Chicago Pneumatic - Air Compressor - Instruction and Maintenance Manual - 6758900 - 01 PDF
Chicago Pneumatic - Air Compressor - Instruction and Maintenance Manual - 6758900 - 01 PDF
Chicago Pneumatic - Air Compressor - Instruction and Maintenance Manual - 6758900 - 01 PDF
Code
2200780017 02
INSTRUCTION AND MAINTENANCE MANUAL Edition 05/2012
HP 10 - 15 - 20
KW 7,5 - 11 - 15
THIS MACHINE MUST BE CONNECTED TO TWO DIFFERENT POWER SUPPLIES: THREE-PHASE OR SINGLE-PHASE
SUPPLY FOR THE COMPRESSOR SINGLE-PHASE SUPPLY FOR THE DRYER.
READ THIS MANUAL CAREFULLY BEFORE CARRYING OUT ANY OPERATIONS ON THE COMPRESSOR
UNIT.
THIS MACHINE IS EQUIPPED FOR BOTH CONTINUOUS AND INTERMITTENT WORKING, HOWEVER TO
AVOID CONDENSATION PROBLEMS IN THE OIL, THE MACHINE MUST OPERATE FILLED WITH AT LEAST
10% OF ITS TOTAL CAPACITY, CHECK FOR SIGNS OF CONDENSATION IN THE OIL BY FOLLOWING THE
INSTRUCTIONS GIVEN IN CHAPTER 15.2
CONTENTS
PART A: INFORMATION FOR THE USER
1.0 GENERAL CHARACTERISTICS
2.0 INTENDED USE
3.0 OPERATION
4.0 GENERAL SAFETY STANDARDS
5.0 DESCRIPTION OF DANGER SIGNALS
6.0 DANGER ZONES
7.0 SAFETY DEVICES
8.0 POSITION OF PLATES
9.0 COMPRESSOR ROOM
10.0 TRANSPORT AND HANDLING
11.0 UNPACKING
12.0 INSTALLATION
13.0 DIMENSIONS AND TECHNICAL DATA
14.0 MACHINE ILLUSTRATION
15.0 ORDINARY MAINTENANCE TO BE DONE BY THE USER
16.0 PERIODS OF INACTIVITY
17.0 SCRAPPING THE UNIT
18.0 LIST OF SPARE PARTS FOR ROUTINE MAINTENANCE
19.0 TROUBLE-SHOOTING AND EMERGENCY REMEDIES
PART B: INFORMATION RESERVED FOR TECHNICALLY SKILLED PERSONNEL
20.0 STARTING UP
21.0 GENERAL ORDINARY MAINTENANCE REQUIRES TRAINED PERSONNEL
22.0 CHANGING THE OIL
23.0 CHANGING THE OIL SEPARATING FILTER
24.0 BELT TENSION
25.0 REPLACING THE BELT
26.0 FLOW DIAGRAM
27.0 CALIBRATIONS FOR DRYER
- WIRING DIAGRAM (ON THE BACK COVER)
IMPORTANT: A COPY OF THE WIRING DIAGRAMS CAN BE FOUND INSIDE THE ELECTRIC BOARD OF THE
COMPRESSOR.
HP 10 - 15 - 20
KW 7,5 - 11 - 15
MACHINE AND MANUFACTURER IDENTIFICATION DATA
FIG. 1
1 1 1
In the event of breakdown or malfunction of the machine, switch it off and do not tamper with it.
If repairs are needed, apply only to a technical assistance centre approved by the manufacturer and insist on the use of
original spare parts.
Failure to comply with the above may endanger the safety of the machine.
INTRODUCTION
Keep this manual with care for future consultation; the use and maintenance manual is an integral part of the
machine. Read this manual carefully before carrying out any operations on the compressor unit.
The installation of the compressor unit and all operations involving it must be performed in conformity with the
regulations in force concerning electric plants and personal safety.
BEFORE REMOVING THE PROTECTIVE GUARDS TO CARRY OUT ANY MAINTENANCE ON THE
MACHINE, SWITCH OFF THE ELECTRIC POWER SUPPLY AND DISCHARGE THE RESIDUAL PRESSURE
INSIDE THE UNIT.
ALL WORK ON THE ELECTRIC PLANT, HOWEVER SLIGHT, MUST BE CARRIED OUT BY
PROFESSIONALLY SKILLED PERSONNEL.
THIS MACHINE CORRESPOND TO THE ESSENTIAL SAFETY REQUIREMENTS FORESEEN FROM THE
EUROPEAN STANDARD (2006/42 CE).
THE LUBRICATING LIQUIDS AND OTHER EVENTUAL FLUIDS MUST NOT BE DISCHARGED IN THE
ENVIRONMENT. THESE POLLUTING AND HAZARDOUS PRODUCTS MUST COMPULSORY BE DISPOSED BY
CHARGING AUTHORISED AND SPECIALISED FIRMS ACCORDING TO THE DIFFERENT TYPOLOGY OF
PRODUCT.
The manufacturer does not accept responsibility for damage caused as a result of negligence or failure to abide by the
instructions given above.
NOT RESPECTING THE ABOVE MENTIONED PRESCRIPTION CAN RESULT IN AIR RECEIVER
BURSTING HAZARD.
The manufacturer does not accept responsibility for damage caused as a result of negligence or failure to abide by the
instructions given above.
The compressor units use single-stage screw rotary air compressors with oil injection.
The system is self-bearing and does not require bolts or other devices to anchor it to the floor.
The unit is completely assembled in the factory; the necessary connections for setting it up are:
connection to the power mains (see installation chapter)
connection to the compressed air network (see installation chapter)
3.0 OPERATION
3.1 OPERATION FOR COMPRESSOR
The electric motor and the compressor unit are coupled by means of a belt transmission.
The compressor unit takes in the outside air through the suction valve. The intake air is filtered by the filter cartridge fitted
upstream from the intake valve. Inside the compressor unit, the air and the lubricating oil are compressed and sent to the
oil separating tank where the oil is separated from the compressed air; the air is then filtered again by the oil separating
cartridge to reduce the amount of suspended oil particles to a minimum. The machine is fitted with a suitable air-cooling
system.
The machine is protected by a special safety thermostat: if the oil temperature reaches 105 ÷ 110 °C the machine cuts
out automatically.
3.2 OPERATION FOR DRYER
At the moment of use the air flows from the tank to the drier and is then dried and sent to the distribution network. Dryer
operation is described below.
The gaseous refrigerant coming from the evaporator (4) is sucked by the refrigeration compressor (1) and it is pumped
into the condenser (2). This one allows its condensation, eventually with the help of the fan (3); the condensed refrigerant
passes through the dewatering filter (8) and it expands through the capillary tube (7) and goes back to the evaporator
where it produces the refrigerating effect.
Due to the heat exchange with the compressed air which passes through the evaporator against the stream, the
refrigerant evaporates and goes back to the compressor for a new cycle.
The circuit is equipped with a bypass system for the refrigerant; this intervenes to adjust the available refrigerating
capacity to the actual cooling load.
This is achieved by injecting hot gas under the control of the valve (9): this valve keeps constant the pressure of the
refrigerant in the evaporator and therefore also the dew point never decreases below 0 °C in order to prevent the
condensate from freezing inside the evaporator.
The drier runs completely automatically; it is calibrated in the factory for a dew point of ~ 3 °C and therefore no further
calibrations are required.
DRYER FLOW DIAGRAM AIR OUTLET
AIR INLET
CONDENSATE
DRAIN
The appliance may be used only by specially trained and authorized personnel.
Any tampering with the machine or alterations not approved beforehand by the Manufacturer relieve the latter of
responsibility for any damage resulting from the above actions.
The removal of or tampering with the safety devices constitutes a violation of the European Standards on safety.
ATTENTION: UPSTREAM OF THE MACHINE INSTALLAN ISOLATOR KNIFE-SWITCH WITH AN AUTOMATIC
CUTOUT AGAINST CURRENT SURGES AND EQUIPPED WITH A DIFFERENTIAL DEVICE FOR CALIBRATIONS
SEE WIRING DIAGRAM.
ALL WORK ON THE ELECTRIC PLANT, HOWERE SLIGHT, MUST BE CARRIED OUT BY PROFRSSIONALLY
SKILLED PERSONEL.
FIG. 3
(2)
(8)
(9)
(2)
(1)
FIG. 3A
(2)
(1) (2)
(9)
(2)
(6)
(6)
(6)
(3)
(2)
(3)
(1)
(6)
(3)
1) Safety screws
2) The front protection can be opened with a special key
3) Fixed protection device - cooling fan / pulley
4) Safety valve
5) Emergency stop
6) Oil filling cap (with safety breather)
FIG. 4
1
1 5
3
4
1
2
2 6
1) Safety valve
2) Protective switch cap.
3) Protective pressure switch cap.
4) Relay for compressor (automatic)
5) Overload protector for compressor
FIG. 5
5 2
FIG. 6
1
1
2
2
8.2 POSITION OF THE DANGER PLATES FOR DRIER UNIT AND TANK
The plates fitted on the compressor unit are part of the machine; they have been applied for safety purposes and must
not be removed or spoiled for any reason.
1) Dangers plate 2202921501
FIG. 7
FIG. 8
6 6
1 1
2 2 1
1 2 3 4 5
FIG. 9
3
1 1
1 3
FIG. 10
FIG. 11
L= m.6 minimum
Tapes ISO 4878
Attention: it is
recommended of to
position the tape like
specific in figure.
11.0 UNPACKING
After removing the packing, ensure that the machine is unbroken and that there are no visibly damaged parts.
If you are in doubt, do not use the machine but apply to the manufacturer technical assistance service or to your dealer.
The packing material (plastic bags, polystyrene foam, nails, screws, wood, metal strapping, etc..) must not be left within
the reach of children or abandoned in the environment, as they are a potential source of danger and pollution.
Dispose of these materials in the approved collection centres.
12.0 INSTALLATION
12.1 POSITIONING
After unpacking the equipment and preparing the compressor room, put the machine into position, checking the following
items:
● Ensure that there is sufficient space around the machine to allow maintenance (see Fig. 12).
● Check that the compressor is standing on a perfectly flat floor.
1 FIG. 12
1
3 2
MINIMUM mt. 2
3
4
PROTECT THE POWER
CABLE WITH A SUITABLE
CHANNEL
MINIMUM mt. 2
SINGLE-PHASE DRYER
SUPPLY LEAD
THREE-PHASE OR
SINGLE-PHASE
SCREW-COMPRESSOR
SUPPLY LEAD.
ENSURE THAT THE OPERATOR CAN SEE THE WHOLE MACHINE FROM THE CONTROL PANEL AND
CHECK THE PRESENCE OF ANY UNAUTHORIZED PERSONS IN THE VICINITY OF THE MACHINE.
ONLY PROFESSIONALLY SKILLED PERSONNEL MAY HAVE ACCESS TO THE ELECTRIC PANEL. SWITCH OFF
THE POWER BEFORE OPENING THE DOOR OF THE ELECTRIC PANEL.
COMPLIANCE WITH THE REGULATIONS IN FORCE CONCERNING ELECTRIC PLANTS IS FUNDAMENTAL FOR
OPERATOR SAFETY AND FOR THE PROTECTION OF THE MACHINE.
CABLES, PLUGS AND ALL OTHER TYPE OF ELECTRIC MATERIAL USED FOR THE CONNECTION MUST BE
SUITABLE FOR THE USE AND COMPLYING WITH THE REQUIREMENTS STATED BY THE REGULATIONS IN
FORCE.
PIPES, FITTINGS AND CONNECTIONS USED FOR THE CONNECTION OF THE ELECTROCOMPRESSOR TO THE
COMPRESSED AIR NETWORK MUST BE SUITABLE TO THE USE ACCORDING TO THE PRESCRIPTIONS OF
THE REGULATIONS IN FORCE IN THE COUNTRY OF USE.
ALL DAMAGE DUE TO THE FAILURE TO COMPLY WITH THESE INDICATIONS CANNOT BE ATTRIBUTED TO
THE MANUFACTURER AND MAY CAUSE INVALIDITY OF THE GUARANTEE CONDITIONS.
1 3
The manual drainage Ref. 2 Fig. 13 the condensate automatic Ref. 3 Fig. 13, are led outside the machine with a flexible
pipe that may be inspected. Drainage must comply with the local regulations in force.
ALL DAMAGE DUE TO THE FAILURE TO COMPLY WITH THESE INDICATIONS CANNOT BE ATTRIBUTED TO
THE MANUFACTURER AND MAY CAUSE INVALIDITY OF THE GUARANTEE CONDITIONS.
12.4 STARTING UP
See part B of this manual, Chpter 20.0
Air Air
Dimensions (mm) Dimensions (mm)
HP 10-15-20 connection HP 10-15-20 connection
KW 7,5-11-15 L W H KW 7,5-11-15 L W H
½” ½”
1935 620 1463 1935 620 1463
Air
Dimensions (mm)
HP 10-15-20 connection
KW 7,5-11-15 L W H
¾”
810 620 975
HP 10 HP 15 HP 20
kW 7,5 kW 11 kW 15
Setting pressure bar(e) 8 bar 10 bar 13 bar 8 bar 10 bar 13 bar 8 bar 10 bar 13 bar
Standard air capacity l/min. 1008 920 557 1428 1310 887 1750 1650 1190
bar
R 134a Nominal Nominal Nominal MAX.
TYPE Weight Kg. Power W Power W Power W
Kg.
DRYER
50 Hz 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz
A2 20 0,290 0,290 161 173 29 49 190 222 bar 16
A3 25 0,350 0,350 233 252 33 54 266 306 bar 16
FIG. 14
9
IT IS FORBIDDEN TO TAMPERE
WITH THE SETTING VALUES
OF THE SAFETY VALVE
3
4
11
10
5 2
6
1 Refrigerant compressor
7 2 Condenser
3 Motor fan
4 Evaporator
5 Condensate drain
6 Hot gas by-pass valve
7 Refrigerant filter
8 Expansion capillary tube
9 Safety valve
1 8 10 Condensate manual drainage
11 Compressed air tank
8 FIG. 15
1
6 14
3
7
10
2
13 15
11
12
5
4
17
16
BEFORE CARRYING OUT THE OPERATION TEST, READ CAREFULLY AND ACQUIRE A GOOD KNOWLEDGE OF
THE COMMAND FUNCTIONS.
DRYER CONTROL
BOARD
6
1
5
3
7
COMPRESSOR CONTROL BOARD FIG. 16
IMPORTANT: WHEN THE SWITCH Ref. 2 IS IN POSITION "OFF" THE TERMINALS ARE STILL LIVE.
Symbol Description
Pressing the pushbutton cancels the stored alarm indication. Pressing the pushbutton for
more than 3 seconds, the central control unit is tested: all the LEDs must be on.
Pressing the pushbutton switches on the compressor. Switch-on is 10 seconds after the card has
been powered.
Pressing the pushbutton starts the compressor switch-off phase: the compressor runs idle
for 30 seconds before stopping.
- -
- Mains power on
ATTENTION: to start up again after a protection has been triggered (alarm) press “RESET”
followed by the start button “I”
The central control unit operation is programmed for Energy Saving; it switches off the compressor, thus reducing idle
running to a minimum.
The card is preset to run idle before switching off for a period that is shorter the lower the consumption of air.
BEFORE CARRYING OUT ANY MAINTENANCE IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT
IT FROM THE POWER MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION NETWORK.
The maintenance jobs described in this chapter may be carried out by the user.
The more complex maintenance jobs which require professionally skilled personnel are listed in the chaper on GENERAL
ROUTINE MAINTENANCE. (See Chap. 21.0)
These maintenance intervals are recommended for work environments that are not dusty and are will ventilated. For
particularly dusty environments, double the frequency of controls.
Every Day (after use) Drain condensate from the air tank
Check automatic condensation emptying
Every 50 working hours Drain condensate from the oil tank
Check the oil level
Clean the filtering panel
Every 500 hours Clean the air suction filter
Clean the condenser battery (on the dryer if fitted)
Clean the dirt collection filter
Check belt tension
Change the suction filter
Every 2000 hours Change the oil
Change the oil filter
Every 4000 hours Clean the finned surface of the air-oil cooler
Change the oil separating filter
If the compressor work cycle contemplates long pauses during which the machine cools down, a certain amount of
condensate will gather in the oil tank. This happens, for example, when stopping overnight or at weekends.
The condensate must be drained off every 50 hours or every week. This operation may be performed only when the
machine is cold, that is when it has been switched off for at least 8 hours.
BEFORE DRAINING THE CONDENSATE IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT
FROM THE POWER MAINS.
Proceed as follows:
- Switch off the machine with pushbutton Ref. 1 Fig. 17: in this way the machine stops after 30 seconds of idle running.
- Turn the isolating switch Ref. 2 to position “0” Fig. 17 and block it with the padlock.
- Press the button switch Rif. 3 Fig. 17 (on the dryer if fitted).
- Turn on the differential supply switch, Ref. 4 (on the screw-compressor) and Ref. 5 (on the dryer if fitted) Fig. 17.
FIG. 17
4 4
7 5 7
6
6
3
2 4
1
11
10 9
USE OIL OF THE SAME TYPE AS THAT ALREADY IN THE MACHINE; DO NOT MIX DIFFERENT TYPES OF OIL
- STOP THE MACHINE, TURNING IN “OFF” POSITION THE ISOLATING SWITCH REF. 2 FIG. 17, ONLY WHEN THE
LAMP LIGHT IS ON REF. 11 FIG. 17
- WAIT A 10 MINUTES FOR THE FOAM IN THE OIL COLLECTOR TO ABATE.
- Check the oil level on the indicator Ref. 9 Fig. 17.
- If the oil level is below minimum, fill up as follows: to the red line
- Press the button switch Rif. 3 Fig. 17 (on the dryer if fitted)
- Turn on the differential supply switch, Ref. 4 (on the screw-compressor) and Ref. 5 (on the dryer if fitted) Fig. 17.
USE OIL OF THE SAME TYPE AS THAT ALREADY IN THE MACHINE; DO NOT MIX DIFFERENT TYPES OF OIL.
BEFORE CARRYING OUT ANY OPERATION ON THE MACHINE, ENSURE THAT THE ELECTRIC POWER SUPPLY
HAS BEEN DISCONNECTED.
- Open the front protection Ref. 6 Fig. 17 using the special key.
- Remove the fixed protection device (machine cover) Ref. 7 Fig. 17.
- Slowly unscrew the oil cap Ref. 10 Fig 17, ensuring there is no pressure inside.
- Top up to maximum level Ref. 9 Fig. 17, with oil of the same type in the compressor.
- Close the oil manifold cap Ref. 10 Fig. 17.
- Close the fixed protection (machine cover) Ref. 7 Fig. 17 device again, using the appropriate safety screws.
- Close the front protection Ref. 6 Fig. 17.
FIG. 17A
- Remove the fixed protection device (machine cover) Ref. 6 Fig. 18.
- Remove the cover Ref. 7 Fig. 18 (Check the direction of the arrow).
- Remove the filter Ref. 8 Fig. 18.
4 4 FIG. 18
5
6 6
4
- Clean the filter with a jet of air, working from inside to outside, DO NOT USE WATER OR SOLVENTS. Alternatively, fit
a new filter.
- Clean the disk on which the filter rests with a clean cloth.
- Fit the filter and the cover
- If necessary, dispose of the old filter in conformity with the local regulations in force.
- Close the fixed protection (machine cover) Ref. 6 Fig. 18 device again, using the appropriate safety screws.
BEFORE CARRYING OUT ANY MAINTENANCE IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT
IT FROM THE POWER MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION NETWORK.
The automatic and manual condensation drain must be checked (Rif. 1 every 500 hours and Ref. 2 every 24 working
hours) Fig. 19.
Proceed as follows:
- Press the "TEST" button, Ref. 1 Fig. 19, for a few seconds to check if the condensation is correctly emptied from the
drainage pipe
- Check manual condensation emptying from the tank, to ensure that condensation is correctly emptied from the valve,
Ref. 2 Fig. 19 (PURGE EVERY DAY).
FIG. 19
BEFORE CARRYING OUT ANY MAINTENANCE IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT
IT FROM THE POWER MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION NETWORK.
5 6 FIG. 20
7
8 9
11
4
12
3 10
15.8 CLEAN THE DIRT COLLECTION FILTER FOR DRYER (Fig. 20)
BEFORE CARRYING OUT ANY MAINTENANCE IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT
IT FROM THE POWER MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION NETWORK.
Proceed as follows:
- Switch off the machine with pushbutton Ref. 2 Fig. 20: in this way the machine stops after 30 seconds of idle running.
- Turn the isolating switch Ref. 3 to position “0” Fig. 20 and block it with the padlock.
- Close the cock Ref. 7 Fig. 20
- Turn on the differential supply switch, Ref. 5 (on the screw-compressor)
- Depressurise the dryer by pressing the "TEST" condensation emptying button (for about 10-20 seconds),
which is fitted on the timer, Ref. 9 Fig. 20.
- Press the button switch Rif. 4 Fig. 20
- Turn on the differential supply switch, Ref. 6 (on the dryer if fitted) Fig. 20.
- Release pressure from the machine by turning on the tap Ref. 12 Fig. 20.
- Remove the stopper Ref. 10 Fig. 20
- Remove the filter Ref. 11 Fig. 20
- Clean the filter with a jet of air, working from inside to outside.
- Install the filter, fix the plug.
- Open the cock Ref. 7 Fig. 20
8 8 Abb. 21
9
7
2
10 1
10
8
6
5 3
During periods of inactivity the weather must be protected against atmospheric agents, dust and humidity which could
damage the motor and the electrical system.
To restart the machine after periods of inactivity, consult the manufacturer.
17.0 SCRAPPING THE UNIT
If the machine is to be scrapped, it must be dismantled into parts of the same material, to be disposed of according to the
local regulations in force.
ALWAYS RESPECT THE REGULATIONS IN FORCE FOR DISPOSING OF OLD OIL AND
OTHER POLLUTING MATERIALS SUCH AS SOUND-DEADENING, INSULATING FOAM, ETC.
HP 10 - 15 - 20
Ref. DESCRIPTION Code kW 7,5 - 11 - 15
8-10-13 bar
1 Suction air filter 6211473950
2 Oil filter 6211472550
3 Separator cartridge 6221372850
4 Filtering panel 2202715000
5 Oil (5L) 6215714000
FIG. 22
2 3
ALL WORK MUST BE CARRIED OUT BY PROFESSIONALLY SKILLED PERSONNEL. BEFORE CARRYNG OUT
ANY MAINTENANCE JOBS IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT FROM THE
POWER MAINS.
1) The machine does not start 1A - no powert - check the power supply line,
1B - the transformer protection fuse is Chapter 12.2
broken
- replace fuse (Ref. 7 Fig. 16)
2) The machine does not start 2A - the thermal protection in the main - To rearm, turn the isolation switch
engine has triggered to “OFF” / “ON”.
3) The machine does not start 3A - the oil high temperature - environment temperature too high;
the pilot lamp 2 is lit (see Fig. A) thermostat has tripped improve ventilation in the
compressor room, Chapter 9.2
- cooling radiator is dirty, clean the
radiator
- oil level too low; top up the oil tank
- Rearm the safety thermostat, refer
to CHAP. 14.3
5) Excess oil consumption 5A - deteriorated oil separating filter - change the oil separating filter,
oil level is too high Chapter 23
1
2
FIG. A
ALL WORK MUST BE CARRIED OUT BY PROFESSIONALLY SKILLED PERSONNEL. BEFORE CARRYNG OUT
ANY MAINTENANCE JOBS IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT FROM THE
POWER MAINS.
2B) The dryer is working outside its -Check the flow rate of treated air
rating -Check the room temperature
-Check the air temperature at the
drier inlet.
2C) The dryer is working under bad -Check the good operation of the
conditions of condensation fan.
3) The compressor head is very hot Make reference to 2B
(> 55 °C) Make reference to 2C
3A) The cooling circuit is not working -Check if there are leaks of
with the right gas charge refrigerating gas.
- Charge it again.
4) Motor cuts out on overload Make reference to 2B
Make reference to 2C
Make reference to 3A
5) The motor hums and does not start. The line voltage is too low. -Contact the electric power
You switched the machine off and company
on again without leaving enough -Wait a few minutes before starting
time for the pressure balancing. the machine again.
The starting system of the motor is -Check the running and starting
defective. relays and condensers (if any)
6) The compressor is very noisy. Troubles with the internal
mechanical parts or with the valves
PART “B”
20.0 STARTING UP
BEFORE CARRYING OUT ANY OPERATION ON THE MACHINE, ENSURE THAT THE ELECTRIC POWER SUPPLY
HAS BEEN DISCONNECTED.
After checking everything as indicated in Chap. 12, folow the instructions in Fig. 23.
- Fit the sound-deadening panels Ref. 1
- These parts are packed in the bodywork.
FIG. 23
ALL WORK ON THE ELECTRIC PLANT, HOWEVER SLIGHT, MUST BE CARRIED OUT BY
PROFESSIONALLY SKILLED PERSONNEL.
- Disconnect the energy supply and invert two connections as per Ref. 1 Fig. B.
IF ALL THE INSTRUCTIONS FOUND IN THIS MANUAL HAVE BEEN OBSERVED THE MACHINE CAN BE
STARTED.
FIG. 24
1 FIG. A 1 FIG. B
3
3
OK
These cables are part of the machine l~ 4 meters
PHASE INCORRECT
Protect the power cable with a suitable channel.
ATTENTION: machine start-up is delayed for 10 seconds from the moment the card is
powered (Led Ref. 1 Fig. 24A flashing)
FIG. 24A
BEFORE CARRYING OUT ANY MAINTENANCE JOBS IT IS OBLIGATORY TO STOP THE MACHINE AND
DISCONNECT IT FROM THE POWER MAINS.
MAINTENANCE SCHEDULE
These maintenance intervals are recommended for work environments that are not dusty and are will ventilated. For
particularly dusty environments, double the frequency of controls.
Every Day (after use) Drain condensate from the air tank
Check automatic condensation emptying
Every 50 working hours Drain condensate from the oil tank
Check the oil level
Clean the filtering panel
Every 500 hours Clean the air suction filter
Clean the condenser battery (on the dryer if fitted)
Clean the dirt collection filter
Check belt tension
Change the suction filter
Every 2000 hours Change the oil
Change the oil filter
Every 4000 hours Clean the finned surface of the air-oil cooler
Change the oil separating filter
N.B.: THE OPERATIONS MARKED ARE DESCRIBED IN PART "A" OF THIS MANUAL ON CHAPTER 15.1
CAUTION: THIS OPERATION MUST BE DONE TOGETHER WITH THE OIL FILTER AND AIR FILTER EXCHANGE
BEFORE CARRYING OUT ANY MAINTENANCE JOBS IT IS OBLIGATORY TO STOP THE MACHINE AND
DISCONNECT IT FROM THE POWER MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION NETWORK.
Oil changing is an important operation for the compressor:
if the lubrication of the bearings is not efficient, the compressor life will be short.
The oil must be changed when the machine is still warm, that is immediately after stopping it.
The suggestions listed below should be scrupulously followed.
After draining the old oil out of the machine Ref. 1 Fig. 25.
- Fill the oil manifold Ref. 2 Fig. 25 up to the level mark
- Close all the protections (cover and front protection)
- Start the compressor.
- After about 1 minute switch off the machine by pressing “STOP” (Ref. 3 Fig. 25) after 30 seconds of idle running the
machine will switch off.
PROCEED AS DESCRIBED AT CHAPTER 15.3
FIG. 25
THE OLD OIL MUST BE DISPOSED OF IN COMPLIANCE WITH THE REGULATIONS IN FORCE.
NOTE ON LUBRICANTS
When delivered the machine is filled with oil.
In normal conditions of use, these lubricants have proved to be able to withstand use for as many as 4.000 hours.
However, due to the external polluting agents that get into the compressor with the air that it takes in, it is advisable to
change the oil at more frequent intervals, as indicated on the routine maintenance chart.
If the compressor is being used at high temperatures (continuous operation above 90 °C) or in particularly severe
conditions, we advise changing the oil at shorter intervals than those recommended in the maintenance chart.
23.0 REPLACE THE OIL SEPARATOR FILTER AND THE OIL FILTER
BEFORE CARRYING OUT ANY MAINTENANCE THE MACHINE MUST BE STOPPED, CUT OFF THE MACHINE
FROM THE ELECTRICAL MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION CIRCUIT, CHECK THAT
THE MACHINE IS NOT UNDER PRESSURE.
Proceed as follows:
- Open the front panel Ref. 1 Fig. 26 with the special key.
- Remove the fixed protection device (machine cover) Ref. 2 Fig. 26.
- Remove the oil separation filter Ref. 3 and oil filter Ref. 4 Fig. 26
- Lubricate the filter seals with a little oil before fitting.
- Tightening must be done by hand.
- Close the fixed protection (machine cover) Ref. 2 Fig. 26 device again, using the appropriate safety screws.
- Close the panel Ref. 1 Fig. 26.
FIG. 26
2
4 3
BEFORE CARRYING OUT ANY MAINTENANCE THE MACHINE MUST BE STOPPED, CUT OFF THE MACHINE
FROM THE ELECTRICAL MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION CIRCUIT, CHECK THAT
THE MACHINE IS NOT UNDER PRESSURE.
BEFORE CARRYING OUT ANY MAINTENANCE THE MACHINE MUST BE STOPPED, CUT OFF THE MACHINE
FROM THE ELECTRICAL MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION CIRCUIT, CHECK THAT
THE MACHINE IS NOT UNDER PRESSURE.
Proceed as follows:
- Open the front panel Ref. 1 Fig. 27 with the special key.
- Remove the fixeds protections device Ref. 2, 3, Fig. 27.
- Slacken the screws by half a turn Ref. 1 Fig. 28
- Release belt tension by unscrewing the screw Ref. 2 Fig. 28
2 FIG. 27
2
1
1
3
4 3
4
6
6
6 mm
5
F f
7 Fig. A
() Tightening torque = N. 30
2 2 FIG. 28
5
3 4
1 - F = 5 kg., force to be applied at the centre line, at right angles to the new belt.
2 - f = 6 mm., clearance after the application of F. (after 100 h operation F = 3 kg.)
STANDARD AIR
CAPACITY
NO DRYER
STANDARD AIR
CAPACITY
WIHT DRYER
AIR CIRCUIT
OIL CIRCUIT
CONTROL CIRCUIT
1) Closing cap
2) Adiusting screw
AIR OUTLET
AIR INLET
CONDENSATE
DRAIN
1 REFRIGERANT COMPRESSOR
2 FREON CONDENSER
3 MOTOR FAN
4 EVAPORATOR
5 DEMISTER CONDENSATE SEPARATOR
6 IMPURITY TRAP
7 EXPANSION CAPILLARY TUBE
8 REFRIGERATION FLUID FILTER
9 HOT GAS BYPASS VALVE
10 AIR-TO-AIR EXCANGER
11 DEW POINT THERMOMETER
12 FAN PRESSURE SWITCH
13 CONDENSATE DISCHARGE SOLENOID VALVE
NOTE