Mattei BLADE 4, Instruction, Use And Maintenance Manual

Page 1: ...or Inc 9635 Liberty Road Suite E Randallstown MD 21133 Tel 410 521 7020 Fax 410 521 7024 email info matteicomp com INSTRUCTION USE AND MAINTENANCE MANUAL TI013G0008 INSTRUCTION USE AND MAINTENANCE MANUAL BLADE series AIR COMPRESSORS ...

Page 2: ...ENEA MATTEI S p A Ing ENEA MATTEI S p A reserves the right to modify the characteristics of the machine subject of this document without prior notice Copyright 04 2013 by Ing ENEA MATTEI S p A Printed 11 2013 This instruction manual meets all require ments of the 2006 42 EC Directive It is to be considered valid for both ma chines those with CE Marking and those without it Important Note This manu...

Page 3: ... connection Connection to the air distribution system Dimensions of compressed air pipings page 4 02 Safety devices Drive and control switches page 5 01 Use of compressor Foreword Operation modes page 6 01 MAESTRO XB controller Managing the compressor failures page 6 02 Maintenance Periodic checks page 7 01 Check of oil level Cleaning and or replacing the air suction filter Cleaning the oil air ra...

Page 4: ...r useful information Additional information This symbol introduces text blocks containing further information Such informations are not directly related to the description of a function or to the development of a procedure They may be cross references to other documents or other sections of this manual Risk of damage Indicating a high risk of damage for an item such as using a wrong tool or assemb...

Page 5: ...lity whatsoever This manual is for the machine user and service engineer and it aims at supplying them with typical system technical data with a technical description of the various operating groups composing the same as well as the essential use procedures and information needed to perform preventive and corrective maintenance The manual is intended for staff with a sound knowledge of mechanical ...

Page 6: ...chine operators a training course is foreseen enabling them to perform all needed actions to operate the machine even with some of the protections disconnected However this involves a certain com petence by the operator and extreme care by the factory manager so that the said operator performs only allowed operations Mechanical Service Engineer Aqualifiedengineerabletooperate the machine under nor...

Page 7: ... p A ALWAYS STATE THE MACHINE SERIAL NUMBER AS WELL AS THE PRINT NUM BER OF THIS MANUAL WHEN MAKING ANY REQUEST TO Mattei Compressors Inc OR ONE OF THEIR SERVICE CEN TRES Final inspection The manufacturer carries out the final inspection of the machine directly during the production phases in compliance with the company quality system Ing ENEA MATTEI S p A is responsible for the machine under its ...

Page 8: ...trical and fluid system integration of the machine into a production reality in compliance with specified requirements Commissioning Commissioning means the functional check of the machine installed Operation Operation means the operating mode at which the machine produces compressed air according to all settings and controls inserted by the control device Decommissioning Decommissioning means to ...

Page 9: ...ob Unskilled personnel should not access the operating area and the machine control panel when the system is ON Before starting the machine carry out following operations C a r e f u l l y r e a d t h e t e c h n i c a l documentation Get information about the operation and position of emergency stop devices on the machine Know which protections and safety devices are fitted on the machine their p...

Page 10: ... position and blocked with the safety lock to prevent any movement to the ON position Before acting people in charge of maintenance should first check following conditions General information that any receiver under pressure has been exhausted Before working on pipes receivers hoses and other components under pressure confirm that all internal pressure has been relived from the system Faulty compo...

Page 11: ...e department or refer to Mattei Compressors Inc Instructions on how to order spare parts In the course of time a machine may need the replacement of those parts subject to wear The Purchaser may order the parts to be replaced Always use genuine Mattei parts when performing maintenance or repairs General information To order spare parts always indicate following data with the utmost accuracy 1 Mach...

Page 12: ...machine is equipped with appropriate safety devices EMERGENCY push button to immediately stop the machine and STOP devices on the push button panel of the control device Fixed guards These are mounted in areas for exclusive access for standard maintenance They are fixed with systems that require specic tools to remove them or have been screwed in Protection and segregation of the electrical electr...

Page 13: ... perform most efficiently if installed in a suitable area that is well ventilated and far from sources of heat Should any duct be installed for the suction and cooling of air always use the data and recommendations given in Section 4 and preferably obtain expert advice during the design stage In the event of outdoors installation discouraged in very cold climates the machine must be placed under a...

Page 14: ... people s skin Protect your hands with gloves or with specific protective products for the skin Never wear clothing contaminated with lubricating oil Avoid contaminating the ground with lubricating oil To prevent pollution store the old lubricating oil in suitable containers and in a safe place To discard observe the recommendations set out by internal regulations and by current laws In case of oi...

Page 15: ...ge of the instructions given by the manufacturer To avoid possible danger situations some of them are highlighted through special signs represented by suitable standardized symbols pictograms Below is the list of the most common symbols applied to our machines Danger pictograms These triangular signs are framed in black with a yellow background and the symbol is black Warning The machine is fitted...

Page 16: ...Direction of rotation Lifting point Possibility to carry out jobs Combination of pictograms The above shown combination of pictograms means Warning Please refer to the Instruction Manual before starting any activity Warning Do not perform any maintenance operation on the compressor before having disconnected power supply and discharged all air pressure General information Safety ...

Page 17: ...s industrial service they guarantee constant performance over time low energy consumptions reliability functionality and easy maintenance The compressor is supplied complete with all components described below and equipped with optional devices Unless differently required the unit is filled with Mattei Rotoroil F2 synthetic lubricant For special requirements regarding lubricant please refer to sec...

Page 18: ...3 02 TI013G0008 Description of machine ...

Page 19: ... the vanes slide that are kept in contact with the stator by the centrifugal energy Sealing cooling and lubrication of all moving parts are guaranteed by an efficient oil injection system that operates due to the pressure difference between the compression chamber and the oil tank Hence no pumps are required for lubricating oil circulation An oil film on the inner stator surface prevents direct co...

Page 20: ...inding Class F Insulation IP 55 Protection Class Power supply according to IEC 38 standard Voltage Frequency Phase 208 230 460 575 60 Hz 3 Ph 230 60 Hz 1 Ph Cooling and Fan Systems The compressor comes with two aluminum radiators suitable for cooling oil and compressed air respectively The cooling air is drawn in by the cooling fan and comes into contact with the radiators and removes the heat gen...

Page 21: ...rrosion Inspections during its running might be required by the different national laws In the on tank version the machine comes complete with a condensate separator and a solenoid valve with timed and adjustable exhaust see condensate exhaust section tank version BLADE TM CONTROL DEVICE MANAGEMENT AND CONTROL OF A MICROPROCES SOR MAESTRO XB MAESTRO XB is a programmable control unit which adapts c...

Page 22: ...ts Check the settings on the integrated dryer if present The remote control by clean contacts of the machine status below Activated compressor optional Compressor blocked standard Communication MAESTRO XB ensures remote monitoring through MODBUS protocol WARNING The compressor has been designed to compress AIR ONLY The compression of other gases is FORBIDDEN OPTIONAL ACCESSORIES The machine can al...

Page 23: ...Description of machine Location of main components 1 Compressor 2 Main motor 3 Fan 4 Suction filter 5 Transmission 6 Oil Separator 7 Radiator 8 Electrical cabin 9 MAESTRTO XB controller 10 Receiver model BLADE TM only ...

Page 24: ...eiver Air Outlet Dimensions inch Weight 3 Phase Weight 1 Phase Model gallon npt L W H lbs net lbs net BLADE 4 Ͳ 3 4 37 28 4 31 1 451 454 BLADE 5 Ͳ 3 4 37 28 4 31 1 462 493 BLADE 7 Ͳ 3 4 37 28 4 31 1 473 Ͳ BLADE 4ͲTM 90 1 54 32 4 57 1 751 754 BLADE 5ͲTM 90 1 54 32 4 57 1 762 793 BLADE 7ͲTM 90 1 54 32 4 57 1 773 Ͳ ...

Page 25: ...both longitudinally and on the side It is recommended to protect the machine with adequate packaging to protect it from environmental factors To unpack the machine remove the guards and place it on the floor by means of a forklift truck to remove the pallet Position of compressor Section Technical Data gives overall dimensions total weight and values on the cooling of the machine The machine shoul...

Page 26: ... air contains a certain amount of water indicated as relative humidity on the compressor easier leave at least 1 m clearance from all other sides Electrical connection Only qualified personnel should make the electrical connections in compliance with current regulations WARNING For safe maintenance of all compressor components the customer should install a disconnect switch and circuit breakerof s...

Page 27: ...SE version It is to be noted that it should be collected and discarded in compliance with ruling laws Dimensions of compressed air distribu tion pipings We mention that the main causes of energy losses are pipings with unsuitable diameter and losses due to an improper setting up of the equipment or deteriorated materials The pipe diameter must be duly selected so as to minimize the pressure drop b...

Page 28: ...t offers greater resistance an au xiliary extractor should be used to prevent any overheating of the machine As an example a duct with a higher or equal section to the coming out of the ma chine the output grid on those versions equipped with a soundproof case made up of some 10 m of straight duct and two 90 elbows properly connected allows the maximum tolerated limits to be maintained However it ...

Page 29: ...ontroller MAESTRO XB is a programmable device to control the machine that can adapt its operation to the spe cific requirements of the network it is connected to It has several programming levels with special possibilities of control analysis of operation and of failures The advanced programming and analysis levels are protected by digital codes so as to prevent any unintentional tampering Maestro...

Page 30: ...umerical varia ble o in Modify mode or to move the selection Enter key It also has different functions to open the memory before a modification and to close it after modification to disable the single working days in Clock mode optional Reset Escape key To jump to next level during menu navigation It also has a Reset function in case of anomalies ...

Page 31: ...mpletely full of oil d to the compressed air system Operation Modes Blade compressors are designed to opera te according to continuous and automatic control logics The factory mode is AUTOMATIC To mo dify the preset mode see Page 16 of MAE STRO XB User Manual An overview of these two options is given below Continuous Cont In this mode the compressor delivers air within a clearly defined pressure r...

Page 32: ...nd not all of them can be accessed by the final customer Some of them are protected by one or more passwords The menus are divided according to the functions that they control The main menus used to manage the com pressor are Menu User access Monitor Menu Yes User Menu Yes Advanced Menu No Clock Menu Yes Log Menu Yes Network Menu Yes Info Menu Yes The various menus also use texts informing the use...

Page 33: ...mpressor is unloaded decompres sed for a preset time basic programming After the motor has stopped the residual pressure inside the compressor discharges completely in approximately one minute The following page shall be displayed The machine can be started ac cording to the previously descri bed sequence but it actually starts only provided that the line pressure is lower than the Pmin value set ...

Page 34: ...ess or lack of lu brication can jeopardize the smooth opera tion of the machine To lubricate only recommended lubricants should be used or lubricants with equiva lent characteristics of a known and tested quality The replacement of used oils should be done when the machine is warm The oil temperature should range between 25 and 30 C See Section 8 The draining and filling holes should not be left o...

Page 35: ...very twelve mpnths or every 2 000 hours Replace the oil filter element Replace the oil separator Replace the air filter Replace the pre filter Each three years or each 6000 opera ting hours replace the belts Oil change Rotoroil F2 every 12 months or 5 000 hours Rotoroil F4 every 12 months or 5 000 hours Rotoroil FG every 12 months or 4 000 hours Rotoroil M1 every 12 months or 2 000 hours At each o...

Page 36: ...radiator from the outside Then remove any possible dirt which may fall into the structure from the inspection panel Cleaning of the Pre filter Pict 3 The pre filter consists of a metal structure including a filtering mesh It is used to filter the air to entering the ca binet so as to prevent any foreign bodies from accessing the machine Important the pre filter has to be cleaned frequently To do t...

Page 37: ... of the machine Dismantle the filter element Pict 7 pos 1 by using chain tongs and replace it with a new unit Before locking the filter element lubricate the gasket Screw the new filter element on using a strap wrench Replacement of the Air Oil separator Fil ter Element Be sure that the machine is switched off Open the inspection panel Dismantle the filter element Pict 7 pos 2 by using chain tongs...

Page 38: ... the separator shows that no more pressure exists inside Fig 10 pos 1 Slowly unscrew the filling plug Pict 9 pos 2 while checking for any foam presence In case wait for some minutes until when the oil demulsifies Open the drain tap Pict 9 pos 1 and the plug located on the oil extraction unit Pict 10 pos 2 to facilitate oil drain Let oil flow in a suitable case Close the drain tap Fill the oil cham...

Page 39: ...ting its use any responsibility for the choice is up to the user and to the lubricant supplier WARNING It is difficult to determine life of an oil as there are different parameters effecting the same among which the operating temperature and quality of the intake air are very impor tant For this reason it is recommended to obtain precise guarantees from the sup plier validated by the analysis of s...

Page 40: ...to the oil choice and to execution of all maintenance operations and specifically carry out regular and complete oil chan ges ascertain that the coolling system is always efficient with often checks to the oil temperature verify that protecting devices installed are always in perfect working order keep the oil consumption under control take care of the machine cleaning Storage and treatment of oil...

Page 41: ...e valve does not operate properly Verify the operation Contact the nearest authorized service center The condensate drain sole noid valve is blocked in the open position if present Clean the specific filter to remo ve the cause of the block and then check operation Please refer to the Installation Use and Maintenance Ma nual Section 12 The minimum pressure valve does not function correctly Verify ...

Page 42: ...xcessive for the compressor operation Verify the cause and remove the problem See chapter 7 The compressor stops due to the over heating of the motor Excessive working pressure Verify the setting and re set to the design value for the machi ne See chapter 7 The main motor cooling is insufficient the cooling air is either too hot or too little Verify the environmental con ditions and the condition ...

Page 43: ... Noises Any abnormal vibrations or noises usually depend on worn bearings In such an event it is suggested to replace the bearings Electrical Checks If the machine has been stored for long pe riod or in the case of long stops in damp places it is recommended to measure the winding insulation value by applying 500 V c c voltage for 60 seconds Insulation should be of at least 10 MΩ Me gaOhms in warm...

Page 44: ...re Dismantling When the machine has reached the end of its technical and operating life it can be demolished i e decommissioned and put in such a condition so as not to be used any longer for the purposes it was designed and built with the possible recycling of raw materials NOTE Ing ENEA MATTEI S p A will not take any responsibility for damages to people or objects that may derive from the recycl...

Page 45: ...ate separator hou sing Unscrew the connection and remove the drain solenoid valve Withdraw the solenoid valve filter using beak pliers remove any dirt and wash with detergent Re assemble in the reverse order while paying special attention to the position of the solenoid valve seal Condensate Unload in Optional Kit ...

Page 46: ... on our machine Model Serial number Intervention to be carried out by Contact person Telephone Failure Description Electrical Mechanical Notes Place Date Stamp and Signature Mattei Compressor Inc 9635 Liberty Road Suite E Randallstown MD 21133 Tel 410 521 7020 Fax 410 521 7024 email info matteicomp com ...

Page 47: ...l 410 521 7020 Fax 410 521 7024 email info matteicomp com TI013G0008 Form to request spare parts Company Address Please note our order no dated with required delivery on for our machine Model Serial number Reference Description Quantity Notes Place Date Stamp and Signature ...

Page 48: ...aintenance Parts to be replaced during maintenance DESCRIPTION COMPONENTS QUANTITY Maintenance kit A BLADE 4 7 IF57A25252 Prefilter 1 Suction filter 1 Oil filter 1 Air Oil separator filter element 1 Intake valve spares kit 1 Maintenance kit B BLADE 4 7 IF57A25253 Combined assembly spares kit 1 Belt 2 ...

Page 49: ... AIR receiver volume TM only gallon Nominal absorbed current A 21 4 31 3 Ͳ 275 230Ͳ60Ͳ1 1800 109 115 95 10 90 Product Specifications LX version BLADE 4 BLADE 5 BLADE 7 Tension Ͳ Frequency Ͳ Phases VͲHzͲph Motor rated speed rpm 3600 Nominal working pressure psi Maximum working pressure psi Nominal delivery scfm 20 4 31 8 39 Terminals absorbed power kW 4 61 6 67 9 00 Noise level max dB A 61 62 64 Oi...

Page 50: ...torage AIR receiver volume TM only gallon Nominal absorbed current A 14 5 21 2 24 3 1800 230Ͳ60Ͳ3 109 115 95 275 10 90 Product Specifications LX version BLADE 4 BLADE 5 BLADE 7 Tension Ͳ Frequency Ͳ Phases VͲHzͲph Motor rated speed rpm 3600 Nominal working pressure psi Maximum working pressure psi Nominal delivery scfm 20 4 31 8 39 Terminals absorbed power kW 4 61 6 67 9 00 Noise level max dB A 61...

Page 51: ...0 mt AWG Storage AIR receiver volume TM only gallon Nominal absorbed current A 5 8 8 5 9 7 575Ͳ60Ͳ3 1800 109 115 90 95 275 14 Product Specifications HX version BLADE 4 BLADE 5 Ͳ Tension Ͳ Frequency Ͳ Phases VͲHzͲph Motor rated speed rpm Ͳ Nominal working pressure psi Maximum working pressure psi Nominal delivery scfm 17 52 29 Ͳ Terminals absorbed power kW 4 81 7 08 Ͳ Noise level max dB A 61 62 Ͳ O...

Page 52: ...orage AIR receiver volume TM only gallon Nominal absorbed current A 16 1 23 5 26 7 208Ͳ60Ͳ3 10 1800 143 150 95 275 90 Product Specifications HX version BLADE 4 BLADE 5 BLADE 7 Tension Ͳ Frequency Ͳ Phases VͲHzͲph Motor rated speed rpm 3600 Nominal working pressure psi Maximum working pressure psi Nominal delivery scfm 17 52 29 36 Terminals absorbed power kW 4 65 6 68 8 94 Noise level max dB A 61 6...

Page 53: ...Storage AIR receiver volume TM only gallon Nominal absorbed current A 7 3 10 6 12 1 143 275 460Ͳ60Ͳ3 1800 150 95 14 90 Product Specifications HX version BLADE 4 BLADE 5 BLADE 7 Tension Ͳ Frequency Ͳ Phases VͲHzͲph Motor rated speed rpm 3600 Nominal working pressure psi Maximum working pressure psi Nominal delivery scfm 17 5 29 36 Terminals absorbed power kW 4 65 6 68 8 94 Noise level max dB A 61 6...

Page 54: ... Storage AIR receiver volume TM only gallon Nominal absorbed current A 7 2 10 7 11 8 168 275 460Ͳ60Ͳ3 1800 175 95 14 90 Product Specifications HHX version BLADE 4 BLADE 5 BLADE 7 Tension Ͳ Frequency Ͳ Phases VͲHzͲph Motor rated speed rpm 3600 Nominal working pressure psi Maximum working pressure psi Nominal delivery scfm 14 8 25 33 Terminals absorbed power kW 4 60 6 75 8 78 Noise level max dB A 61...

Page 55: ... only gallon Nominal absorbed current A 21 3 31 7 Ͳ 168 275 230Ͳ60Ͳ1 1800 175 95 10 90 Product Specifications HHX version BLADE 4 BLADE 5 BLADE 7 Tension Ͳ Frequency Ͳ Phases VͲHzͲph Motor rated speed rpm 3600 Nominal working pressure psi Maximum working pressure psi Nominal delivery scfm 14 8 25 33 Terminals absorbed power kW 4 60 6 75 8 78 Noise level max dB A 61 62 64 Oil carry over ppm w w 1 2...

Page 56: ...ume TM only gallon Nominal absorbed current A 14 4 21 4 23 7 1800 230Ͳ60Ͳ3 90 168 175 95 275 10 Product Specifications HHX version BLADE 4 BLADE 5 BLADE 7 Tension Ͳ Frequency Ͳ Phases VͲHzͲph Motor rated speed rpm 3600 Nominal working pressure psi Maximum working pressure psi Nominal delivery scfm 14 8 25 33 Terminals absorbed power kW 4 60 6 75 8 78 Noise level max dB A 61 62 64 Oil carry over pp...

Page 57: ...ng pressure psi Nominal delivery scfm 14 8 25 33 Terminals absorbed power kW 4 60 6 75 8 78 Noise level max dB A 61 62 64 Oil carry over ppm w w 1 2 3 Total heat recovery Oil circuit capacity inch3 Minimum supply cables section 10 mt AWG Storage AIR receiver volume TM only gallon Nominal absorbed current A 5 8 8 6 9 5 175 575Ͳ60Ͳ3 14 1800 168 90 95 275 PRODUCT SPECIFICATIONS ...