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Manufacturer : POWER SYSTEM s.r.l.
Via Dell'Emigrante, 11/13
36040 Brendola, Vicenza, ITALY
Tel. +39 – 0444 - 401270
Fax +39 – 0444 - 401165
e-mail: info@powersystem.it
web: http://www.powersystem.it
Local Power System agent
1
POWER SYSTEM SRL
Via dell'Emigrante, 11/13 - 36040 Brendola (VI) Italia
INSTRUCTION AND
MAINTENANCE MANUAL
FOR SCREW COMPRESSORS
PS2030/2037PM
Name__________________________________________
Address________________________________________
Telephone______________________________________
Fax___________________________________________
Models:
Codice 900246
OQ7.5ARG114
Istruzioni per l'uso e manutenzione
Cod. OQ7.5ARG114 – GB
Emiss. 19-01-11 Rev. 0 - Agg. /
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Summary of Contents for Power Systems PS2030PM
- Page 1 INSTRUCTION AND MAINTENANCE MANUAL FOR SCREW COMPRESSORS Models: PS2030/2037PM Manufacturer : POWER SYSTEM s.r.l. Via Dell’Emigrante, 11/13 36040 Brendola, Vicenza, ITALY Tel. +39 – 0444 - 401270 Fax +39 – 0444 - 401165 e-mail: info@powersystem.it web: http://www.powersystem.it Local Power System agent Name__________________________________________ Address________________________________________ Telephone______________________________________...
- Page 2 INSPECTION REPORT Power System srl, via Dell’Emigrante 11/13, 36040 Brendola (VI) declares that the screw compressor package: Has successfully passed internal testing. The following aspects were checked: − All the components have been correctly assembled and tightened. − Functioning of all the electric components complies with specified parameters. −...
- Page 3 Dear Customer, First of all we thank you for your trust in buying your new “Rotary screw compressor”. We are sure that you will be satisfied with your purchase, considering the technological level achieved by our products, thanks to our constant commitment which encourages us to grow every day and to cope professionally with the continuous technological, productive and commercial transformations.
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Page 4: Warning
WARNING WARNING 1) Within the limits established in this guarantee, the undersigned manufacturer undertakes to repair all construction defects that may arise during the guarantee period, set at 12 (twelve) months from the date of start or at 15 (fifteen) months from the date of delivery. The obligations deriving from the guarantee cease in the event of suspension or variation of the agreed terms of payment. -
Page 5: Table Of Contents
INDICE WARNING ................................4 EC DECLARATION OF CONFORMITY ......................8 CE MARKING.................................. 9 IMPORTANCE OF THE MANUAL..........................10 NOTES FOR CONSULTATION ........................... 10 INTENDED RECEIVERS (AUTHORISED OPERATORS)..................11 MACHINE OFF STATUS.............................. 12 ABBREVIATIONS................................. 12 RESERVED RIGHTS..............................12 NAMING OF THE COMPRESSOR........................13 NAMING OF THE MODELS ............................ - Page 6 STORAGE................................26 DIRECTIVES AND REFERENCE NORMS ......................27 SAFETY ..................................27 16.1 SAFETY SIGNALS................................ 27 16.2 RESIDUAL RISKS................................. 30 16.3 AUTHORISED OPERATORS: PLACES OCCUPIED ....................30 CONTROL PANEL FOR THE BOARD EPS4.3....................32 17.1 SWITCHING ON THE BOARD AND STARTING THE COMPRESSOR ..............34 17.2 ACCESS TO THE USER PROGRAMMING MENU....................
- Page 7 27.1 REMOTE CONTROL ..............................51 27.2 ROTATION DIRECTION CONTROL .......................... 51 27.3 AUTOMATIC RESTART .............................. 51 27.4 MALFUNCTION OF THE PRESSURE TRANSDUCER ..................... 51 GENERAL WARNINGS ............................51 28.1 ORDERING PROCEDURE ............................51 28.2 DEMOLITION................................51 29 REGISTRATION AND COMMISSIONING REPORT ....................52 30 LOG BOOK TO CHECK MAINTENANCE ........................
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Page 8: Ec Declaration Of Conformity
EC DECLARATION OF CONFORMITY Power System SRL Via dell’Emigrante, 11/13 - 36040 Brendola (VI) - Italia Tel. +39 0444 401270 - Fax +39 0444 401165 info@powersystem.it - www.powersystem.it Declares that the machine: ROTARY SCREW COMPRESSOR PS2000 Model: with dryer without dryer Serial no.: _ _ _ _ _ _ _ _ Year of manufacture: _ _ _ _ Reservoir serial no.:_ _ _ _ _ _ _ _ _... -
Page 9: Ce Marking
CE MARKING The CE marking (FIG. 1) certifies the conformity of the compressor with the essential safety and health requirements contemplated by the European Directives listed in the EC declaration of conformity. It is an adhesive label made of silver coloured polyester with printing in black, with the following dimensions: L = 95 mm - H= 120 mm. -
Page 10: Importance Of The Manual
IMPORTANCE OF THE MANUAL BEFORE USING THE COMPRESSOR THE AUTHORISED OPERATORS MUST READ AND UNDERSTAND ALL PARTS OF THIS MANUAL. This technical manual of “Instructions for use and maintenance” has been drawn up according to the indications given by the European Directives, in order to ensure easy and correct understanding of the topics dealt with by the operators authorised to perform the use and maintenance of the compressor concerned. -
Page 11: Intended Receivers (Authorised Operators)
INTENDED RECEIVERS (AUTHORISED OPERATORS) This technical manual is intended exclusively for the operators authorised to carry out use and maintenance of the compressor, according to the specific technical and professional skills required for the type of activity. The symbols shown below placed at the beginning of a chapter and/or of a paragraph indicate which operator is involved in the subject dealt with. -
Page 12: Machine Off Status
MANUFACTURER’S TECHNICIAN This is a qualified technician made available by the Manufacturer and/or by the authorised Dealer to carry out the requested technical assistance, routine and special maintenance jobs and/or operations not listed in this manual which require a specific knowledge of the compressor, provided with the personal protective equipment (PPE) contemplated in table 7 and occupying the positions described in fig. -
Page 13: Naming Of The Compressor
NAMING OF THE COMPRESSOR The name of the compressor is: ROTARY SCREW COMPRESSOR NAMING OF THE MODELS The models are named according to the motor power. Name example: PS 20 30 – 10 PM Series PM (Permanent Magnet) Pressure (7,5 – 10 – 13 ) Power (kW) Compressor series Power System... - Page 14 Right side Front Left side Overhead view Fig.2 Istruzioni per l’uso e manutenzione POWER SYSTEM SRL Cod. OQ7.5ARG114 – GB Via dell’Emigrante, 11/13 - 36040 Brendola (VI) Italia Emiss. 19-01-11 Rev. 0 - Agg. /...
- Page 15 Rear Fig.3 Key: 1) Air output 2) Left side intake prefilter 3) Right side intake prefilter 4) Isolating switch 5) Control board 6) Cable entry 7) Front panel handle 8) Front panel handle 9) Electric fans 10) Dryer cooling air expulsion (if present) Istruzioni per l’uso e manutenzione POWER SYSTEM SRL Cod.
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Page 16: Overall Dimensions (Mm)
OVERALL DIMENSIONS (mm) Front Left side Fig.4 МОD. PS 2000 1400 1500 Istruzioni per l’uso e manutenzione POWER SYSTEM SRL Cod. OQ7.5ARG114 – GB Via dell’Emigrante, 11/13 - 36040 Brendola (VI) Italia Emiss. 19-01-11 Rev. 0 - Agg. /... -
Page 17: Technical Data
1310 1310 400V/50 Hz Noise dB (A) Compressor weight Compressor weight with dryer * : without packaging 8 bar Mod. PS2030PM PS2037PM Type of drive Direct Direct 400V/50 Hz min. 4 - min. 4 - max. Delivery pressure max. 11... -
Page 18: Intended Use
INTENDED USE The compressor has been designed and made for the following intended use: FIELD OF USE Industrial and handicrafts sector In a closed, covered environment, sufficiently lit, suitable for the legal requirements in force in the country of use concerning safety and health in the work place. -
Page 19: Optional Accessories
OPTIONAL ACCESSORIES THE ACCESSORIES MUST BE REQUESTED EXCLUSIVELY FROM THE MANUFACTURER, COMMUNICATING THE SERIAL NUMBER AND THE YEAR OF MANUFACTURE OF THE COMPRESSOR. The accessories avalaible upon request for the PS2000PM models are the following: integrated dryer oil tank heating resistance heat recovery kit with oil/water heat exchanger triple stage air filter for dusty ambients tropicalized version... -
Page 20: Unpacking And Handling
UNPACKING AND HANDLING The compressor should be lifted only with a pallet truck or a fork lift truck with suitable lifting capacity. • Check the integrity of the packaging. • Unpack the machine (paying attention to any indications on the packaging). •... -
Page 21: Installation
INSTALLATION The dimensions in the figure are in mm. View A-A Overhead view Fig.6 Key fig. 6: 1) Auxiliary reservoir condensate drain 2) Auxiliary reservoir (customer) 3) Compressor 4) Air expulsion 5) Main electric switch 6) Air intake 7) Electric power supply duct 8) Pneumatic system connecting pipe Istruzioni per l’uso e manutenzione POWER SYSTEM SRL... -
Page 22: General Warnings
10.1 GENERAL WARNINGS IT IS ABSOLUTELY FORBIDDEN TO USE AIR PIPES AND COUPLINGS THAT ARE NOT SUITABLE AND/OR DO NOT COMPLY WITH THE REGULATIONS IN FORCE. DURING COMPRESSOR OPERATION IT IS FORBIDDEN TO DISCONNECT THE PRESSURISED AIR PIPES. THERE IS A RESIDUAL RISK. IT IS OBLIGATORY TO INSTALL THE COMPRESSOR IN A PLACE WITH ADEQUATE VENTILATION WHICH ENABLES THE AMBIENT TEMPERATURE TO BE MAINTAINED BETWEEN +2 °C AND +40 °C, WITH HUMIDITY BETWEEN 5 AND 95%. -
Page 23: Air Tank
10.5 AIR TANK An auxiliary air tank is always required if the pipe system is not very long, so as to have a sufficient storage capacity and thus avoid rapid cycles. The air tank must be provided with a safety valve, a suitable pressure gauge and a system for draining condensate. IF AN AIR STORAGE TANK OUTSIDE THE COMPRESSOR IS USED, DO NOT FIT CHECK VALVES BETWEEN THE COMPRESSOR AND THE TANK. -
Page 24: Electrical Connection
ELECTRICAL CONNECTION The electric power supply line must be made using cables with a suitable section (*) for the machine power and it must include 3 phase cables + 1 earth cable. • For models in which there is a dryer or a heating element, 1 neutral cable is also necessary. •... -
Page 25: First Start-Up
FIRST START-UP The first start-up of the compressor (operative test) must obligatorily be carried out by a specialized technician. Ask the testing technician to fill in the R.C.R. form at the end of the manual. Filling in this form allows you to be sure that a complete test has been performed and, in the event of malfunctions of any kind, faster and more effective action can be taken under guarantee. -
Page 26: Storage
STORAGE If for various reasons the compressor cannot be installed at the time of delivery and has to remain some time in storage, it must be placed in a safe environment, with an adequate temperature and degree of humidity, and protected against dust. THE CUSTOMER (EMPLOYER) MUST TAKE ALL NECESSARY STEPS TO ENSURE THAT HIS EMPLOYEES CANNOT ACCESS THE PLACE OF INSTALLATION OF THE COMPRESSOR FOR ANY REASON UNTIL IT HAS BEEN TESTED. -
Page 27: Directives And Reference Norms
DIRECTIVES AND REFERENCE NORMS The compressor has been designed and made considering the assessments emerging from an accurate analysis of risks and aiming to achieve, considering the present state of the art, the objectives established by the essential safety and health requirements contemplated by the European Directives. - Page 28 Fig.8 Istruzioni per l’uso e manutenzione POWER SYSTEM SRL Cod. OQ7.5ARG114 – GB Via dell’Emigrante, 11/13 - 36040 Brendola (VI) Italia Emiss. 19-01-11 Rev. 0 - Agg. /...
- Page 29 RISKS SIGNAL MEANING GENERAL RISK The compressor must work with the doors closed (five languages). RISK OF ELECTRIC CURRENT Inside the compressor and the electric panel. RISK OF NOISE During compressor operation the noise may reach dangerous levels for your hearing. RISK OF PRESSURISED RESERVOIR The reservoir reaches dangerous pressure levels.
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Page 30: Residual Risks
16.2 RESIDUAL RISKS We inform the authorised operators that, although the manufacturer has taken all the technical and constructive precautions possible to make the compressor safe, there remain some potential residual risks described in TAB. 7. RESIDUAL RISK RISK OF BEING STRUCK BY PRESSURISED AIR AND/OR PIPES No.1 Low and accidental. - Page 31 AUTHORISED POSITION DESCRIPTION OF INTERVENTION OPERATORS To perform all the operations of transporting and handling the machine (see chap. 8 - 9) To carry out installation and the necessary maintenance operations, after consent from the safety manager. Standing at the front, facing the control panel, to perform: 1) Switching the control panel on/off with the main electric switch: 2) Setting the work parameters and viewing the machine status on the display;...
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Page 32: Control Panel For The Board Eps4.3
CONTROL PANEL FOR THE BOARD EPS4.3 EPS4.3 EPS4.3 EPS4.3 EPS4.3 RIF. DENOMINATION FUNCTION Led green Rotating motor. Led green Active loading electrovalve Led green Oil heater operating. Remote control enable Led yellow Led white Automatic restart enabled. “AUTO RESTART” Pressing it once allows you to enter the programming parameters menu. Pressing it again allows you to scroll through the various programming Blue “PROG”... - Page 33 RIF. DENOMINATION FUNCTION • Pos. “O - OFF”: Switches off power to the command and control Main electric switch panel. “O - OFF” - “I - ON” Pos. “I - ON”: Switches on power to the command and control panel. Resets alarms Yellow button with danger signal, At the 1...
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Page 34: Switching On The Board And Starting The Compressor
17.1 SWITCHING ON THE BOARD AND STARTING THE COMPRESSOR Status indication STOP 00bar 30°C Air/oil delivery Outlet air pressure temperature When the Start button is pressed the machine “STOP” status changes to “WAIT FOR START”, this is followed by the operation of the compressor showing: “WAIT FOR LOAD”, “LOAD”. -
Page 35: Access To The User Programming Menu
17.2 ACCESS TO THE USER PROGRAMMING MENU THE STORAGE OF ANY CHOSEN PARAMETER TAKES PLACE AFTER 60 SECONDS WITH THE MACHINE TURNED ON. To access the “User programming” menu and programme the electronic board, proceed as follows: press the programming key scroll through the screens by pressing the “PROG”... -
Page 36: Eps4.2 Troubleshooting
17.5 EPS4.2 TROUBLESHOOTING Alarm messages Cause Explanation / Remedies N. Allarm The compressor does not start but stores the start order in the memory. When the min. set temperature is reached for external causes, the compressor starts automatically. The Oil temperature below the Low temperature programmable fixed limit message “T out of scale”... -
Page 37: Function Of The Reset Key
The machine has reached the set number of working hours to carry out Carry out maintenance and hold down the Reset key for at least Maint Group B maintenance of the Group 30 sec. B, follow the instructions on the display System alarm 65 Contact Power System The auxiliary temperature... -
Page 38: Machine Status
17.7 MACHINE STATUS The machine status function is accomplished by means of a dry contact relay located on the power board. To use this switching contact you must operate directly on the terminal board in the electric panel on the terminals C (common), NO (normally open) and NC (normally closed);... -
Page 39: Checks Before Switching On
CHECKS BEFORE SWITCHING ON BEFORE SWITCHING ON THE COMPRESSOR THE AUTHORISED OPERATORS MUST PERFORM THE CHECKS LISTED IN TAB. 9. IT IS ABSOLUTELY FORBIDDEN TO SWITCH ON THE COMPRESSOR IF ANY DAMAGE AND/OR ABNORMAL SITUATION IS FOUND. IF NECESSARY, ASK FOR THE MANUFACTURER’S INTERVENTION AND NOTIFY THE COMPANY SAFETY MANAGER. -
Page 40: Hydraulic Diagram
HYDRAULIC DIAGRAM Fig.10 Ref. Fig. 10: 1- Suction air filter 2- Suction valve 3- Screw 4- Air / oil separator 5- Calibrated nozzle 6- Minimum valve 7- Air / Air exchanger 8- Condensate separator (if present) 9- Thermostatic valve 10- Air / oil radiator 11- Oil filter 12- Temperature sensor 13- Safety valve... -
Page 41: Operating Principle
OPERATING PRINCIPLE • When the motor has reached steady operating speed: in this phase the air passes through the intake valve (2) and arrives at the compressor (3). • In this phase the compressor operates at full speed, compressing the air inside the separator tank (4). •... -
Page 42: Maintenance Programme
MAINTENANCE PROGRAMME Before doing any job inside the machine, unless there are commands that require the machine to be switched on see chapter 3.3: “Machine off status”. Every day the user is recommended to check (before starting the compressor) the following: a) Check the oil level (if necessary top up with the same type of oil through the oil filler cap). -
Page 43: Routine Maintenance
ROUTINE MAINTENANCE By routine maintenance we mean all the activities aimed at maintaining the conditions of use and operation of the equipment with various types of intervention performed by the operator. Use only original parts for replacement. 24.1 PRECAUTIONS DURING MAINTENANCE Maintenance and repairs must be carried out only by sufficiently trained personnel, under the supervision of a technician qualified to do the job. -
Page 44: Oil Characteristics
24.3 OIL CHARACTERISTICS A mineral oil for hydraulic purposes must be used, or for screw compressors with oil injection, with the addition of oxidation inhibitors, and having anti-foam and anti-wear properties. The degree of viscosity must comply with the following table: Environment temperature Degree of viscosity From 0°... -
Page 45: Special Maintenance
SPECIAL MAINTENANCE By special maintenance we mean all the activities aimed at maintaining the conditions of use and operation of the equipment with various types of intervention performed exclusively by the manufacturer’s technician. 25.1 CHANGING THE OIL AND THE OIL FILTER ALWAYS CHECK THE OIL LEVEL WITH THE MACHINE SWITCHED OFF. -
Page 46: Checking And Topping Up The Oil Level
25.2 CHECKING AND TOPPING UP THE OIL LEVEL Indicates the amount of oil in the oil reservoir. Read oil level only when unit is stop. In the operation the oil level will fluctuate as the compressor loads and unloads. Check oil level only when compressor is stop and add oil only when the level is below the minimum (indicator in the red zone fig. -
Page 47: Removal Of The Air/Oil Separator
Stop the machine by pressing the stop pushbutton on the electronic board. Switch off the power: turn the isolating switch to “0”. Ensure that there is no pressurized air or oil in the oil reservoir. Unscrew the filter cartridge from the body using a suitable tool Screw the new cartridge onto the body 6. -
Page 48: Cleaning Or Changing The Filter Suction Panel
IMPROPER OIL FILTER MAINTENANCE WILL CAUSE DAMAGE TO EQUIPMENT. REPLACE FILTER ELEMENT AS INDICATED IN THE “MAINTENANCE” SECTION. MORE FREQUENT REPLACEMENT COULD BE REQUIRED DEPENDING ON OPERATION CONDITIONS. A FILTER ELEMENT LEFT IN SERVICE TOO LONG MAY DAMAGE EQUIPMENT. 25.6 CLEANING OR CHANGING THE FILTER SUCTION PANEL The prefilter panel guarantees a good air filtration in both ventilation and compression;... -
Page 49: 25.11 Changing The Electric Motor And The Electric Fan
25.11 CHANGING THE ELECTRIC MOTOR AND THE ELECTRIC FAN IF THE ELECTRIC MOTOR HAS BEEN CHANGED, WHEN STARTING PRESS “START” FOR A FEW MOMENTS (JUST ENOUGH TO SEE THE COOLING FAN TURNING) AND CHECK THAT IT TURNS IN THE DIRECTION INDICATED BY THE STICKER APPLIED ON THE MOTOR. IF IT IS TURNING IN THE WRONG DIRECTION, SWITCH OFF THE POWER AND INVERT THE CONNECTIONS OF TWO PHASES OF THE MOTOR POWER SUPPLY. -
Page 50: Troubleshooting
TROUBLESHOOTING REMEDIES FAULTS CAUSES THE COMPRESSOR 1) The pressure transmitter does not intervene; LOADS, THE SAFETY 2) The intake valve does not close. 1) Contact Power System VALVE TRIPS 3) Safety valve needs replaced. 1) Clean it; 1) Blocked oil separating nipple or calibrated 2) Check the part and change it if necessary;... -
Page 51: Electric Diagram
ELECTRIC DIAGRAM The wiring diagram for the power is enclosed in the machine documentation 27.1 REMOTE CONTROL Normally all the compressors are set “only with local control”. If you also want to have remote control you must connect a switch with an ON/OFF contact on the terminals CD-CD (max. -
Page 52: Registration And Commissioning Report
29 REGISTRATION AND COMMISSIONING REPORT Power System S.r.l. REGISTRATION AND SETTING ISSUING DATE REPORT SERIAL NUMBER Ref: service department OQ7.5CRG28 Page: Distributor Customer Compressor Model Date of installation Serial Number Year of manufacture INSTALLATION Location (compressors room, department, outside, etc..) Atmosphere (dirty, dusty, humid, closed, etc. -
Page 53: Log Book To Check Maintenance
30 LOG BOOK TO CHECK MAINTENANCE MAINTENANCE ISSUING DATE Power System S.r.l. LOGBOOK SERIAL NUMBER Ref: service department OQ7.5CRG25 Page: 56 di 39 Register here below Working hours and Maintenance carried out Working Air Filter Oil Filter Separator Oil filling Couplings Check electrical absorption Date... -
Page 54: Note
NOTE ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................Istruzioni per l’uso e manutenzione POWER SYSTEM SRL Cod. - Page 55 ..............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................Istruzioni per l’uso e manutenzione POWER SYSTEM SRL Cod.
- Page 56 POWER SYSTEM SRL Via dell’Emigrante, 11/13 36040 Brendola (VI) - Italia Istruzioni per l’uso e manutenzione POWER SYSTEM SRL Cod. OQ7.5ARG114 – GB Via dell’Emigrante, 11/13 - 36040 Brendola (VI) Italia Emiss. 19-01-11 Rev. 0 - Agg. /...
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