GENERAL INFORMATION GB

Contents
General safety rules .......................................................................... 2
Installation ......................................................................................... 4
Technical data ................................................................................... 5
Controls and settings ........................................................................ 6
Safety devices .................................................................................. 8
Working cycle ................................................................................... 8
Start-up ............................................................................................. 9
Maintenance ..................................................................................... 9
Troubleshooting .............................................................................. 12
Wiring diagram ................................................................................ 14

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: SHELL CORENA D46

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

Rotar Mega 50-60 - Cod.197664000 - ed.3 11/2003 1

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

SYMBOLS USED IN THE MANUAL

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

CAUTION! POWER OFF!

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

STOP MACHINE! SPECIALIZED PERSONNEL!

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

SYMBOLS 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

2 Rotar Mega 50-60 - Cod.197664000 - ed.3 11/2003

 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

1 2

3
4 5
6
7

Rotar Mega 50-60 - Cod.197664000 - ed.3 11/2003 3

GB INSTALLATION
COMPRESSOR DESCRIPTION (fig. 1)
Compressors described in this manual
are meant for industrial applications. 1
The compressor essentially consists of 8
the following:
1
1. Air filter
2. Suction regulator 2
3. Screw compressor
4. Oil filter 9
5. Thermal expansion valve
6. Oil separator reservoir + filter
7. Minimum pressure valve 11
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 2

The compressor is usually shipped to the customer with a carton cover. Wear 600 cm (min)
protective 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

350 cm (min)
table) and transport the machine with the utmost care to the place of installation.
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 80 cm (min)
safely deliver the compressor to the Service Center for repair works.
Dispose of the above mentioned materials by taking them to special disposal 120 cm (min)
centres.

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
350 cm (min)

never exceeds 40°C when the compressor is working. If this is not the case, install
one or more exhaust fans to extract hot air. Ideally, the fans 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; 3
seal with Teflon tape. Connect compressor and air tank through the connection hose 0
I
supplied with the machine (do not position check valves between tank and A
compressor).

POWER CONNECTION (fig.3)

Only qualified electricians are authorized to connect the compressor.
• Proceed to power connection with cross-section cables suitable for machine
power: 3 phase cables and 1 ground cable.
• Have a switch (A) provided with plug fuses installed between supply line and
control panel, close to machine cable connections.
• Switch (A) should be installed within the operator’s reach.
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.

4 Rotar Mega 50-60 - Cod.197664000 - ed.3 11/2003

 TECHNICAL FEATURES GB
$7HFKQLFDOIHDWXUHV +3 +3
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 B3 B5 1LG 200L IM B3 B5
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
%3URWHFWLRQGHYLFHV
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
&'LPHQVLRQVDQGZHLJKW
Dimensions cm 175x90x125 175x90x125
Weight Kg 725 745
Air outlet connection Rp 1 - 1/4” 1 - 1/4”

Rotar Mega 50-60 - Cod.197664000 - ed.3 11/2003 5

GB CONTROLS AND SETTINGS
CONTROL PANEL (fig. 4)
The compressor main functions are controlled by an electronic control unit positioned inside the control panel.
1. Alarm pilot light:
when pilot light is on, look at display (5) to display alarm cause.
2. Emergency button:
stops the compressor, to be used only in case of emergency.
3. Display:
displays pressure value.
4. Display:
displays temperature value. 4
3 4 11 12
5. Main display:
displays air delivery temperature and all functions and/or defects.
6. “Up” direction key: 2
scrolls menu upwards. 1
7. “Down” direction key:
scrolls menu downwards.
8. Key to display previous function:
allows to go back to previous function.
9. Key to display next function:
allows to go to next function. 5 6 7 8 9 10 13
10. Enter key:
confirms selected function.
11. Start key:
starts the compressor.
12. Stop key:
stops the compressor with a set delay of 75 seconds.
13. Reset key:
resets pre-set values.
To adjust displays brightness proceed as follows: open front panel, remove rubber plug from upper edge and, with an
insulated screwdriver, turn right to increase brightness and left to decrease.
The diagram on the right of the unit shows the main maintenance operations on the basis of the compressor operating
hours.

OPERATING MODE
(A) AUTOMATIC OPERATION
Stop timer is set at 5 minutes: compressor motor will be running continuously and compressor is automatically stopped only
when no compressed air has been drawn for 5 minutes.

(C) CONTINUOUS OPERATION WITHOUT STOP

The automatic stop timer is cut out. When max. pressure is reached, the compressor idles, i.e. it works without compressing
air. With this setting the compressor can only be stopped manually.

(P) ON/OFF OPERATION

Compressor automatically stops when max. pressure is reached after having idled for 75 seconds.
This setting is recommended when:
1) air consumption is less than 50% of compressor rated efficiency (see “Technical features”)
2) a large-capacity air tank is available (min. 3,000 l)
To select this setting, increase interval between max. and min. operating pressure until reaching 2÷2.5 bar ( ex. P max 10
bar - P min 8 bar). Proceed as specified under “Change functions”.
NOTE: If under these conditions the red alarm light comes on to signal compressor automatic stop (see fig. 4, ref. 1),
allowed max. number of starts per hour (max no. 10) has been exceeded.
This means selected duty cycle is not suitable for your needs. Select Automatic operation mode (follow instructions under
“Change functions”).

• Standard setting (compressor is delivered with the following setting)

Model Operating mode Max Start Stop

press. press. press.
(bar)
5008/6008 A 8 7 8
5010/6010 A 10 9 10
5013/6013 A 13 12 13

6 Rotar Mega 50-60 - Cod.197664000 - ed.3 11/2003

 CONTROLS AND SETTINGS GB
DISPLAY AND MODIFY FUNCTIONS (fig. 4)

HOUR COUNTER
To display:
• TOTAL HOURS – Press twice
• HOURS UNDER LOADING - Press twice and once
• HOURS TO AIR FILTER CHANGE - Press twice and twice
• HOURS TO OIL FILTER CHANGE - Press twice and 3 times
• HOURS TO OIL SEPARATOR FILTER CHANGE – Press twice and 4 times
• HOURS TO OIL CHANGE – Press twice and 5 times

Indications are always shown on display (5)

To go back to main display, press

TYPE OF DUTY
To display:
• Press 3 times - read indication on display (5) (AUTOMATIC)
To modify:
• Press 3 times and once - read indication on display (5) (ON/OFF)
• Press 3 times and once - read indication on display (5) (CONTINUOUS)

To go back to main display, press

STOP PRESSURE
To display:
• Press 3 times and once
To modify:
• Press 3 times and once - the value blinks (ex. 9.7)
To increase value - Press until reaching desired value (ex. 9.8....9.9....10...)
To decrease value - Press until reaching desired value (es. 9.6....9,.....9.4...)
To store value – Press once within 4 seconds

Indications are always shown on display (5)

To go back to main display, press

START PRESSURE
To display:
• Press 3 times and twice
To modify:
• Press 3 times , twice and once - the value blinks (ex. 9.7)
To increase value - Press until reaching desired value (ex. 9.8....9.9....10...)
To decrease value - Press until reaching desired value (ex. 9.6....9.5....9.4...)
To store value – Press once within 4 seconds

Indications always show on display (5)

To go back to main display, press

Rotar Mega 50-60 - Cod.197664000 - ed.3 11/2003 7

GB SAFETY DEVICES
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
4. Pressure switch for air filter clogging: indicates 8
air filter efficiency limit 5
5. Delivered air temperature probe: displays
temperature value of the air delivered from the
radiator.
6. Pressure gauge for max. pressure check:
indicates pressure value inside oil separator
9
reservoir.
7. KR “phase-sequence relay”: prevents 7
compressor start in case of wrong direction of
rotation due to the inversion of power contacts.
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.
• The compressor is kept under these 3 60 HP
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 filter (3). 10 11 4
• During this stage, compressor is working at 13 14
5
full 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 12 8
reservoir (4) and causes it to flow through tube (8) to
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.

8 Rotar Mega 50-60 - Cod.197664000 - ed.3 11/2003

 START-UP GB
FIRST START-UP
Before starting the machine up for the first time, make sure that:
• mains voltage is the same as voltage rating indicated on plate;
• all connections use cables with suitable cross-sections;
• main (wall-mounted) switch is equipped with suitable fuses;
• oil level is above the minimum (if needed, top up with same oil: Shell Corena D46)
• air delivery cock is completely open.
• Warning! Only specialized technicians are allowed to start the compressor (operational testing) for the first time. If the
machine stops soon after starting and the red alarm light turns on, this means that the “WRONG DIRECTION OF ROTATION”
cutout tripped. The message “ shutdown due to defect “ will be displayed.
Proceed as follows:

Press once: the message “Wrong direction of rotation” blinks on the display
Power off and reverse phases inside terminal board.
Power on again, press and restart by pressing

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).

AFTER THE FIRST 100 OPERATING HOURS

Check oil level and top up with same oil, if needed.
Check for proper screw tightening: especially power electric connection screws. 7
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 filter

EVERY 300 OPERATING HOURS

• Clean 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.
NOTE: REPLACE AIR FILTER AFTER THIRD CLEANING.

EVERY 500 OPERATING HOURS

• Check OIL LEVEL (fig. 8).
Remember to bleed all air off oil separator reservoir before topping up: slowly 8
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: Shell Corena D46).
Oil amount necessary for topping up from min. to max. level is about 3 liter.

AFTER THE FIRST 2,000 OPERATING HOURS AND THEN EVERY

4,000 OPERATING HOURS
• Change OIL (fig. 8)
• Change the oil every 4,000 operating hours, when the compressor is still warm
(over 70°C).
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
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.
Allow 3 minutes: check oil level and top up, if necessary.

Rotar Mega 50-60 - Cod.197664000 - ed.3 11/2003 9

GB MAINTENANCE
• Change OIL FILTER (fig. 9)
Oil filter must be replaced at every oil change. Remember to depressurize the 9
reservoir first:
Always apply a thin layer of oil on filter edge and its seal before fitting the filter.

EXHAUSTED OIL IS HIGHLY POLLUTANT! Dispose of exhausted oil in

compliance with current laws on environmental protection.
When changing oil, a different type of oil may be selected. Always use same oil
when topping up.
Recommended oil
SHELL CORENA D 46 FINA EOLAN R 046
AGIP DICREA 46 IP VERETUM OIL 46
BP ENERGOL HLP 46 MOBIL D.T.E. MEDIUM
CASTROL HYSPIN AWS 46 ESSO UNIVIS 46
Never mix different types of oil 10
• Change OIL SEPARATOR FILTER (fig. 10) E
The oil separator filter cannot be cleaned and must be replaced at every oil change.
Anyway, do not exceed 4,000 operating hours.
Remove upper panel lifting it from the inside and removing it from the top. F
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. D
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. F
Tighten bolts in a cross sequence. Be sure to tighten bolts evenly. C
Re-connect all connections.
B
EVERY 8,000 OPERATING HOURS
• Check DRIVE BELT tension (Fig.11)
Use a frequency tester to carry out this check.
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. 11
• 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 the check nut (B) when finished;
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.
C
B
Correct belt tension values
A

50 Hp 60 Hp
Max.P 8 bar 70 76
Max.P 10 bar 71 75
Max.P 13 bar 69 76 TEST

10 Rotar Mega 50-60 - Cod.197664000 - ed.3 11/2003

 MAINTENANCE GB
EVERY 12,000 OPERATING HOURS
• MINIMUM PRESSURE VALVE (fig. 12) 12
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
Loosen hose connections, replace hoses and then tighten firmly hose connections.

EVERY 20,000 OPERATING HOURS

• Replace DRIVE BELT (Fig.11)
To replace drive belt, proceed as follows: 1
Remove left-side panel and inner L-shaped panel.
Loosen screws (A).
Completely loosen tensioner (C) by turning it clockwise.
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. A
Tighten screws (A) and re-assemble cabinet parts.
Check belt tension after three operating hours and adjust again, if necessary.

• To be also replaced
Compressor o-ring
Tank safety valve
Motor bearings

EVERY MONTH
• Drain condensate (see fig. 8)
Oil/air mixture cooling is set at a temperature higher than air dew point. However, oil condensate cannot be totally removed.
Once a month, drain condensate before starting the compressor: open cock (C) and 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.

EACH YEAR
• Clean radiators
Radiators are designed to provide high efficiency and do not become clogged easily. Clean radiators at least yearly and in
the event of abnormally high temperatures.
For cleaning, proceed as follows:
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.

COMPRESSOR DISPOSAL
Dispose of all materials according to prevailing rules.
In particular, after having drained all lubricants out of the compressor, take them to special disposal centres.
Always contact Collection and Recycling Centers.

Rotar Mega 50-60 - Cod.197664000 - ed.3 11/2003 11

GB TROUBLESHOOTING
When compressor stops due to a defect and the message “stop due to defect” is displayed and /or the red alarm light
blinks, press to display failure description.

Problem Cause Remedy

Alarm: oil separator filter Oil separator filter clogged Change oil separator filter
Press and restart by pressing

Alarm: wrong direction of rotation Wrong power connection Reverse phases into terminal board.
Press and restart by pressing

Alarm: number of starts/hour Max. no. of 10 starts / hour Change operating mode.
exceeded exceeded Press and restart by pressing

Alarm: air filter Air filter clogged Replace filtering element

Press and restart by pressing

Alarm: screw temperature Screw compressor is close to Increase shop ventilation,

stop temperature Check radiator clogging degree and clean,
if necessary
Press and restart by pressing

Motor overheating Voltage too low Check voltage

Press and restart by pressing

Motor overheating Allow some minutes.

Press and restart by pressing

Room temperature too high Increase shop ventilation.

Press and restart by pressing

High pressure Suction regulator does not close Check the solenoid valve is powered off
at the end of the cycle. and that the shutter is regularly opened.
Remove and clean suction regulator, if necessary.
Press and restart by pressing

Oil separator filter clogged Change oil separator filter

Press and restart by pressing

Line cock closed Open cock.

Press and restart by pressing

Minimum pressure valve blocked. Check and clean valve. Replace gaskets, if necessary.

12 Rotar Mega 50-60 - Cod.197664000 - ed.3 11/2003

 TROUBLESHOOTING GB
Problem Cause Remedy

High screw temperature High room temperature Increase shop ventilation.

Press and restart by pressing

Oil radiator obstructed Clean radiator.

Press and restart by pressing

Oil level too low Top up oil.

Press and restart by pressing

Oil separator filter obstructed Change oil separator filter

Press and restart by pressing

Faulty thermostat Replace thermostat.

Press and restart by pressing

High oil consumption Faulty drainage Check drainage tube and one-way valve.

Oil level too high Check oil level and drain some, if necessary.

Oil separator filter broken Change oil separator filter

Poor sealing of oil separator filter Replace gaskets

gaskets

Oil leakage from suction filter Suction regulator does not close Check suction regulator and solenoid valve

Low compressor efficiency Slack belt Check and reset to required value.

Compressor is not Suction regulator is closed and Remove filter and check opening.
compressing air does not open because it is dirty. Remove and clean, if necessary.

Suction regulator is closed and Check solenoid valve operation.

does not open because actuating Replace, if necessary.
signal is missing.

Compressor does not restart Min. pressure valve does not Remove valve and clean. If necessary, replace
perfectly close. gaskets

Difficult start Low voltage Check voltage

Temperature in the shop too low Heat up shop.

Oil inside cabinet Tube leakage Tighten connections and/or replace damaged tubes.

Rotar Mega 50-60 - Cod.197664000 - ed.3 11/2003 13

14
GB

1 21 987 6543 21
2 X03
X06 X01
1 R1
L1
FU4 L12
TC2 4
FU6 24 2
3
FU5
4 R2 D
L2 L22 0 5
6 R3 X08
R L1 L11 1 2
7 X09 X02
S FU1 FU3 8 R4
T L3 L31 3
SB 9 1234 123456
+ 10 R5
PE FU2 TC1 NC
A 50

R1
X08

5 2

Rotar Mega 50-60 - Cod.197664000 - ed.3 11/2003

KM1 KM2 KM3
L1 L2 L3 R3 R2 R4 R5
X08 X08 X08 X08
KR 6 8 10 11

Morsettiera superiore
Upper terminal board
19 0 24 50 2 3 5 8 6 10 11 + - 12 13 14 15 16 17 18 19 20 21 22
L1 KM3 KM2
L2
L3 KR 7 9
w1 M w2 KM1 KM2 KM3 YV HL SB P P P
3 + SP1 SP2 KR SP3
15 v1 RT u2 ST2 NC
3 0 24
50 2 3 5 8 6 10 11
u1 v2
+ -
BP ST1
WIRING DIAGRAM

Alla morsettiera superiore 15 21 22

To the upper terminal board
Alla morsettiera inferiore
L11 L31 2 L12 L22 24 22 15 21 U1 V1 W1 W2 U2 V2 L1 L2 L3
To the lower terminal board

FU4-FU5 ........ Fuses 6.3x32 1A BP .................. Pressure transducer

FU1 FU2 FU2 FU4 FU5 FU6 FU3-FU6 ........ Fuses 6.3x32 4A ST1 ................ Screw delivery temp. probe
Morsettiera inferiore
Lower terminal board
22 15 15 21 U1 V1 W1 W2 U2 V2 L1 L2 L3 TC1 ................ Transformer 160VA ST2 ................ Air delivery temperature probe
TC2 ................ Transformer 63VA D ................. .. Electronic controller
KM1 ................ Liner contactor YV .................. Solenoid valve
KM2 ................ Delta contactor HL .................. Red indicator light
L1 L3 1 L1 L2 4 22 15 15 21 U1 V1 W1 W2 U2 V2 L1 L2 L3 KM3 ................ Star contactor
Predisposizione controllo remoto Linea -Line
Motore elettrico - Electric motor SB ..................Emergency button Motor cable cross-section:
Pre-set for remote control
KR .............. .. Phase-sequence relay 50 HP 60 HP
SP1 ................ Air filter pressure switch V 230 ............. 7x25 sq mm 7x35 sq mm
SP2 ................ Oil separator filter pressure V 400 ............. 7x16 sq mm 7x16 sq mm
switch
SP3 ................ Min. pressure switch