User Manual Genisis 5.5-15 KW

GENESIS - FORMULA - MODULO5.5 - 15 kW

USE AND MAINTENANCE HANDBOOK

GB

227 D1273 D2

I

FORMULA

1045

6151030

273

480

545

465

390

1045

227 D1273 D2

560

395

204

430

945

180

262

Fig. 1

Fig. 2

D1 = 5.5-7.5 kW

D2 = 11-15 kW

227 D1273 D2

227 D1273 D2

II

GENESIS 275 l

945

945

560

395

480

1180

1645

530Ø 600

390

465

6151030

480

273

204

262

Fig. 3

Fig. 4

D1 = 5.5-7.5 kW

D2 = 11-15 kW

1015800

530Ø 600

1960

1260

945390

465

395

227 D1273 D2

227 D1273 D2

III

GENESIS 500 l

480

273

945

615 1030

1645

204

262

800

Fig. 5

Fig. 6

D1 = 5.5-7.5 kW

D2 = 11-15 kW

1015

227 D1273 D2

227 D1273 D2

IV

MODULO

1030

480

273

1045

615

945

395

390

1045

560

465

545

180

204

430

262

Fig. 7

Fig. 8

D1 = 5.5-7.5 kW

D2 = 11-15 kW

227 D1273 D2

227 D1273 D2

V

MODULO 270 l1030

480

273

615

945

560

390

465

1645

1180

480

395

800

530Ø 600

204

945

262

Fig. 9

Fig. 10

D1 = 5.5-7.5 kW

D2 = 11-15 kW

1015

227 D1273 D2

VI

MODULO 500 l

1960

1260

560

945

395

390

465

530Ø 600

800 1645

615 1030

273

480

204

945

262

Fig. 11

Fig. 12

D1 = 5.5-7.5 kW

D2 = 11-15 kW

227 D1273 D2

1015

VII

FORMULA 5.5 - 7.5 kW

Fig. 13

Fig. 14

SPA

PE

PC

VAEVPS

BFPFCTVT TRL

ES

FU

RA / RO

PPSS

VS

FD

FOFA

MP

VIII

FORMULA 11 - 15 kWBA 51

Fig. 15

Fig. 16

FOFA

FD

VS

SS

ES

FU

MA

RA / RO

MP

PC

PE

SPA

VAEVPS

BF

VRTRL CT PF

PP

IX

FORMULA 15 kWBA 69

Fig. 17

Fig. 18

PC

PE

SPA

CF / FA

PFCT

TRL

VR

BF

PS

ES

EV

FU

MA

RA / RO

MP

PP

VA FO

FO

VS

SS

X

MODULO 5.5 - 7.5 kW

Fig. 19

Fig. 20

FO

FD

FA

SS

ES

FU

MA

RA / RO

PP

MP

PC

PE

SCE

SF

VAEV

BF

VT

TRLCT PF

VS

PS

XI

MODULO 11 - 15 kWBA 51

Fig. 21

Fig. 22

PC

PE

SCE

SF

PFCT

TRL

SS

VR

PS EV VA

FA FO

FD

VS

SS

MP

PP

RA / RO

MA

FU

ES

BF

XII

MODULO 15 kWBA 69

Fig. 23

Fig. 24

PS

PP

PF

MA

FU

RA / RO

ES

VA FO

FD

VS

SS

MP

CF / FA

SCE

PE

PC

TRL

VRBF

CT

EV

LegendaRif. Italiano English Français Deutsch Español

PS Pannello superiore Top panel Panneau supérieur Oberseite Panel superior

R Raccordo Fitting Raccord Anschluß rACOR

RA/RO Radiatore aria Radiatore olio

After cooler Oil cooler

Radiateur à sir Radiateur à huile

Luftkühler Öl-Kühler

Radiador de aireRadiador de aceite

RF Rotore femmina Female rotor Rotor femelle weiblich Läufer Rotor hembra

RLMAX Riferimento di livello max. olio Max. oil level reference Repère de niveau

maximum huile Bezug Max.Ölstand Referencia de nivel máx. de aceite

RLMIN Riferimento di livello min. olio Min. oil level reference Repère de niveau

minimum huile Bezug MindestÖlstand Referencia de nivel min. de aceite

RM Rotore maschio Male rotor Rotor mâle männlich Läufer Rotor macho

RSC Rubinetto scarico condensa

Air receiver condensate discharge valve

Robinet de vidange de l’eau de condensation du

réservoir à air

Kondenswasser Ablasshahn des Luftanks

Grifo de descarga de la condensación del

depósito de aire

RSO Rubinetto scarico olio Oil drain valve Robinet d’évacuation de l’huile Ölablaßhahn Grifo de descarga de

aceite

SA Serbatoio aria Air receiver Réservoir á air Lufttank Depósito de aire

SCE Sportello cassetta elettrica Electric box panel Panneau

armoire électriqueStarter/Kontroll Box

seitePuerta del

quadro eléctrico

SF Sportello filtri Filter panel Panneau des filtres Filterklappe Puerta de los filtros

SPA Sportello angolare Corner panel Panneau angulaire Eckklappe Puerta angular

SSSerbatoio separatore

miscela aria/olio

Air-oil separator receiver

Réservoir séparateur du

mélange air/huileLuft/Öl-Abscheider

Depósito separador mezcla

aire - aceite

STO Sensore di temperatura olio Oil temperature sensor Capteur de température

de l’huile Öl-Temperaturfühler Sensor temperatura aceite

TM Targhetta metallica dati macchina

Serial number and general

machine data plate

Plaquette métallique

d’identification machine

Seriennumer und allgemeine

Maschinen Daten

Placa metálica con los datos de la

máquina

TO Tappo olio Oil filler plug Bouchon de remplissage huile

Öl-Filter Verschluss Tapón del aceite

TRL Tubetto di riferimento livello olio Oil level reference pipe Tube de référence

niveau huileBezugsleitung

ÖlstandTubo de referencia nivel

de aceite

VA Valvola di aspirazione Intake valve Soupape

d’admission Ansaugventil Válvula de aspiración

VRValvola di ritegno

e di minima pressione

Minimum pressure and check valve

Clapet de retenue et de

pression minimum

Mindestdruck- Kontrollventil

Válvula de retención y de presión mínima

VS Valvola di sicurezza Safety valve Soupape

de surpression Sicherheitsventil Válvula de seguridad

VT Valvola termostatica Thermostatic valve Soupape

thermostatique Thermostatventil Válvula termostática


BF Blocchetto di filtrazione

Oil filter and separator block

Groupe de filtration

Halter für Öl und Abscheiderfilter

Bloque de filtración del aceite

CE Cassetta elettrica Starter/control box Armoire électrique Starter/Kontroll Box Cuadro eléctrico

CF Contenitore filtro aria Air filter container Boîtier du filtre à air Luftfilterbehälter Contenedor del filtro de aire

CT Cinghie di trasmissione

Transmission belts

Courroies de transmission Antriebsriemen Correas de

transmisión

DI Display Display Ecran-afficheur Display Visor

DO Scarico olio/ Drenaggio olio Oil drain valve Orifice de vidange de

l’huile Öl Auslass Drenaje del aceite

ES Essiccatore Dryer Sécheur Trockner Secador

EV Elettroventilatore Electric fan Ventilateur électrique Elektrolüfter Electroventilador

FA Filtro aria Air filter Filtre à air Luftfilter Filtro de aire

FD Filtro disoleatore Oil separator filter Filtre séparateur Feinabscheider Filtro disoleador

FFA Fascetta filtro aria Air filter clip Collier du filtre à huile Luftfilter Clip Abrazadera filtro de aire

FO Filtro olio Oil filter Filtre à huile Öl-Filter Filtro aceite

FU Feritoia uscita aria calda Heated air outlet Orifice de sortie

de l’air chaud Auslass für heisse Luft Rendija de salida del aire caliente

GP Gruppo pompante a vite brevettato Patented Air end Groupe de pompe à vis

breveté Patentierter Verdichter Grupo de bombeo de tornillo patentado

K1/K9 Pulsanti del pannello di controllo Control panel switches Boutons sur panneau de

commandeSchalter der

Kontroll-AnzeigePulsadores del tablero

de control

L1/L5 Led del pannello di controllo Control panel led LED sur panneau de

commande Led Led del tablero de control

MA Mandata aria Compressor air outlet Refoulement d’air Druckluft Auslass Salida aire

MP Motore principale Electric motor Moteur principal Elektromotor Motor principal

PA Prefiltro aspirazione Suction prefilter Pré-filtre d’aspiration Ansaugvorfilter Prefiltro apiración

PC Pannello di controllo Control panel Panneau de commande Kontroll-Anlage Tablero de control

PE Pulsante di arresto di emergenza Emergency stop button Bouton d’arrêt d’urgence Not-Ausschalter Pulsador de

emergencia

PF Pannello frontale Front panel Panneau avant Frontseite Panel frontal

PP Pannello posteriore Rear panel Panneau arrière Hintere Abdeckung Panel trasero

PPA Pannello prefiltro aspirazione Suction prefilter panel Panneau du prréfiltre

d’aspirationAbdeckung der Ansaugvorfilters

Panel del prefiltro de aspiración

XIII XIV


PS Pannello superiore Top panel Panneau supérieur Oberseite Panel superior

R Raccordo Fitting Raccord Anschluß rACOR

RA/RO Radiatore aria Radiatore olio

After cooler Oil cooler

Radiateur à sir Radiateur à huile

Luftkühler Öl-Kühler

Radiador de aireRadiador de aceite

RF Rotore femmina Female rotor Rotor femelle weiblich Läufer Rotor hembra

RLMAX Riferimento di livello max. olio Max. oil level reference Repère de niveau

maximum huile Bezug Max.Ölstand Referencia de nivel máx. de aceite

RLMIN Riferimento di livello min. olio Min. oil level reference Repère de niveau

minimum huile Bezug MindestÖlstand Referencia de nivel min. de aceite

RM Rotore maschio Male rotor Rotor mâle männlich Läufer Rotor macho

RSC Rubinetto scarico condensa

Air receiver condensate discharge valve

Robinet de vidange de l’eau de condensation du

réservoir à air

Kondenswasser Ablasshahn des Luftanks

Grifo de descarga de la condensación del

depósito de aire

RSO Rubinetto scarico olio Oil drain valve Robinet d’évacuation de l’huile Ölablaßhahn Grifo de descarga de

aceite

SA Serbatoio aria Air receiver Réservoir á air Lufttank Depósito de aire

SCE Sportello cassetta elettrica Electric box panel Panneau

armoire électriqueStarter/Kontroll Box

seitePuerta del

quadro eléctrico

SF Sportello filtri Filter panel Panneau des filtres Filterklappe Puerta de los filtros

SPA Sportello angolare Corner panel Panneau angulaire Eckklappe Puerta angular

SSSerbatoio separatore

miscela aria/olio


Réservoir séparateur du

mélange air/huileLuft/Öl-Abscheider

Depósito separador mezcla

aire - aceite

STO Sensore di temperatura olio Oil temperature sensor Capteur de température

de l’huile Öl-Temperaturfühler Sensor temperatura aceite

TM Targhetta metallica dati macchina

Serial number and general

machine data plate

Plaquette métallique

d’identification machine

Seriennumer und allgemeine

Maschinen Daten

Placa metálica con los datos de la

máquina

TO Tappo olio Oil filler plug Bouchon de remplissage huile

Öl-Filter Verschluss Tapón del aceite

TRL Tubetto di riferimento livello olio Oil level reference pipe Tube de référence

niveau huileBezugsleitung

ÖlstandTubo de referencia nivel

de aceite

VA Valvola di aspirazione Intake valve Soupape

d’admission Ansaugventil Válvula de aspiración

VRValvola di ritegno

e di minima pressione

Minimum pressure and check valve

Clapet de retenue et de

pression minimum

Mindestdruck- Kontrollventil

Válvula de retención y de presión mínima

VS Valvola di sicurezza Safety valve Soupape

de surpression Sicherheitsventil Válvula de seguridad

VT Valvola termostatica Thermostatic valve Soupape

thermostatique Thermostatventil Válvula termostática


BF Blocchetto di filtrazione

Oil filter and separator block

Groupe de filtration

Halter für Öl und Abscheiderfilter

Bloque de filtración del aceite

CE Cassetta elettrica Starter/control box Armoire électrique Starter/Kontroll Box Cuadro eléctrico

CF Contenitore filtro aria Air filter container Boîtier du filtre à air Luftfilterbehälter Contenedor del filtro de aire

CT Cinghie di trasmissione

Transmission belts

Courroies de transmission Antriebsriemen Correas de

transmisión

DI Display Display Ecran-afficheur Display Visor

DO Scarico olio/ Drenaggio olio Oil drain valve Orifice de vidange de

l’huile Öl Auslass Drenaje del aceite

ES Essiccatore Dryer Sécheur Trockner Secador

EV Elettroventilatore Electric fan Ventilateur électrique Elektrolüfter Electroventilador

FA Filtro aria Air filter Filtre à air Luftfilter Filtro de aire

FD Filtro disoleatore Oil separator filter Filtre séparateur Feinabscheider Filtro disoleador

FFA Fascetta filtro aria Air filter clip Collier du filtre à huile Luftfilter Clip Abrazadera filtro de aire

FO Filtro olio Oil filter Filtre à huile Öl-Filter Filtro aceite

FU Feritoia uscita aria calda Heated air outlet Orifice de sortie

de l’air chaud Auslass für heisse Luft Rendija de salida del aire caliente

GP Gruppo pompante a vite brevettato Patented Air end Groupe de pompe à vis

breveté Patentierter Verdichter Grupo de bombeo de tornillo patentado

K1/K9 Pulsanti del pannello di controllo Control panel switches Boutons sur panneau de

commandeSchalter der

Kontroll-AnzeigePulsadores del tablero

de control

L1/L5 Led del pannello di controllo Control panel led LED sur panneau de

commande Led Led del tablero de control

MA Mandata aria Compressor air outlet Refoulement d’air Druckluft Auslass Salida aire

MP Motore principale Electric motor Moteur principal Elektromotor Motor principal

PA Prefiltro aspirazione Suction prefilter Pré-filtre d’aspiration Ansaugvorfilter Prefiltro apiración

PC Pannello di controllo Control panel Panneau de commande Kontroll-Anlage Tablero de control

PE Pulsante di arresto di emergenza Emergency stop button Bouton d’arrêt d’urgence Not-Ausschalter Pulsador de

emergencia

PF Pannello frontale Front panel Panneau avant Frontseite Panel frontal

PP Pannello posteriore Rear panel Panneau arrière Hintere Abdeckung Panel trasero

PPA Pannello prefiltro aspirazione Suction prefilter panel Panneau du prréfiltre

d’aspirationAbdeckung der Ansaugvorfilters

Panel del prefiltro de aspiración

XIII XIV

Pag. 15

Table of contents

GB

1 Foreword 20

2 Symbols 2121Symbols in the manual2.121Compressor symbols2.222Control panel mc2 symbols2.3

3 Warranty terms 23

Performance and specifications 24424General data4.124Compressor rating data4.225Air receiver4.325Compressor4.425Electrical motor and drives4.525Power supply data4.627Lubricating and cooling fluid4.787Dryer4.8

Pag. 16

GB

27Clearance requirementsand system layouts4.9

Safety precautions 28528General precautions5.128Safety precautions for maintenance

operations5.2

Handling and installation 30630Handling instructions6.130Installation site requirements6.294Air connection6.333Electrical connection6.433Configuration for remote control6.5

Start-up and operation 35735Checks to be carried out

prior to start-up7.135“mc2” control panel7.236Control unit “mc2”7.2.138Emergency stop button7.2.238Starting and stopping the compressor7.3

Pag. 17

GB

41Parameter configuration -menu tree7.4

42Additional information menu7.4.1

43Menu tree(control and programming)7.4.2

44PASSWORD menu7.4.2.1

44MAINTENANCE menu7.4.2.2

46GENERAL SETTINGS menu7.4.2.3

51NETWORK SETTINGS menu7.4.2.4

52OPERAT. PARAMETERS menu7.4.2.5

54PROGRAMMING menu7.4.2.6

56DIAGNOSTICS menu7.4.2.7

58INFORMATIONS menu7.4.2.8

58Operating warning and faults7.5

Compressors in sequence 618Troubleshooting 629

62The machine does not start9.163The compressor has trouble starting up9.2

Pressure value lower than rated pressure 639.3

Pag. 18

GB

The machine is ready for start or is running and the scheduled maintenance LED is on 649.4The machine is ready for start or is running with critical functioning message 649.5The machine stops when it is running and warning LED comes on 659.6

66Oil in the network9.766Oil in the machine9.867Safety valve VS intervention9.9

Maintenance 681068Operating cycle10.169General maintenance

operation table10.271Replacement of the suction prefilter10.371Cleaning or replacing the air filter10.473Checking oil level, topping up and

changing the oil10.5

75Replacing the oil filter and the separator filter10.6

76Draining the condensate10.777Replacing the fuses10.8

Pag. 19

GB

Spare parts and Service Centres 781178Spare parts and consumable

material codes11.1

Diagrams 801280Hydraulic-pneumatic plant diagram12.182Power circuit wiring diagram

5,5 - 15 kW Machines without air dryer12.2

83Power circuit wiring diagram5,5 - 15 kW Machines with air dryer12.3

84Power circuit wiring diagram11 kW Machines with inverter12.4

85Auxiliary circuit wiring diagram5,5 - 15 kW Machines without air dryer12.5

86Auxiliary circuit wiring diagram5,5 - 15 kW Machines with air dryer12.6

87Auxiliary circuit wiring diagram11 kW Machines with inverter12.7

88Wiring diagram for component location5,5 - 15 kW Machines without air dryer12.8

89Wiring diagram for component location5,5 - 15 kW Machines with air dryer12.9

Pag. 20 - Chap. 1 Foreword

1 Foreword

GB

Dear Customer,Congratulations on buying this compressor and thank you for your confi dence in our Company.

The machine in your possession is a lubricated rotary screw compressor, incorporating state-of-the-art compressed air technology. The GENESIS - FORMULA - MODULO series screw compressors are characterised by high energy output and low noise. Major features incorporated in the design phase include versatility of use, reliability, low running and maintenance costs, compact size, and top fl ight performance. This range of compressors has also been designed and constructed complying with the strict quality control standards that are one of the main features of all products manufactured at our plants.

The product is EC marked and complies with current European Directives, as shown in the Declaration of Conformity attached to this handbook.

The compressor must be installed by specialized personnel of authorized service Centres.

Before starting the machine, read all sections of this handbook and always comply with the instructions provided which explain correct use and routine maintenance of the compressor and the precautions to be taken to ensure operator safety.

This manual must always accompany the compressor so that it is available for all those working with it.

As concerns general maintenance, we recommend arranging a scheduled maintenance contract with our authorized Centres.

P. 21 - Chap. 2 Symbols

2Symbols

GB

2.1Symbols in the manualThis symbol indicates that the instructions manual should be read with great care before car-rying out any operation on the machine

This symbol highlights operations or types of behaviour that could result in fatal injury or seri-ous accidents to operators who must always be informed of these and take the necessary precautions.This symbol also accompanies the description of operations that require special atten-tion on the part of the user.

You will fi nd this symbol next to the descriptions of operations which must be carried out by authorized service Centres only

This symbol is provided to remind you that waste oil, condensate and fi lters removed from the machine are polluting materials and must be disposed of in compliance with local laws

2.2Compressor symbolsThis symbol means that you must not put your hands inside the machine when it is running

This symbol indicates the presence of rotating parts inside the compressorDo not carry out maintenance or repair operations when the machine is running

This symbol indicates the presence of electrical power inside the machine

This symbol indicates the direction of rotation of the main electrical motor and fans

This symbol indicates the oil fi ll plug

These symbols indicate the direction in which to turn the key (provided) to open and close the control panels of the machine and the control box

These symbols indicate compressor rated voltage

This symbol indicates the presence of high temperature components inside the compressor

P. 22 - Chap. 2 Symbols

GB

2.3Control panel mc2 symbolsThis symbol indicates the K1 “START” key

This symbol indicates the K2 “STOP” key

This symbol indicates the K3 “RESET” keyRESET

This symbol indicates the K4”EXIT” keyESC

This symbol indicates the K6 “UP” key

This symbol indicates the K6”DOWN” key

This symbol indicates the K7”PLUS” key+This symbol indicates the K8”MINUS” key-This symbol indicates the K9 “ENTER” confirmation key

This symbol indicates the voltage present LED L1 (yellow)

This symbol indicates switching on of warning LED L2 (yellow)

This symbol indicates switching on of alarm LED L3 (red)

This symbol indicates switching on of LEDs L4 and L5 (red) indicating “AUTORESTART” and “REMOTE/PROGRAM” located on the electronic control unit

This symbol indicates a message on the display of the electronic control unit

P. 23 - Chap. 3 Warranty terms

3Warranty terms

GB

The product was tested before delivery. The machine is guaranteed for twenty-four months from the date of the invoice.

The warranty is valid only if the purchaser has complied with contractual and administrative regulations and if the compressor has been installed and operated according to the instructions provided in this handbook.

The Customer is required to fi ll out all parts of the warranty card and send it within thirty days from the date of purchase (as attested by the postmark). According to the terms of the warranty, the Manufacturer undertakes only to repair or replace, free of charge, the product or parts of this found to be faulty following examination by the Manufacturer’s technical person-nel or authorised repair company. Labour and transport are, in any case, excluded from the clauses of this warranty, and they will therefore be charged to you.

The warranty, which excludes all and any liability for direct or indirect injury or damage, is restricted only to construction and manufacturing defects of machine components. The warranty does not include parts which, due to their specifi c use, are liable to wear and tear such as seals, belts, etc. and all consumables such as air fi lter, oil fi lter, oil separator fi lter, etc The warranty does not cover repairs due to damage caused by insuffi cient or incorrect maintenance or unsuitable application..

The warranty shall be null and void in the case of failure to comply with the instructions given in this handbook, use of non-original spares and scheduled maintenance carried out directly by the Customer without the related invoice for the original parts.

The information given in this handbook is for guidance purposes only and is not binding. The Manufacturer reserves the right to make any product modifi cations it considers necessary without prior notice.

P. 24 - Chap. 4 Performance and specifi cations

GB

4 Performance and specifi cations

4.1General data

-

Model Pressure Motor power Air end Capacity Oil Weight Dimensions Noise

levels*bar kW m3/min Kg Kg mm dB(A) - Lp(A)

Base 270 l 500 l

5.5

8

5.5 BA51

0.78

7

270 + 28

dryer

355+28

dryer

414+28

dryer

1030 x 615 x 10451180 x 600 x 1645 (Genesis 270 l.)1960 x 600 x 1645 (Genesis 500 l.)

6610 0.6913 0.5415 0.40

7.5

8

7.5 BA51

1.20

7

275 + 28

dryer

360 + 28

dryer

419+ 28

dryer


6810 1.0413 0.8015 0.64

11

8

11 BA51

1.65

7

275 + 32

dryer

360 + 32

dryer

419+ 32

dryer


6910 1.4013 1.1715 0.95

15

8

15 BA51

2.01

7

300+ 32

dryer

385+ 32

dryer

444+ 28

dryer


6910 1.7213 1.4915 1.16

15

8

15 BA69

2.32

7

286+ 32

dryer

371+ 32

dryer

430+ 32

dryer


6910 1.9313 1.6215 1.30

± 3 dB(A) to standards PNEUROP/Cagi

4.2Compressor rating data

A metal plate TM indicating the compressor specifi cations is applied to the machine: fi gure 25 shows the position

Fig. 25

TM PF

P. 25 - Chap. 4 Performance and specifications

GB

4.3Air receiverCapacity of 270 or 500 litres according to model; type approved at 11 or 17 bar depending on the model.

4.4Compressor

RM

5.5-15 kWPatented VT series air-end unit, single stage, BA51 model, oil injection lubricated

15 kWPatented VT series air-end unit, single stage, BA69 model, oil injection lubricated:

Drive male rotor RM, five lobes, offset profile

Driven female rotor RF, six flutes, offset profile

RF

4.5Electrical motors and drivesCompressor start-upFixed speed motorsTwo-pole, closed, three-phase asynchronous motor (rated speed of 3000 rpm at 50 Hz, 3600 rpm at 60 Hz, protection rating IP54, insulation class F, service class S1, reference MP in Figs. 14, 16, 18, 20, 22, 24)

Variable speed motorsFour-pole closed three-phase asynchronous motor (rated speed of 1500 rpm at 50 Hz, protection rating IP54, insulation class F, service class S1, reference MP in Figs. 14, 16, 18, 20, 22, 24), intended for use at variable speed through powering with inverter

Electric fanFan coaxial to the electrical motor (reference EV in Figs. 13, 15, 17, 19, 21, 23)

Drives

Compressor motor - drive by means of removable taper bushing pulleys and toothed V-belts (reference CT in Figs. 13, 15, 17, 19, 21, 23)

Electric fan: direct, co-axial transmission

4.6Power supply dataThree-phase power supply; voltage and frequency according to rating data. Supply cables with a minimum cross-section area as shown in tables 1and 2. Mains fuses and ground circuit breaker as shown in the fol-lowing table.

Fig. 26


GB

Model Pressure Power cable cross-section area

Main fuses AM (motor rated) or ground circuit breaker setting

Circuit breaker

bar mm2 A A

5.5

8

2.5 16 16101315

7.5

8

4 20 20101315

11

8

6 25 25101315

15

8

10 40 40101315

15

8

10 40 40101315

400 V

Model Pressure Power cable cross-section area

Main fuses AM (motor rated) or ground circuit breaker setting

Circuit breaker

bar mm2 A A

5.5

8

6 25 25101315

7.5

8

10 40 40101315

11

8

16 50 50101315

15

8

25 63 63101315

15

8

25 63 63101315

230 V


GB

4.7Lubricated and cooling fluidThe compressor is filled with DICREA 46 lubricated and cooling fluid

Total capacity:

7 Kg Top up with lubricated and cooling fluid with the same specifications as the lubricated and cooling fluid in the machine (synthetic coolant I.E. ABAC DURALUBE may be specified)

Contact the Manufacturer’s technical Department before using lubricated and cooling fluids with other specifications

4.8DryerThermostat controlled cooling cycle, direct expansion, with Freon R134a gas; pressure dew point temperature 3°C, clean air filtering degree 0,01mm.

Filtration degree: 1 µm. Oil carryover: 0,1 mg/m3

Displayable dew point temperatureCooling compressor and timed condensate drain, controlled from mc panel2

4.9Clearance requirements and system layoutsThe tables with the overall dimensions of the compressor are provided in figures 1-12The hydraulic/pneumatic system diagram and the wiring diagrams (operation and location) are shown in Chapter 12

P. 28 - Chap 5 Safety precautions

5 Safety precautions

GB

5.1 General precautionsUse of the machine by unskilled personnel without adequate supervision is not allowed. Keep children and animals away from the working area.Do not direct compressed air jets towards yourself or other people.

Always use goggles to protect your eyes from objects which can be lifted by the jet of air.Never operate on the machine with bare feet or wet hands.

The compressor is designed solely to produce compressed air and cannot therefore be used for any other type of gas.

The compressed air produced by the machine cannot be used for respiratory assistance, pharmaceutical or sanitary purposes or in production plants where the output air comes into direct contact with food products unless an additional adequate air treatment system is employed

The air taken in by the compressor must be absolutely free of dust, vapours, explosive or fl ammable gases, solvents or powder paints and toxic fumes of any type.

Use of compressed air requires knowledge of and compliance with the safety precautions to be adopted for the individual applications (infl ating, pneumatic tools, painting, washing with water-based detergents only, etc.).

Machine operation is fully automatic.

The machine carries out the various work cycles, as required by the user, according to the settings.After use, stop the machine and disconnect the main panel power.

Use of the machine for other purposes shall be considered as improper use and the Manufacturer shall not be liable for any resulting damage or injury.

5.2Safety precautions for maintenance operationsRoutine maintenance operations can be carried out by the user as described in this handbook.Only the use of original spare parts will guarantee long, safe and reliable service life of the equip-mentRefer to Chapter 10 for instructions on the operations that can be carried out by the user.

All major maintenance operations can be carried out only by the specialised personnel of authorised Service Centres

P. 29 - Chap 5 Safety precautions

GB

Disconnect the power supply, vent the air and wait for the machine to cool before performing any operation or removing the guards

After disconnecting the power, lock out the circuit breaker to prevent accidental start-up while operating on the compressor. Additionally, close the shut-off valve between the com-pressor and the line

All the air has been discharged from the machine when pressure gauge MPI shows zero pressure

No changes must be made to machine internal electrical, pneumatic, hydraulic circuits and/or to the set-tings. In particular, do not modify the maximum working pressure values and the valve settings, especially the safety valves.

Do not use solvents, flammable or toxic fluids to clean the machine parts. Use alkaline detergents only. Never use detergents to clean the motor or the electrical/electronic components.

Do not weld or carry out mechanical machining operations on the receivers. If damaged or rusted, replace the parts, as they are subject to specific safety regulations.

At the end of each operation, refit the guards carefully. Comply with the same precautions for initial start-up.

Remember that waste oil, condense and machine filters are polluting materials. Dispose of these products in compliance with local legislation

Careful scheduled maintenance will contribute to maintaining machine efficiency and user safety conditions in time.

P. 30 - Chap. 6 Handling and installation

6 Handling andinstallation

GB

6.1Handling instructionsUse a forklift truck to handle the compressor making sure that the forks are positioned in the machine base unit supporting feet (Fig. 27).

Lift the machine from the front only both for the basic version and version with receiver.

For the machine with 270 lt receiver, the maximum width of the forks is 540 mm; no restriction exists for the machine with 500 lt receiver.

Make sure the load is properly balanced.

Alternatively, a pallet truck can be used for short distances. Avoid any excess stress on the metal structure (Fig. 28).

When using a lifting device for handling do not exert force on the sides of the machine to prevent damage to the unit and control panel. Make sure that the load is balanced.

Fig. 27

Fig. 28

Receivers under pressure, even if small, must never be transported

6.2Installation site requirementsGeneral remarksThe machine should be installed by authorised Service Centre skilled personnel to ensure that machine installation site is suitable.

The machine is ready to be installed and does not require foundations. Site the compressor on level ground, in a stable position, with the weight evenly distributed on the supports.


GB

The environmental conditions that represent the operating range of the compressor are indicated below:- Maximum installation altitude (above sea level) ................................................................................ :1000 m - Minimum ambient temperature ......................................................................................................... :+5° C- Maximum ambient temperature ........................................................................................................ :+40° CMachine performance, as indicated in this handbook, is guaranteed only if the machine is installed at an altitude below the operating limit indicated.{228}Contact the Manufacturer’s Technical Department in the case of particular environmental conditions.

Outdoor installation

Figure 29 shows an example of outdoor installation.

The compressor must be protected against atmospheric agents. Suitable protection is required if the compressor is located outdoors. Comply with the minimum distance from the walls (0.6 mm).

Fig. 29

min. 3000

max. 5000

600

Indoor installation

The machine is not suitable for use in environments with a “risk of explosion”.

The air taken in by the compressor must be absolutely free from dust, vapours, explosive or flammable gas, solvents or paint powder and toxic fumes of any sort. Replace the filters more frequently - with special reference to the air filter - if the machine is used in critical environments (presence of ceramic, marble, cement, dust, etc.).

The dimensions of the installation site and ventilation devices must ensure that ambient temperature remains within the limits indicated during duty cycle operating conditions.

If a suitable hot air discharge opening is not provided, install one or more air evacuation hoods. The hoods should be installed as high as possible in relation to the dimen-sions of the premises.

Fig. 30


GB

The machine cooling air and the heating ducts (where relevant) must be dimensioned so that air speed does not exceed 3 m/s. The maxi-mum length of the ducts is 6 m. If this is not so, fit an auxiliary fan in the hot air duct.

Following installation of the hot air ducts, check that any back pressure, measured at the outfeed of the hot air from the compressor, does not exceed 5-6 mm of water column.

For guidance purposes, duct cross-section area should be equal to that of the compressor hot air outlet grill (reference FU in Figs. 14, 16, 18, 20, 22, 24).Heat the environment if the minimum temperature required cannot be guaranteed.

Comply with the minimum distances from the walls shown in figure 31

The position of the compressor in the room should allow easy inspections. If the compres-sor is installed in the working environment, keep at suitable safety distance according to the type of process carried out at the premises in order to prevent hazards or damage to the machine due to the products used.

The compressor should not be installed in a recess which does not allow correct ventila-tion. Hot air flow should not be obstructed in any way and recirculation must be prevented (Fig. 32).

Fig. 31

Fig. 32

600 600

600

6.3Air connection

When connecting the compressor to the receiver or to the distribution line, it is good practice to insert a hose of suitable size and specifications (pressure and temperature) connected to the MA sleeve (Figs. 14, 16, 18, 20, 22, 24). The compressed air lines must be in perfect conditions and suitably fastened.


GB

In particular, hoses which are not perfectly secured may cause severe injuries due to unpredictable move-ments. Make sure that the hose ends are firmly secured before pressurizing them. The condensate drain must be connected to a collection system with a suitable pipe as established by local regulations for the disposal of polluting substances.

6.4Electrical connectionThe electrical power system must include a main circuit breaker with line sectioning function that can be padlocked, with fuses or thermal cut-out suitably rated according to the characteristics of the machine, and a device against accidental contacts in order to protect personnel.The setting of the safety devices and the rating of the line circuit breaker must comply with the indications provided in the table of paragraph 4.6. The circuit breaker must be positioned close to the machine. Comply scrupulously with specific local accident prevention regulations.The power cables must have an adequate cross-section area for current take-off (see the table in paragraph 4.6).Electrical systems must comply with the rules of good workmanship and be installed by a qualified electrician who must check the efficiency of the earthing system. The power cable must be secured in the specific glands and the electrical panel must be tightly closed to achieve the prescribed IP44 protection rating.Connect the machine only to type-approved sockets. The sockets must be earthed and tested.Have correct fastening of the electrical cables of the various components checked regularly by qualified personnel.Chapter 12 contains the operational and layout wiring diagrams of the auxiliary and power circuits. The same diagrams are also shown inside the machine control box.

6.5Configuration for remote controlThis paragraph describes how to configure the compressor for remote starting and stopping of this. Alternatively, it is also possible to check operating mode (load / unload) or both functions by means of an external control logic.

The operations described must be carried out by a qualified electrician.To configure the remote control of the compressor, first of all remove the jumper between terminals 3 and 38 of the terminal strip inside the electrical cabinet (see wiring diagrams in Chapter 12)

One or two switches must be installed as described below according to whether only switching ON/OFF and/or operating mode is to be controlled.

Remote control ON/OFF(see paragraph 7.4.2.3 - Remote control type)The switch must be connected to the following terminals after removing the jumper:

3 digital INPUT common terminal


GB

38 remote control digital INPUT terminal

LOAD/NO-LOAD remote control(see paragraph 7.4.2.3 - Remote control type)

The switch must be connected to the following terminals after removing the jumper: 3 digital INPUT common terminal38 remote control digital INPUT terminal

ON/OFF - LOAD/NO-LOAD remote control(see paragraph 7.4.2.3 - Remote control type)

Two switches must be used for this configuration.The switches must be connected to the terminals after removing the jumper:

ON/OFF SWITCH3 digital INPUT common terminal38 remote control digital INPUT terminal

LOAD / NO-LOAD START SWITCH3 digital INPUT common terminal39 remote control digital INPUT terminal

Following modifications to the wiring, the remote control must be configured as explained in paragraph 7.4.2.3 - Local/remote /program control - Remote control type

P. 35 - Chap. 7 Start-up and operation

7Start-up and operation

GB

7.1Checks to be carried out prior to start-upN.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.

Each machine was thoroughly tested at the plant before shipping. You should monitor the compressor during the fi rst hours of operations to check for faults.

Follow the installation prescriptions given in chapters 5 and 6 Remove all packaging materials and tools Connect the compressor to the distribution line as shown in paragraphs 6.2 and 6.3 Check the oil level in the receiver: see paragraph 10.5. If the level is low, top up with lubricating oil of

suitable specifi cations Check for correspondence between the compressor plate data with the actual specifi cations of the

electrical system. A variation of ± 10% with respect to the rated value is allowed Connect the machine to the electrical system as described in paragraph 6.4

Compliance with the correct voltage phase sequence is fundamental since this defi nes the direction of rotation of the motor. The direction of rotation must be that indicated by the adhe-sive label located to the side of the screw unit (fi gure 33). Note that even a few seconds of incorrect rotation may cause serious damage. A phase sequence checking device to prevent mistakes is fi tted in the electrical panel.

Fig. 33

The machine is now ready to be started.

Before starting the machine read the following paragraph and chapter 10 on maintenance operations for in-depth knowledge of the machine.

7.2“mc2” Control panelThe compressor is fi tted with a “control panel” (reference PC fi gures 13, 15, 17, 19, 21, 23) 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.

The features offered by this electronic control system includes: Fully automatic compressor operation Real-time operating parameter display


GB

Customization operating parameter Programming of compressor operation on a daily or weekly basis Programming and signalling of the Manufacturer’s maintenance schedule Machine self-protection system to signal fault pre-alarms and automatically stop the machine in the

event of serious problems Remote machine control Possibility of connecting the compressor via CAN-BUS interface (optional) to other similar compressors

for integrated management of the set of machines Remote compressor monitoring via personal computer and dedicated software (optional)

Fig. 34

The panel has two sections:

Control unit “mc2” of the compressor

Emergency stop button

7.2.1Control unit “mc2“

Fig. 35

The front panel of the control unit “mc2” comprises:

compressor programming and control keyboard

Indicator / setting LEDs

back-lit LCD display

K4

K5

K3

K6

K1 K2

K7

K8

K9

L1 L2L3 L4

L5

Control and programming keyboard

K1 START button (starting the compressor)Used to start the machine. If remote control or programming (daily/weekly) are enabled, this key is used to enable compressor functioning (priority control from keyboard). If alarm conditions have occurred, pressing of this key has no effect

K2 STOP button (stop the compressor)Permits timed stopping of the machine. If remote control or programming (daily/weekly) have been enabled, this key can be used to disable compressor functioning (priority control). It does not operate at emergency level

K3 RESET buttonMakes it possible to reset compressor fault messages after eliminating the causes of these. As the faults can be displayed only in the main screen page, the RESET key is effective only during display of this.During parameter modification operations, the RESET key can be used to restore the preset factory (default) value for the type of compressor selected

RESET


GB

K4 ESC buttonUsed to return to the main menu (previous level) or to cancel the modifications made. If the key is held down, the control unit returns to the main screen page. If OFF, back-lighting of the display is re-activated the first time the key is pressed without performing any other function

ESC

K5 UP arrow keyUsed for upward scrolling of menu items; during setting of multiple-choice parameters. makes it possible to select one of the available options.

K6 DOWN arrow keyUsed for downward scrolling of menu items; during setting of multiple-choice parameters. makes it possible to select one of the available options.If OFF, back-lighting of the display is re-activated the first time the key is pressed without performing any other function

K7 PLUS keyMakes it possible to increase the value of the parameter being modified.Starting from the main screen page, permits access to additional information and scrolling of thisIf OFF, back-lighting of the display is re-activated the first time the key is pressed without performing any other function

+

K8 MINUS keyMakes it possible to decrease the value of the parameter being modifiedStarting from the main screen page, permits access to additional information and scrolling of thisIf OFF, back-lighting of the display is re-activated the first time the key is pressed without performing any other function

-

K9 ENTER / CONFIRM keyUsed to access the menu displayed (next level).Starting from the main screen page, makes it possible to access the menu tree.Used to confirm the value or selection made during modification of a parameter.If OFF, back-lighting of the display is re-activated the first time the key is pressed without performing any other function

Indicator / setting LED

L1 Voltage present LED (yellow)Must always be ON when the compressor is powered

L2 warning LED (yellow)This LED switches on to indicate critical conditions or a minor fault that does not block the compressor; this indication may refer to the need for maintenance or irregular operating conditions. Switching ON of this LED is always accompanied by a descriptive message that can be displayed in the main screen page

L3 Alarm LED (red)This LED switches on (steady light) to indicate that the compressor has been blocked by a serious fault; the type of fault is described with a message in the main screen page. Once the fault has been reset, the LED starts to flash, informing the operator that the situation can be reset with the RESET key

L4 AUTORESTART LED (red)This LED switches on when the AUTORESTART function is enabled.In the case of automatic restart following a blackout (AUTORESTART function enabled) the LED flashes to indicate that the compressor is about to restart. The display shows the countdown to restart

L5 REMOTE / PROGRAM functions active LED (red)This LED switches on when the remote control function or one of the programming functions (daily-weekly) is enabled.If the compressor is installed in line with other similar compressors and communication on a CAN-BUS is enabled, LED L5 assumes other functions. Refer to chapter 8 “Compressors in sequence”


GB

Display

DI DI Multi-function displayBack-lit LCD display with four lines of twenty characters each: shows compressor operating conditions and is used to carry out all programming and control operations

7.2.2Emergency stop button

Fig.36

The red EMERGENCY STOP button PE (ref. figure 36) stops the machine immediately. Use this button for emergencies only in conditions which appear hazardous for the operator or for the machine (see “Compressor emergency STOP” below).

7.3Starting and stopping the compressor STARTING the compressor

When the machine is switched on (powered) the control unit starts the initial sequence and prepares to control the compressor.According to the sequence, with the LP led ON steadily, the following screen page must be shown on display DI:

This screen page indicates:

LINE 1 name of the compressoLINE 2 /LINE 3 software version which may differ from that

indicatedLINE 4 serial number of control unit, different for each

machine

1

<<<<mc2>>>>

Vers .So f t . : 1 .0 .0 .1S/N: 000-00-01-00001

After a few seconds, the display shows the main screen page:

This screen page indicates:

LINE 1 indication of network pressureLINE 2 indication of compression temperature of air-

oil mixtureLINE 3 messages about operating conditionsLINE 4 hour and date, informations menu access,

tree menu access, quick language change message

2

Pressione XX.X barTemperatura XXX °C Pronto all’avvio10:40 DOM 25/05/2003

To change the language, use the K5 and K6 keys

If the compressor is operating, LINE 1 and LINE 2 always show the above information.Particular indications (error messages), additional information or the information of the management menu are displayed on LINE 3 and on LINE 4.


GB

If LINE 3 shows “Ready for start”, the compressor can be started.

The compressor is started by pressing the green K1-START key

At this point, the compressor may:a) start, displaying the messages referring to the start and functioning phasesb) prepare to start with the following message

In this case, network pressure is above the minimum threshold value set; the compressor will start automatically in the case of a request for air from the network

3

Stand by auto starthour-date

c) prepare to start with the following message

In this case, the remote control function has been enabled (see paragraph 7.4.2.3).The compressor will start when the remote command is received

4

Stand by rem. com.hour-date

d) prepare to start with the following message

In this case, the daily or weekly programming function has been enabled and the compressor is in the OFF programming phase (see paragraph 7.4.2.6). The compressor will start when an ON programming phase is initiated.5

Stand by progr. com.hour-date

If the compressor does not start or none of the cases listed above occurs, refer to chapter 9.

The following contacts will be made in sequence:

LINE - STAR - DELTA

6 Starthour-date

Starthour-date

and one of the two messages will be displayed

7 Unload runhour-date

Load runhour-date

When the display shows “Load run” the intake valve is open and the machine operates at full load (produces the nominal capacity of compressed air).During functioning, delivery pressure increases; once the preset maximum line pressure threshold value has been reached, the control system sets the compressor to idling by closing the intake valve (“Unload run”). When the pressure drops below the preset minimum threshold value, the intake valve opens again and the machine restarts functioning at full load.

During unload run, two cases may arise:

a) Setting of AUTOMATIC functioning (see paragraph 7.4.2.3):


GB

The compressor outputs this message followed by a countdown.8 Unload run

hour-date 04m 59s

At the end of the countdown, the compressor switches off, changing to “Stand-by auto start”, status, ready to restart in the case of a request for air

Stand by auto starthour-date

b) Setting of CONTIN. functioning (see paragraph 7.4.2.3):

The compressor outputs the “Unload run” message, the machine never stops, always remaining available to restart production of compressed air immediately in the case of any request.

9 Unload runhour-date

STOPPING the compressorMachine starting and stopping is timed.

Simply press the K2 button to stop the compressor

The compressor does not stop immediately but initiates a set of operations to stop the machine according to operating conditions when the STOP command is invoked. If, at the time of the STOP command, the compressor was operating at full load, the control unit sets the machine to unload run.

Display DI shows this countdown; at the end of the countdown, the motor is stopped.10 Stop in XXX sec.

hour-date

At this point, the display shows this additional timing: during this phase, the compressor vents the pressure inside the separator reservoir preparing for subsequent restart.

Blowdown in XXX sec.hour-date

If the K1-START key is pressed again before the preset timed restart time has passed, a new timing is shown on display D1 which indicates the time to compressor restart

This function prevents restarting the compressor when it is still pressurized, avoiding electrical motor verload.

Start in XXX sec.hour-date

11

Compressor emergency STOPPress the PE red EMERGENCY STOP button to stop instantaneously the compressor in a hazardous situation


GB

The emergency stop button is intercepted by the monitoring unit which displays the following message with LED L3 on

To reset, release the EMERGENCY STOP button lock and press button K3-RESET

12

EMERGENCY STOPcompress.-BlockRESET

7.4Parameter configuration - menu treeThe machine was configured at the plant during testing; the end user, however, can change some operating parameters to customize machine performance to the specific applications.Other parameter changes cannot be made Customer but only by Authorized Service Centre skilled personnel.

The main screen page is displayed as follows:

LINE 1 net pressureLINE 2 compression temperature of air-oil mixtureLINE 3 messages about operating conditionsLINE 4 hour and date, informations menu access,

tree menu access, quick language change message

13

Pressure XX.X barTemperature XXX °CReady for start10:40 DOM 25/05/2003

To change the language, use the K5 and K6 keys

After 60 seconds from pressing of the last key, the display is set to a low level of brightness. The first time a key is pressed (excluding the K1-START, K2-STOP, K3-RESET control keys), high level brightness of the display is restored while subsequent pressing of the keys produces the associated function.

14

ESCESC

+ -ADDIZIONAL

INFORMATIONSMENUTREE

7.4.1 7.4.2

Pressure XX.X barTemperature XXX °CReady for start10:40 DOM 25/05/2003

b) to MENU TREEusing the K9 (ENTER) keyThis menu permits access to all compressor control and programming functions; the main screen page is redisplayed using the K4-ESC key or automatically after 60 seconds

a) to ADDIZIONAL INFORMATIONSusing the K7 (PLUS) and K8 (MINUS) keys This menu permits fast access to significant information without having to enter the menu tree; the main screen page is redisplayed using the K4-ESC key or automatically after 60 seconds

From the main screen page, it is possible to access:

14


GB

7.4.1Additional information menu

ESC

ESC

ESC

ESC

MAIN SCREEN PAGE

Menu A Pressure XX.X barTemperature XXX °CReady for starthour-date

Indicates the maximum operating pressure of the compressor.(ref. paragraph 7.4.2.5)

Indicates the minimum operating pressure of the compressor. (ref. paragraph 7.4.2.5)

Operating press.Max: 8.0 bar

Operating press.Min: 7.0 bar

Operating modeState: AUTOMATIC

Type of controlControl: LOCAL

AUTORESTART functionState: OFF

+ -

+ -

+ -

+ -

ESC

ESC

ESC

Operating timetotal: XXXX hours

Operating timeon load: XXXX hours

Time to serviceoil: XXXX hours

+ -

+ -

+ -

+ -

Indicates operating mode setting:AUTOMATIC / CONTIN.(ref. paragraph 7.4.2.3)

Indicates setting of the type of control: LOCAL / REMOTE / PROGRAM(ref. paragraph 7.4.2.3)

If enabled, indicates the status of the AUTORESTART function (automatic restart following blackout)(ref. paragraph 7.4.2.3)

Indicates the total hours of operation of the compressor(ref. paragraph 7.4.2.2)

Indicates the hours of operation of the compressor at full load(ref. paragraph 7.4.2.2.)

Indicates the time remaining to initial maintenance: any other maintenance operations to be carried out within 100 hours from initial maintenance are also displayed cyclically(ref. paragraph 7.4.2.2.)

ESC

ESC

+ -

ID compressorN° stazione: 1

+ -

Net sequenceID 4-3-1-2

Only if the CAN-BUS communication module has been installed

Indicates the order in which the machines are started(ref. paragraph 7.4.2.4.)

It provides the information consulted most frequently and is shown below.


GB

This menu can also be accessed with the compressor running.If no key is pressed, the main screen page is redisplayed automatically after 60 seconds.

It is possible to return to the main screen page from any point of the menu by holding down the K4-ESC keyESC

7.4.2Menu tree (control and programming)This is the structured menu used to carry out all compressor control and programming operations.

ESC

MAIN SCREEN PAGE

ESC

Menu B Pressure XX.X barTemperature XXX °CReady for starthour-date

(ref. paragraph 7.4.2.2)


>MAINTENANCE <...

>GENERAL SETTINGS <...

>NETWORK SETTINGS <...

>OPERAT. PARAMETERS <...

>PROGRAMMING <...

>DIAGNOSTICS <...

>PASSWORD <...

>INFORMATION <...

ESC

ESC

ESC

ESC

ESC

ESC

(ref. paragraph 7.4.2.4)visible only if the CAN-BUS interface has been installed






The options and setting in the various menu can be:


GB

CONFIRMEDpressing the K9-ENTER key10 OPERATION

COMPLETED

CANCELLEDpressing the K4-ESC key OPERATION

ABORTEDESC

Each time a parameter is modified, the factory-set (default value) can be restored for the selected compressor pressing the K3-RESET keyRESET

7.4.2.1PASSWORD menuUsed to enter a password to enable particular functions (e.g. AUTORESTART) or to access protected menus.For enabling of the AUTORESTART function, contact the Manufacturer’s Customer ServiceThe password is inserted using:

Menu C

>PASSWORD <

>Enter password <

Enter password: 0000

ESC

ESC

keys K7 and K8 to modify the flashing character; numbers and letters are displayed subsequently

the K5 and K6 keys to move to modification of the previous / next character

After inserting the password, this can be confirmed with the K9-ENTER key or cancelled with the K4-ESC keyESC

+ -

If no other key is pressed, the password entered “expires” after five minutes with possibly display of a re-entry prompt.

7.4.2.2MAINTENANCE menuThis menu is used to display short-term maintenance operations, the remaining service life of each component, to reset the life counters of each component (where this function is enabled), to display compressor hours of operation.


GB

ESCMenu D

>MAINTENANCE <

>Time to service <

Time to service .... xxx hrsESC

>Components life <

Time remaining for air filter xxx hrsESC

Time remaining for oil filter xxx hrsESC

Time remaining for ... other componentsESC

>Compon. replacement<

Replacement made for air filter OK?ESC

Replacement made for oil filter OK?ESC

Replacement made for ...other components...ESC

ESCConfirm replacement air filter OK?

Confirm replacement oil filter OK?ESC

Confirm replacement ...other components...ESC

>Running hours <

Operating time total: xxxx oreESC

Operating time load xxxx ore

Press the K4 key to return to the MAINTENANCE menu from the submenus

ESC

only with access enabled


GB

Time to service Makes it possible to check the first maintenance operation to be carried out on the compressor; the

maintenance operations to be carried out 100 hours after this are also displayed. In this way, the user can schedule maintenance operations and, if necessary, decide whether to replace several components during the same maintenance operation

Components lifeindicates the remaining service life of each component that requires periodic maintenance

Compon. replacementIf the function is enabled, it makes it possible to reset the component life counters after maintenance

Running hoursIndicates compressor operating time (total running hours, running hours at full load)

A table with the schedule of the maintenance operations to be carried out is provided below

InterventionFirst 100 hours maintenance

coupon

First 1000 hours maintenance

couponEvery 1000 hours Every 2000 hours

Check air filter •Replace air filter • •

Change oil •Replace oil filter • • •

Replace separator filter •

Replace air dryer filters • •

Maintenance periods may differ from those indicated.During installation, Service Centre personnel assess compressor operating conditions and if necessary modify the frequency of the operations.

7.4.2.3GENERAL SETTINGS menuThis menu allows to carry out the general settings of compressor operating configuration with the exception of operating parameters (pressures, timings).

LanguageUsed to select the language of the messages

Measur. unitUsed to set the measurement units for pressure and temperature

(continued on p. 49)


GB

continued on p. 48

ESCMenu E (1/3)

>GENERAL SETTINGS <

>Language <

Select language: √ENGLISHESC

Select language: ..OTHER LANGUAGES..ESC

>Measur. unit <

Pressure unit Unit: barESC

Temperature unit Unit: Cels.ESC

>Date and time <

Set date and time hh:mm day dd/mm/yyyyESC

Press the K4 key to return to the GENERAL SETTINGS menu from the submenus

ESC

>Display settings <

Contrast Intensity: XXX%ESC

Lighting ONBrightness: XXX%ESC

Lighting OFFBrightness: XXX%ESC

+ -

+ -

+ -

+ -

+ -

+ -


GB

ESCMenu E (2/3)

>Operating mode <

Operating mode √AUTOMATICESC

Operating mode CONTIN

ESC

>Compress. control <

Compress. control √LOCALESC

Compress. control REMOTEESC


Compress. control PROGRAMESC

Compress. control√NETWORK CONINUOUSESC

Compress. control NETWORK PROGRAMESC

+ -

+ -

only if the CAN-BUS interface has been installed

continued from p. 47

>DRYER control <

DRYER√enabled in ONESC

DRYER DisabledESC

Continued on p. 49

only on machines equipped with integrated dryer


GB

(continued from p.46)

Date & timeUsed to set the current date and timeThe time and date are entered using:

the K7 and K8 keys to modify the flashing values

the K5 and K6 keys to move to modification of the previous / next character

After entry of the values, these can be confirmed with the K9-ENTER key or cancelled with the K4-ESC key.ESC

+ -

Display settings Makes it possible to adjust the settings of the LCD display

Operating mode

ESCMenu E (3/3)

>AUTORESTART func.<

AUTORESTART√DISABLEDESC

AUTORESTART √ENABLEDESC


continued from p. 48

Only with access enabled

>Type remote contr. <

Type remote contr. ON/OFFESC

Type remote contr. LOAD/UNLOADESC

Type remote contr. ON/OFF-LOAD/UNLOADESC


GB

Compressor operating mode may be set AUTOMATIC or CONTINUOUS:AUTOMATIC: this is the setting used in most cases (factory setting). In this operating mode, idling is timed; at the end of the count, the compressor stops, preparing for subsequent automatic start-up (see also paragraph 7.3 STARTING the compressor). This promotes energy saving if there is no or a very low request for compressed air.

CONTINUOUS:this setting should be used in very particular applications characterized by a considerable variation in compressed air consumption combined with a reduced plant accumulation capacity. With this setting, the compressor starts unload run without ever stopping the motor and is therefore able to supply air continuously in the case of a request from the network. The system configured in this way is highly reactive. However, one of the drawbacks of this operating mode is that it entails higher power consumption due to the fact that the compressor is always running (see also paragraph 7.3 STARTING the compressor).

Compress. controlThis menu is used to select the compressor control method from the possible local / remote / program control options.If the compressor is equipped with a CAN-BUS interface, the network-continuous / network-program control options are also visible and can be selected.Compressor control can be set to:

LOCAL: this is the basic (factory) setting that permits control from the keyboard

REMOTE: with this setting, the compressor can be controlled by means of an external remote switch. For the electrical connections, refer to the following submenu (refer to the following paragraph “Type of remote control”)

PROGRAM: enables the daily or weekly programming set and enabled in the PROGRAMMING menu (see paragraph 7.4.2.6)

NET-CONTINUOUS: this is the setting for control of a sequence of compressors, without daily/weekly program

NET-PROGRAM: this is the setting for control of a sequence of compressors according to the daily/weekly program set

Dryer control This menu is used to activate/de-activate the dryer

Type of remote controlFor remote control, modifications must be made to the wiring of the compressor as described in paragraph 6.5.When compressor control is set to REMOTE (see previous submenu), three types of control methods are possible:

ON/OFF is the setting that makes it possible to control switching ON/OFF of the compressor. This is the factory setting (that most frequently used) which makes it possible to exploit the control logic of the compressor using the pressure signal measured locally by the machine


GB

LOAD/UNLOAD is the setting that makes it possible to control full load and unload operation with an external control logic: in this case, the pressure signal measured by the compressor is ignored for the purposes of operating method control (the safety devices remain active)

ON/OFF - LOAD/UNLOAD is the setting that makes it possible to control both switching ON/OFF of the compressor and also operating mode. In this case also, an external control logic must be used as, for control purposes, the pressure signal is ignored (the safety devices remain active)

It should be remembered that control via the keyboard of the control unit always has priority over any remote control or any program: this means that, if remote control is to be effective, the START button must be pressed setting the compressor to “Stand-by rem. con.”. Similarly, the compressor can be stopped without any risk of remote restart of this by pressing the STOP key.

Therefore, to enable functioning with remote control:1) Make the modifications to the wiring connecting one / two switches as described in paragraph 6.52) Select REMOTE control3) Select the control method (ON/OFF, LOAD/UNLOAD, ON/OFF - LOAD/UNLOAD)4) Press the START key on the control unit to enable the compressor for remote control

Autorestart functionIf enabled, this menu makes it possible to set the AUTORESTART function, useful for automatic restart of the machine following a black-out and subsequent power-up.

7.4.2.4NETWORK SETTINGS menuThis menu is used to set the parameters required for operation of the compressor in a network (in communication with other similar compressors)Refer to chapter 8 “Compressors in sequence”.The menu is visible only after connection of the control unit with the CAN-BUS interface module for communication between compressors.

Compressor ID This is the identifier number of the compressor in a set of machines

PrefillWhen the set of compressors is started with the compressed air system discharged (pressure zero or very low), it is usually necessary to increase the pressure to the minimum working value as quickly as possible. With the PREFILL function enabled, the compressor participates in system prefilling, bypassing the global control functions in this phase. The compressors involved in this operation are started quickly in sequence, thus avoiding any overlap of the start-up phases of two or more machines

Rotation timeThis is the time after which compressor start-up priorities are reassigned so that the work load is evenly distributed between the machines available over a long period of time


GB

ESC

>NETWORK SETTINGS <

compressor ID n. of service points: XESC

Prefill n. compr. XESC

Prefill time Val.: 5 minESC

Max n. compr. ON n. compr. 4ESC

Press the K4 key to return to the NETWORK SETTINGS menu from the submenus

Rotation time sequence 24 hrsESC

Reaction time delay ON xxx secESC

+ -

+ -

Menu F

+ -

+ -

Reaction timesT ON When the control system activates a compressor following a reduction in network pressure, timer T ON is started: at the end of this count, the system checks network pressure to establish whether another compressor must be started

T OFF When the control system deactivates a compressor following an increase in network pressure, the T OFF timer is started: at the end of this count, the system checks network pressure to establish whether another compressor is to be deactivated

7.4.2.5OPERAT. PARAMETERS menuThis menu is used to make the configuration settings referring to the timings and operating pressure and timings that regulate unload run and drainage of condensate.

visible only if the CAN-BUS interface has been installed

+ -

+ -

Reaction time delay OFF xxx sec + -

ESC


GB

PressuresMAX. OPERATING PRESS.: The pressure above which the compressor starts to idle. The rated pressure of the machine represents the upper limit of this value.

MIN OPERATING PRESS.: The pressure below which the compressor restarts operation at full load (supply of compressed air) or at which it restarts if it has stopped at the end of unload run (no supply of air). This value must be set so that the minimum supply pressure to the pneumatic service points is guaranteed, taking into account losses of head of the distribution system. The minimum pressure value cannot be close to the maximum pressure by more than the factory setting (minimum difference).

TimingsUNLOAD RUN TIME: This setting defines the time during which the compressor idles when there is no demand for air from the network. At the end of this period, the compressor stops and is ready to start again when network pressure has dropped below the minimum threshold value.

Press the K4 key to return to the OPERAT. PARAMETERS menu from the submenus ESC

Menu G

>OPERAT. PARAMETERS <

>Pressures <

Operating press. Max: xxx barESC

Operating press. Min: xxx barESC

>Timings <

Unload run time val.: xxx minESC

Time DRAIN open val.: xxx minESC

ESC

+ -

Time DRAIN closed val.: xxx minESC

+ -

+ -

+ -

+ -


GB

This parameter is effective only if operating mode has been set to AUTOMATIC (see paragraph 7.4.2.3)

This parameter must be optimized according to the consumption trend of the network and its accumulation capacity.

In the case of low consumption and if it is seen that the compressor remains inactive for long periods (motor stopped), it is advisable to reduce idling time so as to restrict power consumption during the inactive phases to a minimum. Low air consumption will also assure a limited number of automatic start-up operations of the compressor, thus promoting a further reduction in power consumption.

If air consumption is consistent and/or characterized by major variations, it is advisable to extend the idling time in order to “offset”, through the periods of idling, the various periods of operation at full load. This avoid stopping of the compressor with consequent delays in the supply of compressed air due to the start-up phases which are characterized by current take-off peaks tied to frequent starting.

7.4.2.6PROGRAMMING menuThe PROGRAMMING menu is used to set the schedule of compressor activities, defining the days and times when the compressor must be switched on. The compressor can be programmed on a daily basis (same for all the days) or on a weekly basis (a different program for each day of the week).

Reset programming:Makes it possible to cancel all the cycles set in both daily and weekly programming

Programming modeThis parameter informs the controller whether, once PROGRAM control has been activated (see paragraph 7.4.2.3), the machine must follow daily or weekly programming

Daily programmingDaily programming can be used to set up to four start/stop cycles. These cycles are repeated equally each day of the week.

The following rules apply:

- Non-programmed cycles identified by the five hyphens that replace the time are not effective

- Cycles for which the start and stop times coincide are not effective, similarly to those not programmed

- If, in the last cycle programmed, the stopping time has been set to 24:00 and the start time of the first daily cycle has been set to 00:00, the control unit will keep the compressor running during the change over at midnight from one day to the nextdella mezzanotte da un giorno all’altro

Weekly programmingWeekly programming makes it possible to set different start/stop cycles for each day of the week, up to a maximum of three per day.


GB

ESCMenu H

>PROGRAMMING <

>RESET programm. <

Confirm RESET programming OK?ESC

>Programming mode <

Programming mode √DAILYESC

Programming mode √WEEKLYESC

Press the K4 key to return to the PROGRAMMING menu from the submenus

ESC

>Daily programming <

Every day Start 1: -----ESC

Every day Stop 1: -----ESC

...other days......other cycles...ESC

+ -

+ -

>Weekly programming <

Monday Start 1: -----ESC

Monday Stop 1: -----ESC

...other days......other cycles...ESC

+ -

+ -


GB

The following rules apply:

- Non-programmed cycles identified by the five hyphens that replace the time are not effective

- Cycles for which the start and stop times coincide are not effective, similarly to those not programmed

- If, in the last cycle programmed for a given day, the stopping time has been set to 24:00 and the first cycle programmed for the next day has been set to 00:00, the control unit will keep the compressor running during the change over at midnight from one day to the next

NOTE: remember that control via keyboard of the control unit always has priority over any program control: this means that, if the program is to be effective, the K1-START button must be pressed setting the compressor to “Stand-by progr. con.”. Similarly, the compressor can be stopped without any risk of restart by the pre-set program pressing the K2-STOP key.

Therefore, to enable functioning with program control:1) Select PROGRAM control2) Select the programming method to be used (DAILY/WEEKLY)3) Program the daily or weekly schedule selected4) Press the K1-START key on the control unit to enable program control

7.4.2.7DIAGNOSTICS menuFrom the diagnostics menu, it is possible to check functioning of the INPUTS, OUTPUTS and the direction of rotation of the compressor and fan. It is also possible to read the log of faults that have occurred on the compressor.

These diagnostic functions should be used only by expert personnel with in-depth knowledge of the compressor and how this operates.

Diagnostic TESTTo run the diagnostic TEST, comply with all the safety rules described in chapter 5

WARNING!!!When carrying out the test, certain parts of the machine are powered (control coils) and rotating parts are activated (motor, compressor, fan). The operator must therefore take all the necessary precautions during these checks.

Error messagesThe control unit saves all the faults that have occurred and which have caused stoppage of the machine (alarms). The following data are save for each error message:

- Type of error (alarm)

- Time, day, date on which the alarm occurred

- Total hours and hours of load run when the fault occurred

These indications are displayed cyclically on the third and fourth lines of the display.


GB

DIAGNOSTIC TESTRot. direction TEST.

Press for TEST

ESCMenu I

>DIAGNOSTICS <

>DIAGNOSTIC TEST <

Run diagnostic TEST OK?ESC

...other INPUTS...

DIAGNOSTIC TESTTEST digit. INPUTS

INPUT n. 1: statusEmergency OK


ESC

Press if OKPress ESC if NEGAT.

>ERROR MESSAGES <

Lasterror messageESC

...othererror messages...

ESC

DIAGNOSTIC TESTTEST digit. OUTPUTS

OUTPUT n. 1: activeLine

ESC

ESC

ESC

ESC

ESC

ESC...other OUTPUTS...

ESC


GB

7.4.2.8INFORMATION menu

This menu provides information about the serial number of the control unit and the software version installed.The CPU serial No. is indispensable to request enabling of protected functions by the Manufacturer (e.g. AUTORESTART) and to obtain the related access password.

CPU serial No.Indicates the serial number of the control unit

Software versionIndicates the software version installed

Menu L

>INFORMATION <

ESC

>CPU serial No.<

CPU serial No XXX-XX-XX-XXXXXESC

>Software version <

Software version <<<mc2>>> X.X:X:XESC


ESC

7.5Operating warnings and faultsThe diagnostics system of the controller permits continuous monitoring of machine operating conditions and prompt indication of the need for maintenance operations or of any malfunctions.The indications are divided into two categories::

Warning messagesThese messages may refer to scheduled maintenance operations, critical operating conditions or minor faults which do not block the compressor but which must be checked in order to trace their cause.

The warning messages are accompanied by switching on of yellow LED L2 and described with a message shown on the third and fourth lines of the display in the main screen page. Warning messages are displayed in alternating mode so as not to prevent display of basic messages.

To RESET the warning messages, proceed as follows:1) For messages relating to scheduled maintenance operations: carry out the operation and RESET

component life (see paragraph 7.4.2.2)


GB

Messages of this type are as follows:- Replace air filter- Replace oil filter- Replace oil- Replace separator filter- Replace air filter - excess. clogging for this last fault, after replacing the filter, press the K3 - RESET key

2) For critical operating condition messages: If possible eliminate the problem; the message will be cleared automaticallyMessages of this type are as follows:- Compression temp. high- Ambient temperature low

WARNING!!!If the warnings are not reset for a long period of time (e.g. failure to carry out scheduled maintenance) THE COMPRESSOR IS BLOCKED!!! In this case, contact the Service or Customer Centre of the Manufacturer immediately.

Alarm messagesThese messages indicate a serious fault that has blocked the compressor. The alarm may be due to a fault in the system or extremely critical operating conditions.

When a machine stoppage occurs, the compressor stops immediately, the red LED L3 of the alarms switches on and the message relating to the fault is displayed persistently in the main screen page. To RESET, first of all eliminate the fault: at this point, LED L3 starts to flash indicating that reset can be carried out pressing the RESET key.

All faults that cause blocking of the compressor are saved in an error message log file. To consult this log, refer to paragraph 7.4.2.7

The following faults block the machine:- EMERGENCY STOP compress. - block- Compression temp. too high - block- Ambient temperature too low - block- Internal pressure too high - block- Net pressure too high - block- Press Transducer error - block- Temperature sensor error - block- Power supply phase sequence error - block- Short-cir. analog INPUT - block- Compress. motor overload - block- No. starts/hr too high - block- Power supply failure - block- Line voltage cutoff - block

Faults caused by failure to carry out maintenance must also be added to these: if the compressor is used for long periods without carrying out the scheduled maintenance indicated by the control unit, a machine blockage occurs accompanied by a message of the type:


GB

Replace -------------- excess hrs - block

where the component to be replaced is displayed instead of the hyphens.

In this case, it is absolutely necessary to replace the component. If the compressor must be restarted, an emergency start-up procedure must be carried out. Contact the Service or Customer Centre of the Manufacturer immediately.

To find out how to proceed in the case of an alarm, refer to chapter 9 “Troubleshooting”.

P. 61 - Chap. 8 Compressors in sequence

GB

8Compressorsin sequence

The mc2 control unit includes all the control functions of the compressor on which it is directly installed.

For compressor rooms in which several machines equipped with this control unit are installed (up to a maximum of four units), a communication network can be set up between these for automatic, coordinated management of the compressors.

Communication between the compressors provides the following advantages:

constant pressure of the air supplied to pneumatic service points

energy saving:only the compressors necessary to supply the air required are activated

equal distribution of work load on the compressors available with consequent synchronization of scheduled maintenance operations

management of alarms and machine stoppages so as to prevent any interruption in the supply of compressed air

management of the network of compressors according to a program set by the user on a daily or weekly basis

To establish communication between the control units, a communication module is required for each machine to be connected and the related connection cables.Therefore, contact your area dealer to purchase these.

The instructions for installation, programming and operation of the network of compressors are provided in the booklet furnished with the communication module.

P. 62 - Chap 5 Troubleshooting

9 Troubleshooting

GB

The following table shows the most frequent problems.The operation should be carried out by a qualifi ed and skilled person where shown. For all other cases, contact a specialised Centre

When the compressor requires scheduled maintenance, the operation to be performed and the number of excess hours of operation are indicated in the main screen page.In the case of long-term functioning in these conditions, the compressor is blocked and the operation must be carried out immediately

V-F Fixed speed compressorsV.V. Variable speed compressors

9.1The machine does not startV-F V-V Indication Possible cause Intervento

X X L1 OFFDI OFF

No power Restore power

FU2 / FU8 blown Replace damaged fuses

X X L1 ONDI OFF

Problems in the electronic control unit

Call Customer Service Centre

Problems in control unit connections


X X L1 ONDI ON(with normal functioning message)

FU4 blown Replace FU4

Inverter problems Call Customer Service CentreX

X X

L1 ONL3 constant ONDI indicates:“Ambient temperature toolow - block”

Ambient temperature too low

Heat ambient.Check installation requirements

X X

L1 ONL3 constant ONDI indicates:“Press. Transducererror - block”

Problems in the pressure sensor or in its electrical connections


X X

L1 ONL3 constant ONDI indicates:“Temperature sensor error - block”

Problems in the temperature sensor or in its electrical connections


P. 63 - Chap. 9 Troubleshooting

GB

V-F V-V Indication Possible cause Intervention

X X

L1 ONL3 constant ONDI indicates:“Short-circ. Analog INPUT - block”

Problems in the pressure / temperature sensors or in their electrical connections


X X

L1 ONL3 ON flashingDI indicates:“Powersupply failure - block”

An interruption of the power supply of the system has occurred

Carry out the RESET operation (ref. Par. 7.5) and restart the machine

X X

L1 ONL3 constant ONDI indicates:“Power supply phasesequence err. - block”

Power supply phase sequence error Reverse two power phases

X X

L1 ONL3 constant ONDI indicates:“No. starts/hr too high -block”

The No of starts/hr tolerated by the motor has been exceeded

Wait for fault reset

9.2The compressor has trouble starting upV-F V-V Indication Possible cause Intervention

X X

Ambient temperature low Heat ambient

Low voltage Check voltage

VA problems Call Customer Service Centre

Star - delta sequence problems

Call Customer Service CentreX

X Inverter problems Call Customer Service Centre

9.3Pressure value lower than rated pressureV-F V-V Indication Possible cause Intervention

X X Pressure value on DI constant (does not increase)

VA problems Call Customer Service Centre

Belts slipping Call Customer Service Centre

X

X

Variable pressure value on DI but which does not reach the minimum working threshold.Motor speed of rotation remains low.

Control unit mc2 problems Call Customer Service Centre

Problems in the electrical connections between control unit mc2 and inverter


X XPressure value on DI lower than minimum operating pressure

Air demand too high Reduce no. of service points / add compressors in parallel

Internal or external leaks Check leaks


GB

V-F V-V Segnalazione Possibile causa Intervento

X XExcessive FA clogging Replace FA

(see. par. 10.4)

Belts slipping Call Customer Service Centre

9.4The machine is ready for start or is running and the scheduled maintenance LED is ON


X X

L2 flashingDI indicates:“Replace air filterexcess. clogging”

FA clogged Replace FA(see. par. 10.4)

X X

L2 flashingDI indicates:“Replace air filterXXX excess hours”

FA to be replaced for scheduled maintenance

Replace FA(see. par. 10.4)

X X

L2 flashingDI indicates:“Replace oil filterXXX excess hours”

FO to be replaced for scheduled maintenance

Replace FO(see. par. 10.6)

X X

L2 flashingDI indicates:“Replace oilXXX excess hours”

Oil to be replaced for scheduled maintenance

Replace oil(see. par. 10.5)

X X

L2 flashingDI indicates:“Replace oil separatorXXX excess hours”

FD to be replaced for scheduled maintenance

Replace FD(see. par. 10.6)

X X

L2 flashingDI indicates:“Replace dryer filterXXX excess hours”

Dryer filters to be replaced for scheduled maintenance


9.5The machine is ready for start or is running with critical functioning message


X X

L2 flashingDI indicates:“Ambient temperature low”

Ambient temperature low Heat ambient

X X

L2 flashingDI indicates:“Compression temp.High.”

Oil cooling low

Check functioning of the electric fan and its fuses FU3.Call Customer Service Centre

Oil radiator dirty Call Customer Service Centre

Oil low Top up or change oil(see. par. 10.5)


GB


X XL2 flashingDI indicates:“Compression temp.High.”

Excessive ambient or air recirculation temperature

Improve air exchange and check installation requirements

X X FO clogged Replace FO(rif. par. 10.6)

X X FD clogged Replace FD(see. par. 10.6)

X XL2 flashingDI indicates:“Dewpoint probe error”

Problems in the dew temperature sensor or its connection


9.6The machine stops when it is running and warning LED comes on


X X

L3 constant ONDI indicates:“Emergencystop compress. - block”

The PE button has been pressed

Reset the PE button(see. par. 7.2.2)

X X

L3 constant ONDI indicates:“Net pressuretoo high - block”

VA or solenoid valve problems Call Customer Service Centre

Net pressure too high caused by other compressors

Check working pressure of all compressors

X X

L3 constant ONDI indicates:“Compress.motor overload - block”

Low voltage Check voltage

X X Underscaled power cables Check installation requirements

X X

Critical functioning temperature conditions(high ambient temperature, hot air recirculation)

Check functioning conditions


X X FA clogged Replace FA(see. par. 10.4)

X Star delta sequence problems


X Motor thermal protection problems


X X Electrical motor problems Call Customer Service Centre

X X

L3 constant ONDI indicates:“Line voltagecutoff - block”

Line voltage cutoff problems Check line voltage

X X

L3 constant ONDI indicates:“Compression temptoo high - block”

Oil cooling low

Check functioning of the electric fan and its fuses FU3.Call Customer Service Centre


GB


X X

L3 constant ONDI indicates:“Compression temptoo high - block”

Oil radiator dirty Call Customer Service Centre

X X Oil low Top up or change oil(see par. 10.5)

X X Excessive ambient or air recirculation temperature

Improve air exchange and check installation requirements


X X FA clogged Replace FA(see. par. 10.4)

X X

L3 constant ONDI indicates:“Replace air filterexcess hours. - block”

FA to be replaced for scheduled maintenance

Replace FA(see. par. 10.4)

X X

L3 constant ONDI indicates:“Replace oil filterexcess hours. - block”

FO to be replaced for scheduled maintenance

Replace FO(see. par. 10.6)

X X

L3 constant ONDI indicates:“Replace oilexcess hours. - block”

Oil to be replaced for scheduled maintenance

Replace oil(see. par. 10.5)

X X

L3 constant ONDI indicates:“Replace oil separatorexcess hours. - block”

FD to be replaced for scheduled maintenance

Replace FD(see. par. 10.6)

X X

L3 constant ONDI indicates:“Replace dryer filterexcess hours. - block”

Dryer filters to be replaced for scheduled maintenance


X

L1 ONL3 constant ONDI indicates:“INVERTER alarmblock”

Inverter problems Call Customer Service Centre

Problems in the electrical connections between control unit mc2 and inverter


9.7Oil in the networkV-F V-V Indication Possible cause Intervention

X XFD problems Call Customer

Service Centre

Inefficient oil recovery Call Customer Service Centre

9.8Oil in the machineV-F V-V Indication Possible cause Intervention

X X Leaking fittings Fasten the fittings

Safety valve VS intervention Call Customer Service CentreX X


GB


X X FA leaks Call Customer Service Centre

9.9Safety valve VS interventionV-F V-V Indication Possible cause Intervention

X X Pressure detector problems Call Customer Service Centre

FD clogged Replace FD(par. 10.6)X X

P. 68 - Chap. 10 Maintenance

10 Maintenance

GB

Perform the scheduled maintenance operations to maintain compressor performance.

Various routine maintenance operation can be carried out by user provided they are carried out by skilled personnel. If routine maintenance is provided by a Service Centre, the user cannot RESET the components even

if these have been replaced by the user (see paragraph 7.4.2.2)

Use only original spare parts

Instructions are provided in the following paragraphs.

Before performing any maintenance operations read the operator safety precautions in chapter 5 carefully. These precautions must be followed scrupulously for all maintenance operations

Operating cycle 10.1The compressor unit consists of two rotors (male and female) with special asymmetrical profile, patented VT series, mounted on rolling bearings, able to withstand axial and radial thrust. The male rotor is the driving rotor while the female rotor is driven. The male rotor also rotates the female rotor. The two rotors are not however in contact physically as they are separated by a thin film of oil that protects the coupled surfaces. The male rotor drives and the female rotor is driven. The two rotors are not in direct contact thanks to a thin film of oil which protects the coupled surfaces.The oil serves various purposes. It lubricates the bearings and the rotors, eliminates the heat produced by the compressed air, it creates an “airtight fluid seal” and reduces hazardous gaps in the air-end unit.

In fixed speed compressors, starting is of the delta-star type. During the star phase, intake valve VA is closed, thus permitting no-load start-up with less effort and lower energy consumption.After a preset time of a few seconds, the PC control unit invokes changeover to the delta connection; with a short transient phase, the MP motor reaches rated rotation speed. The intake valve opens thus starting the normal work cycle.In variable speed compressors, the start-up phase takes place with acceleration of the electrical motor which, powered by the inverter, is brought to maximum speed of rotation compatible with network pressure.As soon as this is permitted by rotation speed, the intake valve VA opens and the machine work cycle begins.

The air is drawn through the filter FA, passes into the air-end unit where it is mixed with the oil injected. The air is gradually compressed and pushed into the separator receiver where initial oil separation occurs by gravity.The air, which is still mixed with oil droplets, follows the shape of the receiver and passes through the oil separator filter FD. Due to the effect of coalescence, the droplets of oil merge and are deposited on the bottom of the filter from where they are routed towards the air-end unit by means of a pipe.The purified air passes through the check and minimum pressure valve VR which opens only when a threshold of approximately 4 bar is exceeded. This ensures correct system lubrication in all operating conditions.

The oil deposited on the bottom of receiver SS is conveyed under pressure to the oil radiator RO where it is cooled. If the temperature of the oil is below the calibration value of the VT thermostatic valve, flow to the


GB

cooler is bypassed; the oil passes into filter FO and returns to the air end.Temperature sensor STO inserted in the delivery stub pipe and connected to the microprocessor permits constant monitoring of the temperature inside the air-end unit.

The capacity delivered is controlled differently on fixed speed and variable speed machines. In fixed speed compressors, once the rated running pressure has been reached, the intake valve closes. The internal receiver pressure is vented to reach a value of approximately 2 bars.This value is obtained by means of minimal amount of intake air through the intake valve. This ensures that the pressure required for correct system lubrication is maintained. Consequently, the machine can idle with reduced power intake.After the predefined “idling” time, the machine stops, ready to start again automatically if the pressure drops below the minimum threshold.

In variable speed compressors, the control system modifies speed of rotation in order to reach and maintain an average pressure between the minimum and maximum pressure set.In the case of very low air consumption, once the maximum operating pressure has been reached, the com-pressor switches to idling as described for the fixed speed compressorIn this case, the duration of the idling phase is shorter; at the end of this phase, the compressor stops, ready for subsequent automatic restart.

The operator-controlled machine stopping phases also differ as regards the two types of compressor.For fixed speed machines, ordinary stopping is timed; the machine is set to «idling» and the receiver is gradually discharged.For variable speed machines, the stopping phase is controlled through ramping down of the motor, during which the system is depressurised.The machine is also protected against any type of overpressure (internal faults or faults in other compressors in parallel).

General maintenance operation table 10.2The following table shows all the maintenance operations required by the machine.

You will find this symbol next to operations requiring the intervention of Service Centre personnel

-

Operation ReferenceTo be carried

out by a Service Centre

After the first

100 hours

After the first

1000 hours

Every500

hours

Every1000 hours

Every2000 hours

Every4000 hours

Check on suction prefilter 10.3 • • •

Replace suction prefilter 10.3 • •Check air filter 10.4 • • •

Replace air filter 10.4 • •*


GB

-

Operation ReferenceTo be carried

out by a Service Centre

After the first

100 hours

After the first

1000 hours

Every500

hours

Every1000 hours

Every2000 hours

Every4000 hours

Overhaul minimum pressure valve •

Overhaul intake valve •

Replace oil filter 10.6 • • •

Check - top upoil level 10.5 • • •Change

oil 10.5 •Replace

separator filter 10.6 •Check

oil recovery system • •Check

fitting tightness • • •Check

electrical terminal connections • • •

Drain air-oil receiver

condensate10.7 • • •

Cleanradiators • •

Cleandryer condenser • •

Replace air dryer filters • •

Check belt tension and wear • • •

Replacedrive belts •

Checksettings and adjustments •

Checksafety device

operation •

* This frequency relates to operation in normally dust environments. In the case of critically dust environments, the control panel may signal the need to replace the air filter before the scheduled maintenance time. In this case, replace the filter as soon as possible. The skilled personnel employed for installation will be able to objectively evaluate the environmental conditions


GB

Replacement of the suction prefilter 10.3Before performing any maintenance operations read the operator safety precautions in chapter 5 carefully. These precautions must be followed scrupulously for all maintenance operations

Operate on the outside of the compres-sor: back off the screws that support panel PPA of the suction prefilter.

Access the inside of the compressor: extract the grill of the intake prefilter and the filter element PA (Fig. 37)

Replace the filter element PA

Refit the grill of the intake prefilter

Fig. 37

PPA

PA

To reset the scheduled maintenance counter (for enabled users only), see paragraph 7.4.2.2.

Cleaning or replacing the air filter 10.4Before performing any maintenance operations read the operator safety precautions in chapter 5 carefully. These precautions must be followed scrupulously for all maintenance operations

GENESIS - FORMULA - MODULO 5-5-15 kW / 7,5-20 hp (BA 51)

Open the upper panel PS of the com-pressor cabinet, backing off the lock screws

Open the front panel PF of the compres-sor cabinet using the key provided

Loosen the clip FFA shown in Fig. 38 and remove air filter FA

Clean the filter by directing a jet of air inside it or replace the filter as pre-scribed in the maintenance schedule. Do not use fluids or detergents to clean the filter

FFA

Fig. 38

FA


GB

Insert the filter fully on the intake valve

Fasten the clip.

Replace panels PS and PF of the compressor cabinet


GENESIS - FORMULA - MODULO 15 kW / 20 hp (BA 69)

GENESIS - FORMULA:Open the corner panel SPA of the com-pressor cabinet using the key provided

MODULO:Open the filter panel SF of the compres-sor cabinet using the key provided

Release the front part of the filter con-tainer CF pressing on the two fastening tabs (Fig. 39)

Remove air filter FA from its housing as shown in Fig. 40

Clean the filter by directing a jet of air inside it or replace the filter as pre-scribed in the maintenance schedule. Do not use fluids or detergents to clean the filter

Replace filter FA inserting it fully

Re-attach the front part of the filter con-tainer CF pressing on the two fastening tabs

GENESIS - FORMULA:Replace the corner panel SPA of the compressor cabinet

MODULO: Replace the filter panel SF of the com-

pressor cabinet

Fig. 39

Fig. 40

CF

FA



GB

Checking oil level, topping up and changing the oil 10.5Before performing any maintenance operations read the operator safety precautions in chapter 5 carefully. These precautions must be followed scrupulously for all maintenance operations

Checking oil level and topping upCheck the level of the oil in the machine circuit frequently when the machine has been stopped for at least thirty minutes. This operation is very simple: inspect the oil level on the level reference tube TRL (Fig.41) after disassembling the front panel PF

The oil level must be visible but must not exceed the RLMAX maximum level reference.When the level of the lubricant is close to the minimum limit of the level reference tube TRL, top up the oil.

Never let the oil drop to a level which is no longer visible through the reference level tube TRL!

Maximum level is reached when the oil laps the edge of the maximum level reference RLMAX during top-up .Top up when required, as follows:

Remove the front panel PF using the key provided

Loosen oil filler plug TO. Be careful not to lose the seal (Fig. 42)

Use a funnel to pour oil into the filler sleeve (Fig. 42)

Top up the oil level using only the amount indicated in paragraph 4.7

Avoid too much oil!!! Ensure the level of the oil does not exceed the maximum reference level RLM (Fig. 41)

Check that the seal of the plug is cor-rectly positioned and fasten the plug (not too tightly)

Replace the front panel PF using the key provided

Fig. 41

Fig. 42

TRL

RLMAX

RLMIN

TO


GB

Changing the oilChange the oil at the frequency indicated in the scheduled maintenance table of paragraph 10.2 or when you plan to use a different oil from that in the machine.

Carry out this operation when the oil is still warm so that its viscosity is low and fluidity high. Caution: lubricant temperature must not be sufficient to cause burns.

Proceed as follows:


Loosen oil filler plug TO. Be careful not to lose the seal (Fig. 43)

Connect fitting R provided, which must communicate with a suitable collection recipient, to fitting DO after unscrewing the safety plug (Fig. 44)

Open drain valve RSO and drain the lubricant (Fig. 44)

After draining, close oil drain valve RSO

Refill with oil as described in the “Check-ing oil level/topping up” paragraph (Fig. 43)

Check that the seal of plug TO is cor-rectly positioned and fasten the plug (not too tightly)

Replace the front panel PF using the key provided

Open the shut-off valve between the compressor and the distribution line. Switch the circuit breaker on and carry out a test start-up.

Let the compressor run for a few minutes and then make a visual inspection for any oil leaks

Check the oil level again as indicated in the “Checking oil level/topping up” and if necessary top up

Fig. 43

Fig. 44

TO

R

DO

RSO


GB

Remember that waste oil, condensate and all machine filters are polluting materials that must be disposed of in compliance with local legislation


Replacing the oil filter and the separator filter 10.6Before performing any maintenance operations read the operator safety precautions in chapter 5 carefully. These precautions must be followed scrupulously for all maintenance operations


Remove the top panel PS using the key provided

Loosen the oil filter cartridge FO using the specific key provided (Fig. 45)

Lubricate the seal before fitting the new cartridge (Fig. 46)

Fasten the filter and tighten by hand. Do not use tools to fasten the cartridge as these may damage its structure!

Open the shut-off valve between the compressor and the distribution line. Switch the circuit breaker on and carry out a test start-up

Let the compressor run for a few minutes and then make a visual inspection for any oil leaks

Check the oil level again as indicated in the “Checking oil level/topping up” paragraph and if necessary top up

Replace the upper panel PS and the front panel PF

Fig. 45

Fig. 46

FO




GB

Draining the condensate 10.7Before performing any maintenance operations read the operator safety precautions in chapter 5 carefully. These precautions must be followed scrupulously for all maintenance operations

If the machine is equipped with dryer and/or air reservoir, the mc2 control unit assures timed, programmable activation of the solenoid valve of the condensate drain.

On machines equipped with dryer, with or without air reservoir, condensate drainage can be checked using the sleeve located on the rear panel PP

On machines equipped with air reservoir, condensate drainage is checked using the solenoid valve located underneath the air reservoir SA

Air receiver

To eliminate the condensate that forms in the air receiver, proceed as follows:

Place a suitable drip tray under the condensate discharge valve RSC, which is located under the SA receiver

Ensure that the intercept valve between the compressor and the distribution line is closed

Open the condensate discharge valve RSC (fig. 47), using pliers if necessary

Leave the condensate to drain until the tank is completely empty

Close the valve RSC

Fig. 47

SA

RSC



Drain the condensate accumulated in the air-oil separator frequently, by exploiting the fluid stratification principle

The frequency of this operation will depend on environmental conditions (e.g. low temperature, high humidity) and the frequency of compressor cold starts.

In order to carry out this operation, you must stop the compressor at least an hour before intervening


GB

Remove the front panel PF with the key provided

Connect fitting R provided, which must communicate with a suitable collection recipient, to fitting DO after unscrewing the safety plug (Fig. 48)

Partially open drain valve RSO (Fig. 48)

Follow the operation and close oil drain valve RSO as soon as oil starts flowing out

Check the oil level and top up, if required, as described in the paragraph “Checking the level and topping up”

Replace the safety plug and the PF panel Fig. 48

SA

RSC

DO

RSO

The air receiver and separator condensate should be drained manually on a weekly basis - or more frequently. The user is responsible for this maintenance operation.

Replacing the fuses 10.8Before performing any maintenance operations read the operator safety precautions in chapter 5 carefully. These precautions must be followed scrupulously for all maintenance operations

GENESIS - FORMULA:Open the corner panel SPA of the com-pressor cabinet using the key provided

MODULO:Open the electric box panel SCE using the key provided

Replace the damaged fuses. Follow the amperage specifications provided in paragraphs 12.8, 12.9

GENESIS - FORMULA: Close the corner panel SPA

MODULO:Close the electric box panel SCE

Fig. 49

R

P. 78 - Chap. 11 Spare Parts and Service Centres

GB

11 Spare Parts andService Centres

The Manufacturer provides an effi cient after-sales service through a large service network and a Technical Department for solving any problems.Always specify the compressor model and serial number when communicating with Authorized Service Centres and the Manufacturer.To locate the service Centre closest to the compressor installation site, call or send a fax to:

(+44) 01869-326226 Fax: (+44) 01869-326216

E-mail: [email protected]

Spare parts and consumable material codes 11.1The following tables show the most commonly used spare parts. Contact an authorised service Centre for other spare parts.

Model Pressure Air fi lter

Oil fi lter Separator fi lter Suction

prefi lterTransmission

beltsbar Code Code Code Code Code

5.5

8

90562939056238

9056237 9623572

(2) 907525710 (2) 907529013

9056282(2) 9075236

15 (2) 9075290

7.5

8

90562939056238

9056237 9623572

(2) 907525610 (2) 9075236

139056282

(2) 907529015 (2) 9075257

11

8

9056293 9056113 9056292 9623572

(2) 907529110 (2) 9075215

13 (2) 907525415 (2) 9075256

15BA 51

8

9056293 9056113 9056292 9623572

(3) 907521110 (3) 9075291

13 (3) 907521515 (3) 9075262

15BA 69

8

9618034 9056113 9056292 9623572

(3) 907525610 (3) 907525413 (3) 907526215 (3) 9075215

FORMULAGENESIS

P. 79 - Chap. 11 Spere Parts and service Centres

GB

Model Pressure Air filter

Oil filter Separator filter Suction

prefilterTransmission

beltsbar Code Code Code Code Code

5.5

8

90569379056933

9056942 9623572

(2) 907525710 (2) 907529013

9056934(2) 9075236

15 (2) 9075290

7.5

8

90569379056933

9056942 9623572

(2) 907525610 (2) 9075236

139056934

(2) 907529015 (2) 9075257

11

8

9056937 9056935 9056943 9623572

(2) 907529110 (2) 9075215

13 (2) 907525415 (2) 9075256

15BA 51

8

9056937 9056935 9056943 9623572

(3) 907521110 (3) 9075291

13 (3) 907521515 (3) 9075262

15BA 69

8

9056939 9056935 9056943 9623572

(3) 907525610 (3) 907525413 (3) 907526215 (3) 9075215

MODULO

P. 80 - Chap. 12 Diagrams

GB

12 DiagramsHydraulic-pneumatic plant diagram 12.1


GB

Legend1 Air filter2 Intake unit 2.1 Air filter clogging sensor 2.2

3 Drive4 Motor

5 Air-end unit

6 Separator reservoir 6.1 Safety valve 6.2 Oil level indicator 6.3 Air-oil mix temperature sensor 6.4 Oil drain outlet

7 Thermostatic valve8 Oil filter

9 Air-oil exchanger

10 Oil recovery

11 Separator filter

12 Minimum pressure and check valve

13 Air-air exchanger

14 Net pressure transducer

15 Drying unit (only in equipped versions) 15.1 Air dryer 15.2 Dew temperature sensor 15.3 Automatic condensate drain

16 Air receiver unit (only in equipped versions) 16.1 Air receiver 16.2 Safety valve 16.3 Discharge valve 16.4 Condensate drain (only for versions equipped with receiver without air dryer)


GB

Power circuit wiring diagram 5,5 - 15 kWMachines without air dryer

12.2


GB

Power circuit wiring diagram 5,5 - 15 kWMachines with air dryer

12.3


GB

Power circuit wiring diagram 11 kWMachines with inverter

12.4


GB

Auxiliary circuit wiring diagram 5,5 - 15 kWMachines without air dryer

12.5


GB

Auxiliary circuit wiring diagram 5,5 - 15 kWMachines with air dryer

12.6


GB

Auxiliary circuit wiring diagram 11 kWMachines with inverter

12.7


GB

Wiring diagram for component location 5,5 - 15 kWMachines without air dryer

12.8


GB

Wiring diagram for component location 5,5 - 15 kWMachines with air dryer

12.9

Documents

User Manual Genisis 5.5-15 KW