GENERAL INFORMATION GB

TABLE OF CONTENTS

Safety indications .............................................................................. 2

Installation ......................................................................................... 4
Specifications .................................................................................... 5
Settings and controls ........................................................................ 6
Control functions ............................................................................... 8
Operation .......................................................................................... 9
Start-up … ......................................................................................... 9
Maintenance ................................................................................... 10
Trouble-shooting ............................................................................. 13
Wiring diagram ................................................................................ 14

OUTFIT
Check outfit carefully. Later claims for missing parts will not be accepted.
The following accessories are supplied with the compressor:
no. 1 line cock
no. 1 Teflon tape
no. 1 delivery tube
no. 4 anti-vibration elements
no. 1 door key
no. 1 user’s guide

CONDITION OF THE MACHINE WHEN SUPPLIED

Every compressor is shop tested and delivered ready to be installed and to be set at work.
The oil used is SHELL CORENA D.

WARRANTY
The Manufacturer guarantees their products for manufacturing or material defects for 12 months from their delivery
date.
NOTE: Warranty terms are extended as follows only to piston pumping units:
- 18 months for models belonging to “PROFESSIONAL” line,
- 24 months for models belonging to “HEAVY DUTY” line,
- Machines belonging to “ROTAR” line are guaranteed for 3,000 operating hours (as shown by the hour counter)
but limited to 12 months maximum from their delivery date. The above warranty period is extended to 24 months with
no hour limit to the screw pumping unit and the electronic controller.
d) Electric part and parts subject to wear are not covered by this warranty.
e) Any repairs and/or servicing under warranty can be carried out only by Authorized Service Centers and the
Manufacturers.
f) Products can be delivered to the Manufacturer for servicing purposes only after prior authorization by the very
Manufacturer. The Manufacturer shall decide at their discretion whether authorization can be granted or require an
Authorized Service Center to take on servicing.
In any case, products shall be delivered free of any charge and will be returned to the Customer on ex-factory basis.
g) This warranty covers free-of-charge repairs or replacement of those machine parts, which have been acknowledged
as faulty by our authorized technicians.
h) This Warranty becomes null and void in case of accidental damages due to negligence, incorrect or improper
use and installation or in case of use and installation, which do not comply with the instructions given in the Instruction
Manual as well as in case of changes or repairs carried out by non-authorized personnel. All defective parts, which are
replaced under warranty, are collected by the Authorized Service Center.
i) This warranty does not cover any repairs or compensation for transport damages (to or from the Authorized
Service Center).
k) Any compensations for damages caused to objects or injuries caused to people due to improper use of the
purchased compressor are excluded from this warranty.
l) Machines under warranty can be serviced against purchase documents bearing the purchasing date only if the
Purchaser has met all contract and payment requirements.
m) This Warranty is the only one which is acknowledged by the Manufacturer. The issue of any other verbal or
written warranty is not allowed. Also, no changes to the terms of this Warranty are allowed,
Any dispute shall be settled by the Court of Bologna.

Rotar Plus 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004 1

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

area Prohibited! Do not use water on electric
equipment to extinguish fire.

Danger! Pressurized container

Compulsory! Read instructions for use
carefully.

Danger! Mechanical moving parts

Caution! Maintenance works in progress

2 Rotar Plus 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004

 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.
Empty the air tank and/or oil separator and 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.
Carefully read instructions for the installed accessory, especially if painting devices are installed.
Ensure that the installation place is properly ventilated.
Ensure that temperature of the working environment ranges between +5 and + 45 ºC.
The compressor should be installed and operated in a non-explosive environment.
Allow at least 50 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 stop.
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 explosive environment or in case of naked flames.
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 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004 3

GB INSTALLATION
COMPRESSOR DESCRIPTION (fig.1)
Compressor main components are: 7
10
1) Air-oil radiator 9
2) Electric equipment
3) Instrument board
4) Oil separator tank
5) Oil separator filter 8
6) Minimum pressure valve 11 3
7) Electric motor
8) Screw compressor
9) Suction regulator 6
10) Air filter 1
11) Oil filter

5
4

2 1
UNPACKING AND HANDLING
The compressor is usually shipped to the customer with a carton cover. Wear protective gloves and cut outer straps. Remove
then package by lifting it from the top. Before removing the compressor, make sure it is intact (outside), open access doors (if
fitted) and visually check components for damage. Check that all accessories are included.
Lift machine with a transpallet or fork lift truck and transport the machine with the utmost care to the place of installation.
You are advised to keep the packing material for the event you need to re-locate the compressor. Keep package at least for the
duration of the warranty period, so the compressor can be safely shipped to a service centre, if needed.
When no longer needed, deliver packing material to the special collection centres for disposal.

PLACEMENT AND INSTALLATION (fig.2)

Upon installation, make sure that the chosen place is in compliance with all
prevailing national safety standards and meets the following requirements: 350 cm (min)
• low percentage of dust suspended in air,
• shop must be suitably sized and well ventilated so that room tem-
perature never exceeds 40°C when the compressor is working. If this is not
the case, install one or more exhaust fans to extract hot air. Ideally, the fans

300 cm (min)
should be installed close to the ceiling.
Exhaust fan “2000 m3 /h” code 020041000
Exhaust fan “4000 m3 /h” code 020042000 80 cm (min)
Dimensions are just approximate. Try nevertheless to respect them as much
as possible.
A drainage pit or at least a canister shall be used to collect tank condensate
(see chapt. Maintenance). 90 cm (min)

POWER CONNECTION (fig.3)

• Proceed to power connection with cross-section cables suitable for 2
machine power: 3 phase cables and 1 ground cable.
• Have a switch (A) provided with plug fuses installed between supply
line and control panel, close to machine cable connections.
• Switch (A) should be installed within the operator’s reach.
Cables shall be homologated and with a min. protection degree equal to
IP44.
NOTE: To choose cables cross-section, refer to Table page 5. 0
I
A

4 Rotar Plus 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004

 SPECIFICATIONS GB
+3 +3
7HFKQLFDOIHDWXUHV
Pressure EDU      
Compressor type FS 50 TM FS 50 TM
Compressor rotation speed RPM 4830 4330 3460 5640 5200 4120
Air volume supplied l/min 2350 2050 1750 2700 2450 2050
Oil quantity l 7 7 7 7 7 7
Oil quantity for topping-up l 0,5 0,5 0,5 0,5 0,5 0,5
Max. final over temperature °C 5 5 6 10 8 7
Removed heat kJ / h 51300 51300 51300 63270 63270 63270
Fan flow rate m³ / h 3100 3100 3100 2931 2931 2931
Oil residues in the air mg / m³ 4 4 4 4 4 4
Electric motor (bipolar) 132 MD/2 B3 B5 160 L/2 B3 B5
Motor power kW 15 15 15 18,5 18,5 18,5
Max. power absorbed kW 18,4 18,4 18,4 21,5 21,5 21,5
Voltage V/Hz 400 / 50 400/50
Auxiliary voltage V/Hz 230-24 / 50-60 230-24/50-60
Electrical box protection class IP 54 54 54 54 54 54
Motor insulation class F F F F F F
Full load current A 31 31 31 36 36 36
Starting load A 70 75 73 98 104 107
Max. Start-up per hour n° 10 10 10 10 10 10
Ambient limit temperature °C 50 50 50 50 50 50
Noise level at 1 m (Cagi pneurop) dB (A) 70 70 70 71 71 70

3URWHFWLRQGHYLFHV
Max compressor temperature °C 110 110 110 110 110 110
Min. oil temperature °C -7 -7 -7 -7 -7 -7
Thermal motor cut-out A 19,8 19,8 19,8 23 23 23
Safety valve setting bar 14 14 14 14 14 14
Start-up pressure switch setting bar 1,5 1,5 1,5 1,5 1,5 1,5

'LPHQVLRQVDQGZHLJKW
Dimensions mm 1030×680×1030 1030×680×1030
Weight Kg 300 360
Air cock fitting Rp 3/4" 3/4"

3RZHUFRQQHFWLRQ
Power kW 15 15 15 18,5 18,5 18,5
Cable section (max. lenght 3 mt.) mm² 6 6 6 6 6 6
Absorbed current A 31 31 31 36 36 36
Relay setting A 19,8 19,8 19,8 23 23 23
Switch A 50 50 50 63 63 63

Rotar Plus 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004 5

GB SETTINGS AND CONTROLS

1 2 3

4 5 6 7 8 9
4

CONTROL PANEL (FIG. 4)

• All compressor power-on-and-off procedures are 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.

6 Rotar Plus 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004

 SETTINGS AND CONTROLS GB
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).
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.
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

MODIFIABLE PARAMETERS Min. Max. Standard bar Min. Max. Standard

Oil temperature pre-alarm (differential) °C 0 20 5 No-Load/operating pressure set point bar 0 15 10
Maximum oil temperature °C 0 150 110 Load/pressure differential set point 0 15 8,5
Minimum oil temperature °C -14 0 -7 Maximum permissible pressure bar 0 15 11
No-load (EMPTY) time sec. 1 250 20 Maximun alarm pressure bar 0 16 13
Maintenance pre-alarm Hours 0 32768 3000 Load (CHARGED) delay sec. 0 200 10
Automatic start YES NO NO Internal phase sequence control YES NO YES
Pressure sensor YES NO YES Language ITA
PSI/BAR PSI BAR BAR Display contrast level 1 20 5
Enable RS485 SI NO SI

Rotar Plus 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004 7

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

8 Rotar Plus 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004

 OPERATION GB
OPERATING CYCLE
• At first start-up, the motor starts in the
“star” configuration. In this phase the compressor 15
starts slowly, the solenoid valve (1) is open and 3
the suction regulator (2) is closed. 2 14
• The compressor remains in this condition
for about 5÷7 seconds 12 1
• After this time, the motor is powered by 4
the “delta” configured circuit. The solenoid val- 6
13
ve (1) receives current and closes allowing the
opening of the suction regulator (2), which 8 5
intakes atmospheric air through the filter (3).
• At this stage, the compressor runs at full
speed and begins to compress the air in the tank 16 11
(6). 7
• The compressed air cannot come out
from the minimum pressure valve set at 3÷4 bar.
• The compressed air compresses the oil
9
in the tank (6) and forces it to flow towards the
10
tube (7).
• If the oil temperature is below 71°C the
6
oil from the tube (7) flows directly to the
compressor (4) through the tube (8) passing through the filter (9).
• If the oil temperature exceeds 71°C the thermal expansion valve shuts down the ducting to tube (8) and oil flows to the
radiator (11) through the tube (10). Once cooled, oil flows back to the compressor through tubes (12) and (8) and 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).
• From the tank (6) only air comes out, which reaches the radiator (11) through the tube (15) and the mains through the 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 (Shell Corena D46);
• 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 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004 9

GB MAINTENANCE
BEFORE MAINTAINING THE MACHINE ALWAYS PERFORM THE FOLLOWING
• Switch off the motor by means of the switch on the control panel.
• Power the machine off by means of the wall outer switch (do not press the emergency stop button).
• Close the line cock.
• Make sure that no compressed air is inside the oil separator tank by turning the cock anticlockwise and bleed all air off.
• Before removing any protections, double check that wall-mounted switch has been turned to 0.

AFTER THE FIRST 100 HOURS

1) Check the oil level (see next paragraph): top up with the same type of oil if
necessary.
2) Check for proper screw tightening: in particular the power electric connection
screws.
3) Visually check that all fittings seal properly.
4) Check room temperature

EVERY 500 HOURS

Check the oil level (fig.7)
Always blow off air from the oil separator tank before topping up. Slowly unscrew
the cock A until all air comes out and then screw it again.
The max. level is reached when the oil touches the filler.
Check level at oil light (B).
The amount of oil necessary for topping up from the minimum level to the
maximum level is about 1.5 lt.

EVERY 1000 HOURS

Clean the air filter thoroughly (fig.8). Blow filter with compressed air from
inside out.
Hold the filter against the light and look for any tears. Always replace a torn
filter. Install filter cartridge and cover accurately. If badly positioned, they would let
dust into the compression unit.
Replace the air filter when you have cleaned it four times.
7
Clean the radiators
The radiator is highly efficient with a limited clogging degree. However, in case
of abnormal overheating or at least once a year, a check for filter clogging is recommended.
To clean the radiators, proceed as follows:
• remove the rear and upper panels of the pressurized chamber;
• position a protection plastic sheet under the radiator unit;
• spray (spray gun + solvent) from the outside towards the inside;
• check for proper air flow through the radiators.

AFTER THE FIRST 1000 HOURS, EVERY 3000 HOURS AFTERWARDS

Change oil (fig.7)
Change oil every 3000 working hours when compressor is hot – over 70 °C.
Drain pressure from the oil separator tank through cock (A).
• Connect the supplied hose to cock (C).
• Unscrew filler cap, open ball cock (C) and drain all oil into a container. When finished,
close the cock and remove the hose.
• Fill fresh oil through filler plug (D) (a full charge is 6 liters). 8
• Close the plug.
• Power on machine.
• Start machine and let is run for 5 minutes, then stop it.
• Drain all air.
• Allow 3 minutes and check oil level. Top up if needed.

When you change oil, you can change to a different type of lubricant (see table).
SHELL CORENA D AGIP DICREA 46
IP VERETUM OIL 46 BP ENERGOL HLP 46
MOBIL D.T.E. MEDIUM CASTROL AIRCOL MR46
ESSO UNIVIS 46 FINA EOLAN R046
Remember to use the same oil for future top-ups - Never mix different types of oil

Change oil filter (fig.9)

Change oil filter EVERY TIME YOU CHANGE OIL; depressurize tank before proceeding.
Always smear filter edge and filter seal lightly with oil before screwing filter into place by hand. 9

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 MAINTENANCE GB
DRAINED OIL IS A POLLUTANT!
Dispose of according to the environmental protection rules in force.

Change the oil separator filter (fig.10)

The oil separator is not washable and should be changed at each oil change. Never exceed 3000
operating hours. A
• Drain all compressed air through cock (A).
• Unscrew the filter manually (use a special tool for filters, if needed). Rotate counter clockwise
to unscrew.
• Fit a new filter. Screw new filter in clockwise. Smear the gasket of O-ring inside the oil separator
filter lightly with oil before fitting the filter.

Drain the condensate (fig.7)

Air/oil mixture cooling is set to occur below air dew point, however, it is impossible to avoid conden-
sate in oil totally.
Once a month, drain condensate before starting the compressor: open cock (C) and close it as
soon as oil start flowing out instead of water.
10
Always make sure the oil separator tank is depressurized before proceeding. Drain any
pressure through cock (A).
Check oil level and top up if needed.
CONDENSATE IS A POLLUTANT! Do not drain into the sewers. Dispose of according to the environmental protection rules in
force.

EVERY 2000 OPERATING HOURS

Check drive belt tension (Fig.12) 12
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: Test

Higher value = slacken 1

Lower value = stretch

• To adjust, proceed as follows:

turn the screw (1) anti-clockwise to stretch the belt and clockwise to slacken.
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 20 2008 2010 2013 2008 2010
frequency (Hz) 71 73 68 72 71
Rotar Plus 25 2508 2510 2513 2508 2510
frequency (Hz) 79 78 75 81 77

EVERY 12000 HOURS

Minimum pressure valve (fig.11)
Close the mains cock and drain all air from the oil separator tank
through valve (A)
Remove the flange fixing nuts and lift the flange
Change the seals (1) and (2).

Changing the hoses

Loosen the hose fittings, change hose and tighten fittings securely.
Proceed with the last steps of the oil change procedure.

Changing electric motor bearings. 2

This can also be done after 15,000 operating hours. Have wear 1
condition of bearings assessed by a specialized technician. 11

Rotar Plus 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004 11

GB MAINTENANCE
EVERY 20000 HOURS
Change: 12
• Compressor seal ring
• Tank safety valve

Change the drive belt as follows (fig.12):.

2) Tighten the screw (1) turning it clockwise with a hexagon head wrench, until you
feel that the belt is slackening and comes off easily. Test
3) Install the new belt and set the screw (1) back to its original position (turn clockwise).
Leave belt slightly slack. 1
Check frequency value as described on page 11.

12 Rotar Plus 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004

 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 thermo- Room temperature too high Improve ventilation

stat 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 com- available. Replace part, if damaged.
mand 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 clo- Remove and clean the valve. Replace the seal, if necessary
se 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 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004 13

GB WIRING DIAGRAM

20 hp 25hp
230V 400V 230V 400V
TC1 Transformer 150AV
TC2 Transformer
SB Emergency button
FU1-FU2 Fuses 6.3x32 4A 500V
FU3 Fuses 6.3x32 1.6A 500V
FU4-FU5-FU6 Fuses 6.3x32 1A 500V
FU7 Fuses 6.3x32 500 mA 500V
KM1 Line contactor 18,5 kW (*) 11 kW(*) 18,5 kW (*) 11 kW(*)
KM2 Delta contactor 18,5 kW (*) 11 kW(*) 18,5 kW (*) 11 kW(*)
KM3 Star contactor 15 kW (*) 7,5 kW(*) 15 kW (*) 7,5 kW(*)
FR Thermal relay (28-40) (17-22) (28-40) (20-25)
YV Solenoid valve
SP1 Minimum pressure switch
SP2 Pressure switch for oil separator filter
SP3 Pressure switch for air filter
BP Pressure transducer 0-16 bar
D Electronic controller
ST Thermal feeler for electronic controller
Motor cable cross-section (sq mm) 7x10 7x4 7x10 7x6
(*) = 400V AC3

14 Rotar Plus 20-25 Easytronic - Cod.197AA2702 - Edition 00 01/2004