Mark MSU 11 Instruction Book
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Mark MSU 11 Instruction Book

Oil-injected screw compressors
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Oil-injected screw compressors
MSU 11, MSU 15, MSU 20
Instruction book

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  • Page 1 Mark Oil-injected screw compressors MSU 11, MSU 15, MSU 20 Instruction book...
  • Page 3 Mark Oil-injected screw compressors MSU 11, MSU 15, MSU 20 Instruction book Original instructions Copyright notice Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings.

  • Page 4: Table Of Contents

    Instruction book Table of contents Safety precautions......................6 Safety icons..........................6 General safety precautions....................6 Safety precautions during installation................7 Safety precautions during operation..................8 Safety precautions during maintenance or repair.............. 9 Dismantling and disposal......................11 General description...................... 12 Introduction..........................12 Air flow.............................
  • Page 5 Instruction book Shutdown..........................28 Service warning........................31 Remote control........................31 Scrolling through screens....................32 3.10 Calling up/ modifying pressure band settings..............32 3.11 Calling up running hours.......................33 3.12 Calling up Software release....................34 3.13 Calling up Bluetooth pairing/ discovery mode..............35 3.14 Advanced menu.........................
  • Page 6 Instruction book Maintenance........................58 Preventive maintenance schedule..................58 Drive motor ..........................60 Oil specifications........................60 Oil, filter and separator change ..................60 C/G filter change........................62 Storage after installation....................64 Service kits..........................64 Adjustments and servicing procedures..............66 Air filter............................66 Coolers............................. 67 Safety valve ..........................67 Belt set exchange and tensioning ..................69 Problem solving......................72 Technical data.......................
  • Page 7 Instruction book Instructions for use...................... 78 Guidelines for inspection.....................79 Pressure equipment directives................... 80 Declaration of conformity.................... 81 2920 7201 41...

  • Page 8: Safety Precautions

    Instruction book Safety precautions Safety icons Danger: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Warning: Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Notice: Indicates a potential situation which, if not avoided, might result in property damage or in an undesirable result or state.

  • Page 9: Safety Precautions During Installation

    Instruction book Safety precautions for the connectivity module It is important to follow all regulations regarding the use of radio equipment, in particular regarding the possibility of radio frequency (RF) interference. Please follow the safety advice given below carefully. • Respect restrictions on the use of radio equipment in fuel depots, chemical plants or other explosive environments.

  • Page 10: Safety Precautions During Operation

    Instruction book machines shall take adequate precautions to ensure that there is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the start equipment. • Air-cooled machines must be installed in such a way that an adequate flow of cooling air is available and that the exhausted air does not recirculate to the compressor air inlet or cooling air inlet.

  • Page 11: Safety Precautions During Maintenance Or Repair

    Instruction book On machines without bodywork, wear ear protection in the vicinity of the machine. • People staying in environments or rooms where the sound pressure level reaches or exceeds 80 dB(A) shall wear ear protectors. • Periodically check that: •...
  • Page 12 Instruction book • Close the compressor air outlet valve and depressurize the compressor before connecting or disconnecting a pipe. • Before removing any pressurized component, effectively isolate the machine from all sources of pressure and relieve the entire system of pressure. See section Maintenance. •...

  • Page 13: Dismantling And Disposal

    Instruction book These precautions apply to machinery processing or consuming air or inert gas. Processing of any other gas requires additional safety precautions typical to the application which are not included herein. Some precautions are general and cover several machine types and equipment; hence some statements may not apply to your machine.

  • Page 14: General Description

    Electric cabinet Tank-mounted model MSU 11, MSU 15 and MSU 20 tank-mounted units are supplied with an air receiver of 500 l (132 US gal / 110 Imp gal / 17.50 cu.ft). Tank-mounted units are available with or without dryer.
  • Page 15 Instruction book Figure 2: Front view, tank-mounted with dryer Reference Description Electric cabinet Controller Emergency stop button Air outlet Air receiver Manual condensate drain Dryer Dew point indicator (only on units with dryer) Figure 3: Front open view, tank-mounted 2920 7201 41...

  • Page 16: Air Flow

    Instruction book Reference Description Oil cooler Oil filter Oil separator Oil separator tank Figure 4: Rear open view, tank-mounted Reference Description Compressor element Air filter Air flow 2920 7201 41...

  • Page 17: Oil System

    Instruction book Oil system Figure 5: Without dryer Air pressure in the oil separator tank (OT) forces the oil from the tank to compressor element (E) via oil cooler (Co) and oil filter (OF). Compressed air and oil flow into oil separator/tank (OT) where most of the oil is separated from the air by centrifugal action.

  • Page 18: Regulating System

    Instruction book Regulating system Main components Figure 6: Detail view of unloader assembly (UA) The main components of the regulating system are: • Unloader (UA), including inlet valve (IV) and unloading valve (UV). • Loading solenoid valve (Y1). • The controller that regulates the compressor based on the pressure settings and readings of the pressure sensor.

  • Page 19: Control Panel

    Instruction book Control panel Figure 7: Electric cabinet - Control panel Reference Description Electric cabinet Controller Emergency stop button Electrical system The electrical system comprises the following components: 2920 7201 41...
  • Page 20 Instruction book Figure 8: Electric cubicle UL (DOL) Figure 9: Electric cubicle UL (YD) Reference Description Primary fuse, transformer of the control circuit 2920 7201 41...

  • Page 21: Protection Of The Compressor

    Instruction book Reference Description F2-3 Fuses Motor overload relay Delta contactor Line contactor Star contactor Transformer Terminal block of the control circuit Terminal block, voltage change of the motor (only on tri-voltage units) Electrical diagram Diagram number Model description 2205 0367 01 cULus/ cCSAus (YD) for 20 hp The complete electrical diagram can be found in the electric cubicle.
  • Page 22 Instruction book Figure 11: Safety valve on the compressor Reference Description Function To protect the air outlet system if the outlet Safety valve pressure exceeds the operning pressure of the valve. 2920 7201 41...

  • Page 23: Controller

    Instruction book Controller Controller functions Figure 12: ES4000 Controller Introduction The controller has the following functions: • Controlling the unit • Protecting the unit • Monitoring components subject to service • Automatic restart after voltage failure (ARAVF) • Integrated connectivity (Bluetooth 4.2, Wi-Fi 802.11 b/g/n or Ethernet RJ45) Automatic control of the unit The controller maintains the net pressure between programmable limits by automatically loading and unloading the unit.
  • Page 24 Instruction book Protecting the unit Shutdown If the outlet element temperature exceeds the programmed shutdown level, the unit will be stopped. This will be indicated on the display of the controller. The unit will also be stopped in case of overload of the drive motor. Air-cooled units will also be stopped in the event of overload of the fan motor Warning: Before remedying, consult the safety precautions.
  • Page 25 Instruction book If the function is activated and provided the regulator was in the automatic operation mode, the unit will automatically restart if the supply voltage to the module is restored. The ARAVF label shall be attached near to the controller. Figure 13: ARAVF label The ARAVF label is attached on the side panel, next to the controller, with the goal of warning users of the risks linked to the function.

  • Page 26: Control Panel

    Instruction book Control panel Figure 14: Control panel Reference Designation Function Shows the unit operating condition and a number of Display icons to navigate through the menu. Flashes in case of a shutdown, Warning sign is lit in case of a warning condition.

  • Page 27: Icons Used

    Instruction book Icons used Status icons Icon Description Motor stopped Running unloaded Running loaded On: Remote Machine Control Mode, active: compressor can start from Bluetooth or via external switch if wired. Automatic Restart After Voltage Failure, active Emergency stop Main motor Element outlet temperature Units of pressure, outlet Units of temperature, outlet...
  • Page 28 Instruction book Icon Description Multiply value x1000 Value in hours Value in seconds Fixed: Week timer, active Blinking: Waiting Fixed: LAN cable connected Blinking: LAN cable not connected Bluetooth connection: appears only when controller is paired to the app through Bluetooth. Wi-Fi signal 100% Wi-Fi signal 75% Wi-Fi signal 50%...

  • Page 29: Main Screen

    Instruction book Main screen When the voltage is switched on, the first screen is a test screen. The next screen is the Main screen, shown automatically: The Main screen shows: • The unit status by means of pictographs • The air outlet pressure •...

  • Page 30: Shutdown

    Instruction book Figure 15: Main screen with temperature outlet warning The related pictograph will appear flashing with temperature unit °C / °F icon. It remains possible to scroll through other screens, using the Scroll buttons up and down (6 and 8) to check the actual status of other parameters.
  • Page 31 Instruction book Figure 16: Main screen with temperature outlet shutdown The related pictograph will appear flashing with temperature unit °C / °F icon. Press Scroll buttons (6-8) until the actual compressor element temperature appears. The screen shows that the temperature at the outlet of the compressor element is 117 ˚C. •...
  • Page 32 Instruction book The related pictograph will appear flashing. Error pressure/temperature sensor In case of error of the outlet pressure sensor (PT20) or temperature sensor (TT90), compressor will be shutdown. The following screen will appear: Figure 18: Error on pressure and temperature sensor Compressor outlet pressure too high If the outlet pressure of the compressor exceeds the shutdown level (factory setting 1.5bar / 22psi over the maximum pressure of compressor) the compressor will be shutdown, alarm LED (2) will...

  • Page 33: Service Warning

    Instruction book Motor overload In the event of motor overload, the compressor will be shutdown, alarm LED (2) will flash, automatic operation LED (4) will go out and the following screen will appear: Figure 20: Main screen with shutdown indication, motor overload •...

  • Page 34: Scrolling Through Screens

    Instruction book Scrolling through screens Scroll buttons (6-8) can be used to scroll through all screens. For most screens, the unit of measurement and the related pictograph are shown together with the screen number. Example: The screen shows the screen number P.SEt, the unit used bar and the related symbol for pressure unit.

  • Page 35: Calling Up Running Hours

    Instruction book Figure 22: Starting/loading pressure changing • The pictograph shows starting/loading pressure and the value starts blinking. • Press Scroll button (6-8) to modify the starting/loading pressure and press enter button (9) to confirm. The unloading pressure on secondary row will update accordingly to have optimal pressure range.

  • Page 36: Calling Up Software Release

    Instruction book • Press Scroll button (6-8) until HoUr is shown on the display. Figure 24: Running hours screen • Press Enter button (9). Figure 25: Running hours value The screen shows the unit used (x1000 hrs) and the value (11.25): the running hours of the unit are 11250 hours.

  • Page 37: Calling Up Bluetooth Pairing/ Discovery Mode

    Instruction book Figure 26: Software release screen • Press Enter button (9) to show the software release version. 3.13 Calling up Bluetooth pairing/ discovery mode For Bluetooth connectivity a paring with the device is necessary, see section Connectivity. This function is also a way to select the pair to the correct unit when multiple units are in the proximity. During the Bluetooth pairing, the controller generates and stores a random code.

  • Page 38: Advanced Menu

    Instruction book 3.14 Advanced menu To enter inside the advanced menu Press buttons (6) and (8) together. Advanced menu consists by following functions: Controller screens Designation Function See section Calling-up Service SEru Service mode mode See section Calling-up Screen tESt Screen Test Test See section Calling-up Factory...

  • Page 39: Calling Up Factory Reset

    Instruction book Figure 28: Test screen 3.17 Calling up factory reset This function restores the controller to original machine settings for pressure settings/units/starting. This parameter can only be modified after entering a password. Consult your supplier to use this function. Starting from the Main screen: •...
  • Page 40 Instruction book In order to have an overview of all the features available in the App we refer to the APP guidelines document which can be found in the media section of the App. Unit configuration and control are made possible by Bluetooth communication with digital signature. To connect the unit to the cloud for monitoring purposes, a Wi-Fi connection or alternatively an Ethernet network with access to Internet is required.
  • Page 41 Instruction book Machine events and notification The smartphone application sends real time push notifications in case of alarms or shutdown. This allows you to always be up to date on the status of the machine. In case you want more information, you can always press on the pop-up message in your Smartphone and you will redirected to the App.
  • Page 42 Instruction book When the Timer schedule is active, the related pictograph will be shown on the controller display. Figure 29: Main screen with timer schedule active 2920 7201 41...

  • Page 43: Installation

    Instruction book Installation Installation proposal Outdoor/altitude operation If the compressor is installed outdoors or if the ambient temperature can be below 0˚C (32˚F), precautions must be taken. In this case, and also if operating at high altitude, consult your supplier. Moving/lifting Figure 30: Transport by a pallet truck Danger: For transport with a fork truck, use the openings in the frame.
  • Page 44 Instruction book Figure 31: Lifting instructions Reference Description Spacer bars to protect the body Lifting straps: • Minimum length: 6 meter • ISO 4878 It is recommended to position the lifting straps this way. 2920 7201 41...
  • Page 45 Instruction book Installation proposal Figure 32: Installation proposal Reference Description Main power switch for the compressor (three-phase). Power supply cables need to be protected by suitable conduit. Compressor Dryer 1. Install the compressor on a solid, level floor suitable for taking its weight. The recommended minimum distance between the top of the unit and the ceiling is 2 m (78.7 in).

  • Page 46: Dimension Drawings

    Instruction book 3. Install the inlet grids and ventilation fan in such a way that any recirculation of cooling air to the compressor or dryer is avoided. The air velocity to the grids must be limited to 5 m/s (200 in/s). The required ventilation capacity to limit the temperature of the compressor room can be calculated from the following formula: = 0.92 N / ΔT...

  • Page 47: Electrical Connections

    Instruction book Dimension drawing Model 9828 0832 60 Floor-mounted 9828 0832 61 Tank-mounted 9828 0832 63 Tank-mounted with dryer Text on drawings Translation or explanation Emergency stop switch Emergency stop switch Power supply Power supply Cooling air and compressor inlet Cooling air and compressor inlet Cooling air outlet of compressor and motor Cooling air outlet of compressor and motor...
  • Page 48 Instruction book When the compressors leave the factory, the units are connected for 230 V / 3 phase. To modify the wiring for an operating voltage of 208V or 460V, the main cubicle should be rewired as described below: 2920 7201 41...
  • Page 49 Instruction book Figure 33: 208/230/460V 60Hz 1. Adjust the motor overload (FM1) setting. 2920 7201 41...
  • Page 50 Instruction book 2. Control transformer (T1) – Move the primary connection from 230V to the desired voltage. 3. Replace the control fuses (F1) 10.3 x 38mm with the ones provided (see further). Use 1A fuses for 460V or 2A for 208V 4.

  • Page 51: Pictographs

    Instruction book Terminal bridges (1) can be removed using a pair of pliers. Additional terminal bridges are provided with the compressor. Voltage stickers: Locate the yellow voltage labels provided with the compressor. Replace the existing label with the appropriate voltage label (208V, 230V or 460V). Pictographs Reference Description...
  • Page 52 Instruction book Reference Description Warning: hot parts With all bodywork panels in place, push the start button. • If the sheet is pulled downwards: • Stop the compressor immediately and switch off the voltage. • Reverse two incoming electric lines and repeat the previous step. •...

  • Page 53: Operating Instructions

    Instruction book Operating instructions Initial start-up Safety Warning: The operator must apply all relevant safety precautions. General preparation Figure 37: Air receiver port Figure 38: Condensate drain 2920 7201 41...
  • Page 54 Instruction book Figure 39: Condensate drain valve on air receiver 1. Consult the installation instructions (see Installation proposal). 2. Check that the electrical connections correspond to the local codes. The installation must be earthed and protected against short circuits by fuses in all phases. An isolating switch must be installed near the compressor.
  • Page 55 Instruction book Start-up Figure 41: Start-up sheet (5) 1. Affix sheet (5) (explaining the procedure for checking the motor rotation direction) to the cooling air outlet of the compressor. Consult section Dimension drawings. 2. Switch on the voltage. Press the start button. 3.

  • Page 56: Starting

    Instruction book Starting Starting the compressor Figure 42: Automatic drain Figure 43: Condensate drain valve on air receiver Figure 44: Position of oil sight glass and filler plug 2920 7201 41...
  • Page 57 Instruction book Figure 45: Control panel 1. Before starting, check the oil level in accordance with step 5. 2. Switch on the voltage. 3. Open air outlet valve. 4. Push the start button (7). On compressors with a star-delta starter, the drive motor switches over from star to delta 4 seconds after starting.

  • Page 58: Stopping

    Instruction book Stopping Figure 46: Condensate drain valve on air receiver Figure 47: Control panel 1. Push the start/stop button (7) on the controller. The compressor will unload. When the unload time has elapsed, the compressor is stopped and the controller goes back to the main screen. To stop the compressor immediately in the event of an emergency, press button (S3), see section Control panel.

  • Page 59: Taking Out Of Operation

    Instruction book Taking out of operation Figure 48: Condensate drain valve on air receiver Figure 49: Oil filler plug Procedure This procedure should be carried out at the end of the compressor’s service life. 1. Stop the compressor and close the air outlet valve (2). 2.

  • Page 60: Maintenance

    Instruction book Maintenance Preventive maintenance schedule Warning Warning: Before carrying out any maintenance, repair work or adjustments, proceed as follows: • Stop the compressor. • Switch off the voltage and open the isolating switch. • Close the air outlet valve and open the manual condensate drain valves. •...
  • Page 61 Instruction book Running Period (1) Action hours (1) Clean the air filter. Clean the condenser battery on the dryer (if fitted). 3–monthly 500 (2) Clean the dirt collection filter. Check the electrical cables. Make sure that the supply cables are permanently fixed. “...

  • Page 62: Drive Motor

    Instruction book Important Danger: Always consult your supplier if a timer setting has to be changed. Danger: For the change interval of oil and oil filter in extreme conditions of temperature, humidity or cooling air, consult your supplier. Danger: Any leakage should be attended to immediately. Damaged hoses or flexible joints must be replaced.
  • Page 63 Instruction book Procedure Figure 50: Location of oil filter and separator 1. Run the compressor until warm. Stop the compressor, close the air outlet valve and switch off the voltage. See Stopping. 2. Depressurize the air receiver by opening drain valve (8). 3.

  • Page 64: C/G Filter Change

    Instruction book C/G filter change Figure 51: Oil filler plug Figure 52: Condensate drain valve on air receiver Reference Description Oil filler plug Drain valve 2920 7201 41...
  • Page 65 Instruction book Figure 53: Line filters Figure 54: Line filters 2920 7201 41...

  • Page 66: Storage After Installation

    Instruction book Reference Description Air hose (from air receiver) Ball valve (to isolate the filters and dryer) Pre-filter (G type) head G filter housing. This coarse filter cleans the incoming air to the refrigerant dryer from dust and oil mist. Post filter (C type) head C filter housing.
  • Page 67 Instruction book Also a full range of extensively tested lubricants, suitable for your specific needs is available to keep the compressor in excellent condition. Consult the Spare Parts List for part numbers. 2920 7201 41...

  • Page 68: Adjustments And Servicing Procedures

    Instruction book Adjustments and servicing procedures Air filter Replacing the air filter Figure 55: Air filter 1. Stop the compressor, close the air outlet valve and switch off the voltage. 2. Remove the front panel and the top panel of the compressor housing. 3.

  • Page 69: Coolers

    Instruction book Coolers 1. Keep the oil cooler (Co) clean to maintain the cooling efficiency. 2. Stop the compressor, close the air outlet valve and switch off the voltage. Remove any dirt from the oil cooler (Co) with a fibre brush. Safety valve Location Figure 56: Condensate drain valve...
  • Page 70 Instruction book Figure 57: Oil filler plug Testing The valve can be tested on a separate compressed air line. 1. Before removing the safety valve, stop the compressor (see section Stopping), close the air outlet valve and switch off the voltage. 2.

  • Page 71: Belt Set Exchange And Tensioning

    Instruction book Belt set exchange and tensioning Location of parts Danger: Read the warning in section Preventive maintenance. Checking the belt tension 1. Stop the compressor, close the air outlet valve and switch off the voltage. 2. Remove the front door and the internal panel. 3.
  • Page 72 Instruction book Adjusting the tension of the drive belts 1. Stop the compressor, close the air outlet valve and switch off the voltage. 2. Remove the front door, the internal panel, the top cover and the pulley protection. 3. Loosen the 4 bolts (2) by one turn. 4.
  • Page 73 Instruction book 1. Stop the compressor, close the air outlet valve and switch off the voltage. 2. Remove the front door, the internal panel, the top cover, the pulley protection and the left side panel. 3. Loosen the 4 bolts (2) by one turn. 4.

  • Page 74: Problem Solving

    Instruction book Problem solving For the location of the components, see sections: • Introduction • Air dryer • Operating instructions Attention Warning: Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability. Apply all relevant Safety precautions during maintenance or repair.
  • Page 75 Instruction book Condition Fault Remedy Inlet valve (IV) does not fully Have valve checked open Oil separator (OS) clogged Replace separator element Safety valves leaking Replace valves Check for cooling air restriction or improve ventilation of Insufficient cooling air or Air outlet temperature above compressor room.

  • Page 76: Technical Data

    Instruction book Technical data Electric cable size Attention Danger: The voltage on the compressor terminals must not deviate more than 10% from the nominal voltage. It is however highly recommended to keep the voltage drop over the supply cables at nominal current below 5% of the nominal voltage.

  • Page 77: Settings For Overload Relay And Fuses

    Instruction book Settings for overload relay and fuses 7.5 kW 11 kW 15 kW 10hp 15hp 20hp Frequenc Voltage Setting Main Setting Main Setting Main y (Hz) overload fuses overload fuses overload fuses UL/cUL relay FM1 (class J relay FM1 (class J relay FM1 (class J...

  • Page 78: Compressor Data

    Instruction book Compressor data 5.5kW / 7.5HP 7.5kW / 10HP Compressor type 11kW / 15HP 15kW / 20HP Frequency 50/60 Maximum (unloading) pressure IEC units bar (e) Maximum (unloading) pressure IEC units Nominal working pressure bar (e) 12.5 Nominal working pressure Setpoint, thermostatic valve ˚C Setpoint, thermostatic valve...
  • Page 79 Instruction book ˚C Temperature of air leaving outlet valve (ambient +) approx., tank mounted units. ˚F ˚C Temperature of air leaving outlet valve (ambient +) approx., floor mounted units. ˚F Temperature of air leaving outlet valve (ambient ˚C +) approx., units with dryer. ˚F Frequency 60 (UL/cUL)

  • Page 80: Instructions For Use

    Instruction book Instructions for use Oil separator vessel The vessel can contain pressurized air. This can be potentially dangerous if the equipment is misused. This vessel must only be used as a compressed air/oil separator tank and must be operated within the limits specified on the data plate.

  • Page 81: Guidelines For Inspection

    Instruction book Guidelines for inspection Guidelines On the Declaration of Conformity / Declaration by the Manufacturer, the harmonised and/or other standards that have been used for the design are shown and/or referred to. The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is supplied with this compressor.

  • Page 82: Pressure Equipment Directives

    Instruction book Pressure equipment directives Components subject to Pressure Equipment Directive (PED) Components subject to 2014/68/EU PED or Pressure Equipment (Safety) Regulations 2016 - S.I. 2016/1105 greater than or equal to category II: Overall rating The compressors conform to PED smaller than category II. 2920 7201 41...

  • Page 83: Declaration Of Conformity

    Instruction book Declaration of conformity Figure 58: Typical example of a Declaration of Conformity document Contact address: C. Aria C. S.R.L. Via Selva Maiolo, 5/7 Montecchio, Maggiore, Vicenza Italy Applicable directives Standards used On the Declaration of Conformity / Declaration by the Manufacturer, the harmonized and/or other standards that have been used for the design are shown and/or referred to.
  • Page 86 Technology you can trust www.mark-compressors.com...

This manual is also suitable for:

Msu 15Msu 20

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