Home

TI008G0001 - KPM Kompresori

1. 110 112 TI008G0001 General Information Safety 2 06 Description of Pictograms Obligation pictograms These are circular signs on a blue background and the symbol is white Read the instructions manual before carrying out any operation on the machine 003 Use individual protective means against noise Indication pictograms These signs may vary in shape and they give useful information Direction of rotation 908 Lifting point Oil level 209 2 909 AOO Possibility to carry out jobs Combination of pictograms The above shown combination of pictograms means Warning Please refer to the Instruction Manual before starting any activity N Y Y TI008G0001 937 COMPRESSORE ROTATIVO A PALETTE 2 3 4 Li 8 matte Description of the Machine 3 01 Mattei rotary compressors of the AC Series are the result of over 80 years of investments in research and development to improve performance continuously and at the same be environment friendly The modulation operating mode is not available for compressors of the AC 6000 series Designed for continuous industrial service they guarantee constant performance over time low energy consumptions reliability func tionality and easy maintenance The compressor is supplied complete with all components described below and equipped with optional devices Unless differently requi
2. CE MARKING General Delivery Notes Final inspection General Safety Warnings Settings at the Customer s expense Instructions on how to request interventions Instructions on how to order spare parts The manufacturer s address General Information SAFETY Dangers and residual risks and General Information Responsibilities Description of Pictograms Description of Machine General Description of Machine Technical Data and Overall Dimensions Transportation and handling Installation Position of compressor Electrical connection Connection to the air network Dimensions of compressed air distribution piping Heat recovery Safety Devices Commands and control Use of compressor Foreword Operation modes MAESTROXS Operational Failures Start Stop Maintenance R guler Checksums Check of oil level Cleaning and or replacing the air suction filter Cleaning the oil air radiator Cleaning the pre filters Cleaning and or replacing the oil return valves Replacing the oil filter Replacing the oil air separator elements Oil change Lubricants Troubleshooting The electrical motor Storage Decommissioning and dismantling Condensate discharge in optional kit Attachments Form to request Technical Service Form to request spare parts Parts to be replaced during maintenance Technical Data Sheets 0 01 Page 1 01 Page 1 02 Page 1 03 Page 1 0
3. TI008G0001 098 nz oe and dismantling Storage The compressor is protected against corrosion and deterioration for the shipment period and for a rela tively short period of storage 3 months For longer periods please contact the manufacturer considering it can be maximum time 24 months In any case it is suitable to keep the machine in a dry place protected against atmospheric agents In wet climates to protect the electrical and mechanic components the machine should be kept in a heated room or closed in a barrier bag with heaters or light bulbs opecifically for the motor please refer to what mentioned about the winding insulation Decommissioning Decommissioning the machine does not involve any special precautions only collection of the oil contained in the machine and components of the lubrication system like the oil filter and the oil air separators WARNING N Both these elements and the oil should be collected and dumped in compliance with the current regulations on the environment in order to avoid any pollution and danger of fire Dismantling When the machine has reached the end of its technical and operating life it can be demolished i e decommissioned and put in such a condition so as not to be used any longer for the purposes it was designed and built with the possible recycling of raw materials NOTE Ing ENEA MATTEI S p A will not take any responsibility for damage to people or objects tha
4. in case of loss or damage further copies can be purchased from Mattei s sales organisation Checks before start Before starting the machine ensure that n n the electrical system complies with voltage and power of the machine and that wires are of suitable section the machine is earth connected and protected against possible short circuits the mains isolator is installed near the machine the machine oil level is correct When the machine is still and without pressure in the chamber the oil level should be between the MIN and MAX levels shown on the indicator If the level is insufficient fill it up with suitable oil and of the same type as the one used the machine is connected to the compressed air system TI008G0001 072 073 yy bee be oe ot el How to Use the Machine 6 02 Operation Modes To meet the users requirements Mattei compressors have been designed to work in three main operat ing modes Continuous Automatic and Modulation modulation not available for compressors of the AC 6000 series The factory preset mode is AUTOMATIC To change the setting please refer to page 6 04 of MAESTROX S 1 1 03 operating manual An overview of these three options is given below Continuous Cont 5 F mu In this mode the compressor delivers air within a clearly defined pressure range maximum and mini mum values are factory set by Mattei though they can be customised
5. 134 0 993 0 883 0 795 0 722 2 4 0 038 0 033 0 030 0 027 0 024 8 0 138 0 120 0 107 0 096 0 088 16 0 496 0 434 0 386 0 347 0 316 24 1 050 0 919 0 817 0 735 0 669 o 8 0 019 0 017 0 015 0 013 0 011 16 0 069 0 060 0 054 0 048 0 044 32 0 248 0 217 0 193 0 174 0 158 64 0 894 0 783 0 696 0 626 0 570 4 16 0 018 0 015 0 014 0 012 0 011 32 0 064 0 056 0 050 0 045 0 041 64 0 230 0 201 0 179 0 161 0 146 128 0 829 0 725 0 645 0 580 0 528 TI008G0001 278 py bem Le oe ol Installation 4 06 Heat Recovery As mentioned in the above section at Page 3 03 a fan produces an air flow that cools both the oil and the compressed air heating up when it passes through the cooler The recoverable heat rep resents about 100 the installed power in the AC 6000 Series machines The heat produced can be conveniently recovered and used to heat rooms Any duct should be adequately sized and if necessary shaped in such a way to allow for a correct use during Winter and the output of hot air during Summer The duct to recover output hot air should be designed by a competent engineer and should limit the load loss at approximately 20 Pa If the duct offers greater resistance an auxiliary extractor should be used to prevent any overheating of the machine As an example a duct with a higher or equal section to the coming out of the machine the output grid on those versions equipped with a soundproof case made up of some 10 m of straight d
6. Continuous The advanced programming of parameters protected by password allows the qualified engineer to change those parameters to which the user cannot access directly Checking the input and output status of the gear case to detect any failure in the compressor electric equipment Storage of up to 20 failure events The check of the integrated dryer plus models The remote control by clean contacts of the machine status be low Activated compressor optional Running compressor optional Compressor under load optional Compressor blocked standard LDLDLD L LLL LLLL Communication MAESTROS connected to the Mattei supervision device optional allows for Remote monitoring by web interface Alarm signaling by e mail fax or mobile phone WARNING The compressor has been designed to compress AIR ONLY The compression of other gases is FORBIDDEN TI008G0001 Description of the Machine 3 07 OPTIONALS The machine can also be customized according to meet different requirements by purchasing specific accessories such as Separator and Condensate Drain Kit Photo 1 DOCUMENTATION The machine comes complete with 1 Use and Maintenance Manual complying with Machinery direc tive 98 37 CE 1 CE Declaration of conformity 1 Start Report 1 Maintenance Sheet 1 Electrical Diagram inside the control board Documents for the optional accessories CERTIFICATIONS Ing Enea
7. LLL LLL Before intervening on the machine disconnect the electrical supply by means of the mains isolator In fact the machine is equipped with an automatic start system starting the same at any time if required by the compressed air system The key for opening closing the electric box doors should be given only to skilled personnel Maintenance operations should be always carried out with compressor not operating Before carrying out any job on the compressor unit ensure through the gauge that there is no pres sure inside Only use suitable tools for the kind of job Never use solvents and flammable products to clean the machine or individual parts Never carry out weldings or other jobs requiring considerable heat near the machine specifically near the electrical system and the oil circuit Do not make modifications or weldings on vessels under pressure Do not leave tools rags or other loose items on the motor or on the compressor The lubricating oil especially if exhausted may damage the skin protect hands with gloves or spe cific protecting products for the skin Do not wear clothes contaminated by lubricating oil Absolutely avoid contaminating the ground with lubricating oil To prevent pollution store the exhausted lubricant into suitable containers and in a safe place For oil disposal follow what suggested by internal rules and current regulations In case of topping up use the same oil as already contained in t
8. MAESTROXS 10 Oil filter 11 Oil level switch 12 Main motor 13 Fan 14 Minimum pressure valve 15 Oil return valve 16 Oil stop valve 17 Oil temperature feeler 18 Compressor temperature feeler 19 Electricity supply 20 Pre filter 21 Air delivery 22 Safety valve 23 Thermostatic valve 903a TI008G0001 Description of the Machine 3 11 Technical Data and Overall Dimensions eo 0861 neESCITSCIZCQIIICSZIIII 3 ames S3NVLNI HIV Hil Id HIV uz z VIHV OYLIIJ g5 H VIHV ANOIZWHIdSV lt EE U isole MI EE ete anee LAS IJSS TES HUE LUAU m MUTE j H CULES L x LI arohtotttvtt JHIEAAEPPRET DNOTITN TINT WUT MOLAR LLLI FREE EHEEPHEHELLULUUL r ATLL ETE d li WATT TIT N B INSERTI M6 OPZIONALE OPTIONAL FILTRO ARIA AIR FILTER FILTRO ARIA AIR FILTER OF Oe od dad dandas ee ee apepo cera ere os ERI ma Shee vere LI LO ca 23433423 oe K LI eater soars see we RESO canne 9292 c5 19 tam pe se anam S Pat Gla 090 eet Sesh seas A ads pedit sa tee een guae 78 na 0274 va lena ni amano casas UETS 9 7 en e 03 di Eee easan TIT Kg with oil Massa Kg con olio Mass MODELLI ACHOL H 240 AC110HH 2300 134314 vin 19 7 K X tik 1 7 KU R9 50 RE R1 RR P 83 432 F9 9 74 8 E970 3E E RUE IG Tickle em x x x x Q
9. bar For pressure values lower than 7 bar 7 3 0 3 7 the compressor delivers 100 of its capacity For values ranging from 7 to 7 3 bar the modulation band the compressor delivers less than its rated capacity suitable for line demand TI008G0001 099 matte How to Use the Machine 6 04 O Upon delivery the compressor is protected by an alphanumerical code which must il be provided by Mattei and entered the first time it is switched on The compressor will not work if this code is not entered because as soon as the vul compressor is powered the screen shown appears with the cursor flashing in the top left hand corner B Enter code e lt Baagag gt ENTERING THE CODE Press lt gt to move the cursor to the first digit of the code to enter Press lt gt and A to select the letters or numbers to enter and confirm with lt lt gt The cursor automatically moves on to the next position after each digit is confirmed and if the code has been correctly entered the first page of the menu appears MONITOR If the code is entered incorrectly instead MAESTRO xs asks for the entire code to be re entered D After being entered correctly the code will no longer be requested From now on the compressor can be used and configured In order to communicate with the user MAESTRO S features carious menus that allow the compressor to be monitored and programmed These are divided by function and
10. bearings WARNING In dusty environments and or at high temperatures maintenance operations should be car ried out more frequently The manufacturing date is quoted on rubber hoses Their operating life is 3 years after which they should be replaced WARNING Scheduled maintenance agreements are available to help the user keeping the machines at best operating and efficiency conditions Please apply to Ing ENEA MATTEI S p A M T A for further details WARNING For compressors equipped with INVERTER before performing any maintenance job wait at least 5 minutes after you have disconnected the electricity supply TI008G0001 Maintenance 1 03 Check of oil level Photo 1 101 With compressor not operating and with out pressure inside the chamber the oil level should be included between the MIN and MAX levels shown on the specific in dicating sticker fig 1 When the compressor is running and on load the oil level should be over the visual indicator half fig 1 Cleaning replacing the air intake filter Photo 2 Release the fixing hooks to remove the filter cover Firstly take out the outer element then the inner element by using the specific knob Clean with compressed air directing the air jet from the inside to the outside Reassemble in the reverse order Cleaning the oil air radiator Photo 3 Considering the air flow used to wash the compres sor the radiator is crossed by an ai
11. each unit is equipped with a detect valve Electrical connection should be conforming to current regulations The machines should be earth connected and protected by a magneto thermal switch against possible short circuits It is essential to install a mains isolating switch upstream of the compressor O O LL O O O L O TI008G0001 yy bee La le nf i General Information Safety 2 03 Maintenance The person responsible for operation of the compressor should check periodically that all instructions for operation and maintenance are followed by the operator 098 WARNING Fill in the specific Maintenance Sheet supplied with the machine Only trained staff should carry out maintenance with the compressor off and with no pressure inside the same Also disconnect the compressor from the pneumatic equipment Cut out the electricity supply by acting on the mains isolator located upstream of the compressor electric board and indicate with a special sign that the machine MUST NOT BE RESTARTED 098 WARNING N An adequate cleaning of both the machine and the place where it is installed is highly recommended For cleaning DO NOT USE flammable fluids or products not complying with current regulations In case of doubts about the compressor operation or of any of its components it is recommended to contact the after sales service of Ing Enea Mattei S p A The following should be also considered L OL LU LULU LULU
12. lifting is necessary verify first the correct fixing of specific devices for lifting and use adequate slings and equipment The machine installation should be as free as possible from any material preventing or limiting its view If there are any remove fixing brackets or eyebolt blocking devices previously fitted to allow the trans port Check that all the machine safety devices are correctly fixed and there are no moving or loose parts Also check soundness of the control unit components Connect the machine pneumatic system to the air distribution system and carefully check that pressure is set to the correct value Check consistency between the voltage set on power transformers and the voltage value of the electri cal supply Before connecting the machine electrical system check that the mains isolator is blocked in the open position Verify that accident preventing guards are correctly installed and in perfect state According to the different national law regulations the Customer might be required to inform the Certified Authorities of the installation and set up and or to undergo a system check if the machines are provided with tank SPV or pressure devices PED Periodic inspections are also foreseen The machine safety is not guaranteed in case of removal by pass or tampering of the safety devices on the machine To stop the machine during an emergency press the emergency stop button Operating the machine Only auth
13. separation occurs in different stages and ensures excep tionally low oil consumptions The main mechanical separation occurs in the oil chamber through a labyrinth path This mechanical separation works via the continuous changes of direction of the air flow in the labyrinth path The last separation occurs through the coalescing filter removing the remaining oil vapours from the air This particular oil separation system brings to a very reduced oil consumption The large size of the filter and quality of materials ensure a long life of the filter itself 910 Electric Motor The compressor and the electric motor are connected by means of flexible coupling This ensures a perfect alignment no power absorption silent ope ration and no need for maintenance Asynchronous threephase 4 poles electric motor with short circuit winding class F insulation High Efficiency Class P 55 protection degree electrical supply according to IEC 38 voltage frequency V 230 50 Hz V 400 50 Hz V 230 60 Hz V 460 60 Hz Cooling Systems The compressor is complete with two coolers entirely made of alu minium and suitable to cool the oil and the compressed air An air flow produced by the fan placed inside the soundproofing en closure flows through the coolers and removes the heat generated during the compression phase The compressed air outlet tempera ture is slightly over the ambient temperature See enclosed technica
14. using the programming functions in the User menu When pressure reaches the maximum value Pmax the compressor is off loaded suction valve closed and decompressed in order to reduce power consumption As soon as a request for air from the network reduces pressure to the minimum value Pmin the compressor loads again and resumes air delivery The compressor can be stopped at any time by pressing the stop button the stop ping procedure comprises a no load run phase which lasts for a set time during which the compressor is decompressed Nota If the unit is enabled with a line pressure greater than the set minimum pressure the compressor does not start but waits for the pressure to fall below the minimum value Automatic Auto Preset Mode This mode adds another function to the previous one the compressor can automatically stop at low or no air demand conditions The cycle is the following When line pressure reaches Pmax the compressor is off loaded at this point two things can happen 1 if there is no demand for air it runs no load for a certain period of time TMV No load Run Time and stops when this period of time expires it starts again as soon as line pressure falls below Pmin 2 if line pressure falls to Pmin before TMV expires the compressor is recharged The above operating mode can be combined with a special characteristic of MATTEI rotary compres sors the MODULATION phase TI008G0001 074 mattei
15. 16 Installation 4 03 Electrical connection Only qualified personnel should make the electrical connections in compliance with current regula tions 102 WARNING For safe maintenance of all com N pressor components including the electric starter the customer should install a mains isolator and a magneto thermal switch of suitable size as near as possible to the machine 098 The mains isolator and magneto thermal switch should be chosen by keeping into account the start features of the electric motor Adapting the size of wires between the mains isolator and the compressor starter should be made using the values given on the TECHNI CAL DATA sheet All the machine auxiliary components are al ready connected to the start and control panel and are powered through a transformer For further details use the specific electrical diagram supplied with the machine WARNING Please note that the machine should be ALWAYS connected to the earth equipment 098 TI008G0001 900a jp 5 a5 arat AG 132 Installation 4 04 Connection to the air distribution system Compressed air distribution Only qualified personnel should carry out the con nection to the air distribution system in compliance with the regulations in force The aim of distributing air is to bring com pressed air from the machine to the end o users with the lowest pressure drop and energy w
16. 4 Page 1 05 Page 1 09 Page 1 10 Page 2 01 Page 2 04 Page 2 05 Page 3 01 Page 3 11 Page 4 01 Page 4 02 Page 4 03 Page 4 04 Page 4 05 Page 4 06 Page 5 01 Page 5 02 Page 6 01 Page 6 02 Page 6 04 Page 6 05 Page 6 06 Page 7 01 Page 7 02 Page 7 03 Page 7 04 Page 7 05 Page 7 06 Page 7 08 Page 8 01 Page 9 01 Page 10 01 Page 11 01 Page 12 01 TI008G0001 yy bee Lal nf i General Information 1 01 Symbols in the manual In this manual some symbols are used that to attract the reader s attention and underline some particu larly important aspects of the treatment The table below gives the list and describes the meaning of the different symbols used SYMBOL MEANING and NOTES Danger It indicates a danger with the risk for accident even fatal for the user Pay careful attention to text block with this symbol Warning It warns against a possible deterioration of the machine or personal item of the user Notice It shows either a notice or a note on the key functions or useful information Further information This symbol introduces text blocks containing further information This information has no direct relationship with the description of a function or with pro cedure development They could be cross references to other documents or other sections of this manual Damage risk It indicates a high damage risk of a piece for example using a wrong tool or by mounting something with the incor
17. AIR COMPRESSORS AG 6000 Seres co eo e o INSTRUCTION USE AND MAINTENANCE MANUAL TI008G0001 ING ENEA MATTEI SpA Strada Padana Superiore 307 20090 VIMODRONE MI Tel 39 02253051 16 linee Fax 39 0225305243 E Mail info mattei it www matteiaircompressors com Forward Versions AC 6000 AC 6000 plus Voltages Frequencies V 230 50 Hz V 400 50 Hz V 230 60 Hz V 460 60 Hz Standard 3F L Plus 3F L The hard copy of this manual will be available for more than 10 years after the end of the production of the relative machine The content of this document cannot be used reproduced or disclosed to third parties without the explicit written consent of Ing ENEA MATTEI S p A Ing ENEA MATTEI S p A reserves the right to modify the characteristics of the machine subject of this document without prior notice Copyright 2008 by Ing ENEA MATTEI S p A This Instruction Manual meets all the requirements of 98 37 EEC Directive It is to be considered valid for both the machines with the CE Marking and those without it Important Note This manual should always be used together with the MAES TROXS User s Manual code TECA2G 007 TI008G0001 General Index matici General Information Symbols in the manual Purpose of Document Required Qualifications for Operators Identification data of the Manufacturer and the Machine and the location of the nameplate
18. CA TECNICA ASSISTENZA Corso Italia 47 24049 VERDELLO ZINGONIA Bergamo Italy TEL 39 035 4186400 Automatic search FAX 39 035 4186490 e mail info mta bg it C P N 69 Zingonia TI008G0001 yy bee La le nf i General Information Safety 2 01 co To operate the machine under any operating condition including maintenance it is not O necessary that more than one person be present Using more than one person is superfluous and in any case not allowed for safety reasons The employer should instruct the staff on the risks of accidents on safety devices and on the general rules concerning prevention and protection as established by the European Community Directives and by the current legislation in the country where the machine is installed The operator should be aware of the location and operation of all controls and of all the machine features The operator should also have read the entire manual Only skilled engineers should carry out maintenance jobs after having duly prepared the machine Any unauthorized tampering or replacement of one or more parts of the machine or the adoption of accessories that modify the use of the machine and the use of different ma terials than those recommended in this manual may be a potential risk of accidents It is strictly forbidden for the machine to be operated by two persons contemporane ously one inside the guards and one on the control panel 098 Dangers
19. EI S p A is identified as the machine s manufacturer in conformity with the laws in force with the following acts Declaration of conformity CE Marking Instruction Manual 251 602 MODELLO model CODICE code p no N SERIE ANNO s n year PORTATA m min flow rate PRESS NOM MAX bar design max pressure POTENZA NOMINALE kVV rated power VEL ROTAZIONE 1 min rated speed ESSICCATORE a dryer VOL SERBATOIO fair receiver volume PESO Kg weight matto G BEST SOLUTIONS IN DOMPRESSED AIA ING ENEA MATTEI S p A 20090 VIMODRONE MI ITALIA URL httpd www matteiaircompressors com A specific plate on the machine gives the following in delible information on the CE MARKING Model Code Serial number Year of manufacture Delivery Pressure Power Number of runs Dryer Tank Capacity Total Weight Name and address of manufacturer The CE MARKING plate has been applied at the base of the machine The relevant DECLARATION OF CONFORMITY has been attached It is forbidden to remove the CE MARKING plate and or exchange it for other plates of machines of the same model supplied to the Customer or the operator Should the CE MARKING plate be accidentally dam aged or removed from machine the customer is required to inform the Company TI008G0001 yy bee Lal nf i General Information 1 05 General notes on delivery Upon recei
20. How to Use the Machine 6 03 By suitably adjusting the its servo valve the compressor can modulate before reaching Pmax This means that Pmax can only be reached in case of very low or nil demand Nota If the unit is enabled with a line pressure greater than the set minimum pressure the compressor does not start but waits for the pressure to fall below the minimum value Modulation not available for compressors of the AC 6000 series di d D LITT IET IURI m MI All MATTEI compressors are fitted with an automatic system for adjusting pressure according to delivery pressure The internal pressure of the compressor depends partly on line pressure and consequently on the demand for air when the latter drops or is nil line pressure and internal pressure increase In Mattei compressors the maximum pressure at which the unit runs no load can be set by calibrating a valve For values slightly below maximum the suction valve is only partially closed by suitably modu lating machine capacity to line requirements Maximum pressure and values slightly below this define a field or range which is known as a MODULATION BAND This operating mode exploits this potential The control unit ignores the Pmax and Pmin settings and operates the compressor without stopping except in case of an operator command Nota The modulation bandwidth is typically 0 3 bar Suppose maximum no load pressure is set using the SERVO VALVE to 7 3
21. Mattei SpA has its company quality system certified according to standard UNI EN ISO 9001 by DNV while the final inspection procedures comply with standard ISO 1217 and have been certified by T V TI008G0001 matici Manufacturer s name amp address Model 2 Serial No 1 coe L Nominal Flow Rate C__ Nl min Max Air Pressure E barg Max Inlet Air Temp C Ambient Temp C LC lyp Refrig Design Pres uP LP LLL barg Electric Supply Cd ph V Hz Electric Nominal Power CWA A Manufactured CE A AIN Refrigerant Fuse Max 3 08 Description of the Machine Built in Dryer versions plus Each AC unit OPTIMA MAXIMA is supplied with a compressed air cooling radiator Cooling produces condensation that is unload ed from specific separators and drainpipes that can be applied on the front of the machine see this section Optional Accessories Many industrial applications require that the compressed air be al most completely emptied from the water vapour it contains so as to prevent any further condensation from forming inside the line pipes to which it is connected Hence devices that lower the dew point by a few degrees above 0 C should be installed In the plus versions the setting up of the machine includes a dryer with a refrigerator cycle that guarantees an adequate compressed air quality The design of the compressor allows for integrating a dryer with refrige
22. RA Outlet air temperature 5 Temperatura uscita aria 5 Fan residual head 6 Prevalenza residua ventilatore Pa 0 I Oil system capacity Capacit circuito olio 5 D __ Air outiet size Attacco uscita ia O O O O O OOOO O O Reel with condensate sep KIT 7 con KIT separ condensa T o S S d Condensate drain outlet size Attacco scarico di condensa Sooo S O pusversion versioneplus S S O _with_condensate sep KIT 7 con KIT separ condensa T d 10 Water inlet outlet size Attacco ingresso uscita acgua ooo With heat recovery kit_ 7 con KIT recupero calore T O 1 According to ISO 1217 1996 annex C Secondo ISO 1217 1996 annesso C 2 Whitout dryer power only Plus version Esclusa potenza essiccatore versioni Plus 3 According to PN8NTC2 3 measured at 1m distance Secondo PN8NTC2 3 misurato alla distanza di 1m 4 According to IEC 38 Secondo IEC 38 5 According to reference conditions indicated Alle condizioni di riferimento indicate 6 Frequency 50 Hz Frequenza 50 Hz NN 7 Optional Opzionale
23. SISTENZA Corso Italia 47 24049 VERDELLO ZINGONIA Bergamo Italy TEL 39 035 4186400 Ric Aut FAX 39 035 4186490 e mail info mta bg it C P N 69 Zingonia Company Address Please note our request for intervention for our machine Modell Intervention to be carried out at Contact Person Serial Number Telephone Failure Description Electrical Mechanical Notes Place Date Stamp and Signature TI008G0001 e M T A S P A MECCANICA TECNICA ASSISTENZA Corso Italia 47 24049 VERDELLO ZINGONIA Bergamo Italy TEL 39 035 4186400 Ric Aut FAX 39 035 4186490 e mail info mta bg it C P N 69 Zingonia yy bee La cda nd 1 i Form to request spare parts Company Address Please note our order no of with required delivery on for our machine Model Serial Number Reference Description Quantity Notes Place Date Stamp and Signature TI008G0001 matici Parts to be replaced during maintenance DESCRIPTION Maintenance Kit Separator air kit Prefilter COMPONENT Oil F2 Oil F4 Oil FG Grease for motor bearings CODE COMPONENTS QUANTITY IF57A24268 Air filter 1 Oil return valve filter 2 O ring 2 O ring 1 Oil filte
24. UE URI NUR EE Ml ioe toe tT x X RESET CS EH C LAZIALI LALLA LLR rene seam OPTIMA 110 OPTIMA 132 SUPERFICIE DI CARICO CARICO SULLE FONDAZIONI FLOOR LOAD MAX N cm2 LOADING ARE 5 we ko 1 ays A 2 a gt cc LLI N m n FORO SUPPLEMENTARE SUPPLEMENTARY HOLE USCITA ARIA ESSICCATORE USCITA ARIA AIR OUTLET FORO SUPPLEMENTARE ENTRATA ACQUA WATER INLET SUPPLEMENTARY HOLE CENTRO DI GRAVITA CENTER OF GRAVITY USCITA ACQUA WATER OUTLET 919 ITEM CONNECTION TI008G0001 Transportation and handling 4 01 098 The whole area for the machine handling JN resin the space between the parking area for transport means and the machine installing area should be identified and inspected beforehand to find any possible DANGEROUS AREAS Be careful when handling lifting and transporting the machine not to damage it and not to damage things or cause injuries to persons For this purpose Id Verify the total mass of the machine and use a forlift truck or an adequate lifting means Specific pictrograms indicate the lifting points L1 The centre of gravity is near the coupling between motor and compressor before lift ing check lift the unit from the ground just slightly that lifting points are correct and there is not risk of overturning _1 When lifting be careful not to damage the bearing structure base of the machine and the soundproof canopy 905a During the tr
25. YS CONTACT the distributor the technical service or the manufacturer BEFORE HAND i It is recommended to use the compressed air delivered directly by compres e e i MEE a5 arat AG 132 I 900a TI008G0001 General Information Safety 2 05 Description of Pictograms Pictograms have been applied on the machine to explain following situations Danger Obligation Prohibition opecial indications example direction of rotation of the fan etc 002 Many accidents are often caused by the non observance of the simplest safety rules or poor knowledge of the instructions given by the manu facturer To avoid possible danger situations some of them are highlighted through special signs represented by suitable standardized symbols pictograms Below is the list of the most common symbols ap plied to our machines 907 Danger pictograms These triangular signs are framed in black with a yellow background and the symbol is black Warning The machine is with remote control or with automatic system and may start without notice Warning Vessel under pressure Warning Warning Risk of high temperature surface Air delivery gt 70 C Warning Risk of electrical shock 109 107 105 Prohibition pictograms These circular signs are framed in red with white background and the symbol is black No working on the machine E N No pressure in the receiver No voltage
26. _ 21 DIL COOLER a SEPARATORE SCARICATORE CONDENSA OPZIONALE CONDENSATE SEPARATOR DRAIN VALVE OPTIONAL SONDA DI TEMPERATURA ARIA S _JAIR TEMPERATURE SENSOR SONDA DI TEMPERATURA OLIO OPZIONALE 24 OIL TEMPERATURE SENSOR OPTIONAL ELETTROVALVOLA COMANDO VSO 25 WSO SOLENOID VALVE nonu SONDA DI PRESSIONE _ 26 PRESSURE SENSOR Hu VALVOLA DI SCARICO _ 27 DRAIN VALVE TI008G0001 902a 276 Description of the Machine 3 02 All components are enclosed in a soundproofing canopy in sheet stell epoxy powder painted and lined with deadening fire resistant material The canopy has a pre filter to prevent intake of gross particles that might prematurely clog the radiators and air filter Wide detachable panels and hinged doors allow easy access for all The base has openings to allow easy lifting and handling of the compressor See Section 4 Standard packing includes fixing on wooden pallets protective polythene cover and a cardboard box Compressor The vane compressor is a volumetric rotary compressor It consists of a cylinder stator in which a rotor mounted eccentrically and tangential with it rotates and two end covers The rotor has longitudinal slots in which the vanes slide The vanes are pushed against the stator by centrifugal force Sealing of the moving parts cooling and lubrication are provided by an efficient injection of oil through proper ports due to the pressure difference betwee
27. able pressure to avoid injuries to the opera tor Maintenance schedule The time intervals in the maintenance tables are only reference values concerning the machine opera tion at the company s conditions Environment factors affecting these intervals are mainly machine environment temperature humidity and air pollution Machine lubrication Use only the lubricant quantity needed to lubricate the involved mechanism Carefully dry the excess oil or grease with a cloth Sometimes an excess or a lack of lubricant may jeopardize the machine operation Only recommended lubricants or well known and tested equivalent lubricants should be used for lubri cation Replacement of the exhausted oils should be made when the machine is warm The oil temperature should range between 25 and 30 C see section 8 The draining and filling holes should not be left open for more than the time needed to replace the oil Jobs to be performed during maintenance During maintenance operations pay attention to all signs that may precede a failure and specifically presence of corrosion presence of wear presence of loose unions or connections presence of oxidized contacts after each maintenance operation exhaust the air from the pneumatic pipings Minimizing downtimes after a failure It should be noted that correctly performed maintenance interventions may minimize downtimes after a failure A repair made in due time prevents furt
28. and residual risks During the design phase all hazardous areas have been considered and therefore all necessary precau tions have been taken to avoid risks to people and damage to the machine components To guarantee both health and safety of those ex posed the machine is equipped with appropriate safety devices EMERGENCY button to stop the machine immedi ately Fixed protections located in areas with exclusive access for routine maintenance They are fixed by devices that need special tools for their removal or they are locked with screws Protection and segregation of the electrical electronic driving equipment of the machine by metallic box to avoid accidental contacts with live equipment in case the metallic box is open the electric box is IP 54 protected IP 20 is the protection degree of the internal devices against accidental contact Suitable panels or protection to cover moving parts Electrical devices to detect faults of the machine electrical supply and malfunction of motor electrical devices WARNING N For compressors equipped with INVERTER before performing any maintenance job wait at least 5 minutes after you have disconnected the electricity supply 098 WARNING Our machine IS NOT SUITABLE for use in areas with potentially explosive atmos phere 098 TI008G0001 yy bee La le nf i General Information Safety 2 02 After having carefully considered all possible risks con
29. ansport carefully fix the machine to the means used by blocking it lengthways and sideways It is recommended to protect the machine from atmospheric agents with suitable cov ering Unpack the machine by removing the guards and place it on the floor by means of a forklift truck to remove the pallet 906a TI008G0001 282 NON INFERIORE A 2 m 4 02 Installation Position of compressor In the section Technical Data you can find the overall dimensions the weight and the cooling values of the machine The compressor must be installed in a covered and well ventilated area away form heat sources It can be simply placed on a solid and level floor It does not require any type of special foundation opace and ventilation around the machine are essential An air cooled compressor driven by an electrical motor produces heat equal to about 85 the absorbed power For the AC 6000 Series machines having the cooling air outlet on the canopy top panel the di stance from the ceiling should not be lower than 1 5 meters If such a clearance is not possible a hot air con veyor must be installed see further on the sec tion on ducts size and heat recovery The 1 5 meter distance free from any obstruc tions should be also kept on the intake end To make it easier to perform checks and main tenance operations on the compressor leave at least 1 5 m clearance from all other sides TI008G0001 2
30. aste To avoid losses and wastes regu larly check all pipings of the distribu tion equipment and all accessories Filters regulators and other accessories should undergo proper maintenance The connecting pipe to the system should be flexible and with a di ameter not lower than the pipe leaving the machine A detect valve is required to isolate the machine from the air distribu tion system in case of maintenance WARNING The machine is equipped with a NON RETURN VALVE if the detect valve is closed when the air distribution is operating some air under pressure could remain inside the connecting pipe Arrange a draining system for the piece of piping between the compressor and the detect valve In case there is the need to disconnect the machine ensure that the internal pressure is exhausted before the dismantling procedure Near the machine derive a flexible hose from the distribution system and connect it to a blowing gun it is needed for periodic cleaning of the radiator the intake filter and all other machine components The air drawn in by compressors contains in a variable quantity and depending on the ambient conditions a certain quantity of water indicated as relative humidity After air has been compressed it is cooled in a specific radiator which all versions of the Mattei compressors are supplied with Cooling air produces condensate of a good quantity of the water it contains The condensate prod
31. c Mattei Rotoroil 8000 F4 synthetic Mattei Rotoroil 8000 FG synthetic non toxic available in 2 5 and 25 litres cans Their life can reach the hours shown in the table depending on the operating temperature and condi tions of the intake air MATTEI LUBRICANTS Name Ambient temperature Operating hours RAY C Rotoroil 8000 F2 From 15 a 45 C 5000 Rotoroil 8000 F4 From 30 a 30 C 5000 Rotoroil 8000 FG From 5 a 40 C 1000 TI008G0001 co O O 098 Matici os 8 04 Safety Precautions There is a latent risk of fire in almost all compressed air systems and ISO 5388 Standard explains the reasons In fact in compressed air systems both oxygen and oil are always present and are combustible Should for any reason oil vapours form these could burn in presence of a flame an ignition source may start a fire in case of use of excessive or unsuitable oil or when neglecting maintenance Faulty maintenance has been mentioned because a dirty radiator may cause a temperature rise often quickly which leads to oil damage and to the creation of deposits Such processes are accelerated if unsuitable oil is used Based on experience fires are almost never caused by the fact that the oil self ignition temperature is reached 340 400 C Usually the cause is that the oil while decomposing creates carbon residues that when in contact with air and high temperature continue to oxidize and under special cond
32. cerning the use and maintenance of the machine all measures have been adopted to eliminate risks and limit dangers to exposed people Although the machine is equipped with safety devices the following residual risks remain which can be eliminated or reduced by the relevant precaution Risk of bruises tearing cuts during the handling of tools and or elements Risk of bruises during machine intervention Operation d The operator should use the personal protection devices L Use the compressor only for the kind of application for which it is designed air compression for industrial use L Before starting ensure that compressor is filled with oil L Please refer to Section 8 of this manual for the oil type to be used L Never operate the compressor if there is a possibility of inhaling smoke or toxic or flammable va pours L Never operate the compressor at higher pressures than those indicated in the id plate The air delivered by the compressor must not be used for breathing although it is filtered and purified from oil If hoses are used to distribute the air ensure they are properly sized and suitable for the operating pressure and not damaged or worn Please remember that rubber hoses should be replaced at regular intervals _ Never remove the oil filler plug when the machine is running or there is still pressure inside the compressor there would be hot oil leak J Although it has an acceptable sound pressure
33. commission and remove the machine Before setting the machine out of operation it is necessary to disconnect the mains isolator and block itin the open position Discharge oils and fluids remove all moving parts Disconnect the mains isolator cable by cutting out the power wires and then the earth wire Disconnect the power supply cable from the machine main switch and remove it Disconnect the machine pneumatic equipment from the air distribution system Remove the machine from the working area following the instructions given in this manual Before lifting it verify the correct use of lifting devices and use only suitable equipment Waste disposal should be performed in compliance with the laws in force in the country where the ma chine is installed _ Installation setting up and use of compressor should be carried out in compliance with the standards and the rules in force concerning safety at work J The owner of the machine is responsible for its good maintenance an essential condition to ensure safe operation Those machine parts that due to improper use or wear do not ensure safe operation should be quickly replaced L Only trained authorised and skilled staff should perform the installation use maintenance and repairs L In case of difference between the instructions given in this manual and those foreseen by current laws concerning safety it is recommended to apply the more restrictive ones Maintenance and repair Onl
34. d not be compatible Also beware of oil leaks not only being a waste but also polluting causing falls or injuries to people and also fires TI008G0001 General matici Troubleshooting 9 01 As mentioned in the section dedicated to protections the command and control board controls the smooth operation of the compressor It is possible that due to the incorrect use of the machine or in correct maintenance or unforeseen conditions etc malfunctions occur and that only their effects are indicated The table below aims at helping the operator solve some difficulties should they arise while indicating their possible causes Problem Cause Solution Below some possible failures are indicated with their causes and how to identify the correct solution PROBLEM A Start MAESTRO SS works start is allowed but the star triangle commutation does not take function correctly MAESTRO S works it enables the start by turning green LED on but the compressor does not start B Pressure The system pressure does not reach the required value The inside pressure exceeds the set value CAUSE The electrical supply is not sufficient and the excessive voltage drop during the starting causes release of the contactor Pressure inside the compressor is higher than the maximum tolerated value for the start or for an abnormal return of the network air or because the pressure transducer reads an incorrect value The
35. d the way how to operate under safety conditions for the staff and the surrounding environment Machinary Directive Machinary Directive means the DIRECTIVE OF THE EUROPEAN COMMUNITY COUNCIL 89 392 CEE dated 14th June 1989 and its subsequent amendments that modify its content 91 368 CEE dated 20th June 1991 93 44 CEE dated 14th June 1993 and 93 68 CEE dated 22nd July 1993 In June 1998 the Machinary Directive and its subsequent amendments were included into Directive 98 37 CEE without modifications Machine Machine means the functional assembly composed of control unit processing unit working and rest ing equipment systems electrical pneumatic hydraulic cooling lubrication systems and any group completing the system functionality Working area Working area means the protected volume limited by guards to prevent injuries and aimed at operation during the machine processing TI008G0001 mattei General Information 1 06 Authorized staff Authorized staff means personnel duly trained and appointed to perform the activities listed below and that make up the operating instructions for the machine Appointed staff Appointed staff means the personnel who although not participating materially in the work supervise the work of others for example the responsible engineer Transport Transport means all those operations regarding the handling of the machinery or part of it Installation Installation means the mechanical el
36. ectrical and fluid system integration of the machine into a produc tion reality in compliance with specified requirements Commissioning Commissioning means the functional check of the machine installed Operation Operation means the operating mode at which the machine produces compressed air according to all settings and controls inserted by the control device Decommissioning Decommissioning means to disconnect mechanically and electrically the machine from a production line Dismantling Dismantling means dismantling and eliminating the machine components Maintenance and repair Maintenance and repair means the regular check and or replacement of parts or components of the machine and any action to identify the cause of failure ending with the machine resetting to the design operating conditions Improper use Improper use means using the machine out of the limits specified in the technical documentation Applicability The regulations should be applied when performing following activities Transport installation and setting up Manual operation Continuous operation e Decommissioning and dismantling Maintenance and repair that compose the use procedures foreseen for the machine TI008G0001 mattei General Information 1 07 Installation and commissioning The installation and commissioning are only permitted to authorised staff During installation handle the machine components as indicated in this manual if
37. eferences to this manual and always stating the data on the machine id plate For any communication with the service centre always indicate the machine model the serial number and year of manufacture helping to identify every single machine and when possible specify the kind of problem or the defect found for instance electrical mechanical fault or defects in the machining quality and describe the same in the TECHNICAL SERVICE REQUEST FORM enclosed to this manual Please contact the nearest local service department or refer to the headquarters in Italy Instructions on how to order spare parts In the course of time a machine may need the replacement of those parts subject to wear The Purchaser may order the parts to be replaced It is compulsory to always buy original spare parts To order spare parts always indicate following data with the utmost accuracy 1 Machine type and model 2 Serial number 3 Exact description of the item 4 Code and or reference if available 5 Quantity To simplify and speed up the delivery of spare parts it is suggested to forward orders by compiling the SPARE PARTS REQUEST FORM enclosed with this manual and send it to M T A S p A or to the closest distributor The manufacturer s address Any request for intervention of the technical service by the customer or explanations on technical aspects of this document should be made to Technical and Spare Parts Service 075 M T A S P A MECCANI
38. equenza 50 Hz NN 7 Optional Opzionale E EU WERTE ERE SERIE 6000 1 BEST SOLUTIONS IN COMPAESSED AIR SCHEDA TECNICA AC 132 VERSION VERSIONE H H Air end nominal pressure bar g Pressione nom unit di compressione Ts 9 9 12 9 ERFORMANCES PRESTAZIONI bar g Air delivery Portata effettiva l min 5 25160 erminal power Potenza ai morsetti 2 kW 138 4 U T O KW e o ow o o ol 150 4 d who 162 2 157 8 EE eso 167 7 163 2 ee te 168 6 e te da 163 4 147 2 oo wa os 167 4 150 9 ee 1 we 1544 gr ws 160 5 e i fe 165 2 o c Tese 163 6 Sound pressure level 3 6 Livello pressione acustica 3 6 IBA OTD REFERENCE CONDITION CONDIZIONI DI RIFERIMENTO Relative humidity Umidit relativa 9 O O ELECTRICAL CHARACTERISTICS CARATTERISTICHE ELETTRICHE Enclosure Insulation class Grado prot Classe isolamento __ des y O Electric starting Tipo avviamento O o o OO Stellatiangolo Stardeta YPE OF REGULATION TIPO DI REGOLAZIONE Modulation Modulazione On load off load and stop Marcia a carico a vuoto e arresto fo controllo pressostatico pressureswitch On load off load Marcia a carico a vuoto controllo pressostatico pressureswitch Absorbed power Potenza assorbita CSC KW o O IGas
39. fi cations For the operator in charge of our machines a specialization course is held to train the operator to be able to perform all of the actions necessary to operate the machine even with some of the protections disconnected However this requires a certain competence by the operator and extreme care by the manager of the factory so that the said operator carries out only the established operations Mechanical Service Engineer A qualified engineer able to operate the machine under normal conditions to operate it with disconnected protections to intervene on mechanical parts to carry out all adjustments carry out maintenance and all of the necessary repairs This person is not empowered to carry out interventions on electrical systems with live voltage 101 Electrical Service Engineer A qualified engineer able to operate the machine under normal conditions to operate it with disconnected protections He she is in charge of all electrical adjustments maintenance e and repair He she is able to operate with live voltage inside cabins and shunt boxes The Manufacturer s Engineer qualified engineer from the manufacturer to perform complex operations in special situations or according to that which has been agreed upon with the cD Tr user TI008G0001 e moto General Information 1 04 Identification data of the Manufacturer and the Machine and the location of the nameplate CE MARKING Ing ENEA MATT
40. he compressor will not start as the failure ap pears to be still active and re displays the intervention request 0 WARNING The rotation in the wrong direction can seriously damage the compressor TI008G0001 099 yy bee La cda od i How to Use the Machine 6 06 n Once all foreseen operations before starting have been performed and which have i been described in the Sections above the Maestro page displayed to the operator is H TI X HH bbar CA Enabling Uil Teme Li Hir Teme CI Starting Press the key to switch the compressor on b The led lights with yellow colour The compressor is started It starts off load intake valve closed and then goes on load after a pre set time subsequent to the star delta switching delay The compressor from this moment on delivers compressed air according to the set operation mode After starting the page below appears within few seconds Hb n Hoar Enabling Qil Teme Bir emr 864 Stop To stop the compressor press key b 853 The yellow led of the ON key turns off E Hra r bar Enabling HAEE E A Uil Teme Cis BWHy 2 H L Ait Tener ie LO O T co The display shows The compressor is unloaded decompressed for a preset time basic programming After the motor has stopped the residual pressure inside the compressor discharges completely in approximately one minute HH Hbarnr The display will show the follo
41. he machine Mixtures are harmful for both the oil and the compressor life After any maintenance start the machine and check that all control stop or alarm devices are work ing correctly also verify that temperature and pressure values are the correct ones Make checks and overhauls as foreseen in this Manual and use only original spare parts Failing to make checks or using non original spare parts may cause problems that jeopardize the machine operation and the manufacturer s warranty will be no longer valid TI008G0001 mete General Information Safety 2 04 Responsibilities Ing Enea MATTEI S p A refuses any responsibility for injuries to people animals or damages to objects caused by L non observance of the mentioned precautions L improper use of compressed air or of the machine in general L non observance of normal safety regulations or domestic rules in the work field L non observance of the instructions during handling and transport of the machine L wrong machine installation L defects due to the electric power distribution L lacks in periodic maintenance d unauthorised jobs or modifications L use of non original or unsuitable spare parts for the involved model L non observance of the instructions even if only partially L possible inefficiencies caused by malfunction or non use of the compressor 098 WARNING sors only for manufacturing processes For any other use please ALWA
42. heir characteristics and it changes the names and specifications When the warranty period is over during which the use of Mattei Rotoroil lubricant is compulsory the user can decide to use the oil he believes most suitable or the available one provided it is suitable for rotary vane compressors Only manufacturers of lubricants can recommend the most suitable oil for the kind of machine and for its specific application The user should then purchase the lubricant from an oil company or a distributor that guarantees its suitability for the specific use The cost of the best lubricant is a small percentage of the total running cost of the machine it is sug gested to purchase the best available on the market see the section MATTEI LUBRICANTS Please consider that in lubricated and injection cooled compressors the oil performs the listed tasks and it is subject to continuous working cycles therefore it should be highly resistant to oxidation to ensure long life The oil should also provide a good demulsivity Anti oxidizing additives should provide low volatile substances at the compressor operating temperatures so as to ensure protection between one oil filling and the other The user must adopt the kind of oil grade recommended by Mattei Please refer to the specific table for the choice according to the operating conditions Available oils on the market There are several kinds of oils on the market including d mineral based
43. her deterioration Only use original spare parts and repair the damaged component thoroughly by your factory or send it to the nearest authorised service centre TI008G0001 098 Now 102 101 098 D 098 098 yy bee ee ol Maintenance 1 02 Weekly or Regular Checks WARNING After the first 50 hours of operation and every 6 months or 1000 hours tighten nuts and screws fixing the cables in the command and control electrical board and in the terminal board of electrical motors Within the first 300 hours of operation clean the oil return valves Page 7 05 every 50 hours Yearly or every 2 000 hours Check the oil level Replace the oil return valves Check and Clean the condensate drain sole noid valve filter with optional kit Monthly or every 200 hours Clean the intake filter Clean the oil cooler and the compressed air after cool Clean the pre filter of the suction grids Every three months or every 500 hours Oil change Rotoroil 8000 F2 every 12 months or 5 000 hours Rotoroil 8000 F4 every 12 months or 5 000 hours Rotoroil 8000 FG every 12 months or 1 000 hours er Clean the oil return valves Every 6 months or every 1 000 hours Replace the oil filter at every oil change Replace the intake filter Tighten n uts and screws fixing the wires inside the start and control panel and inside the mo tor terminal board Grease the motor
44. hour programming has been en abled The compressor runs within a network with other compressors The load setting valve is not working properly The condensate drain solenoid valve is blocked in the open position Optional kit separator condensate drain The minimum pressure valve does not function correctly Clogged intake filter Request for air greater than the compres sor maximum capacity The setting of the maximum pressure value in the BASIC PROGRAM menu is incorrect SOLUTION Check correct sizing of the electrical supply Please refer to section 4 of the supply Contact the nearest authorised service centre Check the inner pressure on the pressure gauge of the separator body and compare it with the value given by MAESTROYS Verify the correct operation of the pressure detection system transducer collector and switching solenoid valves Contact the nearest authorized service center Check operation Please contact the nearest service cen ter Clean the specific filter to remove the cause of the block and then check opera tion Please refer to the Installation Use and Maintenance Manual Section 12 Check operation Contact the nearest authorized service center Replace the filter Refer to section 7 to the Operating and maintenance manual Please refer to the Sales Organization of Ing Enea Mattei S p A to study equipment improvement Verify the correct setting of
45. industrial oils d synthetic oils Mineral based industrial oils These oils have been designed for different applications and also for some types of compressors In this case too there are standards specifying their features please refer to DIN 51506 which classifies the oils as VB L VC L e VD L according to their possibility of working at different temperatures The latter is suitable for high temperatures and it is resistant to oxidation caused by the continuous mix ing with the air ISO 6743 3A classifies oils based on the operating temperature and pressure and according to this rule for rotary vane compressors ISO L DAH o DAJ oils are recommended which are for medium and heavy applications The table indicates some typical values of the main characteristics Typical featuress Measuring Ambient temperature Ambient temperature of Industrial Oils unit 5 40 5 30 Viscosity ISO VG NM 150 100 Viscosity at 40 cSt 135 165 90 105 Viscosity at 100 cSt 14 16 10 12 Viscosity Index 93 100 100 110 Pour point C 10 5 15 10 Flash point V A C 230 265 250 265 Mass density Kg m 940 960 940 960 Values in the Table are merely indicative TI008G0001 098 yy bee La od fe i Lubricants 8 03 Synthetic oils Many synthetic oils with different basis are available on the market esters glycols etc that sometimes have proved to be suitable and provide a longer life than mineral oils Normall
46. ion Ice Alarm while the dryer compressor is kept active throughout the time corresponding to the parameter Low Temperature Delay Time Once this time has elapsed the dryer compressor is stopped so to prevent any ice from forming As soon as the temperature rises again above 0 C the dryer compressor is re started and the fault warning is automatically turned off Should the dew point temperature rise above the upper limit the controller will indicate the fault condi tion ALARM High Dew Point for the time that corresponds to the parameter High Temperature Delay Time When the set time has elapsed the Alarm warning will stay on As soon as the temperature falls again within the above mentioned operating interval the fault warning will be automatically turned off NOTE The user can request Ing ENEA MATTEI that the fault in the dryer corresponds to a machine BLOCK NOTE The design of the dryer prevents condensate from accumulating and ice from forming inside it In case of any failure in the dryer by passing the device is possible by disconnecting the hose linking it to the air radiator and connecting it directly to the delivery side All joints installed are equivalent TI008G0001 Description of the Machine 3 10 Position of main parts 1 Compressor 2 Intake filter 3 Electric starter 4 Oil cooler 5 Air cooler 6 Oil drain 7 Receiver Final oil separator 8 Oil filler plug 9
47. itions may ignite So it is essential to use suitable lubricants and carry out correct maintenance WARNING It is opportune that to prevent the risk of fires the best attention is given to the oil choice and to execution of all maintenance operations and specifically carry out regular and complete oil changes ascertain that the coolling system is always efficient with often checks to the oil temperature verify that protecting devices installed are always in perfect working order keep the oil consumption under control take care of the machine cleaning Storage and treatment of oils Usually lubricant containers are built so as to prevent any contamination When the user receives the lubricant it is under his responsibility to avoid damages or pollution to the same The lubricant may get damaged due to dust and dirt condensate mainly due to absorbing humidity from the air extreme temperatures mixing with other oil types Please note that dirt in the oil reduces its efficiency and causes wear of those parts it comes into contact with therefore there is the need to increase maintenance Instead condensate cancels the effect of some additives often present in very limited quantities Oil containers should be stored in protected rooms avoiding exposure to extreme temperatures WARNING Absolutely avoid the mixing of oils of a different grade and quality Although looking alike they coul
48. l data Electrical Starter The protection class is IP 54 and it includes Star Delta starter Main motor protection by thermal probe PTC Fan motor protection by magneto thermal switch 110 V transformer for auxiliary circuits 24 V transformer MAESTROXS control device Protection fuses for auxiliary and primary circuits of transformer Terminal board for the remote restarting of start stop controls and signals Emergency push button Micro door Safety block for high temperature in the compressor motor overload oil low level air and oil high temperature emergency stop clogged separator filter failure in the pressure sensors Electrical Diagram inside the starter TI008G0001 mattei Description of the Machine 3 04 Separator receiver The receiver is supplied with an INSTRUCTION USE AND MAIN TENANCE MANUAL which must be kept and consulted before use and with a DECLARATION OF CONFORMITY clearly indicating the main technical data and the operating limits The receiver is built to contain compressed air and oil it acts as a separator and combined with specific filtering elements as a filter please always consider the potential risks in case of incorrect use No modification should be made either to this receiver or to its instal lation when setting up the machine The maximum operating pressure and temperature for this receiver are shown on the attached plate oetting of the safety va
49. level the machine can produce a much higher noise if the room is narrow and reverberating Please note that the continuous presence of an operator is unnecessary For safey against noise in compliance with local laws in force and if necessary place specific warn ing signs near the machine and equip personnel with suitable protections L Installation Besides fulfilment of rules and regulations issued by the authorities it is recommended to con sider the following L The compressor will perform most efficiently if installed in a suitable well ventilated area and far from heat sources Should any duct be installed for the suction and cooling of air always use the data and recommen dations given in Section 4 and preferably obtain expert advice during the design stage In case of outdoor installation not suggested for very cold climates it is necessary to place the machine under a roof or covering to protect it against weather Be careful that no foreign materials clogg the radiator and cause rises of the operating tempera ture The intake air must be clean and free from flammable vapours which could cause fires or explo sions As the machine is air cooled adequate ventilation must be ensured to prevent it from overheating and thus avoiding the recirculation of the expelled hot air Control and safety devices should never be tampered with If one or more compressors are installed on a single pneumatic line it is essential that
50. lu bricants Successive oil changes can be made at the scheduled intervals lf the machine has already operated for a long period with other lubricants and there are traces of sludge or deposits it is suggested to wash with Rotoroil 8000 F2 F4 for about 200 hours so as to remove all residual impurities It is also recommended when filling up with new oil to replace the oil filter and the separator filtering elements TI008G0001 Matici ove 8 01 Lubricants are flammable products Observe the indications given on the containers During the disposal of exhausted lubricants it is necessary to comply with following environment protec tion rules e Lubricants may contaminate water and soil Never pour lubricants on the ground into water or in the sewerage system Any infringement of these rules can be legally prosecuted When handling lubricants keep an oil ag glomerative base near the working area Recover the exhausted lubricants while separating the mineral based from synthetic lubricants Upon disposal please comply with current regulations concerning the disposal of exhausted oils Only the use of lubricants with suitable quality guarantees a safe operation of the machine It is forbidden to mix lubricants of a different quality as their composition and additives are not the same This rule should be mainly applied to synthetic and mineral lubricant mixtures If other lubricants are to be used it sho
51. lve and the feeding pipes of the oil stop valve the load setting valve and the vacuum relief valve Photo 3 5 Dismantle the small squares fixing the separator to the canopy panel Photo 4 6 Remove the minimum pressure valve body unscrew the 4 screws fixing the head to the separator cover Photo 5 To remove the body extract the air delivery pipe from the radiator housing Photo 6 626 TI008G0001 Maintenance 71 08 Replacing the air oil separator elements 7 Unscrew the fixing screws Photo 2 Pos 2 of the cover Photo 2 Pos 1 8 Remove the fixing screws except one that will act as the cover rotation pin 9 Rotate the cover as shown in Photo 3 while avoiding any damage to the o ring Photo 4 10 Unscrew the spark plugs Photo 5 and withdraw them from the separator 11 Replace the spark plugs Photo 6 Act in the reverse order for the assembling while verifying the condition of the o ring Note Carefully tighten the cover screws with a 20 fi Kgm torque ar uin Aft ar oS gt N 628 ATTENTION The tool shown in Photo 7 allows for an easier removal of the cover Please contact MTA for or dering the tool TI008G0001 Maintenance Oil change 7 09 Foreword As mentioned before the oil performs many essential functions for compres sor operation and consequently it is important to check its quantity a
52. lve ensures reaching the maximum allowed operating pressure Thereceiver has been designed and manufactured so as to guarantee its long term use As shown in the manual supplied with the receiver an extra thickness is foreseen to avoid any possible corrosion In some countries the user should request a Notified Board to in spect the machine during installation and before commissioning the same Laws in some countries may also require inspections during opera tion TI008G0001 851 Description of the Machine 3 05 MAESTRO is a programmable control unit which adapts compressor operation to the specific requirements of the air line it is con nected to It features various programming levels and performs operating and fault con trols and analysis Advanced programming and analysis levels are protected by digital codes to prevent unin tentional access Maestro xs also contains a memory which saves settings and operating data even if the compressor is disconnected from the power supply or switches off due to a power cut Hardware Characteristics Microprocessor based technology Ergonomic control panel with rapid access keys to main menus Access keys to menus start stop and reset keys with Led controlled indications LCD display text with blue leds 8 lines 22 types 24 V AC 50 60Hz Power Supply 24 V dc Digital Inputs Digital output with clean contacts up to 230Vac and until 24Vdc A
53. ly in case of a block ii s Scrolling fault description Press the reset key once for more information about the kind of failure occured A page appears that contains the information on the failure and specifically HH Hbar amp Enabling 0350400h 0il Teme Ci 939 9 C Air Tema 039 8 C il Level Low Q t4 860 L The event code U The working time at which the failure occurred LI The detailed description of failure to the main compressor C1 L The detailed description of failure to the additional compressor C 2 when fitted L The chamber pressure at the moment of failure Emergercyu Stor Lha Press emP lil Cl TemFealdil le All these information are stored in the incorporated historical archive together with other information and it is possible to store up to 20 failures When the failure number exceeds the allowed limit the system clears the least recent failure to insert the latest one 1117 Press Reset key a second time to reset the compressor operation HO J ALLARM HETIVE 862 Note for Plus versions the faults frost alarm and high dewpoint are visually signalled when the dewpoint temperature is out of the standard operating range with automatic restoring as soon as the temperature goes back to the normal values See MAESTRO xs manual code TECA2G 007 supplied together with this manual co WARNING AN If the failure cause cannot be solved t
54. n the compression chamber and the oil receiver No pump for fluid circulation is needed An oil film on the inner surface of the stator prevents direct contact of the moving parts and avoids any wear In the vane compressor there are no axial thrusts pushing the rotor against the end covers Therefore there is no need for thrust bearings The rotor is supported by white metal bearings having a practically unlimited lifetime The air drawn in through a filter enters the intake valve and is compressed continuously pul se free due to the decrease in volume of the pockets formed by the stator rotor and vanes Intake valve The intake valve driven by a hydraulic circuit using the same oil used for lubrication delivers to the compressor the air quantity required by the distribution system a ARIA Air TEC 1 Air filter OLIO Oil 2 Automatic intake valve 7 3 Oil chamber 4 Compression chamber 5 Oil filter i cU 6 Rotor RIZZA llc 7 Blades 8 Coalescing separator 9 Air oil cooler radiator TI008G0001 mattei Description of the Machine 3 03 Minimum pressure and non return valve Compressed air is delivered by the compressor through a valve ensuring a minimum pressure inside the oil chamber so as to gua rantee smooth operation when the compressor is delivering air This valve also prevents the compressed air in the system from returning to the compressor Oil separation The air oil
55. nalogue output 0 10 Vdc Pressure analog signals 4 20mA Temperature analog signals NPT Interfaces _I RS485 to communicate with other MAESTRO xs devices Li RS485 optional to communicate with supervising PC and lan Software Characteristics Easy use based on a menu structure Updating possibility Display of I Analogue data Line pressure pressure in the chamber oil temperature output air temperature I General data Alarms operating messages machine status maximum and minimum pressure last start and last stop LJ Hour counter Display of schedules of activation start loading mainte nance warns LJ Events archive Storage of alarms and blocks with the indication of the when the alarm was activated machine status TI008G0001 mattei Description of the Machine 3 06 098 The device allows for User Interface in 8 languages Italian English French German Spanish Polish Czech Portuguese Weekly and time schedule of starts and stops immediate reading on display of data relevant to the compressor operation Compressor hours of activation and line pressure of the equip ment Pressure oil chamber Output air temperature and compressor oil temperature Hours of running and hours of loading Programming of basic parameters for optimum operation of compressor accessible by user Control modes of compressor Local remote master slave Operation modes Automatic
56. nce and troubleshooting jobs all disconnected safety devices should be reset Maintenance repair and troubleshooting should be ended by the checking of the machine operation and of all its safety devices TI008G0001 matte General Information 1 09 Settings to be made by customer Unless different contractual agreements are taken the following items are normally at customer s ex pense L room preparation including building works such as foundations or canalizations etc if required L anti slip levelled flooring L observing the dimensions given in the layout drawing when preparing the site and when installing the machine itself L preparation of auxiliary services suitable for the system requirements such as electricity supply pneumatic system etc d preparation of the electrical equipment in compliance to Directive 2006 95 EEC _ adequate lighting complying with EN 60204 1 Standard d any safety devices upstream and downstream of the electrical supply lines like differential switches earthing systems safety valves etc foreseen by the current laws in the country of installation L earthing equipment complying with CEI 64 8 Standard 900a TI008G0001 mattei General Information 1 10 For any kind of information on the use maintenance installation etc Ing ENEA MATTEI S p A is always available to meet the Purchaser s requests However any enquiry should be made in clear terms with r
57. nd conditions at the suggested times Please refer to the specific tables to choose the most suitable oil types for the different operating conditions First oil change If not differently stated in the nameplate the com pressor is supplied with Rotoroil 8000 F2 oil The first oil change and the first oil filter change should take place within 5000 hours or one year It should be noted that exhausted oil is dangerous for operation of the compressor and therefore it should be replaced when the change interval has expired The oil should be replaced with the machine not operating and with warm oil To drain the oil wait until the compressor is no more pressu rized checking that the pressure gauge on the separator or on the receiver indicates there is no more internal pressure Slowly unscrew the filling hole plug Photo 1 and check if there is any foam wait for some minutes until the oil demulsifies Open the drain plug Photo 2 and drain the oil into a suitable container Close the drain plug Fill the oil chamber with new oil until reaching the MAX level fig 4 Replace the plug gasket and tighten it well Start the compressor and let it operate for few minutes then stop it and verify the correct level by means of the specific indicating sticker fig 4 Top up if necessary TI008G0001 1 bee La eee Maintenance Oil change 7 10 Use of Rotoroil lubricants 101 It is recommended to use Mattei Rotoroil 8000
58. ng Maximum Pressures Version L H HH 918 Maximum pressure 8 bar 10bar 13 bar Note Compressor operation depends on the set values itis suggested to ask for modification of settings only in case of real need and with knowledge Only skilled personnel should make the setting TI008G0001 851 852 853 854 Keypad Commands and Control 5 02 MAESTRO is a program mable device to control the machine that can adapt its operation to the specific re quirements of the network it is connected to Ir VU i P 4 M 099 It has several programming levels with special possibilities of control analysis of operation and of failures The advanced programming and analysis levels are protected by digital codes so as to prevent any unintentional tampering Maestro S has a storage that saves the settings made over time as well as the data on operation even if the machine is not con nected to the electrical line or if voltage drops Occur A weekly schedule of starts stops can be set that is combined with the management of the connection to other machines so as to control any multiple installations as efficien tly as possible Maestro xs is a control device made up of two separate units Display with keypad Data input output device The buttons are backlit for enhanced clarity and in some cases in order to complete the information provided by the device Reset buttons Rese
59. not all of them can be accessed by the final customer Some of them are protected by one or more passwords The menus are divided according to the functions that they control The main menus used to manage the compressor are Menu User access Password Menu ID Monitor Menu Yes No 0 User Menu Yes No 1 Advanced Menu No Yes 2 Clock Menu Yes No 3 Log Menu Yes No 4 Network Menu Yes No 5 Info Menu Yes No 6 To simplify use of the compressor some symbols are used to graphically represent certain functions such as machine status and other settings Other symbols are used to report operating problems special enabled functions etc The various menus also use texts informing the user of the meaning of the variables and the functions they perform To simplify traceability of a variable every menu is identified by a number as shown in table 3 The same applies to the submenus and individual variables For a more detailed description of individual menus please refer to the Maestro xs manual code TE CA2G 007 supplied with this manual TI008G0001 yy bee La ed nf i How to Use the Machine 6 05 Operational Failures 13 Vy Failures can be divided as follows NEN d O Failures with an intervention signal alarms o YI LI Failures causing the immediate stop of the compressor blocks The card signals a failure by lighting of the reset button together with a visual signal through icons and a sliding description Block symbol on
60. nt to the European Directive 98 37 EEC The list below gives the reference Standards used by Ing ENEA MATTEI S p A to design make and to make the final inspection of the machine List of Directives and Technical Harmonized Standards MACHINERY DIRECTIVE 98 37 EEC ELECTROMAGNETIC COMPATIBILITY EMC DIRECTIVE 2004 108 CE LOW VOLTAGE DIRECTIVE 2006 95CE EN 1012 1 Compressors and vacuum pumps Safety Requirements Compressors TI008G0001 yy bee La od nf i General Information 1 03 Required Qualifications for Operators The operator in charge of the operation or the maintenance of the machine should have all the profes sional requirements specific to each foreseen operation The operator should be trained and aware of his responsibilities Below is the description of the professional profiles concerning the operators in charge of the machine Entry Level Machine Operator Qualification 1 Qualified staff able to carry out simple tasks i e to operate the machine with the use of controls on the push button and to carry out typical simple functions of adjustments start 3 1 orstop Second Level Machine Operator Qualification 2 Qualified staff able to carry out the task of qualification 1 and also to operate the machine with disconnected safety protections to perform specific adjustments start or stop functions S 2 I Important This qualification includes those responsibilities typically subdivided into two separate quali
61. operating parameters Please refer to the Installation Use and Maintenance Manual Sections 5 and 6 TI008G0001 matici PROBLEM C Oil Excessive oil consumption the oil the level lowers too quickly clogged oil is detected inside the system D Temperature The compressor stops due to its own over heating The compressor stops due to the over heating of the motor CAUSE The oil return valve filters are clogged The radiator or the cooling air filter are Dirty the ambient temperature is too hight for compressor operation Excessive working pressure The motor cooling is not sufficient There is not enough air or it is too hot Troubleshooting 9 02 SOLUTION Replace filters and verify the causes of the clogging see Section 7 Replace the filters and verify the causes of clogging see section 7 Verify the setting and re set to the value foreseen for the machine see Section 7 Verify the environmental conditions and the condition of the filtering panel see Sections 3 and 7 TI008G0001 yy bee Lal nf i The Electrical Motor 10 01 General The electric motor characteristics are given on the nameplate fixed to the motor itself and specifically Model Serial number Protection degree Insulation class Maximum ambient temperature Service Service factor Supply voltage V Frequency Hz 10 Speed rpm1 11 Power kW 12 Power factor co
62. orised and duly trained staff or at least with a sufficient technical experience should operate the machine The staff in charge of operating the system should be aware that the knowledge and ap plication of safety regulations is in an integral part of their job Unskilled personnel should not access the operating area and the machine control panel when the system is live Before starting the machine carry out following operations Carefully read the technical documentation Get information about the operation and position of emergency stop devices on the machine Know which protections and safety devices are fitted on the machine their position and operation It is forbidden to either disconnect or partially remove the protections and safety devices The same applies for danger signals located in particular areas of the machine It is strictly forbidden to access the working area and the control and power cabins during operation of the equipment even partial or immediately after it is switched off Protections and safety devices should be kept in perfect state so as to allow right operation in case of failure they should be repaired or replaced The use of not authorised components and accessories for the protections and safety devices may lead to malfunctioning and dangerous situations for the operating staff TI008G0001 mattei General Information 1 08 Decommissioning and dismantling Only authorised staff is allowed to de
63. po avviamento Stellatrangolo Stardeta YPE OF REGULATION TIPO DI REGOLAZIONE Modulation Modulazione On load off load and stop Marcia a carico a vuoto e arresto fo controllo pressostatico pressureswitch On load off load Marcia a carico a vuoto controllo pressostatico pressureswitch Absorbed power Potenza assorbita KW _ O Gas ROA Outlet air temperature 5 Temperatura uscita aria 5 O Fan residual head 6 Prevalenza residua ventilatore 6 Pa 200 Oil system capacity Capacit circuito olio 5 D 60 Air outlet size Attacco uscitaaria RAH with condensate sep KIT 7 con KIT separ condensa T Joo ooo ooo Condensatedraoutetsize Ataccoscancodicondena 1 pusversion versioneplus E with condensate sep KIT 7 con KIT separ condensa T 10 Water inlet outlet size Attacco ingresso uscitaacqua o S ooo With heat recovery kit 7 con KIT recupero calore T to 1 According to ISO 1217 1996 annex C Secondo ISO 1217 1996 annesso C 2 Whitout dryer power only Plus version Esclusa potenza essiccatore versioni Plus 3 According to PN8NTC2 3 measured at 1m distance Secondo PN8NTC2 3 misurato alla distanza di 1m 4 According to IEC 38 Secondo IEC 38 5 According to reference conditions indicated Alle condizioni di riferimento indicate 6 Frequency 50 Hz Fr
64. pt of the machine please check that The supply complies with the order specification There are no damages due to transportation or other reasons In the event of damage or missing parts please inform immediately and in detail the forwarding agent or Ing ENEA MATTEI S p A ALWAYS STATE THE MACHINE SERIAL NUMBER AS WELL AS THE PRINT NUMBER OF THIS CATALOGUE WHEN MAKING ANY REQUEST TO Ing ENEA MATTEI S p A OR ONE OF THEIR SERVICE CENTRES Final inspection The manufacturer carries out the final inspection of the machine directly during the production phases in compliance with the company quality system A certificate of conformity is supplied together with the machine Ing ENEA MATTEI S p A is responsible for the machine under its original configuration Ing ENEA MATTEI S p A refuses any responsibility for improper use of the machine for damages due to operations which are not described in this manual or unreasonable jobs Safety precautions The final user should comply with the instructions given by the seller concerning safety devices already installed on the machine instructions for correct machine installation correct use and periodic maintenance of all the machine components including safety devices regulations of current laws The following safety precautions define both the behaviour and obligations to be observed when carrying out the activities listed in the manual the instructions for the machine use an
65. r flow directed from downwards to upwards Therefore the dust deposits mainly on the bottom To clean the oil radiator remove the fan guard panel photo 4 and blow the radiator with a compressed air flow To clean the air end remove the soundproof panel and proceed as above by blow ing the radiator by means of a compressed air flow 222 TI008G0001 224 225 101 Maintenance 1 04 Cleaning the prefilters The machine is equipped with a prefilter to remove dust and is articulated by the intake air The prefilter is composed of a metal frame contai ning a filtering wire mesh It slides on metal guides in the side panel and should be removed from its housing for replacement or cleaning purposes It filters the intake air and washes the compressor while preventing foreign particles from entering the machine Frequent cleaning of panels is essential To do this open the door through the fixing lock take out the panel and blow out with compressed air The synthetic material can be washed whenever necessary No solvents should be used for the washing TI008G0001 925 229 Maintenance 1 05 Cleaning and or replacing the oil return valves Photo 1 Proceed as follows unscrew the screw Photo 2 Pos 1 remove the connection Photo 2 Pos 3 and the gaskets Photo 2 Pos 2 unscrew the filter Photo 4 Pos 4 from its seat Photo 4 Pos 6 wash the
66. r huile 1 Element 1 IF57A23884 O ring 2 O ring 1 O ring 16 Element 8 O ring 1 C052042336 2 Lubrificanti Mattei ROTOROIL 8000 CODE DESCRIPTION QUANTITAY BCLOGFCOO2 Can 2 liters BCL06FC005 Can 5 liters BCL06FC025 Can 25 liters BCLO6SCOO2 Can 2 liters BCLO6SCOO5 Can 5 liters BCLO6SCO25 Can 25 liters BCLOGACOO2 Can 2 liters BCLO6AC005 Can 5 liters BCLO6AC025 Can 25 liters M00566 Cartridge TI008G0001 iii SERIE 6000 TTT odi SCHEDA TECNICA TT AC 110 VERSION VERSIONE bL HJ H Air end nominal pressure bar g Pressione nom unit di compressione Ts 9 9 12 9 ERFORMANCES PRESTAZIONI bar g Air delivery Portata effettiva l min 5 21990 erminal power Potenza ai morsetti 2 kW 115 5 T DESIGN DATA Eu m BEST SOLUTIONS IN U T __ KW e wl o o 128 8 ws own o ol 138 8 112 es me O 121 2 ee v2 125 2 e ds fe 132 5 119 3 1 mw moo 135 8 122 3 ee o ge 125 1 gn gg o o o omo 130 1 ee __ we 133 9 o1 c fo Sound pressure level 3 6 Livello pressione acustica 3 6 BA SO LD REFERENCE CONDITION CONDIZIONI DI RIFERIMENTO Relative humidity Umidit relaiva A 0 O ELECTRICAL CHARACTERISTICS CARATTERISTICHE ELETTRICHE Enclosure Insulation class Grado prot Classe isolamento des y O Electric starting Ti
67. rator cycle directly installed on the machine An electronic controller controls the dryer which manages its func tional parameters according to the different operating load cycles For further details on the dryer please refer to the specific manual supplied with the device ID Plate The product ID plate contains all the machine s essential data Removing or tampering the id plate forfeits the right of guarantee Operating Mode When the compressor is activated the drier also starts after a pre set delay Alarms are inserted with 5 minute delay to allow the drier to reach its operating mode Once this delay has elapsed the alarms start and begin monitoring the system Once started the dryer compressor group stays on until the following conditions occur v The compressor is stopped with the STOP push button V The dryer operating limit conditions are exceeded TI008G0001 mattei Description of the Machine 3 09 The controller manages the dryer operation by monitoring the dew point temperature that allows the system to run correctly The operating limits for such a parameter are as follows vw The dew point temperature gt 0 C v The dew point temperature lt 6 C with Ambient Temperature lt 25 C v The dew point temperature lt T amb f ambient with Ambient Temperature gt 25 C MATTEI sets the f ambient value If the dew point drops below 0 C the controller will indicate the faulty condit
68. rect procedure Visual Check It recommends the reader to carry out a visual check This symbol can also be found in the instructions for use The user is required to read a measure value to check some warning signs etc Acoustic Check It recommends the reader to carry out a sound acoustic check This symbol can also be found in theinstructions for use The user is required to listen to an operational noise TI008G0001 yy bee La od nf i General Information 1 02 Purpose of Document This manual contains the technical characteristics the performance the transportation and installation rules the instructions for use and the preventive and corrective maintenance operations of the machine manufactured by Ing ENEA MATTEI S p A IS NOTE This manual should be considered an integral part of the machine and should stay with it during the entire life span of the equipment Keep this manual and all of the attached documents in a place easily accessible to all staff in charge of the control or the maintenance of the machine Ing ENEA MATTEI S p A reserves the right to subject the supply of further copies to the repayment of charges and the acceptance of special provisions with respect to the legiti mate defense of intellectual patent and executive identity and functional property of the product and or its parts It is understood that forwarding all or part of this manual to third parties is not tolerated unless with the prior writ
69. red the unit is filled with Mattei Rotoroil 8000 F2 synthetic lubricant For special requirements regarding lubricant please refer to section 8 of this manual nn i e R Ll AIR END o AC Be _ j e P COMPRESSED AIR iini p FLUSSO ARIA FLUSSO OLIO FLUSSO ARIA OLIO i ROTARY VANE COMPRESSOR Sa CAMERA OLIO SEPARATORE PRIMARIO a seco ee FI LTRO ASPIRAZIONE mio X Eam ER VALVOLA ASPIRAZIONE INTAKE VALVE IR m LL AIR OIL SEPARATOR MINIMUM PRESSURE NON RETURN VALVE _ _ _ ___________ _ _ __ _T_rr _ 11z11m 1212121212t VALVOLA DI SFIATO ELETTROVALVOLA DI SOCCORSO A VUOTO PRESOSTATO DIFFERENZIALE VAGUUM RELTEF _ SOLENOID VALVE DIFFERENTIAL PRESSURE SWITCH OIL RETURN VALVE 10 WALVOLA DI RITORNO OLIO i VALVOLA TERMOSTATICA BY PASS _ 11 BY PASS THERMOSTATIC VALVE Foe oa DI SCARICO PRESSIONE 12 PRESSURE EXAUST SOLENOID VALVE Lis 13 FILTRO OLIO DIL FILTER 14 VALVOLA STOP OLIO 14 DIL STOP VALVE 45 TERMOSTATO 15 THERMOSTAT celiaca LETTROVALVOLA DI MESSA A VUOTO 16 OFF LOAD SOLENOID VALVE ALVOLA DI MESSA A VUOTO 17 DFF LOAD VALVE INDICATORE DI PRESSIONE 18 PRESSURE GAUGE LIVELLOSTATO OLIO 19 OIL LEVEL SWITCH _ REFRIGERANTE ARIA 20 AIR COOLER REFRIGERANTE OLIO
70. s 13 Rated intensity A 14 Motor weight 15 Type of bearings front and rear O 0 NDOUOKDSDWNH Lubrication The same plate also indicates the type of bearings mounted for which it is recommended to use lithium based grease for lubrication Greasing where necessary should be carried out when the motor is running The lubrication intervals should never be longer than the solar year Cooling The motor is equipped with a cover and fan to guarantee proper cooling Check that dirt does not form on this cover as it could reduce the cooling air passage Abnormal noises Any vibration or abnormal noise is usually due to deterioration of the bearings In this case it is rec ommended to replace the bearings rather than risking more serious problems to the motor or the ma chine Electrical checks If the machine has been stored for a long period or in case of long stops in damp places it is suggested to measure the winding insulation value by applying 500 V d c voltage for 60 seconds The insulation should be at least 10 MQ MegaOhms in warm conditions or 100 MQ in cold condi tions Should these values not be detected and in case the motor has been exposed to damp it is suggested to dry it for 24 hours in a furnace at 100 110 C If no furnaces are available please contact the manufacturer e WARNING A N Before starting the machine verify that the nuts locking the terminals of the power supply wires are well tightened
71. t may de rive from the recycling of individual components of the machine for operation or assembling situations different that the original ones Ing ENEA MATTEI S p A refuses any implicit or explicit acknowledgement of suitability to specific purposes of the machine components re used after the final dismantling in view of its demolition WARNING The deactivation and dismantling of the machine should be carried out only by duly trained and equipped staff Act as follows to deactivate the machine permanently O Drain the oil from the receiver O Disconnect the machine from the electrical and pneumatic supply systems O Lift the machine with suitable lifting means O Disassemble the machine main components O Block all the machine moving parts O Take all the machine components in supervised dumps Residual risks after deactivation After deactivating the machine there are no residual risk if all moving parts have been duly blocked TI008G0001 Condensate Unload in Optional Kit 1 2 0 1 Cleaning the drain solenoid valve filter 101 Unscrew the connection and remove the drain solenoid valve Withdraw the solenoid valve filter using beak pli ers remove any dirt and wash with detergent Re assemble in the reverse order while paying special attention to the position of the solenoid valve seal 253 023 024 TI008G0001 e Form to request Technical Service M T A S P A MECCANICA TECNICA AS
72. ten consent of Ing ENEA MATTEI S p A for both the text the illustrations and the diagrams attached Ing ENEA MATTEI S p A reserves the right to make changes without prior notice Any change supplement or suppression of elements components functions or cycles of the machine not previously agreed upon with Ing ENEA MATTEI S p A releases the manu facturer from any responsibility whatsoever This manual is for the user and the service engineer of the machine and it aims at supplying them with the basic technical data typical of the system a technical description of the several operating groups that form it as well as the essential use procedures and the information necessary to perform preventive and corrective maintenance This manual is for staff with a sound knowledge of the processing technique of mechanical and electrical diagrams and is for both those in charge for the use of the machine and the service engineers This manual is an integral part of the machine and contains information that aims at granting all staff safe working conditions and guaranteeing perfect efficiency during the life span of the machine For a correct use of the machine it is assumed that the working environment is adequate to current regulations concerning safety and hygiene Applied directives and technical standards The machine has been designed made and inspected in compliance with the safety and health es sential requirements stated in attachme
73. ts any faults detected by the system Eliminate the reason for the fault first On Off button Enables and disables the compressor Esc button Accesses the main menu and exits the current menu 855 856 857 Up button Moves around the various menus Also increases the value of a variable in the edit mode Enter button Accesses the selec ted menu and opens and closes the memory in the edit mode Down button Moves around the various menus Also decreases the value of a variable in the edit mode TI008G0001 Technical specifications Display Backlighting Resolution Keypad Material Number of buttons Backlit buttons Power input Voltage Operating conditions Temperature Humidity Overall dimensions 858 yy bee be le ol Commands and Control 5 03 FSTN graphic Light blue LED s 132 x 64 pixel Silicon rubber 6 Yes From basic module via phone cable 20 60 C 90 R H TI008G0001 How to Use the Machine 6 01 Foreword The user should appoint a qualified person for operation and maintenance of the machine He should properly train all operators so that they are acquainted with all needed measures to prevent any accident or injury to people All start and stop procedures as well as emergency ones should be known they should be also periodically checked with the operators The operating and maintenance manual should be always available
74. uced is separated and drained with an automatic device optional Please note that condensate should be collected and eliminated in compliance with current laws TI008G0001 Installation 4 05 matici Dimensions of compressed air distribution pipings We mention that the main causes for wastes are pipings with unsuitable diameter and losses due to an improper setting up of the equipment or deteriorated materials The pipe diameter must be duly selected so as to minimize the pressure drop between the compressor or the storage receiver and the point of use based on the machine features like air delivery and working pressure The pressure drop is proportional to the pipe length and most losses occur during the change of direction curves elbows and in the valves With a pipe having the same diameter as the compressor outlet the length should not exceed 50 m To make a check of one s own equipment Table 1 gives the load losses over 100 metres straight piping according to nominal diameters usually employed and at different air delivery and working pressure conditions A perfect air distribution system should limit the pressure drop from compressor to the point of use within few tenths of bar Table 1 Load losses bar over 100 m straight piping Pipe Free Air Delivery PRESSURE Diameter m min bar 6 7 8 9 10 1 1 0 087 0 076 0 068 0 061 0 056 2 0 315 0 275 0 245 0 220 0 200 3 0 666 0 583 0 518 0 467 0 424 4 1
75. uct and two 90 elbows properly connected allows the maximum tolerated limits to be maintained However it should be noted that 10 Pa increase corresponds to some 2 3 C increase in operating temperatures As for the recoverable heat it should be noted that 1 kW of installed power allows for the heating up a volume of about 30 cubic meters by 1 K 1 kW 860 kcal h In the Section on TECHNICAL DATA attached to this manual the values required to realize that which is mentioned above are indi cated TI008G0001 Safety Devices 5 01 EMERGENCY STOP button The machine stops immediately when the button is pressed This button is to be used also in an emergency situation Frequent stops of the compressor by 098 means of this button may damage its operation WARNING Please refer to the Manual of MA ESTROXS Control attached to this Manual for detailed description of keys programming and all of its functions Safety Valve A SAFETY VALVE protects the compressor in case of air overpressure inside the chamber while limiting the value to its own setting limit The safety valve is set at 12 bar for L and H version of compressors and 15 bar for HH versions Operating pressure check For compressors of the AC 6000 series the operating pressure is checked by MAESTRO XS The maximum operating pressure is set during final inspection at its optimal value and DOES NOT require any further adjustments Setti
76. uld be verified beforehand if the two products are compatible In case of doubts the lubricant used up to that moment should be completely eliminated by means of a washing procedure of the fluid circuit To avoid any risk of contamination the lubrication procedures should be carried out under absolute cleanliness conditions All manufacturers of lubricants mentioned in the table offer a technical information service that may answer all your questions on lubrication WARNING on lubricants The correct use of suitable lubricants considerably helps to obtain the maximum performance and the elimination of failures During the handling of lubricants on equipments it is essential to strictly comply with the following pre cautions for sanitary protection e Avoid any prolonged excessive or repeated contact of the skin with lubricating products as well as avoid inhalation of their vapours or fumes Wear suitable clothing and protections to protect the skin for instance overalls eyeglasses or as far as allowed by the safety rules protection gloves or apply a protective product Clean dirty skin carefully by abundantly washing it with water and soap e Apply a skin cream after washing Take out and change clothes and shoes soaked with oil Never put oil soaked cloths in one s pockets TI008G0001 yy bee La od fe i Lubricants 8 02 General Several oils are available on the market and research continuously improves t
77. valve with detergent and blow with compressed air replace the sintered filter if it is fouled Always check the integrity of the O ring Photo 4 Pos 5 for the assembly and replace it if neces sary Replace it Photo 4 Pos 5 always when chan ging the oil Repeat the operation at every 500 hours of ope ration 228 TI008G0001 Maintenance 1 06 Replacing of the oil filter Replace the oil filter every time you change the oil Do not discharge the oil from the machine to replace the filter Just wait for a few seconds after the last stop to enable the oil in the tubes to flow Proceed as follows unscrew the filter cartridge Photo 1 clean the seat wet the gasket of the new cartridge with oil and screw it Photo 2 i LM ATTENZIONE ACHTUNG 3 Vement quan i uet sans ore d le compresseur est ete Mnn Kompressor ausschalter une Cleaning and replacement of bush filter Photo 3 Proceed as follows unscrew the filter cartridge Photo 3 clean the seat wet the gasket of the new cartridge with oil and screw it TI008G0001 Maintenance 1 07 Replacing the air oil separator elements Photo 1 101 1 Remove the side panels of the soundproof canopy to gain access to the separator 2 Disconnect the separator pressure probe Photo 2 3 Remove the ORV as shown in section ORV Cleaning and Replacement 4 Detach the pressure exhaust solenoid va
78. wing page Enabling Qil Teme Ait Tener 866 TI008G0001 099 098 yy bee La ed nf i How to Use the Machine 6 07 The machine can be restarted according to the above sequence but it will start again only if the internal pressure has lowered under the maximum allowed value for the re start preset factory data not changeable by the user 1 NOTE MAESTROXS has a control logic that prevents an excessive number of consecutives starts This logic is cleared by the user s manual intervention if he she acts directly by turning off and on the machine manually WARNING Operate manually only in case of real need and wait for a reasonable amount of time before restarting the machine An excessive number of consecutive starts may damage the main motor The number of starts depends now on many parameters the rated power the operation cycle the working pressure and the ambient temperature For any requirement please contact MATTEI TI008G0001 mattei voer 701 Suggestions on maintenance Machine cleaning Cleaning of the equipment should be carried out at regular intervals following the schedule in this manual To clean delicate parts of the machine direct the compressed air jet so that neither machining waste nor humidity can penetrate in the mechanic assemblies Only use lint free cloths to clean internal and or moving parts in contact with lubricant Always use perfectlly dry air during the cleaning and at suit
79. y authorised personnel should carry out maintenance troubleshooting and repairs Any maintenance and repair in progress should be signalled by a specific sign stating the maintenance condition and placed on the control panel until completion of the job even if temporarily interrupted All operations for installation maintenance or replacement of components on the machine or on the control unit should be performed with switched off system Therefore the main switch should be on OFF OPEN position and blocked with the safety lock to prevent any movement to the ON position For compressors equipped with INVERTER before performing any maintenance job wait at least 5 minutes after you have disconnected the electricity supply Before acting people in charge of maintenance should first check following conditions that any receiver under pressure has been exhausted Before intervening on pneumatic or lubricating systems and specifically on pipes receivers hoses and other components under pressure the staff in charge of maintenance should reduce the internal pres sure of the plant down to the ambient pressure value Faulty components must be replaced with others having the same code If during troubleshooting it is necessary to carry out jobs with the control unit and the machine live all precautions should be taken as required by the safety standards to operate under dangerous voltages and with moving parts At the end of the maintena
80. y they reduce carbon deposits provide a high self ignition temperature and are remarkably resistant to oxidation As synthetic lubricants are good detergents to change the kind of lubricant in a machine and pass from a conventional mineral based to a synthetic one it is necessary to carry out a thorough washing following the supplier s instructions to avoid damages to the machine if dirt residues and deposits circulate It is also necessary to pay attention to condensate as usually synthetic lubricants are more sensitive to water washing and their thin film may not provide enough protection against rust This problem can be worsened if the compressor is not working continuously but occasionally In this case even though not suggesting its use any responsibility for the choice is up to the user and to the lubricant supplier WARNING N It is difficult to determine life of an oil as there are different parameters affect ing the same among which the operating temperature and quality of the intake air are very important For this reason it is recommended to obtain precise guarantees from the sup plier validated by the analysis of samples taken from the machine to determine the suitability of lubricant and its life MATTEI LUBRICANTS Considering the important role of lubricant for operation of the compressor Mattei offers special lubricants to the users and recommends their use These are Mattei Rotoroil 8000 F2 syntheti

TI008G0001 - KPM Kompresori

Contents

Download Pdf Manuals

Related Search

Related Contents