Compressed Air Advisors HP Series Instruction manual

ENGLISH
. Cod. 2200780027 01 - Edition 05/2012 - 1
MANUAL USE AND MAINTENANCE
QUIET SCREW ROTARY COMPRESSOR UNITS
HP 20-25-30-40 KW 15-18,5-22-30
HP 20-25-30-40 (VSD) KW 15-18,5-22-30 (VSD)
WARNING: THE INVERTER REMAINS CHARGED WITH HIGH VOLTAGE FOR FIVE MINUTES AFTER THE MASTER
SWITCH HAS BEEN OPENED.
ALWAYS WAIT FOR FIVE MINUTES BEFORE REMOVING THE FRONT COVER (INSTRUMENT PANEL).
USE A SPECIFIC INSTRUMENT TO CHECK THAT THERE ARE NO DANGEROUS VOLTAGES BEFORE
PERFORMING OPERATIONS ON THE INVERTER OR MOTOR.
CONTENTS
PART A: INFORMATION FOR THE USER PART B: INFORMATION RESERVED FOR TECHNICALLY SKILLED
PERSONNEL
1.0 GENERAL CHARACTERISTICS 20.0 STARTING UP
2.0 INTENDED USE 21.0 GENERAL ORDINARY MAINTENANCE REQUIRES
TRAINED PERSONNEL
3.0 OPERATION 22.0 CHANGING THE OIL
4.0 GENERAL SAFETY STANDARDS 23.0 CHANGING THE OIL SEPARATING FILTER
5.0 DESCRIPTION OF DANGER SIGNALS 24.0 BELT TENSION
6.0 DANGER ZONES 25.0 REPLACING THE ELECTRIC MOTOR
7.0 SAFETY DEVICES 26.0 OLEOPNEUMATIC DIAGRAM
8.0 POSITION OF PLATES 27.0 CALIBRATIONS FOR DRYER
9.0 COMPRESSOR ROOM 28.0 "VSD" VARIABLE SPEED
10.0 TRANSPORT AND HANDLING IMPORTANT: A COPY OF THE WIRING DIAGRAMS CAN BE FOUND
INSIDE THE ELECTRIC BOARD OF THE COMPRESSOR.
11.0 UNPACKING
12.0 INSTALLATION
13.0 DIMENSIONS AND TECHNICAL DATA
14.0 MACHINE ILLUSTRATION
15.0 ORDINARY MAINTENANCE TO BE DONE BY THE USER
16.0 PERIODS OF INACTIVITY
17.0 SCRAPPING THE UNIT
18.0 LIST OF SPARE PARTS FOR ROUTINE MAINTENANCE
19.0 TROUBLE-SHOOTING AND EMERGENCY REMEDIES
Code
2200780027 01
Edition 05/2012
READ THIS MANUAL CAREFULLY BEFORE CARRYING OUT ANY OPERATIONS ON THE COMPRESSOR UNIT.
THIS MACHINE MUST BE CONNECTED TO TWO DIFFERENT POWER
SUPPLIES: THREE-PHASE SUPPLY FOR THE COMPRESSOR SINGLE-
PHASE SUPPLY FOR THE DRYER

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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 needed, apply only to a technical assistance centre approved by the manufacturer and insist on the use of original spare parts.
Failure to comply with the above may endanger the safety of the machine.
INTRODUCTION
Keep this manual with care for future consultation; the use and maintenance manual is an integral part of the machine. Read this
manual carefully before carrying out any operations on the compressor unit.
The installation of the compressor unit and all operations involving it must be performed in conformity with the regulations in
force concerning electric plants and personal safety.
CHARACTERISTICS AND SAFETY PRECAUTIONS
MACHINE WITH AUTOMATIC START
BEFORE REMOVING THE PROTECTIVE GUARDS TO CARRY OUT ANY MAINTENANCE ON THE
MACHINE, SWITCH OFF THE ELECTRIC POWER SUPPLY AND DISCHARGE THE RESIDUAL PRESSURE
INSIDE THE UNIT.
ALL WORK ON THE ELECTRIC PLANT, HOWEVER SLIGHT, MUST BE CARRIED OUT BY
PROFESSIONALLY SKILLED PERSONNEL.
THIS MACHINE IS NOT SUITABLE FOR EXTERNAL INSTALLATION
THIS MACHINE CORRESPOND TO THE ESSENTIAL SAFETY REQUIREMENTS FORESEEN FROM THE
EUROPEAN STANDARD (2006/42 CE).
THE LUBRICATING LIQUIDS AND OTHER EVENTUAL FLUIDS MUST NOT BE DISCHARGED IN THE
ENVIRONMENT. THESE POLLUTING AND HAZARDOUS PRODUCTS MUST COMPULSORY BE DISPOSED BY
CHARGING AUTHORISED AND SPECIALISED FIRMS ACCORDING TO THE DIFFERENT TYPOLOGY OF
PRODUCT.
DIFFERENTIATE THE COMPRESSOR COMPONENTS ACCORDING TO THE DIFFERENT CONSTRUCTION
MATERIALS (PLASTIC, COPPER, IRON, OIL FILTER, AIR FILTER ECC…)
The manufacturer does not accept responsibility for damage caused as a result of negligence or failure to abide by the
instructions given above.
AIR RECEIVER AND SAFETY VALVE:
- To limit internal corrosion, which could compromise the safety of the compressed air tank, the condensation
that is produced must be discharged at least once a day. If an automatic drain fitted to the air receiver is
present, it is necessary to check that it is working correctly every week and repair it if necessary.
- The thickness of the receiver must be checked every year and also in accordance with legislation
in force in the country where the receiver is installed.
- The tank cannot be used and must be replaced if the thickness falls below the minimum level given
in the instruction documents for the tank.
- The tank can be used within the temperature limits given in the conformity declaration.
- The safety valves of the air receiver and oil receiver must be checked every year and replaced in
accordance with legislation in force.
NOT RESPECTING THE ABOVE MENTIONED PRESCRIPTION CAN RESULT IN AIR RECEIVER
BURSTING HAZARD.
The manufacturer does not accept responsibility for damage caused as a result of negligence or failure to abide by the
instructions given above.
1

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1.0 GENERAL CHARACTERISTICS
The compressor units use single-stage screw rotary air compressors with oil injection.
The central unit comprises:
compressor, dryer and steam trap if present, storage tank.
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 or explosion or where work is carried out which releases substances
into the environment which are dangerous with regard to safety (for example: solvents, inflammable vapours, alcohol, etc.).
In particular the appliance cannot be used to produce air to be breathed by humans or used on direct contact with foodstuffs. These uses
are allowed if the compressed air produced is filtered by means of a suitable filtering system (Consult the manufacturer for these special
uses.) This appliance must be used only for the purpose for which it was specifically designed.
All other uses are to be considered incorrect and therefore unreasonable.
The Manufacturer cannot be held responsible for any damage resulting from improper, incorrect or unreasonable use.
3.0 OPERATION
3.1 OPERATION FOR COMPRESSOR
The electric motor and the compressor unit are coupled by means of a belt transmission.
The compressor unit takes in the outside air through the suction valve. The air taken in is filtered by two panel pre-filter placed on the side
conveyor external and by the filter cartridge fitted upstream from the suction valve. Inside the compressor unit, the air and the lubricating oil
are compressed and sent to the oil separating 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 circuit while the compressed air passes the using network.
3.2 OPERATION FOR DRYER
Dryer operation is described below. The gaseous refrigerant coming from the evaporator (4) is sucked by the refrigeration compressor (1)
and it is pumped into the condenser (2). This one allows its condensation, eventually with the help of the fan (3); the condensed refrigerant
passes through the dewatering filter (8) and it expands through the capillary tube (7) and goes back to the evaporator where it produces the
refrigerating effect.
Due to the heat exchange with the compressed air which passes through the evaporator against the stream, the refrigerant evaporates and
goes back to the compressor for a new cycle. The circuit is equipped with a bypass system for the refrigerant; this intervenes to adjust the
available refrigerating capacity to the actual cooling load. This is achieved by injecting hot gas under the control of the valve (9): this valve
keeps constant the pressure of the refrigerant in the evaporator and therefore also the dew point never decreases below 0 °C (32 °F) in
order to prevent the condensate from freezing inside the evaporator.
The drier runs completely automatically; it is calibrated in the factory for a dew point of
3 °C (37,4 °F) and therefore no further calibrations are required.
DRYER FLOW DIAGRAM
1 COMPRESSOR
2 CONDENSER
3 MOTOR FAN
4 EVAPORATOR
5 SEPARATOR
7 EXPANSION CAPILLARY TUBE
8 REFRIGERANT FILTER
9 HOT GAS BYPASS VALVE
10 AIR-TO-AIR EXCANGER
11 DEW POINT THERMOMETER
12 FAN PRESSURE SWITCH
4.0 GENERAL SAFETY STANDARDS
The appliance may be used only by specially trained and authorized personnel.
Any tampering with the machine or alterations not approved beforehand by the Manufacturer relieve the latter of responsibility for any
damage resulting from the above actions.
The removal of or tampering with the safety devices constitutes a violation of the European Standards on safety.
ATTENTION: UPSTREAM OF THE MACHINE INSTALLAN ISOLATOR KNIFE-SWITCH WITH AN AUTOMATIC CUTOUT AGAINST
CURRENT SURGES AND EQUIPPED WITH A DIFFERENTIAL DEVICE FOR CALIBRATIONS SEE WIRING DIAGRAM.
ALL WORK ON THE ELECTRIC PLANT, HOWERE SLIGHT, MUST BE CARRIED OUT BY
PROFRSSIONALLY SKILLED PERSONEL.
AIR INLET
AIR OUTLET

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5.0 DESCRIPTION OF DANGER SIGNALS
1) FLUID EJECTION 6) HOT PARTS
2) DANGEROUS ELECTRIC
VOLTAGE
7) MOVING PARTS
3) AIR NOT FIT FOR BREATHING
8) MOVING PARTS
4) NOISE 9) MACHINE WITH AUTOMATIC START
5) HIGH PRESSURE
5.1 DESCRIPTION OF COMPULSORY SIGNALS
11) READ THE USE AND MAINTENANCE
INSTRUCTIONS
6.0 DANGERS ZONES
6.1 DANGERS ZONES FOR COMPRESSOR UNIT
Risks present on the whole machine
1 2 3 5 7 8
FIG. 2
FIG. 3
2
2
1
5
3
2
7 8

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6.2 DANGERS ZONES FOR DRYER UNIT AND TANK
Risks present on the whole machine
7.0 SAFETY DEVICES
7.1 SAFETY DEVICES FOR SCREW COMPRESSOR (Fig. 4)
1) Safety screws 4) Emergency stop button with mechanical seal and
rotation release.
2) Side panels and door to the electric panel, opened with a special key 5) Oil filling cap (with safety breather)
3) Fixed protection device - cooling fan 6) Safety valve
3) Fixed protection device - pulleys
123 5 8
5
2
8
2 5
3
2
3
FIG. 3A
1
FIG. 4
5
6
3
2
1
4

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7.2 SAFETY DEVICES FOR DRYER UNIT
1) Safety valve 4) Fan protection
2) Protective pressure switch cap. 5) Relay for compressor (automatic)
3) Earth 6) Overload protector for compressor
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) Danger plate Code 1079990348 3) Danger plate
2) Plate “Machine with automatic start” 2202260791 4) Label “UL”
FIG. 5
2
4
5 6
1
FIG. 6
VSD
1
1
1
3
1
2
4
3

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8.2 POSITION OF THE DANGER PLATES FOR DRYER
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 Cod. 1079990109
8.3 POSITION OF THE DATA PLATE FOR COMPRESSOR UNIT
1) Identification plate
FIG. 7
1
FIG. 8
1

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8.4 POSITION OF THE DATA PLATE FOR DRYER
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 40 °C (104 °F) or lower than 1 °C (33,8 °F)..
The volume of the room must be about 60 m3The room must be provided with 2 openings for ventilation with a surface area of about 0,5
m2each. The first opening must be in a high position to evacuate the hot air, the second opening must be low to allow the intake of external
air for ventilation. If the environment is dusty it is advisable to fit a filtering panel on this opening.
9.3 EXAMPLES OF VENTILATION OF THE COMPRESSOR ROOM
10.0 TRANSPORT AND HANDLING
The machine must be transported as shown in the following figures.
11.0 UNPACKING
After removing the packing, ensure that the machine is unbroken and that there are no visibly damaged parts.
If you are in doubt, do not use the machine but apply to the manufacturer technical assistance service or to your dealer. The packing
material (plastic bags) 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. 10
FIG. 9
Hot air pipe
ATTENTION: Removable
pipe to allow cleaning of the
radiator.
FIG. 11
Fan air
output
This would not be
required here

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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. 12).
ENSURE THAT THE OPERATOR CAN SEE THE WHOLE MACHINE FROM THE CONTROL PANEL AND CHECK THE
PRESENCE OF ANY UNAUTHORIZED PERSONS IN THE VICINITY OF THE MACHINE.
12.2 ELECTRICAL CONNECTION
Check that the supply voltage is the same as the value indicated on the machine data plate.
Check the condition of the line leads and ensure that there is an efficient earth lead.
Ensure that there is an automatic cut-out device upstream for the machine against overcurrents, with
a differential device (see Ref. 1 for compresseur Ref. 2 for dryer ) wiring diagram.
Connect the machine power cables with the greatest care, according to the standards in force.
These cables must be as indicated on the machine wiring diagram.
Connect the cables to the charging clamps on the electric 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.
The standard voltage configuration for the compressor is mentioned on the data plate of the machine.
NEVER OPERATE THE COMPRESSOR ON A VOLTAGE OTHER DIFFERENT THAN SHOWN ON THE ELECTRIC CABINET.
For tri-voltage machine follow the instructions in the electrical diagram (inside cubicle) to convert the
operating voltage of the compressor for either 208V or 230V or 460V
FIG. 12
2 1
PROTECT THE POWER
CABLE WITH A SUITABLE
CHANNEL
SPACE FOR MAINTENANCE
MINIMUM mt 1
,
5
MINIMUM mt 1,5
THREE PHASE SCREW-COMPRESSOR
SUPPLY LEAD.
SINGLE PHASE DRYER SUPPLY
LEAD

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12.3 CONNECTION TO THE COMPRESSED AIR NETWORK
Fit a manual interception valve Ref. 1 between the machine and the compressed air network so that the compressor may be isolated during
maintenance operations (see figure 13 ) .
PIPES, FITTINGS AND CONNECTIONS USED FOR THE CONNECTION OF THE ELECTROCOMPRESSOR TO THE
COMPRESSED AIR NETWORK MUST BE SUITABLE TO THE USE ACCORDING TO THE PRESCRIPTIONS OF THE
REGULATIONS IN FORCE IN THE COUNTRY OF USE.
The automatic condensate drainage Ref. 2 Fig. 13, is led outside the machine with a flexible pipe that may be inspected. Drainage must
comply with the local regulations in force.
ALL DAMAGE DUE TO THE FAILURE TO COMPLY WITH THESE INDICATIONS CANNOT BE ATTRIBUTED TO THE
MANUFACTURER AND MAY CAUSE INVALIDITY OF THE GUARANTEE CONDITIONS.
12.4 STARTING UP
See part B of this manual, Chpter 20.0
13.0 DIMENSIONS AND TECHNICAL DATA
Variable speed / With Dryer
HP20-25-30-40
kW 15-18,5-22-30
Dimensions mm (in) Air connection
LWHD
1659
(65,3) 805 (31,7) 1220 (48) 1”
With Dryer
HP20-25-30-40
kW 15-18,5-22-30
Dimensions mm (in) Air connection
LWHD
1659
(65,3) 805 (31,7) 1220 (48) 1”
Fixed speed / Without Dryer
HP20-25-30-40
kW 15-18,5-22-30
Dimensions mm (in) Air connection
LWHD
1204
(47,4) 805
(31,7) 1220 (48) 1”
Variable speed / Without Dryer
HP20-25-30-40
kW 15-18,5-22-30
Dimensions mm (in) Air connection
LWHD
1204
(47,4) 805 (31,7) 1220 (48) 1”
FIG. 13
THE COMPRESSOR MUST BE CONNECTED TO A TANK
COMPLETE WITH SAFETY VALVE
1
ALWAYS USE A
FLEXIBLE PIPE
2

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Net weight Kg. (Ib)
HP 20 -kW 15 HP 25 -kW 18,5 HP 30 -kW 22 HP 40 - kW 30
Weight (without / with ) dryer 366 - 439 375 - 448 391 - 464 419 - 492
(806,8 - 976,8) (826,7 - 987,7) (862 - 1022) (932 - 1084)
Net weight Kg. (Variable speed)
HP 20 -kW 15 (IVR) HP 25 -kW 18,5
(IVR) HP 30 -kW 22 (IVR) HP 40 - kW 30 (IVR)
Weight (without / with ) dryer 394 - 467 403 - 476 419 - 492 447 - 520
(868 - 1029) (888 - 1049) (923 - 1084) (985 - 1146)
HP 20 - kW 15 HP 25 - kW 18,5 HP 30 - kW 22 HP 40 - kW 30
PSI 125 PSI 125 PSI 125 PSI 125
Standard air capacity
acfm 80 99,7 116,7 135,5
Max. pressure PSI 132 132 132 132
Noise product. dB(A) 69 72 74 77
Power HP - KW 20 - 15 25 - 18,5 30 - 22 40 - 30
Oil operation timer
setting °C (°F) 110 (230)
Oil load kg. (Ib) 10,7 (23,5)
HP 20 - kW 15 (IVR) HP 25 - kW 18,5 (IVR) HP 30 - kW 22 (IVR) HP 40 - kW 30 (IVR)
80 - 138
PSI 80 - 138 PSI 80 - 138 PSI 80 - 138 PSI
Standard air capacity at 100
PSI acfm 24,8 - 92 29,7 - 116 39,7 – 128,1 45,5 - 147
Max. pressure PSI 138 138 138 138
Noiose product. dB(A) 69 72 74 77
Power HP - KW 20 - 15 25 - 18,5 30 - 22 40 - 30
Oil operation timer
setting °C (°F) 110 (230)
Oil load kg. (Ib) 10,7 (23,5)
Type
Dryer
( 230V 60Hz )
Weight
Kg.
(Ib)
Freon
R 404A Kg. (Ib)
Nominal
Power W
(HP)
Bar (PSI)
MAX.
60 Hz 60 Hz 60 Hz 60 Hz
A7 53
(116,8) 0,650 (1,43) 777 (1,04) 84 (0,11) 861 (1,15) bar 13 (188)
A8 65
(143,3) 0,650 (1,43) 1035 (1,38) 90 (0,12) 1125 (1,508) bar 13 (188)
Type
Dryer
( 115V 60Hz )
Weight
Kg.
(Ib)
Freon
R 404A Kg. (Ib)
Nominal
Power W
(HP)
Bar (PSI)
MAX.
60 Hz 60 Hz 60 Hz 60 Hz
A7 53
(116,8) 0,600 (1,32) 646 (0,87) 106 (0,14) 752 (1,01) bar 13 (188)
A8 65
(143,3) 0,650 (1,43) 904 (1,21) 106 (0,14) 1010 (1,35) bar 13 (188)
Reference conditions:
Ambient temperature 25 °C (77 °F)
Inlet air temperature 35 °C (95 °F)
Pressure 7 bar (101 psi)
Dew point in pressure 3 °C (37,4 °F)
Limit conditions:
Max. ambient temperature 43°C (109,4 °F)
Min. ambient temperature 1°C (33,8 °F)
Max. inlet air temperature 55°C (131 °F)
Max. working pressure 13 bar (188 psi)
Nominal
Power
W
(HP)
Nominal
Power
W
(HP)
Nominal
Power
W
(HP)
Nominal
Power
W
(HP)

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14.0 MACHINE ILLUSTRATION
14.1 GENERAL LAYOUT FOR COMPRESSOR AND DRYER
1 Air suction filter
2 Thermostatic valve
3 Oil filter
4 Air-oil cooler
5 Filter panel
6 Belt tightening system
7 Minimum pressure valve
8 Air-oil separator with oil separating filter
9 Top-up or oil filling cap
10 Control panel
11 Oil gauge
12 Oil discharge
13 Oil tank
14 Pressure gauge tank
15 Control card
16 Safety valve ()
17 Suction unit
18 Electric motor
19 Screw compressor
IT IS FORBIDDEN TO TAMPER WITH THE
SETTING VALUES OF THE SAFETY VALVE
21 Refrigerant compressor
22 Condenser
23 Motor fan
24 Evaporator
25 Condensate drain
26 Hot gas by-pass valve
27 Refrigerant filter
28 Expansion capillary tube
29 Pressure switch
FIG. 15
3
8
14 2
24
26
25
21
29
22
27
28 23
4
17
19
18
6
5
11
1
7
9
10
12
13
15
16

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14.2 COMMAND AND CONTROL PANEL
BEFORE CARRYING OUT THE OPERATION TEST, READ CAREFULLY AND ACQUIRE A GOOD KNOWLEDGE OF THE
COMMAND FUNCTIONS.
1) Control card
2) Emergency stop button with mechanical seal and rotation
release
14.3 ELECTRONIC CARD
There is an electronic control and diagnostics card on the electric panel ; this card includes the display of the functions as shown in figure
17.
1) Upper display: indicates the compressor pressure. 4) Tabulation key to move to the next field of the screen on the
display Ref. 2
2) Lower display: indicate the temperature, total hours, loaded
hours. 5) Buttons to programme the board.
3) Button to create a manual unload in the compressor.
FIG. 17
FIG. 16
2
2Variable speed
1
3
2
1
4
5

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Symbol Description
Pressing the pushbutton cancels the stored alarm indication. Pressing the pushbutton for more than 3 seconds, the
central control unit is tested: all the LEDs must be on.
By pressing this button the compressor is switched on. N.B. there is a delay of about 10 seconds before start up.
(ATTENTION: start-up takes place about 15 seconds after the board is supplied with power or from the
moment it is switched off with the button “ 5 “).
Pressing the pushbutton starts the compressor switch-off phase: The compressor runs loadless for 20 seconds
before stopping.
Led – indicates compressor operating status: “RED” pilot lamps (cause machine stoppage)
Symbol Led flashing Led on
Overpressure alarm in progress Machine stopped for overpressure
Alarm inverse rotation in progress Alarm inverse rotation restored
Oil overtemperature alarm in progress
(>95 °C – 203 °F) Machine stopped for oil overtemperature (> 100 °C – 212 °F)
Not enabled
Not enabled
- Motor overload (for F.S.)
- Fault on frequency converter (for VSD)
- Machine stopped for motor overload (for F.S.)
- Machine stopped for fault on frequency converter for VSD)
- General alarm in progress for fault in pressure and
temperature probes. Enabled emergency stop push-button.
N.B. to switch off the red LEDs press “reset”
Led – indicates compressor operating status: “YELLOW” pilot lamps (do not cause machine stoppage.
Symbol Led flashing Led on
Not enabled
Not enabled
Forewarning to replace oil filter Replace oil filter
Forewarning to replace separator filter Replace separator filter
Forewarning to replace suction filter Replace suction filter
Forewarning to change oil Change oil
Forewarning for general check Perform general check
N.B. to switch off the “YELLOW” LEDs see chapter 14.6
Led – indicates compressor operating status: “GREEN” pilot lamps
Symbol Led flashing Led on
Not enabled Not enabled
- Compressor running under load
Manual loadless operation of compressor Loadless operation of compressor
Compressor in stand-by for start-up
(10 seconds) or in shut-down phase
(45 seconds).
Compressor on
(7)
(6)
(5)
(G)
(E)
(F)
(C)
(D)
(B)
(A)
(H)
(I)
(L)
(M)
(N)
(P)
(O)
(R)
(Q)

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ATTENTION: to start up again after a protection has been triggered (alarm) press “RESET” followed by the start
button “I”
ATTENTION: start-up takes place about 15 seconds after the board is supplied with power or from the moment it
is switched off with the button (5).
OPERATION OF THE CENTRAL CONTROL UNIT
The central control unit operation is programmed for Energy Saving; it switches off the compressor, thus reducing idle running to
a minimum.
The control unit also indicates when filters require maintenance etc.. (Yellow LEDS).
14.4 VIEWING THE HOURS OF OPERATION
To view the total hours of operation press Ref. 3, Fig. 17a, the hours of operation appear in the bottom display and a dot lights up in the top
display (confirm LED).
To view the LOADED hours of operation press Ref. 3 Fig. 17a again and a dot lights up on the right side of the top display (confirm LED).
14.5 VIEWING THE HOURS OF OPERATION OF COMPONENTS SUBJECT TO MAINTENANCE
To view the hours of operation of individual components subject to maintenance, proceed according to Chapter 14.6,(1 to point 4); the
operating hours will be viewed on the bottom display.
- Press the button Ref. 3 Fig 17a to exit.
14. 6 RESETTING THE MAINTENANCE INTERVAL COUNTERS (YELLOW LEDs excluding LED “A”)
To reset a counter (i.e. Ref. L air filter) after having performed the relevant maintenance, proceed as follows: (see Fig. 17a)
1) Press buttons Ref. 7 and Ref. 4 simultaneously until the LED ref. H lights up.
2) Release the buttons Ref. 7 and Ref. 4
3) Use the buttons Ref. 1 and Ref. 2 to select the LED Ref. L (air filter) relevant to the component in question.
4) The operating hours of the component Ref. L (air filter) are viewed on the 5-digit bottom display.
5) Press the button Ref. 4 once and the value viewed flashes, press the button Ref. 4 again; the display is now reset and the
LED Ref. L is lit.
6) Press the button Ref. 3 to exit from RESET
7) To reset another component, move to the relevant LED using the buttons Ref. 1 and Ref. 2.
N.B. the board exits automatically from programming after 30 seconds of inactivity
14.7 ACTIVATING / DEACTIVATING THE LOADLESS-LOADED OPERATION MODE
1) Press the button Ref. 1 Fig. 17a and the LED Ref. Q flashes, the machine operates in MANUAL LOADLESS mode.
2) Press the button Ref. 1 Fig. 17a again and the machine returns to the automatic cycle.
14.8 OPERATING PARAMETERS OF THE BOARD.
The board is programmed in the factory with a preset value of the following parameters :
P0 = cut-off pressure (8 –10 bar) / (116 – 145 psi)
P1 = cut-in pressure (7.5 – 9.5 bar) / (108,5 – 137,7 psi)
r 2 = maximum operating temperature (100 °C) – (212 °F)
t 3 = not active
t 4 = not active
C5 = maximum number of starts per hour (10)
FIG. 17a
H
7
L
Q
1
2
3
4

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16 - Edition 05/2012 Cod. 2200780027 01-
The board is also programmed to measure the pressure in “bar” (parameter C7) and the temperature in °C (parameter C6).
The pressure and temperature units of measurement correspond to the table below.
Name of the parameter Value of the parameter
C6 0 = °C 1 = °F
C7 0 = bar 1 = °PSI
All parameters described above can be viewed and modified with the procedure indicated in paragraph 14.9.
The parameter number appears in the top display and the value of the parameter appears in the bottom display.
14.9 VIEWING AND MODIFYING THE VALUE OF BOARD PARAMETERS.
To view the board parameters proceed as follows:
- Press and hold the button 4 Fig. 17a for a few seconds, until “P0” (cut-off pressure) appears on the top display: the value of the cut-off
pressure in bar (8, 10 bar) / (116 – 145 psi) appears simultaneously on the bottom display.
- By pressing the button Ref. 1 Fig. 17a all the board parameters (P0, P1, r2, t3, t4, C5, C6, C7) will appear in sequence on the top display
while the values set for each parameter will appear on the bottom display. To exit press the button Ref. 3 until the luminous dot on the
display is positioned on the symbol.
To change the value of parameters follow the example indicated below:
EXAMPLE: the maximum temperature value is to be modified to 95°C. (203 °F)
- Press and hold the button Ref. 4 fig. 17a for a few seconds, until the parameter “P0” appears on the top display.
- Press the button Ref. 1 Fig. 17a until reaching the parameter “r2” (maximum temperature).
- Press the button Ref. 4 Fig. 17a: the value of the temperature indicated on the bottom display flashes.
- Press the button Ref. 2 Fig. 17a until reaching the value 95.
- Press the button Ref. 4 Fig. 17a to confirm the modification; the value 95 stops flashing.
- Exit from programming by pressing the button Ref. 3 Fig. 17a.
The new maximum temperature value is now 95.
14.10 DISPLAYING A TEMPERATURE LEVEL THAT IS TOO LOW
The card is programmed in the factory with a minimum temperature level set at (+ 4 °C – 39,2 °F), if the read level is
lower, it is shown by the bottom display flashing. This fault signal does not mean the compressor cannot be started, but
warns the operator that the room temperature is too low.
14.11 DRYER STATUS VISUALIZATION (ONLY FOR MACHINES WITH DRYER)
In order to see the visualization of the dryer status you have to press the button Ref. 3 Fig. 17b starting by main visualization.
Dryer status Lower display visualization Status of led ( G )
Local Ambient Temperature too low Empty Fixed ON
Good One square OFF
Good Two squares OFF
Good Three squares OFF
Good Four squares OFF
Local Ambient Temperature too high Five squares Fixed ON
Below an example of the visualization for a good dryer status.
Lower display
FIG. 17b
3

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. Cod. 2200780027 01 - Edition 05/2012 - 17
15.0 ORDINARY MAINTENANCE TO BE DONE BY THE USER
BEFORE CARRYING OUT ANY MAINTENANCE IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT FROM
THE POWER MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION NETWORK.
The maintenance jobs described in this chapter may be carried out by the user.
The more complex maintenance jobs which require professionally skilled personnel are listed in the chaper on GENERAL ROUTINE
MAINTENANCE. (See Chap. 21.0)
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 will ventilated. For particularly dusty
environments, double the frequency of controls.
Every Day (after use) Drain condensate from the air tank
Check automatic condensation emptying (on the dryer if fitted)
Every 50 working hours Drain condensate from the oil tank
Check the oil level
Clean the filtering panel
Every 500 hours Clean the air suction filter (see control board LED)
Clean the condenser battery (on the dryer if fitted)
Clean the dirt collection filter
 Check belt tension
Every 2000 hours Change the suction filter (see control board LED)
 Change the oil (see control board LED)
 Change the oil filter (see control board LED)
Change the filtering panel
Replace the line afterfilter (change the filter cartridge at least once a year)
Every 4000 hours  Clean the finned surface of the air-oil cooler
 Change the oil separating filter (see control board LED)

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15.3 DRAINING CONDENSATE FROM THE OIL TANK
If the compressor work cycle contemplates long pauses during which the machine cools down, a certain amount of condensate will gather in
the oil tank. This happens, for example, when stopping overnight or at weekends.
The condensate must be drained off every 50 hours or every week. This operation may be performed only when the machine is cold, that is
when it has been switched off for at least 8 hours.
BEFORE DRAINING THE CONDENSATE IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT FROM THE
POWER MAINS.
Proceed as follows:
- Switch off the machine with pushbutton Ref. 1 Fig. 18: in this way the machine stops after 45 seconds of idle running.
-Turn on the differential supply switch, Ref. 3 (on the screw-compressor) and Ref. 3A (on the dryer if fitted) Fig. 18.
- Wait for the machine to cool down.
- Remove the panels Ref. 4 Fig. 18 with the key provided.
- SLOWLY turn on the tap Ref. 5 Fig. 18 and let the condensate flow out.
- When the first traces of oil appear, turn off the tap.
CONDENSATE MUST BE DISPOSED OF IN CONFORMITY WITH THE LOCAL REGULATIONS IN FORCE.
- Check the oil level on the indicator Ref. 6 Fig. 18.
- If the oil level is under the minimum, top up as described at point 15.4.
15.4 CHECK OIL LEVEL AND TOP UP
- Switch off the machine with push button Ref. 1 Fig. 18: in this way the machine stops after 45 seconds of idle running.
-Turn on the differential supply switch, Ref. 3 (on the screw-compressor) and Ref. 3A (on the dryer if fitted) Fig. 18.
- Wait a few minutes for the foam in the oil collector to abate.
- Check the oil level on the indicator Ref. 6 Fig. 18
- If the oil level is under the minimum, top up.
USE OIL OF THE SAME TYPE AS THAT ALREADY IN THE MACHINE; DO NOT MIX DIFFERENT TYPES OF OIL.
BEFORE CARRYING OUT ANY OPERATION ON THEMACHINE, ENSURE THAT THE ELECTRIC POWER SUPPLY HAS
BEEN DISCONNECTED.
- Open the front panel Ref. 4 Fig. 18 with the special key.
- Slowly open the oil plug Ref. 7 Fig. 18.
- Top up to maximum level Ref. 6 Fig. 18, with oil of the same type in the compressor.
- Turn off the cap of the oil tank Ref. 7 Fig. 18.
- Close the panel Ref. 4 Fig. 18.
FIG. 18
7
6
5
3
3A
4
1

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15.5 CLEANING THE FILTERING PANEL
- Switch off the machine with pushbutton Ref. 1 Fig. 18: in this way the machine stops after 45 seconds of idle running.
-Turn on the differential supply switch, Ref. 3 (on the screw-compressor) and Ref. 3A (on the dryer if fitted) Fig. 18.
- Remove the filter panel Ref. 1 - 1A Fig. 19.
- Clean the filtering panel with a jet of air or wash it with water. Do not use solvents.
- Once the operation has been completed, reassemble the filtering panel Ref. 1 - 1A Fig. 19.
15.6 CLEANING THE SUCTION FILTER OR CHANGING THE FILTER
- Switch off the machine with pushbutton Ref. 1 Fig. 18: in this way the machine stops after 45 seconds of idle running.
-Turn on the differential supply switch, Ref. 3 (on the screw-compressor) and Ref. 3A (on the dryer if fitted) Fig. 18.
HOT PARTS INSIDE
- Remove the fixed protection device (machine cover) Ref. 2 Fig. 19.
- Remove the cover Ref. 7 Fig. 19A.
- Remove the filter Ref. 8 Fig. 19A.
AVOID DROPPING FOREIGN BODIES INTO THESUCTION MANIFOLD.
- Clean the filter with a jet of air, working from inside to outside, DO NOT USE WATER OR SOLVENTS. Alternatively, fit a new filter.
- Clean the disk on which the filter rests with a clean cloth.
- Fit the filter and the cover.
- If necessary, dispose of the old filter in conformity with the local regulations in force.
-Close the fixed protection (machine cover) Ref. 2 Fig. 19 device again, using the appropriate safety screws.
FIG. 19
1
1
A
2
EVERY 50 WORKING HOURS, CLEAN
THE FILTERING PANEL.
FIG. 19A
HP 25-30-40
8
7

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15.7 CHECKING THE AUTOMATIC CONDENSATION EMPTYING (FOR DRYER )
BEFORE CARRYING OUT ANY MAINTENANCE IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT FROM
THE POWER MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION NETWORK.
The automatic condensation drain must be checked (Rif. 1 every 500 hours working) Fig. 20.
Proceed as follows:
- Remove the panel Réf. 3 Fig. 20
- Press the "TEST" button, Ref. 1 Fig. 20, for a few seconds to check if the condensation is correctly emptied from the drainage pipe
15.8 CLEAN THE DIRT COLLECTION FILTER FOR DRYER (ON THE DRYER IF FITTED)
Proceed as follows:
- Close the tap Ref. 4 Ref. 20
- Remove the panel Réf. 3 Fig. 20
- Depressurise the dryer by pressing the "TEST" condensation emptying button (for about 10-20 seconds) Ref. 1 Fig.20
- Switch off the machine with pushbutton Ref. 1A Fig. 20: in this way the machine stops after 45 seconds of idle running.
- Turn off the disconnect switch, Ref. 5 (on the screw-compressor) and Ref. 6 (on the dryer if fitted) Fig. 20.
- Remove the stopper Ref. 7 Fig. 20
- Remove the filter Ref. 8 Fig. 20
- Clean the filter with a jet of air, working from inside to outside
- Install the filter, fix the plug.
- Install the panel Réf. 3 Fig. 20
FIG. 20
1
8
7
4
6
5
1A
3