User Manual - ThePowerSite.co.uk
Contents
1. AN S AN NV U 5 a ERY amp n 7 3 PART LOCATIONS gt pa DIRECT COMPRESSED AIR OUTLET TANK PRESSURE REDUCER BELT GUARD COMRESSOR UNIT ELECTRIC MOTOR PRESSURE SWITCH PRESSURE GUAGE PIVOT WHEEL CONDENSATE DRAIN WHEEL CHECK VALVE PAGE 8 Rev 2 4 SPECIFIC SAFETY Read and understand all of the operating instructions safety precautions and warnings in the Instruction Manual before operating or maintaining this compressor Most accidents that result from compressor operation and maintenance are caused by the failure to observe basic safety rules or precautions An accident can often be avoided by recognizing a potentially hazardous situation before it occurs and by observing appropriate safety procedures2. HYUNDAI ELECTRIC AIR COMPRESSOR Models HY3050 HY30100 amp HY3150 aa SSS ra Rm ga bli TE I ja 18 3 pm GP o Wi ti 11 V m M ai User Manual Licensed by Hyundai Corporation Korea TITLE 1 SAFETY 2 PARTS 3 APPLICATION 4 INSTALLATION INSTRUCTIONS 5 ADDITIONAL SAFETY 6 INSTALLATION amp COMISSIONING 7 TECHNICAL DATA 8 CLEANING amp MAINTENANCE 9 DISPOSAL amp RECYCLING 10 TROUBLLESHOOTING 11 GENPOWER CONTACT DETAILS 12 DECLARATIONS of CONFORMITY CONTENTS PAGE 2 PAGE No 4 5 6 8 9 10 11 11 12 12 13 14 15 Rev 2 er 1 SAFETY A 1 1 The operator of the machine 1 1 1 Is responsible for and has a duty of care in making sure that the compressor is operated safely and in accordance with the instructions in this user manual 1 1 2 Should never leave it in a condition which would allow an untrained or unauthorised person s to operate this compressor 1 1 2 1 Should take care and show due diligence for the safety of and with regard to those around whilst using the machine to include but not limited to 1 1 2 1 1 Elderly children pets livestock and property 1 2 Some or all of the following PPE Warning Signs and symbols may appear throughout this manual and you must adhere to their warning s Failure to do so May result in personal injury Personal Protective clothing PPE N DANGER WARNING
3. Basic safety precautions are outlined in the SAFETY section of this Instruction Manual and in the sections which contain the operation and maintenance instructions Hazards that must be avoided to prevent bodily injury or machine damage are identified by WARNINGS on the compressor and in this Instruction Manual Never use this compressor in a manner that has not been specifically recommended by manufacturer unless you first confirm that the planned use will be safe for you and others SAFETY IMPORTANT SAFETY INSTRUCTIONS FOR USE OF THE COMPRESSOR AN WARNING Death or serious bodily injury could result from improper or unsafe use of compressor To avoid these risks follow these basic safety instructions READ ALL INSTRUCTIONS 4 1 Never touch moving parts Never place your hands fingers or other body parts near the compressor s moving parts 4 2 Never operate without all the guards in place Never operate this compressor without all guards or safety features in place and in proper working order If maintenance or servicing requires the removal of a guard or safety features be sure to replace the guards or safety feature before resuming operation of the compressor 4 3 Always wear eye protection Always wear safety goggles or equivalent eye protection Compressed air must never be aimed at anyone or any part of the body 4 4 Protect yourself against electric shocks Prevent body contact with grounded surfaces such as pipes radiator
4. 10156 Torino Calculated Sound Power Level 95 06 dB A Guaranteed Sound Power Level 97dB A A copy of this certificate has been submitted to the European Commission and to EU Member State United Kingdom Place of Declaration Pembroke Dock 5A72 4RW Date 29th May 2015 Signed by Kevin Stanley Position in Company Product Manager Name and address of manufacturer or Authorised representative Genpower Ltd Isaac Way Pembroke Dock Pembrokeshire 5472 4RW PAGE 21 Rev 2 PAGE 22 Rev 2 PAGE 23 Rev 2 GENPOWER LTD Isaac Way London Road HY Li DAI Pembroke Dock UNITED KINGDOM SA72 ARW T 44 0 1646 687 880 F 44 0 1646 686 198 E info hyundaipowerequipment co uk www hyundaipowerequipment co uk
5. 4 13 Outdoor extension leads When compressor in used outdoors use only extension leads intended for use outdoors and so marked 4 14 Stay alert Watch what you are doing Use common sense DO NOT operatecompressor when you are tired Compressor should never be used by you if you are under the influence of alcohol drugs or medication that makes you drowsy 4 15 Check for damaged parts and air leaks Before using the compressor if a guard or other part is damaged it should be carefully checked to determine that it will operate properly and perform its intended function Check for alignment of moving parts binding of moving parts breakage of parts mounting air leak and any other conditions that may affect its operation A guard or other part that is damaged should be properly repaired or replaced by an authorised service center unless otherwise indicated elsewhere in this instruction manual Have defective pressure switches replaced by authorised service center DO NOT use compressor if switch does not turn it on and off 4 16 Handle compressor correctly Operate the compressor according to the instructions provided herein Never allow the compressor to be operated by children individuals unfamiliar with its operation or unauthorised personnel 4 17 Keep all screws bolts and covers tight and in place Keep all screws bolts and covers tightly mounted Check their condtion periodically 4 18 Keep motor vent clean The motor air vent must be k
6. AN CAUTION N NOTE DANGER indicates a WARNING indicates a CAUTION indicates a NOTE indicates a hazard which if not hazard which if not hazard which if not situation that could avoided could result in avoided could result in avoided might result easily result in serious injury or death serious injury or death in minor or moderate equipment damage injury E i EXPLOSION KICKBACK 3 HOSES UNDER HOT SURFACE FLYING OBJECTS SLIPPERY FALL MOVING PARTS PRESSURE ER DO NOT OPEN RISK OF ACCIDENTAL GOGGLES WHEN IN USE START UP PAGE 3 Rev 2 1 3 Electrical Safety 1 3 1 Electricity can kill never work on LIVE ENERGISED equipment 1 3 2 Identify electrical isolation method and always isolate all electrical supplies prior to carrying out any maintenance work 1 3 3 Prior to use and with all electrical supplies isolated check all electrical cables plugs and connections for the following 1 3 3 1 Are intact and have no signs of damage to include but not limited to bare wires chaffing cuts and loose wiring If there are any signs of damage the damaged item should be taken out of service until the damage has been repaired by an electrically competent person 1 3 4 All trailing cables should be routed so as not to cause any kind of trip hazard 1 5 Never work on or near electricity with wet hands wet clothing and wet gloves 1 6 PAGE 4 Rev 2 USAGE INSTRUCTION 2 UNPACKING
7. MAINTENANCE N NOTE The information contained in this Instruction Manual is designed to assist you in the safe operation and maintenance of the compressor Some illustrations in this Instruction Manual may show details or attachments that differ from those on your own compressor 5 1 Installation 5 1 1 Remove the compressor from its packing fig 1 makes sure it is in perfect condition checking if it has been damaged during transport and carry out the following operations 5 1 2 Fit the wheels and rubber tab on the tanks on which they are not already fitted observing the instructions in fig 2 In case of infiatable wheels the maximum inflation pressure must be of 1 6 bar 24 psi 5 1 3 Position the compressor on a flat surface or with a maximum permissible inclination of 10 fig 3 in a well aired place protected against atmospheric agents a and not in a place subject to explosion hazard 5 1 4 If the surface is inclined and smooth check if the compressor moves while in operation if it does secure the wheels with two wedges 5 1 5 If the surface is a bracket or a shelf top make sure it cannot fall securing it in a suitable way 5 1 6 To allow for good ventilation and efficient cooling the compressor s belt guard must be at least 100 cm from any wall fig 4 5 1 7 Compressors fitted on the tank with fixed feet should not be rigidly secured to the ground In this case we advise you to fit 4 anti vibration supports 5 2 Ins
8. Tandem compressors with timed control unit fig 17 5 8 1 Fit the plug in the power socket fig 13 and turn the pressure switch to position ON Turn the master power switch A on the control unit to position power On is signalled by white indicator light E going on 5 6 2 Turn switch B to start the compressor 5 6 2 1 Pos 1 pumping element n 1 only is operating 5 8 2 2 Pos 2 pumping element n 2 only is operating 5 6 2 3 Pos 3 both pumping elements are operating simultaneously at staggered starting times 5 9 3 The compressor is fully automatic and is controlled by the pressure switch which stops it when tank pressure reaches maximum value and restarts it when it falls to minimum value The head cylinder delivery tube unit can reach high temperatures Take care when working near these parts and do not touch them to avoid possible burns fig 18 19 IMPORTANT The electro compressors must be connected to a power socket protected by a suitable differential switch thermal breaker The motor of GM TR compressors is equipped with an automatic thermal breaker located inside the winding this stops the compressor when motor temperature reaches excessively high values If the breaker is tripped the compressors restarts automatically after 10 to 15 minutes The motors of compressor models VX are supplied with a manually resetting automatic amperometric thermal breaker located outside the terminal board cover When the
9. breaker is tripped wait for a few minutes and then reset the breaker manually fig 20 The motors of the AB series compressors are supplied with a manually resetting amperometric thermal breaker located on the terminal board cover When the breaker is tripped wait for a few minutes and then reset the breaker manually fig 20 The safety davice is automatic in three phase and silent compressors When the thermal breaker is tripped the pressure switch is released to O OFF position Wait for a few minutes and return the pressure switch to I ON position with the exception of models AB 100 245 335 Three phase AB 150 245 335 Three phase AB 200 245 335 Three phase For compressors supplied with a control unit the thermal breaker is installed inside the control unit When the thermal breaker is tripped observe the following procedure fig 22 e Turn the switches on the control unit cover to position 0 open the cover and press push button 1 of the thermal breaker Close the cover of the control unit and restart the compressor observing the operations described in the paragraph Starting compressors with control unit The same instructions apply to compressors powered at 60 Hz 5 9 Adjusting the operating pressure fig 23 5 9 1 You do not have to use the maximum operating pressure at all times On the contrary the pneumatic tool being used often requires less pressure On compressors supplied with a pressure reducer
10. operating pressure must be correctly adjusted 5 9 2 Release the pressure reducer knob by pulling it up adjust pressure to the required value by turning the knob clockwise to increase pressure and anti clockwise to reduce it 5 9 3 When you have obtained optimum pressure lock the knob by pressing it downward fig 23 For pressure reducers equipped without a pressure gauge the set pressure can be seen on the graduated scale located on the reducer body PAGE 15 Rev 2 5 10 Tandem compressors with timed control unit fig 17 5 10 1 Fit the plug in the power socket fig 13 and turn the pressure switch to position ON Turn the master power switch A on the control unit to position power On is signalled by white indicator light E going on 5 10 2 Turn switch B to start the compressor 5 10 2 1 Pos 1 pumping element n 1 only is operating 5 10 2 2 Pos 2 pumping element n 2 only is operating 5 10 2 3 Pos 3 both pumping elements are operating simultaneously at staggered starting times 5 10 3 The compressor is fully automatic and is controlled by the pressure switch which stops it when tank pressure reaches maximum value and restarts it when it falls to minimum value The head cylinder delivery tube unit can reach high temperatures Take care when working near these parts and do not touch them to avoid possible burns fig 18 19 IMPORTANT The electro compressors must be connected to a power socket protected by a suit
11. trouble is poor tightness of the check valve take the following action fig 31 Air losses Carefully clean both the rubber disk B and its seat Refit all parts accurately These can be caused by poor tightness of a union check all unions wetting them with soapy water Compressor tums but does notload O O S O Coaxial compressors fig 32 GM 203 compressors This may be due to failure of the valves C1 C2 or of a seal B1 2 Pulley drive compressors fig 33 this may be due to failure of the valves F1 and F2 or of a seal D1 D2 replace the damaged part This may be due to the breakage of the valves C1 C2 or of the gasket B1 Replace the damaged part fig 164 Check if there is too much condensate water inside the tank Does mains power match that of the data plater fig 14 Are power cable extensions of adequate diameter or length A Ti 7 Compressor no starting If the Is the work environment too cold under C compressor has trouble starting check the following Compressor nat stopping IMPORTANT For series VX AB was the thermal breaker tripped fig 201 in the silent series fig 21 Is there oil in the housing to ensure lubrication fig 11 15 power supplied to the electrical liner sockets well connected thermal breaker fuses in good condition If the compressor does not stop when maximum pressure is reached the tank safety valve comes into op
12. ON Model Voltage V Number of phases Frequency Hz Connection method Cable length m Motor power hp kw Rated Speed motor RPM Maximum Pressure PSi Bar Cut out Pressure PSi Bar Cut in Pressure PSi Bar Tank Capacity L Free air delivery CFM L min Displacement CFM L min Air Outlet Output pressure regulation type Drive type Overall Unit Dimensions L x W x H mm Net Weight kg Tank material 7 WIRING DIAGRAMS HY3050 230 1 50 3 pin plug BS1363A 3 2 25 2800 145 10 128 8 8 87 6 50 9 255 13 368 Valve Tap Fixed Belt 1010 x 360 x 730 55 Rolled steel HY3150 230 1 50 3 pin plug BS1363A 3 2 25 2800 145 10 128 8 8 87 6 150 9 255 13 368 Valve Tap Fixed Belt 1350 x 540 x 1040 107 Rolled steel Manual amperometric protection switch 7 1 Symbols A Power supply Pressure switch T Automatic thermal protection switch TM 1 2 3 4 Wire connection terminals C Condensor Capacitor M Motor AU Auxiliary winding AM Start winding L Live N Neutral Earth Earth 230V 50Hz 230V 50Hz PAGE 20 Earth HY30100 230 1 50 3 pin plug BS1363A 3 2 25 2800 145 10 128 8 8 87 6 100 9 255 13 368 Valve Tap Fixed Belt 1100 x 400 x 830 64 Rolled steel Rev 2 7 GENPOWER CONTACT DETAILS 7 1 Postal address Genpower Limited Isaac Way Pembroke Dock Pembrokeshire
13. SA72 4RW UK 7 2 Telephone and Fax contact numbers Office 44 0 1646 687880 Fax 44 0 1646 686198 7 3 Email contact Techinical service genpower co uk 7 4 Web site www hyundaipowereguipment co uk 8 DECLARATIONS of CONFORMITY 8 1 Genpower Ltd confirms that this Hyundai product conform to the following CE directives 2004 108 EC EMC Directive 2006 42 EC Machinery Directive 2006 95 EC Low Voltage Directive 2009 105 EC Simple Pressure Directive 2000 14 EC Outdoor Noise Directive EC DECLARATION OF CONFORMITY The undersigned as authorised by Genpower Ltd Declares that the following equipment manufactured under licence by Hyundai Korea Conforms to the Directive 2000 14 EC as amended of the European Parliament and of the council on the approximation of the laws of the Member States relating to the noise emission in the environment by equipment for use outdoors Equipment Category Compressor Product Name Model Hyundai HY3050P HY30100P HY31505 Type Serial No HY3050P Electric Direct Drive 50L Air Compressor HY30100P Electric Direct Drive 100L Air Compressor HY31505 Electric Direct Drive 150L Air Compressor Net installed power 3hp The technical documentation is kept by Kevin Stanley Genpower Ltd Isaac Way Pembroke Dock Pembrokeshire 5472 4RW The conformity assessment procedure followed was in accordance with annex V of the Directive Verified Body Eurofins TECH 5 r 1 nr ld CE0477 Via Cuorgne 21
14. able differential switch thermal breaker The motor of GM TR compressors is equipped with an automatic thermal breaker located inside the winding this stops the compressor when motor temperature reaches excessively high values If the breaker is tripped the compressors restarts automatically after 10 to 15 minutes The motors of compressor models VX are supplied with a manually resetting automatic amperometric thermal breaker located outside the terminal board cover When the breaker is tripped wait for a few minutes and then reset the breaker manually fig 20 The motors of the AB series compressors are supplied with a manually resetting amperometric thermal breaker located on the terminal board cover When the breaker is tripped wait for a few minutes and then reset the breaker manually fig 20 The safety davice is automatic in three phase and silent compressors When the thermal breaker is tripped the pressure switch is released to O OFF position Wait for a few minutes and return the pressure switch to I ON position with the exception of models AB 100 245 335 Three phase AB 150 245 335 Three phase AB 200 245 335 Three phase For compressors supplied with a control unit the thermal breaker is installed inside the control unit When the thermal breaker is tripped observe the following procedure fig 22 e Turn the switches on the control unit cover to position O open the cover and press push button 1 of the th
15. ept clean so that air can freely flow at all times Check for dust build up frequently 4 19 Always operate compressor at its rated voltage Operate the compressor at voltages specified on their nameplates If using the compressor at a higher voltage than the rated voltage it will result in abnormally fast motor revolution and may damage the unit and burn out the motor 4 20 Never use a compressor which has defects or is operating abnormally If the compressor appears to be operating unusually making strange noises or otherwise appears defective stop using it immediately and arrange for repairs by a authorised service center 4 21 DO NOT wipe plastic parts with sovents Solvents such as petrol thinners benzine carbon tetrachloride and alcohol may damage and crack plastic parts DO NOT wipe them with such solvents Wipe plastic parts with a soft cloth light dampened with soapy water and dry thoroughly 4 22 Use only genuine replacement parts Non genuine replacement parts may void your warranty and can lead to malfunction and result in injuries Genuine parts are available from your dealer 4 23 DO NOT modify the compressor DO NOT modify the compressor Always contact the authorised service center for any repairs Unauthorised modification may not only impair the compressor performance but may also result in accident or injury to repair personnel who do not have the required knowledge and technical expertise to perform the repair operations co
16. erating simultaneously at staggered starting times 5 7 3 The compressor is fully automatic and is controlled by the pressure switch which stops it when tank pressure reaches maximum value and restarts it when it falls to minimum value N NOTE The head cylinder delivery tube unit can reach high temperatures Take care when working near these parts and do not touch them to avoid possible burns fig 18 19 IMPORTANT The electro compressors must be connected to a power socket protected by a suitable differential switch thermal breaker The motor of GM TR compressors is equipped with an automatic thermal breaker located inside the winding this stops the compressor when motor temperature reaches excessively high values If the breaker is tripped the compressors restarts automatically after 10 to 15 minutes The motors of compressor models VX are supplied with a manually resetting automatic amperometric thermal breaker located outside the terminal board cover When the breaker is tripped wait for a few minutes and then reset the breaker manually fig 20 The motors of the AB series compressors are supplied with a manually resetting amperometric thermal breaker located on the terminal board cover When the breaker is tripped wait for a few minutes and then reset the breaker manually fig 20 The safety davice is automatic in three phase and silent compressors When the thermal breaker is tripped the pressure switch is released t
17. eration To repair the valve contact your nearest service centre DO NOT on any account unscrew any connection while the tank is pressurised Always check if the tank is pressure free DO NOT drill holes weld DO NOT do any jobs on the compressor unless you have disconnected the power plug or purposely deform the compressed air tank PAGE 18 Rev 2 Temperature in operating ambient 0 C 35 C DO NOT aim jets of water or inflammable liquids on the compressor DO NOT place inflammable objects near the compressor During down times turn the pressure switch to position O OFF Never aim the air jet at people or animals fig 34 DO NOTtransport the compressor while the tank is pressurised Be careful with regard to some parts of the compressor such as the head and delivery tubes as they can reach high temperatures DO NOT touch these parts to avoid burns fig 18 19 Transport the compressor lifting or pulling it with the appropriate grips or handles fig 4 6 Keep children and animals well away from the machine operating area If using the compressor for painting DO NOT work in closed environments or near to naked flames Make sure there is adequate exchange of air at the place of work Protect your nose and mouth with an appropriate mask fig 35 If the electrical cable or plug are damaged do not use the compressor and contact an authorised service centre to replace the faulty eleme
18. ermal breaker Close the cover of the control unit and restart the compressor observing the operations described in the paragraph Starting compressors with control unit The same instructions apply to compressors powered at 60 Hz 5 11 Adjusting the operating pressure fig 23 5 11 1 You do not have to use the maximum operating pressure at all times On the contrary the pneumatic tool being used often requires less pressure On compressors supplied with a pressure reducer operating pressure must be correctly adjusted 5 11 2 Release the pressure reducer knob by pulling it up adjust pressure to the required value by turning the knob clockwise to increase pressure and anti clockwise to reduce it 5 11 3 When you have obtained optimum pressure lock the knob by pressing it downward fig 23 For pressure reducers equipped without a pressure gauge the set pressure can be seen on the graduated scale located on the reducer body PAGE 16 Rev 2 5 11 4 On pressure reducers equipped with a pressure gauge pressure can be seen on the gauge itself AN WARNING Some pressure regulators do not have push to lock therefore simply turn the knob to adjust the pressure 5 12 Maintenance AN WARNING Before attempting any maintenance jobs on the compressor make sure of the following Master power switch in position O Pressure switch and the control unit switches all off in position O No pressure in the air tank 5 12 1 Every 50 hours o
19. f duty we advise you to dismantle the suction filter and clean the filtering element by blowing compressed air on it fig 24 5 12 2 It is recommended to replace the filter element at least once if the compressor operates in a clean environment but more frequently if in a dusty environment In the red head models fig 25 TR200 TR255 the suction filter is located internally under the conveying cover read head Unscrew the three cover securing screws remove the cover from the guard joint remove the filter from its seat and begin cleaning blowing compressed air in opposite to normal flow direction In the Silent model the filtering element can be replaced by taking off the soundproofing cabinet and proceeding in the same way as for the AB models fig 29A 5 12 3 The compressor generates condensate water which accumulates in the tank 5 12 4 The condensate in the tank must be drained at least once a week by opening the drain tap fig 26 under the tank 5 12 5 Take care if there is compressed air inside the cylinder and water could flow out with considerable force Recommended pressure 1 2 bar max 5 12 6 Condensate of compressors that are oil lubricated must not be drained into the sewer or dispersed in the environment as it contains oil 5 13 Oil changes and Topping up with oil 5 13 1 The compressor is filled with synthetic oil FIAC Oil Synthesis 5 13 2 We recommend a full change of oil in the pumping element within
20. nt with an original spare part f the compressor is located on a shelf or on a top above floor height it must be secured to prevent it falling while in operation DO NOT put objects or your hands inside the protective grilles to avoid injury to yourself or damaging the compressor fig 36 When you have finished using the compressor always remove the plug from the power socket Hints for efficient operation For efficient operation of the machineat full continuing load and maximum operating pressure make sure the temperature of the work environment indoors does not exceed 25 C We adivse you to use the compressor at 7096 maximum duty per hour as this make for efficient operation of the product in the long term 5 16 Storing the compressor 5 16 1 During the time that the compressor is unpacked store it in a dry place and a temperature of between 5 C and 45 C and sheltered away from the weather 5 16 2 For the whole time that the compressor is not used after unpacking it while waiting to start it up place sheets over it to protect it from dust which may settle on the components 5 16 3 The oil is to be replaced and the operational efficiency of the compressor is to be checked if it is not used for long periods 5 17 Pneumatic connections 5 17 1 Make sure you use pneumatic tubes for compressed air with maximum characteristics that are adequate for the compressor DO NOT repair faulty tubes PAGE 19 Rev 2 6 SPECIFICATI
21. o 0 OFF position Wait for a few minutes and return the pressure switch to I ON position with the exception of models AB 100 245 335 Three phase AB 150 245 335 Three phase AB 200 245 335 Three phase For compressors supplied with a control unit the thermal breaker is installed inside the control unit When the thermal breaker is tripped observe the following procedure fig 22 e Turn the switches on the control unit cover to position O open the cover and press push button 1 of the thermal breaker Close the cover of the control unit and restart the compressor observing the operations described in the paragraph Starting compressors with control unit The same instructions apply to compressors powered at 60 Hz 5 8 Adjusting the operating pressure fig 23 5 8 1 You do not have to use the maximum operating pressure at all times On the contrary the pneumatic tool being used often requires less pressure On compressors supplied with a pressure reducer operating pressure must be correctly adjusted 5 8 2 Release the pressure reducer knob by pulling it up adjust pressure to the required value by turning the knob clockwise to increase pressure and anti clockwise to reduce it 5 8 3 When you have obtained optimum pressure lock the knob by pressing it downward fig 23 For pressure reducers equipped without a pressure gauge the set pressure can be seen on the graduated scale located on the reducer body PAGE 14 Rev 2 5 8
22. ow conductor in the lead is the grounding earthing wire 4 31 4 Never connect the green and yellow wire to a live terminal 4 32 Extension leads 4 32 1 Use only three extension leads that have three prin grounding earthing type plugs and three pole sockets that accept the compressor s plug 4 32 2 Replace or repair damaged lead Make sure your extension lead is in good condition When using an extension lead be sure to use one heavy enough to carry the current your product will draw An undersized lead will cause a drop in line voltage resulting in loss of power and overheating Tables below shows the correct size to use depending on lead length and name plate ampere rating If in doubt use the next heavier gauge AN WARNING Avoid electrical shock hazard Never use this compressor with a damaged or frayed electrical leador extension lead Inspect all electrical leads regularly Never use in near water or in any environment where electric shock is possible Tab 1 SECTION VALID FOR A MAX LENGTH OF 20 mt single phase CV kW 220 230V 110 120V mm mm 0 75 1 0 65 0 7 1 5 2 5 1 5 1 1 2 5 4 2 1 5 2 5 4 6 2 5 3 1 8 2 2 4 The diameter of the extension cable of the 3 phase compressors must be in proportion to its length see table tab 2 Tab 2 SECTION VALID FOR A MAX LENGTH OF 20 mt three phase CV kW 220 230V 380 400V mm mm 2 3 4 1 5 2 2 3 2 5 1 5 5 5 4 4 2 7 5 5 5 6 2 5 10 7 5 10 4 PAGE 11 Rev 2 5 OPERATION amp
23. provide it with a power cable with plug of a diameter in proportion to its length 5 4 2 Any damage caused by incorrect connections of the power line to the mains automatically excludes warranty of electrical parts To avoid connection errors we advise vou to contact a specialised technician IMPORTANT Never use the ground earth wire instead of the neutral wire The ground connection must be made to meet safety standards EN 60204 The plug of the power cable must not be used as a switch but must be fitted in a power socket controlled by a suitable differential switch thermal breaker 5 5 Starting 5 5 1 Check that the mains power matches that indicated on the electrical data plate fig 14 the permissible tolerance range is 5 5 5 2 When first starting compressors operating on 3 phase voltage check the rotation direction of the cooling fan by comparing it with the direction of the arrow on the belt guard or on the protective housing In the SILENT compressor check if the air flows is in the direction illustrated in fig 21A 5 2 3 Turn or press into position 0 according to the type of pressure switch fitted on the appliance the knob located on the upper section fig 15 5 2 4 Fit the plug in the power socket fig 12 13 and start the compressor turning the pressure switch knob into position I 5 2 5 The compressor is fully automatic and is controlled by the pressure switch which stops it when tank pressure reaches ma
24. rrectly 4 24 Turn off the pressure switch when the compressor is not in use When the compressor is not it use turn the knob of the pressure switch OFF disconnect it from the power source and open the drain cock to discharge the compressed air from the air tank 4 25 Never touch hot surface To reduce the risk of burns DO NOT touch tubes heads cylinder and motors PAGE 10 Rev 2 4 26 DO NOT direct the air stream at body DO NOT direct air stream at persons or animals There is a risk of injury by directing air stream at persons or animals 4 27 Drain tank Drain tank daily or after 4 hours of use Open drain fitting and tilt compressor to empty accumulated water 4 28 DO NOT stop compressor by pulling out the plug Use the AUTO OFF of pressure switch 4 29 Only use recommended air handling parts acceptable for a pressure not less than 125 Psi 8 6 Bar Risk of bursting Use only recommended air handling parts acceptable for pressures not less than 125 psi 8 6 bar 4 30 Replacement parts When servicing use only identical replacement parts Repairs should be conducted only by authorised service center 4 31 Grounding Earthing instructions 4 31 1 This compressor should be grounded earted while in use to protect the operator from electric shock 4 31 2 The compressor is equipped with a three conductor lead and three pin grounding earthing type plug to fit the proper grounding earthing type socket 4 31 3 The green and yell
25. s ranges and refrigeration enclosures Never operate the compressor in damp or wet locations 4 5 Disconnect the compressor Always disconnect the compressor from the power source and remove the compressed air from the air tank before servicing inspecting maintaining cleaning replacing or checking any parts 4 6 Avoid unintentional satrting DO NOT carry or move the compressor while it is connected to its power source or when the air tank is filled with compressed air Be sure the knob of the pressure switch in the OFF position before connecting the compressro to its power source 4 7 Store the compressor properly When not in use the compressor should be stored in dry place Keep out of reach of children Lock the storage area 4 8 Keep work area clean Cluttered areas invite injurues Clear all work areas of unnecessary tools debris furniture etc 4 9 Keep children away All visitors should be kept safely away from work area 4 10 Dress porperly DO NOT wear loose clothing or jewerly They can be caught in moving parts Wear protective hair covering to contain long hair 4 11 DO NOT abuse the power lead Never yank it to disconnect from receptable Keep power lead from heat oil and sharp edges PAGE 9 Rev 2 4 12 Maintain compressor with care Follow instructions for lubricating Inspect power leads periodically and if damaged have repaired by authorised service facility Inspect extension leads periodically and replace if damaged
26. the first 100 hours of duty 5 13 3 The soundproofing cabinet is to be taken off first in the Silent model fig 29A 5 13 4 Unscrew the oil drain plug on the housing cover allow all the oil to flow out and re screw the plug fig 27 28 5 13 5 Pour oil into the upper hole of the housing cover fig 29 30 until it reaches the level indicated on the stick fig 9 or indicator fig 11 5 13 6 Pour oil into the upper hole of the head fig 30 in belt assisted units designed for topping up in that area 5 13 7 For the GM203 series take the cap off and pour in 85 grams of oil directly from the bottle see fig 30a 5 13 8 Once a week check oil level of the pumping element fig 11 and see if it needs topping up 5 13 9 For operation at ambient temperature in the range 5 C to 40 C use synthetic oil The advantage of this oil is that is does not lose its characteristics either in winter or summer 5 13 10 DO NOT drain used oil into the sewer or dispose of it in the environment PAGE 17 Rev 2 5 13 Oil change table Type of oil FIAC oil synthesis Synthetic oil Hours run AGIP Sint 2000 Evolution BP Visco 5000 ESSO Ultron MOBIL Mobil 1 NILS Dimension S NUOVA STILMOIL Arrow5W50 Other types of oil minera SAE15 W40 5 14 Troubleshooting multigrade Discharge all pressure from the tank Unscrew the hexagon head of the valve A Loss of air in valve under pressure switch This
27. tructions for use 5 2 1 Take care to transport the compressor correctly do not overturn it or lift it with hooks or ropes fig 5 6 5 2 2 Replace the plastic plug on the guard cover fig 7 8 with the oil level stick fig 9 or with the relevant breather plug fig 10 supplied with the instructions booklet 5 2 3 Check oil level consulting the reference marks on the stick fig 9 or the oil level inspection window fig 11 5 3 Electrical connections 5 3 1 Single phase compressors are supplied with an electrical cable and a three pin earth plug The compressor must be connected to a grounded power socket fig 12 5 3 2 Three phase compressors L1 L2 L3 PE must be installed by a specialised technician Three phase compressors are supplied without a plug Connect a plug with screw on grommet and securing collar fig 13 to the cable consulting the table below HP kW Power supply volt ph Plug model 2 3 4 1 5 2 2 3 220 380 3 230 400 3 16A 3 pole ground 55 75 10 4 55 75 220 380 3 230 400 3 32A 3 pole ground PAGE 12 Rev 2 AN NOTE Compressors installed on the 500 It tank with capacity of HP7 5 55 kW and HP10 7 5 kW can be supplied a star triangle starting control unit whereas the TANDEM 2 pumping elements on the same tank are supplied with a timed control unit for staggered starting of the two pumping elements 5 4 Installation instructions 5 4 1 Secure the control unit box on a wall or on a fixed support and
28. ximum value and restarts it when it falls to minimum value The pressure difference between maximum and minimum values is usually about 2 bar 29 psi E G The compressor stops when it reaches 8 bar 116 psi maximum operating pressure and restarts automatically when the pressure inside the tank drops to 6 bar 87 psi After connecting the compressor to the power line load it to maximum pressure and check exactly how the machine is operating 5 6 Compressor with D type starting control unit fig 16 5 3 1 Fit the plug in the power socket fig 13 and turn the pressure switch to position ON fig 17 Turn the master power switch A on the control unit to position power On is signalled by white indicator light E going on Turn switch B to position 1 to start the compressor If the solenoid valve indicator light D and the motor C indicator light C go on in that order this means the machine is operating correctly fig 18 PAGE 13 Rev 2 5 7 Tandem compressors with timed control unit fig 17 5 7 1 Fit the plug in the power socket fig 13 and turn the pressure switch to position 1 ON Turn the master power switch A on the control unit to position power On is signalled by white indicator light E going on 5 7 2 Turn switch B to start the compressor 5 7 2 1 Pos 1 pumping element n 1 only is operating 5 7 2 2 Pos 2 pumping element n 2 only is operating 5 7 2 3 Pos 3 both pumping elements are op
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