Start O15 - Compressor Abac - Free user manual and instructions

USER MANUAL Start O15 Abac

WARNING: Please read and understand this manual before operating the compressor

Always wear protection devices.

Condensate drain label. Periodical service inspection of the air receiver is neede

ed. Record the date of intervention on the label.

Read and understand all of the operating instructions, safety precautions and warnings in the Instruction Ma- nual before operating or maintaining this compressor. Most accidents that result from compressor operation and maintenance are caused by the failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing a potentially hazardous si- tuation before it occurs, and by observing appropriate safety procedures. Basic safety precautions are outlined in the “SA- FETY” section of this Instruction Manual and in the sections which contain the operation and maintenance instructions. Hazards that must be avoided to prevent bodily injury or machine damage are identied by WAR- NINGS on the compressor and in this Manual. Never use this compressor in a manner that has not been specically recommended by manufacturer, un- less you are absolutely sure that the planned use will be safe for you and others.

WARNING: indicates a potentially hazardous situa-

tion which, if ignored, could result in personal injury. NOTE: emphasizes essential information.

COULD RESULT FROM IMPROPER OR UNSAFE

your hands, ngers or other body parts near the com- pressor’s moving parts.

2. NEVER OPERATE WITHOUT ALL GUARDS IN

PLACE: if maintenance or servicing requires the remo- val of a guard or safety features, be sure to replace the guards or safety features before resuming operation of the compressor. 3 . ALWAYS WEAR EYE PROTECTION: compres- sed air must never be aimed at anyone or any part of the body.

4 . PROTECT YOURSELF AGAINST ELECTRIC

SHOCK: prevent body contact with grounded surfaces such as pipes, radiators, ranges and refrigeration en- closures. Never operate the compressor in damp or wet locations.

5. DISCONNECT THE COMPRESSOR from the

power source and remove the compressed air from the air tank before servicing, inspecting, maintaining, clea- ning, replacing or checking any parts. 6 . VOID UNINTENTIONAL STARTING: do not carry the compressor while it is connected to its power sour- ce or when the air tank is lled with compressed air. Ensure the knob of the pressure switch is in the “OFF” position before connecting the compressor to the power source.

7. STORE COMPRESSOR PROPERLY: when not in

use, the compressor should be stored in a dry place. Keep out of reach of children. Store in a lockable area when not in use.

8. KEEP WORK AREA CLEAN: cluttered work areas

can cause injuries. Clear all work areas of unnecessary tools, debris, furniture etc.

9. KEEP CHILDREN AND OTHER PEOPLE AWAY

dren or other people interfere with the compressor or extension cord. All visitors should be kept safely away from work area.

10. DRESS PROPERLY: do not wear loose clothing

or jewellery. They can be caught in moving parts. Wear protective hair covering to contain long hair.

11. DO NOT ABUSE POWER CORD: never yank

or pull the power cord to disconnect it from the plug socket. Keep the cord away from heat, oil and sharp edges.

12. MAINTAIN COMPRESSOR WITH CARE: follow

instructions for lubricating. Inspect power cords perio- dically and if damaged, have them repaired by an au- thorized service facility.

13. OUTDOOR USE OF EXTENSION CORDS:

when compressor is in use outdoors, use only exten- sion cords suitable for outdoor use.

14. STAY ALERT: take care. Use common sense. Do

not operate compressor when you are tired or if you are under the inuence of alcohol, drugs or medication that makes you drowsy.

15. CHECK FOR DAMAGED PARTS AND AIR LEA-

KS: if a guard or other part is damaged it should be ca- refully checked to determine that it will operate properly and perform its intended function. A guard or other part that is damaged should be properly repaired or repla- ced by an authorized service center. Defective pressure switches should be replaced by authorized service center. Do not use compressor if power switch does not turn it on and off.

16. OPERATE THE COMPRESSOR ACCORDING

TO THE INSTRUCTIONS PROVIDED HEREIN: this compressor has been designed and manufactured exclusively to produce compressed air. Operate the compressor according to the instructions provided.

17. HANDLE COMPRESSOR CORRECTLY: opera-

te the compressor according to the instructions provi- ded herein. Never allow the compressor to be operated by children, individuals unfamiliar with its operation or unauthorized personnel.

18. KEEP ALL SCREWS, BOLTS AND COVERS

TIGHTLY IN PLACE: check their condtions periodically.

19. KEEP MOTOR AIR VENT CLEAN: frequently

check for dust build-up.

20. OPERATE COMPRESSOR AT THE RATED

VOLTAGE: if using the compressor at a higher voltage than the rated voltage, it will result in abnormally fast motor revolution and may damage the unit.

21. NEVER USE A COMPRESSOR WHICH IS

DEFECTIVE OR OPERATING ABNORMALLY: if the compressor appears to be operating unusually,14 only by qualied electrician The green (or green and yellow) conductor in the cord is the grounding wire. Never connect it to a live terminal. Never disassemble the compressor or carry out other connections to the pressure switch.

1.5 USE OF EXTENSION CABLE

Use only three-way extension cables that have three-pin connecting plugs and three-pole sockets that accept the compressor plug. Do not use extension cables that are damaged or squashed. An under-rated cable will cause a drop in line voltage resulting in loss of power and overheating. Check table A (pag.8) in order to choose cable cor- rect size.

WARNING: Avoid electrical shock hazard.

Never use this compressor with a damaged or frayed electrical cord or extension cord. Never use in or near water or in any environment where electric shocks are possible.

Remove the compressor from its packing (g.1), ma- kes sure it is in perfect condition, checking if it was da- maged during transport, and carry out the following operations:

• If not already tted, t the wheels and rubber feet following the instructions in g.2.

• Transport the compressor correctly, do not overturn it or lift it with hooks or ropes (g. 5/6).

• Position the compressor in a well aired place, pro- tected against atmospheric agents and not in a place subject to explosion hazard.

• If the surface is inclined (g.3), check if the com- pressor moves while in operation, if it does, secure the wheels with two wedges. If the surface is a bracket or a shelf top, make sure it cannot fall, securing it in a suitable way.

• To ensure good ventilation and efcient cooling, the compressor’s belt guard must be at least 50 cm from any wall (g. 4).

• Compressors tted on the tank, with xed feet, should not be rigidly secured to the ground. In this case, we advise you to t 4 anti-vibration supports.

2.2 ELECTRICAL CONNECTION

Single-phase compressors are supplied with an electrical cable and a two-pole + earth plug. The compressor must be connected to a grounded power socket (g.7). Three-phase compressors must be installed by a specialised technician. Three-phase compressors are supplied without a plug. Connect a plug, with screw-on grommet and securing collar (g.7), to the cable, con- sulting the table B (page 8). NOTE: any damage caused by incorrect connections of the power line to the mains, automatically excludes making strange noises, or otherwise appears defective, stop using it immediately and arrange for repairs by an authorized service center.

22. DO NOT WIPE PLASTIC PARTS WITH SOL-

VENT: solvents such as gasoline, thinner, benzene, carbon tetrachloride, and alcohol may damage and crack plastic parts. Wipe plastic parts with a soft cloth lightly dampened with soapy water and dry thoroughly.

23. USE ONLY GENUINE REPLACEMENT PARTS:

replacement parts which are not original may void your warranty and can lead to malfunction and resulting inju- ries.

24. DO NOT MODIFY THE COMPRESSOR. Always

contact the authorized service center for any repairs. Unauthorized modication may not only impair the compressor performance but may also result in acci- dent or injury to repair personnel.

25. TURN OFF THE PRESSURE SWITCH WHEN

THE COMPRESSOR IS NOT IN USE: turn the knob of the pressure switch OFF, disconnect it from the power source and open the drain cock to discharge the com- pressed air from the air tank.

26. NEVER TOUCH HOT SURFACES: do not touch

tubes, heads, motors and cylinder.

ted: depending on the conditions of use, condensate may accumulate inside the tank and must be drained every day. Periodical service inspection of the air recei- ver is needed, as internal corrosion can reduce the ste- el wall thickness with the consequent risk of bursting. Local rules need to be respected, if applicable.

29. DO NOT STOP COMPRESSOR BY PULLING

OUT THE PLUG: use the “0/OFF” knob of pressure switch.

30. USE ONLY RECOMMENDED AIR HANDLING

PARTS ACCEPTABLE FOR PRESSURE not less than the maximum rated pressure.

This compressor has been designed for use with in- termittent (not continuous) operation. Please check service factor on the CE label: Ex. S3 - 25% = 2,5 minutes run and 7 minutes stop, considering ideal enviromental condition (max temp 25°C). Respect of these tips and regular maintenance will ensure good functioning. Compressors on wheels with power greater or equal than 3Hp/2,2 kW, are intended to be use indoor.

1.4 ELECTRICAL CONNECTION

The compressor should be grounded while in use to protect the operator from electric shock. Single- phase compressor is equipped with a three-core cable and three-pin grounding type plug to t the proper grounding type socket. Three-phase compressor is supplied with electrical cable without plug. Connection should be conducted15 warranty of electrical parts. To avoid connection errors, we suggest you to contact a specialised technician.

Check that the mains power matches that indicated on the electrical data-plate (g.8), the permissible tole- rance range is +/-5%. When rst starting compressors operating on 3-pha- se voltage, check the rotation direction of the cooling fan by comparing it with the direction of the arrow on the belt guard or on the protective housing. Fit the plug in the power socket and start the com- pressor, turning the pressure switch knob into position “I/On” (g.9). The compressor is fully automatic, and is controlled by the pressure switch which stops it when tank pressu- re reaches maximum value and restarts it when it falls to minimum value. The pressure difference between maximum and minimum values is usually about 2 bar (29 psi). E.g.: the compressor stops when it reaches 8 bar (116 psi) and restarts automatically when the pressure inside the tank drops to 6 bar (87 psi). After connecting the compressor to the power line, load it to maximum pressure and check corrrect fun- ctioning. NOTE: some models could be equipped with a di- scharge valve on the top of the head, useful to facilitate the next start. In this case it is normal a puff of air when compressor stops

2.4 MOTOR PROTECTION DEVICES

Compressors are equipped with an automatic ther- mal breaker located inside the winding, this stops the compressor when motor temperature reaches exces- sively high values. If the breaker is tripped, the compressors restarts au- tomatically after 10 to 15 minutes If the protection device trips again, it’s higly recco- mended to stop the compressor, disconnect electric plug and contact the nearest service centre. Note for three phases model: compressors must be connected to a power socket protected by a suitable differential switch (magneto-thermal, see. table C-pa- ge.8).

2.5 ADJUSTING THE WORKING PRESSURE

You do not have to use the maximum operating pres- sure at all times. On the contrary, the pneumatic tool being used often requires less pressure. Check correct pressure on tool’s manual. On compressors supplied with a pressure reducer, operating pressure must be correctly adjusted (see g.10). Release the pressure reducer knob by pulling it up, adjust pressure to the required value by turning the knob clockwise to increase pressure and anti-clockwi- se to reduce it. When you have obtained optimum pressure, lock the knob by pressing it downward. For pressure reducers equipped without a pressure gauge, the set pressure can be seen on the graduated scale located on the reducer body. On pressure reducers equipped with a pressre gau- ge, pressure can be seen on the gauge itself.

WARNING: Some pressure regulators do not have

“push to lock”, therefore simply turn the knob to adjust the pressure. For those models without pressure reducer, a sui- table pressure reducer must be tted on the distribution line by the user.

2.6 CAUTIONS WHILE USING

Do not unscrew any connection while the tank is pressurised, always check if the tank is pressure free. Do not drill holes, weld or purposely deform the air tank. Do not do any jobs on the compressor unless you have disconnected the power plug. Temperature in operating ambient: 0°C +35°C. Do not aim jets of water or inammable liquids on the compressor. Do not place inammable objects near the compres- sor. Never aim the air jet at people or animals Do not transport the compressor while the tank is pressurised Be careful with regard to some parts of the com- pressor such as the head and delivery tubes, as they can reach high temperatures. Do not touch these parts (g.11) Transport the compressor, lifting or pulling it with the appropriate grips or handles. Keep children and animals well away from the ma- chine operating area. If using the compressor for painting: a) Do not work in closed environments or near to na- ked ames b) Make sure there is adequate exchange of air c) Protect your nose and mouth with a mask. If the electrical cable or plug are damaged, do not use the compressor and contact an authorised service centre to replace the faulty element. Do not insert hands and/or any object inside pro- tection grilles.

Before attempting any maintenance jobs on the compressor, make sure of the following: Master power switch in position “0/Off”. Compressor power switch in position “0/Off” No pressure in the air tank Wait for all parts to cool down, so to avoid any burn. If necessary, remove shroud in order to access inner parts. Take care to not break or pull any cable or pneu- matic connections. EN16 5 NOTE

• For the European market, compressors are manu- factured in order to meet current legislation (see the declaration of conformity).

• The sound pressure level is measured in a free ran- ge at a distance of 1 mt. ±3dB(A) at the maximum wor- king pressure.

• The value of the sound level may increase from 1 to 10 dB(A) depending on the environment in which the compressor is installed.

For the whole time that the compressor is not used before unpacking it, store it in a dry place at a tempe- rature between +5°C and + 45°C and sheltered away from weather. For the whole time that the compressor is not used after unpacking it, while waiting to start it up or due to production stoppages, place sheets over it to protect it from dust e dirty. The oil is to be replaced and the operational efcien- cy of the compressor is to be checked if it is not used for long periods.

5.3 PNEUMATIC CONNECTIONS

Make sure that pneumatic tubes for compressed air with maximum pressure characteristics that are ade- quate for the compressor used. Do not attempt to re- pair faulty tubes.

Compressor and all materials (package, oil and spa- re parts....) must be correctly disposed according to the local laws.

3.1 CLEAN/REPLACE SUCTION FILTER

Every 50 hours of duty: we advise you to dismant- le the suction lter and clean the ltering element by blowing compressed air on it (g.12). You are recommended to replace the lter element at least once a year if the compressor operates in a clean environment, but more frequently if in a dusty en- vironment.

3.2 CONDENSATE DRAIN

The compressor generates condensate water which accumulates in the tank. The condensate in the tank must be drained daily by opening the drain tap (g.13) under the tank. Periodical service inspection of the air receiver is ne- eded, as internal corrosion can reduce the steel wall thickness with the consequent risk of bursting. Take care if there is compressed air inside the tank, water could ow out with considerable force. Recom- mended pressure: 1-2 bar max.

Loss of air in valve under pressure switch It could depend on poor tightness of the check valve. Take the following action (g.14): Discharge all pressure from the tank Unscrew the hexagon-head of the valve Carefully clean both the rubber disk (A) and its seat. Ret all parts accurately. Air losses These can be caused by poor tightness of a union, check all unions, wetting them with soapy water. Reduction of performance. Frequent start-up. Low pressure values. Excessive performance request. Check for any leaks from the couplings and/or pipes. Intake lter may be clogged. Replace the seals, clean or replace the lter. Compressor turns but does not load This may be due to failure of the valves or of a dama- ged/broken head gasket. Parts must be replaced by service centre. Compressor no starting If the compressor has trouble starting, check the fol- lowing : Does mains power match that of the data-plate? Are power cable extensions of adequate diameter or length? Is the work environment too cold? (under 0°C) Was the thermal-breaker tripped? (see 2.4) Is power supplied to the electrical line? Compressor not stopping If the compressor does not stop when maximum pressure is reached, the tank safety valve comes into operation. Stop the compressor and contact the nearest service centre.17