Manual - Northern Tool + Equipment
Contents
1. 2 2 Introduction In general the INFOLOGIC controller has following functions e Controlling the compressor e Protecting the compressor e Monitoring components subject to service e Automatic restart after voltage failure made inactive in the works Page 3 2 3 Automatic control of the compressor The regulator maintains the net pressure between programmable limits by automatically loading and unloading the compressor A number of programmable settings e g the unloading and loading pressures the minimum stop time and the maximum number of motor starts are taken into account The regulator stops the compressor whenever possible to reduce the power consumption and restarts it automatically when the net pressure decreases 2 4 Protecting the compressor Shut down If the compressor element outlet temperature exceeds the programmed shut down level the compressor will be stopped This will be indicated on display 1 page 3 The compressor will also be stopped in case of overload of the drive motor Before remedying consult the Safety precautions Shut down warning A shut down warning level is a programmable level below the shut down level If one of the measurements exceeds the programmed shut down warning level this will also be indicated to warn the operator before the shut down level is reached 2 5 Service warning If the service timer exceeds a programmed value this will be indicated on display 1 pa2. 3 6 Shut down 3 6 1 Description The compressor will be shut down in case e The temperature at the outlet of the compressor element exceeds the shut down level e Of error of the outlet pressure sensor e Of overload of the drive motor Page 8 3 6 2 Compressor element outlet temperature 5 4 3 If the outlet temperature of the compressor element exceeds the shut down level 110 C 230 F programmable the compressor will be shut down alarm LED 4 will flash automatic operation LED 5 will go out and the following screen will appear Main screen with shut down indication element outlet temperature N EL Psi 95 72 e Press arrow key 3 until the actual compressor element temperature appears Shut down screen element outlet temperature IN fm fo F 231 8 The screen shows that the temperature at the outlet of the compressor element is 231 8 F e Switch off the voltage and remedy the trouble e After remedying and when the shut down condition has disappeared switch on the voltage and restart the compressor 3 6 3 Motor overload e In the event of motor overload the compressor will be shut down alarm LED 4 will flash automatic operation LED 5 will go out and the following screen will appear Main screen with shut down indication motor overload flashing e Switch off the voltage and remedy the trouble e After remedying and when the shut down condition has disappeared s
3. Maintenance A e TA OQUCUON 2 na ara pi nise ao ut al ati ai de ees Sew do a a n Cap ta Eu ora eg ala sta na SADO DR ca a Se 15 DA RC A A oa cin EEE POINTED A a i apa at State RT AR Pda RED a OE IN A ia 16 D Eludand am ECOLE adaga da a SEA A a i i i at De e E ci tata ta ac O ee Ped separador CALUL CEE cara sate iai ta dead ESA A rat pe LO F Fluid return pipe oaza Luc i aaa atata at eee She EDER RAM a r a aaa DA RA nat ee ae ah N O A G Deinido condensati natero EEE A TE AER E A STA O H Temperature safety tests RN PR A el A A EN CAM N NE N SNA A o e SP e I R efasicning electio connections ee a ca a ont o O A Mts eal aaa na atenuat I L Decorimiscionine the conmpressoeat the cndior its usefull life ceea blat Er ae aia a t Gases Gace sees lat atomi 7 e M Belt tensioning wea o NA A eects NI IAA OPRIRE A PI N PN i gi PARI i ACE e E i ee ci IONA INA A Ma a NN et ac i a ia AI ae A i NAC a A TO Chapter 6 Operating incidents ls asma o criado aa i DS ro di a et te n a lua i ante az a a a al i a Ola ener 20 SECTION II INFOLOGIC CONTROLLER SECTION III DRYER 06 2010 Page 4 2200 7800 02 Space requirement and installation diagram Compressors 20 25 30 see chapter 2 installation instructions Fig l 0 78 90 39 18 94 48 03 39 96 27 95 1 38 06 2010 2200 7800 02 Page 5 4 13 VOLTAGE SUPPLY ENTRANCE M25 13 19 10 57 ENTRANCE M50 30 71 VOLTAGE SUPPLY 0 78 26 54
4. e The screen shows the password status on lt On gt or off lt OFF gt Press enter key 1 to modify e Change the value with scroll keys 2 and 3 e Select lt On gt and press enter key 1 e Enter the new password and press enter key 1 to confirm e Enter the password again and press enter key 1 to confirm e lt On gt appears on the display Press reset key to return to the parameter screen Lost passwords can not be recovered Save the password carefully 3 29 Calling up modifying protection settings Protections Page 26 A number of protection settings are provided The protection screens are numbered lt Pr gt the pictograph shown with the protection screen indicates the purpose of the protection Possible combinations are lt Pr gt followed by a number and one of the next pictographs lt Pr gt shown with the pressure pictograph shows the pressure protections lt Pr gt shown with the element outlet temperature pictograph shows the element outlet temperature protections lt Pr gt shown with the dewpoint temperature pictograph shows the dewpoint temperature protections lt Pr gt shown with the ambient temperature pictograph shows the ambient temperature protections Four protection settings are possible e A low warning level shown on the display as lt AL L gt e A high warning level shown on the display as lt AL H gt e A low shut down level shown on the display a
5. Fuses a Check the fuses restart even after a few minutes b The thermostatic protection with b Reload or wait for the head of manualstarting has begun to operate thecompressor to cool down See case 2b and 4 c The high pressure switch has begun c Reload the pressure switch operation d Check the integrity of the d The motor is out of order electricalconnection and its insulation 8 The dryer s compressor makes too Problems with the internal mechanical much noise organs or with the compressor valves 9 The condensation separator does not Automatic condensation bleeding Bleed the unit by opening the manual work system is cleaned bleed valve Have the system checked 10 Dew point under too much pressure a Room temperature is too high a Check and correct the cooling air inlet if required b Lack of coolant b Make sure the circuit is watertight have it recharged c Cooling compressor does not work c Check the dryer electricity d Evaporator pressure is too high supply e Condenser pressure is too high d See 11 11 Evaporator pressure is too high a Maladjustment or breakdown of the by pass valve of the hot coolant gas o b Condenser pressure either too high or b See 12 too low c Lack of coolant a Have the by pass valve readjusted C Make sure the circuit is watertight have it recharged 12 Condenser pressure is too high a Defective fan pressure switch a Carry out a replacem
6. not supplied to which the distribution pipes are connected 2 Fluid circuit see Fig 4 The fluid under discharge pressure flows from the bottom of the tank through the cooler item 51H the fluid filter item 26 which retains solid particles and then into the compressor item 20 At each cold start the thermostatic valve item 47 short circuits the fluid cooler thus enabling the optimum operating temperature to be reached quickly When it leaves the compressor element the fluid 1 returns to the tank Part of the fluid remains suspended in the air as mist This mist passes through the fluid separator item 49 A fraction of this fluid agglomerates in large droplets which return to the tank through the force of gravity The remaining fluid which is separated by the last stage of the fluid separator 1s drawn up by a dip tube and dispatched to the compressor Fig 4 Air fluid circuit CO ETA E FLUID AIR FOIL a 06 2010 Page 12 2200 7800 02 B Control principles 1 On Off Control see Fig 5 Models all versions The compressor 20 25 30 units are fitted with an automatic control system enabling the machine to be stopped after it has run unloaded for a given adjustable period of time This unloaded period 1s necessary to avoid excessively close start ups in periods of unstable compressed air consumption When the compressor reaches the maximum pressure measured by the pressure sensor item
7. 02 Page 17 M Belt tensioning Before doing any maintenance make sure that the compressor is stopped the power supply and compressed air network are isolated and that the machine is totally blown off Take off the rear panel 1 Fig 14 Using an Allen Wrench unscrew the four tightening screws 3 Fig 15 of the plunger from the support Using an hexagonal wrench unscrew the lockup nut as shown in the figure Tight the belts using a hexagonal wrench according the Table 1 If no tension measuring device is available use the method shown on Fig 16 Fix the nut and the locknut using an hexagonal wrench Lockup the tightening nut using an Allen Wrench Place the rear panel back 06 2010 Page 18 Fig 16 0 24 in New Belt After 100h 2200 7800 02 N Belt removal Take off the rear panel 1 Using an Allen Wrench unscrew the four tightening screws 3 of the plunger from the support Using an hexagonal wrench unscrew the lockup nut as shown in the Fig 18 Remove the inlet nozzle Fig 19 Replace the worn out belts Fig 20 Tight the belts using a hexagonal wrench according the Table 1 If no tension measuring device is available use the method shown on Fig 16 Fix the nut and the locknut using an hexagonal wrench Lockup the tightening nut using an Allen Wrench Place the rear panel back Fig 18 06 2010 2200 7800 02 Page 19 Chapter 6 Operating incidents
8. 18 31 69 88 m gt O O CD LO Sor 48 03 e E 2 RR CL lt X E e LU Lo o gt O X no N i s g 00 Cc S ac CN co co N LO gt o O CN 06 2010 Page 6 2200 7800 02 Chapter 1 Description A General The compressor contains a compressed air unit in the form of a self contained complete and fully tested assembly driven by an electric motor and enclosed in an acoustic canopy necessary for proper cooling of the assembly It is an fluid cooled single stage helical screw type compressor There is a vertical mounted receiver for pre separating and storing fluid and air The air fluid mixture is then separated by means of a separator cartridge Both the compressor and the motor are directly fixed on the frame by anti vibration pads B Respect of the environment and Prevention of pollution 1 Maintenance of the machine Make sure that the used components of the machine waste fluid fluid and air filters fluid separators etc are disposed according to national and local regulations 2 Condensate drain pipe Make sure that the condensates water fluid are drained and treated according to national and local regulations 3 End of life of the machine Make sure that the machine as a whole is disposed according to national and local regulations C Standard equipment In its standard version the covered unit includes Operating components 1 A twi
9. 36 the solenoid valve item 35 releases to the atmosphere the compressed air The internal pres sure closes on one hand the suction box and on the other hand the blow off piston This results in the release of the internal pressure of the receiver via the by pass check valve The compressor draws 1n air via a by pass valve item 25 The low pressure obtained in the fluid tank enables the compressor to be lubricated and cooled during the whole unloaded period If the compressed air pressure in the user network reaches the minimum cutting in value before the end of the no load operation time out the solenoid valve item 35 is actuated causing the suction valve to open and the vent to close The compressor then operates at full output rate When the compressor stops the solenoid valve item 35 is no longer powered and closes the suction housing closes and the oil tank is evacuated The receiver is thus brought back to atmospheric pressure for the next start up Key Fig 5 Compressor Inlet valve Built in minimum pressure valve Filter support do Solenoid valve 36 Pressure sensor 38 Pneumatic vacuum piston O l 23 25 26 2 34 8 23 25 26 27 34 38 Era E Eca nel 41 Ventilation 47 49 LA 1H 51 63 Fig 5 On Off Control 71 re P Fa in r 2200 7800 02 A 41 36 eo a 26 06 2010 Page 13 C Rotation direction
10. lo Display the humber or anidad actions ti Me caise spera A Daia vente ca al edie pda aa i a 17 de LOre Calling up r setting service mer araras to O 18 DE OS SONO O 18 3510 22 ESE UNOS SERVICE LINCE ie avarie lait ial ac aliata alu AA AA adu ai ala ut din aaa aa uta al aia 18 3 17 Selection between local remote or LAN control iza cea are a dania vend ii A aaa Ea aaa ages 19 3 18 Calling up modifying node ID for LAN control Seas asezata ice a ela ada E il a 19 3 19 Calling up modifying pressure band settingS cias A A a sl iti AS A E bateti DA at de batai 20 3 20 Modify ing pressure band selection assada iza i da co et iat Va E Dat at i ES acne eet ar hace e d ates 21 3 21 Calling up modifying service Timer setting sarada sons o aa a ca stato Ad 22 3 22 Calling up modifying unit of temperature tas iia Coisas lei is E alei ol Ends Cab sus d cnh E Dali de aos 22 3 25 Calling ip Modifying unit of pressure ini anii aaa a a i a it a a i n ac a i ai a a dai au a 23 3 24 Activating automatic restart after voltage failure ooooccccccccccccccnncccnnnnrnrn nr rr rr 23 3225 8 Selection between 1 D Or DOL starting Sida data snes Pa dee date shes ala aia e dies SS CARTE ae does aa ai tate dadea Di at a 24 3 26 Calling up modify ing load delay TIME en neant ca A ate ale ia n tal ai aa a Da decked 24 3 27 Calling up modify ing minimum stop time e eee eee eee eee eee eee eee n nara n nanda 25 3 28 Activating PassWord PrOt
11. module hours of the compressor are 5000 hours Page 16 62 305 451 99 3 14 Calling up loading hours Control panel Starting from the Main screen The screen shows the unit used lt hrs gt or lt x 1000 hrs gt and the value lt 1755 gt the loading hours of the compressor are 1755 hours 3 15 Display the number of unload actions times Control panel Page 17 Starting from Main screen lt x 1000 gt 10 10 This screen shows the number of unload to load actions times I or if 1 000 gt lits up times 1000 The number of unload to load actions is 10100 3 16 Calling up resetting service timer 3 16 1 Control panel Starting from the Main screen 1 his screen shows the unit used lt hrs gt or lt x 000 gt hours x 1000 and the value lt 1191 gt the compressor has run 1191 hours since the previous service 3 16 2 Resetting the service timer Page 18 After servicing see section Service warning the timer has to be reset e Scroll to register screen lt d 06 gt and press enter key 2 e The reading e g 4000 will appear e Press enter key 2 if a password is set enter the password The reading will flash indicating that resetting is possible e Press enter key 2 to reset the timer to lt 0 000 gt or press reset key 1 to cancel the operation 3 17 Selection between local remote or LAN control Control panel Starting from the Main screen e Press ar
12. or 3 years Whichever comes first in normal conditions 2200 7800 02 06 2010 Page 15 Drain the compressor when warm In order to do this stop it and make sure you disconnect the electric supply and close the compressor outlet valve Loose the filling plug by one tum to depressurize the receiver in case of component failure Open the bleeding valve and drain it Do not forget to close the valve after it has been drained After maintenance a reset has to be done on the counter which indicates the number of remaining hours before the next fluid change see the specific notice on the electronic controller FLUID LEVEL Fig 10 When stopped the MAX level of fluid is 3 4 of the way up from the bottom of the indicator the MINI level is at the lowest visible part of the indicator THE FLUID LEVEL HAS TO BE CHECKED AFTER STOP AND WHILE THE COMPRESSOR IS STILL WARM THERMOSTATIC VALVE OPEN NOTE If the fluid is in poor condition 1 e it gives off an acrid smell or contains particles of varnish or other solids the system will have to be rinsed out pour in around 50 of the normal clean fluid contents run the set for 3 hours and carefully drain During rinsing leave the former fluid filter cartridge in place B Air filter See Fig 11 see B Chapter 1 The air filter is a dry encapsulated type In standard conditions of use change the cartridge every 2 OOOhrs This can be done through an easy access from the fr
13. rd fe Pot idioma aa odin a be tin la E a ol RD crisis al d du e 7 Dede DESCI aurie tale ai aaa aaa a alla data aliata at da ital lata at 7 3 5 2 Compressor clement outlet temperature sn paie casos cs a atata ah havea ce ea asa atat eae atat CAS at at EAA EA ET ud 7 Sd DEW PO MT Le DE Ba UC ceia 2 ayes dd ad dd dd tuia do ELO 8 Ceviche A sas Donas Sp i sacas us dano Be ep e e ol lu e usasse ai aaa la Lar pl ia 8 5 621 sDSSChIPEIOIN seste ia E it iai di lu aia A i ta A E d AR o bt O a A iale 8 3 6 2 Compressor element outlet temperature mmmne eee emana eee era nenea rr 9 3 0 3 Motor Overload AAA ab A nt a all a ata aa atasat a AO ata laud E E D a atat E atasa a ata sia s 9 3 7 Service War NINO ascetic are vaca taia aa a atu aa aaa a ta aa alt 10 Dede dos Description eee masca eee AAA AAA e la ana e al SA n Ea a pi o E a it E gi e E ui 10 3 06 Scroilingo th hrough all SCREENS sizes iai i dde 11 Dad SC OLHO DANO aros rescence cay nana a a E t aaa feat Ra aaa RS aa pate t 11 SO A AN RN RR RN ORI RE RI RR NN NR OE 12 MEN TONE A A a in a lata a dt dara 13 3 10 Calling up outlet and dew point temperatures mmeu cece cece eee eee eee rr rr 14 Se Calingtup running NOUS lt a aa a ia e ap cc ci Son tc coun af 15 3 12 Calling UP MOtOr Starts id eel dada cat aaa a a a a a a i anes 15 3513 gt Calling up Module Mo Sinti 16 3 14 Calling up loading NOUS ceia seste inceta pe ei eS tat DL 17
14. Eaniner Instruction Manual EN QGS Rotary Compressors UNITS Hp 20 25 30 Kw 15 18 5 22 2200 7800 02 ed 02 AN Before carrying out any maintenance ensure that the compressor has been locked out and tagged out from all power sources ORIGINAL PART 06 2010 2200 7800 02 Page 1 The compressor should never be operated beyond its capabilities or in any way which does not comply with the instructions contained in this operating and maintenance guide The manufacturer will decline any responsibility if these instructions are not respected This equipment has been factory tested and satisfies normal operating conditions they must not be exceeded as this would place the machine under abnormal stress and effort INSTALLATION INSTRUCTIONS For the guarantee to be valid the unit must be assembled in covered premises with temperatures not exceeding Mini 39 2 F frost free Maxi 104 F You must also have 3 3 feet space around the compressor Low ventilation fresh air proportionate to the ventilation flow necessary for the machine and protected from any infiltration of humidity splashes of water during bad weather and all pollution Top insulation or extraction to ensure reversal of the flow of warm air and evacuation of the heat to outside the equipment room A link from the condensation water evacuation pipe to the drain discharger In dusty environment pre filtering the room s air intake and a special fi
15. LY OR CREATES Infologic electronic controller contact the after sales department NON EXISTING FAULTS 06 2010 Page 20 2200 7800 02 User Manual Electronic controller INFOLOGIC EN CONTENIS Chapter 1 Salety Measures uu i iris eu a Ud a dde 3 SAFE TN oin PRR GR PN RR IE PN E E RA ARNO RIA READER PIERO RR E a RR NT NEI PN E RTP EI PANN RED E 3 INSTALLATION ut ds AS E oale ar a pdl adi RO ap a aa aa oi s ea 3 E IS Au PO Noi pietate n a a atatia ala a Casca tava ta aa at ataca or at 3 MAINTENANCE AND REPAIRS 4 tati i Da dna E alai SER LES ini tees eee A ai DA ad DUE UNE ni a 3 EXTERNAL CONTROL 2 a E SAS ST DD on Ea A a 3 Chapter 20 Introduction es araras ist ce aa e AA A ad e a Ia re a d es eee 3 2 1 COMMON panel ara dra ia SRA DES riada 3 La NO bic lols ssa eee eT er eer ataca al Da O 3 2 3 Automatic c ontrolof the compressor a azi e cena ut tra aa sa arata pas ar i ana a ca na ct a a a t pa a bao 4 2 4 Protecting the Compressor sessao aid 4 2 5 SEIVICE Warren E cane ati ada ada Dana Do DE ndata AAA AA 4 2 60 AUtomaticirestartiatter voltage alu e 4 Chapter 3 INFOLOGIC regulator asus as cu o de ce o ls a in e ee toi ED te o A le do a e IO A o to 4 Sd CONTO PANG ar A A A A EA RA a a Cca ean A 4 2 Display ANNA 6 3 3 Pictographs Used on Lhe Screen AA A A wa ce ee eee A pee a a a ab i 6 3 4 MAIN Screen isis dekard a i a weed dic Me ale at ada d dati ada a Me ale a aera d ee 7 32 CISNE COW Wali
16. NSIDE THE ENVELOPE DELIVERED WITH THE MACHINE MACHINE AND MANUFACTURER IDENTIFICATION DATA Position of the identification plate Fig 1 06 2010 2200 7800 02 Page 3 CONIENIS SECTION I COMPRESSOR Space requirement and installation diagram compressors 20 25 30 ccccccsssssccesssssceeesssnecesssseeeccsssseeecsscsueecessesecesessseecssseeeeceseaeeeeseseeeesesseeeesessnaseeeeaes 3 Chapter 1 Description SLE r EE E EEA a TEE OAT is aaa cis 7 B Respect of the environment and prevention of pollution eee eee ee eee eee eee eee eee eee eee Ee nee bee e EE ES 7 Es Standard equipes dias a Ac tan E ti ul anus ee Be dt da rau ADO Ro cal a cas aci ale RS 7 DD DeEnmnOnor Ihe PICO STAs ps iati ace a a ana dle a DR E a oe T 8 B Position Or wari label se ora dieta aci dal ds 8 ES Bl cromo DOM ee Da CI a ae a aa sa ana tonnes 9 Chapter 2 Installation E so ASS INDI cs A acu doc Ria sare otel Aa e Cole d cutu DDR Aa dai AA a o IN 10 D AI dISCHALES PPNS A a al ta a A EA ee Gr a Date o ri anti 10 E PIES cabine raca ST daia intaia dado Oa albanesa a aliata a sd Avon A i a ai a la tan ba 10 Chapter 3 Initial setup Chapter 4 Operation alo cat a pt ca a a al EN Do TR d aa d cotata a ata aa al datat a il Sa DR cl ta 12 Bei Control prinCipIcS us ss sds rend radial ern A A 13 C Rotation direction indicator Phase controller eee eee eee eee eee eee ae eee eee eee aaa o sees cessesssees 14 Chapter 5
17. The staff in charge of maintenance of the compressor must become fully acquainted with this machine in order to be able to easily diagnose any anomaly Under normal operating conditions the compressor must provide full satisfaction A Main incidents The main incidents likely to occur are listed below along with the remedies to be applied The markers of the indicator lights relate to the control panel Observed defects Possible causes Solutions 1 THE COMPRESSOR DOES NOT a Main switch open a Close the switch START b Phase missing b Check the circuits c Fuse c Replace d Insufficient voltage at motor terminals d Check the voltage and the e Compressor under pressure connections e Check the vacuum device and change if necessary Check the water tightness of f Low temperature the minimum pressure valve f Maintain temperature 235 6 F 2 THE COMPRESSOR a Ambient temperature too high a Make openings or install ducts OVERHEATS to evacuate the hot air b Obstruction of the passage of cooling b Clean the cooler through the fluid cooler c Fluid level too low c Check and top up fluid level d Fluid circuit blocked d Check that the fluid filter is clean Drain Replace the cartridge 3 THE COMPRESSOR STOPS WHEN a Compressor motor overload a Check the electric connections are THE MOTOR PROTECTION tight Check the pressure of the UNIT TRIPS compressed air and the pressure settings b Phase unb
18. alance b Check the phases currents 4 OPENING OF SAFETY VALVE a Dirty separator cartridge a Change the separator cartridge b Valve of suction box out of use or not b Check valve piston and joints of closed suction box c Faulty pressure switch sensor or c Check that the pressure switch solenoid valve and solenoid valve and pressure d Working pressure too high sensor are in good working order 5 EXCESSIVE FLUID CONSUMPTION a Blocked fluid retainer a Check the fluid return pipes b Fluid leaks in the compressor b Look for fluid leaks and rectify c Faulty fluid separator element c Replace the separator cartridge 6 DELIVERY PRESSURE TOO LOW a Incorrect pressure settings a Adjust the pressure b The desired output is higher than the b Check consumption and possible one of the compressor leaks c Closed suction valve c Check solenoid valve pressure setting d Pressure regulator incorrectly adjusted valve d Check setting 7 COMPRESSED AIR OUTPUT a Blocked air filter a Clean filter TOO LOW b Adjusting solenoid valve not working b Check setting 8 EXCESSIVE NOISE OF UNIT Fixing bolts of compressor or motor a Tighten have come loose Soundproof panels incorrectly closed b Check that they are closed Transport retainer blocks red parts c Remove retainer blocks not removed 9 THE COMPRESSOR STOPS a Electromagnetic disturbance on the a Add an interference suppression kit UNTIME
19. e atmosphere when stopping to thus ensure empty start up which relieves the motor 3 An fluid level gauge on the front panel see Fig 10 An electronic controller including a control keyboard the main safety and control indications 5 The compressed air output is regulated by a pressure sensor 06 2010 Page 7 D Definition of the pictograms Typical examples of pictograms valid for the compressor 1 Water outlet 2 Manual condensation water draining 3 Water inlet 4 Automatic condensation water draining 5 Unplug and unload the compressor before maintenance om 3 4 5 1 FLUID EJECTION 6 HIGH PRESSURE 2 DANGEROUS ELECTRIC VOLTAGE 7 HOT PARIS 3 AIR NOT FIT FOR BREATHING 8 MOVING PARTS 4 NOISE 9 FAN ROTATING 5 MACHINE WITH AUTOMATIC START E Position of the warning labels 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 LEFI SIDE VIEW RIGHT SIDE VIEW FRONT VIEW 06 2010 Page 8 Paris List Pos Qty Partnumber Comments 2 1 1079990348 On Cubicle Door 3 1 2202260791 On Cubicle Door 5 1 2202251293 FLUID LEVEL 6 2 2202260791 On Front amp Back Door 7 1 2202260791 At Air Outlet 8 1 2202260791 See picture 9 1 2202260791 See picture 10 1 Se
20. e electrical diagram inside cubicle to convert the operating voltage of the compressor for either 208V or 230V or 460V SAFETY REGULATIONS It should be remembered that safety regulations require e A ground to be used e A manual isolating switch cutting all three phases This switch must be clearly visible near the compressors unit e The electric current must be cut whenever maintenance work is carried out on the machine 2200 7800 02 Chapter 3 Initial setup A Preparation for start up Before starting up the unit for the first time the operator must be familiar with the different parts of the machine The main parts which should be examined are indicated m the diagrams IMPORTANT Before start up make sure that transport red pads have been effectively removed WARNING Please make sure the electrical mains are disconnected before any maintenance or adjustment on the unit in order to avoid any automatic restart Before start up check the following points 1 Make sure that the unit is properly grounded 2 Check the fluid level in the tank NOTE the tank has been filled with suitable fluid in the factory 3 Make sure the fluid change valve 1s properly closed 4 Check re tighten all power connections ATTENTION The fluid filler cap the fluid change valve and plugs must always remain closed during operation and never be opened before the system has been completely blown off to atmospheric pr
21. e is to remain idle for a long time places with no dust Stop the unit For particularly dusty locations double the maintenance Disconnect the electrical supply from the unit frequency Close the isolation gates Condensate Clean the filter of the Depressurise the unit release valve condensate release valve During the period of inactivity the machine must be protected from atmospheric agents dust and humidity which could damage Clean the fins to the motors and the electrical system Monthly Condenser eliminate o dust To start it up again consult after sales service accumulation 5 Disposing of the unit 2 Cleaning the condenser Fig 4 and 5 If the machine is dismantled it must be separated into equal parts to be recycled or disposed of according to the standards that are The condenser must be cleaned once a month currently in force Proceed as follows Stop the unit Cut off the main supply Remove the rear panel Fig 4 WE STRONGLY RECOMMEND FOLLOWING THE Clean the condenser vanes Fig 5 with a jet of air STANDARDS THAT ARE CURRENTLY IN FORCE FOR RECYCLING USED FLUIDS AND OTHER POLLUTANTS SUCH AS THE THERMAL Fig 4 INSULA TION FOAM AND COOLANT GAS Fig 5 DO NOT USE WATER OR SOLVENTS Page 6 F Trouble shooting and emergency solutions N B THE OPERATIONS SIGNALLED BY MUST BE CARRIED OUT BY PROFESSIONALLY QUALIFIED PERSONNEL WHOARE AUTHORISED BY ALUP KOMPRESSOREN Ob
22. ecil Oli inn E Ina 25 3 29 Calling up modifying protection settings ae 26 CAE EREE E AAA T da alt neg al d it ta ale ia Dat a dt o E E la Dl E gi atata 28 Page 2 Chapter 1 Safety Measures SAFETY The personnel using the INFOLOGIC shall use safe work practices and respect the local instructions and regulations concerning safety and hygiene All electrical tests shall be carried out according to the professional rules Always cut off the electrical power supply before starting any kind of maintenance work INSTALLATION The electrical cabinet should have a free access for facilitating maintenance the location of INFOLOGIC shall allow at any moment the visibility of luminous indicators and the digital display QUALIFICATION The INFOLOGIC shall be used only by competent trained and qualified personnel the manipulation of parameters can modify the characteristics and the performances of the compressor MAINTENANCE AND REPAIRS The works of maintenance and repairs and the configuration of the INFOLOGIC can be carried out only by competent and qualified personnel If spare parts are required use only the original parts supplied by the manufacturer EXTERNAL CONTROL The Stop and Start buttons on the controller are deactivated when the INFOLOGIC control is on remote or LAN To stop the machine with the controller it must first be placed in Local mode see 3 17 Chapter 2 Introduction 2 1 Control panel 1
23. eciprocating compressors is essential The impulses emitted by the reciprocating compressors would seriously damage the non return valve the separator element and disturb system control When the rotary compressor operates in parallel with an alternative compressor the adjustments on the latter will have to be adjusted so that the rotary compressor carries the basic load This will result in more economic operation E Safety The fluid used for cooling the machine is an inflammable liquid under the effect of strong heat In case of fire in the machine it is essential to respect the regulatory measures on the compressor The type of fire in a compressor is defined as class B and in presence of a live electrical conductor it is recommended to use a CO extinguisher functioning by smothering starvation of oxygen while observing the user instructions applicable to the model 06 2010 Page 11 Chapter 4 Operation A Air and fluid circuits aa Key Fig 4 20 1 Air circuit see Fig 4 The air is sucked into the compressor through a filter item 23 This air passes through the compression element where it is mixed with fluid injected during compression Inside the tank the compressed air is separated by shocks and then flows through the fluid separator item 49 It then passes through the Minimum pressure valve item 34 including a check valve the final cooler item 51A condensate separator and finally the outlet valve
24. ent of the part b Defective fan b Check the fan c Room temperature is too high c Check and correct the cooling air inlet if required d Condenser is clogged on the outside d Clean the condenser fins Page 7 ORIGINAL PART Page 8
25. eparator Impurity collector Capillary tube Cooling liquid filter Hot gas by pass valve Air air heat exchanger Dew point temperature probe Ventilator control pressure switch Automatic level bleed Timer C Installation 1 Inspection Upon receiving the machine make sure it is intact by checking for any parts that may be visibly damaged In case of doubt do not use the machine and contact your customer service department 2 Electrical connections ACCESS TO THE ELECTRIC CABINET IS RESTRICTED TO PROFESSIONALLY QUALIFIED PERSONNEL ONLY MAKE SURE ALL POWER SUPPLY TO THE UNIT IS DISCONNECTED BEFORE OPENING THE DOOR OF THE ELECTRIC CABINET IT IS ESSENTIAL THAT YOU RES PECT THE REGULATIONS IN FORCE CONCERNING ELECTRICAL INSTALLATIONS FOR EMPLOYEE SAFETY AND TO PROTECT THE MACHINE e Check that the mains voltage corresponds to the voltage specified on the insert e Check the condition of the conductors and make sure that there is efficient grounding e Check the upper part of the machine for the automatic inter ruption device for overloads with a differential circuit breaker calibrated at 30 mA Transformer option for the dryer s internal electrical supply e The dryer is factory wired its electrical supply is plugged in directly to the machine s general supply 3 Condensate evacuation The dryer is fitted with a condensate separator including an automatic bleed to eliminate condensed water after cool
26. essure B First start up Check the voltage between the three phases before using the unit for the first time Check the direction of rotation following the arrow on the pulley belt support item 1 Fig 3 by pressing the Start button followed immediately by the emergency stop If it does not spin in the right direction reverse two mains cables When it rotates in the correct direction the fluid level Fig 10 should drop after 4 or 5 seconds of operation Fig 3 2200 7800 02 1 Press the ON button the motor starts up 2 Leave it running for a few minutes with the discharge valve slightly open to observe the compressor under load Ensure that there are no leaks Reblock the connectors if necessary 3 Press the STOP button The motor stops and the unit is automatically blown off at atmospheric pressure C Delivery pressure adjustment The unit is adjusted in the factory fora MAXIMUM pressure for the maximum output from the outlet of the central unit of 107 132 or 157 psi depending on the model To adjust the load pressure setting to a lower value refer to the manual of the electronic controller D Adjustment for in parallel operation with other compressor If the compressor has to operate in parallel with other equal or similar compressors the discharge pipes can be connected together If the compressor has to operate in parallel with one or several alternative compressors an air tank common to the r
27. eturn pipe see Fig 13 Placed under the compressor L Decommissioning the compressor at the e Dismantle the complete fluid return check valve end of its useful life Lift the fluid stop valve pipe Check the state of the o ring item 1 Fig 13 Reassemble A dedicated kit allows to replace the complete check valve Stop the compressor and close the air outlet valve Disconnect the compressor from the electric supply Unload the compressor unplug the 4 6 piping on the fluid separator cover sas e 4 Close and unload the section of the air network which is G Draining condensation water linked to the exit valve Disconnect from the compressed air see B Chapter 1 exit pipe from the air network Empty the circuits of fluid and condensates Disconnect the compressor condensate piping from the condensate draining system gt SI Condensation water prevents proper lubrication The resulting substantial wear leads to a reduction in the lifespan of the compressor It is therefore essential to drain condensation water Draining of condensates in the fluid circuit Draining will only take place at least 12 hours after the compressor has been shut down It can be carried out for example at start up Fig 13 Fluid return To do this Slowly open the fluid change tap and let the water escape When the fluid appears close the valve immediately to avoid any Loss Refill with fluid if necessary 06 2010 2200 7800
28. from the fluid tank and on the room temperature The fluid separator cartridge item 1 Fig 12 should be replaced when the corresponding warning message is displayed on the controller After replacing the fluid separator cartridge reset the counter which will let you know how much time is left before it needs to be replaced Excessive fluid consumption Excessive fluid in the discharged air and a sudden drop in the level are signs that the fluid separator cartridge has probably deteriorated and must be changed In the first place the compressor must be checked to make sure that there are no fluid leaks and that the fluid scavenge line is working properly The replacement of the fluid separator cartridge requires the removal of the right top panel 2200 7800 02 Fig 12 H Temperature safety tests IF THE SENSOR DOES NOT DISPLAY THE RIGHT TEMPERATURE OR GIVES AN ERROR MESSAGE ON THE CONTROLLER DISPLAY FIRST CHECK THE CONNECTIONS AND CABLES IT CAN ONLY BE REPLACED IF IT HAS BEEN DETECTED FAULTY WITH CERTAINTY I Refastening electric connections A loosening of the electric power cables leads to the contactors overheating which can lead to their destruction PERIODIC REFASTENING IS THEREFORE NECESSARY AT THE STAR DELTA AND LINE CONTACTOR INPUTS AND OUTPUTS SEE MAINTENANCE TABLE 1 Fluid separator cartridge All electric power supply to the machine must be cut off before opening the electric cabinet F Fluid r
29. fy ing protection settings lt Pr 02 gt lt Pr 03 gt Test screen Designation Related topic lt t 01 gt Display test See sections Test screens lt t 02 gt Safety valve test See sections Test screens Page 12 3 9 Menu flow VI A Ca vila mA Va P JA fin Fn Simplified menu flow Page 13 3 10 Calling up outlet and dew point temperatures Control panel Starting from the Main screen The screen shows that the outlet temperature is 181 4 F e Compressor with incorporated dryer option Press arrow key 2 the dew point temperature will be shown The screen shows that the dew point temperature is 37 4 F e Press arrow keys 2 and 3 to scroll downwards or upwards through the screens Page 14 3 11 Calling up running hours Control panel Starting from the Main screen lt x 1000 hrs gt 11 25 The screen shows the unit used lt x 1000 hrs gt and the value lt 11 25 gt the running hours of the compressor are 11250 hours 3 12 Calling up motor starts Control panel Page 15 Starting from the Main screen lt x 1000 gt 10 10 This screen shows the number of motor starts times 1000 times 1 or if lt x1 000 gt lits up times 1000 The number of motor starts is 10 100 3 13 Calling up module hours Control panel Starting from the Main screen The screen shows the unit used lt hrs gt and the value lt 5000 gt the
30. ge 3 to warn the operator to carry out some service actions 2 6 Automatic restart after voltage failure The regulator has a built in function to automatically restart the compressor when the voltage is restored after voltage failure This function is deactivated in compressors leaving the factory If desired the function can be activated Consult the consumer service centre A If activated and provided the regulator was in the automatic operation mode the compressor will automatically restart when the supply voltage to the module is restored Chapter 3 INFOLOGIC regulator 3 1 Control panel S10 Page 4 Ret Emergency stop button S10 Stop button red Start button green General alarm LED red Automatic operation LED green Upward scroll key N N ES UI N Uo N O Display Enter key Key to select or validate a parameter to open a sub display Downwards scroll key Push button to stop the compressor immediately in the event of an emergency After remedying the trouble unlock the button by pulling it out and press reset key 4 Push button to stop the compressor LED 10 goes out The compressor will stop after running in unloaded condition for about 30 seconds Push button to start the compressor LED 10 lights up indicating that the regulator 1s operative in automatic operation Indicates the compressor operating condition actually measu
31. he fan 3 the condensed cooling fluid passes through the filter of cooling liquid 8 it expands through the capillary tube 7 and returns to the evaporator where it produces a cooling effect Due to the thermal exchange with the compressed air passing through the evaporator against the flow while cooling the cooling liquid evaporates and returns to the compressor to start a new cycle The circuit is completed with a system that bypasses the cooling liquid and adapts the available cooling power to an effec tive thermal load This operation is carried out by injecting hot gas under the valve control 9 maintaining the cooling liquid at a constant pressure in the evaporator and therefore the condenser at the same temperature which never drops below 32 F degrees in order to prevent the condensates from freezing in the evaporator Operation of the dryer is completely automatic the dryer is calibrated in the factory according to a reference dew point and therefore requires no additional calibration Fig 2 Operation principle A7 AIR EXHAUSTS E FE tr rrr rrr ep too leal leo e to Dom loa Sa sos n a O Gl E A Em Arama Ein ge SL TAME El 048000 En EA ni 03 11 1a mem AIR INTAKE Eesti 1 E Se Fm EA CONDENSATION di 7747 DRAINING A amp 000 O i PA i a Page 4 EB DES O AANADUNF WN Key Fig 2 Cooling compressor Condenser Electric fan Evaporator Condensate s
32. hichever has precedence It is very important for the compressor to have an abundant supply of fresh air If operating the compressor causes the ambient temperature to rise above 104 F the warm air leaving the cooler must be discharge outside COMMENT When the atmosphere is contaminated by organic or mineral dust or by corrosive chemical emanations the following precautions must be taken 1 Provide another air intake as close as possible to the suction source of the compressor this recommendation applies if the only room available is excessively humid 2 Use an additional filter for the unit s air supply C Assembly Put the unit on a stable surface The compressor does not need foundations Any flat surface that can support its weight will be sufficient industrial floor D Air discharge piping The diameter of the piping for the air network must at least be equal to 1 DN30 of the gas piping Current legislation requires the installation of a valve which can be locked in a closed position at the outlet of the compressor and connected to the compressor by a pipe union or flexible hose so as to isolate it during servicing E Electric cabling The standard voltage configuration for the compressor 1s mentioned on the data plate of the machine NEVER OPERATE THE COMPRESSOR ON A VOLTAGE OTHER DIFFERENT THAN SHOWN ON THE ELECTRIC CABINET 06 2010 Page 10 For tri voltage machine follow the instructions in th
33. imer reading hrs or xl 000 hrs See section Calling up resetting service timer Designation Related topic Parameter screen lt P 01 gt Selection between local remote or LAN control See section Selection between local remote or LAN control lt P 02 gt Setting a node ID for LAN control See section Calling up modifying node ID lt P 03 gt Pressure band settings See section Calling up modifying pressure band settings lt P 04 gt Setting a pressure band selection See section Modifying pressure band selection lt P 05 gt Modifying a service timer See section Calling up modify ing service timer lt P 06 gt Setting of unit for temperature See section Calling up modifying unit for temperature lt P 07 gt Setting of unit for pressure See section Calling up modifying unit for pressure lt P 08 gt Selection for function Automatic restart See section Activating automatic restart after voltage failure after voltage failure lt P 09 gt Selection between Y D or DOL starting See section Selection between Y D or DOL starting lt P 10 gt Setting of load delay time See section Calling up modifying load delay time lt P 1 1 gt Setting of minimum stop time See section Calling up modifying minimum stop time lt P 12 gt Setting a password See section Activating password protection Protections Designation Related topic screen lt Pr 01 gt Protections screens See section Calling up modi
34. indicator Phase controller 1 Description The night rotation direction of the main motor of the machine is constantly monitored by the relay CP1 Installed inside electric cabinet see service diagram This option prevents any risk of physical damage by disabling the compressor start up in case of phase reversal or if a phase is disconnected and indicates a machine fault CP 1 Green led ON Red ON Phase missing Green led ON Red Flashing gt Reverse phase Green led ON Red OFF OK 06 2010 Page 14 2200 7800 02 Chapter 5 Maintenance A Introduction A Before carrying out any maintenance ensure that the compressor has been locked out and tagged out from all power sources The below maintenance table is relating to standard working conditions Parameters like particular temperature humidity dust chemical environment might significantly impact the component lifetime So in such particular conditions the maintenance table has to be adapted in the field The Original Parts are designed to ensure maintain and safeguard the efficiency of the compressor and protect the machine guaranteeing its long life Regular replacement of fluid air and separator filters with Original Parts is the only way to ensure better quality air and minimal operating costs The first equipment fluid offers maximum performance and protection with its strong resistance to oxidation top protection from rust and wear and o
35. ing Connect the evacuation pipe to the condensate collector Fig 3 D Start up 1 Preparing for start up After carrying out all the checks stipulated in Chapter 3 follow the instructions BEFORE ANY MAINTENANCE WORK IS CARRIED OUT THE MACHINE AND THE DRYER MUST BE TURNED OFF ENSURE THAT THE COMPRESSOR HAS BEEN LOCKED OUT AND TAGGED OUT FROM ALL POWER SOURCES 2 Stopping and starting Activate the dryer before starting the air compressor so that it can reach the desired dew point Only in this way will there not be any condensation water in the compressed air circuit The dryer must remain in operation for the whole time that the air compressor is running IMPORTANT If the dryer is stopped wait at least 5 minutes before restarting it to allow the pressure to be balanced Stopping the dryer is carried out by pushing the dryer control button DEPRESSURISATION PROCEDURE Proceed in the following manner Stop the unit Close the insulation valve at the unit s outlet Open the right hand front door Depressurize the unit by pressing the yellow condensate evacuation button located on the bleed system Rep 1 Fig 3 E Maintenance BEFORE CARRYING OUT ANY MAINTENANCE ENSURE THAT THE COMPRESSOR HAS BEEN LOCKED OUT AND TAGGED OUT FROM ALL POWER SOURCES Page 5 1 Periodic maintenance 4 Shutting off the machine These maintenance intervals are recommended for well ventilated If the machin
36. ing element outlet temperature _ A Psi 95 12 e Press arrow key 3 the actual compressor element temperature appears Warning screen element outlet temperature Page 7 Ol ie SE 222 8 The screen shows that the temperature at the outlet of the compressor element is 222 8 F e It remains possible to scroll through other screens using keys 3 and 5 to check the actual status of other parameters e Press button 1 to stop the compressor and wait until the compressor has stopped e Switch off the voltage inspect the compressor and remedy e The warning message will disappear as soon as the warning condition disappears 3 5 3 Dew point temperature For compressors with Integrated dryer e If the dew point temperature exceeds the warning level not programmable alarm LED 4 will light up and the related pictograph will appear flashing Main screen with warning dew point temperature e Press arrow key 3 until the actual dew point temperature appears Warning screen element outlet temperature The screen shows that the dew point temperature is 48 2 F e It remains possible to scroll through other screens using keys 3 and 5 to check the actual status of other parameters e Press button 1 to stop the compressor and wait until the compressor has stopped e Switch off the voltage inspect the compressor and remedy e The warning message will disappear as soon as the warning condition disappears
37. lter on the machine s ventilation inlets TECHNICAL CHARACTERISTICS STANDARD MACHINES FAD cim 90 84 74 iii 99 94 130 122 109 Residual quantity of fluid ppm 3 66 Noise level at Im dB A Dimensions inch without dryer Lxlxh 53 x 30 x 48 Dimensions inch with dryer Lxlxh 73 x 30 x 48 Weight without dryer 948 Weight with dryer Ib 1021 1041 1076 06 2010 2200 7800 02 Page 2 QGS 60 Hz Motor power kW hp 15 20 18 5 25 22 30 Voltage 208 3 60 Nominal current A Power supply cable AWG Section mm2 L 7m 23ft maximum Upstream fuses Type J or RK Voltage 230 3 60 Nominal current A Power supply cable AWG Section mm2 L 7m 23ft maximum Upstream fuses Type J or RK Voltage 460 3 60 Nominal current A Power supply cable AWG Section mm2 L 7m 23ft maximum Upstream fuses Type J or RK Voltage 575 3 60 Nominal current A Power supply cable AWG 4x4 4x4 4x2 Section mm2 L 7m 23ft maximum 4x25 4x25 4x2 Upstream fuses Type J or RK 30 MACHINE WITH DRYER MUST BE CONNECTED TO TWO DIFFERENT POWER SUPPLIES THREE PHASE OR SINGLE PHASE SUPPLY FOR THE COMPRESSOR SINGLE PHASE SUPPLY FOR THE DRYER DRYER 60 Hz Motor power kW hp 0 5 0 75 Power supply cable AWG 3x14 Section mm2 L 7m 23ft maximum 3x2 5 Upstream fuses Type J or RK 8 IMPORTANT A COPY OF THE WIRING DIAGRAMS CAN BE FOUND INSIDE THE ELECTRIC BOARD OF THE COMPRESSOR AND A COPY CAN BE FOUND I
38. n press enter key 1 The possible settings are lt C gt and lt F gt the actually used unit is shown e Press enter key 1 unit start blinking and use arrow keys 2 and 3 to select another unit of temperature e Press enter key 1 to program the new unit of temperature and press reset key to return to the parameter screens 3 23 Calling up modifying unit of pressure Control panel Starting from the Main screen e Press arrow key 2 until lt P O gt and the possible settings are shown lt Mpa gt lt psi gt and lt bar gt press enter key 1 and the actually used unit is shown e Press enter key 1 unit starts blinking and use arrow keys 2 and 3 to select another unit of pressure e Press enter key 1 to program the new unit of pressure and press reset key to return to the parameter screens 3 24 Activating automatic restart after voltage failure Description This parameter accessible in screen lt P 08 gt can only be modified after entering a code Consult us if this function should be activated Page 23 3 25 Selection between Y D or DOL starting Control panel Starting from the Main screen e Press arrow key 2 until lt P 09 gt and the motor pictograph is shown and then press enter key 1 The actually used starting mode is shown lt Y d gt for Y D star delta or lt doL gt for DOL direct on line e This parameter can only be modified after entering a code Consult us if
39. n screw compressor lubricated with fluid 2 An electric motor 3000 rpm 50Hz or 3600 rpm 60Hz short circuit rotor voltage 380 415 V 50Hz or 208 230 460 575V 60Hz according to type Star delta starting A V Belt and pulley system An air fluid receiver complying to current regulation Start stop flow rate control by suction closing A A A lubrication system using the differential pressure of the circuit which avoids the need for an fluid pump 8 An fluid separation system by means of a separator cartridge 9 A heat exchanging system fluid and compressed air cooler with forced ventilation 10 A dry type air filter 11 An fluid filter 12 A command and control electronic board 13 INFOLOGIC controller as standard 2200 7800 02 Safety devices 1 A safety valve mounted on the fluid receiver An thermal protection device for the motor located in the starting cubicle to protect the motor from excessive over load 3 A air temperature sensor that stops the compressor when the temperature rises abnormally or during an fluid cooling defect 4 A pressure sensor that stops the compressor in order to prevent any excessive rise in pressure Control devices 1 A minimum pressure valve located at the fluid tank outlet just beyond the fluid separator which guarantees minimum pressure in the lubrication circuit 2 Automatic draining allowing the unit to be exposed to th
40. ol panel Control panel Scroll keys 2 and 3 can be used to scroll through all screens The screens are divided into register screens measured data screens digital input screens numbered as lt d in gt lt d 01 gt parameter screens numbered as lt P 01 gt lt P 02 gt protections screens numbered as lt Pr 0 1 gt and test screens numbered as lt t 01 gt During scrolling the numbers of the screens appear consecutively For most screens the unit of measurement and the related pictograph are shown together with the screen number In the event of a warning or a shut down the corresponding pictograph is blinking on the main screen Example The screen shows the screen number lt d 0 gt the unit used lt hrs gt and the related pictograph for running hours Press enter key 1 to call up the actual running hours In the event of a warning or a shut down the corresponding pictograph is blinking on the main screen Page 11 3 8 2 Overview of the screens na Designation Related topic Digital input screen Digital input status Running hours hrs or xl 000 hrs See section Calling up running hours Motor starts x 1 or xl 000 See section Calling up motor starts Module hours hrs or x1 000 hrs See section Calling up module hours Loading hours hrs or x 1000 hrs See section Calling up loading hours Load relay xl or xl 000 See section Calling up load relay Service t
41. ont panel Check the cleanliness of the filter every week and change it if necessary 06 2010 Page 16 IMPORTANT If you do not replace the filtering element when needed permanent dirt build up will result This reduces the air inflow to the compressor and could damage the fluid separator and the compressor Fig 11 Air filter C Turbine Replacement of the complete fan is recommended if one or more blades are deformed or broken If replaced check the fan rotation direction reversal of the rotation direction will reduce machine cooling D Fluid and air cooler The alluminium fluid and air cooler is a vital part in the compressor system Please take care of this element To prevent the nest of tubes from being deformed or damaged when assembling or disassembling the cooler unions and hoses the cooler sleeves must be kept rotating by means of a wrench The outer surface of the nest of tubes must always be kept clean in order to enable proper heat transfer In the event of a leak the source of the leak must be detected In order to do this Stop the Compressor Clean the greasy areas Look for leaks using conventional means soap solution E Fluid separator cartridge Fig 12 see B Chapter 1 The life time of the fluid separator cartridge will depend on the purity of the intake air the regular fluid filter replacements the quality of the fluid used the care taken when draining the condensation
42. ptimal internal cleaning The maintenance period is limited to several essential operations It is strongly recommended that the power supply be cut off during any adjustment or repair The summary on the Compressor instrument panel shows at a glance the type and periodicity of operations to be carried out for T the compressor to function correctly Operations to be carried out Parts E E EO Weekly 20 Mee 2000h 150h 500 h Service A 4 000 h or 2 years 8 000 h or 3 years Ever Ever y y Observations Service B Service C EE x pert a from the cold fluid circuit PES X cing Final coolant elements Cleaning eee Is Daily Check Weekly Check Pressure point Fluid level Fluid level Check drain Temperatures Suction filter Service and maintenance interval Service A B A B A B A D Operating hours Check belt tension Control measured parameters Change air filter ubricant change Change oil filter ilter panel Oil separator Change belts Condenser cleaning hermostatic valve kit IEI AIE Unloader valve kit Minimum pressure valve kit Check valve kit F Retighten all power cable connections C A SS EA Oil check valve kit NE ae PN AS E Tao Hoses Power connections tightening Compressor element J 141 T Service interval 2 000 hours or every 1 year Service interval 4 000 hours or 2 years Service interval 8 000 hours
43. red values and programmed parameters Key to reset the service timer a shut down condition etc or to return to a previous display Voltage on LED green Indicates that the voltage is switched on Pictograph General alarm LED red Is ht if a warning condition exists Flashes in the event of a shut down or emergency stop condition such as phase sequency relay w out pictograph thermal relay main motor w out pictograph jumo thermo switch w out pictograph emergency stop w pictograph temperature sensor element TS 1 outlet disconnected w pictograph pressure transmitter PS1 disconnected w Pictograph Indicates that the regulator is automatically controlling the compressor the compressor is loaded unloaded stopped and restarted depending on the air consumption and the limitations programmed in the regulator The LED is lit during automatic operation and flashes when the unit is remotely controlled Pictograph Automatic operation Key to scroll downwards through the screen or to decrease a setting Key to scroll upwards through the screens or to increase a setting Pictograph Remote operation Page 5 3 2 Display Description Normally display 1 shows o The compressor status by means of pictographs o The air outlet pressure o The actual temperature at the compressor element outlet o The dew point temperature for compressors with incorporated dryer option The display also
44. row key 2 until lt P 01 gt is shown and then press enter key 1 The actually used control mode is shown lt LOC gt for local control lt rE gt for remote control or lt LAn gt for LAN control e Press enter key 1 and if necessary enter the password The actually control mode is blinking Use keys 2 and 3 to change the control mode e Press enter key 1 to program the new starting mode or press reset key to cancel 3 18 Calling up modifying node ID for LAN control Control panel Page 19 Starting from the Main screen e Press arrow key 2 until lt P 02 gt is shown and then press enter key 1 The actually used node ID is shown e Press enter key 1 and if necessary enter the password The actually used node ID is blinking Use keys 2 and 3 to change the node ID e Press enter key 1 to program the new node ID or press reset key to cancel 3 19 Calling up modifying pressure band settings Control panel Starting from the Main screen e Press arrow key 2 until lt P 03 gt is shown and then press enter key 1 Pressure band 1 lt Pb 1 gt is shown on the display key 2 can be used to scroll to pressure band 2 lt Pb 2 gt e Press enter key 1 on desired pressure band The load level of the selected pressure band appears key 2 can be used to scroll to the unload level Loading pressure Page 20 Unloading pressure e Press enter key 1 to modify the load level value star
45. rvice Label 2202965800 20 25 Hp 2202965900 30 Hp 1 1 1 2202261 000 ii ONLY FOR DRYER VERSION 12 1 See BOM Label voltage 13 1 1079990609 Inside Cubicle Door 14 1 16220561900 On base frame 15 1 2202260791 Direction Arrow 16 1 1088100102 17 1 2202967301 QGS 20 TRIV 1 2202967302 QGS 25 TRIV 1 2202967303 QGS 30 TRIV 1 2202967307 QGS 20 575V 1 2202967308 QGS 25 575V 1 2202967309 QGS 30 575V 1 8 1 2202967306 x ONLY FOR DRYER VERSION 19 1 2202967304 Fuses TRI V UL 1 2202967310 Fuses 575V UL 20 1 2202261192 2200 7800 02 F Electronic board The unit is equipped with an INFOLOGIC electronic controller See the specific instructions SECTION II for a description of the electronic controller together with operating instructions at the end of this manual 06 2010 2200 7800 02 Page 9 Chapter 2 Installation A Handling The compressor must always be handled with care It may be lifted either with a forklift truck or by means of a travelling crane In the latter case precautions must be taken so as not to damage the unit s canopy B Room The compressor is designed to operate in a frost free environment supplied with air at a temperature lower than 104 F The premises must be well ventilated and as close as possible to the place where the compressed air is used A space must be left around the unit for cleaning and maintenance purposes in accordance with NEC or local regulations w
46. ry evaporator The air to dry is conveyed to the exchanger in which the water vapor is condensed the water from the condensation is collected in the separator and removed to the exterior A Technical data 1 Technical features TYPE MAX POWER COOLING NOMINAL NOMINAL TOTAL Intake WEIGHT ed POWER POWER e POWER Ib LIQUID LOAD W W psi R 404A lb EREI o Pia fia fre o SoS o Reference conditions Service conditions Room temperature 77 F Maximum room temperature 113 F Air intake temperature 95 F Minimum room temperature 39 F Service pressure 101 psi Maximum air intake temperature 131 F Dew point under pressure 37 F Maximum operational pressure 188 psi Page 2 Exploded views fig 1 A7 SQ la E N Dh N A yy A A K J N NY E Pa IN TYPE Air intake Air exhaust Water removal from condensation Reference Description Reference Description Coolant filter Page 3 Cooling compressor Condenser Fan Evaporator Condensate separator Hot gas by pass valve Pressure switch Condensate bleed solenoid valve Condensate outlet pipe B Operation 1 Operation principle see Fig 2 The gaseous cooling fluid coming from the evaporator 4 is sucked by the cooling compressor 1 m order to be compressed and then cooled in the condenser 2 this enables its condensation if necessary with the help of t
47. s lt Sd L gt e A high shut down level shown on the display as lt Sd H gt Example of protection screen Starting from the Main screen Page 277 e The warning level for the high temperature warning level lt AL H gt and the high temperature shut down level lt Sd H gt Use scroll keys 2 and 3 from the warning level to the shut down level press enter key 1 to modify the value e The value appears on the display e Press enter key 1 to modify the value e An optional password may be required the value starts blinking and arrow keys 2 and 3 can be use to modify the value e Press enter key 1 to program the new value press reset key to cancel Programmable settings can only be modified within allowed limits 3 30 Test screens Display test Starting from the Main screen e Press arrow key 2 until lt t 01 gt is shown and then press enter key 1 Safety valve test In the test screen lt 02 gt a safety valve test is provided The safety valves can only be tested after entering a code Consult us 1f the safety valves are to be tested Page 28 NOTES Page 29 Instruction Manual EN Dryers Type PLUS A7 A A A A A A AN Before carrying out any maintenance ensure that the compressor has been locked out and tagged out from all power sources ORIGINAL PART Page 1 Integrated dryer The A7 integrated dryer is a direct expansion refrigeration machine with a d
48. served defects Possible causes Solutions 1 The air does not pass through to the The interior tubes are blocked by frost Check that the hot gas by pass valve is dryer s outlet correctly adjusted and in good working order 2 There is condensed water in the circuit a The operation of the water separator a Check that the condensation separator bleed valve works properly b Check correct operation of the dryer b The dryer is operating in bad condensation conditions and its fan 3 Continuous leak of air and water from Defective automatic condensation bleeding Check the system the condensation separator system 4 The top of the dryer s compressor is a See 2b h 131 F E bles SR very hot gt 131 F b The refrigeration circuit does not Check all coolant gas leaks work with the correct amount of gas Refill the coolant gas 5 The motor works intermittently See 2b because of the protection thermostat See 4 6 The dryer s motor groans but will a Defective electrical connections a Check the condition and tightness of not start the electrical connections b You have stopped and restarted the dryer without waiting for the pressure readjustment c The dryer motor starting system is defective b Wait a few minutes before restarting the dryer c Check the operation of the relay and the operation of the condensers and engine start up possible 7 The dryer has stopped and will not a
49. shows all measured and programmed parameters see section Scrolling through all screens 3 3 Pictographs used on the screen Pictographs Compressor status LOAD during loaded running the horizontal arrow flashes Compressor status UN LOAD LOAD and UNLOAD indication Element outlet temperature Dew point temperature Motor or motor overload or order of phases if on option Emergency stop pressed Service pictograph LAN control or network setting Page 6 3 4 Main screen Procedure When the voltage is switched on the Main screen is shown automatically showing in short the operation status of the compressor and the outlet pressure Main screen typical example The screen shows that the compressor is running loaded the horizontal arrow flashes and that the outlet pressure is 6 8 bar e Always consult us if lt est gt appears on the display Also consult section Scrolling through all screens 3 5 Shut down warning 3 5 1 Description A shut down warning will appear in the event of e Too high a temperature at the outlet of the compressor element e Too high a dew point temperature for compressors fitted with this option 3 5 2 Compressor element outlet temperature 1 5 4 3 e If the outlet temperature of the compressor element exceeds the shut down warning level 105 C 221 F alarm LED 4 will light up and the related pictograph will appear flashing Main screen with warn
50. the parameter is to be changed 3 26 Calling up modifying load delay time Control panel Starting from the Main screen e Press arrow key 2 until lt P 10 gt and the compressor load pictograph is shown and then press enter key 1 Page 24 2 lt S gt A A e This screen shows the load delay time 10 and the unit lt s gt seconds To modify this value press enter key 1 e An optional password may be required the value starts blinking and arrow keys 2 and 3 can be used to modify the value e Press enter key 1 to program the new value press reset key to cancel 3 27 Calling up modifying minimum stop time Control panel Starting from the Main screen e Press arrow key 2 until lt P 11 gt and the motor pictograph is shown and then press enter key 1 LJ lt S gt 10 e This screen shows the minimum stop time 10 and the unit lt s gt seconds To modify this value press enter key 1 e The value starts blinking and arrow keys 2 and 3 can be used to modify this value e Press enter key 1 to program the new value 3 28 Activating password protection Control panel Important settings such as the setting of the service timer pressure band setting control mode settings can be protected by a password Page 25 Starting from the Main screen e Press arrow key 2 until lt P 12 gt and press enter key 1 e Password lt PASS gt appears on the screen Press enter key I
51. ts blinking A password may be required Use keys 2 and 3 to change the load pressure e Press enter key 1 to program the new values or press reset key to cancel 3 20 Modifying pressure band selection Control panel Starting from the Main screen e Press arrow key 2 until lt P 04 gt is shown and then press enter key 1 The active pressure band 1 lt Pb gt is shown on the display e Press enter key 1 to modify the pressure band selection a password may be required The active pressure band lt Pb 1 gt starts blinking Main screen e Press key 2 to modify the active pressure band Press enter key 1 to confirm or reset key to cancel Page 21 3 21 Calling up modifying service timer setting Control panel Starting from the Main screen e Press arrow key 2 until lt P 05 gt is shown and then press enter key 1 the setting of the service timer is shown in lt hrs gt hours or lt x 1000 hrs gt hours x 1000 Example lt 4000 hrs gt means the timer is set at 4000 running hours e Press enter key 1 to modify this value a password may be required the value blinks Use arrow keys 2 and 3 to modify this setting e Press enter key 1 to program the new value and to return to the parameter screens 3 22 Calling up modifying unit of temperature Control panel Page 22 Starting from the Main screen e Press arrow key 2 until lt P 06 gt is shown and the
52. witch on the voltage and restart the compressor Page 9 3 7 Service warning 3 7 1 Description A service warning will appear when the service timer has reached the programmed time interval 4 3 2 e If the service timer exceeds the programmed time interval alarm LED 3 will light up e Press arrow key 2 to scroll to lt d06 gt and the service symbol is shown Press key 1 the actual reading of the service timer appears and is shown in lt hrs gt or lt A000 hrs gt if the service timer value is higer than 9999 Example of service timer screen The screen shows that the reading of the service timer is 4002 e Press arrow key 2 to scroll to lt d01 gt and the running hours symbol is shown Press key 1 the actual reading of the service timer appears and is shown in lt hrs gt or lt xl 000 hrs gt if the service timer value is higer than 9999 Example of service timer screen e Stop the compressor switch off the voltage and carry out the service actions See section Preventive maintenance schedule e The longer interval service actions must aiso include the shorter interval actions In the example above carry out ail service operations belonging to the 8000 running hours interval as well as those belonging to the 4000 running hours interval e After servicing reset the service timer See section Calling up resetting service timer Page 10 3 8 Scrolling through all screens 3 8 1 Contr
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