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MGF WERTHER CS-COMPACK X Operating & Maintenance Instruction Manual

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CS-COMPACK X
Operating & Maintenance instruction manual
SCREW COMPRESSOR
Tel: 800-972-7668
www.werther.com
Werther Air Compressors
8614 Veterans Memorial Dr.
Houston, TX 77088
Tel : 800-972-7668

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Summary of Contents for MGF WERTHER CS-COMPACK X

  • Page 1 CS-COMPACK X Operating & Maintenance instruction manual SCREW COMPRESSOR Tel: 800-972-7668 www.werther.com Werther Air Compressors 8614 Veterans Memorial Dr. Houston, TX 77088 Tel : 800-972-7668...
  • Page 2 OPERATION AND MAINTENANCE MANUAL page...

  • Page 3: Table Of Contents

    SUMMARY 1. GENERAL WARNINGS AND INFORMATION FOR THE USER ....6 DEFINITION OF REGULATED RELATIONSHIPS ........... 6 1.1.1 DECLARATIONS ....................... 6 1.1.2 WARRANTY ........................7 1.1.3 RETURNS ........................... 7 CE MARKING ....................... 8 CAUTIONS AND SAFETY WARNINGS ..............9 2.2.1 INSTRUCTIONS FOR SAFE OPERATION ..............
  • Page 4 CLEANING AND DISINFECTION ................31 REINSTALLATION AND REUSE ................31 7.10 DEMOLITION AND DISPOSAL ................31 7.11 HEATING RESISTANCE (only in K3) ..............31 OPERATION AND USE ..................32 DESCRIPTION OF THE OPERATION ..............32 RANGE OF APPLICATIONS ................... 32 PROPER AND IMPROPER USE ................
  • Page 5 TROUBLESHOOTING ....................62 10 APPENDIX ......................64 10.1 MAINTENANCE CHECK SHEET ................64 11 SPARE PARTS ....................66 12 TECHNICAL SPECIFICATIONS ............... 73 OPERATION AND MAINTENANCE MANUAL page...

  • Page 6: General Warnings And Information For The User

    ________________ DECLARATION OF CONFORMITY MGF S.r.l., the manufacturer, on its own responsibility, declares that the air compressor identified by the label on the front page of this document, complies with the essential requirements laid out in the following DIRECTIVES – STANDARDS written in the certificate of conformity attached to the machine.

  • Page 7: Warranty

    1.1.2 WARRANTY M.G.F. S.r.l guarantees its products from manufacturing or design defects for a period of 24 months from the date of initial start-up. To inform M.G.F. S.r.l of this date, fill out the special form supplied with the machine technical documentation and send it in. If no communication is received, the warranty shall be recognized for 12 months starting from the date on which the unit was shipped;...

  • Page 8: Ce Marking

    2 CE MARKING The CE marking certifies that the compressor complies with the health and safety requirements outlined in the European Directives indicated in the EC declaration of conformity. The marking is printed with silver lettering on a black polyester adhesive label (L:90mm H:50mm).

  • Page 9: Cautions And Safety Warnings

    2.2 CAUTIONS AND SAFETY WARNINGS Read this operation manual carefully before performing any operations. Non-compliance with the instructions contained herein can lead to injury and property damage. The machine has been designed and built to operate as reported below. Any other use is considered unacceptable.
  • Page 10 Never use the compressor while under the effect of alcohol, drugs or medications that can cause drowsiness. Personnel Intervention Before performing any form of intervention, the personnel must be aware of all compressor functions and controls. Compressor Usage Never use the compressor for any purpose other than those specified in the user's manual. Air Jets Never direct air jet toward persons or animals.
  • Page 11 Keep the ventilation grid clean. If the unit is used in a particularly dirty environment, clean the grid regularly. Never use solvents, thinners or other substances containing hydrocarbons as they can damage the plastic parts. Clean with soapy water or an appropriate liquid cleaner.

  • Page 12: Contacts And Useful Addresses

    CONTACTS AND USEFUL ADDRESSES Our technical services department is at your disposal, ready to provide any information you may need and to help you resolve any problems that may arise. For any information, please log onto our website www.mgfcompressors.com For any clarifications you may require, contact our customer services department or your area retailer.

  • Page 13: Description Of The Machine And Operating Principle

    DESCRIPTION OF THE MACHINE AND OPERATING PRINCIPLE 3.1 MACHINE DESCRIPTION Suction valve Screw compressor Air tank (if present) Pressure relief safety valve Manometer Oil radiator Minimum pressure valve Pressure switch / Pressure transmitter Oil return from separator Oil separator filter Air/oil delivery hose from screw assembly Air/oil separator tank Suction filter...

  • Page 14: Operating Principle

    3.2 OPERATING PRINCIPLE • During the initial phase (unload), the electric motor ref. 29 reach the set operating RPM. The solenoid valve is not powered and thus the suction valve ref. 1 remains closed. The length of this phase can be set. •...

  • Page 15: Presentation Of The Manual: Content And Consultation

    PRESENTATION OF THE MANUAL: CONTENT AND CONSULTATION 4.1 SYMBOLS, GLOSSARY AND NOTES ON GRAPHIC LAYOUT This manual uses symbols to highlight situations that require utmost attention. These symbols can be located beside a text, a figure or at the top of a page. Pay utmost attention to the meaning of the symbols: They are used to avoid redundant repetition of technical concepts or safety warnings and must be considered as “reminders”.

  • Page 16: Data And Technical Specification

    DATA AND TECHNICAL SPECIFICATION Model Machine type Oil injected screw compressor direct drive Drive Type of screw ADAM V50 ADAM V50 ADAM V60 ADAM V60 ADAM 60 ccw Type of fluid handled Flow rate (ISO 1217 annex B /min – 9.5 cfm /min –...

  • Page 17: Dimensions

    6 DIMENSIONS 1092 1140 OPERATION AND MAINTENANCE MANUAL page...
  • Page 18 OPERATION AND MAINTENANCE MANUAL page...
  • Page 19 OPERATION AND MAINTENANCE MANUAL page...

  • Page 20: Installation

    INSTALLATION CHARACTERISTICS AND STORAGE CONDITIONS During periods of inactivity, before being unpacked (storage), the compressor must be kept at a temperature of between +5 °C and +45 °C. If the compressor has remained inactive for a long period of time, before starting it up again, change the oil and check function.

  • Page 21: Location

    LOCATION Install the compressor at the site point indicated at the time the order was placed. If the unit is installed at a different site, the manufacturer cannot be held responsible for any ensuing problems. Unless specified otherwise at the time the order is placed, the compressor must run normally under the environmental conditions indicated below.

  • Page 22: Connection And Start-Up

    CONNECTION AND START-UP 7.6.1 GENERAL WARNINGS When starting up the unit for the first time, make certain that: • The power supply matches the requirements indicated on the label. • The wall-mounted general switch is proportioned according to the indications in the technical data table (see chapter 6.6.2.1).

  • Page 23: Electrical Connection Of Compressor

    7.6.2 ELECTRICAL CONNECTION OF COMPRESSOR The electrical connection to the electrical line is carried out by the end user. He bear the costs and responsibility for quality and compliance standards, which must be performed by trained personnel in accordance with accident prevention regulations EN 60204.

  • Page 24: Ground Connection

    7.6.2.2 GROUND CONNECTION The compressor must be connected to the ground during its use, in order to protect the operator from accidental electric shocks. It’s necessary that the connections are made by a technician or an authorized service center. The grounding conductor yellow / green wire of the power of the compressor must only be connected to terminal of the compressor.
  • Page 25 7.6.2.4 WIRING DIAGRAM ELECTRONIC VERSION - 230V /1ph/50Hz OPERATION AND MAINTENANCE MANUAL page...
  • Page 26 ELECTRONIC VERSION - 230V / 1ph /60Hz OPERATION AND MAINTENANCE MANUAL page...
  • Page 27 COOLING AND AUTOMATIC DISCARGE SISTEMS - 230V / 1ph /50Hz – 220 / 1ph /60Hz OPERATION AND MAINTENANCE MANUAL page...
  • Page 28 ELECTRONIC VERSION - 400V / 3ph /50Hz ( WITHOUT CABINET ) OPERATION AND MAINTENANCE MANUAL page...

  • Page 29: Air Circuit Connection

    7.6.3 AIR CIRCUIT CONNECTION Make certain that the compressed air hoses used have adequate maximum pressure rating and section for the compressor. Never repair defective hoses; they must always be replaced. Connect the compressor to the pneumatic system using the quick port Ø8mm indicated in the figures.

  • Page 30: First Start-Up

    7.7 FIRST START-UP The first compressor start up (operational testing) must be performed by a qualified technician. Remember, for the technical warranty to be valid, that the registered test report (R.C.R.) attached to the documentation must be filled out (see notes on sales clauses). After having taken all compressor assembly steps illustrated in chapter 6, prepare the machine for first start-up.

  • Page 31: Cleaning And Disinfection

    7.8 CLEANING AND DISINFECTION Keeping the installation site and the compressor clean is essential to good machine operation and keeps operating and maintenance costs down. Installation site and compressor disinfection is essential to guarantee good air quality in the compressor room and in the area where the compressed air is used (workshop). 7.9 REINSTALLATION AND REUSE Reinstallation and reuse of the machine must be performed by qualified personnel and only after checking the condition of the machine itself.

  • Page 32: Operation And Use

    8 OPERATION AND USE 8.1 DESCRIPTION OF THE OPERATION For the machine functions, see chap. 2. 8.2 RANGE OF APPLICATIONS The machine is suited to all those applications requiring compressed air at the flow rate and pressure outlined in the technical data sheet (see chap. 4). 8.3 PROPER AND IMPROPER USE CAUTION! The compressor is designed and built solely to produce compressed air.

  • Page 33: Safety Devices And Signals

    8.6 SAFETY DEVICES AND SIGNALS The machine is equipped with safety devices and signals to prevent situations dangerous for the operator and the machine itself. These devices and signals come in the form of labels placed at dangerous points, and alarms that are displayed on the electronic controller.

  • Page 34: Position Of The Labels K2 And K3

    8.6.1 POSITION OF THE LABELS K2 and K3 OPERATION AND MAINTENANCE MANUAL page...
  • Page 35 OPERATION AND MAINTENANCE MANUAL page...
  • Page 36 OPERATION AND MAINTENANCE MANUAL page...

  • Page 37: Compressor Lubrication

    8.7 COMPRESSOR LUBRICATION 8.7.1 GENERAL RECOMMENDATIONS CAUTION! Before performing any operation involving draining or topping up compressor oil, unplug the compressor and wait until the system has reached atmospheric pressure. Use adequate protection when handling lubricants. We recommend a lubricant Mobil DTE FM 46 oil (Food oil) used during testing. The pour point must be at least -8+10°C and the flash point higher than +200°C.

  • Page 38: Using The Compressor With Synthetic Oils

    8.8 USING THE COMPRESSOR WITH SYNTHETIC OILS If you wish to use a synthetic lubricant, carefully follow the procedure below. • Drain all mineral oil from the compressor circuit using the oil drain ball valve. • Feed the synthetic lubricant or detergent oil into the oil tank through the top-up hole and fill up to the correct level.

  • Page 39: Instructions For The User

    INSTRUCTIONS FOR THE USER DESCRIPTION OF THE CONTROL DEVICES ELECTRONIC CONTROLLER Ktronic OPERATION AND MAINTENANCE MANUAL page...

  • Page 40: Description Of The Control Console

    8.9.1 Description of the control console The control console has buttons with multiple functions related to the context in which you are, for example when the machine is stopped, machine running, parameter modification, etc. Fig. 4.1 Compressor start and stop button, machine parameter modification (Button 3) The figure opposite shows the button.

  • Page 41: Escription Of Machine Alarms

    Meaning of the LEDs and symbols of the control console Load symbol With the LED on, the compressor is loading, and the corresponding valve is powered. Phase Engine Valve Load Unloading Stand-by symbol With the LED on, the compressor is in stand-by phase. During the start-up phase of the compressor and before the engine is running, the LED is on.
  • Page 42 Screw unit temperature (conditioned by parameter 03) TYPE OF ALARM DISPLAYED DESCRIPTION MAX TEMPERATURE OF SCREW UNIT CAUSE Alarm conditioned by parameter 3 Check the proper functioning of the thermostatic valve; check that the oil cooler radiator is clean; check and replace the compressor filters if necessary; check the operation of the radiator fan Pressure overload TYPE OF ALARM DISPLAYED...
  • Page 43 Maintenance alarm TYPE OF ALARM DISPLAYED DESCRIPTION ALARM MAINTENANCE CAUSE Alarm conditioned by parameter 07 The working hours count is matching the value set in parameter 07, maintenance is required. Reset the counter with Parameter 08. NTC temperature probe alarm TYPE OF ALARM DISPLAYED DESCRIPTION ALARM...
  • Page 44 Machine alarms list of firmware release 34 When the alarms occur, they are shown on the display by flashing with the alphanumeric code and the meaning given in the table below. describing its type. MESSAGE DESCRIPTION STOP (1) DISPLAYED AL01 MAXIMUM PRESSURE EXCEEDED ALARM.

  • Page 45: Description Of The Operations To Be Performed

    DESCRIPTION OF THE OPERATIONS TO BE PERFORMED 8.9.3 STARTING THE COMPRESSOR When the machine is powered and the compressor is still stopped, the following message appears alternately on the display. Pressing button 3 starts the compressor start-up procedure. The following screen flashes on the display for a few seconds, then the machine starts loading.

  • Page 46: Programming

    PROGRAMMING 8.9.4 INTRODUCTION: the modification and reading of the machine parameters is possible only with the compressor not running. Programming Press button 2 and go to the desired parameter. Note 2: the button performs a complete scan of the parameters and returns to the first at the end.
  • Page 47 8.9.4.1 PARAMETER Machine parameters of firmware release 30 and previous versions PARAM. TYPE DESCRIPTION DEFAULT RANGE Stand-by After this time the unit 30 sec 1 ÷ 240 time enters in stand-by mode Below this temperature, 10÷100 System the unit doesn't turn off 60 °C Temperature when the stand-by time is...
  • Page 48 Machine parameters of firmware release 34 PARAM. TYPE DESCRIPTION DEFAULT RANGE Stand-by After this time the unit 30 sec 20÷600 time enters in stand-by mode Below this temperature, the Motor stop unit doesn't turn off when 50°C 10÷100 temperature the stand-by time is over. At this tempearture of the unit turns off and the 100°C...

  • Page 49: Stopping The Compressor

    Description of operation of machine parameters P5 and P6 In the image below, the curved line represents the real pressure trend of the compressor. At the instant t1 the air load STOP occurs, at the instant t2 the air load START occurs. The parameters P5 and P6 contribute to determining these two levels as follows: Pc = P5 - P6 where Pc = loading pressure...

  • Page 50: Remote Control

    8.10 REMOTE CONTROL For the remote control of the compressor, activate SWITCH 1 ON and connect your controller to Pin shown in the picture below: Remote control - electrical connection The figure on the side shows the connections between the CN8 connector and the REM terminals inside the electrical panel, which constitute the connection point of the remote control by the user.

  • Page 51: Automatic Restart

    The legislation provides for the need to manually reset the system in the event of a shutdown due to the absence of electricity. The aforementioned modification is at the user's discretion, therefore MGF S.r.l. declines all responsibility for damage to persons and property with this type of use.

  • Page 52: Compressor Maintenance

    COMPRESSOR MAINTENANCE SCHEDULED MAINTENANCE CAUTION!!! USE ONLY ORIGINAL SPARE PARTS!!! CAUTION!!! HOT PARTS INSIDE!!! OPERATION AND MAINTENANCE MANUAL page...
  • Page 53 OIL LEVEL CHECKS AND TOP UPS MUST BE PERFORMED WITH THE MACHINE OFF AND WITH THE UNIT AT ATMOSPHERIC PRESSURE. THE OIL REMOVED MUST BE DISCARDED IN COMPLIANCE WITH CURRENT LAW. IN SEVERE WORKING ENVIRONMENTS (e.g.: PARTICULARLY DUSTY WORK SITES), THE MAINTENANCE INTERVAL MUST BE SHORTER. INCORRECT MAINTENANCE OF THE OIL FILTER, AIR FILTER AND OIL SEPARATOR CAN DAMAGE THE UNIT.

  • Page 54: Replacing Oil Filter

    9.2 REPLACING OIL FILTER Perform all maintenance as described in this manual or following the indications provided by the retailer or Authorized Service Centre. Open cover panel and remove the filter cartridge using the special spanner. Then replace the spent cartridge with a new one. Before screwing down the filter cartridge, oil the gasket.

  • Page 55: Replacing Oil Separator Filter

    9.3 REPLACING OIL SEPARATOR FILTER Replace the oil separator filter after the number of hours indicated in the manual or after checking its differential pressure. To do so, open the rear panel and remove the filter cartridge using the special spanner. Then replace the spent cartridge with a new one. Before screwing down the oil separator cartridge, oil the gasket.

  • Page 56: Changing The Oil

    9.4 CHANGING THE OIL Change the oil as indicated in the table on cap 9.1 extending the number of hours before replacement depends on the type of oil used but in no case can oil be used for more than one year.
  • Page 57 ADAM 60 ccw Filling cap Emptying cap Once emptied, close the emptying cap. Then top up the oil until the right level is read on the window (see figure 12). Then tighten the oil filling cap once more. After having replaced the oil and oil filter, run the compressor for about 10 minutes, turn it off and check the oil level.

  • Page 58: Replacing The Air Filter

    9.5 REPLACING THE AIR FILTER Replace the cartridge following the indications in the maintenance table. Take particular attention not to let any material fall into the suction valve. The duration of the air filter and proportionate to the type of environment and air contamination by dust.

  • Page 59: Maintenance Schedule

    Unscheduled maintenance must be performed by an Authorized Service Centre. For any information, please log onto our website www.mgfcompressors.com For any clarifications you may require, contact MGF customer services department or your area retailer. Compack K2 230V 50Hz and 60Hz maintenance schedule...
  • Page 60 Compack K3 400V 50-60Hz maintenance schedule Code Type MOTOR HOURS Content 1000/2000/3000 - Air Filter 5000/6000/7000 - Oil Filter KT-N11L0735 9000/…. - Separator Filter and following. - Oil 3,5kW - Air Filter COMPACK K3 400/50/3 - Oil Filter (ADAM 60 ccw) 460/60/3 - Separator Filter 4000/8000/12000...
  • Page 61 Code HOURS Content 1000/3000 - TA-FL-086-C 5µm Filter cartridge TA-FL-099-K 5000/7000 - TA-FL-085-C 0,01µm Filter cartridge And following - TA-FL-085-OR Filter bowl seal - TA-FL-086-C 5µm Filter cartridge 2000/4000 - TA-FL-085-C 0,01µm Filter cartridge TA-FL-100-K 6000/… - TA-FL-085-OR Filter bowl seal And following - TA-FL-074-C Water separator cartridge...

  • Page 62: Troubleshooting

    TROUBLESHOOTING Problem Cause Resolution High oil Low oil level, Top up oil level temperature limit High environmental temperature Check environmental temperature trips causing Oil cooler clogged Clean oil cooler machine to stop. Temperature probe failure Replace temperature probe. Check the correct calibration of the thermal protection.
  • Page 63 Problem Cause Resolution High oil level. Drain the oil until the correct level is Defective suction valve. Oil leaking from air reached. The compressor during filter. For the valve, contact an Authorized Service transport has been tilted Centre. excessively. Working pressure too high Overpressure in the internal Restore correct working pressure from Opening of the...

  • Page 64: Appendix

    10 APPENDIX 10.1 MAINTENANCE CHECK SHEET OPERATION AND MAINTENANCE MANUAL page...
  • Page 65 CAUTION! Never touch moving parts while the compressor is running. All compressor maintenance operations must be performed with the machine off (at environmental pressure and temperature) and with the unit unplugged. Maintenance must be carried out by qualified personnel. Always follow current accident prevention standards (use adequate protection).

  • Page 66: Spare Parts

    11 SPARE PARTS OPERATION AND MAINTENANCE MANUAL page...
  • Page 67 Codice Code Q.tà N° Descrizione Description Q.ty 180012039-01-106 COMPRESSORE COMPACK SPECIAL COMPRESSOR COMPACK SPECIAL 230/50Hz 230/50Hz 180012057-01-106 COMPRESSORE COMPACK SPECIAL COMPRESSOR COMPACK SPECIAL 230/60Hz 230/60Hz 180022001-01-106 COMPRESSORE COMPACK K3 COMPRESSOR COMPACK SPECIAL 400/50Hz 400/50Hz TR-AV-019 ANTIVIBRANTE 30x30 M8x20 VIBRATION DUMPER 30X30 M8 CA-PA-250-W PANNELLO BASE CS-COMPACK BASE PANEL CS-COMPACK...
  • Page 68 Codice Q.tà N° Descrizione Description Code Q.ty KT-A01Z6021 SEMIGUSCIO INFERIORE COMPACK COMPACK LOWER HALF-SHELL KT-A01Z6020 SEMIGUSCIO SUPERIORE COMPACK COMPACK UPPER HALF-SHELL KT-F06R7290 MANIGLIA HANDLE KT-A01Z6019 COPERCHIO SUPERIORE COMPACK SPECIAL TOP COVER COMPACK SPECIAL KT-G07Q0149 FILTRO DI ASPIRAZIONE COMPLETO COMPLETE INLET FILTER KT-G07Q0153 CARTUCCIA FILTRO ASPIRAZIONE INLET FILTER CARTRIDGE...
  • Page 69 Codice Q.tà N° Descrizione Description Code Q.ty KT-M10M0172 ADAM 50ccw/E 13-3/4UM22C+55° 230V ADAM 50ccw/E 13-3/4UM22C+55° 230V KT-B02V0209 MOTORE ELETT kW2,7/2p V230/1/50Hz MEC90 EL. MOTOR kW2,7/2p V230/1/50Hz MEC90 KT-E05S0107 SCAMBIATORE OLIO OIL COOLER KT-C03U4138 CASSETTA COMPLETA COMPACK 2 SPECIAL ELECTRIC BOX COMPACK 2 SPECIAL KT-G07Q1013 FILTRO DISOLEATORE AIR/OIL SEPARATOR FILTER...
  • Page 70 Codice Q.tà N° Descrizione Description Code Q.ty KT-M10M0122 ADAM 60ccw/E 71°-10-3/4UM22C ADAM 60ccw/E 71°-10-3/4UM22C KT-B02V0118 MOTORE ELETT kW3.5 V400/3/50Hz MEC100 EL. MOTOR kW3.5 V400/3/50Hz MEC100 KT-E05S0117 SCAMBIATORE OLIO OIL COOLER KT-E05S2010 VENTOLA KT-A01Z2234 CASE COMPACK COMPACK BASE PLATE KT-FR06R7314 VITE FORATA PER FISS.RACCORDO AD OCCH. PREFORED BOLT KT-F06R7324 RONDELLA SEALS ¼”...
  • Page 71 Codice Q.tà N° Descrizione Description Code Q.ty KT-N11L3010 KIT RICAMBI NIPPLO SEP.M22-M24 M22-M24 SEP. NIPPLES SPARE PARTS KIT KT-N11L3011 KIT RICAMBI V.M.P. G10 (1/2”-3/4”) V.M.P. G10 (1/2”-3/4”) SPARE PARTS KIT KT-N11L3040 KIT 71° V.TERM PACK SMART A V60 THERMOSTATIC VALVE SPARE PARTS KIT ADAM V60 71°...
  • Page 72 OPERATION AND MAINTENANCE MANUAL page...

  • Page 73: Technical Specifications

    12 TECHNICAL SPECIFICATIONS Versioni – Versions: Descrizione Voltaggio- Serbat Codice MGF Aria resa* Motore modello Frequenza Model Voltage - MGF code Air delivery* Motor receiv description frequency Lt/min RV-CS360-040-X CS-Compack X RV-CS360-040-X-6 CS-Compack X RV-CS400-040-X CS-Compack X3 11,6 RV-CS470-040-XL CS-Compack XL...
  • Page 74 EN 60204-1/2006 For the following products: Brand name: MGF Model type: MGF CSCREW COMPRESSORS MODELS MC B, ME B, ME PLUS, LE PLUS, CS-COMPACK X. Referente per il dossier tecnico/ Contact for technical dossier: ING. DAVIDE FIANI – Via Pascoli 15, 20081 Abbiategrasso ITALY...
  • Page 75 OPERATION AND MAINTENANCE MANUAL page...
  • Page 76 Werther Air Compressors 8614 Veterans Memorial Dr. Houston, TX 77088 www.werther.com OPERATION AND MAINTENANCE MANUAL page...

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