger area must always be kept clear. No objects may be placed in the way of the danger area. An operator may only enter the hazardous area if the power is switched off and the machine is locked.

3.1.3 Notes for trouble shooting and repairing

The following principles apply when troubleshooting and fault finding:

– Only adequately qualified personnel can perform work on the machine.

– The machine must be switched off.

– Disconnect the main plug or disconnect the power supply.

– Take the key out of the control cabinet.

– Secure the external main switch with a safety lock against accidental re-activation.

– Only the company supervisor can take the key.

– Otherwise the safety shutdown must be ensured by a second person.

– Hot machine parts must be allowed to cool down.


– Frequency inverters store electrical charges for several minutes while the power supply is switched off. Wait at least 5 minutes after energizing before working on a frequency converter.

Check the tension-free/power free.

3.1.4 Notes on electrical equipment

The following principles apply to all electrical work:

–

–

The Equipment has an electrical drive. If the electrical equipment is installed incorrectly or the isolation of the machine is damaged, a danger to life may occur.

The access to the electrical components and working with them is only for qualified staff.

–

–

–

The control box must be kept locked.

Only when the main plug is disconnected, the power supply and installed socket circuits are disconnected from the power supply.

Frequency inverters store electrical charges for several minutes with the power supply switched off. Wait at least three minutes after de-energizing before working on a frequency converter.

Check the tension-free.

–

–

Changes to the control system can affect safe operation. All planned changes must be approved in writing by the manufacturer of the machine.

Check the functioning of the protective equipment after all work.

– No unauthorized alterations may be made to the machine. All changes must be approved in writing by the manufacturer of the machine.

3.1.5 Electromagnetic compatibility (EMC)

According to its appropriate usage, this electronic equipment corresponds with the laws concerning electromagnetic compatibility. Those laws define the allowable emission level of the electronic equipment and its necessary resistance to electromagnetic fields.


Radiofrequency signals of high frequency transmitters, for example, of mobile phones or identical mobile radio equipment, that correspond with EMV-directions, can affect the appropriate functioning, if they are used nearby.

NOTE

Note

Make sure there are no electromagnetic fields near the machine.

3.1.6 Information on environmental protection

Safety-conscious and the forward-thinking behaviour of the personnel avoids negative environmental impact.

The following principles apply to environmentally-conscious actions:

–

–

–

–

Environmentally hazardous substances must not be allowed to enter the soil or sewage system.

Provisions on the prevention, disposal and recycling of waste must be complied with.

Environmentally hazardous substances are to be stored in suitable containers.

Containers containing environmentally hazardous substances must be clearly identified.

3.2 Unacceptable operating conditions

–

–

The operating safety of the machine cannot be guaranteed under unacceptable operating conditions. Unacceptable operating conditions must therefore be avoided in all cases. The operation of the machine is prohibited under the following conditions:

If the machine is not used as intended.

–

–

If the machine or parts of the machine are damaged and the electrical system is installed incorrectly, or the insulation is damaged.

Protective and safety equipment is not functional or defective, improperly installed or missing.


–

–

The machine must not be used when faulty.

There are persons or foreign bodies in the danger areas of the machine.

–

–

–

–

–

The machine has been altered or altered without authorization.

The control system has been changed outside the operational design of the machine.

Operating parameters have been changed.

If non-approved tools/equipment are used.

The specified maintenance intervals have been exceeded.

The tampering of limit switches and other control components, especially the safety components, is prohibited. Persons under the influence of alcohol or drugs are not allowed to operate or maintain the machine.

3.3 Responsibility of the operator

The duty of care of the operator includes, inter alia, planning and carrying out safety measures.

All persons carrying out activities with and on the machine, must be trained by the operator/Tolpec on the machine. You must have read and understood the operating instructions. By signing it, they confirm this.

The signatures are kept by the operator on a separate list. The operator has a list of authorized operators.

3.3.1 Minimize the risk of injury

–

–

–

–

–

To minimize the risk of injury, the following principles apply:

Work on the machine must be carried out by qualified personnel only.

The staff must be authorized by the operator for the respective activity.

The staff must have familiarized themselves with all safety devices before starting work.

Make sure that safety switches are never bypassed. This must be checked regularly by the qualified personnel to ensure that this has not occurred.

– If protective equipment has failed or is disrupted, it must be reported immediately to the responsible supervisor. The latter decides on how to proceed further.


–

–

–

The personnel must have familiarized themselves with the operating elements before starting work.

The machine must be kept in a clean and safe working condition as well as the compressor house in the immediate working vicinity of the compressor.

The machine and the immediate working vicinity around the compressor must be adequately lit.

–

–

Personnel must wear the personal protective equipment stipulated for that machine. The necessary protective equipment is laid down in the factory specifications. Operational supervisors are obliged to enforce the wearing of personal protective equipment by their employees.

During operation, qualified first responders must be ready to take the necessary measures to provide first aid.

–

–

Procedures and the responsibilities of operators working with the machine/equipment must be clearly defined. The Emergency procedure in case of accidents must be clear to everyone. The staff must be regularly informed/trained in this regard.

Warning signs and instructions on the machine must be complete and legible. The labels and notes must be regularly cleaned and replaced if needed.

3.3.2 Determine the Operator

The Qualified operator of the machine must determine which persons are permitted to carry out work on the machine. These persons must have the necessary knowledge for the respective work and be adequately trained.

Also refer to: Requirements of an Operator [ 40]

3.3.3 Operator training

The knowledge of general safety regulations is among the requirements to operate the machine safely. The generally applicable safety regulations also include the fact that the operators of the machine wear and use their personal protective equipment

The machine may only be operated if the general safety instructions and the instructions described in this manual are complied with. The operator must periodically train the authorized personnel regularly to operate the machine safely. The obligation of the operator to train the authorized personnel on a regular basis applies to the handling of the machine, to work on the electrical installations as well as to installation, set-up and do maintenance work.


NOTE

The staff must be trained regularly

The operator of the machine is obliged to train the personnel working on the machine on a regular and recurring basis in the work procedures, hazards and safety measures which are important for the personnel. This ensures that the authorized personnel always have the qualification/experience needed

3.3.4 Protective equipment

The operator of the machine must ensure that the operator receives the necessary protective clothing and protective equipment (face protection, hearing protection, eye protection, safety shoes, protective gloves, etc.) when using the machine.


3.4. Requirements of an operator

In the following chapters the requirements and the qualification of maintenance and technical staff are described.

3.4.1. Qualification

All the work on the Equipment require specialised knowledge and skills of the staff. Everybody, who works on the Equipment, must meet the following requirements:

– Personnel should be authorized for the corresponding activities.

– Qualified for the corresponding activities.

– Instructed for safe and correct operation of the Equipment.

– Are familiar with the safety devices and the way they function.

– Are familiar with this manual, especially with the safety instructions and the chapters that relate to the activities performed.

– Are familiar with general instructions for working safely and preventing accidents.

– In general, all the persons must have one of the following minimal qualifications: Qualified staff that can work with the equipment unassisted.

Life cycle

Transport

Installation and commissioning

Examples of activities of maintenance staff

Information about the qualification of maintenance staff1

–

– Lifting

–

Loading

–

Unloading

– building-up and fastening of the Equipment

- qualified staff

–

Connection of the power supply

- qualified staff

–

Filling of the Compressor with compressor oil and lubricating of the motor with grease

- trained/instructed staff

Trained / instructed staff2

X


Professionals3

X

X

Life cycle Examples of activities of maintenance staff

– greasing of the motor


Set up teach / program and / or convert

Operating

–

–

–

–

–

–

–

Adjustment/re-adjustment for other details/check parts enter/change

Testing of programs

Switching on

Operating

Monitoring

Switching off

Cleaning

Maintenance

Trouble shooting and repair

–

–

–

–

Cleaning – trained-/-instructed staff

Refilling of screw compressor oil


Disconnection of the power supply - qualified staff

–

Dismantling/repair of the components - qualified staff

Disconnecting of the power supply

–

–

Trouble shooting

Dismantlement/disconnection

Dismantling,

Decommissioning

–

–

– of the components

Repairs

Disconnecting of the power supply

Dismantling

–

–

Lifting

Loading

– Unloading

Table 9: Qualification of the staff

Information about qualification of maintenance

Trained / instructed

Professionals3 staff2

X X

X

X

X X

X

X

1* According to the definition of the machine guidelines, the operating person is the person or persons, who are responsible for the installation, operation, cleaning or transport of machines.

2* As trained / instructed personnel, a person who has been informed of the tasks assigned to him and the possible dangers of improper conduct and who has been trained as necessary. He will also be instructed on the necessary protective equipment and protective measures. Personnel that are still being trained, may only operate the compressor under the permanent supervision of an experienced person.


3*Experts A qualified person is a person who, based on his professional training, knowledge and experience, can assess the work which has been transferred to him and recognize possible dangers.

He shall also be aware of the relevant provisions.

3.4.2. Operator Groups

In this manual, a distinction is made between operator groups and technical staff:

Staff Qualification

Maintenance staff

Technical staff

Corresponding instruction in the areas:

–

–

Function processes of the Equipment

Operating procedures

Knowledge in the areas:

– Competence and abilities at the workplace

– actions in case of errors and accidents.

Advanced knowledge in the following areas:

– Electrical

- Electro m echanic

Authorization for activities (in accordance with safety technique standards):

–

–

–

Commissioning

Equipment earthing

Knowledge about equipment

– In depth knowledge of construction and the way the equipment functions.

Table 10: Operator Groups

3.4.3 Specialised knowledge

The following activities can only be performed by staff with specialist knowledge:

Activities Qualification

Working with electrical components

Professional electrician


Working with mechanical components

Industrial mechanic or trained technician. The work can only be performed under supervision of an industrial mechanic in accordance with the general rules of technique.

Table 11: Activities and knowledge

3.5. Personal protective equipment

Personal protective equipment is designed to protect personnel against hazards that could affect their safety or health at work.

When carrying out work on the machine, personnel must wear personal protective equipment. These are indicated separately in the individual sections of this manual. This personal protective equipment is explained below:

- Always wear the personal protective equipment required in the various sections of this manual before starting work.

- Follow the instructions given in the work area for personal protective equipment.

Description of personal protective equipment

Symbol Meaning

Protective gloves

Protective gloves are designed to protect the hands from rubbing, scratches, splinters or more serious injuries because of touching hot or cold surfaces.

Protective shoes

Protective shoes are designed to protect against falling parts and materials as well as from sharp objects.

Protective work clothes

Protective clothing is well-fitting workwear with low tear strength, with sleeves and without protruding parts. It is mainly used to protect against movement by moving machine parts. Do not wear rings, chains, jewellery and uncovered long hair.

Protective glasses

Are designed to protect the eyes from flying small parts and liquids.


Light respiratory protection

The light respiratory protection is designed to protect against toxic dust.

Ear protection

Is designated to protect against hearing damage.

Table 12: Mandatory signs

3.6. Residual risk

The following residual hazards cannot be eliminated.

- Danger if unauthorized or unqualified persons operate the machine.

- Danger if the machine is not serviced regularly.

Therefore, the operator must ensure that only authorized and qualified persons have access to the machine and its command centre/control panel.

3.7. Procedure in case of an accident

NOTE

Basic rules for accidents

Get the injured out of danger! Administer first aid and call the rescue service via the nearest telephone immediately as well as inform superiors!

When you call the ambulance, pay attention to the following:

– What happened?

– Where did it happen?

– What are the injuries or symptoms of the injured person?

– How many injured?


NOTE

First aid

Attend a first aid course to help you with emergencies.

4 Transport and installation

The transport can be carried out by means of a forklift truck or a suitable truck. To prevent life threatening injuries and property damage during transport and installation, observe the following:

- Transport and installation may only be carried out by qualified and authorized persons.

- The load holding means and the lifting means must comply with the provisions of the accident prevention regulations.

- When selecting the load receiving means and the lifting means, consider the total weight of the machine, which can be taken from the documentation in the separately attached technical data of the machine.

- Transport routes must be adequately measured/calculated. Doorways must be at least 5 cm wider and higher than the transport unit including the means of transport.

- The transport route should be checked by a third person.

The most effective installation is ensured, when the described installation process Is respected.

The following chapters provide an overview of the necessary steps for the transport and the installation of the machine.

Safety instructions for transport and installation

- All work on electrical equipment may only be carried out by qualified electricians

- This installation guide is not a substitute for the necessary professional training.

See also: Operating and installation conditions page 32


4.1 Required tools

These are the required tools to install the system:

- rotary hammer,

- machine water level

- measuring tape,

- screwdrivers (various sizes)

- Wrench (various sizes)

- Electromechanical tool.

If special tools are required, you will be informed prior to installation.

The transport can be performed using a forklift.

4.2 Transport

CAUTION

Danger of injury by tilting

The centre of gravity of the machine is relatively high. When crossing obstacles, the machine can tilt.

Do not cross obstacles.

- Before proceeding, ensure that the transport route is clean and free of obstacles.

The components of the machine should be transported to the installation site with a forklift truck.


Transport with the forklift

WARNING

Danger of falling loads

-

-

Suddenly dropping lifted loads will result in a risk to life.

-

Do not stand under raised loads!

Ensure that the equipment is correctly placed on the forks of the forklift truck during transport.

Observe the centre of gravity of the goods to be transported !

ATTENTION

Damage by transport with the forklift truck

The machine components can be damaged during transportation with the forklift truck by using unsuitable anchor points.

- When aligning the forks, do not damage any attachments of the system / system components.

- Carefully lift the machine

ATTENTION

Protect from moisture

The machine components in the packs can be damaged by moisture

- Protect the packs from moisture and keep them dry.


Symbol Meaning

Protective gloves

Protective gloves are designed to protect the hands from rubbing, scratches, splinters or more serious injuries because of touching hot or cold surfaces

Table 13: Personal protective equipment

Follow these instructions to transport the equipment safely using a forklift:

- Use only forks with allowable length.

- Lift the Equipment/its components from the side designated for this.

- If necessary, put wooden beams under the Equipment/its components during the transport.

- Transport the Equipment/its components only on the horizontally located forks of the forklift.

Picture 18: Transport with the forklift

A Distance of the forks

Place a wooden beam underneath

C

B Forks must be longer than the load


4.3. Unpacking and removing of package

Remove the consignment carefully and in accordance with environmental protection requirements.

4.4. Installation

In the following chapter the conditions and the instruction plan for the installation of the equipment are explained.

4.4.1. Place of installation and infrastructure

Before the installation, the installation place must meet the following conditions:

- The location surface of the equipment must be flat and firm.

- The safe and secure location of the equipment must be provided.

- The installation place should be roofed, be protected against the weather and frost (minimum +

3 ° C room temperature).

- The installation place must be ventilated.

- The power supply at the drive side is available (see Installation of electrical components (page

52).

- The installation place must be chosen so that the components are easy to reach and in an unhindered position where there is accessibility.

- The machine must not be exposed to direct sunlight.

- Externally heating the machine by other heat sources must be excluded.

- The machine should not be exposed to vibrations.

- At the installation place rescue equipment and escape exits must be freely accessible.

- Fire protection measures should be taken at the installation site.

- There are no machines nearby, that can cause negative electrical or electromagnetic effects.

- The machine room must have forced ventilation and exhaust air Ventilation from the equipment, considering the residual pressure. Exhaust air can be used for heat regeneration.

- The use of equipment in an explosive atmosphere is forbidden.


Before installing the machine, please observe additional conditions for the installation location and the infrastructure, which are contained in the technical data in the complete documentation. These are:

- Observe the cooling air volume and exhaust air volume as well as the ducting cross section to prevent the machine room from heating up.

- Electrical connections.

- Protection of the external isolatable main switch.

- A sufficient safety distance to the building wall should be considered for service work.

The compressor must be connected to the compressed air network of the operator with a flexible hose (max. 1.5 m). Shut-off valves in the compressed air line of the compressor and the following compressed air receiver, must be installed.

See also: Operating and mounting conditions page 32

4.4.2 Installation and Connection

CAUTION

Beware of obstacles on the ground

If you are not careful, there is a risk of injury from stumbling

– Pay attention to obstacles on the ground.

– Avoid tripping points when laying cables, hoses and pipes.

– Use appropriate cable ducts, bridges.

ATTENTION

Material damage caused by condensation

Moisture in the air can cause condensation and damage the compressor.

The cooling air must be dry, cool and dust-free.

NOTE

Install the machine so that the noise and vibration values are as low as possible during operation a) Move the equipment to the location.


See also: Transport page 46

4.4.3 Installation of the mechanical components

Place the machine at the intended location, ensuring the following conditions.

- All legal regulations must be clarified on the spot and their compliance must be ensured.

- The condition of the ground and space available must be clarified before the machine is installed to ensure safe operation for the personnel and the machine in the long run.

- The machine may only be installed, put into service and / or stored by specially trained specialists.

- All installation and infrastructure requirements are met.

- Set up the machine according to the installation plan.

- Ensure sufficient clearance for maintenance and repair work on the machine during installation.

- Ensure that the air circulates freely around the machine.

Remove transport safety devices

- Transport safety devices must be identified and removed during installation


NOTE

Keep transport safety devices with the machine for future possible transport.

NOTE

Equipment damage caused by incorrect installation is excluded from warranty.

NOTE

If you have questions concerning the installation of the pipe system, please contact the Tolpec customer service department.

4.4.4 Installation of the electrical components

To operate the machine, a main switch with a corresponding fuse must be installed.

DANGER

Electric shock due to high voltage when working on the electrical components of the system

An electric shock can result in serious injury or death.

-

-

-

-

-

All work on the electrical system can only be carried out by qualified electricians.

Disconnect the system from the power supply before carrying out any work on the electrical system.

Check the tension-free.

Ground the system.

Cover the adjacent area or barrier it off when working with electricity related parts.


Install a main switch with a blocking device on the operator side and a fuse in the supply line to the machine according to the connection values of your machine.

4.4.5 Final Check

NOTE

You can find all information on the design of the fuse for the machine in the technical data

NOTE

The following tests can only be carried out by specially trained personnel.

Tolpec’s authorized partners give an accurate instruction in the final inspection during commissioning.

Before you start the machine for the first time, the following safety checks must be carried out:

- Are all protective guards installed?

Do all the safety systems work?

5 Commissioning

Before starting the Equipment for the first time, the following must be proven correct:

 Was the installation with its final control fully completed?

 Are all the protection devices installed?

 Does the oil level in the oil tank receiver range within the marked limit?


Picture 19: Rotation direction arrow on the air end

1 Rotation direction arrow

– Check the direction of rotation of the motor on the air end.

– In models with a belt drive: is the belt tension corresponding?

Safety instructions for commissioning

DANGER

Danger to life by electric shock

There is a risk to life when touching energized parts. Electrical components that are inserted can unintentionally cause movements and injuries.

– Switch off the system before maintenance and secure it against accidental restart .

DANGER

Danger to life due to stored charges

Electric charges can be stored in electronic components, which are retained even after switching off and disconnecting from the power supply. Contact with these components can result in serious or fatal injuries.

– Disconnect the components completely from the power supply before working on these components. Allow 3-10 minutes to ensure that the internal capacitors are completely discharged.


WARNING

Danger due to missing safety devices

Missing protective covers can lead to serious injuries.

– Mount all protective covers which may have been removed for installation before commissioning the machine.

– Check all safety devices before starting the machine .

CAUTION

Risk of injury from noise

The noise level in the work area can cause serious hearing damage.

– Always wear ear protection, when working.

– Stay as short as possible in the danger area .

5.1 Check the safety devices

Check the safety devices for perfect function:

- before first use,

- before commissioning after prolonged stoppage,

- daily before work starts. a.) Check:

– Are all protective covers closed?

– No visible defects on the safety valve? b.) Start the machine.

– Monitor the temperature and pressure development to check the function of the sensors c.) Press the emergency stop buttons and check that the machine is safely switched off.

The safety devices are tested.

See also: Commissioning page 53


5.2 First Commissioning

WARNING

Crushing and pulling danger by the drive shaft of the motor and by the

V-belts

When working on an open machine during commissioning, special caution is advised, since moving parts must be used in the working area. a.) Commissioning activities may only be carried out by the specially authorized and trained staff. The setup must be carried out from a safe position.

b.) Ensure that there are no persons in the danger area before the movements are triggered.

c.) Depending on the situation, the danger area must be blocked by a red and white chain during set-up.

d.) Wear protective gloves

NOTE

Before operating the machine, read and follow the safety instructions page 33 of this manual, carefully.

Ensure that all mechanical and electrical work is finished and that no one is in danger.

All safety devices are assembled, tested and ready for operation





All protective covers are installed.

For belt driven models the belt tension is set correctly .


Picture 20: Oil-receiver

1 Pressure gauge 2 Oil filler neck

3 Oil level gauge 4 Oil outlet a.) Check the oil level at the oil level gauge (see compressor oil and lubricant on page 93) .

b.) If necessary, fill the oil tank with the compressor oil at the oil filler neck. The marking indicates the necessary oil level during operation of the machine. Keep the oil quantity and the required technical specifications of the oil exact. Observe the technical data for your model.

Picture. 21: Intake valve mounted on air end

1 Dismantle intake valve from air end


NOTE

For initial start-up or after two weeks or longer

The compressor unit must also be supplied with compressor oil during initial commissioning and after shutdown times.

–

–

–

–

Loosen the intake manifold mounting bolts at the inlet of the compressor unit.

Remove the intake regulator.

Fill approximately 0.5 - 1 l compressor oil into the inlet of the compressor unit.

Assemble the intake regulator and tighten the mounting bolts.

CAUTION

Danger of skidding by leaking oil.

There is a risk or chance of injury. a.) Check the machine for leakage and leaking oil.

b.) c.)

Eliminate leaks and leaked oil immediately.

Immediately remove any excess oil from the machine.

d.) Close the shut-off valve of the compressed air line attached to the compressed air network of the operator after the compressed air storage. e.) f.)

Insert the plug for the power supply, or set the power supply to the machine

Turn the main switch, or reset the emergency stop button.

• The controller starts and a start screen appears after approx. 5 seconds.

• The machine is ready for operation.


CAUTION

Destruction of the compressor unit by an incorrectly connected motor a.) If the power supply is connected incorrectly and the compressor is switched on, the machine can be destroyed in a very short time. An

ALARM signal indicates that the direction of rotation of the motor is wrong and that the rotating field must be corrected.

b.) Before the compressor is started, a qualified electrician must check the power connection and the rotating field.

g.) Open the appropriate guard / panel to have a clear view of the drive and start the compressor briefly with ON.

Picture 22: Direction arrow on air end

1 Direction arrow for direction of rotation of motor or air end .

h.) Stop the machine immediately after 2 seconds with the emergency stop button. When starting and running the motor, the direction of rotation can be checked using the directional arrow on the compressor unit.

i.) j.)

Unlock the emergency stop button and start the machine with ON.

Check the pipe system for leaks.

k.) Mount the protective guards.

l.) Check on the display whether the air compressor reaches the set pressure and then reduces pressure.


m.) Check whether the compressor is switched on again when the set minimum pressure is reached, or again begins to compress and the pressure increases again.

n.) Check the air compressor for the presence of non-characteristic vibrations and noises. Eliminate the causes of abnormal equipment.

o.) Open the ball valve of the compressed air line very slowly to the customers compressed air network after the compressed air tank, so that a controlled pressure equalization can take place.

NOTE

Check the condensing temperature

The compression temperature can be read at 65 ° C and 85 ° C during operation, depending on the ambient conditions .

Set up user settings

a.) Use the operating instructions for the control to configure the user settings.

b.) Start the compressor with [ON] on the control panel.

c.) Stop the compressor with [OFF] on the control panel.

The first commissioning has been completed.

See also: Technical documentation / Annex list page 99 and Operating and installation conditions page 32

5.3 Daily commissioning

The first commissioning has been successfully completed.

The surrounding area is clean, oil-free and illuminated.

The power supply is connected a.) Check the oil level and refill if necessary.

b.) For models with a belt drive, check the belt tension.


c.) Remove the protective covering / panels of the entire machine and check the interior for dust and contamination; Use the fan to remove any contaminants.

d.) Mount the panels.

e.) Check the connection cable for visible damage. Never operate the machine if the cable is damaged!

f.) Ensure that all safety devices and covers are installed.

g.) If fault messages are displayed on the control panel, these must be corrected according to the operating instructions for the machine and the control panel.

Daily commissioning is complete.

See also: First Commissioning page 56

5.4

Commissioning after Storage

WARNING

Danger of injury due to unintentional starting of the machine

Perform the mechanical tests only with the main switch off . a.) The procedure for commissioning after storage corresponds to the first commissioning: b.) Check all components for free movement, if necessary, ensure the free movement of the components.

Carry out commissioning after storage according to the first commissioning.

See also: First commissioning (page 56)

6 Operation

The following principles apply when operating the machine:

This work must be carried out by trained and authorized operators. The machine is only allowed to be operated, if all the safety devices are properly installed and functioning.

The following principles apply when operating the machine:


a.) Check the proper functioning of the safety devices b.) Inform the responsible person immediately if safety devices have failed or are disrupted.

c.) Ensure that nobody is in danger before switching on the machine.

d.) Wear your personal protective equipment (e.g. protective gloves) when operating the machine.

e.) The removal of protective devices during operation of the machine is not permitted.

f.) Smoking and open fires are strictly prohibited near the machine.

Safety instructions for Operating

CAUTION

Danger of skidding on leaking oil.

There is a risk or chance of injury. a.) b.)

Check the machine for leakage and leaking oil.

Eliminate leaks and leaking oil immediately.

CAUTION

Risk of injury from noise.

The noise level in the work area can cause serious hearing damage. a.) b.)

Always wear ear protection when working.

Stay as short as possible in the danger area.

See also: Safety Page 33


6.1 Description of the working area

Picture 23: Areas of work and maintenance

1 Screw compressor 2

3 Working area

Maintenance area

Table 18: Working and maintenance areas

The operating area and the control panel are in front of the machine during automatic operation.

The areas for set-up, maintenance and maintenance work are the areas in front, on the side and behind the machine.

6.2 On and off sequence

6.2.1 Switch on

Before switching on

Carry out the following work and checks: a.) Check the machine and all components for external damage.

b.) Check if there is oil leakage.


c.) Check the soil for contamination:

If you notice any damage or contamination, repair or remedy this.

The machine can be switched on.

6.2.2

Switch off

Switch off the machine with (0) button at the control panel of the unit.

a.) The machine changes from load- to idle mode so that no further air is compressed. b.) Motor stops after run on time. c.) The power supply is shut off. d.) Machine is switched off.

6.3 Operating Modes

A distinction is made between the following operating states or operating modes of the machine:

– Voltage-free: main plug disconnected or main switch switched off.

–

–

–

Emergency stop condition: emergency stop device tripped.

Automatic operation: Automatic execution of the machine program.

The compressed air is generated automatically.

WARNING

Danger of injury due to unintentional starting of the machine

The machine can start automatically in automatic mode.

a.) Perform the mechanical tests only with the main switch off.


6.4 Parameter list

The parameter list can be found in the separate operating instructions for the control unit

7 Faults

Observe the following principles, when you are looking for errors and correcting errors: This work must only be performed by specially trained and authorized specialists. a.) Allow warm components to cool before starting work.

b.) Wear suitable protective clothing.

c.) Before re-commissioning, mount all safety devices that are provided.

d.) Check the proper functioning of the safety devices.

e.) After completion of the work, remove all tools and objects from the movement area of the machine

Safety instructions for faults

DANGER

Danger to life by electric shock.

There is a risk to life when touching energized parts. Electrical components that are inserted can inadvertently cause movements and injuries. a.) Switch off the system before maintenance and secure it against accidental restart .


DANGER

Danger to life due to stored electrical charges

Electric charges can be stored in electronic components, which are retained even after switching off and disconnecting from the power supply. Contact with these components can result in serious or fatal injuries. a.) Disconnect the components completely from the power supply before working on these components. Allow 3-10 minutes to ensure that the internal capacitors are completely discharged

WARNING

Risk of injury from hot surfaces

Some components of the compressor become hot during operation.

a.) Before starting work, let the compressor cool down for 30 minutes.

b.) Wear protective gloves

WARNING

Danger to life by a liquid jet emerging under high pressure

In the case of defective hoses, tubes or components, a liquid jet can escape under high pressure. The liquid jet can lead to the most serious injuries and death.

 Keep persons out of danger and never place objects near the liquid jet.

In case of accidental contact with the liquid jet, first-aid measures must be taken and immediately seek medical advice.

 Immediate emergency stop. If necessary, initiate further measures to reduce the pressure and stop the liquid jet.

 Take out and dispose of leaking liquids properly.

 Repair defective components immediately.


WARNING


Missing protective covers can lead to serious injuries. a.) Mount all protective covers which may have been removed for installation before commissioning the machine.

b.) Check all safety devices before starting the machine .

CAUTION

Risk of injury due to noise.

The noise level in the work area can cause serious hearing damage. a.) Always wear ear protection when working. b.) Stay as short as possible in the danger area.

7.1 Faults during operation

Faults occurring during operation are displayed in the display by means of symbols.

7.1.1. Troubleshooting Table

FAULT / ALARM Probable causes Troubleshooting Fixed by**

The machine does Wrong power connection Check power connection MS


Not starting Compressor is selected as

"Slave" and starts with remote control

See symbols of the control system and data in the controller

MS

Wrong electric phase sequencer Check the phase sequence

Emergency stop button is released

Release the emergency stop button

QT

MS

There are unsolved faults in the operating controller

Solve the Faults and confirm the error message

MS

Check the switch-on timer SP Switch-on time of the program is activated

Network pressure is higher than the switch- on pressure

Check the pressure values and correct them, if necessary

QT

Oil temperature too high

Compressor oil deficiency in the machine

Check the compressor oil level of the oil receiver and refill oil

QT

Environment or suction temperature is too high

Check the environment temperature and ventilation of the machine room

** MS = Maintenance staff, QT = Qualified technicians, SP = Service and distribution partner SCC

MF

FAULT / ALARM Probable causes Troubleshooting Fixed by**

Oil temperature too high

Cooler or filter pad of cooling air is blocked

Oil fine filter is blocked

Clean the cooler or replace filter pad of cooling air

KF

Replace the oil fine filter SP

Network pressure constantly decreases

Compressor oil polluted or aged Check and change the compressor oil

The oil cooler of the compressor is damaged

Check the Oil cooler and replace it, if necessary

The compressed air consumption is higher than the delivery capacity of the

Equipment

Leakages in the compressed air network

Check compressed air network for leaks.

SP

SP

Check function and size of

Equipment

QT

MS


The suction filter is heavily polluted or blocked

Replace the suction filter QT

The drive belt is broken Replace the drive belt SP

The intake valve does not open Check the function and operation of the intake valve

Relief valve at the intake valve is damaged

High pressure fault Oil fine filter is blocked

Check the function and operation of the valve

SP

SP

Replace the oil fine filter SP

The intake valve does not close after reaching the maximal pressure

Higher network pressure in the compressed air network

Ball valve after compressor is closed

High oil expenditure Oil level is too high

Check the function and operation of the intake valve

Stabilize the system pressure; check the pressure settings on other compressors

Slowly open the ball valve to perform stabilization of the pressure in the network.

Check the oil level, and reduce oil level over ball valve at oil outlet of the receiver

SP

SP

QT

MS

Oil return line is blocked or nonreturn valve in the oil return line is defective

Check oil return line and non-return valve.


SP

FAULT / ALARM Probable causes Troubleshooting Fixed by

High oil expenditure

Trouble

Oil level is too high

Oil return line is blocked or nonreturn valve in the oil return line is defective

The pressure sensor does not work

Leakage in the tubing system

Check the oil level, and reduce oil level over ball valve at oil outlet of the receiver

Check oil return line and non-return valve.

MS

SP

Replace the pressure sensor

SP

Check the tubing system, repair the leakage

QT


Error of the control system Contact the Manufacturer SP

SP Unusual noises The distribution and service partner /SCC needs to check

By the distribution and service partner SCC


Table 14: Troubleshooting table

7.1.2 Commissioning after Troubleshooting

 The machine is switched on at the main switch.

a) Reset the emergency stop button.

b) Remedy the fault messages on the control panel c) Ensure that no persons are in the danger area d) Start the Machine at the Controller with button “ON” or “I”

8

Maintenance and testing during operation

The following principles apply to maintenance and testing of the machine:

This work may only be performed by specially trained and authorized specialists. a.) Switch off the machine before starting work and secure it against re-activation.

b.) Hot components must cool down before starting work.

c.) Depressurize the system.

d.) Wear suitable personal protective equipment.

e.) Secure the work area with a red and white chain to prevent unauthorized persons entering.

f.) Use suitable lifting devices for lifting.

g.) Before re-commissioning, mount all safety devices as provided on the factory side.


h.) Check the proper functioning of the safety devices.

i.) After completing the work, remove all tools and objects from the machine.

j.) After the work has been completed, remove all contaminants and oil stains around the machine.

Safety instructions for maintenance and testing during operation

DANGER




DANGER



WARNING


Missing protective covers can lead to serious injuries. a.) b.)

Mount all protective covers which may have been removed for installation before commissioning the machine.

Check all safety devices before starting the machine.

WARNING

Danger of injury due to improper repair

Improper maintenance and repair may result in serious injury. Disassembled components and tools are potential accident hazards. a) Work carefully.

b) Ensure sufficient ting area.

c) Keep the assembly site tidy and clean


WARNING

Risk of injury from compressed air

Unpredictable discharged air can damage the eyes, stir up dust or lead to uncontrolled movement of hoses. a.) Before machine maintenance and repairs, depressurize and bleed the machine, then wait 5 minutes. b.) Have defective components repaired promptly by qualified personnel.

c.) Wear protective glasses

WARNING


Some components of the compressor become hot during operation. a.) Before starting work, let the compressor cool down for 30 minutes.

b.) Wear protective glasses.

WARNING

Danger to life by liquid jet emerging under high pressure

In the case of defective hoses, tubes or components, a liquid jet can escape under high pressure. The liquid jet can lead to the most serious injuries and death. a.) Never place objects near the liquid jet. Keep persons out of danger. In case of accidental contact with the liquid jet, first-aid measures must be taken and immediately seek medical advice.

b.) Immediate emergency stop required. If necessary, initiate further measures to reduce the pressure and stop the liquid jet.

c.) Clean up and dispose of leaking liquids properly.

d.) Repair defective components immediately.


WARNING

Danger to life due to improper work on the pressure receiver

Improper handling of pressure receivers can cause sudden pressure reduction and can lead to serious injuries and death as well as substantial damage to property. a.) Never perform welding or soldering work on the pressure tank.

b.) Do not carry out any mechanical work on the pressure receiver.

c.) Fully reduce the pressure receiver before the pressure hose / tube can be disconnected over the condensate ball valve d.) Start working on the pressure receiver only after the air pressure has been completely reduced .

WARNING

Risk of injury from hot materials

Operating fluids can reach hot temperatures during operation. Skin contact with hot materials causes serious skin burns. a.) b.)

Always wear heat-resistant protective clothing and protective gloves when carrying out any work with fluids.

Before any work with fluids, check that they are not hot. If necessary, wait until they have cooled down .

CAUTION

Danger of skidding on leaking oil.

There is a risk or chance of injury. a.) Check the machine for leakage and leaking oil.

b.) Eliminate leaks and leaking oil immediately.


CAUTION

Risk of irritation to eyes and respiratory system

At hot temperatures or mechanical atomization of cooling liquid due to defective components, irritating fog can escape from the cooling liquid. a.) Allow the compressor to cool before starting work.

b.) Ensure sufficient ventilation at the assembly site.

c.) Wear light respiratory protection and protective glasses

CAUTION

Risk of injury from noise.

The noise level in the work area can cause serious hearing damage. a.) Always wear ear protection when working. b.) Stay as short as possible in the danger area.

CAUTION

Risk of injury from cooling liquid mist

Hot temperatures or mechanical atomization can lead to a cooling liquid mist.

Cooling fluid mist can irritate the eyes and the respiratory tract. a.) Wear respiratory protection and protective glasses, when working on the coolant system and in the event of a coolant mist ensure a fresh air supply .

NOTE

Perform regular maintenance

Regular maintenance increases the service life of the machine and is an absolute prerequisite for safe and efficient operation.


NOTE

Maintenance contract

Tolpec GmbH offers maintenance contracts. Our employees or authorized specialists authorized by Tolpec will provide you with the necessary maintenance and thus ensure a long service life of your machine as well as a reliable, efficient, quality compressed air system. If you would like to use this service, please contact Tolpec Customer Service.

8.1 Secure the machine against restarting

The machine is secured by closing the main switch to prevent restarting.

On the operator side, a main switch with a corresponding fuse must be installed (see Installation of electrical components (page 52)

WARNING

Danger by starting the machine

The uncontrolled start-up of the machine can lead to serious injuries or death. Only when the machine is switched off, can work on it be carried out a.) Switch off the machine at the main switch and secure it against reactivation

Secured /locked Main Switch / Option

Picture. 24: Locked electrical main switch (picture example)

1 Main Switch

Procedure for securing the main switch against accidental reconnection


a.) Turn the main switch to “0” b.) Secure the main switch with a padlock.

The key must be handed over to the employee responsible.

– The machine is protected against reconnection

Release the Main Switch

a.) Before restarting, ensure that there is no danger to persons b.) The lock may only be opened by the employee responsible.

8.2 Maintenance schedule

The following chapter describe the intervals, at which maintenance must be carried out on the machines.

NOTE

Shift of maintenance intervals

The indicated maintenance intervals refer to operation in the specified ambient conditions. Under unfavourable ambient conditions, maintenance intervals can be significantly reduced. Therefore, during the regular maintenance work, the condition of the machine, the components / oil and ambient conditions should be checked to adjust maintenance intervals, if necessary. If you are not sure, please consult the SCC Sales and Service partner.

8.2.1. Daily

Components

Oil level gauge

What is to do*

Whole Equipment V

Ch

Description of works

Visual inspection for wear and damage

Check oil level and correct if necessary

ATTENTION! In the case of a large oil deficiency, there is excessive heating, which in extreme cases can lead to a deflagration.

Display of Controller V Check the actual and set values of the parameters for pressure and temperature.

* V = Visual control, Ch - Check, R = Replacement, C = Cleaning

Performed by**

MS

MS

MS


Table 15: Daily maintenance plan


8.2.2. Weekly

Components Scope of work* Description of works

Whole Equipment V, C

Cooler C

Visual check for cleanness

Cleaning

Condensate (only for machines with pressured air receiver) TD range.

Ch Drain condensate at the compressed air receiver, when no automatic condensate drain is installed

* V= Visual control, Ch= Check, R= Replacement, C= Cleaning

Performed by**

MS

QT

MS

** MS= Maintenance staff, QT= Qualified technicians, SP= Service and distribution partner SCC

Table 16: Weekly maintenance plan

8.2.2.1. After 100 Operation hours


Cooler Ch Check the cooler for contaminations.

Performed by**

QT

Hoses, components Ch

Check condensate Ch

Temperature

Drive

Ch

Ch

Visual check for leaks. QT

Check the Equipment for condensed water. (oil)

QT

Check the Oil temperature QT

Visual check of belt drive and tension. QT



Table 17: Maintenance plan after 100 operation hours

8.2.3. After 500 Operation hours


Oil level Ch Correct the oil level, if necessary

Performed by**

QT

Hoses, components Ch

Drive Ch / R

Visual check for leaks.

Visual check of belt drive and tension.

QT

QT



Table 18: Maintenance plan after 500 operating hours


8.2.4. Each 2000 operating hours


Electromotor

Drive

R

Ch / R

Lubricating of bearings

Visual check of belt drive and tension.


Performed by**

QT (*SP)

QT

** MS = Maintenance staff, QT = Qualified technicians, SP = Service and distribution partner

SCC

Table 19: Maintenance plan for each 2000 operating hours

8.2.5. Each 3000 operation hours or 1 / Year

Compressor size until 18 kW


Electric connections, switches and connection cable

Air filter

V, Ch

R

Visual check for damages, check the electric connections for strength of connection

Replace the air filter /

Performed by**

QT (*SP)

QT (*SP)

Oil filter R Replace the oil filter QT (*SP)

Oil fine filter / separator element.

R

Change of oil R

Replace the oil fine filter / separator element.

Change the oil

QT (*SP)

QT (*SP)



Components Scope of work* Description of works Performed by**


General maintenance of compressor

Ch, R; C, V Maintenance of the entire system. Oil fine separator, safety valve, intake regulator, drive, temperature regulator, minimum pressure check valve, tightness and function test.

Recommendation: (* SP): filter and oil change etc. are carried out by the SCC sales and service partner within the scope of the overall performance)

SP




8.2.6 Each 4000 operation hours or 1 / Year

Compressor size from 22 kW


Electric connections, switches and connection cable

Air filter

Oil filter

V, Ch

R

R

Visual check for damages, check the electric connections for strength of connection

Replace the air filter /

Replace the oil filter

Oil fine filter / separator element.

Change of oil

R

R

Replace the oil fine filter / separator element.

Change the oil

General maintenance of compressor

Ch, R; C, V Maintenance of the entire system. Oil fine separator, safety valve, intake regulator, drive, temperature regulator, minimum pressure check valve, tightness and function test.

Recommendation: (* SP): filter and oil change etc. are carried out by the SCC sales and service partner within the scope of the overall performance)


Performed by**

QT (*SP)

QT (*SP)

QT (*SP)

QT (*SP)

QT (*SP)

SP




8.3 Maintenance work

The following sections describe how maintenance should be performed.

8.3.1

Visual Inspection

Perform the following visual inspections: a.) Check the machine and all components for external damage b.) Check all safety devices for external damage

– If you notice any contamination or damage, Report it and Repair immediately.

The visual inspection of the machine is complete.


8.3.2 Cleaning

ATTENTION

Danger of damage caused by unsuitable cleaning agents and cleaning procedures

Unsuitable cleaning agents can cause damage to the machine or machine components. a.) Wear protective gloves and glasses. b.) Use only mild detergents c.) Do not use high pressure equipment as well as aggressive or corrosive detergents

Components Methods Cleaning agent Notice

General surfaces Clean with cleaning cloth and detergent

Solvent-free detergent

Floor Wet the floor and wipe with mop

Solvent-free detergent

Follow the recommendations of the detergent manufacturer

Follow the recommendations of the detergent manufacturer.

Table 22: Common recommendations for cleaning

NOTE

Special cleaning instructions

Some components must be dismantled for cleaning. For this reason, you will find the specific instructions for cleaning in the Maintenance section under the corresponding component

The surfaces of the machines are easy to clean and antistatic.

8.3.3 Checking and servicing the mechanics

In case of damage to the mechanical devices, immediately take the machine out of operation and start a thorough repair using original spare parts.


ATTENTION

Component damage due to insufficient maintenance

Insufficient maintenance results in more wear and higher repair costs.

a.) b.)

Carry out the necessary maintenance work according to the manufacturer's instructions.

Observe the manufacturer's instructions for the maintenance of the mechanical components .

The following tightening torques apply to the stability and functionality of the mechanical components of the compressor:

Safety screws / -nuts, construction B 158/193/196/251

M5

Class 8.8

3.69 (5)

Unit lbf ft (Nm)

Class 10.9

7.38 (10)

Unit lbf ft (Nm)

M6

M8

M10

M 12

5.9 (8)

14.75 (20)

29.5 (40)

50.89 (69)

M 16 125.39 (170)

Table 23: Tightening torque of the safety screws lbf ft (Nm) lbf ft (Nm) lbf ft (Nm) lbf ft (Nm) lbf ft (Nm)

13.28 (18)

32.45 (44)

64.17 (87)

111.37 (151)

280.27 (380) lbf ft (Nm) lbf ft (Nm) lbf ft (Nm) lbf ft (Nm) lbf ft (Nm)

Safety screws / -nuts, construction DIN 912/931/933/934/982

Class 8.8 Unit Class 10.9

M5 4.43 (6) lbf ft (Nm) 6.27 (8.5)

M6

M8

M10

7.38 (10)

18.44 (25)

36.14 (49) lbf ft (Nm) lbf ft (Nm) lbf ft (Nm)

10.33 (14)

25.81 (35)

50.89 (69)

Unit lbf ft (Nm) lbf ft (Nm) lbf ft (Nm) lbf ft (Nm)

M 12 63.43 (86)

M 16 154.89 (210)

Table 24: Tightening torque of the safety screws lbf ft (Nm) lbf ft (Nm)

55.51 (120)

217.58 (295) lbf ft (Nm) lbf ft (Nm)


The machine is depressurized.

a.) Use the separate key to unscrew the oil filter. Clean the fitting point. Wet the new gasket with oil before installing the new filter. Screw in the new filter. Start the compressor and check if there are any leaks. The oil filter has been repaired

8.3.3.3 Maintenance of the Oil separator

NOTE

Used oil separators depend on the series

In the case of a spin-off oil separator, maintenance is carried out analogously to the oil filter. If the oil fine separator is integrated in the oil tank, maintenance must only be carried out by the SCC service partner.

To maintain the Electric motor, it is necessary to regularly lubricate the bearings with the solid grease Mobile Polyrex EM and Total Multis EP 2 .


8.3.3.4 Maintenance of Motors and Bearings

NOTE

The motor and bearings are serviced by the SCC service partner .

To maintain the Electric motor, it is necessary to regularly lubricate the bearings with the solid grease Mobile Polyrex EM and Total Multis EP 2 .

8.3.3.5 Checking belt tension (depending on the model)

The machine must be depressurized. a.) Open the side cover on the belt drive.

of the belt should be less than 5 mm.

The belt tension is set. b.) Turn the screw on the clamping device. Adjust the spring and then adjust the correct tension of the belt: the average pressure should be 3 kg, the deformation

8.3.3.6 Replacing belts (depending on the model)

The machine must be depressurized.

a.) Open the side cover of the belt drive.

b.) Loosen the screw of belt tensioner to loosen the belt.

c.) Remove the worn belt from the shafts.

d.) Place a new strap on the shafts and tension it.

e.) Mount the side cover of the belt drive and restore the machine to operational condition.

f.) Run the compressor for 10 minutes.

g.) Re-energize and depressurize the machine.

h.) Disassemble the side cover of the belt drive again.

i.) Tighten the belt.

j.) Mount the cover and make the unit ready to operate.

8.3.3.7 Adjust belt pulley (depending on model)


NOTE

The axis alignment motor-compressor stage is set by the SCC service partner .

8.3.3.8 Adjusting axes (depending on the model)

NOTE

The axis alignment motor-compressor air end is serviced by the SCC service partner .

8.3.3.9 Maintenance Minimum pressure and non-return valve

NOTE

The minimum pressure and non-return valve is serviced by the SCC service partner .

8.3.3.10 Maintenance Intake-valve

NOTE

The intake valve is serviced by the SCC service partner .

See also: Contacts page 13

8.3.4 Check and maintenance of electrical parts

a.) Periodically check the electrical system with a visual inspection


b.) Immediately shut down the machine in case of damage to the electrical equipment and start a proper repair with original spare parts.

See also: Repair page [95]

8.3.4.1 Maintenance of safety devices

To ensure the operational safety of the machine at any time, it is necessary to replace different safety-related components at the end of their service life.

In the case of damage or failure of a safety device, the relevant component must be replaced immediately and the entire safety circuit must be subjected to a comprehensive functional test.

Other components may also need replacing.

Contact the SCC sales and service partner.

See also: Contacts page [13]


8.3.5 Check the pneumatic system and service

8.3.5.1 Maintenance of the air receiver on the receiver mounted machine

Picture: 25: Receiver mounted machine TD-range

1 Safety valve

3 Ball valve for condensate drain

(twin - receiver 2 Pcs.)

2

4

Pressure gauge

Oil receiver (behind the cover)

In the case of a receiver mounted unit with a compressor or a compressed-air refrigerated dryer built on the compressed air receiver, condensate accumulates in the compressed-air receiver operation, which must be removed regularly.

Compressed air receivers must comply with the legal requirements of the respective country. A pressure gauge, a safety valve and a condensate ball valve (for twin receivers two) are mounted at the base of the compressed-air receiver.


CAUTION

Environmental hazard

The condensate is oily. Dispose of the condensate according to the applicable environmental and disposal regulations

 Compressor is depressurized and cooled down. a.) Open the ball valve very slowly and collect the condensate in a suitable container.

8.3.5.2 Check for condensation

In the case of a receiver mounted unit with a compressor, a refrigerated dryer built on the compressed air receiver, condensate accumulates in the compressed-air receiver operation, which must be removed regularly.

CAUTION

Danger of injury due to improper work on pneumatic components

 Only qualified personnel can carry out maintenance work on the pneumatic components.

a.) Wear the necessary PPE (protective clothing, protective glasses, protective gloves)

NOTE

Condensation due to low operating temperature

To ensure that the air humidity is not condensed, the operating temperature must be sufficiently high during compression. Frequent turning on and off of the machine may cause the compressor to fail to reach the required operating temperature .


CAUTION

Damage caused by condensation in the circuit of the compressor oil a.) Condensate in the oil circuit can destroy the compressor unit.

Switch off the compressor immediately and secure it against reactivation.

b.) Close the ball valve to the compressed air network and secure it against re-opening.

c.) Contact the SCC sales and service partner immediately.

NOTE

Condensate at the bottom of the oil tank

The condensate is heavier than the compressor oil. Therefore, it accumulates on the bottom of the oil receiver, after a prolonged downtime .

Procedure for testing for condensation

The Compressor is depressurized and cooled down. a.) Close the ball valve to shut-off the valve on the pressure line and secure it against reopening. b.) Remove the protective covers / panels. c.) Place a collecting container under the discharge ball valve of the oil receiver d.) Open the ball valve of the oil receiver and carefully drain approximately 2 litres of compressor oil. e.) Close the ball valve of the oil receiver. f.) Check the discharged compressor oil for contamination with condensate. g.) If there is condensate in the compressor oil, carry out an oil change. h.) Re-fill the oil tank with oil or make an oil change if necessary. i.) Slowly open the ball valve at the oil receiver and make sure that the condensate coming out is safely received by the collecting container. j.) Close the ball valve on the coolant pressure tank. k.) Dispose of used waste oil according to applicable environmental and disposal regulations. l.) Mount all protective guards and panels.

Restore the operating condition of the compressor


8.3.6

Oil level and Oil change

NOTE

Use correct lubricants

Observe the notes in the section on Compressor oil and lubricant [ 93].

Oil level too high

If the oil level is too high:

 The machine is depressurized. a.) Turn off the compressor. b.) Connect an oil drain hose to the shut-off valve on the oil tank. c.) Carefully open the shut-off valve, as residual pressure can still be present in the oil tank and let the oil level go down to the required level. d.) Disassemble the oil drain hose. e.) Close the shut-off valve.

Picture: 26: Oil Change

1 Oil Receiver 2 Oil filler neck at receiver

3 Oil - Drain ball valve

The machine is depressurized a.) Connect the drain hose.

b.) Open the oil - drain ball valve to drain the waste oil into the collection container.

c.) Close the oil- drain ball valve.


d.) Open the plug of the oil filler neck.

e.) Fill the oil receiver with the specified compressor oil to the required level.

f.) Make sure that the sealing ring of the oil filler plug is not damaged.

g.) Close the plug of the oil filler neck and tighten it securely with the wrench.

h.) Carefully remove the remaining oil.

i.) Start the machine.

j.) Check the oil level after 30 minutes and refill oil if necessary.

k.) Ensure that there are no new oil leaks in the machine.

NOTE

Shortened interval for oil change

If the compressor is operated in a non-optimal atmosphere, the oil must be checked and the oil change and service interval must be shortened.

See also: Contact details for Tolpec GmbH and the SCC sales and service partner page 13

Operating and installation conditions page 32

8.3.7 Replacing worn parts

Replace worn parts such as belt drives, filters, etc. at the end of their service life.

For more information, contact Tolpec Customer Service.


Technical documentation / Annex list page 99


8.3

Compressor oil and lubricant

ATTENTION

Damage caused by non-suitable compressor oils

The use of non-approved compressor oils, as well as the mixing of different compressor oils, can damage the compressor. According to the valid accident prevention regulations, lubricating oils with characteristics corresponding to the intended operating conditions must be used.

NOTE

Reduced oil change intervals at higher compression temperatures

At constantly increasing compression temperatures above 90 ° C, the oil change intervals are reduced by 50%. An accurate analysis of the compressor oil according to the actual operating conditions can only be carried out by a compressor oil test in a laboratory

Screw compressor oil:

SCC compressors Oil recommendation: Shell Corena S2 R46 .

High performance screw compressor oil ISO

ISO Viscosity grade (ISO VG) ISO 3448 / DIN 51519

Kinematic Viscosity ASTM D445 at 40 ° C

Kinematic Viscosity ASTM D445 at 100 ° C

Flash point

Demulsifying capacity

Pourpoint

As also SCC compressors Oil recommendation: Shell Corena S4 R46 .


VG 46

46

46 mm² / s

6.9 mm² / s

230 ° C

15min

-33 ° C

Bearing grease for motor bearings

Mobil Polyrex EM or Total Multis

8.5 Wear and tear / spare parts

Spare parts must meet the technical requirements defined by Tolpec. Original spare parts are subject to strict conditions and must meet these requirements.

Tolpec assumes no liability for damage caused by using spare parts from other manufacturers.

Inquiries and orders for wear and tear / spare parts are to be addressed to Tolpec with the following information:

– Type,

– Item number

– Year of construction

– Part name

– Amount

– Shipping mode

Wear and tear / spare parts

For further information please contact the SCC sales and service partner.



8.6 Customer service through the manufacturer

Tolpec recommends a maintenance contract with the SCC sales and service partner.

In addition, Tolpec is interested in information and experience that arises from the use of our products so that improvements can be made if necessary. Please contact Tolpec or your SCC service partner if you have any issues or constructive feedback.

.

See also: Contact Tolpec GmbH and the SCC sales and service partner page 13


9 Repair

The following section describes how the machine is repaired.

NOTE

During the warranty period of the machine, repairs can only be carried out by the

SCC service partner.

Repairs by the operator

After the warranty period of the machine has expired, repairs can be carried out by the operator, with the appropriate specialist. Tolpec assumes no responsibility for these repairs. If you have any questions about repairs, contact your SCC sales – and service partner.

10 Decommissioning, storage and disposal

The following principles apply to the decommissioning, storage and disposal of the machine

This work may only be performed by specially trained and authorized specialists. a.) Switch off the machine before starting work and secure it against re-activation. b.) Hot components must cool down, before starting work. c.) Wear suitable personal protective clothing. d.) Secure the work area with a red and white chain against unauthorized persons entering. e.) Use suitable lifting aids and lifting devices for lifting.

Safety instructions for decommissioning, storage and disposal

DANGER




DANGER



WARNING


Some components of the compressor become hot during operation. a.) Before starting work, let the compressor cool down for 30 minutes.

b.) Wear protective glasses.

WARNING

Danger to life by a liquid jet emerging under high pressure

In the case of defective hoses, tubes or components, a liquid jet can escape under high pressure. The liquid jet can lead to serious injuries and death. a.) Never place objects in the way of the liquid jet. Keep persons out of danger. In case of accidental contact with the liquid jet, first-aid measures must be taken and seek medical advice immediately.

b.) Immediate emergency stop. If necessary, initiate further measures to reduce the pressure and stop the liquid jet.

c.) Take out and dispose of leaking liquids properly d.) Repair defective components immediately.


WARNING

Risk of injury from hot materials

Operating fluids can reach hot temperatures during operation. Skin contact with hot materials causes serious skin burns. a.) Always wear heat-resistant protective clothing and protective gloves when carrying out any work with fluids.

b.) Before any work with fluids, check that they are not hot. If necessary, wait until they have cooled down .

10.1 Temporary Decommissioning

When taking the unit out of service for an extended period, the machine should be carefully shut down according to the following methods, considering the season and humidity in the manufacturing plant/compressor house

CAUTION

Machine damage due to corrosion

Store the machine away from moisture and in a frost-free environment

Close the shut-off valve of the compressor in the customer's compressed air network. The protective cover / panels of the machine must be closed to prevent the penetration of dirt and moisture.

NOTE

Prevention of condensation during temporary standstill.

If the machine remains at its place of use during the downtime period, condensation can be prevented by operating the compressor approximately every 2 weeks for a period of 30 minutes.

Restart after Downtime


Proceed to restart the equipment after downtime as during first commissioning.

See also Final decommissioning page 98

First commissioning page 56

10.2 Final decommissioning

The procedure for the final decommissioning corresponds to the temporary shutdown.

Additionally: Drain the oil.

See also Disposal page 98

10.3 Dismantling

The machine has been taken out of service

The oil is drained. a.) The disassembly takes place in the same way as the installation, in reverse order.

Begin by disassembling the pipe system and then disassemble the individual components.

Installation of safety devices for safe transport

The machine has been taken out of service. a.) Attach the required safety devices to the machine before transport.

The machine is secured for transport.

10.4 Re-packing the machine

The machine is dismantled. a.) Pack the machine so that it is protected from moisture and dust.

The machine is re-packed.

10.5 Store the machine

Store the machine and its components according to the conditions in the technical data.

See also Specifications page 32

10.6 Disposal

The machine is essentially made of reusable materials. The machine does not pose a risk to the operator or the environment if handled properly. However, the machine is operated with materials which can be harmful to the environment and must therefore be properly disposed of according to the regulations (see safety data sheets in the appendix).

Provide individual components of the machine (motors, metal parts, etc.) to a qualified disposal and recycling company. Use a qualified specialist company for the disposal and recycling of the entire machine.


NOTE

Contact Tolpec for any advice regarding your disposal needs.

See also Maintenance schedule page 77


Contact Tolpec GmbH and the SCC sales and service partner on page 13

11 Technical documents / Annex list

The technical documents are divided into several folders. You can find the content table in every folder

.


11.1 Plan of maintenance and repair works

Operating hours Date Spare details


Name

List of Pictures

Picture 1: Front view of the compressor (example picture FOCUS-series) ............................ 15

Picture 2: Side view of the compressor (example picture FOCUS-series) ............................. 16

Picture 3: Example Picture: Back of the compressor / Belt driven (SMART-series) ................ 16

Picture 4: Safety relevant control elements and indicator elements of the compressor ......... 17

Picture 5: Safety valve .......................................................................................................... 18

Picture 6: Operating panel MAM - 890 .................................................................................. 19



Picture 9: Operating panel MAM - 6080 ................................................................................ 22

Picture 10: Areas of work and maintenance .......................................................................... 23

Picture 11: Name plate of the Equipment .............................................................................. 23

Picture 12: Compressor frame with panels ............................................................................ 27

Picture 13: Pressure sensor .................................................................................................. 28

Picture 14: Safety valve of the oil receiver ............................................................................ 28

Picture 15: Safety valve of the air receiver ............................................................................. 29

Picture 16: Oil temperature sensor ........................................................................................ 29

Picture 17: Emergency Stop Button ...................................................................................... 30

Picture 18: Transport with the forklift ..................................................................................... 48

Picture 19: Direction arrow on the air end ............................................................................. 54

Picture 20: Oil receiver .......................................................................................................... 57

Picture 21: Intake valve mounted on the air end ................................................................... 57

Picture 22: Direction arrow on the air end ............................................................................. 59

Picture 23: Areas of work and maintenance .......................................................................... 63

Picture 24: Locked electrical main switch .............................................................................. 76

Picture 25: Receiver mounted machine TD - series .............................................................. 88

Picture 26: Oil Change .......................................................................................................... 91

........................................................................................................................................................................................

List of Tables

Table 1: Warning signs .............................................................................................................. 9

Table 2: Mandatory signs ........................................................................................................ 10

Table 3: Change of history of this document ............................................................................ 12

Table 4: Table of applicable documents .................................................................................. 12


Table 5: Central contacts ........................................................................................................ 13

Table 6: Your SCC sale and service partner ........................................................................... 14

Table 7: Overview of the warning signs ................................................................................... 30

Table 8: Overview of the mandatory signs ............................................................................... 31

Table 9: Qualification of the staff ............................................................................................. 40

Table 10: Groups of operators ................................................................................................ 42

Table 11: Activities and knowledge ......................................................................................... 43

Table 12: Mandatory signs ...................................................................................................... 43

Table 13: Personal protective equipment ................................................................................ 48

Table 14: Troubleshooting table .............................................................................................. 67

Table 15: Daily maintenance plan ........................................................................................... 77

Table 16: Weekly maintenance plan ....................................................................................... 78

Table 17: Maintenance plan after 100 operation hours ........................................................... 78

Table 18: Maintenance plan after 500 operating hours ........................................................... 78

Table 19: Maintenance plan for every 2000 operating hours ................................................... 79



Table 22: Common recommendations for cleaning ................................................................. 82

Table 23: Tightening torque of the screws .............................................................................. 83

Table 24: Tightening torque of the screws .............................................................................. 83

Glossary

EMC Electromagnetic compatibility


Index

A

Additional symbols in the manual

Annex list

Applicable documents

Areas of work and maintenance

Avoiding dangerous situations

C

Change history

Check of Safety devices

Cleaning

Commissioning

Commission after troubleshooting

Commissioning and storage

Condensation check

Construction of the Equipment

Contact Tolpec GmbH

Contact SCC-Sales and Service

Controllers

Customer service

D

Daily commissioning

Decommissioning

Description of the product

Description of the product

Directional indication

Disposal

E

Electromagnetic combability

(EMC)

Emergency stop

Environment protection

F

Faults

Final decommissioning

First commissioning

11

Final check

99

12 G

23 General description

33 General safety Instructions

I

12 Intended use

55

Identification Equipment

82

Incorrect Use

53

Inspection visual

Installation

70 Install. and connection

61,98

Install. of electrical components

89

Install. of mechanical

15

components

13

13 L

15 Limitation of liability

94 List of Pictures

List of tables

60 M

95

Maintenance

15 Maintenance schedule

6 Maintenance belts

11

Maintenance filters

98

Maintenance list and repair list

Maintenance motor

Maintenance Receiver

Maintenance safety devices

35 Maintenance works

30 Mandatory signs

36

N

65

98

Notes for troubleshooting

Notes on electrical equipment


56

53

24

33

51

12

100

101

70

77

85

84

99

85

88

87

81

10

34

35

25

23

25

81

49

50

52

O

Oil

Oil change

Oil temperature sensor

On off sequences

Operating equipment

Operation and installation cond.

Operation instructions

S

93 Safety

91

Safety equipment Overview

29

Safety instructions

63

Safety instructions for faults

32 Safety valve

32 Secure machine against restart

34

Specialised knowledge

33

26

7,33,55

65

28

76

42

Operating mode

Operation of equipment

Operator determination

Operator groups

Operator training

P

Parameters

Personal protective equipment

Place of installation and infrastruct.

Procedure in case of accident

Protection/safety devices

Protective equipment’s

Q

Qualification

R

Re-packing

Requirements of an operator

Residual risk

Responsibility of the operator

Risk of injuries; minimization

64 Storage

32

Storage of the Manual

38

Switch off

42 Switch on

38 Symbols and signs on unit

43

U

65 Unacceptable operation cond.

Unpacking of package

49

Use of machine

44

26

Used Symbols and definitions

39,43

W

Warning signs

40 Warranty and liabilities

Working area

98

40

44

37

37

61,95,98

7

64

63

30

36

49

25

7

9,3

12

63


Original operating manual - SCC Compressors

Original operating manual - SCC Compressors

Imprint

1. Description of the product

1.1. Operating instructions

Copyright protection

1.2. Storage of the Manual / keep it accessible

1.3. Used symbols and definitions

1.3.1. Safety instructions

WARNING

CAUTION

Example:

1.3.2. Warning signs

1.3.3 Mandatory signs

1.3.4

Additional symbols in the manual

1.3.5 Directional indications

1.4 Change history

1.5. Applicable documents

1.6. Warranty and liabilities

Limitation of liability

1.7 Contact information of Tolpec GmbH and the SCC Sales- and

Service partner

Address:

SCC Sales- and Service partner

2 Description of the product

2.1 Construction of the Equipment/Controllers

All compressors consist essentially of :

Safety-relevant operating components

Operating panel MAM – 890

Operating panel MAM – 860

Operating panel MAM – 200

Operating panel MAM 6080

2.1.1. Areas of work and maintenance

2.2. Identification of the Equipment

Data on the name plate of the Equipment

2.3. General descriptions

Operation mode

Compressed Air is produced by drawing air in from the environment

2.4. Use of the machine

2.4.1. Intended use

2.4.2. Incorrect use

2.5. Safety equipment

2.5.1. Overview

2.5.2. Protection/Safety devices

Removal of safety equipment:

Motor frame with protection covers

Non - Contact safety devices

Pressure sensor at the minimum pressure and non-return valve or at the multi-block

Safety valve on the oil receiver

Safety valve on the air receiver of the Equipment

Oil temperature sensor on the discharge/outlet of the air end

2.5.3. Emergency stop system

2.5.4. Symbols and Signs on the Machine

Warning signs

Mandatory signs

2.6. Operating the Equipment

2.7 Operating and installation conditions

General data

3. Safety

3.1 General safety instructions

3.1.1 Avoiding of dangerous situations

3.1.2 Operation Instructions

3.1.3 Notes for trouble shooting and repairing

3.1.4 Notes on electrical equipment

3.1.5 Electromagnetic compatibility (EMC)

3.1.6 Information on environmental protection

3.2 Unacceptable operating conditions

3.3 Responsibility of the operator

3.3.1 Minimize the risk of injury

3.3.2 Determine the Operator

3.3.3 Operator training

3.3.4 Protective equipment

3.4. Requirements of an operator

3.4.1. Qualification

3.4.2. Operator Groups

3.4.3 Specialised knowledge

3.5. Personal protective equipment

Description of personal protective equipment

3.6. Residual risk