Manual Closed Out D60 D75

Machine no longer in production D100 D102

OPERATION AND MAINTENANCE MANUAL

D60 SERIAL No: 1075080 –>>

This manual contains
important safety information D75 SERIAL No: 1080110 –>>
and must be made available to
personnel who operate and D100 SERIAL No: 1085120 –>>
maintain this machine.
D102 SERIAL No: 1090200 –>>

C.P.N. : 89290720 GB
DATE : AUGUST 2000
 Machine models represented in this manual may be used in various locations worldwide. Machines sold and
shipped into European common market countries requires that the machine display the EC Mark and conform
to various directives. In such cases, the design specification of this machine has been certified as complying
with EC directives. Any modification to any part is absolutely prohibited and would result in the CE certification
and marking being rendered invalid. A declaration of that conformity follows:

EC DECLARATION OF CONFORMITY WITH EC DIRECTIVES

98/37/EC, 93/68/EEC, 89/336/EEC

WE,

ECOAIR
GEWERBEALLE 17
D–45478 MÜLHEIM
DEUTSCHLAND

DECLARE THAT, UNDER OUR SOLE RESPONSIBILITY FOR MANUFACTURE AND SUPPLY,
THE PRODUCT(S)

D60 D75 D100 D102

TO WHICH THIS DECLARATION RELATES, IS (ARE) IN CONFORMITY WITH THE PROVISIONS

OF THE ABOVE DIRECTIVES USING THE FOLLOWING PRINCIPAL STANDARDS.

EN29001, EN292, EN60204–1, EN1012, EN50081, EN50082

ISSUED AT MÜLHEIM ON 01/01/2001 BY G BAUER, GENERAL MANAGER

GEORG BAUER
1 CONTENTS & ABBREVIATIONS
ABBREVIATIONS & SYMBOLS
CONTENTS
#### Contact ECOAIR for serial number
1 CONTENTS
–>#### Up to Serial No.
####–> From Serial No.
2 FOREWORD * Not illustrated

Option
3 ISO SYMBOLS NR Not required
AR As required
SM Sitemaster/Sitepack
8 SAFETY
HA High ambient machine
WC Watercooled machine
10 GENERAL INFORMATION AC Aircooled machine
ERS Energy recovery system
25 INSTALLATION / HANDLING T.E.F.C. Totally enclosed fan cooled motor (IP54)
O.D.P. Open drip proof (motor)
28 OPERATING INSTRUCTIONS
D Germany
DK Denmark
37 MAINTENANCE E Spain
F France
45 FAULT FINDING GB Great Britain
I Italy
N Norway
47 OPTIONS
NL Netherlands
P Portugal
S Sweden
SF Finland

D60 D75
D100 D102
 FOREWORD 2
Use of the machine where there is any actual or foreseeable risk of
The contents of this manual are considered to be proprietary and
confidential to ECOAIR and should not be reproduced without the prior hazardous levels of flammable gases or vapours.
written permission of ECOAIR.
Use of the machine fitted with non ECOAIR approved components.

Nothing contained in this document is intended to extend any

promise, warranty or representation, expressed or implied, regarding Use of the machine with safety or control components missing or
the ECOAIR products described herein. Any such warranties or other disabled.
terms and conditions of sale of products shall be in accordance with the
standard terms and conditions of sale for such products, which are
available upon request. The company accepts no responsibility for errors in translation of
this manual from the original English version.
This manual contains instructions and technical data to cover all
routine operation and scheduled maintenance tasks by operation and
 COPYRIGHT 2000
maintenance staff. Major overhauls are outside the scope of this
INGERSOLL–RAND COMPANY
manual and should be referred to an authorised ECOAIR service
department.

The design specification of this machine has been certified as

complying with E.C. directives. Any modification to any part is
absolutely prohibited and would result in the CE certification and
marking being rendered invalid.

All components, accessories, pipes and connectors added to the

compressed air system should be:
. of good quality, procured from a reputable manufacturer and,
wherever possible, be of a type approved by ECOAIR.
. clearly rated for a pressure at least equal to the machine maximum
allowable working pressure.
. compatible with the compressor lubricant/coolant.
. accompanied with instructions for safe installation, operation and
maintenance.

Details of approved equipment are available from ECOAIR Service

departments.

The use of repair parts other than those included within the ECOAIR
approved parts list may create hazardous conditions over which
ECOAIR has no control. Therefore ECOAIR cannot be held
responsible for equipment in which non–approved repair parts are
installed.

ECOAIR reserves the right to make changes and improvements to

products without notice and without incurring any obligation to make
such changes or add such improvements to products sold previously.

The intended uses of this machine are outlined below and examples
of unapproved usage are also given, however ECOAIR cannot
anticipate every application or work situation that may arise.

IF IN DOUBT CONSULT SUPERVISION.

This machine has been designed and supplied for use only in the
following specified conditions and applications:
. Compression of normal ambient air containing no known or
detectable additional gases, vapours. or particles
. Operation within the ambient temperature range specified in the
GENERAL INFORMATION section of this manual.

The use of the machine in any of the situation types listed in

table 1:–
a) Is not approved by ECOAIR,
b) May impair the safety of users and other persons, and
c) May prejudice any claims made against ECOAIR.

TABLE 1
Use of the machine to produce compressed air for:
a) direct human consumption
b) indirect human consumption, without suitable filtration and purity
checks.
Use of the machine outside the ambient temperature range
specified in the GENERAL INFORMATION SECTION of this manual.

D60 D75
D100 D102
3 ISO SYMBOLS

GRAPHIC FORM AND MEANING OF ISO SYMBOLS

Prohibition / Mandatory Information / Instructions Warning

WARNING: Electrical shock risk. WARNING – Pressurised vessel. WARNING – Hot surface.

WARNING – Pressure control. WARNING – Corrosion risk. WARNING – Air/gas flow or Air discharge.

X,X BAR

WARNING – Maintain correct tyre pressure.

WARNING – Pressurised component or
WARNING – Hot and harmful exhaust gas. (Refer to the GENERAL INFORMATION
system.
section of this manual).

0C

WARNING – Before connecting the tow bar WARNING – For operating temperature
WARNING – Flammable liquid. or commencing to tow consult the below 0C, consult the operation and
operation and maintenance manual. maintenance manual.

D60 D75
D100 D102
 ISO SYMBOLS 4

WARNING – Do not undertake any

WARNING – Consult the operation and
maintenance on this machine until the Do not breathe the compressed air from this
maintenance manual before commencing
electrical supply is disconnected and the air machine.
any maintenance.
pressure is totally relieved.

Do not remove the Operating and Maintenance Do not operate the machine without the guard
Do not stack.
manual and manual holder from this machine. being fitted.

Do not stand on any service valve or other Do not operate with the doors or enclosure
Do not use fork lift truck from this side.
parts of the pressure system. open.

XX
km/h
Do not open the service valve before the
Do not exceed the trailer speed limit. No naked lights.
airhose is attached.

Use fork lift truck from this side only. Emergency stop. Tie down point

D60 D75
D100 D102
5 ISO SYMBOLS

Lifting point. On (power). Off (power).

a
Read the Operation and Maintenance manual
When parking use prop stand, handrake and
before operation or maintenance of this Contains asbestos.
wheel chocks.
machine is undertaken.

SET SEQUENCER STATUS LOAD

SEQUENCER (AUTOMATIC CONTROL) COMPRESSOR OFF LOAD (UNLOADED)

RESET COMPRESSOR STATUS MODULATE

MALFUNCTION POWER SOILED FILTER

POWER INLET ELECTRIC MOTOR HOURS

D60 D75
D100 D102
 ISO SYMBOLS 6

COOLANT SEPARATOR PRESSURE AIR DISCHARGE

PRESSURISED TANK ON / OFF CYCLE COOLANT FILTER

AIR FILTER ON / OFF PUSH BUTTON COOLANT PRESSURE

AIR PRESSURE STAR DELTA IEC 617–7 AUTOMATIC RESTART

HEAT EXCHANGER MAINTENANCE MAINTENANCE PROHIBITED

COOLANT DRAIN CONDENSATE DRAIN PRESSURE CONTROL

MANUAL (SELECT) TEMPERATURE HIGH TEMPERATURE

D60 D75
D100 D102
7 ISO SYMBOLS

BELT TENSION FILTER MOTOR LUBRICATION

FRAGILE KEEP DRY THIS WAY UP

USE NO HOOKS NO SIDE CLAMPS ROTATION

POWER INLET (AC) WATER IN WATER OUT

D60 D75
D100 D102
 SAFETY 8
All pressure containing parts, especially flexible hoses and their
WARNINGS
couplings, must be regularly inspected, be free from defects and be
Warnings call attention to instructions which must be followed
replaced according to the Manual instructions.
precisely to avoid injury or death.

CAUTIONS Compressed air can be dangerous if incorrectly handled. Before

Cautions call attention to instructions which must be followed doing any work on the unit, ensure that all pressure is vented from the
precisely to avoid damaging the product, process or its surroundings. system and that the machine cannot be started accidentally.

NOTES
Notes are used for supplementary information. Avoid bodily contact with compressed air.

The safety valve located in the separator tank must be checked

General Information periodically for correct operation.
Ensure that the operator reads and understands the decals and
consults the manuals before maintenance or operation. Materials
The following substances are used in the manufacture of this
Ensure that the Operation and Maintenance manual, and the machine and may be hazardous to health if used incorrectly:
manual holder, are not removed permanently from the machine. . preservative grease
. rust preventative
. compressor coolant
Ensure that maintenance personnel are adequately trained,
competent and have read the Maintenance Manuals.
AVOID INGESTION, SKIN CONTACT AND INHALATION OF
FUMES
Compressed air and electricity can be dangerous. Before
undertaking any work on the compressor, ensure that the electrical
supply has been isolated and the compressor has been relieved of all For further information, consult Material Data Sheets ECOP006/95.
pressure.

Should compressor lubricant come into contact with the eyes, then
Make sure that all protective covers are in place and that the irrigate with water for at least 5 minutes.
canopy/doors are closed during operation.

Should compressor lubricant come into contact with the skin, then
Installation of this compressor must be in accordance with wash off immediately.
recognised electrical codes and any local Health and Safety Codes.

Consult a physician if large amounts of compressor lubricant are

The use of plastic bowls on line filters without metal guards can be ingested.
hazardous. Their safety can be affected by either synthetic lubricants,
or the additives used in mineral oils. Metal bowls should be used on a
pressurised system. Consult a physician if compressor lubricant is inhaled.

Compressed air can be dangerous if incorrectly handled. Before Never give fluids or induce vomiting if the patient is unconscious or
doing any work on the unit, ensure that all pressure is vented from the having convulsions.
system and that the machine cannot be started accidentally.

Transport
Compressed air
When loading or transporting machines ensure that the specified
Ensure that the machine is operating at the rated pressure and that lifting and tie down points are used.
the rated pressure is known to all relevant personnel.

Electrical
All air pressure equipment installed in or connected to the machine
must have safe working pressure ratings of at least the machine rated Keep all parts of the body and any hand–held tools or other
pressure. conductive objects, away from exposed live parts of the compressor
electrical system. Maintain dry footing, stand on insulating surfaces
and do not contact any other portion of the compressor when making
If more than one compressor is connected to one common adjustments or repairs to exposed live parts of the compressor
downstream plant, effective check valves and isolation valves must be electrical system.
fitted and controlled by work procedures, so that one machine cannot
accidently be pressurised / over pressurised by another.
Close and lock all access doors when the compressor is left
unattended.
Compressed air must not be used for a direct feed to any form of
breathing apparatus or mask.
Do not use extinguishers intended for Class A or Class B fires on
electrical fires. Use only extinguishers suitable for class BC or class
The discharged air contains a very small percentage of compressor ABC fires.
lubricating oil and care should be taken to ensure that downstream
equipment is compatible.
Attempt repairs only in clean, dry, well lighted and ventilated areas.

If the discharged air is to be ultimately released into a confined

space, adequate ventilation must be provided. Connect the compressor only to electrical systems that are
compatible with its electrical characteristics and that are within it’s rated
capacity.
When using compressed air always use appropriate personal
protective equipment.

D60 D75
D100 D102
9 SAFETY
Condensate disposal Burn in an approved incinerator, or according to local area or
country regulations.
Condensate cannot be discharged into fresh/surface water drains.
In some regions compressor condensate containing ECOOL can be
fed directly into a drainage system that has downstream sewerage For further information, consult Material Data Sheets ECOP006/95.
treatment.
The above information contains data supplied in support of United
As waste water regulations vary by country and region it is the Kingdom Control of Substances Hazardous to Health (C.O.S.H.H.)
responsibility of the user to establish the limitations and regulations in regulations.
their particular area. ECOAIR and its associated distributors are happy
to advise and assist in these matters.

Coolant disposal
Steps to be taken in the case of spillage: Soak up with a suitable
absorbent material, then sweep into a plastic bag for disposal.

D60 D75
D100 D102
 GENERAL INFORMATION 10
D60 D75 D100 102
COMPRESSOR
Maximum operating 8,0 10,0 13,0 8,0 10,0 13,0 8,0 10,0 13,0 8,0 10,0 13,0
pressure bar bar bar bar bar bar bar bar bar bar bar bar
Normal operating 7,8 9,8 12,8 7,8 9,8 12,8 7,8 9,8 12,8 7,8 9,8 12,8
pressure bar bar bar bar bar bar bar bar bar bar bar bar
Maximum Pressure ratio 9:1 11:1 13:1 9:1 11:1 13:1 9:1 11:1 13:1 9:1 11:1 13:1
Flow rate 7,16 6,27 5,20 8,50 7,45 6,20 11,60 10,10 8,50 12,00 11,90
m3/min m3/min m3/min m3/min m3/min m3/min m3/min m3/min m3/min m3/min m3/min m3/min
Maximum airend 109C 109C 109C 109C
discharge temperature
Ambient operating +2C → +40C +2C → +40C +2C → +40C +2C → +40C
temperature

D60 D75 D100 102

MOTOR
Nominal power 45kW 55kW 75kW 8bar = 75
10bar = 90
Maximum power (Class 49,5kW 60,5kW 82,5kW 8bar = 82,5kW
‘F’ insulation) 10bar = 99kW
Speed (IP23/55) 2940/2960 RPM 2940/2960 RPM 2940/2960 RPM 2940/2960 RPM
IP rating 23/55 23/55 23/55 23/55
Frame B3 / B5 B3 / B5 B3 / B5 B3 / B5
Insulation class F F F F

D60 D75 D100 102

COOLING SYSTEM
Air cooled
Cooling air flow 8100 m3/min 9700 m3/min 13400 m3/min 13400 m3/min
Maximum ∆P in air ducts 59 / 6 Pa/mm WG 59 / 6 Pa/mm WG 59 / 6 Pa/mm WG 59 / 6 Pa/mm WG
Heat to be dissipated 45kW 55kW 75kW 8 bar – 75kW
10 bar – 90kW
Compressed air outlet ∆T 8C – 12C 8C – 12C 8C – 12C 8C – 12C

D60 D75 D100 102

COOLING SYSTEM
Water cooled
Cooling water flow 2,6 / 1,3 m3/min 3,1 / 1,55 m3/min 4,4 / 2,2 m3/min 4,4 / 2,2 m3/min
∆T15/30K
Cooling water ∆P 2 bar 2 bar 2 bar 2 bar
Cooling water inlet 10C / 30C 10C / 30C 10C / 30C 10C / 30C
temperature (min/max)
Cooling water outlet 45C 45C 45C 45C
temperature
Cooling water pressure 3 / 10 bar 3 / 10 bar 3 / 10 bar 3 / 10 bar
(min/max)
Compressed air outlet ∆T 8C – 12C 8C – 12C 8C – 12C 8C – 12C

Cooling water inlet/outlet R1 R1 R1 R1

D60 D75 D100 102

GENERAL DATA
Residual coolant content 1 – 3 mg/m3 1 – 3 mg/m3 1 – 3 mg/m3 1 – 3 mg/m3
Separator vessel 110 l 110 l 110 l 110 l
capacity
Coolant capacity 73 l 73 l 77 l 77 l
Sound pressure level to 71 dB(A) 75 dB(A) 77 dB(A) 76 dB(A)
CAGI–PNEUROP
D60 D75
D100 D102
11 GENERAL INFORMATION
Weight (IP23/55) 990kg/1015kg 1025kg/1070kg 1160kg/1310kg 8bar = 1325kg/1475kg
10bar = 1460kg/1640kg
Discharge connection G2 G2 G2 G2
Dimensions (L x W x H) 1950mm x 1150mm x 1950mm x 1150mm x 1950mm x 1150mm x 1950mm x 1150mm x
1700mm 1700mm 1700mm 1700mm

D60 D75 D100 102

ELECTRICAL DATA
Standard voltage 3 ~ 400V 3 ~ 400V 3 ~ 400V 3 ~ 400V
Drive motor
Power 45kW 55kW 75kW 8 bar – 75
10 bar – 90
Full load current 84A/80A 99A/96A 138A/128A 8 bar – 138A/128A
(nominal) IP23/55 10 bar – 164A/150A
Starting current (approx.) 221A/232A 245A/290A 340A/434A 8 bar – 340A/434A
10 bar – 403A/440A
Starting time 3.5 S 3.5 S 3.5 S 3.5 S
Starts per hour 4 4 4 4
(IP23/54) (IP23/54) (IP23/54) (IP23/54)
Fan motor
Power 1,5kW 1,5kW 1,5kW 1,5kW
Full load current 3,8A 3,8A 3,8A 3,8A
Control voltage
Star/delta combination 230 VAC 230 VAC 230 VAC 230 VAC
Control (ECOMATIC) 24 VDC 24 VDC 24 VDC 24 VDC
Control 12 / 24 VDC 12 / 24 VDC 12 / 24 VDC 12 / 24 VDC
(ECOCONTROL)
Mains supply cable 50 PVC/PVC 70 PVC/PVC 95 PVC/PVC 8 bar – 95 PVC/PVC
(cross section) 1 10 bar – 120 PVC/PVC
Fuse rating 2 125A 160A 200A 8 bar – 200A
10 bar – 250A

1 Local Regulations apply if stricter than above. ECOCONTROL

KEY
The voltage drop must not exceed 5% of the nominal voltage.
It may be necessary to use cables with a larger section than those
stated to comply with this requirement. E10 Power wiring
E11–13 Control wiring
2 gG
E14 Options
NOTE
All data applies to standard product only. E15 Layout of components
E16 Cable numbers

ECOMATIC
KEY

E20 Power wiring

E21–22 Control wiring
E14 Options
E23 Layout of components
E24 Cable numbers

D60 D75
D100 D102
 GENERAL INFORMATION 12

ECOCONTROL

ECOCONTROL
D60 D75
D100 D102
13 GENERAL INFORMATION

ECOCONTROL

ECOCONTROL
D60 D75
D100 D102
 GENERAL INFORMATION 14

U MAX = 220V
I MAX = 8A
P MAX 24V=150 WATTS

ECOCONTROL

ECOCONTROL
D60 D75
D100 D102
15 GENERAL INFORMATION

ECOCONTROL
KEY KEY

STARTER INSTRUMENTS
PE Terminal, earth T2 Transformer 18V ECOCONTROL
L1–L3 Mains terminals T2 Transformer 18V/10V ECOMATIC
CB1/2 Circuit breaker X1 Plug, 24 way
CB3 Circuit breaker S10 Emergency stop
K1M Main contactor P24 Hourmeter (Total)
K2M Delta contactor P25 Hourmeter (Load)
K3M Star contactor V1 Solenoid valve (Load)
M1 Main drive motor Y5 Valve, coolant stop
M31 Fan motor X73 Block, terminal
F20 Relay, thermal overload S33 Air filter, vacuum switch
F30 Relay, thermal overload S34 Coolant filter, vacuum switch
T1 Transformer 230V S17 Switch, maximum pressure
PTC Thermistor protection S1 Switch, auto/continuous
X1 Socket, 24 way S14.1 Gauge, temperature
A11 Indicator board (ECOCONTROL)
S35 Separator, vacuum switch
S40 Rotation, vacuum switch

D60 D75
D100 D102
 GENERAL INFORMATION 16
KEY NLZ Off load timer
S/H Starts per hour
A20 Circuit board ECOMATIC GLW Sequencer connection
A12 Circuit board (option) SO1 Button stop
A13 Circuit board(option) SO2 Button start
A10 Circuit board ECOCONTROL SO3 Switch, Auto/Continuous
X71 Socket (cable loom machine)

ECOMATIC

D60 D75
D100 D102
17 GENERAL INFORMATION

ECOMATIC

ECOMATIC
D60 D75
D100 D102
 GENERAL INFORMATION 18

ECOMATIC

ECOMATIC
D60 D75
D100 D102
19 GENERAL INFORMATION
KEY KEY

STARTER A20 Circuit board ECOMATIC

PE Terminal, earth A12 Circuit board (option)
L1–L3 Mains terminals A13 Circuit board(option)
CB1/2 Circuit breaker A10 Circuit board ECOCONTROL
CB3 Circuit breaker X71 Socket (cable loom machine)
K1M Main contactor NLZ Off load timer
K2M Delta contactor S/H Starts per hour
K3M Star contactor GLW Sequencer connection
M1 Main drive motor SO1 Button stop
M31 Fan motor SO2 Button start
F20 Relay, thermal overload SO3 Switch, Auto/Continuous
F30 Relay, thermal overload
T1 Transformer 230V
PTC Thermistor protection
X1 Socket, 24 way

KEY

INSTRUMENTS
T2 Transformer 18V ECOCONTROL
T2 Transformer 18V/10V ECOMATIC
X1 Plug, 24 way
S10 Emergency stop
P24 Hourmeter (Total)
P25 Hourmeter (Load)
V1 Solenoid valve (Load)
Y5 Valve, coolant stop
X73 Block, terminal
S33 Air filter, vacuum switch
S34 Coolant filter, vacuum switch
S17 Switch, maximum pressure
S1 Switch, auto/continuous
S14.1 Gauge, temperature
A11 Indicator board (ECOCONTROL)
S35 Separator, vacuum switch
S40 Rotation, vacuum switch

D60 D75
D100 D102
 GENERAL INFORMATION 20

KEY

1 Intake filter 24 Airend discharge temperature (thermometer)

2 Intake valve 25 Sump pressure (pressure gauge)
3 Pressure balancing valve 26 Discharge pressure (pressure gauge)
4 Vent valve
5 Control valve (3/2way)
6 Airend
7 Drive motor
8 Separator
9 Coolant separator cartridge
10 Safety valve
11 Non return valve
12 Dirt trap
13 Scavenge check with orifice
14 Minimum pressure valve
15 Compressed air cooler
16 Pressure switch
17 Coolant filler neck
18 Coolant level guage
19 Pressure hold valve
20 Coolant drain valve
21 Coolant filter
22 Thermostatic valve
23 Coolant cooler
D60 D75
D100 D102
21 GENERAL INFORMATION

Fig. 3 Fig. 4 Fig. 5

SCREW AIREND The rotors have a field–proven and energy–saving asymmetrical

profile.
1 The airend is a single–stage screw–type compressor cooled by
coolant injection.
Whilst compression is in progress, coolant is injected into the
compression chamber. This coolant is designed to absorb the
Running in its casing (Fig. 4) are two helical rotors, viz. the male compression heat, to lubricate the rotors, bearings and gear unit, and
rotor (Fig. 3/1) and the female rotor (Fig. 3/2) with meshing teeth. to seal off the gap between the rotors as well as the face–end clearance
between the rotors and the airend casing (there is no metallic contact
Whilst the rotors are in rotating movement, air is taken in at the top and no wear).
through the intake nozzle (Fig. 3/3). The screw–type airend does not have any out of balance forces.
Further, it does not need any intake or discharge valves for control
purposes, and as such warrants quiet and low–wear running of the
The spaces, or flutes, between the rotor teeth, or lobes, are machine unit.
continuously increased on the top side by rotation of the rotors, until
these flutes are opened over their full length and filled with air. The
intake side is closed off by so–called inlet control ledges. In the separator (Fig. 5/2), the coolant is pre–separated from the
compressed air by reduction of the flow velocity along with a change
in the direction of flow (Fig. 5/3). The compressed air then flows above
After an air transport phase, the process of compression is started the coolant level of the coolant sump through a coolant separator
on the underside. The flutes of the female rotor are continuously cartridge (Fig. 5/4) to the min. pressure valve (Fig. 5/5). When the air
reduced on rotation of the rotors by engagement of the male rotor lobes pressure exceeds a level of 5 bar, the air is discharged to the connected
in the flutes. This causes the trapped air to be compressed. consumer.

2 When reaching the outlet control ledges, the compressed air is

completely discharged through the discharge nozzle (Figs. 3/4 and 5/1)
into the separator (Fig. 5/2).

D60 D75
D100 D102
 GENERAL INFORMATION 22

The ECOSET system 11 Thermostatic switch

Trips the compressor when the discharge temperature becomes
1 Intake filter too high.
Used for cleaning the intake air.

12 Coolant control block, coolant filter

2 Intake valve Used for thermostatic control of temperature in the coolant circuit,
Opens when air is delivered, closes during idling and standstill and to clean the full coolant flow.
conditions.
Vents the separator during idling and standstill conditions, being
controlled by the discharge pressure switch and the control valve. 13 Coolant cooler

3 Control valve 14 Screw–type airend

Prevents air delivery if the adjusted max. pressure is exceeded. Used for air compression, with compression heat dissipated
through coolant injection.

4 Separator
Serves as a coolant storage tank and for coolant separation. 15 Safety valve
To safeguard the system against exceeding the maximum pressure
level.
5 Coolant separator cartridge
Separates the residual coolant content from the compressed air.
16 Maintenance indicator on intake filter

6 Min. pressure valve

Valve opens from 5 bar min. pressure onward. 17 Compressed–air discharge
Nonreturn valve prevents reflux from process system to airend.
18 Drainage piping
7 Compressed–air cooler The coolant separated in the coolant separator cartridge (5) flows
back to the airend (14).

8 Pressure gauge
Indicates the process–system pressure. 19 Blowdown

9 Pressure switch 20 Pressure balancing piping

Controls the control valve (3).
21 Pressure gauge
10 Temperature guage Indicates the compressor system pressure.
Indicates the compression discharge temperature (display).

D60 D75
D100 D102
23 GENERAL INFORMATION

Fig. 7

OVERVIEW
1 Operator panel
2 Pressure switch
3 Coolant/compressed air cooler
4 Air filter condition indicator
5 Intake filter
6 Stop valve (opened in operation) for coolant drain
7 Minimum pressure valve
8 Coolant separator cartridge
9 Safety valve
10 Oil drain nozzle
11 Stop valve (coolant drain)
12 Coolant filler neck
13 Separator
14 Coolant flow viewing window
15 Coolant filter cartridge
16 Coolant control block
17 Coolant filter condition indicator
18 Driving motor
19 Starter cabinet

D60 D75
D100 D102
 GENERAL INFORMATION 24

Fig. 8 Fig. 9

CONTROL SYSTEM Back signal that delta contactor has picked up, for resetting the
control upon control voltage failure (wire fracture) in the star–delta
General configuration combination.
The circuitry is designed in CMOS technique, open–loop type, for
industrial use. The circuit board (Fig. 8/1) is rated for top–hat rail Outputs
attachment (TS35). The electric terminations for the inputs and outputs
are Mascon or screwed/plug–in connectors with mechanical Relay output for activation of star–delta combination.
interlocks.
Non–contacting activation of intake/unloading valve; output
Inputs short–circuit–proof.
Control switch (Fig. 9/1) with three switching positions:
– compressor stop Unassigned 24 V DC output, max. load 0.5 A.
– automatic control (= delayed intermittent operation)
– continuous operation
Total service hour meter, 24 V DC.

Discharge pressure switch for detecting the min. and max. system
pressure, with connection for base–load alternating operation. Displays
LED display (green) for compressor operation (load/idling/standstill
Fault signalling input (connections for four transmitters in series phase) (Fig. 9/3).
arrangement on the circuit board), for fault display (centralized fault
indication, Fig. 9/2) and compressor shutdown.
LED display (red) for compressor centralized fault (Fig. 9/2).

D60 D75
D100 D102
25 INSTALLATION / HANDLING

Fig. 10

TRANSPORT AND MOUNTING

CAUTION
Screw compressors must be transported and mounted with
due regard to the applicable regulations for the prevention of
Fig. 11
accidents.

The compressor is to be positioned at a minimum distance from

walls and other machinery (Fig. 11).

If there is no natural ventilation of the compressor mounting location

Transport
(i.e. windows, wall breakthroughs, etc.), or if the openings for supply air
Transport the compressor unit by fork–lift. Weights see table. (F) and exhaust air (G) are of an insufficient cross–section (Fig. 12),
forced ventilation by means of exhaust air fans must be provided. Fan
minimum air throughput see table.
Travel under the unit with the forks of the fork–lift into the openings
(Fig. 10/1 and 2) under the compressor unit.
When setting up several compressors near each other, ensure that
none of them takes in the heated exhaust air of another compressor.
The centre of gravity is about at the compressor centre.

With unfavourable local conditions or where the exhaust heat is to

Mounting location be recovered, it is recommended to fit air guide ducts with a max.
cooling–air flow velocity of 4 m/s.
The screw compressor can be set up without a foundation on a solid
and plane base or ground. When placed on the roof of a building, the
roof supporting capacity is to be checked.
CAUTION
Suitable facilities (crane, etc.) must be available to permit the safe With 4 m/s flow velocity, the duct length may be 5 m with one
handling of heavy plant components (e.g. machine set, motor) which deflection.
must be moved during any maintenance or repair work.

Adequate ventilation of the mounting location must be ensured so Should these values differ, and/or with duct lengths over 5 m and/or
as to dissipate the compression heat. Cooling–air flow see table. more than one deflection, our aftersales service should be consulted.

D60 D75
D100 D102
 INSTALLATION / HANDLING 26
Warm air flow (m3/h) 8100 9700 13400
Recommended duct 0,75 0,9 1,2
cross–section for heating
K (m2)

Fig. 13

AMBIENT TEMPERATURE

CAUTION
The compressor must be set up protected from frost. The
temperature of the intake air shall be min. +2C, and max. +40C
(Fig. 13).

When these temperature limit values are exceeded either way,

contact our aftersales service. If temperatures are less than +2 C, an
Fig. 12
additional heater can be mounted.

Ventilation, and recovery of exhaust–air heat With a high air humidity and the risk that the temperature falls below
the limit value on compressor standstill, use of a switch cabinet heater
is recommended. Contact our aftersales service.
CAUTION
If the discharged air is released into a confined space,
adequate ventilation must be provided.
The air intake is to be so arranged that any loose personal
clothing cannot be sucked in.

A Natural ventilation of compressor location

Supply–air opening F equals exhaust–air opening G

B Forced ventilation of compressor location

Supply–air opening H

C Duct ventilation to the atmosphere (without recycle flap)

Fig. 14
D Recycle flap for winter operation to prevent icing, by mixing warm
air to cold air at intake temperatures around 0C

E Exhaust air for heating

Waste heat recovery

MODEL D60 D75 D100/

D102
Supply–air opening H (m2) 0,9 1,1 1,5
Exhaust–air opening G – – –
(m2)
Fig. 15
Exhaust–air fan B (m3/h) 12600 15400 21000

D60 D75
D100 D102
27 INSTALLATION / HANDLING
COMPRESSED–AIR CONNECTION ELECTRICAL CONNECTION

CAUTION
Connecting pipes shall have the correct size, and must be WARNING
suitable for the respective operating pressure. Connection to the electrical mains and the necessary
protective measures shall be provided and supervised by an
Authorized Specialist according to EN regulations and the rules
of the respective public utility company.
The compressor has been fully assembled at the manufacturer’s A circuit breaker is to be fitted before the compressor by
works and fitted with a nonreturn valve. Connection to the compressed customer.
air process system (Fig. 14/1) shall be effected through a flexible tubing
(Fig. 14/2) as an expansion joint.

A stop valve (Fig. 14/3) is to be mounted in the compressed air The compressor has been completely wired according to EN 60204
piping by customer. regulations at manufacturer’s factory. Pass the power supply cable
through the cable entry (Fig. 16/1), and provide strain relief.
If several compressor units of different design are connected to one
common downstream process, nonreturn or stop valves are to be fitted
to ensure that one machine cannot be pressurized by another.
WARNING
The compressed air piping is connected by a threaded terminal end Verify that the indicated operating voltage is identical to the
(Fig. 15/1). mains voltage.
Consult machine data plate.

D60 DN = G 2”
D75 DN = G 2”
D100 DN = G 2 1/2”
D102 DN = G 2 1/2” (Fig. 15/1)

CAUTION
The discharged air contains a very small percentage of
coolant. Ensure that the downstream equipment is compatible for
use with compressed air containing coolant.

CAUTION
When employing compressed air, always use suitable
personal protective equipment.
Avoid all bodily contact with compressed air.

Fig. 17

Connect the power supply cable in the switch cabinet to the

incoming terminals L1/L2/L3 and PE (Fig. 17/1).

Necessary data for the cross–sectional values of the main power

cables and fusing of the respective types of equipment may be taken
from the electrical documentation section, and must be adapted to local
conditions (e.g. long power supply cable and high temperatures of
supply cable).

WARNING
Prior to commissioning, all terminals in the switch cabinet are
to be checked and re–tightened if necessary.
Fig. 16

D60 D75
D100 D102
 OPERATING INSTRUCTIONS 28
EXPLANATION OF SIGNS
– ECOCONTROL

Compressor ON
Automatic operation

Compressor ON
Continuous operation

Compressor OFF
Fig. 18

OPERATING AND CONTROL INSTRUMENTS – ECOMATIC

Operating lamp 1 Operating lamp.

2 Centralized fault lamp.
3 Discharge pressure gauge.
4 Compression discharge temperature (thermometer).
Centralized fault alarm lamp
5 Total service hour meter.
6 Sump pressure gauge.
7 Control switch with 3 switching positions:
Total service hours – compressor OFF
– automatic operation
– continuous operation
8 EMERGENCY–STOP button.
On–load hours SUMMARY INSTRUCTIONS
1. Before starting
– Check set–up and connections.
Compression discharge temperature
– Close safety valve.

– Check coolant level.

Process pressure
– Check direction of rotation.

– Close the enclosure.

Compressor system pressure

2. Starting the compressor

Compressor not to be operated unless enclosure is closed.

– Switch on the circuit breaker.

– Set control switch to automatic or continuous operation.

– Operating lamp lights up – package is ready for operation.

3. Shutdown of compressor

– Close stop valve towards compressed–air process system.

– Allow compressor system pressure to drop.

– Set control switch to ”0” position.

D60 D75
D100 D102
29 OPERATING INSTRUCTIONS
– Switch off the circuit breaker, lock where applicable.

4. Emergency stop Process pressure

WARNING
If there is a danger situation, the compressor can be stopped
from any operating condition by pressing the emergency–off
Compressor system pressure
button (Fig.20/18).

EXPLANATION OF SIGNS Compression discharge temperature

– ECOMATIC

Compressor ON Total service hours

On–load hours
Compressor OFF

Automatic operation

Continuous operation

Automatic compressor starting

Fig. 20

Fault signals
OPERATING AND CONTROL INSTRUMENTS – ECOMATIC
1 ON button for compressor start.
Compression discharge temperature too high 2 Operating lamp.
3 LED display for automatic compressor starting.
4 LED display for selected ”continuous” operating mode.

Compressor motor overload 5 LED display for selected ”automatic” operating mode.
6 Operating mode selector button.
7–9 LED fault signalling displays.
10–12 LED maintenance signalling displays.
Incorrect direction of rotation
13 Discharge pressure gauge.
14 Total service hour meter.
15 On–load hour meter.
Maintenance displays
16 Compression discharge temperature (thermometer).
17 Sump pressure gauge.

Intake filter 18 EMERGENCY–STOP button.

19 OFF button for compressor shutdown.
SUMMARY INSTRUCTIONS
1. Before starting
Coolant filter cartridge – Check set–up and connections.

– Close safety valve.

Coolant separator cartridge – Check coolant level.

D60 D75
D100 D102
 OPERATING INSTRUCTIONS 30
– Check direction of rotation. 3. Check coolant level.

– Close the enclosure. 4. Check the direction of rotation.

2. Starting the compressor

Compressor not to be operated unless enclosure is closed. WARNING
Incorrect direction of rotation will destroy compressor within
a few seconds.
– Switch on the circuit breaker.

– Switch on compressor with the ON button. Direction of rotation to be checked:

– Operating lamp lights up. – on initial commissioning,

– Choose mode of operation. – when performing any work on electrical equipment,

– Indicator for chosen mode of operation lights up. – when performing any work on driving motor,

3. Shutdown of compressor – when changing the compressor location.

– Close stop valve towards compressed–air process system.
ECOCONTROL
– Allow compressor system pressure to drop. – Switch on the circuit breaker.

– Switch off compressor with the OFF button. – Switch on the control switch, and switch off again immediately.

– Switch off the circuit breaker, lock where applicable.

4. Emergency stop

WARNING
If there is a danger situation, the compressor can be stopped
from any operating condition by pressing the emergency–off
button (Fig.20/18).

Fig. 23

– Compare the motor direction of rotation in the window (Fig. 23/1)

with the arrow (Fig. 23/2) on the motor flange.

Fig. 22

COMMISSIONING

WARNING
Do not operate compressor beyond admissible operating
pressure or admissible discharge temperature.

1. Check for correct set–up and connections.

2. Close safety valve.

Close the safety valve by clockwise turning of knurled screw.
Fig. 24
D60 D75
D100 D102
31 OPERATING INSTRUCTIONS
– Should the direction of rotation be wrong, incoming wires L1 and L2 CAUTION
(Fig. 24/1) require reconnection in the switch cabinet. Setting of the discharge pressure switch should only be
performed with the compressor in continuous operation.
The differential pressure should not be less than 0.5 bar.
ECOMATIC Do not adjust pressure switch beyond maximum pressure on
– Switch on the circuit breaker. machine data plate.

– Press the ON button, and instantly press the OFF button.

Setting of discharge pressure switch at the factory.

– Should the motor fail to start, or if the ”direction of rotation” fault

signal lights up, this indicates incorrect connection of incoming lines.

– Reconnect the incoming wires L1 and L2 in the switch cabinet.

5 Setting of discharge pressure switch.

Operating gauge pressure (bar) Lower switch point (bar) Upper switch point (bar)

8 7 8
10 9 10
13 12 13

Fig. 25 Fig. 26

– Adjusting the switch–off pressure = upper switch point (red pointer,

WARNING
Fig. 26/1):
Observe admissible operating pressure of compressed air
Pressure up:
process system when adjusting the upper switch point, and do
Turn hex. bolt (Fig. 26/4) anticlockwise.
not set unless compressor is in on–load operation.
Pressure down:
Turn hex. bolt (Fig. 26/4) clockwise.

– Screw off the screw (Fig. 25/1). Remove cap (Fig. 25/2) from
discharge pressure switch. WARNING
Adjustment of the lower switch point should be performed
with compressor at standstill and the compressed air discharged.

– Adjusting the switch–on pressure or the switching difference =

lower switch point (green pointer, Fig. 26/2):

Differential pressure (
p) between switch–on and switch–off

pressures to increase:
Turn hex. bolt (Fig. 26/3) anticlockwise.

Differential pressure (
p) between switch–on and switch–off

pressures to decrease:
Turn hex. bolt (Fig. 26/3) clockwise.

D60 D75
D100 D102
 OPERATING INSTRUCTIONS 32
– Fit the cap (Fig. 25/2), and fix by screw (Fig. 25/1).

6. Adjusting the motor running time.

WARNING
The motor running time must be adjusted by an Authorized
Specialist.

The motor running time shall be checked and, where applicable,

corrected on initial commissioning.
Fig. 28
– The motor min. running time (switch cycles/h) has been factory–set,
and must not be changed. ECOMATIC (Fig. 28)
Potentiometer [1]
=min. off–load time.
Potentiometer [2]
= star–delta transfer time.
WARNING
The min. off–load time of the motor has been set at 60 s in the 7. Commissioning after transport of compressor.
factory. If required, this time can be increased by re–adjusting the
potentiometer .
WARNING
Coolant may have entered the coolant separator cartridge in
transit.

– The star–delta transfer time can be adjusted between 2 and 10 s.

Transfer time to be adjusted such that motor has reached rated speed Operate the compressor for approx. 10 min under idling control
on transfer from star phase to delta phase. during initial commissioning.

Adjustment of min. off–load time and star–delta transfer time: – Mount stop valve at the compressed–air discharge, and close the
valve.

– Start the compressor and operate in continuous operation.

STARTING

WARNING
The compressor is to be operated with closed enclosure.
The enclosure may only be opened short time for minor setting
work with running machine.
Full noise damping effect will only be achieved with closed
enclosure.
Check coolant levels before every start–up.
Ensure prior to start–up that nobody is inside the compressor
danger area.

Fig. 27

ECOCONTROL (Fig. 27)

Potentiometer [1]
=min. off–load time.
Potentiometer [2]
= star–delta transfer time. Fig. 29
D60 D75
D100 D102
33 OPERATING INSTRUCTIONS
ECOCONTROL (Fig. 29) Depending on the operating conditions, this mode may have to be
selected if, for instance, loading of the power mains through starting of
1. Switch on the circuit breaker. the electric motor should be avoided.

2. Set the control switch [2] to automatic operation [4] or continuous Transfer between modes is possible in operation of the compressor
operation [1]. Compressor will start up in automatic or continuous at any phase without having to stop the machine.
operation. Operating lamp will light up [5].

MONITORING OF OPERATION
3. Switch–off of compressor:
Set control switch to ”0” position [3]. Operating lamp [5] will go off. Pressure gauges
Switch off the circuit breaker.

WARNING
Do not operate the compressor beyond the admissible
operating pressure.

The discharge pressure gauge indicates the compressor discharge

supply pressure.

The maximum discharge pressure is shown on the machine data

plate.

Fig. 30

ECOMATIC (Fig. 30)

1. Switch on the circuit breaker.

Fig. 31
2. Press the ON button [1]. The operating lamp [2] will light up.

3. When the operating voltage is energized, the ”continuous ECOCONTROL (Fig. 31)
operation” mode will be preselected automatically. Depending on 1. Discharge pressure gauge [1].
actuation of the operating mode selector button [6], one of the displays
for either automatic [5] or continuous operation [4] will light up. 2. Compressor system pressure gauge [2].
3. Thermometer (compression discharge temperature) [3].
4. The display [3] lights up if the compressor is shut down with
preselected automatic operation mode. If the process pressure drops
to Pmin, the unit will be started automatically.

5. Switch–off of compressor:

Press the OFF button [7]. The operating lamp [2] will go off. Switch
off the circuit breaker.

Automatic operation provides optimum efficiency through

combined full–load/idling and intermittent operation. In this control
mode, the compressor delivery flowrate is so adjusted to the air
requirements that according to the demand of the consumer the
compressor runs either under full–load/idling control, or is shut down.

The compressor is automatically stopped in case that the upper

switch point is reached and the motor min. running time and off–load
time have expired. It will restart automatically when system air pressure
drops to the on–line setpoint.
Fig. 32
In the continuous mode, the air flowrate is adapted to
requirements in alternating sequence between full–load and idling ECOMATIC (Fig. 32)
control.
1. Discharge pressure gauge [1].
D60 D75
D100 D102
 OPERATING INSTRUCTIONS 34
2. Compressor system pressure gauge [2].
3. Thermometer (compression discharge temperature) [3].

Fig. 34

ECOCONTROL (Fig. 34)

Fig. 33 Three locations are monitored as a standard feature:

THERMOMETER Detection of a malfunction by the operation monitor causes the

”centralized fault alarm” lamp [2] to light up.

WARNING Starting of the compressor after correction of the malfunction or

Do not operate the compressor beyond the admissible recurrence of mains voltage after a power failure is not possible until the
compression discharge temperature. control switch [1] has first been set to ”0” position and then adjusted to
the intended operating mode, i.e. automatic or continuous control.

The compression discharge temperature is measured by a

temperature sensor and displayed by a thermometer.

The admissible compression discharge temperature is identified on

the thermometer by a red mark.

The compressor is automatically tripped if the admissible

compression discharge temperature is exceeded.

Fault signals
The compressor unit is fitted with an automatic operation monitor to
trip the unit if there is any malfunction.

Fig. 35

ECOMATIC (Fig. 35)

Three locations are monitored as a standard feature:

– Direction of rotation of mains supply.

– Driving motor overload / overtemperature [2].

– Compression discharge temperature [3].

D60 D75
D100 D102
35 OPERATING INSTRUCTIONS
Flashing of any display indicates the faulted location that has Exchange of the coolant filter cartridge becomes necessary if the
caused automatic tripping. red service field is fully visible in the transparent window (Fig. 37/1) with
shutdown compressor.
By actuation of the OFF button [5], the flashing display is switched
to steady light. 3. Monitoring of coolant separator cartridge

The faulted display is not extinguished until actuation of the OFF

button has been repeated after correction of the malfunction.

Emergency stop operation is indicated by alternating flashing of the

fault indication and service indicator lights.

MAINTENANCE CONTROL – ECOCONTROL

Local monitoring:

1. Maintenance indicator for intake filter

Fig. 38

The coolant separator cartridge must be exchanged if the pressure

differential between the process pressure gauge (Fig. 38/1) and
compressor system pressure gauge (Fig. 38/2) is 1 bar with the
compressor at operating temperature.

Fig. 36

Maintenance of the intake filter becomes necessary if the red

service field is fully visible in the transparent window (Fig. 36/1) with
shutdown compressor.

2. Maintenance indicator for coolant filter cartridge

Fig. 39

MAINTENANCE CONTROL – ECOMATIC (Fig. 39)

Electrical monitoring:

Three locations are monitored as a standard feature:

– Coolant separator cartridge [1].

– Coolant filter cartridge [2].

– Intake filter [3].

Flashing of a display indicates the location where maintenance is

required. There is no trip; flashing continues until the compressor is
Fig. 37 shut down.

D60 D75
D100 D102
 OPERATING INSTRUCTIONS 36
Coolant flow check fitting (Fig. 40)
When monitoring the compressor unit, take care that air or an
air/coolant mixture passes by the flow gauge [1] of the coolant flow
check fitting.

If coolant only is visible on the flow gauge without any noticeable

flow movement, the dirt trap [2] and restrictor bore in the coolant fitting
must be checked for soiling and cleaned.

Fig. 40

D60 D75
D100 D102
37 MAINTENANCE

PERIOD MAINTENANCE
Daily Check the coolant level and replenish if
necessary.
When the separator Check the pressure differential when the unit
element indicator is operating on full load at rated pressure.
light flashes
Change the separator element if the
pressure drop is zero or exceeds 1 bar (15
p.s.i.g.)
First 250 hours Change the coolant filter.

Each week Check that the safety valve easing gear

moves freely.
2000 hours / 6 Check the operation of the high temperature
months protection device(s) (109C standard)
Each 3 months Check all hoses for signs of deterioration,
cracks, hardening etc.
Each 2000 hours Change the coolant filter.
1 year / 4000 hours Change the air filter element.
Replace the element sooner if the visual
indicator warning is shown.
8000 hours / 1 year Check the scavenge screen for blockage,
clean if required.

1 year Remove the safety valve from the

compressor, inspect and re–calibrate.

1 year Check the calibration of the pressure guage

2000 hours Lubricate the main motor drive end bearing.

Quantity of grease (ESSO UNIREX N3 cpn
93685832) required:
B: 12g (
)
L: 20g (
)
Lubricate the main motor non–drive end
bearing.
Quantity of grease (ESSO UNIREX N3 cpn
93685832) required:
B: 6g (
)
L: 20g (
)
(
) (
) To determine the correct letter
designation (B,L) consult the CPN field on
the main motor data plate.
2000 hours Lubricate the main motor drive end bearing.
D126/152/183/222 Quantity of grease (ESSO UNIREX N3 cpn
TEFC 93685832) required:
30g
4000 hours Lubricate the main motor non–drive end
bearing.
Quantity of grease (ESSO UNIREX N3 cpn
93685832) required:
20g
Note:
For motor types B or L use ESSO UNIREX N3 grease.
On other types use grease K3K to DIN 51825 e.g. SKF LGTM3,
Shell Alvania G3, Esso Beacon 3, etc.
8000 hours / 2 years Replace the ECOOL at whichever interval
occurs first.
Also replace the separator element and
coolant filter.
4 years Replace all hoses.

D60 D75
D100 D102
 MAINTENANCE 38
ROUTINE MAINTENANCE . all hazards present are known (e.g. pressurised components,
electrically live components, removed panels, covers and guards,
This section refers to the various components which require extreme temperatures, inflow and outflow of air, intermittently moving
periodic maintenance and replacement. parts, safety valve discharge etc.).

The SERVICE/MAINTENANCE CHART indicates the various . appropriate personal protective equipment is worn.
components’ descriptions and the intervals when maintenance has to
take place. Coolant capacities, etc., can be found in the GENERAL
INFORMATION section of this manual. . loose clothing, jewellery, long hair etc. is made safe.

CAUTION: Before beginning any work on the compressor, open, . warning signs indicating that Maintenance Work is in Progress are
lock and tag the main electrical disconnect and close the isolation posted in a position that can be clearly seen.
valve on the compressor discharge. Vent pressure from the unit
by slowly unscrewing the coolant fill cap one turn. Unscrewing
the fill cap opens a vent hole, drilled in the cap, allowing pressure Upon completion of maintenance tasks and prior to returning
to release to atmosphere. Do not remove the fill cap until all the machine into service, ensure that:–
pressure has vented from the unit. Also vent piping by slightly
opening the drain valve. When opening the drain valve or the
. the machine is suitably tested.
coolant fill cap, stand clear of the valve discharge and wear
appropriate eye protection.
. all guards and safety protection devices are refitted.
Compressed air can be dangerous if incorrectly handled. Before
doing any work on the unit, ensure that all pressure is vented from the . all panels are replaced, canopy and doors closed.
system and that the machine cannot be started accidentally.

. hazardous materials are effectively contained and disposed of.

Ensure that maintenance personnel are adequately trained,
competent and have read the Maintenance Manuals.

WARNING
Prior to attempting any maintenance work, ensure that:– Do not under any circumstances open any drain valve or remove
components from the compressor without first ensuring that the
. all air pressure is fully discharged and isolated from the system. If compressor is FULLY SHUT– DOWN, power isolated and all air
the automatic blowdown valve is used for this purpose, then allow pressure relieved from the system.
enough time for it to complete the operation.

. the machine cannot be started accidently or otherwise, by posting INITIAL COMMISSIONING AND DECOMMISSIONING
warning signs and/or fitting appropriate anti–start devices.
Inspection for damage in transit

. all residual electrical power sources (mains and battery) are Every screw compressor has been subjected to a factory test, and
isolated. has been carefully inspected prior to shipment. Inspection ensures that
the compressor corresponds to the indicated technical data and works
properly. However, despite careful factory inspection it may happen
Prior to opening or removing panels or covers to work inside that the compressor is damaged in transit. For this reason it is
a machine, ensure that:– recommended to inspect the compressor for possible transport
damage. Observe the compressor during the initial operating time so
that any malfunction may be discovered.
. anyone entering the machine is aware of the reduced level of
protection and the additional hazards, including hot surfaces and
intermittently moving parts. Maintenance work
For maintenance work prior to initial commissioning see
. the machine cannot be started accidently or otherwise, by posting Maintenance schedule.
warning signs and/or fitting appropriate anti–start devices.
Decommissioning
If the compressor is decommissioned for a prolonged time (more
than approx. 3 months), take care to perform the same maintenance
work prior to re–commissioning as has been specified for initial
Prior to attempting any maintenance work on a running commissioning (see Maintenance schedule).
machine, ensure that:–
COMPRESSOR
. the work carried out is limited to only those tasks which require the Depressurization of compressor
machine to run.
WARNING
. the work carried out with safety protection devices disabled or Whenever performing any work on the compressor package,
removed is limited to only those tasks which require the machine to be make sure that the package is previously completely
running with safety protection devices disabled or removed. depressurized.

D60 D75
D100 D102
39 MAINTENANCE

Fig. 41 Fig. 43

Open the safety valve by anticlockwise turning of knurled screw

(Fig. 43/1).
ECOCONTROL (Fig. 41):
1 Switch compressor to continuous operation. Close stop valve to The compressed air escapes through the safety valve. Close safety
compressed–air process system, and idle for approx. 2 min. Then stop valve again by turning the knurled screw clockwise.
the compressor, and set control switch [1] to ”0” position.

2 Separator must have been depressurized; compressor system

pressure gauge [2] must show ”0” bar.

Fig. 44

CHECKING OF COOLANT LEVEL IN SEPARATOR

WARNING
Fig. 42 Never turn the plug (Fig. 44/2) as long as compressor is
pressurized.
Coolant level to be checked with motor at rest and compressor
depressurized.
ECOMATIC (Fig. 42): Risk of scalding! Do not spill any coolant!
Tightness to be ensured!
1 Switch compressor to continuous operation. Close stop valve to
compressed–air process system, and idle for approx. 2 min. Then stop
the compressor, and set control switch [1] to ”0” position.
The coolant must reach at least the bottom edge of the level gauge
(Fig. 44/1).
2 Separator must have been depressurized; compressor system
pressure gauge [2] must show ”0” bar.
Topping–up of coolant:
Before performing any work on the compressor, lift the safety valve
for security to confirm the air receiver tank has been depressurized. 1 Depressurize the compressor

D60 D75
D100 D102
 MAINTENANCE 40
2 Screw out plug (Fig. 44/2) from coolant filler neck (Fig. 44/3).

3 Fill up the coolant to top edge of level gauge in separator (max.).

Fig. 47

Fig. 45

4 Check seal (Fig. 45/1) on plug; exchange plug if seal is damaged.

5 Screw in and tighten the plug.

WARNING
Plug is pressurized in operation.
Tight fitting of plug to be ensured after starting!

Fig. 48

CHANGE OF COOLANT

WARNING
Coolant change only permissible with motor at rest and
depressurized compressor.
Used oil is drained at pressure of 2 bar.
Risk of scalding when draining any hot coolant!
Collect the used coolant, do not permit coolant to seep into
ground, and ensure ecological disposal.

1 Coolant to be changed in service temperature conditions. Have the

compressor operate for approx. 5 minutes.

2 Stop the compressor.

Fig. 46
3 Observe pressure drop on compressor system pressure gauge.
(Fig. 46/1) System pressure gauge ECOCONTROL
(Fig. 47/1) System pressure gauge ECOMATIC

4 When system pressure has dropped to 2 bar, throw over hand lever
(Fig. 48/1) on stop valve.

5 Screw off the plug (Fig. 49/1) from coolant drain nozzle (Fig. 49/2),
and connect the coolant drain hose.

6 Drain the used coolant:

Carefully throw over the hand lever (Fig. 49/3) on coolant drain
nozzle, and drain the coolant.

7 Having drained the coolant, throw over the hand lever (Fig. 49/3) on
the coolant drain valve, and the lever (Fig. 48/1) on the stop valve.

D60 D75
D100 D102
41 MAINTENANCE
8 Remove coolant drain hose, and screw on plug again (Fig. 49/1).

9 Depressurize the compressor.

10 Drain coolant from coolant cooler.

11 Fill with fresh coolant.

coolant fill: 45 litres

Always re–fill the unit with ECOOL. This coolant has been
developed to optimise the performance of ECOAIR compressors.

12 After starting, check tight fitting of plug and cap nut.

13 When having performed any work on the cooling system (e.g.

change of coolant), check the coolant level after short–time test
operation because coolant will be absorbed by piping and cooling Fig. 51
system.
EXCHANGE OF COOLANT FILTER CARTRIDGE

WARNING
Coolant filter cartridge to be exchanged with motor at rest and
compressor depressurized.
Risk of scalding.
Hot coolant.
Do not spill any coolant.

1 Depressurize the compressor.

2 Loosen coolant filter cartridge (Fig. 50/1) by strap wrench, and

screw off.

WARNING
Collect the escaping used coolant, do not permit coolant to
Fig. 49 seep into ground, and ensure ecological disposal together with
old coolant filter cartridge.

3 Wet gasket with coolant (Fig. 51/1) on new coolant filter cartridge.
Screw on the coolant filter cartridge until gasket is in contact, and
tighten further by 3/4 of a turn manually.

Check gasket for tightness after starting the compressor.

Fig. 50

D60 D75
D100 D102
 MAINTENANCE 42
WARNING
Collect the escaping used coolant, do not permit coolant to
seep into ground, and ensure ecological disposal together with
old coolant separator cartridge.

Fig. 52

EXCHANGE OF COOLANT SEPARATOR CARTRIDGE

WARNING
Coolant separator cartridge to be exchanged with motor at rest
and compressor depressurized! Fig. 53
Risk of scalding.
Hot coolant.
Do not spill any coolant. 5 Clean sealing face, and place new gasket (Fig.53/3).

6 Put new coolant separator cartridge (Fig.53/2) into separator vessel

1 Depressurize the compressor. (Fig.53/1).
Secure to prevent restarting!
7 Place gasket (Fig.53/3) for cover, fit the cover, and re–attach the
2 Separate piping (Fig.52/1) from cover (Fig.52/2). piping (Fig.52/1).

3 Screw out hex. bolts (Fig.52/3).

CAUTION
4 Take off cover (Fig. 52/2) and take out coolant separator cartridge Take care to ensure tight fitting of cover.
with old gaskets. Tighten the hex. bolts crosswise.

D60 D75
D100 D102
43 MAINTENANCE

Fig. 54 Fig. 55

6 If the intake filter is monitored by a maintenance indicator* (Fig

55/1), reset the indicator by pressing the resetting button (Fig. 55/2)
INTAKE FILTER MAINTENANCE after maintenance of the filter.

* with ECOCONTROL only

WARNING
Perform all inspections and all work with motor at rest and
compressor depressurized! Cleaning of cooler

CAUTION
Air blowing direction for cleaning to be in parallel to the fins.
1 Screw off the wing nut (Fig. 54/1). Distance to be approx. 0.3 – 0.5 m; if not, fins may be damaged.

2 Remove filter cover (Fig. 54/2) and take out the intake filter cartridge
(Fig. 54/3).

3 Either exchange or carefully clean the intake filter cartridge.

Intake filter cartridge may be cleaned max. 3 times, then exchange.

Cleaning process:

– Tap (in emergencies only); take care not to damage the cartridge;
or

– Wash according to manufacturer’s specifications.

4 Mark every cleaning operation on the cartridge with an ”X”.

Fig. 56
WARNING
Do not by any means clean the intake filter cartridge with
combustible liquids, solvents, or hot liquids! Check cooler fins (Fig. 56/1) for soiling if compression discharge
temperature or air outlet temperature becomes too high.

If cooler is soiled, blow the fins with compressed air. Extract the dust
Check intake filter cartridge for damage to filter paper (examine obtained.
against light) or gaskets; exchange if necessary.

5 Replace cleaned or new intake filter cartridge, fit filter cover, and WARNING
screw on the wing nut finger–tight. Wear dust mask.

D60 D75
D100 D102
 MAINTENANCE 44
MOTOR NOTE
The safety valve blow–off pressure was set to 1.5 bar above
Cleaning compressor discharge pressure at the factory.
The safety valve has been lead–sealed and may not be
readjusted.
WARNING
Do not hose down motors with water or other liquids.

Depending on soiling, motors are to be regularly cleaned along the

entire cooling–air path.

Rolling–contact bearings with relubrication facility

WARNING
The operational safety of the motors depends on observance
of the relubrication intervals!

All motors have a relubrication facility with grease quantity regulator

as a standard feature. Initial lubrication of the bearings is effected at the
factory. The relubrication intervals and quantities are indicated on the
rating plate.
Fig. 57

Test run
Open the safety valve with running compressor by anticlockwise
turning of the knurled screw (Fig. 57/1). Compressed air must escape
through the safety valve.
NOTE
Perform a test run after all necessary maintenance work has
been completed on the compressor and motor.
WARNING
Escape of hot coolant/air mixture.

1 Start the compressor.

Close safety valve by clockwise turning of knurled screw.
2 Operate the compressor in the AUTOMATIC mode, and check for
proper functions.
5 Check compressor coolant level.

3 Check compressor for tightness during the test run.

After maintenance work has been performed on the cooling coolant
system or after an coolant change or exchange of the coolant filter,
4 Check the safety valve. check the coolant level following the test run.

D60 D75
D100 D102
45 FAULT FINDING

FAULT CAUSE REMEDY

’Power on’. L.E.D. does CONTROL VOLTAGE NOT Check the control circuit breaker CB3.
not illuminate.
ill minate AVAILABLE
Check the transformer secondary windings for the control voltage.
Compressor will not DEMAND TOO HIGH Check for leaks, open service valves or exceptionally high demand.
b ild up
build p rated pressure.
press re
OFFLINE PRESSURE SET TOO Check the offline pressure setting.
LOW
Controller indicates trip CONTROL CIRCUIT Check machine for indicated fault. Attempt to ’reset’ the controller. If the fault
condition. INTERRUPTED BY A SAFETY persists investigate further.
DEVICE
Compressor trips INSUFFICIENT COOLANT Check the coolant level.
indicating a high CIRCULATION
compressor Check the coolant system for blockages.
temperature. Check the operation of thermostatic valve.
POOR ELECTRICAL H.A.T. thermistors fail-safe. The unit will trip due to open or short circuit.
CONNECTION
INSUFFICIENT COOLING TAKING Check that the cooling air flow Is not obstructed at:
PLACE . The cooler matrix
. The exhaust vents
EXCESSIVELY HIGH AMBIENT Improve the ventilation to the compressor room.
TEMPERATURE
(i.e. greater than 40oC.
Compressor trips and EXCESSIVE CURRENT HAS Check the actual operating pressure and lower the setting if it is too high. Isolate
indicates CAUSED THE THERMAL the electrical supply and check that the airend and motor rotate freely. Check the
motor overload. OVERLOAD (MOL) TO TRIP separator element for excessive pressure drop.
Compressor will not INLET VALVE NOT OPENING Check that the valve is free to open.
load
load.
Check the operation of the load solenoid valve Y1.
Compressor fails to INLET VALVE NOT OPENING Check the operation of the inlet valve.
deliver rated
capacity. Check the operation of the load solenoid valve Y1.
Check the offline/online pressure setting.
Check the inlet filter for contamination.
AIR FILTER BLOCKED Check visual (service) indicator.
COOLANT SEPARATOR Change coolant, coolant filter, separator element.
BLOCKED
Excessive coolant BLOCKED SCAVENGE LINE Clear the blockage.
cons mption
consumption.
RUPTURED OR FOULED Change the element.
SEPARATOR ELEMENT
Rapid cycling or RAPID LOAD/UNLOAD CYCLING Duty cycle too rapid – Increase system capacity.
receiver will not
blow–down to unloaded MINIMUM PRESSURE VALVE Strip the MPV, examine and repair if necessary.
running pressure. (MPV) STUCK OPEN

Safety valve blows MPV STUCK CLOSED Strip MPV, examine and repair if necessary.
when compressor goes
on load. OFFLINE PRESSURE SET TOO Check the offline pressure setting.
HIGH
COOLANT SEPARATOR Change coolant, coolant filter, separator element.
BLOCKED
SAFETY VALVE FAULTY Check the setting of the safety valve and the rated pressure.
Centralized fault alarm INCORRECT DIRECTION OF Change phases on incoming wire.
(ECOCONTROL) lights ROTATION OF COMPRESSOR
up, compressor is MOTOR (ECOMATIC)
tripped (with
ECOMATIC, respective DRIVING MOTOR Check setting of thermal overcurrent relay, press reset button on overcurrent
fault signals will light OVERLOADED relay.
up)) COMPRESSION DISCHARGE See compression discharge temperature.
TEMPERATURE TOO HIGH
SHORT–CIRCUIT ON CONTROL Correct short–circuit.
VALVE
SHORT–CIRCUIT TO GROUND Correct short–circuit to ground.
ON FAULT TRANSMITTER

D60 D75
D100 D102
 FAULT FINDING 46
FAULT CAUSE REMEDY
Compression discharge AMBIENT TEMPERATURE TOO Contact the aftersales service.
temperature too high. HIGH
COOLING SYSTEM FOULED Clean cooling system, remove any coolant residues internally.
INSUFFICIENT COOLANT FLOW Renew coolant filter cartridge.
IN COOLANT CIRCUIT
Check for pressure losses in coolant circuit, clean circuit. Check/clean coolant
cooler.
INSUFFICIENT COOLANT LEVEL Refill coolant.
TEMPERATURE SWITCH Exchange.
DEFECTIVE
INSUFFICIENT DUCT CROSS – Greater cross–section as required.
SECTIONS FOR COOLING – AIR
SUPPLY/EXHAUST
SHORT–CIRCUIT BETWEEN Provide screening.
COOLING–AIR OUTLET/
COOLING–AIR INLET
THERMOSTATIC VALVE Exchange.
DEFECTIVE
Maintenance indicator INTAKE VACUUM PRESSURE Exchange or clean filter cartridge.
of compressor air filter TOO HIGH
shows red
red.
AIR FILTER CARTRIDGE SOILED
Coolant in air piping. DRAINAGE LINE CLOGGED Check, clean.
FAULTY COOLANT SEPARATOR Exchange.
CARTRIDGE
COOLANT LEVEL IN SEPARATOR Bring to normal level.
TANK TOO HIGH
MIN. PRESSURE TOO LOW Check min. pressure.
Coolant escaping INTAKE CONTROLLER FAILS TO Check, exchange if necessary.
through intake nozzle CLOSE
after shutdown
sh tdown of
compressor. DRAINAGE LINE FROM Clean and/or connect.
COOLANT SEPARATOR See also malfunction ”Coolant in air piping”.
CARTRIDGE CLOGGED
Compressor unit fails to NO POWER SUPPLY Apply power.
start. Switch on the circuit breaker.
NO CONTROL VOLTAGE Provide voltage supply.
DEFECTIVE CONTROL CURRENT Correct the defect.
CIRCUIT
Sluggish starting of MAINS VOLTAGE TOO LOW (ON Provide sufficient power supply.
compressor unit. LOAD)
TRANSFER TIME STAR – DELTA Readjust: transfer to delta immediately after nominal speed is reached.
TOO LONG
CONTROL VALVE DEFECTIVE Exchange.
2PHASE RUNNING Check the incoming wire.
MIN. PRESSURE VALVE Check.
DEFECTIVE
Compressor unit FAULT SIGNAL See under ”Fault signals on operator panel”.
tripped before
discharge pressure is PRESSURE SWITCH DEFECTIVE Exchange or check.
reached. OR INCORRECTLY SET

NOTE
Whenever there is any operational malfunction on the
control system, you should always contact our aftersales
service.

D60 D75
D100 D102
47 OPTIONS

OPTIONAL OUTFIT
Optional mechanical outfit
– Water cooling
– Heat recovery

Optional electrical outfit

– Compressor anti–condensation heater
– Starter cabinet heater
– Centralized–fault and operation display (zero–potential)
– Automatic starting after power failure
– Motor thermistor protection

With ECOCONTROL only:

– Direction of rotation control
– On–load hour meter
– External ON/OFF control

With ECOMATIC only:

– Unassigned fault input with display
– Unassigned maintenance input with display
– Local/remote transfer

Any questions concerning the optional outfit should be addressed

to our aftersales service.

D60 D75
D100 D102
Printed in the United Kingdom