Renner Kompressoren RS 90/1-110 Operation Manual Download Page 88

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Operation Manual

RENNER Compressors

AW – Maintenance Check Sheet Annex

AW-2

When Due

Latest

Maintenance Work

Parts Required

Month

10,000 h

As for 2000 h

or 1x per year

12,000 h

As for 2000 h plus:

Plus:

or 1x per year

Suction regulator maintenance kit

Suction regulator maint. kit

Separator head maintenance kit

Separator head maint. kit

Change complete front cover

Complete front cover

Change solenoid coil

Solenoid coil

Change V-belt

V-belt

14,000 h

As for 2000 h

or 1x per year

16,000 h

As for 2000 h plus:

Plus:

or 1x per year

Change thermo-valve element

Thermo-valve element

Change O-ring on oil filler plug

O-ring for oil filler plug

Change oil return inspection glass (where fitted)

oil return inspection glass

18,000 h

As for 2000 h plus:

Plus:

or 1x per year

Change V-belt

V-belt

20,000 h

As for 2000 h

or 1x per year

22,000 h

As for 2000 h

or 1x per year

24,000 h

As for 2000 h plus:

Plus:

or 1x per year

Change V-belt

V-belt

Change thermostatic valve element

Thermostatic valve element

Change O-ring on oil filler plug

O-ring for oil filler plug

Change oil return inspection glass (where fitted)

oil return inspection glass

Suction regulator maintenance kit

Suction regulator maint. kit

Separator head maintenance kit

Separator head maint. kit

Change complete front cover

Complete front cover

Complete electric control unit

Electric control unit

² With RENNER SUPER LUB every 4000 h

³ Theoretical service life > 4000 h, from a technical point of view change interval should be 2000 h

Summary of Contents for RS 90/1-110

Page 1: ...ep in a safe place for future use Operation Manual RENNER Kompressoren GmbH Emil Weber Str 32 D 74363 Güglingen Tel 49 0 7135 931 93 0 Fax 49 0 7135 931 93 50 info renner kompressoren de www renner kompressoren de EN RS F 90 1 110 25191_EN_01 ...

Page 2: ...5 Personnel requirements 0 8 No Subject Page 1 1 Symbols 1 2 1 2 Basic safety instructions 1 3 1 3 Conduct in case of accidents 1 6 No Subject Page 2 1 Authorised access points 2 2 2 2 1 Safety devices 2 4 2 2 2 Compressor unit 2 5 2 2 3 Instrumentation panel 2 9 2 2 4 Control optional 2 10 2 2 5 Frequency converter optional 2 11 Chapter 0 General Information Chapter 1 Safety Instructions Chapter ...

Page 3: ...Rtronic plus 4 5 4 4 Control instrumentation RENNERtronic TOUCH 4 6 4 5 Control instrumentation RENNERtronic TOUCH Plus 4 7 4 6 Starting normal operation 4 8 4 7 Switching off the compressor 4 11 4 8 Remedying malfunctions in normal operation 4 13 4 9 Pressure dew point operating temperature 4 18 No Subject Page 5 1 Essential points 5 2 5 2 Rectifying faults 5 5 5 3 Venting the compressor system 5...

Page 4: ...1 5 9 Tensioning changing the V belts 5 11 No Subject Page 6 1 Decommissioning the plant 6 2 6 2 Re commissioning after storage 6 4 6 3 Shut down and disposal 6 5 No Subject Page ASt Wiring diagrams ACE CE Conformity Declaration AW1 Maintenance check sheet AW2 Maintenance motor bearings AW3 Maintenance Control AFU Frequency converter optional Chapter 6 Decommissioning and Disposal Appendices ...

Page 5: ...subjects Utilisation of the INSTALLATION OPERATION MAINTE NANCE MANUAL Compressor Operation and Usage Personnel responsibilities This chapter relates to the following subjects No Subject Page 0 1 General information 0 2 0 2 Structure and use of the manual 0 4 0 3 Intended Usage 0 5 0 4 Requirement of the user 0 6 0 5 Personnel responsibilities 0 7 Contents Survey ...

Page 6: ...ruction Serial number Model Location RENNER Kompressoren Emil Weber Strasse 32 D 74363 Gueglingen This manual should be kept in a clean safe condition and should be readily available to authorised personnel at all times Do not remove any pages from this manual Any lost or mislaid pages should be replaced especially if they relate to health and safety matters Continuation next page Contents Validit...

Page 7: ...the manufac turer If modifications are made without the prior agreement of the manufacturer all warrantees and manufacturers responsibilities will be invalidated In these cases the process for conformity evaluation pursuant to 2006 42 EC for all components may need to be carried out again The following suppliers documents are part of this manual and must be kept save and related to Documents for m...

Page 8: ... regarding the manual its usage personnel responsibilities 1 Definition of the symbols used Basic safety instructions 2 Description and function of the compressor 3 Operating the compressor 4 Maintenance hints A xy Appendix es The pages have been consecutively numbered according to the chapter Example 3 2 Signifies Chapter 3 Page 2 Example AS 1 Signifies Appendix and S for control Page 1 Continuat...

Page 9: ...emperature must be below 40 C Authorized persons only are allowed to work on the com pressor The machine must only be operated with the safety devices installed The safety and operating advice contained in this manual must be observed Any instructions given by the operating company must be observed The legal accident prevention rules must be respected Misuse is regarded as Operation by non authori...

Page 10: ... ensure that the personal protec tive equipment required is available for the operating personnel the service and maintenance personnel the maintenance and repair personnel and that it is used accordingly The operating company must ensure that prior to start up all personnel who will maintain service or operate the compressor are fully aware of the current personal and environmental safety regulat...

Page 11: ...uctions from the operating company as to the labor pro tection law The operator must have a clear understanding of the in structions given by the operating company and must carry them out The service and maintenance personnel must comply with the following duties carry through regular inspection and maintenance work up keep of the compressor carry through test runs of the machine check the integra...

Page 12: ...advice It must be clearly understood that the safety advice given in this manual should only be used as an additional aid to the national safety accident prevention rules and laws currently in force Existing accident prevention rules and regulations must be re tained and adhered to at all times This chapter relates to the following subjects No Subject Page 1 1 Symbols 1 2 1 2 Basic safety advice 1...

Page 13: ...nger This symbol relates to danger of life and health of people due to electric voltage Attention This symbol is a sign of danger for machine material or the environment Advice This symbol is to indicate important advice and information which contribute to your own safety as well as to the better understanding of the compressor operation Disposal This symbol indicates advice as to the disposal of ...

Page 14: ... be excluded These dangers will be ex plained in this chapter Endangerment of people due to lack of qualification and or operational faults of the ser vice personnel Explanation Operational faults may cause personal injury or damage to equipment and property You should only operate this equipment Having the qualification necessary Having received complete instructions from the Op erating Company H...

Page 15: ...e As voltag es of more than 44mA can be fatal corresponding precautions are required Do not touch live cables or connections In case of damaged cables report immediately to the maintenance personnel Ensure all doors to electrical installations are closed se curely Always isolate electrical sup ply before starting any maintenance work on the compressor Only trained personnel must carry out maintena...

Page 16: ...oading Do not exceed the technical limit values stipulated Burns through hot compressor parts Do not touch compressor parts immediately after having opened the doors of the canopy Burns through hot lu brication oil when top ping up or changing oil Turn the oil filler cap slowly anti clockwise during the first 5 rota tions until a tangible snap point Thus the remaining pressure will be slowly relie...

Page 17: ...phone numbers required as well as the contact person At an accident proceed in the following sequence Action If Then 1 there are injured people administer first aid if you are a trained first aider 2 there are injuries to people and damage to proper ty inform the rescue team of the severity of injuries and type of damage to property 3 the disaster fire has happened leave the machine immedi ately u...

Page 18: ...nition of the safe access points for operating the compressor Overview of the compressor and its control instrumentation This chapter is subdivided as follows No Subject Page 2 1 Authorised access points 2 2 2 2 Safety devices 2 4 2 3 Compressor unit 2 5 2 4 Instrumentation panel 2 9 2 5 Frequency converter optional 2 10 Contents Overview ...

Page 19: ...ion and maintenance work Other access points are not intended for operating the compressor and are therefore not permitted as operator stations Safe operation can only be guaranteed from the operator terminals specified Work on the switch box and electrical installations may only be carried out by qualified electricians Approximate illustration Continued overleaf Contents NB Diagram Access points ...

Page 20: ...d for the operation of the machine No Operation Actions permitted 1 of the control panel Check working pressure Check oil and operating temperature Read number of hours of operation Switch on compressor Emergency stop or close down of compressor 2 of the safety devices Carry out inspection and minor maintenance work Description Access points ...

Page 21: ... compressor Item Description Function 1 STOP button Stops compressor immediately in emergency 2 Switch box door Guard door on switch box To be opened by qualified electricians only CAUTION Danger Voltage 3 Top cover Access to pressure switch air filter and control valve 4 Front panel Access to motor drive belt and air filter 5 Side panels Access to oil filter trap cartridge and oil filler neck Con...

Page 22: ...ompressor unit Description Compressor unit Control Switch cabinet Motor Oil flller neck with oil level gauge Oil drain plug Air end Compressed air outlet Pivoting motor base Precision separator with minimum pressure maintaining valve Intake air filter Oil filter Cooling air intake Type plate ...

Page 23: ...The discharge pressure switch may only be adjusted by personnel authorised by the manufacturer Intake regulator The intake regulator is mounted directly on the screw type compressor It controls the air volume sucked in by the screw type compressor via the intake filter Functional principle of the intake regulator The intake regulator has only one master valve This doubles up as an infinitely varia...

Page 24: ...on This cartridge is designed as a screw on screw off type and is secured on the filter support of the separator tank by means of connection nipples cf Fig 4 Diagram of trap cartridge Oil scavenge sight gauge oil scavenge non return valve The sight gauge is located near the oil separator cartridge and indicates the level of oil separated in the cartridge When the compressor is started the level in...

Page 25: ...unit It is integrated in the instrument panel It monitors the maximum permissible operating temperature of the unit which is set at 110 C red mark When this temperature is reached the circuit is broken and the unit cuts out automatically The line capillary connecting the Combistat to the compressor unit must not be kinked as this will break the contact Safety valve The safety valve is fitted on th...

Page 26: ... ratios and excess pressure 13 Combistat temperature indicator Indicates operating temperature and overheating 14 Operating hour meter Counts the number of hours operated by the compressor 15 Start button Switches the compressor on 16 Stop button Switches the compressor off in case of emergency 17 Type plate Summarises the main performance data and compressor model Diagram Instrumentation panel De...

Page 27: ...trumentation controls Item Description Function 1 Compressor ON Switches the compressor on 2 Compressor OFF Switches the compressor off 3 Multiple function keys Navigate in the menus set parameters etc 4 Display Displays the parameters 5 LED green Service LED 6 LED red Fault maintenance LED NB Please see the explanations in Chapter 4 and also the instruction manual for the RENNER Tronic control Co...

Page 28: ...ents Item Description Function 1 Display Displays the parameters 2 Key pad Keys to control and set the operating parameters Danger The frequency converter operates at voltages which can deliver a fatal shock upon contact Installation and maintenance work may be carried out by qualified electricians only NB Please see the explanations in the FC Appendix and the instruction manual for the frequency ...

Page 29: ... components No Name Function 1 Display Displays the parameters 2 Key pad Keys to control and set the operating parameters 3 Control panel Frequency converter control panel Hazard The frequency converter operates at voltages which can deliver a fatal electric shock upon contact Installation and maintenance work may be carried out by qualified electricians only NB Please see the explanations in the ...

Page 30: ...on 1 Display Displays the parameters 2 Key pad Keys to control and set the operating parameters 3 Control panel Frequency converter control panel Hazard The frequency converter operates at voltages which can deliver a fatal electric shock upon contact Installation and maintenance work may be carried out by qualified electricians only NB Please see the explanations in the FU Appendix and the manufa...

Page 31: ...an tip over at an inclination of more than 10 Use suitable transport means such as a forklift lifting gear or loading harness Support it from the side Unpacking the machine has no special requirements and the interim storage in the transport packaging is also not problem atic Protect the compressor against tilting over by storing it on level firm ground Dispose of the packaging material carton mar...

Page 32: ... site is illuminated to read off the instruments carry out maintenance work Lifting work Secure any loose swinging or pivoting parts before lifting the compressor Use suitable lifting gear weight acc to data sheet Always remain outside the danger zone of a raised load Conduits pressure pipes Remove all blank flanges stoppers covers and bags with drying agents before mounting conduits Please ensure...

Page 33: ...owing must be observed when connecting to the com pressed air system Key word Ensure that Pressure Suitable screws and conduits are used for the operating pressure The end pressure of the system is not higher than stated on the rating plate A non return valve between the machine and the compressed air system is not required as it has already been integrated in the machine Connection Connect the sy...

Page 34: ...ltage stated on the engine rating plate Rotation The rotational direction is observed under all circumstances Based on the attached arrows Checking the rotational direction see chap 3 3 3 4 Not necessary for frequency controlled compressors Fuses Customer to install the main fuse and circuit breaker with the EMERGENCY STOP function these must be able to switch at least 1 1 times the motor output a...

Page 35: ...ied out before the first start up Step Task to be carried out Points to be observed 1 Have an electrician tighten all screw and terminal connections in the control cabinet 2 The motor bearings of compressors without perma nent greased motor bearings that are unused longer than 6 month have to be regreased before putting into operation 3 A clearly visible sign must be affixed to machines with remot...

Page 36: ...tion of the V belt pulley must follow the direction of the attached arrows If necessary reconnect the connecting cable electrician WARNING The rotation control must be carried out as a two hand opera tion An incorrect rotation for longer than 2 seconds will lead to faults in the screw compressor There is a danger from moving parts when checking the rotation with the safety doors open Checking the ...

Page 37: ...ows when checking the rotation Step Operation Figure Expl 1 Open the front door 2 Start the compressor by tap ping the green start button once with the one hand im mediately let go of the button 3 Within 2 seconds stop the compressor by pressing the red stop button with the other hand ...

Page 38: ...t a test run so that the oil can be distributed throughout the machine Step Operation Figure Expl 1 Open the shut off valve Press the start button and let the machine run for approx 5 seconds 2 Press the stop button 3 Repeat points 1 and 2 twice Test run INFO Conduct a test run ...

Page 39: ...l instrumentation RENNERlogic 4 2 4 2 Control instrumentation RENNERtronic 4 3 4 3 Control instrumentation RENNERtronic plus 4 5 4 4 Control instrumentation RENNERtronic TOUCH 4 6 4 5 Control instrumentation RENNERtronic TOUCH Plus 4 7 4 6 Starting normal operation 4 8 4 7 Switching off the compressor 4 11 4 8 Remedying malfunctions in normal operation 4 13 4 9 Pressure dew point operating tempera...

Page 40: ...hed on The main switch is installed by the customer 2 Stop button Stops the compressor 3 Emergency Stop Stops compressor im mediately in emergency 4 Operating hour meter Counts the number of hours the compressor has actually run 5 Pressure gauge Working pressure Displays working pres sure setting 6 Temperature display Combistat Displays the oil tempera ture and operating tem perature Content Figur...

Page 41: ...ED 3 Compressor OFF Stop Switches the compressor off 4 Arrow key UP The UP key takes you to the pre vious menu item and increases parameter values Also serves to call up the INFO level in conjunction with the En ter key 5 Arrow key DOWN The DOWN key takes you to the next menu item and decreases parameter values Also serves to call up the INFO level in conjunction with the En ter key Content Figure...

Page 42: ...ve entries or changes 7 LED red Fault maintenance LED 8 Quit Quit discards inputs and ends a selected menu item It also acknowledges warning and error messages 9 Display Displays the parameters and the error warning messages 1st line Displays current opera tional data 2nd line Displays menu values as well as error and warning messages ...

Page 43: ...ault maintenance LED 5 Enter Select a menu item Confirm or save entries or changes 6 Arrow key DOWN The DOWN key takes you to the next menu item and decreases parameter values 7 Arrow key UP The UP key takes you to the pre vious menu item and increases parameter values 8 Function keys F1 F2 F3 On the display 9 to the left of the function keys there is always the current assignment 9 Display Displa...

Page 44: ...art Switches the compressor on 2 Compressor OFF Stop Switches the compressor off 3 Display Displays the parameters 4 Menu button Navigates in the menus sets pa rameters etc 5 Status Display Load running Neutral Standby 6 Maintenance key Information on warnings faults maintenance counters Acknowledgment button Acknowledging fault messages Content Figure Instrumentation control RENNERtronic TOUCH Fu...

Page 45: ...art Switches the compressor on 2 Compressor OFF Stop Switches the compressor off 3 Display Displays the parameters 4 Menu button Navigates in the menus sets pa rameters etc 5 Status Display Load running Neutral Standby 6 Maintenance key Information on warnings faults maintenance counters Acknowledgment button Acknowledging fault messages Content Figure Instrumentation control RENNERtronic TOUCH Pl...

Page 46: ...essor housing which can cause serious injuries Never operate the compressor with the housing open Check the following points before starting the compressor Is the oil level sufficiently high Is the main switch on Are any existing shut off valves open Step Operation Figure Expl 1 Press the Start button to start the compressor Content Before starting the compressor Start compressor and monitor in no...

Page 47: ... Operation Figure Expl 2 Monitor the following points at regular intervals during operation 2a Working pressure The working pressure displayed must not ex ceed the maximum per missible value specified on the type plate If this is the case switch off the compressor immediately ...

Page 48: ...ng hour meter Various maintenance work must be carried out after a specified number of operating hours The exact maintenance intervals and relevant servicing work are listed in the maintenance schedule Caution Observe the minimum oil and operating temperatures Should the operating temperature be below the dew point then condensation can form and become mixed with the oil The oil s lubricating prop...

Page 49: ...n the order listed Step Operation Figure Expl 1 Press the red Stop but ton while the compres sor is running to shut down the compressor 3 The compressor now switches to the follow on time and stops au tomatically after that NB The follow on time must not be shorter than the pre adjusted time A longer period of time is no problem 4 Press the Emergency Stop to secure the compressor Emergency Stop Co...

Page 50: ... machine off via the red emergency stop button can lead to the oil frothing up in the separator tank Possible consequences Exit of oil exit with the discharge air Oil overflow in the separator cartridge The compressed air could contain oil when re starting the machine Although this is not usually critical and is normalised during op erations in certain cases it could however become necessary to re...

Page 51: ... the compressor and main switch off Discharge all the compressed air from the compressor and air vessel The following faults may occur during operation Fault Possible Cause Remedy System starts starting No power Loose cables or fuses Motor protection switch has cut out Combistat cut out defective Connecting lines to Combistat are kinked Establish power supply Retighten cables or fuses Unlock motor...

Page 52: ... seconds adjust on Relay K 1T Determine reason Check solenoid valve and relief valve and change if necessary Heat installation loca tion Select correct type of oil Compressor cuts out before reaching discharge pressure Motor overload tripping Combistat cuts out due to ex cessively high temperature Short circuit in trip line Check and adjust overload setting check and adjust dis charge pressure swi...

Page 53: ... switch setting Ensure adequate ventilation Combistat cuts out due to excessively high temperature Insufficient oil Oil filter clogged Oil thermostat defective Oil cooler dirty Compressor in correctly installed Combistat defec tive or incorrectly set Check and adjust oil level Change oil filter Replace oil thermos tat Clean oil cooler air or oil side Refer to recommen dations for installation Adju...

Page 54: ...igh Solenoid valve defec tive Relief valve defective Minimum pressure valve jamming Reset discharge pressure switch Change solenoid valve Change relief valve Check and adjust minimum pressure valve Compressor vents continuously low vol umetric capacity Solenoid valve defec tive Relief valve defective Electric supply to so lenoid valve discon nected Auxiliary contact on Y contactor defective Change...

Page 55: ...ec tion in oil line Check seal on oil drain plug Machine is shut off if under load e g emergency stop switch Check condition and fit of O ring on intake regula tor Tighten connection Tighten screw seal if necessary Do not switch com pressor off until it has coasted for three minutes or check the minimum run on time and set to three minutes Fit new O ring if nec essary System runs noisily V belts n...

Page 56: ...90 Table value 45 6 g m absolute humidity Pressure dew point at 10 bar approx 92 C Caution Observe the minimum oil and operating temperatures Should the operating temperature be below the dew point then condensation can form and become mixed with the oil The oil s lubricating properties are then degraded The consequences can be damage to the compressor through to seizure of moving parts The operat...

Page 57: ...red This chapter is subdivided as follows No Subject Page 5 1 Essential points 5 2 5 2 Rectifying faults 5 5 5 3 Venting the compressor system 5 6 5 4 Cleaning work 5 7 5 5 Checking the oil level 5 8 5 6 Changing the oil filter 5 9 5 7 Changing the oil 5 10 5 8 Cleaning the oil cooler 5 11 5 9 Tensioning changing the V belts 5 11 Contents Overview ...

Page 58: ...otential Source of Danger Preventive Measures Crushing from moving parts Always maintain a safe distance from all moving parts when carrying out test runs Electric shock Switch off all voltage sources before starting work Take measures to prevent power sources from being switched on again by accident Inappropriate spare parts Always replace self locking nuts and screws Only use spare parts include...

Page 59: ...aterials left lying around 5 Carry out a test run and check the function of the serviced components 6 If you leave the machine before completing the work keep the keys safe and inaccessible to unauthorised persons Only genuine spare parts should be used when replacing components such as the oil filter oil air filter separator cartridge V belt etc Only allow authorised dealers to carry out repair w...

Page 60: ...d from all sources of pressure and all pressure removed before dismounting pressurised parts Scrupulous standards of cleanliness to be maintained during servicing work parts and exposed openings to be covered with a clean cloth paper or masking tape Motor air filter electrical components control equipment etc to be protected from ingress of moisture e g when being wiped Welding or other heat based...

Page 61: ... training in mechanical or electrical engineering Adhere to the general safety instructions contained in this manual for handling the machine Follow the instructions given in this chapter and all other maintenance instructions issued by the operator and pay due regard to the documentation relating to the components included in the unit e g frequency converter refrigerant drier The necessary action...

Page 62: ...The oil filler plug can reach temperatures of up to approx 110 C Therefore always wear safety gloves when touching oil filler plugs When the oil filler plug is unscrewed the residual pressure may cause hot oil to squirt out It is therefore essential to wear safety goggles It is essential to adhere to the following instructions in order to avoid the above risks of personal injury or death Step Oper...

Page 63: ...witch off the unit and take measures to prevent it from being restarted 2 Unscrew filter cover and remove filter cover 3 Remove filter cartridge 4 Wipe dust out of filter housing with a slightly damp cloth 5 Beat the front end of the cartridge soundly against the ball of the thumb taking care not to use force or damage the cartridge Clean seat engaging surfaces of seals 6 Holding the cartridge asl...

Page 64: ...uctions 1 Switch off the unit and take measures to prevent it from being restarted 2 Wait until the unit has been switched off for at least three minutes 3 Unscrew cap on filler neck by hand 4 Remove the dipstick to check the oil level Optimum oil level Oil level should ideally be in the middle of the two markings Under no circumstances should the oil level reach the thread on the filler neck 5 If...

Page 65: ...ting the oil and position it under one of the drain plugs hexagon head on the base of the separator tank and then unscrew and remove this plug 3 Place receptacle in position to collect oil Unscrew oil filter cartridge using a strap wrench 4 Lightly oil the gasket of the new cartridge hold the new cartridge upright and fill with the same type of oil already used 5 Screw the new cartridge onto the s...

Page 66: ... to cool to approx 70 C and then remove the pressure as described in Chapter 5 3 2 Take a receptacle suitable for collecting the oil and position it under one of the drain plugs hexagon head on the base of the separator tank and then unscrew and remove this plug 3 Drain all the oil from the separator tank then replace the drain plug and tighten 4 Pour the new oil into the filler neck up to the max...

Page 67: ...started Allow the unit to cool to approx 70 C disconnect from the power supply and remove the pressure as described in Chapter 5 3 2 Remove the oil cooler 3 Steam clean the oil cooler 4 Refit oil cooler 5 Start the unit and check for leaks 5 9 Tensioning changing the V belts This section outlines the procedure for tensioning and or changing the V belt The V belts are tensioned by the dead weight o...

Page 68: ...eby counterbalancing the starting moment 3 Screw in the adjusting screw Pos 3 clockwise in order to raise the pivoting motor base undo lock nut first 4 Remove the belts individually from the pulley 5 Fit the new V belts individually 6 Lower the pivoting motor base again by means of the adjusting screw until the motor is fully seated in the belts 7 Pretension the two thrust springs evenly on the ri...

Page 69: ...l Survey This chapter contains important advice for temporarily decommissioning or disposing of your compressor This chapter is divided into the following sub sections No Subject Page 6 1 Decommissioning of plant 6 2 6 2 Re commissioning after storage 6 3 6 3 Shut down and disposal 6 4 Content Survey ...

Page 70: ... Step Activity 1 A qualified electrician should disconnect the compressor from power supply and lock off isolator to ensure it can not be restarted by accident 2 Check oil level and fill if necessary see Chapter 5 5 Checking of oil level The unit should be stored with its oil tank filled to the max recommended level 3 Slacken the V belt see Chapter 5 10 Tensioning and changing of belt Do not cover...

Page 71: ...Step Activity 1 Turn the screw compressor in the direction of rotation several times by hand 2 Remove the air inlet filter and manifold and pour approx 0 1 litres of oil manufacturer recommended compressor oil only into the suction port Then turn the screw compressor by hand in the direction of the rotation arrow anti clockwise once more 3 Check the oil level in the reclaimer tank and fill where n...

Page 72: ...arrying out the following disassembly work be aware of sharp corners and edges which may cause cuts For this reason always wear protective gloves Environment The following instructions must be observed properly to prevent any possible damage to the environment The Operating Company must ensure that the regulations are adhered to correctly even where disposal is carried out by an authorized firm of...

Page 73: ...rubber PVC Gaskets Tubes Cables Tin Boards Polyester Boards The following parts materials and fluids must be disposed of separately Denomination Application LCD displays Note LCD displays contain highly poisonous fluids Display devices Electronic scrap Electrical supply Controls SPS etc Boards with electronic parts The environment Dispose of all parts of the unit in a manner that prevents damage f...

Page 74: ...Operating manual RENNER Compressors 010_Schaltpläne APPENDIX St Electric wiring diagrams RENNER screw compressors Wiring diagrams ...

Page 75: ... Motor prot relais relais de prot thermique Lasttrennschalter Isolator switch Seletcionneur RS 90 RS110 200A gl 200A gl L1 L2 L3 PE 2 1 4 3 6 5 Q 11 12 14 F 95 96 97 98 3 M W1 V1 U1 W2 U2 V2 PE M1 1 2 3 4 5 6 K1M 1 2 3 4 5 6 K5M 1 2 3 4 5 6 K3M L2 L1 2 3 1 PE Ölflex Classic PE 2 PE 3 4 5 1 Ölflex Classic 6 2 3 1 Ölflex 5G2 5mm PE 3 M U V W PE M2 1 2 3 4 5 6 K6 31 32 21 22 Motor Ölkühler Motor Oil ...

Page 76: ...essure pression de reseau Temperatur temperature temperature Option Option 1 Option 2 Option 3 Frequenzumrichter Frequency converter convertisseur Programmierb Ausgang 2 programmable output 2 sortie programmable 2 Programmierb Ausgang 1 programmable output 1 sortie programmable 1 4 20mA 4 20mA L2 L1 0 8A F1 1 0 8A F1 2 F5 F4 F3 400V 460V 0V 20V 20V 230V 18V 10V Steuertrafo Control Transformer Tran...

Page 77: ...Eingang 4 programmable input 4 Entrée 4 Programmable Programmierbarer Eingang 5 programmable input 5 Entrée 5 Programmable Spannungsversorgung Supply Alimentation NOT AUS Emergency stop Arret d urgence 24VDC RENNERtronic Störung Frequenzumrichter Fault Inverter Erreur Convertisseur Konfiguration Configuration Configuration Ext E A Exton off mar arrEx Option Fern Ein Aus extern unit on off extern e...

Page 78: ...23 24 25 26 27 28 29 30 31 12 Ein 85 C Aus 80 C On 85 C Off 80 C march 85 C arrêt 80 C N01 Programmierb Ausgang 6 programmable output 6 sortie programmable 6 max 2A 230V Datum 13 14 K3M 21 22 K3M 1 2 3 4 5 6 13 14 21 22 21 22 K5M 1 2 3 4 5 6 13 14 21 22 Ölkühler Oil cooler Refroidisseur de l huile A1 A2 K6 Sternschütz star contactor contacteur etoile A1 A2 K3M Dreieckschütz delta contactor contact...

Page 79: ...re pression de reseau Temperatur temperature temperature Option Pression de reseau commande composite Line Pressure Interconnected Intelligent contr Sys Seulement existant si le compresseur est connecté à la commande compositenet déclaré avec 1 Only available when compressor is related into an interconnected intelligence control system and when is it declared with 1 Nur vorhanden wenn Kompressor a...

Page 80: ... L3 PE PE 2 1 4 3 6 5 Q1 ST0 16 F3 T1 0A F4 T1 6A F5 T0 5A 0 8A F1 1 0 8A F1 2 F5 F4 F3 2 1 S0 400V 460V 0V 20V 20V 230V 18V 10V Steuertrafo Control Transformer Transformateur de commande T1 L 18VAC L 18VAC N01 L01 L3 L1 L2 L 10VAC L 10VAC NOT AUS Emergency stop Arret d urgence Motor Ölkühler Motor Oil cooler Moteur Refroidisseur de l huile 3 M U V W PE M 1 2 3 4 5 6 K6 31 32 21 22 RSF 90 RSF 110 ...

Page 81: ...ck line pressure pression de reseau Temperatur temperature temperature Option 1 Option 2 Option 3 Frequenzumrichter Frequency converter convertisseur Programmierb Ausgang 2 programmable output 2 sortie programmable 2 4 20mA Frequenzumrichter Frequency converter convertisseur L 18VAC L 18VAC L 10VAC L 10VAC B GND A 1 X5 2 3 14 15 16 19 20 21 17 18 32 GND2 33 AA2 34 GNDX 35 AA1 36 GND1 RENNERtronic ...

Page 82: ...erbarer Eingang 4 programmable input 4 Entrée 4 Programmable Programmierbarer Eingang 5 programmable input 5 Entrée 5 Programmable Spannungsversorgung Supply Alimentation NOT AUS Emergency stop Arret d urgence 24VDC RENNERtronic Störung Frequenzumrichter Fault Inverter Erreur Convertisseur Konfiguration Configuration Configuration Umrichter Converter Convertis 1 2 S0 13 12 8 9 10 11 2 3 4 1 Ölflex...

Page 83: ...t 6 sortie programmable 6 max 2A 230V 14 16 17 18 11 Ölflex 21X0 75mm 19 MV N01 L01 1 1 2 2 Vorsicht Fremdspannung Attention external Voltage Prudence la tension étrangère 1 2 3 4 5 6 13 14 21 22 Q1 13 14 K1M NC NO C X2 Option 1 2 3 4 5 6 13 14 21 22 Ölkühler Oil cooler Refroidisseur de l huile A1 A2 K6 Netzschütz main contactor contacteur de reseau A1 A2 K1M 4 6 6 1 6 1 6 1 1 4 1 4 1 4 1 4 4 1 1 ...

Page 84: ...line pressure pression de reseau Temperatur temperature temperature Option Pression de reseau commande composite Line Pressure Interconnected Intelligent contr Sys Seulement existant si le compresseur est connecté à la commande compositenet déclaré avec 1 Only available when compressor is related into an interconnected intelligence control system and when is it declared with 1 Nur vorhanden wenn K...

Page 85: ...asic 1 8 Kompressor Motor Compressor motor Compresseur moteur Störung Umrichter Fault Inverter Erreur Convertisseur PTC KEB Frequenzumrichter Frequency inverter Convertisseur Netzdrossel Power choke Bobine de réactance á courant réseau L1 L2 L3 2 1 X3 L1 M 3 U V W PE M1 L1 L2 L3 PE PE W U V 1 2 8 16 20 T1 T2 26 25 FU1 1 Ölflex Classic CY 2X0 75 2 1 Ölflex 5X0 75 2 3 Ölflex 5X0 75 4 2 3 PE Ölflex C...

Page 86: ...llowing harmonised standards were applied in its current version EN 1012 1 Compressors and vacuum pumps Safety requirements Part 1 Compressors EN 286 1 Simple unfired pressure vessels designed to contain air or nitrogen Part 1 Pressure vessels for general purposes EN 60204 1 Safety of machinery Electrical equipment of machines Part 1 General requirements EN ISO 12100 Safety of machinery General pr...

Page 87: ...ange air filter element Air filter cartridge Change fine separator cartridge Fine separator cartridge Tighten electric terminals Check V belt tension Check V belt for wear and replace if necessary Clean oil cooler Clean oil return inspection glass Check system for leaks Check run on time 3 min Check pressure switch setting and adjust if necessary Re grease motor bearings RS 11 and above High tempe...

Page 88: ...ange oil return inspection glass where fitted oil return inspection glass 18 000 h As for 2000 h plus Plus or 1x per year Change V belt V belt 20 000 h As for 2000 h As for 2000 h or 1x per year 22 000 h As for 2000 h As for 2000 h or 1x per year 24 000 h As for 2000 h plus Plus or 1x per year Change V belt V belt Change thermostatic valve element Thermostatic valve element Change O ring on oil fi...

Page 89: ... As in the past these bearings are of the open type They are filled with high temperature grease The motors have re grease facilities on both ends These facilities make it much easier to re grease the motor When re greasing only use high temperature grease for minimum 175 C Lithium based SKF LGHQ3 1 or equivalent Greasing of the motors should be done every 2000 hours and should be organized togeth...

Page 90: ...il separator cartridge Oil filling Drive belt Other maintenance work use another sheet if required Signature Date replaced replaced Differential pressure P in bar replalced checked replenished replaced checked re tightened replaced Please tick the work which has been done and or record measured data which confirm by signature ...

Page 91: ...requency converter is configured and parameterized at the factory Should an error occur the compressor is switched off and the message Error Converter appears on the display of the RENNERtronic control system Also observe the fault messages on the display of the frequency converter Check the causes and measures in the corresponding chapter of the operating instructions of the frequency inverter se...

Page 92: ...s to commissioning parameters Main menu used to access all parameters Fault alarm memory Online Help shows information on a command parameter or function in the display window Resetting faults Clear text display Main view shows operating information Status LEDs Operating keys status should be on Auto On during normal operation On Warn Alarm Hand on OK Off Auto on Reset ...

Page 93: ...s 2 UP START UP increase parameter number parameter value START start drive 3 ENTER F R ENTER confirm entries save F R direction of rotation 4 FUNC SPEED FUNC function key Toggle between parameter number s and parameter value s SPEED driver mode 5 DOWN STOP DOWN decrease parameter number parameter value STOP Stop drive Figure Control panel Control panel shortcuts ...

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Renner Kompressoren RS 90/1-110, Operation Manual

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Summary of Contents for RS 90/1-110

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