ALUP Kompressoren SCK 21, Maintenance And Operating Instructions

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Commissioning
5. Commissioning
5.1 Preservation
Machines which are standing still after delivery ex works or are to be
stored for a longer period before commissioning, will be filled up with
preservative oil. This preservative oil has to be drained and disposed
together with the flushing oil (appr. 1/3 of the normal oil supply, which
will be flushed through the operating unit for about 30 min.).
Please mind the initial lubrication of section 5.4 before commissioning!
5.2 Oil level check
The maximum oil level is the lower edge of the oil filler neck (11.1).
During operation the oil level will slightly fall by internal distribution.
With rising machine temperature or even a temperature cut-off due
to low oil level, the compressor is to be filled up with fresh oil into the
oil filler neck (11.1).
5.3 Oil quality
With regard to the high load of the lube oil in oil injection cooled
screw-type compressors, we recommend to use very non-aging, water-
repellent, non-foaming, anti-corrosion oils, e.g. our SPECIAL OIL. This
oil is filled in by the works (refer to the oil tank (11) sticker).
F Different kinds of oils must not be mixed. In case other lubricants
are used, you should contact the after-sales service p . We only grant
our warranty for the compressors when the use of equivalent lubricants
is verified.
5.4 Initial lubrication of the compressor stage
(04) (refer to section 1.3)
F
After a longer standstill period, e.g. between initial
commissioning and delivery ex works or after a longer works holiday,
it may happen that there is no oil in the rotor compartment of the
compressor stage (04). This oil, however, is absolutely necessary for
lubricating rotors and bearings in the starting phase. Therefore it is
necessary to fill about 0.2 l. oil into the prelube plug of the suction
valve (06). Manually rotate the compressor stage (04) in the right
direction of rotation until the sensible resistance disappears and the
oil is passed through the stage (04). Mount the prelube plug again
into the suction valve (06).
If no additional oil is available (only use the same kind of oil) the oil
can be drained from the system by means of the oil drain (11.2).
Irregular operating machines and those which are standing still for
several weeks should run for one hour every week, in idle mode, to
prevent corrosion damage.
5.5 Direction of rotating (refer to section 1.3)
F The direction of rotation must comply with the arrow on the
electric motor (01). When checking, the machine must only be switched
on (and immediately off) for a very short time (max. 0.5 sec.) in order
not to damage the compressor stage (04). The direction of rotation
can be changed when two external conductors are exchanged.
5.6 Starting
Before starting the machine, verify that no persons can be endangered.
The sound cover hood is part of the protection against accidental
contact and leads the cooling air of the machine. It must be closed
during operation. Open the shut-off valve between compressor and
compressed-air system. Switch on the power supply.
Push the start key I . The green lamp lights up and indicates operation
or, if the line pressure is above the set cut-in pressure, the start
temperature is below + 5°C or with activated remote control, only
flashes stand-by.
CAUTION! A FLASHING GREEN LAMP MEANS THE
COMPRESSOR CAN ALWAYS START UP AUTOMATICALLY
The lines carrying oil and compressed air are to be checked for leakages.
After the cut-out pressure is achieved the machine shuts down after
the set follow-up time (automatic) or changes over to idle running
(load-idle mode).
5.7 Shutdown
Push the stop key O . The green lamp extinguishes. The compressor
shuts down after the follow-up time, the suction valve (06) closes
and the oil tank (11) is relieved. The line pressure is available up to
the non-return valve integrated in the separator box, i.e. the
compressed-air recooler (09) is admitted with line pressure. Program
changing and setting of pressure or time values can only be carried
out with the required code and the compressor at standstill.
6. Compressor maintenance
6.1 General information
F
All maintenance work is to be carried out by trained specialists
with the machine switched off, at standstill, pressure-relieved and
protected against reconnection.
6.2 Pressure relief
Before any maintenance work is carried out, the pressure relief is to
be checked as follows : disconnect the compressor from the
compressed-air system by closing the shut-off valve. The pressure relief
is to be checked by venting the safety valve (12).
F The temperature of the oil tank (11) may not be more than
+40 °C!
F Attention - caution!
It is absolutely necessary to wear face and body protection
because hot oil mist can penetrate.