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Original operating manual

SCC Compressor

Version E 1.1• 13.07.2018

Operation Manual SCC-Compressors /

Imprint Tolpec GmbH

Wertstrasse 44

73240 Wendlingen

Tel.: +49 (0)7022-789 6040

[email protected]

http://www.scc-aircompressors.com

Copyright protection

Tolpec GmbH is the owner of the copyright for this document.

Disposal, multiplication and recording of this document, remaking and sharing of its content are forbidden, if not

confirmed by Tolpec GmbH in written form.

Non-compliance shall result in the recovery of losses.

All rights in the case of patent issue or registration of design are reserved.

All the mentioned in this guide below, product labelling are trademarks of corresponding firms.

Technical changes reserved. SCC is a registered trade name and all rights in

the case of patent issue or registration of design are reserved.


Inhalt 1. Description of the product ................................................................................................................. 6

1.1. Operating instructions ................................................................................................................. 6

1.2. Storage of the Manual / keep it accessible.................................................................................. 6

1.3. Used symbols and definitions ..................................................................................................... 7

1.3.1. Safety instructions ................................................................................................................ 7

1.3.2. Warning signs ...................................................................................................................... 8

1.3.3 Mandatory signs .................................................................................................................... 9

1.3.4 Additional symbols in the manual ........................................................................................ 10

1.3.5 Directional indications ....................................................................................................... 10

1.4 Change history .......................................................................................................................... 11

1.5. Applicable documents .............................................................................................................. 11

1.6. Warranty and liabilities ............................................................................................................. 11

1.7 Contact information of Tolpec GmbH and the SCC Sales- and Service partner ......................... 12

2. Description of the product ............................................................................................................... 14

2.1 Construction of the Equipment/Controllers ................................................................................ 14

2.1.1. Areas of work and maintenance ......................................................................................... 22

2.2. Identification of the Equipment .................................................................................................. 23

2.3. General descriptions ................................................................................................................. 24

2.4. Use of the machine ................................................................................................................... 24

2.4.1. Intended use ...................................................................................................................... 24

2.4.2. Incorrect use ...................................................................................................................... 25

2.5. Safety equipment...................................................................................................................... 25

2.5.1. Overview ............................................................................................................................ 25

2.5.2. Protection/Safety devices ................................................................................................... 25

2.5.3. Emergency stop system ..................................................................................................... 29

2.5.4. Symbols and Signs on the Machine ................................................................................... 29

2.6. Operating the Equipment .......................................................................................................... 31

2.7. Operating and installation conditions ........................................................................................ 31

3. Safety ............................................................................................................................................. 32

3.1. General safety instructions ....................................................................................................... 32

3.1.1. Avoiding of dangerous situations ...................................................................................... 32

3.1.2. Operation Instructions ........................................................................................................ 32

3.1.3. Notes for trouble shooting and repairing ............................................................................. 33

3.1.4. Notes on electrical equipment ............................................................................................ 33

3.1.5. Electromagnetic compatibility (EMC) .................................................................................. 34

3.1.6. Information on environmental protection ............................................................................ 34


3.2. Unacceptable operating conditions ........................................................................................... 35

3.3. Responsibility of the operator ................................................................................................... 35

3.3.1. Minimize the risk of injury ................................................................................................... 36

3.3.2. Determine the Operator...................................................................................................... 37

3.3.3. Operator training ................................................................................................................ 37

3.3.4. Protective equipment ......................................................................................................... 37

3.4. Requirements of an operator .................................................................................................... 38

3.4.1. Qualification ....................................................................................................................... 38

3.4.2. Operator Groups ................................................................................................................ 40

3.4.3. Specialised knowledge ....................................................................................................... 40

3.5. Personal protective equipment ................................................................................................. 41

3.6. Residual risk ............................................................................................................................. 42

3.7. Procedure in case of an accident .............................................................................................. 42

4. Transport and installation ................................................................................................................ 43

4.1. Required tools .......................................................................................................................... 43

4.2. Transport .................................................................................................................................. 44

4.3. Unpacking and removing of package ........................................................................................ 46

4.4. Installation ................................................................................................................................ 46

4.4.1. Place of installation and infrastructure ................................................................................ 46

4.4.2. Installation and Connection ................................................................................................ 47

4.4.3. Installation of the mechanical components ......................................................................... 48

4.4.4. Installation of the electrical components ............................................................................. 49

4.4.5. Final Check ........................................................................................................................ 50

5. Commissioning ............................................................................................................................... 50

5.1. Check the safety devices .......................................................................................................... 52

5.2. First Commissioning ................................................................................................................. 52

5.3. Daily commissioning ................................................................................................................. 56

5.4. Commissioning after storage .................................................................................................... 57

6. Operation ........................................................................................................................................ 58

6.1. Description of the working area ............................................................................................... 59

6.2. On and off sequence ................................................................................................................ 59

6.2.1. Switch on ........................................................................................................................... 59

6.2.2. Switch off ........................................................................................................................... 60

6.3. Operating Modes ...................................................................................................................... 60

6.4. Parameter list ........................................................................................................................... 60

7. Faults .............................................................................................................................................. 61

7.1. Faults during operation ............................................................................................................. 63

7.1.1. Troubleshooting Table ....................................................................................................... 63


7.1.2. Commissioning after Troubleshooting ................................................................................ 66

8. Maintenance and testing during operation ....................................................................................... 67

8.1. Secure the machine against restarting ...................................................................................... 72

8.2. Maintenance schedule .............................................................................................................. 73

8.2.1. Daily ................................................................................................................................... 73

8.2.2. Weekly ............................................................................................................................... 74

8.2.4. Each 2.000 operating hours ............................................................................................... 75

8.2.5. Each 3.000 operation hours or 1 / year .............................................................................. 75

8.2.6. Each 4.000 operation hours or 1 / year .............................................................................. 76

8.3. Maintenance work .................................................................................................................... 77

8.3.1. Visual Inspection ................................................................................................................ 77

8.3.2. Cleaning ............................................................................................................................. 77

8.3.3. Checking and servicing the mechanics .............................................................................. 78

8.3.4. Check and maintenance of electrical parts ......................................................................... 82

8.3.5. Check the pneumatic system and service .......................................................................... 83

8.3.6. Oil level and oil change ...................................................................................................... 86

8.3.7. Replacing worn parts ........................................................................................................ 87

8.4. Compressor oil and lubricant .................................................................................................... 88

8.5. Wear and tear / spare parts ...................................................................................................... 89

8.6. Customer service through the manufacturer ............................................................................. 89

9. Repair ............................................................................................................................................. 90

10. Decommissioning, storage and disposal ....................................................................................... 90

10.1. Temporary Decommissioning ................................................................................................. 92

10.2. Final decommissioning ........................................................................................................... 93

10.3. Dismantling ............................................................................................................................. 93

10.4. Re-packing the machine ......................................................................................................... 93

10.5. Store the machine .................................................................................................................. 93

10.6. Disposal ................................................................................................................................. 93

11. Technical documents / Annex list .................................................................................................. 94

11.1. Plan of maintenance and repair works .................................................................................... 94

List of Pictures .................................................................................................................................... 95

List of Tables ...................................................................................................................................... 95

Glossary ............................................................................................................................................. 95


1. Description of the product

This operating manual (hereafter - Manual) allows the User to work on SCC-compressors (hereafter

Equipment or Compressor) safely, with optimum efficiency which ensures a long service life of the

compressor. It describes the equipment, manufactured by the company Tolpec GmbH (hereafter –

Tolpec).

– Read the Manual thoroughly.

– Follow all the safety instructions.

1.1. Operating instructions

The Manual serves as a guide for the User and technical staff in relation to questions of

maintenance. All the technical aspects of the Equipment are included.

The technical data relating to settings and upkeep as well as the maintenance and the safe operation

of the equipment is included in the manual. The maintenance and operation of the equipment referred

to in this manual should only be done by qualified persons (see requirements of the operator, [p. 40]).

Before proceeding with the operation of this equipment the operator/s should read and fully

understand the manual. Compliance with all items indicated in the Manual and the explanations

provided are the basis of the safe operation of this equipment.

All local Health and safety regulations need to be adhered to. Work safety orders and common

safety rules for the field of use of the Equipment remain in force.

The Equipment Manual does not contain information about compressed air management control

systems. When working with them, compliance with the relevant manual for such management

systems is required.

In the event of using such management control systems, additional instructions for installed

components are to be followed. Supplied by the manufacturers of such management systems.

Copyright protection

This Manual is protected by copyright and issued for internal use only.

Sharing of this Manual with third parties, their multiplication in any way and form – also selective

– as well as copy/reproduce and/or distribution of its content without written permission, except

for internal use, is forbidden. Non-compliance may lead to a claim for damages. The other

possible claims are defined by the contract.

1.2. Storage of the Manual / keep it accessible The Manual is an integral part of the Equipment and must be kept with the Equipment, so that the

operator/s can have access to it at any time. The User must make the Manual available for

technical staff and all operators during the whole working lifespan of the Equipment.


1.3. Used symbols and definitions In this chapter, the symbols used in this Manual are explained.

1.3.1. Safety instructions

The safety instructions in this manual contain the following elements.

A security note exists next to the symbol and the signal word:

– Signal word

– Type and source of danger

DANGER

Warning of an immediate danger to the user.

This safety instruction warns about immediate danger, that can

lead to hard injuries or death.

WARNING

Warning of an immediate danger to the user.

This safety instruction warns about an immediate dangerous situation, that can

lead to hard injuries or death.

CAUTION

Warning of potential danger to the user.

This safety instruction warns of a potentially hazardous situation that can

result in minor or moderate injury .

ATTENTION

Warning of possible property damage.

This Safety instruction warns of possible property damage.


– Consequences

Escape (= measures to avoid danger)

Example:

1.3.2. Warning signs

The following warning signs are used in the manual. These signs are intended to draw the reader’s

attention primarily to the text of the accompanying warning or safety instructions.

Symbol

Meaning

Warning of high voltage

Warning of hand injury

Warning of hot surfaces around air end, motor, oil receiver and tubing.

Warning of overhead load

DANGER

Electric shock caused by high voltage ( type and source of danger )

Death caused by high voltage! ( aftermaths)

a) Wait 3-10 minutes before starting work with electrical motor

connections.


Symbol Meaning

Warning of poisonous substances

Warning of combustible and flammable materials

Warning of a slip hazard

Table 1: Warning signs

1.3.3 Mandatory signs In the Manual, the following mandatory signs are used.

Symbol

Meaning

Read the operating manual

Wear protective gloves

Wear eye protection glasses


Symbol Meaning

Wear protective clothes

Wear light respiratory protection for protection from dust

Wear ear protection

Wear protective boots

Table 2: Mandatory signs

1.3.4 Additional symbols in the manual 2 Important or helpful notices as well as, information and tips appear as follows:

make the most of all the functions on your machine.

1.3.5 Directional indications Directional indications are clearly marked and refer to the respective position from the control

station, the direction of rotation of electric motors, viewed from the end wall of the driving side,

i.e. from the side where machine / system is coupled. They are either clockwise or anti

clockwise.

NOTE

Note

With this symbol, you will get application tips and information that will help you


1.4 Change history

No. of version

Date

From serial No.

Table 3: Change of history of this document

1.5. Applicable documents

Document

Operation and working manual

Spare parts list

Technical data sheet

Dimensional drawing of the equipment

Table 4: Table of applicable documents

1.6. Warranty and liabilities The General Terms and Conditions of Sale and Delivery (GTC) of Tolpec GmbH are applicable.

The User shall be notified thereof by the latest at the time of signing the contact as to the

correct use of the equipment to make use of the legal liability for defects.

Limitation of liability All information and instructions in this manual have been compiled in accordance with the applicable

standards and regulations, as well as our many years of experience

Non-compliance with the notices and guidance of this manual will render the warranty void.

The Manufacturer shall not take responsibility for damages because of:

– non-compliance with the manual

– improper use

– use of non-trained personnel

– unauthorized conversions

– technical changes

– use of non-approved spare parts


There may be a slight variance from your delivered machine to this manual/ instruction and

schemes described here in relation to construction, and additional options of later /current

edition machines or because of the latest technical changes without prior notice.

The obligations stipulated in the delivery contract, the general terms and conditions as well as

the conditions of delivery of the manufacturer and the statutory regulations valid at the time of

conclusion of the contract apply.

1.7 Contact information of Tolpec GmbH and the SCC Sales- and

Service partner

For technical information, please contact customer service.

In addition, our employees are constantly interested in additional information and experience that can

arise from the use of the equipment and can be valuable for the improvement of our products. If you

have any questions or suggestions regarding the equipment, please contact us on the details below

or visit our website, stating the following information:

– Your name and address,

– Contact person on site,

– data of name plate: type, serial No. and production year, Address:

Address:

Tolpec GmbH

SCC Compressors

Wertstrasse 44

73240 Wendlingen am Neckar

Telephone: +49 (0)7022-789 6041

E-mail: [email protected]

Internet: http://www.scc-aircompressors.com Table 5: Contacts


SCC Sales- and Service partner

Address

Phone:

Email:

Operation manual received at: _____________________

Table 6: Your SCC sales and service partner


2. Description of the product The compressors are available in the Smart, Flexi, Focus and Strong series. The technical design

of the different series is identical except for the type of drive. The Smart series and Flexi series

are driven by a belt. The Focus, Strong and Flexi series are direct drive.

The dimensions of the individual machines vary. The following section describes the machine, and

the use of its main components.

The dimensions of certain Equipment are different.

In the following chapter the main components of the Equipment are described.

2.1 Construction of the Equipment/Controllers

Picture 1: Front view of the Equipment (example picture, Focus series)

1 Oil tank 2 Motor frame

3 Electrical Control box (open) 4 Operation panel/ control


Picture 2: Front view of the Compressor (example picture, Focus series)

1 Oil filter 2 Suction filter

3 Suction controller 4 Air end

5 Oil-level gauge 6 Oil tank

7 Minimal pressure and backswing valve

Not showed: drive behind the air end

Picture 3: Example picture: drive side of the Compressor with belt-drive (Smart series)


1 Electrical Control box 2 Motor

3 Belts 4 Oil filter

5 Air end 6 Suction controller: displaying without suction filter

7 Oil tank

All compressors consist essentially of:

– Air end,

– motor,

– suction filter, oil tank,

– pressure gauge,

– safety valve,

– oil fine filter,

– oil filter,

– ventilator,

– cooler,

– operation panel,

– control box.

Safety-relevant operating components

– 1x emergency stop button next to the control panel,

– 1 x Pressure display by the pressure sensor on the control panel

The emergency stop button is linked to the control panel / control of the machine.


Picture 4: Safety-relevant operating components and indicator elements of the Compressor

1 Safety valve of the oil tank 2 Pressure gauge

3 Operating panel 4 Emergency button

Picture 5: Safety valve

1 Safety valve for pressure tank 2 Pressure gauge


Operating panel MAM – 890

Picture 6: Operating panel MAM - 890

1 ON – Start button for starting of motor 2 OFF – Button for switching off the motor

3 Indication Power – Voltage available 4 Indication Run – Compressor in operation

5

Alarm

1. Notification of warning through

blinking diodes, when the warning

value is reached.

2. Notification of error, when the diode shines constantly, and the Compressor switches off.

6 C-

1 – Reset of error messages

2 – Switching to the previous menu level

7 Switch to submenu / enter

Works as enter button, when the menu is chosen. (in various levels a password is needed)

8 1. Switching from main display to main menu levels.

2. Main menu – choose upwards

3. Increasing of numeric data.

4. Submenu – choose downwards

9 1. Switching from main display to main

menu levels.

2. Main menu – choose downwards

3. Decreasing of numeric data.


10 SET

1. Confirm changed parameters

2. Function of switch to charge to idle run

11 Display indications




1

ON

1. Switching on the Compressor 2. If the Compressor is used as master in

Block mode control, the Block mode control switches on.


3

OFF

1. Switching off the Compressor

2. If the Compressor is used as mode in block mode

control, the block mode control switches off.

3. For reading of software. Press for a few seconds

4 C

1. Reset of error messages

2. Switching to the previous menu level


Works as enter button, when the menu is chosen


2. Choose in the main menu – upwards

3. Increasing of numeric data.


7 1. Switching from main display to main menu

levels.

2. Choose in the main menu – downwards



8 SET



9 Alarm

1. Notification of warning through blinking

diodes, when the warning value is reached. 2. Notification of trouble, when the diode shines

constantly, and the Compressor switches off.

10 Indication Run – Compressor in operation

11 Indication Power – Voltage available




1 START

1. Switching on the compressor 2. If the Compressor is used as

master in Block mode control, the Block mode control switches on.


3 STOP

1. Switching off the compressor

2. If the Compressor is used as master in block mode control, the block mode

control switches off.

3. For reading of software. Press for a few seconds

4 LOAD / UNLOAD

When the Compressor is in operation, it can be switched to charge or idle run

5 RESET

1. Reset of error messages

2. Switch to the previous menu level


Works as enter button, when the menu is chosen. (in various levels a password is needed).

7 1. Switching from main display to main menu

levels. 2. Choose in the main menu – upwards 3. Increasing of numeric data 4. Submenu – choose downwards


2. Choose in the main menu – downwards



9 SET




Operating panel MAM 6080


1 Indication Power – Voltage available 2

Indication Run – Compressor in operation 3 Alarm


diodes, when the warning value is reached.

2. Notification of trouble, when the diode shines constantly, and the Compressor switches off.

4 1. Check the data in the text field.

2. Switching in data editing mode, switching of

numbers from left to right.

3. While changing the data or switching of icons on

the display. Press the button for editing and

changing.

4. For switching of the icon indication to next icon 5

1. Switching the cursor on the icon to next icon

2. Switch to the next page of working parameters.


6 1.Switching the cursor on the icon to the previous

icon

2. Switch to the previous page of working

parameters.

3. Increasing of numeric data. 7

1. Check the data in the text fields.


numbers from right to left.

3. While changing the data or switching of icons on the display. Press the button for editing and changing.

4. For switching of the icon indication to the previous icon.

8 C

1. Reset of error messages. (Press the button for

5 seconds)

2. Switch to previous menu level

9 SET



10

OFF

1. Switching off the Compressor 2. If the Compressor is used as mode in block

mode control, the block mode control switches off.


11 ON

1. Switching the Compressor on

2. If the Compressor is used as master in Block mode control, the Block mode control switches on.

Operating panel MAM 6070

1 Indication Power – Voltage available 2 Indication Run – Compressor in operation

3 Alarm


diodes, when the warning value is reached.

4. Notification of trouble, when the diode shines constantly, and the Compressor switches off.

4 5. Check the data in the text field.


numbers from left to right.

7. While changing the data or switching of icons on the display. Press the button for editing and

changing.

8. For switching of the icon indication to next icon

2.1.1. Areas of work and maintenance

Picture 10: Areas of work and maintenance


1 Screw compressor 2 Area of maintenance

3 Area of work

The working area during automatic operation is in front of the machine. The area for set-up,

maintenance and maintenance work is the area in front, on the side and behind the machine.

POSITIONING After unpacking the equipment and preparing the compressor room, put the

machine into position, checking the following items: Ensure that there is sufficient space around

the machine to allow for maintenance. Check that the compressor is standing on a perfectly flat

floor. Ideally the compressor must have a metre space around the compressor in all directions

2.2. Identification of the Equipment

The Equipment can be identified on basis of the name plate on the outer side of the Equipment.

Picture 11: Name plate of the equipment

1 Name plate on the oil tank 2 Name plate on the air receiver

3 Name plate of the Equipment

Data on the name plate of the Equipment

The name plate contains following data:

– model marking

– power input in kW

– pneumatic capability/output in m3/min

– maximum possible air pressure in bar (g)

– weight of the Equipment in kg

– dimensions in mm

– serial No.


– production date

2.3. General descriptions

The Equipment produces compressed air.

The Equipment must be used only:

– for the intended use

– and in a safe environment.

Situations, that can affect the safety, must be immediately rectified. While the error remains, the

Equipment cannot be used.

Operation mode

Compressed Air is produced by drawing air in from the environment or through an air supply

channel (from outside of the building). The air is drawn in by the air end and the air filter as well as

by the suction controller/suction valve. In the air end the air will be compressed by two

interdependent screw-shaped rotors. The oil is injected into the compressor chamber. The oil is

used for cooling, lubricating, protection of metal contacts of the rotors and for sealing of the rotors in

the air end. The compressed air, after the air end will be mixed with oil and flow through the outlet in

the oil tank. Large quantities of the oil are immediately removed in the lower part of the oil tank

located directly in the oil circuit. The compressed-air oil mixture in the upper part of the oil tank

passes through the separator vessel into the oil filter in which the oil is removed from the

compressed air by filtration. The compressed air is led through a cooler to the compressed air outlet

and the residual oil is returned from the filtration back through the scavenge line into the oil circuit.

A compressed air connection must be provided by the user.

2.4. Use of the machine In this chapter, the intended use of the Equipment is described.

2.4.1. Intended use The Compressor is designed to produce compressed air through the compressing of air from the

environment. The users technical staff shall always be on hand to ensure the safe operation of the

equipment.

Operation of the machine in potentially explosive environments is prohibited.

A prerequisite for the intended use is that the operators read, understand and follow these instructions.

The intended use includes the compliance of all instructions in this operating manual. The machine

must be checked regularly and maintained.

The machine is intended exclusively for industrial and commercial use.

Any other use not previously stated is forbidden


Also refer to Technical data page 32

2.4.2. Incorrect use The following are examples of incorrect use that may occur if the guidelines and instructions outlined

in this manual are not adhered too.

- Suction of media and the use of power with a specification that does not meet the requested

operating specifications.

- Operation without protective cover

- An unauthorized use, for example, when unauthorized access/tampering/modification is made to

relevant safety components.

- A failure may also occur if the specified operating parameters (i.e. temperature, overrun of

maintenance intervals) are not observed.

- An unlawful use is to place or use the machine in areas where explosive environments may

occur as defined by Zone 1

- Any use other than the intended.

2.5. Safety equipment

2.5.1. Overview The Equipment is equipped with safeguards in the dangerous areas.

Without the intended mounted and adjusted safety devices, the Equipment can cause serious injuries

to persons. The safety devices can't be changed or removed from operation. All the safety devices

must always be accessible.

The user should be familiar with all the safety devices that may prevent and minimize injuries and/or

machine failures. The controller with the operational panel is in front of the Equipment.

Automatic operation is carried out from outside the hazardous area. Protective devices ensure

safety from dangerous areas on the system. They have no influence on the movements of the plant.

2.5.2. Protection/Safety devices Protection devices protect the dangerous parts of the machine. They have no effect on the movement

of the machine.


Removal of safety equipment:

The following are part of the safety equipment on this machine:

– motor frame

– protection covers

Separate protective devices prevent or hinder direct access to rotating or moving parts of the

installation. They may only be removed for set-up, maintenance or repair work and must be reinstalled

before restarting.

Motor frame with protection covers

Picture 12: Compressor frame with panels

1 Protection cover / panels 2 Motor frame

The machine is completely enclosed in a machine frame with a protective covering. The machine

frame contains the air end, the motor, the oil tank with the oil fine separator, the multiblock with the

screwed oil filter, oil filter cartridge, the safety valve, the pressure sensor, the electrical control

cabinet and the fan. As a separate protective device, the protective covering offers a comprehensive

protection for the personnel working on the machine from the dangerous moving parts of the

machine.

The protective cover is lockable or secured by a snap mechanism and is manually mounted or

disassembled. The protective covering must be closed during the operation of the machine.

Non - Contact safety devices

The non – contact safety devices are as follows:

– safety valve

– pressure sensor


– temperature sensor

Non-contact safety devices cause the machine to stop. The direct access to rotating or moving parts

of the system is thus prevented. The protective devices may only be switched off for maintenance or

repair work and must be switched on again before restarting.

Pressure sensor at the minimum pressure and non-return valve or at the multi-block

Picture 13: Pressure sensor (example picture)

1 Pressure sensor

The pressure sensor is mounted on the minimum pressure check valve or on the multiblock. It

controls the operation of the compressor. The compressor compresses (load operation) until the max.

operating pressure is reached. The compressor then switches to idle mode. When switching to idle

mode, a run-on time begins, in which the compressor is switched on either when reaching the min.

operating pressure or after the time has elapsed, the motor switches off and goes into the standby

mode.

As soon as the set min. operating pressure is reached, the system starts and operates on load.

Safety valve on the oil receiver

Picture 14: Safety valve on the oil receiver


1 Safety valve

A safety valve on the oil tank opens when the maximum safety pressure exceeds the design

pressure of the oil tank against over pressurisation.

Safety valve on the air receiver of the Equipment

Picture 15: Safety valve of the air receiver

1 Safety valve on the air receiver 2 Pressure gauge

A safety valve at the compressed air receiver is installed on the console between the compressor

and the dryer at the compressed air inlet. The safety valve opens when the set safety pressure is

exceeded and secures the compressed air receiver against high pressurisation.

Oil temperature sensor on the discharge/outlet of the air end

Picture 16: Oil temperature sensor

1 Oil temperature sensor


A temperature sensor monitors the oil temperature of the machine. If the permissible oil temperature

programmed at the control unit is exceeded, a fault message is generated which leads to the

shutdown of the machine.

2.5.3. Emergency stop system Pressing the emergency stop button triggers the emergency stop function. The machine is

safely stopped by immediate interruption of the control voltage. The emergency stop button

is unlocked by turning the button.

Picture 17: Emergency stop button

1 Emergency stop button

The Equipment has following emergency stop devices:

– Emergency stop button at the operator station.

2.5.4. Symbols and Signs on the Machine Warning signs

Dangerous areas on the machine are marked with warning signs.

Warning labels and other instructions on the machine must always be clearly readable. Unreadable

safety signs must be replaced immediately.

Symbol

Meaning

Warning high voltage


Warning of hot surfaces around air end, motor, oil receiver and tubing.

Warning of hand injury

Warning of machine automatically starting

Table 7: Overview of the warning signs

Mandatory signs

Mandatory signs

Meaning

Read the operating manual

Wear eye protection

Wear ear protection

Wear protective clothes


Wear light respiratory protection for protection from dust

Wear protective boots

Table 8: Overview of the mandatory signs

2.6. Operating the Equipment The Equipment works in automatic mode. The machine is operated by an operator in front of

the compressor.

2.7. Operating and installation conditions General data

Manufacturer Tolpec GmbH

Designation: Screw compressor

Production year From 2016

Operation conditions Usage at the 3-shifts-factory

Location Roofed production plant or separate compressor room

Environment temperature During operating

+5 to +40

Environment temperature during storage [°C] +5 to +40

Air quality for the

Equipment The air in the production plant or in the compressor room must be as clean as possible and must contain the least amount of dust, aerosols or soot as possible


3. Safety The machine is built according to state of the art and recognized safety regulations.

Nevertheless, dangers to the life and limb of the operator or third parties may arise if not used

appropriately. Likewise, the machine or other property may be damaged. The Equipment

should be used only:

– for the intended use

– and in safety-perfect conditions for the appropriate usage

The machine must not be put into operation again, after failures that can impair safety, until they have

been remedied/repaired.

3.1. General safety instructions

3.1.1. Avoiding of dangerous situations Dangerous situations while operating can be avoided through diligent and cautious

behaviour of the staff. The following rules are obligatory for everybody who works with or

on the Equipment:

– Keep the operating instructions in a readable form for everyone at the machine location.

– Only use the machine as intended.

– The machine must be functional and clean. Check the condition of the machine before starting

work and at regular intervals.

– Wear close-fitting work clothes during all work on the machine.

– Make sure that nobody is injured by the parts of the machine.

– Report faults or recognizable changes to the machine immediately to the person responsible.

– Observe accident prevention regulations and local Health and Safety regulations.

3.1.2. Operation Instructions The following ground rules are applicable while operating:

– Only one operator may operate the machine.

– The machine must run continuously in automatic mode.

– Safety devices must not be altered, disassembled or taken out of service. Safety devices must

be checked at regular intervals.


– All panels covers and hoods must be fitted as intended.

– Constructional modifications to the machine are not permitted.

– Any modification to the machine must be reported immediately to the person responsible.

– The danger area must always be kept clear. No objects may be placed in the way of the

danger area. An operator may only enter the hazardous area if the power is switched off and

the machine is locked.

3.1.3. Notes for trouble shooting and repairing The following principles apply when troubleshooting and fault finding:

– Only adequately qualified personnel can perform work on the machine.

– The machine must be switched off.

– Disconnect the main plug or disconnect the power supply.

– Take the key out of the control cabinet.

– Secure the external main switch with a safety lock against accidental re-activation.

– Only the company supervisor can take the key.

– Otherwise the safety shutdown must be ensured by a second person.

– Hot machine parts must be allowed to cool down.

– Frequency inverters store electrical charges for several minutes while the power supply is

switched off. Wait at least 5 minutes after energizing before working on a frequency converter.

Check the tension-free/power free.

3.1.4. Notes on electrical equipment

The following principles apply to all electrical work:

– The Equipment has an electrical drive. If the electrical equipment is installed incorrectly or the

isolation of the machine is damaged, a danger to life may occur.

– The access to the electrical components and working with them is only for qualified staff.


– The control box must be kept locked.

– Only when the main plug is disconnected, the power supply and installed socket circuits are

disconnected from the power supply.

– Frequency inverters store electrical charges for several minutes with the power supply switched

off. Wait at least three minutes after de-energizing before working on a frequency converter.

Check the tension-free.

– Changes to the control system can affect safe operation. All planned changes must be

approved in writing by the manufacturer of the machine.

– Check the functioning of the protective equipment after all work.

– No unauthorized alterations may be made to the machine. All changes must be approved in

writing by the manufacturer of the machine.

3.1.5. Electromagnetic compatibility (EMC) According to its appropriate usage, this electronic equipment corresponds with the laws

concerning electromagnetic compatibility. Those laws define the allowable emission level of the

electronic equipment and its necessary resistance to electromagnetic fields.

Radiofrequency signals of high frequency transmitters, for example, of mobile phones or identical

mobile radio equipment, that correspond with EMV-directions, can affect the appropriate functioning,

if they are used nearby.

3.1.6. Information on environmental protection

Safety-conscious and the forward-thinking behaviour of the personnel avoids negative environmental

impact.

The following principles apply to environmentally-conscious actions:

NOTE

Note

Make sure there are no electromagnetic fields near the machine.


– Environmentally hazardous substances must not be allowed to enter the soil or sewage

system.

– Provisions on the prevention, disposal and recycling of waste must be complied with.

– Environmentally hazardous substances are to be stored in suitable containers.

– Containers containing environmentally hazardous substances must be clearly identified.

3.2. Unacceptable operating conditions

– The operating safety of the machine cannot be guaranteed under unacceptable operating

conditions. Unacceptable operating conditions must therefore be avoided in all cases. The

operation of the machine is prohibited under the following conditions:

– If the machine is not used as intended.

– If the machine or parts of the machine are damaged and the electrical system is installed

incorrectly, or the insulation is damaged.

– Protective and safety equipment is not functional or defective, improperly installed or missing.

– The machine must not be used when faulty.

– There are persons or foreign bodies in the danger areas of the machine.

– The machine has been altered or altered without authorization.

– The control system has been changed outside the operational design of the machine.

– Operating parameters have been changed.

– If non-approved tools/equipment are used.

– The specified maintenance intervals have been exceeded.

The tampering of limit switches and other control components, especially the safety components, is

prohibited. Persons under the influence of alcohol or drugs are not allowed to operate or maintain the

machine.

3.3. Responsibility of the operator The duty of care of the operator includes, inter alia, planning and carrying out safety measures.

All persons carrying out activities with and on the machine, must be trained by the operator/Tolpec

on the machine. You must have read and understood the operating instructions. By signing it, they

confirm this.


The signatures are kept by the operator on a separate list. The operator has a list of authorized

operators.

3.3.1. Minimize the risk of injury – To minimize the risk of injury, the following principles apply:

– Work on the machine must be carried out by qualified personnel only.

– The staff must be authorized by the operator for the respective activity.

– The staff must have familiarized themselves with all safety devices before starting work.

– Make sure that safety switches are never bypassed. This must be checked regularly by the

qualified personnel to ensure that this has not occurred.

– If protective equipment has failed or is disrupted, it must be reported immediately to the

responsible supervisor. The latter decides on how to proceed further.

– The personnel must have familiarized themselves with the operating elements before starting

work.

– The machine must be kept in a clean and safe working condition as well as the compressor

house in the immediate working vicinity of the compressor.

– The machine and the immediate working vicinity around the compressor must be adequately lit.

– Personnel must wear the personal protective equipment stipulated for that machine. The

necessary protective equipment is laid down in the factory specifications. Operational

supervisors are obliged to enforce the wearing of personal protective equipment by their

employees.

– During operation, qualified first responders must be ready to take the necessary measures to

provide first aid.

– Procedures and the responsibilities of operators working with the machine/equipment must be

clearly defined. The Emergency procedure in case of accidents must be clear to everyone. The

staff must be regularly informed/trained in this regard.

– Warning signs and instructions on the machine must be complete and legible. The labels and

notes must be regularly cleaned and replaced if needed.


3.3.2. Determine the Operator The Qualified operator of the machine must determine which persons are permitted to carry

out work on the machine. These persons must have the necessary knowledge for the

respective work and be adequately trained.

3.3.3. Operator training

The knowledge of general safety regulations is among the requirements to operate the machine

safely. The generally applicable safety regulations also include the fact that the operators of the

machine wear and use their personal protective equipment

The machine may only be operated if the general safety instructions and the instructions described in

this manual are complied with. The operator must periodically train the authorized personnel regularly

to operate the machine safely. The obligation of the operator to train the authorized personnel on a

regular basis applies to the handling of the machine, to work on the electrical installations as well as

to installation, set-up and do maintenance work.

3.3.4. Protective equipment

The operator of the machine must ensure that the operator receives the necessary protective clothing

and protective equipment (face protection, hearing protection, eye protection, safety shoes,

protective gloves, etc.) when using the machine.

NOTE

The staff must be trained regularly

The operator of the machine is obliged to train the personnel working on the

machine on a regular and recurring basis in the work procedures, hazards

and safety measures which are important for the personnel. This ensures that

the authorized personnel always have the qualification/experience needed .


3.4. Requirements of an operator In the following chapters the requirements and the qualification of maintenance and technical staff are

described.

3.4.1. Qualification All the work on the Equipment require specialised knowledge and skills of the staff. Everybody, who

works on the Equipment, must meet the following requirements:

– Personnel should be authorized for the corresponding activities.

– Qualified for the corresponding activities.

– Instructed for safe and correct operation of the Equipment.

– Are familiar with the safety devices and the way they function.

– Are familiar with this manual, especially with the safety instructions and the chapters that

relate to the activities performed.

– Are familiar with general instructions for working safely and preventing accidents.

– In general, all the persons must have one of the following minimal qualifications: Qualified

staff that can work with the equipment unassisted.

Life cycle Examples of activities of maintenance staff

Information about the qualification of

maintenance staff1

– Trained / instructed

staff2

Professionals3

Transport –

–

–

Lifting

Loading

Unloading

X

Installation and commissioning

–

–

–

building-up and

fastening of the Equipment

- qualified staff

Connection of the power supply

- qualified staff

Filling of the Compressor with

compressor oil and lubricating

of the motor with grease

- trained/instructed staff

X X

Life cycle Examples of activities of maintenance staff

Information about qualification of maintenance


Table 9: Qualification of the staff

1* According to the definition of the machine guidelines, the operating person is the person or

persons, who are responsible for the installation, operation, cleaning or transport of machines.

2* As trained / instructed personnel, a person who has been informed of the tasks assigned to him

and the possible dangers of improper conduct and who has been trained as necessary. He will also

be instructed on the necessary protective equipment and protective measures. Personnel that are

still being trained, may only operate the compressor under the permanent supervision of an

experienced person.

Trained / instructed

staff2

Professionals3

– greasing of the motor


X X

Set up teach / program and / or convert

– Adjustment/re-adjustment for

other details/check parts

– enter/change

– Testing of programs

X

Operating – Switching on

– Operating

– Monitoring

– Switching off

X

Cleaning

Maintenance

– Cleaning – trained-/-instructed staff

– Refilling of screw compressor oil


– Disconnection of the power

supply - qualified staff

– Dismantling/repair of the components - qualified staff

X X

Trouble shooting and repair

– Disconnecting of the power supply

– Trouble shooting

– Dismantlement/disconnection

of the components

– Repairs

X

Dismantling,

Decommissioning

– Disconnecting of the power supply

– Dismantling

– Lifting

– Loading

– Unloading

X


3*Experts A qualified person is a person who, based on his professional training, knowledge and

experience, can assess the work which has been transferred to him and recognize possible dangers.

He shall also be aware of the relevant provisions.

3.4.2. Operator Groups In this manual, a distinction is made between operator groups and technical staff:

Staff Qualification

Maintenance staff Corresponding instruction in the areas:

– Function processes of the Equipment – Operating procedures

Knowledge in the areas: – Competence and abilities at the workplace – actions in case of errors and accidents.

Technical staff Advanced knowledge in the following areas: – Electrical

- Electro mechanic

Authorization for activities (in accordance with safety technique standards):

– Commissioning – Equipment earthing – Knowledge about equipment

– In depth knowledge of construction and the way the

equipment functions.

Table 10: Operator groups

3.4.3. Specialised knowledge

The following activities can only be performed by staff with specialist knowledge:

Activities Qualification

Working with electrical components

Professional electrician

Working with mechanical components

Industrial mechanic or trained technician. The work can only be performed under supervision of an industrial mechanic in accordance with the general rules of technique.

Table 11: Activities and knowledge


3.5. Personal protective equipment

Personal protective equipment is designed to protect personnel against hazards that could affect their

safety or health at work.

When carrying out work on the machine, personnel must wear personal protective equipment. These

are indicated separately in the individual sections of this manual. This personal protective equipment is

explained below:

- Always wear the personal protective equipment required in the various sections of this manual

before starting work.

- Follow the instructions given in the work area for personal protective equipment.

Description of personal protective equipment

Symbol

Meaning

Protective gloves Protective gloves are designed to protect the hands from rubbing, scratches, splinters or more serious injuries because of touching hot or cold surfaces.

Protective shoes Protective shoes are designed to protect against falling parts and materials as well as from sharp objects.

Protective work clothes Protective clothing is well-fitting workwear with low tear strength, with sleeves and without protruding parts. It is mainly used to protect against movement by moving machine parts. Do not wear rings, chains, jewellery and uncovered long hair.

Protective glasses

Are designed to protect the eyes from flying small parts and liquids.

Light respiratory protection

The light respiratory protection is designed to protect against toxic dust.


Ear protection

Is designated to protect against hearing damage.

Table 12: Mandatory signs

3.6. Residual risk

The following residual hazards cannot be eliminated.

- Danger if unauthorized or unqualified persons operate the machine.

- Danger if the machine is not serviced regularly.

Therefore, the operator must ensure that only authorized and qualified persons have access to the

machine and its command centre/control panel.

3.7. Procedure in case of an accident

When you call the ambulance, pay attention to the following:

– What happened?

– Where did it happen?

– What are the injuries or symptoms of the injured person?

– How many injured?

NOTE

Basic rules for accidents

Get the injured out of danger! Administer first aid and call the rescue service

via the nearest telephone immediately as well as inform superiors!

NOTE

First aid

Attend a first aid course to help you with emergencies.


4. Transport and installation

The transport can be carried out by means of a forklift truck or a suitable truck. To prevent life

threatening injuries and property damage during transport and installation, observe the following:

- Transport and installation may only be carried out by qualified and authorized persons.

- The load holding means, and the lifting means must comply with the provisions of the

accident prevention regulations.

- When selecting the load receiving means and the lifting means, consider the total weight of

the machine, which can be taken from the documentation in the separately attached technical

data of the machine.

- Transport routes must be adequately measured/calculated. Doorways must be at least 5 cm

wider and higher than the transport unit including the means of transport.

- The transport route should be checked by a third person.

The most effective installation is ensured, when the described installation process Is respected.

The following chapters provide an overview of the necessary steps for the transport and the

installation of the machine.

Safety instructions for transport and installation

- All work on electrical equipment may only be carried out by qualified electricians

- This installation guide is not a substitute for the necessary professional training.

4.1. Required tools These are the required tools to install the system:

- rotary hammer,

- machine water level

- measuring tape,

- screwdrivers (various sizes)

- Wrench (various sizes)

- Electromechanical tool.


If special tools are required, you will be informed prior to installation. The transport can be performed

using a forklift.

4.2. Transport

- Before proceeding, ensure that the transport route is clean and free of obstacles.

The components of the machine should be transported to the installation site with a forklift truck.

Transport with the forklift

WARNING

Danger of falling loads

Suddenly dropping lifted loads will result in a risk to life.

- Do not stand under raised loads!

- Ensure that the equipment is correctly placed on the

forks of the forklift truck during transport.

- Observe the centre of gravity of the goods to be

transported!

Damage by transport with the forklift truck

The machine components can be damaged during transportation with the forklift

truck by using unsuitable anchor points.

- When aligning the forks, do not damage any attachments of the system /

system components.

- Carefully lift the machine

CAUTION Danger of injury by tilting The centre of gravity of the machine is relatively high. When crossing obstacles, the machine can tilt.

- Do not cross obstacles.

ATTENTION


- Protect the packs from moisture and keep them dry.

Symbol

Meaning

Protective gloves

Protective gloves are designed to protect the hands from rubbing, scratches, splinters or more serious injuries because of touching hot or cold surfaces

Table 13: Personal protective equipment

Follow these instructions to transport the equipment safely using a forklift:

- Use only forks with allowable length.

- Lift the Equipment/its components from the side designated for this.

- If necessary, put wooden beams under the Equipment/its components during the transport.

- Transport the Equipment/its components only on the horizontally located forks of the forklift.

Picture 18: Transport with the forklift

ATTENTION

Protect from moisture

The machine components in the packs can be damaged by moisture


A Distance of the forks B Forks must be longer than the load

C Place a wooden beam underneath

4.3. Unpacking and removing of package Remove the consignment carefully and in accordance with environmental protection requirements.

4.4. Installation In the following chapter the conditions and the instruction plan for the installation of the equipment

are explained.

4.4.1. Place of installation and infrastructure Before the installation, the installation place must meet the following conditions:

- The location surface of the equipment must be flat and firm.

- The safe and secure location of the equipment must be provided.

- The installation place should be roofed, be protected against the weather and frost (minimum +

3 ° C room temperature).

- The installation place must be ventilated.

- The power supply at the drive side is available (see Installation of electrical components (page

52).

- The installation place must be chosen so that the components are easy to reach and in an

unhindered position where there is accessibility.

- The machine must not be exposed to direct sunlight.

- Externally heating the machine by other heat sources must be excluded.

- The machine should not be exposed to vibrations.

- At the installation place rescue equipment and escape exits must be freely accessible.

- Fire protection measures should be taken at the installation site.

- There are no machines nearby, that can cause negative electrical or electromagnetic effects.


- The machine room must have forced ventilation and exhaust air Ventilation from the

equipment, considering the residual pressure. Exhaust air can be used for heat regeneration.

- The use of equipment in an explosive atmosphere is forbidden.

Before installing the machine, please observe additional conditions for the installation location and

the infrastructure, which are contained in the technical data in the complete documentation. These

are:

- Observe the cooling air volume and exhaust air volume as well as the ducting cross section to prevent the machine room from heating up.

- Electrical connections.

- Protection of the external isolatable main switch.

- A sufficient safety distance to the building wall should be considered for service work.

The compressor must be connected to the compressed air network of the operator with a flexible

hose (max. 1.5 m). Shut-off valves in the compressed air line of the compressor and the following

compressed air receiver, must be installed.

4.4.2. Installation and Connection

CAUTION

Beware of obstacles on the ground

If you are not careful, there is a risk of injury from stumbling

– Pay attention to obstacles on the ground.

– Avoid tripping points when laying cables, hoses and pipes.

– Use appropriate cable ducts, bridges.

ATTENTION

Material damage caused by condensation

Moisture in the air can cause condensation and damage the compressor.

The cooling air must be dry, cool and dust-free.

NOTE

Install the machine so that the noise and vibration values are as low as possible during operation

a) Move the equipment to the location.


4.4.3. Installation of the mechanical components Place the machine at the intended location, ensuring the following conditions.

- All legal regulations must be clarified on the spot and their compliance must be ensured.

- The condition of the ground and space available must be clarified before the machine is

installed to ensure safe operation for the personnel and the machine in the long run.

- The machine may only be installed, put into service and / or stored by specially trained

specialists.

- All installation and infrastructure requirements are met.

- Set up the machine according to the installation plan.

- Ensure sufficient clearance for maintenance and repair work on the machine during

installation.

- Ensure that the air circulates freely around the machine.

Remove transport safety devices

- Transport safety devices must be identified and removed during installation

NOTE

Keep transport safety devices with the machine for future possible transport.

NOTE

Equipment damage caused by incorrect installation is excluded from

warranty.

NOTE

If you have questions concerning the installation of the pipe system, please

contact the Tolpec customer service department.


4.4.4. Installation of the electrical components To operate the machine, a main switch with a corresponding fuse must be installed.

DANGER

Electric shock due to high voltage when working on the electrical

components of the system

An electric shock can result in serious injury or death.

- All work on the electrical system can only be carried out by qualified

electricians. - Disconnect the system from the power supply before carrying out any

work on the electrical system.

- Check the tension-free.

- Ground the system.

- Cover the adjacent area or barrier it off when working with electricity

related parts.

Install a main switch with a blocking device on the operator side and a fuse in the supply line to the

machine according to the connection values of your machine.

NOTE

You can find all information on the design of the fuse for the machine in the

technical data


4.4.5. Final Check

Before you start the machine for the first time, the following safety checks must be carried out:

- Are all protective guards installed?

-Do all the safety systems work?

5. Commissioning Before starting the Equipment for the first time, the following must be proven correct:

✓ Was the installation with its final control fully completed?

✓ Are all the protection devices installed?

✓ Does the oil level in the oil tank receiver range within the marked limit?

Picture 19: Rotation direction arrow on the air end

1 Rotation direction arrow

– Check the direction of rotation of the motor on the air end.

– In models with a belt drive: is the belt tension corresponding?

NOTE

The following tests can only be carried out by specially trained personnel. Tolpec’s authorized partners give an accurate instruction in the final inspection

during commissioning.


Safety instructions for commissioning

DANGER

Danger to life by electric shock

There is a risk to life when touching energized parts. Electrical components that are

inserted can unintentionally cause movements and injuries.

– Switch off the system before maintenance and secure it against

accidental restart.

DANGER

Danger to life due to stored charges

Electric charges can be stored in electronic components, which are retained even

after switching off and disconnecting from the power supply. Contact with these

components can result in serious or fatal injuries.

– Disconnect the components completely from the power supply before working

on these components. Allow 3-10 minutes to ensure that the internal capacitors

are completely discharged.

WARNING

Danger due to missing safety devices

Missing protective covers can lead to serious injuries.

– Mount all protective covers which may have been removed for

installation before commissioning the machine.

– Check all safety devices before starting the machine.

CAUTION

Risk of injury from noise

The noise level in the work area can cause serious hearing damage.

– Always wear ear protection, when working.

– Stay as short as possible in the danger area.


5.1. Check the safety devices

Check the safety devices for perfect function:

- before first use,

- before commissioning after prolonged stoppage,

- daily before work starts.

a.) Check:

– Are all protective covers closed?

– No visible defects on the safety valve?

b.) Start the machine.

– Monitor the temperature and pressure development to check the function of the sensors

c.) Press the emergency stop buttons and check that the machine is safely switched off.

The safety devices are tested.

5.2. First Commissioning

WARNING

Crushing and pulling danger by the drive shaft of the motor and by the

V-belts

When working on an open machine during commissioning, special caution is

advised, since moving parts must be used in the working area.

a.) Commissioning activities may only be carried out by the specially

authorized and trained staff. The setup must be carried out from a

safe position.

b.) Ensure that there are no persons in the danger area before the

movements are triggered.

c.) Depending on the situation, the danger area must be blocked by a

red and white chain during set-up.

d.) Wear protective gloves


danger.

All safety devices are assembled, tested and ready for operation

✓ All protective covers are installed.

✓ For belt driven models the belt tension is set correctly.

Picture 20: oil receiver

1 Pressure gauge 2 Oil filler neck

3 Oil level gauge 4 Oil outlet

a.) Check the oil level at the oil level gauge (see compressor oil and lubricant on page 93).

b.) If necessary, fill the oil tank with the compressor oil at the oil filler neck. The marking indicates the

necessary oil level during operation of the machine. Keep the oil quantity and the required

technical specifications of the oil exact. Observe the technical data for your model.

NOTE

Before operating the machine, read and follow the safety instructions page 33

of this manual, carefully.

Ensure that all mechanical and electrical work is finished and that no one is in


Picture 21: Intake valve mounted on air end

1 Dismantle intake valve from air end

For initial start-up or after two weeks or longer

The compressor unit must also be supplied with compressor oil during

initial commissioning and after shutdown times.

– Loosen the intake manifold mounting bolts at the inlet of the

compressor unit.

– Remove the intake regulator.

– Fill approximately 0.5 - 1 l compressor oil into the inlet of the

compressor unit.

– Assemble the intake regulator and tighten the mounting bolts.

a.) Check the machine for leakage and leaking oil.

CAUTION

NOTE

Danger of skidding by leaking oil.

There is a risk or chance of injury.


b.) Eliminate leaks and leaked oil immediately.

c.) Immediately remove any excess oil from the machine.

d.) Close the shut-off valve of the compressed air line attached to the compressed air network of the

operator after the compressed air storage.

e.) Insert the plug for the power supply, or set the power supply to the machine

f.) Turn the main switch, or reset the emergency stop button.

• The controller starts, and a start screen appears after approx. 5 seconds.

• The machine is ready for operation.

CAUTION

Destruction of the compressor unit by an incorrectly connected motor

a.) If the power supply is connected incorrectly and the compressor is

switched on, the machine can be destroyed in a very short time. An

ALARM signal indicates that the direction of rotation of the motor is wrong

and that the rotating field must be corrected.

b.) Before the compressor is started, a qualified electrician must check the

power connection and the rotating field.

g.) Open the appropriate guard / panel to have a clear view of the drive and start the compressor

briefly with ON.

Picture 22: Direction arrow on air end

1 Direction arrow for direction of rotation of motor or

air end.


h.) Stop the machine immediately after 2 seconds with the emergency stop button. When starting

and running the motor, the direction of rotation can be checked using the directional arrow on the

compressor unit.

i.) Unlock the emergency stop button and start the machine with ON.

j.) Check the pipe system for leaks.

k.) Mount the protective guards.

l.) Check on the display whether the air compressor reaches the set pressure and then reduces

pressure.

m.) Check whether the compressor is switched on again when the set minimum pressure is reached,

or again begins to compress and the pressure increases again.

n.) Check the air compressor for the presence of non-characteristic vibrations and noises. Eliminate

the causes of abnormal equipment.

o.) Open the ball valve of the compressed air line very slowly to the customers compressed air

network after the compressed air tank, so that a controlled pressure equalization can take place.

a.) Use the operating instructions for the control to configure the user settings.

b.) Start the compressor with [ON] on the control panel.

c.) Stop the compressor with [OFF] on the control panel.

The first commissioning has been completed.

5.3. Daily commissioning The first commissioning has been successfully completed.

The surrounding area is clean, oil-free and illuminated.

The power supply is connected

a.) Check the oil level and refill if necessary.

NOTE

Check the condensing temperature

The compression temperature can be read at 65 ° C and 85 ° C during

operation, depending on the ambient conditions .

Set up user settings


b.) For models with a belt drive, check the belt tension.

c.) Remove the protective covering / panels of the entire machine and check the interior for dust

and contamination; Use the fan to remove any contaminants.

d.) Mount the panels.

e.) Check the connection cable for visible damage. Never operate the machine if the cable is

damaged!

f.) Ensure that all safety devices and covers are installed.

g.) If fault messages are displayed on the control panel, these must be corrected according to the

operating instructions for the machine and the control panel.

Daily commissioning is complete.

5.4. Commissioning after storage

a.) The procedure for commissioning after storage corresponds to the first commissioning:

b.) Check all components for free movement, if necessary, ensure the free movement of the

components.

Carry out commissioning after storage according to the first commissioning.

WARNING

Danger of injury due to unintentional starting of the machine

Perform the mechanical tests only with the main switch off .


6. Operation The following principles apply when operating the machine:

This work must be carried out by trained and authorized operators. The machine is only allowed to be

operated, if all the safety devices are properly installed and functioning.

The following principles apply when operating the machine:

a.) Check the proper functioning of the safety devices

b.) Inform the responsible person immediately if safety devices have failed or are disrupted.

c.) Ensure that nobody is in danger before switching on the machine.

d.) Wear your personal protective equipment (e.g. protective gloves) when operating the machine.

e.) The removal of protective devices during operation of the machine is not permitted.

f.) Smoking and open fires are strictly prohibited near the machine.

Safety instructions for Operating

CAUTION

Danger of skidding on leaking oil.



b.) Eliminate leaks and leaking oil immediately.

CAUTION

Risk of injury from noise.


a.) Always wear ear protection when working.

b.) Stay as short as possible in the danger area.


6.1. Description of the working area

Picture 23: Areas of work and maintenance

1 Screw compressor 2 Maintenance area

3 Working area

Table 18: Working and maintenance areas

The operating area and the control panel are in front of the machine during automatic operation.

The areas for set-up, maintenance and maintenance work are the areas in front, on the side and

behind the machine.

6.2. On and off sequence

6.2.1. Switch on

Before switching on

Carry out the following work and checks:

a.) Check the machine and all components for external damage.

b.) Check if there is oil leakage.

c.) Check the soil for contamination:

If you notice any damage or contamination, repair or remedy this.

The machine can be switched on.


6.2.2. Switch off Switch off the machine with (0) button at the control panel of the unit.

a.) The machine changes from load- to idle mode so that no further air is compressed.

b.) Motor stops after run on time.

c.) The power supply is shut off.

d.) Machine is switched off.

6.3. Operating Modes

A distinction is made between the following operating states or operating modes of the machine:

– Voltage-free: main plug disconnected, or main switch switched off.

– Emergency stop condition: emergency stop device tripped.

– Automatic operation: Automatic execution of the machine program.

– The compressed air is generated automatically.

WARNING

Danger of injury due to unintentional starting of the machine

The machine can start automatically in automatic mode.

a.) Perform the mechanical tests only with the main switch off.

6.4. Parameter list

The parameter list can be found in the separate operating instructions for the control unit


7. Faults

Observe the following principles, when you are looking for errors and correcting errors: This work

must only be performed by specially trained and authorized specialists.

a.) Allow warm components to cool before starting work.

b.) Wear suitable protective clothing.

c.) Before re-commissioning, mount all safety devices that are provided.

d.) Check the proper functioning of the safety devices.

e.) After completion of the work, remove all tools and objects from the movement area of the

machine

Safety instructions for faults

DANGER Danger to life by electric shock.

There is a risk to life when touching energized parts. Electrical components that

are inserted can inadvertently cause movements and injuries.

a.) Switch off the system before maintenance and secure it against accidental

restart.


DANGER

Danger to life due to stored electrical charges

Electric charges can be stored in electronic components, which are retained even after switching off and disconnecting from the power supply. Contact with these components can result in serious or fatal injuries.

a.) Disconnect the components completely from the power supply before working

on these components. Allow 3-10 minutes to ensure that the internal capacitors

are completely discharged

WARNING

Risk of injury from hot surfaces

Some components of the compressor become hot during operation.

a.) Before starting work, let the compressor cool down for 30 minutes.

b.) Wear protective gloves

WARNING

Danger to life by a liquid jet emerging under high pressure

In the case of defective hoses, tubes or components, a liquid jet can escape

under high pressure. The liquid jet can lead to the most serious injuries and

death.

• Keep persons out of danger and never place objects near the liquid jet.

In case of accidental contact with the liquid jet, first-aid measures must

be taken and immediately seek medical advice.

• Immediate emergency stop. If necessary, initiate further measures to

reduce the pressure and stop the liquid jet.

• Take out and dispose of leaking liquids properly.

• Repair defective components immediately.


WARNING



a.) Mount all protective covers which may have been removed for installation

before commissioning the machine.

b.) Check all safety devices before starting the machine.

CAUTION

Risk of injury due to noise.




7.1. Faults during operation

Faults occurring during operation are displayed in the display by means of symbols.

7.1.1. Troubleshooting Table

FAULT / ALARM Probable causes Troubleshooting Fixed by**

The machine does Not starting

Wrong power connection Check power connection MS

Compressor is selected as "Slave" and starts with remote control

See symbols of the control system and data in the controller

MS

Wrong electric phase sequencer Check the phase sequence

QT

Emergency stop button is released

Release the emergency stop button

MS


There are unsolved faults in the operating controller

Solve the Faults and confirm the error message

MS

Switch-on time of the program is activated

Check the switch-on timer SP

Network pressure is higher than the switch- on pressure

Check the pressure values and correct them, if necessary

QT

Oil temperature too high

Compressor oil deficiency in the machine

Check the compressor oil level of the oil receiver and refill oil

QT

Environment or suction temperature is too high

Check the environment temperature and ventilation of the machine room

MF

** MS = Maintenance staff, QT = Qualified technicians, SP = Service and distribution partner SCC

FAULT / ALARM Probable causes Troubleshooting Fixed by**

Oil temperature too high

Cooler or filter pad of cooling air is blocked

Clean the cooler or replace filter pad of cooling air

KF

Oil fine filter is blocked Replace the oil fine filter SP

Compressor oil polluted or aged Check and change the compressor oil

SP

The oil cooler of the compressor is damaged

Check the Oil cooler and replace it, if necessary

SP

Network pressure constantly decreases

The compressed air consumption is higher than the delivery capacity of the Equipment

Check function and size of Equipment

QT

Leakages in the compressed air network

Check compressed air network for leaks.

MS

The suction filter is heavily polluted or blocked

Replace the suction filter QT

The drive belt is broken Replace the drive belt SP

The intake valve does not open Check the function and operation of the intake valve

SP

Relief valve at the intake valve is damaged

Check the function and operation of the valve

SP

High pressure fault Oil fine filter is blocked Replace the oil fine filter SP


The intake valve does not close after reaching the maximal pressure

Check the function and operation of the intake valve

SP

Higher network pressure in the compressed air network

Stabilize the system pressure; check the pressure settings on other compressors

SP

Ball valve after compressor is closed

Slowly open the ball valve to perform stabilization of the pressure in the network.

QT

High oil expenditure Oil level is too high Check the oil level, and reduce oil level over ball valve at oil outlet of the receiver

MS

Oil return line is blocked or nonreturn valve in the oil return line is defective

Check oil return line and non-return valve.

SP


FAULT / ALARM Probable causes Troubleshooting Fixed by

High oil expenditure

Oil level is too high Check the oil level, and reduce oil level over ball valve at oil outlet of the receiver

MS

Oil return line is blocked or nonreturn valve in the oil return line is defective

Check oil return line and non-return valve.

SP

Trouble The pressure sensor does not work

Replace the pressure sensor

SP

Leakage in the tubing system Check the tubing system, repair the leakage

QT

Error of the control system Contact the Manufacturer SP

Unusual noises The distribution and service partner /SCC need to check

By the distribution and service partner SCC

SP


Table 14: Trouble shooting table


7.1.2. Commissioning after Troubleshooting

✓ The machine is switched on at the main switch.

a) Reset the emergency stop button.

b) Remedy the fault messages on the control panel

c) Ensure that no persons are in the danger area

d) Start the Machine at the Controller with button “ON” or “I”


8. Maintenance and testing during operation

The following principles apply to maintenance and testing of the machine:

This work may only be performed by specially trained and authorized specialists.

a.) Switch off the machine before starting work and secure it against re-activation.

b.) Hot components must cool down before starting work.

c.) Depressurize the system.

d.) Wear suitable personal protective equipment.

e.) Secure the work area with a red and white chain to prevent unauthorized persons entering.

f.) Use suitable lifting devices for lifting.

g.) Before re-commissioning, mount all safety devices as provided on the factory side.

h.) Check the proper functioning of the safety devices.

i.) After completing the work, remove all tools and objects from the machine.

j.) After the work has been completed, remove all contaminants and oil stains around the

machine.

Safety instructions for maintenance and testing during operation

DANGER

Danger to life by electric shock.

There is a risk to life when touching energized parts. Electrical components that are inserted can inadvertently cause movements and injuries.

a.) Switch off the system before maintenance and secure it against

accidental restart.


DANGER



a.) Disconnect the components completely from the power supply before

working on these components. Allow 3-10 minutes to ensure that the

internal capacitors are completely discharged

WARNING



a.) Mount all protective covers which may have been removed for

installation before commissioning the machine.

b.) Check all safety devices before starting the machine.

WARNING

Danger of injury due to improper repair

Improper maintenance and repair may result in serious injury. Disassembled

components and tools are potential accident hazards.

a) Work carefully.

b) Ensure sufficient ting area.

c) Keep the assembly site tidy and clean


WARNING

Risk of injury from compressed air

Unpredictable discharged air can damage the eyes, stir up dust or lead to

uncontrolled movement of hoses.

a.) Before machine maintenance and repairs, depressurize and bleed the

machine, then wait 5 minutes.

b.) Have defective components repaired promptly by qualified personnel.

c.) Wear protective glasses

WARNING




b.) Wear protective glasses.

WARNING

Danger to life by liquid jet emerging under high pressure

In the case of defective hoses, tubes or components, a liquid jet can escape under high

pressure. The liquid jet can lead to the most serious injuries and death.

a.) Never place objects near the liquid jet. Keep persons out of danger. In

case of accidental contact with the liquid jet, first-aid measures must be

taken and immediately seek medical advice.

b.) Immediate emergency stop required. If necessary, initiate further

measures to reduce the pressure and stop the liquid jet.

c.) Clean up and dispose of leaking liquids properly.

d.) Repair defective components immediately.


WARNING

Danger to life due to improper work on the pressure receiver

Improper handling of pressure receivers can cause sudden pressure

reduction and can lead to serious injuries and death as well as

substantial damage to property.

a.) Never perform welding or soldering work on the pressure tank.

b.) Do not carry out any mechanical work on the pressure receiver.

c.) Fully reduce the pressure receiver before the pressure hose / tube can

be disconnected over the condensate ball valve

d.) Start working on the pressure receiver only after the air pressure has

been completely reduced.

a.) Always wear heat-resistant protective clothing and protective gloves

when carrying out any work with fluids.

b.) Before any work with fluids, check that they are not hot. If

necessary, wait until they have cooled down.

Danger of skidding on leaking oil.



b.) Eliminate leaks and leaking oil immediately.

WARNING

Risk of injury from hot materials

Operating fluids can reach hot temperatures during operation. Skin contact with hot materials causes serious skin burns.

CAUTION


CAUTION

Risk of irritation to eyes and respiratory system

At hot temperatures or mechanical atomization of cooling liquid due to

defective components, irritating fog can escape from the cooling liquid.

a.) Allow the compressor to cool before starting work.

b.) Ensure sufficient ventilation at the assembly site.

c.) Wear light respiratory protection and protective glasses

CAUTION

Risk of injury from noise.




CAUTION

Risk of injury from cooling liquid mist

Hot temperatures or mechanical atomization can lead to a cooling liquid mist.

Cooling fluid mist can irritate the eyes and the respiratory tract.

a.) Wear respiratory protection and protective glasses, when working

on the coolant system and in the event of a coolant mist ensure a

fresh air supply.

NOTE

Perform regular maintenance

Regular maintenance increases the service life of the machine and is an

absolute prerequisite for safe and efficient operation.


Maintenance contract

Tolpec GmbH offers maintenance contracts. Our employees or authorized

specialists authorized by Tolpec will provide you with the necessary

maintenance and thus ensure a long service life of your machine as well

as a reliable, efficient, quality compressed air system. If you would like to

use this service, please contact Tolpec Customer Service.

8.1. Secure the machine against restarting

The machine is secured by closing the main switch to prevent restarting.

On the operator side, a main switch with a corresponding fuse must be installed (see Installation

of electrical components

WARNING

Danger by starting the machine

The uncontrolled start-up of the machine can lead to serious injuries or

death. Only when the machine is switched off, can work on it be carried out

a.) Switch off the machine at the main switch and secure it against

reactivation

Secured /locked Main Switch / Option

Picture 24. Locked electrical main switch (picture example)

1 Main Switch

NOTE


Procedure for securing the main switch against accidental reconnection

a.) Turn the main switch to “0”

b.) Secure the main switch with a padlock. The key must be handed over to the employee

responsible.

– The machine is protected against reconnection

Release the Main Switch

a.) Before restarting, ensure that there is no danger to persons

b.) The lock may only be opened by the employee responsible.

8.2. Maintenance schedule

The following chapter describe the intervals, at which maintenance must be carried out on the

machines.

Shift of maintenance intervals

The indicated maintenance intervals refer to operation in the specified

ambient conditions. Under unfavourable ambient conditions, maintenance

intervals can be significantly reduced. Therefore, during the regular

maintenance work, the condition of the machine, the components / oil and

ambient conditions should be checked to adjust maintenance intervals, if

necessary. If you are not sure, please consult the SCC Sales and Service

partner.

8.2.1. Daily

Components What is to do* Description of works Performed by**

Whole Equipment V Visual inspection for wear and damage MS

Oil level gauge Ch Check oil level and correct if necessary ATTENTION! In the case of a large oil deficiency, there is excessive heating, which in extreme cases can lead to a deflagration.

MS

NOTE


Display of Controller V Check the actual and set values of the parameters for pressure and temperature.

MS

* V = Visual control, Ch - Check, R = Replacement, C = Cleaning


Table 15: Daily maintenance plan

8.2.2. Weekly

Components Scope of work* Description of works Performed by**

Whole Equipment V, C Visual check for cleanness MS

Cooler C Cleaning QT

Condensate (only for machines with pressured air receiver) TD range.

Ch Drain condensate at the compressed air receiver, when no automatic condensate drain is installed

MS

* V= Visual control, Ch= Check, R= Replacement, C= Cleaning

** MS= Maintenance staff, QT= Qualified technicians, SP= Service and distribution partner SCC

Table 16: Weekly maintenance plan

8.2.2.1. After 100 Operation hours


Cooler Ch Check the cooler for contaminations. QT

Hoses, components Ch Visual check for leaks. QT

Check condensate Ch Check the Equipment for condensed water. (oil)

QT

Temperature Ch Check the Oil temperature QT

Drive Ch Visual check of belt drive and tension. QT



Table 17: Maintenance plan after 100 operation hours


8.2.3. After 500 Operation hours


Oil filter R Replace the oil filter QT (*SP)

Change of oil R Change the oil QT (*SP)

Hoses, components Ch Visual check for leaks. QT

Drive Ch / R Visual check of belt drive and tension. QT



Table 18: Maintenance plan after 500 operating hours

8.2.4. Each 2.000 operating hours


Electromotor R Lubricating of bearings QT (*SP)

Drive Ch / R Visual check of belt drive and tension. QT



Table 19: Maintenance plan for each 2.000 operating hours

8.2.5. Each 3.000 operation hours or 1 / year Compressor size until 18 kW


Electric connections, switches and connection cable

V, Ch Visual check for damages, check the electric connections for strength of connection

QT (*SP)

Air filter R Replace the air filter / QT (*SP)



Oil fine filter / separator element.

R Replace the oil fine filter / separator element.

QT (*SP)





General maintenance of compressor

Ch, R; C, V Maintenance of the entire system. Oil fine separator, safety valve, intake regulator, drive, temperature regulator, minimum pressure check valve, tightness and function test. Recommendation: (* SP): filter and oil change etc. are carried out by the SCC sales and service partner within the scope of the overall performance)

SP



Table 20: Maintenance plan for each 3.000 operating hours

8.2.6. Each 4.000 operation hours or 1 / year

Compressor size from 22 kW


Electric connections, switches and connection cable

V, Ch Visual check for damages, check the electric connections for strength of connection

QT (*SP)

Air filter R Replace the air filter / QT (*SP)


Oil fine filter / separator element.

R Replace the oil fine filter / separator element.

QT (*SP)



General maintenance of compressor

Ch, R; C, V Maintenance of the entire system. Oil fine separator, safety valve, intake regulator, drive, temperature regulator, minimum pressure check valve, tightness and function test. Recommendation: (* SP): filter and oil change etc. are carried out by the SCC sales and service partner within the scope of the overall performance)

SP



Table 21: Maintenance plan for each 4000 operating hours

8.3. Maintenance work

The following sections describe how maintenance should be performed.

8.3.1. Visual Inspection Perform the following visual inspections:

a.) Check the machine and all components for external damage

b.) Check all safety devices for external damage

– If you notice any contamination or damage, Report it and Repair immediately.

The visual inspection of the machine is complete.

8.3.2. Cleaning

Danger of damage caused by unsuitable cleaning agents and

cleaning procedures

Unsuitable cleaning agents can cause damage to the machine or machine

components.

a.) Wear protective gloves and glasses.

b.) Use only mild detergents

c.) Do not use high pressure equipment as well as aggressive or

corrosive detergents

ATTENTION


Components Methods Cleaning agent Notice

General surfaces Clean with cleaning cloth and detergent

Solvent-free detergent

Follow the recommendations of the detergent manufacturer

Floor Wet the floor and wipe with mop

Solvent-free detergent

Follow the recommendations of the detergent manufacturer.

Table 22: Common recommendations for cleaning

The surfaces of the machines are easy to clean and antistatic.

8.3.3. Checking and servicing the mechanics

In case of damage to the mechanical devices, immediately take the machine out of operation

and start a thorough repair using original spare parts.

Component damage due to insufficient maintenance

Insufficient maintenance results in more wear and higher repair costs.

a.) Carry out the necessary maintenance work according to the manufacturer's instructions.

b.) Observe the manufacturer's instructions for the maintenance of the mechanical components.

The following tightening torques apply to the stability and functionality of the mechanical

components of the compressor:

Safety screws / -nuts, construction B 158/193/196/251

NOTE

Special cleaning instructions

Some components must be dismantled for cleaning. For this reason, you will find the specific instructions for cleaning in the Maintenance section under the corresponding component

ATTENTION


Class 8.8 Unit Class 10.9 Unit

M5 3.69 (5) lbf ft (Nm) 7.38 (10) lbf ft (Nm)




M 12 50.89 (69) lbf ft (Nm) 111.37 (151) lbf ft (Nm)


Table 23: Tightening torque of the safety screws

Safety screws / -nuts, construction DIN 912/931/933/934/982

Class 8.8 Unit Class 10.9 Unit

M5 4.43 (6) lbf ft (Nm) 6.27 (8.5) lbf ft (Nm)






Table 24: Tightening torque of the safety screws

8.3.3.1. Maintenance and cleaning of air filters

To clean the air filter, remove it.

✓ The machine is not supplied with electrical power.

✓ The machine is depressurized

a) Open the cover.

b) Carefully pull out the filter cartridge.

c) Check the condition of the filter cartridge. The cartridge can be cleaned and

reinstalled, if the cartridge is very poor, it must be replaced.

d) Clean the cover.

e) Clean the filter cartridge.

f) Replace, if necessary for a new filter cartridge.

g) Lose the cover.

The air filter has been serviced.


NOTE

8.3.3.2. Maintenance and cleaning oil filter

The oil filter must be removed and replaced for maintenance.

The machine must be depressurized.

a) Use the separate key to unscrew the oil filter.

b) Clean the fitting point.

c) Wet the new gasket with oil before installing the new filter.

d) Screw in the new filter.

e) Start the compressor and check if there are any leaks.

The oil filter has been repaired.

8.3.3.3. Maintenance of the Oil separator

Used oil separators depend on the series

In the case of a spin-off oil separator, maintenance is carried out

analogously to the oil filter. If the oil fine separator is integrated in the oil

tank, maintenance must only be carried out by the SCC service partner.

To maintain the Electric motor, it is necessary to regularly lubricate the bearings with the solid

grease Mobile Polyrex EM and Total Multis EP 2.

8.3.3.4. Maintenance of Motors and Bearings

To maintain the Electric motor, it is necessary to regularly lubricate the bearings with the solid

grease Mobile Polyrex EM and Total Multis EP 2.

NOTE

The motor and bearings are serviced by the SCC service partner .


8.3.3.5. Checking belt tension (depending on the model) The machine must be depressurized.

a.) Open the side cover on the belt drive.

b.) Turn the screw on the clamping device. Adjust the spring and then adjust the

correct tension of the belt: the average pressure should be 3 kg, the deformation

of the belt should be less than 5 mm.

The belt tension is set.

8.3.3.6. Replacing belts (depending on the model) The machine must be depressurized.

a) Open the side cover of the belt drive.

b) Loosen the screw of belt tensioner to loosen the belt.

c) Remove the worn belt from the shafts.

d) Place a new strap on the shafts and tension it.

e) Mount the side cover of the belt drive and restore the machine to operational

condition.

f) Run the compressor for 10 minutes.

g) Re-energize and depressurize the machine.

h) Disassemble the side cover of the belt drive again.

i) Tighten the belt.

j) Mount the cover and make the unit ready to operate.

8.3.3.7. Adjust belt pulley (depending on model)

NOTE

The axis alignment motor-compressor stage is set by the SCC service

partner .


8.3.3.8. Adjusting axes (depending on the model)

8.3.3.9. Maintenance Minimum pressure and non-return valve

8.3.3.10. Maintenance Intake-valve

8.3.4. Check and maintenance of electrical parts a.) Periodically check the electrical system with a visual inspection

b.) Immediately shut down the machine in case of damage to the electrical equipment and

start a proper repair with original spare parts.

8.3.4.1. Maintenance of safety devices To ensure the operational safety of the machine at any time, it is necessary to replace different

safety-related components at the end of their service life.

In the case of damage or failure of a safety device, the relevant component must be replaced

immediately, and the entire safety circuit must be subjected to a comprehensive functional test.

Other components may also need replacing.

Contact the SCC sales and service partner.

NOTE

The axis alignment motor-compressor air end is serviced by the SCC service

partner .

NOTE

The minimum pressure and non-return valve is serviced by the SCC service

partner .

NOTE

The intake valve is serviced by the SCC service partner .


8.3.5. Check the pneumatic system and service

8.3.5.1. Maintenance of the air receiver on the receiver mounted

machine

Picture 25: Receiver mounted machine TD-range

1 Safety valve 2 Pressure gauge

3 Ball valve for condensate drain

(twin - receiver 2 Pcs.)

4 Oil receiver (behind the cover)

In the case of a receiver mounted unit with a compressor or a compressed-air refrigerated dryer

built on the compressed air receiver, condensate accumulates in the compressed-air receiver

operation, which must be removed regularly.

Compressed air receivers must comply with the legal requirements of the respective country. A

pressure gauge, a safety valve and a condensate ball valve (for twin receivers two) are mounted

at the base of the compressed-air receiver.


✓ Compressor is depressurized and cooled down.

a.) Open the ball valve very slowly and collect the condensate in a suitable container.

8.3.5.2. Check for condensation In the case of a receiver mounted unit with a compressor, a refrigerated dryer built on the

compressed air receiver, condensate accumulates in the compressed-air receiver operation,

which must be removed regularly.

CAUTION

Danger of injury due to improper work on pneumatic components

✓ Only qualified personnel can carry out maintenance work on the pneumatic components.

a.) Wear the necessary PPE (protective clothing, protective glasses,

protective gloves)

CAUTION

NOTE

Condensation due to low operating temperature

To ensure that the air humidity is not condensed, the operating temperature

must be sufficiently high during compression. Frequent turning on and off of

the machine may cause the compressor to fail to reach the required operating

temperature .

Environmental hazard

The condensate is oily. Dispose of the condensate according to the applicable

environmental and disposal regulations


CAUTION

Damage caused by condensation in the circuit of the compressor oil

a.) Condensate in the oil circuit can destroy the compressor unit. Switch off the compressor immediately and secure it against re-activation.

b.) Close the ball valve to the compressed air network and secure it

against re-opening.

c.) Contact the SCC sales and service partner immediately.

Procedure for testing for condensation

The Compressor is depressurized and cooled down.

a.) Close the ball valve to shut-off the valve on the pressure line and secure it against re-

opening.

b.) Remove the protective covers / panels.

c.) Place a collecting container under the discharge ball valve of the oil receiver

d.) Open the ball valve of the oil receiver and carefully drain approximately 2 litres of

compressor oil.

e.) Close the ball valve of the oil receiver.

f.) Check the discharged compressor oil for contamination with condensate.

g.) If there is condensate in the compressor oil, carry out an oil change.

h.) Re-fill the oil tank with oil or make an oil change if necessary.

i.) Slowly open the ball valve at the oil receiver and make sure that the condensate coming out

is safely received by the collecting container.

j.) Close the ball valve on the coolant pressure tank.

k.) Dispose of used waste oil according to applicable environmental and disposal regulations.

l.) Mount all protective guards and panels.

Restore the operating condition of the compressor

NOTE

Condensate at the bottom of the oil tank

The condensate is heavier than the compressor oil. Therefore, it accumulates

on the bottom of the oil receiver, after a prolonged downtime .


8.3.6. Oil level and oil change

Oil level too high

If the oil level is too high:

✓ The machine is depressurized.

a.) Turn off the compressor.

b.) Connect an oil drain hose to the shut-off valve on the oil tank.

c.) Carefully open the shut-off valve, as residual pressure can still be present in the oil tank

and let the oil level go down to the required level.

d.) Disassemble the oil drain hose.

e.) Close the shut-off valve.

Picture 26: oil change

1 Oil Receiver 2 Oil filler neck at receiver

3 Oil - Drain ball valve

The machine is depressurized

a.) Connect the drain hose.

b.) Open the oil - drain ball valve to drain the waste oil into the collection container.

c.) Close the oil- drain ball valve.

d.) Open the plug of the oil filler neck.

e.) Fill the oil receiver with the specified compressor oil to the required level.

NOTE

Use correct lubricants

Observe the notes in the section on Compressor oil and lubricant [ 93].


f.) Make sure that the sealing ring of the oil filler plug is not damaged.

g.) Close the plug of the oil filler neck and tighten it securely with the wrench.

h.) Carefully remove the remaining oil.

i.) Start the machine.

j.) Check the oil level after 30 minutes and refill oil if necessary.

k.) Ensure that there are no new oil leaks in the machine.

8.3.7. Replacing worn parts

Replace worn parts such as belt drives, filters, etc. at the end of their service life.

For more information, contact Tolpec Customer Service.

NOTE

Shortened interval for oil change

If the compressor is operated in a non-optimal atmosphere, the oil must be

checked and the oil change and service interval must be shortened.


8.4. Compressor oil and lubricant

Damage caused by non-suitable compressor oils

The use of non-approved compressor oils, as well as the mixing of different compressor oils, can damage the compressor. According to the valid

accident prevention regulations, lubricating oils with characteristics

corresponding to the intended operating conditions must be used.

Reduced oil change intervals at higher compression temperatures

At constantly increasing compression temperatures above 90 ° C, the oil change intervals are reduced by 50%. An accurate analysis of the compressor oil according to the actual operating conditions can only be carried out by a compressor oil test in a laboratory

Screw compressor oil:

SCC compressors Oil recommendation: Shell Corena S2 R46.

High performance screw compressor oil ISO VG 46

ISO Viscosity grade (ISO VG) ISO 3448 / DIN 51519 46

Kinematic Viscosity ASTM D445 at 40 ° C 46 mm² / s

Kinematic Viscosity ASTM D445 at 100 ° C 6.9 mm² / s

Flash point 230 ° C

Demulsifying capacity 15min

Pourpoint -33 ° C

As also SCC compressors Oil recommendation: Shell Corena S4 R46.

ATTENTION

NOTE


Bearing grease for motor bearings

Mobil Polyrex EM or Total Multis

8.5. Wear and tear / spare parts

Spare parts must meet the technical requirements defined by Tolpec. Original spare parts are

subject to strict conditions and must meet these requirements.

Tolpec assumes no liability for damage caused by using spare parts from other manufacturers.

Inquiries and orders for wear and tear / spare parts are to be addressed to Tolpec with the

following information: – Type,

– Item number

– Year of construction

– Part name

– Amount

– Shipping mode

Wear and tear / spare parts

For further information please contact the SCC sales and service partner.

8.6. Customer service through the manufacturer Tolpec recommends a maintenance contract with the SCC sales and service partner.

In addition, Tolpec is interested in information and experience that arises from the use of our

products so that improvements can be made if necessary. Please contact Tolpec or your

SCC service partner if you have any issues or constructive feedback.

.


9. Repair

The following section describes how the machine is repaired.

After the warranty period of the machine has expired, repairs can be carried out by the operator,

with the appropriate specialist. Tolpec assumes no responsibility for these repairs. If you have

any questions about repairs, contact your SCC sales – and service partner.

10. Decommissioning, storage and disposal

The following principles apply to the decommissioning, storage and disposal of the machine

This work may only be performed by specially trained and authorized specialists.

a.) Switch off the machine before starting work and secure it against re-activation.

b.) Hot components must cool down, before starting work.

c.) Wear suitable personal protective clothing.

d.) Secure the work area with a red and white chain against unauthorized persons entering.

e.) Use suitable lifting aids and lifting devices for lifting.

Safety instructions for decommissioning, storage and disposal

DANGER Danger to life by electric shock.

There is a risk to life when touching energized parts. Electrical

components that are inserted can inadvertently cause movements and

injuries.

a.) Switch off the system before maintenance and secure it against

accidental restart.

NOTE

During the warranty period of the machine, repairs can only be carried out by the

SCC service partner.

Repairs by the operator


DANGER



a.) Disconnect the components completely from the power supply

before working on these components. Allow 3-10 minutes to

ensure that the internal capacitors are completely discharged

WARNING




b.) Wear protective glasses.

WARNING

Danger to life by a liquid jet emerging under high pressure

In the case of defective hoses, tubes or components, a liquid jet can

escape under high pressure. The liquid jet can lead to serious injuries

and death.

a.) Never place objects in the way of the liquid jet. Keep persons out of

danger. In case of accidental contact with the liquid jet, first-aid

measures must be taken and seek medical advice immediately.

b.) Immediate emergency stop. If necessary, initiate further measures to

reduce the pressure and stop the liquid jet.

c.) Take out and dispose of leaking liquids properly

d.) Repair defective components immediately.


WARNING

a.) Always wear heat-resistant protective clothing and protective gloves

when carrying out any work with fluids.

b.) Before any work with fluids, check that they are not hot. If necessary,

wait until they have cooled down.

10.1. Temporary Decommissioning When taking the unit out of service for an extended period, the machine should be carefully shut

down according to the following methods, considering the season and humidity in the

manufacturing plant/compressor house

Close the shut-off valve of the compressor in the customer's compressed air network. The

protective cover / panels of the machine must be closed to prevent the penetration of dirt and

moisture.

Proceed to restart the equipment after downtime as during first commissioning.

Risk of injury from hot materials

Operating fluids can reach hot temperatures during operation. Skin contact with hot materials causes serious skin burns.

CAUTION

Machine damage due to corrosion

Store the machine away from moisture and in a frost-free environment

NOTE

Prevention of condensation during temporary standstill.

If the machine remains at its place of use during the downtime period,

condensation can be prevented by operating the compressor approximately

every 2 weeks for a period of 30 minutes.

Restart after Downtime


10.2. Final decommissioning The procedure for the final decommissioning corresponds to the temporary shutdown.

Additionally: Drain the oil.

10.3. Dismantling The machine has been taken out of service

The oil is drained.

a.) The disassembly takes place in the same way as the installation, in reverse order.

Begin by disassembling the pipe system and then disassemble the individual components.

Installation of safety devices for safe transport

The machine has been taken out of service.

a.) Attach the required safety devices to the machine before transport.

The machine is secured for transport.

10.4. Re-packing the machine The machine is dismantled.

a.) Pack the machine so that it is protected from moisture and dust.

The machine is re-packed.

10.5. Store the machine Store the machine and its components according to the conditions in the technical data.

10.6. Disposal The machine is essentially made of reusable materials. The machine does not pose a risk to the

operator or the environment if handled properly. However, the machine is operated with materials

which can be harmful to the environment and must therefore be properly disposed of according to

the regulations (see safety data sheets in the appendix).

Provide individual components of the machine (motors, metal parts, etc.) to a qualified disposal

and recycling company. Use a qualified specialist company for the disposal and recycling of the

entire machine.

NOTE

Contact Tolpec for any advice regarding your disposal needs.


11. Technical documents / Annex list The technical documents are divided into several folders. You can find the content table in

every folder.

11.1. Plan of maintenance and repair works

Operating hours Date Spare details Name


List of Pictures Picture 1: Front view of the Equipment (example picture, Focus series)......................................................................... 14 Picture 2: Front view of the Compressor (example picture, Focus series) ..................................................................... 15 Picture 3: Example picture: drive side of the Compressor with belt-drive (Smart series) ................................................ 15 Picture 4: Safety-relevant operating components and indicator elements of the Compressor ........................................ 17 Picture 5: Safety valve .................................................................................................................................................... 17 Picture 6: Operating panel MAM - 890 ............................................................................................................................ 18 Picture 7: Operating panel MAM - 860 ............................................................................................................................ 19 Picture 8: Operating panel MAM - 200 ............................................................................................................................ 20 Picture 9: Operating panel MAM - 6080 .......................................................................................................................... 21 Picture 10: Areas of work and maintenance .................................................................................................................... 22 Picture 11: Name plate of the equipment ........................................................................................................................ 23 Picture 12: Compressor frame with panels ..................................................................................................................... 26 Picture 13: Pressure sensor (example picture) ............................................................................................................... 27 Picture 14: Safety valve on the oil receiver ..................................................................................................................... 27 Picture 15: Safety valve of the air receiver ...................................................................................................................... 28 Picture 16: Oil temperature sensor.................................................................................................................................. 28 Picture 17: Emergency stop button ................................................................................................................................. 29 Picture 18: Transport with the forklift ............................................................................................................................... 45 Picture 19: Rotation direction arrow on the air end ......................................................................................................... 50 Picture 20: oil receiver ..................................................................................................................................................... 53 Picture 21: Intake valve mounted on air end ................................................................................................................... 54 Picture 22: Direction arrow on air end ............................................................................................................................. 55 Picture 23: Areas of work and maintenance .................................................................................................................... 59 Picture 24. Locked electrical main switch (picture example) ........................................................................................... 72 Picture 25: Receiver mounted machine TD-range .......................................................................................................... 83 Picture 26: oil change ...................................................................................................................................................... 86

List of Tables Table 1: Warning signs ..................................................................................................................................................... 9 Table 2: Mandatory signs ................................................................................................................................................ 10 Table 3: Change of history of this document ................................................................................................................... 11 Table 4: Table of applicable documents .......................................................................................................................... 11 Table 5: Contacts ............................................................................................................................................................ 12 Table 6: Your SCC sales and service partner ................................................................................................................. 13 Table 7: Overview of the warning signs .......................................................................................................................... 30 Table 8: Overview of the mandatory signs ...................................................................................................................... 31 Table 9: Qualification of the staff ..................................................................................................................................... 39 Table 10: Operator groups .............................................................................................................................................. 40 Table 11: Activities and knowledge ................................................................................................................................. 40 Table 12: Mandatory signs .............................................................................................................................................. 42 Table 13: Personal protective equipment ........................................................................................................................ 45 Table 14: Trouble shooting table ..................................................................................................................................... 65 Table 15: Daily maintenance plan ................................................................................................................................... 74 Table 16: Weekly maintenance plan ............................................................................................................................... 74 Table 17: Maintenance plan after 100 operation hours ................................................................................................... 74 Table 18: Maintenance plan after 500 operating hours ................................................................................................... 75 Table 19: Maintenance plan for each 2.000 operating hours .......................................................................................... 75 Table 20: Maintenance plan for each 3.000 operating hours .......................................................................................... 76 Table 21: Maintenance plan for each 4000 operating hours ........................................................................................... 77 Table 22: Common recommendations for cleaning ......................................................................................................... 78 Table 23: Tightening torque of the safety screws ............................................................................................................ 79 Table 24: Tightening torque of the safety screws ............................................................................................................ 79

Glossary EMC Electromagnetic compatibility

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