Operating Instructions: Screw Compressor Delta Screw

OPERATING INSTRUCTIONS
SCREW COMPRESSOR
DELTA SCREW
Read the instructions prior to performing any task!

Keep for future reference!
V4-060 K
Translation of the original operating instructions

Material no.: 2000023686
Doc content: 01.04.2017
Series: VM8R, -15R, -21R, -37R, VML18R, -25R, -40R
GB
Aerzener Maschinenfabrik GmbH
Reherweg 28
31855 Aerzen
Germany
Telephone: +49 (0) 5154 81-0
Fax: +49 (0) 5154 81-9191
Email: [email protected]
Internet: www.aerzen.com
V4-060 K, 1, en_GB
This manual was created by:

Technical documentation department of Aerzener Maschinenfabrik
GmbH
Technical editing and illustration
Heiko Nickel / Angela Pedack
© Aerzener Maschinenfabrik GmbH 2017
2 V4-060 K 11.04.2017
Table of contents
Table of contents
1 General Information............................................................ 8
1.1 Information about these instructions............................. 8
1.2 Explanation of symbols................................................. 8
1.3 Copyright protection.................................................... 10
1.4 Addresses................................................................... 11
1.4.1 Manufacturer............................................................ 11
1.4.2 Customer service..................................................... 11
2 Safety................................................................................. 12
2.1 Residual risks and fundamental risks......................... 12
2.1.1 Electrical hazards.................................................... 13
2.1.2 Hazards associated with the acoustic hood............. 15
2.1.3 Risks of machines with belt guard........................... 18
2.1.4 Hazards at the installation site and operating site... 20
2.1.5 Mechanical hazards................................................. 23
2.1.6 Thermal hazards...................................................... 23
2.1.7 Risks from pressurised components........................ 24
2.1.8 Risks from hazardous substances........................... 25
2.1.9 Risks from flammable substances........................... 26
2.1.10 Risks associated with conveyance of nitrogen...... 27
2.1.11 Environmental risks................................................ 28
2.2 Intended use............................................................... 29
2.3 Foreseeable misuse................................................... 29
2.4 Responsibility of the operator..................................... 31
2.5 Replacement parts...................................................... 34
2.6 Requirements for personnel....................................... 35
2.6.1 Qualifications........................................................... 35
2.6.2 Unauthorised personnel........................................... 37
2.6.3 Training.................................................................... 38
2.7 Personal protective equipment................................... 39
2.8 Safety devices............................................................ 40
2.8.1 EMERGENCY STOP function................................. 40
2.8.2 Hinged support with lifting device............................ 43
2.8.3 Acoustic hood.......................................................... 43
2.8.4 Belt guard ............................................................... 44
2.8.5 Cover of the belt pulley............................................ 44
2.8.6 Discharge silencer insulation................................... 44
2.9 Safety classification.................................................... 44
2.10 Instruction signs........................................................ 47
2.11 Danger zone and operating area.............................. 47
2.12 Securing the machine against restarting.................. 48
2.13 Environmental protection.......................................... 50
3 Design and operation....................................................... 51
3.1 Overview of assemblies.............................................. 51
11.04.2017 V4-060 K 3
Table of contents
3.2 Overview of assemblies.............................................. 52

3.3 Functionality................................................................ 53
3.4 Functionality................................................................ 53
3.5 Nitrogen operation...................................................... 54
3.6 No-load/full-load adjustment....................................... 54
3.7 Operating modes........................................................ 56
3.8 Operating methods..................................................... 57
3.8.1 Switching frequency between load operation and
no-load operation..................................................... 57
3.8.2 Operating information for pneumatic conveyance... 58
3.8.3 Operating information for air-separation systems.... 58
3.9 Description of assemblies........................................... 58
3.9.1 Base support............................................................ 59
3.9.2 Intake side............................................................... 59
3.9.3 Machine stage......................................................... 59
3.9.4 Oil system................................................................ 60
3.9.5 Drive system............................................................ 60
3.9.6 Discharge side......................................................... 61
3.10 Control elements (optional)....................................... 62
3.10.1 Factory-installed control element........................... 62
3.10.2 Customer-installed control element....................... 62
3.11 Accessories............................................................... 63
3.11.1 Drive motor............................................................. 63
3.11.2 AERtronic............................................................... 65
3.11.3 Instrumentation...................................................... 65
3.11.4 Frequency converter.............................................. 66
3.11.5 Machine terminal box............................................. 68
3.11.6 Butterfly throttle...................................................... 68
3.11.7 Shut-off valve......................................................... 69
3.11.8 Discharge pressure gauge..................................... 69
3.11.9 Nitrogen gauge...................................................... 69
3.11.10 Oil pressure gauge .............................................. 70
3.11.11 Maintenance indicator.......................................... 70
3.11.12 Intake filter in the intake silencer.......................... 71
3.11.13 Start-up relief device............................................ 71
3.11.14 Safety valve.......................................................... 72
3.11.15 Non-return flap..................................................... 73
3.11.16 Belt drive.............................................................. 73
3.11.17 Acoustic hood...................................................... 74
3.11.18 Oil filter................................................................. 75
3.11.19 Oil demister.......................................................... 75
3.11.20 Oil pressure regulating valve............................... 75
3.11.21 Oil cooler.............................................................. 76
3.11.22 Ventilator of the oil cooler..................................... 76
3.12 Required tools........................................................... 76
4 V4-060 K 11.04.2017
Table of contents
4 Transport, packaging and storage.................................. 78

4.1 Transport..................................................................... 78
4.1.1 Safety instructions................................................... 78
4.1.2 Delivery method....................................................... 81
4.1.3 Packaging................................................................ 82
4.2 Transport inspection................................................... 89
4.3 Storage and preservation........................................... 90
4.3.1 Storage.................................................................... 90
4.3.2 Preservation............................................................. 91
5 Set-up and installation..................................................... 94
5.1 Safety instructions...................................................... 94
5.2 Requirements for the installation site.......................... 96
5.3 Installation................................................................... 98
5.4 Connecting the system pipeline.................................. 99
5.5 Connecting the drive motor....................................... 100
5.5.1 Preparing the connection....................................... 100
5.5.2 Routing cables....................................................... 101
5.5.3 Connecting the drive motor.................................... 101
5.6 Connecting the drive motor....................................... 102
5.6.1 Preparing the connection....................................... 102
5.6.2 Routing cables....................................................... 102
5.6.3 Connecting the drive motor.................................... 103
5.7 Connecting the machine’s terminal strip................... 103
5.8 Connecting the earthing............................................ 104
5.9 Connecting the earthing............................................ 104
5.10 Laying the insulation mat........................................ 105
6 Initial start-up.................................................................. 106
6.1 Safety instructions.................................................... 106
6.2 Preparation for commissioning................................. 107
6.3 Performing the initial start-up.................................... 112
6.3.1 Hinged motor support with lifting device................ 114
6.3.2 Hinged motor support without lifting device........... 116
6.3.3 Carrying out a test run............................................ 119
6.4 Performing checks after commissioning................... 123
7 Operation......................................................................... 124
7.2 Shut-down in case of emergency............................. 125
7.3 Switching on............................................................. 126
7.3.1 On-site operation................................................... 126
7.3.2 Remote operation.................................................. 127
7.3.3 Automatic operation............................................... 127
7.4 Displaying operating parameters.............................. 128
7.5 Switching off.............................................................. 128
7.5.1 On-site operation................................................... 128
11.04.2017 V4-060 K 5
Table of contents
7.5.2 Remote-controlled operation................................. 128

7.5.3 Automatic operation............................................... 129
7.5.4 Switching off in nitrogen operation......................... 129
7.6 Decommissioning..................................................... 129
7.7 Measures for recommissioning................................. 130
7.7.1 Commissioning after adjustment works................. 130
7.7.2 Commissioning after maintenance work................ 130
7.7.3 Commissioning after fault rectification................... 130
7.8 Adjusting valves........................................................ 130
7.8.1 Adjusting the oil pressure regulating valve............ 131
7.8.2 Adjusting the start-up unloading device................. 132
7.8.3 Adjusting sealing gas pressure in nitrogen opera-
tion......................................................................... 133
7.8.4 Commissioning after adjustments.......................... 134
8 Maintenance.................................................................... 135
8.2 Maintenance schedule.............................................. 138
8.2.1 Maintenance schedule for normal operation.......... 139
8.3 Maintenance work..................................................... 141
8.3.1 Checking the oil level............................................. 141
8.3.2 Checking the oil pressure...................................... 144
8.3.3 Correcting the oil level........................................... 145
8.3.4 Changing oil........................................................... 150
8.3.5 Changing the oil filter............................................. 156
8.3.6 Replacing the intake filter...................................... 157
8.3.7 Checking the sheaves........................................... 157
8.3.8 Moving/checking the protective cover of the
sheaves................................................................. 158
8.3.9 Replacing belts, hinged motor support without a
lifting device .......................................................... 158
8.3.10 Replacing belts, hinged motor support with a
lifting device ........................................................ 162
8.3.11 Checking and servicing the safety valve.............. 164
8.3.12 Checking that sealing plugs have been removed 165
8.3.13 Checking the non-return flap............................... 165
8.3.14 Cleaning the nozzle of the start-up relief device.. 166
8.3.15 Checking the inlet and exhaust air openings on
the acoustic hood................................................. 166
8.3.16 Checking the belt guard....................................... 167
8.3.17 Cleaning the oil cooler lamellas........................... 167
8.3.18 Cleaning the oil demister..................................... 168
8.3.19 Checking pipelines for tightness.......................... 168
8.4 Cleaning after maintenance...................................... 169
8.5 Commissioning after maintenance........................... 169
8.6 Checks after maintenance work............................... 170
6 V4-060 K 11.04.2017
Table of contents
9 Malfunctions.................................................................... 171
9.2 Fault displays............................................................ 174
9.3 Fault diagnosis and troubleshooting......................... 174
9.4 Status and error messages (component suppliers).. 176
9.5 Commissioning after malfunction rectification.......... 177
9.6 Checks after malfunction rectification....................... 177
10 Disassembly and disposal............................................. 178
10.1 Safety instructions.................................................. 178
10.1.1 Disassembly........................................................ 180
10.2 Disposal.................................................................. 180
11 Technical specifications................................................. 184
11.1 Dimensions and weights......................................... 184
11.2 Dimension specifications sheet............................... 184
11.3 Operating data........................................................ 185
11.4 Technical performance data.................................... 186
11.5 Requirements for ambient and intake tempera-
tures........................................................................ 187
11.6 Type plate(s) and placement .................................. 188
11.7 Noise emissions...................................................... 191
11.8 Operating materials................................................. 192
11.8.1 Lubricant oil specifications................................... 192
11.8.2 Lubricant quantities.............................................. 196
11.9 Coating.................................................................... 197
11.10 Electrical details.................................................... 197
11.10.1 Voltage fluctuations............................................ 197
11.10.2 Earthing strap cross-sections ............................ 197
11.10.3 Motor overload protection.................................. 197
11.11 Accessory information........................................... 198
11.11.1 Oil pressure........................................................ 198
11.11.2 Oil filter............................................................... 198
11.11.3 Intake filter.......................................................... 198
11.11.4 Start-up relief device for VML machines............ 198
11.11.5 Machine speed adjustment in the case of
increased number of switchovers....................... 199
11.11.6 Balancing grade................................................. 199
12 Note on the declaration of conformity.......................... 200
13 Glossary........................................................................... 201
14 Index................................................................................. 203
11.04.2017 V4-060 K 7
General Information
Explanation of symbols
1 General Information
1.1 Information about these instructions
These instructions allow for the safe and efficient handling of this
machine. These instructions are an integral part of the machine
and must be kept in the immediate vicinity of the machine so that it
is accessible for personnel at all times. Keep these instructions in a
safe place for future reference.
Personnel must read these instructions carefully and have under-
stood them before beginning work. A fundamental requirement for
working safely is compliance with all specified safety notes and
guidelines in these instructions.
In addition, the local occupational health and general safety regula-
tions apply to the machine’s range of applications.
The diagrams in these instructions serve to provide the user with a
basic understanding and may deviate somewhat from the actual
design.
The following is a list of additional, supplementary documents:
Declaration of Conformity CE MRL 1012-1

Installation drawing
Operating manual
Drive motor
1.2 Explanation of symbols

Safety instructions Safety instructions in this manual are illustrated using symbols.
The safety instructions are organised into signalling words which
designate the level of danger posed.
DANGER!
This combination of symbol and signalling word
points to an imminently dangerous situation that
could be fatal or lead to serious injury if it is not
avoided.
WARNING!
points to a potentially dangerous situation that
could be fatal or lead to serious injury if it is not
avoided.
8 V4-060 K 11.04.2017
General Information
Explanation of symbols
CAUTION!
could lead to minor injuries if it is not avoided.
NOTICE!
could lead to material damage if it is not avoided.
ENVIRONMENT!
points to a potential risk for the environment.
Safety instructions as part of oper- Safety instructions may relate to certain individual operating guide-
ating guidelines lines. These safety instructions are integrated into the operating
guidelines themselves so as to simplify the task of reading while
carrying out work. The signalling words mentioned above are used.
For example:
1. Loosen screw.
2.
CAUTION!
Pinch hazard on the cover!
Close cover carefully.

3. Tighten screw.
Tips and recommendations

This symbol draws attention to useful tips and rec-
ommendations as well as information about effi-
cient and trouble-free operation.
Special safety instructions To draw attention to exceptional hazards, the following symbols are
used as part of the safety instructions:
11.04.2017 V4-060 K 9
General Information
Copyright protection
Warning signs Type of danger

Warning – automatic start-up.
Warning – hand injuries.
Warning – high-voltage.
Warning – flammable sub-

stances.
Warning – danger zone.
Additional designations To draw attention to operating guidelines, events, listings, refer-

ences and other elements in this manual, the following designa-
tions are used:
Designation Explanation
Step-by-step operating guidelines
1., 2., 3. ...
References to sections of this manual and
to relevant documentation
Lists without a designated sequence
[push-button] Control elements (e.g. push-buttons,
switches), display elements (e.g. signal
lamps)
„Display“ Screen elements (e.g. buttons, allocation of
function keys)
1.3 Copyright protection

The contents of this manual is protected by copyright. The use of
this manual is permitted within the framework of machine use. Any
other use is excluded unless there is written approval by the manu-
facturer.
10 V4-060 K 11.04.2017
General Information
Addresses > Customer service
1.4 Addresses
1.4.1 Manufacturer
Tab. 1: Manufacturer
Address Aerzener Maschinenfabrik GmbH
Reherweg 28
31855 Aerzen
Germany
Telephone +49 (0) 51 54 8 10
Fax +49 (0) 51 54 8 1 9191
E-mail [email protected]
Internet www.aerzen.com
1.4.2 Customer service

Our customer service staff are on hand to provide you with tech-
nical information:
Tab. 2: After sales service/service contact

Address Aerzener Maschinenfabrik GmbH
Reherweg 28
31855 Aerzen
Germany
Service hotline +49 171 3 51 18 34
E-mail [email protected]
Internet www.aerzen.com
In addition, we are always interested in receiving information and

feedback pertaining to machine use that could be useful in helping
us improve our products.
11.04.2017 V4-060 K 11
Safety
Residual risks and fundamental risks
2 Safety
This section gives an overview of all important safety aspects rele-
vant to the protection of persons and to safe and trouble-free oper-
ation. Further task-based safety instructions are contained in the
section on the individual phases of the machine’s service life.
Non-compliance with the handling and safety instructions provided
in this manual can lead to serious hazards.
The following section outlines the residual risks and hazards during
the service life of the product that may arise as a result of non-
compliance with safety instructions or the disabling of safety
devices.
In order to reduce health and safety risks and to avoid dangerous
situations, observe the safety and warning notes in this manual.
2.1 Residual risks and fundamental risks

The following chapter states the general residual risks that have
been established on the basis of a risk analysis.
n Compliance with these safety instructions and the safety
instructions in the main chapters reduces the risk of personal
injury, property damage and environmental harm and prevents
dangerous situations.
12 V4-060 K 11.04.2017
Safety
Residual risks and fundamental risks > Electrical hazards
2.1.1 Electrical hazards

Electric current
DANGER!
Risk of fatal injury from electric current!
Coming into contact with live parts poses an imme-
diate and potentially fatal risk of an electric shock.
Damage to insulation or individual components can
prove fatal.
– Work on the electrical system should only be
carried out by qualified electrical personnel.
– If the power supply’s insulation is damaged,
switch off the machine immediately and have
the damage repaired.
– Before starting to work on active parts of the
electrical systems and operating equipment,
ensure that the machine is completely discon-
nected from any power source and remains so
for the for the duration of the work.
When doing this observe the following 5 safety
rules:
– Disconnect the machine completely.
– Secure the machine against restarting.
– Confirm that the machine is completely dis-
connected from any power source.
– Earth and short-circuit the device.
– Cover or shut off adjacent live parts.
– Never bypass or deactivate fuses.
– When changing fuses, comply with the correct
specified amperage.
– Keep moisture away from live parts. Moisture
can cause the machine to short-circuit.
11.04.2017 V4-060 K 13
Safety
Residual risks and fundamental risks > Electrical hazards
Stored charges
DANGER!
There is a risk of fatal injury from stored
charges!
Electrical charges can be stored in electronic com-
ponents and maintained even after the deactiva-
tion and separation of the electric power supply.
Coming into contact with these components can
lead to fatal injuries.
– Observe all applicable safety rules.
– Before performing any work on the listed com-
ponents, disconnect them completely from the
power supply.
– Observe a waiting period of 15 minutes under
all circumstances! This will allow the internal
capacitors to discharge.
– Measure to ensure there is no live voltage!
Operating faults caused by short-

circuiting WARNING!
Risk of injury from operating faults!
If the electrical system short circuits this can render
the entire system inoperable. Operating faults can
lead to serious injuries.
– Connect the machine’s earthing connections
and acoustic hood to the local equipotential
bonding rail.
– Install a fault-current circuit breaker in order to
prevent sparks and contact voltage in the event
of a fault.
– After all work on the machine has been carried
out, ensure that the earthing connection and
equipotential bonding are connected correctly.
14 V4-060 K 11.04.2017
Safety
Residual risks and fundamental risks > Hazards associated with the acoustic hood
2.1.2 Hazards associated with the acoustic hood

Inside the acoustic hood
DANGER!
Risk of injury if the acoustic hood is open
during operation!
By opening the acoustic hood while the machine is
in operation there is a risk of direct contact with
hazardous zones, e.g. hot surfaces or rotating or
moving components.
– Never open the acoustic hood while the
machine is in operation or in stand-by mode.
– Never stand on or reach into the acoustic hood
while the machine is in operation.
– Always lock the acoustic hood with the key pro-
vided and keep it locked.
– Only allow authorised personnel access to the
key.
Falling parts
CAUTION!
Risk of injury from unsecured parts of the
acoustic hood!
Unsecured parts of the acoustic hood can lead to
injuries if they fall from the machine.
– Secure loose elements against falling.
– Always wear protective gear.
– Have a second person help you.
Air flow at the air outlet

CAUTION!
Risk of injury from the strong air flow at the air
outlet of the acoustic hood!
Strong air flows at the air outlet on the acoustic
hood can suck in dirt particles from the environ-
ment and disperse them.
– Avoid standing in the direct vicinity of the air
flow.
– Wear safety goggles and a safety mask.
11.04.2017 V4-060 K 15
Safety
Noise
WARNING!
Risk of injury from noise!
The noise level present at the installation area can
cause hearing damage. The magnitude of the
noise level is dependent on operational data,
among other factors.
– Never undertake measures to bypass or deac-
tivate sound insulation.
– Wear hearing protection while working.
– Only stand in the high-noise-level area if it is
absolutely necessary.
Risk of falling
CAUTION!
Risk of injury from standing on the acoustic
hood!
Standing on the acoustic hood carries with it a risk
of injury from the potential collapse of the roof ele-
ments. Persons could fall into the internal area of
the machine.
– Never stand on the acoustic hood.
– Never exert pressure on roof elements.
Spark-generating work
WARNING!
Risk of fire and injury / damage to property
from spark-generating work in the immediate
vicinity of the machine!
Welding or cutting work on the machine or in the
immediate vicinity of the machine can cause fire to
break out. This can result in damage to property or
personal injury.
Sparks and incandescent or flammable objects
could be sucked in through the air openings on the
acoustic hood or through the intake silencer. The
ventilator can fan flames leading to the formation
of smouldering objects. The insulation material
may, under unfavourable conditions, begin to
smoulder.
– Avoid allowing sparks to fly in the direction of
the machine.
– Never carry out work that generates sparks
16 V4-060 K 11.04.2017
Safety
Risk of fire and injury

WARNING!
Risk of fire from easily-flammable materials
that are sucked into the machine!
Easily-flammable material, fluids or gases can be
sucked into the machine and cause it to catch fire.
This can lead to serious or fatal injuries.
– Never allow flammable materials to be sucked
into the machine.
– In case of emergencies, have extinguishing
agents (fire blanket, fire extinguisher, fire-extin-
guishing powder for fire class A, B, C) at hand.
– Immediately report suspicious materials, liquids
or gases to the responsible persons.
– In case of fire, stop your work immediately and
make an emergency call.
Use of non-original belts

WARNING!
Risk of fire and injury from using non-original
belts!
If, for a number of possible reasons, the machine
is running sluggishly or is blocked, the belts may
slip if non-original belts are being used. This
results in heat generation which may lead to a fire.
– Only use original belts from the machine manu-
facturer.
– Adhere strictly to the designated belt type, as
only this type will have the required character-
istics.
– Never select and use random belts.
– Activate motor overload protection and observe
the setting values.
11.04.2017 V4-060 K 17
Safety
Residual risks and fundamental risks > Risks of machines with belt guard
2.1.3 Risks of machines with belt guard

Noise
WARNING!
Risk of injury from noise!
The noise level present at the installation area can
cause severe hearing damage. The magnitude of
the noise level is dependent on operational data,
among other factors.
– Never undertake measures to bypass or deac-
tivate sound insulation.
– Wear hearing protection while working.
– Only stand in the high-noise-level area if it is
absolutely necessary.
Spark-generating work
WARNING!
Risk of fire and injury / damage to property
from spark-generating work in the immediate
vicinity of the machine!
Welding or cutting work on the machine or in the
immediate vicinity of the machine can cause fire.
Sparks and incandescent or flammable objects
could be sucked in through the intake silencer. The
air flow can fan flames leading to the formation of
smouldering objects. The insulation material may,
under unfavourable conditions, begin to smoulder.
– Avoid allowing sparks to fly in the direction of
the machine.
18 V4-060 K 11.04.2017
Safety
Residual risks and fundamental risks > Risks of machines with belt guard
Risk of fire and injury

WARNING!
Risk of fire from easily-flammable materials
that are sucked into the machine!
Easily-flammable material, fluids or gases can be
sucked into the machine and cause it to catch fire.
This can lead to serious or fatal injuries.
– Never allow flammable materials to be sucked
into the machine.
– In case of emergencies, have extinguishing
agents (fire blanket, fire extinguisher, fire-extin-
guishing powder for fire class A, B, C) at hand.
– In case of fire, stop your work immediately and
make an emergency call.
Use of non-original belts

WARNING!
Risk of fire and injury from using non-original
belts!
If, for a number of possible reasons, the machine
is running sluggishly or is blocked, the belts may
slip if non-original belts are being used. This
results in heat generation which may lead to a fire.
– Only use original belts from the machine manu-
facturer.
– Adhere strictly to the designated belt type, as
only this type will have the required character-
istics.
– Never select and use random belts.
– Activate motor overload protection and observe
the setting values.
11.04.2017 V4-060 K 19
Safety
Residual risks and fundamental risks > Hazards at the installation site and operating site
2.1.4 Hazards at the installation site and operating site

Securing the machine against
restarting DANGER!
An unauthorised or unregulated restart can
have fatal consequences.
An unauthorised or unregulated restart of the
machine can lead to serious or fatal injuries. There
may be people located in the hazard zone. Acti-
vating the energy supply and starting the machine
could result in those people being fatally injured.
– Prevent the machine from restarting by:
– disconnecting the electrical power supply.
– activating the EMERGENCY STOP func-
tion
– operating the main circuit breaker
– attaching a padlock to the main circuit
breaker
– checking and ensuring that the machine is
completely disconnected from the power
source
– displaying a sign on the machine that pro-
hibits a machine start
– displaying a sign on the remote station that
prohibits a machine start
– Before restarting, ensure that safety devices
are installed and functioning correctly and that
there are no potential hazards to the safety of
any persons.
Water contact with live compo-

nents DANGER!
Risk of fatal injury from water contact with live
components!
Risk of fatal injury from cleaning work with water in
areas with live components. Water spray may
enter electrical and electronic components.
– Do not use water.
– When performing cleaning operations, proceed
with care and make sure that no water comes
into contact with live components.
– Water spray must not enter electrical and elec-
tronic components.
– Under no circumstances must areas with live
voltage be cleaned using a high-pressure jet.
20 V4-060 K 11.04.2017
Safety
Unexpected machine start

WARNING!
Risk of injury or personal shock if the machine
starts suddenly!
For example, a superordinate control system could
send a start command to the machine so that it
starts operating.
– Shut down the machine for all work and secure
it against restarting.
– You must be prepared for the machine to start
at any time. Avoid surprise effects.
Sharp edges and corners

CAUTION!
Risk of injury from sharp edges and corners!
Sharp edges and corners can cause excoriations
and cuts on the skin.
– If working in the vicinity of sharp edges and
corners, proceed with caution.
– If in doubt, wear protective gloves.
Intake components
WARNING!
Risk of injury from intake components!
Intake-side silencers, at their inlets, suck in
ambient air with great force.
– During operation, never place body parts or
objects in front of the inlet of the silencer.
– Maintain a safe distance from intake compo-
nents.
11.04.2017 V4-060 K 21
Safety
Sudden gas emission

CAUTION!
Risk of injury from sudden gas emission!
Components such as safety valves and start
unloading devices may open suddenly during oper-
ation and emit hot compressed gas. Dust particles
may be blown around.
– Never attempt to look inside the blow-off
opening.
– Wear safety glasses when in the immediate
vicinity of these components.
– Never close the blow-off opening.
– Always keep the blow-off opening clean.
Vibrations
WARNING!
Risk of injury from vibrations!
Vibrations may, in the long term, lead to injuries
and chronic damage to personal health. The vibra-
tion source is decoupled from the surrounding
environment by means of a vibration damper.
– Do not deactivate the vibration damper.
– Avoid coming into contact with vibrating areas.
Build-up of fluids
CAUTION!
Risk of injury from slipping as a result of a
build-up of fluids!
Slipping on fluids that have built up on the floor
area may lead to a fall. A fall may result in injury.
– Immediately remove built-up fluids with a suit-
able medium.
– Wear non-slip safety shoes.
– Place a warning notice and mandatory sign on
or in the vicinity of any area where there could
be a build-up of fluids on the floor area.
22 V4-060 K 11.04.2017
Safety
Residual risks and fundamental risks > Thermal hazards
2.1.5 Mechanical hazards

Rotating components
WARNING!
Risk of injury from rotating components!
Rotating components may cause serious injury.
– During operation never reach into or perform
work on rotating components.
– Never open covers during operation.
– Observe the lag time: before opening covers,
make sure that no components are still moving.
– When in a hazard area, wear tight-fitting pro-
tective work clothing with minimal tensile
strength.
Risk of crushing and shearing inju-

ries WARNING!
Risk of crushing and shearing injury from the
hinged motor support!
Risk of injury from moving or adjusting the hinged
motor support!
– When transporting the machine, always have
the hinged motor support fixed in place.
– Never step or reach into the swivelling range of
the hinged motor support.
2.1.6 Thermal hazards

Hot surfaces
WARNING!
Risk of injury from hot surfaces!
Component surfaces may become very hot during
operation. Skin contact with hot surfaces causes
serious burns.
– For all work performed in the vicinity of hot sur-
faces, always wear protective work clothing
and protective gloves.
– Before beginning any work, ensure that all sur-
faces have cooled down to the environment
temperature.
11.04.2017 V4-060 K 23
Safety
Residual risks and fundamental risks > Risks from pressurised components
Hot media
WARNING!
There is a risk of injury from the sudden emis-
sion of hot media from the valve, e.g. a pres-
sure valve!
The emission of hot media may lead to scalding.
– Never stand in the immediate vicinity of the
outlet vent.
– Never attempt to look inside the outlet vent.
– Never close or cover the outlet vent.
2.1.7 Risks from pressurised components

Pressurised components
WARNING!
Risk of injury from compressed conveyed
materials!
When disassembling pressurised components, or
in the case of a fault in a pressurised component
such as pipes, containers, hoses or valves, hot
conveying material can escape with a strong gas
flow. This can result in serious injury.
– Before beginning work, fully relieve pressurised
components of pressure.
– Check that components are not pressurised.
– Replace malfunctioning components immedi-
ately.
– Only disassemble pressurised components
when they are not under pressure.
Noise during disassembly

CAUTION!
Risk of injury from noise during the disas-
sembly of pressurised gas pipes!
For the disassembly of pressurised components,
conveying material is released, resulting in noise.
This can cause hearing damage.
24 V4-060 K 11.04.2017
Safety
Residual risks and fundamental risks > Risks from hazardous substances
2.1.8 Risks from hazardous substances

Hazardous substances
WARNING!
Risk of poisoning due to hazardous sub-
stances! Risk of skin irritation and allergic
reactions!
Substances such as lubricants and cleaning
agents contain hazardous components. These can
lead to serious poisoning, skin irritation or allergic
reactions.
– Observe the safety data sheets.
– Avoid shaking these substances and avoid
mist formation.
– If inhalation occurs, bring the affected person
out into fresh air immediately. Seek medical
help.
– If a substance is swallowed, seek medical help
immediately. The mouth must be rinsed out
thoroughly with water.
– Avoid skin and eye contact:
Before working with these substances apply
suitable hand protection cream.
Wear plastic or rubber protective gloves.
– Remove any soiling from the workspace prop-
erly and in an environmentally-friendly way.
Lubricants and cleaning agents must not enter
the sewerage system or run into soil.
– Do not eat, drink or smoke when working with
these substances.
Hazardous dust
WARNING!
Risk of injury from rising dust!
Dust deposits may rise during machine operation.
Inhaling this dust may, in the long term, lead to
lung damage or other health problems.
– Avoid the relevant hazardous area.
– For all work in the hazard zone wear light res-
piratory protection.
11.04.2017 V4-060 K 25
Safety
Residual risks and fundamental risks > Risks from flammable substances
2.1.9 Risks from flammable substances

Fire hazard
WARNING!
Risk of fire from spark-generating work and
ignition sources in the immediate vicinity of the
machine!
Easily-flammable substances, fluids or gases may
catch fire and cause serious or fatal injury.
– Take measures to protect against the build-up
of steam in deep-lying or closed areas.
– Take measures to protect against electro-static
pressure charging.
– Do not smoke in the hazard zone or in the
direct vicinity of the machine.
Do not use naked lights, fire or ignition sources
of any kind.
– Have extinguishing agents (fire-extinguishing
powder) for fire class A, B, and C at hand.
– In case of fire, stop your work immediately.
Leave the hazard zone until it is safe to return
and notify the fire brigade.
Improper fire protection

WARNING!
There is a risk of injury and material damage
from limited or improper fire protection!
If, in the event of fire, the fire extinguisher is not
operational or not suited to the specific class of
fire, there is a risk of serious or fatal injury and con-
siderable material damage.
– Ensure that only suitable fire extinguishers
(fire-extinguishing powder for fire classes A, B
and C) are at hand.
– Inspect fire extinguishers every 2 years to
ensure they are functioning correctly.
– Refill fire extinguishers after each use.
– Only use extinguishing agents and replace-
ment parts that correspond to the recognised
model specified on the fire extinguisher.
– In case of use, observe the safety and oper-
ating instructions on the fire extinguisher.
26 V4-060 K 11.04.2017
Safety
Residual risks and fundamental risks > Risks associated with conveyance of nitrogen
2.1.10 Risks associated with conveyance of nitrogen

Leaking gas
DANGER!
Risk of suffocation from build-up of leaking
gases during nitrogen conveyance!
Gaseous nitrogen displaces the oxygen in the
room. High concentrations can cause persons to
suffocate. Symptoms here include the loss of phys-
ical mobility and loss of consciousness. An
affected person will not notice that they are “suffo-
cating”. Escaping nitrogen can accumulate for
example in recesses, wells, acoustic hoods.
– Avoid the occurrence of leaks.
– Ventilate the installation site properly.
– Set the lag time for the fan of the acoustic hood
and pay close attention to it.
– After a machine downtime, ventilate the
machine for a period.
– Guide leaking gases directly out of the
machine.
– Guide leaking gases directly into a collective
line.
Leaking gases during machine

downtime DANGER!
Risk of suffocation from build-up of leaking
gases during machine downtime!
Depending on the type of sealing used, gaseous
nitrogen can escape into the environment during
machine downtime. This can lead to a build-up of
gases inside the acoustic hood or at the installation
site. High concentrations can cause persons to
suffocate.
– Interrupt the flow of nitrogen into the conveying
system.
– Guide nitrogen away using a collective line.
11.04.2017 V4-060 K 27
Safety
Residual risks and fundamental risks > Environmental risks
Build-up of gas
DANGER!
Risk of suffocation from build-up of nitrogen
during conveyance!
When the safety valve is opened, nitrogen is
released from the system. There may be a build-up
of gas with high concentrations of nitrogen.
Gaseous nitrogen displaces the oxygen in the
room. High concentrations of nitrogen can cause
persons to suffocate. Symptoms here include the
loss of physical mobility and loss of consciousness.
The persons affected do not notice that they are
“suffocating”.
Escaped nitrogen can accumulate in recesses,
wells, acoustic hoods etc.
– Avoid a build-up of gas
– Guide gases directly out of the machine.
– Guide gases directly into a collective line.
2.1.11 Environmental risks

Environmentally hazardous mate-
rials ENVIRONMENT!
Environmental risk due to incorrect and negli-
gent handling of environmentally hazardous
materials!
Improper handling of environmentally hazardous
operating materials and cleaning and sealing
agents and, above all, their improper disposal, can
cause considerable damage to the environment.
These materials contain poisonous substances.
– Operating materials and cleaning and sealing
agents must not be released into the environ-
ment.
– Disposal must be carried out by a certified
waste management operator.
– If these materials are inadvertently released
into the environment, take appropriate action
immediately. If in doubt, contact the respon-
sible local authority and inform them about the
damage.
28 V4-060 K 11.04.2017
Safety
Foreseeable misuse
2.2 Intended use

The screw (-type) compressor machine is intended for the oil-
free conveyance and compression of air and non-flammable
gases.
Fig. 1: Correct use
The screw (-type) compressor machine is intended for opera-

tion with non-flammable gases in a non-explosive atmosphere.
The screw compressor machine has been designed and con-

structed solely for its “intended use” in the industrial field, as
described here.
Observe and comply with the order-related operational data and
operational limits!
This intended use also includes compliance with all information in
this instruction manual.
Any application that deviates from the intended use, or any other
type of non-standard application, is considered misuse.
Operating data that deviate from the standard must

be coordinated with the manufacturer.
2.3 Foreseeable misuse

Serious injury
DANGER!
Danger in case of misuse! Dangerous situa-
tions could occur that may lead to fatal or
serious injury!
– Never disregard the instructions for “intended
use”.
– Never operate the machine in an operating
area other than the one intended.
– Never convey or compress gases that are not
listed in the order confirmation and the tech-
nical data.
– Never disregard the following information on
misuse.
11.04.2017 V4-060 K 29
Safety
Foreseeable misuse
Serious material damage

NOTICE!
Danger in case of misuse! Dangerous situa-
tions could occur that may lead to serious
machine damage!
– Never disregard the instructions for “intended
use”.
– Never operate the machine in an operating
area other than the one intended.
– Never convey or compress gases that are not
listed in the order confirmation and the tech-
nical data.
– Never disregard the following information on
misuse.
Misuse
The machine is not intended for:

n Conveying media in solid, liquid or powder form.
n Conveying caustic media.
Fig. 2: Prohibited use n Conveying corrosive media.
n Conveying flammable or poisonous gases, vapours or mists.
n Alteration, retrofitting or modification of the overall design or
of individual equipment parts, with the aim of altering the field
of application or scope of use.
Further examples of misuse The following operating modes/applications and uses are consid-
ered improper and must be avoided!
30 V4-060 K 11.04.2017
Safety
Responsibility of the operator
n Operation:
– outside the scope of intended use.
– outside the scope of the intended operating data.
– using gases other than those originally intended.
– with the machine operating in the incorrect direction of rota-
tion.
– in a potentially-explosive atmosphere.
– with closed flange connections.
– with missing or damaged components.
– without a correctly connected control system, fault trans-
mitter, EMERGENCY STOP function.
– without any or with damaged protective equipment.
– with contaminated intake filter/starting strainer.
– without sufficient ventilation of the room.
– activation while the machine is coming to a stop or when it
is rotating backwards.
– pole changing to a lower rotational speed before the drive
motor has come to a standstill.
– non-compliance with maintenance intervals.
– filling beyond the maximum oil level.
n Operation without:
– Air filter
– Safety valve
– Intake silencer
– oil
n Applications:
– using the machine to “purge” blockages in the conveying
pipes.
– for exceeding the maximum permissible discharge pres-
sure.
– using the pressure valve to regulate the operational data.
n Installation:
– installation on inclined, sloped or lamellar surfaces.
– installation outdoors or without due consideration of partic-
ular protective measures for avoiding the effects of weather
conditions.
– attachment of transportation equipment to the acoustic
hood.
– open flames or spark formation in the immediate vicinity of
the machine.
2.4 Responsibility of the operator

Operator The operator is the person who either operates the machine him-
self, for commercial or business purposes, or who assigns the use
of the machine to a third party. During operation, the operator holds
legal responsibility pertaining to the product, for the protection of
the user, personnel or a third party.
11.04.2017 V4-060 K 31
Safety
Operator’s obligations The machine is used for commercial purposes. The operator of the
machine is thus subject to the applicable legal obligations for occu-
pational safety.
Alongside the safety instructions in this manual, the safety, occupa-
tional and environmental regulations relevant to the field of applica-
tion for the machine must also be complied with.
The operator is obligated to:
n Inform himself about the applicable occupational protection
regulations. As part of a hazard assessment, the operator must
also establish the hazards that could result from special
working conditions at the machine location. He must implement
these for the operation of the machine in the form of operating
instructions. The necessary safety data sheets can be obtained
from the relevant manufacturer.
n During the entire service life of the machine, check that the
operating instructions created by the manufacturer correspond
to the current status of the applicable regulations. If necessary,
adjust the operating instructions accordingly.
n Clearly structure and specify the responsibilities for installation,
operation, fault rectification, maintenance and cleaning.
n Ensure that all persons who come into contact with the
machine have read and understood these instructions. in addi-
tion, the operator must regularly provide personnel training as
pertains to machine use and inform personnel of the related
hazards.
n Provide personnel with the necessary protective equipment
and communicate to personnel that the wearing of this protec-
tive equipment is compulsory.
In addition, the operator is responsible for ensuring that the
machine is in perfect technical condition.
For this reason the following applies:
n The maintenance intervals described in this instruction manual
must be complied with.
n All safety devices must be regularly inspected to ensure they
are in good working order.
Additional obligations The operator must ensure that the following requirements are com-
plied with and put into practice:
n The machine is only operated in its original delivered condition.
In cases where the operator adds his own fittings or makes
modifications, the manufacturer’s declaration of conformity is
rendered void.
n Any working behaviour that jeopardises the safety of the
machine is prohibited.
n The machine must always be kept in a technically-perfect and
operationally-safe condition. Replace damaged or non-opera-
tional components immediately. If in doubt, be sure to contact
the manufacturer or the responsible contact person.
n Do not operate the machine when the protective equipment
has been disassembled or disabled.
32 V4-060 K 11.04.2017
Safety
n Observe all warnings and notices displayed on the machine

and make sure they are readable. You must replace loose or
illegible signs. Ask the manufacturer for replacements.
n Install the separately provided components listed in the scope
of delivery onto the machine and incorporate these into the
overall safety concept.
n Do not disassemble or incorrectly fit any electrical, mechanical
or hydraulic connections.
n For protection against potential damage caused by lightning,
make sure a suitable earthing system is in place.
n If the conveyed medium tends to form condensate, the conden-
sate must be bled off (e.g. using discharge tanks, residual gas
pipes or by briefly opening the lower condensation holes).
n Separate dusty material before it enters the machine. Material
that collects in the conveying chamber or the rotors presents a
particular danger for the working safety of the machine.
– This also applies to the compression of re-sublimating
gases. Hard particles could be discharged during the gas
phase and collect in the machine.
n Use suitable process control (pressurisation, partial pressurisa-
tion, temperature, speed) to prevent re-sublimation in the
machine.
Safeguards for the machine stage The operator must ensure that the following requirements are com-
and pressurised pipelines plied with and put into practice:
n For machines with oil pressure and discharge pressure moni-
toring, the electrical connection must be safeguarded.
The machine stage is secured by sensors for oil pressure, dis-
charge pressure and discharge temperature.
The sensors are wired at the factory to a fault indicator device
or control system. In the event of deviation from the permis-
sible operating parameters, the fault indicator device or control
system switches off the drive motor.
For systems without a fault indicator or control system, an
operationally reliable control system must be provided by the
customer.
Connect the fault indicator or control system to the safety line
of the drive motor, in accordance with the wiring diagram.
n The fault indicator or control system and drive motor must be
fed from the same electric circuit in order to rule out the possi-
bility of motor operation with no safety line.
Operator’s obligations at the instal- The operator must ensure that the following requirements are com-
lation site plied with and put into practice:
n Machine use only in a stable three-phase power supply.
Voltage fluctuations / drops beyond the tolerance level may
cause serious damage to the drive system.
n Activate motor overload protection.
11.04.2017 V4-060 K 33
Safety
Replacement parts
n For system variants without a main circuit breaker featuring an

EMERGENCY STOP function, the safety circuit of the machine
should be incorporated into the EMERGENCY STOP concept
for the overall system. Ensure the accessibility of additional
EMERGENCY STOP switches in the vicinity of the machine.
The machine must be equipped with one or more EMER-
GENCY STOP command devices for the purposes of opera-
tion.
The EMERGENCY STOP function must be available and
operational at all times, independent of the operating mode.
n It must not be possible for a powered-down machine to start
automatically.
n For the purposes of operation, the machine must be equipped
with a command device that shuts down the machine in dan-
gerous situations.
The power supply to the motor must be cut off.
If this is not possible, the “standstill” operating condition must
be monitored and maintained.
n Avoid electrostatic charges. Connect an equipotential bonding.
n For accidents and emergencies, incorporate emergency meas-
ures for the machine into the overall emergency measures.
Make particular efforts to integrate these measures into the
evacuation and rescue plan and the fire warning plan.
2.5 Replacement parts

Use of incorrect replacement parts
CAUTION!
Safety risk from using incorrect replacement
parts!
Incorrect, defective or unsuitable replacement
parts or copies of original components may
endanger personal safety and lead to damage,
faults or the total failure of the machine.
– Only use the manufacturer’s original replace-
ment parts or parts approved by the manufac-
turer.
– If in doubt, always contact the manufacturer.
Purchase replacement parts from an authorized dealer or from the

manufacturer directly. For contact information see
Customer serviceÄ on page 11.
Replacement parts Replacement parts that have not been provided by AERZEN have
not been tested or approved. They do not correspond to the orig-
inal components. The use of such products can potentially have an
effect on the default design characteristics of the system. The man-
ufacturer assumes no liability for damage resulting from the use of
non-original components.
34 V4-060 K 11.04.2017
Safety
Requirements for personnel > Qualifications
2.6 Requirements for personnel

2.6.1 Qualifications
The various tasks described in this instruction manual represent a
variety of requirements in terms of the qualifications of the persons
responsible for carrying out these tasks.
Insufficient qualifications
WARNING!
Risk if persons are not sufficiently qualified!
Insufficiently qualified persons are unable to gauge
the risks presented by the use the machine and
put themselves, and others, at risk of serious or
fatal injury.
– Only allow work to carried out by suitably quali-
fied persons.
– Observe the information on qualifications in
this manual.
– Keep insufficiently qualified persons away from
the operating range of the machine.
For the purposes of all work with this machine, only allow persons
who are expected to carry out their work reliably to do so. Persons
whose reaction times have been impaired, e.g. through drug or
alcohol consumption or medication, must not be permitted to work.
This instruction manual contains the following qualification require-

ments for the various tasks:
Authorised electricians
Authorised electricians, on the basis of their field-specific training,
expertise, experience and knowledge of the relevant standards and
requirements, are able to carry out their work on electrical systems
safely while independently recognising and avoiding hazards.
Authorised electricians are specially trained for the environment in
which they work and are familiar with the relevant standards and
requirements.
Authorised electricians with additional qualifications

Authorised electricians have the additional qualifications needed
for working in the field of frequency converters and EMC. Author-
ised electricians are familiar with the relevant standards and
requirements.
Written documentation acts as proof of a completed safety instruc-
tional course and evidence of the necessary additional knowledge.
Due to their additional qualifications, these authorised electricians
are able to carry out work on electrical systems with frequency
converters and can independently recognise and avoid possible
hazards. The additional skills that constitute this qualification
should be taught through regular practical application.
11.04.2017 V4-060 K 35
Safety
Requirements for personnel > Qualifications
Manufacturer’s customer service division

Certain work may only be performed by the customer service divi-
sion of the manufacturer. On the basis of its special, field-specific
training, expertise and experience, the customer service division is
up to the task of performing highly-skilled work.
The customer service division is a competent point of contact for all
stages of the machine’s service life. It is able to perform all work on
the machine with the highest efficiency.
Service personnel
Service personnel are able to carry out their work on the basis of
their field-specific training, expertise, experience and knowledge of
the relevant standards and requirements. Personnel recognise
hazards independently and avoid risks.
Service personnel in particular possess practical experience and
extensive field-specific expertise for the variety of tasks.
n Transport
n Set-up / installation
n Commissioning
n Maintenance
n Fault rectification
n Disassembly
Depending on the designated job, the person must have additional
qualifications:
n Operation and handling of compressors.
n Parameterisation of compressors.
n Optimisation work within the persmissible operating data
range.
Skilled staff for industrial waste

Skilled staff for industrial waste posses comprehensive, field-spe-
cific expertise relating to the disposal and recycling of industrial
waste. Skilled staff transports the industrial waste to the waste dis-
posal company and holds responsibility for proper sorting of waste.
The staff incorporates this sorting into the recycling and disposal
processes.
Trained persons
A trained person has been expressly instructed and, if necessary,
trained on site by the responsible management about the tasks
delegated to him or her and the risks that are posed by improper
behaviour. A trained person has been instructed regarding the nec-
essary protective equipment and protective measures. He or she is
in a position to work cautiously and to recognise hazards and react
accordingly. The trained person may not interfere with the handling
and operation of the machine.
Depending on the designated job, the person must have the fol-
lowing expertise:
n Transport and handling of packaged units.
n Ability to perform visual inspections of the machine.
36 V4-060 K 11.04.2017
Safety
Requirements for personnel > Unauthorised personnel
User
The machine user is trained by the system operator in terms of
operation, maintenance work and basic fault rectification. He or
she is informed of possible operational hazards and improper
behaviour. Tasks that go beyond those for which the machine user
is trained or instructed may only be carried out if these tasks are
listed in this instruction manual and the operator has expressly
designated these tasks to the user.
2.6.2 Unauthorised personnel

Unauthorised personnel in the
installation area WARNING!
Risk of fatal injury for unauthorised persons in
the installation area!
Unauthorised persons who do not fulfil the require-
ments described here, are not familiar with the
hazards in the installation area. Therefore, unau-
thorised persons are at risk of serious or fatal
injury.
– Keep unauthorised persons away from the
installation area.
– If in doubt, instruct such persons to leave the
installation area.
– Stop all work as long as unauthorised persons
are in the installation area.
11.04.2017 V4-060 K 37
Safety
Requirements for personnel > Training
2.6.3 Training
The operator must regularly provide safety training for personnel.
For tracking purposes, a training report must be drafted with the
following mandatory content:
n Date of training
n Name of the training participant
n Content of the training
n Name of the training instructor
n Signatures of the participant and instructor
Date Name Type of training Training Signatures

provided by
38 V4-060 K 11.04.2017
Safety
Personal protective equipment
2.7 Personal protective equipment

Personal protective equipment serves to protect persons from
breaches of safety and health hazards when working.
Personnel, when working near or with the machine, must wear the
personal protective equipment described separately in the various
sections of this instruction manual.
Description of personal protective The following is a description of the personal protective equipment:
equipment
Hearing protection
Hearing protection serves to protect against hearing damage from
noise generation.
Industrial hard hat

Industrial hard hats protect the head against falling or stray objects
and loads and from collisions against stationary objects.
Light respiratory protection

Light respiratory protection protects against harmful dusts.
Protective gloves
Protective gloves protect hands from friction, abrasion, puncture
hazards or more serious injuries and from contact with hot sur-
faces.
They are oil-resistant and protect hands from coming into contact
with lubricants.
Protective work clothing

Protective work clothing is tight-fitting work clothing with minimal
tensile strength, tight sleeves and without protruding parts.
Safety goggles
Safety goggles serve to protect the eyes against flying particles
and splashing liquids.
11.04.2017 V4-060 K 39
Safety
Safety devices > EMERGENCY STOP function
Safety shoes
Safety shoes protect feet from being crushed, from falling objects
and from slipping on slippery surfaces.
2.8 Safety devices
Correct functioning of safety

devices WARNING!
Risk of fatal injury from non-functioning safety
devices!
Non-functioning or deactivated safety devices may
cause serious or fatal injury.
– Before beginning work, check that all safety
devices are functioning correctly and are cor-
rectly installed.
– Never deactivate or bypass safety devices.
– Ensure that all safety devices are accessible at
all times.
2.8.1 EMERGENCY STOP function
The EMERGENCY STOP function serves, in cases

where there is a hazard or when one is averting a
hazard, to bring the machine quickly to a safe stop
(standstill).
Depending on the customer’s specifications, machine variants are

available with or without a power circuit breaker system.
Depending on the model, the machine:
n may not feature a control system
n may not feature an EMERGENCY STOP function
Before operating the machine:

Check whether the EMERGENCY STOP function is in place and
installed.
It must function perfectly.
40 V4-060 K 11.04.2017
Safety
EMERGENCY STOP command

device
An EMERGENCY STOP command device includes a special com-
mand unit which is connected to the control system.
The EMERGENCY STOP function allows for the machine to be
shut down safely and immediately in case of a potential or existing
hazard.
The power supply to all turning components is interrupted immedi-
ately when the EMERGENCY STOP function is activated.
Fig. 3: Example: EMERGENCY STOP
It is also possible to install additional EMERGENCY STOP com-
command device
mand devices.
Without a power circuit breaker n For this variant, an EMERGENCY STOP command device is
system not installed on the machine at the factory.
n The machine is delivered without an EMERGENCY STOP
apparatus.
n The operator must provide a power circuit breaker system with
electrical overload protection, an On/Off command unit and an
EMERGENCY STOP function.
n Perform Stop Category 0.
n Detail the performance data of the electrical installation in
accordance with the operating data of the motor. Take into con-
sideration the necessary data, for example: voltage, current,
frequency.
n The connection to the power supply is made using the installed
and delivered power cabinet.
n The lines running to the power supply are fed directly to the
electric motor and are connected inside a terminal box.
n Feed the connection lead through the cable conduit to the ter-
minal box.
n Protect the motor against overheating.
n A main circuit breaker must be installed.
With a power circuit breaker n Depending on the model, an EMERGENCY STOP command
system device is installed at the factory in the power circuit breaker
system.
– If the factory-installed power circuit breaker system does
not feature an EMERGENCY STOP command device, this
must be provided by the operator.
Perform Stop Category 0.
–If the factory-installed power circuit breaker system does
feature an EMERGENCY STOP command device, Stop
Category 0 is performed.
n A main circuit breaker must be installed if it is not part of the
power circuit breaker system.
n The power supply is connected at the power cabinet.
n Observe the wiring scheme!
11.04.2017 V4-060 K 41
Safety
Notes on installation by the oper- The EMERGENCY STOP facility must:

ator
n be installed and integrated into the safety line of the system
controller.
n be clearly recognisable, highly visible and quickly accessible.
n shut down dangerous operation quickly without causing any
additional risks.
n if necessary, trigger specific safety measures or authorise the
triggering of safety measures.
n be installed in such a way that the machine user can activate it
immediately in an emergency.
n be designed in such a way that, in cases where there is an
interruption in the power supply or the power supply is acti-
vated after an interruption, no situations can occur in which
there is a threat of personal injury or material damage.
n supplement other protective measures without acting as a sub-
stitute for them.
Requirements for installation by The EMERGENCY STOP function must be available and opera-
the operator tional at all times, independent of the operating mode.
The EMERGENCY STOP facility must not require the entire
machine to be voltage-free. In situations where a risk is detected, it
must be possible for the user to stop the machine in order to pro-
tect against a hazard. For the purposes of a controlled shut-down,
electrical voltage may be necessary. The electrical system is still
under voltage.
If several EMERGENCY STOP devices are in place, all of these
devices must be able to shut down the machine.
The EMERGENCY STOP function must, after being triggered,
remain effective until authorisation is given for a restart.
It must not be possible to attempt to block the EMERGENCY
STOP device without a “stop” command being issued.
Ensure that it is only be possible to release the EMERGENCY
STOP device by means of authorised activation.
This authorisation must not cause the machine to start operating
again automatically but rather it should make a machine restart
possible.
42 V4-060 K 11.04.2017
Safety
Safety devices > Acoustic hood
2.8.2 Hinged support with lifting device
The hinged support serves to protect against

mechanical hazards.
n The hinged support holds the motor hinge in place during

transport and assembly. It prevents uncontrolled movement of
the motor hinge.
n When operating the machine, the hinged support must be
released and positioned accordingly.
Fig. 4: Hinged support
2.8.3 Acoustic hood
The acoustic hood serves to protect against

mechanical and thermal hazards.
n The acoustic hood is an essential safety component of the

product.
n The elements of the acoustic hood must be locked with the
provided special locks during operation and in stand-by mode.
n Operation with an open acoustic hood is not permissible.
Fig. 5: Acoustic hood, front view n The locking key for the acoustic hood is a component of the
(example) overall safety concept. Access to the key must only be possible
for personnel who have been briefed in the safe operation of
the machine and the contents of the instruction manual.
Fig. 6: Acoustic hood, rear view

(example)
11.04.2017 V4-060 K 43
Safety
Safety classification
2.8.4 Belt guard

Belt guard
The belt guard serves to protect against rotating

components.
n A belt guard is always used in machines without an acoustic

hood. It serves to protect against rotating components.
Fig. 7: Belt guard
2.8.5 Cover of the belt pulley

Cover of the belt pulley
The cover serves to protect against rotating com-

ponents.
n The belt guard features two plastic covers.

n These serve to protect the rotating belt pulleys and prevent
persons from reaching directly into the belt drive.
Fig. 8: Cover
2.8.6 Discharge silencer insulation
The cover serves to protect against contact with

hot surfaces.
n The surface of the discharge silencer is covered with an insula-

tion jacket.
n The cover prevents direct contact with the hot surfaces of the
discharge silencer.
Fig. 9: Insulation jacket
2.9 Safety classification

The following symbols and notices are displayed on the machine.
They relate to the immediate vicinity in which they are located.
44 V4-060 K 11.04.2017
Safety
Unreadable signage
WARNING!
There is a risk from unreadable signage!
There is a risk of injury resulting from dirty or
unreadable signs. It may be impossible to recog-
nise hazards and to follow the necessary operating
information.
– Keep all safety, warning and operating informa-
tion in a thoroughly readable condition.
– Replace damaged signs or stickers immedi-
ately.
Safety and warning signs

The layout of warning signs involves a set of stickers affixed to the
machine. These constitute warning, instruction and prohibition
signs. Furthermore, signs relating to lubricants and their handling
are only visible when the acoustic hood is closed.
Fig. 10: Layout of warning signs
Placement of the sticker set on the acoustic hood.
Fig. 11: Position on the acoustic hood
11.04.2017 V4-060 K 45
Safety
Placement of the sticker set on the belt guard.
Fig. 12: Position on the belt guard

model
Access for unauthorised persons

forbidden
Only persons given authorisation by the operator may enter the
hazard area.
Electrical voltage
Only qualified electrical personnel may work in the signposted
working area.
Unauthorised persons are not permitted to enter the signposted
working area or open the signposted cabinet.
Automatic start-up
The sudden start-up of operational machines in the rest position is
possible at any time.
Take heed of the stand-by mode! A sudden start is possible.
Hot surfaces
Hot surfaces, such as hot machine parts, containers or materials -
but also hot liquids - are not always noticeable. Do not touch them
without protective gloves.
Hand injuries
Keep hands away from areas that carry this warning sign.
There is a risk that hands could be crushed, trapped or injured in
some other way.
46 V4-060 K 11.04.2017
Safety
Danger zone and operating area
Pressure in the piping

Pipelines may be placed under pressure.
Before carrying out disassembly work, deactivate the pressure in
the pipelines.
Draw-in of gas
Pipelines can suck in large volumes of air in the immediate vicinity
of the intake openings.
Avoid the air-intake area. Shut down the machine before under-
taking any activities in this area.
2.10 Instruction signs

Wear hearing protection
In areas where this symbol is displayed there is a risk of hearing
damage. Therefore, wear hearing protection when in these areas.
Information on wearing hearing protection

< 80 dBA Hearing protection is not prescribed as
mandatory but should be worn as a matter
of personal responsibility.
80 to 85 dBA Hearing protection is recommended
> 85 dBA Hearing protection must be worn
Observe the instruction manual

Only use the labelled machine once you have read the instruction
manual.
2.11 Danger zone and operating area

Hazard area
Operating and/or display area
The hazard area is located in the marked zone (in the acoustic
hood interior zone). The opening of acoustic hood elements and
protective covers during operation is not permissible. Opening is
permissible only for maintenance work or for troubleshooting and
provided all safety precautions are observed. The operating and/or
display area is the position marked in green (example).
Fig. 13: Hazard area and operating

and/or display area (top-down view)
11.04.2017 V4-060 K 47
Safety
Securing the machine against restarting
Hazard area
Operating area
The hazard area is located in the marked zone. The operating area
is the position marked in green (example).
Fig. 14: Operating and hazard areas

(bird’s-eye view)
2.12 Securing the machine against restarting

Sudden restart
DANGER!
may be people located in the hazard zone. Acti-
vating the energy supply and starting the machine
could result in those people being fatally injured.
– Prevent the machine from restarting by:
– disconnecting the electrical power supply.
– activating the EMERGENCY STOP func-
tion
– operating the main circuit breaker
– attaching a padlock to the main circuit
breaker
– checking and ensuring that the machine is
completely disconnected from the power
source
– displaying a sign on the machine that pro-
hibits a machine start
– displaying a sign on the remote station that
prohibits a machine start
– Before restarting, ensure that safety devices
are installed and functioning correctly and that
there are no potential hazards to the safety of
any persons.
EMERGENCY STOP button (option)

1. Press the EMERGENCY STOP button
ð The power supply is shut off.
48 V4-060 K 11.04.2017
Safety
Securing the machine against restarting
2. Activate the main circuit breaker.

ð The machine is free of current.
3. Attach a padlock to the main circuit breaker.
4. Ensure that the machine is completely disconnected from the
power source.
5. Inform supervisory personnel of work in the hazard area.
6. Place a sign on the machine and (where applicable) remote
station that notifies persons of the work being carried out in
the hazard area and forbids activation of the machine. The
sign must contain the following information:
n Shut-down on:
n Shut-down at:
n Shut-down by:
n Important: Do not switch on!
n Important: Only switch on the machine once it has been
ensured that there is no risk to personal safety.
EMERGENCY STOP feature (oper-

ator-installed) The particular approach to preventing a restart is
dependent on the operator-installed EMERGENCY
STOP feature.
1. Secure the machine against restarting in accordance with the

operator’s instructions.
2. Follow the instructions of the responsible supervisory per-
sonnel.
3. Once all work has been completed, ensure that there is no
risk to personal safety.
4. Ensure that all safety and protective equipment is installed
and operational.
11.04.2017 V4-060 K 49
Safety
Environmental protection
2.13 Environmental protection

Environmentally hazardous mate-
rials ENVIRONMENT!
Improper handling of environmentally haz-
ardous materials presents a threat to the envi-
ronment!
Incorrect handling of environmentally hazardous
materials, particularly in the case of improper dis-
posal, can cause considerable damage to the envi-
ronment.
– Always observe the information below on the
handling of environmentally hazardous mate-
rials and their disposal.
– If environmentally hazardous materials are
inadvertently released into the environment,
take appropriate action immediately. If in doubt,
inform the responsible local authority about the
damage and seek advice on taking appropriate
measures.
The following environmentally hazardous materials are used:
Lubricants Lubricants such as greases and oils contain poisonous sub-

stances. They must not be released into the environment. Disposal
must be carried out by a certified waste management company.
AERtronic batteries Batteries contain poisonous heavy metals. They require special
waste treatment and must be deposited at local collection points or
disposed of by specialist companies.
Electronics Electrical and electronic components may contain poisonous mate-

rial. These components must be collected separately and depos-
ited at local collection points or disposed of by specialist compa-
nies.
Anti-corrosion agents Anti-corrosion agents may contain poisonous substances. They

must not be released into the environment. Disposal must be car-
ried out by a certified waste management operator.
50 V4-060 K 11.04.2017
Design and operation
Overview of assemblies
3 Design and operation

3.1 Overview of assemblies
Fig. 15: Overview

1 Intake side
2 Machine stage
3 Oil system
4 Drive system
5 Discharge side
11.04.2017 V4-060 K 51
Overview of assemblies
3.2 Overview of assemblies
Fig. 16: Overview

1 Intake side
2 Machine stage
3 Oil system
4 Drive system
5 Discharge side
52 V4-060 K 11.04.2017
Functionality
3.3 Functionality
The medium to be conveyed is drawn in from the ambient air. The
medium to be conveyed enters through an intake filter. This is
located inside the base support. This base support acts as an
intake silencer that is free of absorption media.
There is also the option of attaching an intake-side pipeline.
The screw (-type) compressor draws in, conveys and compresses
the medium to be conveyed. The medium then flows through the
discharge silencer, via a non-return flap, into the customer’s
system. A safety valve is located between the non-return flap and
the discharge silencer. The surface of the discharge silencer is
insulated to protect against contact with hot surfaces.
The screw (-type) compressor is powered by a drive motor using a
belt drive. The belt drive derives tension automatically from the
weight of the motor. The drive motor is powered by connected
electrical cables at the terminal box.
Lubricating oil is supplied using an oil pump. The oil pump begins
operation when the screw (-type) compressor is started. The lubri-
cating oil goes through a filtering and cooling cycle and is then
transported to the consumers. The oil chamber is sealed so that
lubricating oil cannot enter the screw (-type) compressor.
The ventilation of the acoustic hood is carried out by a ventilator.
This is installed at the shaft end of the machine stage.
3.4 Functionality
The medium to be conveyed is drawn in from the ambient air. The
medium to be conveyed enters through an intake filter. This is
located inside the base support. This base support acts as an
intake silencer that is free of absorption media.
There is also the option of a connection to an intake-side pipeline.
The screw (-type) compressor conveys and compresses the
medium to be conveyed. The medium then flows through the dis-
charge silencer, via a non-return flap, into the customer’s system.
A safety valve is located between the non-return flap and the dis-
charge silencer.
The screw (-type) compressor is powered by a drive motor using a
belt drive. The belt drive derives tension automatically from the
weight of the motor. The drive motor is powered by connected
electrical cables at the terminal box.
Lubricating oil is supplied using an oil pump. The oil pump begins
operation when the screw (-type) compressor is started. The lubri-
cating oil goes through a filtering and cooling cycle and is then
transported to the consumers. The oil chamber is sealed so that
lubricating oil cannot enter the screw (-type) compressor.
11.04.2017 V4-060 K 53
No-load/full-load adjustment
3.5 Nitrogen operation

Depending on the design of the seal, the first retaining ring is
relieved of pressure in order to avoid gas leakage during operation.
A pipeline joins the retaining ring connection to the machine’s
intake side. This pipeline contains a valve with a gauge for
adjusting the sealing gas pressure.
Adjusting the valve There should be minimal primary pressure of 50 mbar in the relief
line. The sealing gas pressure is adjusted using the display on the
gauge. Ä Chapter 7.8.3 „Adjusting sealing gas pressure in
nitrogen operation“ on page 133
Primary pressure In machines with primary pressure, this valve is opened fully.
3.6 No-load/full-load adjustment

No-load/full-load adjustment allows for a relieved start-up of the
VM machine stage against an existing mains pressure.
Intake side A throttle butterfly is located in the inlet pipe of the machine stage,
with a drilled hole that corresponds to the conveyed amount.
During the start phase, the machine stage draws in the medium
through this hole. The throttle butterfly is controlled using a sole-
noid valve by means of oil pressurisation.
The corresponding control pulse is produced by a pressure monitor
(min/max). The pressure monitor is installed in the pressure line
downstream of the non-return flap.
Discharge side The discharge side features a bypass line with a shut-off valve.
The shut-off valve performs the function of a relief valve. The
medium to be conveyed is released through the shut-off valve into
the atmosphere during the start phase. The shut-off valve is con-
trolled using a solenoid valve by means of air pressurisation.
The corresponding control pulse is produced by a pressure monitor
(min/max). The pressure monitor is installed in the pressure line
downstream of the non-return flap.
Pressure monitor switching range Set the pressure monitor’s switching range (min/max) to as great
as possible: at least 0.5 bar.
54 V4-060 K 11.04.2017
No-load/full-load adjustment
NOTICE!
Running the machine with a closed throttle but-
terfly and simultaneously closed shut-off valve will
cause massive, irreparable damage to the
machine stage.
Start phase During the start phase, the machine runs with the throttle butterfly
closed and the shut-off valve opened. The pressure monitor is
bypassed for 10 seconds. At the same time the machine stage
starts up and the drive motor accelerates to the rated speed. The
machine stage begins no-load operation.
WARNING!
Warm conveyed medium is released in large vol-
umes through the shut-off valve!
Full-load operation Once the pressure monitor’s bypass period has elapsed, the
throttle butterfly first begins to open and then the shut-off valve
begins to close. The machine stage goes into full-load operation.
No-load operation Once network pressure is reached, the pressure monitor delivers a
pulse to the solenoid valves of the shut-off valve and the throttle
butterfly.
WARNING!
Hot conveyed medium is released in large vol-
umes through the shut-off valve!
n The shut-off valve opens.

n The non-return flap closes.
n The throttle butterfly closes.
Start phase longer than 10 seconds

NOTICE!
If the drive motor’s start phase takes longer than
10 seconds, the solenoid valves must be controlled
externally by direct means.
Example: By means of pulses from the delta con-
nector, after a switch from star to delta. A pressure
monitor is not necessary in this case.
11.04.2017 V4-060 K 55
Operating modes
Diagram
Fig. 17: Example: No-load/full-load control

1 Intake filter 10 Pressure monitor
2 Butterfly throttle 11 Solenoid valve
3 Machine stage 12 Drive motor
4 Discharge silencer 13 Coupling
5 Safety valve 14 Alternating pressure valve
6 Non-return flap 15 Oil pressure
7 Shut-off valve (relief valve) 16 Relief
8 Exhaust silencer (optional) 17 Air pressure
9 Solenoid valve
3.7 Operating modes

On-site operation Operation of the machine is carried out directly on site.
Remote operation Operation of the machine is carried out via control station.
Automatic operation Automatic operation of the machine is carried out by sensors or

system switches.
Load operation Load operation is an operating mode in which the machine oper-
ates within the range of the specified operating data.
56 V4-060 K 11.04.2017
Operating methods > Switching frequency between load operation and no-load operation
No-load/full-load adjustment No-load/full-load adjustment allows for a relieved start-up of the

VM machine stage against an existing system pressure.
3.8 Operating methods

3.8.1 Switching frequency between load operation and no-load operation
Switch between load operation and The number of switches between load operation and no-load oper-
no-load operation ation depends on:
n Discharge pressure
n Conveyed amount
n Speed
n Conveying system’s buffer volume
Permissible switchovers
NOTICE!
Serious damage to the machine through:
– Exceeding the permissible switchovers
– Exceeding the permissible total no-load opera-
tion time
permissible Permissible total no- Measures:

switch- load operation time
overs
Minutes per hour
per hour
1-6 6 none
7 - 20 20 Reduction of tip speed to
max. 90 m/s
Adjustment of machine’s
speed
Ä 11.11.5 „Machine
speed adjustment in the
case of increased number
of switch-
overs“ on page 199
Higher switchover rate If a higher rate of switchovers is required, AERZEN recommends

using a frequency converter-controlled drive. Driving the machine
using a frequency converter allows reduction of the machine’s no-
load operation speed and thus facilitates substantial energy sav-
ings.
11.04.2017 V4-060 K 57
Description of assemblies
3.8.2 Operating information for pneumatic conveyance

Pneumatic conveyance When the machine is being used for the purposes of pneumatic
conveyance, pressure surges must not occur when switching
between different delivery lines.
Pressure surges can be prevented by making the switching
process for the intake-side and discharge-side valves take at least
five seconds. This pre-accelerates the gas column in the pipework.
The gas can no longer accelerate suddenly. This prevents damage
to the machine.
The distance between the switchover valve and the intake-side
flange must be at least 10 x DN. DN = nominal diameter of the
pipework.
This safety note applies to both pressure and vacuum mode.
3.8.3 Operating information for air-separation systems

Operating information for air-sepa- When the machine is being used in air-separation systems with
ration systems alternating air-separation columns, pressure surges must not occur
when switching between different delivery lines.
Pressure surges can be prevented by making the switching
process for the intake-side and discharge-side valves take at least
five seconds. This pre-accelerates the gas column in the pipework.
The gas can no longer accelerate suddenly. This prevents damage
to the machine.
The distance between the switchover valve and the intake-side
flange must be at least 10 x DN. DN = nominal diameter of the
pipework.
This safety note applies to both positive pressure and vacuum
pressure mode.
3.9 Description of assemblies
For the purposes of explaining its functionality, the machine is

divided into several assemblies. Each assembly consists of a
number of components which, combined, perform a specific
machine function. One assembly can consist of sub-assemblies
and additional components.
58 V4-060 K 11.04.2017
Description of assemblies > Machine stage
3.9.1 Base support

The base support serves as the base for the whole bodywork of
the machine. It contains the intake side of the machine, including
the intake filter. The base support is an exhaust silencer which is
free of absorption media.
Fig. 18: Base support with hinged

motor support
3.9.2 Intake side

4010 Intake filter
610 Base support
The base support contains the intake-side assembly. This serves
to reduce noise and to filter the medium to be conveyed before it
enters the machine stage.
Fig. 19: Intake side
3.9.3 Machine stage

100 Machine stage
The machine stage is the core of the machine and includes all
components for gas compression. The gas compression process
takes place in the machine stage.
Fig. 20: Machine stage
11.04.2017 V4-060 K 59
Description of assemblies > Drive system
3.9.4 Oil system

720 Oil cooler
789 Oil filter
1210 Oil demister
The oil system contains all components necessary for providing
lube oil to the machine stage. In the start phase, the appropriate oil
temperature is controlled and adjusted by a thermostat. An oil
cooler ensures the correct oil temperature during operation. The oil
pressure is created by means of the oil pump and the compressor
start-up. The oil pressure can be adjusted using an oil pressure
regulating valve. An oil filter ensures the purity of the lube oil. Oil
mist that materialises in the oil chamber is collected, filtered and
Fig. 21: Oil system released back into the oil chamber by an oil demister.
720 Oil cooler

789 Oil filter
1210 Oil demister
The oil system contains all components necessary for providing
lube oil to the machine stage. In the start phase, the appropriate oil
temperature is controlled and adjusted by a thermostat. An oil
cooler ensures the correct oil temperature during operation. The oil
pressure is created by means of the oil pump and the compressor
start-up. The oil pressure can be adjusted using an oil pressure
regulating valve. An oil filter ensures the purity of the lube oil. Oil
mist that materialises in the oil chamber is collected, filtered and
released back into the oil chamber by an oil mist separator.
Fig. 22: Oil system
3.9.5 Drive system

1810 Motor
2110 Belt drive
The drive system comprises the drive motor and the drive ele-
ments, e.g. the belts and sheaves. The drive system provides a
high revolution speed for the rotational motion of the machine
stage.
Fig. 23: Drive system
60 V4-060 K 11.04.2017
Description of assemblies > Discharge side
3.9.6 Discharge side

3070 Discharge silencer with insulation jacket
3020 Non-return flap
4410 Safety valve
The discharge-side assembly represents the components of the
discharge-side conveying system. The discharge-side assembly
includes all components fitted downstream from the machine stage
gas outlet. All components are pressurised during operation and
have hot surfaces. A discharge silencer serves to reduce noise
emissions. The discharge silencer insulation also serves to protect
against contact with hot surfaces.
Fig. 24: Discharge side
11.04.2017 V4-060 K 61
Control elements (optional) > Customer-installed control element
3.10 Control elements (optional)

3.10.1 Factory-installed control element
Factory-installed control element
Observe the AERtronic instruction manual.
The AERtronic instruction manual is included with the product.
Fig. 25: Operator interface

1 Information menu
2 Service display
3 Local/ LOCATION / START
4 Local/ LOCATION / STOP
5 Pressure ranges register
6 Temperature ranges register
7 Additional operating parameters register
8 Service and setup register
9 Selection buttons of the given display menu within a register
10 Graphic representation
11 Numerical representation
12 Bar graph display
13 Measurement value display
3.10.2 Customer-installed control element

Customer-installed control element
Depending on the model and version - with or
without a corresponding controller - the control ele-
ments are not part of the scope of delivery. The
installation and design of the control elements is
then the responsibility of the customer.
62 V4-060 K 11.04.2017
Accessories > Drive motor
3.11 Accessories
The accessories are the total collection of components belonging
to the machine or to the supplementary equipment.
3.11.1 Drive motor

Motor connection requirements
The cable and lead sheathing must be resistant to
the normal wear expected due to the movement of
the hinged motor support and the effects of con-
taminants in the atmosphere.
General requirements n Fine-core cable is recommended for the connecting leads.

n The connecting hardware must be suitable for the cross-sec-
tion and type of the connecting leads.
n Cables, leads and connections must not be subjected to exces-
sive bending and tensile forces. Install the connecting cable via
a stayed cable bridge (not provided) to prevent the terminal
box being subjected to forces or stress.
n Install cables and leads in such a way that they cannot sustain
any external damage.
n Avoid contact with the machine, excessive friction and exces-
sive radiant heat.
n The connecting cable must be resistant to light movements,
e.g. the changes in the rotational speed of the motor.
General requirements n Fine-core cable is recommended for the connecting leads.

n The connecting hardware must be suitable for the cross-sec-
tion and type of the connecting leads.
n It may be necessary to remove the intake console and the
acoustic hood cover to connect the motor, depending on the
size and output of the machine.
n Cables, leads and connections must not be subjected to exces-
sive bending and tensile forces. Install the connecting cable via
a stayed cable bridge (not provided) to prevent the terminal
box being subjected to forces or stress.
n Install cables and leads in such a way that they cannot sustain
any external damage.
n Avoid contact with the machine, excessive friction and exces-
sive radiant heat.
n The connecting cable must be resistant to light movements,
e.g. the changes in the rotational speed of the motor.
11.04.2017 V4-060 K 63
Accessories > Drive motor
Requirements for the electricity

network NOTICE!
There is a risk of material damage from voltage
fluctuations / drops!
Voltage fluctuations / drops beyond the tolerance
interval may lead to serious damage to the drive
system.
Requirements for operating positive displacement
machines with electric induction motors in a three-
phase AC supply system:
– Use suitable protective equipment that will shut
the motor down and safeguard it against an
automatic restart if impermissible electrical
operating data is detected.
– Connect the motor and control voltage to a
stable common network to ensure that the
power contactor is no longer latched if the
power supply fails.
– Comply with voltage and frequency
limits.Ä Chapter 11.10.1 „Voltage fluctua-
tions“ on page 197
Connection n Only authorised electricians may perform the connection.

n Electricians must observe all applicable regulations when con-
necting the drive motor.
n Observe the tightening torques of the terminal screws.
n Secure all connections against inadvertent release or loos-
ening.
n Ensure that the nominal electrical data is complied with during
operation.
Control circuit types n Star-delta connection

n Pole changing
n Speed control using frequency converter
n Direct start
Permissible starting frequency up to 160 kW 6 starts per hour

from 200 kW 3 cold starts or 2 warm starts per hour
Refer to the operating manual provided by the drive motor manu-
facturer for further specifications and information.
64 V4-060 K 11.04.2017
Accessories > Instrumentation
3.11.1.1 Drive motor - factory installation

Factory installation
Observe the information on the type plate and in
the drive motor instruction manual.
Refer to the drive motor instruction manual for
electrical operating data, maintenance intervals
and suitable lubricants.
3.11.2 AERtronic
AERtronic
The AERtronic is used as a control device and as a display and
monitoring device.
The AERtronic is fitted with a colour graphics display with a touch-
screen interface.
When starting for the first time, these settings can be changed.
Other handling and operation of the controller is defined on the dis-
play; the user is guided through the menu by prompts in a struc-
tured manner.
Fig. 26: AERtronic Display The AERtronic includes all the functions necessary for start and
shut-down procedures and displays the operating parameters and
prompts.
Observe the operating manual for the purposes of commissioning
and operation!
AERZEN reserves the right to change, expand or improve the
hardware and software of this product as required. This does not
include any obligation to update units already shipped.
3.11.3 Instrumentation
The instrumentation consists of several assemblies.
1.) Pressure and temperature sensors in conjunction with the
AERZEN AERtronic control system.
2.) Pressure and temperature sensors in conjunction with display
gauges.
Shut-down locking n The shut-down devices are set at the factory.

n All shut-downs must be self-locking. Once the shut-down has
been given clearance, the machine must not be able to start
automatically.
n Prior to a restart, the cause of the malfunction must be deter-
mined and eliminated. Start-up must then take place manually.
11.04.2017 V4-060 K 65
Accessories > Frequency converter
NOTICE!
The switching points of the switches are fixed and
must not be changed.
Oil pressure switch To enable the machine to start, the oil pressure limit contact is
bypassed for a few seconds by a timer relay.
If the contact is not closed after 25 seconds (there is no oil pres-
sure), the drive motor must switch off.
If the oil pressure drops below the preset limit during operation, the
floating limit contact will open. The machine must switch off!
NOTICE!
The drive motor must switch off, if:
– after the start phase (after 25 seconds), no oil
pressure has been produced.
– the oil pressure drops suddenly during opera-
tion and falls below the preset limit.
Pressure switch If an intake pressure and discharge pressure switch are used to
safeguard the machine, it must also be ensured that the drive
motor switches off when the limit switches trigger.
Contacts open ÞDrive motor off.
Temperature switch If a discharge temperature switch is used to safeguard the

machine, it must be ensured that the drive motor switches off when
the limit switches trigger.
Contacts open ÞDrive motor off.
Pressure switch (optional) It is also possible to use an additional pressure switch. A calibrated
gauge is used to adjust the switching limit point. The scale on the
switch only serves as a guide.
3.11.4 Frequency converter

Description
Observe the frequency converter manufacturer’s
operating manual!
66 V4-060 K 11.04.2017
Accessories > Frequency converter
NOTICE!
– If the electric motor is driven by frequency con-
verters, we strongly recommend using an
engine throttle and power choke. These are
specifically designed for the frequency con-
verter and filter dangerous harmonics from the
actuator current. This prevents damage to the
motor winding. The electromagnetic compati-
bility of the system is also improved. Reactions
of the frequency converter in the current are
reduced.
– The maximum current limit of the motor must
not be exceeded. Observe the information on
the motor name plate.
– To prevent operational faults the function “Inter-
ception circuit” must not be parameterised in
the control of the frequency converter. When
the frequency converter is switched off, a
restart should only be possible after a complete
shut-down of the blower or compressor.
– The machine must shutdown without braking.
The activation of a brake ramp or quick stop is
not permissible.
For machine use, observe the fol- n Take into account the electrical and mechanical properties of
lowing the drive motor.
n The minimum frequency must always be fixed. This frequency
must never fall below the fixed minimum during operation.
n The maximum frequency is to be set by taking into account the
maximum rotational speed of the motor and the maximum
machine speed.
n The run-up time of the drive motor from standstill up to min-
imum speed can be 3 to 6 seconds.
n The frequency converter must be designed with a constant
load torque for operation with a working machine.
n Never exceed maximum and or drop below minimum speed
thresholds.
n When exceeding the value, e.g. due to excessively long
cables, frequency converter type etc. a motor throttle or motor
filter coil to match the frequency converter is to be used.
NOTICE!
Not using these components can lead to damage
of the motor isolation and a motor breakdown.
11.04.2017 V4-060 K 67
Accessories > Butterfly throttle
n The highest admissible voltage increase speed of the motor is

1,200 V/μs.
n The maximum rotational changeover speed must not exceed 1
Hz per second during operation.
n Minimum frequency = 20 Hz // maximum frequency = 50 Hz
results in a control time of 30 seconds from minimum to max-
imum.
Pole changing For a motor speed changeover from a high to a low speed, the
drive motor must have reached zero rotational speed each time.
Changeover from a low to a high speed can take place directly and
instantaneously.
3.11.5 Machine terminal box

Terminal box The machine’s terminal box contains the electrical and electronic
components that are not located directly on the machine (e.g. sen-
sors).
It contains terminals for connecting electrical and electronic com-
ponents with the external power supply.
When the terminal box is closed, accidental or unintended contact
with voltage-carrying components is not possible.
The distribution cabinet is locked due to internal components which
are charged with dangerous voltage. It can only be opened using
special tools (distribution cabinet key, triangular/ square wrench).
3.11.6 Butterfly throttle

Butterfly throttle
A throttle butterfly is located in the intake pipe of the machine
stage. It features a drilled hole that corresponds to the conveyed
amount. During the start phase, the machine stage draws in the
medium through this hole. The throttle butterfly is controlled using
a solenoid valve by means of oil pressurization.
n The start phase occurs in no-load operation with a closed
throttle butterfly.
n In load operation, the throttle butterfly is opened fully.
Fig. 27: Butterfly throttle
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Accessories > Nitrogen gauge
3.11.7 Shut-off valve

Shut-off valve
The shut-off valve is located in the discharge-side area of the
machine stage. The shut-off valve performs the function of a relief
valve. The medium to be conveyed is released through the shut-off
valve into the atmosphere during the start phase. The shut-off
valve is controlled using a solenoid valve by means of air pressuri-
sation.
n During the start phase, the shut-off valve is open.
n In load operation, the shut-off valve is fully closed.
Fig. 28: Shut-off valve
3.11.8 Discharge pressure gauge

Positive pressure mode
The gauge displays the discharge pressure of the compressed
gas.
It is a display instrument without a switching function.
The gauge is connected on the discharge side.
Fig. 29: Gauge
3.11.9 Nitrogen gauge

Nitrogen mode
The gauge is used when conveying nitrogen.
The gauge displays the pressure in the inlet pipe.
The gauge is connected on the intake side.
Fig. 30: Gauge
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Accessories > Maintenance indicator
3.11.10 Oil pressure gauge

Positive pressure and vacuum
pressure mode
The gauge displays the oil pressure in the oil system.Ä Chapter
11.11.1 „Oil pressure“ on page 198
Fig. 31: Gauge
3.11.11 Maintenance indicator

Positive pressure mode The maintenance indicator shows the dirt levels in the intake filter.
The maintenance requirements of the intake filter depend on the
dirt levels of the medium taken in.
Replace the filter element when the following display values are
reached and no later:
At -45 mbar (red display field): replace intake filter

After the filter has been changed, reset the pointer to its initial posi-
tion by “pressing” the reset button.
Fig. 32: Variation a)
When the level of contamination increases, the red trailing pointer

will be pulled over with the black pointer and stay at the maximum
intake pressure.
Replace the filter element when the trailing pointer reaches the red
area of the scale.
Once the filter has been replaced, reposition the trailing pointer
between 0 and -10 mbar.
Fig. 33: Variation b)
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Accessories > Start-up relief device
3.11.12 Intake filter in the intake silencer

Intake filter
The base support contains an intake filter. The intake filter prevents
harmful particulate matter entering the conveying chamber of the
machine.
NOTICE!
Risk of machine damage! Never operate the
machine without the intake filter.
Fig. 34: Open base support with

intake filter
Machine damage resulting from

unsuitable or damaged intake filter NOTICE!
There is a risk of machine damage from the use
of contaminated, damaged or non-original
intake filters!
Heavily contaminated or damaged intake filters
reduce performance. They affect functionality and
may cause machine failure. Copies and reproduc-
tions of intake filters do not have the necessary
properties.
– Inspect for damage.
– Comply with maintenance intervals.
– Only use original replacement parts.
3.11.13 Start-up relief device

Start-up relief device
NOTICE!
Risk of premature wear and tear and breakdown!
The start-up relief is not intended for controlling the
operating data!
The use of the start-up relief device as a controller
for operating data leads to premature wear and
tear and breakdown!
The start-up relief device is used in VML machines that are run by
Fig. 35: Example of start-up relief an electric motor with a “star-delta connection”.
device
This allows for a relieved start-up against existing mains pressure.
In the case of drives with pole-changing motors, it is also possible
to use a start-up relief device with a solenoid valve.
11.04.2017 V4-060 K 71
Accessories > Safety valve
This provides a relieved start-up at higher speeds.

After a correct set-up, the start-up relief device operates mainte-
nance-free.
The start-up relief device is not necessary for

drives with frequency converters.
3.11.14 Safety valve

Gas version
The safety valve is used in the gas version.
The safety valve is a safety device which protects pressurised
pipelines and containers from an impermissible pressure increase.
It dissipates gases into the atmosphere or into collection pipes if
the tripping pressure is exceeded.
Depending on the design, a safety valve is installed, or is to be
installed, between the machine and the non-return flap.
The safety valve is set at the factory. The set values must not be
changed!
The safety valve is NOT a control component and is not to be used
as such.
Fig. 36: Safety valve

NOTICE!
The use of the valve as an operating data con-
troller leads to premature wear and tear and break-
down!
The deactivation of the valve, e.g. by increasing
the opening pressure, may lead to serious material
damage! Risk of total machine failure!
The valve outlet must not be made narrower or
closed. Keep the cross-section unobstructed!
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Accessories > Belt drive
3.11.15 Non-return flap

Non-return flap
The non-return flap prevents the compressed, conveyed medium
from entering the machine stage and causing depressurisation
once the machine has been switched off. “Backwards operation” of
the machine is thus prevented.
Fig. 37: Non-return flap variants
3.11.16 Belt drive

Belt drive
The belt pulleys are mostly fitted and aligned in the factory.
The belt pulley for the machine stage is fitted to the drive shaft
using a taper interference fit. The position and orientation of this
belt pulley therefore affects the alignment of the drive motor belt
pulley.
Check the alignment:
n Before first commissioning
n According to the maintenance plan
Fig. 38: Belt drive n After replacing the pulley(s)
The maximum permitted belt pulley offset is 0.5 mm.
It is extremely important that only original replace-

ment parts be used for the purposes of belt-pulley
operation!
Only use replacement parts that are recommended
and approved by AERZEN!
Original replacement parts

NOTICE!
Risk of material damage! Pulleys must only come
from one manufacturer and from one production
batch.
– Otherwise varying belt tensions can occur
which can result in uneven running and prema-
ture wear.
– As a result of a risk of snapping, the belt pul-
leys must be suitable for the peripheral speed
encountered!
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Accessories > Acoustic hood
3.11.17 Acoustic hood

Acoustic hood
The acoustic hood serves to reduce noise and acts as an isolating
safety device.
The acoustic hood is a component for product safety with lockable
door elements.
Always keep the acoustic hood closed during operation.
The key must only be accessible for authorised personnel.
An earthing strap or threaded hole is located on the outer edge of
the floor tray.
Fig. 39: Acoustic hood, version dia-

gram
Acoustic hood locking

Operation with an open acoustic hood is not per-
missible!
– Always lock the elements of the acoustic hood
with the key provided.
– The key must only be accessible for trained
persons.
Intake from a pipeline The acoustic hood makes intake-side suction possible from the
system pipeline.
The pipeline is guided through the acoustic hood to the machine
through prefabricated openings.
The following steps must be complied with:Ä Chapter 5.3 „Instal-
lation“ on page 98
Acoustic hood heater

NOTICE!
There is a risk of material damage from low
ambient temperatures!
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Accessories > Oil pressure regulating valve
3.11.18 Oil filter

Oil filter
Replace the oil filter each time the lubricating oil is

changed!
The oil filter traps particles from the lubricating oil circuit. An oil
Fig. 40: Oil filter pump pumps the lubricating oil through the oil filter which creates a
particular level of filter resistance. This resistance increases
depending on the contamination level.
3.11.19 Oil demister

Oil demister
The oil demister creates negative pressure in the oil chamber. This
ensures that the machine is sealed against oil leakages to the con-
veying chamber and to the outside environment. The oil demister is
connected to the machine’s oil chamber and draws off the oil
vapour produced. The oil that is drawn off flows through the intake
pipe, back into the oil chamber.
Fig. 41: Pre-inlet filter, complete
3.11.20 Oil pressure regulating valve

Oil pressure regulating valve
The oil pressure is determined by the setting range of the oil pres-
sure regulating valve and the prevailing operating parameters.
Oil pressures outside this range can be implemented with the intro-
duction of special modifications after consultation with AERZEN.
Fig. 42: Oil pressure regulating valve
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Required tools
3.11.21 Oil cooler

Oil cooler
The oil cooler cools down the lubricating oil during operation. In
conjunction with a temperature controller, it provides a consistent
oil temperature. Whether a temperature controller is used or not
depends on the design of the machine. The oil temperature is
approximately 55 °C. The cool air flow is created by the directly
driven ventilator.
Fig. 43: Oil cooler
3.11.22 Ventilator of the oil cooler

Oil cooler ventilator
The oil cooler is cooled down by a mechanical ventilator. The venti-
lator is a rotating component with a high rotational speed. The ven-
tilator must always be sufficiently protected from outside physical
contact.
The ventilator is connected at the factory. The ventilator is acti-
vated in parallel with a machine start.
Fig. 44: Ventilator
3.12 Required tools

The following tools are required:
Auxiliary materials, aids
including collection containers for oil, drain hose, cleaning rags.
Conveyor rails
The conveyor rails must be made of steel. They act as slide-in
modules in the forklift tunnel of the acoustic hood. The cables are
pulled by the conveyor rails and joined above the machine using
the lifting beams.
Drills
Drills for making fastening holes.
Electric drill
Electric drills, e.g. for drilling fixing holes.
General measurement tools and equipment

For example a steel ruler, plumb line, folding yardstick, spirit level.
General tool kit

including various screwdrivers, combination wrenches, set of
socket spanners, set of Allen wrenches, hammers.
76 V4-060 K 11.04.2017
Required tools
Hinged motor support lifting equipment

This lifting equipment is a steel profile for mounting the hinged
motor support. It provides power transmission for lifting and low-
ering the hinged motor support with a hydraulic lift.
Hydraulic lift
The hydraulic lift is a lifting device for lifting the hinged motor sup-
port to enable the installation or change of a belt. Only use the
hydraulic lift on solid, level ground.
Lifting beams
Transverse truss required for crane transport for absorbing cable
force.
Lifting equipment
For lifting loads, e.g. ropes, belt anchorages, shackles, eyebolts
with nuts.
Locking key
The locking key is a component of the overall safety concept. This
must be stored safely and should only be made accessible to
trained personnel. It is intended for the proper opening and closing
of the acoustic hood elements.
Oil funnel
The oil funnel is used for the precise filling of lubricant oil.
Ratchet wrench
The ratchet wrench is used to adjust the hinged motor support fas-
tener.
Strap wrench
The strap wrench is used to disassemble the oil filter.
Test pump
The test pump is used to simulate system pressure in the meas-
urement lines during commissioning. This allows for the operation
of the pressure switch or the pressure sensors to be checked.
Tools for authorised electricians

Basic electrical engineering equipment, e.g. multimeter, voltage
detector, insulated tools.
Transport equipment
for transporting packaged units and the machine, e.g. with lift
trucks, forklifts.
Transport securing rod

The transport securing rod serves to fix the hinged motor support
in place during transport. It also serves as lashing equipment for
the hinged motor support during lifting to relieve and, if necessary,
support the hydraulic lift. The transport securing rod must be
removed for the machine to be operated.
11.04.2017 V4-060 K 77
Transport, packaging and storage
Transport > Safety instructions
4 Transport, packaging and storage

4.1 Transport
4.1.1 Safety instructions
Improper transport
WARNING!
Risk of injury and damage from improper trans-
port!
Improper transport may result in personal injury.
– Proceed with caution upon delivery and
unloading of the machine and during in-house
transport.
– Observe the symbols and information on the
packaging.
– Only use the intended anchorage points.
– Observe the machine’s centre of gravity.
– Attach lifting equipment accordingly and hang
the load so that it is balanced.
– Remove the packaging shortly before setting
up the machine.
Industrial trucks
WARNING!
There is a risk of fatal injury from industrial
trucks!
Transport with industrial trucks can result in objects
and other loads falling accidentally and causing
serious or fatal injury. There is also the risk of the
driver failing to see persons and running them
over.
– Industrial trucks should only be operated by
trained drivers (e.g. forklift drivers).
– Only walk past an industrial truck if the driver
has signalled that he has recognised the
person in his path.
– Only use approved industrial vehicles with suf-
ficient load carrying capacity.
– Never transport materials over persons or the
areas in which persons are located.
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Suspended loads
WARNING!
There is a risk of fatal injury from suspended
loads!
During lifting work, loads may swing out and fall.
This can result in serious or fatal injury.
– Never walk under or into the range of a sus-
pended load.
– Move loads under supervision only.
– Observe lashing points.
– Ensure that the lashing equipment is fitted
securely.
– Do not hang lashing equipment on protruding
machine parts or on the lugs of attached com-
ponents.
– Only use approved hoists and lashing equip-
ment with sufficient load carrying capacity.
– Do not use damaged hoists such as ropes or
pulleys.
– Do not attach hoists such as ropes or belts to
sharp edges and corners and do not knot or
twist them.
– Set down the load when leaving the work area.
Disregard for the machine’s centre

of gravity WARNING!
There is a risk of the unit toppling and falling
over if there is disregard for the machine’s
centre of gravity!
If the machine’s centre of gravity is disregarded the
packaged unit may topple and cause life-threat-
ening injury.
– Take into account the machine’s centre of
gravity.
– Observe the packaging information on the
machine’s centre of gravity.
– Attach lashing equipment in such a way that it
is located above the centre of gravity.
– Raise the load carefully and ensure that it does
not topple. If necessary, change the position of
the lashing equipment.
11.04.2017 V4-060 K 79
Risk of slipping
CAUTION!
Risk of injury due to slipping on the packaging
foil!
The packaging foil features a slippery surface that
can cause persons to slip on it. Moisture, creases,
edges and tension straps on the packaging foil
entail a risk of slipping or stumbling. The pack-
aging foil is not suitable for supporting weight. A
fall may result in injury.
– Never stand on the packaging foil.
– Never lean on the packaging foil or use it for
support.
Requirements for staff Requirements for transport:

Transport of packaged units
Personnel: n Trained persons
Transport of unpacked machines

Personnel: n Service personnel
Requirements for staff When checking storage criteria, you require the following:
When checking and applying preservation, you require the fol-

lowing:
Protective equipment Requirements for transport:

Protective equipment: n Protective work clothing
n Safety shoes
n Protective gloves
Protective equipment Preservation requires:

n Safety shoes
n Protective gloves
n Light respiratory protection
80 V4-060 K 11.04.2017
Transport > Delivery method
Special tools Requirements for transport:
NOTICE!
Risk of damage to the machine! Chains, steel
cables and similar equipment are not suitable
lifting equipment.
Special tool: n Lifting equipment

n Transport equipment
Special tool: n Lifting beams

n Locking key
n Conveyor rails
Transport beams for crane trans-

port
Size Nominal U-beam dimen- U-beam

diameter, dis- sions length
charge side
h x b x t (mm) l [mm]
VM 8R DN 65 100 x 80 x min. 4 1500
VM 15R DN 65 100 x 80 x min. 4 1500
VML 18R DN 80 100 x 80 x min. 4 1500
VM 21R DN 80 100 x 80 x min. 4 1950
VML 25R DN 125 100 x 80 x min. 4 1950
Fig. 45: U-beam dimensions VM 37R DN 150 120 x 80 x min. 5 2205

VML 40R DN 150 120 x 80 x min. 5 2205
Material: S 235 JR
U-beam length is a minimum of 150 mm longer

than the dimensions of the acoustic hood.
4.1.2 Delivery method

4.1.2.1 Delivery of the machine
The machine is shipped using a freight forwarder. In accordance
with the given requirements the machine is sealed in foil and may
be additionally packed in wood.
11.04.2017 V4-060 K 81
Transport > Packaging
Transport on a truck
1. Strap the packaged unit to the truck in accordance with the
diagram.
2. Always use appropriate edge protection to avoid damage to
the packaged unit.
Fig. 46: Transport on a truck
4.1.3 Packaging
4.1.3.1 Symbols on the packaging
Symbols on the packaging
The following symbols are displayed on the packaging. Always
observe these symbols during transport.
Fig. 47: Symbols on the front/rear side
Explanations
Centre of gravity
1. Displays the centre of gravity and weight of the machine.
Observe the location of the centre of gravity for lifting work
and transport.
Fig. 48: Centre of gravity
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Transport on a truck
2. Strap the packaged unit to the truck in accordance with the
diagram.
3. Always use appropriate edge protection to avoid damage to
the packaged unit.
Fig. 49: Transport on a truck
Explanations Comply with the order (pos.1-pos.3) of the work stages.

Transport without a palette
1. Open the operating side of the acoustic hood (pos.1).
2. Open the rear side of the acoustic hood (pos.2).
3. Separate the machine from the transport palette by removing
the holding screws.
4. Drive the fork of the forklift under the machine (pos.3).
WARNING!
Risk of injury if the machine topples or falls!
Observe the machine’s centre of gravity.
5. Determine the machine’s centre of gravity by raising it care-

fully.
Fig. 50: Transport without a palette 6. Transport the machine so that it is balanced. The machine
must not lean to one side.
7. Remove the lifting equipment at the installation area.
4.1.3.2 Handling packaging

Handling packaging The various packaged items are packed in accordance with the
anticipated transport conditions. In as far as it is possible, environ-
mentally-friendly materials are used for the packaging.
The packaging is intended to protect individual components from
transport damage, corrosion and other forms of damage. For this
reason, do not destroy the packaging and only remove it shortly
before assembly.
Only remove packaging for transport to the installation area if it has
been expressly permitted.
11.04.2017 V4-060 K 83
Removing packaging
Packaging materials made of solid wood (e.g.
wooden palettes, wooden crates) comply with the
IPPC standard. This material is re-usable. When
disposing of the material, national and local
requirements must be complied with.
From the machine 1.

CAUTION!
Risk of injury from rough packaging material
and protruding nails!
Remove packaging material.

2. First detach the packaging and then remove it.
3. Separate the machine from the transport pallet by removing
the holding screws.
4.
ENVIRONMENT!
Packaging material is valuable. It can be
used several times or processed and then re-
used. The improper disposal of packaging
material can present a risk to the environ-
ment.
5. Sort packaging according to the material used and dispose of

it properly.Ä Chapter 10.2 „Disposal“ on page 180
From the machine 1. First detach the packaging and then remove it.
the holding screws.
3.
ENVIRONMENT!
Packaging material is valuable. It can be
used several times or processed and then re-
used. The improper disposal of packaging
material can present a risk to the environ-
ment.
4. Sort packaging according to the material used and dispose of

it properly.Ä Chapter 10.2 „Disposal“ on page 180
84 V4-060 K 11.04.2017
4.1.3.3 Transport of packaged units
4.1.3.3.1 Transport using industrial vehicles
1.
NOTICE!
Risk of toppling loads! The transport of pack-
aged units may only be carried out using
lifting equipment that reaches under the
machine and fits into the transport palette
fully.
2. Insert the equipment into the provided opening in the trans-

port palette.
3. Take into account the centre of gravity! See the labelling on
the packaging.
Fig. 51: Transport with acoustic hood 4.

DANGER!
Risk of fatal injury from toppling components!
Determine the packaged unit’s centre of gravity by raising it

carefully.
5. Transport the machine so that it is balanced. The packaged
unit must not lean to one side.
4.1.3.3.2 Transport using a crane
1. Guide the conveyor rails through the openings of the trans-

port palette.
2. Place the lifting beams on to the acoustic hood. Span length
of a minimum of 150 mm longer than the dimensions of the
acoustic hood.
3. Guide lifting equipment, such as cables or straps through the
conveyor rails and join them above the machine using the
lifting beams.
the packaging.
5.
Fig. 52: Transport of packaged units DANGER!

carefully.
11.04.2017 V4-060 K 85

1.
NOTICE!
Risk of toppling loads! The transport of pack-
aged units may only be carried out using
lifting equipment that reaches under the
machine and fits into the transport palette
fully.
2. Insert the equipment into the provided opening in the trans-

port palette.
Fig. 53: Transport with belt guards 3. Take into account the centre of gravity! See the labelling on
the packaging.
4.
DANGER!

carefully.
DANGER!
NOTICE!
Risk of damage to the machine from lifting equip-
ment such as cables or straps.
Transport of the packaged unit with a crane is not permissible! The

transport palette is not designed for crane transport.
Fig. 54: Transport of packaged units
86 V4-060 K 11.04.2017
4.1.3.4 Transport to the installation site

1. Completely remove packaging material.
2. Open the operating side of the acoustic hood (pos.1).
3. Open the rear side of the acoustic hood (pos.2).
the holding screws.
5. Drive the transport fork under the machine (pos.3).
the packaging.
7.
DANGER!
Determine the machine’s centre of gravity by raising it care-

fully.
Fig. 55: Transport with acoustic hood
8. Transport the machine so that it is balanced. The machine
DANGER!
Transport of the packaged unit using an industrial vehicle is not

permissible!
11.04.2017 V4-060 K 87

2. Remove the front and rear elements of the acoustic hood and
store them safely.
3. Guide the conveyor rails through the openings of the forklift
tunnel.
4. Place the lifting beams on to the acoustic hood. Span length
of a minimum of 150 mm longer than the dimensions of the
acoustic hood.
5. Guide lifting equipment, such as cables or straps through the
conveyor rails and join them above the machine using the
lifting beams.
Fig. 56: Transport with acoustic hood
the holding screws.
the packaging.
8.
DANGER!

fully.

the holding screws.
3.
NOTICE!
Risk of machine damage if the material in the
intake nozzle falls! Inspect for cleanliness.
4.
NOTICE!
Risk of damage from the force exerted by
lifting equipment on accessory components!
Only transport the machine with the hinged
motor support fixed in place.
Fig. 57: Transport with belt guards

Attach the lifting equipment carefully to the fixing device.
88 V4-060 K 11.04.2017
Transport inspection

the packaging.
6.
DANGER!

fully.
4.2 Transport inspection
Completeness
Checking for completeness
Check the goods for completeness immediately
after delivery. Register missing parts and contact
the manufacturer.
Check the delivery for completeness on the basis of the packing

slip.
n The packing slip is provided with the product.
Transport damage
Transport damage
Register transport damage claims as soon as
damage is discovered. Compensation claims for
damage are only valid within the applicable claim
periods.
Check the delivery immediately for transport damage.

In case of perceptible external damage, proceed as follows:
n Do not accept the delivery or only accept it under certain condi-
tions.
n Note the scope of the damage in the transport documents or
on the delivery docket provided by the carrier.
n Register the claim.
11.04.2017 V4-060 K 89
Storage and preservation > Storage
4.3 Storage and preservation
4.3.1 Storage
Storage notes Store the packaged unit under the following conditions:
n Keep flange connections closed. Avoid entry of foreign sub-
stances.
n Do not store outdoors.
n Store in a dry and dust-free place.
n Do not expose it to any agressive media.
n Protect the packaged unit from exposure to the sun.
n Avoid mechanical vibrations.
n Avoid extreme temperature fluctuations.
n Avoid adverse water affects.
n Storage temperature: -10 to +40 °C.
n Relative humidity: maximum 80 %.
n If a vibration-free storage area is not available, move the mov-
able components by 2 - 3 rotations every 6 - 8 weeks.
NOTICE!
Risk of corrosion! To avoid potential damage to the
machine, an inspection of the overall scope of
supply should be undertaken by the manufacturer
every 2 years.
There may be information on the packaged unit

regarding storage that goes beyond the require-
ments listed here. Comply with this information.
Storage information for periods of Additional measures:

over 12 months
n Packaging with VPI paper.
n Sealed in PVC foil.
Storage information for periods of Additional measures:

over 12 months in a tropical climate
n Drying agent (VPI power in a bag) inside the packaging.
n Packaging with VPI paper.
n Sealed in PVC foil.
Storage in air-conditioned rooms with minimum

humidity has a positive influence on corrosion pro-
tection!
90 V4-060 K 11.04.2017
Storage and preservation > Preservation
Packaging during storage n Inspect the general condition of the packaging regularly. Imme-
diately rectify damage to the packaging. If necessary, refresh or
replace the anti-corrosion protectionÄ „Carrying out preserva-
tion treatment“ on page 92
n After opening the packaging:
– Inspect uncoated parts for sufficient corrosion protection.
– Protect against humidity and damaging environmental influ-
ences.
– Sealing flaps from the connection openings must not be
removed.
n Replace the drying agent regularly in accordance with climactic
conditions.
NOTICE!
Risk of corrosion! Customised packaging is
required for tropical climate zones and in the case
of special customer requirements.
Damaged packaging
NOTICE!
Risk of corrosion! As a result of damaged pack-
aging, moisture and damaging environmental influ-
ences could directly affect the product.
Measures in case of damaged packaging

n Immediately rectify damage to the packaging. If necessary,
refresh or replace the preservation material.
n Dry the machine, if necessary.
n Inspect the drying agent, replace if necessary.
n Repair or replacement of the packaging.
4.3.2 Preservation
Preservation Factory preservation protects the product for a certain time period
in accordance with the relevant storage and packaging information.
Factory preservation / standard

Conveying chamber BIO-CHEM food biodegradable, does
tech oil not contaminate
groundwater
Oil chamber Delta Lube 06 operating lubricant
oil
Shelf-life up to 12 months with compliance
with storage condi-
tions
11.04.2017 V4-060 K 91
Factory preservation / standard

Repeat after 12 months
Extended shelf-life more than 12 only with suitable
months long-term preserva-
(no standard) tion and packaging
Preservation from assembly to commissioning

Treat the conveying more than 6 weeks avoidance of corro-
chamber and move of non-use sive and standstill
the rotors by 2-3 damage
rotations.
Preservation after period of non-use

Preservation of con- more than 6 months special preservation
veying chamber, oil measures neces-
chamber sary
Carrying out preservation treat-

ment
Preservation measures:
1. Open the packaging. Check the machine for good accessi-
bility.
2.
WARNING!
Risk of poisoning from inhaling oil vapour!
Preservation treatment of the conveying chamber:

spray suitable preservative oil over the intake nozzle at the
machine stage.
NOTICE!
Risk of filter damage!
Do not spray preservative oil into the intake
filter. Never treat filter elements with preser-
vative oil!
92 V4-060 K 11.04.2017
3.
WARNING!
Preservation treatment of the oil chamber:

Spray suitable preservative oil into the machine stage
through the oil fill opening and oil drain opening.
ð Let excess preservative oil flow out of the oil drain
opening.
4. Seal the oil fill opening and oil drain.
5.
WARNING!
Treat the outer, uncoated surfaces with suitable preservative

oil.
6. Inspect the sealing flaps.
7. Check and restore the packaging.
11.04.2017 V4-060 K 93
Set-up and installation
Safety instructions
5 Set-up and installation

5.1 Safety instructions
Improper set-up and installation

WARNING!
Risk of injury from improper set-up and instal-
lation!
Improper set-up and installation can result in
serious injury or damage.
– Before beginning any work, ensure there is suf-
ficient space for installation.
– Check the tidiness and cleanliness of the work
area.
– Only use commercially-available tools or, if
necessary, special tools.
Unsuitable or damaged tools may cause injury!
– Secure components against falling or tipping
over during the installation.
– Install components correctly.
– Comply with the specified screw-tightening tor-
ques.
Electrical system
DANGER!
Risk of fatal injury from electrical current!
There is a risk of fatal injury from touching live
components. Live electrical components may make
uncontrolled movements and cause extremely
serious, or even fatal injury.
– Before beginning work, switch off the electric
power supply and secure it against restarting.
Electrostatic charges
WARNING!
Risk of injury from electrostatic charges!
The belt drive may generate electrostatic charges.
– Before commissioning put in place equipoten-
tial bonding.
– Only use electrically-conductive belts.
Requirements for staff Requirements for set-up and installation:

Set-up and installation of electrical components
94 V4-060 K 11.04.2017
Safety instructions
Personnel: n Authorised electricians
Set-up and installation of mechanical components

Protective equipment Requirements for set-up and installation:

n Safety shoes
n Protective gloves
n Safety goggles
n Industrial hard hat
Special tools Requirements for set-up and installation:

Special tool: n Tools for authorised electricians
n Electric drill
n Drills
n General tool kit
n General measurement tools and equip-
ment
Special tool: n Locking key
11.04.2017 V4-060 K 95
Requirements for the installation site
5.2 Requirements for the installation site

Ground properties Inspect the ground properties. These should be as follows:
n stable
n even
n free of vibrations
n without any incline
n without holes
NOTICE!
Risk of deformation of the acoustic hood substruc-
ture! Do not install or mount the machine on
“hollow” or lamellar foundations.
Subsurface requirements for the cement floor.

The cement floor should have a recommended sur-
face pressure resistance of 30 - 40 N/mm².
Flatness tolerance according to DIN 18202

Distance between measuring points in (m)
0.1 1 4 10 >15 /
Dimension 2 4 10 12 15 /
tolerance in
(mm)
Angular tolerance according to DIN 18202

Distance between measuring points in (m)
over 1 over 3 over 6 over
up to over
up to up to up to 15 up
1 30
3 6 15 to 30
Dimension ±6 ±8 ±12 ±16 ±20 ±30
tolerance in
(mm)
Surroundings n Ensure there is a suitable fresh air supply.

n Avoid heat accumulation.
NOTICE!
Risk of corrosion! There must not be any excessive
levels of dust, acids, steam or explosive or flam-
mable gases at the installation site!
96 V4-060 K 11.04.2017
Requirements for the installation site
Installation with belt guards The machine is only suitable for indoor installation.
Machine installation site

n Comply with the overall dimensions for maintenance work.
Observe the installation drawing.
n Provide measures for sound insulation.
n Take the following precautionary measures:
– If possible, switch off the machine before entering the oper-
ating area. Otherwise wear hearing protection.
– Provide appropriate signage at the installation site.
– The installation site must only be accessible for trained per-
sons.
– Choose an installation site where the duration of time per-
sons spend in the immediate vicinity of the machine is
Fig. 58: Overall dimensions extremely limited.
Installation with acoustic hood The machine is suitable for indoor and outdoor installation.
Machine installation site

n Comply with the overall dimensions for maintenance work. Also
consult the installation drawing.
n Take the following precautionary measures:
– If possible, switch off the machine before entering the oper-
ating area.
– Otherwise wear hearing protection.
– The installation site must only be accessible for trained per-
sons.
– Provide appropriate signage at the installation site.
Fig. 59: Overall dimensions – Choose an installation site where the duration of time per-
sons spend in the immediate vicinity of the machine is
extremely limited.
11.04.2017 V4-060 K 97
Installation
5.3 Installation
Models with acoustic hoods;
aligning and dowelling
1. Carefully align the machine.

2. Position it so that it is balanced.
Fig. 60: Spirit level alignment
3.
NOTICE!
Risk of total machine damage! Installing a
machine at an angle may, as a result of an
undefined oil level, can lead to a total
machine loss. Observe the level and angle
tolerances.
If necessary, use the intended shims on the bolting surfaces.
Fig. 61: Shim alignment
4. Recommendation: Drill and dowel four mounting holes and

screw the machine into these.
Fig. 62: Mounting holes
98 V4-060 K 11.04.2017
Connecting the system pipeline
Models without acoustic hoods;

aligning and dowelling
1. Carefully align the machine.
2. Position it so that it is balanced.
3.
NOTICE!
Risk of irreversible machine failure! Installing
a machine at an angle may, as a result of an
undefined oil level, can lead to a total
machine loss. Observe the level and angle
tolerances.
If necessary, use the intended shims on the bolting surfaces.

4. A single bolt per machine foot is sufficient.
Drilling, dowelling and screwing tight the mounting holes
Fig. 63: Mounting holes
5.4 Connecting the system pipeline

System pipeline
NOTICE!
Risk of machine damage!
The connected pipeline must not exert forces or
moments that affect the machine.
– Secure and fasten the system pipeline.
Observe the labelling and dimensions on the

installation drawing.
11.04.2017 V4-060 K 99
Connecting the drive motor > Preparing the connection
1. Remove the sealing cover from the connection openings.

Connection of a compensator
2. Connect the system pipeline.
3. Close off the pipeline duct using a shim.
Fig. 64: Connection of a compensator
5.5 Connecting the drive motor

5.5.1 Preparing the connection
Preparation with acoustic hood
1. Ä Chapter 3.11.1 „Drive motor“ on page 63
2.
DANGER!
Risk of fatal injury in the case of incorrect
electrical connection data!
Compare the electrical connection data of the drive motor

with those of the operator-side grid.
3. Shut down the power from the operator-side grid.
4. Observe the cable routing on the installation drawing!
Fig. 65: Position on the acoustic hood
5. Prepare the cable feedthroughs.

6.
DANGER!
Check that there is no live current in the connection cable.

7. Lay the connection cable through the cable feedthroughs.
Fig. 66: Preparation
100 V4-060 K 11.04.2017

Connecting the drive motor > Connecting the drive motor
5.5.2 Routing cables

Routing the connection cable
1. Route the connection cable in accordance with the installa-
tion drawing.
2.
NOTICE!
Risk of damage! The minimum bending
radius must not be undershot!
Observe the bending radii.

Fig. 67: Cable laying alignment ð Bending radius of the connection cable = 15 x cable
sheath diameter
5.5.3 Connecting the drive motor

Motor connection
Fig. 68: Connection layout
Star-delta connection Delta connection Star connection Thermal winding shield
1. Open the motor terminal box.

2. Check the alignment of the terminal box.
ð The terminal box must be aligned with openings for the
cable feedthroughs facing in the direction of the motor
fan.
3. Attach a screwed cable gland to the terminal box.
4. Guide the motor cable through the screwed cable gland.
5. Connect the cable connections with the motor terminals cor-
rectly, in accordance with the connection layout.
6. Close the terminal box.
7. Ensure that the connection cable is not damaged by the
movement of the hinged motor support.
11.04.2017 V4-060 K 101

Connecting the drive motor > Routing cables
5.6 Connecting the drive motor

5.6.1 Preparing the connection
Preparation with belt guards
1. Ä Chapter 3.11.1 „Drive motor“ on page 63.
2.
DANGER!
Risk of fatal injury in the case of incorrect
electrical connection data!
Compare the electrical connection data of the drive motor

with those of the grid operator.
3. Shut down the power from the operator-side grid.
4.
DANGER!
Check that there is no live current in the connection cable.
5.6.2 Routing cables

Routing the connection cable
1. Route the connection cable in accordance with the installa-
tion drawing.
2.
NOTICE!
Risk of damage! The minimum bending
radius must not be undershot!
Observe the bending radii.

Fig. 69: Routing cables ð Bending radius of the connection cable = 15 x cable
sheath diameter
102 V4-060 K 11.04.2017

Connecting the machine’s terminal strip
5.6.3 Connecting the drive motor

Motor connection
Fig. 70: Connection layout
Star-delta connection Delta connection Star connection Thermal winding shield
1. Open the motor terminal box.

2. Check the alignment of the terminal box.
ð The terminal box must be aligned with openings for the
cable feedthroughs facing in the direction of the motor
fan.
3. Attach a screwed cable gland to the terminal box.
4. Guide the motor cable through the screwed cable gland.
5. Connect the cable connections with the motor terminals cor-
rectly, in accordance with the connection layout.
6. Close the terminal box.
7. Ensure that the connection cable is not damaged by the
movement of the hinged motor support.
5.7 Connecting the machine’s terminal strip

Machine terminal strip
1. Open the terminal box.

2. Observe the wiring scheme.
The wiring scheme can be found in the terminal box or in the
product documentation.
3.
DANGER!
Fig. 71: Terminal box connections
Ensure that the connecting cable is not live.
11.04.2017 V4-060 K 103

Connecting the earthing
4.
Connection layout according to the AERZEN
wiring scheme!
Guide the external connecting cable to the terminal box.

5. Guide the connecting cable correctly through the cable entry
(dummy cover) to the terminals.
6. The cable entry (dummy cover) can be equipped on site with
screwed cable glands.
7. Close the terminal box properly.
5.8 Connecting the earthing

1.
The exact position of these connections can
be found in the installation drawing.
Earth the machine on the provided connections.

2. Observe the cross-sections of the earthing strap!Ä Chapter
11.10.2 „Earthing strap cross-sections “ on page 197.
Fig. 72: Example connection 3. Beware of uncovered metal contact surfaces.
4. Screw contacts tightly together.
5.9 Connecting the earthing

1.
The exact position of these connections can
be found in the installation drawing.
Earth the machine on the provided connections.

2. Observe the cross-sections of the earthing strap!.
SeeÄ Chapter 11.10.2 „Earthing strap cross-sec-
tions “ on page 197.
Fig. 73: Example connection
4. Beware of uncovered metal contact surfaces.
5. Screw contacts tightly together.
104 V4-060 K 11.04.2017

Laying the insulation mat
5.10 Laying the insulation mat

Laying the insulation mat
n Depending on the scope of delivery, the insulation mat is deliv-
ered separately.
n Lay the insulation mat in the exhaust duct of the acoustic hood.
Fig. 74: Laying of the insulation mat
11.04.2017 V4-060 K 105

Initial start-up
Safety instructions
6 Initial start-up
Improper commissioning
WARNING!
Risk of injury from improper commissioning!
Improper commissioning may lead to serious injury
and considerable material damage.
– Before commissioing, ensure that all installa-
tion work has been carried out and completed
in accordance with the information and notes in
this instruction manual.
– Before commissioing, ensure that there are no
persons in the hazard area.
Requirements for staff Requirements for commissioning:

Commissioning of electrical components
Commissioning the frequency converter:

Personnel: n Authorised electricians with additional
qualifications
Commissioning of mechanical components

Protective equipment Requirements for commissioning:

n Safety shoes
n Hearing protection
n Protective gloves
n Safety goggles
Special tools Requirements for commissioning:
106 V4-060 K 11.04.2017

Initial start-up
Preparation for commissioning
Special tool: n Ratchet wrench

n Oil funnel
n Test pump
n General tool kit
ment
n Tools for authorised electricians
6.2 Preparation for commissioning

Preparation 1. Check that the machine has been correctly installed. See
requirements at the installation site.Ä Chapter 5.2 „Require-
ments for the installation site“ on page 96.
2. Check that the packaging has been fully removed.
3. Check that all seals and covers on the piping connections
have been removed.
4. Check that the piping connections are clean. Remove any
dirt, dust or foreign matter from the intake area.
5. Ensure that the supply air and exhaust air openings on the
acoustic hood are unobstructed.
Ventilation 6.
Take the ambient temperature into consider-
ation. Ä Chapter 11.5 „Requirements for
ambient and intake tempera-
tures“ on page 187 Ä Chapter 11.4 „Tech-
nical performance data“ on page 186
Ensure that the installation site is adequately ventilated.

Take noise protection into consid- 7.
eration. Natural vibrations and sound emissions may
be induced in piping and foundations!
Prevent natural vibrations and sound emissions using suit-

able measures, e.g. insulation.
11.04.2017 V4-060 K 107

Initial start-up
Ventilation gauge
8. Prepare the gauge in line with its specific design.
n Cut off the rubber connections on the upper section.
n Turn the bleeder flap to “OPEN”.
Fig. 75: Ventilation gauge
Maintenance indicator
9. Set to zero.
n Press the front reset button and set the pointer to the
zero position.
Fig. 76: Variation a)
Maintenance indicator
10. Set to zero.
n Remove the plugs on the front.
n Adjust the set screw using a screwdriver.
n Observe the “+” and “-” markings.
n Position the red trailing pointer between 0 and -10 mbar.
Aligning the sheaves 11. Check the alignment of the sheaves.

n The maximum permitted sheave offset is 0.5 mm.
Connecting the piping 12. Connect the depressurised system piping.
108 V4-060 K 11.04.2017

Initial start-up
Checking the balancing holes
Fig. 78: Example for sealing plug con-

figuration
13. Ensure that the balancing holes are unobstructed (visual

inspection).
ð If closed -> Remove the sealing plugs.
Fig. 79: Example for sealing plug con-

figuration
Removing the sealing plugs 14. Remove the sealing plugs from the balancing holes.
The sealing plugs may be coated in machine

paint as part of the manufacturing process.
The number of sealing plugs varies
depending on the machine type!
Depending on the design, they may already
have been removed before shipping.
NOTICE!
Risk of damage if sealing plugs are not
removed! If sealing plugs are not removed,
there is a risk that the machine will start to
leak oil. Lube oil could enter the conveying
chamber.
No lubricant oil
15.
NOTICE!
Risk of damage! Lube oil must not enter
these bore holes!
Fig. 80: Do not pour oil into the bal- These holes are solely intended to discharge leaking gases.
ancing holes. Inserting oil here results in the need for considerable repairs.
11.04.2017 V4-060 K 109

Initial start-up
Checking the acoustic hood venti-

lator
16. Check the fan wheel for smooth movement and contact-free
operation.
If necessary, adjust the cover plate.
Fig. 81: Fan cover
Frequency converter installation 17.

and connection Observe the manufacturer’s instruction
manual!
Position and assemble the frequency converter.

n Connect it according to the manufacturer’s instructions.
n See also the assembly group description for frequency
converters.Ä Chapter 3.11.4 „Frequency con-
verter“ on page 66
Checking the EMERGENCY STOP 18. Check whether the EMERGENCY STOP function is in place
function and installed.
n Check for correct operation.
n Enter the test result in the test book.
Preparing the hinged motor sup-

port
Handling without lifting device
Disassembling transport safety
lock Version a)
1. Disassemble the transport lock.
ð The transport lock (red component) serves later as an aid
for lifting the hinged motor support.
Fig. 82: Version a)
110 V4-060 K 11.04.2017

Initial start-up

lock Version b)
2. Remove the safety screws for transport.

lock Version c)
3. n 1.) Remove the split pin.
n 2.) Disassemble the safety rod for transport.
ð The safety rod (red component) serves later as an aid for
supporting the hinged motor support.
Fig. 84: Version c)
Handling with lifting device

Preparing the hinged motor sup-
port
Remove counternut the (pos.1) and locking sleeve (pos.2).
Fig. 85: Hinged motor support prepa-

ration
11.04.2017 V4-060 K 111

Initial start-up
Performing the initial start-up
6.3 Performing the initial start-up

Checking the lube oil level 1. Check the lube oil level in the compressor sight glass during
machine downtime. See display on base support = oil
chamber. Ä Chapter 8.3.1 „Checking the oil
level“ on page 141.
2. Check the lube oil level in the acoustic hood’s sight glass
during machine downtime.
Fill with lube oil

1. Open the maintenance elements of the acoustic hood.
Models with acoustic hoods
2.
When working with operating materials such
as lube oil, wear personal protective equip-
ment.
ENVIRONMENT!
Environmental risks from incorrect handling
of lubricants!
Fill with lube oil. Ä „Oil drainage/models with acoustic hood“

on page 151.
Fig. 86: Filling with oil
Models without acoustic hoods

3.
When working with operating materials such
as lube oil, wear personal protective equip-
ment.
ENVIRONMENT!
of lubricants!
Fig. 87: Filling machine stage oil

Loosen the RED-marked locking screw (pos. 1). Fill with lube
oil.Ä „Filling with oil (models without acoustic hoods)“
on page 154.
112 V4-060 K 11.04.2017

Initial start-up
Performing the initial start-up
Checking the oil level

4. Check the lube oil level and correct it if necessary.
ð Oil level sight glass is full = correct oil level.
Fig. 88: Required oil level when

machine is idle
Establishing an electrical connec- 5.

tion DANGER!
Supply electrical components with electricity.

See Ä Chapter 5.6 „Connecting the drive
motor“ on page 102.
6. Connect and activate motor overload protection.Ä Chapter
11.10.3 „ Motor overload protection“ on page 197
7. Observe the permissible starting frequency of the drive
motor. Ä „Permissible starting frequency“ on page 64
Checking direction of rotation
(models with acoustic hood)
8.
WARNING!
NOTICE!
Risk of machine damage from incorrect
direction of rotation!
Check the direction of rotation without belts in place.

Fig. 89: Motor direction of rotation n If in place, remove the perforated plate cover of the drive
motor’s belt pulley.
n Observe the sign with direction of rotation on the base
support.
n Start the drive motor briefly (approx. 1 to 2 seconds).
n Direction of rotation is correct = continue commissioning.
n Direction of rotation is incorrect = correct the electrical
connection.
n Where applicable, attach the perforated plate cover of the
drive motor.
9. Remove the belt guard cover.
11.04.2017 V4-060 K 113

Initial start-up
Performing the initial start-up > Hinged motor support with lifting device
Checking the direction of rotation

(models without acoustic hood)
10.
WARNING!
NOTICE!
Risk of machine damage from incorrect
direction of rotation!
Check the direction of rotation without belts in place.

Fig. 90: Example of direction of rota- n Remove the cover from the belt guard.
tion n Observe the sign with direction of rotation on the
machine stage.
n Start the drive motor briefly (approx. 1 to 2 seconds).
n Direction of rotation is correct = continue commissioning.
n Direction of rotation is incorrect = correct the electrical
connection.
n Mount the cover of the belt guard.
Disconnecting the electrical power 11.
supply WARNING!
Risk of injury from an automatic start-up!
Deactivate the machine and secure it against restarting.
6.3.1 Hinged motor support with lifting device

Fitting the belt
1.
WARNING!
Risk of injury from moving or rotating compo-
nents!
Observe and comply with the permissible groove layout.

Fig. 91: Permissible belt layout
114 V4-060 K 11.04.2017

Initial start-up
Performing the initial start-up > Hinged motor support with lifting device
Loosening the self-locking nut

2.
NOTICE!
Prevention of wear and tear on belts.
Screw the self-locking nut (pos.4) all the way downwards.

ð The hinged motor support can be adjusted to the correct
position.
Fig. 92: Loosening the self-locking nut
Pre-tensioning belts
3.
CAUTION!
Risk of injury from tensioning components!
Turn guide bushing (pos.3) clockwise with the ratchet wrench

until the belts are pre-tensioned.
ð The hinged motor support is partly held by the belt drive
and rests lightly on the guide bushing (pos.3).
Fig. 93: Pre-tensioning belts
Adjusting the guide bushing

4. Set gauge A.
n Set self-locking nut (pos.4) to gauge A. Screw guide
bushing (pos.3) on self-locking nut (pos.4) using the
ratchet wrench.
Size Nominal diameter, dis- Gauge A in

charge side mm
VM 8R DN 65 25
VM 15R DN 65 25
VML18R DN 80 25
VM 21R DN 80 25
Fig. 94: Adjusting the gauge of the
guide bushing VML 25R DN 125 25
VM 37R DN 150 30
VML 40R DN 150 30
Delta Screw G5
11.04.2017 V4-060 K 115

Initial start-up
Performing the initial start-up > Hinged motor support without lifting device
Tensioning the belts

5.
CAUTION!
Risk of injury from moving and rotating com-
ponents!
Tension the belts.

n Secure the guide bushing (pos.3) with the self-locking nut
(pos.4).
n The hinged motor support is supported entirely by the
belt drive.
Fig. 95: Tensioning the belts
6.3.2 Hinged motor support without lifting device

Lifting version a.1) and b.2)
1.
NOTICE!
Only use hydraulic lifts on solid, level ground.
Position the hydraulic lift securely.

2.
WARNING!
Risk of shearing and crushing from moving
Fig. 96: Version a.1) and b.2)
loads!
1 Version a.1)
2 Version b.2)
Slowly raise the hinged motor support by pumping the
hydraulic lift.
3.
WARNING!
Risk of injury from the hydraulic lift tipping up
or slipping!
Raise the hinged motor support in small steps. Always use

wedges for bracing!
ð This will prevent sudden downwards movements of the
hinged motor support should the hydraulic lifter topple or
slip.
4. Raise the hinged motor support until the belts can be fitted.
116 V4-060 K 11.04.2017

Initial start-up
Lifting version a.2)

5. Insert the angle bracket for transport safety into the mounting
rail of the motor.
6.
NOTICE!

Fig. 97: Version a.2)
7.
WARNING!
loads!

hydraulic lift.
8.
WARNING!
or slipping!

wedges for bracing!
slip.
Lifting version c)
10.
NOTICE!

11.
WARNING!
Fig. 98: Version c) Risk of shearing and crushing from moving
loads!

hydraulic lift.
11.04.2017 V4-060 K 117

Initial start-up
12.
WARNING!
or slipping!
Raise the hinged motor support in small steps. While doing

so, support the hinged motor support in the recess of the
base support with the safety rod for transport (red rod).
slip.
Fitting the belt
14.
CAUTION!
Fit the belt. Observe and comply with the permissible groove
Fig. 99: Permissible belt layout layout.
Tensioning the belts 15.

WARNING!
Risk of injury from tensioning, moving or
rotating components!
Release the hydraulic lift carefully and slowly.

ð The hinged motor support is lowered.
If released too quickly, the hinged motor

support drops suddenly.
The belts are tautened by the weight of the motor.

16.
NOTICE!
Risk of damage to the belt drive!
The hinged motor support must not rest on
the base support, the transport securing rod
or similar equipment.
118 V4-060 K 11.04.2017

Initial start-up
Performing the initial start-up > Carrying out a test run
17. Check whether the motor can be moved approximately

100 mm upwards and downwards!
ð If no mobility is given, repeat the work steps.
18. Completely remove the hydraulic lifter, transport safety lock
and other auxiliary equipment.
Store them securely for future maintenance.

Fig. 100: Hinged motor support mobi-
lity
6.3.3 Carrying out a test run

Carrying out a test run 1.
CAUTION!
Risk of injury from moving components!
Carry out a test run of the belt drive.

Start the drive motor briefly (approx. 5 to 10 seconds).
Check for correct operation.
Characteristics:
n quiet, even operation.
n even load.
n no excessive vibrations.
n no whistling noises.
n no increased wear.
End the test-run after the inspection.
Checking the protective cover
(models without acoustic hoods)
2. Check the spacing of the pre-mounted protective cover for
the motor drive shaft.
n The protective cover should be at a distance of approx.
10 mm from the motor drive shaft.
n By loosening the fastening screws, the protective cover
can be moved.
n Check the protective cover for firm seating and, if neces-
sary, tighten it.
Fig. 101: Protective cover
11.04.2017 V4-060 K 119

Initial start-up
Adjusting the protective cover/

models without acoustic hood
3. If the protective cover is supplied separately, adjust the cover
plates accordingly. The cover plates can be snapped off at
the required length.
Fig. 102: Adjusting the protective

cover
Assembling and adjusting the pro-

tective cover/models without
acoustic hood
4.
WARNING!
Assemble the protective cover after tensioning the belts.

n The protective cover should be at a distance of approx.
10 mm from the motor drive shaft.
n Operation is only permissible with a mounted cover!
Fig. 103: Assembly/adjusting
Assembling the acoustic hood 5. Mount the roof and the corresponding side elements of the
acoustic hood.
Connecting the power supply 6.
WARNING!
Risk of injury from electric current!
Supply electrical components with electricity.
120 V4-060 K 11.04.2017

Initial start-up
Checking shut-downs (if available)

7. Check the correct operation of all pressure switches/sensors
that can trigger a shut-down.
n Connect the test pump to the corresponding measure-
ment line.
n Simulate the tripping pressure.
n Check to see if a shut-down process is triggered.
n Remove the measurement line from the test pump.
n Fit the measurement line to the measuring point on the
machine.
Fig. 104: Test pump
Opening the system line 8. Open valves on the system side.

Starting briefly 9.
WARNING!
WARNING!
Risk of injury from pressurised components!
Do not loosen or remove any locking screws
or pipe connections.
Switch on the drive motor.

n After approx. 20 seconds, switch it off.
n Make sure the motor coasts down smoothly.
Checking the frequency converter 10.
for correct operation Read and follow the manufacturer’s oper-
ating instructions!
DANGER!
Risk of fatal injury from electric current and
residual energy for all work performed on fre-
quency converters!
See also the assembly group description for frequency con-

verters.Ä Chapter 3.11.4 „Frequency converter“ on page 66
11.04.2017 V4-060 K 121

Initial start-up
Starting the drive motor 11.

WARNING!
As long as there are no malfunctions: restart the drive motor.

n Check the EMERGENCY STOP function.
n Check the machine’s protective equipment.
12. Check the oil pressure. If necessary, correct the pressure.
Ä Chapter 8.3.2 „Checking the oil pressure“ on page 144
Checks after first commissioning 13.
WARNING!
Risk of injury from pulling or opening pressur-
ised lubricating and control oil pipes.
Perform the following checks:

Ä Chapter 6.4 „Performing checks after commis-
sioning“ on page 123.
Acoustic hood protection 14.
WARNING!
Risk of injury if protective equipment is not
present.
Correctly close the elements of the acoustic hood.

n Store the acoustic hood key safely.
n Only allow access for authorised personnel.
Belt protection 15.
WARNING!
Risk of injury if protective equipment is not
present.
Mount the belt protection cover.

Operational readiness 16. If there are no malfunctions, the machine is ready for opera-
tion.
After the first few hours of operation, preservative

oil may gather in the parting faces as a result of
the machine warming up.
122 V4-060 K 11.04.2017

Initial start-up
Performing checks after commissioning
6.4 Performing checks after commissioning

Inspection After the first 3 op. After the first 25 op.
hrs hrs
Screws after the machine has
cooled down, re-
tighten if necessary
Safety valve check for correct
operation
Oil level Check and, if neces- Check and, if neces-
sary, correct sary, correct
Aligning the belt check, if necessary

pulley correct
Condition of the check, change if nec-
belts essary, establish
cause
Control system, check for correct
fault transmitter, operation
pressure and
temperature sen-
sors
Motor overload connected and active
protection
Accumulation of check, remove if nec-
preservative oil essary
Sealing gas check on discharge

pressure side, in nitrogen oper-
ation
Gauge display:
Sealing gas pressure
of 50 mbar
op. hrs = operating hours
11.04.2017 V4-060 K 123

Operation
Safety instructions
7 Operation
Improper operation
WARNING!
Risk of injury from improper operation!
Improper operation may lead to serious injury and
considerable material damage.
– Carry out all activities in accordance with the
information and notes in this instruction
manual.
– Before beginning work, observe the following:
– Ensure that all covers and safety devices
are installed and operating correctly.
– Ensure that there are no persons in the
hazard area.
– Never deactivate or bypass safety devices
during operation.
Open acoustic hood

WARNING!
Risk of injury from operation with an open
acoustic hood!
Open acoustic hoods may lead to dangerous situa-
tions and cause injury during machine operation.
– Always keep the acoustic hood closed during
operation.
Explosion and fire hazards

DANGER!
There is a risk of explosion and fire from igni-
tion hazards!
Avoid allowing ignition hazards (open flames, flying
sparks, weld spatter) into the vicinity of the
machine. Sparks and incandescent or flammable
objects could be sucked in through the supply air
openings on the acoustic hood or through the
intake silencer. The fan may ignite these elements
causing fire or an explosion.
– Avoid ignition hazards.
124 V4-060 K 11.04.2017

Operation
Shut-down in case of emergency
Adjusting valves
DANGER!
Risk of injury when adjusting valves!
When the machine is running and an attempt is
made to adjust a valve, body parts may be injured
by rotating components. Take into account the
stand-by mode and/or automatic start-up
Only make adjustments if:
– The machine is not running.
– The machine is secured against a restart.
Requirements for staff Requirements for operation:

Operating the machine
Personnel: n User
Adjusting valves
Personnel: n User
n Authorised electricians
Protective equipment Requirements for operation:

n Safety shoes
Special tools Adjusting the valves requires:

Special tool: n General tool kit
7.2 Shut-down in case of emergency

In hazardous situations, the movements of components must be
stopped as quickly as possible and the electric power supply must
be shut off.
Shut-down in case of emergency In an emergency, proceed as follows:
1. Activate the EMERGENCY STOP immediately.
2. Inform the responsible staff.
3. Switch off the main circuit breaker and secure it against
restarting.
11.04.2017 V4-060 K 125

Operation
Switching on > On-site operation
4. Assign qualified personnel the task of rectifying the fault.

5.
WARNING!
Before commissioning, ensure that all safety devices are

installed and operational.
7.3 Switching on
Operating modes Depending on the operating mode, the machine can be switched
on in the following ways:
If possible, start up the machine without load!

Observe the control circuit types!
When starting and stopping the drive motor, observe all of the
machine's protective measures. Power take-offs must be actuated
by a potential-free contact or be actuated directly. The start-up of
the power take-offs runs in parallel to the drive motor.
AERtronic The starting and stopping of the drive motor must be carried out by
AERtronic. A potential-free contact is already in place.
7.3.1 On-site operation

On-site manual operation
DANGER!
Risk of injury if protective equipment is
missing!
Manually activate the starter switch on the machine on site.

ð The machine starts and comes on stream.
126 V4-060 K 11.04.2017

Operation
Switching on > Automatic operation
7.3.2 Remote operation

Via remote station
DANGER!
Risk of fatal injury if protective equipment is
missing!
WARNING!
Risk of injury if the machine starts suddenly!
Activate the starter switch in the remote station.

ð The machine is started remotely and comes on stream.
Remote station with AERtronic n Remotely via potential-free contact

n Remotely via MODBUS RTU
n Remotely via PROFIBUS DP
7.3.3 Automatic operation

Automatic activation
DANGER!
Risk of fatal injury if protective equipment is
missing!
WARNING!
Risk of injury if the machine starts suddenly!
The starting command is carried out by sensors or a system

switch.
ð The machine starts automatically and comes on stream.
11.04.2017 V4-060 K 127

Operation
Switching off > Remote-controlled operation
7.4 Displaying operating parameters

AERtronic (optional)
A detailed explanation is contained in the separate

operating manual AS-002.
Fig. 105: AERtronic display
Analogue instruments (optional) Depending on their design, analogue instruments display the given
operating data, e.g. discharge pressure, filter contamination.
Control system (optional) Depending on the customer’s control system, additional operating
parameters can be recorded and displayed.
7.5 Switching off

Operating mode Depending on the operating setup, the machine can be switched
off in the following ways:
7.5.1 On-site operation

On-site manual operation
WARNING!
Risk of injury from unbraked shut-down!
Manually activate the cut-out switch on the machine.

ð The machine is switched off and shuts down. The
machine does not stop immediately.
7.5.2 Remote-controlled operation

Via remote station
WARNING!
Activate the cut-out switch in the remote station.

128 V4-060 K 11.04.2017

Operation
Decommissioning
7.5.3 Automatic operation

Switching off automatically
WARNING!
The shut-down command is carried out by sensors or a

system switch.
7.5.4 Switching off in nitrogen operation

Switching off in nitrogen operation 1.
Switch off as described above!
Switch off the machine.

2.
DANGER!
Risk of fatal injury from gas leaks!
For longer downtimes disconnect the unit from the gas net-
work.
ð Otherwise there is a possibility that gas leaks will occur
during downtime.
7.6 Decommissioning
Decommissioning means the shut-down of a

machine for a longer period.
Measures 1. Switch off the machine properly and secure it against an

unintentional start.
2. Disconnect fuses.
3. Close the shut-off valves of the delivery lines.
4. Prevent condensate from entering the machine.
5. For a downtime of over six weeks: preserve the conveying
chamber.
11.04.2017 V4-060 K 129

Operation
Adjusting valves
Avoiding damage caused by down- For a downtime of over six weeks

time and corrosion
preserve the conveying chamber.Ä „Preservation“
on page 91
Move the rotors every six weeks by 2-3 rotations.
7.7 Measures for recommissioning

7.7.1 Commissioning after adjustment works
after adjustments Work stages Ä Chapter 7.8.4 „Commissioning after adjust-
ments“ on page 134
7.7.2 Commissioning after maintenance work

after maintenance Work stages Ä Chapter 8.5 „Commissioning after mainte-
nance“ on page 169
7.7.3 Commissioning after fault rectification

After fault rectification Work stages Ä Chapter 9.5 „Commissioning after malfunction rec-
tification“ on page 177
7.8 Adjusting valves
DANGER!
Risk of injury when adjusting valves or equipment!
Preparation/models with acoustic 1. Agree adjustments with the responsible staff at the location.
hood
2. Switch off the machine.
3. Activate the EMERGENCY STOP function.
restarting.
5. Ensure there is no live electricity.
6. Open the maintenance elements.
Preparation/models without 1. Agree adjustments with the responsible staff at the location.
acoustic hood
130 V4-060 K 11.04.2017

Operation
Adjusting valves > Adjusting the oil pressure regulating valve

restarting.
5. Ensure there is no live electricity.
6. Disassemble the belt guard.
7.8.1 Adjusting the oil pressure regulating valve

The oil pressure regulating valve is preset at the factory. An adjust-
ment is only necessary if the oil pressure level is outside the nec-
essary parameters.
Ä Chapter 11.11.1 „Oil pressure“ on page 198
Adjusting the valve
1. Remove protective cap (pos.1).

2. Loosen counternut (pos.2) if in place.
3. Turn the spindle (pos.3) anti-clockwise using an Allen key.
ð The oil pressure drops.
4. Turn the spindle (pos.3) clockwise using an Allen key.
ð The oil pressure increases.
5. Adjust the oil pressure accordingly.
6. Tighten counternut (pos.2) if in place.
Fig. 106: Oil pressure regulating valve
7. Attach protective cap (pos.1).
8. Mount all protective hardware and covers.
9. Close the maintenance elements.
10.
NOTICE!
Risk of damage! Observe the starting fre-
quency of the drive motor!
Start the machine.

11. Check oil pressure.
12. If oil pressure is in the permissible range:
ð adjustments are complete.
13. If oil pressure is not in the permissible range:
ð repeat the adjustment steps.
11.04.2017 V4-060 K 131

Operation
Adjusting valves > Adjusting the start-up unloading device
7.8.2 Adjusting the start-up unloading device
Applications in VML machines

The start-up relief device is used in VML machines and is preset
with a maximum closing time at the factory. An adjustment is only
necessary if the start unloading device does not close or the
closing time is too long.
Fig. 107: Example of start-up relief

device
Settings with star-delta starting

The start unloading device closes fully after:
– the switch from star to delta.
– the nominal speed is reached.
The closing procedure can be both heard and seen (on the gauge
for discharge pressure).
Setting the closing time

2. Loosen counternut (pos.1)
3. Move the spindle (pos.2) clockwise.
ð The closing time is reduced.
4. Move the spindle (pos.2) anti-clockwise.
ð The closing time is extended.
5. Set the closing time.
6. Tighten counternut (pos.1).
7. Mount all protective hardware and covers.
Fig. 108: Start-up relief positions
8. Close the maintenance elements.
9.
NOTICE!
Risk of damage! Observe the starting fre-
quency of the drive motor!
Start the machine.

10. Check the closing time.
132 V4-060 K 11.04.2017

Operation
Adjusting valves > Adjusting sealing gas pressure in nitrogen operation
11. If the closing time is in the permissible adjustment range:

ð adjustments are complete.
12. If the closing time is not in the permissible adjustment range:
ð repeat the adjustment steps.
Settings for pole changing Set start unloading device to a lower speed in accordance with
star-delta starting.
The closing time in the lower speed range must be

set as long as possible, so that an acceptably long
closing time is still available for the upper speed
range.
If this is not possible, then an additional solenoid valve is used.

The solenoid valve (pos.3) locks open the start unloading device to
the atmosphere when ramping up to “high-speed” mode directly.
Reasons for the above:
n The differences in conveyed amounts are too large.
n High-speed operation is started from low-speed operation in
“double-star starting”.
The solenoid valve (pos.3) locks open the start unloading device to
the atmosphere before double-star starting of high-speed mode.
Once the nominal speed is reached, the solenoid closes.
The solenoid can be controlled by a timer relay or a pressure mon-
itor.
7.8.3 Adjusting sealing gas pressure in nitrogen operation
Adjusting sealing gas pressure

DANGER!
Risk of injury when adjusting sealing gas pressure!
Risk of injury from hot surfaces and rotating com-
ponents.
The sealing gas pressure can only be adjusted

during machine operation. A high level of caution
and care is required when doing this.
11.04.2017 V4-060 K 133

Operation
Adjusting valves > Commissioning after adjustments
Preparation/models with acoustic 1. Agree adjustments with the responsible staff at the location.
hood
Preparation/models without Agree adjustments with the responsible staff at the location.
acoustic hood
Adjusting sealing gas pressure 1. Read the gauge display.

2. Display: 50 mbar
ð The setting is OK.
3. Display higher or lower than 50 mbar.
ð Correct the setting.
4. Adjust the valve in such a way that it reaches a pressure of
50 mbar.
7.8.4 Commissioning after adjustments

Commissioning 1. Inform the responsible on-site person about the result of the
work carried out and agree commissioning steps with that
person.
2. Check all previously loosened screw connections for tight-
ness.
3. Ensure that there are no persons in the hazard area.
4. Re-attach all safety hardware.
5. Remove all used tools, materials and other equipment from
the workspace.
6. Release the safety on the main circuit breaker and activate it.
7. Release the EMERGENCY STOP function.
ð Start operation in accordance with the instruction in the
“Operation” chapter. Ä Chapter 7.3 „Switching
on“ on page 126
8. Inform the responsible on-site person about the result of the
work carried out.
134 V4-060 K 11.04.2017

Maintenance
Safety instructions
8 Maintenance
Improperly performed maintenance

work WARNING!
Risk of injury from improperly performed main-
tenance work!
Improperly performed maintenance may lead to
serious injury or material damage.
– Only perform maintenance work when the
machine has been decommissioned.
– Secure against a restart.
– Allow the machine to cool down to the ambient
temperature.
– Before beginning work, ensure that there is
sufficient space for installation work.
– Check the tidiness and cleanliness of the work
area.
– Only perform maintenance work with suitable
tools.
– Ensure removed components are re-installed
correctly.
– Re-install all fastening elements and observe
the screw tightening torques.

restarting WARNING!
may be people located in the hazard area.
– Before beginning work, switch off the energy
supply and secure it against restarting.
Electrical system
DANGER!
serious injury.
11.04.2017 V4-060 K 135

Maintenance
Safety instructions
Rotating or moving components

WARNING!
Risk of injury from rotating or moving compo-
nents!
Rotating or moving components can cause serious
injuries.
– Never touch rotating or moving components.
– Never reach into the clamping area of the
belts, for example.
– Keep a safe distance from rotating or moving
components.
– Wear tight-fitting protective work clothing with
low tensile strength within the hazard area.
Hot operating materials

WARNING!
Risk of injury from hot operating substances!
Operating substances may reach high tempera-
tures during operation. Skin contact with hot oper-
ating substances causes serious burns.
– For all work performed with hot operating sub-
stances, always wear protective work clothing
and protective gloves.
– Before any work with operating substances,
check whether they are hot. If necessary, allow
them to cool down to the ambient temperature.
Conveyance of nitrogen
WARNING!
Risk of injury from a ventilator during lag time!
A ventilator during lag time may cause injury to
persons working in its direct vicinity.
– Wait until the ventilator has switched off com-
pletely.
– Never remove the protective guard.
Requirements for staff The maintenance work described here may only be performed by
the designated personnel. The personnel entrusted with the
respective maintenance tasks are listed in the maintenance plan.
For the preparation of the maintenance plan, the following is nec-
essary:
n Service personnel
136 V4-060 K 11.04.2017

Maintenance
Safety instructions
For cleaning after maintenance, the following is necessary:

Personnel: n User
Commissioning after maintenance requires:

n Service personnel
Protective equipment For maintenance, the following is necessary:

n Safety shoes
n Protective gloves
n Safety goggles
Special tools Requirements for maintenance without a lifting device:

Special tool: n Hydraulic lift
n Hinged motor support lifting equipment
n Transport securing rod
n Oil funnel
n General tool kit
ment
n Strap wrench
n Auxiliary materials, aids
Requirements for maintenance with a lifting device:

Special tool: n Ratchet wrench
n Oil funnel
n General tool kit
ment
n Strap wrench
11.04.2017 V4-060 K 137

Maintenance
Maintenance schedule
8.2 Maintenance schedule

The following section describes the maintenance work that is
required for optimal and fault-free operation of the machine.
If regular inspections reveal an increased level of abrasion, reduce
the maintenance intervals in accordance with the signs of wear and
tear. For questions on maintenance work and intervals contact the
manufacturer. See contact details.
138 V4-060 K 11.04.2017

Maintenance
Maintenance schedule > Maintenance schedule for normal operation
8.2.1 Maintenance schedule for normal operation

Interval Maintenance work Personnel
After the first 500 op. Replace the oil filter. Ä Chapter 8.3.5 „Changing the oil Service personnel
hrs filter“ on page 156.
Check the oil level. If necessary, top up. Ä Chapter
8.3.1 „Checking the oil level“ on page 141
Weekly Check the oil pressure. Correct if necessary. Ä Chapter User
8.3.2 „Checking the oil pressure“ on page 144
Check that the belt guard is fully attached and check it for
damage and contamination. Ä Chapter 8.3.16 „Checking the
belt guard“ on page 167
Remove any dirt from the outer belt guard.Ä Chapter
8.3.16 „Checking the belt guard“ on page 167
Check the intake filter for contamination. (display unit, max. User
permissible -45 mbar)
Check the oil pressure. If necessary, correct it. Ä Chapter
8.3.2 „Checking the oil pressure“ on page 144
Check the oil level. If necessary, correct it. Ä Chapter Service personnel
8.3.1 „Checking the oil level“ on page 141
If the maximum value (-45 mbar) is exceeded, change the Service personnel
intake filter. Ä Chapter 8.3.6 „Replacing the intake
filter“ on page 157
Check the tightness of the safety valve. Ä Chapter Service personnel
8.3.11 „Checking and servicing the safety valve“ on page 164
If necessary, replace the seals. Clean the safety valve.
Ä Chapter 8.3.11 „Checking and servicing the safety
valve“ on page 164
Check the safety valve for correct operation. Ä „Movement
test“ on page 164
If the belt guard is insufficiently stable or is damaged, inform Manufacturer’s
customer service. customer service
division
Lubrication intervals Observe the instruction manual and signage of the drive Service personnel
for drive motor motor!
After every 4,000 op. Check and clean the inlet and exhaust air openings on the User
hrs or 6 months acoustic hood. Ä Chapter 8.3.15 „Checking the inlet and
exhaust air openings on the acoustic hood“ on page 166
Check the condition of the belts. If necessary, replace them. Service personnel
Ä Chapter 8.3.9 „Replacing belts, hinged motor support
without a lifting device “ on page 158 Ä Chapter
8.3.10 „Replacing belts, hinged motor support with a lifting
device “ on page 162
Inspect the sheaves for unusual wear and tear or obvious
damage. Inspect for alignment and stability. Ä Chapter
8.3.7 „Checking the sheaves“ on page 157
11.04.2017 V4-060 K 139

Maintenance
Maintenance schedule > Maintenance schedule for normal operation
Interval Maintenance work Personnel

Replace lube oil (if using "Klüberöl Summit SH 46 XS"/"sili-
cone-free" is required). Ä Chapter 8.3.4 „Changing
oil“ on page 150
Replace oil filter (if using "Klüberöl Summit SH 46 XS” lube
oil / or with "silicone-free” requirement). Ä Chapter
8.3.5 „Changing the oil filter“ on page 156
Clean the oil cooler. Ä Chapter 8.3.17 „Cleaning the oil
cooler lamellas“ on page 167
Clean the separating element in the oil demister. Ä Chapter
8.3.18 „Cleaning the oil demister“ on page 168
If necessary, replace the sheaves. Manufacturer’s
customer service
division
After every 8,000 op. Replace the intake filter. Ä Chapter 8.3.6 „Replacing the Service personnel
hours or every 12 intake filter“ on page 157
months
Check the safety valve for correct operation. Ä Chapter
8.3.11 „Checking and servicing the safety valve“ on page 164
Replace lube oil (except when using Delta Lube
06).Ä Chapter 8.3.4 „Changing oil“ on page 150
Replace oil filter (except when using Delta Lube
06).Ä Chapter 8.3.5 „Changing the oil filter“ on page 156
Check non-return flap for correct operation, wear and tight-
ness. Ä „Checking for tightness“ on page 165
If necessary, replace it.Ä „Replacing the non-return flap“
on page 166
Check the control system, fault transmitter and pressure and Manufacturer’s
temperature sensors for correct operation. customer service
division
After every 16,000 op. Replace the belts. Ä Chapter 8.3.9 „Replacing belts, hinged Service personnel
hrs or every 2 years motor support without a lifting device “ on page 158Ä Chapter
Check the alignment of the sheaves. If necessary, correct it.
Ä Chapter 8.3.7 „Checking the sheaves“ on page 157
Check pipe connections on the discharge and intake side for
tightness. If necessary, replace the seals. Ä Chapter
8.3.19 „Checking pipelines for tightness.“ on page 168
After every 20,000 op. Check hose lines for tightness. Replace if necessary. Service personnel
hrs or 3 years
Recommendation: replace hose lines every 6 years.
Recommended main inspection/servicing. Manufacturer’s
customer service
Inspection, changing of replacement and expendable parts. division
Entire machine check.
140 V4-060 K 11.04.2017

Maintenance
Maintenance work > Checking the oil level
8.3 Maintenance work

Preparation 1. Agree maintenance work with the responsible staff at the
location.
restarting.
5.
DANGER!
Risk of injury from electric current!
Ensure there is no live electricity.

6.
DANGER!
Risk of injury during maintenance work!
Open the maintenance elements.

7.
DANGER!
Risk of injury during maintenance work!
Open the belt guard cover.
8.3.1 Checking the oil level
8.3.1.1 Oil system/models with acoustic hood
The litre-difference between 70% and 60%

amounts to approx. 2.3 litres.
11.04.2017 V4-060 K 141

Maintenance
1 Filled oil, screw seal on filling container

2 Oil drain, oil drain valve
3 AERtronic oil level display
Fig. 109: Oil system
Checking the oil level

Select the AERtronic oil level display menu
Fig. 110: AERtronic display menu
Display: 70%
Oil level display at 70% while machine is idle.
Fig. 111: Correct oil level
Display: 65%
Oil level display at 65% during machine operation.
Fig. 112: Correct oil level
Display: 60%
Correct the oil level.
Fig. 113: Impermissible oil level
142 V4-060 K 11.04.2017

Maintenance
8.3.1.2 Oil system/models without acoustic hood

1 Oil fill openings, marked in RED
2 Oil drain, oil drain valve

3 Oil level display on oil container of base support
Fig. 115: Oil drain (machine stage)
8.3.1.3 Checking the lube oil level of the machine stage

1.
NOTICE!
Only check the oil level when the machine is
idle!
2. Open the maintenance elements of the acoustic hood.

3. Check the oil level on the sight glass of the machine stage.
Oil level display on the base support.
Fig. 116: Opening the maintenance

elements
11.04.2017 V4-060 K 143

Maintenance
Maintenance work > Checking the oil pressure
Sight glass is full

4. Machines with “full” oil level display.
ð Oil level is correct.
Fig. 117: full
Sight glass is not full

5. Machines with “not completely full” oil level display.
ð Fill oil to the correct level.
Fig. 118: not completely full
Sight glass not or only partially full

6. Machines with insufficient or no oil displayed.
ð Fill with oil.
Fig. 119: not or only partially full
8.3.2 Checking the oil pressure
1. Select the AERtronic oil pressure display menu

For models without AERtronic: read the display on the oil
pressure gauge.
The pressure changes depending on the

temperature of the lubricant oil. An oil pres-
sure adjustment can only be carried out
when the machine is at operating tempera-
ture.
2. The oil pressure is within the permissible min.-/max. values.

ð The oil pressure is OK.
3. The oil pressure is outside the permissible min.-/max. values.
ð Correct the oil pressure using the oil pressure regulating
valve.
144 V4-060 K 11.04.2017

Maintenance
Maintenance work > Correcting the oil level
8.3.3 Correcting the oil level

8.3.3.1 Oil level too high
Oil drainage (models with acoustic
hood)
1.
WARNING!
Risk of scalding from hot lubricating oil!
NOTICE!
Material damage to the drain hose from lube
Fig. 120: Oil drain oil temperatures over 60°C!
Allow the lube oil to cool down to the ambient temperature.

2.
Observe the volume of the waste oil and the
oil-resistant receptacle. Ä Chapter
11.8.2 „Lubricant quantities“ on page 196.
Have a receptacle ready.

3. Open the oil opening on the oil filling container.
ð Lube oil flows out more evenly from the oil drain.
4. Feed the drain hose into the receptacle.
5.
CAUTION!
Risk of skin irritation from old lube oil!
Remove the sealing cap from the drain valve.

6. Screw the drain hose onto the drain valve.
7. Open the drain valve.
ð The lube oil is drained.
8.
CAUTION!
Risk of slipping from oil spillage!
Guide excess lubricating oil into the receptacle.
11.04.2017 V4-060 K 145

Maintenance
9. Observe and check the oil level.

10. If the permissible oil level is reached, close the drain valve.
ð Oil drain is closed.
11. Remove the drain hose from the drain valve.
Fig. 122: Machine stage display
12. Screw the sealing cap onto the drain valve.
13. Close the oil fill opening.
14.
ENVIRONMENT!
Risk of environmental damage from waste
oil!
Collect waste lubricant and residual oil properly and dispose

of it in an environmentally-friendly manner.Ä Chapter
10.2 „Disposal“ on page 180
Clean the workspace thoroughly.
Clean all auxiliary equipment.
Oil drainage (models without

acoustic hoods)
1.
CAUTION!

If the sealing cap is very tightly in place, secure the drain
valve using a wrench and loosen the sealing cap with an
additional wrench.
2.
Fig. 123: Oil drain
NOTICE!
2 Drain valve Material damage to the drain hose from lube
3 Oil level display on oil container of oil temperatures over 60°C!
base support
Feed the drain hose into the receptacle.

3. Twist the drain hose onto the drain valve.
ð The drain valve opens automatically.
146 V4-060 K 11.04.2017

Maintenance
4.
CAUTION!
Guide any excess lubricating oil into the receptacle.

6. If the oil level has been corrected, remove the drain hose.
ð The drain valve closes automatically.
Fig. 124: Oil level display (machine
stage) 8. Close the oil fill opening.
9.
ENVIRONMENT!
oil!

8.3.3.2 Oil level too low

Oil drainage/models with acoustic
hood
1. Check the drain valve for firm seating and make sure it is
closed properly.
2. Check the sealing cap of the drain valve for firm seating.
3. Open the oil filling container.
4. Ensure that the ventilation pipe in the oil filling container is
unobstructed.
11.04.2017 V4-060 K 147

Maintenance
5.
CAUTION!
Risk of skin irritation from lube oil!
ENVIRONMENT!
of lubricants!
Observe the specifications: Ä Chapter 11.8.1 „Lubricant oil

specifications“ on page 192.
Fill the lube oil in stages and in small quantities.
6. Observe the oil level. Wait 5 - 10 minutes. The lube oil con-
tinues to flow.
ð The oil level regulates itself in the oil system and in the oil
chamber.

8. n When the machine is idle, the lubricant oil level is
located, in its entirety, in the sight glass of the machine
stage.
n The AERtronic display shows a “70%” display when the
Fig. 127: Machine stage display machine idle.
ð The oil level is OK.
9. Lubricating oil not within the sight glass display => there is no
oil or the oil level is too low.
ð Correct the oil level.
10. Close the oil filling container.
11.
ENVIRONMENT!
Risk of environmental damage from incorrect
storage of lube oil!

Dispose of residual lube oil in an environmentally-friendly
way. Ä Chapter 10.2 „Disposal“ on page 180
Filling with oil (models without

acoustic hoods)
148 V4-060 K 11.04.2017

Maintenance
1. Check the drain valve for firm seating.

2. Check that the sealing cap of the drain valve is firmly in
place.
3. Open the oil fill opening, the RED-marked sealing screw.
4.
CAUTION!
ENVIRONMENT!
of lubricants!

specifications“ on page 192.
tinues to flow.
chamber.
6. Check the lubricating oil level.
located, in its entirety, in the sight glass of the com-
pressor.
Fig. 129: Oil level display (machine ð The oil level is OK.
stage) 8. Lubricating oil not within the sight glass display => there is no
oil or the oil level is too low
9. Close the oil fill opening tightly with a seal.
11.04.2017 V4-060 K 149

Maintenance
Maintenance work > Changing oil
10.
ENVIRONMENT!

8.3.4 Changing oil

Oil drainage (models with acoustic
hood)
1.
WARNING!
Risk of scalding from hot lube oil!
NOTICE!
Fig. 130: Draining oil (acoustic hood) oil temperatures over 60°C!

2.
Observe the volume of the waste oil and the

3. Open the oil opening on the oil filling container.
ð Lube oil flows out more evenly from the oil drain.
4. Feed the drain hose into the receptacle.
5.
CAUTION!

6. Screw the drain hose onto the drain valve.
7. Open the drain valve.
ð The lube oil is drained.
150 V4-060 K 11.04.2017

Maintenance
8.
CAUTION!
Guide lube oil into the receptacle.

9. When the lubricating oil has been drained fully, close the
drain valve.
ð Lubricating oil drain is closed.
10. Remove the drain hose from the drain valve.
13.
ENVIRONMENT!
oil!

Oil drainage/models with acoustic

hood
1. Check the drain valve for firm seating and make sure it is
closed properly.
2. Check the sealing cap of the drain valve for firm seating.
3. Open the oil filling container.
4. Ensure that the ventilation pipe in the oil filling container is
unobstructed.
11.04.2017 V4-060 K 151

Maintenance
5.
CAUTION!
ENVIRONMENT!
of lubricants!

specifications“ on page 192
tinues to flow.
chamber.

8. n When the machine is idle, the lube oil level is located, in
its entirety, in the sight glass of the compressor.
n The AERtronic display shows a “70%” display when the
machine is idle.
Fig. 133: Machine stage display
10. Close the oil filling container.
11.
ENVIRONMENT!

152 V4-060 K 11.04.2017

Maintenance
Oil drainage (models without

acoustic hoods)
1.
WARNING!
Risk of scalding from hot lube oil!
NOTICE!
oil temperatures over 60°C!
Fig. 134: Oil drain

2 Drain valve
2.
3 Oil level display located on oil
container of base support Observe the volume of the waste oil and the

3.
CAUTION!

If the sealing cap is very tightly in place, secure the drain
valve using a wrench and loosen the sealing cap with an
additional wrench.
4.
NOTICE!
oil temperatures over 60°C!
Feed the drain hose into the receptacle.

5. Twist the drain hose onto the drain valve.
ð The drain valve opens automatically.
6.
CAUTION!
Guide any lubricating oil into the receptacle.
11.04.2017 V4-060 K 153

Maintenance

8. When the lubricating oil has been drained fully, remove the
drain hose.
ð The drain valve closes automatically.
Fig. 135: Machine stage display 9. Screw the sealing cap onto the drain valve.
11.
ENVIRONMENT!
oil!

Filling with oil (models without

acoustic hoods)
1. Check the drain valve for firm seating.

2. Check that the sealing cap of the drain valve is firmly in
place.
3. Open the oil fill opening, the RED-marked sealing screw.
154 V4-060 K 11.04.2017

Maintenance
4.
CAUTION!
ENVIRONMENT!
of lubricants!

specifications“ on page 192
tinues to flow.
chamber.
Fig. 137: Machine stage display 6. Check the lube oil level.
located, in its entirety, in the sight glass of the com-
pressor.
9. Close the oil fill opening tightly with a seal.
10.
ENVIRONMENT!

Dispose of residual lubricating oil in an environmentally-
friendly way. Ä Chapter 10.2 „Disposal“ on page 180
11.04.2017 V4-060 K 155

Maintenance
Maintenance work > Changing the oil filter
8.3.5 Changing the oil filter

Changing the oil filter
1.
Replace the oil filter each time the lubricating
oil is changed.
Fig. 138: Oil filter

WARNING!
Risk of scalding and skin irritation from hot,
lubricating waste oil!
2. Allow the lube oil to cool down to the ambient temperature.

3.
CAUTION!
Risk of skin irritation from lubricating waste
oil!
Loosen the old oil filter using a strap wrench.

A residual quantity of oil may flow out of the filter. Catch the
residual oil using a receptacle and cloth.
4. Remove the old oil filter.
5. Clean the seal surface.
6. Lightly oil the sealing ring of the new oil filter.
7. Screw in the oil filter by hand.
8.
ENVIRONMENT!
oil!
Properly dispose of used oil filters, cloths and receptacles

with residual oil. Ä Chapter 10.2 „Disposal“ on page 180
156 V4-060 K 11.04.2017

Maintenance
Maintenance work > Checking the sheaves
8.3.6 Replacing the intake filter

Replacing the intake filter
1.
CAUTION!
Risk of air contamination from scattered dust
particles.
First release the handwheel of the maintenance cover and

then remove it.
2. Remove the maintenance cover.
Fig. 139: Releasing the maintenance
cover
3. Loosen the intake filter by turning it anti-clockwise and then

remove it from its housing.
4.
NOTICE!
Risk of machine damage! Objects inside the
intake silencer may enter the intake opening.
Fig. 140: Loosen the intake filter and Remove residual dust inside the intake silencer.
remove it
5. Insert a new intake filter.
6. Fasten the intake filter in place by turning it clockwise. Check
that it is aligned correctly.
7. Fasten the maintenance cover on the housing of the intake
silencer using the handwheel.
8. Reset the maintenance indicator (in accordance with the
given version).
8.3.7 Checking the sheaves

For wear and tear and damage
1. Check for unusual wear and tear or obvious damage.

2. Check for correct alignment and stability.
3. If necessary, replace the sheaves.
4. Install the sheaves.
5. Fit the belt. Ä Chapter 8.3.9 „Replacing belts, hinged motor
support without a lifting device “ on page 158Ä Chapter
Fig. 141: Sheaves
11.04.2017 V4-060 K 157

Maintenance
Maintenance work > Replacing belts, hinged motor support without a lifting device
8.3.8 Moving/checking the protective cover of the sheaves

Moving on models without acoustic
hood
1. Loosen the fitting of the protective cover before lifting the

hinged motor support.
ð The protective cover can now be moved.
2. Lift the hinged motor support, e.g. for changing the belts.
3. Lower the hinged motor support.
ð The weight of the motor creates tension in the belts.
4. Push the protective cover in the direction of the motor shaft
and tighten it.
Fig. 142: Protective cover
Testing on models without acoustic 1. Check the spacing of the protective cover of the motor shaft.
hood
During operation, the protective cover should be at a dis-
tance of approx. 10 mm from the motor drive shaft.
2. Check the protective cover for firm seating and, if necessary,
tighten it.
8.3.9 Replacing belts, hinged motor support without a lifting device
Lifting version a.1) and b.2)

1.
NOTICE!

2.
WARNING!
Fig. 143: Version a.1) and b.2)
loads!
1 Version a.1)
2 Version b.2)
hydraulic lift.
158 V4-060 K 11.04.2017

Maintenance
3.
WARNING!
or slipping!

wedges for bracing!
slip.
Lifting version a.2)
5. Insert the angle bracket for transport safety into the mounting
rail of the motor.
6.
NOTICE!

Fig. 144: Version a.2)
7.
WARNING!
loads!

hydraulic lift.
8.
WARNING!
or slipping!

wedges for bracing!
slip.
11.04.2017 V4-060 K 159

Maintenance
Lifting version c)
10.
NOTICE!

11.
WARNING!
Fig. 145: Version c) Risk of shearing and crushing from moving
loads!

hydraulic lift.
12.
WARNING!
or slipping!
Raise the hinged motor support in small steps. While doing

so, support the hinged motor support in the recess of the
base support with the safety rod for transport (red rod).
slip.
Fitting the belt
14.
CAUTION!
Fit the belt. Observe and comply with the permissible groove
Fig. 146: Permissible belt layout layout.
160 V4-060 K 11.04.2017

Maintenance
Tensioning the belts 15.

WARNING!
Risk of injury from tensioning, moving or
rotating components!
Release the hydraulic lift carefully and slowly.

ð The hinged motor support is lowered.
If released too quickly, the hinged motor

support drops suddenly.
The belts are tautened by the weight of the motor.

16.
NOTICE!
Risk of damage to the belt drive!
The hinged motor support must not rest on
the base support, the transport securing rod
or similar equipment.
17. Check whether the motor can be moved approximately

100 mm upwards and downwards!
ð If no mobility is given, repeat the work steps.
18. Completely remove the hydraulic lifter, transport safety lock
and other auxiliary equipment.
Store them securely for future maintenance.

Fig. 147: Hinged motor support mobi-
lity
11.04.2017 V4-060 K 161

Maintenance
Maintenance work > Replacing belts, hinged motor support with a lifting device
8.3.10 Replacing belts, hinged motor support with a lifting device
Raising the hinged motor support
1.
WARNING!
Risk of injury from moving or rotating compo-
nents!
Lift the hinged motor support using the hinge jig.

2. Turn guide bushing (pos.3) anti-clockwise using the ratchet
wrench.
ð The hinged motor support is raised.
3. Raise the hinged motor support until the belts are fully
Fig. 148: Raising the hinged motor relieved of tension.
support
4.
Only replace belts as a set!
5. Replace belts.
WARNING!
Risk of getting caught by rotating sheaves!
6. Observe the permissible groove layout.
Fig. 149: Permissible belt layout
162 V4-060 K 11.04.2017

Maintenance
Maintenance work > Replacing belts, hinged motor support with a lifting device
Pre-tensioning belts
7.
CAUTION!
Turn guide bushing (pos.3) clockwise with the ratchet wrench

until the belts are pre-tensioned.
ð The hinged motor support is partly held by the belt drive
and rests lightly on the guide bushing (pos.3).
Fig. 150: Pre-tensioning belts
Adjusting the guide bushing

8. Set gauge A.
n Set self-locking nut (pos.4) to gauge A. Screw guide
bushing (pos.3) on self-locking nut (pos.4) using the
ratchet wrench.
Size Nominal diameter, dis- Gauge A in

charge side mm
VM 8R DN 65 25
VM 15R DN 65 25
VML18R DN 80 25
VM 21R DN 80 25
Fig. 151: Adjusting the gauge of the
guide bushing VML 25R DN 125 25
VM 37R DN 150 30
VML 40R DN 150 30
Delta Screw G5
Tensioning the belts

9.
CAUTION!
Risk of injury from moving and rotating com-
ponents!
Tension the belts.

n Secure the guide bushing (pos.3) with the self-locking nut
(pos.4).
n The hinged motor support is supported entirely by the
belt drive.
Fig. 152: Tensioning the belts
11.04.2017 V4-060 K 163

Maintenance
Maintenance work > Checking and servicing the safety valve
Checking the protective cover

10. Check the spacing of the protective cover of the motor shaft.
The protective cover should be at a distance of approx. 10
mm from the motor drive shaft.
By loosening the fastening screws, the protective cover can
be moved.
Check the protective cover for firm seating and, if necessary,
tighten it.
Fig. 153: Protective cover of the

sheaves
8.3.11 Checking and servicing the safety valve

Movement test
1.
The safety valves are set at the factory. Their
settings must not be changed.
WARNING!
In the operating position, an open valve can
cause hot conveyed material to escape.
Turn the activation lever.

2. Move the activation lever back to its original position.
Fig. 154: Safety valve
ð The valve is closed.
An intact valve can be moved and closed normally.
3. Check the seals and seal positions.
Servicing the safety valve 1. Deactivate the pressure before disassembling the machine.
2. The safety valve must be disassembled for maintenance.
3. Change faulty seals.
4. Clean the safety valve.
5.
Other maintenance work may only be carried
out by the manufacturer.
Send the safety valve to the manufacturer for further mainte-

nance work.
164 V4-060 K 11.04.2017

Maintenance
Maintenance work > Checking the non-return flap
8.3.12 Checking that sealing plugs have been removed

Checking balancing holes
Fig. 155: Example of balancing holes
1. Check that the (plastic) sealing plugs have been removed

from the balancing holes.
The sealing plugs are coated in machine-

colour paint as part of the manufacturing
process.
The number and the position of the sealing
Fig. 156: Example of balancing holes
plugs varies depending on the machine type!
Depending on the design, they may already
have been removed before shipping or
during preparations for commissioning.
ð If there are no more sealing plugs in place: Finish the

check.
2. The balancing holes are sealed.
ð Remove the sealing plugs. Finish the check.
8.3.13 Checking the non-return flap

Checking for tightness
1. Check for external tightness.
2. Carry out a visual inspection.
3. If there is no visible damage:
ð The non-return flap is OK.
4. If there is visible damage:
Fig. 157: Example of non-return flaps
ð Replace the non-return flap.
Checking for correct operation and 1. Switch off the machine stage in the operating position.
wear and tear
2. Observe the machine’s shut-down process until it is idle.
ð After a shutdown, the machine stage rotates backwards
for a longer period = the non-return flap is faulty.
11.04.2017 V4-060 K 165

Maintenance
Maintenance work > Checking the inlet and exhaust air openings on the acoustic hood
Replacing the non-return flap

NOTICE!
Inspect for cleanliness! Dirt and particulate matter
can find its way into the machine stage interior.
This can result in extensive damage.
1. Disassemble the flange connections.

2. Remove the non-return flap from the flange connection.
3. Clean the sealing surfaces.
4. Fit new seals to the non-return flap.
5. Guide the non-return flap, with its seals, between the flanges.
6. Insert screws and tighten the flange connection.
8.3.14 Cleaning the nozzle of the start-up relief device

Cleaning the nozzle
1. Loosen the counternut (pos. 1).

2. Remove the spindle (pos. 2).
ð The nozzle (pos. 4) in the hole is accessible.
3.
WARNING!
Risk of injury from escaping dirt particles!
Blow compressed air into the nozzle (pos. 4).

Fig. 158: Start-up relief device ð Unobstructed cross-section of the nozzle.
4. Mount the spindle (pos. 2).
5. Set the closing time of the start-up relief device.Ä Chapter
11.11.4 „Start-up relief device for VML
machines“ on page 198
6. Mount the spindle (pos. 2) with the nut (pos. 1).
8.3.15 Checking the inlet and exhaust air openings on the acoustic hood
Checking the inlet and exhaust air 1. Visual inspection of the inlet and exhaust openings on the
openings acoustic hood.
2. Check the direction of air flow in the operating position with a
closed acoustic hood. Observe the information in the installa-
tion drawing.
3. Clean the openings. Remove dirt.
166 V4-060 K 11.04.2017

Maintenance
Maintenance work > Cleaning the oil cooler lamellas
8.3.16 Checking the belt guard

Damage and stability
1.
WARNING!
Risk of injury from hot surfaces!
Check for damage and thorough stability.

(stable on the base support and machine stage)
2. Remove dirt from the belt guard.
3. If necessary, tighten the belt guard fastener. If damaged,
replace it.
4. Beware of any lubricant bleeding out of the drive motor. If
Fig. 159: Belt guard
lubricant bleeds out, inform the responsible staff at the loca-
tion.
Seal any leaks.
8.3.17 Cleaning the oil cooler lamellas

Cleaning lamellas
1. Clean the oil cooler rough dirt particles using a cloth.
2.
WARNING!
Risk of injury from floating dirt and dust parti-
cles.
Carefully purge the lamellas with air.

3.
WARNING!
Risk of poisoning from cleaning agents and
Fig. 160: Oil cooler
cleaning steam.
If heavily contaminated: use a cleaning agent.

4. Check the oil cooler for damage and leaks (visual inspec-
tion).
11.04.2017 V4-060 K 167

Maintenance
Maintenance work > Checking pipelines for tightness.
8.3.18 Cleaning the oil demister

Replacing the separator element
1.
CAUTION!
Risk of skin irritation from old lubricating oil!
CAUTION!
Fig. 161: Separator element

Remove the separator element from the oil demister.
2. For single-use separators:
ð Insert a separator element.
3.
WARNING!
Risk of injury from floating dirt and dust parti-
cles.
WARNING!
Risk of poisoning from cleaning agents and
cleaning steam.
For wire mesh:

ð Clean wire mesh with an agent and blow it dry.
8.3.19 Checking pipelines for tightness.

Checking discharge-side pipelines 1. Check pipelines for tightness (visual inspection).
for tightness
Ensure that the pipelines have been depressur-
ised!
2. If there are leaks

ð Replace seals or bushing.
3. Reinforce the pipelines if necessary.
4. Disassemble leaking pipe connections.
5. Use new seals or bushing.
6. Assemble pipe connections.
168 V4-060 K 11.04.2017

Maintenance
Commissioning after maintenance
8.4 Cleaning after maintenance

Cleaning after maintenance work 1.
NOTICE!
Risk of damage! Do not used high pressure
cleaners, steam jet pumps, grease removal
agents, thinners, compressed air etc. as
cleaning methods.
2. Dust and dirt must be cleaned with suitable cloths.

3. Clean components susceptible to scratches, display units
and touch panels of control systems, gauges etc. with a soft,
wet towel.
4. Remove all cleaning agents from the immediate vicinity of the
machine before commissioning.
5. Dispose of cloths in an environmentally-friendly way.
8.5 Commissioning after maintenance

Commissioning after maintenance 1. Inform the responsible on-site person about the result of the
work carried out and agree commissioning steps with that
person.
2. Check all previously loosened screw connections for tight-
ness.
3. Mount all protective hardware and covers that were previ-
ously removed.
the workspace.
5. Clean the workspace. Remove operating substances, oper-
ating material, processing material and similar materials and
dispose of them appropriately.
7. Release the main circuit breaker and activate it.
ð Start operation in accordance with the instruction in the
on“ on page 126
work carried out.
11.04.2017 V4-060 K 169

Maintenance
Checks after maintenance work
8.6 Checks after maintenance work

hrs hrs
operation
Oil level Check and, if neces- Check and, if neces-
sary, correct sary, correct
Aligning the check, if necessary
sheaves correct
170 V4-060 K 11.04.2017

Malfunctions
Safety instructions
9 Malfunctions
The following chapters describe possible causes of faults and
steps to be taken to rectify them.
If faults cannot be rectified using the following instructions, contact
the manufacturer.
Improper fault rectification

WARNING!
Risk of injury due to improper operation fault
rectification!
Improper fault rectification may lead to serious
injury or material damage.
– Only rectify faults after decommissioning the
machine.
– Secure the machine against restarting.
– Allow the machine to cool down to the ambient
temperature.
– Before beginning work, ensure that there is
sufficient space for installation work.
– Check the tidiness and cleanliness of the work-
space.
– Only attempt to rectify faults with suitable tools.
– Ensure removed components are re-installed
correctly.
– Re-install all fastening elements and observe
the screw tightening torques.
– Before restarting, check that:
– All safety and protective equipment is
installed and functioning correctly.
– There are no persons in the hazard area.
Electrical system
DANGER!
serious injury.
11.04.2017 V4-060 K 171

Malfunctions
Safety instructions

restarting WARNING!
may be people located in the hazard area.
– Before beginning work, switch off the energy
supply and secure it against restarting.
Requirements for staff The fault rectification work described here may only be performed
by the designated personnel. The personnel entrusted with the
respective fault rectification tasks are listed in the table of fault
descriptions in addition to their designated tasks.
Requirements in the event of malfunctions and for preparations for
fault rectification work:
n Service personnel
for commissioning after rectification of a malfunction, the following

is necessary:
n Service personnel
Protective equipment For fault rectification work the following is necessary:

n Protective gloves
n Safety shoes
Special tools For fault rectification work the following is necessary:

n Ratchet wrench
ment
Requirements for commissioning without a lifting device:
172 V4-060 K 11.04.2017

Malfunctions
Safety instructions
Special tool: n Hydraulic lift

n Hinged motor support lifting equipment
n Transport securing rod
n General tool kit
Requirements for commissioning with a lifting device:

n Ratchet wrench
ment
Behaviour in the event of faults 1.

DANGER!
Risk of injury during fault rectification!
2. In the event of a malfunction, activate the EMERGENCY

STOP immediately.
3. Switch off the main circuit breaker and secure it.
4. Immediately inform the responsible staff on location about
the fault.
5.
DANGER!
6. Ensure there is no live current.

7. Ground and short-circuit the unit.
8. Cover or shut off adjacent live parts.
9. Establish the cause of the fault.
11.04.2017 V4-060 K 173

Malfunctions
Fault diagnosis and troubleshooting
9.2 Fault displays

AERtronic (optional) fault message
A detailed explanation of fault messages is con-

tained in the separate operating manual AS-002.
Control system fault message Depending on the customer’s control system, additional fault mes-
sages can be recorded and displayed.
9.3 Fault diagnosis and troubleshooting

If one of the listed faults occurs and it can only be rectified by the
manufacturer, contact customer service immedi-
ately.Ä on page 11
Fault description Cause Remedy Personnel

Abnormal running Sheaves are not Check and, if necessary, correct align- Service per-
sounds. aligned properly. ment.Ä Chapter 8.3.7 „Checking the sonnel
sheaves“ on page 157
Bearing damage. Replace bearings. Manufactur-
er’s customer
service divi-
sion
Foreign bodies in Check gear wheels, rectify the damaged Manufactur-
gear wheels. areas and if necessary, replace them. er’s customer
service divi-
sion
Shaft deflection. Locate shaft deflection, replace it. Manufactur-
er’s customer
service divi-
sion
Start unloading Nozzle is contami- Clean the nozzle.Ä Chapter 8.3.14 „Cleaning Service per-
device does not nated. the nozzle of the start-up relief sonnel
close. device“ on page 166
The machine Intake filter contami- Replace the intake filter. Ä Chapter Service per-
becomes too hot. nated (display unit: 8.3.6 „Replacing the intake filter“ on page 157 sonnel
max. -45 mbar).
174 V4-060 K 11.04.2017

Malfunctions
Fault diagnosis and troubleshooting

The ambient temper- Ensure there is adequate ventilation. User
ature is too high.
Openings of the Clean the openings. Ä Chapter User
acoustic hood for 8.3.15 „Checking the inlet and exhaust air
supply air and openings on the acoustic hood“ on page 166
exhaust air are con-
taminated.
The permissible Check and comply with the operating data. User
operating data have
been exceeded.
Foreign bodies on Remove dirt. Ä Chapter 8.3.16 „Checking the User
the belt guard. belt guard“ on page 167
Oil present in con- Wear and tear on Replace seals. Manufactur-
veyed medium. seals. er’s customer
service divi-
sion
Oil level too high. Correct the oil level.Ä Chapter 8.3.3 „Cor- Service per-
recting the oil level“ on page 145 sonnel
Balancing holes are Remove the sealing plugs. Ä Chapter Service per-
sealed. 8.3.12 „Checking that sealing plugs have sonnel
been removed“ on page 165
Intake volume is Intake filter contami- Replace the intake filter.Ä Chapter Service per-
too low. nated (display unit: 8.3.6 „Replacing the intake filter“ on page 157 sonnel
max. -45 mbar).
Intake piping is Seal intake piping. Service per-
leaking. sonnel
System-side slide Check and open slide plates. Service per-
plates in inlet pipe- sonnel
lines are partially or
completely closed.
The motor requires The operating data Check operating data, comply with correct User
too much power. differs from the order data.
data.
Mechanical damage. Replace malfunctioning components. Service per-
sonnel
Belts are vibrating. Wear and tear on Replace the belts. Ä Chapter Service per-
belts. 8.3.9 „Replacing belts, hinged motor support sonnel
without a lifting
device “ on page 158Ä Chapter
8.3.10 „Replacing belts, hinged motor support
with a lifting device “ on page 162
Sheaves are not Check and, if necessary, correct them. Service per-
aligned properly. Ä Chapter 8.3.7 „Checking the sonnel
sheaves“ on page 157
11.04.2017 V4-060 K 175

Malfunctions
Status and error messages (component suppliers)

Machine turns in Non-return flap is Replace the non-return flap. Ä „Replacing the Service per-
reverse after being leaking and malfunc- non-return flap“ on page 166 sonnel
shut down. tioning.
Shut-down caused Oil cooler is contami- Clean the oil cooler.Ä Chapter Service per-
by increased oil nated. 8.3.17 „Cleaning the oil cooler sonnel
temperature. lamellas“ on page 167
The oil cooler venti- Replace the ventilator. Manufactur-
lator is faulty. er’s customer
service divi-
sion
The oil temperature Replace the oil temperature switch. Service per-
switch is faulty. sonnel
Shut-down caused Oil filter is contami- Replace the oil filter. Ä Chapter Service per-
by increased oil nated. 8.3.5 „Changing the oil filter“ on page 156. sonnel
pressure.
Oil level is too low. Check the oil level. If necessary, correct it. Service per-
Ä Chapter 8.3.1 „Checking the oil sonnel
level“ on page 141
Oil pump is faulty. Replace the oil pump. Manufactur-
er’s customer
service divi-
sion
The oil pressure reg- Adjust the oil pressure regulating valve. Service per-
ulating valve has Ä Chapter 7.8.1 „Adjusting the oil pressure sonnel
been adjusted incor- regulating valve“ on page 131
rectly.
The oil pressure reg- Replace the oil pressure regulating valve. Manufactur-
ulating valve is faulty. er’s customer
service divi-
sion
The machine stage The oil demister is Clean the separating element in the oil Service per-
is leaking. Oil is contaminated. demister.Ä Chapter 8.3.18 „Cleaning the oil sonnel
seeping out. demister“ on page 168
The screw connec- Tighten or replace the screw connections. Service per-
tions of the oil line sonnel
are loose.
The oil chamber seal Change seals. Manufactur-
is flawed. er’s customer
service divi-
sion
9.4 Status and error messages (component suppliers)

Control system fault message Depending on the customer’s control system, additional fault mes-
sages can be recorded and displayed.
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Malfunctions
Checks after malfunction rectification
9.5 Commissioning after malfunction rectification

Commissioning after fault rectifica- 1. Check all previously loosened screw connections for tight-
tion ness.
2. Mount all protective hardware and covers that were previ-
ously removed.
the workspace.
4. Clean the workspace. Remove operating substances, oper-
ating material, processing material and similar materials and
dispose of them appropriately.
5. Inform the responsible on-site person about the result of trou-
bleshooting.
7. Release the main circuit breaker and activate it.
9. Confirm the removal of the fault in the control system.
10. Start operation in accordance with the instructions in the
on“ on page 126
work carried out.
9.6 Checks after malfunction rectification

hrs hrs
operation
Oil level Check and, if neces- Check, if necessary
sary, correct correct
Oil pressure Check, if necessary Check and, if neces-
correct sary, correct
Aligning the belt Check and, if neces-
pulley sary, correct
11.04.2017 V4-060 K 177

Disassembly and disposal
Safety instructions
10 Disassembly and disposal

Protecting the environment and conserving resources are among
AERZEN’S foremost priorities.
Once the machine’s service life is over, it must be disassembled
and disposed of in an environmentally-friendly way. The following
is a set of recommendations for environmentally-friendly disposal.
Improper disassembly
WARNING!
Risk of injury from improper disassembly!
Stored residual energy, sharp components, edges
and corners on or in the machine or on the neces-
sary tools can cause injury.
– Before beginning work, ensure there is suffi-
cient space.
Allow the machine to cool down to the ambient
temperature.
– Proceed with caution when working with open,
sharp-edged components.
– Ensure the tidiness and cleanliness of the
workspace! Components and tools that are
loosely stacked or lying around can cause acci-
dents.
– Disassemble components correctly. Take into
consideration the weight of each component. If
necessary, use hoists.
– Secure components, so they do not topple or
fall.
– If in doubt, contact the manufacturer.
Electric current
DANGER!
Disassembly of live components can cause serious
or fatal injury.
– Switch off the power to the operating cable.
– Check there is no live current.
178 V4-060 K 11.04.2017

Safety instructions
Disassembling the delivery line

WARNING!
Risk of injury from compressed conveyed
materials!
For the disassembly of pressurised components
conveying material escapes with a strong gas flow.
This can result in serious injury.
For conveyance of nitrogen

DANGER!
Risk of suffocation from escaping residual gas!
Opening piping and screws can allow gas to
escape freely into the atmosphere, potentially
leading to suffocation.
– Minimise residual gas as much as possible.
– Ventilate the work environment properly.
– Make a record of disassembly works after
approval measurement by the operator
Requirements for staff Requirements for disassembly:

Disassembly of electrical components
Personnel: n Authorised electricians with additional

qualifications
Requirements for disassembly:

Disassembly of mechanical components
Protective equipment Requirements for disassembly:
11.04.2017 V4-060 K 179

Disposal

n Safety shoes
n Protective gloves
n Safety goggles
Special tools Requirements for disassembly:

n Lifting equipment
n Transport equipment
10.1.1 Disassembly
Preparing for disassembly: 1. Immediately inform the responsible staff on site about the
disassembly.
2. Switch off the machine and secure it against restarting.
3. Seal off the pressure line and remove it.
4. Physically separate the entire electric power supply from the
machine. Release stored residual energy.
5. If necessary, separate the machine control system from a
connected process control system.
6. Remove operating and auxiliary materials and residual pro-
cessing materials and dispose of them in an environmentally-
friendly way.
7. In addition, clean assemblies and components thoroughly.
Dismantle them in accordance with local regulations for occu-
pational safety and environmental protection.
8. Remove the machine’s foundation bolts.
9. During disassembly, there should be a general sorting of
parts in accordance with disposal categories.Ä „Categories
for sorting“ on page 182
10.2 Disposal
The machine is composed primarily of steel, casting material and
various non-ferrous metals. In general, metallic materials are fully
recyclable.
180 V4-060 K 11.04.2017

Disposal
Proper disposal In as far as no agreement has been made on the return or disposal
of the machine, send dismantled components for recycling:
n Scrap metals.
n Send plastics for recycling.
n Sort and dispose of other components according to material
composition.
Improper disposal
ENVIRONMENT!
Environmental risk from improper disposal!
Improper disposal can present a risk to the envi-
ronment.
– Have insulating materials, electronic waste,
electronic components, auxiliary materials and
chemicals disposed of by professional waste
disposal companies.
– If in doubt, contact the local authorities or spe-
cialist companies for information on environ-
mentally-friendly waste disposal.
Oil and lubricants

ENVIRONMENT!
Environmental risk from oil!
The improper disposal of oil and lubricants can
present a risk to the environment.
– Collect oil carefully, store it and dispose of it
properly or recycle it.
cialist waste disposal companies for informa-
tion on environmentally-friendly waste disposal.
Battery
ENVIRONMENT!
Environmental risk from batteries!
The improper disposal of batteries, e.g. from the
control system, can present a risk to the environ-
ment.
– Collect batteries and dispose of them properly
at local collection points.
cialist waste disposal companies for informa-
tion on environmentally-friendly waste disposal.
11.04.2017 V4-060 K 181

Disposal
Requirements for personnel Disposal requirements:

Personnel: n Skilled staff for industrial waste
Protective equipment Disposal requirements:

n Safety shoes
n Protective gloves
n Safety goggles
Special tools Disposal requirements:

Special tool: n Lifting equipment
Categories for sorting
Scrap iron Non-ferrous metal Insulation material Electronic waste Auxiliary mate-
(except for scrap (encoder elec- rials and chemi-
iron) tronics) cals
Scrap Aluminium Various isolators (in Electrical tools Lubricant and gear
terminal boxes) oils
n Scrap steel
n Foundry scrap Grease
n Scrap from non-
rusting steels
n Stainless steel
scrap
Used metal/2A Copper Voltage and current Measurement, con- Cleaning agents
materials transformers trol and regulatory and solvents
systems
n Steel beams
n Steel sheets
Machines made of Brass Electric cables and Paint residue
metal leads
n Without elec-
tronics
Motor windings Instrument wiring Anti-corrosion
agents
Surge absorbers Cloths (soaked in
agents or chemi-
cals)
182 V4-060 K 11.04.2017

Disposal
Scrap iron Non-ferrous metal Insulation material Electronic waste Auxiliary mate-
(except for scrap (encoder elec- rials and chemi-
iron) tronics) cals
Heat insulation AERtronic batteries
materials
This does not Valve disposal This does not n Solvents,
include: include: cleaning agents
n Remove the and paint res-
n Hazardous medium before n PCB capacitors idue must not
adhesions disposal! be allowed to
n Sealed hollow Neutralise mix!
parts (due to residual
n Sort oils sepa-
danger of defla- medium in the
rately according
gration or haz- valves.
to emulsions
ardous con- and solvents.
tents)
n Agents and
chemicals must
be collected in
separate,
labelled con-
tainers.
Disposal of accessories Motor

n For safety reasons, disposal may only be carried out by spe-
cialists for industrial waste or by return to the manufacturer!
n The encoder electronics are electronic waste.
Frequency inverter
DANGER!
Danger due to explosion of the capacitor and the
formation of toxic gases!
n For safety reasons, disposal may only be carried out by spe-

cialists for industrial waste or by return to the manufacturer!
n The encoder electronics are electronic waste.
11.04.2017 V4-060 K 183

Technical specifications
Dimension specifications sheet
11 Technical specifications
11.1 Dimensions and weights

General information The following dimensions and weights relate to standard variants
and can vary depending on the specific design.
Exact details can be found on the installation drawing.
Information on weight can be found on the packing note and the
designation on the type plate.
Dimensions, including packaging, are included in the forwarding
order.
Tab. 3: Dimensions and weights

Size Width (B) Depth (A) Height (H) Nominal Weight Weight with
diameter without acoustic
mm mm mm acoustic hood,
Nominal hood, without excluding
diameter, motor, motor,
discharge
side approx. kg approx. kg
VM 8R 1250 1350 1776 65 540 770
VM 15R 1250 1350 1776 65 670 900
VM 21 R 1500 1800 1973 80 720 1100
VM 37R 1700 2055 2111 150 1500 2100
VML 18R 1250 1350 1847 80 610 840

VML 25R 1500 1800 1973 125 720 1100
VML 40R 1700 2055 2111 150 1500 2100
These dimensions and weights relate to the standard design and are approximate
values. The information can vary depending on the order.
11.2 Dimension specifications sheet

An accompanying dimension specifications sheet is provided with
the product documentation.
These documents contain important dimensions for installation and
set-up.
184 V4-060 K 11.04.2017

Operating data
11.3 Operating data
11.04.2017 V4-060 K 185

Technical performance data
11.4 Technical performance data
Tab. 4: Operating and application limits

Overpressure operation
Size max. permissible max. differential pres- max. flow rate* max. motor output
inlet pressure sure
m3/h kW
bar a mbar
VM 8R 4.5 3500 471 55
VM 15R 4.5 3500 777 90
21 1.5 3500 1195 132
VM 37R 1.5 3500 2036 200
VML 18R 1.2 2000 1183 75

VML 25R 1.2 2000 1658 110
VML 40R 1.2 2000 2617 132
These operating limits are maximum values. Difficult operating conditions can adversely affect
these data.
*For intake conditions: 1 bar, 20 °C, VML with 1 bar overpressure, VM with 2 bar overpressure.
Tab. 5: Low-load operation

Operating parameters with the following differential pressures must be agreed upon with AERZEN
Customer Service or the sales company!
VM differential pressure Dp = (p2-p1) = 1 to 1.5 bar
VML differential pressure Dp = (p2-p1) = 0 to 0.5 bar
Environmental limits Data Value Unit

Temperature range -10 to 50 °C
Relative humidity 0 to 80 %
Chemical-free atmosphere
Maximum installation elevation Data Value Unit

max. installation elevation above NN* 1000 m
If installing at a different elevation, observe the order-specific

design data sheets.
186 V4-060 K 11.04.2017

Requirements for ambient and intake temperatures
Environmental limits Data Value Unit

Temperature range -10 to 50 °C
Mounting of acoustic hood heating less than -10 °C
Relative humidity 0 to 80 %
Chemical-free atmosphere
operating period Data Value Unit

Maximum continuous operating period 24 hrs
Pause until next operation / h
Sealing gas pressure, nitrogen Data Value Unit

operation
Sealing gas pressure 50 mbar
11.5 Requirements for ambient and intake temperatures

Reference conditions
NOTICE!
– The intake temperature must be no more than
20 K above the ambient temperature.
– If this limit is not adhered to, the compressor
housing must be warmed using suitable addi-
tional measures.
– Conversely, a warm compressor can draw in
cold gas within these temperature limits,
without restrictions.
t1 Intake-side temperature
t2 Discharge-side temperature
VM
-10°C £ t1 £ +50 °C
-10°C £ t0 £ +50 °C
(t1-t0) £ 20 K
t0 Ambient temperature / machine housing tem-
perature
t1 Intake temperature
t2 Discharge temperature
Fig. 163: Temperature measurement Dt t2 - t1
11.04.2017 V4-060 K 187

Type plate(s) and placement
VM
Dt £ 230 K
t2 £ 280 °C
perature
Dt t2 - t1
VML
-10°C £ t1 £ +50 °C
-10°C £ t0 £ +50 °C
(t1-t0) £ 20 K
Dt £ 180 K
t2 £ 230 °C
perature
Dt t2 - t1
11.6 Type plate(s) and placement
Placement on the machine stage Manufacturer/type plate on the machine stage. Depending on the
machine’s size and shape, signage plates can be attached at dif-
ferent positions on the housing. Examples are given in the fol-
lowing diagram.
Pos.1 Manufacturer plate
Pos.2 Type plate
Fig. 164: Layout example
188 V4-060 K 11.04.2017

Manufacturer plate - pos.1

Manufacturer plate
Fig. 165: Manufacturer plate
Type plate - pos.2
Fig. 166: Type plate

Pos.1 Machine type
Pos.2 Factory/serial number
Pos.3 Order no.
Pos.4 Machine rotational speed
Pos.5 Power consumption
Pos.6 Year of manufacture
Pos.7 Weight
Pos.8 Motor rotational speed
Pos.9 Conveyed amount
Pos.10 Intake pressure (absolute) - p1
Pos.11 Positive pressure, discharge - p2e
Placement on the acoustic hood The manufacturer/type plate is on the operating side of the
acoustic hood.
Pos.1 / acoustic hood Manufacturer and type plate
Fig. 167: Acoustic hood signage
11.04.2017 V4-060 K 189

Manufacturer and type plate - pos.1
Fig. 168: Acoustic hood manufacturer/performance data plate

Pos.1 Manufacturer, including address
Pos.2 Designation
Pos.3 Machine type
Pos.4 Customer order no.
Item 5 Serial number
Pos.6 Year of manufacture
Item 7 max. intake pressure (absolute)-p1
Item 8 max. discharge pressure (absolute) -p2
Item 9 Nominal power of motor
Item 10 Machine weight (total)
Type designation The type designation is derived from the following table:
Tab. 6: Explanation using example: VM 8 R

Designation Explanation Details
VM Product designation Screw (-type) Compressor
VM: maximum differential pressure, pe= 3.5 bar
(above)
VML: maximum differential pressure, pe= 2.0 bar
(over)
8 Maximum volume flow in
m³/min (approx.)
R Belt operation
190 V4-060 K 11.04.2017

Noise emissions
11.7 Noise emissions
Information on noise emissions This information is determined in accordance with the performance
data. Ä Chapter 11.4 „Technical performance data“ on page 186.
No-load operation or operation below the maximum performance
values reduces noise emissions.
Machines without an acoustic hood have considerably higher noise
emissions. Observe the measures for noise emission reduc-
tionÄ Chapter 5.2 „Requirements for the installation
site“ on page 96
Measurement requirements n noise measurements as per DIN 45 635

n applied basic standard EN ISO 2151
n measured according to basic standard EN ISO 3744
n with acoustic hood
n connected, insulated pipelines
n tolerance: ±2 dB(A)
Overpressure Size A-weighted sound pressure level, LpAdB(A)

VM 8R 74
VM 15R 77
VM 21 R 76
VM 37R 77
VML 18R 80
VML 25R 78
VML 40R 78
11.04.2017 V4-060 K 191

Operating materials > Lubricant oil specifications
11.8 Operating materials

11.8.1 Lubricant oil specifications
Lube oil specification
Choice of lubricants
When operating the machine, only use lubricants
that comply with this specification!
The quality of lube oil has a considerable effect on the service life
of the machine.
When selecting the type of lube oil, the application conditions and
the relevant additives and viscosity class are decisive.
Taking the operating conditions into account, only use the following
oils with the corresponding viscosities and additives.
* Ambient temperature = the temperature in the immediate vicinity
of the machine all year round.
Low-load operation Using these machines for "low-load operation with minor pres-
sure differences" requires prior consultation with AERZEN Cus-
tomer Service or the sales company. To select a suitable lubricant,
the operating conditions, load and operating data need to be taken
into account.
Lube oil properties

Tab. 7: General requirements of the lube oil properties
Kinematic viscosity at operating oil temperature. min. 10 - 13 cSt (mm2/s)
Kinematic viscosity at -10°C min. £ 3,500 cSt (mm2/s)
Tab. 8: Minimum properties of the oil additive

EP wear-protection additives for use in rolling bearing drives
Oxidisation stability up to 110°C oil sump temperature
Foam suppressor
Detergent for deposit solutions
Neutrality with regard to seal materials of fluoropolymer elastomer (Viton)
Neutrality with regard to one-component resin primers
Sufficient shear stability
192 V4-060 K 11.04.2017

11.8.1.1 Lube oils

Tab. 9: Standard first oil filling
Delta Lube 06
VM differential pressure Dp = (p2-p1) = 1.5 to 3 bar in continuous operation
VML differential pressure Dp = (p2-p1) = 0.5 to 2 bar in continuous operation
Intake temperature (machine stage) up to 50°C
Final compression temperature (machine stage) up to 280°C
Ambient temperature* no constraints
This lube oil is used as initial oil filling for standard use conditions.
11.8.1.1.1 Alternative lube oils
ISO VG 46
Fully-synthetic poly-alpha-olefin (PAO), drive or compressor oil
VML differential pressure Dp = (p2-p1) = 0.5 to 1 bar in continuous operation
Ambient temperature* over 0°C
Example: Castrol Aircol SR 46
ISO VG 68
VM differential pressure Dp = (p2-p1) > 2 bar in continuous operation
VML differential pressure Dp = (p2-p1) = > 1 bar in continuous operation
For example: Mobil SHC 626
AERZEN special rotary piston oil

Ambient temperature* no constraints
11.04.2017 V4-060 K 193

11.8.1.1.2 Lube oil in the food and pharmaceutical industry
ISO VG 46
VML differential pressure Dp = (p2-p1) = 0.5 to 1 bar under continuous opera-
tion
Continuous oil temperature up to 50°C
Final compression temperature up to 280°C
Lubricant to be used: Klüber Oil HySyn FG 46
ISO VG 68
VM differential pressure Dp = (p2-p1) > 2 bar in continuous operation
VML differential pressure Dp = (p2-p1) > 1 bar in continuous operation
Lubricant to be used: Klüber Oil HySyn FG 68
11.8.1.1.3 Lube oil where "silicone-free" is specified
ISO VG 46
VM differential pressure Dp = (p2-p1) > 1.5 bar in continuous operation
VML differential pressure Dp = (p2-p1) > 0.5 bar in continuous operation
Maximum oil temperature £70°C
Oil change interval after every 4,000 op. hours.
Lubricant to be used: Klüber Summit SH 46 XS
Order No. 2000022402
194 V4-060 K 11.04.2017

11.8.1.1.4 Lube oils for "low-load operation with minor pressure differences"
Differential pressure
VM differential pressure Dp = (p2-p1) = 1 to 1.5 bar
VML differential pressure Dp = (p2-p1) = 0 to 0.5 bar
Lubricant to be used: as agreed upon with AERZEN Customer Service or the sales company.
11.8.1.2 Changing oil types

Delta Lube 06, AERZEN special rotary piston oil --> fully syn-
thetic PAO lubricants
The AERZEN lubricants (Delta Lube 06, AERZEN special rotary
piston oil) are fully compatible with fully synthetic PAO lubricants.
Measures: If you change to another oil type, no specific measures
need be taken. However, to preserve the working properties of the
new oil, the oil that is replaced should be drained completely and,
after 100 operating hours and in addition to any scheduled oil
changes, a full oil change including oil filter change (if there are
any filters) should be performed. Only oil of the same type should
be used for topping up.
11.04.2017 V4-060 K 195

Operating materials > Lubricant quantities
11.8.2 Lubricant quantities

Machine lube oil levels
The following values for lube oil levels are guide
values. The main factor in determining the oil fill
quantity is the displays of the relevant oil level
pointer.
Tab. 10: Models with acoustic hoods

Total oil quantity
Oil level: Centre of sight glass on machine stage
Filling quantity,
Operating material Machine type Unit
approx.
Lube oil VM 8R* 20 Litre (l)
VM 15R* 20
VM 21R* 20
VM 37R* 42
VML 18R 17
VML 25R* 20
VML 40R 30
* Compressor with intermediate transmission
Tab. 11: Models without acoustic hoods

Total oil quantity
Oil level: Centre of sight glass on machine stage
Filling quantity,
Operating material Machine type Unit
approx.
Lube oil VM 8R* 20 Litre (l)
VM 15R* 20
VM 21R* 20
VM 37R* 42
VML 18R 17
VML 25R* 20
VML 40R 30
* Compressor with intermediate transmission
196 V4-060 K 11.04.2017

Electrical details > Motor overload protection
11.9 Coating
Corrosion protection The housing surfaces receive the following coatings to protect
them against corrosion:
Standard coating
Undercoat Corrosion protection on alkyd resin basis
End coating Alkyd resin surface coating
Coating for increased corrosion protection

Undercoat Corrosion protection on 2-component,
epoxy resin, micaceous iron oxide basis
Intermediate coating
End coating Polyurethane surface coating
11.10 Electrical details

11.10.1 Voltage fluctuations
Permissible voltage fluctuations Permissible voltage fluctuations are described in the international
standard IEC 60038 subject to country-specific supply voltage tol-
erances.
Machine use only in a stable three-phase power supply. Voltage
fluctuations or drops beyond the tolerance level may cause serious
damage to the drive system.
11.10.2 Earthing strap cross-sections

Earthing strap kW mm2
to 55 14
to 200 70
to 315 2 x 70
11.10.3 Motor overload protection

Setting value Max. ... % value, nominal motor current
110 %
11.04.2017 V4-060 K 197

Accessory information > Start-up relief device for VML machines
11.11 Accessory information
11.11.1 Oil pressure

Technical data Oil pressure Unit
Factory setting 1.8 to 5.0 bar
Recommended oil pressure at 3.0 bar
operating temperature
Shut-down £1.8 bar
Oil pressures outside this range can be implemented with the intro-
duction of special modifications after consultation with AERZEN.
11.11.2 Oil filter

Technical data Oil filter Unit
Filter fineness 7 μm
Filter resistance in clean condition approx. 0.2 bar
max. filter resistance 2.0 bar
11.11.3 Intake filter

Technical data Intake filter Unit
Filter resistance in clean condition > 10 mbar
max. filter resistance 45 mbar
11.11.4 Start-up relief device for VML machines

Technical data Start unloading device Unit
Voltage 230 V
Frequency 50 Hz
Protection type IP 65
Power 8 W
closed without current
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Accessory information > Balancing grade
11.11.5 Machine speed adjustment in the case of increased number of switchovers

Technical data Type Speed of Unit
main rotor x
VM 8R 19,000 rpm
VM 15R 15,200 rpm
VM 21R 15,200 rpm
VM 37R 12,100 rpm
VML 18R 13,200 rpm

VML 25R 13,200 rpm
VML 40R 10,412 rpm
x of 90 m/s tip speed
Speed adjustment is required in the following cases:

n 7 to 20 switchovers per hour
n Total machine operating time of no more than 20 minutes per
hour
11.11.6 Balancing grade

Balancing type
The vibration behaviour of the machines is deter-
mined not only by the balancing grade of the drive
shafts but also by the balancing grade of the drive
elements.
The drive shafts of the pistons and rotors are balanced according
to the half-key principle. Sheaves and couplings must therefore
correspond to balancing type “H”.
11.04.2017 V4-060 K 199

Note on the declaration of conformity
12 Note on the declaration of conformity

This document is provided for informational pur-
poses only and gives an account of the contents of
the declaration of conformity. The original docu-
ment is provided with the product or is sent in a
separate set of documentation.
CE MRL 1012_1
Declaration of Conformity
pursuant to the EC Machinery Directive 2006/42/EC, Annex II 1A

Translation of Original Declaration of conformity
Manufacturer Representative pursuant to the Machinery Directive

Representative for technical documentation
Aerzener Maschinenfabrik GmbH Mr Björn Irtel
Phone: +49 5154 81-0 Aerzener Maschinenfabrik GmbH
Fax: +49 5154 81-9191 Phone: +49 5154 81-0
E-mail: [email protected] Fax: +49 5154 81-9191
Internet: www.aerzen.com E-mail: [email protected]
Reherweg 28 Internet: www.aerzen.com
31855 Aerzen, Germany Reherweg 28
31855 Aerzen, Germany
Product
Designation
Type
Serial no.
Order no.
Year of construction
We hereby declare that the above product complies with all applicable provisions of the Machinery Directive 2006/42/EC.
The aforementioned product fulfils the requirements of the following applicable directives:
► Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on machinery, and amending Directive 95/16/EC
(recast) 2006/42/EC
The following harmonised standards were applied:
► DIN EN ISO 12100:2011-03 Safety of machinery - General principles for design - Risk assessment and risk reduction (ISO 12100:2010)
2011-03 DIN EN ISO 12100:2011-03
► DIN EN 1012-1:2011-02 Compressors and vacuum pumps - Safety requirements - Part 1: Air compressors; German version EN
1012-1:2010 2011-02 DIN EN 1012-1:2011-02
27.10.2014, DocId CE MRL 1012_1 01_2014, 1, en_GB
Information on Managing director Signature Location, date of issue
Signatory
200 V4-060 K 11.04.2017

Glossary
13 Glossary
·Bar chart display A bar chart display is a display method which uses a scale to
represent the size of a signal with a representative bar that
changes in length depending on the signal size.
·Belt run The belt section between two sheaves is termed a “belt run”.
·Discharge temperature Temperature measured at the discharge sockets of the
machine stage.
·EMERGENCY STOP function A function intended to alleviate the danger of impending haz-
ards in terms of injury or damage to persons and machines
during operation or to reduce the danger of hazards that are
already present.
A function that is activated by one single action by an indi-
vidual person.
The purposeful shut-down of the machine to avoid a dan-
gerous situation. Voltage-carrying components are still
active.
Emergency stop.
·Low-load operation Operation of the machine at a speed approaching maximum
but with only minor pressure difference between intake pres-
sure and discharge pressure.
VM differential pressure -->Dp = (p2-p1) = 1 to 1.5 bar
VML differential pressure -->Dp = (p2-p1) = 0 to 0.5 bar
·Machine A machine is an assembly of linked parts or components, at
least one of which moves. A machine is fitted or intended to
be fitted with a drive system. The machine has a proper
intended use and is assembled for a specific purpose.
Another technical term for “machine” is “unit”.
·Machine stage A machine stage is an incomplete machine. It is an
assembly that almost constitutes a machine, but that does
not fulfil a specific function. A machine stage is only intended
to be installed in and added to other machines or other
incomplete machines. The compressor is a machine stage.
·Modbus RTU Modbus RTU transfers data in binary form. This ensures a
good data throughput rate. The data cannot be evaluated
directly by persons, rather they must first be converted into a
readable format.
·No-load/full-load adjustment No-load/full-load adjustment allows for a relieved start-up of
the VM machine stage against an existing mains pressure.
·PROFIBUS-DP PROFIBUS DP involves the communication of central con-
trol equipment via a fast serial connection with decentralized
input /output modules.
·Stop category 0 Stop category 0.
Shut-down by means of immediate interruption of the power
supply to the machine.
11.04.2017 V4-060 K 201

Glossary
Shut-down by means of mechanical separation (uncoupling)

of components that pose a danger and their mechanical
drive elements and, if necessary, by means of a braking pro-
cedure.
Switchover Switch from no-load to load operation and from load opera-
tion back to no-load operation.
202 V4-060 K 11.04.2017

Index
14 Index
A After a malfunction . . . . . . . . . . . . . . . . . . . 130
After adjustment . . . . . . . . . . . . . . . . . . . . . 130
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Performance data . . . . . . . . . . . . . . . . . . . . 198 After maintenance . . . . . . . . . . . . . . . 130, 169
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Acoustic hood . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Safety device . . . . . . . . . . . . . . . . . . . . . . . . 43 Preparation . . . . . . . . . . . . . . . . . . . . . . . . 107
Safety instructions . . . . . . . . . . . . . . . . . . . 106
AERtronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
AERtronic oil level display . . . . . . . . . . . . . . . . 142 Control elements . . . . . . . . . . . . . . . . . . . . . . . . 62
Alignment Copyright protection . . . . . . . . . . . . . . . . . . . . . 10
Dowelling . . . . . . . . . . . . . . . . . . . . . . . . 98, 99 Corrosion protection . . . . . . . . . . . . . . . . . . . . 197
Ambient temperature Customer service . . . . . . . . . . . . . . . . . . . . . . . 11
Intake temperature . . . . . . . . . . . . . . . . . . . 187 D

Application limits . . . . . . . . . . . . . . . . . . . . . . . 186 Decommissioning . . . . . . . . . . . . . . . . . . . . . . 129
Assemblies Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Description . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Dimension specifications sheet . . . . . . . . . . . . 184
B Dimensions
Balancing grade Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Technical data . . . . . . . . . . . . . . . . . . . . . . 199 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Balancing type Safety instructions . . . . . . . . . . . . . . . . . . . 178
Technical data . . . . . . . . . . . . . . . . . . . . . . 199 Discharge-side pipeline
Base support . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Belt Disposal
Replacement . . . . . . . . . . . . . . . . . . . . . . . 162 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Categories for sorting . . . . . . . . . . . . . . . . . 182
Belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Belt guard proper disposal . . . . . . . . . . . . . . . . . . . . . . 181

checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Safety instructions . . . . . . . . . . . . . . . . . . . 178
Safety device . . . . . . . . . . . . . . . . . . . . . . . . 44 Drive motor
Butterfly throttle . . . . . . . . . . . . . . . . . . . . . . . . . 68 factory installation . . . . . . . . . . . . . . . . . . . . 65
C E
Changing oil . . . . . . . . . . . . . . . . . . . . . . 150, 153 Earthing strap, cross-sections . . . . . . . . . . . . 197
Checks Electrical information
after a malfunction . . . . . . . . . . . . . . . . . . . 177 Earthing strap, cross-sections . . . . . . . . . . 197

Motor overload protection . . . . . . . . . . . . . . 197
Cleaning
Maintenance . . . . . . . . . . . . . . . . . . . . . . . 169 Voltage fluctuations . . . . . . . . . . . . . . . . . . 197
Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . 40

Emergency . . . . . . . . . . . . . . . . . . . . . . . . . 125
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . 112
after a fault . . . . . . . . . . . . . . . . . . . . . . . . . 177 Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
11.04.2017 V4-060 K 203

Index
Environmental limits . . . . . . . . . . . . . . . . 186, 187 Lubricants

Environmental protection . . . . . . . . . . . . . . . . . . 50 Filling quantities . . . . . . . . . . . . . . . . . . . . . 196
Anti-corrosion agents . . . . . . . . . . . . . . . . . . 50
M
Batteries / control system . . . . . . . . . . . . . . . 50
Machine terminal strip . . . . . . . . . . . . . . . . . . . 103
Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Maintenance
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Safety instructions . . . . . . . . . . . . . . . 135, 171
F Maintenance indicator . . . . . . . . . . . . . . . . . . . . 70
Fault diagnosis Maintenance schedule
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 174 Normal operation . . . . . . . . . . . . . . . . . . . . 139
Fault displays . . . . . . . . . . . . . . . . . . . . . . . . . 128 Maintenance work . . . . . . . . . . . . . . . . . . . . . . 141
AERtronic . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Frequency converter Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Misuse
Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 foreseeable . . . . . . . . . . . . . . . . . . . . . . . . . 30
Motor overload protection . . . . . . . . . . . . . . . . 197
G
Motor shaft
Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Belt pulley cover . . . . . . . . . . . . . . . . . . . . . . 44
H N
Hazard area
Nitrogen operation . . . . . . . . . . . . . . . . . . . . . . . 54
Operating area . . . . . . . . . . . . . . . . . . . . 47, 48
No-load/full-load adjustment . . . . . . . . . . . . . . . 54
Hinged support . . . . . . . . . . . . . . . . . . . . . . . . . 43
Noise emissions . . . . . . . . . . . . . . . . . . . . . . . 191
I Non-return flap . . . . . . . . . . . . . . . . . . . . . . . . . 73
Information on AERtronic . . . . . . . . . . . . . . . . . 65 Replacement . . . . . . . . . . . . . . . . . . . . . . . 165
Inlet and exhaust air openings . . . . . . . . . . . . . 166 O

Installation Oil cooler
Safety instructions . . . . . . . . . . . . . . . . . . . . 94 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Installation elevation . . . . . . . . . . . . . . . . . . . . 186 Oil demister . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Instrumentation Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Shut-down . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Intake filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 changing . . . . . . . . . . . . . . . . . . . . . . . . . . 156
replacing . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Technical data . . . . . . . . . . . . . . . . . . . . . . 198
Technical data . . . . . . . . . . . . . . . . . . . . . . 198
Oil level
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Acoustic hood . . . . . . . . . . . . . . . . . . . . . . 142
L checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Machine stage . . . . . . . . . . . . . . . . . . . . . . 143
Load operation
No-load operation . . . . . . . . . . . . . . . . . . . . . 57 too high . . . . . . . . . . . . . . . . . . . . . . . 145, 146
too low . . . . . . . . . . . . . . . . . . . . . . . . 147, 148
Lube oil specification
Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
204 V4-060 K 11.04.2017

Index
Oil pressure S
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Technical data . . . . . . . . . . . . . . . . . . . . . . 198
Safety classifications . . . . . . . . . . . . . . . . . . . . . 44
Oil pressure gauge . . . . . . . . . . . . . . . . . . . . . . 70 Safety device . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Oil pressure regulating valve . . . . . . . . . . . . . . . 75 Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 131 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . 66 Sealing gas pressure . . . . . . . . . . . . . . . . . . . 133
Operating Sealing gas pressure, nitrogen operation . . . . 187
Safety instructions . . . . . . . . . . . . . . . . . . . 124
Sealing plug
Operating area Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Hazard area . . . . . . . . . . . . . . . . . . . . . . 47, 48
Securing the machine against restarting . . . . . . 48
Operating data . . . . . . . . . . . . . . . . . . . . . . . . 185 Sheave
Operating mode . . . . . . . . . . . . . . . . . . . . . . . 126 checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
operating period . . . . . . . . . . . . . . . . . . . . . . . 187 Shut-off valve
Operating substances . . . . . . . . . . . . . . . . . . . 196 Relief valve . . . . . . . . . . . . . . . . . . . . . . . . . 69
Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Start unloading device
Overview adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Assemblies . . . . . . . . . . . . . . . . . . . . . . . 51, 52 Technical data . . . . . . . . . . . . . . . . . . . . . . 198
P Start-up relief device . . . . . . . . . . . . . . . . . . . . . 71
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Cleaning the nozzle . . . . . . . . . . . . . . . . . . 166
Performance data . . . . . . . . . . . . . . . . . . . . . . 186 Data: DN 80 to DN 150 . . . . . . . . . . . . . . . 198
Personnel Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Qualifications . . . . . . . . . . . . . . . . . . . . . . . . 35 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Storage for over 12 months

Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . 66 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Protective cover Storage for over 12 months in a tropical climate

Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Protective equipment Switching frequency

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Load operation . . . . . . . . . . . . . . . . . . . . . . . 57
Switching off
Q Operating mode . . . . . . . . . . . . . . . . . . . . . 128
Qualifications Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Switchover
R Machine speed . . . . . . . . . . . . . . . . . . . . . . 199
Replacement parts . . . . . . . . . . . . . . . . . . . . . . 34 Technical data . . . . . . . . . . . . . . . . . . . . . . 199
Requirements Symbols
Installation site . . . . . . . . . . . . . . . . . . . . . . . 96 in the manual . . . . . . . . . . . . . . . . . . . . . . . . . 8
Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . 12 T
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . 184
11.04.2017 V4-060 K 205

Index
Temperature switch . . . . . . . . . . . . . . . . . . . . . . 66
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Transport
Installation site . . . . . . . . . . . . . . . . . . . . . . . 87
Packaged units . . . . . . . . . . . . . . . . . . . . . . 85
Safety instructions . . . . . . . . . . . . . . . . . . . . 78
Transport inspection
Completeness . . . . . . . . . . . . . . . . . . . . . . . 89
Transport damage . . . . . . . . . . . . . . . . . . . . 89
Troubleshooting
Behaviour . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Type designation . . . . . . . . . . . . . . . . . . . . . . . 190
Type plate
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . 189
Type plates
Manufacturer plate . . . . . . . . . . . . . . . . . . . 188
Signage . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
V
Valves
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Ventilator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Voltage fluctuations . . . . . . . . . . . . . . . . . . . . . 197
206 V4-060 K 11.04.2017

Operating Instructions: Screw Compressor Delta Screw

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OPERATING INSTRUCTIONS

Read the instructions prior to performing any task!

Translation of the original operating instructions

This manual was created by:

© Aerzener Maschinenfabrik GmbH 2017

3.2 Overview of assemblies.............................................. 52

4 Transport, packaging and storage.................................. 78

7.5.2 Remote-controlled operation................................. 128

The following is a list of additional, supplementary documents:

Declaration of Conformity CE MRL 1012-1

1.2 Explanation of symbols

Close cover carefully.

Tips and recommendations

Warning signs Type of danger

Warning – hand injuries.

Warning – flammable sub-

Warning – danger zone.

Additional designations To draw attention to operating guidelines, events, listings, refer-

1.3 Copyright protection

1.4.2 Customer service

Tab. 2: After sales service/service contact

In addition, we are always interested in receiving information and

2.1 Residual risks and fundamental risks

2.1.1 Electrical hazards

Operating faults caused by short-

2.1.2 Hazards associated with the acoustic hood

Air flow at the air outlet

Risk of fire and injury

Use of non-original belts

2.1.3 Risks of machines with belt guard

Risk of fire and injury

Use of non-original belts

2.1.4 Hazards at the installation site and operating site

Water contact with live compo-

Unexpected machine start

Sharp edges and corners

Sudden gas emission

2.1.5 Mechanical hazards

Risk of crushing and shearing inju-

2.1.6 Thermal hazards

2.1.7 Risks from pressurised components

Noise during disassembly

2.1.8 Risks from hazardous substances

2.1.9 Risks from flammable substances

Improper fire protection

2.1.10 Risks associated with conveyance of nitrogen

Leaking gases during machine

2.1.11 Environmental risks

2.2 Intended use

The screw (-type) compressor machine is intended for opera-

The screw compressor machine has been designed and con-

Operating data that deviate from the standard must

2.3 Foreseeable misuse

Serious material damage

The machine is not intended for:

2.4 Responsibility of the operator

n Observe all warnings and notices displayed on the machine