Manual Combi PDF

Operating manual
Screw compressor
COMBI 2S - 7S
COMBI 6 - 15.1
COMBI 16 - 22IABLE 35 - 130
ALMiG Kompressoren GmbH
Adolf-Ehmann-Straße 2
73257 Köngen
Telephone: +49 7024 9614 240
Fax: +49 7024 9614 209
email: info@almig.de
Internet: www.almig.de
Service Hotline:
Telephone: +49 1805 25 87 00
Fax: +49 1805 25 87 01
Translation of the original operating instructions
Almi-13257-DE COMBI
© ALMiG Kompressoren GmbH 2010
2 2010-11-04
Screw compressor COMBI 2S – 7S, COMBI 6 – 15.1, COMBI 16 – 22
Table of contents
Table of contents
1 General information ...............................................................7
1.1 Information about these instructions..............................7
1.2 Explanation of symbols..................................................7
1.3 Limitation of liability........................................................9
1.4 Copyright......................................................................10
1.5 Warranty terms ............................................................10
1.6 Customer service .........................................................10
2 Safety ....................................................................................11
2.1 Proper use ...................................................................11
2.2 Responsibility of the customer.....................................12
2.3 Personnel requirements...............................................13
2.3.1 Qualifications ................................................13
2.3.2 Unauthorised persons ..................................15
2.3.3 Training.........................................................15
2.4 Personal protective equipment ....................................15
2.5 Basic dangers ..............................................................17
2.5.1 General dangers in the workplace ...............17
2.5.2 Dangers due to electric power......................18
2.5.3 Dangers due to mechanical elements..........19
2.5.4 Dangers due to hydraulic energies ..............19
2.5.5 Dangers due to high temperatures...............21
2.6 Safety equipment.........................................................22
2.6.1 Position of the safety equipment ..................22
2.6.2 Description of the safety equipment
installed ........................................................23
2.7 Securing to prevent restart ..........................................24
2.8 Behaviour in case of fire or accidents..........................26
2.9 Environmental protection .............................................27
2.10 Signage 28
2.10.1 Warning signs...............................................28
2.10.2 Notes on the machine ..................................29
3 Technical data ......................................................................31

3.1 Type plate ....................................................................31
3.2 Emissions.....................................................................32
3.3 Coolant liquid ...............................................................33
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Table of contents
3.4 COMBI 2S – 7S........................................................... 33

3.4.1 General details............................................. 33
3.4.2 Connection values ....................................... 36
3.4.3 Operating conditions.................................... 37
3.4.4 Lubricants .................................................... 37
3.5 COMBI 6 – 15.1........................................................... 38
3.5.1 General details............................................. 38
3.5.4 Lubricants .................................................... 44
3.6 COMBI 16 – 22............................................................ 45
3.6.1 General details............................................. 45
3.6.4 Lubricants .................................................... 47
4 Structure and function........................................................ 48

4.1 Overview ..................................................................... 48
4.2 Brief description .......................................................... 52
4.3 Component description ............................................... 52
4.3.1 Controller ..................................................... 52
4.3.2 Sound insulation covers .............................. 53
4.3.3 Drive unit...................................................... 53
4.3.4 Intake filter ................................................... 54
4.3.5 Compressor stage ....................................... 54
4.3.6 Coolant liquid tank ....................................... 55
4.3.7 Fine precipitator ........................................... 55
4.3.8 Minimum pressure and return valve ............ 56
4.3.9 Cooler .......................................................... 56
4.3.10 Coolant liquid filter ....................................... 57
4.3.11 Cooling air ventilator .................................... 57
4.3.12 Refrigerant-type dryer.................................. 58
4.4 Interfaces .................................................................... 59
5 Transport, packaging and storage .................................... 61

5.1 Safety notes for transport............................................ 61
5.2 Transport inspection.................................................... 61
5.3 Packaging ................................................................... 61
5.4 Symbols on the packaging.......................................... 62
5.5 Transport..................................................................... 63
5.6 Storage........................................................................ 63
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Table of contents
6 Installation and commissioning .........................................64

6.1 Safety notes for the installation and commissioning....64
6.2 Requirements in the installation location .....................65
6.3 Installation....................................................................66
6.3.1 Ventilation.....................................................66
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 ......................................................74
7 Operation ..............................................................................75
7.1 Safety instructions for the operation ............................75
7.2 Shutdown in emergency situations..............................75
7.3 Operating personnel and personal protective
equipment ....................................................................76
7.4 Controllers....................................................................76
7.4.1 COMBI 2S – 7S controller ............................77
7.4.2 Air Control AC mini controller .......................78
8 Maintenance .........................................................................96
8.1 Safety instructions for maintenance ............................96
8.2 Spare parts ..................................................................99
8.3 Maintenance plan ......................................................100
8.4 Maintenance work......................................................101
8.4.1 Checking the electrical connections...........102
8.4.2 Checking the coolant liquid level/topping
up the coolant liquid ...................................102
8.4.3 Checking for leaks......................................104
8.4.4 Checking the compressor temperature ......105
8.4.5 Checking soiling of the cooler ....................106
8.4.6 Checking the condensation accumulation..107
8.4.7 Changing the coolant liquid/changing the
cooling liquid filter.......................................108
8.4.8 Re-lubricating the electric motor.................111
8.4.9 Change fine precipitator .............................112
8.4.10 Change intake filter ....................................113
8.4.11 Checking the drive unit...............................114
8.5 Measures after maintenance has been performed....115
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Table of contents
9 Faults .................................................................................. 116

9.1 Safety instructions for fault remedy........................... 116
9.2 Fault displays ............................................................ 119
9.3 Fault table ................................................................. 119
9.4 Work to remedy faults ............................................... 122
9.5 Commissioning after remedied fault ......................... 123
10 Dismantling and disposal................................................. 124

10.1 Safety notes for dismantling and disposal ................ 124
10.2 Dismantling ............................................................... 125
10.3 Disposal 125
11 Index ................................................................................... 126
12 Appendix ............................................................................ 130
6 2010-11-04
General information
1 General information
1.1 Information about these instructions
This manual enables safe and efficient handling of the machine. It is
an integral part of the machine, and must be kept in close proximity to
the machine where it is permanently accessible to the personnel.
Before starting any work, the personnel must have read the manual
thoroughly and understood its contents. Compliance with all specified
safety instructions and operating instructions is vital to ensure safe
operation.
In addition, local accident prevention regulations and general safety
instructions must be observed for the operational area of the machine.
Illustrations in this manual are intended to facilitate basic understand-
ing, and may differ from the actual design.
The instructions for the compressor do not include the operation of the
controller. Therefore, the instructions and content of the instructions
for the controller in question must also be taken into account.
Furthermore, the instructions for the installed components found in the
appendices also apply.
1.2 Explanation of symbols

Safety instructions The safety instructions provided in this manual are marked by sym-
bols. The safety instructions are introduced by keywords used to ex-
press 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 si-
tuation of immediate danger which may lead to serious
injury or death unless avoided.
WARNING!
This combination of symbol and keyword points to a si-
tuation of possible danger which may lead to serious in-
jury or death unless avoided.
2010-11-04 7
General information
CAUTION!
This combination of symbol and keyword points to a
possibly dangerous situation which may lead to slight or
minor injury unless avoided.
NOTICE!
This combination of symbol and keyword points to a
possibly dangerous situation which may lead to material
and environmental damage unless avoided.
Tips and recommendations This symbol highlights useful tips and recommendations
as well as information designed to ensure efficient and
smooth operation.
Special safety instructions The following symbols are used in the safety instructions to draw at-
tention to specific dangers:
DANGER!
This combination of symbol and signal word indicates
dangers posed by electric power. If the safety instruc-
tions are not observed, there is a danger of serious or
fatal injuries.
WARNING!
This combination of symbol and signal word indicates
dangers posed by an atmosphere capable of exploding.
If the safety instructions are not observed, there is a
danger of serious or fatal injuries.
8 2010-11-04
General information
Signs used in this manual The following signs and highlighting is used in this manual to identify
instructions, descriptions of results, numerations, references and other
elements:
Sign Explanation
Ö Identifies a state or automatic sequence as result of
steps.
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.
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 de-
pictions in this manual in the case of special designs, take-up of addi-
tional ordering options, or as a result of the latest technical modifica-
tions.
The undertakings agreed in the supply contract as well as the manu-
facturer's Terms and Conditions and Terms of Delivery and the legal
regulations applicable at the time of conclusion of the contract shall
apply.
2010-11-04 9
General information
1.4 Copyright
This manual is protected by copyright and intended solely for internal
use.
This manual must not be made available to third parties, duplicated in
any manner or form – whether in whole or in part – and the content
must not be used and/or communicated, except for internal purposes,
without the written consent of the manufacturer.
Violation of the copyright will result in legal action for damages. We
reserve the right to assert further claims.
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 informa-
tion. 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.
10 2010-11-04
Safety
2 Safety
This section provides an overview of all the main safety aspects in-
volved in ensuring optimal personnel protection and safe and smooth
operation.
Non-compliance with the action guidelines and safety instructions
contained in this manual may result in serious hazards.
2.1 Proper use

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

air in an environment not subject to explosion. The screw com-
pressor may be supplied exclusively with cool, dry and dust-free
cooling air.
The proper use also includes adherence to all details in these instruc-
tions.
Any use beyond the proper use or other type of use counts as misuse.
WARNING!
Danger due to misuse!
Misuse of the compressor can cause dangerous situa-
tions.
- The compressed air may not be used for breathing
without previous preparation.
- The compressed air may not be used directly for
pharmaceutical or sanitary purposes or for the direct
handling of food without appropriate after-treatment.
- The screw compressor may not be operated out-
doors.
- The screw compressor or individual components may
not be rebuilt, modified or re-equipped.
- The screw compressor may not be used in an atmos-
phere subject to explosion.
- The intake of media other than cool, dry and dust-free
cooling air is forbidden.
Claims of any type for damage due to misuse are excluded.
2010-11-04 11
Safety
2.2 Responsibility of the customer

Owner The term 'owner' refers to the person who himself operates the ma-
chine for trade or commercial purposes, or who surrenders the ma-
chine 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 customer The machine is used in the commercial realm. Therefore, the cus-
tomer of the machine is subject to legal occupational safety regula-
tions.
In addition to the safety instructions in these instructions, the valid
safety, accident prevention and environmental protection regulations
for the area of application of the machine must be adhered to.
Here, the following points apply in particular:
The customer must inform himself about the applicable
occupational safety provisions and also determine in a hazard
assessment the dangers that arise due to the special working
conditions in the machine's area of application. He must implement
these in the form of operating instructions for the operation of the
machine.
During the entire time the machine is used, the customer must
check whether the operating instructions he has created
correspond to the current state of the body of rules and regulations
and adapt the operating instructions if necessary.
The customer must regulate and specify clearly the responsibilities
for the installation, operation, troubleshooting, maintenance and
cleaning.
The customer must ensure that all employees who handle the
machine have read and understood these instructions. In addition,
he must train the personnel at regular intervals and inform them
about the dangers.
The customer must provide personnel with the required protective
equipment and instruct them in binding fashion about how to wear
the required protective equipment.
Furthermore, the customer is responsible for ensuring that the ma-
chine is always in technically-perfect condition. Therefore, the follow-
ing points apply:
The customer must ensure that the maintenance intervals
described in these instructions are adhered to.
The customer must have all safety equipment checked regularly to
ensure that it is functional and complete.
The customer must ensure that the appropriate media connections
are provided.
12 2010-11-04
Safety
The customer must ensure that the supply of the required quantity
of cool medium (air/water) is guaranteed.
The customer must ensure that the required heat extraction is
guaranteed.
2.3 Personnel requirements

2.3.1 Qualifications
WARNING!
Danger of injury if personnel are insufficiently quali-
fied!
If unqualified personnel perform work on the machine or
are in the machine's danger zone, hazards may arise
which can cause serious injury and substantial damage
to property.
- Therefore, all work must only be carried out by ap-
propriately qualified personnel.
- Unqualified personnel must be kept away from the
danger zones.
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 phy-
sical and intellectual attributes and character, suited to driving indus-
trial trucks with a driver's seat or driver's platform.
Furthermore, the forklift driver has been trained to drive industrial
trucks with a driver's seat or driver's platform.
The forklift driver has provided the owner with evidence of his skills in
driving industrial trucks with a driver's seat or driver's platform and has
therefore been authorised in writing by the owner to drive the forklift.
Manufacturer
Certain tasks may only be performed by our qualified personnel. Other
personnel is not authorized to perform these tasks. Contact our ser-
vice department to request the execution of any necessary work. For
address information, refer to page 2.
2010-11-04 13
Safety
Qualified Electrician
Based on his technical training, knowledge, experience and knowl-
edge of the applicable standards and regulations, the Qualified Elec-
trician is able to perform work on electrical systems and recognise and
avoid potential hazards himself.
The Qualified Electrician is specially trained for the area of responsi-
bility he is involved with and knows the relevant standards and regula-
tions.
The Qualified Electrician must comply with the requirements of the
applicable legal regulations for accident prevention.
Qualified personnel
Qualified personnel is able to carry out assigned work and to recog-
nize and prevent possible dangers self-reliantly due to its professional
training, knowledge and experience as well as profound knowledge of
applicable regulations.
Trained Person
The trained person has been instructed in an instruction by the owner
about the tasks assigned to him and possible hazards in the case of
improper behaviour.
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.
14 2010-11-04
Safety
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 (ª Appendix A
„Training log“ on page 131).
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 carry-
ing out the different operations at and with the machine. This equip-
ment will be indicated separately in the individual chapters of this ma-
nual. 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.
2010-11-04 15
Safety
Description of the personal protec-

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

Light respiratory protection is used to protect against harmful dusts.
Protective clothing
Protective clothing are tight fitting working clothes with low tear resis-
tance, with tight sleeves and without any parts sticking out. These
clothes primarily protect against getting caught by moving machine
parts. Do not wear rings, chains, necklaces, and other jewellery.
Safety boots
Safety boots are intended to protect against slipping hazards or foot
hazards like heavy gear.
Safety gloves
Safety gloves are intended to protect hands against friction, abrasion,
stabs or deeper wounds and against direct contact with hot surfaces.
Safety goggles
Safety goggles are intended protect the eyes against flying debris and
liquid spray.
16 2010-11-04
Safety
2.5 Basic dangers

The following section specifies residual risks which may result from
using the machine and have been established by means of a risk as-
sessment.
In order to minimize health hazards and avoid dangerous situations,
follow the safety instructions specified here as well as in the following
chapters of this manual.
2.5.1 General dangers in the workplace
Noise
WARNING!
Danger of injury from noise!
The noise levels arising in the workplace may result in
serious hearing damage.
- Always wear ear protection while working.
- Do not stay in the danger zone more than necessary.
Accumulations of liquid
CAUTION!
Danger of injury from slipping in accumulations of
liquid!
Slipping in accumulations of liquid on the floor may result
in a fall. A fall may result in injuries.
- Remove accumulations of liquid immediately using
appropriate means.
- Wear anti-slip safety shoes.
- Post warnings and mandatory signs at or in the vicin-
ity of any area where liquid could accumulate on the
floor.
2010-11-04 17
Safety
2.5.2 Dangers due to electric power
Electric current
DANGER!
Danger to life from electric power.
There is an immediate danger to life from electric shock
in the case of contact with live parts. Damage to the in-
sulation or individual components can be fatal.
- Only allow qualified electricians to work on the elec-
trical system.
- In the case of damage to the insulation, immediately
disconnect the power supply and arrange repairs.
- Establish the absence of voltage before starting work
on active parts of electrical systems and equipment
and ensure this remains so for the duration of the
work. Observe the 5 safety rules:
- Disconnect from the power supply.
- Secure against restarting.
- Verify absence of voltage.
- Earth and short-circuit.
- Cover or shield any neighbouring live parts.
- Never bypass or disable fuses. Comply with the cor-
rect current intensity information when replacing fu-
ses.
- Keep moisture away from live parts. This can result in
short circuits.
Stored charges
DANGER!
Danger to life from stored charges!
Electric charges may be stored in electrical components;
these charges may be maintained even after the system
has been switched off and disconnected from the power
supply. Contact with these components may result in
serious or fatal injury.
- Before working on the specified components, ensure
that they have been completely disconnected from
the power supply. Allow 10 minutes to elapse in order
to ensure that the internal capacitors have been fully
discharged.
18 2010-11-04
Safety
2.5.3 Dangers due to mechanical elements
Moving parts
WARNING!
Danger of injury from moving parts!
Rotating parts and/or parts moving in linear fashion may
cause serious injuries.
- During operation, do not reach into or handle moving
parts.
- Do not open covers during operation.
- Observe the run-on time: Before opening the covers,
make sure that all parts have stopped moving.
- When in the danger zone, wear close-fitting protective
work clothing with low tear strength.
Sharp edges and pointed corners

CAUTION!
Danger of injury posed by sharp edges and pointed
corners!
Sharp edges and pointed corners may cause skin grazes
and cuts.
- Proceed with caution when working in the vicinity of
sharp edges and pointed corners.
- If in doubt, wear safety gloves.
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 acci-
dental contact with the liquid stream, take first aid
measures and consult a doctor immediately.
- Initiate emergency off immediately. If necessary, take
additional measures in order to reduce the pressure
and stop the stream of liquid.
- Catch and dispose of escaping liquids properly.
- Have faulty components repaired immediately.
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Safety
Pressure accumulator(s)
WARNING!
Danger to life from improper work on the pressure
accumulator!
Improper handling of pressure accumulators may cause
a sudden release of pressure, resulting in very serious
injuries or death and in significant damage to property.
- Never carry out welding or soldering work on the
pressure accumulator vessel.
- Never perform any mechanical machining on the
pressure accumulator vessel.
- Once it is connected to the hydraulic line, vent the
pressure accumulator vessel using the fitted vent
screw.
- Only carry out work on systems with a pressure ac-
cumulator once the hydraulic pressure has been
completely relieved and depressurisation has been
verified.
- Do not start work on the pressure accumulator until
the gas charging pressure has been completely re-
leased.
Compressed air
WARNING!
Danger of injury from compressed air!
Compressed air can escape from compressed air hoses
or components under pressure in case of improper han-
dling or in case of a fault. It can injure eyes, whip up dust
or cause uncontrolled movements of hoses.
Components under pressure can move in uncontrolled
fashion with improper handling and cause injuries.
- Before removing hoses or components under pres-
sure, make sure the pressure is relieved.
- Have faulty components that are under pressure dur-
ing operation replaced by appropriate specialist per-
sonnel immediately.
- Before all work, make sure that the compressor is not
under pressure; wait at least 5 minutes.
20 2010-11-04
Safety
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.
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 opera-
tion. Skin contact with hot surfaces will cause severe
skin burns.
- During all work hear hot surfaces, wear heat-resistant
protective clothing and protective gloves.
- Before all work, make sure that all surfaces have coo-
led off to the ambient temperature, wait at least
30 minutes.
Hot consumables
WARNING!
Danger of injury from hot consumables!
Consumables may reach high temperatures during op-
eration. Skin contact with hot consumables will cause
severe skin burns.
- Always wear heat-resistant protective work clothing
and protective gloves as a matter of principle when
carrying out any work with consumables.
- Always check whether consumables are hot before
working with them. Allow to cool down if necessary.
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Safety
2.6 Safety equipment
WARNING!
Danger to life from nonfunctional safety devices!
If safety devices are not functioning or are disabled, the-
re is a danger of grave injury or death.
- Check that all safety devices are fully functional and
correctly installed before starting work.
- Never disable or bypass safety devices.
- Ensure that all safety devices are always accessible.
2.6.1 Position of the safety equipment
The following illustration shows the position of the safety equipment.
Fig. 1: Position of the safety equipment
1 Main switch with emergency off function

2 Emergency stop key
22 2010-11-04
Safety
2.6.2 Description of the safety equipment installed
Main switch with emergency off

function
The main switch is also set up as an emergency stop switch. By turn-
ing 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 seri-
ous injuries including death.
- Before switching the machine back on, make sure the
cause of the emergency stop has been removed and
Fig. 2: Main switch all safety devices have been installed and function
properly.
- Only turn the main switch to the "l" position when the-
re is no more danger.
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 swit-
ching on is possible.
WARNING!
An uncontrolled restart of the machine may cause seri-
ous injuries including death.
Fig. 3: Emergency stop key
- Before switching the machine back on, make sure the
cause of the emergency stop has been removed and
all safety devices have been installed and function
properly.
- Do not unlock the EMERGENCY-STOP button until
there is no more danger.
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Safety
Safety valves
Safety valves belong to the safety taps and are unburdening equip-
ment for the areas under pressure such as the boiler, pressure tank,
pipes, transport container. In case of an impermissible pressure in-
crease, safety valves bleed off gases, vapours or liquids into the at-
mosphere.
Fig. 4: Safety valve
2.7 Securing to prevent restart
WARNING!
Life-threatening danger if restarted without authori-
sation or due to uncontrolled restart!
Uncontrolled or unauthorised switching on of the ma-
chine can cause severe or fatal injuries.
- Prior to restart ensure that all safety devices are
mounted and functional, and that there is no danger
for personnel.
- Always adhere to the procedure described below to
secure against restart.
24 2010-11-04
Safety
Securing to prevent restart

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

functional.
WARNING!
If the main switch is secured with a padlock, people can
Fig. 5: Securing the main switch
be in the danger zone. These people can be fatally in-
jured by the switching on of the power supply.
- Before removing the padlock and switching the power
supply back on, make sure that there are no dangers
to people.
6. Remove the padlock from the main switch.
If no main switch is installed, proceed as follows.
WARNING!
sation or due to uncontrolled restart!
Uncontrolled or unauthorised switching on of the ma-
chine can cause severe or fatal injuries.
for personnel.
- Always adhere to the procedure described below to
secure against restart.
2010-11-04 25
Safety
Securing to prevent restart 1. Switch off the power supply.
2. Inform responsible people about work in the danger zone.
3. Mark machine with a sign that indicates the work in the danger
zone and forbids switching on. Include the following details on the
sign:
Switched off on:
Switched off at:
Switched off by:
Note: do not switch on!
Note: Only switch on after it has been ensured that there are
no dangers to people.
4. After all work has been performed, make sure that there are no
dangers to people.
5. Ensure that all safety and protective equipment is installed and

functional.
WARNING!
People in the danger zone can be fatally injured by the
unauthorised or uncontrolled switching on of the power
supply.
- Before switching the power supply back on, ensure
that there are no dangers for people.
6. Remove the sign.
2.8 Behaviour in case of fire or accidents

Preventive measures Be prepared for fire and accidents at all times!
Keep first-aid equipment (first-aid kit, blankets, etc.) and fire
extinguishing devices operational and readily available.
Make your personnel familiar with accident reporting equipment as
well as first-aid and rescue equipment.
Keep access paths clear for rescue vehicles.
Steps in case of fire and accidents Immediately trigger an Emergency Stop using EMERGENCY-
STOP devices.
Provided your own health is not in danger, rescue all personnel
from the danger area.
If necessary, initiate first aid measures.
26 2010-11-04
Safety
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.
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 envi-
ronment.
- Always observe the instructions below regarding
handling and disposal of pollutants.
- Take the appropriate actions immediately if pollutants
escape accidentally into the environment. If in doubt,
inform the responsible municipal authorities about the
damage and ask about the appropriate actions to be
taken.
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 es-
cape into the environment. Disposal must be carried out by a special-
ist disposal company.
Lubricants Lubricants such as greases and oils contain toxic substances. They
must not be allowed to escape into the environment. Disposal must be
carried out by a specialist disposal company.
2010-11-04 27
Safety
2.10 Signage
The following symbols and information signs can be found in the work
area. They refer to their immediate surroundings.
WARNING!
Danger of injury from illegible symbols!
Stickers and signs can become dirty or otherwise ob-
scured over time, with the result that dangers cannot be
recognised and the necessary operating instructions
cannot be complied with. This, in turn, poses a risk of
injury.
- All safety, warning and operating instructions must
always be maintained in a completely legible condi-
tion.
- Damaged signs or stickers must be replaced immedi-
ately.
2.10.1 Warning signs
Electrical voltage
Only qualified electricians are permitted to work in a work room mark-
ed by this sign.
Unauthorised persons must not enter the workplaces thus marked and
must not open the marked cabinet.
Automatic start-up
Maintain sufficient distance from all parts that can move; there is a
danger of crushing or pulling in there.
Hot surface
Hot surfaces such as hot machine parts, containers or materials, as
well as hot liquids, may not always be detected. Never touch these
without protective gloves.
28 2010-11-04
Safety
2.10.2 Notes 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.
2010-11-04 29
Safety
Brief instructions for commissio- This sticker is on the switch cabinet and contains brief instructions for
ning commissioning.
30 2010-11-04
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
2010-11-04 31
Technical data
3.2 Emissions
COMBI 2S – 7S
COMBI Noise emissions
dB (A)
2S 60
3S 61
4S 62
5S 64
7S 67
COMBI 6 – 15.1
dB (A)
6 63
8 64
11 64
15 68
15.1 67
COMBI 16 – 22
dB (A)
16 71
18 72
22 72
32 2010-11-04
Technical data
3.3 Coolant liquid

The following coolant liquids are tested and approved for use in AL-
MiG 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 2S – 7S
3.4.1 General details
COMBI 2S
COMBI Nominal Weight Length Width Height

motor out-
(on 200 l container)
put
kW kg mm mm mm
2S 2,2 210 1400 550 1250
(standard model)
2S 2,2 190 1100 550 1250

(with pressure tank,
without refrigerant-
type dryer)
2S 2,2 150 1100 550 950

(without pressure
tank, with refrigerant-
type dryer)
2S 2,2 125 720 550 950

(without pressure
tank, without refriger-
ant-type dryer)
2010-11-04 33
Technical data
COMBI 3S

motor out-
put
kW kg mm mm mm
3S 3,0 215 1400 550 1250
(standard model)
3S 3,0 195 1400 550 1250

type dryer)
3S 3,0 155 1100 550 950

(without pressure
type dryer)
3S 3,0 130 720 550 950

(without pressure
ant-type dryer)
COMBI 4S

motor out-
put
kW kg mm mm mm
4S 4,0 220 1400 550 1250
(standard model)
4S 4,0 200 1400 550 1250

type dryer)
4S 4,0 160 1100 550 950

(without pressure
type dryer)
34 2010-11-04
Technical data

motor out-
put
kW kg mm mm mm
4S 4,0 135 720 550 950
(without pressure
ant-type dryer)
Combi5S

motor out-
put
kW kg mm mm mm
5S 5,5 225 1400 550 1250
(standard model)
5S 5,5 205 1400 550 1250

type dryer)
5S 5,5 165 1100 550 950

(without pressure
type dryer)
5S 5,5 140 720 550 950

(without pressure
ant-type dryer)
2010-11-04 35
Technical data
COMBI 7S

motor out-
put
kW kg mm mm mm
7S 7,5 230 1400 550 1250
(standard model)
7S 7,5 210 1400 550 1250

type dryer)
7S 7,5 170 1100 550 950

(without pressure
type dryer)
7S 7,5 145 720 550 950

(without pressure
ant-type dryer)
3.4.2 Connection values
Electrical COMBI 2S – 7S
COMBI Current at 400 V / 50 Hz Current at 500 V / 50 Hz Max. switch

frequency
IN IFuse IN IFuse
A A gL A A gL 1/h
2S 5 10 4 10 55
3S 6,6 10 5,3 10 55
4S 8,5 16 6,8 16 55
5S 11,3 16 9 16 55
7S 11,3 20 12,1 20 55
IN = nominal current
IFuse = building-side fuse
36 2010-11-04
Technical data
Air supply and cooling COMBI 2S – 7S
COMBI Compressed air Cooling air Supply air ope- Cross section of
connection quantity (LK) ning exhaust air duct
G / DN m3/h m2 m2
2S ⅜ 1040 0,15 0,10
3S ⅜ 1050 0,15 0,10
4S ⅜ 1060 0,20 0,15
5S ½ 1080 0,25 0,15
7S ½ 1100 0,25 0,15
3.4.3 Operating conditions
Environment
Data Value Unit
Temperature range +5 to +40 °C
Relative humidity, maximum 60 %
3.4.4 Lubricants
COMBI 2S – 7S
COMBI Lubricant Fill level Unit

2S Coolant liquid 3,2 l
2010-11-04 37
Technical data
3.5 COMBI 6 – 15.1

COMBI 6

motor out-
put
kW kg mm mm mm
6 5,5 435 1120 685 1680
(with 270 l pressure
tank and refrigerant-
type dryer)
6 5,5 400 1120 685 1680

ant-type dryer)
6 5,5 500 1900 685 1680

type dryer)
6 5,5 465 1900 685 1680

ant-type dryer)
6 5,5 320 1120 685 1128

(without pressure
type dryer)
6 5,5 285 1120 685 1128

(without pressure
ant-type dryer)
38 2010-11-04
Technical data
COMBI 8

motor out-
put
kW kg mm mm mm
8 7,5 440 1120 685 1680
type dryer)
8 7,5 405 1120 685 1680

ant-type dryer)
8 7,5 505 1900 685 1680

type dryer)
8 7,5 470 1900 685 1680

ant-type dryer)
8 7,5 325 1120 685 1128

(without pressure
type dryer)
8 7,5 290 1120 685 1128

(without pressure
ant-type dryer)
2010-11-04 39
Technical data
COMBI 11

motor out-
put
kW kg mm mm mm
11 11,0 445 1120 685 1680
type dryer)
11 11,0 410 1120 685 1680

ant-type dryer)
11 11,0 510 1900 685 1680

type dryer)
11 11,0 475 1900 685 1680

ant-type dryer)
11 11,0 330 1120 685 1128

(without pressure
type dryer)
11 11,0 295 1120 685 1128

(without pressure
ant-type dryer)
40 2010-11-04
Technical data
COMBI 15

motor out-
put
kW kg mm mm mm
15 15,0 455 1120 685 1680
type dryer)
15 15,0 420 1120 685 1680

ant-type dryer)
15 15,0 520 1900 685 1680

type dryer)
15 15,0 485 1900 685 1680

ant-type dryer)
15 15,0 340 1120 685 1128

(without pressure
type dryer)
15 15,0 305 1120 685 1128

(without pressure
ant-type dryer)
2010-11-04 41
Technical data
COMBI 15.1

motor out-
put
kW kg mm mm mm
15.1 15,0 475 1120 685 1680
type dryer)
15.1 15,0 440 1120 685 1680

ant-type dryer)
15.1 15,0 540 1900 685 1680

type dryer)
15.1 15,0 505 1900 685 1680

ant-type dryer)
15.1 15,0 360 1120 685 1128

(without pressure
type dryer)
15.1 15,0 325 1120 685 1128

(without pressure
ant-type dryer)
42 2010-11-04
Technical data
Electrical COMBI 6 – 15.1

frequency
IN IFuse IN IFuse
A A gL A A gL 1/h
6 11 16 11 16 55
8 15 20 15 20 55
11 21 25 20 25 40
15 30 40 27 40 30
15.1 30 40 27 40 30
Air supply and cooling COMBI 6 – 15.1
G / DN m3/h m2 m2
6 ¾ 1100 0,30 0,15
8 ¾ 1230 0,35 0,15
11 ¾ 1800 0,50 0,20
15 ¾ 2300 0,60 0,20
15.1 ¾ 2300 0,60 0,20
2010-11-04 43
Technical data
Environment
Data Value Unit
3.5.4 Lubricants
COMBI 6 – 15.1

6 Coolant liquid 6,2 l
15.1 Coolant liquid 6,2 l
44 2010-11-04
Technical data
3.6 COMBI 16 – 22
COMBI 16

motor out-
put
kW kg mm mm mm
16 15 679 1900 780 1950
(with pressure tank
and refrigerant-type
dryer)
16 15 639 1900 780 1950

type dryer)
16 15 494 1480 780 1375

(without pressure
type dryer)
16 15 454 1480 780 1375

(without pressure
ant-type dryer)
COMBI 18

motor out-
put
kW kg mm mm mm
22 22 744 1900 780 1950
(with pressure tank
and refrigerant-type
dryer)
22 22 704 1900 780 1950

type dryer)
2010-11-04 45
Technical data

motor out-
put
kW kg mm mm mm
22 22 559 1480 780 1375
(without pressure
type dryer)
22 22 519 1480 780 1375

(without pressure
ant-type dryer)
Electrical COMBI 16 – 22

frequency
IN IFuse IN IFuse
A A gL A A gL 1/h
16 30 40 27 40 30
18 36 50 30 40 25
22 41 63 34 50 20
Air supply and cooling COMBI 16 – 22
G / DN m3/h m2 m2
16 1 3300 0,60 0,35
18 1 3300 0,60 0,35
22 1 3300 0,60 0,35
46 2010-11-04
Technical data
Environment
Data Value Unit
3.6.4 Lubricants
COMBI 16 – 22

2010-11-04 47
Structure and function
4 Structure and function

4.1 Overview
The following presents an overview of the screw compressors de-
scribed in these instructions. They differ from one another due primar-
ily to their size. However, their basic structure is the same.
For the COMBI type, there are variants which are not
built on a pressure tank. Due to their identical construc-
tion, these variants are only depicted without pressure
tank and not extra as an overview figure.
Screw compressor COMBI 2S – 7S
Fig. 7: Screw compressor COMBI 2S – 7S
1 Main switch with emergency off function

2 On and off switch
3 Refrigerant-type dryer
4 Pressure tank
5 Sound insulation covers
48 2010-11-04
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
2010-11-04 49
Components The basic structure is the same for all screw compressor
variants. The position of the components can vary from
the illustration.
Fig. 9: Components COMBI 2S – 7S
1 Minimum pressure and return valve

2 Fine precipitator
3 Coolant liquid filter
5 Compressed air connection
6 Compressor stage
7 Intake filter
8 Coolant liquid cooler
9 Fan belt
10 Cooling air ventilator
11 Drive unit
12 Pressure tank
13 Coolant liquid pressure tank
50 2010-11-04
Fig. 10: Components COMBI 6 – 22
1 Fine precipitator
3 Coolant liquid filter
4 Coolant liquid cooler
5 Intake filter
6 Compressed air connection
7 Fan belt
8 Compressor stage
9 Cooling air ventilator
10 Drive unit
11 Pressure tank
13 Minimum pressure and return valve
2010-11-04 51
4.2 Brief description

The fresh air supplied by the installed cooling air ventilator is filtered
through the intake filter. The air streams over the intake regulator into
the compressor stage, where it is compressed together with the in-
jected coolant liquid to the final pressure. The compressed air is
largely separated from the coolant liquid in the 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 compres-
sor via the compressed air connection.
The coolant liquid is separated from the compressed air in the pres-
sure 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 by-
pass according to the set point temperature. Finally, the coolant liquid
filter cleans the coolant liquid before it is injected into the compressor
stage once again.
4.3 Component description

4.3.1 Controller
Controller variants
The COMBI 2S – 7S is operated using the two buttons for switching it
on and off.
Fig. 11: COMBI 2S – 7S
52 2010-11-04
The COMBI 6 – 22 is operated using the Air Control AC mini control-

ler.
Fig. 12: COMBI 6 – 22
4.3.2 Sound insulation covers
Only qualified personnel may remove the sound insulation covers

(Fig. 13/1) with the included special spanner. Sound insulation covers
are a part of the electric shock protection.
Fig. 13: Sound insulation covers
4.3.3 Drive unit
With the COMBI, the drive (Fig. 14) takes place using a fan belt
(Fig. 14/1).
Fig. 14: COMBI drive unit
2010-11-04 53
4.3.4 Intake filter
The standard intake filter (Fig. 15/1) sits directly above the compres-
sor stage (Fig. 15/2).
Fig. 15: Standard intake filter
4.3.5 Compressor stage
The air taken in is compressed by the compressor stage (Fig. 16/1)

and added to the coolant liquid pressure tank (Fig. 16/2) together with
the injected coolant liquid.
Fig. 16: Compressor stage
54 2010-11-04
4.3.6 Coolant liquid tank
1 Safety valve
3 Filler plugs
4 Coolant liquid drain
5 Inspection glass
The coolant liquid pressure tank consists of several components. The
safety valve protects the coolant liquid pressure tank against over-
pressure. With the inspection glass, the level of the coolant liquid can
be read. With the drain plugs, the coolant liquid is topped off and it is
removed via the coolant liquid drain.
Coolant liquid heating (optional)

Coolant liquid heating can be installed in the coolant liq-
uid pressure tank at the factory or after the fact. It pre-
vents condensate damage and the freezing of the con-
densate, e.g. for a screw compressor that is set up in the
cold or the humidity.
Fig. 17: Coolant liquid pressure tank with
safety valves
4.3.7 Fine precipitator
Depending on the type of the screw compressor, several

fine precipitators can be installed.
The fine precipitator (Fig. 18/1) removes the remaining coolant liquid
from the compressed air.
Fig. 18: Fine precipitator
2010-11-04 55
4.3.8 Minimum pressure and return valve
The minimum pressure and return valve (Fig. 19/1) only opens if the
system pressure has increased to 5 bar. After the screw compressor
switches off, the minimum pressure and return valve prevents the
compressed air from stream back out of the network.
Fig. 19: Minimum pressure and return

valve
4.3.9 Cooler
The compressed air is cooled off in the compressed air after-cooler

(Fig. 20/2) or in the pressure tank before it leaves the screw compres-
sor via the compressed air connection (Fig. 20/3).
The coolant liquid is cooled off by the coolant liquid cooler (Fig. 20/1)
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
– 15.1, only a coolant liquid cooler is installed.
If the COMBI 2S – 7S and 6 – 15.1 systems are built on
a pressure tank, there is no compressed air after-cooler
present.
Fig. 20: Cooler
56 2010-11-04
4.3.10 Coolant liquid filter
The coolant liquid filter (Fig. 21/1) cleans the coolant liquid before it is
injected into the compressor stage once again.
Fig. 21: Coolant liquid filter
4.3.11 Cooling air ventilator
Depending on the type, two different cooling air ventila-

tors are installed.
Cooling air ventilator
The cooling of the compressed air after-cooler and of the coolant liq-
uid after-cooler is handled by the cooling air ventilator. The cooling air
ventilator also supplies the intake filter with sufficient intake air.
2010-11-04 57
4.3.12 Refrigerant-type dryer
The refrigerant-type dryer (Fig. 22/1) dries the compressed air using a
heat exchange process. The compressed air is thus fed from the
pressure tank into the refrigerant-type dryer and then via the com-
pressed air connection (Fig. 22/3) into the compressed air network.
The condensate which accumulates is discharged via the condensate
drain (Fig. 22/2).
Depending on the variant, a hose for discharging the

condensate is already attached to the condensate drain;
otherwise, the operator must attach one.
Fig. 22: Refrigerant-type dryer
58 2010-11-04
4.4 Interfaces
Fig. 23: Flow chart
The following interfaces are in the screw compressor:

Air supply
z Cooling air ventilator
z Intake filter
Compressed air connection
2010-11-04 59
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. 24: 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. 25: Compressed air connection
60 2010-11-04
Transport, packaging and storage
5 Transport, packaging and storage

5.1 Safety notes for transport
Improper transport
NOTICE!
Damage to property due to improper transport!
Transport units may fall or tip over as a result of im-
proper 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 Transport inspection

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

following detection. Damage compensation claims can
only be asserted within the applicable complaint dead-
lines.
5.3 Packaging
About the packaging The individual screw compressors are packaged in cartons or some-
times on wooden frames and according to the anticipated transport
conditions. Only environmentally-friendly materials are used for the
packaging.
The packaging should protect the individual components against
transport damage, corrosion and other damage until assembly. There-
fore, do not destroy the packaging and only remove it shortly before
assembly.
2010-11-04 61
Handling packaging materials Dispose of packaging material in accordance with the relevant appli-
cable legal requirements and local regulations.
NOTICE!
Danger to the environment due to incorrect disposal!
Packaging materials are valuable raw materials and in
many cases can continue to be used or can be properly
processed and recycled. Incorrect disposal of packaging
materials may pose risks to the environment.
- Dispose of packaging materials in accordance with
the environmental regulations.
- Observe locally applicable waste disposal regula-
tions. If necessary, outsource the disposal to a spe-
cialist company.
5.4 Symbols on the packaging

The following symbols are on the packaging. Always heed these sym-
bols during transport.
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.
62 2010-11-04
5.5 Transport
Transport with a fork lift Transport pieces can be transported with a fork lift under the following
conditions:
The fork lift must be designed for the weight of the transport
pieces.
Existing guide rails on the frame must be used.
The length of the forks must be at least 1400 mm.
Transporting Personnel: Forklift driver
1. Drive the fork lift with the forks as shown in Fig. 26.
2. Insert the forks so that they stick out on the other side.
3. Ensure that the transport piece cannot tip with an off-centre cen-
tre of gravity.
4. Lift the transport piece and begin the transport.
Fig. 26: Transport with a fork lift
5.6 Storage
Storage of the packaging pieces Store the packaging pieces under the following conditions:
Do not store outdoors.
Store dry and dust-free.
Do not expose to any aggressive media.
Protect against solar radiation.
Avoid mechanical jolts.
Storage temperature: 15 to 35 °C.
Relative humidity: max. 60 %.
In case of storage for longer than 3 months, check the general
condition of all parts and the packaging regularly. If necessary,
refresh or replace the rust-proofing.
Under some circumstances there may be notes about

storage on the packaging pieces that extend beyond the
requirements named here. Adhere to these accordingly.
2010-11-04 63
Installation and commissioning
6 Installation and commissioning

6.1 Safety notes 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 from improper initial commission-
ing!
Improper initial commissioning can result in serious in-
jury and significant damage to property.
- Before the initial commissioning, ensure that all instal-
lation work has been carried out and completed in
accordance with the information and instructions in
this manual.
- Ensure that no persons are in the danger zone before
the initial commissioning.

WARNING!
In the event of an unauthorised restart of the power sup-
ply during installation, there is a danger of serious inju-
ries 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.
64 2010-11-04
Improper installation and commis-

WARNING!
sioning
Risk of injury due to improper installation or com-
missioning!
Improperly performed installation and commissioning
may lead to serious injury and significant material dam-
age.
- Provide for sufficient mounting clearance before start-
ing to work.
- Use caution when handling exposed components with
sharp edges.
- Keep the assembly area tidy and clean! Loose com-
ponents 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 per-
formed 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.
6.2 Requirements in the installation location

Set up the screw compressor so that the following conditions are ful-
filled:
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.
A max. relative humidity of 60% is guaranteed.
The machine is not subjected to an explosive atmosphere.
The machine is not subjected to a corrosive atmosphere.
2010-11-04 65
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.
6.3 Installation
6.3.1 Ventilation
DANGER!
Danger to life from the use of explosive gas mix-
tures, vapours, dust or aggressive hazardous sub-
stances!
The use of explosive gas mixtures, vapours, dust or ag-
gressive hazardous substances to ventilate the screw
compressor can cause severe or even fatal injuries as
well as significant property damage.
- Never use explosive gas mixtures, vapours, dust or
aggressive hazardous substances to ventilate the
screw compressor.
- Ensure that no explosive gas mixtures, vapours, dust
or aggressive hazardous substances get into the ven-
tilation of the screw compressor.
The air supplied via the intake openings is used for compression and
system cooling.
Personnel: Qualified personnel
Protective equipment: Safety boots

Protective clothing
66 2010-11-04
NOTICE!
Property damage due to condensation!
Due to cooling air that is too hot or too humid, conden-
sate can arise.
- Only provide cool, dry and dust-free cooling air.
- For the intake of outside air, use a recirculating air
flap.
1. Provide the required quantity of cooling air according to the tech-

nical data for the screw compressor (ª Chapter 3 „Technical
data“ on page 31).
2. Remove the exhaust air according to the technical data for the
screw compressor (ª Chapter 3 „Technical data“ on page 31).
Ö This way, the heating of the installation room and of the screw
compressor will be prevented.
Fig. 27: Overview illustration of cooling air

ventilator
Forced ventilation and bleeding The forced ventilation and bleeding must be dimen-
(optional) sioned so that the required supply and exhaust air can
be supplied and removed taking into account the existing
residual pressure of the cooling air ventilator. The ex-
haust air can also be used for the purpose of heat rec-
lamation.
2010-11-04 67
6.3.2 Connection to the compressed air network
Protective equipment: Protective 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 jer-
ky movements of the compressed air hose with high
force.
- Anchor and fasten the compressed air hose suffi-
ciently.
The prerequisite for the correct installation is the pres-

ence of a professionally-planned, installed and main-
tained 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

(ª Chapter 3 „Technical data“ on page 31).
2. Ensure that the compressed air hose does not represent a stum-
bling hazard.
3. Anchor and fasten the flexible compressed air hose sufficiently.
Fig. 28: Compressed air connection
68 2010-11-04
6.3.3 Connecting to the power supply
Personnel: Qualified Electrician

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, the-
re is a danger that the compressor stage will be de-
stroyed due to a drive turning incorrectly.
- Connect the power according to the wiring diagram
and check the rotating field before starting the screw
compressor.
The prerequisite for the correct installation are profes-

sionally-dimensioned fuses in the network supply (per-
son-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 deviati-
ons 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 (ª Chapter 3
„Technical data“ on page 31).
3. Check right-rotating direction of rotation with a rotating field mea-

surement device.
4. Ensure that the power cable does not represent a stumbling haz-
ard.
2010-11-04 69
6.4 Checking the coolant liquid level


Safety boots
Safety 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. 29/1) to make sure it is com-

pletely moist.
4. If necessary, top up coolant liquidª Chapter 8.4.7 „Changing the

coolant liquid/changing the cooling liquid filter“ on page 108.
Fig. 29: Inspection glass
70 2010-11-04
6.5 Start-up lubrication of the compressor stage


Safety boots
NOTICE!
Property damage due to lacking coolant liquid in the
compressor stage!
Lacking coolant liquid in the compressor stage after lon-
ger downtimes, e.g. between factory delivery and initial
commissioning or after a longer downtime can cause
significant property damage to the screw compressor.
- Top up the coolant liquid directly in the compressor
stage before the initial commissioning or after a lon-
ger downtime.
Coolant liquid quantities for direct filling in the compressor stage
Screw compressor Coolant liquid filling
COMBI 2S – 7S 0,2
COMBI 6 – 15.1 0,5
COMBI 16 – 22 0,5
2010-11-04 71
1. Loosen 4 screws on the intake regulator (Fig. 30/1).
NOTICE!
Property damage due to incorrect coolant liquid!
Mixing different coolant liquids causes significant prop-
erty damage to the screw compressor.
- Only use the coolant liquid prescribed in the technical
data.
If there is no additional coolant liquid available, the cool-

ant liquid must be removed with the help of the coolant
Fig. 30: Screw plug intake regulator
liquid drain ª Chapter 8.4.7 „Changing the coolant li-
quid/changing the cooling liquid filter“ on page 108.
2. Remove the intake regulator and fill the coolant liquid directly into
the compressor stage (Fig. 30/1).
3. Tighten 4 screws on the intake regulator

(Fig. 30/1)(ª Appendix B „Tightening torques for screws“ on pa-
ge 132).
6.6 Switching on after the initial commissioning

Protective equipment: Ear protection

Protective 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 connec-
tion between the screw compressor and the compressed air net-
work.
Ö The screw compressor is now connected to the compressed

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

time.
72 2010-11-04
6.7 Working after the initial commissioning


Safety boots
Safety gloves
Safety goggles
WARNING!
skin burns.
30 minutes.
CAUTION!
fresh air supply.
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 ª Appendix B „Tightening torques for screws“
on page 132.
2010-11-04 73
7. Check the coolant liquid level in the inspection glass (Fig. 31/1)
and top up as in ª Chapter 8.4.2 „Checking the coolant liquid
level/topping up the coolant liquid“ on page 102 if necessary.
8. Install and check that the sound installation covers are sealed.
NOTICE!
Property damage to to compressor temperature that
is too low or too high!
A compressor temperature that is too low or too high can
cause damage to the screw compressor.
- Contact the manufacturer for more precise informa-
tion, for contact information see page 2.
A sufficiently high compressor temperature guarantees

Fig. 31: 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 op-
erating temperature ª Chapter 8.4.6 „Checking the con-
densation accumulation“ on page 107.
9. Check compressor temperature ª Chapter 8.4.4 „Checking the

compressor temperature“ on page 105.
6.8 Setting parameters
Adjustment work for the screw compressor:

ª Chapter 7.4 „Controllers“ on page 76.
74 2010-11-04
Operation
7 Operation
7.1 Safety instructions for the operation
Improper operation
WARNING!
Danger of injury due to improper operation!
Improper operation can cause serious injury and signifi-
cant material damage.
- Carry out all operating steps in accordance with the
information and notices in this manual.
- Pay attention to the following points before starting
work:
- Ensure that all covers and safety devices are in-
stalled and work properly.
- Ensure that that no one is in the danger zone.
- Never override or bridge safety features during opera-
tion.
7.2 Shutdown in emergency situations

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

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

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

again.
7. Keep entry ways clear for rescue vehicles.
8. Give directions to rescue vehicles.
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.
2010-11-04 75
Operation
WARNING!
zation or due to uncontrolled restart!
Uncontrolled or unauthorized switching on of the power
supply can cause severe or fatal injuries.
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 equip-
ment apply for all work on all controllers:
Personnel: Trained Person
Protective equipment: Ear protection
7.4 Controllers
Controller variants
For the controller variant installed, please consult the
label on the controller.
76 2010-11-04
Operation
7.4.1 COMBI 2S – 7S controller
7.4.1.1 Overview
No. Key/icon Description of function

1 Main switch with emergency off
function
2 Displays the hours of operation.
3 Serves to switch on the compres-

sor.
4 Indicates the operating state.

Fig. 32: COMBI 2S – 7S controller
5 Serves to switch off the compres-
sor.
7.4.1.2 Switching the compressor on/off
Switching the compressor on 1. Press .
Ö The operating indicator lights up, the compressor is

ready and can start up automatically at any time.
Switching the compressor off 1. Press .
Ö The operating indicator no longer lights up, the com-

pressor switches itself off.
2010-11-04 77
Operation
7.4.2 Air Control AC mini controller
7.4.2.1 Air Control Mini overview
Fig. 33: Overview of Air Control AC mini

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.
78 2010-11-04
Operation
Indicates warnings with flashing and faults with red

6
LEDs that light up.
7.4.2.2 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.
7.4.2.3 Operating modes
Overview Four operating modes can be set using the controller.
Betriebsart (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 con-
(BLS operation) troller. The compressor is controlled by a superior controller, which
can be connected via freely-programmable inputs (no RS485 pre-
sent).
2010-11-04 79
Operation
Sicherheitsdruck (Safety pressure) The safety pressure is the sum of the set maximum pressure + 0.8
bar. If the pressure exceeds the value of the safety pressure, the
compressor is switched off with a fault message. If the maximum
pressure is exceeded by 0.5 bar, a warning appears on the display.
7.4.2.4 Overview of display
The display shows all operation-relevant information such as the pa-

rameters set.
Fig. 34: 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 tem-

perature can also be shown on the [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.
80 2010-11-04
Operation
Symbol Description
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.
7.4.2.5 Switching the compressor on/off
Switching the compressor on 1. Press .

time.
Switching the compressor off 1. Press .
Ö 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.
7.4.2.6 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 infor-
mation and the parameter displays, it is only necessary to press the
key. The Information menu with parameter number and the pa-
rameter value then appears on the display.
1. Press .
Ö The next parameter value is shown on the display.
In the information menu, the parameter [Switch-on pres-

sure] is always shown as the first value.
After approx. 5 seconds without pressing the key, the

display switches back to the basic display.
2010-11-04 81
Operation
Key Parameter displayed Parameter number Unit of the pa-

rameter value
Einschaltdruck (Switch-on [1] [bar, MPa, psi]
pressure)
Ausschaltdruck (Switch-off [2] [bar, MPa, psi]

pressure)
Sicherheitsdruck (Safety pres- [3] [bar, MPa, psi]

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

in BLS operation
Minimum compressor tempe- [5] [°C, °F, Kelvin]

rature
Maximum compressor tempe- [6] [°C, °F, Kelvin]

rature
Hours of operation [7] [h]
Laststunden (Load hours) [8] [h]
Remaining time intake filter [9] [kh]
Remaining time coolant liquid [10] [kh]

and coolant liquid filter
Remaining time fine precipita- [11] [kh]

tor
Remaining time motor lubrica- [12] [kh]

tion
Remaining time compressor [13] [kh]

maintenance
Remaining time dryer mainte- [14] [kh]

nance
Hours of operation dryer [15] [h]
7.4.2.7 Setting parameters via code input menu
The parameters for all basic settings of the compressor can be chan-
ged with code input insofar as these changes do not influence the
operational stability. However, this is only possible when the com-
pressed air generation is switched off.
82 2010-11-04
Operation
7.4.2.7.1 Calling up the code input menu
1. Press and hold for three seconds.
Ö The code input menu appears on the display.
2. Press .
Ö A 1 appears on the display.
3. Press .
In order to exit the code input menu again, press the

and keys together.
7.4.2.7.2 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 .
Ö 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 parame-
ter is selected automatically in such cases.
2010-11-04 83
Operation
7.4.2.7.3 Select operating mode: Code 2
By entering the code 2, the operating mode can be selected.
2. Press .
3. Press .
4. Set the code 2 with the keys.
6. Press .
Ö 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 .
Ö The set value is saved and the code input menu appears on
the display again.
9. Press the keys together to go back to the basic display.
84 2010-11-04
Operation
Value Betriebsart (Operating Description

mode)
0 Automatic operation After reaching the switch-off pressure, the compressor swit-
ches 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 rea-
ched, the compressor starts up again automatically.
1 Load/idle operation The compressor switches between "Load" and "Idle" opera-
tion; that is, there is an unlimited run-on.
2 Optional automatic The "Automatic" symbol and an additional point are shown on
the display in front of the temperature value. Here it is possible
to influence how frequently the motor stops. To do this, after
the confirmation, the parameters "maximum pressure drop"
(input range 0.0 to 9.9 bar) and "maximum operating cycle"
(input range 1 to 55 operating cycles/hour) are queried.
Maximum pressure drop If the system switches from load operation to idle, the Air Control mini
saves the current network pressure after 10 and 40 seconds. If the
pressure drop determined this way is above the "maximum pressure
drop", the motor switches off after the idle time has elapsed; otherwise
after the shutdown time.
Maximum operating cycles The motor is not switched off after the idle time (run-on) has elapsed if
the number of switch-on processes of the compressor exceeds the
number of the "maximum operating cycles".
7.4.2.7.4 Switch automatic restart on/off: Code 3
By inputting the code 3, the automatic restart can be switched on/off

after a power failure.
2. Press .
3. Press .
2010-11-04 85
Operation
Ö The submenu for switching the automatic restart on/off ap-

pears on the display.
6.
There are two values from which to choose:
- 0: Automatic restart OFF
- 1: Automatic restart ON
the display again.
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. Other-
wise, 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 com-
pressor was operating before the power failure, then after this
time has elapsed, it will start up again. Otherwise, the compres-
sor will then switch to STOP mode.
86 2010-11-04
Operation
7.4.2.7.5 Set on-site operation/remote operation: Code 8
By inputting the code 8, it is possible to switch between on-site opera-

tion and remote operation.
2. Press .
3. Press .
Ö The on-site operation/remote control submenu appears on the

display.
6.
- 0: On-site operation
- 1: Remote control
- 2: BLS-OK
the display again.
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 flash-
ing text on the display of the Air Control 1. If the key is
pressed on the system on-site, the system switches off after 120 sec-
onds and for safety reasons, it can only be started via remote control
after the key has been pressed (acknowledgement) on-site. This
also applies for a start via PLANT CONTROL V/T.
2010-11-04 87
Operation
Value Designation Description

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 exist-
ing low level, the BLS operation is switched off automatically and the
internal pressure sensor is used.
7.4.2.7.6 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 com-
pression. The switch-off pressure specifies the pressure at which the
compressor will be switched off automatically. Both functions are only
active in automatic operation.
2. Press .
3. Press .
6. Press .
Ö The submenu for setting the switch-on pressure appears on

the display.
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.
Ö The set value was saved and the submenu for setting the
switch-off pressure appears on the display.
88 2010-11-04
Operation
9.
The adjustment range for the switch-off pressure is,
with switch-on pressure set at the factory, between
7.1 and 10 bar. The upper limit for the switch-off
pressure is equal to the maximum pressure. The
lower limit for the switch-off pressure is 0.1 bar hig-
her than the switch-on pressure.
Set the desired switch-off pressure with the keys.
10. To confirm the setting, press the key.
the display again.

7.4.2.7.7 Switch Basic load switching mode on/off: Code 18
By inputting the code 18, the Basic load switching mode can be swit-
ched on/off.
2. Press .
3. Press .
Ö The Basic load switching mode submenu appears on the dis-

play.
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
the display again.
2010-11-04 89
Operation
7.4.2.7.8 Switch the pressure unit: Code 90
By entering the code 90, the pressure unit can be switched.
2. Press .
3. Press .
Ö The submenu for setting the pressure unit appears on the

display.
6.
- 0: bar
- 1: MPa
- 2: psi (pounds per square inch)
the display again.
Va- Druckeinheit (Pressu- Description

lue re unit)
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).
90 2010-11-04
Operation
7.4.2.7.9 Switch the temperature unit: Code 95
By entering the code 95, the temperature unit can be switched.
2. Press .
3. Press .
Ö The submenu for setting the temperature unit appears on the

display.
6.
- 0: °C
- 1: °F
- 2: K
the display again.
Va- Druckeinheit (Pressu- Description

lue re unit)
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.
2010-11-04 91
Operation
7.4.2.7.10 Display the software version: Code 9999
By inputting the code 9999, the software version can be displayed.
2. Press .
3. Press .
Ö The software version appears on the display.
6. Press the keys together to go back to the code input me-

nu.
7.4.2.8 Fault and warning messages

7.4.2.8.1 Fault messages
The symbol blinks and the [Current network pressure] indicator

displays the fault message and the current network pressure in alter-
nation. 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
92 2010-11-04
Operation
No. Description
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
NOTICE!
Property damage due to incorrect acknowledgement
of fault messages!
Faults which occur are output as fault messages. Only
after the fault has been eliminated may the fault mes-
sages be acknowledged, since otherwise the service life
of the compressor will be reduced.
- Only have maintenance work performed by qualified
personnel.
- Only acknowledge fault messages after the appropri-
ate work.
- Only use original spare parts.
Acknowledging fault messages Faults may only be acknowledged if the cause has been
eliminated properly. Only have troubleshooting and
maintenance work performed by qualified personnel.
1. Press .
2. Press .

time.
2010-11-04 93
Operation
7.4.2.8.2 Warning messages
The symbol blinks and the [Current network pressure] indicator

displays the warning message and the current network pressure in
alternation.
No. Description
E. 34 Compressor temperature increased
E. 35 Network pressure increased
E. 36 Temperatur zu niedrig (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 (remai-

ning 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)
94 2010-11-04
Operation
Acknowledging warning messages

NOTICE!
Property damage due to incorrect acknowledgement
of warning messages!
Maintenance which needs attention is output as warning
messages. Only after the maintenance has been per-
formed 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 ap-
propriate work.
- Only use original spare parts.
2. Press .
3. Press .
6. Press the key in order to restart the maintenance interval.
2010-11-04 95
Maintenance
8 Maintenance
8.1 Safety instructions for maintenance
Electrical system
DANGER!
on, electric components may be subject to uncontrolled
movements and may cause grave injury.
Moving parts
WARNING!
Danger of injury from moving parts!
Rotating parts and/or parts moving in linear fashion may
cause serious injuries.
- Before carrying out any maintenance work on moving
parts, shut down the machine and take precautions to
prevent restarting. Wait until all parts have stopped
moving.
- When in the danger zone, wear close-fitting protective
work clothing with low tear strength.

WARNING!
ply during maintenance, there is a danger of serious inju-
ries or death for persons in the danger zone.
96 2010-11-04
Maintenance
Hot surfaces
WARNING!
skin burns.
30 minutes.
Improperly performed maintenance

WARNING!
Danger of injury due to improperly performed main-
tenance!
Improperly performed maintenance may lead to serious
injury and significant material damage.
- Provide for sufficient mounting clearance before start-
ing to work.
- Keep the assembly area tidy and clean! Loose com-
ponents 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 prop-
erly, 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 instruc-
tions 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.
2010-11-04 97
Maintenance
Compressed air
WARNING!
sonnel immediately.
Coolant liquid fog

CAUTION!
fresh air supply.
98 2010-11-04
Maintenance
Accumulations of liquid
CAUTION!
Danger of injury from slipping in accumulations of
liquid!
Slipping in accumulations of liquid on the floor may result
in a fall. A fall may result in injuries.
- Remove accumulations of liquid immediately using
appropriate means.
- Wear anti-slip safety shoes.
- Post warnings and mandatory signs at or in the vicin-
ity of any area where liquid could accumulate on the
floor.
Environmental protection Observe the following environmental protection instructions during

maintenance work:
In respect of all lubrication points supplied manually with lubricant,
remove any escaping, used or surplus grease and dispose of in
accordance with applicable local regulations.
Catch replaced oils in suitable containers and dispose of in
accordance with applicable local regulations.
8.2 Spare parts
WARNING!
Danger of injury due to use of incorrect spare parts!
The use of incorrect or defective spare parts can lead to
personal injury, material damage, malfunction or total
failure.
- Use only original manufacturer's spare parts or spare
parts that have been approved of by the manufac-
turer.
- Always contact the manufacturer if in doubt.
Loss of warranty
The manufacturer's warranty will be rendered null and
void if spare parts are used that are not approved.
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.
2010-11-04 99
Maintenance
8.3 Maintenance plan

Maintenance tasks are described in the sections below that are re-
quired for optimal and trouble-free machine operation.
If increased wear is detected during regular inspections, then reduce
the required maintenance intervals according to the actual indications
of wear. Contact the manufacturer (see the service address on page
2), if you have questions concerning maintenance tasks and intervals.
Interval Maintenance work Personnel
After the first Check for leaks ª Chapter 8.4.3 „Checking for leaks“ on Qualified personnel
100 hours of page 104
operation
Check compressor temperature ª Chapter 7.4 Trained Person
„Controllers“ on page 76
Check cooler for soilingª Chapter 8.4.5 „Checking soiling Qualified personnel
of the cooler“ on page 106
Check for condensate formation ª Chapter 8.4.6 Qualified personnel

„Checking the condensation accumulation“ on page 107
After the first Check all electrical connections ª Chapter 8.4.1 Qualified Electrician
500 hours of „Checking the electrical connections“ on page 102
operation
Change coolant liquid ª Chapter 8.4.7 „Changing the Qualified personnel
coolant liquid/changing the cooling liquid filter“ on
page 108
Change coolant liquid filter* ª Chapter 8.4.7 „Changing Qualified personnel

the coolant liquid/changing the cooling liquid filter“ on pa-
ge 108
Daily Checking the coolant liquid level ª Chapter 8.4.2 Qualified personnel
„Checking the coolant liquid level/topping up the coolant
liquid“ on page 102
Check for leaks ª Chapter 8.4.3 „Checking for leaks“ on Qualified personnel
page 104
Every 2000 Re-lubricate electric motor ª Chapter 8.4.8 „Re- Qualified personnel
hours of ope- lubricating the electric motor“ on page 111
ration
Every 4000 Change coolant liquid ª Chapter 8.4.7 „Changing the Qualified personnel
hours of op- coolant liquid/changing the cooling liquid filter“ on
eration, at page 108
least once a
year Change coolant liquid filter* ª Chapter 8.4.7 „Changing Qualified personnel
the coolant liquid/changing the cooling liquid filter“ on pa-
ge 108
100 2010-11-04
Maintenance
Change fine precipitator* ª Chapter 8.4.9 „Change fine Qualified personnel

precipitator“ on page 112
Change intake filter* ª Chapter 8.4.10 „Change intake Qualified personnel

filter“ on page 113
Check safety valve Manufacturer
Check drive unit ª Chapter 8.4.11 „Checking the drive Qualified personnel
unit“ on page 114
General compressor maintenance Manufacturer
One week Check all electrical connections ª Chapter 8.4.1 Qualified Electrician
after initial „Checking the electrical connections“ on page 102
installation
Weekly Check compressor temperature ª Chapter 7.4 Trained Person

Check cooler for soilingª Chapter 8.4.5 „Checking soiling Qualified personnel
of the cooler“ on page 106
Check for condensate formation ª Chapter 8.4.6 Qualified personnel

„Checking the condensation accumulation“ on page 107
* The change intervals refer to:

Ambient temperature of +40 °C
Max. humidity of 60%
Compressor temperature of approx. 85 °C
8.4 Maintenance work
Necessary maintenance work

Necessary maintenance work appears on the display of
the controller as a warning ª Chapter 7.4 „Controllers“
on page 76.
2010-11-04 101
Maintenance
8.4.1 Checking the electrical connections
Personnel: Qualified Electrician

Protective clothing
Safety goggles
Safety 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.
2. Close compressed air network-side gate valve and secure

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

ª Appendix B „Tightening torques for screws“ on page 132.
8.4.2 Checking the coolant liquid level/topping up the coolant liquid
Checking the coolant liquid level Personnel: Qualified personnel

Protective clothing
Safety goggles
Safety gloves
102 2010-11-04
Maintenance

against re-opening.
spanner.
4. Check the inspection glass (Fig. 35/1) to make sure it is com-

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

liquid, the coolant liquid must be topped up.
Fig. 35: Inspection glass
Topping up the coolant liquid Personnel: Qualified personnel

Protective clothing
Safety goggles
Safety gloves
Materials: Collecting tray for coolant liquid

Funnel with filling tool

against re-opening.
spanner.
4. With the help of a collection tray, make sure that the escaping
coolant liquid is collected.
2010-11-04 103
Maintenance
5. Loosen the filler plug (Fig. 36/1), remove and make sure that the
gasket does not get lost.
NOTICE!
data.
Fig. 36: Filler plug
6. With the help of a funnel (Fig. 37/1), fill coolant liquid up to the
filling edge of the filler plug (Fig. 37/3).
7. Position the gasket and check for correct fit.
8. Insert the screw plug (Fig. 37/2) and tighten ª Appendix B

„Tightening torques for screws“ on page 132.
Fig. 37: Filler plugs
8.4.3 Checking for leaks

Protective clothing
Safety goggles
Safety gloves

against re-opening.
104 2010-11-04
Maintenance
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

ª Appendix B „Tightening torques for screws“ on page 132.
8.4.4 Checking the compressor temperature

Protective 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 informa-
tion, 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 au-
tomatically.
Check compressor temperature ª Chapter 7.4 „Controllers“ on pa-

ge 76.
2010-11-04 105
Maintenance
8.4.5 Checking soiling of the cooler

Protective clothing
Safety goggles
Safety gloves

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

doing this, make sure that the soiling from the de-
vice is blown out of rather than into the machine. In
case of severe soiling, consult the manufacturer.
106 2010-11-04
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 op-
erating temperature .

Protective clothing
Safety goggles
Safety 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.

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

Since the condensate is heavier than the coolant liquid,
after longer downtimes, it collects on the bottom of the
coolant liquid pressure tank.
2010-11-04 107
Maintenance
5. Carefully open the coolant liquid drain (Fig. 38/1) and check the
liquid escaping.
6. Slowly drain condensate until coolant liquid escapes.
7. Close ª Appendix B „Tightening torques for screws“ on page 132

the coolant liquid drain (Fig. 38/1).
8. Switch on the compressor and switch off again after a maximum

of one minute ª Controller documentation.
9. Check coolant liquid level and top up if necessary

ª Chapter 8.4.2 „Checking the coolant liquid level/topping up the
coolant liquid“ on page 102.
Fig. 38: Coolant liquid drain
8.4.7 Changing the coolant liquid/changing the cooling liquid filter
Changing the coolant liquid Personnel: Qualified personnel

Protective clothing
Safety goggles
Safety gloves

Funnel with filling tool

against re-opening.
spanner.
108 2010-11-04
Maintenance
5. Loosen the filler plug (Fig. 39/1), remove and make sure that the
gasket does not get lost.
Fig. 39: Filler plug
6. Open the coolant liquid drain (Fig. 40/1).
Ö Coolant liquid is drained.
7. Close the coolant liquid drain (Fig. 40/1).
NOTICE!
data.
Fig. 40: Coolant liquid drain
2010-11-04 109
Maintenance
8. With the help of a funnel (Fig. 41/1), fill coolant liquid up to the
filling edge of the filler plug (Fig. 41/3).
9. Position the gasket and check for correct fit.
10. Insert the screw plug (Fig. 41/2) and tighten ª Appendix B
of one minute ª Chapter 7.4 „Controllers“ on page 76.

ª Chapter 8.4.2 „Checking the coolant liquid level/topping up the
Fig. 41: Filler plugs
Changing the coolant liquid filter* Personnel: Qualified personnel

Protective clothing
Safety goggles
Safety gloves

Strap spanner

against re-opening.
spanner.
110 2010-11-04
Maintenance
5. Using the strap spanner, loosen and remove the old coolant liquid
filter (Fig. 42/1).
6. Remove old gasket remains from the coolant liquid filter housing.
7. Moisten the new gasket with a little coolant liquid.
8. Screw in the new coolant liquid filter (Fig. 42/1) up to the stop.
9. Tighten the new coolant liquid filter (Fig. 42/1) half a turn by hand.
of one minute ª Chapter 7.4 „Controllers“ on page 76.

Fig. 42: Remove coolant liquid filter ª Chapter 8.4.2 „Checking the coolant liquid level/topping up the
8.4.8 Re-lubricating the electric motor
Protective equip- Safety boots

ment: Protective clothing
Safety goggles
Safety gloves
Materials: Lubrication grease ALMiG part number

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

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

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

nal box.
2010-11-04 111
Maintenance
5. Grease the grease nipples (Fig. 43/1) with a grease gun.
Fig. 43: Grease nipples
8.4.9 Change fine precipitator

Protective clothing
Safety goggles
Safety gloves
Materials: Strap spanner

against re-opening.
spanner.
5. Using the strap spanner (Fig. 44/2), loosen and remove the fine
precipitator (Fig. 44/1).
6. Remove old gasket remains from the fine precipitator (Fig. 44/1).
7. Moisten the new gasket with a little coolant liquid.
Fig. 44: Loosen fine precipitator
112 2010-11-04
Maintenance
8. Screw in the new fine precipitator (Fig. 45/1) up to the stop.
9. Tighten the new fine precipitator (Fig. 45/1) half a turn by hand.
Fig. 45: Fine precipitator
8.4.10 Change intake filter
Standard intake filter Personnel: Qualified personnel

Protective clothing
Safety goggles
Safety gloves

against re-opening.
spanner.
2010-11-04 113
Maintenance
4. Loosen the intake filter (Fig. 46/2).
5. Remove the old intake filter (Fig. 46/1).
6. Attach the new intake filter (Fig. 46/1).
7. Tighten the clamp of the intake filter (Fig. 46/2) ª Appendix B

Fig. 46: Loosen the clamp of the intake

filter
8.4.11 Checking the drive unit


Protective clothing
Safety goggles
Safety gloves

against re-opening.
spanner.
4. Visually check the drive unit.
Ö In case of visible defects, contact the manufacturer.
114 2010-11-04
Maintenance
8.5 Measures after maintenance has been performed

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

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

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

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

(ª Appendix C „Service manual“ on page 133).
2010-11-04 115
Faults
9 Faults
The following section describes possible causes of faults and the work
to remedy them.
In case of faults that occur more than once, abbreviate the mainte-
nance intervals according to the actual utilisation.
In case of faults that cannot be remedied using the following instruc-
tions, contact the manufacturer, see contact data on page 2.
9.1 Safety instructions for fault remedy

Electrical system
DANGER!
Hot surfaces
WARNING!
skin burns.
30 minutes.

WARNING!
ply while tracking down and rectifying a fault, there is a
danger of serious injuries or death for persons in the
danger zone.
116 2010-11-04
Faults
Improperly executed troubleshoo-

WARNING!
ting 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!
sonnel immediately.
2010-11-04 117
Faults
Coolant liquid fog

CAUTION!
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 pos-

ing 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 author-

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

authorised to rectify the fault.
118 2010-11-04
Faults
9.2 Fault displays

For the fault displays, consult the ª Controller documentation.
9.3 Fault table
No. Fault description Cause Remedy Personnel
Compressor tempera- Intake or ambient tem- Ventilate compressor Qualified

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

ª Chapter 8.4.7 personnel
„Changing the coolant
liquid/changing the coo-
ling liquid filter“ on
page 108
Coolant liquid low Top up coolant liquid Qualified

„Checking the coolant
liquid level/topping up the
coolant liquid“ on
page 102
Coolant liquid cooler soi- Clean coolant liquid coo- Qualified

led ler ª Chapter 8.4.5 personnel
„Checking soiling of the
cooler“ on page 106
Network pressure Compressed air con- Screw compressor with Manufactu-

drops sumption higher than greater delivery quantity rer
delivery quantity of the necessary
screw compressor
Intake filter soiled Replace intake filter Qualified

„Change intake filter“ on
page 113
Bleeder valve blows dur- Check bleeder valve and Manufactu-

ing compression replace gaskets if neces- rer
sary
2010-11-04 119
Faults
Intake regulator does not Check magnet valve and Manufactu-

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

air network air network personnel
Screw compressor Minimum pressure valve Clean or replace mini- Manufactu-

blows via safety valve blocked mum pressure valve rer
Safety valve faulty Check safety valve and Manufactu-

replace if necessary rer
Fine precipitator soiled Change fine precipitator Qualified

ª Chapter 8.4.9 „Change personnel
fine precipitator“ on pa-
ge 112
"Overpressure fault "or Fine precipitator soiled Change fine precipitator Qualified
"Network pressure too ª Chapter 8.4.9 „Change personnel
high" (red lamp lights fine precipitator“ on pa-
up) ge 112
Higher outside pressure Balance out outside pres- Qualified

present in compressed air sure or disconnect from personnel
network the network
Screw compressor Network pressure set too Reset network pressure Trained
does not start auto- high ª Chapter 7.4 Person
matically or does not „Controllers“ on page 76
discharge after previ-
ous switching-off by Interruption in the power Check power circuit for Qualified
reaching the final pres- circuit interruption Electrician
sure or from idle.
Ambient temperature Install additional heating Qualified
below +1 °C, message or temper compressor personnel
"Coolant liquid tempera- room and also contact the
ture too low" manufacturer
Switching times are acti- Check switching and Trained

vated in the circuitry pressure times in the Person
circuitry ª Chapter 7.4
System does not start Network pressure greater Heed network pressure Trained
up when the start key is than switch-on pressure and change settings Person
pressed ª Chapter 7.4
120 2010-11-04
Faults
Symbol "remote" flashes Remote control activated Trained

ª Chapter 7.4 Person
Lacking voltage on the Check whether there is Qualified

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

troller Electrician
Switching times are acti- Check switching and Trained

vated in the circuitry pressure times in the Person
circuitry ª Chapter 7.4
Compressed air con- Return line for the coolant Clean or replace return Qualified
tains a lot of coolant liquid is blocked line for the coolant liquid personnel
liquid (coolant liquid ª „Clean/change return
consumption too high) line“ on page 122
Flawed fine precipitator Change fine precipitator Qualified

ª Chapter 8.4.9 „Change personnel
fine precipitator“ on pa-
ge 112
System stops before Overtemperature or over- Eliminate fault Trained

reaching the final pres- pressure ª Chapter 7.4 Person
sure (red lamp lights „Controllers“ on page 76
up)
Interruption in the control Check power circuit Qualified
power circuit Electrician
Pressure drop Pressure difference of the Replace filter Qualified

filter too high personnel
2010-11-04 121
Faults
9.4 Work to remedy faults

Clean/change return line Personnel: Qualified personnel

Protective clothing
Safety goggles
Safety gloves

against re-opening.
spanner.
5.
Depending on the type, several fine precipitators
can be installed. There is a return line for each fine
precipitator.
Loosen return line (Fig. 47/2) on separator box (Fig. 47/3) and
compressor stage (Fig. 47/1).
6. Clean return line (Fig. 47/2) and nozzle, if necessary replace with
Fig. 47: return line original spare parts (ª Appendix D „Spare parts list“ on pa-
ge 137).
7. Put nozzle and return line (Fig. 47/2) back in position and tighten
screws (ª Appendix B „Tightening torques for screws“ on
page 132).
122 2010-11-04
Faults
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 ª Controller documentation.
3. no persons are in the danger zone.
4. Start the screw compressor ª Controller documentation.
2010-11-04 123
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 notes for dismantling and disposal

Electrical system
DANGER!
- Before starting the dismantling, switch off the electric
power supply and disconnect completely.
Improper dismantling
WARNING!
Danger of injury due to improper dismantling!
Stored residual energy, angular components, points and
edges on or in the machine or on the tools needed can
cause injuries.
- Ensure sufficient space before starting work.
- Handle exposed, sharp-edged components with care.
- Pay attention to orderliness and cleanliness in the
workplace! Loosely stacked or scattered components
and tools could cause accidents.
- Dismantle the components properly. Note that some
components may have a high intrinsic weight. Use
hoists if necessary.
- Secure components so that they cannot fall down or
topple over.
- Consult the manufacturer if in doubt.
124 2010-11-04
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 compli-
ance with applicable local occupational safety and environmental pro-
tection regulations.
10.3 Disposal
If no return or disposal agreement has been made, send the disman-
tled components for recycling.
Scrap metals.
Send plastic elements for recycling.
Sort and dispose of other components in accordance with their
material composition.
NOTICE!
Danger to the environment due to incorrect disposal!
Incorrect disposal may pose risks to the environment.
- Electrical scrap, electronic components, lubricants
and other auxiliary materials must be disposed of by
authorised specialist companies.
- If in doubt, obtain information about disposal in ac-
cordance with the environmental regulations from the
local municipal authorities or specialised waste dis-
posal companies.
2010-11-04 125
Index
11 Index
Setting parameters....................................... 83
A Sicherheitsdruck (Safety pressure)............ 80
Accident............................................................ 26 Switch automatic restart on/off................... 85
Acknowledging Switch the temperature unit ........................ 92
fault messages ............................................. 94 Switching off ................................................. 81
warning messages ....................................... 96 Switching on ................................................. 81
Air Control AC mini controller........................ 78 Switching the pressure unit ........................ 91
Acknowledging fault messages.................. 94 Warning messages....................................... 95
Acknowledging faults .................................. 94 Warnings ....................................................... 95
Acknowledging warning messages ........... 96
Basic display ................................................ 80 B
Brief description........................................... 79 Brief description .............................................. 52
Calling up information ................................. 81 C

Calling up parameter values ....................... 81 Change
Calling up the code input menu.................. 83 coolant liquid .............................................. 109
Code 11 ......................................................... 88 coolant liquid filter ..................................... 109
Code 18 ......................................................... 89 fine precipitator .......................................... 113
Code 2 ........................................................... 84 return line .................................................... 123
Code 3 ........................................................... 85 Change intake filter........................................ 114
Code 8 ........................................................... 87 Checking
Code 90 ......................................................... 91 the coolant liquid level......................... 70, 103
Code 95 ......................................................... 92 Checking for leaks ......................................... 105
Code 9999 ..................................................... 93 Checking soiling of the cooler...................... 107
Display........................................................... 80 Checking the condensation accumulation.. 108
Display the software version ...................... 93 Checking the temperature............................. 106
Fault messages ............................................ 93 Clean
Faults............................................................. 93 return line .................................................... 123
Inputting a code ........................................... 83 COMBI 2S – 7S controller................................ 77
Maximum operating cycles ......................... 85 Overview........................................................ 77
Maximum pressure drop ............................. 85 Switching off ................................................. 77
Operating modes.......................................... 79 Switching on ................................................. 77
Other display indicators .............................. 80 Components
Overview ....................................................... 78 COMBI drive unit .......................................... 53
Select operating mode................................. 84 Compressed air after-cooler ....................... 56
Set Basic load switching mode .................. 89 Compressor stage........................................ 54
Set on-site operation/remote operation..... 87 Controller ...................................................... 52
Set switch on/off pressure .......................... 88 Coolant liquid cooler.................................... 56
126 2010-11-04
Index
Coolant liquid drain ......................................55 Copyright ...........................................................10

Coolant liquid filter .......................................57 Customer ...........................................................12
Coolant liquid pressure tank .......................55 Customer service..............................................10
Cooler.............................................................56
D
Cooling air ventilator ....................................57
Description of function ....................................52
Filler plugs.....................................................55
Dismantling .....................................................126
Fine precipitator............................................55
Disposal ...........................................................126
Fresh air ventilator........................................57
Drive
Heat exchanger .............................................56
COMBI ............................................................53
Inspection glass............................................55
Drive unit .................................................. 53, 115
Intake filter.....................................................54
Minimum pressure and return valve ...........56 E
Refrigerant-type dryer ..................................58 Electric current .................................................18
Safety valve ...................................................55 Emergency..........................................................75
Sound insulation covers ..............................53 Emergency stop..................................................75
Water cooling ................................................56 Emergency stop key.........................................23
Compressor stage ............................................54 Emissions............................................................32
Connecting air ..................................................68 Environmental protection
Connecting compressed air ............................68 Coolant liquid ................................................27
Connecting the current ....................................69 Lubricants......................................................27
Connecting the power supply .........................69
F
Connection values
Fault
COMBI 16 – 22 air supply...............................46 Return line ...................................................123
COMBI 16 – 22 electric ...................................46 Fault displays..................................................120
Fault messages.................................................93
COMBI 2S – 7S air supply ..............................37
Fault table........................................................120
COMBI 2S – 7S electric ..................................36 Fine precipitator................................................55
Fire .....................................................................26
COMBI 6 – 15.1 air supply..............................43
First aid ..............................................................26
COMBI 6 – 15.1 electric ..................................43 Forced ventilation and bleeding .....................67
Contact person .................................................10
G
Controller...........................................................52
General details
Coolant liquid....................................................33
Start-up lubrication.......................................71 COMBI 16 – 22 ...............................................45
Coolant liquid filter...........................................57 COMBI 2S – 7S...............................................33

Coolant liquid pressure tank...........................55
COMBI 6 – 15.1 ..............................................38
Cooler ................................................................56
Cooling air ventilator........................................57
2010-11-04 127
Index
I N
Inspection at delivery ...................................... 61 Noise emissions................................................. 32
Installation
O
Forced ventilation and bleeding ................. 67
Operating conditions........................... 37, 44, 47
Ventilation ..................................................... 66
Overview
Installation conditions..................................... 65
COMBI 16 – 22 .............................................. 48
Installation location ......................................... 65
COMBI 2S – 7S.............................................. 48
Intake filter........................................................ 54
COMBI 6 – 15.1 ............................................. 48
Interfaces .......................................................... 59
Components.................................................. 50
Air supply...................................................... 60
Compressed air connection........................ 60 P
Media ............................................................. 59 Packaging ......................................................... 61
Personnel.......................................................... 13
L
Proper use ........................................................ 11
Liquid stream ................................................... 19
Protective equipment ...................................... 15
Lubricants
COMBI 16 – 22............................................... 47 R
Refrigerant-type dryer ..................................... 58
COMBI 2S – 7S.............................................. 37
Re-lubricating the electric motor.................. 112
COMBI 6 – 15.1.............................................. 44 Replace
coolant liquid .............................................. 109
M
coolant liquid filter ..................................... 109
Main switch....................................................... 23
Rescue measures .............................................. 75
Maintenance
Change coolant liquid filter* ..................... 109 S
Change fine precipitator............................ 113 Safety
Change intake filter.................................... 114 General .......................................................... 11
Checking for leaks ..................................... 105 Safety devices .................................................. 22
Checking soiling of the cooler.................. 107 Safety equipment ............................................. 22
Checking the compressor temperature ... 106 Safety valves .................................................... 24
Checking the condensation accumulation Service .............................................................. 10

.................................................................. 108 Service manual............................................... 134
Checking the coolant liquid level ............. 103 Signs ................................................................. 28
Checking the drive unit ............................. 115 Sound insulation covers ................................. 53
Coolant liquid change................................ 109 Spare parts ..................................................... 100
Re-lubricating the electric motor.............. 112 Starting up compressed air generation......... 72
Replace coolant liquid ............................... 109 Start-up lubrication.......................................... 71
Replace coolant liquid filter ...................... 109 Storage.............................................................. 63
Top up coolant liquid................................. 103 Switching on after the initial commissioning 72
Minimum pressure and return valve .............. 56 Symbols
128 2010-11-04
Index
in thismanual...................................................7 U
on the machine..............................................29 Use .....................................................................11
on the packaging ..........................................62
V
T Ventilation .........................................................66
Top up
W
coolant liquid...............................................103
Warning messages ...........................................95
Transport ...........................................................63
Warranty terms .................................................10
Type plate ..........................................................31
Working after the initial commissioning ........73
2010-11-04 129
Appendix
12 Appendix
130 2010-11-04
Training log
A Training log
Date Name Type of training Training conducted Signature
by
2010-11-04 131
Tightening torques for screws
B Tightening torques for screws
132 2010-11-04
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:
2010-11-04 133
Service manual
Daily checks Weekly checks
Hours of Coo- Leak- Compres- Cooler Conden- Clean Date Name

operati- lant age sor tempe- soiling sate ac- inta-
on li- rature cumulati- ke
quid on filter
level mats
134 2010-11-04
Service manual
Coolant liquid change Filter change

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

operation operation type
2010-11-04 135
Service manual
Additional maintenance and repair work
Hours of operation Date Spare parts Name
136 2010-11-04
Spare parts list
D Spare parts list

Spare parts list
The spare parts list is included with the documents.
2010-11-04 137
Article number 195 03276

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Operating manual

Translation of the original operating instructions

© ALMiG Kompressoren GmbH 2010

3 Technical data ......................................................................31

3.4 COMBI 2S – 7S........................................................... 33

4 Structure and function........................................................ 48

5 Transport, packaging and storage .................................... 61

6 Installation and commissioning .........................................64

9 Faults .................................................................................. 116

10 Dismantling and disposal................................................. 124

11 Index ................................................................................... 126

12 Appendix ............................................................................ 130

1.2 Explanation of symbols

Identifies references to chapters in this manual and to

Identifies random numerations and list entries.

[Key] Indicates names of keys, buttons and other operating

1.3 Limitation of liability

1.5 Warranty terms

1.6 Customer service

2.1 Proper use

The screw compressor serves exclusively to generate compressed

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

2.2 Responsibility of the customer

2.3 Personnel requirements

This manual specifies the personnel qualifications required for the

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

2.3.2 Unauthorised persons

The personnel must be trained regularly by the customer. For better

2.4 Personal protective equipment

Description of the personal protec-

Light respiratory protection

2.5 Basic dangers

2.5.1 General dangers in the workplace

2.5.2 Dangers due to electric power

2.5.3 Dangers due to mechanical elements

Sharp edges and pointed corners

2.5.4 Dangers due to hydraulic energies

Coolant liquid fog

2.5.5 Dangers due to high temperatures

2.6 Safety equipment

2.6.1 Position of the safety equipment

The following illustration shows the position of the safety equipment.

Fig. 1: Position of the safety equipment

1 Main switch with emergency off function

2.6.2 Description of the safety equipment installed

Main switch with emergency off

Emergency stop key

Fig. 4: Safety valve

2.7 Securing to prevent restart

Securing to prevent restart

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

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

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

6. Remove the padlock from the main switch.

If no main switch is installed, proceed as follows.

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

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

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

6. Remove the sign.

2.8 Behaviour in case of fire or accidents

 Alert the fire department and/or emergency medical services.

2.9 Environmental protection

The following pollutants are used:

Alert the fire department and/or emergency medical services.