A,tUÂA

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OPERATI NG ANN §ËHWIGË MÂTbITTAil-

SECTION 1 . DESCRIPTION AND MAIN SPECIFICATIONS
1.1. - lntroduction
1.2. Warranty
1.3. Warranty exclusions
1.4. Description and technical specifications of screw type air compressor
1.4.1 . Construction
1.4.2. Air suction filter
1.4.3. Air suction check valve
1.4-4. Suction check solenoid valve
1.4.5. Screw block
1.4.6. Air-oil seParator tank
1.4.7. Air cooler
1.4.8. Oil cooler
1.4.9. Air-oil seParator
1.4.10. Oilfilter
1.4.11. Thermostatic mixing valve
1.4.12. Main engine
1.4.13. Fan motor
1.4.14. Min. pressure valve
1.4.15. Belt tension flange
1.4.16. Belt and PulleYs
1.4.17. Pressure adjustment sensors (switch)
1.4.18. Relief valve
1.4.19. Oil drain valve
1.4.20. Oil filler caP (Plug)
1.4.21. Oil level indicator
1.4.22. Return Skavenge line
1.4.23. Screw outlet pressure manometer
1.4.24. LCD screen
1.4.25. Limit Pressure switch
1.4.26. Dischargevalve
1.4.27. Electrical panel ( complete)
1.5. Lighting
1.6. Sound level
1.7. TerminologY
1.8. Paint
1.9. Training

SECTION 2 - GENERAL SAFETY STANDARDS

2.1. Safety
2.2. Terminology adopted
z.é. General safeÿ rules and sYmbols
2.3.1. General safety rules- lnformation about machine safety
2.3.2. General safeÿ signs- Measures for the operator against dangers
Z. J. J. Protective equipment
2.4. Ecology and pollution
2.5. Safety equipment
l.o. Safe service
2.7. Transportation
2.8. Dimensions of compressor

sEcTloN 3 - oPERATION OF ATV-AV SERIAL ( DIP TYPE) SCREW COMPRESSOR

3.1. Controls before commissioning the compressor
3.2. Floor of screw compressor- Floor information
3.3. Handling and packaging of screw compressor
3.4. lnstallation of screw compressor
3.5. Elements of control panel of screw type air compressor
3.6. Electricity system of screw compressor
3.6.1. Electrical connection of screw compressor
3.6.2. Electrical circuit diagram of screw type air compressor
3.6.3. Start-up
3.6.4. Start- delta no load operation
3.6.5. Star-delta starting
3.7. Flow diagram of screw compressor
3.8. Checks following installation
1
TABLE OF CONTENTS
3.9. Operating principie of screw compressor
3.10. Operation of screw compressor
3.10.1. Normal oPeration
3.10.2. Start-up
3.10.3. Stopping comPressor
3.10.4. Stopping compressor for short-time
3.11. Operation of the machine
3.12. CE certificate of conformitY
3.13. Organization
3.14. Authorized service and contact

SECTION 4 - SERVICE
4.1. Controls upon delivery of compressor
4.2. General service rules
4.3. Short periodical services
4.4. Oilchange
4.4.1. Oils
4.4.2. Oildrain
4.4.3. OilTilling
4.4.4. Safeÿ measures
4.5. Replacement of oil filter
4.6. Replacement of air suction filter
4.7. Replacement of air-oil separator filter element
4.7.1. Safety measures for air-oil separator replacement
4.8. Belt replacement
4.8.'l. Safeÿ measures for belt replacement
4.8.2. Belt tensioning mechanism
4.9. Cleaning of screw compressor
4.10. Time foireplacement of spare part and follow-up chart
4.11. Failures, reasons and troubleshooting

5 - SPARE PART TABLE OF ATV-AV SERIAL ( DIP TYPE)

SCREW TYPE AIR COMPRESSOR
sEcTloN
5.1. Spare part list and codes

( DIP TYPE) SCREW TYPE AIR COMPRESSOR

SECTION 6 - MATERIALS SUPPLIED WITH ATV-AV SERIAL
6.1. ldentification of compressor and CE label
6.2. safety, health, warning symbols and signs on the screw type air compressor
6.3. First starting-uP form
6.4. Service check list - protective service chart
6.5. Warranÿ certificate of electrical motor
6.6. Warranty certificate of screw iype air compressor
6.7. Electricity control diagram
6.8. Electricity power diagram
6.9. Compressor laY-out
6.10. CE declaration of conformitY
6.1'1. Pressure vessel test certificate

2
i

DESCRIPTION AND MAIN SPECIFICATIONS

SECTION 1

DESCRIPTION AND MAIN SPECIFICATIONS

1.1. lntroduction
(dip type), screw ÿpe air
This manual includes information necessary for good operating and normal service of ATV-AV series
manufactured by AYDIN TRAFO MAK'
compressor (hereinafter referred to as ATV-AV r"iiut loip type)). ATV-AV serial (dip type) is
SAN. TlC. A.S, located in lzmir, Turkey (hereinafter re{erred to as "manufacturing company").

proper operation, term of use, operator and environmental safety and economy depends on fulfillment and following these
instructions. The manufacturing company may cancel the warranty of the products due to misuse
or non-proper use of ATV-AV
serial (Dip tyPe).

please check the lntegrity and soundness of ATV-AV serial (Dip type) while purchasing. Possible complaints should be presented
in written within eight ia) oays as of the receipt of ATV-AV serial (Dip type) screw type air compressor.

with specialist
Relating to possible repairs and revisions requiring complex operations please consult to authorized services
service and producer can be found in
personÀel or the manufacturing company lmmediately. contact information of authorized
article 3.14.
be at your disposal
ln addition to this, for the maximum efficiency of ATV-AV serial (Dip type), the manufacturing company shall
to provide everything {or fast, accurate technicai assistance and better operation'

1.2. WARRANTY
the date of
The manufacturing company provides warranty for ATV-AV serial (Dip type) for twenty four (24) months as of
purchase. This warranty'is âpplicable for repairs and free part replacement following a correct inspection by the technical
The warranty is limited to only
àepartment of manufaciuring company and it is understood tirat ATV-AV serial (Dip type) if broken.
material defects except res[onsiOitity of direct or consequential damages and if the reason of part damages is disassembling,
repair or tempering other tÀan factory or authorized service, the manufacturing company shall not have any responsibility. ln
addition to this, certificate of delivery to the operator shall be valid. Transportation, customs taxes and expenses for vAT shall be
submitted to the customer. Replacement or
charged for the buyer. Conditions of warranty are specified in the warranty certificate
repair of warranted parts shall not extend the term of warranty.

1.3. Warranty exclusions

serial (Dip
Damages arising from poor maneuvers of the operator, negligent, misuse or non-appropriate operation of ATV-AV
void the warranty and
type) àre not covered by the warranty. Disassemàly of securityelements of ATV-AV serial (Dip type) shall
parts will void warranty and obligations, in addition
ootigations of the manuâcturing co*pany. Moreover, use of non-original spare
of supply.
to this the operator can exercise the rights for warranty if he follows the conditions described in certificate

J
1.4 DESCRIPTION AND TECHNICAL SPECtFICAT|ONS OF ATV-AV SERIAL (DSp rypE) ScREW TypE

ATV-AV serial (Dip type) is presented to the service of the customers in accordance with TS gg33 EN 1012
coMpRESsoRS
AND VACUUI/ PUMPS SAFETY RULES standard/reievant standard references, 2OO6/42.EC MACHINE
SAFETY DtHECTIVE,
2OO6/95/EC LOW VOLTAGE DIRECTIVE, 2OO4I1O8IEC ËLECTROMAGNETiC COMPATIBILITY DIRECTIVE,
87I4O4I EEC
SIMPLE PRESSUFIE VESSELS REGULATIONS and production, safety, operaiion rules and practices required by the
specific
ccnditions of the manufacturer.

Technical Data

0AB|NET SCREW COMPRESSOR (Dtp SEPARATOR)

Free Air Efficiency Engine Separator Tank Dimensions Air

m3 / min.) Power (Dip) (mm) Weight
TYPES Outlet
7q '10
IJ Volume Max. Pressure Widih .x Lenght x
Bar Bar Bar
KW
(Lr) (Bar) Heiqht a" Kg
ATV- 740 x 990 x
AV-l5 2,5 1,75 15 12 la 1
JJ3
15 1225
ATV- 740 x 990 x
AV.lB 3,1 z,o 2,2 18,5 12 I'J 340
18 1225
1

ATV. D AE 740 x 990 x

AV 22 3,6 3,1 22 12
22 IJ
1225
I
345

ATV- 850 x 12i5 x

AV-30 5,1 4,3 3,85 JU 28 13
30 1 1/4" 648
i 560

ATV- 895x133ûx
u1/
AV-37 6,3 c,z +,é Q-
53 13 1 112" 810
1 700

ATV- 895 x 1330 x

A.V-45 7,0 5,7 45 53 13
45 1 1/2" 81B
1 700

ATV. 165 x 1670 x

AV-55 9,6 E,O 7,0 trt 85 1
55 13 2" 1344
1 800

ATV- 165 x 1670 x

-7 Ë' AV-75 12,3 10,7 8,8 7Ë, B5 I,J
1
1 800
Z 1 466

ATV- 't5,8 1420x 1965 x

AV-90 1a I 1'l I 90 13 z
JIJ
2120 1 900

ATV, '18,0 1420 x 1965 x

110
AV-1 1 0 18,3 14,0 110 i oE
IJ I 2250
2120
ATV. i420 x 1965 x
AV-1 32 23,1 20,5 16,2 132 135 IJ
132 212A
Z 2450

ATV.
AV-1 60 27) 19,7 160 ,n^ 13
1 900 x 2300 x
160 1 940
3700

ATV- 1900 x 2300 x

20Ç)
AV-200 29,4 zo, o 200 22A la en 480C
1 940

ATV-
250
AV-25C 43,8 36,5 28,5 250 22A le 1 900 r 2300 x J 5400
1940

TABLE . 1

4
mæ;r-----l
outlet
crew
l3S
lManometers
i
I
tA,tbbr4r----l
Pt i-co s"r"en
Stoct< cooe: arvx oozo { I I

I s,".k 9"d111I i0099!

I

FIGURE - 1

FIGURE . 2
 m,rd", *15. tnrfi.t"-
Sw[crr I
I Lin,t Pressùre I Screw ott tnier I

I StockCode:ATVK-OOo8.ro I lStockCode:ATVK-oo17.13 |

Grtol", 1/2 --l

lArr Suction Fitter I

I
Slock Code: ATVK.Oo29.04
|

Article: 1.4.26
Suction Check Soienoid

Iarti"r", 1a 4 ---l
I Suctron Check Valve I

I
Stock Code: ATK.1 16-01 06 |

I;,t".b,i-r-i-é5 --__l
Iscrew Block I

Stoct Coo", nrvx-ooos.og

I ]

li,tbrer/6-=-]
t-l
I Screw Pulley I

I
Stok Kodu: ATVK-0007.14 |

ll't"b r4i6 ----_l Articie:1.4.16

Engine Puliey Po,y V Bell
] I

]
Stock Code: ATVK-0007 19 I
Stock Code: ATVK-oo1 1.01

FIGURE.3

,o*,,_ r

]D..ra'gevare ] Cooil.gOiFer-.-ilose aoo ^gO, inetHose I

lSloclCode:ATV{-00'3.02 | tsro(!Code:ATVK-oo! r20. I Sroc"Cooe:AIVK-oor7.12.01 I

1.4 10
-_--.,l
Article: 1.4.6- 1.4.9 F,ld"
Separator Tank and
- I oit Fitte, l

Separator lstock Code: AT\/K-0029.i4 i

Stock Code: ATVK-0037

4029.12

lA,t"br4r- --=l
Oil Level lndicator
I I

StocL Code: ATVK-0022.04

I I

Article: .................
Air Oil Outlet Hose
Stock Coder ATVK-0017.10

Articie: 1.4.20
Oil Filling Cap (Stoppe0
Stock Code: ATVK-0024.09
 DESCRIPTION AND MAIN SPECIFICATIONS

1.4.1 Construction
profile double-rotor, bearing and body are the products
Screw block used in our compressor, oil injection asymmetric helical
ensuring high performance and of cutting-edge technology'
ATV-AV series'
conventional type screw block ranging from 3 Kw to 250 Kw ls used in all
the air at the outlet point. Compressed air heats
Male rotor rotates the female rotor and pushes the air forward and compresses
on the rotors a little. Air-oil mixture from screw block is transferred to separator
and this temperature is cooled by the oil injected
value it is circulated from
tank. oil is cooled directly up to certain temperature and when it is above thermostat temperature
radiator and is passed through the filter in the screw block and injected.
in air cooler and transferred to air tank' our
Air-oil mixture in the separator tank is passed through separator filter and cooled
foam to keep the operating sound at the
screw compressors are enclosed in a cabinet coateld with special sound absorbing
designed in the form of completely
lowest level. This allows vibration free and quite operation. iher" is an electricity
cabinet
the oil in the air up to 2-4 mg/m3 has paper
closed type and accommodating all electricity components. Air-oil separator retaining
transmission was designed with belt tension
element air suction filter filteriig the suction air up to 15-25 microns. Power
fan engine is available for cooling and sizes
mechanism for easy tensioning of belts and ls in poly v belt pulley type. A separate
cabinet and frame group is coated with electro static
of coolants were designed as to be used in high ambient temperatures.
powder paint with long service life. compressors were mounted on lower {rame allowing easy handling with forklift or pallet truck'
where either 10 or 1000 employees
our screw compressors meet the compressed air requirements of industrial organizations
air preferred from every section of the industry
work regardless of the size. our screw compressors are the source of compressed
fast and cheap. services performed on time will make your compressor
to health sector. service of screw compressor is easy,
of the screw éo*pr"sor involves air and separator filter and oil replacement capacity
serve for long years smoothly. Service
values for the screw compressors are the net values at the outlet of the compressor'

level and ensures that air suctioned is

1.4.2.Air suction filter: lt is the dry type and sensitive as to hold the dusts in micron
absorbed by the screw block as clean.
permanent or permanent loaded order' Moreover,
1.4.3.Air suction check valve: Ensures off-load permanent, loaded/off-load
(serves as the check valve')
it prevents return of air-oil mixture in the sump ,nàer ptettrre in sudden stops
Ensures discharge of compressed air
1.4.4.Suction check Solenoid valve: Allows loaded/off-load operation of the compressor"
of pipe in the moment of switching off the suction check valve'
(male and female) inserted in parallel to each
1.4.5.Screw block: Ensures pressure by means of micron gap o{ two worm screws
other in a casted shell.
from each other at two steps and
1.4.6.Air - oil separator tank: The oil is stored and air-oil mixture f rom screw blow is separated
cap is available in the tip of it' oil filling cap
oil is returned to screw block again. To drain oil under the tank, a ball valve and blind
should never be opened' Please wait until
and oil level indicator is on the tank. while there is pressure in the tank, oil filling cap
screw outlet pressure monometer is zero
and transfers to air tank'
1.4.7.Air cooler: lt cools the air f rom air-oil separator above 10-15'C of ambient environment
ls air cooled and combined with air
1.4.g.Oil cooler: lt cools the oil circulating in the system to the desired temperature. lt
cooler.
placed between two cylinders
1.4.9.Air-oil separator: Separates air-oil mixture in the tank. lt is made of special fiber material
surrounded by steel perforaied sheet. OH particles in the form of mist in air-oil mixture in the component combines and become
accumulating at the bottom of filter is
oil drops, Oil drops are collected at the outside level of the filter and run downwards. Oil
thin pipe. Oil rate in the air oil of which is removed is
sprayed from Skavenge line to screw block bearing/suction with a separate
max.6 ppm.

1.4.10.11.Oi| filter - Thermostatic mixing valve : oil filter and thermostatic mixing valve
is enclosed in a single body with
provides the transfer of oil to the filter above the cooler provided that it changes the direction of oil flow
terminal head. Thermostat
al 55171'C.

Functions and benefits of thermostat can be summarized as follows:

life of screw block and
a) Keeps the temperature of oil between certain temperature values. This means extension df service
stabile oil viscositY.
thermostat circuit soon'
b) Enables compressor to work at low ambient temperatures. Oil temperature heats in closed
prevents condensation of water in air as oil temperature is not lowered under 55 I 710 C. prevents water accumulation in oil'
c)
 DESCRIPTION AND MAIN SPECIFICATIONS

1 .4.12.Main engine: lt is three-phase, fully closed (1P55), V-belVcouple driven in screw blocks in 83-85 construction, F isolated,
thermal, star/delta automatic starter asynchronous engine and provides actuation of screw block.

1.4.'l3.Fan Motor: lt is three-phase, fully closed (1P55 and 85) asynchronous engine providing the actuation of fam supplying
cooling air in air-cooled systems (lt is in self-fan design in some types.)

1.4.14.Min. pressure valve: Prevents transfer of air to the network until the pressure in the oil sump is 4.5 bar to ensure that oil
circulation in the oil balance of compressor will start soon and prevents network air to return to oil sump in sudden stops or
stopping, (serves as the check valve.)

1.4.15.Be|t tension flange: Screw block was moved to main engine flange by a carrier stay. Carrier stay is slid on flange by
means of a tension bolt and fulfills the belt tensioning operation.

1.4.16.8e1i and pulleys: Provides the power for screw block and poly V type belt and pulleys are used. For coupled types, special
coupling is used instead of belt and pulleys.

1.4.17. Pressure adjustment sensors (switch): Enables compressor to operate in the range of upper and lower pressure adjusted.

1.4.18.Relief valve: When the compressor reaches above max. 1 0% of upper pressure (bar) value adjusted, it relieves the air in
the air-oil separator tank.

1.4.19.Oi1 drain valve: Oil changes in defined periods are pedormed by this valve.

1.4.20.Oi1 f iller cap (plug): lt is in the inlet of the elbow on the side of tank. At the same time, lt detects oil level (Oil upper limit
is the level that the oil is seen at oil filler cap.)

1.4.21 . Oil level indicator: Used to checkthe oil level in the tank (While compressorworks, the oil foams.When the machine
stops completely, level is checked.)

1.4.22. Oil return Skavenge line: To prevent transfer of oil collecting in the lower part of the separator, it is taken by a pipe
(Transparent) and transferred to screw block bearing/suction.

1.4"23.Screw outlet pressure manometer: lndicates the pressure air-oil mixing (in the front of separator).

1.4.24. LCD Screen: lt is the panel allowing us see many functions (operating pressure, airloil outlet temperature, service
periods, failures, etc.) collectively by menu button (details about the programming is presented in the annex)

'l
1.4.25. Limit Pressure switch : Enables upper pressure of compressor adjusted to be above ,5 bar.(ln case of emergency)

1.4.26. Discharge valve : When the switch of compressor stops and/or in case of emergencies, it activates to help discharging
compressed air in the separator tank.

1.5.Lighting :

The below lighting system should be provided by the operator during operation and service of ATV-AV serial (dip type)'screw
compressor. The lighting with this technical specification is required to ensure safety and health requirements to be at maximum
level during service and/or possible misuse of relevant persons while operating and servlcing.

. Lighting with proper intensity should be provided for especially control panel
. Lighting supplied should not blind the operator in any way.
. Lighting to be used during especially service must be min. 100 lux.
. Under any conditions lighting used during control and/or service by the operator/user should lead to reflection, blinding shining
. Service/{ailure symbols providing warning and alarm conditions for ATV-AV serial (dip type) screw compressor are viewed on
LCD screen as lighted (Please see control unit programming specifications in the Annex for details.)

A Generarrairure
ffi ilt"rfl" Eil Freezins point
m
Service requirement nEil vtotor

Emergency stop ffl Oilfailure Power cut failure E*""""lve temperature

m \ ffi
WARNING!!
OUR COMPANY IS NOT RESPONSIBLE FOR DAMAGES ARISING FROM WHONG LIGHTING SYSTEMS
AND/OR INSUFFICIENT LIGHTING DURING OPERATION AND SERVICE

8
 DESCRIPTION AND MAIN SPECIFICATIONS

1.6. SOUND LEVEL

isolation in the cabinet panels of screw type alr
Noise isolation is provided by incombustible, special foam for maximum sound
noise isolation in cabinet covers'
compressor. Moreover, cap seal is used for vibration and

Example:
Sound level measured of ATV-45 screw type air compressor:

78,0 dB (A), K (measurement uncertainÿ);4 dB ( EN lso 3746) ambient was measured as 55,6 dB (A)'

1.7. TERMINOLOGY
zone, person chosen, operator, specialized
Meaning of terms can be found in "section 2- General safety standards": Danger
employees, authorized service.

1.8. Paint
paint technical definitions of ATV-AV serial (dip ÿpe) screw type air compressor are as follows and paint process employed
is

electrostatic Powder Paint.

the paint to have long-service life, cleaning of
The paint does not harm the human and environment health in any contact. For
should be kept away oxidizing factors (leading
compressor should be carried out in accordance with the instructions. compressor
on painted surfaces and thinner, etc' paint removal
to corrosion) and should never wiped with agents leading to deterioratioà
agents.
PE rough powder paint grey
Electrostatic powder paint: RAL 1003 PE rough powder paint yellow, RAL 7039

1.9. Training
provide compressed air. For safe operation of the
ATV-AV serial (dip type) screw ÿpe air compressor was produced to
compressor, it should be operated by persons witn speciat trâining- Theoretical
and practical training for operation, service and
provided for the personnel by specialist staff of Aydin Trafo
applications of ATV-AV serial (dip type) screw type aii compressor-is
trriah. San. Ve Tic. A.S (Please see H 6.3.Starting-up form)
the purposes other than foreseen and for the
AW-AV Serial ( Dip type) screw type air compréssor should not be operated for
has no direct or indirect liability'
purposes not conforming with the purposes described in this manual. Manufacturing company

WARNING!!
(DIP TYPE) SCREW
ONLY AUTHORIZED EMPLOYEES WITH THE TRAINING OF ATV-AV SERIAL
TYPE AIR COMPRESSOR CAN OPERATE THE COMPRESSOR.

(dip type) screw type air compressor must undergo training'

The person or persons other than authorized operator to operate ATV-AV serial
type air compressor should be understood by the operator
vyvr qur rv and service manual provided witn mv-ev seriai loip
operating type) screw
be kept as it will not be damaged externally since it can be necessary for the next processes'
and other authorized persons and should

GENERAL SAFETY STANDARDS

SECTION 2
GENERAL SAFETY STANDARDS
2.1. SAFETY
general accident prevention required by the regulations
The operator has to provide training for the employees about standards of
(dip type) scréw type air compressor, instructions and unit for the safety of operator and risks
of the country where ATV-AV serial
producer' For the production of a new machine,
to lead to accidents. safety/security of the operator is ihe primary concern of the
people try to foresee all possible dangers and therefore to takô sufficient safety measures. ln addition to this, the number of
various machines is very high. For this reason, this manual and especially
accidents arising from incautious or inexpertedly use of
carefully and potentially dangerous operations should be noted.The manufacturing company does
safeÿ standards must be read
not accept any liabilities arising from misusing ÂTV-nü serial (dip type) screw type air compressor and unauthorized
modi{ications.

FROM
THE MANUFACTURING COMPANY DOES NOT ACCEPT ANY LIABILITIES ARISING
NON-FOLLOWING SAFETY STANDARDS IN THIS MANUAL.

I
 GENERAL SAFETY STANDARDS

WARNING!!!

Please note this symbol and pafts where it is seen in this manual. This symbol indicates a potential danger condition or important
information for the user, operator and in the event of non proper performance of processes described, it warns about the fact that
it can lead to serious injury, death or risks to danger health for a long time.

2.2.TERMINOLOGY ADOPTED
Following description of various danger levels, conditions for the people and compressor direcfly and special definitions have
explanations.

Danger Zone: Every region having risk for the safety and health of a person around or vrcinity of the compressor. (2006/42 / EC
dlrective)

Person exposed operator: A person being within the danger zone completely or partially. (2006 I 42 I EC directive) person or
persons in charge of installation, operating, setting, service, cleaning, repair and transporlation of a compressor. (2006 I 42 EC
I
Directive)

User: The user is the entity, company or organization buying, leasing or managing the compressor and using it for the stipulated
purposes.

Skilled employees: lndividuals having training and experience necessary for a compressor, service and/or repair interventions
requiring special knowledge and operation, safety equipment and being able to recognize the dangers to arise from misuse of
the compressor and therefore to avoid them

Authorized service center: The authorized service having specialized and skilled personnel for any kinds of assistance, repair
and service works being complex and necessary for keeping the compressor in good order entitled by the manufacturing
company legally.

2.3. GENERAL SAFETY RULES AND SYMBOLS

2.3.1. General safety rules
* Please read
the operating manual before starting ATV-AV Serial (Dip type) screw type air compressor

WANING!!! lT lS FORBIDDEN TO START UP ATV-AV SERIAL (Dip type) SCREW TYPE AIR COMPRESSOR BEFORE

A READING AND UNDERSTANDING DATA IN THIS MANUAL OR PEHMIT THE OPERATION BY OTHER
PARTIES NOT READING AND UNDERSTANDING, BY THE UNSKILLED EMPLOYEES WITHOUT HEALTH
CONDITIONS NECESSARY TO OPERATE THIS COMPRESSOR.

* Before starting up ATV-AV

Serial (Dip Type) screw type air compressor, meanings of symbols and functions of
control panel should be understood well.

WARN!NG!!
PLEASE SEE THE OPERATING MANUAL FOR THE MEANING OF SYMBOLS ON CONTROL PANEL
( sEcTroN 3.5)

WARNING !!

A PLEASE READ THE OPERATING AND SERVICE MANUAL CAREFULLY AND CERTAINLY WHEN YOU
SEE THE ABOVE SYMBOL

10
 GENERAL SAFETY STANDARDS

-ATV-AV Serial (Dip type) must be operated by mature operator with perfect psycho-physical condition.

.ATV-AV serial (dip type) was produced to provide compressed air'

*operator of ATV-AV serial (dip type) must follow the main and simple behavioral codes to guarantee his safety and safety of
and ability.
other persons and to proteci niV-nV serial against potential damages and must have the necessary knowledge

-The person operating ATV-AV Serial (dip type) must be good for the purpose of the unit. while operating this unit, local
regarded'
opporiunities and conditions must be considered and third parties and especially children must be

"Please check uihether work space is occupied by people or objects or not.

"The contact with moving components or intervening with them is strictly prohibited'

. warning and caution signs mounted on ATV-AV serial (dip type) include beneficial information for the safe operation of the
machine.

.ln addition to the information in the manual, legal accident preventions regulations should be considered

.The operator using ATV-AV serial (dip type) should have the sufficient clothes because there are potentially dangerous and
are prohibited'
mobile components on the equipment" Loose clothes, wide-sleeve clothes, very loose trousers, loose overalls
operator should wear the sufficient clothes to prevent industrial accidents.
*ln case ol dangers to occur during the operation of ATV-AV serial (dip type) "Emergency stop" button on the indicator panel of
is in good order and
the compressor and serving to stop the entire system must be pushed. After making sure that everything
safety is ensured, the surnJbrfton should oe rreio down and rotated in the clockwise and safety prevention should be activated.
please make sure that "Emergency stop" is not held down. (See figure-4)
lf the equipmeni does not work for any reasons,

FIGURE.S

*Easily flammable and combustible materials must be kept away from the machine. Compressor must not be operated unless,special
safety measures are taken in potential combustible environment.

rThe area where ATV-AV serial (dip type) is operated is the "Danger zone"for all people without training about the compressor.

- r there sa person in the "danger zone" operator has to interfere immediately and remove the person from the relevant zone.

r3s,cr. ccmmrssioning the compressor, it must be placed in accordance with the requirements described in the lay-out
of the
ja.:.r- ng placed in separate area inside and outside the plant as guarded.
nieiu company.The compressor must be a

*Compi.:ss:' -;sr be located in a sheltered area against outdoor (Rain,snow,wind,sun,etc.)

*Lighting ercJ'c :r. .olrpressor must not blind the parties.

*Compressed a r co:a ^ec 'oy,,the compressor must not be directed to people and animals.

*After the comciesso. s cc:red due to service or failure, cabinet key/s must be removed and kept by the operator or the person
authorized by the use'

*Compressed air generaiec o., :-e .ompressor must not be utilized in respiration, plunge and food industry without extra precaution'

11
 GENERAL SAFETY STANDARDS

2.3.2. General Safety Signs

The compressor was manufactured to meet all labor safety and protection standards. Moreover, risks other than marked on the
machine properly with adhesive symbols may exist. These symbols (Described in article 6.2) are shown on ATV-AV serial (dip
type) and show different basic insecuriÿ and danger cases

WARNING

A KULLTHE OPERATOR MUST KEEP ALL SIGNS AND SYMBOLS ON THE COMPRESSOR CLEAN, IF
REMOVED OR DAMAGED, THEY MUST BE REPLACED.

By recoursing the tables in section 6.2, information should be read and understood well.

2.3.3. Protective Equipment

The operator serving ATV-AV serial (dip type) should wear sufficient clothes because there are mobile
WARNING!! and potentially dangerous components in the machine. Loose clothes, wide-sleeve clothes, very loose

A trousers, loose overalls, etc. are prohibited. Especially be careful about belts, scarves, silk scarves,
women ribbons, half-belts, necklace, long hair, etc. These objects can constitute danger for the
persons during service of ATV-AV serial (dip type). Wearing any kinds of clothes to deteriorate acting
capability or balance of person is strictly prohibited. Operator should wear sufficient clothes to prevent
industrial accidents.

2.4. ECOLOGY AND POLLUTION

For cleaning and service of ATV-AV serial (Dip type), please follow recommendations of manufacturing
WARNING! company and codes of the country that compressor will be employed. ln the event of damage of

A ATV-AV serial (dip type), please obey anti-pollution laws valid for the relevant country. lf necesèary,
fulfill various legal and internal operations for disposing compressor and,/or parts. Ensure that
parVparts following failure and periodical service of compressor will be disposed in accordance with
environment and health requirements of the relevant country. In cases of usey'leak of materials such as
oil, etc. specified in the instructions, leaving them around the compressor as waste, falling, slipping
and hitting dangers must betaken into consideration. Such wastes must be cleaned immediateiy. lt
must not be carried out in such a way to constitute danger for the environment and living beings.

2.5. SAFETY EQUIPMENT

ATV-AV serial (dip type) has the following safety equipment.

1- 1 button in the shape of red cork marked with "Emergency stop" to push in cases of emergency and danger is available. When
pressed, electricity connection is cut and every component working with electricity is shut down automatically
(See figure 5). The button is released by rotating it in the clockwise.
2- Pressure sensor (switch) enables compressorto work in the range of upper and lower pressure ad.justed.
3- Relief valve, When the compressor reaches above max. 10% of upper pressure (bar) value adlusted, it relieves the âir in the
air-oil separator tank.
4- Heat sensor, it stops when air-oil mixture reaches to 110 O C lor any reasons.
5- Limit pressure switch enables upper pressure of compressor adlusted to be above i,5 bar.(ln case of emergency)
6- Thermal relays ,cuts off the current of thermal relay circuits of both engtnes lnrhen ma n eng ne and fan motor draws excessive
current and in this case when failure lights are on.
Moreover, below components are used in light warning systems (Please see artjcle 1.5 lighting
)
General failure, oil failure, energy cut failure, emergency stop, freezing point, excessive temperature, excessive pressure, motor,
service requirement

2.6. SAFE SERVICE

Subjects such as service, replacement of parts, cleaning of ATV-AV serial (dip type) are described in service manual in detail.
lmportant points about service are as follows:
*Before starting
service or cleaning, part replacement or any other function for ATV-AV serial (dip type) the unit must be shut
down.
*During service
of compressor, service operation should not be started unless screw outlei pressure manometer indicating
in-system pressure on the compressor indicator panel is zero.
*Service
should not be started unless electric energy of the compressor is cut by main switch.
While compressor is running, service or repair should never be carried out

12
 GENERAL SAFETY STANDARDS
of compressor, condition of air hoses and
*
Tightness of screws of the equipment on the frame, screws of various components
periodically and necessary replacements should be performed to
pipes of relevant transmission installation should be checked
avoid combustion, efficiency loss and possible dangers'
*please note the conformiÿ of oils t.""ornr"ni"d by the manufacturing company, follow the forms stipulated by the
manufacturing company and replace filters, separator and oils'
*Use only original
Parts.
*Deactivation and tampering the settings of safety equipment is strictly prohibited'
*service of the machin" l].luËt be perfor-med oy tnê sritteo employee or authorized service personnel carefully in accordance with
instructions specified in this manual.
*Replacement of damaged or abraded parts should be got performed by skilled employee/authorized service personnel'
*periodical service operations for the operator, recordiÀg and followingthem by means of service check lisvprotective service
your compressor'
chart described in article 6.4 are necessary for safe and long-service life of

2.7. TRANSPORTATION
of supplier to the center of customer' This
This section is related to the transportation of ATV-AV serial (dip type) from the center
at the stage of sales contract' Machine
step can be performed by the supplier or the customer depending on the agreement
for transportation. while transporting the compressor
should be supplied with all necessary certificates to obey the laws fôreseen
*ây r. the below forklift warning symbol/logo will be in the middle of pallet
should be handled by qualified persons in a balanced
should be handled without vibrating'
truck or forklift carrying skids. The floor should be proper while transporting. compressor

2.8. DIMENSIONS OF COMPRESSOR

following symbols'
Dimehsions of ATV-AV Serial (dip type ) screw compressors are indicated with the

Width of the compressor ( W) : mm

Length of the comPressor ( L) : mm
Height of the comPressor ( H ): mm
Weight of the comPressor : kg

(Note: See Table-1 for the dimensions.)

FIGURE . 6

13
 THE USE OF SCREW COMPRESSOR

sEcTtoN 3
OPERATION OF ATV - AV SERIAL SCREW COMPRESSOR

3.1. CONTROLS BEFORE COMMISSIONING ATV-AV SERIAL SCREW COMPRESSOR

compressor unit was subject to all tests at our factory and shipped in the package.
ln addition to this, the group should be
checked generally before first starting up due to damagês to occui while
transporting and installation.
*ls the
compressor located in well-ventilated, dust free place and was free flow of
-ls the oil level cooling air for air oil cooler ensured?
OK?
"ls the connection of compressed air network OK?
*ls the voltage proper?
ls electricity power connection OK? (400 V-3ph- 50 Hz, proper section cable)
*ls grounding
connection OK?
*Do V
belts rotate manually in rotation direction?
*Are
all instruments sound?
*Are
the directions of engine rotation correct? (ln spite of phase seguence relay, please pay
attention to directions of rotation for
being in the direction of arrows)

REPLACE THE olL lNoll FTLTER coMpoNENT BEFoRE srART-up oR NoN-usE pERto;GG-
THAN 2 MONTHS AND POUR ABOUT 1/2 LITER OF OIL IN AIR SUCTTON NOZZLE OF THE

3.2. FLOOR FOR ATV.AV SERIAL SCREW COMPRESSOR

-ls the floor
sound?
*ls the unit
located on the floor balanced?
*Please
make sure that the place for compressor wrll be sound enough for the weight
*The of compressor.
floor where the compressor will be installed should have smootÀ screed
and/or furnished with plate stone.

3,3. HANDLING AND PACKAGING OF ATV-AV SERIAL SCREW COMPRESSOR

screw block and main engine are installed on carrier stays and fixed to lower frame
by rubber mounting. By this means, vibrtions
during operation are not transmitted to lower frame and so cabinet. carrier
lower frame can be handled by forklift and pallet truck.
Fixing bolts of carrier stays are designed to prevent transportation damages.
So transfer is very easy in the plant. All compressors
are shipped as wrapped with vacuum nylon and stretch film.
Strict attention was paid not to damage cabinet and especially control panel
during loading, unloading,transportation and
unpacking.

3.4. INSTALLATION OF ATV-AV SERIAL SCREW COMPRESSOR

Compressor unit should be installed in dry, well-ventilated and dust free environment.
For the cooling air from cooler at the
units to be installed in covered volumes not to warm the atmosphere. it should
be discharged compietely. compressor lay-out
can be found in article 6.9 in detail.

check valve must not be instalied between compressor outlet and the warehouse.
other important point for the instailation of
the compressor is to leave space for easy service and maintenance (see Figure-7)
After the compressor has been installed,
fixing screws of carriage stays (red) must be unscrewed.

NOTE: Cooling air of the cooler in winter can be used for heating the business
environment. Hot air can be distributed to the
atmosphere via a duct (load loss should not exceed 5 mmSS). licooling
air is dusty, it should be transferred to the duct with
measure.

14
THE USE OF SCREW COMPRESSOR

NOT BE
IF THERE IS NO SEPARATING SYSTEM, SCREW AND PISTON TYPE COMPRESSORS SHOULD
OPERATED TOGETHER. THIS SEPARATING MECHANISM CAN BE A JOINT TANK. WE RECOMMEND
YOU TO FIX BOTH 2 TYPES OF COMPRESSOR TO THE SAME TANK WITH SEPARATE PIPES.

1- Flexible Hose
2- Air Hose
3- Valve
4- Discharge Line

FIGURE . 7

3.5. ELEMENTS OF ATV-AV SERIAL SCREW 3.6.COMPRESSOR INDICATOR PANEL

o
Appearance:
. Controlled by 6 touch buttons on the front panel.
. lndustrial type emergency stop button is available. lf pressed down, lt is locked
and unlocked by rotating.
. 95 components "LCD" display ls available
Buttons:

"Start"
ffi
\w.
"Stop"
O
Error Detetion "Reset"

o lncreasing the value

0 Decreasingthevalue â
"Entel'
FIGURE - 8
Emergency STOP

1: Basic screen value from 0,1 to 999

2" Basic screen unit BAR, PSl, oC, oF
J. Operator menu screen value from 0,1 to 9999
4: Operator menu screen unit BAR, PSl, oC, oF, Hr, LHr

olstart Motor G't-oaO

Service/failure symbols : [l s",,i." Al r"',rr", AlarmMarning/stop

15
 THE USE OF SCREW COMPRESSOR

Status screen:
P1 indicates the operating status constantly iP1 indicates the operating status constantly ,'status
in symbols,,

e Stand-by: compressor has been started but in stand-by mode. When pressure is necessary,
main engine will work or if remote control is activated when load command is received,main
engine will work.

@@ Main engine engine is on : Compressor main engine is on however suction valve is off ,,ldled,,

@ @ 6lcorpr"ssor is on load : Compressor main engine is working and suction valve generates open
air.

Failure Conditions:

Stable in alarm Flashes in emergency stop

ln both cases failure (warning) and emergency stop symbol is displayed on the operator
screen.

Error Codes

3-6. ELECTRTCITY SYSTEM OF ATV-AV SERIAL SCREW COMPRESSOR

Electricity system of each compressor is located in a control cabinet for easy intervention
by use of the most reliable and high-
quality components. tsy means of cover seal, total sealing is achieved.
Control panel is available on the cover of electricity
cabinet.

3.6.1 Electrical connection of ATV-AV Serial screw compressor :

Main engine and fan motor of the compressor are the motors with 380/400 volt voltage
and tri-phase motors at 50 Hz frequency.
Voltage of control circuit is 24 volts. Unit feed cable (3 phase + ground) should have lhe
section not to Iead to voltage drop. Feed
cable should be chosen based on the compressor power for the safely. Moreover. it
should be guarded with a protective switch
and be close to the compressor. Please see the below table for proper cable sections (Table
2)

GUÇ KABLO KEStrTtr StrGORTA

MODEL
(KW/HP) (mm2) (A)
ATV-15 15t20 4xGmm 404
ATV-18 185125 4x10mm 504
ATV-22 22130 4 x 10 mm 504
ATV-30 30140 3x16mm+10 634
ATV-37 37 150 3x25mm+16 BOA
ATV-45 45t60 3x25mm+16 100 A
ATV.55 3 x 35 mm + 16 125 A
ATV-75 75 I 100 3x50mm+25 160 A
ATV-90 90 I 125 3x70mm+35 200 A
ATV-110 110/150 3x95mm+50 250 A
ATV-132 132 I 180 3x120mm+70 250 A
ATV-I60 160 I 220 3 x 150 mm + 70 300 A
ATV-2OO 200 / 270 3x185mm+95 400 A
ATV-250 250 I 340 3x240 mm + 120 500 A
TABLE - 2

NOTE:

1-IF CABLE LENGTH IS MORE THAN 70 M, USE CABLE WITH BIGGER SECTION.
2-JOINT SHOULD NOT BE USED FOR THE CABLE.
3-DO NOT SUPPLY POWER FROM COMPRESSOR BOARD TO THE OTHER EQUIPMENT.

3'6'2. Electricity circuit diagram of ATV-AV Serial screw compressor (controi/power

diagram)
PIease see 6.7 and 6.8 for control and power circuit diagrams.

16
 THE USE OF SCREW COMPRESSOR

3.6.3. Start-up:

.supply current for the circuit by positioning main switch to (1) in the compressor room
.Disengage emergency stop switch in the arrow direction and press Reset button and remove symbols of service/failure in
section 6 from LCD screen.

*press Start button and start the machine. ln this case, status symbols numbered 5 are displayed on LCD screen' When main
starts to generate air. when tank
engine in triangular, status symbol numbered 5 is dispiayed on Lco screen and compressor
factory, éo*pr"""or idles automatically and time of idling set starts. when the time
pressure reaches to the upper limit set at the
of the tank releases and
is up, compressor stops completely and now it is in automatic standby mode. Air in the outlet
when the pressure is at lower limit set'
compressed air is transferred io the network and network pressure in the tank lowers.
starts working automatically. valve is shut off again and pressure rises.
"orpr"."or
lI the compressor operates in different pressure range than factory-set
pressures, provided that maximum pressure on the label
in annex')
will not be exceeded, it can be set by indicator panel (details about programming can be found

IF THERE IS NO AIR PRESSURE IN THE SYSTEM, PRESSURE SWITCH CANNOT BE SET'

OBSERVE
MAKE SURE THAT OPERATING PRESSURE' OPERATING
FAILURE SIGNALS ON THE PANEL AND
96"C THE
TEMPERATURE IS AT THE REQUIRED VALUE. IF OPERATING TEMPERATURE EXCEEDS
BE CHECKED' PLEASE
PLACE WHERE COOLING SYSTEM AND/OR MACHINE IS INSTALLED SHOULD
SEE FAILURE SECTION FOR MORE INFORMATION

3.6.4. Star delta no load operation

ln other words, suction check solenoid
Automatic star- delta perlorms no-load operation as main engine shifts from star to delta.
to suctiàn check valve. when the compressor shifts from star connection to
valve is not powered and control air is not transferred
to load"
delta connection, suction check solenoid valve is immediately powered and compressor shifts

3.6.5. Star-delta starting

comprises of 3 star contactors
By this means, during stàrt-up, it is avoided that electric motor draws very high current. Star-delta
with star contactor and enables
and a time relay and phase-protected phase sequence relay. Main contactor shut of{ contacts
about double current than nominal current for very short
motor to operate with star connection. At this moment, the motor draws
of engine revolutions, control of time relay opens star contactor and then shuts off
time. After 3-5 seconds necessary for rising
from to delta.burrent drawn by the motor is shared by main contactor and delta contactor
delta contactor. so motor shifts star
and fed. Abrasion of contactors reduces.

3.7. FLOW DIAGRAM OF ATV-AV SERIAL SCREW COMPRESSOR

1-Air suction f ilter

2-Air suction check valve
3-suction check solenoid valve
4-Screw block
5-Air-oil separating tank
6-Air cooler
7-Oil cooler
B-Air-oil separator
9-Oilfilter
1 0-Thermostatic mixing valve
1 1-Main engine
12-Fan Motor
13-Min. Pressure valve
14-Belts and pulleys
1 5-Pressure adjustment sensor (switch)

16-Relief valve
r(-----)
17-Oil discharge valve
18-Oil filter plug
19-Oil level indicator
t I 20-Oil return Skavenge line
AIA LINE AIR.OIL MIXING LINE 21 -Screw outlet pressure manometer
LINE
COMPRESSED AIR OIL LINE 22-LCD screen (operating pressure indicator)
CONTROL LINE POWER LINE 23-Têmperature sensor (air-oil outlet line)
24-Limit pressure switch (Bkz. RESIM 1-2-3-4)

FIGURE . 9 (See Figure 1-2-3-4)

it
 THE USE OF SCREW COMPRESSOR

3.8. CHECKS FOLLOWING INSTALLATION OF ATV-AV SERIAL SCREW COMPRESSOR

' ls the compressor installed in well-ventilated, dust-free rocation ?

ln general, the cooler ambient air is for all compressors, the higher alr efficiency is. Moreover,
cooler air provides less heating of
compressor block and motors and long-service life. For this reason, measures should be taken
for good ventilation and to prevent
holding hot air discharged from successive cooler ln the environment.
Duct inlet is available on the cabinet of AYDIN TRAFO screw type air compressor to
connect the hot air discharged from air-oil
cooler to a duct. Air collected by the duct can be discharged fulÿ and can be utilized for heating
office or the plantl Air resistance
should not be higher than 5 mmSS in such a duct. otherwise, flow of fan decreases and neceésary
cooling cannot be provided.
This leads to failure of compressor as a result of excessive temperature. Another factor for failure
due to eicessive temperature
is the dusty environment. Air-oil cooler surfaces of units working at dusty environment
without taking measures will be covered
by dust and necessary cooling cannot be achieved. oust maÿ damage control devices and electiical
equipment other than
heating and lead to failures.

' ls the floor sound? ls the unit balanced? Were the warnings about location followed for installation?
. is the oil level proper?
Oil filler plug, oil level indicator, oil discharge valve and inlet outlet connections are available
on separator tank. Since screw type
compressors operate by spraying abundant oil, when there is no oil they may stick by winding
screws in a few seconds. For this
reason, compressor must have oil all the time and oils other than speciiied in service manual
should not be used.
AYDIN TRAFO Screw compressors are shipped with oils and tested at the factory. Please
check the oil level before starting up
the unit since oll can discharge or decrease for any reason.
The oil level should be up to oil filler cap pass for the first filling. lf oil level decreases very
much after short time operation,
compressor should be stopped and the same oil should be added after the pressure in
the sümp is zero.
Brand and type of the oil filled at the factory is shown on warning label. lt is recommended
thai various brands and types of oil
should not to be mixed, if oil brand and type needs to be changèd, existing oil should be emptied
in full and new oil should be
filled.

. ls compressed air network connection performed

?
Connections from unit outlet to compressed air tank and to air distribution network should
be performed properly and leaks
should be limited' Connections to the unit should be free of stress, (selËcapped hydraulic
hose is recommended for this
connection.)

. ls electricity power connection performed? ls

voltage proper?
safety measures should be taken for electrical connections. Before commissioning, voltage between
three phases should be
checked, this process is repeated at working condition for the first load and conformity of vàltage
should be confirmed.
. ls ground connection made ?
Since leaks of electrical devices may be dangerous for the person, ground connection must
be made by a separate
cable

. Are screw belt and fan enclosures installed

in place ?
Enclosures should be installed to prevent damage for the operator during transportation,
nstallation and working.

' Are there any breaks for all connections (cable, instrument. air-oil pipes. etc)?
Check visually.

. Are motor/screw revolutions correct?

When current is supplied from main switch to the unit, the screen is disp ayed in n5 63ie;
ca.Ê lf rolatron direction is accurate,
values of pressure and temperature are displayed on the screen. lf rotation direct on 1o:
s accJ:ate. E.0050 error code flashes
on the screen. At the same time one of the lights on MKC (phase sequence phase protect
o. re a,u/ relay is in red position. ln this
case, switch off the current from main switch and replace two of phase ends f rom switch r:ret r^er
cLirrent is supplied to the unit
by main switch and see that both lights on MKC relay are green and at the same trme
obser,",e tiai pressure and temperature
values are displayed on indicator panel instead of error cooL. ln this position, press
of rotation direction visually @ stari b,rion and check the àccuracy

18
 THE USE OF SCREW COMPRESSOR

3.9. OPERATING PRINCIPLE OF ATV-AV SERIAL SCREW COMPRESSOR

This compressor is automatic starVstop type. lf the air requirement changes greatly and big air tank is present or back-up air
capacity to activate automatically and automatic idle/on load control is provided. ln the circuits that requirement is low, if the
pressure in compressed air network lowers, idle time relay activates and it works idle until the end of set time. Compressor breaks
the power of engine coil by activating the contact in the end of time and stops engine. ln this case l(D symbol, temperature and
pressure values are displayed on the screen of indicator panel. So it is understood that compressor is in stand-Qy nnode and when
iank pressure lowers than the set level, it will start automatically. When the compressor staits again@ anO H @] symbols
are displayed on the screen

3.10. OPERATION OF ATV-AV SERIAL SCREW COMPRESSOR

Check oil level, electriciÿ status and whether air tank outlet valve is shut off or not before starting all the time. Position main switch
(1) and supplpgrrent for the circuit. Disengage emergency stop switch in the arrow direction and press Reset button and remove
svmbols of [/\| service/failure in section 6 from LCD screen. Press Start button and operate the machine again. ln this case,
O @ Gtatrs symbols are displayed on LCD screen. When main engine shifts to delta, status symbol numbered
5 fil is displayed on LCD screen and compressor starts to generate air. When tank pressure reaches to the factory-set upper
limiff,compressor shifts to idle running automatically and idle running time set slarts. When the time is up, compressor stops
completely and now lt is in standby mode automatically. Valve at the outlet of tank is opened slowly and delivers compressed air
to the network. When the pressure reaches to set lower limit, compressor starts to run automatically. Shut off the valve again and
\ so the pressure will increase. Check temperature and pressure while operating. lf there is a problem, do not operate the
I
I
compressor unless the failure is eliminated by an authorized person.
I 3.10.1 Normal operation:
Following controls should be pedormed before commissioning the unit all the time.
Check the oil by the oil level indicator of the tank. lf the oil is missing, check the reason and add. lf the compressor has stopped
due to q [çrilure, l/Ù1| failure symbol is displayed on LCD screen. After the failure is remedied, failure symbol is deleted by reset
buton @ on the-control panel and the system runs again. Valve connecting the compressor to the network is shut off again and
water diêcharge valve under the compressed air tank oI the network is switched on again to discharge condensate water.

3.10.2 Start-up:
Press Start button and start the machine. ln this case, status symbols numbered S @ @are displayed on LCD screen. When
main engine shifts to the delta, status symbol numbered 5 E is displayed on LCD screen and compressor starts to generate
air. When tank pressure reaches to the factory-set upper limit, compressor shifts to idle running automatically and idle running
time set starts. When the time is up, compressor stops completely and now it is in standby mode automatically. Valve at the outlet
of tank is opened slowly and delivers compressed air to the network and network pressure in the tank decreases. When the
pressure reaches to set lower limit, compressor starts to run automatically. Shut off the valve again and so the pressure will
increase. When condensate water is discharged from water discharge valve, this valve is shut off.

3.1 0.3. Stopping compressor

Unless an important event occurs, compressor should not be stopped suddenly by pressing emergency stop button while running
on load. lf the compressor ls stopped in the end of work, make sure that there is no pressure in the system and then press Stop
button. At this moment, if compressor reaches to upper pressure limit and is in idle mode, main engine will stop completely, if your
compressor runs on load, when you press Stop button, the system will be in idle position and main engine will stop completely
after 30 seconds. Then shut the valve at the outlet of tank off and lock the switch by pressing Emergency stop switch. Red LED
next to reset button flashes. Cut off the current by positioning main switch to (0) for safety. ln the end of daily work after
compressor is stopped, discharge is fulfilled a little from water discharge inlets under the compressed air tank and water separtor
and water in the pipes is discharged in the evening and so possible freezing at night is prevented.
\I 3.10.4. Stopping compressor for a short-time
lf the compressor has been stopped suddenly while on load for any reasons, lock of emerg.pcy stop button is disgngaged in the
I arrow direction before starting up. Then error code displayed on the screen is deleted by @Reset button and f,ll start button is
pressed.ln this case,compressor will start automatically,if the pressure set in system is higher than
on-load,although ftl symbol is displayed on the screen compressor will not start and will be in automatic standby mode.
When system pressu-re reaches to lower pressure set, compressor will start automatically.

3.11. OPERATION OF THE MACHINE

Please follow recommendations of manufacturing company and laws of the relevant country for cleaning and service of ATV-AV
serial screw type air compressor.
Compressor must not be operated unless technical controls for pressure tank and other components of the compressor as the
legal liability are carried out by the authorized parÿ and/or organizations.

WARNING !!!

A OUR COMPANY IS NOT LIABLE FOR NON-PERFORMANCE OF PERIODICAL TECHNICAL CONTROLS

OF COMPRESSOR AND PRESSURE AIR TANK!!!

19
 THE USE OF SCREW COMPRESSOR

ln the event of damage of ATV-AV serial screw type air compressors, anti-pollution codes effective in the relevant country should
be followed. lf necessary, various legal and internal processes for disposing machines and/or components must be fulfilled.
Our company is not liable for efficiency loss, negative health and safety conditions to arise from operation of compressor,
pressure tank and transmission line installation for different applications and forms other than described in the contract, offer
and/or presentations of the operator/in this manual and instructions.

3.12. CE DECLARATION OF CONFORMITY

ATV-AV Serisi Vidalr Hava Kompresôrlerinin CE uygunluk beyanr 6.10. da belirtilmi tir.

3.'r3. ORGANTZATTON
The user must provide training for the operation of the compressor. The compressor was designed for the qualified, well-trained
operators for professional operation and service. Training is provided for the purpose of sufficient operation capability for the
operators. While operating, it is important to create typical operating steps in case of emergency and to perform necessary
exercises. The user has to provide proper training for the operators of the machine and service technicians.
Operating and service manual should be read and understood and followed as an integral part of the mach ne all the time and
should be kept in the machine throughout the service life as protected against external and internal factors Operating and service
manual should be easily accessible.

3.14. AUTHORIZED SERVICE AND CONTACT

The manufacturing company provides warranty for ATV-AV serial screw type air compressor for twenty lotr Q|) months as of the
date of purchase. This warranty is applicable for free part replacements and repairs to be carried out upon understanding that
ATV-AV serial screw type air compressors is out of order with a direct inspection by the technical departmenr of the manufacturing
company. Except liability of direct or indirect damages, the warranty is limited to only material defects and the manufacturing
company will not have any obligations if reasons of part damage are disassembly, tampering or repair by parties other than the
factor or authorized services. ln addition to this, cielivery certificate will be valid. Replacement of parts described in spare part
replacement table (Article 4.10) as a result of periodical controls stated in this manual within the warranty period by the service
lives (for the compressor to have long service life), replacement of necessary critical components are pedormed against cost.
Reasons and solutions of failure of ATV-AV serial screw type air compressors are explained in service manual. To re[air failures
not described in the service manual, please contact manufacturing company. Updated authorized service contact information can
be found at www.aydintrafo.com.tr to notify the failure exactly.

SERVICE

SECTION 4
4.1- CONTROLS UPON DELIVERY OF COMPRESSOR
Please make sure that you have delivered 2 cabinet switches. oii drain hose and handle, 6.3, 6.4, 6,S, 6.6, 6.7, 6.g, 6.g, 6. j 0, 6.1 1
and service manual with ATV-AV serial screw type air compressor.
4.2.GENERAL SERVICE RULES
No service operation should be performed on ATV-AV serial screw type air compressor without considering general safety
measures explained in 2.3.1.
4.3. SHORT PERIODICAL SERVICES
ACheck oil level of ATV-AV serial screw type air compressor frequently. Only use the oil stated in the manua . Discharge
condensate water in separator tank with short-term ntervais. Remove air filter element and clean inside-out oy the air with 2-3
bar pressure frequently. Replace airloil filter element and separator filters in time. pay attention for non-blocktng of air oil cooler
surfaces by dust and dirt. clean them inside-out by compressed arr at rntervals.
4.4. OIL CHANGE
The first oil change of ATV-AV serial screw type air compressor is recommended in the end of 1000 operation hours rn f ull (please
see table 4 for detailed information). Next oil changes should be done rn the end of each 2000 operation hours or at least once a
year. lt is recommended to change the oil more frequently in abnormal operating conditions, high ambient temperature. and dusty
ambient air. Filler plug is removed and put biu oil drain valve when the oil is cool, Oll filter is removed if you are sure that there is
no oil in the separator tank. Fill the oil until the pass of plug as seen in the figure from Tiller cap. Remove belt enclosure and turn
the belt manually for a few times in the arrow direction and reinstall the belt enclosure and run the compressor for sho( time.
When the oil temperature is 55/71 'C, thermostat circuit activates and oil is circulated through the cooler. After running the
compressor in this way, stop it again and wait for oil foaming to be stabile and check the oil ievei indicator again. lf there is
reduction, add the same oil. The compressor is shipped with full oil. Oils used for the compressors f reeze at - 30;C and fire at +
2'lO"C.Viscosity class is ISO VG 46.

SHELL CORENA 53 R 46
MOBtrL RARUS 424
TOTAL PRESLtrA 46
TABLE - 3
20
4-4.2.Oildrain:
plug in the inlet of the
Make sure that fhe compressor stops completely and there is no pressure in the tank' Remove blind
pass the hose and handle supplied with tÉe compressor. Switch the valve on and drain the oil (switch the filler plug on).
valve.
when the oil is drained in full, close the valve and blind plug tightly. (see figure-10)

Oil filler nozzle (plug)

Oil level indicator Max. oil level

Oil drain valve

WARNING! (to be opened Tor only oil draining)

FIGUBE 1O

4.4.3. Oilfilling :
Fill the recommended oil as it !s seen at pass level by oil filler nozzle. Place the oil filler plug and operate the compressor
by
the oil leaks. Stop the compressor soon and check the oil level again (see Figure-9)
fulfilling the conditions of oil change. Check

4.4.4. Safety measures :

Service and maintenance operations should be carried out by skilled authorized personnel.
-Obey warning and safety labels on the compressor.
-Use proper sets for service and maintenance'
-Stop the compressor and cut off the power from protective switch before service and maintenance operations. Take necessary
measures to prevent switching the electricity on'
-Before removing components under pressure, make sure that air pressure has been released completely. when the oil is
drained, the temperature should be lower enough not to burn the hand.
-Do not use flammable solvent io clean the components. Be careful not to inhale potentially toxic solvent vapours.
-Pay attention to cleaning during service and maintenance'
-No welding and modification should be made on pressure vessels.

When service is completed ;

present in the
Do not operate the compressor unless you check that all connections and enclosures are complete, no set mold is
cabinet and cabinet covers are closed.
WARNING
AyDrN TRAFO MAK. SAN. TIC. À.S tS NOT RESPONSIBLE FOR PERSONAL AND IVIATERIAL LOSS

A AND DAMAGES TO ARISE FROM DISREGARDING SAFETY MEASURES DESCRIBED IN SERVICE

MANUAL AND OTHER GENERAL SAFETY MEASURES DURING SERVICE, MAINTENANCE AND
NORMAL OPERATION.

4,5. REPLACEMENT OF OIL FILTER

Oil filter elements should be replaced once every 2000 hours. Loose old filter elements by removal apparatus' Prevent
contamination of cabinet by the oil by a cap under it. Dispose by taking all measures not to pollute the environment. Lubricate
rubber seal of new oil filteielement Àtigrrtty and fill oil and pass it.Tight manually until the seal is tight. Check leaks visually
by
operating the unit (see Figure 1)
-1

FIGURE 11

21
 SERVICE

4.6. REPLACEMENT OF AIR SUCTION FILTER

Air suction filter element should be replaced once every 2000 hour. Moreover, suction filter element should be cleaned by air for
minimum 2 a month until the time of replacement.This operation should be implemented by the ai al2-3 bar pressure as inside-
out. This can be performed more frequently in the dirtier locations. When air suction filter element is removed for cleaning or
replacing, necessary measures should be taken to prevent dirt or part penetration. While compressor is running, suction filter
element should never be removed. (Figure-12)

FIGURE.12

4.7. REPLACEMENT OF AIR-OIL SEPARATOR FILTERS

This element works with 0.2-A.4 bar pressure loss in general.This difference is the pressure difference seen in manometer on
side and pressure displayed on LCD screen of control panei. When this difference rises to 'l .0 bar to 1 .2 bar optionally, separator
should be replaced. Stop the compressor and release network pressure in the separator tank. Remove all hose connections and
flange bolts of flange core on the separator tank. Remove the old separator as shown in the figure (see Figure-13) and replace
it. Reinstall all connections removed. Start the compressor and check the pipe leaks, Conditions for compressor replacement are
as follows:
- Expiry of service life
* Pressure difference between two manometers/sensor is higher than min. 1,
barl
- Abnormal oil reduction and seeing this oil on the tank or line (Separator explosion!)
. Service life of the compressor is directly proportional with cleaning and replacement of air filter, suction padding and
replacement time shortens retro respectively ln dusty environment!
. Air and air filter element should be replaced when replacing the separator!

4.7.1 Safety measures for air-oil separator replacement

Disconnect electricity by the switch. Then check that pressure in the tank is zero (0) by screw outlet manometer on the control
panel.
1. Remove pipe connections numbered 1,2, 3,4 shown on the figure in detail, socket number 5, Skavenge line pipe number 6
and screws number 7.
2. Rotate flange cover 90" in its place and disengage ground spiral tip connected to the separator and remove flange cover and
its components from separator tankl
3. Remove the separator with its seals by pull ng uplards:
4. lnstall new separator with seals and nstall all compcren'ts resoectrvelvl
5. Afterfulfillingnecessaryconditions,checktheieaxsalcc."ectc.rc"ts:Fgure-13)

Flange Cover
--
,,- SeperatorTop Seal
Grounding
Spiral _,-.* Seperator

Bottom Seal

Seperalor Tank

7 (Çevrede 8 adet)

FIGURE.13

22
4.8 BELT REPLACEMENT (FIGURE-14)
Loose"A"tensileboltI
Loose " B-C-D " bolts by checking nuts at back ends!
Move belt tension flange in loosing direction and release the belt!
Rotate pulleys in the rotation direction and remove the belt!
ducts in belt and pulley.
Rotate the belt in original size slowly in the rotation direction and insert it. There are the same number of
Be sure that belt sits in ducts on both pulleys!
Remove the gaps of " B-C-D " bolts in the direction of screwingl
Tighten "A" tension bolt and adjust the required tension for the belt!
Tighten 'B-C-D" bolts PreciselY!
CÀeck that front sudaces of both pulleys are in the same line with a proper gauge!

4.8.1 Safety measures for belt replacement:

Rotate the pulleys manually once-iwice. Do not leave any tools on rotating ob.iects. while performing these
operations, follow
of the compressor (may be in standby automatic mode).
safety rules. Make sure that electricity is disconnected for Àon-operation
Before starting, remove belt enclosure and reinstall after the operation.

4.8.2 1. Belt tensioning mechanism (Figure-14)

Loose " B-C-D " bolts by checking nuts at back ends!
Tighten " A " tension bolt and adjust at requested tension!
lf belts stretch lor 7-g mm as a result of 3kgf pressing on the belts, it means that belt tensioning is successfully completed
!

.B-C-D" bolts completely!

Tighten
Power and start the compressor again. check correct rotation of the belt!

Engine Block

Loosening Poly V Belt

Éngine Pulley i'

FIGURE - 14

WARNING!
TO PREVENT BREAKING OR EARLY ABRASION OF A NEW BELT (NON-DEFORMATION) BELT

A TENSION SHOULD BE CHECKED. TENSION SHOULD BE CHECKED IN THE END OF THE FIRST 1OO
OPERATION HOURS AND IN THE END OF EVERY lOOO OPERATION HOUR AND TIGHTENED AGAIN
IF NECESSARY.

4.9 CLEANING OF ATV-AV SERIAL (DlP TYPE) SCREW TYPE AIB COMPRESSOR
with
.Suction padding/foam serving as the preJilter outside the cabinet should be removed from the enclosure and cleaned
compressed dry air PeriodicallY.
. Cabinet covers should be opéned and air-oil radiator should be cieaned with compressed dry air as insideout and dust particles
on radiator cores should be cleaned.
. Air filter should be removed at certain times and cleaned with compressed dry air as inside-out and removed.
. Sudace of cabinet should be cleaned with non{lammable and non destructive solvent for the paint.
. Switchboard and electrical panel should be cleaned with compressed dry air not exceeding 2-4 bar periodically.

23
 SERVICE

4.10. TIME FOR REPLACEMENT OF SPARE PART AND FOLLOW-UP CHART

ENGINE TIME FOR REPLACEMENT OF SPARE PART

COMPRESSOR SCREW
TYPE POWERS (KW) TYPES AIR SUCTION AIR. OtL SUCTION PADDING
FILTER OIL FILTER
SEPERATOR / FOAM
FIRST
REPLACEMENT lOOO HOURS

30-75 EVO 9 / 8201

OTHER
2000 - 4000
REPLACEMENT 2OOO HOURS 2OOO HOURS- 4000 HouRS..
ATV HOURS
(DrP TYPE)
FIRST
REPLACEMENT lOOO HOURS
90 - 250 B.260 t ......_.
OTHER 3000 - 6000
3OOO HOURS 3OOO HOURST 6000 HoURS--
REPLACEMENT HOURS

TABLE - 4
- OIL OF COMPRESSOR
) SHOULD BE REPLACED WHEN OIL FILTER IS REPLACED
-) IFTHE NEXTOIL
REPLACEMENTTIME FOLLOWINGTHE FIBST REPLACEI,lE\,T
REPLACE THE OIL ONCE AYEAR
-iO=S NOT EXPIRY IN ONEYEAR,
"-) AIR-OIL SEPARATOR CAN WORK FOR ABOUT 4 OOO _ . 5OO ô OCC _ - 5OC HOURS BY THE
ryPE OF SEPARATOR
USED PROVIDED THAT OIL OF COMPHESSOB OIL FILTER ELEI,,IENT AND AIR FILTERS ARE REPLACED
ON TIME AS
OF THE DELIVERY TIME.

NOTE: FOR 55 KW AND ABOVE MACHINES, GREASE IN THE TIME, TYPE AND QUANTITY
SHOWN ON THE LABEL
SHOULD BE PROVIDED FOR BEARING OF ELECTRIC MOTOR (WITH GREASE FITTING).

24
 FAULTS, CAUSES AND SOLUTIONS

4.11. FAULTS, CAUSES AND SOLUTIONS

INDICATOR A REASON I SOLUTION §

A There may be no Power. Check the power.

B Control fuse may blow. Check the fuse.

Engine proteciion relay has switched off the circuit. Check the light on
c Network voltage may be low,
It, ii it is off, there is a failure for phases. The most common condition is
unbalanced or reverse.
the phase failure while compressor is running in the locations with low
voftàge and correction of this situation after the compressor stops' To
understand it, check light of engine protection relay during star- delta
1 Compressor operation of the compressor, if the light is off when the compressor
does not stands and compressor stops, it means that voltage is low'
work.
Compressor may have stoPPed Tor To understand it please see farlure lights on the panel and relevant
D articles-
any failure.
@voltage drop in the installations made with
Section of power inlet cable is not
thinner section power inlet cable than recommended' Make the
suff icient.
connection with the cable having diameter recommended and at the
recommended distance.

Voltage may be low. To be sure of that while your compressor is at stop position, measure
the input voltage and start the compressor as measuring, lf the
voltage is 360 v and lower than it the problem arises from the network
or installed power of your Plant.

H Ambient temperature maY be low lf ambient temperature is low, oil may thicken and complicate the
operation oÏ compressor.

The air sound heard when the compressor is stopped is the sound of

I
Compressor may be operated without
discharging internal Pressure discharge. Wait Tor stopping oT this sound or see that internal pressure
ls discharged by pressing control button.

Suction valve may be out of order' (1 1-45 kw models) suction valve remains open for short time during the
initial start-up and then closes (during star operation), if it does not
occur, a mechanical problem for the suction valve is possible (control
air cannot push suction valve flap).
Check manually that when the compressor stops and there is no
internal pressure, flap moves back and forth freely, if the Tlap runs hard,
contact the service. (55 kw and above models) check that the flap is
closed completely if it is not, the flap has Iost its position, contact the
2 ffr3ïnî I
service companY.

Minimum pressure valve maY be out
of order.
lf minimum pressure valve is out ol order since it cannot hold.the air
necessary for the initial start-up in the compressor, compressor will rest
against the load and will be Torced. To understand it, while there is no
pi"..rr" in the system start the compressor and check the internal
pressure by control button, if internal pressure does not increase or
increases siightly, it means that mbv does not hold air' Cut off the power
of compressor. Reiease internal and external pressure Remove
minimum pressure valve and check the seal and o-rings damage"

I There may be motor or screw

Replace damaged seal and o-rlngs.

Cut oTf the power of compressor and check Tree rotation of the belt lf
mechanical problems. rotation more diflicult than normal, mechanic damage may be present
in motor or screw unit, contact service company

25
 INDICATOR REASON I soLUTtoN §
A Compressor may not shift from Star delta time relay (ZR1) may be broken or non-set. Check the setting (appr.6
star to delta seconds). start the compressor and check lights of time relay. lf the second light
is not on in the end of time set or color of light does not change, time relay is
broken. Replace it.

(1 1-45 kw) flap may be stuck as completely closed (no return)

B Suction valve may be out of
(55+ kw) air from control solenoid valve may not inflate air piston (internal
order
Compressor cylinder tire is flat) contact the service.
does not
c Minimum pressure valve may
siee arttcle 2-t-
3 generate air be out of order
(not on-load)
D Solenoid valve may be broken Check whether control power is supplied to (11-,+5 krv) solenotd valve or not rf
there is power, sound is audible Jrcr rhe sc encrd. ii sound rs heard. solenord
diagram has been damaged. rf no sound is neard. corl of solenoid has burnt,
replace it.
(55+ kw) control solenord vaive has no power and pressure is delivered by the
piston directly, if the pressure rs not delivered, it means that solenoid is blocked
or powered (if powered. it means that control and by-pass solenoid cables were
connected reverse, reverse it). if no power, solenoid is broken, replace it.

E Setting pressurestat may be While there is no pressure and compressor is not powdered, check
broken pressurestat contacts by multi meter, contacts no 1 and 2 should be closed
normally if you cannot read, rt means that pressurestat is broken, replace it.

A System requirement may be To see that compressor reaches to maximum pressure, turn the ouilet valve
higher than compressor down slowly, check the pressure increase and compressor performs on-load
capacity and no-load operation fasi. lf it is OK, it means that air requirement of the
system is higher than generated by the compressor.

B lf you think that utilization does not citange in your system check air installation
There may be leak in air line
and joints.
Compressor
cannot At the same time, compressor will run at higher temperature than normal
4 reach to c Ai"firle"ra\
uur Ld I die i
:e 9,:i:: ,: .
operating temperature. stop the compressor and check suction filter, if it is dirÿ
maximum replace it.
pressure
There may be conditions that suction valve flap can be opened slightly.while
D Suct on r.,â,,e rnav ce Drc(en compressor is in s.op mode and there is no internal pressure, check that flap
moves back and forth freely, if flap does not run easily, contact the service.

More different operating sound w ll be heard than usuai. lf water is not

E Screw untt may be damaged discharged lrom oii tank regulai.ly, r,vater rn the oil wlll c r-cuiate ,,vith oil and lead
to damage. Contact the se.vice

check the set of setting pressurestat. when pressure set is reached, setting
A Setting pressurestat or setting pressurestat should shift contact (to see more easiÿ, you can bring uppei
may be broken pressure adjusting bolt to the lowest pressure) if contact is not shifted, ii means
that setting pressurestai is broken.

suction valve flap can be seen in shrck pæitxrr when it is fully open. while
Compressor compressor is in stop mode and there is m internal pressure, check that flap is
B Suction valve may be broken
shifts to fully closed and moves back and forÜt freely" tf flap does not close or sticks in
5 pressure open position, contact the service.
set (not idle) Solenoid valve may be out of
(read with c order
See article 3-D
article 9)
D There may be leak in air check sleeves and connections of confu circuit and tighten if loose. Replace
control circuit burst or punctured hose if any.

26
I1 rnuLTS, cAUSES AND
'-'----'- soLUTloNS I

./

INDICATOR REASON I SOLUTION §

A Skavenge line may be blocked. While compressor is running under load, see the oil flow by
skavenge sight glass, if there is no oil flow, stop the compressor
and clean skavenge orifice with a thin wire and compressed air,
check with breath and install it, iT cleaning is successiully
completed, when you start up the compressor you can see the oil
foam in the end of 10-15 seconds. Check again after 15-20
minutes.
Compresor
6 consumes
excessive
oil B Separator element may be damaged If Skavenge runs smoothly, the possibility of separator filter
damage increases and oil and oil smoke is seen at outlet of
compressor. ln such case, replace separator element'

c There may be leak in oil circuit Check all sleeves and connections of oil circuit and tighten them,
if oil leak does not stop, contact the service.

A Thermic or its setting may be out of order Check that main engine thermic has been set for main engine
flow. By means of a
Amprobe, (when compressor is in full Ioad) check that the flow of
thermic is within normal values and balanced. lf thermic is at the
flow set or lower, it has broken, replace it
Main
engine
thermic See 2-B
B Voltages may be low
stops the
7 compressor c The compressor may exceed set pressure See 5
(if during
start-up
D Separaior may be blocked While compressor runs in full load or approximate value, by
please see pressing control button, you can see the pressure difference of
article 2) separator (internal and external pressure difference) !f it is about
1-1,5 bar value, it means that your separator has been blocked,
replace the separator

E Screw unit may be damaged. Can be understood by excessive operating sound Contact the
service.

A Thermic or its setting may be out of order
Check that fan motor thermic has been adjusted for fan motor
flow. By means of a Amprobe, (when compressor is running)
check that the flow of thermic is within normal values and
balanced. lf thermic is ai the flow set or lower, it has broken,
replace it.

Fan motor Dust filter, radiator cores are blocked or Check that ventilation is sufficient for the compressor. Fleplace
B
contaminated filters. Clean radiator cores by compressed air' Do
I thermic
stops the
hot air outlet is closed (ventilation problem)
nôt cover hot air outlet and narrow it.

compressor
lf operating flows are higher than normal, fan motor may be
c There may be problem of fan motor"
overloaded, while all hoods are open, start the compressor for a
short time and listen to the sound ol fan motor and check the
body temperature, the motor may overheat, there may be bearing
problem. Contact the service.

A Adjustment pressurestat or its setting may See 5-A

Safety be out of order
pressur-
B Safety pressurestat may be out of order Check the setting of safety pressurestai, when pressure set ls
estat stops reached, presseurestat should shift contact (to see more easily,
the you can bring pressure adjusting bolt to the lowest pressure) if
9 contact is not shifted, it means that pressurestat is out of order
compressor
(read with
article 5)
c Separator may be blocked See 7-D

27
 INDICATOR A REASON I SOLUTION §
A Setting of contact thermometer may be Check temperature setting of contact thermometer.
out of order

B Ambient temperature may be high Check the ambient temperature and take necessary measures

c Ventilation may be insufficient A smaller suction window than compressor suction area may be
opened or hot air outlet of compressor may nol be discharged
outside the compressor room, radiator may be exposed to direct
sunlight or local winds blast in reverse direction. Check and take
necessary measures.
Contact
thermometer D Oil level may be low Check oil level and add if deficient
10 stops the
E Oil filter may be contaminated or blocked Replace oil filier.
compressor
F Oil may be in the end of service life You can easily understand b.,-ire cc or of oil that its service life
has expired (color darkens arr ih îs) if you have to replace it in
shorter time than usua rec aas.ilent time. review your working
conditions (excessive a-D e': c' 3perating temperature, ambient
gases, humidity, etc. L

G Suction filter may be dirty or blocked Check and replace

H Dust filter may be blocked Check ano c ea^ 'aa )-aa

Radiator cores or fan flaps may be Check anc o ea^

I
contaminated-blocked

K Outlet hole may be very long or narrow ChecK alc ia(e nÊcessary measures

A Setting and safety presurrestat may not See 5-A, and 9-B
be set
B Separator may be blocked See 7-D
Safety valve
opens c Suction valve may be broken See 5-8.
11 See 3-D
D Solenoid valve may be broken

E Safety valve or its setting may be out of if safety valve is switched on at the value lower than set, replace
order it.(55 kw and above) compressor outlet valve may be left as
closed

A Main eng,le therr.,c se:t r! ra: :-. :,', --::.:-:'- : ::: -l

Compressor
stops while Compressor ma-v oe o, e' carg: 1': :=a='='a' : Ierence at iull load.
B
approaching '3^l -: :-'-:-:: :': - ;-,-:,. .: .:=s C:eckthatthereisno
12 to upper -a:-:- : :-:::- - :-: -: :-: >,-.," :.s described in article
pressure 2-3 ' S::a-a::' :':::-': : -:-:-:a s h gh, feplace the
s e: a'::: '

c Setting of contact thermometer may be low utüL^t

^À^^,.F^
ü>- ----^

D Compressor may be overheated Check the cpe.a:'J :a-:='=:--= =' '- ::: ard perform checks
describedinarice'-

A ldle running time relay or its setting may ldle running trne'Ea.. 7=. -2, :::---=- --re-caiibrated.
be out of order Checkthesetling (iora:: : - ---=: .',- = :--p.essorisin idle
mode, posrtion electr!ê :-::- :- :-::-:: - -:=ràt on and check
lights of time relay. lf in i.e r : -= ==. :-: .econd light is not
=- --
Compressor on or color of light does rc: c-a^l: : -3 -3 a! s broken. Replace
does not it.
13 stop in
automatic Compressor may be loaded before time set lf idle running of the compressor- s sroriei than the time set for
B ZR2, since compressor will start to uiork r', ih ioad again, it will not
stop in idle position.

28
\
I

I
FAULTS, CAUSES AND SOLUTIONS
I

I
INDICATOR A REASON I SOLUTION §
1

A Oil level may be low Check the oil level and add if deficient.
I
B Ambient temperature may be high Check the ambient temPerature.
I

li
c There may be ventilation problem in See 10-C
compressor room

D There may be contamination in cooling Check and clean.

\1

Compressor circuit of the compressor

operates at Suction tilter may be contaminated/blocked Check and replace.
1
E
higher
temperature F Belt may loose Check the tension of belt, when the compressor operates, you
I 14 can understand that the belt is loose by observing movement of
than normal
belt. A belt calibrated and tensioned accurately never vibrates.
I

operating
Please see articles of belt replacement and setting and tension
I
temperature
the beli or contact the service.
(moreover the belt may be lubricated, in this case as the pressure
\ increases, a high noise and smoke is applicable for the belt. Apply
baby powder between threads of belt and clean the grease.)
l

i
There may be mechanic problem in screw Can be understood by high operating sound. Contact the service'
G
unit

A There may be blocking in oil circuit or lf there is a cloth in separator tank during periodical service, this
oil filter cloth may cause blocking in oil circuit. During services, pay
I
When
attention to this point. Since element structure may be different Tor
compressor the Tilters other than original oil filters, it can resist to oil
is in idle circulation.
144 position, lf there is very much fine powder or abrasive gas in the
operating environment (Sanding workshop, chemical plants, etc') this will
temperalure cause negative effect on oil, oil filter and separator.
I

A There may be loose connections During periodical services, check that all mechanic connections
have been tightened smoothly (especially tightness of engine,
screw and fan is of great importance in terms of life and property
I

safety.)

Compressor Decalibration of belt See 14-F. Moreover stop the compressor and check that pulleys
B
WOTKS are in the same Iine by a gauge. Pulleys will be in the same line if
15 more noisily they are not, loose engine body connecting bolts and re-calibrate
than normal the engine again.

c There may be bearing problem

D There may be mechanic problem of screw See 2-G

Beli may be loose or worn See 14-F. Moreover, check the belt threads and if there is
Compressor A
damage, replace it.
operates
more noisily B Problem of motor bearing Check the engine bearing and replace it.
154 when upper
pressure is
about to be c There may be mechanic problem oT screw See 2-G.
reached
Suction valve may be broken Suction valve may not deliver the air required to be by-passed
i
Compres A
while it ls in idle position to the screw (at the same time,
I
sor Skavenge is blocked) contact the service.
operates
1sB more noisily B Oil filter or oil circuit may have blocking See 14-8.
I
in idle
I
position
than normal

29
I

I
 INDICATOR A REASON I SOLUTION §
Although A Minimum pressure valve may be broken Air in MBV system returns the compressor. Replace seal and
compressor o-ring of MBV
is in idle B Suction valve may be broken
.......--
suclion valve does not close fully. see s.B.
16 position, Moreover yellow nozzle inside of suction valve or flap by _pass
internal hole may be blocked. Contact the service.
pressure c Solenoid may be out of order or blocked There may be blocking in diagram part of solenoid valve
does not preventing passrng. Clean it.
lower
D There may be blocking in solenoid block Clean air ducts.

Oilloses its
characteristic
17
fast

A Recommended oil or original separator

may not be used

B Ambient humidity may be very high

c No regular water discharge may be from For long-service life of screw unit of your compressor and other
separator tank components, ensure that water discharge is carried out regularly.
Separator
18 blocks fast
D There may be fine powder, gas, etc. While determining sanding workshop, casting workshop,
damaging the characteristics of oil in the chemtcal plants compressor room, this poini should be
environment considered. Remove the compressor from these factors as much
as possible. Read installation and lay_out section for detailed
information.

E May run at high temperature continuously Operating temperature for the compressors running in insufficient
ventilated rooms or close to boiler room, generator room affects
service life of separator negatively.

A Voltages may be low See 2-B

B Star delta transition time may be very short lf set for shorter time than normat, ungin" *iil-E[àîtiZï
operation without speeding and contactor contacts wjll be
Contacts of exposed to higher current than usual. As a result of th s, contacts
contactor may sick and your engine may burn. Star delta t me is 6 seconds
wear fast do not set for shorter time. Replace worn con.iaci sets with the
19 (frequent original.
sticking)

c Compressor may work as start-stop highly Number of starting recommended for an .:;- e _,/p[-@f,i
start-stop will affect mechanic life negat ,,s , a:c rncrease the
operating cost due to high current d.a,,.,r :_- -: siarting. Contact
the service for detailed lnforrnarior

D Original contact set may not be used Electrical ignition of non-origtnal cc-:a.l s::s is very low. Their
appearance can be discrimtnated Êas
., C:":act the service for
supplying original spare part,

Belt wears A Pulley setting may not be accurate

fast
20 B Belt tension may be less or higher than See 14-F. And 15-8. Contact the se-; ce
normal

c May operate at high temperature or Contact the service.

abrasive environment.

30
 SPARE PART LIST AND CODES

SECTION 5
SPARE PART TABLE OF ATV-AV SERIAL (DlP TYPE)SCREW TYPE AIR COMPRESSOR

5.1. SPARE PART LIST AND CODES

NUMBER
NO NAME OF THE PART STOCK CODE REFERENCE
USED

1 SCREW OUTLET PRESSURE MANOM TER 1

2 P1 LCD SCREEN 1

3 SUCTION PADDING / FOAM 1

4 swrrcHBoARD (COMPLETED) 2

5 BELT TENSION FLANGE 1

6 BELT ENCLOSURE 1

7 PRESSURE SWITCH 1

8 LIMIT PRESSURE SWITCH 1

9 SCREW OIL INLET HOSE 1

10 AIR SUCTION FILTER 1

11 SUCTION CONTROL SOLENOID VALVE 1

12 SUCTION CHECK VALVE 1

13 SCREW BLOCK 1 <f

14 SCREW PULLEY 1
(\]
't5 MOTOR PULLEY 1
L]l
16 POLY V BELT ct
l
17 OIL LEVEL INDICATOR 1
LL
18 SEPARATOR TANK AND SEPARATOR 1

19 MINIMUM PRESSURE VALVE 1

20 DISCHARGE VALVE 1

21 COOLER OIL RETURN HOSE 1

'I
22 COOLER OIL INLET HOSE
23 COOLING FAN 1

24 COOLING FAN MOTOR 1

25 AIR OUTLET HOSE 1

26 THERMOSTATIC MIXING VALVE 1

i
27 OIL FILTER 1

28 MAIN ENGINE 1

29 AIR OIL OUTLET HOSE 1

30 OIL DISCHARGE VALVE I

31 OIL FILLER PLUG 1

* * CONTACT AUTHORIZED SERVICES FOR STOCK CODE INFORMATION.

TABLE . 5

31