pilotair ALTA-TEC Series Guide

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Pilot ALTA-TEC 30-37 Variable Speed Rotary Screw
ALTA-TEC SERIES
ALTA-TEC 31 –38VS
User’s Maintenance and Spare Parts Manual

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Dear Customer,
Thank you for choosing Pilot Air.
In order to get the best performance out of this product, please read this manual carefully.
To avoid incorrect operation of the equipment and possible physical risk to the operator, please read and strictly
follow the instructions contained in this manual.
Note, these instructions are in addition to the safety rules that apply in the country where the air compressor is
installed.
Before packing for shipment, each machine undergoes a rigorous test to ensure the absence of any
manufacturing faults and to demonstrate that the device can perform all the functions for which it has been
designed.
This manual must be maintained available in any moment for future references and it has to be intended as
inherent part of the relevant dryer.
Due to the continuous technical evolution, we reserve the right to introduce any necessary change without giving
previous notice.
Should you experience any trouble, or for further information, please do not hesitate to contact us.
Best Regards,
PILOT AIR COMPRESSORS
http://www.pilotair.com
Phone: [phone]
Email: [e-mail] / [e-mail]

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INDEX GB
1 Declaration of Conformity 3
2 General Information 5
3 Overall Dimensions 6
4 Safety Regulations 8
5 Installation 11
6 Technical Features 13
7 Start-up and Operations 14
8 Maintenance 28
9 Troubleshooting 32
10 Wiring Diagram 33
11 Warrant Terms and Conditions 34

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General Information
OUTFIT
The following accessories are supplied with the compressor:
•Use and maintenance manual
•Anti-vibration elements
•Electric box panel key
•Oil/Condensate exhaust tube
Check that the above accessories are available. Once the goods have been delivered and accepted, no
complaints are accepted.
CONDITION OF THE MACHINE WHEN SUPPLIED
Every compressor is shop tested and delivered ready to be installed and to be set at work.
The oil for first filling used is: FSN Original Oil.

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Overall Dimensions

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Overall Dimensions

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Safety Regulations
General Warnings
•The rotating compressors are destined for arduous and continuous industrial use. They are particularly
adapt for application in industries where a large consumption of air is requested for long periods of time.
•The compressor must be used exclusively as indicated in this manual which must be kept carefully in an
easily accessible place known to everyone as it must remain with the machine for its entire duration.
•The company in which the compressor is to be installed must appoint a person n charged of the
compressor itself. Controls, adjustments and maintenance interventions are under his responsibility: if this
person must be replaced, the substitute must read the user and maintenance manual and any notes
made regarding technical and maintenance interventions carried out up to this time.
SYMBOLS USED IN THE MANUAL
Several symbols have been used inside the manual, which highlight dangerous situations, give practical advice
or simple information. These symbols are found at the side of a text, at the side of a figure or at the top of a page
(in this case they refer to all subjects considered o the entire page).
Pay attention to the meaning of this symbols:
READ THIS PAGE CAREFULLY BEFORE PERFORMING ANY OPERATION ON THE COMPRESSOR

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Safety Regulations
SYMBOLS USED ON THE COMPRESSOR
Several different labels are applied to the compressor. Their function is most of all to highlight any hidden
dangers and to indicate correct behavior during use of the machine or in particular situations.
It is of fundamental importance that they are respected.
TO DO:
•Make sure that mains voltage corresponds to the voltage indicated on CE plate and that cable of suitable
cross-section are used for electric connections.
•Always check oil level before starting the compressor.
•Be familiar with emergency stop control and all other controls.
•Unplug the connector before any maintenance work, so to avoid accidental start.
•Ensure that all parts have been correctly reassembled after any maintenance work.
•Keep children and animals off the working area to avoid injuries caused by devices connected to the
compressor.
•Ensure that temperature of the working environment ranges between +2 and + 45 ºC. Compressor
working temperature shall range between 70÷85°C (20-25°C room temperature). Lower temperatures
may cause condensate accumulation inside the oil separator tank (inside the compressor).
•Check for condensate and if necessary, drain it (see maintenance).
•The compressor should be installed and operated in a non-explosive environment.
•Allow at least 80 cm between the compressor and the wall so to allow free air flow to the fan.
•Press the emergency button on the control panel only in case of actual need so as to avoid possible
damages to people or the very compressor.
•When calling for technical assistance and/or advice, always mention model, code and serial number
indicated on CE plate.
•Always follow the maintenance schedule specified in the user’s guide.
READ THIS PAGE CAREFULLY BEFORE PERFORMING ANY OPERATION ON THE COMPRESSOR

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Safety Regulations
DO NOT:
•Do not touch inner parts and pipes as they are very hot during compressor operation and stay hot for a certain
time after compressor stops.
•Do not position inflammable close to and onto the compressor.
•Do not move the compressor when the tank is under pressure.
•Do not operate the compressor if the power cable is damaged or defective or if connection is unstable.
•Do not operate the compressor in wet or dusty environments.
•Never aim the air jet at people or animals.
•Do not allow unauthorized people to operate the compressor and give them all required instructions.
•Do not hit fans with blunt objects as they might break during compressor operation.
•Never operate the compressor without air filter.
•Do not tamper with safety and adjusting devices.
•Never operate the compressor when doors/panels are open or removed.
•Do not strike the fans with contusive or metal objects as they could cause sudden breakage during functioning.
•Do not allow the compressor to function without the filter and/or air pre-filter.
•Do not tamper with safety and adjustment devices.
•Never allow the compressor to function with the hatches/panels open or removed.
PRODUCT IDENTIFICATION
The compressor you have purchased has its own CE plate showing the following data:
1. Manufacturer’s data
2. Year of manufacture
3. TYPE = name
CODE = code
SERIAL NO. = serial number (to be always mentioned when calling for technical assistance)
4. Tech data: air intake/air delivery, max. operating pressure, tank capacity, rotations per minute, weight
5. Electric data: Voltage, frequency, absorption, power
6. Noise level
READ THIS PAGE CAREFULLY BEFORE PERFORMING ANY OPERATION ON THE COMPRESSOR

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Installation
DESCRIPTION OF THE COMPRESSOR

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Installation
DESCRIPTION OF THE COMPRESSOR
1. Electrical Equipment 11. Electric Motor
2. Front Panel 12. Control Panel
3. Lid 13. Air Intake Outlet
4. Electric Fan 14. Suction Regulator
5. Oil Filter 15. Screw Compressor
6. Oil Separator Filter 16. Inverter
7. Minimum Pressure Valve 17/ Emergency Button
8. Oil separator tank
9. Air Filter
10. Air / Oil Radiator
UNPACKING AND HANDLING THE MACHINE
•When delivered, compressor top is protected by cardboard packing.
•Wear suitable protective gloves and then cut outer straps and then remove cardboard from the top.
Check the (outer) good condition of the machine before moving the compressor. Visually check that no
parts are damaged. Also, ensure that all accessories are available.
•Lift the machine using a forklift truck. Fit the anti-vibration elements into their proper seat and move the
machine to the room chosen for its location with maximum care.
•Keep all packing materials at least for the warranty period for possible moving. In case of need, it will
be safer for delivery to technical assistance department.
•Then, dispose of packing materials in compliance with current laws.
LOCATION (fig. 2)
The room chosen for the installation of the compressor should meet
the following requirements and comply with what is specified in the
current safety and accident prevention regulations:
•low percentage of fine dust,
•proper room ventilation and size that allow room
temperature under 45° C. In the event of inadequate hot air
discharge, fit the exhaust fans as high as possible.
Condensate should be collected either into a container or a tank, or a
water/oil separator should be fitted.
CONDENSATE IS A POLLUTING MIXTURE! It must not be let into
the sewage.
The dimensions of the spaces are indicative but it is advisable to
follow them as closely as possible.
ELECTRICAL HOOK-UP (fig. 3)
•The mains cable should have a cross-section suitable for the
machine power and should include no. 3 phase wires and no.
1 earth wire.
•Between the mains cable and the compressor control panel a
fused switch near the point where the cables go into the
machine is absolutely necessary. The switch should be at
least at 1.7 m from the ground.
•The switch (A) should be easily reached by the operator. The
cables should be of the approved type and installed with the
following grade of protection: minimum IP44.
N.B. To determine the cables cross-section follow the sizing
indications in compliance with the “VDE 0100, Part 430 and 523”
Standard, star-delta starter, 30 °C room temperature and cable length
lower than 50 meters.

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Technical Features

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Start-Up and Operation
1 CHECKS TO BE CARRIED OUT PRIOR TO START-UP
N.B.: The customer is responsible for installing the machine and making the required
electrical and air connections.
Initial system start-up must be carried out by skilled personnel who will make the various
checks required and follow the respective instructions.
Each machine was thoroughly tested at the plant before shipping.
You should monitor the compressor during the first hours of operations to check for faults.
•Follow the installation prescriptions given in the previous chapters
•Remove all packaging materials and tools
•Connect the compressor to the distribution line as shown in paragraphs.
•Check the oil level in the tank: refer to section: “Maintenance, Oil Control and Topping Up.” In the
event of low oil level, top up with FSN Original Oil.
•Check for correspondence between the compressor plate data with the actual specification of the
electrical system. A variation of ± 5% with respect to the rated value is allowed.
•Connect the machine to the electrical system as described in the previous chapters.
Compliance with the correct voltage phase
sequence is fundamental since this defines the
direction of rotation of the motor. The direction
of rotation must be that indicated by the
adhesive label located to the side of the screw
unit (see picture).
Note that even a few seconds of incorrect
rotation may cause serious damage.
A phase sequence checking device to prevent
mistakes is fitted in the electrical panel.
Now the machine is ready to go.
Before starting the machine, read the following
sections and the chapter on maintenance
operations for in depth knowledge of the
machine.

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Start-Up and Operation
OPERATING MODE
•At the end of the start cycle, the compressor
goes to the maximum operation speed and
begins to compress air in the tank (5).
•When approaching the desired operating
pressure, the compressor begins to modulate
the frequency of rotation of the motor
(max.100%, min. ~ 40%) so as to maintain a
constant air flow rate according to the pressure
selected.
•Compressed air cannot escape through the
min. pressure valve (7), which is set at ~ 4 bar.
•Compressed air compresses oil inside tank (5)
and causes it to flow through tube (8) to the
radiator (9).
•Cooled oil is returned to filter (11).
•From filter (11), oil reaches compressor (3)
through tube (12). Oil is mixed with sucked air
to form an air/oil mixture that provides sealing
and lubrication of compressor moving parts.
•The air / oil mixture returns into the tank (5) where air undergoes a pre-separation and subsequently a final
separation from the oil through the oil separator filter (6). Then air passes through the minimum pressure valve
(7) and finally is sent to the distribution system.
•Min. pressure valve (7) serves also as a check valve.
•Compressor delivers compressed air to outer air tank.
•Tank inner pressure increases until reaching max. calibration value.
•Once max. value is reached, pressure gauge starts timer and powers off solenoid valve of regulator (2).
•Regulator (2) closes and compressor stops compressing and starts idling.
•Timer continues counting until reaching set value and, if pressure is unchanged, stops the electric motor. If
pressure drops to minimum value set on controller, solenoid valve is powered and opens before timer counting
is over.
•Regulator (2) opens and compressor operates under normal load; timer is reset.
•This cycle is automatically repeated.

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Start-Up and Operation
2 - CONTROL PANEL
The compressor is fitted with a “control panel” for setting up and monitoring machine operation. The operating
parameters were entered by the manufacturer during “testing”. The parameters were tested for several hours in the
various operating conditions.
The features offered by this electronic control system include:
•Fully automatic compressor operation
•Real-time operating parameter display
•Customization operating parameter
•Programming of compressor operation on a daily or weekly basis
•Programming and signalling of the manufacturer’s maintenance schedule.
•Machine self-protection system to signal fault pre-alarms and automatically stop the machine in the event
of serious problems.
•Remote machine control
•Possibility of connecting the compressor to other similar compressors with the same controller for
integrated management of the set of machines.
•Remote compressor monitoring via personal computer and dedicated software (optional)
Compressor Functioning
Start-up procedure:
Press the START (I) button. If no alarms are on, the start-up cycle activates:
Stand-by for start-up: the control unit is waiting to verify the following conditions before starting the compressor:
•If the machine was switched off or a previous stoppage was executed, the control unit waits 15 seconds before
starting the compressor.
•The control unit waits for the pressure to go below the value set in the “Load pressure” set before starting the
compressor. (“STAND -BY” is displayed)
•Star compressor start-up: the line and star remote control switch for the time defined in the parameter
“Star/delta time” (“NO LOAD” is displayed)
•Transition from star to delta: the remote control switch for the line remains active, while the star relay is
deactivated; this phase lasts for the set time of 20 msec. (“NO LOAD” is displayed)
•Fully operational compressor start-up: the line relay is maintained active and also the delta relay is activated;
this phase lasts for the time set in the parameter “Load delay”. (“NO LOAD” is displayed)
•Compressor loading phase: the solenoid valve relay of the load is active. This phase lasts until the pressure
measured reaches the pressure set in the parameter "No load pressure". ("LOADED" is displayed)
•Compressor no load phase: the solenoid valve relay of the load is deactivated; this phase lasts as long as set
in the parameter “No load time”. After this, the cycle re-starts from the Start-up stand-by phase (“NO LOAD” is
displayed).

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Start-Up and Operation
Stoppage procedure:
•Press the STOP button (O) to activate the stoppage
procedure. The load solenoid valve is deactivated and
the no load cycle starts for the time set in the
parameter “Stoppage time” (“NO LOAD” and then
“STATUS - OFF” are displayed)
Remote pressure
•By enabling remote pressure control using the
parameter “Enable remote”, the remote pressure digital input is enabled. The control unit in this
configuration keeps the remote input under control like an external pressure switch. Furthermore, it is also
controlled that this acts within the range of the values set (load set, no load set or working and delta
pressure in the event of an inverter). If the set pressure is surpassed due to an anomaly on the remote
pressure control, the control unit will take command of the compressor cycle by working with the internal set
values, signalling a “remote press. err.”
•If the anomaly is solved, pressure control is again entrusted to the remote pressure input, (at this point the
alarm can be reset).
ON/OFF remote
•Using the “ON/OFF from remote” the compressor can be activated remotely, by pressing the Start (I) key.
Provided no alarms are on, remote start-up takes place. The remote command has less priority over the
Start (I) and Stop (O) keys on the panel.

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Start-Up and Operation
Compressor Functioning with an Inverter
Start-up procedure:
Press the START (I) button. If no alarms are on, the start-up cycle activates:
•Stand-by for start-up: the control unit is waiting to verify the following conditions before starting the
compressor:
•If the machine was switched off or a previous stoppage was executed, the control unit waits 15 seconds
before starting the compressor.
•The control unit waits for pressure to go under the value set in the “working Pressure-working Delta/2” set
before starting the compressor. (“STAND-BY” is displayed)
•Compressor start-up: the line remote control switch is powered.
•Fully operational compressor start-up: the line relay is maintained active and also the delta relay is
activated; this phase lasts for the time set in the parameter “Load delay”. (“NO LOAD” is displayed).
•Compressor loading phase: the solenoid valve relay of the load is active. This phase lasts until the
pressure measured reaches that set in the parameter “working Press. + working Delta/2”. (“LOADED” is
displayed)
•Compressor no load phase: the solenoid valve relay of the load is deactivated; this phase lasts as long as
set in the parameter “No load time”. After this, the cycle re-starts from the Start-up stand-by phase (“NO
LOAD” is displayed)
In this phase, the control unit executes a control algorithm to keep the pressure as close as possible to the
working pressure by adapting the speed of the motor based on air consumption.
Dryer Functioning
•For machines supplied with a dryer, the control unit can control the drying cycle.
•Using the “Dryer ON” parameter, if its functioning is enabled, which can be continuous or linked to
compressor motor functioning, by setting the parameter “Functioning mode”.
•The dryer motor is activated if the temperature is over the total of the temperatures defined in the
parameters “Temperature OFF” and “Thermic drift” and deactivated if lower than the parameter
“Temperature OFF”.
If the temperature remains outside the aforementioned limits for a time over that set in the parameter “Alarms
delay”, an alarm sounds (see ALARMS and WARNINGS paragraph)
To avoid damaging the motor due to over-frequent start-ups you can moderate re-starts for the time defined in
the parameter “Minimum time”. (see DRYER MENU paragraph)
Condensate Drainage Functioning
For machines requiring the condensate drainage function using the parameter “Condensate drainage ON”, the
function can be enabled and defined by setting the parameter “Functioning mode”
The drainage solenoid valve stays on for the time set in the “Interval” parameter and remains deactivated for
the time defined in the parameter “Opening time” (see the CONDENSATE DRAINAGE MENU paragraph).

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Start-Up and Operation
Main Screen
The main screen summarises the current status of the machine.

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Start-Up and Operation
Menus and Parameters
•The menus are structured as vertical drop-down
menus; the title is on top and is followed by the list
of parameters or sub-menus available. If the menu
contains more items than the LCD display can
show, two arrows (Up and Down) appear on the
right to indicate more items are present.
•Use the “Arrow up” and “Arrow down” keys to
find the parameter or sub-menu and highlight it to
then open it by pressing the “Enter” key; go back
by pressing the “Esc” key.
•If you go to a parameter screen you can change its
value using the “Arrow up” and “Arrow down”
keys or you can make this value the default value
using the “reset” key. By pressing the “Enter” key,
you exit the menu, saving the parameter value. Press the “Esc” key to return to the previous menu only.
•Some menus contain exceptions in relation to parameter entries, which will be dealt with individually in the
following paragraphs.