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9828093300 00
USE & MAINTENANCE MANUAL Vers. 04/2019
HP 20 - 25 - 30 - 35 KW 15 – 18.5 - 22 - 26
HP 20 - 25 - 30 - 35 (IVR) KW 15 – 18.5 - 22 - 26(IVR)
(IVR ): Variable speed compressors (INVERTER)
THIS MACHINE IS DESIGNED TO BE CONNECTED TO TWO DIFFERENT SOURCES OF ELECTRICAL POWER: THREE-PHASE
POWER SOURCE FOR COMPRESSOR, SINGLE PHASE POWER SOURCE FOR DRYER
READ THIS MANUAL CAREFULLY BEFORE PERFORMING ANY OPERATIONS ON THE AIR COMPRESSOR.
ATTENTION: THE CAPACITORS INSIDE THE INVERTER MAY REMAIN LIVE FOR 15 MINUTES AFTER THE MACHINE HAS BEEN
DISCONNECTED FROM THE MAINS POWER.
ACTING ON THE INVERTER BEFORE 15 MINUTES HAVE PASSED MAY ENTAIL THE RISK OF ELECTROCUTION AND DEATH.
CONTENTS
PART A: NOTICES FOR THE USER PART B: NOTICES RESERVED FOR PROFESSIONALLY QUALIFIED
PERSONNEL
1.0 GENERAL CHARACTERISTICS 20.0 START-UP
2.0 INTENDED USE 21.0 GENERAL ROUTINE MAINTENANCE REQUIRES TRAINED
PERSONNEL
3.0 OPERATING PRINCIPLE 22.0 OIL REPLACEMENT
4.0 GENERAL SAFETY REGULATIONS 23.0 OIL FILTER AND OIL SEPARATOR FILTER
REPLACEMENT
5.0 DESCRIPTION OF HAZARD SYMBOLS 24.0 MOTOR BEARING GREASING (IVR ONLY)
6.0 HAZARDOUS AREAS 25.0 OLEO-PNEUMATIC DIAGRAM
7.0 SAFETY DEVICES 26.0 DRYER CALIBRATIONS
8.0 POSITION OF LABELS 27.0 VARIABLE SPEED (IVR)
9.0 COMPRESSOR ROOM
10.0 TRANSPORT & HANDLING
11.0 UNPACKING ATTENTION: A COPY OF THE WIRING DIAGRAMS IS INCLUDED IN
THE ELECTRICAL CABINET OF THE COMPRESSOR
12.0 INSTALLATION
13.0 OVERALL DIMENSIONS AND TECHNICAL DATA
14.0 ILLUSTRATION OF MACHINE
15.0 ROUTINE MAINTENANCE BY THE USER
16.0 STORAGE
17.0 DISMANTLING THE AIR COMPRESSOR
18.0 SPARE PARTS LIST FOR ROUTINE MAINTENANCE
19.0 TROUBLESHOOTING AND IMMEDIATE ACTIONS
Lock Out – Tag Out (LOTTO): Open the power disconnect switch and block it with a personal padlock. Perform the power
disconnect switch tag-out procedure by applying a sign with the name of the service technician.
BEFORE REMOVING THE PROTECTIONS TO SERVICE THE MACHINE, DISCONNECT THE ELECTRICAL POWER SUPPLY AND
CHECK THAT THERE IS NO RESIDUAL INTERNAL PRESSURE.
ALL OPERATIONS ON THE ELECTRICAL SYSTEM, EVEN IF MINOR, MUST BE PERFORMED BY PROFESSIONALLY QUALIFIED
PERSONNEL.
THIS MACHINE SATISFIES THE ESSENTIAL HEALTH AND SAFETY REQUIREMENTS OF EUROPEAN DIRECTIVE
(2006/42 EC).
LUBRICATING FLUIDS AND ANY OTHER FLUIDS MUST NEVER BE DISCHARGED IN THE ENVIRONMENT. THESE PRODUCTS,
CONSIDERED POLLUTING AND HAZARDOUS, MUST NECESSARILY BE DISPOSED OF BY AUTHORISED COMPANIES SPECIALISED IN
THE DIFFERENT TYPES OF PRODUCT.
SORT THE PARTS CONSTITUTING THE AIR COMPRESSOR BASED ON THE DIFFERENT TYPES OF CONSTRUCTION MATERIALS
(PLASTIC, COPPER, IRON, OIL FILTER, AIR FILTER, ETC. ...)
The manufacturer is not liable for any damage caused by failure to comply with or observe the aforementioned instructions.
AIR TANK AND SAFETY VALVES:
- In order to limit internal corrosion, which may compromise the safety of the compressed air tank, purge the condensate produced at
least once per day. If there is an automatic drain is connected to the tank, its correct operation must be checked every week and if
necessary, it must be repaired
- The thickness of the tank must be checked each year and in any case in accordance with laws in force in the country where
the tank is installed.
- The tank can no longer be used and must be replaced if the thickness falls below the minimum value indicated in the
documentation regarding tank use.
- The tank can be used within the temperature limits indicated in its declaration of conformity.
- The safety valves of the air and oil tank must be checked every year and replaced in accordance with laws in force.
FAILURE TO COMPLY WITH THE ABOVE PROVISIONS SHALL CREATE A RISK OF EXPLOSION OF THE AIR TANK.
The manufacturer is not liable for any damage caused by failure to comply with or observe the aforementioned instructions.
The compressor units use single stage oil-injected rotary screw air compressors.
The unit includes:
compressor; oil separator; oil cooler and output air cooler; fan; electric starter; safety and regulation devices, instrument panel.
The system is self-supporting and does not require any bolts or floor anchoring devices.
The unit is completely factory assembled; the connections necessary for its operation are:
• connection to mains power: (see installation chapter)
• connection to compressed air network: (see installation chapter)
The compressor-motor unit is mounted on the frame of the machine by means of elastic supports: this allows the compressor unit to be
rested directly on the floor without the need for any additional anti-vibration elements.
2.0 INTENDED USE
The compressor unit has been developed to supply compressed air for industrial use. In any case, the machine cannot be used in
places with an explosion or fire hazard, that is, in places where works are performed that release hazardous substances posing a
risk to safety into the environment (for example: solvents, flammable vapours, alcohols, etc. ...). In particular, the equipment cannot
be used to produce air intended for human respiration or used in direct contact with food substances. These uses are allowed if the
compressed air is treated using a suitable filtration system. (Consult with the manufacturer for these special uses).
This equipment must be used only in accordance with the use for which it was expressly designed.
All other uses shall be considered improper and therefore unreasonable. The Manufacturer shall not be held liable for any damage caused
by improper, erroneous and unreasonable uses.
3.0 OPERATING PRINCIPLE
3.1 OPERATING PRINCIPLE OF SCREW COMPRESSOR
The electric motor and compressor unit are coupled by means of a gear transmission / elastic coupling. The compressor unit withdraws air
from the outside through the intake valve. The withdrawn air is filtered by the filter cartridge installed upstream of the intake valve. Inside the
compressor unit, the air and lubricating oil are compressed and sent to the oil separator, where the oil is separated from the compressed
air; the latter is filtered again by the oil separator cartridge to reduce the suspended oil particles to a minimum. At this point the two flows (of
oil and air) are sent to two distinct coolers where they are cooled, using an air flow withdrawn from the outside using a special fan inside the
machine. The cooled oil is then recirculated while the compressed air is sent to the tank.
3.2 OPERATING PRINCIPLE OF DRYER
The dryer works as described below. The gaseous coolant coming from the evaporator (4) is withdrawn by the refrigeration compressor (1)
and pumped into the capacitor (2). The latter allows its condensation, eventually assisted by the fan (3); the condensed coolant passes
through the filter drier (8), expands through the capillary tube (7) and returns to the evaporator where it produces the refrigeration effect. By
way of the heat exchange with the compressed air flowing upstream through the evaporator, the coolant vaporises and returns to the
compressor to start a new cycle. The circuit is completed by a coolant bypass system, which intervenes to adapt the available cooling
power to the effective thermal load.
It is developed through the injection of hot gas, controlled by the valve (9): this valve keeps the coolant pressure in the evaporator constant,
and therefore also the dew point, which never falls below 0 °C (32 °F) in order to prevent the condensate from freezing inside the
evaporator
The dryer works in a completely automated manner; it is factory calibrated for a dew point of 5 °C (41 °F) and no further calibration is
required.
AIR OUTLET
DRYER FLOW DIAGRAM.
AIR INLET
ALL OPERATIONS ON THE ELECTRICAL SYSTEM, EVEN IF MINOR, MUST BE PERFORMED BY PROFESSIONALLY
QUALIFIED PERSONNEL.
2
8
5
2
2
IVR
1
2 3 2
FIG. 1
1 2 3 5 8
FIG. 2
2
3
5
2 2 5
1 3
8
1 2 3 5 8
1 FIG. 3
2
6
4 3
FIG. 4
FIG. 5
22 1
FIG. 6
2
3
4 4
FIG. 7
FIG. 8
Fresh air
Fresh air
inlet
inlet
FIG. 10
11.0 UNPACKING
After having removed the packaging, inspect the integrity of the machine and check that there are no visibly damaged parts. In case of
doubt, do not use the machine and contact the manufacturer’s service centre or your retailer. Packing materials (plastic bags) must not be
left within reach of children or dispersed in the environment insofar as they are potential sources of danger and pollution. Deposit such
materials in dedicated collection areas.
12.0 INSTALLATION
12.1 POSITIONING
After having unpacked and set up the compressor room, position the machine, performing the following checks:
• check that there is sufficient space around the machine for servicing (see Fig. 11)
FIG. 11
2
1
MINIMUM 1.5 m (in) 59
CHECK THAT THE OPERATOR HAS A FULL VIEW OF ALL THE EQUIPMENT FROM THE CONTROL PANEL AND CHECK
THAT THERE ARE NO UNAUTHORISED PERSONS IN THE VICINITY OF THE MACHINE.
12.2 ELECTRICAL CONNECTION
• Check that the supply voltage corresponds to the value on the machine data plate.
• Check the condition of the line conductors and for the presence of an efficient ground conductor.
• Check for the presence, upstream of the machine, of a circuit breaker switch with automatic overcurrent protection equipped with
differential device (Ref. 1 for screw compressor and Ref. 2 for dryer), see the wiring diagram.
• Connect the electrical cables of the machine with utmost care in compliance with current standards. Such cables must be developed as
indicated by the machine’s wiring diagram.
• Check the cables connected to the terminal block of the electrical cabinet and make sure they are properly tightened (tightening
torque provided in wiring diagram).
The torque of the electrical terminal screws must be checked after the first 50 running hours.
ACCESS TO THE ELECTRICAL CABINET IS ALLOWED ONLY BY PROFESSIONALLY QUALIFIED PERSONNEL. BEFORE
OPENING THE DOOR OF THE ELECTRICAL CABINET, DISCONNECT THE POWER.
COMPLIANCE WITH LEGISLATION IN FORCE REGARDING ELECTRICAL INSTALLATIONS IS ESSENTIAL TO ENSURE
THE SAFETY OF WORKERS AND PROTECTION OF THE MACHINE
THE CABLES, PLUGS AND ANY OTHER TYPE OF ELECTRICAL MATERIAL USED TO MAKE THE CONNECTION MUST
BE SUITABLE FOR USE AND SATISFY THE REQUIREMENTS OF LEGISLATION IN FORCE.
Insert a manual shut-off valve Ref. 1 between the machine and the compressed air distribution network to allow the compressor to be
isolated from the network during servicing (see figure 12).
TUBES, FITTINGS AND COUPLINGS FOR THE CONNECTION OF THE ELECTRIC COMPRESSOR TO THE COMPRESSED
AIR DISTRIBUTION NETWORK MUST BE SUITABLE FOR USE IN COMPLIANCE WITH THE PROVISIONS OF
LEGISLATION IN FORCE IN THE COUNTRY OF INSTALLATION.
1 1
2
3
2
ALWAYS USE A 1
FLEXIBLE HOSE 4
The automatic condensate drainage of the air dryer Ref.2, manual drainage of the air tank Ref.4 and automatic drainage of the WSD
cyclone water separator (optional) Ref.3 (version with dryer) in Fig. 12, is conveyed outside the machine by way of flexible and inspectable
tubing. Drainage must comply with local legislation in force.
THE MANUFACTURER SHALL NOT BE LIABLE FOR ANY DAMAGE CAUSED BY FAILURE TO OBSERVE THE
AFOREMENTIONED INSTRUCTIONS, WHICH MAY ALSO CAUSE THE INVALIDATION OF THE WARRANTY TERMS.
12.5 START-UP
See part B of this manual, Chap. 20.0
500 LT. TANK Dimensions mm (in) Air 500 LT. TANK WITH Dimensions mm (in) Air
WITHOUT DRYER couplings DRYER couplings
L W H D L W H D
HP 20-35 - kW 15- 1950 835 1835 1950 835 1835
1” HP 20-35 - kW 15-26 1”
26 (76.7) (32.9) (72.2) (76.7) (32.9) (72.2)
Weight Kg. (Lb) Weight Kg. (Lb)
HP 20 - kW 15 505 (1113.3) 485 (1069.2) (IVR) HP 20 - kW 15 555 (1223.5) 535 (1179.4) (IVR)
HP 25 - kW 18.5 530 (1168.4) 500 (1102.3) (IVR) HP 25 - kW 18.5 585 (1289.7) 555 (1223.5) (IVR)
HP 30 - kW 22 545 (1201.5) 505 (1113.3) (IVR) HP 30 - kW 22 600 (1322.7) 565 (1245.6) (IVR)
HP 35 - kW 26 560 (1234.5) 525 (1157.4) (IVR) HP 35 - kW 26 615 (1355.8) 580 (1278.6) (IVR)
HP 25 - kW 18.5 HP 30 - kW 22 HP 35 - kW 26
Max. pressure Psi 107 132 157 182 107 132 157 182 107 132 157 182
Rated pressure. Psi 100 125 150 175 100 125 150 175 100 125 150 175
Standard air flow rate m3/h 212.7 192.2 171 150.4 234.3 221.4 212 179.2 239 235.0 220.6 194.4
Noise dB(A) 68 69 71
Oil thermostat calibration °C (°F) 115°C (239° F) 115°C (239° F) 115°C (239° F)
Oil load lt. (Gal) 10 lt (2.64 Gal) 10 lt (2.64 Gal) 10 lt (2.64 Gal)
HP 20 (IVR) HP 25 (IVR) HP 30 (IVR) HP 35 (IVR)
kW 15 (IVR) kW 18.5 (IVR) kW 22 IVR) kW 26 (IVR)
Max. pressure Psi 188.5 188.5 188.5 188.5
Rated pressure. Psi 100 125 175 100 125 175 100 125 175 100 125 175
Standard air flow rate m3/h 172 152 127 212 189 145 237 213 180 251 248 198
Noise dB(A) 68 70 71 72
Oil thermostat calibration °C (°F) 115°C (239 °F) 115°C (239 °F) 115°C (239 °F) 115°C (239 °F)
Oil load lt. (Gal) 10 lt (2.64 Gal) 10 lt (2.64 Gal) 10 lt (2.64 Gal) 10 lt (2.64 Gal)
MAX. bar
Dryer type Load Rated Rated Power (Psi)
R 410A Kg. (Lb) Rated Power Pwr. W (HP)
W (HP) W (HP)
w
50 Hz 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz
E8V 795 (1.07) 835 (1.12) 55 (0.07) 65 (0.09) 850 (1.14) 900 (1.2) bar 14 (203)
E8/9V 4P See dryer data plate 1180 (1.58) 1235 (1.66) 55 (0.07) 65 (0.09) 1235 (1.66) 1300 (1.7) bar 14 (203)
E8/9V 2P 1210 (1.62) 1060 (1.42) 140 (0.19) 140 (0.19) 1350 (1.81) 1200 (1.6) bar 14 (203)
MAX. bar
Dryer type Load Rated Power Rated Pwr.
Rated Power w (HP) (Psi)
R 134a Kg. (Lb.) w (HP) W (HP)
50 Hz 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz
E8/9V 2P See data plate 1230 (1.65) 140 (0.18) 1370 (1.84) 1200 (1,61) bar 14 (203)
FIG. 13
7
4
6
14
3
2
15
1
12
7
8 8
18 17 16
10 11
20
13
24
14
19
9
26
21 Refrigeration compressor
22 Capacitor 29 21
23 Fan motor 25
24 Evaporator
25 Automatic condensate drain
26 Hot gas bypass valve 27
27 Coolant filter
22
28 Capillary tube
29 Pressure switch 14
28
23
BEFORE PERFORMING OPERATIONAL TESTS, READ AND FULLY COMPREHEND THE FUNCTIONS OF THE CONTROLS AND
COMMANDS
FIG. 14
14.3 CONTROLLER (Standard electronic control board for fixed speed compressors)
11 13 9
FIG. 15
8
3
12
15 10
2 6
S3
1 4
5
16 14 17 7
An electronic control board is installed on the electrical cabinet, which displays the functions as indicated in Fig. 15.
ATTENTION: TO RESTART THE MACHINE IMMEDIATELY AFTER A STOP, WAIT AT LEAST 20 SECONDS
Introduction:
the controller performs the following functions:
- Control the compressor and dryer.
- Protect the compressor and dryer.
- Monitor servicing
- Automatic restart after network voltage failure (optional mode).
Automatic control of compressor
The controller keeps the output pressure within programmed limits, controlling the loading and unloading compressor modes. Various set
parameters are taken into account, including: unloading and loading pressure, minimum stop time and maximum number of motor starts.
Protection of compressor
Fail stop
If the temperature at the screw compressor outlet (pumping) exceeds the set fail stop value, the compressor is stopped. This is indicated on the
display (3). The compressor also stops in the event of a motor overload.
Service warning:
If the service timer exceeds the set value, this will be indicated on the display (3) to inform the operator.
Tab. A
Ref. Designation Description
Emergency stop button Press the button to immediately stop the compressor in case of an emergency. After
S3 restoring the fault and eliminating the hazardous conditions, pull the button to
release it, then press the reset key (4).
Stop key Press the key to stop the compressor. The LED (10) will turn off. The compressor
will stop after running in unloading mode for approximately 180s.
1
Start key Press the key to start the compressor. The LED (10) turns on, indicating that the
controller is making the compressor work in automatic mode.
2
3 Display Indicates the compressor operating conditions, the current values measured and the
set parameters.
Reset key Key to reset the service timer, a fault condition, or to return to the previous display
view.
4
Enter key Key to select or confirm a parameter, to enter a sub-menu in the display.
5
6 Voltage present LED Indicates the presence of voltage in the electrical cabinet.
Voltage present symbol
7
8 General alarm LED This is on in the presence of an alarm condition.
It flashes in the presence of a fault or emergency stop.
Alarm symbol
9
10 Automatic operation LED Indicates that the controller is making the compressor work in automatic mode. The
compressor is placed in loading or unloading mode, stopped or restarted depending
on the request for air and the limits set in the electronic control board.
The LED is on during automatic operation and flashes when the compressor is
being controlled by remote.
Automatic operation symbol
11
12 Service warning LED This turns on to indicate that servicing is needed
Service warning symbol
13
Scroll down key Key to scroll down through the screens or reduce the value of a parameter.
14
Scroll up key Key to scroll up through the screens or increase the value of a parameter.
15
Scroll left key Key to scroll left through the screens.
16
Scroll right key Key to scroll right through the screens.
17
Motor stopped.
3)
When the compressor is stopped, the icon is fixed. When the compressor is running, the
4)
icon rotates.
Screw compressor output temperature
5)
Dew point (version with dryer).
6)
Motor overload or incorrect phase connection, or overtemperature of screw compressor
7) detected by thermostats (TSHH11-12).
Emergency stop command activated.
8)
Pictogram: service
9)
Remote Start/Stop
10)
LAN network setting.
11)
Automatic restart after voltage failure active.
12)
Timer
13)
Main screen
When the board is powered, the main screen automatically appears showing the operating status of the compressor and the output pressure:
example:
The display shows that the compressor is working in loading mode and that the supply pressure is 6.8 bar.
Consult the after-sales service if the wording <test> appears.
If the screw compressor output temperature exceeds the alarm limit (110°C / 230°F), the LED (8) turns on and the relative pictogram appears
intermittently. Press key (14) until the current output temperature of the screw compressor appears:
Intermittent
The screen shows that the screw compressor output temperature is 112°C (234 °F).
Using keys (14) and (15) it is possible to scroll through the various screens to check the status of the other parameters.
Stop the compressor by pressing key (1) and wait for the compressor to stop.
Disconnect the power upstream, isolating the unit.
For compressors with incorporated dryer, if the dew point temperature exceeds the alarm limit (non-programmable value), LED (8) turns on and the
relative pictogram appears intermittently
The screen shows the dew point temperature.
Intermittent
Press key (14) until the current dew point temperature appears:
The screen shows that the dew point temperature is 22°C (72 °F).
Using keys (14) and (15) it is possible to scroll through the various screens to check the status of the other parameters.
Stop the compressor by pressing key (1) and wait for the compressor to stop.
Disconnect the power upstream, isolating the unit.
If the output temperature from the screw compressor exceeds the fail stop limit value, (115°C / 239°F), the compressor stops, LED (8) flashes, and
LED (10) - automatic operation, turns off. The following type of screen will appear.
Press key (14) until the current output temperature of the screw compressor appears:
The screen shows that the screw compressor output temperature is 122°C (251°F).
Disconnect the power upstream, isolating the unit.
Motor overload
In case of a motor overload, the compressor will stop, LED (8) turns on, LED (10) - automatic operation, tuns off. The following type of screen will
appear:
Attention: A “Motor overload” shutdown will appear in the event of a motor overload, incorrect phase sequence (detected by the phase sequence
relay), or overtemperature detected by the thermostats (TSHH11-12).
Disconnect the power upstream, isolating the unit.
The screen shows that the service hour counter has recorded 4002 hours.
Press key (14) or (15) to go to screen <d01> and the running hours symbol will be shown.
By pressing key (5), the value of the current running hours will appear in <hrs> or <x1000hrs> (if the value is greater than 9999).
Example of running hours screen:
Press the scroll down key (14) until the screen <d.06> appears, then press the enter key (5):
The screen shows the unit of measure used <hrs> (or <x1000 hrs>) and the value 1191: the compressor has worked for 1191 hours since the last
service.
Example
The screen shows the number <d.1>, the unit of measure in use <hrs> and the symbol relative to the running hours. Press the Enter key (5) to bring
up the effective running hours.
Overview of screens
Advanced password-
Name Associated topic
protected parameters
<P.15> Star time
<P.16> Number of motor starts per day
<P.17> Idle time
Menu sequence
8
3
12
15 10
2 6
1 4
5
16 14 17 7
An electronic control board is installed on the electrical cabinet, which displays the functions as indicated in Fig. 15a.
1 Stop key (O) 10 Automatic operation LED
2 Start key (I) 11 Automatic operation symbol
3 Display 12 Service alarm LED
4 Reset key 13 Service alarm symbol
5 Enter key 14 Scroll down key
6 Voltage present LED 15 Scroll up key
7 Voltage present symbol 16 Scroll left key
8 General alarm LED 17 Scroll right key
9 Alarm symbol
ATTENTION: TO RESTART THE MACHINE IMMEDIATELY AFTER A STOP, WAIT AT LEAST 20 SECONDS
Introduction:
the controller performs the following functions:
- Control the compressor and dryer (for versions with dryer)
- Protect the compressor and dryer (for versions with dryer)
- Monitor servicing
- Automatic restart after network voltage failure (optional mode).
Automatic control of compressor
The controller keeps the output pressure within programmed limits, controlling the loading and unloading compressor modes. Various set
parameters are taken into account, including: unloading and loading pressure, minimum stop time and maximum number of motor starts.
Protection of compressor
Fail stop
If the temperature at the element outlet exceeds the set fail stop value, the compressor is stopped. This is indicated on the display (3). The
compressor also stops in the event of an inverter alarm.
Service warning:
If the service timer exceeds the set value, this will be indicated on the display (3) to inform the operator.
3 Display Indicates the compressor operating conditions, the current values measured and the
set parameters.
4 Reset key Key to reset the service timer, a fault condition, or to return to the previous display
view.
Enter key Key to select or confirm a parameter, to enter a sub-menu in the display.
5
6 Voltage present LED Indicates the presence of voltage in the electrical cabinet.
Voltage present symbol
7
8 General alarm LED This is on in the presence of an alarm condition.
It flashes in the presence of a fault or emergency stop.
Alarm symbol
9
10 Automatic operation LED Indicates that the controller is making the compressor work in automatic mode. The
compressor is placed in loading or unloading mode, stopped or restarted depending
on the request for air and the limits set in the electronic control board.
The LED is on during automatic operation and flashes when the compressor is
being controlled by remote.
Automatic operation symbol
11
12 Service warning LED This turns on to indicate that servicing is needed
Service warning symbol
13
Scroll down key Key to scroll down through the screens or reduce the value of a parameter.
14
Scroll up key Key to scroll up through the screens or increase the value of a parameter.
15
Scroll left key Key to scroll left through the screens.
16
Scroll right key Key to scroll right through the screens.
17
Motor stopped.
3)
When the compressor is stopped, the icon is fixed. When the compressor is running, the
4)
icon rotates.
Screw compressor output temperature
5)
Dew point (version with dryer).
6)
Alarm generated by inverter or overtemperature of screw compressor detected by
7) thermostat TSHH 11-12.
Emergency stop command activated.
8)
Pictogram: service
9)
Remote Start/Stop
10)
LAN network setting.
11)
Automatic restart after voltage failure active.
12)
Timer
13)
Main screen
When the board is powered, the main screen automatically appears showing the operating status of the compressor and the output
pressure:
example:
The display shows that the compressor is working in loading mode and that the supply pressure is 6.8 bar.
Consult the after-sales service if the wording <test> appears.
Alarm warnings
If the screw compressor output temperature exceeds the alarm limit (110°C / 230°F), the LED (8) turns on and the relative pictogram appears
intermittently. Press key (14) until the current output temperature of the screw compressor appears:
Intermittent
The screen shows that the screw compressor output temperature is 112°C / 234°F.
Using keys (14) and (15) it is possible to scroll through the various screens to check the status of the other parameters.
Stop the compressor by pressing key (1) and wait for the compressor to stop.
Disconnect the power upstream, isolating the unit.
For compressors with incorporated dryer, if the dew point temperature exceeds the alarm limit (non-programmable value), LED (8) turns on and the
relative pictogram appears intermittently
The screen shows the dew point temperature.
Intermittent
Press key (14) until the current dew point temperature appears:
The screen shows that the dew point temperature is 22°C (72 °F).
Using keys (14) and (15) it is possible to scroll through the various screens to check the status of the other parameters.
Stop the compressor by pressing key (1) and wait for the compressor to stop.
Disconnect the power upstream, isolating the unit.
Fail stops
If the output temperature from the screw compressor exceeds the fail stop limit value, (115°C / 239°F), the compressor stops, LED (8) flashes, and
LED (10) - automatic operation, turns off. The following type of screen will appear.
Press key (14) until the current output temperature of the screw compressor appears:
The screen shows that the screw compressor output temperature is 122°C (252 °F).
Disconnect the power upstream, isolating the unit.
Inverter alarm
In case of an inverter-generated alarm, the compressor will stop, LED (8) turns on, LED (10) - automatic operation, tuns off. The following type of
screen will appear:
Attention: The “Motor overload” symbol appears in the case of an inverter alarm, an overtemperature detected by thermostat TSHH 11-12
and an overload generated by the fan motor protection.
Disconnect the power upstream, isolating the unit.
Emergency shutdown
The compressor can be stopped at any time by pressing the emergency button.
NOTE:
After 5 seconds from the command, the controller display also shows the “Motor thermal overload” symbol (the inverter has been turned off).
This symbol appears when the emergency button is reset.
A service alarm appears when the service hour counter reaches the set limit value.
LED (12) will turn on.
Use key (14) to go to screen <d06> and view the service pictogram.
By pressing key (5), the current value of the service hour counter will appear in <hrs> or <x1000hrs> (if the value is greater than 9999).
The screen shows that the service hour counter has recorded 4002 hours.
Press key (14) or (15) to go to screen <d01> and the running hours symbol will be shown.
By pressing key (5), the value of the current running hours will appear in <hrs> or <x1000hrs> (if the value is greater than 9999).
Example of running hours screen:
Press the scroll down key (14) until the screen <d.06> appears, then press the enter key (5):
The screen shows the unit of measure used <hrs> (or <x1000 hrs>) and the value 1191: the compressor has worked for 1191 hours since the last
service.
Example
The screen shows the number <d.1>, the unit of measure in use <hrs> and the symbol relative to the running hours. Press the Enter key (5) to bring
up the effective running hours.
Overview of screens
Menu sequence
14.5 GRAPHIC CONTROLLER (for variable speed compressors with fixed speed as an optional).
A controller is installed on the electrical cabinet, which performs the following functions:
- Control of compressor and dryer.
- Protection of compressor and dryer.
- Monitoring of components subject to servicing.
- Automatic restart after voltage failure (optional).
In fixed speed machines, the controller maintains the network pressure within the programmable limits, placing the compressor in unloading
and loading mode. In machines with variable speed (inverter), the controller also modifies the motor speed in order to maintain the
“Regulation point” pressure. The controller considers a series of programmable settings such as loading and unloading pressures, minimum
stop time and maximum motor starts/hours.
The controller shuts down the compressor as soon as possible to reduce energy consumption and automatically restarts it when the
network pressure drops. If the set unloading time is too short, the compressor is kept running.
Protection of compressor
Fail stop
The compressor is stopped and this is shown on the display in the following cases:
- Screw compressor temperature higher than the programmed shutdown value measured by the temperature sensor.
- Screw compressor temperature higher than the programmed shutdown value measured by the thermostats (TSHH11-12).
- Main motor overload
- Phase sequence relay (fixed speed only).
- Fault in one of sensors (incorrect Pressure or Temperature display).
- Fan motor overload.
The chapter “Fail stop display” explains how the stop is shown on the display, how to identify the type of shutdown and how to resolve the
problem.
Alarm warning
Service warning
If the service timer exceeds the programmed value, a warning is shown to inform the operator that servicing is needed.
The controller has an incorporated function to automatically restart the compressor when the power is restored.
The function is not active; contact the customer centre to activate it.
If the controller is set in automatic mode, the compressor automatically restarts when the power is restored.
Control panel
2 8 4
FIG. 16
5
1
9
3
10 7
11 14
13
12 6
8 Service symbol
Status icons
Unloading mode
Loading mode
Or
Network control
Safety shutdown
Alarm
System icons
Menu icons
Test Information
Service General
Navigation arrows
Up Down
Main screen
Function: the main screen is automatically displayed when the controller is powered and when any of the keys are pressed. The screen
automatically turns off after a few minutes if no keys are pressed.
It is normally possible to choose between 5 different types of main screens:
- 2 Value Lines
- 4 Value Lines
- Chart (High Resolution)
- Chart (Medium Resolution)
- Chart (Low Resolution)
Typical main screen (2 value lines), fixed speed compressors Typical main screen (4 value lines), fixed speed compressors
Text in figure
Section A shows information relative to the operation of the compressor (for example, the working pressure or output temperature of the
compressor). On compressors with inverter, the load (flow) rate is provided as a % of the maximum flow.
Section B shows the status icons. This field generally shows the following icons:
- Fixed icons
These icons are always displayed in the main screen and cannot be selected using the cursor, for example, compressor stopped or
running, compressor status (running, in unloading mode or motor stopped).
- Optional icons
These icons are only displayed if the corresponding function has been activated (for example weekly timer, automatic restart after voltage
failure, etc.):
- Pop-up icons
These icons are displayed in the case of warnings (notifications, shutdowns, service, etc.). To bring up more information about the
displayed icons, select the icon using the scroll keys and press the Enter key.
Section C is called the status bar. This bar displays the text corresponding to the selected icon.
Section D shows the action buttons. These buttons are used to:
- bring up or programme the settings;
- reset a motor overload, a service message or emergency shutdown;
- access all data collected by the regulator.
The function of the buttons depends on the displayed menu. The most common functions are Menu (to access the menu), Modify (to modify
the programmable settings) and Reset (to reset a counter or message).
To activate an action button, select the button using the scroll keys and press the Enter key.
To return to the previous menu, press the Escape key.
Chart display
Instead of viewing the values, it is possible to view the chart of one of the input signals (see Input Menu section) based on time.
When Chart (High Resolution) is selected, the chart shows the variations of the selected input (in this case pressure) per minute. The
immediate value is also displayed. The screen shows the values of the last 4 minutes.
The switching button (icon) to select other screens assumes the appearance of a small chart and is highlighted (active).
When Chart (Medium Resolution) is selected, the chart shows the variations of the selected input per hour. The screen shows the values of
the last 4 hours.
When Chart (Low Resolution) is selected, the chart shows the variations of the selected input per day. The screen shows the variations
over the last 10 days.
To move between the various layouts of the screen, select the rightmost icon in the row of command icons (see value lines display icon or
chart display icon in the Icons used section) and press the Enter button. A screen will appear similar to the one shown below:
Select the desired icon and press the Enter key. See also Input Menu section.
Menu recall
Description: when the controller is powered, the main screen is automatically displayed (see Main Screen section):
To switch to the Menu screen, select the Menu button (4) using the scroll keys.
Press the Enter key to select the menu. The following screen appears:
A series of icons are shown on the screen. Each icon represents a menu item. By default, the pressure settings icon (regulation) is
selected. The status bar shows the name of the menu corresponding to the selected icon. Use the scroll keys to select an icon. Press the
Escape key to return to the main screen.
Alarm display
In case of an alarm, a yellow triangle appears in the bottom part of the display, as shown in the left-hand side figure below:
To identify the type of alarm, highlight the yellow triangle using the scroll buttons. Press Enter and the Protections menu will appear as
shown in the right-hand side figure above. Press Enter and the list of active protections in the controller will appear. Use the scroll buttons to
check all the protections and the one generating the alarm will be highlighted, such as the one in the figure below:
Stop the compressor by pressing button (11) in figure 17A and wait for the compressor to stop.
Open the disconnect switch of the compressor’s supply line.
ATTENTION: Before performing any type of servicing, the machine must be stopped, the electrical supply line and
compressed air distribution network must be isolated and a check must be made to ensure the machine is not under pressure.
Inspect the compressor to identify and eliminate the fault.
The warning will disappear once the fault condition has been eliminated.
Shutdown display
In case of a shutdown, a red icon appears in the bottom part of the display, as shown in the left-hand side figure below:
To identify the cause of the shutdown, highlight the red icon (1) using the scroll buttons. Press Enter and the Protections menu will appear
as shown in the right-hand side figure above. Press Enter and the list of active protections in the controller will appear. Use the scroll
buttons to check all the protections and the one generating the shutdown will be highlighted, such as the one in the figure below:
Attention: A “Motor overload” shutdown will appear in the event of a motor overload, incorrect phase sequence (detected by the phase sequence
relay), overtemperature detected by the thermostats (TSHH11-12), and if the fan overload protection is triggered.
Open the disconnect switch of the compressor’s supply line.
ATTENTION: Before performing any type of servicing, the machine must be stopped, the electrical supply line and
compressed air distribution network must be isolated and a check must be made to ensure the machine is not under pressure.
Inspect the compressor to identify and eliminate the fault.
After having eliminated the fault, power and restart the machine.
Alarm cod. on
Error Trip
GRAPHIC control Error text Warning Alarm Cause of problem
number locked
board
The signal on terminal 53 is too low (normal when a
2 Error live zero X X
machine with STD+ controller is started).
16384 Phase loss Missing phase on supply line or voltage imbalance too
4 X X X
on supply line high. Check power supply.
2048 The intermediate circuit voltage is over the limit (check
7 DC overvoltage X X
supply).
1024 The intermediate circuit voltage is below the “low
8 DC undervoltage X X
voltage warning” limit (check supply).
512 Load greater than 100% for too long. Check the
9 Inverter overload X X
compressor mechanics and loading/unloading valve.
256 The motor is too hot due to the load being greater than
High motor ETR
10 X X 100% for too long. Request assistance from the
temperature
distributor.
128 The thermistor or thermistor connection are
Motor thermistor
11 X X disconnected (if thermistors are included). Request
disconnected
assistance from the distributor.
32 The maximum inverter current limit has been
13 Overcurrent X X X
exceeded. Request assistance from the distributor.
14 4 Ground fault X X Discharge from output phases to ground.
16 4096 Short circuit X X Short circuit in motor or on motor terminals.
16 No communication
17 X X Connection cable or settings
(RS 485 port)
Fan malfunction
24 X X Fan malfunction
30 U phase loss X X U phase of motor does not exist. Check phase.
31 V phase loss X X V phase of motor does not exist. Check phase.
32 W phase loss X X W phase of motor does not exist. Check phase.
36 Voltage drop X X Problem with supply.
38 Internal fault X X Compressor contact service.
Discharge from output phases to ground. Request
44 Ground fault X X
assistance from the distributor.
47 Control voltage fault X X X Possible overload of 24V DC supply.
48 VDD1 supply low X X Low control voltage. Compressor contact service.
50÷58 Configuration error X Request assistance from the distributor.
The current is higher than the current limit value.
59 Current limit X
Request assistance from the distributor.
The external interlock has been activated.
60 External interlock X Reset on the compressor control board. If the alarm
doesn’t reset, request assistance from the distributor.
Low heat sink This warning is sent by the temperature sensor in the
66 X
temperature IGBT module.
Power board
The power board temperature sensor is too hot or too
69 temperature X X X
cold.
Incorrect
79 configuration of X X Internal fault. Request assistance from the distributor.
power section
All the parameter settings are initialised as settings in
80 Drive initialised X the default values of the Inverter. Request assistance
from the distributor.
84 Internal error X X Request assistance from the distributor.
85 Button disabled X Drive settings.
LCP inverter display Parameters incompatible or firmware version not
86 X
copy failed correct.
87 Auto DC braking X Inverter internal limiting.
LCP inverter display
88 X
data incompatible
Read-only
89 parameter (not X
editable)
90 Internal error X X Attempt to update the same parameter simultaneously.
94 Internal error X X Request assistance from the distributor.
Inputs menu
Function: allows the effective value of the measured data (analogue inputs) to be viewed, and the status of the digital inputs (for example
the emergency stop contact, the motor overload relay, etc.) and allows the selection of the digital input to be shown on the chart in the main
screen. Procedure: from the Main screen (see main Screen), move the cursor onto the Menu action button and press the Enter key. Using
the scroll keys, move the cursor onto the Inputs icon, as shown in the screen below:
Press the Enter key. A screen will appear similar to the one shown below:
(1) Inputs
(2) Compressor outlet
(3) Element outlet
(4) Ambient Air
(5) Emergency shutdown
The screen displays a list of all the inputs with the relative icons and values.
If an input is found in an alarm or stop condition, the original icon is replaced by the respective stop or warning icon (in this specific case,
the Stop icon and the Alarm icon shown in the screen above).
A small chart icon shown under a screw compressor in the list indicates that this input signal is shown in the chart, in the main screen. Any
analogue input can be selected.
Press the Enter key. A screen will appear similar to the one shown below:
(1) Outputs
(2) Fan motor
(3) Blowoff
(4) General shutdown
(5) Automatic Operation
Counters
Function: to view the running hours, the loading running hours, the number of main motor starts, the number of controller running hours and
the number of loading cycles.
Procedure: from the Main screen (see main Screen), move the cursor onto the Menu action button and press the Enter key.
Using the scroll keys, move the cursor onto the Counters icon (see below):
Press the Enter key. A screen will appear similar to the one shown below:
(1) Counters
(2) Running Hours
(3) Motor Starts
(4) Load relay
VSD 1-20 % rpm (the percentage of time during which the motor speed stays
(5)
between 1 and 20%) (compressors with inverter)
The screen displays the list of all counters and the relative effective values.
Note: the example above refers to an inverter-driven compressor. For a fixed speed compressor, the effective screen will be slightly
different.
Function: to select the Control Mode from among the available modes, specifically Local Control, Remote Control or LAN (Local Area
Network) Control.
Procedure: starting from the main screen, make sure the Menu button (1) is selected:
Then using the scroll buttons, move to the status icons and select the regulation icon (2). The icon is active when it is highlighted on a grey
background.
Press the Enter button:
After having selected the requested Regulation Mode, press the Enter key on the controller to confirm the selection. The new setting is now
visible on the main screen. See the Icons used section for details of their meaning.
To activate remote control, contact the customer centre.
Function: to reset the service warnings, to check when the next service is due, to check which service plans have been previously carried
out, to modify the programmed service intervals.
Procedure: from the Main screen (see main Screen), move the cursor onto the Menu action button and press the Enter key. Using the scroll
keys, move the cursor onto the Service icon (see below).
Press the Enter key. A screen will appear similar to the one shown below:
(1) Service
(2) Overview
(3) Service plan
(4) Next service
(5) History
Scroll the items to select the desired item and press the Enter key to view the details, as explained above.
(1) Overview
(2) Running Hours
(3) Real Time Hours
(4) Reset
Example of service level (A): the digits on the left represent the programmed service intervals. For service interval A, the programmed
number of running hours is 4000 hours (top row, green) and the programmed number of real time hours is 8760 hours, which corresponds
to one year (second row, blue). This means that the controller sends a service warning every 4000 running hours or every 8760 effective
hours, whichever condition occurs first. Note that the real time counter continues to tick over even when the controller is not powered.
The digits at the end of the bar represent the number of hours left until the next service. In the example shown, the compressor has just
been started, therefore it still has 4000 running hours or 8299 effective hours until the next service.
Service plans
Service operations are grouped (level A, level B etc.). Each level entails a series of service operations that need to be carried out in
accordance with deadlines programmed into the controller.
When the service plan interval is reached, a message is shown on the screen. After having performed the service operations relative to the
indicated levels, the timers need to be reset. From the Service menu, select Service Plan (3) and press Enter. The following screen
appears:
History
The History screen shows a list of all service operations performed in the past, in date order. The topmost date corresponds to the most
recent service. To see the details of the service operations performed (that is, the service level, running hours or real time hours), use the
scroll keys to select the desired service and press the Enter key.
Function: in fixed speed compressors, it is possible to programme two different pressure bands. From this menu it is also possible to select
the active pressure band.
Procedure: from the Main screen (see main Screen), move the cursor onto the Menu action button and press the Enter key. Using the scroll
keys, move the cursor onto the Regulation icon (see below):
Press the Enter key. A screen will appear similar to the one shown below:
(1) Regulation/Settings
(2) Unloading pressure 1
(3) Loading pressure 1
(4) Unloading pressure 2
(5) Loading pressure 2
(6) Modify
The screen shows the effective unloading and loading pressure settings for both pressure bands.
To change the settings, move the cursor onto the Modify action button and press the Enter key. The following screen appears:
The first row of the screen is highlighted. Use the scroll keys to highlight the setting to be changed and press the Enter key. The following
screen appears:
The upper and lower limits of the setting are shown in grey, the current settings are shown in black. Use the scroll key ↑ or ↓ to change the
settings as needed and press Enter to confirm.
If necessary, change the other settings following the same procedure explained above.
Press the Enter key. A screen will appear similar to the one shown below:
Scroll the rows, which indicate the date and time of the shutdown, and press the Enter key to view the other data relative to the compressor
status at the time of the shutdown.
Press the Enter key. A screen will appear similar to the one shown below:
This sub-menu screen also displays certain icons. By default, the User Password icon is selected. The status bar also shows the name of
the menu corresponding to the selected icon.
General menu
Starting from a sub-menu screen (see Modification of general settings), using the scroll keys, move the cursor onto the General icon (see
below).
Press the Enter key. A screen will appear similar to the one shown below:
(1) General
(2) Language in use
(3) Time
(4) Date
(5) Date format
(6) Modify
A screen similar to the one shown above appears, with the first item (Language) selected. Use the ↓ key to select the setting to modify and
press the Enter key. To confirm the changes, press the Enter key. A pop-up screen appears. Use the ↑ or ↓ key to select the requested
parameter and press the Enter key to confirm.
Terminology
Term Explanation
ARAVF Automatic restart after voltage failure.
Power return time The period of time within which the voltage must be restored for automatic restart. It is accessible if automatic
restart is active. To activate the automatic restart function, consult the customer centre.
Restart delay This parameter allows compressor restarts to be programmed in such a way that they don’t occur simultaneously
after a voltage failure condition (ARAVF active).
Screw compressor outlet The regulator does not accept conflicting settings. For example, if the alarm level is programmed at 95 ˚C (203
˚F), the minimum shutdown level will become 96 ˚C (204 ˚F). The recommended difference between the alarm
level and shutdown level is 10 °C (18 °F).
Shutdown delay This is the period of time during which the signal must persist before the compressor shuts down. Should it be
necessary to change this setting to another value, contact the customer centre.
Minimum stop time When the compressor shuts down, it remains stopped for the minimum stop time regardless of the compressed
air distribution network pressure. Contact your supplier if a value less than 20 seconds is required.
Unloading pressure / The regulator does not accept illogical settings. For example, if the programmed unloading pressure is 7.0 bar(e)
loading pressure (101 psi(g)), the maximum loading pressure becomes 6.9 bar(e) (100 psi(g)). The recommended minimum
difference between the loading and unloading pressure is 0.6 bar (9 psi(g)).
BEFORE PERFORMING ANY TYPE OF SERVICING, THE MACHINE MUST BE SHUT DOWN AND ISOLATED FROM THE
MAINS POWER AND COMPRESSED AIR DISTRIBUTION NETWORK.
The service operations reported in this chapter can be carried out by the user.
More complex service operations requiring the intervention of professionally qualified personnel are reported in the chapter GENERAL
ROUTINE MAINTENANCE Chap. 21.0
15.1 GENERAL NOTICES
15.2 MAINTENANCE PROGRAMME
◼ OPERATIONS THAT CAN ALSO BE PERFORMED BY THE USER
◼ ◼ OPERATIONS THAT MUST BE PERFORMED BY TRAINED PERSONNEL; THESE OPERATIONS ARE ILLUSTRATED IN
PART “B” OF THIS MANUAL
These service intervals are recommended for non-dusty and well-ventilated environments.
For particularly dusty environments, the frequency of controls must be doubled.
Every day (after use) ◼ Check the automatic drainage of the condensate (dryer) and cyclone water separator (WSD -
optional) if present.
Every 50 running hours ◼ Drain the condensate from the oil catcher
◼ Check the oil level
◼ Clean the filter of the automatic condensate drain (dryer)
IVR only
◼ Clean the filters of the electrical cabinet
Every 4000 hours ◼ ◼ Clean the finned surface of the air-oil cooler
◼ ◼ Replace the oil separator filter
◼ ◼ Replace the air intake panel filter
◼ ◼ Maintenance kit of automatic condensate drain (dryer)
IVR only
◼ Replace the air intake filters of the electrical cabinet
IVR only
◼ ◼ Greasing of electric motor bearings
◼ ◼ Change check valve
Every 8000 hours ◼ ◼ Intake valve service kit
◼ ◼ Servicing of oil return valve and inspection of oil tubes
◼ ◼ Minimum pressure valve and thermostatic valve service kit
◼ ◼ Change the oil (if RXD used)
IVR only
◼ ◼ Visual inspection of elastic element of motor-compressor coupling
Oil specifications:
It is highly recommended to use the manufacturer’s original lubricants. These are the result of years of industry experience and research.
See the Routine maintenance programme section for recommended replacement intervals and consult the list of spare parts for information
on the part number.
DO NOT MIX LUBRICANTS OF DIFFERENT BRANDS OR DIFFERENT TYPES INSOFAR AS THEY MAY NOT BE
COMPATIBLE AND OIL MIXES MAY HAVE INFERIOR PROPERTIES.
3A FIG. 17
3
4
6
1
7
5
- Check the oil level using the tell-tale Ref. 6 Fig. 17.
- If the oil level is below the minimum, top it up as described in point 15.4.
15.4 OIL LEVEL CONTROL AND TOP-UP
- Shut down the machine using the button Ref. 1 Fig. 17: in this way, the machine will stop after the unloading run time.
- Open the power disconnect switch Ref. 3 (for screw compressor) and Ref 3A (for dryer if present) Fig. 17.
- Wait 5 minutes for the foam to settle in the oil tank.
- Check the oil level using the tell-tale Ref. 6 Fig. 17.
- If the oil level is below the minimum, top it up.
USE THE SAME TYPE OF OIL AS THAT PRESENT IN THE MACHINE, DO NOT MIX DIFFERENT TYPES OF OIL
BEFORE PERFORMING ANY OPERATIONS ON THE MACHINE, CHECK THAT IT HAS BEEN ISOLATED FROM THE
ELECTRICAL POWER SUPPLY.
- Open the front panel Ref. 4 Fig. 17 with the special wrench
- Slowly open the oil cap Ref. 7 Fig. 17.
- Top up until the maximum level Ref. 6 Fig. 17 with the same type of oil as that in the compressor.
- Close the tank cap Ref. 7 Fig. 17.
- Close the panel Ref. 4 Fig. 17.
Machine running:
- The foam level is roughly in the middle of the sight glass.
ATTENTION:
- Do not check the oil level on a machine stopped for more than 10 minutes.
- Do not add any extra oil.
BEFORE PERFORMING ANY TYPE OF SERVICING, THE MACHINE MUST BE SHUT DOWN AND ISOLATED FROM THE
MAINS POWER AND COMPRESSED AIR DISTRIBUTION NETWORK.
4
1
FIG. 18A
BEFORE PERFORMING ANY TYPE OF SERVICING, THE MACHINE MUST BE SHUT DOWN AND ISOLATED FROM THE
MAINS POWER AND COMPRESSED AIR DISTRIBUTION NETWORK.
- Clean the filter element with a blast of air from the inside out, DO NOT USE WATER OR SOLVENTS, or: grab a new filter.
- Clean the filter support disc with a clean cloth.
- Mount the filter element and cover.
- If necessary, dispose of the old filter element in accordance with local regulations in force.
- Close the panel Ref. 2 Fig. 18.
FIG. 19
7 8
FIG. 20
3
2
4 9
5 6
7
10
“Green LED”: Condensate drain working properly (Automatic, Manual Drainage, Self-cleaning).
“Blue LED”: Condensate drain in “Timer Drain” mode Request for drain Service (See Chap.15.8).
If normal drain operation is not restored after the drain service (GREEN LED), contact the customer centre.
BEFORE PERFORMING ANY TYPE OF SERVICING, THE MACHINE MUST BE SHUT DOWN AND ISOLATED FROM THE
MAINS POWER AND COMPRESSED AIR DISTRIBUTION NETWORK.
FIG. 21
Ref. A
16.0 STORAGE
5
FIG. 22
4
8 2
During downtime, the machine must be protected against atmospheric agents, dust and humidity, which may damage the motor and
electrical system. Moreover, the compressor must be placed into operation once per month.
For the subsequent start-up, consult the manufacturer’s technical service centre.
If the machine is dismantled, it must be separated into similar parts for disposal in accordance with local regulations in force.
IT IS RECOMMENDED TO COMPLY WITH REGULATIONS IN FORCE FOR THE DISPOSAL OF USED OIL AND OTHER
POLLUTING MATERIALS SUCH AS THERMAL INSULATING SOUNDPROOF FOAM, ETC.
HP 20 HP 25 HP 30 HP 35
Ref NAME Qty. Code
kW 15 kW 18.5 kW 22 kW 37
1 Air/oil separator filter 1 6221 3724 50 ◼ ◼
1 Air/oil separator filter 1 6221 3725 50 ◼ ◼
2 Oil filter 1 6211 4722 50 ◼ ◼ ◼ ◼
3 Intake filter 1 6211 4723 50 ◼ ◼ ◼ ◼
4 Electrical cabinet filters (IVR only) 2 1089 9556 70 ◼ ◼ ◼ ◼
5 Air intake panel filter 1 2204 1213 01 ◼ ◼ ◼ ◼
Motor bearings tube (IVR only) 4 1630 2023 00 ◼ ◼ ◼ ◼
FIG. 23
1
2 2
4
3
1) The machine won't start 1A - no electrical supply - check the electrical supply line Chap.
1B - the transformer protection has tripped 12.2
- replace the fuses
2) The machine won't start, the tell-tale 2A - phases inverted - check phase sequence
(Ref. 8 Fig. 15 – 15a) is flashing. 2B - the main motor thermal relay protection - check for any motor faults
The intermittent pictogram appears (Ref. 7 has tripped - ambient temperature too high; improve
Tab. B). 2C – Screw compressor thermostat tripped ventilation in compressor room Chap.
9.2
3) The machine won't start, the tell-tale 3A - the oil temperature protection has - ambient temperature too high; improve
(Ref. 8 Fig. 15 – 15a) is flashing. tripped ventilation in compressor room Chap.
The intermittent pictogram appears (Ref. 5 9.2
Tab. B).
◼ ◼ - cooler radiator dirty; clean the radiator
- oil level too low; top up the oil tank
4) The compressor doesn’t reach the working 4A - the compressed air consumption in the
pressure network is too high
4B - the loading/unloading solenoid valve
remains closed. ◼ ◼ - check the electrical system
5) Excessive oil consumption 5A - worn oil separator filter ◼ ◼ - replace the oil separator filter
- oil level too high Chap. 23
19.2 TROUBLESHOOTING AND IMMEDIATE ACTIONS FOR SCREW COMPRESSOR (Graphic table for fixed speed and variable
speed compressors).
PROBLEM ENCOUNTERED POSSIBLE CAUSES OBSERVATIONS
1) The machine won't start 1A - no electrical supply - check the electrical supply line Chap.
1B - the transformer protection has tripped 12.2
- replace the fuses
2) The machine won't start, the tell-tale 2A - phases inverted - check phase sequence
(Ref. 5 Fig.16) is flashing. 2B - the main motor thermal relay protection - check for any motor faults
The intermittent pictogram appears (Fail has tripped - ambient temperature too high; improve
stop icon) 2C – Screw compressor thermostat tripped ventilation in compressor room Chap.
9.2
3) The machine won't start, the tell-tale 3A - the oil temperature protection has - ambient temperature too high; improve
(Ref. 5 Fig.16) is flashing. tripped ventilation in compressor room Chap.
The intermittent pictogram appears (Fail 9.2
stop icon)
◼ ◼ - cooler radiator dirty; clean the radiator
- oil level too low; top up the oil tank
4) The compressor doesn’t reach the working 4A - the compressed air consumption is too
pressure high
4B - the loading/unloading solenoid valve
remains closed. ◼ ◼ - check the electrical system
5) Excessive oil consumption 5A - worn oil separator filter ◼ ◼ - replace the oil separator filter
- oil level too high Chap. 23
The refrigeration compressor starter ◼◼ -Check relays and running and starter
system is faulty. capacitors (When included).
6) The dryer has stopped and won't start even The thermal relay has tripped: See cases
after a few minutes’ delay. 2B-2C-3A
PART “B”
THIS PART “B” OF THE INSTRUCTION MANUAL IS RESERVED TO PROFESSIONALLY QUALIFIED PERSONNEL,
AUTHORISED BY THE MANUFACTURER.
IVR MODELS: THE CAPACITORS INSIDE THE INVERTER MAY REMAIN LIVE FOR 15 MINUTES (VARIABLE SPEED) AFTER THE MACHINE
HAS BEEN DISCONNECTED FROM THE MAINS POWER.
WAIT AT LEAST 15 MINUTES (VARIABLE SPEED) AFTER ISOLATING THE SUPPLY VOLTAGE BEFORE PERFORMING SERVICING
OPERATIONS OR REPAIRS TO AVOID THE RISK OF DEATH OR SERIOUS INJURY.
20.0 START-UP
BEFORE PERFORMING ANY OPERATIONS ON THE MACHINE, CHECK THAT IT HAS BEEN ISOLATED FROM THE
ELECTRICAL POWER SUPPLY
2 FIG. 24
3
Oil
1
ALL OPERATIONS ON THE ELECTRICAL SYSTEM, EVEN IF MINOR, MUST BE PERFORMED BY PROFESSIONALLY
QUALIFIED PERSONNEL
IF ALL THE PROVISIONS REPORTED IN THIS MANUAL HAVE BEEN SATISFIED, IT IS POSSIBLE TO PROCEED WITH START-UP
ATTENTION: AFTER EACH STOP, WAIT AT LEAST 20 SECONDS BEFORE RESTARTING THE MACHINE
FIG. 25
1 7
3
5
BEFORE PERFORMING ANY TYPE OF SERVICING, THE MACHINE MUST BE SHUT DOWN AND ISOLATED FROM THE
MAINS POWER AND COMPRESSED AIR DISTRIBUTION NETWORK.
MAINTENANCE PROGRAMME
These service intervals are recommended for non-dusty and well-ventilated environments.
For particularly dusty environments, the frequency of controls must be doubled
Every day (after use) ◼ Check the automatic drainage of the condensate (dryer) and cyclone water separator (WSD -
optional) if present.
Every 50 running hours ◼ Drain the condensate from the oil catcher
◼ Check the oil level
◼ Clean the filter of the automatic condensate drain (dryer)
IVR only
◼ Clean the filters of the electrical cabinet
Every 4000 hours ◼ ◼ Clean the finned surface of the air-oil cooler
◼ ◼ Replace the oil separator filter
◼ ◼ Replace the air intake panel filter
◼ ◼ Maintenance kit of automatic condensate drain (dryer)
IVR only
◼ Replace the air intake filters of the electrical cabinet
IVR only
◼ ◼ Greasing of electric motor bearings
◼ ◼ Change check valve
Every 8000 hours ◼ ◼ Intake valve service kit
◼ ◼ Servicing of oil return valve and inspection of oil tubes
◼ ◼ Minimum pressure valve and thermostatic valve service kit
◼ ◼ Change the oil (if RXD used)
IVR only
◼ ◼ Visual inspection of elastic element of motor-compressor coupling
N.B. OPERATIONS MARKED BY ◼ ARE DESCRIBED IN PART “A” OF THIS MANUAL IN CHAP. 15.2
BEFORE PERFORMING ANY TYPE OF SERVICING, THE MACHINE MUST BE SHUT DOWN AND ISOLATED FROM THE
MAINS POWER AND COMPRESSED AIR DISTRIBUTION NETWORK.
Oil replacement is an important operation for the compressor: if bearing lubrication is inefficient, the service life of the compressor will be
reduced.
The oil must be replaced with the machine warmed up, that is, as soon as it is stopped.
Therefore, it is recommended to strictly follow the suggestions reported below.
After draining the used oil from the machine through the tap Ref. 2 Fig. 26
- Pour the oil into the inlet Ref. 1 Fig. 26 until the maximum level (See Chap. 15.4).
- Pour a bit of oil into the intake unit Ref. 3 Fig. 26
- Start the compressor.
- After about 1 minute, turn the machine off by pressing “STOP” (Ref. 4 Fig. 26), after the unloading run time, the machine will turn off.
- PROCEED AS DESCRIBED IN CHAPTER 15.4
FIG. 26
1 3 Oil
NOTES ON LUBRICANTS
The machine is supplied already filled with oil.
Prolonged use of the lubricant beyond the prescribed service period may entail the risk of fire.
In case of use at high temperatures or particularly heavy duty service, it is recommended to change the oil at more regular intervals than
those prescribed in the maintenance table.
Oil specifications:
It is highly recommended to use the manufacturer’s original lubricants. These are the result of years of industry experience and research.
See the Routine maintenance programme section for recommended replacement intervals and consult the list of spare parts for information
on the part number.
DO NOT MIX LUBRICANTS OF DIFFERENT BRANDS OR DIFFERENT TYPES INSOFAR AS THEY MAY NOT BE
COMPATIBLE AND OIL MIXES MAY HAVE INFERIOR PROPERTIES.
23.0 REPLACE THE OIL SEPARATOR FILTER AND THE OIL FILTER
BEFORE PERFORMING ANY TYPE OF SERVICING, THE MACHINE MUST BE SHUT DOWN AND ISOLATED FROM THE
MAINS POWER AND COMPRESSED AIR DISTRIBUTION NETWORK, AND CHECK THAT THE MACHINE IS NOT UNDER
PRESSURE.
- Shut down the machine using the button Ref. 2 Fig. 27: in this way, the machine will stop after the unloading run time of about 30 seconds.
NB: The internal pressure is automatically discharged after a delay period of about 60 seconds from the complete shutdown of
the machine
- Open the power disconnect switch Ref. 3 (for screw compressor) and Ref 4 (for dryer if present) Fig. 27.
- Close the tap Ref. 5 Fig. 27 (machine with and without tank).
- Depressurise the compressor by unscrewing the cap of the filling inlet Ref.1 by one turn so as to discharge any residual
pressure in the system.
- Depressurise the dryer and tank, opening the condensate drain tap Ref. 8 Fig. 27 (machine with tank).
- Replace the oil filter Ref. 6 and the oil separator filter Ref. 7 Fig. 27
- Lubricate the filter gasket with a bit of oil before remounting it.
- The filters must be tightened by hand.
- Fully screw in the cap of the filling inlet Ref.1 before restarting the machine.
4 FIG. 27
3
5 6
24.0 GRAPHIC CONTROLLER; ELECTRIC MOTOR BEARINGS GREASING (For variable speed only)
BEFORE PERFORMING ANY TYPE OF SERVICING, THE MACHINE MUST BE SHUT DOWN AND ISOLATED FROM THE
MAINS POWER AND COMPRESSED AIR DISTRIBUTION NETWORK, AND CHECK THAT THE MACHINE IS NOT UNDER
PRESSURE.
Proceed as follows:
- Restore the power supply
- Activate the lubrication programme from the MK5 menu:
- Go back to the main menu and press “START” (Ref. 4 Fig. 29).
- The compressor will run the lubrication programme: in unloading mode for (15 minutes at 1700 rpm).
- From the lubrication menu, the operator can check the remaining time.
N.B. During lubrication, it is not possible to stop the machine using the STOP key Ref. (5 Fig. 29).
In any case, in the event of an EMERGENCY the operator can stop the compressor by pressing the emergency button.
Once normal conditions are restored by pressing START (Ref. 4 Fig. 29) the compressor will resume lubrication for the remaining time.
At the end of the lubrication cycle, the standard operating conditions will therefore be automatically restored.
24.1 STANDARD CONTROLLER; ELECTRIC MOTOR BEARINGS GREASING (For variable speed only)
BEFORE PERFORMING ANY TYPE OF SERVICING, THE MACHINE MUST BE SHUT DOWN AND ISOLATED FROM THE MAINS POWER
AND COMPRESSED AIR DISTRIBUTION NETWORK, AND CHECK THAT THE MACHINE IS NOT UNDER PRESSURE.
Proceed as follows:
- Restore the power supply
- Activate the lubrication programme from the controller menu:
- Scroll down using the arrow until parameter (t.03).
4
1
2 3
INTAKE SIDE OF
REFRIGERATION COMPRESSOR 2
Evaporat.
Evaporation
Temperat.
Pressure bar (psi)
°C (°F)
RATED VALUES R134A R410A
Temperat. 20 °C 1÷2 2.1 ÷ 2.3 7.28 ÷ 7.55
(68 °F) (33.8 ÷ 35.6) (30.4 ÷ 33.3) (105.6 ÷ 109.5)
AIR INLET