ENGLISH

Code
USE & MAINTENANCE MANUAL 9828093469 00

SILENCED ROTARY SCREW COMPRESSOR UNITS Edition 03/2021

HP 40 – 50 VSD PM KW 30 - 37 VSD PM

(VSD PM ): Variable speed air-compressors with permanent magnet motors


READ THIS MANUAL CAREFULLY BEFORE ANY OPERATION ON THE COMPRESSOR UNIT.

WARNING: CAPACITORS INSIDE INVERTER MAY REMAIN CHARGED FOR 15 MINUTES AFTER THE UNIT HAS BEEN
DISCONNECTED FROM MAIN SUPPLY.
WAIT AT LEAST 15 MINUTES AFTER POWER SUPPLY HAS BEEN REMOVED BEFORE PERFOM SERVICE OR REPAIR TO
AVOID DEATH OR SERIOUS INJURY.
BEFORE PERFORMING ANY OPERATION, ALWAYS TAKE STEPS TO ENSURE THAT THERE IS NO LONGER ANY VOLTAGE
PRESENT IN THE MACHINE AND INVERTER.
CONTENTS
PART A: INFORMATION FOR THE USER 17.0 SCRAPPING THE UNIT
1.0 GENERAL FEATURES 18.0 LIST OF SPARE PARTS FOR ROUTINE MAINTENANCE
2.0 INTENDED USE 19.0 TROUBLE-SHOOTING AND EMERGENCY REMEDIES
3.0 OPERATION
4.0 GENERAL SAFETY STANDARDS PART B: INFORMATION RESERVED FOR TECHNICALLY SKILLED
PERSONNEL
5.0 DESCRIPTION OF DANGER SIGNALS 20.0 STARTING UP
6.0 DANGER ZONES 21.0 GENERAL ORDINARY MAINTENANCE REQUIRES TRAINED
PERSONNEL
7.0 SAFETY DEVICES 22.0 REPLACING OIL AND OIL FILTER
8.0 POSITION OF PLATES 23.0 REPLACING OIL SEPARATOR FILTER
9.0 COMPRESSOR ROOM 25.0 OLEOPNEUMATIC DIAGRAM
10.0 TRANSPORT AND HANDLING 26.0 CALIBRATION FOR DRYER
11.0 UNPACKING 27.0 “IVR" VARIABLE SPEED
12.0 INSTALLATION
13.0 DIMENSIONS AND TECHNICAL DATA
14.0 MACHINE ILLUSTRATION IMPORTANT: A COPY OF THE WIRING DIAGRAMS CAN BE FOUND IN
14.1 GENERAL SET-UP OF AIR COMPRESSOR (AND DRYER) THE ELECTRIC CABINET OF COMPRESSOR.
14.2 COMMAND AND CONTROL PANEL
14.3 TOUCH CONTROLLER
14.4 WEB SERVER
15.0 ORDINARY MAINTENANCE TO BE DONE BY THE USER
16.0 PERIODS OF INACTIVITY

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MACHINE AND MANUFACTURER IDENTIFICATION DATA

1) 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 required, we recommend that
you contact a technical service centre authorised by the manufacturer and insist that original spare parts are used.
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 work 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 MAINTENANCE ON ELECTRICAL PARTS, MUST BE PERFORMED BY PROFESSIONALLY SKILLED PERSONNEL.

THIS MACHINE IS NOT SUITABLE FOR EXTERNAL INSTALLATION

THIS MACHINE CORRESPONDS TO THE ESSENTIAL SAFETY REQUIREMENTS FORESEEN FROM THE EUROPEAN STANDARD (2006/42
CE).

CAUTION: The compressor controller contains an integrated radio module with an integrated antenna with a maximum
radiated RF power of 2 Watts!
The compressor controller must not be continuously activated by an operator, but only for maintenance and parameter
changes. If the internal controller antenna is used, the operator stand more than 20 cm away from the controller. If the
external antenna is used it shall be placed minimum 20 cm away from an operator. Only the assigned operator can
intervene on the controller with their hands and change the settings, but they must always keep a distance of at least 20 cm
from the antenna.

CAUTION: If the EMERGENCY BUTTON IS PRESSED, the inverters safely stops the motor according to legislation (Safety
Torque Off). However, in compressors with permanent magnets, this function DOES NOT REMOVE THE VOLTAGE FROM
THE INVERTER. Before performing any check or maintenance operation, REMOVE THE POWER SUPPLY!
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.

SAFETY VALVE
The safety valves of the oil receiver must be checked every year and replaced in accordance with legislation in force.

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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 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)
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 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.
3.0 OPERATION
3.1 OPERATION FOR COMPRESSOR
The electric motor and the compressor unit are coupled by means of a gear transmission.
The compressor unit takes in the outside air through the suction valve. The air taken in is filtered by the 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 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. 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 reclaimer, and the compressed air leaves the, machine via the outlet.
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 in order to
prevent the condensate from freezing inside the evaporator.
The dryer operates in a fully automatic manner; it is factory-calibrated, with a dew point of 5 °C and, therefore, no further calibration is
required.
DRYER FLOW DIAGRAM

AIR OUTLET
AIR INLET

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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.
ENSURE THAT THERE ARE DISCONNECTOR SWITCH AND FUSES UPSTREAM THE MACHINE. FOR DETAILS (SIZE AND TYPE)
SEE WIRING/SERVICE DIAGRAM.

ALL WORK ON THE ELECTRIC PLANT, HOWEVER SLIGHT, MUST BE CARRIED OUT BY PROFESSIONALLY SKILLED
PERSONNEL.

5.0 DESCRIPTION OF DANGER SIGNALS

1) FLUID EJECTION 6) HOT PARTS

2) DANGEROUS ELECTRIC VOLTAGE 8) MOVING PARTS

3) AIR NOT FIT FOR BREATHING 9) MACHINE WITH AUTOMATIC START

4) NOISE

5) HIGH PRESSURE

5.1 DESCRIPTION OF COMPULSORY SIGNALS

11) READ THE USE AND MAINTENANCE

INSTRUCTIONS

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6.0 DANGERS ZONES

6.1 DANGERS ZONES FOR COMPRESSOR UNIT

Risks present on the whole machine

2
2
2

3
1
2

FIG. 1

1 2 3 5 8

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6.2 DANGERS ZONES FOR DRYER UNIT

Risks present on the whole machine

FIG. 2

2
2
3
8
2 5

1 2 3 5 8

7.0 SAFETY DEVICES

7.1 SAFETY DEVICES FOR SCREW COMPRESSOR (Fig. 3)
1) Safety screws 4) Emergency stop button with mechanical seal and
rotation release.
2) Side panels and electrical panel door, opened with a special key 5) Oil filling cap (with safety breather)
3) Mobile protection device - cooling fan 6) Safety valve

3 5

FIG. 3

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7.2 SAFETY DEVICES FOR DRYER UNIT

1) Fan guard 2) Ground connection

FIG. 4

8.0 POSITION OF PLATES

8.1 POSITION OF THE DANGER PLATES FOR COMPRESSOR UNIT
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 Code 1079990348 2) Plate “Machine with automatic start” 2202260791

FIG. 5

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8.2 POSITION OF THE DANGER PLATES FOR DRYER UNIT
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 Code 1079990348

FIG. 6

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8.3 POSITION OF THE DATA PLATE FOR COMPRESSOR UNIT

1) Identification plate

FIG. 7

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8.4 POSITION OF THE DATA PLATE FOR DRYER

FIG. 8

9.0 COMPRESSOR ROOM

9.1 FLOOR
The floor must be even and of industrial type; the total weight of the machine is shown in the Chap. 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 or lower than 4 °C.
The volume of the room must be about 60 m3. The room must be provided with 2 openings for ventilation with a surface area of about 1,9m2
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 extract fit a filtering panel on this opening.
9.3 EXAMPLES OF VENTILATION OF THE COMPRESSOR ROOM FIG. 9

CAUTION: Removable pipe to Hot air pipe

allow cleaning of the radiator.

Fan air output

Please ensure the appropriate composition of the air within the machine room: - clean with no damaging contaminants (e.g., dust, fibers,
fine sand) - free of explosive or chemically unstable gases or vapors - free of acid/alkaline forming substances, particularly ammonia,
chlorine or hydrogen sulfide.
Similar failures shall affect warranty reimbursements.

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10.0 TRANSPORT AND HANDLING
The machine must be transported as shown in the following figures.
FIG. 10

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 contact the manufacturer or to your dealer. The packing material (plastic bags) 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.

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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. 11).

FIG. 11

MINIMUM mt 1,5

THREE PHASE SCREW-COMPRESSOR-

DRYER SUPPLY CABLE.

PROTECT THE POWER SPACE FOR MAINTENANCE

CABLE WITH A SUITABLE MINIMUM mt 1,5
CHANNEL

THREE-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.
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 cables and ensure that there is an efficient earth lead.
• Ensure that, upstream from the machine, there is a disconnect switch and fuses for the compressor and dryer. For details (size
and type) see wiring/service 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.
• Connect the cables to the power supply terminals on the electrical panel and make sure they are properly tightened. 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.

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12.3 CONNECTION TO THE COMPRESSED AIR NETWORK

Isolation (ball) valve Ref. 1 between the machine and the compressed air network so that the compressor may be isolated during
maintenance operations (see figure 12).

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 INSTRUCTIONS OF THE
REGULATIONS IN FORCE IN THE COUNTRY OF USE.

THE COMPRESSOR MUST BE CONNECTED TO A TANK

FIG. 12
ALWAYS USE A FLEXIBLE COMPLETE WITH SAFETY VALVE (CAT. “IV” P.E.D. 2014/68/EU).
PIPE

2 2

The automatic condensate drain Ref. 2 Fig. 12, are led outside the machine with a flexible pipe that may be inspected. Drainage must
comply with the local regulations in force.

THE MANUFACTURER CANNOT ACCEPT LIABILITY, FOR ANY DAMAGE AND OR FAILURE CAUSED BY FAILURE TO
COMPLY WITH THESE INSTRUCTIONS.

12.4 STARTING UP
See part B of this manual, Chapter 20.0

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13.0 DIMENSIONS AND TECHNICAL DATA

Dimensions (mm) Air connection Dimensions (mm) Air connection

L W H D L W H D
HP 40 - 50 HP 40 - 50
kW 30 - 37
1320 830 1555 1”1/4 1810 830 1555 1”1/4
kW 30 - 37

Weight Kg. Weight Kg.

HP 40 - kW 30 480 HP 40 - kW 30 598
HP 50 - kW 37 510 HP 50 - kW 37 628

HP 40 - kW 30 HP 50 - kW 37
Max. pressure bar - 10 13 - 10 13
Nominal pressure bar 7 9.5 12.5 7 9.5 12.5
Standard air capacity m3/h: 356 305 251 428 377 303
Noise product. dB(A) 67 70
Oil operation setting °C 71 71
Oil load lt. 21 22

HP 40 - kW 30 HP 50 - kW 37
Max pressure PSI 107 157 182 107 157 182
Nominal pressure PSI 100 150 175 100 150 175
Standard air flow rate m3/h: 344 285 249 418 350 297
Noise product. dB(A) 67 70
Oil operation setting °C 71 71
Oil load lt. 21 22

bar
Type Freon Nominal Nominal Nominal MAX.
Power
Dryer R 410A Kg. Power Power W
W W

50 Hz 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz
E10SX-S90 See data plate dryer 1665 1810 135 190 1800 2000 14
bar
Type Freon Nominal Nominal Nominal MAX.
Power
Dryer R 513A Kg. Power Power W
W W

60 Hz 60 Hz 60 Hz 60 Hz
E10SX-S90-CSA See data plate dryer 1860 220 2080 14

Reference conditions: Limit conditions:

Ambient temperature 25 °C Max. ambient temperature 46°C
Inlet air temperature 35 °C Min. ambient temperature 4°C
Pressure 7 bar Max. working pressure 14 bar
Dew point in pressure 3 °C

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14.0 MACHINE ILLUSTRATION
14.1 GENERAL SET-UP OF AIR COMPRESSOR (AND DRYER)
1 Air suction filter 13 Pressure gauge tank
2 Thermostatic valve 14 Controller
3 Oil filter 15 Safety valve ()
4 Air-oil cooler 16 Fan motor
6 Minimum pressure valve 17 Electric motor
7 Air-oil separator with oil separating filter 18 Screw compressor
8 Oil top-up or filling cap 19 Suction unit
9 Emergency stop push button 20 Water separators and drains (WSD) (Option)
10 Oil gauge
11 Oil discharge  IT IS FORBIDDEN TO TAMPERE WITH THE
12 Oil tank PRESSURE SETTING OF THE SAFETY VALVE

6
4 1
13

16 7

12

8
2

11 10 3

20

19 18 17 14

24 9
21 Refrigerant compressor
22 Condenser
23 Motor fan 26
24 Evaporator
25 Condensate drain 25
26 Hot gas by-pass valve
22
27 Refrigerant filter 28
28 Expansion capillary tube
27

15
23
FIG. 13 21

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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. 14

2
1) Control panel
2) Emergency stop button
with mechanical lock and
rotation release
1

14.3 TOUCH CONTROLLER

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 modifies 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 (converter) or main motor
• Overload of the fan motor
• Incorrect supply sequence (Only for fixed speed machines and all machines with dryer).
• Failure inverter (Only for VSD machines)
• Additional thermostat operation.
• Pressure sensor error.
Example: Temperature sensor error on air outlet of compressor unit. 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.

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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 dew-point temperature for dryer equipped units
• Too high pressure at the compressor element outlet
Example: Too high dew-point temperature for dryer equipped units. In chapter “Shut-down warning 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 (ARAVF).

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. To activate it please contact the customer centre.

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

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Control panel

FIG. 15

Function keys of the controller

Reference Designation Function

1 Touchscreen Shows the unit operating condition and a number of icons to

navigate through the menu.
The screen can be operated by touch.

2 Warning sign Flashes in case of a shut-down, is lit in case of a warning

condition.
3 Service sign Is lit when service is needed.

4 Operation sign Is lit when the unit is running in automatic operation.

5 Voltage sign Indicates that the voltage is switched on.

6 Stop button This button stops the unit.

7 Start button This button starts the unit. The operation sign (4) lights up. The
controller is operative.

CAUTION: WAIT AT LEAST 20 SECONDS BEFORE STARTING THE MACHINE AFTER SWITCH OFF.

CAUTION: IN CASE OF START UP OR RESTART AFTER EMERGENCY STOP /ARAVF/ SHUT DOWN (SEE INSTRUCTION
BOOK), REFRIGERANT DRYER WILL RUN AFTER A DELAY OF 180 SECONDS.

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Menu icons

Menu Icon Menu Icon Menu Icon

Data Status

Inputs

Outputs

Counters

Aux. Equipment Converters

parameters

Service Service Overview

Service plan

Service History

Service functions

Clean Screen

Week Timer Week

Remaining running
time

Event history Saved Data

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Menu Icon Menu Icon Menu Icon

Machine Alarms
Settings

Regulation

Control
Parameters

Auxiliary Converter(s)
equipment
parameters
Fan

Internal SmartBox

Automatic restart

Controller Network Ethernet

Settings Settings Settings

CAN Settings

Localisation Language

Date/Time

Units

User Password

Help

Information

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Status icons

Icon Description
Motor Stopped

Motor Stopped Wait

Running Unloaded

Manual Unload

Running Unloaded Wait

Running Loaded

Failed to Load

Running Loaded Wait

Manual Stop

Machine Control Mode, Local

Machine Control Mode, Remote

Machine Control Mode, LAN

Automatic Restart After Voltage Failure

Week Timer Active

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System icons

Icon Description
Basic User

Advanced User

Service User

Antenna 25%

Antenna 50%

Antenna 75%

Antenna 100%

Change between screens (indication)

Energy recovery

Dryer

Element

Drain(s)

Analogue Output

Menu

Reset

Automatic restart

Filter(s)

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Cooler

Valve(s)

Power Meter

Input icons

Icon Description
Pressure

Temperature

Special Protection

Open

Closed

This chapter gives a general survey of available icons. Not all icons mentioned in this chapter are applicable to
every machine.

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Main screen
Function
The Main screen is the screen that is shown automatically when the voltage is switched on. It is switched off
automatically after a few minutes when there is no touch input.

Description

Reference Designation Function

1 Home button The home button is always shown and can be tapped
to return to the main screen.
2 Screen information On the main screen, the screen information bar shows
the serial number of the machine. When scrolling
through menus, the name of the current menu is
shown.
3 Access level button The access level button is always shown and can be
tapped to change the current user access level.

Reference Designation Function

4 Alarm button The alarm button can be tapped to show the current
alarms. If an alarm occurs, the icon on the button will
be red.
5 Service button The service button can be tapped to show the service
information.
6 Status This icon shows the current status of the unit.
7 Page indicator Indicates which page you currently see. The middle
indication is the main screen, left is the menu screen
and at the right the quick access screen.
Swipe left or right to go to another screen.

8, 9, 10, 11 These fields can contain a history chart, an input or a Tap the field to view the type of measurement.
counter value, depending on the type of the machine. This will be shown in the screen information bar.
Examples of inputs:
• Outlet Pressure
• Oil temperature
• Dryer dewpointExamples of counters:
• Running hours
• Load relay
• Loaded hours

12 Menu button The menu button is always shown and can be tapped
to go to the menu.

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Quick access screen

Function
The screen is used to directly access some frequently used functions.

Procedure
The Quick access screen can be viewed by swiping left, starting from the main screen.

Description

Through this screen, several important settings can be viewed and modified.

Function Description

Setpoints Several setpoints can be modified by tapping this icon.

Control mode The control mode can be changed by tapping this icon.
• Local command via start/stop buttons
• Remote control through digital input(s)

Display language The display language of the controller can be changed by tapping this icon.

Manual unload (only on When tapped, the machine will go in Manual unload mode until the icon is tapped again.
fixed speed units)
Week timer Week timers can be set by tapping this icon.

Remaining running time The Remaining running time can be set and modified by tapping this icon.

Internal SmartBox
The reception quality of the internal antenna can be monitored.
Each bar represents 25% reception strength. If the four bars are filled, the reception strength is 100%.
If only one bar is filled, the reception strength is just 25%.

Automatic restart Auto restart can be activated by tapping this icon.

Shut-down warning

If the element’s outlet temperature exceeds the shutdown warning level (see “Programmable Settings” section), the
warning LED (2) will light up and a yellow warning icon (4) will be displayed on the upper side of the screen, as shown
in the image below:

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Tap on the select warning icon (4) to see the Status menu.
In case of element outlet temperature warning, the display will appear as below:

It remains possible to scroll through other screens, to check the actual status of other parameters. Press stop key (7) to
stop the unit and wait until the unit has stopped. Switch off the voltage, inspect the unit and remedy. The warning
message will disappear as soon the warning condition disappears.

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Safety shutdown
Description
The unit will be shut down in following circumstances:
• In case the element’s outlet temperature element exceeds the programmed shut down level (detected by
temperature sensor TT11).
• In case the main temperature switch (TSHH11) open for too high oil temperature detected .
• In case of too high air/oil temperature (detected by additional temperature switch (TSHH12)).
• In case of inverter alarms or fan motor overload (M2).
• In case of error of the outlet pressure sensor (PT20).
Element outlet temperature (TT11)
If the element outlet temperature, measured by temperature sensor TT11, exceeds the shutdown level (see section
Programmable settings), the unit will be shutdown, alarm LED (2) will flash, automatic operation LED (4) will go out and
the following screen will appear:

Status screen with shutdown indication

Press on shutdown indication on the screen.

Shutdown screen, element outlet temperature

The above screen shows that the temperature at the outlet of the element is 116 ˚C. Actions:

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• Switch off the voltage and remedy the problem cause.
• After remedying and when the shutdown condition has disappeared, switch on the voltage, reset the alarm and
restart the unit.

Other shutdown causes

In case the unit is shut down (or cannot start) by one of following causes:
• Too high element outlet temperature detected by temperature switch (TSHH11) or additional temperature switch
(TSHH12).
• Fan motor overload (M2).
• Main converter alarm.
The unit will be shutdown, alarm LED (2) will flash, automatic operation LED (4) will go out and following screen will
appear:

Main screen with shutdown indication

Actions:
• Switch off the voltage and remedy the problem cause.
• In case of incorrect phase sequence, reverse two phases of the supply cable. (only fixed-speed compressors)
• If the additional temperature switch (TSHH12) has tripped, you must contact the customer center.
• If the main converter alarm is activated, customer support must be contacted.
• After remedying and when the shutdown condition has disappeared, switch on the voltage and restart the unit.
The shutdown message will disappear automatically when the shutdown condition has disappeared.

IF FREQUENCY CONVERTER ALARM RESET does not work:

- Disconnect the unit from power supply for 5 minutes.
- After the power supply is restored, RESET the frequency converter alarm on the electronic controller.
If the problem persists, contact the technical service centre.
Caution: wait 15min before performing any check on the power and supply connections.

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Main frequency converter warnings and alarms

In case of propagation of alarm codes that are not present in the below table, contact the service centre.

Inverter
Touch controller alarm
fault Fault text Warning Alarm Cause of problem
(dec)
(hex)

5023 20515 One or more of the inverter’s STO contacts are

open: Either the emergency stop button has been
5020 20512 Safety Torque Off (STO) X X pressed, or the K7 auxiliary relay intervened
because the TSHH11-12 safety thermostats or the
5021 20513 Q15 fan thermal fuse were triggered
Problems while initialising and launching the
communication, the K09 controller output could
6122 24866 SW CAN stack init fault continue to switch. Disconnect the power supply
and wait for 5min, then start up the machine again.
If the problem persists, contact the service centre.
Communication problems following loss of
8103 33027 SW CAN stack timeout connection or damaged cable. Check that the CAN
X X bus cable and the connectors are intact. Check that
the controller side connector micro-switch is ON
(integrated termination resistor). The K09 controller
output could keep switching. Attempt a reset to
8131 33073 SW CAN stack NG timeout restore communication. If this doesn’t solve the
problem, try turning the machine off for 5min and
then back on again. If the problem persists, contact
the service centre.
Fault in the connections of the controller’s K09
hardware gear release. Check the connection
9001 36865 HW Enable missing x x
cables between the controller’s K09 relay and digital
input 1 on the inverter (see diagram)
Disconnect the machine’s power supply and let it
2312 8978 - SW Inverter overcurrent x x cool. Check that the oil level is good and check the
supply voltage. Wait 15min and check the motor
connections are tightened both on the inverter side
2314 8980 - HW Inverter overcurrent x x and in the motor base. Try to connect the power
supply and reset. If the problem persists, contact the
service centre.
2313 8979 - SW Max common mode current x x Possible current leakage to ground due to isolation
failure between the motor cable and coils.
2315 8981 - HW Max common mode current x x Disconnect the power supply and contact the
service centre.
Supply voltage too low or unstable. Check that the
3221 12833 SW DC-Link undervoltage x x
supply voltage is correct and that no loads requiring
high inrush current (large fixed-speed motors,
5401 21505 HW Main inverter power fault x x
ovens, or welding machines) are connected near
the machine. If the problem persists, contact the
3222 12834 HW DC-Link undervoltage x x
service centre

3135 12597 SW DC-Link fluctuation x x Unstable supply voltage. Check that the installed
electric power is sufficient to supply the machine
3210 12816 SW DC-Link overvoltage x x and that no loads requiring high inrush current
(large fixed-speed motors, ovens, or welding
machines) are connected near the machine. If the
3211 12817 HW DC-Link overvoltage x x problem persists, contact the service centre

Error in identifying the correct rotor position on start-

8403 33795 SW Negative speed x x up. Reset and try to restart. Try to disconnect the
power supply from the machine for 5min, then
SW IPM Init position sequence reconnect and try to restart. If the problem persists,
612E 24878 x x
failed contact the service centre.
4311 17169 SW IGBT overtemperature x x Insufficient or absent inverter-cooling air flow. Check
that the IP54 filters on the panel door are clean.
4320 17184 SW PB PCB overtemperature x x
Check that the inverter ventilators are working and
4321 17185 SW CB PCB overtemperature x x that the air suction grates below the inverter and the
air discharge grates above it are unobstructed. If the
HW Inverter IGBT
4337 17207 x x problem persists, contact the service centre.
overtemperature
Excessive current output from the drive for too much
4335 17205 SW Drive I2t x x
time. Contact the service centre.

The motor has received excessive current for too

4344 17220 SW Motor I2t x x much time (motor overload). Contact the service
centre.

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Menu screen
Function
This screen is used to display the different menus where settings can be viewed or changed.

Procedure
The Menu screen can be viewed by tapping the Menu button or by swiping right, starting from the main screen.

Description

Reference Designation Function

(1) Data The data menu contains the status of the unit, information about the Inputs,
Outputs and Counters. The Auxiliary equipment can also be viewed through this
menu.
(2) Service The service menu contains the Service information. The ‘Clean screen’ function
can be used to clean the touchscreen.
(3) Week timer Multiple Week timers and a Remaining running time can be set through this menu.

(4) Event history In case of an alarm, the Status information of the unit is saved and can be viewed
through this menu.
(5) Machine settings Alarms settings, Regulation settings and Control parameters can be changed
through this menu. Auxiliary equipment parameters can also be changed.
The Auto restart function can be set through this menu. This function is password
protected.

(6) Controller settings Network settings, Localization settings and a User password can be set through
this menu. There is also a Help page available and the Controller information can
be shown.

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Menu structure

Operating the controller can be done by swiping through screens and tapping icons or menu items.

This is the main menu structure. The structure can be different depending on the configuration of the unit.

Data menu
Function
This screen is used to display the following submenus:
• Status
• Inputs
• Outputs
• Counters
• Aux. Equipment
These submenus can be entered by tapping the icons.

Procedure
To enter the Data menu screen:
1. Tap the Menu button
2. Tap the Data icon
Description

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Reference Designation

(1) Status menu

(2) Inputs menu

(3) Outputs menu

(4) Counters menu

(5) Auxiliary equipment menu
Status menu
Tap the Status icon to enter the Status menu.

This menu shows the current status of the unit.

If an alarm is active, it can be viewed by tapping the alarm message. To reset an alarm, tap the reset button (1).
Consult the Safety precautions before performing the repair.
Before resetting a warning or shutdown message, always solve the problem. Frequently resetting these
messages without remedying may damage the unit.

Inputs menu
Tap the Inputs icon to enter the Inputs menu.

This menu shows information about all the inputs.

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Outputs menu
Tap the Outputs icon to enter the Outputs menu.

This menu shows information about all the outputs.

Voltage-free outputs may only be used to control or monitor functional systems.

They should NOT be used to control, switch or interrupt safety related circuits.
Check the maximum allowed load on the label.
Stop the unit and switch off the supply before connecting external equipment. Check the Safety precautions.

Counters menu
Tap the Counters icon to enter the Counters menu.

This menu shows an overview of all actual hours and counters of the unit and controller.

Auxiliary equipment menu

Tap the auxiliary equipment icon to access the auxiliary equipment menu.

This menu shows an overview of all the auxiliary equipment fitted.

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Service menu
Function
This screen is used to display the following submenus:
• Service
• Service functions (Only visible as advanced user)
• Clean Screen
These submenus can be entered by tapping the icons.

Procedure
To enter the Service menu screen:
1. Tap the Menu button
2. Tap the Service icon

Description

Reference Designation

(1) Service

(2) Service functions (Only visible as advanced user)

(3) Clean Screen

Service menu
Tap the Service icon to enter the Service menu.

This menu shows the remaining Running Hours and the remaining Real Time Hours until the next service. The first row
(A) shows the Running Hours when the first service is needed (green), the second row shows the Real Time Hours
(blue)
A service overview can be viewed by tapping icon (1).
The service plan can be viewed by tapping icon (2). Through this menu, the service plan can be modified:
1. Tap the desired service plan. A selection screen pops up.
2. Change the Running Hours by tapping ‘–’ or ‘+’.
3. Confirm by tapping ‘V’ or decline by tapping ‘X’.
The service history can be viewed by tapping icon (3).
When a service plan interval is reached, a message will appear on the screen. When service has been performed, the
service timer can be reset by tapping the reset button (4).

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Service functions (Only visible as advanced user)

Tap the Service Functions icon to enter the Service Functions menu.

Depending on the machine, this menu can have a different set of functions. Many of them are password protected, as
they are only accessible for authorized personnel.

Clean Screen
Tap the Clean Screen icon to start the 15 seconds countdown to perform cleaning of the touchscreen.

The touchscreen and the start and stop button become inactive for 15 seconds.

Week timer menu

Function
This screen is used to set up to 4 different week timers with each up to 8 settings per day.
The week timers can be activated through this screen.
A Remaining Running Time can be set from 5 up to 240 minutes.

Procedure
To enter the Week Timer menu screen:
1. Tap the Menu button
2. Tap the Week Timer icon

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Description

Reference Designation Function

(1) Add or select week If less than 4 weeks are programmed, tap the ‘+’ button to add a week.

(2) Remove week Tap to remove a programmed week timer.

(3) Activate week timer A selection screen pops up. The user can choose the correct week by tapping ‘–’ or
‘+’ and can confirm by tapping ‘V’ or decline by tapping ‘X’.

(4) Remaining running time A selection screen pops up. The user can change the remaining time by tapping ‘–’
or ‘+’ and can confirm by tapping ‘V’ or decline by tapping ‘X’.

(5) Add setting A selection screen pops up. The user can change this setting by scrolling up or
down and confirm by tapping “V” or decline by tapping "X".

Event history menu

Function
This screen is used to display the saved data in case of an alarm.
These submenus can be entered by tapping the icons.
Procedure
To enter the Event history menu screen:
1. Tap the Menu button
2. Tap the Event History icon

Description

Reference Designation
(1) Saved Data

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Saved Data

Tap the Saved Data icon to enter the Saved Data menu.

Scroll through the items swiping up and down in this list. The event date and time is shown at the right side of the
screen.
Press on one of the items in the list for more information reflecting the status of the unit when the shutdown occurred.

Machine settings menu

Function
This screen is used to display the following submenus:
• Alarms
• Regulation
• Control Parameters
Only visible if the machine has adaptable parameters.
• Aux. Equipment parameters
• Automatic restart
These submenus can be entered by tapping the icons.
Procedure
To enter the Machine settings menu screen:
1. Tap the Menu button
2. Tap the Machine Settings icon

Description

Reference Designation

(1) Alarms menu

(2) Regulation menu

(3) Control Parameters menu

(4) Auxiliary equipment parameters menu

(5) Auto restart menu

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Alarms menu
Tap the Alarms icon to enter the Alarms menu.

A list of all alarms is shown.

When pressing on one of the items in this list, the warning and/or shutdown levels are shown for this alarm.

Regulation menu

Tap the Regulation icon to enter the Regulation menu.

Setpoints or pressure bands can be modified through this menu.

Modify a setting
When tapping a list item, a selection screen pops up. The user can modify the setting by tapping ‘–’ or ‘+’ and can
confirm by tapping ‘V’ or decline by tapping ‘X’.
Change a selection
When tapping a list item, a selection screen pops up. The user can change the selection by swiping up or down and
confirm by tapping ‘V’ or decline by tapping ‘X’.

Control Parameters menu

Tap the Control Parameters icon to enter the Control Parameters menu.

This menu shows information about the Control Parameters.

Modify a setting
When tapping a list item, a selection screen pops up. The user can modify the setting by tapping ‘–’ or ‘+’ and can
confirm by tapping ‘V’ or decline by tapping ‘X’.

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Auxiliary equipment parameters menu
Tap the auxiliary equipment icon to access the auxiliary equipment parameters menu.

This menu shows an overview of all the auxiliary equipment fitted.

Through this menu, the parameters of the auxiliary equipment can be changed.
Modify a setting
When tapping a list item, a selection screen pops up. The user can modify the setting by tapping ‘–’ or ‘+’ and can
confirm by tapping ‘V’ or decline by tapping ‘X’.

Auto restart menu

Tap the Auto restart icon to enter the Auto Restart menu.

Through this menu, the automatic restart can be activated. The activation is password protected.
The automatic restart settings can also be changed.
Enter a password

When tapping a password protected item, a selection screen pops up. The user can enter the password by swiping up
or down to select the desired number. Once the 4 digits are entered, the user can confirm by tapping ‘V’ or decline by
tapping ‘X’.
Modify a setting

When clicking a list item, a selection screen pops up. The user can modify the setting by tapping ‘–’ or ‘+’ and can
confirm by tapping ‘V’ or decline by tapping ‘X’.

Controller settings menu

Function
This screen is used to display the following submenus:
• Network Settings
• Localisation
• User Password
• Help
• Information
These submenus can be entered by tapping the icons.

Procedure
To enter the Controller Settings menu screen:
1. Tap the Menu button
2. Tap the Controller Settings icon

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Description

Reference Designation
(1) Network Settings menu

(2) Localization menu

(3) User Password menu

(4) Help menu

(5) Information menu

Network Settings menu

Tap the Network Settings icon to enter the Network Settings menu.

Ethernet Settings
The list of Ethernet Settings is shown. When ethernet is turned off, the settings can be modified.
CAN Settings
The CAN settings list is displayed. Once the CAN has been turned off, the settings can be altered.
Modify a setting

When tapping a list item, a selection screen pops up. The user can modify the setting by tapping ‘–’ or ‘+’ and can
confirm by tapping ‘V’ or decline by tapping ‘X’.
Change a selection

When tapping a list item, a selection screen pops up. The user can change the selection by swiping up or down and
confirm by tapping ‘V’ or decline by tapping ‘X’.

Localization menu

Tap the Localization icon to enter the Localization menu.

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Language
The language setting of the controller can be modified through this menu.
Date/Time
The date and time settings of the controller can be modified through this menu.
Units
The units displayed can be modified through this menu.
Modify a setting
When tapping a list item, a selection screen pops up. The user can modify the setting by tapping ‘–’ or ‘+’ and can
confirm by tapping ‘V’ or decline by tapping ‘X’.
Change a selection
When tapping a list item, a selection screen pops up. The user can change the selection by swiping up or down and
confirm by tapping ‘V’ or decline by tapping ‘X’.

User Password menu

Tap the User Password icon to enter the User Password menu.

The user password can be activated or deactivated through this menu. Enter and confirm a user password to activate,
repeat to deactivate.
Enter a password
When tapping a password protected item, a selection screen pops up. The user can enter the password by swiping up
or down to select the desired number. Once the 4 digits are entered, the user can confirm by tapping ‘V’ or decline by
tapping ‘X’.

Help menu

Tap the Help icon to enter the Help menu.

This menu can show a link to the web page of your supplier, a helpdesk phone number or other helpful information.

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Information menu

Tap the Information icon to enter the Information menu.

This menu shows information about the controller.

Access level
Function
Through this pop-up screen the access level settings can be viewed or changed.

Procedure

The Access Level screen can be viewed or changed by tapping the Access Level button at the upper right corner of the
screen.

Description

Reference Designation Function

(1) User A basic set of parameters is visualized, no password required.

(2) Service A basic set of parameters can be modified, no password required.

(3) Full This access level is not accessible to end users.

(4) Decline Tap to decline the selected user level.

(5) Confirm Tap to confirm the selected user level.

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Service access level

Tap the Service access level icon (1) and confirm (2).

The screen information bar (1) now shows the current status of the unit instead of the machine serial number.
The Received Signal Strength Indicator (RSSI) value is now shown in the Internal SmartBox menu.
See Quick access screen.
In the service menu, an extra menu item is now available. See Service menu.

Programmable settings
Parameters
Minimum Factory setting Maximum
setting setting
Number of motor starts starts/day 0 240

Minimum stop time sec 10 20 30

Power recovery time (ARAVF) sec 60 60 3600

Restart delay sec 60 60 1200

Service plan

The built-in service timers will give a Service warning message after their respective preprogrammed time interval has
elapsed.
Also see the relevant section.
Consult customer center if a timer setting has to be changed. The intervals must not exceed the nominal intervals and
must coincide logically. See section Modifying general settings.

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Terminology
Term Explanation

ARAVF Automatic Restart After Voltage Failure. See section Modifying general settings.

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 Customer Center

Restart delay This parameter allows to program that not all compressors are restarted at the same time after a power
failure (ARAVF active).
Compressor The recommended minimum setting is 70 ˚C (158 ˚F). For testing the temperature sensor the setting can
element outlet be decreased to 50 ˚C (122 ˚F). Reset the value after testing. The regulator does not accept illogical
settings, e.g. if the warning level is programmed at 95 ˚C (203 ˚F), the minimum limit for the shutdown level
changes to 96 ˚C (204 ˚F). The recommended difference between the warning and shutdown levels is 10
˚C (18 ˚F).

Term Explanation

Delay at shutdown Is the time for which the signal must exist before the compressor is shut down. If it is required to program
signal this setting to another value, consult Atlas Copco.
Oil separator Use only original oil separators. The recommended maximum pressure drop over the oil separator element
is 1 bar (14,5 psi).
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. Customer center if a setting lower than 20 seconds is required.

Unloading/ The regulator does not accept inconsistent settings, e.g. if the unloading pressure is programmed at 7.0
Loading pressure bar(e) (101 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 0.6 bar (9 psi(g)).

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14.4 Web server

All controllers have a built-in web server that allows direct connection to the company network or to a dedicated PC via
a local area network (LAN). This allows to consult certain data and settings via a PC instead of via the display of the
controller.

Getting started

Make sure you are logged in as administrator.

• Use the internal network card from your computer or a USB to LAN adapter.
• Use a UTP cable (CAT 5e) to connect to the controller (see picture below).

Configuration of the network card

• Go to Network and Sharing Center (1).

• Click on Change adapter settings (1).

• Select the Local Area Connection, which is connected to the controller.

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• Click with the right button and select Properties (1).

• Use the check box Internet Protocol version +4 (TCP/IPv4) (1) (see picture). To avoid conflicts, uncheck other
properties if they are checked. After selecting TCP/IPv4, click on the Properties button (2) to change the
settings.

• Use the following settings:

• IP Address 192.168.100.200 (1)
• Subnetmask 255.255.255.0 (2)Click OK (3) and close network connections.

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Configure a company network (LAN) connection

• Ask your IT department to generate a fixed IP address in your company’s network.

• That IP address will be excluded from the DNS server, so it will be reserved for the controller.
• Also get the correct Gateway and Subnet mask settings. For example:
▪ IP = 10.25.43.200
▪ Gateway = 10.25.42.250
▪ Subnet mask = 255.255.254.0
• Connect the controller to the company's network (LAN) by using a UTP cable (min. CAT 5e).

Adapt the network settings in the controller:

• Go to Main Menu
o Go to Settings (1)
▪ Go to Network (1)
▪ Go to Ethernet (1)
▪ Switch Off (1) the Ethernet communication to allow editing the settings
• Adapt IP Address (1)
• Adapt Gateway IP (2)
• Adapt Subnet Mask (3)
• Switch On (4) the Ethernet communication
Wait a few minutes so the LAN network can connect to the controller

Configuration of the web server

The internal web server is designed and tested for Microsoft® Internet Explorer.
Also "Opera", "Mozilla Firefox", "Safari" and "Chrome" should work.
Viewing the controller data
All screen shots are indicative. The number of displayed fields depends on the selected options.

• Open your browser and type the IP address of the controller you want to view in your browser (in this example
http://192.168.100.100). The interface opens:

Screen shot (example!)

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Navigation and options
• The banner shows the unit type and the language selector. In this example, three languages are available
on the controller.

• On the left side of the interface, you can find the navigation menu.
If a license for ECONTROL is foreseen, the menu contains 3 buttons.
• Machine: shows all generator settings.
• ECO: shows the status (if a license is provided).
• Preferences: allows to change temperature and pressure unit.

Unit settings
All unit settings can be displayed or hidden. Put a check mark in front of each point of interest and it will be displayed.
Only the machine status is fixed and can not be removed from the main screen.
Analog inputs
Lists all current analog input values. The measurement units can be changed in the preference button from the
navigation menu.

Counters
Lists all current counter values from controller and unit.

Info status
Machine status is always shown on the web interface.

Digital inputs
Lists all digital inputs and their status.

Digital outputs
Lists all digital outputs and their status.

Special protections
Lists all special protections of the unit.

Service plan
Displays all levels of the service plan and their status. This screen shot underneath only shows the running hours. It is
also possible to show the actual status of the service interval.

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15.0 ORDINARY MAINTENANCE TO BE DONE BY THE USER

BEFORE PERFORMING ANY MAINTENANCE, IT IS MANDATORY 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 chapter on GENERAL ROUTINE
MAINTENANCE. (See Chap. 21.0)
15.1 GENERAL INFORMATION
15.2 MAINTENANCE PROGRAMME
◼ 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 well ventilated. For particularly dusty
environments, double the frequency of controls.

Every Day (after use) ◼ Check automatic condensation drain (unit with dryer)

Every 50 working hours ◼ Drain condensate from the oil tank

◼ Check the oil level
◼ Clean the filter of the automatic condensate drain (unit with dryer)
◼ Clean the filtering panel
◼ Check the values displayed on the screen.
◼ Ensure that the condensate is drained during the compressor’s load operation.
◼ Check the dew point temperature at pressure (for compressors with an integrated dryer).
◼ Clean the filters on the electrical cabinet door.

Every 500 hours ◼ Tighten the screws fixing the electric cables (at first 500 hrs)
◼ Clean the air inlet filter
◼ Clean the condenser heat exchanger (unit with dryer)
◼ Clean the inlet filtration panels

Every 4000 hours ◼ Replace the inlet air filter

(or at least every year) ◼ Change the dryer's condensate drain filter mesh (unit with dryer)
◼ Replace the filter panel
◼ Replace the line filter (replace the filter cartridge, if present, at least once a year)
◼ Replace the filters on the electrical cabinet door
◼◼ Tighten the electrical cable fastening screws
◼◼ Replace the standard oil or food-grade oil (optional)
◼◼ Replace the oil filter
◼◼ Retighten all power cable connections
◼◼ Safety temperature test
◼◼ Clean the finned surface of the air-oil cooler
◼◼ Service the dryer’s condensate drain (unit with dryer)

Every 8000 hours ◼◼ Replace the oil (optional)

(or at least every 2 years) ◼◼ Replace the oil separator filter
◼◼ Check oil return valve and oil pipes status
◼◼ Service the non-return valve
◼◼ Service the aspiration valve
◼◼ Service the minimum pressure valve and thermostatic valve

Every 24000 hours ◼ ◼ Service the pumping group

◼ ◼ Service the motor group
◼ ◼ Replace the inverter’s internal valve

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The recommended oil change intervals are valid for standard operating conditions and with standard nominal operating pressure (see the
DIMENSIONS AND TECHNICAL DATA section). Shorter oil change intervals will be required in the case of exposure of the compressor to
external pollutants, operation with high humidity and reduced work cycles, or operation at high temperatures.
In case of doubts, contact your supplier.

15.3 Oil specifications

It is strongly recommended to use lubricants suggested by the manufacturer. These lubricants are the result of years of research and
experience in the field. See the Pre-emptive maintenance schedule section for recommended replacement intervals and consult the basic
list
of replacements for information regarding serial numbers.

Avoid mixing different types or brands of oil, as these might not be compatible and could compromise the
properties of the oil mixture. A label indicating the type of oil used in the factory for the first filling is applied to
the external structure.

Rotair Plus
Rotair Plus is a high-quality lubricant for oil-injection screw compressors that maintains them in excellent working conditions.
See the below table for oil change intervals:

Ambient temperature Output temperature of the Replacement interval Maximum interval

element
up to 30 °C (86 °F) up to 95 °C (203 °F) 4000 1 year
from 30 °C (86 °F) to 35 °C from 95 °C (203 °F) to 100 °C 3000 1 year
(95 °F) (212 °F)
from 35 °C (95 °F) to 40 °C from 100 °C (212 °F) to 105 2000 1 year
(104 °F) °C (221 °F)
higher than 40 °C (higher than higher than 105 °C (higher use Rotair Xtra use Rotair Xtra
104 °F) than 221 °F)

Rotair Xtra
Rotair Xtra is a high-quality synthetic lubricant for keeping oil-injection screw
compressors in excellent conditions.
See the below table for oil change intervals:

Ambient temperature Output temperature of the Replacement interval Maximum interval

element
up to 35 °C (95 °F) up to 100 °C (212 °F) 8000 2 years
from 35 °C (95 °F) to 40 °C from 100 °C (212 °F) to 105 6000 2 years
(104 °F) °C (221 °F)
higher than 40 °C (higher than higher than 105 °C (higher 5000 2 years
104 °F) than 221 °F)

Rotair Foodgrade
Rotair Foodgrade is an exclusive high-quality synthetic lubricant, specifically designed for oil-injection screw compressors used in the food
industry. See the below table for oil change intervals:
Ambient temperature Output temperature of the Replacement interval Maximum interval
element
up to 35 °C (86 °F) up to 100 °C (212 °F) 4000 1 year
from 35 °C (95 °F) to 40 °C from 100 °C (212 °F) to 105 °C 3000 1 year
(104 °F) (221 °F)
from 40 °C (104 °F) to 45 °C from 105 °C (221 °F) to 110 °C 2000 1 year
(113 °F) (230 °F)
higher than 45 °C (higher higher than 110 °C (higher than use not advised use not advised
than 113 °F) 230 °F)

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15.4 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 MANDATORY TO STOP THE MACHINE AND DISCONNECT IT FROM THE
POWER MAINS.
Prceed as follows:
- Switch off the machine with pushbutton Ref. 1 Fig. 16: in this way the machine stops after idle time running.
- Disconnect the power supply by means of the disconnector switch, Ref. 3 Fig. 16 for the screw-compressor and dryer, if fitted

FIG. 16

4
6

- Wait for the machine to cool down.

- Remove the panels Ref. 4 Fig. 16 with the key provided.
- SLOWLY rotate the handle Ref. 5 Fig. 16 and let the condensate drain.
- 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 immediately the oil level on the indicator Ref. 6 Fig. 16.
- If the oil level is under the minimum, top up as described at point 15.4.
15.5 CHECK OIL LEVEL AND TOP UP
- Switch off the machine with push button Ref. 1 Fig. 16: in this way the machine will not stops instantly after idle time running.
- Disconnect the power supply by means of the disconnector switch, Ref. 3 Fig. 16 for the screw-compressor and dryer, if fitted
- Open the front panel Ref. 4 Fig. 16 with the special key.
- Wait approximately 3/4 minutes for the oil foam to settle in the collector.
- Check immediately the oil level on the indicator Ref. 6 Fig. 16.
- If the oil level is below the minimum Fig. 16B, top it up.
USE OIL OF THE SAME TYPE AS THAT ALREADY IN THE MACHINE; DO NOT MIX DIFFERENT TYPES OF OIL.
BEFORE PERFORMING ANY OPERATION ON THE MACHINE, ENSURE THAT THE ELECTRIC POWER SUPPLY HAS
BEEN DISCONNECTED.
- Slowly open the oil plug Ref. 7 Fig. 16.
- Top up to maximum level Ref. 6 Fig. 16, with oil of the same type in the compressor.
- Turn off the cap of the oil tank Ref. 7 Fig. 16.
- Close the panel Ref. 4 Fig. 16.

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OIL LEVEL CHECK

Running unit:
- Foam level is in the center of sight glass.

FIG. 16A

Machine just stopped (3/4 minutes):

- When foam disappears, the oil level must be visible on the sight glass (under the max. level).

FIG. 16B

CAUTION:
- Do not check level if machine is standing for more than 10 minutes.
- Do not overfill (not higher than the max. level).

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BEFORE PERFORMING ANY MAINTENANCE, IT IS MANDATORY TO STOP THE MACHINE AND DISCONNECT IT FROM
THE POWER MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION NETWORK.

15.6 CLEANING THE FILTERS ON THE ELECTRICAL CABINET DOOR

- Switch off the machine with pushbutton Ref. 1 Fig. 16: in this way the machine stops after idle time running.
- Disconnect the power supply by means of the disconnector switch, Ref. 3 Fig. 16 for the screw-compressor and dryer, if fitted.
- Remove the filters covers from cabinet door Ref. 1 Fig. 17.
- Clean the filter pads using compressed air or water. Do not use solvents.
- Once operation is complete, reassemble the filter covers Ref. 1 Fig. 17.

EVERY 50 WORKING HOURS, CLEANING FIG. 17

THE FILTERS ELECTRICAL PANEL.

1
1 2

- CLEANING THE INLET PANEL FILTER

- Switch off the machine with pushbutton Ref. 1 Fig. 16: in this way the machine stops after idle time running.
- Disconnect the power supply by means of the disconnector switch, Ref. 3 Fig. 16 for the screw-compressor and dryer, if fitted.
- Remove the filter from the from the containment grid, sliding it upwards Ref. 1 Fig. 18.
- Clean the filter using compressed air or water. Do not use solvents.
- Once the operation is complete, replace the filter in the containment grid Ref. 1 Fig. 18.

FIG. 18

BEFORE PERFORMING ANY MAINTENANCE, JOBS IT IS MANDATORY TO STOP THE MACHINE AND DISCONNECT IT
FROM THE POWER MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION NETWORK.

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15.7 CLEANING THE AIR INLET FILTER OR REPLACING THE FILTER
- Switch off the machine with pushbutton Ref. 1 Fig. 16: in this way the compressor will not stop instantly.
- Disconnect the power supply by means of the disconnector switch, Ref. 3 Fig. 16 for the screw-compressor and dryer, if fitted.

HOT PARTS INSIDE

- Remove the panel Ref. 2 Fig. 17.

- Remove the cover Ref. 7 Fig. 19.
- Remove the filter Ref. 8 Fig. 19.

AVOID DROPPING FOREIGN BODIES INTO THE INLET DUCT.

- 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 panel Ref. 2 Fig. 17.

FIG. 19

7 8

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15.8 CHECKING THE AUTOMATIC AND MANUAL CONDENSATE DRAIN (FOR THE DRYER, IF FITTED)

BEFORE PERFORMING ANY MAINTENANCE, IT IS MANDATORY TO STOP THE MACHINE AND DISCONNECT IT FROM
THE POWER MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION NETWORK.

The automatic condensation drain must be checked (Rif. 1 every 500 hours) Fig. 20.
Prceed as follows:
- Press the "TEST" button, Ref. 1 Fig. 20, for a few seconds to check if the condensation is correctly emptied from the drainage pipe

FIG. 20

1
8

7
6

15.9 CLEAN THE DRAIN MESH (ONLY FOR UNITS EQUIPPED WITH REFRIGERANT DRYER)
Prceed as follows:
- Close the ball valve at machine at the air outlet Ref. 5 Ref. 20
- Remove the panel Ref. 8 Fig. 20
- Depressurise the dryer by pressing the "TEST" button on drain (for about 10-20 seconds) Ref. 1 Fig.20
- Switch off the machine with pushbutton Ref. 4 Fig. 20: in this way the machine stops after idle time running.
- Disconnect the power supply by means of the disconnector switch, Ref. 2 Fig. 20 for screw-compressor and for the dryer.
- Remove the threaded plug Ref. 6 Fig. 20
- Remove the filter Ref. 7 Fig. 20 (filter mesh)
- Clean the filter mesh using compressed air.
- Install the filter, fix the plug.
- Install the panel Ref. 8 Fig. 20

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15.10 CLEANING CONDENSER HEAT EXCHANGER (ON THE DRYER IF FITTED)

BEFORE PERFORMING ANY MAINTENANCE, IT IS MANDATORY 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.

Prceed as follows:
- Switch off the machine with push button Ref. 1 Fig. 21: in this way the compressor will not stop instantly.
- Disconnect the power supply by means of the disconnect switch, Ref. 2 Fig. 21 for the screw-compressor and the dryer.

HOT PARTS INSIDE THE DRYER

- Remove the filter panel Rif. 4 Fig. 21

- Clean the condenser fins with compressed air (See Fig A). DO NOT USE WATER OR SOLVENTS.
- Re-assemble the back-panel Rif. 4 Fig. 21

FIG. 21

Fig. A

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16.0 PERIODS OF INACTIVITY

If the machine remains inactive for a long period:

- Close the ball valve Ref. 1 Fig. 22.
- Remove the panel Ref. 8 Fig. 22
- Depressurise the dryer by pressing the "TEST" button (for about 10-20 seconds) to drain the condensate Ref. 2 Fig. 22
- Switch off the machine with press Ref. 3 Fig. 22: in this way the machine stops after idle time running.
- Disconnect the power supply by means of the disconnector switch, Ref. 4 Fig. 22 for screw-compressor and for the dryer if fitted.
- Assemble the panel Ref. 8 Fig. 22.

FIG. 22

2
8

During periods of inactivity the unit needs to 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 needs 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-PROFING, INSULATING FOAM, ETC.

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18.0 LIST OF SPARE PARTS FOR ROUTINE MAINTENANCE

HP 40 (VSD) HP 50 (VSD)
Réf DESCRIPTION Q.ty Code kW 30 (VSD) kW 37(VSD)
12,5 bar 12,5 bar
1 Filters electrical panel 2 1630 0589 00 ◼ ◼
1 Filters electrical panel 2 1630 0589 05 ◼ ◼
2 Oil filter 1 2204 2276 03 ◼ ◼
3 Air filter 1 1092 1001 90 ◼
3 Air filter 1 1630 4302 94 ◼
4 Separator cartridge 1 2204 2276 07 ◼ ◼
5 Gaskets separator cartridge 2 2204 1197 00 ◼ ◼
6 Pre filtration 1 2204 1203 03 ◼ ◼

FIG. 23

4-5

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19.0 TROUBLE-SHOOTING AND EMERGENCY REMEDIES
N.B. OPERATIONS MARKED ◼ ◼ MUST BE PERFORMED BY PROFESSIONALLY SKILLED PERSONNEL APPROVED THE
MANUFACTURER.
ALL WORK MUST BE PERFORMED BY PROFESSIONALLY SKILLED PERSONNEL. BEFORE CARRYNG OUT ANY
MAINTENANCE JOBS IT IS MANDATORY TO STOP THE MACHINE AND DISCONNECT IT FROM THE POWER MAINS.

19.1 PROBLEM SOLVING AND EMERGENCY SOLUTIONS FOR SCREW COMPRESSORS (touch
controller for VSD variable compressors)
FAULT FOUND POSSIBLE CAUSES OBSERVATIONS
1) The machine does not start 1A - no power - check the power supply line,
Chapter 12.2
1B - the transformer protection device has
tripped - replace fuses
2) The machine does not start 2A - Incorrect phases; the ventilator rotates - Check the phase sequence and the
the pilot lamp (Ref. 5 Fig.16) is flashes. in reverse, not cooling the machine ventilator’s direction of rotation.
The pictograph appears intermittently (Q15 could be triggered) - environment temperature too high;
(Status icons Shutdown) 2B - The motor ventilator protection device improve ventilation in the compressor
(Q15) has been triggered room, Chapter 9.2

2C – Temperature switch on element oulet ◼ ◼ - cooling radiator is dirty, clean the

has tripped radiator
- oil level too low; top up the oil tank
3) The machine does not start 3A - The oil high temperature protection has - environment temperature too high;
the pilot lamp (Ref. 5 Fig.16) is flashes. tripped improve ventilation in the compressor
The pictograph appears intermittently room, Chapter 9.2
(Status icons Shutdown) ◼ ◼ - 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 consumption of compressed air 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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19.2 TROUBLE-SHOOTING FOR REFRIGERANT DRYER

ALL WORK MUST BE PERFORMED BY PROFESSIONALLY SKILLED PERSONNEL. BEFORE CARRYNG OUT ANY
MAINTENANCE JOBS IT IS MANDATORY TO STOP THE MACHINE AND DISCONNECT IT FROM THE POWER MAINS.
N.B. OPERATIONS MARKED ◼ ◼ MUST BE PERFORMED BY PROFESSIONALLY SKILLED PERSONNEL APPROVED THE
MANUFACTURER
FAULT FOUND POSSIBLE CAUSES OBSERVATIONS
1) No compressed air passes through the 1A) The pipes are frozen inside ◼◼ -Hot gas by-pass the bypass valve is
dryer outlet broken or out-of-calibration
-The room temperature is too low and the
evaporators piping are obstructed with
ice
2) Presence of condensate in the pipings. 2A) The condensate separator does not ◼◼ -Check the solenoid exhaust valve
work correctly ◼◼ -Check the drainage timer

2B) The dryer is working outside its rating -Check the flow rate of treated air
-Check the room temperature
-Check the air temperature at the drier
inlet.

2C) The dryer is working under bad -Clean the condenser.

excessive conditions. ◼◼ -Check dryer fan operation.
3) The compressor head is very hot Make reference to 2B
Make reference to 2C
3A) The cooling circuit is not working with ◼◼ -Check if there are leaks of refrigerating
the right gas charge 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 company

The starting system of the motor is ◼◼ - Check the condenser in use

defective.
6) The machine has stopped and does not The overload protection has been
restart even after a few minutes. triggered: refer back to 2B-2C-3A.

The motor has burnt out.

7) The compressor is very noisy. Troubles with the internal mechanical
parts or with the valves

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

WARNING: CAPACITORS INSIDE INVERTER MAY REMAIN CHARGED FOR 15 MINUTES AFTER THE UNIT HAS BEEN
DISCONNECTED FROM MAIN SUPPLY.

WAIT AT LEAST 15 MINUTES AFTER POWER SUPPLY HAS BEEN REMOVED BEFORE PERFOM SERVICE OR REPAIR TO
AVOID DEATH OR SERIOUS INJURY.

CAUTION: If the EMERGENCY BUTTON IS PRESSED, the inverters safely stops the motor according to legislation (Safety
Torque Off). However, in compressors with permanent magnets, this function DOES NOT REMOVE THE VOLTAGE FROM
THE INVERTER. Before performing any check or maintenance operation, REMOVE THE POWER SUPPLY!

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20.0 STARTING UP

BEFORE PERFORMING ANY OPERATION ON THE MACHINE, ENSURE THAT THE ELECTRIC POWER SUPPLY HAS
BEEN DISCONNECTED.

20.1 PREPARE FOR START

20.2 Preliminary checks

When delivered, the machine is filled with oil;
If unit is installed more than 3 months after factory inspection: lubricate the screw element before start.
According to below procedure:
- Remove the pipe Ref. 2 Fig. 24 by loosening the clamp screw.
- Pour a little oil into the inlet valve.
- Reassemble the pipe Ref. 2 Fig. 24
If more than 6 months elapsed between factory inspection and installation, please contact the service centre.

FIG. 24
2

OIL

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20.3 CHECK THE VENTILATOR’S DIRECTION OF ROTATION, the main motor, as it is powered by the inverter, always rotates in
the correct direction, regardless of the power supply connection.
- Check that all fixed guards are in their correct position.
- Connect the control board to the power supply with the disconnector switch of the line Rif. 1 Fig. 25.
- Check the direction of rotation (following the arrow on the coupling housing Rif. 3 Fig. 25). By pressing the “Start” button Rif. 2 Fig. 25,
followed immediately by the emergency stop Rif. 4 Fig. 25. If it does not spin in the right direction reverse two mains cables. When it
rotates in the correct direction, the oil level Rif. 5 Fig. 25 should drop after 4 or 5 seconds of operation. It is very important to remember to
check the direction of rotation of the fan (shown by an arrow on the fan Rif. 6 Fig. 25).

ALL MAINTENANCE ON ELECTRICAL PARTS, MUST BE PERFORMED BY PROFESSIONALLY SKILLED PERSONNEL.

- IT IS ADVISABLE TO NOT TAMPER WITH ELECTRIC CABINET

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

ATTENTION: wait at least 20 seconds before starting the machine after a switch off

FIG. 25
1

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21.0 GENERAL ORDINARY MAINTENANCE REQUIRES TRAINED PERSONNEL
BEFORE CARRYING OUT ANY MAINTENANCE IT IS MANDATORY 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 well ventilated. For particularly dusty
environments, double the frequency of controls.

Every Day (after use) ◼ Check automatic condensation drain (unit with dryer)

Every 50 working hours ◼ Drain condensate from the oil tank

◼ Check the oil level
◼ Clean the filter of the automatic condensate drain (unit with dryer)
◼ Clean the filtering panel
◼ Check the values displayed on the screen.
◼ Ensure that the condensate is drained during the compressor’s load operation.
◼ Check the dew point temperature at pressure (for compressors with an integrated dryer).
◼ Clean the filters on the electrical cabinet door.

Every 500 hours ◼ Tighten the screws fixing the electric cables (at first 500 hrs)
◼ Clean the air inlet filter
◼ Clean the condenser heat exchanger (unit with dryer)
◼ Clean the inlet filtration panels

Every 4000 hours ◼ Replace the inlet air filter

(or at least every year) ◼ Change the dryer's condensate drain filter mesh (unit with dryer)
◼ Replace the filter panel
◼ Replace the line filter (replace the filter cartridge, if present, at least once a year)
◼ Replace the filters on the electrical cabinet door
◼◼ Tighten the electrical cable fastening screws
◼◼ Replace the standard oil or food-grade oil (optional)
◼◼ Replace the oil filter
◼◼ Retighten all power cable connections
◼◼ Safety temperature test
◼◼ Clean the finned surface of the air-oil cooler
◼◼ Service the dryer’s condensate drain (unit with dryer)

Every 8000 hours ◼◼ Replace the oil (optional)

(or at least every 2 years) ◼◼ Replace the oil separator filter
◼◼ Check oil return valve and oil pipes status
◼◼ Service the non-return valve
◼◼ Service the aspiration valve
◼◼ Service the minimum pressure valve and thermostatic valve

Every 24000 hours ◼ ◼ Service the pumping group

◼ ◼ Service the motor group
◼ ◼ Replace the inverter’s internal valve

N.B.: OPERATIONS MARKED WITH THE ◼ SYMBOL ARE DESCRIBED IN CHAPTER 15.2. OF PART “A” OF THIS MANUAL

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22.0 REPLACING OIL AND OIL FILTER
BEFORE PERFORMING ANY MAINTENANCE, JOBS IT IS MANDATORY TO STOP THE MACHINE AND DISCONNECT IT
FROM THE POWER MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION NETWORK.
Oil change is an important operation for the compressor: if lubrication of the bearings is not efficient, the life expectancy of the compressor
will be significantly reduced.
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 having discharged the waste oil from the machine Ref. 2 Fig. 26 and from the run-off plugs below the pump and motor faceplate,
having then replaced them:
- Remove the oil filter Ref. 7 Fig. 26
- Lubricate the filter seals with a little oil before fitting.
- Tightening must be done by hand.
- Completely fill the oil collector Ref. 1 Fig. 26.
- Remove the pipe Ref. 3 Fig. 26
- Pour a little oil into the suction unit.
- Reassemble the pipe Ref. 3 Fig. 26
- Start the compressor.
- After about 1-minute switch off the machine by pressing “STOP” (Ref. 4 Fig. 26) after idle time running the machine will switch off.
PROCEED AS DESCRIBED AT POINT CHAPTER 15.4

FIG. 26

1
4

2
7 OIL

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 REPLACING OIL SEPARATOR FILTER

BEFORE PERFORMING 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.

REPLACING Oil SEPARATOR FILTER

Before proceeding with the replacement of the oil separator filter and the oil filter, check that there is no pressure in the machine:
check the pressure gauge Ref. 1 Fig. 27.
- Switch off the machine press Ref. 2 Fig. 27: in this way the machine stops after idle time running
- Disconnect the power supply by means of the disconnect switch, Ref. 3 Fig. 27 for the screw-compressor and for the dryer, if fitted.
- Disconnect the unit from compressed air network Ref. 5 Fig. 27
- Check there is no pressure inside the machine: check the pressure gauge Ref. 1 Fig. 27.
- Remove the oil separator cover Ref. 6 Fig. 27
- Replace oil separator filter and gasket.
- Moisturise gaskets with oil.

FIG. 27
3

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24.0 OLEOPNEUMATIC DIAGRAM

1 INLET FILTER 12 COMBI-COOLER

2 INLET VALVE 13 FAN
3 ELECTRIC MOTOR 14 REFRIGERANT DRYER
4 AIR END 100 CONTROL PANEL
5 OIL VESSEL 210 OPTIONAL WATER SEPARATOR
6 OIL SEPARATOR 220 OPTIONAL LINE FILTER
7 SAFETY VALVE
8 OIL DRAIN
9 MINIMUM PRESSURE VALVE
10 CHECK VALVE
11 THERMOSTATIC VALVE

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26.0 CALIBRATION FOR DRYER

HOT GAS BYPASS VALVE

N.B. These valves are calibrated at the factory. A different dew point (from rated) may be related to different cause than HGBP.
1) Closing cap
2) Adjusting screw
OPERATION TEMPERATURE AND PRESSURE R513A - R410A 1
SUCTION SIDE OF REFRIGERATION COMPRESSOR
Evaporat.
Evaporating
Temperat.
Pressure bar (psi) 2
°C ( °F)
R513A R410A
RATED VALUES 1÷2
2.35 ÷ 2.47 7.28 ÷ 7.55
(Temperat. 20 °C) (33,8 ÷ 35,6)
(34,8 ÷ 35,82) (105,6 ÷ 109,5)
(68 °F)

26.1 FLOW DIAGRAM OF THE DRYER

AIR OUTLET
AIR INLET

1 COMPRESSOR 8 REFRIGERANT FILTER

2 CONDENSER 9 HOT GAS BYPASS VALVE
3 MOTOR FAN 10 AIR-TO-AIR EXCANGER
4 EVAPORATOR 11 DEW POINT THERMOMETER
5 SEPARATOR 12 FAN PRESSURE SWITCH
7 EXPANSION CAPILLARY TUBE

27.0 “IVR" VARIABLE SPEED UNIT

The “Variable speed” version of the machine is controlled by a frequency converter.
The equipment is configured at the factory and no adjustments to parameters are required.
The modulating pressure is set at 0.5 bar lower than maximum pressure: depending on the air demand, the frequency converter varies the
motor speed. To meet the air demand of the customer network.
SETTING THE MODULATION PRESSURE
The compressor modulating pressure is set at 0.5 bar less than maximum pressure. By changing the adjustment value also change the
value of the maximum pressure.

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