ZICOM15010 - Compressor Zipper - Free user manual and instructions

USER MANUAL ZICOM15010 Zipper

Green ZIPPER air compressor with attached cooling unit (no visible text or symbols on body)

ZI-COM200-10

EAN: 9120039232942

Green ZIPPER air compressor with attached control panel and wheels (no visible text or symbols on body)

CE

ZI-COM150-10

EAN: 9120039234069

11.1 Intended Use....17
11.2 Security instructions .... 18
11.3 Assembly 19

12 OPERATION 20

12.1 Operation instructions.... 20
12.2 Operation 21

13 MAINTENANCE 21

13.1 Cleaning 21
13.2 Maintenance plan 22

13.2.1 Air filter cleaning 22
13.2.2 Condensation water 22
13.2.3 Storage.... 22

13.3 Disposal....22

14 TROUBLE SHOOTING 23

15 PREDGOVOR (HR) 24

16 SIGURNOST 25

16.1 Namjenska uporaba....25
16.2 Upute o sigurnosti 26

17 MONTAŻA 27

17.1 Sastavljanje....27

18 RAD 28

18.1 Upute o radu....28
18.2 Rukovanje 28

19 ODRŽAVANJE 29

19.1 Čišćenje....29
19.2 Servisiranje i plan održavanja 29

19.2.1 Čišćenje filtra za zrak 29
19.2.2 Kondenzirana voda 29
19.2.3 Skladištenje 30

19.3 Zbrinjavanje 30

20 UKLANJANJE POGREŠAKA 30

21 AVANT-PROPOS (FR) 31

22 SECURITE 32

EN EC-CONFORM: This product complies with EC-directives

HR CE SUKLADNOST: Ovaj proizvod ispunjava direktive EZ-a.

EN READ THE MANUAL! Read the user and maintenance manual carefully and get familiar with the controls in order to use the machine correctly and to avoid injuries and machine defects.

HR ROČITAJTE UPUTU! Pažljivo pročitajte uputu za uporabu i održavanje stroja i dobro se upoznajte s elementima za rukovanje strojem kako biste mogli ispravno rukovati strojem te spriječiti ljudske štete i štete na stroju.

EN ATTENTION! Ignoring the safety signs and warnings applied on the machine as well as ignoring the security and operating instructions can cause serious injuries and even lead to death.

HR UPOZORENJE! Obratite pozornost na simbole za sigurnost! Nepoštivanje propisa i uputa za korištenje stroja može dovesti do teških ljudskih šteta i smrtnih opasnosti.

EN Protective clothing!

EN Attention! Machine starts automatically!

HR Oprez - automatsko pokretanje!

EN Do not operate without safety protection!

Labeled diagram of an air compressor with numbered parts for identification

1	Kompressorpumpe / Compressor pump / Pumpa kompresora / Pompe du compresseur	6	Rad /Wheel / Kotač / Roue
2	Schaltereinheit / Pressure switch unit/ Jedinica s prekidačima / Unité de commutation	7	Druckbehälter / Air tank / Tlačni spremnik / Réservoir sous pression
3	Luftanschluss / Air connection / Priključak za zrak / Prise d'air	8	Sicherheitsventil / Safety valve / Sigurnosni ventil /Sigurnosni ventil / Soupape de sûreté
4	Ruckschlagventil / Not return valve / Nepovratni ventil / Clapet antiretour	9	Motor / Moteur
5	Ablasshahn für Kondenswasser / Drain clock /Slavina za ispuštanje kondenzirane vode / Robinet de décharge de l'eau de condensation	10	Luftfilter / Air filters / Filtar za zrak / Filtre à air

3.1 Technische Daten / Technical data / Tehnički podaci / Données techniques

	ZI-COM150-10	ZI-COM200-10
Spannung / Voltage / Napon Tension	230 V / 50 Hz	230 V / 50 Hz
Leistung / Power / Snaga Puissance	2,2 kW	2,2 kW
Druckbehältervolumen / Tank capacity / Volumen tlačnog spremnika Volume du réservoir sous pression	150 l	200 l
Dauer Druckbehälterfüllung / Tank filling duration/ Trajanje punjenja tlačnog spremnika Durée d remplissage du réservoir sous pression	210 s	250 s
Ansaugleistung / Air power / Usisna snaga Puissance d'aspiration	356 l/min	356 l/min
Betriebsdruck/ Working pressure / Radni tlak Pression de service	max. 10 bar (1,0 MPa)	max. 10 bar (1 MPa)
Motordrehzahl/ Rated speed / Broj okretaja motora Vitesse de rotation du moteur	2850 min ^-1	2850 min ^-1
Schutzklasse / Protection class / Klasa zaštite Classe de protection	IP 20	IP 20
Maschinenmaße / Machine dimension / Dimenzije stroja Dimensions de la machine	1320 x 415 x 950 mm	1370 x 490 x 970 mm
Gewicht / Weight / Težina Poids	94 kg	126 kg
Garantierter Schallleistungspegel / Guaranteed Sound power level / Razina zvučne snage LWA Niveau de puissance acoustique garanti	97 dB(A)	97 dB(A)

4 VORWORT (DE)

This manual contains important information and advice for the correct and safe use and maintenance of the air compressor ZI-COM150-10 and ZI-COM200-10.

Following the usual commercial name of the device (see cover) is substituted in this manual with the name "machine".

The manual is part of the machine and may not be stored separately. Read it profoundly before first use of the machine and keep it for later reference. When the machine is handed to other persons always put the manual to the machine.

Please follow the security instructions!

Please read the entire manual, to prevent misunderstandings, machine damage or even injuries!

Due to continuous development of our products illustrations, pictures might differ slightly.

If you however find errors in this manual, please inform us.

Technical changes excepted!

Copyright law

© 2017

This manual is protected by copyright law – all rights reserved. Especially the reprinting as well as the translation and depiction of pictures will be prosecuted by law. Court of jurisdiction is the Landesgericht Linz or the competent court for 4707 Schlüsslberg, AUSTRIA.

Customer Support

The machine must only be used for its intended purpose! Any other use is deemed to be a case of misuse. To use the machine properly you must also observe and follow all safety regulations, the assembly instructions, operating and maintenance instructions lay down in this manual.

All people who use and service the machine have to be acquainted with this manual and must be informed about the machine's potential hazards.

It is also imperative to observe the accident prevention regulations in force in your area.

The same applies for the general rules of occupational health and safety.

The machine is used for:

Generating compressed air for tools operated by compressed air.

Any manipulation of the machine or its parts is a misuse, in this case ZIPPER-MASCHINEN and its sales partners cannot be made liable for ANY direct or indirect damage.

WARNING

Using compressed air equipment and tools

Please pay attention to the air consumption with the respective manufacturer. Check the performance of your compressor if the power is enough!

Ambient conditions

The machine may be operated:

humidity

max. 70%

temperature

+5°C to +40°C (+41°F to +104°F)

The machine shall not be operated in areas exposed to increased fire or explosion hazard.

Prohibited use:

• The operation of the machine outside the stated technical limits described in this manual is forbidden.
  • The operation of the machine without provided protective devices is prohibited
• Any manipulation of the machine and parts is forbidden.
• The use of the machine not being suitable for the use of the machine and not being certified is forbidden.
  • The operation of the machine without provided protective devices is prohibited.
• The use of the machine for any purposes other than described in this user-manual is forbidden.
  • The unattended operation on the machine during the working process is forbidden!
• It is not allowed to leave the immediate work area during the work is being performed.
• The machine has not been designed for use in commercial, trade or industrial applications. Use the machine only in try areas.
  • To aim the compressed air gun at persons is prohibited.

11.2 Security instructions

Missing or non-readable security stickers have to be replaced immediately!

The locally applicable laws and regulations may specify the minimum age of the operator and limit the use of this machine!

To avoid malfunction, machine defects and injuries, read the following security instructions!

• Keep your work area dry and tidy! An untidy work area may cause accidents. Avoid slippery floor!
• Make sure the work area is lighted sufficiently!
  • Work only in a well ventilated area!
• Do not overload the machine!
• Always stay focused when working. Reduce distortion sources in your working environment. The operation of the machine when being tired, as well as under the influence of alcohol, drugs or concentration influencing medicaments is forbidden!

• Only one person shall operate the machine
• The machine must be operated only by trained persons (knowledge and understanding of this manual), which have no limitations of motor skills compared with conventional workers.
• Do not allow other people, particularly children, to touch the machine or the cable. Keep them away from your work area
• Make sure there is nobody present in the dangerous area. The minimum safety distance is 2m

- Use personal safety equipment: ear protectors, safety goggles and work wear when working with or on the machine!

• The plug of an electrical tool must strictly correspond to the socket. Do not use any adapters together with earthed electric tools
• Each time you work with an electrically operated machine, caution is advised! There is a risk of electric shock, fire;
• Protect the machine from dampness (causing a short circuit)
• When working with the machine outdoors, use extension cables suitable for outdoor use
• Use power tools and machines never in the vicinity of flammable liquids and gases (danger of explosion)
• Check the cable regularly for damage
• Do not use the cable to carry the machine or to fix the work piece
• Protect the cable from heat, oil and sharp edges

• Avoid body contact with earthed components

• Never leave the machine running unattended! Before leaving the working area switch the machine off and wait until the machine stops.

• Always disconnect the machine prior to any actions performed at the machine.
• Avoid unintentional starting
• Do not use the machine with damaged switch

Safety instructions when working with compressed air guns

• Compressor pump and lines reach high temperatures during operation. Touching cause burns
- When removing the hose coupling, hold the coupling piece of the hose is by hand. So the injury from rebounding hose is avoided

Safety instructions when paint spraying

• Do not process paints or solvents with a flash point of less than 55^ .
• Do not heat paints and solvents.
• If harmful liquids processed use dust masks. Note the instructions on protective measures made by the manufacturers of such substances.
• During the paint spraying process and in the work space may not be smoked. Even paint fumes are highly inflammable.
  • In working area smoking and open flames are forbidden during paint spraying.
  • Do not keep or consume food and drinks in the working area. Paint fumes are harmful.
• Work only in a well ventilated area that is bigger than 30m^3 . Do not spray against wind direction. Note the local regulations.
• Do not process white spirit, butyl alcohol and methylene chloride when use PVC hoses because lifetime will substantially reduces

Operation of pressure vessels

• Anyone who operates a pressure vessel has this to get in proper condition, operate it properly, monitor, make any necessary maintenance and repair work without delay and to meet the circumstances necessary security measures.
  • A pressure vessel may not be operated if it has defects or will endanger employees or third persons.
  • The pressure vessel must be regularly checked for damage such rust,...assembly

Please check the product contents immediately after receipt for any eventual transport damage or missing parts. Claims from transport damage or missing parts must be placed immediately after initial machine receipt and unpacking before putting the machine into operation. Please understand that later claims cannot be accepted anymore.

11.3 Assembly

Wheels:

Mount the wheels like on the picture

Hex Bolt Wheel Rim Wheel Bracket Washer Nut

Air filter:

Mount the air filter like on the picture.

Remove any blank cover previously!

Oil:

Place machine on a level ground. Open the oil filler. Fill in Oil SAE30 until it reaches the middle mark of the oil sight glass. Close oil filler

Fit the air filters to cylinder heads of the compressor. Sight glass Oil Filler

WARNING

ATTENTION! For transport oil has been drained. Fill up with oil SAE30 before first operation! Failure to do so will result in permanent engine damage and void guarantee!

12 OPERATION

Device to be operated in a perfect state only. Inspect the device visually every time it is to be used. Check in particular the safety equipment, electrical controls, electric cables and screwed connection for damage and if tightened properly. Replace any damaged parts before operating the device.

12.1 Operation instructions

WARNING

Perform all machine settings with the machine being disconnected from the power supply!

NOTICE

• The oil level in the compressor pump has to be checked before each use
- The machine should be set up near the working consumer. Avoid long air lines and long supply lines (extensions).
• Make sure the intake air is dry and dust-free.
- Do not set up the machine in damp or wet areas.
- The machine must be operated on firm, level ground
- Safety valve must be closed before the start
- When removing the hose coupling, hold the coupling piece of the hose is by hand. So the injury from rebounding hose is avoided

12.2 Operation

Switch on:

Pull out the On-Off-switch

Switch off:

Press back in the On-Off-switch

Setting output pressure:

The output pressure can be set with the pressure regulator

Output pressure:

The output pressure is shown on the manometer output pressure

Air tank pressure:

The air pressure is shown on the manometer air pressure

Output 1 and 2:

To connect a device place the union joint into the coupling. The sleeve will go to starting position automatically. To disconnect pull the sleeve backwards and remove the hose.

On-Off-switch On off Manometer air tank Pressure regulator Manometer output pressure Safety valve Output 1 Output 2

13 MAINTENANCE

ATTENTI ON

Bevor maintenance:

• Switch off and disconnect from the power supply!
• Let cool down the air compressor!
• Depressurize the air tank

The machine does not require intense maintenance. However, to ensure a long lifespan, we strongly recommend following the upkeep and maintenance plan.

Repairs must be carried out by specialists! Use original ZIPPER parts only!

NOTICE

Only a properly maintained equipment may be a satisfactory tool. Care and maintenance deficiencies can cause unpredictable accidents and injuries.

Repairs should be performed only by authorized service centers.

Improper operation may damage the equipment or endanger your safety.

13.1 Cleaning

Keep the safety devices free of dirt and dust as far as possible. Wipe the machine with a clean cloth or blow it with compressed air at low pressure.

NOTICE

Do not use cleaning agents or solvents; these could attack the plastic parts of the machine!

Put on all coatless flats a thin coat of oil.

13.2 Maintenance plan

Controls for the maintenance of the machine
Loose or lost screws, nuts, bolts	Regularly prior to each operation
Damage of any part of the machine	Regularly prior to each operation
Oil level	Regularly prior to each operation
Machine cleaning	Regularly after operation
Air filter cleaning	Every 20-30 working hours
Oil changing	Every 250 working hours

13.2.1 Air filter cleaning

The intake filter prevents dust and dirt being drawn in. It is essential to clean this filter. A clogged intake filter will decrease the compressor's performance dramatically. Open the air filter housing and remove the air filter. Use compressed air at low pressure (approx. 3 bar) to blow out all the parts of the filter and then assemble the filter in reverse order.

13.2.2 Condensation water

To ensure a long service life of the pressure vessel, drain off the condensed water by opening the drain cock each time after using.

The condensation water from the pressure vessel will contain residual oil. Dispose of the condensation water in an environmentally compatible manner

13.2.3 Storage

If the machine is stored for longer than 30 days:

• Let the machine cool down
• Clean the machine and dry
• Depressurize the air tank.
• Store in a dry, out of reach of children place, well packaged (protection against cuts)

13.3 Disposal

Do not dispose the machine, machine components fuel and oil in residual waste. Contact your local authorities for information regarding the available disposal options. When you buy at your local dealer for a replacement unit, the latter is obliged to exchange your old.

14 TROUBLE SHOOTING

Disconnect the machine from the power supply prior to any checks performed at the machine itself!

Trouble	Possible cause	Solution
Pressure can no longer be stored	• Valve seals broken	• Replace the seals
Engine overheats	• low oil level• dirty air filter	• Refill oil• Clean or replace the air filter
Compressor runs but produces no pressure	• Clogged air filters• Defective seals• Defective valves in the cylinder head.	• Clean or replace the old air filter• Replace the seals• Replace the valves
Engine will not start	• No power supply• Overload protection activated	• Check the connection to an existing electrical grid.• Let the engine cool down and then pull the red pressure switch (on / off)
After reaching the escapes cut-off pressure Compressed air through the relief valve und Pressure switch to reach the starting pressure	• Leaking or defective check valve• Check valve is damaged	• Clean or replace check valve insert• Replace check valve
Compressor on frequently	• Very much condensate in the pressure boiler• Overload compressor	• Drain condensate

MANY POTENTIAL SOURCES OF ERROR CAN BE CLEARED BY THE EXPERTLY CONNECTION TO THE ELECTRICITY GRID.

NOTICE

Should you in necessary repairs not able to properly to perform or you have not the prescribed training for it always attract a workshop to fix the problem

15 PREDGOVOR (HR)

Poštovani korisniče!

Ova uputa za uporabu sadrži informacije i važne upute za pokretanje i rukovanje kompresorom ZI-COM150, ZI-COM200-10.

Cher client, chère cliente,

CBB60 (450V,60 μF) MAIN WINDING AUX WINDING OVERLOAD PROTECTED (125/250VAC 12A) PRESSURE SWITCH L N G

28 ERSATZTEILE / SPARE PARTS/ REZERVNI DIJELOVI / PIECES DE RECHANGE

28.1 Ersatzteilbestellung / spare parts order / Naručivanje rezervnih dijelova / Commande de pièces détachées

(EN) With original ZIPPER spare parts you use parts that are attuned to each other shorten the installation time and elongate your machines lifespan.

IMP OR TAN T

The installation of other than original spare parts voids the warranty!

So you always have to use original spare parts

When you place a spare parts order please use the service formular you can find in the last chapter of this manual. Always take a note of the machine type, spare parts number and partname. We recommend to copy the spare parts diagram and mark the spare part you need.

You find the order address in the preface of this operation manual.

Exploded view diagram of a mechanical assembly with numbered parts for identification

NR	DESCRIPTION	QTY	NR	DESCRIPTION	QTY
1	BOLT	6	49	SPRING WASHER	4
2	SPRING WASHER	6	50	NUT	4
3	CYLINDER HEAD	1	51	MOTOR	1
4	GASKET	1	52	PULLEY	1
5	VALVE SEAT	1	53	KEY	1
6	ALUMINUM GASKET	1	54	NUT	1
7	VALVE PLATE	4	55	SPRING WASHER	1
8	VALVE SEAT	1	56	CONNECTING PLATE	1
9	GASKET	1	57	FLAT WASHER	1
10	CYLINDER	1	58	BOLT	1
11	GASKET	1	59	SPRING WASHER	1
12	CRANK CASE	1	60	BOLT	1
13	BOLT	2	61	FENDER	1
14	AIR CLEANER	1	62	NUT	2
15	BOLT	4	63	SPRING WASHER	2
16	SPRING WASHER	4	64	FLAT WASHER	4
17	CRANK CASE COVER	1	65	BOLT	2
18	GASKET	2	66	BELT	1
19	BEARING	2	67	NUT	2
20	CRANK SHAFT	1	68	SPRING WASHER	2
21	OIL FULL	1	69	WHEEL	2
22	OIL SIGHT GLASS	1	70	PIN	2
23	SHAFT SEAL	1	71	AIR COCK	1
24	BOLT	1	72	REGULATOR	1
25	GASKET	1	73	CONNECT	1
26	CRANKCASE COVER	1	74	PRESSURE SWITCH	1
27	BOLT	12	75	WIRE	1
28	NUT	4	76	SAFETY VALVE	1
29	SPRING WASHER	4	77	CONNECT	1
30	FLAT WASHER	8	78	PRESSURE GAUGE	1
31	BOLT	4	79	PRESSURE GAUGE	1
32	CONNECT	1	80	BOLT	4
33	PISTON RING	2	81	FLAT WASHER	8
34	PISTON	2	82	SPRING WASHER	4
35	SNAP RING	4	83	NUT	4
36	WRIST PIN	2	84	DRAIN COCK	1
37	CONNECTING ROD	2	85	TANK	1
38	SPRING WASHER	6	86	WHEEL	1
39	BOLT	6	87	SPRING WASHER	4
40	SHAFT SEAL	1	88	BOLT	4
41	CRANKCASE COVER	1	89	HANDLE	1
42	SPRING WASHER	4	90	PLUG	2
43	BOLT	4	91	CONNECT	1
44	PULLEY	1	92	CHECK VALVE	1
45	BOLT	1	93	EXHAUST PIPE	1
46	FLAT WASHER	1	94	UNLOADING ASSEMBLY	1
47	BOLT	4	95	SCREW
48	FLAT WASHER	8	96	CYLINDER HEAD COVER

Company ZIPPER Maschinen GmbH grants for mechanical and electrical components a warranty period of 2 years for amateur use; and warranty period of 1 year for professional use, starting with the purchase of the final consumer. In case of defects during this period, which are not excluded by paragraph 3, ZIPPER will repair or replace the machine at its own discretion.

2.) Report:

In order to check the legitimacy of warranty claims, the final consumer must contact his dealer. The dealer has to report in written form the occurred defect to ZIPPER. If the warranty claim is legitimate, ZIPPER will pick up the defective machine from the dealer. Returned shippings by dealers which have not been coordinated with ZIPPER, will not be accepted and refused.

3.) Regulations:

a) Warranty claims will only be accepted, when a copy of the original invoice or cash voucher from the trading partner of ZIPPER is enclosed to the machine. The warranty claim expires if the accessories belonging to the machine are missing.
b) The warranty does not include free checking, maintenance, inspection or service works on the machine. Defects due to incorrect usage of the final consumer or his dealer will not be accepted as warranty claims either. Some examples: usage of wrong fuel, frost damages in water tanks, leaving fuel in the tank during the winter, etc.
c) Defects on wear parts are excluded, e.g. carbon brushes, collection bags, knives, cylinders, cutting blades, clutches, sealings, wheels, saw blades, splitting crosses, riving knives, riving knife extensions, hydraulic oils, oil/air/fuel filters, chains, spark plugs, sliding blocks, etc.
d) Also excluded are damages on the machine caused by incorrect or inappropriate usage, if it was used for a purpose which the machine is not supposed to, ignoring the user manual, force majeure, repairs or technical manipulations by not authorized workshops or by the customer himself, usage of non-original ZIPPER spare parts or accessories.
e) After inspection by our qualified personnel, resulted costs (like freight charges) and expenses for not legitimated warranty claims will be charged to the final customer or dealer.
f) In case of defective machines outside the warranty period, we will only repair after advance payment or dealer's invoice according to the cost estimate (incl. freight costs) of ZIPPER.
g) Warranty claims can only be granted for customers of an authorized ZIPPER dealer who directly purchased the machine from ZIPPER. These claims are not transferable in case of multiple sales of the machine.

4.) Claims for compensation and other liabilities:

The liability of company ZIPPER is limited to the value of goods in all cases. Claims for compensation because of poor performance, lacks, damages or loss of earnings due to defects during the warranty period will not be accepted. ZIPPER insists on its right to subsequent improvement of the machine.

32 JAMSTVO (HR)

1.) Jamstvo:

Product experience form

We observe the quality of our delivered products in the frame of a Quality Management policy.

Your opinion is essential for further product development and product choice. Please let us know about your:

• Impressions and suggestions for improvement.
• experiences that may be useful for other users and for product design
• Experiences with malfunctions that occur in specific operation modes

We would like to ask you to note down your experiences and observations and send them to us via FAX, E-Mail or by post:

Erworben von / purchased from:

E-Mail/ e-mail:

Please describe amongst others in the problem: What has cause the problem/defect, what was the last activity before you noticed the problem/defect? For electrical problems: Have you had checked you electric supply and the machine already by a certified electrician?

3. Bitte beachten

/ Additional information

INCOMPLETELY FILLED SERVICE FORMS CANNOT BE PROCESSED! FOR GUARANTEE CLAIMS PLEASE ADD A COPY OF YOUR ORIGINAL SALES / DELIVERY RECEIPT OTHERWISE IT CANNOT BE ACCEPTED. FOR SPARE PART ORDERS PLEASE ADD TO THIS SERVICE FORM A COPY OF THE RESPECTIVE EXPLODED DRAWING WITH THE REQUIRED SPARE PARTS BEING MARKED CLEARLY AND UNMISTAKABLE. THIS HELPS US TO IDENTIFY THE REQUIRED SPARE PARTS FASTLY AND ACCEL- LERATES THE HANDLING OF YOUR INQUIRY.