Original operating manual - scc-aircompressors.com · Operation Manual SCC-Compressors / Page 7...
Transcript of Original operating manual - scc-aircompressors.com · Operation Manual SCC-Compressors / Page 7...
Original operating manual
SCC Compressor
Version E 1.1• 13.07.2018
Operation Manual SCC-Compressors / Page 2
Imprint Tolpec GmbH
Wertstrasse 44
73240 Wendlingen
Tel.: +49 (0)7022-789 6040
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.
Operation Manual SCC-Compressors / Page 3
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
Operation Manual SCC-Compressors / Page 4
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
Operation Manual SCC-Compressors / Page 5
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
Operation Manual SCC-Compressors / Page 6
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.
Operation Manual SCC-Compressors / Page 7
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.
Operation Manual SCC-Compressors / Page 8
– 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.
Operation Manual SCC-Compressors / Page 9
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
Operation Manual SCC-Compressors / Page 10
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
Operation Manual SCC-Compressors / Page 11
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
Operation Manual SCC-Compressors / Page 12
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
Operation Manual SCC-Compressors / Page 13
SCC Sales- and Service partner
Address
Phone:
Email:
Operation manual received at: _____________________
Table 6: Your SCC sales and service partner
Operation Manual SCC-Compressors / Page 14
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
Operation Manual SCC-Compressors / Page 15
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)
Operation Manual SCC-Compressors / Page 16
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.
Operation Manual SCC-Compressors / Page 17
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
Operation Manual SCC-Compressors / Page 18
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.
4. Submenu – choose downwards
10 SET
1. Confirm changed parameters
2. Function of switch to charge to idle run
11 Display indications
Operation Manual SCC-Compressors / Page 19
Operating panel MAM – 860
Picture 7: Operating panel MAM - 860
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.
2 Display indications
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
5 Switch to submenu / enter
Works as enter button, when the menu is chosen
6 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
7 1. Switching from main display to main menu
levels.
2. Choose in the main menu – downwards
3. Decreasing of numeric data.
4. Submenu – choose downwards
8 SET
1. Confirm changed parameters
2. Function of switch to charge to idle run
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
Operation Manual SCC-Compressors / Page 20
Operating panel MAM – 200
Picture 8: Operating panel MAM - 200
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.
2 Display indications
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
6 Switch to submenu / enter
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
8 1. Switching from main display to main menu levels.
2. Choose in the main menu – downwards
3. Decreasing of numeric data.
4. Submenu – choose downwards
9 SET
1. Confirm changed parameters
2. Function of switch to charge to idle run
Operation Manual SCC-Compressors / Page 21
Operating panel MAM 6080
Picture 9: Operating panel MAM - 6080
1 Indication Power – Voltage available 2
Indication Run – Compressor in operation 3 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.
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.
3. Decreasing of numeric data.
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.
2. Switching in data editing mode, switching of
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
1. Confirm changed parameters
2. Function of switch to charge to idle run
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.
Operation Manual SCC-Compressors / Page 22
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
3. Notification of warning through blinking
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.
6. Switching in data editing mode, switching of
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
Operation Manual SCC-Compressors / Page 23
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.
Operation Manual SCC-Compressors / Page 24
– 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
Operation Manual SCC-Compressors / Page 25
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.
Operation Manual SCC-Compressors / Page 26
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
Operation Manual SCC-Compressors / Page 27
– 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
Operation Manual SCC-Compressors / Page 28
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
Operation Manual SCC-Compressors / Page 29
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
Operation Manual SCC-Compressors / Page 30
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
Operation Manual SCC-Compressors / Page 31
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
Operation Manual SCC-Compressors / Page 32
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.
Operation Manual SCC-Compressors / Page 33
– 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.
Operation Manual SCC-Compressors / Page 34
– 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.
Operation Manual SCC-Compressors / Page 35
– 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.
Operation Manual SCC-Compressors / Page 36
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.
Operation Manual SCC-Compressors / Page 37
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 .
Operation Manual SCC-Compressors / Page 38
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
Operation Manual SCC-Compressors / Page 39
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
- trained/instructed staff
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
- trained/instructed staff
– 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
Operation Manual SCC-Compressors / Page 40
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
Operation Manual SCC-Compressors / Page 41
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.
Operation Manual SCC-Compressors / Page 42
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.
Operation Manual SCC-Compressors / Page 43
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.
Operation Manual SCC-Compressors / Page 44
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
Operation Manual SCC-Compressors / Page 45
- 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
Operation Manual SCC-Compressors / Page 46
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.
Operation Manual SCC-Compressors / Page 47
- 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.
Operation Manual SCC-Compressors / Page 48
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.
Operation Manual SCC-Compressors / Page 49
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
Operation Manual SCC-Compressors / Page 50
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.
Operation Manual SCC-Compressors / Page 51
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.
Operation Manual SCC-Compressors / Page 52
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
Operation Manual SCC-Compressors / Page 53
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
Operation Manual SCC-Compressors / Page 54
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.
Operation Manual SCC-Compressors / Page 55
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.
Operation Manual SCC-Compressors / Page 56
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
Operation Manual SCC-Compressors / Page 57
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 .
Operation Manual SCC-Compressors / Page 58
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.
There is a risk or chance of injury.
a.) Check the machine for leakage and leaking oil.
b.) Eliminate leaks and leaking oil immediately.
CAUTION
Risk of injury from noise.
The noise level in the work area can cause serious hearing damage.
a.) Always wear ear protection when working.
b.) Stay as short as possible in the danger area.
Operation Manual SCC-Compressors / Page 59
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.
Operation Manual SCC-Compressors / Page 60
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
Operation Manual SCC-Compressors / Page 61
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.
Operation Manual SCC-Compressors / Page 62
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.
Operation Manual SCC-Compressors / Page 63
WARNING
Danger due to missing safety devices
Missing protective covers can lead to serious injuries.
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.
The noise level in the work area can cause serious hearing damage.
a.) Always wear ear protection when working.
b.) Stay as short as possible in the danger area.
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
Operation Manual SCC-Compressors / Page 64
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
Operation Manual SCC-Compressors / Page 65
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
** MS = Maintenance staff, QT = Qualified technicians, SP = Service and distribution partner SCC
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
** MS = Maintenance staff, QT = Qualified technicians, SP = Service and distribution partner SCC
Table 14: Trouble shooting table
Operation Manual SCC-Compressors / Page 66
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”
Operation Manual SCC-Compressors / Page 67
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.
Operation Manual SCC-Compressors / Page 68
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
Danger due to missing safety devices
Missing protective covers can lead to serious injuries.
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
Operation Manual SCC-Compressors / Page 69
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
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 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.
Operation Manual SCC-Compressors / Page 70
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.
There is a risk or chance of injury.
a.) Check the machine for leakage and 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
Operation Manual SCC-Compressors / Page 71
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.
The noise level in the work area can cause serious hearing damage.
a.) Always wear ear protection when working.
b.) Stay as short as possible in the danger area.
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.
Operation Manual SCC-Compressors / Page 72
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
Operation Manual SCC-Compressors / Page 73
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
Operation Manual SCC-Compressors / Page 74
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
** MS = Maintenance staff, QT = Qualified technicians, SP = Service and distribution partner SCC
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
Components Scope of work* Description of works Performed by**
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
* V= Visual control, Ch= Check, R= Replacement, C= Cleaning
** MS= Maintenance staff, QT= Qualified technicians, SP= Service and distribution partner SCC
Table 17: Maintenance plan after 100 operation hours
Operation Manual SCC-Compressors / Page 75
8.2.3. After 500 Operation hours
Components Scope of work* Description of works Performed by**
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
* V= Visual control, Ch= Check, R= Replacement, C= Cleaning
** MS= Maintenance staff, QT= Qualified technicians, SP= Service and distribution partner SCC
Table 18: Maintenance plan after 500 operating hours
8.2.4. Each 2.000 operating hours
Components Scope of work* Description of works Performed by**
Electromotor R Lubricating of bearings QT (*SP)
Drive Ch / R Visual check of belt drive and tension. QT
* V = Visual control, Ch - Check, R = Replacement, C = Cleaning
** MS = Maintenance staff, QT = Qualified technicians, SP = Service and distribution partner SCC
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
Components Scope of work* Description of works Performed by**
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)
Operation Manual SCC-Compressors / Page 76
Oil filter R Replace the oil filter QT (*SP)
Oil fine filter / separator element.
R Replace the oil fine filter / separator element.
QT (*SP)
Change of oil R Change the oil QT (*SP)
* V = Visual control, Ch - Check, R = Replacement, C = Cleaning
** MS = Maintenance staff, QT = Qualified technicians, SP = Service and distribution partner SCC
Components Scope of work* Description of works Performed by**
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
* V = Visual control, Ch - Check, R = Replacement, C = Cleaning
** MS = Maintenance staff, QT = Qualified technicians, SP = Service and distribution partner SCC
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
Components Scope of work* Description of works Performed by**
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 filter R Replace the oil filter QT (*SP)
Oil fine filter / separator element.
R Replace the oil fine filter / separator element.
QT (*SP)
Change of oil R Change the oil QT (*SP)
Operation Manual SCC-Compressors / Page 77
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
* V = Visual control, Ch - Check, R = Replacement, C = Cleaning
** MS = Maintenance staff, QT = Qualified technicians, SP = Service and distribution partner SCC
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
Operation Manual SCC-Compressors / Page 78
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
Operation Manual SCC-Compressors / Page 79
Class 8.8 Unit Class 10.9 Unit
M5 3.69 (5) lbf ft (Nm) 7.38 (10) lbf ft (Nm)
M6 5.9 (8) lbf ft (Nm) 13.28 (18) lbf ft (Nm)
M8 14.75 (20) lbf ft (Nm) 32.45 (44) lbf ft (Nm)
M10 29.5 (40) lbf ft (Nm) 64.17 (87) lbf ft (Nm)
M 12 50.89 (69) lbf ft (Nm) 111.37 (151) lbf ft (Nm)
M 16 125.39 (170) lbf ft (Nm) 280.27 (380) 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)
M6 7.38 (10) lbf ft (Nm) 10.33 (14) lbf ft (Nm)
M8 18.44 (25) lbf ft (Nm) 25.81 (35) lbf ft (Nm)
M10 36.14 (49) lbf ft (Nm) 50.89 (69) lbf ft (Nm)
M 12 63.43 (86) lbf ft (Nm) 55.51 (120) lbf ft (Nm)
M 16 154.89 (210) lbf ft (Nm) 217.58 (295) 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.
Operation Manual SCC-Compressors / Page 80
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 .
Operation Manual SCC-Compressors / Page 81
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 .
Operation Manual SCC-Compressors / Page 82
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 .
Operation Manual SCC-Compressors / Page 83
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.
Operation Manual SCC-Compressors / Page 84
✓ 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
Operation Manual SCC-Compressors / Page 85
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 .
Operation Manual SCC-Compressors / Page 86
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].
Operation Manual SCC-Compressors / Page 87
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.
Operation Manual SCC-Compressors / Page 88
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
Operation Manual SCC-Compressors / Page 89
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.
.
Operation Manual SCC-Compressors / Page 90
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
Operation Manual SCC-Compressors / Page 91
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 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.
Operation Manual SCC-Compressors / Page 92
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
Operation Manual SCC-Compressors / Page 93
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.
Operation Manual SCC-Compressors / Page 94
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
Operation Manual SCC-Compressors / Page 95
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
Operation Manual SCC-Compressors / Page 96