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Operating instructions
TWIN Powerstation SLZ
Type
Serial number Date
Rev.E 120989 05/2019
EC Declaration of Conformity
according to EC directive 2006/42/EC on machinery (Annex II A)
Name and address of the manufacturer
BlitzRotary GmbH
Hüfinger Str.55
78199 Bräunlingen, Germany
This declaration relates exclusively to the machinery in the state in which it was placed on the market, and excludes components which are added and/or operations carried out subsequently by the final user.
The declaration is no more valid, if the product is modified without agreement.
Herewith we declare, that the machinery described below
product denomination Piston Compressor model / type
VARIS
VERSA
TWIN
VDZ, VDZH, VDZS, VDZHS, VDZD, VDZHD, VGZ, VGZH, VZ, VZH
DZ, DZH, DZS, DZHS, GZ, GZH, DZHP, GZHP, HV, NV,
DZNT, DZNDT, GZNT, GKTE, GKTZ, GKTZH
Airmobil, Airstation, Hobby, Maximat, Maximat Pro, Kitty II,
Whisper, Medicus, VX,
DKD, DET, DEDT, GET, BKE, BKZ, BKES, BKZS, GKE, GKZ,
Logos, Logos H, Logos H Box, Works, Works H, Works H Box
FORMULA: 28M, 36M, 57M, 38H, 52H, 65H, 38V, 52V, 65V
TOURING: GT30H, GT42H, GT50H, GT32V, GT42V, GT50V
POWERSTATION SLZ machinery- / serial number
Year of manufacture
........................................................
20 .............
complies with all key provisions of Machinery Directive 2006/42/EC.
Furthermore, the machine complies with the provisions of the Electromagnetic Compatibility Directive
20
1
4/
30
/E
U
and the Low Voltage Directive 20
14
/
3
5/E
U
(safety standards have been met pursuant to Annex I, No. 1.5.1 of the Machinery Directive 2006/42/EC).
Furthermore, the machine complies with the provisions of the Simple Vessels Directive 20
14
/
29
/E
U
Harmonised Standards used
EN 1012-1 : 201
1-02
EN 60204-1: 20
14-10
EN ISO 12100
:2011-03
EN ISO 12100
:2011-03
EN ISO 1
2100:2011-03
Compressors and vacuum pumps - Safety requirements - Part 1
Safety of machinery - Electrical equipment of machines - Part 1
Safety of machinery - Basic concepts - Part 1
Safety of machinery - Basic concepts - Part 2
Safety of machinery - Risk assessment - Part 1
Other technical standards and specifications used:
The person authorised to compile the relevant technical documentation:
BlitzRotary GmbH; Hüfinger Str. 55, 78199 Bräunlingen
Place, date:
Bräunlingen,
0
1
.
0
5
.201
9
______________________
Doris Wochner-McVey
Geschäftsführer / Managing Director
__________________________________________________________________________________
Reg-Nr. 2014-10_K_en_2006/42/EG
.
GB
MULTIPURPOSE SERVICE UNIT
INSTALLATION, USE AND MAINTENANCE MANUAL
WARNING: Read this manual carefully and in full before using the compressor.
GB
IMPORTANT INFORMATION
Read all the operational instructions, safety recommendations and all warnings provided in the instruction manual.
Most accidents encountered when using the compressor are merely due to the failed observance of basic safety standards.
Accidents are prevented by foreseeing potentially hazardous situations and observing the appropriate safety standards.
The fundamental safety standards are listed in the “SAFETY” section of this manual and also in the section involving the use and maintenance of the compressor.
H azardous situations to be avoided in order to prevent serious personal injuries and machine damages are listed in the “WARNINGS” section of the instruction manual or are actually printed on the machine.
Never use the compressor improperly but only as recommended by the Manufacturer.
The Manufacturer reserves the right to up-date the technical information given in this manual without notice.
All information contained herein is based on data available at the time of printing.
The manufacturer reserves the right to make changes to the products at any time without notice and without incurring any penalty.
It is always advisable to check for updates.
The responsible use of the unit must ensure that all country use safety rules should be applied, ensuring that i t’s used in accordance with the purpose for which it is builded for, and avoid any dangerous situation for users.
READ THE INSTRUCTION MANUAL
Read the use and maintenance manual carefully before installing and starting the compressor.
KEEP THESE USE AND MAINTENANCE INSTRUCTIONS CAREFULLY AND GIVE THEM TO PERSONNEL
WISHING TO USE THE UNIT!
RISK OF SCALDING
Warning: be careful when touching the compressor as some parts of it could be very hot.
RISK OF ELECTRIC SHOCK
Carefully before carrying out any work on the unit is required shut off the main power of the machine.
WARNING
IT IS FORBIDDEN TO TRANSPORT THE UNIT IN CONDITION OF PRESSURIZED AIR IN THE TANK
WARNING
IT IS FORBIDDEN TO MODIFY AND / OR TAMPERING THE MACHINE AND SAFETY PROTECTIONS
WARNING
IT IS FORBIDDEN TO SMOKE AND / OR USING FLAMES NEAR THE MACHINE
WARNING
IT IS FORBIDDEN TO OPEN THE PANELS DURING THE MACHINE WORKING
WARNING
IT IS FORBIDDEN TO MAKE REFUELING AND / OR OIL FILLING DURING THE MACHINE WORKING
WARNING
IT IS FORBIDDEN TO USE THE MACHINE IN CLOSED ENVIRONMENT
THE EXHAUST GAS ALWAYS MUST BE ISSUED IN OPEN ENVIRONMENT.
CAUTION
ALWAYS WEARING SUITABLE PROTECTIONS
2 MSU
– Multipurpose Unit
GB
MSU 981
MAIN FEATURES
14
4
15
1
2
5
6
Nr
Description
1
Safety valve
2
Lubricator filters unit
3
Electrical cabinet
4
External filter for diesel engines
5
22 liters fuel tank
6
Engine battery
7
Hose reel
8
Hose reel
9
Operational indicators
10
Sta rt engine’s key
11
Electrical socket single-phase 230V
12
Electrical socket three-phase 400V
13
Cooling fan grid
14
Compressor air filter
15
Pump unit oil level indicator
4
7
8
11
10
12
3
13
MSU
– Multipurpose Unit
GB
1
General information
The MSU range is composed of double-stage piston compressors with gas engine generator.
The internal combustion engine running with diesel fuel is connected to the air compressor pump unit and generator via belt transmission.
IMPORTANT INFORMATION
Read and understand all of the operating instructions, safety precautions and warnings in the Instruction Manual 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 situation before it occurs, and by observing appropriate safety procedures.
Basic safety precautions are outlined in the “SAFETY” section of this Instruction Manual nad in the sections which contain the operation and maintenance instructions.
Hazards that must be avoided to prevent bodily injury or machine damage are identified by WARNINGS on the compressor and in this Instruction Manual.
Never use this compressor in a manner that has not been specifically recommended by manufacturer, unless you first confirm that the planned use will be safe for you and others.
MEANING OF SIGNAL WORDS
WARNING
CAUTION
NOTE
indicates a potentially hazardous situations which, if ignored, could result in serious personal injury. indicates a hazardous situations which, if ignored, couls result moderate personal injury, or could cause machine damage. emphasizes essential information
1.1
Safety
IMPORTANT SAFETY INSTRUCTIONS FOR USE OF THE COMPRESSOR.
DEATH OR SERIOUS BODILY INJURY COULD RESULT FROM IMPROPER OR UNSAFE USE OF
MULTIPURPOSE UNIT. TO AVOID THESE RISKS, FOLLOW THESE BASIC SAFETY
INSTRUCTIONS.
READ ALL INSTRUCTIONS
1 NEVER TOUCH MOVING PARTS
Never place your hands, fingers or other body parts near the multipurpose unit moving parts.
2 NEVER OPERATE WITHOUT ALL GUARDS IN PLACE
Never operate this multipurpose unit without all guards or safety features in place and in proper working order. If maintenance or servicing requires the removal of a guard or safety features, be sure to replace the guards or safety feature before resuming operation of the compressor.
3 ALWAYS WEAR EYE PROTECTION
Always wear safety goggles or equivalent eye protection.
Compressed air must never be aimed at anyone or any part of the body.
4 TURN OFF THE ENGINE
Always turn off the engine to prevent risks of accidental starts. Always remove the compressed air from the air tank before servicing, inspecting, maintaining, cleaning, replacing or checking any parts.
5 STORE MULTIPURPOSE UNIT PROPERLY
When not in use, the compressor should be stored in dry place.
Keep out of reach of children. Lock-out the storage area.
6 KEEP WORK AREA CLEAN
Cluttered areas invite injurues. Clear all work areas of unnecessary tools, debris
, furniture etc…
Keep the work area well ventilated. Do not use the generator in the presence of flammable liquids or gases. The generator can produce sparks during operation. Do not use the generator in situations where you can find paints, gasoline, chemicals, adhesives and any other flammable or explosive material.
MSU
– Multipurpose unit
5
GB
7 CONSIDER WORK AREA ENVIRONMENT.
Don’t expose compressor to rain. Don’t use compressor in damp or wet locations. Keep work area well lit and well ventilated. Operate this compressor at a stable place all the time. Risk of fire or explosion. Do not carry and operate the compressor or any other electrical device near the spray area. Do not use compressor in the presence of flammable liquids or gases. Restricting any of the compressor ventilation openings will cause serious overheating and could cause fire. Never place objects against or on top of compressor. Gasoline engines produce carbon monoxide; a poisonous odorless gas which may cause death. Do not start or operate this compressor in an enclosed area or in presence of obstructions. Operate compressor in an open area at least 4 feet away from any wall or obstruction that would restrict the flow of fresh air to the ventilation openings. Compressor produces sparks during operation. Never use compressor in sites containing lacquer, paint, benzine, thinner, gasoline, gases, adhesive agents, and other materials which are combustible or explosive. This compressor contains some components parts that tend to produce arcs or sparks, and therefore, when located in a garage, it should be in a room or enclosure provided for this purpose, and should be 18 inches (457 mm) or more above the floor. A spark arrester must be added to the muffler of this engine if it is to be used on any forest covered, brush covered or grass covered unimproved land. The arrester must be maintained in effective working condition by the operator. In order to avoid damaging this compressor, do not allow the unit to be tilted more than 10° when operating.
8 INSTALLATION ON A MOBILE WORKSHOPS (AIR COMPRESSOR WITH GAS ENGINE GENERATOR)
Do not expose the multipurpose unit to the weather.
Do not start and use the multipurpose unit if the vehicle is not perfectly stable on slopes more than 10%.
Do not start and use the multipurpose unit if the car doors
(rear or side) are closed. It is forbidden presence of people or animals in the car during operation of the multipurpose unit (risk of choking). Before starting work check the air vents are not obstructed. Do not use the multipurpose unit with open panels. Do not use the multipurpose unit when the car is in motion/movement. When the car is in motion/movement of the air tank must be discharged (not in pressure). Discharge the air pressure from the tank before any starting up / moving the car. At each start of the multipurpose unit, make sure that the pressure gauge indicate zero. It is forbidden to use the multipurpose unit in not expressly conditions intended in this manual. The manufacturer don’t have responsibility for any damage due to incorrect use.
9 KEEP CHILDREN AWAY
All visitors should be kept safely away from work area.
10 DRESS PROPERLY
Do not wear loose clothing or jewerly. They can be caught in moving parts. Wear protective hair covering to contain long hair.
11 MAINTAIN THE MULTIPURPOSE UNIT WITH CARE
Follow instructions for lubricating.
12 STAY ALERT
Watch what you are doing. Use common sense. Do not operate compressor when you are tired. Compressor should never be used by you if you are under the influence of alcohol, drugs or medication that makes you drowsy.
13 CHECK DAMAGED PARTS AND AIR LEAK
Before further use of the multipurpose unit, a guard or other part is damaged should be carefully checked to determine that it will operate properly and perform its intended function. Check for alignment of moving parts, binding of moving parts, breakage of parts, mounting, air leak, and any other conditions that may affect its operation. A guard or other part that is damaged should be properly repaired or replaced by an authorized service center unless otherwise indicated elsewhere in this Instruction Manual.
NEVER USE THE MULTIPURPOSE UNIT IF THE PILOT VALVE IS DAMAGE
NEVER USE COMPRESSOR FOR APPLICATIONS OTHER THAN THOSE SPECIFIED.
Never use multipurpose unit for applications other than those specified in the Instruction Manual. Never use compressed air for breathing or respiration.
14 HANDLE MULTIPURPOSE UNIT CORRECTLY
Operate the multipurpose unit according to the instructions providedherein. Never allow the multipurpose unit to be operated by children, individuals unfamiliar with its operation or unauthorized personnel. Carrying the multipurpose unit if tilted may result in fuel spillage.
15 KEEP ALL SCREWS, BOLTS AND COVERS TIGHTLY IN PLACE
Keep all screws, bolts, and plates tightly mounted. Check their condtions periodically.
16 NEVER USE THE MULTIPURPOSE UNIT WHICH IS DEFECTIVE OR OPERATING ABNORMALLY
If the multipurpose unit appears to be operating unusually, making strange noises, or otherwise appears defective, stop using it immediately and arrange for repairs by a authorized service center.
17 DO NOT WIPE PLASTIC PARTS WITH SOLVENT
Solvents such as thinner, benzine, carbon tetrachloride, and alcohol may damage and crack plastic parts. Do not wipe them with such solvents. Wipe plastic parts with a soft cloth lightly dampened with soapy water and dry thoroughly.
18 USE ONLY GENUINE REPLACEMENT PARTS
Replacement parts not original may void your warranty and can lead to malfunction and resulting injuries. Genuine parts are available from your dealer.
19 DO NOT MODIFY THE COMPRESSOR
Do not modify the multipurpose unit. Always contact the authorized service center any repairs. Unauthorized modification may not only impair the compressor performance but may also result in accident or injury to repair personnel who do not have the required knowledge and technical expertise to perform the repair operations
6 MSU
– Multipurpose Unit
GB
correctly.
20 TURN OFF THE SWITCH WHEN THE MULTIPURPOSE UNITIS NOT USED
When the multipurpose unit is not used, turn off switch and discharge the compressed air from the air tank.
21 NEVER TOUCH HOT SURFACE
To reduce the risk of burns, do not touch tubes, heads, cylinder and muffler. Never allow any part of your body or other materials to contact with any exposed metal parts on this multipurpose unit. Never allow any part of your body to contact the muffler or adjacent areas. These areas can remain hot for least 45 minutes after this compressor is shutdown. Cool down before servicing.
22 DO NOT DIRECT AIR STREAM AT BODY
Risk of injury, do not direct air stream at persons or animals.
23 DRAIN TANK
Risk of bursting. Water will condense in the air tank. If not drained, water will corrode and weaken the air tank causing a risk of air tank rupture. The compressor is equipped with automatic drain valve. Check and maintain the valve efficient.
24 MAKE SURE THE COMPRESSOR OUTLET PRESSURE IS SET LOWER THAN THE MAXIMUM OPERATING
PRESSURE OF THE TOOL.
Too much air pressure causes a hazardous risk of bursting. Check the manufacturer’s maximum pressure rating for air tools and accessories. The regulator outlet pressure must never exceed the maximum pressure rating.
25
THE SAFETY VALVE MUST WORK PROPERLY
Risk of bursting. Before starting the compressor pull the ring on the safety valve to make sure the valve moves freely. If the safety valve does not work properly, over-pressurization may occur, causing air tank rupture or an explosion.
26 REFUELING APPROPRIATELY
Follow all fueling instructions in operator’s manual. Gasoline is extremely flammable, and gasoline vapor can explode. Do not refuel tank while this compressor is running or hot. Never smoke near gasoline, and keep other flames and sparks away. Do not refuel indoors or in a poorly ventilated area. Do not fill fuel tank to point of overflowing. Always refuel slowly to avoid the possibility of spilled fuel which may cause a fire. Do not operate this compressor if gasoline is spilled. Wipe this compressor clean and move it away from the spill. Avoid creating any ignition until the gosoline has evaporated. Allow approximately 3
/4” of tank space for fuel expansion. Always store fuel away from this compressor while it is running or hot. Always store gasoline in an approved container.
27 BE CAREFUL NOT TO TRIP OVER OR DROP THE COMPRESSOR DURING TRANSPORT.
Exercise utmost caution when you carry this compressor. If you trip over something and drop it, there is a fear that unexpected injury may result. If you drop this compressor or bump it against any objects, air tank or any component parts can cause serious deformation, damage, severe scratches and breakdown on this compressor. If operated under such conditions, it can result in any accidents or bodily injuries by explosion of the air tank or explosion of those damaged component parts. Furthermore, gasoline which spilled out by those damages, may have a great risk of a fire. When there is any deformation and damage on the handle, it may drop during transport, resulting in an accident of injury. Before carrying this compressor, switch off the engine and discharge the drain inside the air tank. Be cautious enough to make sure that there are no obstacles, inflammable articles, and unauthorized people around this compressor.
28 USE PLUGS AND CABLES OF A CORRECT SIZE..
For correct use of plug+socket, the three and single-phase size of the plugs must be the same of compressors sockets; the outlet cables size must be upper than 1.5 mm.
MSU
– Multipurpose unit
7
GB
1.2
Identification data of the manufacturer and the compressor
IDENTIFICATION DATA OF THE MANUFACTURER AND THE COMPRESSOR (Example)
1.3
Technical data
MOTOR
2 cilindri (4 tempi)
COMPRESSOR
Lubried piston unit
CURRENT GENERATOR
Model
Power
Fuel
Start
Stage
Pressure
Air delivery
2
12 bar
35 m3/h
Current Voltage
230 V single-phase+T (1 socket)
400 V trifase+N+T (1 presa)
Protection
Thermal breaker 10 A
Differential circuit breaker (30mA)
Noise level @ 4 mt
82 dB(A)
Ambient temperature range
+5° - +35°
Dimensions
Weight
810x860x1690H
381 kg
LDW 702 FOCS PLUS
17/12,5 Hp/kW
Diesel
Electric
1.4
Information on machine technical/maintenance service
We remind you that our technical service department is at your complete disposal to help you resolve any problems that may possibly be encountered, or to provide you with any other information necessary.
In the case of need contact:
CUSTOMER TECHNICAL SERVICE
department or your local dealer.
The constant and efficient performance of the compressor is ensured only if original spare parts are used.
We recommend therefore that you strictly observe the indications provided in the MAINTENANCE section and to use
EXCLUSIVELY
original spare parts.
The use of NON ORIGINAL spare parts automatically annuls the guarantee.
8 MSU
– Multipurpose Unit
GB
2
Transport, Handling, Storage
In order to use the compressor in complete safety read the safety standards given in section 1.3. before reading this section.
2.1
Transporting and handling the packed machine
The packed compressor must be transported by qualified personnel using a forklift truck.
Before moving the machine ensure that the load-bearing capacity of the forklift truck is sufficient to take the weight to be lifted.
Position the forks exclusively as illustrated below. Once the forks have been positioned in the points indicated, lift slowly without jerking.
Never stand near the area where the compressor is being handled and never stand on the crate while it is being moved.
MSU
– Multipurpose unit
9
GB
2.2
Packing and unpacking
To avoid damages and to protect the compressor during transport it is usually placed on a wooden pallet, to which it is secured by screws and covered with cardboard.
All the shipping and handling information and symbols are printed on the compressor packing. Upon consignment remove the top part of the packing and check if any damages have been encountered during transport. If any damages are found, caused during transport, immediately make a written claim, backed up with photos of the damaged parts if possible and forward everything to your insurance company, with copy to the
Manufacturer
and transporter.
Using a forklift truck take the compressor as near as possible to the place where it is to be installed then carefully remove the protective packing without damaging it, following the instructions below:
•
Remove the packing
1
, by sliding it away upwards.
•
Unscrew the blocking screws at the base.
Note! The compressor can be left on the packing pallet to make it easier to move.
Carefully ensure that the contents correspond with all written in the consignment documents.
Dispose of the packing in compliance with current standards in force in the country of installation.
Note! The machine must be unpacked by qualified personnel using appropriate tools and equipment.
2.3
Storing the packed and unpacked multipurpose service unit
For the whole time that the compressor is not used before unpacking it, store it in a dry place at a temperature between +5°C and + 40°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, which may settle on the components.
The oil is to be replaced and the operational efficiency of the compressor is to be checked if it is not used for long periods.
10 MSU
– Multipurpose Unit
GB
3
Installation
In order to use the compressor in complete safety read the safety standards given in section 1.3. before reading this section.
3.1
Admitted surrounding conditions
Position the machine as established when the order was placed. Failing this the
Manufacturer
is not liable for any inconveniences that may possibly arise. Unless pointed out otherwise when placing the order, the compressor must work regularly in the surrounding conditions indicated below.
ROOM TEMPERATURE
For a good work, the room temperature must not be lower than 5°C or higher than 35°C.
If the compressor works at a room temperature lower than the minimum value, the condensate could be separated within the circuit and therefore the water would mix with the oil, thus deteriorating the quality of the latter, failing to guarantee the even formation of the lubricating film between the moving parts with the possibility of seizure.
If the compressor works at a room temperature higher than maximum value, the compressor would take in air that is too hot, which would prevent the heat exchanger from adequately cooling the oil in the circuit, raising the working temperature of the machine, thus causing the thermal safety device to trip, which stops the compressor due to an excessive temperature of the air/oil mixture at the screw outlet.
LIGHTING
The machine has been designed in compliance with legal prescriptions and in the attempt to minimise shadow zones to facilitate the operator’s job.
The lighti ng system of the factory is to be considered as crucial for the operator’s safety.
The compressor’s placement must not have shadow zones, dazzling lights or stroboscopic effects due to the lighting.
ATMOSPHERE WITH RISK OF EXPLOSION AND/OR FIRE
The standard compressor is not pre-arranged or designed to work in rooms subject to the risk of explosion or fire.
The performance of the compressor may decrease at the maximum permitted ambient temperature, with relative humidity higher than 80% and at an altitude of more than 1,000 mt.
3.2
Space required for maintenance
The machine must be installed in a large room that is well-aired, dust-free and sheltered away from rain and frost.
The machine takes in a large amount of air that is required to ventilate it internally. A dusty atmosphere would in time cause damages and inefficient performance.
Part of the dust once inside is taken in by the air filter causing it to clog rapidly and another part of dust will settle on the components and will be blown against the cooling radiator, consequently compromising the efficiency of the heat exchanger. It is therefore obvious that the cleanliness of the area in which the compressor is installed is crucial for the correct efficiency of the machine, avoiding excessive running and maintenance costs. To facilitate maintenance jobs and to create a favourable circulation of air, the compressor must have a sufficient free space all around it (see following pictures).
MSU
– Multipurpose unit
11
GB
3.2.1
Installing on the ground
In order to use the compressor in complete safety read the safety standards given in section 1.1 before reading this section.
Place the compressor on a flat surface (max inclination: 10 °), in a ventilated place, protected from weather and in not explosive environments. The fuel tank side and inspection / maintenance vents must have placed in accessible side. It is the responsibility of the operator to control and deny access to the area of persons and / or animals, keep it free from objects that may obstruct airflow and flammable objects.
Connect the screw placed on the chassis with the surrounding soil using apropriate
“ground picket” via cable of minimum section 10 mm ². (see chap. 4.4.1)
Min. 500 mm
Min. 600 mm
MULTIPURPOS E
SERVI CE UNIT
Air outlet
S I D E A C C E S S
3.2.2
Installing on the mobile workshops
Type 1
Min. 600 mm
NOTE: Before proceeding with the installation in the vehicle, follow the rules in force concerning workplace safety and vehicle manufacturer indications.
Check the total of vehicle mass is equal to or more than the compressor weight and the tools fitted. The fuel tank side and inspection / maintenance vents must have placed in accessible side. It is the responsibility of the operator to control and deny access to the work area to people and / or animals, keep it free from objects that may obstruct airflow and flammable objects.
Connect the screw placed on the chassis with the surrounding soil using apropriate
“ground picket” via cable of minimum section 10 mm ². (see chap. 4.4.1)
Type 2
S I D E A C C E S S
Min. 500 mm Min. 500 mm
Min. 600 mm
Air outlet
MULTIPURPOSE
SERVICE UNIT
Min. 600 mm
F U E L T A N K
Air inlet
S I D E A C C E S S
12
S I D E
Min. 3800 mm
A C C E S S
MSU
– Multipurpose Unit
GB
4
Using the multipurpose service unit
In order to use the compressor in complete safety read the safety standards given in section 1.1 before reading this section.
4.1
Preparing to use the multipurpose service unit
4.1.1 Operational principle
The multipurpose service unit allows the production of compressed air and single and three-phase alternating current through the combined work of a two-stage lubricated piston pump unit and a power generator connected by belt to the diesel engine combustion.
The application range of this multipurpose service unit includes use in a mobile workshops and maintenance equipped vehicles.
MSU
4
1
5
1
6
1
7
1
8
1
9
1
10
1
1
10
1
3
1
2
1
1
Storage tank
2
Forced ventilation belt drive (pump unit)
3
Air inlet
4
Automatic circuit breaker
5
Security valve
6
Automatic drain condensate filter
7
Pressure gauge
8
Pressure regulator + gauge
9
Lubrificator
10
Quick coupler (compressed air outlet)
MSU
– Multipurpose unit
13
GB
4.2
Motor
Note!: The information in this manual are intendet to assist the operator during use and maintenance operation of the compressor.
Some images contained in this manual may be different from your model.
Take care to transport the compressor correctly, do not overturn it or lift it with hooks or ropes.
4.2.1
General terms of use
Do not allow the engine or muffler to come in contact with flammable vapors, combustible dust, gases or other combustible materials. A spark may cause a fire. Do not place this compressor in an area where flammable gas vapors may be present.
-
Read the engine manual accompanying this compressor for correct engine start-up maintenance procedures.
Read and understand the safety labels located on this compressor.
-
A minimum of 85 octane fuel is recommended for use with this compressor. Do not mix oil with gasoline.
-
Use of clean, fresh, lead free gasoline should be used. Do not use gasoline containing methanol or alcohol.
Check the engine oil level before starting (See engine manual).
-
Fill the fuel tank according to the engine manual instructions.
4.2.2 Refueling
WARNING!
-
Refer to the engine manual for all necessary maintenance and adjustments.
Follow all fueling instructions in operator’s manual.
Gasoline is extremely flammable, and gasoline vapor can explode.
Do not refuel fuel tank while this compressor is running or hot.
Never smoke near gasoline, and keep other flames and sparks away.
Allow this compressor and engine to cool down before refueling.
Do not refuel indoors or in a poorly ventilated area.
Do not fill fuel tank to point of overflowing.
Always refuel slowly to avoid the possibility of spilled fuel which may cause a fire.
Do not operate this compressor if gasoline is spilled.
Wipe this compressor clean and move it away from the spill.
Avoid creating any ignition until the gasoline has evaporated.
Allow approximately 1/4” of tank space for fuel expansion. Always store fuel away from this compressor while it is running or hot.
Always store gasoline in an approved container.
14
1
Disconnect fuel hoses.
2
Remove the security belt.
Refer to the Engine Manual to correct maintenance operation.
3
Remove the fuel tank.
MSU
– Multipurpose Unit
GB
4.2.3
Exhaust hose clamp
WARNING!
Do not operate this compressor in an enclosed area. Use this compressor only in well ventilated areas. The exhaust from the engine contains carbon monoxide, a poisonous, odorless and invisible gas. Breathing the gas can cause serious injury, illness and possible death. Avoid inhalation of exhaust gas. Never run the engine in a closed garage or confined area.
Place the exhaust hose between the outside and the compressor following the shortest path.
Connect the hose to the exhaust outlet using the included clamp.
Check the tightness of the clamp.
WARNING!
The exhaust hose can 'reach high temperatures during compressors operation. Provide to wrap the exhaust hose with fireproof material of adequate insulation. Keep away from compressor moving parts and flammable parts (example: wooden pallets).
MSU
– Multipurpose unit
15
GB
4.3
Pistons air compressor pump unit
4.3.1 Recommended lubrificants
The compressed air is generated by a lubricated piston two-stage pump unit.
Before the first start fill the supplied oil up to the indicated level.
Always use 5W-40 oil and a pour point of -10 ° C.
The flame point must be greater than +200 ° C. Daily check the oil level and add oil if necessary.
Recommended oils:
Synthetic oil FIAC SYNTESIS
Overfilling with oil will cause premature compressor failure.
Do not overfill.
4.4
Connecting the compressor to the sources of energy and relative inspections
4.4.1 Istruction for grounding
All electrical maintenance must be performed by specialized technician.
NOTE FOR MOBILE WORKSHOPS USE:
Before connecting the ground, secure the compressor to the vehicle chassis by appropriate holder.
•
To protect the operator from electric shock this compressor must be grounded when in use.
•
Do not disassemble the compressor and do not make any other connections.
•
Any repair must be performed only by authorized service centers FIAC.
•
REMEMBER: the grounding conductor to the earth is green or yellow / green.
Never connect the grounding conductor to a line terminal.
16 MSU
– Multipurpose Unit
GB
4.5
Commissioning
4.5.1 Preliminary checks
In order to use the compressor in complete safety read the safety standards given in section 1.1 before reading this section.
Once placed, check the following compressor’s parts:
PRELIMINARY CHECKS
ELECTRICAL BATTERY CONNECTION
(optional supply)
Place the battery on proper support and secure it by the 2 supplied screws.
Connect the RED wire to the terminal marked "+" and tighten it.
Connect the BLACK wire to the terminal marked "-" and tighten it.
CHECK PNEUMATIC CIRCUIT
Check the internal pressure gauge is point out zero.
Check that the external pneumatic hoses is not damaged or bent.
Check that the condensate is discharged by automatic discharge valve.
CHECK PUMP UNIT OIL LEVEL
Check (see the oil sight glass) the oil level and add oil if necessary.
CHECK MOTOR ENGINE
Check (see motor oil dipstick) the oil level and add if necessary.
Check the coolant level and add it if necessary.
Check the tank fuel level and add it if necessary.
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– Multipurpose unit
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GB
4.5.2 Start
In order to use the compressor in complete safety read the safety standards given in section 1.1 before reading this section.
Before start:
- Ensure all guards and panels are securely in place and well fastened.
- Ensure that the exhaust hose is placed in a open area.
- Ensure that the air supply is sufficient.
- Note for mobile workshops: ensure that all tailgates or doors are open.
NOTE: DO NOT START THE COMPRESSOR WITH GUARDS OR PANELS OPEN!
Start and use of compressor is reserved only by specialised personnel.
1
2
3
Turn the key in
READY
position
.
Wait for the warning lights off.
Turn the key on
START
position
.
4
After engine start, release the key on
READY
position.
Do not hold the key in START position for longer than 5-10 seconds, if the engine does not start, repeat in multiple attempts to avoid burning the starter.
When the engine is running, ensure that all warning lights are off.
For models with starting panel: ensure that only the engine protection light is
OK
4.5.3 Pressure adjustment
You do not have to use the maximum operating pressure at all times. On the contrary, the pneumatic tool being used often requires less pressure.
To adjust the working pressure:
• Unlock the regulator by pulling it upwards.
• Turn to adjust
• Push down to lock
Check the manufacturer’s maximum pressure rating for tools connected to the compressor and accessories.
Compressor outlet pressure must be regulated so as to never exceed the maximum pressure rating for tools connected to the compressor.
MSU 981
Max working pressure
12 bar
Max using pressure
12 bar
18 MSU
– Multipurpose Unit
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4.6
Safety and control indicators
Symbol Color
GREEN
YELLOW
Description
Engine protection indicator
Indicates the correct engine running.
In case of fault it shut off.
*The fuel solenoid valve, in case of fault, stops the fuel supply, and the engine shutdown.
Battery charger indicator.
When this indicator light up, the battery fail to charge.
After 3 min the engine stops.*
OUT OF ORDER
YELLOW
Glow plug pre-heat indicator
Indicates the glow plug pre-heat time (depending on the ambient temperature).
Models without tachometer: it flashing indicates a glow plugs voltage absence
Models equipped with tachometer: the engine protection indicators become green when a glow plugs fault occurs.
YELLOW
Air filter indicator
Indicates the air filter clogging.
NOTE: this indicator may have differents functions depending the models.
RED
Oil pressure indicator.
Indicate the oil pressure too low.
After 3 min the engine stops.*
RED
Engine head oil temperature.
Indicates the cooland temperature is too hight.
After 3 min the engine stops.*
RED
Warning indicator
This indicator may have differents functions depending the models.
After 3 min the engine stops.*
RED
RED
Warning indicator
This indicator may have differents functions depending the models.
After 3 min the engine stops.*
Battery indicator
Indicates the battery voltage absence.
The machine fail to start.
Hours meter
Indicates the hours of duty (hours and hours tenths).
This compressor operate automatically.
The pilot valve control the tank load status, putting in idle running the compressor in case of tank full charge (max pressure reached) and restarts it in case of air consumption (pressure drop).
WARNING!
IN CASE OF UNUSUAL NOISE OR VIBRATION STOPS THE COMPRESSOR IMMEDIATELY!
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– Multipurpose unit
19
GB
WARNING!
Always wear ears protection. Some work conditions and prolonged exposure to noise may cause hearing loss and deseases.
Sound level measured in a free range at a distance of 4 m: ±3dB(A) at the maximum working pressure.
MOD.
MSU981
HP/CV
18.5
dB (A)
82
The level of acoustic pressure can increase from 1 to 10 Db(A) according to the place in whitch the compressor is installed.
4.7
General safety warnings
This compressor is not intended for outdoor use or open environment.
Do not expose to wheather conditions.
NOTE: The head/cylinder/delivery tube unit can reach high temperatures. Take care when working near these parts, and do not touch them to avoid possible burns
Do not disconnect any part when the tank is pressurized. Discharge the pressure tank before any maintenance.
Do not drill holes, weld or purposely deform the compressed air tank.
Do not do any jobs on the compressor unless it is off.
Temperature in operating ambient: 0 C +35 C.
Do not aim jets of water or inflammable liquids on the compressor.
Do not place inflammable objects near the compressor.
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 compressor such as the head and delivery tubes, as they can reach high temperatures. Do not touch these parts to avoid burns.
Transport the compressor, lifting or pulling it with the appropriate grips or handles.
Keep children and animals well away from the machine operating area.
If using the compressor for painting: a. Do not work in closed environments or near to naked flames b. Make sure there is adequate exchange of air at the place of work c. Protect your nose and mouth with an appropriate mask. (fig. 14)
Do not put objects or your hands inside the protective grilles to avoid injury to yourself or damaging the compressor.
Do not use the compressor as a blunt object toward things or animals, to avoid serious damage.
When you have finished using the compressor,always switch it off.
4.8
Use of electrical sockets
Avoid all risks of electrical shocks. Never use the compressor with damaged electrical cables or extension cables. Regularly check the electrical cables.
Never use the compressor in or near water or near a hazardous area where electrical shocks may be encountered
The machine generates electricity at 230V single phase (1 socket) and three-phase 400V (1 socket).
Check the tools absobtion connected to the sockets is NOT equal and higher than the data plate rates.
20 MSU
– Multipurpose Unit
GB
4.9
Shut down
1
Turn the key in STOP position.
EMERGENCY STOP
In case of disfunctions or faults, immediately shut off the machine by turning the key anticlockwise.
Disconnect the battery and discharge the compressed air tank.
Risk of bursting.
When the tank gets corroded, there is a risk of breakdown.
Water will condense in the air tank. If not drained, water will corrode and weaken the air tank causing a risk of air tank rupture.
The drain contains moisture in the air, abrasion particles, rust, etc.
Keep face and eyes away from drain cock.
Allow the compressor to cool down
Wipe this compressor clean and store in a safe, non-freezing area.
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– Multipurpose unit
21
GB
5
Compressor maintenance
The compressors can be equipped with hourmeter for proper maintenance planning and tachometer for an adequate check of the engine efficiency. A performance engine decrease of 150-200rpm, indicates that the compressor needs maintenance and / or adjustment by an authorized service center.
Discharge the compressed air from the tank before performing any machine maintenance.
Allow the compressor to cool before performing the maintenance operations.
Always stop engine.
WARNING:
Read the instruction manual before performing maintenance.
The following procedures must be performed when stopping the compressor for maintenance or service.
- Shut off the compressor
- Open the discharge tap.
- Allow the compressor to cool before performing the maintenance operations.
5.1
Spare parts
When servicing use only original spare parts.
Repairs should be performed only by authorized service center.
5.2
Maintenance schedule
weekly
300 hours
500 hours
Maintenance performance
Check the automatic discharge valve
Check oil / fuel leaks
Check motor oil level (engine and pump unit)
Panel and guards inspection
Check vibrations and/or noise
Check air leaks
Compressor cleaning
Verify and clean if necessary the engine air filter and pump unit air filter.
Check the electrical connection and tighten
Test the output sockets voltage
Check the differential switch efficiecy ("T" key)
Check the battery fluid
Check the battery coolant
Check the belts tension
Check the security valve
Cleaning cooler radiator
Change pump unit oil
Change engine oil
Replace pump unit air filter
General check by authorised service center
Replace trasmission belts
daily
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
22 MSU
– Multipurpose Unit
GB
5.2.1 Pump unit changing the oil
Change the oil following the initial
100 hours
of use and then every
300 hours
and in event once a year. In case of not frequently use (few hours of duty per day) you should change the oil every
3
months.
1
Before changing the oil, provide a container to collect the exhaust oil.
2 3 4
Open the pump unit oil purge tap.
Collect the exhaust oil in a container Close the oil purge tap.
Add oil until half oil sight glass. Screw the oil tap and close the compressor.
Once the oil and oil filter have been changed leave the compressor to run for roughly 5 minutes then turn it off and check the oil level again. Check the oil level once a month.
Never mix different types of oil, therefore always ensure that the circuit is completely empty before filling-up with oil. Each time the oil is changed the filter is also to be replaced.
5.2.2 Air cartridge replacement
Remove the plastic cover by the clamp.
Replace the air filter cartridge and close firmly.
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– Multipurpose unit
23
GB
5.2.3 Tightening the belt
PUMP UNIT
Every
200 hours
of use it is advisable to check and maybe tighten the belt if necessary.
Using a dynamo meter apply a perpendicular force in point
A
of between 25N and 35N, the belt must give by roughly 5mm.
Open the front panel to gain access inside the machine.
Loosen the pump unit fixing screws (not remove).
Turn the nuts to tighten the belt.
Tight the pump unit fixing screws.
ALTERNATOR
Open the side panel to gain access inside the machine.
Turn the nut to tighten the belt.
5.2.4 Replacing the belt
Every
1000 hours
of use it is advisable to replace the belts.
Loosen the pump unit fixing screws (not remove).
Turn the nut to loosen or replace the belts.
Open the front panel to gain access inside the machine.
Turn the nut to operate on the belts; using a dynamo meter apply a perpendicular force in point
A
of between 25N and
35N, the belt must give by roughly 5mm.
Then, tighten the pump unit screws.
24 MSU
– Multipurpose Unit
GB
5.2.5 Draining the condensate
The compressor is equipped with automatic drain valve.
Check and maintain the valve efficient.
The condensate drained is considered as polluting mix that must not be thrown away outdoors. It is advisable to use special water/oil separators for its disposal in accordance with applicable laws.
5.2.6 Cleaning the air/oil radiator
It is advisable to clean the radiator
1
on a weekly basis to remove impurities, blowing it with an air gun from inside.
Blow compressed air through the radiator, from inside outwards, making sure that no dirt settles inside the compressor.
5.2.7 Grease the battery poles
CAUTION: The battery contains corrosive, toxic and explosive fluids, be very careful during maintenance, always wear goggles and face masks.
Periodically grease the battery poles, using specified grease.
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– Multipurpose unit
25
GB
5.2.8 Topping up engine coolant
Open the filler cap and fill the coolant to the point out level.
Use only the recommended engine coolant (see engine coolant).
5.3
Pneumatic circuit
Always use pneumatic hoses for compressed air with the maximum pressure characteristics and cross section suitable for those of the compressor. Do not try to repair a faulty hose.
26 MSU
– Multipurpose Unit
The compressor run but not load.
Damaged valve plate or air leaks.
GB
5.4
Diagnosing the alarm status/inconveniences-faults
COMPRESSOR
Air filter clogged
Pump unit head gasket damaged
Check and eventually replace the air filter by an Authorised Service Centre.
Replace the head gasket by an
Authorised Service Centre
Connections air leacks and/or pneumatic hoses or damaged head valves.
Replace the defective elements
System not in pressure or non continously pressure
Hoses clogged
Pulire o sostituire le parti difettose c/o
Centro Assistenza Autorizzato.
Defective segments. Oil flow through the segments. (Oil presence in condensate drain hose)
Sostituire i segmenti
Noisiness from the tank.
Abnormal consumption of oil
Metallic noise
Loose or breack belt
Defective discharge valve
Defective security valve or pressure too hight.
Damaged mechanics elements.
Loose or damaged mechanic element
Tighten or replace the belt by an
Authorised Service Centre.
Replace the discharge valve by an
Authorised Service Centre.
Replace the security valve by an
Authorised Service Centre.
Check and replace the damaged mechanins elements by an
Authorised Service Centre.
Check the correct pressure switch setting, fuses and electrical connections.
If the problem persist contact an
Authorised Service Centre.
ENGINE
Engine failure Refer to the engine manual.
Engine stops Oil temperature too hight.
Repair to an Authorised Service
Centre.
Check the oil level, clean the radiator and check if the fan in-take grid is clean or obstructed (paper, leaves, rags). Restart the compressor.
If the problem persist contact an
Authorised Service Centre.
GENERATOR
No voltage to electrical sockets
The magneto thermal circuit breaker switch on.
Loose or damaged belt
Wrong rotation speed of thermal engine.
Generator failure
Disconnect the power tools from the sockets and reset the magneto thermal switch.
Tighten or replace the trasmission belt.
Please, contact an Authorised Service
Centre.
Please, contact an Authorised Service
Centre.
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– Multipurpose unit
27
GB
6
Wiring diagrams
400V/3 ~230V/1~ 50/60Hz
28 MSU
– Multipurpose Unit
BlitzRotary GmbH
Hüfinger Straße 55
78199 Bräunlingen
DEUTSCHLAND
Fon +49.771.9233.0
Fax +49.771.9233.99
www.blitzrotary.com
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