Fini ROTAR PLUS 20, ROTAR PLUS 25 User Manual

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Page 1

GENERAL INFORMATION

TABLE OF CONTENTS

Safety indications .............................................................................. 2

Installation ......................................................................................... 4

Specifications .................................................................................... 5

Settings and controls ........................................................................ 6

Control functions ............................................................................... 8

Operation .......................................................................................... 9

Start-up  ......................................................................................... 9

Maintenance ................................................................................... 10

Trouble-shooting ............................................................................. 13

Wiring diagram ................................................................................ 14

OUTFIT

Check outfit carefully. Later claims for missing parts will not be accepted. The following accessories are supplied with the compressor: no. 1 line cock no. 1 Teflon tape no. 1 delivery tube no. 4 anti-vibration elements no. 1 door key no. 1 users guide

CONDITION OF THE MACHINE WHEN SUPPLIED

Every compressor is shop tested and delivered ready to be installed and to be set at work. The oil used is SHELL CORENA D.

WARRANTY

The Manufacturer guarantees their products for manufacturing or material defects for 12 months from their delivery

date.

NOTE: Warranty terms are extended as follows only to piston pumping units:

- 18 months for models belonging to PROFESSIONAL line,

- 24 months for models belonging to HEAVY DUTY line,

- Machines belonging to ROTAR line are guaranteed for 3,000 operating hours (as shown by the hour counter) but limited to 12 months maximum from their delivery date. The above warranty period is extended to 24 months with no hour limit to the screw pumping unit and the electronic controller.

d) Electric part and parts subject to wear are not covered by this warranty. e) Any repairs and/or servicing under warranty can be carried out only by Authorized Service Centers and the

Manufacturers.

f) Products can be delivered to the Manufacturer for servicing purposes only after prior authorization by the very Manufacturer. The Manufacturer shall decide at their discretion whether authorization can be granted or require an Authorized Service Center to take on servicing.

In any case, products shall be delivered free of any charge and will be returned to the Customer on ex-factory basis.

g) This warranty covers free-of-charge repairs or replacement of those machine parts, which have been acknowledged as faulty by our authorized technicians.

h) This Warranty becomes null and void in case of accidental damages due to negligence, incorrect or improper use and installation or in case of use and installation, which do not comply with the instructions given in the Instruction Manual as well as in case of changes or repairs carried out by non-authorized personnel. All defective parts, which are replaced under warranty, are collected by the Authorized Service Center.

i) This warranty does not cover any repairs or compensation for transport damages (to or from the Authorized Service Center).

k) Any compensations for damages caused to objects or injuries caused to people due to improper use of the purchased compressor are excluded from this warranty.

l) Machines under warranty can be serviced against purchase documents bearing the purchasing date only if the Purchaser has met all contract and payment requirements.

m) This Warranty is the only one which is acknowledged by the Manufacturer. The issue of any other verbal or written warranty is not allowed. Also, no changes to the terms of this Warranty are allowed,

Any dispute shall be settled by the Court of Bologna.

Rotar Plus 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004

Page 2

SAFETY INDICATIONS

GENERAL

 Rotary compressors are intended for heavy continuous industrial use. They are especially suitable for industrial applications

requiring high air consumption for a long time.

 The compressor should be run and operated only in compliance with the indications given in this manual. Safely keep this

manual in a known and easily reachable place for the whole working life of the compressor.

 A supervisor shall be appointed in the company, in which the compressor is installed. He/she shall be responsible for compressor inspections, adjustments and maintenance. Should a substitute be appointed for the supervisor, he/she shall carefully read the users guide and all possible comment on service and maintenance carried out so far.

SYMBOLS USED IN THE MANUAL

Some symbols are used to highlight danger situations, give recommendations or information. These symbols are usually positioned next to the text, a figure or at the top of a page (in this case they refer to all subjects dealt with in that page).

Carefully read symbol meaning below.

CAUTION!

Important description on service, dangerous situation, safety, accident prevention recommendations and/or very important information.

STOP MACHINE!

All operations to be strictly carried out only after stopping the machine.

POWER OFF!

All operations to be strictly carried out only after

powering off the machine.

SPECIALIZED PERSONNEL!

All operations to be strictly carried out only by

specialized technician.

SYMBOLS ON THE COMPRESSOR

The compressor has several labels to highlight possible danger and give recommendations on what to do during machine

operation or in special situations.

Please comply with these indications.

Danger! Hot!

Danger! Electric shock!

Prohibited! Do not open doors during

compressor operation

Prohibited! Press emergency button for compressor immediate stop. Do not use line knife switch.

Danger! Hot gas or harmful gas within working

area

Danger! Pressurized container

Danger! Mechanical moving parts

Caution! Maintenance works in progress

Rotar Plus 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004

Prohibited! Do not use water on electric equipment to extinguish fire.

Compulsory! Read instructions for use carefully.

Page 3

SAFETY INDICATIONS

WHAT TO DO:

Make sure that mains voltage corresponds to the voltage indicated on CE plate and that cable of suitable cross-section are

used for electric connections.

Always check oil level before starting the compressor. Be familiar with emergency stop control and all other controls. Empty the air tank and/or oil separator and unplug the connector before any maintenance work, so to avoid accidental start. Ensure that all parts have been correctly reassembled after any maintenance work. Keep children and animals off the working area to avoid injuries caused by devices connected to the compressor. Carefully read instructions for the installed accessory, especially if painting devices are installed. Ensure that the installation place is properly ventilated. Ensure that temperature of the working environment ranges between +5 and + 45 ºC. The compressor should be installed and operated in a non-explosive environment. Allow at least 50 cm between the compressor and the wall so to allow free air flow to the fan. Press the emergency button on the control panel only in case of actual need so as to avoid possible damages to people or the

very compressor.

When calling for technical assistance and/or advice, always mention model and serial number indicated on CE plate. Always follow the maintenance schedule specified in the users guide.

WHAT NOT TO DO:

Do not touch inner parts and pipes as they are very hot during compressor operation and stay hot for a certain time after

compressor stop.

Do not position inflammable or nylon objects or cloths close to and onto the compressor. Do not move the compressor when the tank is under pressure. Do not operate the compressor if the power cable is damaged or defective or if connection is unstable. Do not operate the compressor in explosive environment or in case of naked flames. Do not operate the compressor in wet or dusty environments. Never aim the air jet at people or animals. Do not allow unauthorized people to operate the compressor and give them all required instructions. Do not hit fans with blunt objects as they might break during compressor operation. Never operate the compressor without air filter. Do not tamper with safety and adjusting devices. Never operate the compressor when doors/panels are open or removed.

PRODUCT IDENTIFICATION

The compressor Your have purchased has its own CE plate showing the following data:

1) Manufacturers data

2) CE mark  year of manufacture

3) TYPE = name of the compressor CODE = compressor code SERIAL NO. = serial number of the compressor You have purchased (to be always mentioned when calling for technical

assistance)

4) air delivered by the compressor expressed in (l/min) and (cfm)

5) max. operating pressure (bar and PSI)  compressor noise level in dB(A)

6) electric data: voltage (V/ph), frequency (Hz), absorption (A) - power (HP and kW), rotations per minute (Rpm).

7) other approvals

Rotar Plus 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004

Page 4

350 cm (min)

COMPRESSOR DESCRIPTION (fig.1)

Compressor main components are:

1) Air-oil radiator

2) Electric equipment

3) Instrument board

4) Oil separator tank

5) Oil separator filter

6) Minimum pressure valve

7) Electric motor

8) Screw compressor

9) Suction regulator

10) Air filter

11) Oil filter

INSTALLATION

UNPACKING AND HANDLING

The compressor is usually shipped to the customer with a carton cover. Wear protective gloves and cut outer straps. Remove then package by lifting it from the top. Before removing the compressor, make sure it is intact (outside), open access doors (if fitted) and visually check components for damage. Check that all accessories are included.

Lift machine with a transpallet or fork lift truck and transport the machine with the utmost care to the place of installation.

You are advised to keep the packing material for the event you need to re-locate the compressor. Keep package at least for the duration of the warranty period, so the compressor can be safely shipped to a service centre, if needed.

When no longer needed, deliver packing material to the special collection centres for disposal.

PLACEMENT AND INSTALLATION (fig.2)

Upon installation, make sure that the chosen place is in compliance with all prevailing national safety standards and meets the following requirements:

low percentage of dust suspended in air,

 shop must be suitably sized and well ventilated so that room temperature never exceeds 40°C when the compressor is working. If this is not the case, install one or more exhaust fans to extract hot air. Ideally, the fans should be installed close to the ceiling.

Exhaust fan 2000 m3 /h code 020041000

Exhaust fan 4000 m3 /h code 020042000

Dimensions are just approximate. Try nevertheless to respect them as much as possible.

A drainage pit or at least a canister shall be used to collect tank condensate (see chapt. Maintenance).

80 cm (min)

90 cm (min)

POWER CONNECTION (fig.3)

 Proceed to power connection with cross-section cables suitable for machine power: 3 phase cables and 1 ground cable.

 Have a switch (A) provided with plug fuses installed between supply line and control panel, close to machine cable connections.

 Switch (A) should be installed within the operators reach.

Cables shall be homologated and with a min. protection degree equal to IP44.

NOTE: To choose cables cross-section, refer to Table page 5.

0 I

300 cm (min)

Rotar Plus 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004

Page 5

SPECIFICATIONS

7HFKQLFDOIHDWXUHV

Pressure Compressor type Compressor rotation speed RPM Air volume supplied l/min Oil quan t it y l Oil quantity for t o pping-up l Max. final over temperat ure °C Remove d heat kJ / h Fan flow rate m³ / h Oil r esidues in the air mg / m³ Electric motor (bipolar) Motor power kW M ax. power absorbed kW Voltage V/Hz Auxiliary voltage V/Hz Electrical box protection class IP Motor insulation c lass Full l oad c urrent A Star t ing load A Max. Start-up per hour n° Ambient limit temperatu r e °C Noise lev el at 1 m (Cagi pneu r op) dB ( A)

EDU      

+3 +3

FS 50 TM FS 50 TM 4830 4330 3460 5640 5200 4120 2350 2050 1750 2700 2450 2050

777777

0,5 0,5 0,5 0,5 0,5 0,5

5561087

51300 51300 51300 63270 63270 63270

3100 3100 3100 2931 2931 2931

444444

132 MD/2 B3 B5

15 15 15 18,5 18,5 18,5

18,4 18,4 18,4 21,5 21,5 21,5

400 / 50 400/50

230-24 / 50-60 230-24/50-60

54 54 54 54 54 54

FFFFFF 31 31 31 36 36 36 70 75 73 98 104 107 10 10 10 10 10 10 50 50 50 50 50 50 70 70 70 71 71 70

160 L/2 B3 B5

3URWHFWLRQGHYLFHV

M ax compressor temperature °C Min. oil t emperature °C Thermal mot or cut- out A Safety v alve setting bar St a r t-up pressure switc h set ting bar

'LPH QVLRQVDQGZHLJKW

Dimensions mm Weight Kg A ir cock f it t ing Rp

3RZHUFRQQHFWLRQ

Power kW Cable section (max . lenght 3 mt. ) mm² A bsorbed current A Relay sett ing A Switch A

110 110 110 110 110 110

-7 -7 -7 -7 -7 -7

19,8 19,8 19,8 23 23 23

14 14 14 14 14 14

1,5 1,5 1,5 1,5 1,5 1,5

1030×680×1030 1030×680×1030

300 360 3/4" 3/4"

15 15 15 18,5 18,5 18,5

666666 31 31 31 36 36 36

19,8 19,8 19,8 23 23 23

50 50 50 63 63 63

Rotar Plus 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004

Page 6

SETTINGS AND CONTROLS

123

45 6 7 8 9

CONTROL PANEL (FIG. 4)

 All compressor power-on-and-off procedures are controlled by the machine power unit. Furthermore, it signals possible

machine problems and gives information on the operation times and servicing times.

1) Display on which information is displayed.

2) OK key: press confirm (see Modifiable Parameters)

3) Direction keys: to scroll the options of the menu

4) Alarm light: if the light turns on and compressor possibly stops, it means that maintenance service is needed or a failure in

the system has occurred. Refer to Alarm messages to identify proper service.

5) Reset key: to stop the alarm (see Alarm Messages)

6) ON/I key: to power the machine on.

The machine power-on cycle is divided into three phases.  wait for power-on the (STAND_BY) message is displayed. If compressor was switched off, 15 seconds are required before

the cycle is started; otherwise compressor remains on stand-by until pressure transducer requires air.

 Starting: compressor power-on in the star mode: the (LOADLESS)message is displayed  Working cycle: shift from star mode to delta mode after five seconds. After two seconds, if required by transducer, the load solenoid valve is excited and (LOAD) message is displayed. Note: This cycle is for compressors with a remote starter. Direct start compressors start immediately after (STAND-BY) phase.

7) OFF/0 key: to power the machine off. Load solenoid valve is disabled, loadless cycle starts, blinking (LOADLESS) message is displayed, once loadless cycle is over

compressor stops and off message is displayed.

8) Emergency stop switch: to stop compressor

9) Functioning diagram/ maintenance operations

only in case of actual need.

WORKING TIMES

Automatic mode

 The compressor operation is controlled by the pressure transducer, which stops the machine when the max. pressure

value is reached and starts it again after the pressure has decreased to the min. set value.

However, the machine stop is of the delayed type, that is it does not occur exactly at the same time when the max. pressure

value is reached but after a certain time, during which no air is taken (see no. 7 of above paragraph).

 Standard setting is 20 seconds, but it is recommended to check that number of start-ups per hour does NOT exceed max number of 10. Should it be a higher value, it is recommended to set longer loadless operation time (see no. 7, Modifiable parameters).

PRESSURE REGULATOR

The User should install a pressure regulator downstream of the compressor to set the power line according to his/her needs.

REMOTE ON/OFF

 The compressor can also be switched on or off using the remote control optional software (remote control will be active only if the control unit at the machine is set to ON).

 This function can also be managed through the remote terminal on the terminal box. In such case, manual controls will be excluded. If the compressor starts up unexpectedly, persons happening to be nearby could be harmed or injured. With this in mind, THIS USE IS GENERALLY NOT RECOMMENDED. The manufacturer will not be liable for any damages.

Any change must be carried out by a qualified technician.

Rotar Plus 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004

Page 7

SETTINGS AND CONTROLS

MODIFIABLE PARAMETERS

Pressing the key with the machine OFF, the operating parameters menu will be displayed; in certain cases a password

is required in order to make changes. The menu is scrolled using the keys and .

0) control unit ID (service password): selects the identification code of the control unit; if several compressors are connected

to the same RS485 line, multiple IDs can be selected.

1) Pre-alarm time lapse (service password): each hour of operation clocked by the machine is counted down automatically;

when the count reaches 0, the control unit trips a Maintenance alarm.

The count, preceded by a minus sign (-), indicates how many hours have elapsed since the last maintenance alarm; the keys

and can be used to set a new value (entering the new value has the effect of overriding the previous alarm).

2) Alarm history (no password required): this menu can be used to display the 30 most recent alarms.

3) Pre-alarm temperature (factory password): this menu is used to set the delta temperature (delta, in °C) referred to the

maximum alarm temperature; the value can be set between 1 and 20.

Example: if the maximum temperature is 120 °C and the differential is 10 °C, the maximum temperature pre-alarm will trip at 110 °C.

4) Maximum temperature (factory password): this menu is used to set the maximum permissible temperature; the adjustment

range is 0 to 150 °C.

5) Minimum temperature (factory password): this menu is used to set the minimum temperature; the adjustment range is 0 to -14 °C.

7) Duration of loadless operation (service password): this menu is used to change the duration of the no-load cycle; the range

of adjustment is 1 to 250 seconds.

8) Auto start (service password): this parameter enables automatic Start; if activated, the compressor will restart automatically

following an electrical power supply failure.

If the compressor starts up unexpectedly, persons happening to be nearby could be harmed or injured. With this in mind, use

of the automatic start function is not generally recommended.

9) Internal phase sequence (service password): this parameter enables control of the phase sequence internally, or disables

internal control and activates the phase sequence control input at the terminals.

10) Language (no password required): this parameter is used to select the language in which messages are displayed; there

are 5 available (English, French, German, Italian, Spanish).

11) Enable RS485 (no password required): this parameter is used to enable data transmission using RS485, and automatically

disable transmission on RS232.

12) Pressure sensor (service password): enables the 4-20 mA input to which the pressure sensor is connected. With this parameter activated, the pressure measurement is displayed. To display machine operation time, press the key; the display will revert to the pressure measurement automatically after 20 seconds.

Enabling this parameter, the external pressure switch contact changes function and becomes an input for the oil separator

minimum pressure switch; in this situation, the compressor is prevented from restarting if pressure in the oil separator is high.

13) PSI/BAR (no password required): selects the unit of measure used to display pressure.

14) No-Load/operating pressure set point (no password required): this parameter is used to set the pressure at which the

compressor must switch off; if inverter drive is enabled, it indicates the operating pressure at which the inverter will begin modulating output to maintain the pressure steady.

15) Load/operating Delta set point (no password required): indicates the pressure at which the control unit enables compressor restart.

For example, if the set differential value is 1 bar and maximum operating pressure is 9 bar, this means that the compressor will

switch off at 9.5 bar and switch on again at 8.5 bar.

16) Maximum pressure (service password): this parameter sets the maximum pressure value permissible in operation, i.e. the maximum pressure of point 14.

17) Maximum alarm pressure (factory password): this parameter sets the maximum pressure value at which an alarm is tripped in the control unit.

18) Remote pressure(service password): enabling this parameter, the pressure and the relative alarms continue to be displayed, but the compressor starting sequence is controlled from an external pressure switch contact.

19) Load delay(factory password): this parameter sets the delay, in seconds, from the moment when the starting cycle terminates to the moment when the air solenoid valve energizes.

ALWAYS HIT KEYS

MODIFIABLE PARAMETERS

Oil temperature pre-alarm (differential)

Maximum oil temperature

Minimum oil temperature

No-load (EMPTY) time

Maintenance pre-alarm

Automatic start

Pressure sensor

PSI/BAR

°C

sec.

Hours

Min.

-14

YES

PSI

AND PRESS TO CONFIRM ENTRY

Max.

Standard

150

250

32768

BAR

110

-7

3000

YES

BAR

No-Load/operating pressure set point

Load/pressure differential set point

Maximum permissible pressure

Maximun alarm pressure

Load (CHARGED) delay

Internal phase sequence control

Language

Display contrast level

Enable RS485

Rotar Plus 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004

bar

sec.

Min.

YES

Max.

200

Standard

8,5

YES

ITA

Page 8

CONTROL FUNCTIONS

ALARM MESSAGES

In the event of a fault occurring or of set safety limits being exceeded, the red alarm light will appear and the current alarm

condition is displayed.

1) Check direction of rotation

Alarm trips in the event of incorrect phase sequence being detected. The compressor locks

up; to restore operation, the correct phase sequence must first be re-established.

NOTE: To reset the alarm, the equipment must be isolated from the a.c. power supply.

2) Check temperature sensor

Alarm trips in the event of temperature sensor fault (sensor open or short circuiting). The

compressor locks up; to restore operation, check the connection and/or replace the sensor,

then press

3) Maximum oil temperature

Alarm trips when the maximum oil temperature is sensed. The compressor locks up; to

restore operation, wait for the temperature to fall below the programmed value, then press

4) Minimum oil temperature

Alarm trips when the minimum oil temperature is sensed. The compressor locks up; to restore

operation, wait for the temperature to rise above the programmed value, then press

5) Oil temperature pre-alarm

Trips when the pre-alarm oil temperature is sensed. The compressor does not lock up. To

override the pre-alarm, press

6) Motor thermal overload

Operates when the thermal overload relay is tripped. The compressor locks up. To silence

the alarm, first verify the cause, then press

7) Emergency

A circuit activates to lock up the compressor when the red emergency button is depressed.

To silence the alarm, first reset the emergency button, then press

8) Machine maintenance pre-alarm

Trips to warn the user than that machine is due for routine maintenance (oil change, service filters, etc.). The alarm must be silenced by the service technician, who when carrying out maintenance operations will select the item Pre-alarm hours from the menu and reset the value as described under the heading Modifiable parameters - point (1).

9) Separator pressure switch

Alarm trips in the event of the separator pressure switch contact opening. The compressor

locks up. To silence the alarm, first reset the separator pressure switch, then press

10) 4-20 mA fault (pressure sensor)

Alarm trips when the pressure sensor connected to the 4-20mA input does not operate correctly. The compressor locks up. To silence the alarm, first restore the pressure switch to

normal status, then press

11) Maximum pressure

Alarm trips when the maximum pressure setting is exceeded. The compressor locks up. To

silence the alarm, first restore the correct pressure, then press

Display status

30°C h00110 m05

Wrong rotation

30°C h00110 m05

Temp sensor faulty

110°C h00110 m05

Max oil temp

-10°C h00110 m05 Min oil temp

105°C h00110 m05

Oil temp pre-alarm

74°C h00110 m05

Motor thermal relay

74°C h00110 m05

Emergency button

74°C h00110 m05

Routine maintenance

75°C h00110 m05

Separator p/switch

74°C h00110 m05

4-20mA fault

74°C h00110 m05

Max pressure

SAFETY DEVICES (FIG. 5)

1) Electronic transducer: controls both STOP and START

pressure.

2) Pressure switch for oil separator filter clogging:

indicates efficiency limit of oil separator filter.

3) Minimum pressure switch:

4) Pressure switch for air filter clogging: indicates air filter

efficiency limit

5) Safety valve: opens the air bleeding unit when the

safety value is reached.

6) Max. temperature sensor: stops motor over +110°C.

Rotar Plus 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004

1 2 3 4

Page 9

OPERATION

OPERATING CYCLE

 At first start-up, the motor starts in the star configuration. In this phase the compressor starts slowly, the solenoid valve (1) is open and the suction regulator (2) is closed.

 The compressor remains in this condition for about 5÷7 seconds

 After this time, the motor is powered by the delta configured circuit. The solenoid valve (1) receives current and closes allowing the opening of the suction regulator (2), which intakes atmospheric air through the filter (3).

 At this stage, the compressor runs at full speed and begins to compress the air in the tank (6).

 The compressed air cannot come out from the minimum pressure valve set at 3÷4 bar.

 The compressed air compresses the oil in the tank (6) and forces it to flow towards the tube (7).

 If the oil temperature is below 71°C the oil from the tube (7) flows directly to the compressor (4) through the tube (8) passing through the filter (9).

 If the oil temperature exceeds 71°C the thermal expansion valve shuts down the ducting to tube (8) and oil flows to the radiator (11) through the tube (10). Once cooled, oil flows back to the compressor through tubes (12) and (8) and filter (9).

 The oil reaches the compressor (4) mixing with the intake air and creating an air/oil mixture which ensures the seal and the lubrication of the moving parts of the compressor.

 The air/oil mixture returns to the tank (6) where the air is pre-separated through spinning and is finally separated from the oil by the oil separator filter (13).

 From the tank (6) only air comes out, which reaches the radiator (11) through the tube (15) and the mains through the cutoff cock (16).

START-UP

FIRST START-UP

Before starting the machine up for the first time, make sure that:

 the mains voltage is the same as the voltage on the CE plate;

 the electric connections have been made using cables of proper cross-section;

 the (wall) main power switch has suitable fuses;

 the oil level is over the minimum level - top up with the same type of oil if necessary (Shell Corena D46);

 the air outlet cock is completely open.

CONNECT THE TANK WITH A HOSE.

 Only specialized technicians can start the compressor (on-site testing) for the first time.

If the machine does not start and the display shows the alarm message Wrong direction of rotation, proceed as follows:

break power supply through the wall switch;

open the electric box door and reverse the two phases in the terminal board;

close the door, power on and start the machine.

Display status during compressor operation

Display status at start (shown for 5 seconds) Display status during normal operation

software release

Easy Tronic II

V.0.0.0 GG/MM/AA

date

oil temp.

100°C 9.5Bar

Status=stand-by

pressure

Press the key to see hours and minutes operation; the information is displayed for 20 seconds.

Rotar Plus 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004

compressor status

Page 10

MAINTENANCE

BEFORE MAINTAINING THE MACHINE ALWAYS PERFORM THE FOLLOWING

 Switch off the motor by means of the switch on the control panel.  Power the machine off by means of the wall outer switch (do not press the emergency stop button).  Close the line cock.  Make sure that no compressed air is inside the oil separator tank by turning the cock anticlockwise and bleed all air off.  Before removing any protections, double check that wall-mounted switch has been turned to 0.

AFTER THE FIRST 100 HOURS

1) Check the oil level (see next paragraph): top up with the same type of oil if

necessary.

2) Check for proper screw tightening: in particular the power electric connection

screws.

3) Visually check that all fittings seal properly.

4) Check room temperature

EVERY 500 HOURS

Check the oil level (fig.7)

Always blow off air from the oil separator tank before topping up. Slowly unscrew

the cock A until all air comes out and then screw it again.

The max. level is reached when the oil touches the filler. Check level at oil light (B). The amount of oil necessary for topping up from the minimum level to the

maximum level is about 1.5 lt.

EVERY 1000 HOURS

Clean the air filter thoroughly (fig.8). Blow filter with compressed air from

inside out.

Hold the filter against the light and look for any tears. Always replace a torn filter. Install filter cartridge and cover accurately. If badly positioned, they would let dust into the compression unit.

Replace the air filter when you have cleaned it four times.

Clean the radiators

The radiator is highly efficient with a limited clogging degree. However, in case

of abnormal overheating or at least once a year, a check for filter clogging is recommended.

To clean the radiators, proceed as follows:  remove the rear and upper panels of the pressurized chamber;  position a protection plastic sheet under the radiator unit;  spray (spray gun + solvent) from the outside towards the inside;  check for proper air flow through the radiators.

AFTER THE FIRST 1000 HOURS, EVERY 3000 HOURS AFTERWARDS

Change oil (fig.7)

Change oil every 3000 working hours when compressor is hot  over 70 °C.

Drain pressure from the oil separator tank through cock (A).

 Connect the supplied hose to cock (C).

 Unscrew filler cap, open ball cock (C) and drain all oil into a container. When finished, close the cock and remove the hose.

 Fill fresh oil through filler plug (D) (a full charge is 6 liters).

 Close the plug.

 Power on machine.

 Start machine and let is run for 5 minutes, then stop it.

 Drain all air.

 Allow 3 minutes and check oil level. Top up if needed.

When you change oil, you can change to a different type of lubricant (see table).

SHELL CORENA D AGIP DICREA 46 IP VERETUM OIL 46 BP ENERGOL HLP 46 MOBIL D.T.E. MEDIUM CASTROL AIRCOL MR46 ESSO UNIVIS 46 FINA EOLAN R046

Remember to use the same oil for future top-ups - Never mix different types of oil

Change oil filter (fig.9)

Change oil filter EVERY TIME YOU CHANGE OIL; depressurize tank before proceeding.

Always smear filter edge and filter seal lightly with oil before screwing filter into place by hand.

Rotar Plus 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004

Page 11

Test

MAINTENANCE

DRAINED OIL IS A POLLUTANT! Dispose of according to the environmental protection rules in force.

Change the oil separator filter (fig.10)

The oil separator is not washable and should be changed at each oil change. Never exceed 3000

operating hours.

 Drain all compressed air through cock (A).  Unscrew the filter manually (use a special tool for filters, if needed). Rotate counter clockwise

to unscrew.

 Fit a new filter. Screw new filter in clockwise. Smear the gasket of O-ring inside the oil separator

filter lightly with oil before fitting the filter.

Drain the condensate (fig.7)

Air/oil mixture cooling is set to occur below air dew point, however, it is impossible to avoid conden-

sate in oil totally.

Once a month, drain condensate before starting the compressor: open cock (C) and close it as

soon as oil start flowing out instead of water.

Always make sure the oil separator tank is depressurized before proceeding. Drain any

pressure through cock (A).

Check oil level and top up if needed. CONDENSATE IS A POLLUTANT! Do not drain into the sewers. Dispose of according to the environmental protection rules in

force.

EVERY 2000 OPERATING HOURS

Check drive belt tension (Fig.12) Use a frequency tester to carry out this check. Proceed as follows:  Move tester microphone closer to the belt about at mid length and hit the belt

with a wrench.

 Read value on tester. Stretch or slacken the belt if the value is different from

values indicated in the table:

Higher value = slacken Lower value = stretch

 To adjust, proceed as follows: turn the screw (1) anti-clockwise to stretch the belt and clockwise to slacken. check frequency value once again. Repeat the above procedure, if necessary, to

reach optimal value.

When finished, re-assemble cabinet parts before starting the compressor.

V 400 / Hz 50 V 400 / Hz 60

Rotar Plus 20 2008 2010 2013 2008 2010

frequency (Hz) 71 73 68 72 71

Rotar Plus 25 2508 2510 2513 2508 2510

frequency (Hz) 79 78 75 81 77

EVERY 12000 HOURS

Minimum pressure valve (fig.11)

Close the mains cock and drain all air from the oil separator tank

through valve (A)

Remove the flange fixing nuts and lift the flange Change the seals (1) and (2).

Changing the hoses

Loosen the hose fittings, change hose and tighten fittings securely. Proceed with the last steps of the oil change procedure.

Changing electric motor bearings.

This can also be done after 15,000 operating hours. Have wear

condition of bearings assessed by a specialized technician.

Rotar Plus 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004

Page 12

Test

MAINTENANCE

EVERY 20000 HOURS

Change:

 Compressor seal ring  Tank safety valve

Change the drive belt as follows (fig.12):.

2) Tighten the screw (1) turning it clockwise with a hexagon head wrench, until you

feel that the belt is slackening and comes off easily.

3) Install the new belt and set the screw (1) back to its original position (turn clockwise).

Leave belt slightly slack.

Check frequency value as described on page 11.

Rotar Plus 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004

Page 13

TROUBLESHOOTING

Problem

Motor stop due to thermal relay tripping

High oil consumption

Oil leakage from suction filter

Safety valve open

Compressor temperature thermostat tripped

Cause

Voltage too low

Overtemperature

Defective drainage

Oil level too high

Oil separator filter broken

Oil separator filter seals leaking

Suction regulator does not close

Pressure too high

Suction regulator does not close at the end of the cycleI

Oil separator filter clogged

Room temperature too high

Radiator clogged

Oil level too low

Thermostat faulty

Remedy

Check voltage, press Reset and start once again

Check motor absorption and check relay settings. If absorption is OK, press Reset and start once again

Check oil drainage tube and non-return valve

Check oil level and drain some, if necessary

Change oil separator filter

Replace gaskets

Check regulator and solenoid valve

Check setting of pressure switch

Check regulator and solenoid valve

Change oil separator filter

Improve ventilation

Clean the radiator with solvent

Top up with oil

Replace thermostat, press Reset and start once again

Low compressor efficiency

The compressor is running but does not compress air

The compressor compresses air beyond set max. pressure

Compressor does not restart

Difficult start

Oil inside cabinet

Belt is slack

Air filter dirty or clogged

Regulator is closed and does not open because it is dirty

Regulator is closed and does not open because it receives no command signal

Regulator is open and does not close because it is dirty

Regulator is open and does not close because it receives no command signal

Oil separator filter clogged

Min. pressure valve does not close perfectly

Voltage too low

Shop too cold

Leakage from tubes

Leakage from front compressor flange

Stretch the belt, press Reset and start once again

Clean or replace filter

Remove the suction filter and check if regulator can be manually opened. Remove and clean, if necessary.

Ensure that signal between pressure switch and solenoid valve is available. Replace part, if damaged.

Remove the regulator and clean

Ensure that signal between pressure switch and solenoid valve is available. Replace part, if damaged.

Change oil separator filter

Remove and clean the valve. Replace the seal, if necessary

Check mains voltage

Heat up shop

Tighten fittings and/or replace damaged tubes

Remove and replace seal ring.

Rotar Plus 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004

Page 14

WIRING DIAGRAM

20 hp 25hp

230V 400V 230V 400V

TC1 Transformer 150AV

TC2 Transformer

SB Emergency button

FU1-FU2 Fuses 6.3x32 4A 500V

FU3 Fuses 6.3x32 1.6A 500V

FU4-FU5-FU6 Fuses 6.3x32 1A 500V

FU7 Fuses 6.3x32 500 mA 500V

KM1 Line contactor 18,5 kW (*) 11 kW(*) 18,5 kW (*) 11 kW(*)

KM2 Delta contactor 18,5 kW (*) 11 kW(*) 18,5 kW (*) 11 kW(*)

KM3 Star contactor 15 kW (*) 7,5 kW(*) 15 kW (*) 7,5 kW(*)

FR Thermal relay (28-40) (17-22) (28-40) (20-25)

YV Solenoid valve

SP1 Minimum pressure switch

SP2 Pressure switch for oil separator filter

SP3 Pressure switch for air filter

BP Pressure transducer 0-16 bar

D Electronic controller

ST Thermal feeler for electronic controller

Motor cable cross-section (sq mm) 7x10 7x4 7x10 7x6

(*) = 400V AC3

Rotar Plus 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004