pilotair DCR 1309, Instruction And Maintenance Manual

Page 1: ...INSTRUCTION AND MAINTENANCE MANUAL FOR SCREW COMPRESSORS Models DCR 1311 1315 DCR 1309 1315 VS Codice 900162 OQ7_5ARG078EN PilotAir 1300 667 579 Spares pilotair com au Sales pilotair com au...

Page 2: ...4 3 SUPPLY CONDITIONS VERSIONS 13 5 OVERALL DIMENSIONS MM 16 6 TECHNICAL DATA 17 7 INTENDED USE 18 7 1 ENERGY SUPPLY SOURCES 18 7 2 STAGES OF USE 18 7 3 LIMITS OF USE 18 7 4 OPTIONAL ACCESSORIES 19 8...

Page 3: ...IAGRAM 41 22 OPERATING PRINCIPLE 42 23 MAINTENANCE PROGRAMME 43 24 ROUTINE MAINTENANCE 44 24 1 PRECAUTIONS DURING MAINTENANCE 44 24 2 LIST OF SPARE PARTS FOR ROUTINE MAINTENANCE NEWTON EDISON DV 1300...

Page 4: ...DIAGRAM 54 28 NOTE ELECTRIC DIAGRAM 54 28 1 REMOTE CONTROL 54 28 2 ROTATION DIRECTION CONTROL 54 28 3 AUTOMATIC RESTART 54 28 4 MALFUNCTION OF THE PRESSURE TRANSDUCER 54 29 GENERAL WARNINGS 54 29 1 OR...

Page 5: ...Operating instructions translation from original IT Cod OQ7_5ARG078EN Emiss 18 07 08 Rev 5 Agg 20 04 16 8 2 EC DECLARATION OF CONFORMITY...

Page 6: ...by the European Directives listed in the EC declaration of conformity It is applied on the outside on the rear of the compressor The following data are indicated legibly and indelibly on the plate The...

Page 7: ...nd that of other people obtain the best compressor performance and ensure the maximum efficiency and long life of all its components This manual must be at the disposal of the authorised operators at...

Page 8: ...the country of use authorised to use fork lift trucks bridge cranes or cranes to transport and handle the compressor and or its parts safely provided with the personal protective equipment PPE contem...

Page 9: ...tenance work and or adjustment on the compressor 1 Main electric switch turned OFF and padlocked 2 Electric power supply switch Customer turned OFF 3 Pressurised air discharged from the compressor see...

Page 10: ...13 15 10 4 2 NAMING OF THE COMPONENTS FIG 2 and 3 show and name the main components of the compressors listed above 4 3 SUPPLY CONDITIONS VERSIONS According to the Customer s specific requests the co...

Page 11: ...ructions translation from original IT Cod OQ7_5ARG078EN Emiss 18 07 08 Rev 5 Agg 20 04 16 14 12 2 13 11 1 3 6 4 7 8 5 9 10 14 15 Pianta Lato dx Lato sx Lato anteriore Fig 2 Left side Right side Front...

Page 12: ...lay 7 Control panel 8 Electric isolating switch 9 Dryer cooling air expulsion 10 Compressor cooling air intake 11 Compressed air outlet G2 12 Compressor cooling air expulsion 13 Reservoir cap 14 Compr...

Page 13: ...18 07 08 Rev 5 Agg 20 04 16 16 5 OVERALL DIMENSIONS mm MOD NEWTON 1300 EDISON 1300 DV Rif Tank 270 lt Tank 500 lt 500 600 A 1581 5 1991 5 B 1532 1645 C 597 597 D 1385 1385 E 1010 1010 F 1070 1070 G 31...

Page 14: ...258 283 250 295 Compressor weight with dryer kg 292 318 343 310 355 Compressor weight with reservoir270 litres 500 litres kg 302 342 338 378 363 403 330 370 375 415 Compressor weight with dryer and r...

Page 15: ...ctric connection 3 Switching on 4 Production of compressed air 5 Switching off 6 Discharge of the residual air in the reservoir 7 Drainage of condensate from the reservoir 7 3 LIMITS OF USE The compre...

Page 16: ...RY NOTE AND SIGN IT STATING ACCEPTED WITH RESERVE 9 UNPACKING AND HANDLING The compressor should be lifted only with a pallet truck or a fork lift truck with suitable lifting capacity Check the integr...

Page 17: ...D HANDLING THE MACHINE The compressor must be transported and handled only as shown in the following figure with a pallet truck or a fork lift truck LIFT THE COMPRESSOR ONLY BY THE BASE DO NOT TRY TO...

Page 18: ...or complete with reservoir dryer and packaging Lifting the compressor or the dryer with the packaging Or the compressor complete with dryer with packaging Lifting the compressor complete with dryer wi...

Page 19: ...sions in the figure are in mm Key fig 6 1 Auxiliary reservoir condensate drain 2 Auxiliary reservoir customer 3 Compressor 4 Air expulsion 5 Main electric switch 6 Air intake 7 Electric power supply d...

Page 20: ...mity with the provisions in the table of Technical data IT IS OBLIGATORY TO ENSURE THE MINIMUM POSITIONING MEASUREMENTS GIVEN IN FIG 6 IT IS OBLIGATORY TO SECURE THE COMPRESSOR TO THE GROUND WITH THE...

Page 21: ...H A VALVE AND A REMOVABLE CONTAINER OR CONNECTED TO SPECIAL EQUIPMENT 10 7 DISTRIBUTION LINE A good distribution network must provide 1 slope of about 1 so that any condensate can be collected in the...

Page 22: ...VIOUS TABLES AND COMPLY WITH THE REQUIREMENTS CONTEMPLATED BY THE REGULATIONS IN FORCE IN THE COUNTRY OF USE THE ELECTRICAL CONNECTION OF THE COMPRESSOR TO THE ELECTRIC POWER LINE MUST BE CARRIED OUT...

Page 23: ...hine can be started COMPRESSOR ACTIVATED BY AN INVERTER Compressors with an inverter are equipped with an electronic system to control the absorbed power and the motor temperature in any case it is im...

Page 24: ...EMPLOYEES CANNOT ACCESS THE PLACE OF INSTALLATION OF THE COMPRESSOR FOR ANY REASON UNTIL IT HAS BEEN TESTED IT IS FORBIDDEN TO SWITCH ON THE COMPRESSOR UNTIL THE INSPECTION CERTIFICATE HAS BEEN SIGNED...

Page 25: ...pproximation of the laws of the Member States relating to Electromagnetic Compatibility and repealing Directive 89 336 EC 2009 105 CE Pressure Equipment Directive 2009 105 EC Of the European Parliamen...

Page 26: ...Operating instructions translation from original IT Cod OQ7_5ARG078EN Emiss 18 07 08 Rev 5 Agg 20 04 16 29 Fig 8...

Page 27: ...During compressor operation the noise may reach dangerous levels for your hearing RISK OF PRESSURISED RESERVOIR The reservoir reaches dangerous pressure levels RISK OF CONTACT WITH THE COOLING FAN Whe...

Page 28: ...decides of his own accord to perform an action that is incorrect forbidden and not reasonably foreseeable EXTENT OF DAMAGE Slight injuries normally reversible STEPS TAKEN Respect of the correct proce...

Page 29: ...l panel to perform 1 Switching the control panel on off with the main electric switch 2 Setting the work parameters and viewing the machine status on the display 3 Switching the compressor on off with...

Page 30: ...e L8 Led white AUTO RESTART Automatic restart enabled P3 Blue PROG button Programming Pressing it once allows you to enter the programming parameters menu Pressing it again allows you to scroll throug...

Page 31: ...he hours worked At the 2nd click it shows the auxiliary temperature P1 Green Start button I symbol Allows the Rotary test Allows starting of the compressor If during programming decreases the values L...

Page 32: ...STARTING THE COMPRESSOR When the Start button is pressed the machine STOP status changes to WAIT FOR START this is followed by the operation of the compressor showing WAIT FOR LOAD LOAD Status indicat...

Page 33: ...RESSURE VALUE SELECT SET PRESSURE 5 LOAD PRESS GAP 1 5 bar 0 2 3 bar 1 bar SELECT THE PRESSURE RANGE IN WHICH THE MACHINE WORKS 6 HISTORY ALARM ALARM HISTORY STORES THE LAST 16 ALARMS 7 CONDENSATE DRA...

Page 34: ...NTC interrupted or disconnected 4 1 Active emergency The mushroom switch has been activated Release the emergency switch by turning it 5 Motor thermal prot The thermal relay of the main motor has trip...

Page 35: ...ressure switch and pressure sensor 1 If present 2 If the phase control is present Check wiring diagram N B Once you have removed the cause of the fault you must press the RESET key 17 6 FUNCTION OF TH...

Page 36: ...e electric panel on the terminals C common NO normally open and NC normally closed see fig A ref 1 The activation of this relay may influence running status alarm status or motor rotation These 3 func...

Page 37: ...HE AIR PIPES ARE CONNECTED TO THE SYSTEM CUSTOMER AND THAT THE AIR OUTLET VALVE IS OPEN 5 ENSURE THAT ROUTINE MAINTENANCE WAS REGULARLY CARRIED OUT THE LAST TIME THE COMPRESSOR WAS SWITCHED OFF SEE CH...

Page 38: ...filter 2 Suction valve 3 Screw 4 Air oil separator 5 Calibrated nozzle 6 Minimum valve 7 Air Air exchanger 8 Condensate separator if present 9 Thermostatic valve 10 Air oil radiator 11 Oil filter 12 T...

Page 39: ...pipe duct making the oil arrive at the compressor through the radiator 10 passing through the filter 11 The oil arrives at the compressor and mixes with the air taken in creating an air oil mixture w...

Page 40: ...oil if using mineral oil 1st oil replacement if using special oil RotEnergyPlus Change the oil filter cartridge Change or clean the panel for pre filtering the cooling air Check correct operation of t...

Page 41: ...parts or cloths are left lying on the compressor on the motor or on the moving parts 9 Before leaving the unit to be started up after maintenance or overhauling check that the pressures the temperatu...

Page 42: ...ssors Power System lubricants are available through your authorized compressor distributor THE IMPROPER USE OF LUBRICANT MAY CAUSE DAMAGE TO THE SYSTEM IT IS ABSOLUTELY FORBIDDEN TO MIX LUBRICANTS OF...

Page 43: ...UT DOWN THE COMPRESSOR AND RELIEVE THE SYSTEM OF ALL PRESSURE BEFORE REMOVING VALVES CAPS PLUGS FITTINGS BOLTS AND FILTERS 4 Always completely empty the circuit It is best to do this operation when th...

Page 44: ...t time 5 minutes 3 Switch off the compressor and check the oil level The oil level must be between the 2 reference marks If the oil level is still below the reference mark B top up with another 0 5 li...

Page 45: ...g 13 turning the hex ring with the special spanner Clean the oil recovery nozzle blowing compressed air through the 4 holes in the oil separating nipple Fig 13 ref A Reassemble the oil separating filt...

Page 46: ...rcuit Unscrew and remove the non return valve connected to the oil recovery flexible pipe Fig 14b turning the hexagon with the special spanner Clean the calibrated nozzle by blowing with compressed ai...

Page 47: ...ure it stays firmly in place 6 Position the new cartridge inside the tank and firmly fit the O ring in place on the top plate 7 Fit the top plate on the separator housing flange install and tighten al...

Page 48: ...ter in conformity with the local regulations in force 25 9 AIR OIL RADIATOR The compressor is provided with a combined radiator for oil and for compressed air fitted in a vertical position It is coole...

Page 49: ...ooth of the semi coupling and the flange of the opposite semi coupling Block the semi coupling retaining screws grub screws 11 Replace the guard on the bell housing DURING ROTATION THE MACHINES CAN CA...

Page 50: ...hermetically sealed 5 Screw compressor 1 Check the appliances connected to the compressed air network 2 Remove and check the filter 3 Check intake valve assembly 4 Remove and check it Change it if nec...

Page 51: ...BE REQUESTED EXCLUSIVELY FROM THE MANUFACTURER COMMUNICATING THE SERIAL NUMBER AND THE YEAR OF MANUFACTURE OF THE COMPRESSOR SEE 2 1 THE ORIGINAL FILTERS MUST BE REQUESTED EXCLUSIVELY FROM THE MANUFAC...

Page 52: ...liary circuit 10 Volt instrument 8 Check correct direction of rotation OK NO OK a check load current Amp verify with test certificate b check overloads protection adjustment motor fan 9 Check right op...

Page 53: ...rtridge Separator Cartridge Oil filling Couplings Belts Check electrical absorption Date Signature C l e a n i n g R e p l a c e m e n t R e p l a c e m e n t Check Press Diff R e p l a c e m e n t C...

Page 54: ...Operating instructions translation from original IT Cod OQ7_5ARG078EN Emiss 18 07 08 Rev 5 Agg 20 04 16 57 32 NOTES...

Page 55: ...Operating instructions translation from original IT Cod OQ7_5ARG078EN Emiss 18 07 08 Rev 5 Agg 20 04 16 58...

Page 56: ...Operating instructions translation from original IT Cod OQ7_5ARG078EN Emiss 18 07 08 Rev 5 Agg 20 04 16 59...

Page 57: ...Series Units c Petrol Industrial Series Units d Three Phase Industrial Series Units will be free from defects due to defective factory workmanship or materials for a period of 3 years from the date o...

Page 58: ...oducts Pilot Air will not be liable for any losses or damages whether direct or indirect including property damage or personal injury consequential loss economic loss or loss of profits arising in con...

Page 59: ...operating faults under any warranty specified herein is to be made only after Pilot Air or its authorised representative have examined the unit to their satisfaction with their decision being final l...

Page 60: ...mer may have under any warranty specified herein are in addition to other rights and remedies of a consumer under a law in relation to the goods to which these warranties relate Nothing in this docume...