USE AND MAINTENANCE MANUAL
Contents
1. F2 F3 FUSIBILI fuse 5x20 1A T F4 FUSIBILE fuse 5x20 1A F FS FUSIBILE fuse 5x20 638mA T FU FUSIBILI MOTORE ELETTROVENTOLA fan motor fuse M MOTORE COMPRESSORE compressor motor MU MOTORE ELETTROVENTOLA fan motor T TRASFORMATORE transformer K1 CONTATTORE LINEA MOTORE COMPRESSORE compressor motor line contactor CONTATTORE TRIANG MOTORE COMPRESSORE compressor motor delta contactor CONTATTORE STELLA MOTORE COMPRESSORE compressor motor star contactor CONTATTORE MOTORE VENTILATORE fan motor contactor Y ELETTROVALVOLA solenoid valve D CENTRALINA FIAC CHECK CONTROL CRS fiac check control Basic BT SENSORE TEMP OLIO oil temperature sensor SE PULSANTE EMERGENZA emergency push button F1 S1 RELE TERMICO MOTORE COMPRESSORE RESET compressor motor thermal relay F6 S6 RELE TERMICO MOTORE VENTILATORE RESET fan motor thermal relay S PRESSOSTATO DI SERVIZIO pressure switch KR RELE SEQUANZA FASI phase sequency relay 19 1182 1 18 17 17 28 17 21 22 17 l l pae bs ea Bs BEI A lA ze 312 La E3 Ss s6 fs S1 fs 19 Es D PE 8 6 13 f 1 K1 K3 K3 K2 7 14 4 2 2 5 7 ni 13 oa ake 4 K a KZa _2. E2 T al SISI i H az fre 1 17 ke fz 21 22 1 F4 La 19 E EA 57 307 B Fore Al 312 2 5 6 L3E3 2 ESA sE ls S6 S16 HA aw E D PE 8 E 13 13 1 1 2 16 Li ses Axa 37 27 E 14 14 2 2 3P2 5 jua LI J8 al 7 B ni 13 3 Kia K2a Kal Y KUa i AZ pu A2 i AZ 8 8 8 C 08 16 4 BT DISPOSIZIONE MORSETTIERA INFERIORE ASEOS ZIONE MORSETTIERA SUPERIORE Lower terminal board connection E eara ra rs rujrulrul e 13 2 2 2 y 119195 L3 L2 L4 PE LEGENDA legend oF F2 F3 FUSIBILI fuse 5x28 1A T F4 FUSIBILE fuse 5x20 1A F TR ER E FS FUSIBILE fuse 5x20 63 mA T FE RE FU FUSIBILI MOTORE ELETTROVENTOLA fan motor fuse SREY FER TENSION 380460 M MOTORE COMPRESSORE compressor motor MU MOTORE ELETTROVENTOLA fan motor T TRASFORMATORE transformer K1 CONTATTORE LINEA MOTORE COMPRESSORE compressor motor line contactor CONTATTORE TRIANG MOTORE COMPRESSORE compressor motor delta contactor CONTATTORE STELLA MOTORE COMPRESSORE compressor motor star contactor KU CONTATTORE MOTORE VENTILATORE fan motor contactor Y ELETTROVALVOLA solenoid valve D CENTRALINA FIAC CHECK CONTROL CRS fiac check control Basic BT SENSORE TEMP OLIO oil temperature sensor SE PULSANTE EMERGENZA emergency push button F1 S1 RELE TERMICO MOTORE COMPRESSORE RESET compressor motor the
3. nico nono ncn naar cnc nanannnnnns 6 1 1 Replace the oil filter 6 1 2 Replace the oil separator filter i 6 1 3 Replace the air filter 6 1 4 Tighten screws cables remote switches K1 K2 K3 and KV just 15 20HP Check cables cion ai Tighten the belt cnn 6 1 5 Check the hydraulic Seals i Replace OR on delivery flange i Tighten SCrOWS i Check cooling fans i Clean the air oil radiator ii 6 1 7 Clean the dust removal pre filter i 6 1 8 Clean the COMPressor i Check the electric fan ii 17000 18000 Ghange the il i cai ea 6 1 1 Replace the oil filter 6 1 2 Replace the oil separator filter i 6 1 3 Replace the air filter i 6 1 4 Tighten screws cables remote switches K1 K2 K3 and KV just 15 20HP Replace the belt ecccccccesseeccceeeeesseeeeneeeeesseeeeeeeeenseeeeeeeeees 6 1 6 Check the hydraulic Seals i Overhaul in take valve i Clean the air oil radiator i 6 1 7 Clean the dust removal pre filter 6 1 8 20000 21000 Change the dll cronica iaa 6 1 1 Replace the oil filter 6 1 2 Replace the oil separator filter i 6 1 3 Replace the air f
4. 41 44 7 DRAWINGS AND DIAGRAMS 7 2 Pneumatic diagrams GABA ORBISOUOUN WOLIWLSOWUELL VIONTVA LI ue 911 99 9 VIOLNIAOYLLITA OL GABA Ajeyes yZZAMNOIS IG VIONTVA 6 Joye pel Jl8 VIV IUOLVIAVU V8 JOJE P81 110 0170 FHOLVIAVI 8 4044 110 0110 OYHINA Z GAJBA eunsseld WNWIU W YWININ INOISSIYd IG WIOATWA 9 Joyy J0 81edes I0 SHOLYITOSIA OY VIOONLYVO S 10 8901 JOJEJEdOS IHOLVUVAAS OIOLYIYAS Y pue Je ALIA VW FHOSSAUANOE SAJBA OAEJUYANOIZVYISV IG WIOATWA Z Jey 118 SNEJUYAINOIZVHIASV IG OWL TIA L puebeyyqN3931 wo LX i e Na dm lt gt CAN 4 lt gt MOL 110 418 ON10 VIHV OSSMA MOB 1I0 OI10 OSSNTI lt lt moyseyidyOssnis lt lt IN weJbejp euopnesodo 3TYNOIZNNI VWAHOS 42 44
5. Connecting the compressor to the electrical mains power supply A The compressor is to be connected to the electrical mains by the customer to his exclusive liability employing specialised personnel and in compliance with the Accident Prevention Norms EN 60204 INSTRUCTIONS FOR CONNECTING TO EARTH This compressor must be connected to earth while in use in orderto safeguard the operator against electrical shocks The electrical connection must be carried out by a skilled engineer Itis advisable never to dismantle the compressor or even to make any other connections All repairs must be carried out exclusively by authorised service centres or other qualified centres The earth wire of the power supply cable of the compressor must be connected only and exclusively to the PE pin of the terminal board of the actual compressor Before replacing the plug of the power supply cable ensure that the earth wire is connected EXTENSION CABLE Use only extension cables with plug and earth connection Never use damaged or squashed extension cables Ensure that the extension cable is in a good state of wear When using an extension cable ensure that the cross section of the cable is sufficient to convey the current absorbed by the product to be connected If the extension cable is too thin there could be drops in voltage and therefore loss in power and overheating of the equipment The extension cable of the three phase compressors must have a cross section in
6. with relative humidity higher than 80 and at an altitude of more than 1 000 mt Space required for maintenance The compressor must be installed in a large room that is well aired dust free and sheltered away from rain and frost The compressor takes in a large amount of air that is required to ventilate it internally A dusty atmosphere would in time cause damages and inefficient performance Part of the dust once inside is taken in by the air filter causing it to clog rapidly and another part of dust will settle on the components and will be blown against the cooling radiator consequently compromising the efficiency of the heat exchanger It is therefore obvious that the cleanliness of the area in which the compressor is installed is crucial for the correct efficiency of the machine avoiding excessive running and maintenance costs To facilitate maintenance jobs and to create a favourable circulation of air the compressor must have a sufficient free space all around it see fig i 2 5 mt 1 mt 1 mt 1 mt 14 44 INSTALLATION 4 GB 4 3 The room must be provided with outlets that lead outdoors near the floor and ceiling that will allow the natural circulation of air If this is not possible install some fans or extractors that guarantee a higher air flow rate than that taken in by the com
7. GB USE AND MAINTENANCE MANUAL SILENT ELECTRIC ROTARY SCREW COMPRESSORS WARNING Read this manual carefully and in full before using the compressor 1 44 IMPORTANT INFORMATION Read all the operational instructions safety recommendations and all warnings provided in the instruction manual Most accidents encountered when using the compressor are merely due to the failed observance of basic safety standards Accidents are prevented by foreseeing potentially hazardous situations and observing the appropriate safety standards The fundamental safety standards are listed in the SAFETY section of this manual and also in the section involving the use and maintenance of the compressor Hazardous situations to be avoided in order to prevent serious personal injuries and machine damages are listed in the WARNINGS section of the instruction manual or are actually printed on the machine Never use the compressor improperly but only as recommended by the Manufacturer The Manufacturer reserves the right to up date the technical information given in this manual without notice 2 44 FOREWORD 0 GB Index q alii ae 5 0 1 How to read and use the instruction Manual 0 0 5 0 1 a Importance of the Manual riiiiiii 5 0 1 b Conserving the Manual rien 5 0 1 c Gonsulting the manual irsliaoglil ai e iii 5 0 1 d
8. GB 7 DRAWINGS AND DIAGRAMS 1 2 3 4 Lt F2 12 A L3 F3 2 Fo i B 3 w c WECTON 730V p u2 wi w LLL D No No M el ill y Wi W E F u y TRATT TERMICO O SUPER MATERIALE y DATA 08 0508 GRADO DI PRECISIONE MEDIO SCALA 244 Dis AV UNI 6307 83 TRY PARTCOLARE Schema elettrico di potenza design AiR COMPRESSORS CHS y Promem neea C ASSOHP 400V 50 60Hz TELEAVV a vistato copiare o divulgare CODICE GREZZO CODICE PARTICOLARE Foa uio li SECRS30POT 1 LOT CIT TT TI 4 1 2 3 l 4 A B c D E E F F TRATT TERMICO O SUPER MATERIALE a Da GRADO DI PRECISIONE MEDIO PR g amp G _ PARTICOLAFE Schema elettrico di potenza pa i Porere nawa ASSOHP 230V 50 60Hz TELEAVV 4 Vietato copiare o dvuigare CODICE GREZZO CODICE PARTICOLARE 230 ce SECRS30POTI I 1 l L I I I I 4 40 44 DRAWINGS AND DIAGRAMS 7 GB KEY IG KR KM KT VC EVB EVS EVF 1 CONDUTTORI DI POTENZA COLORE NERO TIPO CAVO NO7V K SEZ 35 mm2 DA L1 L2 L3 A KI SEZ 16 mm2 DA KI A K2 SEZ 10 mm2 DA K2 A K3 SEZ 1 mm2 PER COLLEGAMENTO A FV KV E KR 2 CONDUTTORI CIRCUITO AUSILIARIO COLORE ROSSO TIPO CAVO NO7V K SEZ 0 75 1 mm2 3 CONDUTTORI ALIMENTAZ PRIMARIO TRASFORMAT COLORE
9. NERO TIPO CAVO N07V K SEZ 1 mm2 Rev DATA DIS DESCRIZIONE TRATT TERMICO O SUPER MATERIALE DATA 210706 DATA _ QUOTE SENZA INDICAZIONE DI TOLLERANZA GRADO DI PRECISIONE MEDIO g Laffi A UNI EN 22768 1 PARTICOLARE PESO SCHEMA ELETTRICO DI POTENZA MACCHINA SCALA PROPRIETA RISERVATA CRS 40 230V 50 60Hz TELEAVV giciato copiare o NOTE CODICE FOGLIO Saute autorizzazione SECRS40POT230 pa Main ON OFF switch Refrigeration compressor Compressor start relay Compressor electric motor Compressor protection trip switch Condenser fan a m Hot gas by pass solenoid valve 1 CONDUTTORI DI POTENZA COLORE NERO TIPO CAVO NO7V K SEZ 10 mm2 DA L1 L2 L3 A KI E K2 SEZ 6 mm2 DA K2 A K3 SEZ I mm2 PER COLLEGAMENTO A FV KV E KR 2 CONDUTTORI CIRCUITO AUSILIARIO COLORE ROSSO TIPO CAVO NO7V K SEZ 0 75 1 mm2 3 CONDUTTORI ALIMENTAZ PRIMARIO TRASFORMAT COLORE NERO TIPO CAVO NO7V K SEZ mm2 Separator condensate drain solenoid valve Filter condensate drain solenoid valve TRATT TERMICO O SUPER MATERIALE DATA 21 07 06 DATA 1 QUOTE SENZA INDICAZIONE DI TOLLERANZ GRADO DI PRECISIONE MEDIO g DIS Laffi A UNI EN 22768 1 P Kg 1 PARTICOLARE SCHEMA ELETTRICO DI POTENZA MACCHINA SCA momraastavara CRS 40 400V 50 60Hz TELEAVV ki vietato copiare 0 divulgare a terzi NOTE CODICE FOGLIO senza la nostra autorizzazione S ECRS 40POT A ESO I ALA 1 4
10. In order to use the compressor in complete safety read the safety standards given in section 1 3 before reading this section Preparing to use the compressor Operational principle The air taken in by the filter passes through a valve that controls its flow rate to the screw where mixing with the oil it is compressed The air oil mix produced by compression reaches a tank where the initial separation by gravity is achieved as the oil is heavier it settles on the bottom it is then cooled and sent through a heat exchanger filtered and injected into the screw again The oil is required to reduce the heat produced by compression to lubricate the bearings and to maintain the coupling of the screw lobes The air is sent through an oil separator filter to be additionally purified from residue oil particles It is cooled by means of another heat exchanger and is finally outlet to be used at low temperature and with acceptable oil residues lt 3p p m A safety system controls the crucial points of the machine and points out any abnormal conditions The temperature of the air oil mix at the screw outlet is controlled by a thermostatic probe which stops the compressor if the temperature is too high 105 C A thermal protection device is fitted on the electric motor which stops the machine if necessary Tank The tank is used to store and ensure further stability of the air pressure The capacity of the tank must be established in relation to
11. K3a h KU al TT AZ AZ AZ i AZ 5 esla 4 4 4 Sora tomoresson g 8 E B es 15 16 a DISPOSIZIONE MORSETTIERA SUPERIORE ST DISPOSIZIONE MORSETTIERA INFERIORE Upper terminal board connection Lower terminal board connection F2 F3 F4 F5 FV Fv Fv e 13 22 19 19 L3 L2 L1 PE LEGENDA legend PA g o D TRET DESCRIZIONE MATERIALE MM COM PMAT DATA 284005 QUOTE SENZA NDIAZDNE DITOLLERANZA GRADO DIPRECISIDNE M EDD os e fon UNTEN 227684 PARTICOLARE SCHEMA ELETT W MACCHINA CRS 25H P 230 400V 50 60H z RING DIAGRAM SECRS25 1 F2 F3 FUSIBILI fuse 5x20 1A T F4 FUSIBILE fuse 5x20 1A F FS FUSIBILE fuse 5x20 638mA T FU FUSIBILI MOTORE ELETTROVENTOLA fan motor fuse M MOTORE COMPRESSORE compressor motor MU MOTORE ELETTROVENTOLA fan motor T TRASFORMATORE transformer CONTATTORE LINEA MOTORE COMPRESSORE compressor motor line contactor CONTATTORE TRIANG MOTORE COMPRESSORE compressor motor delta contactor CONTATTORE STELLA MOTORE COMPRESSORE compressor motor star contactor CONTATTOR
12. compressor works at a room temperature lower than the minimum value the condensate could be separated within the circuit and therefore the water would mix with the oil thus deteriorating the quality of the latter failing to guarantee the even formation of the lubricating film between the moving parts with the possibility of seizure If the compressor works at a room temperature higher than maximum value the compressor would take in air that is too hot which would prevent the heat exchanger from adequately cooling the oil in the circuit raising the working temperature of the machine thus causing the thermal safety device to trip which stops the compressor due to an excessive temperature of the air oil mixture at the screw outlet The maximum temperature of the room is to be measured while the compressor is running LIGHTING The compressor has been designed in compliance with legal prescriptions and in the attempt to minimise shadow zones to facilitate the operator s job The lighting system of the factory is to be considered as crucial for the operator s safety The room in which the compressor is installed must have no shadow zones dazzling lights or stroboscopic effects due to the lighting ATMOSPHERE WITH RISK OF EXPLOSION AND OR FIRE The standard compressor is not pre arranged or designed to work in rooms subject to the risk of explosion or fire The performance of the compressor may decrease at the maximum permitted ambient temperature
13. switch of the compressor motor trips andthe machine stops red LED Message on display COMP TRIP SWITCH ALARM The trip switch of the fan motor trips and the machine stops red LED Message on display FAN TRIP SWITCH ALARM The compressor fails to start the screw unit is running in the wrong direction Excessive temperature of air oil mix outlet from the screw 105 C The trip switch that protects the compressor motor has tripped The trip switch that protects the fan motor has tripped Invert the phase wires press the RESET button on the electronic board and start again Check the electric connections of the probe Check the oil level check if the radiator is clean check if the pre anti dust filter is clean check the ambient temperature check the minimum distance of the compressor from the walls of the room check if the soundproof panels are firmly secured in place pressurization of the ventilation air To start the machine again wait for the tempera ture to drop to 94 C then press the RESET button on the panel of the electronic board If the problem persists the thermostat valve could still be closed Check if the electric power supply is correct check if the 3 power supply phases are roughly the same value Check if the cables are firmly connected to the terminal board check if the electric cables have melted Check if the suction grid of the cooling fan o
14. the consignment documents Dispose of the packing in compliance with current standards in force in the country of installation Note The machine must be unpacked by qualified personnel using appropriate tools and equipment Storing the packed and unpacked compressor For the whole time that the compressor is not used before unpacking it store it in a dry place at a temperature between 5 C and 45 C and sheltered away from weather For the whole time that the compressor is not used after unpacking it while waiting to start it up or due to production stoppages place sheets over it to protect it from dust which may settle on the components The oil is to be replaced and the operational efficiency of the compressor is to be checked if it is not used for long periods 13 44 GB 4 INSTALLATION 4 1 4 2 Installation A In order to use the compressor in complete safety read the safety standards given in section 1 3 before reading this section Admitted surrounding conditions Position the machine as established when the order was placed Failing this the Manufacturer is not liable for any inconveniences that may possibly arise Unless pointed out otherwise when placing the order the compressor must work regularly in the surrounding conditions indicated below ROOM TEMPERATURE The room temperature must not be lower than 5 C or higher than 45 C to ensure the ideal operational efficiency of the compressor If the
15. the new filter cartridge Replacing the filter cartridge of the oil separator Read all indicated in Section 6 1 before starting any maintenance jobs Open the side LH panel to gain access to inside the compressor Disassemble filter cartridge 1 using a chain spanner and replace with a new one Lubricate the sealing gasket before screwing the filter cartridge tight Manually tighten the new filter cartridge 31 44 GB 6 COMPRESSOR MAINTENANCE 6 1 4 6 1 5 Replacing the air filter cartridge Read all indicated in Section 6 1 before starting any maintenance jobs Open the side LH panel to gain access to inside the compressor Remove the screws 2 and also the cover 1 Replace the cartridge of the air filter Tightening the belt Read all indicated in Section 6 1 before starting any maintenance jobs Open the side LH panel to gain access to inside the compressor Every 500 hours of use it is advisable to check and maybe tighten the belt if necessary Using a dynamo meter apply a perpendicular force in point A of between 25N and 35N the belt must give by roughly 5mm Turn the nut 1 to tighten the belt Replacing the belt Read all indicated in Section 6 1 before starting any maintenance jobs Open the side LH and front panel Turn the nut 1 to slacken the belt Slide the belt out replace it with a new one and tighten as described in the previous section 5mm 32 44 COMPRESSOR M
16. the utility The features of the tank must strictly comply with the requirements established by current standards in the country of installation Carefully ensure that the safety devices of the tank are enabled and efficient 20 44 USING THE COMPRESSOR 5 GB 5 2 5 2 1 Controls indicators and safety devices of the compressor Control panel The control panel is made up of a set of buttons required for the main operational and control functions of the compressor 1 START I This button is used to turn the compressor on If there is a power shortage the compressor stops This button is to be pressed to start it again 2 STOP 0 Press this button to stop the compressor within a few seconds Itis better to stop the compressor using this button as the whole pneumatic circuit within the compressor drops to 0 bar 3 REDLED This points out that an alarm has triggered and the compressor stops or it points out that the compressor needs to be serviced in which case the compressor will continue to run regularly 4 DISPLAY The instrument shows the delivery temperature of the air oil mix the compressor stops when the air oil mix reaches 105 C in which case LED 3 lights up 5 GREEN LED This points out that the compressor is powered 6 RESET This button is used to reset an alarm 7 PROGRAM This button is used to activate the programming function 8 EMERGENCY PUSH BUTTON This mechanically blocking push button is used t
17. used for a few hours a day it is advisable to change the oil every 6 months A When you open tap 2 oil starts to drain from the screw unit therefore you need to have a pipe and container ready to collect the oil Unscrew the red cap 1 situated at the base of the screw unit Screw an attachment with tail piece supplied together with the compressor Open tap 2 Once emptied shut off tap 2 and remove the attachment with tail piece Fill up with oil to the rim of the union 4 then screw cap 1 back in place and close up the compressor again Once the oil and oil filter have been changed leave the compressor to run for roughly 5 minutes then turn it off and check the oil level again Check the oil level each month and check that it is up to the rim of the port 4 4 A Never mix differenttypes of oil therefore always ensure thatthe circuit is completely empty before filling up with oil Each time the oil is changed the filter is also to be replaced 30 44 COMPRESSOR MAINTENANCE 6 GB Replacing the oil filter cartridge Read all indicated in Section 6 1 before starting any maintenance jobs Replace the oil filter cartridge after the first 500 hours of use then every 2500 3000 hours and in any event each time the oil is changed Open the rear panel Disassemble filter cartridge 1 using a chain spanner and replace with a new one Lubricate the sealing gasket before screwing the filter cartridge tight Manually tighten
18. weekly and monthly start and stop times CLIENT SET UP Once you have gained access scroll the sub menus using the Up and Down arrow keys of the push button control panel press the DEFAULT to exit 1 PROGRAM CLOCK SET UP TIME hh mm Press PROGRAM again to access the date DATE SETTING gg mm aa The example display illustrates that you need to indicate the present time and date Once you have gained access scroll the sub menus using the Up and Down arrow keys of the push button control panel press the DEFAULT to exit 22 44 USING THE COMPRESSOR 5 GB 1 PROGRAM CLIENT SET UP DAILY WEEKLY AND MONTHLY START AND STOP SETTINGS Enabled YES 1 Disabled NO 2 If enabled you can use this function to set two daily start and two stop times by entering the start time and the stop time where hh stands for hours and mm stands for minutes At the end of the week you can set three inoperative periods where gg stands for days and mm stands for months To disable it press PROGRAM type in 2 using the UP arrow or DOWN arrow button press PROGRAM To enable it press PROGRAM type in 1 using the UP arrow or DOWN arrow button press PROGRAM To exit the menu press the DEFAULT key Once you are back on PRESS START TO START press the START key to start programming the cal
19. AINTENANCE 6 GB Cleaning the air oil radiator Read all indicated in Section 6 1 before starting any maintenance jobs Itis advisable to clean the radiator 1 on a weekly basis to remove impurities blowing it with an air gun from inside Open the rear panel with quick release locks and blow compressed air through the radiator from inside outwards making sure that no dirt settles inside the compressor Cleaning the dust removal pre filter Read all indicated in Section 6 1 before starting any maintenance jobs Clean the pre filter 1 from impurities on a weekly basis Slide the pre filter 1 out and blow with compressed air or replace if necessary Maintenance the electric motor The bearings of the electric motor are already lubricated and are maintenance free In normal surrounding conditions ambient temperature up to 30 C replace the motor bearings every 12000 hours of use In more severe surrounding conditions ambient temperature higher than 30 C replace the motor bearings every 8000 hours of use The bearings are to be replaced in any event every 4 years at the most Warning Before replacing the motor bearings contact our customer service department as established by the maintenance schedule 33 44 GB 6 COMPRESSOR MAINTENANCE 6 1 10 6 2 Draining the condensate only for models equipped with tank Read all indicated in Section 6 1 before starting any maintenance jobs Drain the condensate f
20. E MOTORE VENTILATORE fan motor contactor Y ELETTROVALVOLA solenoid valve D CENTRALINA FIAC CHECK CONTROL CRS fiac check control Basic BT SENSORE TEMP OLIO oil temperature sensor SE PULSANTE EMERGENZA emergency push button F1 S1 RELE TERMICO MOTORE COMPRESSORE RESET compressor motor thermal relay F6 S6 RELE TERMICO MOTORE VENTILATORE RESET fan motor thermal relay S PRESSOSTATO DI SERVIZIO pressure switch KR RELE SEQUANZA FASI phase sequency relay F2 T 13 Lt 1 H as 17 18 17 17 28 17 21 22 17 l 19 i as 5 ho bq w suba of 15E3 23 el a ASSE 19 Es D PE e noes 15 k3 x2 LT 4 2 2 3P2 CA 7 la ha 13 ha sa tT K1ay K2a K3asl Y KU al TT AZ Az AZ i AZ 4 4 4 leaks g 8 E B es 15 16 a DISPOSIZIONE MORSETTIERA SUPERIORE BT DISPOSIZIONE MORSETTIERA INFERIORE Upper terminal board connection Lower terminal board connection F2 F3 F4 F5 FV FU FU o 13 2 2 2 19 19 L3 L2 L1 PE LEGENDA legend man Es PAR Sl MATERIALE MM COM PMAT QUOTE SENZA NDIAZIONE DITOLLERANZA GRADO DIPRECISDNE MEDD UNIEN 227681 PARTICOLARE SCHEM A ELETT W IRING DIAGRAM CRS 30H P 230 550 60H z NOTE CODIE SECRS30230 1 37 44 7 DRAWINGS AND DIAGRAMS
21. NA FIAC CHECK CONTROL CRS fise check comtrol Basie alve BT SENSORE TEMP OLIOVoil temperature sensor SE PULSANTE EMERGENZA emergency pusbbutton STM SENSORE TEMPERATURA MOTORE COMPRESSORE compressor motor temperature sensor TEMPERATURA MOTORE ELETTROVENTOLA fan motor temperature sensor TO DI SERVIZIO pressure switch E F a a ea mS E PARTICOLARE Schema elettrico di potenza mos a CESB5HP 400V 50 60Hz TELEAVV Visio coplare o divulgare CODICE GREZZO CODICE P ab mi SECRS25POT 1 I 4 PISPOSIZIONE MORSETTIERA INFERIORE terminal cu ion TERRA PER MOTORE M MV MOTOR EARTH Rev DATA DIS DESCRIZIONE TRATT TERMICO O SUPER DATA 210706 pata y JOUOTE SENZA INDICAZIONE DI TOLLERANZ ois tama korm o _ UNI EN 22768 1 PARTICOLARE ESO SCHEMA ELETT WIRING DIAGRAM ria MACCHINA PROPRIETA riservata CRS 40 400V 50 60Hz Vietato copiare o CODICE FOGLIO divulgare a terzi SECRS40400 1 MATERIALE senza la nostra autorizzazione U2 v2 w2 u2 v2 w2 ji X lA po EE de v1 wi 230 400V_60Hz MOTOR COMPRESSOR MIBOX 460 193V_60Hz_ 39 44
22. Symbols sed n e lio ia lia ila ili 6 General information 11100s0 rie 7 1 1 Identification data of the manufacturer and the compressor 7 1 2 Information on machine technical maintenance service 7 1 3 General safety warnings ici nia 7 Preliminary machine information ooooncccccnnnnnccnnnnonanconennnnnancnnnnnnns 10 2 1 General IESCTIPI ON viii cone ieenendet cone ciel cevdeatonesixedenenexenenensnenssoundensbeaeiaes 10 2 2 Intended Us icicuciia ia 10 2 3 Technical data iia raana Nian aisada aiaa s hakda aaan idana a 11 Transport Handling Storage cccceeeeee ieee 12 3 1 Transporting and handling the packed machine 12 3 2 Packing and unpacking cccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeesneeeeeneeeneneneeeseeeeeeees 12 3 3 Storing the packed and unpacked compressor 13 Installation lare 14 4 1 Admitted surrounding conditions rrrrrrrrreee rire 14 4 2 Space required for maintenance iiiiin 14 4 3 Positioning the compressor sssserereeeeeeeee nananana nen ze zanne 15 4 4 Connecting the compressor to the sources of energy and relative inspections 16 4 4 1 Connecting the compressor to the electrical mains power SUpplY 16 4 4 2 Connecting to the pneumatic mains
23. asioN Gv s Gv s S1 S SUIS Gv s Gv s Gv S Sv S Gv s xewyulw 3 spw elmyesadula jusiquiy OL OL OL OL OL OL OL OL OL oN Jnoy Jed syejs xe LS LS LS LS LS LS LS LS LS 99IM9S SS SS SS SS SS SS SS SS SS dl Buyyes vonoajoJd 0 0p 0 07 0 07 oc 0 celog cc 0 S 8L S3 S 8L S3 S 8L S3 MY dH indino 08 LON O8LOJMN 08LOJMN O9LOJIA O9LOJIN O9LOJIN 09LOIN 09LOAN O9LOJIA Il 10 0W 949919 a od 2 e gt e gt e gt e gt e gt e gt e gt g gt g gt wdd Jre Ul np s IO y ul yoedeo uey S9 S9 S9 S9 c 9 c 9 G 9 S9 c 9 I Ab yueouqn D ah D ah D ah D ah D ah D ah D ah D ah Dah y Bumy Jepno y ELL E LEL v 0pL 96 ELL Sol 62 96 801 wo 0078 OCLE 086 Occ O6LE 07SE Oreg OLZZ os0e UIWI 2131 OSI Maatjap Je 994 00LMN 00LMN 00LMN pua mesos Aulo jo dA 88L EL Svl OL 9LL 8 88L EL StL OL 9LL 8 88L EL StyL OL 9LL 8 Isd 1eq eunssald Xen OtdH 0 dH G dH 9POIN ejep es1uysa ec 11 44 GB 3 TRANSPORT HANDLING STORAGE 3 1 3 2 AND CONDITIONED FOR SUCH PURPOSE Transport Handling Storage A In order to use the compressor in complete safety read the safety standards given in section 1 3 before reading this section Transporting and handling the packed machine A The packed compressor must be transported by qualified personnel using a forklift truck Before moving the machine ensure that the load bearing capacity of the forklift truck is sufficient to take the weight to be lifted Position the fork
24. be performed section 500 Change the oil ii 6 1 1 Replace the oil filter Cartridge i 6 1 2 Tighten screws cables remote switches K1 K2 K3 and KV just 15 20HP Tighten the Pal reor esrara e EE EETA ARREA 6 1 5 Check hydraulic seals nono 2500 3000 Change the Oil icono apnee la ich 6 1 1 Replace the oil filter cartridge i 6 1 2 Replace the oil separator filter i 6 1 3 Replace the air filter 6 1 4 Tighten screws cables remote switches K1 K2 K3 and KV just 15 20HP Clean the air oil radiator ii 6 1 8 Clean the dust removal pre filter 6 1 9 Draining the Condensate 6 1 10 5000 6000 A ire geen meres 6 1 1 Replace the oil filter Cartridge i 6 1 2 Replace the oil separator filter i 6 1 3 Replace the air filter i 6 1 4 Tighten screws cables remote switches K1 K2 K3 and KV just 15 20HP Tighten the belt aione r nAi EARS 6 1 5 Check the hydraulic Seals i Overhaul the in take valve i Clean the air oil radiator ii 6 1 7 Clean the dust removal pre filter eerren 6 1 8 Test the motor thermal and fan just 15 20HP protection switch Test the oil thermal protection SWitch 8000 9000 A lean 6 1 1 Replace the oil filte
25. compressor a on the ground 19 Using the COMPresSor ccoo uccnocicniciccn canina naciocancccaia ndice anadir 20 5 1 Preparing to use the COMpresSOF cccoccccccononannnncnnnnnnnnnnnnnnncnnnanannnnnnnnnnnnnnnnns 20 5 1 1 Operational Principles ita iii 20 A FL AAA A ee ene ee 20 5 2 Controls indicators and safety devices of the compressor 21 5 2 1 Control panel uil biella leo ital 21 5 2 2 DisplaV ccni hihi Leila LL iii ani 22 5 2 3 Auxiliary control devices riiiiin 25 5 3 Check the efficiency of the safety devices before starting 25 3 44 GB 5 4 Starting the compressofi uu 25 5 5 Stopping the COMPLESSO iii ita 26 6 Compressor maintenance 111srrrrrrsseeaziziiiiini 27 6 1 Instructions relative to inspections and maintenance jobs 27 6 1 1 Changing th Oils etsn aiar 30 6 1 2 Replacing the oil filter cartridge ccseeeceeeeeseeeeeeeeeensneeeeeeeeeesneeeeeeeeesneeaeeeeeensneceeeeeeenanens 31 6 1 3 Replacing the filter cartridge of the oil separator sesseeeeeeesseeeeeeeeeesneneeeeeeenseeseneeeneees 31 6 1 4 Replacing the air filter cartridge ccceceeeeeceeeeeeeeeeeeeeeesneeeeeeeeensneeeeeeeeensneceeeeeeensneceeeeeeenes 32 6 1 5 Tightening the belt rrerezi eri 32 6 1 6 Replacing the belt ccccsseeeeceeeeeseeeeeeeeeen
26. cription The rotary screw compressor has been specifically designed aiming at minimising maintenance and labour costs The outside cabinet is completely covered in sound proof and oil proof panelling thus ensuring its extended and lasting wear The components have been arranged so that all vital parts can be easily reached for maintenance purposes simply by opening dedicated panels with quick release locking devices The filters and adjustment and safety devices oil filter air filter oil separator filter regulator valve minimum pressure valve max pressure safety valve thermostat belt tightener screw compression unit pressure switch and oil separator tank emptying and filling taps are all fitted on the same side The dryer series has been devised with the intention of enclosing a complete compressed air system in one compact machine It is indeed connected to a dryer that is capable of supplying dry air to ensure the perfect and lasting use of the tools Note The tanks of the compressors have been manufactured in compliance with the EEC 404 87 Directive for the European market The compressors have been manufactured in compliance with the EC 37 98 Directive for the European market Note Check your model on the identification nameplate fitted on the compressor Itis also indicated in this manual ADVISED LUBRICANTS Always use oil for turbines with approximately 46 cSt at 40 C and a pour point of at least 8 10 C The flash po
27. e compressor A GENERAL HAZARDOUS SITUATION An additional note will point out the type of hazard involved Meaning of the indications Warning This points out a potentially hazardous situation which if ignored could cause personal injury and machine damage Note This enhances crucial information A RISK OF ELECTRIC SHOCK Warning the electrical power supply of the compressor must be disconnected before doing any jobs on the compressor RISK OF SCOLDING Warning be careful when touching the compressor as some parts of it could be very hot 6 44 GENERALINFORMATION 1 GB 1 1 1 2 1 3 General information Identification data of the manufacturer and the compressor COMPRESSOR IDENTIFICATION NAMEPLATE Example CE TYPE SERAL N ANNO DI PRODUZIONE PRESSURE Mal YEAR OF PROCLETION a ese E ARA RESA POTENZA ASSORBITA FAD iin C INPUT POWER w __ van Re del AMPERE MAX A FESO kgros __ RAM mnl gt Silent electric rotary screw compressor Information on machine technical maintenance service We remind you that our technical service department is at your complete disposal to help you resolve any problems that may possibly be encountered or to provide you with any other information necessary In the case of need contact Our CUSTOMER TECHNICAL SERVICE department or your local dealer The constant and efficient performance of the compressor is ensured only if or
28. e characteristics indicated in the table below Power Hp Rated voltage 380 415V Rated voltage 220 240V Magneto thermal switch Fuse Magneto thermal switch Fuse 25 63 A 63 A 80A 100A 30 80A 80A 125A 125A 40 100A 100A 160A 160A Note The fuse parameters indicated in the table above refer to the gl type standard If cartridge fuses type aM are used delayed the parameters in the table are to be reduced by 20 The parameters of the magneto thermal switches refer to switches type K Ensure that the installed power in kW is at least double the input of the electric motor All silent rotary screw compressors avail of Star Delta starting which enables the motor to start with as little electrical energy consumption upon start up as possible 17 44 GB 4 INSTALLATION The mains voltage must correspond with that indicated on the electrical data nameplate of the machine the admitted tolerance must remain within 6 EXAMPLE Voltage 400 Volt minimum tolerance 376 Volt Voltage 400 Volt maximum tolerance 424 Volt The plug of the power supply cable must never be used as a switch but must be plugged into a power socket that is controlled by an adequate differential switch magneto thermal switch An Never use the earth connection instead of the neutral The earth connection must be achieved according to the EN 60204 industrial safety standards Ensure that the mains voltage corresponds with that required
29. endar Note If an asterisk appears on the digital display while the compressor is running it means that the calendar is activated Dater Key Description Menu Mon Start 1 V hh mm The menu repeats itself you can set two START and two Stop 1 V hh mm STOP times per day by entering the start time and the stop Start 2 V hh mm time where hh stands for hours and mm for minutes Stop 2 V hh mm ATTENTION Do NOT set a start time that is later than the stop time LE START1 15 00 STOP 1 14 00 ON THE SAME DAY THE COMPRESSOR WILL NOT START BUT WILL WAIT FOR THE NEXT STARTING TIME Tue Start 1 V hh mm Stop 1 V hh mm Start 2 V hh mm Stop 2 V hh mm Wed V Thu V Fri V Sat V Sun V No work Start 1 V gg mm You can set 3 Nowork periods at the end of the week Stop 1 V gg mm where dd stands for days and mm for months Start 2 V gg mm Stop 2 V gg mm Start 3 V gg mm Stop 3 V gg mm 23 44 GB 5 USING THE COMPRESSOR STOP ALARMS This type of alarm stops the compressor and is pointed out by the fixed red LED ALARM on control panel and by a flashing message on the display explaining the cause for the alarm 1 The following may appear on the display ALARM ROTATION L JJ THE COMPRESSOR DOES NOT START This alarm means that the electrical power supply cables have been connected incorrectly
30. f the motor is clean and not clogged with anything paper leaves rags To start the machine again see note p 24 25 Check if the electric power supply is correct check if the 3 power supply phases are roughly the same value Check if the cables are firmly connected to the terminal board check if the electric cables have melted check FV fuses Check if the suction grid of the cooling fan of the motor is clean and not clogged with anything paper leaves rags To start the machine again disconnectit from the mains open the front panel of the compressor press the reset key in the electric cabinet see button 3 sect 5 2 3 and press RESET on the board 35 44 GB 6 COMPRESSOR MAINTENANCE Anomalies Causes Solutions Low temperature Temperature too low lt 5 C and Wait for the temperature to rise Message on display LOW TEM the compressor does not start higher or equal to 5 C press PERATURE ALARM RESET on the electronic board and then start again The compressor runs but fails to The suction valve fails to open Check if the operational pressure load switch is working efficiently check if the solenoid valve fitted on the suction regulator works regularly Normally Closed solenoid valve 36 44 DRAWINGS AND DIAGRAMS 7 7 7 1 Drawings and diagrams Wiring diagrams
31. for the correct operation of the compressor CHECK THE ROTATION DIRECTION When connecting the compressor to the electrical mains for the first time ensure that the STOP ALARM is not triggered which is pointed out by the red LED lit steady by a buzzer and by a warning on the display 1 stating ROTATION ALARM This alarm points out the incorrect connection order of the electrical power supply cables relative to the three phases that causes the incorrect rotation direction of the screw unit Once the cable connection has been rectified press the RESET key 3 Warning The incorrect rotation direction for more than 20 seconds will irreparably damage the compressor 18 44 me ED 4 4 2 Connecting to the pneumatic mains compressor a on the ground Always use pneumatic hoses for compressed air with the maximum pressure characteristics and cross section suitable for those of the compressor Do not try to repair a faulty hose Connect the compressor to the pneumatic mains using the fitting 1 pre arranged on the compressor Use hosing with a greater or same diameter as the compressor outlet Install two ball taps with capacity suitable for the compressor between the compressor and tank and between the tank and line Do not install non return valves between compressor and tank The non return valve is already installed inside the compressor 19 44 GB 5 USING THE COMPRESSOR 5 5 1 Using the compressor
32. gasoline thinners gas oil or other compounds that contain hydrocarbons may damage the plastic parts Clean them with a soft cloth and soapy water or other suitable liquids 23 USE ORGINAL SPARE PARTS ONLY The use of non original spare parts involves the annulment of the guarantee and the abnormal running conditions of the compressor Original spare parts are available c o the authorised dealers 24 DO NOT MODIFY THE COMPRESSOR Do not modify the compressor Contact an authorised service centre for all repairs required An unauthorised modification may impair the efficiency of the compressor and may also cause serious accidents for those who do not have the technical skill required to make such modifications 25 TURN THE COMPRESSOR OFF WHEN IT IS NOT IN USE When the compressor is not in use turn the main ON OFF switch OFF position 0 26 DO NOT TOUCH HOT PARTS OF THE COMPRESSOR To avoid scolding do not touch pipes the motor or any other hot part 27 DO NOT DIRECT THE JET OF AIR DIRECTLY TOWARDS THE BODY To avoid all risks never direct the jet of air towards people or animals 28 DO NOT STOP THE COMPRESSOR BY PULLING ON THE POWER SUPPLY CABLE Use the O I ON OFF buttons of the control panel to stop the compressor 29 PNEUMATIC CIRCUIT Use recommended pneumatic hoses and tools that can withstand the same or a higher pressure than the maximum running pressure of the compressor 30 SPARE PARTS Use only original and identical spa
33. heck comtrol Basie BT SENSORE TEMP OLIO oil temperature sensor SE PULSANTE EMERGENZA cmergency push bation STM SENSORE TEMPERATURA MOTORE COMPRESSORE compressor motor temperature sensor STMV SENSORE TEMPERATURA MOTORE ELETTROVENTOLA fan motor temperature sensor S PRESSOSTATO DI SERVIZIO pressure switch KR RELE SEQUENZA FASl phase sequency relay Rev DATA Dis PROPRIETA RISERVAT vietato copiare o divulgare a terzi senza la nostra autorizzazione DISPOSIZIONE MORSE TI Tn RA INFERIORE aan Ait MOTOR YAA DESCRIZIONE TRATT TERMICO O SUPER II e EE QUOTE SENZA INDICAZIONE DI TOLLIRANZ GRADO DI PRECISIONE MEDIO Pos wma form 7 UNS GN ZINE PARTICOLARE SCHEMA ELETT WIRING DIAGRAM MACCHINA CRS 40 _230V 50 60Hz CODICE SECRS40230 1 MATERIALE PESO Kg FOGLIO 38 44 DRAWINGS AND DIAGRAMS 7 GB LEGEND Megend JSIBIL Misse x20 1A T IBILE fase 5x20 1ACF P4 FUSIBILENuse x20 630mACT PV FUSIBILI MOTORE ELETTRO VENTOLA fan motor fuse M MOTORE COMPRESSORE compressor motor MV MOTORE ELETTROVENTOLA fan motor T TRASFORMATOREAransformer KI CONTATTORE LINEA MOTORE COMPRESSORE compressor motor line contactor K2 CONTATTORE TRIANG MOTORE COMPRESSORE compressor motor delta contactor K3 CONTATTORE STELLA MOTORE COMPRESSORE compressor motor star contactor KV CONTATTORE MOTORE VENTILATORE fan motor contactor Y ELETTROVALVOLA solenoid v D CENTRALI
34. iginal spare parts are used We recommend therefore that you strictly observe the indications provided in the MAINTENANCE section and to use EXCLUSIVELY original spare parts The use of NON ORIGINAL spare parts automatically annuls the guarantee General safety warnings Note The procedures provided in this manual have been written to assist the operator throughout the use and maintenance of the compressor A IMPORTANT INSTRUCTIONS FOR THE SAFE USE OF THE COMPRESSOR WARNING THE INAPPROPRIATE USE AND POOR MAINTENANCE OF THIS COMPRESSOR MAY CAUSE PHYSICAL INJURY TO THE USER YOU ARE RECOMMENDED TO CAREFULLY FOLLOW THE INSTRUCTIONS PROVIDED HEREAFTER TO AVOID SUCH RISKS 7 44 GB 1 GENERALINFORMATION 1 DO NOT TOUCH MOVING PARTS Never put your hands fingers or other parts of the body near moving parts of the compressor 2 NEVER USE THE COMPRESSOR WITHOUT THE SAFETY GUARDS FITTED Never use the compressor without all the safety guards fitted perfectly in their correct place i e panelling belt guard safety valve If these parts are to be removed for maintenance or servicing purposes ensure that they are put back in their original place perfectly before using the compressor again 3 ALWAYS WEAR SAFETY GOGGLES Always wear goggles or equivalent eye protection means Never direct compressed air towards any part of your body or that of others 4 PROTECT YOURSELF AGAINST ELECTRIC SHOCKS Avoid accidentally touching the me
35. ilter e 6 1 4 Tighten screws cables remote switches K1 K2 K3 and KV just 15 20HP Check the hydraulic Seals i Replace bearings and screw oil guard Replace the motor bearings i 6 1 9 Check or replace the thermostat valve of the screw unit 23000 24000 Change the Oil itn ati ee ieee 6 1 1 Replace the oil filter 6 1 2 Replace the oil separator filter 6 1 3 Replace the air filter i 6 1 4 Tighten screws cables remote switches K1 K2 K3 and KV just 15 20HP Tighten the belt E EER AA ERE 6 1 5 Replace flexible NOSES i Clean air oil radiator neeite eerieeeinrerrnrsrrrnern 6 1 7 Check the electric fan and replace if necessary The above described maintenance schedule has been planned bearing in mind all the installation parameters and recommended use of the Manufacturer The Manufacturer advises the customer to keep a record of all maintenance jobs performed on the compressor see Section 7 Drawings and diagrams 29 44 GB 6 COMPRESSOR MAINTENANCE 6 1 1 Changing the oil Read all the information provided in Section 6 1 before proceeding with any maintenance jobs Change the oil following the initial 500 hours of use and then every 2500 300 hours and in event once a year Ifthe compressor is only
36. int must be greater than 200 C A NEVER MIX DIFFERENT OIL QUALITIES SCREW OIL ESSO EXXCOLUB 46 BP ENERGOL HLP 46 SHELL CORENA D 46 TOTAL AZOLLA ZS 46 MOBIL DTE OIL 25 DUCKHAMS ZIRCON 46 Use oil with VG32 rating for cold climates and VG68 for tropical climates It is advisable to use synthetic oils for very hot and humid climates Intended use The silent rotary screw compressors have been designed and manufactured exclusively to produce compressed air EVERY OTHER USE DIFFERENT AND NOT FORESEEN BY ALL INDICATED RELIEVES THE MANUFACTURER OF POSSIBLE CONSEQUENT RISKS In any event the use of the compressor different to that agreed in the purchase order RELIEVES THE MANUFACTURER FROM ALL LIABILITIES WITH REGARD TO POSSIBLE MATERIAL DAMAGE AND PERSONAL INJURY The electrical system is not designed for the use in environments subject to explosion or for flammable products A NEVER DIRECT THE JET OF AIR TOWARDS PEOPLE OR ANIMALS NEVER USE THE COMPRESSED AIR PRODUCED BY LUBRICATED COMPRESSORS FOR RESPIRATORY PURPOSES OR IN PRODUCTION PROCESSES WHERE THE AIR IS IN DIRECT CONTACT WITH FOODSTUFFS UNLESS IT HAS BEEN FIRST FILTERED 10 44 PRELIMINARY MACHINE INFORMATION 2 891 0U moyym w Aue ye suonenea 0 alqns ale aulyoeu ay JO SUOISU WIP pue ezep eo1uyoa ay 910N aunsseid Buom wnwxew y ye y gp EF u y jo aguezsip e ye abuei aa e ul palnseau jano punos ZL Zl ZZ OL OL OL 69 69 69 v ap 919
37. is of crucial importance that the compressor works with all the panels firmly closed The failed observance of these and the following standards may lead to accidents that could cause personal injury and serious damages to the compressor or its equipment Before initially starting the compressor or following extended inoperative periods start the machine intermittently by pressing the START I STOP O buttons on and off for 3 or 4 seconds After this it is advisable to run the compressor fora few minutes with the air outlet tap open Then gradually shut off the air tap and load to maximum pressure checking if the inputs on each phase of the power supply are within the limits and also if the pressure switch trips At this stage check if the compressor runs idle for approximately 2 or 5 minutes as it is the electronic board that chooses the idle running time according to the type of use The pressure on the gauge on the panel must be between 1 and 2 bar The compressor will stop at the end of this time Discharge the air from the tank until the starting pressure is reached 2 bar difference compared to maximum pressure Shut off the air outlet tap and wait for the pressure switch to trip which will shut on the in take valve and close the internal discharge For the correct operation of the models equipped with dryer it is advisable to turn the dryer on 20 minutes before air is needed CALIBRATION AND SETTINGS MADE BY THE MANUFACTURER The minimum press
38. lothing ties or jewellery as these may get caught up in moving parts Wear caps to cover your hair if necessary 11 PRECAUTIONS FOR THE POWER SUPPLY CABLE Do not disconnect the power supply plug by pulling on the cable Keep the cable away from heat oil and sharp edges Do not stand on the electrical cable or squash it under heavy weights 12 LOOK AFTER THE COMPRESSOR WITH CARE Follow the maintenance instructions Inspect the power supply cable on a periodic basis and if damaged it must be repaired or replaced by an authorised service centre Visually check the outside appearance of the compressor ensuring that there are no visual anomalies Contact your nearest service centre if necessary 13 ELECTRICAL EXTENSIONS FOR OUTDOOR USE When the compressor is used outdoors use only electrical extensions manufactured for outdoor use and marked as such 14 WARNING Pay attention to everything you do Use your common sense Do not use the compressor if you are tired The compressor must never be used if you are under the effect of alcohol drugs or medicines which could make you tired 15 CHECK FAULTY PARTS OR AIR LEAKS Before using the compressor again if a safety guard or other parts are damaged they must be checked carefully to evaluate whether they may operate as established in complete safety Check the alignment of moving parts hoses gauges pressure reducers pneumatic connections and every other part that may be crucial forthe normal opera
39. o immediately stop the compressor in the case of emergency With the push button blocked it is impossible to start the compressor To start the compressor again turn the emergency button to release it then press button RESET 6 and button START I 9 TASTIFRECCIA These are used to move around within the menus 10 DEFAULT This is used to exit programming and to save the settings GB 5 USING THE COMPRESSOR 5 2 2 Display CHECK THE SETTINGS You can check the general settings of the control unit on the display by pressing the Up arrow or Down arrow key on the push button control panel Note Refer to the descriptions of the menus to find out exactly what the parameters listed below mean WEDNES 01 09 04 10 07 23 STAR DELTA TIME 5 sec AL THERMIC FAN Nr 0 ROTATION AL Nr 0 CRS REL 2 1 TIME STAND BY 27 MAY 2004 15 sec PROGRAM REL OL 00724 MAINTE OC 00483 1607 ALARM TEMP 105 C AL TEMPERATURE Nr 0 START_FOR_ACTIV SELECT LANGUAGE ENGLISH DATE DISABLED IF TEMPERAT UNIT DISABLED CELSIUS To exit press the DEFAULT key or wait a few seconds AL LOW TEMP Nr 0 DATE IF ENABLED AL THERMIC COMP Nr 0 MENUS ACCESSIBLE TO CLIENTS How to access Press the PROGRAM key How to exit Press the DEFAULT key To access press the PROGRAM key to see the following sub menus 1 Setting of the time and date CLOCK SET UP 2 Menu for setting the daily
40. pressor Ducts for the inlet and outlet of the air can be used in unfavourable environments These ducts must be the same size as the in take and delivery grid If these ducts are longer than 3 meters contact the Authorised Service Centre Note Aconveyance system can be fitted to recover the hot ventilation air delivered which can be used to heat the room or for other purposes It is crucial that the cross section of the system that recovers the hot air is greater than the total cross section of the grid slots plus the system must be equipped with a forced extraction system extractor fan to favour a constant downflow Positioning the compressor Once the position in which the compressor is to be installed has been identified ensure that the compressor is set on a flat surface The dryer versions are already internally pre arranged with all pneumatic connections between compressor tank and dryer No special foundations or bases are required for the machine Lift the compressor using a forklift truck forks at least 900 mm long and fit the vibration damping feet 1 and block with the nuts 2 under the four resting points where established Anti vibration feet are fitted on the floor based version as standard They can be fitted on the tank on request A Do not secure the compressor rigidly to the floor 15 44 GB 4 INSTALLATION 4 4 4 4 1 Connecting the compressor to the sources of energy and relative inspections
41. proportion with its length see table below CORRECT CROSS SECTION FOR THE MAXIMIM LENGTH OF 20M 220 240V 380 415V HP kW 50 60 Hz 50 60 Hz 3 ph 3 ph 25 18 5 35 mm 16 mm 30 22 50 mm 25 mm 40 30 70 mm 25 mm An Avoid all risks of electrical shocks Never use the compressor with damaged electrical cables or extension cables Regularly check the electrical cables Never use the compressor in or near water or near a hazardous area where electrical shocks may be encountered ELECTRICAL CONNECTION The three phase compressors L1 L2 L3 PE must be installed by a qualified engineer The three phase compressors are supplied without plug and cable 16 44 INSTALLATION 4 GB The power supply cable must be fed into the electrical cabinet through the dedicated cable clamps 1 situated on the RH side and on the electrical cabinet of the compressor Ensure that the cable cannot accidentally come into contact with moving or hot components possibly secure with clips The cross section of the wires of the power supply cable for lengths of 4 m and ambient temperatures of 50 C at the most must be as follows Power Hp Rated voltage 380 415V Rated voltage 220 240V 25 10 mm 25 mm 30 16 mm 35 mm 40 16 mm 35 mm It is advisable to install the connector magneto thermal switch and fuses near the compressor 3 m away at the most The magneto thermal switch and the fuses must have th
42. r 6 1 2 Replace the oil separator filter i 6 1 3 Replace the air filter i 6 1 4 Tighten screws cables remote switches K1 K2 K3 and KV just 15 20HP Replace the bEIt 6 1 6 Check the hydraulic Seals ii Clean the air oil radiator ii 6 1 7 Clean the dust removal pre filter 6 1 8 11000 12000 Change the Ol ii 6 1 1 Replace the oil filter 6 1 2 Replace the oil separator filter i 6 1 3 Replace the air filter reeniri testine reiia 6 1 4 Tighten screws cables remote switches K1 K2 K3 and KV just 15 20HP Tighten the belt 6 1 5 Check the hydraulic Seals i Check flexible hoses and replace if necessary Overhaul the oil separator flange Lubricate the minimum pressure valve eeeeeeeeees Overhaul the in take valve i Clean the air oil radiator i 6 1 7 Clean the dust removal pre filter nee 6 1 8 Replace the Rilsan hoses 6x4 and 8Xx10 Replace screw oil guard Replace the motor bearings 6 1 9 28 44 COMPRESSOR MAINTENANCE 6 GB Interval Jobs See hours to be performed section 14000 15000 Change the oil
43. re parts to replace worn or damaged ones Repairs must be made exclusively by authorised service centres 31 CORRECT USE OF THE COMPRESSOR The operator must be perfectly familiar with all the controls and compressor characteristics before starting to work with the machine 32 MAINTENANCE JOBS The use and maintenance jobs of the commercial components fitted on the machine but not indicated in this manual are indicated in the enclosed documents 33 DO NOT UNSCREW THE CONNECTION WHEN THE TANK IS PRESSURISED Do not unscrew the connection for any reason whatsoever with the tank pressurised without first checking if the tank is discharged 34 DO NOT MODIFY THE TANK It is prohibited to intentionally drill weld or deform the compressed air tank 35 IF THE COMPRESSOR IS USED FOR PAINTING JOBS a Do not work in closed rooms or near free flames b Ensure that the room in which you are working is sufficiently ventilated c Wear face and nose mask 36 DO NOT PUT OBJECTS OR PARTS OF THE BODY IN THE PROTECTION GRIDS Do not put objects or parts of the body in the protection grids to prevent physical injuries and damage to the compressor A KEEP THESE USE AND MAINTENANCE INSTRUCTIONS CAREFULLY AND GIVE THEM TO PERSONNEL WISHING TO USE THE COMPRESSOR WE RESERVE THE RIGHT TO MAKE MODIFICATIONS WHERE NECESSARY WITHOUT NOTICE 9 44 GB 2 PRELIMINARY MACHINE INFORMATION 2 1 2 2 Preliminary machine information General des
44. regarding the incorrect use and poor maintenance of the compressor The INSTRUCTION MANUAL is integral part of the compressor Ensure that any up dates forwarded by the Manufacturer are actually added to the manual If the compressor is sold on at a later date the manual must be given to the new owner Conserving the manual Use and read the manual with care being careful not to damage any part of it Do not remove tear or re write any parts of the manual for any reason whatsoever Keep the manual in a dry and sheltered place Consulting the manual This instruction manual is made up of the following FRONT COVER WITH MACHINE IDENTIFICATION DETAILED INDEX e INSTRUCTIONS AND OR NOTES ON THE COMPRESSOR The model and serial number of the compressor to which the manual refers and that you have purchased is found on the FRONT COVER The various SECTIONS in which all the notes relative to a certain subject are found in the INDEX All the INSTRUCTIONS AND OR NOTES ON THE COMPRESSOR aim at pointing out safety warnings and procedures required to use the compressor correctly 5 44 E rn 0 1 d Symbols used The SYMBOLS pointed out below are used throughout this manual and their purpose is that of drawing the operator s attention informing the latter how to behave and how to proceed in each operational situation O READ THE INSTRUCTION MANUAL Read the use and maintenance manual carefully before installing and starting th
45. relative to the three phases When connected correctly the screw unit and the fan motor will run in the correct direction To reset the machine Once you have connected the cables correctly press the RESET key on the control dashboard 2 When the maximum oil air limit is exceeded T gt T alarm 105 C 221 F the following appears on the display THE COMPRESSOR STOPS NB The fan of the oil air radiator starts To reset the machine once the temperature T has dropped by at least 10 C 18 F compared to the maximum temperature press the RESET button press the RESET button on the control panel so that the compressor is ready to start 3 The following may appear on the display J LOWTEMP ALARM THE COMPRESSOR FAILS TO START BECAUSE THE TEMPERATURE IS TOO LOW 6C To reset the machine If the temperature rises to 5C press the RESET button on the control panel and inside the machine so that the compressor is ready to start 4 When the trip switch of the electric motor of the compressor trips the following appears on the display COMPRESSOR TRIP SWITCH ALARM THE COMPRESSOR STOPS To reset the machine Wait for the motor to cool down Remove the cause that stopped the motor press the reset key of the trip switch F1 inside the electric cabinet and press the RESET button on the control panel Ver 25 30Hp Wait the automatic reset of thermal protection and pres
46. rmal relay F6 S6 RELE TERMICO MOTORE VENTILATORE RESET fan motor thermal relay S PRESSOSTATO DI SERVIZIO pressure switch KR RELE SEQUANZA FASI phase sequency relay vietato copiare o divukare a terzi senza lanosta autorizzazione PROPRIETA RISERVATA DESCRZDNE TRATT TERM TO O SUPER lt trattam ento tem ico gt MATERIALE MM COM PMAT DATA 281005 vara QUOTE SENZA NDTAZDNE DITOLLERANZA DO D IPRECIIONEM EDD do os poss UNTEN 22768 1 PARTICOLARE SCHEMA ELETT W IRING DIAGRAM CRS 30H P 400V 50 60H z NOTE CODIE SECRS30 1 PESO DISPOSIZIONE MORSETTIERA SUPERIORE Upper terminal board connection LEGEND Mlegend FI F2 FUSIBIL Ulese x20 BA T F3 FUSIBILE fiase x20 1A F Fa FUSIBILE use x20 630m ACT FV FUSIBILI MOTORE ELETTROVENTOLA fan motos fuse M MOTORE COMPRESSORE compressor motor MV MOTORE ELETTROVENTOLA fam motor T TRASFORMATOREAransformer KI CONTATTORE LINEA MOTORE COMPRESSORE compressor motor line contactor K2 CONTATTORE TRIANG MOTORE COMPRESSORE compressor motor delta contactor K3 CONTATTORE STELLA MOTORE COMPRESSORE compressor motor star contactor KV CONTATTORE MOTORE VENTILATOREMan motor contactor Y ELETTROVALVOL A solenoid valve D CENTRALINA FIAC CHECK CONTROL CRS fise c
47. rom the air tank at least once a month by opening tap 1 secured to the foot of the tank 7 For the pressure switch drain the condensate at least once a week when doing so make sure the machine is stopped and no longer electrically powered Get hold of a container to collect the condensate Open the left hatch of the machine with the dedicated key slowly open the cock2 leave itto blow until you no longer see any condensate coming out of the cock making sure to drain the condensate into the dedicated container A The condensate drained is considered as polluting mix that must not be thrown away outdoors It is advisable to use special water oil separators for its disposal Diagnosing the alarm status inconveniences faults A Before doing any job on the compressor ensure that e The main ON OFF switch is turned Off position 0 e The compressor is shut off from the compressed air system e The compressor and the internal pneumatic circuit are completely de pressurised If you are unable to rectify the anomaly encountered on your compressor contact your nearest authorised service centre 34 44 COMPRESSOR MAINTENANCE 6 GB COMPRESSOR Anomalies Causes Solutions The compressor runs inthe wrong direction Message on display ROTATION ALARM Oilalarm triggers and the machine stops red LED Message on display TEMPERA TURE ALARM Check the temperature on the display The trip
48. s RESET button on the board Ver 40Hp 5 The following may appear on the display FAN MOTOR TEMP ALARM 24 44 USING THE COMPRESSOR 5 GB 5 2 3 5 3 5 4 THE COMPRESSOR STOPS To reset the machine If the motor cools down and after you have removed the cause that stopped the motor press the reset key of the trip switch F6 inside the electric cabinet and press the RESET key so that the compressor is ready to start Ver 25 30Hp Wait the automatic reset of thermal protection and press RESET button on the board Ver 40Hp Auxiliary control devices 1 AIR CIRCUIT PRESSURE CONTROL GAUGE 2 MOTOR THERMAL PROTECTION SWITCH RESET BUTTON This is positioned inside the electrical cabinet Press this button to reset the motor thermal protection switch 3 FAN MOTOR TRIP SWITCH RESET BUTTON JUST 15 20 HP It is positioned in the electric cabinet and is pressed to reset the trip switch of the fan motor Check the efficiency of the safety devices before starting OIL LEVEL Check the oil level as indicated in Section 6 Compressor maintenance A DO NOT START THE COMPRESSOR WITH THE GUARDS OPEN TO AVOID INJURY DUE TO MOVING COMPONENTS OR ELECTRICALLY POWERED EQUIPMENT Starting the compressor A Following an electrical shortage the compressor will start only ifthe START I button is pressed Ventilation must occur as illustrated below 25 44 GB 5 USING THE COMPRESSOR 5 5 It
49. s exclusively as illustrated below Once the forks have been positioned in the points indicated lift slowly without jerking A Never stand near the area where the compressor is being handled and never stand on the crate while it is being moved Packing and unpacking To avoid damages and to protect the compressor during transport it is usually placed on a wooden pallet to which it is secured by screws and covered with cardboard All the shipping and handling information and symbols are printed on the compressor packing Upon consignment remove the top part of the packing and check if any damages have been encountered during transport If any damages are found caused during transport immediately make a written claim backed up with photos of the damaged parts if possible and forward everything to your insurance company with copy to the Manufacturer and transporter 12 44 TRANSPORT HANDLING STORAGE 3 GB 3 3 Using a forklift truck take the compressor as near as possible to the place where it is to be installed then carefully remove the protective packing without damaging it following the instructions below e Remove the packing 1 by sliding it away upwards e Unscrew screws 2 that block the feet that secure the compressor to the pallet only for models with tank Note The compressor can be left on the packing pallet to make it easier to move Carefully ensure that the contents correspond with all written in
50. seeeceeeesensseceeeeeseesseeeeceesesseeneneeseasseeeeeeeseaseeeeneaeees 32 6 1 7 Cleaning the air oli radiator ccceesccceseneeeeseeeeeeeeeeeeeseeeeeseaeseneeeesesseeeeesenaeseneneeseaneeeeneeas 33 6 1 8 Cleaning the dust removal pre filter ccccseccceseeeeeeeteeeeeeeeeeeeeeeeeesneaeeeeesesseseeeeesneeeeeneeas 33 6 1 9 Lubricating the electric MOtor rii iii 33 6 1 10 Draining the condensate iii 34 6 2 Diagnosing the alarm status inconveniences faults 34 7 Drawings and diagrams Goal iii 37 7 1 Wiring diagrams uao iii 37 7 2 Pneumatic ADAMS need 40 4 44 FOREWORD 0 GB 0 1 0 1 a 0 1 c Maintenance schedule Foreword How to read and use the instruction manual Importance of the manual This INSTRUCTION MANUAL has been written to guide you through the INSTALLATION USE and MAINTENANCE of the compressor purchased We recommend that you strictly observe all the indications given within as the ideal operational efficiency and lasting wear of the compressor depend on the correct use and methodical application of the maintenance instructions given hereafter Remember that when any doubts or inconveniences arise it is a good rule to always contact the AUTHORISED SERVICE CENTRES They are at your complete disposal for any explanations or jobs required The Manufacturer therefore declines all liabilities
51. tal parts of the compressor with your body such as pipes the tank or metal parts connected to earth Never use the compressor where there is water or in damp rooms 5 DISCONNECT THE COMPRESSOR Disconnect the compressor from the electric power supply and completely discharge the pressure from the tank before carrying out any service inspection maintenance cleaning replacing or inspection jobs of each part 6 ACCIDENTAL START UP Never move the compressor while it is connected to the electrical power supply or when the tank is pressurised Ensure that the main switch is turned OFF before connecting the compressor to the electrical power supply 7 STORE THE COMPRESSOR APPROPRIATELY When the compressor is not in use it must be stored in a dry room away from atmospheric agents Keep it out of children s reach 8 OPERATIONAL AREA Keep the work area clean and remove any tools that are not required Keep the work area sufficiently ventilated Never use the compressor in the presence of flammable liquids or gas The compressor may produce sparks while running Do not use the compressor where there may be paints gasoline chemical compounds glues and any other flammable or explosive material 9 KEEP THE COMPRESSOR OUT OF CHILDREN S REACH Prevent children or anyone else from touching the power supply cable of the compressor All outsiders must be kept at a safe distance from the operational area 10 WORK CLOTHES Do not wear unsuitable c
52. the STOP O button to stop the compressor within a few seconds Note By disconnecting the power supply from the external switch the compressor is completely without power 26 44 COMPRESSOR MAINTENANCE 6 GB 6 1 Compressor maintenance A In order to use the compressor in complete safety read the safety standards given in section 1 3 before reading this section Instructions relative to inspections and maintenance jobs The table that follows summarises the periodic and preventative maintenance jobs required to keep the compressor in an efficient operational state in time A brief description of the running hours after which the type of maintenance job is required A Before performing any jobs within the sound proof cabinet ensure that e The main line switch is turned off position 0 e The compressor is disconnected from the compressed air system e All the pressure has been released from the compressor and internal pneumatic circuit The compressor has been especially designed to facilitate maintenance jobs by simply opening the side panel with quick release locks Weekly it is advisable to inspect the compressor paying special attention to oil leaks and scale due to settled dust and oil Note If the compressor is used for more than 3000 hours year the jobs indicated herewith are to be performed more often 27 44 GB 6 COMPRESSOR MAINTENANCE Interval Jobs See hours to
53. tional efficiency of the compressor All damaged parts must be properly repaired or replaced by an authorised service centre or replaced following the instructions provided in instruction manual 16 USE THE COMPRESSOR EXCLUSIVELY FOR THE APPLICATIONS SPECIFIED IN THIS INSTRUCTION MANUAL The compressor is a machine that produces compressed air Never use the compressor for purposes other than those specified in the instruction manual 17 USE THE COMPRESSOR CORRECTLY Operate the compressor in compliance with the instructions provided in this manual Do not allow children to use the compressor or those who are not familiar with it 8 44 GENERALINFORMATION 1 GB 18 ENSURE THAT EACH SCREW BOLT AND GUARD IS FIRMLY SECURED IN PLACE 19 KEEP THE IN TAKE GRIDS CLEAN Keep the motor ventilation grids clean Regularly clean these grids if the work area is particularly dirty 20 OPERATE THE COMPRESSOR AT THE RATED VOLTAGE Operate the compressor at the voltage specified on the electric data plate You could damage or burn out the motor and other electric components if the compressor is operated at a higher or lower voltage than its rated voltage 21 NEVER USE THE COMPRESSOR IF IT IS FAULTY If the compressor is noisy or vibrates excessively when running or it seems to be faulty stop it immediately and check its efficiency or contact your nearest authorised service centre 22 DO NOT CLEAN PLASTIC PARTS USING SOLVENTS Solvents such as
54. ure values set are 6 8 and 11 for the 8 10 and 13 bar models respectively Warning Disconnect the electrical power supply form the compressor before opening the electrical cabinet The thermal relay 2 F1 is set according to the table below Power Hp Rated voltage 380 415V 3ph Rated voltage 220 240V 3ph 25 22A 38 1A 30 25 7A 44 3A 40 Disconnect the electrical power supply form the compressor before opening the electrical cabinet The setting of trip switch 2 must not differ from the table given above if the trip switch should trip check the input of the fan motor the voltage on the line terminals L1 L2 L3 during operation and the power connections inside the electric control panel and of the fan motor and FV fuses USEFUL TIPS FOR CORRECT COMPRESSOR PERFORMANCE For the correct operational performance of the machine under full continuous load at the maximum working pressure ensure that the temperature of the work area in a closed room does not exceed 40 C It is advisable to use the compressor with a maximum service of 80 in one hour under full load in order to ensure the correct efficiency of the product in time The thermal relay 3 F6 is set according to the table below Power HP Rated voltage 380 415V 3ph Rated voltage 220 240V 3ph 50Hz 50Hz 25 0 49A 0 85A 35 0 51A 1 0A 40 60Hz 60Hz 25 0 44A 0 76A 35 0 60 A 1 15A 40 Stopping the compressor Press
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