Operating instructions firstAir screw compressor FAS03 – 37 Read the instructions before operating the compressor!
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Thank you for deciding on a product from our range of screw compressors. Our company reserves the right to make changes to the design of our products. We are, however, not obliged to modify or optimise any products that have already left the factory. It is, however, possible that we will change the technical data or components without prior notification in future.
Preface Preface Thank you for deciding on a product from our range of screw compressors. Our products undergo thorough checks and tests before leaving the factory. In order to be able to guarantee safe, reliable and long-term use of the system, please read the operating instructions carefully before using the system. Compliance with the information about operation contained in the instructions is a prerequisite for a good working condition of the system in the long term.
TABLE OF CONTENTS 1 Table of contents 2 General information....................................................................................................................................... 8 2.1 Limitation of liability ............................................................................................................................ 8 2.2 Copyright ............................................................................................................................................ 8 2.
TABLE OF CONTENTS 6. Screw compressor installation ................................................................................................................. 35 6.1 Safety instructions for installation and commissioning ..................................................................... 35 6.2 Requirements for the installation location ........................................................................................ 37 6.3 Installation .......................................................
TABLE OF CONTENTS 11.3.6 Break in period ............................................................................................................................ 58 12 Instructions for operation ......................................................................................................................... 60 12.1 Control panel .................................................................................................................................. 60 12.
General information / safety instructions 2 General information 2.1 Limitation of liability All information and instructions in this manual have been compiled taking account of the applicable standards and regulations, state-ofthe-art technology and our years of knowledge and experience.
General information / safety instructions 2.3 Guarantee conditions The guarantee conditions are included in the General Terms and Conditions issued by the manufacturer. 2.4 Customer service Our Customer Service department is available to provide technical information. See page 2 for contact data.
General information / safety instructions 3.0 Safety instructions 3.1 Explanation of symbols Safety instructions The safety instructions and safety information in these instructions are denoted by symbols. The safety instructions are prefaced by signal words which express the extent of the risk. To prevent accidents, personal injury and property damage, comply with the safety instructions at all times and proceed with caution.
General information / safety instructions 3.2 Fundamental dangers The following section describes residual risks that can arise from the machine and were determined by a risk assessment. To minimise health hazards and avoid dangerous situations, follow the safety instructions specified here as well as in the following chapters of these instructions. 3.2.1 General dangers at the workplace Noise WARNING! Danger of injury from noise! The noise level in the work area can cause severe hearing loss.
General information / safety instructions 3.2.2 Dangers due to electric energy Electric power DANGER! Danger to life due to electric current! Imminent risk of fatal injury from electric shock in the event of in contact with live parts. Damage to insulation or individual components can present a danger to life. Stored charges - Any work on the electrical system must be performed by qualified electricians.
General information / safety instructions 3.2.3 Dangers due to mechanical elements Moving parts WARNING! Danger of injury due to moving components! Rotating parts or parts making linear motions can cause serious injuries. Sharp edges and pointed corners - Never reach into moving parts or handle moving parts during operation. - Do not open covers during operation. - Be aware of the stop delay: Make sure that all parts have stopped moving before opening any covers.
General information / safety instructions - Air receiver Have faulty components repaired immediately. WARNING! Danger to life in the event of improperly performed work on the air receiver! Improper handling of air receivers can cause a sudden release of pressure and thereby cause serious or even fatal injuries and considerable material damage. Compressed air - Never carry out welding or soldering work on the air receiver tank. - Do not carry out any mechanical work on the air receiver tank.
General information / safety instructions Oil mist CAUTION! Danger of injury due to Oil mist! In the event of high temperatures or mechanical spray dispersion, Oil mist can form. Oil mist can irritate eyes and the respiratory system. - When working on the Oil system and an Oil mist forms, wear breathing protection and protective goggles and ensure that there is a fresh air supply. 3.2.
General information / safety instructions - Before performing any work with operating materials, check whether they are hot. If necessary, allow them to cool down. 3.3. Proper use The machine is designed and constructed for proper use as described here only. The screw compressor is only used to generate compressed air in a non-explosive environment. The screw compressor may be only supplied with cool, dry and dust-free cooling air.
General information / safety instructions 3.4 Responsibility of the owner Owner The owner is the person who operates the machine for commercial or business purposes themselves, or hands it over to a third party for use/application, and who assumes the legal product responsibility for the protection of the user, the personnel or third parties during operation. Owner obligations The machine is used for commercial purposes.
General information / safety instructions The owner must ensure that the appropriate media connections are provided. The owner must ensure that the supply of the required quantity of cooling medium (air/water) is guaranteed. The owner must make sure that the required heat extraction is guaranteed. 3.5 Description of the installed safety devices Main switch with emergency stop function The main switch is also designed as an emergency stop switch.
General information / safety instructions - Do not unlock the emergency stop button until there is no more danger. Safety valves Safety valves are safety components and are pressure-relief equipment for the areas under pressure such as the boiler, pressure tank, pipes and transport container. In the event of an impermissible pressure increase, safety valves discharge gases, vapours or liquids into the atmosphere. Fig. 3: Safety valve 3.
General information / safety instructions 20 firstAir screw compressor FAS03 – 37
Design and function 4 Design and function 4.1 Design 3 1 2 4 Fig. 1: 37 kW screw compressor 1. Emergency stop button 3. Noise insulation covers 2. Control panel 4. Switch cabinet Note: The dimensions and configuration of different models may vary, however share the same basic structure.
Design and function 4.2 Introduction to the compact, oil-lubricated screw compressor The compact, oil-lubricated screw compressor is characterised by its reliability, low wear, low vibration properties, smooth running operation and high efficiency. 4.2.1 Brief description of the function The fresh air supplied by the installed cooling air ventilator is filtered through the intake filter.
Design and function 4.3 Environmental protection NOTE! Danger to the environment due to incorrect handling of environmentally hazardous substances! If environmentally hazardous substances are handled incorrectly, in particular if they are disposed of incorrectly, there is a risk of considerable harm to the environment. - Always adhere to the instructions below when handling and disposing of environmentally hazardous substances.
Design and function 4.4.1 Warning signs Electric voltage Only qualified electricians may work in a room marked with this sign. Unauthorised persons may not enter workplaces marked with this sign, nor open a cabinet marked with this sign. Automatic start-up Maintain sufficient distance from all parts that can move; they present a danger of crush injuries or being pulled in. Hot surface Hot surfaces, such as machine parts, containers or materials, but also hot liquids, are not always apparent.
Design and function 4.4.2 Instructions on the machine Direction of rotation There is a direction of rotation sticker on the drive unit and on the cooling air fan. This sticker shows the respective direction of rotation. Relubrication The sticker for relubrication is affixed to the drive unit. Oil filling The sticker for Oil filling is affixed to the Oil tank and next to the installed controller.
Design and function Brief commissioning instructions The sticker is affixed to the switch cabinet and contains brief commissioning instructions.
Design and function 5 Technical data 5.1 Type plate Fig. 4: Type plate The type plate is affixed to the rear of the system and contains the following information: • Licence number • Model • Capacity • Maximum pressure • Motor power • Net weight • Dimensions • Manufacturer no.
Design and function 5.2 General specifications 5.2.1 Operating conditions Environment Physical variable Numerical value Unit Temperature range 5 – 45 °C Maximum relative humidity 60 % Maximum installation altitude above sea level 1 000 m 5.2.2 Operating materials FAS03 –06 Type Lubricant Oil quantity Unit FAS03 Oil 1.6 Gal FAS04 Oil 1.6 Gal FAS06 Oil 1.6 Gal Type Lubricant Oil quantity Unit FAS07 Oil 2.1 Gal FAS11 Oil 2.
Design and function FAS18 – 22 Type Lubricant Oil quantity Unit FAS18 Oil 3.2 Gal FAS22 Oil 3.2 Gal Type Lubricant Oil quantity Unit FAS30 Oil 4.75 Gal FAS37 Oil 4.75 Gal FAS30 – 37 5.2.
Design and function FAS15 Compressed air outlet Cooling air volume G/DN m³/h G 3/4 1200 Compressed air outlet Cooling air volume G/DN m³/h FAS18 G 11/4 5300 FAS22 G 11/4 5300 Compressed air outlet Cooling air volume G/DN m³/h FAS30 G 11/2 10 500 FAS37 G 11/2 10 500 Type FAS15 FAS18 – 22 Type FAS30 – 37 Type 30 firstAir screw compressor FAS03 – 37
Design and function 5.3 FAS03 – 37 5.3.1 Power and dimensions FAS03-6 Type Rated motor output Screw compressor (standard) Weight Screw compressor (incl. Screw compressor (incl. compressed air tank) compressed air tank and dryer) kW LxWx H [mm] FAS03 3 660 × 600 × 890 220 1500 × 600 × 1440 335 1450 × 600 × 1440 425 FAS04 4 660 × 600 × 890 230 1500 × 600 × 1440 345 1450 × 600 × 1440 435 FAS06 5.
Design and function FAS07 – 11 Type Screw compressor (standard) Screw compressor (incl. Screw compressor (incl. compressed air tank) compressed air tank and dryer) kW LxW xH [mm] FAS07 7.
Design and function FAS30 – 37 Type Rated motor output kW Screw compressor Weight L x W x H [mm] [kg] FAS30 30 1000 × 1250 × 1310 850 FAS37 37 1000 × 1250 × 1310 880 5.3.2 Connection values FAS03-6 230 V / 460V - 60 Hz current value Type SFA FAS031 20 FAS033 12.8 / 6.4 FAS041 27.5 FAS043 17.7 / 8.8 FAS061 34.6 FAS063 22.9 / 11.5 FAS07 – 11 230 V / 460V - 60 Hz current value Type SFA FAS073 28.2 / 14.2 FAS113 40.9 / 20.
Design and function FAS15 230 V / 460V - 60 Hz current value Type SFA FAS153 61 / 30.4 FAS18 – 22 230V / 460 V - 60 Hz current value Type SFA FAS183 74.4 / 37.1 FAS223 83.8 / 41.9 FAS30 – 37 230V / 460 V - 60 Hz current value 34 Type SFA FAS303 115 / 57.5 FAS373 138.8 / 69.
Installation 6. Screw compressor installation 6.1 Safety instructions for installation and commissioning Electrical system DANGER! Danger to life due to electric current! Danger to life in the event of contact with live components. Active electrical components may make uncontrolled movements and result in severe injuries or even death. - Improper commissioning Switch off the electric power and secure it against a restart before starting work.
Installation Securing against a restart WARNING! Danger of fatal injury due to unauthorised restart! Switching the power supply back on without authorisation during installation presents a danger of severe injuries, or even death, for persons working in the danger zone. - Improper installation and commissioning Switch off all power supplies and secure them against a restart before starting work.
Installation 6.2 Requirements for the installation location Set up the screw compressor so that the following conditions are complied with: • The installation location is level. • The stability of the machine is guaranteed. • The machine is easily accessible and can be accessed from all sides. • There is sufficient lighting. • There is sufficient ventilation. • A power supply is available. • Escape routes and rescue equipment are freely accessible.
Installation 6.4 Information about lines and the foundation 6.4.1 Dangers due to mechanical elements Moving parts WARNING! Danger of injury due to moving components! Rotating parts or parts making linear motions can cause serious injuries. Sharp edges and pointed corners - Never reach into moving parts or handle moving parts during operation. - Do not open covers during operation. - Be aware of the stop delay: Make sure that all parts have stopped moving before opening any covers.
Installation Stored charges - Any work on the electrical system must be performed by qualified electricians. - In the event of damage to insulation, shut down power supply immediately and have repairs performed. - Before working on active parts of electrical systems and equipment, always disconnect these from the mains supply and ensure they remain disconnected for the duration of the work. In doing so, observe the 5 safety rules: - Isolate from electrical supply. - Secure against restart.
Installation In the event of installation in a closed room, install an air extraction device on the top of the machine to discharge the hot air. The cooling air inlet is positioned on this side, and requires a free space of at least 500 mm. The floor must be level and horizontal. Provide rubber padding on the four corners to minimise vibrations and noise development. Ensure their is a free space for maintenance of 700 mm at the front.
Protective and warning devices 7 Interfaces and function of the individual components 7.1 Interfaces 7.1.1 Compressed air route Dust is filtered from the intake air in the intake filter, and is then conducted through the intake regulator to the compressor stage, where it is compressed and mixed with the Oil. It flows from there to the Oil pressure tank. The compressed air enters the consumer network through the oil separator, the minimum pressure valve and the compressed air aftercooler. 7.1.
Protective and warning devices 6. Oil separator The oil separator removes additional Oil from the compressed air. The oil separator needs to be removed in specific time intervals. The maintenance interval is stored in the controller, and can be changed if ambient conditions vary. 7 . Minimum pressure and non-return valve The minimum pressure valve is installed above the Oil–air tank and only opens when the system pressure increases to 4.5 bar.
Protective and warning devices of dust can quickly form on the air cooler fins, impairing the cooling effect. This can result in high compressed air final temperatures and, ultimately, to the system overheating. This is why the cooler fins need to be cleaned regularly. Make sure that the surface of the cooler remains clean. 2 . Oil filter The Oil filter is a paper filter that can filter contaminants out of the Oil, such as metal particles.
Protective and warning devices 8 Protective and warning devices 8.1 Motor overload protection There are two electric motors in the screw compressor – a main drive motor and a motor for the cooling air fan. When the operating current exceeds the set upper limit for the protective device under normal operating conditions, the overload protection device automatically shuts down the power supply.
Protective and warning devices
Electrical circuit diagram 9.
Transportation, packaging, storage FAS03 – 06 3 PHASE (DOL)
Electrical circuit diagram FAS07 – 37 3 PHASE (Y-D) 48 firstAir screw compressor FAS03 – 37
Transportation, packaging, storage 10 Transportation, packaging and storage 10.1 Safety instructions for transportation Improper transportation NOTE! Property damage due to improper transportation! Improper transportation can cause packages to fall or topple over. This can cause considerable property damage. - Proceed with caution when unloading packages upon delivery and when transporting them on the premises, and observe the symbols and instructions on the packaging.
Transportation, packaging, storage 10.3 Packaging About the packaging The individual screw compressors are packaged in cartons or, at times, on wooden frames and in accordance with the expected transport conditions. Only environmentally-friendly materials are used for the packaging. The packaging is designed to protect the individual components from transport damage, corrosion and other damage until they are installed.
Transportation, packaging, storage 10.3.1 Symbols on the packaging The following symbols are affixed to the packaging. Always observe these symbols during transportation. Top The tips of the arrows point to the top of the package. They must always point upwards, as otherwise the content may be damaged. Fragile Identified packages with fragile or sensitive content. Handle the package with care, do not drop it and do not subject it to impacts.
Transportation, packaging, storage Transporting 1. Use the fork lift with the forks inserted as shown in fig. 5. 2. Insert the forks so that they protrude on the other side. 3. Ensure that the package cannot tip if the centre of gravity is offcentre. 4. Lift the package and begin transportation. Fig. 5: Transportation with a fork lift 10.5 Storage Storage of the packages Store the packages under the following conditions: • Do not store outdoors. • Store in a dry and dust-free environment.
Operation 11 Operation 11.1 Operating 11.1.1 Safety instructions for operation Improper operation WARNING! Danger of injury due to improper operation! Improper operation may result in serious injuries and considerable property damage. - Carry out all operating steps in accordance with the specifications and information in these instructions. - Before starting work, observe the following: - - Ensure that all covers and safety equipment are installed and function properly.
Operation 9. Following rescue measures Inform the responsible authorities if the severity of the emergency requires this. 10. Assign specialist personnel to rectify the fault. WARNING! Risk of fatal injury if the machine is restarted without authorisation or in an uncontrolled manner! An uncontrolled or unauthorised restart of the power supply can result in severe or fatal injuries.
Operation 11.3.2 Connecting to the power supply Personnel: Qualified electrician Protective equipment: Protective work clothing Safety shoes NOTE! Danger of material damage to the compressor stage as a result of incorrect connection of the power supply! In the event of incorrect connection of the power supply, the compressor stage may be destroyed due to an incorrectly rotating drive.
Operation 11.3.3 Connecting to the compressed air network Personnel: Qualified personnel Protective equipment: Protective work clothing Materials: Flexible compressed air hose, max. 1.5 m Safety shoes WARNING! Danger of injury due to unpredictable movement of the compressed air hose! Load switches in the compressed air network cause the compressed air hose to move suddenly, and with high force. - Anchor and fasten the compressed air hose sufficiently.
Operation Press “ON”. The compressor starts operation. The current compressor data appear on the controller display. Pressing the “OFF” switch makes the controller switch off the motor once the run-on time has elapsed. (The switch-off delay prevents the compressor from stopping immediately under heavy loads and Oil from escaping from the intake side This does not apply for “EMERGENCY STOP”; in this case, the compressor shuts down immediately!) 11.3.5 Precautionary measures during operation 1.
Operation Condensate is heavier than the Oil Because the condensate is heavier than the Oil, it collects on the bottom of the Oil pressure tank after extended downtime. 11.3.6 Break in period The compressor comes from the factory filled with break-in fluid. This fluid needs to be replaced after 500 hours of operation. After 500 hours, replace the oil and oil filter.
Operation
Operating instructions 12 Instructions for operation 12.1 Control panel 1 2 6 5 4 3 7 12.2 Description of the individual buttons 1 START – Starts and operates the screw compressor, as long as it is free of faults, and switches from “Shutdown” to “Operation” mode. 2 STOP: Stops compressor operation. 3 SET – Press this button after changing parameters to confirm the input data. 4 ARROW UP – Press this button when changing data to increase the value.
Operating instructions 12.3 Characteristics of the digital inputs and outputs Description of the control interface JP1 No.
Operating instructions JP4 No. Designation Description 1 DI0 Air filter signal input (usually open) 2 DI1 Oil filter signal input (usually open) 3 DI2 Precipitator element signal input (usually open) 4 DI3 Pressure switchover input (usually open) 5 DI4 Emergency stop signal input (usually closed) 6 GND Ground 7 A RS485 8 B RS485 JP3 No.
Operating instructions 12.4 Operating the screw compressor 12.4.1 Start and start side After switching on the controller, the operating display on the control panel lights up. A start page appears on the screen. The standard screen appears automatically after 5 seconds. Pa 40C The pressure generated, the compressor temperature and the speed in percent are shown in the screen shown above. 12.4.
Operating instructions Entering a password 0000 If the password entered is correct, press “F” (6) to open the menu. “Controller”, “Time” and “Maintenance” then appear on the screen. Press “ESC” (7) to return to page 1 for the compressor. Controller Maintenance Time The current menu is marked at the right by “◆”. If the symbol “◆” displays the selected function, press “F” (6) to open the operating screen. To change between parameters, press “ARROW UP” (4) or “ARROW DOWN” (5).
Operating instructions 12.5.2 Alarm due to minor faults A minor fault is signalised in the status bar of the control panel. The compressor does not stop; you will, however, be informed that a minor intervention is required. No.
Operating instructions 12.5.3 Alarm due to major faults If a major fault occurs and the system cannot be restarted, the compressor stops. Rectify the problem and restart the compressor. A major fault is displayed in the status line of the controller. No.
Operating instructions 15 Inverter fault An inverter feedback fault has occurred.
Maintenance 13 Maintenance 13.1 Safety instructions for maintenance Electrical system DANGER! Danger to life due to electric current! Danger to life in the event of contact with live components. Active electrical components may make uncontrolled movements and result in severe injuries. - Moving parts Switch off the electric power and secure it against a restart before starting work.
Maintenance Hot surfaces WARNING! Danger of injury due to hot surfaces! The surfaces of components, and operating materials (e.g. Oil or cooling water) may heat up considerably during operation. Contact between the skin and hot surfaces and liquids cause serious burns to the skin. Improperly performed maintenance work - When performing any work near hot surfaces, heatresistant occupational safety clothing and protective gloves must be worn.
Maintenance Compressed air WARNING! Danger of injury due to compressed air! Compressed air can escape from compressed air hoses or components under pressure in the event of improper handling or in the event of a fault. This can result in eye injuries, dust being raised, or hoses making uncontrolled movements. Pressurised components can move in uncontrolled manner and can cause injuries if handled incorrectly. Oil mist - Before removing pressurised hoses or components, depressurise them.
Maintenance Environmental protection Adhere to the following instructions on environmental protection when performing maintenance work: Remove any escaped, used or excess grease from all lubrication points which are supplied with lubricant by hand and dispose of it in accordance with the applicable local regulations. Collect replaced Oils in suitable containers and dispose of them in accordance with the applicable local regulations.
Maintenance 13.3 Maintenance No.
Maintenance No.
Maintenance 13.4 Measures on completion of maintenance After completion of the maintenance work and before switching the machine on, carry out the following steps: 74 1. Check all screw connections which were unfastened beforehand to make sure they are tightened. 2. Check whether all protective devices and covers removed beforehand have been reinstalled properly. 3. Ensure that all tools, materials and other items of equipment that were used have been removed from the work area. 4.
Troubleshooting 14 Troubleshooting the screw compressor Fault description Cause Remedy Personnel Compression temperature too high Intake or ambient temperature too high Ventilate compressor room Trained person Cooling air intake or outlet blocked Unblock cooling air intake or outlet sufficiently Trained person Oil contains contaminants Replace the Oil Qualified personnel Oil low Refill Oil Qualified personnel Oil cooler contains contaminants Clean the Oil cooler Qualified personnel Com
Troubleshooting Fault description Cause Remedy Personnel Screw compressor discharges via safety valve Minimum pressure valve blocked Clean or replace minimum pressure valve Manufacturer Safety valve faulty Check safety valve and replace if necessary Manufacturer Oil separator clogged Replace the oil separator Qualified personnel Oil separator clogged Replace the oil separator Qualified personnel Higher outside pressure present in compressed air network Equalise outside pressure or disconne
Troubleshooting Fault description Cause Remedy Personnel System does not start up when the start switch is pressed Network pressure higher than switch-on pressure Observe network pressure and change settings Trained person “Lokl” or “Remo” symbol flashes Remote control activated Trained person No voltage at the screw compressor Check whether there is voltage Qualified electrician Electrical fault in the controller Check controller Qualified electrician Return line for the Oil is blocked Cl
Troubleshooting 14.1 Commissioning after rectifying a fault After rectifying the fault, carry out the following steps for recommissioning: 1. Check all screw connections which were unfastened beforehand to make sure they are tightened. 2. Ensure that all tools, materials and other items of equipment that were used have been removed from the work area. 3. Check whether all protective devices and covers removed beforehand have been reinstalled properly. 4. Reset emergency stop equipment. 5.
Dismantling and disposal 15 Dismantling and disposal Once the service life has ended, the machine must be dismantled and disposed of in an environmentally responsible manner. 15.1 Safety instructions for dismantling and disposal Electrical system DANGER! Danger to life due to electric current! Danger to life in the event of contact with live components. Active electrical components may make uncontrolled movements and result in severe injuries.
Dismantling and disposal 15.2 Dismantling Before starting dismantling: • Switch the machine off and secure to prevent a restart. • Physically disconnect the entire power supply from the machine, allow stored residual energy to discharge. • Remove operating materials and auxiliary materials, as well as residual processing materials and dispose of them in an environmentally responsible manner.
Dismantling and disposal firstAir screw compressor FAS03 – 37 81
