Original Operating Manual - SCC Compressors: Version 1.0 E - 28.05.2017

Original operating manual - SCC Compressors
Version 1.0 E• 28.05.2017

Imprint
Tolpec GmbH
Wertstrasse 44
73240 Wendlingen
Tel.: +49 (0)7022-789 6040
[email protected] http://www.tolpec.com
Copyright protection
Tolpec GmbH is the owner of the copyright for this document.

Disposal, multiplication and recording of this document, remaking and sharing of its content are forbidden, if not
confirmed by Tolpec GmbH in written form.
Non-compliance shall result in the recovery of losses.
All rights in the case of patent issue or registration of design are reserved.
All the mentioned in this guide below, product labelling are trademarks of corresponding firms.
Technical changes reserved. SCC is a registered trade name and all rights in
the case of patent issue or registration of design are reserved.
Operation Manual SCC-Compressors / Page 2

1. Description of the product ................................................................................................................................. 6
1.1. Operating Instructions .................................................................................................................................. 6
1.2. Storage of the Manual / keep it accessible................................................................................................... 7
1.3. Used Symbols and definitions ..................................................................................................................... 7

1.3.1. Safety instructions ................................................................................................................................... 7
1.3.2. Warning signs ......................................................................................................................................... 9
1.3.3. Mandatory signs ..................................................................................................................................... 10
1.3.4. Additional symbols in the manual .......................................................................................................... 11
1.3.5. Directional indications ............................................................................................................................ 11
1.4. Change history ........................................................................................................................................... 12
1.5. Applicable documents ................................................................................................................................. 12
1.6. Warranty and liabilities .............................................................................................................................. 12
1.7. Contact information of Tolpec GmbH and the SCC-Sales- and Service partner ....................................... 13
2. Description of the product ............................................................................................................................... 15
2.1. Construction of the Equipment / Controllers .............................................................................................. 15
2.1.1. Areas of work and maintenance. ........................................................................................................... 23
2.2. Identification of the Equipment .................................................................................................................. 23
2.3. General descriptions .................................................................................................................................. 24
2.4. Use of the machine ................................................................................................................................... 25
2.4.1. Intended use ......................................................................................................................................... 25
2.4.2. Incorrect Use.......................................................................................................................................... 25
2.5. Safety equipment’s...................................................................................................................................... 26
2.5.1. Overview ............................................................................................................................................... 26
2.5.2. Protection/safety devices ....................................................................................................................... 26
2.5.3. Emergency stop system ......................................................................................................................... 30
2.5.4. Symbols and signs on the machine. ...................................................................................................... 30
2.6. Operating of the Equipment ....................................................................................................................... 32
2.7. Operating and installation conditions .......................................................................................................... 32
3. Safety ................................................................................................................................................................. 33
3.1. General safety instructions ......................................................................................................................... 33
3.1.1. Avoiding of dangerous situations .......................................................................................................... 33
3.1.2. Operation instructions ........................................................................................................................... 34
3.1.3. Notes for trouble shooting and repairing ............................................................................................... 34
3.1.4. Notes on electrical equipment ............................................................................................................... 35
3.1.5. Electromagnetic compatibility (EMC) .................................................................................................... 35
3.1.6. Information for environmental protection ............................................................................................... 36
3.2. Unacceptable operating conditions ........................................................................................................... 36
3.3. Responsibility of the operator .................................................................................................................... 37
3.3.1. Minimize the risk of injuries ................................................................................................................... 37

3.3.2. Determine the operator ......................................................................................................................... 38
3.3.3. Operator training ................................................................................................................................... 38
3.3.4. Protective equipment ............................................................................................................................ 39
3.4. Requirements of an operator ..................................................................................................................... 40
3.4.1. Qualification .......................................................................................................................................... 40
3.4.2 Operator groups ................................................................................................................................... 42
3.4.3 Specialised knowledge ......................................................................................................................... 42
3.5. Personal protective equipment .................................................................................................................. 43
3.6. Residual risk .............................................................................................................................................. 44
3.7. Procedure in case of an accident ................................................................................................................44
4 Transport und installation ................................................................................................................................ 45
4.1 Required tools .............................................................................................................................................. 46
4.2 Transport ....................................................................................................................................................... 46
4.3 Unpacking and removing of package ........................................................................................................... 49
4.4 Installation .................................................................................................................................................... 49
4.4.1 Place of installation and infrastructure ................................................................................................... 49
4.4.2 Installation and connection ................................................................................................................... 50
4.4.3 Installation of the mechanical components ............................................................................................. 51
4.4.4 Installation of the electrical components ................................................................................................. 52
4.4.5 Final Check .............................................................................................................................. 52

5 Commissioning ................................................................................................................................................. 53
5.1 Check of safety devices ............................................................................................................................... 55
5.2 First Commissioning ..................................................................................................................................... 56
5.3 Daily commissioning ..................................................................................................................................... 60
5.4 Commissioning after storage ........................................................................................................................ 61
6 Operation ........................................................................................................................................................... 61
6.1 Description of the working area .................................................................................................................... 63
6.2 On and Off sequences ................................................................................................................................. 63
6.2.1 Switch on .............................................................................................................................................. 63
6.2.2 Switch off .............................................................................................................................................. 64
6.3 Operating modes .......................................................................................................................................... 64
6.4 Parameter list ............................................................................................................................................... 65
7 Faults ................................................................................................................................................................. 65
7.1 Faults during operation ................................................................................................................................. 67
7.1.1 Troubleshooting table ........................................................................................................................... 67
7.1.2 Commissioning after troubleshooting ..................................................................................................... 70
8 Maintenance and testing during operation ...................................................................................................... 70
8.1 Secure the machine against restarting ......................................................................................................... 76
8.2 Maintenance schedule ................................................................................................................................. 77
8.2.1 Daily ...................................................................................................................................................... 77
8.2.2 Weekly .................................................................................................................................................. 78
8.2.2.1 After 100 operation hours ....................................................................................................... 78
8.2.3 After 500 operation hours ..................................................................................................................... 78
8.2.4 Each 2000 operating hours ................................................................................................................... 79

8.2.5 Each 3000 operation hours or 1 / year .................................................................................................. 79
8.2.6 Each 4000 operation hours or 1 / year ................................................................................................... 80
8.3 Maintenance works ...................................................................................................................................... 81
8.3.1 Visual inspection ................................................................................................................................... 81
8.3.2 Cleaning ................................................................................................................................................ 82
8.3.3 Checking and servicing the mechanics ..................................................................................................82
8.3.3.1 Maintenance and cleaning of Air filters .............................................................................. 84
8.3.3.2 Maintenance and cleaning oil filter ..................................................................................... 84
8.3.3.3 Maintenance oil separator ................................................................................................. 84
8.3.3.4 Maintenance of motors and bearings .................................................................................. 85
8.3.3.5 Checking belt and tension ................................................................................................. 85
8.3.3.6 Replacing belts ................................................................................................................... 85
8.3.3.7 Adjust belt pulley ................................................................................................................ 85
8.3.3.8 Adjusting axes ................................................................................................................... 86
8.3.3.9 Maintenance of minimum pressure and non-return valve .................................................. 86
8.3.3.10 Maintenance of Intake valve ............................................................................................. 86
8.3.4 Check and maintenance of electrical parts .............................................................................................. 86
8.3.3.1 Maintenance of safety devices ............................................................................................... 87
8.3.5 Check pneumatic System and service ..................................................................................................... 88
8.3.5.1 Maintenance of air receiver ............................................................................................... 88
8.3.5.2 Check for condensation ..................................................................................................... 89
8.3.6 Oil level and oil change ......................................................................................................................... 91
8.3.7 Replacement of worn parts ..................................................................................................................... 92
8.4 Compressor oil and lubricant ......................................................................................................................... 93
8.5 Wear and tear and spare parts ...................................................................................................................... 94
8.6 Customer service through the Manufacturer ................................................................................................ 94
9 Repair .................................................................................................................................................................. 95
10 Decommissioning, storage, disposal .............................................................................................................. 95
10.1 Temporary decommissioning ....................................................................................................................... 97
10.2 Final removal from operation ........................................................................................................................ 98
10.3 Dismantlement .............................................................................................................................................. 98
10.4 Re-packaging of the machine ....................................................................................................................... 98
10.5 Storage of the Equipment .............................................................................................................................. 98

10.6 Disposal ....................................................................................................................................................... 98
11 Technical Documents / Annex list................................................................................................................. 99

11.1 Plan of maintenance and repair works ......................................................................................................... 99
List of Pictures .......................................................................................................................................................... 100

List of Tables ............................................................................................................................................................ 101
Glossary ................................................................................................................................................................... 101
Index of subjects ...................................................................................................................................................... 102
1. Description of the product

This operating manual (hereafter - Manual) allows the User to work on SSC-compressors (hereafter
Equipment or Compressor) safely, with optimum efficiency which ensures a long service life of the
compressor. It describes the equipment, manufactured by the company Tolpec GmbH (hereafter –
Tolpec).
– Read the Manual thoroughly.
– Follow all the safety instructions.
1.1. Operating instructions
The Manual serves as a guide for the User and technical staff in relation to questions of
maintenance. All the technical aspects of the Equipment are included.
The technical data relating to settings and upkeep as well as the maintenance and the safe
operation of the equipment is included in the manual. The maintenance and operation of the
equipment referred to in this manual should only be done by qualified persons (see requirements of
the operator, [p. 40]).
Before proceeding with the operation of this equipment the operator/s should read and fully
understand the manual. Compliance with all items indicated in the Manual and the explanations
provided are the basis of the safe operation of this equipment.
All local Health and safety regulations need to be adhered to. Work safety orders and common
safety rules for the field of use of the Equipment remain in force.
The Equipment Manual does not contain information about compressed air management control
systems. When working with them, compliance with the relevant manual for such management
systems is required.
In the event of using such management control systems, additional instructions for installed
components are to be followed. Supplied by the manufacturers of such management systems.
Copyright protection
This Manual is protected by copyright and issued for internal use only.
Sharing of this Manual with third parties, their multiplication in any way and form – also
selective – as well as copy/reproduce and/or distribution of its content without written
permission, except for internal use, is forbidden. Non-compliance may lead to a claim for
damages. The other possible claims are defined by the contract.
1.2. Storage of the Manual / keep it accessible

The Manual is an integral part of the Equipment and must be kept with the Equipment, so that the
operator/s can have access to it at any time. The User must make the Manual available for
technical staff and all operators during the whole working lifespan of the Equipment.
1.3. Used symbols and definitions

In this chapter, the symbols used in this Manual are explained.
1.3.1. Safety instructions
The safety instructions in this manual contain the following elements.

DANGER
Warning of an immediate danger to the user.

This safety instruction warns about immediate danger, that can
lead to hard injuries or death.
WARNING
Warning of an immediate danger to the user.

This safety instruction warns about an immediate dangerous situation, that can
lead to hard injuries or death.
CAUTION
Warning of potential danger to the user.
This safety instruction warns of a potentially hazardous situation that can
result in minor or moderate injury.
ATTENTION
Warning of possible property damage.

This Safety instruction warns of possible property damage.
A security note exists next to the symbol and the signal word:
– Signal word
– Type and source of danger
– Consequences
Escape (= measures to avoid danger)

Example:

DANGER
Electric shock caused by high voltage (type and source of danger)
Death caused by high voltage! (aftermaths)
a) Wait 3-10 minutes before starting work with electrical motor
connections.
1.3.2. Warning signs

The following warning signs are used in the manual. These signs are intended to draw the reader’s
attention primarily to the text of the accompanying warning or safety instructions.
Symbol Meaning
Warning of high voltage
Warning of hand injury
Warning of hot surfaces around air end, motor, oil receiver and tubing.
Warning of overhead load

Symbol Meaning
Warning of poisonous substances
Warning of combustible and flammable materials
Warning of a slip hazard
Table 1: Warning signs
1.3.3 Mandatory signs

In the Manual, the following mandatory signs are used.
Symbol Meaning
Read the operating manual
Wear protective gloves
Wear eye protection glasses

Symbol Meaning
Wear protective clothes
Wear light respiratory protection for protection from dust
Wear ear protection
Wear protective boots
Table 2: mandatory signs
1.3.4
Additional symbols in the manual
2 Important or helpful notices as well as, information and tips appear as follows:
NOTE
Note
With this symbol, you will get application tips and information that will help you
make the most of all the functions on your machine.
1.3.5 Directional indications

Directional indications, are clearly marked and refer to the respective position from the control
station, the direction of rotation of electric motors, viewed from the end wall of the driving side,

i.e. from the side where machine / system is coupled. They are either clockwise or anti
clockwise.
1.4 Change history
No. of version Date From serial No.
Table 3: Change of history of this document
1.5. Applicable documents

Document
Operation and working manual
Spare parts list
Technical data sheet
Dimensional drawing of the equipment
Table 4: Table of applicable documents
1.6. Warranty and liabilities

The General Terms and Conditions of Sale and Delivery (GTC) of Tolpec GmbH are
applicable. The User shall be notified thereof by the latest at the time of signing the contact as
to the correct use of the equipment to make use of the legal liability for defects.
Limitation of liability
All information and instructions in this manual have been compiled in accordance with the
applicable standards and regulations, as well as our many years of experience
Non-compliance with the notices and guidance of this manual will render the warranty void.
The Manufacturer shall not take responsibility for damages because of:
– non-compliance with the manual
– improper use
– use of non-trained personnel
– unauthorized conversions

– technical changes
– use of non-approved spare parts
There may be a slight variance from your delivered machine to this manual/ instruction and
schemes described here in relation to construction, and additional options of later /current
edition machines or because of the latest technical changes without prior notice.
The obligations stipulated in the delivery contract, the general terms and conditions as well as
the conditions of delivery of the manufacturer and the statutory regulations valid at the time of
conclusion of the contract apply.
1.7 Contact information of Tolpec GmbH and the SCC Sales- and
Service partner
For technical information, please contact customer service.
In addition, our employees are constantly interested in additional information and experience that
can arise from the use of the equipment and can be valuable for the improvement of our products.
If you have any questions or suggestions regarding the equipment, please contact us on the details
below or visit our website, stating the following information:
– Your name and address,
– Contact person on site,
– data of name plate: type, serial No. and production year, Address:
Address:
Tolpec GmbH
SCC-Compressors Wertstrasse 44
73240 Wendlingen
Telephone: +49 (0)7022-789 6041
E-mail: [email protected]
Internet: http://www.tolpec.com
Table 5: Central contacts

SCC Sales- and Service partner
Address
Phone:
Email:
Operation manual received at: _____________________

Table 6: Your SCC sale and service partner

2 Description of the product
The compressors are available in the Smart, Flexi, Focus and Strong series. The technical design
of the different series is identical except for the type of drive. The Smart series and Flexi series
are driven by a belt. The Focus, Strong and Flexi series are direct drive.
The dimensions of the individual machines vary. The following section describes the machine, and
the use of its main components.
The dimensions of certain Equipment are different.
In the following chapter the main components of the Equipment are described.
2.1 Construction of the Equipment/Controllers
Picture 1: Front view of the Equipment (example picture, Focus series)
1 Oil tank 2 Motor frame
3 Electrical Control box (open) 4 Operation panel/ control

Picture 2: Front view of the Compressor (example picture, Focus series)
1 Oil filter 2 Suction filter
3 Suction controller 4 Air end
5 Oil-level gauge 6 Oil tank
7 Minimal pressure and backswing Not showed: drive behind the air end
valve
Picture 3: Example picture: drive side of the Compressor with belt-drive (Smart series)
1 Electrical Control box 2 Motor

3 Belts 4 Oil filter
5 Air end 6 Suction controller: displaying without suction filter
7 Oil tank
All compressors consist essentially of:

– Air end,
– motor,
– suction filter, oil tank,
– pressure gauge,
– safety valve,
– oil fine filter,
– oil filter,
– ventilator,
– cooler,
– operation panel,
– control box.
Safety-relevant operating components

– 1x emergency stop button next to the control panel,
– 1 x Pressure display by the pressure sensor on the control panel
The emergency stop button is linked to the control panel / control of the machine.
Picture 4: Safety-relevant operating components and indicator elements of the Compressor

1 Safety valve of the oil tank 2 Pressure gauge
3 Operating panel 4 Emergency button
Picture 5: Safety valve
1 Safety valve for pressure tank 2 Pressure gauge

Operating panel MAM – 890
Picture 6: Operating panel MAM - 890
1 ON – Start button for starting of motor 2 OFF – Button for switching off the motor
3 Indication Power – Voltage available 4 Indication Run – Compressor in operation
5 6 C-
Alarm 1 – Reset of error messages

2 – Switching to the previous menu level
1. Notification of warning through
blinking diodes, when the warning
value is reached.
2. Notification of error, when the diode

shines constantly and the
Compressor switches off.
7 Switch to submenu / enter 8 1. Switching from main display to main menu levels.
Works as enter button, when the menu is 2. Main menu – choose upwards
chosen. (in various levels a password is
needed) 3. Increasing of numeric data.
4. Submenu – choose downwards
9 1. Switching from main display to main 10 SET

menu levels.
1. Confirm changed parameters
2. Main menu – choose downwards 2. Function of switch to charge to idle run
3. Decreasing of numeric data.
11 Display indications

1 2 Display indications
ON
1. Switching on the Compressor
2. If the Compressor is used as master in
Block mode control, the Block mode control
switches on.
3 4 C
1. Reset of error messages
OFF
2. Switching to the previous menu level
1. Switching off the Compressor
2. If the Compressor is used as mode in block mode
control, the block mode control switches off.
3. For reading of software. Press for a few seconds
5 Switch to submenu / enter 6 1. Switching from main display to main menu levels.
Works as enter button, when the menu is chosen 2. Choose in the main menu – upwards
3. Increasing of numeric data.
7 1. Switching from main display to main menu 8 SET

levels.
2. Choose in the main menu – downwards 2. Function of switch to charge to idle run
9 Alarm 10 Indication Run – Compressor in operation
1. Notification of warning through blinking
diodes, when the warning value is reached.
2. Notification of trouble, when the diode shines
constantly and the Compressor switches off.
11 Indication Power – Voltage available

1 START 2 Display indications

1. Switching on the compressor
2. If the Compressor is used as
master in Block mode control, the
Block mode control switches on.
3 STOP 4 LOAD / UNLOAD

1. Switching off the compressor When the Compressor is in operation, it can be switched to
charge or idle run
2. If the Compressor is used as master in
block mode control, the block mode
control switches off.
3. For reading of software. Press for a few

seconds
5 RESET 6 Switch to submenu / enter

1. Reset of error messages Works as enter button, when the menu is chosen. (in
various levels a password is needed).
2. Switch to the previous menu level
7 1. Switching from main display to main menu 8 1. Switching from main display to main menu levels.
levels.
2. Choose in the main menu – downwards
2. Choose in the main menu – upwards
3. Increasing of numeric data 3. Decreasing of numeric data.
4. Submenu – choose downwards 4. Submenu – choose downwards
9 SET
2. Function of switch to charge to idle run

Operating panel MAM 6080
1 Indication Power – Voltage available 2 Indication Run – Compressor in operation

3 Alarm 4
1. Check the data in the text field.
1. Notification of warning through blinking
diodes, when the warning value is reached. 2. Switching in data editing mode, switching of
numbers from left to right.
2. Notification of trouble, when the diode shines
constantly and the Compressor switches off. 3. While changing the data or switching of icons on
the display. Press the button for editing and
changing.
4. For switching of the icon indication to next icon
5 6 1.Switching the cursor on the icon to the previous
1. Switching the cursor on the icon to next icon icon
2. Switch to the next page of working parameters. 2. Switch to the previous page of working
parameters.
3. Increasing of numeric data.
7 8 C
1. Check the data in the text fields. 1. Reset of error messages. (Press the button for
5 seconds)
2. Switching in data editing mode, switching of
numbers from right to left. 2. Switch to previous menu level
3. While changing the data or switching of icons on
the display. Press the button for editing and
changing.
4. For switching of the icon indication to the previous
icon.
9 SET 10 OFF
1. Confirm changed parameters 1. Switching off the Compressor
2. Function of switch to charge to idle run 2. If the Compressor is used as mode in block
mode control, the block mode control switches
off.

11
ON
1. Switching the Compressor on
2. If the Compressor is used as master in Block
mode control, the Block mode control switches
on.
2.1.1. Areas of work and maintenance
Picture 10: Areas of work and maintenance
1 Screw compressor 2 Area of maintenance
3 Area of work
The working area during automatic operation is in front of the machine. The area for set-up,
maintenance and maintenance work is the area in front, on the side and behind the machine.
POSITIONING After unpacking the equipment and preparing the compressor room, put the
machine into position, checking the following items: Ensure that there is sufficient space around
the machine to allow for maintenance. Check that the compressor is standing on a perfectly flat
floor. Ideally the compressor must have a metre space around the compressor in all directions
2.2. Identification of the Equipment

The Equipment can be identified on basis of the name plate on the outer side of the Equipment.
Picture 11: Name plate of the Equipment

1 Name plate on the oil tank 2 Name plate on the air receiver
3 Name plate of the Equipment
Data on the name plate of the Equipment

The name plate contains following data:
– model marking
– power input in kW
3
– pneumatic capability/output in m /min
– maximum possible air pressure in bar (g)
– weight of the Equipment in kg
– dimensions in mm
– serial No.
– production date
2.3. General descriptions

The Equipment produces compressed air.
The Equipment must be used only:
– for the intended use
– and in a safe environment.
Situations, that can affect the safety, must be immediately rectified. While the error remains, the
Equipment cannot be used.
Operation mode
Compressed Air is produced by drawing air in from the environment or through an air supply
channel (from outside of the building). The air is drawn in by the air end and the air filter as well as
by the suction controller/suction valve. In the air end the air will be compressed by two
interdependent screw-shaped rotors. The oil is injected into the compressor chamber. The oil is
used for cooling, lubricating, protection of metal contacts of the rotors and for sealing of the rotors in
the air end. The compressed air, after the air end will be mixed with oil and flow through the outlet in
the oil tank. Large quantities of the oil are immediately removed in the lower part of the oil tank
located directly in the oil circuit. The compressed-air oil mixture in the upper part of the oil tank
passes through the separator vessel into the oil filter in which the oil is removed from the
compressed air by filtration. The compressed air is led through a cooler to the compressed air outlet
and the residual oil is returned from the filtration back through the scavenge line into the oil circuit.

A compressed air connection must be provided by the user.
Also refer to Appropriate use [ 25 ]
2.4. Use of the machine

In this chapter, the intended use of the Equipment is described.
2.4.1. Intended use

The Compressor is designed to produce compressed air through the compressing of air from the
environment. The users technical staff shall always be on hand to ensure the safe operation of the
equipment.
Operation of the machine in potentially explosive environments is prohibited.
A prerequisite for the intended use is that the operators read, understand and follow these
instructions. The intended use includes the compliance of all instructions in this operating manual.
The machine must be checked regularly and maintained.
The machine is intended exclusively for industrial and commercial use.
Any other use not previously stated is forbidden
Also refer to Technical data page 32
2.4.2. Incorrect use

The following are examples of incorrect use that may occur if the guidelines and instructions outlined
in this manual are not adhered too.
- Suction of media and the use of power with a specification that does not meet the requested
operating specifications.
- Operation without protective cover
- An unauthorized use, for example, when unauthorized access/tampering/modification is made to

relevant safety components.
- A failure may also occur if the specified operating parameters (i.e. temperature, overrun of
maintenance intervals) are not observed.
- An unlawful use is to place or use the machine in areas where explosive environments may
occur as defined by Zone 1
- Any use other than the intended.

2.5. Safety equipment
2.5.1. Overview
The Equipment is equipped with safeguards in the dangerous areas.
Without the intended mounted and adjusted safety devices, the Equipment can cause serious
injuries to persons. The safety devices can't be changed or removed from operation. All the safety
devices must always be accessible.
The user should be familiar with all the safety devices that may prevent and minimize injuries and/or
machine failures. The controller with the operational panel is in front of the Equipment.
Automatic operation is carried out from outside the hazardous area. Protective devices ensure
safety from dangerous areas on the system. They have no influence on the movements of the
plant.
Also refer to: Installation of the Equipment [ 49]
2.5.2. Protection/Safety devices

Protection devices protect the dangerous parts of the machine. They have no effect on the
movement of the machine.
Removal of safety equipment:

The following are part of the safety equipment on this machine:
– motor frame
– protection covers
Separate protective devices prevent or hinder direct access to rotating or moving parts of the
installation. They may only be removed for set-up, maintenance or repair work and must be
reinstalled before restarting.

Motor frame with protection covers
Picture 12: Compressor frame with panels
1 Protection cover / panels 2 Motor frame
The machine is completely enclosed in a machine frame with a protective covering. The machine
frame contains the air end, the motor, the oil tank with the oil fine separator, the multiblock with the
screwed oil filter, oil filter cartridge, the safety valve, the pressure sensor, the electrical control
cabinet and the fan. As a separate protective device, the protective covering offers a
comprehensive protection for the personnel working on the machine from the dangerous moving
parts of the machine.
The protective cover is lockable or secured by a snap mechanism and is manually mounted or
disassembled. The protective covering must be closed during the operation of the machine.
Non - Contact safety devices

The non – contact safety devices are as follows:
– safety valve
– pressure sensor
– temperature sensor
Non-contact safety devices cause the machine to stop. The direct access to rotating or moving parts
of the system is thus prevented. The protective devices may only be switched off for maintenance or
repair work and must be switched on again before restarting.

Pressure sensor at the minimum pressure and non-return valve or
at the multi-block
Picture 13: Pressure sensor (example picture)

1 Pressure sensor
The pressure sensor is mounted on the minimum pressure check valve or on the multiblock. It
controls the operation of the compressor. The compressor compresses (load operation) until the
max. operating pressure is reached. The compressor then switches to idle mode. When switching to
idle mode, a run-on time begins, in which the compressor is switched on either when reaching the
min. operating pressure or after the time has elapsed, the motor switches off and goes into the
standby mode.
As soon as the set min. operating pressure is reached, the system starts and operates on load.
Safety valve on the oil receiver
Picture 14: Safety valve on the oil receiver
1 Safety valve
A safety valve on the oil tank opens, when the maximum safety pressure exceeds the design
pressure of the oil tank against over pressurisation.

Safety valve on the air receiver of the Equipment
Picture 15: Safety valve of the air receiver
1 Safety valve on the air receiver 2 Pressure gauge
A safety valve at the compressed air receiver is installed on the console between the compressor
and the dryer at the compressed air inlet. The safety valve opens when the set safety pressure is
exceeded and secures the compressed air receiver against high pressurisation.
Oil temperature sensor on the discharge/outlet of the air end
Picture 16: Oil temperature sensor
1 Oil temperature sensor
A temperature sensor monitors the oil temperature of the machine. If the permissible oil temperature
programmed at the control unit is exceeded, a fault message is generated which leads to the
shutdown of the machine.

2.5.3. Emergency stop system
Pressing the emergency stop button triggers the emergency stop function. The machine is
safely stopped by immediate interruption of the control voltage. The emergency stop button
is unlocked by turning the button.
Picture 17: Emergency stop button
1 Emergency stop button
The Equipment has following emergency stop devices:
– Emergency stop button at the operator station.
2.5.4. Symbols and Signs on the Machine
Warning signs
Dangerous areas on the machine are marked with warning signs.
Warning labels and other instructions on the machine must always be clearly readable. Unreadable
safety signs must be replaced immediately.
Symbol Meaning
Warning high voltage

Warning of hot surfaces around air end, motor, oil receiver and tubing.
Warning of hand injury
Warning of machine automatically starting
Table 7: Overview of the warning signs
Mandatory signs
Mandatory Meaning
signs
Read the operating manual
Wear eye protection

Wear ear protection
Wear protective clothes
Wear light respiratory protection for protection from dust
Wear protective boots
Table 8: Overview of the mandatory signs
2.6. Operating the Equipment

The Equipment works in automatic mode. The machine is operated by an operator in front of
the compressor.
2.7 Operating and installation conditions

General data
Manufacturer Tolpec GmbH
Designation: Screw compressor
Production year
From 2016
Operation conditions Usage at the 3-shifts-factory
Location Roofed production plant or separate compressor room

Environment
temperature During
operating
+5 to +40
Environment
temperature during
storage [°C] +5 to +40
Air quality for the The air in the production plant or in the compressor room must be as
Equipment clean as possible and must contain the least amount of dust, aerosols or
soot as possible
3. Safety
The machine is built according to state of the art and recognized safety regulations.
Nevertheless, dangers to the life and limb of the operator or third parties may arise if not used
appropriately. Likewise, the machine or other property may be damaged. The Equipment
should be used only:
– for the intended use
– and in safety-perfect conditions for the appropriate usage
The machine must not be put into operation again, after failures that can impair safety, until they have
been remedied/repaired.
3.1 General safety instructions

3.1.1 Avoiding of dangerous situations
Dangerous situations while operating can be avoided through diligent and cautious
behaviour of the staff. The following rules are obligatory for everybody who works with or
on the Equipment:
– Keep the operating instructions in a readable form for everyone at the machine location.
– Only use the machine as intended.
– The machine must be functional and clean. Check the condition of the machine before starting
work and at regular intervals.
– Wear close-fitting work clothes during all work on the machine.
– Make sure that nobody is injured by the parts of the machine.

– Report faults or recognizable changes to the machine immediately to the person responsible.
– Observe accident prevention regulations and local Health and Safety regulations.
3.1.2 Operation Instructions

The following ground rules are applicable while operating:
– Only one operator may operate the machine.
– The machine must run continuously in automatic mode.
– Safety devices must not be altered, disassembled or taken out of service. Safety devices must
be checked at regular intervals.
– All panels, covers and hoods must be fitted as intended.
– Constructional modifications to the machine are not permitted.
– Any modification to the machine must be reported immediately to the person responsible.
– The danger area must always be kept clear. No objects may be placed in the way of the
danger area. An operator may only enter the hazardous area if the power is switched off and
the machine is locked.
3.1.3 Notes for trouble shooting and repairing

The following principles apply when troubleshooting and fault finding:
– Only adequately qualified personnel can perform work on the machine.
– The machine must be switched off.
– Disconnect the main plug or disconnect the power supply.
– Take the key out of the control cabinet.
– Secure the external main switch with a safety lock against accidental re-activation.
– Only the company supervisor can take the key.
– Otherwise the safety shutdown must be ensured by a second person.
– Hot machine parts must be allowed to cool down.

– Frequency inverters store electrical charges for several minutes while the power supply is
switched off. Wait at least 5 minutes after energizing before working on a frequency converter.
Check the tension-free/power free.
3.1.4 Notes on electrical equipment
The following principles apply to all electrical work:
– The Equipment has an electrical drive. If the electrical equipment is installed incorrectly or the
isolation of the machine is damaged, a danger to life may occur.
– The access to the electrical components and working with them is only for qualified staff.
– The control box must be kept locked.
– Only when the main plug is disconnected, the power supply and installed socket circuits are
disconnected from the power supply.
– Frequency inverters store electrical charges for several minutes with the power supply switched
off. Wait at least three minutes after de-energizing before working on a frequency converter.
Check the tension-free.
– Changes to the control system can affect safe operation. All planned changes must be
approved in writing by the manufacturer of the machine.
– Check the functioning of the protective equipment after all work.
– No unauthorized alterations may be made to the machine. All changes must be approved in
writing by the manufacturer of the machine.
3.1.5 Electromagnetic compatibility (EMC)

According to its appropriate usage, this electronic equipment corresponds with the laws
concerning electromagnetic compatibility. Those laws define the allowable emission level of
the electronic equipment and its necessary resistance to electromagnetic fields.

Radiofrequency signals of high frequency transmitters, for example, of mobile phones or identical
mobile radio equipment, that correspond with EMV-directions, can affect the appropriate functioning,
if they are used nearby.
NOTE
Note
Make sure there are no electromagnetic fields near the machine.
3.1.6 Information on environmental protection

Safety-conscious and the forward-thinking behaviour of the personnel avoids negative environmental
impact.
The following principles apply to environmentally-conscious actions:
– Environmentally hazardous substances must not be allowed to enter the soil or sewage
system.
– Provisions on the prevention, disposal and recycling of waste must be complied with.
– Environmentally hazardous substances are to be stored in suitable containers.
– Containers containing environmentally hazardous substances must be clearly identified.
3.2 Unacceptable operating conditions

– The operating safety of the machine cannot be guaranteed under unacceptable operating
conditions. Unacceptable operating conditions must therefore be avoided in all cases. The
operation of the machine is prohibited under the following conditions:
– If the machine is not used as intended.
– If the machine or parts of the machine are damaged and the electrical system is installed
incorrectly, or the insulation is damaged.
– Protective and safety equipment is not functional or defective, improperly installed or missing.

– The machine must not be used when faulty.
– There are persons or foreign bodies in the danger areas of the machine.
– The machine has been altered or altered without authorization.
– The control system has been changed outside the operational design of the machine.
– Operating parameters have been changed.
– If non-approved tools/equipment are used.
– The specified maintenance intervals have been exceeded.
The tampering of limit switches and other control components, especially the safety components, is
prohibited. Persons under the influence of alcohol or drugs are not allowed to operate or maintain the
machine.
3.3 Responsibility of the operator

The duty of care of the operator includes, inter alia, planning and carrying out safety measures.
All persons carrying out activities with and on the machine, must be trained by the operator/Tolpec
on the machine. You must have read and understood the operating instructions. By signing it, they
confirm this.
The signatures are kept by the operator on a separate list. The operator has a list of authorized
operators.
3.3.1 Minimize the risk of injury

– To minimize the risk of injury, the following principles apply:
– Work on the machine must be carried out by qualified personnel only.
– The staff must be authorized by the operator for the respective activity.
– The staff must have familiarized themselves with all safety devices before starting work.
– Make sure that safety switches are never bypassed. This must be checked regularly by the
qualified personnel to ensure that this has not occurred.
– If protective equipment has failed or is disrupted, it must be reported immediately to the

responsible supervisor. The latter decides on how to proceed further.

– The personnel must have familiarized themselves with the operating elements before starting
work.
– The machine must be kept in a clean and safe working condition as well as the compressor
house in the immediate working vicinity of the compressor.
– The machine and the immediate working vicinity around the compressor must be adequately lit.
– Personnel must wear the personal protective equipment stipulated for that machine. The
necessary protective equipment is laid down in the factory specifications. Operational
supervisors are obliged to enforce the wearing of personal protective equipment by their
employees.
– During operation, qualified first responders must be ready to take the necessary measures to
provide first aid.
– Procedures and the responsibilities of operators working with the machine/equipment must be
clearly defined. The Emergency procedure in case of accidents must be clear to everyone. The
staff must be regularly informed/trained in this regard.
– Warning signs and instructions on the machine must be complete and legible. The labels and
notes must be regularly cleaned and replaced if needed.
3.3.2 Determine the Operator

The Qualified operator of the machine must determine which persons are permitted to carry
out work on the machine. These persons must have the necessary knowledge for the
respective work and be adequately trained.
Also refer to: Requirements of an Operator [ 40]
3.3.3 Operator training

The knowledge of general safety regulations is among the requirements to operate the machine
safely. The generally applicable safety regulations also include the fact that the operators of the
machine wear and use their personal protective equipment
The machine may only be operated if the general safety instructions and the instructions described in
this manual are complied with. The operator must periodically train the authorized personnel regularly
to operate the machine safely. The obligation of the operator to train the authorized personnel on a
regular basis applies to the handling of the machine, to work on the electrical installations as well as
to installation, set-up and do maintenance work.

NOTE
The staff must be trained regularly

The operator of the machine is obliged to train the personnel working on the
machine on a regular and recurring basis in the work procedures, hazards
and safety measures which are important for the personnel. This ensures that
the authorized personnel always have the qualification/experience. needed
3.3.4 Protective equipment

The operator of the machine must ensure that the operator receives the necessary protective clothing
and protective equipment (face protection, hearing protection, eye protection, safety shoes,
protective gloves, etc.) when using the machine.

3.4. Requirements of an operator
In the following chapters the requirements and the qualification of maintenance and technical staff
are described.
3.4.1. Qualification
All the work on the Equipment require specialised knowledge and skills of the staff. Everybody, who
works on the Equipment, must meet the following requirements:
– Personnel should be authorized for the corresponding activities.
– Qualified for the corresponding activities.
– Instructed for safe and correct operation of the Equipment.
– Are familiar with the safety devices and the way they function.
– Are familiar with this manual, especially with the safety instructions and the chapters that
relate to the activities performed.
– Are familiar with general instructions for working safely and preventing accidents.
– In general, all the persons must have one of the following minimal qualifications: Qualified
staff that can work with the equipment unassisted.
Life cycle Examples of activities of Information about the

maintenance staff qualification of
1
maintenance staff
– Trained / 3
Professionals
instructed
2
staff
Transport – Lifting X
– Loading
Unloading
–
Installation and – building-up and X X
commissioning fastening of the Equipment
- qualified staff
–
Connection of the power supply
- qualified staff
Filling of the Compressor with
– compressor oil and lubricating
of the motor with grease
- trained/instructed staff
Life cycle Examples of activities of Information about
maintenance staff qualification of
maintenance
Trained / 3
Professionals
instructed
2
staff
– greasing of the motor X X
Set up teach / – Adjustment/re-adjustment for X
program and / or other details/check parts
convert – enter/change
– Testing of programs
Operating – Switching on X
– Operating
– Monitoring
– Switching off
Cleaning – Cleaning – trained-/-instructed X X
Maintenance staff
– Refilling of screw compressor oil
– Disconnection of the power
supply - qualified staff
– Dismantling/repair of the
components - qualified staff
Trouble shooting – Disconnecting of the power X
and repair supply
– Trouble shooting
– Dismantlement/disconnection
of the components
– Repairs
Dismantling, – Disconnecting of the power X
Decommissioning supply
– Dismantling
– Lifting
– Loading
– Unloading
Table 9: Qualification of the staff
1* According to the definition of the machine guidelines, the operating person is the person or
persons, who are responsible for the installation, operation, cleaning or transport of machines.
2* As trained / instructed personnel, a person who has been informed of the tasks assigned to him
and the possible dangers of improper conduct and who has been trained as necessary. He will also
be instructed on the necessary protective equipment and protective measures. Personnel that are
still being trained, may only operate the compressor under the permanent supervision of an
experienced person.
3*Experts A qualified person is a person who, based on his professional training, knowledge and
experience, can assess the work which has been transferred to him and recognize possible dangers.
He shall also be aware of the relevant provisions.
3.4.2. Operator Groups

In this manual, a distinction is made between operator groups and technical staff:
Staff Qualification
Maintenance staff Corresponding instruction in the

areas:
– Function processes of the Equipment
– Operating procedures
Knowledge in the areas:

– Competence and abilities at the workplace
– actions in case of errors and accidents.
Technical staff Advanced knowledge in the following areas:

– Electrical
- Electro mechanic
Authorization for activities (in accordance with safety technique

standards):
– Commissioning
– Equipment earthing
– Knowledge about equipment
– In depth knowledge of construction and the way the

equipment functions.
Table 10: Operator Groups
3.4.3 Specialised knowledge

The following activities can only be performed by staff with specialist knowledge:
Activities Qualification
Working with electrical Professional electrician

components

Working with Industrial mechanic or trained technician. The work can only
mechanical components be performed under supervision of an industrial mechanic in
accordance with the general rules of technique.
Table 11: Activities and knowledge
3.5. Personal protective equipment

Personal protective equipment is designed to protect personnel against hazards that could affect their
safety or health at work.
When carrying out work on the machine, personnel must wear personal protective equipment. These
are indicated separately in the individual sections of this manual. This personal protective equipment
is explained below:
- Always wear the personal protective equipment required in the various sections of this manual
before starting work.
- Follow the instructions given in the work area for personal protective equipment.
Description of personal protective equipment
Symbol Meaning
Protective gloves
Protective gloves are designed to protect the hands from rubbing,

scratches, splinters or more serious injuries because of touching hot or
cold surfaces.
Protective shoes
Protective shoes are designed to protect against falling parts and

materials as well as from sharp objects.
Protective work clothes
Protective clothing is well-fitting workwear with low tear strength, with

sleeves and without protruding parts. It is mainly used to protect against
movement by moving machine parts. Do not wear rings, chains, jewellery
and uncovered long hair.
Protective glasses
Are designed to protect the eyes from flying small parts and liquids.

Light respiratory protection
The light respiratory protection is designed to protect against toxic dust.
Ear protection
Is designated to protect against hearing damage.
Table 12: Mandatory signs

3.6. Residual risk
The following residual hazards cannot be eliminated.
- Danger if unauthorized or unqualified persons operate the machine.
- Danger if the machine is not serviced regularly.
Therefore, the operator must ensure that only authorized and qualified persons have access to the
machine and its command centre/control panel.
3.7. Procedure in case of an accident
NOTE
Basic rules for accidents
Get the injured out of danger! Administer first aid and call the rescue service
via the nearest telephone immediately as well as inform superiors!
When you call the ambulance, pay attention to the following:
– What happened?
– Where did it happen?
– What are the injuries or symptoms of the injured person?
– How many injured?

NOTE
First aid
Attend a first aid course to help you with emergencies.
4 Transport and installation
The transport can be carried out by means of a forklift truck or a suitable truck. To prevent life
threatening injuries and property damage during transport and installation, observe the following:
- Transport and installation may only be carried out by qualified and authorized persons.
- The load holding means and the lifting means must comply with the provisions of the accident
prevention regulations.
- When selecting the load receiving means and the lifting means, consider the total weight of
the machine, which can be taken from the documentation in the separately attached technical
data of the machine.
- Transport routes must be adequately measured/calculated. Doorways must be at least 5 cm

wider and higher than the transport unit including the means of transport.
- The transport route should be checked by a third person.
The most effective installation is ensured, when the described installation process Is respected.
The following chapters provide an overview of the necessary steps for the transport and the
installation of the machine.
Safety instructions for transport and installation

- All work on electrical equipment may only be carried out by qualified electricians
- This installation guide is not a substitute for the necessary professional training.
See also: Operating and installation conditions page 32

4.1 Required tools
These are the required tools to install the system:
- rotary hammer,
- machine water level
- measuring tape,
- screwdrivers (various sizes)
- Wrench (various sizes)
- Electromechanical tool.
If special tools are required, you will be informed prior to installation. The transport can be performed
using a forklift.
4.2 Transport
CAUTION
Danger of injury by tilting
The centre of gravity of the machine is relatively high. When crossing
obstacles, the machine can tilt.
- Do not cross obstacles.
- Before proceeding, ensure that the transport route is clean and free of
obstacles.
The components of the machine should be transported to the installation site with a forklift truck.

Transport with the forklift
WARNING
Danger of falling loads
Suddenly dropping lifted loads will result in a risk to life.
- Do not stand under raised loads!
- Ensure that the equipment is correctly placed on the
forks of the forklift truck during transport.
- Observe the centre of gravity of the goods to be
transported!
ATTENTION
Damage by transport with the forklift truck

The machine components can be damaged during transportation with the forklift
truck by using unsuitable anchor points.
- When aligning the forks, do not damage any attachments of the system /
system components.
- Carefully lift the machine
ATTENTION
Protect from moisture

The machine components in the packs can be damaged by moisture
- Protect the packs from moisture and keep them dry.

Symbol Meaning
Protective gloves
Protective gloves are designed to protect the hands from rubbing,

scratches, splinters or more serious injuries because of touching hot or
cold surfaces
Table 13: Personal protective equipment
Follow these instructions to transport the equipment safely using a forklift:
- Use only forks with allowable length.
- Lift the Equipment/its components from the side designated for this.
- If necessary, put wooden beams under the Equipment/its components during the transport.
- Transport the Equipment/its components only on the horizontally located forks of the forklift.
Picture 18: Transport with the forklift
A Distance of the forks B Forks must be longer than the load
C Place a wooden beam

underneath

4.3. Unpacking and removing of package
Remove the consignment carefully and in accordance with environmental protection requirements.
4.4. Installation
In the following chapter the conditions and the instruction plan for the installation of the equipment
are explained.
4.4.1. Place of installation and infrastructure

Before the installation, the installation place must meet the following conditions:
- The location surface of the equipment must be flat and firm.
- The safe and secure location of the equipment must be provided.
- The installation place should be roofed, be protected against the weather and frost (minimum +
3 ° C room temperature).
- The installation place must be ventilated.
- The power supply at the drive side is available (see Installation of electrical components (page
52).
- The installation place must be chosen so that the components are easy to reach and in an
unhindered position where there is accessibility.
- The machine must not be exposed to direct sunlight.
- Externally heating the machine by other heat sources must be excluded.
- The machine should not be exposed to vibrations.
- At the installation place rescue equipment and escape exits must be freely accessible.
- Fire protection measures should be taken at the installation site.
- There are no machines nearby, that can cause negative electrical or electromagnetic effects.
- The machine room must have forced ventilation and exhaust air Ventilation from the
equipment, considering the residual pressure. Exhaust air can be used for heat regeneration.
- The use of equipment in an explosive atmosphere is forbidden.

Before installing the machine, please observe additional conditions for the installation location and
the infrastructure, which are contained in the technical data in the complete documentation. These
are:
- Observe the cooling air volume and exhaust air volume as well as the ducting cross section to
prevent the machine room from heating up.
- Electrical connections.
- Protection of the external isolatable main switch.
- A sufficient safety distance to the building wall should be considered for service work.
The compressor must be connected to the compressed air network of the operator with a flexible
hose (max. 1.5 m). Shut-off valves in the compressed air line of the compressor and the following
compressed air receiver, must be installed.
See also: Operating and mounting conditions page 32
4.4.2 Installation and Connection
CAUTION
Beware of obstacles on the ground
If you are not careful, there is a risk of injury from stumbling
– Pay attention to obstacles on the ground.

– Avoid tripping points when laying cables, hoses and pipes.
– Use appropriate cable ducts, bridges.
ATTENTION
Material damage caused by condensation

Moisture in the air can cause condensation and damage the compressor.
The cooling air must be dry, cool and dust-free.
NOTE
Install the machine so that the noise and vibration values are as low as
possible during operation
a) Move the equipment to the location.

See also: Transport page 46
4.4.3 Installation of the mechanical components

Place the machine at the intended location, ensuring the following conditions.
- All legal regulations must be clarified on the spot and their compliance must be ensured.
- The condition of the ground and space available must be clarified before the machine is
installed to ensure safe operation for the personnel and the machine in the long run.
- The machine may only be installed, put into service and / or stored by specially trained
specialists.
- All installation and infrastructure requirements are met.
- Set up the machine according to the installation plan.
- Ensure sufficient clearance for maintenance and repair work on the machine during
installation.
- Ensure that the air circulates freely around the machine.
Remove transport safety devices

- Transport safety devices must be identified and removed during installation

NOTE
Keep transport safety devices with the machine for future possible transport.
NOTE
Equipment damage caused by incorrect installation is excluded from

warranty.
NOTE
If you have questions concerning the installation of the pipe system, please
contact the Tolpec customer service department.
4.4.4 Installation of the electrical components

To operate the machine, a main switch with a corresponding fuse must be installed.
DANGER
Electric shock due to high voltage when working on the electrical
components of the system
An electric shock can result in serious injury or death.
- All work on the electrical system can only be carried out by qualified
electricians.
- Disconnect the system from the power supply before carrying out any
work on the electrical system.
- Check the tension-free.
- Ground the system.
- Cover the adjacent area or barrier it off when working with electricity
related parts.

Install a main switch with a blocking device on the operator side and a fuse in the supply line to the
machine according to the connection values of your machine.
NOTE
You can find all information on the design of the fuse for the machine in the
technical data
4.4.5 Final Check
NOTE
The following tests can only be carried out by specially trained personnel.
Tolpec’s authorized partners give an accurate instruction in the final inspection
during commissioning.
Before you start the machine for the first time, the following safety checks must be carried out:
- Are all protective guards installed?
-Do all the safety systems work?
5 Commissioning
Before starting the Equipment for the first time, the following must be proven correct:
 Was the installation with its final control fully completed?

 Are all the protection devices installed?
 Does the oil level in the oil tank receiver range within the marked limit?

Picture 19: Rotation direction arrow on the air end
1 Rotation direction arrow
– Check the direction of rotation of the motor on the air end.
– In models with a belt drive: is the belt tension corresponding?
Safety instructions for commissioning
DANGER
Danger to life by electric shock
There is a risk to life when touching energized parts. Electrical components that are
inserted can unintentionally cause movements and injuries.
– Switch off the system before maintenance and secure it against
accidental restart.
DANGER
Danger to life due to stored charges
Electric charges can be stored in electronic components, which are retained even
after switching off and disconnecting from the power supply. Contact with these
components can result in serious or fatal injuries.
– Disconnect the components completely from the power supply before working
on these components. Allow 3-10 minutes to ensure that the internal capacitors
are completely discharged.

WARNING
Danger due to missing safety devices
Missing protective covers can lead to serious injuries.
– Mount all protective covers which may have been removed for
installation before commissioning the machine.
– Check all safety devices before starting the machine.
CAUTION
Risk of injury from noise
The noise level in the work area can cause serious hearing damage.
– Always wear ear protection, when working.

– Stay as short as possible in the danger area.
5.1 Check the safety devices
Check the safety devices for perfect function:

- before first use,
- before commissioning after prolonged stoppage,
- daily before work starts.
a.) Check:
– Are all protective covers closed?
– No visible defects on the safety valve?
b.) Start the machine.
– Monitor the temperature and pressure development to check the function of the sensors
c.) Press the emergency stop buttons and check that the machine is safely switched off.
The safety devices are tested.
See also: Commissioning page 53

5.2 First Commissioning
WARNING
Crushing and pulling danger by the drive shaft of the motor and by the
V-belts
When working on an open machine during commissioning, special caution is
advised, since moving parts must be used in the working area.
a.) Commissioning activities may only be carried out by the specially
authorized and trained staff. The setup must be carried out from a
safe position.
b.) Ensure that there are no persons in the danger area before the
movements are triggered.
c.) Depending on the situation, the danger area must be blocked by a
red and white chain during set-up.
d.) Wear protective gloves
NOTE
Before operating the machine, read and follow the safety instructions page 33
of this manual, carefully.
Ensure that all mechanical and electrical work is finished and that no one is in
danger.
All safety devices are assembled, tested and ready for operation
 All protective covers are installed.

 For belt driven models the belt tension is set correctly.

Picture 20: Oil-receiver
1 Pressure gauge 2 Oil filler neck
3 Oil level gauge 4 Oil outlet
a.) Check the oil level at the oil level gauge (see compressor oil and lubricant on page 93).
b.) If necessary, fill the oil tank with the compressor oil at the oil filler neck. The marking indicates the
necessary oil level during operation of the machine. Keep the oil quantity and the required
technical specifications of the oil exact. Observe the technical data for your model.
Picture. 21: Intake valve mounted on air end
1 Dismantle intake valve from air end

NOTE
For initial start-up or after two weeks or longer

The compressor unit must also be supplied with compressor oil during
initial commissioning and after shutdown times.
– Loosen the intake manifold mounting bolts at the inlet of the

compressor unit.
– Remove the intake regulator.
– Fill approximately 0.5 - 1 l compressor oil into the inlet of the
compressor unit.
– Assemble the intake regulator and tighten the mounting bolts.
CAUTION
Danger of skidding by leaking oil.

There is a risk or chance of injury.
a.) Check the machine for leakage and leaking oil.
b.) Eliminate leaks and leaked oil immediately.
c.) Immediately remove any excess oil from the machine.
d.) Close the shut-off valve of the compressed air line attached to the compressed air network of the
operator after the compressed air storage.
e.) Insert the plug for the power supply, or set the power supply to the machine
f.) Turn the main switch, or reset the emergency stop button.
• The controller starts and a start screen appears after approx. 5 seconds.
• The machine is ready for operation.
CAUTION
Destruction of the compressor unit by an incorrectly connected motor
a.) If the power supply is connected incorrectly and the compressor is
switched on, the machine can be destroyed in a very short time. An
ALARM signal indicates that the direction of rotation of the motor is wrong
and that the rotating field must be corrected.
b.) Before the compressor is started, a qualified electrician must check the
power connection and the rotating field.
g.) Open the appropriate guard / panel to have a clear view of the drive and start the compressor
briefly with ON.
Picture 22: Direction arrow on air end
1 Direction arrow for direction of rotation of motor or

air end.
h.) Stop the machine immediately after 2 seconds with the emergency stop button. When starting
and running the motor, the direction of rotation can be checked using the directional arrow on the
compressor unit.
i.) Unlock the emergency stop button and start the machine with ON.
j.) Check the pipe system for leaks.
k.) Mount the protective guards.
l.) Check on the display whether the air compressor reaches the set pressure and then reduces
pressure.

m.) Check whether the compressor is switched on again when the set minimum pressure is reached,
or again begins to compress and the pressure increases again.
n.) Check the air compressor for the presence of non-characteristic vibrations and noises. Eliminate
the causes of abnormal equipment.
o.) Open the ball valve of the compressed air line very slowly to the customers compressed air
network after the compressed air tank, so that a controlled pressure equalization can take place.
NOTE
Check the condensing temperature
The compression temperature can be read at 65 ° C and 85 ° C during
operation, depending on the ambient conditions.
Set up user settings
a.) Use the operating instructions for the control to configure the user settings.
b.) Start the compressor with [ON] on the control panel.
c.) Stop the compressor with [OFF] on the control panel.
The first commissioning has been completed.

See also: Technical documentation / Annex list page 99 and Operating and installation conditions
page 32
5.3 Daily commissioning

The first commissioning has been successfully completed.
The surrounding area is clean, oil-free and illuminated.
The power supply is connected
a.) Check the oil level and refill if necessary.
b.) For models with a belt drive, check the belt tension.

c.) Remove the protective covering / panels of the entire machine and check the interior for dust
and contamination; Use the fan to remove any contaminants.
d.) Mount the panels.
e.) Check the connection cable for visible damage. Never operate the machine if the cable is
damaged!
f.) Ensure that all safety devices and covers are installed.
g.) If fault messages are displayed on the control panel, these must be corrected according to the
operating instructions for the machine and the control panel.
Daily commissioning is complete.
See also: First Commissioning page 56
5.4 Commissioning after Storage
WARNING
Danger of injury due to unintentional starting of the machine
Perform the mechanical tests only with the main switch off.
a.) The procedure for commissioning after storage corresponds to the first commissioning:
b.) Check all components for free movement, if necessary, ensure the free movement of the
components.
Carry out commissioning after storage according to the first commissioning.
See also: First commissioning (page 56)
6 Operation
The following principles apply when operating the machine:
This work must be carried out by trained and authorized operators. The machine is only allowed to be
operated, if all the safety devices are properly installed and functioning.
The following principles apply when operating the machine:

a.) Check the proper functioning of the safety devices
b.) Inform the responsible person immediately if safety devices have failed or are disrupted.
c.) Ensure that nobody is in danger before switching on the machine.
d.) Wear your personal protective equipment (e.g. protective gloves) when operating the machine.
e.) The removal of protective devices during operation of the machine is not permitted.
f.) Smoking and open fires are strictly prohibited near the machine.
Safety instructions for Operating
CAUTION
Danger of skidding on leaking oil.

b.) Eliminate leaks and leaking oil immediately.
CAUTION
Risk of injury from noise.
a.) Always wear ear protection when working.

b.) Stay as short as possible in the danger area.
See also: Safety Page 33

6.1 Description of the working area
Picture 23: Areas of work and maintenance
1 Screw compressor 2 Maintenance area
3 Working area
Table 18: Working and maintenance areas
The operating area and the control panel are in front of the machine during automatic operation.
The areas for set-up, maintenance and maintenance work are the areas in front, on the side and
behind the machine.
6.2 On and off sequence
6.2.1 Switch on
Before switching on
Carry out the following work and checks:
a.) Check the machine and all components for external damage.
b.) Check if there is oil leakage.

c.) Check the soil for contamination:
If you notice any damage or contamination, repair or remedy this.
The machine can be switched on.
6.2.2 Switch off

Switch off the machine with (0) button at the control panel of the unit.
a.) The machine changes from load- to idle mode so that no further air is compressed.
b.) Motor stops after run on time.
c.) The power supply is shut off.
d.) Machine is switched off.
6.3 Operating Modes

A distinction is made between the following operating states or operating modes of the machine:
– Voltage-free: main plug disconnected or main switch switched off.
– Emergency stop condition: emergency stop device tripped.
– Automatic operation: Automatic execution of the machine program.
– The compressed air is generated automatically.
WARNING
Danger of injury due to unintentional starting of the machine
The machine can start automatically in automatic mode.
a.) Perform the mechanical tests only with the main switch off.

6.4 Parameter list
The parameter list can be found in the separate operating instructions for the control unit
7 Faults
Observe the following principles, when you are looking for errors and correcting errors: This work
must only be performed by specially trained and authorized specialists.
a.) Allow warm components to cool before starting work.
b.) Wear suitable protective clothing.
c.) Before re-commissioning, mount all safety devices that are provided.
d.) Check the proper functioning of the safety devices.
e.) After completion of the work, remove all tools and objects from the movement area of the
machine
Safety instructions for faults
DANGER
Danger to life by electric shock.
There is a risk to life when touching energized parts. Electrical components that
are inserted can inadvertently cause movements and injuries.
a.) Switch off the system before maintenance and secure it against accidental
restart.

DANGER
Danger to life due to stored electrical charges

Electric charges can be stored in electronic components, which are retained
even after switching off and disconnecting from the power supply. Contact
with these components can result in serious or fatal injuries.
a.) Disconnect the components completely from the power supply before working
on these components. Allow 3-10 minutes to ensure that the internal capacitors
are completely discharged
WARNING
Risk of injury from hot surfaces
Some components of the compressor become hot during operation.
a.) Before starting work, let the compressor cool down for 30 minutes.
b.) Wear protective gloves
WARNING
Danger to life by a liquid jet emerging under high pressure
In the case of defective hoses, tubes or components, a liquid jet can escape
under high pressure. The liquid jet can lead to the most serious injuries and
death.
 Keep persons out of danger and never place objects near the liquid jet.
In case of accidental contact with the liquid jet, first-aid measures must
be taken and immediately seek medical advice.
 Immediate emergency stop. If necessary, initiate further measures to
reduce the pressure and stop the liquid jet.
 Take out and dispose of leaking liquids properly.
 Repair defective components immediately.
WARNING
a.) Mount all protective covers which may have been removed for installation
before commissioning the machine.
b.) Check all safety devices before starting the machine.
CAUTION
Risk of injury due to noise.

7.1 Faults during operation
Faults occurring during operation are displayed in the display by means of symbols.
7.1.1. Troubleshooting Table

FAULT / ALARM Probable causes Troubleshooting Fixed by**
The machine does Wrong power connection Check power connection MS

Not starting Compressor is selected as See symbols of the MS
"Slave" and starts with remote control system and
control data in the controller
Wrong electric phase sequencer Check the phase QT

sequence
Emergency stop button is Release the MS
released emergency stop button
There are unsolved faults in Solve the Faults and MS

the operating controller confirm the error
message
Switch-on time of the program is Check the switch-on timer SP
activated
Network pressure is higher than Check the pressure QT
the switch- on pressure values and correct them,
if necessary
Oil temperature too Compressor oil deficiency in the Check the compressor QT
high machine oil level of the oil receiver
and refill oil
Environment or suction Check the environment MF
temperature is too high temperature and
ventilation of the machine
room
** MS = Maintenance staff, QT = Qualified technicians, SP = Service and distribution partner SCC
FAULT / ALARM Probable causes Troubleshooting Fixed by**
Oil temperature too Cooler or filter pad of cooling air Clean the cooler or KF
high is blocked replace filter pad of
cooling air
Oil fine filter is blocked Replace the oil fine filter SP
Compressor oil polluted or aged Check and change SP

the compressor oil
The oil cooler of the compressor Check the Oil cooler and SP
is damaged replace it, if necessary
Network pressure The compressed air Check function and size of QT
constantly consumption is higher than the Equipment
decreases delivery capacity of the
Equipment
Leakages in the compressed air Check compressed MS
network air network for leaks.

The suction filter is heavily polluted Replace the suction filter QT
or blocked
The drive belt is broken Replace the drive belt SP
The intake valve does not open Check the function and SP
operation of the intake
valve
Relief valve at the intake valve is Check the function and SP
damaged operation of the valve
High pressure fault Oil fine filter is blocked Replace the oil fine filter SP
The intake valve does not close Check the function and SP
after reaching the maximal operation of the intake
pressure valve
Higher network pressure in the Stabilize the system SP
compressed air network pressure; check the
pressure settings on
other compressors
Ball valve after compressor is Slowly open the ball QT
closed valve to perform
stabilization of the
pressure in the network.
High oil expenditure Oil level is too high Check the oil level, and MS
reduce oil level over ball
valve at oil outlet of the
receiver
Oil return line is blocked or Check oil return line and SP
nonreturn valve in the oil return non-return valve.
line is defective
FAULT / ALARM Probable causes Troubleshooting Fixed by
High oil expenditure Oil level is too high Check the oil level, and MS
reduce oil level over ball
valve at oil outlet of the
receiver
Oil return line is blocked or Check oil return line SP
nonreturn valve in the oil return and non-return valve.
line is defective
Trouble The pressure sensor does not Replace the pressure SP
work sensor
Leakage in the tubing system Check the tubing system, QT
repair the leakage

Error of the control system Contact the Manufacturer SP
Unusual noises The distribution and service By the distribution and SP

partner /SCC needs to check service partner SCC
Table 14: Troubleshooting table
7.1.2 Commissioning after Troubleshooting
 The machine is switched on at the main switch.

a) Reset the emergency stop button.
b) Remedy the fault messages on the control panel
c) Ensure that no persons are in the danger area
d) Start the Machine at the Controller with button “ON” or “I”
8 Maintenance and testing during operation

The following principles apply to maintenance and testing of the machine:
This work may only be performed by specially trained and authorized specialists.
a.) Switch off the machine before starting work and secure it against re-activation.
b.) Hot components must cool down before starting work.
c.) Depressurize the system.
d.) Wear suitable personal protective equipment.
e.) Secure the work area with a red and white chain to prevent unauthorized persons entering.
f.) Use suitable lifting devices for lifting.
g.) Before re-commissioning, mount all safety devices as provided on the factory side.
h.) Check the proper functioning of the safety devices.
i.) After completing the work, remove all tools and objects from the machine.
j.) After the work has been completed, remove all contaminants and oil stains around the
machine.
Safety instructions for maintenance and testing during operation
DANGER
There is a risk to life when touching energized parts. Electrical components
that are inserted can inadvertently cause movements and injuries.
a.) Switch off the system before maintenance and secure it against
accidental restart.

DANGER

a.) Disconnect the components completely from the power supply before
working on these components. Allow 3-10 minutes to ensure that the
internal capacitors are completely discharged
WARNING
a.) Mount all protective covers which may have been removed for
installation before commissioning the machine.
b.) Check all safety devices before starting the machine.
WARNING
Danger of injury due to improper repair
Improper maintenance and repair may result in serious injury. Disassembled
components and tools are potential accident hazards.
a) Work carefully.
b) Ensure sufficient ting area.
c) Keep the assembly site tidy and clean

WARNING
Risk of injury from compressed air
Unpredictable discharged air can damage the eyes, stir up dust or lead to
uncontrolled movement of hoses.
a.) Before machine maintenance and repairs, depressurize and bleed the
machine, then wait 5 minutes.
b.) Have defective components repaired promptly by qualified personnel.
c.) Wear protective glasses
WARNING
b.) Wear protective glasses.
WARNING
Danger to life by liquid jet emerging under high pressure
In the case of defective hoses, tubes or components, a liquid jet can escape under high
pressure. The liquid jet can lead to the most serious injuries and death.
a.) Never place objects near the liquid jet. Keep persons out of danger. In
case of accidental contact with the liquid jet, first-aid measures must be
taken and immediately seek medical advice.
b.) Immediate emergency stop required. If necessary, initiate further
measures to reduce the pressure and stop the liquid jet.
c.) Clean up and dispose of leaking liquids properly.
d.) Repair defective components immediately.

WARNING
Danger to life due to improper work on the pressure receiver
Improper handling of pressure receivers can cause sudden pressure
reduction and can lead to serious injuries and death as well as
substantial damage to property.
a.) Never perform welding or soldering work on the pressure tank.
b.) Do not carry out any mechanical work on the pressure receiver.
c.) Fully reduce the pressure receiver before the pressure hose / tube can
be disconnected over the condensate ball valve
d.) Start working on the pressure receiver only after the air pressure has
been completely reduced.
WARNING
Risk of injury from hot materials
Operating fluids can reach hot temperatures during operation. Skin contact
with hot materials causes serious skin burns.
a.) Always wear heat-resistant protective clothing and protective gloves
when carrying out any work with fluids.
b.) Before any work with fluids, check that they are not hot. If
necessary, wait until they have cooled down.
CAUTION
Danger of skidding on leaking oil.

b.) Eliminate leaks and leaking oil immediately.

CAUTION
Risk of irritation to eyes and respiratory system
At hot temperatures or mechanical atomization of cooling liquid due to
defective components, irritating fog can escape from the cooling liquid.
a.) Allow the compressor to cool before starting work.

b.) Ensure sufficient ventilation at the assembly site.
c.) Wear light respiratory protection and protective glasses
CAUTION
Risk of injury from noise.
CAUTION
Risk of injury from cooling liquid mist
Hot temperatures or mechanical atomization can lead to a cooling liquid mist.
Cooling fluid mist can irritate the eyes and the respiratory tract.
a.) Wear respiratory protection and protective glasses, when working

on the coolant system and in the event of a coolant mist ensure a
fresh air supply.
NOTE
Perform regular maintenance
Regular maintenance increases the service life of the machine and is an
absolute prerequisite for safe and efficient operation.

NOTE
Maintenance contract
Tolpec GmbH offers maintenance contracts. Our employees or authorized
specialists authorized by Tolpec will provide you with the necessary
maintenance and thus ensure a long service life of your machine as well
as a reliable, efficient, quality compressed air system. If you would like to
use this service, please contact Tolpec Customer Service.
8.1 Secure the machine against restarting
The machine is secured by closing the main switch to prevent restarting.

On the operator side, a main switch with a corresponding fuse must be installed (see Installation
of electrical components (page 52)
WARNING
Danger by starting the machine
The uncontrolled start-up of the machine can lead to serious injuries or
death. Only when the machine is switched off, can work on it be carried out
a.) Switch off the machine at the main switch and secure it against
reactivation
Secured /locked Main Switch / Option
Picture. 24: Locked electrical main switch (picture example)
1 Main Switch
Procedure for securing the main switch against accidental reconnection

a.) Turn the main switch to “0”
b.) Secure the main switch with a padlock. The key must be handed over to the employee
responsible.
– The machine is protected against reconnection
Release the Main Switch

a.) Before restarting, ensure that there is no danger to persons
b.) The lock may only be opened by the employee responsible.

8.2 Maintenance schedule
The following chapter describe the intervals, at which maintenance must be carried out on the
machines.
NOTE
Shift of maintenance intervals

The indicated maintenance intervals refer to operation in the specified
ambient conditions. Under unfavourable ambient conditions, maintenance
intervals can be significantly reduced. Therefore, during the regular
maintenance work, the condition of the machine, the components / oil and
ambient conditions should be checked to adjust maintenance intervals, if
necessary. If you are not sure, please consult the SCC Sales and Service
partner.
8.2.1. Daily
Components What is to do* Description of works Performed

by**
Whole Equipment V Visual inspection for wear and damage MS
Oil level gauge Ch Check oil level and correct if necessary MS
ATTENTION! In the case of a large oil
deficiency, there is excessive heating,
which in extreme cases can lead to a
deflagration.
Display of Controller V Check the actual and set values of the MS
parameters for pressure and
temperature.
* V = Visual control, Ch - Check, R = Replacement, C = Cleaning
Table 15: Daily maintenance plan
8.2.2. Weekly
Components Scope of work* Description of works Performed
by**
Whole Equipment V, C Visual check for cleanness MS
Cooler C Cleaning QT
Condensate (only Ch Drain condensate at the compressed air MS

for machines with receiver, when no automatic condensate
pressured air drain is installed
receiver) TD range.
* V= Visual control, Ch= Check, R= Replacement, C= Cleaning
** MS= Maintenance staff, QT= Qualified technicians, SP= Service and distribution partner SCC
Table 16: Weekly maintenance plan
8.2.2.1. After 100 Operation hours

by**
Cooler Ch Check the cooler for contaminations. QT
Hoses, components Ch Visual check for leaks. QT

Check condensate Ch Check the Equipment for condensed QT
water. (oil)
Temperature Ch Check the Oil temperature QT
Drive Ch Visual check of belt drive and tension. QT

Table 17: Maintenance plan after 100 operation hours
8.2.3. After 500 Operation hours

by**
Oil level Ch Correct the oil level, if necessary QT
Hoses, components Ch Visual check for leaks. QT
Drive Ch / R Visual check of belt drive and tension. QT
Table 18: Maintenance plan after 500 operating hours
8.2.4. Each 2000 operating hours
Components Scope of work* Description of works

Performed
by**
Electromotor R Lubricating of bearings QT (*SP)
Drive Ch / R Visual check of belt drive and tension. QT
** MS = Maintenance staff, QT = Qualified technicians, SP = Service and distribution partner

SCC
Table 19: Maintenance plan for each 2000 operating hours
8.2.5. Each 3000 operation hours or 1 / Year
Compressor size until 18 kW

by**
Electric V, Ch Visual check for damages, check the QT (*SP)

connections, electric connections for strength of
switches and connection
connection cable
Air filter R Replace the air filter / QT (*SP)
Oil filter R Replace the oil filter QT (*SP)
Oil fine filter / R Replace the oil fine filter / separator QT (*SP)
separator element. element.
Change of oil R Change the oil QT (*SP)

by**

General Ch, R; C, V Maintenance of the entire system. Oil fine SP
maintenance of separator, safety valve, intake regulator,
compressor drive, temperature regulator, minimum
pressure check valve, tightness and
function test.
Recommendation: (* SP): filter and oil
change etc. are carried out by the SCC
sales and service partner within the scope
of the overall performance)

8.2.6 Each 4000 operation hours or 1 / Year
Compressor size from 22 kW

by**
Electric V, Ch Visual check for damages, check the QT (*SP)
connections, electric connections for strength of
switches and connection
connection cable
Air filter R Replace the air filter / QT (*SP)
Oil filter R Replace the oil filter QT (*SP)
Oil fine filter / R Replace the oil fine filter / separator QT (*SP)
separator element. element.
Change of oil R Change the oil QT (*SP)
General Ch, R; C, V Maintenance of the entire system. Oil fine SP
maintenance of separator, safety valve, intake regulator,
compressor drive, temperature regulator, minimum
pressure check valve, tightness and
function test.
Recommendation: (* SP): filter and oil
change etc. are carried out by the SCC
sales and service partner within the scope
of the overall performance)

8.3 Maintenance work
The following sections describe how maintenance should be performed.
8.3.1 Visual Inspection

Perform the following visual inspections:
a.) Check the machine and all components for external damage
b.) Check all safety devices for external damage
– If you notice any contamination or damage, Report it and Repair immediately.
The visual inspection of the machine is complete.

8.3.2 Cleaning
ATTENTION
Danger of damage caused by unsuitable cleaning agents and

cleaning procedures
Unsuitable cleaning agents can cause damage to the machine or machine
components.
a.) Wear protective gloves and glasses.
b.) Use only mild detergents
c.) Do not use high pressure equipment as well as aggressive or
corrosive detergents
Components Methods Cleaning agent Notice
General surfaces Clean with cleaning cloth and Solvent-free Follow the
detergent detergent recommendations of the
detergent manufacturer
Floor Wet the floor and wipe with Solvent-free Follow the
mop detergent recommendations of
the detergent
manufacturer.
Table 22: Common recommendations for cleaning
NOTE
Special cleaning instructions
Some components must be dismantled for cleaning. For this reason, you will
find the specific instructions for cleaning in the Maintenance section under the
corresponding component
The surfaces of the machines are easy to clean and antistatic.
8.3.3 Checking and servicing the mechanics
In case of damage to the mechanical devices, immediately take the machine out of operation
and start a thorough repair using original spare parts.

ATTENTION
Component damage due to insufficient maintenance
Insufficient maintenance results in more wear and higher repair costs.
a.) Carry out the necessary maintenance work
according to the manufacturer's instructions.
b.) Observe the manufacturer's instructions for the
maintenance of the mechanical components.
The following tightening torques apply to the stability and functionality of the mechanical
components of the compressor:
Safety screws / -nuts, construction B 158/193/196/251
Class 8.8 Unit Class 10.9 Unit
M5 3.69 (5) lbf ft (Nm) 7.38 (10) lbf ft (Nm)
M 12 50.89 (69) lbf ft (Nm) 111.37 (151) lbf ft (Nm)

Table 23: Tightening torque of the safety screws
Safety screws / -nuts, construction DIN 912/931/933/934/982
Class 8.8 Unit Class 10.9 Unit
M5 4.43 (6) lbf ft (Nm) 6.27 (8.5) lbf ft (Nm)

Table 24: Tightening torque of the safety screws

The machine is depressurized.
a.) Use the separate key to unscrew the oil filter. Clean the fitting point. Wet the new gasket
with oil before installing the new filter. Screw in the new filter. Start the compressor and
check if there are any leaks. The oil filter has been repaired
8.3.3.3 Maintenance of the Oil separator
NOTE
Used oil separators depend on the series

In the case of a spin-off oil separator, maintenance is carried out
analogously to the oil filter. If the oil fine separator is integrated in the oil
tank, maintenance must only be carried out by the SCC service partner.
To maintain the Electric motor, it is necessary to regularly lubricate the bearings with the solid
grease Mobile Polyrex EM and Total Multis EP 2.

8.3.3.4 Maintenance of Motors and Bearings
NOTE
The motor and bearings are serviced by the SCC service partner.
To maintain the Electric motor, it is necessary to regularly lubricate the bearings with the solid
grease Mobile Polyrex EM and Total Multis EP 2.
8.3.3.5 Checking belt tension (depending on the model)

The machine must be depressurized.
a.) Open the side cover on the belt drive.
b.) Turn the screw on the clamping device. Adjust the spring and then adjust the
correct tension of the belt: the average pressure should be 3 kg, the deformation
of the belt should be less than 5 mm.
The belt tension is set.
8.3.3.6 Replacing belts (depending on the model)

The machine must be depressurized.
a.) Open the side cover of the belt drive.
b.) Loosen the screw of belt tensioner to loosen the belt.
c.) Remove the worn belt from the shafts.
d.) Place a new strap on the shafts and tension it.
e.) Mount the side cover of the belt drive and restore the machine to operational
condition.
f.) Run the compressor for 10 minutes.
g.) Re-energize and depressurize the machine.
h.) Disassemble the side cover of the belt drive again.
i.) Tighten the belt.
j.) Mount the cover and make the unit ready to operate.
8.3.3.7 Adjust belt pulley (depending on model)

NOTE
The axis alignment motor-compressor stage is set by the SCC service
partner.
8.3.3.8 Adjusting axes (depending on the model)
NOTE
The axis alignment motor-compressor air end is serviced by the SCC service
partner.
8.3.3.9 Maintenance Minimum pressure and non-return valve
NOTE
The minimum pressure and non-return valve is serviced by the SCC service
partner.
8.3.3.10 Maintenance Intake-valve
NOTE
The intake valve is serviced by the SCC service partner.
See also: Contacts page 13
8.3.4 Check and maintenance of electrical parts

a.) Periodically check the electrical system with a visual inspection

b.) Immediately shut down the machine in case of damage to the electrical equipment and
start a proper repair with original spare parts.
See also: Repair page [95]
8.3.4.1 Maintenance of safety devices

To ensure the operational safety of the machine at any time, it is necessary to replace different
safety-related components at the end of their service life.
In the case of damage or failure of a safety device, the relevant component must be replaced
immediately and the entire safety circuit must be subjected to a comprehensive functional test.
Other components may also need replacing.
Contact the SCC sales and service partner.
See also: Contacts page [13]

8.3.5 Check the pneumatic system and service
8.3.5.1 Maintenance of the air receiver on the receiver

mounted machine
Picture: 25: Receiver mounted machine TD-range
1 Safety valve 2 Pressure gauge
3 Ball valve for condensate drain 4 Oil receiver (behind the cover)
(twin - receiver 2 Pcs.)
In the case of a receiver mounted unit with a compressor or a compressed-air refrigerated dryer
built on the compressed air receiver, condensate accumulates in the compressed-air receiver
operation, which must be removed regularly.
Compressed air receivers must comply with the legal requirements of the respective country. A
pressure gauge, a safety valve and a condensate ball valve (for twin receivers two) are mounted
at the base of the compressed-air receiver.

CAUTION
Environmental hazard
The condensate is oily. Dispose of the condensate according to the applicable
environmental and disposal regulations
 Compressor is depressurized and cooled down.
a.) Open the ball valve very slowly and collect the condensate in a suitable container.
8.3.5.2 Check for condensation

In the case of a receiver mounted unit with a compressor, a refrigerated dryer built on the
compressed air receiver, condensate accumulates in the compressed-air receiver operation,
which must be removed regularly.
CAUTION
Danger of injury due to improper work on pneumatic components
 Only qualified personnel can carry out maintenance work on the
pneumatic components.
a.) Wear the necessary PPE (protective clothing, protective glasses,
protective gloves)
NOTE
Condensation due to low operating temperature

To ensure that the air humidity is not condensed, the operating temperature
must be sufficiently high during compression. Frequent turning on and off of
the machine may cause the compressor to fail to reach the required operating
temperature.

CAUTION
Damage caused by condensation in the circuit of the compressor oil
a.) Condensate in the oil circuit can destroy the compressor unit.
Switch off the compressor immediately and secure it against re-
activation.
b.) Close the ball valve to the compressed air network and secure it
against re-opening.
c.) Contact the SCC sales and service partner immediately.
NOTE
Condensate at the bottom of the oil tank
The condensate is heavier than the compressor oil. Therefore, it accumulates
on the bottom of the oil receiver, after a prolonged downtime.
Procedure for testing for condensation

The Compressor is depressurized and cooled down.
a.) Close the ball valve to shut-off the valve on the pressure line and secure it against re-
opening.
b.) Remove the protective covers / panels.
c.) Place a collecting container under the discharge ball valve of the oil receiver
d.) Open the ball valve of the oil receiver and carefully drain approximately 2 litres of
compressor oil.
e.) Close the ball valve of the oil receiver.
f.) Check the discharged compressor oil for contamination with condensate.
g.) If there is condensate in the compressor oil, carry out an oil change.
h.) Re-fill the oil tank with oil or make an oil change if necessary.
i.) Slowly open the ball valve at the oil receiver and make sure that the condensate coming out
is safely received by the collecting container.
j.) Close the ball valve on the coolant pressure tank.
k.) Dispose of used waste oil according to applicable environmental and disposal regulations.
l.) Mount all protective guards and panels.
Restore the operating condition of the compressor

8.3.6 Oil level and Oil change
NOTE
Use correct lubricants
Observe the notes in the section on Compressor oil and lubricant [ 93].
Oil level too high

If the oil level is too high:
 The machine is depressurized.
a.) Turn off the compressor.
b.) Connect an oil drain hose to the shut-off valve on the oil tank.
c.) Carefully open the shut-off valve, as residual pressure can still be present in the oil tank
and let the oil level go down to the required level.
d.) Disassemble the oil drain hose.
e.) Close the shut-off valve.
Picture: 26: Oil Change
1 Oil Receiver 2 Oil filler neck at receiver
3 Oil - Drain ball valve

The machine is depressurized
a.) Connect the drain hose.
b.) Open the oil - drain ball valve to drain the waste oil into the collection container.
c.) Close the oil- drain ball valve.

d.) Open the plug of the oil filler neck.
e.) Fill the oil receiver with the specified compressor oil to the required level.
f.) Make sure that the sealing ring of the oil filler plug is not damaged.
g.) Close the plug of the oil filler neck and tighten it securely with the wrench.
h.) Carefully remove the remaining oil.
i.) Start the machine.
j.) Check the oil level after 30 minutes and refill oil if necessary.
k.) Ensure that there are no new oil leaks in the machine.
NOTE
Shortened interval for oil change
If the compressor is operated in a non-optimal atmosphere, the oil must be
checked and the oil change and service interval must be shortened.
See also: Contact details for Tolpec GmbH and the SCC sales and service partner page 13
Operating and installation conditions page 32
8.3.7 Replacing worn parts

Replace worn parts such as belt drives, filters, etc. at the end of their service life.
For more information, contact Tolpec Customer Service.
Technical documentation / Annex list page 99

8.3 Compressor oil and lubricant
ATTENTION
Damage caused by non-suitable compressor oils

The use of non-approved compressor oils, as well as the mixing of different
compressor oils, can damage the compressor. According to the valid
accident prevention regulations, lubricating oils with characteristics
corresponding to the intended operating conditions must be used.
NOTE
Reduced oil change intervals at higher compression temperatures

At constantly increasing compression temperatures above 90 ° C, the oil
change intervals are reduced by 50%. An accurate analysis of the
compressor oil according to the actual operating conditions can only be
carried out by a compressor oil test in a laboratory
Screw compressor oil:

SCC compressors Oil recommendation: Shell Corena S2 R46.
High performance screw compressor oil ISO VG 46
ISO Viscosity grade (ISO VG) ISO 3448 / DIN 51519 46
Kinematic Viscosity ASTM D445 at 40 ° C 46 mm² / s
Kinematic Viscosity ASTM D445 at 100 ° C 6.9 mm² / s
Flash point 230 ° C
Demulsifying capacity 15min
Pourpoint -33 ° C
As also SCC compressors Oil recommendation: Shell Corena S4 R46.

Bearing grease for motor bearings
Mobil Polyrex EM or Total Multis
8.5 Wear and tear / spare parts
Spare parts must meet the technical requirements defined by Tolpec. Original spare parts are
subject to strict conditions and must meet these requirements.
Tolpec assumes no liability for damage caused by using spare parts from other manufacturers.
Inquiries and orders for wear and tear / spare parts are to be addressed to Tolpec with the
following information:
– Type,
– Item number
– Year of construction
– Part name
– Amount
– Shipping mode
Wear and tear / spare parts
For further information please contact the SCC sales and service partner.
8.6 Customer service through the manufacturer

Tolpec recommends a maintenance contract with the SCC sales and service partner.
In addition, Tolpec is interested in information and experience that arises from the use of
our products so that improvements can be made if necessary. Please contact Tolpec or
your SCC service partner if you have any issues or constructive feedback.
.
See also: Contact Tolpec GmbH and the SCC sales and service partner page 13

9 Repair
The following section describes how the machine is repaired.
NOTE
During the warranty period of the machine, repairs can only be carried out by the
SCC service partner.
Repairs by the operator
After the warranty period of the machine has expired, repairs can be carried out by the operator,
with the appropriate specialist. Tolpec assumes no responsibility for these repairs. If you have
any questions about repairs, contact your SCC sales – and service partner.
10 Decommissioning, storage and disposal

The following principles apply to the decommissioning, storage and disposal of the machine
This work may only be performed by specially trained and authorized specialists.
a.) Switch off the machine before starting work and secure it against re-activation.
b.) Hot components must cool down, before starting work.
c.) Wear suitable personal protective clothing.
d.) Secure the work area with a red and white chain against unauthorized persons entering.
e.) Use suitable lifting aids and lifting devices for lifting.
Safety instructions for decommissioning, storage and disposal
DANGER
There is a risk to life when touching energized parts. Electrical
components that are inserted can inadvertently cause movements and
injuries.
a.) Switch off the system before maintenance and secure it against
accidental restart.

DANGER

a.) Disconnect the components completely from the power supply

before working on these components. Allow 3-10 minutes to
ensure that the internal capacitors are completely discharged
WARNING
b.) Wear protective glasses.
WARNING
Danger to life by a liquid jet emerging under high pressure
In the case of defective hoses, tubes or components, a liquid jet can
escape under high pressure. The liquid jet can lead to serious injuries
and death.
a.) Never place objects in the way of the liquid jet. Keep persons out of
danger. In case of accidental contact with the liquid jet, first-aid
measures must be taken and seek medical advice immediately.
b.) Immediate emergency stop. If necessary, initiate further measures to
reduce the pressure and stop the liquid jet.
c.) Take out and dispose of leaking liquids properly
d.) Repair defective components immediately.

WARNING
Risk of injury from hot materials

Operating fluids can reach hot temperatures during operation. Skin contact
with hot materials causes serious skin burns.
a.) Always wear heat-resistant protective clothing and protective gloves

when carrying out any work with fluids.
b.) Before any work with fluids, check that they are not hot. If necessary,
wait until they have cooled down.
10.1 Temporary Decommissioning

When taking the unit out of service for an extended period, the machine should be carefully shut
down according to the following methods, considering the season and humidity in the
manufacturing plant/compressor house
CAUTION
Machine damage due to corrosion

Store the machine away from moisture and in a frost-free environment
Close the shut-off valve of the compressor in the customer's compressed air network. The
protective cover / panels of the machine must be closed to prevent the penetration of dirt and
moisture.
NOTE
Prevention of condensation during temporary standstill.
If the machine remains at its place of use during the downtime period,
condensation can be prevented by operating the compressor approximately
every 2 weeks for a period of 30 minutes.
Restart after Downtime

Proceed to restart the equipment after downtime as during first commissioning.
See also Final decommissioning page 98

First commissioning page 56
10.2 Final decommissioning

The procedure for the final decommissioning corresponds to the temporary shutdown.
Additionally: Drain the oil.
See also Disposal page 98
10.3 Dismantling
The machine has been taken out of service
The oil is drained.
a.) The disassembly takes place in the same way as the installation, in reverse order.
Begin by disassembling the pipe system and then disassemble the individual components.
Installation of safety devices for safe transport

The machine has been taken out of service.
a.) Attach the required safety devices to the machine before transport.
The machine is secured for transport.
10.4 Re-packing the machine

The machine is dismantled.
a.) Pack the machine so that it is protected from moisture and dust.
The machine is re-packed.
10.5 Store the machine

Store the machine and its components according to the conditions in the technical data.
See also Specifications page 32
10.6 Disposal
The machine is essentially made of reusable materials. The machine does not pose a risk to the
operator or the environment if handled properly. However, the machine is operated with
materials which can be harmful to the environment and must therefore be properly disposed of
according to the regulations (see safety data sheets in the appendix).
Provide individual components of the machine (motors, metal parts, etc.) to a qualified disposal
and recycling company. Use a qualified specialist company for the disposal and recycling of the
entire machine.

NOTE
Contact Tolpec for any advice regarding your disposal needs.
See also Maintenance schedule page 77

Contact Tolpec GmbH and the SCC sales and service partner on page 13
11 Technical documents / Annex list

The technical documents are divided into several folders. You can find the content table in
every folder.

11.1 Plan of maintenance and repair works
Operating hours Date Spare details Name

List of Pictures
Picture 1: Front view of the compressor (example picture FOCUS-series) ............................ 15
Picture 2: Side view of the compressor (example picture FOCUS-series) ............................. 16
Picture 3: Example Picture: Back of the compressor / Belt driven (SMART-series) ................ 16
Picture 4: Safety relevant control elements and indicator elements of the compressor ......... 17
Picture 5: Safety valve .......................................................................................................... 18
Picture 6: Operating panel MAM - 890 .................................................................................. 19
Picture 9: Operating panel MAM - 6080 ................................................................................ 22
Picture 10: Areas of work and maintenance .......................................................................... 23
Picture 11: Name plate of the Equipment .............................................................................. 23
Picture 12: Compressor frame with panels ............................................................................ 27
Picture 13: Pressure sensor .................................................................................................. 28
Picture 14: Safety valve of the oil receiver ............................................................................ 28
Picture 15: Safety valve of the air receiver ............................................................................. 29
Picture 16: Oil temperature sensor ........................................................................................ 29
Picture 17: Emergency Stop Button ...................................................................................... 30
Picture 18: Transport with the forklift ..................................................................................... 48
Picture 19: Direction arrow on the air end ............................................................................. 54
Picture 20: Oil receiver .......................................................................................................... 57
Picture 21: Intake valve mounted on the air end ................................................................... 57
Picture 22: Direction arrow on the air end ............................................................................. 59
Picture 23: Areas of work and maintenance .......................................................................... 63
Picture 24: Locked electrical main switch .............................................................................. 76
Picture 25: Receiver mounted machine TD - series .............................................................. 88
Picture 26: Oil Change .......................................................................................................... 91
........................................................................................................................................................................................
List of Tables
Table 1: Warning signs .............................................................................................................. 9
Table 2: Mandatory signs ........................................................................................................ 10
Table 3: Change of history of this document ............................................................................ 12
Table 4: Table of applicable documents .................................................................................. 12

Table 5: Central contacts ........................................................................................................ 13
Table 6: Your SCC sale and service partner ........................................................................... 14
Table 7: Overview of the warning signs ................................................................................... 30
Table 8: Overview of the mandatory signs ............................................................................... 31
Table 9: Qualification of the staff ............................................................................................. 40
Table 10: Groups of operators ................................................................................................ 42
Table 11: Activities and knowledge ......................................................................................... 43
Table 12: Mandatory signs ...................................................................................................... 43
Table 13: Personal protective equipment ................................................................................ 48
Table 14: Troubleshooting table .............................................................................................. 67
Table 15: Daily maintenance plan ........................................................................................... 77
Table 16: Weekly maintenance plan ....................................................................................... 78
Table 17: Maintenance plan after 100 operation hours ........................................................... 78
Table 18: Maintenance plan after 500 operating hours ........................................................... 78
Table 19: Maintenance plan for every 2000 operating hours ................................................... 79
Table 22: Common recommendations for cleaning ................................................................. 82
Table 23: Tightening torque of the screws .............................................................................. 83
Table 24: Tightening torque of the screws .............................................................................. 83
Glossary
EMC Electromagnetic compatibility

Index
A First commissioning 56
Additional symbols in the manual 11 Final check 53
Annex list 99
Applicable documents 12 G
Areas of work and maintenance 23 General description 24
Avoiding dangerous situations 33 General safety Instructions 33
C I
Change history 12 Intended use 25
Check of Safety devices 55 Identification Equipment 23
Cleaning 82 Incorrect Use 25
Commissioning 53 Inspection visual 81
Installation 49
Commission after troubleshooting 70 Install. and connection 50
Commissioning and storage 61,98 Install. of electrical components 52
Condensation check 89 Install. of mechanical
Construction of the Equipment 15 components 51
Contact Tolpec GmbH 13
Contact SCC-Sales and Service 13 L
Controllers 15 Limitation of liability 12
Customer service 94 List of Pictures 100
List of tables 101
D
Daily commissioning 60 M
Decommissioning 95 Maintenance 70
Description of the product 15 Maintenance schedule 77
Description of the product 6 Maintenance belts 85
Directional indication 11 Maintenance filters 84
Disposal 98 Maintenance list and repair list 99
Maintenance motor 85
E Maintenance Receiver 88
Electromagnetic combability Maintenance safety devices 87
(EMC) 35 Maintenance works 81
Emergency stop 30 Mandatory signs 10
Environment protection 36
F N
Faults 65 Notes for troubleshooting 34
Final decommissioning 98 Notes on electrical equipment 35

O S
Oil 93 Safety 33
Oil change 91 Safety equipment Overview 26
Oil temperature sensor 29 Safety instructions 7,33,55
On off sequences 63 Safety instructions for faults 65
Operating equipment 32 Safety valve 28
Operation and installation cond. 32 Secure machine against restart 76
Operation instructions 34 Specialised knowledge 42
Operating mode 64 Storage 61,95,98

Operation of equipment 32 Storage of the Manual 7
Operator determination 38 Switch off 64
Operator groups 42 Switch on 63
Operator training 38 Symbols and signs on unit 30
P U
Parameters 65 Unacceptable operation cond. 36
Personal protective equipment 43 Unpacking of package 49
Place of installation and
infrastruct. 49 Use of machine 25
Procedure in case of accident 44 Used Symbols and definitions 7
Protection/safety devices 26
Protective equipment’s 39,43 W
Q Warning signs 9,3
Qualification 40 Warranty and liabilities 12
R Working area 63
Re-packing 98
Requirements of an operator 40
Residual risk 44
Responsibility of the operator 37
Risk of injuries; minimization 37

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Operation Manual SCC-Compressors / Page 2

1.3. Used Symbols and definitions ..................................................................................................................... 7

Operation Manual SCC-Compressors / Page 3

4.4.5 Final Check .............................................................................................................................. 52

8.2.4 Each 2000 operating hours ................................................................................................................... 79

Operation Manual SCC-Compressors / Page 5

11 Technical Documents / Annex list................................................................................................................. 99

List of Pictures .......................................................................................................................................................... 100

1. Description of the product

– Read the Manual thoroughly.

– Follow all the safety instructions.

1.1. Operating instructions

1.2. Storage of the Manual / keep it accessible

1.3. Used symbols and definitions

1.3.1. Safety instructions

The safety instructions in this manual contain the following elements.

Operation Manual SCC-Compressors / Page 7

Warning of an immediate danger to the user.

Warning of an immediate danger to the user.

Warning of possible property damage.

– Type and source of danger

Escape (= measures to avoid danger)

Operation Manual SCC-Compressors / Page 8

1.3.2. Warning signs

Warning of high voltage

Warning of hand injury

Warning of overhead load

Operation Manual SCC-Compressors / Page 9

Warning of poisonous substances

Warning of combustible and flammable materials

Warning of a slip hazard

Table 1: Warning signs

1.3.3 Mandatory signs

Read the operating manual

Wear protective gloves

Wear eye protection glasses

Operation Manual SCC-Compressors / Page 10

Wear protective clothes

Wear light respiratory protection for protection from dust

Wear ear protection

Wear protective boots

Table 2: mandatory signs

1.3.5 Directional indications

Operation Manual SCC-Compressors / Page 11

1.4 Change history

No. of version Date From serial No.

Table 3: Change of history of this document

1.5. Applicable documents

Operation and working manual

Spare parts list

Technical data sheet

Dimensional drawing of the equipment

Table 4: Table of applicable documents

1.6. Warranty and liabilities

– non-compliance with the manual

– use of non-trained personnel