Instruction Manual EN

Compressors
ROLLAIR®
Type 80 - 100 - 125 - 150E
80V - 100V - 125V - 150V
62 305 512 00

ROLLAIR® 100

ROLLAIR® 125V

WARRANTY

The ROLLAIR® compressor is guaranteed for 12 months from date of commissioning

or a maximum of 18 months from date of manufacture (which ever occurs first).
The guarantee will only be applicable subject to strict observation of the installation conditions
and the maintenance operations specified in these operating instructions.
The guarantee is limited to replacing parts that are recognised as defective by our services.
NOTE
This instructions manual complies with the stipulation of European 98/37/EC
concerning machine safety and is valid for machines carrying the CE label.
The ROLLAIR® should never be operated beyond its capabilities
or in any way which does not comply with the instructions contained
in this operating and maintenance guide.

Worthington-Creyssensac will decline any responsibility

if these instructions are not respected.

This equipment has been factory tested and satisfies normal

operating conditions: they must not be exceeded
as this would place the machine under abnormal stress and effort.

INSTALLATION INSTRUCTIONS
For the guarantee to be valid, the unit must be assembled in covered
premises with temperatures not exceeding :

Mini: + 4 °C (frost free)

Maxi: + 40 °C
You must also have:
1 meter space around the compressor
-
low ventilation (fresh air) proportionate to the ventilation flow necessary for the machine and protected
from any infiltration of humidity (splashes of water during bad weather) and all pollution
-
top insulation or extraction to ensure reversal of the flow of warm air and evacuation of the heat to
outside the equipment room
-
a link from the condensation water evacuation pipe to the drain discharger.
-
In case of dusty ambient environment, a pre-filtration is made by micro-filter on the air inlet of the room used for cooling and
perhaps a special filter on the compressor air inlet.

TECHNICAL CHARACTERISTICS
STANDARD MACHINES

ROLLAIR® 80 100 125 150E

Nominal pressure at full capacity bar 7.5 8 10 13 7.5 8 10 13 7.5 8 10 13 7.5 8 10 13

Real flow* m /h
3
637 612 536 433 882 834 742 629 965 963,7 880 712 1175 1039 1025 880
(as per ISO 1217 ed 1996)
Motor power kW-ch 55-75 75-100 90-125 110-150
Ø Pressure outlet (F) Pouce 2" 2" 2" 2"
Oil reservoir capacity liter 25 25 35 35
Residual quantity of oil ppm 2 2 2 3
Niveau sonore à 1m (Air/Eau) dB(A) 65/64 66/65 71/67 75/71
(suivant PNEUROP PN 8 NT C2)

* Suction pressure : 1 bar absolute - Relative humidity : 0 % - Ambient temperature : 20 °C

- Effective delivery pressure : 7 bar, 7,5 bar, 9,5 bar or 12,5 bar (effective)

Dimensions (mm) Lxlxh 2160 x 1060 x 1600 2160 x 1060 x 1600 2160 x 1060 x 1600 2160 x 1060 x 1600

Approximate weight (Air/Water) kg 1430/1400 1500/1470 1625/1590 1810/1770

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ROLLAIR® Type 80 100 125 150E

Motor power (kW) 55 75 90 110

Mains voltage 220/230/240 Volt / 3 / 50 Hz

Nominal intensity (230V) (A) 190 266 294 363

Power supply cable H 07 4 x 70 4 x 95 4 x 150 3 x 240mm2 +
Section mm2 (L=10m maximum) (1 x 120mm2)
Upstream fuses (Type aM) 200 250 320 400

Mains voltage 380/400/415 Volt / 3 / 50 Hz

Nominal intensity e (400V) (A) 109 153 169 209

Power supply cable H 07 4 x 50 4 x 70 4 x 95 3 x 120mm2 +
Section mm2 (L=10m maximum) (1 x 70mm2)
Upstream fuses (Type aM) 200 200 250 250

Note : For variable speed machines to see Chapter 6.

TECHNICAL CHARACTERISTICS
VARIABLE SPEED MACHINES
ROLLAIR® 80 100 125 150

V VERSION (as per ISO 1217 ed 1996)

Nominal pressure at full capacity bar 4 7 9.5 4 7 9.5 4 7 9.5 4 7 9.5
Real flow* m /h
3
687 643 550 890 880 766 1094 979 863 1169 1144 1019
V HP VERSION (as per ISO 1217 ed 1996)
Nominal pressure at full capacity bar 9 9.5 12.5 9 9.5 12.5 9 9.5 12.5 9 9.5 12.5
Real flow* m /h
3
- - - 710 705 652 774 769 736 902 897 883
Motor power kW-ch 55-75 75-100 90-125 110-150
Ø Pressure outlet (F) Pouce 2" 2" 2" 2"
Oil reservoir capacity liter 25 25 35 35
Residual quantity of oil ppm 2 2 2 3
Noise level at 1m (Air/Water) dB(A) 65/64 66/65 71/67 75/73
(according to PNEUROP PN 8 NT C2)

* Suction pressure : 1 bar absolute - Relative humidity : 0 % - Ambient temperature : 20 °C

- Effective delivery pressure : 7 bar, 9,5 bar or 12,5 bar (effective)

Dimensions (mm) Lxlxh 2160x1060x1600 2160x1060x1600 2160x1060x1600 2160x1060x1600

V VERSION
Approximate weight (Air/Water) kg 1480/1450 1550/1520 1655/1620 1860/1820
V HP VERSION
Approximate weight (Air/Water) kg - 1550/1520 1675/1640 1860/1820

Connection of the electric plate to an external control box

• Install an RC filter on the KM1 coil.
• Install an RC filter on the KM2 coil.
• All connections between external parts and the compressor must be carried out using a shielded cable, which must be earthed at one of its ends.

WARNING: the operation connection cables between the different elements must never follow the same path as the existing power
cords. A separate installation from the power cords must be carried out.
• Install an RC filter on all the relay coils of the external operation units.

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SUMMARY
Space requirement and installation diagram ROLLAIR® 80, ROLLAIR® 100, ROLLAIR® 125, ROLLAIR® 150E, ROLLAIR® 80V,
ROLLAIR® 100V, ROLLAIR® 125V, and ROLLAIR® 150V - Air cooled .............................................................................................. 6
Space requirement and installation diagram ROLLAIR® 80, ROLLAIR® 100, ROLLAIR® 125, ROLLAIR® 150E, ROLLAIR® 80V,
ROLLAIR® 100V, ROLLAIR® 125V, and ROLLAIR® 150V - Water cooled ......................................................................................... 7

Chapter 1 - Description ................................................................................................................................................................................. 8

A - General Information ..................................................................................................................................................................... 8
B - Respect of the environment and prevention of pollution ............................................................................................................. 8
C - Standard equipment ...................................................................................................................................................................... 8
D - Definition of the pictograms ......................................................................................................................................................... 8
E - Electronic board ........................................................................................................................................................................... 8

Chapter 2 - Installation ................................................................................................................................................................................. 9

A - Handling ....................................................................................................................................................................................... 9
B - Room ............................................................................................................................................................................................ 9
C - Assembly ...................................................................................................................................................................................... 9
D - Air discharge pipes ....................................................................................................................................................................... 9
E - Condensate drain pipes ............................................................................................................................................................... 10
F - Water pipe ................................................................................................................................................................................... 10
G - Electric cabling ........................................................................................................................................................................... 10

Chapter 3 - Implementation ....................................................................................................................................................................... 12

A - Preparation for start-up ............................................................................................................................................................... 12
B - First start-up ............................................................................................................................................................................... 12
C - Discharge pressure adjustment ................................................................................................................................................... 12
D - Parallel compressor assembly ..................................................................................................................................................... 12
E - Cooling water regulation for water cooled sets .......................................................................................................................... 12
F - Safety .......................................................................................................................................................................................... 12

Chapter 4 - Operation ................................................................................................................................................................................. 13

A - Air and oil circuits ...................................................................................................................................................................... 13
B - Regulation principles .................................................................................................................................................................. 14

Chapter 5 - Options ..................................................................................................................................................................................... 15

A - Level detection bleed valve ........................................................................................................................................................ 15
B - Advanced filtration to the compression air inlet ......................................................................................................................... 15
C - Pre-filtration panels .................................................................................................................................................................... 16
D - Automatic restarting ................................................................................................................................................................... 17
E - Remote starting and stopping ..................................................................................................................................................... 17
F - Oil re-heating .............................................................................................................................................................................. 17
G - Rotation direction indicator - Phase controller .......................................................................................................................... 18
H - Special oils ................................................................................................................................................................................. 18
I - "PROGRESSIVE" regulation ..................................................................................................................................................... 19
J - Energy recovery .......................................................................................................................................................................... 20
K - Centrifugal separator .................................................................................................................................................................. 21
L - Oil-water separator ..................................................................................................................................................................... 21

Chapter 6 - Specific information for ROLLAIR® 80 - 100 - 125 - 150 V and V HP ............................................................................ 22
A - Description ................................................................................................................................................................................. 22
B - Safety .......................................................................................................................................................................................... 22
C - Installation .................................................................................................................................................................................. 22
D - Commissioning ........................................................................................................................................................................... 23
E - Operating incidents ..................................................................................................................................................................... 25

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SUMMARY

Chapter 7 - Maintenance ............................................................................................................................................................................ 26

A - Oil level and change ................................................................................................................................................................... 26
B - Air filter ...................................................................................................................................................................................... 27
C - Turbine ........................................................................................................................................................................................ 27
D - Oil and air cooler ........................................................................................................................................................................ 27
E - Oil separator ................................................................................................................................................................................ 28
F - Draining condensation water ...................................................................................................................................................... 28
G - Temperature safety tests .............................................................................................................................................................. 28
H - Refastening electric connections ................................................................................................................................................ 28
I - Decommissioning the compressor at the end of its useful life ................................................................................................... 28

Chapter 8 - Operating incidents ................................................................................................................................................................. 29

A - Main incidents ............................................................................................................................................................................ 29

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Space requirement and installation diagram ROLLAIR® 80, ROLLAIR® 100, ROLLAIR® 125,
ROLLAIR® 150E, ROLLAIR® 80V, ROLLAIR® 100V, ROLLAIR® 125V and ROLLAIR® 150V - Air cooled
(see page 2 - installation instructions)
Fig. 1a

Air outlet female 2" Gaz Entrée d'air 2160

Air delivery 2" Gas female 80 Air inlet

VUE A
1600

1255
150
100

464 186 728 186

Ø20 100
2000

A
28 B C
793 793
24
416

27
832

1060
24

6xØ8

Type A B C 650
810
ROLLAIR® 80 586 320 133
ROLLAIR® 100 838 442 194
ROLLAIR® 125 899 477 211 VUE B
ROLLAIR® 150 1054 555 250 500 500
VUE A 21
100

30

505
405

VUE B
405

Ø600
70

530

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Space requirement and installation diagram ROLLAIR® 80, ROLLAIR® 100, ROLLAIR® 125,
ROLLAIR® 150E, ROLLAIR® 80V, ROLLAIR® 100V, ROLLAIR® 125V and ROLLAIR® 150V -Water cooled
(see page 2 - installation instructions)
Fig. 1b

Sortie d'air Femelle 2" Gaz

Sortie d'eau Air delivery 2" Gas female 2120
R1 Entrée d'air
Water outlet 140 Air inlet

150 250
1600

VUE A

Entrée d'eau
R1 1255
Water inlet
150
100

464 186 728 186

Ø20 100
2000

793 793
1060

650
810

VUE B
VUE A

70 305 305 70
110

505
250

VUE B
250
5

Ø540
110

530

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Chapter 1 - Description - Safety devices:
1. A safety valve mounted on the oil reservoir.
2. An thermal protection device for the motor, situated in the
A - General Information starting box, to protect the motor from excessive over-load.
The Worthington-Creyssensac air compressor, "ROLLAIR® V" 3. An air temperature sensor that stops the compressor when
type, is a compressed air plant and takes the form of a complete the temperature rises abnormally or during an oil cooling
compressor set entirely assembled and tested, driven by an electric defect.
motor and enclosed under a soundproofing cover necessary for - Control devices:
the set to be properly cooled. 1. A minimum pressure valve located at the oil tank outlet,
The compression element is a single-stage, oil-refrigerated, rotary just beyond the oil separator, which guarantees minimum
screw compressor. The oil is stored in a vertical tank, which is pressure in the lubrication circuit.
fitted with an oil separator. 2. Automatic draining allowing the unit to be exposed to the
atmosphere when stopping to thus ensure empty start up
The compression element and the motor are fixed to the frame which relieves the motor,
using silent blocks. 3. An oil level gauge on the front panel ( see fig. 19).
4. An electronic controller including:
B - Respect of the environment and – a control keyboard,
prevention of pollution – the main safety and control indications.
5. The pressure sensor ensures control over the compressed
1 - Maintenance of the machine air flow.
Make sure that the used components of the machine (waste oil, oil The ROLLAIR® compressed air unit has been designed, produced
and air filters, oil separators, etc.) are disposed of according to and tested in accordance with the following recommendations,
national and local regulations. codes and standards :
- machine safety: European Directive 98/37/CE, 91/368/CEE and
2 - Condensate bleed pipe 93/68/CEE.
Make sure that the condensates (water, oil) are drained and treated - pressure vessels: European Directive for simple pressure vessels
according to national and local regulations. n° 87/404/CEE.
- electrical equipment:
3 - Water cooled machines • electrical equipment: European Directive Low tension
73/23/CEE.
For this type of machine, when the cooling circuit is made of an • electromagnetic compatibility European Directive: 89/336/CEE,
open circuit, a hydrocarbons filter is recommended after passing 92/31/CEE.
through the cooler, particularly for installations located in - performance levels: ISO 1217 : 1996.
ecologically sensitive areas. - noise level : PNEUROP PN 8 NT C2.
4 - End of life of the machine - European Directive 97/23/EC
" Pressure Equipment Directive ".
Make sure that the machine as a whole is disposed of according to
national and local regulations. ( Refer J Chapter 7 ) D - Definition of the pictograms
C - Standard equipment Typical examples of pictograms valid for ROLLAIR® compressors:
1. Water outlet
In its standard version, the covered unit includes: 2. Manual condensation water draining
- Operating components: 3. Water inlet
4. Automatic condensation water draining
1. A twinned screw-type compressor.
5. Unplug and decompress the compressor
2. An electric motor: 3000 rpm, short-circuit rotor, 230/240
before maintenance
V or 400/690 V voltage according to the model.
3. Star delta starting.
4. A direct drive or gearbox drive .
5. Air and oil tank in compliance with applicable legislation
(European directive on simple pressure containers n° 87/404),
approved by an accredited inspection organisation and
bearing the CE labelling.
6. "All or nothing" flow regulation for the aspiration vent.
7. A greasing system using the circuit's differential pressure, 1 2
thus avoiding the need for an oil pump.
8. An oil separator based oil separation system.
9. A heat discharge system : oil and compressed air radiator
with forced ventilation.
10. A dry air filter.
11. An oil filter. 3 4 5
12. A command and control electronic board.
E - Electronic board
See the specific instructions for a description of the electronic plate,
together with operating instructions:
Notice N° 62 305 516 99 for version Standard
Notice N° 62 305 517 99 for version V

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Chapter 2 - Installation
Prevailing wind
A - Handling
The ROLLAIR® must always be handled with care. It may be
L
lifted either with a forklift truck or by means of a travelling crane.
In the latter case, precautions must be taken so as not to damage V Flexible fitting
the unit's cowling.

B - Room
The ROLLAIR ® is designed to operate in a frost-free Compressor
environment, supplied with air at a temperature of no more than
40° C. The premises must be well-aired and as close as possible
to the place where the compressed air is used. A space must be
left around the unit, for cleaning and maintenance purposes. It is
very important for the compressor to have an abundant supply of Fig. 2b - Sleeve with an elbow
fresh air. (see page 2).
V maxi = 5.5 m/s
COMMENT (Ratio of volume flow rate of the ventilation to the sleeve
When the atmosphere is contaminated by organic or mineral dust or cross section)
by corrosive chemical emanations the following precautions must be L maxi = 10 m (without mechanical extractor)
taken:
1. Provide another air inlet as close as possible to the Cross section of room air inlet > 2 x Duct outlet cross section
compressor suction.(recommendation which is valid if the 2 elbows accepted with large radius of curve and fluid gui-
only room available is excessively damp). dance vanes
2 - Use an additional air supply filter. Consult us. Ratio (Length/Width of sleeve) maxi = 1.6

Make sure that no outside air, especially if humid, can be fed

Installation with heat dispersion sleeve back into the machine and damage electric and electronic
components or rust metal parts.
If the operation of the compressor increases the ambient
temperature above 40°C, it is necessary to discharge the hot air The maximum admissible pressure loss of the sleeve should not
leaving the radiator to the exterior by means of the sleeve. exceed 30 Pa (3 mmCE). In case of higher value, provide an
additional ventilation (mechanical extractor) with a flow equivalent
to that of the machine.

Prevailing wind
C - Assembly
Put the unit on a stable surface. The ROLLAIR® does not need
foundations. Any flat surface that can support its weight will be
V sufficient (industrial floor).
L
Flexible fitting
D - Air discharge pipes
The diameter of the air discharge pipe must be at least
2"gas.Current legislation requires that a valve which is lockable
in the closed position be installed at the air box outlet, connected
Compressor to the compressor by a union and flexible line to allow it to be
cut off during repair work.
If ROLLAIR ® V has to operate in parallel with other
ROLLAIRs®, or the analog-type compressors, the discharge pi-
Fig. 2a - Sleeve with roof outlet pes can be connected together.
d
If ROLLAIR® V has to operate in parallel with one or several
alternative compressors, an air tank which is common to the al-
Ventilation Duct minimum cross section ternative compressors is essential. The pulses emitted by the al-
L

flow rate ( d ≤ L ≤ 1,6d ) ternative compressors would seriously damage the non-return
m3/s m2 valve, the ROLLAIR® V oil separator component and disturb
ROLLAIR® 80 3,61 0,657 the control system. When the rotary compressor operates in
ROLLAIR® 100 3,61 0,657 parallel with an alternative compressor, the latter have to be
adjusted so that the rotary compressor carries the base load. The
ROLLAIR 125 ®
4,17 0,758 result of this is more economic operation.
ROLLAIR® 150E 4,17 0,758

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62 305 512 00 Page 9
E - Condensate drain pipes G - Electric cabling
A separator with automatic solenoid valve drain is provided Each ROLLAIR ® is wired for a pre-determined voltage,
inside the set ( see Chapter 5-K) to remove the condensate at i.e. 220/230/240 V or 380/400/415 V.
the final cooler outlet and stop the compressor pipe condensate
NEVER OPERATE THE ROLLAIR ® AT A VOLTAGE
return lines. Connect the discharge pipe to a condensate
OTHER THAN THE ONE SHOWN ON THE ELECTRICAL
manifold.(see B chapter 1)
CABINET.

F - Water pipe The electric current supply to the ROLLAIR® must comply with
the following table :
For water-cooled units. Type of cable to be used : H07 RNF
The diameters of the pipes to be provided are as follows: Power cable size
(for a maximum 10-metre length)
- refrigerant input/output: 1" gas thread.
VOLTAGE
The input filter is recommended for protection of refrigerants ROLLAIR® Type
and valves. The set is equipped with an automatic solenoid valve 220/230/240 V 380/400/415 V
for closing off the water. This is situated on the water inlet 80 4 x 70 mm2 4 x 50 mm2
pipe. A manual control and check valve will be installed on the
100 4 x 95 mm2 4 x 70 mm2
water discharge to optimize flow.
125 4 x 150 mm2 4 x 95 mm2
The flow shall be adjusted so that the oil temperature (in outlet of
150E 3 x 240 mm + 2
3 x 120 mm2 +
compression element) displayed on the instrument panel is between
70 and 90 °C, depending on the water inlet temperature Te (refer (1 x 120 mm2) (1 x 70 mm2)
Fig.3, Fig.4, Fig.5 and Fig.6)
SAFETY REGULATIONS
Recommended output for water at 20°C:
It should be remembered that safety regulations require :
ROLLAIR® Type Output
• An earth socket to be used.
80 2 m3/h • A manual isolating switch, cutting all three phases ; this switch
100 4 m /h
3 must be clearly visible near the ROLLAIR® unit.
• The electric current must be cut whenever maintenance work is
125 3 m3/h carried out on the machine (except for pressurized oil change)
150E 6 m3/h
Fuses to be used for
Since both exchangers are installed in series, the water passes ROLLAIR Type ® the isolating switch (Type AM)
firstly via the final refrigerant and then via the oil refrigerant. 220/230/240 V 380/400/415 V
The figures 3, 4, 5 and 6 indicate the water flow rate necessary 80 200 200
for obtaining a correct temperature of the compressed air depending 100 250 200
on the needs and the water inlet temperature Te between 10 and
30°C. 125 320 250
150E 400 250
Note : For variable speed machines to see Chapter 6.

Fig. 3 - Water flow diagram ROLLAIR® 80-80V

100.0

Correction due to ambience (4˚C - 40˚C)

95.0 T oil=T oil 20˚C + 0.25 x (T ambiance -20)
Oil temperature (˚C) in 20˚C ambient condition

90.0

85.0

Te = 30˚C
80.0
Te = 25˚C

75.0
Te = 20˚C

70.0 Te = 15˚C

Te = 10˚C
65.0

60.0
1.00 1.20 1.40 1.60 1.80 2.00 2.20 2.40 2.60 2.80 3.00
Flow rate of water (m3/h)

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Fig. 4 - Water flow diagram ROLLAIR® 100-100V
100.0

Oil temperature (˚C) in 20˚C ambient condition

95.0
Te = 30˚C

90.0 Te = 25˚C

Te = 20˚C
85.0

Te = 15˚C

80.0
Te = 10˚C

75.0 Correction due to ambience (4˚C - 40˚C)

T oil=T oil 20˚C + 0.25 x (T ambiance -20)

70.0
2.00 2.50 3.00 3.50 4.00 4.50 5.00 5.50 6.00
Flow rate of water (m3/h)

Fig. 5 - Water flow diagram ROLLAIR® 125-125V

100,0

Correction due to ambience (4°C - 40°C)

T oil=T oil 20°C + 0.25 x (T ambiance -20)
95,0
Oil temperature (°C) in 20°C ambient condition

Te = 30°C

90,0
Te = 25°C

85,0 Te = 20°C

Te = 15°C
80,0

Te = 10°C

75,0

70,0
2,00 2,50 3,00 3,50 4,00 4,50 5,00 5,50 6,00
Flow rate of water (m3/h)

Fig. 6 - Water flow diagram ROLLAIR® 150E-150V

100,0

Te = 30°C

95,0
Oil temperature (°C) in 20°C ambient condition

Te = 25°C

90,0 Te = 20°C

Te = 15°C
85,0

Te = 10°C

80,0

Correction due to ambience (4°C - 40°C)

T oil=T oil 20°C + 0.25 x (T ambiance -20)
75,0

70,0
4,00 4,50 5,00 5,50 6,00 6,50 7,00 7,50 8,00
Flow rate of water (m3/h)

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Chapter 3 - Implementation
A - Preparation for start-up
Before starting the set for the first time, the operator must get to Check the direction of rotation (following the arrow on the
know the different systems. The main locations which have to be coupling housing rep. 1-fig. 7) by pressing the "Start" button,
examined are shown on the figures. followed immediately by the emergency stop. If it does not spin
in the right direction reverse two stages of the power cord. When
IMPORTANT it rotates in the correct direction, the oil level (fig. 19) should
Before start up, make sure that transport red wedges have been drop after 4 or 5 seconds of operation.
effectively removed. It is also very important to verify the direction of rotation of the
fan (indicated on it by an arrow) anti-clockwise seen from inside
ATTENTION the machine or clockwise seen from outside the machine).
The power circuit must be turned whenever adjusting electrical 1 - Press the ON button, the motor starts up.
equipment or to prevent accidental starting.
2 - Leave it running for a few minutes with the discharge valve
Loosening of electrical power cables that may be due to vibra- slightly open to observe the compressor under load. Ensure
tions caused by transport or initial heating entails abnormal heating that there are no leaks. Reblock the connectors if necessary.
of contactors, which may even destroy them. Therefore, these 3 - Press the OFF button. The motor will stop and the unit will
cables must be re-tightened at line contactor incoming and automatically vent to atmospheric pressure.
outgoing, star and triangle before use.
C -Discharge pressure adjustment
Before start-up, check the following points :
1 - Make sure that the unit is properly earthed. The unit is adjusted in the factory for a MAXIMUM pressure (for
2 - Check the oil level in the tank. the maximum output from the outlet of the central unit) of 7.5, 10
NOTE : the tank has been filled with suitable oil in the or 13 bar depending on the model. To adjust the backflow pres-
factory. See Chapter 7 - A for the quality of oil to be used sure setting to a lower value, refer to the manual of the electronic
or for oil renewal conditions. plate (refer E Chapter 1).
3 - Make sure the oil change valve is properly closed.
D - Parallel compressor assembly
ATTENTION If the ROLLAIR® is intended to operate in parallel with other
The oil filler cap, the oil change valve and plugs must always remain ROLLAIRS® or similar compressors, the discharge piping can be
closed during operation and never be opened before the system linked together.
has been completely vented to atmospheric pressure (except
pressurized oil change : see Chapter 7 - A). If the ROLLAIR® is intended to operate in parallel with other
ROLLAIRS® or similar compressors, there must be an air tank
common to all the alternative compressors. The pulses emitted by
B - First start-up alternative compressors may cause serious damage to the minimum
Check the voltage between the three phases before using the unit pressure valve and the ROLLAIR® oil separator, and disrupt the
for the first time. regulation system. When the rotary compressor is operating in parallel
with an alternative compressor, the latter should be adjusted so that
the rotary compressor takes the main load. It is cheaper to run this
way.

E - Cooling water regulation for water

cooled sets
1 The water flow has to be adjusted manually or automatically in order
to maintain the temperature at the oil cooler outlet at 80°C when
the set is operating at full load (see Chapter 2- F).

F - Safety
The oil used for cooling the machine is a liquid combustible under
the effect of strong heat. In case of fire in the machine, it is essential
to respect the regulatory measures on the compressor. The type of
fire in a compressor is defined as "class B" and in presence of a live
Fig. 7 electrical conductor, it is recommended to use a CO2 extinguisher
functioning by "smothering" (starvation of oxygen) while observing
the user instructions applicable to the model.

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Chapter 4 - Operation
A - Air and oil circuits
1 - Air circuits (see Fig. 8) Key fig. 8
The air is sucked into the compressor through a filter (rep. 23). 20 Compressor
This air passes through the compression element where it is mixed 21 Suction element
with oil injected during compression. Inside the oil tank, the
compressed air is pre-deoiled by shocks, then flows through the 23 Air filter
oil separator (rep 49). It then passes through the mini pressure 26 Oil filter
valve (rep 34) forming a check valve, the aftercooler (rep 51A),
the condensate separator (in option), and lastly the outlet valve 34 Minimum pressure valve
(not supplied) to which the distribution pipe is connected. 41 Ventilator

2 - Oil circuit (see Fig. 8) 44 Drain electrovalve ( in option )

47 Thermostat valve
The oil, under discharge pressure, flows from the bottom of the tank
through the cooler (rep. 51H), the oil filter (rep. 26) which retains 49 Oil separator
solid impurities, and then into the compressor (rep. 20). At each cold 51 A Air cooler
start, the thermostat valve (rep. 47) short circuits the oil radiator, thus
enabling the optimum operating temperature to be attained quickly. 51 H Oil cooler
When it leaves the compressor, the oil returns to the tank. Part of the oil 55 Condensation water separator ( in option )
remains suspended in the air as mist. This mist passes through the oil
separator. (rep. 49). The remaining oil, which is separated by the last 56 Motor
stage of the oil separator, is drawn up by a dip tube and dispatched to 57 Tank
the compressor.

Fig. 8 - Air / oil circuit

34

26
49 47

57

21
23

56 51A
51H
20 55

44

41

Worthington-Creyssensac 02/2008
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B - Regulation principles
1 - "On off Load" regulation (see Fig. 8bis) Key fig. 8bis
Version standard
20 Compressor
The ROLLAIR 80-100-125-150 units are fitted with an
®
21 Suction housing
automatic regulation system, enabling the machine to be stopped 22 Electro-valve
after it has run unladen for a given (adjustable) period of time.
This period of unladen running is necessary to avoid excessively 23 Air filter
close start-ups in highly varied periods of compressed air 25 By-pass valve
consumption.
26 Oil filter
When the compressor reaches its maximum pressure, the pres- 34 Minimum pressure valve
sure switch (rep. 45) closes the electrovalve (rep. 22). The
36 Pneumatic pump out
compressed air on the suction housing piston and the vacuum
piston are depressurised; the housing is closed and complete drai- 37 Safety valve
nage of the tank is carried out. 41 Ventilation

The compressor draws in air via a by-pass valve (rep. 25). 45 Regulation pressure switch
46 Safety temperature sensor
The low pressure obtained in the oil tank enables the compressor
47 Thermostat valve
to be lubricated and cooled during the whole unladen running
period. 49 Oil separator
51 A Air radiator
If the user network's compressed air pressure reaches the mini-
mum pressure switch trip value before the end of the unladen 51 H Oil radiator
running time, the pressure switch (rep. 45) opens the electrovalve 57 Oil tank
(rep. 22), causing the suction valve to open and the vacuum
system to close. The compressor compresses at full rate again.
2 - "PROGRESSIVE" regulation
When the compressor stops, the electrovalve (rep. 22) is no lon- (see J chapter 5)
ger powered and closes; the suction housing closes and the oil
tank is evacuated. The tank is thus vented to atmospheric pres- 3 - Speed regulator
sure, for the next time the unit is started up.
( see chapter 6)

Fig. 8bis - "On off Load" regulation

36

22

41 45
35 34

51A

21 37
51H
23 49

25
57
46
20

47
26

02/2008 Worthington-Creyssensac
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2 - Option overview
Chapter 5 - Options
- This option is used as a replacement for the standard filter
- Certain atmospheric particles are smaller than 2 microns, a
A - Level detection bleed valve (Fig. 9) limiting threshold for traditional paper cartridge filters. The filter
increases filtration effectiveness by eliminating 99.97% of particles
1 - Description that are larger than or equal to 3 microns.
The BEKOMAT type level detection bleed valve allows all air - The quality of the air intake by a compressor is essential. Low
consumption to be avoided while the compressor is not running. quality air creates the following :
• Quick pollution of the oil thus an increase in draining cycles.
2 - Option overview • Binding of the air / oil separator before 4000 hours thus an
- There is no air consumption due to the level detection system : an increase in maintenance cycles and operation costs.
inductive sensor detects the level of condensation and thus controls • Pollution increases the elements that filter into the air and oil,
the opening of the electric bleed valve. A low level of condensation is speeding up the damage to the mechanical components of the
also detected in order to close the electric bleed valve and to prevent compressor, screw element,...
compressed air from being wasted.
Filters in compliance with standard ISO 5011/2000.
- This type of purge valve does not require any maintenance. The - Exceptional filter longevity, from 18 months to 3 years of
purge valve does not require the use of the metallic intake filter that is continuous service (24 hours a day, 7 days a week), which is a
usually installed on electronic purge valves to protect the solenoid little more than 10,000 hours of operation of the compressor under
valve. The solenoid valve will not be damaged. normal conditions.
- Condensate treatment is made easier because it is not evacuated by - Installation of the filter(s), depending on the model, outside the
pressure, which enables easy separation of the water and oil stages. compressor, for intake of fresh air, hence resulting in a lower oil
temperature and more efficient compression (Fig. 10a and 10b).
Fig. 9
Extraction duct

1 4
VORTEX pre-filter

Air filter
2 5

6
3

x y
1 - Condensation intake 4 - Main duct
2 - Capacitive sensor 5 - Electric valve
3 - Receiver 6 - Membrane x y
ROLLAIR® 80-100 2160 345
3 - Technical features ROLLAIR® 125-150E 2160 430
Maximum capacity of the compressor : 20 m3/min
Working pressure : 0,8 / 16 bar
Operating pressure
Electric power supply
: + 1 / + 60°C
: 230 / 110 / 24/ …
Fig. 10a
AC socket in the compressor electric cabinet.

Cartridge
B -Advanced filtration to the compression
air inlet (Fig. 10a and 10b)
1 - Description

This system is equipped for "high efficiency" air filtration in order

to improve the quality of the air intake and to preserve the
compressor's oil and internal filter components.

This option is particularly useful in very dusty surroundings.

Fig. 10b

Worthington-Creyssensac 02/2008
62 305 512 00 Page 15
3 - Technical features

Operating temperature :
-40 °C to +90 °C

C - Pre-filtration panels
1 - Description

Installing air filtration panels on the ventilation intakes (machine

and built-in dryer) guarantees protection of the compressor's
internal components and an increase in air sucked into the com- Galvanised steel covered frame.
pression assembly. This option is recommended if the forced fil- Flammable medium (belonging to fire protection class M1) made
tration option is installed (see § B). of polyester fibres.
Pleated medium on support grid placed downwards in the direc-
2 - Option overview tion of the airflow.
The pre-filtration panels eliminate 90% of the particles normally Support grid
admitted inside the compressor and considerably decrease internal
contamination of the machine. Fig. 12
The high quality of the ventilation air is also essential for protecting
internal components of the compressor and, more specifically, the
motor and the air / air and air / oil exchangers. Clogging in the
exchangers creates an increase in temperature, deterioration of Pre-ventilation
lock
the lubricant and the motor becomes overloaded thus increasing
the energy consumed.
Disassembly
The quality of the air drawn in by a compressor is essential. Low hinges
quality air results in the following :

• Fast pollution of the oil thus an increase in oil change cycles.

• Increased pollution of the air and oil filtering components that 4 pannels pre-filtration
increases the deterioration of the mechanical components in the
compressor, screw block, ...
3 - Technical features
• Binding of the air / oil separator before 6000 Hours thus an
FILTER MEDIUM :
increase in maintenance cycles and maintenance costs.
Degree of filtration : 90% of the dust emitted is filtered.
Access to the filtering medium is allowed by removal that does Total nominal flow : 15 200 m3/h
not require any particular tool. The panel frame can be unlocked Filter panel number : 4
manually in order to clean the medium. Initial charge loss : 75 Pa
Dimensions : Width : 500 mm
Exceptional longevity of the medium that is quick to take apart. Length : 625 mm
The medium can be scoured by blowing compressed air in thus Thickness : 200 mm
increasing the usage term for the filtering medium.
This option may be installed on a compressor already in place.
Fig. 11

Easy to disassemble for rapid cleaning

02/2008 Worthington-Creyssensac
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D -Automatic restarting 2 - Option overview
It avoids any cold starting of the compressor and ensures that the oil
1 - Description injection is carried out under optimum temperature conditions no
This management system enables the compressor to be restarted matter what the exterior conditions may be.
automatically after a power outage.
The thermostat installed in the tank allows a precise readjustment of
the oil temperature to be carried out at any time.
2 - Option overview
Not available in standard version in order to prevent any incident during Thermostat-controlled resistors for automatically triggered reheating
maintenance operations carried out by an untrained person. This op- whenever the oil temperature drops below 10º C. This requires no
tion is proposed in cases where the production of compressed air should intervention from the user.
suffer only the minimum periods of shutdowns. Two condensate separation filters are installed in the controlled air
The standard microcut time accepted by AIRLOGIC is circuits in order to prevent the control circuits from clogging up due
approximately : 40 ms. to condensates freezing because of temperature variations.
However, certain electrical fittings create longer micro cut-offs Automatic starting /stopping of the heating resistor which is powered
that will cause a compressor shut down, then a manual restart. by the compressor electric cabinet.
Automatic compressor restarting enables immediate air produc- It is started at the same time as the compressor stops, providing energy
tion after a power outage and thus avoids the time lapse required when the compressor is in use.
for manual compressor restarting that would mean a fall in pres-
sure in the air circuit. NOTE : this option requires the compressor to be constantly powered.
Particularly used for industries where air production should not be Fig. 13a
subject to shut downs that waste the products manufactured or
damage the production equipment.
Heating resistors
THIS OPERATION REQUIRES THE CONFIGURA-
TION OF MENUS IN THE CONTROLLER, ACCESS
RESTRICTED TO TECHNICIANS CERTIFIED BY
WORTHINGTON CREYSSENSAC.

AN INFORMATIVE INSERT MUST BE PLACED Thermostat

ON THE ELECTRIC CABINET TO WARN THE
USER OF THE RISK THAT THE COMPRESSOR
MAY AUTOMATICALLY RESTART AT ANY
TIME.
Fig. 13b
3 - Technical features
This option requires configuration of the electronic plate and ins-
tallation of an informative insert on the door of the compressor
electric cabinet.

Every time the compressor stops, it must be secured by

opening and locking the electric section switch.

E - Remote starting and stopping

This option allows the compressor to be remotely started and
stopped. However, in all cases, stopping the compressor at the
machine itself is essential. If the compressor is shut down from a
distance, it may be restarted from a distance as well. For any inter-
vention to be conducted on the machine, it is essential to activate
the emergency stop of the machine in order to ensure safe condi-
tions (Refer to AIRLOGIC Manual, E Chapter 1)
Control box for the heating resistor installed on the
F - Oil re-heating oil tank.

1 - Description
3 - Technical features
This oil reheating system is installed in the oil tank in order to
RESISTANCE:
preheat the lubricant at low temperatures (mainly in winter).
Power consumed: 500 Watts
Start-up temperature: 5 à 10 °C

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G -Rotation direction indicator - H - Special oils
Phase controller 1 - Description
1 - Description Different oils meet different needs:

The phase controller option is designed to: Rotair 4000: longer interval between 2 drainage operations - 4000
hours under standard conditions of use.
- control the rotation direction of the machine's electric power
supply phases. Rotair 8000: longer time interval between 2 drainage operations -
- check that electric power is supplied to each phase. 8000 hours (use of special oil filters).
These two functions are permanently guaranteed. Food Grade Oil: use of the compressor in the agricultural foodstuffs
industry.
2 - Option overview Note: if this option is chosen on a machine that has previously
The advantages of this option are: run on standard oil, the rinsing procedure must first be strictly
- starting the machine with the guarantee that it will work (if this complied with.
option was factory-installed), the configuration of the rotation di-
2 - Description of the option
rection having been configured during the production tests.
- protecting the motor and the electrical fittings from any loss of Rotair 4000 - Rotair 8000
power supply (phase cuts, blown fuses, voltage threshold lower The qualities of these oils enable the maintenance planning schedule
than 130 volts). to be based on main drainage operations of 4000 or 8000 hours
- protecting the machine (motor and especially the compression (under standard conditions of use).
assembly) when restarting it following electrical work on the power
The maintenance tasks are consequently less frequent, thus making
supply line or when switching from the mains supply to a backup
for certain savings, such as the availability of the equipment and
power supply, such as a power generator.
lower operating cost of the compressor.
3 - Operation Food Grade Oil
In the event of a phase failure (detectable by this option) or an This oil has been specially developed for use as a lubricant that
incorrect rotation direction, the trip switch sets off the machine's may come into contact with foodstuffs.
safety system (preventing immediate stopping and starting of the
machine) and shows the following message on the display of the
electronic plate: "ventilation flaw".

4 - Features
scanning time / measurement cycle < 80 ms
minimum operating voltage 200 volts
maximum acceptable voltage between phases 500 volts
power consumption 15 VA

02/2008 Worthington-Creyssensac
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I - "PROGRESSIVE" regulation (Fig. 14)
Key fig. 14
This type of regulation means that the compressor's flow-rate can
be adjusted to the required level of compressed air using very slight 20 Compressor
pressure variation in the operating network. 21 Suction housing
22 Electro-valve
The compressor operates at full flow-rate (suction housing valve 23 Air filter
(rep. 21) fully open) as long as the pressure is lower than the
25 By-pass valve
discharger pressure (rep. 38). If compressed air consumption is
26 Oil filter
lower than the compressor flow, the pressure will rise, the
discharger starts to close and orders the partial closure of the 34 Minimum pressure valve
suction housing valve (rep. 21) so that the compressor air flow is 35 Pressure gauge
equal to the air flow consumed and the pressure remains constant 36 Pneumatic vacuum system
as long as air pressure does not vary. 37 Safety valve
38 Discharger
When consumption varies, the discharger progressively controls
the movement of the suction housing valve to maintain constant 41 Ventilation
air flow equal to consumption. 44 Draining electro-valve
47 Thermostat valve
In order to restrict energy consumption for low compressed air 49 Oil separator
requirements, the pressure set point (rep. 62) is adjusted in such a
51 A Air radiator
way that it works with no oil (zero flow and weak pressure in the
51 H Oil radiator
oil tank) when the compressed air consumption is about 30 %
lower than the maximum flow of the compressor. 55 Condensate separator
57 Oil tank
Therefore, when the pressure set point is reached (rep. 62), the 58 Electro-valve
solenoid valves are closed (rep. 22 and rep. 58) which, in turn,
62 Pressure sensor
triggers, on one hand the total close of the suction valve and, on
the other, the full drainage (rep. 36) of the oil tank, as in the "All 63 Temperature sensor
or Nothing" principle.

Fig. 14 - "Progressive" regulation

38
36

22

58 41 62
35 34 55
51A

21 37 44
51H
23 49

25 63
57

20

47
26

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J - Energy recovery Fig. 15
1 - Description
The energy recovery option consists of including a cooling circuit
that bypasses the machine's air-cooled oil circuit in order to heat a
water flow according to the "temperature" parameters, which are
controlled automatically by the thermostatic valve.

2 - Option overview
Optimisation of the compressor's heat capacity:
A certain amount of energy is dispersed by the compressor as heat.
In air-cooled compressors, this dispersion is carried out with the
help of the airflow that passes through the machine. This energy
can be recovered, either as a ventilation air insulation system for
heating purposes, or as a cooling system using water adjacent to
the oil circuit for re-heating the water used in industrial applica- 2 6
tions.
Automatic management of the choice of cooling circuit: 5
The energy recovery system is built-in to the standard air-cooled
compressor. It consists of installing an oil/air heat exchanger in 3
front of the standard oil/air cooler to reheat the water. This
exchanger is sized according to the features of the flow, pressure,
intake temperature and desired water temperature.
4

Key fig. 15
1. Water intake 1
2. Water outlet
3. Water-oil plate heat exchanger
Sized according to the temperature, pressure and flow
of the coolant water features.
Circulation is carried out against the flow within th 3 - Technical features
heat exchanger. The diameters of the tubes to be used are as follows: water inlet/
4. Thermostatic valve outlet: 1'' gas (socket).
Graded at 55 - 60 °C, it authorises or bypasses the
the water-oil heat exchanger, thus producing a recovery We recommend using a filter on the water intake to protect the
of energy. cooling agents and the valves. The central unit is equipped with an
5. Thermostatic valve automatic water shutoff solenoid valve, located on the water intake
Graded at 60 °C, it has the same function as in pipes. A manual valve for insulation and water-flow control will
normal-air-cooled machines, i.e. cooling or not the oil in be installed on the water outlet in order to optimise the flow.
the air-oil heat exchanger
The water must be relatively fresh in order to prevent dangerous
6. Injection of cooled oil into the compression element.
deposits and scaling of the pipes.
The required qualities are given as a general rule in order to avoid
problems caused by the cooling water ( see D-2 chapter 7). If you
have any doubts, please contact Worthington-Creyssensac.

Please contact WORTHINGTON-CREYSSENSAC for the

following specifications depending on the power of the machine:
- Minimum water intake temperature
- Maximum water intake temperature
- Cooling water flow required
- Water circulation pressure
- Recoverable energy

02/2008 Worthington-Creyssensac
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K - Centrifugal separator 2 -Description of the option

Fig. 16 Fig. 17
Integrated oil-water separator

1 - Description
This device allows bleeding of the condensates formed in the air
cooler.
The impurities drawn in by the condensates are recovered in the
2 - Description of the option removable impurities collector. The condensates are collected in
the separation chamber.
The cooling of the compressed air allows the suction air to be
dried, thus removing the humidity that collects in the bottom of Under the effect of gravity, the oil present in the separation chamber
the separator after being condensed in the aftercooler. The moves gradually to the surface. The oil thus collected is carried
condensates are evacuated from the separator through a trap with into the oil collector via the oil spout. The condensates collected
a solenoid drip valve or a trap with level detector if this option is below the oily surface are carried via the filter pipe, passing through
installed. an oleophilic pre-filter and an adsorption filter.
The material of the oleophilic pre-filter binds the remaining droplets
L - Oil-water separator of oil.
The adsorption filters retain the finely dispersed oil particles.
(Refer B Chapter 1)
Note: The successive filtration (oleophilic pre-filter and adsorp-
1 - Description tion filters) guarantees a very high efficacy that is maintained even
with fluctuating quantities of condensates.
The principle of this device is based on de-emulsification and
gravity. It allows the oily condensates to be placed under pressure The clean water comes out from the equipment via the water drain.
(fine drops of oil present in the condensation water) in a container The sampling faucet allows samples of the cleaned water to be
to separate the oil from the water. Decompression takes place in a collected in order to determine whether the filters have to be
decompression (release) chamber to avoid any turbulence in the replaced.
separator tank and favour decantation through the difference in A filter cartridge retaining the aerosols prevents odours from
the density of each fluid. escaping via the cover of the equipment.

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Chapter 6 - Specific The inverter has a load circuit of thermally limited
capacitors. Therefore, it is important to allow minimum
information for ROLLAIR® 80 - 4 5 minutes between two successive power-ons. If this
instruction is not respected, the switch and the resistor
100 - 125 - 150 V and V HP of the load circuit may be damaged.

2 - Safety instructions
Refer also to the chapters concerning the standard machine.
No connection work is allowed when the inverter is
" R O L L A I R ® V" machines are compliant with the 1 under power.
Electromagnetic compatibility in industrial environments Stan-
dards 50081-2 and 50082-2
No measurement work is allowed on the inverter when
2 it is under power.
A - Description (cf Chap. 1)
To undertake any work on the inverter, it is necessary
Standard equipement to disconnect the equipment from the mains. Wait for
A electronic frequency adjusting device replaces the star-delta 3 the internal ventilation to stop and the indicators to be
starter. turned off. Then, wait 5 minutes before opening the
cover.
B - Safety
No voltage or insulation verification test is allowed on
4 the inverter components.
For your safety, please respect the instructions carrying the warning
symbols as given below:
5 Disconnect the cables from the motor and the inverter
before taking measurements on them.
SAFETY RULES

The safety rules require: 6 Do not touch the integrated circuits, the electrostatic
discharges may damage them.
• The presence of an earth socket
• The existence of a manual switch cutting-off the three pha- Before connecting the inverter, make sure that its cover
ses that should be placed visibly near the ROLLAIR® V 7 is properly closed.
• It is necessary to cut out the electric current before any
intervention on the machine (except drainage under pres- Make sure that no compensation capacitor of cosine
sure). 8 phi is connected to the motor cable.

= Dangerous voltage

= Attention
C - Installation

ELECTRICAL INSTALLATIONS MUST ONLY BE The " ROLLAIR ® V" must be installed away from a
CARRIED OUT BY A SPECIALISED AND COMPETENT transformer or autotransformer.
TECHNICIAN (see Chapter 2 and 3).
The fuses for the section switch are defined as follows
1 - Warning
Mains voltage 380/400/415 Volts / 3 / 50Hz
The internal components and the plates (except the 80V 100V 125V 150V
electrically insulated I/O terminals) are at the mains
1 voltage when the inverter is connected to the mains. Nominal voltage 126 A 150 A 180 A 201 A
This voltage is extremely dangerous and can cause ( 400 V )
severe injuries or even death in case of involuntary Power supply cable H 07 4x50mm² 4x70mm² 4x95mm² 3x120mm²
contact. Section mm² L=10 m +(1x50mm²)
maxi
When the inverter is connected to the mains, the
Upstream fuses 160 200 250 250
2 connection terminals U, V, W of the motor as well as ( Type gG )
+/- connectors of the braking resistors are under power
even if the motor is not running.
ATTENTION
The I/O control terminals are insulated from the mains,
Motors and drives can only be guaranteed where the supply voltage
the relay outputs can nevertheless be under power even
does not exceed the rated voltage by more than 10%.
3 if the inverter is disconnected. This also applies to other
The connection of the power supply to the section switch (so
I/O control terminals even if the X4 switch is in OFF
present) requires the use of properly insulated terminals.
position (Stop).

02/2008 Worthington-Creyssensac
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D - Commissioning
1 - Preparation for start-up 4 - Assembly and settings for parallel operation
(See Chapter 3). with other compressors

Pressure for the ROLLAIR® V compressor must be adjusted at a

ATTENTION
value within the range of adjustment values for the rest of the
compressors..
The power circuit will have to be cut off when adjusting the
electrical equipment or if inadvertent start-up is to be avoided.
Before start-up, check the following points: Adjustments pressure
1 - Ensure that the unit has a suitable earth,
2 - Check the oil level in the compressor,
Stop P
NOTE: the tank was filled in the factory with a suitable oil. See
Chapter 8 - A for the quality of oil to be used and for the oil
renewal conditions.
Set
3 - Check that the drainage valve is properly closed.
point 1
4 - Make sure that the conveyor assembly's blocking lugs
(compressor) have been removed from the compressor
silentblocks.
Various
ATTENTION compressors
The oil filler plug, the valve and the drainage plugs have always to
be closed during operation and must never be opened before the RLRV C1 C2 C3
system has reached atmospheric pressure.
5 - Regulating the pressure by changing the speed
2 - Control of rotation direction on start up
This method of regulating the pressure allows precise adjustment
This control must be implemented when the machine is put into
of the compressor's flow-rate at the compressed air demand valve:
operation for the first time, after any work has been carried out on
the motor and after any changes to the mains supply. The accuracy is of the order of 0.1bar when pressure regulation is
achieved by changing the speed, provided that the flow-rate lies
IMPORTANT : between the maximum and minimum rates for the machine.
• Check the direction of rotation (as per the arrow shown on the • The principle of the pressure regulation by changing the speed
sump) by jogging over with the START button.
The AIRLOGIC controller controls the motor and the compressor
If it is incorrect, swap over two of the motor's phase cables under as a function of the system pressure as measured by an internal
the drive. pressure sensor (fig. 18a).
When rotating in the right direction, the oil level (fig. 18) must
drop after 4 to 5 seconds of operation. - If the mains pressure is weaker than the pressure set point
• Also check the direction of rotation of the fan for air-cooled (user-defined parameter in the AIRLOGIC) the motor will
plants (counter-clockwise, as seen from inside the casing). accelerate and the pressure will increase (fig. 18b)
1 - Press the START button so that the motor starts. - If the mains pressure is stronger than the pressure set point, the
2 - Allow to rotate for several seconds with the discharge valve motor will slow down causing the pressure to drop.
slightly open to observe the compressor at load. The AIRLOGIC provides the compressor control functions and
3 - Press the STOP button. The motor stops and the plant also controls the whole pressure feedback loop. It therefore
automatically returns to atmospheric pressure. includes a device to compare the indicated pressure with that from
the pressure sensor, associated with a compensating device,
3 - Setting of pressure - machine Proportional integral control PI (fig. 18c).
(Refer E Chapter 1 refer also to the AIRLOGIC controller manual) The drive, a result of the latest developments in power electronics,
is one of the smallest in size on the market, thanks to its use of
The unit is factory pre-set for a given delivery pressure. As an high cut-out frequencies with IGBT transistors.
energy saving measure, it is strongly advised to reduce the pres- At the same time, the motor control method known as "open loop
sure to the exact requirement by adjusting the "Set point 1"setting. vector flux control " provides good stability for the system against
The stop pressure"Indirect shutdown"used when running at less disruption.
than the minimum flow-rate - must be set to 0.5 bar above that of
In this way, the pressure feedback loop is more stable to sudden
the "Set point 1". In this way, the current used by the compressor
changes in consumption (changes in the flow-rate).
is minimised (seenotice AIRLOGIC).
Do not set the stop pressure at a level beyond the machine's max P.

Worthington-Creyssensac 02/2008
62 305 512 00 Page 23
Fig. 18a
The principle of the pressure regulation by variable speed

Pressure Controller Drive Motor Compressor Tank

required unit

Frequency speed

Pressure sensor

System

• Pressure regulation for low rates of flow • Energy saving

For an air consumption rate lower than the minimum rate of flow For demand of compressed air within the machine's flow range -
for the machine, the pressure is adjusted by the machine's time- min flow to max flow, the frequency converter or the variable
delayed START/STOP controls. speed drive feed the motor in order to ensure that it turns at the
speed required to supply air demand both for pressure and flow.
Since the operation element cannot function below a certain speed
(corresponding to the minimum output), the compressor continues It is used to adjust the power supply to the motor (and thus the
to run and compress at the minimum speed until the pressure reaches machine) to the exact power requirement for the compression of
the limit called "Indirect shutdown ". the air, without a drainage stage being necessary.
Once this threshold has been reached, the motor will stop, the COMMENT :
machine will go into stand-by mode after a certain period of
Energy savings are increased if machine maintenance is carried
inactivity and the full drainage process will be carried out.The pres-
out in accordance with the maintenance instructions and frequency.
sure then drops towards the indicated pressure and, at the end of
the minimum time delay (since reaching the no-load pressure), the
drive allows the motor to restart. The pressure then rises again and
the cycle starts over (fig. 18 d).
To avoid pumping the system - frequent stop / start - drainage
time may be increased
(cf. notice AIRLOGIC).

02/2008 Worthington-Creyssensac
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Fig. 18b
Fig. 5 b Fig.5 18c
Fig. c Fig.
Fig. 518d
d
Pressure
Stop
threshold

Instructions
Required
pressure

Time
Speed

stop timing

minimun time
Min speed

Time
Flow Q

Min Q

Time

E - Operating incidents
The staff in charge of maintenance of the ROLLAIR® compressor must become fully acquainted with this machine, in order to be able to
easily diagnose any anomaly. Under normal operating conditions, the ROLLAIR® compressor must provide full satisfaction.

1 - Main incidents

The main incidents likely to occur are listed below, along with the remedies to be applied. The keys to the control lamps relate to the
instrument panel (refer to the AIRLOGIC Manual - E chapter 1).

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Chapter 7 - Maintenance
The maintenance period is limited to several essential operations. It The summary on the ROLLAIR® instrument panel shows at a glance
is strongly recommended that the power supply be cut off during the type and periodicity of operations to be carried out for the
any adjustment or repair. compressor to function correctly.

Operations to be carried out

Parts Daily Every Every Every Every Every Every Observations
500 h 150 h 2 000 h (*) 4 000 h 6 000 h 12 000 h
Service A Service B Service C
Drain the condensates
Draining cock X from the cold oil circuit
(Chapter 7 - G)
Check and top up if
Oil level X necessary
(Chapter 7 - A)
Air filter X Replace the filter
Oil tank, Oil change, oil refill
Oil change X X with recommended oil
(Chapter 7 - A)
Control Renovation of the
Suction housing cleaning Overhaul kit housing. Use the
lubrication suction housing kit
Check the cleanliness of
Oil return pipe OverhaulKits the oil return pipe and
the state of the seal
(Chapter 7 - F)
Change the part
Oil separator X according to the
instrument panel indication
(Chapter 7 - E)
Oil filter X X Filter change
Oil radiator Blowing of cooling
Final coolant X elements
Cleaning (Chap. 7 - D)
Control Exchange the accessories
Valve at minimum cleaning Overhaul kits supplied with the
pressure lubrication maintenance kit
For motors fitted with
Motor for grease fitting, use
ROLLAIR® X KLUBERQUIET
80-100-125-150E BQH72-102
(16 g per grease fitting)
For motors fitted with
Motor for grease, use
ROLLAIR® X KLUBERQUIET
80-100-125-150 BQH72-102
version V and V HP (16 g per grease fitting)
Electric cabinet X X Retighten power cable
connections.
Safety temperature Check operation
test X (Chapter 7 - H)

NOTE : maintenance kits are available (see spare parts list). (*) or at least every year

A - Oil level and change This ROTAIR 2000 oil was specially designed for Worthington-
(see fig. 19 and B chapter 1) Creyssensac and guarantees to the operator an oil change period
The recommended oil used for the first compressor fill up is a mineral of 2000 hours, with the replacement of the oil separator filter after
oil with the following properties : 6000 hours.
- viscosity: 40 cSt at 40° C
- viscosity index: 90 minimum THE FIRST OIL CHANGE MUST BE CARRIED OUT
- antioxidant additives AFTER THE FIRST 500 HOURS OPERATION.
- anti-rust additives
- anti-foam additives

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Using a synthetic oil for compressors is also acceptable and means • Reinitialise the timers that will warn you when to carry out the
less frequent oil changes : please speak to us about the compatibility next oil change and the next oil filter change
and oil change methodes. (see the AIRLOGIC Manual - E chapter 1),
• Reseal the filler cap when replacing it and check that all openings
The oil change and the replacement of oil filter must be carried out are properly closed.
when the indication is seen on the electronic controller and when • The machine can be restarted only after pressing the button C
the corresponding time counter reaches "0" (refer to electronic several times to return to STATE 0.1. Check the clamping of
plate manual Chap 1 E ). connections.
• After restarting, check that there are no oil leaks.
Drain the compressor when warm. For this, shut it down taking
care to disconnect the power cable. Release pressure in the tank NOTE
by unscrewing the filler plug by a single turn. Open the purge valve
If the oil is in a bad state ; that is a pungent smell or contains
and drain the oil. Do not forget to close the valve after draining
particles or varnish or other solid matter, the system will have to
the oil.
be rinsed : pour about 50% or the normal contents of clean oil and
After maintenance, reset the time counter which tells you how operate the unit for 3 hours and carefully change the oil. During
long you have before the next oil change is due, refer to electronic rinsing, leave the old oil filter cartridge in the machine.
plate manual Chap 1 E.
B - Air filter
OIL LEVEL
(see B chapter 1)
When shut down, the MAXI level of oil is located at ¾ from the
bottom of the indicator, the MINI level corresponds to the lowest The air filter is of the dry, encapsulated type. Change the
visible parts of the indicator (rep. 1 Fig. 19). cartridge every 2,000 hours. Check the cleanliness of the filter
Fig. 19 every week and change it if necessary. (see notice on the
electronic plate for resetting the time).

ATTENTION :
If you do not replace the filtering element when needed, per-manent
dirt build-up will result. This reduces the air inflow to the
compressor and could damage the oil separator and the compressor.

C - Turbine
Replacement of the complete fan is recommended if one or more
blades are deformed or broken If replaced, check the fan rotation
1
direction reversal of the rotation direction will reduce machine
cooling and damage the motor in time.

D - Oil and air cooler

1 -Air-cooled
CHECKING THE OIL LEVEL MUST BE CARRIED OUT
The aluminium air and oil cooler is a vital system in the
JUST AFTER STOPPING THE MACHINE (THERMOS-
ROLLAIR®. It needs special care. In order to avoid deforming
TAT VALVE OPEN).
or destroying the tube bundles, radiator connectors and lines must
be dismantled or assembled while maintaining in rotation the
DRAINAGE UNDER PRESSURE
radiator sleeves using a wrench. The outer surface of the tube
So as to carry out a quick and full oil change, your ROLLAIR® bundle must always be clean to insure the best heat exchange. If
is equip-ped with a system that allows low level pressure to be leaks occur, seek their source by:
maintained in the oil circuit. This pressure is shown by the pres-
sure gauge situated in the tank. (see Notice AIRLOGIC - E - Stopping ROLLAIR®,
chapter 1). - Cleaning any greasy locations,
- Seeking leaks using conventional methods (e.g.: soap solution,
Proceed as follows : etc.).
• When hot, compressor in load for programming a shutdown under
pressure (refer notice AIRLOGIC § 4.9.3). The machine is emptied Pressurized shutdown retains the pressure in the machine circuit
and stops automatically. for a few moments so that any leak can be more easily located.
• Change the oil by opening the oil change valve very slowly.
• When there is no pressure left in the oil tank, change the oil filter
2 - Water cooled
cartridge.
• As soon as the oil is no longer flowing, close the valve and refill The required water quality is given as a general rule to avoid
with new oil. problems caused by the cooling water.
If in doubt, consult Worthington Creyssensac.

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Maximum content F - Draining condensation water
recommended - mg/l Closed system Open system
(see B chapter 1)
Chloride (Cl-) less than 100 less than 100
Sulphate (SO 4--) less than 400 less than 250 Condensation water prevents proper lubrication. The resulting
Total solids less than 3000 less than 750 substantial wear leads to a reduction in the lifespan of the
(like SiO2) less than 10 less than 10 ROLLAIR®. It is therefore essential to drain condensation water.
Free chlorine (Cl2) less than 4 less than 2 Draining of condensates in the oil circuit :
Ammonia (NH4+) less than 0,5 less than 0,5 Draining will only take place at least 12 hours after the
Copper less than 0,5 less than 0,5 ROLLAIR® has been shut down. It can be carried out for example
Iron less than 0,2 less than 0,2 on the morning of the start-up.
Manganese less than 0,1 less than 0,1 To do this :
Oxygen less than 3 less than 3 - Slowly open the oil change tap and let the water escape.
Hardness of carbonates - When the oil appears, close the valve immediately to avoid any
(like CaCO3) 50-1000 50-500 loss.
Organic compounds - Refill with oil if necessary.
(KMnO4 less than 25 less than 10
Consumption) G - Temperature safety tests
The cooling water tends to be acid and often needs special (see Notice AIRLOGIC - E chapter 1).
treatment. The pH level can vary between 7 and 9. For optimum IF THE SENSOR IS NOT WORKING, IT MUST BE
results, the water used must be analysed and treated in order to CHANGED.
meet the above specifications.
H - Refastening electric connections
E - Oil separator
(see B chapter 1) A loosening of the electric power cables leads to the contactors
The oil separator's lifespan depends on the cleanliness of the air ove-rheating which can lead to their destruction.
coming into the compressor, on regular oil filter changes, on the
qua-lity of the oil used, on the attention with which the oil tank Periodic refastening is therefore necessary at the star and triangle
condensate drains are carried out and on the ambient temperature line contactor arrivals and departures. (see Maintenance Table).
of the room. (see notice on the electronic plate for resetting the
time). All electric power supply to the machine must be cut off before
opening the electric cabinet.
Check the cleanliness of the pipe that returns the oil to be aspired
(transparent) to prevent the injector from becoming blocked and to
ensure that the oil recovered can pass through easily. I - Decommissioning the compressor at the
Excessive oil consumption end of its useful life
1. Stop the compressor and close the air outlet valve.
The presence of excess oil in the discharge air, a rapid drop in
level show a probable deterioration in the oil separator that must 2. Unplug the compressor from the electric supply.
be changed. 3. Decompress the compressor : unplug the 4/6 piping on the
oil separator cover.
The unit must first be checked to make sure that there is no oil
loss and that the oil return is working properly. 4. Close and decompress the section of the air network which
is linked to the exit valve. Disconnect from the compressed
Changing the oil separator air exit pipe from the air network.
Dismantle all the piping connected to the tank's upper flange (air 5. Empty the circuits of oil and condensates.
discharge, regulation system supply, and oil return). Undo the 6. Disconnect the compressor condensate piping from the
screws that hold the tank cover and remove it. condensate draining system.
- If the old oil separator musty be remounted, use new seals.
- Be very careful during installation of the oil separator so as to
avoid possible damage.
- The new oil separator is delivered with its two seals on either
side of the flange.
- Slight undulations in the flange will flatten out when the screws
are tightened.
- Apply a 6 mkg torque.

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Chapter 8 - Operating incidents
The staff in charge of maintenance of the ROLLAIR® compressor must become fully acquainted with this machine, in order to be able to
easily diagnose any anomaly. Under normal operating conditions, the ROLLAIR® compressor must provide full satisfaction.

A - Main incidents
The main incidents likely to occur are listed below, along with the remedies to be applied. The markers of the indicator lights relate to the
control panel.

Observed defects Possible causes Solutions

1. THE COMPRESSOR DOES NOT a) Main switch open. a) Close the switch.
START b) Phase missing. b) Check the circuits.
c) Fuse. c) Replace.
d) Insufficient voltage at motor terminals. d) Check the voltage and the connections.
e) Compressor under pressure. e) Check the vacuum device and change if
necessary. Check the water-tightness
of the minimum pressure valve.

2. THE COMPRESSOR a) Ambient temperature too high. a) Make openings or install ducts to
OVERHEATS evacuate the hot air (see Chapter 2).
b) Obstruction of the passage of cooling b) Clean the radiator (see Chapter 7).
through the oil radiator. c) Check and top-up oil level.
c) Oil level too low. d) Check that the oil filter is clean. Drain.
d) Oil circuit blocked. Replace the cartridge. Check the tightness
of connections.

3. THE COMPRESSOR STOPS WHEN a) Compressor motor overload. a) Check it is connected and the electric
THE MOTOR PROTECTION connections are tight. Check the pressure
UNIT TRIPS of the compressed air and the pressure
switch settings.
b) Phase unbalance b) Check the phase intensities

4. OPENING OF SAFETY VALVE a) To clean de-oiling cartridge. a) Change the de-oiling cartridge.
b) Valve of suction box out of use or b) Check valve, piston and joints of suction
not closed. box.
c) Faulty pressure switch, sensor c) Check that the pressure switch and
or solenoid valve. electrovalve and sensor pressure are in
d) Working pressure too high good working order.

5. EXCESSIVE OIL CONSUMPTION a) Blocked oil retainer. a) Check the oil return pipes.
b) Oil leaks in the ROLLAIR® compressor. b) Look for oil leaks and rectify.
c) Faulty oil separator element c) Replace the de-oiling cartridge.
(see Chapter 7-E)

6. DELIVERY PRESSURE TOO LOW a) Incorrect pressure settings. a) Adjust the pressure.
b) The desired output is higher than that b) Check consumption and possible leaks.
of the compressor.
c) Closed suction valve. c) Check electrovalve, pressure switch,
d) Release nozzle incorrectly adjusted valve.
(progressive adjustment option). d) Check setting.

7. COMPRESSED AIR OUTPUT a) Blocked air filter. a) Clean filter.

TOO LOW b) Adjusting electrovalve not working. b) Check setting.

8. EXCESSIVE NOISE OF UNIT a) Fixing bolts of compressor or motor a) Tighten.

have come loose.
b) Soundproof panels incorrectly closed. b) Check that they are closed.
c) Transport retainer blocks (red parts) c) Remove retainer blocks.
not removed.

9. THE COMPRESSOR STOPS a) Electromagnetic disturbance a) Add an interference suppression kit

UNTIMELY OR CREATES on the MCI01 controller. (contact the after sales department)
NON-EXISTING FAULTS

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NOTES

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NOTES

Worthington-Creyssensac 02/2008
62 305 512 00 Page 31
CAUTION
When the compressed air cools, part of the moisture sucked in by the compressor condenses. In order to protect
the dryer against the risk of an ice plug forming, it is essential to check regularly that the condensate drains are
operating properly :

On the compressed air storage receiver and on the filters :

• With a manual drain, drain regularly according to the moisture content of the ambient air.
• With an automatic drain, set the draining cycle accordingly and check that the drain is in good working condi-
tion.

This recommendation is also fundamental in a circuit comprising an absorption dryer (risk of saturation of the
alumina).

U.K. Operation Export Department

Great Britain France

Phone : (01709) 87 69 20 Phone : 33 (0) 3 44 52 67 31

Fax : (01709) 87 62 34 Fax : 33 (0) 3 44 52 67 35

Worthington Creyssensac Air Compressor Products Ltd Zone industrielle – BP 80419

Unit 4 Silverwood Court, Fairfield Park 4, rue Émile Zola
Manvers, Rotherham F-60114 Méru Cedex
South Yorkshire S63 SDB

Worthington – Creyssensac
Zone industrielle - BP 80419 - 4, rue Émile Zola - 60114 Méru Cedex
http://www.airwco.com

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