GB

use & maintenance

MANUAL

Rotar
MEGA 50-60

Rotar Mega 50-60 - Cod.197AA3800 - Rev.03 - 05/2008

 GENERAL INFORMATION GB

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

SAFETY INDICATIONS ....................................................................... 4
INSTALLATION ................................................................................... 6
CONTROLS AND SETTINGS ............................................................. 7
ALARMS .............................................................................................. 9
START-UP PROCEDURE AND DISPLAY INFORMATION ................ 10
SAFETY DEVICES ............................................................................ 11
WORKING CYCLE ............................................................................ 11
MAINTENANCE ................................................................................ 12
TECHNICAL FEATURES ................................................................. 14
MAINTENANCE ................................................................................ 14
TROUBLESHOOTING ...................................................................... 15
WIRING DIAGRAM ........................................................................... 16

STANDARD EQUIPMENT
Your compressor is delivered with the following accessories:
• no. 1 user’s guide
• line cock + connection hose and Teflon tape
• one wrench to open panels + one 5mm Allen wrench
• condensate / oil drainage tube
Check that standard equipment is supplied with the machine. No claims after delivery will be accepted.

CONDITION OF THE MACHINE WHEN SUPPLIED

Every compressor is shop tested and delivered ready to be installed and put into operation.
Used oil is: RotEnergy Plus

Rotar Mega 50-60 - Cod.197AA3800 - Rev.03 - 05/2008 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.

CAUTION! POWER OFF!

Important description on service, dangerous All operations to be strictly carried out only after
situation, safety, accident prevention powering off the machine.
recommendations and/or very important information.

STOP MACHINE! SPECIALIZED PERSONNEL!

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

SYMBOLS USED ON THE COMPRESSOR

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

Danger! Hot! Prohibited! Do not open doors during

compressor operation

Prohibited! Press emergency button for

Danger! Electric shock! compressor immediate stop. Do not use line
knife switch.

Danger! Hot gas or harmful gas within

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

Danger! Pressurized container

Compulsory! Read instructions for use carefully.

Danger! Mechanical moving parts

Caution! Maintenance works in progress

4 Rotar Mega 50-60 - Cod.197AA3800 - Rev.03 - 05/2008

 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.
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.
Ensure that temperature of the working environment ranges between +5 and + 50 ºC.
The compressor should be installed and operated in a non-explosive environment.
Allow at least 80 cm between the compressor and the wall so to allow free air flow to the fan.
Press the emergency button on the control panel only in case of actual need so as to avoid possible damages to people or the
very compressor.
When calling for technical assistance and/or advice, always mention model and serial number indicated on CE plate.
Always follow the maintenance schedule specified in the user’s guide.

WHAT NOT TO DO:

Do not touch inner parts and pipes as they are very hot during compressor operation and stay hot for a certain time after
compressor stop.
Do not position inflammable or nylon objects or cloths close to and onto the compressor.
Do not move the compressor when the tank is under pressure.
Do not operate the compressor if the power cable is damaged or defective or if connection is unstable.
Do not operate the compressor in 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 Mega 50-60 - Cod.197AA3800 - Rev.03 - 05/2008 5

 INSTALLATION
COMPRESSOR DESCRIPTION (fig. 1)
Compressors described in this manual are
meant for industrial applications. 1
The compressor essentially consists of the 8
following:
1
1. Air filter 2
2. Suction regulator
3. Screw compressor 9
4. Oil filter
5. Thermal expansion valve
6. Oil separator reservoir + filter 11
7. Minimum pressure valve 3
8. Oil-air radiator (50) – oil radiator (60) 10
9. Air radiator (only 60)
10. Electric panel
11. Control panel 7

5
6
4

UNPACKING AND HANDLING THE COMPRESSOR

The compressor is usually shipped to the customer with a carton cover. Wear protective
600 cm (min)
2
gloves and cut outer straps. Then remove the carton cover from the top. Before removing
the compressor, make sure it is intact (outside), open access doors and visually check
components for damage. Check that all accessories are included.
Lift machine with a pallet truck or fork lift truck of suitable capacity (see technical table)
and transport the machine with the utmost care to the place of installation.
350 cm (min)
Keep the packing material in case the compressor needs to be re-located. Keep the
packing material at least for the whole warranty period, so that it can be used for safely
deliver the compressor to the Service Center for repair works. 80 cm (min)
Dispose of the above mentioned materials by taking them to special disposal centres.
120 cm (min)
POSITIONING THE COMPRESSOR (fig. 2)
Upon installation, make sure that the chosen place is in compliance with all prevailing
national safety standards and meets the following requirements:
• low percentage of dust suspended in air,
• shop must be suitably sized and well ventilated so that room temperature
never exceeds 40°C when the compressor is working. If this is not the case, install one
350 cm (min)

or more exhaust fans to extract hot air. Ideally, the fans should be installed close to the
ceiling.
Exhaust fan “2000 cu m /h” code 020041000 / Exhaust fan “4000 cu m /h” code
020042000
Dimensions are just approximate. Try nevertheless to respect them as much as possible.
A drainage pit or can shall be used to collect tank condensate.
Once machine is positioned and stable, fit supplied cock in its seat on radiator side;
seal with Teflon tape. Connect compressor and air tank through the connection hose
supplied with the machine (do not position check valves between tank and compressor).

POWER CONNECTION (fig.3) 3

Only qualified electricians are authorized to connect the compressor. 0
• Proceed to power connection with cross-section cables suitable for machine power: I
A
3 phase cables and 1 ground cable.
• Have a switch (A) provided with plug fuses installed between supply line and
control panel, close to machine cable connections.
• Switch (A) should be installed within the operator’s reach.
The cables should be of the approved type and with a minimum protection degree:
IP44.
NOTE: For cable cross-section selection, refer to technical data table.

6 Rotar Mega 50-60 - Cod.197AA3800 - Rev.03 - 05/2008

 CONTROLS AND SETTINGS GB
4 6

1 2 3 4 5

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
• Compressor operation is regulated by the pressure transducer, which stops the machine when the maximum pressure is
reached and restarts it when the pressure has returned to the minimum setting value.
The machine stop is delayed type; that is, it does not coincide precisely with the reaching of P max, but after a defined interval
of time during which there is no air intake.
• The factory setting is 180 seconds, but we recommend checking that the number of starts per hour is NOT greater than the
maximum recommended number of 12. If the number is greater, it is preferable to increase the idle running time (see the section
“Modifiable parameters” point 7).

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 differential value is 10°C, the maximum temperature pre-alarm is
tripped at 110°C.

Rotar Mega 50-60 - Cod.197AA3800 - Rev.03 - 05/2008 7

 CONTROLS AND SETTINGS
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 60 to 900 seconds.
8) Stop Empty Cycle (assistance password): using this menu you can change the duration of the empty operating cycle
following the voluntary stopping of the compressor (OFF button), the range of regulation goes from 30 to 240 seconds.
9) 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.
10) 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.
11) Language (no password required): this parameter allows you to change the language in which messages are displayed.
12) RS485 enable (no password required): this parameter is used to enable data transmission via RS485 and automatically
disenable transmission on RS232.
13) Set time and date (no password required): used for setting the current time and date.
14) PSI/BAR (no password required): for selecting the unit of measurement used to display the pressure.
15) Idle/Operating pressure set point (no password required): this parameter is used to set the pressure at which the compressor
must shut down.
16) Load/Operating differential set point (no password required): indicates the pressure at which the control unit enables
compressor restart.
17) Maximum pressure (service password): this parameter sets the maximum pressure value that can be reached, i.e. the
maximum value set in point 14.
18) Maximum pressure alarm (factory password): this parameter sets the maximum pressure value at which the control unit
trips an alarm and blocks compressor operation.
19) Remote Pressure (assistance password): enabling this parameter, the visualisation of the pressure and respective alarms
is maintained, but the control of the start of the compressor takes place using an external pressure switch linked to a dedicated
digital entry. In this event, it is necessary to pay attention that the setting of the external pressure switch falls within the values
imposed in points 15 and 16. In case of an anomaly, an alarm message will appear.
20) 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.
21) X1 progr. NC-NO (service password): allows you to invert the logic of the inputs of terminal block X1.
22) X7 progr. NC-NO (service password): allows you to invert the logic of the inputs of terminal block X7.
23) Motor therm. separate (service password): with the parameter ON, the thermal relays of the compressor and fan motors
are separated on two different inputs.
24) Temp. unit of measurement (no password required): for selecting the unit of measurement of the temperature (°C-°F).
25) 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.
• The following menus are enabled only if an inverter is present:
26) Inverter
27) Minimum operation %
28) Load delay
29) Inverter integration
30) Inverter parameters

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

0 ID 000 009 000 11 Language ITA
1 General maintenance: hours 0 50000 4000 12 RS485 enable YES
Air filter change: hours 0 50000 2000 13 Time and date
Oil filter change: hours 0 50000 4000 14 PSI/BAR Bar BAR
Oil change: hours 0 50000 8000 15 Idle Bar 0 P.Max. 10
Bearing lubrication: hours 0 50000 4000 16 Load Bar 0 2 0,5
Idle hours: hours 0 50000 0 17 Maximum pressure Bar 0 P.all. - 0,5 11
Total working hours: hours 0 50000 0 18 Maximum pressure alarm Bar 0 16 14
3 Pre-alarm temperature °C 0 20 5 19 Remote pressure Bar NO
4 Maximum temperature °C 0 110 110 20 Start programme OFF
5 Minimum temperature °C -14 0 -7 21 X01 progr. NC-NO 01010110
6 Fan temperature °C 0 150 65 22 X07 progr. NC-NO 111111
7 Idle running cycle sec. 60 900 180 23 Motor therm. separate NO
8 Stop Empty Cycle sec. 30 240 35 24 Temp. unit °C
9 Automatic start NO 25 Max. starts per hour n° 1 200 12
10 Internal phase sequence NO
8 Rotar Mega 50-60 - Cod.197AA3800 - Rev.03 - 05/2008
 ALARMS GB
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 23 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 23 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 the number of starts per hour is greater that that imposed. The alarm does not block the compressor, but persists for
an hour, after which it resets itself automatically.
If this alarm activates itself frequently, check and if necessary increase the empty cycle time.
• Err. remote pressure
this activates itself in case of anomalies of the external pressure switch. The alarm does not block the compressor, but persists
until the resetting of the correct control sequence.
• Inverter error
Alarm tripped only when the inverter is present.

Rotar Mega 50-60 - Cod.197AA3800 - Rev.03 - 05/2008 9

 START-UP PROCEDURE AND DISPLAY INFORMATION
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.1.0.5 dd/mm/yy date
release
Easy Tronic III

--screw.temp:065°C
06.5Bar
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.
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
1. Stand-by for start-up: the message (STAND-BY) is displayed: if the compressor was switched off, there will be a pause of
15 seconds before the cycle starts; otherwise, the compressor remains in stand-by until the request for air comes from the
pressure transducer.
2. Start: the compressor is started in “star” configuration and the message (IDLE) is displayed.
3. Run: after six seconds, the configuration changes from star to delta.
After a few seconds, if requested by the transducer, the load solenoid valve is energised and the message (LOAD) is displayed.

• Pressing the button

the load solenoid valve enable is interrupted; the idle cycle starts and the message (IDLE) is displayed blinking. At the end of
the idle cycle, the compressor switches off and the message “OFF” is displayed.

10 Rotar Mega 50-60 - Cod.197AA3800 - Rev.03 - 05/2008

 SAFETY DEVICES GB
1. Minimum pressure switch: indicates a pressure
drop below the minimum inside the oil separator 5
1
reservoir.
2. Pressure switch for oil separator filter clogging: 6 2
indicates efficiency limit of oil separator filter.
3
3. Pressure transducer: reads pressure value
4. Pressure switch for air filter clogging: indicates air 4
8
filter efficiency limit 5
5. Delivered air temperature probe: displays tempe-
rature value of the air delivered from the radiator.
6. Pressure gauge for max. pressure check: indicates
pressure value inside oil separator reservoir.
7. KR “phase-sequence relay”: prevents compressor
start in case of wrong direction of rotation due to the 9
inversion of power contacts. 7
8. Screw compressor max. temperature probe: stops
motor over +110°C.
9. Safety valve: It opens the air bleeding unit once
the safety value has been reached.

WORKING CYCLE
• At first start-up, the motor starts in the “star”
configuration. In this phase the compressor starts
Aria - Air 6
Olio - Oil 15
slowly, the solenoid valve (1) is open and the suction Aria+olio - Air+oil 9 16
regulator (2) is closed.
3 60 HP
• The compressor is kept under these conditions
for about 4 seconds. 15
• This time over, motor is “delta” powered. The 2
1 6
solenoid valve (1) is energized; it closes and enables
suction regulator (2) opening, which sucks in air through
10 11 4
filter (3).
• During this stage, compressor is working at full 13 14
5
speed and starts compressing air inside the oil
separator reservoir (4) through tube (5).
• Compressed air cannot escape through the
minimum pressure valve (6), which is set at 3÷4 bar.
• Compressed air compresses oil inside
7 8
reservoir (4) and causes it to flow through tube (8) to 12
the thermostat (7). If oil temperature is below 50°C, oil
is directly delivered to screw compressor through tube
(14).
If oil temperature is above 50°C, the thermostat
closes the passage and oil is delivered to radiator (9) through tube (11).
Cooled oil is returned to oil filter (12) through tube (10) and then to screw compressor through tube (14).
• From filter (12), oil reaches compressor (13) through tube (14). Oil is mixed with sucked air to form an air/oil mixture that
provides sealing and lubrication of compressor moving parts.
• The air/oil mixture flows back to reservoir (4) where air and oil are first separated by centrifugation and then by the oil
separator filter.
• As a result, reservoir (4) will deliver air only to air radiator (16) (separate on Rotar 60) or (9) (oil-air radiator on Rotar 50)
through tube (15). Air is then conveyed to mains through a cut-off cock.
• Min. pressure valve (6) serves also as a check valve.
• Compressor delivers compressed air to outer air tank.
• Tank inner pressure increases until reaching max. set value.
• Once max. value is reached, pressure gauge starts timer and powers off solenoid valve (1) 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 (1) is energized and closes before timer counting is over.
• Regulator (2) opens and compressor operates under normal load; timer is reset.
• This cycle is automatically repeated.

Rotar Mega 50-60 - Cod.197AA3800 - Rev.03 - 05/2008 11

 MAINTENANCE
Proper maintenance is fundamental to the efficiency of your compressor and for the prolongation of its operational
lifespan.
• It is also important to respect the manufacturer’s suggested maintenance schedule, keeping in mind that the compressor
has been constructed for use in the best possible environmental conditions. (see the chapter on “Installation”)
• The intervals between maintenance works might have to be reduced to counteract the effects of the environmental
conditions in which the compressor is used.
• The oil used is RotEnergy Plus. Use of a different type of oil could compromise the efficiency of the compressor and
frequency of maintenance work to be performed.
• The normal maintenance operations which can be performed by the person in charge of the compressor will be
described in the following pages. Extraordinary maintenance work must be performed by an authorised customer technical
assistance centre.

Type of maintenance Maintenance schedule

Work hours O At least
ORDINARY MAINTENANCE
Condensation release - Once per month
Oil level check and refill 500
Clean the air filter 1000
Check for clogging and clean the radiator 1000
Check the transmission belt 2000
Grease the electric motor pad 2000
Air filter substitution 2000 Once per year
Oil filter substitution 4000 Once per year
Discharge oil filter substitution 4000 Once per year
Total oil change 8000 Once per year
EXTRAORDINARY MAINTENANCE
One-way draining valve substitution 4000 Once per year
Suction valve overhaul 12000 -
Thermostatic valve overhaul 12000 -
Minimum pressure valve overhaul 12000 -
Solenoid-valve substitution 12000 -
Substitute the fexible tube 12000 -
Substitute the transmission belt 12000 -
Substitute the electric motor bearings 24000 -
Screw compressor overhaul 24000 -

• The maintenance operations indicated in bold type must be performed at least once a year, even if the machine has not
been run for the amount of hours prescribed for such maintenance.

BEFORE SERVICING THE MACHINE, ALWAYS REMEMBER TO:

√ Stop motor by means of the control board switch (do not press the emergency button).
√ Turn off the outer wall-mounted switch.
√ Close line cock.
√ Make sure that no air is present inside the oil separator reservoir: turn cock anti-clockwise (A – fig.8).
√ Before removing any protection, make sure the wall-mounted switch is positioned to (0).

• In order to assure the correct functioning of the compressor, the following items must be checked after the first one hundred
hours of operation:
Check oil level and top up with same oil, if needed.
Check for proper screw tightening: especially power electric connection screws.
Visually check that all fittings seal properly.
Check drive belt tension and tension up, if needed.
Check operating hours and type of duty cycle selected
Check room temperature.
Change oil filte

12 Rotar Mega 50-60 - Cod.197AA3800 - Rev.03 - 05/2008

 MAINTENANCE GB
DRAIN CONDENSATE (SEE FIG. 8)
Once a month, drain condensate before starting the compressor: open cock (C) and 7
close it as soon as oil starts coming out instead of water.
Check oil level and top up if necessary.
CONDENSATE IS A POLLUTANT! It cannot be drained into the sewerage system.
Dispose of condensate in compliance with current laws on environmental protection.

CLEAN THE AIR FILTER (FIG. 7)

With compressed air, from the inside to the outside.
Look at filter against the light and check for tears. Always replace a torn filter.
Filter cartridge and cover should be carefully fitted or dust might enter the
compression unit. REPLACE AIR FILTER AFTER THIRD CLEANING.

CLEAN RADIATORS
For cleaning, proceed as follows: 8
remove back and upper panel from compressor cabinet;
place a protective plastic sheet under radiator fins;
spray (spray gun + solvent) from the outside towards the inside;
check that air flows freely through radiator.

CHECK OIL LEVEL (FIG. 8)

To carry out this check, do NOT wait for the compressor to stop automatically. With
the compressor on, press stop button (rif.12 - fig.4) to control manual stop and wait for
approx 10 minutes. In this way you will be sure that oil has completely drained inside the
oil separator tank.
Remember to bleed all air off oil separator reservoir before topping up: slowly loosen
cock (A) to bleed all air, then tighten again.
Check oil level through the oil dipstick. Top up using the same oil, when level drops
below the mid line (first equipment oil: RotEnergy Plus).
Oil amount necessary for topping up from min. to max. level is about 3 liter.

CHANGE OIL FILTER (FIG. 9)

Oil filter must be replaced at every 4000 operating hours.
Remember to depressurize the reservoir first:
Always apply a thin layer of oil on filter edge and its seal before fitting the filter.
9

CHANGE OIL SEPARATOR FILTER (FIG. 10)

Remove upper panel lifting it from the inside and removing it from the top.
Bleed all air through cock (A) (see fig. 11).
Loosen all hose connections positioned on oil separator upper flange.
Remove flange fastening bolts and lift the oil separator flange + filter unit using
adequate lifting equipment.
Unscrew nut (B) and remove bottom (C).
Replace oil separator filter (D) and gaskets (E) and (F).
Re-assemble oil separator flange + filter unit and fit it inside reservoir. Place gasket
(E) inbetween.
Tighten bolts in a cross sequence. Be sure to tighten bolts evenly. 10
Re-connect all connections. E

CHANGE OIL (FIG. 8)

F
Release pressure inside the oil separator reservoir through cock (A).
Connect the supplied hose to cock (C).
Unscrew the plug of filler (D) and open ball cock (C), then let all oil flow into a collection
container.
Once this operation is over, close cock and remove hose. Then fill fresh oil through D
filler (D) (complete filling: 18 lt.).
Power the machine on.
Start the machine and let it run for 5 minutes, then stop and bleed all air. F
Allow 3 minutes: check oil level and top up, if necessary.
Used oil is: RotEnergy Plus C
EXHAUSTED OIL IS HIGHLY POLLUTANT! Dispose of exhausted oil in compliance
B
with current laws on environmental protection.

Rotar Mega 50-60 - Cod.197AA3800 - Rev.03 - 05/2008 13

 MAINTENANCE
CHECK DRIVE BELT TENSION (FIG.11)
Use a frequency tester to carry out this check. 11
Proceed as follows:
Remove left-side panel and inner L-shaped panel.
• Move tester microphone closer to the belt where “test” is marked (about at mid
length) and hit the belt with a wrench.
• Read value on tester. Tension up or down if the value is different from values
indicated in the table:
Higher value = tension down
Lower value = tension up
• Proceed as follows:
loosen screws (A);
turn tensioner (C) anti-clockwise to tension up and clockwise to tension down. Tighten C
B
the check nut (B) when finished; A
tighten screws (A) and check frequency value once again. Repeat above procedure, if
necessary, to reach optimal value.
Re-assemble cabinet parts before starting the compressor.

REPLACE MIN. PRESSURE VALVE (FIG. 12)

TEST
Close line cock and bleed all air off oil separator reservoir through cock (A).
Remove fastening nuts from flange valve and lift valve.
Replace gasket (1) part no. 010083000.

REPLACE HOSES Correct belt tension values

Loosen hose connections, replace hoses and then tighten firmly hose connections. 50 Hp 60 Hp
Max.P 8 bar 70 76
REPLACE DRIVE BELT (FIG.11) Max.P 10 bar 71 75
To replace drive belt, proceed as follows:
Max.P 13 bar 69 76
Remove left-side panel and inner L-shaped panel.
Loosen screws (A).
Completely loosen tensioner (C) by turning it clockwise. 12
Remove belt and replace it with a new one. Tension belt by turning tensioner (C) anti-
clockwise and then secure it with the check nut (B).
Tension belt up as described above.
Tighten screws (A) and re-assemble cabinet parts.
Check belt tension after three operating hours and adjust again, if necessary.

14 Rotar Mega 50-60 - Cod.197AA3800 - Rev.03 - 05/2008

 TECHNICAL FEATURES GB
Technical features
Power kW / Hp 37 / 50 45 / 60
Pressure bar 8 10 13 8 10 13
Compressor type Enduro 12 Enduro 12
Compressor rotation speed RPM 4473 4010 3318 5332 5318 4244
Air volume supplied l/min 5700 5000 3930 7150 6450 5030
Oil quantity l 18 18
Oil quantity for topping-up l 3 3
Max. final over temperature °C 17 16,8 16 21 23,5 19
Removed heat kJ / h 126.540 153.900
Fan flow rate m³ / h 5000 5200
Oil residues in the air mg / m³ 4 4
Electric motor (bipolar) Type 1LG 200L IM B3B5 1LG 200L IM B3B5
Max. power absorbed kW 37 45
Voltage V/Hz 400 / 50 400 / 50
Auxiliary voltage V/Hz 230 / 50 230 / 50
Electrical box protection class IP 55 55
Motor insulation class F F
Full load current A 65 77
Starting load A 138 168
Max. Start-up per hour n° 10 10
Ambient limit temperature °C 50 50
Noise level at 1 m dB (A) 70 74
Protection devices
Max compressor temperature °C 110 110
Safety valve setting bar 15 15
Oil separator filter pressure switch setting bar 8,9 10,9 12,7 8,9 10,9 12,7
Start-up pressure switch setting bar 1,5 1,5
Air filter pressure switch setting bar -0,008 -0,008
Dimensions and weight
Dimensions cm 180x94x137 180x94x137
Weight Kg 732 795
Air outlet connection Rp 1 - 1/4” 1 - 1/4”

Rotar Mega 50-60 - Cod.197AA3800 - Rev.03 - 05/2008 15

 TROUBLESHOOTING
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 Mega 50-60 - Cod.197AA3800 - Rev.03 - 05/2008

NOTES GB

Rotar Mega 50-60 - Cod.197AA3800 - Rev.03 - 05/2008 17

 WIRING DIAGRAM

A = Inom x 1,5

L1
FU4 L12 4
FU6 24

L2
FU5 L22 0
A TC2
FU1 FU3
L1 L1 L11 1 2
R
L2
S
L3
T L3
FU2 L31 3
SB
TC1 +
50
PE NC
1

X08

5 2

5ù 3 7 9

KM1 KM2 KM3 X08 X08 X08 X08

6 4 8 10
6 8 10 11
L1 L2 L3 19
KM3 KM2
7 9
KR
KM1 KM2 KM3 YV HL
W1 W2
M
15 3 3 0 24
V1 RT U2
15 21

U1 V2

A morsettiera superiore
To upper terminal board

L11 L31 2 L12 L22 24 22 15 21 U1 V1 W1 W2 U2 V2 L1 L2 L3

Morsettiera
inferiore FU1 FU2 FU3 FU4 FU5 FU6
Lower 22 15 15 21 U1 V1 W1 W2 U2 V2 L1 L2 L3
terminal
board
terra - heart

terra - heart

L1 L3 1 L1 L2 4 22 15 15 21 U1 V1 W1 W2 U2 V2 L1 L2 L3

Motore elettrico Linea

Electric motor Line
Predisposizione x collegamento in dual o trial start

Presetting for dual or trial start connection

Power (Hp) 50 50 60 60
Tension (Volt) 230 400 230 400
FU1-FU2 Fuses 6.3x32 4A
FU4-FU5 Fuses 6.3x32 1A
FU3-FU6 Fuses 6.3x32 4A
TC1 Transformer 160VA
TC2 Transformer 63VA
KM1 Liner contactor 37kW* 22kW* 45kW* 30kW*
KM2 Delta contactor 37kW* 22kW* 45kW* 30kW*
KM3 Star contactor 37kW* 22kW* 37kW* 22kW*
SB Emergency button
KR Phase-sequence relay
SP1 Air filter pressure switch

18 Rotar Mega 50-60 - Cod.197AA3800 - Rev.03 - 05/2008

 WIRING DIAGRAM GB

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

CanBus Progr. Com.

Display

50 2 5 8 6 10 11 + - 12 13 14 15 16 17 18 19 20 21 22

Morsettiera superiore
0 24 50 2 3 5 8 6 10 11 + - 12 13 14 15 16 17 18 19 20 21 22 Upper terminal board

P P P
SB
+ SP1 SP2 KR SP3
ST2 NC
BP
50 2 3 5 8 6 10 11
+ - ST1

15 Da morsettiera inferiore 21 22
From lower terminal board

Power (Hp) 50 50 60 60
Tension (Volt) 230 400 230 400
SP2 Oil separator filter pressure switch
SP3 Min. pressure switch
BP Pressure transducer
ST1 Screw delivery temp. probe
ST2 Air delivery temperature probe
D Electronic controller
YV Solenoid valve
HL Red indicator light
Motor cable cross-section (mm²) 7x25 7x16 7x35 7x16
Command contact cross-section (mm²) 1.5 1.5 1.5 1.5

Rotar Mega 50-60 - Cod.197AA3800 - Rev.03 - 05/2008 19