Oil-free compressor stations
EN
0678106020L02

1708V004
Installation and Operating Instructions
Contents
Important information
Installation
1
About this document 3
11 Warnings and symbols 3
12 Copyright information 3
8
2
Safety 4
21 Intended use 4
22 Improper use 4
23 General safety information 4
24 Qualified personnel 4
25 Protection from electric shock 4
26 Only use genuine parts 4
27 Transportation and storage 4
28 Disposal 5
Requirements 21
81 Installation/setup room 21
82 Vibration damping between compressor unit and vessel 21
83 Installation position and fastening 21
84 Silencer 22
85 Start-up cycles 22
9
Commissioning and first start-up 22
91 Remove the transport locks 22
92 Establishing the compressed air
connection 22
93 Condensate 23
94 Electrical installation 23
95 Check of the pressure switch 23
96 Checking the safety valve 24
Product description
3
Overview 6
31 Flexible modular system 6
32 Examples of compressor stations
11
33 Accessories 14
34 Wear parts and spare parts 14
4
Technical data 15
5
Pressure tank 16
51 Overview 16
52 Instructions for use for the pressure vessel (explanation by Behälter-Werk Burgau GmbH) 17
6
Declaration of conformity for machines in accordance with the
2006/42/EC Directive 18
7
Operation 19
71 Compressor station without
membrane-drying unit 19
72 Compressor station with membrane-drying unit 19
10 Adjustment options 24
101 Adjusting the pressure switch 24
102 Adjusting the motor protection
switch 26
103 Setting the pressure reducer 26
104 Adjusting the condensate solenoid valve 27
Operation
11 Operation 28
111 Switching the unit on/off 28
112 Switching the unit on after a power cut 28
113 Pressure vessel test 28
114 Mobile compressor station 28
12 Maintenance 29
121 Maintenance schedule 29
122 Draining the condensation water 30
123 Replacing the air intake filter 30
124 Replacing the filter of the membrane drying unit 30
13 Taking out of use 31
131 Taking the unit out of use 31
132 Storage of the unit 32
0678106020L02 1708V004
1
EN
Contents
Troubleshooting
14 Tips for operators and service technicians 33
EN
Addresses
2
0678106020L02 1708V004
Important information
1
About this document
These installation and operating instructions
represent a part of the unit They correspond to
the relevant version of the unit and the status of
technology valid at the time of its market launch
In the event that the instructions and
notes in these installation and operating
instructions for are not observed, Dürr
Technik accepts no warranty or liability of
any kind for the safe operation and reliable function of the units
This translation was prepared to the best of our
knowledge The original German language version of the manual is the definitive version Dürr
Technik is not liable for translation errors
1.1 Warnings and symbols
Warnings
The warnings in this document are intended to
draw your attention to possible injury to persons
or damage to machinery
The following warning symbols are used:
The signal word differentiates between four
levels of danger:
– DANGER
Immediate danger of severe injury or death
– WARNING
Possible danger of severe injury or death
– CAUTION
Risk of minor injuries
– NOTICE
Risk of extensive material/property damage
Other symbols
These symbols are used in the document and
on or in the unit:
Note, eg specific instructions regarding
efficient and cost-effective use of the unit
CE labelling
De-energize the unit prior to working on it
or in the event of potential danger (e g
pull the mains plug) and prevent it from
being switched back on again
General warning symbol
Comply with the specification in the accompanying documents
Warning – dangerous high voltage
Dispose of the unit properly and in accordance with applicable national, regional and local laws
Warning - automatic start-up of the unit
The warnings are structured as follows:
SIGNAL WORD
Description of the type and source of
danger
Here you will find the possible consequences of ignoring the warning
i Follow these measures to avoid the
danger
0678106020L02 1708V004
EN
Dispose of the packaging material in an
environmentally responsible manner
1.2 Copyright information
All names of circuits, processes, names, software programs and units used in this document
are protected by copyright
The reprinting of the installation and operating
instructions, even in extracts, is only permitted
with the written permission of Dürr Technik
3
Important information
2
Safety
Dürr Technik has developed and constructed
the units in such a way that danger is to a large
extent excluded if the units are used as intended Nevertheless, residual risks can remain You
should therefore observe the following notes
EN
2.1 Intended use
The unit is intended for the compression of atmospheric air The unit has been designed for
operation in dry, ventilated rooms The unit must
not be operated in a damp or wet environment
Its use in the vicinity of gases or flammable liquids is prohibited Only operate the mobile units
in an upright position
2.2 Improper use
Any other usage or usage beyond this scope is
deemed to be improper The manufacturer accepts no liability for damages resulting from this
In these cases the user/operator will bear the
sole risk
WARNING
Serious injury and material damage
due to improper usage
i Conveying explosive mixtures in any
way other than that specified is not
permitted
i Instruct or have every user instructed in handling the unit
Installation and repairs
i Always arrange for any assembly work, readjustments, alterations, extensions, and repairs
to be performed by Dürr Technik or by personnel authorised and trained by Dürr Technik Qualified personnel are defined as those
trained by Dürr Technik; who are familiar with
the unit technology; and are aware of the dangers presented by the unit
2.5 Protection from electric shock
i When working on the units observe all the relevant electrical safety regulations
i Immediately replace any damaged cables or
plugs
2.6 Only use genuine parts
i Only use accessories specified or approved
by Dürr Technik
i Only use original working and spare parts
Dürr Technik accepts no liability for damage resulting from the use of non-approved accessories or any non-original
working or spare parts
2.7 Transportation and storage
2.3 General safety information
i When operating this device always observe all
guidelines, laws, and other rules and regulations that are applicable at the site of operation
i Prior to each use, check condition of the device and make sure it is in perfect working order
i Do not convert or modify the units
i Observe the Installation and Operating Instructions
i Make the Installation and Operating Instructions available to the person operating the device at all times
The original packaging provides optimum protection for the unit during transport
Dürr Technik will not accept any responsibility or liability for damage occurring
during transport due to the use of incorrect packaging, even where the unit is
still under guarantee
– Only transport the unit in its original packaging
– Keep the packing materials out of the reach
of children
2.4 Qualified personnel
Operation
Persons who operate the units must ensure safe
and correct handling based on their training and
knowledge
4
0678106020L02 1708V004
Important information
WARNING
Risk of explosion of the pressure
vessel and pressure hoses
i The pressure vessel and the pressure
hoses must be vented before they are
stored or transported
i Protect the unit from moisture during
transportation
i Always transport the unit in an upright
position
i Only transport the unit using the
transport handles provided
i Do not transport the unit by the air intake filter
EN
The unit may be stored in its original packaging
– in warm, dry and dust-free rooms;
– protected from contaminants
If possible, retain the packaging material
Ambient conditions during storage and
transport
Ambient conditions during storage and
transport
Temperature
°C
-25 to +55
Rel humidity
%
10 % to 90 %
Please refer to the labels on the packaging padding
2.8 Disposal
Unit
Dispose of the unit properly and in accordance with applicable national, regional and local laws
Packaging
Dispose of the packaging material in an
environmentally responsible manner
– Note current disposal routes
– Keep the packing materials out of the reach
of children
0678106020L02 1708V004
5
Product description
3
Overview
3.1 Flexible modular system
EN
The compressor stations can be assembled individually from various components according to requirements
The following components are available:
– Oil-free compressor units with outputs from 25 l/min to 600 l/min Fitted with single-phase AC motors or 3-phase AC motors or special designs with DC permanent-magnet motors
– Different pressure vessels with a capacity of 3 l, 10 l, 25 l, 55 l or 90 l
– Different designs of fittings with the necessary safety valve, pressure gauge and power cord as well
as automatic condensate drainage (optional) or starting relief via a solenoid valve (optional)
– A wide range of accessories such as air intake filters, quick-release couplings, pressure hoses
(optional), pressure reducers (optional) etc
– Membrane-drying unit (optional) as a separate component
6
0678106020L02 1708V004
Product description
Explanation of the product code
2
1
3
EN
T A-200 M
1 Vessel
U
3l
W
10 l
T
25 l
H
55 l
P
90 l
* Vessel with a maximum pressure (PS) of 10 bar (exception: compressor stations with 25-l vessel:
PS = 8 bar)
2 Compressor units
A
Compressor units with single-phase AC motors
B
Compressor units with 3-phase AC motors
M
Compressor units with DC permanent-magnet motors
3 Auxiliary modules
K
Automatic condensate drainage system
AK
Automatic condensate drainage system + starting relief
L
Membrane-drying unit (also performs the function of the AK
module)
The compressor station TA-200M used as an example comprises:
– 25-l vessel (T)
– Compressor unit: A-200 (with single-phase AC motor)
– Membrane-drying unit (M)
0678106020L02 1708V004
7
Product description
Combination options for a compressor station with single-phase AC motor
Series
Unit
KK8
A-025
KK15
KK40
KK70
Marathon
25
3l
l
l
10 l
25 l
55 l
l
l
l
l
l

l
l

l
l

l
l

l
l

l
l
l

l
l

l
l

l
l
A-062
70
A-065
65

l
A-132
130

l
A-100
105


l
A-200
195


l
l

l
38
60

90 l
l
A-038
A-061
l
l
l
l
o
l
l
o
l
l
l
l
l
l
l
l
l
A-080
90


l
l
l
l
l
A-160
160


l
l
l
l
l
l
A-234
230


l
l
l
l
l
l
Standard combination
o
Already included in unit

Not standard
8
Output at 0 bar (l/min)
EN
Module M = module AK + membranedrying unit
Auxiliary modules
Module AK = module K + automatic
starting relief
Vessels
Module K = automatic condensate
drainage system
Compressor units


0678106020L02 1708V004
Product description
Combination options for a compressor station with 3-phase AC motor
38
10 l
25 l
55 l
90 l
l
l
l
l
l
KK15
B-038
B-062
73
l
l
l
l

KK40
B-065
65

l
l
l

Module M = module AK + membranedrying unit
3l
Module AK = module K + automatic
starting relief
Unit
Auxiliary modules
Module K = automatic condensate
drainage system
Series
Vessels
Output at 0 bar (l/min)
Compressor unit
l
l

l
l

l
o
l
BG-132
130

l
l
l
l
l
o
l
KK70
B-100
105


l
l
l
l
l
l
B-200
195


l
l
l
l
l
l
Marathon
B-080
90


l
l

l
l
l
B-160
160


l
l
l
l
l
l
B-304
295



l
l
l
l
l
2x B-304
590




l


l
l
Standard combination
o
Already included in unit

Not standard
0678106020L02 1708V004
EN
9
Product description
Combination options for a compressor station with a DC permanent-magnet motor
EN
Output at 0 bar (l/min)
Compressor unit*
Vessels
Notes on the compressor station
in l
Version
10
12 VDC
Series
Unit
Item number
KK15
D-040
0832-25B-01
40
KK8
D-030
0590 1000
30
3
24 VDC
KK15
D-040
0832-22B-01
40
10
24 V DC
including interference
suppression filter
D-040
0832-22B-02
40
10
24 V DC
including interference
suppression filter
with automatic condensate drain
D-040
0832-22B-03
40
10
24 V DC
including interference
suppression filter
with automatic condensate drain and automatic starting relief
D-040
ZK429T7091298
40
25
24 VDC
D-100
0652 0000
105
10
24 VDC
KK70
* Other versions of the compressor unit are available on request
10
0678106020L02 1708V004
Product description
3.2 Examples of compressor stations
The item numbers designate the spare parts (see "34 Wear parts and spare parts")
12
8
EN
1
7
3
9
13
10
11
2
Figure 1: TA-200M combination: A-200 compressor unit with 25 l vessel (T) and auxiliary module
M (membrane-drying unit)
Figure 2: UA-025 combination: A-025 compressor unit with 3 l vessel (U)
0678106020L02 1708V004
11
Product description
EN
Figure 3: WA-062AK configuration: A-062 compressor unit with 10-l receiver (W) and auxiliary
module AK (automatic condensate drainage system + automatic starting relief)
Figure 4: TA-100K combination: A-100 compressor unit with 25 l vessel (T) and auxiliary module K
(automatic condensate drainage system)
12
0678106020L02 1708V004
Product description
EN
8
20
3
12
9
1
11
4
10
5
2
22
21
Figure 5: WA-062 mobile AK configuration: A-062 compressor unit with 10-l vessel (W), auxiliary
module AK (automatic condensate drainage system + automatic starting relief) and transport rollers
Figure 6: HA-160M combination: A-160 compressor unit with 55 l vessel (H) and auxiliary module
M (membrane-drying unit) and pressure reducer
0678106020L02 1708V004
13
Product description
3.3 Accessories
Item no.
Spare parts for the compressor
station
14
15
16
Relief valve
Air evacuation hose
Surge tank
(art no 9000-330-09)
Quick-release coupling
(art no 9000-312-03)
Seal
Complete control gear
Relay (DC current only)
Power cord
Complete interference suppression filter (DC current only)
Carbon brushes (DC current only)
Sealing cap/screw plug (DC current only)
Accessories for compressor stations
When ordering accessories, always
quote the type designation (eg WA038/0643 1000) and the serial number
EN
Item no.
20 to 22
Spare parts / accessories
Pressure reducer
Quick-release coupling
(art no 9000-312-03)
Hose adapter pieces for SW 10
(art no 9000-312-06)
Hose adapter pieces for SW 6
(art no 9000-311-46)
Operating time counter
Clip*
(art no 0835-999-00)
Transport roller, complete
(art no 0643 0100)1)
*Clip for WA-025 to WA-062
1)
available as optional accessory for WA-038
mobile AK, WA-061 mobile AK, WA-062 mobile
AK, WA-065 mobile AK, WAG-132 mobile K
3.4 Wear parts and spare parts
Spare parts for compressor station with
membrane-drying unit
When ordering spare parts, always quote
the type designation (eg WA-038/083543B-01) and the serial number
Item no.
Spare parts for the compressor
station
1
2
3
4
Compressor
Vessel without stopper
Pressure switch
Start-up solenoid valve (not shown
in pictures)
Condensate solenoid valve
Pressure hose
Air intake filter, complete
Air intake filter cartridge
Pressure gauge
Safety Valve
Vibration damper
Condenser
Manual condensate drain (not
shown in all pictures)
5
7
8
9
10
11
12
13
14
Spare parts for membrane-drying unit
When ordering spare parts, always quote
the type designation (eg WA-038/083543B-01) and the serial number
Article no.
Spare parts for the
membrane drying station
1650-981-0000
1650-101-00
1610-121-00
9000-416-0035ET
Purge air nozzle set
Sintered filter
Fine filter cartridge 3 µm
Fine filter cartridge
001 µm
0678106020L02 1708V004
Product description
4
Technical data
For detailed information on the technical
data of the compressor units, refer to the
assembly and operating instructions "Oilfree piston compressors KK and piston
vacuum pumps KV"
EN
0678106020L02 1708V004
15
Product description
5
Pressure tank
5.1 Overview
Pressure vessels from Behälter-Werk Burgau GmbH are installed in the units
The instructions for use given below apply to the following types of pressure vessel:
EN
Type
Pressure1)
Vessel2)
APP3)
c4)
Remark5)
2
316033 / 0834-000-010
PS 8 bar
V3l
A
c = 10 mm
316053 / 0654-0900
PS 8 bar
V3l
A
c = 10 mm
2
316030 / 0833-320-60
PS 11 bar
V 10 l
A
c = 10 mm
4; 5
316034 / 5430-200-51
PS 10 bar
V 25 l
B
c = 0 mm
1; 6
316016 / 4220-200-50
PS 10 bar
V 55 l
A
c = 10 mm
3; 5
235791 /5450-200-90
PS 11 bar
V 90 l
A
c = 10 mm
4
For serial number and build year refer to the labelling on the vessel
1)
Pressure
Vessel
3)
Application (APP)
2)
4)
Maximum operating pressure PS in bar
Vessel volume V in litres
A = Pressure vessel for compressors
B = Pressure vessel for stationary systems
c in mm
+100 °C
Corrosion allowance
Maximum temperature
Minimum temperature -10 °C
Medium
Air/nitrogen
5)
Remark
1: The vessel is capable of sustained operation within a pressure fluctuation range of
16 bar (10% PS)
2: The vessel is capable of sustained operation within a pressure fluctuation range of
16 bar (20% PS)
3: The vessel is capable of sustained operation within a pressure fluctuation range of
20 bar (20% PS)
4: The vessel is capable of sustained operation within a pressure fluctuation range of
22 bar (20% PS)
5: The wall thicknesses must not be less than 2 mm
6: The condensate must be drained at internal pressure in accordance
with the operating instructions
Applied standards
EN 286-1:1998
16
0678106020L02 1708V004
Product description
5.2 Instructions for use for the
pressure vessel (explanation by
Behälter-Werk Burgau GmbH)
The pressure vessel must only be used in accordance with the aforementioned intended purpose and in accordance with the specified technical data Other forms of use are not permitted
for reasons of safety The pressure vessel has
been designed in accordance with Directive
2014/29/EU and has been manufactured as a
single component without safety equipment for
the application area detailed above The unit has
been designed for internal pressure loads
The supplier must also specify whether the
pressure vessel, when fully equipped for operation, has to undergo an acceptance test before
commissioning The supplier/owner must observe the laws and regulations regarding the operation of the pressure vessel that apply in the
country of operation
The design is intended for predominantly static
internal pressure loads and covers the following
operating parameters:1000 load changes from
0 to PS and capable of sustained operation
within a pressure fluctuation range of 16 bar to
22 bar
Refer to the "51 Overview"Remarks
Before commissioning, the vessel must be fitted
with the necessary safety equipment such as a
pressure gauge and safety equipment designed
to protect against overpressure, etc These
parts are not included in our scope of delivery
No welding work or heat treatment may be carried out on the pressure-retaining walls of the
vessel It must be ensured that the internal pressure does not exceed the operating pressure PS
specified in the labelling on the vessel during
operation However, this pressure may be temporarily exceeded by up to 10% Vibration
stress that would be damaging for the pressure
vessel and corrosion on the vessel must be prevented using appropriate measures
The assembly or installation of the pressure
vessel must be carried out in such a way that
safe use of the vessel is ensured (eg no rigid
connection to the floor or machine base frame
without vibration dampers)
The operating instructions to be provided by the
equipment supplier must include the following
information in accordance with the equipment
fitted:
– a) Instructions for draining the condensate
– b) Instructions and information about maintenance to ensure safety of use
0678106020L02 1708V004
17
EN
Product description
6
EN
Declaration of conformity for machines in accordance with
the 2006/42/EC Directive
We hereby declare that the unit described below conforms to all requirements of the machine directive 2006/42/EC
The unit named below fulfills the requirements of the following directives:
– Electromagnetic Compatibility (EMC) Directive 2014/30/EU
– Simple pressure vessel directive 2014/29/EU
– RoHS directive 2011/65/EU
Manufacturer's name:
Dürr Technik GmbH & Co KG
Manufacturer's address:
Pleidelsheimer Straße 30
D-74321 Bietigheim-Bissingen
Reference number:
UA-025K, WA-038…, TA-100, HB-200…, XB-304…, ZK…,
AATA-100…, BBTAG-132…, CCHA-234…, DDHB-304…, SAS…
Article designation:
Compressor stations / dryer stations
From the serial number:
H400000
We hereby declare that the unit may only be commissioned once it has been established that the machine into which this unit is to be installed complies with the provisions as set out in Machinery Directive 2006/42/EC
The following harmonised standards and other standards have been applied:
DIN EN 1012-1:2011-02
DIN EN 60034-1:2011-02
DIN EN 60034-5:2007-09
DIN EN 60034-7:2001-12
DIN EN 60034-8:2014-10
DIN EN 60335-1:2014-11
DIN EN 61000-6-2:2011-06
DIN EN 61000-6-3:2012-11
DIN EN 60204-1:2010-05
DIN EN ISO 12100:2013-08
Bietigheim-Bissingen, 20/04/2016
Andreas Ripsam
Proof of signature in the
Executive Board of Dürr Technik
Original document held by Dürr Technik
18
0678106020L02 1708V004
Product description
7
Operation
7.1 Compressor station without
membrane-drying unit
7.2 Compressor station with membrane-drying unit
EN
1
2
3
4
5
6
7
8
9
10
11
12
Compressor unit
Pressure vessel
Pressure switch
Start-up solenoid valve*
Condensate solenoid valve*
Operating time counter*
Pressure hose
Air intake filter
Pressure gauge
Safety Valve
Vibration damper
Condenser*
1
2
3
4
5
6
7
8
9
10
11
12
Compressor unit
Pressure vessel
Pressure switch
Cooler
Membrane dryer
Pressure hose
Air intake filter (quick-release coupling)
Pressure gauge
Safety Valve
Vibration damper
Condenser*
*If included in the scope of delivery
*If included in the scope of delivery
Air is drawn in from the surrounding atmosphere
through the air intake filter This air is compressed by the piston in the cylinder The inlet or
outlet valve blocks off one of the directions of
flow The compressed air is guided through the
pressure hose via the integrated non-return
valve into the pressure vessel
The compressor unit supplies compressed air
until the set cut-off pressure is reached The unit
switches off The pressure is indicated by the
pressure gauge The pressure hose is made
pressureless by the integrated relief valve (on
stations with a starting solenoid valve possibly
not until the unit is started)If compressed air is
removed for a consumer, the pressure in the
vessel drops When the switch-on pressure is
reached, the compressor is switched on automatically again via the pressure switch A safety
valve prevents the maximum permissible vessel
pressure from being exceeded
0678106020L02 1708V004
Air is drawn in from the surrounding atmosphere
through the air intake filter This air is compressed by the piston in the cylinder The inlet or
outlet valve blocks off one of the directions of
flow The hot and moist compressed air that
comes from the compressor flows into the cooler In the cooler, the compressed air is cooled
down Water condenses 100% saturated compressed air and condensate leave the cooler
and flow into the water separator
The condensate that is contained is separated
via the sinter filter and accumulates in the water
collecting container The automatic condensate
solenoid valve discharges the water at cyclic intervals
The air then flows to the membrane element
The air flows through the membrane fibres The
water molecules contained in the air diffuse
through the membrane wall and accumulate on
the outside of the fibre The dried air flows
through the fine filter, the pressure relief valve
and the non-return valve to the vessel
19
Product description
For regeneration, a small partial flow of dried air
flows in the membrane via the purge air nozzle
to the outside of the membrane fibre This absorbs the collected moisture and dissipates it to
the environment This regeneration takes place
continuously during operation Standstill periods
are not required
EN
The pressure relief valve in the upper part of the
membrane ensures that the membrane-drying
unit reaches its rated operating pressure within
the shortest time possible A moisture indicator
installed in the upper part of the membrane is
visible through the transparent upper part If the
air is not dried sufficiently, the colour changes
from blue to pink
1
4
2
3
6
5
1
2
3
4
5
6
Hot air
Cooler with ventilating fan
Cold air
Membrane dryer
Condensate drain
Dry air
The compressor unit supplies compressed air
until the set cut-off pressure is reached The unit
switches off The pressure is indicated by the
pressure gauge The pressure hose is made
pressureless by the relief valveIf compressed air
is removed for a consumer, the pressure in the
vessel drops
When the switch-on pressure is reached, the
compressor is switched on automatically again
via the pressure switch A safety valve prevents
the maximum permissible vessel pressure from
being exceeded
20
0678106020L02 1708V004
Installation
8
Requirements
8.1 Installation/setup room
The room chosen for set up must fulfil the following requirements:
NOTICE
Risk of overheating due to insufficient ventilation
The units generates heat Possibility of
heat damage and/or reduced service life
of the unit
i Do not cover the unit
i Air must be able to flow in and out unobstructed
i Ventilation openings must be sufficiently large
i Installed units may require an independent ventilation system in unfavourable cases
30
– Dry, well ventilated room
– Should not be a purpose-made room (e g
boiler room or wet room)
– Set up the unit on a clean, level and sufficiently stable surface (take the weight of the
unit into account)
– The socket-outlet must be easily accessible
– The type plate of the unit must be easily readable (also after installation)
– The unit must be easily accessible for operation and maintenance
– Once the unit has been installed, the connecting terminals must be easily accessible when
removing/opening housing access
– Maintain sufficient distance from the wall (min
30 mm to 40 mm)
The air is filtered when it is sucked in
This does not alter the composition of
the air The source of the air taken in
should be free of any harmful substances
(eg do not draw in air from an underground garage or directly next to a suction machine)
30
8.2 Vibration damping between
compressor unit and vessel
30
The unit generates vibrations Suitable vibration
dampers must be used to damp these vibrations
CAUTION
The use of rigid connections may
damage the units or the system in
which the units have been installed.
i Do not install rigid connection lines
between unit and system
30
8.3 Installation position and fastening
40
0678106020L02 1708V004
40
Install the units as near as possible to the horizontal Other fitting positions must be agreed in
advance with Dürr Technik
21
EN
Installation
8.4 Silencer
EN
In vacuum operation, the noise levels are raised
at the venting port For this reason, a suitable
noise reducer should be used that discharges
the aspirated air into the atmosphere Noise reducers are available as accessories (see "Accessories for piston vacuum pumps KV" for the
relevant series)
For detailed information on the accessories and spare parts sets for the compressor units, refer to the assembly and
operating instructions "Oil-free piston
compressors KK and piston vacuum
pumps KV"
8.5 Start-up cycles
The motors in the compressor stations are designed for 10 starts/stops per hour More frequent switching will lead to increased wear
9
Commissioning and first
start-up
9.1 Remove the transport locks
The unit is securely protected with packaging
material to ensure safe transportation
i Remove the packaging material
i Remove the protective film
i Check the unit for damage in transit
9.2 Establishing the compressed
air connection
The devices are designed as standard for
a nominal pressure of 7 bar Exceeding
the nominal pressure on a regular basis
will reduce the service life of the device
The unit is equipped as standard with a control
gear, which consists of a pressure switch, pressure gauge, safety valve, non-return valve and
condensate drain
In order to avoid the transfer of vibrations, we
recommend installing a flexible pressure hose
between the pressure hose and the pressure
switch A pressure reducer can also be connected
i The compressed-air supply is connected to
the quick-release coupling (incl hose adapter
piece) or to the pressure switch by means of a
G 1/4" internal thread
i Secure the pressure hose to the hose adapter
piece using a hose clip
i Connect the hose adapter piece to the quickrelease coupling
22
0678106020L02 1708V004
Installation
9.3 Condensate
9.5 Check of the pressure switch
During operation, condensed water is continuously separated off in the compressor station
The cut-off pressure is generally set to 7 bar
(07 MPa)
i Switch on the device at the pressure switch
by rotating the switch to the "I" position
i Read off the cut-off pressure from the pressure gauge
The condensate can be drained through
a hose into the waste water system
i Fasten the condensate drain hose to the unit
and secure it so that it cannot slip out
i Secure the condensate drain hose by guiding
it or fastening it to the drain
9.4 Electrical installation
EN
If the value read from the pressure gauge differs
from the factory setting, the pressure switch can
be adjusted (see "101 Adjusting the pressure
switch")
For detailed information on electrical installations refer to the assembly and operating instructions "Oil-free piston compressors KK and piston vacuum pumps
KV"
Electrical connection using a mains plug
i The unit may only be connected to a correctly
installed socket outlet
i Make sure that none of the electrical cables
leading to the unit are under any mechanical
tension
i The socket-outlet must be easily accessible
i Before commissioning, verify that the power
supply voltage complies with the voltage
specifications of the model identification plate
DANGER
Risk of electric shock due to defective power cord
i The power cord must not be allowed
to come into contact with any hot surfaces on the unit
i Route power cords without mechanical tension
i Connect the mains plug to an earthed
socket outlet
i The unit will start immediately after
connection of the mains plug
Electrical connection without a mains plug
DANGER
Connection to the power supply may
only be performed by a qualified
electrician.
0678106020L02 1708V004
23
Installation
9.6 Checking the safety valve
10 Adjustment options
The safety valve must be checked to establish
that it is working correctly when the unit is started up for the first time
10.1 Adjusting the pressure switch
At the factory, the safety valve is set to
10 bar (1 MPa) or 8 bar (08 MPa) (depending on the maximum pressure), inspected and stamped (see also "51
Overview")
EN
DANGER
Explosion of the pressure vessel and
pressure hoses
i Do not change the safety valve settings
WARNING
Risk of damage to the safety valve
Risk of explosion of the pressure vessel
and pressure hoses due to a defective
safety valve
i Do not use the safety valve to vent the
pressure vessel
i Switch on the unit at the pressure switch and
fill the pressure vessel to the cut-off pressure
i Rotate the cap of the safety valve a few turns
anti-clockwise until the valve begins to blow
off Only allow the safety valve to blow for a
short period
i Turn the cap clockwise as far as it will go
DANGER
Exposed live parts
Risk of electric shock due to live parts
i Unplug the unit from the socket-outlet
i Use insulated tools
i Do not touch live parts
The cut-off pressure must be at least 05
bar (005 MPa) below the maximum pressure of 10 bar (1 MPa) or 8 bar (08
MPa) (depending on the maximum pressure) of the safety valve Otherwise the
safety valve can open too early, which
will prevent the compressor unit from attaining the cut-off pressure, and as a result it will run continuously The maximum
pressure is marked by a red line on the
attached pressure gauge
The adjustment of the pressure switch
must be performed under pressure
The code for the pressure switch (MDR3
or MDR2) can be found on the pressure
switch cover
Adjustment of the MDR3
If the read-off values differ from the factory settings or if other settings are required, the cut-off
pressure of the compressor can be adjusted at
the setting screw on the pressure switch The
switch-on pressure can then be adjusted using
the pressure differential Δp
i Take off the pressure switch cover
The valve is closed
24
0678106020L02 1708V004
Installation
i Adjust the cut-off pressure p using the setting
screw
The cut-off pressure increases in the "+" arrow direction and decreases in the "-" arrow
direction The pressure differential ∆p is also
influenced by this adjustment
Adjustment of the MDR2
If the read-off values differ from the factory settings or if other settings are required, the cut-off
pressure of the compressor can be adjusted at
the setting screw on the pressure switch The
switch-on pressure can then be adjusted using
the pressure differential Δp
i Undo the fixing screws in the pressure switch
cover
i Take off the pressure switch cover
i Adjust the cut-off pressure p using the two
setting screws (1)
The cut-off pressure increases in the "+" arrow direction and decreases in the "-" arrow
direction
1
1
2
i Use the setting screw to readjust the pressure
differential ∆p between the switch-on pressure
and the cut-off pressure
The pressure differential increases in the "+"
arrow direction and decreases in the "-" arrow
direction
i The pressure differential ∆p between the
switch-on pressure and the cut-off pressure is
set using the setting screw (2)
Turning the screw in the arrow direction "+"
increases the pressure differential (lower
switch-on pressure), while turning it in the
arrow direction "-" decreases the pressure
differential (higher switch-on pressure)
0678106020L02 1708V004
25
EN
Installation
10.2 Adjusting the motor protection
switch
Not all units have a motor protection
switch
EN
i The motor protection switch is adjusted and
marked at the factory
i Take off the pressure switch cover
i Adjust the motor protection switch with the
setting screw according to the motor current
(note the range between min permissible setting and max permissible setting of the motor
protection switch)
The max permissible motor current is the
current rating on the type plate + 10%
10.3 Setting the pressure reducer
The pressure reducer (optionally available) regulates the vessel pressure (primary pressure) to
the required operating pressure (secondary
pressure) An increase of pressure when the
consumer is switched off is prevented by an additional secondary vent The pressure reducer is
mounted on the pressure switch (G1/4")
Adjusting the pressure reducer:
i Pull up the adjuster knob (1)
i To increase the supply pressure: Turn the
adjuster knob (1) clockwise towards "+"
i To decrease the supply pressure: Turn the
adjuster knob (1) anti-clockwise towards "-"
i Once you have reached the required supply
pressure (this can be read from the pressure
gauge (2)), push the adjuster knob (1) down
until it clicks into place
i Check the supply pressure on the pressure
gauge (2)
1
2
26
Adjuster knob
Pressure gauge
0678106020L02 1708V004
Installation
10.4 Adjusting the condensate solenoid valve
The condensate solenoid valve (optionally available) controls the draining of condensate from
the vessel
Adjustment of the switching times on the
condensate solenoid valve with timer 9000303-0010 (670-000-104) and 9000-303-0013
(601-001-347)
Condensate
solenoid
valve
Switching
time
Ton (valve
switched on)
Switching
time
Toff (valve
switched off)
9000-3030010
01 s min
to
10 s max
36 s min
to
60 min max
9000-3030013
1 s min
to
5 s max
18 s min
to
30 min max
i Adjusting the switching times
i Position the pointer of the push-on adjuster
cap (4) above the notch (3) of the adjuster
knob
i Insert the tongue of the push-on adjuster cap
(1) in the slot of the adjuster knob (2)
i Turn the red push-on adjuster cap between
the min and max positions on the adjuster
knob to select the required switching time for
Ton and Toff
i The position of the pointer (4) on the line scale
shows the selected switching time
i The values on the line scale correspond to the
following percentage values for the switching
times of Ton and T off:
1 corresponds to 10%
5 corresponds to 50%
9 corresponds to 90%
4
3
1
s = seconds
min = minutes
Tein
2
Taus
Ton Adjuster knob "Timer valve switched on"
Toff Adjuster knob "Timer valve switched off"
1
2
3
4
Tongue of the push-on adjuster cap
Slot on the adjuster knob
Notch on the adjuster knob
Pointer of the push-on adjuster cap
NOTICE
Damage to the condensate solenoid valve during adjustment of the
switching times
If a screwdriver is used to turn the adjuster knobs for the switching times, this
can result in irreversible damage to the
solenoid valve
i Use the enclosed red push-on adjuster caps to adjust the switching times
0678106020L02 1708V004
27
EN
Operation
11 Operation
De-energize the unit prior to working on it
or in the event of potential danger (e g
pull the mains plug) and prevent it from
being switched back on again
EN
Units with a start-up volume and mechanical relief valve and units with a membranedrying unit
11.1 Switching the unit on/off
i Switch on the device at the pressure switch
by rotating the switch to the "I" position
The compressor unit will start up automatically and fill the pressure vessel When the
cut-off pressure is reached, the compressor
unit switches itself off automatically
i The unit can be switched off whenever required by turning the pressure switch to the
"0" setting
11.2 Switching the unit on after a
power cut
Some units will generally not start up
against pressure These units can optionally be equipped either with a start-up
volume (1) and a mechanical relief valve
(2) or with an automatic start-up valve
Units with an automatic start-up valve:
If the unit is fitted with an automatic start-up
valve, the valve allows the unit to start up without being pressurised
1
2
3
4
Start-up volume
Mechanical relief valve
Safety Valve
Condensate drain (manual)
i Switch off the unit using the pressure switch
i Switch the unit back on using the pressure
switch once the air has escaped from the
start-up volume (duration: approximately 5
seconds) or via the membrane-drying unit
11.3 Pressure vessel test
The owner must comply with the national
directives
Example for Germany: German Ordinance on
Industrial Safety and Health (BetrSichV)
11.4 Mobile compressor station
NOTICE
Risk of crushing when operating the
articulated joints
i Keep your fingers away from the area
around the articulated joints where
crushing may occur when the angle
and height of the sliding handle are
being adjusted
i Press both of the black knobs on the articulated joints pressed at the same time to adjust
the height and angle of the sliding handle
28
0678106020L02 1708V004
Operation
12 Maintenance
De-energize the unit prior to working on it or in the event of potential danger (e g pull the
mains plug) and prevent it from being switched back on again
12.1 Maintenance schedule
EN
Units without a membrane-drying unit
Maintenance interval
Maintenance work
Weekly
i Requirement on units without a K module: drain the condensed water
– once a day if humidity is high (see "122 Draining the condensation
water")
Every six months
i Check the safety valve (see "96 Checking the safety valve")
Annually
i Replace the air intake filter – if there is a high concentration of dust, this
must be carried out every six months (see "123 Replacing the air intake
filter")
Every 4 years
i Replace the vibration dampers
In accordance with national directives
i Carry out recurring safety tests (eg pressure vessel testing, electrical
safety testing) in accordance with the national directives
Observe the assembly
and operating instructions "Oil-free piston
compressors KK and
piston vacuum pumps
KV"
i Maintenance of the compressor unit
Unit with membrane-drying unit
Maintenance interval
Maintenance work
Every six months
i Drain off the condensed water (see "122 Draining the condensation
water")
i Check the safety valve (see "96 Checking the safety valve")
Annually
i Replace the air intake filter – if there is a high concentration of dust, this
must be carried out every six months (see "123 Replacing the air intake
filter")
i Replace the fine filter 3 µm or fine filter 001 µm (see "124 Replacing
the filter of the membrane drying unit")
i Replace the sinter filter (see "124 Replacing the filter of the membrane
drying unit")
Every 4 years
i Replace the vibration dampers
In accordance with national directives
i Carry out repeat safety tests (eg pressure vessel test, electrical safety
test) in accordance with the national directives
Observe the assembly
and operating instructions "Oil-free piston
compressors KK and
piston vacuum pumps
KV"
i Maintenance of the compressor unit
0678106020L02 1708V004
29
Operation
EN
12.2 Draining the condensation water
12.4 Replacing the filter of the membrane drying unit
Units with an automatic condensate solenoid
valve and/or with membrane-drying units do
not have a manual drainage system.
Condensed water collects in the pressure vessel
during operation
i When the vessel is at maximum pressure,
open the condensate drain
Fine filter
i Switch off the unit
i Disconnect all power from the device
i Unscrew and remove the filter cover
i Remove the fine filter
i Insert the new fine filter
i Replace the filter cover and close
4
Condensate drain (manual)
i Close the condensate drain once all the accumulated condensed water has been blown
out
12.3 Replacing the air intake filter
i Open the cover of the air intake filter by turning it clockwise
i Remove the filter element (white/green)
i Insert a new filter element
i Close the cover of the air intake filter by turning it anti-clockwise
30
0678106020L02 1708V004
Operation
Sintered filter
i Unscrew and remove the filter housing
i Remove the sintered filter
i Insert a new sintered filter
i Replace the filter housing and close
13 Taking out of use
13.1 Taking the unit out of use
If the unit is not to be used for a prolonged period of time, we recommend that it is properly
shut down and taken out of use
To do this, the accumulated condensation water
from the unit must be drained
i Switch on the unit and wait until the cut-off
pressure is reached
Unit with condensate separator
i At maximum tank pressure, unscrew the bottom screw fitting on the condensate separator
i Close the screw connection as soon as all of
the condensate has been blown out
0678106020L02 1708V004
31
EN
Operation
EN
Membrane drying unit
i Open the condensate drain valve on the
membrane drying unit with the compressor
unit running When no more condensation water emerges, close the condensate drain
valve
i Switch off the unit
Pressure tank
i Switch off the unit
i Disconnect the mains plug
i Relieve the full pressure from the compressed
air vessel (eg using a blow-off gun connected to the quick-release coupling or via the
condensate drain valve (if present))
i Disconnect the compressed air connection on
the quick release coupling
13.2 Storage of the unit
WARNING
Risk of explosion of the pressure
tank and pressure hoses
i The pressure tank and the pressure
hoses must be vented before they are
stored or transported
i Protect the unit against moisture, dirt and extreme temperatures during transport (refer to
the section on "Ambient conditions")
i Only store the unit when it has been completely emptied
32
0678106020L02 1708V004
Troubleshooting
14 Tips for operators and service technicians
For further information on trouble-shooting refer to the assembly and operating instructions
"Oil-free piston compressors KK and piston vacuum pumps KV"
EN
Any repairs above and beyond routine maintenance must only be carried out by suitably qualified personnel or by one of our service technicians
De-energize the unit prior to working on it or in the event of potential danger (e g pull the
mains plug) and prevent it from being switched back on again
Fault
Probable cause
Solution
Unit does not start
No power supply voltage
i Inform an electrician Check
mains fuse and if possible,
switch on unit again If the safety
fuse is defective, replace it
Undervoltage or overvoltage
i Inform an electrician Measure
power supply voltage
Condensor defective
i Notify electrician/engineer
Check condensor and replace if
necessary
Motor defective
i Replace the unit
Temperature switch in the motor
(not fitted in all units) has
switched off
1 High ambient temperature
2 Mechanical sluggishness
3 Pressure in the line
1 Allow the unit to cool down
Ensure better cooling
Warning: unit restarts automatically
2 Factory repair
3 Evacuate air from the suction
volume
Air intake filter cartridge blocked
i Insert a new air intake filter
cartridge
0678106020L02 1708V004
33
Troubleshooting
Fault
Probable cause
Output drops.
Lines, hoses or connections leak- i Inform a service technician
ing
Check / renew lines, hoses or
connections
EN
Unit too noisy
Water dripping from air
consumers
Solution
Defective membrane-drying unit
i Inform a service technician Replace the membrane-drying unit
Air intake filter soiled
i Replace the air intake filter at
least 1x per year The air intake
filter must never be cleaned
Head kit leaking as a result of
wear and/or for one or more of
the following reasons:
– Soiling
– Excessive ambient temperature
– Unsuitable materials drawn in
Inform a service technician Replace the head kit
– Install the filter upstream or
replace the filter
– Ensure that cooling is more
effective
– Only convey approved materials
Defective valve plate
i Inform a service technician
Replace the valve plate
Too frequent switching cycles
i Avoid switching on/off too
frequently, or work with a larger
compressed-air vessel
Bearing damaged
i Inform a service technician
Vibrations are being transmitted
to the housing
i Use suitable vibration dampers
Defective vibration dampers
i Install new vibration dampers
Compressor stations with membrane drying unit:
Membrane-drying unit defective
i Inform a service technician Replace the membrane-drying unit
Compressor stations without
membrane drying unit:
Condensed water in the vessel
i Regularly drain the condensed
water
Pressure dew point is not
correct
Purge air nozzle too large or small i Inform a service technician
Replace the purge air nozzle
Moisture indicator on
membrane drying unit is
pink
Unit has not been used for a extended period of time
i When the unit is operated, the
moisture indicator will regenerate itself and turn blue again
During operation: malfunction of
the membrane-drying unit Air
drying insufficient
i Inform a service technician Replace the membrane-drying unit
34
0678106020L02 1708V004
Addresses
Service
Dürr Technik GmbH & Co KG
74301 Bietigheim-Bissingen
Telephone 0 71 42 / 90 22 - 20
Fax 0 71 42 / 90 22 – 99
e-mail: service@duerr-technikde
EN
Replacement order
Telephone 0 71 42 / 9022 - 0
Fax 0 71 42 / 9022 - 99
e-mail: office@duerr-technikde
The following information is required when ordering spare parts:
– Type designation and item number
– Order number as appears on the spare parts
list
– Quantity required
– Exact shipping address
– Shipping information
Repairs/return delivery
Ensure that the unit is depressurized before
transport! Use the original packaging when returning units, if possible Always pack the units
in a plastic bag Use recyclable packing material
Return delivery address:
Dürr Technik GmbH & Co KG
Pleidelsheimer Straße 30
74321 Bietigheim-Bissingen
-GermanyInternational addresses for Dürr Technik
www duerr-technikcom
0678106020L02 1708V004
35
Dürr Technik GmbH & Co. KG
Pleidelsheimer Strasse 30
74321 Bietigheim-Bissingen
Germany
Fon: +49 7142-90 22 -0
www.duerr-technik.com
office@duerr-technik.de