A29B 90 CM3 - Compressor Abac - Free user manual and instructions

USER MANUAL A29B 90 CM3 Abac

Instructions for use manual

The device may not be disposed of with household rubbish. This appliance is labelled in accordance with European Directive 2012/19/UE concerning used electrical and electronic appliances (waste electrical and electronic equipment - WEEE). The guideline determines the framework for the return and recycling of used appliances as applicable throughout the EU. To return your used device, please use the return and collection systems available to you.

Drain label - drain out the tank daily - annually have the thickness of the tank walls checked by a competent body, recording the date of the service task on the label.

• The compressor must be used in a suitable environment (well ventilated with an ambient temperature of between +5°C and +40°C) and never in places affected by dust, acids, vapors, explosive or flammable gases.

• Always maintain a safety distance of at least 4 meters between the compressor and the work area.

• Any coloring of the belt guards of the compressor during painting operations indicates that the distance is too short.

• Insert the plug of the electric cable in a socket of suitable shape, voltage and frequency complying with current regulations.

• For 3-phase versions, have the plug fitted by a qualified electrician according to local regulations. When starting the compressor for the first time, check the correct direction of rotation and that this matches the direction indicated by the arrow on the belt guard (versions with plastic protection) or on the motor (versions with metal protection).

• Use extension cables with a maximum length of 5 meters and of suitable cross-section.

• The use of extension cables of different length and also of adapters and multiple sockets should be avoided.

• Always use the switch of the pressure (5) switch to switch off the compressor or use the switch of the electric panel (20) for models equipped with this. Never switch off the compressor by pulling out the plug in order to avoid restart with pressure in the head.

• Always use the handle to move the compressor. For stationary versions, we recommend using a transpallet or forklifts, making sure that they position themselves within the support feet, only lifting the machine from its front side. If the compressor is handled with lifting devices, you must avoid exerting force on the machine sides, so as not to damage it. Furthermore, make sure that the load is balanced.

• When operating, the compressor must be placed on a stable, horizontal surface to guarantee correct lubrication, see Section A3.

• Position the compressor at least 50 cm from the wall to permit optimal circulation of fresh air and to guarantee correct cooling.

• Never direct the jet of air towards persons, animals or your body. (Always wear safety goggles to protect your eyes from flying objects that may be lifted by the jet).

• Never direct the jet of liquids sprayed by tools connected to the compressor towards the compressor.

• Never use the appliance in your bare feet or with wet hands or feet.

• Never pull the power cable to pull the plug out of the socket or to move the compressor.

• Never leave the appliance exposed to adverse weather conditions (rain, sun, fog, snow).

• Never transport the compressor with the reservoir pressurized

• Never weld or machine the reservoir. In the case of faults or corrosion, replace it completely.

• Do not tamper with the safety valve.

• Never allow inexpert persons to use the compressor. Keep children and animals away from the work area.

• Never position flammable or nylon or fabric articles close to and/or on the compressor.

• Never clean the compressor with flammable liquids or solvents. Clean with a damp cloth only, after making sure that you have unplugged the compressor.

• The compressor is designed only to compress air and must not be used for any other type of gas.

• The compressed air produced by the compressor cannot not be used for pharmaceutical, food or hospital purposes except after particular treatments. It is not suitable for filling the air bottles of scuba divers.

• Never use the compressor without guards (belt guard) and never touch moving parts.

• Do not touch the parts marked with this symbol (Section A), which indicates components that reach high temperatures during operation and maintain a high temperature for some time after a machine stop.

THINGS YOU SHOULD KNOW

• This compressor is built to operate with an intermittence ratio specified on the motor’s rating plate (for example, S3-50 means 5 minutes ON and 5 minutes OFF). In the case of overheating, the thermal cutout of the motor trips, automatically cutting off the power when the temperature is too high due to excess current take-off. To facilitate machine restart, it is important not only to carry out the operations indicated but also to set the button of the pressure switch (5), returning this to the OFF position and then ON again (figures 1a-1b-3a). On single-phase versions, press the reset button on the terminal box of the motor (fig. 2). On 3-phase versions, operate manually on the button of the pressure switch, returning this to the ON position, or press the button of the thermal cutout inside the box of the electric panel (figures 3a-3b-3c). On the two-stage, three-phase versions with power greater than or equal to 7.5 HP, 220V, and on those with power greater than or equal to 10 HP, 400V, the operator must work the motor protector reset button (fig. 3d) and then bring the pressure switch back to position ON (figg. 6a-6b-6c-6d).

• The single-phase versions are fitted with a pressure (5) switch equipped with a delayed closing air vent valve (or with a valve located on the check valve) that facilitates motor start-up (3); therefore a few-second jet of air from this, with the reservoir empty, is to be considered normal.

• To guarantee machine safety, all the compressors are fitted with a safety valve that is activated in the case of failure of the pressure switch (fig. 4).

• All two-stage compressors are equipped with safety valves (14) on the air delivery manifold to the reservoir and on the connection hose between the low and high pressure located on the head. These are activated in the case of malfunctioning (fig. 5a, 5b).

• When connecting an air-powered tool to a hose of compressed air supplied by the compressor, interruption of the flow of air from the hose is compulsory.

• Multiple accessories and pneumatic tools can be applied to the compressor: for instructions for use, please refer to their respective manuals.

• Use of the compressed air for the various purposes envisaged (inflation, air-powered tools, painting, washing with water-based detergents only, etc.) requires knowledge of and compliance with the rules established for each individual use.

• Assemble the wheels (18) and the foot (16), or the swivel wheel (17) for models on which it is featured; see Section A1-A2. For the versions with fixed feet, assemble the front clamp kit or the vibration dampers, if included.

• Check for correspondence between the compressor plate data with the actual specifications of the electrical system. A variation of ± 10% with respect of the rated value is allowed.

• Insert the power plug in a suitable socket checking that the button of the pressure switch (5) located on the compressor is in the “O” (OFF) position (figures 6a-6b-6c-6d).

• For the 3-phase versions, connect the plug to a panel protected by suitable fuses.

• For the versions fitted with electric panel (20) (“Tandem” control units or delta/star starters, type B, E) have installation and connections (to the motor, to the pressure switch and to the electrovalve if any) carried out by qualified personnel.

• Check the oil level through the spy-hole (9) (figures 7a-7b) and if need be, top up the oil by unscrewing the breather plug (fig. 7c), after having disassembled the plastic protection (15) in the case of compressors type F and G (figg. 11a-11c, 12a-12f).

• At this point, the compressor is ready for use.

• Operating on the switch of the pressure switch (5) (or the selector for versions with electric panel, (figures 6a-6b-6c-6d), the compressor starts, pumping air in the reservoir through the delivery hose. On 2-stage versions, air is sucked in to the so-called low pressure cylinder liner and precompressed. It is then routed, through the recirculation hose, into the so-called high pressure liner and then into the reservoir. With this work cycle, it is possible to reach higher pressure, with availability of air at 11 bar (15 bar for special machines).

• On reaching maximum operating pressure (5) (factory-set during testing), the compressor stops, venting the excess air present in the head and in the delivery hose through a valve located under the pressure switch (in delta/ star versions, through an electrovalve that is activated when the motor stops).

• The absence of pressure in the head facilitates subsequent restart. When air is used, the compressor restarts automatically when the lower calibration value is reached (approx. 2 bar between upper and lower). The pressure inside the reservoir can be checked on the gauge (10) provided (fig. 4).

• The compressor continues to operate automatically with this work cycle Preserve this handbook for future reference Instructions for use manual34

until the position of the switch of the pressure switch (5) (or of the selector of the electric panel) figures 6a-6b-6c-6d) is modified. To use the compressor again, wait at least 10 seconds after this has been switched off before restarting.

• In the versions with electric panel, the pressure switch must always be aligned with the I (ON) position.

• In tandem versions (type E), the control unit provided permits use of only one of the two compressor groups (if necessary alternatively) or of both at the same time according to requirements. In this second case, start-up will be differentiated slightly to avoid excessively high current take-off at start-up (timed starting).

• Only the wheel-mounted compressors are fitted with a pressure reducer (in the versions with fixed feet, it is usually installed on the use line). Air pressure can be regulated in order to optimize use of air-powered tools operating on the knob with the valve open (pulling it up and turning it in a clockwise direction to increase pressure and counterclockwise to reduce this) (fig. 8). Once you have set the value required, push the knob down to lock it.

• The value set can be checked on the gauge (for versions equipped with this, fig. 9).

• Please check that the air consumption and the maximum working pressure of the pneumatic tool to be used are compatible with the pressure set on the pressure regulator and with the amount of air supplied by the compressor.

• When you have finished working, stop the machine, pull out the plug and empty the reservoir. AIR RECEIVER (ON TANK-MOUNTED UNITS)

• It is necessary to prevent rust formation: depending on the conditions of use, condensation may accumulate inside the tank (1) and must be discharged daily. This may be done manually, by opening the drain valve, or by means of the automatic drain, if fitted to the tank (4). Nevertheless, a weekly check of correct functioning of the automatic valve is needed. This has to be done by opening the manual drain valve and check for condensate (fig. 14a, 14b).

• It is necessary to have the thickness of the air tank walls (1) annually checked by a competent body, because corrosion inside the tank may reduce thickness of the steel walls, with the consequential risk of explosions. If applicable, observe the local standards. It is not allowed to use the air tank when wall thickness does not reach the minimum value indicated in the tank certification (part of the documentation delivered with the unit).

• Lifetime of the air receiver (1) mainly depends on the working environment. Avoid installing the compressor in a dirty and corrosive environment, as this can reduce the vessel lifetime dramatically.

• Do not anchor the vessel (1) or attached components directly to the ground or fixed structures. Fit the pressure vessel with vibration dampers to avoid possible fatigue failure caused by vibration of the vessel during use.

• Use the vessel (1) within the pressure and temperature limits stated on the nameplate and the testing report.

• No alterations must be made to this vessel by welding, drilling or other mechanical methods. MAINTENANCE

• The service life of the machine depends on maintenance quality.

• PRIOR TO ANY OPERATION SET THE PRESSURE SWITCH TO THE OFF POSITION, PULL OUT THE PLUG AND COMPLETELY DRAIN THE RESERVOIR.

• Perform service tasks with the machine cold, wearing the personal protective equipment. Use the equipment that suits each service task and only use original spare parts.

• Check that all screws, in particular those of the head of the unit (2) are tightly drawn up (fig. 10). Check head tightening before the first start up and after the first hour of work.

TABLE 1 – TIGHTENING OF HEAD TENSION RODS

• To perform the main service tasks on type F compressors, disassemble the plastic protection (15) (figures 11a-11c). When you are finished with the service task, reassemble the plastic protection, following the reverse procedure.

• To perform the main service tasks on type G compressors, disassemble the plastic protection (15) (fiures 12a-12f), removing the front semi-shell first and then the rear one. When you are finished with the service task, reassemble the plastic protection, following the reverse procedure.

• Clean the suction filter (13) according to the type of environment and in any case at least every 100 hours. If necessary, replace the filter (a clogged filter impairs efficiency while an inefficient filter causes harsher wear on the compressor (figures 13a - 13b).

• Change the oil after the first 100 hours of operation and subsequently every 500 hours. Check the oil level periodically (9).

• Use ALTAIR. Never mix different grade oils. If the oil changes color (whitish = presence of water; dark = overheated), it is good practice to replace the oil immediately.

• After topping up (8), tighten the plug (fig. 7c) making sure that there are no leaks during use. Once a week, check the oil level to assure lubrication in time (fig. 7a, 7b).

• Periodically, check the tension of the belts which must have a flexion (f) of around 1 cm (fig. 15). *Spent oil and condensate MUST BE DISPOSED OF in compliance with protection of the environment and current legislation. The compressor must be disposed in conformity with the methods provided for by local regulations

Request the assistance of a qualified electrician for operations on electric components (cables, motor, pressure switch, electric panel, etc). TABLE 2 – MAINTENANCE FUNCTION AFTER THE FIRST 100 HOURS EVERY 100 HOURS EVERY 500 HOURS Cleaning of intake filter and/ or substitution of filtering element

Tightening of head tension rods Check head tightening before the first start up and after the first hour of work Draining tank condensate Daily Checking the tension of the belts Periodically Air tank wall thickness inspection. Annually

Air leak from the valve of the pressure switch. Check valve does not perform its function correctly due to wear or dirt on the seal. Unscrew the hex-shaped head of the check valve, clean the housing and the special rubber disk (replace if worn). Re-assembler and tighten carefully (gures 16a-16b). Condensate drainage cock (4) open. Close the Condensate drainage cock. Rilsan hose not inserted correctly in pressure switch. Insert the Rilsan hose correctly inside the pressure switch (g. 17).35

Reduction of efciency, frequent start-up. Low pressure values. Excessively high consumption. Decrease the demand of compressed air. Leaks from joints and/or pipes. Change gaskets. Clogging of the suction lter. Clean/replace the suction lter (13) (gures 13a-13b). Slipping of the belt. Check belt tension (g. 15). The motor (3) and/or the compressor overheat irregularly. Insufcient ventilation. Improve ambient conditions. Closing of air ducts. Check and if necessary clean the air lter (13). Insufcient lubrication. Top up or change oil (gures 18a-18b-18c-18d). After an attempt to start the compressor, it stops due to tripping of the thermal cutout caused by forcing of the motor. Start-up with head of the compressor charged. Release the compressor head by using the pressure switch push button (5). Low temperature. Improve ambient conditions. Voltage too low. Check that the mains voltage matches that of the dataplate. Eliminate any extensions. After an attempt to start the compressor, it stops due to tripping of the thermal cutout caused by forcing of the motor. Incorrect or insufcient lubrication. Check level (9), top up and if necessary change the oil. Inefcient electrovalve. Call the Service Center. During operation, the compressor stops for no apparent reason. Tripping of the thermal cutout of the motor. Check level oil (9). Single-stage, mono-phase versions: operate on the button of the pressure switch (5) returning this to the OFF position (g. 1a). Reset the thermal cutout (g. 2) and restart (gures 1b). If the fault persists, call the Service Center. Versions with delta-star starter: operate on the button of the thermal cutout located inside the box of the electric panel (20) (g. 3c) and restart (g. 6d). If the fault persists, call the Service Center. Two-stage, three-phase versions with power greater than or equal to 7.5 HP, 220V, Two-stage, three-phase versions with power greater than or equal to 10 HP, 400V: work the motor protector reset button (g. 3d), to bring the pressure switch back into position ON (gures. 6a-6b-6c-6d). Other versions: Operate on the button of the pressure switch (5) returning this to the OFF position and then to ON again (g. 1a-1b). If the fault persists, call the Service Center. Electric fault. Call the Service Center. When operating, the compressor vibrates and the motor emits an irregular buzzing sound. If it stops, it does not restart although the sound of the motor is present. Single-phase motors: faulty capacitor. Have the capacitor replaced. 3-phase motors: One of the phases of the 3-phase power supply is missing due probably to blowing of a fuse. Check the fuses inside the electric panel or the electric box (20) and if necessary replace those that have been damaged (g. 19). Irregular presence of oil in the network. Too much oil inside the unit. Check oil level (9). Wear on segments. Call the Service Center. Leaking of condensate from the vent cock (4). Presence of dirt/grit inside the cock. Clean the cock. Any other type of operation must be carried out by authorized Service Centers, requesting original parts. Tampering with the machine may impair its safety and in any case make the warranty null and void.36

TAULUKKO 2 – HUOLTOVÄLIT

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The device may not be disposed of with household rubbish. This appliance is labelled in accordance with European Directive 2012/19/UE concerning used electrical and electronic appliances (waste electrical and electronic equipment - WEEE). The guideline determines the framework for the return and recycling of used appliances as applicable throughout the EU. To return your used device, please use the return and collection systems available to you.