User Manual Genisis 5.5-15 KW

GENESIS - FORMULA - MODULO
5.5 - 15 kW
USE AND MAINTENANCE HANDBOOK
GB
FORMULA
Fig. 1
1030
615
204
480
1045
262
273
D1 = 5.5-7.5 kW
D2 = 11-15 kW
227 D1
273 D2
560
945
390
227 D1
273 D2
395
430
180
545
Fig. 2
1045
465
GENESIS 275 l
1030
204
615
Fig. 3
480
945
262
273
D1 = 5.5-7.5 kW
D2 = 11-15 kW
227 D1
273 D2
560
945
390
227 D1
273 D2
395
465
1645
800
480
1180
Fig. 4
II
1015
530
600
GENESIS 500 l
1030
204
615
Fig. 5
480
945
262
273
D1 = 5.5-7.5 kW
D2 = 11-15 kW
227 D1
273 D2
945
390
227 D1
273 D2
395
465
1645
800
1015
530
600
1260
1960
Fig. 6
III
MODULO
Fig. 7
1030
204
615
480
1045
262
273
D1 = 5.5-7.5 kW
D2 = 11-15 kW
227 D1
273 D2
560
945
390
227 D1
273 D2
395
430
180
545
Fig. 8
IV
1045
465
MODULO 270 l
1030
204
615
Fig. 9
480
945
262
273
D1 = 5.5-7.5 kW
D2 = 11-15 kW
227 D1
273 D2
560
945
390
227 D1
273 D2
395
465
800
480
1180
Fig. 10
1645
1015
530
600
MODULO 500 l
1030
204
615
Fig. 11
480
945
262
273
D1 = 5.5-7.5 kW
D2 = 11-15 kW
227 D1
273 D2
560
945
390
227 D1
273 D2
395
465
800
1015
1645
530
600
1260
1960
Fig. 12
VI
FORMULA 5.5 - 7.5 kW

PS
VA
EV
PC
PE
SPA
Fig. 13
BF
VT
TRL
CT
PF
FA
FO
FD
ES
FU
VS
RA / RO
PP
SS
Fig. 14
MP
VII
FORMULA 11 - 15 kW
BA 51
PS
EV
VA
PC
PE
BF
SPA
Fig. 15
VR
TRL
CT
PF
FA
FO
FD
ES
FU
VS
MA
RA / RO
SS
MP
Fig. 16
PP
VIII
FORMULA 15 kW
BA 69
PS
EV
PC
PE
SPA
BF
VR
CF / FA
Fig. 17
TRL
CT
PF
VA
FO
FO
ES
VS
FU
MA
RA / RO
SS
MP
Fig. 18
PP
IX
MODULO 5.5 - 7.5 kW

PS
EV
VA
PC
PE
SCE
BF
SF
VT
Fig. 19
TRL
PF
CT
FA
FO
ES
FD
FU
VS
MA
RA / RO
SS
PP
Fig. 20
MP
PS
EV
MODULO 11 - 15 kW
BA 51
VA
PC
PE
SCE
BF
VR
SF
SS
Fig. 21
TRL
CT
FA
PF
FO
FD
ES
FU
VS
MA
RA / RO
PP
SS
Fig. 22
MP
XI
PS
MODULO 15 kW
BA 69
EV
PC
PE
SCE
BF
VR
CF / FA
Fig. 23
TRL
CT
PF
VA
FO
ES
FD
FU
VS
MA
RA / RO
PP
SS
MP
Fig. 24
XII
Legenda
Rif.
Italiano
English
Franais
Deutsch
Espaol
BF
Blocchetto di
ltrazione
Oil lter and

separator block
Groupe de
ltration
Halter fr l und
Abscheiderlter
Bloque de
ltracin del aceite
CE
Cassetta elettrica
Starter/control box
Armoire lectrique
Starter/Kontroll Box
Cuadro elctrico
CF
Contenitore ltro aria
Air lter container
Botier du ltre air
Luftlterbehlter
Contenedor del ltro

de aire
CT
Cinghie di
trasmissione
Transmission
belts
Courroies de
transmission
Antriebsriemen
Correas de
transmisin
DI
Display
Display
Ecran-afcheur
Display
Visor
DO
Scarico olio/
Drenaggio olio
Oil drain valve
Orice de vidange de
lhuile
l Auslass
Drenaje del aceite
ES
Essiccatore
Dryer
Scheur
Trockner
Secador
EV
Elettroventilatore
Electric fan
Ventilateur lectrique
Elektrolfter
Electroventilador
FA
Filtro aria
Air lter
Filtre air
Luftlter
Filtro de aire
FD
Filtro disoleatore
Oil separator lter
Filtre sparateur
Feinabscheider
Filtro disoleador
FFA
Fascetta ltro aria
Air lter clip
Collier du ltre huile
Luftlter Clip
Abrazadera ltro de aire
FO
Filtro olio
Oil lter
Filtre huile
l-Filter
Filtro aceite
FU
Feritoia uscita
aria calda
Heated air outlet
Orice de sortie
de lair chaud
Auslass fr heisse Luft
Rendija de salida del aire

caliente
GP
Gruppo pompante a vite

brevettato
Patented Air end
Groupe de pompe vis

brevet
Patentierter Verdichter
Grupo de bombeo de
tornillo patentado
K1/K9
Pulsanti del pannello di

controllo
Control panel switches
Boutons sur panneau de

commande
Schalter der
Kontroll-Anzeige
Pulsadores del tablero

de control
L1/L5
Led del pannello di

controllo
Control panel led
LED sur panneau de

commande
Led
Led del tablero de control
MA
Mandata aria
Compressor air outlet
Refoulement dair
Druckluft Auslass
Salida aire
MP
Motore principale
Electric motor
Moteur principal
Elektromotor
Motor principal
PA
Preltro aspirazione
Suction prelter
Pr-ltre daspiration
Ansaugvorlter
Preltro apiracin
PC
Pannello di controllo
Control panel
Panneau de commande
Kontroll-Anlage
Tablero de control
PE
Pulsante di arresto di
emergenza
Emergency stop button
Bouton darrt durgence
Not-Ausschalter
Pulsador de
emergencia
PF
Pannello frontale
Front panel
Panneau avant
Frontseite
Panel frontal
PP
Pannello posteriore
Rear panel
Panneau arrire
Hintere Abdeckung
Panel trasero
PPA
Pannello preltro
aspirazione
Panneau du prrltre
daspiration
Abdeckung der
Ansaugvorlters
Panel del preltro de

aspiracin
Suction prelter panel
XIII
Legenda
Rif.
Italiano
English
Franais
Deutsch
Espaol
PS
Pannello superiore
Top panel
Panneau suprieur
Oberseite
Panel superior
Raccordo
Fitting
Raccord
Anschlu
rACOR
RA/RO
Radiatore aria
Radiatore olio
After cooler
Oil cooler
Radiateur sir
Radiateur huile
Luftkhler
l-Khler
Radiador de aire
Radiador de aceite
RF
Rotore femmina
Female rotor
Rotor femelle
weiblich Lufer
Rotor hembra
RLMAX
Riferimento
di livello max. olio
Max. oil level reference
Repre de niveau
maximum huile
Bezug Max.lstand
Referencia de nivel mx.

de aceite
RLMIN
Riferimento
di livello min. olio
Min. oil level reference
Repre de niveau
minimum huile
Bezug Mindestlstand
Referencia de nivel min.

de aceite
RM
Rotore maschio
Male rotor
Rotor mle
mnnlich Lufer
Rotor macho
RSC
Rubinetto scarico
condensa
Air receiver condensate

discharge valve
RSO
Rubinetto scarico olio
Oil drain valve
Robinet dvacuation
de lhuile
lablahahn
Grifo de descarga de
aceite
SA
Serbatoio aria
Air receiver
Rservoir air
Lufttank
Depsito de aire
SCE
Sportello cassetta
elettrica
Electric box panel
Panneau
armoire lectrique
Starter/Kontroll Box
seite
Puerta del
quadro elctrico
SF
Sportello ltri
Filter panel
Panneau des ltres
Filterklappe
Puerta de los ltros
SPA
Sportello angolare
Corner panel
Panneau angulaire
Eckklappe
Puerta angular
SS
Serbatoio
separatore
miscela aria/olio
Air-oil separator
receiver
Rservoir
sparateur du
mlange air/huile
Luft/l-Abscheider
Depsito
separador mezcla
aire - aceite
STO
Sensore di temperatura
olio
Oil temperature sensor
Capteur de temprature
de lhuile
l-Temperaturfhler
Sensor temperatura
aceite
TM
Targhetta metallica
dati macchina
Serial number
and general
machine data plate
Plaquette
mtallique
didentication
machine
Seriennumer und
allgemeine
Maschinen Daten
Placa metlica con

los datos de la
mquina
TO
Tappo olio
Oil ller plug
Bouchon de
remplissage huile
l-Filter
Verschluss
Tapn del aceite
TRL
Tubetto di riferimento
livello olio
Oil level reference pipe
Tube de rfrence
niveau huile
Bezugsleitung
lstand
Tubo de referencia nivel

de aceite
VA
Valvola di
aspirazione
Intake valve
Soupape
dadmission
Ansaugventil
Vlvula de
aspiracin
VR
Valvola di ritegno
e di minima
pressione
Minimum
pressure and
check valve
Clapet de
retenue et de
pression minimum
MindestdruckKontrollventil
Vlvula de
retencin y de
presin mnima
VS
Valvola
di sicurezza
Safety valve
Soupape
de surpression
Sicherheitsventil
Vlvula
de seguridad
VT
Valvola
termostatica
Thermostatic valve
Soupape
thermostatique
Thermostatventil
Vlvula
termosttica
Robinet de vidange de
Kondenswasser
leau de condensation du
Ablasshahn des Luftanks
rservoir air
XIV
Grifo de descarga de
la condensacin del
depsito de aire
Table of contents
1
Foreword
20
Symbols
2.1 Symbols in the manual
2.2 Compressor symbols
2.3 Control panel mc2 symbols
21
Warranty terms
23
Performance and specications
24
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
21
21 G
22 B
General data
24
Compressor rating data
24
Air receiver
25
Compressor
25
Electrical motor and drives
25
Power supply data
25
Lubricating and cooling uid
27
Dryer
87
Pag. 15
4.9
G
B
Clearance requirements
and system layouts
Safety precautions
27
28
5.1
General precautions
5.2
Safety precautions for maintenance 28

operations
Handling and installation

6.1
6.2
6.3
6.4
6.5
7.2
7.3
30
Handling instructions
30
Installation site requirements
30
Air connection
94
Electrical connection
33
Conguration for remote control
33
Start-up and operation

7.1
28
35
Checks to be carried out

prior to start-up
35
mc2 control panel
35
7.2.1
Control unit mc2
36
7.2.2
38
Starting and stopping the compressor 38

Pag. 16
7.4
7.5
Parameter conguration menu tree
41
7.4.1
Additional information menu
42
7.4.2
Menu tree
(control and programming)
43
7.4.2.1 PASSWORD menu
44
7.4.2.2 MAINTENANCE menu
44
7.4.2.3 GENERAL SETTINGS menu
46
7.4.2.4 NETWORK SETTINGS menu
51
7.4.2.5 OPERAT. PARAMETERS menu
52
7.4.2.6 PROGRAMMING menu
54
7.4.2.7 DIAGNOSTICS menu
56
7.4.2.8 INFORMATIONS menu
58
Operating warning and faults
58
Compressors in sequence
61
Troubleshooting
62
9.1 The machine does not start

9.2 The compressor has trouble starting up
9.3
Pressure value lower than rated

pressure
Pag. 17
62
63
63
G
B
G
B
9.4
The machine is ready for start or is running

and the scheduled maintenance LED is on
64
9.5
The machine is ready for start or is running

with critical functioning message
64
9.6
The machine stops when it is running

and warning LED comes on
65
9.7 Oil in the network

9.8 Oil in the machine
9.9 Safety valve VS intervention
10 Maintenance
66
66
67
68
10.1 Operating cycle
maintenance
10.2 General
operation table
10.3 Replacement of the suction prelter
10.4 Cleaning or replacing the air lter
oil level, topping up and
10.5 Checking
changing the oil
the oil lter and the
10.6 Replacing
separator lter
10.7 Draining the condensate
10.8 Replacing the fuses
Pag. 18
68
69
71
71
73
75
76
77
11 Spare parts and Service Centres
parts and consumable

11.1 Spare
material codes
12 Diagrams
78
78
80
12.1 Hydraulic-pneumatic plant diagram

circuit wiring diagram
12.2 Power
5,5 - 15 kW Machines without air dryer
12.3 Power
5,5 - 15 kW Machines with air dryer
80
82 G
B
83

12.4 Power
11 kW Machines with inverter
84

12.5 Auxiliary
85

12.6 Auxiliary
86

12.7 Auxiliary
11 kW Machines with inverter
87
12.8
Wiring diagram for component location
12.9
Wiring diagram for component location
Pag. 19
88
89
Foreword
Dear Customer,
Congratulations on buying this compressor and thank you for your condence in our Company.
G
B
The machine in your possession is a lubricated rotary screw compressor, incorporating state-of-the-art
compressed air technology.
The GENESIS - FORMULA - MODULO series screw compressors are characterised by high energy output
and low noise.
Major features incorporated in the design phase include versatility of use, reliability, low running and
maintenance costs, compact size, and top ight performance. This range of compressors has also been
designed and constructed complying with the strict quality control standards that are one of the main features
of all products manufactured at our plants.
The product is EC marked and complies with current European Directives, as shown in the Declaration of
Conformity attached to this handbook.
The compressor must be installed by specialized personnel of authorized service Centres.
Before starting the machine, read all sections of this handbook and always comply with the
instructions provided which explain correct use and routine maintenance of the compressor
and the precautions to be taken to ensure operator safety.
This manual must always accompany the compressor so that it is available for all those working with it.
As concerns general maintenance, we recommend arranging a scheduled maintenance contract with our
authorized Centres.
Pag. 20 - Chap. 1 Foreword
Symbols
Symbols in the manual
2.1
This symbol indicates that the instructions manual should be read with great care before carrying out any operation on the machine
This symbol highlights operations or types of behaviour that could result in fatal injury or serious accidents to operators who must always be informed of these and take the necessary
precautions.
This symbol also accompanies the description of operations that require special attention on the part of the user.
You will nd this symbol next to the descriptions of operations which must be carried out by
authorized service Centres only
This symbol is provided to remind you that waste oil, condensate and lters removed from the
machine are polluting materials and must be disposed of in compliance with local laws
Compressor symbols
2.2
This symbol means that you must not put your hands inside the machine when it is
running
This symbol indicates the presence of rotating parts inside the compressor
Do not carry out maintenance or repair operations when the machine is running
This symbol indicates the presence of electrical power inside the machine
This symbol indicates the direction of rotation of the main electrical motor and fans
This symbol indicates the oil ll plug

These symbols indicate the direction in which to turn the key (provided) to open and close the
control panels of the machine and the control box
These symbols indicate compressor rated voltage
This symbol indicates the presence of high temperature components inside the compressor
P. 21 - Chap. 2 Symbols
G
B
Control panel mc2 symbols

This symbol indicates the K1 START key
2.3
This symbol indicates the K2 STOP key
RESET
ESC
This symbol indicates the K3 RESET key

This symbol indicates the K4EXIT key
This symbol indicates the K6 UP key
G
B
This symbol indicates the K6DOWN key
+
-
This symbol indicates the K7PLUS key

This symbol indicates the K8MINUS key
This symbol indicates the K9 ENTER conrmation key
This symbol indicates the voltage present LED L1 (yellow)
This symbol indicates switching on of warning LED L2 (yellow)
This symbol indicates switching on of alarm LED L3 (red)
This symbol indicates switching on of LEDs L4 and L5 (red) indicating AUTORESTART and
REMOTE/PROGRAM located on the electronic control unit
This symbol indicates a message on the display of the electronic control unit
P. 22 - Chap. 2 Symbols
Warranty terms
The product was tested before delivery. The machine is guaranteed for twenty-four months from the date of
the invoice.
The warranty is valid only if the purchaser has complied with contractual and administrative regulations and if
the compressor has been installed and operated according to the instructions provided in this handbook.
The Customer is required to ll out all parts of the warranty card and send it within thirty days from the date
of purchase (as attested by the postmark).
According to the terms of the warranty, the Manufacturer undertakes only to repair or replace, free of charge,
the product or parts of this found to be faulty following examination by the Manufacturers technical personnel or authorised repair company. Labour and transport are, in any case, excluded from the clauses of this
warranty, and they will therefore be charged to you.
The warranty, which excludes all and any liability for direct or indirect injury or damage, is restricted only to
construction and manufacturing defects of machine components.
The warranty does not include parts which, due to their specic use, are liable to wear and tear such as seals,
belts, etc. and all consumables such as air lter, oil lter, oil separator lter, etc The warranty does not cover
repairs due to damage caused by insufcient or incorrect maintenance or unsuitable application..
The warranty shall be null and void in the case of failure to comply with the instructions given in this handbook,
use of non-original spares and scheduled maintenance carried out directly by the Customer without the related
invoice for the original parts.
The information given in this handbook is for guidance purposes only and is not binding. The Manufacturer
reserves the right to make any product modications it considers necessary without prior notice.
P. 23 - Chap. 3 Warranty terms
G
B
Performance and
specications
4.1
General data
Model Pressure
bar
G
B
5.5
8
10
13
15
7.5
8
10
13
15
11
8
10
13
15
15
15
8
10
13
15
8
10
13
15
Motor
power
Air end
kW
5.5
7.5
11
Capacity
Oil
m3/min
Kg
Weight
Dimensions
Noise
levels*
mm
dB(A) - Lp(A)
Kg
Base
270 l
500 l
BA51
0.78
0.69
0.54
0.40
270
+
28
dryer
355
+
28
dryer
414
+
28
dryer
1030 x 615 x 1045

1180 x 600 x 1645 (Genesis 270 l.)
1960 x 600 x 1645 (Genesis 500 l.)
66
BA51
1.20
1.04
0.80
0.64
275
+
28
dryer
360
+
28
dryer
419
+
28
dryer
1030 x 615 x 1045

1180 x 600 x 1645 (Genesis 270 l.)
1960 x 600 x 1645 (Genesis 500 l.)
68
BA51
1.65
1.40
1.17
0.95
275
+
32
dryer
360
+
32
dryer
419
+
32
dryer
1030 x 615 x 1045

1180 x 600 x 1645 (Genesis 270 l.)
1960 x 600 x 1645 (Genesis 500 l.)
69
300
+
32
dryer
385
+
32
dryer
444
+
28
dryer
1030 x 615 x 1045

1180 x 600 x 1645 (Genesis 270 l.)
1960 x 600 x 1645 (Genesis 500 l.)
69
286
+
32
dryer
371
+
32
dryer
430
+
32
dryer
1030 x 615 x 1045

1180 x 600 x 1645 (Genesis 270 l.)
1960 x 600 x 1645 (Genesis 500 l.)
69
15
BA51
15
BA69
2.01
1.72
1.49
1.16
2.32
1.93
1.62
1.30
3 dB(A) to standards PNEUROP/Cagi
4.2
Compressor rating data
A metal plate TM indicating the compressor specications is

applied to the machine: gure 25 shows the position
TM
Fig. 25
P. 24 - Chap. 4 Performance and specications
PF
4.3
Air receiver
Capacity of 270 or 500 litres according to model; type approved at 11 or 17 bar depending on the model.
4.4
Compressor
5.5-15 kW
Patented VT series air-end unit, single stage, BA51 model, oil
injection lubricated
RM
15 kW
Patented VT series air-end unit, single stage, BA69 model, oil
injection lubricated:
RF
Drive male rotor RM, ve lobes, offset prole
G
B
Driven female rotor RF, six utes, offset prole

Fig. 26
Electrical motors and drives
4.5
Compressor start-up
Fixed speed motors
Two-pole, closed, three-phase asynchronous motor (rated speed of 3000 rpm at 50 Hz, 3600 rpm at 60 Hz,
protection rating IP54, insulation class F, service class S1, reference MP in Figs. 14, 16, 18, 20, 22, 24)
Variable speed motors
Four-pole closed three-phase asynchronous motor (rated speed of 1500 rpm at 50 Hz, protection rating IP54,
insulation class F, service class S1, reference MP in Figs. 14, 16, 18, 20, 22, 24), intended for use at variable
speed through powering with inverter
Electric fan
Fan coaxial to the electrical motor (reference EV in Figs. 13, 15, 17, 19, 21, 23)
Drives
Compressor motor - drive by means of removable taper bushing pulleys and toothed V-belts (reference CT
in Figs. 13, 15, 17, 19, 21, 23)
Electric fan: direct, co-axial transmission
Power supply data
4.6
Three-phase power supply; voltage and frequency according to rating data. Supply cables with a minimum
cross-section area as shown in tables 1and 2. Mains fuses and ground circuit breaker as shown in the following table.
Pressure
Power cable
cross-section area
Main fuses AM
(motor rated) or ground
circuit breaker setting
Circuit breaker
bar
mm2
8
10
13
2.5
16
16
7.5
8
10
13
15
20
20
11
8
10
13
15
25
25
15
8
10
13
15
10
40
40
15
8
10
13
15
10
40
40
Model
Pressure
Power cable
cross-section area
Main fuses AM
(motor rated) or ground
circuit breaker setting
Circuit breaker
bar
mm2
8
10
13
25
25
Model
5.5
15
400 V
G
B
5.5
15
7.5
8
10
13
15
10
40
40
11
8
10
13
15
16
50
50
15
8
10
13
15
25
63
63
15
8
10
13
15
25
63
63
230 V
Lubricated and cooling uid

The compressor is lled with DICREA 46 lubricated and cooling uid
4.7
Total capacity:
7 Kg
Top up with lubricated and cooling uid with the same specications as the lubricated and cooling uid in
the machine (synthetic coolant I.E. ABAC DURALUBE may be specied)
Contact the Manufacturers technical Department before using lubricated and cooling uids with other
specications
4.8
Dryer
Thermostat controlled cooling cycle, direct expansion, with Freon R134a gas; pressure dew point
temperature 3C, clean air ltering degree 0,01mm.
Filtration degree:
Oil carryover:
1 m.
0,1 mg/m3
Displayable dew point temperature

Cooling compressor and timed condensate drain, controlled from mc panel2
Clearance requirements and system layouts
4.9
The tables with the overall dimensions of the compressor are provided in gures 1-12
The hydraulic/pneumatic system diagram and the wiring diagrams (operation and location) are shown in
Chapter 12
G
B
Safety precautions
General precautions
5.1
Use of the machine by unskilled personnel without adequate supervision is not allowed.
Keep children and animals away from the working area.
Do not direct compressed air jets towards yourself or other people.
Always use goggles to protect your eyes from objects which can be lifted by the jet of air.
Never operate on the machine with bare feet or wet hands.
G
B
The compressor is designed solely to produce compressed air and cannot therefore be used for
any other type of gas.
The compressed air produced by the machine cannot be used for respiratory assistance,
pharmaceutical or sanitary purposes or in production plants where the output air comes
into direct contact with food products unless an additional adequate air treatment system
is employed
The air taken in by the compressor must be absolutely free of dust, vapours, explosive or ammable gases,
solvents or powder paints and toxic fumes of any type.
Use of compressed air requires knowledge of and compliance with the safety precautions to be adopted for the
individual applications (inating, pneumatic tools, painting, washing with water-based detergents only, etc.).
Machine operation is fully automatic.
The machine carries out the various work cycles, as required by the user, according to the settings.
After use, stop the machine and disconnect the main panel power.
Use of the machine for other purposes shall be considered as improper use and the Manufacturer shall not
be liable for any resulting damage or injury.
Safety precautions for maintenance operations
5.2
Routine maintenance operations can be carried out by the user as described in this handbook.
Only the use of original spare parts will guarantee long, safe and reliable service life of the equipment
Refer to Chapter 10 for instructions on the operations that can be carried out by the user.
All major maintenance operations can be carried out only by the specialised personnel of
authorised Service Centres
P. 28 - Chap 5 Safety precautions
Disconnect the power supply, vent the air and wait for the machine to cool before performing
any operation or removing the guards
After disconnecting the power, lock out the circuit breaker to prevent accidental start-up
while operating on the compressor. Additionally, close the shut-off valve between the compressor and the line
All the air has been discharged from the machine when pressure gauge MPI shows zero
pressure
No changes must be made to machine internal electrical, pneumatic, hydraulic circuits and/or to the settings. In particular, do not modify the maximum working pressure values and the valve settings, especially
the safety valves.
Do not use solvents, ammable or toxic uids to clean the machine parts. Use alkaline detergents only. Never
use detergents to clean the motor or the electrical/electronic components.
Do not weld or carry out mechanical machining operations on the receivers. If damaged or rusted, replace
the parts, as they are subject to specic safety regulations.
At the end of each operation, ret the guards carefully. Comply with the same precautions for initial startup.
Remember that waste oil, condense and machine lters are polluting materials. Dispose of
these products in compliance with local legislation
Careful scheduled maintenance will contribute to maintaining machine efciency and user safety conditions
in time.
P. 29 - Chap 5 Safety precautions
G
B
Handling and
installation
6.1
Handling instructions
Use a forklift truck to handle the compressor
making sure that the forks are positioned in the
machine base unit supporting feet (Fig. 27).
G
B
Lift the machine from the front only both for the
basic version and version with receiver.
For the machine with 270 lt receiver, the
maximum width of the forks is 540 mm; no
restriction exists for the machine with 500 lt
receiver.
Make sure the load is properly balanced.
Fig. 27
Alternatively, a pallet truck can be used for

short distances. Avoid any excess stress on
the metal structure (Fig. 28).
When using a lifting device for handling do
not exert force on the sides of the machine to
prevent damage to the unit and control panel.
Make sure that the load is balanced.
Fig. 28
Receivers under pressure, even if small, must never be transported
Installation site requirements
6.2
General remarks
The machine should be installed by authorised Service Centre skilled personnel to ensure that machine
installation site is suitable.
The machine is ready to be installed and does not require foundations. Site the compressor on level ground,
in a stable position, with the weight evenly distributed on the supports.
P. 30 - Chap. 6 Handling and installation
The environmental conditions that represent the operating range of the compressor are indicated below:
- Maximum installation altitude (above sea level) ................................................................................ :1000 m
- Minimum ambient temperature ......................................................................................................... :+5 C
- Maximum ambient temperature ........................................................................................................ :+40 C
Machine performance, as indicated in this handbook, is guaranteed only if the machine is installed at an
altitude below the operating limit indicated.{228}
Contact the Manufacturers Technical Department in the case of particular environmental conditions.
Outdoor installation
Figure 29 shows an example of outdoor
installation.
The compressor must be protected against
atmospheric agents. Suitable protection is
required if the compressor is located outdoors.
Comply with the minimum distance from the
walls (0.6 mm).
max. 5000
min. 3000
600
Fig. 29
Indoor installation
The machine is not suitable for use in environments with a risk of explosion.
The air taken in by the compressor must be absolutely free from dust, vapours, explosive
or ammable gas, solvents or paint powder and toxic fumes of any sort. Replace the lters
more frequently - with special reference to the air lter - if the machine is used in critical
environments (presence of ceramic, marble, cement, dust, etc.).
The dimensions of the installation site and
ventilation devices must ensure that ambient
temperature remains within the limits indicated
during duty cycle operating conditions.
If a suitable hot air discharge opening is not
provided, install one or more air evacuation
hoods. The hoods should be installed as
high as possible in relation to the dimensions of the premises.
Fig. 30
G
B
The machine cooling air and the heating ducts

(where relevant) must be dimensioned so that
air speed does not exceed 3 m/s. The maximum length of the ducts is 6 m. If this is not so,
t an auxiliary fan in the hot air duct.
Following installation of the hot air ducts, check that any back pressure, measured at the outfeed of
the hot air from the compressor, does not exceed 5-6 mm of water column.
For guidance purposes, duct cross-section area should be equal to that of the compressor hot air outlet grill
(reference FU in Figs. 14, 16, 18, 20, 22, 24).
Heat the environment if the minimum temperature required cannot be guaranteed.
G
B
Comply with the minimum distances from the

walls shown in gure 31
600
600
The position of the compressor in the room

should allow easy inspections. If the compressor is installed in the working environment,
keep at suitable safety distance according to
the type of process carried out at the premises
in order to prevent hazards or damage to the
600
machine due to the products used.

Fig. 31
The compressor should not be installed in a

recess which does not allow correct ventilation. Hot air ow should not be obstructed in
any way and recirculation must be prevented
(Fig. 32).
Fig. 32
6.3
Air connection
When connecting the compressor to the receiver or to the distribution line, it is good practice to insert a hose
of suitable size and specications (pressure and temperature) connected to the MA sleeve (Figs. 14, 16, 18,
20, 22, 24). The compressed air lines must be in perfect conditions and suitably fastened.
In particular, hoses which are not perfectly secured may cause severe injuries due to unpredictable movements. Make sure that the hose ends are rmly secured before pressurizing them.
The condensate drain must be connected to a collection system with a suitable pipe as established by local
regulations for the disposal of polluting substances.
Electrical connection
6.4
The electrical power system must include a main circuit breaker with line sectioning function that can be
padlocked, with fuses or thermal cut-out suitably rated according to the characteristics of the machine, and a
device against accidental contacts in order to protect personnel.
The setting of the safety devices and the rating of the line circuit breaker must comply with the indications
provided in the table of paragraph 4.6.
The circuit breaker must be positioned close to the machine. Comply scrupulously with specic local accident
prevention regulations.
The power cables must have an adequate cross-section area for current take-off (see the table in paragraph
4.6).
Electrical systems must comply with the rules of good workmanship and be installed by a qualied electrician
who must check the efciency of the earthing system.
The power cable must be secured in the specic glands and the electrical panel must be tightly closed to
achieve the prescribed IP44 protection rating.
Connect the machine only to type-approved sockets. The sockets must be earthed and tested.
Have correct fastening of the electrical cables of the various components checked regularly by qualied
personnel.
Chapter 12 contains the operational and layout wiring diagrams of the auxiliary and power circuits. The same
diagrams are also shown inside the machine control box.
Conguration for remote control
6.5
This paragraph describes how to congure the compressor for remote starting and stopping of this.
Alternatively, it is also possible to check operating mode (load / unload) or both functions by means
of an external control logic.
The operations described must be carried out by a qualied electrician.
To congure the remote control of the compressor, rst of all remove the jumper between terminals 3 and 38
of the terminal strip inside the electrical cabinet (see wiring diagrams in Chapter 12)
One or two switches must be installed as described below according to whether only switching ON/OFF
and/or operating mode is to be controlled.
Remote control ON/OFF

(see paragraph 7.4.2.3 - Remote control type)
The switch must be connected to the following terminals after removing the jumper:
3 digital INPUT common terminal
G
B
38
remote control digital INPUT terminal
LOAD/NO-LOAD remote control

The switch must be connected to the following terminals after removing the jumper:
3 digital INPUT common terminal
38
ON/OFF - LOAD/NO-LOAD remote control
G
B
Two switches must be used for this conguration.

The switches must be connected to the terminals after removing the jumper:
ON/OFF SWITCH
3
digital INPUT common terminal
38
LOAD / NO-LOAD START SWITCH
3
digital INPUT common terminal
39
Following modications to the wiring, the remote control must be congured as explained in paragraph
7.4.2.3 - Local/remote /program control - Remote control type
Start-up and operation

Checks to be carried out prior to start-up
7.1
N.B.: The Customer is responsible for installing the machine and making the required electrical and
air connections.
Initial system start-up must be carried out by skilled personnel who will make the various
checks required and follow the respective instructions.
Each machine was thoroughly tested at the plant before shipping.
You should monitor the compressor during the rst hours of operations to check for faults.
Follow the installation prescriptions given in chapters 5 and 6
Remove all packaging materials and tools
Connect the compressor to the distribution line as shown in paragraphs 6.2 and 6.3
Check the oil level in the receiver: see paragraph 10.5. If the level is low, top up with lubricating oil of
suitable specications
Check for correspondence between the compressor plate data with the actual specications of the
electrical system. A variation of 10% with respect to the rated value is allowed
Connect the machine to the electrical system as described in paragraph 6.4
Compliance with the correct voltage phase
sequence is fundamental since this denes the
direction of rotation of the motor. The direction
of rotation must be that indicated by the adhesive label located to the side of the screw unit
(gure 33).
Note that even a few seconds of incorrect rotation
may cause serious damage.
A phase sequence checking device to prevent
mistakes is tted in the electrical panel.
Fig. 33
The machine is now ready to be started.
Before starting the machine read the following paragraph and chapter 10 on maintenance
operations for in-depth knowledge of the machine.
mc2 Control panel
7.2
The compressor is tted with a control panel (reference PC gures 13, 15, 17, 19, 21, 23) for setting up and
monitoring machine operation. The operating parameters were entered by the Manufacturer during testing.
The parameters were tested for several hours in the various operating conditions.
The features offered by this electronic control system includes:
Fully automatic compressor operation
Real-time operating parameter display
P. 35 - Chap. 7 Start-up and operation
G
B
Customization operating parameter

Programming of compressor operation on a daily or weekly basis
Programming and signalling of the Manufacturers maintenance schedule
Machine self-protection system to signal fault pre-alarms and automatically stop the machine in the
event of serious problems
Remote machine control
Possibility of connecting the compressor via CAN-BUS interface (optional) to other similar compressors
for integrated management of the set of machines
Remote compressor monitoring via personal computer and dedicated software (optional)
The panel has two sections:

Control unit mc2 of the
compressor
G
B

Fig. 34
Control unit mc2
7.2.1
K4
The front panel of the control unit mc 2

comprises:
K5
K7
K6
K8
compressor programming and

control keyboard
K9
Indicator / setting LEDs

L5
back-lit LCD display
Fig. 35
K1
K2
L1 L3 L2 K3 L4
Control and programming keyboard

K1
START button (starting the compressor)
Used to start the machine. If remote control or programming (daily/weekly) are enabled, this key is used to enable
compressor functioning (priority control from keyboard). If alarm conditions have occurred, pressing of this key
has no effect
K2
STOP button (stop the compressor)
Permits timed stopping of the machine. If remote control or programming (daily/weekly) have been enabled, this
key can be used to disable compressor functioning (priority control). It does not operate at emergency level
RESET
K3
RESET button
Makes it possible to reset compressor fault messages after eliminating the causes of these. As the faults can be
displayed only in the main screen page, the RESET key is effective only during display of this.
During parameter modication operations, the RESET key can be used to restore the preset factory (default)
value for the type of compressor selected
ESC
K4
ESC button
Used to return to the main menu (previous level) or to cancel the modications made.
If the key is held down, the control unit returns to the main screen page.
If OFF, back-lighting of the display is re-activated the rst time the key is pressed without performing any other
function
K5
UP arrow key
Used for upward scrolling of menu items;
during setting of multiple-choice parameters. makes it possible to select one of the available options.
K6
DOWN arrow key
Used for downward scrolling of menu items;
during setting of multiple-choice parameters. makes it possible to select one of the available options.
function
+
-
K7
PLUS key
Makes it possible to increase the value of the parameter being modied.
Starting from the main screen page, permits access to additional information and scrolling of this
function
K8
MINUS key
Makes it possible to decrease the value of the parameter being modied
Starting from the main screen page, permits access to additional information and scrolling of this
function
K9
ENTER / CONFIRM key
Used to access the menu displayed (next level).
Starting from the main screen page, makes it possible to access the menu tree.
Used to conrm the value or selection made during modication of a parameter.
function
Indicator / setting LED

L1
Voltage present LED (yellow)
Must always be ON when the compressor is powered
L2
warning LED (yellow)
This LED switches on to indicate critical conditions or a minor fault that does not block the compressor; this
indication may refer to the need for maintenance or irregular operating conditions. Switching ON of this LED is
always accompanied by a descriptive message that can be displayed in the main screen page
L3
Alarm LED (red)
This LED switches on (steady light) to indicate that the compressor has been blocked by a serious fault; the type
of fault is described with a message in the main screen page. Once the fault has been reset, the LED starts to
ash, informing the operator that the situation can be reset with the RESET key
L4
AUTORESTART LED (red)
This LED switches on when the AUTORESTART function is enabled.
In the case of automatic restart following a blackout (AUTORESTART function enabled) the LED ashes to indicate
that the compressor is about to restart. The display shows the countdown to restart
L5
REMOTE / PROGRAM functions active LED (red)
This LED switches on when the remote control function or one of the programming functions (daily-weekly) is
enabled.
If the compressor is installed in line with other similar compressors and communication on a CAN-BUS is enabled,
LED L5 assumes other functions. Refer to chapter 8 Compressors in sequence
G
B
Display
DI
DI Multi-function display
Back-lit LCD display with four lines of twenty characters each: shows compressor operating conditions and is used
to carry out all programming and control operations
7.2.2
G
B
The red EMERGENCY STOP button PE (ref.

gure 36) stops the machine immediately.
Use this button for emergencies only
in conditions which appear hazardous
for the operator or for the machine (see
Compressor emergency STOP below).
Fig.36
7.3
Starting and stopping the compressor

STARTING the compressor
When the machine is switched on (powered) the control unit starts the initial sequence and prepares to control the
compressor.
According to the sequence, with the LP led ON steadily, the following screen page must be shown on display DI:
This screen page indicates:
LINE 1
LINE 2
LINE 3
LINE 4
name of the compresso

/
software version which may differ from that
indicated
serial number of control unit, different for each
machine
<<<<mc2>>>>
Ve r s . S o f t . : 1 . 0 . 0 . 1
S/N: 000-00-01-00001
After a few seconds, the display shows the main screen page:
This screen page indicates:
LINE 1
LINE 2
LINE 3
LINE 4
indication of network pressure

indication of compression temperature of airoil mixture
messages about operating conditions
hour and date, informations menu access,
tree menu access, quick language change
message
XX.X bar
Pressione
Temperatura XXX C
Pronto allavvio
10:40 DOM 25/05/2003
To change the language, use the K5 and K6 keys

If the compressor is operating, LINE 1 and LINE 2 always show the above information.
Particular indications (error messages), additional information or the information of the management
menu are displayed on LINE 3 and on LINE 4.
If LINE 3 shows Ready for start, the compressor can be started.

The compressor is started by pressing the green K1-START key
At this point, the compressor may:
a)
start, displaying the messages referring to the start and functioning phases
b)
prepare to start with the following message
In this case, network pressure is above the minimum
threshold value set; the compressor will start automatically
in the case of a request for air from the network
Stand by auto start

hour-date
c)
d)
In this case, the remote control function has been enabled

(see paragraph 7.4.2.3).
The compressor will start when the remote command is
received
Stand by rem. com.

hour-date
In this case, the daily or weekly programming function

has been enabled and the compressor is in the OFF
programming phase (see paragraph 7.4.2.6).
The compressor will start when an ON programming
phase is initiated.
Stand by progr. com.

hour-date
If the compressor does not start or none of the cases listed above occurs, refer to chapter 9.
The following contacts will be made in sequence:
LINE - STAR - DELTA
6
Start
hour-date
Start
hour-date
and one of the two messages will be displayed

7
Load run
hour-date
Unload run
hour-date
When the display shows Load run the intake valve is open and the machine operates at full load (produces
the nominal capacity of compressed air).
During functioning, delivery pressure increases; once the preset maximum line pressure threshold value has
been reached, the control system sets the compressor to idling by closing the intake valve (Unload run).
When the pressure drops below the preset minimum threshold value, the intake valve opens again and the
machine restarts functioning at full load.
During unload run, two cases may arise:
a)
Setting of AUTOMATIC functioning

(see paragraph 7.4.2.3):
G
B
The compressor outputs this message followed by a

countdown.
At the end of the countdown, the compressor switches off,

changing to Stand-by auto start, status, ready to restart
in the case of a request for air
b)
Stand by auto start

hour-date
Setting of CONTIN. functioning

(see paragraph 7.4.2.3):
G
B
Unload run
hour-date 04m 59s
The compressor outputs the Unload run message,

the machine never stops, always remaining available to
restart production of compressed air immediately in the
case of any request.
Unload run
hour-date
STOPPING the compressor

Machine starting and stopping is timed.
Simply press the K2 button to stop the compressor
The compressor does not stop immediately but initiates a set of operations to stop the machine according to
operating conditions when the STOP command is invoked.
If, at the time of the STOP command, the compressor was operating at full load, the control unit sets the
machine to unload run.
10
Display DI shows this countdown; at the end of the

countdown, the motor is stopped.
At this point, the display shows this additional timing:

during this phase, the compressor vents the pressure
inside the separator reservoir preparing for subsequent
restart.
11
If the K1-START key is pressed again before the

preset timed restart time has passed, a new timing
is shown on display D1 which indicates the time to
compressor restart
This function prevents restarting the compressor

when it is still pressurized, avoiding electrical motor
verload.
Stop in XXX sec.

hour-date
Blowdown in XXX sec.
hour-date
Start in XXX sec.

hour-date
Compressor emergency STOP

Press the PE red EMERGENCY STOP button to stop instantaneously the compressor in a hazardous
situation
The emergency stop button is intercepted by the

monitoring unit which displays the following message
with LED L3 on
RESET
EMERGENCY STOP
compress.-Block
To reset, release the EMERGENCY STOP button lock

and press button K3-RESET
12
7.4
Parameter conguration - menu tree
The machine was congured at the plant during testing; the end user, however, can change some operating
parameters to customize machine performance to the specic applications.
Other parameter changes cannot be made Customer but only by Authorized Service Centre skilled
personnel.
The main screen page is displayed as follows:
13
LINE 1
LINE 2
LINE 3
LINE 4
net pressure
compression temperature of air-oil mixture
messages about operating conditions
hour and date, informations menu access,
tree menu access, quick language change
message
XX.X bar
Pressure
Temperature XXX C
Ready for start
10:40 DOM 25/05/2003
To change the language, use the K5 and K6 keys

After 60 seconds from pressing of the last key, the display is set to a low level of brightness.
The rst time a key is pressed (excluding the K1-START, K2-STOP, K3-RESET control keys), high level
brightness of the display is restored while subsequent pressing of the keys produces the associated
function.
From the main screen page, it is possible to access:

14
a) to ADDIZIONAL INFORMATIONS
using the K7 (PLUS) and K8 (MINUS)
keys
This menu permits fast access to signicant
information without having to enter the
menu tree; the main screen page is
redisplayed using the K4-ESC key or
automatically after 60 seconds
XX.X bar
Pressure
Temperature XXX C
Ready for start
10:40 DOM 25/05/2003
b) to MENU TREE
using the K9 (ENTER) key
This menu permits access to all compressor
control and programming functions; the
main screen page is redisplayed using
the K4-ESC key or automatically after
60 seconds
ESC
ESC
+ ADDIZIONAL
INFORMATIONS
7.4.1
MENU
TREE
7.4.2
G
B
7.4.1
Additional information menu
Menu A
+
Operating press.
Max:
G
B
8.0 bar
ESC
Operating press.
Min:
+
Type of control
Control:
LOCAL
ESC
AUTORESTART function
State:
OFF
ESC
Operating time
on load:
Time to service
oil:
(ref. paragraph 7.4.2.4.)
Indicates the total hours of operation of the compressor

(ref. paragraph 7.4.2.2)
XXXX hours
ESC
If enabled, indicates the status of the AUTORESTART function

(automatic restart following blackout)
XXXX hours
ESC
Indicates setting of the type of control:

LOCAL / REMOTE / PROGRAM
4-3-1-2
+
Operating time
total:
Indicates operating mode setting:

AUTOMATIC / CONTIN.
Indicates the order in which the machines are started
Net sequence
ID
ESC
Indicates the minimum operating pressure of the compressor.

Only if the CAN-BUS communication module

has been installed
ID compressor
N stazione: 1
ESC
Indicates the maximum operating pressure of the compressor.

Operating mode
State:
AUTOMATIC
ESC
MAIN SCREEN PAGE
7.0 bar
ESC
Pressure
XX.X bar
Temperature XXX C
Ready for start
hour-date
Indicates the hours of operation of the compressor at full load

XXXX hours
Indicates the time remaining to initial maintenance: any other

maintenance operations to be carried out within 100 hours from
initial maintenance are also displayed cyclically
It provides the information consulted most frequently and is shown below.
This menu can also be accessed with the compressor running.

If no key is pressed, the main screen page is redisplayed automatically after 60 seconds.
ESC
It is possible to return to the main screen page from any point of the menu by holding down the
K4-ESC key
7.4.2
Menu tree (control and programming)
This is the structured menu used to carry out all compressor control and programming operations.
Menu B
Pressure
XX.X bar
Temperature XXX C
Ready for start
hour-date
MAIN SCREEN PAGE
ESC
>MAINTENANCE
...
<
>GENERAL SETTINGS
...
<
>NETWORK SETTINGS
<
...

visible only if the
CAN-BUS interface has been installed
ESC
ESC
ESC
>OPERAT. PARAMETERS <

...
>PROGRAMMING
...
<
>DIAGNOSTICS
...
<
>PASSWORD
<
...
ESC
ESC
ESC
ESC
>INFORMATION
...
<
The options and setting in the various menu can be:
G
B
CONFIRMED
pressing the K9-ENTER key
10
OPERATION
COMPLETED
ESC
CANCELLED
pressing the K4-ESC key
RESET
Each time a parameter is modied, the factory-set (default value) can be restored for the selected
compressor pressing the K3-RESET key
OPERATION
ABORTED
PASSWORD menu
G
B
7.4.2.1
Used to enter a password to enable particular functions (e.g. AUTORESTART) or to access protected
menus.
For enabling of the AUTORESTART function, contact the Manufacturers Customer Service
The password is inserted using:
Menu C
>PASSWORD
<
>Enter
password
<
ESC
ESC
+ ESC
Enter password:
0000
keys K7 and K8 to modify the ashing character; numbers and letters are displayed subsequently
the K5 and K6 keys to move to modication of the previous / next character
After inserting the password, this can be conrmed with the K9-ENTER key or cancelled with the K4-ESC
key
If no other key is pressed, the password entered expires after ve minutes with possibly display of a re-entry prompt.
MAINTENANCE menu
7.4.2.2
This menu is used to display short-term maintenance operations, the remaining service life of each component,
to reset the life counters of each component (where this function is enabled), to display compressor hours
of operation.
Menu D
Press the K4 key to return to the MAINTENANCE menu

from the submenus ESC
>MAINTENANCE
<
ESC
>Time to service
<
Time to service
....
ESC
>Components life
xxx hrs
<
ESC
Time remaining for

air lter
xxx hrs
ESC
Time remaining for

oil lter
xxx hrs
ESC
Time remaining for

...
other components
only with access enabled
>Compon. replacement<
Replacement made for
air lter
OK?
ESC
ESC

oil lter
OK?
ESC
ESC
Conrm replacement
air lter
OK?
Conrm replacement
oil lter
ESC
Conrm replacement
...other components...
<
ESC
OK?

...other components...
ESC
>Running hours
G
B
Operating time
total:
xxxx ore
Operating time
load
xxxx ore
Time to service
Makes it possible to check the rst maintenance operation to be carried out on the compressor; the
maintenance operations to be carried out 100 hours after this are also displayed. In this way, the user
can schedule maintenance operations and, if necessary, decide whether to replace several components
during the same maintenance operation
Components life
indicates the remaining service life of each component that requires periodic maintenance
Compon. replacement
If the function is enabled, it makes it possible to reset the component life counters after maintenance
Running hours
Indicates compressor operating time (total running hours, running hours at full load)
G
B
A table with the schedule of the maintenance operations to be carried out is provided below
Intervention
First 100 hours

maintenance
coupon
Check air lter
Replace air lter
First 1000 hours

maintenance
coupon
Every 1000 hours Every 2000 hours
Change oil
Replace oil lter
Replace separator
lter
Replace air dryer
lters
Maintenance periods may differ from those indicated.

During installation, Service Centre personnel assess compressor operating conditions and if necessary modify
the frequency of the operations.
GENERAL SETTINGS menu
7.4.2.3
This menu allows to carry out the general settings of compressor operating conguration with the exception
of operating parameters (pressures, timings).
Language
Used to select the language of the messages
Measur. unit
Used to set the measurement units for pressure and temperature
(continued on p. 49)
Menu E (1/3)
Press the K4 key to return to the GENERAL SETTINGS

menu from the submenus ESC
>GENERAL SETTINGS
<
ESC
>Language
<
ESC
Select language:
ENGLISH
ESC
Select language:
..OTHER LANGUAGES..
>Measur. unit
G
B
<
ESC
Pressure unit
Unit:
ESC
Temperature unit
Unit:
bar
Cels.
Set date and time

hh:mm day dd/mm/yyyy
ESC
Contrast
Intensity:
XXX%
ESC
Lighting
Brightness:
ON
XXX%
ESC
Lighting
Brightness:
OFF
XXX%
>Date and time
<
ESC
>Display settings
<
continued on p. 48
Menu E (2/3)

continued from p. 47
>Operating mode
<
Operating mode
AUTOMATIC
ESC
Operating mode
G
B
CONTIN
ESC
>Compress. control
<
ESC
Compress. control
LOCAL
ESC
Compress. control
REMOTE
ESC
Compress. control
PROGRAM
Compress. control
NETWORK CONINUOUS
ESC
NETWORK PROGRAM
ESC
>DRYER control
Compress. control
only if the CAN-BUS

interface has been
installed
only on machines equipped

with integrated dryer
<
ESC
DRYER
enabled in ON
ESC
DRYER
Disabled
Continued on p. 49
Menu E (3/3)

continued from p. 48
>Type remote contr.
<
ESC
Type remote contr.

ON/OFF
ESC
Type remote contr.

LOAD/UNLOAD
ESC
Type remote contr.

ON/OFF-LOAD/UNLOAD
G
B
Only with access enabled
>AUTORESTART func.<
AUTORESTART
ESC
DISABLED
AUTORESTART
ESC
ENABLED
(continued from p.46)

Date & time
Used to set the current date and time
The time and date are entered using:
+ ESC
the K7 and K8 keys to modify the ashing values

the K5 and K6 keys to move to modication of the previous / next character
After entry of the values, these can be conrmed with the K9-ENTER key or cancelled with the K4-ESC
key.
Display settings
Makes it possible to adjust the settings of the LCD display
Operating mode
Compressor operating mode may be set AUTOMATIC or CONTINUOUS:

AUTOMATIC: this is the setting used in most cases (factory setting). In this operating mode, idling is
timed; at the end of the count, the compressor stops, preparing for subsequent automatic start-up (see
also paragraph 7.3 STARTING the compressor). This promotes energy saving if there is no or a very
low request for compressed air.
CONTINUOUS:this setting should be used in very particular applications characterized by a considerable
variation in compressed air consumption combined with a reduced plant accumulation capacity. With
this setting, the compressor starts unload run without ever stopping the motor and is therefore able to
supply air continuously in the case of a request from the network. The system configured in this way
is highly reactive. However, one of the drawbacks of this operating mode is that it entails higher power
consumption due to the fact that the compressor is always running (see also paragraph 7.3 STARTING
the compressor).
G
B
Compress. control
This menu is used to select the compressor control method from the possible local / remote / program
control options.
If the compressor is equipped with a CAN-BUS interface, the network-continuous / network-program
control options are also visible and can be selected.
Compressor control can be set to:
LOCAL: this is the basic (factory) setting that permits control from the keyboard
REMOTE: with this setting, the compressor can be controlled by means of an external remote switch.
For the electrical connections, refer to the following submenu (refer to the following paragraph Type of
remote control)
PROGRAM: enables the daily or weekly programming set and enabled in the PROGRAMMING menu
(see paragraph 7.4.2.6)
NET-CONTINUOUS: this is the setting for control of a sequence of compressors, without daily/weekly
program
NET-PROGRAM: this is the setting for control of a sequence of compressors according to the daily/weekly
program set
Dryer control
This menu is used to activate/de-activate the dryer
Type of remote control
For remote control, modications must be made to the wiring of the compressor as described in
paragraph 6.5.
When compressor control is set to REMOTE (see previous submenu), three types of control methods
are possible:
ON/OFF is the setting that makes it possible to control switching ON/OFF of the compressor. This is
the factory setting (that most frequently used) which makes it possible to exploit the control logic of the
compressor using the pressure signal measured locally by the machine
LOAD/UNLOAD is the setting that makes it possible to control full load and unload operation with an
external control logic: in this case, the pressure signal measured by the compressor is ignored for the
purposes of operating method control (the safety devices remain active)
ON/OFF - LOAD/UNLOAD is the setting that makes it possible to control both switching ON/OFF of the
compressor and also operating mode. In this case also, an external control logic must be used as, for
control purposes, the pressure signal is ignored (the safety devices remain active)
It should be remembered that control via the keyboard of the control unit always has priority over any
remote control or any program: this means that, if remote control is to be effective, the START button
must be pressed setting the compressor to Stand-by rem. con.. Similarly, the compressor can be
stopped without any risk of remote restart of this by pressing the STOP key.
Therefore, to enable functioning with remote control:
1) Make the modifications to the wiring connecting one / two switches as described in paragraph 6.5
2) Select REMOTE control
3) Select the control method (ON/OFF, LOAD/UNLOAD, ON/OFF - LOAD/UNLOAD)
4) Press the START key on the control unit to enable the compressor for remote control
Autorestart function
If enabled, this menu makes it possible to set the AUTORESTART function, useful for automatic restart
of the machine following a black-out and subsequent power-up.
NETWORK SETTINGS menu
7.4.2.4
This menu is used to set the parameters required for operation of the compressor in a network (in communication
with other similar compressors)
Refer to chapter 8 Compressors in sequence.
The menu is visible only after connection of the control unit with the CAN-BUS interface module for
communication between compressors.
Compressor ID
This is the identifier number of the compressor in a set of machines
Prefill
When the set of compressors is started with the compressed air system discharged (pressure zero or
very low), it is usually necessary to increase the pressure to the minimum working value as quickly as
possible. With the PREFILL function enabled, the compressor participates in system prefilling, bypassing
the global control functions in this phase.
The compressors involved in this operation are started quickly in sequence, thus avoiding any overlap of
the start-up phases of two or more machines
Rotation time
This is the time after which compressor start-up priorities are reassigned so that the work load is evenly
distributed between the machines available over a long period of time
G
B
Menu F
Press the K4 key to return to the NETWORK SETTINGS

>NETWORK SETTINGS
G
B
<
visible only if the

CAN-BUS interface has
been installed
ESC
compressor ID
n. of service points:
ESC
Prell
n. compr.
ESC
Prell time
Val.:
5 min
ESC
Max n. compr. ON
n. compr.
ESC
Rotation time
sequence
24 hrs
ESC
Reaction time
delay
ON xxx sec
ESC
Reaction time
delay
OFF xxx sec
Reaction times
T ON When the control system activates a compressor following a reduction in network pressure, timer T
ON is started: at the end of this count, the system checks network pressure to establish whether another
compressor must be started
T OFF When the control system deactivates a compressor following an increase in network pressure, the
T OFF timer is started: at the end of this count, the system checks network pressure to establish whether
another compressor is to be deactivated
OPERAT. PARAMETERS menu
7.4.2.5
This menu is used to make the conguration settings referring to the timings and operating pressure and
timings that regulate unload run and drainage of condensate.
Pressures
MAX. OPERATING PRESS.: The pressure above which the compressor starts to idle. The rated pressure
of the machine represents the upper limit of this value.
MIN OPERATING PRESS.: The pressure below which the compressor restarts operation at full load
(supply of compressed air) or at which it restarts if it has stopped at the end of unload run (no supply
of air). This value must be set so that the minimum supply pressure to the pneumatic service points is
guaranteed, taking into account losses of head of the distribution system. The minimum pressure value
cannot be close to the maximum pressure by more than the factory setting (minimum difference).
Menu G
Press the K4 key to return to the OPERAT. PARAMETERS

>OPERAT. PARAMETERS <
G
B
ESC
>Pressures
<
ESC
Operating press.
Max:
xxx bar
ESC
Operating press.
Min:
xxx bar
ESC
Unload run time

val.:
xxx min
ESC
Time DRAIN open

val.:
xxx min
ESC
Time DRAIN closed

val.:
xxx min
>Timings
<
Timings
UNLOAD RUN TIME: This setting denes the time during which the compressor idles when there is no
demand for air from the network. At the end of this period, the compressor stops and is ready to start
again when network pressure has dropped below the minimum threshold value.
This parameter is effective only if operating mode has been set to AUTOMATIC (see paragraph
7.4.2.3)
This parameter must be optimized according to the consumption trend of the network and its accumulation
capacity.
In the case of low consumption and if it is seen that the compressor remains inactive for
long periods (motor stopped), it is advisable to reduce idling time so as to restrict power
consumption during the inactive phases to a minimum. Low air consumption will also assure
a limited number of automatic start-up operations of the compressor, thus promoting a further
reduction in power consumption.
If air consumption is consistent and/or characterized by major variations, it is advisable to
extend the idling time in order to offset, through the periods of idling, the various periods
of operation at full load. This avoid stopping of the compressor with consequent delays in
the supply of compressed air due to the start-up phases which are characterized by current
take-off peaks tied to frequent starting.
G
B
PROGRAMMING menu
7.4.2.6
The PROGRAMMING menu is used to set the schedule of compressor activities, dening the days and times
when the compressor must be switched on. The compressor can be programmed on a daily basis (same for
all the days) or on a weekly basis (a different program for each day of the week).
Reset programming:
Makes it possible to cancel all the cycles set in both daily and weekly programming
Programming mode
This parameter informs the controller whether, once PROGRAM control has been activated (see paragraph
7.4.2.3), the machine must follow daily or weekly programming
Daily programming
Daily programming can be used to set up to four start/stop cycles. These cycles are repeated equally
each day of the week.
The following rules apply:
-
Non-programmed cycles identied by the ve hyphens that replace the time are not effective
Cycles for which the start and stop times coincide are not effective, similarly to those not
programmed
If, in the last cycle programmed, the stopping time has been set to 24:00 and the start time of the
rst daily cycle has been set to 00:00, the control unit will keep the compressor running during the
change over at midnight from one day to the nextdella mezzanotte da un giorno allaltro
Weekly programming
Weekly programming makes it possible to set different start/stop cycles for each day of the week, up to
a maximum of three per day.
Menu H
Press the K4 key to return to the PROGRAMMING menu

>PROGRAMMING
<
ESC
>RESET programm.
<
Conrm RESET
programming
ESC
OK?
>Programming mode <
ESC
Programming mode
DAILY
ESC
Programming mode
WEEKLY
>Daily programming
G
B
<
ESC
Every day
Start 1:
-----
ESC
Every day
Stop 1:
-----
ESC
...other days...
...other cycles...
>Weekly programming <
ESC
Monday
Start 1:
-----
ESC
Monday
Stop 1:
-----
ESC
...other days...
...other cycles...
The following rules apply:

-
Non-programmed cycles identied by the ve hyphens that replace the time are not effective
Cycles for which the start and stop times coincide are not effective, similarly to those not
programmed
If, in the last cycle programmed for a given day, the stopping time has been set to 24:00 and the rst
cycle programmed for the next day has been set to 00:00, the control unit will keep the compressor
running during the change over at midnight from one day to the next
NOTE: remember that control via keyboard of the control unit always has priority over any program
control: this means that, if the program is to be effective, the K1-START button must be pressed setting
the compressor to Stand-by progr. con.. Similarly, the compressor can be stopped without any risk
of restart by the pre-set program pressing the K2-STOP key.
G
B
Therefore, to enable functioning with program control:

1)
2)
3)
4)
Select PROGRAM control

Select the programming method to be used (DAILY/WEEKLY)
Program the daily or weekly schedule selected
Press the K1-START key on the control unit to enable program control
DIAGNOSTICS menu
7.4.2.7
From the diagnostics menu, it is possible to check functioning of the INPUTS, OUTPUTS and the direction
of rotation of the compressor and fan. It is also possible to read the log of faults that have occurred on the
compressor.
These diagnostic functions should be used only by expert personnel with in-depth knowledge
of the compressor and how this operates.
Diagnostic TEST
To run the diagnostic TEST, comply with all the safety rules described in chapter 5
WARNING!!!
When carrying out the test, certain parts of the machine are powered (control coils) and
rotating parts are activated (motor, compressor, fan). The operator must therefore take all
the necessary precautions during these checks.
Error messages
The control unit saves all the faults that have occurred and which have caused stoppage of the machine
(alarms). The following data are save for each error message:
-
Type of error (alarm)
Time, day, date on which the alarm occurred
Total hours and hours of load run when the fault occurred
These indications are displayed cyclically on the third and fourth lines of the display.
Menu I

>DIAGNOSTICS
<
ESC
>DIAGNOSTIC TEST
<
Run diagnostic
TEST
ESC
OK?
DIAGNOSTIC TEST
TEST digit. INPUTS
INPUT n. 1:
status
Emergency
OK
ESC
G
B
...other INPUTS...
ESC
DIAGNOSTIC TEST
TEST digit. OUTPUTS
OUTPUT n. 1:
active
Line
ESC
...other OUTPUTS...
ESC
DIAGNOSTIC TEST
Rot. direction TEST.
Press
ESC
for TEST
Press
if OK
Press ESC if NEGAT.
>ERROR MESSAGES
ESC
<
ESC
ESC
Last
error message
...other
error messages...
INFORMATION menu
7.4.2.8
This menu provides information about the serial number of the control unit and the software version
installed.
The CPU serial No. is indispensable to request enabling of protected functions by the Manufacturer (e.g.
AUTORESTART) and to obtain the related access password.
CPU serial No.
Indicates the serial number of the control unit
Software version
Indicates the software version installed
G
B
Menu L

>INFORMATION
<
ESC
>CPU
serial No.<
CPU serial No
XXX-XX-XX-XXXXX
ESC
>Software version
<
Software version
ESC
<<<mc2>>>
Operating warnings and faults
X.X:X:X
7.5
The diagnostics system of the controller permits continuous monitoring of machine operating conditions and
prompt indication of the need for maintenance operations or of any malfunctions.
The indications are divided into two categories::
Warning messages
These messages may refer to scheduled maintenance operations, critical operating conditions or minor faults
which do not block the compressor but which must be checked in order to trace their cause.
The warning messages are accompanied by switching on of yellow LED L2 and described with
a message shown on the third and fourth lines of the display in the main screen page. Warning
messages are displayed in alternating mode so as not to prevent display of basic messages.
To RESET the warning messages, proceed as follows:

For messages relating to scheduled maintenance operations: carry out the operation and RESET
1)
component life (see paragraph 7.4.2.2)
Messages of this type are as follows:

Replace air lter
Replace oil lter
Replace oil
Replace separator lter
Replace air lter - excess. clogging
for this last fault, after replacing the lter, press the K3 - RESET key
For critical operating condition messages:
If possible eliminate the problem; the message will be cleared automatically
Messages of this type are as follows:
Compression temp. high
Ambient temperature low
2)
WARNING!!!
If the warnings are not reset for a long period of time (e.g. failure to carry out scheduled
maintenance) THE COMPRESSOR IS BLOCKED!!! In this case, contact the Service or
Customer Centre of the Manufacturer immediately.
Alarm messages
These messages indicate a serious fault that has blocked the compressor. The alarm may be due to a
fault in the system or extremely critical operating conditions.
When a machine stoppage occurs, the compressor stops immediately, the red LED L3 of the alarms
switches on and the message relating to the fault is displayed persistently in the main screen page.
To RESET, rst of all eliminate the fault: at this point, LED L3 starts to ash indicating that reset
can be carried out pressing the RESET key.
All faults that cause blocking of the compressor are saved in an error message log le. To consult this log,
refer to paragraph 7.4.2.7
The following faults block the machine:
EMERGENCY STOP compress. - block
Compression temp. too high - block
Ambient temperature too low - block
Internal pressure too high - block
Net pressure too high - block
Press Transducer error - block
Temperature sensor error - block
Power supply phase sequence error - block
Short-cir. analog INPUT - block
Compress. motor overload - block
No. starts/hr too high - block
Power supply failure - block
Line voltage cutoff - block
Faults caused by failure to carry out maintenance must also be added to these: if the compressor is used for
long periods without carrying out the scheduled maintenance indicated by the control unit, a machine blockage
occurs accompanied by a message of the type:
G
B
Replace -------------- excess hrs - block

where the component to be replaced is displayed instead of the hyphens.
In this case, it is absolutely necessary to replace the component. If the compressor must be restarted,
an emergency start-up procedure must be carried out. Contact the Service or Customer Centre of the
Manufacturer immediately.
To nd out how to proceed in the case of an alarm, refer to chapter 9 Troubleshooting.
G
B
Compressors
in sequence
The mc2 control unit includes all the control functions of the compressor on which it is directly installed.
For compressor rooms in which several machines equipped with this control unit are installed (up to a maximum
of four units), a communication network can be set up between these for automatic, coordinated management
of the compressors.
Communication between the compressors provides the following advantages:
constant pressure of the air supplied to pneumatic service points
energy saving:
only the compressors necessary to supply the air required are activated
equal distribution of work load on the compressors available with consequent synchronization
of scheduled maintenance operations
management of alarms and machine stoppages so as to prevent any interruption in the supply
of compressed air
management of the network of compressors according to a program set by the user on a
daily or weekly basis
To establish communication between the control units, a communication module is required for each machine
to be connected and the related connection cables.
Therefore, contact your area dealer to purchase these.
The instructions for installation, programming and operation of the network of compressors are provided in
the booklet furnished with the communication module.
P. 61 - Chap. 8 Compressors in sequence
G
B
Troubleshooting
The following table shows the most frequent problems.

The operation should be carried out by a qualied and skilled person where shown. For all other cases,
contact a specialised Centre
When the compressor requires scheduled maintenance, the operation to be performed and
the number of excess hours of operation are indicated in the main screen page.
In the case of long-term functioning in these conditions, the compressor is blocked and the
operation must be carried out immediately
G
B
V-F
V.V.
Fixed speed compressors

Variable speed compressors
9.1
The machine does not start

V-F
X
V-V
Indication
Possible cause
Intervento
L1 OFF
DI OFF
No power
Restore power
FU2 / FU8 blown
Replace damaged fuses
Problems in the electronic

control unit
Call Customer
Service Centre
Problems in control unit

connections
Call Customer
Service Centre
FU4 blown
Replace FU4
Inverter problems
Call Customer
Service Centre
L1 ON
L3 constant ON
DI indicates:
Ambient temperature too
low - block
Ambient temperature
too low
Heat ambient.
Check installation
requirements
L1 ON
L3 constant ON
DI indicates:
Press. Transducer
error - block
Problems in the pressure

sensor or in its electrical
connections
Call Customer
Service Centre
L1 ON
L3 constant ON
DI indicates:
Temperature sensor
error - block
Problems in the temperature

sensor or in its electrical
connections
Call Customer
Service Centre
X
X
L1 ON
DI OFF
L1 ON
DI ON
(with normal functioning
message)
P. 62 - Chap 5 Troubleshooting
V-F
X
V-V
Indication
Possible cause
Intervention
L1 ON
L3 constant ON
DI indicates:
Short-circ. Analog INPUT block
Problems in the pressure /

temperature sensors or in
their electrical connections
Call Customer
Service Centre
L1 ON
L3 ON ashing
DI indicates:
Power
supply failure - block
An interruption of the power

supply of the system has
occurred
Carry out the RESET

operation (ref. Par. 7.5) and
restart the machine
L1 ON
L3 constant ON
DI indicates:
Power supply phase
sequence err. - block
Power supply phase

sequence error
Reverse two power phases
L1 ON
L3 constant ON
DI indicates:
No. starts/hr too high block
The No of starts/hr tolerated

by the motor has been
exceeded
Wait for fault reset
9.2
The compressor has trouble starting up

V-F
V-V
Indication
X
X
Possible cause
Intervention
Heat ambient
Low voltage
Check voltage
VA problems
Call Customer
Service Centre
Star - delta sequence

problems
Call Customer
Service Centre
Inverter problems
Call Customer
Service Centre
9.3
Pressure value lower than rated pressure

V-F
X
V-V
Possible cause
Intervention
VA problems
Call Customer
Service Centre
Belts slipping
Call Customer
Service Centre
Control unit mc2 problems
Call Customer
Service Centre
Variable pressure value on DI

but which does not reach the
minimum working threshold.
Motor speed of rotation remains
low.
Problems in the electrical

connections between
control unit mc2 and inverter
Call Customer
Service Centre
Pressure value on DI lower

than minimum operating
pressure
Air demand too high
Reduce no. of service points /

add compressors in parallel
Internal or external leaks
Check leaks
Indication
G
B
Pressure value on DI constant

(does not increase)
P. 63 - Chap. 9 Troubleshooting
V-F
X
V-V
Segnalazione
Possibile causa
Intervento
Excessive FA clogging
Replace FA
(see. par. 10.4)
Belts slipping
Call Customer
Service Centre
The machine is ready for start or is running and the

scheduled maintenance LED is ON
G
B
V-F
V-V
Indication
Possible cause
Intervention
L2 ashing
DI indicates:
Replace air lter
excess. clogging
FA clogged
Replace FA
(see. par. 10.4)
L2 ashing
DI indicates:
Replace air lter
XXX excess hours
FA to be replaced for
scheduled maintenance
Replace FA
(see. par. 10.4)
L2 ashing
DI indicates:
Replace oil lter
XXX excess hours
FO to be replaced for
Replace FO
(see. par. 10.6)
L2 ashing
DI indicates:
Replace oil
XXX excess hours
Oil to be replaced for

Replace oil
(see. par. 10.5)
L2 ashing
DI indicates:
Replace oil separator
XXX excess hours
FD to be replaced for
Replace FD
(see. par. 10.6)
L2 ashing
DI indicates:
Replace dryer lter
XXX excess hours
Dryer lters to be replaced for

Call Customer
Service Centre
The machine is ready for start or is running with

critical functioning message
V-F
X
V-V
X
9.4
9.5
Indication
Possible cause
Intervention
L2 ashing
DI indicates:
Ambient
temperature low
Heat ambient
Oil cooling low
Check functioning of the

electric fan and its fuses
FU3.
Call Customer
Service Centre
Oil radiator dirty
Call Customer
Service Centre
Oil low
Top up or change oil

(see. par. 10.5)
L2 ashing
DI indicates:
Compression temp.
High.
V-F
V-V
Indication
L2 ashing
DI indicates:
Compression temp.
High.
L2 ashing
DI indicates:
Dewpoint probe error
Possible cause
Intervention
Excessive ambient or air

recirculation temperature
Improve air exchange and

check installation requirements
FO clogged
Replace FO
(rif. par. 10.6)
FD clogged
Replace FD
(see. par. 10.6)
Problems in the dew

temperature sensor or its
connection
Call Customer
Service Centre
The machine stops when it is running and warning

LED comes on
V-F
V-V
9.6
Indication
Possible cause
Intervention
L3 constant ON
DI indicates:
Emergency
stop compress. - block
The PE button has been

pressed
Reset the PE button

(see. par. 7.2.2)
VA or solenoid valve problems
L3 constant ON
DI indicates:
Net pressure
too high - block
Call Customer
Service Centre
Net pressure too high caused

by other compressors
Check working pressure of all

compressors
Low voltage
Check voltage
Underscaled power cables
Check installation
requirements
Critical functioning
temperature conditions
(high ambient temperature, hot
air recirculation)
Check functioning conditions
FD clogged
Replace FD
(see. par. 10.6)
FA clogged
Replace FA
(see. par. 10.4)
Star delta sequence

problems
Call Customer
Service Centre
Motor thermal protection

problems
Call Customer
Service Centre
Electrical motor problems
Call Customer
Service Centre
Line voltage cutoff problems
Check line voltage
Oil cooling low
Check functioning of the

electric fan and its fuses
FU3.
Call Customer
Service Centre
L3 constant ON
DI indicates:
Compress.
motor overload - block
L3 constant ON
DI indicates:
Line voltage
cutoff - block
L3 constant ON
DI indicates:
Compression temp
too high - block
G
B
G
B
V-F
V-V
Indication
Possible cause
Intervention
Oil radiator dirty
Call Customer
Service Centre
Oil low
Top up or change oil

(see par. 10.5)
Excessive ambient or air

recirculation temperature
Improve air exchange and

check installation requirements
FD clogged
Replace FD
(see. par. 10.6)
FA clogged
Replace FA
(see. par. 10.4)
L3 constant ON
DI indicates:
Replace air lter
excess hours. - block
FA to be replaced for
Replace FA
(see. par. 10.4)
L3 constant ON
DI indicates:
Replace oil lter
FO to be replaced for
Replace FO
(see. par. 10.6)
L3 constant ON
DI indicates:
Replace oil
Oil to be replaced for

Replace oil
(see. par. 10.5)
L3 constant ON
DI indicates:
Replace oil separator
FD to be replaced for
Replace FD
(see. par. 10.6)
L3 constant ON
DI indicates:
Replace dryer lter
Dryer lters to be replaced for

Call Customer
Service Centre
Inverter problems
Call Customer
Service Centre
L1 ON
L3 constant ON
DI indicates:
INVERTER alarm
block
Problems in the electrical

connections between
control unit mc2 and inverter
Call Customer
Service Centre
L3 constant ON
DI indicates:
Compression temp
too high - block
9.7
Oil in the network

V-F
X
V-V
Indication
Possible cause
Intervention
FD problems
Call Customer
Service Centre
Inefcient oil recovery
Call Customer
Service Centre
9.8
Oil in the machine

V-F
V-V
X
X
Indication
Possible cause
Intervention
Leaking ttings
Fasten the ttings
Safety valve VS intervention
Call Customer
Service Centre
V-F
V-V
Indication
Possible cause
Intervention
FA leaks
Call Customer
Service Centre
9.9
Safety valve VS intervention

V-F
V-V
X
X
Indication
Possible cause
Intervention
Pressure detector problems
Call Customer
Service Centre
FD clogged
Replace FD
(par. 10.6)
G
B
10
Maintenance
Perform the scheduled maintenance operations to maintain compressor performance.

Various routine maintenance operation can be carried out by user provided they are carried out by
skilled personnel.
If routine maintenance is provided by a Service Centre, the user cannot RESET the components even
if these have been replaced by the user (see paragraph 7.4.2.2)
Use only original spare parts
Instructions are provided in the following paragraphs.
G
B
Before performing any maintenance operations read the operator safety precautions in
chapter 5 carefully. These precautions must be followed scrupulously for all maintenance
operations
10.1
Operating cycle
The compressor unit consists of two rotors (male and female) with special asymmetrical prole, patented VT
series, mounted on rolling bearings, able to withstand axial and radial thrust. The male rotor is the driving rotor
while the female rotor is driven. The male rotor also rotates the female rotor. The two rotors are not however
in contact physically as they are separated by a thin lm of oil that protects the coupled surfaces. The male
rotor drives and the female rotor is driven. The two rotors are not in direct contact thanks to a thin lm of oil
which protects the coupled surfaces.
The oil serves various purposes. It lubricates the bearings and the rotors, eliminates the heat produced by
the compressed air, it creates an airtight uid seal and reduces hazardous gaps in the air-end unit.
In xed speed compressors, starting is of the delta-star type. During the star phase, intake valve VA is closed,
thus permitting no-load start-up with less effort and lower energy consumption.
After a preset time of a few seconds, the PC control unit invokes changeover to the delta connection; with a
short transient phase, the MP motor reaches rated rotation speed. The intake valve opens thus starting the
normal work cycle.
In variable speed compressors, the start-up phase takes place with acceleration of the electrical motor which,
powered by the inverter, is brought to maximum speed of rotation compatible with network pressure.
As soon as this is permitted by rotation speed, the intake valve VA opens and the machine work cycle
begins.
The air is drawn through the lter FA, passes into the air-end unit where it is mixed with the oil injected. The air is
gradually compressed and pushed into the separator receiver where initial oil separation occurs by gravity.
The air, which is still mixed with oil droplets, follows the shape of the receiver and passes through the oil
separator lter FD. Due to the effect of coalescence, the droplets of oil merge and are deposited on the bottom
of the lter from where they are routed towards the air-end unit by means of a pipe.
The puried air passes through the check and minimum pressure valve VR which opens only when a threshold
of approximately 4 bar is exceeded. This ensures correct system lubrication in all operating conditions.
The oil deposited on the bottom of receiver SS is conveyed under pressure to the oil radiator RO where it
is cooled. If the temperature of the oil is below the calibration value of the VT thermostatic valve, ow to the
P. 68 - Chap. 10 Maintenance
cooler is bypassed; the oil passes into lter FO and returns to the air end.
Temperature sensor STO inserted in the delivery stub pipe and connected to the microprocessor permits
constant monitoring of the temperature inside the air-end unit.
The capacity delivered is controlled differently on xed speed and variable speed machines. In xed speed
compressors, once the rated running pressure has been reached, the intake valve closes. The internal receiver
pressure is vented to reach a value of approximately 2 bars.
This value is obtained by means of minimal amount of intake air through the intake valve. This ensures that
the pressure required for correct system lubrication is maintained. Consequently, the machine can idle with
reduced power intake.
After the predened idling time, the machine stops, ready to start again automatically if the pressure drops
below the minimum threshold.
In variable speed compressors, the control system modies speed of rotation in order to reach and maintain
an average pressure between the minimum and maximum pressure set.
In the case of very low air consumption, once the maximum operating pressure has been reached, the compressor switches to idling as described for the xed speed compressor
In this case, the duration of the idling phase is shorter; at the end of this phase, the compressor stops, ready
for subsequent automatic restart.
The operator-controlled machine stopping phases also differ as regards the two types of compressor.
For xed speed machines, ordinary stopping is timed; the machine is set to idling and the receiver is
gradually discharged.
For variable speed machines, the stopping phase is controlled through ramping down of the motor, during
which the system is depressurised.
The machine is also protected against any type of overpressure (internal faults or faults in other compressors
in parallel).
10.2
General maintenance operation table

The following table shows all the maintenance operations required by the machine.
You will nd this symbol next to operations requiring the intervention of Service Centre
personnel
Operation
Reference
Check on
suction prelter
10.3
Replace
suction prelter
10.3
Check air lter
10.4
Replace
air lter
10.4
To be carried
out by a
Service Centre
After the
rst
100 hours
After the
rst
1000 hours
Every
500
hours
Every
1000
hours
Every
2000
hours
Every
4000
hours
G
B
Operation
Reference
To be carried
out by a
Service Centre
After the
rst
100 hours
After the
rst
1000 hours
Every
500
hours
Every
1000
hours
Every
2000
hours
Overhaul minimum
pressure valve
Overhaul
intake valve
G
B
Replace
oil lter
10.6
Check - top up
oil level
10.5
Change
oil
10.5
Replace
separator lter
10.6
Check
oil recovery system
Check
tting tightness
Check
electrical terminal
connections
Drain
air-oil receiver
condensate
10.7
Clean
radiators
Clean
dryer condenser
Replace
air dryer lters
Check
belt tension and wear
Replace
drive belts
Check
settings and
adjustments
Check
safety device
operation
Every
4000
hours
* This frequency relates to operation in normally dust environments. In the case of critically dust
environments, the control panel may signal the need to replace the air lter before the scheduled maintenance
time. In this case, replace the lter as soon as possible. The skilled personnel employed for installation will
be able to objectively evaluate the environmental conditions
10.3
Replacement of the suction prelter
operations
Operate on the outside of the compressor: back off the screws that support
panel PPA of the suction prelter.
PA
Access the inside of the compressor:

extract the grill of the intake prelter
and the lter element PA (Fig. 37)
Replace the lter element PA
Ret the grill of the intake prelter
PPA
Fig. 37
To reset the scheduled maintenance counter (for enabled users only), see paragraph 7.4.2.2.
10.4
Cleaning or replacing the air lter
operations
GENESIS - FORMULA - MODULO 5-5-15 kW / 7,5-20 hp (BA 51)
FA
Open the upper panel PS of the compressor cabinet, backing off the lock
screws
Open the front panel PF of the compressor cabinet using the key provided
Loosen the clip FFA shown in Fig. 38
and remove air lter FA
Clean the lter by directing a jet of air
inside it or replace the filter as prescribed in the maintenance schedule.
Do not use uids or detergents to clean
the lter
FFA
Fig. 38
G
B
Insert the lter fully on the intake valve

Fasten the clip.
Replace panels PS and PF of the
compressor cabinet
GENESIS - FORMULA - MODULO 15 kW / 20 hp (BA 69)
G
B
GENESIS - FORMULA:
Open the corner panel SPA of the compressor cabinet using the key provided
MODULO:
Open the lter panel SF of the compressor cabinet using the key provided
Release the front part of the lter container CF pressing on the two fastening
tabs (Fig. 39)
Remove air lter FA from its housing as
shown in Fig. 40
Clean the lter by directing a jet of air
inside it or replace the filter as prescribed in the maintenance schedule.
Do not use uids or detergents to clean
the lter
Fig. 39
CF
Replace lter FA inserting it fully

Re-attach the front part of the lter container CF pressing on the two fastening
tabs
GENESIS - FORMULA:
Replace the corner panel SPA of the
compressor cabinet
MODULO:
Replace the lter panel SF of the compressor cabinet
FA
Fig. 40
Checking oil level, topping up and changing the oil
10.5
operations
Checking oil level and topping up

Check the level of the oil in the machine circuit frequently when the machine has been stopped for at least
thirty minutes.
This operation is very simple: inspect the oil level on the level reference tube TRL (Fig.41) after disassembling
the front panel PF
The oil level must be visible but must not exceed the RLMAX maximum level reference.
When the level of the lubricant is close to the minimum limit of the level reference tube TRL, top up the oil.
Never let the oil drop to a level which is no longer visible through the reference level tube
TRL!
Maximum level is reached when the oil laps the edge of the maximum level reference RLMAX during top-up
.
Top up when required, as follows:
Remove the front panel PF using the
key provided
Loosen oil ller plug TO. Be careful not
to lose the seal (Fig. 42)
TRL
Use a funnel to pour oil into the ller

sleeve (Fig. 42)
RLMAX
Top up the oil level using only the

amount indicated in paragraph 4.7
RLMIN
Avoid too much oil!!! Ensure the

level of the oil does not exceed the
maximum reference level RLM (Fig.
41)
Fig. 41
Check that the seal of the plug is correctly positioned and fasten the plug (not
too tightly)
Replace the front panel PF using the
key provided
Fig. 42
TO
G
B
Changing the oil

Change the oil at the frequency indicated in the scheduled maintenance table of paragraph 10.2 or when you
plan to use a different oil from that in the machine.
Carry out this operation when the oil is still warm so that its viscosity is low and uidity high.
Caution: lubricant temperature must not be sufcient to cause burns.
Proceed as follows:
key provided
Loosen oil ller plug TO. Be careful not
to lose the seal (Fig. 43)
G
B
Connect tting R provided, which must

communicate with a suitable collection
recipient, to tting DO after unscrewing
the safety plug (Fig. 44)
Open drain valve RSO and drain the
lubricant (Fig. 44)
After draining, close oil drain valve
RSO
Rell with oil as described in the Checking oil level/topping up paragraph
(Fig. 43)
TO
Fig. 43
Check that the seal of plug TO is correctly positioned and fasten the plug (not
too tightly)
Replace the front panel PF using the key
provided
Open the shut-off valve between the
compressor and the distribution line.
Switch the circuit breaker on and carry
out a test start-up.
Let the compressor run for a few minutes
and then make a visual inspection for
any oil leaks
RSO
Check the oil level again as indicated

in the Checking oil level/topping up
and if necessary top up
DO
Fig. 44
Remember that waste oil, condensate and all machine lters are polluting materials that must
be disposed of in compliance with local legislation
Replacing the oil lter and the separator lter
10.6
operations
key provided
FO
Remove the top panel PS using the key

provided
Loosen the oil lter cartridge FO using
the specic key provided (Fig. 45)
Lubricate the seal before tting the new
cartridge (Fig. 46)
Fasten the lter and tighten by hand.
Do not use tools to fasten the cartridge
as these may damage its structure!
Fig. 45
Open the shut-off valve between

the compressor and the distribution
line. Switch the circuit breaker on and
carry out a test start-up
Let the compressor run for a few minutes
and then make a visual inspection for
any oil leaks
Check the oil level again as indicated
in the Checking oil level/topping up
paragraph and if necessary top up
Replace the upper panel PS and the
front panel PF
Fig. 46
G
B
10.7
Draining the condensate
operations
If the machine is equipped with dryer and/or air reservoir, the mc2 control unit assures timed, programmable
activation of the solenoid valve of the condensate drain.
On machines equipped with dryer, with or without air reservoir, condensate drainage can be checked using
the sleeve located on the rear panel PP
On machines equipped with air reservoir, condensate drainage is checked using the solenoid valve located
underneath the air reservoir SA
Air receiver
G
B
To eliminate the condensate that forms in the air receiver, proceed as follows:
Place a suitable drip tray under the
condensate discharge valve RSC,
which is located under the SA
receiver
RSC
SA
Ensure that the intercept valve between

the compressor and the distribution line
is closed
Open the condensate discharge valve
RSC (g. 47), using pliers if necessary
Leave the condensate to drain until the
tank is completely empty
Fig. 47
Close the valve RSC

Air-oil separator receiver

Drain the condensate accumulated in the air-oil separator frequently, by exploiting the uid stratication
principle
The frequency of this operation will depend on environmental conditions (e.g. low temperature, high humidity)
and the frequency of compressor cold starts.
In order to carry out this operation, you must stop the compressor at least an hour before
intervening
Remove the front panel PF with the key

provided
RSC
Connect tting R provided, which must

communicate with a suitable collection
recipient, to tting DO after unscrewing
the safety plug (Fig. 48)
SA
RSO
Partially open drain valve RSO (Fig.

48)
Follow the operation and close oil drain
valve RSO as soon as oil starts owing
out
Check the oil level and top up, if

required, as described in the paragraph
Checking the level and topping up
Replace the safety plug and the PF
panel
G
B
DO
Fig. 48
The air receiver and separator condensate should be drained manually on a weekly basis - or more
frequently. The user is responsible for this maintenance operation.
10.8
Replacing the fuses
operations
GENESIS - FORMULA:
Open the corner panel SPA of the compressor cabinet using the key provided
MODULO:
Open the electric box panel SCE using
the key provided
Replace the damaged fuses. Follow
the amperage specications provided
in paragraphs 12.8, 12.9
Fig. 49
GENESIS - FORMULA:
Close the corner panel SPA
MODULO:
Close the electric box panel SCE
Spare Parts and

Service Centres
11
The Manufacturer provides an efcient after-sales service through a large service network and a Technical
Department for solving any problems.
Always specify the compressor model and serial number when communicating with Authorized Service
Centres and the Manufacturer.
To locate the service Centre closest to the compressor installation site, call or send a fax to:
G
B
Fax:
(+44) 01869-326226
(+44) 01869-326216
E-mail: support@abac.co.uk
Spare parts and consumable material codes
11.1
The following tables show the most commonly used spare parts. Contact an authorised service Centre for
other spare parts.
Model
Pressure
bar
Air
lter
Code
8
10
5.5
13
FORMULA
GENESIS
13
Suction
prelter
Transmission
belts
Code
Code
Code
9056237
9623572
(2) 9075257
9056282
8
10
Separator lter
9056238
9056293
15
7.5
Oil
lter
Code
(2) 9075256
9056237
9623572
9056282
15
11
13
9056293
9056113
9056292
9623572
13
9056113
9056292
9623572
13
(3) 9075291
(3) 9075215
(3) 9075262
8
10
(2) 9075254
(3) 9075211
9056293
15
15
BA 69
(2) 9075215
(2) 9075256
8
10
(2) 9075290
(2) 9075291
15
15
BA 51
(2) 9075236
(2) 9075257
8
10
(2) 9075236
(2) 9075290
9056238
9056293
(2) 9075290
(3) 9075256
9618034
9056113
9056292
9623572
15
P. 78 - Chap. 11 Spare Parts and Service Centres
(3) 9075254
(3) 9075262
(3) 9075215
Model
Pressure
Air
lter
Oil
lter
Separator lter
Suction
prelter
Transmission
belts
bar
Code
Code
Code
Code
Code
8
10
5.5
13
9056937
8
10
13
9623572
13
9623572
9056934
15
BA 69
(2) 9075236
(2) 9075290
(2) 9075257
(2) 9075291
9056937
9056935
9056943
9623572
15
15
BA 51
(2) 9075236
(2) 9075256
9056942
8
10
11
(2) 9075290
(2) 9075290
9056933
9056937
15
MODULO
9056942
9056934
15
7.5
(2) 9075257
9056933
(2) 9075215
(2) 9075254
(2) 9075256
(3) 9075211
10
(3) 9075291
13
9056937
9056935
9056943
9623572
(3) 9075215
15
(3) 9075262
(3) 9075256
10
13
9056939
9056935
9056943
9623572
15
P. 79 - Chap. 11 Spere Parts and service Centres
(3) 9075254
(3) 9075262
(3) 9075215
G
B
12
Diagrams
Hydraulic-pneumatic plant diagram
G
B
P. 80 - Chap. 12 Diagrams
12.1
Legend
1
2
2.1
2.2
Air lter
Intake unit
Air lter clogging sensor
3
4
Drive
Motor
Air-end unit
6.1
6.2
6.3
6.4
Separator reservoir
Safety valve
Oil level indicator
Air-oil mix temperature sensor
Oil drain outlet
7
8
Thermostatic valve
Oil lter
Air-oil exchanger
10
Oil recovery
11
Separator lter
12
Minimum pressure and check valve
13
Air-air exchanger
14
Net pressure transducer
15
16
15.1
15.2
15.3
16.1
16.2
16.3
16.4
Drying unit (only in equipped versions)

Air dryer
Dew temperature sensor
Automatic condensate drain
Air receiver unit (only in equipped versions)
Air receiver
Safety valve
Discharge valve
Condensate drain
(only for versions equipped with receiver without air dryer)
G
B
Power circuit wiring diagram 5,5 - 15 kW

Machines without air dryer
G
B
12.2
Power circuit wiring diagram 5,5 - 15 kW

Machines with air dryer
12.3
G
B
Power circuit wiring diagram 11 kW

Machines with inverter
G
B
12.4
Auxiliary circuit wiring diagram 5,5 - 15 kW

12.5
G
B
Auxiliary circuit wiring diagram 5,5 - 15 kW

G
B
12.6
Auxiliary circuit wiring diagram 11 kW

Machines with inverter
12.7
G
B
Wiring diagram for component location 5,5 - 15 kW

G
B
12.8
Wiring diagram for component location 5,5 - 15 kW

12.9
G
B

User Manual Genisis 5.5-15 KW

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GENESIS - FORMULA - MODULO

USE AND MAINTENANCE HANDBOOK

FORMULA 5.5 - 7.5 kW

MODULO 5.5 - 7.5 kW

Oil lter and

Contenitore ltro aria

Air lter container

Botier du ltre air

Contenedor del ltro

Oil drain valve

Drenaje del aceite

Oil separator lter

Fascetta ltro aria

Air lter clip

Collier du ltre huile

Abrazadera ltro de aire

Heated air outlet

Auslass fr heisse Luft

Rendija de salida del aire

Gruppo pompante a vite

Patented Air end

Groupe de pompe vis

Pulsanti del pannello di

Control panel switches

Boutons sur panneau de

Pulsadores del tablero

Led del pannello di

Control panel led

LED sur panneau de

Led del tablero de control

Compressor air outlet

Emergency stop button

Bouton darrt durgence

Panel del preltro de

Suction prelter panel

Max. oil level reference

Referencia de nivel mx.

Min. oil level reference

Referencia de nivel min.

Air receiver condensate

Rubinetto scarico olio

Oil drain valve

Electric box panel

Panneau des ltres

Puerta de los ltros

Oil temperature sensor

Placa metlica con

Oil ller plug

Tapn del aceite

Oil level reference pipe

Tubo de referencia nivel

Performance and specications

Compressor rating data

Electrical motor and drives

Power supply data

Lubricating and cooling uid

Safety precautions for maintenance 28

Handling and installation

Installation site requirements

Conguration for remote control

Start-up and operation

Checks to be carried out

mc2 control panel

Control unit mc2