Manual Combi PDF
Manual Combi PDF
Manual Combi PDF
Screw compressor
COMBI 2S - 7S
COMBI 6 - 15.1
COMBI 16 - 22IABLE 35 - 130
ALMiG Kompressoren GmbH
Adolf-Ehmann-Straße 2
73257 Köngen
Telephone: +49 7024 9614 240
Fax: +49 7024 9614 209
email: [email protected]
Internet: www.almig.de
Service Hotline:
Telephone: +49 1805 25 87 00
Fax: +49 1805 25 87 01
Almi-13257-DE COMBI
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Table of contents
Table of contents
1 General information ...............................................................7
1.1 Information about these instructions..............................7
1.2 Explanation of symbols..................................................7
1.3 Limitation of liability........................................................9
1.4 Copyright......................................................................10
1.5 Warranty terms ............................................................10
1.6 Customer service .........................................................10
2 Safety ....................................................................................11
2.1 Proper use ...................................................................11
2.2 Responsibility of the customer.....................................12
2.3 Personnel requirements...............................................13
2.3.1 Qualifications ................................................13
2.3.2 Unauthorised persons ..................................15
2.3.3 Training.........................................................15
2.4 Personal protective equipment ....................................15
2.5 Basic dangers ..............................................................17
2.5.1 General dangers in the workplace ...............17
2.5.2 Dangers due to electric power......................18
2.5.3 Dangers due to mechanical elements..........19
2.5.4 Dangers due to hydraulic energies ..............19
2.5.5 Dangers due to high temperatures...............21
2.6 Safety equipment.........................................................22
2.6.1 Position of the safety equipment ..................22
2.6.2 Description of the safety equipment
installed ........................................................23
2.7 Securing to prevent restart ..........................................24
2.8 Behaviour in case of fire or accidents..........................26
2.9 Environmental protection .............................................27
2.10 Signage 28
2.10.1 Warning signs...............................................28
2.10.2 Notes on the machine ..................................29
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Table of contents
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Table of contents
7 Operation ..............................................................................75
7.1 Safety instructions for the operation ............................75
7.2 Shutdown in emergency situations..............................75
7.3 Operating personnel and personal protective
equipment ....................................................................76
7.4 Controllers....................................................................76
7.4.1 COMBI 2S – 7S controller ............................77
7.4.2 Air Control AC mini controller .......................78
8 Maintenance .........................................................................96
8.1 Safety instructions for maintenance ............................96
8.2 Spare parts ..................................................................99
8.3 Maintenance plan ......................................................100
8.4 Maintenance work......................................................101
8.4.1 Checking the electrical connections...........102
8.4.2 Checking the coolant liquid level/topping
up the coolant liquid ...................................102
8.4.3 Checking for leaks......................................104
8.4.4 Checking the compressor temperature ......105
8.4.5 Checking soiling of the cooler ....................106
8.4.6 Checking the condensation accumulation..107
8.4.7 Changing the coolant liquid/changing the
cooling liquid filter.......................................108
8.4.8 Re-lubricating the electric motor.................111
8.4.9 Change fine precipitator .............................112
8.4.10 Change intake filter ....................................113
8.4.11 Checking the drive unit...............................114
8.5 Measures after maintenance has been performed....115
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Table of contents
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General information
1 General information
1.1 Information about these instructions
This manual enables safe and efficient handling of the machine. It is
an integral part of the machine, and must be kept in close proximity to
the machine where it is permanently accessible to the personnel.
Before starting any work, the personnel must have read the manual
thoroughly and understood its contents. Compliance with all specified
safety instructions and operating instructions is vital to ensure safe
operation.
In addition, local accident prevention regulations and general safety
instructions must be observed for the operational area of the machine.
Illustrations in this manual are intended to facilitate basic understand-
ing, and may differ from the actual design.
The instructions for the compressor do not include the operation of the
controller. Therefore, the instructions and content of the instructions
for the controller in question must also be taken into account.
Furthermore, the instructions for the installed components found in the
appendices also apply.
DANGER!
This combination of symbol and keyword points to a si-
tuation of immediate danger which may lead to serious
injury or death unless avoided.
WARNING!
This combination of symbol and keyword points to a si-
tuation of possible danger which may lead to serious in-
jury or death unless avoided.
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General information
CAUTION!
This combination of symbol and keyword points to a
possibly dangerous situation which may lead to slight or
minor injury unless avoided.
NOTICE!
This combination of symbol and keyword points to a
possibly dangerous situation which may lead to material
and environmental damage unless avoided.
Tips and recommendations This symbol highlights useful tips and recommendations
as well as information designed to ensure efficient and
smooth operation.
Special safety instructions The following symbols are used in the safety instructions to draw at-
tention to specific dangers:
DANGER!
This combination of symbol and signal word indicates
dangers posed by electric power. If the safety instruc-
tions are not observed, there is a danger of serious or
fatal injuries.
WARNING!
This combination of symbol and signal word indicates
dangers posed by an atmosphere capable of exploding.
If the safety instructions are not observed, there is a
danger of serious or fatal injuries.
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General information
Signs used in this manual The following signs and highlighting is used in this manual to identify
instructions, descriptions of results, numerations, references and other
elements:
Sign Explanation
Ö Identifies a state or automatic sequence as result of
steps.
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General information
1.4 Copyright
This manual is protected by copyright and intended solely for internal
use.
This manual must not be made available to third parties, duplicated in
any manner or form – whether in whole or in part – and the content
must not be used and/or communicated, except for internal purposes,
without the written consent of the manufacturer.
Violation of the copyright will result in legal action for damages. We
reserve the right to assert further claims.
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Safety
2 Safety
This section provides an overview of all the main safety aspects in-
volved in ensuring optimal personnel protection and safe and smooth
operation.
Non-compliance with the action guidelines and safety instructions
contained in this manual may result in serious hazards.
The proper use also includes adherence to all details in these instruc-
tions.
Any use beyond the proper use or other type of use counts as misuse.
WARNING!
Danger due to misuse!
Misuse of the compressor can cause dangerous situa-
tions.
- The compressed air may not be used for breathing
without previous preparation.
- The compressed air may not be used directly for
pharmaceutical or sanitary purposes or for the direct
handling of food without appropriate after-treatment.
- The screw compressor may not be operated out-
doors.
- The screw compressor or individual components may
not be rebuilt, modified or re-equipped.
- The screw compressor may not be used in an atmos-
phere subject to explosion.
- The intake of media other than cool, dry and dust-free
cooling air is forbidden.
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Safety
Duties of the customer The machine is used in the commercial realm. Therefore, the cus-
tomer of the machine is subject to legal occupational safety regula-
tions.
In addition to the safety instructions in these instructions, the valid
safety, accident prevention and environmental protection regulations
for the area of application of the machine must be adhered to.
Here, the following points apply in particular:
The customer must inform himself about the applicable
occupational safety provisions and also determine in a hazard
assessment the dangers that arise due to the special working
conditions in the machine's area of application. He must implement
these in the form of operating instructions for the operation of the
machine.
During the entire time the machine is used, the customer must
check whether the operating instructions he has created
correspond to the current state of the body of rules and regulations
and adapt the operating instructions if necessary.
The customer must regulate and specify clearly the responsibilities
for the installation, operation, troubleshooting, maintenance and
cleaning.
The customer must ensure that all employees who handle the
machine have read and understood these instructions. In addition,
he must train the personnel at regular intervals and inform them
about the dangers.
The customer must provide personnel with the required protective
equipment and instruct them in binding fashion about how to wear
the required protective equipment.
Furthermore, the customer is responsible for ensuring that the ma-
chine is always in technically-perfect condition. Therefore, the follow-
ing points apply:
The customer must ensure that the maintenance intervals
described in these instructions are adhered to.
The customer must have all safety equipment checked regularly to
ensure that it is functional and complete.
The customer must ensure that the appropriate media connections
are provided.
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Safety
The customer must ensure that the supply of the required quantity
of cool medium (air/water) is guaranteed.
The customer must ensure that the required heat extraction is
guaranteed.
WARNING!
Danger of injury if personnel are insufficiently quali-
fied!
If unqualified personnel perform work on the machine or
are in the machine's danger zone, hazards may arise
which can cause serious injury and substantial damage
to property.
- Therefore, all work must only be carried out by ap-
propriately qualified personnel.
- Unqualified personnel must be kept away from the
danger zones.
Forklift driver
The forklift driver must be at least 18 years old and, based on his phy-
sical and intellectual attributes and character, suited to driving indus-
trial trucks with a driver's seat or driver's platform.
Furthermore, the forklift driver has been trained to drive industrial
trucks with a driver's seat or driver's platform.
The forklift driver has provided the owner with evidence of his skills in
driving industrial trucks with a driver's seat or driver's platform and has
therefore been authorised in writing by the owner to drive the forklift.
Manufacturer
Certain tasks may only be performed by our qualified personnel. Other
personnel is not authorized to perform these tasks. Contact our ser-
vice department to request the execution of any necessary work. For
address information, refer to page 2.
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Safety
Qualified Electrician
Based on his technical training, knowledge, experience and knowl-
edge of the applicable standards and regulations, the Qualified Elec-
trician is able to perform work on electrical systems and recognise and
avoid potential hazards himself.
The Qualified Electrician is specially trained for the area of responsi-
bility he is involved with and knows the relevant standards and regula-
tions.
The Qualified Electrician must comply with the requirements of the
applicable legal regulations for accident prevention.
Qualified personnel
Qualified personnel is able to carry out assigned work and to recog-
nize and prevent possible dangers self-reliantly due to its professional
training, knowledge and experience as well as profound knowledge of
applicable regulations.
Trained Person
The trained person has been instructed in an instruction by the owner
about the tasks assigned to him and possible hazards in the case of
improper behaviour.
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Safety
WARNING!
Risk to life for unauthorised persons due to hazards
in the danger and working zone!
Unauthorised persons who do not meet the requirements
described here will not be familiar with the dangers in the
working zone. Therefore, unauthorised persons face the
risk of serious injury or death.
- Unauthorised persons must be kept away from the
danger and working zone.
- If in doubt, address the persons in question and ask
them to leave the danger and working zone.
- Cease work while unauthorised persons are in the
danger and working zone.
2.3.3 Training
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Safety
Protective clothing
Protective clothing are tight fitting working clothes with low tear resis-
tance, with tight sleeves and without any parts sticking out. These
clothes primarily protect against getting caught by moving machine
parts. Do not wear rings, chains, necklaces, and other jewellery.
Safety boots
Safety boots are intended to protect against slipping hazards or foot
hazards like heavy gear.
Safety gloves
Safety gloves are intended to protect hands against friction, abrasion,
stabs or deeper wounds and against direct contact with hot surfaces.
Safety goggles
Safety goggles are intended protect the eyes against flying debris and
liquid spray.
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Safety
Noise
WARNING!
Danger of injury from noise!
The noise levels arising in the workplace may result in
serious hearing damage.
- Always wear ear protection while working.
- Do not stay in the danger zone more than necessary.
Accumulations of liquid
CAUTION!
Danger of injury from slipping in accumulations of
liquid!
Slipping in accumulations of liquid on the floor may result
in a fall. A fall may result in injuries.
- Remove accumulations of liquid immediately using
appropriate means.
- Wear anti-slip safety shoes.
- Post warnings and mandatory signs at or in the vicin-
ity of any area where liquid could accumulate on the
floor.
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Safety
Electric current
DANGER!
Danger to life from electric power.
There is an immediate danger to life from electric shock
in the case of contact with live parts. Damage to the in-
sulation or individual components can be fatal.
- Only allow qualified electricians to work on the elec-
trical system.
- In the case of damage to the insulation, immediately
disconnect the power supply and arrange repairs.
- Establish the absence of voltage before starting work
on active parts of electrical systems and equipment
and ensure this remains so for the duration of the
work. Observe the 5 safety rules:
- Disconnect from the power supply.
- Secure against restarting.
- Verify absence of voltage.
- Earth and short-circuit.
- Cover or shield any neighbouring live parts.
- Never bypass or disable fuses. Comply with the cor-
rect current intensity information when replacing fu-
ses.
- Keep moisture away from live parts. This can result in
short circuits.
Stored charges
DANGER!
Danger to life from stored charges!
Electric charges may be stored in electrical components;
these charges may be maintained even after the system
has been switched off and disconnected from the power
supply. Contact with these components may result in
serious or fatal injury.
- Before working on the specified components, ensure
that they have been completely disconnected from
the power supply. Allow 10 minutes to elapse in order
to ensure that the internal capacitors have been fully
discharged.
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Safety
Moving parts
WARNING!
Danger of injury from moving parts!
Rotating parts and/or parts moving in linear fashion may
cause serious injuries.
- During operation, do not reach into or handle moving
parts.
- Do not open covers during operation.
- Observe the run-on time: Before opening the covers,
make sure that all parts have stopped moving.
- When in the danger zone, wear close-fitting protective
work clothing with low tear strength.
Liquid stream
WARNING!
Danger to life due to escaping liquid stream under
high pressure!
In case of defective lines or components, a stream of
liquid under high pressure can escape. The stream of
liquid can cause extremely severe injuries or even death.
- Never hold body parts or objects in the liquid stream.
Keep people out of the danger zone. In case of acci-
dental contact with the liquid stream, take first aid
measures and consult a doctor immediately.
- Initiate emergency off immediately. If necessary, take
additional measures in order to reduce the pressure
and stop the stream of liquid.
- Catch and dispose of escaping liquids properly.
- Have faulty components repaired immediately.
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Safety
Pressure accumulator(s)
WARNING!
Danger to life from improper work on the pressure
accumulator!
Improper handling of pressure accumulators may cause
a sudden release of pressure, resulting in very serious
injuries or death and in significant damage to property.
- Never carry out welding or soldering work on the
pressure accumulator vessel.
- Never perform any mechanical machining on the
pressure accumulator vessel.
- Once it is connected to the hydraulic line, vent the
pressure accumulator vessel using the fitted vent
screw.
- Only carry out work on systems with a pressure ac-
cumulator once the hydraulic pressure has been
completely relieved and depressurisation has been
verified.
- Do not start work on the pressure accumulator until
the gas charging pressure has been completely re-
leased.
Compressed air
WARNING!
Danger of injury from compressed air!
Compressed air can escape from compressed air hoses
or components under pressure in case of improper han-
dling or in case of a fault. It can injure eyes, whip up dust
or cause uncontrolled movements of hoses.
Components under pressure can move in uncontrolled
fashion with improper handling and cause injuries.
- Before removing hoses or components under pres-
sure, make sure the pressure is relieved.
- Have faulty components that are under pressure dur-
ing operation replaced by appropriate specialist per-
sonnel immediately.
- Before all work, make sure that the compressor is not
under pressure; wait at least 5 minutes.
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Safety
Hot surfaces
WARNING!
Danger of injury from hot surfaces!
Surfaces of components can heat up a lot during opera-
tion. Skin contact with hot surfaces will cause severe
skin burns.
- During all work hear hot surfaces, wear heat-resistant
protective clothing and protective gloves.
- Before all work, make sure that all surfaces have coo-
led off to the ambient temperature, wait at least
30 minutes.
Hot consumables
WARNING!
Danger of injury from hot consumables!
Consumables may reach high temperatures during op-
eration. Skin contact with hot consumables will cause
severe skin burns.
- Always wear heat-resistant protective work clothing
and protective gloves as a matter of principle when
carrying out any work with consumables.
- Always check whether consumables are hot before
working with them. Allow to cool down if necessary.
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Safety
WARNING!
Danger to life from nonfunctional safety devices!
If safety devices are not functioning or are disabled, the-
re is a danger of grave injury or death.
- Check that all safety devices are fully functional and
correctly installed before starting work.
- Never disable or bypass safety devices.
- Ensure that all safety devices are always accessible.
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Safety
WARNING!
Danger to life from an unauthorised restart!
An uncontrolled restart of the machine may cause seri-
ous injuries including death.
- Before switching the machine back on, make sure the
cause of the emergency stop has been removed and
Fig. 2: Main switch all safety devices have been installed and function
properly.
- Only turn the main switch to the "l" position when the-
re is no more danger.
WARNING!
Danger to life from an unauthorised restart!
An uncontrolled restart of the machine may cause seri-
ous injuries including death.
Fig. 3: Emergency stop key
- Before switching the machine back on, make sure the
cause of the emergency stop has been removed and
all safety devices have been installed and function
properly.
- Do not unlock the EMERGENCY-STOP button until
there is no more danger.
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Safety
Safety valves
Safety valves belong to the safety taps and are unburdening equip-
ment for the areas under pressure such as the boiler, pressure tank,
pipes, transport container. In case of an impermissible pressure in-
crease, safety valves bleed off gases, vapours or liquids into the at-
mosphere.
WARNING!
Life-threatening danger if restarted without authori-
sation or due to uncontrolled restart!
Uncontrolled or unauthorised switching on of the ma-
chine can cause severe or fatal injuries.
- Prior to restart ensure that all safety devices are
mounted and functional, and that there is no danger
for personnel.
- Always adhere to the procedure described below to
secure against restart.
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Safety
4. After all work has been performed, make sure that there are no
dangers to people.
WARNING!
Danger to life from an unauthorised restart!
If the main switch is secured with a padlock, people can
Fig. 5: Securing the main switch
be in the danger zone. These people can be fatally in-
jured by the switching on of the power supply.
- Before removing the padlock and switching the power
supply back on, make sure that there are no dangers
to people.
WARNING!
Life-threatening danger if restarted without authori-
sation or due to uncontrolled restart!
Uncontrolled or unauthorised switching on of the ma-
chine can cause severe or fatal injuries.
- Prior to restart ensure that all safety devices are
mounted and functional, and that there is no danger
for personnel.
- Always adhere to the procedure described below to
secure against restart.
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Safety
3. Mark machine with a sign that indicates the work in the danger
zone and forbids switching on. Include the following details on the
sign:
Switched off on:
Switched off at:
Switched off by:
Note: do not switch on!
Note: Only switch on after it has been ensured that there are
no dangers to people.
4. After all work has been performed, make sure that there are no
dangers to people.
WARNING!
Danger to life from an unauthorised restart!
People in the danger zone can be fatally injured by the
unauthorised or uncontrolled switching on of the power
supply.
- Before switching the power supply back on, ensure
that there are no dangers for people.
Steps in case of fire and accidents Immediately trigger an Emergency Stop using EMERGENCY-
STOP devices.
Provided your own health is not in danger, rescue all personnel
from the danger area.
If necessary, initiate first aid measures.
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Safety
NOTICE!
Danger to the environment from incorrect handling
of pollutants!
Incorrect handling of pollutants, particularly incorrect
waste disposal, may cause serious damage to the envi-
ronment.
- Always observe the instructions below regarding
handling and disposal of pollutants.
- Take the appropriate actions immediately if pollutants
escape accidentally into the environment. If in doubt,
inform the responsible municipal authorities about the
damage and ask about the appropriate actions to be
taken.
Coolant liquid Coolant liquids can contain poisonous substances and substances
that are harmful to the environment. They must not be allowed to es-
cape into the environment. Disposal must be carried out by a special-
ist disposal company.
Lubricants Lubricants such as greases and oils contain toxic substances. They
must not be allowed to escape into the environment. Disposal must be
carried out by a specialist disposal company.
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Safety
2.10 Signage
The following symbols and information signs can be found in the work
area. They refer to their immediate surroundings.
WARNING!
Danger of injury from illegible symbols!
Stickers and signs can become dirty or otherwise ob-
scured over time, with the result that dangers cannot be
recognised and the necessary operating instructions
cannot be complied with. This, in turn, poses a risk of
injury.
- All safety, warning and operating instructions must
always be maintained in a completely legible condi-
tion.
- Damaged signs or stickers must be replaced immedi-
ately.
Electrical voltage
Only qualified electricians are permitted to work in a work room mark-
ed by this sign.
Unauthorised persons must not enter the workplaces thus marked and
must not open the marked cabinet.
Automatic start-up
Maintain sufficient distance from all parts that can move; there is a
danger of crushing or pulling in there.
Hot surface
Hot surfaces such as hot machine parts, containers or materials, as
well as hot liquids, may not always be detected. Never touch these
without protective gloves.
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Safety
Direction of rotation
There is a direction of rotation sticker on the drive unit and on the
cooling air ventilator. This sticker shows the appropriate direction of
rotation.
Re-lubrication
The sticker for re-lubrication is on the drive unit.
Oil filling
The sticker for oil filling is on the coolant liquid pressure tank and next
to the installed controller.
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Safety
Brief instructions for commissio- This sticker is on the switch cabinet and contains brief instructions for
ning commissioning.
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Technical data
3 Technical data
3.1 Type plate
The type plate is on the lower frame on the maintenance side and on
the sound insulation cover on the Cooling air exhaust side or cooling
water intake and outlet side and includes the following details:
Manufacturer
Product type
Manufacturer no.
Year of construction
Direction of rotation
Volume flow rate
Part number
Final pressure
Motor output
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Technical data
3.2 Emissions
COMBI 2S – 7S
dB (A)
2S 60
3S 61
4S 62
5S 64
7S 67
COMBI 6 – 15.1
dB (A)
6 63
8 64
11 64
15 68
15.1 67
COMBI 16 – 22
dB (A)
16 71
18 72
22 72
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Technical data
3.4 COMBI 2S – 7S
3.4.1 General details
COMBI 2S
kW kg mm mm mm
2S 2,2 210 1400 550 1250
(standard model)
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Technical data
COMBI 3S
kW kg mm mm mm
3S 3,0 215 1400 550 1250
(standard model)
COMBI 4S
kW kg mm mm mm
4S 4,0 220 1400 550 1250
(standard model)
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Technical data
kW kg mm mm mm
4S 4,0 135 720 550 950
(without pressure
tank, without refriger-
ant-type dryer)
Combi5S
kW kg mm mm mm
5S 5,5 225 1400 550 1250
(standard model)
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Technical data
COMBI 7S
kW kg mm mm mm
7S 7,5 230 1400 550 1250
(standard model)
Electrical COMBI 2S – 7S
A A gL A A gL 1/h
2S 5 10 4 10 55
3S 6,6 10 5,3 10 55
4S 8,5 16 6,8 16 55
5S 11,3 16 9 16 55
7S 11,3 20 12,1 20 55
IN = nominal current
IFuse = building-side fuse
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Technical data
COMBI Compressed air Cooling air Supply air ope- Cross section of
connection quantity (LK) ning exhaust air duct
G / DN m3/h m2 m2
2S ⅜ 1040 0,15 0,10
Environment
3.4.4 Lubricants
COMBI 2S – 7S
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Technical data
COMBI 6
kW kg mm mm mm
6 5,5 435 1120 685 1680
(with 270 l pressure
tank and refrigerant-
type dryer)
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Technical data
COMBI 8
kW kg mm mm mm
8 7,5 440 1120 685 1680
(with 270 l pressure
tank and refrigerant-
type dryer)
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Technical data
COMBI 11
kW kg mm mm mm
11 11,0 445 1120 685 1680
(with 270 l pressure
tank and refrigerant-
type dryer)
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Technical data
COMBI 15
kW kg mm mm mm
15 15,0 455 1120 685 1680
(with 270 l pressure
tank and refrigerant-
type dryer)
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Technical data
COMBI 15.1
kW kg mm mm mm
15.1 15,0 475 1120 685 1680
(with 270 l pressure
tank and refrigerant-
type dryer)
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Technical data
A A gL A A gL 1/h
6 11 16 11 16 55
8 15 20 15 20 55
11 21 25 20 25 40
15 30 40 27 40 30
15.1 30 40 27 40 30
IN = nominal current
IFuse = building-side fuse
COMBI Compressed air Cooling air Supply air ope- Cross section of
connection quantity (LK) ning exhaust air duct
G / DN m3/h m2 m2
6 ¾ 1100 0,30 0,15
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Technical data
Environment
3.5.4 Lubricants
COMBI 6 – 15.1
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Technical data
3.6 COMBI 16 – 22
3.6.1 General details
COMBI 16
kW kg mm mm mm
16 15 679 1900 780 1950
(with pressure tank
and refrigerant-type
dryer)
COMBI 18
kW kg mm mm mm
22 22 744 1900 780 1950
(with pressure tank
and refrigerant-type
dryer)
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Technical data
kW kg mm mm mm
22 22 559 1480 780 1375
(without pressure
tank, with refrigerant-
type dryer)
Electrical COMBI 16 – 22
A A gL A A gL 1/h
16 30 40 27 40 30
18 36 50 30 40 25
22 41 63 34 50 20
IN = nominal current
IFuse = building-side fuse
COMBI Compressed air Cooling air Supply air ope- Cross section of
connection quantity (LK) ning exhaust air duct
G / DN m3/h m2 m2
16 1 3300 0,60 0,35
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Technical data
Environment
3.6.4 Lubricants
COMBI 16 – 22
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
For the COMBI type, there are variants which are not
built on a pressure tank. Due to their identical construc-
tion, these variants are only depicted without pressure
tank and not extra as an overview figure.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
1 Controller
2 Emergency stop key/main switch with emergency stop function
3 Switch cabinet
4 Pressure tank
5 Sound insulation covers
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Components The basic structure is the same for all screw compressor
variants. The position of the components can vary from
the illustration.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
1 Fine precipitator
2 Refrigerant-type dryer
3 Coolant liquid filter
4 Coolant liquid cooler
5 Intake filter
6 Compressed air connection
7 Fan belt
8 Compressor stage
9 Cooling air ventilator
10 Drive unit
11 Pressure tank
12 Coolant liquid pressure tank
13 Minimum pressure and return valve
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Controller variants
The COMBI 2S – 7S is operated using the two buttons for switching it
on and off.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
With the COMBI, the drive (Fig. 14) takes place using a fan belt
(Fig. 14/1).
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
The standard intake filter (Fig. 15/1) sits directly above the compres-
sor stage (Fig. 15/2).
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
1 Safety valve
2 Coolant liquid pressure tank
3 Filler plugs
4 Coolant liquid drain
5 Inspection glass
The coolant liquid pressure tank consists of several components. The
safety valve protects the coolant liquid pressure tank against over-
pressure. With the inspection glass, the level of the coolant liquid can
be read. With the drain plugs, the coolant liquid is topped off and it is
removed via the coolant liquid drain.
The fine precipitator (Fig. 18/1) removes the remaining coolant liquid
from the compressed air.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
The minimum pressure and return valve (Fig. 19/1) only opens if the
system pressure has increased to 5 bar. After the screw compressor
switches off, the minimum pressure and return valve prevents the
compressed air from stream back out of the network.
4.3.9 Cooler
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
The coolant liquid filter (Fig. 21/1) cleans the coolant liquid before it is
injected into the compressor stage once again.
The cooling of the compressed air after-cooler and of the coolant liq-
uid after-cooler is handled by the cooling air ventilator. The cooling air
ventilator also supplies the intake filter with sufficient intake air.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
The refrigerant-type dryer (Fig. 22/1) dries the compressed air using a
heat exchange process. The compressed air is thus fed from the
pressure tank into the refrigerant-type dryer and then via the com-
pressed air connection (Fig. 22/3) into the compressed air network.
The condensate which accumulates is discharged via the condensate
drain (Fig. 22/2).
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
4.4 Interfaces
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Air supply
The cooling air ventilator directs the fresh air to the intake filter and
also serves the purpose of process cooling. The intake filter filters the
fresh air and directs it into the compressor unit for compression.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
5.3 Packaging
About the packaging The individual screw compressors are packaged in cartons or some-
times on wooden frames and according to the anticipated transport
conditions. Only environmentally-friendly materials are used for the
packaging.
The packaging should protect the individual components against
transport damage, corrosion and other damage until assembly. There-
fore, do not destroy the packaging and only remove it shortly before
assembly.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Handling packaging materials Dispose of packaging material in accordance with the relevant appli-
cable legal requirements and local regulations.
NOTICE!
Danger to the environment due to incorrect disposal!
Packaging materials are valuable raw materials and in
many cases can continue to be used or can be properly
processed and recycled. Incorrect disposal of packaging
materials may pose risks to the environment.
- Dispose of packaging materials in accordance with
the environmental regulations.
- Observe locally applicable waste disposal regula-
tions. If necessary, outsource the disposal to a spe-
cialist company.
Top
The arrow tips on the sign mark the top of the package. They must
always point upwards; otherwise the content could be damaged.
Fragile
Marks packages with fragile or sensitive contents.
Handle the package with care; do not allow to fall and do not expose
to impacts.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
5.5 Transport
Transport with a fork lift Transport pieces can be transported with a fork lift under the following
conditions:
The fork lift must be designed for the weight of the transport
pieces.
Existing guide rails on the frame must be used.
The length of the forks must be at least 1400 mm.
1. Drive the fork lift with the forks as shown in Fig. 26.
2. Insert the forks so that they stick out on the other side.
3. Ensure that the transport piece cannot tip with an off-centre cen-
tre of gravity.
5.6 Storage
Storage of the packaging pieces Store the packaging pieces under the following conditions:
Do not store outdoors.
Store dry and dust-free.
Do not expose to any aggressive media.
Protect against solar radiation.
Avoid mechanical jolts.
Storage temperature: 15 to 35 °C.
Relative humidity: max. 60 %.
In case of storage for longer than 3 months, check the general
condition of all parts and the packaging regularly. If necessary,
refresh or replace the rust-proofing.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
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2010-11-04 65
Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
6.3 Installation
6.3.1 Ventilation
DANGER!
Danger to life from the use of explosive gas mix-
tures, vapours, dust or aggressive hazardous sub-
stances!
The use of explosive gas mixtures, vapours, dust or ag-
gressive hazardous substances to ventilate the screw
compressor can cause severe or even fatal injuries as
well as significant property damage.
- Never use explosive gas mixtures, vapours, dust or
aggressive hazardous substances to ventilate the
screw compressor.
- Ensure that no explosive gas mixtures, vapours, dust
or aggressive hazardous substances get into the ven-
tilation of the screw compressor.
The air supplied via the intake openings is used for compression and
system cooling.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
NOTICE!
Property damage due to condensation!
Due to cooling air that is too hot or too humid, conden-
sate can arise.
- Only provide cool, dry and dust-free cooling air.
- For the intake of outside air, use a recirculating air
flap.
2. Remove the exhaust air according to the technical data for the
screw compressor (ª Chapter 3 „Technical data“ on page 31).
Ö This way, the heating of the installation room and of the screw
compressor will be prevented.
Forced ventilation and bleeding The forced ventilation and bleeding must be dimen-
(optional) sioned so that the required supply and exhaust air can
be supplied and removed taking into account the existing
residual pressure of the cooling air ventilator. The ex-
haust air can also be used for the purpose of heat rec-
lamation.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
WARNING!
Danger of injury due to unpredictable movement of
the compressed air hose!
Load switches in the compressed air network cause jer-
ky movements of the compressed air hose with high
force.
- Anchor and fasten the compressed air hose suffi-
ciently.
2. Ensure that the compressed air hose does not represent a stum-
bling hazard.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
NOTICE!
Property damage to the compressor stage due to
incorrect connection of the power supply!
In case of incorrect connection of the power supply, the-
re is a danger that the compressor stage will be de-
stroyed due to a drive turning incorrectly.
- Connect the power according to the wiring diagram
and check the rotating field before starting the screw
compressor.
1. Using the data in the wiring diagram (in the switch cabinet), check
whether the existing supply network is suitable. Voltage deviati-
ons of more than 10 % are not permitted.
4. Ensure that the power cable does not represent a stumbling haz-
ard.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
2. Open and remove the sound insulation covers with the special
spanner.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
NOTICE!
Property damage due to lacking coolant liquid in the
compressor stage!
Lacking coolant liquid in the compressor stage after lon-
ger downtimes, e.g. between factory delivery and initial
commissioning or after a longer downtime can cause
significant property damage to the screw compressor.
- Top up the coolant liquid directly in the compressor
stage before the initial commissioning or after a lon-
ger downtime.
COMBI 2S – 7S 0,2
COMBI 16 – 22 0,5
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
NOTICE!
Property damage due to incorrect coolant liquid!
Mixing different coolant liquids causes significant prop-
erty damage to the screw compressor.
- Only use the coolant liquid prescribed in the technical
data.
2. Remove the intake regulator and fill the coolant liquid directly into
the compressor stage (Fig. 30/1).
3. Install and check that the sound installation covers are sealed.
4. Carefully open the gate valve after the compressed air connec-
tion between the screw compressor and the compressed air net-
work.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
WARNING!
Danger of injury from hot surfaces!
Surfaces of components can heat up a lot during opera-
tion. Skin contact with hot surfaces will cause severe
skin burns.
- During all work hear hot surfaces, wear heat-resistant
protective clothing and protective gloves.
- Before all work, make sure that all surfaces have coo-
led off to the ambient temperature, wait at least
30 minutes.
CAUTION!
Danger of injury from coolant liquid fog!
In case of high temperatures or mechanical dust, coolant
liquid fog can form. Coolant liquid fog can irritate eyes
and the respiratory system.
- When working on the coolant liquid system and if a
coolant liquid fog arises, wear breathing protection
and protective goggles and ensure that there is a
fresh air supply.
2. Open and remove the sound insulation covers with the special
spanner.
4. Check all coolant liquid and compressed air lines for leaks.
2010-11-04 73
Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
7. Check the coolant liquid level in the inspection glass (Fig. 31/1)
and top up as in ª Chapter 8.4.2 „Checking the coolant liquid
level/topping up the coolant liquid“ on page 102 if necessary.
8. Install and check that the sound installation covers are sealed.
NOTICE!
Property damage to to compressor temperature that
is too low or too high!
A compressor temperature that is too low or too high can
cause damage to the screw compressor.
- Contact the manufacturer for more precise informa-
tion, for contact information see page 2.
74 2010-11-04
Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Operation
7 Operation
7.1 Safety instructions for the operation
Improper operation
WARNING!
Danger of injury due to improper operation!
Improper operation can cause serious injury and signifi-
cant material damage.
- Carry out all operating steps in accordance with the
information and notices in this manual.
- Pay attention to the following points before starting
work:
- Ensure that all covers and safety devices are in-
stalled and work properly.
- Ensure that that no one is in the danger zone.
- Never override or bridge safety features during opera-
tion.
After the rescue measures 9. Depending on the seriousness of the emergency situation, inform
the responsible government agencies.
2010-11-04 75
Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Operation
WARNING!
Life-threatening danger if restarted without authori-
zation or due to uncontrolled restart!
Uncontrolled or unauthorized switching on of the power
supply can cause severe or fatal injuries.
- Prior to restart ensure that all safety devices are
mounted and functional, and that there is no danger
for personnel.
11. Prior to restarting the machine check and ensure that all safety
devices are installed and functioning.
7.4 Controllers
Controller variants
For the controller variant installed, please consult the
label on the controller.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Operation
7.4.1.1 Overview
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Operation
78 2010-11-04
Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Operation
Load/idle operation The compressor switches between "Load" and "Idle" operation;
that is, there is an unlimited run-on.
Optional automatic After reaching the switch-off pressure, the compressor switches to
idle. After 10 and 40 seconds, the respective network pressure is
measured. If the pressure drop determined this way is above the
threshold "Max. pressure drop", the compressor remains in idle for
the duration of the run-on time. If the value determined is below the
threshold "Max. pressure drop", the compressor switches off after
the shutdown time has elapsed.
Basic load switching mode The switch on/off pressure set is not taken into account by the con-
(BLS operation) troller. The compressor is controlled by a superior controller, which
can be connected via freely-programmable inputs (no RS485 pre-
sent).
2010-11-04 79
Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Operation
Sicherheitsdruck (Safety pressure) The safety pressure is the sum of the set maximum pressure + 0.8
bar. If the pressure exceeds the value of the safety pressure, the
compressor is switched off with a fault message. If the maximum
pressure is exceeded by 0.5 bar, a warning appears on the display.
Other display indicators The following symbols can also appear on the display:
Symbol Description
Warning/maintenance message present.
Fault present.
80 2010-11-04
Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Operation
Symbol Description
Flashing: compressed air generation on/off via remote switch.
Static: compressed air generation is controlled by superior controller.
Motor is running.
1. Press .
2010-11-04 81
Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Operation
The parameters for all basic settings of the compressor can be chan-
ged with code input insofar as these changes do not influence the
operational stability. However, this is only possible when the com-
pressed air generation is switched off.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Operation
2. Press .
3. Press .
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Operation
2. Press .
3. Press .
6. Press .
7.
There are three values from which to choose:
- 0: Automatic operation
- 1: Load/idle operation
- 2: Optional automatic
Ö The set value is saved and the code input menu appears on
the display again.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Operation
1 Load/idle operation The compressor switches between "Load" and "Idle" opera-
tion; that is, there is an unlimited run-on.
2 Optional automatic The "Automatic" symbol and an additional point are shown on
the display in front of the temperature value. Here it is possible
to influence how frequently the motor stops. To do this, after
the confirmation, the parameters "maximum pressure drop"
(input range 0.0 to 9.9 bar) and "maximum operating cycle"
(input range 1 to 55 operating cycles/hour) are queried.
Maximum pressure drop If the system switches from load operation to idle, the Air Control mini
saves the current network pressure after 10 and 40 seconds. If the
pressure drop determined this way is above the "maximum pressure
drop", the motor switches off after the idle time has elapsed; otherwise
after the shutdown time.
Maximum operating cycles The motor is not switched off after the idle time (run-on) has elapsed if
the number of switch-on processes of the compressor exceeds the
number of the "maximum operating cycles".
2. Press .
3. Press .
2010-11-04 85
Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Operation
6.
There are two values from which to choose:
- 0: Automatic restart OFF
- 1: Automatic restart ON
Ö The set value is saved and the code input menu appears on
the display again.
1 Automatic restart ON If the automatic restart after power failure is switched on, the time
set in the "shutdown time" parameter must elapse. If the com-
pressor was operating before the power failure, then after this
time has elapsed, it will start up again. Otherwise, the compres-
sor will then switch to STOP mode.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Operation
2. Press .
3. Press .
6.
There are three values from which to choose:
- 0: On-site operation
- 1: Remote control
- 2: BLS-OK
Ö The set value is saved and the code input menu appears on
the display again.
1 Remote control The compressed air generation can only be switched on via a positive
edge (24 VDC) on terminal 23 and switched off via low level (0 V) on
terminal 23 or via the key. This functionality is identified by the flash-
ing text on the display of the Air Control 1. If the key is
pressed on the system on-site, the system switches off after 120 sec-
onds and for safety reasons, it can only be started via remote control
after the key has been pressed (acknowledgement) on-site. This
also applies for a start via PLANT CONTROL V/T.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Operation
By inputting the code 11, it is possible to set the switch-on and switch-
off pressure. The switch-on pressure specifies the pressure at which
the switched-on compressor will begin automatically with the com-
pression. The switch-off pressure specifies the pressure at which the
compressor will be switched off automatically. Both functions are only
active in automatic operation.
2. Press .
3. Press .
6. Press .
7.
The adjustment range for the switch-on pressure is,
with switch-off pressure set at the factory, between
3.5 and 7.9 bar. The upper limit for the switch-on
pressure is 0.1 bar less than the switch-off pressure.
Ö The set value was saved and the submenu for setting the
switch-off pressure appears on the display.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Operation
9.
The adjustment range for the switch-off pressure is,
with switch-on pressure set at the factory, between
7.1 and 10 bar. The upper limit for the switch-off
pressure is equal to the maximum pressure. The
lower limit for the switch-off pressure is 0.1 bar hig-
her than the switch-on pressure.
Ö The set value is saved and the code input menu appears on
the display again.
By inputting the code 18, the Basic load switching mode can be swit-
ched on/off.
2. Press .
3. Press .
6.
There are two values from which to choose:
- 0: Basic load switching mode is switched off
- 1: Basic load switching mode is switched on
Ö The set value is saved and the code input menu appears on
the display again.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Operation
2. Press .
3. Press .
6.
There are three values from which to choose:
- 0: bar
- 1: MPa
- 2: psi (pounds per square inch)
Ö The set value is saved and the code input menu appears on
the display again.
2 psi All pressure displays will be in psi (pounds per square inch).
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Operation
2. Press .
3. Press .
6.
There are three values from which to choose:
- 0: °C
- 1: °F
- 2: K
Ö The set value is saved and the code input menu appears on
the display again.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Operation
2. Press .
3. Press .
No. Description
E. 1 Pressure set points incorrect
E. 3 Low voltage
E. 4 Power failure
E. 9 Overcurrent
E. 10 Overpressure
E. 11 Dryer fault
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Operation
No. Description
E. 12 Sensor compression temperature
E. 14 Sensor pressure
NOTICE!
Property damage due to incorrect acknowledgement
of fault messages!
Faults which occur are output as fault messages. Only
after the fault has been eliminated may the fault mes-
sages be acknowledged, since otherwise the service life
of the compressor will be reduced.
- Only have maintenance work performed by qualified
personnel.
- Only acknowledge fault messages after the appropri-
ate work.
- Only use original spare parts.
Acknowledging fault messages Faults may only be acknowledged if the cause has been
eliminated properly. Only have troubleshooting and
maintenance work performed by qualified personnel.
1. Press .
2. Press .
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Operation
No. Description
E. 34 Compressor temperature increased
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Operation
2. Press .
3. Press .
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Maintenance
8 Maintenance
8.1 Safety instructions for maintenance
Electrical system
DANGER!
Danger to life from electric power!
Contact with live parts may prove fatal. When switched
on, electric components may be subject to uncontrolled
movements and may cause grave injury.
- Switch off the power supply before starting work and
make sure that it cannot be switched on again.
Moving parts
WARNING!
Danger of injury from moving parts!
Rotating parts and/or parts moving in linear fashion may
cause serious injuries.
- Before carrying out any maintenance work on moving
parts, shut down the machine and take precautions to
prevent restarting. Wait until all parts have stopped
moving.
- When in the danger zone, wear close-fitting protective
work clothing with low tear strength.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Maintenance
Hot surfaces
WARNING!
Danger of injury from hot surfaces!
Surfaces of components can heat up a lot during opera-
tion. Skin contact with hot surfaces will cause severe
skin burns.
- During all work hear hot surfaces, wear heat-resistant
protective clothing and protective gloves.
- Before all work, make sure that all surfaces have coo-
led off to the ambient temperature, wait at least
30 minutes.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Maintenance
Compressed air
WARNING!
Danger of injury from compressed air!
Compressed air can escape from compressed air hoses
or components under pressure in case of improper han-
dling or in case of a fault. It can injure eyes, whip up dust
or cause uncontrolled movements of hoses.
Components under pressure can move in uncontrolled
fashion with improper handling and cause injuries.
- Before removing hoses or components under pres-
sure, make sure the pressure is relieved.
- Have faulty components that are under pressure dur-
ing operation replaced by appropriate specialist per-
sonnel immediately.
- Before all work, make sure that the compressor is not
under pressure; wait at least 5 minutes.
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Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Maintenance
Accumulations of liquid
CAUTION!
Danger of injury from slipping in accumulations of
liquid!
Slipping in accumulations of liquid on the floor may result
in a fall. A fall may result in injuries.
- Remove accumulations of liquid immediately using
appropriate means.
- Wear anti-slip safety shoes.
- Post warnings and mandatory signs at or in the vicin-
ity of any area where liquid could accumulate on the
floor.
WARNING!
Danger of injury due to use of incorrect spare parts!
The use of incorrect or defective spare parts can lead to
personal injury, material damage, malfunction or total
failure.
- Use only original manufacturer's spare parts or spare
parts that have been approved of by the manufac-
turer.
- Always contact the manufacturer if in doubt.
Loss of warranty
The manufacturer's warranty will be rendered null and
void if spare parts are used that are not approved.
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Maintenance
After the first Check for leaks ª Chapter 8.4.3 „Checking for leaks“ on Qualified personnel
100 hours of page 104
operation
Check compressor temperature ª Chapter 7.4 Trained Person
„Controllers“ on page 76
Check cooler for soilingª Chapter 8.4.5 „Checking soiling Qualified personnel
of the cooler“ on page 106
After the first Check all electrical connections ª Chapter 8.4.1 Qualified Electrician
500 hours of „Checking the electrical connections“ on page 102
operation
Change coolant liquid ª Chapter 8.4.7 „Changing the Qualified personnel
coolant liquid/changing the cooling liquid filter“ on
page 108
Daily Checking the coolant liquid level ª Chapter 8.4.2 Qualified personnel
„Checking the coolant liquid level/topping up the coolant
liquid“ on page 102
Check for leaks ª Chapter 8.4.3 „Checking for leaks“ on Qualified personnel
page 104
Every 2000 Re-lubricate electric motor ª Chapter 8.4.8 „Re- Qualified personnel
hours of ope- lubricating the electric motor“ on page 111
ration
Every 4000 Change coolant liquid ª Chapter 8.4.7 „Changing the Qualified personnel
hours of op- coolant liquid/changing the cooling liquid filter“ on
eration, at page 108
least once a
year Change coolant liquid filter* ª Chapter 8.4.7 „Changing Qualified personnel
the coolant liquid/changing the cooling liquid filter“ on pa-
ge 108
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Maintenance
Check drive unit ª Chapter 8.4.11 „Checking the drive Qualified personnel
unit“ on page 114
One week Check all electrical connections ª Chapter 8.4.1 Qualified Electrician
after initial „Checking the electrical connections“ on page 102
installation
Check cooler for soilingª Chapter 8.4.5 „Checking soiling Qualified personnel
of the cooler“ on page 106
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Maintenance
DANGER!
Danger to life from stored charges!
Electric charges may be stored in electrical components;
these charges may be maintained even after the system
has been switched off and disconnected from the power
supply. Contact with these components may result in
serious or fatal injury.
- Before working on the specified components, ensure
that they have been completely disconnected from
the power supply. Allow 10 minutes to elapse in order
to ensure that the internal capacitors have been fully
discharged.
3. Open and remove the sound insulation covers with the special
spanner.
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Maintenance
3. Open and remove the sound insulation covers with the special
spanner.
3. Open and remove the sound insulation covers with the special
spanner.
4. With the help of a collection tray, make sure that the escaping
coolant liquid is collected.
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Maintenance
5. Loosen the filler plug (Fig. 36/1), remove and make sure that the
gasket does not get lost.
NOTICE!
Property damage due to incorrect coolant liquid!
Mixing different coolant liquids causes significant prop-
erty damage to the screw compressor.
- Only use the coolant liquid prescribed in the technical
data.
6. With the help of a funnel (Fig. 37/1), fill coolant liquid up to the
filling edge of the filler plug (Fig. 37/3).
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Maintenance
3. Open and remove the sound insulation covers with the special
spanner.
NOTICE!
Property damage to to compressor temperature that
is too low or too high!
A compressor temperature that is too low or too high can
cause damage to the screw compressor.
- Contact the manufacturer for more precise informa-
tion, for contact information see page 2.
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Maintenance
3. Open and remove the sound insulation covers with the special
spanner.
4. Check compressed air and coolant liquid cooler from inside and
outside for soiling.
5. Remove soiling.
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Maintenance
NOTICE!
Property damage due to condensation in the coolant
liquid circuit!
Condensate in the coolant liquid circuit can cause the
destruction of the compressor stage.
- In case of condensate in the coolant liquid pressure
tank, contact our service immediately; see page 2 for
the contact data.
3. Open and remove the sound insulation covers with the special
spanner.
4. With the help of a collection tray, make sure that the escaping
coolant liquid is collected.
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Maintenance
5. Carefully open the coolant liquid drain (Fig. 38/1) and check the
liquid escaping.
3. Open and remove the sound insulation covers with the special
spanner.
4. With the help of a collection tray, make sure that the escaping
coolant liquid is collected.
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Maintenance
5. Loosen the filler plug (Fig. 39/1), remove and make sure that the
gasket does not get lost.
NOTICE!
Property damage due to incorrect coolant liquid!
Mixing different coolant liquids causes significant prop-
erty damage to the screw compressor.
- Only use the coolant liquid prescribed in the technical
data.
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Maintenance
8. With the help of a funnel (Fig. 41/1), fill coolant liquid up to the
filling edge of the filler plug (Fig. 41/3).
10. Insert the screw plug (Fig. 41/2) and tighten ª Appendix B
„Tightening torques for screws“ on page 132.
11. Switch on the compressor and switch off again after a maximum
of one minute ª Chapter 7.4 „Controllers“ on page 76.
3. Open and remove the sound insulation covers with the special
spanner.
4. With the help of a collection tray, make sure that the escaping
coolant liquid is collected.
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Maintenance
5. Using the strap spanner, loosen and remove the old coolant liquid
filter (Fig. 42/1).
6. Remove old gasket remains from the coolant liquid filter housing.
8. Screw in the new coolant liquid filter (Fig. 42/1) up to the stop.
9. Tighten the new coolant liquid filter (Fig. 42/1) half a turn by hand.
10. Switch on the compressor and switch off again after a maximum
of one minute ª Chapter 7.4 „Controllers“ on page 76.
3. Open and remove the sound insulation covers with the special
spanner.
4. For the quantity of lubricating grease, consult the type plate of the
electric motor.
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Maintenance
3. Open and remove the sound insulation covers with the special
spanner.
4. With the help of a collection tray, make sure that the escaping
coolant liquid is collected.
5. Using the strap spanner (Fig. 44/2), loosen and remove the fine
precipitator (Fig. 44/1).
6. Remove old gasket remains from the fine precipitator (Fig. 44/1).
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Maintenance
9. Tighten the new fine precipitator (Fig. 45/1) half a turn by hand.
3. Open and remove the sound insulation covers with the special
spanner.
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Maintenance
3. Open and remove the sound insulation covers with the special
spanner.
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Maintenance
3. Ensure that all tools, materials and other equipment used has
been removed from the work area.
5. Clean the work area and remove any substances such as liquids,
processing material or similar that may have escaped.
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Faults
9 Faults
The following section describes possible causes of faults and the work
to remedy them.
In case of faults that occur more than once, abbreviate the mainte-
nance intervals according to the actual utilisation.
In case of faults that cannot be remedied using the following instruc-
tions, contact the manufacturer, see contact data on page 2.
Hot surfaces
WARNING!
Danger of injury from hot surfaces!
Surfaces of components can heat up a lot during opera-
tion. Skin contact with hot surfaces will cause severe
skin burns.
- During all work hear hot surfaces, wear heat-resistant
protective clothing and protective gloves.
- Before all work, make sure that all surfaces have coo-
led off to the ambient temperature, wait at least
30 minutes.
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Faults
Compressed air
WARNING!
Danger of injury from compressed air!
Compressed air can escape from compressed air hoses
or components under pressure in case of improper han-
dling or in case of a fault. It can injure eyes, whip up dust
or cause uncontrolled movements of hoses.
Components under pressure can move in uncontrolled
fashion with improper handling and cause injuries.
- Before removing hoses or components under pres-
sure, make sure the pressure is relieved.
- Have faulty components that are under pressure dur-
ing operation replaced by appropriate specialist per-
sonnel immediately.
- Before all work, make sure that the compressor is not
under pressure; wait at least 5 minutes.
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Faults
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Faults
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Faults
"Overpressure fault "or Fine precipitator soiled Change fine precipitator Qualified
"Network pressure too ª Chapter 8.4.9 „Change personnel
high" (red lamp lights fine precipitator“ on pa-
up) ge 112
Screw compressor Network pressure set too Reset network pressure Trained
does not start auto- high ª Chapter 7.4 Person
matically or does not „Controllers“ on page 76
discharge after previ-
ous switching-off by Interruption in the power Check power circuit for Qualified
reaching the final pres- circuit interruption Electrician
sure or from idle.
Ambient temperature Install additional heating Qualified
below +1 °C, message or temper compressor personnel
"Coolant liquid tempera- room and also contact the
ture too low" manufacturer
System does not start Network pressure greater Heed network pressure Trained
up when the start key is than switch-on pressure and change settings Person
pressed ª Chapter 7.4
„Controllers“ on page 76
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Faults
Compressed air con- Return line for the coolant Clean or replace return Qualified
tains a lot of coolant liquid is blocked line for the coolant liquid personnel
liquid (coolant liquid ª „Clean/change return
consumption too high) line“ on page 122
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Faults
3. Open and remove the sound insulation covers with the special
spanner.
4. With the help of a collection tray, make sure that the escaping
coolant liquid is collected.
5.
Depending on the type, several fine precipitators
can be installed. There is a return line for each fine
precipitator.
Loosen return line (Fig. 47/2) on separator box (Fig. 47/3) and
compressor stage (Fig. 47/1).
6. Clean return line (Fig. 47/2) and nozzle, if necessary replace with
Fig. 47: return line original spare parts (ª Appendix D „Spare parts list“ on pa-
ge 137).
7. Put nozzle and return line (Fig. 47/2) back in position and tighten
screws (ª Appendix B „Tightening torques for screws“ on
page 132).
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Faults
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Improper dismantling
WARNING!
Danger of injury due to improper dismantling!
Stored residual energy, angular components, points and
edges on or in the machine or on the tools needed can
cause injuries.
- Ensure sufficient space before starting work.
- Handle exposed, sharp-edged components with care.
- Pay attention to orderliness and cleanliness in the
workplace! Loosely stacked or scattered components
and tools could cause accidents.
- Dismantle the components properly. Note that some
components may have a high intrinsic weight. Use
hoists if necessary.
- Secure components so that they cannot fall down or
topple over.
- Consult the manufacturer if in doubt.
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10.2 Dismantling
Before starting dismantling:
Shut down the machine and secure to prevent restarting.
Physically disconnect the power supply from the machine;
discharge stored residual energy.
Remove consumables, auxiliary materials and other processing
materials and dispose of in accordance with the environmental
regulations.
Then clean assemblies and parts properly and dismantle in compli-
ance with applicable local occupational safety and environmental pro-
tection regulations.
10.3 Disposal
If no return or disposal agreement has been made, send the disman-
tled components for recycling.
Scrap metals.
Send plastic elements for recycling.
Sort and dispose of other components in accordance with their
material composition.
NOTICE!
Danger to the environment due to incorrect disposal!
Incorrect disposal may pose risks to the environment.
- Electrical scrap, electronic components, lubricants
and other auxiliary materials must be disposed of by
authorised specialist companies.
- If in doubt, obtain information about disposal in ac-
cordance with the environmental regulations from the
local municipal authorities or specialised waste dis-
posal companies.
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Index
11 Index
Setting parameters....................................... 83
A Sicherheitsdruck (Safety pressure)............ 80
Accident............................................................ 26 Switch automatic restart on/off................... 85
Acknowledging Switch the temperature unit ........................ 92
fault messages ............................................. 94 Switching off ................................................. 81
warning messages ....................................... 96 Switching on ................................................. 81
Air Control AC mini controller........................ 78 Switching the pressure unit ........................ 91
Acknowledging fault messages.................. 94 Warning messages....................................... 95
Acknowledging faults .................................. 94 Warnings ....................................................... 95
Acknowledging warning messages ........... 96
Basic display ................................................ 80 B
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Index
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Index
I N
Inspection at delivery ...................................... 61 Noise emissions................................................. 32
Installation
O
Forced ventilation and bleeding ................. 67
Operating conditions........................... 37, 44, 47
Ventilation ..................................................... 66
Overview
Installation conditions..................................... 65
COMBI 16 – 22 .............................................. 48
Installation location ......................................... 65
COMBI 2S – 7S.............................................. 48
Intake filter........................................................ 54
COMBI 6 – 15.1 ............................................. 48
Interfaces .......................................................... 59
Components.................................................. 50
Air supply...................................................... 60
Compressed air connection........................ 60 P
Media ............................................................. 59 Packaging ......................................................... 61
Personnel.......................................................... 13
L
Proper use ........................................................ 11
Liquid stream ................................................... 19
Protective equipment ...................................... 15
Lubricants
COMBI 16 – 22............................................... 47 R
Refrigerant-type dryer ..................................... 58
COMBI 2S – 7S.............................................. 37
Re-lubricating the electric motor.................. 112
COMBI 6 – 15.1.............................................. 44 Replace
coolant liquid .............................................. 109
M
coolant liquid filter ..................................... 109
Main switch....................................................... 23
Rescue measures .............................................. 75
Maintenance
Change coolant liquid filter* ..................... 109 S
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Index
in thismanual...................................................7 U
on the machine..............................................29 Use .....................................................................11
on the packaging ..........................................62
V
T Ventilation .........................................................66
Top up
W
coolant liquid...............................................103
Warning messages ...........................................95
Transport ...........................................................63
Warranty terms .................................................10
Type plate ..........................................................31
Working after the initial commissioning ........73
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Appendix
12 Appendix
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Training log
A Training log
Date Name Type of training Training conducted Signature
by
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Service manual
C Service manual
Compressor type:
System number:
Please specify in case of inquiries, orders and
correspondence.
Motor number:
Date of commissioning:
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Service manual
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Service manual
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Service manual
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2010-11-04 137
Article number 195 03276