ENGLISH

Code
2200788100 04
MANUAL USE AND MAINTENANCE Edition 05/2012

SILENCED SCREW ROTARY COMPRESSOR UNITS

HP 5,5 - 7,5 - 10 - 15 - 20
KW 4 - 5,5 - 7,5 - 11 - 15

READ THIS MANUAL CAREFULLY BEFORE CARRYING

OUT ANY OPERATIONS ON THE COMPRESSOR UNIT.

CONTENTS
PART A: INFORMATION FOR THE USER
1.0 GENERAL CHARACTERISTICS 16.0 PERIODS OF INACTIVITY
2.0 INTENDED USE 17.0 SCRAPPING THE UNIT
3.0 OPERATION 18.0 LIST OF SPARE PARTS FOR ROUTINE MAINTENANCE
4.0 GENERAL SAFETY STANDARDS 19.0 TROUBLE-SHOOTING AND EMERGENCY REMEDIES
5.0 DESCRIPTION OF DANGER SIGNALS PART B: INFORMATION RESERVED FOR TECHNICALLY
SKILLED PERSONNEL
6.0 DANGER ZONES 20.0 STARTING UP
7.0 SAFETY DEVICES 21.0 GENERAL ORDINARY MAINTENANCE REQUIRES
TRAINED PERSONNEL
8.0 POSITION OF PLATES 22.0 CHANGING THE OIL
9.0 COMPRESSOR ROOM 23.0 REPLACE THE DE-OILER FILTER AND THE OIL FILTER
10.0 TRANSPORT AND HANDLING 24.0 BELT TENSION
11.0 UNPACKING 25.0 REPLACING THE ELECTRIC MOTOR
12.0 INSTALLATION 26.0 OLEOPNEUMATIC DIAGRAM
13.0 DIMENSIONS AND TECHNICAL DATA IMPORTANT: THERE IS A COPY OF THE WIRING DIAGRAM
INSIDE THE ELECTRIC PANEL
14.0 MACHINE ILLUSTRATION
15.0 ORDINARY MAINTENANCE TO BE DONE BY THE
USER

MACHINE AND MANUFACTURER IDENTIFICATION DATA

FIG. 1

1 1) Position of the identification plate

Fig. 1

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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.

1.0 GENERAL CHARACTERISTICS

The compressor units use single-stage screw rotary air compressors with oil injection.
The central unit comprises:
compressor; oil separator; oil cooler and output air cooler; fan; electric start; safety and regulation devices; instrument panel.
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)
The compressor-motor unit is fitted on the machine chassis by means of flexible supports: this allows the compressor unit to be laid directly
on the floor without any need of further vibration-damping systems.

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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
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 panel pre-filter fitted one the panel of
the external covering 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 filter 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 is sent to the using network.
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 ON LAST PAGE

ALL WORK ON THE ELECTRIC PLANT, HOWERE SLIGHT, MUST BE CARRIED OUT BY PROFRSSIONALLY SKILLED PERSONEL.

5.0 DESCRIPTION OF DANGER SIGNALS

FIG. 2

1) FLUID EJECTION 5) HIGH PRESSURE

2) DANGEROUS ELECTRIC VOLTAGE 6) HOT PARTS

3) AIR NOT FIT FOR BREATHING 7) MOVING PARTS

4) NOISE 8) FAN ROTATING

9) MACHINE WITH AUTOMATIC START

5.1 DESCRIPTION OF COMPULSORY SIGNALS

10) READ THE USE AND MAINTENANCE

INSTRUCTIONS

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6.0 DANGERS ZONES

Risks present on the whole machine

FIG. 3
2
3

2
7

2
8

1 2 3 7 8

7.0 SAFETY DEVICES

1) Safety screws 5) Door blocking device (electrical equipment)

2) Side panels and door to the electric panel, opened with a special key 6) Oil filling cap (with safety breather)
3) Fixed protection device - cooling fan 7) Safety valve
4) Fixed protection device - pulleys

1 FIG. 4
2
7

1 5

2
6

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8.0 POSITION OF PLATES

8.1 POSITION OF THE DANGER PLATES

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 Code 2202209688 3) Air not filt for breathing Code 2202209688
2) Plate “Machine with automatic start” 2202251089

FIG. 5

1 2
2202251089

8.2 POSITION OF THE DATA PLATE

1) Identification plate “CE” 5) Plate direction of rotation
2) Service kit 7) Air not filt for breathing code 2202209688

FIG. 6

3
1 2202251293

2 4 5
2202204289 2200610109

6
2202251258

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9.0 COMPRESSOR ROOM

9.1 FLOOR
The floor must be even and of industrial type; the total weight of the machine is about Kg. (See Ch. 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 or lower than 1 °C.
The volume of the room must be about 30 m3
The room must be provided with 2 openings for ventilation with a surface area of about 0,3 m2 each.
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.
The hot air ejected by the compressor may be led outside with a pipe.
This pipe must have a minimum section of 0,5 m2 and it must not be longer than 2 m.
For longer pipes an extra fan must be fitted.

9.3 EXAMPLES OF VENTILATION OF THE COMPRESSOR ROOM

FIG. 7
HOT AIR EJECTION FAN AIR OUTPUT HOT AIR PIPE
ATTENTION: REMOVABLE
PIPE TO ALLOW CLEANING
OF THE RADIATOR

10.0 TRANSPORT AND HANDLING

IT IS FORBIDDEN TO USE METAL CABLES FOR LIFTING

ATTENTION: DO NOT PASS UNDER OVERHEAD WEIGHTS

The machine must be transported as shown in the following figures.

FORK LIFT TRUCK FIG. 8

CARDBOARD PROTECTION
AVOID DAMAGING THE
BODYWORK

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11.0 UNPACKING

CUTTING THE METAL STRAPPING IS A DANGEROUS OPERATION, SEE FIG.9 DO NOT ABANDON THE CUT PIECES IN
THE ENVIRONMENT.

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, polystyrene
foam, nails, screws, wood, metal strapping, etc.) 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. 9

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. 10).

FIG. 10

2
1500

Protect the power cable with a suitable 3

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 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.
 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

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12.3 CONNECTION TO THE COMPRESSED AIR NETWORK
Fit a manual interception valve Ref. 2 Fig. 10 between the machine and the compressed air network so that the compressor may be
isolated during maintenance operations.
Condensate must be drained Ref. 3 Fig. 10 from the oil receiver (manually) in conformity 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, Chapter 20.0
13.0 DIMENSIONS AND TECHNICAL DATA

ELECTRICAL
ENTRY

(A)
Air delivery (A)
HP 5,5-7,5-10-15-20
kW 4-5,5-7,5-11-15
¾” Gas

HP 5,5 - kW 4 HP 7,5 - kW 5,5 HP 10 - kW 7,5 HP 15 - kW 11 HP 20 - kW 15

8 10 8 10 8 10 13 8 10 13 8 10 13
bar bar bar bar bar bar bar bar bar bar bar bar bar

Standard air
600 485 820 670 1153 1000 810 1665 1435 1210 2000 1790 1480
capacity 1/min.

Max. pressure bar

8 10 8 10 8 10 13 8 10 13 8 10 13

Noiose product. dB(A) 60 64 64 63 65

Net weight Kg. 180 195 200 220 245
Power HP 5,5 7,5 10 15 20
KW
4 5,5 7,5 11 15

Oil operation
timer setting °C 100 100 100 100 100

Oil load l. ~4 ~4 ~4 ~4 ~4

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14.0 MACHINE ILLUSTRATION

14.1 GENERAL LAY-OUT

1) Air suction filter 12) Oil discharge
2) Thermostatic valve 13) Oil tank
3) Oil filter 14) Pressure gauge tank
4) Air-oil cooler 15) Control card
5) Filter panel 16) Safety valve ()
6) Belt tightening system 17) Isolating switch
7) Minimum pressure valve 18) Electric motor
8) Air-oil separator with oil separating filter 19) Screw compressor
9) Top-up or oil filling cap 20) Suction unit
10) Control panel
11) Oil gauge  IT IS FORBIDDEN TO TAMPERE WITH THE
SETTING VALUES OF THE SAFETY VALVE

FIG. 11

8
3
1
7

14
2

9
6 15
11

13 12

17
16

4
20
10
19

18

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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.

FIG. 12

1) Control card
2) Door blocking isolating switch two positions: in position “0” the control panel may be opened;
in position “1” the machine may be started

IMPORTANT: WHEN THE SELECTOR REF. 2 IS IN POSITION “0” THE BOTTOM TERMINALS ARE STILL LIVE.

14.3 ELECTRONIC CARD MODELS “ ES 3000 “

1 3 FIG. 13

There is an electronic control and diagnostics card on the electric panel ; this card includes the display of the functions as shown
in figure 13.

1) Superior display: indicates the compressor pressure.

2) Inferior display: indicate the temperature, total hours, loaded hours.
3) Button to create a vacuum in the compressor.
4) Tabulation key to move to the next field of the screen on the display Ref. 2
5) Buttons to programme the board.

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Symbol Description
Pressing the pushbutton cancels the stored alarm indication. Pressing the pushbutton for more than 3 seconds, the
(7) 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.
(6) (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 45 seconds
(5) before stopping.

Led – indicates compressor operating status: “RED” pilot lamps (cause machine stoppage)
Symbol Led flashing Led on

(B) Overpressure alarm in progress Machine stopped for overpressure

(C) Alarm rotation inverse in progress Alarm rotation inverse restored

Oil overtemperature alarm in progress Machine stopped for oil overtemperature (> 100 °C)
(D)
(>95 °C)

(E) Not enabled Not enabled

- Machine stopped for motor overload (for F.S.)
- Motor overload (for F.S.)
(F) - Machine stopped for fault on frequency converter for VSD)
- Fault on frequency converter (for VSD)

General alarm in progress for fault in pressure and

-
(G) 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

(A) Not enabled Not enabled

(H) Forewarning to replace oil filter Replace oil filter

(I) Forewarning to replace separator filter Replace separator filter

(L) Forewarning to replace suction filter Replace suction filter

(M) Forewarning to change oil Change oil

(N)
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
(O) Not enabled Not enabled

(P)
- Compressor running under load

(Q)
Manual loadless operation of compressor Loadless operation of compressor
Compressor in stand-by for start-up
(R) (10 seconds) or in shut-down phase Compressor on
(45 seconds).

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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. 13a, 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. 13a 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, to point 4); the
operating hours will be viewed on the bottom display.
- Press the button Ref. 3 Fig 13a 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. 13a)
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

Q FIG. 13a
H
1

3
L
4

14.7 ACTIVATING / DEACTIVATING THE LOADLESS-LOADED OPERATION MODE

1) Press the button Ref. 1 Fig. 13a and the LED Ref. Q flashes, the machine operates in MANUAL LOADLESS mode.
2) Press the button Ref. 1 Fig. 13a 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 - 13bar)
P1 = cut-in pressure (6,5 - 8.5 – 11.5 bar)
r2 = maximum operating temperature (100 °C)
t3 = not active
t4 = not active
C5 = maximum number of starts per hour (10)

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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. 13a 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) appears simultaneously on the bottom display.
- By pressing the button Ref. 1 Fig. 13a 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.

- Press and hold the button Ref. 4 fig. 13a for a few seconds, until the parameter “P0” appears on the top display.
- Press the button Ref. 1 Fig. 13a until reaching the parameter “r2” (maximum temperature).
- Press the button Ref. 4 Fig. 13a: the value of the temperature indicated on the bottom display flashes.
- Press the button Ref. 2 Fig. 13a until reaching the value 95.
- Press the button Ref. 4 Fig. 13a to confirm the modification; the value 95 stops flashing.
- Exit from programming by pressing the button Ref. 3 Fig. 13a.
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), 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.
15.0 ORDINARY MAINTENANCE TO BE DONE BY THE USER

BEFORE CARRYING OUT ANY MAINTENANCE JOBS IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT
FROM THE POWER MAINS.
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 SCHEDULE
 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 50 working hours  Drain condensate from the oil collector

 Check the oil level
 Clean the filtering panel

Every 500 hours  Clean the air suction filter (see control board LED)
 Check belt tension

Every 2000 hours  Change the oil (see control board LED)
 Change the oil filter (see control board LED)
 Change the suction filter (see control board LED)

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:
- Press the “STOP” button Ref. 1 Fig. 14
- Turn the isolating switch Ref. 2 to position “0” and block it with the padlock.
- Turn on the supply automatic differential switch.

FIG. 14

1
2
5

- Wait for the machine to cool down.

- Remove the panels with the key provided.
- SLOWLY turn on the tap Ref. 3 Fig. 14 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. 4 Fig. 14

- 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 pushbutton Ref. 1 Fig. 14: in this way the machine stops after 45 seconds of idle running.
- Wait a few minutes for the foam in the oil collector to abate.
- Check the oil level on the indicator Ref. 4 Fig. 14
- 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 THE MACHINE, ENSURE THAT THE ELECTRIC POWER SUPPLY HAS
BEEN DISCONNECTED.

- Open the front panel with the special key

- Slowly open the oil plug Ref. 5 Fig. 14
- Top up to maximum level Ref. 5 Fig. 14, with oil of the same type in the compressor.
- Turn off the cap of the oil tank Ref. 5 Fig. 14.
- Close the panel.
15.5 CLEANING THE FILTERING PANEL
- Press the “STOP” button Ref. 1 Fig. 14
- Turn the isolating switch Ref. 2 to position “0” and block it with the padlock.
- Turn on the supply automatic differential switch.
- Remove the filter panel Ref. 1 Fig. 15.
- Clean the filtering panel with a jet of air wash it with water, do not use solvents.
- Once the operation has been completed, reassemble the filter panel.

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FIG. 15 HP 5-7,5-10 FIG. 15a

7 7

8
1 8

HP 15-20

15.6 CLEANING THE SUCTION FILTER OR CHANGING THE FILTER

- Press the “STOP” button Ref. 1 Fig. 14
- Turn the isolating switch Ref. 2 to position “0” and block it with the padlock.
- Turn on the supply automatic differential switch.

HOT PARTS INSIDE

- Remove the fixed protection device (machine cover)

- Remove the cover Ref. 7 Fig. 15a.
- Remove the filter Ref. 8 Fig. 15a.
AVOID DROPPING FOREIGN BODIES INTO THE SUCTION 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 device again, using the appropriate safety screws.

16.0 PERIODS OF INACTIVITY

If the machine has to remain inactive for a long period:
- Press the “STOP” button Ref. 1 Fig. 14
- Turn the isolating switch Ref. 2 to position “0” and block it with the padlock.
- Turn on the supply automatic differential switch.
- Turn off the tap.
During periods of inactivity the weather must be protected against atmospheric agents, dust and humidity which could damage the motor
and the electrical system.
To restart the machine after periods of inactivity, consult the manufacturer technical assistance service.
17.0 SCRAPPING THE UNIT

If the machine is to be scrapped, it must be dismantled into parts of the same material, to be disposed of according to the local regulations
in force.
ALWAYS RESPECT THE REGULATIONS IN FORCE FOR DISPOSING OF OLD OIL AND OTHER POLLUTING MATERIALS
SUCH AS SOUND-DEADENING, FOAM, ETC.

18.0 LIST OF SPARE PARTS FOR ROUTINE MAINTENANCE (Fig. 16)

HP 5,5 HP 7,5 HP 10 HP 15 HP 20
kW 4 kW 5,5 kW 7,5 kW 11 kW 15
Ref. DESCRIPTION Code
8 10 8 10 8 10 13 8 10 13 8 10 13
bar bar bar bar bar bar bar bar bar bar bar bar bar
1 Filtering panel 2202251210             
2 Suction filter 6211473950       
3 Suction filter 2200640551      
4 Oil filter 6211472650             
5 Separator cartridge 6221372850             

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FIG. 16
4 5

2 3
1

HP 5-7,5-10 HP 15-20

19.0 TROUBLE-SHOOTING AND EMERGENCY REMEDIES

ALL WORK MUST BE CARRIED OUT BY PROFESSIONALLY SKILLED PERSONNEL. BEFORE CARRYNG OUT ANY
MAINTENANCE JOBS IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT FROM THE POWER MAINS.
N.B. OPERATIONS MARKED   MUST BE CARRIED OUT BY PROFESSIONALLY SKILLED PERSONNEL APPROVED THE
MANUFACTURER
FAULT FOUND POSSIBLE CAUSES OBSERVATIONS
1) The machine does not start 1A - no powert - check the power supply line,
Chapter 12.2
1B - the transformer protection device has
tripped - replace fuses
2) The machine does not start 2A - the main motor protection device has - Disconnect voltage and enable again
the pilot lamp Ref. 1 (F) is flashes tripped
(see Fig. A)
3) The machine does not start 3A - The oil high temperature protection has - environment temperature too high;
the pilot lamp Ref. 2 (D) is flashes tripped improve ventilation in the compressor
(see Fig. A) room, Chapter 9.2
  - cooling radiator is dirty, clean the
radiator
- oil level too low; top up the oil tank
4) The compressor does not reach working 4A - the compressed air consumption is
pressure too high
4B - the discharge electrovalve remains
open, Ref. EV/SC wiring diagram   - check the electric system

5) Excess oil consumption 5A - deteriorated oil separating filter   - change the oil separating filter,
oil level is too high Chapter 23

FIG. A 1

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PART “B”

THIS PART “B” OF THE INSTRUCTIONS MANUAL IS RESERVED FOR

PROFESSIONALLY SKILLED PERSONNEL APPROVED THE MANUFACTURER.

20.0 STARTING UP

BEFORE CARRYING OUT ANY OPERATION ON THE MACHINE, ENSURE THAT THE ELECTRIC POWER SUPPLY HAS
BEEN DISCONNECTED.
20.1 PREPARING FOR SETTING UP
After checking everything as indicated in Chap. 12, folow the instructions in Fig. 17
- Fit the sound-deadening panels Ref. 4 Fig 17
These parts are packed inside the bodywork.
20.2 PRELIMINART CHECKS
Check the oil level Ref. 1 Fig. 17 when supplied the machine is filled with oil;if the oil is not at the correct level, top up with the same oil as
the original type. If more than 3 months have passed between the inspection in the factory and the date of installation, lubricate the screw
group before starting up, following the procedure described below:
- Remove the cover Ref. 2 Fig. 17
- Remove the air filter Ref. 3 Fig. 17
- Pour a little oil into the suction unit.
- Reassemble the air filter Ref. 3 Fig. 17
- Reassemble the cover Ref. 2 Fig. 17
If more than 6 months have passed between the inspection in the factory and the date of installation, consul
the Manufacturer assistance service.

FIG. 17
2

3 OIL

4
4

FIG. A FIG. B
OK

This cable is part of the machine

l~ 4 metres

Protect the power cable with a suitable channel. PHASES INCORRECT

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20.3 CHECK THE DIRECTION OF ROTATION

- Check that all fixed guards are in their correct position.
- Connect the control board to the power supply with the automatic circuit-breaker switch of the line Ref. 7 Fig. A and the master
switch of the machine Ref. 5 Fig. A.
- Start up the compressor pushing in sequence I button Fig. 17A and immediately after about 5 seconds the 0 button
Fig. 17A to stop if.
- If the rotation is correct, the paper sheet Ref. 6 is blown up (See Fig. A)
- If the rotation is not correct, the paper sheet Ref. 6 remains flat (See Fig. B) REFER TO THE CUSTOMER CARE SERVICE

ALL WORK ON THE ELECTRIC PLANT, HOWEVER SLIGHT, MUST BE CARRIED OUT BY PROFESSIONALLY SKILLED
PERSONNEL.

- Disconnect the energy supply and invert two connections as per Ref. 7a Fig. B.

IT IS ADVISABLE NOT TO DO ANYTHING ON THE MACHINE PANEL.

IF ALL THE INSTRUCTIONS FOUND IN THIS MANUAL HAVE BEEN OBSERVED THE MACHINE CAN BE STARTED.

ATTENTION: machine start-up is delayed for a few seconds from the moment the card is
power ed or of the scheduled stop.

FIG. 17a

21.0 GENERAL ORDINARY MAINTENANCE REQUIRES TRAINED PERSONNEL

BEFORE CARRYING OUT ANY MAINTENANCE JOBS IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT
FROM THE POWER MAINS.

MAINTENANCE SCHEDULE
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 50 working hours  Drain condensate from the oil collector

 Check the oil level
 Clean the filtering panel

Every 500 hours  Clean the air suction filter (see control board LED)
 Check belt tension

Every 2000 hours  Change the oil (see control board LED)
 Change the oil filter (see control board LED)
 Change the suction filter (see control board LED)

Every 4000 hours  Clean the finned surface of the air-oil cooler
 Change the oil separating filter (see control board LED)

N.B.: THE OPERATIONS MARKED  ARE DESCRIBED IN PART "A" OF THIS MANUAL ON CHAPTER 15.3

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22.0 CHANGING THE OIL

BEFORE CARRYING OUT ANY MAINTENANCE JOBS IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT
FROM THE POWER MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION NETWORK.
Oil changing is an important operation for the compressor:
if the lubrication of the bearings is not efficient, the compressor life will be short.
The oil must be changed when the machine is still warm, that is immediately after stopping it.
The suggestions listed below should be scrupulously followed.
After draining the old oil out of the machine Ref. 2 Fig. 18.
- Completely fill the oil collector Ref. 1 Fig. 18.
- Pour a little oil into the suction unit.
- Start the compressor.
- After about 1 minute switch off the machine by pressing “STOP” (Ref. 3 Fig. 18) after 45 seconds of idle running the machine will switch
off.
PROCEED AS DESCRIBED AT POINT CHAPTER 15.4

FIG. 18

OIL

THE OLD OIL MUST BE DISPOSED OF IN COMPLIANCE WITH THE REGULATIONS IN FORCE.
NOTE ON LUBRICANTS
When delivered the machine is filled with oil.
In normal conditions of use, these lubricants have proved to be able to withstand use for as many as 4.000 hours. However, due to the
external polluting agents that get into the compressor with the air that it takes in, it is advisable to change the oil at more frequent intervals,
as indicated on the routine maintenance chart.
If the compressor is being used at high temperatures (continuous operation above 90 °C) or in particularly severe conditions, we advise
changing the oil at shorter intervals than those recommended in the maintenance chart.
DO NOT TOP UP WITH DIFFERENT OILS

23.0 REPLACE THE DE-OILER FILTER AND THE OIL FILTER

BEFORE CARRYING OUT ANY MAINTENANCE THE MACHINE MUST BE STOPPED, CUT OFF THE MACHINE FROM THE
ELECTRICAL MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION CIRCUIT, CHECK THAT THE MACHINE IS NOT
UNDER PRESSURE.
Before proceeding with the replacement of the de-oiler filter or the oil filter check that there is no pressure in the machine: check the
pressure gauge Ref. 1 Fig. 19.
- Lubricate the filter seals with a little oil before fitting.
- Tightening must be done by hand.

FIG. 19 FIG. 19 A

1 A

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24.0 BELT TENSION

BEFORE CARRYING OUT ANY MAINTENANCE THE MACHINE MUST BE STOPPED, CUT OFF THE MACHINE FROM THE
ELECTRICAL MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION CIRCUIT, CHECK THAT THE MACHINE IS NOT
UNDER PRESSURE.

Tightening or retightening new belts

Proceed as follows:
- Remove the fixed protection device Ref. A Fig. 19A.
- Slacken the screws by half a turn Ref. 1 Fig. 20
- Loosen the locknut Ref. 2 Fig. 20
- Adjust the belt tension by turning the screw Ref. 3 Fig. 20, with an allen wrench Ref. 4 Fig. 20.
- Lock the locknut again Ref. 2 Fig. 20
- Close the screws again Ref. 1 Fig. 20
- Refit the fixed protection device with its safety screws Ref. A Fig. 19A.

FIG. 20

1
1

1
3

1 - F = 4 kg., force to be applied at the centre line, at right angles to the new belt.
2 - f = 6 mm., clearance after the application of F. (after 100 h operation F = 2 ÷ 2,5 kg.)
25.0 REPLACING THE ELECTRIC MOTOR

BEFORE CARRYING OUT ANY MAINTENANCE THE MACHINE MUST BE STOPPED, CUT OFF THE MACHINE FROM THE
ELECTRICAL MAINS AND FROM THE COMPRESSED AIR DISTRIBUTION CIRCUIT, CHECK THAT THE MACHINE IS NOT
UNDER PRESSURE.

25.1 DISASSEMBLING THE COOLING FAN AND CONVEYOR (Fig. 21)

Proceed as follows:
- Remove the external panels.
- Block the rotation of the motor; insert the spanner Ref. 1 into the pulley holes.
- Unscrew the fan fastening screw Ref. 2 (), use a spanner with an extension.
- Remove the cooling fan Ref. 3.
- Remove the screws that fasten the conveyor Ref. 5 to the electric motor.
- Extract the conveyor Ref. 5 from the suction side.

FIG. 21

2
5
3

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25.2 DISASSEMBLING THE ELECTRIC MOTOR (Fig. 22)
- Slacken the screws Ref. 5 ().
- Loosen the locknut Ref. 6
- Slacken off the adjustment screw Ref. 7, using an Allen wrench .
- Remove the transmission belt.
- Remove the motor pulley.
- Disconnect the electric cables from the base-plate Ref. 9.
- Loosen the supporting pad Ref. 10.
- Remove the screws Ref. 11 (),
- Extract the motor Ref. 12.

FIG. 22

5 12
5

7 5
11
6
9

10

Rif. 2 () Tightening torque = N.m 70

Rif. 5 () Tightening torque = N.m 30
Rif. 11() Tightening torque = N.m 45
26.0 OLEOPNEUMATIC DIAGRAM
1 SUCTION FILTER
2 SUCTION REGULATOR
3 SCREW COMPRESSOR
4 OIL DISCHARGE VALVE
5 AIR-OIL PRESEPARATOR
6 OIL FILTER
7 THERMOSTATIC VALVE
8 AIR-OIL COOLER
9 PRESSURE SENSOR
10 MINIMUM PRESSURE VALVE
11 AIR-OIL SEPARATOR
12 PRESSURE GAUGE
13 SAFETY VALVE
14 TEMPERATURE SENSOR
15 ELECTRIC MOTOR
16 NO-LOAD RUNNING SOLENOID VALVE
17 OIL LEVEL
18 BLED VALVE

AIR CIRCUIT

OIL CIRCUIT

CONTROL CIRCUIT

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