CPF 175, CPVS 175 Instruction book
Chicago Pneumatic CPF 175, CPVS 175 Instruction book Original instructions Copyright Notice Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings. This instruction book is valid for CE as well as non-ce labelled machines. It meets the requirements for instructions specified by the applicable European directives as identified in the Declaration of Conformity. 2013-02 No. 2920 1804 02 www.cp.com
Table of contents 1 Safety precautions...6 1.1 SAFETY ICONS...6 1.2 SAFETY PRECAUTIONS, GENERAL...6 1.3 SAFETY PRECAUTIONS DURING INSTALLATION...7 1.4 SAFETY PRECAUTIONS DURING OPERATION...8 1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR...9 2 General description...11 2.1 INTRODUCTION...11 2.2 AIR AND OIL SYSTEM...13 2.3 COOLING AND CONDENSATE SYSTEM...18 2.4 REGULATING SYSTEM...19 2.5 ENERGY RECOVERY SYSTEM...20 3 Electronic regulator...23 3.1 ELECTRONIC CONTROLLER...23 3.2 CONTROL PANEL...25 3.3 CHANGING THE DISPLAY LANGUAGE...27 3.4 REGULATION...28 3.5 STRUCTURE OF MENUS...29 3.6 MODIFYING A PARAMETER...33 3.7 STATUS MENUS...34 3.8 INPUTS IN THE MAIN MENUS...40 3.9 ERROR MENU...42 3.10 SETTINGS MENU...44 3.11 COUNTERS MENU...46 3.12 SERVICE MENU...48 3.13 WEEKLY PROGRAM - TIMER FUNCTION...53 2 2920 1804 02
3.14 HISTORY MENU...55 3.15 SAFETY MENU...56 3.16 CONFIGURATION USER MENU...64 3.17 CONFIGURATION DISTRIBUTOR MENU...66 3.18 INPUT STATE MENU...69 3.19 OUTPUT TEST MENU...71 3.20 VERSION MENU...73 3.21 INFORMATION DISTRIBUTOR MENU...73 3.22 PASSWORD MENU...73 3.23 MCC MENU...73 3.24 EXTERNAL CONNECTION...74 3.25 EXTERNAL COMMUNICATION (OPTIONAL)...74 3.26 COMMON OPERATIONS...75 3.27 REINITIALISATION OF MAINTENANCE COUNTERS...75 3.28 OPERATIONAL INCIDENTS...76 3.29 LIST OF MESSAGES...76 4 Installation...83 4.1 DIMENSION DRAWING...83 4.2 INSTALLATION REMARKS...95 4.3 INSTALLATION PROPOSAL...97 4.4 ELECTRIC CABLE SIZE...101 4.5 PICTOGRAPHS...107 5 Operating instructions...109 5.1 INITIAL START-UP...109 5.2 BEFORE STARTING...111 5.3 STARTING...112 5.4 DURING OPERATION...113 5.5 CHECKING THE DISPLAY...114 2920 1804 02 3
5.6 STOPPING...115 5.7 STORAGE AFTER INSTALLATION...116 5.8 TAKING OUT OF OPERATION...117 5.9 USE OF AIR RECEIVER...117 6 Maintenance...119 6.1 PREVENTIVE MAINTENANCE SCHEDULE...119 6.2 MOTORS...120 6.3 OIL SPECIFICATIONS...121 6.4 OIL CHANGE...122 6.5 STORAGE AFTER INSTALLATION...126 6.6 SERVICE KITS...126 6.7 DISPOSAL OF USED MATERIAL...127 7 Adjustments and servicing procedures...128 7.1 AIR FILTERS...128 7.2 COOLERS...129 7.3 SAFETY VALVE...129 8 Problem solving...130 8.1 PROBLEM SOLVING...130 9 Technical data...132 9.1 READINGS ON DISPLAY...132 9.2 REFERENCE CONDITIONS...132 9.3 LIMITS...133 9.4 SETTINGS OF SAFETY VALVE...133 9.5 SETTINGS FOR OVERLOAD RELAY AND FUSES...133 9.6 COMPRESSOR DATA...135 10 Pressure equipment directives...146 4 2920 1804 02
11 Declaration of conformity...148 2920 1804 02 5
1 Safety precautions 1.1 Safety icons Explanation Danger for life Warning Important note 1.2 Safety precautions, general General precautions 1. The operator must employ safe working practices and observe all related work safety requirements and regulations. 2. If any of the following statements does not comply with the applicable legislation, the stricter of the two shall apply. 3. Installation, operation, maintenance and repair work must only be performed by authorized, trained, specialized personnel. 4. The compressor is not considered capable of producing air of breathing quality. For air of breathing quality, the compressed air must be adequately purified according to the applicable legislation and standards. 5. Before any maintenance, repair work, adjustment or any other non-routine checks, stop the compressor, press the emergency stop button, switch off the voltage and depressurize the compressor. In addition, the power isolating switch must be opened and locked. On units powered by a frequency converter, wait 10 minutes before starting any electrical repair. If the machine is equipped with an automatic restart after voltage failure function and if this function is active, be aware that the machine will restart automatically when the power is restored if it was running when the power was interrupted! 6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people. Never use the air to clean dirt from your clothes. When using the air to clean equipment, do so with extreme caution and wear eye protection. 7. The owner is responsible for maintaining the unit in safe operating condition. Parts and accessories shall be replaced if unsuitable for safe operation. 8. It is not allowed to walk or stand on the unit or on its components. 6 2920 1804 02
1.3 Safety precautions during installation All responsibility for any damage or injury resulting from neglecting these precautions, or non observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer. Precautions during installation 1. The machine must only be lifted using suitable equipment in accordance with the applicable safety regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to dwell or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept within safe limits. Wear a safety helmet when working in the area of overhead or lifting equipment. 2. The unit is designed for indoor use. If the unit is installed outdoors, special precautions must be taken; consult your supplier. 3. Place the machine where the ambient air is as cool and clean as possible. If necessary, install a suction duct. Never obstruct the air inlet. Care must be taken to minimize the entry of moisture at the inlet air. 4. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes. 5. Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or worn hoses. Distribution pipes and connections must be of the correct size and suitable for the working pressure. 6. The aspirated air must be free of flammable fumes, vapors and particles, e.g. paint solvents, that can lead to internal fire or explosion. 7. Arrange the air intake so that loose clothing worn by people cannot be sucked in. 8. Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to expand under heat and that it is not in contact with or close to flammable materials. 9. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain. 10. If remote control is installed, the machine must bear a clear sign stating: DANGER: This machine is remotely controlled and may start without warning. The operator has to make sure that the machine is stopped and depressurized and that the electrical isolating switch is open, locked and labelled with a temporary warning before any maintenance or repair. As a further safeguard, persons switching on or off remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the start equipment. 11. Air-cooled machines must be installed in such a way that an adequate flow of cooling air is available and that the exhausted air does not recirculate to the compressor air inlet or cooling air inlet. 12. The electrical connections must correspond to the applicable codes. The machines must be earthed and protected against short circuits by fuses in all phases. A lockable power isolating switch must be installed near the compressor. 13. On machines with automatic start/stop system or if the automatic restart function after voltage failure is activated, a sign stating "This machine may start without warning" must be affixed near the instrument panel. 14. In multiple compressor systems, manual valves must be installed to isolate each compressor. Non-return valves (check valves) must not be relied upon for isolating pressure systems. 15. Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure must be protected by a pressure relieving device or devices as required. 16. Piping or other parts with a temperature in excess of 70 C (158 F) and which may be accidentally touched by personnel in normal operation must be guarded or insulated. Other high temperature piping must be clearly marked. 2920 1804 02 7
17. For water-cooled machines, the cooling water system installed outside the machine has to be protected by a safety device with set pressure according to the maximum cooling water inlet pressure. 18. If the ground is not level or can be subject to variable inclination, consult the manufacturer. Also consult following safety precautions: Safety precautions during operation and Safety precautions during maintenance. These precautions apply to machinery processing or consuming air or inert gas. Processing of any other gas requires additional safety precautions typical to the application which are not included herein. Some precautions are general and cover several machine types and equipment; hence some statements may not apply to your machine. 1.4 Safety precautions during operation All responsibility for any damage or injury resulting from neglecting these precautions, or non observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer. Precautions during operation 1. Never touch any piping or components of the compressor during operation. 2. Use only the correct type and size of hose end fittings and connections. When blowing through a hose or air line, ensure that the open end is held securely. A free end will whip and may cause injury. Make sure that a hose is fully depressurized before disconnecting it. 3. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote start equipment. 4. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapors or particles. 5. Never operate the machine below or in excess of its limit ratings. 6. Keep all bodywork doors shut during operation. The doors may be opened for short periods only, e.g. to carry out routine checks. Wear ear protectors when opening a door. On compressors without bodywork, wear ear protection in the vicinity of the machine. 7. People staying in environments or rooms where the sound pressure level reaches or exceeds 80 db(a) shall wear ear protectors. 8. Periodically check that: All guards are in place and securely fastened All hoses and/or pipes inside the machine are in good condition, secure and not rubbing No leaks occur All fasteners are tight All electrical leads are secure and in good order Safety valves and other pressure relief devices are not obstructed by dirt or paint Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good repair, free of wear or abuse Air cooling filters of the electrical cabinet are not clogged 9. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom, take precautions against air pollution and possible contamination of the breathing air. 10. On water-cooled compressors using open circuit cooling towers, protective measures must be taken to avoid the growth of harmful bacteria such as Legionella pneumophila bacteria. 8 2920 1804 02
11. Do not remove any of, or tamper with, the sound-damping material. 12. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure shall be protected by a pressure relieving device or devices as required. 13. Yearly inspect the air receiver. Minimum wall thickness as specified in the instruction book must be respected. Local regulations remain applicable if they are more strict. Also consult following safety precautions: Safety precautions during installation and Safety precautions during maintenance. These precautions apply to machinery processing or consuming air or inert gas. Processing of any other gas requires additional safety precautions typical to the application which are not included herein. Some precautions are general and cover several machine types and equipment; hence some statements may not apply to your machine. 1.5 Safety precautions during maintenance or repair All responsibility for any damage or injury resulting from neglecting these precautions, or non observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer. Precautions during maintenance or repair 1. Always use the correct safety equipment (such as safety glasses, gloves, safety shoes, etc.). 2. Use only the correct tools for maintenance and repair work. 3. Use only genuine spare parts. 4. All maintenance work shall only be undertaken when the machine has cooled down. 5. A warning sign bearing a legend such as "Work in progress; do not start" shall be attached to the starting equipment. 6. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote start equipment. 7. Close the compressor air outlet valve and depressurize the compressor before connecting or disconnecting a pipe. 8. Before removing any pressurized component, effectively isolate the machine from all sources of pressure and relieve the entire system of pressure. 9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against toxic vapours of cleaning liquids. 10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts and exposed openings with a clean cloth, paper or tape. 11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely purged, e.g. by steam cleaning, before carrying out such operations. Never weld on, or in any way modify, pressure vessels. 12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has elapsed; this to avoid the risk of spontaneous ignition of the oil vapour when air is admitted. 13. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc. 14. Make sure that no tools, loose parts or rags are left in or on the machine. 2920 1804 02 9
15. All regulating and safety devices shall be maintained with due care to ensure that they function properly. They may not be put out of action. 16. Before clearing the machine for use after maintenance or overhaul, check that operating pressures, temperatures and time settings are correct. Check that all control and shut-down devices are fitted and that they function correctly. If removed, check that the coupling guard of the compressor drive shaft has been reinstalled. 17. Every time the separator element is renewed, examine the discharge pipe and the inside of the oil separator vessel for carbon deposits; if excessive, the deposits should be removed. 18. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from entering them, e.g. when steam cleaning. 19. Make sure that all sound-damping material and vibration dampers, e.g. damping material on the bodywork and in the air inlet and outlet systems of the compressor, is in good condition. If damaged, replace it by genuine material from the manufacturer to prevent the sound pressure level from increasing. 20. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls. 21. The following safety precautions are stressed when handling refrigerant: Never inhale refrigerant vapours. Check that the working area is adequately ventilated; if required, use breathing protection. Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with water. If liquid refrigerant contacts the skin through clothing, never tear off or remove the latter; flush abundantly with fresh water over the clothing until all refrigerant is flushed away; then seek medical first aid. Also consult following safety precautions: Safety precautions during installation and Safety precautions during operation. These precautions apply to machinery processing or consuming air or inert gas. Processing of any other gas requires additional safety precautions typical to the application which are not included herein. Some precautions are general and cover several machine types and equipment; hence some statements may not apply to your machine. 10 2920 1804 02
2 General description 2.1 Introduction General view Description These units are single-stage, oil-injected screw compressors, driven by an electric motor and enclosed in sound-insulated bodywork. Compressors with variable speed drive optimize energy consumption and reduce the operating pressure band by continuously matching the speed of the drive motor to the air net pressure. The following features are available as an option: Foodgrade Foodgrade oil is a unique high quality synthetic lubricant, specially created for oil-injected screw compressors that provide air for the food industry. Rotair Xtra oil RXD oil is a special, long-life lubricant for oil-injected screw compressors. It provides better cooling and extends the oil change interval. Water separator drain The water separator drain prevents water from entering in the compressed air net. 2920 1804 02 11
Oil preheater (only for 400 V-50 Hz) This oil preheating system is installed in the oil tank in order to preheat the lubricant at low temperatures. High efficiency air filtration The high efficiency air filtration improves the quality of the air at the intake. This option is particularly useful in very dusty surroundings. Pre-filtration panel The pre-filtration panel protects the compressor's internal from dust and helps to avoid clogging of the air coolers (cooling air side). High pre-filtration panel The pre-filtration panel protects the compressor's internal from dust and helps to avoid clogging of the air coolers (cooling air side). This option is particularly useful in very dusty surroundings. Modulating control The modulating control system is designed to maintain a narrow net pressure band by throttling the air inlet, thus reducing the air flow (50% - 100%). Electronic drain (only for 400 V-50 Hz) The electronic water drain assures proper draining of condensate and prevents water from entering the compressed air net. For any malfunction of the draining process, the electronic water drain generates a warning message on the display of the electronic regulator. Energy recovery The compressor is provided with an energy recovery system to recover the major part of the compression heat in the form of hot water without any influence on the compressor performance. Phase Sequence Relay The phase sequence relay prevents the drive motor from rotating in the wrong direction. Automatic restart after voltage failure For compressors leaving the factory, this function is made inactive. If desired, the function can be activated. Consult your Customer Centre. If activated and provided the regulator was in the automatic operation mode and the compressor control mode (local, remote 1 or remote 2) was not changed during the voltage failure, the compressor will automatically restart if the supply voltage to the module is restored within a programmed time period (this time period is called the power recovery time). The power recovery time can be set between 1 and 254 seconds or to 0. If the power recovery time is set to 0, the compressor will always restart after a voltage failure, no matter how long it takes to restore the voltage. 12 2920 1804 02
2.2 Air and oil system Flow diagrams Flow diagram, air-cooled compressor 2920 1804 02 13
Flow diagram, air-cooled compressor with energy recovery Flow diagram, air-cooled compressor with modulating control 14 2920 1804 02
Flow diagram, air-cooled compressor with energy recovery and with modulating control Flow diagram, water-cooled compressor 2920 1804 02 15
Flow diagram, water-cooled compressor with modulating control 16 2920 1804 02
Air flow Air-cooled compressor Air drawn through filter and unloader (UA) is compressed in compressor element (E). Compressed air and oil are discharged through check valve (CV) to air receiver/oil separator (AR) where oil is separated from the compressed air. The air is blown through minimum pressure valve (Vp) to air cooler (Ca). The cooled air is discharged through the outlet towards the air net. An optional condensate trap may be provided between the air cooler and outlet valve. Check valve (CV) prevents blow-back of compressed air. Minimum pressure valve (Vp) prevents the receiver pressure from dropping below a minimum pressure. Oil system Air pressure forces the oil from receiver (AR) through oil cooler (Co), filters (OF), oil stop valve (Vs) and an oil injection valve to the compressor element (E) and the lubrication points. On air-cooled compressors, an oil injection valve will open at higher ambient temperatures to keep the element outlet temperature low. For air-cooled units, the oil temperature is controlled by regulating the speed of the fans (FN), to avoid overcooling and consequently condensation in the air receiver (AR). On air-cooled compressors with energy recovery or on water-cooled compressors, the oil temperature is controlled by a thermostatic valve to avoid overcooling and consequently condensation in the air receiver (AR). In the air receiver (AR) most of the oil is removed from the air centrifugally. Almost all of the remaining oil is removed by the separator element. 2920 1804 02 17
2.3 Cooling and condensate system Condensate drain system Position of condensate drain (1) Automatic condensate drain As an option, a condensate trap can be installed downstream of the air cooler to prevent condensate from entering the air outlet pipe. The trap is provided with a float valve for automatically draining condensate and with a manual drain valve. Cooling system On air-cooled compressors, the air and oil coolers are cooled by fans. Water-cooled compressors are provided with a cooling water system, including combined oil and air coolers. 18 2920 1804 02
2.4 Regulating system Flow diagrams Flow diagram Reference A B Designation To air cooler To/from oil cooler 2920 1804 02 19
Regulating system The compressor is controlled by electronic regulator (1). The regulator keeps the net pressure within programmable pressure limits by automatically loading and unloading the compressor depending on the air consumption. It also protects the compressor and monitors components subject to service. Unloading If the air consumption is less than the air delivery of the compressor, the net pressure increases. When the net pressure reaches the upper limit of the working pressure (unloading pressure), solenoid valve (5) is deenergized by the electronic regulator (1). The plunger of solenoid valve (5) moves downwards by spring force: Phase Description 1 The plunger of solenoid valve (5) shuts off the supply of receiver pressure towards chamber (2). 2 Control pressure present in chamber (2) is vented to atmosphere. Plunger (3) of blow-off valve (4) is moved by air receiver pressure allowing air receiver pressure to chamber (6). 3 Valve (7) is pushed upwards closing off the air inlet. 4 A small flow of air remains drawn in via channel (8), and is finally blown from receiver via channel (10) to the air inlet. 5 Air delivery is stopped (0%), the compressor runs unloaded while chamber (6) contains a steady overpressure (receiver unload pressure minus Blow Off valve (4) pressure drop). Loading When the net pressure decreases to the lower limit of the working pressure (loading pressure), solenoid valve (5) is energized. The plunger of solenoid valve (5) moves upwards against spring force: Phase 1 The plunger of solenoid valve (5) opens the supply of receiver pressure towards chamber (2). Plunger (3) of blow-off valve (4) moves, closing off the air pressure supply towards chamber (6). 2 Valve (7) moves downwards since the pressure in chamber (6) drops below atmospheric pressure, opening the air inlet to the compressor element. 3 Air delivery is resumed (100%), the compressor runs loaded while the piston-rod-valve assembly is only surrounded by atmospheric pressure. 2.5 Energy recovery system General description The maximum allowed pressure at the water side of the heat exchanger is 10 bar (145 psi). When the energy recovery system is not used, make sure that all water is out of the energy recovery system. The energy required in any compression process is mainly transformed into heat. The major part of the compression heat is dissipated through the oil system. The energy recovery systems are designed to recover 20 2920 1804 02
most of the above-mentioned heat as warm or hot water without any adverse influence on the compressor performance. After the compression stage, the oil is separated from the compressed air. The compressed air flows to the aftercooler and the oil flows to the oil cooler. The energy in the oil can be recovered by installing a heat exchanger in front of the oil cooler. The energy recovery systems can be applied as low temperature rise / high water flow systems (e.g. central heating in closed water circuits) or as high temperature rise / low water flow systems (e.g. pre-heating of boiler feed water in open water circuits). Main components The system mainly comprises: Oil/water heat exchanger Energy recovery valve Oil by-pass valve The necessary pipes, brackets, bolts, etc. Installation The compressor frame is prepared for the Energy recovery system. The connections must be 1". The use of a filter on the water intake is recommended to protect the cooling agents and the valves. A manual valve for isolation and water flow control will be installed on the water outlet in order to optimize the flow. The required qualities are given as a general rule in order to avoid problems caused by the cooling water. If in any doubt, contact your service representative. For the following specifications, dependent on the compressor type, contact your service representative: Minimum water inlet temperature Maximum water inlet temperature Required cooling water flow Maximum water pressure Recoverable energy Energy recovery system The recovery water enters the unit at the heat exchanger inlet connection. In the heat exchanger the compression heat is transferred from the compressor to the water. The water leaves the heat exchanger via the outlet connection. The oil flow of the compressor is controlled by a by-pass valve to ensure a reliable compressor operation and an optimum recovery of energy. Formula for recovered energy is : ==> Q = m x c x dt ==> m = Q / (c x dt) Q = the recovered energy in w m = the mass flow in kg/s c = the specific heat capacity in J/kgK (4.2 J/kgK for water) dt = the specific temperature change (inlet versus outlet) in K 2920 1804 02 21
Additional safety precautions The parts must only be lifted using suitable equipment in accordance with the applicable safety regulations. Loose or pivoting parts must be securely fastened before lifting. Wear a safety helmet when working in the area of overhead or lifting equipment. Protect hands to avoid injury from hot machine parts, e.g. during draining of oil. Protection caps, bags, etc. must be removed before connecting the pipes. Water hoses must be of correct size and suitable for the working pressure. The water connections must be free of strain. Pipe work or other parts with a temperature in excess of 80 C (176 F) must be guarded or insulated. Other high-temperature pipe work must be clearly marked. The water system installed outside the machine has to be protected by a safety device with set pressure according to the maximum cooling water inlet pressure. All maintenance work shall only be undertaken when the machine has cooled down. Never weld or perform any operation involving heat near the oil system. 22 2920 1804 02
3 Electronic regulator 3.1 Electronic controller Control panel The display and the luminous indicator of AIRLOGIC allows: Viewing the operational status of the compressor at a given instant Viewing the maintenance messages (alarms, faults) Viewing the setting parameters of the compressor Description The AIRLOGIC is an electronic control plate equipped with a microprocessor used for the surveillance, management and monitoring of the compressor range of compressors at fixed speed and compressors with variable speed, as well as the compressors with integrated dryer. The AIRLOGIC offers several functions including the management of control, management of alarms and faults, information on the operational status of the unit, the configuration of remote control and the multicontroller management (optional). The AIRLOGIC allows in particular: The management of multiple analog inputs: An oil temperature sensor An internal pressure sensor A unit output pressure sensor The control and the management of fixed speed or variable speed compressor. The programming of operating time of loading and shutdown with possible selection of two control bands. The control, the fault reporting and the display of the operational status of the compressor by remote control. The automatic restarting in cascade after a mini-outage in power supply. The management of the integrated dryer module. 2920 1804 02 23
In option, the centralized management of up to 4 compressors equipped with an AIRLOGIC. The exceptional modularity of the AIRLOGIC allows connecting additional electronic modules to add logical and/or analog inputs/outputs necessary for certain special applications (the modules available are described in section External communication). For example, the pressure loss of the air treatment chain can be managed from the AIRLOGIC. Indication of maintenance operations When a maintenance operation becomes necessary, either because the machine has reached the number of hours necessary before an intervention or because a sensor has detected a limit, a red indicator flashes and a message is displayed indicating the nature of the operation. The machine does not stop. Management of warnings The warning characterizes either a maintenance operation or a warning limit before reaching the limit of the fault, which when reached, would stop the machine. This allows anticipating a malfunctioning and dealing with it without compromising your production of compressed air. The indication of the nature of warning is transmitted to the AIRLOGIC. Management of functional faults On the appearance of a functional fault, the AIRLOGIC stops the compressor, indicates the fault by a red fault indicator and displays the message allowing rapid identification of the cause of the incident. An entry is added to the menu Historyof faults, displaying the nature of the fault, the date and the time as well as the value of certain parameters recorded when the fault appeared. Programming of pressure timers The real time clock of the AIRLOGIC allows, after programming the pressure timers, automatic starting and stopping of the compressor. While programming the loaded running, two pressure limits are available allowing to vary the control pressure over a time, depending on the applications. 24 2920 1804 02
3.2 Control panel Regulator Display The screen displays all the information necessary for the navigation, the control of functional parameters and the error messages. The choice of 3 languages among 25 (configurable by the software) simplifies the understanding of the messages and the parameters. 2920 1804 02 25
Luminous indicators Power supply indicator (green lamp lit): controller powered on. Automatic operation mode: green lamp on (the compressor was not stopped manually, it was either loaded or unloaded or stopped but ready to start automatically, if necessary). Error: red flashing light Warning: fixed red light Keys Start button, to start the compressor in automatic mode (the compressor will stop and restart automatically depending on the pressure variations in the network). Stop button, to stop the compressor when it is in automatic operation mode. The complete shutdown takes place only after a depressurization cycle of a modifiable period of 30 seconds. 26 2920 1804 02
Cancel button: to cancel a modification of the value of a parameter. to return to a previous level in the menus. Shortcut to the menu Control Mode. Validate button: to enter the menu currently displayed while navigating the menu (the screen then displays the list of parameters of this menu) to validate the modification of the value of a parameter to enter the mode of modification of the value of a parameter. The value starts flashing. to rearm after a fault or a warning when the cause has been eliminated. Navigation Up to display the previous menu or parameter to increment the value of a parameter during its modification. Navigation Down to display the next menu or parameter to decrement the value of a parameter during its modification. 3.3 Changing the display language Procedure The display language can be configured according to the following operating procedure, described starting from one of the status screens: Press the Validate key for accessing the list of menus. Using the vertical navigation buttons, select Conf. User. from the menu. Press the Validate key for accessing the list of menu parameters. Using the vertical navigation buttons, select Language in use from the parameters menu. Activate the language parameter by pressing the Validate key. The language currently used is displayed. Press the Validate key again for activating the modification mode. The parameter flashes. A list with three languages is shown. Scroll to the desired language using the Navigation buttons. Validate your choice by pressing the Validate key. The parameter stops flashing. 2920 1804 02 27
Use the Cancel button to return to the operational screen. 3.4 Regulation Command of the regulation In the case of ON/OFF regulation, the AIRLOGIC manages: The command of unloading when the pressure measured by the analog sensor reaches the idling pressure. The command of loading when the pressure measured by the analog sensor reaches the minimum regulation pressure (loading pressure). The command of motor shutdown after a period of idling. The restriction on restarting the motor if the pressure in the oil tank is higher than 1.5 bar (21.7 psi) or if the oil temperature at the outlet of the compression block is less than 2 C (35.6 F). If it is necessary to intervene on the machine when it is stopped, it should be placed in total safety by cutting off the electrical power supply. Stop on fault The following inputs and parameters will stop the compressor on fault when their status switches (for inputs) or when their value crosses the predefined values (top or bottom limits for the analog parameters or inputs): Input : Emergency stop Input : Motor overload Input : Turbine motor overload Input : Phase controller (option) Input : External fault (dryer, filter, other equipment ) Analog Input: temperature in outlet of compression block. In addition to the value of this temperature, its increase is also monitored during about 15 seconds after the starting of the compressor. If the temperature does not increase sufficiently, the controller considers that the motor is running in the wrong direction (the air is not compressed therefore the air is not heated) and stops the compressor. It is then necessary to cut off the power supply to the compressor, interchange the two phases of the supply to the main motor, then restart the power. This error cannot be cancelled by manipulations of the controller! Analog input: dryer temperature (estimate of the dew point set as a dryer "LAT parameter") too high or too low. There will be a warning if the temperature moves out of these high and low limits. Analog input internal pressure: this input replaces the high and low pressure switches of older regulation systems. If the internal pressure of the tank is too high, the controller displays a first warning notifying the user that the pressure is approaching dangerously close to the maximum limit. Then an error will be triggered (and shutdown the compressor) if the pressure continues increasing. Parameter differential pressure: a calculation of the difference of pressure between the machine outlet and the internal tank also replaces the differential pressure switches. Analog Input : motor temperature (sensors in option on certain machines) Warning before stop on fault Most of the values measured or calculated have before fault warning thresholds whose values are slightly below (or above) the maximum (or minimum) fault thresholds. The operator is warned that the operation of the compressor is approaching an error threshold. Control mode The AIRLOGIC has three control modes, Local/Remote/LAN. 28 2920 1804 02
In Local mode, it is possible to start or stop the compressor directly from the controller. In Remote mode, the stop and start control is via a dry external contact (adjustment may still be internal (via the machine's sensor) or external (pressure switch.)) In LAN mode, start and stop control is by using the CANBUS compressor network through a master supervisor. For the latter two cases, the compressor is stopped by the local controller (maintenance..). The control mode must be first changed and returned to local mode. A shortcut using the Cancel key is provided for this. 3.5 Structure of menus Description The screens displayed on the controller are organized into menus, submenus, display screens and/or modification of parameter screens. The following section describes the general structure of the menus. However, depending on the options of the compressor, additional screens and/or parameters may be displayed. The logic of navigation and modification of parameters remains identical. 2920 1804 02 29
General structure The structure of the AIRLOGIC is composed of two sections. The left hand column represents the status menus transmitting the parameters relating to the functional status of the machine; these are usable as check lists. The rest of the structure offers the parameters for configuring the compressor. Some of these parameters are read only while others can be modified, with restriction of access through password, depending on the qualification of the operator. 30 2920 1804 02
Menu structure for fixed speed compressors 2920 1804 02 31
Menu structure for variable speed compressors 32 2920 1804 02
Reading the structure A vertical arrow pointing to a screen indicates that this screen is reached from the screen located above (the origin of the arrow) by pressing the navigation down key. A horizontal arrow indicates that it is possible to: go to the menu located at the top of the arrow by pressing the validate key. go to the screen for modifying the parameter displayed by pressing the validate key. return to the screen located at the end of the arrow pointing to the screen by pressing the cancel key. A vertical arrow leaving from a screen indicates that the screen can be reached from the one located below (at the tip of the arrow) by pressing on the navigation down key. 3.6 Modifying a parameter Description Use the vertical navigation buttons to select a menu item. Use the horizontal navigation keys to enter or leave a submenu. The cancel key allows to reach the parameter to be modified. Screen for fixed speed compressors Screen for variable speed compressors Displaying the parameter value When the cursor is positioned against the parameter (loading press/setpoint 1), press the validate key to display the value of the parameter. This value is displayed along with its minimum and maximum limits. Activating the modification mode 2920 1804 02 33
Press the validate key; the flashing of the value indicates that the parameter can be modified within programming limits. Modifying the value Using the navigation up key to increase or the navigation down key to decrease the value within the defined limits. Validating a parameter By pressing the validate key, the modification of the parameter is validated. The value stops flashing. Canceling a modification By pressing the cancel key, the modification is cancelled and the parameter returns to its initial value. Exiting the menu Press the cancel key to return to the parameter selection list of the menu. 3.7 Status menus Description These status menus only display the different parameters/values relating to the functional state or settings of the compressor. Fixed speed compressors Screen Description Compressor outlet pressure: Indication of the pressure read by the sensor in the machine outlet Element outlet temperature: Indication of the temperature read by the sensor in the outlet of the compressor element Manual operation/local control/timer inactive: Indicates that the compressor is in autonomous operating mode (it is not controlled by an external controller) / indicates that the pressure sensor read by the compressor is the integrated sensor (and not an external sensor) / Indicates that the weekly programming function is not activated. Max. pressure : Maximum limit of unloading pressure setting. 34 2920 1804 02
Screen Description Pres. Band used : Range of pressure used. Two different pressure bands can be chosen. Running hours : Number of running hours of the compressor motor operation (unloaded or loaded) from its start-up. Loaded hours : Number of hours of loaded operation of the compressor from its start-up. Number of motor starts : Number of motor starts from its start-up. Module hours : Number of hours during which the AIRLOGIC remains powered on. Load relay : Number of passages of the compressor in load from its start-up. Compressor outlet pressure: Reuse of the first parameter. From this parameter, the menu displays the status of all the analog and logical inputs that are activated. Receiver press. : Pressure as read by the sensor placed on the deoiling tank of the compressor Element outlet temperature: Indicates the temperature read by the sensor in the outlet of the compression element 2920 1804 02 35
Screen Description Pressure difference: Indicates the difference between the internal tank pressure and the pressure in the compressor outlet. Emergency stop : Status of the logical input emergency stop (closed = no error) Start/stop remote : Status of the logical inputs indicating to the AIRLOGIC that it is remotely started (input closed) in the Remote control operating mode Load/unload remote : Status of the logical input of regulation control. Used when the compressor is remotely controlled (Input "Remote pressure" closed). Remote pressure : Input determining whether the control is local (open) or remote (closed). Overload motor : Overload of main motor -- input activated by the thermal protection relay of the main motor. Overload fan motor : Overload of turbine motor - input activated by the thermal protection relay of the turbine motor. Phase sequence : Input triggering an error if the phase controller (in option) detects a wrong direction of the phases (and therefore the motor) or else, an absence of phase. Status of the input for selection of the pressure band. Pressure band 1 if open, pressure band 2 if closed (active if the parameter Digital PB set of the menu Conf.distr is activated) Variable speed compressors 36 2920 1804 02
Screen Description Compressor outlet pressure: Indication of the pressure read by the sensor in the machine outlet Element outlet temperature: Indication of the temperature read by the sensor in the outlet of the compressor element Manual operation/local control/timer inactive: Indicates that the compressor is in autonomous operating mode (it is not controlled by an external controller) / indicates that the pressure sensor read by the compressor is the integrated sensor (and not an external sensor) / Indicates that the weekly programming function is not activated. Max. pressure : Maximum limit of unloading pressure setting. Setpoint 1 : Setpoint pressure. Two programmable setpoint pressures can be chosen. Compress. Speed : Indicates the motor rotation speed. Running hours : Number of running hours of the compressor motor operation (unloaded or loaded) from its start-up. Loaded hours : Number of hours of loaded operation of the compressor from its start-up. Number of motor starts : Number of motor starts from its start-up. 2920 1804 02 37
Screen Description Module hours : Number of hours during which the AIRLOGIC remains powered on. Accumulated vol : for compressors at variable speed, an internal calculation in the AIRLOGIC enables the display of an estimated volume of air produced since commissioning. Load relay : Number of passages of the compressor in load from its start-up. VSD 1-20% RPM : Percentage of operating time during which the compressor has operated between 1 and 20% of its maximum speed. VSD 20-40% RPM: Percentage of operating time during which the compressor has operated between 20 and 40% of its maximum speed. VSD 40-60% RPM : Percentage of operating time during which the compressor has operated between 40 and 60% of its maximum speed. VSD 60-80% RPM : Percentage of operating time during which the compressor has operated between 60 and 80% of its maximum speed. VSD100-80% RPM : Percentage of operating time during which the compressor has operated between 80 and 100% of its maximum speed. Compressor outlet pressure: Reuse of the first parameter. From this parameter, the menu displays the status of all the analog and logical inputs that are activated. 38 2920 1804 02
Screen Description Receiver press. : Pressure as read by the sensor placed on the deoiling tank of the compressor Element outlet temperature: Indicates the temperature read by the sensor in the outlet of the compression element Pressure difference: Indicates the difference between the internal tank pressure and the pressure in the compressor outlet. Emergency stop : Status of the logical input emergency stop (closed = no error) Start/stop remote : Status of the logical inputs indicating to the AIRLOGIC that it is remotely started (input closed) in the Remote control operating mode Overload fan motor : Overload of turbine motor - input activated by the thermal protection relay of the turbine motor. Phase sequence : Input triggering an error if the phase controller (in option) detects a wrong direction of the phases (and therefore the motor) or else, an absence of phase. Status of the input for selection of the pressure band. Pressure band 1 if open, pressure band 2 if closed (active if the parameter Digital PB set of the menu Conf.distr is activated) 2920 1804 02 39
3.8 Inputs in the main menus Description From each of the inputs in the status menu, pressing the enter key will show the first menu of the following list: Screen Description Error: this menu will show when an error or a warning is activated/active. Pressing the enter key allows deactivating the display of error, if, of course, the cause of this error has been resolved. If no error/warning is active, then the message All conditions are OK is displayed. Settings: In this menu appear all the basic settings used for controlling the compressor (unloading pressures and loaded running for each of the two usable pressure bands, pressure band used) Counters: In this menu, the different counters for reading can be accessed: running hours, loaded hours, number of motor starts, number of passages into load. Service: Access menu for data relating to compressor maintenance (delay from last intervention, before next intervention, type of maintenance performed), to the menus for parameterizing types of maintenance periods and also to menu Stop Under Pres. Timer function: Menu of weekly programming of pressures History: This menu and its submenus allow displaying the latest errors occurred as well as a list of values of certain parameters and inputs recorded at the time of this error. Safety: Access to menus reserved for advanced users having to deal with the compressor safety parameters (warning and error thresholds, delays) on the analog inputs and certain logical inputs Conf. User: Menu for configuring the date, time, units, language, etc. 40 2920 1804 02
Screen Description Conf. Distrib: Menu reserved for the distributor (password protected) in which the parameters of compressor control and operation can be modified. Status of inputs: Displays the protection elements configured on certain logical and analog inputs (those having a protection). Test outputs: Menus allowing to test the display, the LED's as well as each of the logical outputs. (Caution, coils may be powered). Version: Indicates the version number of the application uploaded into the controller. Info Distrib: Menu for displaying information, can be customized by the distributor using the FSP software. Password: In this menu, the password coded on 4 digits is entered. See section MCC Menu. See section MCC Menu. 2920 1804 02 41
3.9 Error Menu Description This menu will show when an error or a warning is activated/active. Pressing the enter key allows deactivating the display of error, if, of course, the cause of this error has been resolved. If no error or warning is active, the message All conditions are OK is displayed. Definition of different types of error Fixed speed compressors 42 2920 1804 02
Variable speed compressors When there is a warning, the error LED is lit fixed. A message flashes on the last line of the screen STATUS 0.1 stipulating the type of warning: Alarm Sensor error Pre-alarm Fault Key absent Internal fault Starting fault Pressing the enter key shows the Error menu and the parameter corresponding to the type of warning flashes. This indicates the menu that has to be entered in order to identify the input port of the warning and the protection that is activated. When the cause of the warning has been removed, the flashing message of the menu Status 0.1 disappears and the message All conditions are OK is displayed on the Error menu. When an error occurs, the compressor stops and the screen displays the name of the input in fault as well as the cause of the error. For example: 2920 1804 02 43
Pressing the cancel key then displays the menu Error with the type fault flashing. Pressing on the enter key then displays again the same error message. When the cause of the error has been removed (rearming the thermal protection relays, for example), pressing the enter key displays the message All conditions are OK. The error indicator is turned off and the compressor can be restarted. When an error occurs, a new entry is added in the menu History with the corresponding saved data. 3.10 Settings Menu Description In this menu all the basic settings appear that are used to control the compressor (unloading pressures and loaded running for each of the two usable pressure bands, pressure band used) The AIRLOGIC allows configuring two bands of operating pressures and selecting one of them depending on your needs at a given time. Fixed speed compressors Structure Definition Minimum Maximum Pressure (at machine outlet) below which the compressor passes into load (the suction box is open). Pressure above which the compressor passes to unloading (the suction box is closed). The same applies to Loading Pres. 1 but for the second pressure band. The same applies to Unloading Pres. 1 but for the second pressure band. Selection of pressure band to use : 1 or 2 depending on the settings above. 4 bar (58 psi) < value of next parameter > value of previous parameter Value of parameter Setpoint Limit of Safety menu 4 bar (58 psi) < value of next parameter > value of previous parameter Value of parameter Setpoint Limit of Safety menu Pres. Band 1 Pres. band 2 Variable speed compressors 44 2920 1804 02
Structure Definition Minimum Maximum Setpoint 1: the compressor will try to maintain this pressure in the network if this setting is selected. Setpoint pressure 2: the compressor will try to maintain this pressure in the network if this setting is selected. Selection of the setpoint pressure to be applied for operation of the compressor. Value added to the current setpoint pressure above which the compressor will switch to no-load operation. Value added to the actual setpoint pressure above which the compressor will stop and switch to default. No error is generated. Minimum rotation speed of the main compressor motor. This new setpoint is only taken into account when it is greater than the standard minimum speed. Percentage maximum speed reduction. Allows the user to limit this maximum speed for certain applications. 4 bar (58 psi) Value of parameter Setpoint Limit Safety menu 4 bar (58 psi) Value of parameter Setpoint Limit Safety menu Setpoint 1 Setpoint 2 0.1 bar (1.4 psi) 10.0 bar (145 psi) Value of previous parameter 460RPM depends on the compressor 75 % 100 % 1.5 bar (21.7 psi) 900RPM depends on the compressor If the unloaded running period is too long (if the pressure remains high in the customer network -- due to decreased demand for air, for example), the compressor will stop automatically (the period depends on the parameter Progr. Stop Time in the menu Conf. Distri). The compressor will be ready to restart if the pressure drops again below the setting of Loading Pres. 1. The pressure bands used can also be configured in the menu clock for using the weekly programming of startstop cycles. 2920 1804 02 45
3.11 Counters Menu Description In this menu, the different counters for reading can be accessed : running hours, loaded hours, number of motor starts, number of passages into load. Fixed speed compressors Structure Definition Running hours : Number of hours during which the motor has run from the first powering on of the controller. Loaded hours : Number of hours during which the compressor has operated "in load" from the first powering on of the controller. Number of motor starts: From the first powering on of the controller. Number of module hours: Period during which the AIRLOGIC remained powered on Number of load relays: Number of times the output Run in load is passed from deactivated to activated from the first powering on of the controller. Variable speed compressors 46 2920 1804 02
Structure Definition Running hours : Number of hours during which the motor has run from the first powering on of the controller. Loaded hours : Number of hours during which the compressor has operated "in load" from the first powering on of the controller. Number of motor starts : From the first powering on of the controller. Number of module hours : Period during which the AIRLOGIC remained powered. Accumulated volume: volume of compressed air produced when the controller is first switched on. Number of transitions from no-load operation to on-load operation starting from the point at which the controller is first switched on. Percentage of operating time during which the compressor has operated between 1 and 20% of its maximum speed. Percentage of operating time during which the compressor has operated between 20 et 40% of its maximum speed. Percentage of operating time during which the compressor has operated between 40 and 60% of its maximum speed. Percentage of operating time during which the compressor has operated between 60 and 80% of its maximum speed. Percentage of operating time during which the compressor has operated between 80 and 100% of its maximum speed. 2920 1804 02 47
3.12 Service Menu Description Access menu for data relating to compressor maintenance (delay from last intervention, before next intervention, type of maintenance performed), to the menus for parameterizing types of maintenance periods and also to menu Stop Under Pres. Fixed speed compressors 48 2920 1804 02
Variable speed compressors Service counter This menu allows the operator to find out when the last maintenance operation took place and when the next should take place. Fixed speed compressors 2920 1804 02 49
Structure Definition Number of hours at which the next service should be conducted and the corresponding service type (from A to J). The running hours displayed are incremented with the functioning of the compressor. Number of running hours at which the last service was carried out and the corresponding service type (from A to J). Number of hours of the machine (calculated from its date of commissioning -- machine powered on or not) at which the next service has to take place and the corresponding service type (from A to J). The life period displayed increments with the functioning of the compressor. Number of hours of the machine (calculated from its date of commissioning - machine powered on or not) at which the last service was conducted and the corresponding type (from A to J) Variable speed compressors Structure Definition Number of hours at which the next service should be conducted and the corresponding service type (from A to J). The running hours displayed are incremented with the functioning of the compressor. Number of running hours at which the last service was carried out and the corresponding service type (from A to J). Number of hours of the machine (calculated from its date of commissioning -- machine powered on or not) at which the next service has to take place and the corresponding service type (from A to J). The life period displayed increments with the functioning of the compressor. Number of hours of the machine (calculated from its date of commissioning - machine powered on or not) at which the last service was conducted and the corresponding service type (from A to J) Volume of air produced (calculated since start commissioning) at which the next service should be carried out and the corresponding service type (from A to J). Volume of air produced (calculated since commissioning) at which the last service was carried out and the corresponding service type (from A to J). Service Plan This menu allows viewing and modifying (not recommended) the maintenance intervals according to their level as defined in the compressor instruction manual. 50 2920 1804 02
Please refer to the compressor instruction manual for finding the correspondence between the service level displayed and the maintenance operations to be performed. The first maintenance at 500 hours does not take place at regular intervals. It is necessary to deactivate it after it is completed. For this, the value of the parameter Level J has to be changed from 500 Hours to ----- by decrementing the value displayed. Fixed speed compressors Structure Definition Interval of number of running hours at which the type A service has to be performed. Interval of number of running hours at which the type B service has to be performed. And so on up to the type J service level Interval of number of running hours at which the service type J has to be performed. This service at 500h takes place only once. It is necessary to deactivate this timer after it has completed by replacing the period 500h by ------. Interval of number of hours of service life (with or without functioning) at which type A service has to be performed. If the compressor remains without functioning during one year, an oil change has to be made nevertheless. Interval of number of hours of service life (with or without functioning) at which type B service has to be performed. Interval of number of hours of service life (with or without functioning) at which type J service has to be performed. Variable speed compressors 2920 1804 02 51
Structure Definition Interval of number of running hours at which the type A service has to be performed. Interval of number of running hours at which the type B service has to be performed. And so on up to the type J service level Interval of number of hours of service life (with or without functioning) at which type A service has to be performed. If the compressor remains without functioning during one year, an oil change has to be made nevertheless. Interval of number of hours of service life (with or without functioning) at which type B service has to be performed. And so on up to the type J service level Interval of number of hours of service life (with or without functioning) at which type J service has to be performed. Interval of volume of compressed air produced by the machine at which service type A should be carried out. And so on up to the type J service level When a maintenance becomes due, the menu Status 0.1 displays on its last line the flashing message *Service Required*. Pressing the enter will call up the Error menu, pressing the enter key again displays the following menu: 52 2920 1804 02
The service level required is displayed. The message Reset flashes at the bottom of the screen. Press the enter key again and confirm that the maintenance operation has been completed correctly. The message All conditions are OK confirms the validation of the service performed. Stop Under Pressure Please refer to the compressor instruction manual for a detailed description of unloading under pressure. Structure Definition If the machine is running in load, the validation of this menu allows to program a stop under pressure. The compressor passes to unload, then a few seconds later, the motor stops. When the pressure has dropped below a given limit, the unloading solenoid is again supplied with power for stopping the depressurization of the internal tank. When the unloading is completed, press the cancel key several times to return to the screen Status 0.1 3.13 Weekly program - Timer Function Description This menu allows weekly programming of pressures. 2920 1804 02 53
Text on figure: Reference Description (1) Activation or deactivation of the programming timer. The parameter is saved in memory. (2) Selection of the day of the week giving access to the 6 steps of timer programming. (3) Selection of timer programming steps (6 max). The command will be made in the order of display. (4) Configuring the hour. (5) Configuring the minutes. 54 2920 1804 02
Reference Description (6) Configuration of the action to be performed on the programmed date. (7) Refer to the definition of actions given below. (8) Scroll (9) Validation (10) Modification (11) Setting (12) Selection The menu Weekly Program allows programming over a week, the starts and stops of the compressor as well as the pressure regulation bands. For each day of the week, up to 6 programme steps can be defined. For each of these steps, the time and type of the action to be performed can be defined from the following list: ---------: cancellation of the programme step. No action shall be taken into account. Start: the compressor is started at the indicated time, the pressure band is used as defined in the menu Settings. Stop: the compressor is stopped at the time indicated. Settings 1: the use of the control parameters as defined in the menu Settings for the pressure band 1 starting from the time indicated. Settings 2: same as Settings 1 but with pressure band 2 If the compressor is part of the multi-compressor MULTILOGIC network (in option) and when it is the master compressor, the following choices are also possible: Start.sys: is used when the controller is the master of a network of several compressors in MULTILOGIC mode. It indicates that the entire network will be ready to start at the indicated time. The pressure band used is the one defined in the menu Settings of the master compressor. Stop sys: is used when the controller is the master of a network of several compressors in MULTILOGIC mode and indicates that the entire network will be stopped at the indicated time. MCC P1: is used when the controller is the master of a network of several compressors in MULTILOGIC mode. It indicates that the entire network will be ready to start at the indicated time. The pressure band used is the one defined in the menu MCC Settings for the band 1 of the MULTILOGIC mode. MCC P 2: is used when the controller is the master of a network of several compressors in MULTILOGIC mode. It indicates that the entire network will be ready to start at the indicated time. The pressure band used is the one defined in the menu MCC Settings for the band 2 of the MULTILOGIC mode 3.14 History menu Description This menu and its submenus allow displaying the latest errors occurred as well as a list of values of certain parameters and inputs recorded at the time of this error. This menu displays the data recorded during the last 5 errors. 2920 1804 02 55
Structure Definition The first screen indicates which input has triggered error number 1. Indicates the time at which error number 1 occurred. Indicates the date on which error number 1 occurred. Indicates the number of running hours of the compressor when error number 1 occurred. Indicates the number of loaded running hours of the compressor at which error number 1 occurred. Indicates the status of different logical and analog inputs at the time when error number 1 occurred. Starting point of indications recorded for error number 2. Starting point of indications recorded for error number 3. Starting point of indications recorded for error number 4. Starting point of indications recorded for error number 5. 3.15 Safety Menu Description The access to this menu for modification is restricted to advanced users. It allows modifying the safety parameters of the compressor (warning thresholds of errors, delays) on the analog inputs and on certain logical inputs. On fixed speed compressors, the tree structure is large and is divided into 3 main sections: 56 2920 1804 02
Fixed speed compressors On variable speed compressors, the tree structure is large and is divided into 2 main sections: Variable speed compressors Safety of Inputs Summary of the structure of the menu Safety/inputs 2920 1804 02 57
Fixed speed compressors 58 2920 1804 02
Variable speed compressors This menu displays logical and analog inputs for which one or more protections can be defined. Some inputs may appear several times if they have several protections. For example, the input T element outlet corresponding to the temperature sensor at the outlet of the compression element has a first protection for stopping the compressor if this temperature exceeds a certain value and a second protection preventing the compressor from starting if this temperature is too low. A detailed description of the protections of each of these inputs is provided on the following pages. Receiver pressure Protections of the input: internal pressure receiver. The pressure sensor is installed with a pressure tap in the oil tank, before the Air-oil separator. 2920 1804 02 59
Structure Definition Minimum Maximum Signifies that an error will be generated if the pressure crosses 9.0 bar (130.5 psi). Corresponding to the pressure (7.5 bar (108 psi)) at which a pre-alarm will be displayed for informing the user that a protection limit is being approached. The pressure must cross the maxi threshold plus 5 seconds (value of this parameter) when an error will be generated. This parameter defines the maxi value that can be set for the parameter shd.maxi. Signifies that the compressor cannot start as long as the tank pressure is higher than this value (1.5 bar (21.7 psi)) This parameter defines the maximum value that can be set for the parameter P start.maxi. > value of next parameter Limit P maxi of this parameter 0 bar (0 psi) < value of the above parameter 0 s 10 s 0 bar (0 psi) 17 bar (246.5 psi) 0 bar (0 psi) 2.5 bar (36 psi) 0 bar (0 psi) 17 bar (246.5 psi) Element outlet Protects the input Temperature at element outlet. Analog input corresponding to the temperature sensor installed at the outlet of the compression element, taking AIR-OIL temperature at the highest point. 60 2920 1804 02
Structure Definition Minimum Maximum Signifies that an error will be generated if the temperature crosses 110 C (230 F). Corresponding to the temperature (105 C (221 F)) at which a pre-alarm will be displayed to inform the operator that a protection limit is being approached. Time after the starting of the compressor when this protection becomes active. An error shall be generated if the temperature crosses the maximum threshold (110 C (230 F)) plus 3 seconds (value of this parameter). Protection against the wrong direction of rotation, no parameter is modifiable but the protection is active. > value of fixed parameter 120 C (248 F) 0 C (32 F) < value of the above parameter 0 s 120 s 0 s 10 s Delta P Protections on the calculated analog input Delta P. This dummy analog input corresponds to the difference between the pressure in the internal tank and the pressure at the compressor outlet. 2920 1804 02 61
Structure Definition Minimum Maximum Maximum value of the differential pressure beyond which an error is triggered. Maximum value of the differential pressure beyond which a warning appears in the menu Status 0.1 Delay after starting during which this protection is inactive. The differential pressure must exceed the maximum thresholds during more than 3 s for an error to be generated. Maximum value of the differential pressure beyond which a warning is displayed. Delay after starting during which this protection is inactive. The differential pressure must exceed the maximum thresholds during more than 5 minutes for an error to be generated. 0 bar (0 psi) (3 bar (43.5 psi) 0 bar (0 psi) < value of the previous parameter 0 s 120 s 0 s 10 s 0 bar (0 psi) 1.8 bar (26 psi) 0 s 120 s 0 min 15 min The presence of two similar protections on this input can be explained as follows: The first protection at 1.8 bar (26 psi) is the safety limit beyond which the oil separator faces the risk of implosion. An error shall therefore be generated if this value is crossed for more than 3 s. The second protection at 1.3 bar (19 psi) allows warning the operator that the de-oiler filter is saturated and has to be replaced. Only a warning shall be displayed if the value of the differential pressure crosses this threshold for more than 5 minutes. Emergency Stop The protections on the input Emergency Stop. Information about the status of the analog input. Structure Definition Minimum Maximum An error shall be generated if the input Emergency Stop is open. Open Closed 62 2920 1804 02
Overload motor (only for fixed speed compressors) Protections on the input overload main motor. Logical input corresponding to the magnetothermic switch of the main motor. Structure Definition Minimum Maximum An error is generated if the input Overload motor is open. The opening of the input must be detected during one second so that the absence of the signal can be considered an error. Open Closed 0 s 10 s Overload fan motor Structure Definition Minimum Maximum An error is generated if the input Overload fan motor is open. The opening of the input must be detected during one second so that the absence of the signal can be considered an error. Open Closed 0 s 10 s Phase sequence (option) Protections on the input of the option "phase control ". Logical input in option corresponding to the phase controller of the electrical cabinet. Structure Definition Minimum Maximum An error is generated if the input phase sequence (activated only if the option phase controller is available) is open. The opening of the input must be detected during one second so that the absence of the signal can be considered an error. Open Closed 0 s 10 s Setting Limit P Settings of safety limits that cannot be crossed on the input pressure at compressor outlet. Analog input corresponding to the pressure sensor at the compressor outlet. 2920 1804 02 63
The modification of this parameter is justified only if a change is made in the transmission ratio. No other reason can justify increasing the value of this parameter. Structure Definition Minimum Maximum This menu has only one parameter that allows limiting the maxi pressure serving as the limit of all the user pressure settings (loading, unloading pressure). 7.5 bar (108 psi) 17 bar (246.5 psi) Motor Rotations (only for fixed speed compressors) The parameters of this menu allow defining the protection against the wrong direction of motor rotation. This protection intervenes only after turning on the power to the AIRLOGIC controller. At the time of first loading of the compressor, after turning on the power, the controller measures the temperature increase at the outlet of the compression block during a certain time. If during this time interval Temp Duration, the temperature has not increased more than the value of the parameter Diffr.Temp., it is considered that the compressor is running in the wrong direction. For deactivating this error message, it is necessary to switch off the power to the compressor, interchange two of the three power supply phases to the motor and switch on the power again. Setting these two parameters to zero deactivates this protection. Structure Definition Minimum Maximum Period, after the first passage in load (after restarting the power), during which the temperature is scanned. Minimum temperature variation that should be exceeded during Temp. Duration for considering that the motor is rotating in the wrong direction. 0 s 255 s -3277 C (-590.6 F) 3277 C (5930.6 F) 3.16 Configuration user menu Description Configuration menu for numerous parameters, making it possible to adapt signals to the standards of the customer: date, time, unit, language, etc 64 2920 1804 02
Structure Definition Mode of control of compressor: Local (by the keyboard) Remote (by the inputs/outputs) LAN (through the network). Current local time Current date in the format indicated below. Date display format: DD/MM/YY MM/DD/YY YY/MM/DD Language used: One language from among the 3 that were loaded in the controller. A choice of 3 languages out of 25 is possible by reloading the application. Choice of the unit for displaying the pressure : bar, kg/ cm², MPa or psi Choice of the unit for displaying the temperatures : C, F or K Choice of the unit for displaying the vibrations : microns or mils Choice of the unit for displaying the levels (not used in our application) : mm or inches In the factory, 3 languages are configured out of a choice of 25 available. If the compressor is shipped to a particular location, contact your local after-sale service to update the language configuration. 2920 1804 02 65
3.17 Configuration distributor menu Description Menu reserved for the distributor (password), in which he can modify the control and operating parameters of the compressor. Fixed speed compressors Structure Definition Minimum Maximum Type of starter : Choice between Y/D (star/triangle) and Direct (direct starting - no management of passage from star to triangle) Automatic restart after break in power supply. Activated allows the restarting if the outage does not exceed a certain time T.energy saving. Infinite allows restarting without any time limit. Compressor number in the LAN network The Multilogic (MCC). It is used when several (up to 4) compressors are connected in a network and are controlled by a master. The pressure band selection menu allows activating or deactivating the possibility of using input 10 for selecting the pressure band to use. Load delay: delay between the passage in triangle (in the case of a star-triangle starting) and opening of the suction valve. Number of starts per day. Allows limiting the frequency of motor starts by increasing if necessary the unloaded running period. The value 360 corresponds to 15 restarts/hour. This minimum stop time allows depressurization of the tank to prevent a restart under pressure and to limit the forces on the motor during this restart. Y/D Not activated Activated Infinite 1 31 Activated Activated Direct 0 s 10 s 0 360 0 s 30 s Not activated Not activated 66 2920 1804 02
Structure Definition Minimum Maximum Programmed stop time : Period of unloaded running before stopping. Power recovery time: time beyond which the automatic restarting shall not take place if it is parameterized as Active. Automatic restart delay. Allows restarts in cascade when several compressors are working together. Permissive start time: time during which the compressor starter protections (type permissive START) are tested. Communication time out: time beyond which a communication fault with other elements of a LAN network is displayed as a fault. Dryer status: allows activating/ deactivating the integrated dryer management parameters. Drain time: opening period of the condensates purge solenoid valve. Drain interval: interval between two condensate purges. 0 s 60 s 10 s 3600 s 0 s 1200 s 0 s 15 min 10 s 60 s Activated 1 s 25 s Not activated 1 min 60 min 2920 1804 02 67
Variable speed compressors Structure Definition Minimum Maximum ID number of the compressor in the LAN network. Automatic restart after break in power supply. Activated allows the restarting if the outage does not exceed a certain time T.energy saving. Infinite allows restarting without any time limit. The Multilogic (MCC). It is used when several (up to 4) compressors are connected in a network and are controlled by a master. Allows activating or deactivating the possibility of using input 10 for selecting the pressure band to use. Maximum number of turbine starts per day. Facilitates limitation of the frequency of turbine starts by increasing the operating time where necessary. The value 240 is equal to 10 starts/hour. This minimum stop time allows depressurization of the tank to prevent a restart under pressure and to limit the forces on the motor during this restart. 1 31 Not activated Activated Infinite Activated Activated 0 720 0 s 30 s Not activated Not activated 68 2920 1804 02
Structure Definition Minimum Maximum Power recovery time: time beyond which the automatic restarting shall not take place if it is parameterized as Active. Automatic restart delay. Allows restarts in cascade when several compressors are working together. Permissive start time: time during which the compressor starter protections (type permissive START) are tested. Communication time out: time beyond which a communication fault with other elements of a LAN network is displayed as a fault. Dryer status: allows activating/ deactivating the integrated dryer management parameters. Drain time: opening period of the condensates purge solenoid valve. Drain interval: interval between two condensate purges. 10 s 3600 s 0 s 1200 s 0 s 15 min 10 s 60 s Activated 1 s 25 s Not activated 1 min 60 min 3.18 Input State Menu Description This menu displays the values and the different protections of all the active logical and analog inputs. It does not allow modifying the values of the protections. It reproduces a part of the Status menu and the Safety menu in read only. 2920 1804 02 69
Fixed speed compressors 70 2920 1804 02
Variable speed compressors 3.19 Output test menu Description Menu used for testing the display, the LEDs and each of the logical outputs. 2920 1804 02 71
Fixed speed compressors Variable speed compressors The first submenu Test screen allows testing the display as well as the LEDs of the controller (they are all lit as long as the key C is not pressed). The second submenu Outputs allows testing the correct activation of the outputs of the controller one by one. The compressor has to be stopped before these tests can be performed. 72 2920 1804 02
3.20 Version menu Description Displays the version number of the application uploaded in the controller. 3.21 Information distributor menu Description Displays information that can be customized using the FSP software. 3.22 Password menu Description This menu is used to enter a password, needed to modify the parameters (only used by the distributor). This password is used to modify the parameters in the Conf distr menu. In case no key is activated during a period of 2 minutes, the password is no longer valid. 3.23 MCC menu Description The Multilogic (noted M.C.C.) is a function that can be activated in the presence of an electronic key allowing the connection of four compressors equipped with an AIRLOGIC. The operating principle is based on a control managed by a master compressor commanding the regulation of other machines of the network. The Multilogic allows maximum one variable speed compressor in the network. 2920 1804 02 73
The Multilogic is a simple device for optimizing the operation of a multiple compressor installation. Control within one same pressure band eliminating the mode of control by pressure cascade. The energy consumptions are reduced and the pressure delivered is more stable. Balances the operating hours in order to facilitate the after-sales management of the production of air. Programs the timings of pressures for defining two pressure bands depending on the applications during the week. Simultaneous starting of compressors, programmable, for an immediate output of air, in order to rapidly inflate an unloaded network during an extended shutdown period. Instant programmable shutdown of all the compressors in the network to stop the production of air instantly at the end of the day. Starting in cascade to eliminate the intensity peak. This menu is described in a separate document delivered with the option. 3.24 External connection Fault report The output K09 is an inverter contact free of potential that allows to make a general fault report. The output is activated when an error occurs. Remote start-stop The input DI02 allows remote controlling, the start and stop of the compressor through an external contact. For this input to be operational, the parameter Control Mode of the menu Conf Distr must have the value Remote control. Connection to a Leadair The compatibility of a network of several compressors with control by a Leadair is provided through a Com- Box module for CAN <-> Serial protocol conversion. 3.25 External communication (optional) Box electronic modules Electronic modules are boxes connected to the AIRLOGIC that can manage signals from supplementary optional sensors installed either in the compressor fairing or close-by. From the AIRLOGIC, only the thresholds of faults parametered using the software (only for use by factory technicians) will be visible and will make it possible to centralize management of compressed air production. A few examples of applications: Controlling the pressure loss on the air treatment network indicating the acceptable limits of pressure loss. Measurement of ventilation air temperature Delta for indicating a radiator clogging. Measurement of the humidity of the compressed air for controlling the quality of air produced. All other applications that can use measurements from a sensor 4-20 ma. Sensors must be controlled separately from the electronic module Box. A parameter modification software (only to be used by qualified personnel) is necessary to configure warning thresholds and sensor errors or logic inputs connected to the electronic module. 74 2920 1804 02
Al-BOX3 5 temperature inputs PT 100 Al-BOX4 5 temperature inputs PT 10000 AIO-BOX SPM-BOX DIO-BOX MIX-BOX 4 analog inputs 16 bits + 2 analog outputs 4-20 ma Shock Pulse Meter, device used for vibration measurements of bearing (or bush) wear, for example, on the main motor or a compression element. 4 logical inputs + 4 logical outputs 2 pressure inputs 1 Temperature input PT 1000 3 logical inputs 2 logical outputs Communication modules MOD-BOX PROFI-BOX COM-BOX Modbus communication Profibus communication Conversion of protocols. Contact our local after-sale service for more details. All the parameters of the status menu can be displayed in order to obtain an instant diagnosis of the operation of the compressor. The alarms or error messages can be displayed and managed by remote control for triggering an intervention at the site. 3.26 Common operations Quick start The minimum settings required for starting the compressor are listed below: LANGUAGE: access by the menu Conf.user, see section Changing the display language. DATE: access by the menu Conf.user, see section Configuration user Menu. TIME: access by the menu Conf.user, see section Configuration user Menu. PRESSURE UNIT: access by the menu Conf.user, see section Configuration user Menu. TEMPERATURE UNIT: access by the menu Conf.user, see section Configuration user Menu. LOADING PRESSURE: access by the menu Settings, parameter Loading pressure, see section Settings Menu. UNLOADING PRESSURE: access by the menu Settings, parameter Loading pressure, see section Settings Menu. SELECTION OF THE CONTROL BAND: access by the menu Settings, parameter Pressure band used, see section Settings Menu. The mode of accessing and modifying the above parameters is described in section Modifying a parameter. This procedure enables starting a compressor and producing air according to the pressure needs of the air net. 3.27 Reinitialisation of maintenance counters Description See section Service Menu. 2920 1804 02 75
3.28 Operational incidents Description The operational incidents are indicated both by the faults/warning LEDs as well as by displaying the nature of faults on the AIRLOGIC. An error is indicated by a flashing red light, a warning is indicated by a fixed red light. 3.29 List of messages Warning messages Description Main screen message Solution (Definition of the type of alarm in the Error\Protection\Alarms menu) High oil temperature pre-alarm **Shutd.Warn.** The oil temperature has exceeded the high alarm threshold (105 C/221 F) but is less than the maximum temperature, which then generates an error (110 C/230 F ). Tank high pressure pre-alarm **Shutd.Warn.** The tank pressure has exceeded the high alarm threshold but is less than the maximum pressure, which then generates an error De-oiler clogging pre-alarm **Shutd.Warn.** Verify the loss of de-oiler load, verify deoiling, and replace the de-oiler if necessary. Verify the VPM. Maintenance cycle J lasting 500 h has been reached * Serv.Requir.* Carry out J type maintenance as described in the instructions.once maintenance is completed, Reset 76 2920 1804 02
Alarm messages Description The approximate loss of load has exceeded the alarm threshold but remains less than the maximum threshold. (P tank - P output) The approximate loss of load has exceeded the alarm threshold but remains less than the maximum threshold. (P tank - P output) Dryer frozen. Dryer temperature less than - 1 C/-33.8 F. The dryer is stopped and restarts at LAT = 7 C/44.6 F Dryer temperature too high. The alarm will disappear when the temperature drops Dryer temperature too high. The alarm will disappear when the temperature drops Main screen message ** Warning ** Error menu message AC Approach 1.5 bar/22 psi Shd Max. 1.3 bar/19 psi Delta P 1.6 bar/23 psi Shdw Max 1.3 bar/19 psi Dryer LAT -5 C/ 41 F Min. frze -1 C/33.8 F ** Warning ** Dryer LAT Dewp Not normal ** Warning ** Dryer LAT 232 C/ 449.6 F Max. alarm 25 C/77 F Solution Verify de-oiler loss of load, verify deoiling, and replace de-oiler if necessary. Verify the VPM.2 Verify de-oiler loss of load, verify deoiling, and replace de-oiler if necessary. Verify the VPM. Verify ambient temperature.verify correct operation of the drier. (HGBV + PS) Error messages Description Main screen message Error menu message High temperature error Elem. outlet 113 C/235 F Shd Max. 110 C/230 F Rotation direction. The Airlogic has calculated that the oil temperature has not increased sufficiently during starting and therefore the compressor turns in the wrong direction. The temperature sensor measures a temperature out of the normal range (-40 C/340 C) (-104 F/644 F) The tank pressure sensor measures a pressure outside the normal range (0/17 bars) (0/246.5 PSI) during operation under load Elem. outlet 88 C/190.4 F Rota Elem. outlet ****** C/ F Shd Max. 110 C/230 F Receiver Press. ****** bar/psi Shd Max. 9.0 bar/ 130.5 psi Solution The oil temperature has exceeded the high error threshold (110 C/230 F ) Verify the direction of rotation of the compressor and the power supply cable. Down-powering required for reset + phase changes. Do not carry out too many tests. Verify connections, condition of cables. Disconnect the sensor. It should then indicate the ambient temperature. It is also possible to measure the resistance indicated by the sensor and to verify whether or not it has drifted, using the tables. Verify connections, condition of cables. Disconnect the sensor. It must then indicate 0 bar/0 psi. Verify the sensor for correct operation. 2920 1804 02 77
Description The tank pressure is greater than the maximum starting pressure (1.5 bar/21.7 psi) The pressure regulation sensor (machine output), measures a pressure outside the normal range (0/17 bars) ( 0/246.5 psi) during operation under load. The tank pressure sensor measures a pressure outside the normal range (0/17 bars) (0/246.5 psi) during operation under load The tank pressure is greater than the maximum service pressure (here, 9.0 bar/130.5 psi) The approximate loss of load has exceeded the maximum threshold. (P tank - P output) The approximate loss of load has exceeded the maximum threshold (P tank - P output) Emergency stopping triggered The phase controller indicates that the connection of phases is reversed. The main motor is overloaded. The fan motor is overloaded Main screen message ****** (flashing) Compressor Off/* Sensor Error* Error menu message Receiver Press. 1.7 bar/24.7 psi Max.PeSt 1.5 bar/ 21.7 psi Receiver Press. ****** bar/psi Shd Max. 9.0/130.5 psi Receiver Press. 9,3 bar/135 psi Shd Max. 9.0 bar/ 130 psi AC Approach 3.0 bar/43.5 psi Shd Max. 1.8 bar/26 psi Delta P 2.1 bar/ 30.5 psi Shd Max. 1.8 bar/26 psi Emergency stop Shd Open Phase Sequence Fail. Open Overload Motor Fail. Open Overl. Fanmotor Fail. Open Solution Verify the emptying circuit (solenoid valve and/or valve). VPM blocked open, network pressure returned to the tank. Verify connections, condition of cables. Disconnect the sensor. It must then indicate 0 bar/0 psi. Verify the sensor for correct operation. Verify connections, condition of cables. Disconnect the sensor. It must then indicate 0 bar/0 psi. Verify the sensor for correct operation. Verify the regulation sensor (machine output), verify the emptying circuit (solenoid valve and/or valve), suction box remains open. VPM blocked closed. Verify de-oiler loss of load, verify deoiling, and replace de-oiler if necessary. Verify the VPM. Verify de-oiler loss of load, verify deoiling, and replace de-oiler if necessary. Verify the VPM. Release the emergency stop device. Verify connection and operation of the emergency stop push-button. Verify the value and its use, and supply of each phase. Verify operation of the controller. Change the phase connection order. An error has been generated **Shutdown** Go to the error menu to identify the fault Communication problem Airlogic/regulator Compr. Motor Convert.Timeout Verify: the regulator is in good condition the communication cables continuity of shielding earths of regulator/regulator control module link cables regulator communication parameters 78 2920 1804 02
Information messages Description Permissible starting conditions not reached The machine is under load. It is automatically regulated by its internal sensor. The compressor is stopped, as well as the motor. The compressor as well as the motor are stopped, but could re-start at any time. The machine is operating under no load. It is automatically regulated by its internal sensor. Stopping is requested. The machine switches to no load. The temperature sensor measures a temperature out of the normal range (-40 C/340 C) (-104 F/644 F) The tank pressure sensor measures a pressure outside the normal range (0/17 bar) (0/246.5 psi) The pressure regulation sensor (machine output), measures a pressure outside the normal range (0/17 bar) (0/246.5 psi) No load switch-over command given by the Airlogic (max. internal pressure of the machine reached), whereas the machine is controlled by an external regulation device (Digital, LAN ), giving it the under load operating command. Remote stopping/starting Main screen message Process Starts Compressor Off Motor Stopped Auto Unloaded Progr. stop ****** * Sensor Error* * Sensor Error* Error menu message Auto Loaded Solution The machine is verifying the following parameters (time is adjustable depending on whether the dryer is enabled or disabled) : -ambient temperature measured by Element outlet temperature (>2 C/35.6 F)- tank pressure (<1.5 bar/21.7 psi)- Dryer LAT (correct), dryer temperature>-1 C/-33.8 F Verify connections, condition of cables. Disconnect the sensor. It should then indicate the ambient temperature. It is also possible to measure the resistance indicated by the sensor and to verify whether or not it has drifted, using the tables. Verify connections, condition of cables. Disconnect the sensor. It must then indicate 0 bar/0 psi. Verify the sensor for correct operation. * Sensor Error* Verify connections, condition of cables. Disconnect the sensor. It must then indicate 0 bar/0 psi. Verify the sensor for correct operation. Unload: Overpr. Remote control Adjustment of the external operating order to a lower threshold than the maximum permissible pressure of the machine. 2920 1804 02 79
Description Main screen message Error menu message Solution Control carried out via a LAN type network LAN control The Airlogic is in remote control mode, internal regulation and receives a remote emptying command. Manual Unload The regulator is starting the motor but cannot yet give the signal to the Airlogic concerning motor speed. Motor starting Inverter messages (variable speed compressors) Fault code Fault Possible cause Correcting measures 1 Overcurrent Frequency converter has detected too high a current (>4*In) in the motor cable: sudden heavy load increase short circuit in motor cables unsuitable motor 2 Overvoltage The DC-link voltage has exceeded the limits defined in table 4.2 (NX manual) too short a deceleration time high over voltage spikes in supply 3 Earth fault Current measurement has detected that the sum of motor phase current is not zero. insulation failure in cables or motor 5 Charging switch The charging switch is open, when the START command has been given. faulty operation component failure 6 Emergency stop Stop signal has been given from the option board. 7 Saturation trip Very high overload. Defective component 8 Unknown fault The frequency converter troubleshooting system is unable to locate the fault. 9 Undervoltage DC-link voltage is under the voltage limits. most probable cause: too low a supply voltage frequency converter internal fault Check loading. Check motor size. Check cables. Make the deceleration time longer. Check motor cables and motor. Reset the fault and restart. Should the fault re-occur, contact the distributor near to you. Cannot be reset from the keypad. Switch off power. If this does not help, contact the distributor near to you. Reset the fault and restart. Should the fault re-occur, contact the distributor near to you. In case of temporary supply voltage break, reset the fault and restart the frequency converter. Check the supply voltage. If it is adequate, an internal failure has occurred. Contact the distributor near to you. 80 2920 1804 02
Fault code Fault Possible cause Correcting measures 10 Input line supervision 11 Output phase supervision 12 Brake chopper supervision 13 Frequency converter under temperature 14 Frequency converter over temperature Input line phase is missing. Current measurement has detected that there is no current in one motor phase. no brake resistor installed brake resistor is broken brake chopper failure Heatsink temperature is under -10 C/-50 F Heatsink temperature is over 90 C/ 194 F. Over temperature warning is issued when the heatsink temperature exceeds 85 C/185 F. 15 Motor stalled Motor stall protection has tripped. Check motor. 16 Motor overtemperature Motor overheating has been detected by frequency converter motor temperature model. Motor is overloaded. 17 Motor underload Motor underload protection has tripped. 22 23 EEPROM checksum fault 24 Changed data warning 25 Microprocessor watchdog fault Parameter save fault faulty operation component failure Changes may have occurred in the different counter data due to mains interruption faulty operation component failure 32 Fan cooling Cooling fan of the frequency converter does not start, when ON command is given 36 Control unit NXS Control Unit can not control NXP Power Unit and vice versa 37 Device change Option board changed. Different power rating of drive. 38 Device added Option board added. Drive of different power rating added. 39 Device removed Option board removed. Drive removed. 40 Device unknown Unknown option board or drive. 41 IGBT temperature IGBT Inverter Bridge over temperature protection has detected too high a short term overload current Check supply voltage and cable. Check motor cable and motor. Check brake resistor. If the resistor is ok, the chopper is faulty. Contact the distributor near to you. Check the correct amount and flow of cooling air. Check the heatsink for dust. Check the ambient temperature. Make sure that the switching frequency is not too high in relation to ambient temperature and motor load. Decrease the motor load. If no motor overload exists, check the temperature model parameters. Decrease the motor load. If no motor overload exists, check the temperature model parameters. No special actions required. Take a critical attitude to the counter data. Reset the fault and restart. Should the fault re-occur, contact the distributor near to you. Contact the distributor near to you. Change control unit Reset Reset Reset Check loading. Check motor size. 2920 1804 02 81
Fault code Fault Possible cause Correcting measures 42 Brake resistor overtemperature 50 Analogue input Iin < 4mA (selected signal range 4 to 20 ma) Brake resistor over temperature protection has detected too heavy braking 51 External fault Digital input fault. 52 Keypad communication fault Current at the analogue input is < 4mA. control cable is broken or loose signal source has failed The connection between the control keypad and the frequency converter is broken. Set the deceleration time longer. Use external brake resistor. Set the deceleration time longer. Use external brake resistor. Check the current loop circuitry. Check keypad connection and possible keypad cable. 82 2920 1804 02
4 Installation 4.1 Dimension drawing Compressor dimensions Dimension drawing (in mm) of air-cooled compressor 110 kw with prefiltration panel 2920 1804 02 83
Dimension drawing (in mm) of air-cooled compressor 110 kw with high efficiency prefiltration panel 84 2920 1804 02
Dimension drawing (in mm) of air-cooled compressor 110 kw with prefiltration panel and heavy duty air inlet filter 2920 1804 02 85
Dimension drawing (in mm) of air-cooled compressor 110 kw with high efficiency prefiltration panel and heavy duty air inlet filter 86 2920 1804 02
Dimension drawing (in mm) of air-cooled compressor 132 kw with prefiltration panel 2920 1804 02 87
Dimension drawing (in inch) of air-cooled compressor 132 kw with prefiltration panel 88 2920 1804 02
Dimension drawing (in mm) of air-cooled compressor 132 kw with prefiltration panel and heavy duty filter 2920 1804 02 89
Dimension drawing (in inch) of air-cooled compressor 132 kw with prefiltration panel and heavy duty filter 90 2920 1804 02
Dimension drawing (in mm) of air-cooled compressor 132 kw with high efficiency prefiltration panel 2920 1804 02 91
Dimension drawing (in inch) of air-cooled compressor 132 kw with high efficiency prefiltration panel 92 2920 1804 02
Dimension drawing (in mm) of air-cooled compressor 132 kw with high efficiency prefiltration panel and heavy duty air inlet filter 2920 1804 02 93
Dimension drawing (in inch) of air-cooled compressor 132 kw with high efficiency prefiltration panel and heavy duty air inlet filter Text on drawing Reference (1) Compressed air outlet (2) Cooling air outlet (3) Outlet energy recovery Explanation 94 2920 1804 02
Reference Explanation (4) Automatic drain outlet (5) Opening for transportation (6) 4 slotted holes to pull unit horizontally out of container (7) Cooling air inlet (8) COG (Center Of Gravity) (9) Compressed air outlet According to DIN 2566 DN80 PN16(1:5) (10) Cooling water Outlet G 1 3/4" (11) Cooling water Inlet G 1 3/4" (12) Outlet WSD diameter 20 mm 4.2 Installation remarks General The compressor is intended for indoor use only. Working with machinery controlled by a frequency converter requires special safety precautions, which depend on the type of network (TN, TT or IT). Consult the manufacturer. The compressors comply with class A limits for radiated emissions according to EN 55011-A (2007). Beware of possible electromagnetic interference if stricter limits are valid. The compressors comply with limits in accordance with the EN61800-3:2004, EN61000-4-2:2009, EN61000-4-3:2006, EN61000-4-4:2004 and EN61000-4-6:2009 standards regarding the immunity of the equipment. 2920 1804 02 95
Safety precautions for the frequency converter This equipment is used in high-voltage installations. During operation, this equipment contains rotating and live, bare parts. For this reason, it could cause severe injury or significant material damage if the required covers are removed or have not been properly maintained. When the machines are used in non-industrial areas, the installation location must be protected against unauthorized access (protective fencing, appropriate signs). All connection procedures must be carried out with the cabinet de-energized. All the work on the units must be carried out by trained personnel only. Death, serious injury, or substantial material damage can result if these warnings are not taken into account. Work on an open device must be carried out with extreme caution because external supply voltages may be present. The power and control terminals may be live even when the motor is not running. Dangerously high voltage levels are still present in the cabinet up to five minutes after it has been disconnected due to the DC link capacitors. For this reason, the cabinet should not be opened until after a reasonable period of time has elapsed. The operator is responsible for ensuring that the Power Module and other components are installed and connected in accordance with the recognized technical rules in the country of installation and applicable regional guidelines. Special attention should be paid to cable dimensioning, fuses, grounding, shutdown, disconnection, and overcurrent protection. If an item of protecting gear trips in a branch circuit, a leakage current may have been disconnected. To reduce the risk of fire or an electric shock, the current-carrying parts and other components in the cabinet unit should be inspected and damaged parts replaced. When an item of protective gear trips, the cause of tripping must be identified and rectified. The storage period should not exceed two years. If the device is stored for more than two years, the DC link capacitors of the devices must be reformed during commissioning. Consult your Service Centre for the reforming procedure. 96 2920 1804 02
4.3 Installation proposal Compressor room lay-out Compressor room lay-out (in mm) 2920 1804 02 97
Compressor room lay-out (in inch) Text on drawing Drawing reference Designation (1) Minimum free area to be reserved for compressor installation (2) Ventilation proposals (3) Alt.1 (= Alternative 1) (4) Notations 98 2920 1804 02
Drawing reference Designation (5) Motor ventilation air outlet (6) Motor ventilation air inlet (7) Compressor air inlet (8) Cooling air outlet (9) Cooling air inlet Description Unused holes in the cubicle should be plugged. All electrical screens in the control cubicle and drive cubicle should be installed before start-up and shouldn't be removed during operation. Drawing reference Description 1 Install the compressor on a level floor suitable for taking its weight. For ventilation alternatives 1 and 2 (indicated as Alt. 1 and Alt. 2), the minimum distance between the compressor unit roof and the compressor room ceiling is 1200 mm (47.2 in). 2 Compressed air outlet valve (not in scope of supply) 3 Air delivery pipe: The pressure drop over the air outlet pipe can be calculated as follows: For SI Units: dp = (L x 450 x Qc 1.85 ) / (d 5 x p) dp = Pressure drop (recommended maximum = 0.1 bar) L = Length of outlet pipe in m Qc = Free air delivery of the compressor in l/s d = Inner diameter of the outlet pipe in mm p = Absolute pressure at the compressor outlet in bar(a) For British/American Units: dp = (L x Qc 1.85 ) / (1470 x d 5 x p) dp = Pressure drop (recommended maximum = 1.45 psi) L = Length of outlet pipe in ft Qc = Free air delivery of the compressor in cfm d = Inner diameter of the outlet pipe in in p = Absolute pressure at the compressor outlet in psig 2920 1804 02 99
Drawing reference Description 4 The inlet grids and ventilation fan should be installed in such a way that any recirculation of cooling air to the compressor inlet grid is avoided. The maximum air velocity through the grids is 5 m/s (16.5 ft/s). If cooling air ducts are installed, the maximum allowable pressure drop over the ducts is 30 Pa (0.12 in wc). The air temperature at the compressor inlet grid should be between 0 C and 46 C (32 F and 114.8 F). The required ventilation to limit the compressor room temperature can be calculated as follows: For SI Units: On air-cooled compressors: Qv = 0.92 N/dT Qv = Required ventilation capacity in m 3 /s N = Shaft input of compressor in kw (for Pack compressors) N = Shaft input of compressor in kw + heat dissipated by dryer in kw (for Full-Feature compressors) dt = Temperature increase in compressor room For British/American Units: On air-cooled compressors: Qv = 2618.5 N/dT Qv = Required ventilation capacity in cfm N = Shaft input of compressor in hp (for Pack compressors) N = Shaft input of compressor in hp + heat dissipated by dryer in hp (for Full-Feature compressors) dt = Temperature increase in compressor room 5 Drain pipes to condensate collector. The drain pipes should be connected to an open circuit. 6 Control cubicle with monitoring panel 7 Main cable entry - A water shut-off valve and water drain valve in the energy recovery water inlet pipe and outlet pipe can be installed by the customer. If water shut-off valves are installed, a safety device with set pressure according to the maximum water inlet pressure has to be installed between the energy recovery water outlet pipe and the shut-off valve. Notes For more information concerning air nets, cooling systems, etc. check the compressor installation manual. All pipes should be connected stress free to the compressor unit. For dimensions and air flow directions check the dimension drawings. 100 2920 1804 02
4.4 Electric cable size Electrical connections Electrical connections for IEC fixed speed compressors 2920 1804 02 101
Electrical connections for IEC variable speed compressors 102 2920 1804 02
Electrical connections for CSA/UL fixed speed compressors 2920 1804 02 103
Electrical connections for CSA/UL variable speed compressors Cable connection Cable glands Always use the correct cable glands: Cable section Cable diameter 70 C Cable diameter 90 C Cable gland size Ordering number 25 mm 2 7.6 mm 16 0698 5140 71 35 mm 2 9.2 mm 20 0698 5140 72 50 mm 2 11 mm 25 0698 5140 73 70 mm 2 13 mm 25 0698 5140 73 95 mm 2 15 mm 25 0698 5140 73 120 mm 2 17 mm 32 0698 5140 74 150 mm 2 19 mm 40 0698 5140 75 185 mm 2 21 mm 40 0698 5140 75 AWM 3 10.2 mm 20 0698 5140 72 AWM 2 10.8 mm 20 0698 5140 72 AWM 2/0 15.2 mm 25 0698 5140 73 AWM 4/0 19.5 mm 32 0698 5140 74 104 2920 1804 02
Cable section Cable diameter 70 C Cable diameter 90 C Cable gland size Ordering number MCM 300 22.2 mm 40 0698 5140 75 MCM 400-40 0698 5140 75 Cable size See table if cables need to be spaced! Connect cables in the cubicle with the correct cable lugs. Spacing of 10 mm between naked cable parts should be obtained. Supply Cables : IEC type: XLPE 90 C CSA/UL type: 110 C insulation cable Fixed speed compressors, IEC 50 Hz water-cooled Compressor type Voltage Cable size, water-cooled compressors Remark 110 kw 400V 2X (3X 70 mm 2 + 35 mm 2 ) grouping 2 cables bunched 132 kw with 4-pole motor 400V 2X (3X 70 mm 2 + 35 mm 2 ) grouping 2 cables bunched Fixed speed compressors, IEC 50 Hz air-cooled Compressor type Voltage Cable size, air-cooled compressors Remark 110 kw 400V 2X (3X 70 mm 2 + 35 mm 2 ) grouping 2 cables bunched 132 kw with 4-pole motor 400V 2X (3X 70 mm 2 + 35 mm 2 ) grouping 2 cables bunched Fixed speed compressors, IEC 60 Hz water-cooled Compressor type Voltage Cable size, water-cooled compressors Remark 110 kw 380V 2X (3X 70 mm 2 + 35 mm 2 ) grouping 2 cables bunched 110 kw 440V 2X (3X 50 mm 2 + 25 mm 2 ) grouping 2 cables bunched 132 kw 380V 2X (3X 70 mm 2 + 35 mm 2 ) grouping 2 cables bunched 132 kw 440V 2X (3X 70 mm 2 + 35 mm 2 ) grouping 2 cables bunched 2920 1804 02 105
Fixed speed compressors, IEC 60 Hz air-cooled Compressor type Voltage Cable size, air-cooled compressors Remark 110 kw 380V 2X (3X 70 mm 2 + 35 mm 2 ) grouping 2 cables bunched 110 kw 440V 2X (3X 70 mm 2 + 35 mm 2 ) grouping 2 cables bunched 132 kw 380V 2X (3X 70 mm 2 + 35 mm 2 ) grouping 2 cables bunched 132 kw 440V 2X (3X 70 mm 2 + 35 mm 2 ) grouping 2 cables bunched Fixed speed compressors, CSA/UL air-cooled Compressor type Voltage Cable size, air-cooled compressors Remark 132 kw 460V 2X (3X AWG4/0 + AWG4) Grouping 2 cables bunched Variable speed compressors, IEC Compressor type Voltage Cable size, air-cooled compressors Remark 132 kw 400V 2X (3X 95 mm 2 + 50 mm 2 ) Grouping 2 cables bunched Variable speed compressors, CSA/UL Compressor type Voltage Cable size, air-cooled compressors Remark 132 kw 460V 2X (3X AWG4/0 + AWG3) Grouping 2 cables bunched 106 2920 1804 02
4.5 Pictographs Control panel Ref. Designation 1 Start 2 Stop 3 Cancel key 4 Enter key 5 Scroll keys 6 Alarm 7 Automatic operation 8 Voltage on 9 Emergency stop 2920 1804 02 107
Other locations Reference Description 13 Automatic condensate drain 14 Automatic condensate drain 15 Manual condensate drain 16 Stop the compressor before maintenance or repair 17 Warning: under tension 18 Read Instruction book before starting the compressor 19 Switch off the voltage and depressurize the compressor before maintenance or repair 20 Before connecting the compressor electrically, consult the Instruction book for the motor rotation direction 21 Torques for steel (Fe) or brass (CuZn) bolts 22 Consult the Instruction book before greasing 23 Switch off the voltage before removing the protecting cover inside the electric cabinet 24 Oil the gaskets, screw on the filters and tighten by hand (approx. one half turn) 25 Consult the Instruction book before maintenance or repair 28 Oil outlet 108 2920 1804 02
5 Operating instructions 5.1 Initial start-up Warning The operator must apply all relevant Safety precautions. Switch off the voltage before making any adjustment. Outdoor/altitude operation If the compressor is installed outdoors or if the air inlet temperature can be below freezing point, precautions must be taken. In this case, and also if operating at high altitude, consult your service representative. Moving/lifting The compressor can be moved by a lift truck using the slots in the frame. Make sure that the forks protrude from the other side of the frame. The compressor can also be lifted after inserting beams in the slots. Make sure that the beams cannot slide and that they protrude from the frame equally. The chains must be held parallel to the bodywork by chain spreaders in order not to damage the compressor. The lifting equipment must be placed in such a way that the compressor is lifted perpendicularly. Lift gently and avoid twisting. General preparations Step Action 1 Install the compressor, see the sections Dimension drawing, Installation proposal and Electric cable size. 2 Stick labels near the control panel to warn the operator that: the compressor may start automatically after a voltage failure the compressor is automatically started and stopped the compressor may be remotely controlled 3 A number of VCI (Volatile Corrosion Inhibitor) plates are provided inside the bodywork to protect the compressor against corrosion. Remove the plates. 4 If the compressor has not run for the past 6 months, it is required to improve the lubrication of the compressor element before starting. Fill up the compressor element as described in section Oil change (paragraph: Filling the compressor element with oil). 5 Check that the compressor is filled with oil; the pointer of the oil level indicator should be in the green range (see the section Oil change). 2920 1804 02 109
Protection during transport Transport fixtures Step Action 1 The gear casing supports and motor support are secured to the frame, immobilizing the vibration dampers during transport. 2 Remove the bushes (1) from the gear casing supports and the motor support. Electric cabinet Environmental condition for the electrical equipment: 3K3 according to IEC 60721-3-3 Step Action 1 Check that the electrical connections correspond to the local codes. The installation must be earthed and protected by fuses in all phases. An isolating switch must be fitted. 2 Check the wires on transformers for correct connection. 3 Check the setting of the circuit breakers (see the section Settings of circuit breakers). 4 Check that overload relay (F21) is set for automatic resetting and check its setting (see the section Setting of overload relay and fuses). 110 2920 1804 02
Start up Step Action 1 Close the drain valves (see the section Cooling and condensate system). 2 Switch on the voltage. 3 Start the compressor and stop it immediately. Check the rotation direction of the drive motor while the motor is coasting to a stop. To determine the rotation direction of the motor, look at the fan through the grating at the non-drive end of the motor. The correct rotation direction is indicated by an arrow on the gear casing and on the fan cowl. On air-cooled compressors, check the rotation direction of the fan motor, the fan is visible through the grating in the air inlet panel (see section Dimension drawing). The correct rotation direction is indicated by arrows on the fan inlet plate. 4 If the rotation direction is wrong, press the emergency stop button, switch off the voltage and reverse two incoming electric lines. If the rotation direction of the fan motor is wrong, consult your customer centre. 5 Run the compressor for a few minutes and check that it is operating normally. 5.2 Before starting Warning The operator must apply all relevant Safety precautions. Control panel Control panel 2920 1804 02 111
Step Action 1 Switch on the voltage. Voltage on LED (6) lights up. 2 Close the condensate drain valves (see the section Cooling and condensate system). 3 Open the air outlet valve. 4 Check the oil level indicator (see the section Oil change). The pointer should be in the green range or orange range. 5.3 Starting Warning The operator must apply all relevant Safety precautions. Control panel Control panel Step Action 1 Press start button (1). The compressor starts running in unloaded condition. Automatic operation LED (8) lights up. 2 Approx. 10 seconds later (programmable), the compressor starts running loaded. The message on display (2) changes from Automatically unloaded to Automatically loaded. 112 2920 1804 02
Reference Name A Air inlet temperature in C B Condensation temperature in C C Effective working pressure in bar D Relative air humidity in % 5.4 During operation Warning The operator must apply all relevant Safety precautions. The operator should immediately stop the machine in case of oil leaks internally in the machine as well as externally and consult a competent technician to resolve the cause. The machine should not be restarted before the problem has been remedied. The load cycle of the compressor must be limited to maximum two cycles per minute. 2920 1804 02 113
Control panel Control panel 1. When the automatic operation LED (8) is lit, the starting and stopping of the motor is controlled automatically. 2. Check the outlet temperature of the compressor element and other readings on display (2). If the compressor is stopped, it may start automatically. 5.5 Checking the display Warning Before carrying out any maintenance, repair work or adjustment, stop the compressor, press the emergency stop button and switch off the voltage. Close the air outlet valve. If an optional water separator drain is installed, open the manual condensate drain valve. 114 2920 1804 02
Control panel Control panel Step Action 1 Regularly check the display for readings and messages. Normally, the main display is shown, indicating the compressor outlet pressure, the status of the compressor and the functions of the keys below the display. 2 Always check the display and remedy the problem if alarm LED (7) is lit or flashing. 3 The display will show a service message if a service plan interval has been exceeded or if a service level for a monitored component has been exceeded. Carry out the service actions of the indicated service plans or replace the component and reset the relevant timer. 4 Regularly check the actual compressor status by pressing the arrow down key from the main screen. 5.6 Stopping Important After pressing stop button (9), the compressor will run unloaded for 30 seconds. The compressor stops after this period. A start command during this period is ignored. After stopping, the compressor is prevented from restarting within a programmable time (20 seconds). A start command given during this minimum stop time will be memorised; the automatic operation LED lights up. The compressor will start when the minimum stop time has elapsed. 2920 1804 02 115
Control panel Control panel Reference Name 1 Press stop button (9). LED (8) goes out. The message Programmed stop appears. The compressor runs unloaded for 30 seconds and then stops. 2 To stop the compressor in the event of an emergency, press emergency stop button (S2). Alarm LED (7) blinks. After remedying the fault, unlock the button by pulling it out 3 Close the air outlet valve. 4 If an optional water separator drain is installed, open the condensate drain valve. For compressors equipped with electronic water drains, press the test buttons on top of the electronic drains until the air system between the air receiver and the outlet valve is fully depressurized. 5 Switch off the voltage. 5.7 Storage after installation Procedure Run the compressor, e.g. twice a week, until warm. Load and unload the compressor a few times to operate the components of the unloading/loading system. If the compressor is going to be stored without running from time to time, protective measures must be taken. Consult your Customer Centre. 116 2920 1804 02
5.8 Taking out of operation Disconnecting the compressor At the end of the service life of the compressor, proceed as follows: Step Action 1 Stop the compressor and close the air outlet valve. 2 Switch off the voltage and disconnect the compressor from the mains. 3 Depressurize the compressor by opening the drain valve and loosening the oil filler plug one turn. For compressors equipped with electronic water drains, press the test buttons on top of the electronic drains until the air system between the air receiver and the outlet valve is fully depressurized. 4 Shut off and depressurize the part of the air net which is connected to the outlet valve. Disconnect the compressor air outlet pipe from the air net. 5 Drain the oil and condensate circuits. On water-cooled compressors, drain the water circuits. 6 Disconnect the compressor condensate piping from the condensate drain net. 7 On water-cooled compressors, disconnect the cooling water pipes from the compressor. 8 Also read section Disposal of used material. 5.9 Use of air receiver Instructions Step Action 1 This equipment can contain pressurized air and oil; be aware of its potential danger if used improperly. 2 This equipment must only be used as compressed air/oil separator and must be operated within the specified limits. 3 No alterations must be made to this equipment by welding, drilling, grinding or other methods of mechanical working without written permission of the manufacturer. If there is damage to a part under pressure from any cause, the complete part must be replaced. 4 For the oil separator vessel: original bolts have to be used after opening for inside inspection. The bolts must be removed and fitted with the correct tool. The bolts must be tightened with a torque of 185 Nm (+/- 45 Nm). Damaged bolts must not be re-used. O- rings must be replaced. 5 The safety valve is designed in such a way that the pressure will not permanently exceed the maximum allowable operating pressure of the vessel, except for short pressure surges up to 1.1 times the design pressure. 6 Only use oil specified by the manufacturer. 7 Make sure the vessel is fully depressurized before opening the drain plug or fill plug. 2920 1804 02 117
Step Action 8 This vessel and other parts under pressure have been designed and built to guarantee an operational lifetime in excess of 20 years and an infinite number of pressure load cycles. A visual inspection (for damage, non-authorized alterations,...) of the vessel (at the outside and inside) is recommended every 5 years. Make sure the vessel is fully depressurized and isolated before carrying out an internal inspection. 9 At every inspection, also check the oil drain flexible. Replace if there is any wear or damage. 118 2920 1804 02
6 Maintenance 6.1 Preventive maintenance schedule Warning Before carrying out any maintenance, repair work or adjustment, proceed as follows: Stop the compressor. Press emergency stop button (S2). Close the air outlet valve and open the manual condensate drain valves. For compressors equipped with electronic water drains, press the test buttons on top of the electronic drains until the air system between the air receiver and the outlet valve is fully depressurized. Switch off the voltage. Open and lock the isolating switch. The operator must apply all relevant Safety precautions. Warranty - Product Liability Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability. General When servicing, replace all removed gaskets, O-rings and washers. Preventive maintenance schedule Period Running hours Operation Daily 8 Check readings on display. Daily 8 Check oil level. Before starting, the level should be in the middle of the sight-glass. Daily 8 If an optional water sepatator drain is installed, chek that condensate is discharged during loading. Weekly -- Check the cleanliness of the cubicle filters. Replace or clean if dusty. Weekly -- Drain condensate from air receiver, if installed Monthly 150 Clean air cooler by air jet, cooling air side 3-Monthly -- Clean compressor. -- 500 After first start, retighten power cable connections. 3-Monthly -- Check for possible leaks. 3-Monthly -- Remove air filter elements and inspect. 3-Monthly 500 Check the coolers; clean them if necessary. See the section Coolers. 3-Monthly 500 Check measured parameters Yearly -- Have safety valve tested. The valves can be tested on a separate compressed air line. Yearly -- Have all flexibles inspected. 2920 1804 02 119
Period Running hours Operation Yearly 2000 Test safety temperature. Yearly 2000 Retighten the power connections. Yearly 2000 Check coupling. Yearly 2000 Replace air filter element. Yearly 2000 If Rotair oil is used, change oil. Yearly 4000 If Rotair Plus oil is used, change oil. Yearly 4000 If Foodgrade oil is used, change oil. Yearly 6000 Replace oil filters. Yearly 8000 If RXD oil is used, change oil. Yearly -- Regrease motor. For the interval and quantity, see section Motors. 2-Yearly 6000 Have oil separator element replaced. When operating in a dusty atmosphere, inspect the air filters more frequently. Use always genuine filters. The separator element must also be replaced when the pressure difference over the element exceeds 0.8 bar (12 psi). Check the pressure drop when the compressor is running loaded and preferably with a stable working pressure. Damaged flexibles must be replaced immediately. Service plan A number of service operations are grouped (called Level A, Level B, Level C...). Each level stands for a number of service actions to be carried out at the time intervals programmed in the electronic regulator. When a level is reached, a message will appear on the screen. After carrying out all service actions, the interval timers must be reset using the Reset key in the Service menu. Consult your Service Centre. 6.2 Motors Warning Stop the compressor and switch off the voltage. The operator must apply all relevant Safety precautions. Never mix greases of different brands or types. Fan motors The bearings of the fan motors are greased for life. The bearings of the fan motor must be replaced after 24000 operating hours. ABB drive motor ABB motors must be greased with Screwguard Slide Amber 120 2920 1804 02
Interval D end Amount D end 110 kw (150 hp) 4 pole 6000 h 70 gr (2.47 oz) 132 kw (175 hp) 2 pole 4000 h 20 gr (0.71 oz) 132 kw (175 hp) 4 pole 4000 h 90 gr (3.17 oz) Interval ND end Amount ND end 6000 h 70 gr (2.47 oz) 2000 h 20 gr (0.71 oz) 4000 h 70 gr (2.47 oz) WEG drive motor WEG motors must be greased with Screwguard Slide Blue Compressor type Interval D end Amount D end 132 kw (175 hp) 460 V 4 pole 6000 h 45 gr (1.59 oz) 132 kw (175 hp) variable speed 2x2 pole 4000 h 27 gr (0.95 oz) Interval ND end Amount ND end 6000 h 35 gr (1.23 oz) 4000 h 27 gr (0.95 oz) 6.3 Oil specifications Rotair Rotair oil is a specially developed lubricant for use in single stage oil-injected screw compressors. Its specific composition keeps the compressor in excellent condition. Rotair oil can be used for compressors operating at ambient temperatures between 1 C (34 F) and 40 C (104 F). If the compressor is regularly operating in ambient temperatures close to 40 C (104 F), the oil lifetime is reduced. In such case it is recommended to use RXD oil. Rotair Plus Rotair Plus oil is a specially developed lubricant for use in single stage oil-injected screw compressors. Its specific composition keeps the compressor in excellent condition. Rotair Plus oil can be used for compressors operating at ambient temperatures between 1 C (34 F) and 40 C (104 F). If the compressor is regularly operating in ambient temperatures close to 40 C (104 F), the oil lifetime is reduced. In such case it is recommended to use RXD oil. Rotair Xtra Rotair Xtra oil is a high-quality synthetic lubricant for oil-injected screw compressors which keeps the compressor in excellent condition. RXD oil can be used for compressors operating at ambient temperatures between 1 C (34 F) and 40 C (104 F) (see section Service kits). Foodgrade Special oil, delivered as an option. 2920 1804 02 121
Foodgrade oil is a unique high quality synthetic lubricant, specially created for oil-injected screw compressors that provide air for the food industry. This lubricant keeps the compressor in excellent condition. Foodgrade oil can be used for compressors operating at ambient temperatures between 0 C (32 F) and 40 C (104 F). Important Never mix oils of different brands or types. 6.4 Oil change Warning The operator must apply all relevant Safety precautions. Control panel Control panel 122 2920 1804 02
Procedure 1. Run the compressor until warm. Stop the compressor, close the air outlet valve and switch off the voltage. Wait a few minutes and depressurize by unscrewing the vent plug on top of the air receiver to permit any pressure in the system to escape. Wait until all the pressure in the system is released. 2. To drain the oil, remove the drain plug (Dp) and open the valve. Draining the oil cooler on air-cooled compressors: 2920 1804 02 123
1. Take off the side panel of the compressor. 2. Remove the drain plug (1) of the oil coolers. 3. Reinstall the plugs after draining. 4. Reinstall the side panel of the compressor. Draining the compressor element, oil filter housing and oil stop valve 1. Remove the drain plug (1) to drain the oil stop valve. 2. Remove the drain plug of the flexible (2) to drain the oil from the gearbox. 3. Reinstall the drain plugs after draining. Oil filter change 124 2920 1804 02
1. Use an oil pan to avoid oil spillage. Unscrew the oil filters (OF). 2. Clean the filter seats on the manifold. 3. Oil the gaskets of the new filters and screw the filters into place until the gaskets contact their seats. Then tighten by hand. Filling the compressor element with oil Disconnect the air inlet hose, pour 3 l (0.79 US gal, 0.66 Imp gal, 0.11 cu.ft) of oil into the compressor element. Reinstall the air inlet hose after filling the element. Filling the air receiver with oil 1. Reinstall and tighten the oil drain plug of the air receiver. 2. Remove filler plug (FC). 3. Fill the air receiver with oil until the maximum level of oil is located at ¾ from the bottom of the indicator. 4. Refit and tighten filler plug (FC) and tighten the vent plug on top of the air receiver. 2920 1804 02 125
5. Run the compressor loaded for a few minutes. 6. Stop the compressor and wait a few minutes. 7. Depressurize the system by unscrewing the vent plug on top of the air receiver. 8. Remove the filler plug and fill the air receiver with oil until the maximum level of oil is located at ¾ from the bottom of the indicator. 9. Tighten filler plug (FC). 10. Tighten the vent plug on top of the air receiver. Resetting the electronic regulator After carrying out all service actions in the relevant Service Plan, reset the service warning as follows: 1. Press the Menu key (3). 2. Press key (1) until Service is followed by an arrow pointing to the right. Activate the menu by pressing key (2). 3. Press key (1) until the related Service Plan is followed by an arrow pointing to the right and activate by pressing key (2). 4. Press the Reset key (3); the timer is reset to 0. 6.5 Storage after installation Procedure Run the compressor, e.g. twice a week, until warm. Load and unload the compressor a few times to operate the components of the unloading/loading system. If the compressor is going to be stored without running from time to time, protective measures must be taken. Consult your Customer Centre. 6.6 Service kits General Service kits comprise all parts needed for servicing components and offer the benefits of genuine parts while keeping the maintenance budget low. All service kits are indicated in the relevant Parts Lists. Rotair Rotair oil can be ordered in the following quantities: 5-litre can: 6215 7140 00 20-litre can: 6215 7141 00 209-litre can: 6215 7142 00 1000-litre can: 6215 7143 00 See the section Oil specifications Rotair Plus Rotair Plus oil can be ordered in the following quantities: 126 2920 1804 02
5-litre can: 6215 7144 00 20-litre can: 6215 7145 00 209-litre can: 6215 7146 00 1000-litre can: 6215 7147 00 See Oil specifications. Rotair Xtra Rotair Xtra oil can be ordered in the following quantities: 5-litre can: 6215 7148 00 20-litre can: 6215 7149 00 209-litre can: 6215 7150 00 See Oil specifications. Foodgrade Foodgrade oil can be ordered in the following quantities: 5-litre can: 1630 0821 00 20-litre can: 1630 0605 00 209-litre can: 1630 0821 01 See Oil specifications. Grease Grease can be ordered with following ordering numbers: Grease type Ordering number Screwguard Slide Amber 2901 0338 13 Screwguard Slide Green 2908 8514 10 Screwguard Slide Blue 2908 8521 10 Screwguard Slide Beige 2908 8523 10 6.7 Disposal of used material Used filters or any other used material (e.g. desiccant, lubricants, cleaning rags, machine parts, etc.) must be disposed of in an environmentally friendly and safe manner, and in line with the local recommendations and environmental legislation. 2920 1804 02 127
7 Adjustments and servicing procedures 7.1 Air filters Warning Stop the compressor, close the air outlet valve, press the emergency stop button and switch off the voltage. The operator must apply all relevant Safety precautions. Position of air filter Procedure Step Action 1 Remove the panel in front of the air filter from the compressor. 2 Remove the filter element. 3 Fit the new filter element. 4 Reinstall the panel. 5 Reset the message and service timer (see section Electronic regulator). 128 2920 1804 02