ABAC GENESIS Series, Use And Maintenance Handbook

Page 1: ...GENESIS FORMULA MODULO 5 5 15 kW USE AND MAINTENANCE HANDBOOK GB...

Page 2: ......

Page 3: ...227 D1 273 D2 I FORMULA 1045 615 1030 273 480 545 465 390 1045 227 D1 273 D2 560 395 204 430 945 180 262 Fig 1 Fig 2 D1 5 5 7 5 kW D2 11 15 kW...

Page 4: ...227 D1 273 D2 227 D1 273 D2 II GENESIS 275 l 945 945 560 395 480 1180 1645 530 600 390 465 615 1030 480 273 204 262 Fig 3 Fig 4 D1 5 5 7 5 kW D2 11 15 kW 1015 800...

Page 5: ...530 600 1960 1260 945 390 465 395 227 D1 273 D2 227 D1 273 D2 III GENESIS 500 l 480 273 945 615 1030 1645 204 262 800 Fig 5 Fig 6 D1 5 5 7 5 kW D2 11 15 kW 1015...

Page 6: ...227 D1 273 D2 227 D1 273 D2 IV MODULO 1030 480 273 1045 615 945 395 390 1045 560 465 545 180 204 430 262 Fig 7 Fig 8 D1 5 5 7 5 kW D2 11 15 kW...

Page 7: ...227 D1 273 D2 227 D1 273 D2 V MODULO 270 l 1030 480 273 615 945 560 390 465 1645 1180 480 395 800 530 600 204 945 262 Fig 9 Fig 10 D1 5 5 7 5 kW D2 11 15 kW 1015...

Page 8: ...227 D1 273 D2 VI MODULO 500 l 1960 1260 560 945 395 390 465 530 600 800 1645 615 1030 273 480 204 945 262 Fig 11 Fig 12 D1 5 5 7 5 kW D2 11 15 kW 227 D1 273 D2 1015...

Page 9: ...VII FORMULA 5 5 7 5 kW Fig 13 Fig 14 SPA PE PC VA EV PS BF PF CT VT TRL ES FU RA RO PP SS VS FD FO FA MP...

Page 10: ...VIII FORMULA 11 15 kW BA 51 Fig 15 Fig 16 FO FA FD VS SS ES FU MA RA RO MP PC PE SPA VA EV PS BF VR TRL CT PF PP...

Page 11: ...IX FORMULA 15 kW BA 69 Fig 17 Fig 18 PC PE SPA CF FA PF CT TRL VR BF PS ES EV FU MA RA RO MP PP VA FO FO VS SS...

Page 12: ...X MODULO 5 5 7 5 kW Fig 19 Fig 20 FO FD FA SS ES FU MA RA RO PP MP PC PE SCE SF VA EV BF VT TRL CT PF VS PS...

Page 13: ...XI MODULO 11 15 kW BA 51 Fig 21 Fig 22 PC PE SCE SF PF CT TRL SS VR PS EV VA FA FO FD VS SS MP PP RA RO MA FU ES BF...

Page 14: ...XII MODULO 15 kW BA 69 Fig 23 Fig 24 PS PP PF MA FU RA RO ES VA FO FD VS SS MP CF FA SCE PE PC TRL VR BF CT EV...

Page 15: ...ria calda Heated air outlet Ori ce de sortie de l air chaud Auslass f r heisse Luft Rendija de salida del aire caliente GP Gruppo pompante a vite brevettato Patented Air end Groupe de pompe vis brevet...

Page 16: ...roll Box seite Puerta del quadro el ctrico SF Sportello ltri Filter panel Panneau des ltres Filterklappe Puerta de los ltros SPA Sportello angolare Corner panel Panneau angulaire Eckklappe Puerta angu...

Page 17: ...r symbols 2 2 22 Control panel mc2 symbols 2 3 3 Warranty terms 23 Performance and speci cations 24 4 24 General data 4 1 24 Compressor rating data 4 2 25 Air receiver 4 3 25 Compressor 4 4 25 Electri...

Page 18: ...nstallation 30 6 30 Handling instructions 6 1 30 Installation site requirements 6 2 94 Air connection 6 3 33 Electrical connection 6 4 33 Con guration for remote control 6 5 Start up and operation 35...

Page 19: ...RAL SETTINGS menu 7 4 2 3 51 NETWORK SETTINGS menu 7 4 2 4 52 OPERAT PARAMETERS menu 7 4 2 5 54 PROGRAMMING menu 7 4 2 6 56 DIAGNOSTICS menu 7 4 2 7 58 INFORMATIONS menu 7 4 2 8 58 Operating warning a...

Page 20: ...s on 65 9 6 66 Oil in the network 9 7 66 Oil in the machine 9 8 67 Safety valve VS intervention 9 9 Maintenance 68 10 68 Operating cycle 10 1 69 General maintenance operation table 10 2 71 Replacement...

Page 21: ...ines with air dryer 12 3 84 Power circuit wiring diagram 11 kW Machines with inverter 12 4 85 Auxiliary circuit wiring diagram 5 5 15 kW Machines without air dryer 12 5 86 Auxiliary circuit wiring dia...

Page 22: ...ing 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 sho...

Page 23: ...ste oil condensate and lters removed from the machine are polluting materials and must be disposed of in compliance with local laws 2 2 Compressor symbols This symbol means that you must not put your...

Page 24: ...indicates the K7 PLUS key This symbol indicates the K8 MINUS key This symbol indicates the K9 ENTER con rmation key This symbol indicates the voltage present LED L1 yellow This symbol indicates switc...

Page 25: ...luded 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 constr...

Page 26: ...nesis 500 l 68 10 1 04 13 0 80 15 0 64 11 8 11 BA51 1 65 7 275 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 10 1 40 13 1 17 1...

Page 27: ...ulation 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 in...

Page 28: ...5 5 8 2 5 16 16 10 13 15 7 5 8 4 20 20 10 13 15 11 8 6 25 25 10 13 15 15 8 10 40 40 10 13 15 15 8 10 40 40 10 13 15 400 V Model Pressure Power cable cross section area Main fuses AM motor rated or gr...

Page 29: ...bricated and cooling uids with other speci cations 4 8 Dryer Thermostat controlled cooling cycle direct expansion with Freon R134a gas pressure dew point temperature 3 C clean air ltering degree 0 01m...

Page 30: ...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 individua...

Page 31: ...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 det...

Page 32: ...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...

Page 33: ...s located outdoors Comply with the minimum distance from the walls 0 6 mm Fig 29 min 3000 max 5000 600 Indoor installation The machine is not suitable for use in environments with a risk of explosion...

Page 34: ...mum distances from the walls shown in gure 31 The position of the compressor in the room should allow easy inspections If the compres sor is installed in the working environment keep at suitable safet...

Page 35: ...eck the ef ciency of the earthing system The power cable must be secured in the speci c glands and the electrical panel must be tightly closed to achieve the prescribed IP44 protection rating Connect...

Page 36: ...AD remote control see paragraph 7 4 2 3 Remote control type Two switches must be used for this con guration The switches must be connected to the terminals after removing the jumper ON OFF SWITCH 3 di...

Page 37: ...riation 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 si...

Page 38: ...tor setting LEDs back lit LCD display K4 K5 K3 K6 K1 K2 K7 K8 K9 L1 L2 L3 L4 L5 Control and programming keyboard K1 START button starting the compressor Used to start the machine If remote control or...

Page 39: ...l Starting from the main screen page makes it possible to access the menu tree Used to con rm the value or selection made during modi cation of a parameter If OFF back lighting of the display is re ac...

Page 40: ...owing screen page must be shown on display DI This screen page indicates LINE 1 name of the compresso LINE 2 LINE 3 software version which may differ from that indicated LINE 4 serial number of contro...

Page 41: ...led 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 5 Stand by progr com hour date If the compressor does n...

Page 42: ...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...

Page 43: ...X X bar 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 brightn...

Page 44: ...aragraph 7 4 2 3 Indicates setting of the type of control LOCAL REMOTE PROGRAM ref paragraph 7 4 2 3 If enabled indicates the status of the AUTORESTART function automatic restart following blackout re...

Page 45: ...carry out all compressor control and programming operations ESC MAIN SCREEN PAGE ESC Menu B Pressure XX X bar Temperature XXX C Ready for start hour date ref paragraph 7 4 2 2 ref paragraph 7 4 2 3 M...

Page 46: ...inserted using Menu C PASSWORD Enter password Enter password 0000 ESC ESC keys K7 and K8 to modify the ashing character numbers and letters are displayed subsequently the K5 and K6 keys to move to mo...

Page 47: ...onents ESC Compon replacement Replacement made for air lter OK ESC Replacement made for oil lter OK ESC Replacement made for other components ESC ESC Con rm replacement air lter OK Con rm replacement...

Page 48: ...running hours running hours at full load A table with the schedule of the maintenance operations to be carried out is provided below Intervention First 100 hours maintenance coupon First 1000 hours ma...

Page 49: ...uage OTHER LANGUAGES ESC Measur unit Pressure unit Unit bar ESC Temperature unit Unit Cels ESC Date and time Set date and time hh mm day dd mm yyyy ESC Press the K4 key to return to the GENERAL SETTIN...

Page 50: ...l REMOTE ESC Press the K4 key to return to the GENERAL SETTINGS menu from the submenus Compress control PROGRAM ESC Compress control NETWORK CONINUOUS ESC Compress control NETWORK PROGRAM ESC only if...

Page 51: ...se can be con rmed with the K9 ENTER key or cancelled with the K4 ESC key ESC Display settings Makes it possible to adjust the settings of the LCD display Operating mode ESC Menu E 3 3 AUTORESTART fun...

Page 52: ...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...

Page 53: ...AD 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 automati...

Page 54: ...ted 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...

Page 55: ...osses 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 Timings UNLOAD RUN TIME This setting de...

Page 56: ...he schedule of compressor activities de ning 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 d...

Page 57: ...ramming mode Programming mode DAILY ESC Programming mode WEEKLY ESC Press the K4 key to return to the PROGRAMMING menu from the submenus ESC Daily programming Every day Start 1 ESC Every day Stop 1 ES...

Page 58: ...3 Program the daily or weekly schedule selected 4 Press the K1 START key on the control unit to enable program control 7 4 2 7 DIAGNOSTICS menu From the diagnostics menu it is possible to check funct...

Page 59: ...K ESC other INPUTS DIAGNOSTIC TEST TEST digit INPUTS INPUT n 1 status Emergency OK Press the K4 key to return to the PROGRAMMING menu from the submenus ESC Press if OK Press ESC if NEGAT ERROR MESSAGE...

Page 60: ...tics 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 divi...

Page 61: ...ately 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 star...

Page 62: ...f 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 C...

Page 63: ...ressors 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 o...

Page 64: ...ible cause Intervento X X L1 OFF DI OFF No power Restore power FU2 FU8 blown Replace damaged fuses X X L1 ON DI OFF Problems in the electronic control unit Call Customer Service Centre Problems in con...

Page 65: ...rting up V F V V Indication Possible cause Intervention X X Ambient temperature low Heat ambient Low voltage Check voltage VA problems Call Customer Service Centre Star delta sequence problems Call Cu...

Page 66: ...X X L2 ashing DI indicates Replace oil XXX excess hours Oil to be replaced for scheduled maintenance Replace oil see par 10 5 X X L2 ashing DI indicates Replace oil separator XXX excess hours FD to be...

Page 67: ...r solenoid valve problems Call Customer Service Centre Net pressure too high caused by other compressors Check working pressure of all compressors X X L3 constant ON DI indicates Compress motor overlo...

Page 68: ...ce oil excess hours block Oil to be replaced for scheduled maintenance Replace oil see par 10 5 X X L3 constant ON DI indicates Replace oil separator excess hours block FD to be replaced for scheduled...

Page 69: ...on Possible cause Intervention X X FA leaks Call Customer Service Centre 9 9 Safety valve VS intervention V F V V Indication Possible cause Intervention X X Pressure detector problems Call Customer Se...

Page 70: ...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...

Page 71: ...he case of very low air consumption once the maximum operating pressure has been reached the com pressor switches to idling as described for the xed speed compressor In this case the duration of the i...

Page 72: ...rical 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 adjus...

Page 73: ...To reset the scheduled maintenance counter for enabled users only see paragraph 7 4 2 2 Cleaning or replacing the air lter 10 4 Before performing any maintenance operations read the operator safety pr...

Page 74: ...nt part of the lter con tainer 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 fil...

Page 75: ...e 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...

Page 76: ...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 Re ll with oil as descr...

Page 77: ...e speci c 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 Op...

Page 78: ...the air receiver proceed as follows Place a suitable drip tray under the condensate discharge valve RSC which is located under the SA receiver Ensure that the intercept valve between the compressor an...

Page 79: ...e air receiver and separator condensate should be drained manually on a weekly basis or more frequently The user is responsible for this maintenance operation Replacing the fuses 10 8 Before performin...

Page 80: ...ble 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 Air lter Oil lter Separator lter Suction...

Page 81: ...9075290 13 9056934 2 9075236 15 2 9075290 7 5 8 9056937 9056933 9056942 9623572 2 9075256 10 2 9075236 13 9056934 2 9075290 15 2 9075257 11 8 9056937 9056935 9056943 9623572 2 9075291 10 2 9075215 13...

Page 82: ...P 80 Chap 12 Diagrams G B 12 Diagrams Hydraulic pneumatic plant diagram 12 1...

Page 83: ...valve 8 Oil lter 9 Air oil exchanger 10 Oil recovery 11 Separator lter 12 Minimum pressure and check valve 13 Air air exchanger 14 Net pressure transducer 15 Drying unit only in equipped versions 15 1...

Page 84: ...P 82 Chap 12 Diagrams G B Power circuit wiring diagram 5 5 15 kW Machines without air dryer 12 2...

Page 85: ...P 83 Chap 12 Diagrams G B Power circuit wiring diagram 5 5 15 kW Machines with air dryer 12 3...

Page 86: ...P 84 Chap 12 Diagrams G B Power circuit wiring diagram 11 kW Machines with inverter 12 4...

Page 87: ...P 85 Chap 12 Diagrams G B Auxiliary circuit wiring diagram 5 5 15 kW Machines without air dryer 12 5...

Page 88: ...P 86 Chap 12 Diagrams G B Auxiliary circuit wiring diagram 5 5 15 kW Machines with air dryer 12 6...

Page 89: ...P 87 Chap 12 Diagrams G B Auxiliary circuit wiring diagram 11 kW Machines with inverter 12 7...

Page 90: ...P 88 Chap 12 Diagrams G B Wiring diagram for component location 5 5 15 kW Machines without air dryer 12 8...

Page 91: ...P 89 Chap 12 Diagrams G B Wiring diagram for component location 5 5 15 kW Machines with air dryer 12 9...