Mattei AC 6000 Series Instruction, Use And Maintenance Manual Download

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AIR COMPRESSORS

INSTRUCTION, USE AND

MAINTENANCE MANUAL

TI008G0001

ING. ENEA MATTEI

SpA

Strada Padana Superiore 307 - 20090 VIMODRONE (MI)

Tel +39 - 02253051 (16 linee) - Fax +39 - 0225305243

E-Mail: [email protected] - www.matteiaircompressors.com

933GB

900a

Summary of Contents for AC 6000 Series

Page 1: ...TRUCTION USE AND MAINTENANCE MANUAL TI008G0001 ING ENEA MATTEI SpA Strada Padana Superiore 307 20090 VIMODRONE MI Tel 39 02253051 16 linee Fax 39 0225305243 E Mail info mattei it www matteiaircompress...

Page 2: ...dify the characteristics of the machine subject of this document without prior notice Copyright 2008 by Ing ENEA MATTEI S p A This Instruction Manual meets all the requirements of 98 37 EEC Directive...

Page 3: ...n of compressor Page 4 02 Electrical connection Page 4 03 Connection to the air network Page 4 04 Dimensions of compressed air distribution piping Page 4 05 Heat recovery Page 4 06 Safety Devices Page...

Page 4: ...introduces text blocks containing further information This information has no direct relationship with the description of a function or with pro cedure development They could be cross references to o...

Page 5: ...responsibility whatsoever General Information This manual is for the user and the service engineer of the machine and it aims at supplying them with the basic technical data typical of the system a t...

Page 6: ...is held to train the operator to be able to perform all of the actions necessary to operate the machine even with some of the protections disconnected However this requires a certain competence by th...

Page 7: ...s been attached It is forbidden to remove the CE MARKING plate and or exchange it for other plates of machines of the same model supplied to the Customer or the operator Should the CE MARKING plate be...

Page 8: ...concerning safety devices already installed on the machine instructions for correct machine installation correct use and periodic maintenance of all the machine components including safety devices reg...

Page 9: ...s the operating mode at which the machine produces compressed air according to all settings and controls inserted by the control device Decommissioning Decommissioning means to disconnect mechanically...

Page 10: ...evices PED Periodic inspections are also foreseen The machine safety is not guaranteed in case of removal by pass or tampering of the safety devices on the machine To stop the machine during an emerge...

Page 11: ...ore restrictive ones Maintenance and repair Only authorised personnel should carry out maintenance troubleshooting and repairs Any maintenance and repair in progress should be signalled by a specific...

Page 12: ...paring the site and when installing the machine itself preparation of auxiliary services suitable for the system requirements such as electricity supply pneumatic system etc preparation of the electri...

Page 13: ...structions on how to order spare parts In the course of time a machine may need the replacement of those parts subject to wear The Purchaser may order the parts to be replaced It is compulsory to alwa...

Page 14: ...ave read the entire manual Only skilled engineers should carry out maintenance jobs after having duly prepared the machine Any unauthorized tampering or replacement of one or more parts of the machine...

Page 15: ...ne can produce a much higher noise if the room is narrow and reverberating Please note that the continuous presence of an operator is unnecessary For safey against noise in compliance with local laws...

Page 16: ...ld be always carried out with compressor not operating Before carrying out any job on the compressor unit ensure through the gauge that there is no pres sure inside Only use suitable tools for the kin...

Page 17: ...nd transport of the machine wrong machine installation defects due to the electric power distribution lacks in periodic maintenance unauthorised jobs or modifications use of non original or unsuitable...

Page 18: ...represented by suitable standardized symbols pictograms Below is the list of the most common symbols ap plied to our machines Danger pictograms These triangular signs are framed in black with a yellow...

Page 19: ...tion on the machine Use individual protective means against noise Indication pictograms These signs may vary in shape and they give useful information Lifting point Direction of rotation 003 908 909 1...

Page 20: ...mpressors of the AC 6000 series Designed for continuous industrial service they guarantee constant performance over time low energy consumptions reliability func tionality and easy maintenance The com...

Page 21: ...wo end covers The rotor has longitudinal slots in which the vanes slide The vanes are pushed against the stator by centrifugal force Sealing of the moving parts cooling and lubrication are provided by...

Page 22: ...r maintenance Asynchronous threephase 4 poles electric motor with short circuit winding class F insulation High Efficiency Class IP 55 protection degree electrical supply according to IEC 38 voltage f...

Page 23: ...modification should be made either to this receiver or to its instal lation when setting up the machine The maximum operating pressure and temperature for this receiver are shown on the attached plat...

Page 24: ...alogue data Line pressure pressure in the chamber oil temperature output air temperature General data Alarms operating messages machine status maximum and minimum pressure last start and last stop Hou...

Page 25: ...ontinuous The advanced programming of parameters protected by password allows the qualified engineer to change those parameters to which the user cannot access directly Checking the input and output s...

Page 26: ...with 1 Use and Maintenance Manual complying with Machinery direc tive 98 37 CE 1 CE Declaration of conformity 1 Start Report 1 Maintenance Sheet 1 Electrical Diagram inside the control board Documents...

Page 27: ...design of the compressor allows for integrating a dryer with refrigerator cycle directly installed on the machine An electronic controller controls the dryer which manages its func tional parameters...

Page 28: ...re rises again above 0 C the dryer compressor is re started and the fault warning is automatically turned off Should the dew point temperature rise above the upper limit the controller will indicate t...

Page 29: ...rator 8 Oil filler plug 9 MAESTROXS 10 Oil filter 11 Oil level switch 12 Main motor 13 Fan 14 Minimum pressure valve 15 Oil return valve 16 Oil stop valve 17 Oil temperature feeler 18 Compressor tempe...

Page 30: ...3 11 Description of the Machine TI008G0001 Technical Data and Overall Dimensions 919...

Page 31: ...means Specific pictrograms indicate the lifting points The centre of gravity is near the coupling between motor and compressor before lift ing check lift the unit from the ground just slightly that l...

Page 32: ...n air cooled compressor driven by an electrical motor produces heat equal to about 85 the absorbed power For the AC 6000 Series machines having the cooling air outlet on the canopy top panel the di st...

Page 33: ...solator and magneto thermal switch should be chosen by keeping into account the start features of the electric motor Adapting the size of wires between the mains isolator and the compressor starter sh...

Page 34: ...aning of the radiator the intake filter and all other machine components The air drawn in by compressors contains in a variable quantity and depending on the ambient conditions a certain quantity of w...

Page 35: ...1 gives the load losses over 100 metres straight piping according to nominal diameters usually employed and at different air delivery and working pressure conditions A perfect air distribution system...

Page 36: ...d loss at approximately 20 Pa If the duct offers greater resistance an auxiliary extractor should be used to prevent any overheating of the machine As an example a duct with a higher or equal section...

Page 37: ...the chamber while limiting the value to its own setting limit The safety valve is set at 12 bar for L and H version of compressors and 15 bar for HH versions Operating pressure check For compressors o...

Page 38: ...management of the connection to other machines so as to control any multiple installations as efficien tly as possible Maestro xs is a control device made up of two separate units Display with keypad...

Page 39: ...TN graphic Backlighting Light blue LED s Resolution 132 x 64 pixel Keypad Material Silicon rubber Number of buttons 6 Backlit buttons Yes Power input Voltage From basic module via phone cable Operatin...

Page 40: ...mage further copies can be purchased from Mattei s sales organisation Checks before start Before starting the machine ensure that the electrical system complies with voltage and power of the machine a...

Page 41: ...compressor loads again and resumes air delivery The compressor can be stopped at any time by pressing the stop button the stop ping procedure comprises a no load run phase which lasts for a set time...

Page 42: ...range which is known as a MODULATION BAND This operating mode exploits this potential The control unit ignores the Pmax and Pmin settings and operates the compressor without stopping except in case of...

Page 43: ...r MAESTROxs features carious menus that allow the compressor to be monitored and programmed These are divided by function and not all of them can be accessed by the final customer Some of them are pro...

Page 44: ...nd specifically The event code The working time at which the failure occurred The detailed description of failure to the main compressor C1 The detailed description of failure to the additional compre...

Page 45: ...hen goes on load after a pre set time subsequent to the star delta switching delay The compressor from this moment on delivers compressed air according to the set operation mode After starting the pag...

Page 46: ...ber of consecutives starts This logic is cleared by the user s manual intervention if he she acts directly by turning off and on the machine manually WARNING An excessive number of consecutive starts...

Page 47: ...or grease with a cloth Sometimes an excess or a lack of lubricant may jeopardize the machine operation Only recommended lubricants or well known and tested equivalent lubricants should be used for lu...

Page 48: ...inside the start and control panel and inside the mo tor terminal board Grease the motor bearings Yearly or every 2 000 hours Replace the oil return valves Oil change Rotoroil 8000 F2 every 12 months...

Page 49: ...the outer element then the inner element by using the specific knob Clean with compressed air directing the air jet from the inside to the outside Reassemble in the reverse order To clean the air end...

Page 50: ...side panel and should be removed from its housing for replacement or cleaning purposes It filters the intake air and washes the compressor while preventing foreign particles from entering the machine...

Page 51: ...unscrew the filter Photo 4 Pos 4 from its seat Photo 4 Pos 6 wash the valve with detergent and blow with compressed air replace the sintered filter if it is fouled Always check the integrity of the O...

Page 52: ...ds after the last stop to enable the oil in the tubes to flow Proceed as follows unscrew the filter cartridge Photo 1 clean the seat wet the gasket of the new cartridge with oil and screw it Photo 2 6...

Page 53: ...cement 4 Detach the pressure exhaust solenoid valve and the feeding pipes of the oil stop valve the load setting valve and the vacuum relief valve Photo 3 5 Dismantle the small squares fixing the sepa...

Page 54: ...move the fixing screws except one that will act as the cover rotation pin 9 Rotate the cover as shown in Photo 3 while avoiding any damage to the o ring Photo 4 10 Unscrew the spark plugs Photo 5 and...

Page 55: ...re it should be replaced when the change interval has expired The oil should be replaced with the machine not operating and with warm oil To drain the oil wait until the compressor is no more pressu r...

Page 56: ...cheduled intervals If the machine has already operated for a long period with other lubricants and there are traces of sludge or deposits it is suggested to wash with Rotoroil 8000 F2 F4 for about 200...

Page 57: ...are compatible In case of doubts the lubricant used up to that moment should be completely eliminated by means of a washing procedure of the fluid circuit To avoid any risk of contamination the lubri...

Page 58: ...anges the names and specifications When the warranty period is over during which the use of Mattei Rotoroil lubricant is compulsory the user can decide to use the oil he believes most suitable or the...

Page 59: ...ase even though not suggesting its use any responsibility for the choice is up to the user and to the lubricant supplier WARNING It is difficult to determine life of an oil as there are different para...

Page 60: ...oil choice and to execution of all maintenance operations and specifically carry out regular and complete oil changes ascertain that the coolling system is always efficient with often checks to the oi...

Page 61: ...tching solenoid valves Contact the nearest authorized service center Check operation Please contact the nearest service cen ter Clean the specific filter to remove the cause of the block and then chec...

Page 62: ...ection 7 Replace the filters and verify the causes of clogging see section 7 Verify the setting and re set to the value foreseen for the machine see Section 7 Verify the environmental conditions and t...

Page 63: ...tee proper cooling Check that dirt does not form on this cover as it could reduce the cooling air passage Abnormal noises Any vibration or abnormal noise is usually due to deterioration of the bearing...

Page 64: ...n the machine has reached the end of its technical and operating life it can be demolished i e decommissioned and put in such a condition so as not to be used any longer for the purposes it was design...

Page 65: ...ilter Unscrew the connection and remove the drain solenoid valve Withdraw the solenoid valve filter using beak pli ers remove any dirt and wash with detergent Re assemble in the reverse order while pa...

Page 66: ...r machine Modell Serial Number Intervention to be carried out at Contact Person Telephone Failure Description Electrical Mechanical Notes Place Date Stamp and Signature Corso Italia 47 24049 VERDELLO...

Page 67: ...no of with required delivery on for our machine Model Serial Number Reference Description Quantity Notes Place Date Stamp and Signature Corso Italia 47 24049 VERDELLO ZINGONIA Bergamo Italy TEL 39 03...

Page 68: ...ring 1 O ring 16 Element 8 O ring 1 Prefilter C052042336 2 TI008G0001 Lubrificanti Mattei ROTOROIL 8000 COMPONENT CODE DESCRIPTION QUANTITAY Oil F2 BCL06FC002 Can 2 liters BCL06FC005 Can 5 liters BCL...

Page 69: ...KIT recupero calore 7 2350 x 1390 x 1980 mm 60 Oil carry over Residuo olio nell aria compressa 3 ppm l On load off load and stop Marcia a carico a vuoto e arresto controllo pressostatico pressureswitc...

Page 70: ...sostatico pressureswitch Oil system capacity Capacit circuito olio Nominal dew point Punto di rugiada nominale 3 Fan residual head 6 Prevalenza residua ventilatore 6 Outlet air temperature 5 Temperatu...

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