Bsc R-evo GB - fps-compressors.co.uk · Rotar Bsc R-Evo - Cod.197BB6800 - ed.00 09/2006 333 ......

Rotar Bsc R-Evo - Cod.197BB6800 - ed.00 09/2006

GB

RotarRotarRotarRotarRotar

BSC R-EvoBSC R-EvoBSC R-EvoBSC R-EvoBSC R-Evo

10 - 15 - 2010 - 15 - 2010 - 15 - 2010 - 15 - 2010 - 15 - 20

MANUALuse & maintenance

Rotar Bsc R-Evo - Cod.197BB6800 - ed.00 09/2006 33333

GBGENERAL INFORMATION

SUPPLIESThe following accessories will be supplied with your compressor:• 1 compressor user and maintenance manual + 1 dryer user and maintenance manual (where envisioned)• 4 buffer pads,• 1 hatch opening key• 1 delivery pipe (version without tank)• 1 line tap• 1 Teflon beltAlways check that these accessories are present, claims successive to delivery will not be accepted.

STATUS OF THE DELIVERYEvery compressor undergoes an inspection period in the factory and is delivered ready for installation and functioning. The oil

used is: RotEnergy Plus.

INDEX

GENERAL INFORMATION ................................................................. 3SAFETY REGULATIONS .................................................................... 4INSTALLATION ................................................................................... 7TECHNICAL DATA .............................................................................. 8CONTROLS AND SETTINGS ............................................................. 9CONTROL FUNCTIONS ..................................................................... 1FUNCTIONING ................................................................................. 12COMMISSIONING ............................................................................ 12MAINTENANCE ................................................................................ 13MAINTENANCE AND WARNING SUMMARY TABLE ...................... 16TROUBLESHOOTING ...................................................................... 17WIRING DIAGRAM 18


GB

44444

SYMBOLS USED IN THE MANUALSeveral symbols have been used inside this manual to highlight situations where maximum attention must be paid, practical

advice or simple information. These symbols can be found at the side of a text, at the side of a figure or at the head of a page (inthis case they refer to all of the subjects considered in that page).Pay attention to the meanings of the symbols.

SYMBOLS USED ON THE COMPRESSORDifferent labels are applied to the compressor, which highlight any hidden dangers and indicate correct behaviour during use of

the machine or in particular situations.It is fundamental that they are respected.

.

ATTENTION!Highlights an important description regarding:

technical interventions, dangerous conditions,warnings, prudential advice and/or very importantinformation.

MACHINE AT A STANDSTILL!Every operation highlighted with this symbol must

only be carried out with the machine at a standstill.

REMOVE VOLTAGE!Before any interventions on the machine is it

compulsory to deactivate the machine’s electricpower supply.

SPECIALISED STAFF!Every intervention highlighted by this symbol

must only be carried out by specialised staff..

Warning symbols Prohibition symbols

High temperature hazard

Risk of electric shock

Risk of hot or dangerous gases in the work area

Pressurised container

Moving mechanical parts

Maintenance interventions in progress

Machine with automatic start-up

Do not open the hatches with the machinefunctioning

If necessary, always use the emergency stopand not the line isolator switch

Do not use water to put out fires on electricalappliances

Compulsory signals

Read the user instructions carefully

AGENERAL WARNINGS• The rotary compressors are meant for continuous, heavy duty industrial use. They are particularly adapt for industries that

require a great consumption of air over expended periods of time.• The compressor should be used only as indicated in the manual and kept in a known and easily accessible place, as it must

accompany the machine for the whole of its working life.• An employee of the company where the compressor is to be installed must be appointed responsible for the compressoritself. Controls, adjustments and maintenance interventions must be under his/her responsibility: whenever this person must bereplaced, the substitute must read the user and maintenance manual thoroughly along with any notes regarding technical and

maintenance interventions carried out up to that time.

SAFETY REGULATIONSlre

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GBALWAYS:

Check that the network voltage corresponds to the voltage indicated on the CE label and that the electric connection has beencarried out with adequately-sectioned cables.

Always check the oil level before starting up the compressor.Understand how to stop the compressor in the case of emergency and understand the use of all commands.Before every maintenance operation remove the power supply in order to prevent accidental start-up.After maintenance operations check that all components have been re-mounted correctly.Keep children and animals away from the work area to prevent injury caused by any equipment connected to the compressor.Ensure that the working environmental temperature is between +5 and + 45 ºC.Install and use the compressor in an environment that is not potentially explosive and in the absence of free flames.Leave at least 50 cm free between the compressor and the wall; so as not to obstruct the cooling air passage.Use the emergency button positioned on the command board only when really necessary in order to prevent injury to persons.

The continual use of this device can damage the compressor.If an intervention and/or enquiry is requested always specify the model and serial number stated on the CE label.

Follow the maintenance programme present in the manual.

NEVER:Touch internal components or pipes as they reach very high temperatures during functioning, remaining so even for a certain

period of time after shutdown.Position inflammable objects, nylon or material near to and/or on the compressor.Transport the compressor with a pressurised tank.Use the compressor if the power supply cable is faulty or id the attachment is precarious.Use the compressor in particularly humid or dusty environments.Aim the jet of air towards persons or animals.Allow inadequately trained persons to run the compressor.Strike the fan with contusive objects as they could cause unexpected breakage during functioning.Run the compressor without air filter.Camper with safety and adjustment devices.

Run the compressor with the hatches/panels open or removed.

PRODUCT IDENTIFICATIONThe product you have purchased is identified by the EC label, which contains the following data:1) Manufacturer data2) CE mark – year of manufacture3) TYPE = compressor name CODE = compressor code SERIAL N. = the serial number of the compressor you have purchased (always state when requesting assistance)4) air yielded by the compressor measured in (l/min) and (cfm)5) maximum working pressure (bar and PSI) – compressor noise dB(A)6) electric data: power supply voltage (V/ph), frequency(Hz), absorption (A) - power (HP and kW), revs per minute (Rpm).

7) any other type-approvements

SAFETY REGULATIONS

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GB

66666

INSTALLATION

DESCRIPTION OF THE MACHINE (fig.1)The compressor is essentially made up of:

1) Command board2) Electric appliance compartment3) Suction chamber4) Air outlet tap5) Cooling fan6) Air-oil radiator7) Screw-motor plate / Belt-tightener

8) Electric motor9) Screw compressor10) Oil-separator tank11) Minimum pressure valve12) Oil-separator filter13) Air filter/ Suction adjuster14) Oil filter

UNPACKINGThe compressor must only be lif ted using transp allets or forklif t trucks with adequate cap acity (see technical dat a

table) .• Check the perfect integrity of the package.• Unpack the machine (paying attention to any instruction on the packaging itself).• Check the perfect integrity (external) of the machine.• Open the hatches and visually check the internal parts.• Dispose of the packaging according to the laws in force regarding this subject.It is however recommended to keep the packaging at least for the warranty period.

LIFTING AND MOVING THE MACHINELift the machine using a fork lift truck. This operation must be carried out by inserting the forks inside the support feet.Mount the anti-vibrating elements in the relevant housing and transport with care to the place chosen for positioning.

POSITIONING (fig.2)The pre-selected place for installation of the compressor must have the

following requisites as well as having the features requested by the Accident-prevention Standards in force:

A) Low percentage of dust particles.B) Adequate ventilation and dimensions that allow (with machine

running) to maintain the environmental temperature (5 °C ÷ 45 °C) .C) In the case of inadequate output of hot air, install the suction devices

as high as possible.

N.B.: The dimensions of the spaces are indicative.

The condensation is a polluting mixture and must be dispersed in theenvironment or in the drain system. Prepare a collection container, whichmust have a valve and a removable recipient or recipient connected toappropriate EW18 cod.548200000 water-oil separator appliance.

Dispose of the oil and/or condensation according to laws in force.

1

2


GBINSTALLATION

PREPARATION FOR INSTALLA TION (fig.3/4)Mount the supplied delivery pipe (A), positioning the line tap (B).• Check the correct oil level using the inlet well D (the max. level just

touches the inside of the inlet well).If the oil level is lower than the MIN level top-up through the inlet well (D)

using the same type of oil.

DO NOT MIX DIFFERENT TYPES OF OILS

INSTALLATION• Position the machine in a stable manner on a horizontal surface, paying

particular attention to leave at least 50 cm free between the machine and thewall; in this way the air passage will not be blocked.

Position the air tank and connect the compressor and tank using the suppliedflexible pipe.

NB. The flexible pipe is used so as not to transmit the vibrations produced bythe compressor to the distribution line.Do not introduce the non-return valve between the compressor and the tank.

HOT AIR EXIT CONVEYING• Hot air escapes from the rear of the compressor at a temperature of about 15÷35 °C higher than the environment al

temperature.• If the ventilation in the room is inefficient, a pipe with section more or less equal to the radiator must be installed (see

“Technical data”). It must be equipped with a valve that conveys the hot air outside during the summer months and releases itinside the room in the winter, in this way making use of the heat energy produced by the compressor as an auxiliary heating unit(see fig.2).

These channels must not exceed 4 metres in length; on the contrary an auxiliary fan must be installed on the exit.

ELECTRIC CONNECTION• The electric power supply line must be realised with cables that have an adequate section for the power of the machine and

must include n° 3 phase cables and n° 1 earth cable.• A switch must be installed between the power supply line and the compressor control board and a fuse in proximity of cable

entry into the machine. This switch must be positioned at least 1.7 m from the ground.• The switch must be easily reached by the operator.The cables must be type-approved and installed with a minimum protection level of IP54.

N.B. Follow the indications in the table when selecting the section of the cable.

PotenzakW

400V 230V 400V 230V 400V 230VBSC10 7,5 4 10 18 30,8 32 40BSC15 11 6 10 25 42,8 40 63BSC 20 15 6 16 31 54 50 80

Interruttore magnetotermicoAmpere

Sezione min.conduttorimmq

Corrente assorbitaAmpere

3

4

MIN.

MAX

D


GB

88888

TECHNICAL DATA

Pressure bar 8 10 13 8 10 13 8 10 13 Power supply voltage V/Hz Auxiliary voltage V/Hz Screw unit type Rotor rotation speed rpm 5095 4566 3525 7460 6690 5650 4830 4345 3700 Air yielded l/min 1300 1100 800 1700 1650 1250 2400 2050 1700 Amount of oil

l Amount of top-up oil

l Final air max. over-temperature °C 7.5 9 7.5 17 17 16 18.4 17.5 15.4 Heat removed kJ/h

Fan capacity

m³/h Oil residues in the air

mg/m³

Electric motor

type Nominal power kW

Level of protection of electric cabinet

IP

Isolation class Current absorption at loading A Current absorption on start-up

A 34 36 34 68 66.5 66.5 79 83 75.4 Max. start-ups per hour

n° Environmental temperature limits

°C Sound pressure at 1 m (according to ISO 1217)

dB(A) 69.8 69 69 68 68 68 68 68 67

Max. compression temperature

°C Motor circuit breaker relay calibration

A Safety valve calibration

bar Start-up pressure switch calibration

bar Motor protection Type

54 F

14 1.5

10 50

11015,5

37600 2000

4

11

1

230-24/50 400/50

BSC15

400/50 230-24/50

BSC 20

FS50TF

51

1.5

Technical specifications

110 11 14

10

M132-MC/2 IEC34

23

400/50230-24/50

110 15,5 14 1.5

10 50

54

51300 2000

4 M132-MC/2 IEC34

15

F 30

M132-SB/2 IEC34

BSC 10

50

54 F

5 1

FS26TF

16

circuit breaker circuit breaker

FS26TF

circuit breaker

Protection devices

5

7.5

25650 2000

4

58.5

100

880

587

133

685

500

48.5

Rp3/4

693

810

524

265

300

cm

562159

64.5

258

303.

5

225

280

Kg.

BSC10 ...... 195BSC15 ...... 212BSC20 ...... 230


GBCONTROLS AND SETTINGS

COMMAND BOARD (FIG.5)• The electronic control unit allows to

manage all functions relative to the start-up andswitch-off of the compressor. It also signals anyanomalies and supplies information regardingfunctioning times and the carrying out ofmaintenance operations.

1) Display on which the information isvisualised.

2) OK key : to confirm settings (see “Adjustableparameters” paragraph)

3) Arrow keys : used to scroll the menu.4) Alarm signal warning light : if this warning

light switches on followed by the shutdown of thecompressor it means that maintenance isrequired or malfunctioning has occurred. Referto the “Alarm messages” paragraph in order toidentify the intervention to be carried out.

5) Reset key : used to silence an alarm (seethe “Alarm messages” paragraph).

6) ON/I key : machine switch-on.The switch-on cycle is divided into three phases.• Switch-on standby: the STAND-BY message is visualised: if the compressor has been switched off 15 seconds are required

before the cycle starts, otherwise the compressor waits for a request for air by the pressure transducer.• Start-up: the compressor is started in the “star” configuration and the EMPTY message is visualised• Normal start-up: after five seconds the configuration is changed from star to triangleIf the transducer makes a request, after two seconds the load electrovalve is excited and the LOAD message is visualised.N.B. The cycle described is valid for compressors with remote starter, for machines with direct start-up the compressor starts

immediately after the STAND-BY phase7) OFF/0 key : machine switch-off.Enabling of the load electrovalve is interrupted, the empty cycle is started and the flashing EMPTY message is visualised. At the

end of the empty cycle the compressor switches off and the “OFF” message is visualised.8) Emergency stop switch : used to stop the compressor suddenly only in the case of real emergency.9) Functioning layout / maintenance memorandum.

FUNCTIONING TIMESFor correct functioning of the compressor , it is recommended to apply a service factor greater than 50%: this parameter can

be verified using the “Total functioning time (h) / total empty running time (h)” formula.This permits the maintenance of an optimal heating system and therefore helps to reduce the presence/formation of condensation

inside the oil circuit to a minimum.• To visualise the tot al functioning hours press key

• To visualise the tot al empty running hours press key In both cases the display goes back to standard visualisation after about 20 seconds.Automatic functioning• Compressor functioning is adjusted by the pressure transducer, which determines machine shutdown when reaching the

max. Pressure and start-up when the pressure re-descends below the minimum calibration level.Machine shutdown is the delayed-type, i.e. it does not take place with perfect coincidence of reaching the P max, but rather after

an established interval of time during which air is not withdrawn (see point 7 successive paragraph).• Factory regulation is 75 seconds however it is advised to check that the n° of switch-ons per hour DOES NOT exceed the

max recommended n° of 10. If it should be higher it is preferable to increase the empty functioning time “Modifiable p arameters”point 7).

REMOTE SWITCH ON/OFF• By means of software (optional), it is possible to control the compressor at a distance (the remote control is only activated

if the control unit on the machine is put in the “ON” position).• This function can also be managed by means of the “remote” contact positioned on the control unit terminal board. In this

case the manual commands are excluded and therefore the unexpected start-up of the compressor can be the cause of accidentsand injury to staff that are in proximity of the machine.

The manufacturer refuses any liability for any damage caused by the lack of signals indicating remote start-up of the compressor.All modifications must be carried out by specialised staff

.

5


GB

1010101010

CONTROLS AND SETTINGS

ALWAYS USE THE AND KEYS TO SET THE VALUE AND CONFIRM USING THE KEY

MODIFIABLE PARAMETERSBy pressing the key the machine stop s (OFF), access the functioning p arameters menu. Sometimes the p assword

must be introduced in order to access modifications. Use the and keys to scroll the menu.

0) Control unit ID (assistance password): selects the identification of the control unit. It is possible to select several identificationsif several compressors are connected to the same line RS485.

1) Pre-alarm time (assistance password): the counter is automatically graduated every hour of machine functioning, when thecounter arrives at 0 the control unit enters maintenance alarm conditions.

The counter with the negative sign (-) in front indicate show many hours have passed since the last maintenance alarm. Usingthe and keys it is possible to set the new value desired (in this way excluding the previous alarm).

2) Historical alarms (no password required): by means of this menu it is possible to visualise the last 3° alarms.3) Pre-alarm temperature (factory password): by means of this menu it is possible to set the temperature “delta” (expressed in

°C) with respect to the maximum alarm temperature. This value can be set from 1 to 20.Example: if the maximum temperature is 120 °C and the delt a value is 10°C, on reaching 110 °C the maximum temperature

pre-alarm will be tripped.4) Maximum temperature (factory password): by means of this menu it is possible to set the maximum accepted temperature.

The field of regulation goes from 0 to 150°C.5) Minimum temperature (factory password): by means of this menu it is possible to set the minimum accepted temperature.

The field of regulation goes from 0 a -14 °C.6) Fan temperature (assistance password): by means of this menu it is possible to adjust the activation temperature of the

cooling fan. The field of regulation is between 0 to 150°C. The fan starts at the pre-fixed temperature. The hysteresis is fixed by10°C.

7) During the empty functioning cycle (assistance password): by means at of this menu it is possible to change the durationtime of the machine empty cycle. The field of regulation goes from 1 to 250 seconds.

8) Automatic S tart (assistance password): if activated, this parameter enables automatic start-up if there is a power cut. Whenthe voltage is restored the compressor re-starts automatically.

9) Internal phase sequences (assistance password): this parameter allows the control on the internal phase sequences ordisables it by activating the phase sequence input on the terminal board.

10) Language (no password required): this parameter allows to change the language in which the messages are displayed.There are 5 languages available (Italian, English, German, Spanish, French).

11) Enabling of RS485 (no password required): this parameter is used to enable the transmission by means of RS485 andautomatically disable that on RS232.

12) Pressure sensor (assistance password): enables “4-20 mA” input where the pressure sensor must be connected. Byenabling this parameter the pressure measurement appears on the display.

By enabling this parameter the external pressure gauge contact changes function and becomes the minimum pressure inputpressure gauge of the oil-separator. As such it prevents the re-start of the compressor if the pressure in the oil-separator is high.

13) PSI/BAR (no password required): selects the unit of measurement of the pressure.14) Set empty/pressure functioning (no password required): using this parameter it is possible to set the pressure at which the

compressor must stop. If the inverter is activated this parameter indicates the functioning pressure at which the inverter must startto choke in order to keep it stable.

15) Set load (no password required): indicates the pressure at which the control unit enables re-start of the compressor.16) Maximum pressure (assistance password): this parameter sets the maximum pressure value that can be reached i.e. the

max. value that can be set as per point 14.17) Maximum alarm pressure (factory password): this parameter sets the maximum pressure value at which the control unit

goes into alarm.18) Remote Pressure (assistance password): by enabling this parameter visualisation of the pressure and relative alarms is

maintained but the control of start-up of the compressor takes place by means of external pressure switch contact.19) Load delay (factory password): this parameter is used to set the delay, in seconds, from the moment in which the start-up

cycle has ended to the moment in which the air loading electrovalve is activated.


GBCONTROL FUNCTIONS

ALARM MESSAGESIn the case of anomalies or if the set safety limits are exceeded, the red alarm light switches on and the alarm in progress isvisualised on the display.

1) Control of the direction of rot ationIt is activated in the case of incorrect phase sequence. The alarm blocks the compressor. To

re-activate functioning the phases must be first restored.N.B To reset the alarm completely the electric power supply must be removed2) Control temperature probeIt is activated if the temperature probe breaks (probe open or in short circuit). The alarm

blocks the compressor. To restore functioning check the connection and/or replace the probe

and press the key .3) Maximum oil temperatureIt is activated when the maximum oil temperature is reached. The alarm blocks the compressor.

To re-start wait for the temperature to fall below the programmed value and act on the button

4) Minimum oil temperatureIt is activated when the minimum oil temperature is reached. The alarm blocks the compressor.

To re-start wait for the temperature to rise above the programmed value and act on the button

5) Oil temperature pre-alarmIt is activated when the oil pre-alarm value has been reached. The alarm does not block the

compressor. Act on the button to silence the alarm

6) Motor circuit breakerIt is activated when the motor circuit breaker relay intervenes. The alarm blocks the compressor.

Act on the button to silence the alarm after the cause has been verified.

7) EmergencyIt is activated when the emergency button is pressed which blocks the compressor. Act on the

button to silence the alarm after having restored the status of the emergency button.

8) Machine maintenance pre-alarmThis alarm informs the user that the machine requires routine maintenance (oil change, filters,

etc.). The alarm must be silenced by the operator that carries out the maintenance by selecting“Pre-alarm times” from the menu and by restoring the value as described in the “Parameters thatcan be modified” – chapter point (1).

9) Pressure sep arator switchIt is activated on opening of the pressure separator gauge contact. The alarm blocks the

compressor. To silence the alarm press the key after having restored the normal status of the

pressure separator gauge.

10) Fault 4-20 mA (pressure sensor)It is activated when the pressure sensor connected to the 4-20mA input does not function

correctly. The alarm blocks the compressor. To silence the alarm press the key after

having restored the normal status of the pressure sensor

11) Maximum pressureIt is activated when the maximum set pressure is exceeded. The alarm blocks the compressor. To

silence the alarm press the key after having restored the correct pressure.

30°C h00110 m05

Incorrect dir.of rot.

30°C h00110 m05

Temp. sens. fault

110°C h00110 m05

Max. oil temp.

-10°C h00110 m05

Min. oil temp.

105°C h00110 m05

Oil temp. pre-alarm

74°C h00110 m05

Motor circuit breaker

74°C h00110 m05

Emergency button

74°C h00110 m05

Routine maintenance

74°C h00110 m05

4-20Ma fault

74°C h00110 m05

Press.Separate. switch

74°C h00110 m05

Max. pressure

Display st atus

°C

°C

°C

sec.

Hours

°C

bar

bar

bar

Max.

20

150

0

250

32768

150

NO

NO

BAR

15

15

Min.

0

0

-14

1

0

0

YES

YES

PSI

0

0

Standard

5

110

-7

75

4000

80

NO

YES

BAR

8/10/13

7,5/8,5/11,5

PARAM.THAT CAN BE MODIFIED

Oil temp. pre-alarm (delta)

Maximum oil temperature

Minimum oil temperature

Empty time

Maintenance pre-alarm

Fan temperature

Automatic start

Pressure sensor

PSI/BAR

Set empty/press.functioning

Set load/delta functioning

bar

bar

sec.

Max pressure that can be set

Max pressure alarm

Load delay

Internal phase sequence

Language

Display contrast levelEnabling of RS485

Min .

0

0

0

YES

1

YES

Max.

15

16

200

NO

20

NO

Standard

9/11/14

14

10

YES

ITA

5

YES


GB

1212121212

FUNCTIONING

SAFETY AND CONTROL DEVICES

1) Pressure transducer: adjusts the START and STOP pressure2) Safety valve: opens the air discharge at the safety value.3) Maximum temperature probe: stops the motor

when +110°C is exceeded

CONTROL FUNCTIONS

FUNCTIONING PRINCIPLES• On commissioning, the motor starts fed in the

“star” connection. In this phase the electrovalve (1) isopen, the suction adjuster (2) is closed.

• The compressor remains in these conditions forabout 5÷7 seconds.

• After this period of time , the motor is “triangle-fed”: the electrovalve (1) receives current and closesallowing the suction adjuster to open (2), which sucks inatmospheric air through the filter (3).

• In this phase the compressor functions in fullworking order and starts to compress the air inside thetank (7).

• The compressed air cannot exit from theminimum pressure valve (5) which is adjusted at 3÷4bar.

• The compressed air compresses the oil insidethe tank (7) and makes it flow through the pipes (8).

• The oil reaches the radiator (9) and passing through the filter (11) and the piping (12) reaches the compressor (4) where itmixes with the sucked air creating an air/oil mixture, which guarantees tightness and lubrication of the compressor’s moving parts.

• The air/oil mixture returns into the tank (7), where the air undergoes a centrifugal pre-separation and successively adefinitive separation of the oil by means of the oil-separator filter (6).

• Therefore only air exit s the t ank , which through the pipes (13) reaches the radiator (9) and through the interception tap(14) goes to the network.

• The light residues of oil deposited on the base of the oil-separator filter are re-introduced into the compressor.

Display status during start-up (remains for 5 seconds) Display status during normal functioning

In order to visualise the total functioning time at any moment, press the key. The visualisation will last for 20 seconds.

Easy Tronic II

V.0.0.0 GG/MM/AA dataSoftwareversion Compr. status

Oil temp. pressure100°C 9.5Bar

Stato=stand-by

COMMISSIONINGBefore commissioning the machine, ensure that:• the power supply voltage corresponds to that indicated on the CE label,• the electric connections have been carried out using cables with adequate section and that they are fastened well,• the master switch (on the wall) has suitable fusing,• the oil level is above minimum (top-up with the same type of oil if necessary),• the air exit tap is completely open.THE CONNECTION TO THE TANK MUST BE CARRIED OUT USING A FLEXIBLE PIPE .• Commissioning of the compressor must be carried out by a specialised technician.If the machine does not st art-up and the “Dir . of rot ation error” message appears on the displayInterrupt the electric power supply using the wall-mounted master switch,open the electric cabinet door and invert the position of the two phases in the terminal board,

close the door, restore the voltage and re-start the machine.Display st atus during functioning

START-UP

2 3

1

6

7


GBBEFORE CARRYING OUT TYPE OF INTERVENTION INSIDE THE MACHINE:• Stop the compressor using the OFF key (not using the emergency button).• Remove the current using the external wall-mounted switch• Close the line tap.• Make sure there is no compressed air inside the oil-separator tank by turning tap A in an

anti-clockwise direction and allowing the air to flow out completely (fig.9) .

AFTER THE FIRST 100 HOURS• Check the oil level and top-up using the same type of oil if necessary.• Check screw tightness: in particular, electric power contact screws.• Visually check tightness of connections.• Check the environmental temperature

EVERY 100 HOURSCheck oil (fig.10)• It is recommended to check the oil level every 100 hours of work.• Always discharge the air from the oil-separator tank before topping-

up : open the tap slowly A until all air has escaped and then tighten (fig.9).• The maximum oil level is considered when it touches the inside of the inlet

well D. The warning device C is used to indicate the approach to the minimumallowed level.

• When carrying out this check, if the warning C does not resultCOMPLETELY “full” it is recommended to top-up the oil through inlet well D, untilthe maximum level is reached.

• About 1 litre of oil is required to top-up from the minimum to the

maximum.

EVERY 500 HOURSCleaning of the air suction filter (fig.11)• Clean the air filter using compressed air, acting from the inside towards the outside.Control for any tears against the light: in this case replace the filter.• The filtering cartridge and the lid must be mounted carefully in order not to allow the passage

of dust inside the compression unit.• After the third cleaning intervention replace the air filter (max. every 1500 hours).

EVERY 1000 HOURSCheck transmission belt tension (fig.12)An appropriate measuring device is required to carry out this control, which allows to precisely

establish the degree of tension of the belt by means of a frequency measurement. Operate asfollows:

Disassemble the rear panel• Place the measuring device microphone near to the belt in the

point indicated by “test” (about halfway) and strike the belt using awrench.

• Read the value measured and if it is different from the valuesindicated in table 1, adjust the tension:

Higher value = belt too taughtLower value = belt too loose• Act in the following way:Loosen the 4 screws (C) until the screw compressor support plate

can be moved, loosen the counter-nut (B) and turn the screw (A) in aclockwise direction to increase the tension and in an anti-clockwisedirection to decrease it. Re-block the counter nut (B) and the screws(C) before checking the frequency value again. Repeat the operationuntil the optimal value has been obtained.Once the desired value has been reached, block all components and

re-mount the rear panel before re-starting the compressor.

MAINTENANCE

Power supply(V/Hz) 400/50 400/60 400/50 400/60 400/50 400/60

BSC10 08 80 82 BSC15 08 92 88 BSC2008 110 94

BSC10 10 81 71 BSC15 10 93 86 BSC2010 100 94

BSC10 13 84 101 BSC15 13 95 91 BSC2013 98 72

Table 1 – Final belt tensioning values (tolerance +1 / -4 Hz)

AB

TEST

C

MIN

MAX

D

C

B

9

11

A

10

12


GB

1414141414

Check for blocking and cleaning of the radiatorThe radiator has high efficiency and a limited level of blocking. In the case of anomalous over-temperatures it is recommended

to check the degree of blockage and in normal conditions at least once a year.Proceed as following for cleaning:• remove the rear and upper panels from the compressor cab;• position a sheet of protective plastic under the radiant pack;• spray (with washing gun + solvent) from inside towards the outside.

• check the perfect passage of air towards the radiator.

EVERY 4000 HOURSOil replacement (fig.10)Every 4000 hours of work (with hot compressor) replace the oil.• Discharge the pressure in the oil-separator tank using tap A (fig.9).• Insert the supplied flexible pipe into tap B.• Unscrew the inlet well cap D, open tap B and allow the oil to flow out into

a collection recipient until it is completely discharged.• When discharge has been completed close tap B and remove the pipe• Pour in new oil through the inlet well D (quantity for complete filling: about 5

litres), and tighten the cap.• Apply current to the machine.• Start-up the machine and leave it running for 5 minutes then stop it.• Discharge all air.• Wait 3 minutes and check the oil level; top-up if necessary.The oil must be replaced at the same time as replacement of the oil and oil-separator filters.

Recommended oil: RotEnergy Plus. (do not mix different types of oil).

WASTE OIL IS HIGHLY POLLUTANT: dispose of it in compliance with legal provisions.

Replacement of the oil-separator filter (fig.13)The oil-separator filter cannot be cleaned but must be replaced at every oil change.In particular, pay attention to the pressure shown on the manometer (B). If, with the machine in

full working order (e.g. P max 10 bar), the pressure measured by the manometer is above 1 bar (=11bar), it is ABSOLUTELY NECESSARY to replace the filter even if it is outside of the recommendedintervals.

• Discharge the compressed air completely by means of tap (A) (fig. 9).• Loosen the filter manually by turning it in an anticlockwise direction.• Replace it with a new filter, turning it in a clockwise direction after having lightly greased the

seal and the OR ring inside the oil-separator filter.

Replacement of the oil filter (fig.14)At every oil change it is indispensable to replace the oil filter ; this operation must be carried out

when the tank is not pressurised.Always pass a thin layer of oil on the edge of the filter and on the seal before tightening.

MONTHLYDischarge condensation• Oil-separator tank (fig.10)Cooling of the oil/air mixture is adjusted at a higher temperature with respect to the air dew point;

however, it is not possible to totally eliminate the presence of condensation in the oil.Discharge the condensation once a month before starting up the compressor: open tap B and

close it again as soon as oil starts to escape instead of water.Check the oil level and top-up if necessary.• External air tankOpen the discharge valve positioned under the air tank by turning it in an anti-clockwise direction.

Position a collection recipient and leave it open until only air escapes.CONDENSATION IS A POLLUTANT MIXTURE! And must not be introduced into the drain system.

Dispose of it in compliance with laws in force concerning environmental protection.

EVERY 12000 HOURS

Check minimum flow valve

Replacement of electric motor bearings

MAINTENANCE

13

14

10

MIN

MAX

D

C

B


GB

Table 1 – Final belt tensioning values(tolerance +1 / -4 Hz)

EVERY 20000 HOURS

• Replace the sealing ring and bearings in the screw unit

MAINTENANCE

Power supply(V/Hz) 400/50 400/60 400/50 400/60 400/50 400/60

BSC10 08 80 82 BSC15 08 92 88 BSC2008 110 94

BSC10 10 81 71 BSC15 10 93 86 BSC2010 100 94

BSC10 13 84 101 BSC15 13 95 91 BSC2013 98 72

Replacement of flexible pipesIt is advised to replace the pipes when changing the oil. Loosen the connections, replace them and tighten the connections again

firmly. Now change the oil.

Replacement of the transmission belt (fig.12)Act in the following way:• loosen the 4 screws (C) until the screw compressor support

plate can be moved. Loosen the counter nut (B) and turn the screw (A)in an anti-clockwise direction until the belt is completely relaxed.

• Remove the belt and replace it• Tighten the screw partially (A), block the counter nut (B) and

check the frequency value by means of the relative instrument (see“check belt tension” page12).

• If necessary, repeat the operations described until the optimalvalue stated in table 1 has been reached.

Higher value = belt too taughtLower value = belt to loose

Once the desired value has been reached, block all componentsfirmly and re-mount the rear panel before re-starting the compressor.

AB

TEST

C

12


GB

1616161616

MAINTENANCE AND WARNING SUMMARY TABLE

It is important to indicate that the oil used is extremely significant. In fact, the use of oil different to that recommended (RotEnergyPlus.) leads to the modification of maintenance intervals.

The passage to a different lubricant must be carried out ONLY AND EXCLUSIVELY on occasion of the first entire oil change andit is EXTREMELY IMPORTANT NEVER TO MIX DIFFERENT TYPES OF OILS. Always use the same type of oil for successivetop-ups.

WASTE OIL IS HIGHLY POLLUTANT: dispose of it in compliance with legal provisions

Attention:maintenance intervals are strongly influenced by environmental conditions and working conditions of the compressor.

Oil used:

RotEnergy Plus

Type of maintenance Hours of service

Check oil level and top-up if necessary 100

Clean suction filter 500

Check transmission belt tension 1000

Check blockage and cleaning of the radiator 1000

Complete oil replacement 4000

Oil filter replacement 4000

Oil-separator filter replacement 4000

Discharge condensation At least once a month

Check minimum pressure valve 12000

Replace flexible pipes 12000

Replace transmission belt 12000

Replace electric motor bearings 12000

Replace screw unit sealing ring and bearings 20000


GBProblem

Motor stop due to circuitbreaker relay intervention

High oil consumption

Oil leak from suction filter

Opening of safety valve

Compressor temperaturethermostat intervention: themachine blocks

The compressor ha slowperformance

The compressor is runningbut does not compress air

The compressor continuesto compress air above themax. pressure

Difficult start-up

Oil presence in the cab

Cause

Voltage too low

Motor over-temperature

Faulty drainage

Oil level too high

Oil-separator filter broken

Bad sealing of the oil-separator nipple

The suction adjuster doesnot close

Pressure too high

The suction adjuster doesnot close at cycle end

Oil-separator filter blocked

Environmental temperaturetoo high

Radiator blocked

Oil level too low

The electrovalve does notstart-up

Air filter dirty or blocked

The adjuster is closed, itdoes not open because it isdirty or has no command

The adjuster is open, it doesnot close because it is dirtyor has no command

Malfunctioning of thepressure transducer

The voltage is too low

Leaks from the pipes

Leak from the screw unitfront flange

Solution

Check the voltage, press Reset and re-set

Check motor absorption and check relay calibration. Ifabsorption is normal press reset and re-start

Check the oil drainage pipe and the non-return valve

Check the oil level and discharge if necessary

Replace the oil-separator filter

Replace the oil-separator nipple seal

Check functioning of the adjuster and the electrovalve

Check calibration of the pressure transducer

Check functioning of the adjuster and the electrovalve

Check the difference between the line pressure and the oil-separator tank. Replace the oil-separator filter if necessary.

Increase ventilation

Clean the radiator using solvent

Add oil

Check the command relay and the motor of the fan motor.

Clean or replace the filter

Remove the suction filter and check if the adjuster opensmanually. If necessary, disassemble and clean.Check the presence of the signal between the pressuregauge and electrovalve. Replace any damaged parts

Disassemble and replace the adjusterCheck the presence of the signal between the pressuregauge and electrovalve. Replace any damaged parts

Replace the transducer

Control network voltage

Tighten connections and/or replace damaged pipes

Replace the sealing rings

TROUBLESHOOTING


GB

1818181818

v1

u1

u2

v2

w2w1

FR1

R

S

PE

KM1 KM2 KM3

A

SB

T

YVKM3KM2KM1

5

11 12

8

10

3

10

3

15

10

20

ST

19

014

17

PE

1506 1 024

1014

FR1

10

Pont

e

13

3

06

FU3FU4

FU1

FU2

FU5

FU6

(0)

(230)

(24)

(0)

(6)

(0)

L11

L31

L22

L32

TC1

TC2

L1

L2

L3

230 02

24

02414

2

FU7060

1 2 3 4 5 6 7 8 9 10 11

12 13 14 15 16 17 18 19 24 25 2620 27

D

21 22 2328 29 30

A B

KM4

u3

3MV

w3v3

FR2 FR2

18

9

KM4

Rs485 Rs2324-20mAin out(+)

PL2

BP

PL1

(**)

(**)

(**)

A =Inom x 1,5

A B

COMPRESSORMOTOR

AIR FANMOTOR

PE

KM3 KM2

6 7

MC3

L3

L1PE

L2

38

1310

01414

2

(YV)

LINE

02

TC2 (FU6)TC2 (FU5)(FU4)

JUMPER - REMOTE EMERGENGY STOP

TC1 (FU2)TC1 (FU1)

(FU3)

U3V3W3

AIR FAN

TC2 (FU7)

BA

RS485

JUMPER - REMOTE EMERGENGY STOP

JUMPER - REMOTE PRESSURE CONTROL

(**)

WIRING DIAGRAM

N.B1) Sezione contatto comando = 1 mmq2) (*) = 400V AC33) (**) = 400 V

V 400Alimentazione: nero/blu/marronePonte: giallo/verde/bianco

V230Alimentazione: (marrone-bianco)/(blu-verde)/(nero-giallo)

BSC10-15-20 (230-400/50-60)

Reference Description

230V 400V 230V 400V 230V 400V

TC1 Pr. transformer .0/230/400 Sec.0/230/024

TC2 Pr. transformer .0/230/400 Sec.0/6

SB Emergency button

FU1 - FU2 Ceramic fuses 6.3x32 4A 500V

FU3-FU4-FU5-FU6 Ceramic fuses 6.3x32 1A 500V

FU7 Ceramic fuses 6.3x32 500mA 500V

KM1 Line contactor 230V/50-60Hz 11KW(*) 5,5KW(*) 11KW(*) 7,5KW(*) 18,5kW(*) 11kW(*)

KM2 Delta contactor 230V/50-60Hz 11KW(*) 5,5KW(*) 11KW(*) 7,5KW(*) 18,5kW(*) 11kW(*)

KM3 Star contactor 230V/50-60Hz 7,5KW(*) 4KW(*) 11KW(*) 7,5KW(*) 15kW(*) 7,5kW(*)

KM4 Fan contactor 230V/50-60Hz 3KW(*) 3KW(*) 3KW(*) 3KW(*) 3KW(*) 3KW(*)

FR1 Compressor motor thermal relay (17-22) (9-12) (22-32) (11-16) (28-40) (17-22)

FR2 Fan motor thermal relay (0,7-1) (0,35-0,5) (0,7-1) (0,35-0,5) (0,7-1) (0,35-0,5)

YV Solenoid valve

BP Pressure transducer 0-16 bar

D Electronic controller

ST Temperature sensor

MV Fan motor

MC Compressor motor

Motor cable cross-section (sq mm) 7x4 7x2,5 7x6 7x2,5 7x10 7x4

BSC10 BSC15 BSC20

195/275W 195/275W 195/275W

Bsc R-evo GB - fps-compressors.co.uk · Rotar Bsc R-Evo - Cod.197BB6800 - ed.00 09/2006 333 ......

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Transcript of Bsc R-evo GB - fps-compressors.co.uk · Rotar Bsc R-Evo - Cod.197BB6800 - ed.00 09/2006 333 ......