Abac User Manual Genisis 5-5-15 KW

GENESIS - FORMULA - MODULO
5.5 - 15 kW
USE AND MAINTENANCE HANDBOOK
GB
FORMULA
Fig. 1
1030
615
204
480
1045
262
273
D1 = 5.5-7.5 kW
D2 = 11-15 kW
227 D1
273 D2
560
945
390
227 D1
273 D2
395
1045
465
430
180
545
Fig. 2
I
GENESIS 275 l
1030 Fig. 3
615 204
480
945
262
273
D1 = 5.5-7.5 kW
D2 = 11-15 kW
227 D1
273 D2
560
945
390
227 D1
273 D2
395
465
1645
800
1015
480 530
Ø 600
1180
Fig. 4
II
GENESIS 500 l
1030
615
204 Fig. 5
480
945
262
273
D1 = 5.5-7.5 kW
227 D1 D2 = 11-15 kW
273 D2
945
390
227 D1
273 D2
395
465
800 1645
1015
1260 530
Ø 600
1960
Fig. 6
III
MODULO
Fig. 7
1030
615 204
480
1045
262
273
D1 = 5.5-7.5 kW
D2 = 11-15 kW
227 D1
273 D2
560
945
390
227 D1
273 D2
395 1045
465
430
180
545
Fig. 8
IV
MODULO 270 l
1030
615
204 Fig. 9
480
945
262
273
D1 = 5.5-7.5 kW
D2 = 11-15 kW
227 D1
273 D2
560
945
390
227 D1
273 D2
395
465
1645
800
1015
480 530
Ø 600
1180
Fig. 10
V
MODULO 500 l
1030
615 204 Fig. 11
480
945
262
273
D1 = 5.5-7.5 kW
D2 = 11-15 kW
227 D1
273 D2
560
945
390
227 D1
273 D2
395
465
1015 1645
800
1260 530
Ø 600
1960
Fig. 12
VI
FORMULA 5.5 - 7.5 kW
PS EV VA
PC
PE
SPA
Fig. 13
BF
VT TRL CT PF FA FO
FD
ES
FU
VS
RA / RO
PP
SS
Fig. 14
MP
VII
FORMULA 11 - 15 kW
BA 51
PS EV VA
PC
PE
BF
SPA
Fig. 15
VR
TRL CT PF
FA FO
FD
ES
FU
VS
MA
RA / RO
SS
MP
Fig. 16
PP
VIII
FORMULA 15 kW
BA 69
PS EV
PC
PE
SPA
BF
VR
CF / FA
Fig. 17
TRL
CT PF
VA FO
FO
ES
VS
FU
MA
RA / RO
SS
MP
Fig. 18
PP
IX
MODULO 5.5 - 7.5 kW
PS EV VA
PC
PE
SCE
BF
SF
VT
Fig. 19
TRL
CT PF
FA FO
ES
FD
FU
VS
MA
RA / RO
SS
PP
Fig. 20
MP
X
MODULO 11 - 15 kW
PS EV VA BA 51
PC
PE
SCE
BF
VR
SF
SS
Fig. 21
TRL
CT PF FA FO
FD
ES
FU VS
MA
RA / RO
PP
SS
Fig. 22
MP
XI
MODULO 15 kW
PS EV BA 69
PC
PE
SCE
BF
VR
CF / FA
Fig. 23
TRL
CT PF
VA FO
ES
FD
FU VS
MA
RA / RO
PP
SS
MP
Fig. 24
XII
Legenda
Rif. Italiano English Français Deutsch Español
Blocchetto di Oil filter and Groupe de Halter für Öl und Bloque de
BF filtrazione separator block filtration Abscheiderfilter filtración del aceite
CE Cassetta elettrica Starter/control box Armoire électrique Starter/Kontroll Box Cuadro eléctrico
Contenedor del filtro

CF Contenitore filtro aria Air filter container Boîtier du filtre à air Luftfilterbehälter
de aire
Cinghie di Transmission Courroies de Correas de

CT trasmissione belts transmission
Antriebsriemen
transmisión
DI Display Display Ecran-afficheur Display Visor
Scarico olio/ Orifice de vidange de

DO Drenaggio olio
Oil drain valve
l’huile
Öl Auslass Drenaje del aceite
ES Essiccatore Dryer Sécheur Trockner Secador
EV Elettroventilatore Electric fan Ventilateur électrique Elektrolüfter Electroventilador
FA Filtro aria Air filter Filtre à air Luftfilter Filtro de aire
FD Filtro disoleatore Oil separator filter Filtre séparateur Feinabscheider Filtro disoleador
FFA Fascetta filtro aria Air filter clip Collier du filtre à huile Luftfilter Clip Abrazadera filtro de aire
FO Filtro olio Oil filter Filtre à huile Öl-Filter Filtro aceite
Feritoia uscita Orifice de sortie Rendija de salida del aire

FU aria calda
Heated air outlet
de l’air chaud
Auslass für heisse Luft
caliente
Gruppo pompante a vite Groupe de pompe à vis Grupo de bombeo de

GP brevettato
Patented Air end
breveté
Patentierter Verdichter
tornillo patentado
Pulsanti del pannello di Boutons sur panneau de Schalter der Pulsadores del tablero
K1/K9 controllo
Control panel switches
commande Kontroll-Anzeige de control
Led del pannello di LED sur panneau de

L1/L5 controllo
Control panel led
commande
Led Led del tablero de control
MA Mandata aria Compressor air outlet Refoulement d’air Druckluft Auslass Salida aire
MP Motore principale Electric motor Moteur principal Elektromotor Motor principal
PA Prefiltro aspirazione Suction prefilter Pré-filtre d’aspiration Ansaugvorfilter Prefiltro apiración
PC Pannello di controllo Control panel Panneau de commande Kontroll-Anlage Tablero de control
Pulsante di arresto di Pulsador de

PE emergenza
Emergency stop button Bouton d’arrêt d’urgence Not-Ausschalter
emergencia
PF Pannello frontale Front panel Panneau avant Frontseite Panel frontal
PP Pannello posteriore Rear panel Panneau arrière Hintere Abdeckung Panel trasero
Pannello prefiltro Panneau du prréfiltre Abdeckung der Panel del prefiltro de

PPA aspirazione
Suction prefilter panel
d’aspiration Ansaugvorfilters aspiración
XIII
Legenda
Rif. Italiano English Français Deutsch Español
PS Pannello superiore Top panel Panneau supérieur Oberseite Panel superior
R Raccordo Fitting Raccord Anschluß rACOR
Radiatore aria After cooler Radiateur à sir Luftkühler Radiador de aire

RA/RO Radiatore olio Oil cooler Radiateur à huile Öl-Kühler Radiador de aceite
RF Rotore femmina Female rotor Rotor femelle weiblich Läufer Rotor hembra
Riferimento Repère de niveau Referencia de nivel máx.

RLMAX di livello max. olio
Max. oil level reference
maximum huile
Bezug Max.Ölstand
de aceite
Riferimento Repère de niveau Referencia de nivel min.

RLMIN di livello min. olio
Min. oil level reference
minimum huile
Bezug MindestÖlstand
de aceite
RM Rotore maschio Male rotor Rotor mâle männlich Läufer Rotor macho
Robinet de vidange de Grifo de descarga de

Rubinetto scarico Air receiver condensate Kondenswasser
RSC condensa discharge valve
l’eau de condensation du
Ablasshahn des Luftanks
la condensación del
réservoir à air depósito de aire
Robinet d’évacuation Grifo de descarga de

RSO Rubinetto scarico olio Oil drain valve
de l’huile
Ölablaßhahn
aceite
SA Serbatoio aria Air receiver Réservoir á air Lufttank Depósito de aire
Sportello cassetta Panneau Starter/Kontroll Box Puerta del

SCE elettrica
Electric box panel
armoire électrique seite quadro eléctrico
SF Sportello filtri Filter panel Panneau des filtres Filterklappe Puerta de los filtros
SPA Sportello angolare Corner panel Panneau angulaire Eckklappe Puerta angular
Serbatoio Réservoir Depósito

Air-oil separator
SS separatore
receiver
séparateur du Luft/Öl-Abscheider separador mezcla
miscela aria/olio mélange air/huile aire - aceite
Sensore di temperatura Capteur de température Sensor temperatura
STO olio
Oil temperature sensor
de l’huile
Öl-Temperaturfühler
aceite
Plaquette
Serial number Seriennumer und Placa metálica con
Targhetta metallica métallique
TM dati macchina
and general
d’identification
allgemeine los datos de la
machine data plate Maschinen Daten máquina
machine
Bouchon de Öl-Filter
TO Tappo olio Oil filler plug
remplissage huile Verschluss
Tapón del aceite
Tubetto di riferimento Tube de référence Bezugsleitung Tubo de referencia nivel

TRL livello olio
Oil level reference pipe
niveau huile Ölstand de aceite
Valvola di Soupape Válvula de

VA aspirazione
Intake valve
d’admission
Ansaugventil
aspiración
Valvola di ritegno Minimum Clapet de Válvula de
Mindestdruck-
VR e di minima pressure and retenue et de
Kontrollventil
retención y de
pressione check valve pression minimum presión mínima
Valvola Soupape Válvula
VS di sicurezza
Safety valve
de surpression
Sicherheitsventil
de seguridad
Valvola Soupape Válvula

VT termostatica
Thermostatic valve
thermostatique
Thermostatventil
termostática
XIV
Table of contents
1 Foreword 20
2 Symbols 21
2.1 Symbols in the manual 21
2.2 Compressor symbols 21 G
2.3 Control panel mc2 symbols 22 B
3 Warranty terms 23
4 Performance and specifications 24

4.1 General data 24
4.2 Compressor rating data 24
4.3 Air receiver 25
4.4 Compressor 25
4.5 Electrical motor and drives 25
4.6 Power supply data 25
4.7 Lubricating and cooling fluid 27
4.8 Dryer 87
Pag. 15
Clearance requirements
4.9 and system layouts
27
5 Safety precautions 28
5.1 General precautions 28
Safety precautions for maintenance 28
5.2 operations
6
G
B Handling and installation 30
6.1 Handling instructions 30
6.2 Installation site requirements 30
6.3 Air connection 94
6.4 Electrical connection 33
6.5 Configuration for remote control 33
7 Start-up and operation 35

Checks to be carried out
7.1 prior to start-up
35
7.2 “mc2” control panel 35

7.2.1 Control unit “mc2” 36
7.2.2 Emergency stop button 38
7.3 Starting and stopping the compressor 38
Pag. 16
Parameter configuration -
7.4 menu tree
41
7.4.1 Additional information menu 42
Menu tree
7.4.2 (control and programming)
43
7.4.2.1 PASSWORD menu 44
7.4.2.2 MAINTENANCE menu 44
7.4.2.3 GENERAL SETTINGS menu 46

G
7.4.2.4 NETWORK SETTINGS menu 51
B
7.4.2.5 OPERAT. PARAMETERS menu 52
7.4.2.6 PROGRAMMING menu 54
7.4.2.7 DIAGNOSTICS menu 56
7.4.2.8 INFORMATIONS menu 58
7.5 Operating warning and faults 58
8 Compressors in sequence 61
9 Troubleshooting 62
9.1 The machine does not start 62
9.2 The compressor has trouble starting up 63
Pressure value lower than rated
9.3 pressure
63
Pag. 17
The machine is ready for start or is running
9.4 and the scheduled maintenance LED is on
64
The machine is ready for start or is running

9.5 with critical functioning message
64
The machine stops when it is running

9.6 and warning LED comes on
65
9.7 Oil in the network 66
9.8 Oil in the machine 66

G
B 9.9 Safety valve VS intervention 67
10 Maintenance 68
10.1 Operating cycle 68
10.2 General maintenance

operation table
69
10.3 Replacement of the suction prefilter 71

10.4 Cleaning or replacing the air filter 71
10.5 Checking oil level, topping up and

changing the oil
73
10.6 Replacing the oil filter and the

separator filter
75
10.7 Draining the condensate 76

10.8 Replacing the fuses 77
Pag. 18
11 Spare parts and Service Centres 78
11.1 Spare parts and consumable
material codes
78
12 Diagrams 80
12.1 Hydraulic-pneumatic plant diagram 80
12.2 Power circuit wiring diagram

5,5 - 15 kW Machines without air dryer
82 G
B
5,5 - 15 kW Machines with air dryer
83

11 kW Machines with inverter
84
12.5 Auxiliary circuit wiring diagram

5,5 - 15 kW Machines without air dryer
85

5,5 - 15 kW Machines with air dryer
86

11 kW Machines with inverter
87
Wiring diagram for component location

12.8 5,5 - 15 kW Machines without air dryer
88
Wiring diagram for component location

12.9 5,5 - 15 kW Machines with air dryer
89
Pag. 19
1
Dear Customer,
Foreword
Congratulations on buying this compressor and thank you for your confidence in our Company.
The machine in your possession is a lubricated rotary screw compressor, incorporating state-of-the-art
compressed air technology.
The GENESIS - FORMULA - MODULO series screw compressors are characterised by high energy output
and low noise.
Major features incorporated in the design phase include versatility of use, reliability, low running and
maintenance costs, compact size, and top flight performance. This range of compressors has also been
designed and constructed complying with the strict quality control standards that are one of the main features
G of all products manufactured at our plants.
B
The product is EC marked and complies with current European Directives, as shown in the Declaration of
Conformity attached to this handbook.
The compressor must be installed by specialized personnel of authorized service Centres.
Before starting the machine, read all sections of this handbook and always comply with the
instructions provided which explain correct use and routine maintenance of the compressor
and the precautions to be taken to ensure operator safety.
This manual must always accompany the compressor so that it is available for all those working with it.
As concerns general maintenance, we recommend arranging a scheduled maintenance contract with our
authorized Centres.
Pag. 20 - Chap. 1 Foreword

Symbols 2
Symbols in the manual 2.1
This symbol indicates that the instructions manual should be read with great care before car-
rying out any operation on the machine
This symbol highlights operations or types of behaviour that could result in fatal injury or seri-
ous accidents to operators who must always be informed of these and take the necessary
precautions.
This symbol also accompanies the description of operations that require special atten-
tion on the part of the user.
You will find this symbol next to the descriptions of operations which must be carried out by
authorized service Centres only G
This symbol is provided to remind you that waste oil, condensate and filters removed from the
B
machine are polluting materials and must be disposed of in compliance with local laws
Compressor symbols 2.2

This symbol means that you must not put your hands inside the machine when it is
running
This symbol indicates the presence of rotating parts inside the compressor
Do not carry out maintenance or repair operations when the machine is running
This symbol indicates the presence of electrical power inside the machine
This symbol indicates the direction of rotation of the main electrical motor and fans
This symbol indicates the oil fill plug
These symbols indicate the direction in which to turn the key (provided) to open and close the
control panels of the machine and the control box
These symbols indicate compressor rated voltage
This symbol indicates the presence of high temperature components inside the compressor
P. 21 - Chap. 2 Symbols
Control panel mc2 symbols 2.3
This symbol indicates the K1 “START” key
This symbol indicates the K2 “STOP” key
This symbol indicates the K3 “RESET” key

RESET
This symbol indicates the K4”EXIT” key

ESC
This symbol indicates the K6 “UP” key
This symbol indicates the K6”DOWN” key

G
B
+ This symbol indicates the K7”PLUS” key
- This symbol indicates the K8”MINUS” key
This symbol indicates the K9 “ENTER” confirmation key
This symbol indicates the voltage present LED L1 (yellow)
This symbol indicates switching on of warning LED L2 (yellow)
This symbol indicates switching on of alarm LED L3 (red)
This symbol indicates switching on of LEDs L4 and L5 (red) indicating “AUTORESTART” and
“REMOTE/PROGRAM” located on the electronic control unit
This symbol indicates a message on the display of the electronic control unit
P. 22 - Chap. 2 Symbols
Warranty terms 3
The product was tested before delivery. The machine is guaranteed for twenty-four months from the date of
the invoice.
The warranty is valid only if the purchaser has complied with contractual and administrative regulations and if
the compressor has been installed and operated according to the instructions provided in this handbook.
The Customer is required to fill out all parts of the warranty card and send it within thirty days from the date
of purchase (as attested by the postmark).
According to the terms of the warranty, the Manufacturer undertakes only to repair or replace, free of charge,
the product or parts of this found to be faulty following examination by the Manufacturer’s technical person-
nel or authorised repair company. Labour and transport are, in any case, excluded 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 G
construction and manufacturing defects of machine components.
The warranty does not include parts which, due to their specific use, are liable to wear and tear such as seals,
B
belts, etc. and all consumables such as air filter, oil filter, oil separator filter, etc The warranty does not cover
repairs due to damage caused by insufficient or incorrect maintenance or unsuitable application..
The warranty shall be null and void in the case of failure to comply with the instructions given in this handbook,
use of non-original spares and scheduled maintenance carried out directly by the Customer without the related
invoice for the original parts.
The information given in this handbook is for guidance purposes only and is not binding. The Manufacturer
reserves the right to make any product modifications it considers necessary without prior notice.
P. 23 - Chap. 3 Warranty terms

Performance and
4 specifications
General data 4.1
Motor Noise
Model Pressure Air end Capacity Oil Weight Dimensions
power levels*
bar kW m3/min Kg Kg mm dB(A) - Lp(A)
Base 270 l 500 l
8 0.78 270 355 414
10 0.69 1030 x 615 x 1045
+ + +
5.5 5.5 BA51 7 1180 x 600 x 1645 (Genesis 270 l.) 66
G 13
15
0.54
0.40
28
dryer
28
dryer
28
dryer
1960 x 600 x 1645 (Genesis 500 l.)
B 8 1.20 275 360 419

10 1.04 1030 x 615 x 1045
+ + +
7.5 7.5 BA51 7 1180 x 600 x 1645 (Genesis 270 l.) 68
13 0.80 28 28 28
1960 x 600 x 1645 (Genesis 500 l.)
15 0.64 dryer dryer dryer
- 8 1.65 275 360 419

10 1.40 1030 x 615 x 1045
+ + +
11 11 BA51 7 1180 x 600 x 1645 (Genesis 270 l.) 69
13 1.17 32 32 32
1960 x 600 x 1645 (Genesis 500 l.)
8 2.01 300 385 444

10 1.72 1030 x 615 x 1045
+ + +
15 15 BA51 7 1180 x 600 x 1645 (Genesis 270 l.) 69
13 1.49 32 32 28
1960 x 600 x 1645 (Genesis 500 l.)
8 2.32 286 371 430

10 1.93 1030 x 615 x 1045
+ + +
15 15 BA69 7 1180 x 600 x 1645 (Genesis 270 l.) 69
13 1.62 32 32 32
1960 x 600 x 1645 (Genesis 500 l.)
± 3 dB(A) to standards PNEUROP/Cagi
Compressor rating data 4.2
A metal plate TM indicating the compressor specifications is

applied to the machine: figure 25 shows the position
TM
PF
Fig. 25
P. 24 - Chap. 4 Performance and specifications

Air receiver 4.3
Capacity of 270 or 500 litres according to model; type approved at 11 or 17 bar depending on the model.
Compressor 4.4
5.5-15 kW
Patented VT series air-end unit, single stage, BA51 model, oil
injection lubricated
RM
15 kW
Patented VT series air-end unit, single stage, BA69 model, oil
injection lubricated:
RF
Drive male rotor RM, five lobes, offset profile
Driven female rotor RF, six flutes, offset profile G

Fig. 26
B
Electrical motors and drives 4.5

Compressor start-up
Fixed speed motors
Two-pole, closed, three-phase asynchronous motor (rated speed of 3000 rpm at 50 Hz, 3600 rpm at 60 Hz,
protection rating IP54, insulation 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,
insulation class F, service class S1, reference MP in Figs. 14, 16, 18, 20, 22, 24), intended for use at variable
speed through powering with inverter
Electric fan
Fan coaxial to the electrical motor (reference EV in Figs. 13, 15, 17, 19, 21, 23)
Drives
Compressor motor - drive by means of removable taper bushing pulleys and toothed V-belts (reference CT
in Figs. 13, 15, 17, 19, 21, 23)
Electric fan: direct, co-axial transmission
Power supply data 4.6

Three-phase power supply; voltage and frequency according to rating data. Supply cables with a minimum
cross-section area as shown in tables 1and 2. Mains fuses and ground circuit breaker as shown in the fol-
lowing table.

Main fuses AM
Power cable
Model Pressure (motor rated) or ground Circuit breaker
cross-section area
circuit breaker setting
bar mm2 A A
8
10
5.5
13
2.5 16 16
15
8
10
7.5 4 20 20
13
15
400 V 8
10
11 6 25 25
13
15
G 8
B 15
10
13
10 40 40
15
8
10
15 10 40 40
13
15
Main fuses AM
Power cable
Model Pressure (motor rated) or ground Circuit breaker
cross-section area
circuit breaker setting
bar mm2 A A
8
10
5.5
13
6 25 25
15
8
10
7.5 10 40 40
13
15
230 V
8
10
11 16 50 50
13
15
8
10
15 25 63 63
13
15
8
10
15 25 63 63
13
15

Lubricated and cooling fluid
The compressor is filled with DICREA 46 lubricated and cooling fluid
4.7
Total capacity:
7 Kg
Top up with lubricated and cooling fluid with the same specifications as the lubricated and cooling fluid in
the machine (synthetic coolant I.E. ABAC DURALUBE may be specified)
Contact the Manufacturer’s technical Department before using lubricated and cooling fluids with other
specifications
Dryer 4.8 G
Thermostat controlled cooling cycle, direct expansion, with Freon R134a gas; pressure dew point
temperature 3°C, clean air filtering degree 0,01mm. B
Filtration degree: 1 µm.
Oil carryover: 0,1 mg/m3
Displayable dew point temperature

Cooling compressor and timed condensate drain, controlled from mc panel2
Clearance requirements and system layouts 4.9

The tables with the overall dimensions of the compressor are provided in figures 1-12
The hydraulic/pneumatic system diagram and the wiring diagrams (operation and location) are shown in
Chapter 12

5 Safety precautions
General precautions 5.1
Use of the machine by unskilled personnel without adequate supervision is not allowed.
Keep children and animals away from the working area.
Do not direct compressed air jets towards yourself or other people.
Always use goggles to protect your eyes from objects which can be lifted by the jet of air.
Never operate on the machine with bare feet or wet hands.
The compressor is designed solely to produce compressed air and cannot therefore be used for
G any other type of gas.
B The compressed air produced by the machine cannot be used for respiratory assistance,
pharmaceutical or sanitary purposes or in production plants where the output air comes
into direct contact with food products unless an additional adequate air treatment system
is employed
The air taken in by the compressor must be absolutely free of dust, vapours, explosive or flammable 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
individual applications (inflating, pneumatic tools, painting, washing with water-based detergents only, etc.).
Machine operation is fully automatic.
The machine carries out the various work cycles, as required by the user, according to the settings.
After use, stop the machine and disconnect the main panel power.
Use of the machine for other purposes shall be considered as improper use and the Manufacturer shall not
be liable for any resulting damage or injury.
Safety precautions for maintenance operations

Routine maintenance operations can be carried out by the user as described in this handbook.
5.2
Only the use of original spare parts will guarantee long, safe and reliable service life of the equip-
ment
Refer to Chapter 10 for instructions on the operations that can be carried out by the user.
All major maintenance operations can be carried out only by the specialised personnel of
authorised Service Centres
P. 28 - Chap 5 Safety precautions

Disconnect the power supply, vent the air and wait for the machine to cool before performing
any operation or removing the guards
After disconnecting the power, lock out the circuit breaker to prevent accidental start-up
while operating on the compressor. Additionally, close the shut-off valve between the com-
pressor and the line
All the air has been discharged from the machine when pressure gauge MPI shows zero
pressure
No changes must be made to machine internal electrical, pneumatic, hydraulic circuits and/or to the set-
tings. In particular, do not modify the maximum working pressure values and the valve settings, especially
the safety valves.
Do not use solvents, flammable or toxic fluids to clean the machine parts. Use alkaline detergents only. Never
use detergents to clean the motor or the electrical/electronic components.
Do not weld or carry out mechanical machining operations on the receivers. If damaged or rusted, replace
the parts, as they are subject to specific safety regulations. G
B
At the end of each operation, refit the guards carefully. Comply with the same precautions for initial start-
up.
Remember that waste oil, condense and machine filters are polluting materials. Dispose of
these products in compliance with local legislation
Careful scheduled maintenance will contribute to maintaining machine efficiency and user safety conditions
in time.
P. 29 - Chap 5 Safety precautions

Handling and
6 installation
Handling instructions 6.1
Use a forklift truck to handle the compressor
making sure that the forks are positioned in the
machine base unit supporting feet (Fig. 27).
Lift the machine from the front only both for the
G basic version and version with receiver.
B For the machine with 270 lt receiver, the

maximum width of the forks is 540 mm; no
restriction exists for the machine with 500 lt
receiver.
Make sure the load is properly balanced. Fig. 27
Alternatively, 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 damage to the unit and control panel.
Make sure that the load is balanced.
Fig. 28
Receivers under pressure, even if small, must never be transported
Installation site requirements 6.2

General remarks
The machine should be installed by authorised Service Centre skilled personnel to ensure that machine
installation site is suitable.
The machine is ready to be installed and does not require foundations. Site the compressor on level ground,
in a stable position, with the weight evenly distributed on the supports.
P. 30 - Chap. 6 Handling and installation

The environmental conditions that represent the operating range of the compressor are indicated below:
- Maximum installation altitude (above sea level) ................................................................................ :1000 m
- Minimum ambient temperature ......................................................................................................... :+5° C
- Maximum ambient temperature ........................................................................................................ :+40° C
Machine performance, as indicated in this handbook, is guaranteed only if the machine is installed at an
altitude below the operating limit indicated.{228}
Contact the Manufacturer’s Technical Department in the case of particular environmental conditions.
Outdoor installation
Figure 29 shows an example of outdoor

installation.
The compressor must be protected against max. 5000

atmospheric agents. Suitable protection is
required if the compressor is located outdoors. G
Comply with the minimum distance from the
walls (0.6 mm).
B
min. 3000
600
Fig. 29
Indoor installation
The machine is not suitable for use in environments with a “risk of explosion”.
The air taken in by the compressor must be absolutely free from dust, vapours, explosive
or flammable gas, solvents or paint powder and toxic fumes of any sort. Replace the filters
more frequently - with special reference to the air filter - if the machine is used in critical
environments (presence of ceramic, marble, cement, dust, etc.).
The dimensions of the installation site and

ventilation devices must ensure that ambient
temperature remains within the limits indicated
during duty cycle operating conditions.
If a suitable hot air discharge opening is not

provided, install one or more air evacuation
hoods. The hoods should be installed as
high as possible in relation to the dimen-
sions of the premises.
Fig. 30

The machine cooling air and the heating ducts
(where relevant) must be dimensioned so that
air speed does not exceed 3 m/s. The maxi-
mum length of the ducts is 6 m. If this is not so,
fit an auxiliary fan in the hot air duct.
Following installation of the hot air ducts, check that any back pressure, measured at the outfeed of
the hot air from the compressor, does not exceed 5-6 mm of water column.
For guidance purposes, duct cross-section area should be equal to that of the compressor hot air outlet grill
(reference FU in Figs. 14, 16, 18, 20, 22, 24).
Heat the environment if the minimum temperature required cannot be guaranteed.
Comply with the minimum distances from the

G walls shown in figure 31 600
600
B
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 safety distance according to 600
the type of process carried out at the premises
in order to prevent hazards or damage to the
machine due to the products used.
Fig. 31
The compressor should not be installed in a

recess which does not allow correct ventila-
tion. Hot air flow should not be obstructed in
any way and recirculation must be prevented
(Fig. 32).
Fig. 32
Air connection 6.3

When connecting the compressor to the receiver or to the distribution line, it is good practice to insert a hose
of suitable size and specifications (pressure and temperature) connected to the MA sleeve (Figs. 14, 16, 18,
20, 22, 24). The compressed air lines must be in perfect conditions and suitably fastened.

In particular, hoses which are not perfectly secured may cause severe injuries due to unpredictable move-
ments. Make sure that the hose ends are firmly secured before pressurizing them.
The condensate drain must be connected to a collection system with a suitable pipe as established by local
regulations for the disposal of polluting substances.
Electrical connection 6.4

The electrical power system must include a main circuit breaker with line sectioning function that can be
padlocked, with fuses or thermal cut-out suitably rated according to the characteristics of the machine, and a
device against accidental contacts in order to protect personnel.
The setting of the safety devices and the rating of the line circuit breaker must comply with the indications
provided in the table of paragraph 4.6.
The circuit breaker must be positioned close to the machine. Comply scrupulously with specific local accident
prevention regulations.
The power cables must have an adequate cross-section area for current take-off (see the table in paragraph G
4.6). B
Electrical systems must comply with the rules of good workmanship and be installed by a qualified electrician
who must check the efficiency of the earthing system.
The power cable must be secured in the specific glands and the electrical panel must be tightly closed to
achieve the prescribed IP44 protection rating.
Connect the machine only to type-approved sockets. The sockets must be earthed and tested.
Have correct fastening of the electrical cables of the various components checked regularly by qualified
personnel.
Chapter 12 contains the operational and layout wiring diagrams of the auxiliary and power circuits. The same
diagrams are also shown inside the machine control box.
Configuration for remote control 6.5

This paragraph describes how to configure the compressor for remote starting and stopping of this.
Alternatively, it is also possible to check operating mode (load / unload) or both functions by means
of an external control logic.
The operations described must be carried out by a qualified electrician.

To configure the remote control of the compressor, first of all remove the jumper between terminals 3 and 38
of the terminal strip inside the electrical cabinet (see wiring diagrams in Chapter 12)
One or two switches must be installed as described below according to whether only switching ON/OFF
and/or operating mode is to be controlled.
Remote control ON/OFF

(see paragraph 7.4.2.3 - Remote control type)
The switch must be connected to the following terminals after removing the jumper:
3 digital INPUT common terminal

38 remote control digital INPUT terminal
LOAD/NO-LOAD remote control

The switch must be connected to the following terminals after removing the jumper:
ON/OFF - LOAD/NO-LOAD remote control

Two switches must be used for this configuration.

The switches must be connected to the terminals after removing the jumper:
G
B ON/OFF SWITCH
LOAD / NO-LOAD START SWITCH

Following modifications to the wiring, the remote control must be configured as explained in paragraph
7.4.2.3 - Local/remote /program control - Remote control type

Start-up and operation 7
Checks to be carried out prior to start-up 7.1
N.B.: The Customer is responsible for installing the machine and making the required electrical and
air connections.
Initial system start-up must be carried out by skilled personnel who will make the various
checks required and follow the respective instructions.
Each machine was thoroughly tested at the plant before shipping.

You should monitor the compressor during the first hours of operations to check for faults.
Follow the installation prescriptions given in chapters 5 and 6
Remove all packaging materials and tools G
Connect the compressor to the distribution line as shown in paragraphs 6.2 and 6.3
Check the oil level in the receiver: see paragraph 10.5. If the level is low, top up with lubricating oil of
B
suitable specifications
Check for correspondence between the compressor plate data with the actual specifications of the
electrical system. A variation 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 since this defines the
direction of rotation of the motor. The direction
of rotation must be that indicated by the adhe-
sive label located to the side of the screw unit
(figure 33).
Note that even a few seconds of incorrect rotation
may cause serious damage.
A phase sequence checking device to prevent
mistakes is fitted in the electrical panel.
Fig. 33
The machine is now ready to be started.
Before starting the machine read the following paragraph and chapter 10 on maintenance
operations for in-depth knowledge of the machine.
“mc2” Control panel 7.2

The compressor is fitted with a “control panel” (reference PC figures 13, 15, 17, 19, 21, 23) for setting up and
monitoring machine operation. The operating parameters were entered by the Manufacturer during “testing”.
The parameters were tested for several hours in the various operating conditions.
The features offered by this electronic control system includes:

Fully automatic compressor operation
Real-time operating parameter display
P. 35 - Chap. 7 Start-up and operation
Customization operating parameter
Programming of compressor operation on a daily or weekly basis
Programming and signalling of the Manufacturer’s maintenance schedule
Machine self-protection system to signal fault pre-alarms and automatically stop the machine in the
event of serious problems
Remote machine control
Possibility of connecting the compressor via CAN-BUS interface (optional) to other similar compressors
for integrated management of the set of machines
Remote compressor monitoring via personal computer and dedicated software (optional)
The panel has two sections:
Control unit “mc2” of the

compressor
G
B Emergency stop button
Fig. 34
Control unit “mc2“ 7.2.1

K4
The front panel of the control unit “mc 2” K5
comprises: K7
K6
K8
compressor programming and K9
control keyboard
Indicator / setting LEDs

L5
back-lit LCD display
Fig. 35 K1 K2 L1 L3 L2 K3 L4
Control and programming keyboard
K1 START button (starting the compressor)

Used to start the machine. If remote control or programming (daily/weekly) are enabled, this key is used to enable
compressor functioning (priority control from keyboard). If alarm conditions have occurred, pressing of this key
has no effect
K2 STOP button (stop the compressor)

Permits timed stopping of the machine. If remote control or programming (daily/weekly) have been enabled, this
key can be used to disable compressor functioning (priority control). It does not operate at emergency level
K3 RESET button
RESET Makes it possible to reset compressor fault messages after eliminating the causes of these. As the faults can be
displayed only in the main screen page, the RESET key is effective only during display of this.
During parameter modification operations, the RESET key can be used to restore the preset factory (default)
value for the type of compressor selected

K4 ESC button
ESC Used to return to the main menu (previous level) or to cancel the modifications made.
If the key is held down, the control unit returns to the main screen page.
If OFF, back-lighting of the display is re-activated the first time the key is pressed without performing any other
function
K5 UP arrow key
Used for upward scrolling of menu items;
during setting of multiple-choice parameters. makes it possible to select one of the available options.
K6 DOWN arrow key

Used for downward scrolling of menu items;
during setting of multiple-choice parameters. makes it possible to select one of the available options.
function
+
K7 PLUS key
Makes it possible to increase the value of the parameter being modified.
Starting from the main screen page, permits access to additional information and scrolling of this
function
G
B
- K8 MINUS key
Makes it possible to decrease the value of the parameter being modified
Starting from the main screen page, permits access to additional information and scrolling of this
function
K9 ENTER / CONFIRM key

Used to access the menu displayed (next level).
Starting from the main screen page, makes it possible to access the menu tree.
Used to confirm the value or selection made during modification of a parameter.
function
Indicator / setting LED
L1 Voltage present LED (yellow)

Must always be ON when the compressor is powered
L2 warning LED (yellow)

This LED switches on to indicate critical conditions or a minor fault that does not block the compressor; this
indication may refer to the need for maintenance or irregular operating conditions. Switching ON of this LED is
always accompanied by a descriptive message that can be displayed in the main screen page
L3 Alarm LED (red)

This LED switches on (steady light) to indicate that the compressor has been blocked by a serious fault; the type
of fault is described with a message in the main screen page. Once the fault has been reset, the LED starts to
flash, informing the operator that the situation can be reset with the RESET key
L4 AUTORESTART LED (red)

This LED switches on when the AUTORESTART function is enabled.
In the case of automatic restart following a blackout (AUTORESTART function enabled) the LED flashes to indicate
that the compressor is about to restart. The display shows the countdown to restart
L5 REMOTE / PROGRAM functions active LED (red)

This LED switches on when the remote control function or one of the programming functions (daily-weekly) is
enabled.
If the compressor is installed in line with other similar compressors and communication on a CAN-BUS is enabled,
LED L5 assumes other functions. Refer to chapter 8 “Compressors in sequence”

Display
DI DI Multi-function display
Back-lit LCD display with four lines of twenty characters each: shows compressor operating conditions and is used
to carry out all programming and control operations
Emergency stop button 7.2.2
The red EMERGENCY STOP button PE (ref.

figure 36) stops the machine immediately.
Use this button for emergencies only
in conditions which appear hazardous
for the operator or for the machine (see
“Compressor emergency STOP” below).
G
B Fig.36
Starting and stopping the compressor 7.3

STARTING the compressor
When the machine is switched on (powered) the control unit starts the initial sequence and prepares to control the
compressor.
According to the sequence, with the LP led ON steadily, the following screen page must be shown on display DI:
This screen page indicates:
LINE 1 name of the compresso

<<<<mc2>>>>
LINE 2 /
1 LINE 3 software version which may differ from that Ve r s . S o f t . : 1 . 0 . 0 . 1
indicated
LINE 4 serial number of control unit, different for each S/N: 000-00-01-00001
machine
After a few seconds, the display shows the main screen page:
This screen page indicates:
LINE 1 indication of network pressure Pressione XX.X bar

LINE 2 indication of compression temperature of air-
2 oil mixture
Temperatura XXX °C
LINE 3 messages about operating conditions Pronto all’avvio
LINE 4 hour and date, informations menu access, 10:40 DOM 25/05/2003
tree menu access, quick language change
message
To change the language, use the K5 and K6 keys
If the compressor is operating, LINE 1 and LINE 2 always show the above information.
Particular indications (error messages), additional information or the information of the management
menu are displayed on LINE 3 and on LINE 4.
If LINE 3 shows “Ready for start”, the compressor can be started.
The compressor is started by pressing the green K1-START key
At this point, the compressor may:

a) start, displaying the messages referring to the start and functioning phases
b) prepare to start with the following message
In this case, network pressure is above the minimum

threshold value set; the compressor will start automatically
Stand by auto start
in the case of a request for air from the network hour-date
3
c) prepare to start with the following message
In this case, the remote control function has been enabled

(see paragraph 7.4.2.3).
The compressor will start when the remote command is
Stand by rem. com.
hour-date
G
4
received
B
d) prepare to start with the following message
In this case, the daily or weekly programming function
has been enabled and the compressor is in the OFF Stand by progr. com.
programming phase (see paragraph 7.4.2.6). hour-date
The compressor will start when an ON programming
5 phase is initiated.
If the compressor does not start or none of the cases listed above occurs, refer to chapter 9.
The following contacts will be made in sequence:
LINE - STAR - DELTA
6 Start Start
hour-date hour-date
and one of the two messages will be displayed
7 Load run Unload run

hour-date hour-date
When the display shows “Load run” the intake valve is open and the machine operates at full load (produces
the nominal capacity of compressed air).
During functioning, delivery pressure increases; once the preset maximum line pressure threshold value has
been reached, the control system sets the compressor to idling by closing the intake valve (“Unload run”).
When the pressure drops below the preset minimum threshold value, the intake valve opens again and the
machine restarts functioning at full load.
During unload run, two cases may arise:
a) Setting of AUTOMATIC functioning

(see paragraph 7.4.2.3):
The compressor outputs this message followed by a
8 countdown. Unload run
hour-date 04m 59s
At the end of the countdown, the compressor switches off,

changing to “Stand-by auto start”, status, ready to restart Stand by auto start
in the case of a request for air hour-date
b) Setting of CONTIN. functioning

(see paragraph 7.4.2.3):
The compressor outputs the “Unload run” message,

9 the machine never stops, always remaining available to Unload run
restart production of compressed air immediately in the hour-date
case of any request.
G
B STOPPING the compressor
Machine starting and stopping is timed.
Simply press the K2 button to stop the compressor
The compressor does not stop immediately but initiates a set of operations to stop 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 run.
Display DI shows this countdown; at the end of the

10 countdown, the motor is stopped. Stop in XXX sec.
hour-date
At this point, the display shows this additional timing:

during this phase, the compressor vents the pressure Blowdown in XXX sec.
inside the separator reservoir preparing for subsequent hour-date
restart.
If the K1-START key is pressed again before the

11 preset timed restart time has passed, a new timing
is shown on display D1 which indicates the time to
compressor restart
Start in XXX sec.
hour-date
This function prevents restarting the compressor
when it is still pressurized, avoiding electrical motor
verload.
Compressor emergency STOP

Press the PE red EMERGENCY STOP button to stop instantaneously the compressor in a hazardous
situation

The emergency stop button is intercepted by the
monitoring unit which displays the following message
with LED L3 on
EMERGENCY STOP
RESET compress.-Block
To reset, release the EMERGENCY STOP button lock
and press button K3-RESET
12
Parameter configuration - menu tree 7.4

The machine was configured at the plant during testing; the end user, however, can change some operating
parameters to customize machine performance to the specific applications.
Other parameter changes cannot be made Customer but only by Authorized Service Centre skilled
personnel.
The main screen page is displayed as follows: G

LINE 1 net pressure Pressure XX.X bar B
13
LINE 2
LINE 3
compression temperature of air-oil mixture
messages about operating conditions
Temperature XXX °C
LINE 4 hour and date, informations menu access, Ready for start
tree menu access, quick language change 10:40 DOM 25/05/2003
message
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 brightness.
The first time a key is pressed (excluding the K1-START, K2-STOP, K3-RESET control keys), high level
brightness of the display is restored while subsequent pressing of the keys produces the associated
function.
From the main screen page, it is possible to access:

14
a) to ADDIZIONAL INFORMATIONS Pressure XX.X bar b) to MENU TREE
using the K7 (PLUS) and K8 (MINUS)
keys Temperature XXX °C using the K9 (ENTER) key
This menu permits access to all compressor
This menu permits fast access to significant
information without having to enter the
Ready for start control and programming functions; the
main screen page is redisplayed using
menu tree; the main screen page is 10:40 DOM 25/05/2003 the K4-ESC key or automatically after
redisplayed using the K4-ESC key or 60 seconds
automatically after 60 seconds
ESC ESC
+ -
ADDIZIONAL MENU
INFORMATIONS TREE
7.4.1 7.4.2

Additional information menu 7.4.1
Menu A Pressure XX.X bar

Temperature XXX °C MAIN SCREEN PAGE
Ready for start
hour-date
+ -
Indicates the maximum operating pressure of the compressor.
Operating press. (ref. paragraph 7.4.2.5)
Max: 8.0 bar
ESC + -
Indicates the minimum operating pressure of the compressor.
Operating press. (ref. paragraph 7.4.2.5)
Min: 7.0 bar
G
+ -
B
ESC
Indicates operating mode setting:

Operating mode AUTOMATIC / CONTIN.
State: AUTOMATIC (ref. paragraph 7.4.2.3)
ESC + -
Indicates setting of the type of control:
Type of control LOCAL / REMOTE / PROGRAM
Control: LOCAL (ref. paragraph 7.4.2.3)
ESC + -
If enabled, indicates the status of the AUTORESTART function
AUTORESTART function (automatic restart following blackout)
State: OFF (ref. paragraph 7.4.2.3)
ESC + -
Only if the CAN-BUS communication module
ID compressor
N° stazione: 1 has been installed
ESC + -
Net sequence Indicates the order in which the machines are started
(ref. paragraph 7.4.2.4.)
ID 4-3-1-2
ESC + -
Indicates the total hours of operation of the compressor
Operating time
(ref. paragraph 7.4.2.2)
total: XXXX hours
ESC + -
Indicates the hours of operation of the compressor at full load
Operating time
on load: XXXX hours
ESC + -
Indicates the time remaining to initial maintenance: any other
Time to service maintenance operations to be carried out within 100 hours from
oil: XXXX hours initial maintenance are also displayed cyclically
It provides the information consulted most frequently and is shown below.

This menu can also be accessed with the compressor running.
If no key is pressed, the main screen page is redisplayed automatically after 60 seconds.
It is possible to return to the main screen page from any point of the menu by holding down the
ESC K4-ESC key
Menu tree (control and programming) 7.4.2

This is the structured menu used to carry out all compressor control and programming operations.
Menu B Pressure XX.X bar

Temperature XXX °C MAIN SCREEN PAGE
Ready for start
hour-date
ESC
G
(ref. paragraph 7.4.2.2) B
>MAINTENANCE <
...
ESC

>GENERAL SETTINGS <
...
ESC

>NETWORK SETTINGS < visible only if the
... CAN-BUS interface has been installed
ESC

>OPERAT. PARAMETERS <
...
ESC

>PROGRAMMING <
...
ESC

>DIAGNOSTICS <
...
ESC

>PASSWORD <
...
ESC

>INFORMATION <
...
The options and setting in the various menu can be:

CONFIRMED
10 pressing the K9-ENTER key OPERATION
COMPLETED
CANCELLED
ESC pressing the K4-ESC key OPERATION
ABORTED
Each time a parameter is modified, the factory-set (default value) can be restored for the selected
RESET
compressor pressing the K3-RESET key
PASSWORD menu 7.4.2.1

Used to enter a password to enable particular functions (e.g. AUTORESTART) or to access protected
G menus.
B For enabling of the AUTORESTART function, contact the Manufacturer’s Customer Service
The password is inserted using:
Menu C
>PASSWORD <
>Enter password <

ESC
Enter password:
ESC
0000
+ -
keys K7 and K8 to modify the flashing character; numbers and letters are displayed subsequently
the K5 and K6 keys to move to modification of the previous / next character
After inserting the password, this can be confirmed with the K9-ENTER key or cancelled with the K4-ESC
ESC key
If no other key is pressed, the password entered “expires” after five minutes with possibly display of a re-entry prompt.
MAINTENANCE menu 7.4.2.2

This menu is used to display short-term maintenance operations, the remaining service life of each component,
to reset the life counters of each component (where this function is enabled), to display compressor hours
of operation.

Menu D Press the K4 key to return to the MAINTENANCE menu
from the submenus ESC
>MAINTENANCE <
ESC
>Time to service <
Time to service
ESC .... xxx hrs
>Components life <
ESC
Time remaining for
air filter xxx hrs G
B
Time remaining for
ESC oil filter xxx hrs
Time remaining for

ESC ... other components
only with access enabled

>Compon. replacement<
Replacement made for

ESC air filter OK?
Confirm replacement
ESC
air filter OK?
ESC oil filter OK?
ESC
oil filter OK?
ESC ...other components...
ESC
...other components...
>Running hours <
Operating time
ESC total: xxxx ore
Operating time
load xxxx ore

Time to service
Makes it possible to check the first maintenance operation to be carried out on the compressor; the
maintenance operations to be carried out 100 hours after this are also displayed. In this way, the user
can schedule maintenance operations and, if necessary, decide whether to replace several components
during the same maintenance operation
Components life
indicates the remaining service life of each component that requires periodic maintenance
Compon. replacement
If the function is enabled, it makes it possible to reset the component life counters after maintenance
Running hours
Indicates compressor operating time (total running hours, running hours at full load)
G A table with the schedule of the maintenance operations to be carried out is provided below
B
First 100 hours First 1000 hours
Intervention maintenance maintenance Every 1000 hours Every 2000 hours
coupon coupon
Check air filter •

Replace air filter • •
Change oil •
Replace oil filter • • •
Replace separator
filter •
Replace air dryer
filters • •
Maintenance periods may differ from those indicated.
During installation, Service Centre personnel assess compressor operating conditions and if necessary modify
the frequency of the operations.
GENERAL SETTINGS menu 7.4.2.3

This menu allows to carry out the general settings of compressor operating configuration with the exception
of operating parameters (pressures, timings).
Language
Used to select the language of the messages
Measur. unit
Used to set the measurement units for pressure and temperature
(continued on p. 49)
Menu E (1/3) Press the K4 key to return to the GENERAL SETTINGS
menu from the submenus ESC
>GENERAL SETTINGS <
ESC
>Language <
Select language:
ESC √ENGLISH
Select language:
..OTHER LANGUAGES..
G
ESC
>Measur. unit < B
Pressure unit + -
ESC Unit: bar
Temperature unit + -
ESC Unit: Cels.
>Date and time <
Set date and time + -

ESC hh:mm day dd/mm/yyyy
>Display settings <
Contrast -
ESC Intensity: XXX% +
Lighting ON + -
ESC Brightness: XXX%
Lighting OFF -
ESC Brightness: XXX% +
continued on p. 48

continued from p. 47
>Operating mode <
Operating mode
ESC √AUTOMATIC
Operating mode
CONTIN
G
ESC
B >Compress. control <
Compress. control
ESC √LOCAL
Compress. control
ESC REMOTE
Compress. control
ESC PROGRAM
only if the CAN-BUS

Compress. control + - interface has been
ESC √NETWORK CONINUOUS installed
Compress. control -
ESC NETWORK PROGRAM +
only on machines equipped

with integrated dryer
>DRYER control <
DRYER
ESC √enabled in ON
DRYER
ESC Disabled
Continued on p. 49

continued from p. 48
>Type remote contr. <
Type remote contr.

ESC ON/OFF
Type remote contr.

ESC LOAD/UNLOAD
G
ESC
Type remote contr.
ON/OFF-LOAD/UNLOAD
B
Only with access enabled

>AUTORESTART func.<
AUTORESTART
ESC √DISABLED
AUTORESTART
ESC
√ENABLED
(continued from p.46)
Date & time

Used to set the current date and time
The time and date are entered using:
+ -
the K7 and K8 keys to modify the flashing values
the K5 and K6 keys to move to modification of the previous / next character
After entry of the values, these can be confirmed with the K9-ENTER key or cancelled with the K4-ESC
ESC key.
Display settings
Makes it possible to adjust the settings of the LCD display
Operating mode
Compressor operating mode may be set AUTOMATIC or CONTINUOUS:
AUTOMATIC: this is the setting used in most cases (factory setting). In this operating mode, idling is
timed; at the end of the count, the compressor stops, preparing for subsequent automatic start-up (see
also paragraph 7.3 STARTING the compressor). This promotes energy saving if there is no or a very
low request for compressed air.
CONTINUOUS:this setting should be used in very particular applications characterized by a considerable

variation in compressed air consumption combined with a reduced plant accumulation capacity. With
this setting, the compressor starts unload run without ever stopping the motor and is therefore able to
supply air continuously in the case of a request from the network. The system configured in this way
is highly reactive. However, one of the drawbacks of this operating mode is that it entails higher power
consumption due to the fact that the compressor is always running (see also paragraph 7.3 STARTING
the compressor).
Compress. control
G This menu is used to select the compressor control method from the possible local / remote / program
B control options.
If 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 (factory) setting that permits control from the keyboard
REMOTE: with this setting, the compressor can be controlled by means of an external remote switch.
For the electrical connections, refer to the following submenu (refer to the following paragraph “Type of
remote control”)
PROGRAM: enables the daily or weekly programming set and enabled in the PROGRAMMING menu
(see paragraph 7.4.2.6)
NET-CONTINUOUS: this is the setting for control of a sequence of compressors, without daily/weekly
program
NET-PROGRAM: this is the setting for control of a sequence of compressors according to the daily/weekly
program set
Dryer control
This menu is used to activate/de-activate the dryer
Type of remote control

For remote control, modifications must be made to the wiring of the compressor as described in
paragraph 6.5.
When compressor control is set to REMOTE (see previous submenu), three types of control methods
are possible:
ON/OFF is the setting that makes it possible to control switching ON/OFF of the compressor. This is
the factory setting (that most frequently used) which makes it possible to exploit the control logic of the
compressor using the pressure signal measured locally by the machine

LOAD/UNLOAD is the setting that makes it possible to control full load and unload operation with an
external control logic: in this case, the pressure signal measured by the compressor is ignored for the
purposes of operating method control (the safety devices remain active)
ON/OFF - LOAD/UNLOAD is the setting that makes it possible to control both switching ON/OFF of the
compressor and also operating mode. In this case also, an external control logic must be used as, for
control purposes, the pressure signal is ignored (the safety devices remain active)
It should be remembered that control via the keyboard of the control unit always has priority over any
remote control or any program: this means that, if remote control is to be effective, the START button
must be pressed setting the compressor to “Stand-by rem. con.”. Similarly, the compressor can be
stopped without any risk of remote restart of this by pressing the STOP key.
Therefore, to enable functioning with remote control:

1) Make the modifications to the wiring connecting one / two switches as described in paragraph 6.5
2) Select REMOTE control G
3) Select the control method (ON/OFF, LOAD/UNLOAD, ON/OFF - LOAD/UNLOAD)
4) Press the START key on the control unit to enable the compressor for remote control
B
Autorestart function
If enabled, this menu makes it possible to set the AUTORESTART function, useful for automatic restart
of the machine following a black-out and subsequent power-up.
NETWORK SETTINGS menu 7.4.2.4

This menu is used to set the parameters required for operation of the compressor in a network (in communication
with other similar compressors)
Refer to chapter 8 “Compressors in sequence”.
The menu is visible only after connection of the control unit with the CAN-BUS interface module for
communication between compressors.
Compressor ID
This is the identifier number of the compressor in a set of machines
Prefill
When the set of compressors is started with the compressed air system discharged (pressure zero or
very low), it is usually necessary to increase the pressure to the minimum working value as quickly as
possible. With the PREFILL function enabled, the compressor participates in system prefilling, bypassing
the global control functions in this phase.
The compressors involved in this operation are started quickly in sequence, thus avoiding any overlap of
the start-up phases of two or more machines
Rotation time
This is the time after which compressor start-up priorities are reassigned so that the work load is evenly
distributed between the machines available over a long period of time

Menu F Press the K4 key to return to the NETWORK SETTINGS
>NETWORK SETTINGS <

visible only if the
CAN-BUS interface has
been installed
compressor ID + -
ESC n. of service points: X
Prefill + -
ESC n. compr. X
Prefill time + -
Val.: 5 min
G ESC
B
Max n. compr. ON + -
ESC n. compr. 4
Rotation time -
ESC sequence 24 hrs +
Reaction time + -
ESC delay ON xxx sec
Reaction time + -
ESC delay OFF xxx sec
Reaction times
T ON When the control system activates a compressor following a reduction in network pressure, timer T
ON is started: 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 network pressure, the
T OFF timer is started: at the end of this count, the system checks network pressure to establish whether
another compressor is to be deactivated
OPERAT. PARAMETERS menu 7.4.2.5

This menu is used to make the configuration settings referring to the timings and operating pressure and
timings that regulate unload run and drainage of condensate.

Pressures
MAX. OPERATING PRESS.: The pressure above which the compressor starts to idle. The rated pressure
of the machine represents the upper limit of this value.
MIN OPERATING PRESS.: The pressure below which the compressor restarts operation at full load
(supply of compressed air) or at which it restarts if it has stopped at the end of unload run (no supply
of air). This value must be set so that the minimum supply pressure to the pneumatic service points is
guaranteed, taking into account losses 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).
Menu G Press the K4 key to return to the OPERAT. PARAMETERS

>OPERAT. PARAMETERS <

G
ESC
B
>Pressures <
Operating press. + -
ESC Max: xxx bar
Operating press. + -
ESC Min: xxx bar
>Timings <
Unload run time + -

ESC val.: xxx min
Time DRAIN open + -

ESC val.: xxx min
Time DRAIN closed + -

ESC val.: xxx min
Timings
UNLOAD RUN TIME: This setting defines the time during which the compressor idles when there is no
demand for air from the network. At the end of this period, the compressor stops and is ready to start
again when network pressure has dropped below the minimum threshold value.

This parameter is effective only if operating mode has been set to AUTOMATIC (see paragraph
7.4.2.3)
This parameter must be optimized according to the consumption trend of the network and its accumulation
capacity.
In the case of low consumption and if it is seen that the compressor remains inactive for
long periods (motor stopped), it is advisable to reduce idling time so as to restrict power
consumption during the inactive phases to a minimum. Low air consumption will also assure
a limited number of automatic start-up operations of the compressor, thus promoting a further
reduction in power consumption.
If air consumption is consistent and/or characterized by major variations, it is advisable to
extend the idling time in order to “offset”, through the periods of idling, the various periods
of operation at full load. This avoid stopping of the compressor with consequent delays in
the supply of compressed air due to the start-up phases which are characterized by current
take-off peaks tied to frequent starting.
G
B PROGRAMMING menu 7.4.2.6
The PROGRAMMING menu is used to set the schedule of compressor activities, defining 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 different program for each day of the week).
Reset programming:
Makes it possible to cancel all the cycles set in both daily and weekly programming
Programming mode
This parameter informs the controller whether, once PROGRAM control has been activated (see paragraph
7.4.2.3), the machine must follow daily or weekly programming
Daily programming
Daily programming can be used to set up to four start/stop cycles. These cycles are repeated equally
each day of the week.
The following rules apply:
- Non-programmed cycles identified by the five hyphens that replace the time are not effective
- Cycles for which the start and stop times coincide are not effective, similarly to those not
programmed
- If, in the last cycle programmed, the stopping time has been set to 24:00 and the start time of the
first daily cycle has been set to 00:00, the control unit will keep the compressor running during the
change over at midnight from one day to the nextdella mezzanotte da un giorno all’altro
Weekly programming
Weekly programming makes it possible to set different start/stop cycles for each day of the week, up to
a maximum of three per day.

Menu H Press the K4 key to return to the PROGRAMMING menu
>PROGRAMMING <
ESC
>RESET programm. <
Confirm RESET
ESC programming OK?
>Programming mode <
Programming mode
G
ESC √DAILY
B
Programming mode
ESC √WEEKLY
>Daily programming <
Every day -
ESC Start 1: ----- +
Every day + -
ESC Stop 1: -----
...other days...
ESC ...other cycles...
>Weekly programming <
Monday -
ESC Start 1: ----- +
Monday + -
ESC Stop 1: -----
...other days...
ESC ...other cycles...

The following rules apply:
- Non-programmed cycles identified by the five hyphens that replace the time are not effective
- Cycles for which the start and stop times coincide are not effective, similarly to those not
programmed
- If, in the last cycle programmed for a given day, the stopping time has been set to 24:00 and the first
cycle programmed for the next day has been set to 00:00, the control unit will keep the compressor
running during the change over at midnight from one day to the next
NOTE: remember that control via keyboard of the control unit always has priority over any program
control: this means that, if the program is to be effective, the K1-START button must be pressed setting
the compressor to “Stand-by progr. con.”. Similarly, the compressor can be stopped without any risk
of restart by the pre-set program pressing the K2-STOP key.
G Therefore, to enable functioning with program control:
B 1)
2)
Select PROGRAM control
Select the programming method to be used (DAILY/WEEKLY)
3) Program the daily or weekly schedule selected
4) Press the K1-START key on the control unit to enable program control
DIAGNOSTICS menu 7.4.2.7

From the diagnostics menu, it is possible to check functioning of the INPUTS, OUTPUTS and the direction
of rotation of the compressor and fan. It is also possible to read the log of faults that have occurred on the
compressor.
These diagnostic functions should be used only by expert personnel with in-depth knowledge
of the compressor and how this operates.
Diagnostic TEST
To run the diagnostic TEST, comply with all the safety rules described in chapter 5
WARNING!!!
When carrying out the test, certain parts of the machine are powered (control coils) and
rotating parts are activated (motor, compressor, fan). The operator must therefore take all
the necessary precautions during these checks.
Error messages
The control unit saves all the faults that have occurred and which have caused stoppage of the machine
(alarms). The following data are save for each error message:
- Type of error (alarm)
- Time, day, date on which the alarm occurred
- Total hours and hours of load run when the fault occurred
These indications are displayed cyclically on the third and fourth lines of the display.

Menu I Press the K4 key to return to the PROGRAMMING menu
>DIAGNOSTICS <
ESC
>DIAGNOSTIC TEST <
Run diagnostic
ESC TEST OK?
DIAGNOSTIC TEST
TEST digit. INPUTS
INPUT n. 1: status
ESC
Emergency OK G
B
...other INPUTS...
ESC
DIAGNOSTIC TEST
TEST digit. OUTPUTS ESC
OUTPUT n. 1: active
Line
...other OUTPUTS... ESC
DIAGNOSTIC TEST
Rot. direction TEST.
ESC Press for TEST
Press if OK
Press ESC if NEGAT. ESC
>ERROR MESSAGES <
Last
ESC error message
ESC
...other
error messages...

INFORMATION menu 7.4.2.8
This menu provides information about the serial number of the control unit and the software version
installed.
The CPU serial No. is indispensable to request enabling of protected functions by the Manufacturer (e.g.
AUTORESTART) and to obtain the related access password.
CPU serial No.

Indicates the serial number of the control unit
Software version
Indicates the software version installed
Menu L Press the K4 key to return to the PROGRAMMING menu

G
B >INFORMATION <
>CPU serial No.<

ESC
CPU serial No
ESC XXX-XX-XX-XXXXX
>Software version <
Software version
ESC <<<mc2>>> X.X:X:X
Operating warnings and faults 7.5

The diagnostics 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 divided into two categories::
Warning messages
These messages may refer to scheduled maintenance operations, critical operating conditions or minor faults
which do not block the compressor but which must be checked in order to trace their cause.
The warning messages are accompanied by switching on of yellow LED L2 and described with
a message shown on the third and fourth lines of the display in the main screen page. Warning
messages are displayed in alternating mode so as not to prevent display of basic messages.
To RESET the warning messages, proceed as follows:

1) For messages relating to scheduled maintenance operations: carry out the operation and RESET
component life (see paragraph 7.4.2.2)

Messages of this type are as follows:
- Replace air filter
- Replace oil filter
- Replace oil
- Replace separator filter
- Replace air filter - excess. clogging
for this last fault, after replacing the filter, press the K3 - RESET key
2) For critical operating condition messages:

If possible eliminate the problem; the message will be cleared automatically
Messages of this type are as follows:
- Compression temp. high
- Ambient temperature low
WARNING!!!
If the warnings are not reset for a long period of time (e.g. failure to carry out scheduled
maintenance) THE COMPRESSOR IS BLOCKED!!! In this case, contact the Service or
G
Customer Centre of the Manufacturer immediately. B
Alarm messages
These messages indicate a serious fault that has blocked the compressor. The alarm may be due to a
fault in the system or extremely critical operating conditions.
When a machine stoppage occurs, the compressor stops immediately, 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, first of all eliminate the fault: at this point, LED L3 starts to flash indicating that reset
can be carried out pressing the RESET key.
All faults that cause blocking of the compressor are saved in an error message log file. To consult this log,
refer to paragraph 7.4.2.7
The following faults block the machine:

- EMERGENCY STOP compress. - block
- Compression temp. too high - block
- Ambient temperature too low - block
- Internal pressure too high - block
- Net pressure too high - block
- Press Transducer error - block
- Temperature sensor error - block
- Power supply phase sequence error - block
- Short-cir. analog INPUT - block
- Compress. motor overload - block
- No. starts/hr too high - block
- Power supply failure - block
- Line voltage cutoff - block
Faults caused by failure to carry out maintenance must also be added to these: if the compressor is used for
long periods without carrying out the scheduled maintenance indicated by the control unit, a machine blockage
occurs accompanied by a message of the type:

Replace -------------- excess hrs - block
where the component to be replaced is displayed instead of 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 Centre of the
Manufacturer immediately.
To find out how to proceed in the case of an alarm, refer to chapter 9 “Troubleshooting”.
G
B

Compressors
in sequence 8
The mc2 control unit includes all the control functions of the compressor on which it is directly installed.
For compressor rooms in which several machines equipped with this control unit are installed (up to a maximum
of four units), a communication network can be set up between these for automatic, coordinated management
of the compressors.
Communication between the compressors provides the following advantages: G

B
constant pressure of the air supplied to pneumatic service points
energy saving:
only the compressors 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 of alarms and machine stoppages so as to prevent any interruption in the supply
of compressed air
management of the network of compressors according to a program set by the user on a

daily or weekly basis
To establish communication between the control units, a communication module is required for each machine
to be connected and the related connection cables.
Therefore, contact your area dealer to purchase these.
The instructions for installation, programming and operation of the network of compressors are provided in
the booklet furnished with the communication module.
P. 61 - Chap. 8 Compressors in sequence

9 Troubleshooting
The following table shows the most frequent problems.
The operation should be carried out by a qualified and skilled person where shown. For all other cases,
contact a specialised Centre
When the compressor requires scheduled maintenance, the operation to be performed and
the number of excess hours of operation are indicated in the main screen page.
In the case of long-term functioning in these conditions, the compressor is blocked and the
operation must be carried out immediately
G V-F Fixed speed compressors

V.V. Variable speed compressors
B
The machine does not start 9.1
V-F V-V Indication Possible cause Intervento
L1 OFF No power Restore power
X X
DI OFF FU2 / FU8 blown Replace damaged fuses
Problems in the electronic Call Customer
L1 ON control unit Service Centre
X X
DI OFF Problems in control unit Call Customer
connections Service Centre
L1 ON FU4 blown Replace FU4

X X
DI ON
(with normal functioning Call Customer
Inverter problems
X message) Service Centre
L1 ON
L3 constant ON Heat ambient.
Ambient temperature
X X DI indicates: Check installation
too low
“Ambient temperature too requirements
low - block”
L1 ON
L3 constant ON Problems in the pressure
Call Customer
X X DI indicates: sensor or in its electrical
Service Centre
“Press. Transducer connections
error - block”
L1 ON
L3 constant ON Problems in the temperature
Call Customer
X X DI indicates: sensor or in its electrical
Service Centre
“Temperature sensor connections
error - block”
P. 62 - Chap 5 Troubleshooting
V-F V-V Indication Possible cause Intervention
L1 ON
L3 constant ON Problems in the pressure /
Call Customer
X X DI indicates: temperature sensors or in
Service Centre
“Short-circ. Analog INPUT - their electrical connections
block”
L1 ON
L3 ON flashing An interruption of the power Carry out the RESET
X X DI indicates: supply of the system has operation (ref. Par. 7.5) and
“Power occurred restart the machine
supply failure - block”
L1 ON
L3 constant ON
Power supply phase
X X DI indicates: Reverse two power phases
sequence error
“Power supply phase
sequence err. - block”
L1 ON
L3 constant ON The No of starts/hr tolerated
X X DI indicates:
“No. starts/hr too high -
by the motor has been
exceeded
Wait for fault reset G
block” B
The compressor has trouble starting up 9.2
Ambient temperature low Heat ambient
Low voltage Check voltage
X X
Call Customer
VA problems
Service Centre
Star - delta sequence Call Customer
X problems Service Centre
Call Customer
X Inverter problems
Service Centre
Pressure value lower than rated pressure 9.3

Call Customer
VA problems
Pressure value on DI constant Service Centre
X X
(does not increase) Call Customer
Belts slipping
Service Centre
Variable pressure value on DI Call Customer

X Control unit mc2 problems
but which does not reach the Service Centre
X minimum working threshold. Problems in the electrical
Motor speed of rotation remains Call Customer
connections between
low. Service Centre
control unit mc2 and inverter
Pressure value on DI lower Reduce no. of service points /

Air demand too high
X X than minimum operating add compressors in parallel
pressure Internal or external leaks Check leaks
P. 63 - Chap. 9 Troubleshooting
V-F V-V Segnalazione Possibile causa Intervento
Replace FA
Excessive FA clogging
(see. par. 10.4)
X X
Call Customer
Belts slipping
Service Centre
The machine is ready for start or is running and the

scheduled maintenance LED is ON 9.4
L2 flashing
DI indicates: Replace FA
X X FA clogged
“Replace air filter (see. par. 10.4)
excess. clogging”
L2 flashing
G X X
DI indicates: FA to be replaced for Replace FA
“Replace air filter scheduled maintenance (see. par. 10.4)
B XXX excess hours”
L2 flashing
DI indicates: FO to be replaced for Replace FO
X X
“Replace oil filter scheduled maintenance (see. par. 10.6)
XXX excess hours”
L2 flashing
DI indicates: Oil to be replaced for Replace oil
X X
“Replace oil scheduled maintenance (see. par. 10.5)
XXX excess hours”
L2 flashing
DI indicates: FD to be replaced for Replace FD
X X
“Replace oil separator scheduled maintenance (see. par. 10.6)
XXX excess hours”
L2 flashing
DI indicates: Dryer filters to be replaced for Call Customer
X X
“Replace dryer filter scheduled maintenance Service Centre
XXX excess hours”
The machine is ready for start or is running with

critical functioning message 9.5
L2 flashing
DI indicates:
X X Ambient temperature low Heat ambient
“Ambient
temperature low”
Check functioning of the
electric fan and its fuses
Oil cooling low FU3.
L2 flashing Call Customer
DI indicates: Service Centre
X X
“Compression temp.
Call Customer
High.” Oil radiator dirty
Service Centre
Top up or change oil
Oil low
(see. par. 10.5)
Excessive ambient or air Improve air exchange and
X X
recirculation temperature check installation requirements
L2 flashing
DI indicates: Replace FO
X X FO clogged
“Compression temp. (rif. par. 10.6)
High.”
Replace FD
X X FD clogged
(see. par. 10.6)
L2 flashing Problems in the dew
Call Customer
X X DI indicates: temperature sensor or its
Service Centre
“Dewpoint probe error” connection
The machine stops when it is running and warning

LED comes on 9.6
G
L3 constant ON B
DI indicates: The PE button has been Reset the PE button
X X
“Emergency pressed (see. par. 7.2.2)
stop compress. - block”
L3 constant ON Call Customer

VA or solenoid valve problems
DI indicates: Service Centre
X X
“Net pressure Net pressure too high caused Check working pressure of all
too high - block” by other compressors compressors
X X Low voltage Check voltage
Check installation
X X Underscaled power cables
requirements
Critical functioning
temperature conditions
X X Check functioning conditions
(high ambient temperature, hot
air recirculation)
L3 constant ON
Replace FD
X X DI indicates: FD clogged
(see. par. 10.6)
“Compress.
motor overload - block” Replace FA
X X FA clogged
(see. par. 10.4)
Star delta sequence Call Customer
X
problems Service Centre
Motor thermal protection Call Customer
X
problems Service Centre
Call Customer
X X Electrical motor problems
Service Centre
L3 constant ON
DI indicates:
X X Line voltage cutoff problems Check line voltage
“Line voltage
cutoff - block”
Check functioning of the
L3 constant ON
electric fan and its fuses
DI indicates:
X X Oil cooling low FU3.
“Compression temp
Call Customer
too high - block”
Service Centre
Call Customer
X X Oil radiator dirty
Service Centre
Top up or change oil
X X Oil low
(see par. 10.5)
L3 constant ON
DI indicates: Excessive ambient or air Improve air exchange and
X X
“Compression temp recirculation temperature check installation requirements
too high - block”
Replace FD
X X FD clogged
(see. par. 10.6)
Replace FA
X X FA clogged
(see. par. 10.4)
L3 constant ON
DI indicates: FA to be replaced for Replace FA
X X
“Replace air filter scheduled maintenance (see. par. 10.4)
excess hours. - block”
L3 constant ON
DI indicates: FO to be replaced for Replace FO
G X X
“Replace oil filter scheduled maintenance (see. par. 10.6)
B L3 constant ON
DI indicates: Oil to be replaced for Replace oil
X X
“Replace oil scheduled maintenance (see. par. 10.5)
L3 constant ON
DI indicates: FD to be replaced for Replace FD
X X
“Replace oil separator scheduled maintenance (see. par. 10.6)
L3 constant ON
DI indicates: Dryer filters to be replaced for Call Customer
X X
“Replace dryer filter scheduled maintenance Service Centre
L1 ON Call Customer
Inverter problems
L3 constant ON Service Centre
X DI indicates: Problems in the electrical
“INVERTER alarm Call Customer
connections between
block” Service Centre
control unit mc2 and inverter
Oil in the network 9.7

Call Customer
FD problems
Service Centre
X X
Call Customer
Inefficient oil recovery
Service Centre
Oil in the machine 9.8

X X Leaking fittings Fasten the fittings
Call Customer
X X Safety valve VS intervention
Service Centre
Call Customer
X X FA leaks
Service Centre
Safety valve VS intervention 9.9

Call Customer
X X Pressure detector problems
Service Centre
Replace FD
X X FD clogged
(par. 10.6)
G
B
10 Maintenance
Perform the scheduled maintenance operations to maintain compressor performance.
Various routine maintenance operation can be carried out by user provided they are carried out by
skilled personnel.
If routine maintenance is provided by a Service Centre, the user cannot RESET the components even
if these have been replaced by the user (see paragraph 7.4.2.2)
Use only original spare parts
Instructions are provided in the following paragraphs.
Before performing any maintenance operations read the operator safety precautions in
G chapter 5 carefully. These precautions must be followed scrupulously for all maintenance
operations
B
Operating cycle 10.1
The compressor unit consists of two rotors (male and female) with special asymmetrical profile, patented VT
series, mounted on rolling bearings, able to withstand axial and radial thrust. The male rotor is the driving rotor
while the female rotor is driven. The male rotor also rotates the female rotor. The two rotors are not however
in contact physically as they are separated by a thin film of oil that protects the coupled surfaces. The male
rotor drives and the female rotor is driven. The two rotors are not in direct contact thanks to a thin film of oil
which protects the coupled surfaces.
The oil serves various purposes. It lubricates the bearings and the rotors, eliminates the heat produced by
the compressed air, it creates an “airtight fluid seal” and reduces hazardous gaps in the air-end unit.
In fixed 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 time of a few seconds, the PC control unit invokes changeover to the delta connection; with a
short transient phase, the MP motor reaches rated rotation speed. The intake valve opens thus starting the
normal work cycle.
In variable speed compressors, the start-up phase takes place with acceleration of the electrical motor which,
powered by the inverter, is brought to maximum speed of rotation compatible with network pressure.
As soon as this is permitted by rotation speed, the intake valve VA opens and the machine work cycle
begins.
The air is drawn through the filter FA, passes into the air-end unit where it is mixed with the oil injected. The air is
gradually compressed and pushed into the separator receiver where initial oil separation occurs by gravity.
The air, which is still mixed with oil droplets, follows the shape of the receiver and passes through the oil
separator filter FD. Due to the effect of coalescence, the droplets of oil merge and are deposited on the bottom
of the filter from where they are routed towards the air-end unit by means of a pipe.
The purified air passes through the check and minimum pressure valve VR which opens only when a threshold
of approximately 4 bar is exceeded. This ensures correct system lubrication in all operating conditions.
The oil deposited on the bottom of receiver SS is conveyed under pressure to the oil radiator RO where it
is cooled. If the temperature of the oil is below the calibration value of the VT thermostatic valve, flow to the
P. 68 - Chap. 10 Maintenance
cooler is bypassed; the oil passes into filter FO and returns to the air end.
Temperature sensor STO inserted in the delivery stub pipe and connected to the microprocessor permits
constant monitoring of the temperature inside the air-end unit.
The capacity delivered is controlled differently on fixed speed and variable speed machines. In fixed speed
compressors, once the rated running pressure has been reached, the intake valve closes. The internal receiver
pressure is vented to reach a value of approximately 2 bars.
This value is obtained by means of minimal amount of intake air through the intake valve. This ensures that
the pressure required for correct system lubrication is maintained. Consequently, the machine can idle with
reduced power intake.
After the predefined “idling” time, the machine stops, ready to start again automatically if the pressure drops
below the minimum threshold.
In variable speed compressors, the control system modifies speed of rotation in order to reach and maintain
an average pressure between the minimum and maximum pressure set.
In the case of very low air consumption, once the maximum operating pressure has been reached, the com- G
pressor switches to idling as described for the fixed speed compressor
In this case, the duration of the idling phase is shorter; at the end of this phase, the compressor stops, ready
B
for subsequent automatic restart.
The operator-controlled machine stopping phases also differ as regards the two types of compressor.
For fixed speed machines, ordinary stopping is timed; the machine is set to «idling» and the receiver is
gradually discharged.
For variable speed machines, the stopping phase is controlled through ramping down of the motor, during
which the system is depressurised.
The machine is also protected against any type of overpressure (internal faults or faults in other compressors
in parallel).
General maintenance operation table 10.2

The following table shows all the maintenance operations required by the machine.
You will find this symbol next to operations requiring the intervention of Service Centre
personnel
To be carried After the After the Every Every Every Every

Operation Reference out by a first first 500 1000 2000 4000
Service Centre 100 hours 1000 hours hours hours hours hours
Check on
suction prefilter
10.3
• • •
- Replace
suction prefilter
10.3
• •
Check air filter 10.4
• • •
Replace
air filter
* 10.4
• •
To be carried After the After the Every Every Every Every
Operation Reference out by a first first 500 1000 2000 4000
Service Centre 100 hours 1000 hours hours hours hours hours
Overhaul minimum
pressure valve •
Overhaul
intake valve •
Replace
oil filter
10.6
• • •
Check - top up
oil level
10.5
• • •
Change
oil
10.5
•
G
Replace
separator filter
10.6
•
B Check
oil recovery system • •
Check
fitting tightness • • •
-
• • •
Check
electrical terminal
connections
• • •
Drain
air-oil receiver 10.7
condensate
Clean
radiators • •
Clean
dryer condenser • •
Replace
air dryer filters • •
Check
belt tension and wear • • •
Replace
drive belts •
•
Check
settings and
adjustments
•
Check
safety device
operation
* This frequency relates to operation in normally dust environments. In the case of critically dust
environments, the control panel may signal the need to replace the air filter before the scheduled maintenance
time. In this case, replace the filter as soon as possible. The skilled personnel employed for installation will
be able to objectively evaluate the environmental conditions
Replacement of the suction prefilter 10.3
chapter 5 carefully. These precautions must be followed scrupulously for all maintenance
operations
Operate on the outside of the compres-

PA
sor: back off the screws that support
panel PPA of the suction prefilter.
Access the inside of the compressor:

extract the grill of the intake prefilter
and the filter element PA (Fig. 37)
Replace the filter element PA
Refit the grill of the intake prefilter

G
B
PPA
Fig. 37
To reset the scheduled maintenance counter (for enabled users only), see paragraph 7.4.2.2.
Cleaning or replacing the air filter 10.4

operations
GENESIS - FORMULA - MODULO 5-5-15 kW / 7,5-20 hp (BA 51)
Open the upper panel PS of the com- FA

pressor cabinet, backing off the lock
screws
Open the front panel PF of the compres-

sor cabinet using the key provided
Loosen the clip FFA shown in Fig. 38 FFA

and remove air filter FA
Clean the filter by directing a jet of air Fig. 38

inside it or replace the filter as pre-
scribed in the maintenance schedule.
Do not use fluids or detergents to clean
the filter
Insert the filter fully on the intake valve
Fasten the clip.
Replace panels PS and PF of the

compressor cabinet
GENESIS - FORMULA - MODULO 15 kW / 20 hp (BA 69)
GENESIS - FORMULA:
Open the corner panel SPA of the com-
pressor cabinet using the key provided
G
MODULO:
B Open the filter panel SF of the compres-
sor cabinet using the key provided
Release the front part of the filter con-

tainer CF pressing on the two fastening
tabs (Fig. 39)
Remove air filter FA from its housing as

shown in Fig. 40
Clean the filter by directing a jet of air CF

inside it or replace the filter as pre- Fig. 39
scribed in the maintenance schedule.
Do not use fluids or detergents to clean
the filter
Replace filter FA inserting it fully
Re-attach the front part of the filter con-

tainer CF pressing on the two fastening
tabs
GENESIS - FORMULA:
Replace the corner panel SPA of the
compressor cabinet
MODULO:
Replace the filter panel SF of the com-
pressor cabinet
FA
Fig. 40
Checking oil level, topping up and changing the oil 10.5
operations
Checking oil level and topping up

Check the level of the oil in the machine circuit frequently when the machine has been stopped for at least
thirty minutes.
This operation is very simple: inspect the oil level on the level reference tube TRL (Fig.41) after disassembling
the front panel PF
The oil level must be visible but must not exceed the RLMAX maximum level reference.
When the 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 G
TRL!
B
Maximum level is reached when the oil laps the edge of the maximum level reference RLMAX during top-up
.
Top up when required, as follows:
Remove the front panel PF using the

key provided
Loosen oil filler plug TO. Be careful not

to lose the seal (Fig. 42) TRL
Use a funnel to pour oil into the filler RLMAX

sleeve (Fig. 42)
Top up the oil level using only the RLMIN

amount indicated in paragraph 4.7
Avoid too much oil!!! Ensure the Fig. 41

level of the oil does not exceed the
maximum reference level RLM (Fig.
41)
Check that the seal of the plug is cor-

rectly positioned and fasten the plug (not
too tightly)
Replace the front panel PF using the

key provided
TO
Fig. 42
Changing the oil
Change the oil at the frequency indicated in the scheduled maintenance table of paragraph 10.2 or when you
plan to use a different oil from that in the machine.
Carry out this operation when the oil is still warm so that its viscosity is low and fluidity high.
Caution: lubricant temperature must not be sufficient to cause burns.
Proceed as follows:

key provided
Loosen oil filler plug TO. Be careful not

to lose the seal (Fig. 43)
Connect fitting R provided, which must

G communicate with a suitable collection
recipient, to fitting DO after unscrewing
B the safety plug (Fig. 44)
Open drain valve RSO and drain the

lubricant (Fig. 44)
After draining, close oil drain valve

RSO
Refill with oil as described in the “Check-

TO
ing oil level/topping up” paragraph Fig. 43
(Fig. 43)
Check that the seal of plug TO is cor-

rectly positioned and fasten the plug (not
too tightly)
Replace the front panel PF using the key

provided
Open the shut-off valve between the

compressor and the distribution line.
Switch the circuit breaker on and carry RSO
out a test start-up.
Let the compressor run for a few minutes
and then make a visual inspection for
any oil leaks
Check the oil level again as indicated

in the “Checking oil level/topping up” R
and if necessary top up
DO
Fig. 44
Remember that waste oil, condensate and all machine filters are polluting materials that must
be disposed of in compliance with local legislation
Replacing the oil filter and the separator filter 10.6

operations

key provided
Remove the top panel PS using the key FO

provided G
Loosen the oil filter cartridge FO using B
the specific key provided (Fig. 45)
Lubricate the seal before fitting the new

cartridge (Fig. 46)
Fasten the filter and tighten by hand.

Do not use tools to fasten the cartridge
as these may damage its structure!
Fig. 45
Open the shut-off valve between
the compressor and the distribution
line. Switch the circuit breaker on and
carry out a test start-up
Let the compressor run for a few minutes

and then make a visual inspection for
any oil leaks
Check the oil level again as indicated

in the “Checking oil level/topping up”
paragraph and if necessary top up
Replace the upper panel PS and the

front panel PF
Fig. 46
Draining the condensate 10.7
operations
If the machine is equipped with dryer and/or air reservoir, the mc2 control unit assures timed, programmable
activation of the solenoid valve of the condensate drain.
On machines equipped with dryer, with or without air reservoir, condensate drainage can be checked using
the sleeve located on the rear panel PP
On machines equipped with air reservoir, condensate drainage is checked using the solenoid valve located
underneath the air reservoir SA
Air receiver
G To eliminate the condensate that forms in the air receiver, proceed as follows:
B Place a suitable drip tray under the

condensate discharge valve RSC,
which is located under the SA RSC
receiver
Ensure that the intercept valve between SA

the compressor and the distribution line
is closed
Open the condensate discharge valve

RSC (fig. 47), using pliers if necessary
Fig. 47
Leave the condensate to drain until the
tank is completely empty
Close the valve RSC
Air-oil separator receiver

Drain the condensate accumulated in the air-oil separator frequently, by exploiting the fluid stratification
principle
The frequency of this operation will depend on environmental conditions (e.g. low temperature, high humidity)
and the frequency of compressor cold starts.
In order to carry out this operation, you must stop the compressor at least an hour before
intervening
Remove the front panel PF with the key
provided
RSC
Connect fitting R provided, which must
communicate with a suitable collection
recipient, to fitting DO after unscrewing SA RSO
the safety plug (Fig. 48)
Partially open drain valve RSO (Fig.

48)
Follow the operation and close oil drain

valve RSO as soon as oil starts flowing R
out
Check the oil level and top up, if

required, as described in the paragraph
“Checking the level and topping up”
DO
G
Replace the safety plug and the PF B
panel Fig. 48
The 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

operations
GENESIS - FORMULA:
Open the corner panel SPA of the com-
pressor cabinet using the key provided
MODULO:
Open the electric box panel SCE using
the key provided
Replace the damaged fuses. Follow

the amperage specifications provided
in paragraphs 12.8, 12.9
Fig. 49
GENESIS - FORMULA:
Close the corner panel SPA
MODULO:
Close the electric box panel SCE
Spare Parts and
11 Service Centres
The Manufacturer provides an efficient after-sales service through a large service network and a Technical
Department for solving any problems.
Always specify the compressor model and serial number when communicating with Authorized Service
Centres and the Manufacturer.
To locate the service Centre closest to the compressor installation site, call or send a fax to:
(+44) 01869-326226 Fax: (+44) 01869-326216

G
B E-mail: support@abac.co.uk
Spare parts and consumable material codes 11.1

The following tables show the most commonly used spare parts. Contact an authorised service Centre for
other spare parts.
Air Oil Suction Transmission
Model Pressure Separator filter
filter filter prefilter belts
bar Code Code Code Code Code
8 (2) 9075257
9056238
10 (2) 9075290
5.5 9056293 9056237 9623572
13 (2) 9075236
9056282
15 (2) 9075290
8 (2) 9075256
9056238
10 (2) 9075236
7.5 9056293 9056237 9623572
13 (2) 9075290
9056282
15 (2) 9075257
FORMULA
GENESIS 8
10
(2) 9075291
(2) 9075215
11 9056293 9056113 9056292 9623572
13 (2) 9075254
15 (2) 9075256
8 (3) 9075211
15 10 (3) 9075291
9056293 9056113 9056292 9623572
BA 51 13 (3) 9075215
15 (3) 9075262
8 (3) 9075256
15 10 (3) 9075254
9618034 9056113 9056292 9623572
BA 69 13 (3) 9075262
15 (3) 9075215
P. 78 - Chap. 11 Spare Parts and Service Centres

Air Oil Suction Transmission
Model Pressure Separator filter
filter filter prefilter belts
bar Code Code Code Code Code
8 (2) 9075257
9056933
10 (2) 9075290
5.5 9056937 9056942 9623572
13 (2) 9075236
9056934
15 (2) 9075290
8 (2) 9075256
9056933
10 (2) 9075236
7.5 9056937 9056942 9623572
13 (2) 9075290
9056934
15 (2) 9075257
MODULO 8 (2) 9075291

10 (2) 9075215
11 9056937 9056935 9056943 9623572
13 (2) 9075254
15 (2) 9075256
8 (3) 9075211 G
15
BA 51
10
13
9056937 9056935 9056943 9623572
(3) 9075291
(3) 9075215
B
15 (3) 9075262
8 (3) 9075256
15 10 (3) 9075254
9056939 9056935 9056943 9623572
BA 69 13 (3) 9075262
15 (3) 9075215
P. 79 - Chap. 11 Spere Parts and service Centres

12 Diagrams
Hydraulic-pneumatic plant diagram 12.1
G
B
P. 80 - Chap. 12 Diagrams
Legend
1 Air filter
2 Intake unit
2.1 Air filter clogging sensor
2.2
3 Drive
4 Motor
5 Air-end unit
6 Separator reservoir
6.1 Safety valve
6.2 Oil level indicator G
6.3 Air-oil mix temperature sensor
6.4 Oil drain outlet B
7 Thermostatic valve
8 Oil filter
9 Air-oil exchanger
10 Oil recovery
11 Separator filter
12 Minimum pressure and check valve
13 Air-air exchanger
14 Net pressure transducer
15 Drying unit (only in equipped versions)

15.1 Air dryer
15.2 Dew temperature sensor
15.3 Automatic condensate drain
16 Air receiver unit (only in equipped versions)

16.1 Air receiver
16.2 Safety valve
16.3 Discharge valve
16.4 Condensate drain
(only for versions equipped with receiver without air dryer)
Power circuit wiring diagram 5,5 - 15 kW 12.2
Machines without air dryer
G
B
Power circuit wiring diagram 5,5 - 15 kW 12.3
Machines with air dryer
G
B
Power circuit wiring diagram 11 kW 12.4
Machines with inverter
G
B
Auxiliary circuit wiring diagram 5,5 - 15 kW 12.5
G
B
Auxiliary circuit wiring diagram 5,5 - 15 kW 12.6
G
B
Auxiliary circuit wiring diagram 11 kW 12.7
Machines with inverter
G
B
Wiring diagram for component location 5,5 - 15 kW 12.8
G
B
Wiring diagram for component location 5,5 - 15 kW 12.9
G
B

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GENESIS - FORMULA - MODULO

USE AND MAINTENANCE HANDBOOK

Contenedor del ﬁltro

Cinghie di Transmission Courroies de Correas de

DI Display Display Ecran-afﬁcheur Display Visor

Scarico olio/ Oriﬁce de vidange de

ES Essiccatore Dryer Sécheur Trockner Secador

EV Elettroventilatore Electric fan Ventilateur électrique Elektrolüfter Electroventilador

FA Filtro aria Air ﬁlter Filtre à air Luftﬁlter Filtro de aire

FO Filtro olio Oil ﬁlter Filtre à huile Öl-Filter Filtro aceite

Feritoia uscita Oriﬁce de sortie Rendija de salida del aire

Gruppo pompante a vite Groupe de pompe à vis Grupo de bombeo de

Led del pannello di LED sur panneau de

MP Motore principale Electric motor Moteur principal Elektromotor Motor principal

PA Prefiltro aspirazione Suction prefilter Pré-filtre d’aspiration Ansaugvorfilter Prefiltro apiración

PC Pannello di controllo Control panel Panneau de commande Kontroll-Anlage Tablero de control

Pulsante di arresto di Pulsador de

PF Pannello frontale Front panel Panneau avant Frontseite Panel frontal

Pannello prefiltro Panneau du prréfiltre Abdeckung der Panel del prefiltro de

PS Pannello superiore Top panel Panneau supérieur Oberseite Panel superior

R Raccordo Fitting Raccord Anschluß rACOR

Radiatore aria After cooler Radiateur à sir Luftkühler Radiador de aire

Riferimento Repère de niveau Referencia de nivel máx.

Riferimento Repère de niveau Referencia de nivel min.

Robinet de vidange de Grifo de descarga de

Robinet d’évacuation Grifo de descarga de

SA Serbatoio aria Air receiver Réservoir á air Lufttank Depósito de aire

Sportello cassetta Panneau Starter/Kontroll Box Puerta del

Serbatoio Réservoir Depósito

Tubetto di riferimento Tube de référence Bezugsleitung Tubo de referencia nivel

Valvola di Soupape Válvula de

Valvola Soupape Válvula

4 Performance and speciﬁcations 24

4.2 Compressor rating data 24

4.3 Air receiver 25

4.5 Electrical motor and drives 25

4.6 Power supply data 25

4.7 Lubricating and cooling ﬂuid 27

7 Start-up and operation 35

7.2 “mc2” control panel 35

7.2.2 Emergency stop button 38

7.3 Starting and stopping the compressor 38

7.4.1 Additional information menu 42

7.4.2.1 PASSWORD menu 44

7.4.2.2 MAINTENANCE menu 44

7.4.2.3 GENERAL SETTINGS menu 46

7.4.2.6 PROGRAMMING menu 54

7.4.2.7 DIAGNOSTICS menu 56

7.4.2.8 INFORMATIONS menu 58

7.5 Operating warning and faults 58

The machine is ready for start or is running

The machine stops when it is running

9.7 Oil in the network 66

9.8 Oil in the machine 66

10.2 General maintenance

10.3 Replacement of the suction preﬁlter 71

10.5 Checking oil level, topping up and

10.6 Replacing the oil ﬁlter and the

10.7 Draining the condensate 76

12.2 Power circuit wiring diagram

12.4 Power circuit wiring diagram

12.5 Auxiliary circuit wiring diagram

12.6 Auxiliary circuit wiring diagram

12.7 Auxiliary circuit wiring diagram