Servicing and operating manual

Reciprocating compressors
Booster series
General information
Table of contents Page
Safety instructions 3
Function description 4
Installation and Operating 5
Commissioning 6
Servicing 7
Troubleshooting 9
Servicing intervals 10
Technical data 11
To maintain the high availability of your reciprocating compressor we
recommend that you keep a set of servicing and wear parts in stock.
Our after-sales team p will be delighted to help you selecting your
spare parts.
p On the reverse of this brochure you will find our address, telephone
number and fax number.
p If you have any questions, particularly for ordering spare parts,
please quote the data shown on the system model plate (on the bottom
of the casing).
fSymbol for instructions that must be obeyed.
Transport information:
Only transport the compressor with a hand truck or forklift truck.

Individual machine data:
Model: Booster
Machine No.:
System with the following design/options that
differ from the standard:
General information
This servicing and operating manual contains information that you
will require to ensure the perfect, trouble-free operation of your
reciprocating compressor. Read this manual carefully before
commissioning the compressor because damage caused by incorrect
handling of the compressor is not covered by the warranty.
f Directives, use and safety instructions
This compressor complies with the EC Machine Directive
89/392 EEC. All the details for noise emissions comply with
the Third Directive for the Equipment Safety Law dated 18
January 1991 and the EC Machine Directive, Appendix I,
Section 1.7.4.ff. The system is designed to be state of the
art and complies with the acknowledged safety regulations.
Nevertheless its use may result in risks for users or third
parties and damage to the system and other property.
The system is designed exclusively for the compression of
air. No other use is permitted. The manufacturer cannot
accept liability for damage resulting from other uses.
THESE BRIEF SAFETY INSTRUCTIONS DO NOT RELEASE USERS
FROM THEIR OBLIGATION TO COMPLY PRECISELY WITH THE
FOLLOWING DETAILED INSTRUCTIONS!
 Safety instructions

F 1. Safety instructions 1.2 Safety instructions before commissioning

1.1 Safety instructions and compressor function
Only trained personnel who have been authorised by the operator may
be commissioned with the installation, operation and servicing of the
compressor system and they must have read and understood the
complete servicing and operating manual. Unauthorised modifications
and changes that affect the safety level of the reciprocating compressor
are not permitted.
All work on the compressor is only to be completed when the
compressor is at a standstill, has been disconnected from the mains
supply and depressurised. The compressor system is to be secured to
prevent its being switched on again without authorisation.
Danger!
f The permitted compressor chamber temperature is +5°C to +35°C.
The electrical connection of the system may only be made by an
authorised electrician. Check the conformity of the current type, voltage
and frequency with the system data. The power supply lead must be
designed and fused to suit the electrical connection data on page 11.
1.3 Safety instructions during commissioning
f Check the oil level on the oil window or using a dipstick (see 5.1).
Check that the electric motor is turning in the correct direction (see
the arrow on the belt safety grille) when it starts. For this purpose the
compressor system should be switched on and off again briefly.

The belt safety grille and noise reduction hood on the

compressor system are designed to prevent contact and may
not be removed until the above measures have been
completed.
1.4 Safety action for servicing
and operating the system
All work must be completed with the machine at a standstill and
depressurised. Switch off the main switch and secure it to prevent its
being switched on again. Close the shut-off valve to the compressed
air line (tank). Check the oil level when the compressor has warmed
up.

Important. Do not drain compressed air condensate into the

sewer without prior treatment (see 3.4).

3 11 5 6

12

1 7
2
8

13

10

1 Motor 6 Compressed air manifold 11 Start-up relief and condsate

2 Belt pulley 7 Compressor model plate drain valve SMV
3 V-belt 8 Oil dipstick and ail filler cap 12 Final cooler / cooling pipe
4 Compressor 9 Start-up relief valve OMV 13 Oil drain cock
5 Safety valves 10 Non-return valve


Function description

2. Function description
2.1 The drive 2.3 Safety valves
The electric motor drives the compressor via the belt pulleys and the The reciprocating compressor is protected against excess pressure by
V-belt. a safety valve. On two-stage systems there is another safety valve
between the first and second stage to protect the intermediate pressure.
This is calibrated to the appropriate maximum pressure and sealed to
2.2 The airway prevent its being adjusted unintentionally.
Boosters compress compressed air from a low input press to a higher The seal must not be removed. The manufacturer cannot accept any
final pressure. The compressed air is distributed evenly among all the liability for damage caused by removing the seal.
cylinders by the compressed air header pipe on the intake side and is
fed into the compression chamber. The air input and output is controlled
by the input / output valve in the cylinder head. After the compression 2.4 Pressurised tank (tank systems only)
process the hot compressed air is fed into the air header pipe on the Pressurised tanks are subject to the Pressurised Tank Directive and
output side and then into the final cooler. must be registered with the local monitoring authorities (for example
TÜV) using the test certificates provided.
As a result of the vibration of the compressor it must be connected to
Keep these test certificates safely.
the compressed air systems at the input and output sides using flexible
hoses. Shut-off fittings upstream and downstream of the compressor
are helpful for completing servicing work.
An initial filter positioned immediately upstream, of the compressor
prevents the compressor suffering damage due to dirt particles carried
in the low pressure system. If the low pressure system is subject to
large fluctuations a pressure controller is to be installed so that the
compressor is supplied with constant pressure.

Compressor 11
10

1 9

7 8 12 15
2
13
6
PSHL
3 4 4
14

5 1

16

1 Shut-off valve 7 Compressor 13 Pressure switch

2 Initial filter 8 Motor 14 Compressed air tank
3 Pressure reducer 9 Final pressure safety valve 15 Tank safety valve
4 Hose 10 Intermediate cooler 16 Compressed air tank condensate valve
5 Pressure relief valve OMV 11 Pressure relief valve and condensate drain
6 Initial pressure safety valve 12 Non-return valve


 Installation and Operation

3. Installation 3.4 Condensate disposal

Cooling the compressed air in the cooler produces condensate that is
3.1 General information drained automatically when the line pressure is released after it cuts
f The compressor is mounted on a sturdy frame. A flat, solid floor is out automatically when it reaches the final pressure.
required for its installation. Vibration dampers must be used to reduce
vibration. The reciprocating compressor is to be placed in a cool, dry, Important: After it reaches the final pressure the system will
dust-free room with good ventilation. The room temperature must not release the pressure automatically. During this pressure relief
fall below 5°C and should not exceed +35°C. If the room temperature process the condensate line will be pressurised briefly.
is below 5°C the compressor room is to be fitted with a temperature
control system. In adverse conditions, the warm flue air is to be removed In addition the condensate that forms in the tank must be
through flue air ducts or blowers and an adequate fresh air supply is drained at regular intervals. This condensate contains oil and
to be provided. The installation site should offer easy access. must not be drained straight into the sewer without first
undergoing treatment (oil – water separation p).
Important – Compressors without noise reduction hoods must
be installed in a separate room. Ear protection is to be
worn. 4. Operation
4.1 Control elements
3.2 Pneumatic connection Compressors with a star-delta control cabinet (optional) have the
Reciprocating compressors are supplied ready for connection. The following control elements:
connection to the pipework may only be made using flexible hose so
that the compressor can be installed without casing stress in the
pipework. The end of the pipe on the compressed air system must be
properly secured.
A non-return valve between the compressed air line or compressed air Hour counter Main switch Operating lamp
tank and the compressor is already integrated in your reciprocating Start-Stop button
compressor. A shut-off device must be fitted in the compressed air line
so that the reciprocating compressor can be disconnected from the
compressed air system.

Connection of units to a separate compressed air tank

Line pressure switch

35 bar compressors that are equipped with a control cabinet without
Control line
a star-delta switch have an On-Off switch on the control cabinet with
a switch contactor.
The control elements on 10 and 15 bar compressors without a
Outlet line
star-delta switch (machines that can be switched on direct) are on the
actual pressure switch.
If the control cabinet has not been sourced from us, the compressor
will be controlled by the site control cabinet.

CAUTION: IF THE COMPRESSOR HAS BEEN SWITCHED ON IT

MAY START AUTOMATICALLY.
3.3 Electrical connection
f The electrical connection of the system may only be made by an
authorised electrician who must check the conformity of the current 4.2 Shut-down
type, voltage and frequency with the data on the model plate. In The compressor cuts out when it reaches the final pressure set on the
particular the technical connection conditions of the local electricity pressure switch and cuts in again automatically when the pressure falls
supply company must be complied with. below the line pressure set on the pressure switch.
The size of the power supply lead and the fuse must comply with
IEC 60 364. See page 11.
For power units the supplied pressure switch must be connected to
the compressed air tank.


Commissioning
5. Commissioning
5.0 General instructions
Before you commission the system check the following points.
5.1 Check the oil level
The oil level must be checked every day at the oil window or oil dipstick
(see illustration on page 7). The minimum oil level must always be
above the bottom of the red circle / bottom mark on the oil dipstick.
You must top up the system with fresh oil before the oil level reaches
this mark.
Error lamp RESET button
We recommend that you use the OIL LEVEL CONTROL (optional as
from 4 kW and in conjunction with a control cabinet with a star-delta
switch) to monitor the oil level and prevent the compressor being
damaged due to a lack of oil. A sensor that uses the calorific principle
is screwed into the crank casing instead of the oil dipstick and is
immersed in the oil. As soon as this sensor is no longer covered by oil
a signal is sent to the electronic evaluation system that triggers an
error signal (the red lamp is lit) and shuts down the compressor.
After eliminating the error by topping up the oil and pressure the
Reset button, the compressor can be restarted.

5.2 Oil quality
F Do not mix different types of oil. If you use different types of
lubricant, contact our after-sales team p.
Only if you use verifiably equivalent lubricants can we offer a warranty
for our compressors.
Our special oil has been specially developed for heavily used
compressors and is suitable for all reciprocating compressors. This
special oil has a viscosity of 60 mm+/s at a temperature of 50°C. It is
suitable for high temperatures and ideal for permanent operation.
Our special oil quality 3 is a synthetic oil for heavy use single-stage
compressors with very high thermal stresses. Before use the compressor
must be flushed out with this oil and the oil window must be replaced
with a version that is resistant to synthetic oil. Precise instructions are
available from our after-sales team p.
5.3 Direction of rotation of the motor (see 1.3)
f The direction of rotation must comply with the arrows
on the belt safety grille and the electric motor. To check the
direction of rotation the system must be switched on and
off again briefly to ensure that the compressor does not
suffer any damage. The direction of rotation can be changed
by swapping two supply cables.
5.4 Starting
Before switching on the system ensure that nobody is in danger. The
belt safety grille and noise reduction hood act as contact guards and
may only be removed when the compressor is at a standstill, has been
disconnected from the power supply and depressurised. Open the
shut-off slide valve between the system and the compressed air line
(tank). Connect the system to the line.
Switch on the main switch and press the green Start button.
IMPORTANT. THE COMPRESSOR MAY START AUTOMATICALLY
AT ANY TIME ONCE THE START BUTTON HAS BEEN PRESSED.
Pressurised lines are to be checked for leaks. When it reaches the final
pressure the system will cut out.
5.5 Stopping
Press the red Stop button.
The white operating lamp will go out and the compressor cuts out.
F Only press the EMERGENCY STOP main switch in an
emergency.
The system may otherwise only be switched off using the red Stop
button.
 Servicing

6. Servicing the system
6.1 General information
All servicing work must be completed in compliance with the local
health and safety regulations.
In addition servicing work may only be completed by trained personnel
(ask our after-sales team about training courses p) when the
compressor system has been switched off, has reached a standstill and
has also been depressurised.
The compressor must be secured to prevent its being switched on again
without authorisation.
6.2 Cleaning and checking
The valves must be checked after 2,000 to 5,000 hours and replaced
if they are defective. When you install them ensure that you do not
correctly. If heavy oil carbon deposits are found when the compressor
is exposed to normal loads, check the oil and, if necessary, replace it
with a more suitable oil. Information on this is available from our
after-sales team p.
The cooling ribs on the cylinder heads and cooling system are to be
checked at regular intervals and any deposits are to be removed from
them if necessary.
6.5 Changing the oil and cleaning the cooling
pipe / cooler
The oil is to be changed and the cooling pipe / cooler cleaned (when
dirty) as set out in the servicing interval table (page 11). The required
are listed on page 11. If you use different lubricants please contact our
after-sales team p.
Only if you use verifiably equivalent lubricants can we offer a warranty
for our compressors.
6.6 Changing the oil when the compressor is
warm
Change the oil by draining the oil through the oil drain cock / oil drain
screw into a suitable vessel. After this close the oil cock / oil drain screw
again and pour oil of a suitable quality into the oil filler neck up to the
top mark on the oil window (see illustration) or up to the top mark on
the oil dipstick. When the compressor has reached operating
temperature check for leaks. Dispose of the old oil as special waste.

Oil window
6.3 Belt drive
When you replace the V-belts you must replace all the belts at the same
time. To do this, push the electric motor towards the compressor after
Max.
released the motor tensioning device. Place the new V-belts over the
V-belt pulley in sequence and tensioned by pulling back the electric
motor with the tensioning device. Min.

6.4 Condensate
Cooling the compressed air results in the formation of condensate in
the cooler. The condensate is drained during the drainage phase when
the compressor is at a standstill through the SMV solenoid valve. The
condensate must be collected and disposed of as described in 3.4.
Oil dipstick
IMPORTANT: On two-stage systems that are not operated at
full load condensate is also formed in the crank casing. If the
oil level rises and the compressor only runs briefly, switch it
off and take a specimen of the oil. If there is condensate in
the oil contact our after-sales team p to select a more
suitable oil. Remove the condensate by cover the cooler in
stages, or by wrapping spiral rib cooling pipes. Until the Max.
problem has been remedied, change the oil after every 30
hours. Min.


Servicing
6.7 Safety valves
The function of the safety valves must be checked at regular intervals.
This check is to be conducted at a line pressure of at least 85% of the
trip pressure of the safety valve. To do this the safety valve is to be
turned anti-clockwise several turns until the valve blows off and then
turned clockwise again until the valve is sealed again.
If the valve is obviously dirty or the seal is damaged the safety valve
must be replaced. To do this clean the screw-in thread and screw in
the new safety valve with sealing tape or sealing compound. When it
has reached operating temperature check for leaks.
Safety valve

6.8 Line pressure switch
The line pressure switch setting depends on the compressor type. A
precise description is provided with the relevant pressure switches. The
pressure is to be read off the pressure gauge to achieve a precise
adjustment. To do this build up pressure slowly at the air outlet by
throttling until the cut-out pressure is reached (read off the gauge)
and then release the pressure slowly until the cut-in pressure is reached.
IMPORTANT. Only make this adjustment when the system is
pressurised.
Line pressure switch 10-15 bar
Line pressure switch 16-40 bar

Error Cause
7.1 System does not start when you - Line pressure still too high
press the green Start button - Line pressure set too high
- Line pressure switch defective
- Control power circuit broken
- No voltage at the compressor
- Electrical error in the controller
- Control fuse defective
7.2 Line pressure drops - Cylinder head seal defective
- Valve fault
- Pistons, piston rings or cylinders
defective
- Compressed air consumption higher
than compressor delivery rate
- Leaks in the line
- Solenoid valve does not close
7.3 Compressor safety valve or tank - Flow to the tank defective
safety valve blows off
- Line pressure set too high
- Safety valve defective
7.4 Strange noises - V-belts loose
- Belt safety grille loose
- Piston striking valve head
- Piston rod out of its mountings
- Bearing defective
- Non-return valve defective
7.5 Compressed air escapes when the - Non-return valve (seat) defective
compressor is at a standstill
7.6 Compressed air escapes whilst the - Pressure release valve seat defective - Replace the valve
compressor is operating
7.7 Electric motor (7) becomes hot - Too frequent switch cycles
- Inadequate air supply
Troubleshooting
Action Section
- Watch line pressure indicator
- Reset line pressure switch 6.8
- Replace line pressure switch 6.8
- Check with the circuit diagram
- Check with the circuit diagram
- Check with the circuit diagram
- Check with the circuit diagram
- Fit a new seal
- Replace the valve plate 6.2
- Send in the compressor to be repaired
- You require a compressor with a higher
delivery rate p
- Seal the line
- Clean or replace
- Check for blocked cooler / pipe 6.5
- Check non-return valve
- Reset line pressure switch 6.8
- Replace safety valve 6.7
- Retension V-belts 6.3
- Secure belt safety grille
- Remove foreign bodies
- Send the compressor for repair
- Send the compressor for repair
- Replace non-return valve
- Clean valve seat or replace the valve
- Reduce switch cycles, increase tank
volume with a larger or additional
tank p
- Improve ventilation and venting

Servicing intervals

Servicing and inspection of the compressor Before Every Every After After Every ... hours
commissio- day week 50 150
ning hours hours 100 500 2.000 10.000

Check direction of rotating

Oil level
Condensate formation
Tighten electrical connections
Check for condensate in the oil
Tighten screw connections
First oil change
Second oil change
Further oil changes
Check valves/pistons/cylinders/safety valves
Check and, if required, change V-belt
Overhaul compressor

10
 Technical data

Type Booster 2-42-55 Booster 2-42-70 Booster 2-42-74 Booster 3-42-74

Minimum initial pressure (bar) 5 5 5 7,5 10 5 7,5 10
Maximum final pressure (bar)) 35 20 40 40

Number of cylinders 2 2 2 3

Compressor speed (rpm) 600 600 775 860

Delivery rate (l/min) 15 bar 440 560 720 1120 1470 1300 1980 2590
pursuant to DIN 1945 at 20 bar 420 540 689 1085 1440 1230 1910 2530
final pressure ... 25 bar 410 – 671 1050 1405 1190 1840 2480
30 bar 400 – 646 1025 1385 1140 1800 2440
35 bar 390 – 634 995 1349 1110 1755 2330
40 bar – – 585 958 1305 1060 1700 2300

Nominal motor rating 15 bar 2,2 2,2 3,0 3,0 3,0 5,5 5,5 5,5
(kW) 20 bar 2,2 3,0 4,0 4,0 4,0 7,5 7,5 7,5
at final pressure ... 25 bar 3,0 – 4,0 4,0 4,0 7,5 11,0 11,0
30 bar 3,0 – 4,0 5,5 5,5 11,0 11,0 11,0
35 bar 3,0 – 4,0 5,5 7,5 11,0 11,0 15,0
40 bar – – 5,5 5,5 7,5 11,0 11,0 15,0
Weight (kg) 15 bar 100 100 120 120 120 165 165 165
at final pressure ... 20 bar 100 110 130 130 130 220 220 220
25 bar 110 – 130 130 130 220 220 220
30 bar 110 – 130 160 160 220 220 220
35 bar 110 – 130 160 180 220 220 220
40 bar – – 160 160 180 220 220 220
Dimensions (mm) L 1110 1110 1110 1110
B 480 480 500 590
H 720 720 720 720

Compressed air connection /2“

1
/2“
1
/2“
1 3
/4“

Quantity of oil l 0,50 0,50 1,40 1,80

� �

11
ALMIG-Kompressoren GmbH
Manual_Booster_gb_12-2007

Adolf-Ehmann-Str. 2 D-73257 Köngen

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

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

E-mail: service@almig.de
Internet: www.almig.de