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Dürr Technik BG-132 Installation And Operating Instructions Manual
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Dürr Technik BG-132 Installation And Operating Instructions Manual

Oil-free compressor station
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Oil-free compressor station
EN
BG-132, 8011100162
Installation and operating instructions
8011100350L02
*8011100350L02*

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Summary of Contents for Dürr Technik BG-132

  • Page 1 Oil-free compressor station BG-132, 8011100162 Installation and operating instructions 8011100350L02 *8011100350L02*...
  • Page 3 Contents Contents Important information Assembly About this document ....Requirements ....Warnings and symbols .
  • Page 4 Contents 12.3 Replacing the handle on the cover ..... . 12.4 Replacing the edge protector . . . 12.5 Replacing the terminal box ..12.6 Replacing the seal for the fan cover .
  • Page 5 Important information The signal word differentiates between four levels Important information of danger: – DANGER Immediate danger of severe injury or death About this document – WARNING Possible danger of severe injury or death These installation and operating instructions rep- resent a part of the unit.
  • Page 6 Important information Safety Specialist personnel Dürr Technik has developed and constructed the Operation units in such a way that danger is to a large Unit operating personnel must ensure safe and extent excluded if the units are used as intended. correct handling based on their training and Nevertheless, residual risks can remain.
  • Page 7 Important information Depending on the application, control systems, Disposal valve units, containers or other accessories are Unit required for safe operation. Dispose of the unit properly and in accor- Transportation and storage dance with applicable national, regional The original packaging provides optimum protec- and local laws.
  • Page 8 Product description Product description Scope of delivery The following items are included in the scope of delivery: Product name ............Article number Oil-free compressor station .
  • Page 9 Product description Overview Unit, exploded view Fig. 1: BG-132 article no. 8011100162 - complete exploded view 8011100350L02 1907V001...
  • Page 10 Seal, cooler side Grid plate, cooler side WASHER A6.4 HEXAGONAL NUT M6 INDEP. Cooler assembly HEXAGONAL SCREW M8 x 16 COMPRESSOR UNIT BG-132 PRESSURE HOSE 500 mm M16 x 1.5-R1/4k Complete fan assembly Filter, fan side Seal, fan side 8011100350L02 1907V001...
  • Page 11 Product description Item no. Description Number Grid plate, fan side Complete terminal box Temperature limiter assembly Heating element assembly EARTH STRAP 20 mm Ø 6.5 EARTH SYMBOL ADHESIVE LABEL, HOT SUR- FACE ADHESIVE LABEL, TRIANGLE WITH LIGHTNING VELCRO BINDER CABLE 300 x ADHESIVE, DELO-ML 5249, 50 0.001 Auxiliary compressor station...
  • Page 12 Product description Housing, exploded view Fig. 2: BG-132 article no. 8011100162 - exploded view of housing Item no. Description Number TENSION LOCK GP 75. HEXAGONAL SCREW M5 x 16 Earth bolt M10 DETENT-EDGED WASHER 10.2 HEXAGONAL NUT M10 A2 DIN 934...
  • Page 13 Product description Item no. Description Number Type plate BLIND RIVET 3.2 x 6 Earth bolt M6 Maintenance flap seal 8011100350L02 1907V001...
  • Page 14 Product description Cooler, exploded view Fig. 3: BG-132 article no. 8011100162 - exploded view of cooler Item no. Description Number FAN FIXING PLATE Fan assembly Cylinder head screw M4 x 12 Fan grille D = 115.6 BINDER CABLE 152 x 3.4...
  • Page 15 Product description Item no. Description Number WASHER A4.3 HEXAGONAL NUT M8 DETENT-EDGED WASHER 8.2 Anti-vibration buffer, M8 x 8, internal 8011100350L02 1907V001...
  • Page 16 Product description Fan assembly, exploded view 53,65 Fig. 4: BG-132 article no. 8011100162 - exploded view of fan assembly Item no. Description Number Holding plate, fan side Fan grille D = 115.6 Fan assembly Cylinder head screw M4 x 12 Hexagonal nut M4 WASHER A4.3...
  • Page 17 ÖLFLEX TRAIN 340 600V 15340000 2X1,5 15°C 65°C X (1 : 1) Female Plug 2 ways REP 102 contact-Female (0151832-20-N1) Fig. 5: BG-132 article no. 8011100162 - exploded view of terminal box Item no. Description Number Terminal box, machined Motor protection switch MS132-2.5B...
  • Page 18 Product description Dryer, exploded view Fig. 6: BG-132 article no. 8011100162 - exploded view of dryer Item no. Description Number MEMBRANE DRYER 150 mm Thermal switch assembly Silicone heating mat assembly Fixing plate, dryer DETENT-EDGED WASHER 8.2 HEXAGONAL SCREW M8 x 16...
  • Page 19 Product description Cover, exploded view Fig. 7: BG-132 article no. 8011100162 - exploded view of cover Item no. Description Number Cover INJECTION EARTHING SCREW M6 COVER FRONT BRACKET Rivet clamping area 6.0 - 8.0 HOUSING BRACKET FILM Bracket Heat-shrinkable end flap...
  • Page 20 Product description Spare parts and accessories Spare part sets Article no., spare part sets Figure Complete fan ....8011100342 see "4.1 Unit, exploded view" Item 340 Ventilator .
  • Page 21 Product description Spare part sets Article no., spare part sets Figure Membrane dryer ... . . 8011100339 see "4.1 Unit, exploded view" Item 130 Membrane dryer silicone heating see "4.6 Dryer, mat .
  • Page 22 Product description Spare part sets Article no., spare part sets Figure Cooler ..... 8011100340 see "4.1 Unit, exploded view" Item 280 Complete terminal box .
  • Page 23 Product description Spare part sets Article no., spare part sets Figure Buffer ..... 8011100325 see "4.6 Dryer, exploded view" Item 120 Tension lock .
  • Page 24 Product description Spare part sets Article no., spare part sets Figure Seal, fan side ....8011100327 see "4.1 Unit, exploded view" Item 360 Maintenance flap seal ..8011100357 see "4.1 Unit, exploded view"...
  • Page 25 Product description Technical data Schematic drawing Fig. 8: Article no. 8011100162 8011100350L02 1907V001...
  • Page 26 Product description Technical data Electrical data Type BG-132 Article no. 8011100162 Electrical frequency Nominal voltage 3 ph. 400 Rated power P1 (W) Nominal current Speed 1440 Maximum duty cycle S3 / 60% (10 min.) Valid for the temperature range -40°C to +40°C...
  • Page 27 Product description Controller Electrical data Article no. 24 V controller Electrical frequency Nominal voltage 24 V Rated power P1 (W) Nominal current 8011100350L02 1907V001...
  • Page 28 Product description Performance diagram 8011100162 Druck p [bar] Fig. 9: Delivery quantity at 50 Hz 8011100350L02 1907V001...
  • Page 29 Product description Declaration of conformity for machines in accordance with the 2006/42/EC Directive We hereby declare that the unit described below conforms to all requirements of the machine directive 2006/42/EC. The unit named below fulfills the requirements of the following directives: –...
  • Page 30 Product description Operation Type plate Air is drawn in from the surrounding atmosphere The compression station type plate is located at through the air intake filter. This air is compressed the front, on the housing box. by the piston in the cylinder. The inlet or outlet valve blocks off one of the directions of flow.
  • Page 31 Product description * Vessels, pressure switches and safety valves are provided by the customer and are not included in the scope of delivery. 8011100350L02 1907V001...
  • Page 32 Assembly 10 Commissioning Assembly 10.1 Remove the transport locks The unit is securely protected with packaging Requirements material to ensure safe transportation. Remove the packaging material. ❯ Setup Remove the protective film. ❯ The location chosen for setup must fulfil the fol- Check the unit for damage in transit.
  • Page 33 Assembly Pneumatics plan Air intake filter Compressor Motor Flexible pressure hose Cooler with 2 ventilating fans MD Thermal switch Dryer SV Condensate solenoid valve 8011100350L02 1907V001...
  • Page 34 Assembly 10.4 Electrical installation DANGER Insufficient fuse protection of the Electrical connection without a mains plug units DANGER Insufficient fuse protection of the units can result in fire, electric shock, per- Connection to the power supply may sonal injury or material damage. only be performed by a qualified elec- trician.
  • Page 35 Assembly DANGER Insufficient fuse protection of the electric motors in unmonitored instal- lations Insufficient fuse protection of the electric motors can result in fire, electric shock, personal injury or material damage. Installation of a circuit breaker. ❯ The temperature switch must be con- ❯...
  • Page 36 Assembly Terminal box Fig. 10: Terminal box 8011100350L02 1907V001...
  • Page 37 Assembly 10 Terminal box, machined 20 Auxiliary contactor 30 Auxiliary switch 40 Motor protection switch 50 Interference suppression filter 60 Sealing insert 70 Cable gland M20 x 1.5 80 Cable gland M25 x 1.5 90 Soleinoid valve 100 Bushing, 2-pole 110 Pin contact, female 120 Cylinder head screw 130 Pin, AWG18...
  • Page 38 Assembly Circuit diagram F1 Motor protection switch + auxiliary switch F2 Microfuse, 100 mA F3 24 V MOV surge protector F4 24 V Type III GDT surge protector K1 Control relay, 400 V K2 Timer relay, 24 V M1 3~ motor M2 24 V fan motor (cooler side) M3 24 V fan motor (cooler side) 8011100350L02 1907V001...
  • Page 39 Assembly M4 24 V fan motor (fan side) M5 24 V fan motor (fan side) B2 Thermal switch, motor B3 Thermal switch NO, 30 °C B4 Thermal switch NC, 15 °C B5 Thermal switch NC, 15 °C B6 Thermal switch NC, 65 °C R1 24 V heating element R2 24 V silicone heating mat Y1 24 V solenoid valve...
  • Page 40 Only allow qualified electricians to work on electrical systems. ❯ Spare parts sets for Maintenance intervals (in years) preventative mainte- nance Description Article no. Compressor BG-132 8010100020 Fan assembly 8011100316 Complete fan assem- 8011100342 Filter, cooler side 8011100317 Filter, fan side...
  • Page 41 Pressure hose, 500 mm M16 x 1.5 8011100335 Hose, AD6-ID4-W1 8011100336 Maintenance work for the compressor is described in the "Oil-free piston compressor BG-132, 8010100090" installation and operating instructions. Maintenance interval Maintenance work on compressor 8010100090 (see external installa- tion and operating instructions 8010100130Lxx) Monthly Clean the surface of the unit with a non-fuzzing cloth.
  • Page 42 Assembly The maintenance intervals are shortened if, for example, the ambient air is particularly dirty/contami- nated, the number of operating hours is higher than the basic value stated above, or the ambient tem- peratures deviate from the stated temperature range (see "6.2 Technical data"). The stated maintenance intervals are regularly checked during the test phase of the unit and are adapted based on the test results.
  • Page 43 Assembly 11.2 Tightening torques Item no. Description Tightening Remark torque see "4.1 Unit, exploded view" Hexagonal nut M6 (fan grille) Item 270 see "4.1 Unit, exploded view" Hexagonal nut M5 (fan, com- Item 220 plete) see "4.1 Unit, exploded view" Hexagonal nut M8 (dryer) Medium- Item 150...
  • Page 44 Assembly Anaerobic adhesive for intermediate strength thread-locking agent: © Loctite 242 for intermediate strength screw-locking agent, blue colour medium, reference 0893 243 050 © Alternative: WÜRTH DOS-intermediate thread-locking agent, colour blue) 8011100350L02 1907V001...
  • Page 45 Assembly 11.3 Removing the cover Unscrew the fastening nuts on the earth strap ❯ and remove the strap. Snap-lock catch Cover Remove the cover by moving it forwards. ❯ Cover Earth strap Open the snap-lock catches and slide the ❯ cover upwards.
  • Page 46 Assembly 11.4 Removing the maintenance 11.5 Replacing the air intake filter flap Open the cover; see "11.3 Removing the ❯ cover" Loosen the fixing screws on the maintenance ❯ flap. Remove the maintenance flap and seal. Open the cover of the air intake filter by turning ❯...
  • Page 47 Assembly 11.6 Replacing the filter of the Unscrew and remove the filter housing. ❯ Remove the sinter filter. membrane dryer ❯ Insert a new sinter filter. ❯ Remove the cover; see "11.3 Removing the ❯ cover" Disconnect all plug connections. ❯...
  • Page 48 Assembly 11.7 Changing the filter on the fan side Unscrew the fan grille fixing screws and ❯ remove the grille. Replace the filter on the fan side. ❯ 81 Fan grille 82 Filter (cooler side) Install the fan grille. ❯ 31 Fan grille 32 Filter (fan side) Install the fan grille.
  • Page 49 Assembly 11.9 Replacing the fan unit on the 11.10 Replacing individual fans fan side Remove the cover; see "11.3 Removing the ❯ cover" Remove the cover; see "11.3 Removing the ❯ Disconnect all plug connections. cover" ❯ Disconnect the pressure hoses. ❯...
  • Page 50 Assembly 11.11 Replacing the compressor unit Remove the cover; see "11.3 Removing the ❯ cover" Remove the maintenance flap; see "11.4 ❯ Removing the maintenance flap" Disconnect all plug connections. ❯ Disconnect all pressure hoses. ❯ Loosen the fastening nuts for the compressor ❯...
  • Page 51 Assembly 11.12 Changing the membrane 11.13 Replacing the silicone heating dryer mat in the membrane dryer Remove the cover; see "11.3 Removing the Remove the cover; see "11.3 Removing the ❯ ❯ cover" cover" Disconnect all plug connections. Disconnect all plug connections. ❯...
  • Page 52 Assembly Remove the mounting brackets from the mem- 11.14 Replacing the solenoid valve ❯ brane dryer. Remove the cover; see "11.3 Removing the ❯ cover" Remove the maintenance flap; see "11.4 ❯ Removing the maintenance flap". Disconnect all plug connections from the ❯...
  • Page 53 Assembly 11.15 Replacing the heating ele- 11.16 Solenoid valve thermal switch ment Remove the cover; see "11.3 Removing the ❯ cover" Remove the cover; see "11.3 Removing the ❯ Remove the maintenance flap; see "11.4 cover" ❯ Removing the maintenance flap". Remove the maintenance flap;...
  • Page 54 Assembly Install a new thermal switch and reinstall the 11.18 Replacing the temperature ❯ support plate together with the solenoid valve, limiter heating element and thermal switch in the sta- Remove the cover; see "11.3 Removing the ❯ tion. cover" Remove the maintenance flap;...
  • Page 55 Assembly 11.19 Replacing the buffer 12 Repair work Remove the cover; see "11.3 Removing the ❯ 12.1 Replacing the cooler cover" Remove the cover; see "11.3 Removing the Remove the maintenance flap; see "11.4 ❯ ❯ cover" Removing the maintenance flap". Disconnect all plug connections.
  • Page 56 Assembly 12.2 Replacing the snap-lock 12.3 Replacing the handle on the catches cover Unscrew the fixing screws on the snap-lock Loosen the fixing screws for the handle. ❯ ❯ catches and remove the catches. Remove the handle by moving it upwards. ❯...
  • Page 57 Assembly 12.4 Replacing the edge protector 12.5 Replacing the terminal box Remove the cover; see "11.3 Removing the Remove the cover; see "11.3 Removing the ❯ ❯ cover" cover" Remove the maintenance flap; see "11.4 Disconnect all plug connections. ❯ ❯...
  • Page 58 Assembly 12.6 Replacing the seal for the fan 12.7 Replacing the seal for the cover cooler side cover Unscrew the fan grille fixing screws and Unscrew the fan grille fixing screws and ❯ ❯ remove the grille. remove the grille. Remove the filter (fan side).
  • Page 59 Assembly 12.8 Replacing the maintenance flap seal Loosen the fixing screws on the maintenance ❯ flap and remove the flap. Remove the seal. ❯ Insert a new seal. ❯ 11 Maintenance flap 12 Maintenance flap seal Install the maintenance flap. ❯...
  • Page 60 Troubleshooting Troubleshooting 13 Tips for operators and service technicians Any repairs exceeding routine maintenance may only be carried out by qualified personnel or our service. De-energise the unit prior to working on it or in the event of potential danger (e. g. pull the mains plug) and prevent it from being switched back on again.
  • Page 61 Troubleshooting Error Possible cause Remedy Output drops. Lines, hoses or connections Inform a service technician. ❯ leaking Check / renew lines, hoses or connections. Defective membrane-drying unit Inform a service technician. ❯ Replace the membrane-drying unit. Air intake filter soiled Replace the air intake filter at ❯...
  • Page 62 Troubleshooting Error Possible cause Remedy Condensate is not draining off Frozen solenoid valve Check heating element and ❯ replace it if necessary. Check the thermal switch. Solenoid valve faulty Replace the solenoid valve. ❯ Condensate hose blocked Clean or replace condensate ❯...
  • Page 63 Contact Contact 14 Addresses 14.1 Returns / Repairs Dürr Technik GmbH & Co. KG Pleidelsheimer Straße 30 74321 Bietigheim-Bissingen -Germany- WARNING Risk of explosion of the pressure tank and pressure hoses The pressure tank and the pressure hoses must be vented before they are stored or trans- ❯...
  • Page 68 Dürr Technik GmbH & Co. KG Pleidelsheimer Strasse 30 74321 Bietigheim-Bissingen Germany Fon: +49 7142 9022-0 www.duerr-technik.eu office@duerr-technik.de...

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8011100162