of x

Blower

Published on November 2016 | Categories: Documents | Downloads: 31 | Comments: 0
155 views

Comments

Content

 

          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. COMPRESSOR Serial no.

62008043 8043 8044 8045

PROJECT:

Nevsehir WWTP

Energy Sector

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. EC Declaration of Conformity Important Machinery - Safety Requirements Shipment - Storage - Installation Shipment Storage Installation Pipe Connect./Permissible Loads Tech. Doc. "Allowable Load" Tech. Doc. "Installation" Technical Specifications Technical Specifications for Compressor. Tech. Doc. "Oil Specification" Tech. Doc. "Oil Specification" 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 Drive Motor Reference to Manufacturers instruction Acoustic Enclosure 930 940 083 930 940 077

1. 1.1 1.2 1.3 1.3.1

930 910 007 930 840 008

2.

930 870 003 930 870 005

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 4.

933 005 7240

5.

6. 6.1 6.2 6.3

Lubricating Oil System Design and function Oil filling Oil Types Accessories Control System Local Control PI-Diagram Compressor Instability Surge Recirculation

7. 7.1 7.2 7.3 7.3.1 7.3.2

935 004 939

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 3/54

8. 8.1 8.2 8.3 8.4 8.5 8.6 9. 9.1 9.2 9.3 9.4 9.5 9.6 10. 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8

Instrumentation Thermostat E151 Thermostat E138 Thermostat E104 Thermostat E111 Pressostat E106 Surge Controller SUC-3, Drawing Start-up Preparations Simulated Test Run of Compressor Test Run of Compressor Master Control Start General 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

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 12. 12.1 12.2 12.3 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 Maintenance Introduction Service intervals Service Simulated Test Run Test Run of Compressor Master Control Panel Inlet Silencer Disposal of waste Orders for spare parts Dismounting and Mounting 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 930 920 041UK

930 920 036UK

9330502950 9330523220 9330554160 9330554180 GK200S017 9330503140

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 4/54

Chapter 3 Dimension Drawing
Dimension drawing no.14541

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

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 5/54

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

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: Installation: Direction of Rotation:

See the handbook, § 0 (See the handbook) 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) Check of alignment before start. (See the handbook) After about 10 operating hours the coupling bolts shall be re-tightened. (See the handbook) 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) 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.

Coupling:

Re-tightening:

Oil Check:

Electric motors

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

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 7/54

0.

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. 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.

AUTOMATIC START/STOP

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

Page 9/54

1. 1.1

SHIPPING - STORAGE - INSTALLATION SHIPPING 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.

Created on 16-02-2009 at 16:00:35, LF 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

= = =

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

TYPE KA2 KA5 KA10 KA22 KA44 KA66 KA80 KA100

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

Page 12/54

INSTALLATION 930840008UK

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 13/54

2.

TECHNICAL SPECIFICATIONS
UNIT Serial No. Year Weight, approx. Dimension Drawing : : : : 8043, 8044, 8045 2009 2360 kg 14541

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. : : : : : : : : : : : : 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

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

DRIVE MOTOR - Pos. No. A401 Make Type Weight Insulation class Degree of protection Power, nominal Mains frequency Voltage Revolutions : : : : : : : : : Schorch KN7 315M-AB01B-Z 860 kg F/B IP 23 200 kW 50 Hz 400 V 2975 rpm

COUPLING (Motor/Gear)- Pos. No. A301 Make Type : Rexnord Thomas : SR52-MSH-225

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

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 FAN MOTOR Type Make Revolutions Insulation class Degree of protection Main frequency Voltage Power : : : : : : : : : : Oil Tech LAC2-011-2-D

Oil Tech 3000 F IP 54 50 3 x400 1.1

rpm

Hz V kW

AIR INLET FILTER - Insert - Pos. No. L102 Make Type EU-class DIN 24185 Filter clean/replace at max. Manometer Pos. No. E137 : : : : Camfil Pocket filter G4 + 20 mm WC

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

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 Thermometer - Pos. No. E122 : : 80°C 55 - 75°C

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

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

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

Pressure Switch - Pos. No. E107 Make Type Sensor Function Set point Difference : : : : : : Danfoss RT 110 In the gearbox oil lubrication system Stops compressor at low oil pressure 0.8 bar Minimum

THERMOSTAT - Pos. No. E138 Make Type Sensor Function Set point Difference : : : : : : Danfoss RT 101 In oil reservoir Start/stop of oil cooler fan 50°C Minimum

SURGE DETECTOR - Pos. No. E113 Make Type Sensor Function : : : : Siemens SUC-3 In compressor's inlet Stops compressor at surging

Created on 16-02-2009 at 16:00:35, LF 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 ACTUATOR FOR BLOW-OFF VALVE Make Type Degree of protection Insulation class Mains frequency Voltage Power Operating time (90°) : : : : : : : : Bernard OA6 F IP 67 50 Hz 400 V 0.03 kW 6 sec : : : Wouter Witzel Euronomic / DN100 Pressure relief during

start/stop

NON RETURN CHECK VALVE Make Type Size : : : Cast Flow GNECVB DN350

SILENCER FOR BLOW-OFF VALVE Make Size : : STE DN100

COMPENSATOR- Pos. No. P102 Make Type SIZE : : : STE/Bredan Steel DN150

CONE DIFFUSER - Pos. No. P116 Make Type SIZE : : : STE Cone diffuser DN150/350 – 1100mm

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 18/54

OIL SPECIFICATIONS (TECH.DOC. 930870003UK)

COMPRESSOR

YEAR OF CONSTRUCTION

OIL TYPE DIN 51502

SIEMENS REFERENCIES

VISCOSITY INDEX MIN. ISO 2909

VISCOSITY MIN. at 120°C

FZG STAGE MIN. DIN 51354

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

1986 2003 1982 1996 1999 1996 1987 1993 1992 1998 1997 1988 1986 1992 1987 1979 1983 1993 1989 1981 1981 1983 1993 1992 1995 1982 1992 1982 1990 1984

PAO 1 PAO PAO PAO HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP46 HL/HLP68

930870005 930870005 930870005 930870005 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004 930870004

137 137 137 137 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100

4.20 4.20 4.20 4.20

10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10

1

PAO = Synthetic oil, polyalfaolifine

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 19/54

OIL PUMP CAPACITY AND OIL RESERVOIR
OIL RESERVOIR LITER +/- 10%

COMPRESSOR

YEAR OF CONSTRUCTION

OIL PUMP CAPACITY STANDARD LITER/MIN.

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

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

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

2

Oil pump integrated in the gear.

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

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).

Note:

Turbochargers Journal bearing gearboxes

}

Please see different specification

Supplier Company Oil type BP BP BP Total Fina Elf Total Fina Elf Total Fina Elf Esso Esso Exxon Mobil Mobil Mobil Kuwait Petroleum Kuwait Petroleum ----------------------Statoil --------------------Shell Shell Shell Square Oil A/S Tribol Tribol Klüber Klüber Klüber Lubrication Fuchs Fuchs Fuchs

Scandinavia Europe North America

BP

BP ENERGOL RC-S 46

TOTAL

DACNIS SH 46

ESSO

ESSO COMPRESSOR OIL RS32

MOBIL

MOBIL SHC 624

Q8

Q8 SCHUMANN 32

STATOIL

COMPWAY SX 32

SHELL

MADRELA AS 46

TRIBOL

TRIBOL 1550/32

KLÜBER

KLÜBER SYNTH GEM 4-32

FUCHS

FUCHS COFRABAR P32

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 21/54

3. 3.1

UNIT DESIGN MAIN CONSTRUCTION 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 P101 P102 P106 P110 S301 S303 E123

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

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 22/54

3.2

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.

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 23/54

3.2.1

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 24/54

3.2.3

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

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

HANDBOOK FOR OPERATION AND MAINTENANCE

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

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

HANDBOOK FOR OPERATION AND MAINTENANCE

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 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

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

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.

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 28/54

3.6

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.

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 29/54

3.9

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: 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.

3.10

INLET FILTER See Manufacturer's material.

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 30/54

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 31/54

4.

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.

Created on 25-05-2009 at 09:39:32, LF 01-Operation_KA5S-GK200.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 32/54

930910056UK
Revision: 15

ELECTRIC MOTORS COMPRESSORS KA2 – KA100 GENERAL REQUIREMENTS
MC FP Date: Date: 91.12.09 07.02.07

Prepared by: Latest revision:

1.

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. 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) (single stage) (single stage) : CCW : CW : CW : CW : CCW : CCW : 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.

4.

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. 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.

6.

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 33/54

7.

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. 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. Terminal markings/wiring specifications for motor winding protection. Noise emission at full load specified as sound power emission Lw, A-weighted value and/or octave bands (dB, reference 2*10-12 W).

b.

c. d.

8.

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. If used under tropical conditions the motors shall be equipped with electrical heaters and drains. Manuals including instructions for installation and operation shall be provided in English, German, French or Spanish, whatever is specified. 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). The information specified herein must be at our disposal not later than 3 weeks from receipt of order.

11. 12.

13.

14.

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 34/54

5.

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 2 63 6 125 6 250 10 500 14 1000 19 2000 21 4000 40 8000 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.

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 35/54

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 36/54

7.

CONTROL AND MONITORING SYSTEMS

7.1

DESIGN AND FUNCTION 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. When the compressor has been started the blow-off valve will close. During operation the diffuser will be adjusted continuously corresponding to the operational conditions. 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. When the error has been located and corrected the monitoring system has to be reset.

2. 3.

4.

5.

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 37/54

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 38/54

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.

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 39/54

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 40/54

7.3

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.

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 41/54

8.

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

8.1

Data : See § 2, Tech. Specifications : -40 - +70°C : 100°C : Start and stop of ventilator fan at temperature above/below 30ºC in acoustic enclosure. : 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.

MAX ambient temperature MAX sensor temperature Function

Setting

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 42/54

8.2

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 Function

: :

-50 - +70°C 300°C

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

Setting

Testing :

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.

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 43/54

8.3

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

Data : See also “Accessories”

MAX ambient temperature MAX sensor temperature Function

: :

-50 - +70°C 300°C

: To stop the driving motor of the compressor at rising oil temperature, exceeding 80°C. : Dismount the front cover of the thermostat and set the differential roll 9 on MIN.

Setting

Testing :

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.

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 44/54

8.4

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

MAX ambient temperature MAX sensor temperature Function

: :

-50 - +70°C 300°C

: 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.

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 45/54

8.5

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 Function : 70°C : 100°C : 25 bar : To start the electric oil pump if the oil pressure drops below 0,8 bar o. : 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.

Setting

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.

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 46/54

8.6

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 Function : 70°C : 100°C : 25 bar : To stop the drive motor of the compressor if the oil pressure drops below 1 bar o. : 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.

Setting

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.

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 47/54

8.7

PRESSURE SWITCH SUC-3 - Pos. No. E113

Function

: Surge indicator, gives alarm (stop of the drive motor) in case of surging. : Inductive sensor. : In the compressor inlet housing.

Sensor Mounting

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)

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 48/54

9. 9.1

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 49/54

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.

• • •



• • • • • •

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 50/54

9.4

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

Check and adjustment of step controller (adjustment of diffuser via mA-signal). Check of output signal from pressure and oxygen transmitter.

9.5

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 Pos. No. E122 E104 Pos. No. E121 Pos. No. E107 Pos. No. 113 Pos. No. 111 Sight glass Level switch Thermometer Min. 10°C at start-up Thermostat Pressure gauge, Min 1,0 bar. Pressure switch SUC-3, pressure switch Thermostat To be measured at the SIEMENS test point; 10-1000 Hz: ISO. Ammeter on control panel. Test by means of a tongs ammeter. Pressure gauge, Pos. E137.

Oil temperature:

Oil pressure:

Compressor surging Compressor recirculation Vibrations:

Power consumption:

Differential Pressure at inlet filter:

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 51/54

9.6

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.

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 52/54

10.

TROUBLE SHOOTING

When trouble shooting, compare all operational data with the specifications in § 2. § Flow, no pressure at start-up Insufficient flow Excessive power consumption Surge (pressure pulsation)/ Recirculation (overheating) Noisy operation/too high vibration level Bearing temperature too high Lubricating oil pressure too high Lubricating oil temperature too high Drive motor Oil cooler 10.1 10.2 10.3

10.4 10.5 10.6 10.7 10.8 See separate instruction: Section 5 See separate instruction, section 6

10.1

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: 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.

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

HANDBOOK FOR OPERATION AND MAINTENANCE 10.3

COMPRESSOR KA5S-GK200

Page 53/54

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: - 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.

10.5

NOISY OPERATION /VIBRATION LEVEL TOO HIGH Possible causes: Gear: - Defective gearwheel or bearings. - Defective coupling or bad alignment. Compressor: Defective bearings. Rotor/impeller out of balance. Defective sealings. Defective coupling or bad alignment.

10.6

Bearing TEMPERATURE TOO HIGH Possible causes: Wrong type of oil. Defective bearings, gearwheels, etc. Insufficient cooling of lubricating oil Insufficient oil feed. Lubricating oil pressure too low. Defective oil pump.

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 54/54

10.7

OIL PRESSURE TOO LOW Possible causes: Defective oil pump Oil filter blocked Oil temperature too high Safety valve defective Leaks on pressure pipe (under tank cover). Too low oil level

10.8

OIL TEMPERATURE TOO HIGH Possible causes: - Too high ambient temperature. - Wrong type of oil. - Defective bearings, gearwheels, etc.

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

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 1/50

11.

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 Oil Filter Change Bearing change gearbox, pinion shaft incl. O-rings, Bearing change gearbox, inlet shaft Service Inlet filter Inlet silencer Drive motor Oil cooler Acc. 11.6 See § 6 Acc. 3.3.3 3.3.3 11.2 Intervals First oil change after 8,000 hours of operation. Subsequent changes every 8,000 hours., however, at least once a year When changing the oil or at max. differential pressure, acc. To tech. spec., §2. Every 40000 hrs, change oil too. See drawings next page Every 80000 hrs, change oil too. Every 18,000 hours of operation / every 3 years, whichever comes first. At max. pressure drop according to technical specifications. Shall be cleaned during service. See manufacturer’s instructions or contact the local SIEMENS representative. See manufacturers instructions

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

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. Rotor shaft 24,000 40,000 40,000 Pinion shaft 48,000 80,000 80,000

KA2-GK190 KA5-KG200* KA10-GK200

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

1 Bearing housing 2 Race 3 Spring

4 O-ring 5 Washer 6 Screw

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 3/50

11.2

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 Test run of compressor to check oil-tightness. Vibration level in test point (RMS-value) measured before disassembling of compressor. 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. Dismounting of outer diffuser drive system. 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.
Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

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

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 5/50

11.3

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: 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). Function of non-return valve. Build-up and stability of air pressure in pressure pipe. Lubricating oil pressure and temperature shall be stabilized. Test diffuser adjustment manually. Test normal start and stop sequence. Adjust motor overload protection (diffuser limit). Check for oil leaks at operating temperature.
*)

Test safety monitoring system and emergency stop during operation.

OBSERVATIONS AND MEASUREMENTS DURING MAINTENANCE
• • • • • • •

Vibration level before service Diffuser throat area after maintenance Clearance rotor/covering Limit switch diffuser Coupling alignment round/flat impact Vibration level after maintenance Hour counter

RMS (mm/S): (mm): (mm): MIN/MAX: ± (mm): RMS mm/S: (hours):

*)

Lubricating oil pressure and temperature see technical specifications § 2.

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 6/50

11.5

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. Check of cable connections from Local Control Panels to Master Control Panel. Check and adjustment of step controller (adjustment of diffuser via mA signal). 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.

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE 12. 12.1 1.

COMPRESSOR KA5S-GK200

Page 7/50

DISMOUNTING / REMOUNTING

COUPLING ALIGNMENT FLENDER ARPEX TYPE

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.

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 8/50

6.

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.

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 9/50

TABLE 1

Coupling Size (Flange diameter) *

S Tolerance ** + Tolerance to be used ± 0,3 ± 0,4 ± 0,4 ± 0,4 ± 0,4 ± 0,5 ± 0,5 ± 0,5 ± 0,6 ± 0,6

Concentric Running RL** Gauge indic. 0,24 0,24 0,24 0,24 0,24 0,31 0,31 0,31 0,31 0,31

Gyratory Running PL** Gauge indic. 0,29 0,31 0,34 0,36 0,38 0,41 0,44 0,44 0,52 0,56

Gyratory Running mm/100mm 0,17 0,17 0,17 0,17 0,17 0,17 0,17 0,17 0,17 0,17

168 or less
180 200 205 215 235 250 270 300 320 ***

*

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.

**

***

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 10/50

Figure 1.

GEAR

MOTOR

Figure 2.

Concentric Running: RL

GEAR

MOTOR

Figure 3.

Gyratory Running: PL

GEAR

MOTOR

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

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 225 262 312 350 375 425 450 500

Shaft Diam. mm 145 168 198 221 246 267 287 327

Dowel Screws metric M8 × 1 M10 × 1 M10 × 1 M12 × 1,25 M14 × 1,5 M16 × 1,5 M18 × 1,5 M20 × 1,5

Key Width mm 13 17 17 19 22

*Torque TA Nm 34 41 54 129 176 237 271 353

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 3 2 2 3

1 3

TA

TA

Description of Coupling: See section “Accessories”

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 12/50

12.2

DISMOUNT/REMOUNT OF OUTER DIFFUSER SYSTEM See drawing next page. Aids: Joint paste: Dismount: Torque wrench and ordinary hand tools. None 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.

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 13/50

OUTER DIFFUSER SYSTEM

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 14/50

12.3

ADJUSTMENT OF CLEARANCES See drawing next page.

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 15/50

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 16/50

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

TYPE KA5-GK200

SP1
0,9

MAX MIN +0,1 0

SP2

MAX MIN +0,05 0

SP5

MAX MIN +0,05 0

(SP5)*

0,7

0,3

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.

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 17/50

12.4

WEIGHT OF SINGLE PARTS Pos. No. Description Weight approx.

H701 H501 R400 D101 R100 H101 H102

Inlet housing / Inner volute casing Rotor complete Diffuser plate Drive shaft Gear casing - part A Gear housing - part B 85 kg 12 kg 23 kg 53 kg 28 kg 225 kg

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 18/50

12.5

SPECIAL TOOLS

Info V999 V102

qty Description 1 Tool box 1 3 1 1 1 1 1 1 1 1 3 6 3 6 3 1 1 1 1 3 3 3 1 Lifting tool for inlet Screw M10 x 20 Eyebolt (N69R12) for outer volute casing Eyebolt M20 (N69R20) for gearbox Screw for play setting Washer, MG Nut, M12 Extractor for compressor impeller Rotor tightening tool complete Lifting tool for inlet shaft Screw M8 x 20 Nut M8 Threaded rod M8 x 120 for bearing housing Nut M6 Threaded rod M6 x 90 for sealing Screw for securing of shim T218 Dowel for rotor nut Drift for dismounting of stop nut (spinner) Guide rod M8 x 100 Screw M6 x 70 Screw M8 x 110 Nut M8 Tool for dismounting of oil pump

Order no. 9332270330 93330570160 N61V10020 434002879 434004511 GK200V004 N64S13 N91M12 9330570480 9330570450 GK200V001 NG1V08020 N91M08 9330570550 N91M06 9330570540 GK200V005 N1P06060 9330570530 9332270215 N61V06070 N61V08110 N91M08 GK200V008

Illustr.

A B C D E F G H I J

V103 V202 V405 V405 V405 V501 V504 V701

V304

V305

V306 V503 V503 V901 V903 V903 V903 V912

K

L

M

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 19/50

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 20/50

12.6

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 1,37

4 3,10

5 6,15

6 10,5

8 26

10 51

12 89

14 141

16 215

20 390

24 675

30 1160

Wrench Width: Hexagon Screws
M Width 3 5,5 4 7 5 8 6 10 8 13 16 10 (17) 18 12 (19) 21 14 (22) 16 24 20 30 24 36 30 46

Wrench Width: Insex Screws
M Width 5 4 6 5 8 6 10 8 12 10 14 12 16 14 20 17 24 30

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

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 21/50

12.7

DISMOUNT / REMOUNT DRAWINGS

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 22/50

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 23/50

Rotor: See next page

3.

Fasteninq (Fig. 1): 1. 2. 3. Mount screw R411 in the rotor drive R401. Lubricate both threads of the central screw R405 and between rotor drive R401 and pinion shaft R201 with an agent to protect against scratches. 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. Pump again to 410 bar. Tighten the rotor nut again until complete contact. Remove the oil pressure and the fastening tools. The assembled rotor is balanced according to balancing instruction. All parts are to be marked with serial number for the balancing.

4. 5.

Dismountinq of impeller complete (fig. 2):

1. 2. 3. 4.

Mount fastening tools 933 057 045 0. 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. Dismount the central screw R405. Dismount impeller R414 with dismounting tools 933 057 048 0.

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 24/50

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 25/50

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 26/50

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 27/50

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 28/50

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 29/50

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 30/50

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 31/50

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 32/50

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 33/50

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 34/50

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 35/50

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 36/50

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 37/50

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 38/50

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 39/50

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 40/50

12.8.1

COMPRESSOR GEARBOX DRAWING No.9330502950.0

Pos. Nr. D100 D200 E130 E134 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

Description

Pos. Nr. R100 R400 S112 S113 S124 S129 S131 S132 S155 S156 S161 S162 S425 S426 T101 T102 T103 T106 T112 T114 T124 T204 T207 T208 T210 T213 T215 T218 T220 T221 T222 T234

Description

Inner diffuser drive Outer diffuser drive Sight glas (oil level) Snesor pocket 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

Drive shaft Rotor, complete 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 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

Created on 19-02-2009 at 12:21:06, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 41/50

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 42/50

12.8.2

Rotor Drawinq No. 933.052.322.0.0

Pos. No.
R201 R401 R405 R407 R409 R410 R411 R412 R414

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

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 43/50

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 44/50

12.8.3

Outer Diffuser System, Drawinq No. 9330554160.0 Pos. No.
D201 D202 D203 D205 D206 D207 D208 D209 D210 D211 D212 D213 D214 D219 D224 D229 D230 D231 D240 D241 D248

Description
Excenter housing Screw for D201 Screw for D201 Positioning lever Screw for D205 Excenter shaft Mounting plate Screw for D208 Limit switch Screw for D210 Backstop Scale Screw for D213 Pin bolt for D224 Linear motor Screw for console Console for D224 Screw Bearing for D201/D207 Gasket for D201/D207 Support for D210

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 45/50

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 46/50

12.8.4

INNER DIFFUSER SYSTEM, DRAWING No. 9330554180.0

Pos. No.

Description

D101 D102 D108 D109 D110 D113 D114 D115 D116 D117 D118

Diffuser plate Swivel joint Guide ring Dowel End stop Retaining plate for guide ring Screw Screw Diffuser blade Shaft for diffuser blade Screw

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 47/50

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE 12.8.5

COMPRESSOR KA5S-GK200

Page 48/50

Lube oil pump, DRAWING NO.GK200S017

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

HANDBOOK FOR OPERATION AND MAINTENANCE

COMPRESSOR KA5S-GK200

Page 49/50

12.8.6

AGGREGATE DRAWING NO.9330503140

Pos. No.
A101 A103 A104 A105 A107 A200 A201 A202 A301 A302 A401 A402 D200 E100 E105 E109 E110 E121 E122 E134 E139 E187 F101 F105 S203 S204 S205 S206 S213 S215 S216 S217 S301 S302 S303 S313 S318 S322 S334 S336 S901 S902

Description
Serial number plate Plate Mobil SHC 624 Plate Rivet Compressor/Gear KA5S-GK200 Screw Dowel Coupling Guard Electric motor Screw Outer diffuser drive 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 Frame Shim 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

Created on 17-02-2009 at 09:42:56, LF 02-Maintenance.doc

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

Page i

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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.

Page ii

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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.

Page iii

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

Contents
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 1 2 3 4

Page iv

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

1

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

Page 1 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

3
• • • • • • • • •

Definitions
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.

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



• • • •

• •

Page 2 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

4

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

Page 3 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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.

Page 4 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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

Page 5 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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.
Page 6 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

Password table: The table below shows the default password for password level 3 when the HMI is shipped.
Password Level 0 1 2 3 3 3 3 Plant STE Yes User Name Password Changes Allowed

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.

Page 7 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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).

Page 8 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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).
Page 9 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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.
Page 10 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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.

Page 11 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

5

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.
Page 12 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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).

Page 13 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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.

Page 14 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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).

Page 15 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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).

Page 16 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

6

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

Page 17 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

• 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.

Page 18 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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

Page 19 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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”.

Page 20 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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.

Page 21 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

7

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

Page 22 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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.

Page 23 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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.

Page 24 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

8

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
Page 25 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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

Page 26 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

9

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.

Page 27 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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 145 147 148 153 161 201 233-236 265 273 435 443 Lube Oil Pressure L Lube Oil Temperature H Lube Oil Filter Differential Pressure H Lube Oil Level L Gearbox Vibration Level H Inlet Air Filter Differential Pressure H Main Drive Motor Winding Temperature H Inlet Guide Vane system Circuit Breaker Tripped Diffuser system Circuit Breaker Tripped Inlet Temperature Transmitter Wire-break Differential Pressure Transmitter Compressor Wire-break Alarm Message Text

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 1 17 19 25 33 65 66 105-108 Trip Message Text Emergency Stop Activated Lube Oil Pressure LL Lube Oil Temperature HH Lube Oil Level LL Gearbox Vibration Level HH Compressor Surging HH Compressor Recirculation HH Main Drive Motor Winding Temperature HH Stop Sequence Hard Hard Soft Soft Hard Soft Soft Soft

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.

Page 28 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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

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. 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.

Page 29 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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.

Page 30 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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.

Page 31 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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.

Page 32 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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.

Page 33 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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.

Page 34 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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.

Page 35 / 44

Operations Manual Local 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 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.

Page 36 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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:

Page 37 / 44

Operations Manual Local 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 LCP Operator Interface”.

Page 38 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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 1 Message Text Emergency Stop Activated 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.

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

Page 39 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

Number 65

Message Text Compressor Surging HH

Remedy 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.

66

Compressor Recirculation HH

81 82 83 84 85 97

Gearbox Bearing Temperature HH

98

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). Main Drive Motor Running Feedback Lost During Operation 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. Check the state of the MCC switchgear (overload, fuses, power supply and voltage level). Check motor cooling conditions (cooling air or water flow) and the motor power consumption (overloading?).

99

100

Main Drive Motor Starter Not Ready

101

Main Drive Motor Starter Failure

105 106 107 108

Main Drive Motor Winding Temperature HH

Page 40 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

Number 113 114 115

Message Text

Remedy

148

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

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

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

273

284

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

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

Number 435

Message Text Inlet Temperature Transmitter Wirebreak

Remedy 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.

Page 42 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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 White

State Description Off Fully Closed Position On Midway Position Fully Open Position

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

Grey

Black

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 43 / 44

Operations Manual Local Control Panel

17-03-2008 Revision: 2.01

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

Colour White

State Description Off Fully Closed Position Available

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

Grey

Black

Reset

1. Reset pushbutton

Red Flashing Green

Abnormal Condition

1. Transmitter out of range 2. Motor circuit breaker tripped 1. Lube oil pump running 2. Diffuser open (maximum) 1. Diffuser between open and closed position 1. Motor circuit breaker tripped

On Fully Open Position Midway Position

Blue

Yellow

Unavailable

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 2.01 Date 08-09-2004 21-09-2004 16-01-2006 04-04-2008 By KJH KJH KJH 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

Page i

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

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.

Page ii

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

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.

Page iii

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

Contents
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 1 2 3 4

Page iv

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

1

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

Page 1 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

3
• • • • •

Definitions
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.

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



• • • • •

Page 2 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

4

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

Page 3 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

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.

Page 4 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

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

Page 5 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

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.
Page 6 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

Password table: The table below shows the default password for password level 3 when the HMI is shipped.
Password Level 0 1 2 3 3 3 3 Plant HVT Yes User Name Password Changes Allowed

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.

Page 7 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

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).

Page 8 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

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).

Page 9 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

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.

Page 10 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

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.

Page 11 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

5

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.

Page 12 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

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.

Page 13 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

6

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.
Page 14 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

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 0 1 3 B 3 4 2 C 1 2 5 D 2 0 1 E 0 3 4

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

Compressor A 1 2 3 B 2 4 2 C 4 1 5 D 0 2 0 E 0 3 4 Priority sequence with “hole” (3 is missing). Priority 2 is selected twice. 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.

Page 15 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

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.

Page 16 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

7

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.
Page 17 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

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)

Page 18 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

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.

Page 19 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

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.

Page 20 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

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.

Page 21 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

8

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.

Page 22 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

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 81 82 83 84 85 86 97 98 131 139 147 155 163 Header Air Pressure L Header Air Pressure H Header Air Flow L Header Air Flow H Dissolved Oxygen Level L Dissolved Oxygen Level H Header Air Temperature L Header Air Temperature H Load Controller Set Point Wire-break Header Air Pressure Transmitter Wire-break Header Air Flow Transmitter Wire-break Header Air Temperature Transmitter Wire-break Dissolved Oxygen Transmitter Wire-break Alarm Message Text

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.

Page 23 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

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 1 17 18 19 20 21 22 33 34 Header Air Pressure LL Header Air Pressure HH Header Air Flow LL Header Air Flow HH Dissolved Oxygen Level LL Dissolved Oxygen Level HH Header Air Temperature LL Header Air Temperature HH Trip Message Text System Emergency Stop Activated

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.

Page 24 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

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

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. 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.

Page 25 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

9

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

Page 26 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

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.

Page 27 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

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.

Page 28 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

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.

Page 29 / 38

Operations Manual Master Control Panel

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 1 Message Text System Emergency Stop Activated Remedy 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. Check the process conditions and the number of compressors running. Check the process conditions and the function of the air after cooler, if any 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.

18

Header Air Pressure HH

19

Header Air Flow LL

21

Dissolved Oxygen Level LL

34

Header Air Temperature HH

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

Page 35 / 38

Operations Manual Master Control Panel

17-03-2008 Revision: 2.01

Number 70

Message Text MCP<=>LCP F: Communication Link Interrupted

Remedy 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. Check the process conditions and the number of compressors running. Check the process conditions and the function of the air after cooler, if any Check the signal output (e.g. in the process control system). Check the wire connections. Check the transmitter output. Check the wire connections. Check the transmitter output. Check the wire connections. Check the transmitter output. Check the wire connections. Check the transmitter output. Check the wire connections.

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

98

Header Air Temperature H

131

Load Controller Set Point Wire-break

139

Header Air Pressure Transmitter Wirebreak Header Air Flow Transmitter Wirebreak Header Air Temperature Transmitter Wire-break Dissolved Oxygen Transmitter Wirebreak

147

155

163

Page 36 / 38

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 White

State Description Off Fully Closed Position On Midway Position Fully Open Position

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

Grey

Black

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 White

State Description Off Fully Closed Position Available

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

Grey

Black

Reset

1. Reset pushbutton

Red Flashing Green

Abnormal Condition

1. Transmitter out of range 2. Motor circuit breaker tripped 1. Lube oil pump running 2. Diffuser open (maximum) 1. Diffuser between open and closed position 1. Motor circuit breaker tripped

On Fully Open Position Midway Position

Blue

Yellow

Unavailable

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
1.1 1.2 1.3 1.4 1.5 1.6 1.7

Page

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
2.1 2.2 2.3 2.4 2.5 2.6

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

3
3.1 3.2 3.3 3.4

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

4
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 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3.7

Assembly and Commissioning
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 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 5
5.1 5.2 5.3 5.3.1 5.3.2 5.4 5.5 5.5.1 5.5.2 5.5.3 5.5.4 5.6 5.6.1 5.6.2 5.6.3 5.6.4 5.7

Page Maintenance
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
6.1 6.2 6.3

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

7
7

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

8
8.1 8.2

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

9
9.1 9.2 9.3 9.3.1 9.3.2

Instructions for Electrical Machines Which Are To Be Stored
Storage Site .................................................................................... 48 Securing the Machine for Transportation ........................................ 48 Checks before Commissioning ...................................................... 48 Bearings .......................................................................................... 48 Insulating Resistance ..................................................................... 49 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
1.1

Safety Instructions
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 Requirements for the Operation of High-Voltage Plant

1.5

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
2.1

Important Instructions
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 180 200 225 250 280 315S/M 315L 315X 355 Type 3000 [min-1] V p [m3/min] [Pa] 11,0 12,0 15,0 21,0 23,0 28,0 34,01) 39,0 50,0 70 70 60 90 60 70 70 80 100 1500 [min-1] V p [m3/min] [Pa] 8,0 9,0 14,0 19,0 26,0 34,0 36,0 38,0 51,0 20 20 40 40 50 60 60 70 80 1000 [min-1] V p [m3/min] [Pa] 5,5 6,0 7,0 13,0 17,0 23,0 24,0 25,5 34,0 15 20 20 30 40 50 50 50 50 750 [min-1] V p [m3/min] [Pa] 4,5 5,0 6,5 9,0 13,5 17,0 18,0 19,0 25,0 10 10 15 20 30 30 30 30 30

KN7 180.KN7 200.KN7 225.KN7 250.KN7 280.KN7 315.KN7 315LKN7 315XKN7 355.-

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
3.1

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



3.2

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: – – Undo bolts (1) and remove clamp fixing (2). Stop up the threaded hole with the plug. Plug is attached to the information plate (drive shaft).

4


• – 5 – •

Rod fixing: Undo bolts (3) and remove the rod fixing (4). Screw in and tighten the shorter bolts supplied.

3

6

Clamping screw fixing: – – Loosen the nut (5) and undo the clamping screw (6). Stop up the threaded holes with the plug.

8

7



Clamp fixing: – – 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.

Diag.3: Example of securing procedures for transportation


3.4

Transport Damage

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

12

Assembly and Commissioning
4
4.1

Assembly and Commissioning
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
4.2.1

Mechanical
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
• 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. 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.

S

M

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 up to 500 hrs more than 500 hrs

Rate of Vibration 0,4 mm/s 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. 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.



16

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) 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) 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.

E

Diag.8: Parallel alignment

E

Diag.9: Combined angular and parallel alignment

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.



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

18

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. 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.


4.3.2

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 2 M6 3 M8 6 M10 10 M12 15,5 M16 30 M20 52 M24 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 right (cw) left (ccw)

U1 - V1 - W1 W1 - V1 - U1



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 Direct switch-on and pole-shift motors with separate windings Star or delta connection and pole-shift motors with DAHLANDER winding Measures Exchange twosupply-cable conductors on the motor terminal board. 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
5.1

Maintenance
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: – – – Drop point Ash content Water content approx. 190°C 4% 0,3%


5.3.2

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
1 5.4 without grease Bearing Seals (Diag.11) 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). When fitting V-rings onto flat sealing surfaces the dimension „X“ must be maintained. Non-compliance will lead to overheating or destruction of the V-ring, or will result in a bad seal.

x
greased



2

• •

3

greased

2
4

+ 0.5

V-ring type V-25 to V-38

Fitting dimensionX (mm) 9,0 11,0 13,5 15,5 -0,3 -0,3 -0,5 -0,5

Diag.11: 1 2 3 4

V-ring Felt ring Neoprene sealing ring Labyrinth ring
x

V-40 to V-65 V-70 to V-100 V-110 to V-150



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.

Diag.12: V-type sealing ring

26

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 15 16.1

14 12 11 10 13

16.2

7 6 3 4 5

8
SM

2

1 9

A 2.2
SM

2.1

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 15 16.1

14 12 11 10 13

16.2

7 6 3 4 5

8
SM

2

1 9

A 2.2
SM

2.1

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 14 15 16.1

12 11 10

13

16.2

8.1 7.1 6.1 3.1 4.1 5.1
SM

1.1

2.1

6.2

3.1.1 2.1.1

A

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 15.1 14.1.1 14.1 12.1 10.1 11.1 16.1.1 17.1.1

9.1 8.1 5.1.1 4.1 5.1 7.1
SM

3.1 2.1 1.1

6.1

3.1.1 2.1.1

A

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 15.1 14.1.1 14.1 12.1 10.1 11.1 16.1.1 17.1.1

9.1 8.1 5.1.1 4.1 5.1 7.1
SM

3.1 2.1 1.1

6.1

3.1.1 2.1.1

A

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 15.1 14.1.1 14.1 12.1 10.1 11.1 16.1.1 17.1.1

9.1 8.1 5.1.1 4.1 5.1 6.2 7.1
SM

3.1 2.1 1.1

6.3

3.1.1 2.1.1

A

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 15.1 14.1.1 14.1 12.1 10.1 11.1 16.1.1 17.1.1

9.1 8.1 5.1.1 4.1 5.1 6.2 7.1
SM

3.1 2.1 1.1

6.3

3.1.1 2.1.1

A

SM

Diag.16: Bearing change AH355

40

Maintenance
5.7 Maintenance Schedule – Models Fitted with Roller Bearings
DAILY WEEKLY EVERY 3 MONTHS For lubrication deadlines see rating plate ANNUALLY(minor overhaul) EVERY 5 YEARS (major overhaul) - bearing change, check shaft seals, replace if necessary;- remove old grease; Clean Clean

COMPONENT

Bearing

Heat exchangerAirwa ys Driven appliance (Observe the manufacturer´s specifications) Terminal boxEarth Stator winding

Check

Check alignment and that the machine is secure

Check alignment and make sure that machine is secure

Check alignment and that machine is secure;Change grease / oil Clean internally; Retighten screws Check that feed cables are not torn, that they are firmly seated,check keys; measure insulating resistance Check function

Clean internally; Retighten screws Measure insulating resistance

Auxiliary monitoring connections Motor as a whole

Record measurement data Pay attention to operating noise and quiet running

Check function

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
6.1

Trouble shooting
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
POSSIBLE CAUSES OF MALFUNCTION Overload Interruption of a phase in the feed REMEDIAL MEASURES Reduce load Check switch and feeds Check switch and feeds Check mains supply state Check mains supply state Check the winding circuitry Determine winding and insulating resistances; Overhaul after consulting the manufacturer Overhaul after consulting the manufacturer Swap the mains connections U and W Clean the airways,Check seals Do not exceed 105% of the rated voltage

l l l l l l l l l l l l l l l l l l l

l l

l l

Interruption of a phase in the feed after switching on Mains voltage too low,Frequency too high Mains voltage too high,Frequency too low Stator winding connected up wrongly Winding or phase break in the stator winding Asymmetry in short-circuit cage

l l l

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

43

Trouble shooting
6.3 Malfunctions - Mechanical

MECHANICAL MALFUNCTION CHARACTERISTICS – Rubbing noise – Rapid rise in temperature – Strong vibration – Bearings overheating – Bearing noise
POSSIBLE CAUSES OF MALFUNCTION Rotating parts rubbing REMEDIAL MEASURES Determine cause, readjust parts * Check airways, clean filter, if necessary, replace fan * Uncouple rotor and re-balance * Consult the manufacturer Align machine group, check coupling Re-balance coupled machine Check the coupled machine Repair the gearbox After consultation, alter the rigidity of the foundations Determine the cause of the change, if applicable, eliminate; align machine anew Remove excess grease Clean or renew bearing * Use grease which is suitable for high temperatures* Replace felt rings Grease according to instructions Renew bearing * Fit a bearing with more play * Fit a bearing with less play * Renew bearing * Renew bearing, avoid shocks when the machine is standing idle Align the machine more accurately Reduce drive belt tension Check the bearing hub bore *

l

l l l l l l l l l l l l l l l l l l l l l l l

Air feed choked, filter dirty, if applicable, wrong direction of rotation Rotor out of balance Rotor out of true, shaft distorted Faulty alignment Driven appliance out of balance Impact from the driven appliance Noisy gearbox Resonance with foundations Changes in the foundations Too much grease in the bearings Bearing dirty Ambient temperature > 40°C Felt rings pressing on the shaft Insufficient lubrication Bearing corroded Too little play in the bearing Too much play in the bearing Areas of rubbing on bearing track Furrows on the bearing Coupling pressing or pulling Too much belt tension Bearing twisted or skew

l l l l
*

if necessary, inform the manufacturer

44

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
8.1

Spare Parts
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
1 2 3 4 5 6 7 8 9 10 11 12 13 13a 14 15 16 17 18 19 20 21 22 23

Exploded View, IP23, Model Size 180M-355L
Sealing ring DS, outer or labyrinth plate Bearing shield DS Grease nipple Compensation washer Spring clip DS or shaft nut Collar oiler DS Ball and Roller bearing DS Sealing ring DS, inner Bearing cover, DS inner Stator housing IMB3 with core and windings Terminal box, complete Fan cover Air baffle Securing clamp Rotor with core and windings Key Key for fan Fan Fan safety ring Sealing cover Bearing cover NS, inner Sealing ring NS, inner Ball and Roller bearing NS Safety ring for NS bearing

46

Spare Parts
24 25 26 27 28 29 Collar oiler NS Spring clip NS or shaft nut Bearing shield NS Sealing ring NS, outer or labyrinth plate Flange bearing shield Stator housing without feet, complete

8 3 2 1 4 6 5 7

9 17 16

15 14 13 12

11

10 3 26 13a 23 22
SM

19 27

24

25

21 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 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:


9.1

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
9.3.1

Checks before Commissioning
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

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

SCH 12.01 / S7.2.2 en

930940099UK
Revision: 1 Page: 1 of (9) Prepared by: LHR Latest revision: LHR

ACOUSTIC ENCLOSURE

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.

930940099UK
Revision: 1 Page: 2 of (9)

ACOUSTIC ENCLOSURE

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.

930940099UK
Revision: 1 Page: 3 of (9)

ACOUSTIC ENCLOSURE

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

6.

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. 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.

11.

930940099UK
Revision: 1 Page: 4 of (9)

ACOUSTIC ENCLOSURE

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
Revision: 1 Page: 5 of (9)

ACOUSTIC ENCLOSURE

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.

930940099UK
Revision: 1 Page: 6 of (9)

ACOUSTIC ENCLOSURE

930940099UK
Revision: 1 Page: 7 of (9)

ACOUSTIC ENCLOSURE

930940099UK
Revision: 1 Page: 8 of (9)

ACOUSTIC ENCLOSURE

930940099UK
Revision: 1 Page: 9 of (9)

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

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. 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.

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. 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. 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. 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

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

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. 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.

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: 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.

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. 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 Coupling Size ÆA 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 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 Thread Size Torque 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 0,64 001 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.

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

Setscrew

89301E232a

3

05/01

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

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. 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. 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

Center Spool One per Cplg.

Disc Pack Two per Cplg. TomStainaloy less Part Part No. No. 910618 310618 710663 310663 210665 710665 210984 610984 010985 010957 810952 410943 810986 210987 420735 110962 710959 Not available 210985 210957 010952 610943 010986 410987 620735 310962 910959 420803 921021 220851 020793 020958 Washer Bolt Locknut

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.

Part No. 128790 034406 234407 434408

Part Qty. Part No. No. 212706 16 916087 212706 24 916087 712610 32 116008 712610 32 116088 014762 017142 019099 019101 019102 516100 711460 311750 612127 511413 111803 911800 611402 812176 32 32 32 32 32 32 32 32 32 32 32 32 32 32 316089 516090 716091 916092 116093 316094 516095 716096 916097 116098 316099 616200 816201 016202

Qty. 8 12 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16

Part No. 916504 916504 316505 316505 716506 116507 516508 916509 316510 716511 116512 516514 020253* 020254* 020255* 020256* 020257* 913898

Qty 8 12 16 16 16 16 16 16 16 16 16 16 16 16 16 16 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

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

89301E232a

4

05/01

Instructions de mise en service, stockage et entretien Instructions for start-up, storage and maintenance Modèles / Models : OA, OAP, AS, ASP, BS, SRA, SRC, ASM

TMS - 300 - SD F / A rev. D

Gamme Range

SD

SOMMAIRE
PAGE 1. SECURITE 2. MONTAGE 3. COMMANDE MANUELLE ET DEBRAYAGE 4. RACCORDEMENT ET TESTS ELECTRIQUES 5. REGLAGE DES BUTEES MECANIQUES ET DES CONTACTS DE FIN DE COURSE 6. REGLAGE DU LIMITEUR DE COUPLE 7. POTENTIOMETRE DE RECOPIE DE POSITION (OPTION) 8. TRANSMETTEUR DE POSITION TYPE TAM (OPTION) 9. ENTRETIEN ET STOCKAGE DES SERVOMOTEURS SCHEMAS DE CABLAGE INTERNE ET EXEMPLES DE CIRCUITS DE PUISSANCE EXEMPLES DE REALISATION DE COFFRETS DE COMMANDE LE RESEAU INTERNATIONAL L.BERNARD 2 2 2 2 3 3 4 5 6 7 8 14

TABLE OF CONTENTS
PAGE INTERNAL WIRING DIAGRAMS AND EXAMPLES OF POWER SUPPLY CIRCUITS CONTROL PANEL DESIGN EXAMPLES 1. SAFETY INFORMATION 2. ASSEMBLY 3. HANDWHEELOPERATION AND DECLUTCHING 4. ELECTRICAL CONNECTIONS AND PRELIMINARY TESTS 5. SETTING OF MECHANICAL STOPS AND TRAVEL LIMIT SWITCHES 6. SETTING OF TORQUE LIMIT SWITCHES 7. POSITION FEEDBACK POTENTIOMETER (OPTION) 8. "TAM" POSITION TRANSMITTER (OPTION) 9. MAINTENANCE AND STORAGE INSTRUCTIONS L.BERNARD INTERANATIONAL NETWORK 7 8 9 9 9 9 10 10 11 12 13 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 MULTIS COMPLEX EP2 SHELL ALVANIA EP2 MOBIL MOBILUX EP2 ESSO 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
Moteur / Motor Contact limiteur d'effort ouverture / Torque limit switch opening Contact limiteur d'effort fermeture / Torque limit switch closing Fin de course ouverture / Travel limit switch opening Potentiomètre / Potentiometer Fin de course suppl. ouverture / Extra travel limit switch opening

Fin de course suppl. fermeture/ Extra travel limit switch closing Résistance de chauffage / Heating resistance

Fin de course fermeture / Travel limit switch closing Protection thermique moteur Motor thermal protection Note 1 : Sens de rotation / Direction of rotation : Ouverture : anti-horaire. Fermeture : horaire / Opening : anti-clockwise. Closing : clockwise 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. Note 3 : Fins de course / Travel limit switches : Délivrent un contact maintenu / Provide a maintained contact.

Sécurité débrayage volant / Handwheel clutching security Contact clignotant (moteur en rotation) / Flashing contact running motor indication) Second potentiomètre / Second potentiometer Transmetteur de position 4-20 mA de type TAM / Position transmitter 4-20 mA model TAM 12-32 VCC/VDC 2 fils / wires

12-32 VCC/VDC 2 ou 3 fils / 2 or 3 wires

3 PHASES

1 PHASE
version non pré-câblée (*) / not valid for prewired versions (*) Légende : C1 = contacteur ouverture ; C2 = contacteur fermeture Legend : C1 = opening contactor ; C2 = closing contactor

EEx e d Connection

Sectionneur / Circuit breaker + fusible / fuse

Sectionneur / Circuit breaker + fusible / fuse

Th : Protection thermique intégrée au bobinage / Thermal cutout (integrated into the motor wiring

Relais thermique / Thermal relay

Relais thermique / Thermal relay

Boîte à bornes moteur indépendante / Independant motor terminal box Condensateur / Capacitor Note : En monophasé : le condensateur est livré séparément / In single phase, the capacitor is supplied separately

Autres versions (VCC par ex.) : nous consulter / Other versions (VDC i.e) : please consult us

(*) 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

E1 E2 TR
Arrêt Arr t / Stop

Acquittement défaut limiteur d'effort / d faut Torque limit default acknoledgement
Légende / Legend E1 E2 C1 C2 C3 FCO FCF LEO LEF LT TR B1 B2 E1 E2 C1 C2 C3 FCO FCF LEO LEF LT TR B1 B2 : 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 : 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

C3

Servomoteur / Actuator
10 13 4 7

FCO
12 11 15

FCF
14 6

LEO
9

LEF

B1

C1 C3 C2

B2

C2 C3 C1 C2 C3
Defaut / Default

Ouvert / Open

Fermé Ferm / C1 Closed

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
Condensateur / Capacitor

CABLAGE CLIENT / CUSTOMER WIRING

M 1

10 11 12 1 2 3 4

ouvert / open Alimentation monophasée / Single phase power supply

Protection thermique moteur Motor thermal protection

fermé / closed

OUVERT / OPEN Contacts fin de course / Travel limit switches FERME / CLOSED
5

OUVERT / OPEN

6

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 MULTIS COMPLEX EP2 SHELL ALVANIA EP2 MOBIL MOBILUX EP2 ESSO 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]

PEGLER BEACON AUSTRALIA Pty Ltd 3, corporate avenue ROWVILLE, VICTORIA 3178 Tel : + 61 3 9765 6111 Fax : + 61 3 9765 6165 IPU ING PAUL UNGER Hardtmuthgasse 53 1100 WIEN Tel : +43 1 602 41 49 Fax : +43 1 603 29 43 BERNARD BENELUX SA

MALAYSIA
[email protected]

ACTUATION & CONTROLS ENGINEER 7, Jalan Bayu 2/5 - Taman Perindustrian. Tampoi Jaya - 81200 JOHOR BAHRU Tel : +60 7 23 50 277 / 23 50 281 Fax : +60 7 23 50 280 / 23 50 285 BERNARD MIDDLE-EAST Villa N°5-P.O. box 34079, 39b Street Al Jaffliya Compound, Al Jaffliya DUBAI - U.A.E. Tel : +971 4 39 80 726 Fax : +971 4 39 80 726 BERNARD BENELUX NV Sophialaan 5 3542 AR UTRECHT Tel : +31 30 24 14 700 Fax : +31 30 24 13 949 FAGERBERG NORGE a.s Pancoveien 28 1522 GRESSVIK Tel : +47 69 35 55 30 Fax : +47 69 35 55 31 MARCO Ul. Ksiezycowa 1 01-934 WARSZAWA Tel : +48 22 864 94 21 Fax : +48 22 864 94 22 PINHOL, GOMES & GOMES LDA. Caminho dos Confeiteiros, 41 - 41 A Portela de Carnaxide 2790-051 Carnaxide Tél : +351 21 425 68 50 Fax : +351 21 425 68 59 ACTUATION &CONTROLS ENG. (ASIA) Block 2 Bukit Batok Street 24 N°07-19 Skytech SINGAPOUR 659480 Tel : +65 65 654 227 Fax : +65 65 650 224 BERNARD SOUTH-EAST ASIA Liaison office Thailand Bangkok 10110 Thailand Tel : +66 1 814 57 30 Fax : +66 2 255 26 38 BERNARD SERVOMOTORES C/ Valentin Beato, 11 - 1°D 28037 MADRID Tel : +34 91 30 41 139 Fax : +34 91 32 73 442 G. FAGERBERG AB Postbox 12105 40241 GOETEBORG Tel : +46 31 69 37 00 Fax : +46 31 69 38 00 MATOKEM AG Binningerstrasse 86 CH - 4123 ALLSCHWIL Tel : +41 61 483 15 40 Fax : +41 61 483 15 42 CIMTEK A.S. Genclik Caddesi N°9 Isiklar Binasi TANDOGAN 06570 - ANKARA Tel : +90 312 232 67 00 Fax : +90 312 232 53 64 EMIRATES HOLDINGS P.O. Box 984 ABU DHABI Tel : +97 12 644 73 73 Fax : +97 12 644 40 66 ZOEDALE Plc Stannard Way / Priory Business Park BEDFORD MK44 3WG Tel : +44 12 83 28 32 Fax : +44 12 83 28 00 BERNARD CONTROLS Inc 15740 Park Row, Suite 100 HOUSTON - TEXAS 77084 Tel : +1 281 578 66 66 Fax : +1 281 578 27 97

AUSTRIA
[email protected]

MIDDLE-EAST
[email protected]

BELGIUM

[email protected] bernard-benelux.com Rue Saint-Denis, 135

THE NETHERLANDS
[email protected]

1190 BRUXELLES Tel : +32 2 34 34 122 Fax : +32 2 34 72 843 BRAZIL
[email protected]

JCN Av. Mutinga, 3188 - Pirituba CEP 05110-000 Sao Paulo SP Tel : +55 11 39 02 26 00 Fax : +55 11 39 02 40 18 TADELLA LIMITED B701, Hong-an mansion, 188 Chanoei Street, Dongcheng District, BEIJING - CHINE 100010 Tel : +86 10 6517 0601 / 0602 Fax : +86 10 6517 0603 FLUIDTECHNIK BOHEMIA s.r.o. Olomoucka 87 627 00 Brno Tel : +420 548 213 233-5 Fax : +420 548 213 238 ARMATEC A/S Mjolnersvej 4-8 DK 2600 Glostrup Tel : +45 46 96 00 00 Fax : +45 46 96 00 01 OY SOFFCO AB Karapellontie 11 FIN-02610 ESPOO Tel : +358 9 54 04 620 Fax : +358 9 54 04 6250 DEUFRA GMBH Kasinostrasse 22 53840 TROISDORF Tel : +49 22 41 98 340 Fax : +49 22 41 98 34 44 PI&MS 3 Pendelis Str. Pallini 153 51 Athènes - Hellas Tel : +30 210 66 69 129 Fax : +30 210 66 69 130 APAGYI TRADEIMPEX KFT 1145 Budapest Stefania u. 63/c. Tel : +36 1 223 1958 Fax : +36 1 273 0680 INSTRUMENTATION LTD Kanjikode West 678623 PALGHAT-KERALA Tel : +91 491 56 61 27 / 56 61 28 Fax : +91 491 56 61 35 / 56 62 40 BERNARD SERVOMOTORI Via Giuseppe di Vittorio 1 20017 MAZZO DI RHO (MI) Tel : +39 02 93 90 60 22 Fax : +39 02 93 90 42 46 BERNARD JAPAN c/o Pechiney Japan 29 Fl. Shinjuku Mitsui Bldg 2-1-1 Nishi Shinjuku, Shinjuku-ku, Tokyo 163-0429 JAPAN Tel : +81 3 33 49 66 39 Fax : +81 3 33 49 67 50 HUMAN INFRASTRUCTURE TECH. 3 Fl. SungWon Building 813-1 Bangbae-Dong, Seocho-Gu SEOUL 137-832 Tel : +82 2 532 2604 Fax : +82 2 3478 7089

NORWAY
[email protected] www.fagerberg.no

CHINA
[email protected] www.tadella.com

POLAND
[email protected]

CZECH REPUBLIC
[email protected]

PORTUGAL
[email protected]

DENMARK
[email protected] www.armatec.dk

SINGAPORE
[email protected]

FINLAND
[email protected] www.soffco.fi

SOUTH-EAST ASIA
[email protected]

GERMANY
[email protected] www.deufra.de

SPAIN
[email protected]

GREECE
[email protected]

SWEDEN
[email protected] www.fagerberg.se

HUNGARY
[email protected]

SWITZERLAND
[email protected] www.matokem.com

INDIA
[email protected]

TURKEY
[email protected]

ITALY
[email protected]

UNITED ARABS EMIRATES
[email protected]

JAPAN
[email protected]

UNITED-KINGDOM
[email protected] www.zoedale.co.uk

KOREA (Rep of)
[email protected] www.humanitc.com

USA
[email protected] www.bernardcontrols.com

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

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

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.

C

A

B

C

Part list
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 *

Liste des composants
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.

Komponentenverzeichnis
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. A B C D E F G H I *

Lista de componentes
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

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 *

Équipements en option
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.

Accessories
F G Lifting eye Vibration dampener F G

Accessoires
Anneaux de levage Patins antivibratoires

Sonderzubehör
A B C D E * Steinschutz Staubschutz S-Bypass, Einzeldurchlauf* T-Bypass, Doppeldurchlauf* Thermoschalter Mit Drucksteuerung oder Temperatur- und Drucksteuerung lieferbar. A B C D E *

Equipamientos opcionales
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.

Zubehör
F G Hebeösen Vibrationsdämpfer F G

Accesorios
Cáncamos de elevación Silent blocs

1

2
A B

C

D

3
½A ½A A

4
B C

D A

5

B A D

6

7

1

2

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

1)

2)

3) 4)

8

U1 = Svart Black U2 = Grön Green V1 = Blå Blue V2 = Vit White W1 = Brun Brown W2 = Gul Yellow

Schwarz Noir Negro Grün Vert Verde Blau Bleu Azul Weiß Blanc Blanco Braun Marron Maron Gelb Jaune Amarillo Schwarz Noir Negro Grün Vert Verde Blau Bleu Azul Weiß Blanc Blanco Braun Marron Maron Gelb Jaune Amarillo

Y-koppling (3x400 V) Y-connection (3x400 V) Y-Anschluss (3x400 V) Connexion en Y (3x400 V) Conexión en Y (3x400 V)

9

U1 = Svart Black U2 = Grön Green V1 = Blå Blue V2 = Vit White W1 = Brun Brown W2 = Gul Yellow

D-koppling (3x230 V) D-connection (3x230 V) D-Anschluss (3x230 V) Connexion en D (3x230 V) Conexión en D (3x230 V)

10

Y-koppling Y-connection Y-Anschluss Connexion en Y Conexión en Y

D-koppling D-connection D-Anschluss Connexion en D Conexión en D

11

12

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.

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.

Use
The LAC-series of air oil coolers is designed to cool hydraulic fluids in systems for industrial applications.

13

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. 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.

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. Precaution This alerts you to an action or procedure that, if performed improperly, is likely to cause an accident with physical harm. Notifications concerning other safety issues (property, process or environment) and maintenance work are classified as follows.

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 Danger Electrical shock hazard. All electrical connections must be made by a qualified electrician!

14

Operation, handling and maintenance Caution Risk of bodily injury. Disconnect the motor power supply prior to maintenance. Caution Risk of bodily injury. Before disconnecting the hydraulic connections, make sure the system is depressurized. 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. 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.

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. Note! Use hearing protection when standing close to an operating air oil cooler for long periods of time.

Warning label
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.

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. 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.

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.

16

Installation
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. Air oil coolers as from size 033 can accommodate lifting eyes. Lifting eyes are available from Oiltech/Olaer on request.

Mounting
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. 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. 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! Note! A motor overload protection is recommended. Some motors are fitted with plugged holes, which can be used for draining condensed water.

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

18

Handling
Prior to initial start-up
Check that the air oil cooler is securely fixed and correctly connected. 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. See Technical specification for recommended fluid compatibility.

During operation
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. Maximum permitted fluid temperature in the cooler matrix is 120 °C. Do not overload the electric motor. See label on the electric motor. The cooler matrix is designed for maximum allowed dynamic working pressure 14 bar. Note! Use hearing protection when standing in the immediate vicinity of an operating air oil cooler for long periods of time.

Prior to start up
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.

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

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. Annually: Check the electrical installation. This may only be made by a qualified electrician. 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.

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
Dismounting the cooler matrix
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. 1 2 3 4 5 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.

Removing the electric motor and the fan
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 harm. Prior to maintenance, disconnect the electric motor power supply. The fan is balanced together with the hub at delivery. Note! 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.

1 2 3 4

6

Mounting of the cooler matrix
1 2 3 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

4 5

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.

6

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
Note! 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.

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.

1

2 3

4 5

22

Technical specification
For further technical specification, refer to separate Technical data sheet, LAC air oil cooler.

Cooler matrix
Maximum static working pressure: Maximum dynamic working pressure: Heat transfer allowance: Maximum fluid temperature in the cooler matrix: 21 bar 14 bar Tested according to ISO/DIS 10771-1 ±6% 120 °C

Fluid compatibility
Mineral oil: Oil/water emulsion: Water glycol: Phosfatester: HL/HLP according to DIN 51524 HFA, HFB according to CETOP RP 77H HFC according to CETOP RP 77H HFD-R according to CETOP RP 77H

Material
Cooler matrix: Fan housing: Fan blades/hub: Fan guard: Other parts: Surface treatment: Aluminium Steel Glass fibre reinforced polypropylene/ aluminium Steel Steel 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. 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.
20009201

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

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

ISO VG 46 14,0 75 45 0 6,45

l/min °C °C m kW

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

73 58 50 0,23 0,052 0,99 1,10 82 IP 55 25 2,5

°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.
_______________________________________________________________________________________________________________

"##$%#$%"& '$("

7 5$& "56 ''9' 859: "#

7 "5

;' 8 9:
"&# &&

7 &# 6 859:

*)

&'# &&#
!

"# "# 55#

&#

Ritad/Drawn

Datum/Date/YYYY-MM-DD

+

,-

"##$%#*%#'

Svetsklass om annat ej angetts: Welding class if not indicated:

01

Toleranser om annat ej angetts enligt: Tolerances if not indicated according to:

Projekt/Project

#

' *
Skala/Scale

.+/ "$*)% -

4#"#
Filnamn/File name

'(& &) *#''##
Rev. sign.

Ersätter/Replaces

OLAER GROUP

Phone: +46 (0)8 636 07 00 Fax: +46 (0)8 767 97 56 www.oiltech.se

OILTECH AB FÖRRÅDSVÄGEN 2 SE-181 41 LIDINGÖ SWEDEN

2 3"%#''%"% %##% ###%#%#

Rev.datum/Date/YYYY-MM-DD Dokument typ/Type of doc.

+
Ritning/Drawing Revision

&) *#''## %+ %

5$#
Vyplac./ Projection method

;<

" #

*5

7 '&

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
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.

Extended surface filter with controlled media spacing (CMS) for longer life and consistent lifetime high efficiency

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 Hi-Flo®

Product sheet 1203 - 0907

Camfil Farr—clean air solutions

Controlled Media Spacing (continued) 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: • • • • Increased filter life Reduced maintenance costs Minimized fan horsepower requirements Reduced energy expenditures.

Leak-Free Filter Performance 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. 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.

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.

Camfil Farr Hi-Flo® Selection Chart
Model Number Dimensionsa (precede with HF Number of (nominal size) and insert (inches) Pockets efficiency for *) HxWxD */24/24/32/12 */24/20/32/9 */24/12/32/6 */20/20/32/9 */24/24/15/12 */24/20/15/9 */24/12/15/6 */20/20/15/9 */24/24/30/10 */24/20/30/8 */24/12/30/5 */20/20/30/8 */24/24/22/10 */24/20/22/8 */24/12/22/5 */20/20/22/8 */24/24/36/8 */24/20/36/7 */24/12/36/4 */20/20/36/7 */24/24/30/8 */24/20/30/7 */24/12/30/4 */20/20/30/7 */24/24/22/8 */24/20/22/7 */24/12/22/4 */20/20/22/7 */24/24/36/6 */24/20/36/5 */24/12/36/3 */20/20/36/5 */24/24/30/6 */24/20/30/5 */24/12/30/3 */20/20/30/5 */24/24/22/6 */24/20/22/5 */24/12/22/3 */20/20/22/5 12 9 6 9 12 9 6 9 10 8 5 8 10 8 5 8 8 7 4 7 8 7 4 7 8 7 4 7 6 5 3 5 6 5 3 5 6 5 3 5 24 x 24 x 32
d

Airflow Capacityb Low 2000 1500 1000 1250 1000 750 500 650 2000 1600 1000 1350 1500 1200 750 1000 2000 1600 1000 1350 1600 1400 800 1150 1500 1300 750 1100 1500 1300 750 1050 1500 1300 750 1050 1500 1300 750 1050 Med 2500 1875 1250 1575 1500 1100 750 950 2400 1900 1200 1625 1750 1400 875 1175 2400 1900 1200 1625 2000 1750 1000 1450 1750 1500 875 1300 1750 1500 875 1225 1750 1500 875 1225 1750 1500 875 1225 High 3000 2250 1500 1875 2000 1500 1000 1275 2800 2250 1400 1875 2000 1600 1000 1350 2800 2250 1400 1875 2400 2100 1200 1750 2000 1750 1000 1450 2000 1700 1000 1400 2000 1700 1000 1400 2000 1700 1000 1400 0.60 0.47 0.45 0.48 0.46 0.54 0.45 0.54 0.29 0.40 Low

Initial Resistance to Airflow (inches w.g.)c MERV 14 Med High Low MERV 13 Med MERV 11 MERV 9 High Media Area (sq. ft.) 129 0.54 0.72 0.30 0.40 0.54 0.20 0.27 0.36 0.16 0.21 0.29 97 65 81 58 0.49 0.70 0.20 0.34 0.48 0.13 0.21 0.30 0.09 0.15 0.21 44 29 37 101 0.69 0.84 0.36 0.46 0.56 0.23 0.29 0.36 0.17 0.22 0.27 81 50 68 73 0.54 0.64 0.30 0.36 0.43 0.18 0.22 0.26 0.13 0.15 0.18 58 36 49 97 0.69 0.84 0.36 0.46 0.56 0.23 0.29 0.36 0.17 0.22 0.22 85 49 71 81 0.60 0.77 0.30 0.40 0.51 0.19 0.25 0.32 0.14 0.18 0.23 70 40 59 58 0.57 0.68 0.32 0.38 0.45 0.20 0.24 0.28 0.14 0.17 0.20 51 29 43 76 0.54 0.64 0.29 0.35 0.42 0.18 0.21 0.25 0.13 0.15 0.18 63 38 53 63 0.56 0.67 0.31 0.37 0.44 0.19 0.23 0.27 0.13 0.16 0.19 52 31 44 45 0.71 0.85 0.39 0.46 0.55 0.23 0.28 0.33 0.15 0.18 0.22 38 23 32

High Low Med High Low Med

24 x 20 x 32d 24 x 12 x 32d 20 x 20 x 32d 24 x 24 x 15 24 x 20 x 15 24 x 12 x 15 20 x 20 x 15 24 x 24 x 30 24 x 20 x 30 24 x 12 x 30 20 x 20 x 30 24 x 24 x 22 24 x 20 x 22 24 x 12 x 22 20 x 20 x 22 24 x 24 x 36d 24 x 20 x 36d 24 x 12 x 36d 20 x 20 x 36d 24 x 24 x 30 24 x 20 x 30 24 x 12 x 30 20 x 20 x 30 24 x 24 x 22 24 x 20 x 22 24 x 12 x 22 20 x 20 x 22 24 x 24 x 36d 24 x 20 x 36d 24 x 12 x 36d 20 x 20 x 36d 24 x 24 x 30 24 x 20 x 30 24 x 12 x 30 20 x 20 x 30 24 x 24 x 22 24 x 20 x 22 24 x 12 x 22 20 x 20 x 22

HF
HF = Hi-Flo SF = S-Flo

MV14
Efficiency MV14 = MERV 14 MV13 = MERV 13 MV11 = MERV 11 MV 9 = MERV 9

24
Height (nominal)

24
Width (nominal)

22
Depth (nominal)

8
Number Of Pockets

1
Options 1 = UL Class 1 W = 1 1/8” header Consult factory for additional options.

DATA NOTES:
a

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.

Extended Surface Pocket Filter Options
UL Class 1 Hi-Flo 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. 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. Cambridge-Style Header

Hi-Flo®

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. 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. 2.0 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. 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. 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

Items in parentheses () require selection.

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

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 Hi-Flo® 22” Deep

Technical Data 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 Hi-Flo® 30” Deep

Technical Data 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
Thermometer execution straight angle 90°, backwards angle 135°, backwards Immersion tube type

174
Type 174 175 176 B Bdr1) = =

2 35 1

1

030

2

1

Type 174 B

2 6 35 06 10 12 16 20 1 2

Ranges

-30+50°C = 0+60°C = 0+100°C = 0+120°C = 0+160°C = 0+200°C =

Division Celsius (°C) Celsius + Fahrenheit (°C + °F) Columns (Filling) Blue fluid is standard for ranges up to +200°C Optional: mercury Immersion tube lenghts l1 in mm (incl. thread)

Fü = Hg = 30 40 63 100 160 250 400

1 2 = = = = = = = 030 040 063 100 160 250 400 = = = = 1 2 5 7

Type 175 B

Thread connection

G 3/8A/SW 22 G 1/2A/SW 27 M16 x 1,5/SW 22 M20 x 1,5/SW 27

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) See page 8 for protecting tubes to be screwed in or welded.

1 2 3 4 5

Type 176 B

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)

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.

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 Nominal size 63 and 100 mm Accuracy class NS 63: 1.6 NS 100: 1.0 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. Working pressure NS 63: Steady: Fluctuating: Short time: NS 100: Steady: Fluctuating: Short time: 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 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

¾ x of full scale range B x of full scale range full scale range

WIKA Data Sheet PM 02.06 · 10/2005

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 Dial NS 63: white plastic, with pointer stop pin NS 100: white aluminium With black lettering Pointer Black aluminium Window Non-splintering clear acrylic glass

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 %

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

Dimensions in mm
radial bottom pressure connection
1034 804

NS 63, centre back pressure connection
1034 812

NS 100, lower back pressure connection
1034 839

NG 63 100

Dimension in mm b1 a b 12 13.5 36 53.5 36 53.5

Weight in kg b2 56 86 D1 62 99 D2 62 99 e 10.5 11.5 f 30 G e±1 SW 14 22 0.30 1.10 G ¼ B 54 G ½ B 87

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
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.
9019804 10/2005 GB

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

SIEMENS Compressors
Surge Controller SUC-3

Function

: To give alarm (stop the drive motor) in case of surging. : Inductive sensor. : In the compressor inlet housing.

Sensor Mounting

A: B:

Pressure direction at normal operation. 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 Output 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 [mm] [mm] [% of Sr] [% of Sr] [Hz] DC PNP normally closed 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 yellow (4 x 90°) M12 connector; gold-plated contacts *) "Coolant" 2 lock nuts

[°C]

Housing material Function display Switching status Connection Remarks Accessories (included) Wiring

LED

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
Revision: 2 Page: 1 of (1) Prepared by: Latest revision: FP SJ Date: Date:

COMPENSATOR DN100-DN600

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

Compressor KA2 KA4/5 KA10 KA22 KA44 KA66 KA80 KA100

DN 125 150 200 250 300 400 450 600

Ln 150 150 150 200 200 250 250 250

Di MIN. 132 148 196 244 292 390 440 588

Alignement Reuirements dz dx mm mm ±4 ±4 ±4 ±8 ±8 ±12 ±12 ±12 ±2 ±2 ±2 ±3 ±3 ±5 ±5 ±5

Flange Measures A 250 285 340 395 445 565 615 780 DCD 210 240 295 350 400 515 565 725 N 8 8 8 12 12 16 20 20 Ød 18 22 22 22 22 26 26 30 T 15 15 15 22 22 22 22 22

kg 8 10 12 22 26 35 39 55

930910053UK
Revision: 3 Page: 1 of (1) Prepared by: Latest revision: FW LHR

OUTLET DIFFUSER CONE - SILENCER
1991 16.11.1993

Material Outside : Inside :

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.

Compressor

B-E 125-250 125-300 150-250 150-300 150-350 200-350 200-400 200-500 250-500 250-600 300-600 300-700 400-700 400-800 400-900 450-900 450-1000 600-1000 600-1200

L 700 850 600 800 1100 800 1100 1700 1400 1900 1700 2000 1700 2000 2500 2300 2700 2000 3000

C 210 210 240 240 240 295 295 295 350 350 400 400 515 515 515 565 565 725 725

D 250 250 285 285 285 340 340 340 395 395 445 445 565 565 565 615 615 780 780

F 350 400 350 400 460 460 515 620 620 725 725 840 840 950 1050 1050 1160 1160 1380

G 395 445 395 445 505 505 565 670 670 780 780 895 895 1015 1115 1115 1230 1230 1455

H 26 26 26 26 28 28 32 34 34 36 36 38 38 42 46 46 52 52 56

K 24 24 24 24 24 24 24 24 26 26 26 26 32 32 32 34 34 36 36

Nxd 8 × 18 8 × 18 8 × 22 8 × 22 8 × 22 8 × 22 8 × 22 8 × 22 12 × 22 12 × 22 12 × 22 12 × 22 16 × 26 16 × 26 16 × 26 20 × 26 20 × 26 20 × 30 20 × 30

RxS 12 × 22 12 × 22 12 × 22 12 × 22 16 × 22 16 × 22 16 × 26 20 × 26 20 × 26 20 × 30 20 × 30 24 × 30 24 × 30 24 × 33 28 × 33 28 × 33 28 × 36 28 × 36 32 × 39

kg 55 65 55 70 90 80 110 170 160 220 210 270 270 340 430 420 520 480 720

KA2 KA2 KA4/5 KA4/5 KA4/5 KA10 KA10 KA10 KA22 KA22 KA44 KA44 KA66 KA66 KA66 KA80 KA80 KA100 KA100

930910016UK
Revision: 4 Page: 1 (1) Prepared by: Latest revision: FW DRo

SILENCER FOR BLOW-OFF VALVE
Date: 1991 Date: 1998.04.06

Material:

R.St. 37.2, ANSI 1015 (surface: Aluzink) Mineral wool Flange according to DIN 2501, PN 10

Compressor KA2 KA4 KA5 KA10 KA22 KA44 KA66 KA80 KA100

Dn 65 80 100 125 150 200 250 300 350

A 390 440 490 580 670 860 1040 1240 1440

B 220 230 245 255 285 320 410 445 490

C 100 100 100 100 100 150 150 150 150

D 145 160 180 210 240 295 350 400 460

E 185 200 220 250 285 340 395 445 505

F 18 20 22 24 24 24 26 26 28

N × ∅d 4 × 18 8 × 18 8 × 18 8 × 18 8 × 22 8 x 22 12 × 22 12 × 22 16 × 22

kg 14 17 21 26 40 70 110 150 220

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

ebm-papst · Mulfingen
Max. back pressure

Perm. amb. temp.

Nominal data
Type Motor M4D110-GF *4D 500 M4D110-GF M4D094-HA
subject to alterations

VAC 0° -5° -10°
(1)

Hz 50 50 50 50 50 50

min-1 1330 1020 1360 1110 1330 980

kW 0,83 0,56 0,69 0,49 0,64 0,42

A 1,65 0,98 1,43 0,86 1,26 0,74

Pa 160 100 160 105 180 100

°C -40..+60 -40..+60 -40..+90 -40..+90 -40..+60 -40..+60

kg 11,0 11,0 8,5

kg 12,8 12,8 10,3

kg 18,8 18,8 14,3

kg 13,5 13,5 11,0 5a)/5b) 5a)/5b) 5a)/5b)

1 2 3 4 5 6

400 400 Y 400 400 Y 400 400 Y

in operating point 3 with maximum load

n P1 [min-1] [kW]
1 1 1 2 2 2 3 3 3 1 2 3 1 2 3 1 2 3

I [A] 1,49 1,54 1,65 0,89 0,93 0,98 1,30 1,34 1,43

LpA [dBA] 72 71 72 67 67 66 71 71 70
4 4 4 5 5 5 6 6 6 1 2 3 1 2 3 1 2 3

n P1 [min-1] [kW] 1165 1135 1110 1375 1360 1330 1105 1060 980 0,44 0,47 0,49 0,50 0,54 0,64 0,37 0,39 0,42

I [A] 0,74 0,79 0,86 1,09 1,13 1,26 0,65 0,69 0,74

LpA [dBA] 68 67 66 71 72 72 66 66 65

1360 1350 1330 1090 1060 1020 1380 1370 1360

0,73 0,77 0,83 0,51 0,53 0,56 0,60 0,65 0,69

Characteristics
[in H O] [Pa]
2

3 5 3 3 2 22

120
0,4 3 6 2 3 3 2 1 0,2 1

0,6

160

80

3 1 1 1 1 1 2

4

40

0

1250

2500

3750

5000

[CFM] [m3/h] 0°

2000

4000
-10°

6000

8000
-5°

46

Electr. connection

Nominal voltage

Characteristic

Blade angle

Max. power input(1)

Max. current draw(1)

Speed/rpm(1)

Mass S... C

Mass S... A

Frequency

Mass W...

Mass A...

Direction of air flow

Type

S/A/B S "V" "V" "V" 0° -5° -10° A4D500-AD03 -01 A4D500-AE03 -01 A4D500-AZ14 -01 S4D500-CD03 -01 S4D500-CE03 -01 S4D500-CZ14 -01 W4D500-GD03 -01 W4D500-GE03 -01 W4D500-GZ14 -01 S4D500-AD03 -01 S4D500-AE03 -01 S4D500-AZ14 -01

c

d

g

s

t

u

v

104 101 182,5 103 143 44 84 98 89 182,5 97 143 38 84 92 78 186,5 91 147 32 88

*4D 500

S S

Cable gland M20

Depth of screw max. 12 mm View X

6,5

Í "V"

Í "V"

47
Electr. connection p. 286 f.

Contacts

Technology

Accessories

EC-SYSTEMS

Í "V"

Í "V"

ESM

Q-motor

Selection

Cable exit

Blade angle

Dimensions

EC axial

AC axial

General information

W4D500-DE03-02

AC axial fan with full square nozzle
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 Motor Phase Nominal voltage Connection Frequency Type of data definition Valid for approval / standard Speed Power input Current draw Max. back pressure Max. ambient temperature Air flow Back pressure Sound pressure level [Hz] [V] W4D500-DE03-02 M4D110-GF 3~ 400 ∆ 50 ml CE [min-1] 1360 [W] 690 [A] [Pa] [°C] [m3/h] [Pa] [dB(A)] 1.43 160 90 8930 0 3~ 400 Y 50 ml CE 1110 490 0.86 105 90 7760 0 3~ 400 ∆ 60 ml CE 1500 1010 1.8 195 65 10130 0 3~ 400 Y 60 ml CE 1030 575 1.05 95 65 7760 0 3~ 480 ∆ 60 ml CE 1600 1100 1.72 215 55 10350 0 73 3~ 480 Y 60 ml CE 1240 740 1.08 125 55 8710 0

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]

W4D500-DE03-02

AC axial fan with full square nozzle
sickled blades (S series)

Technical features
Size Operation mode Electrical leads Direction of air flow Insulation class Cable exit Bearing-motor Mass Material of electronics housing Material of impeller Motor protection Product conforming to standard Number of blades Type of protection Protection class 500 mm Continuous operation (S1) Via terminal box "A" "F" Axial Ball bearing 21 kg Rotor: Cast in aluminum Aluminum sheet Thermal overload protector (TOP) brought out CE 5 IP 54 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]

W4D500-DE03-02

AC axial fan with full square nozzle
sickled blades (S series)

Product drawing
209,5±5 43

Ø517

16 120

615±1 656-3

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]

Ø11

W4D500-DE03-02

AC axial fan with full square nozzle
sickled blades (S series)

Connection screen
Delta
PE U1 L1 V1 L2 W1 L3 TOP

Star
U1 U2 V1 V2 W1 W2 = = = = = = = BK GN BU WH BN YE GNYE
PE L1 L2 L3 TOP

U1

V1

W1

U2

V2

W2

U2

V2

W2

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]

W4D500-DE03-02

AC axial fan with full square nozzle
sickled blades (S series)

Charts: Air flow
[Pa] [in H O]
2

160 140
0,6

3

120
2

2

100

80 60
0,2 1

40

20

0,4 0

1250

2500

3750

5000

[CFM] [m3/h] 0˚

2000

4000

6000
-10˚

8000
-5˚

n [min-1] 1 2 3 1390 1380 1360

P1 [W] 570 62 690

I [A] 1.23 1.29 1.43

LwAss [dB(A)] 76 77 80

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: Build number: Order Number: Order Name: Testmotor: Type of test motor: STC−GO(7−1−KA1KG) ............. 8043 62008043 Nevsehir SCHORCH KN7315M−AB01B−Z (KA5−S−GK200) Curves valid for nominel conditions: Inlet Pressure: Inlet Temperature: Relative Humidity: Motor Speed: 0.88400 [bar] 308.15 [K] 60.0 [%] 2975. [1/min]

Serial number of test motor:21360801/03

.700 Pressure rise − [bar] .650 .600 .550 .500 .450 .400 .350 .300 2000 00 3000 4000 5000 6000 7000 8000 9000 10000 Volumetric flow at inlet conditions − [m3/h]
Average test condition Inlet Pressure: Inlet Temperature: Relative Humidity: Motor Speed: 1.02540 [bar] 299.81 [K] 3.6 [%] 2968. [1/min] Used evaluation standards for Compressor: ISO5389/VDI2045 Used evaluation standards for Volumeflow: ISO 5167−1:1991/Amd.1:1998(E) Accepted by: Test day:

220 200 08 09 180 160 04 05 02 06 140 120 100 80 60 11000

HANSE07C 18−02−2009

Power consumption at coupling − [kW]

.750

240

Performance Certificate for STC−GO Compressor
Compressor type: Build number: Order Number: Order Name: Testmotor: Type of test motor: STC−GO(7−1−KA1KG) ............. 8043 62008043 Nevsehir SCHORCH KN7315M−AB01B−Z (KA5−S−GK200) Curves valid for nominel conditions: Inlet Pressure: Inlet Temperature: Relative Humidity: Motor Speed: 0.88400 [bar] 298.35 [K] 60.0 [%] 2975. [1/min]

Serial number of test motor:21360801/03

.780 Pressure rise − [bar] .720 .660 .600 .540 .480 .420 .360 .300 2000 3000 00 4000 5000 6000 7000 8000 9000 10000 02 04 05 06 08 09

220 200 180 160 140 120 100 80 60 11000

Volumetric flow at inlet conditions − [m3/h]
Average test condition Inlet Pressure: Inlet Temperature: Relative Humidity: Motor Speed: 1.02540 [bar] 299.81 [K] 3.6 [%] 2968. [1/min] Used evaluation standards for Compressor: ISO5389/VDI2045 Used evaluation standards for Volumeflow: ISO 5167−1:1991/Amd.1:1998(E) Accepted by: Test day: HANSE07C 18−02−2009

Power consumption at coupling − [kW]

.840

240

Performance Certificate for STC−GO Compressor
Compressor type: Build number: Order Number: Order Name: Testmotor: Type of test motor: STC−GO(7−1−KA1KG) ............. 8043 62008043 Nevsehir SCHORCH KN7315M−AB01B−Z (KA5−S−GK200) Curves valid for nominel conditions: Inlet Pressure: Inlet Temperature: Relative Humidity: Motor Speed: 0.88400 [bar] 274.15 [K] 60.0 [%] 2975. [1/min]

Serial number of test motor:21360801/03

.845 Pressure rise − [bar] .780 .715 .650 .585 .520 .455 .390 .325 2000 3000 00 4000 5000 6000 7000 8000 9000 10000 02 04 05 06 08 09

220 200 180 160 140 120 100 80 60 11000

Volumetric flow at inlet conditions − [m3/h]
Average test condition Inlet Pressure: Inlet Temperature: Relative Humidity: Motor Speed: 1.02540 [bar] 299.81 [K] 3.6 [%] 2968. [1/min] Used evaluation standards for Compressor: ISO5389/VDI2045 Used evaluation standards for Volumeflow: ISO 5167−1:1991/Amd.1:1998(E) Accepted by: Test day: HANSE07C 18−02−2009

Power consumption at coupling − [kW]

.910

240

Performance Certificate for STC−GO Compressor
Compressor type: Build number: Order Number: Order Name: Testmotor: Type of test motor: STC−GO(7−1−KA1KG) ............. 8044 62008043 Nevsehir SCHORCH KN7315M−AB01B−Z (KA5−S−GK200) Curves valid for nominel conditions: Inlet Pressure: Inlet Temperature: Relative Humidity: Motor Speed: 0.88400 [bar] 308.15 [K] 60.0 [%] 2975. [1/min]

Serial number of test motor:21360801/2

.700 Pressure rise − [bar] .650 .600 .550 .500 .450 .400 .350 .300 2000 3000 02 00 4000 5000 6000 7000 8000 9000 10000 05 04 06 08 09

220 200 180 160 140 120 100 80 60 11000

Volumetric flow at inlet conditions − [m3/h]
Average test condition Inlet Pressure: Inlet Temperature: Relative Humidity: Motor Speed: 1.02613 [bar] 296.66 [K] 4.6 [%] 2969. [1/min] Used evaluation standards for Compressor: ISO5389/VDI2045 Used evaluation standards for Volumeflow: ISO 5167−1:1991/Amd.1:1998(E) Accepted by: Test day: HANSE07C 17−02−2009

Power consumption at coupling − [kW]

.750

240

Performance Certificate for STC−GO Compressor
Compressor type: Build number: Order Number: Order Name: Testmotor: Type of test motor: STC−GO(7−1−KA1KG) ............. 8044 62008043 Nevsehir SCHORCH KN7315M−AB01B−Z (KA5−S−GK200) Curves valid for nominel conditions: Inlet Pressure: Inlet Temperature: Relative Humidity: Motor Speed: 0.88400 [bar] 298.35 [K] 60.0 [%] 2975. [1/min]

Serial number of test motor:21360801/2

.770 Pressure rise − [bar] .715 .660 .605 .550 .495 .440 .385 .330 2000 00 3000 4000 5000 6000 7000 8000 9000 10000 Volumetric flow at inlet conditions − [m3/h]
Average test condition Inlet Pressure: Inlet Temperature: Relative Humidity: Motor Speed: 1.02613 [bar] 296.66 [K] 4.6 [%] 2969. [1/min] Used evaluation standards for Compressor: ISO5389/VDI2045 Used evaluation standards for Volumeflow: ISO 5167−1:1991/Amd.1:1998(E) Accepted by: Test day:

220 200 180 09 160 140 120 05 02 04 06 08 100 80 60 11000

HANSE07C 17−02−2009

Power consumption at coupling − [kW]

.825

240

Performance Certificate for STC−GO Compressor
Compressor type: Build number: Order Number: Order Name: Testmotor: Type of test motor: STC−GO(7−1−KA1KG) ............. 8044 62008043 Nevsehir SCHORCH KN7315M−AB01B−Z (KA5−S−GK200) Curves valid for nominel conditions: Inlet Pressure: Inlet Temperature: Relative Humidity: Motor Speed: 0.88400 [bar] 274.15 [K] 60.0 [%] 2975. [1/min]

Serial number of test motor:21360801/2

.840 Pressure rise − [bar] .780 .720 .660 .600 .540 .480 .420 .360 2000 00 3000 4000 5000 6000 7000 8000 9000 10000 Volumetric flow at inlet conditions − [m3/h]
Average test condition Inlet Pressure: Inlet Temperature: Relative Humidity: Motor Speed: 1.02613 [bar] 296.66 [K] 4.6 [%] 2969. [1/min] Used evaluation standards for Compressor: ISO5389/VDI2045 Used evaluation standards for Volumeflow: ISO 5167−1:1991/Amd.1:1998(E) Accepted by: Test day:

220 200 09 180 160 140 120 05 02 04 06 08 100 80 60 11000

HANSE07C 17−02−2009

Power consumption at coupling − [kW]

.900

240

Performance Certificate for STC−GO Compressor
Compressor type: Build number: Order Number: Order Name: Testmotor: Type of test motor: STC−GO(7−1−KA1KG) ............. 8045 62008043 Nevsehir SCHORCH KN7315M−AB01B−Z (KA5−S−GK200) Curves valid for nominel conditions: Inlet Pressure: Inlet Temperature: Relative Humidity: Motor Speed: 0.88400 [bar] 308.15 [K] 60.0 [%] 2975. [1/min]

Serial number of test motor:21360801/1

.700 Pressure rise − [bar] .650 .600 .550 .500 .450 .400 .350 .300 2000 00 3000 4000 5000 6000 7000 8000 9000 10000 Volumetric flow at inlet conditions − [m3/h]
Average test condition Inlet Pressure: Inlet Temperature: Relative Humidity: Motor Speed: 1.02410 [bar] 294.10 [K] 4.6 [%] 2971. [1/min] Used evaluation standards for Compressor: ISO5389/VDI2045 Used evaluation standards for Volumeflow: ISO 5167−1:1991/Amd.1:1998(E) Accepted by: Test day:

200 180 08 09 160 140 120 100 80 02 04 05 06 60 40 11000

HANSE07C 17−02−2009

Power consumption at coupling − [kW]

.750

220

Performance Certificate for STC−GO Compressor
Compressor type: Build number: Order Number: Order Name: Testmotor: Type of test motor: STC−GO(7−1−KA1KG) ............. 8045 62008043 Nevsehir SCHORCH KN7315M−AB01B−Z (KA5−S−GK200) Curves valid for nominel conditions: Inlet Pressure: Inlet Temperature: Relative Humidity: Motor Speed: 0.88400 [bar] 298.35 [K] 60.0 [%] 2975. [1/min]

Serial number of test motor:21360801/1

.780 Pressure rise − [bar] .720 .660 .600 .540 .480 .420 .360 .300 2000 3000 02 00 4000 5000 6000 7000 8000 9000 10000 04 05 06 08 09

200 180 160 140 120 100 80 60 40 11000

Volumetric flow at inlet conditions − [m3/h]
Average test condition Inlet Pressure: Inlet Temperature: Relative Humidity: Motor Speed: 1.02410 [bar] 294.10 [K] 4.6 [%] 2971. [1/min] Used evaluation standards for Compressor: ISO5389/VDI2045 Used evaluation standards for Volumeflow: ISO 5167−1:1991/Amd.1:1998(E) Accepted by: Test day: HANSE07C 17−02−2009

Power consumption at coupling − [kW]

.840

220

Performance Certificate for STC−GO Compressor
Compressor type: Build number: Order Number: Order Name: Testmotor: Type of test motor: STC−GO(7−1−KA1KG) ............. 8045 62008043 Nevsehir SCHORCH KN7315M−AB01B−Z (KA5−S−GK200) Curves valid for nominel conditions: Inlet Pressure: Inlet Temperature: Relative Humidity: Motor Speed: 0.88400 [bar] 274.15 [K] 60.0 [%] 2975. [1/min]

Serial number of test motor:21360801/1

.845 Pressure rise − [bar] .780 .715 .650 .585 .520 .455 .390 .325 2000 3000 02 00 4000 5000 6000 7000 8000 9000 10000 04 05 06 08 09

220 200 180 160 140 120 100 80 60 11000

Volumetric flow at inlet conditions − [m3/h]
Average test condition Inlet Pressure: Inlet Temperature: Relative Humidity: Motor Speed: 1.02410 [bar] 294.10 [K] 4.6 [%] 2971. [1/min] Used evaluation standards for Compressor: ISO5389/VDI2045 Used evaluation standards for Volumeflow: ISO 5167−1:1991/Amd.1:1998(E) Accepted by: Test day: HANSE07C 17−02−2009

Power consumption at coupling − [kW]

.910

240

Sponsor Documents


Recommended

No recommend documents

Or use your account on DocShare.tips

Hide

Forgot your password?

Or register your new account on DocShare.tips

Hide

Lost your password? Please enter your email address. You will receive a link to create a new password.

Back to log-in

Close