pilotair PAC Series Guide

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PAC SERIES
PAC SERIES 56-75 KW
User’s Maintenance & 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
G
B
1 Declaration of Conformity 3
2 General Information 5
3 Overall Dimensions 6
4 Safety Regulations 8
5 Installation 11
6 Technical Features 14
7 Start-Up and Operation 15
8 Maintenance 31
9 Troubleshooting 36
10 Wiring Diagram 37
11 Warrant Terms and Conditions 39

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General Information
OUTFIT
The following accessories are supplied with the compressor:
•Use and maintenance manual
•Electric box panel key
•Oil/Condensate Exhaust tube
CONDITION OF THE MACHINE WHEN SUPPLIED
Every compressor is shop tested and delivered ready to be installed and to be set at work.
Oil Used is: ROTENERGY PLUS.

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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 in charge 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 on the entire page).
Pay attention to the meaning of the 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 behaviour 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 the 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

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Installation
DESCRIPTION OF THE COMPRESSOR
1) Electrical equipment 9) Air Filter
2) Front panel / Oil Indicator Level 10) Air/Oil Radiator
3) Lid 11) Electric Motor
4) Electric fan 12) Control Panel
5) Oil filter 13) Air Intake Outlet
6) Oil separator filter 14) Suction Regulator
7) Minimum pressure valve 15) Screw Compressor
8) Oil separator tank
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 fork lift truck. 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 the technical assistance dept.
•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:
olow percentage of fine dust,
oproper 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 only but
it is advisable to follow them as closely as possible.

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Installation
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, no. 1
neutral cable 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 and the type of switch, refer to the data reported on the technical
table. Sizing according to “VDE 0100, Part 430 and 523”, star-delta starter, 30° C ambient 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 6.2 and 6.3.
•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 RotEnergy Plus.
•Check for correspondence between the compressor plate data with the actual specifications 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
•During first start-up, motor is
started and “star” powered. During
this phase compressor starts slowly,
solenoid valve is closed and suction
regulator (2) is closed.
•The compressor is kept under
these conditions for about 6
seconds.
•This time over, motor is “delta”
powered. Solenoid valve is powered
and enables suction regulator (2)
opening. The regulator sucks in air
through filter (1).
•During this phase compressor is
working at peak rpm and starts
compressing air inside oil separator
tank (5), through tube (4).
•Compressed air cannot escape
through the min. pressure valve (7),
which is set at 3÷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)
through tube (10).
•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 goes back to tank (5), where air and oil are first separated by centrifugation and
then by the oil separator filter (6).
•As a result, tank (5) will deliver air only to air radiator (9) through tube (13). Air is then conveyed to
mains through a cut-off cock.
•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 - “ET-IV” 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 includes:
•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 via CAN-BUS interface (optional) to other similar compressors
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:
oIf the machine was switched off or a previous stoppage was executed, the control unit waits 15
seconds before starting the compressor.
oThe 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