CompAir D50H RS Service manual

Original Operating and Service Manual
Screw Air Compressor
D50H RS -D110H RS
V2
●
GB Id. no. ZS1098950 / 04 - June 2014

Deutsche Basis BA - ZS1098949 / 04 1
General Information
These compressors are for compressing atmospheric air and are not suitable for compressing any other gas. They are
designed and manufactured to give optimum performance with long life and reliability.
This manual gives the user all the information required to install and operate the compressors and carry out the regular
schedules for servicing and maintenance, which will ensure the maximum satisfactory service life.
Servicing facilities and the supply of genuine replacement parts are provided through a worldwide network of CompAir
Companies and Distributors. If replacement parts are needed, the user should, in the first instance, contact the local
CompAir Company or Distributor.
The information given in this manual was correct at the time of printing, however, as part of continuous development,
modifications to parts and procedures may be made without notice which could affect the servicing requirements of the
compressors. Before any servicing or maintenance work is undertaken the user is advised to contact the local CompAir
Company or Distributor who is supplied with revised and up-dated information.
In any communication concerning the compressor it is essential to quote the MODEL, SERIAL NUMBER and where
possible the YEAR of MANUFACTURE.
All pressure data given in this manual refer to overpressures (pressure gauge pressures) unless specified otherwise.
Maintenance
To ensure the continued trouble-free operation of the compressor unit it is important that periodic maintenance and
servicing is carried out in accordance with the information given in the ʻMaintenanceʼsection of this manual. To assist in
this matter your local CompAir Company or Distributor can provide a number of optional maintenance agreements to suit
your requirements. These agreements provide the user with the expertise of our factory trained technicians and the
guarantee that only Genuine CompAir parts will be used.
Warranty
The conditions of the CompAir Warranty are set out in the Companyʼs standard Conditions of Sale available from the
Gardner Denver Company or Distributor supplying the machine.
USE ONLY COMPAIR GENUINE PARTS. YOUR WARRANTY
COULD BE AFFECTED IF A SERVICE OR REPAIR IS
CARRIED OUT USING NON-GENUINE PARTS.

Data sheet for users
2
Fig. 1
Your CompAir distributor
Name:
Address: _____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
Telephone: Fax:
Contact: Spare Parts:
Service:

1. Foreword
3
1Fore w ord
1.1 Notes on the compressor
CompAir screw compressors are the result of many
years of research and development. These
prerequisites combined with high quality standards
guarantee the manufacture of screw compressors
providing a long service life, high reliability and cost-
effective operation. It stands to reason that all
requirements concerning environmental protection are
met.
1.2 Intended use
The machine/unit has been constructed in accordance
with state-of-the-art technology and the recognized
safety regulations. Nevertheless, its use may constitute
a risk to life and limb of the user or third persons or
cause damage to the machine or to other material
property, if
•it is not used as intended,
•it is operated by unqualified personnel,
•it is improperly modified or changed,
•the safety regulations are not observed.
Therefore, any person entrusted with the operation,
maintenance or repair of the machine must read and
follow the safety regulations. If required, this has to be
acknowledged by signature.
In addition,
•relevant accident prevention regulations,
•generally recognized safety regulations and
•national regulations
have to be observed.
The machine/unit must only be used in technically
perfect condition and in accordance with its intended
use and the instructions set out in the operating
manual, and only by safety-conscious persons who are
fully aware of the risks involved in operating the
machine/unit! Any functional defects, especially those
affecting safety, have to be rectified immediately (or
rectified by others)!
The machine/unit is designed exclusively for the
generation of compressed air to power air-driven
devices. Using the machine/unit for purposes other than
those mentioned above is considered contrary to its
intended use. The manufacturer/supplier cannot be held
responsible for damage resulting from such use. The
risk of such misuse lies solely with the user.
Operating the machine within the limits of its intended
use also involves observing the instructions set out in
the operating manual and complying with the inspection
and maintenance directives.
1.3 Maintenance
Carefully performed maintenance is imperative, this
ensures that your screw compressor can meet all the
requirements placed upon it. It is therefore imperative to
adhere to the specified maintenance intervals and to
carry out the maintenance work with particular care,
especially when the unit is utilized under harsh
operating conditions.
Servicing
Please contact your authorized CompAir dealer in the
case of malfunctions or when spare parts are required.
In the case of damage, our fully trained personnel will
ensure that a quick and proper repair is carried out
using genuine CompAir spare parts. Genuine CompAir
spare parts are manufactured utilizing state-of-the-art
technology, thus guaranteeing the further reliable
operation of the unit.
In case of queries
Please enter the data on the nameplate of your
compressor into the nameplate shown in fig.1 on p. 2.
In the case of queries or spare parts orders, please
refer to the compressor type indicated on the
nameplate, the identification no. and the year of
construction. With this information at hand it can be
guaranteed that you will receive the right information or
required spare parts.
1.4 Notes
General
These operating instructions are intended to familiarize
the user with the machine/unit and its intended use. The
instructions contain important notes on how to operate
the compressor safely, properly and cost-effectively.
Observing these instructions helps to avoid risks, to
reduce repair costs and downtimes and to increase the
reliability and service life of the machine/unit.
The operating instructions have to be supplemented by
the respective national rules and regulations regarding
the prevention of accidents and environmental
protection. They must always be available at the
location of the machine/unit. The operating instructions
must be read and followed by any person carrying out
work in connection with the machine/unit, e.g.
operation, including setting up, trouble-shooting in the
operation cycles, disposal of production waste, care,
service, and disposal of waste fuels and consumables,
upkeep (maintenance, inspection, repair), transport.

1. Foreword
4
Besides the operating instructions and the binding
regulations for the prevention of accidents, which are
valid in the country and place of operation of the
machine/unit, the generally recognized technical
regulations for safe and proper working have also to be
observed.
Guarantee
Operate this compressor only if you have an exact
knowledge of the machine taking into respect these
instructions.
Gardner Denver cannot be held responsible for the safe
operation of the machine/unit if it is used in a manner
which does not correspond to the intended use, or for
other applications which are not mentioned in these
instructions.
Warranty claims will not be accepted in the case of
•Operating errors
•Incorrect maintenance
•Wrong auxiliary materials
•Use of spare parts other than CompAir genuine
spare parts
•Modifications and changes to the installation
The warranty and liability conditions of the general
terms and conditions of Gardner Denver will not be
extended by the notes above.
Any unauthorized change to the compressor unit/
station, or the installation of components not accepted
by the manufacturer (e.g. air filter) will result in the
withdrawal of the CE mark. As a consequence, any
liability and warranty claims will not be accepted by the
manufacturer.
Safety regulations
Danger
The safety regulations in chapter 3of the operating
instructions have to be strictly observed.
Technical changes
In the course of technical development we reserve the
right to modify the units without further notice.

2. Table of contents
5
2Tab le of c ont e nts
1Foreword...............................................................................................................................................................................3
1.1 Notes on the compressor .............................................................................................................................................3
1.2 Intended use..................................................................................................................................................................3
1.3 Maintenance..................................................................................................................................................................3
1.4 Notes .............................................................................................................................................................................3
2Table of contents.................................................................................................................................................................5
3Safety regulations ...............................................................................................................................................................7
3.1 Identification of safety guidelines .................................................................................................................................7
3.2 General safety regulations ...........................................................................................................................................7
3.3 Particular dangers associated with compressed air ...................................................................................................8
3.4 Particular dangers associated with machines...........................................................................................................10
3.5 Particular dangers associated with water-cooled units.............................................................................................10
3.6 Dangers present when loading/moving machines ....................................................................................................11
3.7 General workplace dangers .......................................................................................................................................11
3.8 Dangers resulting from neglecting to perform maintenance.....................................................................................12
3.9 Dangers during maintenance and repairs .................................................................................................................12
3.10 Dangers resulting from conversion work/modifications on the machine..................................................................14
3.11 Symbols and explanations .........................................................................................................................................15
4Design and functioning ....................................................................................................................................................17
4.1 Design of the unit ........................................................................................................................................................17
4.1.1 Design of the water-cooled D110H RS-W .....................................................................................................17
4.1.2 Design of the water-cooled D50H RS-W -D75H RS-W................................................................................18
4.1.3 Design of the air-cooled D50H RS-A -D75H RS-A.......................................................................................19
4.2 Schematic diagram .....................................................................................................................................................20
4.2.1 Schematic diagram -D110H RS ....................................................................................................................20
4.2.2 Schematic diagram -D50H RS -D75H RS ...................................................................................................21
4.3 Water circuit ................................................................................................................................................................22
4.4 Air circulation...............................................................................................................................................................22
4.5 Control .........................................................................................................................................................................22
5Transport and installation ................................................................................................................................................24
5.1 Transport .....................................................................................................................................................................24
5.2 Installation ...................................................................................................................................................................25
6Preparations for commissioning ....................................................................................................................................26
6.1 Cooling air volume/minimum cross ............................................................................................................................26
6.2 Compressed air connection........................................................................................................................................26
6.3 Water connection for W type ......................................................................................................................................27
6.3.1 Limit values of the constituent elements in water..........................................................................................28
6.4 Electrical connection...................................................................................................................................................29
6.4.1 Electrical connection (EUROPE-Version only)..............................................................................................29
6.4.2 Check setting of the fan protection switch .....................................................................................................30
6.4.3 Checking the control transformer setting .......................................................................................................31
6.5 Water supply ...............................................................................................................................................................31
6.5.1 First-time water filling ......................................................................................................................................31
6.6 Extraction of water samples .......................................................................................................................................32
6.7 Sound pressure level..................................................................................................................................................32
7Commissioning ..................................................................................................................................................................33
7.1 First commissioning ....................................................................................................................................................33
7.2 Putting a decommissioned compressor back into operation....................................................................................34
7.3 Display of the compressor control DELCOS XL........................................................................................................34
7.4 Routine commissioning ..............................................................................................................................................35
7.5 Commissioning after malfunction...............................................................................................................................35
7.6 Shutoff .........................................................................................................................................................................35
7.7 Emergency stop ..........................................................................................................................................................35
8Storage of compressors...................................................................................................................................................36
8.1 Shutdown.....................................................................................................................................................................36

2. Table of contents
6
9Service and maintenance.................................................................................................................................................37
9.1 Maintenance recommendations.................................................................................................................................37
9.2 Maintenance electric motor ........................................................................................................................................37
9.2.1 Motor lubrication system.................................................................................................................................37
9.2.2 Structure of the lubricators..............................................................................................................................37
9.2.3 Changing the LC unit ......................................................................................................................................37
9.2.4 Function display on lubricator.........................................................................................................................38
9.2.5 Troubleshooting and fault rectification for lubricator .....................................................................................39
9.3 Maintenance and inspection schedule ......................................................................................................................39
9.4 Change of air intake filter............................................................................................................................................42
9.5 Change water filter......................................................................................................................................................42
9.6 Replace prefilter RO unit ............................................................................................................................................43
9.7 Change the RO membrane cartridge.........................................................................................................................43
9.8 Safety valve.................................................................................................................................................................44
9.9 Connecting terminals in the switch cabinet/control transformer setting...................................................................44
9.10 Fittings .........................................................................................................................................................................45
9.11 General maintenance and cleaning ...........................................................................................................................45
9.12 Clean / change filter with cooling air inlet and control cabinet inlet..........................................................................45
9.13 Cleaning of the bearing flushing system....................................................................................................................46
9.14 Inspection of the compressor stage ...........................................................................................................................47
9.15 Inspection intervals for pressure vessels and electrical installations.......................................................................47
9.16 Checking the water level sensor ................................................................................................................................48
10 Trouble-shooting ...............................................................................................................................................................49
11 Annex...................................................................................................................................................................................51
11.1 Technical data.............................................................................................................................................................51
11.1.1 Technical data EUROPE version water-cooled D110H RS-W .....................................................................51
11.1.2 Technical data EUROPE version water-cooled D75H RS-W .......................................................................52
11.1.3 Technical data EUROPE version air-cooled D75H RS-A .............................................................................53
11.1.4 Technical data EUROPE version water-cooled D50H RS-W .......................................................................54
11.1.5 Technical data EUROPE version air-cooled D50H RS-A .............................................................................55
11.2 Layout plan..................................................................................................................................................................56
11.2.1 Layout plan D110H RS ...................................................................................................................................56
11.2.2 Layout plan D50H RS-D75H RS ....................................................................................................................58
11.3 Declaration of conformity............................................................................................................................................60

3. Safety regulations
7
3Safety re gulations
3.1 Identification of safety guidelines
Gardner Denver is not liable for any damage or injury
resulting from the non-observance of these safety
instructions or negligence of the usual care and
attention required during handling, operation,
maintenance or repair, even if this is not explicitly
mentioned in these operating instructions.
If any of the regulations contained in these instructions
-especially with regard to safety -does not correspond
to the local legal provisions, the stricter of both shall
prevail.
These safety regulations are general and valid for
various types of machines and equipment. It is
therefore possible that some references do not apply to
the unit(s) described in these instructions.
Danger
Passages marked with this sign indicate a possible
danger to persons.
Important
Passages marked with this sign indicate a possible
danger to machines or part of machines.
Note
Passages marked with this sign provide technical
information on an optimal cost-effective use of the
machine.
3.2 General safety regulations
Danger
Safety measure required
Working with compressors involves
dangers that are not immediately
apparent.
Everyone working with the machine must have first read and understood the
operating manual. Donʼt leave this until you start work –itʼs too late.
Please keep this operating manual handy at all times on the site of the
machine / installation, in the bag provided.
Pay attention to all safety and danger warnings on the machine/ installation!
Deploy trained staff only. The responsibility of the personnel for operating,
setting up and maintaining the machine / installation must be clearly defined.
Make sure that only authorized personnel use the machine.
Define who is responsible for operating the machine, and authorize him to
ignore instructions from third parties if these instructions could compromise
safety.
Symbols on the machine indicating
dangers may become dirty or
disappear.
Ensure that all safety and danger notices on the machine/system stay fully
legible.
Faults and modifications to the machine
may jeopardise safety.
In the event of malfunctions, shut the machine/system down immediately and
secure it from being switched on again! Have malfunctions corrected
immediately.
Check the machine / installation for external damage and faults at least once
per shift.
Any changes noticed (including changes in operating performance) must be
reported immediately to the authority or person in charge. If necessary, shut
down and secure it from being switched on again.

3. Safety regulations
8
3.3 Particular dangers associated with compressed air
Danger
Safety measure required
Compressed air is very powerful. It can
be used for example to break open
concrete but can also put lives at risk.
Never play about with compressed air.
Small parts propelled at high speed by
compressed air can penetrate the skin
or destroy an eye.
When using compressed air to clean equipment, work with extreme caution
and always wear suitable eye protection.
Never direct compressed air onto the skin or towards another person.
Never use compressed air for cleaning clothing.
Compressed air connections may split
and put people at risk.
Only connect the compressor to the existing compressed air system when the
service temperatures and service pressures are correct and the connecting
flange and connecting thread are in full working order.
All connected components must be of the correct size and be suitable for the
specified operating pressure and temperature (i.e. distributing pipes and pipe
connections).
A hose connected to an air valve must be fitted with a safety wire for
operating pressures above 7 bars; it is in fact recommended that this safety
device should be used for pressures above 4 bars. The steel wire has a
diameter of 8 mm and is firmly clamped to the hose at least every 500 mm.
Both ends are fitted with cable lugs.
Do not use chafed, damaged or poor-quality hoses.
Only use the correct type and size of hose coupling and connection.
The compressed air line connected at the air exit of the unit must not be
under strain.
No force should be applied to the outlet thread or the outlet flange by, for
example, pulling on the lines or by mounting additional equipment
(e.g. a water separator or a pneumatic oiler, etc.)
Compressed air lines may be breached
by accident.
Compressed-air lines have to be marked distinctly according to local
regulations.
Compressed air lines get hot and
expand.
Make sure that the compressed air line from the compressor to the air
network can expand as a result of heat.
Loose hose ends may flog and result in
injury.
Fix the hose in such a way that it does not lash if the connection is broken.
Before blowing through a hose or air line, it is essential to hold the open end
firmly.
Before disconnecting a hose, always make sure that it is not under pressure.

3. Safety regulations
9
Danger
Safety measure required
Compression results in high
temperatures.
The system should be set up such that hazardous mixtures (inflammable
solvent vapours etc. but also dusts and other dangerous or toxic materials)
cannot be drawn in. The same applies to flying sparks.
Never use the machine in environments where the possibility cannot be ruled
out that inflammable or toxic vapours may be taken in.
The installation is to be set up in such a way that it is adequately accessible
and that the necessary cooling is ensured. Never block the admission of air.
Compressor units must never be operated in areas subject to explosion
hazards! (Exception: Special units with the corresponding technical
modifications)
There is strong suction at the air inlet.
The air intake is to be designed in such a way that no loose clothing can be
drawn in.
There is a risk of injury, e.g. from getting
stuck or being drawn in.
The personnel must not have long, loose hair, or wear loose clothing or
jewellery, including rings, due to risk of injury through catching. Personal
protective equipment should be worn if necessary.
Connected compressed air tools may
start up unexpectedly when switching
on.
Before switching on the machine / installation, or starting it up, make sure that
nobody can be injured by the machine / installation as it starts up.
Compressed air may contain
substances that may damage your
health if inhaled.
The compressed air produced by these compressors must not be used as
breathable air, unless it has been processed specially for such an application
in accordance with the “Safety requirements for breathable air.”
When breathing apparatus with cartridges is used, make sure that the correct
cartridge has been inserted and that its service life has not expired.
The safety valves in the system only
guarantee the pressure relief for the
compressor unit.
The pressure devices/systems connected to the compressor must be secured
allowing for the weakest pressurised component (safety valve or similar).
As a rule:
If several compressors are arranged in a system, manually operated valves
have to be installed so that each machine may be shut off individually. For the
purpose of shutting off pressurized systems, you should never rely on the
effectiveness of return valves alone.
All pressure tanks located outside the unit with an approved operating
pressure higher than atmospheric pressure and fitted with two or more
pressure feed lines must be equipped with an additional safety device to
automatically prevent the approved operating pressure from being exceeded
by more than 10%.
Never operate the system at temperatures and/or pressures below or above
the values indicated in the technical data sheet.

3. Safety regulations
10
3.4 Particular dangers associated with machines
Danger
Safety measure required
Risk of electric shock.
Electrical connections must meet the local regulations. Power units must be
connected to earth and protected from short-circuits by means of fuses.
Insufficient power quality could have
a strong effect on health & safety and
may constitute a risk to life and limb
of the user or third persons.
Always check a correct power supply to the compressor before commissioning.
The voltage supply has to fulfill the requirements of EN60204-1/IEC60204-1 for
such kind of industrial equipment.
Remote-controlled units may start up
unexpectedly.
If a remote control is used, the system must carry a clearly visible sign with the
following note: Attention! This installation is operated by remote control and can
start up without prior warning!
As an additional safety measure, persons, who start remotely controlled systems,
have to take sufficient safety precautions in order to ensure that nobody is
checking the system or working on it. For this, a label with a corresponding
warning notice has to be attached to the remote control equipment.
Noise, even when it is not very loud,
can make us nervous and irritated,
and after a longer period of time our
nervous system can suffer serious
damage.
We recommend a separate machine room in order to keep the noise of the
machine away from the workshop.
Where necessary, wear the personal hearing protection.
In order to consider all noise-relevant parameters and to adequately protect the
health of the operator, the European Regulation 2003/10/EC must be satisfied
completely by the user. In states outside the European Community, the
respective noise protection directives must be taken into consideration.
Shielding and doors must be closed during operation so that the efficiency of the
sound insulating is not reduced.
3.5 Particular dangers associated with water-cooled units
Danger
Safety measure required
If open cooling towers are used in the
cooling water circuit, it is possible for
legionella (Legionella pneumophila)
and other bacteria to grow and
spread.
The growth and spread of bacteria must be prevented by corresponding service
and water treatment methods.

3. Safety regulations
11
3.6 Dangers present when loading/moving machines
Danger
Safety measure required
Loose parts may fall off when lifting.
All loose parts must first be removed or secured; parts fitted so that they can
turn like doors etc. must be secured and made immobile.
Parts to be removed for transport purposes must be carefully refitted and
fixed again before putting the machine / installation back into operation.
The compressor may fall if mistakes are
made when lifting.
Only use lifting tackle approved for the weight in question.
Observe the operating manual for the lifting tackle.
When heavy loads are being conveyed by means of hoisting gear, it is
imperative to keep well clear of the load in order to avoid accidents.
The person giving the instructions must be within sight or voice contact with
the operator.
Safety components may be damaged if
lifted incorrectly.
Machines may only be hoisted correctly using hoisting gear in accordance
with the information in the operating manual (lifting spots for heavy-lift
facilities etc.)
To avoid damage to the system or external installations, the compressed air
connection, cooling water connection, condensate drain and electrical
connection should be isolated from external lines and hoses.
The system must be set up on a level surface with full contact between its
base frame and the supporting surface.
3.7 General workplace dangers
Danger
Safety measure required
This manual only describes how to work
safely with the compressor itself. But
other dangers will arise during work.
Please note and pass on general statutory and other binding regulations that
may supplement the operating manual for the prevention of accidents and the
protection of the environment. Such obligations may be for example the
handling of hazardous materials, or the provision and/or wearing of personal
protective equipment, or traffic regulations.
Instructions, including supervisory responsibility and duty of notification for
taking account of special in-plant factors, for example regarding work
organization, sequences of operations, personnel assigned to certain tasks,
are to be added to the operating manual.
Before starting work, make yourself familiar with the working environment at
the installation site.
The location and operation of fire extinguishers must be made known.
Observe the instructions concerning fire alarm and fire fighting.
Set up the machine in such a way that no inlets, outlets or gates are blocked.
When handling chemical substances observe the safety regulations
applicable for the product.
Caution when handling process materials (risk of burning / scalding).

3. Safety regulations
12
3.8 Dangers resulting from neglecting to perform maintenance
Danger
Safety measure required
Components of importance to safety
wear over time.
Observe the setting, maintenance, and inspection work and intervals
stipulated in the operating manual, including information about the
replacement of parts / partial sections. This work may only be carried out by
specialists.
Observe the intervals stipulated or those given in the operating manual for
routine checks and inspections.
Verify regularly that safety valves and other pressure-relief devices are in
perfect condition and are not blocked, for example by dirt or paint
Check regularly that the safety mechanisms are fully functional. Have
malfunctions corrected immediately.
Lines perish.
Check regularly that all hoses and/or pipes within the system are in good
condition, firmly fixed and do not chafe.
Spurting water can result in injuries.
Check all lines, hoses, and bolted connections regularly for leaks and visible
damage. Repair damage immediately and always arrange for damaged parts
to be replaced!
Risk of electric shock.
Have the electrical equipment on a machine/system checked regularly. Have
defects like loose connections or charred cables rectified immediately.
Use only original fuses with the specified current rating. In the event of faults
with the electrical power supply, switch the machine/system off immediately,
and secure it from being switched on again!
In the event of faulty sensors, the
system can be led into a dangerous
state of operation.
Check the accuracy of pressure and temperature indicators at regular
intervals. If the admissible tolerance limits have been exceeded, these
devices have to be replaced.
3.9 Dangers during maintenance and repairs
Danger
Safety measure required
During maintenance and repairs, parts
that may be pressurised must be
removed. If you maintain the
compressor and have not been trained
by CompAir, you will put yourself and
others at risk.
The compressor can only be maintained by specially trained technicians.
Contact your CompAir agent.
Incorrectly configured spare parts may
jeopardise safety, e.g. tear when loaded.
Spare parts must meet the technical requirements laid down by the
manufacturer. This is always guaranteed when original spare parts are used.

3. Safety regulations
13
Danger
Safety measure required
Risk of electric shock.
Work on the electrical systems of the machine / installation may only be
carried out by a trained electrician in accordance with electrical regulations.
The system must be secured from being switched on. Seal off the main switch
and remove the key and/or attach a warning sign to the main switch.
Danger of electric shock from loaded condensers! Always first disconnect the
system from the power supply and wait another 10 minutes before touching
the electrical components. The power condensers require this time in order to
discharge!
The machine may start up
unexpectedly.
Only carry out maintenance and repair work when the system is not in
operation and the power supply disconnected. Ensure that the power unit
cannot be switched on inadvertently. The system must be secured from being
switched on.
Seal off the main switch and remove the key and/or attach a warning sign to
the main switch.
Risk of injury from pressurised or
moving parts.
Only carry out inspection, maintenance, and repair work when the screw com-
pressor system is at a standstill and is not under pressure. The system must
be secured from being switched on.
Before removing or opening pressurized components, positively isolate any
source of pressure and depressurize the entire system.
During the course of maintenance and
repairs, parts can be damaged which
are important for safety.
Never weld any pressure reservoir or change it in any way.
If work which produces heat, flames or sparks has to be carried out on a
machine, the adjacent components have to be protected by means of non
inflammable material.
Motor, air filter, electrical components and regulating equipment have to
protected from the ingress of humidity, e.g. when cleaning the system by
means of a steam jet.
Under no circumstance must the sound-proofing material be removed or
modified.
Never use etching solvents which could attack the materials used.
Before cleaning the machine with water or steam jet (high pressure cleaner)
or other cleaning agents, cover/mask all openings which have to be protected
from the ingress of water, steam or detergents for safety and/or functional
reasons, in particular electric motors and switch cabinets. After cleaning,
remove the covers/masking completely.
Modifications to the machine impair
safety.
After completing repair work, always check to see whether any tools, loose
parts or cloths have been left in or on the machine, driving engine or driving
equipment.
After the work has been completed, replace any protective devices that have
been removed. Operation without protective devices is not permissible.
Always re-tighten screwed connections which have been loosened for
maintenance and repair work.
Machines performing a rotating movement have to be cycled several times in
order to ensure that there are no mechanical faults in the machine or the drive
member.
Before releasing the power unit for operation after maintenance or overhaul,
check that the operating pressures, temperatures and time settings are
correct and that the regulating and shut-down equipment function properly.

3. Safety regulations
14
3.10 Dangers resulting from conversion work/modifications on the machine
Danger
Safety measure required
Genuine parts are designed especially
for the machine. Modifications may
interfere with safety equipment or give
rise to new dangers for which protection
is not provided.
No alterations, additions, or modifications to the machine may be carried out
without the approval of the manufacturer. Unauthorized modifications to the
machine are prohibited for reasons of safety.
Original parts are specially designed for our machines. We must explicitly
point out that parts and special accessories not supplied by us are not
approved by us. Installing or using such products may thus adversely affect
active and/or passive safety.
The manufacturer accepts no liability whatsoever for damage resulting from
the use of non-original parts or special accessories.
This also applies to the installation and adjustment of safety devices and
valves as well as to welding on bearing and pressurized parts
If protective equipment is not
functioning, operating the system may
put lives at risk.
Only operate the machine when all protective devices, shutdown devices,
sound-insulating equipment and extraction equipment are in place and
working.
Safety devices, protective covers, or insulations mounted on the system must
not be removed or modified in any way.

3. Safety regulations
15
3.11 Symbols and explanations
Carefully read the operating manual before
commissioning or servicing this compressor.
Never breathe in compressed air from this system.
Never operate the unit with open doors or loose access
panels.
Warning: Hot surface
Warning: Pressurized part or system
Warning: This system can start up by means of a remote
control or automatically after a power failure.

3. Safety regulations
16
Warning: The system continues to run for 30 seconds
after pressing the O-key
Warning: Danger of electric shock
Attention: Lifting point
Attention: Check and, if required, re-tighten connection
terminals. For further details, see the operating
instructions.
Attention: Opening pressure safety valve = xx bar
(value "xx" see sticker on compressor)
Attention: Danger of electric shock from loaded
condensers! Please always first disconnect the system
from the power supply and wait another 10 minutes
before touching the electrical components. The power
condensers require this time in order to discharge!
Check the DC bus voltage at the system terminal strip
of the frequency converter by measuring this between
the +DC and -DC terminals (the exact position can be
found in the supplied operating manual of the frequency
converter), between the +DC terminal and the chassis
as well as between the -DC terminal and the chassis.
The voltage must read zero in the case of all three
measurements.

4. Design and functioning
17
4Design and f unctioning
4.1 Design of the unit
4.1.1 Design of the water-cooled D110H RS-W
Fig. 2
1 Intake filter
2 Suction inlet
3 Electric motor
4 Screw compressor
5 Pressure reservoir
6 Water filter
7 RO-Unit
8 Safety valve
9 Pressure holding and check valve
10 Water connection
11 Cooling air ventilator
12 Cooling air inlet filter mat
13 Compressed air outlet
14 Base frame
15 Control keypad
16 EMERGENCY OFF
push-button
17 Control cabinet
18 Supply cable gland
19 Opening for lifting gear
20 Water cooler
21 Cooling water inlet
22 Cooling water outlet
23 Fan protection panel
24 Water level indicator
25 Water level sensor
26 Network pressure sensor
27 Final compression
pressure sensor
28 Final compression temperature
sensor

4. Design and functioning
18
4.1.2 Design of the water-cooled D50H RS-W -D75H RS-W
Fig. 3
1 Intake filter
2 Suction inlet
3 Electric motor
4 Screw compressor
5 Pressure reservoir
6 Water filter
7 RO-Unit
8 Safety valve
9 Pressure holding and check valve
10 Water connection
11 Cooling air ventilator
12 Cooling air inlet filter mat
13 Compressed air outlet
14 Base frame
15 Control keypad
16 EMERGENCY OFF
push-button
17 Control cabinet
18 Supply cable gland
19 Opening for lifting gear
20 Water cooler
21 Cooling water inlet
22 Cooling water outlet
23 Fan protection panel
24 Water level indicator
25 Water level sensor
26 Network pressure sensor
27 Final compression
pressure sensor
28 Final compression temperature
sensor