ENGLISH

Code
2200771697 00
Edition 11/2010

MANUAL USE AND MAINTENANCE

SILENCED SCREW ROTARY COMPRESSOR UNITS

HP 75 - 100 - 125 -75IVR-100IVR

kW 55 - 75 – 90-55IVR-75IVR

READ THIS MANUAL CAREFULLY BEFORE CARRYING OUT ANY OPERATIONS ON THE
COMPRESSOR UNIT.

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CONTENTS
PART A: INFORMATION FOR THE USER
1.0 GENERAL CHARACTERISTICS
2.0 INTENDED USE
3.0 OPERATION
4.0 GENERAL SAFETY STANDARDS
5.0 DESCRIPTION OF DANGER SIGNALS
6.0 DANGER ZONES
7.0 SAFETY DEVICES
8.0 POSITION OF PLATES
9.0 COMPRESSOR ROOM
10.0 TRANSPORT AND HANDLING
11.0 UNPACKING
12.0 INSTALLATION
13.0 DIMENSIONS AND TECHNICAL DATA
14.0 MACHINE ILLUSTRATION
15.0 ORDINARY MAINTENANCE TO BE DONE BY THE USER
16.0 PERIODS OF INACTIVITY
17.0 SCRAPPING THE UNIT
18.0 LIST OF SPARE PARTS FOR ROUTINE MAINTENANCE
19.0 TROUBLE-SHOOTING AND EMERGENCY REMEDIES

PART B: INFORMATION RESERVED FOR TECHNICALLY SKILLED PERSONNEL

20.0 STARTING UP
21.0 GENERAL ORDINARY MAINTENANCE REQUIRES TRAINED PERSONNEL
22.0 CHANGING THE OIL
23.0 REPLACE THE DE-OILER FILTER AND THE OIL FILTER
24.0 BELT TENSION
25.0 OLEOPNEUMATIC DIAGRAM
26.0 MULTICONTROL
- WIRING DIAGRAM (ON THE BACK COVER)

IMPORTANT: THERE IS A COPY OF THE WIRING DIAGRAM INSIDE THE ELECTRIC PANEL

SILENCED SCREW ROTARY COMPRESSOR UNITS

HP 75 - 100 - 125
kW 55 - 75 - 90

MACHINE AND MANUFACTURER IDENTIFICATION DATA

FIG. 1

1) Position of the identification plate

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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.

THE FAILED COMPLIANCE WITH THE INSTRUCTIONS CONTAINED IN THIS HANDBOOK DETERMINES THE
EXPIRATION OF THE WARRANTY TERMS.

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

The manufacturer does not accept responsibility for damage caused as a result of negligence of failure to abide by the
instructions given above.

THIS MACHINE IS NOT SUITABLE FOR EXTERNAL INSTALLATION

THIS MACHINE CORRESPOND TO THE ESSENTIAL SAFETY REQUIREMENTS FORESEEN FROM THE
EUROPEAN STANDARD (98/37 CE), AND THE RULE EN 292

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…)

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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.

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.

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5.0 DESCRIPTION OF DANGER SIGNALS

FIG. 2

1) DANGEROUS ELECTRIC VOLTAGE 5) HIGH PRESSURE

2) AIR NOT FIT FOR BREATHING 6) HOT PARTS

3) NOISE 7) MOVING PARTS

4) FAN ROTATING 8) FLUID EJECTION

9) MACHINE WITH AUTOMATIC START

5.1 DESCRIPTION OF COMPULSORY SIGNALS

10) READ THE USE AND MAINTENANCE

INSTRUCTIONS

6.0 DANGERS ZONES

FIG. 3

Risks present on the whole machine

(2)

(1) (8)

(1)

(4)
(1)
(7) (1)

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7.0 SAFETY DEVICES

1) Safety screws
2) Side guard and electric board door can be opened using a special key.
3) Fixed protection device - pulleys
4) Isolating switch (electrical equipment)
5) Oil filling cap (with safety breather)
6) Safety valve

FIG. 4

4
5

3
1

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 D09688 5) Dangerous electric voltage
2) Plate “Machine with automatic start” 6) Hazard Plate (atmospheric events)
3) Air not filt for breathing
4) Moving parts

FIG. 5

2
D51089
5

1 4
1
2
4

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8.2 POSITION OF THE DATA PLATE

1) Identification plate 5) Oil plate

2) Maintenance program 6) Draining condensate
3) Plate direction of rotation 7) Electric lead fixing plate
4) Air not filt for breathing

FIG. 6

Oil
plate

7
6 D51258
D04289 3
610109

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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 100 m3
The room must be provided with 2 openings for ventilation with a surface area of about 2 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 1 m2 and it must not be longer than 3 m.
For longer pipes an extra fan must be fitted .

9.3 EXAMPLES OF VENTILATION OF THE COMPRESSOR ROOM

FIG. 7

FAN AIR OUTPUT

HOT AIR EJECTION

HOT AIR PIPE

ATTENTION: REMOVABLE PIPE TO

ALLOW CLEANING OF THE
RADIATOR

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10.0 TRANSPORT AND HANDLING

ATTENTION: the machine must only be moved with the panels fitted (fig. 8)
The machine must be transported as shown in the following figures.

DURING THE PROCEDURES THERE MUST NOT BE ANY PERSON, ANIMAL AND/THING WITHIN THE
OPERATION AREA WHOSE SAFETY MAY BE ENDANGERED.

FIG. 8

RFC 5-7-10

CARDBOARD PROTECTION
AVOID DAMAGING THE
BODYWORK

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11.0 UNPACKING

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

ALL DAMAGE DUE TO FAILURE TO OBSERVE THE INDICATIONS GIVEN BELOW CANNOT BE ATTRIBUTED
TO THE MANUFACTURER AND MAY CAUSE THE GUARANTEE TERMS TO BECOME INVALID.

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).
 check the compressor is standing on a perfectly flat floor.

FIG. 10
1

SPACE FOR MAINTENANCE

MINIMUM mt 1,5

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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

MACHINE WITH AUTOMATIC START

 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. 3 Fig. 10 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

CABLES, PLUGS AND ALL OTHER TYPE OF ELECTRIC MATERIAL USED FOR THE CONNECTION MUST BE
SUITABLE FOR THE USE AND COMPLYING WITH THE REQUIREMENTS STATED BY THE REGULATIONS IN
FORCE.

12.3 CONNECTION TO THE COMPRESSED AIR NETWORK

Fit a manual interception valve Ref. 1 Fig. 10 between the machine and the compressed air network so that the
compressor may be isolated during maintenance operations.
Condensate must be drained from the oil receiver (manually) Ref. 2 Fig. 10, in conformity with the local regulations in
force.

PIPES, FITTINGS AND CONNECTIONS USED FOR THE CONNECTION OF THE COMPRESSOR TO THE
COMPRESSED AIR NETWORK MUST BE SUITABLE TO THE USE ACCORDING TO THE PRESCRIPTIONS OF
THE REGULATIONS IN FORCE IN THE COUNTRY OF USE.

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

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13.0 DIMENSIONS AND TECHNICAL DATA

(A)

Air connection (A)

HP 75 - 100 - 125
kW 55 - 75 - 90 Dimensions (mm)
L W H
1” 1/2 Gas 1100 1930 1765

HP75 (IVR) HP100 (IVR)

HP75 - kW55 HP100 – kW75 HP125 – kW90
kW55 (IVR) kW75 (IVR)
4280~10700

4141~10180

5644~14110

5552~13880

4744~11860

Standard air capacity

3540~8850
10700

10180

14110

13880

11860

10480

15400

14980

13020

11340

l/min.
8850

7150

Max. pressure bar 7 8 10 13 7 8 10 7 8 10 13 7 8 10 7 8 10 13

Noise product.dB(A) 71 71 74 74 75
Net weight Kg. 1410 1735 1540 1795 1660
Power HP / KW HP 75 / kW 55 HP 75 / kW 55 HP 100 / kW 75 HP 100 / kW 90 HP 125 / kW 90
Oil load l ~ 34 ~ 34 ~36 ~ 36 ~38

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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 collector
3 Oil filter 14 Pressure gauge tank
4 Air 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 ( inside the oil collector) 19 Screw compressor
9 Top-up or oil filling cap 20 Suction unit
10 Control panel 21 Electri fann
11 Oil gauge 22 Oil radiator

 IT IS FORBIDDEN TO TAMPERE WITH THE SETTING VALUES OF THE SAFETY VALVE

FIG. 11
4

22

13
3

11
7
12 14
20
1
19

10 16

15

17
21

2
18
6

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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 - It also operates as an emergency stop.

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

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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.

Symbol Description
Pressing the pushbutton cancels the stored alarm indication. Pressing the pushbutton for
(7) more than 3 seconds, the 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 15
(6) seconds before start up.

Pressing the pushbutton starts the compressor switch-off phase: The compressor runs
(5) loadless for a few seconds before stopping.

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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 - -
)
Oil overtemperature alarm in progress
(D (>95 °C) Machine stopped for oil overtemperature (> 100 °C)
) Fan magnetothermal alarm
(E) Machine lock out due to fan motor thermal trigger

Motor thermal relay alarm in progress Machine stopped for motor thermal relay cut-in

General alarm in progress for fault in

(F)
(G) pressure and temperature probes. -

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) (15 seconds) or in shut-down phase Compressor on
(30 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 card is preset to run idle before switching off for a period that is shorter the lower the consumption of air.
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

2
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.

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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 - 13 bar)
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 start-ups per hour (10)

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 or 13 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.

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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)

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

THE MAINTENANCE INTERVENTIONS ON THE COMPRESSOR CAN BE PERFORMED EXCLUSIVELY BY

QUALIFIED MECHANICAL MAINTENANCE TECHNICAL ENGINEERS AND/OR BY SPECIALISED TECNICAL
PERSONNEL AUTHORISED BY THE MANUFACTURER.

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15.3 DRAINING CONDENSATE FROM THE OIL COLLECTOR

If the compressor work cycle contemplates long pauses during which the machine cools down, a certain amount of
condensate will gather in the oil collector. 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 Fig. 14 to position "0" and block it with the padlock.
- Turn on the supply automatic differential switch Ref. 3 Fig. 14

FIG. 14

3
6

4
2

5
1

- Wait for the machine to cool down.

- Remove the side maintenance guard using the supplied key.
- SLOWLY turn on the tap Ref. 4 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. 5 Fig. 14

- If the oil level is under the minimum, top up as described at point 15.4

USE OIL OF THE SAME TYPE AS THAT ALREADY IN THE MACHINE; DO NOT MIX DIFFERENT TYPES OF OIL

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15.4 CHECK OIL LEVEL AND TOP UP

- Switch off the machine using the button Ref. 1 Fig. 14: the machine will stop after running loadless for a few seconds.
- Turn the isolating switch Ref. 2 Fig. 14 to position "0" and block it with the padlock.
- Turn on the supply automatic differential switch Ref. 3 Fig. 14
- Remove the side maintenance guard using the supplied key.
- Wait a few minutes for the foam in the oil collector to abate.
- Check the oil level on the indicator Ref. 5 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.

- Slowly open the oil plug Ref. 6 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. 6 Fig. 14.
- Close the side maintenance guard using the supplied key

15.5 CLEANING THE FILTERING PANEL

- Press the “STOP” button Ref. 1 Fig. 15
- Turn the isolating switch Ref. 2 Fig. 15 to position "0" and block it with the padlock.
- Turn on the supply automatic differential switch Ref. 3 Fig. 15.
- Remove the filters panels Ref. 4 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.

FIG. 15

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15.6 CLEANING THE SUCTION FILTER OR CHANGING THE FILTER

- Press the “STOP” button Ref. 1 Fig. 15a.

- Turn the isolating switch Ref. 2 Fig. 15a to position "0" and block it with the padlock.
- Turn on the supply automatic differential switch Ref. 3 Fig. 15a.

HOT PARTS INSIDE

- Remove the side maintenance guard using the supplied key.

- Remove the cover Ref. 4 Fig. 15a.
- Remove the filter Ref. 5 Fig. 15a.

6 FIG. 15a
5
3

2
4

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.
- Reclose the side maintenance guard using the supplied key.

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16.0 PERIODS OF INACTIVITY

If the machine has to remain inactive for a long period:

- Press the “STOP” button Ref. 1 Fig. 15a
- Turn the isolating switch Ref. 2 Fig. 15a to position "0" and block it with the padlock.
- Turn on the supply automatic differential switch Ref. 3 Fig. 15a.
- Turn off the tap Ref. 6 Fig. 15a.
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.

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 .

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.

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

HP75 HP100 HP125

kW55 kW75 kW90
Ref. DESCRIPTION Code Q.ty
8 10 13 8 10 13 8 10 13
bar bar bar bar bar bar bar bar bar
1 Filtering panel 2205 1372 00 2         
2 Filter separator 2205 4065 19 1         
3 Oil filter 6211 4722 50 2         
4 Air filter 6211 4745 50 1         

FIG. 16

3
1

4
2

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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 - reset the automatic switch that
the pilot lamp Ref. 1 (F) is flashes has tripped protects the fan
(see Fig. A)

3) The machine does not start 3A - the oil high temperature - environment temperature too high;
the pilot lamp Ref. 2 (D) is flashes thermostat has tripped improve ventilation in the
(see Fig. A) compressor room, Chapter 9.2
  - cooling radiator is dirty, clean the
radiator
- oil level too low; top up the oil tank

4) The machine does not start 4A - The fan motor thermal protection - Rearm the fan motor thermal
the pilot lamp Ref. 3 (E) is flashes has triggered protection.
(see Fig. A)

5) The compressor does not reach 5A - the compressed air consumption

working pressure is
too high
5B - the discharge electrovalve   - check the electric system
remains open, Ref. EV/SC wiring
diagram

6) Excess oil consumption 6A - deteriorated oil separating filter   - change the oil separating filter,
oil level is too high Chapter 23

FIG. A

1
3

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PART “B”

THIS PART “B” OF THE INSTRUCTIONS MANUAL IS RESERVED

FOR PROFESSIONALLY SKILLED PERSONNEL APPROVED THE
MANUFACTURER.

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20.0 STARTING UP

MACHINE WITH AUTOMATIC START

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. 1 Fig 17.
These parts are packed inside the bodywork.
20.2 PRELIMINARI CHECKS
- Check the oil level Ref. 2 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 6 months have passed between the inspection in the factory and the date of installation, consul
the manufacturer.

FIG. 17

1
1
1

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20.3 CHECK THE DIRECTION OF ROTATION

- Check that all fixed guards are in their correct position.

- Remove the side maintenance guard using the supplied key (Ref. 1 Fig. 17a).
- Connect the control board to the power supply with the automatic circuit-breaker switch of the line Ref. 2 Fig. 17a and
the master switch of the machine Ref. 3 Fig. 17a.
- Start up the compressor pushing in sequence I button Fig. 17a and immediately after about 1 second the 0
button Fig. 17a to stop if.
- Check the motor rotation direction is the same as the arrow marked on the compressor.

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

- If the rotation direction is not correct, turn off the power and invert the two connections at point Ref. 2 Fig. 17a

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
Powered or of the scheduled stop.
FIG. 17a

Rotation direction

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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. 1 Fig. 18.
- Fill the oil tank to the MAX level, Ref. 2 Fig. 18.
- Start the compressor.
- After about 1 minute switch off the machine by pressing “STOP” (Ref. 3 Fig. 18) after a few seconds of idle running
the machine will switch off.
PROCEED AS DESCRIBED AT POINT CHAPTER 15.4

FIG. 18

3
2

THE OLD OIL MUST BE DISPOSED OF IN COMPLIANCE WITH THE REGULATIONS IN FORCE.
DO NOT TOP UP WITH DIFFERENT OILS

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.

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23.0 CHANGING THE OIL SEPARATING 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.

- Press the “STOP” button Ref. 1 Fig. 19

- Turn the isolating switch Ref. 2 Fig. 19 to position "0" and block it with the padlock.
- Turn on the supply automatic differential switch Ref. 3 Fig. 19.
- Check there is no pressure inside the machine: check the pressure gauge Ref. 4 Fig. 19.
- Let off the internal pressure through the minimum valve Ref. 5 Fig. 19 and the manual valve Ref. 6 Fig.19.
Proceed as follows:
- Unecrew the oil recovery pipe Ref. 8
- Take off the cover Ref. 7 fig. 19
- Change the oil-separating filter.

FIG. 19

6
1

5
7

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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:
- Press the “STOP” button Ref. 1 Fig. 20.
- Turn the isolating switch Ref. 2 Fig. 20 to position "0" and block it with the padlock.
- Turn on the supply automatic differential switch Ref. 3 Fig. 20.
- Remove the fixed protection device Ref. 4 Fig. 20.
- Slacken the screws by half a turn Ref. 5 Fig. 20
- Loosen the locknut Ref. 6 Fig. 20
- Adjust the belt tension by turning the nut Ref. 7 Fig. 20.
- Lock the locknut again Ref. 6 Fig. 20
- Close the screws again Ref. 5 Fig. 20
- Refit the fixed protection device with its safety screws Ref. 4 Fig. 20.

FIG. 20
3

F f

6 2

1
4
7
5 5

HP 75 - 100 - 125 / kW 55 - 75 - 90
F = 3 Kg. Force to be applied at the centre line, at right angles to the new belt.

f = 7,5 mm Clearance after the application of F.

24.1 TIGHTENING TORQUE (Fig. 21) TYPE

Tightening torque
Type bush Key
N.m
2012 31 5
2517 48 6
3020 90 8
FIG. 21
3535 112 10

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25.0 OLEOPNEUMATIC DIAGRAM

AIR CIRCUIT

OIL CIRCUIT

CONTROL CIRCUIT

1 SUCTION FILTER 10 MINIMUM PRESSURE VALVE

2 SUCTION REGULATOR 11 AIR-OIL SEPARATOR
3 SCREW COMPRESSOR 12 PRESSURE GAUGE
4 OIL DISCHARGE VALVE 13 SAFETY VALVE
5 AIR-OIL PRESEPARATOR 14 TEMPERATURE SENSOR
6 OIL FILTER 15 ELECTRIC MOTOR
7 THERMOSTATIC VALVE 16 NO-LOAD RUNNING SOLENOID VALVE
8 AIR-OIL COOLER 17 OIL LEVEL
9 PRESSURE TRANSDUCER 18 BLED VALVE

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26.0 MULTICONTROL

1) Push button ON-OFF operation mode

2) Push button MODULANTE operation mode
3) Push button AUTOMATICO operation mode
4) Display

Push button F4 – the compressor operates in the ON/OFF mode (all-nothing)

Push button F5 – the compressor operates in the MODULATING mode
Push button F6 – the compressor operates in the AUTOMATIC mode: it will work in the ON-OFF mode for low
consumption up to about 66% of its maximum capacity and will work in the MODULATING mode when consumption is
greater (from 66% to 100% of the capacity).
The compressor calibration is factory-set to operate in this mode; every 5 minutes the "MULTICONTROL" system will
check the consumption of air and will decide to operate in the "ON-OFF" mode or in the "MODULATING" mode.

NOTE ON THE OPERATING MODES

ON-OFF: this is the traditional way of operation: it is suitable for all applications and the in-line pressure will be
oscillating, between the rated pressure and minimal pressure (1 bar).
MODULATING: this type of operation is ideal when the compressor is running at raised output: this way, constant
pressure is guaranteed even when the air intake changes.
AUTOMATIC: ideal for variable intake: the compressor automatically chooses the most suitable operating mode from
the two available.

FIG. 22

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3/__V/,50Hz/60Hz

L1 L2 L3 PE 1 2 3 4 9 17 20 23 42 43 45 46 53 56 57 60 1U 1V 1W 2U 2V 2W 3 11 29 30 31 32 PE

Q
FU1
T
12V 50 FU3 46
Technical Requirements
L12 L22 L32 1
59 1 46
0V 45
2 2 45 Power cable with 50mm2 of copper wire ,
FU2 3
52 3 44
KM3 58 2
24V
4
4 43
43 and other cable with 1.5mm copper wire
L13 L23 L33 FU4 5 42
0V 42
6 41
53 7 40
SB1
1 8 39
42 FR1 9
2 9 38
43 + 37
3 56 10 37
KM1 Simulation Remote 11 36 BP
Input 4 11
ES3000 36
5 12 -
L14 L24 L34 35
12 TYPE Quantity
U1 6 SB1 13 34 34 ID Description Remarks
V1 7 19 33 R
FU5 FU6 FU7 14 33 FU5-7 Fuse 3
W1 8 KM3 15 32 32 Run
31 SB1 Emergency stop button ZB2-BS54C + ZB2-104C 1
L15 L25 L35 PE 9 16 31 Stop
KM2 17 17 30 30 Common T Transformer 1
FR1 45
U2 10 18 29 29 Fault Fuse 6A 1
46 FU4
V2 IVR 11 19 28
28
W2 YV1 57 20 20 27 FU3 Fuse 1A 1
12 27
1U 1V 1W PE 13 SB1 26 FU1-2 Fuse 2A 2
26
Digital
14 25 A1 Controller ES3000 1
M2 Input
15 24
3 23 YV1 AC solenoid valves AC24V 1
16 23
BP Pressure sensor 0~18bar 1 4-20mA
17 22
60
18 R Temperature Sensor NTC 100K -20/+120℃ 1
U1 V1 W1 21
FR2 Thermal relay 1
19
KM3 Power relay 1
20
21 IVR Inverter 1
KM1
KM1~2 Power relay 1
M1 4
3 19 Q Breaker 1
3
20
M2 Fan motor 1
21
M1 Main motor 1

19
20
21
CSD IVR
Electrical diagram

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NOTE

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