GB

use & maintenance

MANUAL

Rotar Plus
30-40 TF

Rotar Plus 30-40 TF / 04 - cod.197AA3700 - Rev.02 09/2011

 GENERAL INFORMATION GB

GENERAL INFORMATION .............................................. 3

SAFETY INDICATIONS .................................................. 4
INSTALLATION ................................................................ 6
TECHNICAL DATA ........................................................... 7
CONTROLS AND SETTINGS .......................................... 8
CONTROL FUNCTIONS ................................................ 10
OPERATION .................................................................. 11
START-UP ...................................................................... 11
MAINTENANCE ............................................................. 12
TROUBLESHOOTING ................................................... 15
WIRING DIAGRAM ........................................................ 16

STANDARD EQUIPMENT
Your compressor is delivered with the following accessories:
• user’s guide
• anti-vibration elements
• key to open panels / electric box – Allen wrench to remove the back panel
• oil/condensate exhaust tube
Check that standard equipment is supplied with the machine. No claims after delivery will be accepted.

CONDITION OF THE MACHINE WHEN SUPPLIED

Every compressor is shop tested and delivered ready to be installed and put into operation.
Used oil is: RotEnergy Plus.

Rotar Plus 30-40 TF / 04 - cod.197AA3700 - Rev.02 09/2011 3

GB SAFETY INDICATIONS
GENERAL
• Rotary compressors are intended for heavy continuous industrial use. They are especially suitable for industrial applications
requiring high air consumption for a long time.
• The compressor should be run and operated only in compliance with the indications given in this manual. Safely keep
this manual in a known and easily reachable place for the whole working life of the compressor.
• A supervisor shall be appointed in the company, in which the compressor is installed. He/she shall be responsible for
compressor inspections, adjustments and maintenance. Should a substitute be appointed for the supervisor, he/she shall
carefully read the user’s guide and all possible comment on service and maintenance carried out so far.

SYMBOLS USED IN THE MANUAL

Some symbols are used to highlight danger situations, give recommendations or information. These symbols are usually
positioned next to the text, a figure or at the top of a page (in this case they refer to all subjects dealt with in that page).
Carefully read symbol meaning below.

CAUTION! POWER OFF!

Important description on service, dangerous All operations to be strictly carried out only after
situation, safety, accident prevention powering off the machine.
recommendations and/or very important
information.

STOP MACHINE! SPECIALIZED PERSONNEL!

All operations to be strictly carried out only after All operations to be strictly carried out only by
stopping the machine. specialized technician.

SYMBOLS ON THE COMPRESSOR

The compressor has several labels to highlight possible danger and give recommendations on what to do during machine
operation or in special situations.
Please comply with these indications.

Danger! Hot! Prohibited! Do not open doors during

compressor operation

Prohibited! Press emergency button for

Danger! Electric shock! compressor immediate stop. Do not use line knife
switch.

Danger! Hot gas or harmful gas within working Prohibited! Do not use water on electric
area equipment to extinguish fire.

Danger! Pressurized container

Compulsory! Read instructions for use carefully.

Danger! Mechanical moving parts

Caution! Maintenance works in progress

4 Rotar Plus 30-40 TF / 04 - cod.197AA3700 - Rev.02 09/2011

 SAFETY INDICATIONS GB
WHAT TO DO:
Make sure that mains voltage corresponds to the voltage indicated on CE plate and that cable of suitable cross-section are
used for electric connections.
Always check oil level before starting the compressor.
Be familiar with emergency stop control and all other controls.
Unplug the connector before any maintenance work, so to avoid accidental start.
Ensure that all parts have been correctly reassembled after any maintenance work.
Keep children and animals off the working area to avoid injuries caused by devices connected to the compressor.
Ensure that temperature of the working environment ranges between +5 and + 50 ºC.
The compressor should be installed and operated in a non-explosive environment.
Allow at least 80 cm between the compressor and the wall so to allow free air flow to the fan.
Press the emergency button on the control panel only in case of actual need so as to avoid possible damages to people or the
very compressor.
When calling for technical assistance and/or advice, always mention model and serial number indicated on CE plate.
Always follow the maintenance schedule specified in the user’s guide.

WHAT NOT TO DO:

Do not touch inner parts and pipes as they are very hot during compressor operation and stay hot for a certain time after
compressor stops.
Do not position inflammable or nylon objects or cloths close to and onto the compressor.
Do not move the compressor when the tank is under pressure.
Do not operate the compressor if the power cable is damaged or defective or if connection is unstable.
Do not operate the compressor in wet or dusty environments.
Never aim the air jet at people or animals.
Do not allow unauthorized people to operate the compressor and give them all required instructions.
Do not hit fans with blunt objects as they might break during compressor operation.
Never operate the compressor without air filter.
Do not tamper with safety and adjusting devices.
Never operate the compressor when doors/panels are open or removed.

PRODUCT IDENTIFICATION
The compressor Your have purchased has its own CE plate showing the following data:
1) Manufacturer’s data
2) CE mark – year of manufacture
3) TYPE = name of the compressor
CODE = compressor code
SERIAL NO. = serial number of the compressor You have purchased (to be always mentioned when calling for technical
assistance)
4) air delivered by the compressor expressed in (l/min) and (cfm)
5) max. operating pressure (bar and PSI) – compressor noise level in dB(A)
6) electric data: voltage (V/ph), frequency (Hz), absorption (A) - power (HP and kW), rotations per minute (Rpm).
7) other approvals

Rotar Plus 30-40 TF / 04 - cod.197AA3700 - Rev.02 09/2011 5

GB INSTALLATION
COMPRESSOR DESCRIPTION (FIG. 1)
Compressors which are described in this guide are intended for industrial use. Models may include different outfit with/
without tank and/or drier.

The compressor essentially consists of the following:

1) Air/oil radiator 7) Motor
2) Electrical equipment 8) Screw compressor
3) Control panel 9) Suction regulator
4) Oil separator reservoir 10) Air filter
5) Oil separator filter 11) Oil filter
6) Minimum pressure valve

UNPACKING AND HANDLING THE COMPRESSOR

The compressor is usually shipped to the customer with a carton cover.
Wear protective gloves and cut outer straps. Then remove the carton cover from the top. Before removing the compressor,
make sure it is intact (outside), open access doors and visually check components for damage. Check that all accessories are
included.
Lift the machine using a fork lift truck. Fit the anti-vibration elements into their seats and move the machine to the room
chosen for its location with maximum care.
Keep the packing material in case the compressor needs to be re-located. Keep the packing material at least for the whole
warranty period so that it can be used to safely deliver the compressor to the Service Center for repair works.
Dispose of the packing material in compliance with current laws at the end of the warranty period.

POSITIONING THE COMPRESSOR (FIG. 2)

The room chosen for the installation of the compressor should meet the following 2
requirements and comply with what specified in the current safety and accident
prevention regulations:
• low percentage of fine dust,
• proper room ventilation and size so to keep room temperature under
50°C. In the event of inadequate hot air discharge, fit one or more exhaust
fans. Fit the exhaust fans as high as possible
.
Exhaust flow rate “2000 cu.m./h” part no. 020041000
Exhaust flow rate “4000 cu.m./h” part no. 020042000

A drainage pit or can shall be used to collect tank condensate.

Dimensions are just approximate. Try nevertheless to respect them as much as
possible.

6 Rotar Plus 30-40 TF / 04 - cod.197AA3700 - Rev.02 09/2011

 INSTALLATION GB
POWER CONNECTION (FIG. 3)
• The mains cable should have a cross-section suitable for the machine
power and should include no. 3 phase wires and no. 1 earth wire.
• Between the mains cable and the compressor control panel a fused
switch near the point where the cables go into the machine is absolutely
necessary. This switch should be at least 1.7 m from the ground.
• Position the switch (A) so that it can be easily reached by the operator.
The cables should be of the approved type and installed with the following
grade of protection: at least IP44
NOTE: Follow the instructions in the table to select proper cable section.

TECHNICAL DATA

 
   

  
 
 
   
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Rotar Plus 30-40 TF / 04 - cod.197AA3700 - Rev.02 09/2011 7

GB CONTROLS AND SETTINGS
CONTROL PANEL (FIG. 4)
• All compressor power-on-and-off procedures are 4
controlled by the machine power unit. Furthermore, it signals
possible machine problems and gives information on the
operation times and servicing times.
1) Display on which information is displayed.
2) OK key: press confirm (see “Modifiable Parameters”)
3) Direction keys: to scroll the options of the menu
4) Alarm light: if the light turns on and compressor possibly
stops, it means that maintenance service is needed or a failure
in the system has occurred. Refer to “Alarm messages” to
identify proper service.
5) Reset key: to stop the alarm (see “Alarm Messages”)
6) ON/I key: to power the machine on.
The machine power-on cycle is divided into three phases.
• wait for power-on the (STAND_BY) message is
displayed. If compressor was switched off, 15 seconds are
required before the cycle is started; otherwise compressor
remains on stand-by until pressure transducer requires air.
• Starting: compressor power-on in the “star” mode: the
(LOADLESS)message is displayed
• Working cycle: shift from “star” mode to “delta” mode after five seconds.
After two seconds, if required by transducer, the load solenoid valve is excited and (LOAD) message is displayed.
Note: This cycle is for compressors with a remote starter. Direct start compressors start immediately after (STAND-BY) phase.
7) OFF/0 key: to power the machine off.
Load solenoid valve is disabled, loadless cycle starts, blinking (LOADLESS) message is displayed, once loadless cycle is over
compressor stops and “off” message is displayed.
8) Emergency stop switch: to stop compressor only in case of actual need.
9) Functioning diagram/ maintenance operations

WORKING TIMES
Automatic mode
• The compressor operation is controlled by the pressure transducer, which stops the machine when the max. pressure
value is reached and starts it again after the pressure has decreased to the min. set value.
However, the machine stop is of the delayed type, that is it does not occur exactly at the same time when the max. pressure
value is reached but after a certain time, during which no air is taken (see no. 7 of above paragraph).
• Standard setting is 20 seconds, but it is recommended to check that number of start-ups per hour does NOT exceed max
number of 10. Should it be a higher value, it is recommended to set longer loadless operation time (see no. 7, “Modifiable
parameters”).

PRESSURE REGULATOR
The User should install a pressure regulator downstream of the compressor to set the power line according to his/her needs.

REMOTE ON/OFF
• The compressor can also be switched on or off using the “remote” control optional software (remote control will be active
only if the control unit at the machine is set to “ON”).
• This function can also be managed through the “remote” terminal on the terminal box. In such case, manual controls will
be excluded. If the compressor starts up unexpectedly, persons happening to be nearby could be harmed or injured. With this
in mind, THIS USE IS GENERALLY NOT RECOMMENDED. The manufacturer will not be liable for any damages.
Any change must be carried out by a qualified technician.

MODIFIABLE PARAMETERS
Pressing the key with the machine OFF, the operating parameters menu will be displayed; in certain cases a password
is required in order to make changes. The menu is scrolled using the keys and .

0) control unit ID (service password): selects the identification code of the control unit; if several compressors are connected
to the same RS485 line, multiple IDs can be selected.
1) Pre-alarm time lapse (service password): each hour of operation clocked by the machine is counted down automatically;
when the count reaches 0, the control unit trips a Maintenance alarm.
The count, preceded by a minus sign (-), indicates how many hours have elapsed since the last maintenance alarm; the keys
and can be used to set a new value (entering the new value has the effect of overriding the previous alarm).

8 Rotar Plus 30-40 TF / 04 - cod.197AA3700 - Rev.02 09/2011

 CONTROLS AND SETTINGS GB
2) Alarm history (no password required): this menu can be used to display the 30 most recent alarms.
3) Pre-alarm temperature (factory password): this menu is used to set the “delta” temperature (“delta”, in °C) referred to the
maximum alarm temperature; the value can be set between 1 and 20.
Example: if the maximum temperature is 120 °C and the differential is 10 °C, the maximum temperature pre-alarm will trip at 110 °C.
4) Maximum temperature (factory password): this menu is used to set the maximum permissible temperature; the adjustment
range is 0 to 150 °C.
5) Minimum temperature (factory password): this menu is used to set the minimum temperature; the adjustment range is 0 to
-14 °C.
6) Fan temperature (service password): this menu is used to set the temperature at which the cooling fan comes into operation;
the range of adjustment is 0 to 150 °C. The fan cuts in at the set temperature. Hysteresis is fixed at 10 °C.
7) Duration of loadless operation (service password): this menu is used to change the duration of the no-load cycle; the range
of adjustment is 1 to 250 seconds.
8) Auto start (service password): this parameter enables automatic Start; if activated, the compressor will restart automatically
following an electrical power supply failure.
If the compressor starts up unexpectedly, persons happening to be nearby could be harmed or injured. With this in mind, use
of the automatic start function is not generally recommended.
9) Internal phase sequence (service password): this parameter enables control of the phase sequence internally, or disables
internal control and activates the phase sequence control input at the terminals.
10) Language (no password required): this parameter is used to select the language in which messages are displayed; there
are 5 available (English, French, German, Italian, Spanish).
11) Enable RS485 (no password required): this parameter is used to enable data transmission using RS485, and automatically
disable transmission on RS232.
12) Pressure sensor (service password): enables the “4-20 mA” input to which the pressure sensor is connected. With this
parameter activated, the pressure measurement is displayed. To display machine operation time, press the key; the display will
revert to the pressure measurement automatically after 20 seconds.
Enabling this parameter, the external pressure switch contact changes function and becomes an input for the oil separator
minimum pressure switch; in this situation, the compressor is prevented from restarting if pressure in the oil separator is high.
13) PSI/BAR (no password required): selects the unit of measure used to display pressure.
14) No-Load/operating pressure set point (no password required): this parameter is used to set the pressure at which the
compressor must switch off; if inverter drive is enabled, it indicates the operating pressure at which the inverter will begin modulating
output to maintain the pressure steady.
15) Load/operating Delta set point (no password required): indicates the pressure at which the control unit enables compressor
restart.
For example, if the set differential value is 1 bar and maximum operating pressure is 9 bar, this means that the compressor will
switch off at 9.5 bar and switch on again at 8.5 bar.
16) Maximum pressure (service password): this parameter sets the maximum pressure value permissible in operation, i.e. the
maximum pressure of point 14.
17) Maximum alarm pressure (factory password): this parameter sets the maximum pressure value at which an alarm is
tripped in the control unit.
18) Remote pressure(service password): enabling this parameter, the pressure and the relative alarms continue to be displayed,
but the compressor starting sequence is controlled from an external pressure switch contact.
19) Load delay(factory password): this parameter sets the delay, in seconds, from the moment when the starting cycle terminates
to the moment when the air solenoid valve energizes.

ALWAYS HIT KEYS AND PRESS TO CONFIRM ENTRY

STANDARD SETTINGS
MODIFIABLE PARAMETERS Min. Max. Standard Min. Max. Standard
Oil temperature pre-alarm (differential) °C 0 20 5 Maximum permissible pressure bar 0 15 11
Maximum oil temperature °C 0 150 110 Maximun alarm pressure bar 0 16 13
Minimum oil temperature °C -14 0 -7 Load (CHARGED) delay sec. 0 200 10
No-load (EMPTY) time sec. 1 250 20 Internal phase sequence control YES NO YES
Maintenance pre-alarm Ore 0 32768 4000 Language ITA
Fan temperature °C 0 150 80 Display contrast level 1 20 5
Automatic start YES NO NO Enable RS485 SI NO SI
Pressure sensor YES NO YES
PSI/BAR PSI BAR BAR
No-Load/operating pressure set point bar 0 15 10
Load/pressure differential set point bar 0 15 8,5

Rotar Plus 30-40 TF / 04 - cod.197AA3700 - Rev.02 09/2011 9

GB CONTROL FUNCTIONS
ALARM MESSAGES
In the event of a fault occurring or of set safety limits being exceeded, the red alarm light will appear and the current alarm
condition is displayed.
Display status
1) Check direction of rotation
Alarm trips in the event of incorrect phase sequence being detected. The compressor locks 30°C h00110 m05
up; to restore operation, the correct phase sequence must first be re-established.
Wrong rotation
NOTE: To reset the alarm, the equipment must be isolated from the a.c. power supply.
2) Check temperature sensor
Alarm trips in the event of temperature sensor fault (sensor open or short circuiting). The 30°C h00110 m05
compressor locks up; to restore operation, check the connection and/or replace the sensor,
Temp sensor faulty
then press .
3) Maximum oil temperature
Alarm trips when the maximum oil temperature is sensed. The compressor locks up; to 110°C h00110 m05
restore operation, wait for the temperature to fall below the programmed value, then press Max oil temp
.
4) Minimum oil temperature
Alarm trips when the minimum oil temperature is sensed. The compressor locks up; to restore -10°C h00110 m05
operation, wait for the temperature to rise above the programmed value, then press . Min oil temp
5) Oil temperature pre-alarm
Trips when the pre-alarm oil temperature is sensed. The compressor does not lock up. To 105°C h00110 m05
override the pre-alarm, press . Oil temp pre-alarm
6) Motor thermal overload
Operates when the thermal overload relay is tripped. The compressor locks up. To silence
74°C h00110 m05
the alarm, first verify the cause, then press . Motor thermal relay
7) Emergency
A circuit activates to lock up the compressor when the red emergency button is depressed.
74°C h00110 m05
To silence the alarm, first reset the emergency button, then press . Emergency button
8) Machine maintenance pre-alarm
Trips to warn the user than that machine is due for routine maintenance (oil change, service
74°C h00110 m05
filters, etc.). The alarm must be silenced by the service technician, who when carrying out
maintenance operations will select the item “Pre-alarm hours” from the menu and reset the Routine maintenance
value as described under the heading “Modifiable parameters - point (1).
9) Separator pressure switch
Alarm trips in the event of the separator pressure switch contact opening. The compressor 75°C h00110 m05
locks up. To silence the alarm, first reset the separator pressure switch, then press . Separator p/switch
10) 4-20 mA fault (pressure sensor)
Alarm trips when the pressure sensor connected to the 4-20mA input does not operate
74°C h00110 m05
correctly. The compressor locks up. To silence the alarm, first restore the pressure switch to
4-20mA fault
normal status, then press .
11) Maximum pressure
Alarm trips when the maximum pressure setting is exceeded. The compressor locks up. To 74°C h00110 m05
silence the alarm, first restore the correct pressure, then press . Max pressure

SAFETY DEVICES (FIG. 5)

1) Electronic transducer: controls both STOP and
START pressure. 5
2) Pressure switch for oil separator filter clogging:
indicates efficiency limit of oil separator filter.
3) Minimum pressure switch:
4) Pressure switch for air filter clogging: indicates
air filter efficiency limit
5) Safety valve: opens the air bleeding unit when
the safety value is reached.
6) Max. temperature sensor: stops motor over
+110°C.

10 Rotar Plus 30-40 TF / 04 - cod.197AA3700 - Rev.02 09/2011

 OPERATION GB
WORKING CYCLE
• At first start-up, the motor starts in the “star” 6
configuration. In this phase the compressor starts
slowly, the solenoid valve (1) is open and the
suction regulator (2) is closed.
• The compressor remains in this condition
for about 5÷7 seconds.
• This time over, motor is “delta” powered. The
solenoid valve (1) is energized; it closes and
enables suction regulator (2) opening, which sucks
in air through filter (3).
• At this stage, the compressor runs at full
speed and begins to compress the air in the tank
(6).
• The compressed air cannot come out from
the minimum pressure valve, which is set at 3÷4
bar.
• The compressed air compresses the oil in
the tank (6) and forces it to flow towards the tube
(7).
• If oil temperature is under 71°C, oil is
returned to compressor (4) from the tube (7)
through filter (9) and tube (8).
• If oil temperature is over 71°C, the thermostat closes the tube line (8) so that the oil reaches the radiator (11) through the
tube (10).
Cooled oil returns to the compressor through tubes (12) and (8) via filter (9).

• The oil reaches the compressor (4) mixing with the intake air and creating an air/oil mixture which ensures the seal and the
lubrication of the moving parts of the compressor.
• The air/oil mixture returns to the tank (6) where the air is pre-separated through spinning and is finally separated from the
oil by the oil separator filter (13).
• As a result, the tank (6) will deliver only air to radiator (11) through tube (15). Air is then conveyed to mains through a cut-
off cock (16).

START-UP
FIRST START-UP
Before starting the machine up for the first time, make sure that:
• the mains voltage is the same as the voltage on the CE plate;
• the electric connections have been made using cables of proper cross-section;
• the (wall) main power switch has suitable fuses;
• the oil level is over the minimum level - top up with the same type of oil if necessary;
• the air outlet cock is completely open.

CONNECT THE TANK WITH A HOSE.

• Only specialized technicians can start the compressor (on-site testing) for the first time.
If the machine does not start and the display shows the alarm message “Wrong direction of rotation”, proceed as
follows:
break power supply through the wall switch;
open the electric box door and reverse the two phases in the terminal board;
close the door, power on and start the machine.

Display status during compressor operation

Display status at start (shown for 5 seconds) Display status during normal operation

Easy Tronic II oil temp. 100°C 9.5Bar pressure

software
V.0.0.0 GG/MM/AA date Status=stand-by
release

compressor
status

Press the key to see hours and minutes operation; the information is displayed for 20 seconds.

Rotar Plus 30-40 TF / 04 - cod.197AA3700 - Rev.02 09/2011 11

GB MAINTENANCE
• Proper maintenance is fundamental to the efficiency of your compressor and for the prolongation of its operational
lifespan.
• It is also important to respect the manufacturer’s suggested maintenance schedule, keeping in mind that the compressor
has been constructed for use in the best possible environmental conditions. (see the chapter on “Installation”)
• The intervals between maintenance works might have to be reduced to counteract the effects of the environmental
conditions in which the compressor is used.
• The oil used is RotEnergy Plus. Use of a different type of oil could compromise the efficiency of the compressor and
frequency of maintenance work to be performed.
• The normal maintenance operations which can be performed by the person in charge of the compressor will be
described in the following pages. Extraordinary maintenance work must be performed by an authorised customer technical
assistance centre.

Maintenance table

Type of maintenance Maintenance schedule

Work hours O At least
ORDINARY MAINTENANCE
Condensation release - Once per month
Oil level check and refill 500
Clean the air filter 1000
Check for clogging and clean the radiator 1000
Check the transmission belt 2000
Air filter substitution 2000 Once per year
Oil filter substitution 4000 Once per year
Discharge oil filter substitution 4000 Once per year
Total oil change 8000 Once per year
EXTRAORDINARY MAINTENANCE
One-way draining valve substitution 4000 Once per year
Suction valve overhaul 12000 -
Thermostatic valve overhaul 12000 -
Minimum pressure valve overhaul 12000 -
Solenoid-valve substitution 12000 -
Substitute the fexible tube 12000 -
Substitute the transmission belt 12000 -
Substitute the electric motor bearings 24000 -
Screw compressor overhaul 24000 -

• The maintenance operations indicated in bold type must be performed at least once a year, even if the machine has
not been run for the amount of hours prescribed for such maintenance.

• In order to assure the correct functioning of the compressor, the following items must be checked after the first one
hundred hours of operation:
Oil level: refill, if needed, with the same type of oil.
Make sure that the screws are still tightly screwed: in particular those of the high voltage electrical contacts.
Check to make sure, visually, that all of the connecting parts are still firmly in place.
Check the air temperature of the immediate area.

BEFORE CARRYING OUT ANY INTERVENTION ON THE MACHINE:

• Command compressor shutdown using the switch (do not use the emergency button).
• Place the line switch in the 0/OFF position so that the machine is in total safety conditions.
• Close the line tap and wait for the manometer positioned on the deoiler tank to show pressure equal to 0 (zero).
• Remove the air from the deoiler tank, by loosening the cap and only partially opening in the discharge tap (fig.7).
• Before removing any protections, ensure that the line switch has been positioned in the 0/OFF position.

12 Rotar Plus 30-40 TF / 04 - cod.197AA3700 - Rev.02 09/2011

 MANUTENZIONE GB
DRAIN CONDENSATE (SEE FIG. 7)
Always ensure that the oil separator tank is depressurized and blow all air 7
off the cock (A) before draining the condensate.
Once a month, drain condensate before starting the compressor. Unscrew
the plug of the filler (D), connect the supplied hose to the cock (C) and let
condensate flow into a collection container. Disconnect the hose when oil starts
flowing out instead of water.
Check oil level and top up if necessary.
CONDENSATE IS A POLLUTING MIXTURE! It may not be discharged into the
sewage. Dispose of condensate in compliance with current laws on
environmental protection.

CHECK OIL LEVEL (FIG. 7)

Remember to bleed all air off oil separator reservoir before topping up: slowly
loosen cock (A) to bleed all air off, then tighten again.
Oil is at its max. level if it is at filler max. level; also check through oil sight
glass (B).
Oil amount necessary for topping up from min. level is about 1.5 liters.
WHEN DELIVERED, THE COMPRESSOR IS FILLED WITH RotEnergy Plus

CLEAN THE AIR FILTER

• Clean the air filter (Fig. 8) from the inside towards the outside using
compressed air.
• Look at filter against the light and check for tears. Always replace a torn
filter.
• Filter cartridge and cover should be carefully fitted or dust might enter the 8
compression unit.
CHANGE THE AIR FILTER AFTER FOUR CLEANINGS

CLEAN RADIATORS
For cleaning, proceed as follows:
• remove back and upper panel from compressor cabinet;
• place a protective plastic sheet under radiator fins;
• spray (spray gun + solvent) from the outside towards the inside;
• check that air flows freely through radiator.

CHANGE OIL FILTER (FIG. 9)

9
• Always blow off air from the oil separator tank before topping up: slowly
unscrew the cock (A) until all air has blown off and then screw it again.
Always apply some oil on filter edge and seal before refitting the filter.

CHANGE OIL SEPARATOR FILTER (FIG. 10)

• Always blow off air from the oil separator tank before topping up: slowly
unscrew the cock (A) until all air has blown off and then screw it again.
• Turn anticlockwise to unscrew the filter. Use a proper tool for filters, if
necessary.
• Replace with a new filter: first, apply a thin layer of oil to seal and O-ring into
the oil separator filter and then turn clockwise to fit.

10
CHANGE OIL (FIG. 7)
When the compressor is still warm, i.e. over 70°C.
• Always blow off air from the oil separator tank before topping up: slowly
unscrew the cock (A) until all air has blown off and then screw it again.
• Unscrew the plug of the filler (D), connect the hose to the cock (C) and let
all oil flow into a collection container. When finished, disconnect the hose.
• Pour fresh oil through the filler (D) - quantity for complete filling: 6 liters.
• Fit the plug.
• Power the machine on.
• Start the machine and wait for 5 minutes, then stop the machine.

Rotar Plus 30-40 TF / 04 - cod.197AA3700 - Rev.02 09/2011 13

GB MANUTENZIONE
• Blow all air off.
• Wait for 3 minutes and check the oil level, top up if necessary. 11

WHEN DELIVERED, THE COMPRESSOR IS FILLED WITH RotEnergy Plus

EXHAUSTED OIL IS HIGHLY POLLUTANT! Dispose of exhausted oil in compliance
with current laws on environmental protection.

CHECK DRIVE BELT TENSION (FIG.11)

Use a frequency tester to carry out this check.
Proceed as follows:
• Move tester microphone closer to the belt about at mid length and hit the belt with
a wrench.
• Read value on tester. Stretch or slacken the belt if the value is different from values
indicated in the table:
Higher value = slacken
Lower value = stretch
• To adjust, proceed as follows:
loosen the nuts (E) and turn the screw (F) anti-clockwise to stretch the belt and
clockwise to slacken.
tighten nuts (E) and check frequency value once again. Repeat the above procedure,
if necessary, to reach optimal value.
When finished, re-assemble cabinet parts before starting the compressor.

V 400 / Hz 50 V 400 / Hz 60
Rotar Plus 3008 3010 3013 3008 3010
frequency (Hz) 68 71 71 72 72
Rotar Plus 4008 4010 4013 4008 4010
frequency (Hz) 87 81 81 78 79

MINIMUM PRESSURE VALVE (FIG. 12)

Close line cock and bleed all air off oil separator tank through the 12
valve (A).
Remove the fastening nuts from the flange and lift.
Replace gaskets: (1) (2).

REPLACE HOSES
Loosen hose fittings, replace the hose and then tighten the fittings.
Then follow last steps for oil change.
Thermostat – radiator oil tube
Radiator – thermostat oil tube
Thermostat – oil separator tank oil tube
Min. pressure valve – radiator air tube
Screw compressor – oil separator tank air tube

REPLACE THE DRIVE BELT (FIG. 11)

Proceed as follows:
• remove the belt guard;
• loosen the nuts (E) and turn the screw (F) clockwise until the belt is completely slack.
• remove the old belt and replace with a new one;
• turn the screw (F) counterclockwise a bit;
• tighten the nuts (E) and check for belt tension as described under “Check drive belt tension”. Adjust, if necessary.

14 Rotar Plus 30-40 TF / 04 - cod.197AA3700 - Rev.02 09/2011

 TROUBLESHOOTING GB
Problem Cause Remedy

Motor stop due to thermal relay Voltage too low Check voltage, press Reset and start once again
tripping
Overtemperature Check motor absorption and check relay settings. If absorption is
OK, press Reset and start once again

High oil consumption Defective drainage Check oil drainage tube and non-return valve

Oil level too high Check oil level and drain some, if necessary

Oil separator filter broken Change oil separator filter

Oil separator filter seals leaking Replace gaskets

Oil leakage from suction filter Suction regulator does not close Check regulator and solenoid valve

Safety valve open Pressure too high Check setting of pressure switch

Suction regulator does not close Check regulator and solenoid valve
at the end of the cycleI

Oil separator filter clogged Change oil separator filter

Compressor temperature Room temperature too high Improve ventilation

thermostat tripped
Radiator clogged Clean the radiator with solvent

Oil level too low Top up with oil

Thermostat faulty Replace thermostat, press Reset and start once again

Low compressor efficiency Belt is slack Stretch the belt, press Reset and start once again

Air filter dirty or clogged Clean or replace filter

The compressor is running but Regulator is closed and does not Remove the suction filter and check if regulator can be manually
does not compress air open because it is dirty opened. Remove and clean, if necessary.

Regulator is closed and does not Ensure that signal between pressure switch and solenoid valve is
open because it receives no available. Replace part, if damaged.
command signal

The compressor compresses air Regulator is open and does not Remove the regulator and clean
beyond set max. pressure close because it is dirty

Regulator is open and does not Ensure that signal between pressure switch and solenoid valve is
close because it receives no available. Replace part, if damaged.
command signal

Compressor does not restart Oil separator filter clogged Change oil separator filter

Min. pressure valve does not Remove and clean the valve. Replace the seal, if necessary
close perfectly

Difficult start Voltage too low Check mains voltage

Shop too cold Heat up shop

Oil inside cabinet Leakage from tubes Tighten fittings and/or replace damaged tubes

Leakage from front compressor Remove and replace seal ring.

flange

Rotar Plus 30-40 TF / 04 - cod.197AA3700 - Rev.02 09/2011 15

GB WIRING DIAGRAM - ROTAR PLUS

Plus 30 Plus 40
230V 400V 230V 400V
TC1 Transformer pr.0/230/400 sec.0/230/0/24 100/150/200VA
TC2 Transformer pr.0/230/400 sec.0/6
SB Emergency button + n.2 NC 230V 10A
FU1-FU2 Fuses6,3x32 GF 4A 500V
FU3 Fuses 6,3x32 GF 1,6A 500V
FU4-FU5-FU6 Fuses 6,3x32 GF 1A 500V
FU7 Fuses 6,3x32 GF 500 mA 500V
KM1 Line contactor 230V 50/60Hz 22 kW * 15kW * 30kW * 18,5 kW *
KM2 Delta contactor 230V 50/60Hz 22 kW * 15kW * 30kW * 18,5 kW *
KM3 Star contactor 230V 50/60Hz 22 kW * 15kW * 30kW * 15kW *
FR Thermal relay reset MAN/AUT - 1L+1R (40-50) (22-32) (45-63) (28-40)
YV Solenoid valve 220/230/VAC 50/60 Hz 15VA
SP1 Minimum pressure switch 1NC 250VAC
SP2 Pressure switch for oil separator filter 1NC 250VAC
SP3 Pressure switch for air filter 1NC 250VAC
BP Pressure transducer 0-16 bar 4-20 mA
D Electronic controller Easytronic II 24VAC
ST Thermal feeler for electronic controller
Motor cable cross-section (sq mm) 7x16 7x6 7x25 7x10
(*) = 400V AC3

16 Rotar Plus 30-40 TF / 04 - cod.197AA3700 - Rev.02 09/2011