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MCi 40-50 - 04 - GB Fini
MCi 40-50 - 04 - GB Fini
INDEX
STANDARD SUPPLIES
The following accessories are supplied with your compressor:
• user and mainteance manual,
• line tap + flexible connection pipe and Teflon strips
• 1 panel opening spanner
• condensate/oil discharge pipe
Always check that these accessories are present, claims successive to delivery will not be accepted.
• The company in which the compressor is to be installed must appoint a person in charge of the compressor itself.
Controls, adjustments and maintenance interventions are under his responsibility: if this person must be replaced, the substitute
must read the user and maintenance manual and any notes made regarding technical and maintenance interventions carried
out up to this time.
Obligation symbols
Pressurised container
Maintenance in progress
read this page carefully before carrying out any intervention on the compressor
compressor.
Ensure that the environmental working temperature is between +5 and + 45 ºC.
The compressor must be installed and used in an environment that is not potentially explosive and in the absence of flames.
Leave at least 80 cm free between the compressor and the wall; so as not to obstruct the air passage to the motor fan.
The emergency button placed on the bridge must only be used in the cases of real necessity to prevent injury to persons or
damage to the machine.
In the case of intervention and/or consultancy request always specify the model and serial number stated on the CE label.
Always follow the maintenance programme in the manual.
DO NOT:
Do not touch the internal components or pipes as they reach high temperatures during functioning and remain hot for a
period of time after shutdown.
Do not position inflammable, nylon or textile objects near to and/or on the compressor.
Do not transport the compressor with the tank pressurised.
Do not use the compressor if the power supply cable is faulty or the attachment is precarious.
Do not use the compressor in damp, dusty environments.
Never direct the jet of air towards persons or animals.
Do not allow anyone to use the compressor that has not received adequate training.
Do not strike the fans with contusive or metal objects as they could cause sudden breakage during functioning.
Do not allow the compressor to function without the filter and/or air pre-filter.
Do not tamper with safety and adjustment devices.
Never allow the compressor to function with the hatches/panels open or removed.
1
L
D
E
C I
F
H
G
A
N
External view
A. Electrical-command bridge appliance compartment
B. Front panel
C. Cover
D. Radiator compartment
E. Rear panel
F. Suction compartment panel
Internal view
G. Screw compressor
H. Suction adjuster
I. Deoiler filter
L. Air suction filter
M. Deoiler tank
N. Electric motor
O. Air-oil radiator
350 cm (min)
to prevent, with the compressor functioning, that the
environmental temperature exceeds 45 °C. If it is not possible 100 cm 100 cm
to respect these conditions one or more suction devices must
be installed to convey the hot air. It is advised that they are
installed as high as possible. 120 cm (min)
350 cm (min)
nitive manner, assemble the supplied line tap and flexible pipe,
ensuring tightness using the Teflon strip.
Connect the compressor to the mains air distribution without
placing the non-return valve between the tank and the mains
distribution so as not to cause reading errors of the line
pressure.
1. Display: 4
displays information on compressor state.
2. Alarm indicator light: I 5
if the light switches on, consult the display to view cause of 1 O
6
alarm.
2
3. Emergency button: 7
this stops the compressor and should only be used in the
8
real event of an emergency.
4. Start button (ON): 9
starts the compressor.
5. Programmed stop button (OFF):
stops the compressor with programmed delay.
3
6. Menu button:
to view contents of the menu
7. Increase button
8. Decrease button
9. Reset/Enter button:
use after resolving causes of an alarm,
use to confirm set values,
use after maintenance to reset maintenance hour counter.
N.B. Before switching on, open the door of the electric equipment cabinet (A-fig.1) and check that the connectors behind the
electronic circuit card are properly on.
• When the compressor to the electricity supply is connected and the wall switch is in the I/ON position, pressure of the
transducer and compressor temperature are shown in the first line of the display and compressor state is shown on the second
line.
0 BAR 35°C
OFF
A relevant message appears instead if there is an alarm or programmed maintenance (see “Search Failures”)
Press
TYPE OF SERVICE
The compressor functions automatically by means of the pressure transducer. In fact on reaching the set maximum pressure
(stop pressure) it will start -up empty, i.e. it will start to function but without the production of air. In this way the mechanical parts
will not be stressed, and at the same time absorption peaks will be avoided. These derive from continuous switching-on and
off of the electric motor.
When the transducer detects a line pressure (start pressure) lower than the set value, the compressor will re-start to
compress the air.
The stand-by Timer is adjusted at 4 minutes: in these conditions the compressor will function with the motor always moving
and automatic shutdown will only occur after 4 minutes of non-withdrawal of compressed air.
• Factory settings: on purchase the compressor will be delivered with the following settings.
* The empty run time can be modified. In this case contact an authorised assistance centre.
SAFETY DEVICES
SAFETY DEVICES (fig.5)
vista posteriore - back side Aria - Air vista anteriore - front side 6
Olio - Oil
12
12 13 8
2 1 3
4
11
5
9
7
9
6/10
• During commissioning, the motor starts powered by the “star” connection. In this phase the compressor starts up
slowly, the electrovalve (1) is open, the suction adjuster (2) is closed.
• The compressor remains in these conditions for about 4 seconds.
• When this time has passed, the motor is fed by “triangle”. The electrovalve (1) receives current and closes allowing the
opening of the suction adjuster (2), which sucks atmospheric air through the air filter (3).
• In this phase the compressor functions in normal working conditions and starts to compress air inside the deoiler tank
(4).
• The compressed air cannot escape through the minimum pressure valve (5) which is adjusted at 3.5÷4.5 bar.
• The compressed air compresses the oil inside the tank (4) and forces it to flow towards the thermostatic valve (6).
If the oil temperature is lower than 80°C, the oil is sent directly to the screw compressor.
If the oil temperature exceeds 80°C the thermostatic valve closes the passage and the oil, by means of the oil delivery pipe
(7), goes to the radiator (8).
The cooled oil returns to the screw compressor through the oil return pipe (9).
• Transiting through the oil filter (10) the oil reaches the compressor, through the connection pipe (11), and mixing with
the aspired air creates an air/oil mix that guarantees tightness and lubrication of moving parts.
• The air/oil mix returns to the tank (4), where the air undergoes centrifugal pre-separation and definitive separation from
the oil, by means of the deoiler filter (12).
• Therefore, only air exits from the tank (4), which through the piping (13) reaches the radiator (8) and through the line tap
goes to the distribution network.
• The minimum pressure valve (5) acts as a non-return valve.
• The compressor sends the compressed air to the external air tank.
• The internal pressure of the tank rises to the maximum calibration value.
• On reaching the maximum set level, the pressure sensor sends a signal that starts the timer and removes current from
the electrovalve(1).
• The adjuster (2) closes and the compressor stops compressing and enters empty run.
• The timer continues to count up to the set value. On reaching this value, if there has been no pressure variation, it
commands shutdown of the electric motor. If the pressure has descended to the minimum set value (start P), before the timer
has finished counting, the electrovalve (1) receives current and closes, the adjuster (2) opens and the compressor re-starts
normal loading; the timer is zeroed.
• This cycle is repeated automatically.
SHUTDOWN
Normal shutdown
Press O :
“COMPRESSOR IN VACUUM MODE” will appear,
after about 30 seconds it will change to “OFF”.
At this point place the line switch at 0/OFF to put the machine in
total safety conditions.
The compressor could shutdown following interruption of the electric power supply line.
• In the case of micro-interruptions, the warning light 2 (see fig.4) will light up and “PHASE MISSING” will appear on the
display
press and “OFF” will appear,
press I to re-start.
• If longer interruptions occur, it is recommended to place the line switch in the 0/OFF position and wait for the current to
return.
Emergency shutdown
Only use the emergency button 3 in extreme cases (see fig.4). In this case place the line switch immediately in the 0/OFF
position, eliminate the cause leading to the emergency and ONLY AFTER, re-arm the emergency button. Successively, press
. Re-start by pressing I .
Maintenance table
• 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.
• In order to assure the correct functioning of the compressor, the following items must be checked after the first one
hundred hours of operation:
Oil level: refill, if needed, with the same type of oil.
Make sure that the screws are still tightly screwed: in particular those of the high voltage electrical contacts.
Check to make sure, visually, that all of the connecting parts are still firmly in place.
Check the air temperature of the immediate area.
“MOTOR OVERLOADED” 1. Excessive load. 1. Control the work pressure and check
compressor blocked calibration of motor protection relay. Carry out new
calibration if necessary.
2. High environmental temperature 2. Provide good air circulatio in order to maintain
the temperature below 45°C.
3. Low line voltage 3. Control voltage.
“INVERTED PHASE” Inverted wire phases Invert the phases (see “Commissioning” page 11).
compressor blocked
“HIGH PRESSURE” 1. Pmax value too high 1. Check the value and modify if necessary.
compressor blocked 2. The suction adjuster does not 2. Check that current is removed from the
close at cycle end. electrovalve and that the sealing plug opens regularly.
If necessary, disassemble and clean the suction
adjuster.
3. Deoiler filter blocked 3. Replace the deoiler filter.
4. Line tap closed 4. Open the tap.
5. Minimum pressure valve blocked 5. Control and clean the valve, if necessary
. replace the seal.
“EMERGENCY STOP” Emergency switch intervention Remove the cause that lead to emergency shutdown
compressor blocked
“LINE MISSING” No power supply. Check the power supply line, if it is an external power
compressor blocked cut wait for the power supply to return.
ONCE THE PROBLEM THAT CAUSED BLOCKING HAS BEEN SOLVED, PRESS .
High oil consumption. 1. Faulty draining. 1. Control drainage pipe and the unidirectional
valve.
2. Oil level too high. 2. Check the oil level and discharge if necessary.
3. Replace the deoiler filter.
3. Deoiler filter broken. 4. Replace the seals
4. Deoiler filter seal not tight. .
Oil leak from suction filter The suction adjuster does not close Check the suction adjuster and the electrovalve
in emergency stop phase
The compressor does not 1. The suction adjuster is closed and 1. Check opening, if necessary disassemble
compress air does not open because dirty. and clean.
2. The suction adjuster is closed and 2. Check electrovalve functioning, replace if
does not open due to lack of command. necessary.
3. The minimum pressure valve does
not close perfectly. 3. Disassemble the valve and clean it, replace
the seals if necessary.
Comp. does not re-start Low line voltage Check the mains voltage.
Presence of oil in the cabin Leak from pipes Tighten the connections and/or replace the damaged
piping
TECHNICAL DATA
Technical features MC40 -DMC40- KD40 MC50 -DMC50- KD50
Work pressure bar 8 10 13 8 10 13
Pumping unit type IKD100 IKD100
Dragging rotor rotation speed rpm 4550 4200 3700 5950 5600 4500
Air yield l/min 4500 4000 3400 5900 5200 4000
(ISO 1217 annex C)
Q.ty of oil l 15 15
Q.ty of top-up oil l 4,5 4,5
Final max. air overtemperature °C 5 10
Heat removed kJ/h 102600 126540
Fan capacity m3/h 5000 5000
Oil residue in the air mg/m3 4 4
Electric motor type 180LBB3 180LBB3
Nominal power kW 30 37
Max. power absorbed by the mains kW 34 42
Max. start-ups per hour n° 10 10
Environmental temperature limits °C 45 45
Sound pressure dB(A) 71 72
(Pneurop/Cagi PN2CPTC2)
Electrical data
Power supply voltage V/Hz 400/50-60 400/50-60
Secondary voltage V/Hz 24/50-60 24/50-60
Current absorption on start-up Amp 144 180
Max. current absorbed Amp 57 76
Current absorbed when empty Amp 29 32
Electric motor protection level IP 54 54
Insulation class F F
Factor services 1,2 1,2
Protection devices
Oil circuit max. temperature °C 110 110
Oil temperature pre-alarm calibration °C 105 105
Motor circuit breaker relay calibration Amp 36 44,5
Safety valve calibration bar 14 14
Dimensions
Length mm 1530 1530
Width mm 835 835
Height mm 1440 1440
Weight kg 595 615
Air exit Rp 1-1/4" 1-1/4"
16 Rotar MCi 40-50 - DMC 40-50 - KD 40-50 - Cod.197BB1000 - Rev.04 02/2010
WIRING DIAGRAM GB
PE ST BP
R1 R2 TR 24 1 FU2 2
6
S1 12 19 FU3 20
3 - + RS232
T1 S2 0 0
- - - - - - - - - - TX RX GND
M11
FU FU1 M5 M4 M3 M2
R2
S2 D
T2
M8 M7 M6 12Vac
1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 R S T GND
0
12 10 8
6
SF
IN2 IN1 0V 4 7 8 3 16 15 17 0 20
4 5 6
X4
X7 9 11 10 12
2
FR1 KM2 KM3
KM1 KM3 KM2 14 13
X12
X2 X2
KM1 KM3 KM2 EV
16 15 17
X0
FR1
w1 w2
M
v1
3 u2
0 2 2 4 7 12
u1 v2
MOTORE COMPRESSORE
COMPRESSOR MOTOR