SENCO AC4504 Low Noise Compressors Instruction Manual

AC4504 Low Noise Compressors
Instruction Manual AC4504 • AC8305 • AC10304
AC12810 • AC12824 • AC24016
AC24050 • AC24080 • AC32024
Operating Instructions
(Original Instructions)

AC4504 Low Noise Compressors

WARNING: Please read the instructions and warnings for this tool carefully before use.

THE IMPORTANCE OF THE MANUAL

Before using the machine, the authorized operators Must read and understand this manual in all its parts.
This manual of “use and maintenance instructions” was drawn up according to the provisions foreseen by the “Machinery Directive” 2006/42/EC in order to assume an easy and correct comprehension of the contents handled by the authorized operators. Therefore, it must always be placed, well guarded and preserved, near the the machine.

This manual is integral part of the machine and must be preserved for future reference until disposal of the same. This manual must always be available for the charged operators and has to be placed well stored and preserved near to the machine.

The manufacturer cannot be made liable for damages to persons, animals and things, due to the inobservance of the standards and of the instructions described in this manual.
The manual has compulsorily to be delivered together with the machine, in case this latter is transferred to another user.
This manual meets the state of art when the machine is traded and cannot be considered improper just because following to new experiences it can then be updated.
In case of loss or wear of the manual, eques a new copy from the manufacturer or authorized dealer specifying the model of the machine and the revision quoted on the cover.

ADDRESSEES

This technical manual is destined exclusively to authorized operators charged with the use and maintenance of the machine according to the specific technical and professional competences required for the type of intervention involved.  The symbols here below are placed at the beginning of a paragraph and indicate the operator involved in the handed topic.

The authorized operators must perform on the machine only the interventions of their specific competence.
Before performing any intervention on the machine, the authorized operators must make sure they are in full possession of their physical and psychological abilities in order to assure at any time the respect of the safety conditions.
CHARGED OPERATOR: This is an operator being at least 18 years old (private user or worker), who, in compliance with the provisions of the laws in force in the country of use on safety and health in work places, can perform  exclusively the switching-on, use and switching-off of the machine in full observance of the instructors container in the manual, being equipped with the personal protection equipment.

MECHANICAL / PNEUMATIC MAINTENANCE ENGINEER: This is the trained technical engineer qualified to perform exclusively interventions on the mechanical / pneumatic parts in order to carry out adjustment, maintenance  and/or repair procedures even with disabled protections in full observance of the instructions contained in this manual or in any other specific document exclusively supplied by the manufacturer, being equipped with the personal protection equipment.

ELECTRICAL MAINTENANCE ENGINEER: This is a trained technical engineer qualified to perform intervention exclusively on electrical devices in order to carry out adjustment, maintenance and or repair procedures also with live voltage and with disabled protections in full observance of the instructions contained in this manual or in another specific documents exclusively supplied by the manufacturer, being equipped with the personal protection equipment.

COMPANY SAFERY MANAGER: This is a qualified technical engineer, appointed by the employer (in case the machine is used in a company), meeting the technical and professional requirements foreseen by the regulators in force  concerning the safety and health of workers in the place of work.
MANUFACTURER’S TECHNICAL ENGINEER: This is a qualified technical engineer supplied by the manufacturer and/or authorized dealer to perform the required technical assistance, as well as interventions of routine and  supplementary maintenance and/or procedures not described in this manual requiring a specific knowledge of the machine, being equipped with the personal protection equipment.

SAFETY WARNINGS

APPLIED SAFETY DEVICES

1. SAFETY VALVE : this is a certified safety valve (calibrated on 10,5 bar), installed on the pneumatic plant under the pressure switch. It is used to discharge the overpressure of the plant, when the pressure switch does not work due to possible malfunctions. The tripping of the safety valve obliges the operator to switch off the machine and require the intervention of the maintenance technical engineers.
2. PRESSURE SWITCH: this is an elector-pneumatic device (calibrated on min. 7 bar and max. 10 bar) installed on the pneumatic plant. It is used to command the automatic start of the machine, when the operation pressure falls under 7 bar, as well as the automatic stop when the operation pressure reaches 10 bars.
3. FIXED PROTECTION GRATING OF THE COOLING FAN : This is affixed protection made up of a grating in plastic material fastened by screws to the base of the bi-cylindrical pumping assembly. It is used to avoid accidental contact with the moving cooling fan.
4. RESTORABLE THERMAL SWITCH: this is a thermal protection installed on the electric plant, stopping the electric motor in case of current overload and/or short-circuit. The restoration can be performed by the related push-button .
5. TANK PRESSURE GAUGE: this is a measuring device installed on the machine tank. It displays the compressed air pressure present within the tank.
6. PRESSURE GAUGE AT OUTPUT: this is a measuring device installed on the machine pneumatic plant upstream of the fast air outlet tap. It displays the output pressure, which is adjustable through the proper pressure regulator (0 ÷ 10 bar).

It is strictly to tamper, disconnect and/or remove any safety device existing in the machine.
It is strictly forbidden to replace any safety device or any of their components with not original spare parts.
It is compulsory to constantly check the correct operation of all safety devices installed on the machine.
It is compulsory to immediately replace any safety device malfunctioning and/or being damaged.

SAFETY MARKING
The safety marking used is represented by an adhesive label, applied on the outside of the machine.
Meaning of the signals:

| |
---|---|---
Hazard: Power supply| Hazard: Automatic start| Hazard: High temperature
| |
Read the instructions compulsorily| It is compulsory to disconnect power supply| It is compulsory to protect the hearing

It is compulsory to keep the safety signal well clean to ensure their good visibility.
It is absolutely forbidden to remove and/or damage the safety signals applied to the machine.
It is compulsory to replace the safety signals worn out requesting to the manufacturer and/or authorized dealer.

PERSONAL PROTECTION EQUIPMENT (PPE)
The authorized operators are not allowed to wear cloths and accessories that may be entangled in the machine.
It is compulsory to use the ppe foreseen by the manufacturer.
The authorized operators must compulsorily use the ppe foreseen by the manufacturers of the tools used and according to the processing type.

Hands Protection

(Heart protecting gloves)

| In case maintenance interventions are required without waiting that the electric motor and the bi-cylindrical pumping element cool down.
| Hearing Protection (Ear muff)| During all processing phases.
| Feet protection (Footwear with reinforced cap)| During machine transport.

RESIDUAL RISKS
The authorized operators shall be aware that even though the manufacturer has adopted all possible technical manufacturing precautions to make the machine safe, there is still a potential residual risk.

RESIDUAL RISK| Hazard of burning by accidental contact with the bi- cylindrical pumping assembly and the electric motor.
---|---
EXPOSURE FREQUENCY| Low and accidental. There can be exposure if the operator decides to perform voluntary a wrong action, forbidden and not reasonably foreseeable.
DAMAGE RELEVANCE| Light lesions (usually reversible).
DAMAGE RELEVANCE| Safety sings. / Obligation of use of the personal protection equipment (PPE) and/ or wait until the machine has cooled.

MACHINE USE

DESTINATION OF USE

atmospheric agents) sufficiently lighted, ventilated, with ambient air temperature and humidity values complying, suitable in compliance with the law provision in force in the country of use on safety and health in the places of work. The machine has to lean on a surface assuring its stability with reference to its weight and its  overall dimensions.
CAUTION IT IS COMPULSORY TO KEEP THE MACHINE OUT OF THE REACH OF CHILDREN.
FORESEEN USE| Air compression (without oil) for the use of suitable pneumatic tools complying with the regulations in force. (ex: guns for blowing, inflation, washing, painting or sandblasting; strewers; spot welders, riveters or greasers).
OPERATORS CHARGED WITH THE USE| An authorized operator meeting the professional requirements described.

USE LIMITS
This machine was designed and produced exclusively for the intended use described in par.9 , any other use and operation is therefore absolutely forbidden in order to assure in every moment the safety of the charged operators, as well as  the efficiency of machine itself.

COMMAND DEVICES
They are shown

1. Power supply cable
2. Pressure switch
3. “ON-OFF” switch
4. Pressure regulator at output
5. Fast air outlet tape
6. Pressure gauge at output
7. Tank pressure gauge

It is strictly forbidden to commission the machine in environments with potentially explosive atmosphere and/or in presence of combustible dusts (ex: wood dusts, flours, sugars and middling’s).
Limitations in use: it is strictly forbidden to use the machine for improper used, differing from the foreseen use (par.9).
It is compulsory to keep the machine out of the reach of children.
During the use, it is compulsory to verify that nonauthorized people do not get close to the machine.
It is strictly forbidden to use air tubes (extensions), fittings, and tools not suitable and/or not complying with the regulations in force.
It is strictly forbidden to life the machine with cranes and/or fork lift trucks.
It is strictly forbidden to direct compressed air jets against persons, animals and things.
It is strictly forbidden to use the machine to transport and/or lift persons, animals and things.
It is strictly forbidden to get on the machine.
It is strictly forbidden to tow the machine by any means and/or vehicle whatsoever.
It is strictly forbidden to move the machine manually on upwards and/or downwards slopes with hazardous grade.
Hazard of burning by accidental contact with the bi-cylindrical pumping assembly and the electric motor. Caution! There is a residual risk.

CHECKS BEFORE SWITCHING ON

Before switching-on of the machine, the authorized operators must compulsory perform the following checks.

1. Make sure that there are not any non-authorized persons close to the machine.
2. Make sure that the safety devices are integral and properly installed and working .
3. Make sure that the machine is properly positioned .
4. Make sure that the “ON-OFF” switch or selector is positioned on “OFF (0)”.
5. Make sure that the condensate drain valve is closed .
6. Use the compulsory personal protection devices (PPE) .
7. Make sure that you have read and understood the “Use and Maintenance Instructions ” in all its parts.

MACHINE SWITCHING ON

The authorized operators can switch on the machine only after having compulsorily performed the checks described. Before using this machine, the authorized operators must read and understand this manual in all its part. During the  use, it is compulsory to verify that nonauthorized people do not get close to the machine. The authorized operators are not allowed to let the machine unattended during operation and maintenance interventions.
Hazard of burning by accidental contact with the bi-cylindrical pumping assembly and the electric motor. Caution! There is a residual risk.
The manufacturer declines all liability for damages to persons, animals and things, due to the inobservance of the standards and warnings described in this manual.
The manufacturer declines all liability on the final result of the processing given that it depends expends exclusively on the type of tool used and on the professional skills of the authorized operators.

1. Connect the machine to the mains by inserting the power supply plug in the proper outlet;

2. Switch on the machine by pulling the “ON-OFF” switch in pos. “ON (I)” (the machine works until the max. operation pressure of 10 bar is reached, then it stops automatically);

3. Adjust pressure at output using the proper regulator, according to the used tool and to the type of processing. Check pressure in the proper pressure gauge ;
   It is forbidden to screw the pressure regulator at output. Beyond the end of stroke, in order to avoid damaging the membrane.

4. Connect the tool to the air tube (extension);

5. Connect the air tube (extension) to the fast air outlet tap of the machine;
   It is strictly forbidden to use air tubes (extensions), fittings, and tools not suitable and/or not complying with the regulations in force.
   It is compulsory to use air tubes (extensions), fittings, and tools, complying with the provisions contained in the use and maintenance instructions supplied by the related manufacturers.

6. Perform the processing (the machine restarts automatically when the operation pressure falls under 7 bar);

7. Once the processing has ended, switch off the machine as described.

MACHINE SWITCHING OFF
At the end of the work cycle, switch off the machine as follows:

1. Switch off the machine by pressing the “ON-OFF” switch on pos. “OFF (0)”;
2. Disconnect the machine from the mains by removing the power supply plug from the proper outlet;
3. Disconnect the tool from the air tube (extension);
4. Disconnect the air tube (extension) from the fast air outlet tap of the machine;
5. Drain the condensate from the tank only in case of work cycle end.

RESTORABLE THERMAL PROTECTION TRIPPING RESET
Should a current overload and/or short-circuit occur in the electric plant of the machine, the restorable thermal switch trips stopping the electric motor. To reset the restorable thermal switch, proceed as follows;

1. Press the “ON-OFF” switch on pos. “OFF (0)”;
2. Press the restorable thermal push-button;
3. Before restarting the machine wait some minutes.

Should the machine, after having performed the rest, not switch on, the charged operator must compulsory seek the intervention of the maintenance technical engineers and/or of the authorized dealer.

CONNECTIONS

ELECTRICAL CONNECTIONS
The machine can be connected to the mains by inserting the power supply plug in the proper outlet.

The mains to which the machine is connected must comply with the requirements foreseen by the regulation in force in the country of use, as well as meet the technical features quoted in par.2 And be equipped with a proper “earthing” plant. Any type of electric material used for the connection must suit the use, be marked “cu” if subjected to the low voltage directive 2006/95/ec, and comply with the requirements set forth by the regulations in force in the country of use  of the machine. The inobservance of the above described warnings can cause irreparable damages to the electric equipment of the machine and the following expiration of the warranty.
The manufacturers declines all liability for faults or malfunctions of the machine due to voltage sudden changes exceeding the tolerances foreseen by the distributing entity (voltage ± 10% – frequency ± 2%). Should it be necessary, it is  compulsory to connect the machine exclusively to generating sets with a power greater than the installed electric power. To support the absorption peak at start.

CONNECTION OF THE AIR TUBE (EXTENSION) AND OF THE TOOLS

1. Connect the tools to the air tube (extension);
2. Connect the air tube (extension) to the fast air outlet tap of the machine.

It is strictly forbidden to use air tubes (extensions), fittings, and tools not suitable and/or not complying with the regulations in force.
It is compulsory to use air tubes (extensions), fittings, and tools, complying with the provisions contained in the use and maintenance instructions supplied by the related manufacturers.
The manufacturer declines all liability for damages to persons, animals and things due to the inobservance of the above described warnings.

EMERGENCY STOP

EMERGENCY STOP

The switching-off of the machine can be performed by pressing the “ON-OFF” switch on pos. “OFF (0)”. In order to avoid situations of imminent or close hazard, the authorized operators must compulsorily perform the following operations:

1. Press the “on-off” switch On pos. “Off (0)” in the right time.
2. Immediately inform the “safety manager” of the emergency (if the machine is used in a company).

SWITCHING ON AFTER AN EMERGENCY STOP
Only and exclusively after having removed the emergency causes and having carefully assessed that the same have not caused damaged and/or anomalies to the machine, with the consent of the “Safety Manager” (In case the machine is seed in a company), switch on the machine as described.

MAINTENANCE

STATE OF “SWITCHED OFF MACHINE”
Before performing any type of maintenance and/or adjustment intervention on the machine, it is necessary to compulsorily drain the tank (no pressure), to disconnect power supply source, as well as to verify that the machine is actually  stopped and cannot be switched on suddenly (ON-OFF switch on pos. ‘’OFF (0)” and power supply cable disconnected from the mains outlet and positioned close to the machine).
ROUTINE MAINTENANCE
It includes all activities performed in order to maintain the proper use and operation conditions of the machine through different type of intervention (adjustments, visual checks, cleaning of air filters, etc.) carried out by the authorized  maintenance technical engineer at the established frequency.

The authorized operators must perform exclusively the operations of their specific competence. And with the consent of the company safety manager (if the machine is used in a company).
The authorized operators are not allowed to leave the machine unattended during its operation and during maintenance operations.

ROUTINE MAINTENANCE TABLE

installed and working.
Power supply cable and plug| Visual check of the wear state.
| Tank| At every work cycle end lean the machine on the ground and drain the condensate from the tank, opening the condensate valve .
EVERY WEEK| Wheels| Tire pressure control. If necessary, inflate with compressed air up to max. 2.5 bar
| No.2 Air filters, front and rear side| Unscrew the screw; Remove the cover; Extract the filter; and clean it with air;
Re-assemble the cover properly. N.B.:REPLACE IN CASE OF CLEAR WEAR.

SUPPLEMENTARY MAINTENANCE
It includes all activities performed in order to maintain the proper use and operation conditions of the machine through different types of interventions (adjustments, replacements, etc.) carried out exclusively by the technicians of the  manufacturer at the established frequency or in case of failure or wear.
For any supplementary maintenance intervention, compulsory request the technical assistance to the manufacturer of the authorized dealer.

DEMOLITION
When the machine is demolished, compulsorily observe the provisions of the regulations in force. Separate the parts making up the machine according to the different construction materials (plastic, copper, iron, etc.).
TROUBLE – CAUSES – TROUBLESHOOTING
The following table gives a series of situations that can occur during the use of the machine.

The authorized operators must perform exclusively the operations of their specific competence. And with the consent of the company safety manager (if the machine is used in a company).

2. Check that the power sup- ply cable plug is working and properly inserted in the suitable outlet;
3. Check that possible exten- sions used and the power supply outlet are working;
4. Check that the main switch of the mains is working and positioned on “ON (I)”.
Tripping of the restorable thermal switch due to current overload and/or short-circuit.| Follow the procedure described.
The machine starts many times without using the tools.| Leaks from the air tube, the tool or the pneumatic plant.| 1. Check that the pneumatic plant has not been dam- aged;

2. Check the integrity and the connection of the air tube and of the tool.

on the machine and wait until the tank is loaded verifying the pressure on the proper pressure gauge.
Wrong adjustment of the output pressure.| Check that the value indicated on the pressure gauge at output is greater than 0 (zero) bar.
The tool is damaged.| Check the integrity and efficiency of the tool.
Pressure decrease in the air tank.| Leaks from the air tube, the tool or the pneumatic plant.| 1.   Check the integrity of the pneumatic plant.
2.   Check the integrity of the air tube and of the tool.
3. Verify that the machine air tube and air tube tool connections are right.
4. Make sure that the condensate drain valve is well closed.
Tripping of the safety valve.| Pressure switch faulty.| Apply to an authorized dealer.
Air leak from the valve of the pressure switch with stopped machine.|

Check valve dirty or worn.

The machine vibrates and/ or emits a lot of noise.|

Mechanical break.

Frequent starts and low yield.| Air filters dirty.| Clean the filters.

PACKAGING

MACHINE TRANSPORT AND HANDLINGT
The machine can be transported manually by two charged operators by seizing it by the bearing foot and the handle or handled manually by a charged operator using the handle and the wheels with which it is equipped.

The transport of the machine must compulsorily be carried out by two charged operators in compliance with the regulations on the “manual handling of loads”, in order to avoid unfavorable ergonomic conditions that may involve risks  of spine/lumbar lesions.

PACKAGING
The machine is packed by the Manufacturer in a cardboard box equipped with two handles and containing No. 1 Dry compressor and No. 1 Use and maintenance instructions.

UNPACKING
Once the package has been positioned on the floor, on an even surface assuring its stability, unpack the machine removing it from the package observing the instructions contained.
It is recommended to dispose the package according to the different types of materials in full observance of the laws in force in the country of use.

POSITIONING
The machine must be used in a work place having the features described, positioned on an even floor assuring its stability relation to its overall dimensions and weight.
Ain order to allow the authorized operators to work in safe places, it is suggested to assure a minimum distance (1 m) from others, objects and/or obstructions.

STORAGE
If the machine is not used for a long time, it is necessary to store it in a safe place, provided with proper temperature and humidity, as well as to protect it against dust.
Before storing the machine, it is recommended to drain the condensate from the air tank.

TECHNICAL SPECIFICATIONS

AC4504

AC8305

AC24050

AC24016

AC10304

AC24080

AC12810

AC32024

AC12824

Service class for all modes: S3 – 20mn ON/ 10mn OFF

RESERVED RIGHTS

The reserved rights on this manual ”use and maintenance instructions” remain property of the manufacturer. None part of this manual can be reproduced and disclosed (totally or partially) by any reproduction means without written authorization of the Manufacturer. All quoted trademarks belong to the respective owners.

Kyocera Semco Europe
Pascallaan 88
8212 NJ Lely tad, The Netherlands
+31 320 295 575
www.senco.eu

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