Almig Screw Compressor Operating Instructions

Operating
instructions
Screw compressor
BELT 38 ‒ 132
DIRECT 37 ‒ 90
GEAR 30 ‒ 110
VARIABLE 35 ‒ 130
Read the instructions prior to performing

any task!
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
Translation of the original operating instructions
© ALMiG Kompressoren GmbH 2015
2 2015-03-13
BELT 38 ‒ 132, DIRECT 37 ‒ 90, GEAR 30 ‒ 110, VARIABLE 35 ‒ 130
Table of contents
Table of contents
1 General information ............................................................... 7
1.1 Information about this manual ....................................... 7
1.2 Explanation of symbols .................................................. 8
1.3 Limitation of liability...................................................... 10
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 owner .......................................... 12
2.3 Staff requirements ....................................................... 13
2.3.1 Qualifications ................................................ 13
2.3.2 Unauthorised persons .................................. 14
2.3.3 Training......................................................... 14
2.4 Personal protective equipment .................................... 15
2.5 Basic dangers .............................................................. 16
2.5.1 General dangers in the workplace ............... 16
2.5.2 Dangers due to electric energies ................. 17
2.5.3 Dangers due to mechanical elements .......... 18
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 installed safety devices ... 23
2.7 Securing to prevent restart .......................................... 25
2.8 Behaviour in case of fire or accidents .......................... 27
2.9 Environmental protection ............................................. 28
2.10 Signage 29
2.10.1 Warning signs ............................................... 29
2.10.2 Instructions on the machine ......................... 30
3 Technical data ...................................................................... 32

3.1 Type plate .................................................................... 32
3.2 Emissions..................................................................... 32
3.3 Coolant liquid ............................................................... 33
3.4 BELT ............................................................................ 33
3.4.1 General details ............................................. 33
3.4.2 Connection values ........................................ 34
3.4.3 Operating conditions .................................... 35
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3.4.4 Lubricants .....................................................36

3.4.5 Water-cooled compressors (optional)...........36
3.5 DIRECT ........................................................................37
3.5.1 General details..............................................37
3.5.2 Output values................................................37
3.5.3 Connection values ........................................38
3.5.4 Operating conditions .....................................39
3.5.5 Lubricants .....................................................39
3.6 GEAR ...........................................................................40
3.6.1 General details..............................................40
3.6.4 Lubricants .....................................................42
3.7 VARIABLE ....................................................................44
3.7.1 General details..............................................44
3.7.2 Output values................................................45
3.7.5 Lubricants .....................................................47
4 Construction and function ..................................................49

4.1 Overview ......................................................................49
4.2 Brief description ...........................................................52
4.3 Component description ................................................52
4.3.1 Switch cabinet...............................................52
4.3.2 Controller ......................................................53
4.3.3 Sound insulation covers ...............................53
4.3.4 Drive unit .......................................................54
4.3.5 Intake filter ....................................................54
4.3.6 Compressor stage ........................................55
4.3.7 Coolant liquid pressure tank .........................55
4.3.8 Fine precipitator ............................................56
4.3.9 Minimum pressure and return valve .............56
4.3.10 Cooler ...........................................................57
4.3.11 Coolant liquid filter ........................................58
4.3.12 Cooling air ventilator .....................................58
4.4 Interfaces .....................................................................59
5 Transportation, packaging and storage.............................61
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5.1 Safety instructions for transportation ........................... 61

5.2 Transportation inspection ............................................ 61
5.3 Packaging .................................................................... 62
5.4 Symbols on the packaging........................................... 63
5.5 Transportation .............................................................. 64
5.6 Storage ........................................................................ 64
6 Installation, commissioning and operation ....................... 65

6.1 Safety instructions for the installation and
commissioning ............................................................. 65
6.2 Requirements in the installation location ..................... 67
6.3 Installation .................................................................... 68
6.3.1 Ventilation ..................................................... 68
6.3.2 Water cooling (optional) ............................... 70
6.3.3 Heat reclamation for heating and drinking
water (optional) ............................................. 71
6.3.4 Connection to the compressed air network .. 72
6.3.5 Connecting to the power supply ................... 73
6.4 Checking the coolant liquid level ................................. 74
6.5 Start-up lubrication of the compressor section ............ 75
6.6 Switching on after the initial commissioning ................ 76
6.7 Working after the initial commissioning ....................... 77
6.8 Setting parameters ...................................................... 79
6.9 Measures in case of low compressed air requirement
..................................................................................... 79
7 Operation .............................................................................. 80
7.1 Safety instructions for operation .................................. 80
7.2 Shutdown in emergency situations .............................. 80
7.3 Controller ..................................................................... 81
8 Maintenance ......................................................................... 82
8.1 Safety instructions for maintenance ............................ 82
8.2 Spare parts .................................................................. 85
8.3 Maintenance schedule ................................................. 86
8.4 Maintenance work ........................................................ 88
8.4.1 Checking the electrical connections ............. 88
8.4.2 Checking the coolant liquid level/topping up
the coolant liquid .......................................... 89
8.4.3 Checking the compressor temperature ........ 91
8.4.4 Checking for leaks ........................................ 91
8.4.5 Checking soiling of the cooler ...................... 92
8.4.6 Checking the condensation accumulation .... 92
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8.4.7 Changing the coolant liquid/changing the

coolant liquid filter .........................................94
8.4.8 Re-lubricating the electric motor ...................97
8.4.9 Changing the fine precipitator.......................98
8.4.10 Changing the intake filter ..............................99
8.4.11 Checking the drive unit ...............................100
8.5 Measures after maintenance has been performed ....101
9 Faults ...................................................................................102
9.1 Safety instructions for fault clearance ........................102
9.2 Fault displays .............................................................105
9.3 Fault table ..................................................................106
9.4 Work for fault clearance .............................................109
9.5 Commissioning after remedied fault ..........................109
10 Dismantling and disposal ..................................................110

10.1 Safety instructions for dismantling and disposal ........110
10.2 Dismantling ................................................................111
10.3 Disposal 111
11 Index ....................................................................................112
12 Appendix .............................................................................116
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General information
1 General information
1.1 Information about this manual
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.
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General information
1.2 Explanation of symbols

Safety instructions The safety instructions provided in this manual are marked by symbols.
The safety instructions are introduced by keywords used to express the
extent of the danger.
Strictly adhere to all safety instructions and use caution to prevent
accidents, personal injury and material damage.
DANGER!
This combination of symbol and keyword points to a
situation of immediate danger which may lead to serious
injury or death unless avoided.
WARNING!
situation of possible danger which may lead to serious
injury or death unless avoided.
CAUTION!
possibly dangerous situation which may lead to slight or
minor injury unless avoided.
NOTICE!
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.
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General information
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 instructions
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.
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
1., 2., 3., … Identifies step-by-step instructions.
 Identifies a state or automatic sequence as result of

steps.
Identifies references to chapters in this manual and

to other valid documents.
Identifies random numerations and list entries.
[Key] Indicates names of keys, buttons and other oper-

ating controls.
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General information
1.3 Limitation of liability

All specifications and instructions in this manual have been compiled
taking account of applicable standards and regulations, the current state of
technology and the experience and insights we have gained over the
years.
The manufacturer accepts no liability for damage due to:
 Failure to observe this manual
 Improper use
 Deployment of untrained personnel
 Unauthorised modifications
 Technical modifications
 Use of unauthorised spare parts
The actual scope of supply may differ from the explanations and depictions
in this manual in the case of special designs, take-up of additional ordering
options, or as a result of the latest technical modifications.
The undertakings agreed in the supply contract as well as the manufac-
turer's Terms and Conditions and Terms of Delivery and the legal regula-
tions applicable at the time of conclusion of the contract shall apply.
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.
1.5 Warranty terms

The warranty terms are included in the manufacturer's Terms and
Conditions.
1.6 Customer service

Our customer service division is available to provide technical infor-
mation. See page 2 for contact details.
In addition, our employees are always interested in acquiring new
information and experience gained from practical application; such
information and experience may help improve our products.
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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.
2.1 Proper use

The machine is designed and constructed exclusively for the proper
use described here.
The screw compressor serves exclusively to generate compressed

air in an environment not subject to explosion. The screw com-
pressor may be supplied exclusively with cool, dry and dust-free
cooling air.
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
situations.
- 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 outdoors.
- The screw compressor or individual components may
not be rebuilt, modified or re-equipped.
- The screw compressor may not be used in an
atmosphere subject to explosion.
- The intake of media other than cool, dry and dust-free
cooling air is forbidden.
Claims of any type for damage due to misuse are excluded.
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Safety
2.2 Responsibility of the owner

Owner The term 'owner' refers to the person who himself operates the machine
for trade or commercial purposes, or who surrenders the machine to a
third party for use/application, and who bears the legal product liability for
protecting the user, the personnel or third parties during the operation.
Duties of the owner The machine is used in the commercial realm. Therefore, the owner of
the machine is subject to legal occupational safety regulations.
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 owner 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 owner 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 owner must regulate and specify clearly the responsibilities for
the installation, operation, troubleshooting, maintenance and
cleaning.
 The owner 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 owner must provide personnel with the required protective
equipment and instruct them in binding fashion about how to wear
the required protective equipment.
Furthermore, the owner is responsible for ensuring that the machine is
always in technically-perfect condition. Therefore, the following points
apply:
 The owner must ensure that the maintenance intervals described in
these instructions are adhered to.
 The owner must have all safety equipment checked regularly to
ensure that it is functional and complete.
 The owner must ensure that the appropriate media connections are
provided.
 The owner must ensure that the supply of the required quantity of
cool medium (air/water) is guaranteed.
 The owner must ensure that the required heat extraction is guar-
anteed.
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Safety
2.3 Staff requirements

2.3.1 Qualifications
WARNING!
Danger of injury if personnel are insufficiently
qualified!
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
appropriately qualified personnel.
- Unqualified personnel must be kept away from the
danger zones.
This manual specifies the personnel qualifications required for the

different areas of work, listed below:
Forklift driver
The forklift driver must be at least 18 years old and, based on his
physical and intellectual attributes and character, suited to driving
industrial 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 service
department to request the execution of any necessary work. For
address information, refer to page 2.
Qualified electrician
Based on his technical training, knowledge, experience and knowledge
of the applicable standards and regulations, the qualified electrician 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 responsibility
he is involved with and knows the relevant standards and regulations.
The qualified electrician must comply with the requirements of the
applicable legal regulations for accident prevention.
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Safety
Qualified personnel
Qualified personnel is able to carry out assigned work and to recognize
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.
The workforce must only consist of persons who can be expected to

carry out their work reliably. Persons with impaired reactions due to, for
example, the consumption of drugs, alcohol, or medication are prohib-
ited.
When selecting personnel, the age-related and occupation-related
regulations governing the usage location must be observed.
2.3.2 Unauthorised persons
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
The personnel must be trained regularly by the customer. For better
tracing, the execution of the training must be logged ( Appendix A
‘Training log’ on page 117).
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Safety
2.4 Personal protective equipment

Personal protective equipment is used to protect the personnel from
dangers which could affect their safety or health while working.
The personnel must wear personal protective equipment while carrying
out the different operations at and with the machine. This equipment will
be indicated separately in the individual chapters of this manual. This
personal protective equipment is described below:
 It is mandatory to put on the personal protective equipment specified
in the different chapters of this manual before starting work.
 Always comply with the instructions governing personal protective
equipment posted in the work area.
Description of the personal

protective equipment
Ear protection
Ear protection provides protection against hearing damage.
Light respiratory protection

Light respiratory protection is used to protect against harmful dusts.
Protective gloves
Protective gloves protect hands from friction, abrasion, puncture
wounds, or deeper injuries, as well as from contact with hot surfaces.
Protective work clothing

Protective clothing are tight fitting working clothes with low tear re-
sistance, 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 goggles
The protective goggles protect the eyes from flying parts and liquid
splashes.
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Safety
2.5 Basic dangers

The following section specifies residual risks which may result from
using the machine and have been established by means of a risk as-
sessment.
In order to minimize health hazards and avoid dangerous situations,
follow the safety instructions specified here as well as in the following
chapters of this manual.
2.5.1 General dangers in the workplace
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 vicinity
of any area where liquid could accumulate on the floor.
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Safety
2.5.2 Dangers due to electric energies
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
insulation or individual components can be fatal.
- Only allow qualified electricians to work on the
electrical 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
correct current intensity information when replacing
fuses.
- 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
2.5.3 Dangers due to mechanical elements
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.
Sharp edges and pointed corners

CAUTION!
Danger of injury posed by sharp edges and pointed
corners!
Sharp edges and pointed corners may cause skin grazes
and cuts.
- Proceed with caution when working in the vicinity of
sharp edges and pointed corners.
- If in doubt, wear safety gloves.
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Safety
2.5.4 Dangers due to hydraulic energies
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
accidental 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.
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
accumulator 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 released.
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Safety
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
handling 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
pressure, make sure the pressure is relieved.
- Have faulty components that are under pressure
during operation replaced by appropriate specialist
personnel immediately.
- Before all work, make sure that the compressor is not
under pressure; wait at least 5 minutes.
Coolant liquid fog

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.
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Safety
2.5.5 Dangers due to high temperatures
Hot surfaces
WARNING!
Danger of injury from hot surfaces!
Surfaces of components can heat up a lot during
operation. 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
cooled 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
operation. 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
2.6 Safety equipment
WARNING!
Danger to life from nonfunctional safety devices!
If safety devices are not functioning or are disabled, there
is a danger of serious 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.
2.6.1 Position of the safety equipment

The following illustration shows the position of the safety equipment.
Fig. 1: Position of the safety equipment
1 Main switch with emergency off function

2 Emergency stop key
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Safety
2.6.2 Description of the installed safety devices
Main switch with emergency off

function
The main switch is also set up as an emergency stop switch. By turning
the main switch to the "0" position, the machine is stopped by switching
off the power immediately and an emergency stop is thus triggered.
WARNING!
Danger to life from an unauthorised restart!
An uncontrolled restart of the machine may cause serious
injuries including death.
- 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
Fig. 2: Main switch properly.
- Only turn the main switch to the "l" position when there
is no more danger.
Emergency stop key

By pressing the emergency stop key, the machine is stopped by an
immediate switching off of the power supply. After an emergency stop
key has been pressed, it must be unlocked by turning it so that a
switching on is possible.
WARNING!
An uncontrolled restart of the machine may cause serious
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 equipment
for the areas under pressure such as the boiler, pressure tank, pipes,
transport container. In case of an impermissible pressure increase,
safety valves bleed off gases, vapours or liquids into the atmosphere.
Fig. 4: Safety valve
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Safety
2.7 Securing to prevent restart
WARNING!
Life-threatening danger if restarted without
authorisation or due to uncontrolled restart!
Uncontrolled or unauthorised switching on of the machine
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.
Securing to prevent restart

1. Switch off the power supply. To do this, turn the main switch to the
"0" position.
2. Secure the main switch with a padlock (Fig. 5).
3. Have a responsible employee keep the key for the padlock.
4. After all work has been performed, make sure that there are no
dangers to people.
5. Ensure that all safety and protective equipment is installed and

functional.
WARNING!
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 injured
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.
6. Remove the padlock from the main switch.
If no main switch is installed, proceed as follows.
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Safety
WARNING!
authorisation or due to uncontrolled restart!
Uncontrolled or unauthorised switching on of the machine
can cause severe or fatal injuries.
personnel.
- Always adhere to the procedure described below to
secure against restart.
Securing to prevent restart 1. Switch off the power supply.
2. Inform responsible people about work in the danger zone.
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.
5. Ensure that all safety and protective equipment is installed and

functional.
WARNING!
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.
6. Remove the sign.
26 2015-03-13
Safety
2.8 Behaviour in case of fire or accidents

Preventive measures  Be prepared for fire and accidents at all times!
 Keep first-aid equipment (first-aid kit, blankets, etc.) and fire
extinguishing devices operational and readily available.
 Make your personnel familiar with accident reporting equipment as
well as first-aid and rescue equipment.
 Keep access paths clear for rescue vehicles.
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.
 Alert the fire department and/or emergency medical services.
 In case of fire: provided your own health is not in danger, extinguish
the fire using fire extinguishing equipment and continue to do so
until the fire department arrives.
 Notify the person in charge at the machine's place of installation.
 Clear access paths for rescue vehicles.
 Wave rescue vehicles into position.
2015-03-13 27
Safety
2.9 Environmental protection
NOTICE!
Danger to the environment from incorrect handling of
pollutants!
Incorrect handling of pollutants, particularly incorrect
waste disposal, may cause serious damage to the
environment.
- 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.
The following pollutants are used:
Coolant liquid Coolant liquids can contain poisonous substances and substances that
are harmful to the environment. They must not be allowed to escape
into the environment. Disposal must be carried out by a specialist
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 specialised 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
obscured 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
condition.
- Damaged signs or stickers must be replaced
immediately.
2.10.1 Warning signs
Electrical voltage
Only qualified electricians are permitted to work in a work room marked
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
2.10.2 Instructions on the machine
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 This sticker is on the switch cabinet and contains brief instructions for
commissioning commissioning.
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Technical data
3 Technical data
3.1 Type plate
Fig. 6: 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
3.2 Emissions
Noise emissions The values for noise emission are included in the
enclosed data sheet.
32 2015-03-13
Technical data
3.3 Coolant liquid

The following coolant liquids are tested and approved for use in ALMiG
compressors:
Designation Type Order number

Standard coolant liquid (semi-synthetic) ALUB BLUE S+ 583.04055
(10l container)
Synthetic coolant liquid ALUB Syn S 583.00004

(10l container)
Food-compatible coolant liquid ALUB Food H1 583.04010

(10l container)
Biodegradable coolant liquid ALUB GREEN S 583.10051

(10l container)
For high temperature systems, only fully synthetic coolant

(ALUB Syn S) is suitable.
3.4 BELT
3.4.1 General details
BELT 38 – 132
BELT Nominal Weight Length Width Height

motor output
kW kg mm mm mm
38 38 880 1750 1080 1600
45 45 1100 1750 1080 1600
55 55 1170 1750 1080 1600
76 76 2020 2300 1400 1860
90 90 2150 2300 1400 1860
110 110 2300 2300 1400 1860
132 132 2700 2600 1400 1860
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Technical data
3.4.2 Connection values
Electrical
BELT 38 – 132
BELT Current at 220 V / Current at 400 V / Current at 500 V / Max.

60 Hz 50 Hz 50 Hz switching
frequency
IN IFuse IN IFuse IN IFuse
A A gL A A gL A A gL 1/h
38 124 160 68 100 54 100 12
45 147 160 81 125 65 125 10
55 175 200 100 125 79 125 8
76 221 300 133 160 107 160 6
90 279 355 163 200 129 200 5
110 342 400 196 250 158 224 4
132 401 500 233 315 185 300 4
IN = nominal current
IFuse = building-side fuse
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Technical data
Air supply and cooling
BELT 38 – 132
BELT Compressed Heat Cooling air Supply air Cross-section

air connection reclamation / quantity (LK) opening air outlet duct
cooling water
connection
3 2 2
G / DN G m /h m m
38 1 ½ 1 5600 0.65 0.40
45 1 ½ 1 5800 0.70 0.45
55 1 ½ 1 7500 0.70 0.45
76 2 ½ 1 17 100 1.90 1.10
90 2 ½ 1 17 100 1.90 1.10
110 2 ½ 1 ½ 17 100 1.90 1.10
132 2 ½ 1 ½ 18 000 2.00 1.10
3.4.3 Operating conditions
Environment Data Value Unit
Temperature range +5 to +40 °C
Relative humidity, maximum 60 %
Maximum installation height above sea 1000 m

level
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Technical data
3.4.4 Lubricants
BELT 38 – 132
BELT Lubricant Fill level Unit

38 Coolant liquid 25 l
3.4.5 Water-cooled compressors (optional)
BELT 38 – 132
BELT Weight Cooling Cooling water stream for supply/ Cooling

air return temperature water
quantity connection
10/40 °C 25/40 °C 35/45 °C
3 3 3 3
kg m /h m /h m /h m /h G
38 860 3000 1.20 2.40 3.20 1
45 1080 3000 1.40 2.80 3.80 1
55 1150 3000 1.70 3.30 4.40 1
76 2000 3000 2.40 4.80 5.50 1
90 2130 3000 2.90 5.60 7.60 1
110 2300 3000 3.60 7.00 9.40 1 ½
132 2700 6000 4.30 8.5 11.30 1 ½
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Technical data
3.5 DIRECT
Screw compressor with direct drive Type 37 – 90
Type Nominal Weight Length Width Height

motor output
kW kg mm mm mm
37 37 1000 1750 1080 1600
45 45 1100 1750 1080 1600
75 75 1970 2300 1400 1860
90 90 2200 2300 1400 1860
3.5.2 Output values
DIRECT 37 – 90
DIRECT Operating overpressure
bar
37 7.5
45 10
75 11
90 13
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Technical data
Electrical
DIRECT 37 – 90
DIRECT Current at 220 V / Current at 400 V / Current at 500 V / Max.

60 Hz 50 Hz 50 Hz switching
frequency
37 124 160 68 100 54 63 15
45 147 200 81 125 65 80 12
75 221 300 133 160 107 125 6
90 279 355 163 200 129 160 5
DIRECT 37 – 90
DIRECT Compressed Heat Cooling air Supply air Cross-section

air connection reclamation / quantity (LK) opening air outlet duct
cooling water
connection
3 2 2
G / DN G m /h m m
37 1 ½ 1 5600 0.60 0.35
45 1 ½ 1 5800 0.60 0.35
75 2 ½ 1 17 100 1.90 1.10
90 2 ½ 1 17 100 1.90 1.10
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Technical data
Maximum installation height above sea level 1000 m
3.5.5 Lubricants
DIRECT 37 – 90
DIRECT Lubricant Fill level Unit

DIRECT 37 – 90
Type Weight Cooling Cooling water stream for supply/return - Cooling

air temperature water
quantity connection
10/40 °C 25/40 °C 35/45 °C
3 3 3 3
37 1000 3000 1.20 2.40 3.20 1
45 1100 3000 1.40 2.80 3.80 1
75 1970 3000 2.40 4.80 5.50 1
90 2200 3000 2.90 5.60 7.60 1
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Technical data
3.6 GEAR
GEAR 30 – 110
GEAR Nominal motor Weight Length Width Height

output
kW kg mm mm mm
30 30 920 1750 1080 1600
37 37 980 1750 1080 1600
45 45 1100 1850 1080 1600
55 55 1250 1950 1080 1600
75 75 1270 1950 1080 1600
90 90 2700 2600 1400 1860
110 110 2950 2600 1400 1860
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Technical data
Electrical
GEAR 30 – 110
GEAR Current at 220 V / Current at 400 V / Current at 500 V / Max.

60 Hz 50 Hz 50 Hz switch
frequency
30 96 125 57 80 44 63 15
37 124 160 67 100 54 63 12
45 147 160 81 125 65 80 10
55 175 200 98 125 79 100 8
75 221 300 133 160 107 125 6
90 - - 163 200 129 160 5
110 - - 199 250 157 200 4
GEAR Compressed Heat Cooling air Supply air Cross section

air connection reclamation/ quantity (LK) opening of exhaust air
cooling water duct
connection
3 2 2
G / DN G m /h m m
30 1 ½ 1 5600 0,65 0,40
45 1 ½ 1 5600 0,65 0,40
55 1 ½ 1 5800 0,70 0,40
75 1 ½ 1 7500 0,70 0,45
76 1 ½ 1 8500 1,15 0,65
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Technical data
GEAR Compressed Heat Cooling air Supply air Cross section

air connection reclamation/ quantity (LK) opening of exhaust air
cooling water duct
connection
3 2 2
G / DN G m /h m m
90 2½ 1 17 100 1,90 1,10
110 2½ 1 17 100 1,90 1,10
3.6.4 Lubricants
GEAR 30 – 110
GEAR Lubricant Fill level Unit

42 2015-03-13
Technical data
GEAR 30 – 110
GEAR Weight Cooling Cooling water stream for supply/ Cooling

air return temperature water
quantity connection
10/40 °C 25/40 °C 35/40 °C
3 3 3 3
30 900 3000 0.9 1.9 2.6 1
37 960 3000 1.2 2.4 3.2 1
45 1080 3000 1.4 2.8 3.8 1
55 1230 3000 1.7 3.3 4.4 1
75 1250 3000 2.4 4.8 5.5 1
90 2700 3000 2.9 5.6 7.6 1
110 2950 3000 3.6 7.0 9.4 1 ½
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Technical data
3.7 VARIABLE
VARIABLE 35 – 130
VARIABLE Nominal Weight Length Width Height

motor output
kW kg mm mm mm
35 40 940 2090 1080 1600
37 50 980 2090 1080 1600
55 60 1160 2090 1080 1600
65 80 1240 2090 1080 1600
70 85 1270 2090 1080 1600
90 100 2050 2300 1400 1860
115 115 2200 2300 1400 1860
130 130 2200 2300 1400 1860
44 2015-03-13
Technical data
3.7.2 Output values
VARIABLE 35 – 130
VARIABLE Operating overpressure
bar
35 5 – 13
37 5 – 13
55 5 – 13
65 5 – 13
70 5 – 13
90 5 – 13
115 5 – 13
130 5 – 13
2015-03-13 45
Technical data
Electrical
VARIABLE 35 – 130
VARIABLE Current at 400 V / 50 Hz
IN IFuse
A A gL
35 68 100
37 81 125
55 100 125
65 134 160
70 161 200
90 161 200
115 196 250
130 231 315
Variable Compressed Heat Cooling air Supply air Cross section

air reclamation/ quantity (LK) opening of exhaust air
connection cooling water duct
connection
3 2 2
G / DN G m /h m m
35 1 ½ 1 5600 0,65 0,40
37 1 ½ 1 5800 0,70 0,40
55 1 ½ 1 7500 0,70 0,45
65 1 ½ 1 8500 1,15 0,70
46 2015-03-13
Technical data
Variable Compressed Heat Cooling air Supply air Cross section

air reclamation/ quantity (LK) opening of exhaust air
connection cooling water duct
connection
3 2 2
G / DN G m /h m m
70 1 ½ 1 8500 1,20 0,70
90 2½ 1 17 100 1,90 1,10
115 2½ 1 17 100 1,90 1,10
130 2½ 1 18 000 1,90 1,10
3.7.5 Lubricants
VARIABLE 35 – 130
VARIABLE Lubricant Fill level Unit

2015-03-13 47
Technical data
VARIABLE 35 – 130
VARIABLE Weight Cooling Cooling water stream for supply/return Cooling

air temperature water
quantity connection
10/40 °C 25/40 °C 35/45 °C
3 3 3 3
35 920 3000 0,90 1,90 2,60 1
37 960 3000 1,30 2,60 3,46 1
55 1140 3000 1,85 3,60 4,80 1
65 1220 3000 2,90 5,70 7,60 1
70 1250 3000 2,90 5,70 7,60 1
90 2050 3000 3,20 6,40 8,50 1
115 2200 3000 3,68 7,90 9,80 1½
130 2200 3000 4,40 8,50 11,30 1½
48 2015-03-13
Construction and function
4 Construction and function

4.1 Overview
The following presents an overview of the screw compressors de-
scribed in these instructions. The compressors distinguish themselves
primarily through their size and the installed drive. However, their basic
structure is the same. From the outside, they distinguish themselves
only through the position of the switch cabinet.
Screw compressor with integrated

switch cabinet
Fig. 7: Screw compressor with integrated switch cabinet (BELT, DIRECT,

GEAR and VARIABLE 90 – 130)
1 Controller
2 Emergency stop key/main switch with emergency stop function
3 Switch cabinet
4 Sound insulation covers
2015-03-13 49
Screw compressor with attached

switch cabinet
Fig. 8: Screw compressor with attached switch cabinet (VARIABLE 35 – 70)
1 Controller
2 Switch cabinet
3 Emergency stop key/main switch with emergency stop function
4 Sound insulation covers
50 2015-03-13
Components The basic structure is the same for all screw compressor
variants. The position of the components can vary from
the illustration.
Fig. 9: Overview of the components
1 Intake filter
2 Compressor stage
3 Cooling air ventilator
4 Drive unit
5 Coolant liquid pressure tank
6 Coolant liquid filter
7 Minimum pressure and return valve
8 Coolant liquid cooler
9 Compressed air connection
10 Compressed air after-cooler
11 Fine precipitator
2015-03-13 51
4.2 Brief description

The fresh air supplied by the installed cooling air ventilator is filtered
through the intake filter. The air streams over the intake regulator into
the compressor stage, where it is compressed together with the in-
jected coolant liquid to the final pressure. The compressed air is largely
separated from the coolant liquid in the coolant liquid pressure tank.
The subsequent fine precipitator removes the remaining coolant liquid
from the compressed air. The compressed air then streams over the
minimum pressure and return valve into the compressed air after-cooler
and is cooled down before it leaves the screw compressor via the
compressed air connection.
The coolant liquid is separated from the compressed air in the coolant
liquid pressure tank and the fine precipitator and streams to the coolant
liquid cooler. The coolant liquid temperature regulator adds the
cooled-off coolant liquid to the hot coolant liquid via the coolant liquid
cooler bypass according to the set point temperature. Finally, the
coolant liquid filter cleans the coolant liquid before it is injected into the
compressor stage once again.
4.3 Component description

4.3.1 Switch cabinet
The switch cabinet houses the electrical equipment. The main switch
and the emergency stop key are on the outside of the switch cabinet
(Fig. 10/3) and the controller (Fig. 10/1) for the machine. Only a quali-
fied electrician may open the switch cabinet with the included two-way
spanner. The two switch cabinet filters (Fig. 10/2) ensure a constant air
exchange inside the switch cabinet.
Fig. 10: Switch cabinet operating elements

and switch cabinet filter
52 2015-03-13
4.3.2 Controller
Controller variants
For the controller variant installed, please consult the
label on the controller. For detailed information about the
controller installed, consult the separate  Controller
documentation.
4.3.3 Sound insulation covers
Only qualified personnel may remove the sound insulation covers

(Fig. 11/1) with the included special spanner. Sound insulation covers
are a part of the electric shock protection.
Fig. 11: Sound insulation covers
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4.3.4 Drive unit

Various drive units are installed in the screw compressors, which dis-
tinguish themselves through their structure, their output values and
their functional principle as follows:
BELT DIRECT, GEAR and VARIABLE
 With the BELT, the drive takes  With the DIRECT, the drive takes place using a clutch.
place using a fan belt.  With the GEAR, the drive takes place using a transmission.
 With the VARIABLE, the electric motor of the frequency
converter in the switch cabinet is speed-controlled. With the
VARIABLE, the drive also takes place directly using a clutch.
4.3.5 Intake filter

There are two types of intake filters that are installed in the screw
compressors. Depending on the option and size, a standard intake filter
or a high-performance intake filter is installed.
Standard intake filter High-performance intake filter
The standard intake filter sits directly above or The high-performance intake filter is attached above the
to the side of the compressor stage. compressor stage.
54 2015-03-13
4.3.6 Compressor stage
The air taken in is compressed by the compressor stage (Fig. 12/1) and
added to the coolant liquid pressure tank (Fig. 12/2) together with the
injected coolant liquid.
Fig. 12: Compressor stage
4.3.7 Coolant liquid pressure tank
1 Coolant liquid pressure tank

2 Filler plugs
3 Inspection glass
4 Coolant liquid drain
5 Safety valves
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.
Fig. 13: Coolant liquid pressure tank with
safety valves Coolant liquid heating (optional)
Coolant liquid heating can be installed in the coolant liquid
pressure tank at the factory or after the fact. It prevents
condensate damage and the freezing of the condensate,
e.g. for a screw compressor that is set up in the cold or the
humidity.
2015-03-13 55
4.3.8 Fine precipitator
Depending on the type of the screw compressor, several

fine precipitators can be installed.
The fine precipitator (Fig. 14/1) removes the remaining coolant liquid
from the compressed air.
Fig. 14: Fine precipitator
4.3.9 Minimum pressure and return valve
The minimum pressure and return valve (Fig. 15/1) 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.
Fig. 15: Minimum pressure and return

valve
56 2015-03-13
4.3.10 Cooler
The compressed air is cooled off in the compressed air after-cooler

(Fig. 16/3) before it leaves the screw compressor via the compressed
air connection (Fig. 16/1).
The coolant liquid is cooled off by the coolant liquid cooler (Fig. 16/2)
and fed back into the coolant circuit.
Fig. 16: Cooler
Heat reclamation and water cooling (optional)

The heat exchangers in question are incorporated into the
coolant liquid circuit of the screw compressor and transfer
the heat arising from the compression from the coolant
liquid to the water.
Fig. 17: Heat reclamation (optional)
2015-03-13 57
4.3.11 Coolant liquid filter
The coolant liquid filter (Fig. 18/1) cleans the coolant liquid before it is
injected into the compressor stage once again.
Fig. 18: Coolant liquid filter
4.3.12 Cooling air ventilator
Depending on the type, two different cooling air

ventilators are installed.
Cooling air ventilator
The cooling of the compressed air after-cooler and of the coolant liquid
after-cooler is handled by the cooling air ventilator. The cooling air
ventilator also supplies the intake filter with sufficient intake air.
Water-cooled screw compressors

With water-cooled screw compressors, a fresh air
ventilator ensures sufficient fresh intake air and the
removal of the radiation heat.
58 2015-03-13
4.4 Interfaces
Fig. 19: Flow chart
The following interfaces are in the screw compressor:

 Air supply
 Cooling air ventilator
 Intake filter
 Compressed air connection
 Water cooling and heat reclamation (optional)
 Water intake
 Water outlet
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.
Fig. 20: Cooling air ventilator and intake

filter
2015-03-13 59
Compressed air connection

The air compressed by the compressor is available to the compressed
air network at the compressed air connection after it has been filtered.
Fig. 21: Compressed air connection
Water cooling and heat reclamation

(optional)
The cooling water required for the water cooling is used via the water
intake to cool the system. After the cooling process, the cooling water is
output again via the water outlet.
The water required for the hear reclamation (WRG) is used via the
water intake to cool the system. After the cooling process, the heated
water is output again via the water outlet.
The water circuit for WRG is only released after the

operating temperature is reached. Changes to the pre-set
temperature cause a voiding of the warranty.
Fig. 22: Water connection
60 2015-03-13
Transportation, packaging and storage
5 Transportation, packaging and storage

5.1 Safety instructions for transportation
Improper transport
NOTICE!
Damage to property due to improper transport!
Transport units may fall or tip over as a result of improper
transport. This can cause a significant level of property
damage.
- Proceed carefully when unloading transport units at
delivery and during in-house transport; observe the
symbols and instructions on the packaging.
- Only use the attachment points provided.
- Only remove the packaging shortly before assembly.
5.2 Transportation inspection

On receipt, immediately inspect the delivery for completeness and
transport damage.
Proceed as follows in the event of externally apparent transport dam-
age:
 Do not accept the delivery, or only accept it subject to reservation.
 Note the extent of the damage on the transport documentation or
the shipper's delivery note.
 Initiate complaint procedures.
Issue a complaint in respect of each defect immediately

following detection. Damage compensation claims can
only be asserted within the applicable complaint
deadlines.
2015-03-13 61
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.
Therefore, do not destroy the packaging and only remove it shortly
before assembly.
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 regulations.
If necessary, outsource the disposal to a specialist
company.
62 2015-03-13
5.4 Symbols on the packaging

The following symbols are on the packaging. Always adhere to these
symbols during transportation.
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.
Protect against moisture

Protect packages against moisture and keep dry.
2015-03-13 63
5.5 Transportation
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.
Transporting Personnel:  Forklift driver
1. Drive the fork lift with the forks as shown in Fig. 23.
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 centre
of gravity.
4. Lift the transport piece and begin the transport.
Fig. 23: Transport with a fork lift
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.
Under some circumstances there may be notes about

storage on the packaging pieces that extend beyond the
requirements named here. Adhere to these accordingly.
64 2015-03-13
Installation, commissioning and operation
6 Installation, commissioning and operation

6.1 Safety instructions for the installation and commissioning
Electrical system
DANGER!
Danger to life from electric power!
Contact with live parts may prove fatal. When switched
on, electric components can be subject to uncontrolled
movements and may cause grave injury or death.
- Switch off the power supply before starting work and
make sure that it cannot be switched on again.
Improper initial commissioning

WARNING!
Danger of injury due to improper initial
commissioning!
Improper initial commissioning can result in serious injury
and significant damage to property.
- Before the initial commissioning, ensure that all
installation work has been carried out and completed
in accordance with the information and instructions in
this manual.
- Ensure that no persons are in the danger zone before
the initial commissioning.

WARNING!
In the event of an unauthorised restart of the power
supply during installation, there is a danger of serious
injuries or death for persons in the danger zone.
- Switch off all power supplies before starting work and
make sure they cannot be switched on again.
2015-03-13 65
Improper installation and

WARNING!
commissioning
Risk of injury due to improper installation or
commissioning!
Improperly performed installation and commissioning
may lead to serious injury and significant material
damage.
- Provide for sufficient mounting clearance before
starting to work.
- Use caution when handling exposed components with
sharp edges.
- Keep the assembly area tidy and clean! Loose
components and tools lying around or on top of each
other may lead to accidents.
- Mount all components properly. Tighten all screws to
the prescribed torque.
- Secure components to prevent them from falling down
or tipping over.
- Observe the following prior to commissioning:
- make sure that all installation work has been
performed and completed following the instructions
and information provided in this manual.
- make sure that no persons are still in the danger
zone of the machine.
66 2015-03-13
6.2 Requirements in the installation location

Set up the screw compressor so that the following conditions are
fulfilled:
 The installation location is level.
 The secure standing of the machine is guaranteed.
 The machine is easily accessible and can be accessed from all
sides.
 There is sufficient lighting.
 There is sufficient ventilation.
 There is a power supply available.
 Escape paths and rescue equipment are freely accessible.
 The machine is not subjected to an explosive atmosphere.
 The machine is not subjected to a corrosive atmosphere.
 The machine is not subjected to direct solar radiation.
 Outside heating from surrounding heat sources is excluded.
 There is no dust accumulation.
 Fire protection measures have been taken.
 The machine is not subjected to vibrations.
 The surface is resistant to solvents, impermeable to liquids,
anti-static and easy to clean.
 There are no machines in the vicinity that cause electrical or
electromagnetic disturbance.
2015-03-13 67
6.3 Installation
6.3.1 Ventilation
DANGER!
Danger to life from the use of explosive gas mixtures,
vapours, dust or aggressive hazardous substances!
The use of explosive gas mixtures, vapours, dust or
aggressive 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
ventilation of the screw compressor.
The air supplied via the intake openings is used for compression and
system cooling.
Personnel:  Qualified personnel
Protective equipment:  Safety boots

 Protective work clothing
NOTICE!
Material damage due to condensation!
Due to cooling air that is too hot or too humid, condensate
can arise.
- Only provide cool, dry and dust-free cooling air.
- For the intake of outside air, use a recirculating air flap.
1. Provide the required quantity of cooling air according to the tech-

nical data for the screw compressor ( Chapter 3 ‘Technical data’
on page 32).
2. Extract the exhaust air according to the technical data for the
screw compressor ( Chapter 3 ‘Technical data’ on page 32).
 This way, you prevent the installation room and the screw
compressor from heating up.
Fig. 24: Overview illustration of cooling air

ventilator
68 2015-03-13
Forced ventilation and bleeding The forced ventilation and bleeding must be dimensioned
(optional) so that the required supply and exhaust air can be
supplied and extracted taking into account the existing
residual thrust from the cooling air ventilator. The exhaust
air can also be used for heat reclamation.

1. For the nominal diameters of the duct connections and details

about residual thrust refer to the technical data ( Chapter 3
‘Technical data’ on page 32) and the installation diagrams in-
cluded in the scope of delivery.
2. When connecting air ducts include the appropriate additional

supporting fans for installation in the ducts.
Fig. 25: Overview illustration of air duct

connection
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6.3.2 Water cooling (optional)
For water-cooled systems, the compressed air

after-cooler and the coolant liquid cooler are cooled with
external cooling water.
The cooling water must fulfil the following criteria:
Data Value Unit
Input temperature max. +35 °C
Pre-pressure 4 – 10 bar
Pre-filtering with mesh width 0.1 – 0.3 mm
Fig. 26: Water cooling

Electrical conductivity 10 – 500 µS/cm
pH–value 7.0 – 9.0
Total hardness 0.716 – 1.52 mMol/l
Solenoid valve
An solenoid valve (optional) must be attached upstream
of the cooling water inlet.

1. Connect the cooling water connections with flexible and wa-

ter-resistant hoses  Chapter 3 ‘Technical data’ on page 32.
Fig. 27: Cooling water connections
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6.3.3 Heat reclamation for heating and drinking water (optional)
Screw compressors can be equipped with an optional

heat reclamation function for heating water or with an
optional heat reclamation function for drinking water
(safety heat exchanger with blocking medium).
The water must fulfil the following criteria:
Data Value Unit
Pre-pressure 4 – 10 bar
Minimum mesh width for pre-filtering 0.1 mm

Fig. 28: Heat reclamation
1. For the water quantity, water temperatures and pressure consult

the technical data ( Chapter 3 ‘Technical data’ on page 32).
2. Connect heat reclamation with the connections.
Fig. 29: Connections for heat reclamation
2015-03-13 71
6.3.4 Connection to the compressed air network

Protective equipment:  Protective work clothing

 Safety boots
Materials:  Flexible compressed air hose, max. 1.5 m
WARNING!
Risk of injury due to unpredictable movement of the
compressed air hose!
Load switches in the compressed air network cause jerky
movements of the compressed air hose with high force.
- Anchor and fasten the compressed air hose
sufficiently.
A properly projected, installed and serviced compressed

air network and an additional stop valve at the input to the
compressed air network are prerequisites for correct
installation.
1. Connect the compressed air according to the technical data

( Chapter 3 ‘Technical data’ on page 32).
2. Ensure that the compressed air hose does not represent a stum-
bling hazard.
3. Anchor and fasten the flexible compressed air hose sufficiently.
Fig. 30: Compressed air connection
72 2015-03-13
6.3.5 Connecting to the power supply

Personnel:  Qualified electrician

 Safety boots
NOTICE!
Risk of material damage to the compressor section
as a result of incorrect connection of the power
supply!
In case of incorrect connection of the power supply, the
compressor section may be destroyed due to a drive
turning incorrectly.
- Connect the power according to the wiring diagram
and check the rotating field before starting the screw
compressor.
The prerequisite for the correct installation are

professionally-dimensioned fuses in the network supply
(person-system protection) and an appropriate main
switch (for switching the supply on and off).
1. Using the data in the wiring diagram (in the switch cabinet), check
whether the existing supply network is suitable. Voltage deviations
of more than 10 % are not permitted.
2. Connect the power according to the included wiring diagram (in the
switch cabinet) and the technical data ( Chapter 3 ‘Technical
data’ on page 32).
3. Check right-rotating direction of rotation with a rotating field

measurement device.
4. Ensure that the power cable does not represent a stumbling hazard.
2015-03-13 73
6.4 Checking the coolant liquid level


 Safety boots
 Protective gloves
1. Switch the machine off and secure to prevent restarting.
2. Open and remove the sound insulation covers with the special
spanner.
3. Check the inspection glass (Fig. 31/1) to make sure it is completely

moist.
4. If necessary, top up coolant liquid Chapter 8.4.7 ‘Changing the

coolant liquid/changing the coolant liquid filter’ on page 94.
Fig. 31: Inspection glass
74 2015-03-13
6.5 Start-up lubrication of the compressor section


 Safety boots
NOTICE!
Property damage due to lacking coolant liquid in the
compressor stage!
Lacking coolant liquid in the compressor stage after
longer 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 longer
downtime.
Coolant liquid quantities for direct filling in the compressor stage
Screw compressor Coolant liquid filling

(sorted according to drive unit) l
BELT 38 – 55 2.5
BELT 76 – 132 5.0
DIRECT 37 – 45 2.5
DIRECT 75 – 90 5.0
GEAR 30 – 75 2.5
GEAR 90 – 110 6.0
VARIABLE 35 – 70 2.5
VARIABLE 90 – 130 5.0
2015-03-13 75
1. Loosen the screw plug of the intake regulator (Fig. 32/1).
NOTICE!
Property damage due to incorrect coolant liquid!
Mixing different coolant liquids or using incorrect coolant
liquids causes significant property damage to the screw
compressor.
- Only use the coolant liquid prescribed in the technical
data.
- For high temperature systems, use only fully synthetic
coolant ALUB Syn S.
Fig. 32: Screw plug intake regulator

If there is no additional coolant liquid available, the
coolant liquid will have to be removed using of the coolant
liquid drain  Chapter 8.4.7 ‘Changing the coolant
liquid/changing the coolant liquid filter’ on page 94.
2. Fill coolant liquid in the screw plug of the intake regulator (Fig. 32/1).
3. Tighten the screw plug of the intake regulator (Fig. 32/1)( Appendix B
‘Tightening torques for screws’ on page 118).
6.6 Switching on after the initial commissioning

Protective equipment:  Ear protection

 Safety boots
1. Check the media connections for correct installation.
2. Ensure that no tools or loose objects are in or on the machine.
3. Install and check that the sound installation covers are sealed.
4. Carefully open the gate valve after the compressed air connection
between the screw compressor and the compressed air network.
 The screw compressor is now connected to the compressed air

network.
5. Switch on the main switch.
6. Start the screw compressor  Controller documentation.
 The compressor is ready and can start up automatically at any

time.
76 2015-03-13
6.7 Working after the initial commissioning


 Safety boots
 Light respiratory protection
 Safety goggles
WARNING!
severe skin burns.
30 minutes.
CAUTION!
supply.
1. Switch the screw compressor off and secure to prevent restarting.
spanner.
3. Wait until the components have cooled off.
4. Check all coolant liquid and compressed air lines for leaks.
5. If there is coolant liquid in the system, it must be removed.
6. The connectors of the components must be checked and the

screws tightened  Appendix B ‘Tightening torques for screws’ on
page 118.
2015-03-13 77
7. Check the coolant liquid level in the inspection glass ( Fig. 33/1)
and top up as in  Chapter 8.4.2 ‘Checking the coolant liquid
level/topping up the coolant liquid’ on page 89 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
Fig. 33: Checking the coolant liquid level cause damage to the screw compressor.
in the inspection glass - Contact the manufacturer for more precise
information, for contact information see page 2.
A sufficiently high compressor temperature guarantees

that the humidity taken in will not become condensate.
Frequent switching on and off of the screw compressor
can cause the compressor not to reach the required
operating temperature  Chapter 8.4.6 ‘Checking the
condensation accumulation’ on page 92.
9. Check compressor temperature  Chapter 8.4.3 ‘Checking the

compressor temperature’ on page 91.
78 2015-03-13
6.8 Setting parameters
Refer to the  controller documentation for the setting

work required for the screw compressor.
6.9 Measures in case of low compressed air requirement

Measures
NOTICE!
Risk of material damage in case of an excessively
long downtime!
Frequent operating cycles and a longer system downtime
can cause increased wear.
To prevent damage in case of a low compressed air re-
quirement, take the following measures:
- Adjust the compressor to the actual compressed air
requirement.
- Use a compressed air buffer tank with sufficient
dimensions.
- Perform at least one hour of continuous on-load
operation in the control range every week.
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Operation
7 Operation
7.1 Safety instructions for operation
Improper operation
WARNING!
Danger of injury due to improper operation!
Improper operation can cause serious injury and
significant 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
installed and work properly.
- Ensure that that no one is in the danger zone.
- Never override or bridge safety features during
operation.
7.2 Shutdown in emergency situations

In dangerous situations component movements must be stopped as
quickly as possible and the power supply must be switched off.
Shutdown in emergency situations In an emergency situation proceed as follows:

1. Immediately trigger an emergency stop through the emergency
stop device.
2. If there is no danger to your own health get people out of the

danger zone.
3. Initiate first-aid measures if necessary.
4. Alert the fire department and/or rescue service.
5. Inform the responsible parties at the implementation site.
6. Switch off the machine and safeguard it from being switched on

again.
7. Keep entry ways clear for rescue vehicles.
8. Give directions to rescue vehicles.
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Operation
After the rescue measures 9. Depending on the seriousness of the emergency situation, inform
the responsible government agencies.
10. Assign specialized personal to resolve the malfunction.
WARNING!
authorization or due to uncontrolled restart!
Uncontrolled or unauthorized switching on of the power
supply can cause severe or fatal injuries.
personnel.
11. Prior to restarting the machine check and ensure that all safety
devices are installed and functioning.
7.3 Controller
Controller documentation
Refer to the  controller documentation for information
on how the screw compressor if controlled.
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Maintenance
8 Maintenance
8.1 Safety instructions for maintenance
Electrical system
DANGER!
on, electric components may be subject to uncontrolled
movements and may cause grave injury.
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.

WARNING!
supply during maintenance, there is a danger of serious
injuries or death for persons in the danger zone.
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Maintenance
Hot surfaces
WARNING!
severe skin burns.
30 minutes.
Improperly performed
WARNING!
maintenance
Danger of injury due to improperly performed
maintenance!
Improperly performed maintenance may lead to serious
injury and significant material damage.
- Provide for sufficient mounting clearance before
starting to work.
- Keep the assembly area tidy and clean! Loose
components and tools lying around or on top of each
other may lead to accidents.
- When reinstalling previously removed components,
make sure that the components are mounted properly,
all fixing elements are reinstalled, and all screws are
tightened to torque.
- Before putting the machine back into operation:
- make sure that all maintenance work has been
performed and completed following the instructions
and information provided in this manual.
- make sure that no persons are still in the danger
zone of the machine.
- make sure that all covers and safety devices have
been installed and function properly.
2015-03-13 83
Maintenance
Compressed air
WARNING!
Coolant liquid fog

CAUTION!
supply.
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 vicinity
of any area where liquid could accumulate on the floor.
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Maintenance
Environmental protection Observe the following environmental protection instructions during

maintenance work:
 In respect of all lubrication points supplied manually with lubricant,
remove any escaping, used or surplus grease and dispose of in
accordance with applicable local regulations.
 Catch replaced oils in suitable containers and dispose of in
accordance with applicable local regulations.
8.2 Spare parts
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 manufacturer.
- 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.
Spare parts must be procured through an authorised dealer or directly

from the manufacturer. Contact details, see page 2.
The spare parts list can be found in the Appendix.
2015-03-13 85
Maintenance
8.3 Maintenance schedule

Maintenance tasks are described in the sections below that are re-
quired for optimal and trouble-free machine operation.
If increased wear is detected during regular inspections, then reduce
the required maintenance intervals according to the actual indications
of wear. Contact the manufacturer (see the service address on page 2),
if you have questions concerning maintenance tasks and intervals.
Interval Maintenance work Personnel
Daily Check the coolant liquid level  Chapter 8.4.2 ‘Checking the Qualified personnel
coolant liquid level/topping up the coolant liquid’ on page 89
Check for leaks  Chapter 8.4.4 ‘Checking for leaks’ on page 91 Qualified personnel
One week Check all electrical connections  Chapter 8.4.1 ‘Checking the Qualified electrician
after initial electrical connections’ on page 88
installation
Weekly Check the compressor temperature  controller documentation Trained Person
Check cooler for soiling Chapter 8.4.5 ‘Checking soiling of the Qualified personnel
cooler’ on page 92
Check for condensate formation  Chapter 8.4.6 ‘Checking the Qualified personnel
condensation accumulation’ on page 92
Check drive belts for wear*** Trained Person
After the first Check for leaks  Chapter 8.4.4 ‘Checking for leaks’ on page 91 Qualified personnel
100 hours of
operation Check the compressor temperature  Controller documentation Trained Person
Check cooler for soiling  Chapter 8.4.5 ‘Checking soiling of the Qualified personnel
Check for condensate formation  Chapter 8.4.6 ‘Checking the Qualified personnel
condensation accumulation’ on page 92
After the first Check all electrical connections  Chapter 8.4.1 ‘Checking the Qualified electrician
500 hours of electrical connections’ on page 88
operation
Change coolant liquid  Chapter 8.4.7 ‘Changing the coolant Qualified personnel
liquid/changing the coolant liquid filter’ on page 94
Change coolant liquid filter*  Chapter 8.4.7 ‘Changing the Qualified personnel
coolant liquid/changing the coolant liquid filter’ on page 94
Retighten drive belts*** Qualified personnel
86 2015-03-13
Maintenance
Interval Maintenance work Personnel
Every 2000 Re-lubricate electric motor  Chapter 8.4.8 ‘Re-lubricating the Qualified personnel
hours of electric motor’ on page 97
operation
Every 4000 Change coolant liquid*  Chapter 8.4.7 ‘Changing the coolant Qualified personnel
hours of op- liquid/changing the coolant liquid filter’ on page 94
eration, at
,
least once a Change coolant liquid filter* **  Chapter 8.4.7 ‘Changing the Qualified personnel
year coolant liquid/changing the coolant liquid filter’ on page 94
Change fine precipitator*  Chapter 8.4.9 ‘Changing the fine Qualified personnel
precipitator’ on page 98
Change intake filter*  Chapter 8.4.10 ‘Changing the intake Qualified personnel
filter’ on page 99
Check safety valve Manufacturer
Check drive unit  Chapter 8.4.11 ‘Checking the drive unit’ on Qualified personnel
page 100
Re-lubricate electric motor  Chapter 8.4.8 ‘Re-lubricating the Qualified personnel

electric motor’ on page 97
General compressor maintenance Manufacturer
Check tension of drive belt*** Qualified personnel
Every 8000 Replace drive belt*** Qualified personnel

hours of
operation
* The change intervals refer to:

 Ambient temperature of +40 °C
 Max. humidity of 60%
 Compressor temperature of approx. 85 °C
** On high-temperature plants reduce the indicated maintenance in-
tervals by 20%.
***On systems with belt drive
2015-03-13 87
Maintenance
8.4 Maintenance work
Necessary maintenance work

Necessary maintenance work appears on the display of
the controller as a warning  Controller documentation.
8.4.1 Checking the electrical connections

Personnel:  Qualified electrician

 Safety goggles
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.
2. Close compressed air network-side gate valve and secure against

re-opening.
spanner.
4. Check all electrical connections and tighten if necessary

 Appendix B ‘Tightening torques for screws’ on page 118.
88 2015-03-13
Maintenance
8.4.2 Checking the coolant liquid level/topping up the coolant liquid
Checking the coolant liquid level Personnel:  Qualified personnel

 Safety goggles

re-opening.
spanner.
4. Check the inspection glass (Fig. 34/1) to make sure it is completely

moist.
5. If the whole inspection glass height is not covered with coolant

liquid, the coolant liquid must be topped up.
Fig. 34: Inspection glass
2015-03-13 89
Maintenance
Topping up the coolant liquid Personnel:  Qualified personnel

 Safety goggles
Materials:  Collecting tray for coolant liquid

 Funnel with filling tool

re-opening.
spanner.
4. With the help of a collection tray, make sure that the escaping
coolant liquid is collected.
5. Loosen the filler plug (Fig. 35/1), remove and make sure that the
gasket does not get lost.
NOTICE!
compressor.
data.
Fig. 35: Filler plug
coolant ALUB Syn S.
6. With the help of a funnel (Fig. 36/1), fill coolant liquid up to the
filling edge of the filler plug (Fig. 36/3).
7. Position the gasket and check for correct fit.
8. Insert the screw plug (Fig. 36/2) and tighten  Appendix B

‘Tightening torques for screws’ on page 118.
Fig. 36: Filler plugs
90 2015-03-13
Maintenance
8.4.3 Checking the compressor temperature


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
information, for contact information see page 2.
- The compressor temperature should be between

70 °C and 100 °C.
- At 105 °C a warning is output.
- At 110 °C the screw compressor is switched off
automatically.
1. Check the compressor temperature  Controller documentation.
8.4.4 Checking for leaks


 Safety goggles

re-opening.
spanner.
4. Check all lines and the base for leaks.
5. If there is coolant liquid in the system, remove it.
6. Check the connectors of the components and tighten the screws

 Appendix B ‘Tightening torques for screws’ on page 118.
2015-03-13 91
Maintenance
8.4.5 Checking soiling of the cooler


 Safety goggles

re-opening.
spanner.
4. Check compressed air and coolant liquid cooler from inside and
outside for soiling.
5. Remove soiling.
Soiling can be removed by blowing it out, e.g. While

doing this, make sure that the soiling from the device
is blown out of rather than into the machine. In case
of severe soiling, consult the manufacturer.
8.4.6 Checking the condensation accumulation
A sufficiently high compressor temperature guarantees

that the humidity taken in will not become condensate.
Frequent switching on and off of the screw compressor
can cause the compressor not to reach the required
operating temperature .

 Safety goggles
92 2015-03-13
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.

re-opening.
spanner.
Condensate is heavier than the coolant liquid

Since the condensate is heavier than the coolant liquid,
after longer downtimes, it collects on the bottom of the
coolant liquid pressure tank.
5. Carefully open the coolant liquid drain (Fig. 37/1) and check the
liquid escaping.
6. Slowly drain condensate until coolant liquid escapes.
7. Close  Appendix B ‘Tightening torques for screws’ on page 118

the coolant liquid drain (Fig. 37/1).
8. Switch on the compressor and switch off again after a maximum of

one minute  Controller documentation.
9. Check coolant liquid level and top up if necessary  Chapter 8.4.2

Fig. 37: Coolant liquid drain ‘Checking the coolant liquid level/topping up the coolant liquid’ on
page 89.
2015-03-13 93
Maintenance
8.4.7 Changing the coolant liquid/changing the coolant liquid filter
Changing the coolant liquid Personnel:  Qualified personnel

 Safety goggles

 Funnel with filling tool

re-opening.
spanner.
5. Loosen the filler plug (Fig. 38/1), remove and make sure that the
gasket does not get lost.
Fig. 38: Filler plug
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Maintenance
6. Open the coolant liquid drain (Fig. 39/1).
 Coolant liquid is drained.
7. Close the coolant liquid drain (Fig. 39/1).
NOTICE!
compressor.
Fig. 39: Coolant liquid drain
data.
coolant ALUB Syn S.
8. With the help of a funnel (Fig. 40/1), fill coolant liquid up to the
filling edge of the filler plug (Fig. 40/3).
9. Position the gasket and check for correct fit.
10. Insert the screw plug (Fig. 40/2) and tighten  Appendix B
‘Checking the coolant liquid level/topping up the coolant liquid’ on
Fig. 40: Filler plugs page 89.
2015-03-13 95
Maintenance
Changing the coolant liquid filter Personnel:  Qualified personnel

 Safety goggles

 Strap spanner

re-opening.
spanner.
5. Using the strap spanner, loosen and remove the old coolant liquid
filter (Fig. 41/1).
6. Remove old gasket remains from the coolant liquid filter housing.
7. Moisten the new gasket with a little coolant liquid.
8. Screw in the new coolant liquid filter (Fig. 41/1) up to the stop.
9. Tighten the new coolant liquid filter (Fig. 41/1) half a turn by hand.
‘Checking the coolant liquid level/topping up the coolant liquid’ on
page 89.
Fig. 41: Remove coolant liquid filter
96 2015-03-13
Maintenance
8.4.8 Re-lubricating the electric motor

Protective  Safety boots

equipment:  Protective work clothing
 Safety goggles
Materials:  Lubrication grease ALMiG part number

183.00099
If there is no grease nipple on the electric motor, this has

encapsulated, permanently-lubricated bearings.

re-opening.
spanner.
4. For the quantity of lubricating grease, consult the type plate of the
electric motor.
The grease nipples are always on the side of the terminal

box.
5. Grease the grease nipples (Fig. 42/1) with a grease gun.
Fig. 42: Grease nipples
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Maintenance
8.4.9 Changing the fine precipitator


 Safety goggles
Materials:  Strap spanner

re-opening.
spanner.
5. Using the strap spanner (Fig. 43/2), loosen and remove the fine
precipitator (Fig. 43/1).
6. Remove old gasket remains from the fine precipitator (Fig. 43/1).
7. Moisten the new gasket with a little coolant liquid.
Fig. 43: Loosen fine precipitator

8. Screw in the new fine precipitator (Fig. 44/1) up to the stop.
9. Tighten the new fine precipitator (Fig. 44/1) half a turn by hand.
10. Proceed the same way with additional fine precipitators (Fig. 44/1).
Fig. 44: Fine precipitator
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Maintenance
8.4.10 Changing the intake filter
Standard intake filter Personnel:  Qualified personnel

 Safety goggles

re-opening.
spanner.
4. Loosen the intake filter (Fig. 45/2).
5. Remove the old intake filter (Fig. 45/1).
6. Attach the new intake filter (Fig. 45/1).
7. Tighten the clamp of the intake filter (Fig. 45/2)  Appendix B

Fig. 45: Loosen the clamp of the intake

filter
High-performance intake filter Personnel:  Qualified personnel

 Safety goggles

re-opening.
spanner.
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Maintenance
4. Remove the cover of the intake filter (Fig. 46/2).
5. Remove the old intake filter (Fig. 46/1).
6. Insert the new intake filter (Fig. 46/1).
7. Replace the cover of the intake filter (Fig. 46/2).
Fig. 46: Remove the cover of the intake

filter
8.4.11 Checking the drive unit


 Safety goggles

re-opening.
spanner.
4. Visually check the drive unit.
 In case of visible defects, contact the manufacturer.
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Maintenance
8.5 Measures after maintenance has been performed

After completion of the maintenance work and before switching the
machine on, carry out the following steps:
1. Check all previously-loosened screw connections to make sure

they are tight.
2. Check whether all previously-removed protective equipment and

covers have been replaced properly.
3. Ensure that all tools, materials and other equipment used has
been removed from the work area.
4. Carefully open the compressed air network-side gate valve.
5. Clean the work area and remove any substances such as liquids,
processing material or similar that may have escaped.
6. Ensure that all safety equipment on the machine functions per-

fectly.
7. Document work on the machine in the service manual

( Appendix C ‘Service manual’ on page 119).
2015-03-13 101
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 maintenance
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.
9.1 Safety instructions for fault clearance

Electrical system
DANGER!
Hot surfaces
WARNING!
severe skin burns.
30 minutes.
102 2015-03-13
Faults

WARNING!
supply while tracking down and rectifying a fault, there is a
danger of serious injuries or death for persons in the
danger zone.
Improperly executed
WARNING!
troubleshooting work
Danger of injury from improper troubleshooting!
Improperly executed troubleshooting work may result in
serious injury and significant damage to property.
- Ensure sufficient assembly space before starting work.
- Pay attention to orderliness and cleanliness in the
assembly location! Loosely stacked or scattered
components and tools could cause accidents.
- If components have been removed, pay attention to
correct assembly, refit all fixing elements and comply
with bolt tightening torques.
- Before the restart, ensure that
- all troubleshooting work has been carried out and
completed in accordance with the information and
instructions in this manual.
- no persons are in the danger zone.
- all covers and safety devices are installed and
functioning properly.
2015-03-13 103
Faults
Compressed air
WARNING!
Coolant liquid fog

CAUTION!
supply.
104 2015-03-13
Faults
Behaviour in the event of faults The following applies in principle:
1. Immediately initiate an emergency stop in the event of faults

posing an immediate danger to people or property.
2. Ascertain the cause of the fault.
3. If fault rectification requires work in the danger zone, shut down the
machine and secure to prevent restarting.
Immediately notify those responsible at the place of use about the
fault.
4. Depending on the nature of the fault, have it rectified by authorised

specialised personnel or rectify it yourself.
The fault table below provides information about who is

authorised to rectify the fault.
9.2 Fault displays

Refer to the  controller documentation for information on fault
displays.
2015-03-13 105
Faults
9.3 Fault table
Fault description Cause Remedy Personnel
Compressor tempera- Intake or ambient tem- Ventilate compressor Qualified personnel

ture too high (red lamp perature too high room
lights up)
Cooling air intake or outlet Unblock cooling air intake Qualified personnel
blocked or outlet sufficiently
Coolant liquid is soiled Change coolant liquid Qualified personnel

 Chapter 8.4.7
‘Changing the coolant
liquid/changing the cool-
ant liquid filter’ on page 94
Coolant liquid low Top up the coolant liquid Qualified personnel

 Chapter 8.4.2
‘Checking the coolant
liquid level/topping up the
coolant liquid’ on page 89
Coolant liquid cooler Clean coolant liquid cool- Qualified personnel

soiled er  Chapter 8.4.5
‘Checking soiling of the
Network pressure drops Compressed air con- Screw compressor with Manufacturer
sumption higher than greater delivery quantity
delivery quantity of the necessary
screw compressor
Intake filter soiled Replace intake filter Qualified personnel

 Chapter 8.4.10
‘Changing the intake filter’
on page 99
Bleeder valve blows dur- Check bleeder valve and Manufacturer

ing compression replace gaskets if neces-
sary
Intake regulator does not Check magnet valve and Manufacturer

open plunger and replace if
necessary
Leaks in the compressed Seal up the compressed Qualified personnel

air network air network
106 2015-03-13
Faults
Screw compressor Minimum pressure valve Clean or replace minimum Manufacturer

blows via safety valve blocked pressure valve
Safety valve faulty Check safety valve and Manufacturer

replace if necessary
Fine precipitator soiled Change fine precipitator Qualified personnel

 Chapter 8.4.9
‘Changing the fine precip-
itator’ on page 98
"Overpressure fault" or Fine precipitator soiled Change fine precipitator Qualified personnel
"Network pressure too  Chapter 8.4.9
high" (red lamp lights ‘Changing the fine precip-
up) itator’ on page 98
Higher outside pressure Balance out outside Qualified personnel

present in compressed air pressure or disconnect
network from the network
Screw compressor Network pressure set too Reset network pressure Trained Person
does not start automat- high  Controller documenta-
ically or does not dis- tion
charge after previous
switching-off by reach- Interruption in the power Check power circuit for Qualified electrician
ing the final pressure or circuit interruption
from idle.
Ambient temperature Install additional heating Qualified personnel
below +1 °C, message or temper compressor
"Coolant liquid tempera- room and also contact the
ture too low" manufacturer
Switching times are acti- Check switching and Trained Person

vated in the circuitry pressure times in the
circuitry  Controller
documentation
2015-03-13 107
Faults
System does not start Network pressure greater Heed network pressure Trained Person
up when the start key is than switch-on pressure and change settings
pressed  Controller documenta-
tion
Symbol "remote" flashes Remote control activated Trained Person

 Controller documenta-
tion
Lacking voltage on the Check whether there is Qualified electrician

screw compressor voltage
Electrical fault in the con- Check controller Qualified electrician

troller
Switching times are acti- Check switching and Trained Person

vated in the circuitry pressure times in the
circuitry  Controller
documentation
Compressed air con- Return line for the coolant Clean or replace return Qualified personnel
tains a lot of coolant liquid is blocked line for the coolant liquid
liquid (coolant liquid  ‘Clean/change return
consumption too high) line’ on page 109
Flawed fine precipitator Change fine precipitator Qualified personnel

 Chapter 8.4.9
‘Changing the fine precip-
itator’ on page 98
System stops before Overtemperature or Remedy fault Trained Person

reaching the final overpressure  Controller documenta-
pressure (red lamp tion
lights up)
Interruption in the control Check power circuit Qualified electrician
power circuit
Pressure drop Pressure difference of the Replace filter Qualified personnel

filter too high
108 2015-03-13
Faults
9.4 Work for fault clearance

Clean/change return line Personnel:  Qualified personnel

 Safety goggles

re-opening.
spanner.
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
original spare parts ( Appendix D ‘Spare parts list’ on page 123).
7. Put nozzle and return line (Fig. 47/2) back in position and tighten
screws ( Appendix B ‘Tightening torques for screws’ on
page 118).
Fig. 47: Return line
9.5 Commissioning after remedied fault

After remedying the fault, carry out the following steps for
re-commissioning:
1. Reset emergency stop equipment.
2. Acknowledge fault  Controller documentation.
3. no persons are in the danger zone.
4. Start the screw compressor  Controller documentation.
2015-03-13 109
Dismantling and disposal
10 Dismantling and disposal

Following the end of its useful life, the machine must be dismantled and
disposed of in accordance with the environmental regulations.
10.1 Safety instructions for dismantling and disposal

Electrical system
DANGER!
- Before starting the dismantling, switch off the electric
power supply and disconnect completely.
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.
110 2015-03-13
Dismantling and disposal
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 compliance
with applicable local occupational safety and environmental protection
regulations.
10.3 Disposal
If no return or disposal agreement has been made, send the dismantled
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
accordance with the environmental regulations from
the local municipal authorities or specialised waste
disposal companies.
2015-03-13 111
Index
11 Index
Safety valve .................................................... 55

A Sound insulation covers ................................. 53
Accident ..............................................................27 Switch cabinet ................................................ 52
B Switch cabinet filter ........................................ 52
Brief description ..................................................52 VARIABLE drive unit ...................................... 54

Water cooling ................................................. 57
C
Compressor stage .............................................. 55
Changing the
Connecting air .................................................... 72
fine precipitator ................................................98
Connecting compressed air ............................... 72
Changing the intake filter ....................................99
Connecting the current ....................................... 73
Checking for leaks ..............................................91
Connecting the power supply............................. 73
Checking soiling of the cooler .............................92
Connection values
Checking the condensation accumulation ..........92
BELT 38 – 132 air supply ............................... 35
Checking the coolant liquid
level .................................................................74 BELT 38 – 132 electric ................................... 34
Checking the temperature ..................................91
DIRECT 37 – 90 air supply ............................. 38
Components
BELT drive unit ................................................54 DIRECT 37 – 90 electric ................................. 38
Compressed air after-cooler............................57 GEAR 30 – 110 air supply .............................. 41

Compressor stage ...........................................55
GEAR 30 – 110 electric .................................. 41
Controller .........................................................53
Coolant liquid cooler ........................................57 VARIABLE 35 – 130 air supply....................... 46
Coolant liquid drain .........................................55 VARIABLE 35 – 130 electric........................... 46
Coolant liquid filter ...........................................58
Contact person ................................................... 10
Coolant liquid pressure tank............................55
Controller............................................................ 53
Cooler ..............................................................57
Coolant liquid ..................................................... 33
Cooling air ventilator .......................................58
changing ......................................................... 94
DIRECT drive unit ...........................................54
replacing ......................................................... 94
Filler plugs .......................................................55
Start-up lubrication ......................................... 75
Fine precipitator ..............................................56
topping up ....................................................... 89
Fresh air ventilator ..........................................58
Coolant liquid filter ............................................. 58
GEAR drive unit...............................................54
changing ......................................................... 94
Heat exchanger ...............................................57
replacing ......................................................... 94
Inspection glass ..............................................55
Coolant liquid level
Intake filter .......................................................54
checking ......................................................... 89
Minimum pressure and return valve ................56
112 2015-03-13
Index
Coolant liquid pressure tank ............................... 55 GEAR 30 – 110 ...............................................40

Cooler ................................................................. 57
VARIABLE 35 – 130 ........................................44
Cooling air ventilator ........................................... 58
Copyright ............................................................ 10 with direct drive Type 37 – 90 .........................37
Customer service ................................................ 10
H
D Heat reclamation .................................................71
Description of function ........................................ 52
I
Dismantling ....................................................... 111
Inspection at delivery ..........................................61
Disposal ............................................................ 111
Installation
Drive
Forced ventilation and bleeding ......................69
BELT ............................................................... 54
Heat reclamation .............................................71
DIRECT ........................................................... 54
Ventilation .......................................................68
GEAR .............................................................. 54
Water cooling ..................................................70
VARIABLE ...................................................... 54
Installation conditions .........................................67
Drive unit..................................................... 54, 100
Installation location .............................................67
E Intake filter ..........................................................54
Electric current .................................................... 17 Interfaces ............................................................ 59
Emergency ......................................................... 80 Air supply ........................................................59
Emergency stop .................................................. 80 Compressed air connection ............................60
Emergency stop key ........................................... 23 Heat reclamation (WRG) .................................60
Emissions ........................................................... 32 Media............................................................... 59
Environmental protection Water cooling ..................................................60
Coolant liquid .................................................. 28 WRG................................................................ 60
Lubricants ....................................................... 28
L
F Liquid stream ......................................................19
Fault Lubricants
Return line ..................................................... 109
BELT 38 – 132 ................................................36
Fault displays .................................................... 105
Fault table ......................................................... 106 DIRECT 37 – 90 ..............................................39
Fine precipitator .................................................. 56 GEAR 30 – 110 ...............................................42

Fire...................................................................... 27
VARIABLE 35 – 130 ........................................47
First aid ............................................................... 27
Forced ventilation and bleeding ......................... 69 M
G Main switch .........................................................23
General details Maintenance

Changing the coolant liquid filter .....................94
BELT 38 – 132 ................................................ 33
Changing the fine precipitator .........................98
2015-03-13 113
Index
Changing the intake filter ................................99 Rescue measures .............................................. 80

Checking for leaks ...........................................91 Return line
Checking soiling of the cooler .........................92 change .......................................................... 109
Checking the compressor temperature ...........91 clean ............................................................. 109
Checking the condensation accumulation ......92
S
Checking the coolant liquid level .....................89
Safety
Checking the drive unit ..................................100
General ........................................................... 11
Coolant liquid change ......................................94
Safety devices .................................................... 22
Re-lubricating the electric motor .....................97
Safety equipment ............................................... 22
Replacing the coolant liquid ............................94
Safety valves ...................................................... 24
Replacing the coolant liquid filter ....................94
Service ............................................................... 10
Topping up the coolant liquid ..........................89
Service manual ................................................ 119
Minimum pressure and return valve ...................56
Signs .................................................................. 29
N Sound insulation covers ..................................... 53
Noise emissions ..................................................32 Spare parts......................................................... 85
Starting up compressed air generation .............. 76
O
Start-up lubrication ............................................. 75
Operating conditions ........................ 35, 39, 42, 47
Storage............................................................... 64
Output values
Switch cabinet .................................................... 52
DIRECT 37 – 90 ..............................................37
Switch cabinet filter ............................................ 52
VARIABLE 35 – 130 ........................................45 Switching on after the initial commissioning ...... 76
Overview Symbols
BELT ...............................................................49 in this manual ................................................... 8
Components ....................................................51 on the machine ............................................... 30
DIRECT ...........................................................49 on the packaging ............................................ 63
GEAR ..............................................................49 T
VARIABLE 35 – 70 ..........................................50 Transport ............................................................ 64
Type plate .......................................................... 32
VARIABLE 90 – 130 ........................................49
Owner .................................................................12 U
Use ..................................................................... 11
P
Packaging ...........................................................62 V
Personnel ............................................................13 Ventilation .......................................................... 68
Proper use ..........................................................11
W
Protective equipment ..........................................15
Warranty terms .................................................. 10
R Water cooling ..................................................... 70
Re-lubricating the electric motor .........................97 Water-cooled compressors
114 2015-03-13
Index
BELT 38 – 132 ................................................ 36 VARIABLE 35 – 130 ........................................48
DIRECT 37 – 90 .............................................. 39 Working after the initial commissioning ..............77
GEAR 30 – 110 ............................................... 43
2015-03-13 115
Appendix
12 Appendix
116 2015-03-13
Training log
A Training log
Date Name Type of training Training conducted Signature
by
2015-03-13 117
Tightening torques for screws
B Tightening torques for screws
118 2015-03-13
Service manual
C Service manual
Compressor type:
System number:
Please specify in case of inquiries, orders and
correspondence.
Motor number:
Pressure tank number:
Date of commissioning:
Your ALMiG customer service:
2015-03-13 119
Service manual
Daily checks Weekly checks
Hours Coola Leak- Compressor Cooler Condensate Clean Date Name

of nt age temperature soiling accumulation intake
opera- liquid filter
tion level mats
120 2015-03-13
Service manual
Coolant liquid change Filter change

(coolant liquid filter / intake filter / fine precipitator)
Hours of Date Name Hours of Date Filter type Name

operation operation
2015-03-13 121
Service manual
Additional maintenance and repair work
Hours of Date Spare parts Name

operation
122 2015-03-13
Spare parts list
D Spare parts list

Spare parts list
The spare parts list is included with the documents.
2015-03-13 123
ALMiG Kompressoren GmbH
Adolf-Ehmann-Straße 2
73257 Köngen
Phone +49 7024 9614 0

Email [email protected]
Internet www.almig.de
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Almig Screw Compressor Operating Instructions

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Operating

Read the instructions prior to performing

Translation of the original operating instructions

© ALMiG Kompressoren GmbH 2015

3 Technical data ...................................................................... 32

3.4.4 Lubricants .....................................................36

4 Construction and function ..................................................49

5 Transportation, packaging and storage.............................61

5.1 Safety instructions for transportation ........................... 61

6 Installation, commissioning and operation ....................... 65

8.4.7 Changing the coolant liquid/changing the

10 Dismantling and disposal ..................................................110

1.2 Explanation of symbols

 Identifies a state or automatic sequence as result of

Identifies references to chapters in this manual and

Identifies random numerations and list entries.

[Key] Indicates names of keys, buttons and other oper-

1.3 Limitation of liability

1.5 Warranty terms

1.6 Customer service

2.1 Proper use

The screw compressor serves exclusively to generate compressed

Claims of any type for damage due to misuse are excluded.

2.2 Responsibility of the owner

2.3 Staff requirements

This manual specifies the personnel qualifications required for the

The workforce must only consist of persons who can be expected to

2.3.2 Unauthorised persons

2.4 Personal protective equipment

Description of the personal

Light respiratory protection

Protective work clothing

2.5 Basic dangers

2.5.1 General dangers in the workplace

2.5.2 Dangers due to electric energies

2.5.3 Dangers due to mechanical elements

Sharp edges and pointed corners

2.5.4 Dangers due to hydraulic energies

Coolant liquid fog

2.5.5 Dangers due to high temperatures

2.6 Safety equipment

2.6.1 Position of the safety equipment

Fig. 1: Position of the safety equipment

1 Main switch with emergency off function

2.6.2 Description of the installed safety devices

Main switch with emergency off

Emergency stop key

Fig. 4: Safety valve

2.7 Securing to prevent restart

Securing to prevent restart

2. Secure the main switch with a padlock (Fig. 5).

3. Have a responsible employee keep the key for the padlock.

5. Ensure that all safety and protective equipment is installed and

6. Remove the padlock from the main switch.

If no main switch is installed, proceed as follows.

Securing to prevent restart 1. Switch off the power supply.

2. Inform responsible people about work in the danger zone.

5. Ensure that all safety and protective equipment is installed and

6. Remove the sign.

2.8 Behaviour in case of fire or accidents