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Summary of Contents for Pilot Air PAC Series
- Page 1 PAC SERIES PAC SERIES 56-75 KW User’s Maintenance & Spare Parts Manual P a g e PLUS 56-75-Cod.197DD8805...
- Page 2 Dear Customer, Thank you for choosing Pilot Air. In order to get the best performance out of this product, please read this manual carefully. To avoid incorrect operation of the equipment and possible physical risk to the operator, please read and strictly follow the instructions contained in this manual.
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Page 3: Declaration Of Conformity
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Page 4: Table Of Contents
INDEX Declaration of Conformity General Information Overall Dimensions Safety Regulations Installation Technical Features Start-Up and Operation Maintenance Troubleshooting Wiring Diagram Warrant Terms and Conditions P a g e PLUS 56-75-Cod.197DD8805... -
Page 5: General Information
General Information OUTFIT The following accessories are supplied with the compressor: • Use and maintenance manual • Electric box panel key • Oil/Condensate Exhaust tube CONDITION OF THE MACHINE WHEN SUPPLIED Every compressor is shop tested and delivered ready to be installed and to be set at work. Oil Used is: ROTENERGY PLUS. -
Page 6: Overall Dimensions
Overall Dimensions P a g e PLUS 56-75-Cod.197DD8805... - Page 7 Overall Dimensions P a g e PLUS 56-75-Cod.197DD8805...
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Page 8: Safety Regulations
Safety Regulations READ THIS PAGE CAREFULLY BEFORE PERFORMING ANY OPERATION ON THE COMPRESSOR GENERAL WARNINGS • The rotating compressors are destined for arduous and continuous industrial use. They are particularly adapt for application in industries where a large consumption of air is requested for long periods of time. - Page 9 Safety Regulations READ THIS PAGE CAREFULLY BEFORE PERFORMING ANY OPERATION ON THE COMPRESSOR SYMBOLS USED ON THE COMPRESSOR Several different labels are applied to the compressor. Their function is most of all to highlight any hidden dangers and to indicate correct behaviour during use of the machine or in particular situations. It is of fundamental importance that they are respected.
- Page 10 Safety Regulations READ THIS PAGE CAREFULLY BEFORE PERFORMING ANY OPERATION ON THE COMPRESSOR DO NOT: • Do not touch inner parts and pipes as they are very hot during compressor operation and stay hot for a certain time after compressor stops. •...
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Page 11: Installation
Installation 11 | P a g e PLUS 56-75-Cod.197DD8805... - Page 12 Installation DESCRIPTION OF THE COMPRESSOR Electrical equipment Air Filter Front panel / Oil Indicator Level Air/Oil Radiator Electric Motor Electric fan Control Panel Oil filter Air Intake Outlet Oil separator filter Suction Regulator Minimum pressure valve Screw Compressor Oil separator tank UNPACKING AND HANDLING THE MACHINE •...
- Page 13 Installation ELECTRICAL HOOK-UP (fig. 3) • The mains cable should have a cross- section suitable for the machine power and should include no. 3 phase wires, no. 1 neutral cable and no. 1 earth wire. • Between the mains cable and the compressor control panel a fused switch near the point where the cables go into the machine is absolutely necessary.
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Page 14: Technical Features
Technical Features 14 | P a g e PLUS 56-75-Cod.197DD8805... -
Page 15: Start-Up And Operation
Start-Up and Operation 1 – CHECKS TO BE CARRIED OUT PRIOR TO START UP N.B.: The customer is responsible for installing the machine and making the required electrical and air connections. Initial system start-up must be carried out by skilled personnel who will make the various checks required and follow the respective instructions. - Page 16 Start-Up and Operation OPERATING MODE • During first start-up, motor is started and “star” powered. During this phase compressor starts slowly, solenoid valve is closed and suction regulator (2) is closed. • The compressor is kept under these conditions for about 6 seconds.
- Page 17 Start-Up and Operation 2 - “ET-IV” CONTROL PANEL The compressor is fitted with a “control panel” for setting up and monitoring machine operation. The operating parameters were entered by the Manufacturer during “testing”. The parameters were tested for several hours in the various operating conditions.
- Page 18 Start-Up and Operation Stoppage Procedure: Press the STOP button (O) to activate the stoppage procedure. The load solenoid valve is deactivated and the no load cycle starts for the time set in the parameter “Stoppage time” (“NO LOAD” and then “STATUS –...
- Page 19 Start-Up and Operation Compressor Functioning with an Inverter Start-up procedure: Press the START (I) button. If no alarms are on, the start-up cycle activates: Stand-by for start-up: the control unit is waiting to verify the following conditions before starting the compressor: If the machine was switched off or a previous stoppage was executed, the control unit waits 15 seconds before starting the compressor.
- Page 20 Start-Up and Operation MAIN SCREEN The main screen summarises the current status of the machine 20 | P a g e PLUS 56-75-Cod.197DD8805...
- Page 21 Start-Up and Operation Menus and Parameters - The menus are structured as vertical drop-down menus; the title is on top and is followed by the list of parameters or sub-menus available. If the menu contains more items than the LCD display can show, two arrows (Up and Down) appear on the right to indicate more items are...
- Page 22 Start-Up and Operation 22 | P a g e PLUS 56-75-Cod.197DD8805...
- Page 23 Start-Up and Operation Password Certain menus are password protected. A password is requested if you try to access the reserved areas. Removal of menu protection persists until you go back to the main screen. Main Menu User : Menu containing the user parameters (see USER MENU paragraph). Support : Menu containing the Support parameters (see SUPPORT MENU paragraph).
- Page 24 Start-Up and Operation Support Menu Oil hours : Indicates the hours remaining before the oil needs to be changed. Oil filter hours : Indicates the hours remaining before the oil filter needs to be changed. Air filter hours : Indicates the hours remaining before the air filter needs to be changed. Oil separator hours : Indicates the hours remaining before the oil separator filter needs to be changed.
- Page 25 Start-Up and Operation Fan temperature hysteresis : Defines the delta temperature in which the main cooling fan must work. Diagnostic : Using the diagnostic menu, you can control the various inputs and outputs of the control unit. Input : The status of 9 digital inputs can be controlled Output : Using the right and left keys, you can move on the relay output you want to command, while using the up and down buttons to activate the output...
- Page 26 Start-Up and Operation Inverter Menu Enable Inverter : Inverter enabling. % Min functioning : Defines the frequency minimum percentage at which the inverter must work. The maximum is 100% Inverter Integral : Defines the integral part on the PID calculation of the inverter percentage. Inverter Proportional : Defines the proportional part on the PID calculation of the inverter percentage.
- Page 27 Start-Up and Operation Condensate Drainage Menu Condensate drainage on: Condensate drainage enabling. Interval : Defines the time in which the condensate drainage solenoid valve remains closed. Opening time : Defines the time in which the condensate drainage solenoid valve must stay open. Functioning mode : Defines the functioning mode of condensate drainage: Automatic : Condensate drainage only takes place when the compressor is on and in loaded mode.
- Page 28 Start-Up and Operation Input configuration: Sub-menu allowing you to configure the logic of all the control unit inputs and associate a function of your choice to input CN2-1, among: “oil filter, “air filter” and “air pressure switch”. By setting the configuration equal to 1, the input logic will be denied.
- Page 29 Start-Up and Operation Warning! Pre-alarm temp.: Having reached the oil pre-alarm temperature, the alarm DOES NOT BLOCK The compressor. Alarm! Temp. sen. fault: When an anomaly occurs on the oil temperature sensor (sensor short-circuits or open), the alarm BLOCKS the compressor. To re-start the compressor, you need to replace the probe.
- Page 30 Start-Up and Operation Warning! Ice alarm: The dryer temperature remains under the temperature defined in the parameter “Temperature OFF” for the time defined in the parameter “Alarms delay” (NOTE: there is an alarm only if the dryer is enabled) Alarm! Dryer sen. fault: When an anomaly occurs on the dryer temperature sensor (sensor short circuited or open), if the parameter “Alarm type”...
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Page 31: Maintenance
Maintenance Correct maintenance is crucial to achieve maximum efficiency of your compressor, and to lengthen its operating life. It is also important to comply with the maintenance intervals recommended, but it must be remembered that such intervals are suggested by the manufacturer in the event that the environmental conditions of use of the compressor are optimal (see “Installation”... - Page 32 Maintenance DRAIN CONDENSATE (fig. 5) The oil/air mixture cooling is set at a higher temperature with respect to the dew point of the air (under standard operating conditions of the compressor). However, the condensate in the oil cannot be fully removed. Blow off compressed air through cock B and then close it as soon as oil begins to flow out instead of water.
- Page 33 Maintenance REPLACING THE OIL FILTER (Fig. 7) (Reporting maintenance alarm on the command keypad) With the compressor stopped, remove the front panel. At each change replace also the oil filter E, unscrew the old filter and replace it. Always apply some oil on the edge of the filter and on the seal before refitting manually the filter.
- Page 34 Maintenance CHECKING THE TRANSMISSION BELT TENSION (Fig. 9) When the compressor is stopped, remove the right side panel C e the rear panel D and check the belt tension. Use a suitable measuring instrument that determines with precision the belt tension degree by means of a frequency measuring device in order to perform this control.
- Page 35 Maintenance REPLACING THE MINIMUM VALVE (Fig.10) Replace the seals highlighted with the letter G. CLEAN AIR PREFILTER (Fig.11) Remove the prefilter A from his seat. Wash it with soapy water solution, dry it completely before restarting the machine. 35 | P a g e PLUS 56-75-Cod.197DD8805...
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Page 36: Troubleshooting
Troubleshooting 36 | P a g e PLUS 56-75-Cod.197DD8805... -
Page 37: Wiring Diagram
Wiring Diagram 37 | P a g e PLUS 56-75-Cod.197DD8805... - Page 38 Wiring Diagram Wiring Diagram of the CONTROL UNIT ET-IV 38 | P a g e PLUS 56-75-Cod.197DD8805...
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Page 39: Warrant Terms And Conditions
1. 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; and 2. For a period of 12 months from the date of purchase that Pilot Air branded accessories supplied by Pilot Air will be free from defects due to defective factory workmanship or materials. - Page 40 Pilot Air will not be liable for a breach of any of its warranties unless the Claimant provides proof of purchase of the Product and makes a written claim to Pilot Air at the address set out below, either within 30 days after the defect would have become reasonably apparent, or if the defect was reasonably apparent prior to installation, then the claim must be made prior to installation;...
- Page 41 In the circumstances where Pilot Air accepts or it is determined by Pilot Air that the claimant has a valid claim under this warranty, and subject to paragraph (m) below, Pilot Air will bear all of the claimant's reasonable and proximate expenses incurred as a result of claiming under this warranty.
- Page 42 Important Note: If you acquire goods from Pilot Air as a consumer according to the Australian Consumer Law, our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage.
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