Operating Instructions

for compressor serie

45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03
release: 02

air cooled compressor, 3-stages

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Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

Contents
1 Preface ....................................................................................................................... 5
2 Safety ......................................................................................................................... 6
2.1 Safety instructions ............................................................................................... 6
2.2 Safety regulations................................................................................................ 6
2.3 Intended use ....................................................................................................... 8
2.4 Potential dangers ................................................................................................ 9
2.5 Residual risks ......................................................................................................10
2.6 Protective devices ............................................................................................... 10
2.7 Obligations of the operator .................................................................................. 10
2.8 Obligations of the operating and maintenance personnel ................................... 11
2.9 Influences on the work environment and the environment .................................. 11
3 General technical information................................................................................... 12
3.1.1 Technical data 45.2.3.02.02 – 80.2.3.02.03: ..................................................... 12
3.2 Assembly drawing and dimensions .................................................................. 13
4 Description of workplace, startup and operation....................................................... 14
4.1 Guarantee ......................................................................................................... 14
4.2 Transport and storage ....................................................................................... 14
4.2.1 Transport damage ................................................................................................................... 15
4.2.2 Storage regulations.................................................................................................................. 15
4.3 Installation, description of workplace................................................................. 16
4.3.1 Special mounting aids.............................................................................................................. 17
4.3.2 Installation on land and as stationary systems........................................................................ 17
4.3.3 Installation on ships ................................................................................................................. 17
4.3.4 Room ventilation and cool air supply....................................................................................... 17
4.3.5 Compressed air connection..................................................................................................... 17
4.3.6 Electrical connection................................................................................................................ 17
4.3.7 Removing the compressor....................................................................................................... 18
4.4 Operation and startup........................................................................................ 18
4.4.1 Basics concerning the operation and startup of the compressor ............................................ 18
4.4.2 Operating principle................................................................................................................... 19
4.4.3 Initial startup or startup after extended interruptions ............................................................... 20
4.4.4 Normal startup of the compressor without automatic mode.................................................... 21
4.4.5 Normal startup of the compressor with automatic mode ......................................................... 21
4.4.6 Inspections............................................................................................................................... 22
5 Servicing, maintenance and troubleshooting............................................................ 23
5.1 Design of the compressor ................................................................................. 23
5.1.1 Piston ....................................................................................................................................... 24
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Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

5.1.2 Cylinder................................................................................................................................... 24
5.1.3 Cylinder head........................................................................................................................... 24
5.1.4 Valves ...................................................................................................................................... 24
5.1.5 Lubrication system................................................................................................................... 24
5.2 Maintenance instructions................................................................................... 25
5.3 Cleaning ............................................................................................................ 26
5.4 Malfunctions and troubleshooting...................................................................... 26
5.5 Maintenance instructions................................................................................... 28
5.5.1 Disassembly and assembly of the tongue valve in the 3rd stage ........................................... 28
5.5.2 Disassembly and assembly of the combined valve in the 1st stage ....................................... 29
5.5.3 Disassembly and assembly of the suction and pressure valve in the 2nd stage .................... 30
5.5.4 Disassembly and assembly of the piston ................................................................................ 31
5.5.5 Removing the crankshaft bearing............................................................................................ 33
5.5.6 Gaskets.................................................................................................................................... 34
5.5.7 Final inspection........................................................................................................................ 35
5.6 Setting data ....................................................................................................... 35
5.6.1 Table for stage pressures........................................................................................................ 35
5.6.2 Pressure settings of the safety valves ..................................................................................... 35
5.6.3 Table for torques of the screws and nuts ................................................................................ 35
5.6.4 Table for gap clearances for pistons ....................................................................................... 35
6 Spare part supply and special tools.......................................................................... 36
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Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

1 Preface
Before operating the compressor, the customer must ensure that this operating manual has been
read carefully by the operators and maintenance personnel and that the notices and warnings, in
particular the safety regulations, are observed down to the last detail.
Furthermore, this operating manual will help you to achieve optimum operating results with the
compressor, and to ensure trouble-free operation and a long system life and fulfillment of the
applicable safety requirements for your employees.
The manual makes no claim to be exhaustive. General specialized knowledge is assumed.
Likewise, "NEUENHAUSER KOMPRESSORENBAU GMBH" shall assume no responsibility for individual
statements in third-party manufacturer’s documents, insofar as they are part of this operating
manual and are included with the latter.
Each compressor is subjected to an extensive, successful testbench run before being delivered.
The reproduction of the text and the illustrations and/or drawings, even in excerpts, is prohibited.
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Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

2 Safety
2.1 Safety instructions
The following symbols are used in these operating instructions to highlight important information

! Designates danger to health or equipment.

DANGER!

Designates application tips and other useful information.

IMPORTANT!

Designates important assembly instructions.

NOTE

2.2 Safety regulations

For the operation of the compressor and all measures specified in these operating instructions,
the currently valid work protection and accident prevention regulations (UVV) as well as those of
the trade association (BG) applicable to the operator of the compressor and the location of the
machinery, must be adhered to.
These include:
♦ VBG1 - 1: "General regulations"
♦ VBG - 4: "Electrical Systems and Equipment"
♦ VBG - 5: "Power driven equipment"
♦ VBG - 10: "Continuous flow conveyors"
♦ VBG - 121: "Noise"
♦ VBG - 16: "Compressors”
For safety when working on the electrical equipment of the compressor, the DIN2 and VDE3
regulations apply. In addition to the above directives and safety regulations, the following must be
observed:
♦ Safety requirements applicable to the installation site of the compressor and of the relevant
supervisory bodies.
♦ National, regional, local and internal regulations and guidelines relevant to the equipment
and / or site of installation.
In addition to the technical safety regulations, industrial medicine and hygiene regulations or
guidelines and instructions must be observed.
In the event that information in this operating manual does not correspond to the local
requirements, then the more strict (national) version shall apply.
For the handling of hazardous and/or groundwater-contaminating liquids, such as oils or
lubricants, solvents or cleaners and other chemical substances, the regulations of the WHG4 and
the UVV5 1.0 must be observed.

1 VBG = Industrial Trade Association

2 DIN = German Industrial Standard
3 VDE = Association of German Electricians
4 WHG = Water Resources Law
5 UVV = Accident Prevention Regulations
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Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

The following applies to all maintenance and repair work on the compressor:
♦ The compressor must be effectively protected against unauthorised activation and equipped
with a repair note.
♦ Disconnect compressor from compressed air system
♦ Close all shut-off valves in the pipes
♦ Before commencing repair / maintenance work vent (depressurised) all pipes and pressure
chambers on the compressor – open condensate drain cocks / -valves
♦ Mount protective devices before startup of the compressor
♦ Make sure that maintenance personnel are familiar with the compressor, i.e. sufficiently
trained, and that they perform all tasks safely and in accordance with this operating manual
and the instructions of the third-party manufacturer.

IT IS PROHIBITED TO STAY IN THE DANGER AREA !!!

REPAIRS, SETUP, MAINTENANCE AND CLEANING MAY BE CONDUCTED
IMPORTANT! ONLY WHEN THE MACHINE IS SWITCHED OFF, DISCONNECTED AND
SECURED !!!
Cleaning and maintenance work must only be performed when the compressor is turned off,
disconnected and protected against accidental and erroneous activation. When cleaning, do not
use aggressive, flammable or hazardous solvents or cleaners, or materials that contain tri-, per-
or tetrachloroethylene.
In case of defective fuses, use only original fuses with the required current.
Make sure that the settings of all regulation and control devices are not changed during
maintenance tasks! Loose screw connections must be tightened immediately using the customary
tools and in compliance with the required torque (Ch. 5). Worn or damaged parts must be
replaced immediately; use only original parts. The guarantee shall expire if original parts are not
used.
Repairs may be performed only by specially trained personnel who have carefully read the
operating manual.
Welding:
When welding, the main switch must be switched off and the system must be disconnected from
the power supply. The control unit of the compressor must be protected separately (contact
separation, etc.).
All welding and safety regulations must be observed. All tools must be in perfect working order
and must be used in accordance with the relevant regulations.
The operator is responsible for ensuring that all occupational safety and health and accident
prevention regulations, as well as the instructions and warnings in accordance with chapter 4, are
observed for all inspection and maintenance work.
Work on the electric components:
Use only original fuses. The use of heavy-duty fuses will destroy the electronic components!
Damaged cables must be replaced immediately.
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Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

Non-observance of these operating instructions and inadequate or incorrect

maintenance is regarded as improper use. The consequences of improper
IMPORTANT! use are the operator’s responsibility!

After performing maintenance and repairs, the direction of rotation of all drives must be checked
(see Ch. 4.4.1) and the electrical connection changed accordingly, if necessary. A change in the
direction of rotation may be effected only by switching two outer conductors of the connection
cable.

Assembly / disassembly work must only be performed by specialist

personnel.
Make sure that the compressor is completely disconnected from the power
IMPORTANT!
supply.

2.3 Intended use

The intended use of the compressor includes the compression of atmospheric air that is free from
aggressive, abrasive and / or explosive components.
The use of technical or pre-compressed gases is permitted after consulting NEUENHAUSER
KOMPRESSORENBAU GMBH and obtaining the company’s approval.
The compressor may be operated only intermittently (no continuous operation – duty cycle: max.
70%), whereby the consuming air capacity must not exceed 70% of the specific output of the
compressor. If the duty cycle exceeds one hour or if the relative humidity of the intake air is
greater than 80%, the compressor must be periodically drained (about once every hour).
Any use beyond this intended use is regarded as improper use. "NEUENHAUSER
KOMPRESSORENBAU GMBH" shall not be liable for any damages resulting from such unauthorized
use, or for damages resulting from improper handling and / or treatment of the compressor. The
operator takes the risk.
Any use of this compressor other than the use intended by the manufacturer and as
described in this operating manual is not permitted.

If the conditions of use change, e.g. the ambient conditions and the
connected load, changes in design, modifications of the original
IMPORTANT! compressor, etc., NEUENHAUSER KOMPRESSORENBAU GMBH must be consulted.

If the compressor was delivered with accessories for automatic operation, special descriptions
and instructions apply, which are also enclosed. This and other facilities can be retrofitted in
coordination with NEUENHAUSER KOMPRESSORENBAU GMBH.
NEUENHAUSER COMPRESSORS require very little maintenance and are rugged, due to the
construction. Except for the checks and inspections described in this manual you should not
perform any disassembly or inspection, unless it becomes necessary due to faults in the
operation of the machine.
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Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

2.4 Potential dangers

The compressor and the fan wheel are driven by the motor via a coupling. Reaching into the
running machine can result in personal injury! Before performing any maintenance or repairs,
the machine must be disconnected from the power supply and depressurized and protected
against being switched on by others.
Danger of injury!
♦ Compressor parts can become very hot and can cause burns and fires.
! Always allow the compressor to cool before performing maintenance.
DANGER! ♦ The emerging compressed air and the condensation water contain oil and can
cause injury to the eyes and skin.

Danger to life!
! ♦ Compressed air can cause death to living beings. Compressed air is
DANGER! concentrated energy. Therefore: never aim compressed air at living beings.

Do not remove or disable safety devices! Repair defective safety devices immediately.
Repairs to the electrical components should be performed only by a qualified electrician!
Preparing for operation:
Check the compressor for visible external damage and ensure that the safety devices are fully
functional.
Before connecting the machine to the power supply, make sure that the voltage and frequency
correspond to the power supply.
Normal operation:
The oil level can be checked only when the compressor is switched off.
In case there is danger of frost, the compressor must be protected against freezing or drained
(condensation, coolant, etc.).
Operation and monitoring of the compressor is permitted only at the switch cabinet. It is strictly
forbidden to remain in the danger area6. When performing maintenance, the compressor must be
switched off and the safety regulations and obligations of the operating and maintenance
personnel (Ch. 2.2 and 2.8) must be observed.
Abnormal operation:
In the case of defects or disturbances, such as:
♦ abnormal operating noises,
♦ unusually loud noises, smoke formation,
♦ unsteady running and/or excessive oscillation or vibration,
♦ excessively high operating data (end pressure, ambient temperature, coolant
NOTICE temperature),
♦ blowing off of safety valves,
♦ a fault displayed at the switch cabinet, etc.,
the compressor must be shut down immediately and checked thoroughly.

6 Danger area:
Hot elements (e.g.: lines, pipes, cylinders, ...)
Safety, drain and condensation valves
Rotating and other moving mechanical parts
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Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

2.5 Residual risks

The compressor has been manufactured in accordance with state-of-the-art technology and
approved safety regulations. It complies with the current requirements of the relevant
classification societies, as well as the accident prevention regulations valid at the time of
delivery / manufacture and is equipped with safety equipment.
The compressor was inspected for proper functioning and safety before delivery. Improper
operation or misuse, however, can endanger
♦ the health of the operator,
♦ the machine and other material assets of the operator,
♦ the efficiency of the piston compressor.
All persons who are involved with setting up, putting into operation, operating, maintaining and
repairing the piston compressor must
♦ possess the proper qualifications and
♦ have read, understood and observe all details of this operating manual.
2.6 Protective devices
The compressor is equipped with a flywheel guard, safety valves and pressure gauges in all
stages and insulation on all hot pipes.
The system is shut down
♦ in case of emergency and during normal operation by pressing the STOP button
♦ before performing maintenance/repairs by throwing the main switch.
2.7 Obligations of the operator
Before each startup the operator of the compressor has to inspected in sole responsible the
working reliability.
The operator must supervise that the respective statutory health and safety and accident
prevention regulations and the health and safety guidelines of this operating manual are observed
at all times.
Furthermore, the operator is responsible for the necessary qualification of his employees, for
training on the compressor and for knowledge of the potential dangers and of the operating
manual. Dangers due to unclear competences must be ruled out during operation of the machine.
The operator must ensure that the operating personnel use the required protective clothing7. If
necessary, the protective clothing must be provided by the operator. He must supervise its use
and compliance with other required protective and disposal measures.
Furthermore, the operator must ensure that the compressor is monitored according to the
following table and that the operating data is documented (see Appendix: Operating data entry
form).

Type of When required? Check whether

inspection
Manometer 2 x daily Operating pressures correspond to those
pressures provided in chap. 5.6.1

Safety valves 2 x daily air is escaping (tightness)

Oil level 2 x daily Filling level is sufficient

Visual check 1 x daily Noticeable damage and defects

Table 1

7 Protective clothing: Helmet, ear protection, safety shoes, etc.

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Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

2.8 Obligations of the operating and maintenance personnel

Every person who is entrusted with performing any of the measures listed in these operating
instructions at the compressor’s place of installation or in the workshop must have read and
understood these operating instructions.
All operating and maintenance personnel must employ safe working practices and observe the
occupational safety and accident prevention, including local regulations, at all times.
The operator’s operating and maintenance personnel must ensure that:
♦ no work method is used that impairs the safety of human life or of the compressor in any way
♦ work on the compressors and the operation of the compressors is performed only by trained
personnel
♦ all persons are familiarized, before beginning work, with the devices and operating elements
and their function and the danger area of the compressor
♦ before switching on the machine that the compressor is in proper working condition, is
equipped with required safety devices and no one will be endangered by the compressor
during startup
♦ no persons who are not expressly authorized to do so, remain in the danger area during
operation of the compressor, work or perform other tasks on the compressor or interfere with
the operation
♦ the compressors are checked at least once each day for externally visible damages and
defects messages about changes in the compressors or operating conditions are sent
immediately to the body / person designated by the operator
♦ the compressor is shut down immediately in the event of disruptions that impair safety
♦ maintenance is performed only when the compressor is disconnected from the power supply
and is in protected condition before it is started up again
♦ safety, health and danger notices are attached to the compressor by the operator and are
legible
♦ no unauthorized alterations or modifications are performed on the compressors
♦ the environmental protection regulations, e.g. for the disposal of waste, are strictly observed
♦ the installation location is clean and uncluttered and that access to the switch cabinet of the
compressor is free at all times
♦ all operating and monitoring elements are clearly labeled.
2.9 Influences on the work environment and the environment
The compressor was manufactured using standard machine materials in accordance with the
intended use and is not sensitive to normal environmental influences. Atmospheric or ambient
temperatures that exceed the maximum or minimum operating limits can cause a decrease in
performance and / or malfunctions. Please notify "NEUENHAUSER KOMPRESSORENBAU GMBH" of any
extreme operating conditions (temperatures, humidity, dust, etc.), so that special protective
measures can be taken, if necessary. For operating limits and / or special measures for the drive
motor, see the respective manufacturer’s operating manual in the Appendix.
The continuous sound pressure level can be found in Chapter 3.
If the compressor is used properly and in compliance with the appropriate operating and safety
conditions for the individual application, it poses no risks. Third-party interference is not an issue.
The condensation in the compressed air tank and piping contains oil. Without proper treatment, it
may not be disposed of in the sewage system: always comply with the regulations of the
responsible environmental protection agency.
Packaging materials (cardboard / labeled foils) should be disposed of separately.
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Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

3 General technical information

The technical data for the drive and other accessory parts can be found in the appendix.
Note:
♦ The capacity data refers to 1013 mbar and 20 °C
♦ The capacity data assumes a tolerance of ± 5 %
♦ The drive power should be set about 10 % higher
♦ Sound pressure level 92 +/- 3 dB(A) acc. to CAGI Pneurop (if specified)

3.1 Technical data 45.2.3.02.02 – 80.2.3.02.03:

piston diameter

average piston

oil capacity
cylinder
Power

weight
stroke
speed

speed
Capacity
type 30 / 40 bar
consumption
30 / 40 bar

[1/min] [m³/h] [kW] [mm] [mm] [m/s] [l] [kg]

45.2.3.03.02… 1000 62 / 56 18 / 21 2 68 114/97/35 2,3 6,5 850
1200 74 / 66 19 / 22 2 68 114/97/35 2,7 6,5 850
1500 92 / 84 24 / 26 2 68 114/97/35 3,4 6,5 850

45.2.3.03.03… 1000 93 /84 27 / 31,5 3 68 114/97/35 2,3 6,5 870

1200 111 / 99 28,5 / 33 3 68 114/97/35 2,7 6,5 870
1500 138 / 126 36 / 39 3 68 114/97/35 3,4 6,5 870

60.2.3.02.02... 1000 80 / 73 19 / 21 2 68 130/110/35 2,3 6,5 870

1200 100 / 89 23 / 24 2 68 130/110/35 2,7 6,5 870
1500 120 / 107 27 / 28 2 68 130/110/35 3,4 6,5 870
1800 144 / - 30 / - 2 68 130/110/35 4,1 6,5 870

60.2.3.02.03... 1000 115 / 108 27 / 28 3 68 130/110/35 2,3 6,5 990

1200 150 / 131 29 / 34 3 68 130/110/35 2,7 6,5 990
1500 185 / 165 39 / 41 3 68 130/110/35 3,4 6,5 990
1800 205 / - 44 / - 3 68 130/110/35 4,1 6,5 990

80.2.3.02.02... 1000 105 / 95 24 / 26 2 80 130/110/35 2,7 6,5 950

1200 125 / 114 28 / 31 2 80 130/110/35 3,2 6,5 950
1500 145 / 132 33 / 37 2 80 130/110/35 3,2 6,5 950

80.2.3.02.03... 1000 156 / 140 30 / 25 3 80 130/110/35 2,7 6,5 970

1200 188 / 168 33 / 39 3 80 130/110/35 3,2 6,5 970
1500 230 / 210 44 / 52 3 80 130/110/35 3,2 6,5 970

Table 2
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Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

3.2 Assembly drawing and dimensions

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Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

4 Description of workplace, startup and operation

4.1 Guarantee
The supplied compressor has been manufactured in accordance with state-of-the-art technology
and complies with all of the safety regulations valid at the time of delivery/manufacture.
The compressor’s warranty does not apply to damage to the compressor that was caused by any
of the following:
♦ Non observance of these operating instructions
♦ Inadequately trained or instructed operating personnel
♦ Normal wear of parts
♦ Incorrect or negligent treatment of the compressor
♦ Compression / delivery of incorrect media
♦ the compressor is not monitored and checked for proper operation by operating / service
personnel within the required intervals
♦ repairs and/or modifications conducted during the guarantee period without the approval of
NEUENHAUSER KOMPRESSORENBAU GMBH release NEUENHAUSER KOMPRESSORENBAU GMBH
from any obligation of guarantee
Moreover, the operater is solely responsible for ensuring that:
♦ the accident prevention regulations and safety regulations are observed during the transport,
setup and preparation for operation, during operation and maintenance
♦ access to the danger zones is not possible while the compressor is running
♦ no improper modifications or changes are made to the compressor, especially to the safety
devices, without the prior approval of "NEUENHAUSER KOMPRESSORENBAU GMBH"
♦ incorrect startup and non-permissible operation are not possible
♦ the compressor will not be used for an unsuitable or improper use
♦ the compressor is used only as authorized and any operating condition not contractually
agreed shall be ruled out
♦ the compressor is not monitored and checked for proper operation by operating/service
personnel within the required intervals
4.2 Transport and storage
The compressor is packaged upon delivery. The type of packaging and the scope of delivery can
be found in the order confirmation. The delivery must be checked for completeness immediately
upon receipt. This applies in particular to any upgrade components packaged separately. Missing
or damaged parts must be reported to NEUENHAUSER KOMPRESSORENBAU GMBH immediately!

Danger of tipping!
! The compressor can tip over if tilted more than 10°
DANGER!

For transporting the compressor, suitable transport and load suspension devices (fork lift,
platform truck, loading harness, eye bolts, etc.) must be used. In addition, the general transport,
stop and safety regulations must be observed.
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Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

4.2.1 Transport damage

Immediately after receipt, the compressor and any accessory part must be checked for damages
from transport (this also includes damaged gaskets on the safety valves!).
If damages from transport are detected or even supposed, they must be recorded and
documented by means of photos and / or a sketch showing the damage, and a detailed written
report of the damage. Damages from transport must be reported in writing to the transport
company that delivers the compressor and to NEUENHAUSER KOMPRESSORENBAU GMBH. As a
precaution, include any hidden transport damages in your report.
If the report / claim is not submitted immediately after receipt, this may result in the loss of
insurance coverage.
A damaged compressor must never be put into operation.
4.2.2 Storage regulations
The (interim) storage of the compressor requires a location with a level, solid floor, and the
compressor must be secured against tipping. When in (interim) storage, the compressor must be
protected from extreme environmental influences (heat, cold, moisture, etc.).
The compressors provided by NEUENHAUSER KOMPRESSORENBAU GMBH are treated on the inside
with anti-corrosive oil, which when stored in a dry, dust-free location at a room temperature of
max. 15 °C provides protection against corrosion for 12 months or as stated in the order
confirmation.
The compressor can be delivered without oil filling. The combined valve of the 1st stage should be
coated with oil. If the valve is dry, coat it with about 0.2 cm³ of lubrication oil acc. to the lubricating
oil regulation before turning the crankshaft.
The crankshafts of the compressor must be turned at intervals of two weeks throughout the entire
storage and installation period, so that the necessary locations in the crankcase are coated with
oil. The flywheel of the respective compressor must be moved manually 2 – 3 revolutions without
the help of tools.
We shall assume no liability for damages due to improper handling and corrosion before and
during installation or due to incorrect maintenance during this period.
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Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

4.3 Installation, description of workplace

Set up the compressor horizontally on a level, solid floor. A solid floor or an elastic construction
with a rubber-metal connection on a solid floor prevents malfunctions due to vibrations. A
foundation is not necessary. If installed on the roof a building, do not exceed the maximum
permissible roof load.
When installing the compressor at the operating location, the applicable accident prevention
regulations for the operator’s company and, in addition, the safety instructions for the specified
location must be observed.
In addition to the regulations of the local authorities, please observe the following information:
♦ use suitable lifting table for lifting the compressor (weight acc. to order confirmation or delivery
note)
♦ secure loose or movable parts before lifting
♦ always stay outside the danger zone of a hoisted load
♦ remove all blind flanges, packing and bags with drying agents before assembling the pipes
♦ select an installation location with cool and clean ambient air, however keep the compressor
room frost-free when the equipment is not in use; ambient temperature between +3°C and
+45°C; regulate by means of cool or warm air, if necessary (after consult with “Neuenhauser
Kompressorenbau GmbH” could be the ambient temperature depending on duty cycle and
operating lifetime between +3°C and +55°C)
♦ never block air vent
♦ keep humidity in intake air as low as possible
♦ provide for adequate cool air supply and removal, e.g. through windows or room fans
♦ if more than one compressor is installed, make sure that no compressor intakes warmed
exhaust air from another compressor
♦ air intake opening should be located such that no loose objects can be sucked in
♦ the control panel on the compressor must always be freely accessible, and escape routes
must also remain free
♦ make sure that the pressure line from the compressor to the aftercooler or air network can
expand due to heat and does not come into contact with flammable substances
♦ during installation, note dimensions according to drawing (the respective drawing number can
be found in the order confirmation)
♦ provide for adequate space for the operation according to the compressor dimensions (see
drawing and installation recommendation) and service space for maintenance work
♦ installation location must be sufficiently lighted, e.g. in order to read instruments or to perform
maintenance.
For systems equipped with remote control, a highly visible sign with the following notice must be
applied:
Caution! This system is remote-controlled and can start up without warning!

If the system is controlled remotely, take proper safety measures to prevent the
! system from starting during inspection or maintenance; apply a notice to this effect
at the remote control switch.
DANGER!

If installed in a dusty atmosphere, the maintenance intervals in Ch. 5.2 must be

shortened (halved if necessary).
IMPORTANT!
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Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

4.3.1 Special mounting aids

♦ Equipment: Crane with suitable lifting table
♦ Personnel: 2 x locksmiths, 1 x electrician
4.3.2 Installation on land and as stationary systems
The machine has to be installed on a solid, vibration-free surface. In order to prevent the transfer
of vibrations the compressor-unit is fitted out with elastic supports. The fixing points of the
compressor are clearly marked in the assembly drawing (chapter 3.2). It is essential for proper
operation of the compressor to fasten the unit at all indicated points.
4.3.3 Installation on ships
The machine is installed and connected by the shipyard. Installation on tank bay decks should be
avoided in order to prevent the transfer of vibrations. The installation “center of compressor on
center of web frame” is tried and tested.
4.3.4 Room ventilation and cool air supply
The required cool air for cooling the compressor is taken from the machine room. Since the
ambient temperature significantly affects the proper operation of the compressor, make sure that
the room temperature is never allowed to exceed max. 40°C, even after extended operation. If
there is no guarantee of this, then provisions must be made for fresh air supply by means of
additional fans.
In addition, frost should be avoided at the installation location. In case of doubt, heat the
installation location and make sure that there is no condensation in the coolers. Moreover, at
temperatures below 3 °C the viscosity of the oil is unacceptably high.
Further instructions are included in the installation recommendations!
4.3.5 Compressed air connection
The type and location of the compressed air and condensate connections are shown on the
compressor drawing. The relevant drawing number is stated in the order confirmation.
The following points must be observed for the compressed air and condensate connection:
♦ use suitable screw connections and lines for the operating pressure
♦ do not run the system with an ultimate pressure higher than the pressure indicated on the
rating plate
♦ connect the system to the compressed air network by means of a stress-free and vibration
insulated hose (see Appendix)
♦ the additional installation of a shut-off valve behind the flexible hose is recommended, in order
to facilitate maintenance without depressurizing the compressed air network
♦ a non return valve between the system and the compressed air network is not necessary,
since this is already built into the system.
♦ The dimensions of the pipes for the condensate connections must be sufficient and they must
be pressure free.
4.3.6 Electrical connection
The customer connects the compressor to the electric supply. The customer must therefore also
inspect the electrical connection of the entire machine.

Approx. 1 week after startup, the screws of the connection terminals of the
switching devices and the screws of the connector blocks in the control cabinet
must be tightened. In addition, maintenance instructions in Ch. 5.2 must be
IMPORTANT! observed.
The electrical connection should always be carried out by an electrician!
 Page 18
Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

4.3.7 Removing the compressor

When removing the compressor and / or motor, the compressor must be disconnected from the
power supply. In addition, all lines must be vented and the power cable disconnected. Whenever
the compressor is serviced, always follow the instructions in Chapters 2 and 4.
Before the compressor or the motor can be removed from the frame, it is a good idea to pin the
compressor and motor together with two clamping sleeves. This will avoid the necessity of complex
adjustments during re-assembly.

When reinstalled, the alignment of the compressor and the drive must be
checked carefully. Misalignment of the compressor shaft and the drive shaft
IMPORTANT! will cause strong wear of the coupling and bearings.

4.4 Operation and startup

4.4.1 Basics concerning the operation and startup of the compressor
The supplied compressor has been manufactured in accordance with state-of-the-art technology,
has successfully passed extensive tests and is fail-safe and reliable.

The function of the safety valves are tested by the manufacturer and by the
inspection of the classification society.
NOTICE A frequent or long term operation of the safety valves during a test can harm them
and entails a loss of guarantee.

Before connecting the machine to the power supply, make sure that the voltage
and frequency correspond to the mains network.
After the electrical connection is made, it is necessary to check the direction of
IMPORTANT! rotation of the electric motor (see direction of arrow on the flywheel guard of the
compressor). Correct the electrical connection, if necessary.

The compressor can pose danger to life and limb for the operating personnel or
! others, or can impair the system itself, if it is used in an incorrect or unauthorized
DANGER! manner by inadequately qualified or trained personnel.

The compressor may be operated only by trained personnel.

Authorized use according to Chapter 2.3 must be ensured.
The operator / operating authority of the compressor must ensure that no one is in the danger
area during operation.

Systems with remote control must bear the following label:

“Caution! This system is remote-controlled and can start up without
IMPORTANT! warning!”

The compressor may be used, maintained and repaired only by persons who have thoroughly
read this operating manual and are aware of all dangers.
 Page 19
Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

4.4.2 Operating principle

This machine is a 3-stage air compressor which, in contrast to conventional 2-stage air
compressors, compresses the air in three steps and is cooled after each stage. Together with
the differential piston, valves, a finned cooler for each stage and controls and instruments,
each cylinder comprises a closed, 3-stage unit.
The ambient air is sucked in through a noise-absorbing air filter by the 1st stage and is
compressed to approx. 2.5 bar. The air is cooled down to approx. intake temperature by the 1st
stage cooler and flows through the 2nd stage suction valve into the chamber of the 2nd stage
(figure 1).

Fig. 1

The air is compressed to about 10 bar in the 2nd stage. The air flows through the cooler of the 2nd
stage where it is cooled to approximately intake temperature, and enters the compression space
of the 3rd stage (Fig.).

Fig. 2
 Page 20
Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

In the 3rd stage, the air is compressed to the final pressure. The after cooler cools the
compressed air again to approx. 50 – 60° C. Then, the air flows through a non return valve to the
compressed air bottle (figure 3).

Fig. 3

1st and 3rd stage compression takes place simultaneously with the upward movement of the
piston. The air in the 2nd stage is compressed with the downward movement of the piston and is
sucked into the 1st and 3rd stage. The cooling air is supplied through an axial fan which is
mounted on the flywheel. The condensate generated during cooling must be drained at regular
intervals. Depending on the compressor’s equipment, the condensate is either drained manually
or automatically through corresponding valves.
4.4.3 Initial startup or startup after extended interruptions
The compressor must be prepared for operation before a work or before shift is commenced. The
checks and inspections must be performed in steps. For daily maintenance (such as lubrication),
please consult the maintenance table (Ch. 4.4.6 / Tab. 3). New machines must be inspected and
require maintenance at shorter intervals (according to operating hours) (chapter 5.2).

Caution! Check oil level!

The compressor is delivered without oil for transport reasons. Please add
IMPORTANT! only the recommended oils of the “lubrication oil chart” (See oil chart Ch. 7).

In Chapter 4.4.6, Table 3 lists the checks that must be conducted before and during the startup of
the compressor. Make sure that the sequence specified in the table is followed for each task.
The information provided in the appendix “Maintenance instructions for the lubrication oil pump“
must be observed.
In addition, follow the instructions in Chapter 4.4.1.
In order to check the movement of the moving parts of the compressor, the flywheel must be
turned manually several times before startup of the compressor.
 page 21
Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

NOTE IMPORTANT!

Safetyinstructions:
The operating personnel are responsible for reading the entire operating manual before startup of
the compressor and taking only measures in compliance with the rules and safety regulations
described herein. Upon delivery or after the initial installation of the compressor, the operating
and maintenance personnel can receive thorough training by NEUENHAUSER KOMPRESSORENBAU
GMBH at the request of the customer. If the information provided is not sufficient, or special
problems arise during operation or maintenance that are not described in sufficient detail in this
operating manual, you can request the necessary information directly from NEUENHAUSER
KOMPRESSORENBAU GMBH. Safe work methods must be applied at all times and the local health
and safety regulations must be observed. Any action that threatens the safety of persons and / or the
compressor is prohibited.
The cause of a malfunction must always be determined and eliminated. Do not switch on the
compressor again until after the malfunction has been eliminated!
After completion of the preparations for operation the compressor is started up and operated from
the switch cabinet, only when all covers and protective devices are closed and in place.
The regulations, warnings and instructions must be observed at all times, such as during operation,
startup or shut-down of the compressor.
Before switching on the compressor for the first time and before every subsequent startup, the
operator is responsible for ensuring that:
♦ the compressor has been correctly installed and is protected
♦ the operating personnel are familiar with the compressor and its safety devices and is aware of
and will comply with all relevant notices in this operating manual
♦ the preparations for operation have been completed
♦ no one is present or working within the danger zone of the compressor.
4.4.4 Normal startup of the compressor without automatic mode
If the compressor is equipped with manual drain valves, they must be opened each time before
the compressor is started. They are used to alleviate the load at startup and to drain the
condensate.
♦ Open valves in the air line on the compressed air bottle
♦ Switch on the drive motor
♦ After the operating speed is reached and if condensation no longer escapes, close
condensation drain valve
♦ The air flow begins
♦ Check pressure gauge pressures. If the displayed pressures deviate more than 20 % from the
values shown in the table (Chapter 5.6.1), there is a malfunction (see Chapter 5: Maintenance,
Repairs and Troubleshooting).
♦ Check the functioning and oil feed rate of the cylinder lubrication system (see chapter 4.4.6,
table 3 and appendix “Maintenance instructions for the lubrication oil pump“)
♦ After the ultimate pressure has been reached, shut off the motor!
♦ Close the valves in the air line.
♦ Open the condensation drain valves.
4.4.5 Normal startup of the compressor with automatic mode
If the compressor is equipped with solenoid valves for automatic operation, the solenoid valves
control the automatic condensation draining and load alleviation at startup by means of time relay.
After switching on the compressor, the solenoid valves remain open (7-15 sec., configurable), drain
the condensation and alleviate the load on the compressor.
In the ‘Automatic’ position of the ‘Hand-O-Automatic’ selector switch, the compressor starts up
automatically when the cut-in pressure is not reached and automatically shuts off when the cut-off
pressure is reached. The cut-in and cut-off pressures can be set at the pressure switch.
Once the solenoid valves are closed the compression starts. In automatic mode the pressure is
controlled through the pressure switches. Start at e.g. 22 bar and stop at 30 bar (for starting air).

When the stop pressure of 30 bar is reached all solenoid valves open and the compressor runs 1 – 2
minutes unloaded to cool the components.

During operation the solenoid valves open every 7 to 10 minutes to drain the condensate.
 page 22
Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

In the ‘Hand’ position, the compressor is started manually. The compressor starts up immediately,
regardless of the cut-in pressure set at the pressure switch. The alleviated startup and the
condensation draining take place automatically. When the ultimate pressure is reached, the
compressor must be switched off manually (switch position ‘O’), since the pressure switch has no
function in the ‘Hand’ position.
In manual mode it can happen that the compressor safety valves blow off if the unit is not switched off
in time. This can damage the safety valves! This operation mode should be used for service and
maintenance purposes.

If the compressor runs for more than one hour or if the relative humidity of the intake air is greater
than 80 %, the compressor must be periodically drained (min. four times each hour). Depending on
the compressor’s equipment, regular drainage can be performed automatically.
The compressor must be started up under observance of the inspections listed in chapter 4.4.6,
table 3.
4.4.6 Inspections

Type of inspection When required? Procedure / Action

Cleanliness of the ♦ upon initial startup Open the engine compartment. Remove oil
engine compartment ♦ after interruptions > residues and dirt with a clean cloth.
12 weeks Caution: Do not use cotton waste. If very
♦ every 6 months dirty, use spray oil or diesel fuel. Do not
use petrol or benzene
Add oil / check oil ♦ upon initial startup Check oil level at oil gauge. Oil level must
level ♦ after interruptions > be within the marking
12 weeks
♦ min. 2x daily
♦ every 6 months
Valve and piston ♦ upon initial startup Remove air filter and add a few drops of oil
lubrication (oil ♦ after interruptions > into the air intake.
lubrication pump) 4 weeks Monitor oil supply at the visual gear device
♦ every 6 months while the compressor is operating.
The oil flow rate has been specified at the
*8
factory . Further information can be found
in the appendix “ Maintenance instructions
for the lubrication oil pump“
Check safety valves ♦ upon initial startup Visually inspect the safety valves for leaks
for leaks ♦ after interruptions >
12 weeks
Condensate drainage / ♦ before checking the Open condensation drain valves in order to
Start-up alleviation direction of rotation ensure drainage of the cooler and oil and
♦ before switching on water separator
the compressor (not
necessary for
automatic systems)
Direction of rotation ♦ upon initial startup Briefly turn on motor and observe direction
♦ after repairs of of rotation
compressor or work on Allow condensation to blow out
the electric system Normal direction of rotation is clockwise
looking from the drive side at the flywhee
(see arrow direction on flywheel guard)
Water in the ♦ Once a week Remove an oil sample from the drain plug
lubricating oil ♦ every 6 months
Table 3

8
Changing the setting nullifies the warranty
 Page 23
Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

5 Servicing, maintenance and troubleshooting

5.1 Design of the compressor

Fig. 4
 Page 24
Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

5.1.1 Piston
The piston has been designed as a differential piston and divides 3. Stufe
the compression chamber into three compression stages. The 1st rd
3 stage
compression stage is formed by the bottom of the piston (large
diameter) and is sealed off from the compression chamber of the
3rd stage by the piston rings of that stage. The 2nd compression
1. Stufe
stage is formed by the ring surface of the offset piston diameter and st
1 stage
is sealed off from the crankcase by several piston rings and one
oil scraper ring. The oil scraper ring prevents the excessive
penetration of lubricating oil from the crankcase into the 2. Stufe
nd
compression chamber. The relationship of the piston surfaces 2 stage
result in the stage pressure ratio.
The piston is cast of special pressure sealed cast metal with good
emergency running properties. The piston pin is fitted in the holes
on its lower section and secured by two retaining rings. Fig. 5
5.1.2 Cylinder
The cylinder is made of special cast metal with good emergency running properties and has two
nd
seats on the side of the compression chamber of the 2 stage for the suction and pressure valve
nd
of the 2 stage. The cast cooling fins are large enough to ensure adequate heat dissipation under
normal operating conditions (see Ch. 4.3.4 Room ventilation and cool air supply).
5.1.3 Cylinder head
The cylinder head closes the compression chamber of the 1st stage toward the top and
accommodates the combined suction and pressure valve of the 1st stage. The 3rd stage is
located above the compression chamber of the 1st stage. The heat dissipation is effected by
means of adequately sized cooling fins.
5.1.4 Valves
The valves of all stages are high-quality, automatic, spring-loaded special ring plate valves. In the
1st stage there is a combined suction and pressure valve, in the 2nd stage there is one suction and
one pressure valve and in the 3rd stage there is one tongue valve. Each stage is equipped with a
safety valve which is located on the top of the cooler.
5.1.5 Lubrication system
All engine parts are lubricated by the oil in the crankcase. The oil that splashes up from the
centrifugal pin lubricates all parts of the crank mechanism and the cylinder and piston of the 2nd
stage.
The 1st stage is lubricated by a lubrication oil
pump which intermittently delivers oil into the
suction port of the 1st stage. The oil mixes with
the intake air and is then sucked into the 1st
cylinder stage.
The oil level can be inspected at the oil gauge
when the compressor is turned off. The two
holes next to the oil gauge mark the minimum
and maximum oil level.
On request, we can provide an oil monitoring Bild6
device with an alarm and / or automatic
compressor shut-down.
 Page 25
Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

5.2 Maintenance instructions

A well-maintained machine is always an indication of a meticulous machinist and helps to limit
malfunctions and extends the life of the machine.

When performing cleaning and maintenance tasks, always observe the

safety instructions in Chapter 2 and the installation/workplace description in
IMPORTANT! Chapter 4.3.

Keyword Time interval Procedure / Action

Oil change ♦ first oil change after 60 ♦ Open oil drain plug, allow oil to drain
hours of operation Remove both covers and clean gear
♦ second oil change after mechanism with a clean cloth
300 hours CAUTION! Do not use steel wool,
♦ all further oil changes naphtha or benzene
after 500 hours. ♦ Re-insert oil drain plug, using a new
sealing ring if necessary
♦ Re-attach both covers
♦ Fill with lubricating oil acc. to
lubrication oil list (see Appendix) to
upper oil level mark via oil fill screw
Drive mechanism ♦ 500 hours of operation ♦ Remove both covers and check all
inspection areas for abnormal bearing play.
Close covers. A bearing temperature
of up to 80°C is permissible under
normal operating conditions
Cylinder lubrication ♦ first lubrication upon Visual inspection of the oil supply:
delivery or after 60 ♦ The combined valve of the 1st stage
hours of operation must be coated with oil
♦ second check after 300 ♦ The piston head and the cylinder of
hours the 1st stage must be coated with oil
♦ all further checks after (see Ch. 4.4.3)
500 hours ♦ during operation at the visual gear
device
Pressure gauge ♦ 500 hours of operation To damp vibrations, the pressure gauges
are filled with glycerin, but they must still
be protected from shocks and impacts
(see Ch. 5.6.1)
Intake air filter ♦ 100 hours of operation, ♦ remove filter cap and blow out or
depending on condition replace paper filter
of air; use oil bath air
cleaner, if necessary
Safety valves ♦ 1x per year Check acc. to the maintenance
♦ minimum requirement: instructions in Appendix Ch. 13.6
acc. to the applicable
regulations
Non return valve in ♦ 500 hours of operation Check for perfect seal in order to prevent
the compressed air accidents
line between Opening the condensation drain valve
compressor and when the compressor is turn off to
compressed air bottle depressurizes the compressor-side
compressed air line. After closing the
valve, pressure should not build up
again. If pressure builds up, clean the
non return valve or replace it, if
necessary
 Page 26
Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

Keyword Interval Task

3rd stage valve ♦ 1000 hours of operating Remove and clean valves. The valve
gaskets can be checked by pouring a low
2nd stage valve viscosity solvent into the recesses of the
valves in the direction of air flow. If the
1st stage valve valve plates leak, the solvent flows out of
the recesses across the valve plates.
In case of coking deposits, clean valves
thoroughly or replace (see Ch. 5.5.1 -
5.5.3)
Piston rings / ♦ every 1000 hours of Dismantle cylinder head, dismantle cover
oil scraper rings operation or upon and remove the piston.
obvious decline in For more detailed description, see
output and increased oil “Maintenance” (Ch. 5.5.4)
consumption
Connecting rod ♦ every 1000 hours of There should be no noticeable bearing
bearing operating clearance by moving the connecting rod
back and forth with opened crankcase.
Oil and water ♦ first maintenance after Clean filter mash
separator 60 hours of operation (see attachment)
♦ afterwards, after every
100 hours of operation
Accessories for ♦ 500 operating hours Check for proper function and clean dirty
automatic operation (if solenoid valves and the filters, if
supplied) necessary (see appendix "solenoid
valve")
Consult separate description of
compressor controls
Table 4
5.3 Cleaning
Loose dirt is polluted with operating supplies (grease etc) and must therefore be collected and
disposed correctly (see chapter 2).
5.4 Malfunctions and troubleshooting
The malfunctions described below and the measures for locating and eliminating the malfunctions
should help you to conduct repairs yourself. Instructions on troubleshooting can be found
primarily in Chapters 5.2 and 5.5.

Malfunction Cause Troubleshooting

Rapid abrasion of the Insufficient lubrication of cylinder Pressure rise in the crankcase,
piston rings oil level low
Water in the lubricating Condensation from the air Drain cooler more frequently. If
oil precipitates through the piston using automatic operation,
rings of the 2nd stage as check the functioning of the
condensation water condensate drain or of the
electric solenoids.
Coupling rattles Coupling flange is defective Replace coupling flange
 Page 27
Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

Malfunction Cause Troubleshooting

The compressor needs Intake filter is dirty Remove intake filter and
unusually long to fill the inspect (see Ch. 5.2)
compressed air tank(s). Valves are dirty or gaskets on the Check function of valves via
valves are not in perfect condition display of pressure gauge in
the individual stages (operating
pressures acc. to Table 7, Ch.
5.6.1)
Suction valve side Irregular valve closing noises,
Combined valve 1st stage leaks repulsion of air from the filter
Pressure valve side The interim pressure acc. to
Combined valve 1st stage leaks Ch. 5.6.1 is not reached
Suction valve 2nd stage leaks The interim pressure at the
pressure gauge 1st stage is
more than 20 % above the
value specified in Ch. 5.6.1
Pressure valve 2nd stage leaks The air temperature at the
exhaust is unusually high
Suction valve side The interim pressure at the
tongue valve of the 3rd stage leaks pressure gauge 2nd stage is
more than 20 % above the
value specified in Ch. 5.6.1
Pressure valve side The air temperature at the
tongue valve of the 3rd stage leaks exhaust is unusually high.
Piston rings and oil scraper rings The pressure gauges display
are worn normal pressure, but the flow
rate is insufficient. Unusually
high pressure build-up is
detected in the crankcase by
blowing off of the pressure
control valve
Oil and water separator Filter cartridge is dirty,
excessive pressure build-up in
the 3rd stage, safety valve
blows off
Valves are carbonized Remove valves and check for
permeability; if necessary,
clean or replace. (see Ch. 5.5.1
- 5.5.3)
Safety valves blow off Coolers or pipes are blocked
The ball valve in the piping for
disconnecting the compressor
is closed
(also see oil and water
separator)
Grating noise in Crankshaft bearing is defective Excessive warming of bearings.
crankcase Can be felt on bearing cover
 Page 28
Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

Malfunction Cause Troubleshooting

Unusually high oil Leakage at crankcase Check all gaskets, especially
consumption shaft seals and spacer
Cylinder worn Replace cylinder
Oil scraper ring seized or broken Check oil scraper ring
Piston rings worn Pressure build-up in crankcase
Check piston rings
Table 5
5.5 Maintenance instructions
The illustrations in this chapter show a compressor with 3 cylinders.
5.5.1 Disassembly and assembly of the tongue valve in the 3rd stage

Fig. 7
♦ Dismantle the piping
♦ Loosen the allen screws for dismantling the valve cover
♦ Remove copper ring, flat gasket and valve
♦ Clean dirty parts
♦ Replace valve, if necessary
♦ Replace seals
♦ Assemble in reverse sequence
Caution:
Read instructions on “Care and maintenance”. Tighten the nuts only to the specified torque (see
Chapter 5.6.3).
 Page 29
Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

5.5.2 Disassembly and assembly of the combined valve in the 1st stage

Fig. 8

♦ Remove air filter, piping, venting hose and lubrication pipe

♦ Loosen allen screws to disassemble the 3rd stage cylinder
♦ Carefully pull the cylinder off the piston
♦ Remove the copper ring
♦ Turn the cylinder upside down and carefully remove both valve plates
♦ Loosen the countersunk screws of the valve and remove valve support incl. both valve plates
♦ Remove copper ring
♦ Clean dirty parts
♦ Replace valve, if necessary
♦ Replace copper ring and flat gasket
♦ Assemble in reverse sequence. The countersunk screws must be in perfect line with the valve
plate. When reassembling the cylinder head, the clamping tool, item no.: 0217130, must be
used to press the piston rings together (see chapter 6 “Spare part supply and special tools”).
Note:
The last two valve plates can be stuck into place using a little grease to prevent them from falling
down during assembly.
Caution:
Read instructions on “Care and maintenance”. Tighten the nuts only to the specified torque (see
Chapter 5.6.3).
 Page 30
Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

5.5.3 Disassembly and assembly of the suction and pressure valve in the 2nd stage

Fig. 9

Removal of suction valve:

♦ Remove suction pipe
♦ Loosen four hexagon nuts for removing the connecting piece
♦ Remove gaskets and suction valve
♦ Clean dirty parts
♦ Replace suction valve, if necessary
♦ Replace gaskets
♦ Assemble in reverse sequence
Removal of pressure valve:
♦ Remove pressure pipe
♦ Loosen four hexagon nuts for removing the connecting piece
♦ Remove gaskets and pressure valve
♦ Clean dirty parts
♦ Replace pressure valve, if necessary
♦ Replace gaskets
♦ Assemble in reverse sequence
Caution:
If both valves are checked at the same time, make sure not to switch the valves. Read
instructions on “Care and maintenance”. Tighten the nuts only to the specified torque (see Ch.
5.6.3).
 Page 31
Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

5.5.4 Disassembly and assembly of the piston

Fig. 10

♦ Remove valves as described in chap. 5.5.1, 5.5.2 and 5.5.3

♦ Remove both inspection covers
♦ Move the piston to the bottom dead centre
♦ Remove locking screws (+vent pipe by a compressor with 3 cylinders) from the bearing cover
♦ Use the special tool, item no.: 0057278, to remove the piston pin (see chap. 6 “Spare part
supply and special tools”)

Fig. 11

♦ Pull the piston upwards out of the cylinder

♦ Clean or replace piston rings and oil scraper ring. Before inserting the piston, make sure that
the joints of the piston rings are offset by 180° and that the piston ring joints are offset to the
valve holes of the 2nd stage by 90°.
 Page 32
Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

Kolbenring 1 stufe
Kolben piston ring 3rd stage
piston
Kolbenring 1 stufe
Piston ring 1st stage

Kolbenbolzen
Piston pin

Kolbenring 2 stufe
piston ring 2nd stage

Ölabstreifring
oil scraper ring

Sicherungsring
retaining ring
Fig. 12

Before inserting the piston, the cylinder surface must be lightly lubricated (see
oil chart).
IMPORTANT! Insert the piston in association to each cylinder

♦ If a piston fitting sleeve (see chap. 6 “Spare part

supply and special tools”) is available, this is pushed
over the piston rings of the 1st stage from the
direction of the connecting rod. The piston is then
inserted into the cylinder and driven down into the
cylinder by giving it light blows with the handle of a
hammer.
♦ As soon as any resistance is felt, the piston rings of
the 2nd stage must be pressed down through the
valve bore of the 2nd stage using suitable objects
and guided over the ledge in the cylinder, as there is
otherwise a risk that the rings will break during fitting.
♦ Insert the piston pin
♦ When fitting a new piston, the upper and lower
clearances must be adhered to (see chap. 5.6.4).
The 1st stage clearance comprises the entire
distance between the bottom of the piston and the
valve of the 1st stage. The clearance of the piston is
measured at the upper dead centre using a depth
gauge between the bearing surface for the copper
Fig. 13
gasket on which the combined suction and pressure
valve of the 1st stage rests and the bottom of the piston. The thickness of the copper gasket
should be added to this.
♦ The clearance of the 2nd stage comprises the distance between the bevel of the piston
(transition from the large to the small diameter) and the corresponding bevel of the cylinder in
the bottom dead centre position. The clearance is measured by sticking a small strip of lead or
solder wire through the valve bore of the suction or pressure valve of the 2nd stage and
turning the crankshaft by hand over the bottom dead centre. In this way, the comparatively soft
metal deforms and the remaining thickness corresponds to the clearance, which should be
within the range stated in chapter 5.6.4.
♦ The entire clearance of the 3rd stage comprises the distance from the bottom of the piston to
the valve of the 3rd stage. The clearance of the piston is measured in the upper dead centre
using a depth gauge between the bearing surface for the copper gasket on which the tongue
valve of the 3rd stage rests and the bottom of the piston. The thickness of the copper gasket
should be added to this. Please refer to chapter 5.6.4 for permissible clearances.
♦ Once the valves have been assembled as described in chapter 5.5.1, 5.5.2 and 5.5.3, the
inspection covers can be reassembled.
 Page 33
Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

5.5.5 Removing the crankshaft bearing

Fig. 14

♦ Proceed as described in ch. 5.5.4: Disassembly and assembly of the piston

♦ Drain oil
♦ Disassemble the oil pipes
♦ Remove the front cover including oil pump

Fig. 15
 Page 34
Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

♦ Remove the compressor block from the frame by removing the 4 screws on the base of the
housing and replace on the frame turned by 180°.
♦ Disassemble the fan wheel
♦ Remove the hexagon head screw and retaining washer at the flywheel and remove the
flywheel from the crankshaft using an extraction tool.
♦ Disassemble the spacer ring together with the shaft seal.
♦ Remove the retaining ring at the crankshaft and take off the bearing cover with the outer ring
of the bearing. The inner ring of the bearing stays on the crankshaft.
♦ The crankshaft can now be pulled out of the front bearing.
♦ The radial shaft seal and the spacer ring must be inspected and replaced with new ones if
required
♦ Pull the inner ring from the cylindrical roller bearing using a suitable tool
♦ Pull off the needle bearing (on the side of the floating bearing) using a suitable tool

Bild 16

♦ The bearing body must be pulled from the cone using a suitable tool before the big end
bearings can be disassembled.
♦ The big end bearings can be pulled off once the slotted round nuts have been loosened.

When changing the ball bearings, the new bearings must be heated to approx. 90 -
NOTE 100°C in an oil bath immediately before installation.

Assembly:
Assembly is always performed in reverse sequence. Strict observance of the following
instructions is highly recommended to prevent mistakes during assembly:

Keep all bearings perfectly clean, protected against dirt and slightly oil them before
assembly. Label disassembled parts so that they can be reassembled in the same
NOTE place and protect them against damage. Tighten screws and nuts with normal
spanners and fit with the provided locking devices.
5.5.6 Gaskets
Leaks at gaskets can often be eliminated by tightening the respective bolts. If the leakage
continues after tightening the bolts, use new gaskets. If the shaft sealing ring leaks, it must be
replaced as described in Chapter 5.5.5.
 Page 35
Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

5.5.7 Final inspection

After each maintenance, the following inspections are necessary: Turn the flywheel by hand
several times and check as follows:

If Then
the valves are not installed the piston does not run Check whether valves were
correctly, smoothly or knocks at dead switched during installation.
center.
the gap clearances were not the piston knocks at lower or Check the gap clearance with
maintained acc. to Ch. 5.6.4 upper dead center. valves removed.
at the piston head and the
shoulder (2nd stage),
Table 6
5.6 Setting data
5.6.1 Table for stage pressures

Operating pressure 3rd stage 20 25 30 35 40 Bar

Operating pressure 2nd stage 9,8 9,8 10,4 10,4 10,5 Bar
Operating pressure 1st stage 2,4 2,4 2,6 2,6 2,7 Bar
Table 7
5.6.2 Pressure settings of the safety valves

operating pressure 3rd stage 20 25 30 35 40 Bar

Safety valve 3rd stage 22 27,5 35 38,5 44 Bar
Safety valve 2nd stage 15 15 15 15 15 Bar
Safety valve 1st stage 5 5 5 5 5 Bar
Table 8
The safety valve of the 3rd stage is adjusted in dependence on the operating pressure of the
machine. The opening pressure is a minimum of 10% / maximum of 20% above the operating
pressure. The pipes as well as all other system components must be protected separately. The
safety valve of the 1st stage is set to 5 bar due to the design pressure of the compressor. The
safety valve of the 2nd stage is set to 15 bar. Further information can be found in the
manufacturer’s instructions in the appendix.
5.6.3 Table for torques of the screws and nuts

Compressor type Position Tightening

torque
45.2.3.02.02 - Valve cover (M8) 16 Nm
80.2.3.02.03 Cylinder 3rd stage (M8) 16 Nm
Cylinder 1st stage (M12) 24 Nm
Intermediate pieces HD valves (M10) 20 Nm
Bearing body crankshaft (M24) 320 Nm
Table 9
5.6.4 Table for gap clearances for pistons

Compression chamber 1st stage: Clearance 0.6 to 1.5 mm

Compression chamber 2nd stage: Clearance 0.4 to 1.2 mm
Compression chamber 3rd stage: Clearance 0.6 to 1.5 mm
Table 10
 Page 36
Operating instructions for compressor series 45.2.3.02.02....- 80.2.3.02.03....

6 Spare part supply and special tools

All replacement parts are available at all times in our extensive parts warehouse. Parts are sent
as quickly as possible – on request, to anyplace in the world. In especially urgent situations, you
can even receive replacement parts on Sundays and holidays. Expert mechanics are available for
repairs and maintenance.
Please include the following information when ordering replacement parts:
♦ Compressor model
♦ Plant no.
♦ Article no. and name of the needed part
♦ Dispatch address
♦ Type of dispatch desired

The item no. and name are included in the spare parts list in the appendix.
NOTE

Spare parts and special tools can be ordered directly from the following address:
NEUENHAUSER KOMPRESSORENBAU GMBH
Hans – Voshaar – Str. 5
D - 49828 Neuenhaus
Germany

Tel.: +49 (0) 5941 – 604-0

Fax: +49 (0) 5941 – 604-202
Email: [email protected]
Website: www.neuenhauser.de
NEUENHAUSER KOMPRESSORENBAU GMBH recommends stocking the following replacement
parts in order to quickly eliminate malfunctions due to ordinary wear or unforeseeable operating
conditions:

♦ 1 set of valves for each the first, second and third stage
♦ 1 set of piston rings and oil scraper rings each
♦ 1 set of gaskets each
♦ 1 set of safety valves each

Furthermore, the following special tools are recommended:

Name Item no.
Piston pin dismounting device 0057278

Piston fitting sleeve

for compressor type 40.2.3...... 0057279
45.2.3......

Piston fitting sleeve 0291537

for compressor type 60.2.3......
for compressor type 80.2.3......

Piston fitting device 0217130

Table 11
Ersatzteilliste / spare parts
für Kompressorserie / for compressor serie

45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03
Ausbaustufe / release: 02
luftgekühlter Kompressor, 3-stufig
air cooled compressor, 3-stages
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

1 Inhaltsangabe / Content
1 Inhaltsangabe / Content ...................................................................................... 3
2 Gesamtzeichnung / General Drawing .................................................................. 5
3 Kompressorblock / Compressor Block................................................................. 6
3.1 Gehäuse / Housing ........................................................................................ 8
3.2.1 Kurbelwelle 2-Zylinder / Crankshaft 2-Cylinders .......................................... 10
3.2.2 Kurbelwelle 3-Zylinder / Crankshaft 3-Cylinders .......................................... 11
3.3.1 Zylinder / Cylinder 45.2.3............................................................................. 12
3.3.2 Zylinder / Cylinder 60.2.3. – 80.2.3 .............................................................. 14
3.4.1 Kolben / Piston 45.2.3. ................................................................................ 16
3.4.2 Kolben / Piston 60.2.3. + 80.2.3. ................................................................. 17
3.5.1 Taktpumpe 2-Zylinder / Lub. Oil Pump 2-Cylinders ..................................... 18
3.5.2 Taktpumpe 3-Zylinder / Lub. Oil Pump 3-Cylinders ..................................... 19
4 Rahmen / Frame................................................................................................ 20
5 Schwungrad / Flywheel ..................................................................................... 21
6.1 Kühler 2-Zylinder / Cooler 2-cylinder .............................................................. 22
6.2 Kühler 3-Zylinder / Cooler 3-cylinder .............................................................. 24
7.1a Kondensatablass 2-Zyl. / Condensate Drain 2-cyl. ...................................... 26
7.1b Kondensatablass 3-Zyl. / Condensate Drain 3-cyl. ...................................... 28
7.2 entk. Kondensatabl. 2-Zyl. / Decoupled Cond. Dr. 2-cyl. ................................ 30
8.1 Antrieb 2-Zylinder / Drive 2-cylinder ................................................................ 32
8.2 Antrieb 3-Zylinder / Drive 3-cylinder ................................................................ 33
9.1 Verrohrung 2-Zylinder / Piping 2-cylinder ....................................................... 34
9.2 Verrohrung 3-Zylinder / Piping 3-cylinder ....................................................... 36
10 Schaltschrankrahmen / Switch Box Frame ..................................................... 38

© by Neuenhauser Kompressorenbau GmbH 2018 Stand November 2018

3
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

2 Gesamtzeichnung / General Drawing

Menge/
Pos. Ersatzteil spare part
quantity
45.2.3.02 60.2.3.02 80.2.3.02
10 Rahmen frame 1 Seite/page 20 Seite/page 20 Seite/page 20
20 Kompressorblock compressor block 1 Seite/page 6 Seite/page 6 Seite/page 6
30 Schwungrad flywheel 1 Seite/page 21 Seite/page 21 Seite/page 21
40 Kühler cooler 1 Seite/page 22 Seite/page 22 Seite/page 22
50 Kondensatablass condensate drain 1 Seite/page 26 Seite/page 26 Seite/page 26
60 Antrieb drive 1 Seite/page 30 Seite/page 30 Seite/page 30
70 Schaltschrankrahmen switch box frame 1 Seite/page 36 Seite/page 36 Seite/page 36
80 Verrohrung piping 1 Seite/page 32 Seite/page 32 Seite/page 32
90 Dichtring gasket ring 2 0056878 0056878 0056878
100 Ölstandssensor lub oil controller 1 0234704 0234704 0234704
110 Sicherheitsventil safety valve 1 0201072 0201072 0201072
Druckschalter (≤ 30 bar) pressure switch (≤ 30 bar) 1 0057666 0057666 0057666
120
Druckschalter (> 30 bar) pressure switch (> 30 bar) 1 0058059 0058059 0058059
130 Schlauchleitung flexible hose 3 0058317 0058317 0058317
140 Schlauchleitung flexible hose 1 0058302 0058302 0058302
150 Thermostat (optional) thermostate (optional) 1 0084411 0084411 0084411
160 Verschraubung (optional) screwing (optional) 1 0058626 0058626 0058626
170 Adapter (optional) adapter (optional) 1 0084528 0084528 0084528
180 Scheibe washer 4 0072039 0072039 0072039
190 Zylinderschraube head screw 4 0051400 0051400 0051400

© by Neuenhauser Kompressorenbau GmbH 2016 Stand Januar 2016 Rev: 000

5
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

3 Kompressorblock / Compressor Block

2-Zylinder / 2-Cylinders

Menge/
Pos. Ersatzteil spare part
quantity
xx.2.3.02.02
10 Kurbelwelle 2-Zylinder crankshaft 2-cylinder 1 Seite/page 10
20 Kolben piston 2 Seite/page 16
30 Zylinder cylinder 2 Seite/page 12
40 Gehäuse housing 1 Seite/page 8
50 Taktpumpe 2-Zylinder lubrication oil pump 2-cylinder 1 Seite/page 18
60 Dichtung gasket 1 0058523
70 Deckel cover 1 0252253
80 Federring washer 4 0050264
90 Zylinderschraube head screw 4 0052952

© by Neuenhauser Kompressorenbau GmbH 2016 Stand Januar 2016 Rev: 000

6
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

3-Zylinder / 3-Cylinders

Menge/
Pos. Ersatzteil spare part
quantity
xx.2.3.02.03
10 Gehäuse housing 1 Seite/page 8
20 Kurbelwelle 3-Zylinder crankshaft 3-cylinder 1 Seite/page 11
30 Zylinder cylinder 3 Seite/page 12
40 Kolben piston 3 Seite/page 16
50 Taktpumpe 3-Zylinder lubrication oil pump 3-cylinder 1 Seite/page 19

© by Neuenhauser Kompressorenbau GmbH 2016 Stand Januar 2016 Rev: 000

7
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

3.1 Gehäuse / Housing

Position 210; 220 : 25 Nm

Position 240 : 220 Nm
© by Neuenhauser Kompressorenbau GmbH 2016 Stand Januar 2016 Rev: 000
8
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

Menge/
Pos. Ersatzteil spare part
quantity
45.2.3.02 60.2.3.02 80.2.3.02
10 Kurbelgehäuse crankcase 1 1013630 1013630 1013630
20 Lagerdeckel bearing cover 1 0201496 0201496 0201496
30 Schaulochdeckel inspection cover 2 0058395 0058395 0058395
40 Abschlussdeckel cover 1 0230652 0230652 0230652
50 Distanzring distance ring 1 0058434 0058434 0058434
60 Verschlussring lock ring 1 0058428 0058428 0058428
70 Rohrleitung pipe 1 1052179 1052179 1052179
80 Dichtung gasket 2 0058516 0058516 0058516
90 Verschlussschraube locking screw 1 0273641 0273641 0273641
100 Typenschild name plate 1 0124701 0124701 0124701
110 Ölstandsauge oil gauge 1 0250810 0250810 0250810
120 Belüftungsfilter filter 1 0326228 0326228 0326228
Belüftungsfilter Einsatz ventilation filter insert 1 0764665 0764665 0764665
130 Verschraubung screwing 1 0058691 0058691 0058691
140 Verschraubung screwing 1 0058732 0058732 0058732
150 O-Ring O-ring 1 0261123 0261123 0261123
160 O-Ring O-ring 1 0057002 0057002 0057002
170 O-Ring O-ring 1 0201447 0201447 0201447
180 Radialwellendichtring radial seal 2 0056603 0056603 0056603
190 Sperrzahnscheibe disk 20 0059096 0059096 0059096
200 Zylinderschraube head screw 20 0058700 0058700 0058700
210 Skt.-Schraube hexagon head screw 26 0058692 0058692 0058692
220 Skt.-Schraube hexagon head screw 6 0052202 0052202 0052202
230 Skt.-Schraube hexagon head screw 4 0052199 0052199 0052199
240 Verschlussschraube locking screw 6 0059251 0059251 0059251
250 Verschlussschraube locking screw 1 0054421 0054421 0054421
260 Halbrund-Kerbnagel round head grove pin 4 0059524 0059524 0059524
270 Dichtring gasket ring 1 0056877 0056877 0056877
280 Dichtring gasket ring 6 0056908 0056908 0056908
290 Sprengring retainer 1 0059733 0059733 0059733
300 Winkel fitting 1 0266502 0266502 0266502

© by Neuenhauser Kompressorenbau GmbH 2018 Stand November 2018

9
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

3.2.1 Kurbelwelle 2-Zylinder / Crankshaft 2-Cylinders

Position 150 : 210 Nm

Menge/
Pos. Ersatzteil spare part
quantity
45.2.3.02 60.2.3.02 80.2.3.02
10 Kurbelwelle crankshaft 1 0215960 0215960 1000785
20 Gegengewicht counter weight 1 1004766 1004766 1040089
30 Gegengewicht counter weight 1 1004764 1004764 1040090
40 Pleuelstange connection rod 2 0057242 0057242 0057242
50 Distanzring spacer ring 1 0225370 0225370 0225370
60 Distanzscheibe distance washer 1 0057086 0057086 0057086
70 Distanzring spacer ring 2 0057087 0057087 0057087
80 Distanzring spacer ring 1 0057089 0057089 0057089
90 Passfeder tongue 1 0080148 0080148 0080148
100 Sicherungsring retaining ring 1 0070454 0070454 0070454
110 Zylinderrollenlager roller bearing 1 0056804 0056804 0056804
120 Zylinderrollenlager roller bearing 2 0056831 0056831 0056831
130 Nadellager needle bearing 1 0056808 0056808 0056808
140 Nadellager needle bearing 2 0056822 0056822 0056822
150 Zylinderschraube head screw 2 0050437 0050437 0050437
160 Senkschraube countersunk screw 1 0464058 0464058 0464058
170 Gewindestift allen screw 2 0059786 0059786 0059786
180 Sicherungsring retaining ring 1 0056652 0056652 0056652

© by Neuenhauser Kompressorenbau GmbH 2016 Stand Januar 2016 Rev: 000

10
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

3.2.2 Kurbelwelle 3-Zylinder / Crankshaft 3-Cylinders

Position 140 : 210 Nm

Menge/
Pos. Ersatzteil spare part
quantity
45.2.3.02 60.2.3.02 80.2.3.02
10 Kurbelwelle crankshaft 1 0215960 0215960 1000785
20 Gegengewicht counter weight 1 0338570 0338570 1039518
30 Gegengewicht counter weight 1 0338566 0338566 1039507
40 Pleuelstange connection rod 3 0057242 0057242 0057242
50 Distanzscheibe distance washer 1 0057086 0057086 0057086
60 Distanzring spacer ring 2 0057087 0057087 0057087
70 Distanzring spacer ring 1 0057089 0057089 0057089
80 Passfeder tongue 1 0080148 0080148 0080148
90 Sicherungsring retaining ring 1 0070454 0070454 0070454
100 Zylinderrollenlager roller bearing 1 0056804 0056804 0056804
110 Zylinderrollenlager roller bearing 3 0056831 0056831 0056831
120 Nadellager needle bearing 1 0056808 0056808 0056808
130 Nadellager needle bearing 3 0056822 0056822 0056822
140 Zylinderschraube head screw 2 0050437 0050437 0050437
150 Senkschraube countersunk screw 1 0464058 0464058 0464058
160 Gewindestift allen screw 2 0059786 0059786 0059786
170 Sicherungsring retaining ring 1 0056652 0056652 0056652

© by Neuenhauser Kompressorenbau GmbH 2016 Stand Januar 2016 Rev: 000

11
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

3.3.1 Zylinder / Cylinder 45.2.3.

Position 100 : Beschreibung des Zusammenbaus im Anhang auf Seite A19-1

Description of assembly in the appendix on page A19-1
Position 150 : 25 Nm
Position 160 : 16 Nm
Position 170 : 86 Nm
© by Neuenhauser Kompressorenbau GmbH 2016 Stand März 2016 Rev: 000
12
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

Menge/
Pos. Ersatzteil spare part
quantity
45.2.3.02
10 Zylinder cylinder 1 0283675
20 Zylinder 3.Stufe
rd
cylinder 3 stage 1 0261153
30 Ventildeckel valve flap 1 0127317
40 Zwischenstück intermediate piece 2 0283743
60 Dichtung gasket 1 0058503
70 Dichtung gasket 1 0220607
80 Dichtung gasket 1 0058523
90 Zungenventil tonge valve 1 0126666
100 Ringlamellenventil ring laminated valve 1 0055155
Reparatursatz repair kit ring laminated
Ringlamellenventil valve
1 0477140
110 Saugventil suction valve 1 0054522
Reparatursatz Saugventil repair kit suction valve 1 0477143
120 Druckventil pressure valve 1 0054525
Reparatursatz Druckventil repair kit pressure valve 1 0477151
130 Luftfilter air filter 1 0238578
Filtereinsatz filter element 1 0280696
140 Senkschraube screw 4 0464058
150 Zylinderschraube head screw 12 0050847
160 Zylinderschraube head screw 8 0051460
170 Zylinderschraube head screw 4 0050416
180 Sperrzahnscheibe disk 12 0059096
190 Sperrzahnscheibe disk 8 0216763
200 Sperrzahnscheibe disk 4 0216764
210 Dichtring gasket ring 4 0056902
220 Dichtring gasket ring 1 0127671
230 Dichtring gasket ring 1 0056952

© by Neuenhauser Kompressorenbau GmbH 2016 Stand März 2016 Rev: 000

13
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

3.3.2 Zylinder / Cylinder 60.2.3. – 80.2.3

Position 110 : Beschreibung des Zusammenbaus im Anhang auf Seite A19-1

Description of assembly in the appendix on page A19-1
Position 140 : 25 Nm
Position 150 : 16 Nm
Position 170/180 : 86 Nm
© by Neuenhauser Kompressorenbau GmbH 2016 Stand März 2016 Rev: 000
14
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

Menge/
Pos. Ersatzteil spare part
quantity
60.2.3.02 80.2.3.02
10 Zylinder cylinder 1 0212452 0227766
20 Zylinder 3.Stufe
rd
cylinder 3 stage 1 0127688 0127688
30 Ventildeckel valve flap 1 0127317 0127317
40 Zwischenstück intermediate piece 2 0262876 0262876
50 Dichtung gasket 1 0058522 0058522
60 Dichtung gasket 1 0058523 0058523
70 Dichtung gasket 1 0220607 0220607
80 Zungenventil tonge valve 1 0126666 0126666
90 Druckventil pressure valve 1 0055133 0055133
Reparatursatz Druckventil repair kit pressure valve 1 0477157 0477157
100 Saugventil suction valve 1 0055132 0055132
Reparatursatz Saugventil repair kit suction valve 1 0477155 0477155
110 Ringlamellenventil ring laminated valve 1 0055156 0055156
Reparatursatz repair kit ring laminated
Ringlamellenventil valve
1 0477154 0477154
120 Luftfilter air filter 1 0244986 0244986
Filtereinsatz filter element 1 0408006 0408006
130 Senkschraube counter sunk screw 4 0058874 0058874
140 Zylinderschraube head screw 14 0050847 0050847
150 Skt.-Schraube hexagon head screw 8 0050907 0050907
160 Stiftschraube stud 4 0292864 0292864
170 Sechskantmutter hexagonal nut 4 0058860 0058860
180 Sperrzahnscheibe disk 4 0216764 0126764
190 Sperrzahnscheibe disk 22 0059096 0059096
200 Dichtring gasket ring 4 0056913 0056913
210 Dichtring gasket ring 1 0056938 0056938
220 Dichtring gasket ring 1 0127671 0127671

© by Neuenhauser Kompressorenbau GmbH 2016 Stand März 2016 Rev: 000

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 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

3.4.1 Kolben / Piston 45.2.3.

Menge/
Pos. Ersatzteil spare part
quantity
45.2.3.02.02
10 Kolben piston 1 0288326
20 Kolbenbolzen piston pin 1 0056762
30 Ölabstreifring oil scaper ring 2 0055822
40 Kolbenring piston ring 6 0055788
50 Kolbenring piston ring 3 0055784
60 Kolbenring piston ring 3 0055747
70 Sicherungsring retaining ring 2 0050644

© by Neuenhauser Kompressorenbau GmbH 2018 Stand Juli 2019

16
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

3.4.2 Kolben / Piston 60.2.3. + 80.2.3.

Menge/
Pos. Ersatzteil spare part
quantity
60.2.3.02.02 80.2.3.02.02
10 Kolben piston 1 0238015 0238015
20 Kolbenbolzen piston pin 1 0056763 0056763
30 Sicherungsring retaining ring 2 0050644 0050644
40 Kolbenring piston ring 3 0055752 0055752
50 Kolbenring piston ring 1 0055745 0055745
60 Kolbenring piston ring 5 0055788 0055788
70 Ölabstreifring oil scraper ring 1 0239724 0239724
80 Minutenring minute ring 1 0422140 0422140
90 Nasenring nose ring 1 0422141 0422141
© by Neuenhauser Kompressorenbau GmbH 2018 Stand Juli 2019
17
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

3.5.1 Taktpumpe 2-Zylinder / Lub. Oil Pump 2-Cylinders

Menge/
Pos. Ersatzteil spare part
quantity
45.2.3.02 60.2.3.02 80.2.3.02
10 Taktpumpe lubrication oil pump 1 0217807 0217807 0217807
20 Dichtung gasket 1 0241276 0241276 0241276
30 Antriebswelle transmission shaft 1 0250702 0250702 0250702
40 Sperrzahnscheibe disk 2 0063568 0063568 0063568
50 Zylinderschraube head screw 4 0050838 0050838 0050838
60 Halterung holder 1 0251657 0251657 0251657
70 Zahnradsichtkontrolle visual gear control device 2 0237229 0237229 0237229
80 Verschraubung screwing 1 0058694 0058694 0058694
90 Verschraubung screwing 4 0240323 0240323 0240323
100 Verschraubung screwing 1 0119893 0119893 0119893
110 Saugleitung suction pipe 1 0252219 0252219 0252219
120 Druckleitung pressure pipe 1 0252224 0252224 0252224
130 Druckleitung pressure pipe 1 0252225 0252225 0252225
140 Druckleitung pressure pipe 1 1004424 0256681 1005705
150 Druckleitung pressure pipe 1 1004418 0256677 1005703
160 Sperrzahnscheibe disk 2 0059096 0059096 0059096
170 Zylinderschraube head screw 2 0051424 0051424 0051424
© by Neuenhauser Kompressorenbau GmbH 2016 Stand Januar 2016 Rev: 000
18
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

3.5.2 Taktpumpe 3-Zylinder / Lub. Oil Pump 3-Cylinders

Menge/
Pos. Ersatzteil spare part
quantity
45.2.3.02 60.2.3.02 80.2.3.02
10 Antriebswelle transmission shaft 1 0250702 0250702 0250702
20 Dichtung gasket 1 0241276 0241276 0241276
30 Halterung holder 1 0251657 0251657 0251657
40 Saugleitung suction pipe 1 0251671 0251671 0251671
50 Druckleitung pressure pipe 1 0251677 0251677 0251677
60 Druckleitung pressure pipe 1 0251673 0251673 0251673
70 Druckleitung pressure pipe 1 0251689 0251689 0251689
80 Druckleitung pressure pipe 1 1004418 0256677 1005703
90 Druckleitung pressure pipe 1 1004454 0256676 1005704
100 Druckleitung pressure pipe 1 1004424 0256681 1005705
110 Taktpumpe lubrication oil pump 1 0230962 0230962 0230962
120 Zahnradsichtkontrolle visual gear control device 3 0237229 0237229 0237229
140 Verschraubung screwing 1 0058694 0058694 0058694
150 Einschraubverschraubung screwing 1 0090594 0090594 0090594
160 Verschraubung screwing 6 0240323 0240323 0240323
170 Zylinderschraube head screw 4 0050838 0050838 0050838
180 Zylinderschraube head screw 3 0051424 0051424 0051424
190 Sperrzahnscheibe disk 2 0063568 0063568 0063568
200 Sperrzahnscheibe disk 3 0059096 0059096 0059096
© by Neuenhauser Kompressorenbau GmbH 2016 Stand Januar 2016 Rev: 000
19
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

4 Rahmen / Frame

Menge/
Pos. Ersatzteil spare part
quantity
45.2.3.02 60.2.3.02 80.2.3.02
10 Rahmengestell base frame 1 0252599 0252599 0252599
20 Tragrahmen frame 1 0252602 0252602 0252602
30 Unterrahmen links base frame left 1 0252620 0252620 0252620
40 Unterrahmen rechts base frame right 1 0252621 0252621 0252621
50 Schwingmetall anti vibration element 4 0202051 0202051 0202051
60 RIPP-Schraube RIPP-screw 4 0243193 0243193 0243193
70 Skt.-Schraube hexagon bolt 12 0052378 0052378 0052378
80 Skt.-Schraube hexagon bolt 8 0052495 0052495 0052495
90 Skt.-Schraube hexagon bolt 4 0052246 0052246 0052246
100 Sechskantmutter hexagonal nut 12 0052693 0052693 0052693
110 Sechskantmutter hexagonal nut 8 0052024 0052024 0052024
120 Sechskantmutter hexagonal nut 4 0052026 0052026 0052026
130 Scheibe washer 4 0072040 0072040 0072040
140 Scheibe washer 24 0225248 0225248 0225248
150 Scheibe washer 4 0221161 0221161 0221161
160 Scheibe washer 16 0451805 0451805 0451805
170 Dichtring gasket ring 2 0418729 0418729 0418729
180 Verschlussschraube locking screw 2 0206616 0206616 0206616

© by Neuenhauser Kompressorenbau GmbH 2016 Stand Januar 2016 Rev: 000

20
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

5 Schwungrad / Flywheel

Menge/
Pos. Ersatzteil spare part
quantity
45.2.3.02 60.2.3.02 80.2.3.02
10 Schwungrad flywheel 1 0252848 0252848 0252848
20 Scheibe washer 1 0057683 0057683 0057683
30 Innenring inner ring 1 0201870 0201870 0201870
40 O-Ring O-ring 1 0056980 0056980 0056980
50 Skt.-Schraube hexagon head screw 1 0058677 0058677 0058677
60 Federring spring washer 1 0200396 0200396 0200396

© by Neuenhauser Kompressorenbau GmbH 2016 Stand Januar 2016 Rev: 000

21
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

6.1 Kühler 2-Zylinder / Cooler 2-cylinder

© by Neuenhauser Kompressorenbau GmbH 2016 Stand Oktober 2016 Rev: 000

22
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

Menge/
Pos. Ersatzteil spare part
quantity
45.2.3.02 60.2.3.02 80.2.3.02
10 Lüfterhaube impeller covering 1 0261761 0261761 0261761
20 Berührungsschutz touch protection 1 0268782 0268782 0268782
30 Distanzblech plate 4 0261620 0261620 0261620
40 Verbindungsrohr pipe 4 0276976 0260321 0260321
50 Luftleitblech air baffle plate 1 0273955 0273955 0273955
60 Distanzstück distance piece 3 0274327 0274327 0274327
70 Distanzstück distance piece 4 0274314 0274314 0274314
80 Nachkühler after cooler 1 0250338 0250338 0250338
90 Flanschblech plate 2 --- 1107931 1107931
100 Axialventilator fan 1 0253504 0253504 0253504
110 Sicherheitsventil safety valve 2 0201068 0201068 0201068
120 Sicherheitsventil safety valve 2 0255742 0255742 0255742
130 Manometer 6 bar pressure gauge 6 bar 2 0058387 0058387 0058387
140 Manometer 16 bar pressure gauge 16 bar 2 0058389 0058389 0058389
150 Manometer 60 bar pressure gauge 60 bar 1 0058391 0058391 0058391
160 Rohrschelle pipe clamp 4 0058636 0261635 0261635
170 Verschraubung screwing 5 0053950 0053950 0053950
180 Manometerverschraubung pressure gauge screwing 5 0233754 0233754 0233754
190 Winkeleinschraubverschr. screwing 4 0259356 0089344 0089344
200 Skt.-Schraube hexagon head screw 8 0248738 0248738 0248738
210 Zwischenkühler inter cooler 4 0250301 1063481 1063481
220 RIPP-Schraube RIPP-screw 27x 0243190 9x 0243190 9x 0243190
230 RIPP-Schraube RIPP-screw 20 --- 0243193 0243193
240 Scheibe washer 7 0059096 0072040 0072040
250 Sechskantmutter hexagonal nut 14 0116848 0116848 0116848
260 Käfigmutter nut 35x 0204016 11x 0204016 11x 0204016
270 Sperrzahnscheibe disk 24 0063568 0063568 0063568
280 Zylinderschraube head screw 8 0069322 0051409 0051409
290 Dichtring gasket ring 4 0056878 0056878 0056878
300 Zylinderschraube head screw 16 0051404 0051404 0051404
310 Versteifungsblech stiffening plate 2 --- 1107893 1107893
320 Abdeckblech covering 2 0253756 0253756 0253756

© by Neuenhauser Kompressorenbau GmbH 2016 Stand Oktober 2016 Rev: 000

23
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

6.2 Kühler 3-Zylinder / Cooler 3-cylinder

© by Neuenhauser Kompressorenbau GmbH 2016 Stand Oktober 2016 Rev: 000

24
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

Menge/
Pos. Ersatzteil spare part
quantity
45.2.3.02 60.2.3.02 80.2.3.02
10 Lüfterhaube impeller covering 1 0261761 0261761 0261761
20 Berührungsschutz touch protection 1 0268782 0268782 0268782
30 Distanzblech plate 6 0261620 0261620 0261620
40 Verbindungsrohr pipe 6 0260321 0260321 0260321
50 Luftleitblech air baffle plate 1 0273955 0273955 0273955
60 Distanzstück distance piece 3 0274327 0274327 0274327
70 Distanzstück distance piece 4 0274314 0274314 0274314
80 Nachkühler after cooler 1 0250338 0250338 0250338
90 Flanschblech plate 2 --- 1107931 1107931
100 Axialventilator fan 1 0253504 0253504 0253504
110 Sicherheitsventil safety valve 3 0201068 0201068 0201068
120 Sicherheitsventil safety valve 3 0255742 0255742 0255742
130 Manometer 6 bar pressure gauge 6 bar 3 0058387 0058387 0058387
140 Manometer 16 bar pressure gauge 16 bar 3 0058389 0058389 0058389
150 Manometer 60 bar pressure gauge 60 bar 1 0058391 0058391 0058391
160 Rohrschelle pipe clamp 6 0261635 0261635 0261635
170 Verschraubung screwing 7 0053950 0053950 0053950
180 Manometerverschraubung pressure gauge screwing 7 0233754 0233754 0233754
190 Winkeleinschraubverschr. screwing 6 0089344 0089344 0089344
200 Skt.-Schraube hexagon bolt 12 0248738 0248738 0248738
210 Zwischenkühler inter cooler 6 0258919 1063481 1063481
220 RIPP-Schraube RIPP-screw 27x 0243190 9x 0243190 9x 0243190
230 RIPP-Schraube RIPP-screw 20 --- 0243193 0243193
240 Scheibe washer 7 0059096 0072040 0072040
250 Sechskantmutter hexagon nut 14 0116848 0116848 0116848
260 Käfigmutter nut 35x 0204016 11x 0204016 11x 0204016
270 Sperrzahnscheibe disk 28 0063568 0063568 0063568
280 Zylinderschraube head screw 12 0051409 0051409 0051409
290 Dichtring gasket ring 6 0056878 0056878 0056878
300 Zylinderschraube head screw 16 0051404 0051404 0051404
310 Versteifungsblech stiffening plate 2 --- 1107893 1107893

© by Neuenhauser Kompressorenbau GmbH 2016 Stand Oktober 2016 Rev: 000

25
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

7.1a Kondensatablass 2-Zyl. / Condensate Drain 2-cyl.

© by Neuenhauser Kompressorenbau GmbH 2017 Stand August 2017

26
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

Menge/
Pos. Ersatzteil spare part
quantity
45.2.3.02 60.2.3.02 80.2.3.02
10 Aufnahme holding device 1 1001314 1001314 1001314
20 Kondensatrohr 1. Stufe, Zyl. 1
st
condensate pipe 1 stage, cyl. 1 1 1001320 1001320 1001320
30 Druckluftaustritt air outlet 1 0253638 0253638 0253638
40 Kondensatrohr 1. Stufe, Zyl. 3
st
condensate pipe 1 stage, cyl. 3 1 1001318 1001318 1001318
50 Kondensatrohr 2. Stufe, Zyl. 1
nd
condensate pipe 2 stage, cyl. 1 1 1001316 1001316 1001316
70 Kondensatrohr 2. Stufe, Zyl. 3
nd
condensate pipe 2 stage, cyl. 3 1 1001322 1001322 1001322
90 Kondensatrohr 3. Stufe
rd
condensate pipe 3 stage 1 1001321 1001321 1001321
100 Scheibe washer 2 0072039 0072039 0072039
110 Skt.-Schraube hexagon head screw 2 0052320 0052320 0052320
120 Scheibe washer 2 0050213 0050213 0050213
130 Zylinderschraube head screw 2 0051393 0051393 0051393
140 RIPP-Schraube RIPP-screw 4 0243190 0243190 0243190
150 Verschraubung screwing 1 0054068 0054068 0054068
160 Verschraubung screwing 4 0054069 0054069 0054069
170 Verschraubung screwing 2 0263088 0263088 0263088
180 Verschraubung screwing 1 0212338 0212338 0212338
190 Verschraubung screwing 2 0053951 0053951 0053951
200 Verschraubung screwing 4 0053952 0053952 0053952
210 Verschraubung screwing 8 0053954 0053954 0053954
220 Verschraubung screwing 4 0053957 0053957 0053957
230 Verschraubung screwing 4 0232702 0232702 0232702
240 Rückschlagventil non return valve 1 0233374 0233374 0233374
250 Verteilerstück manifold 2 0255218 0255218 0255218
260 Verschlusskappe lock 2 0255289 0255289 0255289
270 Öl- und Wasserabscheider oil and water separator 1 0057957 0057957 0057957
Filterelement (einzeln) filter element (single) 1 0057959 0057959 0057959
280 Spannring locking ring 5 0323858 0323858 0323858
290 Einbaufilter filter 5 0323857 0323857 0323857
300 Elektromagnetventil solenoid valve 5 0661206 0661206 0661206
310 Verschlussschraube locking screw 2 0054421 0054421 0054421

© by Neuenhauser Kompressorenbau GmbH 2017 Stand August 2017

27
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

7.1b Kondensatablass 3-Zyl. / Condensate Drain 3-cyl.

© by Neuenhauser Kompressorenbau GmbH 2017 Stand August 2017

28
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

Menge/
Pos. Ersatzteil spare part
quantity
45.2.3.02 60.2.3.02 80.2.3.02
10 Aufnahme holding device 1 1001314 1001314 1001314
20 Kondensatrohr 1. Stufe, Zyl. 1
st
condensate pipe 1 stage, cyl. 1 1 1001320 1001320 1001320
30 Kondensatrohr 1. Stufe, Zyl. 2
st
condensate pipe 1 stage, cyl. 2 1 1001319 1001319 1001319
40 Kondensatrohr 1. Stufe, Zyl. 3
st
condensate pipe 1 stage, cyl. 3 1 1001318 1001318 1001318
50 Kondensatrohr 2. Stufe, Zyl. 1
nd
condensate pipe 2 stage, cyl. 1 1 1001316 1001316 1001316
60 Kondensatrohr 2. Stufe, Zyl. 2
nd
condensate pipe 2 stage, cyl. 2 1 1001317 1001317 1001317
70 Kondensatrohr 2. Stufe, Zyl. 3
nd
condensate pipe 2 stage, cyl. 3 1 1001322 1001322 1001322
80 Kondensatrohr 3. Stufe
rd
condensate pipe 3 stage 1 1001321 1001321 1001321
90 Druckluftaustritt 3. Stufe
rd
air outlet 3 stage 1 0253638 0253638 0253638
100 Scheibe washer 2 0072039 0072039 0072039
110 Skt.-Schraube hexagon head screw 2 0052320 0052320 0052320
120 Scheibe washer 2 0050213 0050213 0050213
130 Zylinderschraube head screw 2 0051393 0051393 0051393
140 RIPP-Schraube RIPP-screw 4 0243190 0243190 0243190
150 Verschraubung screwing 1 0054068 0054068 0054068
160 Verschraubung screwing 6 0054069 0054069 0054069
170 Verschraubung screwing 2 0263088 0263088 0263088
180 Verschraubung screwing 1 0212338 0212338 0212338
190 Verschraubung screwing 2 0053951 0053951 0053951
200 Verschraubung screwing 6 0053952 0053952 0053952
210 Verschraubung screwing 12 0053954 0053954 0053954
220 Verschraubung screwing 4 0053957 0053957 0053957
230 Verschraubung screwing 6 0232702 0232702 0232702
240 Rückschlagventil non return valve 1 0233374 0233374 0233374
250 Verteilerstück manifold 2 0255218 0255218 0255218
260 Verschlusskappe lock 2 0255289 0255289 0255289
270 Öl- und Wasserabscheider oil and water separator 1 0057957 0057957 0057957
Filterelement (einzeln) filter element (single) 1 0057959 0057959 0057959
280 Spannring locking ring 7 0323858 0323858 0323858
290 Einbaufilter filter 7 0323857 0323857 0323857
300 Elektromagnetventil solenoid valve 7 0661206 0661206 0661206

© by Neuenhauser Kompressorenbau GmbH 2017 Stand August 2017

29
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

7.2 entk. Kondensatabl. 2-Zyl. / Decoupled Cond. Dr. 2-cyl.

© by Neuenhauser Kompressorenbau GmbH 2018 Stand November 2018

30
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

Menge/
Pos. Ersatzteil spare part
quantity
45.2.3.02 60.2.3.02 80.2.3.02
10 Halteblech plate 2 1003148 1003148 1003148
20 Aufnahme holding device 1 1075586 1075586 1075586
nd
30 Kondensatrohr 2. Stufe, Zyl. 1 condensate pipe 2 stage, cyl. 1 1 1075701 1075701 1075701
st
40 Kondensatrohr 1. Stufe, Zyl. 3 condensate pipe 1 stage, cyl. 3 1 1075685 1075685 1084303
nd
50 Kondensatrohr 2. Stufe, Zyl. 3 condensate pipe 2 stage, cyl. 3 1 1075684 1075684 1084301
rd
60 Kondensatrohr 3. Stufe condensate pipe 3 stage 1 1075659 1075659 1075659
70 Druckluftaustritt air outlet 1 0253638 0253638 0253638
80 Verschraubung screwing 1 0217148 0217148 0217148
90 Verschraubung screwing 1 0212338 0212338 0212338
100 Verschraubung screwing 4 0053952 0053952 0053952
110 Verschraubung screwing 1 0053951 0053951 0053951
120 Verschraubung screwing 9 0053954 0053954 0053954
130 Verschraubung screwing 3 0053957 0053957 0053957
140 Verschraubung screwing 1 0053882 0053882 0053882
150 Verschraubung screwing 3 0053883 0053883 0053883
160 Verschraubung screwing 1 0054143 0054143 0054143
170 Verschraubung screwing 3 0054069 0054069 0054069
180 Verschraubung screwing 5 0232702 0232702 0232702
190 Verschraubung screwing 1 0054421 0054421 0054421
200 Verschraubung screwing 1 0058606 0058606 0058606
210 Überwurfmutter screw cap 2 0096014 0096014 0096014
220 Überwurfmutter screw cap 6 0054100 0054100 0054100
230 Überwurfmutter screw cap 3 0127672 0127672 0127672
240 Schneidring cutting ring 2 0054112 0054112 0054112
250 Schneidring cutting ring 6 0054113 0054113 0054113
260 Schneidring cutting ring 2 0127673 0127673 0127673
270 Rückschlagventil non-return valve 1 0233374 0233374 0233374
280 Rohrschelle pipe clamp 2 0308775 0308775 0308775
290 Rohrschelle pipe clamp 1 0058633 0058633 0058633
300 Deckplatte cover plate 2 0278249 0278249 0278249
310 Sicherheitsventil safety valve 1 0222443 0222443 0222443
320 Öl- und Wasserabscheider oil and water separator 1 0057957 0057957 0057957
Filterelement (einzeln) filter element (single) 1 0057959 0057959 0057959
330 Verteilerstück manifold 2 0255218 0255218 0255218
340 Verschlusskappe lock 1 0255289 0255289 0255289
Elektromagnetventil 24V solenoid valve 24V 5 0661199 0661199 0661199
350
Elektromagnetventil 230V solenoid valve 230V 5 0661206 0661206 0661206
360 Einbaufilter filter 5 0323857 0323857 0323857
370 Spannring locking ring 5 0323858 0323858 0323858
380 Dichtring gasket ring 2 0059125 0059125 0059125
390 Skt.-Schraube hexagon head screw 2 0096908 0096908 0096908
400 Skt.-Schraube hexagon head screw 4 0052348 0052348 0052348
410 RIPP-Schraube RIPP-screw 2 0243197 0243197 0243197
420 RIPP-Schraube RIPP-screw 4 0243190 0243190 0243190
430 Zylinderschraube head screw 2 0051405 0051405 0051405
440 Scheibe washer 8 0072040 0072040 0072040
450 Sechskantmutter hexagon nut 4 0052011 0052011 0052011
460 Schlauchleitung flexible hose 1 0058302 0058302 0058302
470 Schlauchleitung flexible hose 4 0552939 0552939 0552939

Pos.350: 24 V – xx.2.3.02.02.10.6x
230 V – xx.2.3.02.02.10.2x

© by Neuenhauser Kompressorenbau GmbH 2018 Stand November 2018

31
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

8.1 Antrieb 2-Zylinder / Drive 2-cylinder

Position 40 : 14 Nm
Menge/
Pos. Ersatzteil spare part
quantity
45.2.3.02 60.2.3.02 80.2.3.02
10 Antriebsrahmen base frame 1 0252605 0252605 0252606
20 E-Motor e-motor 1 Auf Anfrage / on request
30 Kupplung coupling 1 0253542 0253542 0253736
40 Zylinderschraube head screw 8 0259131 0259131 0259131
50 Skt.-Schraube hexagon head screw 8 0052378 0052378 0052378
60 Skt.-Schraube hexagon head screw 4 0052504 0052504 0052504
70 Sechskantmutter hexagonal nut 8 0052693 0052693 0052693
80 Sechskantmutter hexagonal nut 4 0222964 0222964 0222964
100 Scheibe washer 16 0225248 0225248 0225248
110 Scheibe washer 8 0451805 0451805 0451805

© by Neuenhauser Kompressorenbau GmbH 2016 Stand Januar 2016 Rev: 000

32
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

8.2 Antrieb 3-Zylinder / Drive 3-cylinder

Position 40 : 14 Nm

Menge/
Pos. Ersatzteil spare part
quantity
45.2.3.02 60.2.3.02 80.2.3.02
10 Antriebsrahmen base frame 1 0252605 0252606 0252606
20 E-Motor e-motor 1 Auf Anfrage / on request
30 Kupplung coupling 1 0253542 0253736 0253736
40 Zylinderschraube head screw 8 0259131 0259131 0259131
50 Skt.-Schraube hexagon head screw 8 0052378 0052378 0052378
60 Skt.-Schraube hexagon head screw 4 0052504 0052504 0052504
70 Sechskantmutter hexagonal nut 8 0052693 0052693 0052693
80 Sechskantmutter hexagonal nut 4 0222964 0222964 0222964
100 Scheibe washer 16 0225248 0225248 0225248
110 Scheibe washer 8 0451805 0451805 0451805

© by Neuenhauser Kompressorenbau GmbH 2016 Stand Januar 2016 Rev: 000

33
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

9.1 Verrohrung 2-Zylinder / Piping 2-cylinder

© by Neuenhauser Kompressorenbau GmbH 2016 Stand Januar 2016 Rev: 000

34
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

Menge/
Pos. Ersatzteil spare part
quantity
45.2.3.02 60.2.3.02 80.2.3.02
10 Verschraubung screwing 0053957 (3x) 0053957 (1x) 0053957 (1x)
20 Verschraubung screwing 0058691 (2x) 0088262 (4x) 0088262 (4x)
30 Verschraubung screwing 8 0263088 0263088 0263088
Reduzierverschraubung für reduction screwing for
Position 30 position 30
0059345 (2x) - -
40 Rohrleitung pipe 1 0055012 0274258 0274258
50 Rohrleitung pipe 1 0276889 0274254 0274254
60 Verschraubung screwing 0088262 (6x) 0233158 (2x) 0233158 (2x)
70 Rohrleitung pipe 1 1023295 0265793 0265793
80 Verschraubung screwing 2 0058732 0204505 0204505
90 Verschraubung screwing Position 60 0068937 (2x) 0068937 (2x)
100 Rohrleitung pipe 1 0276371 0265789 0265789
110 Rohrleitung pipe 1 0276360 0265799 0265799
120 Rohrleitung pipe 1 1023268 0265797 0265797
130 Verschraubung screwing 4 0078153 0263239 0263239
140 Rohrleitung pipe 1 0276368 0265796 0265796
150 Rohrleitung pipe 1 1023297 0265790 0265790
160 Rohrleitung pipe 1 1023296 0265798 0265798
170 Rohrleitung pipe 1 0276356 0265800 0265800
180 Verschraubung screwing 1 0058626 0058626 0058626
190 Rohrleitung pipe 1 0276886 0274467 0274467

© by Neuenhauser Kompressorenbau GmbH 2016 Stand Januar 2016 Rev: 000

35
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

9.2 Verrohrung 3-Zylinder / Piping 3-cylinder

© by Neuenhauser Kompressorenbau GmbH 2016 Stand Januar 2016 Rev: 000

36
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

Menge/
Pos. Ersatzteil spare part
quantity
45.2.3.02 60.2.3.02 80.2.3.02
10 Verschraubung screwing 1 0053957 0053957 0053957
Verschraubung screwing 0088262 (3x) 0088262 (6x) 0088262 (6x)
20
Verschraubung screwing 0058691 (3x) - -
30 Verschraubung screwing 1 0058606 0058606 0058606
40 Verschraubung screwing 1 0067045 0067045 0067045
Verschraubung screwing 0263088 (8x) 0263088 (12x) 0263088 (12x)
50
Verschraubung screwing 0058732 (4x) - -
Reduzierverschraubung für reduction screwing for
Position 50 position 50
2 0059345 - -
60 Rohrleitung pipe 1 0256833 0256833 0256833
70 Rohrleitung pipe 1 0256889 0256889 0256889
80 Rohrleitung pipe 1 1065585 0256874 0256874
90 Verschraubung screwing 3 0233158 0233158 0233158
100 Rohrleitung pipe 1 1023295 0265793 0265793
110 Verschraubung screwing 3 0057370 0204505 0204505
120 Verschraubung screwing 3 0233158 0068937 0068937
130 Rohrleitung pipe 1 0276371 0265789 0265789
140 Rohrleitung pipe 1 1065481 0265809 0265809
150 Rohrleitung pipe 1 1065483 0265804 0265804
160 Rohrleitung pipe 1 0276360 0265799 0265799
170 Rohrleitung pipe 1 1023268 0265797 0265797
180 Verschraubung screwing 6 0078153 0263239 0263239
190 Rohrleitung pipe 1 1065519 0265796 0265796
200 Rohrleitung pipe 1 1023297 0265790 0265790
210 Rohrleitung pipe 1 1065537 0265753 0265753
220 Rohrleitung pipe 1 1065549 0265806 0265806
230 Rohrleitung pipe 1 1023296 0265798 0265798
240 Rohrleitung pipe 1 1065561 0265800 0265800

© by Neuenhauser Kompressorenbau GmbH 2016 Stand Januar 2016 Rev: 000

37
 Ersatzteilliste / spare parts
45.2.3.02.02 – 80.2.3.02.02
45.2.3.02.03 – 80.2.3.02.03

10 Schaltschrankrahmen / Switch Box Frame

Menge/
Pos. Ersatzteil spare part
quantity
45.2.3.02 60.2.3.02 80.2.3.02
10 Frontblech front panel 1 0253248 0253248 0253248
20 Schaltschrankrahmen rechts switch box frame right 1 0253260 0253260 0253260
30 Schaltschrankrahmen links switch box frame left 1 0253261 0253261 0253261
40 Schaltschrank switch box 1 0204568 0204568 0204568
50 Linsenschraube lens screw 6 0107297 0107297 0107297
60 Sechskantmutter hexagonal nut 4 0052693 0052693 0052693
70 Scheibe washer 10 0072040 0072040 0072040
80 Scheibe washer 8 0225248 0225248 0225248
90 Skt.-Schraube hexagon head screw 4 0052377 0052377 0052377
100 Sperrzahnscheibe disk 4 0059096 0059096 0059096
110 Sechskantmutter hexagonal nut 6 0116848 0116848 0116848
120 Sechskantmutter hexagonal nut 4 0052011 0052011 0052011

© by Neuenhauser Kompressorenbau GmbH 2016 Stand Januar 2016 Rev: 000

38
 Annex
Version 1.2

Neuenhauser Kompressorenbau GmbH

Hans-Voshaar-Straße 5
49828 Neuenhaus
Tel. No. +49-5941-604-0
Fax +49-5941-604-202
Internet www.neuenhauser.de
 Appendix

Contents

A1 Recommended installation A1-1

A1.1 Compressed-air and condensate manifolds - - - - - - - - - - - - - - - A1-1
A1.2 Venting manifolds - - - - - - - - - - - - - - - - - - - - - - - - - - - A1-1
A1.3 Recommended venting- - - - - - - - - - - - - - - - - - - - - - - - - A1-2
A1.4 Recommended minimum distances- - - - - - - - - - - - - - - - - - - A1-2
A1.5 Cooling air flow - - - - - - - - - - - - - - - - - - - - - - - - - - - - A1-2
A2 Installation of flexible hoses A2-1
A2.1 Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A2-1
A2.2 Installation note - - - - - - - - - - - - - - - - - - - - - - - - - - - - A2-1
A3 Base load change control A3-1
A3.1 Mode of operation - - - - - - - - - - - - - - - - - - - - - - - - - - - A3-1
Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A3-1
Normal operation - - - - - - - - - - - - - - - - - - - - - - - - - - - A3-1
A4 Maintenance inspection sheet A4-1
A5 Operating data acquisition A5-1
2- and 3-step compressors, air-cooled - - - - - - - - - - - - - - - - - A5-1
A6 Warranty/repair form A6-1
A7 List of recommended lubricating oils (revision 007) A7-1
A8 Oil lubrication pump A8-1
A8.1 Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A8-1
Setting the output - - - - - - - - - - - - - - - - - - - - - - - - - - - A8-1
A8.2 Mode of action - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A8-2
A9 Gear-type visual control of oil lubrication quantity A9-1
A9.1 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A9-1
A9.2 Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A9-1
Prefiltering of the medium - - - - - - - - - - - - - - - - - - - - - - - A9-1
A10 Oil level monitoring A10-1
A10.1 PLCA-50 oil level sensor - - - - - - - - - - - - - - - - - - - - - - - A10-1
Positive switching - closed circuit principle
with Bayonet connection DIN 72585 - - - - - - - - - - - - - - - - - - A10-1
A10.2 PLS-40 oil level sensor- - - - - - - - - - - - - - - - - - - - - - - - A10-3

Neuenhauser Kompressorenbau Version 1.2 A-I

 Appendix

Positive-switching - closed circuit principle

with Bayonet connection DIN 72585- - - - - - - - - - - - - - - - - - A10-3
A11 Installation and maintenance instructions for 40 bar filters A11-1
Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A11-2
Clean- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A11-2
A12 Solenoid valve type 5404 DN 12 A12-1
A12.1 Operating Instructions - - - - - - - - - - - - - - - - - - - - - - - - A12-1
A12.2 Intended Use - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A12-1
A12.3 Basic Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - A12-1
A12.4 Technical Data - - - - - - - - - - - - - - - - - - - - - - - - - - - - A12-1
A12.5 Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A12-2
A12.6 Maintenance, Troubleshooting - - - - - - - - - - - - - - - - - - - - A12-2
A12.7 Repair Kits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A12-3
A13 Safety valve, operation instructions A13-1
A13.1 Application - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A13-1
A13.2 Permitted media - - - - - - - - - - - - - - - - - - - - - - - - - - - A13-1
A13.3 Storage- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A13-1
A13.4 Assembly/installation - - - - - - - - - - - - - - - - - - - - - - - - - A13-1
Personnel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A13-1
Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A13-1
Sealant - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A13-1
Installation position - - - - - - - - - - - - - - - - - - - - - - - - - - A13-1
Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A13-2
Permitted tightening torques - - - - - - - - - - - - - - - - - - - - - A13-2
Cleanness - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A13-2
Connection to and installation of other fittings - - - - - - - - - - - - - A13-2
Weather protection - - - - - - - - - - - - - - - - - - - - - - - - - - A13-2
Section drawing - - - - - - - - - - - - - - - - - - - - - - - - - - - A13-2
Dimensions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A13-3
Place of installation - - - - - - - - - - - - - - - - - - - - - - - - - - A13-3
Start-up - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A13-3
A13.5 Operation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A13-3
Use - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A13-3
Operating pressure - - - - - - - - - - - - - - - - - - - - - - - - - - A13-3
Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A13-3
A13.6 Maintenance and inspection - - - - - - - - - - - - - - - - - - - - - A13-4

A-II Version 1.2 Neuenhauser Kompressorenbau

 Appendix

Maintenance interval - - - - - - - - - - - - - - - - - - - - - - - - - - A13-4

Visual inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - A13-4
Opening - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A13-4
Opening the safety valve - - - - - - - - - - - - - - - - - - - - - - - - A13-4
Cleaning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A13-4
A13.7 Repairs/warranty- - - - - - - - - - - - - - - - - - - - - - - - - - - A13-4
Mechanical changes - - - - - - - - - - - - - - - - - - - - - - - - - - A13-5
Material specifications - - - - - - - - - - - - - - - - - - - - - - - - - A13-5
general specifications - - - - - - - - - - - - - - - - - - - - - - - - - A13-5
Marking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A13-5
A14 Pressure switches MDR-F A14-1
A14.1 Safety instructions - - - - - - - - - - - - - - - - - - - - - - - - - - A14-1
A14.2 Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A14-2
A14.3 Setting- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A14-2
A14.4 Electrical connection - - - - - - - - - - - - - - - - - - - - - - - - - A14-2
A14.5 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - A14-2
A14.6 Electrical switching capacity - - - - - - - - - - - - - - - - - - - - - A14-2
A14.7 Type code FF 4-a b cde - - - - - - - - - - - - - - - - - - - - - - - A14-3
A14.8 Note - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A14-3
A15 Pressure switches and thermostats, type KPS A15-1
A15.1 Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A15-1
A15.1.1 Specifications and order details - - - - - - - - - - - - - - - - - - - A15-1
A15.1.2 Pressure switches - - - - - - - - - - - - - - - - - - - - - - - - - - A15-2
A15.1.3 Pressure switches for high pressures and media with strong pulsation- A15-2
A15.1.4 Terminology - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A15-2
A15.1.5 Parameter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A15-3
Contact system - - - - - - - - - - - - - - - - - - - - - - - - - - - - A15-3
Contact load - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A15-3
Ambient temperature- - - - - - - - - - - - - - - - - - - - - - - - - - A15-4
Media temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - A15-4
Shock resistance- - - - - - - - - - - - - - - - - - - - - - - - - - - - A15-4
Type of protection - - - - - - - - - - - - - - - - - - - - - - - - - - - A15-4
Cable entry - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A15-4
Identification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A15-5
Scale accuracy - - - - - - - - - - - - - - - - - - - - - - - - - - - - A15-5
Switching point variation after 400,000 switching operations (mean) - - - A15-5
Material in contact with media - - - - - - - - - - - - - - - - - - - - - A15-5
A15.1.6 Accessories - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A15-6
A15.1.7 Dimension drawings and weights - - - - - - - - - - - - - - - - - - - A15-7
A15.2 Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A15-7

Neuenhauser Kompressorenbau Version 1.2 A-III

 Appendix

KPS 31 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A15-7
Other KPS pressure switches - - - - - - - - - - - - - - - - - - - - - A15-8
Example 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A15-8
Example2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A15-8
Example 3 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A15-8
A16 Pressure switches and thermostats, type CAS A16-1
A16.1 Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A16-1
A16.1.1 Specifications and order details - - - - - - - - - - - - - - - - - - - - A16-1
A16.1.2 Dimension drawings and weights - - - - - - - - - - - - - - - - - - - A16-4
A16.1.3 Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A16-5
Setting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A16-6
Scale correction - - - - - - - - - - - - - - - - - - - - - - - - - - - A16-6
Electrical connection - - - - - - - - - - - - - - - - - - - - - - - - - A16-7
A16.1.4 Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A16-7
Difference terminology - - - - - - - - - - - - - - - - - - - - - - - - A16-7
Thermostat function - - - - - - - - - - - - - - - - - - - - - - - - - A16-8
A16.1.5 Examples- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A16-8
Example 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A16-8
Example2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A16-8
A17 Three-phase motor Operation instructions 12AA / 12BA A17-1
A17.1 Sizes and types - - - - - - - - - - - - - - - - - - - - - - - - - - - A17-1
Sizes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A17-1
Types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A17-1
A17.2 Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A17-1
A17.2.1 Application - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A17-1
A17.2.2 Installation and mode of operation - - - - - - - - - - - - - - - - - - A17-2
A17.2.3 Operation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A17-2
A17.2.4 Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A17-2
A17.2.5 Balancing the rotor and related drive components - - - - - - - - - - - A17-2
A17.2.6 Electrical connection - - - - - - - - - - - - - - - - - - - - - - - - - A17-2
A17.2.7 Insulation test - - - - - - - - - - - - - - - - - - - - - - - - - - - - A17-2
A17.3 Maintenance/repairs - - - - - - - - - - - - - - - - - - - - - - - - - A17-4
Motors of series 160 ... 355 (with relubrication mechanism) - - - - - - A17-4
Motors of services 56 ... 132 (without relubrication mechanism) - - - - A17-4
A17.4 Annex - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A17-5
A17.4.1 Tightening torques for electrical bolt/screw connections at the
terminal board – terminal board connections (except terminal strips) - - A17-5
A17.4.2 Lubricant and relubrication intervals - - - - - - - - - - - - - - - - - - A17-5

A-IV Version 1.2 Neuenhauser Kompressorenbau

 Appendix

Lubricant - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A17-5
Relubrication intervals: 2-pole motors, series 12AA/BA - - - - - - - - - A17-5
Relubrication intervals: 4-pole motors, series 12AA/BA - - - - - - - - - A17-6
Relubrication intervals: 6-pole motors, series 12AA/BA - - - - - - - - - A17-6
A18 Technical data sheet for IP 55, ISO F electric motor A18-1
A18.1 Electrical data for 380 ... 420 V and 50 Hz - - - - - - - - - - - - - - A18-1
A18.2 Electrical data for 440 ... 480 V and 60 Hz - - - - - - - - - - - - - - A18-2

A19 Ring Laminated Valve 1st Stage A19-1

A19.1 Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A19-1
A20 Technical data sheet for temperature switch TSM - - - - - - - - - - - A20-1
A21 Short Instructions Compressor Control LOGO 0BA8 - - - - - - - - - A21-1
 Appendix

A-VI Version 1.2 Neuenhauser Kompressorenbau

 Appendix

List of figures

Figure A1-1 Compressed-air plan, condensate plan A1-1

Figure A1-2 Venting A1-2
Figure A1-3 Minimum distances A1-2
Figure A2-1 Dimensions - flexible hoses A2-1
Figure A7-1 List of recommended lubricating oils A7-1
Figure A8-1 Setting the output A8-1
Figure A8-2 Mode of action of the lubricating oil pump A8-2
Figure A9-1 Gear-type visual control A9-2
Figure A10-1 Block diagram A10-1
Figure A10-2 Functional diagram of minimum sensors A10-2
Figure A10-3 Dimension drawing PLCA-50 A10-2
Figure A10-4 Dimension drawing PLS40 A10-3
Figure A13-1 Safety valve section drawing A13-2
Figure A14-1 Pressure switches A14-1
Figure A15-1 Pressure switches and thermostats A15-1
Figure A15-2 Order designation A15-1
Figure A15-3 Pressure profiles A15-3
Figure A15-4 d.c. load A15-4
Figure A15-5 Dimension drawing A15-7
Figure A15-6 Function KPS 31 A15-7
Figure A15-7 Function of other KPS pressure switches A15-8
Figure A15-8 Nomogram A15-9
Figure A16-1 CAS with remote sensor, armored capillary tube and
sensor sleeve (accessory) A16-1
Figure A16-2 Dimension drawing of CAS with remote sensor and
2 m armored capillary tube A16-4
Figure A16-3 Permitted media pressure on sensor sleeves as a
function of temperature A16-5
Figure A16-4 Thermostat settings A16-6
Figure A16-5 Electrical connection A16-7
Figure A16-6 Thermostat function A16-8
Figure A17-1 Types of 3-phase current motors, versions A17-1

Neuenhauser Kompressorenbau Version 1.2 A-VII

 Appendix

A-VIII Version 1.2 Neuenhauser Kompressorenbau

 Appendix

List of tables

Table A2-1 Dimensions - flexible hoses 2-1

Table A2-2 Installation note 2-2
Table A4-1 Maintenance inspection sheet 4-1
Table A5-1 Operating data acquisition 5-1
Table A6-1 Warranty/repair form 6-1
Table A10-1 Specifications PLS-40 oil level sensor (1) 10-3
Table A10-2 Specifications PLS-40 oil level sensor (2) 10-4
Table A11-1 40 bar filters 11-1
Table A11-2 Filter 40 bar, marking 11-1
Table A13-1 Dimensions 13-3
Table A13-2 Material specifications 13-5
Table A14-1 Specifications FF4 - 32, FF 4 - 60 14-2
Table A14-2 Electrical switching capacity FF4 - 32, FF 4 - 60 14-3
Table A14-3 Type code 14-3
Table A15-1 Pressure switches 15-2
Table A15-2 Pressure switches for high pressures and media with strong pulsation 15-2
Table A15-3 Scale accuracy 15-5
Table A15-4 Switching point variation after 400,000 switching operations (mean) 15-5
Table A15-5 Material in contact with media 15-5
Table A15-6 Accessories, pressure switch type KPS 15-6
Table A16-1 Order numbers 16-2
Table A16-2 Accessories: Sensor sleeve for thermostats 16-3
Table A16-3 More accessory items 16-4
Table A16-4 Scale correction: Correction factors 16-6
Table A16-5 Scale correction 16-7
Table A17-1 Tightening torques for electrical bolt/screw connections 17-5
Table A17-2 Lubricant 17-5
Table A17-3 Relubrication intervals: 2-pole motors, series 12AA/BA 17-5
Table A17-4 Relubrication intervals: 4-pole motors, series 12AA/BA 17-6
Table A17-5 Relubrication intervals: 6-pole motors, series 12AA/BA 17-6
Table A18-1 Electrical data for 400 V and 50 Hz, model sizes 100 L04 to 160 L06 18-1
Table A18-2 Electrical data for 400 V and 50 Hz, model size 180 L04 zo 225 M06 18-1
Table A18-3 Electrical data for 440/480 V and 60 Hz, model sizes100 L04 to160 L06 18-2
Table A18-4 Electrical data for 440/480 V and 60 Hz, model sizes180 L04 to 225 M06 18-2

Neuenhauser Kompressorenbau Version 1.2 A-IX

 Appendix
A1 Recommended installation
A1.1 Compressed-air and condensate manifolds

A1 Recommended installation

A1.1 Compressed-air and condensate manifolds

a) Manifold at a gradient
The manifold should be installed at a 1.5 to 2 % gradient in the direction of
flow.
b) Connecting line from above
The connecting pipeline must be connected to the manifold from above.
c) Water separator in risers of greater length
If a long riser connects to the manifold, a water separator with automatic
drainage should be installed downstream the compressor to collect the con-
densate return flow.

A1.2 Venting manifolds

If venting lines are gathered into manifolds, items A1.1 a) and b) also apply.
In addition, venting manifolds should be provided with an expansion vessel
with venting silencer.
Compressed air Condensate

1 Piston compressor 1 Piston compressor

2 Water separator 2 Connecting line
3 Condensate drain 3 Manifold
4 Connecting line 4 Expansion vessel
5 Manifold 5 Venting silencer
6 Oil-water separator
Figure A1-1 Compressed-air plan, condensate plan

A1-1 Version 1.2 Neuenhauser Kompressorenbau

 Appendix
A1 Recommended installation
A1.3 Recommended venting

A1.3 Recommended venting

2
3

1 Fan, outlet
2 Compressor
3 Cooling air, inlet
Figure A1-2 Venting

A1.4 Recommended minimum distances

700-900 mm
1

700-900 mm 700-900 mm
2

3
700-900 mm

1 Fan, outlet
2 Compressor
3 Cooling air, inlet
Figure A1-3 Minimum distances

A1.5 Cooling air flow

The required cooling air flow as a function of the room temperature can be
calculated as follows:
Qv = 1.06 N / dT
Qv = Required cooling air volume
N = Nominal output of the drive motor
DT = Required temperature rise in the compressor space

Neuenhauser Kompressorenbau Version 1.2 A1-2

 Appendix
A2 Installation of flexible hoses
A2.1 Dimensions

A2 Installation of flexible hoses

A2.1 Dimensions

Figure A2-1 Dimensions - flexible hoses

AD [mm] L1 [mm] L2 [mm] L3 [mm] Minimum Max. operat-

bending ing pressure
radius Rmin pmax [bar]
[mm]
Ø 10 25 460 510 150 88
Ø 18 25 460 510 150 88
Ø 28 25 460 510 150 88

Table A2-1 Dimensions - flexible hoses

A2.2 Installation note

All hoses should be installed in natural position forming a "U", as far as possi-
ble, observing the permitted bending radii. Lengthwise rotation should be
avoided at any rate. Even the smallest amount of torsion will cause early fail-
ure of the hose. When tightening the connections, hold the hose in position
until the connection is tightened fully. Avoid any kinking of hose. A kink guard
installed behind the connection can relieve the hose .

A2-1 Version 1.2 Neuenhauser Kompressorenbau

 Appendix
A2 Installation of flexible hoses
A2.2 Installation note

correct wrong

Table A2-2 Installation note

Neuenhauser Kompressorenbau Version 1.2 A2-2

 Appendix
A3 Base load change control
A3.1 Mode of operation

A3 Base load change control

A3.1 Mode of operation

Note: The operation of the base load change control is described with refer-
ence to the example of three compressors. It is essential the same for sys-
tems with two or more compressors. The pressure settings of the pressure
switches specified below are merely by way of example and only illustrate the
mode of operation. The real settings depend on the operating pressure and
the required air of the compressed-air supply system.

Requirements
 All 3 compressors must be set to Automatic mode and must be running.
 All compressors will be running for initial start-up (pressureless com-
pressed-air system).

Normal operation
Pressure switch One, with a pressure setting of 24/30 bar, switches on the
first compressor at a cylinder pressure of 24 bar. The position of the prese-
lector switch decides whether this is compressor 1, 2 or 3.
If the first compressor supplies more air than needed, it cuts out at 30 bar
pressure.
If more air is required, the pressure switch starts at a pressure setting of
23/29 bar. The second compressor starts running at 23 bar mains pressure.
If both compressors generate more air than required, both compressors
will be switched off simultaneously by pressure switch One at a mains pres-
sure of 30 bar.
If this is not the case and more air is needed, pressure switch Three
switches on the third compressor at 22 bar mains pressure at a pressure set-
ting of 22/29 bar. The position of the preselector switch determines which
compressor starts running when.
If the mains pressure rises to 30 bar, all three compressors are switched
off simultaneously by pressure switch One.
Of course, all three compressors can be switched on or off in manual
mode at any time.

A3-1 Version 1.2 Neuenhauser Kompressorenbau

 A4 Maintenance inspection sheet

Work completed: 1 = cleaned, 2 = replaced, 3 = checked

Date Oil Air filter Cylinder Conrod Oil and Safety Valves Non- Piston Crank- Elec. Signature
change lubrica- bearing water valves return rings/oil shaft solenoid
tion separa- valve scraper bearing valves
tor rings

Neuenhauser Kompressorenbau
Version 1.2
A4 Maintenance inspection sheet

Table A4-1 Maintenance inspection sheet

Check work done or enter measuring values, add date and signature for confirmation.

A4-1
 A5 Operating data acquisition
2- and 3-step compressors, air-cooled

Date Time Oil level Safety Step 1 Step 1 Step 2 Step 3 Detect- Room Signature
valve valve wet- pressure pressure pressure able tempera-
checked ted with gauge gauge gauge defects ir ture
for leaks oil damage

Neuenhauser Kompressorenbau
Version 1.2
A5 Operating data acquisition

Table A5-1 Operating data acquisition

Check work done or enter measuring values, add date and signature for confirmation.

A5-1
 Appendix
A6 Warranty/repair form

A6 Warranty/repair form

Customer's name & address: Ship-to address:

Contact person/tel. No.:

Commission No.:
Type:
Machine No.:
Start-up date: Damage date: Operating hours (total):

Brief characterization of the defect/damage:

Parts to be replaced:
Article No.: Quantity: Designation:

Technician required on site: YES [ ]

NO [ ]
Completed by: Date:

NK-internal processing notes:

Defective parts received by NK on:
Warranty accepted [ ] Reason:
rejected [ ]
Order: Expected time to delivery:
Signature: Date:

Table A6-1 Warranty/repair form

Neuenhauser Kompressorenbau Version 1.2 A6-1

 Benennung/Designation:

Rev: 007
Schmierölempfehlung / Lubrication chart
Page: 1/1

Empfohlener Lieferant/ Bezeichnung / Designation Bemerkungen

Recommended Supplier DIN 51506 / VDL 100/150 Remarks

Aral Motanol HE 150 Mineralöl / mineral oil

BP Energol RC 150 Mineralöl / mineral oil

Castrol Aircol PD 150 Mineralöl / mineral oil

Castrol Aircol SN 150 Synthetiköl / synthetic oil

Agip DICREA 150 Mineralöl / mineral oil

RENOLIN 505 VDL 150 Mineralöl / mineral oil

RENOLIN UNISYN OL 150 Synthetiköl / synthetic oil

Mobil RARUS 429 Mineralöl / mineral oil

Mobil RARUS 829 Synthetiköl / synthetic oil

Shell Corena S2 P 150 Mineralöl / mineral oil

TOTAL DACNIS 150 Mineralöl / mineral oil

Gulf Sea Compressor Mineralöl / mineral oil

Oil 100
Compressor Oil 150
Gulf Sea DE Synthetiköl / synthetic oil
Compressor Oil 100

Datum/Date: 04.05.2017
Technische Änderungen vorbehalten / Subject to be changed

Neuenhauser Kompressorenbau Version 1.2 A7-1

 Appendix
A8 Oil lubrication pump
A8.1 Maintenance

A8 Oil lubrication pump

A8.1 Maintenance
The lubrication pump does not need any particular maintenance. Thoroughly
pump petrol or kerosin through the pump once every year.

CAUTION Cleaning is also necessary if the pump is started up a long time after delivery
or if it has not been used for several months. The oil residue in the control
ducts can harden and disturb the function of the pump.
Non-compliance with these instructions can cause failure of the lubricant
pump.

1 2 1 Less oil
2 More oil

Figure A8-1 Setting the output

Setting the output

The stroke is adjusted by means of the control screw in the pump piston.
Turning the screw clockwise increases the output, turning counter-clockwise
reduces the output. The pump is set in the factory and the setting should
not be changed during the warranty period.
Set the pump to ensure the supply of sufficient amount of lubricant to the
last compressor stage.

Neuenhauser Kompressorenbau Version 1.2 A8-1

 Appendix
A8 Oil lubrication pump
A8.2 Mode of action

A8.2 Mode of action

The pump is driven by worm gear that moves the geared stroke plate with
control shaft. An output piston is provided for every outlet port in the pump
body (e.g., with 4 outlet ports for 2 outlets each), which is moved by the stroke
plate that moves between the control screw and the pressure edge of the pis-
ton. During suction stroke, when the pressure port is completely closed, the
pump piston takes in oil from an oil tank or the oil sump of the machine
through a suction port. Control is obtained by the rotation of the control shaft
across a groove and a hole. At the end of the suction stroke, the control shaft
closes the suction port and opens the pressure port so that the pressurised
oil is supplied to the lubricating point during the next following stroke of the
pump piston.
1 Pump housing
2 Pump cover
3 Control shaft
4 Stroke plate
5 Poston
6 Control screw
7 Locknut
8 Spring

Figure A8-2 Mode of action of the lubricating oil pump

A8-2 Version 1.2 Neuenhauser Kompressorenbau

 Appendix
A9 Gear-type visual control of oil lubrication quantity
A9.1 Specifications

A9 Gear-type visual control of oil lubrication quantity

A9.1 Specifications
Use
Oil and liquid media of 20 cSt viscosity and more
Permitted operating pressure
max. 100 bar
Permitted operating temperature
max. 100 °C
Theoretical flow
115 mm³ / revolution
Flow resistance
Depends on the viscosity of the medium and the flow per
unit of time

A9.2 Description
Gear-type visual controls with soldered connections have a coarse filter on
one side, types with cutting-ring coupler have no integrated filter.

Prefiltering of the medium

The medium must be pre-filtered in gear-type visual control applications with-
out filter (i.e., with cutting ring coupler).
Prefiltration of the medium is recommended with gear-type visual controls
with filter; it is required for contaminated media.

Neuenhauser Kompressorenbau Version 1.2 A9-1

 Appendix
A9 Gear-type visual control of oil lubrication quantity
A9.2 Description

Figure A9-1 Gear-type visual control

A9-2 Version 1.2 Neuenhauser Kompressorenbau

 Appendix
A10 Oil level monitoring
A10.1 PLCA-50 oil level sensor

A10 Oil level monitoring

A10.1 PLCA-50 oil level sensor

Positive switching - closed circuit principle

with Bayonet connection DIN 72585

German Document language

Spannungsregler Voltage controller
Sensorelektrode Sensor electrode
HF-Oszillator HF oscillator
Zeitgenerator Time generator
Schaltverzögerung Switching delay
Ausgang: kurzschlussfest Output: short-circuit-proof
EMV-Filter EMC filter
Überspannungsschutz Overvoltage protection
Verpolungsschutz Reverse pole protection
Signal Signal
Justierung Adjustment
MINIMAX Status MINIMAX status
Kontrollzeit Control time
Figure A10-1 Block diagram

Neuenhauser Kompressorenbau Version 1.2 A10-1

 Appendix
A10 Oil level monitoring
A10.1 PLCA-50 oil level sensor

E Water/oil level
E
ET Depth of immersion
Ub Operating voltage
Ua Output voltage

Figure A10-2 Functional diagram of minimum sensors

1 Positive (+)
2 Negative (-)
3 Signal (S)

A Thread undercut DIN 3852-shape-A

B To be tightened to max. 25 Nm
C Relay connection

A
B

1
3
2

C
Figure A10-3 Dimension drawing PLCA-50

A10-2 Version 1.2 Neuenhauser Kompressorenbau

 Appendix
A10 Oil level monitoring
A10.2 PLS-40 oil level sensor

A10.2 PLS-40 oil level sensor

Positive-switching - closed circuit principle

with Bayonet connection DIN 72585
1 Positive (+)
A 2 Negative (-)
3 Signal (S)

A Plug connection
DIN 72585-A1-3.1-Sn/K1
B To be tightened to max. 25 Nm
C Switching point with vertical installation
position 20 mm ± 6, with horizontal in-
stallation position 2.5 mm ±1
D Relay connection

1
3
2 C

D
Figure A10-4 Dimension drawing PLS40

Specifications
TU = 25 °C
Operating voltage DC 12/24 V (-25% / +50%)
Closed-circuit current con- typically 8 mA
sumption
Output current 1 A across the entire operating voltage range short-circuit-
proof and overload-proof across the entire temperature
range. For inductive loads, the flywheel diode, e.g., 1N4007,
is required as protective circuit at the load.
Switching point with verti- 20 mm ± 6 mm
cal installation
Switching point with hori- 2.5 mm ± 1 mm
zontal installation
Switching hysteresis typically < 3 mm

Table A10-1 Specifications PLS-40 oil level sensor (1)

Neuenhauser Kompressorenbau Version 1.2 A10-3

 Appendix
A10 Oil level monitoring
A10.2 PLS-40 oil level sensor

Specifications
Temperature of medium -30 °C to +125 °C
Ambient temperature -30 °C to +125 °C
Storage temperature -50 °C to +125 °C
Signaling delay 20 seconds
Function test 0 seconds
Reverse pole protection Integrated between positive and negative poles
Function Minimum closed circuit current (rc)

Table A10-1 Specifications PLS-40 oil level sensor (1)

CAUTION Positive-switching sensors can be destroyed if a positive charge is connected

to the signal terminal and a negative charge is connected to the positive ter-
minal.

Specifications
Voltage drop <200 mV at 1A
Vibration IEC68-2 5- 57 Hz ± 1.5 mm
57 - 2000 Hz 20 g

Cab Frame
5 Hz 0.007 g2Hz 20 Hz 0.001 g2Hz
20 Hz 0.07 g2Hz 119 Hz 0.08 g2Hz
100 Hz 0.007 g2Hz 223 Hz 0.011 g2Hz
300 Hz 0.007 g2Hz 391 Hz 0.091 g2Hz
2000 Hz 0.0035 g2Hz 797 Hz 0.10 g2Hz
1212 Hz 0.001 g2Hz
1780 Hz 0.0005 g2Hz
1980 Hz 0.0004 g2Hz
Pressure resistance 25 bar at 25 °C/h
Type of protection IP 69K acc. to DIN40050
Installation position any

Table A10-2 Specifications PLS-40 oil level sensor (2)

A10-4 Version 1.2 Neuenhauser Kompressorenbau

 Appendix
A10 Oil level monitoring
A10.2 PLS-40 oil level sensor

Specifications
Housing CuZn38Pb2En12164; CW608N capacitive to ground
Sensor pin insulation Tefzel * ETFE
Weight approx. 120 g
Thread M18x1.5
Marking Manufacturer; manufacturer No.; function; date: year/week;
registration

EMC

Electrostatic discharge EN 61000-4-2 8 kV air discharge

6 kV contact discharge
Electromagnetic fields EN 61000-4-3 30 V/m; 27 MHz up to 1000 MHz
80 % AM (1 kHz)
Line-bound transient inter- EN 61000-4-4
ference 2.5 V Supply line 1.5 kV signal line
Line-bound surge EN 61000-4-5 0.5 kV supply line
1 kV signal line
Line-bound high-frequ. EN 61000-4-6; 10 kHz up to 80 MHz
interference 80 % AM (1 kHz)
CE label acc. to EC directive 89/336/EEC (EMC)

Table A10-2 Specifications PLS-40 oil level sensor (2)

Neuenhauser Kompressorenbau Version 1.2 A10-5

 Appendix
A11 Installation and maintenance instructions for 40 bar filters

A11 Installation and maintenance instructions for 40 bar

filters

Standard filter Fine filter

445.005 G3/8 445.105 G3/8
445.006 G1/2 445.106 G1/2
445.008 G3/4 445.108 G3/4
445.009 G1 445.109 G1
445.015 G3/8 445.115 G3/8
445.016 G1/2 445.116 G1/2
445.017 G1/2
445.411 G1 1/2
445.422 G2

Table A11-1 40 bar filters

Compressed air in the pipeline which is contaminated with condensate, dirt

and deposited material can impair the function of pneumatically powered or
controlled tools, valves, cylinders, etc.
Compressed air should be filtered for all applications requiring clean com-
pressed air. Depending on the required purity of the compressed air, the filter
can be equipped with standard, sintered or fine filter elements.
Labelling Meaning
Acc. to AD bulletin A 4, housings and fittings
Ewo Manufacturer's logo
AIMgSi1 Material
PN40 Rated pressure
DN40 Connection type

Table A11-2 Filter 40 bar, marking

A11-1 Version 1.2 Neuenhauser Kompressorenbau

 Appendix
A11 Installation and maintenance instructions for 40 bar filters

Maintenance
 Drain water regularly at the condensate drain
 Clean soiled sintered filters.
 Replace soiled fine filter.

Clean
1. Relieve pressure.
2. Remove filter hood.
3. Remove locking screw at sintered filter.
4. Remove filter element.
5. Clean the filter element in solvent and dry filter element.
6. Install the filter element.
7. Fit the filter hood.

Neuenhauser Kompressorenbau Version 1.2 A11-2

 Anhang
A12 Solenoid Valve Type 5404 DN 12

A12 Solenoid Valve Type 5404 DN 12

© by Neuenhauser Kompressorenbau GmbH 2017 Version 1.3 A12-1

 Anhang
A12 Solenoid Valve Type 5404 DN 12

© by Neuenhauser Kompressorenbau GmbH 2017 Version 1.3 A12-2

 Anhang
A12 Solenoid Valve Type 5404 DN 12

© by Neuenhauser Kompressorenbau GmbH 2017 Version 1.3 A12-3

 Anhang
A12 Solenoid Valve Type 5404 DN 12

© by Neuenhauser Kompressorenbau GmbH 2017 Version 1.3 A12-4

 Anhang
A12 Solenoid Valve Type 5404 DN 12

© by Neuenhauser Kompressorenbau GmbH 2017 Version 1.3 A12-5

 Anhang
A12 Solenoid Valve Type 5404 DN 12

Verschleißteillisten für Kondensatventil Typ 5404 - DN12 / G1/2

Repair kits condensate valve type 5404 - DN12 / G1/2

Anzugsmoment 5Nm
coil set 12V DC tightening torque 5Nm
art.-no.: 0688471

coil set 24V DC

art.-no.: 0688466

coil set 120V AC

art.-no.: 0688475

coil set 230V AC

art.-no.: 0682761

packing set
art.-no.: 0688432

Piston set
art.-no.: 0688365

© by Neuenhauser Kompressorenbau GmbH 2017 Version 1.3 A12-6

 Appendix
A13 Safety valve, operation instructions
A13.1 Application

A13 Safety valve, operation instructions

LORCH safety valve
Type 2108
Zulassung / Homologation: 97/23/CE DEKRA
Anforderungen / Requirement: DGR 97/23/CE
DIN EN ISO 4126-1
AD 2000-A2
VdTÜV-Merkblatt Sicherheitsventil 100

A13.1 Application
The safety valve must only be used with excess pressure in vessels and pipe-
lines. It is not permitted for use as overflow device, control valve or release
valve in continuous service. Permanent release will damage the valve.

A13.2 Permitted media

Compressed air and other neutral and non-flammable vapors and gases
which can escape freely. Permitted temperature range: -50 °C to +250 °C.
Media containing particles, liquid, sticky media (flammable, toxic, etc.) can be
dangerous to the user or the environment and can destroy the safety valve.

A13.3 Storage
Store safety valves in a clean and dry environment. !!! A dusty, aggressive or
humid environment can damage the valve.

A13.4 Assembly/installation

Personnel

WARNING The valve should be installed by trained technical personnel.

Installation
Prepare a suitable counter-thread and useful thread length.

Sealant
Choose sealant suitable for the temperatures and stress situations expected.

Installation position
Install the safety valve vertically upright. In this position, foreign material can
drop back into the vessel or the main pipeline.

Neuenhauser Kompressorenbau Version 1.2 A13-1

 Appendix
A13 Safety valve, operation instructions
A13.4 Assembly/installation

Installation
Tighten the thread with a suitable open-end wrench or adjustable wrench with
smooth jaws. Apply the tool to the hexagon at the valve base. Unsuitable
tools can damage the valve base and render it useless.

Permitted tightening torques

Make sure not to exceed the permitted tightening torques. For table see
reverse.

Cleanness
Make sure that all sealant debris is removed from the valve.

Connection to and installation of other fittings

Installation of a dirt trap or shutoff valve in the supply feeding pipeline is not
permitted by the rules. Make sure of sufficiently large pipeline cross section.

Weather protection
If the safety valve is exposed to weather, protect it from snow, ice and solid
particles. A roof which does not prevent outflow is a suitable protection.

Section drawing

1
Figure A13-1 Safety valve section drawing

A13-2 Version 1.2 Neuenhauser Kompressorenbau

 Appendix
A13 Safety valve, operation instructions
A13.5 Operation

Dimensions
G Pressure range (bar) H (mm) L (mm) Tightening SW (mm) D1 (mm)
torque (Nm)
2108 2108 2108 2108 2108 2108
G3/8 0,3 – 9,3 72 10 40 22 21,8
9,4 – 21,0 81 10 40 22 21,8

21,1 – 47,0 88 10 40 24 23,8

G½ 0,3 – 9,3 73 12 65 27 26,8

9,4 – 21,0 82 12 65 27 26,8

21,1 – 47,0 90 12 65 27 26,8

Table A13-1 Dimensions

Place of installation
The place of installation should be chosen to ensure that when the valve
operates and large volumes of medium escape nobody can be injured or
damage to equipment near the place of escape can occur. The safety valve
should be accessible for maintenance and should not project into space in
which persons or vehicles move.

Start-up
Slightly vent the safety valve for first start-up. This ensures that particles
which can be present are blown off . See item "Opening the safety valve".

A13.5 Operation

Use
Use the safety valve only for the intended purpose.

Operating pressure
The operating pressure should be at least 5 % lower than the set pressure.

Maintenance
Observe all prescribed maintenance intervals.

Neuenhauser Kompressorenbau Version 1.2 A13-3

 Appendix
A13 Safety valve, operation instructions
A13.6 Maintenance and inspection

A13.6 Maintenance and inspection

WARNING Risk of burn injury!

The safety valve and the medium can become very hot during operation.
Wear personal protection equipment (gloves, protective goggles).

Maintenance interval
The safety valves need maintenance in regular intervals to ensure the proper
function. We recommend to maintain the valves at least once a year acc. to the
following procedure.
Visual inspection
Visually inspect the safety valve for contamination and mechanical damage .

Opening
To remove stubborn particles, open the safety valve a little.
Note: Wear protective goggles, ear protection and gloves when opening the
safety valve. The escaping medium can eject solid particles, make noise and
have high temperature.

Opening the safety valve

The system should be pressurized, at least 80-90 % of the valve position.
Turn the opening screw a few turns anti-clockwise until the safety valve until
medium escapes, then turn the screw fully clockwise to close the valve.

Cleaning
Clean with a dry cloth. Cover the safety valve when the system is cleaned.
Aggressive media can impair the valve function.

A13.7 Repairs / warranty

WARNING Do not remove the safety valve. The manufacturer's warranty and registration
are void if the seal at the valve is broken.

A13-4 Version 1.2 Neuenhauser Kompressorenbau

 Appendix
A13 Safety valve, operation instructions
A13.7 Repairs/warranty

Mechanical changes

WARNING Opening the valve or changing the pressure setting must only be made in the
manufacturer's factory or by an authorized institution.
These installation and operation instructions should be submitted to the TÜV
expert at the time of acceptance.

Material specifications

Eintrittskörper / Body in CW614N-R430

Austrittskörper / Body out CW614N-R430

Innenteile / Innert part CW614N-R430

Druckfeder / Spring 1.4310

Table A13-2 Material specifications

general specifications
Inlet diameter: 8.00 mm
Outflow index: 2108: 0.73
Temperature range: -50 °C to +250 °C

Marking
XX/XX-XXXXX Sl. product number -Month/year-sl. number
TÜV-SV.xx-874.8.D/G.aw.p
part designation TÜV
TÜV-SV.xx-917.10.D/G.aw.p
xx bar Pressure setting
Lorch Supplier

Neuenhauser Kompressorenbau Version 1.2 A13-5

 Appendix
A14 Pressure switches MDR-F 32 and 60
A14.1 Safety instructions

A14 Pressure switches MDR - F

For use in industrial and commercial applications such as air compressors,
water pumps, pressure boosters, fire extinguishing systems, oil pumping sys-
tems, high-pressure cleaning systems.

CAUTION Observe all rules and regulations for the start-up of electrical equipment

A B C

A Pressure switch type MDR-F Legend for C

B Terminals - overview 1 Setting screw, top pressure switching
C Mechanical configuration 2 Indicator, top pressure switching point (red)
3 Setting screw, bottom pressure switching
4 Indicator, bottom pressure switching point (green)

Figure A14-1 Pressure switches

A14.1 Safety instructions

 Read the installation instructions attentively. Ignorance of these instruc-
tions can cause failure or destruction of the MDR - F, equipment
connected to the MDR - F or cause injury.
 The equipment must be installed by trained technical personnel.
 Do not exceed the specified limits for voltage, amperage, pressure or tem-
perature.
 Avoid strong pulsation and liquid surges.
 Avoid very strong vibration.
 Install cables and strain relief.

Neuenhauser Kompressorenbau Version 1.2 A14-1

 Appendix
A14 Pressure switches MDR-F 32 and 60
A14.2 Installation

A14.2 Installation
 Install the pressure switch on a level surface; the two tapped holes at the
console can be used.
 Do not seal the plastic pressure connection in the thread, use suitable
sealing ring.
Installation position: The pressure switch can be installed in any position.

A14.3 Setting
See Figure A14-1 C
 Set the top pressure switching point at setting screw 1. Indication by
pointer 2.
 Set the top pressure switching point at setting screw 3; the top switching
pressure remains unchanged. Indication by pointer 4.
 The setting scale is not calibrated. Use a pressure gauge for more exact
settings.

A14.4 Electrical connection

 Standard versions: see Figure A14-1 B

A14.5 Specifications
Type of protection acc. to DIN 40 050 / IEC 529 with rubber grom- IP 54
met
Type of protection acc. to DIN 40 050 / with screw connection type IP 65
M20
Operating temperature TS, plastic pressure connection -20 to +50 °C
Operating temperature TS, all other pressure connections -20 to +70 °C
Vibration resistance at 10 to 1000 Hz 4g

A14.6 Electrical switching capacity

Ohmic load (AC1; 230 V AC) 10 A
Inductive load (AC15; 230 V AC) 4A
Inductive load (DC13; 230 V DC) 0.1 A

A14-2 Version 1.2 Neuenhauser Kompressorenbau

 Appendix
A14 Pressure switches MDR-F 32 and 60
A14.7 Electrical switching capacity

A14.7 Type code FF 4-a b cde

Pressure range (bar) PS (bar) PT (bar)

32 = 2 ... 32 52 64
60 = 8 ... 60 100 120

Expansion body = D: Perbunane

Reset = A: Automatic
Pressure connection = H:G 3/8” female, silumin, DIN ISO 228/I

A14.8 Note: Installation in vessels recommended; otherwise functional failure pos- sible due
to pulsation imported from the compressor.

Neuenhauser Kompressorenbau Version 1.2 A14-3

 Appendix
A15 Pressure switches and thermostats, type KPS
A15.1 Description

A15 Pressure switches and thermostats, type KPS

A15.1 Description

Figure A15-1 Pressure switches and thermostats

KPS pressure switches are pressure-controlled toggle switches in which the

position of the contacts depends on the pressure at the inlet socket and the
setting of the scale value.
The compact and encapsulated design makes the devices robust, shock
and impact resistant and complying with high requirements for installation
indoors or outdoors.
The pressure switches are used for control, warning and monitoring tasks,
e.g., in diesel generating sets, power plants or watercraft.
A15.1.1 Specifications and order details
Please specify type and order number

KPS 31, 33 KPS 35, 37, 39 KPS 43, 45, 47

Figure A15-2 Order designation

Neuenhauser Kompressorenbau Version 1.2 A15-1

 Appendix
A15 Pressure switches and thermostats, type KPS
A15.1 Description

A15.1.2 Pressure switches

Control Settable / Perm. Max. test Pressure Order No. Type

range Pe fixed dif- operating pressure connec-
[bar] ference pressure [bar] tion
[bar] Pe [bar]

0 - 2.5 0.1 6 6 G 1/4 060-311066 KPS 31

0 - 2.5 0,1 6 6 G 3/8 A 060-310966 KPS 31
0 - 3.5 0.2 10 10 G 1/4 060-310466 KPS 33
0 - 3.5 0.2 10 10 G 3/8 A 060-310366 KPS 33
0-8 0.4 - 1.5 12 12 G 1/4 060-310566 KPS 35
0-8 0.4 - 1.5 12 12 G 3/8 A 060-310066 KPS 35
0-8 0.4 12 12 G 1/4 060-310866 KPS 35
6 - 18 0.85 - 2.5 22 27 G 1/4 060-310666 KPS 37
6 - 18 0.85 - 2.5 22 27 G 3/8 A 060-310166 KPS 37
10 - 35 2.0 - 6 45 53 G 1/4 060-310766 KPS 39
10 - 35 2.0 - 6 45 53 G 3/8 A 060-310266 KPS 39

Table A15-1 Pressure switches

A15.1.3 Pressure switches for high pressures and media with strong pulsation

Control Settable Perm. Max. test Min. Pressure Order No. Type
range differ- gauge pres- bursting connec-
Pe [bar] ence pres- sure pres- tion
[bar] sure [bar] sure
[bar] [bar]

1 - 10 0.7 - 2.8 120 180 240 G 1/4 060-312066 KPS 43

4 - 40 2.2 - 11 120 180 240 G 1/4 060-312166 KPS 45

6 - 60 3.5 - 17 120 180 240 G 1/4 060-312266 KPS 47

Table A15-2 Pressure switches for high pressures and media with strong pulsation

A15.1.4 Terminology

Range setting Pressure range within which the device can send a
signal (contact change).
Difference Difference between make and break pressure (also see
Figure A15-3).
Permitted gauge pressure
Highest constant or frequently recurring pressure to
which the device can be exposed.

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 Appendix
A15 Pressure switches and thermostats, type KPS
A15.1 Description

Max. test pressure: Maximum pressure to which the device can be exposed
during start-up of the respective system, e.g., in connec-
tion with a leak test. Hence, this must not be a recurring
system pressure.
Min. bursting pressure: The pressure at which the sealing capability of the
pressure-sensitive element is ensured.
A15.1.5 Parameter

A Range setting
B Differential scale
C Difference obtained
Figure A15-3 Pressure profiles

Contact system
Single-pole changeover contact (SPDT)
Contact material: Silver, gold-plated.

Contact load
(if Au surface is burnt )
1. 1. Alternating current:Ohmic load 10 A, 440 V, AC-1
Inductive load 6 A, 440 V, AC-3
4 A, 440 V, AC-15
Start-up current: Max. 50 A (blocked rotor).
2. 2. Direct current: 12 W, 220 V, DC-13
See characteristic Figure A15-4.

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 Appendix
A15 Pressure switches and thermostats, type KPS
A15.1 Description

A maximum load
B hatched area: Permitted load
of the gold plating

Figure A15-4 d.c. load

Ambient temperature
KPS 31 - 39: -40 to +70 °C
KPS 43 - 47: -25 to +70 °C

Media temperature
KPS 31 - 39: -40 to +100 °C
KPS 43 - 47: -25 to +100 °C
For water and sea water max. 80 °C

Shock resistance
Vibration resistance in the range 2-30 Hz
Amplitude 1.1 mm and 30-300 Hz, 4 G.

Type of protection
IP 67 acc. to IEC 529 and DIN 40050.
Pressure switch housing: die-cast aluminium, painted (GD-AISi 12). Cover
fixed by 4 screws. When removed, the cover is protected by a loop. The
encapsulation can be sealed with a lock wire.

Cable entry
Pg 13.5 for cable diameter from 5 to 14 mm.

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 Appendix
A15 Pressure switches and thermostats, type KPS
A15.1 Description

Identification
The type designation and order number are marked at the side of the device.

Scale accuracy

KPS 31: ±0.2 bar KPS 39: ±3.0 bar

KPS 33: ±0.3 bar KPS 43: ±1.0 bar

KPS 35: ±0.5 bar KPS 45: ±4.0 bar

KPS 37: ±1.0 bar KPS 47: ±6.0 bar

Table A15-3 Scale accuracy

Switching point variation after 400,000 switching operations (mean)

KPS 31: ±0.1 bar KPS 39: ±0.7 bar

KPS 33: ±0.2 bar KPS 43: ±0.2 bar

KPS 35: ±0.3 bar KPS 45: ±1.0 bar

KPS 37: ±0.4 bar KPS 47: ±1.5 bar

Table A15-4 Switching point variation after 400,000 switching operations (mean)

Material in contact with media

KPS 31, 33 Corrugated tube capsule: Deep-drawn sheet, material No. 1.0524
Corrugated tube: Pressure (DIN 1624)
socket: Corrosion-free steel, material No. 1.4306
(DIN 17440
Chasing steel C20, Material No. 1.0402
(DIN 1652)

KPS 35, 37.39 Corrugated tube: Pressure Corrosion-free steel, material No. 1.4306
socket: (DIN 17440)
Brass, material no. 2.0401 (DIN 17660)

KPS 43, 45, 47 Membrane capsule: Mem- Nickel-plated brass DIN 50 968
brane: Cu/Ni 5 (DIN 1756)
Nitrilobutadiene rubber

Table A15-5 Material in contact with media

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 Appendix
A15 Pressure switches and thermostats, type KPS
A15.1 Description

A15.1.6 Accessories

Part Description Order No.

Cap nut with nipple G 3/8 cap nut, nipple and 017-436866
seal (10 mm outside) for
soldering

Cap nut with nipple G 3/8 cap nut, nipple and 017-422966
seal (10 mm outside x 6.5
mm inside), for welding

Reducer G 3/8 x 7/16 - 20 UNF (1/4 017-420566

flare) reducer with seal

Sleeve G 3/8 x 1/8 - 27 NPT with 060-333466

seal

Nipple G 3/8 outside x 7/16 - 20 060-324066

UNF (1/4 flare)

Nipple G 3/8 A - 1/4 NPT with seal 060-333566

Sleeve G 3/8 x 1/4 - 18 NPT with 060-333666

seal

Nipple # G 1/4 A x G 3/8 A 060-333266

G 1/4 A x outside M10 x 1 060-333866

with seal

Attenuating loop Attenuating loop with 1/4 060-007166

beaded cap nut and 1 m
copper capillary tube. If the
attenuation loop is used
with devices having 3/8 RG
connections, an additional
reducer is needed. Informa-
tion on the length of the
capillary tube can be
obtained from Danfoss
Attenuating loop Attenuating loop with cap 060-104766
nut G 3/8 and 1.5 m copper
capillary tube

Table A15-6 Accessories, pressure switch type KPS

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 Appendix
A15 Pressure switches and thermostats, type KPS
A15.2 Function

A15.1.7 Dimension drawings and weights

I

Figure A15-5 Dimension drawing

KPS 31 - 39 approx. 1.0 kg

KPS 43 - 47 approx. 1.3 kg

A15.2 Function

KPS 31
Contacts 1-2 make and 1-4 break when the pressure drops below the set
pressure range. The contacts return to their original position if the pressure
drops to range level plus the difference (see Figure A15-6).
I
C

A Scale setting I A warning signal for dropping pres-

B Mechanical difference sure is released if the pressure drops
to the set range level.
II A warning signal for rising pressure is
released if the set range level plus
the difference is obtained.
Figure A15-6 Function KPS 31

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 Appendix
A15 Pressure switches and thermostats, type KPS
A15.2 Function

Other KPS pressure switches

Contacts 1-4 make and 1-2 break if the pressure exceeds the set range level.
The contacts return to their original position if the pressure drops to the range
point less the difference (see Figure A15-7).
C

A
II I II
B

A Scale setting I A warning for rising pressure is re-

B Mechanical difference leased if the level of the set range is
obtained.
II A warning signal for dropping pres-
sure is released at the set range val-
ue minus the difference.
Figure A15-7 Function of other KPS pressure switches

Example 1
A warning is required if the lubricating oil pressure in a certain motor drops
below 0.8 bar.
The warning is indicated by a lamp. KPS 31 (range 0 to 2.5 bar) is chosen.
The lowest permitted lubricating oil pressure of 0.8 bar is set at the range
spindle. The fixed difference setting is 0.1 bar. This means that the warning
persists until the pressure rises to 0.9 bar. The indicator lamp is connected to
terminals 1 and 2 of the pressure switch.

Example2
An audible warning is required (alarm bell) if the normal operating pressure
in a vessel rises from 9 bar to 10 bar. KPS 37 (range 6 to 18 bar) is chosen.
The range value of the pressure switch is set to 10 bar, the difference to 1
bar. The alarm bell is connected to terminals 1 and 4.

Example 3
The pressure in a start air reservoir is to be regulated by a KPS controlled
compressor in such a way that the pressure is maintained between 30 and
36 bar.

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 Appendix
A15 Pressure switches and thermostats, type KPS
A15.2 Function

KPS 45 (range 4 to 40 bar) is chosen. The range value is set to 36 bar.

The difference of 6 bar is set to approximately 2 on the differential scale
according to the nomogram in Figure A15-8.
The required start function is obtained by combining terminals 1and 2.

Figure A15-8 Nomogram

Neuenhauser Kompressorenbau Version 1.2 A15-9

 Appendix
A16 Pressure switches and thermostats, type CAS
A16.1 Description

A16 Pressure switches and thermostats, type CAS

A16.1 Description
A CAS thermostat is a temperature controlled toggle switch whose contact
position depends on the sensor temperature and the scale value setting.
These devices have very little switching difference - even at high tempera-
ture. The CAS series is designed for applications aboard watercraft and also
in industry.
The robust and tight encapsulation and resistance to vibration meet high
requirements. The thermostats are used for control, warning and monitoring
tasks, e.g., in diesel generating sets, power plants or watercraft.
A16.1.1 Specifications and order details

Figure A16-1 CAS with remote sensor, armored capillary tube and sensor sleeve (accessory)

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 Appendix
A16 Pressure switches and thermostats, type CAS
A16.1 Description

Control Mechanical Max. Suitable sensor sleeve length Capillary Order No. Type
range difference sensor (see "Accessories") tube (colored
Settable/ tempera- length background:
fixed ture preferred ver-
sions)

°C °C °C mm m

20 - 80 2.0 130 65 75 110 160 2 060L315166 CAS 178

70 - 120 2.0 220 65 75 110 160 2 060L315366 CAS 180
60 - 150 2.0 250 65 75 110 160 2 060L315566 CAS 181
Please specify type and order number

Table A16-1 Order numbers

Contact system Microswitch with single-pole changeover contact

(SPDT).
Contact load Alternating current: 220 V, ~0.1 A, AC-14 and AC-15
(inductive load)
Direct current 125 V, 12 W DC-13 (inductive load)
Ambient temperature
CAS 178.180 and 181: -25 to +70 °C
Shock resistance
Vibration resistance in the range 2-30 Hz, amplitude 1.1
mm and 30-100 Hz, 4 G.
Type of protection IP 67 acc. to IEC 529 and DIN 40050.
Thermostat housing: die-cast aluminium, painted (GD-
AISi 12). Cover fixed by 4 screws. When removed, the
cover is protected by a loop. The encapsulation can be
sealed with a lock wire.
Cable inlet Pg 13.5 for cable diameter from 5 to 14 mm.
Identification The type designation and order number are marked at
the side of the device.

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 Appendix
A16 Pressure switches and thermostats, type CAS
A16.1 Description

Sensor sleeve A [mm] Thread B Order No.

All sensor sleeves are delivered without sealing screw,

seals and washers.

Brass 65 ½ NPT 060L326566

Brass 75 ½ NPTG 060L326466
75 ½ AG 060L326266
75 ¾ AG 060L326666
75 ½ A (ISO 228/1) 060L328166
Brass 110 ½ NPT 060L328066
110 G½A 060L327166
110 G ½ A (ISO 228/1) 060L340666
110 G ¾ A (ISO 228/1) 060L340366
Brass 160 G½A 060L326366
160 G ¾ A (ISO 228/1) 060L340566
Brass 200 G½A 060L320666
200 G ½ A (ISO 228/1) 060L340866
200 G ¾ A (ISO 228/1) 060L340266
Brass 250 G½A 060L325466
Brass 350 G½A 060L325566
Brass 400 G½A 060L325666
Steel 18/8 75 G½A 060L326766
Steel 18/8 110 G½ 060L326866
110 A ½ NPT 060L327066
Steel 18/8 160 G½A 060L326966
Steel 18/8 200 G½A 060L323766
200 G¾A 060L324866

Table A16-2 Accessories: Sensor sleeve for thermostats

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 Appendix
A16 Pressure switches and thermostats, type CAS
A16.1 Description

Other accessory items Description Qty./ Order No.

device

Taut band For CAS thermostats with remote 10 017-420466

sensor (L = 392 mm)

Heat-transfer compound For CAS thermostats with sensor in 1 041E0114

(tube with 4.5 cm3) sensor sleeve. For improved heat
transfer between sensor and sleeve.
Paste application range : -20 to +150
°C, briefly up to 220 °C

Table A16-3 More accessory items

A16.1.2 Dimension drawings and weights

Weight: approx 1.4 kg

Figure A16-2 Dimension drawing of CAS with remote sensor and 2 m armored capillary tube

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 Appendix
A16 Pressure switches and thermostats, type CAS
A16.1 Description

A16.1.3 Installation
Arrangement of the device: CAS thermostats generally can withstand the
shocks and vibrations, e.g., aboard watercraft, in compressors or large
machine systems. The device can be installed at a bracket of 3 mm iron plate
fixed directly to a wall, bulkhead or the like.

Media resistance Material specifications of sensor sleeves:

Sensor sleeve of brass
Tube of Ms 72 acc. to DIN 17660, threaded end of So
Ms 58 Pb acc. to DIN 17661.
Sensor sleeve of stainless steel 18/8
material reference 1.4305 acc. to DIN 17440.
Sensor arrangement
Preferably, the sensor should be arranged so that its
longitudinal axis is at right angles to the direction of flow.
The active part of the sensor is Ø13 mm x 47.5 mm.
Media behavior The fastest response is obtained with media of high spe-
cific heat and high heat conductivity. So if a medium can
be chosen it is an advantage if it can meet these require-
ments. The flow velocity of the medium is also important.
(The optimum flow velocity for liquids is approx. 0.3 m/s)
Permitted media pressure: See Figure A16-3.
A Brass
A B B Stainless steel 18/8

Figure A16-3 Permitted media pressure on sensor sleeves as a function of temperature

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 Appendix
A16 Pressure switches and thermostats, type CAS
A16.1 Description

Setting
1. Remove the housing cover.
2. Slacken locking screw (3), Figure A16-4, and then set the range at spin-
dle (1) and reading scale (2).
1 Range spindle
2 Range scale
3 Locking screw

Figure A16-4 Thermostat settings

Scale correction
The sensors of CAS thermostats contain what is called an adsorption filling
which allows their arrangement warmer or colder than the remaining part of
the thermostatic element (corrugated tube and capillary tube) without impair-
ment of their function. A filling of this kind may be susceptible to changes of
the corrugated tube or capillary tube temperatures which, however, is without
significance under normal conditions.
On the other hand, if the thermostats are exposed to extreme ambient
temperatures, scale deviations can occur which can be compensated in the
following way:
Scale correction = Z x a
Z is defined by means of Table A16-4, whereas a is the correction factor
according to Table A16-5 (see example below).

Type Setting range[°C] Correction factor a

CAS 178 20 - 80 2.5

CAS 180 70 - 120 2.4
CAS 181 60 - 150 3.7

Table A16-4 Scale correction: Correction factors

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 Appendix
A16 Pressure switches and thermostats, type CAS
A16.1 Description

Z Factor for scale deviation

X Relative scale setting in %

Table A16-5 Scale correction

Electrical connection
CAS thermostats are provided with Pg 13.5 cable gland for cable diameters
from 5 to 14 mm. For contact functions, see Figure A16-5.
Z

Figure A16-5 Electrical connection

A16.1.4 Function

Difference terminology
Mechanical reference (intrinsic difference) is the switching difference, which
is fixed for every device. The difference at which the system will work is
referred to as thermic difference (operating difference). The thermic differ-
ence is always larger than the mechanical difference and depends on three
factors:
c) Flow velocity of the medium

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 Appendix
A16 Pressure switches and thermostats, type CAS
A16.1 Description

d) Speed of change of the medium temperature and

e) Heat transfer to the sensor.

Thermostat function
Contacts 1-4 make and contacts 1-2 break as soon as the temperature rises
above the scale-set value (set point). The contacts return to their original
position if the temperature drops to set-point less the mechanical difference
(see Figure A16-6).

A Range setting I A warning signal is released when the temperature

B Mechanical difference reaches the set range level.
II A warning signal for temperature drop is released at the
set range value minus the mechanical difference.
Figure A16-6 Thermostat function

A16.1.5 Examples

Example 1
Diesel engine with cooling water temperature of 85 °C (normal state). A warn-
ing signal is required when the cooling water temperature exceeds 95 °C.
Select a thermostat CAS 180 (range +70 to 120¬°C). Setting at the main
spindle: 95 °C. The required warning function is obtained by combining ter-
minals 1-4.

Example2
Define the required scale temperature for a CAS 180 which is set for ambient
temperature of +50 °C to +95 °C. The relative scale setting is calculated by
the following equation:

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 Appendix
A16 Pressure switches and thermostats, type CAS
A16.1 Description

Setting – min. scale value

x 100 = %
max. scale value – min. scale value

Relative scale value:

95 – 70 x 100
= 50%
max. 120 – 70

Factor for scale deviation Z (Table A16-4)

Z approx. 0.7
Correction factor a (Table A16-5)
a = 2.4.
Scale correction = Z x a = 0.7 x 2,4 = 1.7 °C
CAS should be set to 95 + 1.7 = 96.7 °C.

A16-9 Version 1.2 Neuenhauser Kompressorenbau

 Appendix
A17 Three-phase motor Operation instructions 12AA / 12BA
A17.1 Sizes and types

A17 Three-phase motor Operation instructions 12AA /

12BA

A17.1 Sizes and types

Sizes
 BG56...90L-IMB3
 BG100L-IMB3
 BG112M...132M-IMB3
 BG160M…315-IMB3

Types

IM V 5 IM V 6 IM V 18

IM B 5 IM V 1 IM V 3 IM B 14 IM B 35
IM B 34
IM B 6 IM B 7 IM B 8 IM V 19

Figure A17-1 Types of 3-phase current motors, versions

WARNING Observe the information and data contained in the supplier documentation.
This is necessary for avoiding hazards and damage. Additional safety inst-
ructions with more safety instructions for electrical machinery and equipment
are included. The safety instructions complement all other operation and
other instructions supplied.
In addition, all applicable national, local and plant-related provisions and re-
quirements should be observed.
The technical details of special versions and types can vary. If you are in
doubt it is important to ask back with the manufacturer; when contacting the
manufacturer, specify the type designation and the factory number of the mo-
tor.

A17.2 Description
A17.2.1 Application
The motors are of protection type IP54/IP55 and can be installed in a dusty
or wet environment. If stored properly or installed outdoors, normally no spe-
cial protection of the motors is required.

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 Appendix
A17 Three-phase motor Operation instructions 12AA / 12BA
A17.2 Description

Unless specified otherwise, the rated output is for continuous operation at

a coolant temperature of –30°C to +40°C and altitude up to 1000 m above
sea level.
A17.2.2 Installation and mode of operation
The motors have intrinsic cooling (by fans). The cooling air flow in and out
should not be obstructed. Motors with feet have their feet cast or bolted to the
motor housing.
A17.2.3 Operation
All work should be performed when the unit is electrically isolated.
A17.2.4 Installation
If the time between the delivery and the start-up of a motor under favorable
conditions (storage in dry rooms free of dust and vibration) is more than 4
years or more than 2 years in unfavorable conditions, new bearings should
be fitted.
Special protection should be provided for motors with shaft stub on top or
bottom or exposed to direct sunshine (e.g., provide shelter).
The top of the terminal box of a terminal board with 6 terminals can be tur-
ned 4x90 degrees.
A17.2.5 Balancing the rotor and related drive components
The rotors are balanced dynamically by a half key inserted in the shaft end.
Make sure that the correct method of balancing the drive component is
applied in relation to the balancing of the rotor.
A17.2.6 Electrical connection
Mains voltage and mains frequency of the supplying mains should be the
same as those on the machine nameplate. Make the connection and arran-
gement of the
terminal links as shown in the circuit plan inside the terminal box. Connect
the protective earth at this terminal.
Tightening torques for screw/bolt connections of the electrical connec-
tions/terminal board connections (see Table A17-1).
The external conductors are connected by a bent eyelet or a cable lug.
A17.2.7 Insulation test
The insulation resistance of the windings to ground should be measured by
applying direct voltage before the first start-up and after extended times of no
use.

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 Appendix
A17 Three-phase motor Operation instructions 12AA / 12BA
A17.2 Description

WARNING During the measurement and immediately after it, the terminals can be live
with dangerous voltage and should not be touched.

When carrying out the measurement wait until the resistance end value is
reached.
Design voltage
UN <=1 kV
Winding temperature
<25°C
Measuring voltage 500 V DC
Minimum insulation resistance of new, cleaned or repaired windings
10 MOhm
Specific critical insulation resistance after extended period of operation
0.5 MOhm/kV
The winding insulation resistance can drop in the course of service due to
environment and operation effects. The critical level of the insulation resis-
tance at a winding temperature of 25°C can be calculated for different design
voltages by multiplying the design voltage (kV) with the specific critical insu-
lation resistance; e. g., critical resistance for UN 690 V:
0.69 kV×0.5 MOhm/kV = 0.345 MOhm.
If the insulation resistance measured during operation is higher than the cal-
culated critical resistance of the insulation, the motor can continue operation.
If the insulation reaches the critical resistance level or drops below it, the win-
dings should be dried or cleaned thoroughly and dried after removing the
rotor.
If the measured resistance is near the critical value, the insulation resis-
tance should be checked regularly in short intervals or the winding cleaned.

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 Appendix
A17 Three-phase motor Operation instructions 12AA / 12BA
A17.3 Maintenance/repairs

A17.3 Maintenance/repairs

WARNING All work should be performed when the unit is electrically isolated.

Motors of series 160 ... 355 (with relubrication mechanism)

The following maintenance is required:
 Relubrication.
The ball bearings of the motors are provided with high-quality ball bearing
grease (K3N acc. to DIN 51825) in the factory.
The grease used in the factory can be mixed with equivalent grease (i.e.,
grease of the same grade and the same characteristics, viz. K3N grease)
For details of lubricant and lubricating intervals, see section A17.4.2 "Lub-
ricant and relubrication intervals".
 Check the operating temperature
 Listen for bearing noise during operation
 Damaged parts should be replaced.
Standard parts of the required size, material and surface finish can be
obtained in the market.
Spare parts are available on request.
Relubrication:
 Pull off the antifriction bearings with a suitable puller.
 For installation, heat bearings equally to approx. 80 to 100°C. Avoid hard
bangs (e.g., with a hammer).
 Adjacent lubricant spaces should be filled with lubricant (e.g., in the bea-
ring plate for sealing the shaft bore‚ – provide a 2/3 filling of the space).
Use lubricant of the same grade as for the bearings. Do not mix different
lubricant grades.
Note: It is recommended when bearings are exchanged also to replace
worn seals (e.g., shaft seals).

Motors of services 56 ... 132 (without relubrication mechanism)

Motors of series 56 ... 132 are shipped ex works with ball bearing sealed on
both sides (ZZ design) provided with life lubrication. These ball bearings
require no maintenance. The following maintenance is required:
 Check the operating temperature
 Listen for bearing noise during operation
 Damaged parts should be replaced.
Standard parts of the required size, material and surface finish can be
obtained in the market.
Spare parts are available on request.

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 Appendix
A17 Three-phase motor Operation instructions 12AA / 12BA
A17.4 Annex

A17.4 Annex
A17.4.1 Tightening torques for electrical bolt/screw connections at the terminal board –
terminal board connections (except terminal strips)

Thread + M4 M5 M6 M8 M10 M12 M16

Tightening min. 0.8 1.8 2.7 5.5 9 14 27

torque [Nm]
max. 1.2 2.5 4 8 13 20 40

Table A17-1 Tightening torques for electrical bolt/screw connections

The above tightening torques apply if no other tightening torques are speci-
fied.

A17.4.2 Lubricant and relubrication intervals

Lubricant

Motors of thermal class Motor cooling temperature Lubricant grade for bearings
acc. to VDE0530

F –20 to +60°C K3N according to DIN 51825

Table A17-2 Lubricant

For example UNIREX N3* (ESSO)

According to supplier information: Run test B acc. to DIN 51806 passed at
+160 °C test temperature.

Relubrication intervals: 2-pole motors, series 12AA/BA

Model size Ambient tem- Operation hours [h] Lubricant Bearing A side Bearing B side
(axle height) perature [°C] volume [g]
3600 rpm ( 3000 rpm
(60 Hz) (50 Hz)

160 40 3200 4200 20 6309 C3 6309 C3

180 40 3200 4200 20 6311 C3 6311 C3
200 40 1800 3100 25 6312 C3 6312 C3
225 <=25 1800 3100 25 6312 C3 6312 C3
225 >=25 1800 3100 25 6312 C3 6312 C3
250 40 800 2000 35 6314 C3 6314 C3
280 <=25 800 2000 35 6314 C3 6314 C3

Table A17-3 Relubrication intervals: 2-pole motors, series 12AA/BA

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 Appendix
A17 Three-phase motor Operation instructions 12AA / 12BA
A17.4 Annex

Model size Ambient tem- Operation hours [h] Lubricant Bearing A side Bearing B side
(axle height) perature [°C] volume [g]
3600 rpm ( 3000 rpm
(60 Hz) (50 Hz)

280 >=25 800 2000 35 6314 C3 6314 C3

315 <=25 800 2000 50 6317 C3 6317 C3
315 >=25 800 2000 50 6317 C3 6317 C3
355 1000 60 6319 C3 6319 C3

Table A17-3 Relubrication intervals: 2-pole motors, series 12AA/BA

Relubrication intervals: 4-pole motors, series 12AA/BA

Model size Ambient tem- Operation hours [h] Lubricant Bearing A side Bearing B side
(axle height) perature [°C] volume [g]
1800 rpm ( 1500 rpm
(60 Hz) (50 Hz)

160 40 6000 7000 20 6309 C3 6309 C3

180 40 6000 7000 20 6311 C3 6311 C3
200 40 5500 6500 25 6312 C3 6312 C3
225 40 5500 6500 25 6313 C3 6313 C3
250 40 5000 6000 35 6314 C3 6314 C3
280 40 5000 6000 35 6317 C3 6317 C3
315 4600 5500 50 6319 C3 6319 C3
355 4000 5000 60 6322 C3 6319 C3

Table A17-4 Relubrication intervals: 4-pole motors, series 12AA/BA

Relubrication intervals: 6-pole motors, series 12AA/BA

Model size Ambient tem- Operation hours [h] Lubricant Bearing A side Bearing B side
(axle height) perature [°C] volume [g]
1200 rpm ( 1000 rpm
(60 Hz) (50 Hz)

160 40 8000 9000 20 6309 C3 6309 C3

180 40 8000 9000 20 6311 C3 6311 C3
200 40 7500 8500 25 6312 C3 6312 C3
225 40 7500 8500 25 6313 C3 6313 C3
250 40 7000 8000 35 6314 C3 6314 C3

Table A17-5 Relubrication intervals: 6-pole motors, series 12AA/BA

A17-6 Version 1.2 Neuenhauser Kompressorenbau

 Appendix
A17 Three-phase motor Operation instructions 12AA / 12BA
A17.4 Annex

Model size Ambient tem- Operation hours [h] Lubricant Bearing A side Bearing B side
(axle height) perature [°C] volume [g]
1200 rpm ( 1000 rpm
(60 Hz) (50 Hz)

280 40 7000 8000 35 6317 C3 6317 C3

315 <=25 6500 7500 50 6319 C3 6319 C3
315 >=25 6500 7500 50 6319 C3 6319 C3
355 6000 7000 60 6322 C3 6319 C3

Table A17-5 Relubrication intervals: 6-pole motors, series 12AA/BA

Neuenhauser Kompressorenbau Version 1.2 A17-7

 Appendix
A18 Technical data sheet for IP 55, ISO F electric motor
A18.1 Electrical data for 380 ... 420 V and 50 Hz

A18 Technical data sheet for IP 55, ISO F electric motor

A18.1 Electrical data for 380 ... 420 V and 50 Hz

Model size 100 132 132 132 132 160 160 160 160
L04 S04 S06 M04 M06 M04 M06 L04 L06

Rated output kW 3 5.5 3 7.5 5.5 11.0 7.5 15.0 11

Rated speed min-1 1410 1455 950 1455 950 1460 960 1460 960

Rated torque Nm 20.4 36.3 30.2 49.4 55.2 72.3 74.9 98.6 110
Rated current A 6.4 11.4 7.5 15.2 11.9 21.5 17.2 28.5 24.5
Power factor cos 0.83 0.81 0.74 0.82 0.71 0.84 0.75 0.84 0.75
Efficiency % 82.6 85.7 78.0 87 81.0 88.4 84.0 89.4 86.0
Statring current la/ ln 5.6 6.3 4.2 6.7 5.3 6.2 4.6 6.5 4.8
Starting torque Ma/Mn 2.7 2.5 1.9 2.7 2.5 2.2 2.0 2.6 2.2
Breakdown torque Mk/Mn 3.0 3.1 2.1 3.2 2.9 2.7 2.2 3.0 2.6
Inertia GD° 0.0058 0.018 0.015 0.024 0.025 0.040 0.041 0.052 0.049
Weight IM B3 kg 25 43 37.5 49 52 92 97 118 118

Table A18-1 Electrical data for 400 V and 50 Hz, model sizes 100 L04 to 160 L06

Model size 180 180 200 200 225 225 225

L04 L06 L04 L06 S04 M04 M06

Rated output kW 22 15 30 22 37 45 30
Rated speed min-1 1480 970 1480 970 1480 1480 1480

Rated torque Nm 143 148 161 216 198 290 292

Rated current A 41.0 30.0 54.7 42.4 66.4 80.4 56.3
Power factor cos 0.88 0.84 0.87 0.83 0.87 0.89 0.88
Efficiency % 91.6 89.1 92.6 90.1 92.8 93.4 91.8
Statring current la/ ln 7.5 7.0 7.2 7.0 7.2 7.2 7.0
Starting torque Ma/Mn 2.2 2.1 2.2 2.1 2.2 2.2 2.1
Breakdown torque Mk/Mn 2.3 2.0 2.3 2.0 2.3 2.3 2.0
Inertia GD° 0.158 0.207 0.262 0.360 0.406 0.469 0.547
Weight IM B3 kg 182 178 245 228 258 290 265

Table A18-2 Electrical data for 400 V and 50 Hz, model size 180 L04 zo 225 M06

Test conditions
 Output in continuous service S1
 Ambient temperature 40°C

A18-1 Version 1.2 Neuenhauser Kompressorenbau

 Appendix
A18 Technical data sheet for IP 55, ISO F electric motor
A18.2 Electrical data for 440 ... 480 V and 60 Hz

A18.2 Electrical data for 440 ... 480 V and 60 Hz

Model size 100 132 132 132 132 160 160 160 160
L04 S04 S06 M04 M06 M04 M06 L04 L06

Rated output kW 3.45 6.3 3.45 8.6 6.3 12.6 8.6 17.3 12.6
Rated speed min-1 1720 1755 1150 1755 ´115 1760 1155 1760 1160
0
Rated torque Nm 19.1 34.3 28.7 46.8 52.2 68.7 71.1 94.2 104
Rated current A 6.2 10.9 7.3 14.7 12.9 21.5 16.7 28.0 24.6
Power factor cos 0.83 0.82 0.74 0.83 0.73 0.85 0.75 0.85 0.74
Efficiency % 84.5 88.0 80.0 88.5 84.0 89.0 86.0 90.0 87.0
Statring current la/ ln 5.9 6.8 4.7 7.1 5.9 6.5 4.6 6.9 4.8
Starting torque Ma/Mn 2.8 2.7 1.9 2.8 2.4 2.3 2.0 2.7 2.2
Breakdown torque Mk/Mn 3.1 3.3 2.1 3.3 3.0 2.8 2.2 3.1 2.2
Inertia GD° 0.0058 0.018 0.015 0.024 0.025 0.040 0.041 0.052 0.049
Weight IM B3 kg 25 43 37.5 49 52 92 97 118 118

Table A18-3 Electrical data for 440/480 V and 60 Hz, model sizes100 L04 to160 L06

Model size 180 180 200 200 225 225 225

L04 L06 L04 L06 S04 M04 M06

Rated output kW 26.4 18.8 36.0 26.4 44.4 54 36

Rated speed min-1 1776 1164 1776 1164 1776 1776 1776

Rated torque Nm 143 148 161 216 198 290 292

Rated current A 41.0 30.0 54.7 42.4 66.4 80.4 56.3
Power factor cos 0.88 0.84 0.87 0.83 0.87 0.89 0.88
Efficiency % 91.6 89.1 92.6 90.1 92.8 93.4 91.8
Statring current la/ ln 7.5 7.0 7.2 7.0 7.2 7.2 7.0
Starting torque Ma/Mn 2.2 2.1 2.2 2.1 2.2 2.2 2.1
Breakdown torque Mk/Mn 2.3 2.0 2.3 2.0 2.3 2.3 2.0
Inertia GD° 0.158 0.207 0.262 0.360 0.406 0.469 0.547
Weight IM B3 kg 182 178 245 228 258 290 265

Table A18-4 Electrical data for 440/480 V and 60 Hz, model sizes180 L04 to 225 M06

Test conditions
 Output in continuous service S1
 Ambient temperature 40 °C

Neuenhauser Kompressorenbau Version 1.2 A18-2

 Appendix
A19 Ring Laminated Valve 1st Stage
A19.1 Assembly

A19.1 Assembly

Valid for Position 100 (0055155) on Page 12 and Position 110 (0055156) on Page 14 in the chapter
“spare parts”.

A19-1 Version 1.2 Neuenhauser Kompressorenbau

 Appendix
A20 Technical data sheet for temperature switch TSM

A20 Technical data sheet for temperature switch TSM

A20-1
 Appendix
A21 Short Instructions Compressor Control LOGO 0BA8

A21 Short Instructions Compressor

Control LOGO 0BA8

A21-1 Table of contents

Table of contents
A21-1 Table of contents .......................................................................................................................... 1

A21-2 General Information ..................................................................................................................... 2

A21-3 Information Display....................................................................................................................... 3

A21-4 Selection Switch “Service” ............................................................................................................ 4

A21-5 Selection Switch “Automatic” ....................................................................................................... 6

A21-6 Remote .......................................................................................................................................... 8

A21-7 Fault .............................................................................................................................................. 9

A21-8 Emergency OFF / Emergency-Stop ............................................................................................. 10

19/06/2017 A21 - 1/10

 Appendix
A21 Short Instructions Compressor Control LOGO 0BA8

A21-2 General Information

1. Control Display
2. Switch “On/off”
3. Selection Switch “Automatic/Service”
4. Fault “Reset”
5. Emergency-Stop
6. Emergency-Stop “Reset”

19/06/2017 A21 - 2/10

 Appendix
A21 Short Instructions Compressor Control LOGO 0BA8

A21-3 Information Display

a. Display colour yellow Compressor standing

b. Display colour white Compressor running

c. Display colour red Compressor fault

19/06/2017 A21 - 3/10

 Appendix
A21 Short Instructions Compressor Control LOGO 0BA8

A21-4 Selection Switch “Service”

1. Selection switch (item 3) to service.

a. Is displayed.
2. Switch on via button (item 2).
a. The compressor starts up directly and is no longer switched off by the
pressure switch.
b. If there are any faults in service mode, the condenser valves are permanently
live (tightness test option)
3. The compressor is operated by switching the display lighting. It switches from yellow
to white. The display shows the following information:
a. Compressor ON-OFF
b. Compressor LOAD/UNLOAD (condensate distributor closed / open)
c. PRESSURE LOW/HIGH (information shows current pressure, since the
compressor does not switch off via the pressure switch in service)
4. In case of fault in service mode, the condensate valves remain live; this is meant as
tightness test if service is needed.

19/06/2017 A21 - 4/10

 Appendix
A21 Short Instructions Compressor Control LOGO 0BA8

5. The stop button (item 2) switches the compressor to its lag time. The compressor will
run without load for the set time to cool off. The time will be displayed.

6. After the end of the time, the compressor will switch off again and switch to the home
screen before waiting for the next starting command.

19/06/2017 A21 - 5/10

 Appendix
A21 Short Instructions Compressor Control LOGO 0BA8

A21-5 Selection Switch “Automatic”

Information display auto:

a. Compressor: LOAD Condensate valves closed
(Interval switch 10 min closed – 7 s open)
b. Compressor: UNLOAD Condensate valves open
c. Compressor: STAND BY Compressor is on and waiting for the
starting signal from the printer

1. Selection switch (item 3) to auto

2. The compressor is operated by switching the display lighting. It switches from yellow
to white. The display shows the following information:
a. Compressor ON-OFF
b. Compressor LOAD/UNLOAD (condensate distributor closed / open)
c. PRESSURE LOW/HIGH (information on current pressure, since the
compressor does not switch off via the
pressure switch in service)
3. Switch on via button (item 2).
a. The compressor does not start up directly; it is switched via the pressure
switch.
b. If there are any faults in auto mode, the condenser valves are not live and they
are open. The compressor is depressurised.

19/06/2017 A21 - 6/10

 Appendix
A21 Short Instructions Compressor Control LOGO 0BA8

4. When the pressure drops and the pressure switch switches the compressor on.

5. The compressor has reached its deactivation pressure.

6. The compressor continues to run for the lag time.
The compressor will run without load for the set time to cool off. The time is shown in
the display. After expiration, the compressor will switch OFF again and wait for the
next starting signal from the pressure switch.

19/06/2017 A21 - 7/10

 Appendix
A21 Short Instructions Compressor Control LOGO 0BA8

A21-6 Remote
1. Switching LOCAL-REMOTE takes place via the function button F1 at the display. The
display will show the condition.

Service mode is only possible in the position LOCAL. When LOCAL is selected and
the selection switch is set to service, it goes just as described above.

2. Remote start is now active.

3. When switching the pressure switch, the compressor normally runs via its pressure
switch while the external starting signal is pending. At signal change from the
pressure switch, the display colour turns white. The condensate valves close and the
compressor switches to lag time again when the deactivation pressure is reached.

19/06/2017 A21 - 8/10

 Appendix
A21 Short Instructions Compressor Control LOGO 0BA8

A21-7 Fault

1. "TEMP" - Temperature error (OPTION):

a. Display indicator flashes red; compressor continues to run.
b. Potential-free contact is switched.
c. The compressor can be switched off optionally as well.
2. "OIL" - error OIL magnet:
a. Delayed for 7 s.
b. Display indicator flashes red; compressor stops.
c. Potential-free contact is switched.

3. "MOTOR" - Motor protection switch has tripped:

a. Display indicator flashes red.
b. Compressor stops.

All errors must be confirmed via RESET fault button (item 4), at the control cabinet.

After confirmation, the compressor can be restarted.

19/06/2017 A21 - 9/10

 Appendix
A21 Short Instructions Compressor Control LOGO 0BA8

A21-8 Emergency OFF / Emergency-Stop

1. The switch Emergency Stop (item 5), is depressed.

2. The display lights up red and E-STOP is displayed as fault.

3. The compressor is powered down entirely.

4. This condition can only be revoked in the home position and after confirmation with
the button Reset Emergency Stop (item 6).

5. Home position = main contactors of the compressors are not controlled, in order to
prevent direct start-up of the compressors.

6. Reset Emergency Stop cannot confirm any faults, just as Reset fault cannot confirm
Emergency Stop.

19/06/2017 A21 - 10/10

 Benennung/Designation:

Fundamentausführung für Kompressoren /

Foundation for Compressors

Fundamentausführung für den Kompressorrahmen

Maximal 3mm (hmax) Höhendifferenz innerhalb einer Messtrecke (d) von
1500mm. Jedoch nicht mehr als 5mm über die gesamte Länge / Breite /
Diagonale des Kompressors.

Boden

Bei Einhaltung dieser Werte kann auf Ausgleichsmaßnahmen (Ausgleichs-

bleche) verzichtet werden.

Foundation compressor frame structure:

Maximum 3mm difference in height (hmax) within 1500mm distance (d) of the
measuring points. But not exceeding 5mm on the total length / width / slant of
the compressor.

Floor

If a.m. requirements are fulfilled the compressors can be directly fixed to the
ground without further compensation measures (filler plates).

Datei/ File: Fundamentausführung.docx

Rev. Changes Date Prepared Page
18.09.2013 Brm 1/1
 Glossary
EN(GB) – DE – ES – FR – PT(BR)
 Glossary - EN(GB) - DE - ES - FR - PT(BR)

EN(GB) DE ES FR PT(BR)

adapter Adapter Adaptador adaptateur adaptador

after cooler Nachkühler Radiador posterior radiateur secondaire radiador posterior

air baffle plate Luftleitblech Deflector de aire déflecteur d’air chapa defletora de ar

air filter Luftfilter Filtro de aire filtre à air filtro de ar

air outlet Druckluftaustritt Salida de aire a presión sortie d’air comprimé saída de ar comprimido
saída de ar comprimido x.
air outlet x. stage Druckluftaustritt x. Stufe Salida aire a presión X etapa sortie d’air comprimé x. niveau
etapa
allen screw Gewindestift Perno roscado tige filetée pino roscado

anti vibration element Schwingmetall Pata forrada de goma joint métallocaoutchouté metal forrado de borracha

bar bar bar bar bar

base frame Antriebsrahmen Bastidor châssis d’entraînement quadro de acionamento

base frame Rahmengestell Bastidor bâti du châssis quadro suporte

base frame left Unterrahmen links Bastidor auxiliar izdo bâti inférieur, gauche quadro inferior esquerda

base frame right Unterrahmen rechts Bastidor auxiliar dcho bâti inférieur, droite quadro inferior direita

bearing cover Lagerdeckel Cubierta de cojinete chapeau de palier cobertura do mancal

compressor block Kompressorblock Bloque compresor bloc compresseur bloco compressor

évacuation de l’eau de
condensate drain Kondensatablass Purga purga de condensado
condensation
évacuation de l’eau de
condensate drain x-cyl. Kondensatablass x-Zyl. Purga X-cil purga de condensado x-cil.
condensation cyl. x
condensate pipe Kondensatrohr Tubería de condensado tuyau d’eau condensée tubo de condensado

Page 2 of 9 12.09.2013
 Glossary - EN(GB) - DE - ES - FR - PT(BR)

EN(GB) DE ES FR PT(BR)
Tubería de condensado X- tuyau d’eau condensée x. tubo de condensado x. etapa,
condensate pipe x stage, cyl. X Kondensatrohr x. Stufe, Zyl. X
etapa, cil. X niveau, cyl. X cil. X
connection rod Pleuelstange Biela articulada bielle motrice biela de conexão

content Inhaltsangabe Tabla de contenidos contenu conteúdo

cooler Kühler Radiador radiateur radiador

cooler x-cylinder Kühler x-Zylinder Radiador x- cilindros radiateur cylindre x radiador x-cilindros

counter weight Gegengewicht Contrapeso contrepoids contrapeso

countersunk screw Senkschraube Tornillo de cabeza avellanada vis à tête conique parafuso de cabeca escareada

coupling Kupplung Acoplamiento accouplement acoplamento

cover Abschlussdeckel Tapa superior couvercle cobertura superior

covering Abdeckblech Chapa protectora tôle de protection chapa protetora

crankcase Kurbelgehäuse Carter carter de vilebrequin cárter

crankshaft Kurbelwelle Cigüeñal vilebrequin cambota

crankshaft x-cylinder Kurbelwelle x-Zylinder Cigüeñal x-cilindros vilebrequin cylindre x cambota x-cilindros

cyl. Zyl. (Zylinder) cil. cyl. (cylindre) cilindro

cylinder Zylinder cilindro cylindre cilindro

cylinder x. stage Zylinder x. Stufe cilindros x etapa cylindre x. niveau cilindro x. etapa

disk Sperrzahnscheibe Arandela dentada rondelle dentée de blocage disco dentado de bloqueio

distance piece Distanzstück Espaciador pièce d’écartement espaçador

Page 3 of 9 12.09.2013
 Glossary - EN(GB) - DE - ES - FR - PT(BR)

EN(GB) DE ES FR PT(BR)

distance ring Distanzring Anillo distanciador bague d’écartement anel espaçador

distance washer Distanzscheibe Arandela rondelle d’écartement arruela espaçadora

drive Antrieb Accionamiento entraînement acionamento

e-motor E-Motor Motor-E moteur électrique motor elétrico

fan Axialventilator Ventilador axial ventilateur axial ventilador axial

filter Belüftungsfilter Filtro de ventilación filtre d’aération filtro de ventilação

filter Einbaufilter Bloque filtros filtre encastré filtro

filter element Filtereinsatz Cartucho filtrante cartouche filtrante cartucho do filtro

fitting Fitting Adecuado fitting apropriado

flexible hose Schlauchleitung Manguera tuyauterie souple mangueira

flywheel Schwungrad Volante de inercia volant d’inertie volante do motor

frame Rahmen Marco soporte châssis quadro

frame Tragrahmen Marco soporte cadre porteur quadro de suporte

front panel Frontblech Panel frontal tôle frontale chapa dianteira

gasket Dichtung Junta joint vedação

gasket ring Dichtring Junta anular bague d’étanchéité anel de vedação

general drawing Gesamtzeichnung Dibujo total schéma d’ensemble desenho geral

grove pin Kerbnagel Pasador clou cannelé pino com ranhuras

Page 4 of 9 12.09.2013
 Glossary - EN(GB) - DE - ES - FR - PT(BR)

EN(GB) DE ES FR PT(BR)

head screw Zylinderschraube Tornillo cilíndrico vis à tête cylindrique parafuso do cilindro

hexagon Skt. (Sechkant) hexagonal hex. (hexagonal) hexagonal

hexagon head screw Sechskantschraube Tornillo hexagonal vis hexagonale parafuso hexagonal

hexagon head screw Skt.-Schraube Tornillo hexagonal vis hexagonale parafuso hexagonal

hexagon nut Sechskantmutter Tuerca hexagonal écrou hexagonal porca hexagonal

holder Halterung Sujeción support suporte

holding device Aufnahme Soporte logement suporte

housing Gehäuse Carcasa boîtier carcaça

impeller covering Lüfterhaube Cubierta del ventilador manche d’aspiration cobertura do ventilador

inner ring Innenring Aro interior bague intérieure anel interior

inspection cover Schaulochdeckel Tapa de inspección couvercle du trou de regard cobertura de inspeção

inter cooler Zwischenkühler Radiador intermedio refroidisseur intermédiaire radiador intermediário

intermediate piece Zwischenstück Pieza intermedia pièce intercalaire peça intermediária

left links izdo gauche esquerda

lens screw Linsenschraube Tornillo alomado vis à tête cylindrique bombée parafuso lente

lock Verschlusskappe Tapón roscado capuchon tampa

lock ring Verschlussring Anillo de bloqueo bague de fermeture anel de bloqueio

locking ring Spannring Anillo de apriete anneau tendeur anel de aperto

Page 5 of 9 12.09.2013
 Glossary - EN(GB) - DE - ES - FR - PT(BR)

EN(GB) DE ES FR PT(BR)

locking screw Verschlussschraube Tornillo de cierre bouchon fileté parafuso de bloqueio

lub oil controller Ölstandssensor Sensor de nivel de aceite capteur du niveau d’huile sensor de controle de óleo

lubrication oil pump Taktpumpe Bomba de ciclo pompe cyclique bomba de ciclo

lubrication oil pump x-cylinder Taktpumpe x-Zylinder lubrication oil pump x-cilindros pompe cyclique cylindre x bomba de ciclo x-cilindros

manifold Verteilerstück Pieza de distribución pièce de distribution peça de distribuição

name plate Typenschild Placa de características plaque signalétique placa de identificação

needle bearing Nadellager Cojinete de agujas roulement à aiguilles mancal de agulhas

Nm Nm Nm Nm Nm

non return valve Rückschlagventil Válvula antirretorno clapet antiretour válvula de retenção

nut Käfigmutter Tuerca de jaula écrou cage porca gaiola

oil and water separator Öl- und Wasserabscheider Colector de aceite y agua séparateur d’huile et d’eau separador de óleo e água

oil gauge Ölstandsauge Vista nivel de aceite regard du niveau d’huile medidor do nível de óleo

oil scraper ring Ölabstreifring Segmento de engrase segment racleur d’huile anel raspador de óleo

optional optional opcional en option opcional

O-ring O-Ring Junta tórica joint torique junta tórica

pipe Rohrleitung Tubo de unión tuyau tubo de conexão

pipe Verbindungsrohr Tubería tube de raccordement tubo de conexão

pipe clamp Rohrschelle Abrazadera collier d’attache pour tuyaux abraçadeira

Page 6 of 9 12.09.2013
 Glossary - EN(GB) - DE - ES - FR - PT(BR)

EN(GB) DE ES FR PT(BR)

piping Verrohrung Tuberías tuyauterie tubgem

piping 2-cylinder Verrohrung x-Zylinder Tuberías x-cilindros tuyauterie cylindre x tubagem x-cilindros

piston Kolben Pistón piston pistão

piston pin Kolbenbolzen Bulón del pistón axe de piston pino do pistão

piston ring Kolbenring Segmento del pistón segment de piston anel do pistão

plate Distanzblech Calzo tôle d’écartement chapa

Pos. (position) Pos. (Position) pos. pos. (position) pos.

postion Position posición position posição

pressure gauge Manometer Manómetro manomètre manômetro

pressure gauge screwing Manometerverschraubung Atornilladura manómetro vissage du manomètre roscagem do manômetro

pressure pipe Druckleitung Tubería de presión conduite sous pression tubo de pressão

pressure pipe cyl. X Druckleitung Zyl. X Tubería de presión cil. X conduite sous pression cyl. X tubo de pressão cil. X

pressure switch Druckschalter Preostato manostat pressostato

pressure valve Druckventil Válvula de descarga soupape de pression válvula de pressão

quantity Menge Cantidad quantité quantidade

radial seal Radialwellendichtring Retén radial bague à lèvres avec ressort anel de vedação radial

repair kit Reparatursatz Juego de reparación kit de réparation kit de reparos

Juego de reparación válvula de kit de réparation soupape de kit de reparos válvula de
repair kit pressure valve Reparatursatz Druckventil
descarga pression pressão

Page 7 of 9 12.09.2013
 Glossary - EN(GB) - DE - ES - FR - PT(BR)

EN(GB) DE ES FR PT(BR)
Reparatursatz Juego de reparación válvula de kit de réparation soupape kit de reparos válvula de
repair kit ring laminated valve
Ringlamellenventil lámina anular annulaire à lamelles lamelas anelares
Juego de reparación válvula de kit de réparation soupape kit de reparos válvula de
repair kit suction valve Reparatursatz Saugventil
succión d’aspiration sucção
retainer Sprengring Anillo de sujeción circlip anel de retenção

retaining ring Sicherungsring Anillo de seguridad bague de retenue anel de retenção

right rechts derecho droite direita

ring laminated valve Ringlamellenventil Válvula de lámina anular soupape annulaire à lamelles válvula de lamelas anelares

RIPP-screw RIPP-Schraube Tornillo RIPP vis RIPP parafuso RIPP

roulement à rouleaux
roller bearing Zylinderrollenlager Rodamiento de rodillo cilíndrico rolamento do cilindro
cylindriques
pino com ranhuras
round head grove pin Halbrund-Kerbnagel Pasador ranurado semicircular clou cannelé à tête demi-ronde
semiredondo
safety valve Sicherheitsventil Válvula de seguridad soupape de sûreté válvula de segurança

screw Schraube Tornillo vis parafuso

screw cap Einschraubstutzen Atornilladura manchon vissé bocal roscado

screw cap Verschr. (Verschraubung) Atornilladura viss. (vissage) roscagem

screw cap Verschraubung Atornilladura vissage roscagem

screwing Gerade Verschraubung Atornilladura vissage droit roscagem reta

screwing Gerader Zwischenstutzen Atornilladura manchon intermédiaire droit bocal intermediário reto

screwing Zwischenstutzen Atornilladura manchon intermédiaire bocal intermediário

solenoid valve Elektromagnetventil Válvula electromagnética soupape à électroaimant válvula solenóide

Page 8 of 9 12.09.2013
 Glossary - EN(GB) - DE - ES - FR - PT(BR)

EN(GB) DE ES FR PT(BR)

spare part Ersatzteil Pieza de repuesto pièce de rechange peça de reposição

nomenclature des pièces de
spare parts Ersatzteilliste piezas de repuesto lista de peças de reposição
rechange
spring washer Federring Arandela elástica rondelle-ressort mola-prato

stage Stufe etapa niveau etapa

suction pipe Saugleitung Tubería de succión conduite d’aspiration tubo de sucção

suction valve Saugventil Válvula de succión soupape d’aspiration válvula de sucção

switch box Schaltschrank Armario de distribución armoire de distribution armário de distribuição

châssis de l’armoire de quadro do armário de
switch box frame Schaltschrankrahmen Marco armario distribución
distribution distribuição
Marco izquierdo del armario de châssis de l’armoire de quadro do armário de
switch box frame left Schaltschrankrahmen links
distribución distribution, gauche distribuição esquerda
Marco derecho del armario de châssis de l’armoire de quadro do armário de
switch box frame right Schaltschrankrahmen rechts
distribución distribution, droite distribuição direita
thermostate Thermostat Termostato thermostat termostato

tongue Passfeder Muelle de ajuste ressort d’ajustage mola de ajuste

tongue valve Zungenventil Válvula de lengüeta clapet à languette válvula de membrana

protection contre les contacts
touch protection Berührungsschutz Protección contra el contacto proteção contra toque
accidentels
transmission shaft Antriebswelle Árbol de transmisión arbre d’entraînement eixo de transmissão

valve flap Ventildeckel Tapa de válvula couvercle de soupape cobertura da válvula

Control visual de rueda contrôle visuel de la roue
visual gear control device Zahnradsichtkontrolle controle visual da roda dentada
dentada dentée
washer Scheibe Disco rondelle disco

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