ROTAR Giga 75 Specification sheet

Rotar Giga 75-100 - Cod.197AA3900 - Rev.03 - 05/2007
GB
use & maintenance
MANUAL
RotarRotar
RotarRotar
Rotar
Giga 75-100Giga 75-100
Giga 75-100Giga 75-100
Giga 75-100

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GENERAL INFORMATION
STANDARD EQUIPMENT
Check outfit carefully. Later claims for missing parts will not be accepted.
The following accessories are supplied with the compressor:
no. 1 oil drain tube
no. 1 door key
no.1 user’s guide
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 used is: RotEnergy Plus
GENERAL INFORMATION............................................................................3
SAFETY INDICATIONS.................................................................................4
INSTALLATION .............................................................................................6
CONTROLS AND SETTINGS .......................................................................8
ALARMS......................................................................................................10
START-UP PROCEDURE AND DISPLAYINFORMATION.......................... 11
OPERATION ...............................................................................................12
MAINTENANCE ..........................................................................................13
TROUBLE-SHOOTING ...............................................................................16
TECHNICAL FEATURES ............................................................................17
WIRING DIAGRAM .....................................................................................18

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SAFETY INDICATIONS
Read this page carefully before servicing the compressor.
SYMBOLS ON THE COMPRESSOR
The compressor has several labels to highlight possible danger and give recommendations on what to do during machine
operation or in special situations.
Please comply with these indications.
GENERAL
•Rotarycompressorsareintendedforheavycontinuousindustrial use.They are especially suitable for industrial applications
requiring high air consumption for a long time.
•The compressor should be run and operated only in compliance with the indications given in this manual. Safely keep this
manual in a known and easily reachable place for the whole working life of the compressor.
•Asupervisor shall be appointed in the company, in which the compressor is installed. He/she shall be responsible for
compressor inspections, adjustments and maintenance. Should a substitute be appointed for the supervisor, he/she shall carefully
read the user’s guide and all possible comment on service and maintenance carried out so far.
SYMBOLS USED IN THE MANUAL
Some symbols are used to highlight danger situations, give recommendations or information. These symbols are usually
positioned next to the text, a figure or at the top of a page (in this case they refer to all subjects dealt with in that page).
Carefully read symbol meaning below.
CAUTION!
Important description on service, dangerous
situation, safety, accident prevention
recommendationsand/orvery importantinformation.
STOP MACHINE!
All operations to be strictly carried out only after
stopping the machine.
POWER OFF!
All operations to be strictly carried out only after
powering off the machine.
SPECIALIZED PERSONNEL!
All operations to be strictly carried out only by
specialized technician.
Danger! Hot!
Danger! Electric shock!
Danger! Hot gas or harmful gas
within working area
Danger! Pressurized container
Danger! Mechanical moving parts
Caution! Maintenance works in progress
Danger! Machine can restar automatically
Prohibited!Donotopendoorsduringcompressor
operation
Prohibited! Press emergency button for
compressorimmediatestop.Donotuselineknife
switch.
Prohibited! Do not use water on electric
equipment to extinguish fire.
Compulsory! Read instructions for use carefully.

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SAFETY INDICATIONS
Read this page carefully before servicing the compressor.
WHAT 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.
Empty the air tank and/or oil separator and 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.
Carefully read instructions for the installed accessory, especially if painting devices are installed.
Ensure that the installation place is properly ventilated.
Ensure that temperature of the working environment ranges between +5 and + 45 ºC.
The compressor should be installed and operated in a non-explosive environment.
Allow at least 50 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 and serial number indicated on CE plate.
Always follow the maintenance schedule specified in the user’s guide.
WHAT NOT TO DO:
Do not touch inner parts and pipes as they are very hot during compressor operation and stay hot for a certain time after
compressor stop.
Do not position inflammable or nylon objects or cloths 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 explosive environment or in case of naked flames.
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.
PRODUCT IDENTIFICATION
The compressor Your have purchased has its own CE plate showing the following data:
1) Manufacturer’s data
2) CE mark – year of manufacture
3) TYPE = name of the compressor
CODE = compressor code
SERIAL NO. = serial number of the compressor You have purchased (to be always mentioned when calling for technical
assistance)
4) air delivered by the compressor expressed in (l/min) and (cfm)
5) max. operating pressure (bar and PSI) – compressor noise level in dB(A)
6) electric data: voltage (V/ph), frequency (Hz), absorption (A) - power (HP and kW), rotations per minute (Rpm).
7) other approvals

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150 cm (min)
600 cm (min)
350 cm (min)
h min = 350 cm
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COMPRESSOR DESCRIPTION (fig.1)
The compressor essentially consists of:
1) Condensate trap / condensate drain (Autodrain)
2) Screw/motor support plate
3) Motor
4) Suction regulator
5) Air intake filter
6) Air-oil radiator
7) Electric box /control panel
8) Min. pressure valve
9) Oil separator tank/oil separator filter
10) Oil filter
11) Screw compressor
UNPACKINGAND HANDLING
Thecompressorisusuallyshipped to a Customer into a special packingsotoprotectthecompressoragainst transport damages.
As the compressor is very heavy (see “technical features” table), it must be lifted only by means of suitable capacity driven by
specialized personnel.
Compressor base has slots, whereas compressor top has four anchoring points for eyebolts in case the compressor needs to
be lifted from the top by crane or hoist.
Do not stand within fork lift truck working area and keep safety distance.
Perform the following after moving the compressor to the installation place:
• Unpack the compressor. Wear protective gloves and use suitable tools (follow instructions on the crate)
• Check the (outer) good condition of the machine.
• Open the access doors and check all inner parts (visual check)
• Dispose of the packaging in compliance with the current waste disposal regulations.
PLACEMENT (fig.2)
The room chosen for the installation of the compressor should
meet the following requirements and comply with current safety and
accident prevention regulations:
A) low percentage of dust suspended in air,
B) Proper room ventilation and size that allow room temperatu-
re (5°C ÷ 50°C) to be maintained - with the machine running.
Min. air intake opening: 2 sq. m
C) In the event of inadequate hot air discharge, fit three or more
exhaust fans as high as possible.
Exhaust fan “4,000 cu. m/h” part no. 020042000
•The condensate is a polluting mixture and should not be
disposed of into the sewage system or wasted in the environment.
The sump should be equipped either with a valve and a removable
container or connected to a suitable piece of equipment (oil-water
separator, part no. 048203000).
Dimensions shown in fig. 2 are indicative. It is recommended to
comply with given indications.
INSTALLATION
•Position the machine at the final place of installation. Make
sure it is stable and leave at least 90 cm between the machine
and the wall so as not to obstruct proper air flow to the fan.
Position the air tank. Connect the compressor and tank using the
supplied delivery hose.
Do not fit check valves between compressor and tank.
INSTALLATION
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2

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INSTALLATION
HOT AIR PIPING
• Hot air comes out from the upper side of the compressor at a temperature 15 ÷ 35°C higher than the room temperature.
• If the room ventilation is not enough (door/window opening: under 2 sq. m), a pipe having the same cross-section as the
radiator pipe is absolutely necessary. This pipe should be equipped with a valve conveying the hot air outside in summertime and
inside in wintertime, thus using the compressor heat energy as auxiliary heating unit.
These pipes should not be longer than 4 m. Otherwise, an auxiliary fan should be installed on the outlet side.
POWER CONNECTION
•Proceed to power connection with cross-section cables suitable for machine power: no. 3 phase cables and no.1 ground
cable.
•Have a switch providedwithplugfusesinstalled between supply lineandcontrolpanel,closetomachinecableconnections.
This switch should be installed at at least 1.7 m from the ground.
•Switch should be within operator’s reach. Cables shall be homologated and with a min. protection degree equal to IP54.
Note: To choose cables cross-section, refer to the “technical features” table.

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CONTROL PANEL
The main functions of the compressor are controlled by means of an electronic control unit installed in the control panel.
1. Buttons for menu scrolling / modifying values
2. OK button – for confirming settings
Reset button – for silencing alarms
3. Alarm LED
4. I/ON Button – switch-on
5. 0/ OFF Button – switch-off.
6. Display
To adjust the contrast, press together (with machine in OFF status).
The contrast can be adjusted from 1 (darker) to 20 (lighter). Press OK to save the value.
7. Emergency button – to be used for stopping the compressor immediately only in the event of a real emergency.
TYPE OF SERVICE
Automatic operation
•Compressor operation is regulated by the pressure transducer, which stops the machine when the maximum pressure is
reached and restarts it when the pressure has returned to the minimum setting value.
The machine stop is delayed type; that is, it does not coincide precisely with the reaching of P max, but after a defined interval
of time during which there is no air intake.
•The factory setting is 180 seconds, but we recommend checking that the number of starts per hour is NOT greater than the
maximum recommended number of 12. If the number is greater, it is preferable to increase the idle running time (see the section
“Modifiable parameters” point 7).
MODIFIABLE PARAMETERS
Pressing the OK button with the machine OFF takes you to the menu of operating parameters. In certain cases a
password is required in order to access the modifications. Use the buttons to scroll the menu.
0) Control unit ID (servicepassword):selects the identification number of the control unit;ifseveral compressors are connected
to the same RS485 line, multiple IDs can be selected.
1) Maintenance – Pre-alarm hours (service password) : each working hour of the machine is counted down automatically;
when the counter reaches 0, the control unit trips a Maintenance Alarm.
Use the XX buttons to scroll the items of the menu:
1. General maintenance: hours remaining
2. Air filter change: hours remaining
3. Oil filter change: hours remaining
4. Oil change: hours remaining
5. Bearing lubrication: hours remaining
6. Idle hours: displays the hours of idle running
7. Total working hours: displays the total working hours
The count preceded by the (-) sign indicates the number of hours that have elapsed since the last maintenance alarm.
The buttons can be used to set a new value (in this way overriding the previous alarm).
2) Alarm history (no password required): with this menu you can view the last 100 alarms.
3) Pre-alarm temperature (factory password): on this menu you can set the temperature differential (“delta”, expressed in °C)
with respect to the maximum alarm temperature; the value can be set between 1 and 20.
Example: If the maximum temperature is 120°C and the differential value is 10°C, the maximum temperature pre-alarm is
tripped at 110°C.
4) Maximum temperature (factory password): with this menu you can set the maximum temperature allowed; the setting range
CONTROLS AND SETTINGS

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CONTROLS AND SETTINGS
is from 0 to 150°C.
5) Minimum temperature (factory password): with this menu you can set the minimum temperature; the setting range is from
0 to -14°C.
6) Fan temperature (service password): with this menu you can adjust the temperature for activating the cooling fan; the
setting range is from 0 to 150°C. At the preset temperature the fan starts; hysteresis is fixed at 10°C.
7) Duration of the idle running cycle (service password): with this menu you can change the duration of the machine idle
cycle; the setting range is from 60 to 900 seconds.
8) Stop Empty Cycle (assistance password): using this menu you can change the duration of the empty operating cycle
following the voluntary stopping of the compressor (OFF button), the range of regulation goes from 30 to 240 seconds.
9) Automatic start (service password): this parameter enables the automatic start; if it is activated, the compressor will restart
automatically following an interruption of the electrical power supply.
10) Internal phase sequence (service password): this parameter enables the internal phase sequence control, or disenables
the internal control by activating the input without phases on the terminal block.
11) Language (no password required): this parameter allows you to change the language in which messages are displayed.
12) RS485 enable (no password required): this parameter is used to enable data transmission via RS485 and automatically
disenable transmission on RS232.
13) Set time and date (no password required): used for setting the current time and date.
14) PSI/BAR (no password required): for selecting the unit of measurement used to display the pressure.
15) Idle/Operating pressure set point (nopasswordrequired):thisparameterisusedtosetthe pressure atwhichthecompressor
must shut down.
16) Load/Operating differential set point (no password required): indicates the pressure at which the control unit enables
compressor restart.
17) Maximum pressure (service password): this parameter sets the maximum pressure value that can be reached, i.e. the
maximum value set in point 14.
18) Maximum pressure alarm (factory password): this parameter sets the maximum pressure value at which the control unit
trips an alarm and blocks compressor operation.
19) Remote Pressure (assistance password): enabling this parameter, the visualisation of the pressure and respective
alarms is maintained, but the control of the start of the compressor takes place using an external pressure switch linked to a
dedicated digital entry. In this event, it is necessary to pay attention that the setting of the external pressure switch falls within
the values imposed in points 15 and 16. In case of an anomaly, an alarm message will appear.
20) Start programme (service password): this menu allows you to programme the starts and stops of the compressor. Use
to select one of the five programmes available and press OK to enter the desired data (start time, stop time, and day of
the week).
To disactivate the programming, go to the menu and enter the same time of start and stop.
21) X1 progr. NC-NO (service password): allows you to invert the logic of the inputs of terminal block X1.
22) X7 progr. NC-NO (service password): allows you to invert the logic of the inputs of terminal block X7.
23) Motor therm. separate (service password): with the parameter ON, the thermal relays of the compressor and fan motors
are separated on two different inputs.
24) Temp. unit of measurement (no password required): for selecting the unit of measurement of the temperature (°C-°F).
25) Maximum starts per hour (service password): for selecting the maximum number of restarts per hour allowed. If this
value is exceeded, a signal is given.
•The following menus are enabled only if an inverter is present:
26) Inverter
27) Minimum operation %
28) Load delay
29) Inverter integration
30) Inverter parameters
Parameter min. max. Def. Parameter min. max. Def.
0 ID 000 009 000 11 Language ITA
1 General maintenance: hours 0 50000 4000 12 RS485 enable YES
Air filter change: hours 0 50000 2000 13 Time and date
Oil filter change: hours 0 50000 4000 14 PSI/BAR Bar BAR
Oil change: hours 0 50000 8000 15 Idle Bar 0 P.Max. 10
Bearing lubrication: hours 0 50000 4000 16 Load Bar 0 2 0,5
Idle hours: hours 0 50000 0 17 Maximum pressure Bar 0 P.all. - 0,5 11
Total working hours: hours 0 50000 0 18 Maximum pressure alarm Bar 0 16 14
3 Pre-alarm temperature °C 0 20 5 19 Remote pressure Bar NO
4 Maximum temperature °C 0 110 110 20 Start programme OFF
5 Minimum temperature °C -14 0 -7 21 X01 progr. NC-NO 01 010110
6 Fan temperature °C 0 150 65 22 X07 progr. NC-NO 111111
7 Idle running cycle sec. 60 900 180 23 Motor therm. separate NO
8 Stop EmptyCycle sec. 30 240 35 24 Temp. unit °C
9 Automatic start NO 25 Max. starts per hour n° 1 200 12
10 Internal phase sequence NO

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ALARM MESSAGES
When a fault occurs or the safety limits set are exceeded, the red alarm light comes on and the alarm in progress is shown on
the display.
In the case of multiple alarms, use to scroll through the items.
To silence an alarm, press the RESET button.
To delete all the non-active alarms, press RESET and hold it down for at least 2 seconds.
•rot.dir.error
Alarm tripped in the event of an incorrect phase sequence. The alarm blocks compressor operation; to restart operation, the
correct phase sequence must be re-established.
N.B.: To completely reset the alarm you have to switch off the electrical power supply.
•air.temp.sens. fault
Alarm tripped in the event of a temperature sensor fault (sensor open or short circuit). The alarm blocks compressor operation;
to restore operation, check the connection and/or replace the sensor, then press the RESET button XX.
•screw.temp.sens. fault
Alarm tripped in the event of a temperature sensor fault (sensor open or short circuit). The alarm blocks compressor operation;
to restore operation, check the connection and/or replace the sensor, then press the RESET button XX.
•max.oil.temp.
Alarm tripped when the maximum oil temperature is reached. The alarm blocks compressor operation; to restore operation,
wait for the temperature to fall below the programmed value, then press the RESET button XX.
•min.oil.temp.
Alarm tripped when the minimum oil temperature is reached. The alarm blocks compressor operation; to restore operation, wait
for the temperature to rises above the programmed value, then press the RESET button XX.
•oil.temp.pre-alarm
Alarm tripped when the pre-alarm oil temperature is reached. The alarm does not block compressor operation. To silence the
alarm, press the RESET button XX.
•Motor thermal overload
Alarm tripped when the motor PTC thermal relay + fan motor thermal relay is tripped. The alarm blocks compressor operation.
To silence the alarm, first verify the cause and then press the RESET button XX.
•Emergency button
Alarm tripped when the emergency button is pressed, which blocks compressor operation. To silence the alarm, first reset the
emergency button, then press the RESET button XX.
•Maintenance
This alarm signals the user that the machine is due for routine maintenance (oil change, filters, etc.).
The alarm must be silenced by the service technician who performs the maintenance, as described in the section “Modifiable
Parameters”.
•max.press.alarm
Alarm tripped when the maximum pressure set is exceeded. The alarm blocks compressor operation.
To silence the alarm, first restore the correct pressure, then press the RESET button XX.
•press.sens.fault
Alarm tripped when the pressure sensor connected to the 4-20mA input is not working correctly. The alarm blocks compressor
operation.
To silence the alarm, first restore the normal status of the pressure sensor, then press the RESET button XX.
•comm.error
Alarm tripped when communication between the control unit and the display is interrupted. The alarm blocks compressor
operation.
Check the connections and press RESET XX.
•screw.motor.therm. (only if parameter 23 is activated)
Alarm tripped in the event that the screw motor thermal relay is tripped. The alarm blocks compressor operation.
To silence the alarm, first verify the cause, then press the RESET button XX.
•fan.motor.therm. (only if parameter 23 is activated)
Alarm tripped in the event that the fan motor thermal relay is tripped. The alarm blocks compressor operation.
To silence the alarm, first verify the cause, then press the RESET button XX.
•Max starts/hour
indicates the number of starts per hour is greater that that imposed. The alarm does not block the compressor, but persists for
an hour, after which it resets itself automatically.
If this alarm activates itself frequently, check and if necessary increase the empty cycle time.
•Err. remote pressure
this activates itself in case of anomalies of the external pressure switch. The alarm does not block the compressor, but persists
until the resetting of the correct control sequence
•Inverter error
Alarm tripped only when the inverter is present.
ALARMS

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FIRST START-UP
Before starting the machine for the first time, make sure that:
•the power supply voltage corresponds to the voltage indicated on the CE plate
•the electrical connections have been made using adequately sized cables
•the master switch (on the wall) has suitable fuses
•the oil level is higher than the minimum (where necessary, fill using oil of the same type)
•the air outlet cock is completely open.
The first start-up of the compressor must only be carried out by a specialised technician.
Press the button:
If the machine does not start and the message “rot.dir.error” appears on the display:
switch off the electrical power using the wall switch, open the electrical cabinet door and invert the position of two phases in the
terminal block, close the door, restore voltage and restart the machine.
If the machine starts on the first try:
display status at start-up (remains for 5 seconds)
display status during normal operation
Line 1
Default display “——screw.temp.” = temperature of the screw.
Using you can view the following information:
Inside temp. indicates the temperature inside the electrical compartment
——air.temp. indicates the temperature of the air at outlet
——total hours indicates the total working hours
—load hours indicates the working hours with load
—idle hours indicates the idle running hours
maint.hours indicates the hours remaining until maintenance is required
air filter h. indicates the hours remaining until air filter replacement is required
bearing.lubric. indicates the hours remaining until lubrication of the bearings is required
oil filter h. indicates the hours remaining until oil filter replacement is required
starts/hour indicates the number of starts recorded in the last hour
After 25 seconds without any buttons being pressed, the default display returns.
Line 2
Indicates the pressure inside the screw compressor.
Line 3
Compressor status:
IDLE idle running
LOAD the compressor is loading
STAND-BY waiting for start command
REMOTE-OFF waiting for remote start command
OFF the compressor is powered but not operating
Line 4
DATEAND TIME if a start-up has been programmed, a blinking clock appears in the lower right-hand corner.
START/STOP CYCLE
•Pressing the button
1. Stand-by for start-up: the message (STAND-BY) is displayed: if the compressor was switched off, there will be a pause of
15 seconds before the cycle starts; otherwise, the compressor remains in stand-by until the request for air comes from the
pressure transducer.
2. Start: the compressor is started in “star” configuration and the message (IDLE) is displayed.
3. Run: after six seconds, the configuration changes from star to delta.
After a few seconds, if requested by the transducer, the load solenoid valve is energised and the message (LOAD) is displayed.
•Pressing the button
the load solenoid valve enable is interrupted; the idle cycle starts and the message (IDLE) is displayed blinking.At the end of
the idle cycle, the compressor switches off and the message “OFF” is displayed.
START-UP PROCEDURE AND DISPLAYINFORMATION
date
software
release
Easy Tronic III
V.1.0.5 dd/mm/yy
Easy Tronic III
--screw.temp:065°C
06.5Bar
STATUS=OFF
time..... date.....

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olio / oil
aria+olio / air+oil
aria / air
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TECHNICAL DIAGRAM
A
Motor
B
Compressor
C
Suction regulator
D
Oil separator tank
VO
Fast exhaust valve
S(NG)
Solenoid valve N.C
DS
Pressure transducer
MAX
Selector valve
PR MIN
Min. pressure switch
PR MAX
Max. pressure switch
MPVL
Min. pressure valve
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 ispoweredand enables suction regulator(2) opening.
The regulator sucks in air through filter (1).
•Duringthisphasecompressorisworkingatpeakrpm
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 ismixedwithsucked airtoforman 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) throughtube (13). Air is then conveyed tomains 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.
AB
C
D
VO
7
6
4
6 1
2
5
5
MAX
1 2
4
S(NG)
DS
PR MAX
PR MIN
MPVL
HDKG
7
2
5
OPERATION
6
5
Air discharge
Signal
Air+oil

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F
E
A
B
C
D
CAUTION! Before carrying out any maintenance operation:
•Activate automatic motor stop.
•Turn off the external wall-mounted switch (do not use the emergency button).
•Close line cock.
•Make sure that no air is present inside the oil separator tank.
Legend to to figure 7
A) front door (electric box)
B) r.h. side door (air filter and prefilter)
C) r.h. side panel (condensate trap)
D) rear panel (roller chamber)
E) l.h. side door (motor)
F) l.h. side door (oil separator)
AFTER THE FIRST 100 OPERATING HOURS
• Check oil level and top-up with same oil, if needed
• Check screw tightening: pay special attention to power electric contact screws.
• Visually check sealing of all connectors.
• Check drive belt tension and tension up, if needed
• Check operating hours and type of duty cycle chosen
• Check room temperature.
• Change oil filter.
EVERY300 OPERATING HOURS
Carefully clean AIR FILTER AND PREFILTER (fig. 8)
• Open door B with supplied key.
• Manually undo the knob (1) and remove filter cover.
• Manually undo the knob (2) and remove filtering element.
• Clean filtering element with compressed air from the inside to the
outside. Check against the light for possible cuts: replace element, if any.
CHANGE THE AIR FILTER ELEMENT EVERY3000 HOURS.
•Undo retainingscrews(3) from support panel(4)andremove prefilter.
• Wash with water and soapy solution. Fully dry before refitting the
prefilter and then restart the compressor.
EVERY500 OPERATING HOURS
Check oil level (fig.9)
• Open door F with supplied key.
• Bleed air off the tank through the cock (1).
• Check oil level through dipstick. If under or close to min. level, top up
with same oil - RotEnergy Plus.
NEVER MIX DIFFERENT TYPES OF OIL TOGETHER
EVERY4000 HOURS
GREASE THE ELECTRIC MOTOR BEARINGS USING SUITABLE GREASERS.
Follow the instructions on the electric motor manual. Required grease quantity:
20g. Use soapy lithium grease.
EVERY8000 HOURS
Change OIL (fig.9)
• Open door F with supplied key.
• Bleed air off the tank through cock (1).
• Connect drain tube (3) to cock (2).
• Unscrew filler plug, open ball cock (2) and collect oil in a container, waiting for
complete drainage.
•Oncethisoperationisover, close cock (2) and removehose(3)(Amountneeded
for filling up the tank: 37 lt.)
• Start the machine and let it run for 5 minutes.
• Allow some minutes and then bleed off all air. Check oil level and top up, if
necessary.
The oil used is: RotEnergy Plus
NEVER MIX DIFFERENT TYPES OF OIL TOGETHER, OTHERWISE
COMPRESSOR MIGHT DAMAGE. Refer to the table for oil selection.
7
MAINTENANCE
2
1
4
3
8
1
MAX.
MIN.
2
3
9

Rotar Giga 75-100 - Cod.197AA3900 - Rev.03 - 05/2007
1414
1414
14
12
Rotar 75 Rotar 100
P max. 8 bar 56 Hz 63 Hz
P max. 10 bar 55 Hz 62 Hz
1
2
3
4
H
G
I
L
MAINTENANCE
AFTER THE FIRST 2,000 OPERATING HOURS AND THEN
EVERY4,000 OPERATNG HOURS
Change OIL FILTER (fig.10)
•Change the filter at any oil change with the oil separator tank not under
pressure. Always bleed all air off the cock (1) (see fig. 11).
•Open door (E) (see fig.7). The oil filter is inside the middle stand, as shown
in the figure.
•Undo the filter with the proper tool. Replace with a new filter.Always apply a
film of oil on filter edge and gasket before tightening.
Change OIL SEPARATOR FILTER (fig.11)
•Open door (F) (see fig.7) and bleed all air off the tank through cock (1).
•Disconnect tubes G, H, I and L.
•Fully undo fitting (2) and remove copper drain tube.
•Undo and remove screws (3).
•Turn screw (4) anti-clockwise with a hex. wrench, until lifting oil separator
cover by about 0.5 cm.
•Manually turn the cover to reach tank inside.
•Remove oil separator filter (using a proper tool) and replace with a new
filter. Also replace the two seal rings and make sure they are properly seated.
EVERY10000 HOURS
DRIVE BELT tension (fig.12)
To perform this check you need a special measurement instrument that that
provides a precise indication of the level of tension of the belt by means of a
frequency measurement.
Proceed as follows:
•Open the door (D) (see fig.7).
•Bring the microphone of the measurement instrument up to the belt at the
point indicated with “test” (about halfway) and strike the belt with a spanner.
•Read the value detected by the instrument and if it is different from the
values indicated on the table, adjust the tension:
Higher value = belt too tight
Lower value = belt too loose
•Loosen screws Ato allow the attachment plate on which the screw unit is
fixed to slide, and use adjusting nut Bto adjust the tension.
Turn the nut anti-clockwise to increase tension and clockwise to reduce tension.
Re-tighten screws A and check the frequency value; if necessary, repeat the
operation until the desired value has been reached.
EVERY20000 HOURS
Replace the DRIVE BELT(fig.12)
Proceed as follows:
•Open the door (D) (see fig.7) and remove the
protective panel of the belt/pulley compartment.
•LoosenscrewsAtoallowtheattachment plate
on which the screw unit is fixed to slide.
•Loosen nut Buntil the belt is completely
relaxed and remove it.
•Fit the new belt and tighten it as described in
the previous section.
Also replace
•Compressor seal ring
•Tank safety valve
10
11
A
B
Test

Rotar Giga 75-100 - Cod.197AA3900 - Rev.03 - 05/2007
GB
1515
1515
15
2
3
1
MAINTENANCE
13
EVERY15,000 OPERATING HOURS
MIN. PRESSURE valve (fig.13)
Open door (F) (see fig.7) and bleed all air off the tank through the cock (1).
Replace gaskets (2) and (3)
.
SERVICE TABLE - WARNING
Oil is an essential factor. When using an oil type which is different from the recommended one - RotEnergy Plus - some service
intervals must be changed. Please refer to table.
Inanycase,adifferentoil MUSTbeusedONLYwhen oil is fully changed. NEVER MIX DIFFERENTTYPESOFOILTOGETHER.
Never top up with a different type of oil.
EXHAUSTED OIL IS HIGHLYPOLLUTANT! Dispose of exhausted oil in compliance with current laws.
Used oil RotEnergyPlus
Different compatible oil
(see table)
Service description Operating hours Operating hours
Check and top up oil level 300 300
Clean intake filter and prefilter 500 500
Grease the electric motor bearings 4000 4000
Replace intake filter element 2000 2000
Replace oil filter 4000 4000
Replace oil separator filter 4000 4000
Change oil 8000 4000
Check driving belt tension 10000 10000
Check min. pressure valve 15000 15000
Replace driving belt 20000 20000
Replace compressor seal ring 20000 20000
Replace tank safetyvalve 20000 20000
Compatible oils:SHEEL Corena D46 - BP Energol HLP 46 - MOBIL D.T.E.
MEDIUM- AGIP Dicrea 46 - CASTROL Aircol MR46 - ESSO Univis 46 -
IP Veretum Oil 46 - FINAEolan R046

Rotar Giga 75-100 - Cod.197AA3900 - Rev.03 - 05/2007
1616
1616
16
TROUBLE-SHOOTING
When a fault occurs or the safety limits set are exceeded, the red alarm light comes on and the alarm in progress is shown on
the display.
In the case of multiple alarms, use to scroll through the items.
To silence an alarm, press the RESET button.
Fault/Alarm message Cause Solution
rot.dir.error Power supply phases inverted Open the electrical cabinet and invert the
phases.
air.temp.sensor fault Fault of the temperature sensor Replace the air temperature sensor
screw.temp.sensor fault Fault of the temperature sensor Replace the screw temperature sensor
Radiator clogged Clean the radiator
Low oil level Fill the oil
Oil mist separator filter clogged Replace the filter
min.oil.temp. Low room temperature Heat the room. Wait
Low line voltage Check the voltage.
Motor temperature overload Check the operation of the cooling fan; if
necessary activate it in “manual” or with
the switch inside the electrical
compartment.
High room temperature Increase the ventilation in the room. Wait
The intake regulator did not close at
the end of the cycle. Check that current to the solenoid valve is switched off and that the shutter opens
normally. If necessary, remove and clean
the intake regulator.
Oil mist separator filter clogged. Replace the oil mist separator filter.
Line cock closed. Open the cock.
Minimum pressure valve blocked. Check and clean the valve, if necessary
replace the gaskets.
press.sensor fault The pressure sensor is faulty. Replace the pressure sensor.
Defective draining Check the drain hose.
Oil level too high Check the oil level and if necessary
remove some.
Oil mist separator filter faulty Replace the oil mist separator filter.
Poor seal of the oil mist separator
filter gaskets Replace the gaskets.
Oil leakage from the intake
filter The intake regulator does not close Check the intake regulator and the solenoid valve.
The compressor performs
poorly Belt loose Tighten the belt.
The intake regulator is closed and
does not open because it is soiled.
Remove the filter and check the opening; if
necessary disassemble and clean it.
The intake regulator is closed and
does not open due to lack of
control.
Check the operation of the solenoid valve;
replace if necessary.
The compressor does not
restart The minimum pressure valve does not close perfectly. Disassemble the valve and clean it; if necessary replace the gaskets.
Low line voltage Check the mains voltage.
Cold room Heat the room.
Oil in the cabin Leakage from hoses Tighten the unions.
High oil consumption
The compressor does not
compress air
Difficult start-up
max.oil.temp.
Motor thermal overload
max.press.alarm

Rotar Giga 75-100 - Cod.197AA3900 - Rev.03 - 05/2007
GB
1717
1717
17
TECHNICAL FEATURES
Power Hp
Pressure bar 7,5 10 7,5 10
Compressor type
Rotation speed of male rotor rpm 3888 3445 4960 4440
Delivered air l/min 9300 8300 12200 10500
Oil quantity l
Topping-up oil quantity l
Max. final air overtemperature °C
Removed heat kJ/h
Fan capacity m³/h
Oil residues in the air mg/m³
Motor type
Rated power kW
Max. power absorbed by network kW
Protection degree of electric box IP
Insulation class
Max. starts per hour no.
Ambient temperature °C
Noise level (1 m) dB(A)
Max. compression temperature °C
Safety valve setting bar
Separator pressure switch setting bar 8,9 10,9 8,9 10,9
Start-up pressure switch setting bar
Motor protection type
Weight kg
Air outlet bsp
Input voltage V/Hz
Auxiliary voltage V/Hz
Current absorption under load conditions A 98 100,8 131,3 133
Current absorption at start-up A
Cable cross section mm²
Thermal relay setting (radiator ventilator) A
Switch A
ENDURO 25 ENDURO 25
37 37
10 10
11 11
188.000 256.500
W-DF25SN-H
55 75
5700 8800
4 4
1LA6280-2AC66-Z
55 75
400 / 50 400 / 50
F F
54 54
218 296
10 10
230 / 50 230 / 50
50 50
70 72
1870 1940
PTC
110 110
11 11
1,5 1,5
PTC
160
200
75 100
50 70
2,5 2,7
2"
2"

Rotar Giga 75-100 - Cod.197AA3900 - Rev.03 - 05/2007
1818
1818
18
WIRING DIAGRAM
V3 W3 U1 V1 W1 W2 U2 V2 L1 L2 L3
U1 W1V1 W2 U2 V2 L1 L2 L3V3 W3
LINEA
LINE
MOTORE COMPRESSORE
COMPRESSOR MOTOR
U3
U3
MOTORE VENTILATORE
FAN - MOTOR
RT
21 1515 22
Predisposizione x collegamento
controllo pressione remoto
M2
15
+ -
SP1
SP3
NC
+
SB
P
SP2
SB+NC
FR
FU2
FU3
FU4
FU5
FU6
FU7
0
3
3
5
5
6
8
10
12
13
14
15
15
15
15
16
17
18
19
20
24 L22
L12
2
L31
L11 FU1
3
3
5
6
8
10
HL+YV
BULBO TERM.
THERM.PROBE
YV
5
25
AUTO.DRAIN
BULBO TERM.
THERM.PROBE
3
3
PL1
PL2
10
8
6
5
12
13
22 021
ST2
BP
V
P
V
021
22
23
21
+
-
SB+NC 50
11
HL 11
2
50
14
M1
A: X08 (9)
A: X08 (1)
A: X08 (10)
2
14
123456789
D
24
X08
12345 1061234567812312
987654321 4321 221 221
X02X07
X10
X03
X01 X09 Rs485 X05
PLUG 6
PLUG 8
Rs232
0
12 11
CanBus Progr. Com.
Display
ST1
+AUTO.DRAIN
0
15
16
17
18
19
20
22
021
V
V
P
V
21
A : M1 A : M1
KR
121314 _+11 210 5 6 850
Remote pressure control

Rotar Giga 75-100 - Cod.197AA3900 - Rev.03 - 05/2007
GB
1919
1919
19
WIRING DIAGRAM
Power 75 75 100
V/Hz 220-230/50-60 400/50-60 400/50-60
FU1-FU2 Ceramic fuses 6,3x32 4A 500V
FU4-FU5 Ceramic fuses 6,3x32 1A 500V
FU3-FU6-FU7 Ceramic fuses 6,3x32 4A 500V
FU8 Cooler fan motor fuses 6A
FR Reset radiat. fan mot. therm. relay 3,5-5 2.2 - 3.2 2.2 - 3.2
RT Compressor motor thermistors
TC1 Transformer Pr.230/400 Sec.230V OCM 250 VA220 VA250 VA
TC2 Transformer 63VAPr.230/400 Sec.24V
KM1 Compressor motor line contactor 55 kW (*) 37 kW (*) 45kW (*)
KM2 Compressor motor delta contactor 55 kW (*) 37 kW (*) 45kW (*)
KM3 Compressor motor star contactor 55 kW (*) 30 kW (*) 37 kW (*)
KM4 Radiator fan motor contactor 4kW (*) 4kW (*) 4 kW (*)
HL Red light
SB Emergency button
KR Phase sequence relay
SP1 Air filter pressure switch
SP2 Oil separator filter pressure switch
SP3 Min. pressure switch
SA Radiator fan emergency control
BP Line pressure transducer
ST1 Screw delivery temperature probe
ST2 Outlet air temperature probe
DElectronic controller
YV Solenoid valve
M1 Upper terminal board
M2 Lower terminal board
MC Compressor motor 55 kW 55 kW 75 kW
MV Radiator fan motor 1,1 kW 6P 0.8 kW6P/1,1kW 6P 1.1kW4P/0,95kW4P
Compressor motor cable cross-section (sq. mm) 7X35 7x25 7x35
Radiator motor cable cross-section (sq. mm) 4G1.5 4G1.5 4G1.5
Control contact cross-section (sq. mm²) 1.5 1.5 1.5
Compressor motor terminal cross-section (sq. mm) 35 35 35
Line terminal cross-section (sq. mm) 95 95 95
Note: (*) = 400V AC3
V1
U1
U2
V2
W2
W1
3
MC
FU1
KM1 KM2 KM3
15 21
RT
1
3
2
KM1 KM2 KM3
X08
X08 X08
KM3 KM2
3
79
6 8
5 5
YV
X08
10
HL
X08
11
2
0 24
SB
NC
+
A
50
L1 L2 L3PE
FU8
KM4
MV
3
FR
U3
V3
W3
FU2
KM4
SA
23
25 5 23
Morsettiera M1 -Teminal board M1
FU4
FU5 0
4
TC2
TC1
L12
L22
L11
L31
L1
L2
L1
L3
FU6
FU3
24
FU7
XB
Autodrain
Morsettiera M1
Terminal board M1
FU6
1
2
5
6
3
4
7
8
9
10
= Inom x 1,5
L1
KR
15
19
L2 L3