Operating

instructions

Screw compressor

COMBI 3S - 5S
COMBI 6 - 15
COMBI 16 - 22
COMBI 11SC / 22SC

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
Help line:
Telephone: +49 1805 25 87 00
Fax: +49 1805 25 87 01
Item no. 195.03275

Translation of the original operating instructions

Almi-13257-DE COMBI

© ALMiG Kompressoren GmbH 2015

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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 COMBI 3S – 5S ........................................................... 33
3.4.1 General details ............................................. 33
3.4.2 Connection values ........................................ 35
3.4.3 Operating conditions .................................... 36

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Table of contents

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

3.5 COMBI 6 – 15 ..............................................................37
3.5.1 General details..............................................37
3.5.2 Connection values ........................................41
3.5.3 Operating conditions .....................................42
3.5.4 Consumables ................................................42
3.6 COMBI 16 – 22 ............................................................43
3.6.1 General details..............................................43
3.6.2 Connection values ........................................45
3.6.3 Operating conditions .....................................46
3.6.4 Consumables ................................................46

4 Construction and function ..................................................47

4.1 Overview ......................................................................47
4.2 Brief description ...........................................................50
4.3 Assembly description ...................................................51
4.3.1 Controller ......................................................51
4.3.2 Sound insulation covers ...............................52
4.3.3 Drive unit .......................................................53
4.3.4 Intake filter ....................................................53
4.3.5 Compressor stage ........................................54
4.3.6 Coolant liquid tank ........................................54
4.3.7 Fine precipitator ............................................55
4.3.8 Minimum pressure and return valve .............55
4.3.9 Cooler ...........................................................56
4.3.10 Coolant liquid filter ........................................56
4.3.11 Cooling air fan...............................................57
4.3.12 Refrigerant-type dryer ...................................57
4.4 Interfaces .....................................................................58

5 Transportation, packaging and storage.............................60

5.1 Safety instructions for transportation ...........................60
5.2 Transportation inspection .............................................60
5.3 Packaging ....................................................................61
5.4 Symbols on the packaging ...........................................62
5.5 Transportation ..............................................................62
5.6 Storage .........................................................................63

6 Installation, commissioning and operation .......................64

6.1 Safety instructions for the installation and
commissioning .............................................................64
6.2 Requirements in the installation location .....................66
6.3 Installation ....................................................................67

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Table of contents

6.3.1 Ventilation ..................................................... 67

6.3.2 Connection to the compressed air network .. 68
6.3.3 Connecting to the power supply ................... 69
6.4 Checking the coolant liquid level ................................. 70
6.5 Start-up lubrication of the compressor stage ............... 71
6.6 Switching on after the initial commissioning ................ 72
6.7 Working after the initial commissioning ....................... 73
6.8 Setting parameters ...................................................... 75
6.9 Measures in case of low compressed air
requirement .................................................................. 75

7 Operation .............................................................................. 76
7.1 Safety instructions for operation .................................. 76
7.2 Shutdown in emergency situations .............................. 76
7.3 Operating personnel and personal protective
equipment .................................................................... 77
7.4 Controllers.................................................................... 78
7.4.1 Controller COMBI 3S – 4S ........................... 78
7.4.2 Controller COMBI 5S .................................... 80
7.4.3 Air Control AC mini controller ....................... 81

8 Maintenance ....................................................................... 102

8.1 Safety instructions for maintenance .......................... 102
8.2 Spare parts ................................................................ 105
8.3 Maintenance schedule ............................................... 106
8.4 Maintenance work ...................................................... 108
8.4.1 Checking the electrical connections ........... 108
8.4.2 Checking the coolant liquid level/topping
up the coolant liquid ................................... 109
8.4.3 Checking for leaks ...................................... 111
8.4.4 Checking the compressor temperature ...... 112
8.4.5 Checking soiling of the cooler .................... 113
8.4.6 Checking the condensation accumulation .. 114
8.4.7 Changing the coolant liquid/changing the
cooling liquid filter ....................................... 115
8.4.8 Re-lubricating the electric motor................. 118
8.4.9 Change fine precipitator ............................. 119
8.4.10 Change intake filter .................................... 120
8.4.11 Checking the drive unit ............................... 121
8.5 Measures after maintenance has been performed .... 121

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Table of contents

9 Faults ...................................................................................122
9.1 Safety instructions for fault clearance ........................122
9.2 Fault displays .............................................................124
9.3 Fault table ..................................................................125
9.4 Work for fault clearance .............................................128
9.5 Commissioning after remedied fault ..........................128

10 Dismantling and disposal ..................................................129

10.1 Safety instructions for dismantling and disposal ........129
10.2 Dismantling ................................................................130
10.3 Disposal ....................................................................130

11 Index ....................................................................................131

12 Appendix .............................................................................135

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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
understanding, 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!
This combination of symbol and keyword points to a
situation of possible danger which may lead to serious
injury or death unless avoided.

CAUTION!
This combination of symbol and keyword points to a
possibly dangerous situation which may lead to slight or
minor injury unless avoided.

NOTICE!
This combination of symbol and keyword points to a
possibly dangerous situation which may lead to material
and environmental damage unless avoided.

Tips and recommendations This symbol highlights useful tips and recommendations
as well as information designed to ensure efficient and
smooth operation.

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General information

Special safety instructions The following symbols are used in the safety instructions to draw
attention 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

operating 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
manufacturer's Terms and Conditions and Terms of Delivery and the
legal regulations 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
information. 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
involved 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
compressor may be supplied exclusively with cool, dry and dust-
free cooling air.

The proper use also includes adherence to all details in these

instructions.
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
guaranteed.

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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
prohibited.
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 136).

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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
resistance, 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
assessment.
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

CAUTION!
pointed corners
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 devices

1 Main switch with emergency stop function

2 Emergency stop button

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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
Fig. 2: Main switch all safety devices have been installed and function
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!
Danger to life from an unauthorised restart!
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!
Danger to life from an unauthorised restart!
If the main switch is secured with a padlock, people can
Fig. 5: Securing the main switch
be in the danger zone. These people can be fatally
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!
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.

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!
Danger to life from an unauthorised restart!
People in the danger zone can be fatally injured by the
unauthorised or uncontrolled switching on of the power
supply.
- Before switching the power supply back on, ensure
that there are no dangers for people.

6. Remove the sign.

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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  Immediately trigger an Emergency Stop using EMERGENCY-

and accidents 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.

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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.

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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 ALUB BLUE S+ 583.04055
(10 l container)

Synthetic coolant liquid ALUB Syn S 583.00004

(10 l container)

Food-compatible coolant liquid ALUB Food H1 583.04010

(10 l container)

Biodegradable coolant liquid ALUB GREEN S 583.10051

(10 l container)

3.4 COMBI 3S – 5S
3.4.1 General details

COMBI 3S

COMBI Nominal motor Weight Length Width Height

output

kW kg mm mm mm
3S 3.0 215 1400 550 1250
(with compressed air tank 200 l
and refrigeration dryer)

3S 3.0 195 1400 550 1250

(with compressed air tank 200 l,
without refrigeration dryer)

3S 3.0 155 1100 550 950

(without pressure tank, with
refrigerant-type dryer)

3S 3.0 130 720 550 950

(without pressure tank, without
refrigerant-type dryer)

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Technical data

COMBI 4S

COMBI Nominal motor Weight Length Width Height

output

kW kg mm mm mm
4S 4.0 220 1400 550 1250
(with compressed air tank 200 l
and refrigeration dryer)

4S 4.0 200 1400 550 1250

(with compressed air tank 200 l,
without refrigeration dryer)

4S 4.0 160 1100 550 950

(without pressure tank, with
refrigerant-type dryer)

4S 4.0 135 720 550 950

(without pressure tank, without
refrigerant-type dryer)

COMBI 5S

COMBI Nominal motor Weight Length Width Height

output

kW kg mm mm mm
5S 5.5 225 1400 550 1250
(with compressed air tank 200 l
and refrigeration dryer)

5S 5.5 205 1400 550 1250

(with compressed air tank 200 l,
without refrigeration dryer)

5S 5.5 165 1100 550 950

(without pressure tank, with
refrigerant-type dryer)

5S 5.5 140 720 550 950

(without pressure tank, without
refrigerant-type dryer)

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Technical data

3.4.2 Connection values

Electrical

COMBI 3S – 5S

COMBI Current at 400 V / 50 Hz Current at 500 V / 50 Hz Max. switching

frequency
IN IFuse IN IFuse

A A gL A A gL 1/h
3S 6.6 16 5.3 10 55

4S 8.5 16 6.8 16 55

5S 11.3 16 9 16 55

IN = nominal current
IFuse = building-side fuse

Air supply and cooling

COMBI 3S – 5S

COMBI Compressed air Cooling air Supply air Cross-section air

connection quantity (LK) opening outlet duct
3 2 2
G / DN m /h m m
3S ⅜ 1050 0.15 0.10

4S ⅜ 1060 0.20 0.15

5S ½ 1080 0.25 0.15

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Technical data

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

3.4.4 Lubricants

COMBI 3S –5S

COMBI Lubricant Fill level Unit

3S Coolant liquid 3.2 l

4S Coolant liquid 3.2 l

5S Coolant liquid 3.2 l

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Technical data

3.5 COMBI 6 – 15
3.5.1 General details

COMBI 6

COMBI Nominal Weight Length Width Height

motor output

kW kg mm mm mm
6 5.5 455 1180 770 1680
(with 270 l pressure tank and
refrigerant-type dryer)

6 5.5 420 1180 770 1680

(with 270 l pressure tank, without
refrigerant-type dryer)

6 5.5 520 1900 770 1680

(with 500 l pressure tank and
refrigerant-type dryer)

6 5.5 485 1900 770 1680

(with 500 l pressure tank, without
refrigerant-type dryer)

6 5.5 340 1180 770 1128

(without pressure tank, with
refrigerant-type dryer)

6 5.5 305 1180 770 1128

(without pressure tank, without
refrigerant-type dryer)

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Technical data

COMBI 8

COMBI Nominal Weight Length Width Height

motor output

kW kg mm mm mm
8 7.5 460 1180 770 1680
(with 270 l pressure tank and
refrigerant-type dryer)

8 7.5 425 1180 770 1680

(with 270 l pressure tank, without
refrigerant-type dryer)

8 7.5 525 1900 770 1680

(with 500 l pressure tank and
refrigerant-type dryer)

8 7.5 490 1900 770 1680

(with 500 l pressure tank, without
refrigerant-type dryer)

8 7.5 345 1180 770 1128

(without pressure tank, with
refrigerant-type dryer)

8 7.5 310 1180 770 1128

(without pressure tank, without
refrigerant-type dryer)

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Technical data

COMBI 11 / 11SC

COMBI Nominal Weight Length Width Height

motor output

kW kg mm mm mm
11 / 11SC 11.0 465 / 470 1180 770 1680
(with 270 l pressure tank and
refrigerant-type dryer)

11 / 11SC 11.0 430 / 435 1180 770 1680

(with 270 l pressure tank, without
refrigerant-type dryer)

11 / 11SC 11.0 530 / 535 1900 770 1680

(with 500 l pressure tank and
refrigerant-type dryer)

11 / 11SC 11.0 495 / 500 1900 770 1680

(with 500 l pressure tank, without
refrigerant-type dryer)

11 / 11SC 11.0 350 / 355 1180 770 1128

(without pressure tank, with
refrigerant-type dryer)

11 / 11SC 11.0 315 / 320 1180 770 1128

(without pressure tank, without
refrigerant-type dryer)

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Technical data

COMBI 15

COMBI Nominal Weight Length Width Height

motor output

kW kg mm mm mm
15 15.0 475 1180 770 1680
(with 270 l pressure tank and
refrigerant-type dryer)

15 15.0 440 1180 770 1680

(with 270 l pressure tank, without
refrigerant-type dryer)

15 15.0 540 1900 770 1680

(with 500 l pressure tank and
refrigerant-type dryer)

15 15.0 505 1900 770 1680

(with 500 l pressure tank, without
refrigerant-type dryer)

15 15.0 360 1180 770 1128

(without pressure tank, with
refrigerant-type dryer)

15 15.0 325 1180 770 1128

(without pressure tank, without
refrigerant-type dryer)

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Technical data

3.5.2 Connection values

Electrical

COMBI 6 – 15

COMBI Current at 400 V / 50 Hz Current at 500 V / 50 Hz Max. switching

frequency
IN IFuse IN IFuse

A A gL A A gL 1/h
6 11 25 9 16 55

8 15 32 12 25 55

11 / 11SC 22 / 22 40 / 40 17 / - 32 / - 40 / -

15 30 50 23 40 30

IN = nominal current
IFuse = building-side fuse

Air supply and cooling

COMBI 6 – 15

COMBI Compressed air Cooling air Supply air Cross-section air

connection quantity (LK) opening outlet duct
3 2 2
G / DN m /h m m
6 ¾ 1100 0.30 0.15

8 ¾ 1230 0.35 0.15

11 / 11SC ¾ 1800 0.50 0.20

15 ¾ 2300 0.60 0.20

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Technical data

3.5.3 Operating conditions

Environment Data Value Unit

Temperature range +5 to +40 °C

Relative humidity, maximum 60 %

Maximum installation height above sea 1000 m

level

3.5.4 Consumables

COMBI 6 – 15

COMBI Lubricant Fill level Unit

6 Coolant liquid 6.2 l

8 Coolant liquid 6.2 l

11 / 11SC Coolant liquid 6.2 l

15 Coolant liquid 6.2 l

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Technical data

3.6 COMBI 16 – 22
3.6.1 General details

COMBI 16

COMBI Nominal motor Weight Length Width Height

output
(on 500 l container)
kW kg mm mm mm
16 15 679 1900 780 1950
(with pressure tank and
refrigerant-type dryer)

16 15 639 1900 780 1950

(with pressure tank, without
refrigerant-type dryer)

16 15 494 1480 780 1375

(without pressure tank, with
refrigerant-type dryer)

16 15 454 1480 780 1375

(without pressure tank,
without refrigerant-type dryer)

COMBI 18

COMBI Nominal motor Weight Length Width Height

output
(on 500 l container)
kW kg mm mm mm
18 18.5 698 1900 780 1950
(with pressure tank and
refrigerant-type dryer)

18 18.5 658 1900 780 1950

(with pressure tank, without
refrigerant-type dryer)

18 18.5 513 1480 780 1375

(without pressure tank, with
refrigerant-type dryer)

18 18.5 473 1480 780 1375

(without pressure tank,
without refrigerant-type dryer)

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Technical data

COMBI 22 / 22SC

COMBI Nominal Weight Length Width Height

motor
(on 500 l container)
output

kW kg mm mm mm
22 / 22SC 22 744 / 750 1900 780 1950
(with pressure tank
and refrigerant-type
dryer)

22 / 22SC 22 704 / 710 1900 780 1950

(with pressure tank,
without refrigerant-
type dryer)

22 / 22SC 22 559 / 565 1480 780 1375

(without pressure
tank, with refrigerant-
type dryer)

22 / 22SC 22 519 / 525 1480 780 1375

(without pressure
tank, without
refrigerant-type
dryer)

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Technical data

3.6.2 Connection values

Electrical
COMBI 16 – 22 / 22SC

COMBI Current at 400 V / 50 Hz Current at 500 V / 50 Hz Max. switching

frequency
IN IFuse IN IFuse

A A gL A A gL 1/h
16 30 50 23 40 30

18 36 63 30 50 25

22 / 22SC 41 / 41 63 / 63 34 / - 50 / - 20 / -

IN = nominal current
IFuse = building-side fuse

Air supply and cooling

COMBI 16 – 22 / 22SC

COMBI Compressed air Cooling air Supply air Cross-section air

connection quantity (LK) opening outlet duct
3 2 2
G / DN m /h m m
16 1 3300 0.60 0.35

18 1 3300 0.60 0.35

22 / 22SC 1 3300 0.60 0.35

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Technical data

3.6.3 Operating conditions

Environment Data Value Unit

Temperature range +5 to +40 °C

Relative humidity, maximum 60 %

Maximum installation height above sea 1000 m

level

3.6.4 Consumables

COMBI 16 – 22 / 22SC

COMBI Lubricant Fill level Unit

16 Coolant liquid 11.5 l

18 Coolant liquid 11.5 l

22 / 22SC Coolant liquid 11.5 l

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Construction and function

4 Construction and function

4.1 Overview
The following presents an overview of the screw compressors
described in this manual. They differ from one another due primarily to
their size. However, their basic construction is the same.

For the COMBI type, there are variants which are not
built on a pressure tank. Due to their identical
construction, these variants are only depicted without
pressure tank and not extra as an overview figure.

Screw compressor COMBI 3S – 5S

Fig. 7: Screw compressor COMBI 3S – 5S

1 Main switch with emergency stop function

2 On and off switch
3 Refrigerant-type dryer
4 Pressure tank
5 Sound insulation covers

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Construction and function

Screw compressor COMBI 6 – 22

Fig. 8: Screw compressor with pressure tank

1 Controller
2 Emergency stop key / main switch with emergency stop function
3 Switch cabinet
4 Pressure tank
5 Sound insulation covers

Assemblies The basic construction is the same for all screw

compressor variants. The position of the assemblies may
vary from the illustration.

Fig. 9: Assemblies COMBI 3S – 5S

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Construction and function

1 Minimum pressure and non-return valve

2 Fine precipitator
3 Coolant liquid filter
4 Refrigerant-type dryer
5 Compressed air connection
6 Compressor stage
7 Intake filter
8 Coolant liquid cooler
9 Fan belt
10 Cooling air fan
11 Drive unit
12 Pressure tank
13 Coolant liquid tank

Fig. 10: Assemblies COMBI 6 – 22

1 Fine precipitator
2 Refrigerant-type dryer
3 Coolant liquid filter
4 Coolant liquid cooler
5 Intake filter
6 Compressed air connection
7 Fan belt
8 Compressor stage
9 Cooling air fan
10 Drive unit
11 Pressure tank
12 Coolant liquid tank
13 Frequency converter
14 Minimum pressure and non-return valve

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Construction and function

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
injected coolant liquid to the final pressure. The compressed air is
largely separated from the coolant liquid in the pressure tank. The
subsequent fine precipitator removes the remaining coolant liquid from
the compressed air. The compressed air then flows over the minimum
pressure and return valve into the compressed air after-cooler or the
pressure tank and is cooled off there. Finally, the compressed air is
dried in the refrigerant-type dryer before it leaves the screw
compressor via the compressed air connection.
The coolant liquid is separated from the compressed air in the
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.

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Construction and function

4.3 Assembly description

4.3.1 Controller

Controller variants
The COMBI 3S – 4S is operated using the pressure switch.

Fig. 11: COMBI 3S – 4S

The COMBI 5S is operated using the two buttons for switching on and
off.

Fig. 12: COMBI 5S

The COMBI 6 – 22 is operated using the Air Control AC mini

controller.

Fig. 13: COMBI 6 – 22

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Construction and function

Screw compressors with Screw compressors with frequency converters can be

frequency converters operated with the following controllers: AC 1, AC 3,
AC B, AC P.
Refer to the separately enclosed operating instructions
for the controller for information.

4.3.2 Sound insulation covers

Only qualified personnel may remove the sound insulation covers

(Fig. 14/1) with the included special spanner. Sound insulation covers
are a part of the electric shock protection.

Fig. 14: Sound insulation covers

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Construction and function

4.3.3 Drive unit

With the COMBI, the drive (Fig. 15) takes place using a fan belt
(Fig. 15/1).

Fig. 15: COMBI drive unit

On the COMBI 11SC and COMBI 22SC screw compressors the speed
of the electric motor is controlled by a frequency converter (Fig. 16/1).

Fig. 16: Drive unit with frequency

converter

4.3.4 Intake filter

The standard intake filter (Fig. 17/1) sits directly above the
compressor stage (Fig. 17/2).

Fig. 17: Standard intake filter

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Construction and function

4.3.5 Compressor stage

The air taken in is compressed by the compressor stage (Fig. 18/1)

and added to the coolant liquid pressure tank (Fig. 18/2) together with
the injected coolant liquid.

Fig. 18: Compressor stage

4.3.6 Coolant liquid tank

1 Safety valve
2 Coolant liquid pressure tank
3 Filler plugs
4 Coolant liquid drain
5 Inspection glass
The coolant liquid pressure tank consists of several components. The
safety valve protects the coolant liquid pressure tank against
overpressure. 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.

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.
Fig. 19: Coolant liquid pressure tank with
safety valves

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Construction and function

4.3.7 Fine precipitator

Depending on the type of the screw compressor, several

fine precipitators can be installed.

The fine precipitator (Fig. 20/1) removes the remaining coolant liquid
from the compressed air.

Fig. 20: Fine precipitator

4.3.8 Minimum pressure and return valve

The minimum pressure and return valve (Fig. 21/1) 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. 21: Minimum pressure and return

valve

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Construction and function

4.3.9 Cooler

The compressed air is cooled off in the compressed air after-cooler

(Fig. 22/2) or in the pressure tank before it leaves the screw
compressor via the compressed air connection (Fig. 22/3).
The coolant liquid is cooled by the coolant liquid cooler (Fig. 22/1) and
fed back into the coolant circuit.

The compressed air after-cooler and coolant liquid cooler

are only present on the COMBI 16 – 22. In the
COMBI 6 – 15, only a coolant liquid cooler is installed.

Fig. 22: Cooler

4.3.10 Coolant liquid filter

The coolant liquid filter (Fig. 23/1) cleans the coolant liquid before it is
injected into the compressor stage once again.

Fig. 23: Coolant liquid filter

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Construction and function

4.3.11 Cooling air fan

Depending on the type, two different cooling air

ventilators are installed.

Cooling air fan

The cooling of the compressed air after-cooler and of the coolant

liquid cooler is performed by the cooling air fan. The cooling air fan
also supplies the intake filter with sufficient intake air.

4.3.12 Refrigerant-type dryer

The refrigerant-type dryer (Fig. 24/1) dries the compressed air using a
heat exchange process. The compressed air is thus fed from the
pressure tank into the refrigerant-type dryer and then via the
compressed air connection (Fig. 24/3) into the compressed air
network.
The condensate which accumulates is discharged via the condensate
drain (Fig. 24/2).

Depending on the variant, a hose for discharging the

condensate is already attached to the condensate drain;
otherwise, the operator must attach one.

Fig. 24: Refrigerant-type dryer

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Construction and function

4.4 Interfaces

Fig. 25: Flow chart

The following interfaces are in the screw compressor:

 Air supply
 Cooling air ventilator
 Intake filter
 Compressed air connection

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Construction and function

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. 26: Cooling air ventilator and intake

filter

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. 27: Compressed air connection

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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
damage:
 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.

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5.3 Packaging
About the packaging The individual screw compressors are packaged in cartons or
sometimes 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
applicable 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.

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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.

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. 28.

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. 28: Transport with a fork lift

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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.

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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.

Securing to prevent restart

WARNING!
Danger to life from an unauthorised restart!
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.

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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.

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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.

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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!
Property 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

technical data for the screw compressor ( Chapter 3 ‘Technical
data’ on page 32).

2. Remove the exhaust air according to the technical data for the
screw compressor ( Chapter 3 ‘Technical data’ on page 32).

 This way, the heating of the installation room and of the screw
compressor will be prevented.

Fig. 29: Overview illustration of cooling air

ventilator

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Installation, commissioning and operation

Forced ventilation and bleeding The forced ventilation and bleeding must be
(optional) dimensioned so that the required supply and exhaust air
can be supplied and removed taking into account the
existing residual pressure of the cooling air ventilator.
The exhaust air can also be used for the purpose of heat
reclamation.

6.3.2 Connection to the compressed air network

Personnel:  Qualified personnel

Protective equipment:  Protective work clothing

 Safety boots

Materials:  Flexible compressed air hose, max. 1.5 m

WARNING!
Danger 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.

The prerequisite for the correct installation is the

presence of a professionally-planned, installed and
maintained compressed air network and an additional
cut-off valve installed at the entrance to the compressed
air network.

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

stumbling hazard.

3. Anchor and fasten the flexible compressed air hose sufficiently.

Fig. 30: Compressed air connection

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6.3.3 Connecting to the power supply

Personnel:  Qualified electrician

Protective equipment:  Protective work clothing

 Safety boots

NOTICE!
Property damage to the compressor stage due to
incorrect connection of the power supply!
In case of incorrect connection of the power supply,
there is a danger that the compressor stage will 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.

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6.4 Checking the coolant liquid level

Personnel:  Qualified personnel

Protective equipment:  Protective work clothing

 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 cooling liquid filter’ on page 115.

Fig. 31: Inspection glass

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6.5 Start-up lubrication of the compressor stage

Personnel:  Qualified personnel

Protective equipment:  Protective work clothing

 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

l
COMBI 3S – 5S 0.5

COMBI 6 – 15 0.5

COMBI 16 – 22 0.5

COMBI 11SC / 22SC 0.5

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Installation, commissioning and operation

1. Loosen 4 screws on the intake regulator (Fig. 32/1).

NOTICE!
Property damage due to incorrect coolant liquid!
Mixing different coolant liquids causes significant
property damage to the screw compressor.
- Only use the coolant liquid prescribed in the technical
data.

If there is no additional coolant liquid available, the

coolant liquid will have to be removed using of the
Fig. 32: Screw plug intake regulator
coolant liquid drain  Chapter 8.4.7 ‘Changing the
coolant liquid/changing the cooling liquid filter’ on
page 115.

2. Remove the intake regulator and fill the coolant liquid directly into
the compressor stage (Fig. 32/1).

3. Tighten 4 screws on the intake regulator (Fig. 32/1)

( Appendix B ‘Tightening torques for screws’ on page 137).

6.6 Switching on after the initial commissioning

Personnel:  Qualified personnel

Protective equipment:  Ear protection

 Protective work clothing
 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.

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Installation, commissioning and operation

6.7 Working after the initial commissioning

Personnel:  Qualified personnel

Protective equipment:  Protective work clothing

 Safety boots
 Protective gloves
 Light respiratory protection
 Safety goggles

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.

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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Installation, commissioning and operation

1. Switch the machine off and secure to prevent restarting.

2. Open and remove the sound insulation covers with the special
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 137.

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 109 if necessary.

8. Install and check that the sound installation covers are sealed.

NOTICE!
Property damage to to compressor temperature that
is too low or too high!
A compressor temperature that is too low or too high can
cause damage to the screw compressor.
- Contact the manufacturer for more precise
information, for contact information see page 2.

A sufficiently high compressor temperature guarantees

Fig. 33: Checking the coolant liquid level that the humidity taken in will not become condensate.
in the inspection glass 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 114.

9. Check compressor temperature  Chapter 8.4.4 ‘Checking the

compressor temperature’ on page 112.

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Installation, commissioning and operation

6.8 Setting parameters

Adjustment work for the screw compressor:

 Chapter 7.4 ‘Controllers’ on page 78.

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
requirement, 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 In an emergency situation proceed as follows:

situations
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!
Life-threatening danger if restarted without
authorization or due to uncontrolled restart!
Uncontrolled or unauthorized switching on of the power
supply can cause severe or fatal injuries.
- Prior to restart ensure that all safety devices are
mounted and functional, and that there is no danger
for personnel.

11. Prior to restarting the machine check and ensure that all safety
devices are installed and functioning.

7.3 Operating personnel and personal protective equipment

The following personnel qualifications and personal protective
equipment apply for all work on all controllers:

Personnel:  Trained Person

Protective equipment:  Ear protection

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7.4 Controllers

Controller variants
For the controller variant installed, please consult the
label on the controller.

7.4.1 Controller COMBI 3S – 4S

7.4.1.1 Overview

No. Description of function

1 Main switch with emergency stop function

2 Operating hours counter

3 Pressure gauge

Fig. 34: Controller COMBI 3S – 4S

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7.4.1.2 Switching the compressor on/off

Switching the compressor on

1. Turn the twist switch to the right.

 The compressor starts up automatically.

The compressor is shut off automatically by the

pressure switch (automatic mode) once
operating pressure is achieved. If the operating
pressure drops again, the compressor is
switched back on again automatically by the
pressure switch.

Fig. 35: Switching the compressor on

Switching the compressor off

1. Turn the twist switch to the left.

 The compressor is switched off.

Fig. 36: Switching the compressor off

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Operation

7.4.2 Controller COMBI 5S

7.4.2.1 Overview

No. Key/icon Description of function

1 Main switch with emergency stop
function

2 Displays the hours of operation.

3 Serves to switch on the

compressor.

4 Indicates the operating state.

Fig. 37: Controller COMBI 5S

5 Serves to switch off the
compressor.

7.4.2.2 Switching the compressor on/off

Switching the compressor on 1. Press .

 The operating indicator lights up, the compressor is

ready and can start up automatically at any time.

Switching the compressor off 1. Press .

 The operating indicator no longer lights up, the

compressor switches itself off.

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7.4.3 Air Control AC mini controller

7.4.3.1 Air Control Mini overview

Fig. 38: Overview of Air Control AC mini

No. Key/icon Description of function

1 Display Displays settings and operating parameters.

Serves to switch on the compressor. The integrated

2 green LED indicates the operating state.
Serves to scroll and increase values.

Serves to switch off the compressor, to acknowledge

fault/warning messages and to call up the code input
3 menu.
Serves to scroll and reduce values.

4 Serves to call up additional operating data.

5 Indicates the operating state.

Indicates warnings with flashing and faults with red

6
LEDs that light up.

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7.4.3.2 Brief description

The Air Control AC mini controller serves

 to display operating data/the compressor state
 to switch on/off the compressor/the compressed air generation
 to program the compressor and the compressed air generation.

7.4.3.3 Operating modes

Overview Four operating modes can be set using the controller.

Operating mode Description

Automatic operation After reaching the switch-off pressure, the system switches to idle for
the duration of the idle time (run-on). After the run-on time has
elapsed, the motor switches off. The compressor can start up by
itself at any time if the machine drops below the switch-on pressure.

Load/idle operation The compressor switches between "Load" and "Idle" operation;
that is, there is an unlimited run-on.

Optional automatic After reaching the switch-off pressure, the compressor switches to
idle. After 10 and 40 seconds, the respective network pressure is
measured. If the pressure drop determined this way is above the
threshold "Max. pressure drop", the compressor remains in idle for
the duration of the run-on time. If the value determined is below the
threshold "Max. pressure drop", the compressor switches off after
the shutdown time has elapsed.

Basic load switching mode The switch on/off pressure set is not taken into account by the
(BLS operation) controller. The compressor is controlled by a superior controller,
which can be connected via freely-programmable inputs (no RS485
present).

Safety pressure The safety pressure is the sum of the set maximum pressure
+ 0.8 bar. If the pressure exceeds the value of the safety pressure,
the compressor is switched off with a fault message. If the maximum
pressure is exceeded by 0.5 bar, a warning appears on the display.

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7.4.3.4 Overview of display

The display shows all operation-relevant information such as the

parameters set.

Fig. 39: Overview of basic display

1 Display [Aktueller Netzdruck (Current network pressure)]: Displays

the current network pressure.
2 Display [Aktuelle Verdichtertemperatur (Current compressor
temperature)]: Displays the current compressor temperature.
3 [Betriebsart (Operating mode)] display: Displays the current
operating mode.

By pressing the key, the current coolant liquid

temperature can also be shown on the [Aktuelle
Verdichtertemperatur (Current compressor temperature)]
display.

Other display indicators The following symbols can also appear on the display:

Symbol Description
Warning/maintenance message present.

Fault present.

Operating mode automatic/optional automatic active.

Automatic restart after power failure is activated.

Flashing: compressed air generation on/off via remote switch.

Static: compressed air generation is controlled by superior controller.

Motor is running.

Compressor is compressing air.

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7.4.3.5 Switching the compressor on/off

Switching the compressor on 1. Press .

 The compressor is ready and can start up automatically at any

time.

Switching the compressor off 1. Press .

 When switching off, the compressor switches for the duration

of the shutdown time to "idle" (motor runs, compressor does
not compress any air, blinks on the display). After the
shutdown time, the compressor switches off.

7.4.3.6 Calling up information

It is possible to display various information about operating states and

parameter values on the display. In order to switch between the
information and the parameter displays, it is only necessary to press
the key. The Information menu with parameter number and the
parameter value then appears on the display.

1. Press .

 The next parameter value is shown on the display.

In the information menu, the parameter [Einschaltdruck

(Switch-on pressure)] is always shown as the first value.

After approx. 5 seconds without pressing the key, the

display switches back to the basic display.

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Key Parameter displayed Parameter number Unit of the

parameter value
Switch-on pressure [1] [bar, MPa, psi]

Switch-off pressure [2] [bar, MPa, psi]

Safety pressure [3] [bar, MPa, psi]

Minimum pressure monitoring [4] [bar, MPa, psi]

in BLS operation

Minimum compressor [5] [°C, °F, Kelvin]

temperature

Maximum compressor [6] [°C, °F, Kelvin]

temperature

Hours of operation [7] [h]

Load hours [8] [h]

Remaining time intake filter [9] [kh]

Remaining time coolant liquid [10] [kh]

and coolant liquid filter

Remaining time fine [11] [kh]

precipitator

Remaining time motor [12] [kh]

lubrication

Remaining time compressor [13] [kh]

maintenance

Remaining time dryer [14] [kh]

maintenance

Hours of operation dryer [15] [h]

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7.4.3.7 Setting parameters via code input menu

The parameters for all basic settings of the compressor can be

changed with code input insofar as these changes do not influence
the operational stability. However, this is only possible when the
compressed air generation is switched off.

7.4.3.7.1 Calling up the code input menu

1. Press and hold for three seconds.

 The code input menu appears on the display.

2. Press .

 A 1 appears on the display.

3. Press .

In order to exit the code input menu again, press the

and keys together.

7.4.3.7.2 Inputting a code

Prerequisite: the code input menu has been called up.

1. Set the desired code with the keys.

2. To confirm the selected code, press .

 The submenu for the selected code appears on the display.

For some codes, several parameters can be input one

after another. By pressing the key, the next
parameter is selected automatically in such cases.

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Operation

7.4.3.7.3 Select operating mode: Code 2

By entering the code 2, the operating mode can be selected.

1. Press and hold for three seconds.

 The code input menu appears on the display.

2. Press .

 A 1 appears on the display.

3. Press .

4. Set the code 2 with the keys.

5. To confirm the selected code, press .

6. Press .

 The submenu for setting the operating mode appears on the

display.

7.
There are three values from which to choose:
- 0: Automatic operation
- 1: Load/idle operation
- 2: Optional automatic

Set the desired value with the keys.

8. To confirm the selected value, press .

 The set value is saved and the code input menu appears on
the display again.

9. Press the keys at the same time to go back to the basic

display.

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Operation

Value Operating mode Description

0 Automatic operation After reaching the switch-off pressure, the compressor switches
to idle for the duration of the idle time (run-on). After the idle time
has elapsed, the compressor then switches off, but it remains
ready for operation. If the switch-on pressure is reached, the
compressor starts up again automatically.

1 Load/idle operation The compressor switches between "Load" and "Idle" operation;
that is, there is an unlimited run-on.

2 Optional automatic The "Automatic" symbol and an additional point are shown on the
display in front of the temperature value. Here it is possible to
influence how frequently the motor stops. To do this, after the
confirmation, the parameters "maximum pressure drop" (input
range 0.0 to 9.9 bar) and "maximum operating cycle" (input
range 1 to 55 operating cycles/hour) are queried.

Maximum pressure drop If the system switches from load operation to idle, the Air Control mini
saves the current network pressure after 10 and 40 seconds. If the
pressure drop determined this way is above the "maximum pressure
drop", the motor switches off after the idle time has elapsed; otherwise
after the shutdown time.

Maximum operating cycles The motor is not switched off after the idle time (run-on) has elapsed if
the number of switch-on processes of the compressor exceeds the
number of the "maximum operating cycles".

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Operation

7.4.3.7.4 Switch automatic restart on/off: Code 3

By inputting the code 3, the automatic restart can be switched on/off

after a power failure.

1. Press and hold for three seconds.

 The code input menu appears on the display.

2. Press .

 A 1 appears on the display.

3. Press .

4. Set the code 3 with the keys.

5. To confirm the selected code, press .

 The submenu for switching the automatic restart on/off

appears on the display.

6.
There are two values from which to choose:
- 0: Automatic restart OFF
- 1: Automatic restart ON

Set the desired value with the keys.

7. To confirm the selected value, press .

 The set value is saved and the code input menu appears on
the display again.

8. Press the keys at the same time to go back to the basic

display.

Value Setting Description

0 Automatic restart OFF If the automatic restart after power failure is switched off, then
after a power failure, the fault "no AC" is displayed. This fault
must be acknowledged manually by pressing the key.
Otherwise, the compressor will not restart.

1 Automatic restart ON If the automatic restart after power failure is switched on, the time
set in the "shutdown time" parameter must elapse. If the
compressor was operating before the power failure, then after
this time has elapsed, it will start up again. Otherwise, the
compressor will then switch to STOP mode.

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Operation

7.4.3.7.5 Dryer dew-point monitoring: Code 6

The dew-point monitoring can be switched on and off by entering code 6.

1. Press and hold for three seconds.

 The code input menu appears on the display.

2. Press .

 A 1 appears on the display.

3. Press .

4. Set code 6 using keys.

5. To confirm the selected code, press .

The dew-point temperature is monitored at the set limits

and the temperature sensor is monitored for defects, if
the function is activated.
- Dew-point temperature max. 0 °C – +50 °C
- Dew-point temperature min.. -10 ℃ – +50 °C
(when the dew-point is set to min/max auf 0 °C the
monitoring is switched off)
- Setting Warning 0
Setting Malfunction 1

6. Using key and set the desired maximum dew-point and

confirm with .

7. Using key and set the desired minimum dew-point and

confirm with .

8. Using key and carry out setting Warning/Malfunction and

confirm with .

 The set values are saved and the code input menu appears
on the display again.

9. Press the keys at the same time to go back to the basic

display.

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Operation

7.4.3.7.6 Set on-site operation/remote operation: Code 8

By inputting the code 8, it is possible to switch between on-site

operation and remote operation.

1. Press and hold for three seconds.

 The code input menu appears on the display.

2. Press .

 A 1 appears on the display.

3. Press .

4. Set the code 8 with the keys.

5. To confirm the selected code, press .

 The on-site operation/remote control submenu appears on the

display.

6.
There are three values from which to choose:
- 0: On-site operation
- 1: Remote control
- 2: BLS-OK

Set the desired value with the keys.

7. To confirm the selected value, press .

 The set value is saved and the code input menu appears on
the display again.

8. Press the keys at the same time to go back to the basic

display.

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Operation

Value Designation Description

0 On-site operation The compressed air generation can only be switched on or off on the
control console/display of the Air Control 1.

1 Remote control The compressed air generation can only be switched on via a positive
edge (24 VDC) on terminal 23 and switched off via low level (0 V) on
terminal 23 or via the key. This functionality is identified by the
flashing text on the display of the Air Control 1. If the key is
pressed on the system on-site, the system switches off after 120
seconds and for safety reasons, it can only be started via remote control
after the key has been pressed (acknowledgement) on-site. This
also applies for a start via PLANT CONTROL V/T.

2 BLS-OK The input on terminal 23 serves to report the operational readiness of an

external controller. Only with an existing high level (24 VDC) can the
external controller switch between load operation and idle. During
existing low level, the BLS operation is switched off automatically and
the internal pressure sensor is used.

7.4.3.7.7 Set switch on/off pressure: Code 11

By inputting the code 11, it is possible to set the switch-on and switch-
off pressure. The switch-on pressure specifies the pressure at which
the switched-on compressor will begin automatically with the
compression. The switch-off pressure specifies the pressure at which
the compressor will be switched off automatically. Both functions are
only active in automatic operation.

1. Press and hold for three seconds.

 The code input menu appears on the display.

2. Press .

 A 1 appears on the display.

3. Press .

4. Set the code 11 with the keys.

5. To confirm the selected code, press .

6. Press .

 The submenu for setting the switch-on pressure appears on

the display.

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Operation

7.
The adjustment range for the switch-on pressure is,
with switch-off pressure set at the factory, between
3.5 and 7.9 bar. The upper limit for the switch-on
pressure is 0.1 bar less than the switch-off pressure.

Set the desired switch-on pressure with the keys.

8. To confirm the setting, press the key.

 The set value was saved and the submenu for setting the
switch-off pressure appears on the display.

9.
The adjustment range for the switch-off pressure is,
with switch-on pressure set at the factory, between
7.1 and 10 bar. The upper limit for the switch-off
pressure is equal to the maximum pressure. The
lower limit for the switch-off pressure is 0.1 bar
higher than the switch-on pressure.

Set the desired switch-off pressure with the keys.

10. To confirm the setting, press the key.

 The set value is saved and the code input menu appears on
the display again.

11. Press the keys at the same time to go back to the basic
display.

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Operation

7.4.3.7.8 Switch Basic load switching mode on/off: Code 18

By inputting the code 18, the Basic load switching mode can be
switched on/off.

1. Press and hold for three seconds.

 The code input menu appears on the display.

2. Press .

 A 1 appears on the display.

3. Press .

4. Set the code 18 with the keys.

5. To confirm the selected code, press .

 The Basic load switching mode submenu appears on the

display.

6.
There are two values from which to choose:
- 0: Basic load switching mode is switched off
- 1: Basic load switching mode is switched on

Set the desired value with the keys.

7. To confirm the selected value, press .

 The set value is saved and the code input menu appears on
the display again.

8. Press the keys at the same time to go back to the basic

display.

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Operation

7.4.3.7.9 Switch the pressure unit: Code 90

By entering the code 90, the pressure unit can be switched.

1. Press and hold for three seconds.

 The code input menu appears on the display.

2. Press .

 A 1 appears on the display.

3. Press .

4. Set the code 90 with the keys.

5. To confirm the selected code, press .

 The submenu for setting the pressure unit appears on the

display.

6.
There are three values from which to choose:
- 0: bar
- 1: MPa
- 2: psi (pounds per square inch)

Set the desired value with the keys.

7. To confirm the selected value, press .

 The set value is saved and the code input menu appears on
the display again.

8. Press the keys at the same time to go back to the basic

display.

Value Pressure unit Description

0 bar All pressure displays will be in bar.

1 MPa All pressure displays will be in Megapascals.

2 psi All pressure displays will be in psi (pounds per square inch).

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Operation

7.4.3.7.10 Switch the temperature unit: Code 95

By entering the code 95, the temperature unit can be switched.

1. Press and hold for three seconds.

 The code input menu appears on the display.

2. Press .

 A 1 appears on the display.

3. Press .

4. Set the code 95 with the keys.

5. To confirm the selected code, press .

 The submenu for setting the temperature unit appears on the

display.

6.
There are three values from which to choose:
- 0: °C
- 1: °F
- 2: K

Set the desired value with the keys.

7. To confirm the selected value, press .

 The set value is saved and the code input menu appears on
the display again.

8. Press the keys at the same time to go back to the basic

display.

Value Pressure unit Description

0 Degrees Celsius All temperature displays will be in °C.

1 Degrees Fahrenheit All temperature displays will be in °F.

2 Kelvin All temperature displays will be in Kelvin.

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Operation

7.4.3.7.11 Display the software version: Code 9999

By inputting the code 9999, the software version can be displayed.

1. Press and hold for three seconds.

 The code input menu appears on the display.

2. Press .

 A 1 appears on the display.

3. Press .

4. Set the code 9999 with the keys.

5. To confirm the selected code, press .

 The software version appears on the display.

6. Press the keys together to go back to the code input menu.

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Operation

7.4.3.8 Fault and warning messages

7.4.3.8.1 Fault messages

The symbol blinks and the [Aktueller Netzdruck (Current network

pressure)] indicator displays the fault message and the current
network pressure in alternation. The compressor stops automatically.

No. Description
E. 1 Pressure set points incorrect

E. 2 Setting parameter incorrect

E. 3 Low voltage

E. 4 Power failure

E. 5 Air Control mini faulty

E. 6 Emergency stop pressed

E. 7 Direction of rotation incorrect

E. 8 Motor temperature too high

E. 9 Overcurrent

E. 10 Overpressure

E. 11 Dryer fault

E. 12 Sensor compression temperature

E. 13 Sensor coolant liquid temperature

E. 14 Sensor pressure

E. 15 Compressor temperature too high

E. 16 Network pressure too high

E.17 Dew-point temperature too low

E.18 Dew-point temperature too high

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NOTICE!
Property damage due to incorrect acknowledgement
of fault messages!
Faults which occur are output as fault messages. Only
after the fault has been eliminated may the fault
messages be acknowledged, since otherwise the service
life of the compressor will be reduced.
- Only have maintenance work performed by qualified
personnel.
- Only acknowledge fault messages after the
appropriate work.
- Only use original spare parts.

Acknowledging fault messages Faults may only be acknowledged if the cause has been
eliminated properly. Only have troubleshooting and
maintenance work performed by qualified personnel.

1. Press .

2. Press .

 The compressor is ready and can start up automatically at any

time.

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7.4.3.8.2 Warning messages

The symbol blinks and the [Aktueller Netzdruck (Current network

pressure)] indicator displays the warning message and the current
network pressure in alternation.

No. Description
E.33 Dew-point temperature

E. 34 Compressor temperature increased

E. 35 Network pressure increased

E. 36 Temperature too low

E. 39 Lower pressure threshold reached

E. 42 Maintenance dryer (remaining maintenance time < 100 h)

E. 43 Maintenance intake filter

(remaining maintenance time < 100 h)

E. 44 Maintenance coolant liquid / coolant liquid filter

(remaining maintenance time < 100 h)

E. 45 Maintenance fine precipitator (remaining maintenance

time < 100 h)

E. 46 Maintenance motor lubrication (remaining maintenance

time < 100 h)

E. 47 Maintenance compressor (remaining maintenance time

< 100 h)

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Operation

Acknowledging warning
NOTICE!
messages
Property damage due to incorrect acknowledgement
of warning messages!
Maintenance which needs attention is output as warning
messages. Only after the maintenance has been
performed may the warning messages be
acknowledged, since otherwise the service life of the
compressor will be reduced.
- Only have maintenance work performed by qualified
personnel.
- Only acknowledge warning messages after the
appropriate work.
- Only use original spare parts.

1. Press and hold for three seconds.

 The code input menu appears on the display.

2. Press .

 A 1 appears on the display.

3. Press .

4. Set the code 21 with the keys.

5. To confirm the selected code, press .

6. Press the key in order to restart the maintenance interval.

7. Press the keys at the same time to go back to the basic

display.

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Maintenance

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

Moving parts
WARNING!
Danger of injury from moving parts!
Rotating parts and/or parts moving in linear fashion may
cause serious injuries.
- Before carrying out any maintenance work on moving
parts, shut down the machine and take precautions to
prevent restarting. Wait until all parts have stopped
moving.
- When in the danger zone, wear close-fitting protective
work clothing with low tear strength.

Securing to prevent restart

WARNING!
Danger to life from an unauthorised restart!
In the event of an unauthorised restart of the power
supply during maintenance, 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.

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.

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Maintenance

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.

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.

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Maintenance

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.

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.

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.

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Maintenance

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.

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Maintenance

8.3 Maintenance schedule

Maintenance tasks are described in the sections below that are
required 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 Checking the coolant liquid level  Chapter 8.4.2 ‘Checking Qualified personnel
the coolant liquid level/topping up the coolant liquid’ on
page 109

Check for leaks  Chapter 8.4.3 ‘Checking for leaks’ on Qualified personnel
page 111

One week Check all electrical connections  Chapter 8.4.1 ‘Checking Qualified electrician
after initial the electrical connections’ on page 108
installation

Weekly Check compressor temperature  Chapter 7.4 ‘Controllers’ on Trained Person

page 78

Check cooler for soiling  Chapter 8.4.5 ‘Checking soiling of Qualified personnel
the cooler’ on page 113

Check for condensate formation  Chapter 8.4.6 ‘Checking Qualified personnel

the condensation accumulation’ on page 114

Check the drive belt for wear Trained Person

After the first Check for leaks  Chapter 8.4.3 ‘Checking for leaks’ on Qualified personnel
100 hours of page 111
operation
Check compressor temperature  Chapter 7.4 ‘Controllers’ on Trained Person
page 78

Check cooler for soiling  Chapter 8.4.5 ‘Checking soiling of Qualified personnel
the cooler’ on page 113

Check for condensate formation  Chapter 8.4.6 ‘Checking Qualified personnel

the condensation accumulation’ on page 114

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Maintenance

Interval Maintenance work Personnel

After the first Check all electrical connections  Chapter 8.4.1 ‘Checking Qualified electrician
500 hours of the electrical connections’ on page 108
operation
Change coolant liquid  Chapter 8.4.7 ‘Changing the coolant Qualified personnel
liquid/changing the cooling liquid filter’ on page 115

Change coolant liquid filter*  Chapter 8.4.7 ‘Changing the Qualified personnel
coolant liquid/changing the cooling liquid filter’ on page 115

Retighten the drive belt Qualified personnel

Every Re-lubricate electric motor  Chapter 8.4.8 ‘Re-lubricating the Qualified personnel
2000 hours electric motor’ on page 118
of operation,
at least once Change coolant liquid  Chapter 8.4.7 ‘Changing the coolant Qualified personnel
a year liquid/changing the cooling liquid filter’ on page 115

Change coolant liquid filter*  Chapter 8.4.7 ‘Changing the Qualified personnel
coolant liquid/changing the cooling liquid filter’ on page 115

Change fine precipitator*  Chapter 8.4.9 ‘Change fine Qualified personnel

precipitator’ on page 119

Change intake filter*  Chapter 8.4.10 ‘Change intake filter’ Qualified personnel
on page 120

Check safety valve Manufacturer

Check drive unit  Chapter 8.4.11 ‘Checking the drive unit’ on Qualified personnel
page 121

Check the belt tension of the drive Qualified personnel

Perform general compressor maintenance Manufacturer

Every Replace the drive belt Qualified personnel

4000 hours of
operation

* The change intervals refer to:

 Ambient temperature of +40 °C
 Max. humidity of 60%
 Compressor temperature of approx. 85 °C

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Maintenance

8.4 Maintenance work

Necessary maintenance work

Necessary maintenance work appears on the display of
the controller as a warning  Chapter 7.4 ‘Controllers’
on page 78.

8.4.1 Checking the electrical connections

Personnel:  Qualified electrician

Protective equipment:  Safety boots

 Protective work clothing
 Light respiratory protection
 Safety goggles
 Protective gloves

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.

1. Switch the machine off and secure to prevent restarting.

2. Close compressed air network-side gate valve and secure

against re-opening.

3. Open and remove the sound insulation covers with the special
spanner.

4. Check all electrical connections and tighten if necessary

 Appendix B ‘Tightening torques for screws’ on page 137.

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Maintenance

8.4.2 Checking the coolant liquid level/topping up the coolant liquid

Checking the coolant liquid level Personnel:  Qualified personnel

Protective equipment:  Safety boots

 Protective work clothing
 Light respiratory protection
 Safety goggles
 Protective gloves

1. Switch the machine off and secure to prevent restarting.

2. Close compressed air network-side gate valve and secure

against re-opening.

3. Open and remove the sound insulation covers with the special
spanner.

4. Check the inspection glass (Fig. 40/1) 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. 40: Inspection glass

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Maintenance

Topping up the coolant liquid Personnel:  Qualified personnel

Protective equipment:  Safety boots

 Protective work clothing
 Light respiratory protection
 Safety goggles
 Protective gloves

Materials:  Collecting tray for coolant liquid

 Funnel with filling tool

1. Switch the machine off and secure to prevent restarting.

2. Close compressed air network-side gate valve and secure

against re-opening.

3. Open and remove the sound insulation covers with the special
spanner.

4. With the help of a collection tray, make sure that the escaping
coolant liquid is collected.

5. Loosen the filler plug (Fig. 41/1), remove and make sure that the
gasket does not get lost.

NOTICE!
Property damage due to incorrect coolant liquid!
Mixing different coolant liquids causes significant
property damage to the screw compressor.
- Only use the coolant liquid prescribed in the technical
data.

Fig. 41: Filler plug

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Maintenance

6. With the help of a funnel (Fig. 42/1), fill coolant liquid up to the
filling edge of the filler plug (Fig. 42/3).

7. Position the gasket and check for correct fit.

8. Insert the screw plug (Fig. 42/2) and tighten  Appendix B

‘Tightening torques for screws’ on page 137.

Fig. 42: Filler plugs

8.4.3 Checking for leaks

Personnel:  Qualified personnel

Protective equipment:  Safety boots

 Protective work clothing
 Light respiratory protection
 Safety goggles
 Protective gloves

1. Switch the machine off and secure to prevent restarting.

2. Close compressed air network-side gate valve and secure

against re-opening.

3. Open and remove the sound insulation covers with the special
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 137.

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Maintenance

8.4.4 Checking the compressor temperature

Personnel:  Qualified personnel

Protective equipment:  Safety boots

 Protective work clothing

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 compressor temperature  Chapter 7.4 ‘Controllers’ on

page 78.

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Maintenance

8.4.5 Checking soiling of the cooler

Personnel:  Qualified personnel

Protective equipment:  Safety boots

 Protective work clothing
 Light respiratory protection
 Safety goggles
 Protective gloves

1. Switch the machine off and secure to prevent restarting.

2. Close compressed air network-side gate valve and secure

against re-opening.

3. Open and remove the sound insulation covers with the special
spanner.

4. Check compressed air and coolant liquid cooler from inside and
outside for soiling.

5. Remove soiling.

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.

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Maintenance

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.

Personnel:  Qualified personnel

Protective equipment:  Safety boots

 Protective work clothing
 Light respiratory protection
 Safety goggles
 Protective gloves

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.

1. Switch the machine off and secure to prevent restarting.

2. Close compressed air network-side gate valve and secure

against re-opening.

3. Open and remove the sound insulation covers with the special
spanner.

4. With the help of a collection tray, make sure that the escaping
coolant liquid is collected.

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.

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Maintenance

5. Carefully open the coolant liquid drain (Fig. 43/1) and check the
liquid escaping.

6. Slowly drain condensate until coolant liquid escapes.

7. Close  Appendix B ‘Tightening torques for screws’ on page 137

the coolant liquid drain (Fig. 43/1).

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 ‘Checking the coolant liquid level/topping up the
coolant liquid’ on page 109.

Fig. 43: Coolant liquid drain

8.4.7 Changing the coolant liquid/changing the cooling liquid filter

Changing the coolant liquid Personnel:  Qualified personnel

Protective equipment:  Safety boots

 Protective work clothing
 Light respiratory protection
 Safety goggles
 Protective gloves

Materials:  Collecting tray for coolant liquid

 Funnel with filling tool

1. Switch the machine off and secure to prevent restarting.

2. Close compressed air network-side gate valve and secure

against re-opening.

3. Open and remove the sound insulation covers with the special
spanner.

4. With the help of a collection tray, make sure that the escaping
coolant liquid is collected.

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Maintenance

5. Loosen the filler plug (Fig. 44/1), remove and make sure that the
gasket does not get lost.

Fig. 44: Filler plug

6. Open the coolant liquid drain (Fig. 45/1).

 Coolant liquid is drained.

7. Close the coolant liquid drain (Fig. 45/1).

NOTICE!
Property damage due to incorrect coolant liquid!
Mixing different coolant liquids causes significant
property damage to the screw compressor.
- Only use the coolant liquid prescribed in the technical
data.

Fig. 45: Coolant liquid drain

8. With the help of a funnel (Fig. 46/1), fill coolant liquid up to the
filling edge of the filler plug (Fig. 46/3).

9. Position the gasket and check for correct fit.

10. Insert the screw plug (Fig. 46/2) and tighten  Appendix B
‘Tightening torques for screws’ on page 137.

11. Switch on the compressor and switch off again after a maximum
of one minute  Chapter 7.4 ‘Controllers’ on page 78.

12. Check coolant liquid level and top up if necessary

 Chapter 8.4.2 ‘Checking the coolant liquid level/topping up the
coolant liquid’ on page 109.

Fig. 46: Filler plugs

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Maintenance

Changing the coolant liquid filter* Personnel:  Qualified personnel

Protective equipment:  Safety boots

 Protective work clothing
 Light respiratory protection
 Safety goggles
 Protective gloves

Materials:  Collecting tray for coolant liquid

 Strap spanner

1. Switch the machine off and secure to prevent restarting.

2. Close compressed air network-side gate valve and secure

against re-opening.

3. Open and remove the sound insulation covers with the special
spanner.

4. With the help of a collection tray, make sure that the escaping
coolant liquid is collected.

5. Using the strap spanner, loosen and remove the old coolant liquid
filter (Fig. 47/1).

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. 47/1) up to the stop.

9. Tighten the new coolant liquid filter (Fig. 47/1) half a turn by hand.

10. Switch on the compressor and switch off again after a maximum
of one minute  Chapter 7.4 ‘Controllers’ on page 78.

11. Check coolant liquid level and top up if necessary

Fig. 47: Remove coolant liquid filter  Chapter 8.4.2 ‘Checking the coolant liquid level/topping up the
coolant liquid’ on page 109.

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Maintenance

8.4.8 Re-lubricating the electric motor

Personnel:  Qualified personnel

Protective  Safety boots

equipment:  Protective work clothing
 Light respiratory protection
 Safety goggles
 Protective gloves

Materials:  Lubrication grease ALMiG part number

183.00103

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

encapsulated, permanently-lubricated bearings. Replace
these motor bearings when worn.

1. Switch the machine off and secure to prevent restarting.

2. Close compressed air network-side gate valve and secure

against re-opening.

3. Open and remove the sound insulation covers with the special
spanner.

4. For the quantity of lubricating grease, consult the type plate of the
electric motor.

The grease nipples are always on the side of the

terminal box.

5. Grease the grease nipples (Fig. 48/1) with a grease gun.

Fig. 48: Grease nipples

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Maintenance

8.4.9 Change fine precipitator

Personnel:  Qualified personnel

Protective equipment:  Safety boots

 Protective work clothing
 Light respiratory protection
 Safety goggles
 Protective gloves

Materials:  Strap spanner

1. Switch the machine off and secure to prevent restarting.

2. Close compressed air network-side gate valve and secure

against re-opening.

3. Open and remove the sound insulation covers with the special
spanner.

4. With the help of a collection tray, make sure that the escaping
coolant liquid is collected.

5. Using the strap spanner (Fig. 49/2), loosen and remove the fine
precipitator (Fig. 49/1).

6. Remove old gasket remains from the fine precipitator (Fig. 49/1).

7. Moisten the new gasket with a little coolant liquid.

Fig. 49: Loosen fine precipitator

8. Screw in the new fine precipitator (Fig. 50/1) up to the stop.

9. Tighten the new fine precipitator (Fig. 50/1) half a turn by hand.

Fig. 50: Fine precipitator

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Maintenance

8.4.10 Change intake filter

Standard intake filter Personnel:  Qualified personnel

Protective equipment:  Safety boots

 Protective work clothing
 Light respiratory protection
 Safety goggles
 Protective gloves

1. Switch the machine off and secure to prevent restarting.

2. Close compressed air network-side gate valve and secure

against re-opening.

3. Open and remove the sound insulation covers with the special
spanner.

4. Loosen the intake filter (Fig. 51/2).

5. Remove the old intake filter (Fig. 51/1).

6. Attach the new intake filter (Fig. 51/1).

7. Tighten the clamp of the intake filter (Fig. 51/2)  Appendix B

‘Tightening torques for screws’ on page 137.

Fig. 51: Loosen the clamp of the intake

filter

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Maintenance

8.4.11 Checking the drive unit

Personnel:  Qualified personnel

Protective equipment:  Safety boots

 Protective work clothing
 Light respiratory protection
 Safety goggles
 Protective gloves

1. Switch the machine off and secure to prevent restarting.

2. Close compressed air network-side gate valve and secure

against re-opening.

3. Open and remove the sound insulation covers with the special
spanner.

4. Visually check the drive unit.

 In case of visible defects, contact the manufacturer.

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

perfectly.

7. Document work on the machine in the service manual

( Appendix C ‘Service manual’ on page 138).

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Faults

9 Faults
The following section describes possible causes of faults and the work
to remedy them.
In case of faults that occur more than once, abbreviate the
maintenance intervals according to the actual utilisation.
In case of faults that cannot be remedied using the following
instructions, contact the manufacturer, see contact data on page 2.

9.1 Safety instructions for fault clearance

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

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.

Securing to prevent restart

WARNING!
Danger to life from an unauthorised restart!
In the event of an unauthorised restart of the power
supply while tracking down and rectifying a fault, 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.

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Faults

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.

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.

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Faults

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.

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.

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Faults

9.3 Fault table

Fault description Cause Remedy Personnel

Compressor Intake or ambient Ventilate compressor Qualified personnel

temperature too high temperature too high room
(red lamp lights up)
Cooling air intake or Unblock cooling air intake Qualified personnel
outlet blocked or outlet sufficiently

Coolant liquid is soiled Change coolant liquid Qualified personnel

 Chapter 8.4.7
‘Changing the coolant
liquid/changing the
cooling liquid filter’ on
page 115

Coolant liquid low Top up coolant liquid Qualified personnel

 Chapter 8.4.2
‘Checking the coolant
liquid level/topping up the
coolant liquid’ on
page 109

Coolant liquid cooler Clean coolant liquid Qualified personnel

soiled cooler  Chapter 8.4.5
‘Checking soiling of the
cooler’ on page 113

Network pressure Compressed air Screw compressor with Manufacturer

drops consumption higher than greater delivery quantity
delivery quantity of the necessary
screw compressor

Intake filter soiled Replace intake filter Qualified personnel

 Chapter 8.4.10
‘Change intake filter’ on
page 120

Bleeder valve blows Check bleeder valve and Manufacturer

during compression replace gaskets if
necessary

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

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Faults

Fault description Cause Remedy Personnel

Screw compressor Minimum pressure valve Clean or replace Manufacturer

blows via safety valve blocked minimum 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 ‘Change
fine precipitator’ on
page 119

"Overpressure fault "or Fine precipitator soiled Change fine precipitator Qualified personnel
"Network pressure too  Chapter 8.4.9 ‘Change
high" (red lamp lights fine precipitator’ on
up) page 119

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 high  Chapter 7.4
automatically or does ‘Controllers’ on page 78
not discharge after
previous switching-off Interruption in the power Check power circuit for Qualified electrician
by reaching the final circuit interruption
pressure or from idle.
Ambient temperature Install additional heating Qualified personnel
below +1 °C, message or temper compressor
"Coolant liquid room and also contact the
temperature too low" manufacturer

Switching times are Check switching and Trained Person

activated in the circuitry pressure times in the
circuitry  Chapter 7.4
‘Controllers’ on page 78

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Faults

Fault description Cause Remedy Personnel

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  Chapter 7.4
‘Controllers’ on page 78

Symbol "remote" flashes Remote control activated Trained Person

 Chapter 7.4
‘Controllers’ on page 78

Lacking voltage on the Check whether there is Qualified electrician

screw compressor voltage

Electrical fault in the Check controller Qualified electrician

controller

Switching times are Check switching and Trained Person

activated in the circuitry pressure times in the
circuitry  Chapter 7.4
‘Controllers’ on page 78

Compressed air Return line for the coolant Clean or replace return Qualified personnel
contains a lot of coolant liquid is blocked line for the coolant liquid
liquid (coolant liquid  ‘Clean/change return
consumption too high) line’ on page 128

Flawed fine precipitator Change fine precipitator Qualified personnel

 Chapter 8.4.9 ‘Change
fine precipitator’ on
page 119

System stops before Overtemperature or Eliminate fault Trained Person

reaching the final overpressure  Chapter 7.4
pressure (red lamp ‘Controllers’ on page 78
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

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Faults

9.4 Work for fault clearance

Clean/change return line Personnel:  Qualified personnel

Protective equipment:  Safety boots

 Protective work clothing
 Light respiratory protection
 Safety goggles
 Protective gloves

1. Switch the machine off and secure to prevent restarting.

2. Close compressed air network-side gate valve and secure

against re-opening.

3. Open and remove the sound insulation covers with the special
spanner.

4. With the help of a collection tray, make sure that the escaping
coolant liquid is collected.

5.
Depending on the type, several fine precipitators
can be installed. There is a return line for each fine
precipitator.

Loosen return line (Fig. 52/2) on separator box (Fig. 52/3) and
compressor stage (Fig. 52/1).

6. Clean return line (Fig. 52/2) and nozzle, if necessary replace with
Fig. 52: return line original spare parts ( Appendix D ‘Spare parts list’ on
page 142).

7. Put nozzle and return line (Fig. 52/2) back in position and tighten
screws ( Appendix B ‘Tightening torques for screws’ on
page 137).

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.

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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!
Danger to life from electric power!
Contact with live parts may prove fatal. When switched
on, electric components may be subject to uncontrolled
movements and may cause grave injury.
- 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.

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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.

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Index

11 Index

Set switch on/off pressure ...............................92

A Setting parameters ..........................................86
Accident .............................................................. 27 Switch automatic restart on/off ........................89
Air Control AC mini controller ............................. 81 Switch the temperature unit ............................96
Acknowledging fault messages ...................... 99 Switching off ....................................................84
Acknowledging faults ...................................... 99 Switching on ....................................................84
Acknowledging warning messages ............... 101 Switching the pressure unit .............................95
Basic display ................................................... 83 Warning messages .......................................100
Brief description .............................................. 82 Warnings .......................................................100
Calling up information ..................................... 84 Assemblies
Calling up parameter values ........................... 84 COMBI drive unit .............................................53
Calling up the code input menu ...................... 86 Compressed air after-cooler ...........................56
Code 11........................................................... 92 Controller .........................................................51
Code 18........................................................... 94 Coolant liquid cooler........................................56
Code 2............................................................. 87 Cooler .............................................................. 56
Code 3............................................................. 89 Cooling air fan .................................................57
Code 6 ............................................................. 90 Fresh air fan ....................................................57
Code 8............................................................. 91 Heat exchanger ...............................................56
Code 90........................................................... 95 Water cooling ..................................................56
Code 95........................................................... 96
Code 9999 ...................................................... 97 B

Dew-point monitoring ....................................... 90 Brief description ..................................................50

Display ............................................................ 83 C
Display the software version ........................... 97 Change
Fault messages ............................................... 98 coolant liquid .................................................115
Faults .............................................................. 98 coolant liquid filter .........................................115
Inputting a code .............................................. 86 fine precipitator ..............................................119
Maximum operating cycles ............................. 88 return line ......................................................128
Maximum pressure drop ................................. 88 Change intake filter ...........................................120
Operating modes ............................................ 82 Checking
Other display indicators .................................. 83 the coolant liquid level .............................70, 109
Overview ......................................................... 81 Checking for leaks ............................................111
Safety pressure ............................................... 82 Checking soiling of the cooler ...........................113
Select operating mode .................................... 87 Checking the condensation accumulation ........114
Set Basic load switching mode ....................... 94 Checking the temperature ................................112
Set on-site operation/remote operation .......... 91

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Index

Clean Switching on ................................................... 80

return line ......................................................128 Coolant liquid ..................................................... 33
Components Start-up lubrication ......................................... 71
Compressor stage ...........................................54 Coolant liquid filter ............................................. 56
Coolant liquid drain .........................................54 Coolant liquid pressure tank .............................. 54
Coolant liquid filter ...........................................56 Cooler................................................................. 56
Coolant liquid pressure tank............................54 Cooling air fan .................................................... 57
Filler plugs .......................................................54 Copyright ............................................................ 10
Fine precipitator ..............................................55 Customer service ............................................... 10
Inspection glass ..............................................54
D
Intake filter .......................................................53
Description of function ....................................... 50
Minimum pressure and return valve ................55
Dismantling ...................................................... 130
Refrigerant-type dryer .....................................57
Disposal ........................................................... 130
Safety valve .....................................................54
Drive
Sound insulation covers ..................................52
COMBI ............................................................ 53
Compressor stage ..............................................54
Drive unit .................................................... 53, 121
Connecting air .....................................................68
Connecting compressed air ................................68 E
Connecting the current .......................................69 Electric current ................................................... 17
Connecting the power supply .............................69 Emergency ......................................................... 76
Connection values Emergency stop ................................................. 76
COMBI 16 – 22 electric ...................................45 Emergency stop key .......................................... 23
COMBI 16 –22 air supply ................................45 Emissions ........................................................... 32
COMBI 3S – 5S air supply ..............................35 Environmental protection
COMBI 3S – 5S electric ..................................35 Coolant liquid .................................................. 28
COMBI 6 – 15 air supply .................................41 Lubricants ....................................................... 28
COMBI 6 – 15 electric .....................................41
F
Consumables
Fault
COMBI 16 – 22................................................46
Return line .................................................... 128
COMBI 6 – 15..................................................42
Fault displays ................................................... 124
Contact person....................................................10
Fault messages .................................................. 98
Controller ............................................................51
Acknowledging ............................................... 99
Controller COMBI 3S – 4S
Fault table ........................................................ 125
Overview .........................................................78
Fine precipitator ................................................. 55
Switching off ....................................................79
Fire ..................................................................... 27
Switching on ....................................................79
First aid .............................................................. 27
Controller COMBI 5S
Forced ventilation and bleeding ......................... 68
Overview .........................................................80

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Index

G Replace coolant liquid ...................................115

General details Replace coolant liquid filter ...........................115
COMBI 16 – 22 ............................................... 43 Top up coolant liquid .....................................109
COMBI 3S –5S ............................................... 33 Minimum pressure and return valve ...................55
COMBI 6 – 15 ................................................. 37
N
I Noise emissions ..................................................32
Inspection at delivery .......................................... 60
O
Installation
Operating conditions ...............................36, 42, 46
Forced ventilation and bleeding ...................... 68
Overview
Ventilation ....................................................... 67
Assemblies ......................................................48
Installation conditions ......................................... 66
COMBI 3S – 5S ...............................................47
Installation location ............................................. 66
COMBI 6 – 22 .................................................47
Intake filter .......................................................... 53
Owner ................................................................. 12
Interfaces ............................................................ 58
Air supply ........................................................ 59 P
Compressed air connection ............................ 59 Packaging ...........................................................61
Media .............................................................. 58 Personnel ............................................................ 13
Proper use ..........................................................11
L
Protective equipment ..........................................15
Liquid stream ...................................................... 19
Lubricants R
COMBI 3S – 5S .............................................. 36 Refrigerant-type dryer .........................................57
Re-lubricating the electric motor .......................118
M
Replace
Main switch ......................................................... 23
coolant liquid .................................................115
Maintenance
coolant liquid filter .........................................115
Change coolant liquid filter* .......................... 115
Rescue measures ...............................................76
Change fine precipitator ................................ 119
Change intake filter ....................................... 120 S
Checking for leaks ........................................ 111 Safety
Checking soiling of the cooler ....................... 113 General............................................................ 11
Checking the compressor temperature......... 112 Safety devices ....................................................22
Checking the condensation accumulation .... 114 Safety valves ......................................................24
Checking the coolant liquid level .................. 109 Service ................................................................ 10
Checking the drive unit ................................. 121 Service manual .................................................139
Coolant liquid change ................................... 115 Signs ................................................................... 29
Re-lubricating the electric motor ................... 118 Sound insulation covers......................................52

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Index

Spare parts .......................................................105 U

Starting up compressed air generation ...............72 Use ..................................................................... 11
Start-up lubrication ..............................................71
V
Storage ...............................................................63
Ventilation .......................................................... 67
Switching on after the initial commissioning .......72
Symbols W
in this manual ....................................................8 Warning messages .......................................... 100
on the machine ................................................30 Acknowledging ............................................. 101
on the packaging .............................................62 Warranty terms .................................................. 10
Working after the initial commissioning ............. 73
T
Top up
coolant liquid .................................................109
Transport.............................................................62
Type plate ...........................................................32

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Appendix

12 Appendix

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Training log

A Training log
Date Name Type of training Training conducted Signature
by

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Tightening torques for screws

B Tightening torques for screws

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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:

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Service manual

Daily checks Weekly checks

Hours of Coolant Leakage Compressor Cooler Condensate Clean Date Name

operation liquid temperature soiling accumulation intake
level filter
mats

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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

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Service manual

Additional maintenance and repair work

Hours of Date Spare parts Name

operation

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Spare parts list

D Spare parts list

Spare parts list
The spare parts list is included with the documents.

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ALMiG Kompressoren GmbH
Adolf-Ehmann-Straße 2
73257 Köngen

Phone +49 7024 9614 0

Email [email protected]
Internet www.almig.de

ArtNo. 195. 03276REV06_gb