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AIB 9828093469 Ed 00 C90 PM (A2) - EN
AIB 9828093469 Ed 00 C90 PM (A2) - EN
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USE & MAINTENANCE MANUAL 9828093469 00
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
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.
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.
The manufacturer does not accept responsibility for damage caused as a result of negligence or failure to abide by the instructions given above.
AIR OUTLET
AIR INLET
ALL WORK ON THE ELECTRIC PLANT, HOWEVER SLIGHT, MUST BE CARRIED OUT BY PROFESSIONALLY SKILLED
PERSONNEL.
4) NOISE
5) HIGH PRESSURE
2
2
2
3
1
2
FIG. 1
1 2 3 5 8
FIG. 2
2
2
3
8
2 5
1 2 3 5 8
3 5
FIG. 3
FIG. 4
FIG. 5
FIG. 6
1) Identification plate
FIG. 7
FIG. 8
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.
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.
FIG. 11
MINIMUM mt 1,5
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.
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.
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
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
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
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
Introduction
The electronic controller has following functions:
• Controlling the compressor
• Protecting the compressor
• Monitoring components subject to service
• Automatic restart after voltage failure (option)
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.
Provided the controller is in the automatic restart mode, the compressor will automatically restart when the
supply voltage to the module is restored.
FIG. 15
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.
Inputs
Outputs
Counters
Service plan
Service History
Service functions
Clean Screen
Remaining running
time
Regulation
Control
Parameters
Auxiliary Converter(s)
equipment
parameters
Fan
Internal SmartBox
Automatic restart
CAN Settings
Localisation Language
Date/Time
Units
User Password
Help
Information
Icon Description
Motor Stopped
Running Unloaded
Manual Unload
Running Loaded
Failed to Load
Manual Stop
Icon Description
Basic User
Advanced User
Service User
Antenna 25%
Antenna 50%
Antenna 75%
Antenna 100%
Energy recovery
Dryer
Element
Drain(s)
Analogue Output
Menu
Reset
Automatic restart
Filter(s)
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.
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
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.
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.
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
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%.
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:
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.
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:
The above screen shows that the temperature at the outlet of the element is 116 ˚C. Actions:
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.
Inverter
Touch controller alarm
fault Fault text Warning Alarm Cause of problem
(dec)
(hex)
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
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
(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.
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
Reference Designation
Inputs menu
Tap the Inputs icon to enter the Inputs menu.
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.
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
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).
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.
Procedure
To enter the Week Timer menu screen:
1. Tap the Menu button
2. Tap the Week Timer icon
(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".
Description
Reference Designation
(1) 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.
Description
Reference Designation
Regulation menu
Tap the Control Parameters icon to enter the Control Parameters 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’.
Procedure
To enter the Controller Settings menu screen:
1. Tap the Menu button
2. Tap the Controller Settings icon
Reference Designation
(1) 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
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’.
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
This menu can show a link to the web page of your supplier, a helpdesk phone number or other helpful information.
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
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
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.
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)).
Getting started
• 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.
• 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:
• 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.
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 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
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:
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:
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)
FIG. 16
4
6
- 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.
Running unit:
- Foam level is in the center of sight glass.
FIG. 16A
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).
1
1 2
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.
- 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
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
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.
FIG. 21
Fig. A
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.
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.
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
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
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.
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!
BEFORE PERFORMING ANY OPERATION ON THE MACHINE, ENSURE THAT THE ELECTRIC POWER SUPPLY HAS
BEEN DISCONNECTED.
FIG. 24
2
OIL
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
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 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
N.B.: OPERATIONS MARKED WITH THE ◼ SYMBOL ARE DESCRIBED IN CHAPTER 15.2. OF PART “A” OF THIS MANUAL
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
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.
FIG. 27
3