Dürr Technik Marathon 1035300100 User manual

EN
Marathon 1- and 2-cylinder oil-
free compressor
Installation and operating instructions
1035200220L02
*1035200220L02*
1911V002

Contents
Important information
1About this document .. . . . . . . . . . . . . 2
1.1 Warnings and symbols .. . . . . . . 2
1.2 Copyright information .. . . . . . . . 2
2 Safety .. . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Intended use .. . . . . . . . . . . . . . . 3
2.2 Improper use .. . . . . . . . . . . . . . . 3
2.3 General safety information .. . . . . 3
2.4 Specialist personnel .. . . . . . . . . 3
2.5 Electrical safety .. . . . . . . . . . . . . 3
2.6 Only use original parts .. . . . . . . . 3
2.7 Transportation and storage .. . . . 3
2.8 Disposal .. . . . . . . . . . . . . . . . . . 4
Product description
3 Overview .. . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Scope of delivery .. . . . . . . . . . . . 5
3.2 Wear parts and replacement
parts .. . . . . . . . . . . . . . . . . . . . . 6
4Technical data .. . . . . . . . . . . . . . . . . . . 8
4.1 Schematic drawing .. . . . . . . . . . 8
4.2 Technical data .. . . . . . . . . . . . . . 12
4.3 Declaration of conformity for
machines in accordance with the
2006/42/EC Directive .. . . . . . . . 18
Assembly
5Requirements .. . . . . . . . . . . . . . . . . . . 19
5.1 Setup .. . . . . . . . . . . . . . . . . . . . 19
5.2 Vibration dampening .. . . . . . . . . 19
5.3 Installation position and fasten-
ing .. . . . . . . . . . . . . . . . . . . . . . . 19
5.4 Noise reduction .. . . . . . . . . . . . . 19
6 Electrical installation .. . . . . . . . . . . . . . 20
6.1 Electrical connection without a
mains plug .. . . . . . . . . . . . . . . . 20
6.2 IP protection type .. . . . . . . . . . . 20
6.3 Fuse protection of the supply
current circuit .. . . . . . . . . . . . . . 20
6.4 Circuit diagrams .. . . . . . . . . . . . 21
6.5 Motor protection - temperature .. 21
7 Commissioning .. . . . . . . . . . . . . . . . . . 22
7.1 Remove the transport locks .. . . 22
7.2 Connect oil-free piston compres-
sor .. . . . . . . . . . . . . . . . . . . . . . . 22
8 Maintenance .. . . . . . . . . . . . . . . . . . . . 23
8.1 Maintenance schedule .. . . . . . . . 23
8.2 Replacing the air intake filter .. . . 24
8.3 Replace the vibration dampers .. 24
Troubleshooting
9Tips for operators and service techni-
cians .. . . . . . . . . . . . . . . . . . . . . . . . . . 25
Contact
10 Addresses .. . . . . . . . . . . . . . . . . . . . . . 26
10.1 Returns / Repairs .. . . . . . . . . . . 26
10.2 To order spare parts .. . . . . . . . . 26
10.3 Service .. . . . . . . . . . . . . . . . . . . 26
10.4 Addresses worldwide .. . . . . . . . 26
Contents
1035200220L02 1911V002 1
EN

Important information
1 About this document
These installation and operating instructions rep-
resent a part of the unit. They correspond to the
relevant version of the unit and the status of
technology valid at the time of its market launch.
In the event that the instructions and
notes in these installation and operating
instructions for are not observed, Dürr
Technik accepts no warranty or liability of
any kind for the safe operation and reli-
able function of the units.
This translation was prepared to the best of our
knowledge. The original German language ver-
sion of the manual is the definitive version. Dürr
Technik is not liable for translation errors.
1.1 Warnings and symbols
Warnings
The warnings in this document are intended to
draw your attention to possible injury to persons
or damage to machinery.
The following warning symbols are used:
General warning symbol
Warning – dangerous high voltage
Warning – hot surfaces
Warning - automatic start-up of the unit
The warnings are structured as follows:
SIGNAL WORD
Description of the type and source of
danger
Here you will find the possible conse-
quences of ignoring the warning
❯Follow these measures to avoid the
danger.
The signal word differentiates between four levels
of danger:
–DANGER
Immediate danger of severe injury or death
–WARNING
Possible danger of severe injury or death
–CAUTION
Risk of minor injuries
–NOTICE
Risk of extensive material/property damage
Other symbols
These symbols are used in the document and on
or in the unit:
Note, e.g. specific instructions regarding
efficient and cost-effective use of the unit.
CE labelling
Serial number
Order number
Observe the operating instructions.
Date of manufacture
Dispose of the unit properly and in accor-
dance with applicable national, regional
and local laws.
Disconnect all power from the unit.
1.2 Copyright information
All names of circuits, processes, names, software
programs and units used in this document are
protected by copyright.
The reprinting of the installation and operating
instructions, even in extracts, is only permitted
with the written permission of Dürr Technik.
Important information
2 1035200220L02 1911V002
EN

2 Safety
Dürr Technik has developed and constructed the
units in such a way that danger is to a large
extent excluded if the units are used as intended.
Nevertheless, residual risks can remain. You
should therefore observe the following notes.
2.1 Intended use
Oil-free piston compressors KK
The unit is intended for the compression of atmo-
spheric air. It provides oil-free air for a range of
applications. The unit has been designed for
installation into systems and machines. The unit
has been designed for operation in dry, ventilated
rooms. The unit must not be operated in a damp
or wet environment. When deployed outside, the
unit must be protected against mechanical dam-
age, moisture and excessive soiling by a housing
(e.g. sheet casing). The unit may only be com-
missioned after the manufacturer has ensured
that all requirements requisite to safe operation
have been fulfilled.
Its use in the vicinity of gases or flammable liq-
uids is prohibited.
2.2 Improper use
Any use of this appliance / these appliances
above and beyond that described in the Installa-
tion and Operating Instructions is deemed to be
incorrect usage. The manufacturer cannot be
held liable for any damage resulting from incor-
rect usage. The operator will be held liable and
bears all risks.
WARNING
Serious injury and material damage
due to improper usage
❯Conveying explosive mixtures in any
way other than that specified is not
permitted.
2.3 General safety information
❯Always comply with the specifications of all
guidelines, laws, and other rules and regula-
tions applicable at the site of operation for the
operation of this unit.
❯Check the function and condition of the unit
prior to every use.
❯Do not convert or modify the unit.
❯Comply with the specifications of the Installa-
tion and Operating Instructions.
❯The Installation and Operating Instructions
must be accessible to all operators of the unit
at all times.
2.4 Specialist personnel
Operation
Unit operating personnel must ensure safe and
correct handling based on their training and
knowledge.
❯Instruct or have every user instructed in han-
dling the unit.
Installation and repairs
❯Always arrange for any assembly work, read-
justments, alterations, extensions, and repairs
to be performed by Dürr Technik or by person-
nel authorised and trained by Dürr Technik.
Qualified personnel are defined as those
trained by Dürr Technik; who are familiar with
the unit technology; and are aware of the dan-
gers presented by the unit.
2.5 Electrical safety
❯Observe and comply with all the relevant elec-
trical safety regulations when working on the
unit.
❯Replace any damaged cables or plugs immedi-
ately.
2.6 Only use original parts
❯Only use accessories and special accessories
that are specified or approved by Dürr Technik.
❯Only use original working and spare parts.
Dürr Technik accepts no liability for dam-
age resulting from the use of non-
approved accessories, special acces-
sories or any working parts or spare parts
other than original parts.
2.7 Transportation and storage
The original packaging provides optimum protec-
tion for the unit during transport.
Dürr Technik will not accept any responsi-
bility or liability for damage occurring dur-
ing transport due to the use of incorrect
packaging, even where the unit is still
under guarantee.
Important information
1035200220L02 1911V002 3
EN

– Only transport the unit in its original packaging.
– Keep the packing materials out of the reach of
children.
NOTICE
Damage to the unit due to incorrect
transportation/storage
Incorrect storage and transportation can
cause damage to the unit.
❯Protect the unit from moisture during
transportation.
❯Transport the unit with the motor base
pointing downwards.
The unit may be stored in its original packaging
– in warm, dry and dust-free rooms;
– protected from contaminants.
If possible, retain the packaging material.
Ambient conditions during storage and trans-
port
Ambient conditions during storage and
transport
Temperature °C -25 to +55
Rel. humidity % 10 % to 90 %
Please refer to the labels on the packaging
padding.
2.8 Disposal
Unit
Dispose of the unit properly and in accor-
dance with applicable national, regional
and local laws.
Packaging
Dispose of the packaging material in an
environmentally responsible manner.
– Note current disposal routes.
– Keep the packing materials out of the reach of
children.
Important information
4 1035200220L02 1911V002
EN

Product description
3 Overview
3.1 Scope of delivery
The following items are included in the scope of
delivery:
Marathon 1035300100
Product name .. . . . . . . . . . . . . Article number
Compressor unit .. . . . . . . . . . . . . . 1035300100
Including air intake filter
Installation and Operating
Instructions .. . . . . . . . . . . . . . . 1035200220Lxx
The vibration damper set is not included in the
scope of delivery and must be ordered separately
Vibration damper set .. . . . . . . . . . . 1035100410
Marathon 1035300200
Product name .. . . . . . . . . . . . . Article number
Compressor unit .. . . . . . . . . . . . . . 1035300200
Including air intake filter
Installation and Operating
Instructions .. . . . . . . . . . . . . . . 1035200220Lxx
The vibration damper set is not included in the
scope of delivery and must be ordered separately
Vibration damper set .. . . . . . . . . . . 1035100410
Marathon 1035200100
Product name .. . . . . . . . . . . . . Article number
Compressor unit .. . . . . . . . . . . . . . 1035200100
Including air intake filter
Installation and Operating
Instructions .. . . . . . . . . . . . . . . 1035200220Lxx
The vibration damper set is not included in the
scope of delivery and must be ordered separately
Vibration damper set .. . . . . . . . . . . 1035100410
Marathon 1035200200
Product name .. . . . . . . . . . . . . Article number
Compressor unit .. . . . . . . . . . . . . . 1035200200
Including air intake filter
Installation and Operating
Instructions .. . . . . . . . . . . . . . . 1035200220Lxx
The vibration damper set is not included in the
scope of delivery and must be ordered separately
Vibration damper set .. . . . . . . . . . . 1035200202
Product description
1035200220L02 1911V002 5
EN

3.2 Wear parts and replacement parts
Wear parts
The following working parts need to be changed at regular intervals (refer to the "Maintenance" section):
Wear part 1035300100
1035300200
1035200100 1035200200
Air intake filter cartridge, long .. . 0714200050 1 units 2 units 2 units
Vibration damper set .. . . . . . . . . 1035100410 1 set 1 set -
Vibration damper set .. . . . . . . . . 1035200202 - - 1 set
Spare parts
NOTICE
Damage to the unit due to faulty assembly
Replacing the spare parts requires specialist knowledge. Faulty assembly will result in unit out-
age.
❯Repairs must only be performed by Dürr Technik or by personnel trained by Dürr Technik.
Spare part sets Item no.
See the fol-
lowing draw-
ing
1035300100
1035200200
1035200100
1035200200
Pistons and flywheel .. . . . . . . . . 0735100006 10, 100, 105,
110, 120, 130
1 SP set 2 SP sets
Seal set .. . . . . . . . . . . . . . . . . . 5150-981-00 140, 150, 160,
170, 180
1 SP set 2 SP sets
Product description
6 1035200220L02 1911V002
EN

110
100
10
120 120
130
10
180
140
160
170
150
105
Fig. 1: Marathon 2-cylinder (schematic diagram)
Product description
1035200220L02 1911V002 7
EN

4 Technical data
4.1 Schematic drawing
180,3
289
194,8
425,3
201,9
156,4
G1/4
A
A
153,7
SCHNITT A-A
116,3
100
125
Ø10,2
Fig. 2: Dimensions 1035300100
Product description
8 1035200220L02 1911V002
EN

289,3
176,6
215,5
433,3
G1/4
A
A
VZ - Revision nur für Form, Fit, Function
VZ - revision only for form, fit, function
Änderungen vorbehalten
Subject to change without notice
M 1:5
Ø
10,3
125
100
124,6
173,5
A-A
1 : 5
Fig. 3: Dimensions 1035300200
Product description
1035200220L02 1911V002 9
EN

350,4
278
425,3
22,8
201,2
156,4
G1/4
A
A
183,7
SCHNITT A-A
116,3
100
125
Ø10,2
Fig. 4: Dimensions 1035200100
Product description
10 1035200220L02 1911V002
EN

VZ - Revision nur für Form, Fit, Function
VZ - revision only for form, fit, function
Änderungen vorbehalten
Subject to change without notice
350,2
284,4
433,5
Ø175
215,5
12,5
G1/4
A
A
M 1:5
124,3
100
125
204
A-A
1 : 5
Fig. 5: Dimensions 1035200200
Product description
1035200220L02 1911V002 11
EN

4.2 Technical data
Marathon 1-cylinder
Electrical data
1-cylinder
Type A-080
Article no. 1035300100
Electrical frequency Hz 50 60
Nominal voltage V AC 230 3~ 230 3~
Rated power P1 (W) 800 980
Nominal current A 4.3 4.4
Speed min-1 1440 1710
Type of protection (motor) IP 54 54
Temperature switch (motor) PTC Yes Yes
Motor protection switch (motor) No No
VFD (variable-frequency drive)-capable Yes Yes
Mains connection Total length: 890
mm; length from
terminal box con-
nection: approx.
770 mm
General technical data
Delivery quantity pe0 bar l/min 80 80
Delivery quantity pe5 bar l/min 60 70
Nominal pressure bars 7 7
Safety pressure PS bars 10 10
Noise level db(A) 66 69
Weight kg 24 24
Dimensions (LxWxH) mm 425 x 180 x 289 425 x 180 x 289
Ambient conditions during operation
temperature °C +5 to +40
Product description
12 1035200220L02 1911V002
EN

Marathon 1-cylinder
Electrical data
1-cylinder 1-cylinder
Type B-080 B-080
Article no. 1035300200 1035300200
Electrical frequency Hz 50 60
Nominal voltage V AC 230 3~230 3~
Rated power P1 (W) 1330 840
Nominal current A 4.5 3.1
Speed min-1 1488 1777
Type of protection (motor) IP 54 54
Temperature switch (motor) PTC Yes Yes
Motor protection switch (motor) No No
VFD (variable-frequency drive)-capable Yes Yes
Mains connection Total length: 890 mm; length from terminal
box connection: approx. 770 mm
General technical data
Delivery quantity pe0 bar l/min 78 78
Delivery quantity pe5 bar l/min 60 70
Nominal pressure bars 7 7
Safety pressure PS bars 10 10
Noise level dB(A) 66 69
Weight kg 28 28
Dimensions (LxWxH) mm 434 x 177 x 290 434 x 177 x 290
Ambient conditions during operation
temperature °C +5 to +40
Product description
1035200220L02 1911V002 13
EN

Marathon 1-cylinder
Electrical data
1-cylinder 1-cylinder
Type B-080 B-080
Article no. 1035300200 1035300200
Electrical frequency Hz 50 60
Nominal voltage V AC 400 3~400 3~
Rated power P1 (W) 1330 840
Nominal current A 2.6 1.8
Speed min-1 1488 1777
Type of protection (motor) IP 54 54
Temperature switch (motor) PTC No No
Motor protection switch (motor) No No
VFD (variable-frequency drive)-capable Yes Yes
Mains connection Total length: 890 mm; length from terminal
box connection: approx. 770 mm
General technical data
Delivery quantity pe0 bar l/min 78 78
Delivery quantity pe5 bar l/min 60 70
Nominal pressure bars 7 7
Safety pressure PS bars 10 10
Noise level dB(A) 66 69
Weight kg 28 28
Dimensions (LxWxH) mm 434 x 177 x 290 434 x 177 x 290
Ambient conditions during operation
temperature °C +5 to +40
Product description
14 1035200220L02 1911V002
EN

Marathon 2-cylinder
Electrical data
2-cylinder 2-cylinder
Type A-160 A-160
Article no. 1035200100 1035200100
Electrical frequency Hz 50 60
Nominal voltage V AC 230
3~
230
3~
Rated power P1 (W) 1300 1600
Nominal current A 6.3 7.0
Speed min-1 1360 1600
Type of protection (motor) IP 54 54
Temperature switch (motor) PTC Yes Yes
Motor protection switch (motor) No No
VFD (variable-frequency drive)-capable Yes Yes
Mains connection Total length: 890 mm; length from terminal
box connection: approx. 770 mm
General technical data
Delivery quantity pe0 bar l/min 160 160
Delivery quantity pe5 bar l/min 120 135
Nominal pressure bars 10 10
Safety pressure PS bars 12 12
Noise level dB(A) 66 69
Weight kg 26 26
Dimensions (LxWxH) mm 425 x 350 x 278 425 x 350 x 278
Ambient conditions during operation
temperature °C +5 to +40
Product description
1035200220L02 1911V002 15
EN

Marathon 2-cylinder
Electrical data
2-cylinder
Type B-160 B-160
Article no. 1035200200 1035200200
Electrical frequency Hz 50 60
Nominal voltage V AC 230 3~ 230 3~
Rated power P1 (W) 1730 1460
Nominal current A 5.4 4.4
Speed min-1 1488 1777
Type of protection (motor) IP 54 54
Temperature switch (motor) PTC Yes Yes
Motor protection switch (motor) No No
VFD (variable-frequency drive)-capable Yes Yes
Mains connection Total length: 890 mm; length from terminal
box connection: approx. 770 mm
General technical data
Delivery quantity pe0 bar l/min 160 160
Delivery quantity pe5 bar l/min 120 135
Nominal pressure bars 10 10
Safety pressure PS bars 12 12
Noise level dB(A) 66 69
Weight kg 30 30
Dimensions (LxWxH) mm 425 x 350 x 285 425 x 350 x 285
Ambient conditions during operation
temperature °C +5 to +40
Product description
16 1035200220L02 1911V002
EN

Marathon 2-cylinder
Electrical data
2-cylinder 2-cylinder
Type B-160 B-160
Article no. 1035200200 1035200200
Electrical frequency Hz 50 60
Nominal voltage V AC 400 3~400 3~
Rated power P1 (W) 1730 1460
Nominal current A 3.1 2.5
Speed min-1 1488 1777
Type of protection (motor) IP 54 54
Temperature switch (motor) PTC No No
Motor protection switch (motor) No No
VFD (variable-frequency drive)-capable Yes Yes
Mains connection Total length: 890 mm; length from terminal
box connection: approx. 770 mm
General technical data
Delivery quantity pe0 bar l/min 160 160
Delivery quantity pe5 bar l/min 120 135
Nominal pressure bars 10 10
Safety pressure PS bars 12 12
Noise level dB(A) 66 69
Weight kg 30 30
Dimensions (LxWxH) mm 425 x 350 x 285 425 x 350 x 285
Ambient conditions during operation
temperature °C +5 to +40
Product description
1035200220L02 1911V002 17
EN

4.3 Declaration of conformity for machines in accordance with the
2006/42/EC Directive
We hereby declare that the unit described below conforms to all requirements of the machine directive
2006/42/EC.
The unit named below fulfills the requirements of the following directives:
– Electromagnetic Compatibility (EMC) Directive 2014/30/EU
– RoHS directive 2011/65/EU
Manufacturer's name: Dürr Technik GmbH & Co. KG
Manufacturer's address: Pleidelsheimer Straße 30
D-74321 Bietigheim-Bissingen
Reference number: Marathon
Article designation: Compressor
From the serial number: H400000
We hereby declare that the unit may only be commissioned once it has been established that the
machine into which this unit is to be installed complies with the provisions as set out in Machinery Direc-
tive 2006/42/EC.
The following harmonised standards and other standards have been applied:
DIN EN 1012-1:2011-02
DIN EN 60034-1:2011-02
DIN EN 60034-5:2007-09
DIN EN 60335-1:2014-11
DIN EN 61000-3-2:2015-03
DIN EN 61000-6-3:2012-11
DIN EN 60204-1:2010-05
DIN EN 50106:2009-05
DIN EN ISO 12100:2013-08
Bietigheim-Bissingen, 20/04/2016
Andreas Ripsam Proof of signature in the
Executive Board of Dürr Technik Original document held by Dürr Technik
Product description
18 1035200220L02 1911V002
EN