ENGLISH Code 9828093309 00 INSTRUCTION AND MAINTENANCE MANUAL Edition 05/2019 SILENCED SCREW ROTARY COMPRESSOR UNITS HP 3 - 4 - 5,5 - 7,5 - 10 KW 2,2 - 3 - 4 - 5,5 - 7,5 THIS MACHINE MUST BE CONNECTED TO TWO DIFFERENT POWER SUPPLIES: THREE-PHASE OR SINGLEPHASE SUPPLY FOR THE COMPRESSOR SINGLE-PHASE SUPPLY FOR THE DRYER READ THIS MANUAL CAREFULLY BEFORE CARRYING OUT ANY OPERATIONS ON THE COMPRESSOR UNIT.
ENGLISH CONTENTS PART A: INFORMATION FOR THE USER 1.0 GENERAL CHARACTERISTICS 2.0 INTENDED USE 3.0 OPERATION 4.0 GENERAL SAFETY STANDARDS 5.0 DESCRIPTION OF DANGER SIGNALS 6.0 DANGER ZONES 7.0 SAFETY DEVICES 8.0 POSITION OF PLATES 9.0 COMPRESSOR ROOM 10.0 TRANSPORT AND HANDLING 11.0 UNPACKING 12.0 INSTALLATION 13.0 DIMENSIONS AND TECHNICAL DATA 14.0 MACHINE ILLUSTRATION 15.0 ORDINARY MAINTENANCE TO BE DONE BY THE USER 16.0 PERIODS OF INACTIVITY 17.0 SCRAPPING THE UNIT 18.
ENGLISH ADDRESSES OF ASSISTANCE CENTRES In the event of breakdown or malfunction of the machine, switch it off and do not tamper with it. If repairs are needed, apply only to a technical assistance centre approved by the manufacturer and insist on the use of original spare parts. Failure to comply with the above may endanger the safety of the machine. INTRODUCTION Keep this manual with care for future consultation; the use and maintenance manual is an integral part of the machine.
ENGLISH 2.0 INTENDED USE The compressor has been built to supply compressed air for industrial use. The machine cannot be used in premises where there is a risk of fire or explosion or where work is carried out which releases substances into the environment which are dangerous with regard to safety (for example: solvents, inflammable vapours, alcohol, etc.). In particular the appliance cannot be used to produce air to be breathed by humans or used on direct contact with foodstuffs.
ENGLISH 5.0 DESCRIPTION OF DANGER SIGNALS 1) FLUID EJECTION 6) HIGH PRESSURE 2) DANGEROUS ELECTRIC VOLTAGE 7) HOT PARTS 3) AIR NOT FIT FOR BREATHING 8) MOVING PARTS 4) NOISE 9) FAN ROTATING 10) PURGE EVERY DAY 5) MACHINE WITH AUTOMATIC START 5.1 DESCRIPTION OF COMPULSORY SIGNALS 11) READ THE USE AND MAINTENANCE INSTRUCTIONS 6.0 DANGERS ZONES 6.1 DANGERS ZONES FOR COMPRESSOR UNIT Risks present on the whole machine FIG.
ENGLISH 6.2 DANGERS ZONES FOR DRIER UNIT AND TANK Risks present on the whole machine FIG. 3A (1) (6) (2) (6) (3) (2) (9) (2) (2) (3) (1) (6) (3) 7.0 SAFETY DEVICES 7.1 SAFETY DEVICES FOR SCREW COMPRESSOR (Fig. 4) 1) 2) 3) 4) 5) 6) Safety screws The front protection can be opened with a special key Fixed protection device - cooling fan / pulley Safety valve Emergency stop Oil filling cap (with safety breather) 6 - Edition 05/2019 Cod.
ENGLISH FIG. 4 1 5 1 4 3 2 1 2 6 1 7.2 SAFETY DEVICES FOR DRIER UNIT AND TANK 1) 2) 3) 4) 5) Safety valve Protective switch cap. Protective pressure switch cap. Relay for compressor (automatic) Overload protector for compressor FIG. 5 1 4 5 2 Cod.
ENGLISH 8.0 POSITION OF PLATES 8.1 POSITION OF THE DANGER PLATES FOR COMPRESSOR UNIT The plates fitted on the compressor unit are part of the machine; they have been applied for safety purposes and must not be removed or spoiled for any reason. 1) Dangers plate Code 2202 2607 90 2) Plate “Machine with automatic start” Code 2202 2510 89 FIG. 6 1 1 2 2 8.
ENGLISH 8.3 POSITION OF THE DATA PLATE FOR COMPRESSOR UNIT FIG. 8 6 6 2 2 1 1 5 6 3 2 1 4 6 1 2 3 4 5 Cod.
ENGLISH 8.4 POSITION OF THE DATA PLATE FOR DRYER – AIR RECEIVER FIG. 9 1 2 1 2 9.0 COMPRESSOR ROOM 9.1 FLOOR The floor must be even and of industrial type; the total weight of the machine is shown in the Chap. 13.0 Remember the total weight of the machine when positioning it. 9.2 VENTILATION When the machine is operating, the room temperature must not be higher than 40 °C or lower than 5 °C.
ENGLISH 10.0 TRANSPORT AND HANDLING The machine must be transported as shown in the following figures. FIG. 11 11.0 UNPACKING After removing the packing, ensure that the machine is unbroken and that there are no visibly damaged parts. If you are in doubt, do not use the machine but apply to the manufacturer technical assistance service or to your dealer. The packing material (plastic bags, polystyrene foam, nails, screws, wood, metal strapping, etc..
ENGLISH 12.0 INSTALLATION 12.1 POSITIONING After unpacking the equipment and preparing the compressor room, put the machine into position, checking the following items: ● Ensure that there is sufficient space around the machine to allow maintenance (see Fig. 12). ● Check that the compressor is standing on a perfectly flat floor. FIG. 12 1 1 MINIMUM mt.
ENGLISH CABLES, PLUGS AND ALL OTHER TYPE OF ELECTRIC MATERIAL USED FOR THE CONNECTION MUST BE SUITABLE FOR THE USE AND COMPLYING WITH THE REQUIREMENTS STATED BY THE REGULATIONS IN FORCE. 12.3 CONNECTION TO THE COMPRESSED AIR NETWORK Fit a manual interception valve Ref. 1 between the machine and the compressed air network so that the compressor may be isolated during maintenance operations; (see figure 13 ) .
ENGLISH 13.
ENGLISH TYPE DRYER R 134a Kg. Weight Kg. 19 20 25 A1 A2 A3 Nominal Power W bar MAX. Nominal Power W Nominal Power W 50 Hz 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz 0,170 0,290 0,350 0,170 0,290 0,350 135 161 233 125 173 252 29 29 33 42 49 54 164 190 266 172 222 306 Reference conditions: Ambient temperature 25 °C Inlet air temperature 35 °C Pressure 7 bar Dew point in pressure 3 °C bar 16 bar 16 bar 16 Limit conditions: Max. ambient temperature 45°C Min.
ENGLISH 14.
ENGLISH 14.3 COMMAND AND CONTROL PANEL BEFORE CARRYING OUT THE OPERATION TEST, READ CAREFULLY AND ACQUIRE A GOOD KNOWLEDGE OF THE COMMAND FUNCTIONS. DRYER CONTROL BOARD FIG. 16 COMPRESSOR CONTROL BOARD 1 7 6 2 3 4 5 Hp10 / kW7,5 Start 1) 2) 3) 4) 5) 6) 7) No load Delivery pressure gauge Isolating switch - also used as emergency stop and for resetting the motor thermal protection.
ENGLISH 15.0 ORDINARY MAINTENANCE TO BE DONE BY THE USER BEFORE CARRYING OUT ANY MAINTENANCE IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT FROM THE POWER MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION NETWORK. The maintenance jobs described in this chapter may be carried out by the user. The more complex maintenance jobs which require professionally skilled personnel are listed in the chaper on GENERAL ROUTINE MAINTENANCE. (See Chap. 21.0) 15.
ENGLISH 15.2 DRAINING CONDENSATE FROM THE OIL TANK If the compressor work cycle contemplates long pauses during which the machine cools down, a certain amount of condensate will gather in the oil tank. This happens, for example, when stopping overnight or at weekends. The condensate must be drained off every 50 hours or every week. This operation may be performed only when the machine is cold, that is when it has been switched off for at least 8 hours.
ENGLISH - Wait for the machine to cool down. - Remove the panel Ref. 5 Fig. 17 with the key provided. - SLOWLY turn on the tap Ref. 6 Fig. 17 and let the condensate flow out. - When the first traces of oil appear, turn off the tap. CONDENSATE MUST BE DISPOSED OF IN CONFORMITY WITH THE LOCAL REGULATIONS IN FORCE. - Check the oil level on the indicator Ref. 7 Fig. 17. - If the oil level is under the minimum, top up as described at point 15.3.
ENGLISH 15.5 CLEANING THE SUCTION FILTER OR CHANGING THE FILTER - Stop the machine, (See pag. 17). - Press the button switch Rif. 2 Fig. 18 (on the dryer if fitted) - Turn on the differential supply switch, Ref. 3 (on the screw-compressor) and Ref. 4 (on the dryer if fitted) Fig. 18. HOT PARTS INSIDE - Remove the fixed protection device (machine cover) Ref. 5 Fig. 18. - Remove the cover Ref. 6 Fig. 18 (Check the direction of the arrow). - Remove the filter Ref. 7 Fig. 18. 5 FIG.
ENGLISH 15.6 CHECKING THE AUTOMATIC AND MANUAL CONDENSATION EMPTYING (FOR DRYER AND TANK) BEFORE CARRYING OUT ANY MAINTENANCE IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT FROM THE POWER MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION NETWORK. The automatic and manual condensation drain (Rif. 8 and Ref. 11 Fig. 19) must be checked every day. Proceed as follows: - Press the "TEST" button, Ref. 8 Fig.
ENGLISH - Stop the machine, (See pag. 17). - Press the button switch Rif. 2 Fig. 19 - Turn on the differential supply switch, Ref. 3 (on the screw-compressor) and Ref. 4 (on the dryer) Fig. 19. - Remove pressure from the dryer and tank by opening the condensation outlet valve Ref. 11 Fig. 19. - Remove the stopper Ref. 9 Fig. 19 - Remove the filter Ref. 10 Fig. 19 - Clean the filter Ref. 10 Fig. 19 with a jet of air, working from inside to outside. - Install the filter, fix the plug. 16.
ENGLISH 18.0 LIST OF SPARE PARTS FOR ROUTINE MAINTENANCE Ref. 1 1 2 2 3 3 4 DESCRIPTION Suction air filter Suction air filter Oil filter Oil filter Separator cartridge Separator cartridge Filtering panel Code HP 3 - 4 - 5,5 - 7,5 kW 2,2 - 3 - 4 - 5,5 HP 10 kW 7,5 8 - 10 bar 8 - 10 bar ◼ 6211 4737 50 6211 4739 50 6211 4726 50 6211 4725 50 6221 3726 50 6221 3728 50 2202 2607 00 ◼ ◼ ◼ ◼ ◼ ◼ ◼ FIG. 21 2 1 4 24 - Edition 05/2019 Cod.
ENGLISH 19.0 TROUBLE-SHOOTING AND EMERGENCY REMEDIES N.B. OPERATIONS MARKED ◼ ◼ MUST BE CARRIED OUT BY PROFESSIONALLY SKILLED PERSONNEL APPROVED THE MANUFACTURER ALL WORK MUST BE CARRIED OUT BY PROFESSIONALLY SKILLED PERSONNEL. BEFORE CARRYNG OUT ANY MAINTENANCE JOBS IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT FROM THE POWER MAINS. 19.
ENGLISH 19.2 TROUBLE-SHOOTING AND EMERGENCY REMEDIES FOR DRYER ALL WORK MUST BE CARRIED OUT BY PROFESSIONALLY SKILLED PERSONNEL. BEFORE CARRYNG OUT ANY MAINTENANCE JOBS IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT FROM THE POWER MAINS. N.B. OPERATIONS MARKED ◼ ◼ MUST BE CARRIED OUT BY PROFESSIONALLY SKILLED PERSONNEL APPROVED THE MANUFACTURER FAULT FOUND 1) No compressed air passes through the dryer outlet POSSIBLE CAUSES 1A) The pipes are frozen inside 2) Presence of condensate in the pipings.
ENGLISH PART “B” THIS PART "B" OF THE INSTRUCTIONS MANUAL IS RESERVED FOR PROFESSIONALLY SKILLED PERSONNEL APPROVED THE MANUFACTURER. 20.0 STARTING UP BEFORE CARRYING OUT ANY OPERATION ON THE MACHINE, ENSURE THAT THE ELECTRIC POWER SUPPLY HAS BEEN DISCONNECTED. 20.1 PREPARING FOR SETTING UP After checking everything as indicated in Chap. 12, folow the instructions in Fig. 22. - Fit the sound-deadening panels Ref. 1 - These parts are packed in the bodywork. FIG. 22 1 1 Cod.
ENGLISH 20.2 PRELIMINARY CHECKS Check the oil level Ref. 1 Fig. 23; when delivered the machine is filled with oil; if the oil level is not as intended, top up with the same oil as the original type. If more than 3 months have passed between the inspection in the factory and the date of installation, lubricate the screw group before starting up, following the procedure described below: - Remove the protection Ref. 2 Fig. 23 - Remove the fixed protection device (machine cover) Ref. 3 Fig. 23.
ENGLISH 20.4 CHECK THE COMPRESSOR ROTATION DIRECTION AND START UP - Check that all the protective shields are in place. - Apply voltage to the control panel by operating the automatic differential switch of the line Ref. 1 Fig. 24. - Start the compressor by turning the selector to “ I ”, Ref. 2 Fig. 24 and after 1 second, stop it by turning the isolating switch to “OFF” Ref. 2a Fig. 24. - If the rotation is correct, the paper sheet Ref. 3 is blown up (See Fig.
ENGLISH 22.0 CHANGING THE OIL CAUTION: THIS OPERATION MUST BE DONE TOGETHER WITH THE OIL FILTER AND AIR FILTER EXCHANGE BEFORE CARRYING OUT ANY MAINTENANCE JOBS IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT FROM THE POWER MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION NETWORK. Oil changing is an important operation for the compressor: if the lubrication of the bearings is not efficient, the compressor life will be short.
ENGLISH 23.0 REPLACE THE OIL SEPARATOR FILTER AND THE OIL FILTER BEFORE CARRYING OUT ANY MAINTENANCE THE MACHINE MUST BE STOPPED, CUT OFF THE MACHINE FROM THE ELECTRICAL MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION CIRCUIT, CHECK THAT THE MACHINE IS NOT UNDER PRESSURE. N.B. INTERNAL PRESSURE IS AUTOMATICALLY DISCHARGED AFTER ABOUT 30 SECONDS WHEN THE MACHINE IS TURNED OFF Proceed as follows: - Open the front panel Ref. 1 Fig. 26 with the special key.
ENGLISH 25.0 REPLACING THE BELT (Hp 3-4-5,5-7,5 / kW 2,2-3-4-5,5) Fig. 27 BEFORE CARRYING OUT ANY MAINTENANCE THE MACHINE MUST BE STOPPED, CUT OFF THE MACHINE FROM THE ELECTRICAL MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION CIRCUIT, CHECK THAT THE MACHINE IS NOT UNDER PRESSURE. Proceed as follows: - Open the front panel Ref. 1 Fig. 27 with the special key. - Remove the fixeds protections device Ref. 2, 3, 4 Fig. 27. - Slacken the screws by half a turn Ref. 5 Fig.
ENGLISH Hp 3-4-5,5-7,5 / kW 2,2-3-4-5,5 FIG. 27 2 6 1 5 5 3 F f 4 2 1 () 4 Tightening torque = 25 N•m 3 6 5 5 Fig. A 6 mm 9 8 7 1 - F = 5 kg., force to be applied at the centre line, at right angles to the new belt. 2 - f = 6 mm., clearance after the application of F. (after 100 h operation F = 3 kg.) Cod.
ENGLISH Hp 10 / kW 7,5 FIG. 28 2 2 1 1 3 3 4 6 4 6 5 6 mm 5 F 7 Fig. A () 2 f Tightening torque = N. 30 2 FIG. 29 1 1 5 3 1 - F = 5 kg., force to be applied at the centre line, at right angles to the new belt. 2 - f = 6 mm., clearance after the application of F. (after 100 h operation F = 3 kg.) 34 - Edition 05/2019 Cod.
ENGLISH 26.
ENGLISH 26.1 OLEOPNEUMATIC DIAGRAM (Hp 10 / kW 7,5) STANDARD AIR CAPACITY NO DRYER STANDARD AIR CAPACITY WIHT DRYER AIR CIRCUIT OIL CIRCUIT CONTROL CIRCUIT 1 2 3 4 5 6 7 8 9 10 11 12 SUCTION FILTER SUCTION REGULATOR SCREW COMPRESSOR OIL DISCHARGE VALVE OIL MANIFOLD OIL FILTER THERMOSTATIC VALVE AIR-OIL COOLER AIR PRESSURE SWITCH AIR PRESSURE GAUGE MINIMUM PRESSURE VALVE AIR-OIL SEPARATOR 36 - Edition 05/2019 Cod.
ENGLISH 27.0 CALIBRACION FOR DRYER BYPASS VALVE FOR HOT GAS N.B. Tthese valves have already been calibrated and they do not require any adjistment. A dew point different from the rated one generally depends on causes which are not attributable to their operation. 1) Closing cap 2) Adiusting screw 1 WORKING PRESSURES AND TEMPERATURES OF R134a SUCTION SIDE OF REFRIGERATION COMPRESSOR Evaporat. Temperat. °C RATED VALUES (Temperat. 20 °C) 1÷2 2 Evaporating Pressure bar R134A 2,1 ÷ 2,3 27.
