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ABAC FORMULA Series, Use And Maintenance Handbook

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ABAC FORMULA Series Use And Maintenance Handbook Download Page 62

P. 60 - Chap. 7 Start-up and operation

G

B

Replace -------------- excess hrs - block

where the component to be replaced is displayed instead of the hyphens.

In this case, it is absolutely necessary to replace the component. If the compressor must be restarted, 

an emergency start-up procedure must be carried out. Contact the Service or Customer Centre of the 

Manufacturer immediately.

To find out how to proceed in the case of an alarm, refer to chapter 9 “Troubleshooting”.

Summary of Contents for FORMULA Series

Page 1: ...GENESIS FORMULA MODULO 5 5 15 kW USE AND MAINTENANCE HANDBOOK GB ...

Page 2: ......

Page 3: ...227 D1 273 D2 I FORMULA 1045 615 1030 273 480 545 465 390 1045 227 D1 273 D2 560 395 204 430 945 180 262 Fig 1 Fig 2 D1 5 5 7 5 kW D2 11 15 kW ...

Page 4: ...227 D1 273 D2 227 D1 273 D2 II GENESIS 275 l 945 945 560 395 480 1180 1645 530 Ø 600 390 465 615 1030 480 273 204 262 Fig 3 Fig 4 D1 5 5 7 5 kW D2 11 15 kW 1015 800 ...

Page 5: ...530 Ø 600 1960 1260 945 390 465 395 227 D1 273 D2 227 D1 273 D2 III GENESIS 500 l 480 273 945 615 1030 1645 204 262 800 Fig 5 Fig 6 D1 5 5 7 5 kW D2 11 15 kW 1015 ...

Page 6: ...227 D1 273 D2 227 D1 273 D2 IV MODULO 1030 480 273 1045 615 945 395 390 1045 560 465 545 180 204 430 262 Fig 7 Fig 8 D1 5 5 7 5 kW D2 11 15 kW ...

Page 7: ...227 D1 273 D2 227 D1 273 D2 V MODULO 270 l 1030 480 273 615 945 560 390 465 1645 1180 480 395 800 530 Ø 600 204 945 262 Fig 9 Fig 10 D1 5 5 7 5 kW D2 11 15 kW 1015 ...

Page 8: ...227 D1 273 D2 VI MODULO 500 l 1960 1260 560 945 395 390 465 530 Ø 600 800 1645 615 1030 273 480 204 945 262 Fig 11 Fig 12 D1 5 5 7 5 kW D2 11 15 kW 227 D1 273 D2 1015 ...

Page 9: ...VII FORMULA 5 5 7 5 kW Fig 13 Fig 14 SPA PE PC VA EV PS BF PF CT VT TRL ES FU RA RO PP SS VS FD FO FA MP ...

Page 10: ...VIII FORMULA 11 15 kW BA 51 Fig 15 Fig 16 FO FA FD VS SS ES FU MA RA RO MP PC PE SPA VA EV PS BF VR TRL CT PF PP ...

Page 11: ...IX FORMULA 15 kW BA 69 Fig 17 Fig 18 PC PE SPA CF FA PF CT TRL VR BF PS ES EV FU MA RA RO MP PP VA FO FO VS SS ...

Page 12: ...X MODULO 5 5 7 5 kW Fig 19 Fig 20 FO FD FA SS ES FU MA RA RO PP MP PC PE SCE SF VA EV BF VT TRL CT PF VS PS ...

Page 13: ...XI MODULO 11 15 kW BA 51 Fig 21 Fig 22 PC PE SCE SF PF CT TRL SS VR PS EV VA FA FO FD VS SS MP PP RA RO MA FU ES BF ...

Page 14: ...XII MODULO 15 kW BA 69 Fig 23 Fig 24 PS PP PF MA FU RA RO ES VA FO FD VS SS MP CF FA SCE PE PC TRL VR BF CT EV ...

Page 15: ...oia uscita aria calda Heated air outlet Orifice de sortie de l air chaud Auslass für heisse Luft Rendija de salida del aire caliente GP Gruppo pompante a vite brevettato Patented Air end Groupe de pompe à vis breveté Patentierter Verdichter Grupo de bombeo de tornillo patentado K1 K9 Pulsanti del pannello di controllo Control panel switches Boutons sur panneau de commande Schalter der Kontroll Anze...

Page 16: ...Kontroll Box seite Puerta del quadro eléctrico SF Sportello filtri Filter panel Panneau des filtres Filterklappe Puerta de los filtros SPA Sportello angolare Corner panel Panneau angulaire Eckklappe Puerta angular SS Serbatoio separatore miscela aria olio Air oil separator receiver Réservoir séparateur du mélange air huile Luft Öl Abscheider Depósito separador mezcla aire aceite STO Sensore di temper...

Page 17: ...r symbols 2 2 22 Control panel mc2 symbols 2 3 3 Warranty terms 23 Performance and specifications 24 4 24 General data 4 1 24 Compressor rating data 4 2 25 Air receiver 4 3 25 Compressor 4 4 25 Electrical motor and drives 4 5 25 Power supply data 4 6 27 Lubricating and cooling fluid 4 7 87 Dryer 4 8 ...

Page 18: ...installation 30 6 30 Handling instructions 6 1 30 Installation site requirements 6 2 94 Air connection 6 3 33 Electrical connection 6 4 33 Configuration for remote control 6 5 Start up and operation 35 7 35 Checks to be carried out prior to start up 7 1 35 mc2 control panel 7 2 36 Control unit mc2 7 2 1 38 Emergency stop button 7 2 2 38 Starting and stopping the compressor 7 3 ...

Page 19: ...ERAL SETTINGS menu 7 4 2 3 51 NETWORK SETTINGS menu 7 4 2 4 52 OPERAT PARAMETERS menu 7 4 2 5 54 PROGRAMMING menu 7 4 2 6 56 DIAGNOSTICS menu 7 4 2 7 58 INFORMATIONS menu 7 4 2 8 58 Operating warning and faults 7 5 Compressors in sequence 61 8 Troubleshooting 62 9 62 The machine does not start 9 1 63 The compressor has trouble starting up 9 2 Pressure value lower than rated pressure 63 9 3 ...

Page 20: ...s on 65 9 6 66 Oil in the network 9 7 66 Oil in the machine 9 8 67 Safety valve VS intervention 9 9 Maintenance 68 10 68 Operating cycle 10 1 69 General maintenance operation table 10 2 71 Replacement of the suction prefilter 10 3 71 Cleaning or replacing the air filter 10 4 73 Checking oil level topping up and changing the oil 10 5 75 Replacing the oil filter and the separator filter 10 6 76 Draining...

Page 21: ...hines with air dryer 12 3 84 Power circuit wiring diagram 11 kW Machines with inverter 12 4 85 Auxiliary circuit wiring diagram 5 5 15 kW Machines without air dryer 12 5 86 Auxiliary circuit wiring diagram 5 5 15 kW Machines with air dryer 12 6 87 Auxiliary circuit wiring diagram 11 kW Machines with inverter 12 7 88 Wiring diagram for component location 5 5 15 kW Machines without air dryer 12 8 89...

Page 22: ...ying with the strict quality control standards that are one of the main features of all products manufactured at our plants The product is EC marked and complies with current European Directives as shown in the Declaration of Conformity attached to this handbook The compressor must be installed by specialized personnel of authorized service Centres Before starting the machine read all sections of ...

Page 23: ...ste oil condensate and filters removed from the machine are polluting materials and must be disposed of in compliance with local laws 2 2 Compressor symbols This symbol means that you must not put your hands inside the machine when it is running This symbol indicates the presence of rotating parts inside the compressor Do not carry out maintenance or repair operations when the machine is running Th...

Page 24: ...l indicates the K7 PLUS key This symbol indicates the K8 MINUS key This symbol indicates the K9 ENTER confirmation key This symbol indicates the voltage present LED L1 yellow This symbol indicates switching on of warning LED L2 yellow This symbol indicates switching on of alarm LED L3 red This symbol indicates switching on of LEDs L4 and L5 red indicating AUTORESTART and REMOTE PROGRAM located on t...

Page 25: ...luded from the clauses of this warranty and they will therefore be charged to you The warranty which excludes all and any liability for direct or indirect injury or damage is restricted only to construction and manufacturing defects of machine components The warranty does not include parts which due to their specific use are liable to wear and tear such as seals belts etc and all consumables such a...

Page 26: ...nesis 500 l 68 10 1 04 13 0 80 15 0 64 11 8 11 BA51 1 65 7 275 32 dryer 360 32 dryer 419 32 dryer 1030 x 615 x 1045 1180 x 600 x 1645 Genesis 270 l 1960 x 600 x 1645 Genesis 500 l 69 10 1 40 13 1 17 15 0 95 15 8 15 BA51 2 01 7 300 32 dryer 385 32 dryer 444 28 dryer 1030 x 615 x 1045 1180 x 600 x 1645 Genesis 270 l 1960 x 600 x 1645 Genesis 500 l 69 10 1 72 13 1 49 15 1 16 15 8 15 BA69 2 32 7 286 3...

Page 27: ...nsulation class F service class S1 reference MP in Figs 14 16 18 20 22 24 Variable speed motors Four pole closed three phase asynchronous motor rated speed of 1500 rpm at 50 Hz protection rating IP54 insulation class F service class S1 reference MP in Figs 14 16 18 20 22 24 intended for use at variable speed through powering with inverter Electric fan Fan coaxial to the electrical motor reference ...

Page 28: ...A 5 5 8 2 5 16 16 10 13 15 7 5 8 4 20 20 10 13 15 11 8 6 25 25 10 13 15 15 8 10 40 40 10 13 15 15 8 10 40 40 10 13 15 400 V Model Pressure Power cable cross section area Main fuses AM motor rated or ground circuit breaker setting Circuit breaker bar mm2 A A 5 5 8 6 25 25 10 13 15 7 5 8 10 40 40 10 13 15 11 8 16 50 50 10 13 15 15 8 25 63 63 10 13 15 15 8 25 63 63 10 13 15 230 V ...

Page 29: ...ubricated and cooling fluids with other specifications 4 8 Dryer Thermostat controlled cooling cycle direct expansion with Freon R134a gas pressure dew point temperature 3 C clean air filtering degree 0 01mm Filtration degree 1 µm Oil carryover 0 1 mg m3 Displayable dew point temperature Cooling compressor and timed condensate drain controlled from mc panel2 4 9 Clearance requirements and system layo...

Page 30: ...s explosive or flammable gases solvents or powder paints and toxic fumes of any type Use of compressed air requires knowledge of and compliance with the safety precautions to be adopted for the individual applications inflating pneumatic tools painting washing with water based detergents only etc Machine operation is fully automatic The machine carries out the various work cycles as required by the ...

Page 31: ... the maximum working pressure values and the valve settings especially the safety valves Do not use solvents flammable or toxic fluids to clean the machine parts Use alkaline detergents only Never use detergents to clean the motor or the electrical electronic components Do not weld or carry out mechanical machining operations on the receivers If damaged or rusted replace the parts as they are subjec...

Page 32: ... a pallet truck can be used for short distances Avoid any excess stress on the metal structure Fig 28 When using a lifting device for handling do not exert force on the sides of the machine to prevent damage to the unit and control panel Make sure that the load is balanced Fig 27 Fig 28 Receivers under pressure even if small must never be transported 6 2 Installation site requirements General rema...

Page 33: ...s located outdoors Comply with the minimum distance from the walls 0 6 mm Fig 29 min 3000 max 5000 600 Indoor installation The machine is not suitable for use in environments with a risk of explosion The air taken in by the compressor must be absolutely free from dust vapours explosive or flammable gas solvents or paint powder and toxic fumes of any sort Replace the filters more frequently with spec...

Page 34: ...imum distances from the walls shown in figure 31 The position of the compressor in the room should allow easy inspections If the compres sor is installed in the working environment keep at suitable safety distance according to the type of process carried out at the premises in order to prevent hazards or damage to the machine due to the products used The compressor should not be installed in a rece...

Page 35: ...heck the efficiency of the earthing system The power cable must be secured in the specific glands and the electrical panel must be tightly closed to achieve the prescribed IP44 protection rating Connect the machine only to type approved sockets The sockets must be earthed and tested Have correct fastening of the electrical cables of the various components checked regularly by qualified personnel Chap...

Page 36: ...OAD remote control see paragraph 7 4 2 3 Remote control type Two switches must be used for this configuration The switches must be connected to the terminals after removing the jumper ON OFF SWITCH 3 digital INPUT common terminal 38 remote control digital INPUT terminal LOAD NO LOAD START SWITCH 3 digital INPUT common terminal 39 remote control digital INPUT terminal Following modifications to the w...

Page 37: ...iation of 10 with respect to the rated value is allowed Connect the machine to the electrical system as described in paragraph 6 4 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 adhe sive label located to the side of the screw unit figure 33 Note that even a few second...

Page 38: ...ator setting LEDs back lit LCD display K4 K5 K3 K6 K1 K2 K7 K8 K9 L1 L2 L3 L4 L5 Control and programming keyboard K1 START button starting the compressor Used to start the machine If remote control or programming daily weekly are enabled this key is used to enable compressor functioning priority control from keyboard If alarm conditions have occurred pressing of this key has no effect K2 STOP butt...

Page 39: ...vel Starting from the main screen page makes it possible to access the menu tree Used to confirm the value or selection made during modification of a parameter If OFF back lighting of the display is re activated the first time the key is pressed without performing any other function Indicator setting LED L1 Voltage present LED yellow Must always be ON when the compressor is powered L2 warning LED yel...

Page 40: ...lowing screen page must be shown on display DI This screen page indicates LINE 1 name of the compresso LINE 2 LINE 3 software version which may differ from that indicated LINE 4 serial number of control unit different for each machine 1 mc2 Vers Soft 1 0 0 1 S N 000 00 01 00001 After a few seconds the display shows the main screen page This screen page indicates LINE 1 indication of network pressu...

Page 41: ...bled and the compressor is in the OFF programming phase see paragraph 7 4 2 6 The compressor will start when an ON programming phase is initiated 5 Stand by progr com hour date If the compressor does not start or none of the cases listed above occurs refer to chapter 9 The following contacts will be made in sequence LINE STAR DELTA 6 Start hour date Start hour date and one of the two messages will...

Page 42: ... the machine according to operating conditions when the STOP command is invoked If at the time of the STOP command the compressor was operating at full load the control unit sets the machine to unload run Display DI shows this countdown at the end of the countdown the motor is stopped 10 Stop in XXX sec hour date At this point the display shows this additional timing during this phase the compress...

Page 43: ...X X bar Temperature XXX C Ready for start 10 40 DOM 25 05 2003 To change the language use the K5 and K6 keys After 60 seconds from pressing of the last key the display is set to a low level of brightness The first time a key is pressed excluding the K1 START K2 STOP K3 RESET control keys high level brightness of the display is restored while subsequent pressing of the keys produces the associated f...

Page 44: ...paragraph 7 4 2 3 Indicates setting of the type of control LOCAL REMOTE PROGRAM ref paragraph 7 4 2 3 If enabled indicates the status of the AUTORESTART function automatic restart following blackout ref paragraph 7 4 2 3 Indicates the total hours of operation of the compressor ref paragraph 7 4 2 2 Indicates the hours of operation of the compressor at full load ref paragraph 7 4 2 2 Indicates the ...

Page 45: ...o carry out all compressor control and programming operations ESC MAIN SCREEN PAGE ESC Menu B Pressure XX X bar Temperature XXX C Ready for start hour date ref paragraph 7 4 2 2 ref paragraph 7 4 2 3 MAINTENANCE GENERAL SETTINGS NETWORK SETTINGS OPERAT PARAMETERS PROGRAMMING DIAGNOSTICS PASSWORD INFORMATION ESC ESC ESC ESC ESC ESC ref paragraph 7 4 2 4 visible only if the CAN BUS interface has bee...

Page 46: ... inserted using Menu C PASSWORD Enter password Enter password 0000 ESC ESC keys K7 and K8 to modify the flashing character numbers and letters are displayed subsequently the K5 and K6 keys to move to modification of the previous next character After inserting the password this can be confirmed with the K9 ENTER key or cancelled with the K4 ESC key ESC If no other key is pressed the password entered e...

Page 47: ...onents ESC Compon replacement Replacement made for air filter OK ESC Replacement made for oil filter OK ESC Replacement made for other components ESC ESC Confirm replacement air filter OK Confirm replacement oil filter OK ESC Confirm replacement other components ESC Running hours Operating time total xxxx ore ESC Operating time load xxxx ore Press the K4 key to return to the MAINTENANCE menu from the sub...

Page 48: ...unning hours running hours at full load A table with the schedule of the maintenance operations to be carried out is provided below Intervention First 100 hours maintenance coupon First 1000 hours maintenance coupon Every 1000 hours Every 2000 hours Check air filter Replace air filter Change oil Replace oil filter Replace separator filter Replace air dryer filters Maintenance periods may differ from th...

Page 49: ...guage OTHER LANGUAGES ESC Measur unit Pressure unit Unit bar ESC Temperature unit Unit Cels ESC Date and time Set date and time hh mm day dd mm yyyy ESC Press the K4 key to return to the GENERAL SETTINGS menu from the submenus ESC Display settings Contrast Intensity XXX ESC Lighting ON Brightness XXX ESC Lighting OFF Brightness XXX ESC ...

Page 50: ...ol REMOTE ESC Press the K4 key to return to the GENERAL SETTINGS menu from the submenus Compress control PROGRAM ESC Compress control NETWORK CONINUOUS ESC Compress control NETWORK PROGRAM ESC only if the CAN BUS interface has been installed continued from p 47 DRYER control DRYER enabled in ON ESC DRYER Disabled ESC Continued on p 49 only on machines equipped with integrated dryer ...

Page 51: ...hese can be confirmed with the K9 ENTER key or cancelled with the K4 ESC key ESC Display settings Makes it possible to adjust the settings of the LCD display Operating mode ESC Menu E 3 3 AUTORESTART func AUTORESTART DISABLED ESC AUTORESTART ENABLED ESC Press the K4 key to return to the GENERAL SETTINGS menu from the submenus continued from p 48 Only with access enabled Type remote contr Type remot...

Page 52: ... the compressor is equipped with a CAN BUS interface the network continuous network program control options are also visible and can be selected Compressor control can be set to LOCAL this is the basic factory setting that permits control from the keyboard REMOTE with this setting the compressor can be controlled by means of an external remote switch For the electrical connections refer to the fol...

Page 53: ...OAD 4 Press the START key on the control unit to enable the compressor for remote control Autorestart function If enabled this menu makes it possible to set the AUTORESTART function useful for automatic restart of the machine following a black out and subsequent power up 7 4 2 4 NETWORK SETTINGS menu This menu is used to set the parameters required for operation of the compressor in a network in c...

Page 54: ...rted at the end of this count the system checks network pressure to establish whether another compressor must be started T OFF When the control system deactivates a compressor following an increase in network pressure the T OFF timer is started at the end of this count the system checks network pressure to establish whether another compressor is to be deactivated 7 4 2 5 OPERAT PARAMETERS menu Thi...

Page 55: ...losses of head of the distribution system The minimum pressure value cannot be close to the maximum pressure by more than the factory setting minimum difference Timings UNLOAD RUN TIME This setting defines the time during which the compressor idles when there is no demand for air from the network At the end of this period the compressor stops and is ready to start again when network pressure has dr...

Page 56: ...he schedule of compressor activities defining the days and times when the compressor must be switched on The compressor can be programmed on a daily basis same for all the days or on a weekly basis a different program for each day of the week Reset programming Makes it possible to cancel all the cycles set in both daily and weekly programming Programming mode This parameter informs the controller w...

Page 57: ...gramming mode Programming mode DAILY ESC Programming mode WEEKLY ESC Press the K4 key to return to the PROGRAMMING menu from the submenus ESC Daily programming Every day Start 1 ESC Every day Stop 1 ESC other days other cycles ESC Weekly programming Monday Start 1 ESC Monday Stop 1 ESC other days other cycles ESC ...

Page 58: ...LY 3 Program the daily or weekly schedule selected 4 Press the K1 START key on the control unit to enable program control 7 4 2 7 DIAGNOSTICS menu From the diagnostics menu it is possible to check functioning of the INPUTS OUTPUTS and the direction of rotation of the compressor and fan It is also possible to read the log of faults that have occurred on the compressor These diagnostic functions sho...

Page 59: ...OK ESC other INPUTS DIAGNOSTIC TEST TEST digit INPUTS INPUT n 1 status Emergency OK Press the K4 key to return to the PROGRAMMING menu from the submenus ESC Press if OK Press ESC if NEGAT ERROR MESSAGES Last error message ESC other error messages ESC DIAGNOSTIC TEST TEST digit OUTPUTS OUTPUT n 1 active Line ESC ESC ESC ESC ESC ESC other OUTPUTS ESC ...

Page 60: ...stics system of the controller permits continuous monitoring of machine operating conditions and prompt indication of the need for maintenance operations or of any malfunctions The indications are divided into two categories Warning messages These messages may refer to scheduled maintenance operations critical operating conditions or minor faults which do not block the compressor but which must be...

Page 61: ...diately the red LED L3 of the alarms switches on and the message relating to the fault is displayed persistently in the main screen page To RESET first of all eliminate the fault at this point LED L3 starts to flash indicating that reset can be carried out pressing the RESET key All faults that cause blocking of the compressor are saved in an error message log file To consult this log refer to paragr...

Page 62: ...f the hyphens In this case it is absolutely necessary to replace the component If the compressor must be restarted an emergency start up procedure must be carried out Contact the Service or Customer Centre of the Manufacturer immediately To find out how to proceed in the case of an alarm refer to chapter 9 Troubleshooting ...

Page 63: ...pressors necessary to supply the air required are activated equal distribution of work load on the compressors available with consequent synchronization of scheduled maintenance operations management of alarms and machine stoppages so as to prevent any interruption in the supply of compressed air management of the network of compressors according to a program set by the user on a daily or weekly b...

Page 64: ...sible cause Intervento X X L1 OFF DI OFF No power Restore power FU2 FU8 blown Replace damaged fuses X X L1 ON DI OFF Problems in the electronic control unit Call Customer Service Centre Problems in control unit connections Call Customer Service Centre X X L1 ON DI ON with normal functioning message FU4 blown Replace FU4 Inverter problems Call Customer Service Centre X X X L1 ON L3 constant ON DI i...

Page 65: ...arting up V F V V Indication Possible cause Intervention X X Ambient temperature low Heat ambient Low voltage Check voltage VA problems Call Customer Service Centre Star delta sequence problems Call Customer Service Centre X X Inverter problems Call Customer Service Centre 9 3 Pressure value lower than rated pressure V F V V Indication Possible cause Intervention X X Pressure value on DI constant ...

Page 66: ... X X L2 flashing DI indicates Replace oil XXX excess hours Oil to be replaced for scheduled maintenance Replace oil see par 10 5 X X L2 flashing DI indicates Replace oil separator XXX excess hours FD to be replaced for scheduled maintenance Replace FD see par 10 6 X X L2 flashing DI indicates Replace dryer filter XXX excess hours Dryer filters to be replaced for scheduled maintenance Call Customer Serv...

Page 67: ... or solenoid valve problems Call Customer Service Centre Net pressure too high caused by other compressors Check working pressure of all compressors X X L3 constant ON DI indicates Compress motor overload block Low voltage Check voltage X X Underscaled power cables Check installation requirements X X Critical functioning temperature conditions high ambient temperature hot air recirculation Check f...

Page 68: ...ce oil excess hours block Oil to be replaced for scheduled maintenance Replace oil see par 10 5 X X L3 constant ON DI indicates Replace oil separator excess hours block FD to be replaced for scheduled maintenance Replace FD see par 10 6 X X L3 constant ON DI indicates Replace dryer filter excess hours block Dryer filters to be replaced for scheduled maintenance Call Customer Service Centre X L1 ON L...

Page 69: ...ion Possible cause Intervention X X FA leaks Call Customer Service Centre 9 9 Safety valve VS intervention V F V V Indication Possible cause Intervention X X Pressure detector problems Call Customer Service Centre FD clogged Replace FD par 10 6 X X ...

Page 70: ... fixed speed compressors starting is of the delta star type During the star phase intake valve VA is closed thus permitting no load start up with less effort and lower energy consumption After a preset time of a few seconds the PC control unit invokes changeover to the delta connection with a short transient phase the MP motor reaches rated rotation speed The intake valve opens thus starting the no...

Page 71: ...e case of very low air consumption once the maximum operating pressure has been reached the com pressor switches to idling as described for the fixed speed compressor In this case the duration of the idling phase is shorter at the end of this phase the compressor stops ready for subsequent automatic restart The operator controlled machine stopping phases also differ as regards the two types of comp...

Page 72: ...ctrical terminal connections Drain air oil receiver condensate 10 7 Clean radiators Clean dryer condenser Replace air dryer filters Check belt tension and wear Replace drive belts Check settings and adjustments Check safety device operation This frequency relates to operation in normally dust environments In the case of critically dust environments the control panel may signal the need to replace t...

Page 73: ...To reset the scheduled maintenance counter for enabled users only see paragraph 7 4 2 2 Cleaning or replacing the air filter 10 4 Before performing any maintenance operations read the operator safety precautions in chapter 5 carefully These precautions must be followed scrupulously for all maintenance operations GENESIS FORMULA MODULO 5 5 15 kW 7 5 20 hp BA 51 Open the upper panel PS of the com pre...

Page 74: ... part of the filter con tainer CF pressing on the two fastening tabs Fig 39 Remove air filter FA from its housing as shown in Fig 40 Clean the filter by directing a jet of air inside it or replace the filter as pre scribed in the maintenance schedule Do not use fluids or detergents to clean the filter Replace filter FA inserting it fully Re attach the front part of the filter con tainer CF pressing on th...

Page 75: ...e level of the lubricant is close to the minimum limit of the level reference tube TRL top up the oil Never let the oil drop to a level which is no longer visible through the reference level tube TRL Maximum level is reached when the oil laps the edge of the maximum level reference RLMAX during top up Top up when required as follows Remove the front panel PF using the key provided Loosen oil filler...

Page 76: ...h a suitable collection recipient to fitting DO after unscrewing the safety plug Fig 44 Open drain valve RSO and drain the lubricant Fig 44 After draining close oil drain valve RSO Refill with oil as described in the Check ing oil level topping up paragraph Fig 43 Check that the seal of plug TO is cor rectly positioned and fasten the plug not too tightly Replace the front panel PF using the key prov...

Page 77: ...the specific key provided Fig 45 Lubricate the seal before fitting the new cartridge Fig 46 Fasten the filter and tighten by hand Do not use tools to fasten the cartridge as these may damage its structure Open the shut off valve between the compressor and the distribution line Switch the circuit breaker on and carry out a test start up Let the compressor run for a few minutes and then make a visual i...

Page 78: ...he air receiver proceed as follows Place a suitable drip tray under the condensate discharge valve RSC which is located under the SA receiver Ensure that the intercept valve between the compressor and the distribution line is closed Open the condensate discharge valve RSC fig 47 using pliers if necessary Leave the condensate to drain until the tank is completely empty Close the valve RSC Fig 47 SA ...

Page 79: ...The air receiver and separator condensate should be drained manually on a weekly basis or more frequently The user is responsible for this maintenance operation Replacing the fuses 10 8 Before performing any maintenance operations read the operator safety precautions in chapter 5 carefully These precautions must be followed scrupulously for all maintenance operations GENESIS FORMULA Open the corne...

Page 80: ...le material codes 11 1 The following tables show the most commonly used spare parts Contact an authorised service Centre for other spare parts Model Pressure Air filter Oil filter Separator filter Suction prefilter Transmission belts bar Code Code Code Code Code 5 5 8 9056293 9056238 9056237 9623572 2 9075257 10 2 9075290 13 9056282 2 9075236 15 2 9075290 7 5 8 9056293 9056238 9056237 9623572 2 907525...

Page 81: ... 2 9075290 13 9056934 2 9075236 15 2 9075290 7 5 8 9056937 9056933 9056942 9623572 2 9075256 10 2 9075236 13 9056934 2 9075290 15 2 9075257 11 8 9056937 9056935 9056943 9623572 2 9075291 10 2 9075215 13 2 9075254 15 2 9075256 15 BA 51 8 9056937 9056935 9056943 9623572 3 9075211 10 3 9075291 13 3 9075215 15 3 9075262 15 BA 69 8 9056939 9056935 9056943 9623572 3 9075256 10 3 9075254 13 3 9075262 15 ...

Page 82: ...P 80 Chap 12 Diagrams G B 12 Diagrams Hydraulic pneumatic plant diagram 12 1 ...

Page 83: ... valve 8 Oil filter 9 Air oil exchanger 10 Oil recovery 11 Separator filter 12 Minimum pressure and check valve 13 Air air exchanger 14 Net pressure transducer 15 Drying unit only in equipped versions 15 1 Air dryer 15 2 Dew temperature sensor 15 3 Automatic condensate drain 16 Air receiver unit only in equipped versions 16 1 Air receiver 16 2 Safety valve 16 3 Discharge valve 16 4 Condensate drain ...

Page 84: ...P 82 Chap 12 Diagrams G B Power circuit wiring diagram 5 5 15 kW Machines without air dryer 12 2 ...

Page 85: ...P 83 Chap 12 Diagrams G B Power circuit wiring diagram 5 5 15 kW Machines with air dryer 12 3 ...

Page 86: ...P 84 Chap 12 Diagrams G B Power circuit wiring diagram 11 kW Machines with inverter 12 4 ...

Page 87: ...P 85 Chap 12 Diagrams G B Auxiliary circuit wiring diagram 5 5 15 kW Machines without air dryer 12 5 ...

Page 88: ...P 86 Chap 12 Diagrams G B Auxiliary circuit wiring diagram 5 5 15 kW Machines with air dryer 12 6 ...

Page 89: ...P 87 Chap 12 Diagrams G B Auxiliary circuit wiring diagram 11 kW Machines with inverter 12 7 ...

Page 90: ...P 88 Chap 12 Diagrams G B Wiring diagram for component location 5 5 15 kW Machines without air dryer 12 8 ...

Page 91: ...P 89 Chap 12 Diagrams G B Wiring diagram for component location 5 5 15 kW Machines with air dryer 12 9 ...

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