QUALITY SYSTEM CERTIFIED ENVIRONMENTAL MANAGEMENT SYSTEM

Transcription

1 INSTRUTION MNUL Serial nº Model nº QULITY SYSTM RTII NVIRONMNTL MNGMNT SYSTM ROTRY SRW OMPRSSOR SRP 0 SRP 00 SRP 00 SRP 00 Visit website

2 TTNTION The Warranty on your SHULZ compressor will only be effective following the receipt of the warranty registration form completed by a SHULZ uthorized- Technical/istributor. See Warranty Registration orm (Page ). SHULZ O MRI, Inc.! IMPORTNT This Instruction Manual contains important use, installation, maintenance and safety information and should always be available to the machinery operator. To prevent personal injuries or material damage to your rotary screw compressor, always familiarize yourself with the contents of this manual before operating or maintaining your equipment.! IMPORTNT Use only SHULZ original parts for your rotary screw compressor maintenance. These are available through your SHULZ uthorized-technical/istributor. See table 6 (page ). I N X Introduction ompressor Inspection Use Safety Technical ata Main omponents Installation Working Principles Instrument Panel ontrol System ontrol Mode Technical elivery Start Procedure Stop Procedure Preventive Maintenance Maintenance Parts isposal of Maintenance Parts/Materials Oil onsumption orrective Maintenance Troubleshooting Tips Service Log Technical elivery Log Warranty Terms nvironmental Guidance and Recomendations nclosed ocument: Hidrostatic Test Sheet/Instruction lectric Motor

3 WLOM TO TH WORL O SHULZ THNOLOGY INSTRUTION MNUL SRW IR OMPRSSOR SRP 0 SRP 00 SRP 00 SRP 00 ongratulations on your purchase of a SHULZ quality product. company with a Quality System certified: environmental management system: INTROUTION Instruction Manual ISO 900 ISO 00 Scope of supply - design, development and manufacture of air compressors and pressure vessels for compressed air - Joinville s plant - razil. The design, inspection and manufacturing of your SHULZ receiver is according to SM, Section VIII, iv.. SHULZ products blend high technology with easy use. Warranty PLS R THIS MNUL RULLY. It will help you guide you in the installation, use and maintenance of your equipment. If you encounter a question that is not answered by the manual, please feel free to contact your nearest SHULZ uthorized - Technical/istributor for assistance. To maintain the SHULZ warranty and to ensure your equipment's safe operation, the exclusive use of SHULZ original parts and oil SHULZ LU SH 6 lubricant is required. Repairs ny repairs must be made by SHULZ uthorized-technical/istributor. ollowing any repair or maintenance, make the appropriate annotations in the equipment Service Log supplied in this manual (page 9). Inquiries When addressing questions to the SHULZ service center, please refer to the model and serial numbers of your machine. They can be found on the air end and inside the electrical control cabinet. Installation It is the end user's responsibility to install, inspect, maintain, operate and provide specific documentation for the compressor and air/oil receiver as required by applicable federal, state and local legislation OMPRSSOR INSPTION Immediately inspect your compressor for both obvious and unseen freight damage. Report this to the freight company immediately! Repair any freight damage before operating the air compressor. US SHULZ air compressors are designed for the compression of atmospheric air only and within the pressure parameters indicated in the SHULZ literature.

4 ROTRY SRW OMPRSSOR STY WRNING Keep these Instructions SRP 0 - SRP 00 - SRP 00 - SRP 00 Improper installation or improper use of this equipment can result in personal injury and material damage. In order to avoid injury or damage, please adhere to the following recommendations:. This equipment presents the following hazards: - extremely hot parts, energized electrical components, compressed air parts and moving parts; - the compressor has high and dangerous voltage in the motor, the starter and control box. ll installations must be in accordance with recognized electrical procedure. efore working on the electrical system, ensure that the system s power has been shut off by use of a manual disconnect switch. circuit breaker or fuse switch must be provided in the electrical supply line to be connected to the compressor. The preparation work for installation of this unit must be done in suitable grounds, maintenance clearance and lighting arrestors for all electrical components. - turns on or off automatically relative to system pressure or actuation of the thermal protection elements; - may cause mechanical or electrical interference in nearby equipment; - installation must be protected from access by unauthorized persons, children or animals; - operate and maintain this equipment with appropriate supervision and appropriate use of personal protective equipment; - unit must be installed and operated in well ventilated areas with protection from elements;. Never attempt to exceed the maximum operating pressure indicated on the compressor.. o not attempt maintenance before disconnecting the electrical power supply.. o not adjust the safety valve and pressure switch. They are permanently adjusted at the factory.. o not attempt to repair or air/oil receiver. ertification and operation receiver may be adversely affected. onsult your SHULZ uthorized-technical/istributor. 6. Never run the air/oil receiver above the maximum pressure indicated in its identification tag. 7. The end user must have a new inspection in the air/oil receiver carried out after years from the manufacturing date shown in its identification tag. This inspection must be made and approved by an authorized engineer (skilled professional), according to local technical norms. We recommend the replacement of the receiver for a new one every ten years. 8. ir compressing is a heat generating process. Surfaces and parts are subject to high temperatures, therefore, to avoid burns, be careful when handling them. 9. The compressed air would contain damages contaminants to the human, animal, ambient or nourishing health, among others. The compressed air must be treated with adjusted filters, as requisite of its application and use. Get more information about it at Schulz uthorized- Technical/istributor or the factory (sales@schulzamerica.com). 0. efore connecting the compressor re-fastening of the electrical conection.. Keep the refrigeration air inlet always clean, to prevent the propeller from sucking remains (item 6, igures up to 6, pages and 6).. Never use solvent to clean the compressor's internal/external parts. Use neutral detergent.. Never activate the safety valve if the compressor is operating/pressurized, to avoid burns.. void the accumulation of solvents, paints or other chemicals that can cause explosion risks, or compressor damage.. o not carry out maintenance jobs with the compressor on. or safety reasons, press the emergency button 8 (igures to 7, page ) located in the instrument panel. 6. If the equipment shows any irregularities, stop its operation immediately and get in touch with the nearest SHULZ uthorized-technical/istributor.

5 THNIL T WORKING PRSSUR IR LIVRY RPM RIVING MTHO MIN MOTOR N S MOTOR ONTROL VOLTG TMPRTUR IR RRIGRT OMPRSSOR OIL LURINT IR OUTLT PIPING SIZ WIGHT MOLS SRP 0 SRP 00 barg/psig cfm l/min Male rotor hp / kw Voltage (V) RPM - requency (Hz) Start Mode hp / kw Voltage (V) RPM Vca llowed ambient temperature ischarge air temperature ir intake dimension (inch) ir outlet dimension (inch) ap (gal) enomination IN Kg/lb /08 9,67 8.6/,0 irect Start 0. / /60,7 6,0,900,0 V - elt ( VX x ) / / 60, /08 8.6/ ,78,0,78 8,00 7,990 7,00 VX x 0 / 08-0 / 60, / inlet air temperature + 0 inlet air temperature + 0 inlet air temperature x x / irect Start - inlet air temperature x.7.9 SHULZ LU SH 6 7 x 6 SHULZ LU SH 6 / 00 / / 6 WORKING PRSSUR IR LIVRY RPM RIVING MTHO MIN MOTOR N S MOTOR ONTROL VOLTG TMPRTUR IR RRIGRT OMPRSSOR OIL LURINT IR OUTLT PIPING SIZ WIGHT MOLS SRP 00 SRP 00 barg/psig cfm l/min Male rotor hp / kw Voltage (V) RPM - requency (Hz) Start Mode hp / kw Voltage (V) RPM Vca llowed ambient temperature ischarge air temperature ir intake dimension (inch) ir outlet dimension (inch) ap (gal) enomination IN Kg/lb /08 8.6/ /60 7./08 8.6/ 97 8,,70,77 6, 6,000,,800,0,00,00,00,700 V - elt (VX x ) POLY V (8L) 0 / / 60,0-60 irect Start inlet air temperature + 0 / 90 / 88 0 / / 60,0-60 Star-elta Start inlet air temperature x 0 7 x 6 / inlet air temperature + 0 inlet air temperature x 8 x SHULZ LU SH 6 SHULZ LU SH 6./ 790 / 78 TL - THNIL T

6 ROTRY SRW OMPRSSOR SRP 0 - SRP 00 - SRP 00 - SRP 00 THNIL T W H L 8in / m IGUR IGUR Models SRP 0 SRP 00 SRP 00 SRP W L H.. 6. * imensions (in).

7 7 9 MIN OMPONNTS Thermostatic valve. elt tensiometer 6. ooling air inlet 7. Safety valve 8. Receiver 9. Hot air outlet 0. Oil replacement plug. Oil level sight gauge. Oil drain valve. ir/oil separator element. elt guard. ox with fan 6. Relief valve IGUR - SRP 00 IGUR - SRP 0. ftercooler. abinet. Minimum pressure check valve. ir/oil receiver. ir filter/air inlet valve 6. Pulley 7. elt 8. Pulley (motor) 9. lectric motor 0. Oil filter. ir end. ontrol panel. Instrument panel (igures up to 7, page ) 9

8 ROTRY SRW OMPRSSOR SRP 0 - SRP 00 - SRP 00 - SRP 00 MIN OMPONNTS IGUR - SRP IGUR 6 - SRP ftercooler. abinet. Minimum pressure check valve. ir/oil receiver. ir filter/air inlet valve 6. Pulley 7. elt 8. Pulley (motor) 9. lectric motor 0. Oil filter. ir end. ontrol panel. Instrument panel (igures up to 7, page ). Thermostatic valve. elt tensiometer 6. ooling air inlet 7. Safety valve 8. Receiver 9. Hot air outlet 0. Oil replacement plug. Oil level sight gauge. Oil drain valve. ir/oil separator element. elt guard. ox with fan 6. Relief valve

9 INSTLLTION. Location: Install the compressor in a covered, well ventilated area, free from dust gases, toxic gases, humidity or any other sources of contamination. The presence of contaminants in the air (dust, fibers, etc.) may cause premature obstruction to the air filter and the air/oil after-cooler (please see chapter on Preventive Maintenance, pages 0 and, items.. and ). hemical gases may pass through the air inlet filter and contaminate the oil, causing lubricating problems and diminished air quality. or installation in highly contaminated areas, a heavy duty remote air inlet filter kit can be purchased and installed. (onsult your SHULZ uthorized-technical/istributor for price and 0 0 availability). The maximum recommended working ambient temperature is 0 (0 ). Should temperature be higher, exhaust fans or must be provided in order to bring ambient temperature to its required level. The lower the temperature, the better the compressor's working conditions. The installation of a hot air duct from the compressor's cooling air outlet may be installed. are should be taken to insure that NO IR LOW RSTRITION is created. onnection to the compressor cabinet must also be accomplished in such a manner as to insure the ease of maintenance. (onsult your SHULZ uthorized-technical/istributor for assistance and recommendations). TTNTION o not install the compressor in chemically hazardous areas.. Position Place compressor a minimum distance as igure, page from any wall or obstacle to facilitate adequate air flow and ease of maintenance.. Mounting Remove compressor from pallet and crating and place it on a level concrete floor. It is not necessary to install antivibration devices or to anchor the frame to the floor.. lectrical onnection To change the compressor voltage: call to the authorized technical assistance or the nearest Schulz dealer. IMPORTNT The voltage changing need to be realized by qualified people. efore connecting electrical power supply it is recommended that internal electrical connections be checked for security following shipping. onsult a licensed electrician to evaluate power supply and install appropriate electrical connections for your air compressor. Your compressor must be installed in accordance with federal state and local electrical codes. Wiring must be sized appropriately to accommodate in-rush current and distance to power supply (See Table, page 0). fused disconnect (with timed delay fuses)should be installed near the compressor (see Table ). TTNTION lways check if the transformer's capacity can stand the compressor's power. If a separate transformer is not available, check whether the energy supply and main circuit breakers can stand a voltage load increase. The electrical power supply should not have a voltage variation greater than ± 0%. The voltage drop caused by the motor's start up should not exceed 0%. The frame of the compressor should be grounded appropriately. Terminal block power supply: supplies compressor according to nominal voltage indicated in the start switch cabinet. The motor starter configuration includes a thermal overload relay for the protection of the compressor and fan motors. igures 7 to 8, pages 8 to 9, shows the power and command electric circuit and the control panel layout for all compressors models. On page 0 there are some guidelines and diagrams and for the capacitors installation ontrol voltage for all models is Vac. USS TL - USS MOL VOLTG 08-0 V VOLTG 60 V SRP 0 SRP 00 SRP 00 SRP

10 ROTRY SRW OMPRSSOR SRP 0 - SRP 00 - SRP 00 - SRP 00 INSTLLTION 6 K M ~ In:,0 TO 08V In: 0,6 TO 0V In: 0, TO 60V T 0V/00V INPUT VOLTG= 08V V/7V OMMN TRNSORMR ONNTIONS OR OTHR VOLTGS T 0V/00V INPUT VOLTG = 0V V/7V T 0V/00V INPUT VOLTG = 60V V/7V 6 POWR IRUIT SRP 0 - IRT STRTR IGUR 7 8

11 OMMN IRUIT SRP 0 - IRT STRTR IGUR 8 ROM POWR IRUIT V K XS. XS. PR H MR 0V 0V K 6 XS. XS. INSTLLTION K P P X.7 N T X.8 S K Kt 6 K K K X.9 X.0 S K Kt 6 ROM POWR IRUIT V K K XS. H V XS.0 X X KT XS. X. H R X X K VS (N) X. X. PURG X.6 K 6 8 X. VS (N) X. KP XS. H VM 6 X X KP 8 TRM K KT K KT XS. H M X X 6 9

12 0 IGUR 9 LYOUT OMPONNTS SRP 0 - IRT STRTR LS,,,,, 6 e 9. KP KT// T X K K W0 K W0 X LS 7 e 8. TG K K K T KT/KT KT X X PNL / KP XS XS XS SRIPTION POLS ONTTOR V 60Hz TYP: WM0. UXILIRY ONTTOR V 60Hz TYP: W0. UXILIRY ONTTOR V 60Hz TYP: W0. TRO. MONO.00+7V PRIM.08/0/60V-S./0V TIMR RLY V 60Hz TYP: RTW R.0-0 TIMR RLY V 60Hz TYP: RTW R OMMN ONNTORS POWR ONNTORS GLVNZ STL PLT x 0 mm LY GLSS USS LY GLSS USS THRMI RLY PROTTION OR PT TYP: RPW V PT SINL ONNTOR pç In: - 0V SINL ONNTOR pç In: - 0V SINL ONNTOR pç In: - 0V 6 6 INSTLLTION ROTRY SRW OMPRSSOR SRP 0 - SRP 00 - SRP 00 - SRP 00

13 POWR IRUIT SRP 00 - IRT STRTR IGUR 0 INPUT VOLTG = 08V T 6 TO OMMN IRUIT INSTLLTION TO OMMN IRUIT OMMN TRNSORMR ONNTIONS OR OTHR VOLTGS T INPUT VOLTG = 0V K T INPUT VOLTG = 60V M ~ In: 66, TO 08V In: 9,9 TO 0V In: 0,0 TO 60V 6

14 OMMN IRUIT SRP 00 - IRT STRTR IGUR ROM POWR IRUIT V ROM POWR IRUIT K K KT 6 V K XS. V H XS.0 X X K KT 6 XS. R H X X P K K X. VS (N) X. P K K KT 8 X. VS (N) X. 6 XS. H Z X X KP 6 XS. VM H 6 X X T N KP TRM 8 X. X.6 X.7 X.8 K K S S XS. XS. K K KT 6 KT K H KT PR MR XS. M H X X INSTLLTION ROTRY SRW OMPRSSOR SRP 0 - SRP 00 - SRP 00 - SRP 00

15 IGUR LYOUT OMPONNTS SRP 00 - IRT STRTRS LS,,,,, 6 LS 7 e T X K W0 K W0 TG K K/K T KT/KT KT X PNL KP XS XS SRIPTION POLS ONTTOR V 60Hz TYP: WM80. UXILIRY ONTTOR V 60Hz TYP: W0. TRO. MONO.7V PRIM.08/0/60V-S.V TIMR RLY V 60Hz TYP: RTW R.0-0 TIMR RLY V 60Hz TYP: RTW R OMMN ONNTORS GLVNZ STL PLT x 0 mm LY GLSS USS LY GLSS USS THRMI PROTTION RLY OR PT SINL ONNTOR 0V - 6pç SINL ONNTOR 0V - pç INSTLLTION KT KT KT KP K WM0 6

16 POWR IRUIT SRP 00 - IRT STRTR IGUR R S T K M ~ In: 9, TO 08V In: 86, TO 0V In:, TO 60V T 0v 0v 0v INPUT VOLTG = 08V K T M ~ In: 0, T V R S T RS 0V 6 TO OMMN IRUIT TO OMMN IRUIT OMMN TRNSORMR ONNTIONS OR OTHR VOLTGS T INPUT VOLTG = 0V T INPUT VOLTG = 60V 6 INSTLLTION ROTRY SRW OMPRSSOR SRP 0 - SRP 00 - SRP 00 - SRP 00

17 OMMN IRUIT SRP 00 - IRT STRTR IGUR 6 V INSTLLTION XS. K H PR MR XS. T N K 6 6 K K P P KS 8 X.7 X.8 S K 6 KT K K K K T KP X.9 97 S K X.0 KT K K V K X. VS (N) X.6 K XS. H V XS.0 X X KT XS. H R X X X. VS (N) X. KT X. VS (N) X. 6 8 XS. H Z X X KP XS. H VM X X TRM T 9 96 K KT K KT XS. H M X X 6

18 / PRIM. ONTR LIG. S. ONTR 08V V 0V V 60V LIG IGUR LYOUT OMPONNTS SRP 00 - IRT STRTR LS 7 e 8. LS,,,,, 6 KT KT KT K T - T X,, KP KS K K T K X0 TG K K K/K T T KT/KT KT X PNL KP KS XS XS K T 6 SRIPTION POLS ONTTOR V 60Hz TYP: WM0. POLS ONTTOR V 60Hz TYP: W07.0 UXILIRY ONTTOR V 60Hz TYP: W0. TRO. MONO.7V PRIM.08/0/60V-S.V UTOTRO. TRI. 00V PRIM.08/0/60V-S.0V TIMR RLY V 0/60Hz TYP: RTW R.0-0 TIMR RLY V 0/60Hz TYP: RTW R OMMN ONNTORS GLVNIZ STL PLT 0x67mm LY GLSS USS LY GLSS USS THRMI RLY PROTTION OR PT - V ULT N SQUN PHS RLY 0V SINL ONNTOR In: 0V 6pç SINL ONNTOR In: 0V pç LY GLSS USS 6 POLS ONTTOR V 60Hz TYP: W07.0 THRMI RLY RW7. - N: 0,...0,6 6 INSTLLTION ROTRY SRW OMPRSSOR SRP 0 - SRP 00 - SRP 00 - SRP 00

19 POWR IRUIT SRP 00 - LT / SRT STRTR IGUR 6-08/0/60V R S T INPUT VOLTG = 08V T 6 INSTLLTION T 0v 0v 0v T INPUT VOLTG = 60V K 6 K 6 K 6 K 6 R S T KS 0V T t INPUT VOLTG = 0V V U W U W V U V W M P M P OMPRSSOR MOTOR "M" In: 8, PR 08V In:, PR 0V In: 7,6 PR 60V N S OMPRSSOR In:,6 6 7

20 8 OMMN IRUIT SRP 00 - LT / STR STRTR IGUR 7 K 6 XS. XS. PR H MR P V T/TR T VM 6 H KP KS 8 T/TR M 8 9 a a 96 KP H X.8 X.7 K 6 a a S KT KT K K a a K6 K6 6 a a K S X.9 X.0 (N) P P X. X. (N) K K6 VS X. X.6 Z K VS XS. H KT K (N) a a K6 X. VS X. KT 6 K R XS. H K V P a a XS. K H KT a a K K 8 a a K a a K a K KT KT K K 6 a 8 6 K INSTLLTION ROTRY SRW OMPRSSOR SRP 0 - SRP 00 - SRP 00 - SRP 00

21 PRIM. 08V 0V 60V ONTR LIG S. V ONTR LIG. 7-8 / 0 IGUR 8 LYOUT OMPONNTS SRP 00 - LT / STR STRTR 6 X, "" LS,,,,, 6 KT// KP K K6 K TG K-K K PNL X0 SRIPTION POLS ONTTOR V 60Hz TYP: WM9. POLS ONTTOR V 60Hz TYP: WM6.00 PL MONT. M HP ÇO ZIN 60 x 0mm X OMMN ONTORS T KT KT KT POWR ONNTORS THRMI RLY RW7. - N:,8... TIMR RLY V 0/60Hz TYP: RTW R.0-800Seg Vca TIMR RLY V 0/60Hz TYP: RTW T.0-0Seg Vca TIMR RLY V 0/60Hz TYP: RTW R.0-0Seg Vca INSTLLTION T T K K/6 / KS T T KP POLS ONTTOR V 60Hz TYP: W07.0 UXILIRY ONTTOR V 60Hz TYP: W 0. LY GLSS USS LY GLSS USS 6 ULT N SQUN PHS RLY 0V TRNS. MONO. OMNO 0V 08/0/60 - V UTOTRO,6KV 08/0/60-0V THRMI PROTTION RLY OR PT - V L 7 T LS 9, 0 L KS K K K X

22 ROTRY SRW OMPRSSOR SRP 0 - SRP 00 - SRP 00 - SRP 00 INSTLLTION mm²,0,,,0 6, WYS TO INSTLL Maximun istances for Voltage rop % (meters) UILT IN URRI HUT UILT IN HUT Maximun istances for Voltage rop % (meters) mm² xample: Motor s current (0V) - mm² cable section maximun distance found 66 meters. WYS TO INSTLL WLLS POLS 0 TL - ORINTTION TL OR OPPR LS

23 INSTLLTION INSTLLTION O PITORS Power actor orrection rational and economic way to obtain the necessary reactive energy for your compressor's proper operation is the installation of capacitors next to it. The capacitors installation, however, must be preceded by operational measures that reduce the reactive energy necessity, as the switching off of motors or other idle inductive loads. The advantage of the power factor correction is a meaningful voltage improvement. RS URING INSTLLTION O PITORS Installation location: - void sun exposure or installation near high temperature equipment; - o not block cabinets' air inlet and outlet; - Locations must be protected against suspended solid and liquid materials (dust, oil, etc); - void capacitor installations next to the ceiling (heat); - void capacitor installations next to non linear loads. PROTTION GINST SHORT IRUITS uses: esign fuses according to equation: In x.6 NOT: "In" capacitor's plate datum Use the commercial value of immediately superior retarded type fuse. onductors: Use conductors over-designed in. times the capacitor's nominal current and take into consideration other criteria such as: the way to install, ambient temperature, etc. NOT: The installation of capacitors to correct the power factor shall be made by a certified professional. See in the iagrams and bellow, the proper way to connect the capacitors during the installation of your compressor. K K K K 6 6 M ~ 6 6 M ~ iagram - Y / elta Start IGUR 9 iagram - irect Start IGUR 0

24 ROTRY SRW OMPRSSOR SRP 0 - SRP 00 - SRP 00 - SRP 00 INSTLLTION. ir distribution ball valve is supplied with the compressor for connection to the air distribution network. To maximize air delivery to point(s) of use, air distribution piping diameter should be no smaller than the air outlet diameter. o not use air line filters or regulators whose ports are smaller than the air piping diameter. In smaller systems it is recommended that an air receiver (condensed separator) be installed. It should have a minimum storage th capacity that is equal to or greater than / of the capacity (in gallons/liters per minutes) of the compressor. Installing an air receiver in this manner will significantly reduce the interval of the demand fluctuations within the control system of the compressor. If SRP,000 series compressors are properly sized for a facility, the installation of a receiver is not necessary. However, a good compressed air network design always includes the installation of a receiver in order to cushion control fluctuations caused by erratic air consumption, gather condensed water and to maintain an adequate air supply during consumption peaks. We recommend that the installation, at the compressor's outlet, include an auxiliary air outlet with a hose and nozzle to clean the cooler and other tasks which may require the use of local compressed air. or more information and guidance in the design of your air distribution system, please consult your SHULZ uthorized - Technical/istributor. IMPORTNT To maintain compressed air quality, do not locate condensed separator, filters or refrigerated dryers in vicinity of cooling air exhaust stream (See igure ). OMMON INUSTRIL IR PR-ILTR N RY INUSTRIL IR LN N RY INUSTRIL IR Network. SRW OMPRSOR. ONNS SPRTOR. PS 6 LTRONI RIN. OLSNT PR-ILTR. IR RYR Y RRIGRTION 6. OLSNT POST-ILTR 7. TIVT HROL ILTR (Y SORPTION) 8. HOS/ XPNL JOINT ir quality according to ISO 87. Norm lass.. RMRK.: or others configurations, please consult the factory. Note: arry out the other components maintenance, according to their instruction manuals. IGUR - OMPRSSOR S TYPIL INSTLLTION WITH TTHMNTS OR OMPRSS IR TRTMNT. Note: Installation expenses and accessories are the customer s responsability.

25 WORKING PRINIPLS 0 IGUR - IR N ir end The main parts of a air end are: Unit's body. Two screw rotors, and, operating on ball bearings on body, a discharge flange and a ball bearing cover 6. The driving shaft is retained by a seal. - IGUR - IR/OIL LOW

26 ROTRY SRW OMPRSSOR SRP 0 - SRP 00 - SRP 00 - SRP 00 WORKING PRINIPLS. ir low (igure, page ) When the motor is started, power is transmitted to the air end by pulleys and belts. The rotation of the screws creates a vacuum and the air production cycle begins when suction occurs. The [atmospheric] air flows through filter (item ) and enters in the air end (item ) [radially] through the holes located in the inlet control valve (item ). ir compression [axial] is accomplished as air is forced between the lobes of the screws (rotors) and the air end housing. ir is then forced through the discharge port. IGUR - IR N WORKING uring this start sequence, the air end is lubricated by residual oil. (See oil flow description). ir suction through the partially opened inlet control valve does not require the full power of the motor. Initial air compression at start-up (minimal pressure) and the minimum pressure valve facilitate the rapid pressurization of the air/oil receiver (item ) causing, by positive pressure, the flow of lubricant (item ) into the air end. t the discharge of the unit, the compressed air, mixed with lubricant oil, is introduced tangentially and at high velocity into the receiver. Here, the centrifugal force separates the [denser] oil from the air. ue to its density, the oil settles to the bottom of the receiver. The compressed air and residual oil then passes through the separator element (item 6). ue to the selectively restrictive nature of the filtering media the air flows freely through the element and the oil loses its velocity and falls to the bottom of the air-oil separator (item 7). In a few seconds the internal pressure of the receiver rises to.7 to. bar ( to 0 psig), the motor is operating at its' nominal rotation and the air can be introduced and compressed at full capacity with the inlet control valve (item ) completely open. or compressors with starting method star-delta, it is at this point that the star-delta starting system introduces full voltage to the electric motor. With the inlet control valve totally open and the air being compressed at full capacity, the pressure in the receiver rises rapidly and overcomes the spring tension which maintains closure of the minimum pressure valve (item 8) and the air passes through the after-cooler (item ) and into the compressed air network. The minimum pressure valve has the following functions:. Operates as a check valve, preventing network air from re-entering to the air-oil receiver of the compressor when it is off or modulated;. Maintains minimum pressure of about. bar (0 psig) to ensure adequate lubrication;. Maintains minimum pressure to prevent inappropriate oil consumption rate.. Oil low (igure, page ) There is a residual quantity of oil present in the air end. This residual oil provides lubrication for the first few seconds. Once the compressor starts and pressure of around.0 bar (0 psig) is achieved in the air-oil receiver, the positive pressure (item ) forces oil into the air end thereby insuring lubrication. 0 uring the first few minutes of operation the oil will not be heated to its ideal working temperature (80 to 90 or 0 76 to 9 ). In order to rapidly achieve the desired temperature, the oil circuit has a thermostatic valve (item 0) with two circulation routes. 0 0 elow 80 or 76, the oil flows into the compressing unit through an oil by-pass (item ). The thermostatic valve (item 0) prevents oil flow through the oil cooler. The oil warms up quickly from the heat of compression and very quickly reaches the ideal operating temperature.

27 WORKING PRINIPLS 0 0 t 80 or 76 the thermal element expands, displacing the piston inside the valve that progressively closes the oil by-pass (item ) and allows oil flow through the oil cooler (item )., 0 In addition to rapid warming of the oil the thermostatic valve prevents oil cooling to temperatures below 80 or y regulating oil flow through the cooler and the by-pass, the valve ensures that all the oil injected into the air end is at the ideal working temperature. This reduces the condensation of water vapor in the separator and receiver which maintains the quality of the oil and reduces air system contamination. The oil from the two circulation routes (cooler and by-pass) mixes and is filtered (item ) before being injected into the compressing unit. The oil deposited at the bottom of the separator element is continuously evacuated back to the inlet side of the air end. INSTRUMNT PNL IGUR - INSTRUMNT PNL - SRP IGUR 7 - INSTRUMNT PNL - SRP IGUR 6 - INSTRUMNT PNL - SRP 00 N SRP 00. Pressure gauge - to show pressure in the network. Thermometer discharge temperature. ON button ( green), O button ( red). Indicator light - to indicate if the compressor is energized. Indicator light - to indicate if the compressor is in operation 6. Indicator light - to indicate if the compressor is unloaded 7. Indicator light - to indicate overload electric motor overload 8. mergency shut off button 9. Hourmeter 0. Separator differential pressure gauge. Oil filter differential pressure gauge. Indicator light to indicate if the compressor is in partial load. Quick instructions

28 ROTRY SRW OMPRSSOR SRP 0 - SRP 00 - SRP 00 - SRP 00 ONTROL SYSTM VS VS IR IR + OIL OIL - INPUT ORIIS SYSTM S SUPPLY HOLS WHN IN RLI - TIMR IGUR 8 - ONTROL SYSTM 6 The compressor operates with a double control as follows: OMPRSSOR ONTROL T ULL LO. When the pressure rises attaining the adjusted value in the pressure switch P, it de-energizes the solenoid valve of the by-pass VS closing the control way which maintained the intake valve totally open. OMPRSSOR ONTROL T TH PRTIL LO. In this control phase, the intake valve will be closed, stopping the full flow of air in the suction, but the air continues to be taken in by the holes "" called by-pass. s the passage section of these holes is small, it reduces the volume of air taken in, and consequently the power due to reduction of the flow of mass to be compressed. The compressor starts to deliver to the air network approximately 0% of its total suction capacity.. With the reduction of the air taken in, the power of the motor required to maintain the system is also reduced, and so it is possible to increase the final work pressure in this control phase.. The exit of the compressor from this control system, and the return to operation at full load, only occurs if the consumption is greater than the production of the compressor (0% of the total), because it causes the pressure in the system to drop and the return of the compressor to its previous working status, i.e. at full load.. Operating at full load, if the air consumption is lower than the production of the compressor, the pressure will slowly rise (above the pressure indicated in barg/psig in Table Technical ata, page ) and then the compressor will start to operate in the partial load system. If there is no air consumption, it will operate in the unloaded system. OMPRSSOR ONTROL UNLO. ven taking in air via the by-pass the pressure in the system may increase up to the adjusted value in the pressure switch P, where it will de-energize the solenoid valve VS closing it, which in turn will drain the air which maintained the relief valve closed, allowing the release of compressed air.. With the relief valve open, it will start the depressurization of the receiver up to the volume taken in by the bypass holes entering into balance with the volume of air drained by the relief valve, equaling the pressure in the receiver between. and. barg (0 and 60 psig) necessary to ensure lubrication in the system, reducing the power required.. In this control phase the compressor will not produce air for the network. If there is consumption at this moment, the pressure may be reduced in the system, causing the solenoid valve VS is energized by the pressure switch P and returning the compressor to partial load.. If there is a pressure drop because of an increase in consumption, the solenoid valve of the by-pass VS will be energized by the pressure switch P, returning the compressor to full load.

29 ONTROL MO The compressor runs at full load and it starts to unload as soon as the maximum work pressure is reached. The time it remains unloaded is adjusted through " KT" minute timer, located in the electric panel, according to the air network's behavior. The motor can have up to 0 starts per hour, but it is not economically viable. We recommend that the timer's minimum adjusting time should be of 6 minutes. If during this time there is no consumption that causes pressure to drop from.0 to. bar ( to 0 psig), the compressor will switch off. It will return as soon as this pressure drop occurs. If the above mentioned pressure drop occurs, the compressor starts operating at full load. The " KT" minute timer's adjustment is at the customer's choice, depending on the air network behavior. When the off button * ( red) is pressed, the compressor starts to unload, after the time adjusted in " KT" timer. The motor's switching off will occur right after. or safety reasons, your compressor is supplied with emergency button 8* that, when pressed, will switch off the equipment immediately. To re-start the compressor, turn the button (see orientation arrow on it) to release it and, right after, press the on button * ( green). * See igures to 7, page. THNIL LIVRY fter all the compressor is installed and connected as per the customers requirements, the compressor must be started in the presence of a representative of the nearest SHULZ uthorized-technical/istributor. This technician will validate the Warranty as required by SHULZ and will guide the customer on starting procedures, and provide owner/operator training in the compressor's operation and preventive maintenance. The compressor's warranty will be validated and the warranty period initiated only a) upon production of the Technical elivery report provided by SHULZ uthorized-technical/istributor during the first start procedure - one copy of which will remain with the customer and b) the filling in of the Technical elivery Log (page ) which will be sent to the factory by the technician. Instructions contained in item "" of the Warranty Terms (page ), under General Warranty onditions, must be followed. STRT PROUR SRP,000 series compressors are tested in the factory and supplied with SHULZ LU SH 6. efore the compressor s initial start, check the belt s strain (igure 0, page 9), re-fasten the connections of the hydraulic circuit hoses and of the electric! X contacts, then, turn on the air dryer minutes before starting the compressor (when installed). irst start procedure:. Open the cabinet's left side door (facing the panel) and check the oil level; the oil level sight (item, pages and 6) must be covered;. If the ambient temperature is different from specifications, change to screw compressor lubricant oil consult your SHULZ utorized-technical/ istributor.. Indicator light (item, page ) of the instrument panel must be on showing IGUR 9 that the controls are energized;. lose the air outlet valve;. heck Rotation by quickly pressing the Start Key ( green) to switch on the compressor and immediately pressing the emergency stop ( red) button, switching the compressor off and observing the direction of rotation. It must be in the direction indicated by the arrow located in the air end casting or the belt guard. The rotation of the cooling fan must be checked as well. The correct air flow is toward the cooler. Notes: If the rotation is incorrect, disconnect input power from the compressor and interchange two of three main cables on terminal board installed in the control box. Repeat procedure.. fter making sure that the rotation direction is correct, close the side door and press the Start Key (green) to run the compressor again, keeping the valve closed until the compressor reaches its maximum pressure and starts to unload. Slowly open the valve and your rotary screw air compressor is now ready to supply compressed air to the network. Note: The air dryer should already be turned on. 7

30 ROTRY SRW OMPRSSOR SRP 0 - SRP 00 - SRP 00 - SRP 00 STRT PROUR IMPORTNT - The compressor should never run with its doors open for more than three () minutes. - In the first start, the motor must not work for more than three seconds () with the inverted rotation. Item is accomplished quickly and will be easily observed. In case of problems during the start-up, consult the Troubleshooting Tips hapter, page. - In emergencies, press the emergency button 8 (page ) that will switch off the compressor. - The emergency button must only be used when the compressor needs to be stopped immediately. Its use under normal conditions will cause failure in the equipment. This is not covered by the warranty. - In normal operations, use the Stop Key (red) on the instrument panel, where a timed unload will occur before the compressor stops. 6- Under no circumstances allow the compressor to function without the short circuit protection. STOP PROUR. lose the air outlet valve;. To switch off (manual stop), press the stop key/button ( red) located in the instrument panel, when the timed unload will occur before the compressor s full stop. PRVNTIV MINTNN. ILY. heck oil leaks.. heck unusual noise or vibration.. Monitor gage and indicators for normal operation.. or receiver mounted compressor, check the functioning of the electronic drain. If it does not work, use the stopcock located in the lower part of the air receiver. 8. WKLY. WITH TH OMPRSSOR TURN O:.. Verify the oil level:... Wait for at least minutes after turning off the compressor so that the oil which there is in the circuit returns to the receiver... If the oil level sight is completely or partially filled up, the level is suitable. Otherwise, proceed as follows:... nsure that there is no pressure in the air/oil receiver, slowly opening the filling plug 0, pages and 6;... Top up the level, filling all the oil level sight. Note: do not exceed this limit, or oil may be taken into the network;... Install and tighten the plug. It is not necessary to tighten it a lot, as the plug is self-sealing. IMPORTNT - If working temperature is consistently over 9 (90 ), reduce oil change interval to 0% of the recommended... Verify the tension of the belts and, if required, adjust them according to the instructions: ) or compressor with automatic belt tension device (igure 0, page 9): - Remove the belt guard; - Loosen the lock-nut ; - Turn the adjustment nut to increase or reduce the tension of the belts according to the table of the igure 0, page 9; - Lock the position of the nut tightening the lock-nut. This procedure should be executed with the aid of (two) wrenches; - ssemble the belt guard.

31 PRVNTIV MINTNN ) or compressor without automatic belt tension device: - Loosen screws ( pieces). - Loosen the lock-nut. - Tighten screw to stretch the belt. - Partially tighten screws until they touch the plate and check belt s tension according to table bellow. - If belt s tension is right, tighten screws and the lock-nut ; if not, repeat procedures above. SL.00 Maintain at least (/8 ) LIGNMNT RULLR IR N PLT LTION STRIN With automatic belt tension Without automatic belt tension MOLS SRP 0 SRP 00 SRP 00 SRP 00 TNSION N (Newton) Min Máx Min lbf Máx. 0 X (cm) IGUR 0 - LTS TNSION... In the order to measure the force, use a tensiometer-code , which should be aequired from the nearest Schulz uthorized-technical/istributor.... Use an appropriat level ruller to align the pulleys. If the alignments is incorrect, get in touch with Schulz utorized-technica/istributor. 9

32 ROTRY SRW OMPRSSOR SRP 0 - SRP 00 - SRP 00 - SRP 00 PRVNTIV MINTNN IMPORTNT - When the tension of the belts(s) is incorrect, they will overheat and slip. squealing sound may be noticed. - nother way to check the belt tension is to monitor the air end's rpm and observing its variation. - The belts must be replaced when they show signs of wear or when there is difference in belt tension (see table igure 0, page 9). - o not remove the safety nut and lock-nut.... heck the air filter restriction: If indicator (item, igure, page ) is red, or if it has been used for,000 hours (whichever occurs first) change air inlet filter (item, igure, page )and unlock the differential pressure indicator (unlocking instructions are given on its body).... rain the condensed (water) from the air/oil receiver weekly, or daily, according to the ambient relative humidity, as follows: - Switch off the compressor and wait for one hour until the condensed water is deposited on the receiver s bottom; - onnect a hose to the drain valve (item, igures and ), open it and collect the condensed water in a container; - lose the valve as soon as the oil starts to flow from the receiver.. WITH TH OMPRSSOR ON: heck operating temperature. It should be between 80 and 90 or 76 and 9. Note: bove 0 or, the thermostat will shut off the compressor due to the overheating. - If working temperature is consistently over 9 (90 ), reduce oil change interval to 0% of the recommended... heck the differential pressure of the air/oil separator element. When the differential pressure gauge (item, igures to 7, page ) reaches psig, change separator element (item, igures and ).. ir/oil separator element. Oil fill in plug. Oil level sight. Oil drain valve. olt 0 IGUR IGUR

33 PRVNTIV MINTNN. VRY,000 HOURS. OIL N OIL ILTR - If the compressor uses mineral oil, change the compressor oil and oil filter every,000 hours. - If the compressor uses synthetic or non-toxic synthetic oil change the compressor oil every 8,000 hours. The oil filter change must occur at every,000 hours. IMPORTNT - If working temperature is consistently over 9 (90 ), reduce oil change interval to 0% of the recommended. - The first oil filter change must be carried out with 00 operating hours. - See Table, item 8, page, compressor operational condition. - hanging oil types is not highly recommended, as chemical incompatibilities can cause damage to the machine. - We recommend the SHULZ LU SH 6 oil. onsult your SHULZ uthorized-technical/istributor for additional information. IGUR - OIL ILTR IGUR IGUR. OIL HNG PROURS... Turn off the compressor and wait for three minutes until the system pressure is depleted.... ttach a hose to oil drain valve (item, igure, page 0), open it and collect the used oil in an approved container. lose the valve when draining is completed.... Open plug and fill compressor with lubricant.... lose the plug as soon as filling is completed.... Turn on the compressor and let it run for about minutes.. R-STNING O TH LTRIL ONNTIONS heck the tightness of all electrical connections in the cabinet. Tighten as necessary.. IR ILTR LMNT (item, igure ) hange the air filter element.

34 ROTRY SRW OMPRSSOR SRP 0 - SRP 00 - SRP 00 - SRP 00 PRVNTIV MINTNN. QURTRLY lean the cooler using compressed air (igure, page ): It must be blown against the fan's flow. Note: Whenever there is high incidence of material deposited inside the compressor or on the cooler's fins, increase the frequency of this cleaning.!. VRY,000 HOURS hange the air/oil separator element (item, igures and, page 0). See table page about how increase the changing interval... INSTLLTION O TH IR/OIL SPRTING LMNT (item, igures and, page 0):.. t the moment of installing the separating element apply a small film of oil to the sealing of the element;.. or external element, assemble the element on the adaptor and turn it until there is a slight tightening. Then give a half-turn to tighten it a little more. Note: o not tighten the element too much, as it will make it difficult to be disassembled... or internal element, change the air/oil separator element* (item, igure, page 0) as following: 7 ispose of the used separator element according to current local norms. llow the compressor to cool down before starting the maintenance job. IGUR 6 Removal - Remove the hose connected to the minimum pressure valve, and take off the oil return pipe 7 unscrewing the connector, igure 6. - Remove the screws that fasten the cover, but keep one of them fastened. - Turn the cover as shown by igure 7. - Remove the separator element 6 located inside the receiver, igure 8, page. Installation - lean the insulation surfaces of the receiver and of the cover and replace the gaskets. - lean the receiver, if necessary. - Install the new separator element 6, making sure it is well coupled. Warning: Take care for do not contaminate the element. Handle the element only metallic parts (top or botton). - ssemble the receiver s cover taking care for that the upper gasket is properly coupled. - lternately in diagonal, tighten the bolts to level strain using and calibrated torquimeter, like recomendation on the adhesive located on receiver. 6- Reconnect the hose and install the oil return pipe. IGUR 7 IGUR 8 6 * It's important to check the sealing gasket of the separator element for a grounding clip (staple)or clamp. If there is no grounding clip the element must be exchanged for an element that has a grounding clip installed.

35 PRVNTIV MINTNN IMPORTNT When installing this element, electrical continuity must be established and maintained between the element itself and the separator receiver. ailure to maintain continuity can result in the build-up of static electricity in the compressor. The spark resulting from the discharge of this static electricity can ignite the air/oil mixture within the compressor resulting in severe damage to equipment and injury or loss of life! 6. NNULLY If required by state or local codes, a technically certified organization must calibrate the safety valve, pressure switch and the pressure gauge(s). If this is not possible, replacement of certified items with new (recently certified) items is an alternative. 7. IR N xperience has shown that it is extremely difficult to estimate the life expectancy of an air end. Routine maintenance of the compressor has been proven to maintain the life expectancy of the roller bearings. ny noticeable change in the air end's noise level should be carefully investigated as it may indicate the need for maintenance. If preventive maintenance procedures are closely followed, bearings will have a life expectancy of 0,000 hours. It is strongly recommended that roller bearings be changed, before they are damaged, because the failure can compromise the rotors and the case. 8. SRVI LOG ny maintenance to your equipment always fill in the Service Log on page 9. Notes: o not clean and reuse filter elements if the number of accumulated operating hours exceeds the prescribed maintenance interval (as indicated in this Manual.) Routine maintenance can be performed by the end user, but any additional maintenance should be carried out by a representative of the nearest SHULZ uthorized-technical/istributor. Operating conditions and demands on the machine may dictate a modification of the maintenance intercal(s). Maintenance intervals must be reduced to 0% in high demand situations or contaminated environments. onsult with your SHULZ uthorized-technical/istributor for additional information as failure to follow these recommendations may cause damage to the compressor and void the Warranty.

36 ROTRY SRW OMPRSSOR SRP 0 - SRP 00 - SRP 00 - SRP 00 PRVNTIV MINTNN PROUR ILLY WKLY VRY 000 h VRY 000 h VRY 8000 h NNULLY WHN RQUIR HK ILUR INITING LIGHTS HK OIL LVL OIL HNG RPL OIL ILTR LMNT RPL IR/OIL SPRTOR LMNT HK SPRTOR LMNT RSTRITION HK OIL ILTR RSTRITION RPL IR ILTR IR ILTR RSTRITION LVL LN OOLR XTRNLLY HK OIL LKG HK STY VLV HK HOSS' ONITION STN ONNTIONS N SRWS HK N STN TH LTRI SWITH ONNTIONS LN OMPRSSOR HK LT TNSION N ONITION HK MOTOR'S RINGS (ORING TO ITS INSTRUTION MNUL) TL () () () (6) IMPORTNT () heck the oil level when the compressor is not running (wait until the air and the oil are separated and that the bubbles (foam) are eliminated, in order to get an accurate oil level checking). () The first time at 00 hours. () Separator element differential gauge. () Oil filter differential gauge. () Quarterly. (6) hange the filter if indicator (igure, page ) shows some restriction. (7) The useful life of the separator element is at least,000 run hours, provided that all the requirements below are satisfied: - installation conditions according to items and of the Installation chapter page 7; - preventive maintenance executed correctly (according to the relevant chapter); - machine operation system (load/relief cycle) not frequent. The deadline for replacing the separator element should always be evaluated by the Technical ssistance which attends to your screw compressor, (recommendations also valid for factory supply of both mineral and synthetic oil). (8) Operational conditions such as, ambient temperature, air/oil radiator obstruction for contamination, air renewal of the house of machine, cleanness of air, oil and separator element filters, can promote air end discharge temperature in levels that modify the useful life of the oil. When the air end discharge temperature be over 9 (90 ), the period of oil change must be modified to 000 hours. (7) (8) () () MINTNN PRTS In order to maintain your warranty and maximize serviceability, your Schulz compressor needs routine maintenance (as outlined in the Preventive Maintenance chapter). The following table shows the parts and code of the maintenance materials that should be purchased from your SHULZ uthorized-technical/istributor.

37 MINTNN PRTS enomination Lubricant mineral/synthetic oil ir filter Oil filter Oil filter element ir/oil separator element elt stretcher Heavy duty filter kit Heavy duty filter Heavy duty element filter primary Heavy duty element filter secondary VX belt (kit) 7. bar POLY V 60 Hz belt SRP / SRP / /X - SRP / /X - SRP TL 6 ISPOSL O MINTNN PRTS/MTRILS When the maintenance is completed, the used compressor oil, used oil filter and the used oil separator element must be disposed of in accordance with local state and federal guidelines. See instructions chapter in environmental guidance and recommendation, page. OIL ONSUMPTION Oil consumption may be increased due to any of the following conditions:. High temperature of operation. If temperature is consistently over 90º or 9º, reduce the normal oil change interval to 0% of recommended life expectancy;. If air/oil separator elements are clogged;. If there is varnish formation: it affects cooling and oil separation. Varnish formation (oil oxidation) can be seen, in metal levels, as a brown varnish/lacquer layer. Note: We suggest not to change the oil type because there might be contamination caused by chemical incompatibility, decreasing the oil's lifetime and causing lubrication problems. ORRTIV MINTNN! In order to guarantee the product's STY and RLIILITY, repairs, maintenance and adjustments must be carried out with original parts by your nearest SHULZ uthorized-technical/istributor. TROULSHOOTING TIPS Listed below are a number of malfunctions/difficulties that may be encountered which may cause the compressor to operate incorrectly or to stop operating completely. Many simple procedures, designed to solve problems, are offered to the operator through the lectronic Interface display. These are valid corrective measures that can be attempted without the need for specialized technical assistance. However, should the problem persist after having tried the established corrective actions, please contact the nearest SHULZ uthorized-technical/istributor.