Quality Assurance

DIN ISO 9001 certified

Maintenance and Operating Instructions

Spare Parts List

Screw-type Compressors
SCK 21 - SCK 52

Ident number: 195.02022 BA 101/04.01/03/GB

 Index Page Individual machine data:
General information and safety instructions 4
Functional description 5
Erection 6 Type: SCK
Operating 7
Commissioning 9
Maintenance 10
Troubleshooting 12 Machine-No.
Options 13
Technical Data 14
Spare parts overviews 15
Plan and electric parts 15 System with the following design/options
Unit parts 16 that differ from the standard version:
Lines and gaskets 18
Suction control and temperature control 20
Separatorbox 21
Spare parts list 22
Service completed 26

For the perfect and troublefree operation you expect from your screw- Validity:
type compressor, we recommend to keep in stock one set of
maintenance and wearing parts, e.g. suction filter, oil filter, oil separator This manual and spare parts list is valid as from makers n
and lube oil. Our after-sales service p would be pleased to assist you
in the selection of these spare parts.
SCK 51 - SCK 151 : 260.607
Date : 02.04.2001
p On the reverse of this brochure you will find our address, telephone
number and fax number.

p In case of further inquiries please specify the data shown on the

compressor nameplate (electric box back side).

3
General information and safety instructions
General information
These maintenance and operating instructions contain information
necessary for the perfect and troublefree operation of your screw-
type compressor. Thoroughly read these instructions before
commission, because damage caused by improper handling is not
covered by our warranty.
F Regulations, laws and important information
This compressor has been built in accordance with the EG machine
regulations 98/37/EG. All our specifications about the noise emission
are in accordance with EN ISO 3746 and the EG machine regulation,
chapter I, section 1.5.8 etc., this manual in according to section 1.7.4,
etc.
The machine has been built in accordance with the general technical
rules. Operation can still mean danger for user or others, or even
result in damage to the machine and other values.
The machine may only be used to produce compressed air. Other use
is strictly not allowed.
Neither the manufacturer nor the supplier take the responsibility for
damage caused by other use as to produce compressed air.
THESE BRIEF SAFETY INSTRUCTIONS DO NOT RELIEVE YOU
FROM OBSERVING THE FURTHER DETAILED INSTRUCTIONS!
F Sign for instructions which have to be
strictly observed
Transport:
Transport is only allowed with a (fork) lift truck.
4
F 1. Safety instructions
1.1 Safety instructions for personnel and
compressor function
F The compressor system must only be erected, operated and
maintained by trained p and from the user authorized personnel.
Each authorized person must have read and understood the complete
manual. Unauthorized conversions and modifications which influence
the safety of the compressor are not allowed.
F In any case all work to be carried out on the compressor is to be
done in cut-off and pressure-relieved condition. The compressor system
is to be protected against unauthorized reconnection.
Attention - caution! The sound absorbing bonnet of the
compressor is part of the protection against accidental
contact and may only be opened upon completion of the
above mentioned measures.
1.2 Safety measures to be taken before
commissioning
F The allowable compressor room temperature is : +5 C to +40
C. The electric connection must only be carried out by an authorized
specialist. Check the correctness of current, voltage and frequency.
The correct supply line is to be dimensioned and protected in
compliance with the electrical data mentioned on page 13.
1.3 Safety measures to be taken during
commissioning
F Check the maximum oil level at the lower edge of the oil filler
neck (11.1). Fill about 0.2 l. oil into the oil prefill plug of the suction
unit (06). Check the correct direction of rotation (see arrow on the
electric motor). Switch on (and immediately off) for only a very short
(max. 0.5 sec.) time.
1.4 Safety measures for maintenance and
operation
F All work is to be carried out with the machine at standstill and
pressure-relieved. Switch off the power supply and protect it against
reconnection. Close the shut-off valve to the compressed-air piping
system (or compressed-air receiver tank). Damaging condensate water
in the oil tank (11) should only be checked out in cold condition and
must be drained. Check the oil level only with the compressor in warm
condition.
Attention: all cooler nozzles are to be counterbacked with a
sufficient key; mind not to overturn the cooler connections.
Caution! The compressor system oil tank (11) can be under
residual pressure! Hot and oily compressed air penetrates
when the safety valve (12) is operated! Do not discharge
the compressed-air condensate into the sewage system (refer
to section 3.4).
 Functional description

2. Functional description Flow diagram 14 13

2.1 The drive 15

The electric motor (01) drives the compressor stage (04) through the
V-belt pulleys (02) and the V-belts (03). 09 08 06 05
11 04

10
2.2 The air path 12 01
Air flows into the suction filter (05) and the suction valve (06) into
the compressor stage (04), which compresses the air. The relief valve
(07) closes and the suction valve (06) opens at star delta and the 07
revers way at the upper pressure point into the idle running phase.
The oil separator (08) decreases the residual oil to 2 - 4 mg/m3. In the
compressed-air recooler (09) the compressed-air temperature reduces
to 9-13C above ambient temperature and leaves the machine through 2.3 The oil circuit
the compressed-air outlet (10).
Cooling and sealing lube oil flows into the compressor stage (04) by
the produced pressure in the oil tank (11). The oil leaves the compressor
stage (04) mixed with the compressed air. The - placed according to
18 the regulations - safety valve (12) protects the machine against excess
pressure. The oil will be separated from the air up to 98% by our
05 special design of the oil tank (11), which collects the oil. The residual
06 08 separation of the oil will be carried out by the oil separator (08). The
15 working temperature of the oil is optimized by the oil temperature
14
02 controller (13). The oil passes the by-pass line or the oil cooler (14)
04
12 and flows through the oil filter (15) back into the compressor stage
03 (04).
16
17
11 2.4 The air cooling
10 09
The cooling air fan (16) on the rear motor shaft (17) takes in cooling
01 13
air and leads it over the electric motor (01), passing the oil cooler
(14) and the compressed-air recooler (09) and leads it through the
for exhaust shaft connection prepared exhaust air grid (18) out of the
machine.

5
Erection

3. Erection
3.1 General information
F The screw-type compressor is mounted on a solid frame ready
for operation. Only a level solid floor is necessary for erection.
The screw-type compressor is to be placed in a cool, dry and dust-free
room with proper ventilation and a room temperature between + 5
C and + 40 C.
When the room temperature might fall below + 5C, an additional
compressor heating is to be installed into the compressor system oil
tank (11) or the room is to be heated.
When the room conditions are inconvenient, it may be necessary, owing
to excess heating, to dissipate the hot exhaust air by means of exhaust
shafts or cooling fans for a sufficient supply of fresh air.
The place of installation shall be well accessible. Refer for assembly
dimensions and required quantities of fresh air to the technical data
on page 13.
3.3 Electric connection
F Electric connection is only to be carried out by skilled electricians.
Check if current, voltage and frequency is according to the nameplate
data. The cross section of the feed line and the fuses are to be
dimensioned in accordance with the local prescriptions ! Refer to the
data on page 13.
3.4 Condensate trap
F The condensate collected in the condensate trap (refer 3.2) is
oily and must not be fed into the sewage system without further treat
(Our after-sales service would be pleased to assist you in the selection
of sufficient air-oil separation systems p).

3.2 Pneumatic connection

F Screw-type compressors will be delivered complete and ready
for connection. The connection from the compressed-air outlet (10)
to the piping system must only take place through a tape-sealed fle-
xible hose, so that no forces can be transmitted between the
compressed air piping system and the compressor unit.
The pipe end of the piping system is to be thoroughly secured.
In order to avoid that the condensate collected in the compressed-air
recooler (09) is fed into the piping system or into the downstream
receiver tank, a condensate trap with automatic separator is to be
installed in the discharge line, if possible in direct vicinity of the
compressed-air outlet (10). Refer page 13 for the outlet dimensions.
A non-return valve between piping system or receiver tank and
machine is not required, because this device is already installed in the
screw-type compressor. It is, however, recommended to install a shut-
off valve in the compressed-air line, so that the compressor is able to
be disconnected from the piping system, if necessary.

6
 Operating

4. Operating 4.2 Key assignment

The Air-Control is the central control element of the Compressors. I On key

The green lamp flashes: The compressor i ready for use
and may start automatically at any time
___ A LUP The green lamp is lit: The compressor is running
Kompressoren
bar
Warning and error display
AIR CONTROL 1 M The red lamp is lit: Compressor error
The red lamp flashes: Warning
o
C
Automatik
O Stop key to shut down the compressor (via idling)
for input of codes
ENTER INFO for acknowledgement of errors
INFO Information can be obtained on the set values by
pressing several times:
1x Cut-in pressure (bar)
4.1 Display 2x Cut-out pressure (bar)
3x Safety pressure (bar)
The display permanently displays the line pressure, final compression
4x Min. start temperature (5.0 C)
temperature and operating status of the compressor. 5x Max. compressor temperature (110 C)
6x Total operating hours (h)
7x Load hours (h)
8x Residual service life air filter (h)
Network 9x Residual service life oil and oil filter (h)
pressure 10x Residual service life oil separator (h)
11x Residual service life lubricant (h)
12x Residual service life to service (h)
bar
ENTER Confirm entered values and parameters
Error number,
Warning number,
Programming level
! M Change values and parameters

Only in case of emergency the system may be shut down with the
Compressor o EMERGENCY STOP switch.
C
temperature Restart Automatic Remote

4.3 Warnings
The red lamp and the symbol ! are flashing. The corresponding
Symbol Error
warning number flashes:
2 High compressor final temperature
! Symbol Warning 3 High network pressure
11 Residual service life air filter < 100 h
M Symbol Motor operates 12 Residual service life oil/oil filter < 100 h
13 Residual service life oil separator < 100 h
14 Residual service life motor lubrication < 100 h
Symbol Compressor compresses
15 Residual service life to maintenance < 100 h
Realised maintenance have to be acknowledged with Code 21.
Symbol Heating on

Restart Automatic restart after power failure

Automatic Operation mode Automatic

Remote Flashing: Operation in Remote On/Off mode

Constant: Operation through lead / lag control

7
Operating

4.4 Errors Code 2 Mode

0 = Automatic
The red lamp shines and the symbol is flashing. The corresponding
(Automatic appears in the display)
error number flashes:
Idling time according to code 51
1 Pressure rated value wrong
1 = Load-idling operation
2 Parameters wrong
Unlimited idling time
3 Low voltage
2 = Automatic optional
4 Voltage failure
(an additional point appears in the display befor the
5 AirControl defect
temperature value)
6 Emergency stop actuated
Progr. level 1: max. pressure drop
7 Wrong direction of rotating
Progr. level 2: max. switching frequency
8 Motor temperature to high
9 Over current In all modes the compressor cuts in when the pressure falls below the
10 Over pressure cut-in pressure level and goes into idling mode when the cut-out
11 Pressure drop through oil separator pressure is reached. After the end of the idling time the motor cuts
12 Maximum compressor temperature sensor off.
13 Oil temperature sensor Code 3 Automatic Restart
14 Pressure sensor 0 = no automatic restart
15 Maximum compressor final temperature exceeded 1 = with automatic restart
16 Network pressure exceeded (Restart appears in the display)
Errors have to be acknowledged by pressing the O-key. In the event of a power failure, which is shorter than the programmable
restart time, the compressor will restart automatically
4.5 Programming Code 8 Local / Remote / GLW
The factory settings may be changed by programming Generally the system will be controlled locally.
1. Press the O-key until the message cod appears 0 = Local mode (standard)
1 = Remote On/Off mode (Remote appears flashing
2. Select the codes described below using the in the display)
keys; confirm your selection using ENTER 2 = Operation with a lead / lag control unit with automatic
3. The code appears with 3 digits in the display. Change switch to to local operation (Option)
of the flashing value ( ) with the keys; Code 11 Cut-in and cut-out pressure
confirm your selection with ENTER
When pressing the INFO key once the current cut-in pressure (bar)
appears in the display and can then be changed.
After pressing the INFO key a second time the current cut-out pressure
Set code appears (bar) in the display. The cut-out pressure can be changed and
must always be at least 0.1 bar higher than the cut-in pressure.
Code 18 Lead / lag operation
Programming
0 = Standard without lead / lag control unit
level
1 = Operation with a lead / lag control unit
(Remote appears in the display)
Code 21 Maintenance acknowledgement
Flashing number Relaised maintenance can be acknowledged by immediately pressing
value ( ) the ENTER key and after that the O key.
Code 51 Idling, standstill and ru-up time
Progr. level 1: Idling time (10 - 1200 s)
4. Certain codes allow settings in the second and third Progr. level 2: Standstill time (0 60 s)
programming level after pressing of the ENTER key Progr. level 3: run-up time (3 - 30 s)
5. Press the O-key to return to the main menue Code 90 Change of pressure unit
0 = Pressure in bar (g)
1 = Pressure in Mpa (g)
2 = Pressure in psi (g)
Code 95 Change of temperature unit
0 = Temperature in C
1 = Temperature in F
2 = Temperature in K

8

5. Commissioning
5.1 Preservation
Machines which are standing still after delivery ex works or are to be
stored for a longer period before commissioning, will be filled up with
preservative oil. This preservative oil has to be drained and disposed
together with the flushing oil (appr. 1/3 of the normal oil supply, which
will be flushed through the operating unit for about 30 min.).
Please mind the initial lubrication of section 5.4 before commissioning!
5.2 Oil level check
The maximum oil level is the lower edge of the oil filler neck (11.1).
During operation the oil level will slightly fall by internal distribution.
With rising machine temperature or even a temperature cut-off due
to low oil level, the compressor is to be filled up with fresh oil into the
oil filler neck (11.1).
5.3 Oil quality
With regard to the high load of the lube oil in oil injection cooled
screw-type compressors, we recommend to use very non-aging, water-
repellent, non-foaming, anti-corrosion oils, e.g. our SPECIAL OIL. This
oil is filled in by the works (refer to the oil tank (11) sticker).
F Different kinds of oils must not be mixed. In case other lubricants
are used, you should contact the after-sales service p. We only grant
our warranty for the compressors when the use of equivalent lubricants
is verified.
5.4 Initial lubrication of the compressor stage
(04) (refer to section 1.3)
F After a longer standstill period, e.g. between initial
commissioning and delivery ex works or after a longer works holiday,
it may happen that there is no oil in the rotor compartment of the
compressor stage (04). This oil, however, is absolutely necessary for
lubricating rotors and bearings in the starting phase. Therefore it is
necessary to fill about 0.2 l. oil into the prelube plug of the suction
valve (06). Manually rotate the compressor stage (04) in the right
direction of rotation until the sensible resistance disappears and the
oil is passed through the stage (04). Mount the prelube plug again
into the suction valve (06).
If no additional oil is available (only use the same kind of oil) the oil
can be drained from the system by means of the oil drain (11.2).
Irregular operating machines and those which are standing still for
several weeks should run for one hour every week, in idle mode, to
prevent corrosion damage.
5.5 Direction of rotating (refer to section 1.3)
F The direction of rotation must comply with the arrow on the
electric motor (01). When checking, the machine must only be switched
on (and immediately off) for a very short time (max. 0.5 sec.) in order
not to damage the compressor stage (04). The direction of rotation
can be changed when two external conductors are exchanged.
Commissioning
5.6 Starting
Before starting the machine, verify that no persons can be endangered.
The sound cover hood is part of the protection against accidental
contact and leads the cooling air of the machine. It must be closed
during operation. Open the shut-off valve between compressor and
compressed-air system. Switch on the power supply.
Push the start key I. The green lamp lights up and indicates operation
or, if the line pressure is above the set cut-in pressure, the start
temperature is below + 5C or with activated remote control, only
flashes stand-by.
CAUTION! A FLASHING GREEN LAMP MEANS THE
COMPRESSOR CAN ALWAYS START UP AUTOMATICALLY
The lines carrying oil and compressed air are to be checked for leakages.
After the cut-out pressure is achieved the machine shuts down after
the set follow-up time (automatic) or changes over to idle running
(load-idle mode).
5.7 Shutdown
Push the stop key O. The green lamp extinguishes. The compressor
shuts down after the follow-up time, the suction valve (06) closes
and the oil tank (11) is relieved. The line pressure is available up to
the non-return valve integrated in the separator box, i.e. the
compressed-air recooler (09) is admitted with line pressure. Program
changing and setting of pressure or time values can only be carried
out with the required code and the compressor at standstill.
6. Compressor maintenance
6.1 General information
F All maintenance work is to be carried out by trained specialists
with the machine switched off, at standstill, pressure-relieved and
protected against reconnection.
6.2 Pressure relief
Before any maintenance work is carried out, the pressure relief is to
be checked as follows : disconnect the compressor from the
compressed-air system by closing the shut-off valve. The pressure relief
is to be checked by venting the safety valve (12).
F The temperature of the oil tank (11) may not be more than
+40 C!
F Attention - caution!
It is absolutely necessary to wear face and body protection
because hot oil mist can penetrate.
9
Maintenance

6.3 V-belt drive
Our constructions keeps the V-belts (03) at the required tension;
nevertheless they must be checked every 500 hours and retensioned if
necessary.
Place the test pin (p Order No. 180.02030) at right-angles to a V-belt
(03) in the middle of the section between the rollers and press it down.
Deflection at 50 N testing force: SCK 21 - 31 = 11 - 9 mm
SCK 42, 52 = 8 mm
If you have to replace one V-belt, you must replace all the V-belts (03)
at the same time. To do this release the motor rocker arm upwards
using the adjustment screws. Place the new V-belts (03) individually
around the V-belt pulleys (02) and lower the motor rocker arm using
the adjustment screws until the test force is achieved. Then lock the
adjustment screws again.
6.4.1 Replacement of the suction filter (05) SCK 21-42
Warning 11 - with flashing red lamp. Replace the suction filter (05),
confirm the maintenance with Code 21 and reset with the O key.
The used suction filter is to be disposed of as special waste.
manually tighten it half a turn. Check for leakage at operating
temperature, confirm the main-tenance with Code 21 and reset with
the O key.
The used oil separator is to be disposed of as special waste.
6.7 Condensate water
When the full capacity of the compressor is not utilized, condensate
water may deposit at the lowest point (heavier than oil) of the oil
tank (11).
This condensate water should be drained through the oil drain (11.2)
regularly, when the compressor is at standstill for a longer period,
e.g. at the weekend (ref. sect. 3.4).
If any condensate water is observed, please contact immediately the
after-sales service p, otherwise your warranty might be endangered.
Condensate and
oil drain
11.2

6.4.2 Replacement of the suction filter (05) SCK 52
Warning 11 - with flashing red lamp. Loosen the filter cap with the
butterfly nut. Replace the suction filter (05) and secure the filter cap
with the butterfly nut again. Confirm the maintenance with Code 21
and reset with the O key.
6.8 Oil level check (mind residual pressure when
opening)
Check the oil level at the oil filler neck (11.1) and refill oil, if necessary.
Different kinds of oil must not be mixed. Works oil filling: SPECIAL OIL.

The used suction filter is to be disposed of as special waste. 6.9 Oil change
always together wiht the oil filter (15)
Suction filter SCK 21-42 Suction filter SCK 52
Warning 15 - with flashing red lamp. The oil is to be changed in
accordance with the maintenance intervals on page 13 with the
required oil quantity. In case other lubricants shall be used, please
05 contact the after-sales service p. We only grant our warranty for the
05
compressors when the use of equivalent lubricants is verified.
Oil change: (only in warm condition) open the filler neck (11.1) as
6.5 Replacement of the oil Oil filter 15 well as the oil drain (11.2) and drain the used oil. Close the oil drain
filter (15) (11.2) and fill in fresh oil up to the lower edge of the filler neck (11.1).
Check for leakage at operating temperature. Confirm the maintenance
Warning 12 - with flashing red lamp. with Code 21 and reset with the O key.
Loosen the oil filter (15) with a strap
wrench (p order n 180.06075) and The used oil is to be disposed of as special waste.
remove it. Remove residues of the old
sealing from the housing. Lubricate the seal of the new oil filter. Screw Oil filler 11.1
in the new oil filter (15) up to the limit stop and manually tighten it
half a turn. Check for leakage at operating temperature, confirm the
maintenance with Code 21 and reset with the O key.
The used oil filter is to be disposed of as special waste.
6.6 Replacement of the oil 11.2
Oil
separator (08) separator 6.10 Motor bearings (01)
Warning 13 - with flashing red lamp.
Warning 14 - with flashing red lamp. Regreasing of the electric
Loosen the oil separator (08) with a strap
motor (01) must strictly be carried out and is performed by means of
wrench (p order n 180.06075) and
a grease gun with a lubrication nipple according to DIN 3404 (order
remove it. Remove the residues of the
n 180.06076 p). If the electric motor (01) does not have any grease
old sealing and lubricate the seal of the 08 nipples, it is equipped with long-life grease closed roller bearings.
new oil separator. Screw in the new oil
After their lifetime these bearings are to be changed completely.
separator (08) up to the limit stop and

10
 Maintenance

6.11 Safety valve (12) 6.12 Set pressure switch points with Code 11
In order to maintain the proper
function of the safety valve (12), Safety valve
it is necessary to check the valve
(12) every 2,000 operating hours
or at least once a year.
After 3 seconds continuous pushing the O-key, CODE 11 can be called
Checking: dismount the safety with the keys followed by ENTER. Call the lower pressure
valve (12) from the unit and check switch point with the INFO key. Set the required value with the
it in a suitable device. keys and save it with ENTER. After pushing the INFO key again, the
If no device is available, the safety upper pressure switch point can be called and set with the keys
valve (12) can be checked by us and saved the same way with ENTER.
p. 6.13 General compressor maintenance
Remove the residues from the
Warning 15 - with flashing red lamp - to carry out a general
thread connection. Wrap the
compressor maintenance. This general compressor maintenance
thread of the safety valve (12) with
includes all maintenance work which is to be done, with the unit in
sealing tape and screw the safety valve in. Check for leakage at
normal condition and normal ambient. Our after-sales service p would
operating temperature.
be pleased to assist you.

#) Warning 100 h before run out service time

Maintenance intervals

Maintenance work before after after every each ... operating hours
and compressor erection erection the 1st week #) #) #)
checks week 500 2000 4000

Direktion of rotation (01)

Oil level check (11)

Leak check, discharge temperatur

Reteighten electric connections

Condensate collection (11)

cooler contamination (09,14)

First oil (11) + oil filter (15) change,

V-belts check (03)

Suction filter (05), l (11) + oil filter (15)

change, oil separator (08), safety valve (12)
at least once a year

Regreasing of motor bearings (01)

- maintenance intervals depending on
compressor type (refer section 6.10)

General compressor maintenance,

at least once a year

11
Troubleshooting

A reminding information due to a run out service time or a run out service interval must be confirmed with Code 21 and reset with the
O - key, after proper service.
A warning has occured when the red lamp flashes with the machine still operating. The warning cause is shown in the display screen. After
proper service, reset the warning with the O - key.
A trouble has occured when the red lamp lights up continuously and the machine is at standstill. The trouble cause is shown in the display
screen. After proper maintenance, reset the trouble with the O - key and the machine can be started up again.

Trouble Cause Measures to be taken refer to

7.1 Machine switches off through - Sound absorbing bonnet not closed
compressor dis-charge - Suction/ambient temperature too high
temperature; display screen - Cooling air inlet or outlet blocked
information ! 15 (red lamp - Oil filter (15) dirty
lights up) - Lack of oil
- Oil cooler (14) outside contamination
Attention : all cooler nozzles are to be
counterbacked with a sufficient key;
mind not to overturn the cooler
connections.
- Oil temperature controller (13) defective
7.2 Falling line pressure - Air consumption exceeds air supply
quantity
- Suction filter (05) dirty
- Relief valve (07) blows off when loading
- Suction valve (06) does not open
- Leakages in the line system
section
- Close the sound absorbing bonnet 1.1, 5.6
- Vent the compressor compartment 1.2, 3.1
- Clear the cooling air inlet/outlet 3.1
- Change the oil filter (15) 6.5
- Refill with fresh compressor oil 6.8, 6.9
- Clean with compressed air. At severe 2
contamination, remove the cooler (09, 14)
unit and clean it with a water jet device
Caution - danger of short circuit!
FNo water jets on electric components!
- Replace the controller (13) insert 2
- Compressor with higher discharge quantity page 2
required p
- Change the suction filter (05). 6.4
- Check the relief valve (07) and replace the 2
seals, if necessary
- Check the solenoid valve and the suction 2
valve piston (06) and replace, if necessary
- Check and seal the line system 3.2

7.3 Machine blows off through - Upper pressure switch point too high - Adjust the upper pressure switch point 6.12
the safety valve (12). - Safety valve (12) defective - Replace the safety valve (12) 6.11

7.4 ! 10, or ! 16 - means oil separator (08) dirty - Change the oil separator (08) 6.6
(red lamp lights up) - means external high pressure source - Lower the high pressure source or 3.2
eliminate it from the line

7.5 No automatic start or - Upper pressure switch point too high - Adjust the upper pressure switch point 6.12
switching to load after - Interruption in the control circuit - Check the control circuit for interruption Circuit
previous shutdown when the (only by a skilled electrician) diagram
set cut-out pressure is - Ambient temperature below +1C; the - Install a standstill heating device or heat 3.1
reached or from idling symbol for temperature flashes the compressor compartment properly

7.6 Machine does not start when - Line pressure above upper switch point - Observe the line pressure at the display. 4.1
the start key I is pushed - Remote control function active - Check flashing display "remote" symbol. 4.2
- No power at the compressor - Check whether power is applied. Circuit
- Electric defect in the control - Check the control (only by a skilled el.) diagram

7.7 High oil content in the - Oil return line clogged - Clean the oil return line. 2
compressed air (excess oil - Oil separator (08) defective - Change the oil separator (08) 6.6
consumption).

7.8 Compressor switches off - Excess temperature or pressure - Eliminate the defect in compliance with 7.1, 7.4
before the set cut-out chapter point : Circuit
pressure is reached - Interruption in the control circuit - Check the control circuit for interruption diagram
(red lamp lights up). (only by a skilled electrician)

7.9 Information ! 3 (red lamp - Power voltage below appr. 180 Vac - Check the power supply (only by a skilled Circuit
lights up) electrician) diagram

12

Tropical version (T) *
The tropical version is suitable for installation in ambient temperatures
of up to 45 C. Please refer to the separate attached sheet
Special voltage / Frequency 60 Hz *
If your compressor is operated with a non-standard 400 V or with a
frequency of 60 Hz, please refer to the separate, attached description.
Direction of rotation control *
The direction of rotation control prevents damage resulting from the
incorrect polarity of the electrical voltage (phase confusion). The
direction of rotation control causes the automatic shut-down of the
compressor.
The controller shuts down the motor if the pressure switch mounted
on the compressor stage trips. Please see the attached circuit dia-
gram for further details.
Additional heating system *
The additional electric heating system is housed in the compressors
oil tank. The oil heating system cuts in automatically as soon as the
temperature falls below the factory set nominal temperature in the
oil tank, which is measured by a temperature sensor.
This prevents the condensation of the airs humidity in the compressed
air. The additional heating system is required on systems that cut in
and out frequently and temporarily and therefore do not reach the
required operating temperature.
Floating error signal *
An error on the compressor can be forwarded by means of a floating
contact. For example the error message can be connected to a central
controller or a contactor. Please see the attached circuit diagram for
details of the connection terminals.
Floating operating signal *
An operating signal showing whether the main compressor motor is
running, can be connected to the central controller, for example, using
a floating contact or can also be used, for example, to control blowers
of refrigeration driers. Please refer to the attached circuit diagram for
connection details.
Options
Remote On/Off *
The compressed can be switched on and off using a floating contact.
Please refer to the attached circuit diagram for further details.
Proportional controller *
The proportional controller makes it possible to adjust the delivery
rate to the actual consumption of compressed air. To achieve this the
air delivery rate is throttle in the intake controller by narrowing the
cross-section.
Soiling indicator, intake filter *
If the intake filter becomes soiled this is shown on the display. The
filter element must then be replaced. The filter soiling is measured by
a differential pressure sensor over the intake filter.
Soiling indicator, oil filter *
If the oil filter becomes soiled this is shown on the display. The oil
filter cartridge must then be replaced. The filter soiling is measured by
a differential pressure sensor over the oil filter.
Soiling indicator, oil separator cartridge *
If the oil separator becomes soiled, this is shown by the controller on
the display. The oil separator cartridge must then be replaced. The
fine separator soiling is measured by a differential pressure sensor
over the oil filter.
Heat recovery system *
If you system is fitted with a heat recovery system or is prepared for a
heat recovery system, please refer to the separate attached description.
* The above options are not included in the standard version. These
instructions must only be observed if your compressor is fitted with
the appropriate option.
13
Technical Data

Performance and erection data: 669

4 x M5 int.
dashboard

1270 exhaust shaft

219
waste air connection

power
supply

1070
PG 36 compr. air
compr. air outlet
outlet
65

412
fresh air

M10 int. 973 M10 int. 677

795

service side
dashboard

cooling air opening

without shutter or mash

min. wall distance 50 cm

General data:
Com- Weight Cooling Supply Flue air Oil tank Number of Type of Compressed
pressor air air duct cross capacity V belts V belts air
volume opening section connection
kg m3/h m2 m2 l G
SCK 21 435 3300 0,40 0,37 8,0 3 XPA 1
SCK 26 450 3300 0,40 0,37 8,0 3 XPA 1
SCK 31 485 3500 0,40 0,39 8,0 3 XPA 1
SCK 42 580 5300 0,60 0,60 17,0 3 XPA 1 1/2
SCK 52 595 5700 0,65 0,65 17,0 4 XPA 1 1/2

Electrical data:
Com- Motor Currents at 220V/60Hz Currents at 400V/50Hz Currents at 550V/50Hz Maximum
pressor rating Site Site Site switching
back-up back-up back-up
I(rated) I(max) fuse I(rated) I(max) fuse I(rated) I(max) fuse frequency
kw A A A gL A A A gL A A A gL 1/h
SCK 21 15,0 48 52 63 30 32 50 22 24 35 30
SCK 26 18,5 58 64 80 34 38 50 25 27 35 25
SCK 31 22,0 70 77 80 40 45 63 29 32 50 20
SCK 42 30,0 90 99 125 57 63 80 42 46 50 15
SCK 52 37,0 119 131 160 67 73 100 48 53 80 12

14
 Spare parts: Plan and electric parts

136.00064
136.00185

The serial number of the screw

176.00163
compressor (on the name plate) is to
be indicated in any spare parts order.
The required part number can be
defined by the following views.

132.00602 K1
132.00603
132.00607
137.00009
132.00602 K3
132.00603
137.08744
132.00607

K2
132.00600
132.00602
132.00603 136.00272
136.00278

132.05001

136.00120

15
Spare parts: Unit parts

213.00490

172.02550 273.00040
172.07787 273.00041
213.00489 273.01852
273.01853
120.00110

172.11102
172.58111

172.00222

278.00224
273.01578
273.01579 154.00150
154.00154
136.00103

228.00851
228.00852

137.00462
278.00222
278.00230 174.00007
278.00246
278.00519

213.00456

226.00376
226.00377
176.00369
176.00381
176.00384

16
 Spare parts: Unit parts

226.03112 226.03150 163.00009 163.00066

226.03118 226.03180 163.00026 163.00068
226.03125 226.04095 163.00029 136.00128
226.03132 226.04106 163.00044 163.00129
226.03140 226.04126 163.00051 136.00131
278.00277 163.00168
276.00440

213.00457

278.00338
278.00339

127.00066
127.00177

278.00366
173.00003 278.00377

126.03180
126.03224
126.03280
126.04280

172.07800

176.00095

131.00301
131.00302 213.00489
131.00303
131.00304
131.00305

260.00047

278.00237 174.00013

17
Spare parts: Lines and gaskets

165.04418 173.00286
165.00168
165.01332
173.00039
173.00199

167.00077
173.00011

167.00544

173.00107

165.00246
165.83202

167.08026
167.01249
173.00290
173.00292

165.00017

167.00077

165.83202

18
 Spare parts: Lines and gaskets

173.00286 165.00331 165.00330

173.00291
165.00120

167.00077
173.08176 229.00038
229.00039

167.00077
165.83202

165.03416

165.83202
165.83202

173.00288
173.00289

19
Spare parts: Suction control and temperature control

212.00211

173.04003

173.04001

212.00210

212.00211

172.00222
212.00213

165.15101

273.02055

20
 Spare parts: Separator box

172.01017
172.01036

273.00552 172.11102
273.01529 172.58111

167.02228
167.03036

169.02110
169.02250

165.00449

165.00015 273.02513

212.00215

165.00247
273.00578
273.00579

165.00329 273.04018

21
Spare parts list

Article number Description SCK model

120 00110 Compressor stage 21 26 31 42 52

126 03180 Motor pulley 21 26

126 03224 Motor pulley 31
126 03280 Motor pulley 42
126 04280 Motor pulley 52

127 00066 Oil / air cooler 21 26 31

127 00177 Oil / air cooler 42 52

131 00301 Electric motor 42

131 00302 Electric motor 26
131 00303 Electric motor 21
131 00304 Electric motor 31
131 00305 Electric motor 52

132 00196 Fuses 21 26 31 42 52

(optional heating)
132 00377 Relais 21 26 31 42 52
(optional heating)
132 00600 Power relais 21 26
132 00602 Power relais 21 26
132 00602 Power relais 31 42
132 00603 Power relais 31 42
132 00603 Power relais 52
132 00607 Power relais 52
132 05001 Relais (option) 21 26 31 42 52

136 00064 Emergency button 21 26 31 42 52

136 00103 Temperature sensor 21 26 31 42 52
136 00120 Pressure sensor 21 26 31 42 52
136 00185 Air Control 1 system 21 26 31 42 52
136 00272 Transformator 52
136 00278 Transformator 21 26 31 42

137 00009 Primer fuses 21 26 31 42 52

137 00462 Heating (option) 21 26 31 42 52
137 08744 Transformer fuse 21 26 31 42 52

154 00150 Security valve 21 26 31

154 00154 Security valve 42 52

163 00009 V-belt set 26-08

163 00026 V-belt set 21-08 26-13
163 00029 V-belt set 21-13 31-13
163 00044 V-belt set 31-10
163 00051 V-belt set 26-10
163 00066 V-belt set 31-08
163 00068 V-belt set 42-13
163 00128 V-belt set 42-08
42-10
163 00129 V-belt set 21-10
163 00131 V-belt set 52-08
52-10
163 00168 V-belt set 52-13

22
 Spare parts list

Article number Description SCK model

165 00015 Stud coupling 21 26 31 42 52

165 00017 Blanking end 21 26 31 42 52
165 00120 Compressed-air elbow 21 26 31
165 00168 Blanking end 21 26 31 42 52
165 00246 Stud adaptor 21 26 31 42 52
165 00247 Stud elbow 21 26 31 42 52
165 00278 Stud elbow 21 26 31 42 52
165 00329 Stud elbow 21 26 31 42 52
165 00330 Stud coupling 42 52
165 00331 Stud elbow 21 26 31
165 00449 Stud coupling 21 26 31 42 52
165 01332 Banjo T coupling 21 26 31 42 52
165 03416 T coupling adjustable 21 26 31 42 52
165 04418 Stud adaptor 21 26 31 42 52
165 15101 Temp. control double male stud 21 26 31 42 52
165 83202 Banjo screw 21 26 31 42 52

167 00077 Bajo screw sealing 21 26 31 42 52

edge ring
167 00544 Oil tank o-ring 21 26 31 42 52
167 01249 Bolt joint 21 26 31 42 52
167 02228 Variseal oil separator 21 26 31
167 03036 Variseal oil separator 42 52
167 08026 Oil separator 21 26 31 42 52

169 02110 Injection nozzle 21 26 31

169 02250 Injection nozzle 42 52

172 00222 Oil filter cartridge 21 26 31 42 52

172 01017 Oil separator double stud 42 52
172 01036 Oil separator double stud 21 26 31
172 02550 Heavy duty air filter cartridge (option) 21 26 31 42 52
172 07787 Air filter cartridge 21 26 31 42 52
172 07800 Dust filter (option) 21 26 31 42 --
172 11102 Oil separator 21 26 31
172 58111 Oil separator 42 52

173 00003 Oil return line clamp 21 26 31 42 52

173 00011 Oil return line 21 26 31 42 52
173 00039 Non-return valve 21 26 31 42 52
173 00107 Pressure sensor line 21 26 31 42 52
173 00199 Discharge line 21 26 31 42 52
173 00286 Compressed air line 21 26 31 42 52
173 00288 Initial oil line 21 26 31
173 00289 Initial oil line 42 52
173 00290 Bypass oil line 42 52
173 00291 Oil return line 21 26 31 42 52
173 00292 Bypass oil line 21 26 31
173 04001 Suction control connection nozzle 21 26 31 42 52
173 04003 Suction control housing 21 26 31 42 52
173 08176 Oil drain valve 21 26 31 42 52

23
Spare parts list

Article number Description SCK model

174 00007 Oil tank support 21 26 31 42 52

174 00013 Elastic supports 21 26 31 42 52

176 00095 Fresh air grid 21 26 31 42 52

176 00163 Operation panel 21 26 31 42 52
176 00369 Ventilator with hub 42
176 00381 Ventilator 21 26 31
176 00384 Ventilator with hub 52
176 09038 Key 21 26 31 42 52

183 04050 Special oil 8 ltr. 21 26 31

183 04050 Special oil 14 ltr. 42 52

195 02021 Operating instructions D 21 26 31 42 52

195 02022 Operating instructions GB 21 26 31 42 52
195 02023 Operating instructions NL 21 26 31 42 52
195 02024 Operating instructions F 21 26 31 42 52
195 02025 Operating instructions I 21 26 31 42 52
195 02026 Operating instructions E 21 26 31 42 52

212 00165 Line kit 21 26 31 42 52

212 00210 Discharge valve service kit 21 26 31 42 52
212 00211 Suction control service kit 21 26 31 42 52
212 00213 Temperature control service kit 21 26 31 42 52
212 00215 Minimum pressure valve service kit 21 26 31 42 52
212 01130 Joint kit 21 26 31 42 52
212 01131 Service kit 21 26 31 42 52
212 02160 Filter kit 21 26 31
212 02162 Filter kit 42 52

213 00456 Front side board 21 26 31 42 52

213 00457 Rear side board 21 26 31 42 52
213 00458 Sound cover hood 21 26 31 42 52
213 00459 Service board 21 26 31 42 52

226 00376 Ventilator hub 21 26

226 00377 Ventilator hub 31
226 03112 Compressor pulley 26-08
226 03118 Compressor pulley 31-08 42-08
226 03125 Compressor pulley 26-10 42-10
226 03132 Compressor pulley 21-08 31-10
226 03140 Compressor pulley 26-13 42-13
226 03150 Compressor pulley 21-10 31-13
226 03180 Compressor pulley 21-13
226 04095 Compressor pulley 52-08
226 04106 Compressor pulley 52-10
226 04126 Compressor pulley 52-13

228 00851 Oil tank 21 26 31

228 00852 Oil tank 42 52

24
 Spare parts list

Article number Description SCK model

229 00038 Compressed air connection socket 21 26 31

229 00039 Compressed air connection socket 42 52

260 00047 Support distance 21 26 31 42 52

273 00040 Suction control 21 26 31 42 52

273 00041 Proportional suction control (option) 21 26 31 42 52
273 00552 Separator bush 21 26 31
273 00578 Separator housing 21 26 31
273 00579 Separator housing 42 52
273 01529 Separator bush 42 52
273 01578 Separator box 21 26 31
273 01579 Separator box 42 52
273 01852 Temperature control unit 21 26 31 42 52
273 02055 Temperature control housing 21 26 31 42 52
273 02513 Non-return valve set 21 26 31 42 52
273 04018 Minimum pressure valve cover 21 26 31 42 52

276 00440 Exhaust air grid 21 26 31 42 52

278 00222 Air intake plate 31

278 00224 Electric box 21 26 31 42 52
278 00230 Air intake plate 42
278 00237 Frame with oil protection carter 21 26 31 42 52
278 00246 Air intake plate 21 26
278 00277 Compressor flange 21 26 31 42 52
278 00338 Front plate 21 26 31
278 00339 Front plate 42 52
278 00366 Cooler side board 21 26 31
278 00377 Cooler side board 42 52
278 00519 Air intake plate 52

25
Services completed

Operating Date Servicing work completed Name/Signature

hours

26
ALUP-Kompressoren GmbH
Postfach 1161 D-73253 Kngen
Adolf-Ehmann-Str. 2 D-73257 Kngen

Phone.: +49-(0)1 80-5 25 87 00

Fax: +49-(0)1 80-5 25 87 01

E-mail: service@alup.com
Internet: www.alup.com

28