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ITEM ‐1.16 
BLOWERS 
for  
AERATION TANK  
 
 
022‐MEK‐001/1‐2‐3 
 
 
 

Handbook for
Operation and Maintenance
of Compressor
KA5S-GK200
STC-GO (7-1-KA1KG)

SIEMENS Order no.

62008043

COMPRESSOR Serial no.

8043
8044
8045

PROJECT:

Energy Sector

Nevsehir WWTP

Siemens
Turbomachinery

Turbomachinery Equipment A/S

Allegade 2, DK-3000 Helsingør, Denmark
Tel.: +45 4921 1400 · Fax: +45 4921 5225

Siemens Turbomachinery Equipment A/S
Allegade 2, DK-3000 Helsingør, Denmark
Tel.: +45 4921 1400 · Fax: +45 4921 5225

HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 2/54

CONTENTS
Chapter 1 Operation of the compressor
§
0.

1.
1.1
1.2
1.3
1.3.1

2.

3.
3.1
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.3
3.3.1
3.3.2
3.3.3
3.3.4
3.4
3.5
3.6
3.7
3.8
3.9
3.10

EC Declaration of Conformity
Important
Machinery - Safety Requirements

930 940 083
930 940 077

Shipment - Storage - Installation
Shipment
Storage
Installation
Pipe Connect./Permissible Loads
Tech. Doc. "Allowable Load"
Tech. Doc. "Installation"

930 910 007
930 840 008

Technical Specifications
Technical Specifications for Compressor.
Tech. Doc. "Oil Specification"
Tech. Doc. "Oil Specification"

930 870 003
930 870 005

Unit Design
Main Construction
Compressor - Main Parts
Compressor Casings
Impeller/Rotor Shaft
Sealings
Diffuser System
Gearbox - Main Parts
Gear Casings
Shafts - Gearwheels
Bearings
Oil Sealing
Base
Cone Diffuser
Blow-off Valve
Check Valve
Coupling - Drive Motor/Gearbox
Inlet Silencer
Drawing
Inlet Filter

4.

Drive Motor
Reference to Manufacturers instruction

5.

Acoustic Enclosure

6.
6.1
6.2
6.3

Lubricating Oil System
Design and function
Oil filling
Oil Types
Accessories

7.
7.1
7.2
7.3
7.3.1
7.3.2

Control System
Local Control
PI-Diagram
Compressor Instability
Surge
Recirculation

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01-Operation_KA5S-GK200.doc

933 005 7240

935 004 939

HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

8.
8.1
8.2
8.3
8.4
8.5
8.6

Instrumentation
Thermostat E151
Thermostat E138
Thermostat E104
Thermostat E111
Pressostat E106
Surge Controller SUC-3, Drawing

9.
9.1
9.2
9.3
9.4
9.5
9.6

Start-up
Preparations
Simulated Test Run of Compressor
Test Run of Compressor
Master Control
Start
General

10.
10.1
10.2
10.3
10.4
10.5
10.6
10.7
10.8

Trouble Shooting
No Flow, no Pressure at Start
Insufficient Flow
Too Great Power Consumption
Surge / Recirculation
Noisy Operation / Vibration Level High
Bearing Temperature too high
Oil Pressure too Low
Oil Temperature too high

Page 3/54

933 0061480

Chapter 2 Maintenance of the compressor
11.
11.1
11.2
11.3
11.4
11.5
11.6
11.7
11.8

Maintenance
Introduction
Service intervals
Service
Simulated Test Run
Test Run of Compressor
Master Control Panel
Inlet Silencer
Disposal of waste
Orders for spare parts

12.

Dismounting and Mounting

12.1
12.2
12.3

Tech. doc. Coupling Alignment
Outer diffuser System
Adjustment of Clearances and axial play
Tech. doc. Internal Gaps
Weight of single parts
Special tools
Tightening torque
Dismounting and remounting drawings
Compressor-gearbox, drawing
Rotor drawing
Outer diffuser System drawing
Inner diffuser System drawing
Lube oil pump drawing
Aggregate drawing

12.4
12.5
12.6
12.7
12.8.1
12.8.2
12.8.3
12.8.4
12.8.5
12.8.6

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01-Operation_KA5S-GK200.doc

930 920 041UK

930 920 036UK

9330502950
9330523220
9330554160
9330554180
GK200S017
9330503140

HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 4/54

Chapter 3 Dimension Drawing
Dimension drawing

Chapter 4 Local Control Panel
Operation Manual
Circuit diagram LC-1AT

Chapter 5 Master Control Panel
Operation Manual
Circuit diagram MCP-3T

Chapter 6 Main Motor
Operating instructions for Schorch motors

Chapter 7 Acoustic Enclosure
Mounting instructions for Acoustic Enclosure
Acoustic Enclosure, drawing

Chapter 8 Accessories
Coupling
Blow off Valve
Actuator for Blow off Valve
Check Valve
Actuators for Diffuser
Lube Oil Filter
Lube Oil Cooler
Air Filter Bags
Thermostats
Pressostat
Thermometer
Manometer
Surge Detector
Compensator
Cone Diffuser
Silencer for Blow of valve
Noise hood Fan

Chapter 9 Performance Certificates
Compressor test certificate

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01-Operation_KA5S-GK200.doc

no.14541

HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

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01-Operation_KA5S-GK200.doc

Page 5/54

HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 6/54

IMPORTANT (TECH.DOC. 930940077UK)
This compressor unit is a high-capacity machine. If not operated correctly it will be damaged and also
expose the personnel in the immediate vicinity of the machine or the electric wiring to hazards.
The Instruction Handbook shall be studied entirely prior to final installation, electric connection, and start-up. Especially, note the following sections.

Safety of Machinery:

See the handbook, § 0

Installation:

(See the handbook)

Direction of Rotation:

Note that even a minor period of operation in the wrong direction
of rotation will damage the bearings in gear and compressor.
(See the handbook)

Coupling:

Check of alignment before start.
(See the handbook)

Re-tightening:

After about 10 operating hours
the coupling bolts shall be re-tightened.
(See the handbook)

Oil Check:

SIEMENS recommends having the oil analyzed after approx. 500
operating hours, and then to decide the intervals of oil change on
the basis of regular oil analyses.
(See the handbook)

Electric motors

Grease lubricated bearings in electric motors must be lubricated
immediately after start-up of the unit. Correct type and quantity of
grease as well as frequency are stated on the motor nameplate
and/or in motor supplier's instruction.
In case of oil lubricated bearings in electric motor, oil quality and
oil level should be checked before start-up.
The customer is obliged to and responsible for compliance with
the lubrication instructions.

In case of defects, damage, or faulty delivery, the supplier shall be notified immediately.

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01-Operation_KA5S-GK200.doc

HANDBOOK FOR
OPERATION AND MAINTENANCE

0.

COMPRESSOR KA5S-GK200

Page 7/54

MACHINERY SAFETY REQUIREMENTS

PUTTING INTO
SERVICE

The compressor unit shall only be operated in compliance with the
operating conditions agreed upon, as indicated on the nameplate
and described in Technical Data.

LIFT

The weight of the compressor unit is stamped on the consignment.
Lifting is carried out according to Instruction Concerning Straps.

The compressor is started from the local panel.
START BY
MANUAL CONTROL See operation manual for Local Control Panel.

The compressor is stopped from the local panel.
STOP BY
MANUAL CONTROL See operation manual for Local Control Panel.

EMERGENCY
STOP

An emergency stop (EN418) is positioned on the front of the local
control panel. The emergency stop is not to be activated unless
hazardous situations threaten or have already occurred. The safety
monitor activates the emergency stop function when a control device
is activated by a malfunction. All functions will stop immediately. Under these circumstances the compressor will emit a lot of noise. The
emergency stop shall not be used as an ordinary stop function, as
repeated emergency stops may damage the compressor.

AUTOMATIC
START/STOP

Compressor units may be set in remote control.
See operation manual for Local Control Panel and Master Control
Panel in section 4 and 5 of the Operation Manual.
In this mode the compressor can start and stop without forewarning.
An ISO 7000-0017 symbol warns of remote control start/stop. In this
mode all guards must be correctly mounted and no persons allowed
in the immediate vicinity of the rotating machine parts.

MECHANICAL
HAZARD

Fixed guards acc. to EN294 & EN953 shall protect all rotating parts.
The guards are not to be removed unless the machine is safeguarded against unintentional start. Loose clothing is to be avoided
and it is advisable to keep a safe distance as long as the machine is
in the remote control mode.
Do not mount the compressor; the surface may be greasy and slippery.

INLET SYSTEM

The inlet system shall be correctly mounted before start of the compressor. Avoid blocking the inlet and staying near connected inlet
channels when the machine is ready to start.

Created on 01-04-2009 at 15:30:27, LF
01-Operation_KA5S-GK200.doc

HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 8/54

HOT SURFACES

A sign warning of hot surfaces has been placed directly on the machine. It is indicated by symbol EN1012-annex 3. Avoid touching the
hottest surfaces, which are normally more than 70°C.

NOISE HAZARD

Noise emission from the compressor unit is measured acc. to
ISO3744, normally without silencer hood. The measurements are
recorded in the noise certificate. See certificates.
At the entrance to the compressor room and/or silencer hoods an
ISO3864 warning sign is placed which illustrates the use of ear protection.

ELECTRICAL
HAZARD

Any contact with electrical high-/low-voltage installations is to be
avoided as long as the machine is connected to the power supply.
See EN60204-1. Check at regular intervals that all main components
of the machine are correctly grounded.

SPECIAL TOOLS

The compressor delivery includes a toolbox with special tools. The
tools shall only be used as described in the paragraph on assembly
and disassembly of the compressor.

MAINTENANCE &
REPAIRS

Repairs and maintenance work is only to be performed when all energy sources to the machine have been properly isolated/insulated.
The emergency stop shall be activated, the motor disconnected and
the terminals short-circuited. The danger of back flow from the pipe
system is safeguarded against by either closing and locking a valve
positioned immediately after the check valve or by placing a blind
flange upstream by the check valve.
Sign: "Warning: Maintenance work in progress".

NOTIFY!

In case SIEMENS deliver consignments that are neither assembled
nor serviceable machine units, e.g. compressor units without drive
motor and/or control systems, the following will apply:
"The compressor unit is comprehended by Machine Directive
89/392/EEC and appurtenant amendment directives, and shall not
be put into service until the entire unit, of which it is a part, complies
with the said Directive and appurtenant normative standards.

Created on 01-04-2009 at 15:30:27, LF
01-Operation_KA5S-GK200.doc

HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

1.

SHIPPING - STORAGE - INSTALLATION

1.1

SHIPPING

Page 9/54

On receipt of the compressor unit, check that the individual parts correspond with those
listed on the delivery note.
When unloading, check immediately for possible damage of the compressor unit that may
have happened during shipment, such as damaged dents, scratches, corrosion, torn electric
cables, bent pipes, or the like. In case of defects or damage, the carrier and supplier shall
be informed immediately.
The aggregate shall only be lifted with straps fastened to the 4 lifting hooks mounted on the
base. In order to avoid squeezing of instruments, piping, etc., use a lifting yoke.
Weight of compressor aggregate: See section 2.
Use of straps: See fig. below.

1.2

STORAGE
Prior to leaving SIEMENS, the compressor aggregate has been submitted to a test run.
After the test the lubricating oil has been drained off, preservative oil applied and pumped
through the lubricating oil system, and all excess preservative oil drained off. All untreated
parts of the aggregate, which are likely to corrode, have been treated with a corrosionpreventing agent.

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01-Operation_KA5S-GK200.doc

HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 10/54

This ensures that the compressor aggregate is protected against corrosion for a minimum of
6 months, provided that it is stored indoors. It is not necessary to remove the corrosionpreventing agent before starting up the aggregate, as the preventive agent does not affect
the lubricating oil.
If the compressor is stored for more than 6 months, it shall be treated with a long-term
preventive agent. A corrosion-preventing agent used for long-term storage will have to be
removed before start-up. This is done by disassembling and cleaning all the compressor
parts. In this case only SIEMENS service engineers shall prepare the compressors for
operation. The preparation shall be carried out in a dry and clean environment.
Do not use the compressor unit or parts of it as scaffolding. For further information, require
technical information 930920009UK.

1.3

INSTALLATION
It is possible to mount / install the compressor prior to removing a long-term corrosion
protection. The compressor can be mounted on any level floor that can carry the weight. A
special vibration damping concrete foundation is only used in exceptional cases.

The compressor shall be mounted on
vibration damping machine mounts, the
underside of which can be glued directly to
the concrete floor (see mounting
instructions) or the machine mounts can
be screwed or welded to its base,
depending on the floor construction. In
case of uneven floor construction insert
shims in order that the machine mounts
get in touch with the floor (see fig.).

Important! Before the compressor aggregate is fastened to the floor, check its position to
make sure that flanges (and possibly other pipe connections) are placed correctly with a
view to the final pipe installation. Do not uncover the flanges until the pipe system is ready
for installation. This prevents foreign substance from entering the compressor. All pipe
systems shall be cleaned and inspected before they are connected to the aggregate.
If the drive motor shaft has been securely fastened for shipping, this fastening shall be
removed and the dismounted coupling remounted.

1.3.1

PIPE CONNECTIONS/PERMISSIBLE LOADS
It is essential that there is a flexible connection in the following places:
- between compressor discharge and cone diffuser
- between compressor inlet and air inlet duct.
Permissible loads: See Technical Information 930910007.UK.

Created on 16-02-2009 at 16:00:35, LF
01-Operation_KA5S-GK200.doc

HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 11/54

ALLOWABLE LOAD ON COMPRESSOR DISCHARGE FLANGE
930910007UK

Reactions of piping systems connected to turbocompressors, if of sufficient magnitude, will result in
misalignment of the compressor sufficient to cause rough operation and in worst case serious
mechanical damage.
The external load comes from thermal expansion, pressure loads the weight of the pipe system, and is
mainly transmitted to the compressor through the expansion joint, attached on the discharge flange.
If the external loads on the compressor are limited to the figures in the table below, the loads should
not influence the compressor operation.

FAX
FLAT
M

TYPE
KA2
KA5
KA10
KA22
KA44
KA66
KA80
KA100

=
=
=

Forces in the discharge pipe direction
Forces perpendicular to FAX
Moment in any direction

FAX
N
1100
2700
4000
5500
7600
10000
13500
17500

FLAT
N
330
800
1200
1600
2200
3000
4000
5000

M
NM
65
225
350
600
900
1500
2000
3500

The pipe system must be supported thus minimizing the external loads.
The allowable loads, alignment tolerances etc. of the flexible joint positioned at the discharge flange,
must be carefully considered, when designing the pipe system.
The external loads on the compressor are transmitted through the base to the machinery supports and
must be included when sizing the supports.
For further information, see the standards NEMA SM23-1985, section 9.4 and API 672, section 2.2.3
and 2.3.4.

Created on 16-02-2009 at 16:00:35, LF
01-Operation_KA5S-GK200.doc

HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

INSTALLATION 930840008UK

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01-Operation_KA5S-GK200.doc

Page 12/54

HANDBOOK FOR
OPERATION AND MAINTENANCE

2.

COMPRESSOR KA5S-GK200

Page 13/54

TECHNICAL SPECIFICATIONS
UNIT
Serial No.
Year
Weight, approx.
Dimension Drawing

:
:
:
:

8043, 8044, 8045
2009
2360 kg
14541

:
:
:
:
:
:
:
:
:
:
:
:

Siemens
KA5S
Air
3943 m³/h
8762 m³/h
0.898 bar abs.
1.590 bar abs.
10,4°C
25,2°C
18952 rpm
92.7 kW
184.2 kW

COMPRESSOR - Pos. No. K100
Make
Type
Medium flow
Inlet flow, min.
Inlet flow, max.
Inlet pressure
Discharge pressure, max.
Inlet temperature, normal
Inlet temperature, max.
Revolutions
Power consumption, min.
Power consumption, max.

The power is indicated at min./max. inlet flow, inlet pressure normal and inlet temperature normal

GEAR - Pos. No. G100
Make
Type
Gear ratio
Oil requirement

:
:
:
:

Siemens
GK200
172 / 27
14 litres / min

:
:
:
:
:
:
:
:
:

Schorch
KN7 315M-AB01B-Z
860 kg
F/B
IP 23
200 kW
50 Hz
400 V
2975 rpm

DRIVE MOTOR - Pos. No. A401
Make
Type
Weight
Insulation class
Degree of protection
Power, nominal
Mains frequency
Voltage
Revolutions

COUPLING (Motor/Gear)- Pos. No. A301
Make
Type

Created on 16-02-2009 at 16:00:35, LF
01-Operation_KA5S-GK200.doc

: Rexnord Thomas
: SR52-MSH-225

HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 14/54

LINEAR MOTOR - Diffuser - Pos. No. D224
Make
Type
Pull-/push power
Max. length of stroke
Velocity
Degree of protection
Mains frequency
Voltage

:
:
:
:
:
:
:
:

Framo Antriebtechnik
Unipush - Mini 0
1000 N
100 mm
2.7 mm/s
IP 54
50 Hz
1 x 230 V

Mechanical oil pump – Pos. No. S129
Make
Type

:
:

SIEMENS
Integrated in gearbox

OIL FILTER - Pos. No. S303
Make
Type

:
:

FBO
FRCA 60/1

OIL COOLER (AIR-COOLED) - Pos. No. S301
Make
Type

:
:

Oil Tech
LAC2-011-2-D

:
:
:
:
:
:
:
:

Oil Tech
3000
F
IP 54
50
3 x400
1.1

FAN MOTOR
Type
Make
Revolutions
Insulation class
Degree of protection
Main frequency
Voltage
Power

AIR INLET FILTER - Insert - Pos. No. L102
Make
Type
EU-class DIN 24185
Filter clean/replace at max.
Manometer Pos. No. E137

Created on 20-03-2009 at 11:33:47, LF
01-Operation_KA5S-GK200.doc

:
:
:
:

Camfil
Pocket filter
G4
+ 20 mm WC

rpm

Hz
V
kW

HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 15/54

LUBRICATING-OIL PRESSURE
Min.
Normal operating pressure, approx.

:
:

0,8
1,0 – 1,2

bar
bar*

* The oil pressure depends on temperature and load
MANOMETER Pos. No. E121

LUBRICATING-OIL TEMPERATURE
Max.
Normal operating temperature

:
:

80°C
55 - 75°C

Thermometer - Pos. No. E122

LUBRICATING OIL
Normal filling, see enclosure:
OIL SPECIFICATION, SIEMENS Tech. Info. 930.870.003 (2 pages)
Lubricating oil types, see enclosure:
OIL SPECIFICATION, SIEMENS Tech. Info. 930.870.005 (1 page)
- both inserted after "TECHNICAL SPECIFICATIONS".
OIL RESERVOIR IN GEAR - Pos. No. G100
Normal filling

:

35 litres

FAN FOR SILENCER HOOD
Make
Type
Flow
Degree of protection
Mains frequency
Voltage
Power
Speed

:
:
:
:
:
:
:
:

EMB Papst
W4D500-DD03-02
9,000 m3/h
IP 54
50 Hz
400 V
0.83 kW
1360 rpm

THERMOSTAT - Pos. No. E151
Make
Type
Sensor
Function
Set point
Difference

Created on 20-03-2009 at 11:33:47, LF
01-Operation_KA5S-GK200.doc

:
:
:
:
:
:

Danfoss A/S
RT103
In air at compressor panel
Start / Stop of Ventilator fan
30
°C
Minimum

HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 16/54

THERMOSTAT - Pos. No. E104
Make
Type
Sensor
Function

:
:
:
:

Set point
Difference

:
:

Danfoss
RT 107
In oil reservoir
Stops compressor at high oil
temperature
80°C
Minimum

THERMOSTAT - Pos. No. E111
Make
Type
Sensor
Function

:
:
:
:

Set point
Difference

:
:

Danfoss
RT 101
In oil reservoir
Stops compressor at recirculation
(high inlet air temperature)
65°C
Minimum

:
:
:
:
:
:

Danfoss
RT 110
In the gearbox oil lubrication system
Stops compressor at low oil pressure
0.8 bar
Minimum

:
:
:
:
:
:

Danfoss
RT 101
In oil reservoir
Start/stop of oil cooler fan
50°C
Minimum

:
:
:
:

Siemens
SUC-3
In compressor's inlet
Stops compressor at surging

Pressure Switch - Pos. No. E107
Make
Type
Sensor
Function
Set point
Difference

THERMOSTAT - Pos. No. E138
Make
Type
Sensor
Function
Set point
Difference

SURGE DETECTOR - Pos. No. E113
Make
Type
Sensor
Function

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01-Operation_KA5S-GK200.doc

HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 17/54

BLOW-OFF VALVE - Pos. No. P106
Make
Type / size
Function

:
:
:

Wouter Witzel
Euronomic / DN100
Pressure relief during

:
:
:
:
:
:
:
:

Bernard
OA6
F
IP 67
50 Hz
400 V
0.03 kW
6 sec

:
:
:

Cast Flow
GNECVB
DN350

:
:

STE
DN100

:
:
:

STE/Bredan
Steel
DN150

:
:
:

STE
Cone diffuser
DN150/350 – 1100mm

ACTUATOR FOR BLOW-OFF VALVE
Make
Type
Degree of protection
Insulation class
Mains frequency
Voltage
Power
Operating time (90°)

NON RETURN CHECK VALVE
Make
Type
Size

SILENCER FOR BLOW-OFF VALVE
Make
Size

COMPENSATOR- Pos. No. P102
Make
Type
SIZE

CONE DIFFUSER - Pos. No. P116
Make
Type
SIZE

Created on 31-03-2009 at 12:44:43, LF
01-Operation_KA5S-GK200.doc

start/stop

HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 18/54

OIL SPECIFICATIONS (TECH.DOC. 930870003UK)

VISCOSITY
INDEX MIN.
ISO 2909

VISCOSITY
MIN. at 120°C

FZG STAGE
MIN.
DIN 51354

4.20
4.20
4.20
4.20

10
10
10
10

COMPRESSOR

KA2-GK2
KA2-GK190
KA4-GK4
KA5-GK200

1986
2003
1982
1996

PAO 1
PAO
PAO
PAO

930870005
930870005
930870005
930870005

137
137
137
137

KA2-GL180
KA2-GB255
KA5-GA200
KA5-GA250
KA5-GL210
KA5-GL285
KA5-GB400
KA5-GC150

1999
1996
1987
1993
1992
1998
1997
1988

HL/HLP46
HL/HLP46
HL/HLP46
HL/HLP46
HL/HLP46
HL/HLP46
HL/HLP46
HL/HLP46

930870004
930870004
930870004
930870004
930870004
930870004
930870004
930870004

100
100
100
100
100
100
100
100

10
10
10
10
10
10
10
10

KA10-GA200
KA10-GL210
KA10-GA250
KA10-GC150

1986
1992
1987
1979

HL/HLP46
HL/HLP46
HL/HLP46
HL/HLP46

930870004
930870004
930870004
930870004

100
100
100
100

10
10
10
10

KA22-GA250
KA22-GL225
KA22-GL315
KA22-GC150
KA22-GC215

1983
1993
1989
1981
1981

HL/HLP46
HL/HLP46
HL/HLP46
HL/HLP46
HL/HLP46

930870004
930870004
930870004
930870004
930870004

100
100
100
100
100

10
10
10
10
10

KA44-GA250
KA44-GL225
KA44-GL315
KA44-GL400
KA44-GC215

1983
1993
1992
1995
1982

HL/HLP46
HL/HLP46
HL/HLP46
HL/HLP46
HL/HLP46

930870004
930870004
930870004
930870004
930870004

100
100
100
100
100

10
10
10
10
10

KA66-GL400
KA66-GC215

1992
1982

HL/HLP46
HL/HLP46

930870004
930870004

100
100

10
10

KA80-GL500

1990

HL/HLP46

930870004

100

10

KA100-GL500

1984

HL/HLP68

930870004

100

10

1

OIL TYPE
DIN 51502

SIEMENS
REFERENCIES

YEAR OF
CONSTRUCTION

PAO = Synthetic oil, polyalfaolifine

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OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 19/54

OIL PUMP CAPACITY AND OIL RESERVOIR

COMPRESSOR

KA2-GK2
KA2-GK190
KA4-GK4
KA5-GK200
KA2-GL180
KA2-GB255
KA5-GA200
KA5-GA250
KA5-GL210
KA5-GL285
KA5-GB400
KA5-GC150-EM
KA5-GC150-GM
KA10-GA200
KA10-GL210
KA10-GA250
KA10-GC150-EM
KA10-GC150-GM
KA22-GA250
KA22-GL225
KA22-GL315
KA22-GC150-EM
KA22-GC150-GM
KA22-GC215-EM
KA22-GC215-GM
KA44-GA250
KA44-GL225
KA44-GL315
KA44-GL400
KA44-GC215-EM
KA44-GC215-GM
KA66-GL400
KA66-GC215-EM
KA66-GC215-GM
KA80-GL500
KA100-GL500

2

YEAR OF
CONSTRUCTION

OIL PUMP CAPACITY
STANDARD LITER/MIN.

1986
2003
1982
1996
1999
1996
1987
1993
1992
1998
1997
1988
1988
1986
1992
1987
1979
1979
1983
1993
1989
1981
1981
1981
1981
1983
1993
1992
1995
1982
1982
1992
1982
1982
1990
1990

--- ----- ----- --14 2
44
58
58
82
58
82
170
58
58
58
58
108
58
58
82
82
170
58
58
82
82
82
82
170
120
82
82
170
108
108
235
235

Oil pump integrated in the gear.

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OIL RESERVOIR
LITER +/- 10%

6
13
19
35
230
230
230
300
230
300
570
230
150
230
230
300
230
150
330
330
570
230
150
500
330
330
330
570
480
500
330
680
500
330
1000
1000

HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 20/54

OIL SPECIFICATION (TECH.DOC. 930870005UK)
Specification of lubricating oils applicable for SIEMENS compressors with anti-friction bearings
(ball/roller bearings).

Turbochargers
Journal bearing gearboxes

Note:

}

Please see different specification

Supplier
Company

Oil type

BP

BP ENERGOL RC-S 46

TOTAL

DACNIS SH 46

ESSO

ESSO COMPRESSOR OIL RS32

Esso
Esso
Exxon

MOBIL

MOBIL SHC 624

Mobil
Mobil
Mobil

Q8

Q8 SCHUMANN 32

Kuwait Petroleum
Kuwait Petroleum
-----------------------

STATOIL

COMPWAY SX 32

Statoil
---------------------

SHELL

MADRELA AS 46

Shell
Shell
Shell

TRIBOL

TRIBOL 1550/32

Square Oil A/S
Tribol
Tribol

KLÜBER

KLÜBER SYNTH GEM 4-32

Klüber
Klüber
Klüber Lubrication

FUCHS

FUCHS COFRABAR P32

Fuchs
Fuchs
Fuchs

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BP
BP
BP
Total Fina Elf
Total Fina Elf
Total Fina Elf

Scandinavia
Europe
North America

HANDBOOK FOR
OPERATION AND MAINTENANCE

3.

UNIT DESIGN

3.1

MAIN CONSTRUCTION

COMPRESSOR KA5S-GK200

Page 21/54

The SIEMENS compressor consists of the following main parts:
Gearbox
Compressor
Coupling, motor/gearbox
Drive motor
Base
Diffuser Drive
Mech. Oil Pump

G100
K100
A300
A401
F101
D200
S129

Cone diffuser
Compensator
Blow off Valve
Check Valve
Oil cooler
Oil Filter
Local panel

The entire unit is built according to the drawing.
Individual parts placed outside the unit are not shown on the drawing.

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P101
P102
P106
P110
S301
S303
E123

HANDBOOK FOR
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3.2

COMPRESSOR KA5S-GK200

Page 22/54

COMPRESSOR
Main parts:
Inlet
Outer vol. casing
Inner vol. casing

H701
H401
H501

Inner diffuser
Pinion shaft
Impeller

D100
R201
R414

The SIEMENS compressor is a single-stage centrifugal compressor.
The passage of the medium through the compressor:
The medium is led through the inlet and past the inlet guide vanes to the impeller, which
speeds up the medium. From the impeller the medium is led through the diffuser (variable),
where most of the speed energy is changed into pressure, to the volute casing where it is
collected, and from there out into the cone diffuser where the speed is reduced before it is
led into the discharge system.

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HANDBOOK FOR
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3.2.1

COMPRESSOR KA5S-GK200

Page 23/54

COMPRESSOR CASINGS
The compressor casings, consisting of outer/inner volute casing and inlet are manufactured
from cast items that have been heat-treated, cleaned, and then machined. The casings
have been assembled vertically, in order to facilitate handling of the individual casings when
mounting or dismounting the compressor.

3.2.2

IMPELLER/ROTOR SHAFT
The rotor consists of the following main parts:
Impeller
Pinion shaft
Dowel
Stop ring
Special screw
Stop nut
Positioning dowel

R414
R201
R411
R409
R410
R412
R415

Rotor nut
Central screw
Rotor drive

R407
R405
R401

The impeller has been milled out in one forged, solid piece, ensuring great strength and
accuracy. The blades have been formed so as to ensure optimal control of the compressor
as well as an optimal and stable current flow. The outer contour and diameter of the
impeller have been specially adapted to the operating conditions defined in the order
specification.
The overhung design with the impeller positioned at the end of the pinion shaft secures an
operation well above first critical speed and well below second critical speed.
The impeller rotor can be removed from the unit by disassembling the impeller from the
pinion shaft. Note that the impeller is positioned on the outlet shaft by means of a screw.
Dismounting of the rotor: See section 12.
By means of hydraulic tools the impeller, the rotor shaft rod, and the rotor drive are held
together with the rotor and the central screw. The complete unit (rotor) has been balanced
dynamically.
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HANDBOOK FOR
OPERATION AND MAINTENANCE

3.2.3

COMPRESSOR KA5S-GK200

Page 24/54

SEALINGS
Consisting of:
- Labyrinth sealing
- Oil sealing ring

H303
T220

Air and oil shaft seals, made of aluminium, are non-contact types and designed to prevent
air and oil leakage, thus avoiding contaminating the air with oil. This type of sealing does
not get worn due to the clearance between the pointed sealings and the shaft. However, a
minor running-in wear may occur. The sealing prevents oil from entering into the
compressor. The chambers of the sealing ring are fitted with drains, through which the oil is
led back into the gear housing.

3.2.4

DIFFUSER SYSTEM
The compressor is equipped with one regulating system, a diffuser system. It can be
regulated continuously within the range of two limit switches. Even a small change of the
system setting will influence the ability of the compressor to make pressure and volume
flow, and consequently the power consumption of the compressor will be affected.
SIEMENS has developed a procedure, implemented in a process computer, to regulate the
diffuser system to an optimum, based on measurements of:
- inlet temperature
- differential pressure across compressor
- volume flow demand

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COMPRESSOR KA5S-GK200

Page 25/54

Any change of the system setting will cause increased power consumption or, at worst, that
the compressor starts to surge, which will release an emergency stop. If the system has
been disassembled, it must be assembled and adjusted exactly as it was before the disassembling.

ADJUSTABLE DIFFUSER SYSTEM
Main parts:
Guide ring
Diffuser blades
Positioning lever
Mounting plate

D108
D116
D205
D208

Limit switches
Scale
Linear motor *)

D210
D213
D224

The diffuser system consists of a number of adjustable vanes (optimized vanes) placed
radially around the periphery of the impeller. An electric linear motor regulates the diffuser
blades. A scale is mounted on the mounting plate for indication of the position of the blades.
Two limit switches have been installed, which - when activated - will signal the respective
MAX. and MIN. positions of the diffuser blades to the control panel.
The linear motor is controlled by the local control panel.

*)

See enclosed description

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COMPRESSOR KA5S-GK200

Page 26/54

The position of the limit switches shall not be altered, as this may cause overload of the
compressor/drive motor. A signal value for the exact position of the vanes can be obtained
by way of the built-in potentiometer in the linear motor.

3.3

GEARBOX
Main parts:
Gear casing part A
Gear casing part B
Drive shaft
Pinion shaft
Sealing ring

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H101
H102
R100
R200
T101

Deep groove ball bearing
Deep groove ball bearing
Angular contact ball bearing
Angular contact ball bearing
Oil pump, mech.

T103
T106
T208
T210
S129

HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 27/54

The SIEMENS GK200 gearbox is a single-stage, helical gear, where the pinion shaft is
placed above the drive shaft. The pinion shaft is supported by bearings on both sides of the
gearwheel. The gear ratio has been adapted to the operating conditions as specified in the
order.
The gearbox is vertically split for easy access to the shafts, bearings, and sealings.

3.3.1

GEAR CASING
The gear casing, consisting of part A and B, is manufactured from cast elements which
have been heat-treated, cleaned, and then machined.

3.3.2

SHAFTS - GEARWHEELS
Shafts and gearwheels have been carburized and ground with great accuracy, to allow for
the high speed and resulting stress on the teeth. A moderate backlash allows for oil film,
deformations, etc.
The gearwheel on the drive shaft has been shrunk on. The gearwheel on the pinion shaft
has been machined in one piece with the shaft.

3.3.3

BEARINGS
The pinion shaft is supported by angular contact ball bearings. Double bearings are used in
the compressor end, while single bearings are used in the motor end. The bearings are
pressure lubricated and cooled by an oil flow on the exterior bearing housing. The inlet shaft
is supported by deep groove ball bearings.

3.3.4

OIL SEALING
The sealing is a non-contact, labyrinth type sealing, which does not get worn due to the
clearance between the pointed sealings and the shaft. However, a minor running-in wear
may occur.
This sealing ensures that oil is not leaking from the gear.
Drains in the sealing chambers lead oil back into the gear casing.

3.4

BASE
The base is a welded box-like construction manufactured with frame of steel profiles and
steel plate. It serves additionally as base for all safety equipment and the local panel.

3.5

CONE DIFFUSER
The cone diffuser is manufactured from steel plate milled into shape and welded together.
The two flanges are likewise welded on.
The cone diffuser is mounted on the discharge side, thereby transforming the last part of
the air velocity into pressure, thus reducing the air velocity.

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OPERATION AND MAINTENANCE

3.6

COMPRESSOR KA5S-GK200

Page 28/54

BLOW-OFF VALVE
The blow-off valve is a butterfly valve with electric or pneumatic actuator and end stops.
The blow-off valve is mounted between two flanges. The blow-off valve functions as a
pressure relief valve during start/stop to avoid surging. (For tech. data, see § 2).

3.7

CHECK VALVE
The check valve is a spring-loaded butterfly valve (dual plate) built in between two flanges.
The check valve prevents the compressed air from passing backwards, thereby keeping the
compressor from running backwards when not in operation. (For technical data, see § 2).

3.8

COUPLING/DRIVE MOTOR/GEARBOX
The coupling between drive motor and gear is a flexible disc type coupling which is flexible
in both radial and axial direction and at the same time able to withstand excessive torsional
stress. To ensure optimal operating conditions the coupling shall be aligned as described in
§ 12.

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OPERATION AND MAINTENANCE

3.9

COMPRESSOR KA5S-GK200

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INLET SYSTEM
See enclosed drawing no. 9330057240.0, Inlet Silencer.
The inlet system consists of inlet silencer, filter, front grid or extension piece fastened
together into a unit. The inlet silencer is fitted with height adjustable feet, approx. ± 20mm
from nominal centre height.
Mounting
The height of the inlet silencer stud is adjusted in relation to the compressor stud, and the
inlet silencer is positioned so that the air conduit between the studs is 3 - 7 mm. If the air
conduit between the studs is 10 mm or more, the compressor may be damaged.
The holes in the base plate are then marked out on the floor, the silencer is removed, and
the holes are bored, after which the nylon dowels supplied are placed in the holes, and the
silencer put back and fastened with the supplied screws.
The air conduit between the studs of the inlet silencer and the compressor is checked and
taped with the special tape supplied, after which it is covered with lead rubber and tightened
together with the flexible connection supplied.
The U-pipe manometer, which registers pressure drops, is filled up with liquid from the flask
supplied.
Maintenance
Pressure drops must not exceed 100 mmWC, because a too high negative pressure may
cause the intake silencer plates to collapse. The filters are replaced when the pressure drop
during start is observed to have increased by 20 mmWC.

Suction from the compressor room: Dismount the front grid and the filter locks and take out
the filters. Vacuum clean the inside with a soft brush
mouthpiece. Insert new filters.
Suction from the air duct:

3.10

INLET FILTER
See Manufacturer's material.

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Dismount the side covers of the filter box and the filter
locks and remove the filters through the side. Vacuum
clean the inside with a soft brush mouthpiece. Insert
new filters.

HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

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HANDBOOK FOR
OPERATION AND MAINTENANCE

4.

COMPRESSOR KA5S-GK200

Page 31/54

DRIVE MOTOR
See enclosed technical document “Electric Motors Compressors KA2 - KA100 General
Requirements”.
For motor specifications etc. see manufacturer’s instructions.

General remarks to monitoring and maintenance of electric motors.
Immediately after the first start-up of the compressor, it is necessary to make the first lubrication of the electric motor on site.
The type of grease must always be identical to the type which was used from the factory.
It must be avoided to mix two different types of grease that might contain different additives not being able to be integrated. This might result in poor lubrication quality and
damage to the bearings.
After the first lubrication on site, it is necessary to lubricate according to intervals' indicated on the manufacturer’s plate at the motor. Greasing is done only with the motor running. Keep record of all the greasings in the list of lubrication.
After the startup, it is necessary to control the motor once per week. To check that the
sound and the temperature are correct and that there are not false vibrations. This might
be done by using a large screwdriver to listen at the bearings by putting the end against
the bearing cover and the wrist against the ear.
If the compressor unit is not in operation for a rather long period, the compressor should
remain oil-filled. Start the oil pump for some minutes and turn the compressor and the
electric motor a few turns manually once per week.
Engine IP23 passes the cooling air between the stator and the rotor. That is why the
room in which the compressor / electric motor are placed will have to be completely
clean. In general all the motors and compressors will have to be held in a state of cleanliness. If the interior of a motor is more or less filled with dirt, a short-circuit will be able to
occur. The cooling air must be dry.
It is always necessary to monitor the temperature as well as the absorptive current.
After a long period of stop it is necessary to make sure, by the means of a measuring instrument that the electric insulation is intact, and no false currents can escape through
the bearings, in order not to start a wet motor.
If the motor has remained inactive for a long time, without to be turned regularly, it could
be necessary to change the bearings. That is detected by touching the motor while listening to the bearings. Permanent monitoring is necessary.
Any repair or any disassembling of the engine requires control of the alignment of the
coupling and, if necessary, a corrective alignment.

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HANDBOOK FOR
OPERATION AND MAINTENANCE

930910056UK

1.

Page 32/54

ELECTRIC MOTORS
COMPRESSORS KA2 – KA100
GENERAL REQUIREMENTS

Revision: 15

Prepared by:
Latest revision:

COMPRESSOR KA5S-GK200

MC
FP

Date:
Date:

91.12.09
07.02.07

The motors shall be manufactured according to standard IEC 60034-14, vibration grade A. This
also applies to fully loaded motors.
Unless otherwise specified, the motors shall be balanced according to the "HALF KEY CONVENTION" ISO 8821, and the shaft end shall be marked with an "H" according to section 4.2. of
this standard.

2.

Starting: The compressor torque-speed curve follows a square law. The max. torque during start
is 67% of the motor nominal torque. Note that there could be specific demands on the acceleration at certain rpm intervals. Such demands will be noted on the compressor speed-torque curve.
Low-voltage motors: The motor should be capable of star/delta start within 12 seconds.
High-voltage motors: The motor should be capable of starting the compressor at 80% of the normal voltage.

3.

The motors shall be equipped with a "low noise" design fan. Maximum free field sound pressure,
according to ISO 3744, is 87 dB(A) at 1 m distance.

4.

Direction of rotation, when viewing the motor from the drive shaft end, see figure 1.:
Gearbox GK2, GL180, GK190
Gearbox GK200
Gearbox GA
Gearbox GB255
Gearbox GB400
Gearbox GC
Gearboxes GL210, GL225,
GL285, GL315 and GL400
Gearbox GL500

(single stage)
(single stage)
(single stage)
(two stage)
(two stage)
(two stages)

: CCW
: CW
: CW
: CW
: CCW
: CCW

(single stage)
(single stage)

: CW
: CCW
Figure 1.

Gearbox type according to order specification.
A terminal box with terminals shall be mounted on the motor.
Unless otherwise specified, the position of the terminal box, when viewed from the motor drive
end, shall be on top of the motor with terminal entry to the right or on the right side of the motor
with terminal entry downwards. Cable entry location shall permit proper cable bending radius
when the motor is installed on the base plate.
5.

The motor windings shall be protected by 1*PTC thermistor or 1*PT100 sensor in each end winding. Thermistors are preferred. All sensors shall be galvanically separated.

6.

The motors shall be shipped to Siemens Turbomachinery Equipment A/S’ (STE) works in
Helsingør, Denmark, according to the signed "Statement of Availability" document 930940025UK.

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7.

8.

COMPRESSOR KA5S-GK200

Page 33/54

As a minimum the documentation must include:
a.

A certified dimension sketch, including shape and dimensions of the motor fan cover, location
of the coolant inlet, shape and exact position of the feet, weight and centre of gravity. The
drawing must be available both in paper version and as scaleable AutoCad data in dwg format (Version: AutoCad Mechanical 2004 or previous versions). Alternatively, the data can be
supplied in dxf data format (Version: AutoCad 2000/AutoCad Light 2000 or previous versions). In case of doubt, please contact STE.

b.

Technical data including full-load torque, full-load speed, full-load current, speed-torque
curve, speed-current curve, load-power-factor curve, load efficiency curve (shaft power/ terminal power ratio), inertia of rotor and drive shaft torsional stiffness to be specified and/or
filled in acc. to "Standard Specification for 3-Phase Squirrel Cages" 930920063UK and "Efficiency of Electric Motors" 930920064UK.

c.

Terminal markings/wiring specifications for motor winding protection.

d.

Noise emission at full load specified as sound power emission Lw, A-weighted value and/or
octave bands (dB, reference 2*10-12 W).

When equipped with sleeve bearings, the rotor shall be locked in place during transport.
If the rotor is to be axially positioned by means of external thrust bearings, the maximum axial
load of the motor and the predicted thermal expansion shall be specified.
Lubricating oil system requirements, including oil/grease type, shall be specified.
Grease nipples shall be according to DIN 71412.
Minimum grease lubrication interval: 1500 hours.

9.

In cases where the compressor applications include an acoustic enclosure covering the whole
compressor unit, the motor fan shall provide the necessary amount of cooling air when working
against an external pressure of 60-80 Pa.
The fan capacity, at maximum pressure drop, shall be specified. The fan cover dimension (shape)
shall be specified.

10.

The motors shall be protected for normal shipment and storage indoors, not heated, up to 6
months.
Special requirements during shipment and storage shall be specified or the STE instruction "Conservation, Transportation, Storage, Start-up" 930920009UK approved of.

11.

If used under tropical conditions the motors shall be equipped with electrical heaters and drains.

12.

Manuals including instructions for installation and operation shall be provided in English, German,
French or Spanish, whatever is specified.

13.

Electric motors to be mounted on compressor units for the EU and EFTA markets shall comply
with European Directives and Harmonized Standards in force at the specified time of delivery.
The documentation shall include a Declaration of Conformity (EN45014).

14.

The information specified herein must be at our disposal not later than 3 weeks from receipt of
order.

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5.

COMPRESSOR KA5S-GK200

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ACOUSTIC ENCLOSURE
On request SIEMENS supplies an enclosure, which through careful choice of design,
assembly methods and sealing strips, will provide optimal noise reduction. The enclosure is
equipped with sound muffling material adapted to the prevailing conditions.
The SIEMENS acoustic enclosure is built up as a modular system on a chassis frame in
which panels and doors can be inserted. This simple construction means fast mounting and
dismounting of the complete enclosure or parts of it.
The enclosure is delivered as a construction kit, which requires only a minimum of space
during storage and transport.
"Do it yourself" mounting instruction - technical info 930940099 - is included in the delivery.
However, SIEMENS will be pleased to mount the enclosure on request.

CONSTRUCTION
Frame construction made of OMEGA profiles (channel section with webs) mounted
on bottom rails bolted to the floor. Sound absorbing elements are placed in the
frames.
Dimensions: Modular system for individual adaptation.
NOISE REDUCTION
The sound absorbing elements are made of alu-zinc coated steel plate on the outside, and of alu-zinc coated perforated steel plate on the inside. The interspace is
filled up with mineral wool.
The ceiling elements are placed in webs in the cross braces. The wall elements are
placed in top and bottom rails.
The enclosure is fitted with detachable wall panels for inspection and service.
VENTILATION
The silencer hood is ventilated by means of a fan mounted inside the hood in one of
the ceiling elements. Intake and discharge of ventilating air is done via noise reducing ducts. The outlet can be connected to a pipe channel leading the hot air out of
the compressor room.

TYPICAL NOISE REDUCTION
Octave band (Hz)
Noise reduction (dB)

31,5

63

125

250

500

1000

2000

4000

8000

2

6

6

10

14

19

21

40

18

Note:
From compressor, valves etc., sound is emitted into the pipe system. Therefore, the
nearest parts of the pipe system outside the enclosure shall be insulated in order to obtain optimal noise reduction.

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COMPRESSOR KA5S-GK200

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6. LUBRICATING OIL SYSTEM
6 1 Design and Function
The lubricating oil system provides oil for all bearings in the gear and for the gear meshing.
The lubricating oil system has been designed as shown on the P & I diagram and the aggregate
drawing.
In the technical specification, the P & I diagram and the aggregate drawing (section 2, 7.2,
and 12 respectively), control of the oil/cooling system is shown as well as the function and
location of sensors, thermometers, manometers, thermostats, and pressostats.
The lubricating oil system is equipped with one oil pump which can deliver the quantity of oil required.
The oil reservoir may be equipped with electric oil heaters to heat the oil after a period of stand-still,
i.e. when the temperature has fallen below the 10°C necessary during startup
The oil is pumped via oil cooler and oil filter to the lubricating points.
The oil cooler may be either air-cooled or water-cooled.
When cooling by air the cooler shall not be placed in such a way that the warm air blows towards the
LC-panel or other electric installations.
When cooling by water the regulating valve shall be mounted on the inlet pipe to ensure that the water
pressure is always kept lower than the oil pressure; thereby preventing water from penetrating to
the oil. The inlet pipe shall be connected to the lowest pipe connection to keep air out of the system.
The aggregate is equipped with 1 pressure switch (pressostat:).
The pressostat E107 gives signal to stop the compressor. If - due to power failure or damage (oil leakages)
to the lubricating system - the pressure falls below approx. 1 bar excess pressure, the compressor
will be stopped via the pressostat and the electric control system, and also if the oil pressure has not been
established within 30 seconds from start-up.
The aggregate is equipped with thermostats for oil temperature:
The thermostat E104 gives signal to stop the compressor if the oil temperature gets too high.
The thermostat E138 gives signal to start and stop the oil cooler fan.
For lubricating oil pressure and temperature, see § 2.
The lubricating oil system has been cleaned in advance by SIEMENS. Therefore, be extra careful
when dismounting, etc., in order to avoid contamination of the oil system.
6.2 Oil filling
Fill oil pipe S215, on top of oil cooler, and oil filter S303 with oil before first start-up and at each oil
change.
Check the oil level in the level glass E130, see the unit (aggregate) drawing.
6.3 Oil types
The compressor must only operate with synthetic oil types, which are approved by SIEMENS
(see § 2 “Technical Specifications”). Different types of oil must not be mixed, i.e. if the oil type
is changed all oil must be changed. Oil from tanks, which have been opened for some time,
must not be used, as particles from the atmosphere will be absorbed in the oil.
Accessories:
The lube oil pump is integrated in the gear, see §12.
Lube oil filter and cooler: See section Accessories
Lube oil heater : not included.
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COMPRESSOR KA5S-GK200

7.

CONTROL AND MONITORING SYSTEMS

7.1

DESIGN AND FUNCTION

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The control and monitoring systems shall ensure correct operating conditions at start and
stop of the compressor as well as during operation.
The control system runs the start and stop functions, the compressor operation, the lubricating oil system, and the activation of the blow-off valve, the diffuser and/or the pre- rotation.
The monitoring system consists of minimum 5 current circuits connected to pressostats,
thermostats, and sensors. The current circuits are part of a safety chain which stops the
compressor immediately on indication of error.
Important: The design of the local control panel and all its electric functions are described
in the separate “Operation Manual for the Local Control Panel”.

7.1.1

START AND STOP FUNCTIONS
START AND OPERATION
The start function ensures that the compressor only starts if it has been correctly prepared.
The conditions for a correct start are as follows:
-

no alarms or emergency stops activated
blow-off valve open
diffuser and/or prerotation in MIN position.

The start sequence may now be activated as follows:
Compressors with gear:
- GK2, GK4 and GK200:

Start of compressor at once while feed back signal is awaited
from motor starter.

If the unit is equipped with SIEMENS electric control system “LC-”, Local Control panel, the
panel controls the daily operation and monitoring.
The following conditions of start and operation will be observed by the logic system of the
local control panel:
1.

When the START button is activated the automatics will open the blow-off valve and set
the diffuser in MIN position. At the same time the instruments of the safety chain are
checked, and if they are in order the drive motor of the compressor will start.

2.

When the compressor has been started the blow-off valve will close.

3.

During operation the diffuser will be adjusted continuously corresponding to the operational conditions.

4.

In case of errors, as too high oil temperature, too low oil level, too high counter pressure
in the outlet pipe etc., the compressor is stopped.

5.

When the error has been located and corrected the monitoring system has to be reset.

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STOP
The stop function ensures that the compressor stops under controlled conditions:
NORMAL STOP
1. Diffuser moves to MIN position.
2. As soon as the diffuser is in MIN position, the blow-off valve opens quickly.
3. When the blow-off valve is open, the compressor motor stops (however, max. 100 seconds after "Normal Stop" has been activated).
ALARM STOP (NOT OIL PRESSURE)
1. Blow-off valve opens quickly (max. 8 seconds after "Alarm Stop" has been activated).
2. Compressor stops.
3. Diffuser and prerotation move to MIN position.
EMERGENCY STOP (ONLY EMERGENCY AND OIL PRESSURE)
The compressor stops at once, while the blow-off valve, the diffuser and/or the prerotation
open simultaneously and move to MIN position.
For KA2-GK2, KA4-GK4 and KA5-GK200 please note:
After each stop the compressor cannot be restarted for 1 minute.

7.1.2

CONTROLLING THE LUBRICATING OIL SYSTEM
COMPRESSORS WITH MECHANICAL OIL PUMP
Compressors with gear GK200 only have a mechanical oil pump. The pump starts directly
and the control records the oil pressure during operation. If the oil pressure is insufficient,
the control stops the compressor.

7.1.3

ACTUATION OF BLOW-OFF VALVE, DIFFUSER AND/OR PREROTATION
The monitoring system ensures that the blow-off valve, the diffuser and/or the prerotation
are controlled within the range of the respective end stop switches.

7.1.4

SAFETY CHAIN (CLOSED-CIRCUIT PROOF)
The Safety Chain consists of minimum 5 current circuits:
-

oil level and/or oil pressure
oil temperature
surging
recirculation
motor temperature (motor windings)

If an error occurs in one of the current circuits, the Safety Chain ensures that the compressor is stopped at once.
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COMPRESSOR KA5S-GK200

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IMPORTANT! Operation without monitoring (Safety Chain) must not take place!

7.1.5

SUPPLY OF AUTO-CONTROL
If the control automation is supplied by SIEMENS, please see the electrical documentation
LC/MCP for further information.
If the control automation is not Siemens’s make, the minimum design criteria shall be in accordance with Siemens’s technical specifications:
Control automation for SIEMENS compressors
Type KA2-GK2, KA4-GK4 and KA5-GK200
Minimum Design Criteria No. 930920011UK
Control automation for SIEMENS compressors
Type KA5-KA100
Minimum Design Criteria No. 930920010UK

7.2

P/I DIAGRAM
See enclosed P/I diagram.

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7.3

COMPRESSOR KA5S-GK200

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COMPRESSOR INSTABILITY (SURGE)
Surge (Stalling) and recirculation are both situations which arise in connection with operational errors or errors in the automatic control system or the controlled functions. In both
cases the compressor will run an unstable operating range and must be stopped at once.

7.3.1

SURGE
Pressure air expands jerkily through the operating compressor. Usually stalling is caused by
operating at too high differential pressure. Stalling may also arise if the inlet temperature is
much higher than the maximum design temperature. At increasing inlet temperature the
max. achievable discharge pressure of the compressor will drop.
Stalling reveals itself through audible pressure blows the frequency and strength of which
are determined by among others the resonant conditions of the connected piping system on
the pressure side. Strong pressure blows mean heavy load on the mechanical parts of the
compressor, and therefore the compressor must be stopped. (see the manual for the local
control panel).
Operating under these conditions will expose the mechanical parts of the compressor to
heavy loads and should, therefore, be avoided.
If the compressor is operating within the unstable range, the SUC-switch (SU = Surge, C =
Control) will activate the alarm and stop the compressor immediately.
The following malfunction may cause surge:
1. Too high header pressure
2. Too high inlet temperature
3. Decrease in compressor RPM as well as mechanical errors, etc.

7.3.2

RECIRCULATION
The medium recirculates through the compressor, whereby a large amount of energy is added to a small amount of medium (the medium heats up).
The following malfunctions may cause recirculation when:
1. The diffusor/prerotation is closed completely (MIN.-setting of the limit switches has been
moved)
2. The discharge from the blow-off valve is led back to the inlet duct, causing the medium
to recirculate for a long time
Operating with recirculation must be avoided, as it may cause damage through overheating,
and - at worst - fire in the compressor.
If the compressor is operating for a long time with recirculation, a thermostat with sensor in
the compressor inlet will activate the alarm signal and stop the compressor immediately.

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8.

INSTRUMENTATION

8.1

THERMOSTAT RT103 »Acoustic Enclosure Temperature above 30°C« Pos. no. E 151

Data : See § 2, Tech. Specifications

MAX ambient temperature
MAX sensor temperature

: -40 - +70°C
: 100°C

Function

: Start and stop of ventilator fan at temperature above/below
30ºC in acoustic enclosure.

Setting

: Dismount the front cover of the thermostat and set the differential adjusting nut 19 on MIN.
Set scale 9 on 30°C using knob 5.

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8.2

COMPRESSOR KA5S-GK200

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THERMOSTAT RT101 »Oil Temperature above 55˚C« Pos. No. E138
By Air Cooling of the Oil System
Data : (See also § 2, Tech. Specifications)

MAX ambient temperature
MAX sensor temperature

Testing :

:
:

-50 - +70°C
300°C

Function

: Start and stop the ventilation motor of the oil cooler at rising oil
temperature, exceeding 60°C.

Setting

: Dismount the front cover of the
thermostat and set the differential
adjusting nut 19 on MIN. Set scale
9 on 60˚C using knob 5.

If the ventilator is running, the thermostat is set on a value higher than the indication of the oil thermometer: The ventilator must stop.
If the ventilator is not running, a value lower than the indication of the oil thermometer is chosen: The ventilator must start.

The thermostat is closed but not sealed, as adjustments will have to be made occasionally,
according to changes in the surrounding temperature.

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8.3

COMPRESSOR KA5S-GK200

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THERMOSTAT RT107 »Oil Temperature too high« Pos. No. E104

Data : See also “Accessories”

MAX ambient temperature
MAX sensor temperature

Testing :

:
:

-50 - +70°C
300°C

Function

: To stop the driving motor of the
compressor at rising oil temperature, exceeding 80°C.

Setting

: Dismount the front cover of the
thermostat and set the differential
roll 9 on MIN.

Using knob 5 the thermostat is set at dropping temperature until the switch
opens. If the compressor is operating, it must be stopped. If the compressor is
not operating, it must not be possible to start it. Adjust scale 9 until indicator
setting of the thermostat corresponds with the oil thermometer of the gear.
Adjust thermostat with knob 5 to 80°C on scale 9.
Remount the front cover.

The thermostat is part of the electric safeguard, and it is sealed with lead after adjustment.
Important: During the period of guarantee set for the compressor, sealed thermostats and
pressure controllers must only be adjusted by SIEMENS personnel.
The guarantee no longer applies if the seal is broken.

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8.4

COMPRESSOR KA5S-GK200

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THERMOSTAT RT101 »Air Temperature too high« Pos. No. E111
Data : See also “Accessories”

MAX ambient temperature
MAX sensor temperature

:
:

-50 - +70°C
300°C

Function

: To stop the drive motor of the
compressor at rising air inlet temperature, exceeding 65°C. Securing against overheating caused by
recirculation.

Setting

: Dismount the front cover of the
thermostat and set the differential
roll 9 on MIN.
Set scale 9 on 65°C, using knob 5.

Testing :

Set the scale on 65°C. the sensor is taken out of the inlet and heated in water
to above 65°C. If the compressor is operating, it must be stopped. If the compressor is not operating, it must not be possible to start it.
Remount the front cover.

The thermostat is part of the electric safeguard, and it is sealed with lead after adjustment.
Important: During the period of guarantee set for the compressor, sealed thermostats and
pressure controllers must only be adjusted by SIEMENS personnel.
The guarantee no longer applies if the seal is broken.

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8.5

COMPRESSOR KA5S-GK200

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Pressure Controller RT110 »Oil Pressure too low« - Pos. No. E106

Data : (See also section 2, Tech. Specifications)
MAX ambient temperature
MAX medium temperature
MAX testing pressure

: 70°C
: 100°C
: 25 bar

Function

: To start the electric oil pump if the oil pressure drops below
0,8 bar o.

Setting

: Dismount the front cover of the pressure controller and set
the differential roll to MIN.
Set scale 9 to 0,8 bar o using knob 5.

Testing : Set the pressure controller to scale value below the oil pressure shown on the lubricating oil manometer. If the compressor is operating, it must be stopped. If the compressor is not operating, it must not be possible to start it. After testing, the scale is reset to 0,8
bar o.
Remount the front cover.
The pressure controller is part of the electric safeguard, and it is sealed with lead after adjustment.
Important: During the period of guarantee set for the compressor, sealed thermostats and
pressure controllers must only be adjusted by STE personnel.
The guarantee no longer applies if the seal is broken.

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8.6

COMPRESSOR KA5S-GK200

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Pressure Controller RT200 »Oil Pressure too low« - Pos. No. E107

Data : (See also section 2, Tech. Specifications)
MAX ambient temperature
MAX medium temperature
MAX testing pressure

: 70°C
: 100°C
: 25 bar

Function

: To stop the drive motor of the compressor if the oil pressure drops below 1 bar o.

Setting

: Dismount the front cover of the pressure controller and set
the differential roll to MIN.
Set scale 9 to 1 bar o using knob 5.

Testing : Set the pressure controller to scale value below the oil pressure shown on the lubricating oil manometer. If the compressor is operating, it must be stopped. If the compressor is not operating, it must not be possible to start it. After testing, the scale is reset to 1
bar o.
Remount the front cover.
The pressure controller is part of the electric safeguard, and it is sealed with lead after adjustment.
Important: During the period of guarantee set for the compressor, sealed thermostats and
pressure controllers must only be adjusted by SIEMENS personnel.
The guarantee no longer applies if the seal is broken.

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8.7

COMPRESSOR KA5S-GK200

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PRESSURE SWITCH SUC-3 - Pos. No. E113

Function

: Surge indicator, gives alarm (stop
of the drive motor) in case of
surging.

Sensor

: Inductive sensor.

Mounting

: In the compressor inlet housing.

A: Pressure direction at normal operation.
B:

Pressure direction at surging.

The surge indicator is mounted vertically on the compressor inlet.
At normal operation a small steel disc is forced down (away from the inductive sensor) by
the vacuum in the inlet housing.
At surging the direction of the pressure is reversed, this causes the steel disc to approach
the inductive sensor, which then gives alarm.

BLUE (MINUS)

WHITE (SIGNAL)

BROWN (PLUS)

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9.

START-UP

9.1

PREPARATIONS

COMPRESSOR KA5S-GK200

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The list below is applicable to the first start-up.
The automatic control system shall fulfil the minimum requirements as described in § 7.
When the automatic control system is delivered by SIEMENS the customer is referred to
the LC/MCP documentation, which includes operating instructions for the local control
panel.
1. Check oil pan for impurities and/or water. Drain-off possible condensate.

Fill up the compressor with lubricating oil, check the oil level. Fill on only NEW and absolutely CLEAN oil. Check oil level in sight glass.
If lubricating oil has already been filled on, check quality of oil as well as oil level.
For type of oil, see technical specifications, § 2.
2. Check lubricating oil piping for damage that may have occurred during mounting.
In case the oil system has been disassembled or modified, the system shall be flushed
with oil that has been bypassed gear and compressor, using the procedure described
below:
Dismount pipe connections leading to gear and compressor.
Lead oil back to the oil reservoir via clean pipes.
The external oil system is then flushed out for one hour with oil at temperature above
10°C
Pipe connections for gear are remounted and new oil is filled.
Check that the passage through connections to gear and compressor is
Important!
free.
The oil system is then flushed out for at least ½ hour with the oil temperature above
10°C and the oil pressure at 1,5 – 3,0 bar.
Turn the compressor manually, very carefully, one entire revolution in reverse. (This is
easily done by means of the coupling between drive motor and gear).
Then flush further for at least ½ hour.
Check oil filter insert. Replace if necessary.
3. Check the compressor suction system, silencer(s), compensators and air filters (internal/external) for correct mounting and cleanliness.

Important!

Check especially the area in front of the impeller, the inlet, and the inlet
pipe. Check the flexible connection between the inlet pipe and inlet filter/inlet duct for correct mounting.

4. Check diffuser cone, blow-off valve and non-return check valve on pressure side of compressor for correct mounting. The check valve must be mounted with vertical shaft. An
arrow indicates the sense of direction of the air.
5. Check the non-return check valve for correct function and control. Check the limit switch
function.
6. Check that function and adjustment of the regulation system of the diffuser are correct.
Check the limit switch function.
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7. Check oil cooler for correct function and control.
8. Check the acoustic enclosure fan for correct function and check the sense of rotation.
(If installed)

9.2

SIMULATED TEST RUN OF COMPRESSOR
In order to check start/stop sequence and cable connections a simulated test run is performed. It may be performed with dismounted coupling lamellas on the motor-end.
When simulating operation the safety monitoring equipment (pressostats and thermostats)
shall be tested with satisfactory result. (For pressure and temperature see § 2).


Turn compressor manually to check that rotation is smooth. This is most easily done at
the coupling between drive motor and gear.



Start up compressor (motor) briefly, max. 2-3 seconds, to check direction of rotation.
If direction of rotation is wrong, repole motor.
IMPORTANT!

Wrong direction of rotation of the gear for more than a few seconds may
cause permanent damage to gear bearings and journals.

Note: Do not restart more than 4 times per hour. Repeated starts within 15 minutes will
block the drive motor for restart for one hour (to protect motor coils).
Check that mounting of the coupling and tightening of the screws is correct (see § 12).
Check the coupling alignment before start-up (see § 12).

9.3

TEST RUN OF COMPRESSOR
During test run the following shall be checked and/or adjusted:


Opening and closing of blow-off valve. Normally the blow-off valve will indicate "closed"
max. 180 sec. after start-up (depending on valve type and site conditions).



Function of recirculation-valve.



Build-up of air pressure in pressure pipe.



Lubricating oil pressure and temperature shall be stable.
Lubricating oil pressure and temperature during operation (see § 2).
Function of mechanical oil pump



Lubricating oil cooler adjusted.
When air-cooled, the thermostat is adjusted for start and stop of fan motor.
Lubricating oil temperature during operation.



Test diffuser adjustment manually.



Test safety monitoring, oil level switch and emergency stop during operation.



Test normal start and stop sequence.



Motor overload protection (diffuser limitation).



Check for oil leaks at operating temperature.



Check of cable connections from compressor control panel to master control panel.

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9.4

COMPRESSOR KA5S-GK200

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MASTER CONTROL (if installed)
Check at start-up of Master Control (MCP): Start/stop function, priority sequence and adjustment procedure for all compressors.

9.5



Check and adjustment of step controller (adjustment of diffuser via mA-signal).



Check of output signal from pressure and oxygen transmitter.

START
5 seconds approx. after start-up the valve between the compressor and the manifold is
opened. The blow-off valve is closed.
At plants equipped with non-return valve between compressor and manifold: Close the blowoff valve approx. 5 seconds after start.
The compressor can now be set for max airflow, during which the counter pressure and the
power consumption of the motor are surveyed. At low counter pressure the airflow may increase considerably and the motor will be overloaded (see performance certificate).
The compressor electric control system (Local Control Panel) will monitor all necessary
functions before and after start, when the start order is given by pressing the respective
button. In case of errors or if the starting conditions are not fulfilled the local control panel
will indicate “ERROR” (see “Manual for Electric Control System”).

DURING OPERATION
Pos. Nos. refer to aggregate drawing/instrument panel drawing. Operating temperature
(see § 2).
During operation the following is checked:
Oil level:

Pos. No E130
E120

Sight glass
Level switch

Oil temperature:

Pos. No. E122
E104

Thermometer Min. 10°C at start-up
Thermostat

Oil pressure:

Pos. No. E121
Pos. No. E107

Pressure gauge, Min 1,0 bar.
Pressure switch

Compressor surging
Compressor recirculation

Pos. No. 113
Pos. No. 111

SUC-3, pressure switch
Thermostat

Vibrations:

To be measured at the SIEMENS test point;
10-1000 Hz: ISO.

Power consumption:

Ammeter on control panel. Test by means of
a tongs ammeter.

Differential Pressure at inlet filter:

Pressure gauge, Pos. E137.

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9.6

COMPRESSOR KA5S-GK200

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GENERAL
When the compressor has been put into operation, the starting priority of the machines
shall be changed periodically by the machine operator in order that all compressors of an
installation are frequently in operation and over a period will have an equal number of operation hours.
On plants where the diffuser system is not frequently run from fully open to fully closed, due
to special operating conditions, the local panel shall be set on "Manual" at least once a
week, and the diffuser run from fully closed to fully open at least twice. This also applies to
compressors which are not in operation.
If the compressors have not been in operation for a month, the following procedure shall be
followed, to avoid that the ball bearings are damaged by standstill in the same position:
Rotate the compressor for about a minute in the normal direction of operation. This can
most easily be done by turning the coupling between drive motor and gear by hand.

NOTE AFTER START-UP
1. The screws of the coupling shall be checked after approx. 10 hours of operation.
2. Operation with electric motor: Grease lubricated bearings must be lubricated according
to the prescriptions in the supplier's manual or acc. to indications on the name plate of
the motor. The first lubrication is to take place immediately after start-up (always with a
warm compressor). The lubrications are to be continued at stated intervals. A scheme of
lubrication intervals should be established.
3. Lube oil quality must be checked according to prescriptions (See section 11)
4. Check for possible oil leaks. Retighten pipe joints if needed.

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10.

COMPRESSOR KA5S-GK200

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TROUBLE SHOOTING

When trouble shooting, compare all operational data with the specifications in § 2.
§

10.1

Flow, no pressure at start-up

10.1

Insufficient flow

10.2

Excessive power consumption

10.3

Surge (pressure pulsation)/
Recirculation (overheating)

10.4

Noisy operation/too high vibration level

10.5

Bearing temperature too high

10.6

Lubricating oil pressure too high

10.7

Lubricating oil temperature too high

10.8

Drive motor

See separate instruction: Section 5

Oil cooler

See separate instruction, section 6

NO FLOW, NO PRESSURE AT START
Possible causes:

- Drive motor error, current failure.
- Wrong direction of rotation.
NOTE: Drive motor and compressor are rotating in opposite directions.
- A coupling or shaft has broken.
- A shaft has been blocked.

10.2

INSUFFICIENT FLOW
Possible causes:

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-

Blow-off valve completely or partly open.
Pipe system leaking or a valve is open.
Inlet diffuser blades/- guide vanes completely closed.
Inlet system partly blocked.

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10.3

COMPRESSOR KA5S-GK200

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TOO GREAT POWER CONSUMPTION
Possible causes:

- Low flow pressure compared to design pressure with
stuck diffuser.
- Maladjusted diffuser.
- Mechanical defect in gear or compressor (defective
bearings, gearwheels or shaft).
NOTE: If the electric motor has been wrongly poled
(connected to the external power supply), the power
consumption may rise excessively.

10.4

SURGE (PRESSURE PULSATION)/ RECIRCULATION (OVER-HEATING)
Possible causes:

10.5

- Too low RPM.
- Header pressure too high compared to design pressure (see rating plate).
- Inlet duct/- silencer defective/ fouled up.
- Inlet air filters blocked due to fouling (inlet pressureloss too high).
- Inlet temperature too high.
- Inlet guide vanes/diffuser blades maladjusted or too
closed.
- Clearance between impeller and contour ring too large.
- Impeller damaged.
- Blow-off valve defective; causes surging at start/stop
only.
- Defective counter valve and blow-off valve.

NOISY OPERATION /VIBRATION LEVEL TOO HIGH
Possible causes:

Gear:
- Defective gearwheel or bearings.
- Defective coupling or bad alignment.
Compressor:

10.6

-

Defective bearings.
Rotor/impeller out of balance.
Defective sealings.
Defective coupling or bad alignment.

-

Wrong type of oil.
Defective bearings, gearwheels, etc.
Insufficient cooling of lubricating oil
Insufficient oil feed.
Lubricating oil pressure too low.
Defective oil pump.

Bearing TEMPERATURE TOO HIGH
Possible causes:

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OPERATION AND MAINTENANCE

10.7

COMPRESSOR KA5S-GK200

OIL PRESSURE TOO LOW
Possible causes:

10.8

-

Defective oil pump
Oil filter blocked
Oil temperature too high
Safety valve defective
Leaks on pressure pipe (under tank cover).
Too low oil level

OIL TEMPERATURE TOO HIGH
Possible causes:

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01-Operation_KA5S-GK200.doc

- Too high ambient temperature.
- Wrong type of oil.
- Defective bearings, gearwheels, etc.

Page 54/54

HANDBOOK FOR
OPERATION AND MAINTENANCE

11.

COMPRESSOR KA5S-GK200

Page 1/50

MAINTENANCE
INTRODUCTION
The SIEMENS compressor is designed to operate for many thousand hours with a minimum of
maintenance.
Control and cleaning is most important. Some vital parts of the compressor and gear require
dismounting. Instructions of such dismounting and remounting are given below. Follow these
instructions carefully, and if any doubt please contact SIEMENS for assistance.
The SIEMENS compressor is built with very fine tolerances and operates at very high speeds.
Therefore, be very careful during maintenance works. Use the correct tools only and avoid any
kind of bumps and blows on the compressor parts.
Observe proper cleanliness.
Do not use cotton waste for cleaning or drying as it may contain unobserved particles of dirt or
metal.

11.1

SERVICE INTERVALS GEARBOX / COMPRESSOR
Below is a table of the service intervals recommended by SIEMENS, with references to the
various §s giving a more detailed description of what is to be done.
Local conditions may cause deviations from the norm. Therefore, read each § carefully with a
view to local conditions before the service intervals are laid down. This applies especially to the
parts in touch with the medium. The frequency with which these parts shall be cleaned may
vary to some extent, and the service instructions shall be progressively evaluated.
SIEMENS's standard instructions are as follows:
Job to be done
Oil change

See §
6

Intervals
First oil change after 8,000 hours of operation.
Subsequent changes every 8,000 hours., however, at least once a year

Oil Filter Change

Acc.

When changing the oil or at max. differential
pressure, acc. To tech. spec., §2.

Bearing change gearbox,
pinion shaft incl. O-rings,
Bearing change gearbox,
inlet shaft
Service

3.3.3

Every 40000 hrs, change oil too.
See drawings next page
Every 80000 hrs, change oil too.

3.3.3
11.2

Every 18,000 hours of operation / every 3
years, whichever comes first.
At max. pressure drop according to technical
specifications.

11.6

Shall be cleaned during service.

Acc.

See manufacturer’s instructions or contact the
local SIEMENS representative.
See manufacturers instructions

Inlet filter
Inlet silencer
Drive motor
Oil cooler

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HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 2/50

Oil Change
Under normal operating conditions, the compressor can operate 8000 hours before an oil
change is required.
A pump and a suction pipe is used to drain off the oil. The oil is sucked up through the filler stud
(See aggregate / unit drawing) The pump and suction pipe is not standard equipment.
Prior to filling on new oil, the oil filter shall always be cleaned / changed according to filter type,
see filter description.
Important!

Do not use other types of oil than the one specified in the technical specifications,
as bearings gearwheels etc. have all been dimensioned for this specific type of oil.
Damage caused by using wrong type of oil is not covered by the guarantee.
Oil level(when unit is not operating)between min and max on the sight glass / dipstick. Oil type and amount: see technical specifications in §2.

Change of Bearings
Operational hours between changing of bearings for GK gear mounted with hybrid
bearings onto the rotor shaft.

KA2-GK190
KA5-KG200*
KA10-GK200

Rotor shaft
24,000
40,000
40,000

Pinion shaft
48,000
80,000
80,000

See instructions and illustrations for disassembling and assembling of the compressor and gearbox later in this chapter

BEARING HOUSING GEARBOX

1 Bearing housing
2 O-ring

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02-Maintenance.doc

1 Bearing housing
2 Race
3 Spring

4 O-ring
5 Washer
6 Screw

HANDBOOK FOR
OPERATION AND MAINTENANCE

11.2

COMPRESSOR KA5S-GK200

Page 3/50

SERVICE
Service 1 includes:
















Inspection of inlet filter and silencer
Dismantling of compressor
Cleaning and check of compressor impeller
Inspection and cleaning of diffuser system
Check of diffuser geometry
Inspection and cleaning of inlet guide vanes
Check of inlet guide vanes geometry
Changing of flexible seals (o-rings etc.)
Check of lubricating oil
Changing of oil filter
Visual check of gearwheels (only GL gears)
Assembly of compressor and accessories
Check / test of control and safety functions (thermostats, pressure switches, transmitters etc.)
Test run of compressor with accessories and electric equipment
Preparation of service and state report for customer

Estimated time consumption for Service 1 (depending of e.g. plant conditions – silencer hood –
crane facilities etc.):
Preconditions: KA5 - 10:
Participation of 1 STE service engineer + 1 local assistant.
Complete special tools should be available.
KA5 / KA10 SV-GK200

11 hours

Detailed description of the service activities.
Service requires cleaning and checking of all parts exposed to the medium; as well as checking/replacing of all flexible gaskets; test and, if necessary, adjustment of control panel; test run.
If the diffuser ceases to operate smoothly (due to impurities in the compressor) before the
18.000 hrs have lapsed, the first service check shall be moved forward and the services following it timed accordingly, as a dirty compressor is less effective than a clean one.
CHECK LIST FOR SERVICE
ƒ Test run of compressor to check oil-tightness.
ƒ Vibration level in test point (RMS-value) measured before disassembling of compressor.
ƒ Dismounting of air inlet duct.

- Dismounting of silencer and air-inlet filter.
- Dismounting of silencer.
- Check and cleaning/replacement of air-inlet filter.
- Check of silencer.
- Repair of silencer.
ƒ Dismounting of outer diffuser drive system.
ƒ Dismounting of inlet housing, spiral casing, contour ring, impeller/rotor and diffuser plate.

- Check and cleaning of all air-exposed surfaces, especially of impeller/rotor.
- Disassembling of inner diffuser drive system.
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COMPRESSOR KA5S-GK200

Page 4/50

- Check, lubrication, and cleaning of all parts in the diffuser drive system.
- Assembling and measuring of diffuser drive system. Check of throat area.
ƒ Disassembling of gear.

- Visual check of gearwheel and sealings.
- Replacement of sealings (optional).
- Replacement of ball bearings and O-rings.
- Cleaning of all parts.
- Assembling of gear.
- Check and measuring of axial play in gear.
ƒ Assembling of compressor. Visual check of all parts, including check of clearance of axial

bearing in rotor.
- Check of clearance between impeller and covering.
- Replacement of O-rings.
ƒ Mounting, check, and adjustment of outer diffuser drive system. Check of mechanical limit

switch to stop at scale value "0". Check of limit switch.
ƒ Mounting of silencer.
ƒ Mounting of silencer and air-inlet filter.
ƒ Mounting of air-inlet duct.
ƒ Replacement or cleaning of oil filter
ƒ Check of coupling (alignment).
ƒ Check of drive motor (cleaning of fan and lubrication).
ƒ Check of blow-off valve and non-return valve (functional test).
ƒ Check of lube oil pump.
ƒ Replacement of bearing and seals in lube oil pump.

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02-Maintenance.doc

HANDBOOK FOR
OPERATION AND MAINTENANCE

11.3

COMPRESSOR KA5S-GK200

Page 5/50

SIMULATED TEST RUN OF COMPRESSOR
In order to check the start/stop sequence as well as the cable connections a simulated test run
shall be undertaken.
When simulating operation the entire safety monitoring equipment shall be tested with satisfactory result. For pressure and temperatures, see technical specifications § 2.
Turn compressor manually to check that rotation is smooth. This is most easily done at the coupling between drive motor and gear.

11.4

TEST RUN OF COMPRESSOR
During the test run the following shall be checked/adjusted:
ƒ Opening and closing time of blow-off valve. The blow-off valve shall normally signal "closed"

at max 180 seconds after start (depending on type of valve and plant conditions).
ƒ Function of non-return valve.
ƒ Build-up and stability of air pressure in pressure pipe.
ƒ Lubricating oil pressure and temperature shall be stabilized.
ƒ Test diffuser adjustment manually.

*)

ƒ Test safety monitoring system and emergency stop during operation.
ƒ Test normal start and stop sequence.
ƒ Adjust motor overload protection (diffuser limit).
ƒ Check for oil leaks at operating temperature.

OBSERVATIONS AND MEASUREMENTS DURING MAINTENANCE

*)



Vibration level before service



Diffuser throat area after maintenance

(mm):



Clearance rotor/covering

(mm):



Limit switch diffuser



Coupling alignment round/flat impact



Vibration level after maintenance



Hour counter

Lubricating oil pressure and temperature see technical specifications § 2.

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02-Maintenance.doc

RMS (mm/S):

MIN/MAX:
± (mm):
RMS mm/S:
(hours):

HANDBOOK FOR
OPERATION AND MAINTENANCE

11.5

COMPRESSOR KA5S-GK200

Page 6/50

MASTER CONTROL PANEL (if supplied)
Check and start-up of Master Control Panel (MCP), during which the start/stop sequence, the
priority sequence and control sequence are tested on all compressors.
ƒ Check of cable connections from Local Control Panels to Master Control Panel.
ƒ Check and adjustment of step controller (adjustment of diffuser via mA signal).
ƒ Check of output signal from pressure/oxygen transmitter.

11.6

INLET SILENCER
The inlet silencer is designed for atmospheric air and lined with sound-absorbing material.
Cleaning of the sound-absorbing baffles can be done by a vacuum cleaner during service.
Avoid bending the baffles.
The sound absorbing material shall never be exposed to steam or washed with water.
IMPORTANT: Organic solvents will damage the material and its adhesion to the supporting
frames.

11.7

DISPOSAL OF WASTE
Disposal of waste according to the instructions of the local authorities.
A compressor in operation shall have air filter elements and lubricating oil changed at regular
intervals.
Used air filter elements or used filter cloth can be disposed of as combustible waste. Used lubricating oil to be treated as chemical waste and disposal according to the instructions of the local authorities. Oil moistened cloths used for oil absorption and used oil filters can be disposed
of as combustible waste. Iron and metal from the replacement of compressor parts can be removed as scrap.

11.8

ORDER FOR SPARE PARTS
Orders for spare parts shall state in writing serial number, type of compressor and gear, and
position number of each part.

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HANDBOOK FOR
OPERATION AND MAINTENANCE
12.
12.1

COMPRESSOR KA5S-GK200

Page 7/50

DISMOUNTING / REMOUNTING

COUPLING ALIGNMENT FLENDER ARPEX TYPE

1.

The following directions are only applicable when aligning couplings on standard, single-stage
turbocompressor units operated by an asynchronous motor with anti-friction bearings. The coupling must be of the Flender Arpex type, but not necessarily a Flender product. The alignment requirements apply only to couplings with standard "spacer lengths" mounted between motor and
gear, hence they are not to be used when aligning "fast running" couplings mounted between
gear and compressor.

2.

The alignment requirements, as indicated in Table 1, correspond to approx. 25% of the max.
allowable deviations specified by the suppliers of couplings, and have thus been approved by
suppliers of couplings and drive motors to SIEMENS.
Improved alignment requirements ensure that vibrations caused by errors of alignment will not be
affecting the overall vibration level.

3.

The couplings are aligned during mounting of the unit in SIEMENS's workshop. The alignment is
safeguarded against changes during transport/erection, due to the fact that the bases are very
stiff. The coupling alignment must always be checked prior to starting up the compressor.

4.

The procedure stated in the following points describes alignment with application of a dial gauge.
Alternatively laser equipment can be used for the same purpose.

5.

Having shrunk one of the coupling halves onto the drive shaft, the compressor/gear unit is
mounted on its base. Two guide rods are then placed in the gear support. Now place the electric
motor - with the other coupling half mounted - on the four supports with four 10 mm shims between motor and base. Make sure that the motor is resting on all four points of support; this prevents it from being twisted during the tightening. If more than 0,05 mm of shims is needed under
any one of the supports, place a suitable number of 'thin' shims under the support until the motor
is resting evenly on all points of support.
Make sure that measure S is maintained while positioning the motor; see Table 1 and figure 1.
On GA, GB, GC, GL, and GK2/B3 the drive shafts of gear and motor shall be pulled towards one
another while measuring S. While bearing in mind the possibility of heat expansion make sure
that the tolerance of S is a +tolerance in order to minimize the load on the thrust bearing of the
gear. In other words, the gear shaft and the drive shaft shall be pulled towards one another.
On GK190 and GK200 the shaft of the motor shall be pulled towards the gear, while the drive
shaft of the gear shall be pressed away from the motor when measuring S. While bearing in mind
the possibility of heat expansion, make sure that the tolerance of S is a +tolerance.

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HANDBOOK FOR
OPERATION AND MAINTENANCE

6.

COMPRESSOR KA5S-GK200

Page 8/50

As indicated in figures 2 and 3, the angular and parallel misalignments are measured with a dial
gauge, which is bolted to the coupling shaft and measures on the motor shaft (see fig. 2 & 3).
Do not use a dial gauge with magnet foot. The rest of the measuring setting-up should also be as
inflexible as possible to avoid measuring faults caused by deflexion.
When measuring, make sure that the two coupling halves are rotating synchronously, e.g. by
using a trailing rod.
When the coupling is rotated one full revolution, the measuring dial must not go beyond the tolerances set for parallel and angular misalignments, as indicated in Table 1.
The alignment is carried out partly by adjusting the thickness of the shims, partly by adjusting the
motor position on the base.
The parallel misalignment should be suppressed, partly because a major display will entail an
important deviation of the radial misalignment, partly to adjust for unevenness between the two
plate packs.
As already stated (point 4), the motor is not to be tightened definitively until it is resting evenly on
all four supports. If necessary, use thin shims under one of the supports.
When measuring the angular and parallel misalignments, it is a good idea to mount a spring between the flange on which the dial gauge is fixed and the flange too measured on. In this way the
axial position of motor shaft and gear shaft is maintained.

7.

The coupling bolts are tightened by means of a torque wrench or by measuring the elongation of
the bolts. When mounting and tightening, follow the instructions of the supplier.
In general, couplings of the Flender Arpex, Mönninghoff Arcoflex, and Thomas Rexnord SR52
types are used. The mounting instructions for these makes are different. See instructions on
page 5 - 8. For all types the thread of the bolts must be greased. Do not use Molykote or similar
instead of oil for the greasing. When tightening the bolts, the bolt head must be fixed while the nut
is turned.
If other types of couplings than the three ones above are mounted, the mounting instructions for
the coupling make in question must be required.

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HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 9/50

TABLE 1

S Tolerance **
+ Tolerance
to be used

Concentric Running RL**
Gauge indic.

Gyratory Running PL**
Gauge indic.

Gyratory Running
mm/100mm

168 or less

± 0,3

0,24

0,29

0,17

180

± 0,4

0,24

0,31

0,17

200

± 0,4

0,24

0,34

0,17

205

± 0,4

0,24

0,36

0,17

215

± 0,4

0,24

0,38

0,17

235

± 0,5

0,31

0,41

0,17

250

± 0,5

0,31

0,44

0,17

270

± 0,5

0,31

0,44

0,17

300

± 0,6

0,31

0,52

0,17

320 ***

± 0,6

0,31

0,56

0,17

Coupling Size
(Flange diameter) *

*

For deviating flange diameters, the tolerances for the closest - and smaller - flange diameter are
used.

**

The misalignment tolerances are valid for standard spacer lengths of 250 mm, but may also be
used at spacer lengths over 250 mm.

***

For high torque series, the same alignment tolerances apply.
All measurements are in mm.

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HANDBOOK FOR
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COMPRESSOR KA5S-GK200

Page 10/50

Figure 1.

MOTOR

GEAR

Concentric Running: RL

Figure 2.

GEAR

MOTOR

Gyratory Running: PL

Figure 3.

GEAR

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MOTOR

HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 11/50

THOMAS REXNORD SR52-MSH COUPLINGS TYPE XXX

Coherence between type of coupling, shaft diameter, dowel screws, key width and torque TA.
*NB! The torque TA of the dowel screws only applies to clean, greased threads. Use compressor lube oil.

Coupling
Type XX

Shaft Diam.
mm

Dowel Screws
metric

*Torque
TA Nm

Key Width mm

225

145

M8 × 1

13

34

262

168

M10 × 1

17

41

312

198

M10 × 1

17

54

350

221

M12 × 1,25

19

129

375

246

M14 × 1,5

22

176

425

267

M16 × 1,5

237

450

287

M18 × 1,5

271

500

327

M20 × 1,5

353

The correct mounting of the plate packs is shown on below drawing. The screws must be mounted in the
coupling flanges (shaft/spacer) pos. 2. Do not forget to mount the washers pos. 3 on each side of the
plate packs.
Important! Check the screw torque after approx. 10 hrs of operation.

1
3

1
3

2

2

TA

TA

Description of Coupling:
See section “Accessories”

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3

3

HANDBOOK FOR
OPERATION AND MAINTENANCE

12.2

COMPRESSOR KA5S-GK200

Page 12/50

DISMOUNT/REMOUNT OF OUTER DIFFUSER SYSTEM
See drawing next page.
Aids:

Torque wrench and ordinary hand tools.

Joint paste:

None

Dismount:

Positioning motor D224 on mounting plate D208 to be dismounted as one unit.
Dismount pin bolt connection D219 at the positioning lever D205.
Unscrew D206 and remove pin bolt D219 from the positioning shaft D207.
Separate the limit switch cables from their compressor fixings without disconnecting the cables from the terminal box. The position of the limit
switches, defined and set by SIEMENS, shall not be changed, as this will influence the capacity of the compressor.
The cables on the linear motor D224 shall not be disconnected.
After removal of screw D209 the mounting plate D208 and the positioning motor
can be dismounted. To be placed safely.

Remount:

Mounting and assembly in reverse order. Take care that the electric cables are
mounted correctly.

IMPORTANT! Positioning lever D205 to be replaced in exactly the same position
on the positioning shaft D207 as before. Tighten the screw D206.
When the diffuser is closed at Min. mechanical end-stop, the lever position
must be 0.

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02-Maintenance.doc

HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

OUTER DIFFUSER SYSTEM

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Page 13/50

HANDBOOK FOR
OPERATION AND MAINTENANCE

12.3

COMPRESSOR KA5S-GK200

ADJUSTMENT OF CLEARANCES
See drawing next page.

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HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

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HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 16/50

INTERNAL GAPS - TURBOCOMPRESSORS WITH ALU IMPELLER
OVER PRESSURE DUTY (TECH. DOC. 930920036UK)

TYPE

SP1

KA5-GK200
0,9

MAX
MIN

SP2

MAX
MIN

SP5

MAX
MIN

(SP5)*

+0,1
0

0,7

+0,05
0

0,3

+0,05
0

0,55

(SP5)*: When measuring gap SP5 by means of lead-imprinting (min. 4 measuring points evenly
distributed) at least one measuring point shall be within the tolerance stated in column SP5
MAX/MIN, and no other measuring points must exceed the gap (SP5)*. (SP5)* indicates max.
permitted non-parallelism in the diffuser.

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02-Maintenance.doc

HANDBOOK FOR
OPERATION AND MAINTENANCE

12.4

COMPRESSOR KA5S-GK200

Page 17/50

WEIGHT OF SINGLE PARTS
Pos. No.

Description

H701

Inlet housing /

H501

Inner volute casing

85 kg

R400

Rotor complete

12 kg

D101

Diffuser plate

23 kg

R100

Drive shaft

53 kg

H101

Gear casing - part A

28 kg

H102

Gear housing - part B

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02-Maintenance.doc

Weight approx.

225 kg

HANDBOOK FOR
OPERATION AND MAINTENANCE

12.5

COMPRESSOR KA5S-GK200

Page 18/50

SPECIAL TOOLS

Info
V999

qty Description
1 Tool box

Order no.
9332270330

Illustr.

V102

1
3

Lifting tool for inlet
Screw M10 x 20

93330570160
N61V10020

A
B

V103

1

Eyebolt (N69R12) for outer volute casing

434002879

C

V202

1

Eyebolt M20 (N69R20) for gearbox

434004511

D

V405
V405
V405

1
1
1

Screw for play setting
Washer, MG
Nut, M12

GK200V004
N64S13
N91M12

E
F
G

V501
V504

1
1

Extractor for compressor impeller
Rotor tightening tool complete

9330570480
9330570450

H
I

V701

1
3

Lifting tool for inlet shaft
Screw M8 x 20

GK200V001
NG1V08020

J

V304

6
3

Nut M8
Threaded rod M8 x 120 for bearing housing

N91M08
9330570550

V305

6
3

Nut M6
Threaded rod M6 x 90 for sealing

N91M06
9330570540

V306

1

Screw for securing of shim T218

GK200V005

V503

1

Dowel for rotor nut

N1P06060

V503

1

Drift for dismounting of stop nut (spinner)

9330570530

V901
V903
V903
V903

1
3
3
3

Guide rod M8 x 100
Screw M6 x 70
Screw M8 x 110
Nut M8

9332270215
N61V06070
N61V08110
N91M08

V912

1

Tool for dismounting of oil pump

GK200V008

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K

L

M

HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

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HANDBOOK FOR
OPERATION AND MAINTENANCE

12.6

COMPRESSOR KA5S-GK200

Page 20/50

Tightening Torque

Where nothing else is stated for the tightening torque of the bolts and screws used in
SIEMENS compressors, the below mentioned values (ISO-m) are valid. The values are for
ordinary bolts with strength 8.8 (DIN 267) and socket head bolts and Insex screws.

M
Nm

3

4

5

6

8

10

12

14

16

20

24

30

1,37

3,10

6,15

10,5

26

51

89

141

215

390

675

1160

Wrench Width: Hexagon Screws
M
Width

3

4

5

6

8

5,5

7

8

10

13

10
16

12

(17)

18

14

(19)

21

(22)

16

20

24

30

24

30

36

46

Wrench Width: Insex Screws
M

5

6

8

10

12

14

16

20

Width

4

5

6

8

10

12

14

17

24

30

NB! Wrench widths are in accordance with ISO 4014/4017, except figures in () which are according to DIN 931/933.

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02-Maintenance.doc

HANDBOOK FOR
OPERATION AND MAINTENANCE

12.7

COMPRESSOR KA5S-GK200

DISMOUNT / REMOUNT DRAWINGS

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HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

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HANDBOOK FOR
OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Rotor: See next page

Page 23/50

3.

Fasteninq (Fig. 1):
1.

Mount screw R411 in the rotor drive R401.

2.

Lubricate both threads of the central screw R405 and between rotor drive R401 and pinion
shaft R201 with an agent to protect against scratches.

3.

Tighten the central screw R405 the whole way down into the pinion shaft R201. Mount the
rotor drive with impeller and stop ring on the pinion shaft. Check that screw R411 locks with
the keyway in the pinion shaft. Tighten the rotor nut R407 on the central screw. Mount
the fastening tools 933 057 045 0 on the central screw. Pump to an oil pressure of 410 bar (420
kp/cm 2). Tighten the rotor nut R407 until complete contact with a 06 mandrel in one of the two holes and
check with a feeler gauge (0.05 mm) that the nut is completely abutting the stop ring. Remove the oil pressure for the threads to settle.

4.

Pump again to 410 bar. Tighten the rotor nut again until complete contact. Remove the oil
pressure and the fastening tools.

5.

The assembled rotor is balanced according to balancing instruction. All parts are to be marked with serial number for the balancing.

Dismountinq of impeller complete (fig. 2):

1.

Mount fastening tools 933 057 045 0.

2.

Pump to an oil pressure of 410 bar (420 kp/cm2) so rotor nut R407 can be loosened. Remove the
oil pressure and the tools.

3.

Dismount the central screw R405.

4.

Dismount impeller R414 with dismounting tools 933 057 048 0.

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12.8.1

Pos.
Nr.

COMPRESSOR KA5S-GK200

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COMPRESSOR GEARBOX DRAWING No.9330502950.0

Description

Pos.
Nr.

Description

D100
D200

Inner diffuser drive
Outer diffuser drive

R100
R400

Drive shaft
Rotor, complete

E130
E134

Sight glas (oil level)
Snesor pocket

H101
H102
H113
H115
H116
H127
H128
H129
H186
H194
H303
H304
H311
H313
H316
H317
H401
H402
H403
H404
H410
H502
H505
H701
H704

Gear casing/bearing shield part A
Gear housing part B
Plug for oil duct
Screw
Dowels
Plug
Gasket
Plug
Plug
O-ring
Labyrinth sealing
Screw for H303
Cover for aeration
Screw
Flange
Screw
Outer volute casing
Screw/stud
Screw for spiral casing positions
Plug
Plug
Screw
Contour ring with inner volute casing
Inlet housing
Screw

S112
S113
S124
S129
S131
S132
S155
S156
S161
S162
S425
S426

Stud for oil mist filter
Oil mist filter
Angle fitting
Oil pump, mechanical
Screw
Union
O-ring
O-ring
Fitting
Fitting
Copper pipe
Fitting, straight

T101
T102
T103
T106
T112
T114
T124
T204
T207
T208
T210
T213
T215
T218
T220
T221
T222
T234

Sealing ring
Screw
Ball bearing, motor end
Ball bearing, compressor end
O-ring
Washer
Crinkle washer
Bearing housing
Screw
Angular contact ball bearing, motor end
Double contact ball bearing, compressor end
Shim
Washer
Shim
Sealing ring, inner
Screw
Bearing housing
Screw

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12.8.2

COMPRESSOR KA5S-GK200

Rotor Drawinq No. 933.052.322.0.0

Pos. No.

Description

R201
R401
R405
R407
R409
R410
R411
R412
R414

Pinion shaft
Rotor drive
Centre screw
Rotor nut
Stop ring
Special screw
Dowel
Stop nut
Impeller

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12.8.3

COMPRESSOR KA5S-GK200

Outer Diffuser System, Drawinq No. 9330554160.0
Pos. No.

Description

D201

Excenter housing

D202

Screw for D201

D203

Screw for D201

D205

Positioning lever

D206

Screw for D205

D207

Excenter shaft

D208

Mounting plate

D209

Screw for D208

D210

Limit switch

D211

Screw for D210

D212

Backstop

D213

Scale

D214

Screw for D213

D219

Pin bolt for D224

D224

Linear motor

D229

Screw for console

D230

Console for D224

D231

Screw

D240

Bearing for D201/D207

D241

Gasket for D201/D207

D248

Support for D210

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12.8.4

COMPRESSOR KA5S-GK200

INNER DIFFUSER SYSTEM, DRAWING No. 9330554180.0

Pos. No.

Description

D101

Diffuser plate

D102

Swivel joint

D108

Guide ring

D109

Dowel

D110

End stop

D113

Retaining plate for guide ring

D114

Screw

D115

Screw

D116

Diffuser blade

D117

Shaft for diffuser blade

D118

Screw

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12.8.5

COMPRESSOR KA5S-GK200

Lube oil pump, DRAWING NO.GK200S017

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12.8.6

COMPRESSOR KA5S-GK200

AGGREGATE DRAWING NO.9330503140

Pos. No.

Description

A101
A103
A104
A105
A107
A200
A201
A202

Serial number plate
Plate
Mobil SHC 624
Plate
Rivet
Compressor/Gear KA5S-GK200
Screw
Dowel

A301
A302

Coupling
Guard

A401
A402

Electric motor
Screw

D200

Outer diffuser drive

E100
E105
E109
E110
E121
E122
E134
E139
E187

Control and monitoring
Sensor pocket
Ermeto fitting
Copper pipe
Manometer (Oil pressure)
Thermometer (Oil temperature)
Sensor pocket for recirculation
Sensor pocket for start/stop of oil cooler
Manometer fitting

F101
F105

Frame
Shim

S203
S204
S205
S206
S213
S215
S216
S217
S301
S302
S303
S313
S318
S322
S334
S336
S901
S902

Ermeto fitting
Ermeto fitting
Ermeto fitting
Ermeto fitting
Ermeto fitting
Hose
Hose
Ermeto fitting
Oil cooler
Screw
Oil filter
Oil distributor
Base for oil cooler
Screw
Plug
Oil drain
Ermeto fitting
Washer

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Siemens Turbomachinery Equipment A/S
Operations Manual
Local Control Panel
Revision: 2.01
January 2006

Siemens Turbomachinery Equipment A/S
Allégade 2
DK-3000 Helsingør
Denmark
Telephone: +45 49 21 14 00
Facsimile: +45 49 21 52 25
Web: www.powergeneration.siemens.com

Copyright: The concepts and information contained in this document are the property of Siemens Turbomachinery Equipment A/S (STE). Use or copying of this document in whole or in part without the written permission of STE constitutes an infringement of copyright.
Disclaimer of Liability: We have checked the contents of this manual with the equipment described. Since
deviations cannot be precluded entirely, we cannot guarantee full agreement. However, the data in this manual
are reviewed regularly and any necessary corrections included in subsequent editions. Suggestions for improvements are welcomed.

Operations Manual
Local Control Panel

17-03-2008
Revision: 2.01

Document Control
Document Information
Title:
Number of Pages:
Revision:
Author:
File Name:
Last Printed:
Last Saved:

Operations Manual: Local Control Panel
52
2.01
KJH
R:\Automation\Manuals\LCP-T\LCP-T Manual English V2.01.doc

08/04/2008 14:34:00
04/04/2008 16:28:00

Revision History
Rev.
0.0
1.0
2.0
2.01

Date
02-06-2004
21-06-2004
16-01-2006
04-04-2008

By
KJH
KJH
KJH
LC

Approved Description
Original issue (for review)
AKOP
First release
AKOP
Sections 6, 7 and 10.2 revised, 10.6 added
AKOP
HVT changed to Siemens

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Safety Instructions
Make sure that this Operations Manual is at the disposal of everybody who is involved in
operation, maintenance and repairs and that the contents have been understood.
If the operating instructions in this Operations Manual are not observed, the result may be
function interruptions and damages to the system as well as personal injuries, for which the
manufacturer does not undertake any responsibility.

By unprofessional treatment of equipment and components there will be a risk of
personal injury.

The Operations Manual and the compressor handbook contain the necessary information for
the correct use of the functions described. They are intended for qualified personnel.
Qualified personnel in connection with the safety instructions in this Operations Manual is


either projecting personnel who is familiar with the safety regulations of automation
technology,



or personnel who has been instructed in handling automation technology equipment
as operational personnel and who knows the contents of the documentation related to
the operation.



or service personnel who has an education qualified for the repair of such automation
technology equipment, respectively who is entitled to put electric circuits and devices/systems into operation according to the relevant safety standards.

The system is solely constructed for the application described in the scope of delivery (defined by the manufacturer of the equipment, application according to description). Any application beyond this is not according to description. The manufacturer is not responsible for
resulting damages. Only the user has the responsibility for this.

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To the application according to description also belongs the observation of the conditions of
operation, maintenance, and repair lain down by the manufacturer. The system must only be
used, serviced, and repaired by persons who are familiar with this and have been instructed
in the risk.
If work can only be carried out with an open control panel at voltage, corresponding safety
measures shall be taken.
Instructions for protection against accidents as well as other generally recognized safety and
work regulations shall be observed.
At maintenance work all automatic processes, controls and functions must stand still. They
have to be blocked and secured against unintentional restart.
It is a condition for the qualified maintenance and repair that all necessary devices and tools
are at disposal and that the condition of the tools is completely satisfactory.
Maintenance work or repairs must only be carried out in voltage-free condition by qualified
personnel.
In order to be clear the instruction does not include all details for all versions of the product
in question, and it can neither consider every imaginable way of installation, operation or
maintenance. If you wish further information or in case problems occur that have not been
described in enough details, necessary information can be obtained at STE.

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Contents
1
2
3
4

Preface ........................................................................................................................................... 1
Related Documents....................................................................................................................... 1
Definitions ..................................................................................................................................... 2
General Information .................................................................................................................... 3
4.1 Basic Screen Design ............................................................................................................... 3
4.2 Screen Navigation ................................................................................................................... 4
4.3 Language Selection ................................................................................................................. 5
4.4 Password Protection................................................................................................................ 5
4.5 Message System...................................................................................................................... 8
5 Operation Modes ........................................................................................................................ 12
5.1 Selecting Modes.................................................................................................................... 12
5.2 Off Mode............................................................................................................................... 13
5.3 Local Mode ........................................................................................................................... 13
5.4 Remote Mode........................................................................................................................ 14
5.5 Service Mode ........................................................................................................................ 14
5.6 Test Modes............................................................................................................................ 16
6 Starting the Compressor............................................................................................................ 17
6.1 Start Conditions .................................................................................................................... 17
6.2 Start Sequence....................................................................................................................... 19
6.3 Local Start............................................................................................................................. 20
6.4 Remote Start.......................................................................................................................... 21
7 Stopping the Compressor .......................................................................................................... 22
7.1 Normal Stop Sequence.......................................................................................................... 22
7.2 Local Stop ............................................................................................................................. 23
7.3 Remote Stop.......................................................................................................................... 24
8 Controlling the Compressor Capacity...................................................................................... 25
8.1 Local Capacity Control ......................................................................................................... 25
8.2 Remote Capacity Control...................................................................................................... 25
8.3 Minimizing the Power Consumption .................................................................................... 26
9 Abnormal Operating Conditions .............................................................................................. 27
9.1 Soft Stop Sequence ............................................................................................................... 27
9.2 Hard Stop Sequence .............................................................................................................. 27
9.3 Alarms/Trips ......................................................................................................................... 28
9.4 System Messages .................................................................................................................. 29
10 Settings ........................................................................................................................................ 30
10.1 Calibrating the diffuser and the inlet guide vanes................................................................. 30
10.2 Setting the blow-off valve closing time ................................................................................ 31
10.3 Setting the main drive motor current limiting....................................................................... 32
10.4 Setting instrument scalings ................................................................................................... 33
10.5 Setting alarm set points ......................................................................................................... 34
10.6 Save and restore settings ....................................................................................................... 35
11 Appendix ..................................................................................................................................... 37
11.1 Basic Screen Navigation Diagram ........................................................................................ 37
11.2 Troubleshooting Guide ......................................................................................................... 39
11.3 Colour Conventions .............................................................................................................. 43
11.3.1 Mono Version ................................................................................................................ 43
11.3.2 Colour Version............................................................................................................... 44

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Preface

Purpose:
This manual provides information about how to:
• Operate the STE Compressors.
• Handle abnormal operating conditions.
• Change basic settings.
Audience:
This manual is designed for Operators and Maintenance personnel who have a general
knowledge about rotating machinery and instrumentation.
Scope of the Manual:
The information contained in this manual pertains in particular the following equipment:
• STE Compressors, KA series
• STE Local Control Panels
• STE Human Machine Interfaces, mono edition
• STE Human Machine Interfaces, colour edition
Note:
Not every option or Human Machine Interface screen in this manual is relevant for each
Local Control Panel.
Text Conventions:
The following text conventions are used throughout this manual:
Vibration system
<Off>

Optional devices and conditions are presented in this italic font.
The names of keys and buttons are displayed in this bold font.

Further Support:
If you have any technical questions, please get in touch with your local STE representative or
agent responsible.
http://www.STE.com/english/index.htm

2

Related Documents

Refer to the following documentation for more detailed information about selected topics:
• Navigation Diagram LCP Operator Interface
• Circuit Diagram Local Control Panel
• Sequential Function Charts Local Control Panel

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Definitions

This section describes the important technical terms used in this manual.




















Actuator
Electrical driven mechanical device used to open/close valves, diffuser and IGV.
Alarm
An Alarm signals that a process condition or process value is approaching a critical
value. The compressor will remain in operation.
BOV
Blow-Off Valve. A valve mounted in the compressor outlet system used to unload the
compressor during start and stop.
Consumer
Electrical device (lube oil pump, lube oil heater, ventilation fan, etc.)
Diffuser
Flow and pressure control device mounted in the compressor outlet.
HMI
Human Machine Interface
HMI Screen
A HMI Screen is a group of logically related process data. A HMI Screen consists of e.g.
input and output fields, text, graphics and pushbuttons (Example Figure 4-2).
Inlet Guide Vanes (IGV)
Flow and pressure control device mounted in the compressor inlet.
Local Control Panel (LCP)
Control panel connected to one compressor. The control panel is used to monitor the
conditions of the compressor and start/stop the compressor according to the automatic
sequence.
Master Control Panel (MCP)
Control panel connected to a group of compressors. The control panel is used to start and
stop the compressors according to the selected sequence and to regulate the compressor
capacity to match the airflow demanded by the process.
MCC
Motor Control Centre
PLC
Programmable Logic Controller
PRC-4
STE’s algorithm for minimizing power consumption.
Surging
An aerodynamically unstable condition where a moderate increase in discharge pressure
causes a significantly decrease in throughput. This instability can be extremely severe,
with visible vibration and audible noise.
System Message
System messages display states and faults of the HMI and the PLC.
Trip
A Trip signals that a process condition or process value has exceeded a critical value.
The compressor will make a quick shut down.

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4

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General Information

This section provides basic information about the use of the compressor HMI from STE. Describing among others basic screen design, screen navigation, language selection, password
protection, and the message system.
4.1
Basic Screen Design
All the HMI screens are basically divided in three areas (Figure 4-1) the fixed area, the basic
area, and the navigation area.

Figure 4-1

Fixed Area:
The fixed area is used to provide general information about the compressor status and the
operation mode currently selected. The fixed area (Figure 4-2) is the same for all HMI
screens.
Basic Area:
The basic area is different for all HMI screens. Depending on the screen currently selected
the basic area provides access to process values, settings, start/stop pushbuttons, language
selection and links to other screens (Figure 4-2).

Figure 4-2

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Navigation Area:
The navigation area holds the pushbuttons used to navigate between the HMI screens in the
screen hierarchy. The number of pushbuttons in the navigation area depends on the position
of the current screen in the screen hierarchy.
The functions of the individual navigation pushbuttons are described in section 4.2.
4.2
Screen Navigation
The HMI screens are all arranged in a screen hierarchy that lay down how the individual
screens are linked together. Each HMI screen has a unique number according to its position
in the screen hierarchy. The screen number is shown in the lower right corner on every
screen. The screen numbering system is shown in Figure 4-3.

Figure 4-3

The pushbuttons in the navigation area of the HMI screens are used to move/navigate around
in the screen hierarchy. The functions of the individual navigation pushbuttons are described
in Figure 4-4.

Figure 4-4

For details about screen navigation please refer to the appendix in section 11.1.

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4.3
Language Selection
The STE HMI provides the possibility to let the user switch between two HMI languages.
The default HMI language is English. The second language is project dependent.

Figure 4-5

Switching the HMI languages is done on the “MAIN SCREEN” No. 1 (Figure 4-2) by clicking the “FLAG” pushbutton (Figure 4-5). The currently selected HMI language is shown in
the text field above the pushbutton.
4.4
Password Protection
Critical functions and settings are protected by passwords to avoid activation or change by
accident. The password level currently logged on can be seen on the “MAIN SCREEN”
No. 1 (Figure 4-2) and on the “MAIN SCREEN” No. 2 (Figure 4-12).
Password levels:
The HMI provides hierarchically organized password levels from level 0 to 9. If a user is
logged on with password level 3, for example, this user is authorized to execute the functions
of password levels 0 to 3.
The following password levels are used in the STE HMI:
• Password level 0 is the default level i.e. the lowest level in the password hierarchy. A
password does not need to be entered to execute functions on password level 0.
• Password level 3 is used to protect functions intended only for the plant maintenance
personnel. A password has to be entered in order to execute these functions.
Logging on:
Password log on can be done in two different ways:
• Directly by using the “SETTINGS: PASSWORD MANAGEMENT” screen
No. 2.1.2 (Figure 4-6).
1. Enter the password in the “Input Password” field.
2. Click the <Log On> pushbutton (Figure 4-7).
3. Result: The password level is shown in the “Current Password Level” field.

Figure 4-6

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Figure 4-7

• Indirectly by clicking a password protected pushbutton or input field.
1. Click the pushbutton or input field.
2. Result: The LOGIN window opens (Figure 4-8).

Figure 4-8

3.
4.
5.
6.
7.
8.

Click the Password field.
Result: The on-screen keyboard opens (Figure 4-9).
Enter the password and click the <Enter> key.
Result: The on-screen keyboard closes.
Click the <OK> pushbutton in the LOGIN window.
The user is now logged on.

Figure 4-9

Logging off:
Password log off can be done in two different ways:
• Automatically by the HMI after 15 minutes.
• Manually by using the “SETTINGS: PASSWORD MANAGEMENT” screen
No. 2.1.2 (Figure 4-6).
1. Click the <Log Off> pushbutton (Figure 4-7).
2. Result: The password level is reset to 0.
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Password table:
The table below shows the default password for password level 3 when the HMI is shipped.
Password Level

User Name

Password

Changes Allowed

1

-

-

-

2

-

-

-

3

Plant

STE

Yes

0

3
3
3

The empty rows in the table above can be used to keep record of new passwords created or
of changes to existing passwords.
Changing passwords:
When logged onto password level 3, changes can be made to the password levels 1 to 3 as
described below:
1. Navigate to screen No. 2.1.2 (Figure 4-6)
2. Log onto password level 3 as described in the section Password Protection (Logging
on directly).
3. Click in the relevant field in the Password column.
4. Result: The on-screen keyboard opens.
5. Enter the new password and click the <Enter> key.
6. Result: The on-screen keyboard closes and the password has been changed.
Creating passwords:
When logged onto password level 3, new passwords can be created for the password levels 1
to 3 as described below:
1. Navigate to screen No. 2.1.2 (Figure 4-6)
2. Log onto password level 3 as described in the section Password Protection (Logging
on directly).
3. Click an empty field in the User column.
4. Result: The on-screen keyboard opens.
5. Enter the new user name and click the <Enter> key.
6. Repeat step 3-5 for the Password and Level columns.
7. Result: The on-screen keyboard closes and the password has been created.

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4.5
Message System
The message system is responsible for reporting events or states that can occur in the compressor system or in the control system. The message system consists of the following components:
• The message indicator.
• The alarm messages window.
• The alarm page.
• The message buffers.
These components and the three message types that are distinguished between in the message system are described below.
Message Types:
• Alarm messages display critical or hazardous operating and process states and require the operating personnel to react by issuing an acknowledgement.
• Event messages display routine operating and process states.
• System messages display states and faults of the HMI, the PLC or the communication between them. They are issued by the HMI or by the PLC and are automatically
displayed on the HMI when they occur.
Message Indicator:
As soon as an alarm message is arriving, the alarm message window (Figure 4-11) and the
message indicator (Figure 4-10) are displayed. The message indicator shows the number of
active alarm messages and will remain visible as long as alarm messages still are active (i.e.
not cleared). The message indicator can assume two states:
• Flashing: As soon as at least one unacknowledged alarm message is queued.
• Static: When all queued alarm messages have been acknowledged but at least one of
them is not yet cleared.

Figure 4-10

Clicking the message indicator will:
• Open the alarm message window if unacknowledged alarm messages still remain.
• Open the alarm page if active alarm messages still remain.
Alarm Message Window:
The alarm message window (Figure 4-11) opens automatically whenever an alarm message
arrives. The following information is provided in the alarm messages window:
• No. column displays a unique alarm message number. Please inform this number
when calling STE for service support.
• Status column displays the current status of the alarm message:
- A: The message is Active
- C: The message is Cleared
- R: The message has been Reset/acknowledged
• PLC column displays the PLC from which the alarm message originates (always
PLC_1).

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The following pushbuttons are available for handling alarm messages:
• <Help>: Displays the help text to the selected alarm message (example Figure 4-14).
• <Edit>: Triggers message specific functions (not used).
• <ACK>: Resets / acknowledges the selected alarm message.

Figure 4-11

The alarm message window is closed by clicking the
the window.

button in the upper right corner of

Alarm Page:
The alarm page has the same layout and provides the same information as the alarm message
buffer (Figure 4-13). The alarm page, however, shows only currently active alarms and will
be empty when all alarms have cleared.
Message Buffers:
The message buffers provide access to historical alarm and event messages. All messages are
stored in chronological order in the message buffer. The most recent message is displayed at
the top of the message buffer. The message buffer is a “First-In-First-Out” buffer type i.e. the
first message stored in the buffer will be the first message to be deleted when the message
buffer is full.

Figure 4-12

Alarm and event messages are stored in separate buffers that can be accessed from HMI
screen No. 2 (Figure 4-12).
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Alarm Buffer:
The following information is provided in the alarm buffer (Figure 4-13):
• No. column displays a unique alarm message number. Please inform this number
when calling STE for service support.
• Time column displays the time when the status of the alarm changed.
• Date column displays the date when the status of the alarm changed.
• Status column displays the status of the alarm message:
- A: The message is Active
- C: The message is Cleared
- R: The message has been Reset/acknowledged
• GR column displays the reset group that the alarm message belongs to.
• Message text.
The following pushbuttons are available for handling alarm messages:
• <Help>: Displays the help text to the selected alarm message (example Figure 4-14).
• <Edit>: Triggers message specific functions (not used).

Figure 4-13

The alarm buffer is closed by clicking the

button in the upper right corner of the window.

The help text linked to the alarm message provides useful guidelines when troubleshooting
the compressor system. In addition the alarm help text makes a reference to the relevant
page(s) in the Circuit Diagrams.

Figure 4-14

The help text is closed by clicking the

button in the upper right corner of the window.
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Event Buffer:
The following information is provided in the event buffer (Figure 4-15):
• No. column displays a unique event message number. Please inform this number
when calling STE for service support.
• Time column displays the time when the status of the event changed.
• Date column displays the date when the status of the event changed.
• Status column displays the status of the event message:
- A: The message is Active
- C: The message is Cleared
• Message text.
The following pushbuttons are available for handling event messages:
• <Help>: Displays the help text to the selected event message.
• <Edit>: Triggers message specific functions (not used).

Figure 4-15

The event buffer is closed by clicking the

button in the upper right corner of the window.

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Operation Modes

This section explains the compressor operation modes, their selection and use. Each operation mode is described by its definition, target audience, selection and the possible user actions.
5.1
Selecting Modes
The compressor operation modes are selected from the “MODE SELECTION” screen
No. 1.1 (Figure 5-1). The modes are selected by clicking the pushbutton for the relevant operation mode. The currently selected operation mode is shown in the fixed area.

Figure 5-1

The operation modes are linked together according to Figure 5-2. The figure shows in detail
the conditions to switch between the operation modes.

Figure 5-2

Example: Service Mode can only be selected from Local Mode when the compressor is out
of operation. Service Mode can be deselected by selecting Local Mode or Off Mode.
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5.2
Off Mode
Definition:
In Off Mode the compressor is permanently out of operation and can neither be started locally from the LCP nor remotely from the MCP. The Off Mode is intended for situations
where the compressor is not needed for longer periods.
Target Audience:
Off Mode is intended for:
• The every-day operator.
• The plant maintenance personnel.
Selection: (Figure 5-2)
Off Mode can be selected when the compressor is in operation or out of operation from:
• Local Mode.
• Remote Mode.
• Service Mode.
• Test Modes.
Possible User Actions:
The user can perform the following tasks in Off Mode:
• Acknowledge alarms.
• Acknowledge trips.
5.3
Local Mode
Definition:
In Local Mode the compressor can only be started and stopped locally from the LCP. After
the compressor start sequence has been completed, the compressor capacity can be increased
and decreased locally from the LCP.
Target Audience:
Local Mode is intended for:
• The every-day operator.
Selection: (Figure 5-2)
Local Mode can be selected when the compressor is in operation or out of operation from:
• Remote Mode.
• Service Mode.
• Test Modes.
• Off Mode.
Possible User Actions:
The user can perform the following tasks in Local Mode:
• Acknowledge alarms.
• Acknowledge trips.
• Select automatic/manual mode for the IGV.
• Start/stop the compressor.
• Open/Close the diffuser.
• Open/Close the IGV (only by IGV manual mode).

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5.4
Remote Mode
Definition:
In Remote Mode the compressor can only be started and stopped remotely by the MCP. After the compressor start sequence has been completed, the compressor capacity will be increased and decreased remotely by the MCP according to the selected set point and the actual airflow to the process.
Target Audience:
Remote Mode is intended for:
• The every-day operator.
Selection: (Figure 5-2)
Remote Mode can be selected when the compressor is in operation or out of operation from:
• Local Mode.
• Off Mode.
Possible User Actions:
The user can perform the following tasks in Remote Mode:
• Acknowledge alarms.
• Acknowledge trips.
• Select automatic/manual mode for the IGV.
5.5
Service Mode
Definition:
In Service Mode the compressor can neither be started locally nor remotely. For maintenance
purposes the auxiliary components (main lube oil pump, blow-off valve etc.) can be operated
independently of each other. The auxiliary components can be operated from the consumer
and actuator screens, see examples in Figure 5-3 and Figure 5-4.

Figure 5-3

Target Audience:
Service Mode is intended for:
• The plant maintenance personnel.
• STE’s maintenance personnel.

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Selection: (Figure 5-2)
Service Mode can be selected only when the compressor is out of operation from:
• Local Mode.

Figure 5-4

Possible User Actions:
The user can perform the following tasks in Service Mode:
• Acknowledge alarms.
• Acknowledge trips.
• Select automatic/manual mode for the IGV.
• Open/close diffuser.
• Open/close IGV (only in IGV manual mode).
• Open/close blow-off valve.
• Open/close isolation valves (inlet/outlet).
• Start/stop lube oil pump(s).
• Start/stop lube oil cooler fan(s).
• Start/stop lube oil heater.
• Start/stop enclosure ventilation fan(s).

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5.6
Test Modes
Definition:
Test Mode is differentiated between Test Local and Test Remote. In Test Local Mode the
compressor start/stop is initiated locally from the LCP. In Test Remote Mode the compressor
start/stop is initiated remotely from the MCP. The Test Modes are intended for testing the
automatic compressor start sequence without actually starting the main drive motor. The Test
Modes are typically used during commissioning or troubleshooting.
Target Audience:
Test Modes are intended for:
• The plant maintenance personnel.
• STE’s maintenance personnel.
Selection: (Figure 5-2)
The password level 3 has to be logged on before the Test Modes can be selected. Please proceed as described in the section “Password Protection logging on directly” to log onto the
password level 3. The Test Modes can be selected only when the compressor is out of operation from:
• Local Mode.
Possible User Actions:
The user can perform the following tasks in Test Mode:
• Acknowledge alarms.
• Acknowledge trips.
• Select automatic/manual mode for the IGV.
• Start/stop the compressor (only Test Local).
• Open/close the diffuser (only Test Local).
• Open/close the IGV (only by IGV manual mode).

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Starting the Compressor

This section provides basic information about the compressor start conditions, the automatic
start sequence and how to start the compressor in Local and Remote Mode.
6.1
Start Conditions
The following conditions need to be fulfilled to start the compressor:
• No active or unacknowledged alarm messages are pending, i.e. the message indicator
is not displayed (section 4.5). Please refer to the Troubleshooting Guide in section
11.2 if the messages indicator is displayed.
• The main drive motor starter (MCC) is ready.
• The blow-off valve is fully open (Figure 6-1).

Figure 6-1

• The diffuser is fully closed i.e. in minimum position (Figure 6-2).

Figure 6-2

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• The IGV is fully closed i.e. in minimum position (Figure 6-3).

Figure 6-3

The status field in the fixed area will indicate “Not Ready To Start” as long as all the above
conditions are not fulfilled.

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6.2
Start Sequence
The automatic compressor start sequence proceeds as described below when a local or remote start has been initiated. The start sequence is described separately for compressor types
with and without IGV.
Compressor with IGV:
1. The electric lube oil pump starts the pre-lubrication phase (duration 60 seconds).
2. The inlet and outlet isolation valves open.
3. The main drive motor “Run Command” is sent to the MCC when the pre-lubrication
phase finishes and the inlet and outlet isolation valves are fully open.
4. The main drive motor starts.
5. The IGV opens fully when the main drive motor “Running Feedback” signal has
been received from the MCC.
6. The blow-off valve closes slowly when the IGV has reached its fully open position.
7. The electric lube oil pump stops 20 seconds after the main drive motor “Running
Feedback” signal has been received, if the lube oil pressure from the mechanical
lube oil pump is OK.
8. The compressor is in operation and the diffuser/IGV are released for capacity control
when the blow-off valve is fully closed.
Compressor without IGV:
1. The electric lube oil pump starts the pre-lubrication phase (duration 60 seconds).
2. The inlet and outlet isolation valves open.
3. The main drive motor “Run Command” is sent to the MCC when the pre-lubrication
phase finishes and the inlet and outlet isolation valves are fully open.
4. The main drive motor starts.
5. The blow-off valve closes slowly when the main drive motor “Running Feedback”
signal has been received from the MCC.
6. The electric lube oil pump stops 20 seconds after the main drive motor “Running
Feedback” signal has been received, if the lube oil pressure from the mechanical
lube oil pump is OK.
7. The compressor is in operation and the diffuser is released for capacity control when
the blow-off valve is fully closed.
The progress in the compressor start sequence can be monitored in the status field in the
fixed area of all HMI screens (see example in Figure 6-4). The following information is provided in the status field during the start sequence:
• Not Ready To Start
• Ready To Start
• Pre-Lubrication
• Starting
• IGV Opening
• BOV Closing
• Operation

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6.3
Local Start
Starting the compressor in Local Mode is done from the “OPERATION: COMPRESSOR”
screen No. 1.2 (Figure 6-4).

Figure 6-4

Operator procedure:
1. Select Local Mode as described in section 5.1.
2. Check that the status field in the fixed area reads “Ready To Start”. If not then please
refer to section 6.1 before proceeding to step 3.
3. Push the “Start Compressor” pushbutton in screen No. 1.2 (Figure 6-4).
4. Observe the remaining “Pre-Lubrication” field to see when the main drive motor will
start.
5. Monitor the compressor start sequence in the status field in the fixed area.
1. Ready To Start
2. Pre-Lubrication
3. Starting
4. IGV Opening
5. BOV Closing
6. Operation
When the status field reads “Operation”, the compressor is ready for capacity control. The
compressor capacity is controlled by means of the pushbuttons “Increase Capacity” and “Decrease Capacity”.

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6.4
Remote Start
Starting the compressor in Remote Mode is done by the MCP and can be monitored from the
“OPERATION: COMPRESSOR” screen No. 1.2 (Figure 6-5).

Figure 6-5

Operator procedure:
1. Select Remote Mode as described in section 5.1.
2. Check that the status field in the fixed area reads “Ready To Start”. If not then please
refer to section 6.1 before proceeding to step 3.
3. The MCP will start the compressor when necessary.
4. Observe the remaining “Pre-Lubrication” field to see when the main drive motor will
start.
5. Monitor the compressor start sequence in the status field in the fixed area.
1. Ready To Start
2. Pre-Lubrication
3. Starting
4. IGV Opening
5. BOV Closing
6. Operation
When the status field reads “Operation”, the compressor is ready for capacity control. The
compressor capacity is controlled by the MCP.

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Stopping the Compressor

This section provides basic information about the normal compressor stop sequence and how
to stop the compressor in Local and Remote Mode.
7.1
Normal Stop Sequence
The normal compressor stop sequence proceeds as described below when a local or remote
stop has been initiated.
1. The diffuser closes.
2. The blow-off valve opens when the diffuser has reached its fully closed position.
3. The main drive motor “Run Command” to the MCC is reset and the IGV closes when
the blow-off valve has reached its fully open position.
4. The electric lube oil pump starts the after-lubrication phase (duration 5 minutes)
when the main drive motor “Running Feedback” signal has been reset by the MCC.
5. The inlet and outlet isolation valves close during the after-lubrication phase.
The progress in the compressor stop sequence can be monitored in the status field in the
fixed area of all HMI screens (see example in Figure 7-1). The following information is provided in the status field during the stop sequence:
• Operation
• Stop: Diffuser Closing
• Stop: BOV Opening
• Stop: IGV Closing
• Ready To Start

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7.2
Local Stop
Stopping the compressor in Local Mode is done from the “OPERATION: COMPRESSOR”
screen No. 1.2 (Figure 7-1).

Figure 7-1

Operator procedure:
1. Push the “Stop Compressor” pushbutton in screen No. 1.2 (Figure 7-1).
2. Observe the remaining “After-Lubrication” field to see when the electric lube oil
pump will stop.
3. Monitor the compressor stop sequence in the status field in the fixed area.
1. Operation
2. Stop: Diffuser Closing
3. Stop: BOV Opening
4. Stop: IGV Closing
5. Ready To Start
When the status field reads “Ready To Start”, the compressor is stopped and ready for
another start.

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7.3
Remote Stop
Stopping the compressor in Remote Mode is done by the MCP and can be monitored from
the “OPERATION: COMPRESSOR” screen No. 1.2 (Figure 7-2).

Figure 7-2

Operator procedure:
1. The MCP will stop the compressor when necessary.
2. Observe the remaining “After-Lubrication” field to see when the electric lube oil
pump will stop.
3. Monitor the compressor stop sequence in the status field in the fixed area.
1. Operation
2. Stop: Diffuser Closing
3. Stop: BOV Opening
4. Stop: IGV Closing
5. Ready To Start
When the status field reads “Ready To Start”, the compressor is stopped and ready for
another start.

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Controlling the Compressor Capacity

This section describes how to control the compressor capacity in Local and Remote Mode.
The section is closed with a description on how to use the power minimizing function.
8.1
Local Capacity Control
In Local Mode the capacity control can be done from the “OPERATION” screen No. 1.2
(Figure 6-4) or from the “DIFFUSER” screen No. 1.5.2.2 (Figure 8-1) and by compressors
without diffuser also from the “INLET GUIDE VANES” screen No. 1.5.2.1. The compressor
capacity control is enabled when the status field in the fixed area reads “Operation”.

Figure 8-1

Operator procedure:
• Push the “Decrease Capacity” pushbutton to decrease the compressor capacity.
• Push the “Increase Capacity” pushbutton to increase the compressor capacity.
The capacity control can be monitored by means of the current diffuser position in the “Position” field (0-100%) and the status in the “DIFFUSER Status” field:
1. Opening
2. Open
3. Closing
4. Closed
5. Midway
8.2
Remote Capacity Control
In Remote Mode the capacity control is done by increase/decrease signals from the MCP.
The remote capacity control can be monitored from the “DIFFUSER” screen No. 1.5.2.2
(Figure 8-1) or from the “INLET GUIDE VANES” screen No. 1.5.2.1 by compressors without diffuser. The compressor capacity control is enabled when the status field in the fixed
area reads “Operation”.
The capacity control can be monitored by means of the current diffuser position in the “Position” field (0-100%) and the status in the “DIFFUSER Status” field:
1. Opening
2. Open
3. Closing
4. Closed
5. Midway
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8.3
Minimizing the Power Consumption
The STE function to minimize the compressor power consumption can be turned On or Off
from the “INLET GUIDE VANES” screen No. 1.5.2.1 (Figure 8-2 and Figure 8-3). The
power minimization function is turned:
• On by selecting “AUTO” mode for the IGV.
• Off by selecting “MAN” mode for the IGV.
Inlet Guide Vanes “AUTO” mode (Figure 8-2):
The inlet guide vanes are released for automatic control when the blow-off valve has reached
its fully closed position. In “AUTO” mode the inlet guide vanes are continuously positioned
according to the current operation conditions (i.e. inlet air temperature, differential pressure
and diffuser position) in order to obtain the lowest possible power consumption. The current
inlet guide vanes position can be read in the “Position” field (0-100%) and the status in the
“INLET GUIDE VANES Status” field.

Figure 8-2

Inlet Guide Vanes “MAN” mode (Figure 8-3):
The inlet guide vanes remain fully open (in maximum) when the automatic start sequence
has ended. By means of the “Open” and “Close” pushbuttons the inlet guide vanes can be
positioned manually. This method can however not be recommended due to the risk of surging if the inlet guide vanes are closed too much. Please operate the inlet guide vanes with
great caution and only according to instructions from STE.

Figure 8-3

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Abnormal Operating Conditions

This section explains how the compressor will react to abnormal operating conditions. The
description covers the compressor soft and hard stop sequences plus the HMI / PLC system
messages.
9.1
Soft Stop Sequence
The soft stop sequence is initiated when an abnormal operating condition occurs that demands a quick stop of the compressor. The soft stop sequence proceeds as described below.
1. An abnormal operating condition occurs.
2. The blow-off valve opens and the diffuser closes.
3. The main drive motor “Run Command” to the MCC is reset when the blow-off valve
has reached its fully open position or at the latest 8 seconds after the abnormal operating condition occurred.
4. The IGV closes when the blow-off valve has reached its fully open position.
5. The electric lube oil pump starts the after-lubrication phase (duration 5 minutes)
when the main drive motor “Running Feedback” signal has been reset by the MCC.
6. The inlet and outlet isolation valves close during the after-lubrication phase.
The progress in the soft stop sequence can be monitored in the status field in the fixed area of
all HMI screens (see example in Figure 7-1).
Refer to the Troubleshooting Guide in section 11.2 to determine the cause of the soft stop.
9.2
Hard Stop Sequence
The hard stop sequence is initiated when a critical operating condition occurs that demands
an instant stop of the compressor. The hard stop sequence proceeds as described below.
1. A critical operating condition occurs.
2. The main drive motor “Run Command” to the MCC is instantly reset.
3. The electric lube oil pump starts the after-lubrication phase (duration 5 minutes)
when the main drive motor “Running Feedback” signal has been reset by the MCC.
4. The blow-off valve opens, the diffuser closes and the IGV closes.
5. The inlet and outlet isolation valves close during the after-lubrication phase.
The progress in the hard stop sequence can be monitored in the status field in the fixed area
of all HMI screens (see example in Figure 7-1).
Refer to the Troubleshooting Guide in section 11.2 to determine the cause of the hard stop.
Emergency Stop and Power Failure are two special conditions initiating the following
Hard Stop Sequence:
1. The emergency stop pushbutton is activated or a power failure occurs.
2. The main drive motor “Run Command” to the MCC is instantly reset.
3. All auxiliaries i.e. the electric lube oil pump, the blow-off valve, the diffuser, the
IGV, the inlet and outlet isolation valves are stopped and remain in their current position.
When the emergency stop pushbutton has been reset or the power supply has been restored,
the LCP will automatically re-establish the start conditions (section 6.1).
Note: The emergency stop pushbutton is only to be used by risk of personal injury or
property damage.

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9.3
Alarms/Trips
Two categories of alarm messages are defined in the compressor message system. The two
categories are described below:
Alarms are operating and process states that require the operating personnel to react by issuing an acknowledgement but not require the compressor to be stopped. Examples of alarms
that will not stop the compressor are listed in the table below.
Number

Alarm Message Text

145

Lube Oil Pressure L

147

Lube Oil Temperature H

148

Lube Oil Filter Differential Pressure H

153

Lube Oil Level L

161

Gearbox Vibration Level H

201

Inlet Air Filter Differential Pressure H

233-236

Main Drive Motor Winding Temperature H

265

Inlet Guide Vane system Circuit Breaker Tripped

273

Diffuser system Circuit Breaker Tripped

435

Inlet Temperature Transmitter Wire-break

443

Differential Pressure Transmitter Compressor Wire-break

Refer to the Troubleshooting Guide in section 11.2 or click the <Help> pushbutton in the
alarm buffer window to determine a possible cause of the alarm.
Trips are critical or hazardous operating and process states that require the compressor to be
stopped and the operating personnel to react by issuing an acknowledgement. Examples of
trips that will stop the compressor are listed in the table below.
Number

Trip Message Text

Stop Sequence

1

Emergency Stop Activated

Hard

17

Lube Oil Pressure LL

Hard

19

Lube Oil Temperature HH

Soft

25

Lube Oil Level LL

Soft

33

Gearbox Vibration Level HH

Hard

65

Compressor Surging HH

Soft

66

Compressor Recirculation HH

Soft

Main Drive Motor Winding Temperature HH

Soft

105-108

Refer to the Troubleshooting Guide in section 11.2 or click the <Help> pushbutton in the
alarm buffer window to determine a possible cause of the trip.

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9.4
System Messages
This section contains a selection of the most important system messages that can be shown
on the HMI. System messages provide information about the HMI and the PLC operating
modes. System messages can range from information to serious errors. The table below indicates when the messages occur and how they, or their cause, can be cleared.
Note:
Not every message in the table is relevant for each LCP.
Number
4003

Effect/Cause

Remedy

Stop caused by the PLC mode switch
being switched to STOP position.

Switch the PLC mode switch to RUN
position.

110000 The operating mode status has been
changed. The operating mode is now
off-line.
110001 The operating mode status has been
changed. The operating mode is now
on-line.
140000 On-line connection to the PLC has been
successfully established.
140001 On-line connection to the PLC has been
disconnected.
140003 No tag updating or writing is executed.

140010 No communication peer could be found
because the PLC is switched Off.
140011 No tag updating or writing is executed
because the communication is interrupted.
230002 Entry rejected. The current password
level is inadequate or the password dialog box was closed with <Cancel>.
230005 Range exceeded. The value entered is
outside the valid range.

Check the cable connection between the
HMI and the PLC.
Check that the PLC is switched On and
in RUN mode.
Restart the system
(Power Off → Power On)
Switch the PLC On.

Check the cable connection between the
HMI and the PLC.
Check that the PLC is switched On and
in RUN mode.
Activate an adequate password level by
logging on as described in section 4.4.
Enter a value within the range specified.

If serious system messages are shown that are not in the table above, then please get in touch
with your local STE representative or agent responsible.

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10 Settings
This section provides information about how basic parameters for the operation of the compressor are set or changed through the HMI. The section describes amongst others how to
calibrate the diffuser and IGV, how to set the blow-off valve closing time and how to set the
main drive motor current limiting. Unless described otherwise changing the settings in this
section requires that password level 3 is logged on.
10.1 Calibrating the diffuser and the inlet guide vanes
The diffuser and IGV position feedback is calibrated from 0% to 100% between the fully
closed position (minimum) and the fully open position (maximum). The following procedure
has to be followed if the diffuser or IGV limit switches have been adjusted:
1. Stop the compressor if it is in operation.
2. Select Service Mode as described in section 5.1.
3. Navigate to the “CALIBRATION: DIFFUSER” screen No. 1.5.2.2.1 (Figure 10-1) or
the “CALIBRATION: INLET GUIDE VANES” screen No. 1.5.2.1.1.
4. Initiate the automatic calibration sequence by clicking the “Start Calibration”
pushbutton.

Figure 10-1

The calibration sequence can be monitored by means of the “Status:” field.
1. Opening
2. Open
(the current position is stored as 100%)
3. Closing
4. Closed
(the current position is stored as 0%)
The automatic calibration sequence can be interrupted at any point by clicking the “Cancel
Calibration” pushbutton.
The navigation pushbuttons in the navigation area are disabled as long as the calibration sequence is running, that is the calibration screen can only be deselected when the calibration
sequence has ended.

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10.2 Setting the blow-off valve closing time
Setting the blow-off valve closing time is done on the “SETTINGS: BLOW-OFF VALVE”
screen No. 1.5.3.1.1 (Figure 10-2). The closing time of the blow-off valve determines at
which rate the compressor discharge pressure is increased when the compressor is started.

Figure 10-2

The closing time of the blow-off valve is set by means of two parameters (Figure 10-3):
• On Pulse Closing [ms]
• Off Pulse Closing [ms]

Figure 10-3

Recommended settings:
• On Pulse Closing < Off Pulse Closing
• Blow-off valve closing time: 60 – 120 sec.
After setting the two parameters, switch to Service Mode as described in section 5.1 and test
the actual blow-off valve closing time on the “BLOW-OFF VALVE” screen No. 1.5.3.1
(Figure 5-4).
Note:
By setting a too short closing time, i.e. closing the blow-off valve too fast, there is a risk of
surging the compressor during start-up.

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10.3 Setting the main drive motor current limiting
The main drive motor current limiting function is provided to avoid overloading of the main
drive motor. The function limits the main drive motor current by blocking the signal to increase the compressor capacity. The parameters associated with the main drive motor current
limiting function can be set on the “SETTINGS: CURRENT (I)” screen No. 1.5.5.1 (Figure
10-4).

Figure 10-4

Function: (Figure 10-4)
• The “Increase Capacity” signal is blocked as long as the main drive motor current exceeds the nominal current of the drive motor.
• The compressor capacity is decreased when the main drive motor current is exceeded
by the “Permitted Overload” percentage.
Recommended settings:
• Maximum Scaling is the maximum current of the current transformer in the MCC.
• Nominal Current is the In specified on the drive motor rating plate.
• Hysteresis Overload ≤ Permitted Overload
• Permitted Overload = 5%
• Hysteresis Nominal Current = 2%
• Hysteresis Overload = 5%
• Response Time = 2 sec. (the time the limits have to be exceeded before action).
All the %-values above are with reference to the Nominal Current.

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10.4 Setting instrument scalings
The range for analog instruments is set by means of the parameters Minimum Scaling and
Maximum Scaling. Instrument scalings are grouped according to the physical location of the
instrument:
• Inlet Air System
• Compressor (example in Figure 10-5)
• Outlet Air System
• Lube Oil System
• Main Drive Motor
• Gearbox

Figure 10-5

Note:
Changing the parameters Minimum Scaling or Maximum Scaling also requires the instrument range to be changed / recalibrated.
Do not change these settings without contacting your local STE representative or agent responsible.

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10.5 Setting alarm set points
The alarm and trip set points are set through standardized HMI screens. An example for the
lube oil temperature is shown in Figure 10-6.
The following parameters can be set for alarms and trips:
• Alarm Setpoint
• Alarm Hysteresis
- High Alarm: Hysteresis below the set point
- Low Alarm: Hysteresis over the set point
• Alarm Delay
• Trip Setpoint
• Trip Hysteresis
- High Trip: Hysteresis below the set point
- Low Trip: Hysteresis over the set point
• Trip Delay
Note:
Setting trip parameters require that password level 6 is logged on.

Figure 10-6

Changes to the alarm/trip parameters must be saved by clicking the “Save Settings” pushbutton.
Note:
Changing the trip parameters may result in damages to the compressor as well as personal
injuries. Do not change these settings without contacting your local STE representative or
agent responsible.

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10.6 Save and restore settings
The changes made to settings as described in the previous sections are all automatically
stored in a non-volatile memory. This means that the settings will be available even after a
power failure. However the changes made to settings will not be available after a total system reset (i.e. the default settings will be re-loaded) unless the settings were saved as described below.

Figure 10-7

The save and restore functions are depicted in Figure 10-7.

Figure 10-8

Save settings
To save the current settings as the new default settings please follow the procedure described
below:
1. Log on with password level 3 (Figure 4-6)
2. Select the “SAVE / RESTORE SETTINGS” screen No. 2.1.1.1 (Figure 10-8)
3. Push the “Save” pushbutton.

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The current settings will now be saved as the new default settings. A running save procedure
is indicated as shown in Figure 10-9.

Figure 10-9

Restore settings
To restore the default settings as the current settings please follow the procedure described
below:
1. Log on with password level 3 (Figure 4-6)
2. Select the “SAVE / RESTORE SETTINGS” screen No. 2.1.1.1 (Figure 10-8)
3. Push the “Restore” pushbutton.
The default settings will now be restored as the current settings. A running restore procedure
is indicated as shown in Figure 10-10.

Figure 10-10

Note:
Saving and restoring settings require that password level 3 is logged on.

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11 Appendix
This appendix will provide the operator with detailed information about the screen navigation, compressor troubleshooting, and the HMI colour conventions.
11.1 Basic Screen Navigation Diagram
This section will provide the user with an overview of the basic HMI screens available and
their position in the screen hierarchy.
Legend:

Basic Screen Navigation Part 1:

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Basic Screen Navigation Part 2:

Note:
If more information about the screen hierarchy is needed then please refer to the detailed
document “Navigation Diagram LCP Operator Interface”.

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11.2 Troubleshooting Guide
This section provides basic information about how to remedy abnormal conditions. Not
every message in the tables below is relevant for each LCP.
Note:
If the message of interest cannot be found in the table below, please use the <Help>
pushbutton in the alarm buffer window to gain more information about possible remedies.
Number

Message Text

1

Emergency Stop Activated

17

Lube Oil Pressure LL

19

Lube Oil Temperature HH

25

Lube Oil Level LL

33

Gearbox Vibration Level HH

34

Motor Vibration Level HH

Remedy
Re-establish safe conditions and deactivate the emergency stop button.
Reset the emergency stop on the start
screen and acknowledge the alarm message in the alarm message window.
Do not restart the compressor before a
thorough check of the lubrication system: Electrical/mechanical lube oil
pump, gear bearings, pressostates etc.
Perform a start in Test Local Mode to
check the lubrication system.
Water Cooling: Check water pressure,
water flow, water inlet temperature and
the function of the thermostatic control
valve. Clean the water cooler if necessary.
Air Cooling: Check cooling air temperature, airflow, the function of the ventilator, the function of the thermostat and
the set point to start the cooling fan.
Clean the air/oil cooler if necessary.
Perform a visual check of the lube oil
level. Check the function of the sensor.
If necessary refill the lube oil reservoir
to the normal indication on the dipstick.
NOTE! Check the lube oil system,
coolers, and pumps for leaks.
NOTE! Do not restart before a check of
the gear bearings/gaps, impeller and
coupling. Check the vibration system/set
point.
NOTE! Do not restart before a check of
the motor bearings (lubrication?) and
coupling. Check the vibration system/set
point. Lubricate bearings if necessary.

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Number

Message Text

Remedy

65

Compressor Surging HH

66

Compressor Recirculation HH

81
82
83
84
85
97

Gearbox Bearing Temperature HH

98

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Revision: 2.01

High counter pressure! Check regulation
valve(s) in outlet air system and inlet
side (air filter/silencer). Check diffuser
adjustment. See compressor type plate
for maximum performance (pressure /
temperature).
Inlet air temperature high! Check conditions at inlet air system and outlet air
system compared with the compressor
performance. Check for blow-off air in
the inlet air system.
NOTE! Do not restart before a visual
check of the relevant bearing. Check
also the temperature sensor system and
the set points.

Main Drive Motor Excessive Number of The maximum allowed number of starts
Starts. Please Wait.
within one hour has been exceeded.
Please Wait.
The compressor will automatically revert to its ready condition when the necessary time has expired.
Main Drive Motor Excessive Start Time The allowed main motor starting time
has been exceeded. Check the state of
the MCC (voltage, ampere and fuses).

99

Main Drive Motor Running Feedback
Lost During Operation

100

Main Drive Motor Starter Not Ready

101

Main Drive Motor Starter Failure

Check the state of the MCC switchgear
(overload, fuses, power supply and voltage level).

105
106
107
108

Main Drive Motor Winding Temperature HH

Check motor cooling conditions (cooling air or water flow) and the motor
power consumption (overloading?).

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NOTE! Do not restart the compressor
before a check of the MCC switchgear
and the feedback contactor/wiring to the
Local Control Panel has been carried
out.
Check the state of the MCC switchgear
(on/off/ready?).
Check the MCC control voltage supply.

Operations Manual
Local Control Panel

Number
113
114
115

148

Message Text

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Remedy

Main Drive Motor Bearing Temperature NOTE! Do not restart the compressor
HH
before a check of the bearings. Check
the bearings for adequate lubrication?
Check also the temperature sensor system and the set points.
Lube Oil Filter Differential Pressure H The lube oil filter is clogged. Replace
the filter bag inserts or clean them if
possible.

201

Inlet Air Filter Differential Pressure H

261

Inlet Isolation Valve Excessive Opening Check the mechanical state of the actuaTime
tor and the valve. See also O&M manual.

265

Inlet Guide Vane system Circuit Breaker Check the circuit breaker function and
Tripped
the set point. Check mechanical mobility
of IGV system and the power (ampere)
consumption.

273

Diffuser system Circuit Breaker Tripped Check the circuit breaker function and
the set point. Check mechanical mobility
of diffuser system and the power (ampere) consumption.

284

Blow-off Valve Excessive Closing Time Check the mechanical state of the blowoff valve and the actuator. See also
O&M manual.

285

Blow-off Valve Excessive Opening
Time

Check the mechanical state of the blowoff valve and the actuator. See also
O&M manual.

293

Outlet Isolation Valve Excessive Opening Time

Check the mechanical state of the actuator and the valve. See also O&M manual.

Page 41 / 44

The inlet air filter is clogged. Replace
the filter bag inserts or clean them if
possible.

Operations Manual
Local Control Panel

Number

Message Text

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Revision: 2.01

Remedy

435

Inlet Temperature Transmitter Wirebreak

Measure Transmitter Output. Check
wire connections.

443

Differential Pressure Transmitter Compressor Wire-break

Measure Transmitter Output. Check
wire connections.

451

Enclosure Temperature Transmitter
Wire-break

Measure Transmitter Output. Check
wire connections.

483

Lube Oil Temperature Transmitter
Wire-break

Measure Transmitter Output. Check
wire connections.

499

Main Motor Current Wire-break

Measure Current Transformer / Transmitter Output in the MCC.
Check wire connections.

507
515
523

Main Motor Winding Temperature
(U/V/W) Wire-break

Check Sensor Output. Check wire connections.

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11.3 Colour Conventions
This section provides information about the colours used in the HMI screens. The colours
and the operation states/conditions they describe are listed in the tables below.
11.3.1 Mono Version
The table below lists the colours used and the operation states/conditions they describe.

Colour

State Description

Example

White

Off
Fully Closed Position

1. Lube oil pump stopped
2. Diffuser closed (minimum)

Grey

On
Midway Position

Black

Fully Open Position

1. Lube oil pump running
2. Diffuser between open and
closed position
1. Diffuser open (maximum)

Black
Flashing

Abnormal Condition

1. Transmitter out of range
2. Motor circuit breaker tripped

Note:
Please use the <?> pushbutton in the navigation area of the screen to see the relevant help
text.

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11.3.2 Colour Version
The table below lists the colours used and the operation states/conditions they describe.

Colour

State Description

Example

White

Off
Fully Closed Position

1. Lube oil pump stopped
2. Diffuser closed (minimum)

Grey

Available

Black

Reset

Red
Flashing

Abnormal Condition

1. Transmitter out of range
2. Motor circuit breaker tripped

Green

On
Fully Open Position

1. Lube oil pump running
2. Diffuser open (maximum)

Blue

Midway Position

1. Diffuser between open and
closed position

Yellow

Unavailable

1. Lube oil pump available

1. Reset pushbutton

1. Motor circuit breaker tripped

Note:
Please use the <?> pushbutton in the navigation area of the screen to see the relevant help
text.

Page 44 / 44

Siemens Turbomachinery Equipment A/S
Operations Manual
Master Control Panel
Revision: 2.01
January 2006

Siemens Turbomachinery Equipment A/S
Allégade 2
DK-3000 Helsingør
Denmark
Telephone: +45 49 21 14 00
Facsimile: +45 49 21 52 25
Web: www.powergeneration.siemens.com

Copyright: The concepts and information contained in this document are the property of Siemens Turbomachinery Equipment A/S (STE). Use or copying of this document in whole or in part without the written permission of STE constitutes an infringement of copyright.
Disclaimer of Liability: We have checked the contents of this manual with the equipment described. Since
deviations cannot be precluded entirely, we cannot guarantee full agreement. However, the data in this manual
are reviewed regularly and any necessary corrections included in subsequent editions. Suggestions for improvements are welcomed.

Operations Manual
Master Control Panel

17-03-2008
Revision: 2.01

Document Control
Document Information
Title:
Number of Pages:
Revision:
Author:
File Name:
Last Printed:
Last Saved:

Operations Manual: Master Control Panel
46
2.01
KJH
R:\Automation\Manuals\MCP-T\MCP-T Manual English V2.01.doc

08/04/2008 14:37:00
04/04/2008 16:28:00

Revision History
Rev.
0.0
1.0
2.0

Date
08-09-2004
21-09-2004
16-01-2006

By
KJH
KJH
KJH

2.01

04-04-2008

LC

Approved Description
Original issue (for review)
AKOP
First release
AKOP
Sections 6.2, 7.1, 8.1 and 9.1 revised, 9.5
added
AKOP
HVT changed to Siemens

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Safety Instructions
Make sure that this Operations Manual is at the disposal of everybody who is involved in
operation, maintenance and repairs and that the contents have been understood.
If the operating instructions in this Operations Manual are not observed, the result may be
function interruptions and damages to the system as well as personal injuries, for which the
manufacturer does not undertake any responsibility.

By unprofessional treatment of equipment and components there will be a risk of
personal injury.

The Operations Manual and the compressor handbook contain the necessary information for
the correct use of the functions described. They are intended for qualified personnel.
Qualified personnel in connection with the safety instructions in this Operations Manual is


either projecting personnel who is familiar with the safety regulations of automation
technology,



or personnel who has been instructed in handling automation technology equipment
as operational personnel and who knows the contents of the documentation related to
the operation.



or service personnel who has an education qualified for the repair of such automation
technology equipment, respectively who is entitled to put electric circuits and devices/systems into operation according to the relevant safety standards.

The system is solely constructed for the application described in the scope of delivery (defined by the manufacturer of the equipment, application according to description). Any application beyond this is not according to description. The manufacturer is not responsible for
resulting damages. Only the user has the responsibility for this.

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To the application according to description also belongs the observation of the conditions of
operation, maintenance, and repair lain down by the manufacturer. The system must only be
used, serviced, and repaired by persons who are familiar with this and have been instructed
in the risk.
If work can only be carried out with an open control panel at voltage, corresponding safety
measures shall be taken.
Instructions for protection against accidents as well as other generally recognized safety and
work regulations shall be observed.
At maintenance work all automatic processes, controls and functions must stand still. They
have to be blocked and secured against unintentional restart.
It is a condition for the qualified maintenance and repair that all necessary devices and tools
are at disposal and that the condition of the tools is completely satisfactory.
Maintenance work or repairs must only be carried out in voltage-free condition by qualified
personnel.
In order to be clear the instruction does not include all details for all versions of the product
in question, and it can neither consider every imaginable way of installation, operation or
maintenance. If you wish further information or in case problems occur that have not been
described in enough details, necessary information can be obtained at STE.

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Contents
1
2
3
4

Preface ...............................................................................................................................1
Related Documents...........................................................................................................1
Definitions .........................................................................................................................2
General Information ........................................................................................................3
4.1 Basic Screen Design ....................................................................................................3
4.2 Screen Navigation........................................................................................................4
4.3 Language Selection......................................................................................................5
4.4 Password Protection.....................................................................................................5
4.5 Message System ..........................................................................................................8
5 Operation Modes ............................................................................................................12
5.1 Selecting Modes ........................................................................................................12
5.2 Off Mode ...................................................................................................................13
5.3 Automatic Mode ........................................................................................................13
6 Compressor/Priority allocation.....................................................................................14
6.1 Selecting Priorities.....................................................................................................14
6.2 Validating Priorities...................................................................................................15
7 Capacity Control ............................................................................................................17
7.1 Monitoring the Operation ..........................................................................................17
7.2 Start Compensation....................................................................................................18
7.3 The Load Controller ..................................................................................................19
7.4 Increasing Capacity ...................................................................................................20
7.5 Decreasing Capacity ..................................................................................................21
8 Abnormal Operating Conditions ..................................................................................22
8.1 General.......................................................................................................................22
8.2 Alarms/Trips ..............................................................................................................23
8.3 System Messages .......................................................................................................25
9 Settings ............................................................................................................................26
9.1 Setting the Load Controller .......................................................................................26
9.2 Adjusting the dynamics of the system .......................................................................28
9.3 Setting instrument scalings ........................................................................................29
9.4 Setting alarm set points..............................................................................................30
9.5 Save and restore settings............................................................................................31
10 Appendix .........................................................................................................................33
10.1 Basic Screen Navigation Diagram.............................................................................33
10.2 Troubleshooting Guide ..............................................................................................35
10.3 Colour Conventions ...................................................................................................37
10.3.1 Mono Version .....................................................................................................37
10.3.2 Colour Version....................................................................................................38

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Preface

Purpose:
This manual provides information about how to:
• Operate the STE Compressors.
• Handle abnormal operating conditions.
• Change basic settings.
Audience:
This manual is designed for Operators and Maintenance personnel who have a general
knowledge about rotating machinery and instrumentation.
Scope of the Manual:
The information contained in this manual pertains in particular the following equipment:
• STE Compressors, KA series
• STE Master Control Panels
• STE Human Machine Interfaces, mono edition
• STE Human Machine Interfaces, colour edition
Note:
Not every option or Human Machine Interface screen in this manual is relevant for each
Master Control Panel.
The Human Machine Interface screens shown in this manual are all taken from a Master
Control Panel controlling 3 compressors (MCP-3). The functional descriptions contained
in this manual are, however, valid for Master Control Panels controlling any number of
compressors between 2 and 9.
Text Conventions:
The following text conventions are used throughout this manual:
Vibration system
<Off>

Optional devices and conditions are presented in this italic font.
The names of keys and buttons are displayed in this bold font.

Further Support:
If you have any technical questions, please get in touch with your local STE representative or
agent responsible.

2

Related Documents

Refer to the following documentation for more detailed information about selected topics:
• Navigation Diagram MCP Operator Interface
• Circuit Diagram Master Control Panel

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Definitions

This section describes the important technical terms used in this manual.














Alarm
An Alarm signals that a process condition or process value is approaching a critical
value.
HMI
Human Machine Interface
HMI Screen
A HMI Screen is a group of logically related process data. A HMI Screen consists of e.g.
input and output fields, text, graphics and pushbuttons (Example Figure 4-2).
Load Controller
The Load Controller controls the capacity of the compressor system so the demand from
the process is met.
Local Control Panel (LCP)
Control panel connected to one compressor. The control panel is used to monitor the
conditions of the compressor and start/stop the compressor according to the automatic
sequence.
Master Control Panel (MCP)
Control panel connected to a group of compressors. The control panel is used to start and
stop the compressors according to the selected sequence and to regulate the compressor
capacity to match the airflow demanded by the process.
PLC
Programmable Logic Controller
Priority
A unique number assigned to every compressor. The priority determines the compressor’s place in the capacity control sequence.
Start Compensation
Start Compensation is an option that limits overshooting of the set point when a compressor is started.
System Message
System messages display states and faults of the HMI and the PLC.
Trip
A Trip signals that a process condition or process value has exceeded a critical value.
The compressor will make a quick shut down.

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General Information

This section provides basic information about the use of the compressor HMI from STE. Describing among others basic screen design, screen navigation, language selection, password
protection, and the message system.
4.1
Basic Screen Design
All the HMI screens are basically divided in three areas (Figure 4-1) the fixed area, the basic
area, and the navigation area.

Figure 4-1

Fixed Area:
The fixed area is used to provide general information about the status of the compressor system and the operation mode currently selected. The fixed area (Figure 4-2) is the same for all
HMI screens.
Basic Area:
The basic area is different for all HMI screens. Depending on the screen currently selected
the basic area provides access to process values, settings, start/stop pushbuttons, language
selection and links to other screens (Figure 4-2).

Figure 4-2

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Navigation Area:
The navigation area holds the pushbuttons used to navigate between the HMI screens in the
screen hierarchy. The number of pushbuttons in the navigation area depends on the position
of the current screen in the screen hierarchy.
The functions of the individual navigation pushbuttons are described in section 4.2.
4.2
Screen Navigation
The HMI screens are all arranged in a screen hierarchy that lay down how the individual
screens are linked together. Each HMI screen has a unique number according to its position
in the screen hierarchy. The screen number is shown in the lower right corner on every
screen. The screen numbering system is shown in Figure 4-3.

Figure 4-3

The pushbuttons in the navigation area of the HMI screens are used to move/navigate around
in the screen hierarchy. The functions of the individual navigation pushbuttons are described
in Figure 4-4.

Figure 4-4

For details about screen navigation please refer to the appendix in section 10.1.

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4.3
Language Selection
The STE HMI provides the possibility to let the user switch between two HMI languages.
The default HMI language is English. The second language is project dependent.

Figure 4-5

Switching the HMI languages is done on the “MAIN SCREEN” No. 1 (Figure 4-2) by clicking the “FLAG” pushbutton (Figure 4-5). The currently selected HMI language is shown in
the text field above the pushbutton.
4.4
Password Protection
Critical functions and settings are protected by passwords to avoid activation or change by
accident. The password level currently logged on can be seen on the “MAIN SCREEN”
No. 1 (Figure 4-2) and on the “MAIN SCREEN” No. 2 (Figure 4-12).
Password levels:
The HMI provides hierarchically organized password levels from level 0 to 9. If a user is
logged on with password level 3, for example, this user is authorized to execute the functions
of password levels 0 to 3.
The following password levels are used in the STE HMI:
• Password level 0 is the default level i.e. the lowest level in the password hierarchy. A
password does not need to be entered to execute functions on password level 0.
• Password level 3 is used to protect functions intended only for the plant maintenance
personnel. A password has to be entered in order to execute these functions.
Logging on:
Password log on can be done in two different ways:
• Directly by using the “SETTINGS: PASSWORD MANAGEMENT” screen
No. 2.1.2 (Figure 4-6).
1. Enter the password in the “Input Password” field.
2. Click the <Log On> pushbutton (Figure 4-7).
3. Result: The password level is shown in the “Current Password Level” field.

Figure 4-6

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Figure 4-7

• Indirectly by clicking a password protected pushbutton or input field.
1. Click the pushbutton or input field.
2. Result: The LOGIN window opens (Figure 4-8).

Figure 4-8

3.
4.
5.
6.
7.
8.

Click the Password field.
Result: The on-screen keyboard opens (Figure 4-9).
Enter the password and click the <Enter> key.
Result: The on-screen keyboard closes.
Click the <OK> pushbutton in the LOGIN window.
The user is now logged on.

Figure 4-9

Logging off:
Password log off can be done in two different ways:
• Automatically by the HMI after 15 minutes.
• Manually by using the “SETTINGS: PASSWORD MANAGEMENT” screen
No. 2.1.2 (Figure 4-6).
1. Click the <Log Off> pushbutton (Figure 4-7).
2. Result: The password level is reset to 0.
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Password table:
The table below shows the default password for password level 3 when the HMI is shipped.
Password Level

User Name

Password

Changes Allowed

1

-

-

-

2

-

-

-

3

Plant

HVT

Yes

0

3
3
3

The empty rows in the table above can be used to keep record of new passwords created or
of changes to existing passwords.
Changing passwords:
When logged onto password level 3, changes can be made to the password levels 1 to 3 as
described below:
1. Navigate to screen No. 2.1.2 (Figure 4-6)
2. Log onto password level 3 as described in the section Password Protection (Logging
on directly).
3. Click in the relevant field in the Password column.
4. Result: The on-screen keyboard opens.
5. Enter the new password and click the <Enter> key.
6. Result: The on-screen keyboard closes and the password has been changed.
Creating passwords:
When logged onto password level 3, new passwords can be created for the password levels 1
to 3 as described below:
1. Navigate to screen No. 2.1.2 (Figure 4-6)
2. Log onto password level 3 as described in the section Password Protection (Logging
on directly).
3. Click an empty field in the User column.
4. Result: The on-screen keyboard opens.
5. Enter the new user name and click the <Enter> key.
6. Repeat step 3-5 for the Password and Level columns.
7. Result: The on-screen keyboard closes and the password has been created.

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4.5
Message System
The message system is responsible for reporting events or states that can occur in the compressor system or in the control system. The message system consist of the following components:
• The message indicator.
• The alarm messages window.
• The alarm page.
• The message buffers.
These components and the three message types that are distinguished between in the message system are described below.
Message Types:
• Alarm messages display critical or hazardous operating and process states and require the operating personnel to react by issuing an acknowledgement.
• Event messages display routine operating and process states.
• System messages display states and faults of the HMI, the PLC or the communication between them. They are issued by the HMI or by the PLC and are automatically
displayed on the HMI when they occur.
Message Indicator:
As soon as an alarm message is arriving, the alarm message window (Figure 4-11) and the
message indicator (Figure 4-10) are displayed. The message indicator shows the number of
active alarm messages and will remain visible as long as alarm messages still are active (i.e.
not cleared). The message indicator can assume two states:
• Flashing: As soon as at least one unacknowledged alarm message is queued.
• Static: When all queued alarm messages have been acknowledged but at least one of
them is not yet cleared.

Figure 4-10

Clicking the message indicator will:
• Open the alarm message window if unacknowledged alarm messages still remain.
• Open the alarm page if active alarm messages still remain.
Alarm Message Window:
The alarm message window (Figure 4-11) opens automatically whenever an alarm message
arrives. The following information is provided in the alarm messages window:
• No. column displays a unique alarm message number. Please inform this number
when calling STE for service support.
• Status column displays the current status of the alarm message:
- A: The message is Active
- C: The message is Cleared
- R: The message has been Reset/acknowledged
• PLC column displays the PLC from which the alarm message originates (always
PLC_1).

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The following pushbuttons are available for handling alarm messages:
• <Help>: Displays the help text to the selected alarm message (example Figure 4-14).
• <Edit>: Triggers message specific functions (not used).
• <ACK>: Resets / acknowledges the selected alarm message.

Figure 4-11

The alarm message window is closed by clicking the
the window.

button in the upper right corner of

Alarm Page:
The alarm page has the same layout and provides the same information as the alarm message
buffer (Figure 4-13). The alarm page, however, shows only currently active alarms and will
be empty when all alarms have cleared.
Message Buffers:
The message buffers provide access to historical alarm and event messages. All messages are
stored in chronological order in the message buffer. The most recent message is displayed at
the top of the message buffer. The message buffer is a “First-In-First-Out” buffer type i.e. the
first message stored in the buffer will be the first message to be deleted when the message
buffer is full.

Figure 4-12

Alarm and event messages are stored in separate buffers that can be accessed from HMI
screen No. 2 (Figure 4-12).

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Alarm Buffer:
The following information is provided in the alarm buffer (Figure 4-13):
• No. column displays a unique alarm message number. Please inform this number
when calling STE for service support.
• Time column displays the time when the status of the alarm changed.
• Date column displays the date when the status of the alarm changed.
• Status column displays the status of the alarm message:
- A: The message is Active
- C: The message is Cleared
- R: The message has been Reset/acknowledged
• GR column displays the reset group that the alarm message belongs to.
• Message text.
The following pushbuttons are available for handling alarm messages:
• <Help>: Displays the help text to the selected alarm message (example Figure 4-14).
• <Edit>: Triggers message specific functions (not used).

Figure 4-13

The alarm buffer is closed by clicking the

button in the upper right corner of the window.

The help text linked to the alarm message provides useful guidelines when troubleshooting
the compressor system. In addition the alarm help text makes a reference to the relevant
page(s) in the Circuit Diagrams.

Figure 4-14

The help text is closed by clicking the

button in the upper right corner of the window.

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Event Buffer:
The following information is provided in the event buffer (Figure 4-15):
• No. column displays a unique event message number. Please inform this number
when calling STE for service support.
• Time column displays the time when the status of the event changed.
• Date column displays the date when the status of the event changed.
• Status column displays the status of the event message:
- A: The message is Active
- C: The message is Cleared
• Message text.
The following pushbuttons are available for handling event messages:
• <Help>: Displays the help text to the selected event message.
• <Edit>: Triggers message specific functions (not used).

Figure 4-15

The event buffer is closed by clicking the

button in the upper right corner of the window.

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Operation Modes

This section explains the MCP operation modes, their selection and use. Each operation
mode is described by its definition, target audience, selection and the possible user actions.
5.1
Selecting Modes
The MCP operation modes are selected from the “MODE SELECTION” screen No. 1.1
(Figure 5-1). The modes are selected by clicking the pushbutton for the relevant operation
mode. The currently selected operation mode is shown in the fixed area.

Figure 5-1

The operation modes are linked together according to Figure 5-2. The MCP operation modes
can be selected without any restrictions.

Figure 5-2

Note:
Switching from Automatic Mode to Off Mode will stop all compressors running, i.e. the
complete compressor system will be stopped.

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5.2
Off Mode
Definition:
In Off Mode the MCP is permanently out of operation and the compressors are not started or
stopped by the MCP. The complete compressor system is out of operation and the automatic
capacity control is disabled. The compressors are, however, still available for local control
from the LCP’s.
Target Audience:
Off Mode is intended for:
• The every-day operator.
• The plant maintenance personnel.
Selection: (Figure 5-2)
Off Mode can be selected when the compressors are in operation or out of operation from:
• Automatic Mode.
Possible User Actions:
The user can perform the following tasks in Off Mode:
• Acknowledge alarms.
• Acknowledge trips.
5.3
Automatic Mode
Definition:
In Automatic Mode the MCP controls the compressors selected to Remote Mode on the LCP
HMI. The compressors are automatically started/stopped and the capacity controlled to meet
the airflow currently demanded by the process.
Target Audience:
Automatic Mode is intended for:
• The every-day operator.
Selection: (Figure 5-2)
Automatic Mode can be selected when the compressors are in operation or out of operation
from:
• Off Mode.
Possible User Actions:
The user can perform the following tasks in Automatic Mode:
• Acknowledge alarms.
• Acknowledge trips.
• Allocate priorities to the compressors.
• Select internal or external set point for the Load Controller.
• Select manual or automatic mode for the Load Controller.
• Select Start Compensation On/Off.

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Compressor/Priority allocation

This section provides information about the allocation of priorities to the compressors. The
section starts with a description on how to select priorities for the compressors. The section
is ended with a description of the procedure for priority validation.
6.1
Selecting Priorities
Each compressor is allocated a unique priority. The priorities selected determine the sequence in which the compressors are started by the MCP. The compressors are identified by
letters (A, B, C, etc.) and the priorities by numbers (0, 1, 2, 3, etc.). The priority numbers that
can be selected depends on the number of compressors controlled by the MCP:
• 2 Compressors → Priorities 0, 1, 2
• 9 Compressors → Priorities 0, 1, 2, 3, 4, 5, 6, 7, 8, 9
The MCP will not control a compressor allocated the priority 0. The compressor that is allocated the priority 1 will be the first one to be started and the compressor allocated the priority
9 will be the last one to be started.
The priorities are selected from the “PRIORITY SELECTION” screen No. 1.2.2 (Figure
6-1). The selection of priorities is described below.
Operator procedure:
1. Click the “Select Compressor” pushbuttons to select the compressor for which the
priority has to be allocated. A grey frame around the ”Accepted” and ”Selected”
fields indicates that the compressor is currently selected.
2. Click the “Select Priority” pushbuttons to change the priority for the currently
selected compressor.

Figure 6-1

The “Accepted” row in Figure 6-1 shows the priority sequence currently used by the MCP
when controlling the compressors.
The “Selected” row shows the priorities selected with the “Select Priority” pushbuttons.
Note:
It is recommended only to change the priorities for two compressors at a time to avoid upsetting the airflow to the process.
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6.2
Validating Priorities
The priority sequence selected (refer to section 6.1) needs to be validated before it can be
used in the compressor control. The rules for selecting priorities are described in the section
below.
Rules for selecting priorities:
The following rules need to be observed when selecting priorities:
• Priority sequence must be selected without “holes”.
• Priority numbers 1 to 9 must only be selected once.
• Priority number 0 can be allocated to as many compressors as desired.
The tables below show examples of valid (Table 1) and not valid (Table 2) priority sequences.
Table 1: Examples of valid priority sequences (MCP-5)

Compressor
A

B

C

D

E

0

3

1

2

0

1

4

2

0

3

3

2

5

1

4

Table 2: Examples of not valid priority sequences (MCP-5)

Compressor
A

B

C

D

E

1

2

4

0

0

Priority sequence with “hole” (3 is missing).

2

4

1

2

3

Priority 2 is selected twice.

3

2

5

0

4

Priority sequence with “hole” (1 is missing).

Accepting priorities:
The priority sequence selected is accepted by clicking the pushbutton “Accept Priorities” on
the “PRIORITY SELECTION” screen No. 1.2.2 (Figure 6-1). Only a valid priority sequence
can be accepted.
The priorities in the “Selected” row will be copied to the “Accepted” row when they are accepted. The compressors will then be controlled according to the new priorities.
Note:
It is recommended only to change the priorities for two compressors at a time to avoid upsetting the airflow to the process.

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Priority failure:
If a not valid priority sequence has been selected then it is signalled on the “PRIORITY SELECTION” screen No. 1.2.2 (Figure 6-2) by:
• Flashing priority fields in the “Selected” row.
• “Priority Failure” in the status field of the fixed area.

Figure 6-2

Selecting valid priorities will automatically disable the flashing of the priority fields and enable the “Accept Priorities” pushbutton.
Note:
Only valid priorities can be accepted.

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Capacity Control

This section provides information about how the compressors are controlled to meet the airflow demanded by the process. The description covers monitoring of the operation, the function of the start compensation, the operation of the Load Controller and the increase and decrease capacity sequences.
7.1
Monitoring the Operation
The sequence of compressor start/stop when increasing or decreasing the capacity can be
monitored on the “OPERATION” screen No. 1.2 (Figure 7-1).

Figure 7-1

The “OPERATION” screen No. 1.2 (Figure 7-1) provides among others an overview of the
current operational status of each compressor. The status of each compressor is signalled
graphically as described below:
(Steady)
(Steady)
(Flashing)
(Steady)
(Flashing)

The compressor is out of operation and ready to start.
The compressor is out of operation and not ready to start.
The compressor is starting.
The compressor is in operation.
The compressor has tripped due to a failure.

In addition the currently accepted priority numbers are shown for each compressor.
The “OPERATION” screen No. 1.2 (Figure 7-1) also provides information about the current
set point and the current process value.
The set point can be changed by clicking the set point input field. The prerequisite for changing the set point from the “OPERATION” screen is that internal set point mode has been selected on the “LOAD CONTROLLER” screen No. 1.2.1 (Figure 7-3)
The “LOAD CONTROLLER” screen No. 1.2.1 (Figure 7-3) and the “PRIORITY SELECTION” screen No. 1.2.2 (Figure 6-1) can both be accessed from the “OPERATION” screen
No. 1.2 by clicking the appropriate pushbutton.
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7.2
Start Compensation
Start Compensation is provided to limit overshooting of the set point when starting an additional compressor. The operation of the start compensation is described below:
1. The MCP sends a command to an LCP to start the attached compressor.
2. The compressor starts and the LCP returns an “Operation” signal to the MCP.
3. The MCP activates the start compensation on the compressor with the next lower priority number than the compressor just started.
Example: The compressor with priority number 2 starts → Start Compensation is activated
on the compressor with priority number 1. The Start Compensation activates a timer and the
MCP controls the capacity of the compressor (priority number 1) down until the timer has
expired. The normal capacity control will be enabled again when the Start Compensation
time has expired.
The Start Compensation time can be adjusted through the “SETTINGS: GENERAL” screen
No. 2.1.3 (Figure 9-3).

Figure 7-2

Start Compensation is an optional feature and it can be switched “On” by clicking the
On/Off pushbutton on the “OPTIONS” screen No. 1.3 (Figure 7-2)

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7.3
The Load Controller
The Load Controller is responsible for controlling the compressors so the airflow demanded
by the process is obtained. The compressors are normally controlled to keep a constant pressure in a main air header. The pressure in the air main header is measured by a pressure
transmitter and fed through the PLC to the Load Controller. The pressure set point can either
be set manually through the “LOAD CONTROLLER” screen No. 1.2.1 (Figure 7-3) or externally, e.g. from a process control system. The Load Controller is configured as a PI step
controller. Based on the measured pressure and the set point the Load Controller generates
signals to increase or decrease the capacity of the compressor system.

Figure 7-3

The “LOAD CONTROLLER” screen No. 1.2.1 (Figure 7-3) provides the following:
• Pushbutton to select internal (SP INT) or external (SP EXT) set point.
• Pushbuttons to increase/decrease the internal set point.
• Pushbutton to select manual (MAN) or automatic (AUTO) controller mode.
• Pushbuttons to increase/decrease the capacity of the compressor system in manual
controller mode.
• Bargraph for display of the controller set point (SP).
• Bargraph for display of the controller process value (PV).
• Bargraph for display of the controller output (Out).
• Pushbutton to access the controller parameters.
• Pushbutton to access the controller trends of the set point and the process value.
Note:
No capacity control will be performed if the Load Controller is switched to manual mode.

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7.4
Increasing Capacity
When the current capacity of the compressor system does not meet the capacity demanded
by the process, the LOAD CONTROLLER will increase the capacity of the compressors in
operation and if necessary start additional compressors. The philosophy of the MCP is to
control the capacity of only one compressor at a time and then keep the rest of the compressors in operation at their maximum capacity.
Below a description of the sequence when the capacity is increased:
1. A start command will be sent to the priority 1 compressor as soon as “Automatic”
mode is selected on the “MODE SELECTION” screen No. 1.1 (Figure 5-1).
2. The capacity of the priority 1 compressor will be increased until the set point is
reached or the priority 1 compressor has reached its maximum capacity.
3. A start command will be sent to the priority 2 compressor when the LOAD CONTROLLER has generated the “Number Of Pulses To Start” set on the “SETTINGS:
GENERAL” screen No. 2.1.3 (Figure 9-3).
4. The capacity of the priority 1 compressor will be decreased when the priority 2 compressor signals that it is in operation. (Only if Start Compensation is switched “On”,
refer to section 7.2).
5. When the Start Compensation time (refer to Figure 9-3) has expired the capacity of
the priority 1 compressor is increased until the set point is reached or the compressor
has reached its maximum capacity.
6. The capacity of the priority 2 compressor will be increased until the set point is
reached or the priority 2 compressor has reached its maximum capacity.
7. A start command will be sent to the priority 3 compressor when the LOAD CONTROLLER has generated the “Number Of Pulses To Start”.
The above sequence will continue in the same way until the set point has been reached or all
compressors controlled by the MCP are in operation.
The current status of the compressors system can be monitored on the “OPERATION”
screen No. 1.2 (Figure 7-1).

Figure 7-4

Figure 7-4 shows the LOAD CONTROLLER in “AUTO” mode operating with an external
set point during a phase where the capacity is increased.

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7.5
Decreasing Capacity
When the current capacity of the compressor system is higher than the capacity demanded by
the process, the LOAD CONTROLLER will decrease the capacity of the compressors in operation and if necessary stop compressors. The philosophy of the MCP is to control the capacity of only one compressor at a time and then keep the rest of the compressors in operation at their maximum capacity.
Below a description of the sequence when the capacity is decreased:
1. The capacity of the priority 3 compressor will be decreased until the set point is
reached or the priority 3 compressor has reached its minimum capacity.
2. The capacity of the priority 2 compressor will be decreased until the set point is
reached or the priority 2 compressor has reached its minimum capacity.
3. The start command to the priority 3 compressor will be reset when the LOAD CONTROLLER has generated the “Number Of Pulses To Stop” set on the “SETTINGS:
GENERAL” screen No. 2.1.3 (Figure 9-3).
4. When the priority 3 compressor is out of operation, the capacity of the priority 1
compressor will be decreased until the set point is reached or the priority 1 compressor has reached its minimum capacity.
5. The start command to the priority 2 compressor will be reset when the LOAD CONTROLLER has generated the “Number Of Pulses To Stop”.
The above sequence will continue in the same way until the set point has been reached or
only the priority 1 compressor is in operation in its minimum capacity.
The MCP will not automatically stop the priority 1 compressor. The priority 1 compressor
can only be stopped by selecting Off Mode (refer to section 5.1) or by initiating a remote
stop command, e.g. from a process control system.
The current status of the compressors system can be monitored on the “OPERATION”
screen No. 1.2 (Figure 7-1).

Figure 7-5

Figure 7-5 shows the LOAD CONTROLLER in “AUTO” mode operating with an internal
set point during a phase where the capacity is decreased.

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Abnormal Operating Conditions

This section explains how the compressor system and the MCP will react to abnormal operating conditions. The description covers the MCP alarms/trips and the HMI / PLC system
messages.
8.1
General
The MCP behaviour to different abnormal situations is described below.
MCP power failure:
When the MCP fails due to a power outage, the compressors running in Remote Mode will
automatically be switched to Local Mode and the compressors remain in operation at their
current capacity. The compressor capacity can then be controlled manually from the LCP.
When the power supply to the MCP is restored and it is in Automatic Mode then switch:
1. The priority 1 compressor to Remote Mode (When switched to Remote Mode the
compressor will stop. The MCP will restart the compressor when it is ready to start).
2. The priority 2 compressor to Remote Mode (only when the priority 1 compressor is
started by the MCP).
3. The priority 3 compressor to Remote Mode (only when the priority 2 compressor is
started by the MCP).
Continue the above sequence until the compressor with the highest priority number has been
switched to Remote Mode.
Total power failure (MCP + LCP’s):
When the complete compressor control system (MCP + LCP’s) fails due to a power outage
then all the compressors will stop instantly.
When the power supply to the MCP and LCP’s has been restored, the MCP automatically
starts the priority 1 compressor and resumes capacity control to meet the airflow demanded
by the process.
Compressor trip:
When a compressor trips due to a critical operating or process state, the MCP automatically
starts the next compressor that is ready in the priority sequence.
Example with MCP-4:
1. The priority A=1 and priority B=2 compressors are in operation. The priority C=3
compressor is not ready for operation (e.g. in Local Mode). The priority D=4 compressor is not in operation.
2. The priority B=2 compressor trips due to a critical operating state.
3. The MCP automatically starts the priority D=4 compressor.
When the reason for the compressor trip has been found and rectified then the LCP will signal “Ready to start” to the MCP. The MCP will automatically restart the compressor when it
is ready again.

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8.2
Alarms/Trips
Two categories of alarm messages are defined in the MCP message system. The two categories are described below:
Alarms are operating and process states that require the operating personnel to react by issuing an acknowledgement but not require the compressor system to be stopped. Examples of
alarms that will not stop the compressor system are listed in the table below.
Number

Alarm Message Text

81

Header Air Pressure L

82

Header Air Pressure H

83

Header Air Flow L

84

Header Air Flow H

85

Dissolved Oxygen Level L

86

Dissolved Oxygen Level H

97

Header Air Temperature L

98

Header Air Temperature H

131

Load Controller Set Point Wire-break

139

Header Air Pressure Transmitter Wire-break

147

Header Air Flow Transmitter Wire-break

155

Header Air Temperature Transmitter Wire-break

163

Dissolved Oxygen Transmitter Wire-break

Refer to the Troubleshooting Guide in section 10.2 or click the <Help> pushbutton in the
alarm buffer window to determine a possible cause of the alarm.

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Trips are critical or hazardous operating and process states that require the operating personnel to react by issuing an acknowledgement. Examples of trips are listed in the table below.
Number

Trip Message Text

1

System Emergency Stop Activated

17

Header Air Pressure LL

18

Header Air Pressure HH

19

Header Air Flow LL

20

Header Air Flow HH

21

Dissolved Oxygen Level LL

22

Dissolved Oxygen Level HH

33

Header Air Temperature LL

34

Header Air Temperature HH

Refer to the Troubleshooting Guide in section 10.2 or click the <Help> pushbutton in the
alarm buffer window to determine a possible cause of the trip.

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8.3
System Messages
This section contains a selection of the most important system messages that can be shown
on the HMI. System messages provide information about the HMI and the PLC operating
modes. System messages can range from information to serious errors. The table below indicates when the messages occur and how they, or their cause, can be cleared.
Note:
Not every message in the table is relevant for each MCP.
Number
4003

Effect/Cause

Remedy

Stop caused by the PLC mode switch
being switched to STOP position.

Switch the PLC mode switch to RUN
position.

110000 The operating mode status has been
changed. The operating mode is now
off-line.
110001 The operating mode status has been
changed. The operating mode is now
on-line.
140000 On-line connection to the PLC has been
successfully established.
140001 On-line connection to the PLC has been
disconnected.
140003 No tag updating or writing is executed.

140010 No communication peer could be found
because the PLC is switched Off.
140011 No tag updating or writing is executed
because the communication is interrupted.
230002 Entry rejected. The current password
level is inadequate or the password dialog box was closed with <Cancel>.
230005 Range exceeded. The value entered is
outside the valid range.

Check the cable connection between the
HMI and the PLC.
Check that the PLC is switched On and
in RUN mode.
Restart the system
(Power Off → Power On)
Switch the PLC On.

Check the cable connection between the
HMI and the PLC.
Check that the PLC is switched On and
in RUN mode.
Activate an adequate password level by
logging on as described in section 4.4.
Enter a value within the range specified.

If serious system messages are shown that are not in the table above, then please get in touch
with your local STE representative or agent responsible.

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Settings

This section provides information about how basic parameters for the operation of the compressor system are set or changed through the HMI. The section describes amongst others
how to set the parameters of the Load Controller, how to adjust the dynamics of the compressor system and how to set instrument scalings. Unless described otherwise changing the
settings in this section requires that password level 3 is logged on.
9.1
Setting the Load Controller
The Load Controller is responsible for controlling the compressors so the airflow demanded
by the process is obtained. The parameters of the Load Controller (Figure 9-1) have to be set
and fine-tuned during commissioning of the compressor system to obtain an optimum operation of the process. When the operation of the process is changed after commissioning of the
MCP then the Load Controller might need to be fine-tuned again. The Load Controller parameters are described below:
• Internal Set Point
The Internal Set Point is used for control when internal set point mode (SP INT) is selected on the Load Controller screen No. 1.2.1 (Figure 7-3). The Internal Set Point is
entered in percent (of the process value span) and is additionally shown in the relevant unit.
• Safety Set Point
The Safety Set Point is used for control when external set point mode (SP EXT) is selected on the Load Controller screen No. 1.2.1 (Figure 7-3) and the external set point
signal is interrupted. The Safety Set Point is entered in percent (of the process value
span) and is additionally shown in the relevant unit.
• Dead Band
The Dead Band is applied on both “sides” of the set point and in this band the Load
Controller will not increase or decrease the capacity. It should be noted that the
steady-state deviation may be equal to the value of the dead band.
• Proportional Gain
The Proportional Gain determines the response of the proportional component in the
Load Controller.
• Integral Action Time
The Integral Action Time determines the time response of the integral component in
the Load Controller.

Figure 9-1

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Tuning the Load Controller:
The Load Controller parameters (Figure 9-1) need to be fine-tuned during commissioning
and if the operation of the process is changed. The Load Controller Trend screen No. 1.2.1.2
(Figure 9-2) is intended as an aid when this fine-tuning has to be performed. The Load Controller Trend screen shows the dynamics of the Process Value (%) and the Set Point (%)
while the Load Controller is operating.
The trend curves can be started and stopped by clicking the <Start/Stop> pushbutton.

Figure 9-2

The Load Controller Trend screen No. 1.2.1.2 (Figure 9-2) is selected by clicking the
<Trend> pushbutton on the Load Controller screen No. 1.2.1 (Figure 7-3).
• Dead Band
Decrease the Dead Band if the process value requires more accurate control.
Increase the Dead Band if the process value requires further stabilization.
Note that the steady-state deviation between the set point and the process value may
have the same value as the dead band (i.e. the control becomes less accurate when the
dead band is increased).
• Proportional Gain
Decrease the Proportional Gain if the process value requires a smaller control response.
Increase the Proportional Gain if the process value requires a greater control response.
• Integral Action Time
Decrease the Integral Action Time if the process value requires a faster control response.
Increase the Integral Action Time if the process value requires a slower control response.
Note:
It is recommended only to change one of the above parameters at a time and then observe the
reaction of the Load Controller on the Load Controller Trend screen before changing further
parameters.

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9.2
Adjusting the dynamics of the system
The dynamic behaviour of the compressor system can be changed by means of the parameters on the “SETTINGS: GENERAL” screen No. 2.1.3 (Figure 9-3).

Figure 9-3

The parameters on screen No. 2.1.3 are described below:
• Start Delay After Power-Up
After power-up the MCP will not start any compressors until the delay time has expired. The delay time is used by the LCP’s to re-establish the compressor start conditions (e.g. open the blow-off valve and close the diffuser).
Recommended setting: 300 sec.
• Number Of Pulses To Start
The “Number Of Pulses To Start” parameter determines how many “Increase” pulses
the Load Controller has to generate with a compressor in maximum capacity before
an additional compressor is started.
Recommended setting for pressure control: 6 pulses.
Recommended setting for oxygen control: 80 pulses.
• Number Of Pulses To Stop
The “Number Of Pulses To Stop” parameter determines how many “Decrease” pulses
the Load Controller has to generate with a compressor in minimum capacity before a
compressor is stopped.
Recommended setting for pressure control: 6 pulses.
Recommended setting for oxygen control: 80 pulses.
• Start Compensation Time
The “Start Compensation Time” parameter determines how long time the capacity of
the compressor currently under “Start Compensation” control is forced down.
Recommended setting: 60 sec.

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9.3
Setting instrument scalings
The range for analog instruments is set by means of the parameters Minimum Scaling and
Maximum Scaling. Instrument scalings are grouped according to the physical location of the
instrument:
• Air Header System (example in Figure 9-4)
• Aeration System

Figure 9-4

Note:
Changing the parameters Minimum Scaling or Maximum Scaling also requires the instrument range to be changed / recalibrated.
Do not change these settings without contacting your local STE representative or agent responsible.

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Operations Manual
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17-03-2008
Revision: 2.01

9.4
Setting alarm set points
The alarm and trip set points are set through standardized HMI screens. An example for the
header air pressure is shown in Figure 9-5.
The following parameters can be set for alarms and trips:
• Alarm Setpoint
• Alarm Hysteresis
- High Alarm: Hysteresis below the set point
- Low Alarm: Hysteresis over the set point
• Alarm Delay
• Trip Setpoint
• Trip Hysteresis
- High Trip: Hysteresis below the set point
- Low Trip: Hysteresis over the set point
• Trip Delay
Note:
Setting trip parameters require that password level 6 is logged on.

Figure 9-5

Changes to the alarm/trip parameters must be saved by clicking the “Save Settings” pushbutton.
Note:
Changing the trip parameters may result in damages to the compressor as well as personal
injuries. Do not change these settings without contacting your local STE representative or
agent responsible.

Page 30 / 38

Operations Manual
Master Control Panel

17-03-2008
Revision: 2.01

9.5
Save and restore settings
The changes made to settings as described in the previous sections are all automatically
stored in a non-volatile memory. This means that the settings will be available even after a
power failure. However the changes made to settings will not be available after a total system reset (i.e. the default settings will be re-loaded) unless the settings were saved as described below.

Figure 9-6

The save and restore functions are depicted in Figure 9-6.

Figure 9-7

Save settings
To save the current settings as the new default settings please follow the procedure described
below:
1. Log on with password level 3 (Figure 4-6)
2. Select the “SAVE / RESTORE SETTINGS” screen No. 2.1.1.1 (Figure 9-7)
3. Push the “Save” pushbutton.

Page 31 / 38

Operations Manual
Master Control Panel

17-03-2008
Revision: 2.01

The current settings will now be saved as the new default settings. A running save procedure
is indicated as shown in Figure 9-8.

Figure 9-8

Restore settings
To restore the default settings as the current settings please follow the procedure described
below:
1. Log on with password level 3 (Figure 4-6)
2. Select the “SAVE / RESTORE SETTINGS” screen No. 2.1.1.1 (Figure 9-7)
3. Push the “Restore” pushbutton.
The default settings will now be restored as the current settings. A running restore procedure
is indicated as shown in Figure 9-9.

Figure 9-9

Note:
Saving and restoring settings require that password level 3 is logged on.

Page 32 / 38

Operations Manual
Master Control Panel

17-03-2008
Revision: 2.01

10 Appendix
This appendix will provide the operator with detailed information about the screen navigation, compressor troubleshooting, and the HMI colour conventions.
10.1 Basic Screen Navigation Diagram
This section will provide the user with an overview of the basic HMI screens available and
their position in the screen hierarchy.
Legend:

Basic Screen Navigation Part 1:

Page 33 / 38

Operations Manual
Master Control Panel

17-03-2008
Revision: 2.01

Basic Screen Navigation Part 2:

Note:
If more information about the screen hierarchy is needed then please refer to the detailed
document “Navigation Diagram MCP Operator Interface”.

Page 34 / 38

Operations Manual
Master Control Panel

17-03-2008
Revision: 2.01

10.2 Troubleshooting Guide
This section provides basic information about how to remedy abnormal conditions. Not
every message in the tables below is relevant for each MCP.
Note:
If the message of interest cannot be found in the table below, please use the <Help>
pushbutton in the alarm buffer window to gain more information about possible remedies.
Number

Message Text

Remedy

1

System Emergency Stop Activated

18

Header Air Pressure HH

19

Header Air Flow LL

21

Dissolved Oxygen Level LL

Check the process conditions and the
number of compressors running.

34

Header Air Temperature HH

Check the process conditions and the
function of the air after cooler, if any

65

MCP<=>LCP A: Communication Link
Interrupted

66

MCP<=>LCP B: Communication Link
Interrupted

67

MCP<=>LCP C: Communication Link
Interrupted

68

MCP<=>LCP D: Communication Link
Interrupted

69

MCP<=>LCP E: Communication Link
Interrupted

Check the power supply to the LCP A.
Check the cable connection of the communication link between the MCP and
the LCP A.
Check the power supply to the LCP B.
Check the cable connection of the communication link between the MCP and
the LCP B.
Check the power supply to the LCP C.
Check the cable connection of the communication link between the MCP and
the LCP C.
Check the power supply to the LCP D.
Check the cable connection of the communication link between the MCP and
the LCP D.
Check the power supply to the LCP E.
Check the cable connection of the communication link between the MCP and
the LCP E.

Page 35 / 38

Re-establish safe conditions and deactivate the emergency stop button.
Acknowledge the alarm message in the
alarm message window.
Check the process conditions. Check
that the aeration valves and isolation
valves are not closed.
Check the process conditions and the
number of compressors running.

Operations Manual
Master Control Panel

Number

Message Text

17-03-2008
Revision: 2.01

Remedy

70

MCP<=>LCP F: Communication Link
Interrupted

71

MCP<=>LCP G: Communication Link
Interrupted

72

MCP<=>LCP H: Communication Link
Interrupted

73

MCP<=>LCP I: Communication Link
Interrupted

82

Header Air Pressure H

83

Header Air Flow L

85

Dissolved Oxygen Level L

Check the process conditions and the
number of compressors running.

98

Header Air Temperature H

Check the process conditions and the
function of the air after cooler, if any

131

Load Controller Set Point Wire-break

139

Header Air Pressure Transmitter Wirebreak

Check the signal output (e.g. in the
process control system). Check the wire
connections.
Check the transmitter output. Check the
wire connections.

147

Header Air Flow Transmitter Wirebreak

Check the transmitter output. Check the
wire connections.

155

Header Air Temperature Transmitter
Wire-break

Check the transmitter output. Check the
wire connections.

163

Dissolved Oxygen Transmitter Wirebreak

Check the transmitter output. Check the
wire connections.

Page 36 / 38

Check the power supply to the LCP F.
Check the cable connection of the communication link between the MCP and
the LCP F.
Check the power supply to the LCP G.
Check the cable connection of the communication link between the MCP and
the LCP G.
Check the power supply to the LCP H.
Check the cable connection of the communication link between the MCP and
the LCP H.
Check the power supply to the LCP I.
Check the cable connection of the communication link between the MCP and
the LCP I.
Check the process conditions. Check
that the aeration valves and isolation
valves are not closed.
Check the process conditions and the
number of compressors running.

Operations Manual
Master Control Panel

17-03-2008
Revision: 2.01

10.3 Colour Conventions
This section provides information about the colours used in the HMI screens. The colours
and the operation states/conditions they describe are listed in the tables below.
10.3.1 Mono Version
The table below lists the colours used and the operation states/conditions they describe.

Colour

State Description

Example

White

Off
Fully Closed Position

1. Lube oil pump stopped
2. Diffuser closed (minimum)

Grey

On
Midway Position

Black

Fully Open Position

1. Lube oil pump running
2. Diffuser between open and
closed position
1. Diffuser open (maximum)

Black
Flashing

Abnormal Condition

1. Transmitter out of range
2. Motor circuit breaker tripped

Note:
Please use the <?> pushbutton in the navigation area of the screen to see the relevant help
text.

Page 37 / 38

Operations Manual
Master Control Panel

17-03-2008
Revision: 2.01

10.3.2 Colour Version
The table below lists the colours used and the operation states/conditions they describe.

Colour

State Description

Example

White

Off
Fully Closed Position

1. Lube oil pump stopped
2. Diffuser closed (minimum)

Grey

Available

Black

Reset

Red
Flashing

Abnormal Condition

1. Transmitter out of range
2. Motor circuit breaker tripped

Green

On
Fully Open Position

1. Lube oil pump running
2. Diffuser open (maximum)

Blue

Midway Position

1. Diffuser between open and
closed position

Yellow

Unavailable

1. Lube oil pump available

1. Reset pushbutton

1. Motor circuit breaker tripped

Note:
Please use the <?> pushbutton in the navigation area of the screen to see the relevant help
text.

Page 38 / 38

ELECTRICAL MACHINES, DRIVE SYSTEMS AND INSTALLATIONS

Operating Manual

IP23

Three-Phase-Low-Voltage
Squirrel-Cage Machines
GB

1

Table of Contents
Chapter
1
Safety Instructions

Page

1.1
1.2
1.3
1.4
1.5
1.6
1.7

General Instructions .......................................................................... 5
Symbols ............................................................................................ 5
Safety Regulations ........................................................................... 6
Regulations, Standards .................................................................... 6
Conditions of Connection ................................................................. 6
Inscriptions, Warning Signs .............................................................. 7
Working on the Electrical Machine ................................................... 7

2

Important Instructions

2.1
2.2
2.3
2.4
2.5
2.6

Stipulated Usage .............................................................................. 8
General Instructions .......................................................................... 8
Installation ......................................................................................... 9
Ventilation ......................................................................................... 9
Electromagnetic Compatibility ........................................................ 10
Feet Anchoring Holes (Diag.2) ....................................................... 10

3

Transportation

3.1
3.2
3.3
3.4

Safety Instructions ........................................................................... 11
Lifting Eyes ..................................................................................... 11
Securing Procedures for Transportation ......................................... 11
Transport Damage .......................................................................... 12

4

Assembly and Commissioning

4.1
4.2
4.2.1
4.2.2
4.2.2.1
4.2.3
4.2.3.1
4.2.3.2
4.2.3.3
4.2.4
4.3
4.3.1

Safety Instructions ........................................................................... 13
Mechanical ..................................................................................... 14
Transmission Components ............................................................. 14
Machine Base ................................................................................. 16
Assessment Criteria for Vibration ................................................... 16
Alignment ........................................................................................ 17
Angular Alignment (Diag.7) ............................................................ 17
Parallel Alignment (Diag.8) ............................................................ 17
Combined Angular and Parallel Alignment (Diag.9) ..................... 17
Additional Fitted or Attached Parts ................................................. 18
Electrical ......................................................................................... 19
Insulating Resistance ..................................................................... 19

4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
4.3.7

Voltage and Circuit ......................................................................... 19
Connection ..................................................................................... 20
Terminal box position (side) ........................................................... 21
Direction of Rotation ....................................................................... 21
Y/D -start ......................................................................................... 22
Electrical Machine Protection ......................................................... 22

2

Table of Contents
Chapter

Page

5

Maintenance

5.1
5.2
5.3
5.3.1
5.3.2
5.4
5.5
5.5.1

5.7

Safety Instructions ........................................................................... 23
Cleaning ......................................................................................... 24
Ball and Roller Bearing Maintenance ............................................ 24
Grease Nipple ................................................................................. 25
Lubrication ...................................................................................... 25
Bearing Seals ................................................................................. 26
Bearing Change – Shaft Height (AH) 180 to 315 ........................... 27
Dismantling Procedure for Drive and Non-drive Side
Deep Groove Ball Bearings ............................................................ 27
Assembly Procedure for Drive and Non-drive Side
Deep Groove Ball Bearing ............................................................. 29
Dismantling Procedure for Drive Side Cylindrical Roller Bearing . 31
Assembly Procedure for Drive Side Cylindrical Roller Bearing .... 31
Bearing Change – Shaft Height (AH) 355 ...................................... 33
Dismantling Procedure for Drive and Non-drive Side
Deep Groove Ball Bearings ............................................................ 33
Assembly Procedure for Drive and Non-drive Side
Deep Groove Ball Bearing ............................................................. 35
Dismantling Procedure for Drive Side Cylindrical Roller Bearing
and Non-drive Side Deep Groove Ball Bearing ............................. 37
Assembly Procedure for Drive Side Cylindrical Roller Bearing
and Non-drive Side Deep Groove Ball Bearing ............................. 39
Maintenance Schedule – Models Fitted with Roller Bearings ....... 41

6

Trouble shooting

6.1
6.2
6.3

Safety Instructions ........................................................................... 42
Malfunctions - Electrical .................................................................. 43
Malfunctions - Mechanical .............................................................. 44

7

Repair Instructions

7

Repair Instructions .......................................................................... 45

8

Spare Parts

8.1
8.2

Order Details ................................................................................... 46
Exploded View, IP23, Model Size 180M-355L ............................... 46

9

Instructions for Electrical Machines Which Are To Be Stored

9.1
9.2
9.3
9.3.1
9.3.2

Storage Site .................................................................................... 48
Securing the Machine for Transportation ........................................ 48
Checks before Commissioning ...................................................... 48
Bearings .......................................................................................... 48
Insulating Resistance ..................................................................... 49

5.5.2
5.5.3
5.5.4
5.6
5.6.1
5.6.2
5.6.3
5.6.4

3

Model Sizes 180M-355L
Squirrel-cage rotors
Type BN7, BX7, KN7, KT7, KX7, KR7, DN7, EN7
Example, Diag.1
Three phase squirrel-cage motor with squirrel-cage rotor
Basic model KN7

SM

Diag.1: Model size 180M-355L - Type KN7

4

Safety Instructions
1

Safety Instructions

1.1

General Instructions

Read the operating manual before transportation, assembly, commissioning,
maintenance and repair, and comply with its instructions!

1.2

Symbols

In this operating manual 4 symbols are used which must receive special attention:

Instructions concerning safety and the guarantee:
The possibility of personal injury is included here.
Warns of electrical voltage.
Points out that damage to the electrical machine and / or auxiliary fittings can occur.



Indicates useful advice and explanations.

5

Safety Instructions
1.3

Safety Regulations

Observe




the safety regulations,
accident prevention regulations,
guide lines and acknowledged technical rules,

cited in this operating manual!

Non-compliance with safety regulations will result in the endangering of personnel
and damage to the machine, e.g.:



endangering personnel through contact with voltages exceeding 42V,
failure to observe the prescribed methods of transportation, assembly,
commissioning, maintenance and repair of the machine.

1.4

Regulations, Standards

When working on the electrical machine observe all valid accident prevention
regulations and generally acknowledged technical rules!


Accident prevention regulations laid down by the professional associations



„General Regulations (VBG 1)“
„Electrical Plant and Operational Means (VBG 4)“



Harmonized European standards EN 60034



VDE requirements
DIN VDE 0105

1.5

Requirements for the Operation of High-Voltage Plant

Conditions of Connection

Observe the regulations and conditions of connection laid down by the local electrical supply utility when connecting the electrical machine to the mains supply!

All work on the electrical machine’s electrical connections may only be
carried out by electricians (as defined in DIN VDE 0105 and IEC 364)!

6

Safety Instructions
1.6

Inscriptions, Warning Signs

Comply with all instructions located on the electrical machine itself, such as, rotational direction arrows, instruction signs, inscriptions or warning signs, and keep
the same in a readable condition.

1.7

Working on the Electrical Machine

Only qualified personnel may work on the electrical machine.
Qualified personnel are those persons who, on account of their professional training, experience and instruction, have sufficient knowledge of




safety regulations,
accident prevention regulations,
guide lines and acknowledged technical rules
(e.g. VDE requirements, DIN standards).

The qualified personnel must



be able to assess the work assigned to them and recognize and avoid possible
dangers.
be authorized by those responsible for the safety of the plant to carry out the required work.

7

Important Instructions
2

Important Instructions

2.1

Stipulated Usage

This operating manual is valid for ventilated-enclosures electrical machines designed for low-voltage use and of protection type IP 23, in accordance with
EN 60034 - Part V.
In explosive environments only electrical machines which possess a registered
explosion-protection type may be used.
Any other usage which goes above and beyond that stipulated is considered as
non-stipulated usage. Within the terms of his guarantee the manufacturer accepts
no liability for damage resulting from any such usage.

2.2

General Instructions

Use of this operating manual alleviates safe and proper transportation, assembly,
commissioning, maintenance and repair of the electrical machine.
We reserve the right to technical changes made through further development of
the electrical machine dealt with in this operating manual.
Illustrations and drawings presented in this operating manual are simplified portrayals. On account of improvements and changes it is possible that the illustrations do not agree exactly with the electrical machine operated by you. Technical
specifications and dimensions are not binding, and any possible claim cannot be
based thereupon.
We reserve all copyright to this operating manual and the drawings and other
documents contained there in.

The manufacturer accepts no liability for damages,



which arise during the period covered by the guarantee as a result of





negligent maintenance,
improper operation,
faulty installation,
wrong or inexpert connecting of the electrical machine.



which result directly or indirectly either from unilateral changes to the machine
by the user or from non-compliance with the manufacturer’s recommendations.



which arise from the use of spare parts / accessories not recommended or
supplied by the manufacturer.

8

Important Instructions
2.3

Installation

The electrical machines are suitable for indoor installation.
The machines may be operated at heights of ≤ 1000 m above sea level, at ambient temperatures of – 20 to + 40°C. Exceptions are specified on the rating plate.

2.4

Ventilation

The distance between the air intake and any driven appliances, covers etc., must
be at least 1/4 of the diameter of the air intake aperture. As a rule, air stream flow is
from the drive side to the non-drive side.
The exhausting air stream must not be directly sucked in again. Keep the
air intake and exit apertures free from dirt.
Models with upward-facing shaft ends are to be fitted (to be undertaken by
the customer) with a suitable cover which prevents foreign objects falling
into the ventilation aperture and also protects against water penetration.
Cooling of the electrical machine must not be adversely affected by the
cover.
For pipe-ventilated electrical machines air intake and exit is effected, as a rule, via
a system of pipes. When supplied, the electrical machines correspond to protection type IP 00 (rating plate specification). Protection type IP 54 can be achieved
through suitable modifications to the piping system. In doing this, however, the
pressure drop in the outer circuit must not exceed the permitted values as stated in
the table.
Air-flow rate ”V” and allowable pressure reduction ”p” in the exterior circuit
Shaft
centre
height

Type

3000 [min-1]
V
p
[m3/min] [Pa]

1500 [min-1]
V
p
[m3/min] [Pa]

1000 [min-1]
V
p
[m3/min] [Pa]

750 [min-1]
V
p
[m3/min] [Pa]

180

KN7 180.-

11,0

70

8,0

20

5,5

15

4,5

200

KN7 200.-

12,0

70

9,0

20

6,0

20

5,0

10

225

KN7 225.-

15,0

60

14,0

40

7,0

20

6,5

15

250

KN7 250.-

21,0

90

19,0

40

13,0

30

9,0

20

280

KN7 280.-

23,0

60

26,0

50

17,0

40

13,5

30

315S/M

KN7 315.-

28,0

70

34,0

60

23,0

50

17,0

30

315L

KN7 315L-

34,01)

70

36,0

60

24,0

50

18,0

30

10

315X

KN7 315X-

39,0

80

38,0

70

25,5

50

19,0

30

355

KN7 355.-

50,0

100

51,0

80

34,0

50

25,0

30

1) Air-flow rate for model KN7318L and KN7319L = 40m3/min,
allowable pressure reduction = 50 Pa

9

Important Instructions
2.5

Electromagnetic Compatibility

The electrical machines correspond at least EN 50081 Part 2 (electromagnetic
compatibility, generic commisson standard part 2: industrial environment) in accordance with VDE 0839 Part 81-2. This suffices for the operation of electrical machines in industrial areas.
For the operation of electrical machines in residential areas suppression classes N
(normal degree of interference) or K (small degree of interference) can be requested.
We recommend that, according to local conditions, a measurement of interference
voltage is undertaken and suitable means of suppression is fitted accordingly.

2.6

Feet Anchoring Holes (Diag.2)

Electrical machines with shaft heights of 180, 200, 250, 280 and 315 each have
only one housing length.
On the non-drive side the securing feet each have 2 drilled holes.
Secure the electrical machine in accordance with the model-size abbreviations, S,
M or M, L or L, X, which are cast into the base plate.

SM

or
M L
or
L X
Diag.2: Feet anchoring holes S,M or M,L or L,X

10

Transportation
3

Transportation

3.1

Safety Instructions
When raising and transporting the machine observe the applicable
accident prevention regulations and any generally acknowledged
technical rules!



Accident prevention regulations
– General Regulations (VBG 1),
– Cranes (VBG 9),
– Load Suspension Device in the Lifting Gear Industry (VBG 9a)



DIN standards
– DIN 15003
– DIN 7540
– DIN 82101

3.2

Lifting Gear, Load Suspension Devices
Eye-hooks, Goods Class 5
Shackles

Lifting Eyes
Only suspend electrical machines from the lifting eyes provided.
Do not attach any additional load to the electrical machine; the lifting eyes
are only designed to take the weight of the electrical machine.
Other supplementary lifting eyes which may possibly be available, e.g. on
fan hoods, cooler fittings etc., are only suitable for the lifting of the respective individual parts.

3.3

Securing Procedures for Transportation

Electrical machines fitted with cylindrical roller bearings are protected against
bearing damage by a transportation securing device.
Remove this device before commissioning and pack the securing hole with
the plug supplied.
Use the transportation securing device again if further transportation is
required.

11

Transportation
Securing procedures for
transportation, examples
2

1



Clamp fixing:





4


3
5

6

8

7







Undo bolts (3) and remove the rod
fixing (4).



Screw in and tighten the shorter
bolts supplied.

Clamping screw fixing:


Loosen the nut (5) and undo the
clamping screw (6).



Stop up the threaded holes with
the plug.

Clamp fixing:




3.4

Plug is attached to the information
plate (drive shaft).

Rod fixing:



Diag.3: Example of securing procedures
for transportation

Undo bolts (1) and remove clamp
fixing (2).
Stop up the threaded hole with the
plug.

Undo bolts (7) and remove transportation shackle (8).
Stop up the threaded hole with the
plug.
The machine is fitted either with a
clamp fixing or a rod fixing.

Transport Damage

Document any transport damage and immediately inform the transport company,
insurance company and the manufacturer!

12

Assembly and Commissioning
4

Assembly and Commissioning

4.1

Safety Instructions
During assembly and commissioning observe the following:
– safety instructions pages 5-7,
– important instructions pages 8-10!
Assembly work may only be carried out by qualified personnel who, on
account of their professional training, experience and instruction, have
sufficient knowledge of
– safety regulations,
– accident prevention regulations,
– guide lines and acknowledged technical rules
(e.g. VDE requirements, DIN standards).
The qualified personnel must
– be able to assess the work assigned to them and recognize and
avoid possible dangers.
– be authorized by those responsible for the safety of the plant to
carry out the required work.



It is recommended that you request the assistance of the manufacturer’s
assembly personnel.

13

Assembly and Commissioning
4.2

Mechanical

4.2.1

Transmission Components
Only use flexible couplings;
rigid couplings require special bearings.
The keys located in the shaft ends are not particularly secured against falling out.
Should a machine with two shaft ends have no drive element fitted on one
of these shaft ends, ensure that the unused key cannot spin off the shaft. If
the machine is of balance type „H“ then the key should be shortened by
half!
When using transmission components which cause radial or axial shaft
loadings (e.g. drive belt wheels, sprockets etc.), take care that the permitted
loading is not exceeded. Refer to the specifications given in our respective
applicable technical list.

Each rotor is dynamically balanced according to its balance type with a full, a half
or no key and, in accordance with ISO 8821, is labelled thus:
F = full key,
H = half key,
N = no key.
Rotors balanced with a full key → balance the drive component with open
key groove.
Rotors balanced with a half key → balance the drive component in a
ungrooved state.



Balance the drive component in accordance with the type of balance of the rotor. For shorter drive components machine off that part of the key which projects
beyond the drive component and above the surface of the shaft.



Before fitting the drive component onto the shaft remove the anti-corrosion film
on the shaft end with a suitable cleaning agent (e.g. naphtha).
Do not use emery or rub down the shaft to remove the protective film!

14

Assembly and Commissioning


S

Lightly grease or oil all seating surfaces and fit the drive element.
In order to protect the roller bearing, the drive element should only
be fitted (→ Diags.4 & 5) / dismantled (→ Diag.6) with the aid of suitable tools.
If necessary heat (according to
amount of shrinkage needed) the
drive component prior to fitting.

M

Avoid hard blows and knocks
when fitting the drive component.
The bearings and / or the shaft will
be damaged and the manufacturer’s guarantee will be null and
void.

Diag.4: Fitting without a centre bore.

S

M

Diag.5: Fitting with a centre bore.

S

M

Diag.6: Dismantling.

15

Assembly and Commissioning
4.2.2

Machine Base

The kind of supporting surface required for the machine base is one which can
ensure machine operation which is shock-free, low in vibration and torsionally
rigid.



Secure the electrical machine on a level shock-free supporting surface.
All securing feet must lie on an even, level plane in order to avoid stress in
the housing.
Wrong installation can lead to resonances in rotary frequency and double
mains frequency range.
In order to avoid damage to electrical machines in an idle state (stand-by
operation) the following maximum rates of vibration must not be exceeded.

Idle Time

Rate of Vibration

up to 500 hrs

0,4 mm/s

more than 500 hrs

0,2 mm/s

4.2.2.1 Assessment Criteria for Vibration
With regard to vibration at the site location, the assessment criteria laid down in
DIN ISO 3945 are to be complied with.
For rigid foundations the following measured values on the bearing housing can
be considered as limiting values:



5.5 mm/s for the alarm,
11 mm/s for switch-off.



16

Should vibration values between the alarm and switch-off values become
apparent, operation of the electrical machine can continue under observation. The possibility of resultant damage to the electrical machine cannot be
excluded. If necessary, inform the manufacturer.

Assembly and Commissioning
4.2.3

Alignment



Align the electrical machine precisely
in accordance with the already
aligned driven appliance.



Clamp on the dial gauges firmly. Carry
out measurements at four measuring
points, each separated by 90°, whilst
simultaneously turning both halves of
the coupling.

E

4.2.3.1 Angular Alignment (Diag.7)
Diag.7: Angular alignment

Compensate for any differences by inserting plates. Ensure that any residual inaccuracy, in reference to a measured radial
diameter of 200 mm, does not exceed
0.03 mm.
4.2.3.2 Parallel Alignment (Diag.8)

E

Diag.8: Parallel alignment

Compensate for any differences by re-positioning or by inserting suitable plates so
that the residual inaccuracy does not exceed 0.03 mm. Adjust the axial air gap
between the two halves of the coupling
(dimension „E“) in accordance with the
specifications given by the coupling
manufacturer.
Check alignment when the machine is in an operationally warm
state.
4.2.3.3 Combined Angular and Parallel
Alignment (Diag.9)

E

Diag.9: Combined angular and parallel
alignment

Diag.9 shows a method of combining
both measurements which is relatively
simple in concept. The dial gauges are
placed in the corresponding holes of the
flat bars (which are screwed or clamped
on) and are then fixed by means of, for
example, grub screws.

17

Assembly and Commissioning
4.2.4

Additional Fitted or Attached Parts

In order to protect the electrical machine various accessories may be fitted or attached subject to order, e.g.:




temperature sensor for monitoring windings and bearings,
space heater,
measuring nipple for bearing monitoring.



18

Special instructions for assembly and operation of fittings and attachments
obtained elsewhere than from the manufacturer, are included.

Assembly and Commissioning
4.3

Electrical
All work on the electrical machine’s electrical connections must only be
carried out by electricians (as defined in DIN VDE 0105 and IEC 364)!

4.3.1

Insulating Resistance
Do not touch the connection terminals either during or after measuring.
The terminal connections can carry high voltages! After carrying out
the check earth the terminal connections briefly (5 seconds).



Using a hand generator (max. D.C. voltage = 630V) measure the insulating resistance of each individual phase to earth. Continue measuring until the measured value is constant.



The insulating resistance of new windings is > 10 MΩ.
Dirty and damp windings have considerably lower resistance values.
Should a measurement of less than 0,5 MΩ be registered in the air space,
clean and / or dry the winding. During this process the winding temperature
must not exceed 80°C. Dry by means of a space heater or heating appliance, or by applying an alternating voltage with a value equivalent to 5-6%
of the rated voltage (make the ∆ - circuit) at the stator terminal connections
U1 and V1.



Repeat the measurement. With resistance values of > 0,5 MΩ the electrical machine can be put into operation.


4.3.2

Insulating resistance values are dependent on temperature.
Standard values: A rise or fall in winding temperature by 10 K has the effect
of respectively halving or doubling the resistance value.

Voltage and Circuit

Observe the circuit details given on the rating plate and compare the operating
voltage to the mains voltage.
The permitted fluctuation in mains voltage amounts to ± 5%. Exceptions are specified on the rating plate.

19

Assembly and Commissioning
4.3.3

Connection
Connect the connection cables in accordance with the applicable regulations of the local electricity supply utility and in accordance with:
– the DIN VDE requirements
– the safety regulations
– the accident prevention regulations.



Connect mains feeds with care, so that the contact force required for an electrical connection will be maintained over a long period (→ table on tightening
torques, terminal layout and special arrangement of securing nuts [see
Illustration]).
If no other precise specifications have been made, the following tightening torques are valid for normal connections of securing screws and nuts used for
electrical connections.
Tightening torques (Nm with a tolerance of ±10%)
for thread sizes of
M5

M6

M8

M10

M12

M16

M20

M24

2

3

6

10

15,5

30

52

80

In electrical connecting work, the permitted torque is
usually limited by the bolt material and / or the loading
capacity of the insulators.



All electrical machines have a connection diagram on the inner side of the
terminal box cover.
The cable feed aperture can be turned by 90° or 180° .

Match the cross-sectional area of the connecting cable to the rated
current strength.
To avoid tension in the terminal connections fit the cable so it is not pulling
from the connectors.
Take care that there are no foreign bodies, dirt and / or dampness present
in the terminal box.
To guarantee the protective type when sealing the terminal box, use original seals.
Seal any unused cable feed apertures so that they are dust- and watertight.

20

Assembly and Commissioning
4.3.4

Terminal box position (side)

Swapping the side-fitted terminal box position from RIGHT to LEFT or vice versa, is
not possible (with the exception of model size 315X and shaft height 355).

4.3.5

Direction of Rotation

Under normal conditions the electrical machines are suitable for operation in both
directions of rotation. Exceptions are indicated on the rating plate with a corresponding directional arrow. For each respective direction of rotation the following
stator connections are given:



Connection of L1, L2, L3

Direction of rotation viewed on the
drive side

U1 - V1 - W1

right (cw)

W1 - V1 - U1

left (ccw)

Check the direction of rotation by quickly switching the electrical machine (which has
been connected in accordance with the regulations) „On / Off“ in its uncoupled state.
When checking the rotary field only the tester may remain in the danger
area of the machine / driven appliance. Switch on the machine and
check the direction of rotation (observe DIN VDE 0105).

Reversal of direction of rotation:
Type of switch-on and winding

Measures

Direct switch-on and pole-shift motors
with separate windings

Exchange twosupply-cable conductors
on the motor terminal board.

Star or delta connection and pole-shift
motors with DAHLANDER winding

Exchange two supply-cable
conductors at the incoming supply to
the contactor combination.

21

Assembly and Commissioning
4.3.6

Y/D -start
To avoid unpermitted transient current and torque impacts, the cross-over
from Y to ∆ may only be effected if the start current of the Y stage has decayed.
During the run-up phase the machine should only be switched off in an
emergency, in order to protect the switchgear and the machine itself.

4.3.7

Electrical Machine Protection



Connect the built-in semi-conductor temperature sensor to the trigger mechanism in accordance with the circuit diagram.



Any possibly required continuity check of the temperature sensor should only
be carried out using a measuring bridge (max. 5V).
In order to achieve total thermal
protection of the machine, fit a
supplementary thermally-delayed
overload protector (→ Bild 10).
Safety fuses alone tend to just protect the mains supply and not the
electrical machine.

M

+
Diag.10: Protection using over-current
relay,
thermistor protector and
fuse.

22

Maintenance
5

Maintenance

5.1

Safety Instructions
Maintenance work (except for greasing work) is only to be carried out
when the machine is standing idle.
Ensure that the machine is safeguarded against accidental switch-on
and is labelled with a corresponding warning sign.
Observe the safety regulations and accident prevention regulations of
the corresponding manufacturer when using oils and greases, cleaning
agents and spare parts!
Maintenance work on the machine’s electrical power supply or to the
electrical auxiliary / control supplies may only be carried out by electricians in compliance with DIN VDE 0105.

Ensure that the machine is switched so that it is not live.
Ensure that the machine cannot be switched on again and label it with a
warning sign!
Ascertain that the machine is not live!
Earth and short-circuit!
Cover or cordon off any neighbouring parts which are still live!

Ensure that the auxiliary power circuits e.g. space heater etc., are
switched so as not to be live.

23

Maintenance
5.2

Cleaning
Do not wash down the machine with water or other liquids.



Check the whole cooling airway for dirt annually.



In the event of severe dirt deposits dismantle the electrical machine and remove the deposits using suitable cleaning agents (e.g. superheated steam).



Finally dry the winding and measure the insulating resistance.



During these procedures observe the specifications on page 19 given under 4.3.1 Insulating resistance.

5.3

Ball and Roller Bearing Maintenance



Monitor bearing temperature during operation.



Check the bearing for noise when running.



Greasing of roller bearings.



Renewing the bearings.





Should a rise in temperature or running noises occur during operation,
switch off the electrical machine immediately in order to avoid any
resulting damage.



Dismantle the bearing and check for damage.



Should there be darkly coloured, matt- or polished-effect areas on the
bearing, fit a new bearing.

The operational safety of the electrical machine is dependent upon maintenance of the lubrication schedule.
As a standard feature all electrical machines are supplied with a lubricating
appliance which has a grease volume regulator.
Initial lubrication of the bearing is carried out at our factory. The lubricating
schedule and lubricant volumes are specified on the rating plate.
In the basic model the electrical machines are fitted with a button head
grease nipple, M10 x 1, in accordance with DIN 3404.

24

Maintenance
5.3.1

Grease Nipple

The use of special grease, provided that the special operational circumstances
were known at the time of ordering, can be taken from the rating plate specifications.
For basic model electrical machines the bearing can be re-filled (without cleaning)
using lithium-saponified roller bearing grease K3k in accordance with DIN 51825,
for example, SKF LGMT3, Shell Alvania G3, Esso Beacon 3 etc..
Clean the bearing assemblies thoroughly if changing over to a grade of
grease with a different saponification base. Take care that the roller bearing
grease to be used fulfils the following conditions:





5.3.2

Drop point
Ash content
Water content

approx. 190°C
4%
0,3%

Changing over to a grade of grease with a different saponification base requires consultation with the machine manufacturer (specify lubricant plate).

Lubrication
Only carry out lubricating work when the machine is running:
Be careful of moving parts!




Observe the lubricant specification given on the rating or lubricant plate.

Clean the grease nipple and apply the corresponding amount of grease (using
the correct grade of grease) by means of a grease gun. To achieve this weight
the grease gun both before and after use.

25

Maintenance
5.4

1

Bearing Seals (Diag.11)

without grease

x



Before fitting new felt rings (2) into
the bearing cover, soak them in highviscosity oil heated to 80°C.
The shaft must slide easily in the felt
ring and be completely sealed
radially.



Lightly grease the running faces.



Push on the sealing rings (3) and Vrings (1), e.g. using a screwdriver
whilst simultaneously turning the
shaft (→ Diag. 12).

greased

2

3

When fitting V-rings onto flat sealing surfaces the dimension „X“
must be maintained.

greased

2

Non-compliance will lead to
overheating or destruction of the
V-ring, or will result in a bad seal.

+ 0.5

4

V-ring type

Diag.11: 1
2
3
4

V-ring
Felt ring
Neoprene sealing ring
Labyrinth ring

Fitting dimensionX
(mm)

V-25 to V-38

9,0

-0,3

V-40 to V-65

11,0

-0,3

V-70 to V-100

13,5

-0,5

V-110 to V-150

15,5

-0,5

x



Diag.12: V-type sealing ring

26

Before assembling the labyrinth ring
heat it up to approx. 60 - 80°C and
push it against the bearing cover,
whilst simultaneously laying spacing
plates (2mm) in between.

Maintenance
5.5

Bearing Change – Shaft Height (AH) 180 to 315
The prior agreement of the electrical machine manufacturer is required for
bearing changes undertaken within the warranty period!

5.5.1

Dismantling Procedure for Drive and Non-drive Side Deep Groove Ball
Bearings (® Diag. 13)
(For drive side cylindrical roller bearing, see 5.5.3)

1. Loosen screws (2.1), (2.2), (16.1) and (16.2). Pull off the bearing shields (2)
and (16), together with the bearing seals (1) and (17), taking care not to tilt
them.
Take off the compensation washer (3) – only present on electrical machines ≤
AH200.
2. Loosen and pull off the spring clips (4) and (15) – only present on electrical
machines AH225. Pull off the collar oilers (5) and (14). (Collar oilers fitted in
electrical machines of the range AH180 + AH200 have holes in the hub section
which can be used for pulling off).
3. Loosen and pull off the securing ring (13).
4. By using a pulling tool and heating the inner ring slightly, remove the deep
groove ball bearings (6) and (12).
Remove the pressure springs (9) – only present on electrical machines
AH225.
5. Pull off the inner bearing covers (8) and (10) together with the seals (7) and
(11).
6. The rotor remains in the stator housing.

27

Maintenance

16

14
12

16.1

15

13

11
10
16.2

7

8

6
3

2

4

SM

5

1
9

A

2.1

2.2
SM

Diag. 13: Bearing change AH180 to AH315

28

Maintenance
5.5.2

Assembly Procedure for Drive and Non-drive Side Deep Groove Ball
Bearing (® Diag. 13)
(For drive side cylindrical roller bearing, see 5.5.4)
All securing screws must be fitted with the spring washers provided
(DIN 6796)

1. Clean off the bearing seats with a suitable cleaning agent, check for any damage and measure the shaft with a micrometer after it has cooled (measurement
specifications refer to a temperature of 20°C).
2. Remove the old grease from the inner bearing covers (8) and (10), wash them
out using a suitable cleaning agent and allow to dry.
Fill bearing covers (8) and (10) with new grease (note the correct grade of
grease) and push them (along with their seals [7] and [11]) onto the shaft.
Grease and set the pressure springs provided (9) into the drilled holes of the
bearing cover (8).
3. Heat the new bearing in an oil bath (or using inductive means – de-magnetize
afterwards) to a temperature of 80°-90°C .
To ensure proper fitting push the heated bearings (6) and (12) onto their
shaft seating and press them against the shaft shoulder for approx. 10
secs.
After cooling, pack fresh grease into the bearing spaces (note the grade of
grease).
4. Push on the circlip (13) and secure it. Push on the collar oilers (5) and (14).
Push on and tighten up the spring clips provided (4) and (15).
5. Remove the old grease from the bearing cover (2) and (16), wash out using a
suitable cleaning agent and allow to dry. Pack fresh grease into the grease
drain bores and place the compensation washer provided in position on the
bearing shield hub.
6. For easy assembly screw in two studs (A) – about 100 mm long – into the
threaded holes in the inner bearing cover (8) and (10).
Push on the bearing shields (2) and (16) and screw down tightly using screws
(2.2) and (16.2), together with mounting plate 16.3).
Tighten up screws (2.1) and (16.1) (at this stage the studs (A) must be removed).
7. Fit the bearing seals (1) and (17) as described on page 26.

29

Maintenance

16

14
12

16.1

15

13

11
10
16.2

7

8

6
3

2

4

SM

5

1
9

A

2.1

2.2
SM

Diag. 13: Bearing change AH180 to AH315

30

Maintenance
5.5.3

Dismantling Procedure for Drive Side Cylindrical Roller Bearing
(® Diag. 14)
(For non-drive side deep groove ball bearing, see 5.5.1)

1. Loosen screws (2.1.1) and pull off the bearing cover (2.1) together with the
bearing seal (1.1).
2. Loosen and pull off the spring clip (4.1) – only present on electrical machines
AH225. Pull off the collar oiler (5.1) (on electrical machines AH180 + AH200
the collar oilers have holes in their hub section which can be used for pulling
off).
3. Loosen screws (3.1.1) and pull off the bearing shield (3.1). Press the outer
bearing ring (6.1) out of the bearing shield hub.
4. Using a welding torch quickly heat up the inner bearing ring (6.2) and force off
using, for example, a screwdriver.
5. Pull off the bearing cover (8.1) together with the bearing seal (7.1).

5.5.4

Assembly Procedure for Drive Side Cylindrical Roller Bearing
(® Diag. 14)
(For non-drive side deep groove ball bearing, see 5.5.2)
All securing screws must be fitted with the spring washers provided (DIN
6796).

1. Clean off the bearing seats with a suitable cleaning agent. Check for any damage and measure the shaft with a micrometer after it has cooled (measurement
specifications refer to a temperature of 20°C).
2. Remove the old grease from the inner bearing cover (8.1), wash it out using a
suitable cleaning agent and allow to dry.
Fill the bearing cover with new grease (note the correct grade of grease) and
push it (complete with bearing seal [7.1]) onto the shaft.
3. Heat the new inner bearing ring (6.2) in an oil bath (or using inductive means de-magnetize afterwards) to a temperature of 80°-90°C.
To ensure proper fitting push the heated inner bearing ring (6.2) onto its
shaft seating and press it against the shaft shoulder for approx. 10 secs..
Lightly grease inner bearing ring (6.2) after cooling.
4. Wash out the hub of the bearing shield (3.1) using a suitable cleaning agent
and allow to dry.
5. Press a new outer bearing ring (6.1) into the bearing shield hub and fill the
bearing spaces with new grease (note the correct grade of grease).
6. For easy assembly screw in a stud (A) – about 100mm long – into the threaded
hole located in the bearing cover (8.1). Push on the bearing shield (3.1) and
tighten up using the screws (3.1.1).
31

Maintenance
7. Push on the collar oiler (5.1), push on and tighten up the spring clip (4.1) provided.
8. Remove the old grease from the bearing cover (2.1), wash out the cap using a
suitable cleaning agent, allow it to dry and pack the grease drain holes with
new grease. Push the bearing cover (2.1) onto the shaft and tighten up using
screws (2.1.1) (in doing this remove stud [A]).
9. Fit the bearing seal (1.1) as described on page 26.

16

12

13

14

15

16.1

11
10
16.2

8.1
7.1
6.1
3.1

1.1

4.1

2.1

SM

5.1

6.2

3.1.1

A

2.1.1

SM

Diag. 14: Bearing change AH180 to AH315

32

Maintenance
5.6

Bearing Change – Shaft Height (AH) 355
The prior agreement of the electrical machine manufacturer is required for
bearing changes undertaken within the warranty period!

5.6.1

Dismantling Procedure for Drive and Non-drive Side Deep Groove Ball
Bearings (® Diag. 15)
(For drive side cylindrical roller bearing, see 5.6.3)

1. Screw in two threaded rods into the threaded holes in the labyrinth plate (1.1)
and pull the plate away from the shaft end by means of the threaded rods.
Loosen screws (2.1.1/17.1.1) and pull off the bearing covers (2.1/17.1).
2. Loosen the locking screws (shaft nuts), unscrew the shaft nuts (4.1/15.1) using
a hook spanner and pull them off the shaft end.
Pull off the collar oiler (5.1/14.1), taking care not to damage the torque device
(5.1.1/14.1.1) (note fitting position).
Support the rotor at the shaft end! Make sure there is sufficient room to
pull out the bearing shield and bearing!
3. Loosen screws (3.1.1/16.1.1) and pull off the bearing shields (3.1/16.1). Dismantle the rotor supports and pull the bearing shield away from the shaft end.
Carefully lay down the rotor in the stator plates.
4. Using a pulling tool and whilst heating the inner ring slightly, pull off the deep
groove ball bearing (6.2/12.1). Remove the pressure spring (9.1) – only on the
non – drive side bearing cover (17.1).
5. Pull off the inner bearing covers (8.1/10.1) together with the seal (7.1/11.1).
6. The rotor remains in the stator housing.

33

Maintenance

17.1
16.1

17.1.1

15.1
14.1.1
14.1
12.1
10.1
11.1

16.1.1

9.1
8.1
5.1.1

3.1

4.1

7.1

SM

5.1

2.1
1.1
6.1

3.1.1

A

2.1.1

SM

Diag. 15: Bearing change AH355

34

Maintenance
5.6.2

Assembly Procedure for Drive and Non-drive Side Deep Groove Ball
Bearing (® Diag. 15)
(For drive side cylindrical roller bearing see 5.6.4)
All bearing shield securing screws must be fitted with the spring washers
provided, and bearing cover screws must be fitted with the sealing washers
provided!

1. Clean off the bearing seats with a suitable cleaning agent, check for any damage and after allowing it to cool measure the shaft with a micrometer (measurement specifications refer to a temperature of 20°C).
2. Remove the old grease from the inner bearing covers (8.1/10.1), wash them
out using a suitable cleaning agent, allow to dry and then fill them with new
grease (note the correct grade of grease, → rating plate). Push the bearing
covers (8.1/10.1) with their seals (7.1/11.1) onto the shaft. Set the pressure
springs provided (greased) into the drilled holes of the inner bearing cover
(10.1).
3. Heat the new bearing, either in an oil bath or using inductive means (de-magnetize afterwards) to a temperature of 80°-90°C.
To ensure proper fitting push the heated bearings (6.1/12.1) onto their
shaft seatings and press them against the shaft shoulder for approx. 10
secs..
After cooling, pack fresh grease into the bearing spaces (note the grade of
grease).
4. Push on the collar oilers (5.1/14.1). Place in the torque devices (5.1.1/14.1.1)
(Attention! Angled end towards the bearing!). Screw on the shaft nuts (4.1/
15.1), tighten them using a hook spanner and secure the shaft nuts by means
of the locking screws.
5. Remove the old grease from the outer bearing cover (2.1/17.1), wash out using
a suitable cleaning agent, allow to dry and pack fresh grease into the grease
drain bores.
6. For easy assembly screw in two studs (A) – about 100 mm long – into the
threaded holes in the inner bearing cover (8.1/10.1).
Push on the bearing shields (3.1/16.1) and screw down tightly using screws
(3.1.1/16.1.1) (with spring washers).
Push the outer bearing covers (2.1/17.1) onto the shaft and screw down tightly
using screws (2.1.1/17.1.1) (with sealing washers).
Pack the labyrinth ways in the bearing cover (2.1) with a small amount of
grease.
Heat the labyrinth plate to approx. 60°-80°C, and push it against the bearing
cover (2.1). Note the gap between the bearing cover (2.1) and the labyrinth
plate (1.1) (→ page 26).

35

Maintenance

17.1
16.1

17.1.1

15.1
14.1.1
14.1
12.1
10.1
11.1

16.1.1

9.1
8.1
5.1.1

3.1

4.1

7.1

SM

5.1

2.1
1.1
6.1

3.1.1

A

2.1.1

SM

Diag. 15: Bearing change AH355

36

Maintenance
5.6.3

Dismantling Procedure for Drive Side Cylindrical Roller Bearing and
Non-drive Side Deep Groove Ball Bearing (® diag.16)

1. Screw in two threaded rods into the threaded holes in the labyrinth plate (1.1)
and pull the plate away from the shaft end with the threaded rods. Loosen
screws (2.1.1/17.1.1) and pull off the bearing covers (2.1/17.1).
2. Loosen the locking screws (shaft nuts), undo the shaft nuts (4.1/15.1) using a
hook spanner and pull them off the shaft end.
Pull off the collar oiler (5.1/14.1), taking care not to damage the torque device
(5.1.1/14.1.1) (note fitting position).
Support the rotor at the shaft end! Make sure there is sufficient room to
pull out the bearing shield and bearing!
3. Loosen screws (3.1.1/16.1.1) and pull off the bearing shields (3.1/16.1). Dismantle the rotor supports and pull the bearing shield away from the shaft end.
Carefully lay down the rotor in the stator plates!
4. Pull the outer ring of the cylindrical roller bearing (6.2), together with the bearing shield (3.1), from the inner bearing ring (6.3) and then press it out of the
bearing shield (3.1). Heat the inner ring of the cylindrical roller bearing and pull
it off the rotor shaft. After heating the inner ring slightly, pull off the deep groove
ball bearing (12.1) using a pulling tool.
5. Pull off the inner bearing covers (8.1/10.1) together with the seals (7.1/11.1).
6. The rotor remains in the stator housing.

37

Maintenance

17.1
16.1

17.1.1

15.1
14.1.1
14.1
12.1
10.1
11.1

16.1.1

9.1
8.1
5.1.1

3.1

4.1

6.2

7.1

SM

5.1

2.1
1.1
6.3

3.1.1

A

2.1.1

SM

Diag. 15: Bearing change AH355

38

Maintenance
5.6.4

Assembly Procedure for Drive Side Cylindrical Roller Bearing and
Non-drive Side Deep Groove Ball Bearing (® Diag.16)
All bearing shield securing screws must be fitted with the spring washers
provided, and bearing cover screws must be fitted with the sealing washers
provided!

1. Clean off the bearing seats with a suitable cleaning agent, check for any damage and after the shaft has cooled measure it with a micrometer (measurement
specifications refer to a temperature of 20°C).
2. Remove the old grease from the inner bearing covers (8.1/10.1), wash them
out using a suitable cleaning agent, allow to dry and then fill them with new
grease (note the correct grade of grease, → rating plate). Push the bearing
covers (8.1/10.1), together with their seals (7.1/11.1), onto the shaft.
3. Heat the new inner bearing ring (6.3) and deep groove ball bearing (12.1) either in an oil bath or using inductive means (de-magnetize afterwards) to a
temperature of 80°-90°C.
To ensure proper fitting push the heated inner bearing ring (6.3) and
deep groove ball bearing (12.1) onto their shaft seatings and press
them against the shaft shoulder for approx. 10 secs..
After cooling lightly grease inner bearing ring (6.3).
4. Clean the hubs of the bearing shields (3.1/16.1).
5. Push on the collar oiler (14.1). Place in the torque device (14.1.1) (Attention!
Angled end towards the bearing!). Screw on the shaft nut (15.1), tighten it using
a hook spanner and secure the shaft nut with locking screws.
6. For easy assembly screw in two studs (A) – about 100 mm long – into the
threaded holes in the inner bearing cover (10.1).
Push on the bearing shield (16.1) and screw down tightly using screws (16.1.1)
(with spring washers).
7. Remove the old grease from the outer bearing cover (17.1), wash out with a
suitable cleaning agent, allow to dry and pack the grease drain bores with
fresh grease. Push the outer bearing cover (17.1) into the centring of the bearing shield and screw down tightly using screws (17.1.1) (with sealing washers).
8. Press the new outer bearing ring (6.2) into the bearing shield hub (3.1) and
pack the bearing spaces with fresh grease (note correct grade of grease, →
rating plate).
9. Screw two studs (A) – about 100 mm long – into the inner bearing cover (8.1)
and push the inner bearing cover to the inner bearing ring. Push the bearing
shield (3.1) and outer ring (6.2) over the rotor shaft and studs onto the inner
ring, whilst simultaneously raising the rotor shaft.

39

Maintenance
The rotor shaft should only be raised so far as to allow the bearing
shield (with outer ring) and the inner ring of the roller bearing to be
pushed on without tilting.
Tighten screws (3.1.1).
10. Push on the collar oiler (5.1). Place in the torque device (5.1.1) (Attention! Angled end towards the bearing!). Screw on the shaft nut (4.1), tighten it using a
hook spanner and secure the shaft nut with locking screws.
11. Push the outer bearing cover (2.1) onto the shaft and screw down tightly using
screws (2.1.1) (with sealing washers).
Pack the labyrinth channel with a small amount of grease, heat the labyrinth
plate to approx. 60°-80°C, and push it against the bearing cover (2.1). Note the
gap between the bearing cover (2.1) and the labyrinth plate (1.1) (→ page 26).

17.1
16.1

17.1.1

15.1
14.1.1
14.1
12.1
10.1
11.1

16.1.1

9.1
8.1
5.1.1

3.1

4.1

6.2

7.1

SM

5.1

2.1
1.1
6.3

3.1.1

A

2.1.1

SM

Diag.16: Bearing change AH355

40

Maintenance
5.7

Maintenance Schedule – Models Fitted with Roller Bearings

COMPONENT

DAILY

Bearing

Heat
exchangerAirwa
ys

WEEKLY

EVERY 3
MONTHS

ANNUALLY(minor
overhaul)

For lubrication
deadlines see
rating plate

Check

EVERY 5 YEARS
(major overhaul)
- bearing change,
check shaft seals,
replace if
necessary;- remove
old grease;

Clean

Clean

Check alignment and
make sure that
machine is secure

Check alignment and
that machine is
secure;Change
grease / oil

Terminal
boxEarth

Clean internally; Retighten screws

Clean internally; Retighten screws

Stator winding

Measure insulating
resistance

Check that feed
cables are not torn,
that they are firmly
seated,check keys;
measure insulating
resistance

Driven
appliance
(Observe the
manufacturer´s
specifications)

Check alignment
and that the
machine is secure

Auxiliary
monitoring
connections

Record
measurement
data

Check function

Check function

Motor as a
whole

Pay attention
to operating
noise and
quiet running

Re-tighten screws

Dismantle rotor;
check that the rotor
plates, fan and stator
plates are firmly
seated; Check that
rotor bars are not
broken; Clean

41

Trouble shooting
6

Trouble shooting

6.1

Safety Instructions

Malfunctions of the electrical machine may only be rectified by qualified personnel
who have been so authorized by those responsible for the plant.
When determining the cause of a malfunction take into consideration all facets of the
electrical machine (driven appliance, foundations, type of set-up, switchgear etc.).
Inform the manufacturer when damage occurs during the warranty period.

When determining the cause of a malfunction, or when rectifying the
malfunction, observe the following:



DIN VDE 0105
Accident prevention regulations, VBG 1, VBG 4!

Ensure that the machine is switched so as not to be live.
Make sure the machine cannot be switched on again and label it with a
warning sign!
Ascertain that the machine is not live!
Earth and short-circuit!
Cover or cordon off any neighbouring parts which are live!
Ensure that the auxiliary circuits, e.g. space heater etc., are switched
so as not to be live.

42

Trouble shooting
6.2

Malfunctions - Electrical

ELECTRICAL MALFUNCTION CHARACTERISTICS
- Motor does not start
- Motor runs, but with difficulty
- Droning noise when starting
- Droning noise during operation
- Droning noise in time to the doubled induction frequency
- Rapid rise in temperature when running without load
- Rapid rise in temperature when running under load
- Rapid rise in temperature of individual winding sectors

l l
l
l
l l l

l
l

l l
l
l l l l
l l l l

l
l
l
l
l
l

POSSIBLE CAUSES OF
MALFUNCTION

REMEDIAL MEASURES

Overload

Reduce load

Interruption of a phase in the feed

Check switch and feeds

Interruption of a phase in the feed
after switching on
Mains voltage too low,Frequency too
high
Mains voltage too high,Frequency
too low

Check switch and feeds
Check mains supply state
Check mains supply state

Stator winding connected up wrongly

Check the winding circuitry

Winding or phase break in the stator
winding

Determine winding and insulating
resistances; Overhaul after
consulting the manufacturer

Asymmetry in short-circuit cage

Overhaul after consulting the
manufacturer
Swap the mains connections U and
W

wrong direction of rotation of motor
Insufficient cooling due to dirty
airways
Voltage too high, hence eddy current
loss too high

Clean the airways,Check seals
Do not exceed 105% of the rated
voltage

43

Trouble shooting
6.3

Malfunctions - Mechanical

MECHANICAL MALFUNCTION CHARACTERISTICS
– Rubbing noise
– Rapid rise in temperature
– Strong vibration
– Bearings overheating
– Bearing noise

l

l
l
l
l
l
l
l
l
l
l

l
l
l
l
l
l

l
l
l
l
l
l
l

l
l
l l
*

44

POSSIBLE CAUSES OF
MALFUNCTION

REMEDIAL MEASURES

Rotating parts rubbing

Determine cause, readjust parts *

Air feed choked, filter dirty, if applicable,
wrong direction of rotation

Check airways, clean filter, if necessary,
replace fan *

Rotor out of balance

Uncouple rotor and re-balance *

Rotor out of true, shaft distorted

Consult the manufacturer

Faulty alignment

Align machine group, check coupling

Driven appliance out of balance

Re-balance coupled machine

Impact from the driven appliance

Check the coupled machine

Noisy gearbox

Repair the gearbox

Resonance with foundations

After consultation, alter the rigidity of the
foundations

Changes in the foundations

Determine the cause of the change, if
applicable, eliminate; align machine anew

Too much grease in the bearings

Remove excess grease

Bearing dirty

Clean or renew bearing *

Ambient temperature > 40°C

Use grease which is suitable for high
temperatures*

Felt rings pressing on the shaft

Replace felt rings

Insufficient lubrication

Grease according to instructions

Bearing corroded

Renew bearing *

Too little play in the bearing

Fit a bearing with more play *

Too much play in the bearing

Fit a bearing with less play *

Areas of rubbing on bearing track

Renew bearing *

Furrows on the bearing

Renew bearing, avoid shocks when the
machine is standing idle

Coupling pressing or pulling

Align the machine more accurately

Too much belt tension

Reduce drive belt tension

Bearing twisted or skew

Check the bearing hub bore *

if necessary, inform the manufacturer

Repair Instructions
7

Repair Instructions
Only carry out repair work when the machine is standing idle.
Ensure that the machine cannot be accidentally switched on and that it
has been labelled with a corresponding warning sign.
Repair work may only be carried out by qualified personnel who, because of their professional training, experience and instruction, possess a comprehensive knowledge of




safety regulations,
accident prevention regulations,
guidelines and acknowledged technical rules
(e.g. VDE requirements, DIN standards).

The qualified personnel must



be able to assess the work assigned to them, and to recognise and
avoid possible dangers;
be authorized by those responsible for the safety of the machine /
plant to carry out the required work and activities.

Repair work carried out within the warranty period requires the prior agreement of the electrical machine manufacturer.



We recommend that only original replacement parts be used for overhauls.

1

When winding damage occurs it is possible that the air guide plate (1) could be
partially or totally destroyed.
When replacing a winding take care that
the new winding specification corresponds to the original. If necessary, fit a
new air guide plate in the prescribed
manner.

SM

Diag.17: Air guide plate

45

Spare Parts
8

Spare Parts

8.1

Order Details



When ordering spare parts be sure to specify the electrical machine type,
electrical machine number (→ rating plate) and the exact description of the
parts (part numbers if applicable).
When replacing bearings, in addition to the bearing type, please note also
the engraved symbol for the bearing designation (can be read off from the
bearing when fitted, e.g. C3 or C4)!

8.2

Exploded View, IP23, Model Size 180M-355L

1

Sealing ring DS, outer or labyrinth plate

2

Bearing shield DS

3

Grease nipple

4

Compensation washer

5

Spring clip DS or shaft nut

6

Collar oiler DS

7

Ball and Roller bearing DS

8

Sealing ring DS, inner

9

Bearing cover, DS inner

10

Stator housing IMB3 with core and windings

11

Terminal box, complete

12

Fan cover

13

Air baffle

13a

Securing clamp

14

Rotor with core and windings

15

Key

16

Key for fan

17

Fan

18

Fan safety ring

19

Sealing cover

20

Bearing cover NS, inner

21

Sealing ring NS, inner

22

Ball and Roller bearing NS

23

Safety ring for NS bearing

46

Spare Parts
24

Collar oiler NS

25

Spring clip NS or shaft nut

26

Bearing shield NS

27

Sealing ring NS, outer or labyrinth plate

28

Flange bearing shield

29

Stator housing without feet, complete

8
6

3
2

9

7

17

5
4

16

1
15
14
13

11

12

10

19

3

27

26
13a
23

24

25

22
21

SM

20
18
11
29

3
28

Diag.18: Exploded view, IP23, Model Size 180M-355L

47

Instructions for Electrical Machines Which Are
To Be Stored
9


9.1

Instructions for Electrical Machines Which Are To Be Stored
Electrical machines which will be stored for long periods of time before use
are to be dealt with as follows:

Storage Site

Store the machine (complete with its transportation packing) in a dry place which can
be heated and which is free from shock, and protect it from mechanical damage.
After long periods of standing (more than 1 year) check the bearings for
corrosion damage. Even the smallest amount of corrosion damage can reduce the bearing’s serviceable life.

9.2

Securing the Machine for Transportation

If the electrical machine is fitted with cylindrical roller bearings, fix the rotor by
means of a suitable transportation securing device (for protection against scoring
of the rotor by shock see chapter 3.3).
If the electrical machines are despatched on vibration dampers, then they should
not be removed during the period of standing.
If drive sprockets, couplings etc. are already assembled onto the shaft ends, then
fit the transportation securing devices where possible or place the machine onto
vibration dampers.

Any further transportation should only be carried out using transportation
securing devices or by placing the machine onto vibration dampers.

9.3

Checks before Commissioning

9.3.1

Bearings

After long periods of standing (> 1 year) check the bearings. For dismantling and
assembly of the bearings → pages 27 – 40.
Even the smallest amount of corrosion damage considerably reduces the
bearing’s serviceable life. If bearing change is not necessary, re-grease the
bearing.

48

Instructions for Electrical Machines Which Are
To Be Stored
The specifications for type / amount of grease can be taken from the rating
plate or lubricating plate (on the electrical machine). Observe the specifications given in the operating instructions on page 25, Bearing Lubrication,
Grease Nipple. The measures specified above can be ignored if the period
of standing has been relatively short (< 1 year) and storage has been carried out in the proper manner.

9.3.2

Insulating Resistance
All work on the electrical machine’s electrical connections may only be
carried out by electricians (as defined in DIN VDE 0105 and IEC 364)!
Do not touch the connection terminals either during or after measurement. The connection terminals can carry high-voltages! After checking, earth the connection terminals for a short time (5 seconds).



Using a hand generator (max. DC voltage = 630V), measure the insulating resistance of each individual phase to earth continuously until the measured
value is constant.



The insulating resistance of new windings is > 10 MΩ. Dirty and damp
windings demonstrate considerably lower resistance values.
Should a measurement of less than 0.5 MΩ be registered in the air space,
clean and / or dry the winding. During this process the winding temperature
must not exceed 80°C. Dry by means of a space heater or heating appliance or by applying an alternating voltage with a value equivalent to 5-6%
of the rated voltage (make the ∆ − circuit) at the stator terminal connections
U1 and V1.



Repeat the measurement. With resistance values of > 0.5 MΩ the electrical
machine can be put into operation.



Insulating resistance values are dependent on temperature.
Standard values: A rise or fall in winding temperature by 10 K has the effect
of respectively halving or doubling the resistance value.

49

50

SCH 12.01 / S7.2.2 en

SCHORCH Elektrische Maschinen und Antriebe GmbH
Breite Straße 131
D-41238 Mönchengladbach
Telefon +49 (0) 2166-925-0
Telefax +49 (0) 2166-925-100
E-mail: [email protected]
Internet: http://www.schorch.de

930940099UK

ACOUSTIC ENCLOSURE

Revision: 1
Page:
1 of (9)
Prepared by:
LHR
Latest revision: LHR

Date:
Date:

94.11.08
07.02.22

MOUNTING INSTRUCTIONS FOR STE STANDARD ACOUSTIC ENCLOSURE

IMPORTANT:

Avoid loading the top of the acoustic enclosure with more than 100 kg at any
point.
Temperature inside the acoustic enclosure is not to exceed 40°C during operation.
Prior to mounting of the acoustic enclosure, the components shall be kept indoor
to prevent water damage (rain, dew).
Having completed the assembly, the adhesive labels, included in the delivery, and
showing the necessity of using hearing protection as well as warning of automatic
start, shall immediately be pasted to the side panels (on the outside).
The mounted acoustic enclosure shall be connected to earth.

0.

Pre-assembly Instructions
Check that no components listed on the bill of delivery are missing and that all components are
undamaged.
First the compressor is erected and fixed to the base plate/floor, after which it is carefully
aligned in relation to the discharge pipe and the inlet channel (if any).
To ensure correct cabling, the electric cables and cooling water pipe(s) (if any) are mounted
after erection of the acoustic enclosure.

The following tools are used for the assembly:
-

Impact drilling machine with 10 mm impact drill
16 or 17 mm open-end wrench
10 mm socket spanner for drilling machine
Level gauge
Tape measure
Hammer
Degreasing agent
Chalk line

Silicone spray (L289), with which to grease sealing strips, is included in the delivery.

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ACOUSTIC ENCLOSURE

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An assembly drawing and seven A-4 drawings (No. 1, 2, 3, 4, 5, 6, 7) are delivered with the
Mounting Instructions for the plant in question.
A thin plastic film protects the surface of the components against damage during transport and
mounting. Therefore, remove this film as late as possible during the assembly. When the film
has been removed the parts must be treated with the utmost care to avoid damage to the
surface.
All item numbers of the Mounting Instructions, e.g. L232, are shown on the above-mentioned
drawings and the bill of delivery.

1.

See Assembly Drawing and Drawing No. 1
Placement of the floor profiles is carried out in accordance with the distances indicated to the
compressor's centre line as well as the length measurements.
The gable profiles are placed under the side floor profiles.
Parallelism, right angles, and measurements shall be carefully aligned.

2.

See Assembly Drawing and Drawing No. 3
Place slide rail (L259) for motor cross panel (L257/L258) (if any) on the floor.

3.

Having laid out the profiles, weight them down with available heavy objects to avoid
dislocation during drilling of the ∅ 10 mm holes for Simplex expansion bolts (L275). The
holes are drilled 55mm and 65 mm, respectively, down in the base plate through the holes in
the floor profiles and the slide rail.
With a view to possible later adjustment, be careful to drill in the centre of the slide rail holes,
as reinforcement iron in the concrete may cause problems when positioning.

4.

See Assembly Drawing and Drawing Nos. 1 + 3
Put floor profiles aside and clean boreholes of drill cuttings (dust). Insert expansion bolts
(L275) while making sure that the tops of the bolts are approximately 40 mm above floor
level.

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ACOUSTIC ENCLOSURE

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3 of (9)

5.

See Drawing Nos. 1, 3 + 7
Clean underside of floor profiles and slide rail (L259) thoroughly with degreasing agent.
Fasten sealing strips (L283) as shown on drawings 1, 3, and 7. Make sure that all slits are
sealed to avoid passage of sound.
NB!

6.

Even small openings in the joints will considerably reduce the damping effect of the
acoustic enclosure.

Now place sufficient number of washers (L277) on each expansion bolt (L275), so that the
profiles are raised approx. 9 mm above floor level.
Exactitude of alignment: ±1 mm from theoretical horizontal level.

7.

See Assembly Drawing and Drawing Nos. 1 + 2
Place the posts as indicated on Assembly Drawing; hammer down expansion bolts (L275) acc.
to the measurements indicated on drwg. 1 + 2. Press posts firmly against the inner edge of
floor profile and tighten nuts lightly.

8.

When placing top profiles follow Assembly Drawing closely; Put them up and fasten them to
posts with screws (L270) and washers (L278). The side top profiles are placed under the gable
top profiles. Fasten the 4 panels (L246, L247, L248, L249) in the gable next to the compressor
inlet. The gable panels (L246, L247, L248, L249) are held together by 4 screws (L271). There
are pop nuts in panels L246 and L247.

9.

See Assembly Drawing and Drawing No. 2
Place the rafters acc. to Assembly Drawing and tighten with screw (L269) and washer (L278).

10.

Now tighten up on nuts for expansion bolts (L275), and check that all posts are erect (vertical),
and that the angles are correct. Any slants and off-centres shall be corrected.

11.

As a safety measure all panels are shipped without mounted handles (L287). The handles are
fixed to the panels with UNBRACO screw M6 x 20 (L288). All panels are delivered prepared
for handles to be mounted.

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ACOUSTIC ENCLOSURE

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12.

See Drawing Nos. 4, 5 and 6
To prevent sound passage a rolled up, special sealing strip (L284) is included in the delivery.
Press this strip tightly against the panel edge of posts and rafters. The sealing strip is mounted
in an unbroken line, as shown on drawings 4, 5, and 6.
When mounting the sealing strip, start at the bottom in the middle of the opening. Use hammer
when fixing strip to the panel edge and continue around the opening while paying special
attention to the corners.

13.

See Assembly Drawing
Spray all sealing strips (L284) with silicone (L289) from spray included in delivery. Then
insert side- and gable panels by tilting the panel up into the top profile, lifting it so high that it
slides over the vertical, outer edge of the floor profile, after which it is lowered vertically into
the floor panel.
Having mounted all the panels, check that the rubber sealing strips (L284) bear against the
panels. If not, adjust the posts against the outer edge of the floor profile.
Remove side panels and the top panel(s) opposite the ventilation hood, see later Item 15.

14.

Sealing of the connection between the inlet silencer and the acoustic enclosure is made with
Ikalon sealing strip (L282) 30 x 50 mm.

15.

See Assembly Drawing and Drawing No. 3 for Mounting of Baffle Plate and Motor Panel
The baffle plates (L262, L263) are mounted inside the acoustic enclosure on the wall panels
(L232, L233) with screw and washer (L271, L276) in the pop nuts already mounted in the
panel.
After thorough cleaning with degreasing agent, place the sealing strips as follows:
-

U-rail (L260)
Slide rail L259)
Upper motor panel (L257)
Lower motor panel (L258)

strip type (L282)
strip type (L281 + L283)
strip type (L282)
strip type (L282) in the curvature and 2
parallel strips (L281) on the horizontal
jointed surface.

930940099UK

ACOUSTIC ENCLOSURE

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Tilt lower motor panel (L258) and lower into floor rail (L259), then raise into vertical position
around motor's ventilation hood.
Place upper motor panel (L257) over motor's ventilation hood.
Press the 2 U-rails (L260) firmly into each side of the motor panel (L257/L258).

16.

See Assembly Drawing
Remount wall panels.
Remount top panel(s).

17.

See Assembly Drawing for mounting of air/oil cooler
The air/oil cooler (if any) is mounted on the slide rails prepared on the rafters with screws to
match. The oil hoses are led from the compressor aggregate through the holes in the rafter,
where they meet the oil hoses from the oil cooler. The hoses are connected outside the acoustic
enclosure with retaining ring fittings to match.

18.

See Assembly Drawing for noise insulation around cone diffuser
Use sealing strip (L282) to insulate hole around cone diffuser in the top panel.

19.

See Assembly Drawing for mounting of ventilator and vent canal
The vent channel (L261) is mounted by means of self-cutting screws (L272), drilled into the
top panel with the ventilator. Ventilator's blow direction: See Assembly Drawing.

20.

Removal of acoustic enclosure refuse
Refuse, such as mineral and/or glass wool, also in wet condition, can be taken to a refuse
dump. So can all sealing strips.
All the iron can be sold as scrap iron.

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ACOUSTIC ENCLOSURE

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ACOUSTIC ENCLOSURE

Accessories
Coupling
Blow off Valve
Actuator for Blow off Valve
Check Valve
Actuators for Diffuser
Lube Oil Filter
Lube Oil Cooler
Air Filter Bags
Thermostats
Pressostat
Thermometer
Manometer
Surge Detector
Compensator
Cone Diffuser
Silencer for Blow of valve
Noise hood Fan

Thomas Rexnord
Wouter Witzel
Bernard
Cast Flow
Framo Unipush
FBO
Oiltech
Camfil
Danfoss
Danfoss
Sika
Wika
Siemens
Bredan
Siemens
Siemens
EMB Papst

SERIES 52 Couplings
Installation Instruction
(Metric Version)

Warning: All rotating power transmission products are potentially dangerous and must be
properly guarded in compliance with OSHA standards for the speed and applications for which
they are intended. It is the responsibility of the user to provide proper guarding.

Figure 1

I. Purpose: These instructions are intended to help
you to install, align, and maintain your THOMAS
coupling.

IV. Hub Mounting:
A. General. Clean hub bores and shafts.
Remove any nicks or burrs. If bore is
tapered, check for good contact pattern. If the
bore is straight, measure the bore and shaft
diameters to assure proper fit. The key(s) should
have a snug side-to-side fit with a small
clearance over the top.

Il. Scope: Covered here will be general information,
hub mounting, alignment, assembly, locknut
torquing, disc pack replacement, and part
numbers.

B. Straight Bore. Install key(s) in the shaft. If the hub is
an interference fit, heat the hub in an oil bath or oven
until bore is sufficiently larger than the shaft. 350
degrees F. is usually sufficient. An open flame s not
recommended. However, if flame heating is
necessary, use a very large rose bud tip to give even
heat distribution. A thermal heat stick wiII help
determine hub temperature. DO NOT SPOT HEAT
THE HUB OR DISTORTION MAY OCCUR. With the
hub expanded, slide it quickly up the shaft to the
desired axial position. A pre-set axial stop device
can be helpful.

III. General Information: The coupling, as received,
may or may not be assembled. If assembled, the
Iocknuts are not torqued. Examine the parts to
assure there is no visible damage. If coupling is
assembled, remove the bolts, Iocknuts, and
washers that attach the hubs to the discpacks.
Remove both hubs. Leave the disc packs attached
to the center member assembly.

89301E232a

1

05/01

C. Taper Bore. Put the hub on the shaft without
key(s) in place. Lightly tap hub up the shaft with
a soft hammer. This will assure a metal-to-metal
fit between shaft and hub. This is the starting
point for the axial draw. Record this position
between shaft end and hub face with a depth
micrometer. Mount a dial indicator to read axial
hub movement. Set the indicator to "0”. Remove
hub and install key(s). Remount hub, drawing it
up the shaft to the "0" set point. Continue to
advance hub up the taper to the desired axial
position. Use the indicator as a guide only. A
pre-set axial stop device can be helpful. Check
the final results with depth micrometer. The hub
may have to be heated in order to reach the
desired position on the shaft. DO NOT SPOT
HEAT THE HUB OR DISTORTION MAY
OCCUR. Install shaft locknut to hold hub in
place.

within .001 inch per inch of the axial length between flex
elements.
NOTE:
If the driver or driven equipment alignment
specification is tighter than these recommendations, the
specification should be used. Also, be sure to
compensate for thermal movement in the equipment.
The coupling is capable of approximately six times the
above shaft misalignment tolerances. However, close

V. SHAFT ALIGNMENT. Move equipment into
place.
A. Soft Foot. The equipment must sit fIat on its
base. Any soft foot must be corrected now.
B. Axial Spacing. The axial spacing of the shafts
should be positioned so that the disc packs
(flexing elements) are flat when the equipment is
running under normal conditions. This means
there is a minimal amount of waviness in the disc
pack when viewed from the side. This wilI result
in a flexing element that is centered and parallel
to its mating flange faces. Move the connected
equipment to accomplish the above. As a guide,
maximum and minimum values for dimension “N”
are given. These dimensions are suggested for
initial installation. Additional capacity is available
to compensate for thermal and structural
movement. Maximum axial capacity values for
these couplings are also given. See Table 1 and
Figure 1.

Figure 3

alignment at installation will provide longer service with
smoother operation.
VI. FINAL ASSEMBLY. With the coupling in good
alignment, the bolts will fit through the holes in the
flanges and the disc packs more easily
A. If the coupling arrived assembled, the disc packs
are still attached to the center member assembly.
Before taking the disc packs off, first install one
hub boIt through each disc pack and secure with a
locknut. This will help when the pack is reinstalled
later. if the coupling was shipped disassembled,
the boIt through the pack is not required as the
discs in the pack are factory-taped together.

NOTE:
L=2N+Center Member Length.
C. Angular Alignment. Rigidly mount a dial
indicator on one hub or shaft, reading the face of
the other hub flange, as shown in Figure 2.
Rotate both shafts together making sure the
shaft axial spacing remains constant. Adjust the
equipment by shimming and/or moving so that
the indicator reading is within .001 inch per inch
of coupling flange diameter.

B. With the hubs mounted and the span Iength “C”
set, proceed to put the center member into place
between the two hubs. Care should be taken when
handling the center member as the tube can be
damaged.
Support the center member at both ends on wood
blocks, with nylon straps from a hoist, or some
other convenient way. it may help to support the
end not being worked on with bolts through the
spool flange boIt holes and into the hub flange boIt
holes. This will hold the parts in line at that end.

D. Parallel Offset. Rigidly mount a dial indicator on
one hub or shaft, reading the other hub flange
outside diameter, as shown in Figure 3.
Compensate for indicator set-up sag. Rotate
both shafts
together. Adjust the equipment by shimming
and/or moving 50 that the indicator reading is
89301E232a

2

05/01

C. Now install the disc pack. Rotate the hub or
center member so that the hub boIt holes line up
with the center member flange clearance holes.
If the coupling was assembly balanced, also
align the matchmarks. Start a boIt through the
washer. The beveled side of the washer
should always be against the disc pack. Hold
the disc pack in one hand, slip it down between
the two flanges until one hole in the pack lines
up with a clearance hole in the hub. Slide the
boIt through this hole into the disc pack. Add a
washer. Then push the boIt through the boIt hole
in the center spool and install the locknut.

NOTE: When installing the washer, it may be helpful to
use a stiff wire with one end bent into a hook to put
around the O.D. of the washer. This will help to line up
the washer with the hole.
The remaining bolts for this end can be put through
the center member clearance holes, washer, disc
pack, washer into the bolt hole in the hub flange and
add a locknut. The Iocknuts can be snugged up at
this time. Disc pack when installed should look flat
and parallel with the mating flanges.
D. Now proceed to the other end of the coupling.
Remove the support bolts, if used, supporting the
center member in one of the other ways. Using
paragraph "Vl. C above install the second disc pack.

NOTE: All boIt threads should be lubricated. A
clean motor oil is recommended.
Do not torque any Iocknuts at this time.
Remove the disc pack alignment boIt if used.
Now pivot the pack around until it lines up
with the rest of the boIt holes in the center
spool. Install the rest of the bolts through the
hub clearance holes, washer disc pack,
washer into the boIt hole of the center
member flange, and add a locknut.

E. Make the final coupling alignment check at this time.
F. Torque Up the Iocknuts. See Table 1 for torque
values.
NOTE: With the coupling in good alignment the bolts will
fit through the holes in the flanges and the disc pack
more easily.

Table 1 Locknut Tightening Torques
ÆA

Coupling
Size

mm
94
110
138
144
168
198
221
246
267
287
327
367
406
464
503
546
584
635

Dimension "N"
Mini.
mm
6,9
7,4
9,4
9,4
12,2
13,0
13,7
15,2
16,0
18,5
20,1
23,4
25,1
30,5
32,0
33,8
36,1
38,4

Maxi.
mm
7,1
7,6
9,7
9,7
12,4
13,2
14,0
15,5
16,3
19,1
20,6
23,9
25,7
31,2
32,8
34,5
36,8
39,4

Axial
Capacity

Thread
Size

mm
0,9
0,9
0,9
0,9
1,1
1,3
1,4
1,6
1,7
1,8
2,1
2,3
2,6
2,9
3,2
3,5
3,7
4,0

Torque

Nm
18
18
34
34
41
54
129
176
237
271
353
475
454
576
759
1003
1288
2440

Alignment
Total Indicator
Reading
Angular
Parallel
mm
mm
0,10
0,10
0,13
0,15
0,18
0,20
0,23
0,25
0,28
0,30
0,33
0,36
0,41
0,46
0,51
0,56
0,58
0,64

Setscrew

89301E232a

3

001 mm per mm lof “C” dimension

125
M6x1
162
M6x1
200
M8x1
225
M8x1
262
M10x1
312
M11x1
350
M12x1,25
375
M14x1,5
425
M16x1,5
450
M18x1,5
500
M20x1,5
550
M22x1,5
Locknut Setscrew
600
M25x2
700
750
Thread
Torque
800
size
Nm
850
925
3/8-16
17
NOTE:
1. These torque values are approximate for steel bolts with lubricated threads. Modification will be necessary for stainless
steel. For stainless steel the tightening torque must be reduced to 60% of the values shown. BoIt and locknut threads
must also be liberally coated with molybdenum disulfide grease.
2. Bolts should be held from rotating while the Iocknuts are torqued to the values shown.

05/01

It is recommended that all locknuts be
retightened after several hours of initial
operation.

through the pack securing it with a locknut.
This will keep the discs together and
maintain the disc orientation for later
reinstallation. Remove the last bolt and slide
the pack out supporting the center member
at this end.

G. For further help with the installation or alignment
consult Rexnord.
VIl. Disc Pack Replacement. If it becomes
necessary to replace the disc pack, it can be
done as follows:

B. Now disassemble the other end per “VlI. A”
above being sure to support the center
member when taking out the last boIt.
Remove the center member.

A. At one end of the coupling remove all
locknuts and washers. Back out and remove
ah but one bolt. It may be necessary to tap
the ends of the bolts with a soft hammer to
start them out. Pivot the disc pack out. Put
one of the coupling bolts

C. Replace parts as necessary. Recheck
alignment per Section V. Reassemble per
Section VI.
VIII.

For replacement parts, see Table 2.

Table 2
Part Numbers and Quantity Required

Size
of
SR 52

Hub

Part
No.
128790
034406
234407
434408

Center Spool
One per Cplg.

Part
Dim.
No.
“C”
125
328791
4”
162
634420
5”
200
734421
5”
225
834422
5”
934422
7”
262
634409
034423
5”
134423
7”
312
834410
234424
5½”
334424
7”
350
034411
434425
6”
534425
7”
375
234412
634426
7”
425
434413
734427
7”
450
634414
834428
7”
934428
8”
500
834415
034429
9”
550
034416
134430
10”
600
234417
234431
10”
700
434418
003125
11”
750
663126
003131
11”
800


850



925



*These locknuts are cad plated.

Disc Pack
Two per Cplg.
TomStainaloy
less
Part
Part
No.
No.
910618
310618
710663
310663
210665
710665
210984
610984

Part
Qty.
Part
No.
No.
212706 16 916087
212706 24 916087
712610 32 116008
712610 32 116088

010985

210985

014762

32

010957

210957

017142

810952

010952

410943
810986
210987
420735
110962
710959
Not
available

Washer

Bolt

Locknut

Qty.

Qty

8
12
16
16

Part
No.
916504
916504
316505
316505

316089

16

716506

16

32

516090

16

116507

16

019099

32

716091

16

516508

16

610943
010986
410987

019101
019102
516100

32
32
32

916092
116093
316094

16
16
16

916509
316510
716511

16
16
16

620735
310962
910959
420803
921021
220851
020793
020958

711460
311750
612127
511413
111803
911800
611402
812176

32
32
32
32
32
32
32
32

516095
716096
916097
116098
316099
616200
816201
016202

16
16
16
16
16
16
16
16

116512
516514
020253*
020254*
020255*
020256*
020257*
913898

16
16
16
16
16
16
16
16

8
12
16
16

For further assistance, call
Rexnord Hansen, PTP Operation, Raon l'Etape, France TEL: +33 (0)3 29 52 62 72
FAX: +33 (0)3 29 41 80 40
Or
Rexnord, BSD, Dortmund, Germany

89301E232a

4

TEL: + 49 (0)231/82 94 - 0
FAX: + 49 (0)231/82 94 250

05/01

Instructions de mise en service, stockage
et entretien
Instructions for start-up, storage
and maintenance

TMS - 300 - SD F / A rev. D

Modèles / Models : OA, OAP, AS, ASP, BS, SRA, SRC, ASM

Gamme
Range

SD

SOMMAIRE
PAGE
1. SECURITE

2

2. MONTAGE

2

3. COMMANDE MANUELLE ET DEBRAYAGE

2

4. RACCORDEMENT ET TESTS ELECTRIQUES

2

5. REGLAGE DES BUTEES MECANIQUES ET DES CONTACTS DE FIN DE COURSE

3

6. REGLAGE DU LIMITEUR DE COUPLE

3

7. POTENTIOMETRE DE RECOPIE DE POSITION (OPTION)

4

8. TRANSMETTEUR DE POSITION TYPE TAM (OPTION)

5

9. ENTRETIEN ET STOCKAGE DES SERVOMOTEURS

6

SCHEMAS DE CABLAGE INTERNE ET EXEMPLES DE CIRCUITS DE PUISSANCE

7

EXEMPLES DE REALISATION DE COFFRETS DE COMMANDE

8

LE RESEAU INTERNATIONAL L.BERNARD

14

TABLE OF CONTENTS
PAGE
INTERNAL WIRING DIAGRAMS AND EXAMPLES OF POWER SUPPLY CIRCUITS

7

CONTROL PANEL DESIGN EXAMPLES

8

1. SAFETY INFORMATION

9

2. ASSEMBLY

9

3. HANDWHEELOPERATION AND DECLUTCHING

9

4. ELECTRICAL CONNECTIONS AND PRELIMINARY TESTS

9

5. SETTING OF MECHANICAL STOPS AND TRAVEL LIMIT SWITCHES

10

6. SETTING OF TORQUE LIMIT SWITCHES

10

7. POSITION FEEDBACK POTENTIOMETER (OPTION)

11

8. "TAM" POSITION TRANSMITTER (OPTION)

12

9. MAINTENANCE AND STORAGE INSTRUCTIONS

13

L.BERNARD INTERANATIONAL NETWORK

14

1

1. SECURITE
Cet appareil répond aux normes de sécurité en vigueur. Toutefois, seule une
installation, une maintenance et une utilisation effectuées par un personnel
qualifié et formé permettront d'assurer un niveau de sécurité adéquat.
ATTENTION
Pour les servomoteurs antidéflagrants, veuillez aussi lire
attentivement les instructions spécifiques TMS1132 avant de procéder
au montage et au démarrage.
Avant montage et démarrage, lire attentivement l'ensemble de ce document.
2. MONTAGE
Le servomoteur doit être boulonné sur l’appareil à motoriser.
Les servomoteurs BERNARD peuvent fonctionner dans n’importe quelle
position. Cependant, les presse-étoupes ne devraient par être orientés vers
le haut (étanchéité) et le moteur de préférence pas placé en position basse
(condensation d'eau interne potentielle).
Note 1 : ne pas transporter les servomoteurs par le volant sous peine
d’endommager le couple roue et vis.
Note 2 : si le servomoteur a été fourni monté sur la vanne, les réglages de
base ont en principe été effectués ; se reporter alors aux seuls § 3,4 et 9.
Note 3 : voir §.9 pour les précautions de stockage avant mise en route.
3. COMMANDE MANUELLE ET DEBRAYAGE
Dans le cas général, le volant ne tourne pas pendant les manoeuvres
électriques. Si le volant tourne, il est alors plein et exempt de parties
saillantes et ne présente aucun risque pour l'opérateur.
De plus, pour les servomoteurs à couple élevé, le dispositif de limiteur d'effort
assure une protection complémentaire.
Modèles OA :
Ils sont équipés d’une commande manuelle débrayable manuellement.
Pour passer en mode manuel, il faut tourner le volant tout en tirant dessus
afin de l’engager mécaniquement.
Le débrayage du volant s’effectue en le repoussant en butée vers le carter.
Modèles AS100/AS200/AS400/SRA/SRC/ASM :
Ils disposent d’une commande manuelle à débrayage automatique à priorité
électrique.
Pour passer en mode manuel, aligner la flèche de la poignée d’embrayage
avec le repère triangulaire situé sur le carter (il peut être nécessaire de
tourner le volant de quelques degrés pour dégager les crabots).
Le retour en mode électrique s’effectue automatiquement au démarrage du
moteur, ou bien manuellement si on le désire.
AS100/AS200/AS400/SRA/SRC/ASM

Modèles ASP/AS50/AS80 :
Certains de ces modèles sont équipés d'un levier de débrayage du moteur
monté sur un étage de réduction intermédiaire.
En fin de manoeuvre manuelle, ne pas oublier de réembrayer le moteur.
Sinon, celui-ci tournera à vide jusqu'à l'activation de la protection thermique.
Si cet incident se répète, un risque de détérioration du moteur existe.
4. RACCORDEMENT ET TESTS ÉLECTRIQUES
Si le servomoteur est équipé d'une commande type INTEGRAL, MINIGAM
ou MINIGRAL, veuillez vous reporter aux documentations spécifiques.
Sinon, tous les fils électriques venant des différents éléments du
servomoteur sont ramenés sur un bornier dont les bornes portent des
numéros correspondant aux schémas de câblage inclus dans ce document.
Le contact de protection thermique du moteur et les deux contacts du limiteur

2

de couple doivent être intégrés dans votre logique de commande (cf.
exemples de câblage) afin de limiter les risques de casse mécanique.
Une fois le câblage terminé, les points suivants sont à contrôler :
a) A partir des informations gravées sur la plaque d'identification du
servomoteur, vérifier que l'alimentation électrique utilisée est correcte,
b) Vérifier que les presse-étoupe ont bien été resserrés après câblage,
c) A l'aide de la commande manuelle, amener la vanne en position médiane,
d) Actionner la commande électrique d'ouverture. Vérifier que le sens de
rotation du servomoteur est correct. Actionner manuellement le contact de
fin de course "OPEN" (ouvert) ; le moteur doit s'arrêter.
Vérifier de la même manière la commande électrique de fermeture et le
contact de fin de course "CLOSED" (fermé).
e) Tous modèles sauf OA : actionner la commande électrique d'ouverture.
Actionner manuellement le contact du limiteur d'effort "OPEN" ; le moteur
doit s'arrêter. Vérifier de la même manière le contact du limiteur d'effort
"CLOSED" pendant une manoeuvre de fermeture.
En cas de problème sur un de ces tests, vérifier l'ensemble du cablâge.
Pour les servomoteurs d’un couple supérieur à 300 Nm, après avoir vérifié le
sens de rotation, il est préférable d’alimenter seulement le courant de
contrôle, sans alimenter le courant de puissance, afin de contrôler le
branchement en toute sécurité.
5. RÉGLAGE DES BUTÉES MECANIQUES ET DES CONTACTS DE FIN
DE COURSE
Description et fonction des butées mécaniques (1/4 Tour uniquement)
Ce dispositif limite mécaniquement la course lors de la commande manuelle
de la vanne et de ce fait évite tout déréglage. Suivant les cas, les butées sont
localisées sur le servomoteur ou sur le réducteur 1/4 Tour.
Les servomoteurs sont réglés dans nos usines pour une rotation de 90°. Un
réglage est possible grâce aux vis d’arrêt dans la limite de 2° à chaque
extrémité.
Description et fonction du bloc à cames et des contacts fin de course
Les cames actionnant les micro-contacts forment un ensemble monobloc
dont les éléments peuvent être réglés indépendamment les uns des autres.
Les cames blanche et noire servent aux contacts fin de course. Les autres
cames sont pour des contacts additionnels optionnels (2 à 4 selon version).
Les cames se manoeuvrent de la façon suivante :
a) Introduire un petit tournevis dans la fente entourée d'une bague de la
même couleur que la came à déplacer,
b) Appuyer légèrement pour libérer la came,
c) Tourner indifféremment dans un sens ou dans l’autre pour amener la
came dans la position recherchée,
d) Relâcher la pression en s’assurant que la tête est remontée en position
d’origine, ce qui verrouille automatiquement la came.
Mode opératoire de réglage des butées mécaniques et du bloc à cames :
a) Desserrer les deux butées mécaniques de 2 tours (1/4 Tour seulement).
b) Amener la vanne en position fermée. Pour les appareils 1/4 Tour, si l'on
arrive en butée mécanique avant d'avoir atteint la fermeture complète de
la vanne, cela signifie que la tolérance de réglage de 2° maximum a été
dépassée ; ne pas tenter de passer outre à cette limite.
c) Régler la position de la came du contact de fin de course "CLOSED".
d) Revisser la butée jusqu’au contact et la desserrer d’un tour et demi ; puis
bloquer la vis de la butée avec le contre-écrou (1/4 Tour uniquement).
Respecter la même procédure pour l’ouverture.
Effectuer une fermeture et une ouverture complète avec la commande
électrique. Il est impératif que l'arrêt du moteur sur fin de course électrique
intervienne avant l'arrivée en butée mécanique.

3

6. RÉGLAGE DU LIMITEUR DE COUPLE
IMPORTANT : Les microrupteurs limiteurs de couple donnent un contact à
impulsion. En option, il est possible de mémoriser électriquement l’indication
du limiteur d’effort par un système de relais incorporé au servomoteur.
Les servomoteurs BERNARD sont réglés et vérifiés pour la valeur des
couples demandés à la commande. Un réajustement peut s’effectuer si
nécessaire en agissant sur les écrous qui compriment les ressorts du limiteur
de couple. Le couple préréglé peut-être augmenté ou diminué en serrant ou
desserrant les écrous. Nous consulter.
Dans le cas où des valeurs de couple précises n’ont pas été indiquées à la
commande, le jeu de ressorts livré est ajusté à la valeur du couple maximum
que le servomoteur peut fournir (valeur indiquée dans les tableaux
techniques de nos catalogues).
7. POTENTIOMETRE DE RECOPIE DE POSITION (OPTION)
Le système de recopie de position est constitué d'un potentiomètre entraîné
par le bloc cames des fins de course.
Le 0% correspond à une vanne fermée. Le 100% à une vanne ouverte.
Version sur circuit imprimé
Pour monter l'ensemble potentiomètre sur la platine du servomoteur,
emboîtez-le sans l'indicateur de position et vissez-le sur la colonette de
maintien. Revissez l'indicateur de position.
Le réglage du zéro du potentiomètre s'effectue à l'aide de la vis repérée "0%
position".
Mettre le servomoteur en position fermée.
La mesure de résistance s'effectuera entre les bornes 16 et 17.
Tout en maintenant manuellement en position la pignonnerie située juste
sous la plaque marquée "0% position", tourner la vis du potentiomètre
jusqu'à obtenir une valeur de résistance qui dépasse 0 Ohm et augmente
régulièrement puis tourner en sens inverse afin de revenir à une valeur
proche de 0 Ohm.
Mettre le servomoteur en position ouverte et noter la valeur de résistance
pour le 100%.
Revenir en position fermée et vérifier que la valeur du 0% est bien répétable
et proche de 0 Ohm.
Version sur colonette (servomoteur modèle OA)
Pour monter l'ensemble potentiomètre sur la platine du servomoteur, fixer la
colonnette de maintien et engager le pignon d'entraînement du potentiomètre
avec la roue du bloc cames.
Le réglage du zéro du potentiomètre s'effectue à l'aide d'une petite clé en
desserrant l'écrou de maintien afin de pouvoir faire tourner le potentiomètre.
Mettre le servomoteur en position fermée.
La mesure de résistance s'effectuera entre les bornes 16 et 17.
Tourner le potentiomètre jusqu'à obtenir une valeur de résistance qui
dépasse 0 Ohm et augmente régulièrement puis tourner en sens inverse afin
de revenir à une valeur proche de 0 Ohm.
Resserrer l'écrou en maintenant le potentiomètre en position.
Mettre le servomoteur en position ouverte et noter la valeur de résistance
pour le 100%.
Revenir en position fermée et vérifier que la valeur du 0% est bien répétable
et proche de 0 Ohm.
Remarques : Si l'équipement possède 2 potentiomètres, chaque
potentiomètre est réglé indépendamment l'un de l'autre.
Inversion du signal
Pour changer le sens de variation du signal, croiser les fils du potentiomètre

4

au niveau du bornier du servomoteur (exemple : pour un raccordement
16/17/18, inverser 16 et 18).
8. TRANSMETTEUR DE POSITION TYPE TAM (OPTION)
Le TAM transmet à distance une position angulaire. Le signal de sortie est un
courant variant de 0 à 20mA ou de 4 à 20mA, suivant une loi linéaire en
fonction de l'angle de rotation de l'axe d'entrée d'un potentiomètre.
Raccordement électrique
Effectuer le raccordement électrique conformément au schéma fourni avec le
servomoteur. Voir aussi des exemples de branchement typiques ci-dessous.
L'alimentation doit être comprise entre 12 et 32V en courant continu redressé
filtré ou stabilisé et avec une charge maxi admissible précisée dans le tableau.
Alimentation
VOLT
12
24
30

Charge maxi
admissible Ohm
150
750
1050

Adaptation du signal au sens de rotation
Le transmetteur de position TAM qui équipe un servomoteur standard délivre
un signal qui augmente de la position fermée à la position ouverte, le sens
d'ouverture de l'organe entrainé correspondant au sens antihoraire.
Pour que le signal diminue de la position fermée à la position ouverte ou si
l'organe entrainé ouvre dans le sens horaire, le signal peut être inversé en
déplaçant les cavaliers : sens direct 1-3 / 2-4 , sens inverse 1-2 / 3-4.
Réglages
Brancher un milliampèremètre avec ou sans charge pour lire le courant de sortie.
- Le réglage doit toujours commencer par le 0/4mA.
- Amener le servomoteur dans la position qui doit correspondre au signal
0/4mA (en standard c'est la fin de manoeuvre de l'organe entrainé dans le
sens horaire ou position fermée).
- Tout en maintenant manuellement en position la pignonnerie située juste
sous la plaque marquée "0% position", tourner la vis du potentiomètre
jusqu'à atteindre la plage où le courant à sa valeur minimale. Chercher la
zone où le signal augmente régulièrement puis tourner en sens inverse afin
de revenir à la valeur minimale précédemment trouvée. Le potentiomètre est
ainsi calé en début de piste.
- Régler précisément le 0/4 mA grâce à la vis du TAM marquée "0/4mA".
- Amener maintenant le servomoteur dans la position qui doit correspondre
au signal 20mA (en standard c'est la fin de manoeuvre de l'organe entrainé
dans le sens antihoraire ou position ouverte).
- Tourner la vis de réglage repérée "20mA" pour lire exactement sur le
milliampèremètre 20mA.
- Revenir en position fermée et vérifier que la valeur du 0% est bien répétable
et proche de 0/4 mA.

5

9. ENTRETIEN ET STOCKAGE DES SERVOMOTEURS
Entretien
Si le servomoteur est utilisé en atmosphère particulièrement humide, il est préférable de vérifier une fois par
an si de la condensation ne s’est pas produite à l’intérieur du boîtier comportant les parties électriques. Pour
empêcher cette condensation, les servomoteurs peuvent être équipés en option d’une résistance de
chauffage, ainsi que d’un aérateur permettant une circulation de l’air à l’intérieur du boîtier.
Nos servomoteurs sont graissés pour 100.000 manoeuvres environ. En cas de renouvellement de la graisse
d’origine, utiliser une graisse de qualité au moins équivalente (voir tableau ci-après).
NOTA : Lors du renouvellement de la graisse, veiller à l’extraction totale de la graisse à remplacer.
Caractéristiques générales des graisses (performances de la graisse et non du servomoteur données pour
des conditions de service normales) :
• Température de service : -30°C à +135°C.
• Pénétration ASTM à 25°C : 265 - 295
• Point de goutte : 180°C
TABLEAU D’ÉQUIVALENCE DES GRAISSES
(conditions de service normales)
TOTAL FINA ELF

SHELL

MOBIL

ESSO

MULTIS COMPLEX EP2

ALVANIA EP2

MOBILUX EP2

BEACON EP2

Stockage
Un servomoteur est composé d’éléments électriques et d’une partie mécanique lubrifiée à la graisse. Malgré
l’étanchéité de cet ensemble, les risques d’oxydation, de gommage et de grippage peuvent apparaître lors de
la mise en service du servomoteur, si son stockage n’a pas été correctement réalisé.
Servomoteur stocké en magasin
a) Les servomoteurs doivent être stockés sous abri, dans un endroit propre et sec, et protégé des
changements successifs de température. Eviter le stockage à même le sol.
b) Pour les servomoteurs équipés de résistance de chauffage, alimenter celle-ci dans le cas de présence
d’humidité (tension standard 230 Volts, sauf précision particulière à la commande).
c) Vérifier que les bouchons plastiques provisoires des entrées de câble soient bien en place. S’assurer de
la bonne étanchéité des couvercles et des boîtiers renfermant les éléments électriques.
d) Dans le cas de vanne dont la levée de tige est importante, vérifier que le capot de protection est bien
monté sur le servomoteur. Sinon, monter celui-ci avec une pâte à joint.
Servomoteur installé mais en attente de raccordement électrique
Si une longue attente est prévue entre le montage du servomoteur et les travaux de raccordement électrique:
a) S’assurer de la bonne étanchéité des presses-étoupe et des boîtiers électriques,
b) Recouvrir la motorisation d’un film plastique,
c) Pour les servomoteurs équipés de résistance de chauffage, alimenter celle-ci dans le cas de présence
d’humidité (tension standard 230 Volts, sauf précision particulière à la commande).
Stockage des servomoteurs équipés de composants électroniques
Le stockage de long durée de composants électroniques hors tension peut entraîner des risques de mauvais
fonctionnement. Il est donc fortement déconseillé de le pratiquer.
Dans les cas contraire, il y a lieu de faire réviser en usine les cartes électroniques avant mise en service.
Contrôle après stockage
a) Contrôler visuellement l’équipement électrique,
b) Actionner manuellement contacts, boutons, sélecteurs, ... pour en vérifier le bon fonctionnement
mécanique,
c) Procéder à quelques manoeuvres manuelles,
d) Vérifier la bonne consistance de la graisse,
e) Pour les servomoteurs équipés de graisseurs, faire un apport de graisse neuve,
f) Procéder à la mise en service du servomoteur suivant les instructions jointes à chaque appareil.

6

SCHEMAS CABLAGE INTERNE - INTERNAL WIRING DIAGRAMS
EXEMPLES DE CIRCUITS PUISSANCE - EXAMPLES OF POWER SUPPLY WIRING
Potentiomètre /
Potentiometer

Moteur / Motor
Contact limiteur d'effort
ouverture /
Torque limit switch opening

Fin de course suppl. ouverture /
Extra travel limit switch opening

Contact limiteur d'effort
fermeture /
Torque limit switch closing

Fin de course suppl. fermeture/
Extra travel limit switch closing

Fin de course ouverture /
Travel limit switch opening

Résistance de chauffage /
Heating resistance
Fin de course fermeture /
Travel limit switch closing

Sécurité débrayage volant /
Handwheel clutching security

Protection thermique moteur
Motor thermal protection

Contact clignotant (moteur en
rotation) / Flashing contact
running motor indication)
Second potentiomètre /
Second potentiometer

Note 1 : Sens de rotation / Direction of rotation :
Ouverture : anti-horaire. Fermeture : horaire /
Opening : anti-clockwise. Closing : clockwise

Transmetteur de position 4-20 mA de type TAM /
Position transmitter 4-20 mA model TAM
12-32 VCC/VDC

Note 2 : Limiteurs d'effort / Torque limit switches :
Pas disponible sur modèle OA. Délivrent un signal fugitif non
maintenu sauf configuration spécifique sur demande /
Not available on OA model. Provide a short duration contact
excepted specific configuration on request.

2 fils / wires

Note 3 : Fins de course / Travel limit switches :
Délivrent un contact maintenu / Provide a maintained contact.

12-32 VCC/VDC
2 ou 3 fils /
2 or 3 wires

3 PHASES

1 PHASE

EEx e d
Connection

version non pré-câblée (*) / not valid for prewired versions (*)
Légende : C1 = contacteur ouverture ; C2 = contacteur fermeture
Legend : C1 = opening contactor ; C2 = closing contactor

Sectionneur / Circuit breaker
+ fusible / fuse

Relais thermique /
Thermal relay

Sectionneur / Circuit breaker
+ fusible / fuse

Th : Protection thermique intégrée
au bobinage /
Thermal cutout (integrated
into the motor wiring

Relais thermique /
Thermal relay

Boîte à bornes moteur indépendante /
Independant motor terminal box
Condensateur /
Capacitor

Autres versions (VCC par ex.) : nous consulter /
Other versions (VDC i.e) : please consult us

Note :
En monophasé : le condensateur est
livré séparément /
In single phase, the capacitor is
supplied separately

(*) pour les modèles OA pré-câblés, voir examples de
réalisation de coffret de commande page suivante /
for prewired single phase OA models, refer to control
design example on next page

7

EXEMPLES DE REALISATIONS DE COFFRETS DE COMMANDE /
CONTROL PANEL SAMPLE DESIGN
Les servomoteurs sont représentés en position médiane / Actuators are represented in an intermediate position

Exemple 1 - Arrêt en position ouverture et fermeture sur contact fin de course avec limiteur d'effort en sécurité
avec réarmement. Schéma valable pour toute la gamme SD sauf OA monophasés pré-câblés (voir exemple 2).
Pour les servomoteurs modèle OA, non équipés de limiteurs d'effort : partie A du schéma seulement./
Example 1 - Stop on travel limit switch on closing and opening directions, torque limit switch in safety action with
manual reset. Diagram valid for the entire SD range excepted the pre-wired one phase OA model (cf. example 2).
For OA actuators, not equipped with torque limit switch : side A of the diagram only.
A
Acquittement défaut
d faut limiteur d'effort /
Torque limit default acknoledgement

E1

Légende / Legend

E2

E1
E2
C1
C2
C3
FCO
FCF
LEO
LEF
LT
TR
B1
B2

TR
Arrêtt / Stop
Arr

C3

Servomoteur /
Actuator
10

13

FCO
12

FCF

11

15

B1

Ouvert /
Open

4

C1

7

LEO

14

6

B2

E1
E2
C1
C2
C3
FCO
FCF
LEO
LEF
LT
TR
B1
B2

LEF
9

C2

C3

C3

C2

C1

Ferm /
Fermé
C1 Closed

C2

: Sectionneur + fusible
: Relais thermique
: Contacteur OUVERTURE
: Contacteur FERMETURE
: Contacteur DEFAUT
: Fin de course OUVERTURE
: Fin de course FERMETURE
: Limiteur d'effort OUVERTURE
: Limiteur d'effort FERMETURE
: Protection thermique moteur
: Transformateur
: Bouton poussoir OUVERTURE
: Bouton poussoir FERMETURE

Defaut /
Default

C3

: Circuit breaker+ fuse
: Thermal relay
: OPENING Contactor
: CLOSING Contactor
: DEFAULT Contactor
: OPEN travel limit switch
: CLOSE travel limit switch
: OPEN torque limit switch
: CLOSE torque limit switch
: motor thermal protection
: Transformer
: Opening push button
: Closing push button

Arrêt sur limiteur d'effort à
la fermeture : nous consulter./
Stop on torque limit switch in the
closing direction : please consult us.

Exemple 2 - Servomoteurs OA monophasés pré-câblés - Arrêt en position ouverture et fermeture sur fin de course /
Example 2 - Pre-wired one phase OA actuators - Stop on travel limit switch on both opening and closing directions
CABLAGE SERVOMOTEUR / ACTUATOR WIRING

CABLAGE CLIENT / CUSTOMER WIRING

Condensateur / Capacitor
10

M

11

1

12

Protection thermique moteur
Motor thermal protection

ouvert / open
1
2
3

fermé / closed

Alimentation monophasée /
Single phase power supply

4

OUVERT / OPEN
Contacts fin de course /
Travel limit switches
FERME / CLOSED

5

6

OUVERT / OPEN

FERME / CLOSED

Résistance de chauffage /
Heating resistance

8

1. SAFETY INFORMATION
This device complies to current applicable safety standards.
Installation, maintenance and use of this apparatus will have to be done by
skilled and trained staff only.
Please read carefully the whole document prior to mounting and starting-up.
WARNING
For explosionproof actuators, please also read carefully the special
instructions TMS1132 prior to mounting and starting-up
2. ASSEMBLY
Actuator should be secured directly to the valve using proper bolts or via a
proper interface.
After assembly, the actuator can operate in any position. However, cable
glands should not be oriented upwards (loss of water tightness) and the
motor will preferably not be positioned at the bottom (potential internal
condensation trap)
Note 1 : do not handle the actuator by handwheel, it could damage the
gearworm.
Note 2 : if the actuator was delivered mounted on the valve, the basic settings
should have been done. In this case, refer to § 3,4 and 9 only.
Note 3 : see §.9 for details on storage precaution prior to starting-up.
3. HANDWHEEL OPERATION AND DECLUTCHING
In general, the handwheel does not turn during electrical operation. Even if
turning, the solid handwheel does not have any protruding part and therefore
does not present any risk of any kind for the operator. Moreover, for the
actuators with the highest torque, the torque limit system brings an additional
level of protection.
OA models :
These actuators are equipped with a manually declutchable handwheel.
To operate manually the actuator, turn while pulling the handwheel in order to
mechanically engage it.
To declutch the handwheel, just push it back towards the actuator body.
AS100/AS200/AS400/SRA/SRC/ASM models :
These actuators are provided with an automatic declutching handwheel, with
motor drive priority. In order to operate manually the actuator, turn the arrow
of the handwheel clutch button in front of the triangular sign on the housing
(it might be necessary to turn the handwheel by a few degrees to release the
claws). When the motor starts, it returns automatically into declutched
position.
AS100/AS200/AS400/SRA/SRC/ASM

OAP/OA15/ASP/AS50/AS80 models :
Some of these actuators are equipped with declutchable intermediate gears.
By moving the clutch lever, the motor is physically disengaged from the
gears. Once the manual handwheel operation has been completed, do not
forget to clutch the motor back. Otherwise, once started-up, it would run and
heat up until the motor thermal protection switch closes. If repeated, these
conditions can generate a motor breakdown .
4. ELECTRICAL CONNECTIONS AND PRELIMINARY TESTS
If the actuator is equipped with INTEGRAL, MINIGRAL or MINIGAM
commands, please report to the specific documentation for wiring details.
Otherwise, all components of the actuator are wired to a common terminal
strip. Remove the cover and pass the cables through the cable glands (M20).
Refer to the wiring diagram for details on the terminals numbering system.
Both torque and travel limit switches must be integrated into your control

9

system (see wiring examples) in order to prevent potential damage to the
actuator or valve.
The following points must be checked :
a) Make sure that power supply voltage is in accordance with the data
engraved on the actuator nameplate,
b) Check that all cable glands are correctly tightened,
c) Move the valve manually to an half-open position,
d) Operate an electrical opening and check that the motor rotates in the right
direction. Press manually on the "OPEN" travel limit switch ; the motor
should stop.
In the same way, check that the closing electrical command as well as the
"CLOSED" travel limit switch are working correctly,
e) All models except OA : operate an electrical opening. Press manually on
the "OPEN" torque limit switch ; the motor should stop.
In the same way, operate an electrical closing check that the "CLOSED"
torque limit switch is working correctly,
If any misfunction was detected at this stage, please check the overall wiring.
For safer working conditions, we recommend that the power supply now be
switched off especially if the actuator output max. torque exceeds 300 N.m.
5. SETTING OF MECHANICAL STOPS AND TRAVEL LIMIT SWITCHES
Mechanical stops description and function (1/4 Turn only) :
These items avoid any over-travelling during handwheel operations. The
stops can be positioned either on the actuator itself or on the 1/4 Turn worm
gearbox if any.
Actuators and gears are supplied and tested for a 90° operation. Fine
adjustment of the stop screws position is possible within a limit of ± 2°
maximum.
Travel limit switches description and function :
The cams operating the limit switches are on a cylindrical block which does
not require any disassembly. Each cam can be set independently of the
others. The white and black cams are for open and close travel limits. The
other ones are for optional additional limit switches (2 or 4).
How to operate the cams :
a) Put a screwdriver in the slot of the button encircled by the same color as
the cam to be set,
b) Press lightly to disengage the cam of locked position,
c) By turning the screwdriver rotate the cam to the position in which it can
trip the limit switch,
d) Remove screwdriver and ensure that the button has come back to its
original position, thus locking the cam in chosen place.
Procedure of mechanical stops and travel limit switches setting :
a) Loosen stop screws by 2 turns (1/4 Turn only).
b) Manually drive the valve to the closed position. For the 1/4 Turn devices,
if mechanical stops are reached before the valve closing is completed, it
means that the 2° maximum adjustment tolerance has been exceeded ;
do not try to go beyond this limit.
c) Set the cam of the "CLOSED" travel limit switch.
d) Turn stop screws clockwise to the mechanical contact, reloosen 1.5 turn,
and secure by lock nut (1/4 Turn only).
Proceed in the same way in open position.
Perform complete electrical valve opening and closing operations. It is
mandatory that the motor stops on the travel limit switch and not on the
mechanical stop (check available extra travel to the stop with handwheel).

10

6. SETTING OF TORQUE LIMIT SWITCHES
IMPORTANT : the torque limit switch design of BERNARD actuators gives a
short duration contact only. On request, relays holding this contact
maintained can be fitted into the actuator.
Actuators are set and tested in accordance with the torque stated on orders.
If no torque is specified, the actuator is supplied with torque springs set to the
maximum output (refer to our catalogue technical datasheets).
If necessary, this torque setting can be readjusted by rotating the nuts which
compress the torque springs. So the torque can be increased or decreased
by tightening or loosening the nuts. Please consult us.
7. POSITION FEEDBACK POTENTIOMETER (OPTION)
The potentiometer used for actuator signal feedback is driven by the travel
cam block system.
The potentiometer has no mechanical stop and has a non-resistive area
(dead zone) at both the beginning and end of track.
0% position corresponds to a closed valve. 100% to an open valve.
Circuit board mounted version
To mount the potentiometer device on the switch plate, clip it without the
position indicator on the camblock and screw it on the support column. Screw
the position indicator back.
Setting of potentiometer zero is achieved thanks to the "0% postion" screw.
Drive the actuator to the closed position.
Resistance value is measured between terminals 16 and 17.
Hold the pinion located just under the plate with the "0% position" marking
while driving the potentiometer screw. Adjust the potentiometer so that the
resistance value exceeds 0 Ohm and regularly increases then turn
backwards to reach a value as close to 0 Ohm as possible.
Drive the actuator to the open position and write down the resistance value
corresponding to the 100% position.
Come back to the closed position and check that, for the 0% position, the
resistance shows a close to zero repeatable value.
On support column mounted version (OA type of actuactors)
To mount the potentiometer device, screw the support column on the
mounting plate and engage the driving pinion into the camblock wheel.
To adjust the potentiometer resistance value, loosen the nut with the wrench
and rotate potentiometer until the signal requested is archieved.
To set the 0%, drive the actuator to the closed position.
Resistance value is measured between terminals 16 and 17.
Rotate the potentiometer so that the resistance value exceeds 0 Ohm and
regularly increases then turn backwards to reach a value as close to 0 Ohm
as possible.
Retighten nut after setting.
Drive the actuator to the open position and write down the resistance value
corresponding to the 100% position.
Come back to the closed position and check that, for the 0% position, the
resistance shows a close to zero repeatable value.
Note : If actuator is equipped with 2 potentiometers, each potentiometer is set
independently of the other.
Signal inversion :
To inverse the signal variation direction, invert potentiometer wires on the
actuator terminal board (e.g. for a connection on 16/17/18, invert 16 and 18).

11

8. "TAM" POSITION TRANSMITTER (OPTION)
The TAM transmitter delivers a 0/4 to 20 mA signal linearly proportional to the
angular position of the valve.
Electric connections
Refer to the wiring diagram supplied with the actuator. See also some typical
wiring examples below.
FIltered or stabilised power supply should be provided within the 12 to 32
VDC range.
Maximum admissible ohmic load values are given in the table :
Energy Supply Max. admissible
DC (VOLT)
load Ohm
12
150
24
750
30
1050

Signal direction inversion
The TAM transmitter, when supplied with a standard actuator, provides a
signal that rise from close position to open position, the standard opening
direction being counter-clockwise.
If an opposite signal variation is required, simply move 2 jumpers on the
board near the potentiometer.
Direct signal
: jumpers on 1-3 and 2-4
Reversed signal : jumpers on 1-2 and 3-4
Settings
Connect a milliampermeter at the place of burden.
- Always start by adjusting the 0/4mA.
- Drive actuator to the position corresponding to the 0/4 mA (closed in
standard),
- Hold the pinion located just under the plate with the "0% position" marking
while driving the potentiometer screw. Adjust the potentiometer so that the
output current reaches a minimum value. Turn backwards until the current
value regularly increases then turn backwards again and stop as soon as the
minimum value determined here above has been reached.
The potentiometer is then positioned at the very beginning of its track.
- Then, use the TAM adjustment screw marked as "0/4mA" to adjust the
current to a value as close to the 0/4 mA as possible.
- Drive actuator to the position corresponding to the 20 mA (open in
standard),
- Turn the screw marked "20mA" in order to read exactly 20 mA on the
milliampermeter.
- Come back to the closed position and check that, for the 0% position, the
signal current shows a close to 0/4 mA and repeatable value.

12

9. MAINTENANCE AND STORAGE INSTRUCTIONS
Maintenance
If actuators is correctly mounted and sealed, no special maintenance is required. Check once a year function
of motor and make sure that switch compartment is condensation free. If environment is humid, we
recommend installation of an anti-condensation heater resistance and/or breathers, thus protecting electric
parts from alteration.
Actuators are lubricated with grease for about 100.000 operations. If the grease requires to be renewed, use
one of the products listed hereafter.
NOTE : When renewing the grease, first remove the integrality of the old one.
General characteristics of lubricant ; grease specifications only (not actuator) given for standard duty
conditions :
• Grease duty temperature : -30°C to +135°C,
• Penetration ASTM at +25°C : 265/295,
• Drop point : +180°C.
EQUIVALENT GREASE TABLE
(Normal conditions)
TOTAL FINA ELF

SHELL

MOBIL

ESSO

MULTIS COMPLEX EP2

ALVANIA EP2

MOBILUX EP2

BEACON EP2

Storage
The actuators includes electric equipment as well as grease lubricated gear stages. In spite of the
weatherproof enclosure, oxydising, jamming and other alterations are possible if actuator is not correctly
stored.
Actuators stored in a stock room
a) The actuators should be stored under a shelter, in a clean and dry place and protected from wide
temperature variations. Avoid placing the actuators directly on the floor.
b) For actuators equipped with an heating resistance, it is recommended to connect and power supply it
especially if the storage area is humid (standard 230 VAC, unless other specification).
c) Check that the temporary sealing plugs of the cable entries are well in place. Make sure that the covers
and the boxes are well closed to ensure weatherproof sealing.
d) In the case of a valve with rising stem having a long stroke, verify that the protection tube is well mounted
on the actuator. If not, fix it with sealing paste.
Actuators installed but waiting for electrical connection
If a long period of time is expected between the actuator mounting and the electrical wiring works :
a) Visually check the tightness of electrical box cover and cable glands.
b) Cover the device with a plastic protective film.
c) For actuators equipped with an heating resistance, it is recommended to connect and power supply it
especially if the storage area is humid (standard 230 VAC, unless other specification).
Storage of actuators equipped with electronic components:
Long term storage of electronic components which are not in service increases the malfunction risk. This
practice is therefore highly unadvisable.
If a long term storage is absolutely necessary, we strongly recommend a revision of the electronic boards in
our factory before actuator usage.
Control after storage :
a) Visually check the electric equipment,
b) Operate manually the microswitches, buttons, selectors, etc., to insure the correct mechanical function,
c) Operate apparatus manually,
d) Verify the correct grease consistency,
e) For actuators equipped with grease nipple, remember to complete with some fresh grease.

13

AUSTRALIA
[email protected]

AUSTRIA
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BELGIUM

PEGLER BEACON AUSTRALIA Pty Ltd
3, corporate avenue
ROWVILLE, VICTORIA 3178
Tel : + 61 3 9765 6111
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IPU ING PAUL UNGER
Hardtmuthgasse 53
1100 WIEN
Tel : +43 1 602 41 49
Fax : +43 1 603 29 43

MALAYSIA
[email protected]

MIDDLE-EAST
[email protected]

ACTUATION & CONTROLS ENGINEER
7, Jalan Bayu 2/5 - Taman Perindustrian.
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Tel : +60 7 23 50 277 / 23 50 281
Fax : +60 7 23 50 280 / 23 50 285
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1190 BRUXELLES
Tel : +32 2 34 34 122
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[email protected]

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L. BERNARD

TADELLA LIMITED
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BEIJING - CHINE 100010
Tel : +86 10 6517 0601 / 0602
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Olomoucka 87
627 00 Brno
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[email protected]
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4 rue d'arsonval - BP 91 - 95505 GONESSE. France
Tel. +33.1.34.07.71.00 - Fax +33.1.34.07.71.01
E-mail : [email protected] - Internet . http://www.bernard-actuators.com

14

Accessoires de la gamme SD / SD Range accessories

TAM
Transmetteur de position
Position Transmitter

MINIGAM - MINIGRAL +
Commande électronique monophasé
One phase actuator electronic controls

INTEGRAL +
Commande électronique
Electronic controls

Systèmes à bielle
Lever systems

Autres gammes de produits / Other products ranges

ST Intelli+
Servomoteurs multi-tours intelligents
Multi-turn intelligent actuators
Catalogue n° 114

Régulation / Modulating
Précision & usage intensif
High duty & precision
Catalogue n° 103

FQ
Sécurité positive à retour par ressort
Failsafe spring-return actuators
Catalogue n° 105

L. BERNARD

4 rue d'arsonval - BP 91 - 95505 GONESSE. France
Tel. +33.1.34.07.71.00 - Fax +33.1.34.07.71.01
E-mail : [email protected] - Internet . http://www.bernard-actuators.com

13

Linear actuator Mini 0

D8-20-113e/01.06

Mini 0

Subject to technical changes
Framo Morat GmbH & Co. KG
Höchst 7 • D-79871 Eisenbach

Tel.: +49 (0) 7657 / 88-0
Fax: +49 (0) 7657 / 88-333

www.framo-morat.com
[email protected]

14

Linear actuator Mini 0
[mm]

Dimensions of standard drive and fixing versions
Standard version: AC, stroke 100 mm, transmission ratio 1-stage or 1:1, fixing version A

*
The * marked dimensions specify the drive length, of a standard drive (that means stroke length 100mm and
transmission ratio 1-stage or 1:1). For longer stroke length and/or gear stages please add the corresponding
dimensions x and y from the table below.
Gear
x

1:1 1-stage 2-stage 3-stage
0
0
12
24

+

Stroke length
y

100
0

150
50

200 250 300
100 150 200

Fixing version C

*

Fixing version D, E, F
*
*

*

Fixing version G
*

D8-20-114e1/11.06

*

Subject to technical changes
Framo Morat GmbH & Co. KG
Höchst 7 • D-79871 Eisenbach

Tel.: +49 (0) 7657 / 88-0
Fax: +49 (0) 7657 / 88-333

www.framo-morat.com
[email protected]

15

Linear actuator Mini 0
[mm]

Dimensions options
Brake or
Encoder

*

Potentiometer

*

Force dependent shut off

*

Brake and Encoder

*
Brake and Potentiometer

*

D8-20-115e/01.06

Brake and Force dependent shut off

*
Subject to technical changes
Framo Morat GmbH & Co. KG
Höchst 7 • D-79871 Eisenbach

Tel.: +49 (0) 7657 / 88-0
Fax: +49 (0) 7657 / 88-333

www.framo-morat.com
[email protected]

16

Linear actuator Mini 0
[mm]

Dimensions connection heads

Standard connection head

without connection head
pressure disc

deep

Adjustment ring

Adjustable connection head

D8-20-116e/01.06

Cushioned connection head

Subject to technical changes
Framo Morat GmbH & Co. KG
Höchst 7 • D-79871 Eisenbach

Tel.: +49 (0) 7657 / 88-0
Fax: +49 (0) 7657 / 88-333

www.framo-morat.com
[email protected]

17

Linear actuator Mini 0
[mm]

Dimensions DC-version
Standard version: AC, stroke 100 mm, transmission ratio 1-stage or 1:1, fixing version A
DC fixing version A

*

DC fixing version C

*

DC fixing version D, E, F

D8-20-117e/01.06

*

Subject to technical changes
Framo Morat GmbH & Co. KG
Höchst 7 • D-79871 Eisenbach

Tel.: +49 (0) 7657 / 88-0
Fax: +49 (0) 7657 / 88-333

www.framo-morat.com
[email protected]

18

Linear actuator Mini 0
Power tables
AC 1 x 230 V - 50 Hz
Motor
speed

Motor
power

Duty cycle

min-1
1200
1200
1200
1200
1200
1200
1200
1200
1200
1200
1200
1200

kW
0,030
0,030
0,030
0,030
0,030
0,030
0,030
0,015
0,015
0,015
0,015
0,015

%
15
15
15
15
15
15
15
30-40
30-40
50-60
50-60
50-60

Motor
speed

Motor
power

Duty cycle

min-1
1600
2000
2000
2100
2300
2500
2600
2600
2600

kW
0,055
0,055
0,055
0,055
0,055
0,055
0,055
0,055
0,055

%
25
25
25
25
50
50
50
50
50

Planetary
gear
stages
1:1
1:1
1:1
1-st.
1-st.
1-st.
2-st.
2-st.
2-st.
3-st.
3-st.
3-st.

Trapezoidal
thread

Stroke
speed

mm
10x6 So
10x3 Sd
10x2 Sd
10x6 So
10x3 Sd
10x2 Sd
10x6 So
10x3 Sd
10x2 Sd
10x6 So
10x3 Sd
10x2 Sd

mm/s
120*
60*
40*
30*
15
10
8
4
2,7
2
1
0,7

Trapezoidal
thread

Stroke
speed

mm
10x6 So
10x3 Sd
10x2 Sd
10x6 So
10x3 Sd
10x2 Sd
10x6 So
10x3 Sd
10x2 Sd

mm/s
40*
25*
16*
14*
7,5
5,5
4,5
2,2
1,5

maximum stroke force [N]
at stroke length [mm]
100
150
200
110
155
175
450
600
600
1000
1000
1000
1000
1000
1000

110
155
175
450
600
600
1000
1000
1000
1000
1000
1000

110
155
175
450
600
600
1000
1000
1000
1000
1000
1000

250
300
110
155
175
450
600
600
600
600
600
600
600
600

DC 24 V DC
Planetary
gear
stages
1-st.
1-st.
1-st.
2-st.
2-st.
2-st.
3-st.
3-st.
3-st.

maximum stroke force[N]
at stroke lenght [mm]
100
150
200
450
600
600
900
1000
1000
1000
1000
1000

450
600
600
900
1000
1000
1000
1000
1000

450
600
600
900
1000
1000
1000
1000
1000

250
300
450
600
600
600
600
600
600
600
600

So = no self-locking; Ss = static self-locking; Sd = dynamic self-locking
1-stage = 3,9:1
2-stage = 15,2:1
3-stage = 59,3:1

D8-20-118e/01.06

* Brake requested.
Duty cycle applies to 10 min. duty time.
For tensile loading applies the maximum stroke force of the particular stroke speed.

Subject to technical changes
Framo Morat GmbH & Co. KG
Höchst 7 • D-79871 Eisenbach

Tel.: +49 (0) 7657 / 88-0
Fax: +49 (0) 7657 / 88-333

www.framo-morat.com
[email protected]

19

Linear actuator Mini 0
Spare parts list
AC, transmission ratio 1:1
17

20

19

31

1-stage planetary gear

22

16

1

2

4

9

2-stage planetary gear

10

15

14

21

13

3-stage planetary gear

30

33

Item
1
2
4
7
9
10
13
14
15
16
17
19
20
21
22

Part name
Article-No.
Stator ..................................................................................................................Serial-No.
Rotor cpl..............................................................................................................Serial-No.
Grooved ball bearing ..........................................................................................00300100600383
Limit switch ........................................................................................................ 02450100000700
Terminal board cpl...............................................................................................Serial-No.
Pressure spring .................................................................................................. 8-2000-01.02
Connection head ................................................................................................ Serial-No.
Pressure disc ..................................................................................................... Serial-No.
Switch jack 1 with quadring and limit switch ...................................................... 8-2000-02.01N
Switch jack 2 with limit switch ............................................................................ 8-2000-03.00
Spindle cpl...........................................................................................................Serial-No.
Felt ring .............................................................................................................. 8-2001-01.12
Gear cover ......................................................................................................... Serial-No.
Bearing plate with quadring ................................................................................8-2000-01.12N
Spindlenut, piston tube .......................................................................................Serial-No.

30
31
33

Planet wheel .......................................................................................................8-2000-60.03R
Internal ring gear with grooved ball bearing ....................................................... Serial-No.
Planet wheel carrier toothed .............................................................................. Serial-No.

Subject to technical changes
Framo Morat GmbH & Co. KG
Höchst 7 • D-79871 Eisenbach

Tel.: +49 (0) 7657 / 88-0
Fax: +49 (0) 7657 / 88-333

www.framo-morat.com
[email protected]

D8-20-119e/01.06

33

20

Linear actuator Mini 0
Spare parts list
Spring applied single disc brake

Force dependent shut off

40

Potentiometer

50

Encoder
60

70

Part name

Article-No.

40

Spring applied single disc brake ........................................................................ Serial-Nr.

50

Force dependent shut off ................................................................................... Serial-Nr.

60

Potentiometer ..................................................................................................... Serial-Nr.

70

Encoder .............................................................................................................. Serial-Nr.

D8-20-120e/01.06

Item

Subject to technical changes
Framo Morat GmbH & Co. KG
Höchst 7 • D-79871 Eisenbach

Tel.: +49 (0) 7657 / 88-0
Fax: +49 (0) 7657 / 88-333

www.framo-morat.com
[email protected]

21

Linear actuator Mini 0
Spare parts list
DC, transmission 1:1

80

82

83

84

Part name
Article-No.
DC field .............................................................................................................. Serial-Nr.
DC armature .......................................................................................................8-2000-21.00
Bronze-carbon ....................................................................................................8-2000-10.05
Brush holder ....................................................................................................... 8-2000-10.03
Jack .................................................................................................................... 8-2000-10.04

D8-20-121e/01.06

Item
80
81
82
83
84

81

Subject to technical changes
Framo Morat GmbH & Co. KG
Höchst 7 • D-79871 Eisenbach

Tel.: +49 (0) 7657 / 88-0
Fax: +49 (0) 7657 / 88-333

www.framo-morat.com
[email protected]

7

Linear actuator Mini

D8-20-107e/01.06

Operating
Manual

Subject to technical changes
Framo Morat GmbH & Co. KG
Höchst 7 • D-79871 Eisenbach

Tel.: +49 (0) 7657 / 88-0
Fax: +49 (0) 7657 / 88-333

www.framo-morat.com
[email protected]

8

Linear actuator Mini
Installation and operating instructions
1.0 Safety precautions
• Please read all documents carefully before assembling and putting into operation Strictly
follow the instructions of this operating manual.
• Only trained personnel should perform the installation, electrical connection and
operational work.
• Please follow the technical operating data and instructions attached to the actuator.
• Please secure movable parts against unintended contact Failings during the set-up can
cause injuries. The manufacturer explicitly states that this is the user's responsibility.
• Do not modify the actuator. This can lead to additional hazards and will result in nonliability.
• Do not block the motor during stroke movement.
• Never overload the motor; stroke force and duty cycle cannot exceed the levels indicated
on the name plate. Disregarding the warnings can cause serious damage to the actuator.

• Before working on electrical lines, ensure that the electricity supply is disrupted and
secured against unintended turn-on.
• Connect the actuator only to a circuit with working protective ground wire.
• It is imperative to read the respective electrical connection diagrams.
• Do not touch the actuator during operation, it can reach temperatures of up to 90°C, failure
to abide may result in burns.

1.1 Conditions of use
Only use the actuator to operate machinery, apparatuses and equipment where direct or indirect
endangerment of persons is eliminated and the ambient temperature is -20°C up to 60°C.
The transport of passengers is not permitted without first consulting the manufacturer (or
responsible representative).
If direct or indirect endangerment of persons cannot be eliminated, additional mandatory measures
(cover, barrier, etc.) need to be implemented minimizing the risk potential accordingly.

D8-20-108e1/11.06

Do not use the actuator in dangerously explosive areas. Our actuators are certified according to
directive 94 / 9 / EG (ATEX 95) and have the following symbols (optional):

EEx II 3D,

bck II T5

Please ensure that the actuator cannot be overloaded.
Subject to technical changes
Framo Morat GmbH & Co. KG
Höchst 7 • D-79871 Eisenbach

Tel.: +49 (0) 7657 / 88-0
Fax: +49 (0) 7657 / 88-333

www.framo-morat.com
[email protected]

9

Linear actuator Mini
2.0 Accessories
The installation and operating instructions include the following:
1. Brochure
2. Technical description
3. Electrical connection diagram
It is attached to the drive in a protective envelope when supplied.
The documentation is available in German and English.
3.0 Installation, attaching parts and electrical start-up
3.1 Installation and attaching parts
Always wear protective footwear during transport and assembly. A falling actuator can cause
injuries. Assemble the actuator without rigging. Do not push or strike when assembling attaching
parts.
The strength category of the fixing bolts must be at least 8.8.

3.2 Electrical start-up
• Before start-up ensure that the electricity supply is disrupted and secured against
unintended turn-on.
• Connect the actuator only to a circuit with working protective ground wire.
• Carefully read the wiring diagram and pay attention to the correct operating voltage (see
name plate).
• All external cables have to be connected according to the wiring diagram. The actuator can
be destroyed, if limit or thermal motor protection switches are not connected. If the
actuators thermal protection responds, it must be totally switched off with allowance to cool
down (Break contact element).
Attention!
When temperatures decline the actuator will automatically resume operation (bimetal).
• Determine the lifting stroke direction by using cyclic operation mode. To reverse the lifting
direction switch two supply lead phases.
• IP 54 is the standard protection class for all Framo linear actuators.

4.0 Important notices
4.1 Piston rod blocking

4.2 Special safety equipment
By using a cushioned connection head or a force dependent shut-off (see options), the actuator can
achieve a high safety standard. Generally, enough safety features should be included when
choosing the actuator size.
Subject to technical changes
Framo Morat GmbH & Co. KG
Höchst 7 • D-79871 Eisenbach

Tel.: +49 (0) 7657 / 88-0
Fax: +49 (0) 7657 / 88-333

www.framo-morat.com
[email protected]

D8-20-109e/01.06

Piston rod blocking through excessive stroke force or permanent stop forcing can damage the
actuator!

10

Linear actuator Mini
4.3 Ambient temperatures, condensate
Consult the manufacturer if the actuator operates in environmental temperatures below 0°C.
Delayed start-up performance must be expected with minus temperatures. In the minus
temperature range suitable connection cables have to be used.
Constantly changing temperatures facilitate condensate formation. This is also the case when used
outside of buildings or in high humid environments. The default application of condensation holes (ø
2 mm) by specifying the respective installation position (combined with humidification seal coating
for rotor and stator) causes significant improvement.
Attention!
The condensation holes will impact the protection class (IP65).
For low temperature applications constant unit heating is necessary. Please contact the
manufacturer for details.
Do not stop the actuator by reversing the mains polarity, this will shorten the durability significantly.

4.4 Operating temperature
Consult the manufacturer if the actuator's temperature exceeds 90°C despite correct use. A defect
could be possible.

4.6 Lubrication loss:
If a defect should cause a loss of lubrication, the floors will be slippery as grease might spill
on the floor! Caution, danger of injury!
Under certain conditions an adverse effect on the environment is possible.

4.7 Self-locking ability
The self-locking ability depends on spindle pitch, the surface quality of the spindle/nut, the sliding
speed, lubrication and temperature. We distinguish between dynamic (out of motion) and static
(stationary) self-locking.
Vibrations can eliminate self-locking.
A certain number of factors such as lubrication, sliding speed and load can also create such
favorable sliding characteristics that the self-locking is negatively impacted. A theoretically selflocking spindle cannot therefore replace a brake. Therefore it is impossible to assume guarantee
obligations regarding self-locking.
Important: Self-locking is not intended to satisfy security-related characteristics!

D8-20-110e/01.06

To minimize additional dangers, observe the usual care for technical products.

Subject to technical changes
Framo Morat GmbH & Co. KG
Höchst 7 • D-79871 Eisenbach

Tel.: +49 (0) 7657 / 88-0
Fax: +49 (0) 7657 / 88-333

www.framo-morat.com
[email protected]

11

Linear actuator Mini
5.0 Maintenance and lubrication
The drives have long-term lubrication and are maintenance-free. The actuator's durability depends on the
actual situation (e.g. ambient temperature, force, stroke speed, duty cycle and environmental impact).
Faulty actuators can only be opened and repaired in our factory, otherwise all warranty claims against
Framo Morat GmbH & Co. KG will be void.
5.1 Warranty and repair
All actuators pass through a 100% test run before dispatch and are checked according to order data
and marked with the CE sign. During the warranty period, the actuator must not be opened. Any
disassembly releases the manufacturer of any guarantees.
If repairs are necessary, send the unit to the manufacturer or to the appropriate representative. At
extra cost, the manufacturer can dispatch a service technician on short notice.
6.0 End of service life
6.1 If the service life of the product has ended you can send it to the manufacturer for reconditioning.

D8-20-111e/01.06

6.2 If you would like to dispose of the actuator, you have to find an environmentaly friendly way and
abide by all legal regulations.

Subject to technical changes
Framo Morat GmbH & Co. KG
Höchst 7 • D-79871 Eisenbach

Tel.: +49 (0) 7657 / 88-0
Fax: +49 (0) 7657 / 88-333

www.framo-morat.com
[email protected]

55

Linear actuator Mini

D8-20-155e/01.06

Connection
diagrams

Subject to technical changes
Framo Morat GmbH & Co. KG
Höchst 7 • D-79871 Eisenbach

Tel.: +49 (0) 7657 / 88-0
Fax: +49 (0) 7657 / 88-333

www.framo-morat.com
[email protected]mo-morat.com

56

Linear actuator Mini

0

D8-20-156e/04.06

Connection diagram Version AC

Subject to technical changes
Framo Morat GmbH & Co. KG
Höchst 7 • D-79871 Eisenbach

Tel.: +49 (0) 7657 / 88-0
Fax: +49 (0) 7657 / 88-333

www.framo-morat.com
[email protected]

Linear actuator Mini

57

0

D8-20-157e/04.06

Connection diagram version D.C. with permanent magnetic field

Subject to technical changes
Framo Morat GmbH & Co. KG
Höchst 7 • D-79871 Eisenbach

Tel.: +49 (0) 7657 / 88-0
Fax: +49 (0) 7657 / 88-333

www.framo-morat.com
[email protected]

58

Linear actuator Mini

01, 1, 2

D8-20-158e1/11.06

Connection diagram version A.C.

Subject to technical changes
Framo Morat GmbH & Co. KG
Höchst 7 • D-79871 Eisenbach

Tel.: +49 (0) 7657 / 88-0
Fax: +49 (0) 7657 / 88-333

www.framo-morat.com
[email protected]

Linear actuator Mini

59

01, 1, 2, 3

D8-20-159e1/11.06

Connection diagram version 3-phase

Subject to technical changes
Framo Morat GmbH & Co. KG
Höchst 7 • D-79871 Eisenbach

Tel.: +49 (0) 7657 / 88-0
Fax: +49 (0) 7657 / 88-333

www.framo-morat.com
[email protected]

1

Linear actuator Mini

D8-20-101e/01.06

Technical
Description

Subject to technical changes
Framo Morat GmbH & Co. KG
Höchst 7 • D-79871 Eisenbach

Tel.: +49 (0) 7657 / 88-0
Fax: +49 (0) 7657 / 88-333

www.framo-morat.com
[email protected]

2

Linear actuator Mini
Technical description
1.Design
Framo linear actuators are electromechanical drives which convert the rotating motion of the integrated electric
motor into a linear forward or backward motion.
Framo actuators are primarily designed for industrial use. They are particularly robust and equipped with many
safety standards. All installation positions are permissible.
Special technical features are:
Complete stainless steel housing (except Mini 3) which protects all mechanical and electrical parts (including
terminal board). Only the connecting cables and the movable piston rod needs to be retracted.
2. Piston rod
The stainless steel piston rod is ground (except for Mini 3).
The piston rod is not locked to prevent torsion. The customer must provide a locking facility with the part that is
moved.
3. Motors
The built-in electric motor has a hollow rotor shaft which permits the lifting spindle and the piston rod to be guided
through it and therefore allows particularly short dimensions.
Depending on the size, the motors can be delivered with three-phase, single-phase or direct current (special voltage
on request). With the exception of the direct current motor, all motors are fitted with a thermal protection switch
(trigger temperature +125°C. The motor winding is ISO class B. Standard protection class: IP 54. The three-phase
motors can be connected to 3 x 230 or 3 x 400 V AC.
3.1 DC actuators
Separate power tables are available for DC actuators.
If the DC motor operates as an individual unit, a suitable EMC interference suppressor shall be provided close to the
motor terminal drive. For unit installation, the unit has to be suppressed.
For this reason direct interference elimination is not always necessary and the interference suppressor is not
located in the drive, therefore the customer has to plan for this possible requirement.
4. Duty cycle
The indicated duty cycles relate to a maximum load time of 10 minutes, a maximum ambient temperature of 40°C
and a maximum installation height of 1000 m above sea level.
5. Gears, stroke lengths
Implementation without gears or the installation of 1- to 3-stage planetary gears allows the selection of different
stroke speeds for every type (0.5 to 181 mm/s). Depending on the type, special travel lengths of 10 to 800 mm are
possible.
6. Spindle

D8-20-102e/01.06

Framo Mini actuators with a rolled acme lead screw are predominantly dynamically self-locking.

Subject to technical changes
Framo Morat GmbH & Co. KG
Höchst 7 • D-79871 Eisenbach

Tel.: +49 (0) 7657 / 88-0
Fax: +49 (0) 7657 / 88-333

www.framo-morat.com
[email protected]

3

Linear actuator Mini
7. Limit switches
A limit switch is incorporated for each stroke-end position. The Mini 01 up to Mini 3 are also equipped with a safety
limit switch (forced separator) which protects the actuator against destruction in case of faulty wiring or if a limit switch
fails. The limit switches are installed in a fixed position and cannot be adjusted.
8. Brake
At stroke speeds of more than 20 mm/s, three-phase and single-phase actuators should be equipped with a brake
because of their tendency to overrun (DC actuators see performance table notes).
We also recommend that a brake is installed if the drive has a spindle that is not self-locking and if the demands on
disconnection accuracy are exacting. A magnetic-electric single-disc brake is available for all sizes.
9. Connection cables
The standard actuators are supplied with external connection cables (1m length). Longer or special cables are
available upon request, e.g. for low temperatures or with shielding.
10. Fixing options, connection heads
Flange, foot and attachment bolts can be supplied in addition to standard attachment configuration A (attachment
eye to eye). The drive can also be delivered with different connection heads (see dimensional drawings).
11. Paint coating (only Mini 3)
The standard drive housing (tubular steel) is sprayed with a special acrylic resin lacquer (RAL 7031, bluish grey)
which is also suitable as primer for other lacquers (artificial or acrylic).
12. Reliability and quality assurance
Every actuator is produced according to order and tested under nominal load conditions. A proven modular system
makes it possible to produce a large number of different models and to adapt them to customer requirements. All
individual parts and sub-assemblies are generally kept in stock.
13. Conditions of use

D8-20-103e/01.06

The conditions of actuator use prohibit the movement of loads whereby persons can be directly or
indirectly endangered.
The application of actuators in equipment intended to transport passengers is not permitted without first
consulting the manufacturer (or responsible representative).
In this context we refer to EU Machinery Directive 98 / 37 / EC and the Act on Technical Equipment
(Equipment Safety Act) where the user is responsible for the implementation of "protective
guards/barriers" to prevent touching (crushing hazard) during operation.
This also applies for the application of actuators with suspended loads where persons can be
endangered.

Subject to technical changes
Framo Morat GmbH & Co. KG
Höchst 7 • D-79871 Eisenbach

Tel.: +49 (0) 7657 / 88-0
Fax: +49 (0) 7657 / 88-333

www.framo-morat.com
[email protected]

4

Linear actuator Mini
14. Special safety instructions
It is possible to bring the actuator to a higher safety standard by using the following options:
1. cushioned connection head
2. force-dependent shut-off
Generally, enough safety features should be included when choosing the actuator size.
15. Self-locking ability
The self-locking ability depends on the spindle pitch, the surface quality of the spindle/nut, the sliding
speed, lubrication and temperature. We distinguish between dynamic (out of motion) and static
(stationary) self-locking.
Vibrations can eliminate self-locking. A certain number of factors such as lubrication, sliding speed and
load can also create such favorable sliding characteristics that the self-locking is negatively influenced.
A theoretically self-locking spindle cannot therefore replace a brake. Therefore it is impossible to
assume guarantee obligations regarding self-locking.
Important: Self-locking is not intended to satisfy security-related characteristics!
To minimize additional dangers, observe the usual care for technical products.

16. Options
The following options allow individual applications:
1. Force-dependent shut-off (as protection for block movement or if a preset stroke force is exceeded)
2. Cushioned connecting head (e.g. approaching a permanent stop)
3. Adjustable connection head (for small changes to the attachment position)
4. Adjusting ring on piston rod (for simple retracting position adjustment)
5. Brake (for precise switch-off and non-self-locking actuators)
6. Mounting angles in combination with fixing version D (attachment bolts)
7. Integrated helical potentiometer (for travel monitoring and/or position control)
8. Rotary pulse encoder (for digital pulse processing for position and speed control)
9. Different fixing possibilities (installation conditions can be taken into account)
10. Humidification seal coating of rotor and stator and/or condensation hole (if there is danger of condensation).
11. Explosion proof according to directive 94 / 9 / EG (ATEX 95)

D8-20-104e/01.06

12. Connection cable motor and/or helical potentiometer shielded (for frequency converter operation etc.)

Subject to technical changes
Framo Morat GmbH & Co. KG
Höchst 7 • D-79871 Eisenbach

Tel.: +49 (0) 7657 / 88-0
Fax: +49 (0) 7657 / 88-333

www.framo-morat.com
[email protected]

5

Linear actuator Mini
Limit switches

2 limit switches (two-way contact) arranged below 45° to each other.
Force separated safety limit switch (not for Mini 0) lying in-between

Housing
Front cover

Switching jack
'Extended' position

Switching jack
'Retracting' position

Piston rod

Terminal board with
Connector

System advantages:
• No continuous contact of limit switch and piston rod
• Improved insulation and more stability, no switching grooves
• End of stroke damping through installed spring
• Better control of the piston rod

Grub screws

D8-20-105e/01.06

Adjusting ring for retracted position

Adjusting ring

Subject to technical changes
Framo Morat GmbH & Co. KG
Höchst 7 • D-79871 Eisenbach

Tel.: +49 (0) 7657 / 88-0
Fax: +49 (0) 7657 / 88-333

www.framo-morat.com
[email protected]

The Professional Choice
– in fluid management

LAC
With AC motor – adapted for industrial use
Installation and servicing manual
SE

GB

DE

FR

ES

Komponentförteckning, Tillval/Tillbehör
Inledning ........................................................................................................................... 1
Säkerhetsföreskrifter ......................................................................................................... 2
Beskrivning ....................................................................................................................... 4
Installation ......................................................................................................................... 5
Handhavande .................................................................................................................... 7
Förebyggande underhåll ................................................................................................... 8
Underhåll ........................................................................................................................... 9
Tekniska data .................................................................................................................. 11
Försäkran om överensstämmelse ................................................................................... 12
Part list, Options/Accessories
Introduction ..................................................................................................................... 13
Safety instructions ........................................................................................................... 14
Description ...................................................................................................................... 16
Installation ....................................................................................................................... 17
Handling .......................................................................................................................... 19
Preventive maintenance ................................................................................................. 20
Maintenance ................................................................................................................... 21
Technical specification .................................................................................................... 23
Declaration of conformity ................................................................................................ 24
Komponentenverzeichnis, Sonderzubehör/Zubehör
Einleitung ........................................................................................................................ 25
Sicherheitsvorschriften .................................................................................................... 26
Beschreibung .................................................................................................................. 28
Installation ....................................................................................................................... 29
Bedienung ....................................................................................................................... 31
Vorbeugende Wartung .................................................................................................... 32
Wartung ........................................................................................................................... 33
Technische Daten ........................................................................................................... 35
Übereinstimmungserklärung ........................................................................................... 36
Liste des composants, Équipements en option/Accessoires
Introduction ..................................................................................................................... 37
Consignes de sécurité .................................................................................................... 38
Description ...................................................................................................................... 40
Installation ....................................................................................................................... 41
Consignes d’emploi ......................................................................................................... 43
Entretien préventif ........................................................................................................... 44
Entretien .......................................................................................................................... 45
Caractéristiques techniques ............................................................................................ 47
Déclaration de conformité ............................................................................................... 48
Lista de componentes, Equipamientos opcionales/Accesorios
Introducción .................................................................................................................... 49
Instrucciones de seguridad ............................................................................................. 50
Descripción ..................................................................................................................... 52
Instalación ....................................................................................................................... 53
Modo de empleo ............................................................................................................. 55
Mantenimiento preventivo ............................................................................................... 56
Mantenimiento ................................................................................................................ 57
Características técnicas .................................................................................................. 59
Declaración de conformidad ........................................................................................... 60

A

B

D

E

F

G

H

D

I

C
Komponentförteckning
A
B
C
D
E
F
G
H
I
*

Kylelement
Pluggar och gummistålbrickor
Fötter
Fläkthus
Fläktenhet*
Motorfäste
Fläktgaller
Elmotor
Fläktenhet med ytterrotormotor
Utförandet, fast eller löst nav, varierar med
kylarmodell.

A
B
C
D
E
F
G
H
I
*

Cooler matrix
Plugs and rubber steel washers
Support
Fan housing
Fan unit*
Motor attachment
Fan guard
Electric motor
Fan unit with outer rotor motor
The design, fixed or loose hub, is depending on
type of cooler.

A
B
C
D
E
F
G
H
I
*

Kühlelement
Stopfen und Gummistahlscheiben
Füße
Lüftergehäuse
Lüftereinheit*
Motorhalterung
Schutzgitter
Elektromotor
Lüftereinheit mit Außenrotormotor
Die Ausführung mit starrer oder loser Nabe hängt
vom Kühlermodell ab.

C

A

B

C

Liste des composants

Part list
A
B
C
D
E
F
G
H
I
*

Komponentenverzeichnis

Radiateur
Bouchons et joints à lèvres
Pieds
Caisson ventilateur
Hélice complète*
Support moteur
Grille ventilateur
Moto-ventilateur
Unité ventilateur avec moteur à rotor externe
La conception, moyeu fixe ou non fixe, varie
suivant le modèle d’échangeur.

Lista de componentes
A
B
C
D
E
F
G
H
I
*

Radiador
Tapón ciego con junta metalbuna
Patas
Caja del ventilador
Ventilador completo*
Suporte del motor
Rejilla de protección
Motor eléctrico
Unidad compacta moto-ventilador
El asiento del ventilador, fijo o desmontable,
dependerá del tipo de intercambiador.

A

B

C

F

D
E

Tillval
A
B
C
D
E
*

Stenskydd
Dammskydd
S-Bypass, enpassage*
T-Bypass, tvåpassage*
Termokontakt
Kan fås som tryckstyrd eller temperatur- och
tryckstyrd bypass.

G

Tillbehör
F
G

Lyftöglor
Vibrationsdämpare

Équipements en option

Options
A
B
C
D
E
*

Stone guard
Dust guard
S by-pass, single-pass
T by-pass, two-pass
Thermo contact
Pressure controlled or temperature and pressure
controlled by-pass valves are available.

A
B
C
D
E
*

Accessories
F
G

Lifting eye
Vibration dampener

Accessoires
F
G

Anneaux de levage
Patins antivibratoires

A
B
C
D
E
*

Rejilla protectora para piedras
Filtro antipolvo
By-pass tipo S, modelo de 1 paso*
By-pass tipo T, modelo de 2 pasos*
Termostato
Disponible como by-pass controlado por presión o
por temperatura y presión.

F
G

Cáncamos de elevación
Silent blocs

Sonderzubehör
A
B
C
D
E
*

Steinschutz
Staubschutz
S-Bypass, Einzeldurchlauf*
T-Bypass, Doppeldurchlauf*
Thermoschalter
Mit Drucksteuerung oder Temperatur- und
Drucksteuerung lieferbar.

Equipamientos opcionales

Zubehör
F
G

Hebeösen
Vibrationsdämpfer

Grille de protection
Filtre antipoussière
Bypass type S, modèle 1 passe*
Bypass type T, modèle 2 passes*
Thermocontact
Disponible comme bypass commandé par
pression ou par température et pression.

Accesorios

1

2
A

C

B

D

3
½A
½A
A

4
B
C

D
A

5

B
A
D

6

7

1

2

8

9

3
Blå
Blue
Blau
Bleu
Azul
4
Gul/grön
Yellow/green
Gelb/grün
Jaune/vert
Amarillo/verde

Svart
Black
Schwarz
Noir
Negro
Brun
Brown
Braun
Marron
Maron

U1 = Svart
Black

Schwarz
Noir
Negro

U2 = Grön
Green

Grün
Vert
Verde

V1 = Blå
Blue

Blau
Bleu
Azul

V2 = Vit
White

Weiß
Blanc
Blanco

W1 = Brun
Brown

Braun
Marron
Maron

W2 = Gul
Yellow

Gelb
Jaune
Amarillo

U1 = Svart
Black

Schwarz
Noir
Negro

U2 = Grön
Green

Grün
Vert
Verde

V1 = Blå
Blue

Blau
Bleu
Azul

V2 = Vit
White

Weiß
Blanc
Blanco

W1 = Brun
Brown

Braun
Marron
Maron

W2 = Gul
Yellow

Gelb
Jaune
Amarillo

1)

2)

3)
4)

Y-koppling (3x400 V)
Y-connection (3x400 V)
Y-Anschluss (3x400 V)
Connexion en Y (3x400 V)
Conexión en Y (3x400 V)

D-koppling (3x230 V)
D-connection (3x230 V)
D-Anschluss (3x230 V)
Connexion en D (3x230 V)
Conexión en D (3x230 V)

10

11

12

Y-koppling
Y-connection
Y-Anschluss
Connexion en Y
Conexión en Y

D-koppling
D-connection
D-Anschluss
Connexion en D
Conexión en D

13

14

15

A

B

16

17

Introduction
The purpose of this manual is to serve as
a reference guide for installation,
maintenance and operation of the LAC
series of air oil coolers.
Keep the manual at hand. A lost manual
should be replaced as soon as possible.
For optimum performance and in order
to prevent incorrect use, please read this
manual carefully and observe all safety
precautions prior to putting the air oil
cooler into service.
Installation and maintenance work
should only be carried out by qualified
personnel. Oiltech/Olaer reserve the
right to make technical alternations
without notice.

Use
The LAC-series of air oil coolers is
designed to cool hydraulic fluids in
systems for industrial applications.

13

Warranty and claims
In the event of breakdown, consult your
local Olaer office. Olaer/Oiltech shall
not be held responsible for any
consequences due to modification and/or
variation made by the customer.

Safety instructions
The installation contractor as well as the
user should be aware of, understand and
observe all safety precautions in this
manual, including any information
mentioned on labels fixed to the product.

Definition of Safety Warning
Levels
All precautions concerning personal
safety are classified as per below,
depending on how severe the
consequences of an incident could be.
Danger
This alerts you to an action or
procedure that, if performed
improperly, will produce bodily
harm or death.
Caution
This alerts you to an action or
procedure that, if performed
improperly, is likely to produce
bodily harm or death.

Important
This alerts you to an action or
procedure that, if performed
improperly, is likely to result in
damages to the product, process or
environment.
Additional information is marked as
follows.
Note!

This alerts you to important
information related to the text in
a paragraph.

Overall instructions
Lifting
Caution
Risk of bodily injury. To prevent
physical harm when lifting the unit,
ensure correct lifting technique.
Make sure that all lifting devices are
free from damage and approved for
the weight of the air oil cooler.
Installation

Precaution
This alerts you to an action or
procedure that, if performed
improperly, is likely to cause an
accident with physical harm.

Danger
Electrical shock hazard. All
electrical connections must be
made by a qualified electrician!

Notifications concerning other safety
issues (property, process or environment)
and maintenance work are classified as
follows.

14

Operation, handling and
maintenance
Caution
Risk of bodily injury. Disconnect the
motor power supply prior to
maintenance.

Important!
Static electricity. Fans generate static
electricity. Do not put sensitive
devices (electronics etc.) in the
immediate vicinity of the air oil cooler.
Antistatic fans are available on
request.

Caution
Risk of bodily injury. Before
disconnecting the hydraulic
connections, make sure the system
is depressurized.

Note!

Use hearing protection when
standing close to an operating
air oil cooler for long periods of
time.

Caution
Risk of severe burns. This indicates
danger from high temperature
surfaces. The oil cooler could
become extremely hot during
operation. Always make sure the
cooler is cool before touching.

The warning label shown below is fitted
to the air oil cooler at delivery. Always
replace a damaged or missing label.
• Caution! High temperature surface!
Use hearing protection! Rotating
fan!
(P/N 500029 - 70x30 mm or P/N
5000291 - 120x50 mm)
See Figure 1.

Warning label

Precaution
Risk of bodily injury. If the air oil
cooler is fitted with a thermo
contact, the fan will start
automatically when the preset
temperature has been reached. Be
careful when standing close to
rotating units.
Precaution
This indicates a toxic hazard. To
prevent bodily injury, damage to
property or environment, used fluid
should be collected and taken to a
special depôt.

15

Description
Principally the air oil cooler consists of a
cooler matrix, an AC-motor, a fan, a fan
housing and a fan guard. Depending on
electric motor size, the air oil cooler is
equipped with a motor bracket.
Different motor types are used on the
LAC-series of air oil cooler. Small
cooler fans are fitted with a single phase
or three phase outer-rotor motor. The fan
on larger air oil coolers is fitted with a
standard three phase asynchronous
inner-rotor, which meets the IEC 72 and
EN 60034 requirements.
The electrical motor should be connected
to the electricity supply system
according to instructions. See “Electrical
connection”. Connect the cooler matrix
to the hydraulic system using hydraulic
hoses.

Manufacturers type plate
The type plate of the air oil cooler is
fitted on the fan housing. See Figure 2.
The type plate contains the following
information:
A Part number
B Designation
C Serial number
D Date of delivery (year and week, e.g.
0418, i.e. year 04 and week 18)
Replace a damaged or missing type plate
as soon as possible.

If the air oil cooler is fitted with a
thermo contact, the fan will start
automatically when the preset temperature has been reached.
Acoustic pressure could reach
50-90 dB(A) at 1 m distance depending
on air oil cooler size.
For information such as capacity,
nominal voltage and protection standard
etc., see marking sign on the motor.
Temperature for the electric motor:
-20 °C - +40 °C.
Refer to Technical specification for
maximum permitted static working
pressure, maximum permitted dynamic
pressure, maximum permitted fluid
temperature in the cooler matrix, etc.

16

Installation
Lifting

Mounting

Caution
Risk of bodily injury. To prevent
physical harm when lifting the unit,
ensure correct lifting technique.
Make sure that all lifting devices are
free from damage and approved for
the weight of the air oil cooler.

Precaution
Risk of bodily harm. Make sure that
the air oil cooler is securely fixed.
The air oil cooler can be mounted in any
position. However, an upright installation standing on its feet is recommended.
A free space corresponding to a minimum of half the height of the matrix (A)
should be available in front of and
behind the air oil cooler to allow for
good air flow, i.e. optimal cooling
capacity as well as low acoustic power
level. See Figure 3.

Air oil coolers as from size 033 can
accommodate lifting eyes. Lifting eyes
are available from Oiltech/Olaer on
request.

Inappropriate location of the air oil
cooler could generate increased noise
level and reduce cooling capacity.
Consult your local Olaer office.

17

Connection of cooler matrix
Connect the cooler matrix using flexible
hydraulic hoses both to and from the
cooler. Make sure that all connections
and hoses are sized according to the
system pressure, flow, temperature and
fluid.
Connect the cooler matrix as illustrated
below. See Figure 4 or Figure 5.
A Inlet.
B Outlet for standard and S by-pass,
single-pass.
C Outlet for T by-pass, two-pass.
D Thermo contact connection.
Dimensions on connections are cooler
matrix size dependent.
Maximum permitted fluid temperature in
the cooler matrix: 120 °C.
Flow chart, see Figure 6.
Important
The cooler matrix is designed for
maximum dynamic working pressure
14 bar. When the cooler is installed
in a return line, there should be no
pressure spikes. If this is not
possible, an offline cooling system
should be used.

Electrical connection
Danger
Risk of electrical shock. All
electrical connections must be
made by a qualified electrician!
Prior to connecting the motor to the
electricity supply system, make sure the
information on the motor label

corresponds to the line voltage and
frequency. The motor should be installed
according to general and electrical safety
rules and should be made by a qualified
electrician.
Precaution
Be careful when connecting.
Improperly made connections,
damaged cables, etc. could cause
components to become live or
result in the incorrect direction of
rotation of the electric motor.
• Connection of a single phase outerrotor motor: Connect the live to L
(blue), neutral to N (black) and
ground to PE (yellow/green). See
Figure 7.
• Connection of three phase outerrotor motor. See Figure 8 or
Figure 9.
• Connection of three phase innerrotor motor. See Figure 10.
Example for motor:
220-240 V D/380-420 V Y.
The direction of rotation of three phase
motors is altered by changing connection
of two phases.
If the cooler is fitted with a thermo
contact, use a relay if the current load
exceeds the maximum load for the
thermo contact.
Note!

A motor overload protection is
recommended.

Note!

Some motors are fitted with
plugged holes, which can be
used for draining condensed
water.

18

Handling
Prior to initial start-up

During operation

Check that the air oil cooler is securely
fixed and correctly connected.

Caution
Risk of severe burns. The air oil
cooler could become extremely hot
during operation. Make sure that
the air oil cooler is cool before
touching.

We recommend that you proceed as
follows prior to start-up:
1 Run the air oil cooler with the
system fluid.
2 Filter the fluid after passing through
the cooler.

Maximum permitted fluid temperature in
the cooler matrix is 120 °C.

See Technical specification for
recommended fluid compatibility.

Do not overload the electric motor. See
label on the electric motor.

Prior to start up

The cooler matrix is designed for
maximum allowed dynamic working
pressure 14 bar.

Check:
• that all air oil cooler parts are free
from damages
• that the fan rotates freely (use hand
force)
• that all hydraulic connections are
tight
• that the inside of the fan housing is
free from objects that could be
thrown around and cause bodily
injury or damage to property.

Note!

At start-up
Check:
• that the direction of rotation of the
fan and the air flow corresponds to
indications on the fan housing
• that the air oil cooler is free from
abnormal noise and vibrations.

19

Use hearing protection when
standing in the immediate
vicinity of an operating air oil
cooler for long periods of time.

Preventive maintenance
Preventive maintenance work must be
carried out at regular intervals.
Make sure:
• that there is no abnormal noise or
vibrations
• that air oil cooler is securely fixed
• that the cooler matrix is clean debris will reduce the cooling
capacity
• that the air oil cooler is free from
damage, replace damaged
components
• that the air oil cooler is free from
leaks
• that warning labels are in good
condition, replace any damaged/
missing label immediately.

Cooler matrix
The air fins of the matrix can be cleaned
by blowing through with compressed air.
If necessary a high-pressure washing
system and degreasing agent can be
used. When using a high-pressure
washing system point the jet parallel to
the air fins. See Figure 11.
Fan housing
Remove the cooler matrix when cleaning
the inside of the fan housing.
To clean the inside of the fan housing,
use compressed air. If necessary a
degreasing agent can be used.
Blow with compressed air from the
electric motor side through the fan
guard.

Annually: Check the electrical installation. This may only be made by a
qualified electrician.

Cleaning
Danger
Risk of bodily injury. Prior to
cleaning, disconnect all motor
power supplies.
Note!

The air oil cooler might be hot.

Air oil cooler
When cleaning the exterior of the cooler,
for instance using water, disconnect all
power supplies. Be aware of the electric
motor protection standard.

20

Maintenance
Removing the electric motor
and the fan

Dismounting the cooler
matrix

1
2
3
4
5

6

Warning
Risk of severe burns. The air oil
cooler could become extremely hot
during operation. Make sure the air
oil cooler is cool before touching.

Warning
Risk of severe burns. The air oil
cooler could become extremely hot
during operation. Make sure the air
oil cooler is cool before touching.

Warning
Risk of bodily injury. Disconnect the
motor power supply prior to
maintenance.

Warning
Risk of bodily harm. Prior to
maintenance, disconnect the
electric motor power supply.
The fan is balanced together with the
hub at delivery.

Turn off the system.
Disconnect the electric motor power
supply.
Make sure that the system is
depressurized.
Disconnect the flexible hydraulic
hoses from the cooler matrix.
Unscrew the screws with washers
fixing the cooler matrix to the fan
housing. See Figure 12.
Remove the cooler matrix.

Note!

1
2
3
4

Mounting of the cooler
matrix
1
2
3

4
5

Locate the cooler matrix.
Fit the cooler matrix to the fan
housing. See Figure 12.
Connect the flexible hydraulic hoses
to the cooler matrix. See Figure 4
and Figure 5.
Connect the electric motor power
supply
Proceed to Prior to start-up and At
start-up.
21

5

Some fan hubs are fixed. See
Figure 14, and some are loose
Figure 15 A and Figure 15 B.
Turn off the system.
Disconnect the electric motor power
supply.
Secure the electric motor.
Unscrew the screws with washer
fixing the motor attachment to the
fan housing. See Figure 13. If the air
oil cooler is fitted with a motor
bracket, unscrew the screws with
washers fixing the motor bracket to
the feet.
Unscrew the screw with washer
fixing the fan to the motor shaft.
See Figure 14. Pull with care the fan
and hub from the motor shaft. Use a
pulley if required.

6

7

Unscrew the screws fixing the motor
to the motor attachment.
See Figure 16.
If the air oil cooler is fitted with
motor bracket, unscrew the screws
with washers fixing the motor to the
motor bracket.
Remove the motor.

If further dismounting of the fan is
required, label all details to ensure
correct mounting, first of all with regard
to balance and direction of rotation. See
Figure 17.

Mounting of the electric
motor and fan

6

Adjust the fan guard and motor and
secure the motor attachment in the
fan housing with screws.
See Figure 13.
Secure the bracket with screws.
7 Make sure that the fan is centred and
rotates freely (using hand force).
If required, adjust the location of the
fan guard and motor.
8 Check the screws for tightness.
9 Connect the electric motor power
supply.
10 Proceed to Prior to start-up and At
start-up.

Note!

1

2
3

4
5

There are models with fixed hub
and models with detachable hub
(see Figure 15 A and
Figure 15 B).
If the air oil cooler is fitted with
motor bracket, fit the motor to the
motor bracket.
Secure the electric motor to the
motor attachment. See Figure 16.
Fit the hub in the groove against the
key on the motor. Lube the hub with
ethanol and secure the fan/hub to the
motor shaft. If required, knock
carefully with e.g. a rubber mallet.
Use Loctite on the screw and secure
the fan/hub on the motor shaft with
screws. See Figure 14.
Make sure that the fan is fitted to the
motor shaft without too much play
Place the motor attachment with fan,
fan guard, motor and bracket, if any,
in the fan housing.

22

Technical specification
For further technical specification, refer to separate Technical data sheet, LAC air oil
cooler.

Cooler matrix
Maximum static working pressure:

21 bar

Maximum dynamic working pressure:

14 bar
Tested according to ISO/DIS 10771-1

Heat transfer allowance:

±6%

Maximum fluid temperature
in the cooler matrix:

120 °C

Fluid compatibility
Mineral oil:

HL/HLP according to DIN 51524

Oil/water emulsion:

HFA, HFB according to CETOP RP 77H

Water glycol:

HFC according to CETOP RP 77H

Phosfatester:

HFD-R according to CETOP RP 77H

Material
Cooler matrix:

Aluminium

Fan housing:

Steel

Fan blades/hub:

Glass fibre reinforced polypropylene/
aluminium

Fan guard:

Steel

Other parts:

Steel

Surface treatment:

Electrostatic powder coated.

LAC air oil coolers could have different material and surface treatments.

23

24

Olaer Industry

Olaer Mobile

Olaer Energy

Olaer Oil & Gas

Olaer Special

Olaer Services

The Olaer Group develops, manufactures and markets products and systems in six business areas.

Global perspective
and local entrepreneurial flair
The Olaer Group is a global player specialising in innovative, efficient system solutions for temperature optimisation and
energy storage. The Group develops, manufactures and markets products and systems for a number of different sectors, e.g.
the aircraft, engineering, steel and mining industries, as well as for sectors such as oil and gas, contracting and transport,
farming and forestry, renewable energy, etc. All over the world, our products operate in the most diverse environments and
applications. One constantly repeated demand in the market is for optimal energy storage and temperature optimisation.
We work at a local level with a whole world as our workplace
– local entrepreneurial flair and a global perspective go hand in
hand. Our local presence, long experience and a wealth of knowledge combine with our cutting-edge expertise to give you the
best possible conditions for making a professional choice.

The Professional Choice – in Fluid Management

Olaer Group Network

THE OLAER GROUP: AUSTRALIA Olaer FCH. Tel: +61 2 9981 6888. AUSTRIA Olaer Austria GmbH. Tel: +43 7229 80306. BELGIUM S.A. Olaer Benelux, Tel: +32 2 466 15 15.
CZECH REPUBLIC Olaer CZ s.r.o. Tel: +42 5 47125 601-8. DENMARK Oiltech DK. Tel: +45 86 69 20 38. FINLAND Oiltech Hydraulics OY. Tel: +358 9 413 755 00.
FRANCE Olaer Industries S.A. Tel: +33 1 41 19 17 00. GERMANY Olaer Industries GmbH. Tel: +49 6842 9204-0. HOLLAND Olaer Nederland B.V. Tel: +31 76 5412453.

NORWAY Oiltech AS. Tel: +47 64 91 11 80. POLAND Oiltech Polska. Tel: +48 22 6738162. SOUTH AFRICA FCH c/o Rolton Products CC. Tel: +27 11 474 3095.
SPAIN Olaer-Oiltech Iberica SAU. Tel: +34 933 368 900. SWEDEN Oiltech AB. Tel: +46 8 636 07 00. SWITZERLAND Olaer (Schweiz) AG. Tel: +41 26 492 70 00.
UK FCH Ltd. Tel: +44 1244 535515. USA Oil Air Hydraulics Inc. Tel: +1 713 937 89 00.

w w w. o i l t e c h . s e

20009201

INDIA FCH India. Tel: +91 802 6533587. ITALY Olaer Italiana S.p.A. Tel: +39 011 991 85 11. KOREA Hyundai Olaer Hydraulic Co. Tel: +82 31 499 0897.

LAC2 011-2-D
Date: 10-02-2009
Your reference: 62008043
Our reference:

Input data:
Hydraulic oil
Oil flow
Max. oil temperature
Air temperature
Altitude
Heat dissipation

Calculated data:
Inlet oil temperature
Outlet oil temperature
Outlet air temperature
Spec. heat dissipation
Oil pressure drop
Air flow
Motor capacity
LpA, 1 m
Protection standard, motor
Weight
Full load current

ISO VG 46
14,0
75
45
0
6,45

73
58
50
0,23
0,052
0,99
1,10
82
IP 55
25
2,5

l/min
°C
°C
m
kW

°C
°C
°C
kW/°C
bar
m³/s
kW
dB(A)
kg
A

Information:
This calculation is based upon more parameters than in catalogue.
Subject to technical alterations.
_______________________________________________________________________________________________________________

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hi-flo®
Extended Surface Multi-Pocket Air Filters

The Camfil Farr Hi-Flo® offers high efficiency
ASHRAE grade filtration to address today's indoor air
quality problems. The Hi-Flo can remove
contaminants such as fumes, smoke, bacteria, fungi,
and virus-bearing droplet nuclei. The Hi-Flo is also
the filter of choice for the removal of nuisance
contaminants such as pollens, paper dust, and other
atmospheric impurities. Hi-Flos are available in
efficiencies of MERV 9, MERV 11, MERV 13 and
MERV 14 when evaluated per ASHRAE Standard
52.2-1999.

High Lofted Air Laid Media

Extended surface filter
with controlled media
spacing (CMS) for longer
life and consistent
lifetime high efficiency

The Camfil Farr Hi-Flo incorporates high lofted air
laid micro fiber glass media to ensure reliable
efficiency throughout the life of the filter. Its small
fiber diameter and uniform lofting results in
consistent sub-micron particle capture and a low
resistance to airflow throughout the life of the filter. A
synthetic micro mesh media backing ensures media
protection and support in turbulent or varying
airflows. The Hi-Flo's particle capture performance
and filter configuration are unaffected by dust loading
and/or humidity.

Controlled Media Spacing
Camfil Farr is the only
manufacturer to offer controlled
media spacing to minimize pocketto-pocket contact, ensure uniform
airflow and allow full utilization of
the media area. The effect results
in the lowest life cycle product cost
for your facility. Your selection of
the length and number of pockets
should be based upon the required
airflow through the system.

Values are Minimum Efficiency Reporting Values (MERVs)
when evaluated per ASHRAE Standard 52.2-1999.

A 5-star rating indicates that this filter performs in the top 20% of all products of similar
construction in the HVAC industry. Factors of consideration include maintained efficiency, energy usage and resistance to air flow. Detailed evaluation information is
available from your Camfil Farr sales outlet or on the web at www.camfilfarr.com.

Camfil Farr

Product sheet

Hi-Flo®

1203 - 0907

Camfil Farr—clean air solutions

Controlled Media Spacing (continued)

Leak-Free Filter Performance

Typical bag filters allow pocket-to-pocket contact,
causing loss of effective media area, non-uniform
airflow and an excessive pressure drop over the
life of the filter. Camfil Farr’s variable length pocket
stitching, through the use of continuous thread
filaments, helps keep as many as 12 individual
pockets in a perfectly aligned V-shaped
configuration. This tapered pocket effect equalizes
the media entrance and exiting areas. Air travels
evenly through the filter at an even media velocity
for uniform dust loading and a maintained low
pressure drop. The benefits include:

Every Camfil Farr Hi-Flo includes a gasket on the
vertical edge of the filter header. In a side-access
housing, filters are mated header-to-header. The gasket
prevents air bypass and ensures that the air filter will
clean all of the air moving through the system.



Increased filter life



Reduced maintenance costs



Minimized fan horsepower requirements



Reduced energy expenditures.

Stitch Sealant & Adhesive Bonding
Camfil Farr completely seals pocket stitching to
eliminate the possibility of
air leakage through the
stitching penetrations.
This unique sealant
maintains a flexibility that
is unaffected by varying
airflows. The media is
also bonded around the
pocket retainers to ensure a strong pocket-toretainer seal and minimizes potential for pocket
failure.
Sure-Clench® Crimp
Each galvanized steel pocket retainer is fastened
with Camfil Farr’s exclusive Sure‑Clench crimp,
creating a positive lock between pockets and
eliminating the possibility of air bypass. The pocket
retainers include rolled edges to prevent damage
to the media area and minimize sharp edges that
may create a hazard to filter installers. Four
retainer clips assist in securing pocket retainers to
the header frame.
Galvanized Steel Header
A box-channel header, of one-piece corrosion
resistant galvanized steel, includes rolled edges to
prevent damage to
the filter media. When
combined with the
Sure-Clench Crimp
and galvanized
pocket retainers, a
rigid and durable
assembly is created.
Camfil Farr
manufactures the Hi-Flo to be capable of
withstanding up to 5.0” w.g. in normal HVAC
application.

Performance
Hi-Flo filters are manufactured from microfine glass
fibers for consistent and long-term high efficiency
performance. They are available in fractional
efficiencies from 40% to 95% on particles as small as
0.3 micron in size. MERV values range from 9 to 14
when evaluated under ASHRAE Standard 52.2-1999.
Configurations for any Application
Camfil Farr Hi-Flos are available in a variety of
configurations to suit your air movement requirements.
Common configurations include from 3 to 12 pockets,
depths of 15" to 36", and up to 129 square feet of
effective media area.
When selecting a Hi-Flo for your system, you should
select a filter with the greatest effective media area
within the airflow parameters and space limitations for
your system. This will ensure a long filter life and a
consistent low resistance to airflow over the life of the
filter. Fewer filter changes will be required, thus
reducing replacement, labor and disposal costs. An
additional benefit includes reduced system horsepower
requirements, thus lowering the facility’s energy
expenditure.
Lowest Life Cycle Cost
All of these components combine for the lowest life
cycle cost, the lowest average pressure drop (energy
savings), and consistent high efficiency particulate
filtration throughout the life of the filter.

Camfil Farr Hi-Flo® Selection Chart
Model Number
Dimensionsa
(precede with HF Number of (nominal size)
and insert
(inches)
Pockets
efficiency for *)
HxWxD

Low

Med

High

d

Low

MERV 14

MERV 13

Med

Med

High Low

MERV 11

MERV 9

High Low Med High Low Med

High

Media
Area
(sq. ft.)

*/24/24/32/12

12

24 x 24 x 32

2000

2500

3000

*/24/20/32/9

9

24 x 20 x 32d

1500

1875

2250

*/24/12/32/6

6

24 x 12 x 32d

1000

1250

1500

*/20/20/32/9

9

20 x 20 x 32d

1250

1575

1875

81

*/24/24/15/12

12

24 x 24 x 15

1000

1500

2000

58

*/24/20/15/9

9

24 x 20 x 15

750

1100

1500

*/24/12/15/6

6

24 x 12 x 15

500

750

1000

*/20/20/15/9

9

20 x 20 x 15

650

950

1275

37

*/24/24/30/10

10

24 x 24 x 30

2000

2400

2800

101

*/24/20/30/8

8

24 x 20 x 30

1600

1900

2250

*/24/12/30/5

5

24 x 12 x 30

1000

1200

1400

*/20/20/30/8

8

20 x 20 x 30

1350

1625

1875

68

*/24/24/22/10

10

24 x 24 x 22

1500

1750

2000

73

*/24/20/22/8

8

24 x 20 x 22

1200

1400

1600

*/24/12/22/5

5

24 x 12 x 22

750

875

1000

36

*/20/20/22/8

8

20 x 20 x 22

1000

1175

1350

49

*/24/24/36/8

8

24 x 24 x 36d

2000

2400

2800

97

*/24/20/36/7

7

24 x 20 x 36d

1600

1900

2250

*/24/12/36/4

4

24 x 12 x 36d

1000

1200

1400

*/20/20/36/7

7

20 x 20 x 36d

1350

1625

1875

71

*/24/24/30/8

8

24 x 24 x 30

1600

2000

2400

81

*/24/20/30/7

7

24 x 20 x 30

1400

1750

2100

*/24/12/30/4

4

24 x 12 x 30

800

1000

1200

*/20/20/30/7

7

20 x 20 x 30

1150

1450

1750

59

*/24/24/22/8

8

24 x 24 x 22

1500

1750

2000

58

*/24/20/22/7

7

24 x 20 x 22

1300

1500

1750

*/24/12/22/4

4

24 x 12 x 22

750

875

1000

*/20/20/22/7

7

20 x 20 x 22

1100

1300

1450

43

*/24/24/36/6

6

24 x 24 x 36d

1500

1750

2000

76

*/24/20/36/5

5

24 x 20 x 36d

1300

1500

1700

*/24/12/36/3

3

24 x 12 x 36d

750

875

1000

*/20/20/36/5

5

20 x 20 x 36d

1050

1225

1400

53

*/24/24/30/6

6

24 x 24 x 30

1500

1750

2000

63

*/24/20/30/5

5

24 x 20 x 30

1300

1500

1700

*/24/12/30/3

3

24 x 12 x 30

750

875

1000

*/20/20/30/5

5

20 x 20 x 30

1050

1225

1400

44

*/24/24/22/6

6

24 x 24 x 22

1500

1750

2000

45

*/24/20/22/5

5

24 x 20 x 22

1300

1500

1700

*/24/12/22/3

3

24 x 12 x 22

750

875

1000

*/20/20/22/5

5

20 x 20 x 22

1050

1225

1400

HF
HF = Hi-Flo
SF = S-Flo

DATA NOTES:
a

Initial Resistance to Airflow (inches w.g.)c

Airflow Capacityb

MV14
Efficiency

129
0.40

0.29

0.54

0.45

0.54

0.46

0.48

0.45

0.47

0.60

0.54

0.49

0.69

0.54

0.69

0.60

0.57

0.54

0.56

0.71

0.72 0.30

0.70 0.20

0.84 0.36

0.64 0.30

0.84 0.36

0.77 0.30

0.68 0.32

0.64 0.29

0.67 0.31

0.85 0.39

0.40

0.34

0.46

0.36

0.46

0.40

0.38

0.35

0.37

0.46

0.54 0.20 0.27 0.36 0.16 0.21

0.29

0.48 0.13 0.21 0.30 0.09 0.15

0.21

0.56 0.23 0.29 0.36 0.17 0.22

0.27

0.43 0.18 0.22 0.26 0.13 0.15

0.18

0.56 0.23 0.29 0.36 0.17 0.22

0.22

0.51 0.19 0.25 0.32 0.14 0.18

0.23

0.45 0.20 0.24 0.28 0.14 0.17

0.20

0.42 0.18 0.21 0.25 0.13 0.15

0.18

0.44 0.19 0.23 0.27 0.13 0.16

0.19

0.55 0.23 0.28 0.33 0.15 0.18

0.22

65

44
29

81
50

58

85
49

70
40

51
29

63
38

52
31

38
23
32

24

24

22

8

1

Height
(nominal)

Width
(nominal)

Depth
(nominal)

Number
Of
Pockets

Options

MV14 = MERV 14
MV13 = MERV 13
MV11 = MERV 11
MV 9 = MERV 9

97

1 = UL Class 1
W = 1 1/8” header
Consult factory for
additional options.

Standard Hi-Flo includes 0.88” (1” nominal) header. For 1.12” (1¼” nominal) header add a W to the end of the model number.

Contact factory for lead times.
b
Select 100% for constant volume systems and 80% of maximum design airflow for VAV systems. Hi-Flo filters perform satisfactorily over listed CFM range.
Rated capacity is medium on chart.
c
d

Recommended final resistance is 1.0” w.g. The Hi-Flo may be operated to 1.5” w.g. without affecting performance.
Pocket loops are recommended for 32" & 36" deep filters.

The Hi-Flo is classified by Underwriters Laboratories as UL Class 2. Maximum operating temperature 158° F (70° C).
20” by 24” header size available, consult factory for pricing and availability. System resistance is the same as 24” by 20” listed in above chart.
Performance tolerances conform to Section 7.4 of ARI Standard 850-78.

Hi-Flo®

Extended Surface Pocket Filter Options
UL Class 1 Hi-Flo

Cambridge-Style Header

The Hi-Flo is also available in an Underwriters
Laboratories UL Class 1 configuration. It is important to
note that both classes of filters will burn when attacked
by flames, and both will self-extinguish when clean.
Consult factory for pricing and availability.

Standard Hi-Flos include a 0.88” header for filter
installation into a nominal 1” deep filter track. The
Cambridge Air Filter Company manufactured sideaccess housings that required a 1.12” header to fit in a
nominal 1¼” filter track. To order Hi-Flos for these
housings, add a ‘W’ to your model number or seek
factory guidance.

UL Class 1 - Air filters which, when clean, do not
contribute fuel when attacked by flame and emit only
negligible amounts of smoke.
UL Class 2 - Air filters which, when clean, burn
moderately when attacked by flame, or emit moderate
amounts of smoke, or both.

Synthetic Media Option
Camfil Farr also offers an electrostatically enhanced
synthetic media extended surface pocket filter.
Available in efficiencies of MERV 9, MERV 11, MERV
13 and MERV 14, the Camfil Farr S-Flo offers an
additional economical choice for less demanding
applications. Consult Camfil Farr Bulletin 1205-0602.

SPECIFICATIONS
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •• • • • • • •
1.0 General
1.1 - Air filters shall be high efficiency ASHRAE
extended surface pocket style filters consisting of high
loft air laid microfine glass media, a galvanized steel
header, galvanized steel pocket retainers, and
bonding agents to prevent air bypass and ensure leak
free performance.
1.2 - Sizes shall be as noted on drawings or other
supporting materials.

2.4 - Support members shall include a galvanized steel
header and galvanized steel pocket retainers. The header
shall be bonded to the media to prevent air bypass.
Individual pocket retainers shall be fastened with a
mechanical crimp to lock individual pockets together. The
media pockets shall be bonded to the pocket retainers to
prevent air bypass. The frame shall form a rigid and
durable support assembly.
2.5 - A filter-to-filter sealing gasket shall be installed on
one of the vertical members of the filter header.
3.0 Performance

2.0 Construction
2.1 - Filter media shall consist of high-density air laid
lofted microfine glass media that is chemically bonded
to a permeable media support backing forming a lofted
filter blanket.
2.2 - Individual pockets shall contain a minimum of 40
stitching support points per square foot of media area.
All stitching centers shall be sealed through the use of
a foam based sealant that shall remain pliable
throughout the life of the filter. The sides and ends of
each pocket shall be sewn with a chain-link over lock
stitch.
2.3 - Pockets shall be formed into tapered pleats,
supported by controlled media space stitching, to
promote uniform airflow across the surface of the
media. At any point, the sizes of the upstream and
downstream passages shall be proportional to the
volume of filtered air.

Camfil Farr has a policy of uninterrupted research,
development and product improvement. We reserve the right
to change designs and specifications without notice.
Camfil Farr, Inc.
United States Tel: (973) 616-7300 Fax: (973) 616-7771
Canada Tel: (450) 629-3030 Fax: (450) 662-6035
E-mail: [email protected]
© Camfil Farr

http://www.camfilfarr.info
http://www.camfilfarr.com

3.1 - The filter shall have a Minimum Efficiency Reporting
Value of (MERV 9, MERV 11, MERV 13, MERV 14) per
ASHRAE Standard 52.2‑1999.
3.2 - The filter shall be capable of withstanding 5.0” w.g.
without failure of the filter.
3.3 - The filter shall be classified by Underwriters
Laboratories as UL Class 2.
3.4 - Manufacturer shall provide evidence of facility
certification to ISO 9001:2000.
Supporting Data - Provide laboratory test reports for
each listed efficiency including all details as prescribed in
ASHRAE Standards 52.1 and 52.2.

Items in parentheses () require selection.

hi-flo®
22” Deep 8-Pocket High Efficiency Bag Filter

Final resistance (maximum recommended) is 1.0” w.g. (250 Pa.)
System design may dictate a lower change out point.
Maximum continuous operating temperature 160° F (71° C).
Consult factory before operating in dotted line region.

Camfil Farr

Technical Data

Hi-Flo® 22” Deep

1203 - IRVA - 0907

Camfil Farr - clean air solutions
© Camfil Farr

hi-flo®
30” Deep 8-Pocket High Efficiency Bag Filter

Final resistance (maximum recommended) is 1.0” w.g. (250 Pa.)
System design may dictate a lower change out point.
Maximum continuous operating temperature 160° F (71° C).
Consult factory before operating in dotted line region.

Camfil Farr

Technical Data

Hi-Flo® 30” Deep

1203 - IRVA - 0907

Camfil Farr - clean air solutions
© Camfil Farr

Industrial Thermometers
Details of Design
Casings
Aluminum, V-shaped, completely polished, gold-coloured anodized (or silvercoloured upon request). Numerals of
reading scale printed on the right side.
Printing black-colored for easy readability. Adjustable to any desired viewing
position and locked by brass nut, spanner size 22 mm. Angle thermometers (90
degrees) have a grooved adapter piece
with set screw. Advantage: When mounting the thermometer, it is not necessary
to turn the casing.

Glass Inserts (Capillaries)
Capillary tube of solid glass, bar-shaped,
prismatic (optic enlargement of the
column), diameter approx. 6mm, oval
opening, with yellow background for
mercury and white background for blue
fluid column. Calibration is deeply burnt,
in black, thus being absolutely resistant.
The main graduations, which correspond
with the printing on the casing, are especially clearly outlined.

Capillary Fluid
For standard executions from -60° to
+200° C, blue fluid and red fluid, respectively, for -60° C (code „Fü“). For
temperatures of more than +200° C, only
mercury columns (code „Hg“) are possible. Upon request, thermometers can be
delivered with mercury filling from -30° C
onwards.

Immersion Tubes (Pockets)
As a standard, manufactured of brass
(code „Ms“) for temperatures up to 300°
C, for temperatures of more than 300° C
made of steel (Code „St“). Seawater resistant alloys are available upon request
(special alloy SoMs 59, SoMs 76 or
„CuNiS30Fe“). For corrosive alkalis or
acids, material 1.4571 (stainless steel)
or other resistant kinds of steel are available. With immersion tube type „B“, diameter is 10 mm, thickness 1 mm.

Accuracy
About 1 % of maximum scale value,
for thermometers with mercury column.
The accuracy of thermometers with an
alcoholic fluid meets DIN 16 195 requirements and, consequently, corresponds
with the requirements for local reading
thermometers.

SIKA-Thermometers
Casing 110 x 30 mm gold-coloured anodized
DIN 16181 B, B1
DIN 16182 S, S1

Order-Example

174

Thermometer execution
straight
angle 90°, backwards
angle 135°, backwards
Immersion tube type

Ranges

2 35 1

B
Bdr1)

=
=

-30+50°C =
0+60°C =
0+100°C =
0+120°C =
0+160°C =
0+200°C =

Columns (Filling)
Blue fluid is standard for ranges
up to +200°C
Optional: mercury

Thread connection

030

2

1

Type
174
175
176

Division Celsius (°C)
Celsius + Fahrenheit (°C + °F)

Immersion tube lenghts
l1 in mm (incl. thread)

1

2
6
35
06
10
12
16
20
1
2

Fü =
Hg =
30
40
63
100
160
250
400

1
2
=
=
=
=
=
=
=

G 3/8A/SW 22
G 1/2A/SW 27
M16 x 1,5/SW 22
M20 x 1,5/SW 27

Type
175 B

030
040
063
100
160
250
400
=
=
=
=

1
2
5
7

Immersion tube materials
Brass (hex. nut Ms58/tube special brass Ms76, or MS63 brazed)
or up to immersion lenght l1 = 63, G 1/2 A available in Ms58 solid material
Steel (hex.nut 9SMnPb28K/tube steel St. 35, welded)
Stainless steel1.4571 (hex.nut and tube)
Special brass Ms76 (hex.nut SoMs 59 / tube SoMs 76)
CuNi30Fe (hex.nut and tube)

1
2
3
4
5

See page 8 for protecting tubes to be screwed in or welded.
Immersion tubes of all right-angled thermometers are manufactured with a grooved adapter
piece on top, which is installed in the casing and kept in its place by a set screw.
Advantage: Immersion tube can be installed independently of thermometer casing. No turning
of thermometer casing is necessary on installation.

1)

Type
174 B

Bdr: Special execution of angle-type thermometer: After installation, casing can be turned by
360° in any direction. See page 9 for description and illustration.

Type
176 B

Mechanical
Pressure Measurement

Bourdon Tube Pressure Gauge
Model 213.40, with Liquid Filling and Forged Brass Case
WIKA Data Sheet PM 02.06

Applications
! Intended for adverse service conditions where pulsating
or vibration exists
! Suitable for all gaseous and liquid media that will not
obstruct the pressure system or attack copper alloy
parts
! Mining industry
! Hydraulics
! Shipping industry

Special Features
!
!
!
!

Vibration- and shock resistant
Robust pressure gauge
Approval German Lloyd
Scale ranges up to 0 ... 1000 bar

Bourdon Tube Pressure Gauge Model 213.40,
radial connection

Description
Design
EN 837-1

NS 100:

Nominal size
63 and 100 mm

Scale range
NS 50:
0 ... 1 up to 0 ... 600 bar
NS 63, 80, 100: 0 ... 0,6 up to 0 ... 1000 bar
Or other equivalent units of pressure or vacuum.

WIKA Data Sheet PM 02.06 · 10/2005

full scale range
0,9 x full scale range
1,3 x full scale range

Operating temperature
Ambient:
-20 ... +60 °C
Medium:
+60 °C maximum

Accuracy class
NS 63: 1.6
NS 100:
1.0

Working pressure
NS 63:
Steady:
Fluctuating:
Short time:

Steady:
Fluctuating:
Short time:

¾ x of full scale range
B x of full scale range
full scale range

Temperature effect
When temperature of the pressure element deviates from
reference temperature (+20 °C):
Max. ±0.3 %/10 K of true scale value.
Ingress of protection
IP 65 (EN 60 529 / lEC 529)
Pressure connection
Material:
brass forging
NS 63:
G ¼ B, 14 mm flats
NS 100:
G ½ B, 22 mm flats
Page 1 of 2

Pressure element
NS 63:
< 60 bar: Cu-alloy, C-type, soft soldered
≥ 60 bar: Cu-alloy, helical type, soft soldered
NS 100:
< 100 bar: Cu-alloy, C-type, soft soldered
≥ 100 bar: stainless steel 1.4571, helical type, brazed
Movement
Cu-alloy

Case
Solid brass forging with integral entry stem
Pressure relief in case top
Ranges ≤ 0 ... 16 bar with case venting provision
Ranges < 0 ... 6 bar fully sealed
Bezel ring
Roll formed stainless steel
Liquid filling
Glycerine 99,7 %

Dial
NS 63:
white plastic, with pointer stop pin
NS 100:
white aluminium
With black lettering

Optional extras
! Other pressure connection
! Internal pressure compensation
! Medium temperature up to 100°C with special soft
solder
! 3-hole surface or panel mounting flange
! Triangular bezel with clamp

Pointer
Black aluminium
Window
Non-splintering clear acrylic glass

Dimensions in mm
radial bottom pressure connection

NS 100, lower back pressure
connection

NG
63
100

1034 839

1034 804

1034 812

NS 63, centre back pressure
connection

Dimension in mm
b1
a
b

b2

D1

D2

e

f

G

12
13.5

56
86

62
99

62
99

10.5
11.5

30

G ¼ B 54
G ½ B 87

36
53.5

36
53.5

Weight in kg
e±1

SW
14
22

0.30
1.10

Standard pressure entry with parallel thread and sealing to EN 837-1 / 7.3

Ordering information
Pressure gauge model / Nominal size / Scale range / Location and size of connection / Optional extras required

Page 2 of 2

WIKA Data Sheet PM 02.06 · 10/2005

WIKA Alexander Wiegand Gmbe & Co. KG
Alexander-Wiegand-Straße 30
63911 Klingenberg/Germany
Phone (+49) 93 72/132-0
Telefax (+49) 93 72/132-406
E-Mail [email protected]
www.wika.de

9019804 10/2005 GB

Specifications and dimensions given in this leaflet represent the state of engineering at the time of printing.
Modifications may take place and materials specified may be replaced by others without prior notice.

SIEMENS Compressors
Surge Controller SUC-3

Function

: To give alarm (stop the drive motor)
in case of surging.

Sensor

: Inductive sensor.

Mounting

: In the compressor inlet housing.

A:

Pressure direction at normal operation.

B:

Pressure direction at surging.

The surge indicator is mounted vertically on the compressor inlet.
At normal operation a small steel disc is forced down (away from the inductive sensor) by the
vacuum in the inlet housing.
At surging the direction of the pressure is reversed, this causes the steel disc to approach the
inductive sensor, which then gives alarm.

Blue (MINUS)

White (SIGNAL)

Brown (PLUS)

Inductive sensors

IGC209
IGB3008BAPKG/M/US
Inductive sensor
Metal thread M18 x 1
Plug and socket
Increased sensing range
gold-plated contacts
Sensing range 8 mm [f]
flush mountable
Electrical design

DC PNP

Output

normally closed

Operating voltage
[V]
Current rating
[mA]
Short-circuit protection
Reverse polarity protection
Overload protection
Voltage drop
[V]
Current consumption
[mA]
Real sensing range
Operating distance
Switch-point drift
Hysteresis
Switching frequency
Correction factors
Operating temperature
Protection
EMC

Housing material
Function display
Switching status

[mm]
[mm]
[% of Sr]
[% of Sr]
[Hz]

[°C]

10...36 DC
100
pulsed
yes
yes
< 2.5
< 10
8 ± 10 %
0...6.5
-10...10
3...15
400
mild steel = 1 / stainless steel approx. 0.7 / brass approx. 0.5 / Al approx. 0.4 / Cu
approx. 0.3
-25...70
IP 68 *), II
EN 61000-4-2 ESD:
4 kV CD / 8 kV AD
EN 61000-4-3 HF radiated: 10 V/m (80...1000 MHz)
EN 61000-4-4 Burst:
2 kV
EN 61000-4-6 HF conducted: 10 V (0.15...80 MHz)
EN 55011:
class B
housing: brass white bronze coated; active face: ceramics

LED

yellow (4 x 90°)

Connection
Remarks
Accessories (included)

M12 connector; gold-plated contacts
*) "Coolant"
2 lock nuts

Wiring

ifm electronic gmbh • Teichstraße 4 • 45127 Essen — We reserve the right to make technical alterations without prior notice. — GB — IGC209 — 30.03.2004

930950031.UK

COMPENSATOR
DN100-DN600

Revision: 2
Page:
1 of (1)
Prepared by:
Latest revision:

FP
SJ

Date:
Date:

November 2, 1995
April 7, 2008

Materials
Bellow:
Guide tube:
Flanges:

W.no. 1.4541 / AISI 321
W.no. 1.4541 / AISI 321
R.st. 37-2, DIN 1626

Flange dimensions according to DIN 2501, PN 10
Design:
Pressure:
Temperature:

2,5 bar
180ºC

Alignement
Reuirements
dz
dx
mm
mm

Compressor

DN

Ln

Di
MIN.

A

DCD

N

Ød

T

KA2

125

150

132

±4

±2

250

210

8

18

15

8

KA4/5

150

150

148

±4

±2

285

240

8

22

15

10

KA10

200

150

196

±4

±2

340

295

8

22

15

12

KA22

250

200

244

±8

±3

395

350

12

22

22

22

KA44

300

200

292

±8

±3

445

400

12

22

22

26

KA66

400

250

390

±12

±5

565

515

16

26

22

35

KA80

450

250

440

±12

±5

615

565

20

26

22

39

KA100

600

250

588

±12

±5

780

725

20

30

22

55

Flange Measures

kg

930910053UK
Revision:
3
Page:
1 of (1)
Prepared by:
Latest revision:

Material
Outside :
Inside :

OUTLET DIFFUSER
CONE - SILENCER
FW
LHR

1991
16.11.1993

Mild steel ANSI 1015, painted according to standard of Siemens Turbomachinery Equipment
A/S.
Mineral wool, covered by glass-fiber fabric and perforated plate.

Flanges acc. to DIN2501, PN10
Special dimensions on request.

B-E

L

C

D

F

G

H

K

Nxd

RxS

kg

KA2
KA2

125-250
125-300

700
850

210
210

250
250

350
400

395
445

26
26

24
24

8 × 18
8 × 18

12 × 22
12 × 22

55
65

KA4/5
KA4/5
KA4/5

150-250
150-300
150-350

600
800
1100

240
240
240

285
285
285

350
400
460

395
445
505

26
26
28

24
24
24

8 × 22
8 × 22
8 × 22

12 × 22
12 × 22
16 × 22

55
70
90

KA10
KA10
KA10

200-350
200-400
200-500

800
1100
1700

295
295
295

340
340
340

460
515
620

505
565
670

28
32
34

24
24
24

8 × 22
8 × 22
8 × 22

16 × 22
16 × 26
20 × 26

80
110
170

KA22
KA22

250-500
250-600

1400
1900

350
350

395
395

620
725

670
780

34
36

26
26

12 × 22
12 × 22

20 × 26
20 × 30

160
220

KA44
KA44

300-600
300-700

1700
2000

400
400

445
445

725
840

780
895

36
38

26
26

12 × 22
12 × 22

20 × 30
24 × 30

210
270

KA66
KA66
KA66

400-700
400-800
400-900

1700
2000
2500

515
515
515

565
565
565

840
950
1050

895
1015
1115

38
42
46

32
32
32

16 × 26
16 × 26
16 × 26

24 × 30
24 × 33
28 × 33

270
340
430

KA80
KA80

450-900
450-1000

2300
2700

565
565

615
615

1050
1160

1115
1230

46
52

34
34

20 × 26
20 × 26

28 × 33
28 × 36

420
520

KA100
KA100

600-1000
600-1200

2000
3000

725
725

780
780

1160
1380

1230
1455

52
56

36
36

20 × 30
20 × 30

28 × 36
32 × 39

480
720

Compressor

930910016UK
Revision:
4
Page:
1 (1)
Prepared by:
Latest revision:

Material:

SILENCER FOR
BLOW-OFF VALVE
FW
DRo

Date: 1991
Date: 1998.04.06

R.St. 37.2, ANSI 1015 (surface: Aluzink)
Mineral wool
Flange according to DIN 2501, PN 10

Compressor

Dn

A

B

C

D

E

N × ∅d

F

kg

KA2

65

390

220

100

145

185

18

4 × 18

14

KA4

80

440

230

100

160

200

20

8 × 18

17

KA5

100

490

245

100

180

220

22

8 × 18

21

KA10

125

580

255

100

210

250

24

8 × 18

26

KA22

150

670

285

100

240

285

24

8 × 22

40

KA44

200

860

320

150

295

340

24

8 x 22

70

KA66

250

1040

410

150

350

395

26

12 × 22

110

KA80

300

1240

445

150

400

445

26

12 × 22

150

KA100

350

1440

490

150

460

505

28

16 × 22

220

AC axial fans
S-Range, Ø 500, direction of air flow "V"
- Material: impeller blades made of sheet aluminium
- Direction of rotation: counter-clockwise, seen on rotor
- Type of protection: IP 54 (please note mounting position and drilled condensate
discharges)
- Insulation class: "F"
- Motor protection: TOP brought out
- Product conforming to standard: CE

(1)

subject to alterations

A

Pa

400 ⌬
400 Y
400 ⌬
400 Y
400 ⌬
400 Y

50
50
50
50
50
50

1330
1020
1360
1110
1330
980

0,83
0,56
0,69
0,49
0,64
0,42

1,65
0,98
1,43
0,86
1,26
0,74

160
100
160
105
180
100

-40..+60
-40..+60
-40..+90
-40..+90
-40..+60
-40..+60

in operating point 3 with maximum load

n
P1
[min-1] [kW]

I
[A]

LpA
[dBA]

n
P1
[min-1] [kW]

LpA
[dBA]

1

1

1360

0,73

1,49

72

4

1

1165

0,44

0,74

68

1

2

1350

0,77

1,54

71

4

2

1135

0,47

0,79

67

1

3

1330

0,83

1,65

72

4

3

1110

0,49

0,86

66

2

1

1090

0,51

0,89

67

5

1

1375

0,50

1,09

71

2

2

1060

0,53

0,93

67

5

2

1360

0,54

1,13

72

2

3

1020

0,56

0,98

66

5

3

1330

0,64

1,26

72

3

1

1380

0,60

1,30

71

6

1

1105

0,37

0,65

66

3

2

1370

0,65

1,34

71

6

2

1060

0,39

0,69

66

3

3

1360

0,69

1,43

70

6

3

980

0,42

0,74

65

[Pa]

2

3
3
3

5
0,6

160

[in H O]

Characteristics

2
22

0,4

120
3
3

3
6

80

1

2

3

2

1
1

1
1

0,2

4
1

40

1
2

0

1250

2000

2500

3750

4000

6000
-10°

46

I
[A]

5000

8000
-5°

[CFM]
[m3/h]


°C

kg

kg

kg

kg

11,0

12,8

18,8

13,5

5a)/5b)

11,0

12,8

18,8

13,5

5a)/5b)

8,5

10,3

14,3

11,0

5a)/5b)

Electr. connection

Mass S... A

6

kW

Mass W...

-10°

min-1

Mass S... C

5

Hz

Mass A...

M4D094-HA

4

VAC

Perm. amb. temp.

-5°

Max. back pressure

3

Max.
current draw(1)

M4D110-GF

2

Max.
power input(1)

*4D 500

1



Speed/rpm(1)

M4D110-GF

Frequency

Motor

Nominal voltage

Blade angle

Nominal data
Type

Characteristic

ebm-papst · Mulfingen

General information
AC axial
EC axial
Blade angle

Direction of air flow

Dimensions

S/A/B

d

g

s

t

u

v

S

"V"



A4D500-AD03 -01

S4D500-CD03 -01

W4D500-GD03 -01

S4D500-AD03 -01

104 101 182,5 103 143 44 84

S

"V"

-5°

A4D500-AE03 -01

S4D500-CE03 -01

W4D500-GE03 -01

S4D500-AE03 -01

98 89 182,5 97 143 38 84

S

"V"

-10°

A4D500-AZ14 -01

S4D500-CZ14 -01

W4D500-GZ14 -01

S4D500-AZ14 -01

92 78 186,5 91 147 32 88

ESM

*4D 500

c

Q-motor

Type

Cable exit

Selection

Í "V"

EC-SYSTEMS

Í "V"

Accessories

Cable gland
M20

6,5

Depth of screw
max. 12 mm
View X

Technology

Í "V"

47
Electr. connection
p. 286 f.

Contacts

Í "V"

AC axial fan with full square nozzle

W4D500-DE03-02

sickled blades (S series)

ebm-papst Mulfingen GmbH & Co. KG
Bachmühle 2
74673 Mulfingen
Phone: +49 7938 81-0
Fax: +49 7938 81-110
www.ebmpapst.com
[email protected]

Nominal data
Type

W4D500-DE03-02

Motor

M4D110-GF

Phase
Nominal voltage

[V]

Connection
Frequency

[Hz]

Type of data definition
Valid for approval / standard

3~

3~

3~

3~

3~

3~

400

400

400

400

480

480



Y



Y



Y

50

50

60

60

60

60

ml

ml

ml

ml

ml

ml

CE

CE

CE

CE

CE

CE

1110

1500

1030

1600

1240

Power input

[min-1] 1360
[W]
690

490

1010

575

1100

740

Current draw

[A]

1.43

0.86

1.8

1.05

1.72

1.08

Max. back pressure

[Pa]

160

105

195

95

215

125

Max. ambient temperature

[°C]

90

90

65

65

55

55

Air flow

8930

7760

10130

7760

10350

8710

Back pressure

[m3/h]
[Pa]

0

0

0

0

0

0

Sound pressure level

[dB(A)]

Speed

73

ml = max. load · me = max. efficiency · rfa = running at free air · cs = customer specs · cu = customer unit
Subject to alterations

Web data sheet B · Page 1 of 5
ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · 74673 Mulfingen · Phone: +49 7938 81-0 · Fax: +49 7938 81-110 · www.ebmpapst.com · [email protected]

AC axial fan with full square nozzle

W4D500-DE03-02

sickled blades (S series)

Technical features
Size

500 mm

Operation mode

Continuous operation (S1)

Electrical leads

Via terminal box

Direction of air flow

"A"

Insulation class

"F"

Cable exit

Axial

Bearing-motor

Ball bearing

Mass

21 kg

Material of electronics housing

Rotor: Cast in aluminum

Material of impeller

Aluminum sheet

Motor protection

Thermal overload protector (TOP) brought out

Product conforming to standard

CE

Number of blades

5

Type of protection

IP 54

Protection class

I

Web data sheet B · Page 2 of 5
ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · 74673 Mulfingen · Phone: +49 7938 81-0 · Fax: +49 7938 81-110 · www.ebmpapst.com · [email protected]

AC axial fan with full square nozzle

W4D500-DE03-02

sickled blades (S series)

Product drawing
209,5±5

Ø11

Ø517

43

16

615±1

120

656-3

Web data sheet B · Page 3 of 5
ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · 74673 Mulfingen · Phone: +49 7938 81-0 · Fax: +49 7938 81-110 · www.ebmpapst.com · [email protected]

AC axial fan with full square nozzle

W4D500-DE03-02

sickled blades (S series)

Connection screen
Delta

Star
L1

PE

L2

U1

V1

U2

V2

L3

TOP

W1

W2

U1
U2
V1
V2
W1
W2

=
=
=
=
=
=
=

BK
GN
BU
WH
BN
YE
GNYE

PE

L1

L2

U1

V1

W1

U2

V2

W2

L3

TOP

U1
U2
V1
V2
W1
W2

=
=
=
=
=
=
=

BK
GN
BU
WH
BN
YE
GNYE

Web data sheet B · Page 4 of 5
ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · 74673 Mulfingen · Phone: +49 7938 81-0 · Fax: +49 7938 81-110 · www.ebmpapst.com · [email protected]

AC axial fan with full square nozzle

W4D500-DE03-02

sickled blades (S series)

2

[Pa]

[in H O]

Charts: Air flow

160
0,6

3

140
2

120

0,4

2

100

80
1

0,2

60

40

20

0

1250

2500

2000

4000

3750

6000
-10˚

n

P1

I

LwAss

[min-1]

[W]

[A]

[dB(A)]

1

1390

570

1.23

76

2

1380

62

1.29

77

3

1360

690

1.43

80

5000

8000
-5˚

[CFM]
[m3/h]


Web data sheet B · Page 5 of 5
ebm-papst Mulfingen GmbH & Co. KG · Bachmühle 2 · 74673 Mulfingen · Phone: +49 7938 81-0 · Fax: +49 7938 81-110 · www.ebmpapst.com · [email protected]

Performance Certificate for STC−GO Compressor
Compressor type:

STC−GO(7−1−KA1KG) .............

(KA5−S−GK200)

Curves valid for nominel conditions:

Build number:

8043

Inlet Pressure:

0.88400 [bar]

Order Number:

62008043

Inlet Temperature:

308.15 [K]

Order Name:

Nevsehir

Relative Humidity:

60.0 [%]

Testmotor:

SCHORCH

Motor Speed:

2975. [1/min]

Type of test motor:

KN7315M−AB01B−Z

.750

240

.700

220

.650

200
08

.600

09

.550

160

.500

140

04

.450

120

05

.400

100

06

02

.350
.300
2000

180

80

00
3000

4000

5000

6000

7000

8000

9000

10000

60
11000

Volumetric flow at inlet conditions − [m3/h]
Average test condition

Used evaluation standards for Compressor:

Inlet Pressure:

1.02540 [bar]

ISO5389/VDI2045

Inlet Temperature:

299.81 [K]

Used evaluation standards for Volumeflow:

Relative Humidity:

3.6 [%]

ISO 5167−1:1991/Amd.1:1998(E)

Motor Speed:

2968. [1/min]

Accepted by:

HANSE07C

Test day:

18−02−2009

Power consumption at coupling − [kW]

Pressure rise − [bar]

Serial number of test motor:21360801/03

Performance Certificate for STC−GO Compressor
Compressor type:

STC−GO(7−1−KA1KG) .............

(KA5−S−GK200)

Curves valid for nominel conditions:

Build number:

8043

Inlet Pressure:

0.88400 [bar]

Order Number:

62008043

Inlet Temperature:

298.35 [K]

Order Name:

Nevsehir

Relative Humidity:

60.0 [%]

Testmotor:

SCHORCH

Motor Speed:

2975. [1/min]

Type of test motor:

KN7315M−AB01B−Z

.840

240

.780

220

.720

200

.660

08

.600

180
09

.540

140
04

.480

120
05

.420

100

06

02

.360
.300
2000

160

80

00
3000

4000

5000

6000

7000

8000

9000

10000

60
11000

Volumetric flow at inlet conditions − [m3/h]
Average test condition

Used evaluation standards for Compressor:

Inlet Pressure:

1.02540 [bar]

ISO5389/VDI2045

Inlet Temperature:

299.81 [K]

Used evaluation standards for Volumeflow:

Relative Humidity:

3.6 [%]

ISO 5167−1:1991/Amd.1:1998(E)

Motor Speed:

2968. [1/min]

Accepted by:

HANSE07C

Test day:

18−02−2009

Power consumption at coupling − [kW]

Pressure rise − [bar]

Serial number of test motor:21360801/03

Performance Certificate for STC−GO Compressor
Compressor type:

STC−GO(7−1−KA1KG) .............

(KA5−S−GK200)

Curves valid for nominel conditions:

Build number:

8043

Inlet Pressure:

0.88400 [bar]

Order Number:

62008043

Inlet Temperature:

274.15 [K]

Order Name:

Nevsehir

Relative Humidity:

60.0 [%]

Testmotor:

SCHORCH

Motor Speed:

2975. [1/min]

Type of test motor:

KN7315M−AB01B−Z

.910

240

.845

220

.780

200
08

.715

09

.650

160

.585

140

04

.520

120

05

.455

06

02

.390
.325
2000

180

100
80

00
3000

4000

5000

6000

7000

8000

9000

10000

60
11000

Volumetric flow at inlet conditions − [m3/h]
Average test condition

Used evaluation standards for Compressor:

Inlet Pressure:

1.02540 [bar]

ISO5389/VDI2045

Inlet Temperature:

299.81 [K]

Used evaluation standards for Volumeflow:

Relative Humidity:

3.6 [%]

ISO 5167−1:1991/Amd.1:1998(E)

Motor Speed:

2968. [1/min]

Accepted by:

HANSE07C

Test day:

18−02−2009

Power consumption at coupling − [kW]

Pressure rise − [bar]

Serial number of test motor:21360801/03

Performance Certificate for STC−GO Compressor
Compressor type:

STC−GO(7−1−KA1KG) .............

(KA5−S−GK200)

Curves valid for nominel conditions:

Build number:

8044

Inlet Pressure:

0.88400 [bar]

Order Number:

62008043

Inlet Temperature:

308.15 [K]

Order Name:

Nevsehir

Relative Humidity:

60.0 [%]

Testmotor:

SCHORCH

Motor Speed:

2975. [1/min]

Type of test motor:

KN7315M−AB01B−Z

.750

240

.700

220

.650

200
09

.600

180

.550

160

.500

140

.450

120
05

.400
.350
.300
2000

04

02

06

08

80

00
3000

4000

5000

100

6000

7000

8000

9000

10000

60
11000

Volumetric flow at inlet conditions − [m3/h]
Average test condition

Used evaluation standards for Compressor:

Inlet Pressure:

1.02613 [bar]

ISO5389/VDI2045

Inlet Temperature:

296.66 [K]

Used evaluation standards for Volumeflow:

Relative Humidity:

4.6 [%]

ISO 5167−1:1991/Amd.1:1998(E)

Motor Speed:

2969. [1/min]

Accepted by:

HANSE07C

Test day:

17−02−2009

Power consumption at coupling − [kW]

Pressure rise − [bar]

Serial number of test motor:21360801/2

Performance Certificate for STC−GO Compressor
Compressor type:

STC−GO(7−1−KA1KG) .............

(KA5−S−GK200)

Curves valid for nominel conditions:

Build number:

8044

Inlet Pressure:

0.88400 [bar]

Order Number:

62008043

Inlet Temperature:

298.35 [K]

Order Name:

Nevsehir

Relative Humidity:

60.0 [%]

Testmotor:

SCHORCH

Motor Speed:

2975. [1/min]

Type of test motor:

KN7315M−AB01B−Z

.825

240

.770

220

.715

200

.660

180
09

.605

160

.550

140

.495

120

.440

05

.330
2000

04

02

.385

06

08

80

00
3000

4000

5000

6000

7000

8000

9000

100

10000

60
11000

Volumetric flow at inlet conditions − [m3/h]
Average test condition

Used evaluation standards for Compressor:

Inlet Pressure:

1.02613 [bar]

ISO5389/VDI2045

Inlet Temperature:

296.66 [K]

Used evaluation standards for Volumeflow:

Relative Humidity:

4.6 [%]

ISO 5167−1:1991/Amd.1:1998(E)

Motor Speed:

2969. [1/min]

Accepted by:

HANSE07C

Test day:

17−02−2009

Power consumption at coupling − [kW]

Pressure rise − [bar]

Serial number of test motor:21360801/2

Performance Certificate for STC−GO Compressor
Compressor type:

STC−GO(7−1−KA1KG) .............

(KA5−S−GK200)

Curves valid for nominel conditions:

Build number:

8044

Inlet Pressure:

0.88400 [bar]

Order Number:

62008043

Inlet Temperature:

274.15 [K]

Order Name:

Nevsehir

Relative Humidity:

60.0 [%]

Testmotor:

SCHORCH

Motor Speed:

2975. [1/min]

Type of test motor:

KN7315M−AB01B−Z

.900

240

.840

220

.780

200

.720

09

180

.660

160

.600

140

.540

120

.480

05

.360
2000

04

02

.420

06

08

80

00
3000

4000

5000

6000

7000

100

8000

9000

10000

60
11000

Volumetric flow at inlet conditions − [m3/h]
Average test condition

Used evaluation standards for Compressor:

Inlet Pressure:

1.02613 [bar]

ISO5389/VDI2045

Inlet Temperature:

296.66 [K]

Used evaluation standards for Volumeflow:

Relative Humidity:

4.6 [%]

ISO 5167−1:1991/Amd.1:1998(E)

Motor Speed:

2969. [1/min]

Accepted by:

HANSE07C

Test day:

17−02−2009

Power consumption at coupling − [kW]

Pressure rise − [bar]

Serial number of test motor:21360801/2

Performance Certificate for STC−GO Compressor
Compressor type:

STC−GO(7−1−KA1KG) .............

(KA5−S−GK200)

Curves valid for nominel conditions:

Build number:

8045

Inlet Pressure:

0.88400 [bar]

Order Number:

62008043

Inlet Temperature:

308.15 [K]

Order Name:

Nevsehir

Relative Humidity:

60.0 [%]

Testmotor:

SCHORCH

Motor Speed:

2975. [1/min]

Type of test motor:

KN7315M−AB01B−Z

.750

220

.700

200

.650

180

.600

160

08

.550

09

140

.500

120

.450

100

.400

80

.300
2000

04

02

.350

05

06

60

00
3000

4000

5000

6000

7000

8000

9000

10000

40
11000

Volumetric flow at inlet conditions − [m3/h]
Average test condition

Used evaluation standards for Compressor:

Inlet Pressure:

1.02410 [bar]

ISO5389/VDI2045

Inlet Temperature:

294.10 [K]

Used evaluation standards for Volumeflow:

Relative Humidity:

4.6 [%]

ISO 5167−1:1991/Amd.1:1998(E)

Motor Speed:

2971. [1/min]

Accepted by:

HANSE07C

Test day:

17−02−2009

Power consumption at coupling − [kW]

Pressure rise − [bar]

Serial number of test motor:21360801/1

Performance Certificate for STC−GO Compressor
Compressor type:

STC−GO(7−1−KA1KG) .............

(KA5−S−GK200)

Curves valid for nominel conditions:

Build number:

8045

Inlet Pressure:

0.88400 [bar]

Order Number:

62008043

Inlet Temperature:

298.35 [K]

Order Name:

Nevsehir

Relative Humidity:

60.0 [%]

Testmotor:

SCHORCH

Motor Speed:

2975. [1/min]

Type of test motor:

KN7315M−AB01B−Z

.840

220

.780

200

.720

180

.660

160
08

.600

140
09

.540

120

.480

100

.420

80

.300
2000

04

02

.360

05

06

60

00
3000

4000

5000

6000

7000

8000

9000

10000

40
11000

Volumetric flow at inlet conditions − [m3/h]
Average test condition

Used evaluation standards for Compressor:

Inlet Pressure:

1.02410 [bar]

ISO5389/VDI2045

Inlet Temperature:

294.10 [K]

Used evaluation standards for Volumeflow:

Relative Humidity:

4.6 [%]

ISO 5167−1:1991/Amd.1:1998(E)

Motor Speed:

2971. [1/min]

Accepted by:

HANSE07C

Test day:

17−02−2009

Power consumption at coupling − [kW]

Pressure rise − [bar]

Serial number of test motor:21360801/1

Performance Certificate for STC−GO Compressor
Compressor type:

STC−GO(7−1−KA1KG) .............

(KA5−S−GK200)

Curves valid for nominel conditions:

Build number:

8045

Inlet Pressure:

0.88400 [bar]

Order Number:

62008043

Inlet Temperature:

274.15 [K]

Order Name:

Nevsehir

Relative Humidity:

60.0 [%]

Testmotor:

SCHORCH

Motor Speed:

2975. [1/min]

Type of test motor:

KN7315M−AB01B−Z

.910

240

.845

220

.780

200

.715

180

08

.650

09

.585

160
140

.520

120

.455

100

.325
2000

04

02

.390

05

06

80

00
3000

4000

5000

6000

7000

8000

9000

10000

60
11000

Volumetric flow at inlet conditions − [m3/h]
Average test condition

Used evaluation standards for Compressor:

Inlet Pressure:

1.02410 [bar]

ISO5389/VDI2045

Inlet Temperature:

294.10 [K]

Used evaluation standards for Volumeflow:

Relative Humidity:

4.6 [%]

ISO 5167−1:1991/Amd.1:1998(E)

Motor Speed:

2971. [1/min]

Accepted by:

HANSE07C

Test day:

17−02−2009

Power consumption at coupling − [kW]

Pressure rise − [bar]

Serial number of test motor:21360801/1

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