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Summary of Contents for pilotair DCR 1311
- Page 1 INSTRUCTION AND MAINTENANCE MANUAL FOR SCREW COMPRESSORS Models: DCR 1311/1315 DCR 1309/1315 VS PilotAir 1300 667 579 Spares@pilotair.com.au; Sales@pilotair.com.au Codice 900162 OQ7_5ARG078EN...
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Page 2: Table Of Contents
INDICE GUARANTEE CONDITIONS ..........................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 ........................ - Page 3 STORAGE ................................27 DIRECTIVES AND REFERENCE NORMS ......................28 SAFETY ..................................28 16.1 SAFETY SIGNALS ................................ 28 16.2 RESIDUAL RISKS ................................. 31 16.3 AUTHORISED OPERATORS: PLACES OCCUPIED ....................31 CONTROL PANEL FOR THE BOARD EPS4.3 ....................33 17.1 SWITCHING ON THE BOARD AND STARTING THE COMPRESSOR ..............35 17.2 ACCESS TO THE USER PROGRAMMING MENU .....................
- Page 4 ELECTRIC DIAGRAM ............................. 54 NOTE ELECTRIC DIAGRAM ..........................54 28.1 REMOTE CONTROL ..............................54 28.2 ROTATION DIRECTION CONTROL .......................... 54 28.3 AUTOMATIC RESTART .............................. 54 28.4 MALFUNCTION OF THE PRESSURE TRANSDUCER ....................54 GENERAL WARNINGS ............................54 29.1 ORDERING PROCEDURE ............................54 29.2 DEMOLITION................................
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Page 5: Ec Declaration Of Conformity
EC DECLARATION OF CONFORMITY Operating instructions (translation from original IT) Cod. OQ7_5ARG078EN Emiss. 18-07-08 Rev. 5 - Agg. 20-04-16... -
Page 6: 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 applied on the outside, on the rear of the compressor. The following data are indicated legibly and indelibly on the plate: •... -
Page 7: 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 8: 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 9: 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 10: 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: DCR;DCRVS 13 15 - 10 Pressure (8 – 10 – 13) Power (kW) Compressor series Series: DCR: fixed speed... - Page 11 Right side Lato dx Lato anteriore Lato sx Front Left side Pianta Overhead view Fig.2 Operating instructions (translation from original IT) Cod. OQ7_5ARG078EN Emiss. 18-07-08 Rev. 5 - Agg. 20-04-16...
- Page 12 Lato posteriore Rear Fig.3 Key: 1) Reservoir condensate drain 2) Reservoir support feet 3) Reservoir (270 / 500 lt – if supplied) 4) Front inspection panel lock 5) Electric fan cable clamp 6) LCD display 7) Control panel 8) Electric / isolating switch 9) Dryer cooling air expulsion 10) Compressor cooling air intake 11) Compressed air outlet G2...
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Page 13: Overall Dimensions (Mm)
OVERALL DIMENSIONS (mm) Lato anteriore Lato sx Front Left side Fig.4 NEWTON 1300 MOD. EDISON 1300 DV Tank 270 lt. Tank 500 lt Rif. Ø 1581,5 1991,5 1532 1645 1385 1385 1010 1010 1070 1070 Operating instructions (translation from original IT) Cod. -
Page 14: Technical Data
TECHNICAL DATA DCR 1311 DCR 1315 MODEL 1309 VS 1315 VS Max. delivery temperature °C Intake air temperature min. 0° - max. 40° °C Motor power / service factor kW/Hp FS1.1 FS1.1 FS1.1 FS1.1 FS1.1 Full load current 16.5 400V/50 Hz (230V/60 Hz) -
Page 15: Intended Use
INTENDED USE The compressor has been designed and made for the following intended use: Industrial and handicrafts sector FIELD OF USE In a closed, covered environment, sufficiently lit, suitable for the legal requirements in force in the country of use concerning PLACE OF USE safety and health in the work place. -
Page 16: 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 compressor may be fitted with an additional dryer and/or with a reservoir with two different capacities: 270 litres or 500 litres, which increase its versatility. -
Page 17: Lifting And Handling The Machine
LIFTING AND HANDLING THE MACHINE The compressor must be transported and handled only as shown in the following figure, with a pallet truck or a fork lift truck. Fig.5 LIFT THE COMPRESSOR ONLY BY THE BASE; DO NOT TRY TO LIFT IT BY OTHER PARTS SUCH AS THE CANOPY, MOTOR, PIPES AND SO ON. - Page 18 Lifting the compressor complete with reservoir, dryer and packaging Rear Left side Lifting the compressor or the dryer with the packaging Or the compressor complete with dryer with packaging Rear Left side Lifting the compressor complete with dryer without packaging KEY: 1) Reservoir 2) Cardboard...
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Page 19: Installation
INSTALLATION The dimensions in the figure are in mm. View Vista A - A 3500 Overhead view Vista in pianta 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... -
Page 20: 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 21: 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 22: 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 23: 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 24: 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 25: 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 26 Fig.8 Operating instructions (translation from original IT) Cod. OQ7_5ARG078EN Emiss. 18-07-08 Rev. 5- Agg. 20-04-16...
- Page 27 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 28: 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 FREQUENCY OF Low and accidental. - Page 29 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 30: Control Panel For The Board Eps4.3
CONTROL PANEL FOR THE BOARD 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 31 RIF. DENOMINATION FUNCTION Signal voltage present The display is always on when the compressor is powered Resets alarms Yellow button with danger signal, At the 1 click it shows information on the hours worked clock “h” - “RESET” At the 2 click it shows the auxiliary temperature Allows the “Rotary test”...
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Page 32: Switching On The Board And Starting The Compressor
17.1 SWITCHING ON THE BOARD AND STARTING THE COMPRESSOR Status indication STOP Air/oil delivery 00bar 30°C 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 33: 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 34: Eps4.3 Troubleshooting
17.5 EPS4.3 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 message “T out of scale”... -
Page 35: 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 Contact Power System System alarm 65 The auxiliary temperature... -
Page 36: 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 37: 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 38: 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 39: 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 40: 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 41: 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 42 When supplied by Power System, the compressor is filled with RotEnergyPlus oil. Type of oil Maintenance intervals (hours) RotEnergyPlus 4000 This lubricant is formulated to the highest quality standards and is factory authorized, tested and approved for use in rotary screw compressors.
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Page 43: 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 44: Checking And Topping Up The Oil Level
25.2 CHECKING AND TOPPING UP THE OIL LEVEL N.B.: If the oil level is below the reference mark “B”, top up the oil. Always check the oil level with the machine switched off. Procedure to be followed to top up the oil: 1) Top up with 0.5 litre of oil 2) Start the compressor and let it run for sufficient time (5 minutes) 3) Switch off the compressor and check the oil level. -
Page 45: Changing The Oil Separating Filter (Fig.12 Rif.a)
25.3 CHANGING THE OIL SEPARATING FILTER (fig.12 rif.A) The oil separating filter with coalescence (fig.12 rif. A) completes the phase of separating the oil from the compressed air. The filter has a spin-on cartridge that is easy to replace. ATTENTION: HOT PARTS INSIDE. Procedure to be followed for changing the spin-on cartridge: - Give the command for automatic stop of the motor. -
Page 46: Versions With Direct Transmission
28.4.2 Versions with direct transmission Procedure to be followed for cleaning or changing the calibrated nozzle: - Give the automatic stop command. - Turn off the power with the switch on the wall. - Turn off the line tap. - Ensure that there is no compressed air inside the separator, checking the pressure gauge provided. - Discharge the pressure from the circuit. -
Page 47: Removal Of The Air/Oil Separator
IMPROPER MAINTENANCE OF THE OIL FILTER CAN DAMAGE THE PLANT. CHANGE THE FILTER CARTRIDGE AS INDICATED IN THE MAINTENANCE TABLE. THE CARTRIDGE SHOULD BE CHANGED MORE OFTEN IF OPERATING CONDITIONS REQUIRE IT. CARTRIDGES LEFT UNCHANGED FOR LONGER THAN THE RECOMMENDED PERIOD CAN DAMAGE THE UNIT. 25.6 REMOVAL OF THE AIR/OIL SEPARATOR Procedure to be followed to change the cartridge. -
Page 48: Cleaning Or Changing The Filter Suction Panel
25.8 CLEANING OR CHANGING THE FILTER SUCTION PANEL The prefilter panel guarantees a good air filtration in both ventilation and compression; in this way the internal filters do not become easily obstructed. Fig.16 Procedure to be followed to change the pre-filter. Stop the machine with the stop pushbutton on the electronic board. -
Page 49: Checking And Changing The Transmission Coupling
25.11 CHECKING AND CHANGING THE TRANSMISSION COUPLING (Only versions with DIRECT transmission) The motor and the compressor are directly connected with a coupling fitted with an elastic element. The coupling must not be lubricated. Use the following procedure to change the elastic element and the joints if necessary. Switch off the compressor by pressing the stop pushbutton on the electronic board. -
Page 50: Troubleshooting
TROUBLESHOOTING REMEDIES FAULTS CAUSES 1) The pressure transmitter does not intervene; THE COMPRESSOR 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 EXCESSIVE OIL 2) Check the part and change it if necessary;... -
Page 51: Cod. Oq7_5Arg078En
ELECTRIC DIAGRAM The wiring diagram for the power is enclosed in the machine documentation NOTE ELECTRIC DIAGRAM 28.1 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
30 REGISTRATION AND COMMISSIONING REPORT ISSUING DATE REGISTRATION AND SETTING Power System SERIAL REPORT 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
31 LOG BOOK TO CHECK MAINTENANCE MAINTENANCE ISSUING DATE Power System LOGBOOK SERIAL NUMBER Ref: service department OQ7.5CRG25 Page: 56 di 60 Register here below Working hours and Maintenance carried out Couplings Working Air Filter Oil Filter Separator Oil filling Check electrical absorption Date Signature... - Page 54 NOTES ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................Operating instructions (translation from original IT) Cod. OQ7_5ARG078EN Emiss.
- Page 55 ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... Operating instructions (translation from original IT) Cod. OQ7_5ARG078EN Emiss. 18-07-08 Rev. 5 - Agg. 20-04-16...
- Page 56 Operating instructions (translation from original IT) Cod. OQ7_5ARG078EN Emiss. 18-07-08 Rev. 5- Agg. 20-04-16...
- Page 57 WARRANTY Pilot Air Compressors Pty Ltd manufactured goods - 1 Year Warranty and 3 Year Warranty (where applicable) February 2012 Pilot Air Compressors Pty Ltd (Pilot Air) warrants to the first purchaser of goods (manufactured by it) (Product) from Pilot Air and the last purchaser prior to installation that, subject to compliance with the Conditions of Warranties below that: For a period of 12 months from the date of purchase, the Product will be free from defects due to defective factory workmanship or materials;...
- Page 58 Pilot Air literature. To obtain copies of such literature go to www.pilotair.com.au or telephone Pilot Air on (02) 9648 3099; If the claimant chooses to rely upon any warranty specified herein the claimant’s sole remedy under the warranty for breach of the warranty is (at Pilot Air’s option) that Pilot Air will either supply...
- Page 59 The warranties specified herein do not apply to the following parts or conditions and cannot be relied upon in the situation whereby: any Pilot Air product or part has been subject to misuse, negligence, accidental damage, improper or inadequate use, inadequate maintenance or improper storage or been operated under unusual conditions or continuously under excessive load;...
- Page 60 Contact details if you wish to make a claim under any warranty specified herein: For more information or to make a claim under any warranty specified herein please telephone Pilot Air on http://www.pilotair.com.au (02) 9648 3099, email Pilot Air via our website:...
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