ENGLISH

Code
9828093035 00
MANUAL USE AND MAINTENANCE Edition 08/2015

SILENCED SCREW ROTARY COMPRESSOR UNITS

HP 10 - 15 - 20 (IVR)
kW 7,5 - 11 - 15 (IVR)

THIS MACHINE MUST BE

CONNECTED TO TWO DIFFERENT
POWER SUPPLIES: THREE-PHASE
SUPPLY FOR THE COMPRESSOR
SINGLE-PHASE SUPPLY FOR THE
DRYER

READ THIS MANUAL CAREFULLY BEFORE CARRYING OUT ANY OPERATIONS ON THE COMPRESSOR UNIT.

WARNING: THE INVERTER REMAINS CHARGED WITH HIGH VOLTAGE FOR 15 MINUTES AFTER THE MASTER
SWITCH HAS BEEN OPENED.
ALWAYS WAIT FOR 15 MINUTES BEFORE REMOVING THE FRONT COVER (INSTRUMENT PANEL) OR
DISCONNECT CONVERTER SUPPLY WIRES OR MOTOR CABLE.
ALWAYS WAIT FOR FIVE MINUTES BEFORE REMOVING THE FRONT COVER (INSTRUMENT PANEL).
USE A SPECIFIC INSTRUMENT TO CHECK THAT THERE ARE NO DANGEROUS VOLTAGES BEFORE
PERFORMING OPERATIONS ON THE INVERTER OR MOTOR.

CONTENTS
PART A: INFORMATION FOR THE USER
1.0 GENERAL CHARACTERISTICS 16.0 PERIODS OF INACTIVITY
2.0 INTENDED USE 17.0 SCRAPPING THE UNIT
3.0 OPERATION 18.0 LIST OF SPARE PARTS FOR ROUTINE MAINTENANCE
4.0 GENERAL SAFETY STANDARDS 19.0 TROUBLE-SHOOTING AND EMERGENCY REMEDIES
5.0 DESCRIPTION OF DANGER SIGNALS PART B: INFORMATION RESERVED FOR TECHNICALLY
SKILLED PERSONNEL
6.0 DANGER ZONES 20.0 STARTING UP
7.0 SAFETY DEVICES 21.0 GENERAL ORDINARY MAINTENANCE
REQUIRES TRAINED PERSONNEL
8.0 POSITION OF PLATES 22.0 CHANGING THE OIL
9.0 COMPRESSOR ROOM 23.0 REPLACE THE DE-OILER FILTER AND THE OIL FILTER
10.0 TRANSPORT AND HANDLING 24.0 GREASING MOTOR BEARINGS
11.0 UNPACKING 25.0 OLEOPNEUMATIC DIAGRAM
12.0 INSTALLATION 26.0 "IVR" VARIABLE SPEED
13.0 DIMENSIONS AND TECHNICAL DATA
14.0 MACHINE ILLUSTRATION IMPORTANT: THERE IS A COPY OF THE WIRING DIAGRAM
INSIDE THE ELECTRIC PANEL
15.0 ORDINARY MAINTENANCE TO BE DONE BY THE USER

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MACHINE AND MANUFACTURER IDENTIFICATION DATA

Position of the identification

plate

ADDRESSES OF ASSISTANCE CENTRES

In the event of breakdown or malfunction of the machine, switch it off and do not tamper with it.
If repairs are needed, apply only to a technical assistance centre approved by the manufacturer and insist on the use of original spare parts.
Failure to comply with the above may endanger the safety of the machine.
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.

CHARACTERISTICS AND SAFETY PRECAUTIONS

MACHINE WITH AUTOMATIC START

Lock Out – Tag Out (LOTO): Open the power isolating switch and lock it with a personal lock. Tag the power isolating switch
with the name of the service technician.

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 IS NOT SUITABLE FOR EXTERNAL INSTALLATION

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.

DIFFERENTIATE THE COMPRESSOR COMPONENTS ACCORDING TO THE DIFFERENT CONSTRUCTION

MATERIALS (PLASTIC, COPPER, IRON, OIL FILTER, AIR FILTER ECC…)

The manufacturer does not accept responsibility for damage caused as a result of negligence or failure to abide by the
instructions given above.

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AIR RECEIVER AND SAFETY VALVE:

- To limit internal corrosion, which could compromise the safety of the compressed air tank, the condensation
that is produced must be discharged at least once a day. If an automatic drain fitted to the air receiver is
present, it is necessary to check that it is working correctly every week and repair it if necessary.
- The thickness of the receiver must be checked every year and also in accordance with legislation
in force in the country where the receiver is installed.
- The tank cannot be used and must be replaced if the thickness falls below the minimum level given
in the instruction documents for the tank.
- The tank can be used within the temperature limits given in the conformity declaration.
- The safety valves of the air receiver and oil receiver must be checked every year and replaced in
accordance with legislation in force.

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.

1.0 GENERAL CHARACTERISTICS

The compressor units use single-stage screw rotary air compressors with oil injection.
The central unit comprises:
compressor; oil separator; oil cooler and output air cooler; fan; electric start; safety and regulation devices; instrument panel.
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)
The compressor-motor unit is fitted on the machine chassis by means of flexible supports: this allows the compressor unit to be laid directly
on the floor without any need of further vibration-damping systems.

2.0 INTENDED USE

The compressor has been built to supply compressed air for industrial use.
The machine cannot be used in premises where there is a risk of fire or explosion or where work is carried out which releases substances
into the environment which are dangerous with regard to safety (for example: solvents, inflammable vapours, alcohol, etc.).
In particular the appliance cannot be used to produce air to be breathed by humans or used on direct contact with foodstuffs. These uses
are allowed if the compressed air produced is filtered by means of a suitable filtering system
(Consult the manufacturer for these special uses.)
This appliance must be used only for the purpose for which it was specifically designed.
All other uses are to be considered incorrect and therefore unreasonable.
The Manufacturer cannot be held responsible for any damage resulting from improper, incorrect or unreasonable use.

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3.0 OPERATION
3.1 OPERATION FOR COMPRESSOR

The electric motor and the compressor unit are coupled by means of a flexible coupling transmission.
The compressor unit takes in the outside air through the suction valve. The air taken in is filtered by panel pre-filter fitted one the panel of
the external covering and by the filter cartridge fitted upstream from the suction valve. Inside the compressor unit, the air and the lubricating
oil are compressed and sent to the oil separating filter 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. At this point the two flows (of oil and air) are sent to
two separate coolers where they are cooled, using a flow of air taken from the environment by a special fan inside the machine.
The cooled oil returns to the circuit while the compressed air is sent to the using network.

3.2 OPERATION FOR DRYER

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 (32 °F) 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 (37,4 °F) and therefore no further calibrations are required.

DRYER FLOW DIAGRAM

AIR OUTLET
AIR INLET

4.0 GENERAL SAFETY STANDARDS

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.

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5.0 DESCRIPTION OF DANGER SIGNALS

1) FLUID EJECTION 6) HOT PARTS

2) DANGEROUS ELECTRIC VOLTAGE 7) MOVING PARTS

3) AIR NOT FIT FOR BREATHING 8) FAN ROTATING

4) NOISE 9) MACHINE WITH AUTOMATIC START

10) PURGE EVERY DAY

5) HIGH PRESSURE

5.1 DESCRIPTION OF COMPULSORY SIGNALS

10) READ THE USE AND MAINTENANCE

INSTRUCTIONS

6.0 DANGERS ZONES

Risks present on the whole machine

2
1

7
3

FIG. 2

1 2 3 7 8

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6.2 DANGERS ZONES FOR DRIER UNIT AND TANK

Risks present on the whole machine

FIG. 3

5
3

2 8

3
2
2 2
8

5
2

1
1 2 3 5 8

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7.0 SAFETY DEVICES

1) Safety screws 5) Oil filling cap (with safety breather)

2) Side panels and door to the electric panel, opened with a special key 6) Safety valve
3) Fixed protection device - cooling fan 7) Protective switch cap
4) Emergency stop button with mechanical retention and rotation release 8) Earth

FIG. 4
1 3

3
3

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8.0 POSITION OF PLATES

8.1 POSITION OF THE DANGER PLATES

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 3) Hazard Plate (atmospheric events)

2) Plate “Machine with automatic start” 4) "INVERTER" danger plate

FIG. 5
3

1
2

3 2
1

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8.2 POSITION OF THE DATA PLATE

1) Identification plate “CE” 4) Air not filt for breathing

2 Service kit 5) Condensate drain plate
3) Plate direction of rotation

FIG. 6

2 1

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9.0 COMPRESSOR ROOM

9.1 FLOOR
The floor must be even and of industrial type; the total weight of the machine is about Kg. (See Ch. 13.0).
Remember the total weight of the machine when positioning it.

9.2 VENTILATION
When the machine is operating, the room temperature must not be higher than 46 °C (114,8 °F)or lower than 1 °C (33,8 °F).
The volume of the room must be about 30 m3 The room must be provided with 2 openings for ventilation with a surface area of about 0,3
m2 each. The first opening must be in a high position to evacuate the hot air, the second opening must be low to allow the intake of external
air for ventilation. If the environment is dusty it is advisable to fit a filtering panel on this opening.
The hot air ejected by the compressor may be led outside with a pipe. This pipe must have a minimum section of 0,5 m2 and it must not be
longer than 2 m. For longer pipes an extra fan must be fitted.
9.3 EXAMPLES OF VENTILATION OF THE COMPRESSOR ROOM

FIG. 7
HOT AIR EJECTION FAN AIR OUTPUT HOT AIR PIPE
ATTENTION: REMOVABLE
PIPE TO ALLOW CLEANING
OF THE RADIATOR

10.0 TRANSPORT AND HANDLING

IT IS FORBIDDEN TO USE METAL CABLES FOR LIFTING

ATTENTION: DO NOT PASS UNDER OVERHEAD WEIGHTS

The machine must be transported as shown in the following figures.

FORK LIFT TRUCK FIG. 8

CARDBOARD PROTECTION
AVOID DAMAGING THE
BODYWORK

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11.0 UNPACKING

CUTTING THE METAL STRAPPING IS A DANGEROUS OPERATION, SEE FIG.9 DO NOT ABANDON THE CUT PIECES IN
THE ENVIRONMENT.

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.

FIG. 9

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. 10).

FIG. 10
2
MINIMUM mt 2
1 (inch 78,7)
1

PROTECT THE POWER

CABLE WITH A SUITABLE PROTECT THE POWER
CHANNEL. CABLE WITH A SUITABLE
CHANNEL. SPACE FOR MAINTENANCE
SPACE FOR MAINTENANCE MINIMUM mt 1,5 (inch 59)
MINIMUM mt 1,5 (inch 59)

THREE PHASE SCREW-

COMPRESSOR SUPPLY LEAD.

SINGLE PHASE DRYER SUPPLY

LEAD.

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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.

12.2 ELECTRICAL CONNECTION

 Check that the supply voltage is the same as the value indicated on the machine data plate.
 Check the condition of the line leads and ensure that there is an efficient earth lead.
 Ensure that there is an automatic cut-out device upstream for the machine against overcurrents,with a differential device (see Ref. 1 for
compresseur Ref. 2 for dryer ) wiring diagram.
 Connect the machine power cables with the greatest care, according to the standards in force. These cables must be as indicated on the
machine wiring diagram.
 After the first 50 working hours, check that the screws on the electric terminals are tight.

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.

12.3 CONNECTION TO THE COMPRESSED AIR NETWORK

Fit a manual interception valve Ref. 1 Fig. 10A between the machine and the compressed air network so that the compressor may be
isolated during maintenance operations.
Condensate must be drained Ref. 2 Fig. 10A from the oil receiver (manually) in conformity with the local regulations in force.
The manual drainage Ref. 2 Fig. 10A the condensate automatic Ref. 4 Fig. 10A, are led outside the machine with a flexible pipe that may be
inspected. Drainage must comply with the local 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.

THE COMPRESSOR MUST BE CONNECTED TO A

TANK COMPLETE WITH SAFETY VALVE (CAT. “IV” FIG. 10a
P.E.D. 97/23).

ALWAYS USE A
FLEXIBLE PIPE
1

1
4
3

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, Chapter 20.0

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13.0 DIMENSIONS AND TECHNICAL DATA

Air receiver 500 LT. Air receiver 500 LT.

Air Air
Dimensions mm (inch) Dimensions mm (inch)
connection connection
HP 10-15-20 HP 10-15-20
kW 7,5-11-15
L W H D kW 7,5-11-15
L W H D
1935 655 1680 1935 655 1665
3 / 4” 3 / 4”
(76) (25,7) (66) (76) (25,7) (65,5)

Without dryer With dryer

Air Air
Dimensions mm (inch) Dimensions mm (inch)
connection connection
HP 10-15-20 HP 10-15-20
L W H D kW 7,5-11-15
L W H D
kW 7,5-11-15
995 655 1045 1415 655 1045
3 / 4” 3 / 4”
(39) (25,7) (41) (55,7) (25,7) (41)

HP 10 (IVR) HP 15 (IVR) HP 20 (IVR)

kW 7,5 (IVR) kW 11 (IVR) kW 15 (IVR)
7 10 12,1 7 10 12,1 7 10 12,1
(101,5) (145) (175.5) (101,5) (145) (175.5) (101,5) (145) (175.5)
1226 1058 833 1822 1470 1205 2217 1860 1394
Standard air capacity l/min(cfm).
(43.3) (37.4) (29.4) (64.3) (51.9) (42.6) (78.3) (65.7) (49.2)
12.6 12.6 12.6 12.6 12.6 12.6 12.6 12.6 12.6
Max. pressure bar (psi)
(182.7) (182.7) (182.7) (182.7) (182.7) (182.7) (182.7) (182.7) (182.7)
Noiose product. dB(A) 62 63 64
Power HP - kW 10 – 7,5 15 - 11 20 - 15
Oil operation timer setting °C (°F) 115 (239)
Oil load l. (Gal) ~ 4 (1,05) ~ 4 (1,05) ~ 4 (1,05)

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HP 10 (VSD) HP 15 (VSD) HP 20 (VSD)

Net weight Kg. (lb)
kW 7,5 (VSD) kW 11 (VSD) kW 15 (VSD)
Air receiver Air receiver Air receiver Air receiver Air receiver Air receiver
270 LT. (Gal 71,3) 500 LT. (Gal 132) 270 LT. (Gal 71,3) 500 LT. (Gal 132) 270 LT. (Gal 71,3) 500 LT. (Gal 132)

440 (967) 458 (1009) 476 (1049)

Air receiver Air receiver Air receiver Air receiver Air receiver Air receiver
270 LT. (Gal 71,3) 500 LT. (Gal 132) 270 LT. (Gal 71,3) 500 LT. (Gal 132) 270 LT. (Gal 71,3) 500 LT. (Gal 132)

393 (866,4) 409 (901,6) 412 (908,3)

Without dryer Without dryer Without dryer

235 (518) 251 (553) 254 (600)

With dryer With dryer With dryer

281 (619,4) 299 (659) 317 (698,8)

Type dryer A4 A4+ A6

Nominal Nominal
Type dryer Freon Power w
Nominal bar
Power w (HP) Power w (HP)
R 134a Kg. (lb) (HP) MAX.
(psi)
See data plate 60 Hz 60 Hz 60 Hz bar 13
A4 dryer 326 (0,44) 46 (0,06) 372 (0,51) (188)

Nominal Nominal
Type dryer Freon Nominal bar
Power w (HP) Power w Power w (HP)
R 134a Kg. (lb) (HP) MAX.
(psi)
See data plate 60 Hz 60 Hz 60 Hz bar 13
A 4+ dryer 350 (0,48) 46 (0,06) 380 (0,52) (188)

Nominal Nominal
Type dryer Freon Nominal bar
Power w Power w
R 404a Kg. (lb) Power w MAX.
(psi)
See data plate 60 Hz 60 Hz 60 Hz bar 13
A6 dryer 608 (0,83) 60 (0,08) 668 (0,91) (188)

Nominal Nominal
Type dryer Freon Nominal bar
Power w Power w Power w
R 134a Kg. (lb) MAX.
(psi)
See data plate 60 Hz 60 Hz 60 Hz bar 13
A6 dryer 560 (0,76) 60 (0,08) 620 (0,84) (188)

Reference conditions: Limit conditions:

Ambient temperature 25 °C (77 °F) Max. ambient temperature 46°C (114,8 °F)
Inlet air temperature 35 °C (95 °F) Min. ambient temperature 5°C (41 °F)
Pressure 7 bar (101,5 psi) Max. inlet air temperature 55°C (131 °F)
Dew point in pressure 3 °C (37,4 °F) Max. working pressure 13 bar (188 psi)

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14.0 MACHINE ILLUSTRATION

14.1 GENERAL LAY-OUT FOR DRYER AND TANK

 IT IS FORBIDDEN TO TAMPERE WITH THE

SETTING VALUES OF THE SAFETY VALVE FIG. 11

5
9
10 9

6
4

2 8 3
1

1 Refrigerant compressor
2 Condenser
3 Motor fan
4 Evaporator
5 Compressed air tank
6 Hot gas bypass valve
7 Refrigerant filter
8 Expansion capillary tube
9 Safety valve ()
10 Condensate manual drainage

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14.1 GENERAL LAY-OUT

1) Air suction filter 12) Oil discharge
2) Minimum pressure valve 13) Oil tank
3) Oil filter 14) Pressure gauge tank
4) Air-oil cooler 15) Control card
5) Filter panel 16) Safety valve ()
6) Inverter 17) Emergency stop button with mechanical retention and
7) Thermostatic valve rotation release
8) Air-oil separator with oil separating filter 18) Electric motor
9) Top-up or oil filling cap 19) Screw compressor
10) Control panel 20) Suction unit
11) Oil gauge
 IT IS FORBIDDEN TO TAMPERE WITH THE
SETTING VALUES OF THE SAFETY VALVE

FIG. 12
4 3 8

15

14
17

10
13
1

18
20 11 9
19
12

7
6

16

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14.2 COMMAND AND CONTROL PANEL

BEFORE CARRYING OUT THE OPERATION TEST, READ CAREFULLY AND ACQUIRE A GOOD KNOWLEDGE OF THE
COMMAND FUNCTIONS.

FIG. 13

2 1

1) Control card
2) Emergency stop button with mechanical retention and rotation release

14.3 ELECTRONIC CARD MODELS “ ES 4000 “ (Controller version inverter – standard controller)

3 11 13 9 8
FIG. 14

15 12

10

2
6

4
1
5

Electronic controller buttons and leds: 16 14 17 7

1 Stop button (0) 10 Automatic operation led
2 Start button (I) 11 Automatic operation symbol
3 Display 12 Service warning led
4 Reset button 13 Service warning symbol
5 Enter key 14 Downward scroll key
6 Voltage on led 15 Upward scroll key
7 Voltage on symbol 16 Left scroll key
8 General alarm led 17 Right scroll key
9 General alarm symbol

CAUTION: WAIT AT LEAST 30 SECONDS BEFORE STARTING THE MACHINE AFTER SWITCH OFF.

Introduction:
The ES4000 controller performs the following functions:
- Compressor control
- Compressor protection
- Maintenance monitoring
- Automatic restart after supply interruption (optional).

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Automatic control of the compressor

The controller maintains the outlet pressure within defined limits, commanding the load and unload operations of the compressor. Various
parameters are considered, among them are: the unload pressure, the load pressure, the minimum stop time and the maximum number of motor
starts.
Compressor protection
Shutdown
If element outlet temperature of the element exceeds the programmed shut down level, the compressor will be stopped. This will be indicated on
the display (3). The compressor will be stopped also in case of inverter alarm.
Before remedying, consult the safety precautions.
Shut down warning:
A shut-down warning level is a programmable level below the shut-down level.
If one of the measured values exceeds the value of the alarm threshold, this will be indicated before reaching the threshold stop for
failure.
Service warning:
If the service timer exceeds the programmed value, this will be indicated on the display (3) to warn the operator to perform the required service
operations

Tab. A
Ref. Name Description
Emergency stop push button Push the button to stop the compressor immediately in case of an emergency. After
S3 remedying the trouble, unlock the button by rotate it according to the arrow indication
and press the reset key (4).
Stop button Push the button to stop the compressor. The led (10) switches off. The compressor will
stop after running in unloaded conditions (30 seconds).
1
Start button Push the button in order to start the compressor. The led (10) lights up, indicating that
the controller is operating automatically the compressor.
2
3 Display It shows the operating conditions of the compressor, the actual measured values and
the programmed parameters.
Reset button Button to reset the service timer, a shut-down condition, or in order to return to a
previous visualization on the display.
4
Enter key Key to select or to confirm a parameter, or to open a sub display.

5
6 Voltage on led It indicates that the voltage is switched on
Voltage on symbol
7
8 General alarm led It is lit in case of warning condition.
It blinks in case of shut-down or emergency stop condition.
General alarm symbol
9
10 Automatic operation led It indicates that the controller is operating the compressor automatically. The
compressor is loaded, unloaded, stopped and restarted depending on the air demand
and on the limitations programmed in the controller.
The led is lit in during the automatic operations.
It blinks when the unit is remotely controlled.
Automatic operation symbol
11
12 Service warning led It is lit in case of service is needed
Service warning symbol
13
Downward scroll key Key to scroll downward through the screens or to decrease a parameter value.

14
Upward scroll key Key to scroll upwards through the screens or to increase a parameter value.

15
Left scroll key Key to scroll left through the screens.

16
Right scroll key Key to scroll right through the screens.

17

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Display

The display (3) shows :

- The compressor status by means of pictographs.
- The air outlet pressure.
- The actual temperature of the compressor element outlet.
- The actual dew-point temperature in case of compressor equipped with dryer..
The display also shows all measured and programmed parameters.

Pittographs used on the screen (Tab. B)

Ref. Pictograph Description

Compressor on status load.
1)

Compressor status unload.

2)

Motor stopped.
3)

When the compressor is stopped, the icon stands still.

4)
When the compressor is running, the icon is rotating.
Element outlet temperature.
5)
Dew-point (dryer equipped version).
6)
Propagated by the inverter or in case of overtemperature detected by temperature switch
7)
TSHH11-12
Emergency stop activated.
8)
Pictograph: service.
9)
Remote start / stop
10)
LAN control or network setting.
11)
Automatic restart after voltage failure is active
12)
Timer
13)

Main screen
When the voltage is switched on, the main screen is shown automatically, indicating the operation status of the compressor and the outlet
temperature.
example:

The display is showing that the compressor is running loaded (when the horizontal arrow is blinking) and the outlet pressure is 6.8bar.
Consult the service dept. if <test> appears on the display.

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Shut down warning

A shut-down warning will appear in the event of:

- Too high temperature at the compressor element outlet.
- Too high dew-point temperature for dryer equipped units.

Compressor element outlet temperature

If the compressor temperature of the compressor element exceeds the shut down warning level (105°C / 221°F), the alarm led (8) will light up and
the related pictograph will appear blinking. Pushing the button (14) until the actual compressor element temperature appears:

Blinking

The screen shows that the temperature at the compressor element outlet is 107°C (224,6 °F).
Using the keys (14) and (15), it is possible to scroll through other screens to check the actual status of other parameters.
Stop the compressor using the button (1) and wait until the compressor stops.
Open the disconnect switch in the supply line of the compressor.

WARNING: The unit must be disconnected from the supply net!

Inspect the compressor and remedy.
The message warning will disappear as soon as the warning condition disappears.

Dew-point temperature
For compressors with integrated dryer:
If the dew point temperature exceeds the warning level (not programmable), the alarm led (8) will lit up and the related pictograph will appear
blinking.
Main screen with warning dew point temperature

Blinking

Press the arrow key (14) until the actual dew point appears:

The screen shows that the actual dew-point temperature is 22°C (71,6 °F).
Using the keys (14) and (15), it is possible to scroll through other screens to check the actual status of other parameters.
Stop the compressor using the button (1) and wait until the compressor has stopped.
Open the disconnect switch in the supply line of the compressor.

WARNING: The unit must be disconnected from the supply net!

Inspect the unit and remedy.
The message warning will disappear as soon as the warning condition disappears.

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SHUT DOWN
The compressor will be shut-down in the following cases:
- The temperature at the outlet of the compressor element exceeds the shut-down level
- Error of the outlet pressure sensor
- Fan Overload or Converter fault

Compressor element outlet temperature

If the outlet temperature of the compressor element exceeds the shut-down level (115°C / 239°F), the compressor will be shut-down, the alarm led
(8) will blink, the automatic operation led (10) will switch off.
The following type of screen will appear.

Press the arrow key (14) until the actual compressor element temperature appears:

The screen shows that the temperature at the outlet of the compressor element is 122°C (251,6 °F).
Open the disconnect switch in the supply line of the compressor.

WARNING: The unit must be disconnected from the supply net!

Inspect the unit and remedy.
After remedying and when the shut-down condition has disappeared, switch on the voltage and restart the compressor.

Converter Allarm
In case of converter fault, the compressor will be shut-down, the alarm led (8) will blink, the automatic operation led (10) will switch off and the
following type of screen will appear:

Warning: The symbol of "Motor Overload" appears both in case of an alarm in the event of converter fault or temperature switches
TSHH11-12 have been tripped.
Open the disconnect switch in the supply line of the compressor.

WARNING: The unit must be disconnected from the supply net!

Inspect the unit and remedy.
After remedying and when the shut-down condition has disappeared, switch on the voltage and restart the compressor.

Emergency stop
Compressor can be manually shut down by pressing the emengency stop pushbutton.
NOTE:
5 seconds after the stop command, the controller displays “Motor thermal overload” icon (converter has been shut down).
This icon disappears once the pushbutton is reset.

If FREQUENCY CONVERTER ALARM RESET does not work:

- Disconnect the unit from power supply for 15 minutes.
- After power supply is restored, RESET frequency converter alarm on Elektronikon controller.
If the problem is not solved, please contact the manufacturer’s technical support.

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Service warning
A service warning will appear when the service timer has reached the programmed time interval.
The alarm led (12) will light up.
Press the arrow key (14) to reach the screen <d06> with the service symbol.
Push the button (5) and the actual reading of the service timer will appear in <hrs> (or in <x1000hrs> if the service timer value is higher than 9999).

The screen shows that the reading of the service timer is 4002h.
Using the keys (14) or (15), scroll to the screen <d.01> and the running hours symbol will be shown.
Press the key (5) and the actual running hours will appear in <hrs> (or in <x1000hrs> if the value is higher than 9999).

Stop the unit.

Open the disconnect switch in the supply line of the compressor.

WARNING: The unit must be disconnected from the supply net!

Carry out the service actions. See the preventive maintenance schedule section.
After servicing, reset the service timer. See section Calling up/ resetting service timer.
Visualization of the time since last maintenance
Starting from the main screen:

Press the scroll key (14) until the screen <d.06> appears, then press enter key (5):

This screen shows the unit used is <hrs> (or <x1000 hrs>) and the value 1191: the compressor has run 1191 h since the previous service.
Resetting the service timer
After servicing, see section Service warning, the timer has to be reset:
Scroll to register screen <d.06> and press enter key (5).
The reading (e.g. 4000) will appear.
Press the enter key (5). If a password is set, enter the password.
The icon will flash (indicating that resetting is possible).
Press the enter key (5) to reset the timer to <0.000> or press reset key (4) to cancel the operation.
S c r o l l i n g th r o u g h a l l s c r e e n s
Scroll buttons (14) can be used to scroll through all screens. The screens are divided into register screens, measured data screens, digital input
screens (numbered as <d.in>, <d.1>, ...), parameter screens (numbered as <P.1>, <P.2>, ...), protections screens (numbered as
<Pr.2>,...) and test screens (numbered as <t.1>,...).
During scrolling, the numbers of the screens appear consecutively. For most screens, the unit of measurement and the related pictograph are
shown together with the screen number.

Example
The screen shows the screen number <d.1>, the unit used <hrs> and the related symbol for running hours. Press Enter key (5) to call up the actual
running hours.

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Overview of the screens

Digital input screens Designation Related topic

<d.in> Digital input status

< Spd> Motoor speed
< d.1> Running hours (hrs or x 1000 hrs)
<d.2> Motor starts (x1 or x 1000)
<d.3> Module hours (hrs or x 1000 hrs)
<d.4> Loading hours (hrs or x1 000 hrs)
<d.5> Load relay (x1 or x 1000)
<d.6> Service timer reading (hrs or x 1000 hrs)
<d.7> Number of stops for emergency
<d.8> Actual program version

Parameter screens Designation Related topic

<P.1> Selection between local, remote or LAN control

<P.2> Setting a node ID for LAN control and the channels for Mk 4
and Mk 5
<P.3> Settings for IP, gateway and Subnet mask

<P.4> Pressure band settings

<P.5> Setting a pressure band selection

<P.6> Enable remote pressure band selection
<P.7> % Reduction of maximun motor speed
<P.8> Hours on the first maintenance interval
<P.9> Setting of unit for temperature
<P.10> Setting of unit for pressure
<P.11> Enable automatic restar in case of power failure
<P.12> Setting a password

Parameter screens Designation Related topic

<Pr.2> Protections screens

Test screens Designation Related topic

<t.1> Display test

<t.2> Safety valve test
<t.3> Bearing regreasing

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Menu flow

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Simplified menu flow

Ref. Description Ref. Description

(1) Compressor outlet pressure (16) IP settings
(2) Compressor outlet temperature (17) Settings working pressure
(3) Dewpoint temperature (18) Setting of the pressure band
(4) Digital input status (19) Enable remote pressure band selection
(5) Motor speed (20) % Reduction of maximun motor speed
(6) Working hours (21) Maintenance interval setting
(7) Motor starts (22) Temperatures unit
(8) Module hours (23) Pressure units
(9) Working hours in load condition (24) Autorestart
(10) Load relay (25) Password settings
(11) Value of the maintenance interval (26) Protections
(12) Number of emergency stops (27) Display test
(13) Software version (28) Safety valve test
(14) Network settings (29) Enable bearing regreasing
(15) Settings node ID

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14.5 Graphic controller (Option)

Introduction
The electronic controller has following functions:
 Controlling the compressor
 Protecting the compressor
 Monitoring components subject to service
 Automatic restart after voltage failure (option)

Automatic control of the compressor

The controller maintains the net pressure between programmable limits by automatically loading and unloading the compressor in case of
fixed speed machines. For VSD machines the controller also alters the motor speed in order to maintain the setpoint pressure. A number of
programmable settings, e.g. the unloading and loading pressures, the minimum stop time and the maximum number of motor starts are
taken into account.
The controller stops the compressor whenever possible to reduce the power consumption and restarts it automatically when the net
pressure decreases. If the expected unloading period is to short, the compressor is kept running to prevent too short stand-still periods.

Protecting the compressor

Shut-down
The compressor will be stopped and it will be indicated on the display in the following events:
 compressor element outlet temperature bigger than the programmed shut-down level detected by temperature sensor
 compressor element outlet temperature bigger than the programmed shut-down level detected by temperature switch
 overload of the drive motor or converter fault
 compressors overload of the fan motor
In chapter “Shut-down visualization” it’s explained how it appears on the display, how to recognize which is the shut-down and how to solve
it.

Shut-down warning
A shut-down warning level is a programmable level below the shut-down level. If one of the measurements exceeds the programmed shut-
down warning level, this will also be indicated to warn the operator before the shut-down level is reached.The shut-down warning appears in
case of:
 Too high temperature at the compressor element outlet
 Too high or too low dew-point temperature for dryer equipped units
In chapter “Shut-down warinig visualization” it’s explained how it appears on the display, how to recognize which is the warning and how to
solve it.

Service warning
If the service timer exceeds a programmed value, this will be indicated on the display to warn the operator to carry out some service actions.

Automatic restart after voltage failure

The controller has a built-in function to automatically restart the compressor when the voltage is restored after voltage failure.
The function is not active and to activate it please contact the customer centre.

Provided the controller is in the automatic operation mode, the compressor will automatically restart when
the supply voltage to the module is restored.

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Control panel

2 8 4 FIG. 14a

5
1
9
3

10 7
11 14
13

12 6

Function keys of the controller

Reference Designation Function
1 Display Shows icons and operating conditions.

2 Automatic operation symbol

3 LED, Automatic operation Indicates that the regulator is automatically controlling the compressor: the compressor is loaded,
unloaded, stopped and restarted depending on the air consumption and the limitations
programmed in the regulator.
4 Warning symbol
5 LED, Warning Is lit if a warning condition exists.
6 Voltage symbol
7 LED, Voltage on Indicates that the voltage is switched on.
8 Service symbol
9 LED, Service Is lit when service is needed.
10 Start button This button starts the compressor. Automatic operation LED (3) lights up. The Elektronikon is
operative.
11 Stop button This button is used to stop the compressor. Automatic operation LED (3) goes out.
12 Scroll buttons Use these buttons to scroll through the menu .
13 Enter button Use this button to confirm the last action.
14 Escape button Use this button to go to previous screen or to end the current action.

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Icons used
Status icons
Name Icon Description
Stopped / Running When the compressor is stopped, the icon stands still. When the compressor is running, the icon
is rotating.

Compressor status Motor stopped

Running unloaded

Running loaded

Machine control mode Local start / stop

Or

Remote start / stop

Network control

Automatic restart after Automatic restart after voltage failure is active

voltage failure

Week timer Week timer is active

Active protection functions Emergency stop

Shutdown

Warning

Service Service required

Main screen display Value lines display icon

Chart display icon

General icons No communication / network problem

Not valid

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Input icons
Icon Description Icon Description
Pressure Digital input

Temperature Special protection

System icons
Icon Description Icon Description
Compressor element (LP, HP, ...) Motor

Dryer Failure expansion module

Fan Network problem

Frequency converter General alarm

Menu icons
Icon Description Icon Description
Inputs Event history (saved data)

Outputs Access key / User password

Protections (Warnings, shutdowns) Network

Counters Setpoint

Test Information

Regulation (Settings) Week Timer

Service General

Navigation arrows
Up Down

Main screen
Function
The Main screen is the screen that is shown automatically when the voltage is switched on and one of the keys is pushed. It is switched off
automatically after a few minutes when no keys are pushed.
Typically, 5 different main screen views can be chosen:
 Two value lines
 Four value lines
 Chart (High resolution)
 Chart (Medium resolution)
 Chart (Low resolution)

Two and four value lines screens

This type of Main screen shows the value of 2 or 4 parameters (see section Inputs menu).

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Typical Main screen (2 value lines) Typical Main screen (4 value lines)

Text on figures
(1) Compressor Outlet
(2) Element outlet
(3) Load, ... (text varies upon the compressors actual condition)
(4) Menu
(5) Running hours
(6) Flow

Section A shows information regarding the compressor operation (e.g. the outlet pressure or the temperature at the compressor outlet). On
compressors with a frequency converter, the load degree (flow) is given in % of the maximum flow.

Section B shows Status icons. Following icon types are shown in this field:
 Fixed icons
These icons are always shown in the main screen and cannot be selected by the cursor (e.g. Compressor stopped or running, Compressor
status (running, running unloaded or motor stopped).
 Optional icons
These icons are only shown if their corresponding function is activated (e.g. week timer, automatic restart after voltage failure , etc.)
 Pop up icons
These icons pop up if an abnormal condition occurs (warnings, shutdowns, service,...)
To call up more information about the icons shown, select the icon concerned using the scroll keys and press the enter key.

Section C is called the Status bar. This bar shows the text that corresponds to the selected icon.

Section D shows the Action buttons. These buttons are used:

 To call up or program settings
 To reset a motor overload, service message or emergency stop
 To have access to all data collected by the regulator
 The function of the buttons depends on the displayed menu. The most common functions are “Menu” (To go to the menu),
“Modify” (To modify programmable settings), “Reset” (To reset a timer or message)

To activate an action button, highlight the button by using the Scroll keys and press the Enter key. To go back to the previous menu, press
the Escape key.

Chart views
Instead of viewing values, it is also possible to view a graph of one of the input signals (see section Inputs menu) in function of the time.

High Resolution Medium Resolution Low Resolution

When Chart (High Resolution) is selected, the chart shows the variation of the selected input (in this case the pressure) per minute. Also the
instantaneous value is displayed. The screen shows the last 4 minutes.
The switch button (icon) for selecting other screens is changed into a small Chart and is highlighted (active).
When the Chart (Medium Resolution) is selected, the chart shows the variation of the selected input per hour. The screen shows the last 4
hours.
When the Chart (Low Resolution) is selected, the chart shows the variation of the selected input per day. The screen shows the evolution
over the last 10 days.

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Selection of a main screen view
To change between the different screen layouts, select the far right icon in the control icons line (see value lines display icon or chart display
icon in section Used icons) and press the Enter key. A screen similar to the one below opens:

Select the layout required and press the Enter key. See also section Inputs menu.

Calling up menus
Description
When the voltage is switched on, the main screen is shown automatically (see section Main screen):

To go to the Menu screen, highlight the Menu button (4), using the Scroll keys. Press the Enter key to select the menu. Following screen
appears:

The screen shows a number of icons. Each icon indicates a menu item. By default, the Pressure Settings (Regulation) icon is selected. The
status bar shows the name of the menu that corresponds with the selected icon.
Use the Scroll keys to select an icon. Press the Escape key to return to the Main screen.

Shut-down warning visualization

In case of shut-down warning a yellow triangle (1) pops up in the lower side of the display as in the picture below in the left side:

To check which is the warning, highlight the yellow triangle, using the Scroll keys. Press the Enter key and it will appears the Protections
menu as in picture above in the right side. Press Enter key and then in the display will appear the list of the Protection that are active on the
controller. Use Scroll key to check all the protections and the one who is causing the warning will be highlighted as in picture below:

Stop the compressor pressing the button (11) in the Fig. 14a and wait until the compressor stops.
Isolate the compressor from the power supply, and de pressurize / isolate compressed air system..

WARNING: 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.
Inspect the compressor and remedy.

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The message warning will disappear as soon as the warning condition disappears.
Shut-down visualization
In case of shut-down red icon (1) pops up in the lower side of the display as in the picture below in the left side:

To check which is the shutdown, highlight the red icon, using the Scroll keys. Press the Enter key and it will appears the Protections menu
as in picture above in the right side. Press Enter key and then in the display will appear the list of the Protection that are active on the
controller. Use Scroll key to check all the protections and the one THAT is causing the shutdown will be highlighted as in picture below:

Take care that the shut-down “Overload motor” appears in case of main motor fan motor OVERLOAD or overtemperature detected by
temperature switch.
Isolate the compressor from the power supply.

WARNING: Before carrying out any maintenance isolate the compressor from the power supply, and de pressurize / isolate
compressed air system., cut off the machine from the electrical mains and from the compressed air distribution circuit, check that the machine
is not under pressure.
Inspect the compressor and remedy.
After remedying and when the shut-down condition has disappear, switch on the voltage and restart the compressor.
WARNING: CONVERTER FAULT
If FREQUENCY CONVERTER ALARM RESET does not work:
- Disconnect the unit from power supply for 15 minutes.
- After power supply is restored, RESET frequency converter alarm on Elektronikon controller.
If the problem is not solved, please contact the manufacturer’s technical support.
Inputs menu
Function: to display the actual value of the measured data (analog inputs) and the status of the digital inputs (e.g. emergency stop contact,
motor overload relay, etc.) and to select the digital input to be shown on the chart in the main screen.
Procedure
Starting from the main screen (see Main screen),m ove the cursor to the action button Menu and press the Enter key.
Using the Scroll keys, move the cursor to the Inputs icon, as shown in the following screen:

Press the Enter key. A screen similar to the one below appears:

(1) Inputs
(2) Compressor outlet
(3) Element outlet
(4) Ambient air
(5) Emergency stop
The screen shows a list of all inputs with their corresponding icons and readings.
If an input is in warning or shutdown, the original icon is replaced by the warning or shutdown icon respectively (i.c. the Stop icon and the
Warning icon in the screen shown above).
A small chart icon, shown below an item in the list means this input signal is shown on the chart at the main screen. Any analog input can be
selected.

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Outputs menu
Function: to call up information regarding the actual status of some outputs.
Procedure: starting from the Main screen (see Main screen), move the cursor to the action button Menu and press the Enter key, move the
cursor to the Outputs icon (see below).

Press the Enter key. A screen similar to the one below appears:

(1) Outputs
(2) Fan motor contact
(3) Blow-off contact
(4) General shutdown
(5) Automatic operation

Outputs screen (typical)

The screen shows a list of all outputs with their status.

Counters
Function: to call up the running hours, the loaded hours, the number of motor starts, the number of hours that the regulator has been
powered and the number of load cycles.
Procedure: starting from the Main screen (see Main screen), move the cursor to the action button Menu and press the Enter key. Using the
Scroll keys, move the cursor to the Counters icon (see below)

Press the Enter key. A screen similar to the one below appears:

(1) Counters
(2) Running hours
(3) Motor starts
(4) Load relay
VSD 1-20 % rpm in % (the percentage of the time during which the motor speed
(5) was between 1 and 20 %)

The screen shows a list of all counters with their actual readings.
Note: the example above is for a frequency converter driven compressor. For a fixed speed compressor, the actual screen will be somewhat
different.

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Control mode selection
Function: to select the control mode, i.e. whether the compressor is in local control, remote control or controlled via a local area network
(LAN).
Procedure: starting from the main screen, make sure the action button Menu (1) is selected:

Next, use the scroll buttons to go to the Status icons (see Main screen) and select the Regulation icon (2). When the icon is active, this icon
is highlighted with a grey background colour.
Press the enter button:

There are 2 possibilities:

Local control
LAN (network) control

After selecting the required regulation mode, press the enter button on the controller to confirm your selection. The new setting is now visible
on the main screen. See section Used icons for the meaning of the icons.
To activate the remote start/stop please contact the customer centre.

Service menu
Function: to reset the service plans which are carried out, to check when the next service plans are to be carried out, to find out which
service plans were carried out in the past and to modify the programmed service intervals.
Procedure: starting from the Main screen (see Main screen), move the cursor to the action button Menu and press the Enter key.
Using the Scroll keys, move the cursor to the Service icon (see below).

Press the Enter key. Following screen appears:

(1) Service
(2) Overview
(3) Service plan
(4) Next service
(5) History

Scroll through the items to select the desired item and press the Enter key to see the details as explained below.

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Overview

(1) Overview
(2) Running Hours
(3) Real Time hours
(4) Reset

Example for service level (A): the figures at the left are the programmed service intervals. For Service interval A, the programmed number of
running hours is 4000 hours (upper row, green) and the programmed number of real time hours is 8760 hours, which corresponds to one
year (second row, blue). This means that the controller will launch a service warning when either 4000 running hours or 8760 real hours are
reached, whichever comes first. Note that the real time hours counter keeps counting, also when the controller is not powered.
The figures at the end of the bars are the number of hours to go till the next service intervention. In the example above, the compressor was
just started up, which means it still has 4000 running hours or 8299 hours to go before the next Service intervention.

Service plans
A number of service operations are grouped (called Level A, Level B, etc...). Each level stands for a number of service actions to be carried
out at the time intervals programmed in the controller.
When a service plan interval is reached, a message will appear on the screen.
After carrying out the service actions related to the indicated levels, the timers must be reset. From the Service menu above, select Service
plan (3) and press Enter. Following screen appears:

(1) Service plan

(2) Level
(3) Running hours
(4) Real time hours
(5) Modify

In the example above, the A Service level is programmed at 4000 running hours, of which 0 hours have passed. History
The History screen shows a list of all service actions done in the past, sorted by date. The date at the top is the most recent service action.
To see the details of a completed service action (e.g. Service level, Running hours or Real time hours), use the Scroll keys to select the
desired action and press the Enter key.

Regulation menu
Function: on fixed speed compressors , the operator can program two different pressure bands. This menu is also used to select the active
pressure band.
Procedure: starting from the Main screen (see Main screen), move the cursor to the action button Menu and press the Enter key.
Using the Scroll keys, move the cursor to the Setpoint icon (see below).

Press the Enter key. Following screen appears:

(1) Regulation
(2) Unloading pressure 1
(3) Loading pressure 1
(4) Unloading pressure 2
(5) Loading pressure 2
(6) Modify

The screen shows the actual unloading and loading pressure settings for both pressure bands. To modify the settings, move the cursor to
the action button Modify and press the Enter key. Following screen appears:

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The first line of the screen is highlighted. Use the Scroll keys to highlight the setting to be modified and press the Enter key. Following
screen appears:

The upper and lower limit of the setting is shown in grey, the actual setting is shown in black. Use the ↑ or ↓ key of the Scroll keys to modify
the settings as required and press the Enter key to accept.
If necessary, change the other settings as required in the same way as described above.

Event history menu

Function: to call up the last shut-down and last emergency stop data.
Procedure: starting from the Main screen (see Main screen), move the cursor to the action button Menu and press the Enter key.
Using the Scroll keys, move the cursor to the Event History icon (see below).

Press the Enter key. The list of last shut-down and emergency stop cases is shown.

Example of Event History screen

Scroll through the items to select the desired shut-down or emergency stop event.
Press the Enter key to find the date, time and other data reflecting the status of the compressor when that shut-down or emergency stop
occurred.

Modifying general setting

Function: to display and setting a number of general settings.
Procedure: starting from the Main screen (see Main screen), move the cursor to the action button Menu and press the Enter key.
Using the Scroll keys, move the cursor to the Settings icon (see below).

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Press the Enter key. A second menu screen appears:

This submenu screen shows again a number of icons. By default, the User Password icon is selected. Also the status bar shows the name
of the menu that corresponds with the selected icon.

General menu
Function: this menu covers a list of general settings:
 Language
 Time
 Date
 Date Format
 Units

Procedure: starting from the submenu screen (see Modifying general settings), using the Scroll keys, move the cursor to the General icon
(see below).

Press the Enter key. A screen similar to the one below appears:

(1) General
(2) Language in use
(3) Time
(4) Date
(5) Date format
(6) Modify

A screen similar to the one above is shown, a selection bar is covering the first item (Language). Use the ↓ key of the Scroll keys to select
the setting to be modified and press the Enter key.
To modify, select the Modify button using the Scroll keys and press the Enter key.
A pop-up screen appears. Use the ↑ or ↓ key to select the required parameter and press the Enter key to confirm.

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Terminology
Term Explanation
ARAVF Automatic restart after voltage failure.
Power recovery time Is the period within which the voltage must be restored to have an automatic restart. Is accessible if the automatic
restart is activated. To activate the automatic restart function, consult your supplier.

Restart delay This parameter allows you to programme the controller so that not all compressors are restarted at the same
time after a power failure (ARAVF active).
Compressor element outlet The regulator does not accept inconsistent settings, e.g. if the warning level is programmed
at 95 ˚C (203 ˚F), the minimum limit for the shut-down level changes to 96 ˚C (204 ˚F). The
recommended difference between the warning level and shut-down level is 10 ˚C (18 ˚F).

Delay at shut- down signal Is the time for which the signal must exist before the compressor is shut down. If it is required to program this
setting to another value, consult your supplier.
Minimum stop time Once the compressor has automatically stopped, it will remain stopped for the minimum stop time, whatever
happens with the net air pressure. Consult your supplier if a setting lower than 20 seconds is required.

Unloading/ Loading The regulator does not accept incorrect settings, e.g. if the unloading pressure is programmed at 7.0 bar(e) (101
pressure psi(g)), the maximum limit for the loading pressure changes to 6.9 bar(e) (100 psi(g)). The recommended
minimum pressure difference between loading and unloading is 0.5 bar (7 psi(g)).

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15.0 ORDINARY MAINTENANCE TO BE DONE BY THE USER

BEFORE CARRYING OUT ANY MAINTENANCE JOBS IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT
FROM THE POWER MAINS.
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)

15.1 GENERAL INFORMATION

15.2 MAINTENANCE SCHEDULE
 OPERATIONS THAT MAY BE CARRIED OUT BY THE USER
 OPERATIONS THAT REQUIRE SKILLED PERSONNEL; THESE OPERATIONS ARE ILLUSTRATED IN PART B OF THIS
MANUAL.

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.

 Drain condensate from the air tank

Every Day (after use)  Check automatic condensation emptying
Every 50 working hours  Drain condensate from the oil collector
 Check the oil level
 Clean the filtering panel

Every 500 hours  Clean the air suction filter (see control board LED)

Every 2000 hours  Change the oil (see control board LED)
 Change the oil filter (see control board LED)
 Change the suction filter (see control board LED)

Every 4000 hours  Clean the finned surface of the air-oil cooler
 Change the oil separating filter (see control board LED)
 Greasing motor bearings
Every 8000 hours  Visual inspection of motor element elastic coupling

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15.3 DRAINING CONDENSATE FROM THE OIL TANK

If the compressor work cycle contemplates long pauses during which the machine cools down, a certain amount of condensate will gather in
the oil tank. This happens, for example, when stopping overnight or at weekends.
The condensate must be drained off every 50 hours or every week. 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. 15: in this way the machine stops after 50 seconds of idle running.
- Open the differential supply switch, Ref. 2 Fig. 15 (on the screw-compressor) and Ref. 3 Fig. 15 (on the dryer if fitted).

2
FIG. 15

2 3

4
7

- Wait for the machine to cool down.

- Remove the panels with the key provided Ref. 4 Fig. 15.
- SLOWLY turn on the tap Ref. 5 Fig. 15 and let the condensate flow out.
- When the first traces of oil appear, turn off the tap.

CONDENSATE MUST BE DISPOSED OF IN CONFORMITY WITH THE LOCAL REGULATIONS IN FORCE.

- Check the oil level on the indicator Ref. 6 Fig. 15

- If the oil level is under the minimum, top up as described at point 15.4

USE OIL OF THE SAME TYPE AS THAT ALREADY IN THE MACHINE; DO NOT MIX DIFFERENT TYPES OF OIL

15.4 CHECK OIL LEVEL AND TOP UP

- Switch off the machine with pushbutton Ref. 1 Fig. 15: in this way the machine stops after 50 seconds of idle running.
- Wait a few minutes for the foam in the oil collector to abate.
- Check the oil level on the indicator Ref. 6 Fig. 15
- If the oil level is under the minimum, top up.

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 panel with the special key Ref. 4 Fig. 15.
- Slowly open the oil plug Ref. 7 Fig. 15
- Top up to maximum level Ref. 6 Fig. 15, with oil of the same type in the compressor.
- Turn off the cap of the oil tank Ref. 7 Fig. 15.
- Close the panel Ref. 4 Fig. 15.

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15.5 CLEANING THE FILTERING PANEL

BEFORE DRAINING THE CONDENSATE IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT FROM THE
POWER MAINS.

- Switch off the machine with pushbutton Ref. 1 Fig. 15: in this way the machine stops after 50 seconds of idle running.
- Open the differential supply switch, Ref. 2 Fig. 15 (on the screw-compressor) and Ref. 4 Fig. 15 (on the dryer if fitted).
- Remove the filter panel Rif. 1 e Rif. 2 Fig. 15a.
- Clean the filtering panel with a jet of air wash it with water, do not use solvents.
- Once the operation has been completed, reassemble the filter panel.

FIG. 15a

1
1

2 2

15.6 CLEANING THE SUCTION FILTER OR CHANGING THE FILTER

BEFORE DRAINING THE CONDENSATE IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT FROM THE
POWER MAINS.

FIG. 16

2
2
3

HP 10 - 15 HP 20

- Switch off the machine with pushbutton Ref. 1 Fig. 15: in this way the machine stops after 50 seconds of idle running.
- Open the differential supply switch, Ref. 2 Fig. 15 (on the screw-compressor) and Ref. 3 Fig. 15 (on the dryer if fitted).

HOT PARTS INSIDE

- Remove the panel Ref. 1 Fig. 16

- Remove the cover Ref. 2 Fig. 16
- Remove the filter Ref. 3 Fig. 16
AVOID DROPPING FOREIGN BODIES INTO THE SUCTION MANIFOLD.
- 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 and fasten with the nut.
- If necessary, dispose of the old filter in conformity with the local regulations in force.
- Close the panel Ref. 1 Fig. 16

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15.7 CHECKING THE AUTOMATIC CONDENSATION EMPTYING
BEFORE DRAINING THE CONDENSATE IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT FROM THE
POWER MAINS.

The automatic and manual condensation drain must be checked every day (Rif. 1 and Ref. 2 Fig. 17).
Proceed as follows:
- Press the "TEST" button, Ref. 1 Fig. 17, 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. 17
(PURGE EVERY DAY AFTER USE).

FIG. 17

2 1

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15.8 CLEANING THE CONDENSER BATTERY (ON THE DRYER IF FITTED)

BEFORE CARRYING OUT ANY MAINTENANCE IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT FROM
THE POWER MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION NETWORK.

The condenser must be cleaned every month.

Proceed as follows:
- Switch off the machine with pushbutton Ref. 1 Fig. 18: in this way the machine stops after 50 seconds of idle running.
- Open the differential supply switch, Ref. 2 Fig. 18 (on the screw-compressor) and Ref. 3 Fig. 18 (on the dryer if fitted).

HOT PARTS INSIDE THE DRYER

- Remove the protection Rif. 4 Fig. 18

- Clean the condenser fins Ref. with compressed air. DO NOT USE WATER OR SOLVENTS.
- Close the protection Rif. 4 Fig. 18.

FIG. 18
3
2
4

10

6
8
8
7 9
9
5

15.9 CLEAN THE DIRT COLLECTOR FILTER (DRYER and AIR TANK)

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. 1 Fig. 18: in this way the machine stops after 50 seconds of idle running.
- Close the cock Ref. 5 Fig. 18
- Open the differential supply switch, Ref. 2 Fig. 18 (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. 6
Fig. 18.
- Open the differential supply switch, Ref. 3 Fig. 18 (on the dryer if fitted).
- Close the cock Ref. 10 Fig. 18
- Release pressure from the machine by turning on the cock Ref. 7 Fig. 18.
- Remove the stopper Rif. 8 Fig. 18
- Remove the filter Rif. 9 Fig. 18
- Clean the filter Ref. 9 with a jet of air, working from inside to outside.
- Install the filter, fix the plug. Rif. 8 - 9 Fig. 18.

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15.10 REPLACE THE LINE PRE-CLEANER AND AFTER-CLEANER (ON THE DRYER IF FITTED)
BEFORE CARRYING OUT ANY MAINTENANCE IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT FROM
THE POWER MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION NETWORK.

WARNING: internal corrosion can seriously compromise the safety of installation; check it when changing cartridge.

Proceed as follows:
- Switch off the machine with pushbutton Ref. 2 Fig. 19: in this way the machine stops after 50 seconds of idle running.
- Open the differential supply switch, Ref. 3 Fig. 19 (on the screw-compressor).
- Close the cock Ref. 1 and Ref. 5 Fig. 19.
- Remove the protection Rif. 10 Fig. 19
- Depressurise the filters by pressing the "TEST" condensation emptying button (for about 10-20 seconds), which is fitted on the timer, Ref.
6 Fig. 19.
- Open the differential supply switch, Ref. 4 Fig. 19 (on the dryer if fitted).
- Release pressure from the machine by turning on the cock Ref. 5 Fig. 19.
- Change the filters Ref. 8 – 9 Fig. 19.
- Stick the adhesive label showing the month and year for the next filtering element change (max. one year) on the filter bowl.

FIG. 19
4

3
6

Afterfilter Afterfilter
Pre-filter

10
9
9
8
8
Pre-filter

Type 1
A4 - A4+ Type A6

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16.0 PERIODS OF INACTIVITY

If the machine has to remain inactive for a long period:

- Close the cock Ref. 5 Fig. 18.
- Depressurise the dryer by pressing the "TEST" condensation emptying button (for about 10-20 seconds) which is fitted on the timer, Ref. 6
Fig. 18 (on the dryer if fitted).
- Switch off the machine with pushbutton Ref. 1 Fig. 18: in this way the machine stops after 50 seconds of idle running.
- Open the differential supply switch, Ref. 2 Fig. 18 (on the screw-compressor) and Ref. 3 Fig. 18 (on the dryer if fitted).
- Release pressure from the machine by turning on the cocks Ref. 7 Fig. 18.
- Close the cocks Rif. 7 Fig. 18 off again after discharging all the residual air pressure
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 technical assistance service.
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, FOAM, ETC.

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18.0 LIST OF SPARE PARTS FOR ROUTINE MAINTENANCE

HP 10 (VSD) HP 15 (VSD) HP 20 (VSD)

Ref. DENOMINATION Code kW 7,5 (VSD) kW 11 (VSD) kW 15 (VSD)
7,5 bar 9,5 bar 12,5 bar 7,5 bar 9,5 bar 12,5 bar 7,5 bar 9,5 bar 12,5 bar
108 psi (137,7 psi) (181,2 psi) 108 psi (137,7 psi) (181,2 psi) 108 psi (137,7 psi) (181,2 psi)
1 Filtering panel 2202 2512 10         
2 Filtering panel (VSD) 1089 9556 67         
3 Suction filter 6211 4739 50   
4 Suction filter 6211 4723 50      
5 Oil filter 6211 4726 50         
6 Separator cartridge 6221 3728 50         
7 Prefilter 2258 2901 14         
8 Afterfilter 2258 2901 25         
9 Filtering panel 2204 1241 00
Grease tube
- 1630 2015 08      
(pack of 7 grams)

FIG. 20
5
6 4

2
HP 20- kW 15

3
HP 10 – 15 / kW 7,5-11 7
1
Prefilter

9 Option

Afterfilter
2
8

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19.0 TROUBLE-SHOOTING AND EMERGENCY REMEDIES

ALL WORK MUST BE CARRIED OUT BY PROFESSIONALLY SKILLED PERSONNEL. BEFORE CARRYNG OUT ANY
MAINTENANCE JOBS IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT FROM THE POWER MAINS.

N.B. OPERATIONS MARKED   MUST BE CARRIED OUT BY PROFESSIONALLY SKILLED PERSONNEL APPROVED THE
MANUFACTURER

FAULT FOUND POSSIBLE CAUSES OBSERVATIONS

1) The machine does not start 1A – Supply voltage is not present - check the power supply line,
Chapter 12.2
1B - the transformer protection device has - replace fuses
tripped

2) The machine does not start 2A – Hight oil temperature protection has -environment temperature too high;
the pilot lamp (Ref. 8 Fig. 13) is flashes. tripped ( oil Temp > 115°C – 239 °F) improve ventilation in the compressor
The pictograpf appears intermittently (Ref. room, Chapter 9.2
7 Tab. B)

3) The machine does not start 3A – Compressor screw temperature - environment temperature too high;
the pilot lamp (Ref. 8 Fig. 13) is flashes. switches have tripped (TSHH11-12) improve ventilation in the compressor
The pictograpf appears intermittently (Ref. 3B - Converter alarm. room, Chapter 9.2
5 Tab. B) 3C – Fan motor overload protection has - Check Converter alarm code: Read alarm
tripped. code on converter display and consult
converter user manual.

  - cooling radiator is dirty, clean the

radiator
- oil level too low; top up the oil tank
4) The compressor does not reach working 4A - the compressed air consumption is
pressure too high
4B - the discharge electrovalve remains   - check the electric system
closed.

5) Excess oil consumption 5A - deteriorated oil separating filter   - change the oil separating filter,
- oil level is too high Chapter 23

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PART “B”
THIS PART “B” OF THE INSTRUCTIONS MANUAL IS RESERVED FOR PROFESSIONALLY SKILLED PERSONNEL
APPROVED THE MANUFACTURER.

WARNING: THE INVERTER REMAINS CHARGED WITH HIGH VOLTAGE FOR 15 MINUTES AFTER THE MASTER
SWITCH HAS BEEN OPENED.
ALWAYS WAIT FOR 15 MINUTES BEFORE REMOVING THE FRONT COVER (INSTRUMENT PANEL) OR
DISCONNECT CONVERTER SUPPLY WIRES OR MOTOR CABLE.
ALWAYS WAIT FOR FIVE MINUTES BEFORE REMOVING THE FRONT COVER (INSTRUMENT PANEL).
USE A SPECIFIC INSTRUMENT TO CHECK THAT THERE ARE NO DANGEROUS VOLTAGES BEFORE
PERFORMING OPERATIONS ON THE INVERTER OR MOTOR.

20.0 STARTING UP
BEFORE CARRYING OUT ANY OPERATION ON THE MACHINE, ENSURE THAT THE ELECTRIC POWER SUPPLY HAS
BEEN DISCONNECTED.

20.1 PREPARING FOR SETTING UP

After checking everything as indicated in Chap. 12, folow the instructions in Fig. 21
- Fit the sound-deadening panels Ref. 1 Fig 21
These parts are packed inside the bodywork.
20.2 PRELIMINART CHECKS
- Check the oil level Ref. 2 Fig. 21 when supplied the machine is filled with oil;if the oil is not at the correct level, top up with the same oil as
the original type.
If more than 3 months have passed between the inspection in the factory and the date of installation, lubricate the screw group before
starting up, following the procedure described below:
- Remove the cover Ref. 3 Fig. 21
- Remove the air filter Ref. 4 Fig. 21
- Pour a little oil into the suction unit.
- Reassemble the air filter Ref. 4 Fig. 21
- Reassemble the cover Ref. 3 Fig. 21
If more than 6 months have passed between the inspection in the factory and the date of installation, consul the Manufacturer assistance
service.

3 FIG. 21

OIL

1 1

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20.3 CHECK THE DIRECTION OF ROTATION

- Check that all fixed guards are in their correct position.
- Connect the control board to the power supply with the automatic circuit-breaker switch of the line Rif. 1 Fig. 22.
- Check the direction of rotation (following the arrow on the coupling housing Rif. 2 Fig. 22). By pressing the “Start” button Rif. 3 Fig. 22,
followed immediately by the emergency stop Rif. 4 Fig. 22. When it rotates in the correct direction, the oil level Rif. 2 Fig. 17. Should drop
after 4 or 5 seconds of operation. It is very important to remember to check the direction of rotation of the fan Rif. 5 Fig. 22 (shown by an
arrow on the fan).

- If the rotation is correct, the paper sheet Ref. 6 is blown up (See Fig. A)
- If the rotation is not correct, the paper sheet Ref. 6 remains flat (See Fig. B)

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. 22.

IT IS ADVISABLE NOT TO DO ANYTHING ON THE MACHINE PANEL.

IF ALL THE INSTRUCTIONS FOUND IN THIS MANUAL HAVE BEEN OBSERVED THE MACHINE CAN BE STARTED.

FIG. 22
1

4
3
2
WANING: Motor start is ihnibit for a few seconds immediately after the
control card has power up or compressor motor has been stopped.

6
OK 6

This cable is part of the

machine l~ 4 metres

Protect the power cable with a suitable

PHASES
FIG. A channel. FIG. B INCORRECT

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21.0 GENERAL ORDINARY MAINTENANCE REQUIRES TRAINED PERSONNEL

BEFORE CARRYING OUT ANY MAINTENANCE JOBS IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT
FROM THE POWER MAINS.

MAINTENANCE SCHEDULE
These maintenance intervals are recommended for work environments that are not dusty and are will ventilated. For particularly dusty
environments, double the frequency of controls.

 Drain condensate from the air tank

Every Day (after use)  Check automatic condensation emptying
Every 50 working hours  Drain condensate from the oil collector
 Check the oil level
 Clean the filtering panel

Every 500 hours  Clean the air suction filter (see control board LED)

Every 2000 hours  Change the oil (see control board LED)
 Change the oil filter (see control board LED)
 Change the suction filter (see control board LED)

Every 4000 hours  Clean the finned surface of the air-oil cooler
 Change the oil separating filter (see control board LED)
 Greasing motor bearings
Every 8000 hours  Visual inspection of motor element elastic coupling

N.B.: THE OPERATIONS MARKED  ARE DESCRIBED IN PART "A" OF THIS MANUAL ON CHAPTER 15.3

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22.0 CHANGING THE OIL

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. 23.
- Completely fill the oil collector Ref. 2 Fig. 23.
- Pour a little oil into the suction unit.
- Start the compressor.
- After about 1 minute switch off the machine by pressing “STOP” (Ref. 3 Fig. 23) after 50 seconds of idle running the machine will switch
off.
PROCEED AS DESCRIBED AT POINT CHAPTER 15.4

2 FIG. 23
2
OIL

1 3

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.
Extending the use of the oil over the scheduled replacement interval result in the risk of fire. If the compressor is used at high
temperatures or in particularly severe conditions, we advise shorter oil replacement interval.
DO NOT TOP UP WITH DIFFERENT OILS

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23.0 REPLACE THE DE-OILER 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.
Before proceeding with the replacement of the de-oiler filter or the oil filter check that there is no pressure in the machine: check the
pressure gauge Ref. 1 Fig. 24.
- Lubricate the filter seals with a little oil before fitting.
- Tightening must be done by hand.

FIG. 24

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24.0 GREASING MOTOR BEARINGS (CONTROLLER STANDARD)

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: (Fig. 25)
- Switch off machine
- Remove machine rear panel Rif. 1.
- Before lubricating, clean the up grease nipple and immediate vicinity thoroughly.
- Lift grease inlet protection
- Remove the grease outlet plug
- Pump in approximately half of the total grease indicated on motor data plate (7grams)
- Close rear panel Rif. 1.
- Press down arrow on controller Ref. 4, till parameter "t. 03 "Regreasing is shown on Display Ref. 5, then press Enter button Ref. 6.
- Insert password (1807), and enable Regreasing procedure changing set from "OFF" to "ON" and press Enter Ref. 6.
- Press start button Ref. 7, the compressor start and will run for 60 seconds at 1560 rpm. When regreasing time will be elapsed controller will
reset automatically to return to standard operative conditions.
- Remove machine rear panel Ref. 1.
- Pump in the remaining grease.
- Lower again the grease inlet protection Ref. 2 and close reinstall the grease outlet protection Ref. 3.

DURING THE REGREASING COMPRESSOR REMAIN IN OFF LOAD CONDITION AT 1560RPM.

DURING THIS MAINTEINANCE PHASE IT’S NOT POSSIBLE TO STOP IT BY PUSHIN STOP BUTTON.
IN CASE OF EMERGECY IT’S ALWAYS POSSIBLE TO STOP THE MACHINE BY PUSHING THE EMERGENCY STOP
BUTTON.
When emergency will be resetted the compressor start regreasing phase again for the residual time. When this time will
be elapsed compressor recovery automatically it normal working condition.

5
FIG. 25

1 7

6
4

Grease: KLUBER SYNTH BHP 72-102

Quantity Quantity
of 7 grams of 7 grams
(A) (B)
Motor
 
HP 15
Motor
 
3 HP 20

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24.1 GRAPHIC CONTROLLER; MOTOR BEARING LUBRICATION

BEFORE PERFORMING ANY MAINTENANCE THE MACHINE MUST BE STOPPED, DISCONNECT THE MACHINE FROM
THE ELECTRIC SUPPLY AND FROM THE COMPRESSED AIR DISTRIBUTION CIRCUIT, CHECK THAT THE MACHINE IS
NOT UNDER PRESSURE.

LUBRIFICATION WITH GREASE BLISTERS

- Switch off machine
- Remove machine rear panel Ref. 1 Fig. 25
- Before lubricating, clean the up grease nipple and immediate vicinity thoroughly.
- Lift grease inlet protection
- Remove the grease outlet plug
- Pump in approximately half of the total grease indicated on motor data plate (7 grams).
- Close the panel (fixed protection) Ref. 1 Fig. 25

Follow procedure below:

- Restore supply voltage
- Active lubricating menu on controller

- Insert password (1807), and enable Regreasing procedure changing set from “OFF” to “ON”.

- Come back to manin menù then press Start button, the compressor Start and will run for 60 seconds at 1560 rpm. When Regreasing
time will be elapsed controller will reset automatically to return to standard operative conditions

- Remove machine rear panel Ref. 1 Fig. 25

- Pump in the remaining grease
- Lower again the grease inlet protection Ref. 2 and close reinstall the grease outlet protection Ref. 3 Fig. 25

- During regreasing it is not possible to stop the unit

- Anyway the operator can always “STOP” the unit by pressing emergency “STOP”push button.
- Once reset is done the machine can restart and wil complete the regreasing cycle automatically.
- At the end of the regreasing cycle the standard operating conditions wil be automatically restored.

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25.0 OLEOPNEUMATIC DIAGRAM

1 SUCTION FILTER
2 SUCTION REGULATOR
3 SCREW COMPRESSOR
4 OIL DISCHARGE VALVE
5 AIR-OIL PRESEPARATOR
6 OIL FILTER
7 THERMOSTATIC VALVE
8 AIR-OIL COOLER
9 PRESSURE SENSOR
10 MINIMUM PRESSURE VALVE
11 AIR-OIL SEPARATOR
12 PRESSURE GAUGE
13 SAFETY VALVE
14 TEMPERATURE SENSOR
15 ELECTRIC MOTOR
16 NO-LOAD RUNNING SOLENOID VALVE
17 OIL LEVEL
18 BLED VALVE

AIR CIRCUIT

OIL CIRCUIT

CONTROL CIRCUIT

26.0 "IVR" VARIABLE SPEED

The “IVR variable speed” version of the machine is controlled by an INVERTER.

The equipment is set in the factory and no adjustments to the parameters are required.
The modulating pressure is set at 0.5 bar (7,2 °F)lower than maximum pressure: depending on the air intake, the INVERTER changes the
motor speed.
SETTING THE MODULATION PRESSURE
The compressor modulating pressure is set at 0.5 bar (7,2 °F)less than maximum pressure. By changing this value (Parameter P4), the
maximum pressure level is also changed.

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