GB

use & maintenance

MANUAL

Rotar Giga
75-100 STC

Rotar Giga 75/100 STC - Cod.197BB0700 - Rev.00 - 04/2007

 GENERAL INFORMATION GB

GENERAL INFORMATION ............................................................................. 3

SAFETY INDICATIONS .................................................................................. 4
INSTALLATION .............................................................................................. 6
CONTROLS AND SETTINGS ........................................................................ 8
ALARMS ....................................................................................................... 10
START-UP PROCEDURE AND DISPLAY INFORMATION ........................... 11
OPERATION ................................................................................................ 12
MAINTENANCE ........................................................................................... 13
TROUBLE-SHOOTING ................................................................................ 16
TECHNICAL FEATURES ............................................................................. 17
WIRING DIAGRAM ...................................................................................... 18

STANDARD EQUIPMENT
Check outfit carefully. Later claims for missing parts will not be accepted.
The following accessories are supplied with the compressor:
no. 1 oil drain tube
no. 1 door key
no.1 user’s guide

CONDITION OF THE MACHINE WHEN SUPPLIED

Every compressor is shop tested and delivered ready to be installed and to be set at work.
The oil used is: RotEnergy Plus

Rotar Giga 75/100 STC - Cod.197BB0700 - Rev.00 - 04/2007 3

 SAFETY INDICATIONS
GENERAL
• Rotary compressors are intended for heavy continuous industrial use. They are especially suitable for industrial applications
requiring high air consumption for a long time.
• The compressor should be run and operated only in compliance with the indications given in this manual. Safely keep this
manual in a known and easily reachable place for the whole working life of the compressor.
• A supervisor shall be appointed in the company, in which the compressor is installed. He/she shall be responsible for
compressor inspections, adjustments and maintenance. Should a substitute be appointed for the supervisor, he/she shall carefully
read the user’s guide and all possible comment on service and maintenance carried out so far.

SYMBOLS USED IN THE MANUAL

Some symbols are used to highlight danger situations, give recommendations or information. These symbols are usually
positioned next to the text, a figure or at the top of a page (in this case they refer to all subjects dealt with in that page).
Carefully read symbol meaning below.
Read this page carefully before servicing the compressor.

CAUTION! All operations to be strictly carried out only after

Important description on service, dangerous powering off the machine.
situation, safety, accident prevention
recommendations and/or very important information.

STOP MACHINE! SPECIALIZED PERSONNEL!

All operations to be strictly carried out only after All operations to be strictly carried out only by
stopping the machine. specialized technician.

POWER OFF!

SYMBOLS ON THE COMPRESSOR

The compressor has several labels to highlight possible danger and give recommendations on what to do during machine
operation or in special situations.
Please comply with these indications.

Danger! Hot!
Prohibited! Do not open doors during compressor
operation

Danger! Electric shock!

Prohibited! Press emergency button for
compressor immediate stop. Do not use line knife
switch.
Danger! Hot gas or harmful gas
within working area
Prohibited! Do not use water on electric
equipment to extinguish fire.
Danger! Pressurized container

Compulsory! Read instructions for use carefully.

Danger! Mechanical moving parts

Caution! Maintenance works in progress

Danger! Machine can restar automatically

4 Rotar Giga 75/100 STC - Cod.197BB0700 - Rev.00 - 04/2007

 SAFETY INDICATIONS GB
WHAT TO DO:
Make sure that mains voltage corresponds to the voltage indicated on CE plate and that cable of suitable cross-section are
used for electric connections.
Always check oil level before starting the compressor.
Be familiar with emergency stop control and all other controls.
Empty the air tank and/or oil separator and unplug the connector before any maintenance work, so to avoid accidental start.
Ensure that all parts have been correctly reassembled after any maintenance work.
Keep children and animals off the working area to avoid injuries caused by devices connected to the compressor.
Carefully read instructions for the installed accessory, especially if painting devices are installed.
Ensure that the installation place is properly ventilated.
Ensure that temperature of the working environment ranges between +5 and + 45 ºC.
The compressor should be installed and operated in a non-explosive environment.
Allow at least 50 cm between the compressor and the wall so to allow free air flow to the fan.
Press the emergency button on the control panel only in case of actual need so as to avoid possible damages to people or the

Read this page carefully before servicing the compressor.

very compressor.
When calling for technical assistance and/or advice, always mention model and serial number indicated on CE plate.
Always follow the maintenance schedule specified in the user’s guide.

WHAT NOT TO DO:

Do not touch inner parts and pipes as they are very hot during compressor operation and stay hot for a certain time after
compressor stop.
Do not position inflammable or nylon objects or cloths close to and onto the compressor.
Do not move the compressor when the tank is under pressure.
Do not operate the compressor if the power cable is damaged or defective or if connection is unstable.
Do not operate the compressor in explosive environment or in case of naked flames.
Do not operate the compressor in wet or dusty environments.
Never aim the air jet at people or animals.
Do not allow unauthorized people to operate the compressor and give them all required instructions.
Do not hit fans with blunt objects as they might break during compressor operation.
Never operate the compressor without air filter.
Do not tamper with safety and adjusting devices.
Never operate the compressor when doors/panels are open or removed.

PRODUCT IDENTIFICATION
The compressor Your have purchased has its own CE plate showing the following data:
1) Manufacturer’s data
2) CE mark – year of manufacture
3) TYPE = name of the compressor
CODE = compressor code
SERIAL NO. = serial number of the compressor You have purchased (to be always mentioned when calling for technical
assistance)
4) air delivered by the compressor expressed in (l/min) and (cfm)
5) max. operating pressure (bar and PSI) – compressor noise level in dB(A)
6) electric data: voltage (V/ph), frequency (Hz), absorption (A) - power (HP and kW), rotations per minute (Rpm).
7) other approvals

Rotar Giga 75/100 STC - Cod.197BB0700 - Rev.00 - 04/2007 5

 INSTALLATION
COMPRESSOR DESCRIPTION (fig.1)
7
The compressor essentially consists of:
6
1) Condensate trap / condensate drain (Autodrain)
2) Screw/motor support plate 12
3) Motor
4) Suction regulator
5) Air intake filter 5 8
6) Air-oil radiator
7) Electric box /control panel 4
8) Min. pressure valve
9) Oil separator tank/oil separator filter 9
10) Oil filter
11) Screw compressor 1
12) Electrical cabinet
10

2
11

3 1

UNPACKING AND HANDLING

The compressor is usually shipped to a Customer into a special packing so to protect the compressor against transport damages.
As the compressor is very heavy (see “technical features” table), it must be lifted only by means of suitable capacity driven by
specialized personnel.
Compressor base has slots, whereas compressor top has four anchoring points for eyebolts in case the compressor needs to
be lifted from the top by crane or hoist.
Do not stand within fork lift truck working area and keep safety distance.
Perform the following after moving the compressor to the installation place:
• Unpack the compressor. Wear protective gloves and use suitable tools (follow instructions on the crate)
• Check the (outer) good condition of the machine.
• Open the access doors and check all inner parts (visual check)
• Dispose of the packaging in compliance with the current waste disposal regulations.

PLACEMENT (fig.2)
The room chosen for the installation of the compressor should
meet the following requirements and comply with current safety and 600 cm (min)
accident prevention regulations:
A) low percentage of dust suspended in air,
B) Proper room ventilation and size that allow room temperatu-
re (5°C ÷ 50°C) to be maintained - with the machine running.
Min. air intake opening: 2 sq. m
350 cm (min)

C) In the event of inadequate hot air discharge, fit three or more

exhaust fans as high as possible.
Exhaust fan “4,000 cu. m/h” part no. 020042000
• The condensate is a polluting mixture and should not be
disposed of into the sewage system or wasted in the environment.
The sump should be equipped either with a valve and a removable 150 cm (min)
container or connected to a suitable piece of equipment (oil-water
separator, part no. 048203000). h min = 350 cm
Dimensions shown in fig. 2 are indicative. It is recommended to
comply with given indications.

INSTALLATION 2
• Position the machine at the final place of installation. Make
sure it is stable and leave at least 90 cm between the machine
and the wall so as not to obstruct proper air flow to the fan.
Position the air tank. Connect the compressor and tank using the
supplied delivery hose.
Do not fit check valves between compressor and tank.

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 INSTALLATION GB
HOT AIR PIPING
• Hot air comes out from the upper side of the compressor at a temperature 15 ÷ 35°C higher than the room temperature.
• If the room ventilation is not enough (door/window opening: under 2 sq. m), a pipe having the same cross-section as the
radiator pipe is absolutely necessary. This pipe should be equipped with a valve conveying the hot air outside in summertime and
inside in wintertime, thus using the compressor heat energy as auxiliary heating unit.
These pipes should not be longer than 4 m. Otherwise, an auxiliary fan should be installed on the outlet side.

POWER CONNECTION
• Proceed to power connection with cross-section cables suitable for machine power: no. 3 phase cables and no.1 ground
cable.
• Have a switch provided with plug fuses installed between supply line and control panel, close to machine cable connections.
This switch should be installed at at least 1.7 m from the ground.
• Switch should be within operator’s reach. Cables shall be homologated and with a min. protection degree equal to IP54.
Note: To choose cables cross-section, refer to the “technical features” table.

Rotar Giga 75/100 STC - Cod.197BB0700 - Rev.00 - 04/2007 7

 CONTROLS AND SETTINGS

1 2 3 4 5 3

CONTROL PANEL
The main functions of the compressor are controlled by means of an electronic control unit installed in the control panel.
1. Buttons for menu scrolling / modifying values
2. OK button – for confirming settings
Reset button – for silencing alarms
3. Alarm LED
4. I/ON Button – switch-on
5. 0/ OFF Button – switch-off.
6. Display
To adjust the contrast, press together (with machine in OFF status).
The contrast can be adjusted from 1 (darker) to 20 (lighter). Press OK to save the value.
7. Emergency button – to be used for stopping the compressor immediately only in the event of a real emergency.

TYPE OF SERVICE
Automatic operation
• In inverter-controlled operation, the compressor runs continuously based on a preset fixed pressure (factory setting)
and automatically regulates motor rotation frequency to constantly meet the demand for compressed air. In other words, the
compressor operates in such way to match air supply to actual plant requirement.
When there is no air demand, the compressor runs at the set minimum frequency.
Upon reaching “unloaded” pressure – which is calculated by the formula operating pressure + (start enable delta pressure/2)
- the stop procedure begins, while message (STAND-BY) is displayed.
The compressor is started again at a pressure calculated by the formula: operating pressure - (start enable delta pressure/2).

MODIFIABLE PARAMETERS
Pressing the OK button with the machine OFF takes you to the menu of operating parameters. In certain cases a
password is required in order to access the modifications. Use the buttons to scroll the menu.

0) Control unit ID (service password): selects the identification number of the control unit; if several compressors are connected
to the same RS485 line, multiple IDs can be selected.
1) Maintenance – Pre-alarm hours (service password) : each working hour of the machine is counted down automatically;
when the counter reaches 0, the control unit trips a Maintenance Alarm.
Use the XX buttons to scroll the items of the menu:
1. General maintenance: hours remaining
2. Air filter change: hours remaining
3. Oil filter change: hours remaining
4. Oil change: hours remaining
5. Bearing lubrication: hours remaining
6. Idle hours: displays the hours of idle running
7. Total working hours: displays the total working hours
The count preceded by the (-) sign indicates the number of hours that have elapsed since the last maintenance alarm.
The buttons can be used to set a new value (in this way overriding the previous alarm).
2) Alarm history (no password required): with this menu you can view the last 100 alarms.
3) Pre-alarm temperature (factory password): on this menu you can set the temperature differential (“delta”, expressed in °C)
with respect to the maximum alarm temperature; the value can be set between 1 and 20.
Example: If the maximum temperature is 120°C and the dif ferential value is 10°C, the maximum temperature pre-alarm is
tripped at 110°C.
8 Rotar Giga 75/100 STC - Cod.197BB0700 - Rev.00 - 04/2007
 CONTROLS AND SETTINGS GB
4) Maximum temperature (factory password): with this menu you can set the maximum temperature allowed; the setting range
is from 0 to 150°C.
5) Minimum temperature (factory password): with this menu you can set the minimum temperature; the setting range is from
0 to -14°C.
6) Fan temperature (service password): with this menu you can adjust the temperature for activating the cooling fan; the
setting range is from 0 to 150°C. At the preset temperature the fan starts; hysteresis is fixed at 10°C.
7) Duration of the idle running cycle (service password): with this menu you can change the duration of the machine idle
cycle; the setting range is from 0 to 250 seconds.
8) Automatic start (service password): this parameter enables the automatic start; if it is activated, the compressor will restart
automatically following an interruption of the electrical power supply.
9) Internal phase sequence (service password): this parameter enables the internal phase sequence control, or disenables
the internal control by activating the input without phases on the terminal block.
10) Language (no password required): this parameter allows you to change the language in which messages are displayed.
11) RS485 enable (no password required): this parameter is used to enable data transmission via RS485 and automatically
disenable transmission on RS232.
12) Set time and date (no password required): used for setting the current time and date.
13) PSI/BAR (no password required): for selecting the unit of measurement used to display the pressure.
14 Operating pressure set point (no password required): this parameter is used to set the pressure at which the compressor
must shut down.
15) Operating differential set point (no password required): indicates the pressure at which the control unit enables compressor
restart.
16) Maximum pressure (service password): this parameter sets the maximum pressure value that can be reached, i.e. the
maximum value set in point 14.
17) Maximum pressure alarm (factory password): this parameter sets the maximum pressure value at which the control unit
trips an alarm and blocks compressor operation.
18) Remote pressure (service password): when this parameter is enabled, the pressure and the related alarms continue to
be displayed, but the compressor start is controlled by means of an external pressure switch contact.
19) Start programme (service password): this menu allows you to programme the starts and stops of the compressor. Use
to select one of the five programmes available and press OK to enter the desired data (start time, stop time, and day of
the week).
To disactivate the programming, go to the menu and enter the same time of start and stop.
20) X1 progr. NC-NO (service password): allows you to invert the logic of the inputs of terminal block X1.
21) X7 progr. NC-NO (service password): allows you to invert the logic of the inputs of terminal block X7.
22) Motor therm. separate (service password): with the parameter ON, the thermal relays of the compressor and fan motors
are separated on two different inputs.
23) Temp. unit of measurement (no password required): for selecting the unit of measurement of the temperature (°C-°F).
24) Maximum starts per hour (service password): for selecting the maximum number of restarts per hour allowed. If this
value is exceeded, a signal is given.
25) Inverter (service password): inverter enable.
26) Minimum operation % (service password): minimum operation rate at which inverter must operate (max. rate is 100%).
27) Load delay (service password): this parameter is a time delay in seconds before load solenoid valve is energized to bring
compressor from minimum to maximum frequency.
28) Inverter integration (service password): this parameter modifies the time constant of the integrative component of
inverter rate calculation.
29) Inverter parameters (service password): allowed to only visualize inverter parameters.

Parameter min. max. Def. Parameter min. max. Def.

0 ID 000 009 000 13 PSI/BAR Bar BAR
1 General maintenance: hours 0 50000 4000 14 Idle Bar 0 P.Max. 10
Air filter change: hours 0 50000 2000 15 Load Bar 0 2 0,5
Oil filter change: hours 0 50000 4000 16 Maximum pressure Bar 0 P.all. - 0,5 11
Oil change: hours 0 50000 8000 17 Maximum pressure alarm Bar 0 16 14
Bearing lubrication: hours 0 50000 4000 18 Remote pressure Bar NO
Idle hours: hours 0 50000 0 19 Start programme OFF
Total working hours: hours 0 50000 0 20 X01 progr. NC-NO 01010110
3 Pre-alarm temperature °C 0 20 5 21 X07 progr. NC-NO 111 111
4 Maximum temperature °C 0 110 110 22 Motor therm. separa te NO
5 Minimum temperature °C -14 0 -7 23 Temp. unit °C
6 Fan temperature °C 0 150 65 24 Starts per hour n° 1 200 12
7 Idle running cycle sec. 0 250 180 25 Inverter YES
8 Automatic start NO 26 Minimum operation % % 0 100 50
9 Internal phase sequence NO 27 Load delay sec. 0 250 10
10 Language ITA 28 Inverter integration 001 250 001
11 RS485 enable YES 29 Inverter parameters
12 Time and date

Rotar Giga 75/100 STC - Cod.197BB0700 - Rev.00 - 04/2007 9

 ALARMS
ALARM MESSAGES
When a fault occurs or the safety limits set are exceeded, the red alarm light comes on and the alarm in progress is shown on
the display.
In the case of multiple alarms, use to scroll through the items.
To silence an alarm, press the RESET button.
To delete all the non-active alarms, press RESET and hold it down for at least 2 seconds.

• rot.dir.error
Alarm tripped in the event of an incorrect phase sequence. The alarm blocks compressor operation; to restart operation, the
correct phase sequence must be re-established.
N.B.: To completely reset the alarm you have to switch off the electrical power supply.
• air.temp.sens. fault
Alarm tripped in the event of a temperature sensor fault (sensor open or short circuit). The alarm blocks compressor operation;
to restore operation, check the connection and/or replace the sensor, then press the RESET button XX.
• screw.temp.sens. fault
Alarm tripped in the event of a temperature sensor fault (sensor open or short circuit). The alarm blocks compressor operation;
to restore operation, check the connection and/or replace the sensor, then press the RESET button XX.
• max.oil.temp.
Alarm tripped when the maximum oil temperature is reached. The alarm blocks compressor operation; to restore operation,
wait for the temperature to fall below the programmed value, then press the RESET button XX.
• min.oil.temp.
Alarm tripped when the minimum oil temperature is reached. The alarm blocks compressor operation; to restore operation, wait
for the temperature to rises above the programmed value, then press the RESET button XX.
• oil.temp.pre-alarm
Alarm tripped when the pre-alarm oil temperature is reached. The alarm does not block compressor operation. To silence the
alarm, press the RESET button XX.
• Motor thermal overload
Alarm tripped when the motor PTC thermal relay + fan motor thermal relay is tripped. The alarm blocks compressor operation.
To silence the alarm, first verify the cause and then press the RESET button XX.
• Emergency button
Alarm tripped when the emergency button is pressed, which blocks compressor operation. To silence the alarm, first reset the
emergency button, then press the RESET button XX.
• Maintenance
This alarm signals the user that the machine is due for routine maintenance (oil change, filters, etc.).
The alarm must be silenced by the service technician who performs the maintenance, as described in the section “Modifiable
Parameters”.
• max.press.alarm
Alarm tripped when the maximum pressure set is exceeded. The alarm blocks compressor operation.
To silence the alarm, first restore the correct pressure, then press the RESET button XX.
• press.sens.fault
Alarm tripped when the pressure sensor connected to the 4-20mA input is not working correctly. The alarm blocks compressor
operation.
To silence the alarm, first restore the normal status of the pressure sensor, then press the RESET button XX.
• comm.error
Alarm tripped when communication between the control unit and the display is interrupted. The alarm blocks compressor
operation.
Check the connections and press RESET XX.
• screw.motor.therm. (only if parameter 22 is activated)
Alarm tripped in the event that the screw motor thermal relay is tripped. The alarm blocks compressor operation.
To silence the alarm, first verify the cause, then press the RESET button XX.
• fan.motor.therm. (only if parameter 22 is activated)
Alarm tripped in the event that the fan motor thermal relay is tripped. The alarm blocks compressor operation.
To silence the alarm, first verify the cause, then press the RESET button XX.
• Max.starts.hour
Indicates that the number of starts per hour is greater than the value set. The alarm does not block compressor operation.
If this alarm is tripped frequently, check and if necessary increase the idle running time.
• Inverter error
The alarm blocks compressor operation. Press the key RESET to silence the alarm. If problem persists, contact a service
center without delay.

10 Rotar Giga 75/100 STC - Cod.197BB0700 - Rev.00 - 04/2007

 START-UP PROCEDURE AND DISPLAY INFORMATION GB
FIRST START-UP
Before starting the machine for the first time, make sure that:
• the power supply voltage corresponds to the voltage indicated on the CE plate
• the electrical connections have been made using adequately sized cables
• the master switch (on the wall) has suitable fuses
• the oil level is higher than the minimum (where necessary, fill using oil of the same type)
• the air outlet cock is completely open.
The first start-up of the compressor must only be carried out by a specialised technician.

Press the button:

If the machine does not start and the message “rot.dir.error” appears on the display:
switch off the electrical power using the wall switch, open the electrical cabinet door and invert the position of two phases in the
terminal block, close the door, restore voltage and restart the machine.

If the machine starts on the first try:

Easy Tronic III
software
display status at start-up (remains for 5 seconds) V.0.0.0 dd/mm/yy date
release
Easy Tronic III

--screw.temp:065°C
06.5Bar 000% 000%
display status during normal operation STATUS=OFF
time..... date.....
Line 1
Default display “——screw.temp.” = temperature of the screw.
Using you can view the following information:
Inside temp. indicates the temperature inside the electrical compartment
——air.temp. indicates the temperature of the air at outlet
——total hours indicates the total working hours
—load hours indicates the working hours with load
—idle hours indicates the idle running hours
maint.hours indicates the hours remaining until maintenance is required
air filter h. indicates the hours remaining until air filter replacement is required
bearing.lubric. indicates the hours remaining until lubrication of the bearings is required
oil filter h. indicates the hours remaining until oil filter replacement is required
starts/hour indicates the number of starts recorded in the last hour
After 25 seconds without any buttons being pressed, the default display returns.
Line 2
Indicates the pressure inside the screw compressor.
Indicates the inverter pilotage value.
Indicates the inverter operation rate.
Line 3
Compressor status:
IDLE idle running
LOAD the compressor is loading
STAND-BY waiting for start command
REMOTE-OFF waiting for remote start command
OFF the compressor is powered but not operating
Line 4
DATE AND TIME if a start-up has been programmed, a blinking clock appears in the lower right-hand corner.

START/STOP CYCLE
• Pressing the button
Stand-by: a (STAND-BY) message is displayed. If the compressor had been switched off, it will take 15 seconds before cycle
starts; otherwise the compressor remains in the stand-by mode until the pressure switch signals a demand for compressed air.
Starting: the compressor “ramps up” to 50% of set maximum frequency and the message (UNLOADED) is displayed
Full-load starting: when the set “load delay” time times out, the compressor reaches maximum frequency and the message
(LOADED) is displayed.
• Pressing the button
The load solenoid valve is disabled, the unload cycle is started and a flashing (UNLOADED) message is displayed (during
this time, the compressor operates at the set minimum frequency). When the unload cycle is over, the compressor shuts down
and the message “OFF” is displayed.

Rotar Giga 75/100 STC - Cod.197BB0700 - Rev.00 - 04/2007 11

 OPERATION
TECHNICAL DIAGRAM
A
Motor Air discharge
S(NG)
B 7
DS
Compressor Signal 4
C
C 2
Suction regulator Air+oil MAX
D 1 2
Oil separator tank HDKG 7
4
VO VO 5
6 MPVL PR MAX
Fast exhaust valve
S(NG)
5
Solenoid valve N.C A B 2
6 1 PR MIN
DS
Pressure transducer
MAX 5
Selector valve
PR MIN
Min. pressure switch
PR MAX D
Max. pressure switch
MPVL 5
Min. pressure valve

OPERATING MODE
• At the end of the starting cycle, the compressor
reaches maximum operating speed and starts to compress
air in the tank (5).
olio / oil
• When close to reaching desired operating pressure,
aria+olio / air+oil
the compressor begins to vary motor rotation frequency aria / air
(max.100%, min. 50%) so as to keep air delivery steady 9
depending on operating pressure.
• Compressed air cannot escape through the min.
pressure valve (7), which is set at 3÷4 bar.
• Compressed air compresses oil inside tank (5) and
causes it to flow through tube (8) to the radiator (9). 10
Cooled oil is returned to filter (11) through tube (10). 1 13 7
• From filter (11), oil reaches compressor (3) through 8
tube (12). Oil is mixed with sucked air to form an air/oil
mixture that provides sealing and lubrication of compressor 2
6
moving parts.
• The air/oil mixture goes back to tank (5), where air 3
and oil are first separated by centrifugation and then by the 4
oil separator filter (6). 12
• As a result, tank (5) will deliver air only to air radiator
(9) through tube (13). Air is then conveyed to mains through 11
a cut-off cock. 5
• Min. pressure valve (7) serves also as a check val-
ve. 6
• Compressor delivers compressed air to outer air tank.
• Tank inner pressure increases until reaching max.
calibration value.
• Once max. value is reached, pressure gauge starts timer and powers off solenoid valve of regulator (2).
• Regulator (2) closes and compressor stops compressing and starts idling.
• Timer continues counting until reaching set value and, if pressure is unchanged, stops the electric motor. If pressure drops
to minimum value set on controller, solenoid valve is powered and opens before timer counting is over.
• Regulator (2) opens and compressor operates under normal load; timer is reset.
• This cycle is automatically repeated.

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 MAINTENANCE GB
CAUTION! Before carrying out any maintenance operation:
• Activate automatic motor stop.
• Turn off the external wall-mounted switch (do not use the emergency button).
• Close line cock.
• Make sure that no air is present inside the oil separator tank.

Legend to to figure 7
A) front door (electric box) B
A
B) r.h. side door (air filter and prefilter)
C
C) r.h. side panel (condensate trap)
D) rear panel (roller chamber)
E) l.h. side door (motor)
F) l.h. side door (oil separator)

AFTER THE FIRST 100 OPERATING HOURS D

• Check oil level and top-up with same oil, if needed
• Check screw tightening: pay special attention to power electric contact screws.
• Visually check sealing of all connectors.
• Check drive belt tension and tension up, if needed
• Check operating hours and type of duty cycle chosen
• Check room temperature. F
• Change oil filter. E
7
EVERY 300 OPERATING HOURS
Carefully clean AIR FILTER AND PREFILTER (fig. 8)
• Open door B with supplied key.
• Manually undo the knob (1) and remove filter cover. 2
• Manually undo the knob (2) and remove filtering element. 1
• Clean filtering element with compressed air from the inside to the
outside. Check against the light for possible cuts: replace element, if any.
CHANGE THE AIR FILTER ELEMENT EVERY 3000 HOURS.
• Undo retaining screws (3) from support panel (4) and remove prefilter.
• Wash with water and soapy solution. Fully dry before refitting the 3
prefilter and then restart the compressor.

EVERY 500 OPERATING HOURS 4

Check oil level (fig.9)
• Open door F with supplied key.
• Bleed air off the tank through the cock (1).
• Check oil level through dipstick. If under or close to min. level, top up
with same oil - RotEnergy Plus. 8
NEVER MIX DIFFERENT TYPES OF OIL TOGETHER

EVERY 4000 HOURS

GREASE THE ELECTRIC MOTOR BEARINGS USING SUITABLE GREASERS. 1
Follow the instructions on the electric motor manual. Required grease quantity:
20g. Use soapy lithium grease.

EVERY 8000 HOURS

Change OIL (fig.9)
• Open door F with supplied key.
• Bleed air off the tank through cock (1).
• Connect drain tube (3) to cock (2).
• Unscrew filler plug, open ball cock (2) and collect oil in a container, waiting for MAX.
complete drainage.
• Once this operation is over, close cock (2) and remove hose (3) (Amount needed MIN.
for filling up the tank: 37 lt.)
• Start the machine and let it run for 5 minutes.
• Allow some minutes and then bleed off all air. Check oil level and top up, if
necessary.

The oil used is: RotEnergy Plus

2
NEVER MIX DIFFERENT TYPES OF OIL TOGETHER, OTHERWISE
COMPRESSOR MIGHT DAMAGE. Refer to the table for oil selection. 9 3

Rotar Giga 75/100 STC - Cod.197BB0700 - Rev.00 - 04/2007 13

 MAINTENANCE
AFTER THE FIRST 2,000 OPERATING HOURS AND THEN
EVERY 4,000 OPERATNG HOURS
Change OIL FILTER (fig.10)
• Change the filter at any oil change with the oil separator tank not under
pressure. Always bleed all air off the cock (1) (see fig. 11).
• Open door (E) (see fig.7). The oil filter is inside the middle stand, as shown
in the figure.
• Undo the filter with the proper tool. Replace with a new filter. Always apply a
film of oil on filter edge and gasket before tightening.

Change OIL SEPARATOR FILTER (fig.11)

• Open door (F) (see fig.7) and bleed all air off the tank through cock (1).
• Disconnect tubes G, H, I and L.
• Fully undo fitting (2) and remove copper drain tube.
• Undo and remove screws (3).
• Turn screw (4) anti-clockwise with a hex. wrench, until lifting oil separator
cover by about 0.5 cm.
10
• Manually turn the cover to reach tank inside.
• Remove oil separator filter (using a proper tool) and replace with a new
filter. Also replace the two seal rings and make sure they are properly seated. 11
EVERY 10000 HOURS
DRIVE BELT tension (fig.12)
To perform this check you need a special measurement instrument that that
provides a precise indication of the level of tension of the belt by means of a
frequency measurement.
Proceed as follows:
• Open the door (D) (see fig.7).
• Bring the microphone of the measurement instrument up to the belt at the
point indicated with “test” (about halfway) and strike the belt with a spanner. I H
• Read the value detected by the instrument and if it is different from the G
values indicated on the table, adjust the tension: L
1
Higher value = belt too tight 2
Lower value = belt too loose 3

• Loosen screws A to allow the attachment plate on which the screw unit is
fixed to slide, and use adjusting nut B to adjust the tension.
Turn the nut anti-clockwise to increase tension and clockwise to reduce tension.
Re-tighten screws A and check the frequency value; if necessary, repeat the 4
operation until the desired value has been reached.

EVERY 20000 HOURS

Replace the DRIVE BELT (fig.12)
Proceed as follows:
• Open the door (D) (see fig.7) and remove the
protective panel of the belt/pulley compartment.
• Loosen screws A to allow the attachment plate
on which the screw unit is fixed to slide. B
• Loosen nut B until the belt is completely
relaxed and remove it. A
• Fit the new belt and tighten it as described in
the previous section.
Test

Also replace
• Compressor seal ring
• Tank safety valve

Rotar 75 Rotar 100

P max. 8 bar 56 Hz 63 Hz
P max. 10 bar 55 Hz 62 Hz 12

14 Rotar Giga 75/100 STC - Cod.197BB0700 - Rev.00 - 04/2007

 MAINTENANCE GB
EVERY 15,000 OPERATING HOURS
MIN. PRESSURE valve (fig.13) 3 13
Open door (F) (see fig.7) and bleed all air off the tank through the cock (1).
Replace gaskets (2) and (3)

2
1

SERVICE TABLE - WARNING

Oil is an essential factor. When using an oil type which is different from the recommended one - RotEnergy Plus - some service
intervals must be changed. Please refer to table.

In any case, a different oil MUST be used ONLY when oil is fully changed. NEVER MIX DIFFERENT TYPES OF OIL TOGETHER.
Never top up with a different type of oil.

EXHAUSTED OIL IS HIGHLY POLLUTANT! Dispose of exhausted oil in compliance with current laws.

Different compatible oil

Used oil RotEnergy Plus
(see table)
Service description Operating hours Operating hours
Check and top up oil level 300 300
Clean intake filter and prefilter 500 500
Grease the electric motor bearings 4000 4000
Replace intake filter element 2000 2000
Replace oil filter 4000 4000
Replace oil separator filter 4000 4000
Change oil 8000 4000
Check driving belt tension 10000 10000
Check min. pressure valve 15000 15000
Replace driving belt 20000 20000
Replace compressor seal ring 20000 20000
Replace tank safety valve 20000 20000
Compatible oils: SHEEL Corena D46 - BP Energol HLP 46 - MOBIL D.T.E.
MEDIUM - AGIP Dicrea 46 - CASTROL Aircol MR46 - ESSO Univis 46 -
IP Veretum Oil 46 - FINA Eolan R046

Rotar Giga 75/100 STC - Cod.197BB0700 - Rev.00 - 04/2007 15

 TROUBLE-SHOOTING
When a fault occurs or the safety limits set are exceeded, the red alarm light comes on and the alarm in progress is shown on
the display.
In the case of multiple alarms, use to scroll through the items.
To silence an alarm, press the RESET button.

Fault/Alarm message Cause Solution

rot.dir.error Power supply phases inverted Open the electrical cabinet and invert the
phases.
air.temp.sensor fault Fault of the temperature sensor Replace the air temperature sensor
screw.temp.sensor fault Fault of the temperature sensor Replace the screw temperature sensor
max.oil.temp. Radiator clogged Clean the radiator
Low oil level Fill the oil
Oil mist separator filter clogged Replace the filter
min.oil.temp. Low room temperature Heat the room. Wait
Motor thermal overload Low line voltage Check the voltage.
Motor temperature overload Check the operation of the cooling fan; if
necessary activate it in “manual” or with
the switch inside the electrical
compartment.
High room temperature Increase the ventilation in the room. Wait
max.press.alarm The intake regulator did not close at Check that current to the solenoid valve is
the end of the cycle. switched off and that the shutter opens
normally. If necessary, remove and clean
the intake regulator.
Oil mist separator filter clogged. Replace the oil mist separator filter.
Line cock closed. Open the cock.
Minimum pressure valve blocked. Check and clean the valve, if necessary
replace the gaskets.
press.sensor fault The pressure sensor is faulty. Replace the pressure sensor.
High oil consumption Defective draining Check the drain hose.
Oil level too high Check the oil level and if necessary
remove some.
Oil mist separator filter faulty Replace the oil mist separator filter.
Poor seal of the oil mist separator Replace the gaskets.
filter gaskets
Oil leakage from the intake The intake regulator does not close Check the intake regulator and the
filter solenoid valve.
The compressor performs Belt loose Tighten the belt.
poorly
The compressor does not The intake regulator is closed and Remove the filter and check the opening; if
compress air does not open because it is soiled. necessary disassemble and clean it.
The intake regulator is closed and Check the operation of the solenoid valve;
does not open due to lack of replace if necessary.
control.
The compressor does not The minimum pressure valve does Disassemble the valve and clean it; if
restart not close perfectly. necessary replace the gaskets.
Difficult start-up Low line voltage Check the mains voltage.
Cold room Heat the room.
Oil in the cabin Leakage from hoses Tighten the unions.

16 Rotar Giga 75/100 STC - Cod.197BB0700 - Rev.00 - 04/2007

 TECHNICAL FEATURES GB
Power Hp 75 100
Pressure bar 7,5 10 7,5 10
Compressor type ENDURO 25 ENDURO 25
Rotation speed of male rotor rpm 3888 3445 4960 4440
Delivered air l/min 9300 8300 12200 10500
Oil quantity l 37 37
Topping-up oil quantity l 10 10
Max. final air overtemperature °C 11 11
Removed heat kJ/h 188.000 256.500
Fan capacity m³/h 5700 8800
Oil residues in the air mg/m³ 4 4
Motor type W-DF25SN-H 1LA6280-2AC66-Z
Rated power kW 55 75
Max. power absorbed by network kW 55 75
Protection degree of electric box IP 54 54
Insulation class F F
Max. starts per hour no. 10 10
Ambient temperature °C 50 50
Noise level (1 m) dB(A) 70 72
Max. compression temperature °C 110 110
Safety valve setting bar 11 11
Separator pressure switch setting bar 8,9 10,9 8,9 10,9
Start-up pressure switch setting bar 1,5 1,5
Motor protection type PTC PTC
Weight kg 1870 1940
Air outlet bsp 2" 2"
Input voltage V/Hz 400 / 50 400 / 50
Auxiliary voltage V/Hz 230 / 50 230 / 50
Current absorption under load conditions A 98 100,8 131,3 133
Current absorption at start-up A 218 296
Cable cross section mm² 50 70
Thermal relay setting (radiator ventilator) A 2,5 2,7
Switch A 160 200

Rotar Giga 75/100 STC - Cod.197BB0700 - Rev.00 - 04/2007 17

 WIRING DIAGRAM
KEB
KEB mors.20-16/14(15)
mors.X2A X2A
26 A; KM2(B)-SA2
9
PL2 PL1 6 7
5 A/TO: KM1(B)-KM1-SA1
26
11
10
BP
QM2 + - 8
6
2
25 14
0 13
12
24 28 25

2 1 3 2 1 8 7 6 5 4 3 2 1 6 5 4 3 2 1 12 11 10 9 8 7 6 5 4 3 2 1
X03 X10 X07 X02 X08

PLUG 8
PLUG 6
Rs232
X01 X09 Rs485 X05
1 2 3 4 5 6 7 8 9 1 2 3 4 1 2 1 2

A:TC2 CanBus Progr. Com.

Display

- KEB
2
4-20 mA +
1 mors.X2A

M
L1 L11
FU1
L3
FU2 L31
1 A/TO: SB+NC
FU3 2
L1
FU4 L12
L2
FU5 L22

FU6 4
1 A/TO: AUTO.DRAIN
FU7 25
15 17 21
3
A/TO: YV+AUTO.DRAIN+HL
3
A/TO: SA1-SA2-KM1 8 8 A/TO: SB+NC

10 10 A/TO: YV

11 A/TO: HL
11

12 12
16
13 13
17
14 14
ST1
18 14
ST2
15
SB
15 +

15
NC
15
P
V

16
17
SP1
17 Predisposizione
21
SP2 15 collegamento
V

P
V

RT controllo pressione
20 15 remoto
21
SP3 P
V

21
22 Remote pressure
22 control connection.

Power 75 100
FU9 Three-phase fuses holder base NH00-160A NH1-200A
FU1-FU2-FU6 Ceramic fuses 6,3x32 4A 500V
FU4-FU5 Ceramic fuses 6,3x32 1A 500V
FU3-FU8 Ceramic fuses 6,3x32 1,6A 500V
FU7 Ceramic fuses 6,3x32 500 mA 500V
L KEB Inductance three-phase relay 0,2 mH 150A 0,16 mH 180A
Z KEB Three-phase filter 400V
GF KEB inverter 55 kW 75 kW
KM1 Compressor motor-inverter line contactor 92kW (**) 181 kW (**)
KM2 Radiator fan-motor contactor 4 kW (*) 4 kW (*)
QM1 Inlet fan-motor protection switch (0.22-0.32)(0.28-0.4) (0.22-0.32)(0.28-0.4)
18 Rotar Giga 75/100 STC - Cod.197BB0700 - Rev.00 - 04/2007
 WIRING DIAGRAM GB
FU4 L12 TC2 4 FU6
L1 24

A = Inom x 1,5
FU5
L2 L22 0
0 24
L1 L2 L3 PE A/TO : X03 (D)

FU1 L11 TC1 1 FU3 2

L1

FU2 L31 3
L3
SB
+ 8
NC 8
FU9
QM2 1 7 11 9
L13 FU8
L23
L33
XB D D D D
TC3 0
X08 KM1 SA1 X08 X0? X08
KM1 KM2 2 8 12 10
L14 06
5
L24 8
L34 FU7
6
U1 V1 W1
A X10 (2)
L QM1
SA2
11
U2 V2 W2
5 10 9
L1 L2 L3
Z

KM1 YV KM2 HL
L1 L2 L3

GF
25

A/TO: Autodrain
U V W

V4 V3
V1
U1 U2 W1 U4 W4 U3 W3
W2 V2
MC
3 MVA MVR
RT
3 3

QM2 Radiator fan-motor protection switch (2.2-3.2) (2.2-3.2)

RT Compressor motor thermistors
TC1 Transformer Pr.230/400V Sec.230V 220 VA 220 VA
TC2 Transformer Pr.230/400V Sec.24V 63 VA 63 VA
TC3 Transformer Pr.400V Sec.0-6V
SA1 Inverter setting selector
SB Emergency button
SP1 Air filter pressure switch
SP2 Oil separator filter pressure switch
SP3 Min. pressure - pressure switch
SA2 Radiator Fan Emergency command
BP Line pressure transducer
ST1 Screw delivery temperature probe
ST2 Outlet air temperature probe
D Electronic controller
YV Solenoid valve
M Terminal board
MC Compressor motor 55 kW 75 kW
MVR Radiator fan motor 0.8/1.1 kW 6p 1.1/0.95 kW 4p
MVA Inlet fan motor 148/205 W 148/205 W
Compressor motor cable cross-section (sq. mm) 3x50+1x25GV 3x70+1x35GV
Radiator motor cable cross-section (sq. mm) 4G1.5 4G1.5
Note: (*) = 400V AC3 - (**) = 400V AC1

Rotar Giga 75/100 STC - Cod.197BB0700 - Rev.00 - 04/2007 19