SCREW COMPRESSORS
Models: VE
Operation and Maintenance Manual
9200.3000-00
01/2014
Editions Record
Code
Revision
Edition
9200.3000
00
01/2014
Changes
Original instructions: ITALIAN
DE
FR
EN
ES
IT
NL
PT
Übersetzung der Originalbetriebsanleitung
Traduction de la notice originale
Translation of the original instructions
Traducción del manual original
Traduzione delle istruzioni originali
Vertaling van de oorspronkelijke gebruiksaanwijzing
Tradução do manual original
SV
Översättning av bruksanvisning i original
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
3
SYMBOLS DEFINITION
This manual makes use of the following terms and symbols to highlight data or information of
special importance:
NOTICE
This symbol is used to provide the user with useful information for the proper
procedures and proper operation of the equipment.
CAUTION
This symbol indicates mandatory rules and procedures or prohibitions to be
followed in order to avoid minor personal injury and substantial property damage
to the equipment.
WARNING
This symbol indicates mandatory rules and procedures or prohibitions to be
followed in order to avoid potentially hazardous situations such as dangerous
electrical voltage and risk of serious personal injury.
POWER OFF
Always disconnect the compressor from all sources of electrical power supply
before performing any maintenance procedure.
MACHINE STOPPED
Indicates the operations to be performed only when the compressor is not
running (powered off and no part is moving).
SPECIALIZED TECHNICIAN
Indicates the operations to be performed exclusively by the specialized and
properly trained technical personnel.
4
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
CONTENTS
1 General Information ...........................................................................................................7
Warranty ..........................................................................................................................7
Warranty life ............................................................................................................................. 7
Application Mode ..................................................................................................................... 7
Material Return......................................................................................................................... 7
Exclusions and Limitations....................................................................................................... 8
Quality, CE Directives and Standards Conformity ...........................................................8
Factory Test Notes ..........................................................................................................8
2 Safety ..................................................................................................................................9
General Safety Rules ......................................................................................................9
Safety Rules for Installation ..................................................................................................... 9
Safety Rules for Operation..................................................................................................... 10
Safety Rules for Cleaning ...................................................................................................... 10
Safety Rules for Maintenance ................................................................................................ 10
Refuse Disposal ..................................................................................................................... 11
First Aid Measures ........................................................................................................11
Inhalation................................................................................................................................ 11
Skin Contact ........................................................................................................................... 11
Eye Contact............................................................................................................................ 11
Ingestion................................................................................................................................. 11
3 Unloading, Unpacking and Handling .............................................................................13
Unloading ......................................................................................................................13
Unpacking .....................................................................................................................13
Handling ........................................................................................................................13
Storage ..........................................................................................................................14
4 Installation ........................................................................................................................15
Positioning .....................................................................................................................15
Ventilation ......................................................................................................................15
WARM AIR DUCTING ........................................................................................................... 16
Electrical Connection .....................................................................................................17
Electric Connections Procedure............................................................................................. 17
Remote Control ...................................................................................................................... 17
Checking Motor Rotation Direction ........................................................................................ 17
5 System Description..........................................................................................................19
Intended Use .................................................................................................................19
System Main Components ............................................................................................19
Inlet Air Filter .......................................................................................................................... 19
Suction Valve ......................................................................................................................... 19
Screw Compressor (Air End) ................................................................................................. 20
Air/Oil Separator (Receiver) ................................................................................................... 20
Air/Oil Separator Cartridge..................................................................................................... 20
Oil Drain Valve ....................................................................................................................... 20
Oil Recover Visor (Oil Scavenge Line Visor) ......................................................................... 20
Oil Filter .................................................................................................................................. 20
Minimum Pressure Valve/Non Return Valve ......................................................................... 20
Safety Valve ........................................................................................................................... 20
Thermostatic Valve ................................................................................................................ 20
Air/Oil After cooler .................................................................................................................. 20
Pressure Transducer ............................................................................................................. 21
Operation Description ....................................................................................................22
Air Circuit................................................................................................................................ 22
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
5
Oil Circuit ................................................................................................................................ 22
Control and Regulation Circuit ............................................................................................... 22
6 Control System Description ........................................................................................... 23
Electronic Control Panel P1 .......................................................................................... 23
7 Operating Instructions .................................................................................................... 33
8 Maintenance..................................................................................................................... 35
Oil Maintenance ..................................................................................................................... 35
Suction Valve Kit Substitute Procedure ................................................................................. 36
Minimum Pressure Valve (MPV) Kit Substitute Procedure .................................................... 36
Thermostatic Valve Kit Substitute Procedure ........................................................................ 37
9 RCR (Registration and Commissioning Report) .......................................................... 39
A Individual Equipment Specifications............................................................................. 41
Technical Specifications ......................................................................................................... 41
Dimensional Drawing ............................................................................................................. 41
Electrical Schematics ............................................................................................................. 41
FIGURES
Figure 3–1 Machine handling by fork lift ................................................................................ 14
Figure 4–1 Natural air ventilation ........................................................................................... 16
Figure 4–2 Forced air ventilation ........................................................................................... 16
Figure 4–3 Forced/Ducted air ventilation ............................................................................... 16
Figure 5-1 Compressor Front and Rear Internal View ........................................................... 19
Figure 5-2 Simplified Operating Diagram ............................................................................... 22
Figure 8–1 Oil Level ............................................................................................................... 35
TABLES
Table 4-1 Ventilation Requirements ....................................................................................... 16
Table 5-1 Operating Diagram Legend ................................................................................... 22
6
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
1
GENERAL INFORMATION
The compressor ensures the maximum safety for the operator, the best production quality and
highest economical operation provided that all operation and maintenance instructions and
recommendations included in this manual are followed with strict attention. To achieve the best
performance, we recommend to keep constantly the system under its best operating and cleaning
conditions. The related operations shall be carried out regularly, making sure that the personnel
in charge of the system operation and maintenance is properly trained and compliant with all
safety rules here included.
1. This operations and maintenance manual is an integral part of the
compressor and must always follow it. This manual must be located close
to the compressor, suitably protected and remain at the operator’s
disposal.
2. The operator must read carefully the instructions herein included and
become familiar with the safety instructions and the operation of the
compressor before beginning any operation. Personal injury or
equipment damage may result if safety or operational information are not
understood perfectly nor followed properly.
WARRANTY
Warranty terms and conditions to be referred to are described here below unless there are
different agreements specified by the contract.
Warranty life
adicomp S.r.l. guarantees the proper operation and good quality of the machine for a period
of 12 months starting from the commissioning date or 18 months starting from the delivery
note, which expires earlier. The term is unique and may not be postponed after replacements or
repairment.
adicomp S.r.l., during the warranty period, reserves, at its option, to replace or repair free of
charge the parts damaged by defects in materials or workmanship. The warranty does not
include labour costs. In case of an on-site intervention, travel, board and lodging expenses will
be charged to the Customer.
To be eligible for warranty, fill in accurately (indicating the model and
serial number of the compressor) the “Registration & Commissioning
Report” (RCR) included at the end of this manual and send it to
adicomp.
Application Mode
To identify the fault reasons and apply the warranty, it is necessary to send to adicomp the
parts to be replaced or to advance an on-site intervention.
Repairing or replacing will be carried out by the adicomp at its workshops, or by a third
party or on site.
Material Return
Before sending back the parts to be replaced or repaired under warranty, it is necessary to
proceed to relevant communication and to ask for the adicomp’s approval. All parts shall be
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
7
properly packed to avoid damages during transportation and provided with the following
information:
1.
2.
3.
4.
5.
Machine type
Machine serial number
Manufacturing year
Part number
Detailed description of the defect and of how it occurred.
The parts that will be accepted under the warranty will be sent back EXW (Ex Works). The
replaced parts will be the property of adicomp.
Exclusions and Limitations
a) The warranty does not apply when the parts are damaged due to the following:
 Noncompliance with the instructions included in this manual, specifically:
 Not or incorrectly performed maintenance.
 Erroneous electric power connections.
 Not or incorrectly cleaning of the system parts which need to be cleaned on a regular
basis.
 Not checking of levels, leaks
 Use of not suitable tools for planned and extraordinary maintenance.
 Changes or alterations made by the user or by a third party, not approved by. adicomp.
 Use of non-original spare parts.
 Use of an oil different from the one recommended by the Manufacturer.
b) The warranty does not apply to the following materials:
 All parts subject to normal wear and tear such as gaskets, seals etc. as well as parts with not
defined life duration such as lamps, fuses, etc.
As concerns all components and accessories provided by external suppliers, are guaranteed at
the same conditions granted by the suppliers.
QUALITY, CE DIRECTIVES AND STANDARDS CONFORMITY
adicomp is certified with the Standard Quality ISO9001-2008.
The air compression system has been realized according to the EC community standards
regarding the free circulation of industrial products, specifically:





Machine Directive 2006/42 CE
Low Voltage Directive 2006/95 CE
Electromagnetic Compatibility Directive 2004/108 CE
Pressure Equipment Directive 97/23 CE
Simple Pressure Vessels Directive 2009/105/CE
FACTORY TEST NOTES
Each machines is tested at the factory where it is carefully checked and adjusted by specialized
personnel before delivery. Working tests are simulated under normal conditions. The tests aim
to verify:
1. The general operating phases of the machine.
2. The machine features and performance meet the project requirements.
3. The calibration of safety devices, adjustment and control systems.
4. The sealing efficiency.
However once installed the machine, it is recommended to test its operating under real working
conditions.
8
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
2
SAFETY
Read carefully all the instructions contained in this manual for an in-depth knowledge of the
machine operation. Above all, consider that the safety devices installed into the system by the
Manufacturer represent a protection against the accidents that may occur during the normal use
of the machine. All personnel with installation, operation, and maintenance responsibilities
should become familiar with the contents of these instructions to ensure high quality and safe
performance.
For further information regarding the maintenance program and
identification of spare parts, please refer to the individual equipment
documentation attached to this manual in the appendices
GENERAL SAFETY RULES
This system works at 400 V / 50 Hz according to the CENELEC HD 472S1-04/11/1988
Regulation on the “Standardization of electric circuits within European countries”.
It is strictly forbidden to cut out the electric and mechanical safety devices or to dismantle the
protections created by the Manufacturer.
All control, fixing and maintenance operations shall be performed by
qualified personnel only.
 The operator shall wear work clothing complying with EN standards.
 Always wear specific protections such as gloves, helmet, glasses, ear protection headset
against noise.
 Do not allow unqualified personnel to use or access the electric panel or any other electric
equipment.
 Do not perform maintenance or cleaning operations without turning off the main power
disconnector switch in the electric panel.
 The owner shall be liable for keeping all the plates showing the danger signs and the system
data in perfect visibility and readability conditions. All damaged plates may be ordered at the
Spare Part Department at any time.
Safety Rules for Installation
 The system installation may be executed by internal technicians or by adicomp’s
technicians in cooperation with the Customer’s personnel.
 Before starting the installation all system parts and equipment shall be checked to make sure
that there are no damages caused during transportation.
 Should the packaging be damaged, immediately inform both the forwarder agent and the
adicomp’s Technical Support Department.
 The compressor should be installed in premises where no explosion, fire or flooding risk
exists.
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
9
Safety Rules for Operation
Do not use the compressor for purposes other than those for which it has
been designed and conceived.
 Do not leave the system unattended while operating.
 Make sure that the personnel using the system has been previously trained, is aware of all the
instructions, and is in the proper physical and mental condition to work.
 Before starting the machine, make sure that all objects, tools or obstacles that may disturb
the operations are removed.
 The operator should remove jewellery, rings or necklaces, etc., that could get caught in the
machine.
 Never touch nor approach any part of body to the machines while operating.
 The flexible pipes for distributing compressed air must have adequate dimensions and must
be suitable for the working pressure.
 Never use flexible pipes that are worn, damaged or deteriorated. As regards couplings and
connections, use only the correct type and size.
 When feeding compressed air into a flexible pipe or an air line, ensure that the free end of
the pipe is securely fastened. A free end will give "whip lashes" and could cause injury to
people in the vicinity.
 Never play with compressed air. Never turn the jet of air against your own body or any other
people.
 Never use compressed air to remove dust from clothing. If using it to clean equipment, take
great care and wear protective goggles.
 Never inhale compressed air, if you are not sure that it has been suitably purified for this
purpose.
 Never operate the compressor in places where the presence of in inflammable or toxic fumes
is possible.
 All parts of the casing must be closed when the unit is working.
Safety Rules for Cleaning
 Do not perform cleaning while the system is operating.
 Before cleaning make sure that the system general disconnector switch on the electric panel
is turned off.
 Never wash the electric components with water or other liquids.
 Always wear specific protections, such as clothing, gloves, helmet, glasses resistant to highly
corrosive cleaning products.
Safety Rules for Maintenance
 No unauthorized personnel should adjust or service the machine nor replace any part.
 The operator should remove jewellery, rings or necklaces, etc., that could get caught in the
machine.
 Do not perform maintenance operations while the system is operating. All maintenance
operations shall be executed with disconnected pressure and electric power. To avoid starting
the machine unintentionally, lock the general electric switch.
 The maintenance of electric parts shall be executed only by specialized personnel.
 Always use original spare parts to replace faulty parts or worn equipment. The use of nonoriginal spare parts may result in irreversible damages to the system and to the personnel in
charge of operation and maintenance. The manual includes a complete list of original spare
parts to be used for order placement.
 Before performing any operation on the machine make sure the upstream and downstream
ball valves have been closed and the unit is completely depressurized.
10
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
Refuse Disposal
 Follow the law in force for the disposal of Residual Oil, Condensates, Filter Elements, etc..
 In case of leakage of liquids dry with absorbing material.
 Do not allow the oil to contaminate the groundwater.
FIRST AID MEASURES
In case the Operator comes into contact with fluids or vapors dispersed by the system, it is
necessary to follow these basic measures of first aid as described below.
Inhalation
Remove patient from exposure into fresh air, keep warm and at rest. Obtain medical attention if ill
effects occur. If there is any suspicion of aspiration into the lungs (for example during vomiting) admit
to hospital immediately.
Skin Contact
Remove contaminated clothing. Wash skin immediately with cold water and soap. If symptoms
develop, obtain medical attention.
Eye Contact
Irrigate with eyewash solution or wash copiously with warm water holding the eyelids apart for at
least 10 minutes. Obtain medical attention.
Ingestion
DO NOT induce vomiting. Wash out mouth with cold water. Give 200-300 ml (a glass) of milk to
drink. Obtain medical attention.
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
11
3
UNLOADING, UNPACKING AND HANDLING
The machine could be shipped to the Customer with one of the following packaging options:
 Wooden case
 Wrapped in a plastic film
 Packed in cartons
UNLOADING
The machine shall be unloaded from the means of transport by using appropriate lift trucks,
cranes or bridge cranes.
1. Upon delivery check that the packing list effectively corresponds to the delivered package.
2. Inspect the package for evidence of any damage.
3. If the machine is delivered with serious damages, report the damage to the carrier and
contact adicomp as soon as possible.
UNPACKING
1.
2.
3.
4.
Unpack and remove the compressor from its shipping package.
After unpacking, inspect the compressor for evidence of external damage.
Report the damage to the carrier at once.
Retain package for storage or return shipment.
HANDLING
Before starting the handling operations, make sure that the path and the
installation areas are free from any obstacle.
In case of handling by lift truck, it is necessary to put the truck forks under the pallet to which
the machine is secured. Place the duly spaced forks (according to the width of the section to be
handled) whose length has to be suitable to support the entire chassis base. Slowly lift it with
the assembly center of gravity (G) placed at the center of lifting forks.
All the transportation and handling activities shall be carried out by highly
specialized personnel. The people in charge have to know the weight of
the different components, how to use a crane and lift trucks, the accidentprevention rules and have to verify that the components of the hoisting
equipment (cables, hooks, bands, etc.) are suitable for lifting the required
load.
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
13
Insert fork lift
here
Alternatively
insert fork lift here
Figure 3–1 Machine handling by fork lift
STORAGE
In case the unit is going to be not operated for over one month:
1. Disconnect the electric panel from the power supply.
2. Move the skid to a clean and dry location. The location must be well-ventilated. The
location temperature shall be higher than 0 °C.
3. Wrap safety valve with oil paper or an equivalent to avoid rust.
4. Apply a suitable corrosion inhibitor spray to electric panel components.
5. Put a desiccant bag in the electric panel.
6. Cover the air inlet and outlet ports to prevent dust entry.
Prior to put the unit into service again:
1. Remove all covers, wraps and desiccant bags used for the storage.
2. In case of storage periods longer than 3 months, fill the air end with 0.3 L of oil.
3. Check the oil level on the sight glass of the air/oil receivers and fill up with additional oil
if necessary.
4. In case of storage periods longer than one year, replace the oil, oil filter and deoiler
cartridge.
14
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
4
INSTALLATION
POSITIONING
The right positioning of the compressor allows its correct operation and its accessibility for
planned and extraordinary maintenance.
 Position the compressor in a location with adequate ventilation.
 A minimum clearance of 100 cm on each side and 150 cm above the compressor shall be left
for maintenance purposes and ventilation.
 The floor on which the compressor is placed has to be suitable for supporting its weight. It is
necessary to respect a surrounding area, according to the size of the machine, to simplify the
activities of the personnel in charge of installation. When possible, it is also recommended to
install the compressor inside a reinforced concrete building of at least 3x3m (wall thickness
of at least 20 cm) with a side completely open.
 Normally it is not necessary to bolt the unit down, given its low vibrations.
 The unit shall be protected from weathering in a well leveled position. The building floor
shall have a slight slope (maximum 1-2%) towards the outside.
 The unit should be positioned as far as possible from sources of dirt, coarse solids, abrasive
particles, steams, fine dust, liquids and gaseous impurities.
 The compressor room must have proper ventilation and adequate air intake openings which
allow to keep the right temperature with the running machine.
The ambient temperature must be between 3 °C and 40 °C. An extra
cooling fan with minimum capacity as indicated below shall be installed
when warm air is ducted.
 In the event of inadequate hot air discharge, fit the exhaust fans as high as possible.
If the room temperature could fall below 0 °C, fit a heating resistance for
the oil tank.
VENTILATION
Normally any cooling-air inlet should be positioned downside allowing unrestricted air-flow to
the compressor intake. The warm-air outlet should be positioned upside and far enough from the
inlet, to ensure a positive cooling air-flow through the compressor.
 Locate the cooling air inlet close to the floor and that for warm air outlet air in the ceiling or
at the top of the wall.
 Fit the air inlet openings with adjustable shutters so that the room temperature does not fall
below the minimum temperature in winter. If this is not sufficient the compressor should be
equipped with its own heating unit.
 The hot air may have to be expelled by ventilators. The capacity of the ventilators should be
as indicated in the following table.
 If air ducting is fitted, it must not cover or restrict the cooling air flow of the compressor.
The total resistance of the complete system must not exceed 5 mm w.g. (0.2in. water gauge).
If the resistance is expected or found to be higher, a ventilator shall be required
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
15
A
Figure 4–1 Natural air ventilation
Figure 4–2 Forced air ventilation
C
Figure 4–3 Forced/Ducted air ventilation
WARM AIR DUCTING
Hot air is expelled from the side of the compressor at a temperature 10-20°C higher than the
room temperature. If the room ventilation is not enough a duct having the same cross-section as
the radiator area is absolutely necessary .This duct should be equipped with a valve conveying
the hot air outside in summertime and inside in wintertime thus using the heat energy genrated
by the unit as auxiliary heating unit.
Table 4-1 Ventilation Requirements
Model
VE15B
VE18B
VE22B
VE22C
VE30C
VE30CS
VE37C
VE37H
VE45H
16
Case 1
Case 2
Case 3
(Figure 4–1)
(Figure 4–2)
(Figure 4–3)
A (air inlet
section)
B ( air outlet
section)
A (air inlet section)
C (flow of forced air)
A-C
A (air inlet section)
C (flow of forced air)
D (duct dimensions)
A–C-D
0.40 m2
0.40 m2
0.50 m2
0.50 m2
0.75 m2
0.75 m2
0.75 m2
0.75 m2
0.75 m2
0.40 m2 - 4000 m3/h
0.40 m2 - 5000 m3/h
0.50 m2 - 6000 m3/h
0.50 m2 - 6000 m3/h
0.75 m2 - 10000 m3/h
0.75 m2 - 10000 m3/h
0.75 m2 - 10000 m3/h
0.75 m2 - 10000 m3/h
0.75 m2 - 10000 m3/h
0.40 m2 - 4000 m3/h - 600 x 400
0.40 m2 - 5000 m3/h- 600 x 400
0.50 m2 - 6000 m3/h- 600 x 400
0.50 m2 - 6000 m3/h- 600 x 400
0.75 m2 - 10000 m3/h- 750 x 750
0.75 m2 - 10000 m3/h- 750 x 750
0.75 m2 - 10000 m3/h- 750 x 750
0.75 m2 - 10000 m3/h- 750 x 750
0.75 m2 - 10000 m3/h- 750 x 750
Min. room
dimensions
A x B x C (m)
3.0 x 2.2 x 3.0
3.0 x 2.2 x 3.0
3.0 x 2.2 x 3.0
3.0 x 2.2 x 3.0
4.0 x 3.5 x 3.0
4.0 x 3.5 x 3.0
4.0 x 3.5 x 3.0
4.0 x 3.5 x 3.0
4.0 x 3.5 x 3.0
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
ELECTRICAL CONNECTION
The user is responsible for the dimensioning of the power line and the grounding cable of the
machine, as well as for the choice of the relevant protections against short-circuits and contact
voltage.
The power supply voltage must be the same as indicated on the nameplate.
The electrical supply line must stand the load indicated on the motor nameplate.
Make sure that before the compressor power supply inlet a differential
circuit breaker is installed on the wall having an adequate size, class type A
or AC, proper sensitivity (300 mA), and trip type D
Grounding: firmly connect the electrical line ground cable to the
machine grounding bar within the electrical panel by means of an
appropriate cable.
Before starting the operation, ensure that the mainline fuses have been
removed from the distribution board.
Precautions should be taken to prevent them being refitted while the
installation is in progress.
Electric Connections Procedure
While making the electrical connections observe the following:
 The disconnector should be positioned close to the compressor with clear unrestricted access.
 The electric panel must be connected to the main power supply, through the door
disconnector switch. Fix the three phase cables to the connectors of the door disconnector
switch and the Ground cable to the Grounding bar inside the electrical panel.
 For the electric connection it is necessary to use proper electric cable at least with double
PVC insulation. For minimum section of the cables please refer to technical data and to the
electric connection diagram in the Appendix. If the compressor is located far away from the
circuit breaker or the ambient temperature normally exceeds 35°C, then cable size must be
increased.
 Ensure that all electrical connections are well tighten.
 Ensure that every electrical component of the machine with grounding cable is connected to
the ground bar within the canopy.
Remote Control
For the connection of remote controls for Start/Stop and the use of potential free contacts,
please refer to the Chapter “Description of the Control System”.
Checking Motor Rotation Direction
Motor running in reverse direction for a period longer than a few seconds
will result in serious damage to the air end unit. In order to check the
motor rotation direction two technicians should be involved. One
technician has to press the start button and the other checks the direction
of motor rotation is the same as the sticker arrow on the screw block
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
17
This type of compressors are equipped with a safety device (RSF) that
prevents the motor to run in the wrong direction (immediate shutdown trip
with error E:0020). Nonetheless it is highly recommended to check the
motor rotation direction during the first start up to avoid serious damages
to the air end.
Open the door of the canopy to be able to check the rotation of the screw block by looking
through the coupling safety guard.
The first technician pushes the Start button on the control panel P1 to make the compressor run
and soon after presses the emergency push button to stop immediately the compressor. In the
meanwhile the second technician checks the correct motor rotation direction according to the
sticker arrow attached on the screw block.
During this procedure do not use the STOP button to stop the unit as it
will not be stopped immediately due to the temporisation.
If the rotation direction is not correct follow the procedure below:
a. Push the emergency push button.
b. Switch “OFF” the main switch
c. Bring the line main switch in the position “OFF” and tag it in order to prevent it to be
turned ON.
d. Make sure that no voltage is present at the cable feeding the electric motor and then
exchange any two incoming phase cables of the power supply in terminal box.
e. Reset the wrong rotation alarm.
f. Release the emergency push button.
g. Check again the correct rotation direction.
18
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
5
SYSTEM DESCRIPTION
INTENDED USE
The compressor equipment is designed to supply compressed air with rated pressure and
capacity for general industrial applications.
SYSTEM MAIN COMPONENTS
The system consists of a rotary screw compressor, oil injected, coupled by transmission V-belts
to an electric motor with all usual accessories such as electric control panel, compressed air
after cooler, all included into a silencing canopy.
The system is totally air cooled and is designed and built for continuous duty 24 hours
operation.
Figure 5-1 Compressor Front and Rear Internal View
A brief description of system main components follows.
Inlet Air Filter
The inlet air filter is recommended to prevent particles to enter the compressor.
Suction Valve
The suction valve regulates the intake of the air inside the air end. Depending on whether it is
opened or closed it determines the operation state of the machine.
Open
Load
Close Off-load
The compressor is running and delivering compressed air
The compressor is running but not delivering any compressed air
During Off-load state, a nozzle allows a minimum air quantity to enter the screw in order to
have a minimum pressure for oil circulation. Intake air is then re-circulated and sent to suction.
Higher size compressors have also a valve for air injection to lower the noise during Off-load
operation.
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
19
Screw Compressor (Air End)
The air end is of screw type, single stage, oil injected and consists of two rotors: one male with
5 lobes and one female with 6 caves with asymmetric profile. The rotation of the two rotors
results in the compression of the air sucked in with continuity and without pulsation.
The air end is coupled by transmission belts to an electric motor.
The compression is achieved in an unique stage.
The oil is injected to:
1. Sealing between the two rotors and between the rotors and the housing.
2. Lubrication of all mechanical rotating parts.
3. Removal of the heat generated by the compression process.
Air/Oil Separator (Receiver)
It contains the compressed air/oil mix. It allows the first mechanical separation between air and
oil with the oil collecting in the bottom. It is fitted with a visor to verify the oil quantity in the
oil circuit is enough. The separator is designed to handle the maximum capacity at the lowest
discharge pressure and the highest discharge temperature.
Air/Oil Separator Cartridge
This filter separates the oil mixed with the compressed air through a filtering element.
Oil Drain Valve
This valve allows, prior to switching off the power supply and removing the safety plug, to
drain the oil when it has to be changed.
Oil Recover Visor (Oil Scavenge Line Visor)
This visor carries back to the air end the oil which has been separated by the air inside the
air/oil separator cartridge. A nozzle is fitted inside it to get the ideal oil flow for a good oil
separation inside the separator cartridge.
Oil Filter
It is extremely important that the oil injected into the air end is as clean as possible. This
component filters the oil before it is re-injected into the air end.
Minimum Pressure Valve/Non Return Valve
This valve maintains a minimum pressure in the air/oil separator. It also prevents the back-flow
of the compressed air from the discharge to the compressor when it is stopped. Furthermore
during the startup sequence it remains closed unless the minimum pressure of 3÷4 bar is
reached.
Safety Valve
The safety valve discharges the air in case of overpressure inside the air/oil internal circuit due
to a failure.
Thermostatic Valve
This valve controls the injection temperature of the oil into the air end. It allows the oil leaving
the air/oil receiver to by-pass the oil cooler depending on the temperature of the oil itself by
draining it directly to the oil filter.
Air/Oil After cooler
This combined cooler is an air-cooled heat exchanger using an electric fan and is divided into
two sectors: the air cooler circuit and the oil cooler circuit.
20
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
The oil cooler is sized to suit the capacity of the compressor being cooled. The cooler is
designed to handle the worst operating condition which is usually based on the lowest suction
pressure and the highest discharge pressure.
Pressure Transducer
The pressure transducer measures the discharge pressure and converts it in a 4-20 mA current
signal which is sent to the compressor electronic controller. When the upper operating pressure
set in the electronic controller is reached, the compressor works in Off-load mode until the
pressure descends to the lower operating limit when it works in Load mode. If, due to low
demand for compressed air, the Off-load operation time lasts longer than the time set in the
electronic controller, the compressor will stop in stand-by condition. It will re-start
automatically as soon as there will be a new demand for compressed air.
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
21
OPERATION DESCRIPTION
Air Circuit
The sucked air is filtered through the air filter (1) before entering the suction valve (2) and the
air end (3) to be compressed. During compression cycle the air is mixed with oil. Air/oil
mixture goes then into the air/oil separator receiver (16) where, firstly by centrifugal action and
secondly by filtration by air/oil separator cartridge (6) the oil is removed. Compressed air flows
through the minimum pressure/non return valve (8) when reaches the minimum set pressure. An
after cooler (12) cools down the compressed air temperature to around 10/15 °C above the
ambient temperature. Finally through the outlet connection the compressed air is delivered and
can be used directly or stored into the built-in or an external tank (11).
Oil Circuit
The oil is collected at the lower part of air/oil separator receiver (16). The air pressure acting on
top of it pushes the oil through an oil cooler (10), an oil filter (5) that retains all the impurities
and then is re-injected into the air end for a new compression cycles. The pressure differential
between discharge and suction is such that an oil pump is not required.
During start up when the oil is too cold there is a thermostatic valve (7) that lets by-pass the
cooler in order to reach the ideal oil operating temperature as soon as possible. A small quantity
of oil is collected at the bottom of the air/oil separator cartridge (6) during the last stage of
filtration and this is returned to the air end suction side though the scavenge line and oil return
visor (4).
1
2
3
4
5
6
7
8
9
11
10
15
22
21
13
14
18 17 16
20 19
12
Figure 5-2 Simplified Operating Diagram
Table 5-1 Operating Diagram Legend
Ref.
1
2
3
4
5
6
7
8
9
10
11
Description
Suction air filter
Suction control valve
Air end
Oil scavenge visor
Oil filter
Air/oil separator cartridge
Thermostatic valve
Minimum pressure valve
Oil filling plug
Oil cooler
Buil-in or external storage receiver
Ref.
12
13
14
15
16
17
18
19
20
21
22
Description
Air cooler
Pressure transducer
Fan
Safety valve
Air/oil separator receiver
Oil level visor
Oil drain valve
Temperature probe
Main electric motor
Motor terminal box
Drive coupling transmission belts
Control and Regulation Circuit
The electronic control panel allows to set the operating parameters as required (within the pre-set
limits). It elaborates the pressure signals received by the pressure transducer and regulates the
delivery of compressed air. It ensures a steady flow of compressed air to match the variable demand
with a minimum pressure variation.
22
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
6
CONTROL SYSTEM DESCRIPTION
ELECTRONIC CONTROL PANEL P1
The control panel (controller) allows to start/stop the compressor and to control its functioning
based on the detected delivery pressure. When there is a start request by pushing the start button
or by a remote start command, if enabled, the controller will perform safety checks and starts
the compressor if no inhibiting condition is detected.
If there is a run inhibiting condition, the main motor will not run. The compressor will remain
in the standby condition and a run inhibit message is displayed.
When the run/load inhibit condition ceases the main motor starts running and loading. If the
Off-load pressure setting is reached, or a remote Off-load command is received, the suction
valve is closed and the compressor will run Off-load for the “Run On Time”, before the main
motor stops and the compressor goes into the standby mode.
The compressor will load again if the pressure falls below the load setting before the Run On
Time expires. During the Standby mode, a motor start sequence followed by the load delay time
is executed before loading.
In the event of a motor stop, initiated by a stop command or when entering standby mode, a
“Blowdown” timer is started. If a start request is made during the Blowdown time the
compressor will enter standby mode until the Blowdown time has expired.
When stopped manually, or by a remote command, the suction valve is closed and the main
motor allowed to run-on for the “Stop” run on time.
Safety checks are made continuously, so if a hazardous condition is detected an immediate
shutdown is performed and its reason is displayed as an Error message. If a warning condition is
detected an Alarm message is displayed and normal operation continues.
The AirMaster P1 control board allows the user interaction through:
 6 push button keys
 Industrial push button Emergency Stop Self
locking; twist to unlock.
 95 element custom backlit LCD display
Keys:
Start
Up or Increment Value
Stop
Down or Decrement Value
Reset
Enter
Display:
1
2
5
1:
2:
3:
4:
Main Display Value
Main Display Value Units
User Menu Item Display Value
User Menu Item Display Units
5: Status Symbols
6
3
6: Service/Fault Symbols
0.1 to 999
o
o
BAR, PSI, C, F
0.1 to 99999
BAR, PSI, oC, oF, Hr, LHr
Started,
Service,
Running,
Loaded
Fault: Alarm/Warning/Trip
4
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
23
The following figure shows the connectors layout of the controller board.
144
A2
A1
-
-
+
+
C6
28
10
C2
96
R1
4 x M4 clearance
24Vac 0V
R2 R3 R4
C
R1C
X01 – Power Supply:
Controller: 24Vac +-15%; 50VA @ 50/60Hz
R1C R1 C R2 R3 R4
Di
ES
0Vac
24Vac
24Vac
0Vac
It is recommended the 0Vac power supply is securely bonded to a suitable earth connection.
Polarity of power supply connection to the controller is important.
Emergency Stop (ES) activation is detected on R1C (relay #1 common pin); 24Vac only.
If common 24Vac power supply is used for motor contactor coil energisation the ‘VA’ power supply rating
must be increased accordingly.
Di
Main 24Vac power supply is used for digital input activation (digital inputs are 24Vac detecting).
X02 – Analogue Inputs:
Pin Function
1
2
3
4
A1+
A1A2+
A2-
Pressure Sensor
Pressure Sensor
Temperature Sensor
Temperature Sensor
+ 16VDC
4-20mA Signal
KTY (NTC 10k, PT100, PT1000)
0VDC
X03 – Digital Inputs:
Pin Function
ON: 24Vac
1
2
3
4
5
see Relay Outputs R1C
C1
C2
C3
C4
C5
C6
Emergency Stop
Shutdown Trip Fault (e.g. Motor Fault)
Shutdown Trip Fault (e.g. Oil Filter)
Shutdown Trip Fault (e.g. Separator Element)
Menu Configurable (Default: Alarm)
Menu Configurable (Default: Alarm)
OK
OK
OK
Alarm
Alarm
OFF: 0Vac
Shutdown
Shutdown
Shutdown
OK
OK
ON= > 19.8Vac, OFF = < 1.0Vac
24
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
X04 – Relay Outputs:
Pin Function
1
2
3
4
5
6
R1C
R1
C
R2
R3
R4
Emergency Stop Detection; Relay #1 Common
Load Solenoid
Relay #2, #3 and #4 Common
Main/Line Motor Contactor Coil
Start Motor Contactor Coil
Delta Motor Contactor Coil
24Vac only (<1.0Vac = E.Stop)
max. 130Vac/dc
User Display:
Main Display Value; Pressure (bar/psi menu selectable)
Default User Menu Item; Temperature (oC/oF menu selectable)
To view alternative User Menu items press Up or Down
Total Run Hours
Hours Run Onload
Hours Until Service Due (countdown timer based on total run hours)
RS485 Communication Network Address (*only show if RS485 option installed)
If a timer event occurs (run-on, stop, blowdown or auto restart time) the User item display will show the
time countdown in seconds. While a countdown is being displayed normal User items can still be viewed; press
Down.
The display will default back to the User Temperature item after a short period of no key activity or after a timer
event has completed.
If operating in ‘Pressure Switch Mode’ the main display will show the detected temperature and the default
User Menu item will be total run hours. Pressure is not displayed in pressure switch mode.
Pressure Switch Mode
Status Display:
The operating status is continuously displayed using status symbols.
Standby: The compressor is in a started state but is not running. The compressor will
automatically re-start and load when pressure falls to the lower pressure set point; or a
remote load signal.
Running: The compressor is running offload (run-on-time active)
Loaded: The compressor is running onload
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
25
Fault Conditions:
If a Fault condition occurs the Fault triangle symbol will switch on steady (Alarm/Warning) or flash
(Trip/Shutdown)
The User menu display item will show a ‘Fault Code’ dependant on the fault.
Fault Codes
Service Due Countdown Timer:
If the Service Due countdown timer reaches 0 (zero) hours the Service and Alarm symbols will flash and
the service Alarm (Warning) code will be displayed. The alarm code can be reset but the service symbol
will remain on the display until the service due timer is reset; the service hours will continue to decrement
in negative hours. The service countdown timer can be reset, using the menu routine, when the required
service has been carried out. Set to any value greater than 0(zero) hours before reset.
The Service Due countdown timer can be reset to any hours value, dependant on the required service interval.
The timer will countdown dependant on total run hours.
Menu Routine:
Parameters, Values and Options can be adjusted and set using the Menu Routines. There are two menu lists:
1) Operational Menu – Access Code “0009”
2) Configuration Menu – Access Code “----”
To access a menu stop the compressor first then press the Up and Down buttons simultainiously.
After several seconds the display will show four “0” characters; the first character will flash. Press Up or Down to
adjust the first character to match the first character of the required access code. Press Enter to increment to the
second code character.
When all four access code characters have been set, and the last code character is
flashing, press Enter. If the access code is correct for access to one of the two menus the first menu item of the
appropriate menu will be displayed. If the access code is incorrect the display will return to the normal operational
display.
To select a menu item for adustement press Up or Down until the menu item is displayed. To adjust an item
setting press Enter, the value or option will flash. Press Up or Down to adjust as required then press Enter to
store in memory.
To exit a menu and return to the normal operational display, at any time, press Reset.
Any adjustement that has not be entered to memory will be abandoned and the previous setting maintained.
Operational Menu:
Item
1:
2:
3:
4:
5:
6:
7:
8:
9:
1.Sh
1.Pu
1.PL
1.rt
1.bt
1.St
1.P1.t1.At
Description
Service Interval Hours
Upper Pressure Set point
Lower Pressure Set point
Run-On-Time
Blowdown Time
Stop Time
Pressure Display Units
Temperature Display Units
Auto Resetart Time
Range
-999 to 9999 hours
1 to 68bar
0.8 to 67.8bar
0 to 600 seconds
0 to 120 seconds
0 to 30 seconds
bar/psi
o
C/oF
0 to 120 seconds
Default
2000 hours
7.0bar
6.8 bar
300 seconds (5 minutes)
30 seconds
10 seconds
bar
o
C
10 seconds
Operational Menu Items:
1.Sh - Service Interval Hours:
When the set service interval hours counts down to zero an alarm is dispalayed warning that the service is dued.
1.Pu 1.PL - Pressure Control:
The compressor will maintain pressure between the set Pu (Unload Pressure Set Point) and PL (Load Pressure
Set Point. When Pressure reaches the set ‘Pu’ level the compressor will unload. When pressure falls to the ‘PL’
level the compressor will load.
26
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
1.rt - Run-On-Time:
When the compressor unloads the run-on-timer is initiated. If the set run-on-time expires before the compressor
loads again the main motor will stop and the compressor enter the Standby state.
1.bt - Blowdown Timer:
When the main motor stops the compressor will allow a period of blowdown (the Blowdown Time) before a motor
start can be re-initiated. A motor re-start is inhibited during this time period. This time is intended to allow internal
pressure (or sump pressure) to be vented before a motor start sequence is permitted. Set to 0(zero) seconds if
not required.
1.St - Stop Time:
When the Stop button is pressed the compressor will unload and the main motor will continue to run for the set
Stop Time. This time is intended to allow internal pressure (or sump pressure) to reduce before the compression
element is stopped; preventing potential oil blow-back through the compression element and air filter. The stop
time is initiated from the moment the compressor is unloaded. If the compressor has been offload for a period of
time prior to a stop command the time is automatically reduced accordingly. If the compressor is stopded after the
compressor has been running offload for the stop time, or longer, the compressor is stopped immediately; no stop
time is applied.
Set to 0(zero) seconds if not required.
1.At - Auto Restart Time:
The P1 is equipped with low voltage (<19.8Vac) and power failure detection (>40ms). If a power disturbance or
failure occures while the controller is in a Started state (running or in Standby mode) the compressor will be
automatically restarted when power is restored. The controller will display a Power Failure Detected alarm code to
indicate this event has occured.
To enable this function select an Auto Restart Time greater than 0(zero) seconds. When power is restored the
controller will wait for the set Auto Restart Time before initiating a motor start sequence. This time is intended as a
warning period and/or a method of stagger starting a number of compressors on the same power supply
distribution system.
To disable (inhibit) the Auto Restart function set the time to 0(zero) seconds.
Configuration Menu:
Item
1:
2:
3:
4:
5:
6:
7:
8:
9:
10:
11:
12:
2.Sd
2.Ad
2.LS
2.SS
2.PA
2.PF
2.tA
2.tF
2.d2
2.d3
2.d4
2.d5
Description
Motor Star/Delta Time
Network Address (RS485 option)
Load Source
Start Source
High Pressure Alarm Level
High Pressure Trip Fault Level
High Temperature Alarm Level
High Temperature Trip Fault Level
Digital Input ‘C2’ configuration
Range
0.0 to 20.0 seconds
1 to 12
0=local, 1=RS485
0=local, 1=RS485
1.0 to 68.0bar
0.8 to 67.8bar
50 to 248 oC
52 to 250 oC
Default
5.0 seconds
1
0=local
0=local
7.6bar
8.0bar
110 oC
120 oC
2: Eno - Shutdown Trip @ 24Vac (0Vac=OK)
3: Enc - Shutdown Trip @ 0Vac (24Vac=OK) -
default
2: Eno - Shutdown Trip @ 24Vac (0Vac=OK)
3: Enc - Shutdown Trip @ 0Vac (24Vac=OK) -
default
2: Eno - Shutdown Trip @ 24Vac (0Vac=OK)
3: Enc - Shutdown Trip @ 0Vac (24Vac=OK) -
default
Digital Input ‘C3’ configuration
Digital Input ‘C4’ configuration
Digital Input ‘C5’ configuration
0: Ano - Alarm @ 24Vac (0Vac=OK) 1: Anc - Alarm @ 0Vac (24Vac=OK)
2: Eno - Shutdown Trip @ 24Vac (0Vac=OK)
3: Enc - Shutdown Trip @ 0Vac (24Vac=OK)
13:
2.d6
default
Digital input ‘C6’ configuration
0: Ano - Alarm @ 24Vac (0Vac=OK) default
1: Anc - Alarm @ 0Vac (24Vac=OK)
2: Eno - Shutdown Trip @ 24Vac (0Vac=OK)
3: Enc - Shutdown Trip @ 0Vac (24Vac=OK)
4: rLu - Remote Load/Unload (24Vac=Load)
5: PSr - Pressure Switch Regulation (24Vac=Load)
14:
15:
16:
17:
2.Po
2.Pr
2.tL
2.tr
Pressure sensor ‘offset’ calibration
Pressure sensor ‘range’ calibration
Low Temperature Load Inhibit
Low Temperature Run Inhibit
-1.5 to 1.5bar
0.0 to 105bar
1 to 70oC (0 = disable function)
-20 to 10oC
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
0.0bar
16.0bar
2.0oC
-10.0oC
27
Configuration Menu Items:
2.Sd - Motor Star/Deta Time:
The number of seconds the main motor will run in Star configuration, during a motor start sequence, before
transition to Delta configuration.


The Star motor contractor is energised 200ms before the Main motor contactor.
The Star to Delta contactor transition time is fixed at 50ms.
2.Ad - Network Address:
The RS485 network communication address and the compressor number. Each compressor, connected to the
same network, must be assigned a unique address starting from 1 to the number of compressors on the network
system.
RS485 Communications Option
2.LS - Load Source:
1) Compressor will operate using the local set ‘Pu’ and ‘PL’ pressure set points.
2) The compressor will respond to remote RS485 system management pressure control.
Local pressure control (Pu and PL) is automatically resumed if RS485 communications is disrupted
or lost. When RS485 communications are resumed, pressure control is automatically reverted back to
RS485 control.
2.SS - Start Source:
1) The compressor can be started using the local Start button.
2) The compressor can be started using remote RS485 communications; the local start button is
inhibited.
Local and remote Stop functions are always active.
2.d6:rLu - Remote Load/Unload:
The controller can be set to load and unload in responce to a 24Vac signal (derived from the main 24Vac power
supply). When this option is selected the local pressure set points ‘Pu’ and ‘PL’ are ignored. The compressor will
load when 24Vac is detected on digital input C6, and unload when the voltage is removed from C6. This feature is
intended for remote pressure switch control or remote sequence management control.
Local pressure continues to be displayed; high pressure Alarm (Warning) and shutdown Trip settings remain
active.
2.d6:PSr - Pressure Switch Mode:
In Pressure Switch Mode the controller will load and unload in response to a 24Vac signal (derived from the main
24Vac power supply). When this option is selected the local pressure set points ‘Pu’ and ‘PL’ are ignored. The
compressor will load when 24Vac is detected on digital input C6, and unload when the voltage is removed. This
feature is intended for operation from a local pressure switch device (PS).
A2
-
+
A1
C6
-
-
- C2
PS
24Vac
Di
The local detected pressure input ‘A1’ is ignored and pressure is not displayed. The main display value will show
the detected Temperature. There is no requirement to connect a 4-20mA pressure sensor to analogue input ‘A1’
in this mode.
A temperature sensor is compulsary in all modes.
The high pressure Alarm (Warning) and shutdown Trip settings are ignored. It is recommended alternative
excess pressure shutdown, utilising a shutdown digital input, is implemented.
Pressure Switch Mode is intended for compressor units that are equipped with a pressure switch but are not
equipped with a pressure sensor.
28
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
2.Po/2.Pr - Pressure Sensor Type:
The controller is designed for use with a 4-20mA type pressure sensor that can operate from a 16VDC supply.
The ‘range’ of the sensor, and sensor calibration, can be adjusted using the ‘Po’ (pressure sensor offset) and ‘Pr’
(pressure sensor range) values. As default these values are set for a 0-16.0bar (0-232psi) sensor.
+VDC
signal
+
-
+VDC
+VDC
signal
signal
A1+
A1-
A1+
A1-
Wire polarity is important
If a sensor with a different range is used, initially set the ‘Pr’ range value to match the sensor; then calibrate.
For example: for a 0-60bar sensor set the ‘Pr’ range value to 60.0bar.
If the sensor has a non-zero lower pressure limit, -1.0 (minus one) to 15bar for example, initially set the ‘Po’ offset
to –1.0 (minus one) bar and the ‘Pr’ range to 15.0bar; then calibrate.
Pressure Sensor Calibration:
1) Expose the sensor to atmosphere (0.0bar gauge). Adjust the ‘Po’ offset value until the displayed pressure is
0.0bar.
2) Apply a known accurate pressure to the sensor. The pressure can be static or dynamic (changing). Adjust
the ‘Pr’ range value until the displayed pressure matches the applied pressure. The applied pressure can be
any value but It is recommended the pressure be equivalent to, or greater than, normal working pressure to
ensure an accurate calibration.
Detected pressure is displayed when the ‘Po’ and Pr’ menu items are selected for adjustment.
The controller will automatically adjust the pressure fault levels, and the pressure set points, to ensure they
remain within the pressure sensor range. Always check and comfirm these values after a pressure sensor ‘offset’
or ‘range’ adjustment.
2.tL - Low Temperature Load Inhibit
If detected temperature is below the set low temperature limit, and a load condition is required, the controller will
inhibit the compressor from loading, and the compressor will run offload, untill temperature increases above the
set limit. When this condition occurs the controller will display an Alarm indication (A3423 Err). The Alarm will self
reset when temperature increases above the set limit. The alarm cannot be manually reset.
To disable this function set to 0(zero).
2.tr - Low Temperature Run Inhibit
If detected temperature is below the set low temperature limit, and a load condition is required, the controller will
inhibit a main motor start, and the compressor will remain in a standby condition, untill temperature increases
above the set limit. If a load condition is still required when temperature increases above the set limit the
compressor will automatically start and run. When this condition occurs the controller will display an Alarm
indication (A3123 Err). The Alarm will self reset when temperature increases above the set limit. The alarm
cannot be manually reset. This feature cannot be disabled.
This function will not stop or inhibit a compressor from operating if the main motor is already running; the function
only applies when the main motor is stopped and the controller is required to initiate a motor start sequence.
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
29
Service Function:
To force the compressor in to an offload condition, regardless of pressure level, press and hold RESET for 5
seconds.

The lower display will indicate ‘OFF’ (press DOWN to view the temperature or other user menu items)


The load status symbol will flash (without the delivery arrow)
The motor run-on-timer is inhibited; the compressor will continue to run indefinantly in an offload
condition.
To exit the service function, and resume normal operation, press RESET.
The service function will self cancel if the compressor is stopped; normal operation will resume when the
compressor is re-started.
Temperature Sensor:
signal
The P1 is designed as standard to use
a KTY type temperature sensor. A
KTY sensor offers a calibration
o
o
temperature range of –32 C to 150 C.
A2+
0VDC
A2-
Special builds (on request) can accommodate 10k NTC, PT100 or PT1000 type sensors in instances where a
o
o
different or higher temperature range (-50 C to 250 C) is required; reciprocating compressor application for
example.
RS485 Communications Option:
Multi485
The P1 can be factory fitted, or retro-fitted,
with an optional 2-wire RS485 serial
communications port. The RS485 option is
automatically
detected,
no
menu
adjustments are required.
L2
1
X06
RS485
L1
3
X06
X06
3
2 1
L1
1
5
2
L2
4
L1
L2
RS485
X06
2
RS485
6
RS485
X06
X05
a: Remove the P1 rear cover plate (1).
b: Attach the RS485 PCB (2) to the underside of the P1 rear cover plate using the two screw fixings provided (3);
the P1 rear cover plate is equipped with two mounting holes for this purpose.
c: Connect the RS485 PCB cable (4) to the RS485 PCB socket (5)
d: Connect the second end of the RS485 PCB cable (4) to plug X05 on the P1 PCB (6).
Ensure the RS485 PCB cable plugs are tight and secure.
e: Replace the P1 rear cover plate (1)
Handle with care - ensure the RS485 PCB cable plugs are not pulled from the sockets during this procedure.
Multi485 Protocol:
The port utilises the CMC Multi485 protocol enabling connectivity to a range of system management products,
remote communications monitoring and control options or MODBUS RTU connectivity using a MODBUS Gateway
module.
30
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
Fault Codes:
Fault conditions are separated in to two categories:
A: Alarm (Warning) – symbol illuminated on steady, the compressor will continue to operate
A:2050
A:2060
A:2118
A:2128
C5 (if set for alarm warning function)
C6 (if set for alarm warning function)
High Pressure: alarm limit exceeded
High Temperature: alarm limit exceeded
A:2816
Power Failure Detected
A:3123
Run Inhibited - temperature is below set low temperature run inhibit limit
(will self reset when temperature increases above the set temperature limit; cannot be manually reset)
A:3423
Load Inhibited - temperature is below set low temperature load inhibit limit
(will self reset when temperature increases above the set temperature limit; cannot be manually reset)
A:4804
Service Due – service interval hours counter has reduced to zero
E: Shutdown (Trip) – symbol will flash, the compressor will stop.
E:0010
E:0020
E:0030
E:0040
E:0050
E:0060
Emergency Stop – 24Vac in not being detected on terminal R1C
C2 – fault condition detected on digital input C2
C3 – fault condition detected on digital input C3
C4 – fault condition detected on digital input C4
C5 (if set for shutdown trip function)
C6 (if set for shutdown trip function)
E:0115
E:0119
Pressure Sensor Fault: 4-20mA signal out-of-range (< 3.8mA or > 20.8mA)
Excess Pressure: shutdown limit exceeded
E:0125
E:0129
Temperature Sensor Fault: signal out-of-range (< -50oC or > 250oC)
Excess Temperature: shutdown limit exceeded
Master Reset:
The controller can be reset to factory default.
This function will reset all menu parameters and options.
1) Press the Up and Down buttons simulaniously to display the access code entry screen
2) Enter an access code of ‘9750’
3) DO NOT press Enter when the last numeric character “0” is flashing
4) While the “9750” access code is still being displayed on the screen, press and hold the Stop button
5) After 10 seconds the controller will reset; all values, parameters and options will reset to factory default.
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
31
7
OPERATING INSTRUCTIONS
The compressor should only be operated by authorized persons fully
trained in operating procedures.
Before starting the compressor, read the section 2 “Safety”.
Checking Procedure Before Starting
1. Check oil level in sight glass.
2. Check filler and drain plugs are tight securely.
3. Check for any signs of air or oil leaks.
4. Check that the stop/emergency push button is released.
5. Turn ON the disconnector switch on the electric panel door.
6. An adequate size air receiver must be connected by using flexible pipes.
7. Before the first starting up or after a long time of non usage of the compressor pour 0.3 litre
of oil into the suction of the air end after removing air filter
Starting Procedure
1. Depending on the configured operating mode (local by electronic controller or remote) press
Start button on the electronic controller or activate remote start.
After about 50 hours of operation it is compulsory to check and
eventually re-tight the belts and all electrical connections
At start-up, the air pressure displayed on the pressure gauge will rise and should not exceed the
pressure 3-4 bar. After a few seconds the compressor starts compressing the air. The system
pressure rises and should not exceed the electronic controller setting of Set point.
If the pressure rises the Set Point, the automatic stopping sequence begins: the machine enters
the Off-load state, the Run-on timer starts and stops the compressor after some seconds. If there
is the air demand during the run-on time the automatic stopping sequence is cancelled.
The compressor will remain stopped until there is a demand which allows system pressure to
fall about 1 bar below to the Set Point.
If a power interrupt occurs and it is restored later, the compressor will be
set to start automatically. This option can be enabled/disabled.
Stopping Procedure
1. To stop the compressor push the stop button on the electronic controller. This works also in
case remote operating mode is enabled. The compressor stops after a “depressurizing” time
has expired.
2. Once the “depressurizing” sequence has expired, it will be possible to see that the internal
pressure air/oil is decreased to zero.
Emergency Stop Procedure
1. If an emergency occurs hit the emergency push button located on main the electric panel or
on the compressor controls located on starter panel. The compressor will stop immediately
2. .Clear any faults which may have occurred. Do not reset emergency stop button nor reset the
electronic controller unless the fault cause is cleared.
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
33
8
MAINTENANCE
All the adjustments and maintenance operations on the compressor
must be carried out only by authorized and fully trained technicians.
Before making any adjustment and maintenance operation, read
the section 2 “Safety”.
The tasks listed in the service schedule must be carried out at the
indicated running hours. In dusty, hot or humid conditions more
frequent servicing may be necessary.
Before starting any servicing, fit a safety notice to the disconnector
selector advising that maintenance is being carried out on the
compressor and make it inoperative by disconnecting the power
supply.
Oil Maintenance
The compressor is designed to give optimum performance and trouble free service life when the
oil temperature is maintained as follows:
70°C ÷ 75°C Compressors with operating pressure up to 10 bar
80°C ÷ 85°C Compressors with operating pressure 13 bar
90°C ÷ 95°C Compressors with operating pressure 15 bar.
To check the compressor air/oil temperature, use the thermometer located in the canopy or use
the electronic controller display. Assuming the compressor is serviced correctly the machine is
capable of operating in ambient temperature up to a maximum of 40°C.
Use only the prescribed oil.
Do not mix different types of oil.
Oil Level Restoring Procedure
1. Stop the compressor. Do not proceed until the compressor unit pressure gauge shows zero.
2. Isolate the unit from the mains electrical supply by turning off the disconnector.
3. Carefully unscrew the oil filling plug and refill with fresh oil to the right level. The oil
should cover the top edge of the sight-glass.
4. Carefully close the compressor filler plug.
Oil filling plug
RIGHT OIL LEVEL
WHEN COMPRESSOR
IS STANDSTILL
Oil level visor
RIGHT OIL LEVEL
WHEN COMPRESSOR
IS OPERATING
Figure 8–1 Oil Level
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
35
Oil Drain and Filling Procedure
1. Stop the compressor. Do not proceed until the compressor unit pressure gauge shows zero.
2. Isolate the unit from the mains electrical supply by turning off the disconnector.
3. Open both the oil drain valve plug and the oil filling plug and let the oil drain from the air/oil
receiver.
4. Refill with fresh oil to the right level. The oil should cover the top edge of the sight-glass.
5. Carefully close the oil filling plug.
6. Proceed to replace the oil filter and air/oil separator cartridge.
Oil Filter and Air/Oil Separator Replacement Procedure
1. Follow the previous procedure to replace the existing oil with the fresh one.
2. Carefully unscrew and remove the oil filter and the air/oil separator cartridge. All discarded
filters must be disposed according to the local laws.
3. Substitute with new adicomp filters and carefully screw.
Oil Seal Check Procedure
1. Stop the compressor and look at through the coupling structure to check for any oil leaks
from the shaft of the air end. If there are any oil leaks, replace the oil seal.
Suction Valve Kit Substitute Procedure
1. Stop the compressor. Do not proceed until the compressor unit pressure gauge shows zero.
2. Isolate the unit from the mains electrical supply by turning off the disconnector.
3. Replace the worn parts with original adicomp spare parts and reassemble the valve
Minimum Pressure Valve (MPV) Kit Substitute Procedure
1. Stop the compressor. Do not proceed until the compressor unit pressure gauge shows zero.
2. Isolate the unit from the mains electrical supply by turning OFF the disconnector.
3. Replace the worn parts with original spare parts and reassemble the valve
Prior to replace the spare parts kit or the whole valve take note how long the setting screw leans
out in order to restore the original setting pressure. Alternatively to set to a precise pressure:
1. Disconnect the compressor outlet.
2. Start the compressor and look at the internal pressure shown on air/oil receiver
manometer. Initially you will note an increase of the pressure and then, after a short
time, you will hear the MPV opening and at the same time the discharge of the gas from
outlet pipe. At this point you will read a stable pressure on the manometer. This is the
pressure at which MPV opens (set pressure).
3. The set pressure can be changed while the compressor is running by following the
procedure below:
a. Unscrew the blocking nut on the MPV.
b. Turn counterclockwise the adjusting screw of MPV to decrease the set pressure, or
clockwise to increase the set pressure in order to read the right pressure on the
manometer.
c. Rescrew the blocking nut.
4. Reconnect the compressor outlet
MPV
Manometer
(internal pressure)
Adjusting screw
Blocking nut
36
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
Thermostatic Valve Kit Substitute Procedure
1.
2.
3.
4.
Stop the compressor. Do not proceed until the compressor unit pressure gauge shows zero.
Isolate the unit from the mains electrical supply by turning off the disconnector.
Carefully unscrew the thermostatic bulb plug positioned on the thermostatic valve.
Replace the bulb, the spring and the ring with adicomp original spare parts and reclose the
plug.
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
37
RCR (REGISTRATION AND COMMISSIONING REPORT)
9
Distributor………………………………………………..…..
Customer name……………………………………………….
Compressor model……………………………………Date of installation……………………..…….…
Serial number…………………………………………Manufacturing Year………………
Number/Date of adicomp invoice…………….……………………………
INSTALLATION
1. Location of compressor (compressor room, shop floor, outside, etc....)………………………………………..
2. Atmosphere (dirty, dusty, damp, enclosed, ventilated, etc. )………………………….…………………………
3. Ambient temperature (min and max)………………………….(°C)
4. System of layout (compressor, receiver, dryer, filter, etc.) ……………………………………………………...
COMMISSIONING
5. Check oil level .....................................................................................................................…………………….
6. Check tightness of all electric components .....................................................................................…………….
7. Connect electrical supply:
a) Check voltage at input
(Volt)
b) Check control voltage (auxiliary)
(Volt)
8. Confirm correct direction of rotation:
a) Check on load current
(Amp)
b) Check off load current
(Amp)
c) Check overloads protection device (value) main motor
d) Check overloads protection device (value) fan motor...........................................................………
9. Run compressor up to temperature and then check compressor for:
a) Air leaks .......................................................….........................................................……………
b) b) Oil leaks .....................................................……............................................................……...
c) Oil in scavenge transparent pipe.......................................................................................……….
10. Fill system to working pressure, then check:
a) System pressure set in / set out
(bar)
b) Air/oil receiver pressure on load/off load
(bar)
c) Load/off load cycles
(Min)
d) Oil temperature with ambient temperature at
°C
(°C)
HANDOVER
a) compressor startup/shut down procedure explained
Yes/No
b) Customer servicing responsibility explained
Yes/No
c) Service contract required
Yes/No
d) Handover
1. Cabinet key ......................................................................................................……….…..…...
2. Instruction book ...................................................................................................………….….
3. Parts book ...........................................................................................................……….……..
4. Copy registration and commissioning report (R.C.R.) ...............................................…….......
I am satisfied with the condition, installation and operation of my adicomp compressor
Customer signature ……………………………………..Engineer signature……………………………..….…….
Print name ………………………………………………Print name……………………………………………….
Position in company ................................................…....
One copy for customer - one copy for distributor - one copy for adicomp
Date of fault………………………. at operating hours ………………………
Faulty part .................................................................................................................................……..……………..
Reason…...…………………………………………………………………………………………………………
…………………..…………………………………………………………………………………………………
…………………………..…………………………………………………………………………………………
…………………………………………………………………………………………………………………….
.
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
39
A
INDIVIDUAL EQUIPMENT SPECIFICATIONS
Technical Specifications
Dimensional Drawing
Electrical Schematics
SCREW COMPRESSORS Models: VE - Operation and Maintenance Manual
41
adicomp srl
Via del Progresso 35
36050 Sovizzo (Vicenza)
ITALY
Tel. +39 0444 573979
Fax +39 0444 809186
info@adicomp.com
www.adicomp.com