Page 1: Table Of Contents
ENGLISH Code 2200780027 01 MANUAL USE AND MAINTENANCE Edition 05/2012 QUIET SCREW ROTARY COMPRESSOR UNITS HP 20-25-30-40 KW 15-18,5-22-30 HP 20-25-30-40 (VSD) KW 15-18,5-22-30 (VSD) THIS MACHINE MUST BE CONNECTED TO TWO DIFFERENT POWER SUPPLIES: THREE-PHASE SUPPLY FOR THE COMPRESSOR SINGLE- PHASE SUPPLY FOR THE DRYER READ THIS MANUAL CAREFULLY BEFORE CARRYING OUT ANY OPERATIONS ON THE COMPRESSOR UNIT.
Page 2 ENGLISH MACHINE AND MANUFACTURER IDENTIFICATION DATA 1) Position of the identification plate 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.
Page 3: General Characteristics
ENGLISH 1.0 GENERAL CHARACTERISTICS The compressor units use single-stage screw rotary air compressors with oil injection. The central unit comprises: compressor, dryer and steam trap if present, storage tank. The system is self-bearing and does not require bolts or other devices to anchor it to the floor. The unit is completely assembled in the factory;...
Page 4: Description Of Danger Signals
ENGLISH 5.0 DESCRIPTION OF DANGER SIGNALS FIG. 2 1) FLUID EJECTION 6) HOT PARTS 2) DANGEROUS ELECTRIC 7) MOVING PARTS VOLTAGE 3) AIR NOT FIT FOR BREATHING 8) MOVING PARTS 4) NOISE 9) MACHINE WITH AUTOMATIC START 5) HIGH PRESSURE 5.1 DESCRIPTION OF COMPULSORY SIGNALS 11) READ THE USE AND MAINTENANCE INSTRUCTIONS...
Page 5: Safety Devices
ENGLISH 6.2 DANGERS ZONES FOR DRYER UNIT AND TANK Risks present on the whole machine FIG. 3A 7.0 SAFETY DEVICES 7.1 SAFETY DEVICES FOR SCREW COMPRESSOR (Fig. 4) 1) Safety screws 4) Emergency stop button with mechanical seal and rotation release. 2) Side panels and door to the electric panel, opened with a special key 5) Oil filling cap (with safety breather) 3) Fixed protection device - cooling fan...
Page 6: Position Of Plates
ENGLISH 7.2 SAFETY DEVICES FOR DRYER UNIT 1) Safety valve 4) Fan protection 2) Protective pressure switch cap. 5) Relay for compressor (automatic) 3) Earth 6) Overload protector for compressor FIG. 5 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;...
Page 7 ENGLISH 8.2 POSITION OF THE DANGER PLATES FOR DRYER 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 Cod. 1079990109 FIG.
Page 8: Compressor Room
ENGLISH 8.4 POSITION OF THE DATA PLATE FOR DRYER FIG. 9 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 or lower than...
Page 9: Installation
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). FIG. 12 SPACE FOR MAINTENANCE MINIMUM mt 1,5 mt 1,5...
Page 10: Dimensions And Technical Data
ENGLISH 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 ) . PIPES, FITTINGS AND CONNECTIONS USED FOR THE CONNECTION OF THE ELECTROCOMPRESSOR TO THE COMPRESSED AIR NETWORK MUST BE SUITABLE TO THE USE ACCORDING TO THE PRESCRIPTIONS OF THE REGULATIONS IN FORCE IN THE COUNTRY OF USE.
Page 11 ENGLISH Net weight Kg. (Ib) HP 20 -kW 15 HP 25 -kW 18,5 HP 30 -kW 22 HP 40 - kW 30 Weight (without / with ) dryer 366 - 439 375 - 448 391 - 464 419 - 492 (806,8 - 976,8) (826,7 - 987,7) (862 - 1022)
Page 12: Machine Illustration
ENGLISH 14.0 MACHINE ILLUSTRATION 14.1 GENERAL LAYOUT FOR COMPRESSOR AND DRYER 1 Air suction filter 12 Oil discharge 2 Thermostatic valve 13 Oil tank 3 Oil filter 14 Pressure gauge tank 4 Air-oil cooler 15 Control card 5 Filter panel 16 Safety valve () 6 Belt tightening system 17 Suction unit...
Page 13 ENGLISH 14.2 COMMAND AND CONTROL PANEL BEFORE CARRYING OUT THE OPERATION TEST, READ CAREFULLY AND ACQUIRE A GOOD KNOWLEDGE OF THE COMMAND FUNCTIONS. FIG. 16 Variable speed 1) Control card 2) Emergency stop button with mechanical seal and rotation release 14.3 ELECTRONIC CARD FIG.
Page 14 ENGLISH Symbol Description Pressing the pushbutton cancels the stored alarm indication. Pressing the pushbutton for more than 3 seconds, the central control unit is tested: all the LEDs must be on. By pressing this button the compressor is switched on. N.B. there is a delay of about 10 seconds before start up. (ATTENTION: start-up takes place about 15 seconds after the board is supplied with power or from the moment it is switched off with the button “...
Page 15 ENGLISH ATTENTION: to start up again after a protection has been triggered (alarm) press “RESET” followed by the start button “I” ATTENTION: start-up takes place about 15 seconds after the board is supplied with power or from the moment it is switched off with the button (5).
Page 16 ENGLISH The board is also programmed to measure the pressure in “bar” (parameter C7) and the temperature in °C (parameter C6). The pressure and temperature units of measurement correspond to the table below. Name of the parameter Value of the parameter 0 = °C 1 = °F 0 = bar...
Page 17: Ordinary Maintenance To Be Done By The User
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.
Page 18 ENGLISH 15.3 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.
Page 19 ENGLISH 15.5 CLEANING THE FILTERING PANEL - Switch off the machine with pushbutton Ref. 1 Fig. 18: in this way the machine stops after 45 seconds of idle running. - Turn on the differential supply switch, Ref. 3 (on the screw-compressor) and Ref. 3A (on the dryer if fitted) Fig. - Remove the filter panel Ref.
Page 20 ENGLISH 15.7 CHECKING THE AUTOMATIC CONDENSATION EMPTYING (FOR DRYER ) 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 condensation drain (Rif.
Page 21 ENGLISH 15.9 CLEANING THE CONDENSER BATTERY (ON THE DRYER IF FITTED) 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 condenser must be cleaned every month. Proceed as follows: - Switch off the machine with pushbutton Ref.
Page 22 ENGLISH 15.10 REPLACE THE LINE AFTER FILTER 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. WARNING: internal corrosion can seriously compromise the safety of installation; check it when changing cartridge. Proceed as follows: - Close the cock Ref.
Page 23: Periods Of Inactivity
ENGLISH 16.0 PERIODS OF INACTIVITY If the machine has to remain inactive for a long period: - Close the valve Ref. 1 Fig. 23. - Remove the panel Ref. 2 Fig. 23 - Depressurise the dryer by pressing the "TEST" condensation emptying button (for about 10-20 seconds) Ref. 3 Fig.22 - Switch off the machine with pushbutton Ref.
Page 24: List Of Spare Parts For Routine Maintenance
ENGLISH 18.0 LIST OF SPARE PARTS FOR ROUTINE MAINTENANCE HP 20 HP 25 HP 30 HP 40 DENOMINATION Code kW 15 kW 18,5 kW 22 kW 30 125 psi 125 psi 125 psi 125 psi 6211472350 Suction air filter  ...
Page 25: Trouble-Shooting And Emergency Remedies
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. 19.1 TROUBLE-SHOOTING AND EMERGENCY REMEDIES FOR SCREW COMPRESSOR FAULT FOUND POSSIBLE CAUSES...
Page 26 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 POSSIBLE CAUSES...
Page 27: Personnel
ENGLISH 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. 12.0, (installation) follow these instructions - Remove the brackets that hold the compressor-motor group to the base. These brackets, which are painted red, are required only during transport.
Page 28 ENGLISH IF ALL THE INSTRUCTIONS FOUND IN THIS MANUAL HAVE BEEN OBSERVED THE MACHINE CAN BE STARTED. ATTENTION: wait at least 45 seconds before starting the machine after a switch off FIG. 26 FIG. 26/A machine start-up is delayed for a ATTENTION: few seconds after the microprocessor is powered and after the scheduled stop...
Page 29: General Ordinary Maintenance Requires Trained Personnel
ENGLISH 21.0 GENERAL ORDINARY MAINTENANCE REQUIRES TRAINED PERSONNEL BEFORE CARRYING OUT ANY MAINTENANCE JOBS IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT FROM THE POWER MAINS. MAINTENANCE SCHEDULE These maintenance intervals are recommended for work environments that are not dusty and are well ventilated. For particularly dusty environments, double the frequency of maintenance.
Page 30: Belt Tension
ENGLISH NOTE ON LUBRICANTS When delivered the machine is filled with oil. In normal conditions of use, these lubricants have proved to be able to withstand use for as many as 4.000 hours. However, due to the external polluting agents that get into the compressor with the air that it takes in, it is advisable to change the oil at more frequent intervals, as indicated on the routine maintenance chart.
Page 31: Replacing The Electric Motor
ENGLISH 25.0 REPLACING THE ELECTRIC MOTOR 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. 25.1 DISASSEMBLING THE COOLING FAN AND CONVEYOR (Fig. 31) Proceed as follows: Remove the external panels.
Page 32: Oleopneumatic Diagram
ENGLISH 26.0 OLEOPNEUMATIC DIAGRAM 1 AIR FILTER 12 AIR-OIL SEPARATOR 2 REGULATING VALVE 14 SAFETY VALVE 3 COMPRESSOR 15 SAFETY TERMOSTATIC 4 OIL DRAIN 16 ELECTRIC MOTOR 5 AIR-OIL RECEIVER 17 NO-LOAD RUNNING SOLENOID VALVE 6 OIL FILTER 18 MANOMETER 7 THERMOSTATIC VALVE 20 IMPURITY TRAP 8 OIL COOLER...
Page 33: Calibrations For Dryer
ENGLISH 27.0 CALIBRATION FOR DRYER BYPASS VALVE FOR HOT GAS N.B. These valves have already been calibrated and they do not require any adjustment. 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 WORKING PRESSURES AND TEMPERATURES OF R134a / R404a...
Page 34 ENGLISH 34 - Edition 05/2012 Cod. 2200780027 01-...
Page 35 ENGLISH Cod. 2200780027 01 - Edition 05/2012 - 35...

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