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USE AND MAINTENANCE MANUAL

SILENT ELECTRIC ROTARY SCREW COMPRESSORS

WARNING

: Read this manual carefully and in full before using the compressor.

Summary of Contents for AIRBLOK 40

Page 1: ...1 68 GB USE AND MAINTENANCE MANUAL SILENT ELECTRIC ROTARY SCREW COMPRESSORS WARNING Read this manual carefully and in full before using the compressor ...

Page 2: ...afety standards The fundamental safety standards are listed in the SAFETY section of this manual and also in the section involving the use and maintenance of the compressor Hazardous situations to be avoided in order to prevent serious personal injuries and machine damages are listed in the WARNINGS section of the instruction manual or are actually printed on the machine Never use the compressor i...

Page 3: ...12 3 3 Storing the packed and unpacked compressor 13 4 Installation 14 4 1 Admitted surrounding conditions 14 4 2 Space required for maintenance 14 4 3 Positioning the compressor 15 4 4 Connecting the compressor to the sources of energy and relative inspections 16 4 4 1 Connecting the compressor to the electrical mains power supply 16 4 4 2 Connecting the dryer to the electrical mains 18 5 Using t...

Page 4: ...idge 34 6 1 3 Replacing the filter cartridge of the oil separator 34 6 1 4 Replacing the air filter cartridge 35 6 1 5 35 6 1 6 Cleaning the air oil radiator 36 6 7 7 Cleaning the dust removal pre filter 36 6 1 8 Grease the bearings of the motor 36 6 1 9 37 6 1 10 37 6 1 11 38 6 2 Diagnosing the alarm status inconveniences faults 38 7 Drawings and diagrams 41 7 1 Wiring diagrams 41 7 2 Pneumatic d...

Page 5: ...e INSTRUCTION MANUAL is integral part of the compressor Ensure that any up dates forwarded by the Manufacturer are actually added to the manual If the compressor is sold on at a later date the manual must be given to the new owner 0 1 b Conserving the manual Use and read the manual with care being careful not to damage any part of it Do not remove tear or re write any parts of the manual for any r...

Page 6: ...g and starting the compressor GENERAL HAZARDOUS SITUATION An additional note will point out the type of hazard involved Meaning of the indications Warning This points out a potentially hazardous situation which if ignored could cause personal injury and machine damage Note This enhances crucial information RISK OF ELECTRIC SHOCK Warning theelectricalpowersupplyofthecompressormustbedisconnectedbefo...

Page 7: ... ensured only if original spare parts are used We recommend therefore that you strictly observe the indications provided in the MAINTENANCE section and to use EXCLUSIVELY original spare parts The use of NON ORIGINAL spare parts automatically annuls the guarantee 1 3 General safety warnings Note The procedures provided in this manual have been written to assist the operator throughout the use and m...

Page 8: ...E COMPRESSOR OUT OF CHILDREN S REACH Prevent children or anyone else from touching the power supply cable of the compressor All outsiders must be kept at a safe distance from the operational area 10 WORK CLOTHES Do not wear unsuitable clothing ties or jewellery as these may get caught up in moving parts Wear caps to cover your hair if necessary 11 PRECAUTIONS FOR THE POWER SUPPLY CABLE Donotdiscon...

Page 9: ...RESSOR To avoid scolding do not touch pipes the motor or any other hot part 27 DO NOT DIRECT THE JET OF AIR DIRECTLY TOWARDS THE BODY To avoid all risks never direct the jet of air towards people or animals 28 DO NOT STOP THE COMPRESSOR BY PULLING ON THE POWER SUPPLY CABLE Use the O I ON OFF switch to stop the compressor 29 PNEUMATIC CIRCUIT Use recommended pneumatic hoses and tools that can withs...

Page 10: ...oil in rotary screw compressors has the function of lubricating and cooling the screw unit The oil also has a sealing function to ensure a perfect compression seal within the block Therefore it is extremely important to choose the correct type of oil for this type of compressor NEVER MIX DIFFERENT OIL QUALITIES SCREW OIL FOR DR SD VERSIONS FIAC SYNT RS D 46 OR IN ALTERNATIVE SHELL CORENA AS46 MOBI...

Page 11: ...9 69 1750 X 950 X 1700 1750 X 950 X1700 980 1000 2 3 Technical data Model Max pressure Free air delivery ISO 1217 Air outlet fitting Lubricant qty Fan capacity Oil residue in air 2 pole electric motor Output Protection rating Service Max starts per hour Ambient temperature limits Noise level 2000 14 CE Dimensions mm Weight Kg Sound level measured in a free range at a distance of 1 m 3dB A at the m...

Page 12: ... indicated lift slowly without jerking Never stand near the area where the compressor is being handled and never stand on the crate while it is being moved 3 2 Packing and unpacking To avoid damages and to protect the compressor during transport it is usually placed on a wooden pallet to which it is secured by screws and covered with cardboard All the shipping and handling information and symbols ...

Page 13: ...the packing in compliance with current standards in force in the country of installation Note The machine must be unpacked by qualified personnel using appropriate tools and equipment 3 3 Storing the packed and unpacked compressor Forthewholetimethatthecompressorisnotusedbeforeunpackingit storeitinadryplaceatatemperature between 5 C and 45 C and sheltered away from weather For the whole time that ...

Page 14: ...d in compliance with legal prescriptions and in the attempt to minimise shadow zones to facilitate the operator s job The lighting system of the factory is to be considered as crucial for the operator s safety The room in which the compressor is installed must have no shadow zones dazzling lights or stroboscopic effects due to the lighting ATMOSPHERE WITH RISK OF EXPLOSION AND OR FIRE The standard...

Page 15: ...ch canbeusedtoheattheroomorforotherpurposes Itiscrucialthatthecrosssection of the system that recovers the hot air is greater than the total cross section of the grid slots plus the system must be equipped with a forced extraction system extractor fan 1 to favour a constant downflow minimum cross section 1200 cm 4 3 Positioning the compressor Once the position in which the compressor is to be inst...

Page 16: ...ver use the compressor with damaged electrical cables Regularly check the electrical cables Never use the compressor in or near water or near a hazardous area where electrical shocks may be encountered ELECTRICAL CONNECTION The three phase compressors L1 L2 L3 PE must be installed by a qualified engineer The three phase compressors are supplied without plug and cable The power supply cable must be...

Page 17: ...to thermal switch Never use the earth connection instead of the neutral The earth connection must be achieved according to the EN 60204 industrial safety standards Ensure that the mains voltage corresponds with that required for the correct operation of the compressor Itisadvisedtoquarterlyverifytheserrationoffeedingcablesmachineonthemagnetotermic CHECK THE ROTATION DIRECTION When connecting the c...

Page 18: ... repair a faulty hose Connect the compressor to the pneumatic mains using the fitting 1 pre arranged on the compressor Use hosing with a greater or same diameter as the compressor outlet Install two ball taps with capacity suitable for the compressor between the compressor and tank and between the tank and line Do not install non returnvalvesbetweencompressorandtank Thenon returnvalveisalreadyinst...

Page 19: ...motor is equipped with a trip switch that immediately stops the compressor in the case of an over current caused by a mechanical or electric fault 5 1 2 Compressor operation with inverter versions SD speed driven Principle of the speed of the inverter controlled compressor The mains pressure is monitored by a pressure transducer and transmitted to the frequency converter by means of an analogue in...

Page 20: ...the required air output restoring the pressure at the correct values 5 2 Controls indicators and safety devices of the compressor 5 2 1 Control panel The control panel is made up of a set of buttons required for the main operational and control functions of the compressor 1 GREEN LED This points out that the compressor is powered 2 START I This button is used to turn the compressor on 3 STOP O Pre...

Page 21: ...which is described in point 5 2 1 The ECU controls machine operation in an efficient and safe manner When the compressor is connected for the first time at the rated electrical voltage ensure the STOPPED ALARM does not trigger which is pointed out by the red LED that lights up steady ALARM on dashboard by a beeping buzzer and by a message that flashes on the display indicating ALARM ROTATION This ...

Page 22: ...S THE CLIENT CAN ACCESS PASSWORD MENU HOW TO ACCESS HOW TO EXIT DEFAULT AUTOTEST Keys and DEFAULT pressed together STOP key DEFAULT CLIENT Keys and DEFAULT pressed together DEFAULT key AUTOTEST DEFAULT simultaneously To access the menu press the and DEFAULT keys simultaneously The AUTOTEST function automatically checks the electrical connections of the machine TESTING STOP TO EXIT TH 150 MAINTEIN ...

Page 23: ...equal to 1 bar 14 5 psi To exit the menu press the DEFAULT key 2 To change the Max P value equal to 10 bar in the example given press PROGRAM and enter the replacement value in decimals without commas using the DOWN arrow and UP arrow keys of the push button control panel and press PROGRAM Note Max P must be at least 0 5 bar 7 2 psi lower than the Alarm P Max P Min P must be greater than or equal ...

Page 24: ...lay indicating the cause for the actual alarm 1 When the Pressure exceeds the limit alarm pressure case in which the increase in pressure is so quick that the max cut off pressure is unable to intervene the following appears on the display ALARM PRESSURE THE COMPRESSOR STOPS To reset the machine Once the pressure has dropped P Alarm P press the RESET key to set the compressor ready to start again ...

Page 25: ...achine Once you have connected the cables correctly press the RESET key on the control dashboard 5 The following may appear on the display THE COMPRESSOR WILL NOT START BACAUSE THE SCREW UNIT IS TOO COLD 6 C To reset the machine If the temperature increase to 5 C press the RESET key to set the compressor ready to start 6 The following may appear on the display THE COMPRESSOR STOPS The PTC in the m...

Page 26: ...g LED and buzzer A list of all the types of alarms that may trigger together with their possible solutions follows below The following could appear on the display 1 Short circuit in motor cables or motor To restore machine operation Eliminate the cause for the fault Press the RESET button on the keypad of the ACS550 INVERTER inside the electric cabinet Press the RESET key on the control board to s...

Page 27: ...SETbuttononthekeypadoftheACS550INVERTERinsidetheelectriccabinet Thenpress also the RESET key on the control board to set the compressor ready to start 5 Possible fault in the motor or in the motor cables THE COMPRESSOR STOPS Solution Check and eliminate the cause for the fault in to the wiring harness To restore machine operation Eliminate the cause for the fault PresstheRESETbuttononthekeypadofth...

Page 28: ... PresstheRESETbuttononthekeypadoftheACS550INVERTERinsidetheelectriccabinet Thenpress also the RESET key on the control board to set the compressor ready to start 9 The analogue control signal is lower than the minimum value admitted due to an insufficient signal level or to an error in the connection of the control unit THE COMPRESSOR STOPS Solution Check if the levels of the analogue control sign...

Page 29: ...ck the motor and motor cable To restore machine operation Eliminate the cause for the fault PresstheRESETbuttononthekeypadoftheACS550INVERTERinsidetheelectriccabinet Thenpress also the RESET key on the control board to set the compressor ready to start 5 3 Check the efficiency of the safety devices before starting OIL LEVEL Check the oil level as indicated in Section 6 Compressor maintenance DO NO...

Page 30: ...d is correct and if the maximum pressure set triggers compressor idle running mode At this stage check if the compressor runs idle for roughly 2 minutes The pressure on the gauge of the oil separator tank must be between 2 and 3 bar At the end of this time the compressor stops triggered by the timer Release the air from the tank to restore the starting pressure 9 bar shut off the air outlet tap an...

Page 31: ...binet ensure that The main line switch is turned off position 0 The electrical compressor switch is Off in position 0 The compressor is disconnected from the compressed air system Allthepressurehasbeenreleasedfromthecompressorandinternalpneumaticcircuit The front panels are equipped with quick release locks to facilitate maintenance and any other jobs necessary Weekly it is advisable to inspect th...

Page 32: ...ry Change the oil Check the hydraulic seals Test motor trip switch for DR versions Test oil trip switch Overhaul the suction valve Check the hoses and replace if necessary Overhaul oil separator flange Grease the minimum pressure valve Replace Fluorflon pipes 6x4 and 10x10 Replace the screw oil seal Replace the bearings of the radiator fan motor to be done by Technical Service centre Replace the d...

Page 33: ...ts to seep out from the screw unit therefore use a hose and container to collect the oil Once all the oil has been drained remove the knurled fitting 3 and screw cap 2 manually Top up with oil to half way up inspection glass 4 then screw cap 1 back on and close the compressor Once the oil and oil filter have been changed leave the compressor to run for roughly 5 minutes then turn it off and check ...

Page 34: ...sealing gasket before screwing the filter cartridge tight Manually tighten the new filter cartridge 6 1 3 Replacing the filter cartridge of the oil separator Read all indicated in Section 6 1 before starting any maintenance jobs Open the front panel to gain access to inside the compressor Disconnect the compressed air hoses from the hose fittings 1 Loosen nut 3 and disconnect pipe 2 Unscrew the nu...

Page 35: ...intenance table Ensure it operates silently and that there are no splits or other damages in the orange flexible part Proceed as follows Check if there are any abnormal noises during operation Stop the compressor Disconnect the power supply of the compressor by switching the main ON OFF switch OFF and make sure it cannot be switched ON again accidentally Unscrew the protection grid 1 Manually turn...

Page 36: ...rease by 10 15 just momentarily to then settle back down at the normal temperature when the grease has spread evenly and any excess grease has been expelled from the bearing tracks If bearings are lubricated excessively they would overheat Once you have re lubricated and after a few minutes of testing put the caps back on the holes of the motor shields which discharge any excess grease Clean the s...

Page 37: ...moving the guard 2 and blowing them with compressed air If the machine works in a dusty environment it is advisable to clean the filters more frequently based on their condition Replace the filter after it has been cleaned five times or if the environment is particularly dusty 6 1 10 Replacing the inverter fan and radiator fan bearings The fan of the inverter and the supplementary fan above it are...

Page 38: ...ion SD Dust transported by the cooling air may settle on the fins of the dissipator If the dissipator is not cleaned regularly the drive may encounter alarms and faults due to overheating In normal surroundings the dissipator must be cleaned and inspected on a yearly basis but more often in dusty surroundings Clean the dissipator as follows Remove the cooling fan Blow DRY compressed air from the b...

Page 39: ... to below 45 C Ensuretheelectricalpowersupplyiscorrect checking if the three power supply phases are around about the same value Ensure the cables are firmly connected to the terminal board and make sure the electrical cables have not melted Ensure the suction grid of the cooling fan of the motor is not dirty or obstructed with foreign objects paper leaves rags To start the machine again wait for ...

Page 40: ...e faulty The machine fails to depressurise during idle running mode the oil separator cartridge is clogged Oil not suitable for the use of the compressor air oil separator cartridge torn The screws of the cover of the oil separator tank are loose oil level too high Check the line pressure release the pressure to take it back to the set working values Invert two phases of the power supply on switch...

Page 41: ... W2 U U FU FU MV MV 3 3 PE PE FUV FUV KG KG KV KV U1 U1 V1 V1 W1 W1 1 1 3 3 4 4 V V U U 2 2 4 4 6 6 2 2 6 6 5 5 3 3 5 5 1 1 F1 F1 F2 F2 V V U U PE PE MC MC U1 U1 V1 V1 W1 W1 16 16 13 13 U3 U3 V3 V3 W3 W3 3 3 7 Drawings and diagrams 7 1 Wiring diagrams KEY OF THE WIRING DIAGRAMS versions DR QS Main ON OFF switch FUV Fan motor fuses 10 3x38 aM 6A 100HP 400V Fan motor fuses 10 3x38 aM 4A 75HP 400V Fa...

Page 42: ...0 0 8 8 9 10 13 13 13 13 20 17 18 19 26 27 5 5 9 10 RS232 25 M7 U V 24 24 23 5 6 5 8 9 10 M10 16 17 18 19 20 21 22 23 24 D 26 27 28 M1 15 14 13 12 11 10 9 8 7 6 20 19 18 17 16 15 13 13 14 CONTATTO COMPRESSORE IN ALLARME PREDISPOSIZIONE PER CCOMANDO REMOTO DISPOSIZIONE MORSETTIERA Terminal board connection alarm compressor contact remote control contact DATA DATA TRATT TERMICO O SUPER DIS PARTICOLA...

Page 43: ...tor 16 Machine temperature probe 17 Cooling fan 18 Electric motor 19 Direct transmission 20 Screw compressor unit 21 Adjustment valve 22 Idle running choker 23 Solenoid valve only for V100 A ADJUSTMENT VALVE UNIT B COMPRESSOR UNIT C OIL SEPARATOR UNIT D RADIATOR BATTERY UNIT 1 oil air mix delivery circuit 2 air delivery to radiator battery 3 idle running and adjustment valve pilot circuit 4 oil pr...

Page 44: ...44 68 GB 7 DRAWINGS AND DIAGRAMS ...

Page 45: ...45 68 GB DRAWINGS AND DIAGRAMS 7 ...

Page 46: ...1 4 CF75G AIRBLOK40 SD ...

Page 47: ...rings and oil seal kit See kit assemb table Kit cuscinetti e paraolio Vede tavola assemb kit 81 7014480000 2 Screw Vite STEI M12x60 28 7082600000 1 Suction valve maintenanca kit Kit manutenzione valvola aspirazione 82 7180110000 1 Sight Spia recupero olio 29 7043011500 2 Clamp Fascetta 83 7235400000 1 Hose Tubo recupero olio 30 7233960000 1 Hose Tubo aspirazione 84 7364450000 3 Shok adsorber Antiv...

Page 48: ... Joint Nipplo 1 8 110 7011040000 2 Screw Vite T E M6x20 UNI 5739 111 7030190000 4 Washer Rondella Ø6x18x1 5 112 7043320000 1 Filter clamp Collare filtro aspirazione 113 5168670008 1 Support Supporto filtro 114 7230010000 1 Rilsan hose Tubo rilsan 115 7011290000 2 Screw Vite T E M6x35 UNI 5739 VALID FROM 14 01 2008 VALIDO DAL 14 01 2008 REV 02 1 4 CF75G 8 BAR AIRBLOK40 SD 1 4 CF75G 10 BAR AIRBLOK40...

Page 49: ...2 4 CF75G AIRBLOK40 SD ...

Page 50: ... Pannello 117 5168260008 1 Panel Pannello 118 7433220000 1 Electronic panel Scheda elettronica 119 5168200008 2 Support Supporto montanti 120 5168160008 2 Culumn Montante 121 5168180008 1 Culumn Montante 122 5168170008 1 Culumn Montante 123 5168300008 1 Pre filter panel Pannello prefiltro 124 5168410008 2 Angular Angolare prefiltro 125 7210860000 1 Pre filter Prefiltro 126 7012300000 16 Screw Vite...

Page 51: ...3 4 CF75G AIRBLOK40 SD ...

Page 52: ...0008 1 Support Angolare dx 216 5168400008 1 IP54 protection Protezione IP54 217 5168320008 1 Panel Pannello radiatore 218 7500440000 1 Stretch eliminator Pressacavo M20x1 5 219 5168330008 1 Panel Pannello superiore 220 7014140000 8 Screw Vite T S P E I M6x22 221 7018590000 4 Hinge Cerniera 222 7011040000 16 Screw Vite T E M6x20 UNI 5739 223 7212420000 1 Electrical fan filter Filtro elettroventola ...

Page 53: ...4 4 CF75G AIRBLOK40 SD ...

Page 54: ...tretch eliminator Pressacavo M50x1 5 322 7500470010 2 Blocking nut Controdado M50x1 5 323 7012250000 2 Screw Vite T C cross 4X20 TAP TITE 324 7084750000 1 Joint Raccordo L Ø10 1 4 325 7082970000 4 Joint Raccordo L 1 4 x6 326 7562980000 1 Filter Filtro condensa 327 7081160000 1 Joint Raccordo 328 7191010000 1 Valve Valvola unidirezionale 1 8 329 7084420000 1 Joint Raccordo diritto 1 4 330 701224000...

Page 55: ...1 4 CF90LD1 AIRBLOK50 SD ...

Page 56: ...earings and oil seal kit See kit assemb table Kit cuscinetti e paraolio Vede tavola assemb kit 81 7063010000 1 Spacer Distanziale 28 7082600000 1 Suction valve maintenanca kit Kit manutenzione valvola aspirazione 82 7180110000 1 Sight Spia recupero olio 29 7043150000 2 Clamp Fascetta 83 7235450000 1 Hose Tubo recupero olio 30 7232360000 1 Hose Tubo aspirazione 84 7364450000 3 Shok adsorber Antivib...

Page 57: ...1040000 2 Screw Vite T E M6x20 UNI 5739 111 7030190000 4 Washer Rondella Ø6x18x1 5 112 7043240000 1 Filter clamp Collare filtro aspirazione 113 5168670008 1 Support Supporto filtro 114 7230010000 1 Rilsan hose Tubo rilsan 115 7011290000 2 Screw Vite T E M6x35 UNI 5739 116 7488320000 1 Cover Coperchio disoleatore VALID FROM 14 01 2008 VALIDO DAL 14 01 2008 REV 02 1 4 CF90LD1 8 BAR AIRBLOK50 SD 1 4 ...

Page 58: ...2 4 CF90LD1 AIRBLOK50 SD ...

Page 59: ...nnello 117 5168260008 1 Panel Pannello 118 7433220000 1 Electronic panel Scheda elettronica 119 5168200008 2 Support Supporto montanti 120 5168160008 2 Culumn Montante 121 5168180008 1 Culumn Montante 122 5168170008 1 Culumn Montante 123 5168300008 1 Pre filter panel Pannello prefiltro 124 5168410008 2 Angular Angolare prefiltro 125 7210860000 1 Pre filter Prefiltro 126 7012300000 16 Screw Vite T ...

Page 60: ...3 4 CF90LD1 AIRBLOK50 SD ...

Page 61: ...8 1 Support Angolare dx 216 5168400008 1 IP54 protection Protezione IP54 217 5168320008 1 Panel Pannello radiatore 218 7500440000 1 Stretch eliminator Pressacavo M20x1 5 219 5168330008 1 Panel Pannello superiore 220 7014140000 8 Screw Vite T S P E I M6x22 221 7018590000 4 Hinge Cerniera 222 7011040000 16 Screw Vite T E M6x20 UNI 5739 223 7212420000 1 Electrical fan filter Filtro elettroventola 224...

Page 62: ...4 4 CF90LD1 AIRBLOK50 SD ...

Page 63: ...Stretch eliminator Pressacavo M50x1 5 322 7500470010 2 Blocking nut Controdado M50x1 5 323 7012250000 2 Screw Vite T C cross 4X20 TAP TITE 324 7084750000 1 Joint Raccordo L Ø10 1 4 325 7082970000 4 Joint Raccordo L 1 4 x6 326 7562980000 1 Filter Filtro condensa 327 7081160000 1 Joint Raccordo 328 7191010000 1 Valve Valvola unidirezionale 329 7084420000 1 Joint Raccordo diritto 1 4 330 7012240000 6...

Page 64: ... box Kit guarnizioni cuscinetti per scatola ingranaggi 1 3 4094850000 Oil seal kit bearing kit Kit paraolio kit cuscinetti 4 7082600000 Suction valve kit Kit valvola di aspirazione 4A 7196740000 Suction valve kit Kit valvola di aspirazione 4084750000 Air end gaskets oil seal Kit Kit guarnizioni gruppo vite paraolio CF75G 4 4A ...

Page 65: ...o 1 2 4094840000 Oil seal kit bearing kit Kit paraolio kit cuscinetti 3 7082600000 Suction valve kit Kit valvola di aspirazione OLD 3A 7196740000 Suction valve kit Kit valvola di aspirazione NEW 4084740000 Air end gaskets oil seal Kit Kit guarnizioni gruppo vite paraolio CF90LD1 3A ...

Page 66: ...46 68 GB 7 DRAWINGS AND DIAGRAMS ...

Page 67: ...Date Job description Hours of use Operator ssignature ...

Page 68: ...Revisione 1 2 0 1 2008 Cod 1120013906 ...

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