GB use & maintenance MANUAL Rotar Cube 5-7-1 Rotar Cube - Cod.197AA33 - Rev.1 1/28
GENERAL INFORMATION GB GENERAL INFORMATION... 3 SAFETY INDICATIONS... 4 INSTALLATION... 6 TECHNICAL FEATURES... 7 CONTROLS AND SETTINGS... 8 CONTROL FUNCTIONS... 1 OPERATION... 11 START-UP... 11 MAINTENANCE... 12 TROUBLESHOOTING... 15 WIRING DIAGRAM... 16 OUTFIT The following accessories are supplied with the compressor: user s guide anti-vibration elements electric box key oil/condensate exhaust tube Check that the above accessories are available. Once the goods have been delivered and accepted, no complaints are accepted. CONDITION OF THE MACHINE WHEN SUPPLIED Every compressor is shop tested and delivered ready to be installed and to be set at work. Oil used is: ROTENERGY PLUS. Rotar Cube - Cod.197AA33 - Rev.1 1/28 3
GB SAFETY INDICATIONS GENERAL Rotary compressors are intended for heavy continuous industrial use. They are especially suitable for industrial applications requiring high air consumption for a long time. The compressor should be run and operated only in compliance with the indications given in this manual. Safely keep this manual in a known and easily reachable place for the whole working life of the compressor. A supervisor shall be appointed in the company, in which the compressor is installed. He/she shall be responsible for compressor inspections, adjustments and maintenance. Should a substitute be appointed for the supervisor, he/she shall carefully read the user s guide and all possible comment on service and maintenance carried out so far. SYMBOLS USED IN THE MANUAL Some symbols are used to highlight danger situations, give recommendations or information. These symbols are usually positioned next to the text, a figure or at the top of a page (in this case they refer to all subjects dealt with in that page). Carefully read symbol meaning below. CAUTION! Important description on service, dangerous situation, safety, accident prevention recommendations and/or very important information. STOP MACHINE! All operations to be strictly carried out only after stopping the machine. POWER OFF! All operations to be strictly carried out only after powering off the machine. SPECIALIZED PERSONNEL! All operations to be strictly carried out only by specialized technician. SYMBOLS ON THE COMPRESSOR The compressor has several labels to highlight possible danger and give recommendations on what to do during machine operation or in special situations. Please comply with these indications. Danger! Hot! Prohibited! Do not open doors during compressor operation Danger! Electric shock! Prohibited! Press emergency button for compressor immediate stop. Do not use line knife switch. Danger! Hot gas or harmful gas within working area Prohibited! Do not use water on electric equipment to extinguish fire. Danger! Pressurized container Compulsory! Read instructions for use carefully. Danger! Mechanical moving parts Caution! Maintenance works in progress 4 Rotar Cube - Cod.197AA33 - Rev.1 1/28
SAFETY INDICATIONS WHAT TO DO: Make sure that mains voltage corresponds to the voltage indicated on CE plate and that cable of suitable cross-section are used for electric connections. Always check oil level before starting the compressor. Be familiar with emergency stop control and all other controls. Unplug the connector before any maintenance work, so to avoid accidental start. Ensure that all parts have been correctly reassembled after any maintenance work. Keep children and animals off the working area to avoid injuries caused by devices connected to the compressor. Ensure that temperature of the working environment ranges between +5 and + 5 ºC. The compressor should be installed and operated in a non-explosive environment. Allow at least 8 cm between the compressor and the wall so to allow free air flow to the fan. Press the emergency button on the control panel only in case of actual need so as to avoid possible damages to people or the very compressor. When calling for technical assistance and/or advice, always mention model and serial number indicated on CE plate. Always follow the maintenance schedule specified in the user s guide. GB WHAT NOT TO DO: Do not touch inner parts and pipes as they are very hot during compressor operation and stay hot for a certain time after compressor stops. Do not position inflammable or nylon objects or cloths close to and onto the compressor. Do not move the compressor when the tank is under pressure. Do not operate the compressor if the power cable is damaged or defective or if connection is unstable. Do not operate the compressor in wet or dusty environments. Never aim the air jet at people or animals. Do not allow unauthorized people to operate the compressor and give them all required instructions. Do not hit fans with blunt objects as they might break during compressor operation. Never operate the compressor without air filter. Do not tamper with safety and adjusting devices. Never operate the compressor when doors/panels are open or removed. PRODUCT IDENTIFICATION The compressor Your have purchased has its own CE plate showing the following data: 1) Manufacturer s data 2) CE mark year of manufacture 3) TYPE = name of the compressor CODE = compressor code SERIAL NO. = serial number of the compressor You have purchased (to be always mentioned when calling for technical assistance) 4) air delivered by the compressor expressed in (l/min) and (cfm) 5) max. operating pressure (bar and PSI) compressor noise level in db(a) 6) electric data: voltage (V/ph), frequency (Hz), absorption (A) - power (HP and kw), rotations per minute (Rpm). 7) other approvals Rotar Cube - Cod.197AA33 - Rev.1 1/28 5
GB MACHINE DESCRIPTION (fig. 1) The compressor essentially consists of the following: 1) Electrical equipment 2) Control panel 3) Air/oil radiator 4) Air-air intercooler (only in Cube 1) 5) Oil filter 6) Air filter 7) Suction regulator 8) Screw compressor 9) Motor 1) Oil separator filter 11) Minimum pressure valve 12) Oil separator tank INSTALLATION UNPACKING AND HANDLING THE MACHINE When delivered, compressor top is protected by cardboard packing. Wear suitable protective gloves and then cut outer straps and then remove cardboard from the top. Check the (outer) good condition of the machine before moving the compressor. Visually check that no parts are damaged. Also ensure that all accessories are available. Lift the machine using a fork lift truck. Fit the anti-vibration elements into their proper seat and move the machine to the room chosen for its location with maximum care. Keep all packing materials at least for the warranty period for possible moving. In case of need, it will be safer for delivery to the technical assistance dept. Then, dispose of packing materials in compliance with current laws. 1 LOCATION (fig. 2) The room chosen for the installation of the compressor should meet the following requirements and comply with what specified in the current safety and accident prevention regulations: low percentage of fine dust, proper room ventilation and size that allow room temperature under 5 C. In the event of inadequate hot air discharge, fit the exhaust fans as high as possible. Exhaust flow rate 2 cu.m./h part no. 241 Exhaust flow rate 4 cu.m./h part no. 242 Condensate should be collected either into a pit or a tank. The dimensions of the spaces are indicative only but it is advisable to follow them as closely as possible. ELECTRICAL HOOK-UP (fig. 3) The mains cable should have a cross-section suitable for the machine power and should include no. 3 phase wires, no. 1 neutral cable and no. 1 earth wire. Between the mains cable and the compressor control panel a fused switch near the point where the cables go into the machine is absolutely necessary. The switch should be at least at 1.7 from the ground. The switch (A) should be easily reached by the operator. The cables should be of the approved type and installed with the following grade of protection: minimum IP44. NOTE: Follow the instructions in the table to select proper cable section. 2 3 6 Rotar Cube - Cod.197AA33 - Rev.1 1/28
TECHNICAL FEATURES CUBE 5 Direct start CUBE 7 Star-Delta starter CUBE 1 Star-Delta starter A - Technical features Voltage V/Hz 4/5 4/6 4/5 4/6 4/5 4/6 Auxiliary voltage V/Hz 23/5 23/6 23/5 23/6 23/5 23/6 Pressure bar 1 1 1 1 1 1 Compressor type type FS26TFC FS26TFC FS26TMC FS26TMC FS26TFC FS26TFC Compressor rotation speed rpm 215 26 289 3428 431 513 Air volume supplied l/min 46 6 615 685 99 118 Oil quantity l 3,5 3,5 3,5 3,5 3,5 3,5 Oil quantity for topping-up l,5,5,5,5,5,5 Max. final over temperature C / / / / 16 16 Removed heat kj/h 1368 1368 188 188 256 256 Fan flow rate m³/h 67 67 67 67 16 16 Oil residues in the air mg/m³ 4 4 4 4 4 4 Electric motor type 112 MC/4 112 MC/4 112 MC/2 112 MC/2 112 MC/2 112 MC/2 Motor power kw 4 4 5,5 5,5 7,4 7,4 Max. power absorbed kw 4 4 5,5 5,5 7,5 7,5 Electrical box protection class IP 54 54 54 54 54 54 Motor insulation class F F F F H H Full load current A 1 1 1,3 11,8 15,2 16,3 Starting load A 52 52 23 22 34 36,3 Max. Start-up per hour n 1 1 1 1 1 1 Ambient limit temperature C 5 5 5 5 5 5 Noise level at 1 m db(a) 63 65 68 7 68 7 B - Protection devices Max compressor temperature C 11 11 11 11 11 11 Safety valve setting bar 14 14 14 14 14 14 Motor protection type Thermal Thermal Thermal Thermal Thermal Thermal C - Dimensions and weight Length mm 57 57 57 57 57 57 Width mm 63 63 63 63 63 63 Height mm 8 8 8 8 8 8 Weight kg 96 96 99 99 1 1 Air cock fitting bsp 1/2" 1/2" 1/2" 1/2" 1/2" 1/2" D - Power connection Power kw 4 4 5,5 5,5 7,5 7,5 Absorbed current A 1 11 1,6 11,6 16,5 18 Cable section mm² 7G1.5 7G1.5 7G1.5 7G1.5 7G2.5 7G2.5 Relay setting A 1,5 11,8 6,8 7,5 1,5 11,5 Switch A 2 2 2 2 25 3 Fuses A gl 25 25 25 25 3 32 GB Rotar Cube - Cod.197AA33 - Rev.1 1/28 7
GB CONTROL PANEL All compressor power-on-and-off procedures are controlled by the machine power unit. Furthermore, it signals possible machine problems and gives information on the operation times and the maintenance operation times. CONTROLS AND SETTINGS 4 1) Display on which information is displayed. 2) OK key: to confirm (see Modifiable Parameters ) 3) Arrow keys: to scroll the options of the menu 4) Alarm lights: if the light turns on and compressor possibly stops, it means that maintenance service is needed or a failure in the system has occurred. Refer to Alarm messages to identify proper service. 5) Reset key: to stop the alarm (see Alarm Messages ) 6) ON/1 key: to power the machine on. The machine power-on cycle is divided into three phases: wait for power-on: the (STAND_BY) message is displayed. If compressor was switched off, it requires 15 seconds; otherwise compressor remains on stand-by until pressure switch requires air. Starting: compressor power-on in the star mode: the (EMPTY)message is displayed; Working cycle: shift from star mode to delta mode after five seconds. After two seconds, if required by transducer, the load solenoid valve is excited and (LOAD) message is displayed. NOTE: This cycle is for compressors with a remote starter. Direct start compressors start immediately after (STAND-BY) phase. 7) OFF/ key: to power the machine off. Load solenoid valve is disabled, emptying cycle starts, blinking (EMPTY) message is displayed, once emptying cycle is over compressor stops and off message is displayed. 8) Emergency stop switch: to stop compressor only in case of actual need 9) Functioning scheme/ maintenance operations WORKING TIMES Automatic mode The compressor operation is controlled by the pressure switch, which stops the machine when the max. pressure value is reached and starts it again after the pressure has decreased to the min. set value. However, the machine stop is of the delayed type, that is it does not occur exactly at the same time when the max. pressure value is reached but after a certain time, during which no air is taken (see no. 7 of above paragraph). Standard setting is 2 seconds, but it is recommended to check that number of start-ups per hour does NOT exceed max number of 1. Should it be a higher value, it is recommended to set longer loadless operation time (see no. 7, Modifiable parameters ). PRESSURE REGULATOR The User should install a pressure regulator downstream of the compressor to set the power line according to his/her needs. REMOTE ON/OFF The compressor can also be switched on or off using the remote control by way of a software (remote control will be active only if the control unit at the machine is set to ON ). This function can be used through the remote terminal on the terminal box. In such case, manual controls will be excluded. If the compressor starts up unexpectedly, persons happening to be nearby could be harmed or injured. With this in mind, THIS USE IS GENERALLY NOT RECOMMENDED.The manufacturer will not be liable for any damages. Any change must be carried out by a qualified technician 8 MODIFIABLE PARAMETERS Pressing the key with the machine OFF, the operating parameters menu will be displayed; in certain cases a password is required in order to make changes. The menu is scrolled using the and. keys ) control unit ID (service password): selects the identification code of the control unit; if several compressors are connected to the same RS485 line, multiple IDs can be selected. 1) Pre-alarm time lapse (service password): each hour of operation clocked by the machine is counted down automatically; when the count reaches, the control unit trips a Maintenance alarm. The count, preceded by a minus sign (-), indicates how many hours have elapsed since the last maintenance alarm; the and keys can be used to set a new value (entering the new value has the effect of overriding the previous alarm). 2) Alarms history (no password required): this menu can be used to display the 3 most recent alarms. 3) Pre-alarm temperature (factory password): Rotar Cube - Cod.197AA33 - Rev.1 1/28
CONTROLS AND SETTINGS this menu is used to set the temperature differential ( delta, in C) referred to the maximum alarm temperature; the value can be set between 1 and 2. Example: if the maximum temperature is 12 C and the differential is 1 C, the maximum temperature pre-alarm will trip at 11 C. 4) Maximum temperature (factory password): this menu is used to set the maximum permissible temperature; the adjustment range is to 15 C. 5) Minimum temperature (factory password): this menu is used to set the minimum temperature; the adjustment range is to -14 C. 6) Fan temperature (service password): this menu is used to set the temperature at which the cooling fan comes into operation; the range of adjustment is to 15 C. The fan cuts in at the set temperature. Hysteresis is fixed at 1 C. 7) Duration of no-load operation (service password): this menu is used to change the duration of the no-load cycle; the range of adjustment is 1 to 25 seconds. 8) Auto start (service password): this parameter enables Start in automatic mode; if activated, the compressor will restart automatically following an electrical power supply failure. If the compressor starts up unexpectedly, persons happening to be nearby could be harmed or injured. With this in mind, use of the automatic start function is not generally recommended. 9) Internal phase sequence (service password): this parameter enables control of the phase sequence internally, or disables internal control and activates the phase sequence control input at the terminals. 1) Language (no password required): this parameter is used to select the language in which messages are displayed; there are 5 available (English, French, German, Italian, Spanish). 11) Enable RS485 (no password required): this parameter is used to enable data transmission using RS485, and automatically disable transmission on RS232. 12) Pressure sensor (service password): enables the 4-2 ma input to which the pressure sensor is connected. With this parameter activated, the pressure measurement is displayed. To display lapsed time (hours and minutes), press the key; the display will revert to the pressure measurement automatically after 2 seconds. Enabling this parameter, the external pressure switch contact changes function and becomes an input for the deoiler minimum pressure switch; in this situation, the compressor is prevented from restarting if pressure in the deoiler is high. 13) PSI/BAR (no password required): selects the unit of measure used to display pressure. 14) No-Load/operating pressure set point (no password required): this parameter is used to set the pressure at which the compressor must switch off; if inverter drive is enabled, it indicates the operating pressure at which the inverter will begin modulating output to maintain the pressure steady. 15) Load/operating differential set point (no password required): indicates the pressure at which the control unit enables compressor restart. For example, if the set differential value is 1 bar and maximum operating pressure is 9 bar, this means that the compressor will switch off at 9.5 bar and switch on again at 8.5 bar. 16) Maximum pressure (service password): this parameter sets the maximum pressure value permissible in operation, i.e. the maximum pressure of point 14. 17) Maximum alarm pressure (factory password): this parameter sets the maximum pressure value at which an alarm is tripped in the control unit. 18) Remote pressure(service password): enabling this parameter, the pressure and the relative alarms continue to be displayed, but the compressor starting sequence is controlled from an external pressure switch contact. 19) Load delay(factory password): this parameter sets the delay, in seconds, from the moment when the starting cycle terminates to the moment when the air solenoid valve energizes. GB ALWAYS USE THE AND KEYS TO SELECT THE VALUE AND CONFIRM WITH MODIFIABLE PARAMETERS Oil temperature pre-alarm (differential) Maximum oil temperature Minimum oil temperature No-load (EMPTY) time Maintenance pre-alarm Fan temperature Automatic start Pressure sensor PSI/BAR NoLoad/operating pressure set point Load/pressure differential set point Maximum permissible pressure C C C sec. Ore C bar bar bar Min. -14 1 YES YES PSI Max. 2 15 25 32768 15 NO NO BAR 15 15 15 Standard 5 11-7 2 4 8 NO YES BAR 1 8,5 11 Maximun alarm pressure Load (CHARGED) delay Internal phase sequence control Language Display contrast level Enable RS485 bar sec. Min. YES 1 SI Max. 16 2 NO 2 NO Standard 13 1 YES ITA 5 SI Rotar Cube - Cod.197AA33 - Rev.1 1/28 9
GB CONTROL FUNCTIONS ALARM MESSAGES In the event of a fault occurring or of set safety limits being exceeded, the red alarm light will appear and the current alarm condition is displayed. 1) Check direction of rotation Alarm trips in the event of incorrect phase sequence being detected. The compressor locks up; to restore operation, the correct phase sequence must first be re-established. NOTE: To reset the alarm, the equipment must be isolated from the a.c. power supply. 2) Check temperature sensor Alarm trips in the event of temperature sensor fault (sensor open or short circuiting). The compressor locks up; to restore operation, check the connection and/or replace the sensor, then press. 3) Maximum oil temperature Alarm trips when the maximum oil temperature is sensed. The compressor locks up; to restore operation, wait for the temperature to fall below the programmed value, then press. 4) Minimum oil temperature Alarm trips when the minimum oil temperature is sensed. The compressor locks up; to restore operation, wait for the temperature to rise above the programmed value, then press. 5) Oil temperature pre-alarm Trips when the pre-alarm oil temperature is sensed. The compressor does not lock up. To override the pre-alarm, press. 6) Motor thermal overload Operates when the thermal overload relay is tripped. The compressor locks up. To silence the alarm, first verify the cause, then press. 7) Emergency A circuit activates to lock up the compressor when the red emergency button is depressed. To silence the alarm, first reset the emergency button, then press. 8) Machine maintenance pre-alarm Trips to warn the user than that machine is due for routine maintenance (oil change, service filters, etc.). The alarm must be silenced by the service technician, who when carrying out maintenance operations will select the item Pre-alarm hours from the menu and reset the value as described under the heading Modifiable parameters - point (1). 9) Separator pressure switch Alarm trips in the event of the separator pressure switch contact opening. The compressor locks up. To silence the alarm, first reset the separator pressure switch, then press. 1) 4-2 ma fault (pressure sensor) Alarm trips when the pressure sensor connected to the 4-2mA input does not operate correctly. The compressor locks up. To silence the alarm, first restore the pressure switch to normal status, then press. 11) Maximum pressure Alarm trips when the maximum pressure setting is exceeded. The compressor locks up. To silence the alarm, first restore the correct pressure, then press. Display status 3 C h11 m5 Wrong rotation 3 C h11 m5 Temp sensor faulty 11 C h11 m5 Max oil temp -1 C h11 m5 Min oil temp 15 C h11 m5 Oil temp pre-alarm 74 C h11 m5 Motor thermal relay 74 C h11 m5 Emergency button 74 C h11 m5 Routine maintenance 75 C h11 m5 Separator p/switch 74 C h11 m5 4-2mA fault 74 C h11 m5 Max pressure SAFETY AND CONTROL DEVICES (FIG. 7) 1) Pressure switch: adjusts both STOP and START pressure. 2) Safety valve: opens the air bleeding unit when the safety value is reached. 3) Minimum pressure valve 4) Maximum temperature feeler : stops the compressor when a temperature of +11 C is exceeded. 5 1 Rotar Cube - Cod.197AA33 - Rev.1 1/28
OPERATING CYCLE Cube 5 Direct starting 1) The motor starts directly; it reaches standard speed after 5-7 seconds. Cube 5 Remote starting 1) At first start-up, the motor starts in the star configuration. In this phase the compressor starts slowly, the solenoid valve (1) is open and the suction regulator (2) is closed. The compressor remains in this condition for about 5 7 seconds. After this time, the motor is powered by the delta configured circuit. OPERATION GB 2) The solenoid valve (1) receives current and closes allowing the opening of the suction regulator (2), which intakes atmospheric air through the filter (3). 3) At this stage, the compressor runs at full speed and begins to compress the air in the tank (6). 4) The compressed air cannot come out from the minimum pressure valve set at 3 4 bar. 6 5) The compressed air compresses the oil in the tank (6) and forces it to flow towards the tube (7) to the radiator (9). 6) If the oil temperature is below 65 the solenoid valve stays still. 7) If the oil temperature exceeds 65 C the solenoid valve starts operating and cooled oil returns to the compressor through tubes (5) and filter (8). 8) The oil reaches the compressor (4) mixing with the intake air and creating an air/oil mixture which ensures the seal and the lubrication of the moving parts of the compressor. 9) The air/oil mixture returns to the tank (6) where the air is pre-separated through spinning and is finally separated from the oil by the oil separator filter (1). 1) Models Cube 5 and 7 convey the compressed air directly to the distribution network. On the contrary, model Cube 1 conveys the air through the tube (11) and the radiator (12) and then to the network. START-UP FIRST START-UP Before starting the machine for the first time, check that: the mains voltage is the same as the voltage on the CE plate; the electric connections have been made using cables of proper cross-section, the (wall) main power switch has suitable fuses; the oil level is over the minimum level - top up with the same type of oil if necessary; the air outlet cock is completely open. CONNECT THE TANK WITH A HOSE. Only specialized technicians can start the compressor (on-site testing) for the first time. If at this stage the machine does not start and the display shows the alarm message Rotation Err. proceed as follows: break power supply through the wall switch. Open the electric box door and reverse the phase position in the terminal board. Close the door, power on and start the machine. Display status at start (shown for 5 seconds) Display status during normal operation oil temp pressure Easy Tronic II V... GG/MM/AA date 1 C 9.5Bar Status=stand-by compressor status Press the key to see hours and minutes operation; the information is displayed for 2 seconds. 11 Rotar Cube - Cod.197AA33 - Rev.1 1/28 11
GB MAINTENANCE Proper maintenance is fundamental to the efficiency of your compressor and for the prolongation of its operational lifespan. It is also important to respect the manufacturer s suggested maintenance schedule, keeping in mind that the compressor has been constructed for use in the best possible environmental conditions. (see the chapter on Installation ) The intervals between maintenance works might have to be reduced to counteract the effects of the environmental conditions in which the compressor is used. The oil used is RotEnergy Plus. Use of a different type of oil could compromise the efficiency of the compressor and frequency of maintenance work to be performed. The normal maintenance operations which can be performed by the person in charge of the compressor will be described in the following pages. Extraordinary maintenance work must be performed by an authorised customer technical assistance centre. Type of maintenance Maintenance schedule working hours or at least Normal maintnance Condensate drain - Once per month Check oil level. 5 - Clean the air filter 1 - Clean radiators 1 - - Change the air filter 2 Once per year Change the oil filter 4 Once per year Change the oil separator filter 4 Once per year Change oil 8 Once per year Extraordinary maintenance Change one-way drain valve 4 Once per year Suction valve overhaul 12 - Thermostatic valve ovherhaul 12 - Minimum pressure valve overhaul 12 - Solenoid-valve substitution 12 - Substitute the electric motor bearings 12 - Substitute the fexible tube 12 - - Screw compressor overhaul 24 - AFTER THE FIRST 1 WORKING HOURS 1) Check the oil level (see next paragraph): top up with the same type of oil if necessary. 2) Check for proper screw tightening: in particular the power electric connection screws. 3) Visually check that all fittings seal properly. 4) Check room temperature BEFORE MAINTAINING THE MACHINE ALWAYS PERFORM THE FOLLOWING. Press the machine automatic stop button Power the machine off by means of the wall outer switch (do not press the emergency stop button) Close the line cock Remove outer fairing (where fitted) Ensure that the wall switch is positioned to before removing any protections. Make sure that no compressed air is inside the oil separator tank by turning the cock A (fig. 7) and bleed all air off 12 Rotar Cube - Cod.197AA33 - Rev.1 1/28
MAINTENANCE GB 7 DRAIN CONDENSATE The oil/air mixture cooling is set at a higher temperature with respect to the dew point of the air (under standard operating conditions of the compressor). However, the condensate in the oil cannot be fully removed. Blow off compressed air through cock A and then open the cock D to drain the condensate. Close it as soon as oil begins to flow out instead of water. Check the oil level and top up if necessary CONDENSATE IS A POLLUTING MIXTURE! It must not be let into the sewage. For its disposal comply with the current laws on environmental protection. CHECK OIL LEVEL Always blow off air from the oil separator tank before topping up: slowly unscrew the cock A until all air comes out and then screw it again. Unscrew the plug B and check oil level. Oil is at its max. level if it is at filler max. level. Top up, if necessary. Oil amount necessary for topping up from min. level is about.5 liters. CLEAN THE AIR FILTER Clean the air filter C from the inside towards the outside using compressed air. Check against the light for possible cuts: replace the filter if any. The filter cartridge and the cover should be assembled with care, so that no dust goes into the compression unit. CHANGE THE AIR FILTER AFTER THREE CLEANINGS (IN ANY CASE BEFORE 2 WORKING HOURS). CLEAN RADIATORS Clean the radiator in case of excessive overtemperature and at least once a year. Proceed as follows: Undo the four screws of the radiator and remove it; spray (spray gun + solvent) from the outside towards the inside; check for proper air flow through the radiators. CHANGE OIL Bleed off the pressure inside the oil separator tank through the cock A. Connect the supplied hose to the cock D. Unscrew the plug B of the filler and open the cock, then let all oil flow into a collection container. Close the cock and withdraw the hose. Pour fresh oil from the filler - quantity for complete filling: abt. 3.5 lt. Close the plug. Power the machine on. Start the machine and wait for 5 minutes, then stop the machine. Blow all air off. Wait for 5 minutes and check the oil level, top up if necessary. THE EXHAUSTED OIL IS HIGHLY POLLUTANT! For its disposal comply with the current laws on environmental protection. Oil used is: ROTENERGY PLUS. 13 Rotar Cube - Cod.197AA33 - Rev.1 1/28 13
GB MAINTENANCE 8 CHANGE OIL FILTER Change the filter E AT ANY OIL CHANGE with the tank not under pressure. Always apply some oil on filter edge and seal before refitting the filter. CHANGE OIL SEPARATOR FILTER The oil separator filter F cannot be cleaned but should be replaced at any oil change. Blow off all compressed air through the cock (A). Turn anticlockwise to unscrew the filter. Use a proper tool for filters, if necessary. After having slightly greased the oil separator filter seal and O-ring, fit the new filter by turning clockwise. 14 Rotar Cube - Cod.197AA33 - Rev.1 1/28
TROUBLESHOOTING GB Problem Motor stopped by thermal relay Oil consumption high Intake filter leaks oil Safety valve opening Thermostat for compressor temperature triggered Compressor performance low Compressor does not compress air while running Compressor compresses air over max. pressure value Compressor does not start Compressor hardly starts Oil in the cabinet Cause Voltage too low Overtemperature Drainage faulty Oil level too high Oil separator filter broken Oil separator filter seal leaking Intake regulator stays open Pressure too high Intake regulator does not close at the end of the cycle Oil separator filter clogged Room temperature too high Radiator clogged Oil level too low Cooling fan does not start Air filter dirty or clogged Regulator closed. It cannot open because dirty. Regulator closed. It cannot open because no command is received. Regulator open. It cannot open because dirty. Regulator open. It cannot open because no command is received. Oil separator filter clogged Min. pressure valve does not close perfectly Voltage too low Tube leaking Screw-motor flange leaking Remedy Check voltage, press Reset and then restart. Check motor absorption and relay setting. In case of regular absorption press Reset and restart. Check oil drain hose and check valve Check oil level and drain some, if necessary Replace oil separator filter Replace oil separator nipple seals Check regulator and solenoid valve Check service pressure switch setting Check regulator and solenoid valve Replace oil separator filter Improve ventilation Clean radiator with solvent Top up oil Check control relay and fan motor Clean or replace filter Remove intake filter and check for proper manual opening. Remove and clean, if necessary. Check for signal on solenoid valve. Replace damaged part, if any. Remove and clean regulator Check for signal availability between pressure switch and solenoid valve. Replace damaged part, if any. Replace oil separator filter Remove the valve, clean and replace seal, if necessary Check mains voltage Tighten fittings Replace damaged tubes Replace the seal ring. 15 Rotar Cube - Cod.197AA33 - Rev.1 1/28 15
GB WIRING DIAGRAM - ROTAR CUBE 5 23-4V / 5-6 Hz 23V 4V (*) = 4V AC3 TC1 Transformer 63VA Pr./23/4 Sec./23//24 TC2 Transformer Pr./23/4 Sec./6 SB Emergency button + 2NC 23V 1A FU1 / FU2 Fuses 6,3x32 GF 4A 5V FU3 / FU6 Fuses 6,3x32 GF 1A 5V FU7 Fuses 6,3x32 GF 5mA 5V KM1 Compressor motor contactor 23V/5-6Hz 11 kw(*) 5,5 kw(*) KM4 Radiator fan contactor 23V/5-6Hz 3 kw(*) 3 kw(*) FR1 Thermal relay / manual reset - 1L+1R (17-22) (9-12) FR2 Thermal relay / manual reset - 1L+1R (,22-,32) (,14-,2) YV Solenoid valve 22/23 VAC 5/6 Hz 15VA BP Pressure transducer.-16 bar 4-2 ma D Electronic controller Easytronic II 24V/AC ST Thermal feeler MV Motor for radiator electric fan 23/4V 5/6Hz 68/7W 68/7W Cable cross-section (sq.mm) 4G4 4G1,5 16 Rotar Cube - Cod.197AA33 - Rev.1 1/28
WIRING DIAGRAM - ROTAR CUBE 5-7-1 TA 23-4V / 5-6 Hz GB Cube 5 TA Cube 7 TA Cube 1 TA 23V 4V 23V 4V 23V 4V TC1 Transformer 63VA Pr./23/4 Sec./23//24 TC2 Transformer Pr./23/4 Sec./6 SB Emergency button + 2NC 23V 1A FU1 / FU2 Fuses 6,3x32 GF 4A 5V FU3 / FU6 Fuses6,3x32 GF 1A 5V FU7 Fuses 6,3x32 GF 5mA 5V KM1 Line contactor 23V/5-6Hz 5,5kW(*) 4kW(*) 7,5kW(*) 4kW(*) 11kW(*) 5,5kW(*) KM2 Delta contactor23v/5-6hz 5,5kW(*) 4kW(*) 7,5kW(*) 4kW(*) 11kW(*) 5,5kW(*) KM3 Star contactor 23V/5-6Hz 4kW(*) 4kW(*) 5,5kW(*) 4kW(*) 7,5kW(*) 4kW(*) KM4 Radiator fan contactor 23V/5-6Hz 3kW(*) 3kW(*) 3kW(*) 3kW(*) 3kW(*) 3kW(*) FR1 Thermal relay / manual rese t- 1L+1R (9-12) (5,5-8) (9-12,5) (7-1) (14-2) (3-12) FR2 Thermal relay / manual reset - 1L+1R (,22-,32) (,14-,2) (,22-,32) (,14-,2) (,28-,4) (,18-,25) YV Solenoid valve 22/23 VAC 5/6 Hz 15VA BP Pressure transducer.-16 bar 4-2 ma D Electronic controller Easytronic II 24V/AC ST Thermal feeler MV Motor for radiator electric fan 23/4V 5/6Hz 68/7W 68/7W 68/7W 68/7W 15/145W 15/145W Cable cross-section (sq.mm) 7G1,5 7G1,5 7G2,5 7G1,5 7x4 7G2,5 (*) = 4V AC3 17 Rotar Cube - Cod.197AA33 - Rev.1 1/28 17