Professional Documents
Culture Documents
16
BLOWERS
for
AERATIONTANK
022MEK001/123
Handbook for
Operation and Maintenance
of Compressor
KA5S-GK200
STC-GO (7-1-KA1KG)
62008043
8043
8044
8045
PROJECT:
Energy Sector
Nevsehir WWTP
Siemens
Turbomachinery
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 2/54
CONTENTS
Chapter 1 Operation of the compressor
0.
1.
1.1
1.2
1.3
1.3.1
2.
3.
3.1
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.3
3.3.1
3.3.2
3.3.3
3.3.4
3.4
3.5
3.6
3.7
3.8
3.9
3.10
EC Declaration of Conformity
Important
Machinery - Safety Requirements
Technical Specifications
Technical Specifications for Compressor.
Tech. Doc. "Oil Specification"
Tech. Doc. "Oil Specification"
Unit Design
Main Construction
Compressor - Main Parts
Compressor Casings
Impeller/Rotor Shaft
Sealings
Diffuser System
Gearbox - Main Parts
Gear Casings
Shafts - Gearwheels
Bearings
Oil Sealing
Base
Cone Diffuser
Blow-off Valve
Check Valve
Coupling - Drive Motor/Gearbox
Inlet Silencer
Drawing
Inlet Filter
4.
Drive Motor
Reference to Manufacturers instruction
5.
Acoustic Enclosure
6.
6.1
6.2
6.3
7.
7.1
7.2
7.3
7.3.1
7.3.2
Control System
Local Control
PI-Diagram
Compressor Instability
Surge
Recirculation
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
8.
8.1
8.2
8.3
8.4
8.5
8.6
Instrumentation
Thermostat E151
Thermostat E138
Thermostat E104
Thermostat E111
Pressostat E106
Surge Controller SUC-3, Drawing
9.
9.1
9.2
9.3
9.4
9.5
9.6
Start-up
Preparations
Simulated Test Run of Compressor
Test Run of Compressor
Master Control
Start
General
10.
10.1
10.2
10.3
10.4
10.5
10.6
10.7
10.8
Trouble Shooting
No Flow, no Pressure at Start
Insufficient Flow
Too Great Power Consumption
Surge / Recirculation
Noisy Operation / Vibration Level High
Bearing Temperature too high
Oil Pressure too Low
Oil Temperature too high
Page 3/54
933 0061480
Maintenance
Introduction
Service intervals
Service
Simulated Test Run
Test Run of Compressor
Master Control Panel
Inlet Silencer
Disposal of waste
Orders for spare parts
12.
12.1
12.2
12.3
12.4
12.5
12.6
12.7
12.8.1
12.8.2
12.8.3
12.8.4
12.8.5
12.8.6
9330502950
9330523220
9330554160
9330554180
GK200S017
9330503140
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 4/54
Chapter 8 Accessories
Coupling
Blow off Valve
Actuator for Blow off Valve
Check Valve
Actuators for Diffuser
Lube Oil Filter
Lube Oil Cooler
Air Filter Bags
Thermostats
Pressostat
Thermometer
Manometer
Surge Detector
Compensator
Cone Diffuser
Silencer for Blow of valve
Noise hood Fan
no.14541
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 5/54
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 6/54
Safety of Machinery:
Installation:
Direction of Rotation:
Coupling:
Re-tightening:
Oil Check:
Electric motors
In case of defects, damage, or faulty delivery, the supplier shall be notified immediately.
HANDBOOK FOR
OPERATION AND MAINTENANCE
0.
COMPRESSOR KA5S-GK200
Page 7/54
PUTTING INTO
SERVICE
LIFT
EMERGENCY
STOP
AUTOMATIC
START/STOP
MECHANICAL
HAZARD
Fixed guards acc. to EN294 & EN953 shall protect all rotating parts.
The guards are not to be removed unless the machine is safeguarded against unintentional start. Loose clothing is to be avoided
and it is advisable to keep a safe distance as long as the machine is
in the remote control mode.
Do not mount the compressor; the surface may be greasy and slippery.
INLET SYSTEM
The inlet system shall be correctly mounted before start of the compressor. Avoid blocking the inlet and staying near connected inlet
channels when the machine is ready to start.
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 8/54
HOT SURFACES
A sign warning of hot surfaces has been placed directly on the machine. It is indicated by symbol EN1012-annex 3. Avoid touching the
hottest surfaces, which are normally more than 70C.
NOISE HAZARD
ELECTRICAL
HAZARD
SPECIAL TOOLS
MAINTENANCE &
REPAIRS
Repairs and maintenance work is only to be performed when all energy sources to the machine have been properly isolated/insulated.
The emergency stop shall be activated, the motor disconnected and
the terminals short-circuited. The danger of back flow from the pipe
system is safeguarded against by either closing and locking a valve
positioned immediately after the check valve or by placing a blind
flange upstream by the check valve.
Sign: "Warning: Maintenance work in progress".
NOTIFY!
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
1.
1.1
SHIPPING
Page 9/54
On receipt of the compressor unit, check that the individual parts correspond with those
listed on the delivery note.
When unloading, check immediately for possible damage of the compressor unit that may
have happened during shipment, such as damaged dents, scratches, corrosion, torn electric
cables, bent pipes, or the like. In case of defects or damage, the carrier and supplier shall
be informed immediately.
The aggregate shall only be lifted with straps fastened to the 4 lifting hooks mounted on the
base. In order to avoid squeezing of instruments, piping, etc., use a lifting yoke.
Weight of compressor aggregate: See section 2.
Use of straps: See fig. below.
1.2
STORAGE
Prior to leaving SIEMENS, the compressor aggregate has been submitted to a test run.
After the test the lubricating oil has been drained off, preservative oil applied and pumped
through the lubricating oil system, and all excess preservative oil drained off. All untreated
parts of the aggregate, which are likely to corrode, have been treated with a corrosionpreventing agent.
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 10/54
This ensures that the compressor aggregate is protected against corrosion for a minimum of
6 months, provided that it is stored indoors. It is not necessary to remove the corrosionpreventing agent before starting up the aggregate, as the preventive agent does not affect
the lubricating oil.
If the compressor is stored for more than 6 months, it shall be treated with a long-term
preventive agent. A corrosion-preventing agent used for long-term storage will have to be
removed before start-up. This is done by disassembling and cleaning all the compressor
parts. In this case only SIEMENS service engineers shall prepare the compressors for
operation. The preparation shall be carried out in a dry and clean environment.
Do not use the compressor unit or parts of it as scaffolding. For further information, require
technical information 930920009UK.
1.3
INSTALLATION
It is possible to mount / install the compressor prior to removing a long-term corrosion
protection. The compressor can be mounted on any level floor that can carry the weight. A
special vibration damping concrete foundation is only used in exceptional cases.
Important! Before the compressor aggregate is fastened to the floor, check its position to
make sure that flanges (and possibly other pipe connections) are placed correctly with a
view to the final pipe installation. Do not uncover the flanges until the pipe system is ready
for installation. This prevents foreign substance from entering the compressor. All pipe
systems shall be cleaned and inspected before they are connected to the aggregate.
If the drive motor shaft has been securely fastened for shipping, this fastening shall be
removed and the dismounted coupling remounted.
1.3.1
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 11/54
FAX
FLAT
M
TYPE
KA2
KA5
KA10
KA22
KA44
KA66
KA80
KA100
=
=
=
FAX
N
1100
2700
4000
5500
7600
10000
13500
17500
FLAT
N
330
800
1200
1600
2200
3000
4000
5000
M
NM
65
225
350
600
900
1500
2000
3500
The pipe system must be supported thus minimizing the external loads.
The allowable loads, alignment tolerances etc. of the flexible joint positioned at the discharge flange,
must be carefully considered, when designing the pipe system.
The external loads on the compressor are transmitted through the base to the machinery supports and
must be included when sizing the supports.
For further information, see the standards NEMA SM23-1985, section 9.4 and API 672, section 2.2.3
and 2.3.4.
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
INSTALLATION 930840008UK
Page 12/54
HANDBOOK FOR
OPERATION AND MAINTENANCE
2.
COMPRESSOR KA5S-GK200
Page 13/54
TECHNICAL SPECIFICATIONS
UNIT
Serial No.
Year
Weight, approx.
Dimension Drawing
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
Siemens
KA5S
Air
3943 m/h
8762 m/h
0.898 bar abs.
1.590 bar abs.
10,4C
25,2C
18952 rpm
92.7 kW
184.2 kW
The power is indicated at min./max. inlet flow, inlet pressure normal and inlet temperature normal
:
:
:
:
Siemens
GK200
172 / 27
14 litres / min
:
:
:
:
:
:
:
:
:
Schorch
KN7 315M-AB01B-Z
860 kg
F/B
IP 23
200 kW
50 Hz
400 V
2975 rpm
: Rexnord Thomas
: SR52-MSH-225
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 14/54
:
:
:
:
:
:
:
:
Framo Antriebtechnik
Unipush - Mini 0
1000 N
100 mm
2.7 mm/s
IP 54
50 Hz
1 x 230 V
:
:
SIEMENS
Integrated in gearbox
:
:
FBO
FRCA 60/1
:
:
Oil Tech
LAC2-011-2-D
:
:
:
:
:
:
:
:
Oil Tech
3000
F
IP 54
50
3 x400
1.1
FAN MOTOR
Type
Make
Revolutions
Insulation class
Degree of protection
Main frequency
Voltage
Power
:
:
:
:
Camfil
Pocket filter
G4
+ 20 mm WC
rpm
Hz
V
kW
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 15/54
LUBRICATING-OIL PRESSURE
Min.
Normal operating pressure, approx.
:
:
0,8
1,0 1,2
bar
bar*
LUBRICATING-OIL TEMPERATURE
Max.
Normal operating temperature
:
:
80C
55 - 75C
LUBRICATING OIL
Normal filling, see enclosure:
OIL SPECIFICATION, SIEMENS Tech. Info. 930.870.003 (2 pages)
Lubricating oil types, see enclosure:
OIL SPECIFICATION, SIEMENS Tech. Info. 930.870.005 (1 page)
- both inserted after "TECHNICAL SPECIFICATIONS".
OIL RESERVOIR IN GEAR - Pos. No. G100
Normal filling
35 litres
:
:
:
:
:
:
:
:
EMB Papst
W4D500-DD03-02
9,000 m3/h
IP 54
50 Hz
400 V
0.83 kW
1360 rpm
:
:
:
:
:
:
Danfoss A/S
RT103
In air at compressor panel
Start / Stop of Ventilator fan
30
C
Minimum
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 16/54
:
:
:
:
Set point
Difference
:
:
Danfoss
RT 107
In oil reservoir
Stops compressor at high oil
temperature
80C
Minimum
:
:
:
:
Set point
Difference
:
:
Danfoss
RT 101
In oil reservoir
Stops compressor at recirculation
(high inlet air temperature)
65C
Minimum
:
:
:
:
:
:
Danfoss
RT 110
In the gearbox oil lubrication system
Stops compressor at low oil pressure
0.8 bar
Minimum
:
:
:
:
:
:
Danfoss
RT 101
In oil reservoir
Start/stop of oil cooler fan
50C
Minimum
:
:
:
:
Siemens
SUC-3
In compressor's inlet
Stops compressor at surging
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 17/54
:
:
:
Wouter Witzel
Euronomic / DN100
Pressure relief during
:
:
:
:
:
:
:
:
Bernard
OA6
F
IP 67
50 Hz
400 V
0.03 kW
6 sec
:
:
:
Cast Flow
GNECVB
DN350
:
:
STE
DN100
:
:
:
STE/Bredan
Steel
DN150
:
:
:
STE
Cone diffuser
DN150/350 1100mm
start/stop
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 18/54
VISCOSITY
INDEX MIN.
ISO 2909
VISCOSITY
MIN. at 120C
FZG STAGE
MIN.
DIN 51354
4.20
4.20
4.20
4.20
10
10
10
10
COMPRESSOR
KA2-GK2
KA2-GK190
KA4-GK4
KA5-GK200
1986
2003
1982
1996
PAO 1
PAO
PAO
PAO
930870005
930870005
930870005
930870005
137
137
137
137
KA2-GL180
KA2-GB255
KA5-GA200
KA5-GA250
KA5-GL210
KA5-GL285
KA5-GB400
KA5-GC150
1999
1996
1987
1993
1992
1998
1997
1988
HL/HLP46
HL/HLP46
HL/HLP46
HL/HLP46
HL/HLP46
HL/HLP46
HL/HLP46
HL/HLP46
930870004
930870004
930870004
930870004
930870004
930870004
930870004
930870004
100
100
100
100
100
100
100
100
10
10
10
10
10
10
10
10
KA10-GA200
KA10-GL210
KA10-GA250
KA10-GC150
1986
1992
1987
1979
HL/HLP46
HL/HLP46
HL/HLP46
HL/HLP46
930870004
930870004
930870004
930870004
100
100
100
100
10
10
10
10
KA22-GA250
KA22-GL225
KA22-GL315
KA22-GC150
KA22-GC215
1983
1993
1989
1981
1981
HL/HLP46
HL/HLP46
HL/HLP46
HL/HLP46
HL/HLP46
930870004
930870004
930870004
930870004
930870004
100
100
100
100
100
10
10
10
10
10
KA44-GA250
KA44-GL225
KA44-GL315
KA44-GL400
KA44-GC215
1983
1993
1992
1995
1982
HL/HLP46
HL/HLP46
HL/HLP46
HL/HLP46
HL/HLP46
930870004
930870004
930870004
930870004
930870004
100
100
100
100
100
10
10
10
10
10
KA66-GL400
KA66-GC215
1992
1982
HL/HLP46
HL/HLP46
930870004
930870004
100
100
10
10
KA80-GL500
1990
HL/HLP46
930870004
100
10
KA100-GL500
1984
HL/HLP68
930870004
100
10
OIL TYPE
DIN 51502
SIEMENS
REFERENCIES
YEAR OF
CONSTRUCTION
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 19/54
COMPRESSOR
KA2-GK2
KA2-GK190
KA4-GK4
KA5-GK200
KA2-GL180
KA2-GB255
KA5-GA200
KA5-GA250
KA5-GL210
KA5-GL285
KA5-GB400
KA5-GC150-EM
KA5-GC150-GM
KA10-GA200
KA10-GL210
KA10-GA250
KA10-GC150-EM
KA10-GC150-GM
KA22-GA250
KA22-GL225
KA22-GL315
KA22-GC150-EM
KA22-GC150-GM
KA22-GC215-EM
KA22-GC215-GM
KA44-GA250
KA44-GL225
KA44-GL315
KA44-GL400
KA44-GC215-EM
KA44-GC215-GM
KA66-GL400
KA66-GC215-EM
KA66-GC215-GM
KA80-GL500
KA100-GL500
YEAR OF
CONSTRUCTION
1986
2003
1982
1996
1999
1996
1987
1993
1992
1998
1997
1988
1988
1986
1992
1987
1979
1979
1983
1993
1989
1981
1981
1981
1981
1983
1993
1992
1995
1982
1982
1992
1982
1982
1990
1990
OIL RESERVOIR
LITER +/- 10%
6
13
19
35
230
230
230
300
230
300
570
230
150
230
230
300
230
150
330
330
570
230
150
500
330
330
330
570
480
500
330
680
500
330
1000
1000
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 20/54
Turbochargers
Journal bearing gearboxes
Note:
Supplier
Company
Oil type
BP
BP ENERGOL RC-S 46
TOTAL
DACNIS SH 46
ESSO
Esso
Esso
Exxon
MOBIL
Mobil
Mobil
Mobil
Q8
Q8 SCHUMANN 32
Kuwait Petroleum
Kuwait Petroleum
-----------------------
STATOIL
COMPWAY SX 32
Statoil
---------------------
SHELL
MADRELA AS 46
Shell
Shell
Shell
TRIBOL
TRIBOL 1550/32
KLBER
Klber
Klber
Klber Lubrication
FUCHS
Fuchs
Fuchs
Fuchs
BP
BP
BP
Total Fina Elf
Total Fina Elf
Total Fina Elf
Scandinavia
Europe
North America
HANDBOOK FOR
OPERATION AND MAINTENANCE
3.
UNIT DESIGN
3.1
MAIN CONSTRUCTION
COMPRESSOR KA5S-GK200
Page 21/54
G100
K100
A300
A401
F101
D200
S129
Cone diffuser
Compensator
Blow off Valve
Check Valve
Oil cooler
Oil Filter
Local panel
P101
P102
P106
P110
S301
S303
E123
HANDBOOK FOR
OPERATION AND MAINTENANCE
3.2
COMPRESSOR KA5S-GK200
Page 22/54
COMPRESSOR
Main parts:
Inlet
Outer vol. casing
Inner vol. casing
H701
H401
H501
Inner diffuser
Pinion shaft
Impeller
D100
R201
R414
HANDBOOK FOR
OPERATION AND MAINTENANCE
3.2.1
COMPRESSOR KA5S-GK200
Page 23/54
COMPRESSOR CASINGS
The compressor casings, consisting of outer/inner volute casing and inlet are manufactured
from cast items that have been heat-treated, cleaned, and then machined. The casings
have been assembled vertically, in order to facilitate handling of the individual casings when
mounting or dismounting the compressor.
3.2.2
IMPELLER/ROTOR SHAFT
The rotor consists of the following main parts:
Impeller
Pinion shaft
Dowel
Stop ring
Special screw
Stop nut
Positioning dowel
R414
R201
R411
R409
R410
R412
R415
Rotor nut
Central screw
Rotor drive
R407
R405
R401
The impeller has been milled out in one forged, solid piece, ensuring great strength and
accuracy. The blades have been formed so as to ensure optimal control of the compressor
as well as an optimal and stable current flow. The outer contour and diameter of the
impeller have been specially adapted to the operating conditions defined in the order
specification.
The overhung design with the impeller positioned at the end of the pinion shaft secures an
operation well above first critical speed and well below second critical speed.
The impeller rotor can be removed from the unit by disassembling the impeller from the
pinion shaft. Note that the impeller is positioned on the outlet shaft by means of a screw.
Dismounting of the rotor: See section 12.
By means of hydraulic tools the impeller, the rotor shaft rod, and the rotor drive are held
together with the rotor and the central screw. The complete unit (rotor) has been balanced
dynamically.
Created on 16-02-2009 at 16:00:35, LF
01-Operation_KA5S-GK200.doc
HANDBOOK FOR
OPERATION AND MAINTENANCE
3.2.3
COMPRESSOR KA5S-GK200
Page 24/54
SEALINGS
Consisting of:
- Labyrinth sealing
- Oil sealing ring
H303
T220
Air and oil shaft seals, made of aluminium, are non-contact types and designed to prevent
air and oil leakage, thus avoiding contaminating the air with oil. This type of sealing does
not get worn due to the clearance between the pointed sealings and the shaft. However, a
minor running-in wear may occur. The sealing prevents oil from entering into the
compressor. The chambers of the sealing ring are fitted with drains, through which the oil is
led back into the gear housing.
3.2.4
DIFFUSER SYSTEM
The compressor is equipped with one regulating system, a diffuser system. It can be
regulated continuously within the range of two limit switches. Even a small change of the
system setting will influence the ability of the compressor to make pressure and volume
flow, and consequently the power consumption of the compressor will be affected.
SIEMENS has developed a procedure, implemented in a process computer, to regulate the
diffuser system to an optimum, based on measurements of:
- inlet temperature
- differential pressure across compressor
- volume flow demand
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 25/54
Any change of the system setting will cause increased power consumption or, at worst, that
the compressor starts to surge, which will release an emergency stop. If the system has
been disassembled, it must be assembled and adjusted exactly as it was before the disassembling.
D108
D116
D205
D208
Limit switches
Scale
Linear motor *)
D210
D213
D224
The diffuser system consists of a number of adjustable vanes (optimized vanes) placed
radially around the periphery of the impeller. An electric linear motor regulates the diffuser
blades. A scale is mounted on the mounting plate for indication of the position of the blades.
Two limit switches have been installed, which - when activated - will signal the respective
MAX. and MIN. positions of the diffuser blades to the control panel.
The linear motor is controlled by the local control panel.
*)
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 26/54
The position of the limit switches shall not be altered, as this may cause overload of the
compressor/drive motor. A signal value for the exact position of the vanes can be obtained
by way of the built-in potentiometer in the linear motor.
3.3
GEARBOX
Main parts:
Gear casing part A
Gear casing part B
Drive shaft
Pinion shaft
Sealing ring
H101
H102
R100
R200
T101
T103
T106
T208
T210
S129
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 27/54
The SIEMENS GK200 gearbox is a single-stage, helical gear, where the pinion shaft is
placed above the drive shaft. The pinion shaft is supported by bearings on both sides of the
gearwheel. The gear ratio has been adapted to the operating conditions as specified in the
order.
The gearbox is vertically split for easy access to the shafts, bearings, and sealings.
3.3.1
GEAR CASING
The gear casing, consisting of part A and B, is manufactured from cast elements which
have been heat-treated, cleaned, and then machined.
3.3.2
SHAFTS - GEARWHEELS
Shafts and gearwheels have been carburized and ground with great accuracy, to allow for
the high speed and resulting stress on the teeth. A moderate backlash allows for oil film,
deformations, etc.
The gearwheel on the drive shaft has been shrunk on. The gearwheel on the pinion shaft
has been machined in one piece with the shaft.
3.3.3
BEARINGS
The pinion shaft is supported by angular contact ball bearings. Double bearings are used in
the compressor end, while single bearings are used in the motor end. The bearings are
pressure lubricated and cooled by an oil flow on the exterior bearing housing. The inlet shaft
is supported by deep groove ball bearings.
3.3.4
OIL SEALING
The sealing is a non-contact, labyrinth type sealing, which does not get worn due to the
clearance between the pointed sealings and the shaft. However, a minor running-in wear
may occur.
This sealing ensures that oil is not leaking from the gear.
Drains in the sealing chambers lead oil back into the gear casing.
3.4
BASE
The base is a welded box-like construction manufactured with frame of steel profiles and
steel plate. It serves additionally as base for all safety equipment and the local panel.
3.5
CONE DIFFUSER
The cone diffuser is manufactured from steel plate milled into shape and welded together.
The two flanges are likewise welded on.
The cone diffuser is mounted on the discharge side, thereby transforming the last part of
the air velocity into pressure, thus reducing the air velocity.
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3.6
COMPRESSOR KA5S-GK200
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BLOW-OFF VALVE
The blow-off valve is a butterfly valve with electric or pneumatic actuator and end stops.
The blow-off valve is mounted between two flanges. The blow-off valve functions as a
pressure relief valve during start/stop to avoid surging. (For tech. data, see 2).
3.7
CHECK VALVE
The check valve is a spring-loaded butterfly valve (dual plate) built in between two flanges.
The check valve prevents the compressed air from passing backwards, thereby keeping the
compressor from running backwards when not in operation. (For technical data, see 2).
3.8
COUPLING/DRIVE MOTOR/GEARBOX
The coupling between drive motor and gear is a flexible disc type coupling which is flexible
in both radial and axial direction and at the same time able to withstand excessive torsional
stress. To ensure optimal operating conditions the coupling shall be aligned as described in
12.
HANDBOOK FOR
OPERATION AND MAINTENANCE
3.9
COMPRESSOR KA5S-GK200
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INLET SYSTEM
See enclosed drawing no. 9330057240.0, Inlet Silencer.
The inlet system consists of inlet silencer, filter, front grid or extension piece fastened
together into a unit. The inlet silencer is fitted with height adjustable feet, approx. 20mm
from nominal centre height.
Mounting
The height of the inlet silencer stud is adjusted in relation to the compressor stud, and the
inlet silencer is positioned so that the air conduit between the studs is 3 - 7 mm. If the air
conduit between the studs is 10 mm or more, the compressor may be damaged.
The holes in the base plate are then marked out on the floor, the silencer is removed, and
the holes are bored, after which the nylon dowels supplied are placed in the holes, and the
silencer put back and fastened with the supplied screws.
The air conduit between the studs of the inlet silencer and the compressor is checked and
taped with the special tape supplied, after which it is covered with lead rubber and tightened
together with the flexible connection supplied.
The U-pipe manometer, which registers pressure drops, is filled up with liquid from the flask
supplied.
Maintenance
Pressure drops must not exceed 100 mmWC, because a too high negative pressure may
cause the intake silencer plates to collapse. The filters are replaced when the pressure drop
during start is observed to have increased by 20 mmWC.
Suction from the compressor room: Dismount the front grid and the filter locks and take out
the filters. Vacuum clean the inside with a soft brush
mouthpiece. Insert new filters.
Suction from the air duct:
3.10
INLET FILTER
See Manufacturer's material.
Dismount the side covers of the filter box and the filter
locks and remove the filters through the side. Vacuum
clean the inside with a soft brush mouthpiece. Insert
new filters.
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COMPRESSOR KA5S-GK200
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HANDBOOK FOR
OPERATION AND MAINTENANCE
4.
COMPRESSOR KA5S-GK200
Page 31/54
DRIVE MOTOR
See enclosed technical document Electric Motors Compressors KA2 - KA100 General
Requirements.
For motor specifications etc. see manufacturers instructions.
HANDBOOK FOR
OPERATION AND MAINTENANCE
930910056UK
1.
Page 32/54
ELECTRIC MOTORS
COMPRESSORS KA2 KA100
GENERAL REQUIREMENTS
Revision: 15
Prepared by:
Latest revision:
COMPRESSOR KA5S-GK200
MC
FP
Date:
Date:
91.12.09
07.02.07
The motors shall be manufactured according to standard IEC 60034-14, vibration grade A. This
also applies to fully loaded motors.
Unless otherwise specified, the motors shall be balanced according to the "HALF KEY CONVENTION" ISO 8821, and the shaft end shall be marked with an "H" according to section 4.2. of
this standard.
2.
Starting: The compressor torque-speed curve follows a square law. The max. torque during start
is 67% of the motor nominal torque. Note that there could be specific demands on the acceleration at certain rpm intervals. Such demands will be noted on the compressor speed-torque curve.
Low-voltage motors: The motor should be capable of star/delta start within 12 seconds.
High-voltage motors: The motor should be capable of starting the compressor at 80% of the normal voltage.
3.
The motors shall be equipped with a "low noise" design fan. Maximum free field sound pressure,
according to ISO 3744, is 87 dB(A) at 1 m distance.
4.
Direction of rotation, when viewing the motor from the drive shaft end, see figure 1.:
Gearbox GK2, GL180, GK190
Gearbox GK200
Gearbox GA
Gearbox GB255
Gearbox GB400
Gearbox GC
Gearboxes GL210, GL225,
GL285, GL315 and GL400
Gearbox GL500
(single stage)
(single stage)
(single stage)
(two stage)
(two stage)
(two stages)
: CCW
: CW
: CW
: CW
: CCW
: CCW
(single stage)
(single stage)
: CW
: CCW
Figure 1.
The motor windings shall be protected by 1*PTC thermistor or 1*PT100 sensor in each end winding. Thermistors are preferred. All sensors shall be galvanically separated.
6.
The motors shall be shipped to Siemens Turbomachinery Equipment A/S (STE) works in
Helsingr, Denmark, according to the signed "Statement of Availability" document 930940025UK.
HANDBOOK FOR
OPERATION AND MAINTENANCE
7.
8.
COMPRESSOR KA5S-GK200
Page 33/54
A certified dimension sketch, including shape and dimensions of the motor fan cover, location
of the coolant inlet, shape and exact position of the feet, weight and centre of gravity. The
drawing must be available both in paper version and as scaleable AutoCad data in dwg format (Version: AutoCad Mechanical 2004 or previous versions). Alternatively, the data can be
supplied in dxf data format (Version: AutoCad 2000/AutoCad Light 2000 or previous versions). In case of doubt, please contact STE.
b.
Technical data including full-load torque, full-load speed, full-load current, speed-torque
curve, speed-current curve, load-power-factor curve, load efficiency curve (shaft power/ terminal power ratio), inertia of rotor and drive shaft torsional stiffness to be specified and/or
filled in acc. to "Standard Specification for 3-Phase Squirrel Cages" 930920063UK and "Efficiency of Electric Motors" 930920064UK.
c.
d.
Noise emission at full load specified as sound power emission Lw, A-weighted value and/or
octave bands (dB, reference 2*10-12 W).
When equipped with sleeve bearings, the rotor shall be locked in place during transport.
If the rotor is to be axially positioned by means of external thrust bearings, the maximum axial
load of the motor and the predicted thermal expansion shall be specified.
Lubricating oil system requirements, including oil/grease type, shall be specified.
Grease nipples shall be according to DIN 71412.
Minimum grease lubrication interval: 1500 hours.
9.
In cases where the compressor applications include an acoustic enclosure covering the whole
compressor unit, the motor fan shall provide the necessary amount of cooling air when working
against an external pressure of 60-80 Pa.
The fan capacity, at maximum pressure drop, shall be specified. The fan cover dimension (shape)
shall be specified.
10.
The motors shall be protected for normal shipment and storage indoors, not heated, up to 6
months.
Special requirements during shipment and storage shall be specified or the STE instruction "Conservation, Transportation, Storage, Start-up" 930920009UK approved of.
11.
If used under tropical conditions the motors shall be equipped with electrical heaters and drains.
12.
Manuals including instructions for installation and operation shall be provided in English, German,
French or Spanish, whatever is specified.
13.
Electric motors to be mounted on compressor units for the EU and EFTA markets shall comply
with European Directives and Harmonized Standards in force at the specified time of delivery.
The documentation shall include a Declaration of Conformity (EN45014).
14.
The information specified herein must be at our disposal not later than 3 weeks from receipt of
order.
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OPERATION AND MAINTENANCE
5.
COMPRESSOR KA5S-GK200
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ACOUSTIC ENCLOSURE
On request SIEMENS supplies an enclosure, which through careful choice of design,
assembly methods and sealing strips, will provide optimal noise reduction. The enclosure is
equipped with sound muffling material adapted to the prevailing conditions.
The SIEMENS acoustic enclosure is built up as a modular system on a chassis frame in
which panels and doors can be inserted. This simple construction means fast mounting and
dismounting of the complete enclosure or parts of it.
The enclosure is delivered as a construction kit, which requires only a minimum of space
during storage and transport.
"Do it yourself" mounting instruction - technical info 930940099 - is included in the delivery.
However, SIEMENS will be pleased to mount the enclosure on request.
CONSTRUCTION
Frame construction made of OMEGA profiles (channel section with webs) mounted
on bottom rails bolted to the floor. Sound absorbing elements are placed in the
frames.
Dimensions: Modular system for individual adaptation.
NOISE REDUCTION
The sound absorbing elements are made of alu-zinc coated steel plate on the outside, and of alu-zinc coated perforated steel plate on the inside. The interspace is
filled up with mineral wool.
The ceiling elements are placed in webs in the cross braces. The wall elements are
placed in top and bottom rails.
The enclosure is fitted with detachable wall panels for inspection and service.
VENTILATION
The silencer hood is ventilated by means of a fan mounted inside the hood in one of
the ceiling elements. Intake and discharge of ventilating air is done via noise reducing ducts. The outlet can be connected to a pipe channel leading the hot air out of
the compressor room.
31,5
63
125
250
500
1000
2000
4000
8000
10
14
19
21
40
18
Note:
From compressor, valves etc., sound is emitted into the pipe system. Therefore, the
nearest parts of the pipe system outside the enclosure shall be insulated in order to obtain optimal noise reduction.
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COMPRESSOR KA5S-GK200
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HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
7.
7.1
Page 36/54
The control and monitoring systems shall ensure correct operating conditions at start and
stop of the compressor as well as during operation.
The control system runs the start and stop functions, the compressor operation, the lubricating oil system, and the activation of the blow-off valve, the diffuser and/or the pre- rotation.
The monitoring system consists of minimum 5 current circuits connected to pressostats,
thermostats, and sensors. The current circuits are part of a safety chain which stops the
compressor immediately on indication of error.
Important: The design of the local control panel and all its electric functions are described
in the separate Operation Manual for the Local Control Panel.
7.1.1
If the unit is equipped with SIEMENS electric control system LC-, Local Control panel, the
panel controls the daily operation and monitoring.
The following conditions of start and operation will be observed by the logic system of the
local control panel:
1.
When the START button is activated the automatics will open the blow-off valve and set
the diffuser in MIN position. At the same time the instruments of the safety chain are
checked, and if they are in order the drive motor of the compressor will start.
2.
When the compressor has been started the blow-off valve will close.
3.
During operation the diffuser will be adjusted continuously corresponding to the operational conditions.
4.
In case of errors, as too high oil temperature, too low oil level, too high counter pressure
in the outlet pipe etc., the compressor is stopped.
5.
When the error has been located and corrected the monitoring system has to be reset.
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COMPRESSOR KA5S-GK200
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STOP
The stop function ensures that the compressor stops under controlled conditions:
NORMAL STOP
1. Diffuser moves to MIN position.
2. As soon as the diffuser is in MIN position, the blow-off valve opens quickly.
3. When the blow-off valve is open, the compressor motor stops (however, max. 100 seconds after "Normal Stop" has been activated).
ALARM STOP (NOT OIL PRESSURE)
1. Blow-off valve opens quickly (max. 8 seconds after "Alarm Stop" has been activated).
2. Compressor stops.
3. Diffuser and prerotation move to MIN position.
EMERGENCY STOP (ONLY EMERGENCY AND OIL PRESSURE)
The compressor stops at once, while the blow-off valve, the diffuser and/or the prerotation
open simultaneously and move to MIN position.
For KA2-GK2, KA4-GK4 and KA5-GK200 please note:
After each stop the compressor cannot be restarted for 1 minute.
7.1.2
7.1.3
7.1.4
If an error occurs in one of the current circuits, the Safety Chain ensures that the compressor is stopped at once.
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COMPRESSOR KA5S-GK200
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IMPORTANT! Operation without monitoring (Safety Chain) must not take place!
7.1.5
SUPPLY OF AUTO-CONTROL
If the control automation is supplied by SIEMENS, please see the electrical documentation
LC/MCP for further information.
If the control automation is not Siemenss make, the minimum design criteria shall be in accordance with Siemenss technical specifications:
Control automation for SIEMENS compressors
Type KA2-GK2, KA4-GK4 and KA5-GK200
Minimum Design Criteria No. 930920011UK
Control automation for SIEMENS compressors
Type KA5-KA100
Minimum Design Criteria No. 930920010UK
7.2
P/I DIAGRAM
See enclosed P/I diagram.
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COMPRESSOR KA5S-GK200
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HANDBOOK FOR
OPERATION AND MAINTENANCE
7.3
COMPRESSOR KA5S-GK200
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7.3.1
SURGE
Pressure air expands jerkily through the operating compressor. Usually stalling is caused by
operating at too high differential pressure. Stalling may also arise if the inlet temperature is
much higher than the maximum design temperature. At increasing inlet temperature the
max. achievable discharge pressure of the compressor will drop.
Stalling reveals itself through audible pressure blows the frequency and strength of which
are determined by among others the resonant conditions of the connected piping system on
the pressure side. Strong pressure blows mean heavy load on the mechanical parts of the
compressor, and therefore the compressor must be stopped. (see the manual for the local
control panel).
Operating under these conditions will expose the mechanical parts of the compressor to
heavy loads and should, therefore, be avoided.
If the compressor is operating within the unstable range, the SUC-switch (SU = Surge, C =
Control) will activate the alarm and stop the compressor immediately.
The following malfunction may cause surge:
1. Too high header pressure
2. Too high inlet temperature
3. Decrease in compressor RPM as well as mechanical errors, etc.
7.3.2
RECIRCULATION
The medium recirculates through the compressor, whereby a large amount of energy is added to a small amount of medium (the medium heats up).
The following malfunctions may cause recirculation when:
1. The diffusor/prerotation is closed completely (MIN.-setting of the limit switches has been
moved)
2. The discharge from the blow-off valve is led back to the inlet duct, causing the medium
to recirculate for a long time
Operating with recirculation must be avoided, as it may cause damage through overheating,
and - at worst - fire in the compressor.
If the compressor is operating for a long time with recirculation, a thermostat with sensor in
the compressor inlet will activate the alarm signal and stop the compressor immediately.
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COMPRESSOR KA5S-GK200
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8.
INSTRUMENTATION
8.1
THERMOSTAT RT103 Acoustic Enclosure Temperature above 30C Pos. no. E 151
: -40 - +70C
: 100C
Function
Setting
: Dismount the front cover of the thermostat and set the differential adjusting nut 19 on MIN.
Set scale 9 on 30C using knob 5.
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OPERATION AND MAINTENANCE
8.2
COMPRESSOR KA5S-GK200
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Testing :
:
:
-50 - +70C
300C
Function
: Start and stop the ventilation motor of the oil cooler at rising oil
temperature, exceeding 60C.
Setting
If the ventilator is running, the thermostat is set on a value higher than the indication of the oil thermometer: The ventilator must stop.
If the ventilator is not running, a value lower than the indication of the oil thermometer is chosen: The ventilator must start.
The thermostat is closed but not sealed, as adjustments will have to be made occasionally,
according to changes in the surrounding temperature.
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8.3
COMPRESSOR KA5S-GK200
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Testing :
:
:
-50 - +70C
300C
Function
Setting
Using knob 5 the thermostat is set at dropping temperature until the switch
opens. If the compressor is operating, it must be stopped. If the compressor is
not operating, it must not be possible to start it. Adjust scale 9 until indicator
setting of the thermostat corresponds with the oil thermometer of the gear.
Adjust thermostat with knob 5 to 80C on scale 9.
Remount the front cover.
The thermostat is part of the electric safeguard, and it is sealed with lead after adjustment.
Important: During the period of guarantee set for the compressor, sealed thermostats and
pressure controllers must only be adjusted by SIEMENS personnel.
The guarantee no longer applies if the seal is broken.
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OPERATION AND MAINTENANCE
8.4
COMPRESSOR KA5S-GK200
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:
:
-50 - +70C
300C
Function
Setting
Testing :
Set the scale on 65C. the sensor is taken out of the inlet and heated in water
to above 65C. If the compressor is operating, it must be stopped. If the compressor is not operating, it must not be possible to start it.
Remount the front cover.
The thermostat is part of the electric safeguard, and it is sealed with lead after adjustment.
Important: During the period of guarantee set for the compressor, sealed thermostats and
pressure controllers must only be adjusted by SIEMENS personnel.
The guarantee no longer applies if the seal is broken.
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OPERATION AND MAINTENANCE
8.5
COMPRESSOR KA5S-GK200
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Pressure Controller RT110 Oil Pressure too low - Pos. No. E106
: 70C
: 100C
: 25 bar
Function
: To start the electric oil pump if the oil pressure drops below
0,8 bar o.
Setting
Testing : Set the pressure controller to scale value below the oil pressure shown on the lubricating oil manometer. If the compressor is operating, it must be stopped. If the compressor is not operating, it must not be possible to start it. After testing, the scale is reset to 0,8
bar o.
Remount the front cover.
The pressure controller is part of the electric safeguard, and it is sealed with lead after adjustment.
Important: During the period of guarantee set for the compressor, sealed thermostats and
pressure controllers must only be adjusted by STE personnel.
The guarantee no longer applies if the seal is broken.
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OPERATION AND MAINTENANCE
8.6
COMPRESSOR KA5S-GK200
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Pressure Controller RT200 Oil Pressure too low - Pos. No. E107
: 70C
: 100C
: 25 bar
Function
: To stop the drive motor of the compressor if the oil pressure drops below 1 bar o.
Setting
Testing : Set the pressure controller to scale value below the oil pressure shown on the lubricating oil manometer. If the compressor is operating, it must be stopped. If the compressor is not operating, it must not be possible to start it. After testing, the scale is reset to 1
bar o.
Remount the front cover.
The pressure controller is part of the electric safeguard, and it is sealed with lead after adjustment.
Important: During the period of guarantee set for the compressor, sealed thermostats and
pressure controllers must only be adjusted by SIEMENS personnel.
The guarantee no longer applies if the seal is broken.
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OPERATION AND MAINTENANCE
8.7
COMPRESSOR KA5S-GK200
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Function
Sensor
: Inductive sensor.
Mounting
BLUE (MINUS)
WHITE (SIGNAL)
BROWN (PLUS)
HANDBOOK FOR
OPERATION AND MAINTENANCE
9.
START-UP
9.1
PREPARATIONS
COMPRESSOR KA5S-GK200
Page 48/54
Fill up the compressor with lubricating oil, check the oil level. Fill on only NEW and absolutely CLEAN oil. Check oil level in sight glass.
If lubricating oil has already been filled on, check quality of oil as well as oil level.
For type of oil, see technical specifications, 2.
2. Check lubricating oil piping for damage that may have occurred during mounting.
In case the oil system has been disassembled or modified, the system shall be flushed
with oil that has been bypassed gear and compressor, using the procedure described
below:
Dismount pipe connections leading to gear and compressor.
Lead oil back to the oil reservoir via clean pipes.
The external oil system is then flushed out for one hour with oil at temperature above
10C
Pipe connections for gear are remounted and new oil is filled.
Check that the passage through connections to gear and compressor is
Important!
free.
The oil system is then flushed out for at least hour with the oil temperature above
10C and the oil pressure at 1,5 3,0 bar.
Turn the compressor manually, very carefully, one entire revolution in reverse. (This is
easily done by means of the coupling between drive motor and gear).
Then flush further for at least hour.
Check oil filter insert. Replace if necessary.
3. Check the compressor suction system, silencer(s), compensators and air filters (internal/external) for correct mounting and cleanliness.
Important!
Check especially the area in front of the impeller, the inlet, and the inlet
pipe. Check the flexible connection between the inlet pipe and inlet filter/inlet duct for correct mounting.
4. Check diffuser cone, blow-off valve and non-return check valve on pressure side of compressor for correct mounting. The check valve must be mounted with vertical shaft. An
arrow indicates the sense of direction of the air.
5. Check the non-return check valve for correct function and control. Check the limit switch
function.
6. Check that function and adjustment of the regulation system of the diffuser are correct.
Check the limit switch function.
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COMPRESSOR KA5S-GK200
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9.2
Turn compressor manually to check that rotation is smooth. This is most easily done at
the coupling between drive motor and gear.
Start up compressor (motor) briefly, max. 2-3 seconds, to check direction of rotation.
If direction of rotation is wrong, repole motor.
IMPORTANT!
Wrong direction of rotation of the gear for more than a few seconds may
cause permanent damage to gear bearings and journals.
Note: Do not restart more than 4 times per hour. Repeated starts within 15 minutes will
block the drive motor for restart for one hour (to protect motor coils).
Check that mounting of the coupling and tightening of the screws is correct (see 12).
Check the coupling alignment before start-up (see 12).
9.3
Opening and closing of blow-off valve. Normally the blow-off valve will indicate "closed"
max. 180 sec. after start-up (depending on valve type and site conditions).
Function of recirculation-valve.
Test safety monitoring, oil level switch and emergency stop during operation.
Check of cable connections from compressor control panel to master control panel.
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OPERATION AND MAINTENANCE
9.4
COMPRESSOR KA5S-GK200
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9.5
START
5 seconds approx. after start-up the valve between the compressor and the manifold is
opened. The blow-off valve is closed.
At plants equipped with non-return valve between compressor and manifold: Close the blowoff valve approx. 5 seconds after start.
The compressor can now be set for max airflow, during which the counter pressure and the
power consumption of the motor are surveyed. At low counter pressure the airflow may increase considerably and the motor will be overloaded (see performance certificate).
The compressor electric control system (Local Control Panel) will monitor all necessary
functions before and after start, when the start order is given by pressing the respective
button. In case of errors or if the starting conditions are not fulfilled the local control panel
will indicate ERROR (see Manual for Electric Control System).
DURING OPERATION
Pos. Nos. refer to aggregate drawing/instrument panel drawing. Operating temperature
(see 2).
During operation the following is checked:
Oil level:
Pos. No E130
E120
Sight glass
Level switch
Oil temperature:
Oil pressure:
Compressor surging
Compressor recirculation
Vibrations:
Power consumption:
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9.6
COMPRESSOR KA5S-GK200
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GENERAL
When the compressor has been put into operation, the starting priority of the machines
shall be changed periodically by the machine operator in order that all compressors of an
installation are frequently in operation and over a period will have an equal number of operation hours.
On plants where the diffuser system is not frequently run from fully open to fully closed, due
to special operating conditions, the local panel shall be set on "Manual" at least once a
week, and the diffuser run from fully closed to fully open at least twice. This also applies to
compressors which are not in operation.
If the compressors have not been in operation for a month, the following procedure shall be
followed, to avoid that the ball bearings are damaged by standstill in the same position:
Rotate the compressor for about a minute in the normal direction of operation. This can
most easily be done by turning the coupling between drive motor and gear by hand.
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10.
COMPRESSOR KA5S-GK200
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TROUBLE SHOOTING
When trouble shooting, compare all operational data with the specifications in 2.
10.1
10.1
Insufficient flow
10.2
10.3
10.4
10.5
10.6
10.7
10.8
Drive motor
Oil cooler
10.2
INSUFFICIENT FLOW
Possible causes:
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10.3
COMPRESSOR KA5S-GK200
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10.4
10.5
Gear:
- Defective gearwheel or bearings.
- Defective coupling or bad alignment.
Compressor:
10.6
Defective bearings.
Rotor/impeller out of balance.
Defective sealings.
Defective coupling or bad alignment.
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10.7
COMPRESSOR KA5S-GK200
10.8
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OPERATION AND MAINTENANCE
11.
COMPRESSOR KA5S-GK200
Page 1/50
MAINTENANCE
INTRODUCTION
The SIEMENS compressor is designed to operate for many thousand hours with a minimum of
maintenance.
Control and cleaning is most important. Some vital parts of the compressor and gear require
dismounting. Instructions of such dismounting and remounting are given below. Follow these
instructions carefully, and if any doubt please contact SIEMENS for assistance.
The SIEMENS compressor is built with very fine tolerances and operates at very high speeds.
Therefore, be very careful during maintenance works. Use the correct tools only and avoid any
kind of bumps and blows on the compressor parts.
Observe proper cleanliness.
Do not use cotton waste for cleaning or drying as it may contain unobserved particles of dirt or
metal.
11.1
See
6
Intervals
First oil change after 8,000 hours of operation.
Subsequent changes every 8,000 hours., however, at least once a year
Acc.
3.3.3
3.3.3
11.2
11.6
Acc.
Inlet filter
Inlet silencer
Drive motor
Oil cooler
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COMPRESSOR KA5S-GK200
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Oil Change
Under normal operating conditions, the compressor can operate 8000 hours before an oil
change is required.
A pump and a suction pipe is used to drain off the oil. The oil is sucked up through the filler stud
(See aggregate / unit drawing) The pump and suction pipe is not standard equipment.
Prior to filling on new oil, the oil filter shall always be cleaned / changed according to filter type,
see filter description.
Important!
Do not use other types of oil than the one specified in the technical specifications,
as bearings gearwheels etc. have all been dimensioned for this specific type of oil.
Damage caused by using wrong type of oil is not covered by the guarantee.
Oil level(when unit is not operating)between min and max on the sight glass / dipstick. Oil type and amount: see technical specifications in 2.
Change of Bearings
Operational hours between changing of bearings for GK gear mounted with hybrid
bearings onto the rotor shaft.
KA2-GK190
KA5-KG200*
KA10-GK200
Rotor shaft
24,000
40,000
40,000
Pinion shaft
48,000
80,000
80,000
See instructions and illustrations for disassembling and assembling of the compressor and gearbox later in this chapter
1 Bearing housing
2 O-ring
1 Bearing housing
2 Race
3 Spring
4 O-ring
5 Washer
6 Screw
HANDBOOK FOR
OPERATION AND MAINTENANCE
11.2
COMPRESSOR KA5S-GK200
Page 3/50
SERVICE
Service 1 includes:
Estimated time consumption for Service 1 (depending of e.g. plant conditions silencer hood
crane facilities etc.):
Preconditions: KA5 - 10:
Participation of 1 STE service engineer + 1 local assistant.
Complete special tools should be available.
KA5 / KA10 SV-GK200
11 hours
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 4/50
- Check, lubrication, and cleaning of all parts in the diffuser drive system.
- Assembling and measuring of diffuser drive system. Check of throat area.
Disassembling of gear.
bearing in rotor.
- Check of clearance between impeller and covering.
- Replacement of O-rings.
Mounting, check, and adjustment of outer diffuser drive system. Check of mechanical limit
HANDBOOK FOR
OPERATION AND MAINTENANCE
11.3
COMPRESSOR KA5S-GK200
Page 5/50
11.4
at max 180 seconds after start (depending on type of valve and plant conditions).
Function of non-return valve.
Build-up and stability of air pressure in pressure pipe.
Lubricating oil pressure and temperature shall be stabilized.
Test diffuser adjustment manually.
*)
*)
(mm):
Clearance rotor/covering
(mm):
Hour counter
RMS (mm/S):
MIN/MAX:
(mm):
RMS mm/S:
(hours):
HANDBOOK FOR
OPERATION AND MAINTENANCE
11.5
COMPRESSOR KA5S-GK200
Page 6/50
11.6
INLET SILENCER
The inlet silencer is designed for atmospheric air and lined with sound-absorbing material.
Cleaning of the sound-absorbing baffles can be done by a vacuum cleaner during service.
Avoid bending the baffles.
The sound absorbing material shall never be exposed to steam or washed with water.
IMPORTANT: Organic solvents will damage the material and its adhesion to the supporting
frames.
11.7
DISPOSAL OF WASTE
Disposal of waste according to the instructions of the local authorities.
A compressor in operation shall have air filter elements and lubricating oil changed at regular
intervals.
Used air filter elements or used filter cloth can be disposed of as combustible waste. Used lubricating oil to be treated as chemical waste and disposal according to the instructions of the local authorities. Oil moistened cloths used for oil absorption and used oil filters can be disposed
of as combustible waste. Iron and metal from the replacement of compressor parts can be removed as scrap.
11.8
HANDBOOK FOR
OPERATION AND MAINTENANCE
12.
12.1
COMPRESSOR KA5S-GK200
Page 7/50
DISMOUNTING / REMOUNTING
1.
The following directions are only applicable when aligning couplings on standard, single-stage
turbocompressor units operated by an asynchronous motor with anti-friction bearings. The coupling must be of the Flender Arpex type, but not necessarily a Flender product. The alignment requirements apply only to couplings with standard "spacer lengths" mounted between motor and
gear, hence they are not to be used when aligning "fast running" couplings mounted between
gear and compressor.
2.
The alignment requirements, as indicated in Table 1, correspond to approx. 25% of the max.
allowable deviations specified by the suppliers of couplings, and have thus been approved by
suppliers of couplings and drive motors to SIEMENS.
Improved alignment requirements ensure that vibrations caused by errors of alignment will not be
affecting the overall vibration level.
3.
The couplings are aligned during mounting of the unit in SIEMENS's workshop. The alignment is
safeguarded against changes during transport/erection, due to the fact that the bases are very
stiff. The coupling alignment must always be checked prior to starting up the compressor.
4.
The procedure stated in the following points describes alignment with application of a dial gauge.
Alternatively laser equipment can be used for the same purpose.
5.
Having shrunk one of the coupling halves onto the drive shaft, the compressor/gear unit is
mounted on its base. Two guide rods are then placed in the gear support. Now place the electric
motor - with the other coupling half mounted - on the four supports with four 10 mm shims between motor and base. Make sure that the motor is resting on all four points of support; this prevents it from being twisted during the tightening. If more than 0,05 mm of shims is needed under
any one of the supports, place a suitable number of 'thin' shims under the support until the motor
is resting evenly on all points of support.
Make sure that measure S is maintained while positioning the motor; see Table 1 and figure 1.
On GA, GB, GC, GL, and GK2/B3 the drive shafts of gear and motor shall be pulled towards one
another while measuring S. While bearing in mind the possibility of heat expansion make sure
that the tolerance of S is a +tolerance in order to minimize the load on the thrust bearing of the
gear. In other words, the gear shaft and the drive shaft shall be pulled towards one another.
On GK190 and GK200 the shaft of the motor shall be pulled towards the gear, while the drive
shaft of the gear shall be pressed away from the motor when measuring S. While bearing in mind
the possibility of heat expansion, make sure that the tolerance of S is a +tolerance.
HANDBOOK FOR
OPERATION AND MAINTENANCE
6.
COMPRESSOR KA5S-GK200
Page 8/50
As indicated in figures 2 and 3, the angular and parallel misalignments are measured with a dial
gauge, which is bolted to the coupling shaft and measures on the motor shaft (see fig. 2 & 3).
Do not use a dial gauge with magnet foot. The rest of the measuring setting-up should also be as
inflexible as possible to avoid measuring faults caused by deflexion.
When measuring, make sure that the two coupling halves are rotating synchronously, e.g. by
using a trailing rod.
When the coupling is rotated one full revolution, the measuring dial must not go beyond the tolerances set for parallel and angular misalignments, as indicated in Table 1.
The alignment is carried out partly by adjusting the thickness of the shims, partly by adjusting the
motor position on the base.
The parallel misalignment should be suppressed, partly because a major display will entail an
important deviation of the radial misalignment, partly to adjust for unevenness between the two
plate packs.
As already stated (point 4), the motor is not to be tightened definitively until it is resting evenly on
all four supports. If necessary, use thin shims under one of the supports.
When measuring the angular and parallel misalignments, it is a good idea to mount a spring between the flange on which the dial gauge is fixed and the flange too measured on. In this way the
axial position of motor shaft and gear shaft is maintained.
7.
The coupling bolts are tightened by means of a torque wrench or by measuring the elongation of
the bolts. When mounting and tightening, follow the instructions of the supplier.
In general, couplings of the Flender Arpex, Mnninghoff Arcoflex, and Thomas Rexnord SR52
types are used. The mounting instructions for these makes are different. See instructions on
page 5 - 8. For all types the thread of the bolts must be greased. Do not use Molykote or similar
instead of oil for the greasing. When tightening the bolts, the bolt head must be fixed while the nut
is turned.
If other types of couplings than the three ones above are mounted, the mounting instructions for
the coupling make in question must be required.
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 9/50
TABLE 1
S Tolerance **
+ Tolerance
to be used
Gyratory Running
mm/100mm
168 or less
0,3
0,24
0,29
0,17
180
0,4
0,24
0,31
0,17
200
0,4
0,24
0,34
0,17
205
0,4
0,24
0,36
0,17
215
0,4
0,24
0,38
0,17
235
0,5
0,31
0,41
0,17
250
0,5
0,31
0,44
0,17
270
0,5
0,31
0,44
0,17
300
0,6
0,31
0,52
0,17
320 ***
0,6
0,31
0,56
0,17
Coupling Size
(Flange diameter) *
For deviating flange diameters, the tolerances for the closest - and smaller - flange diameter are
used.
**
The misalignment tolerances are valid for standard spacer lengths of 250 mm, but may also be
used at spacer lengths over 250 mm.
***
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 10/50
Figure 1.
MOTOR
GEAR
Concentric Running: RL
Figure 2.
GEAR
MOTOR
Gyratory Running: PL
Figure 3.
GEAR
MOTOR
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 11/50
Coherence between type of coupling, shaft diameter, dowel screws, key width and torque TA.
*NB! The torque TA of the dowel screws only applies to clean, greased threads. Use compressor lube oil.
Coupling
Type XX
Shaft Diam.
mm
Dowel Screws
metric
*Torque
TA Nm
Key Width mm
225
145
M8 1
13
34
262
168
M10 1
17
41
312
198
M10 1
17
54
350
221
M12 1,25
19
129
375
246
M14 1,5
22
176
425
267
M16 1,5
237
450
287
M18 1,5
271
500
327
M20 1,5
353
The correct mounting of the plate packs is shown on below drawing. The screws must be mounted in the
coupling flanges (shaft/spacer) pos. 2. Do not forget to mount the washers pos. 3 on each side of the
plate packs.
Important! Check the screw torque after approx. 10 hrs of operation.
1
3
1
3
TA
TA
Description of Coupling:
See section Accessories
HANDBOOK FOR
OPERATION AND MAINTENANCE
12.2
COMPRESSOR KA5S-GK200
Page 12/50
Joint paste:
None
Dismount:
Remount:
Mounting and assembly in reverse order. Take care that the electric cables are
mounted correctly.
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 13/50
HANDBOOK FOR
OPERATION AND MAINTENANCE
12.3
COMPRESSOR KA5S-GK200
ADJUSTMENT OF CLEARANCES
See drawing next page.
Page 14/50
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 15/50
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 16/50
TYPE
SP1
KA5-GK200
0,9
MAX
MIN
SP2
MAX
MIN
SP5
MAX
MIN
(SP5)*
+0,1
0
0,7
+0,05
0
0,3
+0,05
0
0,55
(SP5)*: When measuring gap SP5 by means of lead-imprinting (min. 4 measuring points evenly
distributed) at least one measuring point shall be within the tolerance stated in column SP5
MAX/MIN, and no other measuring points must exceed the gap (SP5)*. (SP5)* indicates max.
permitted non-parallelism in the diffuser.
HANDBOOK FOR
OPERATION AND MAINTENANCE
12.4
COMPRESSOR KA5S-GK200
Page 17/50
Description
H701
Inlet housing /
H501
85 kg
R400
Rotor complete
12 kg
D101
Diffuser plate
23 kg
R100
Drive shaft
53 kg
H101
28 kg
H102
Weight approx.
225 kg
HANDBOOK FOR
OPERATION AND MAINTENANCE
12.5
COMPRESSOR KA5S-GK200
Page 18/50
SPECIAL TOOLS
Info
V999
qty Description
1 Tool box
Order no.
9332270330
Illustr.
V102
1
3
93330570160
N61V10020
A
B
V103
434002879
V202
434004511
V405
V405
V405
1
1
1
GK200V004
N64S13
N91M12
E
F
G
V501
V504
1
1
9330570480
9330570450
H
I
V701
1
3
GK200V001
NG1V08020
V304
6
3
Nut M8
Threaded rod M8 x 120 for bearing housing
N91M08
9330570550
V305
6
3
Nut M6
Threaded rod M6 x 90 for sealing
N91M06
9330570540
V306
GK200V005
V503
N1P06060
V503
9330570530
V901
V903
V903
V903
1
3
3
3
9332270215
N61V06070
N61V08110
N91M08
V912
GK200V008
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 19/50
HANDBOOK FOR
OPERATION AND MAINTENANCE
12.6
COMPRESSOR KA5S-GK200
Page 20/50
Tightening Torque
Where nothing else is stated for the tightening torque of the bolts and screws used in
SIEMENS compressors, the below mentioned values (ISO-m) are valid. The values are for
ordinary bolts with strength 8.8 (DIN 267) and socket head bolts and Insex screws.
M
Nm
10
12
14
16
20
24
30
1,37
3,10
6,15
10,5
26
51
89
141
215
390
675
1160
5,5
10
13
10
16
12
(17)
18
14
(19)
21
(22)
16
20
24
30
24
30
36
46
10
12
14
16
20
Width
10
12
14
17
24
30
NB! Wrench widths are in accordance with ISO 4014/4017, except figures in () which are according to DIN 931/933.
HANDBOOK FOR
OPERATION AND MAINTENANCE
12.7
COMPRESSOR KA5S-GK200
Page 21/50
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
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HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 23/50
3.
2.
Lubricate both threads of the central screw R405 and between rotor drive R401 and pinion
shaft R201 with an agent to protect against scratches.
3.
Tighten the central screw R405 the whole way down into the pinion shaft R201. Mount the
rotor drive with impeller and stop ring on the pinion shaft. Check that screw R411 locks with
the keyway in the pinion shaft. Tighten the rotor nut R407 on the central screw. Mount
the fastening tools 933 057 045 0 on the central screw. Pump to an oil pressure of 410 bar (420
kp/cm 2). Tighten the rotor nut R407 until complete contact with a 06 mandrel in one of the two holes and
check with a feeler gauge (0.05 mm) that the nut is completely abutting the stop ring. Remove the oil pressure for the threads to settle.
4.
Pump again to 410 bar. Tighten the rotor nut again until complete contact. Remove the oil
pressure and the fastening tools.
5.
The assembled rotor is balanced according to balancing instruction. All parts are to be marked with serial number for the balancing.
1.
2.
Pump to an oil pressure of 410 bar (420 kp/cm2) so rotor nut R407 can be loosened. Remove the
oil pressure and the tools.
3.
4.
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OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
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COMPRESSOR KA5S-GK200
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COMPRESSOR KA5S-GK200
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COMPRESSOR KA5S-GK200
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COMPRESSOR KA5S-GK200
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COMPRESSOR KA5S-GK200
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COMPRESSOR KA5S-GK200
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COMPRESSOR KA5S-GK200
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COMPRESSOR KA5S-GK200
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COMPRESSOR KA5S-GK200
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HANDBOOK FOR
OPERATION AND MAINTENANCE
12.8.1
Pos.
Nr.
COMPRESSOR KA5S-GK200
Page 40/50
Description
Pos.
Nr.
Description
D100
D200
R100
R400
Drive shaft
Rotor, complete
E130
E134
H101
H102
H113
H115
H116
H127
H128
H129
H186
H194
H303
H304
H311
H313
H316
H317
H401
H402
H403
H404
H410
H502
H505
H701
H704
S112
S113
S124
S129
S131
S132
S155
S156
S161
S162
S425
S426
T101
T102
T103
T106
T112
T114
T124
T204
T207
T208
T210
T213
T215
T218
T220
T221
T222
T234
Sealing ring
Screw
Ball bearing, motor end
Ball bearing, compressor end
O-ring
Washer
Crinkle washer
Bearing housing
Screw
Angular contact ball bearing, motor end
Double contact ball bearing, compressor end
Shim
Washer
Shim
Sealing ring, inner
Screw
Bearing housing
Screw
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 41/50
HANDBOOK FOR
OPERATION AND MAINTENANCE
12.8.2
COMPRESSOR KA5S-GK200
Pos. No.
Description
R201
R401
R405
R407
R409
R410
R411
R412
R414
Pinion shaft
Rotor drive
Centre screw
Rotor nut
Stop ring
Special screw
Dowel
Stop nut
Impeller
Page 42/50
HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 43/50
HANDBOOK FOR
OPERATION AND MAINTENANCE
12.8.3
COMPRESSOR KA5S-GK200
Description
D201
Excenter housing
D202
D203
D205
Positioning lever
D206
D207
Excenter shaft
D208
Mounting plate
D209
D210
Limit switch
D211
D212
Backstop
D213
Scale
D214
D219
D224
Linear motor
D229
D230
D231
Screw
D240
D241
D248
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HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
Page 45/50
HANDBOOK FOR
OPERATION AND MAINTENANCE
12.8.4
COMPRESSOR KA5S-GK200
Pos. No.
Description
D101
Diffuser plate
D102
Swivel joint
D108
Guide ring
D109
Dowel
D110
End stop
D113
D114
Screw
D115
Screw
D116
Diffuser blade
D117
D118
Screw
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HANDBOOK FOR
OPERATION AND MAINTENANCE
COMPRESSOR KA5S-GK200
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HANDBOOK FOR
OPERATION AND MAINTENANCE
12.8.5
COMPRESSOR KA5S-GK200
Page 48/50
HANDBOOK FOR
OPERATION AND MAINTENANCE
12.8.6
COMPRESSOR KA5S-GK200
Pos. No.
Description
A101
A103
A104
A105
A107
A200
A201
A202
A301
A302
Coupling
Guard
A401
A402
Electric motor
Screw
D200
E100
E105
E109
E110
E121
E122
E134
E139
E187
F101
F105
Frame
Shim
S203
S204
S205
S206
S213
S215
S216
S217
S301
S302
S303
S313
S318
S322
S334
S336
S901
S902
Ermeto fitting
Ermeto fitting
Ermeto fitting
Ermeto fitting
Ermeto fitting
Hose
Hose
Ermeto fitting
Oil cooler
Screw
Oil filter
Oil distributor
Base for oil cooler
Screw
Plug
Oil drain
Ermeto fitting
Washer
Page 49/50
Copyright: The concepts and information contained in this document are the property of Siemens Turbomachinery Equipment A/S (STE). Use or copying of this document in whole or in part without the written permission of STE constitutes an infringement of copyright.
Disclaimer of Liability: We have checked the contents of this manual with the equipment described. Since
deviations cannot be precluded entirely, we cannot guarantee full agreement. However, the data in this manual
are reviewed regularly and any necessary corrections included in subsequent editions. Suggestions for improvements are welcomed.
Operations Manual
Local Control Panel
17-03-2008
Revision: 2.01
Document Control
Document Information
Title:
Number of Pages:
Revision:
Author:
File Name:
Last Printed:
Last Saved:
08/04/2008 14:34:00
04/04/2008 16:28:00
Revision History
Rev.
0.0
1.0
2.0
2.01
Date
02-06-2004
21-06-2004
16-01-2006
04-04-2008
By
KJH
KJH
KJH
LC
Approved Description
Original issue (for review)
AKOP
First release
AKOP
Sections 6, 7 and 10.2 revised, 10.6 added
AKOP
HVT changed to Siemens
Page i
Operations Manual
Local Control Panel
17-03-2008
Revision: 2.01
Safety Instructions
Make sure that this Operations Manual is at the disposal of everybody who is involved in
operation, maintenance and repairs and that the contents have been understood.
If the operating instructions in this Operations Manual are not observed, the result may be
function interruptions and damages to the system as well as personal injuries, for which the
manufacturer does not undertake any responsibility.
The Operations Manual and the compressor handbook contain the necessary information for
the correct use of the functions described. They are intended for qualified personnel.
Qualified personnel in connection with the safety instructions in this Operations Manual is
either projecting personnel who is familiar with the safety regulations of automation
technology,
or service personnel who has an education qualified for the repair of such automation
technology equipment, respectively who is entitled to put electric circuits and devices/systems into operation according to the relevant safety standards.
The system is solely constructed for the application described in the scope of delivery (defined by the manufacturer of the equipment, application according to description). Any application beyond this is not according to description. The manufacturer is not responsible for
resulting damages. Only the user has the responsibility for this.
Page ii
Operations Manual
Local Control Panel
17-03-2008
Revision: 2.01
To the application according to description also belongs the observation of the conditions of
operation, maintenance, and repair lain down by the manufacturer. The system must only be
used, serviced, and repaired by persons who are familiar with this and have been instructed
in the risk.
If work can only be carried out with an open control panel at voltage, corresponding safety
measures shall be taken.
Instructions for protection against accidents as well as other generally recognized safety and
work regulations shall be observed.
At maintenance work all automatic processes, controls and functions must stand still. They
have to be blocked and secured against unintentional restart.
It is a condition for the qualified maintenance and repair that all necessary devices and tools
are at disposal and that the condition of the tools is completely satisfactory.
Maintenance work or repairs must only be carried out in voltage-free condition by qualified
personnel.
In order to be clear the instruction does not include all details for all versions of the product
in question, and it can neither consider every imaginable way of installation, operation or
maintenance. If you wish further information or in case problems occur that have not been
described in enough details, necessary information can be obtained at STE.
Page iii
Operations Manual
Local Control Panel
17-03-2008
Revision: 2.01
Contents
1
2
3
4
Preface ........................................................................................................................................... 1
Related Documents....................................................................................................................... 1
Definitions ..................................................................................................................................... 2
General Information .................................................................................................................... 3
4.1 Basic Screen Design ............................................................................................................... 3
4.2 Screen Navigation ................................................................................................................... 4
4.3 Language Selection ................................................................................................................. 5
4.4 Password Protection................................................................................................................ 5
4.5 Message System...................................................................................................................... 8
5 Operation Modes ........................................................................................................................ 12
5.1 Selecting Modes.................................................................................................................... 12
5.2 Off Mode............................................................................................................................... 13
5.3 Local Mode ........................................................................................................................... 13
5.4 Remote Mode........................................................................................................................ 14
5.5 Service Mode ........................................................................................................................ 14
5.6 Test Modes............................................................................................................................ 16
6 Starting the Compressor............................................................................................................ 17
6.1 Start Conditions .................................................................................................................... 17
6.2 Start Sequence....................................................................................................................... 19
6.3 Local Start............................................................................................................................. 20
6.4 Remote Start.......................................................................................................................... 21
7 Stopping the Compressor .......................................................................................................... 22
7.1 Normal Stop Sequence.......................................................................................................... 22
7.2 Local Stop ............................................................................................................................. 23
7.3 Remote Stop.......................................................................................................................... 24
8 Controlling the Compressor Capacity...................................................................................... 25
8.1 Local Capacity Control ......................................................................................................... 25
8.2 Remote Capacity Control...................................................................................................... 25
8.3 Minimizing the Power Consumption .................................................................................... 26
9 Abnormal Operating Conditions .............................................................................................. 27
9.1 Soft Stop Sequence ............................................................................................................... 27
9.2 Hard Stop Sequence .............................................................................................................. 27
9.3 Alarms/Trips ......................................................................................................................... 28
9.4 System Messages .................................................................................................................. 29
10 Settings ........................................................................................................................................ 30
10.1 Calibrating the diffuser and the inlet guide vanes................................................................. 30
10.2 Setting the blow-off valve closing time ................................................................................ 31
10.3 Setting the main drive motor current limiting....................................................................... 32
10.4 Setting instrument scalings ................................................................................................... 33
10.5 Setting alarm set points ......................................................................................................... 34
10.6 Save and restore settings ....................................................................................................... 35
11 Appendix ..................................................................................................................................... 37
11.1 Basic Screen Navigation Diagram ........................................................................................ 37
11.2 Troubleshooting Guide ......................................................................................................... 39
11.3 Colour Conventions .............................................................................................................. 43
11.3.1 Mono Version ................................................................................................................ 43
11.3.2 Colour Version............................................................................................................... 44
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Preface
Purpose:
This manual provides information about how to:
Operate the STE Compressors.
Handle abnormal operating conditions.
Change basic settings.
Audience:
This manual is designed for Operators and Maintenance personnel who have a general
knowledge about rotating machinery and instrumentation.
Scope of the Manual:
The information contained in this manual pertains in particular the following equipment:
STE Compressors, KA series
STE Local Control Panels
STE Human Machine Interfaces, mono edition
STE Human Machine Interfaces, colour edition
Note:
Not every option or Human Machine Interface screen in this manual is relevant for each
Local Control Panel.
Text Conventions:
The following text conventions are used throughout this manual:
Vibration system
<Off>
Further Support:
If you have any technical questions, please get in touch with your local STE representative or
agent responsible.
http://www.STE.com/english/index.htm
Related Documents
Refer to the following documentation for more detailed information about selected topics:
Navigation Diagram LCP Operator Interface
Circuit Diagram Local Control Panel
Sequential Function Charts Local Control Panel
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Definitions
This section describes the important technical terms used in this manual.
Actuator
Electrical driven mechanical device used to open/close valves, diffuser and IGV.
Alarm
An Alarm signals that a process condition or process value is approaching a critical
value. The compressor will remain in operation.
BOV
Blow-Off Valve. A valve mounted in the compressor outlet system used to unload the
compressor during start and stop.
Consumer
Electrical device (lube oil pump, lube oil heater, ventilation fan, etc.)
Diffuser
Flow and pressure control device mounted in the compressor outlet.
HMI
Human Machine Interface
HMI Screen
A HMI Screen is a group of logically related process data. A HMI Screen consists of e.g.
input and output fields, text, graphics and pushbuttons (Example Figure 4-2).
Inlet Guide Vanes (IGV)
Flow and pressure control device mounted in the compressor inlet.
Local Control Panel (LCP)
Control panel connected to one compressor. The control panel is used to monitor the
conditions of the compressor and start/stop the compressor according to the automatic
sequence.
Master Control Panel (MCP)
Control panel connected to a group of compressors. The control panel is used to start and
stop the compressors according to the selected sequence and to regulate the compressor
capacity to match the airflow demanded by the process.
MCC
Motor Control Centre
PLC
Programmable Logic Controller
PRC-4
STEs algorithm for minimizing power consumption.
Surging
An aerodynamically unstable condition where a moderate increase in discharge pressure
causes a significantly decrease in throughput. This instability can be extremely severe,
with visible vibration and audible noise.
System Message
System messages display states and faults of the HMI and the PLC.
Trip
A Trip signals that a process condition or process value has exceeded a critical value.
The compressor will make a quick shut down.
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General Information
This section provides basic information about the use of the compressor HMI from STE. Describing among others basic screen design, screen navigation, language selection, password
protection, and the message system.
4.1
Basic Screen Design
All the HMI screens are basically divided in three areas (Figure 4-1) the fixed area, the basic
area, and the navigation area.
Figure 4-1
Fixed Area:
The fixed area is used to provide general information about the compressor status and the
operation mode currently selected. The fixed area (Figure 4-2) is the same for all HMI
screens.
Basic Area:
The basic area is different for all HMI screens. Depending on the screen currently selected
the basic area provides access to process values, settings, start/stop pushbuttons, language
selection and links to other screens (Figure 4-2).
Figure 4-2
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Navigation Area:
The navigation area holds the pushbuttons used to navigate between the HMI screens in the
screen hierarchy. The number of pushbuttons in the navigation area depends on the position
of the current screen in the screen hierarchy.
The functions of the individual navigation pushbuttons are described in section 4.2.
4.2
Screen Navigation
The HMI screens are all arranged in a screen hierarchy that lay down how the individual
screens are linked together. Each HMI screen has a unique number according to its position
in the screen hierarchy. The screen number is shown in the lower right corner on every
screen. The screen numbering system is shown in Figure 4-3.
Figure 4-3
The pushbuttons in the navigation area of the HMI screens are used to move/navigate around
in the screen hierarchy. The functions of the individual navigation pushbuttons are described
in Figure 4-4.
Figure 4-4
For details about screen navigation please refer to the appendix in section 11.1.
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4.3
Language Selection
The STE HMI provides the possibility to let the user switch between two HMI languages.
The default HMI language is English. The second language is project dependent.
Figure 4-5
Switching the HMI languages is done on the MAIN SCREEN No. 1 (Figure 4-2) by clicking the FLAG pushbutton (Figure 4-5). The currently selected HMI language is shown in
the text field above the pushbutton.
4.4
Password Protection
Critical functions and settings are protected by passwords to avoid activation or change by
accident. The password level currently logged on can be seen on the MAIN SCREEN
No. 1 (Figure 4-2) and on the MAIN SCREEN No. 2 (Figure 4-12).
Password levels:
The HMI provides hierarchically organized password levels from level 0 to 9. If a user is
logged on with password level 3, for example, this user is authorized to execute the functions
of password levels 0 to 3.
The following password levels are used in the STE HMI:
Password level 0 is the default level i.e. the lowest level in the password hierarchy. A
password does not need to be entered to execute functions on password level 0.
Password level 3 is used to protect functions intended only for the plant maintenance
personnel. A password has to be entered in order to execute these functions.
Logging on:
Password log on can be done in two different ways:
Directly by using the SETTINGS: PASSWORD MANAGEMENT screen
No. 2.1.2 (Figure 4-6).
1. Enter the password in the Input Password field.
2. Click the <Log On> pushbutton (Figure 4-7).
3. Result: The password level is shown in the Current Password Level field.
Figure 4-6
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Figure 4-7
Figure 4-8
3.
4.
5.
6.
7.
8.
Figure 4-9
Logging off:
Password log off can be done in two different ways:
Automatically by the HMI after 15 minutes.
Manually by using the SETTINGS: PASSWORD MANAGEMENT screen
No. 2.1.2 (Figure 4-6).
1. Click the <Log Off> pushbutton (Figure 4-7).
2. Result: The password level is reset to 0.
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Password table:
The table below shows the default password for password level 3 when the HMI is shipped.
Password Level
User Name
Password
Changes Allowed
Plant
STE
Yes
3
3
3
The empty rows in the table above can be used to keep record of new passwords created or
of changes to existing passwords.
Changing passwords:
When logged onto password level 3, changes can be made to the password levels 1 to 3 as
described below:
1. Navigate to screen No. 2.1.2 (Figure 4-6)
2. Log onto password level 3 as described in the section Password Protection (Logging
on directly).
3. Click in the relevant field in the Password column.
4. Result: The on-screen keyboard opens.
5. Enter the new password and click the <Enter> key.
6. Result: The on-screen keyboard closes and the password has been changed.
Creating passwords:
When logged onto password level 3, new passwords can be created for the password levels 1
to 3 as described below:
1. Navigate to screen No. 2.1.2 (Figure 4-6)
2. Log onto password level 3 as described in the section Password Protection (Logging
on directly).
3. Click an empty field in the User column.
4. Result: The on-screen keyboard opens.
5. Enter the new user name and click the <Enter> key.
6. Repeat step 3-5 for the Password and Level columns.
7. Result: The on-screen keyboard closes and the password has been created.
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4.5
Message System
The message system is responsible for reporting events or states that can occur in the compressor system or in the control system. The message system consists of the following components:
The message indicator.
The alarm messages window.
The alarm page.
The message buffers.
These components and the three message types that are distinguished between in the message system are described below.
Message Types:
Alarm messages display critical or hazardous operating and process states and require the operating personnel to react by issuing an acknowledgement.
Event messages display routine operating and process states.
System messages display states and faults of the HMI, the PLC or the communication between them. They are issued by the HMI or by the PLC and are automatically
displayed on the HMI when they occur.
Message Indicator:
As soon as an alarm message is arriving, the alarm message window (Figure 4-11) and the
message indicator (Figure 4-10) are displayed. The message indicator shows the number of
active alarm messages and will remain visible as long as alarm messages still are active (i.e.
not cleared). The message indicator can assume two states:
Flashing: As soon as at least one unacknowledged alarm message is queued.
Static: When all queued alarm messages have been acknowledged but at least one of
them is not yet cleared.
Figure 4-10
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Figure 4-11
Alarm Page:
The alarm page has the same layout and provides the same information as the alarm message
buffer (Figure 4-13). The alarm page, however, shows only currently active alarms and will
be empty when all alarms have cleared.
Message Buffers:
The message buffers provide access to historical alarm and event messages. All messages are
stored in chronological order in the message buffer. The most recent message is displayed at
the top of the message buffer. The message buffer is a First-In-First-Out buffer type i.e. the
first message stored in the buffer will be the first message to be deleted when the message
buffer is full.
Figure 4-12
Alarm and event messages are stored in separate buffers that can be accessed from HMI
screen No. 2 (Figure 4-12).
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Alarm Buffer:
The following information is provided in the alarm buffer (Figure 4-13):
No. column displays a unique alarm message number. Please inform this number
when calling STE for service support.
Time column displays the time when the status of the alarm changed.
Date column displays the date when the status of the alarm changed.
Status column displays the status of the alarm message:
- A: The message is Active
- C: The message is Cleared
- R: The message has been Reset/acknowledged
GR column displays the reset group that the alarm message belongs to.
Message text.
The following pushbuttons are available for handling alarm messages:
<Help>: Displays the help text to the selected alarm message (example Figure 4-14).
<Edit>: Triggers message specific functions (not used).
Figure 4-13
The help text linked to the alarm message provides useful guidelines when troubleshooting
the compressor system. In addition the alarm help text makes a reference to the relevant
page(s) in the Circuit Diagrams.
Figure 4-14
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Event Buffer:
The following information is provided in the event buffer (Figure 4-15):
No. column displays a unique event message number. Please inform this number
when calling STE for service support.
Time column displays the time when the status of the event changed.
Date column displays the date when the status of the event changed.
Status column displays the status of the event message:
- A: The message is Active
- C: The message is Cleared
Message text.
The following pushbuttons are available for handling event messages:
<Help>: Displays the help text to the selected event message.
<Edit>: Triggers message specific functions (not used).
Figure 4-15
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Operation Modes
This section explains the compressor operation modes, their selection and use. Each operation mode is described by its definition, target audience, selection and the possible user actions.
5.1
Selecting Modes
The compressor operation modes are selected from the MODE SELECTION screen
No. 1.1 (Figure 5-1). The modes are selected by clicking the pushbutton for the relevant operation mode. The currently selected operation mode is shown in the fixed area.
Figure 5-1
The operation modes are linked together according to Figure 5-2. The figure shows in detail
the conditions to switch between the operation modes.
Figure 5-2
Example: Service Mode can only be selected from Local Mode when the compressor is out
of operation. Service Mode can be deselected by selecting Local Mode or Off Mode.
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5.2
Off Mode
Definition:
In Off Mode the compressor is permanently out of operation and can neither be started locally from the LCP nor remotely from the MCP. The Off Mode is intended for situations
where the compressor is not needed for longer periods.
Target Audience:
Off Mode is intended for:
The every-day operator.
The plant maintenance personnel.
Selection: (Figure 5-2)
Off Mode can be selected when the compressor is in operation or out of operation from:
Local Mode.
Remote Mode.
Service Mode.
Test Modes.
Possible User Actions:
The user can perform the following tasks in Off Mode:
Acknowledge alarms.
Acknowledge trips.
5.3
Local Mode
Definition:
In Local Mode the compressor can only be started and stopped locally from the LCP. After
the compressor start sequence has been completed, the compressor capacity can be increased
and decreased locally from the LCP.
Target Audience:
Local Mode is intended for:
The every-day operator.
Selection: (Figure 5-2)
Local Mode can be selected when the compressor is in operation or out of operation from:
Remote Mode.
Service Mode.
Test Modes.
Off Mode.
Possible User Actions:
The user can perform the following tasks in Local Mode:
Acknowledge alarms.
Acknowledge trips.
Select automatic/manual mode for the IGV.
Start/stop the compressor.
Open/Close the diffuser.
Open/Close the IGV (only by IGV manual mode).
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5.4
Remote Mode
Definition:
In Remote Mode the compressor can only be started and stopped remotely by the MCP. After the compressor start sequence has been completed, the compressor capacity will be increased and decreased remotely by the MCP according to the selected set point and the actual airflow to the process.
Target Audience:
Remote Mode is intended for:
The every-day operator.
Selection: (Figure 5-2)
Remote Mode can be selected when the compressor is in operation or out of operation from:
Local Mode.
Off Mode.
Possible User Actions:
The user can perform the following tasks in Remote Mode:
Acknowledge alarms.
Acknowledge trips.
Select automatic/manual mode for the IGV.
5.5
Service Mode
Definition:
In Service Mode the compressor can neither be started locally nor remotely. For maintenance
purposes the auxiliary components (main lube oil pump, blow-off valve etc.) can be operated
independently of each other. The auxiliary components can be operated from the consumer
and actuator screens, see examples in Figure 5-3 and Figure 5-4.
Figure 5-3
Target Audience:
Service Mode is intended for:
The plant maintenance personnel.
STEs maintenance personnel.
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Figure 5-4
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5.6
Test Modes
Definition:
Test Mode is differentiated between Test Local and Test Remote. In Test Local Mode the
compressor start/stop is initiated locally from the LCP. In Test Remote Mode the compressor
start/stop is initiated remotely from the MCP. The Test Modes are intended for testing the
automatic compressor start sequence without actually starting the main drive motor. The Test
Modes are typically used during commissioning or troubleshooting.
Target Audience:
Test Modes are intended for:
The plant maintenance personnel.
STEs maintenance personnel.
Selection: (Figure 5-2)
The password level 3 has to be logged on before the Test Modes can be selected. Please proceed as described in the section Password Protection logging on directly to log onto the
password level 3. The Test Modes can be selected only when the compressor is out of operation from:
Local Mode.
Possible User Actions:
The user can perform the following tasks in Test Mode:
Acknowledge alarms.
Acknowledge trips.
Select automatic/manual mode for the IGV.
Start/stop the compressor (only Test Local).
Open/close the diffuser (only Test Local).
Open/close the IGV (only by IGV manual mode).
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This section provides basic information about the compressor start conditions, the automatic
start sequence and how to start the compressor in Local and Remote Mode.
6.1
Start Conditions
The following conditions need to be fulfilled to start the compressor:
No active or unacknowledged alarm messages are pending, i.e. the message indicator
is not displayed (section 4.5). Please refer to the Troubleshooting Guide in section
11.2 if the messages indicator is displayed.
The main drive motor starter (MCC) is ready.
The blow-off valve is fully open (Figure 6-1).
Figure 6-1
Figure 6-2
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Figure 6-3
The status field in the fixed area will indicate Not Ready To Start as long as all the above
conditions are not fulfilled.
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6.2
Start Sequence
The automatic compressor start sequence proceeds as described below when a local or remote start has been initiated. The start sequence is described separately for compressor types
with and without IGV.
Compressor with IGV:
1. The electric lube oil pump starts the pre-lubrication phase (duration 60 seconds).
2. The inlet and outlet isolation valves open.
3. The main drive motor Run Command is sent to the MCC when the pre-lubrication
phase finishes and the inlet and outlet isolation valves are fully open.
4. The main drive motor starts.
5. The IGV opens fully when the main drive motor Running Feedback signal has
been received from the MCC.
6. The blow-off valve closes slowly when the IGV has reached its fully open position.
7. The electric lube oil pump stops 20 seconds after the main drive motor Running
Feedback signal has been received, if the lube oil pressure from the mechanical
lube oil pump is OK.
8. The compressor is in operation and the diffuser/IGV are released for capacity control
when the blow-off valve is fully closed.
Compressor without IGV:
1. The electric lube oil pump starts the pre-lubrication phase (duration 60 seconds).
2. The inlet and outlet isolation valves open.
3. The main drive motor Run Command is sent to the MCC when the pre-lubrication
phase finishes and the inlet and outlet isolation valves are fully open.
4. The main drive motor starts.
5. The blow-off valve closes slowly when the main drive motor Running Feedback
signal has been received from the MCC.
6. The electric lube oil pump stops 20 seconds after the main drive motor Running
Feedback signal has been received, if the lube oil pressure from the mechanical
lube oil pump is OK.
7. The compressor is in operation and the diffuser is released for capacity control when
the blow-off valve is fully closed.
The progress in the compressor start sequence can be monitored in the status field in the
fixed area of all HMI screens (see example in Figure 6-4). The following information is provided in the status field during the start sequence:
Not Ready To Start
Ready To Start
Pre-Lubrication
Starting
IGV Opening
BOV Closing
Operation
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6.3
Local Start
Starting the compressor in Local Mode is done from the OPERATION: COMPRESSOR
screen No. 1.2 (Figure 6-4).
Figure 6-4
Operator procedure:
1. Select Local Mode as described in section 5.1.
2. Check that the status field in the fixed area reads Ready To Start. If not then please
refer to section 6.1 before proceeding to step 3.
3. Push the Start Compressor pushbutton in screen No. 1.2 (Figure 6-4).
4. Observe the remaining Pre-Lubrication field to see when the main drive motor will
start.
5. Monitor the compressor start sequence in the status field in the fixed area.
1. Ready To Start
2. Pre-Lubrication
3. Starting
4. IGV Opening
5. BOV Closing
6. Operation
When the status field reads Operation, the compressor is ready for capacity control. The
compressor capacity is controlled by means of the pushbuttons Increase Capacity and Decrease Capacity.
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6.4
Remote Start
Starting the compressor in Remote Mode is done by the MCP and can be monitored from the
OPERATION: COMPRESSOR screen No. 1.2 (Figure 6-5).
Figure 6-5
Operator procedure:
1. Select Remote Mode as described in section 5.1.
2. Check that the status field in the fixed area reads Ready To Start. If not then please
refer to section 6.1 before proceeding to step 3.
3. The MCP will start the compressor when necessary.
4. Observe the remaining Pre-Lubrication field to see when the main drive motor will
start.
5. Monitor the compressor start sequence in the status field in the fixed area.
1. Ready To Start
2. Pre-Lubrication
3. Starting
4. IGV Opening
5. BOV Closing
6. Operation
When the status field reads Operation, the compressor is ready for capacity control. The
compressor capacity is controlled by the MCP.
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This section provides basic information about the normal compressor stop sequence and how
to stop the compressor in Local and Remote Mode.
7.1
Normal Stop Sequence
The normal compressor stop sequence proceeds as described below when a local or remote
stop has been initiated.
1. The diffuser closes.
2. The blow-off valve opens when the diffuser has reached its fully closed position.
3. The main drive motor Run Command to the MCC is reset and the IGV closes when
the blow-off valve has reached its fully open position.
4. The electric lube oil pump starts the after-lubrication phase (duration 5 minutes)
when the main drive motor Running Feedback signal has been reset by the MCC.
5. The inlet and outlet isolation valves close during the after-lubrication phase.
The progress in the compressor stop sequence can be monitored in the status field in the
fixed area of all HMI screens (see example in Figure 7-1). The following information is provided in the status field during the stop sequence:
Operation
Stop: Diffuser Closing
Stop: BOV Opening
Stop: IGV Closing
Ready To Start
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7.2
Local Stop
Stopping the compressor in Local Mode is done from the OPERATION: COMPRESSOR
screen No. 1.2 (Figure 7-1).
Figure 7-1
Operator procedure:
1. Push the Stop Compressor pushbutton in screen No. 1.2 (Figure 7-1).
2. Observe the remaining After-Lubrication field to see when the electric lube oil
pump will stop.
3. Monitor the compressor stop sequence in the status field in the fixed area.
1. Operation
2. Stop: Diffuser Closing
3. Stop: BOV Opening
4. Stop: IGV Closing
5. Ready To Start
When the status field reads Ready To Start, the compressor is stopped and ready for
another start.
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7.3
Remote Stop
Stopping the compressor in Remote Mode is done by the MCP and can be monitored from
the OPERATION: COMPRESSOR screen No. 1.2 (Figure 7-2).
Figure 7-2
Operator procedure:
1. The MCP will stop the compressor when necessary.
2. Observe the remaining After-Lubrication field to see when the electric lube oil
pump will stop.
3. Monitor the compressor stop sequence in the status field in the fixed area.
1. Operation
2. Stop: Diffuser Closing
3. Stop: BOV Opening
4. Stop: IGV Closing
5. Ready To Start
When the status field reads Ready To Start, the compressor is stopped and ready for
another start.
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This section describes how to control the compressor capacity in Local and Remote Mode.
The section is closed with a description on how to use the power minimizing function.
8.1
Local Capacity Control
In Local Mode the capacity control can be done from the OPERATION screen No. 1.2
(Figure 6-4) or from the DIFFUSER screen No. 1.5.2.2 (Figure 8-1) and by compressors
without diffuser also from the INLET GUIDE VANES screen No. 1.5.2.1. The compressor
capacity control is enabled when the status field in the fixed area reads Operation.
Figure 8-1
Operator procedure:
Push the Decrease Capacity pushbutton to decrease the compressor capacity.
Push the Increase Capacity pushbutton to increase the compressor capacity.
The capacity control can be monitored by means of the current diffuser position in the Position field (0-100%) and the status in the DIFFUSER Status field:
1. Opening
2. Open
3. Closing
4. Closed
5. Midway
8.2
Remote Capacity Control
In Remote Mode the capacity control is done by increase/decrease signals from the MCP.
The remote capacity control can be monitored from the DIFFUSER screen No. 1.5.2.2
(Figure 8-1) or from the INLET GUIDE VANES screen No. 1.5.2.1 by compressors without diffuser. The compressor capacity control is enabled when the status field in the fixed
area reads Operation.
The capacity control can be monitored by means of the current diffuser position in the Position field (0-100%) and the status in the DIFFUSER Status field:
1. Opening
2. Open
3. Closing
4. Closed
5. Midway
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8.3
Minimizing the Power Consumption
The STE function to minimize the compressor power consumption can be turned On or Off
from the INLET GUIDE VANES screen No. 1.5.2.1 (Figure 8-2 and Figure 8-3). The
power minimization function is turned:
On by selecting AUTO mode for the IGV.
Off by selecting MAN mode for the IGV.
Inlet Guide Vanes AUTO mode (Figure 8-2):
The inlet guide vanes are released for automatic control when the blow-off valve has reached
its fully closed position. In AUTO mode the inlet guide vanes are continuously positioned
according to the current operation conditions (i.e. inlet air temperature, differential pressure
and diffuser position) in order to obtain the lowest possible power consumption. The current
inlet guide vanes position can be read in the Position field (0-100%) and the status in the
INLET GUIDE VANES Status field.
Figure 8-2
Figure 8-3
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This section explains how the compressor will react to abnormal operating conditions. The
description covers the compressor soft and hard stop sequences plus the HMI / PLC system
messages.
9.1
Soft Stop Sequence
The soft stop sequence is initiated when an abnormal operating condition occurs that demands a quick stop of the compressor. The soft stop sequence proceeds as described below.
1. An abnormal operating condition occurs.
2. The blow-off valve opens and the diffuser closes.
3. The main drive motor Run Command to the MCC is reset when the blow-off valve
has reached its fully open position or at the latest 8 seconds after the abnormal operating condition occurred.
4. The IGV closes when the blow-off valve has reached its fully open position.
5. The electric lube oil pump starts the after-lubrication phase (duration 5 minutes)
when the main drive motor Running Feedback signal has been reset by the MCC.
6. The inlet and outlet isolation valves close during the after-lubrication phase.
The progress in the soft stop sequence can be monitored in the status field in the fixed area of
all HMI screens (see example in Figure 7-1).
Refer to the Troubleshooting Guide in section 11.2 to determine the cause of the soft stop.
9.2
Hard Stop Sequence
The hard stop sequence is initiated when a critical operating condition occurs that demands
an instant stop of the compressor. The hard stop sequence proceeds as described below.
1. A critical operating condition occurs.
2. The main drive motor Run Command to the MCC is instantly reset.
3. The electric lube oil pump starts the after-lubrication phase (duration 5 minutes)
when the main drive motor Running Feedback signal has been reset by the MCC.
4. The blow-off valve opens, the diffuser closes and the IGV closes.
5. The inlet and outlet isolation valves close during the after-lubrication phase.
The progress in the hard stop sequence can be monitored in the status field in the fixed area
of all HMI screens (see example in Figure 7-1).
Refer to the Troubleshooting Guide in section 11.2 to determine the cause of the hard stop.
Emergency Stop and Power Failure are two special conditions initiating the following
Hard Stop Sequence:
1. The emergency stop pushbutton is activated or a power failure occurs.
2. The main drive motor Run Command to the MCC is instantly reset.
3. All auxiliaries i.e. the electric lube oil pump, the blow-off valve, the diffuser, the
IGV, the inlet and outlet isolation valves are stopped and remain in their current position.
When the emergency stop pushbutton has been reset or the power supply has been restored,
the LCP will automatically re-establish the start conditions (section 6.1).
Note: The emergency stop pushbutton is only to be used by risk of personal injury or
property damage.
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9.3
Alarms/Trips
Two categories of alarm messages are defined in the compressor message system. The two
categories are described below:
Alarms are operating and process states that require the operating personnel to react by issuing an acknowledgement but not require the compressor to be stopped. Examples of alarms
that will not stop the compressor are listed in the table below.
Number
145
147
148
153
161
201
233-236
265
273
435
443
Refer to the Troubleshooting Guide in section 11.2 or click the <Help> pushbutton in the
alarm buffer window to determine a possible cause of the alarm.
Trips are critical or hazardous operating and process states that require the compressor to be
stopped and the operating personnel to react by issuing an acknowledgement. Examples of
trips that will stop the compressor are listed in the table below.
Number
Stop Sequence
Hard
17
Hard
19
Soft
25
Soft
33
Hard
65
Compressor Surging HH
Soft
66
Compressor Recirculation HH
Soft
Soft
105-108
Refer to the Troubleshooting Guide in section 11.2 or click the <Help> pushbutton in the
alarm buffer window to determine a possible cause of the trip.
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9.4
System Messages
This section contains a selection of the most important system messages that can be shown
on the HMI. System messages provide information about the HMI and the PLC operating
modes. System messages can range from information to serious errors. The table below indicates when the messages occur and how they, or their cause, can be cleared.
Note:
Not every message in the table is relevant for each LCP.
Number
4003
Effect/Cause
Remedy
If serious system messages are shown that are not in the table above, then please get in touch
with your local STE representative or agent responsible.
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10 Settings
This section provides information about how basic parameters for the operation of the compressor are set or changed through the HMI. The section describes amongst others how to
calibrate the diffuser and IGV, how to set the blow-off valve closing time and how to set the
main drive motor current limiting. Unless described otherwise changing the settings in this
section requires that password level 3 is logged on.
10.1 Calibrating the diffuser and the inlet guide vanes
The diffuser and IGV position feedback is calibrated from 0% to 100% between the fully
closed position (minimum) and the fully open position (maximum). The following procedure
has to be followed if the diffuser or IGV limit switches have been adjusted:
1. Stop the compressor if it is in operation.
2. Select Service Mode as described in section 5.1.
3. Navigate to the CALIBRATION: DIFFUSER screen No. 1.5.2.2.1 (Figure 10-1) or
the CALIBRATION: INLET GUIDE VANES screen No. 1.5.2.1.1.
4. Initiate the automatic calibration sequence by clicking the Start Calibration
pushbutton.
Figure 10-1
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Figure 10-2
The closing time of the blow-off valve is set by means of two parameters (Figure 10-3):
On Pulse Closing [ms]
Off Pulse Closing [ms]
Figure 10-3
Recommended settings:
On Pulse Closing < Off Pulse Closing
Blow-off valve closing time: 60 120 sec.
After setting the two parameters, switch to Service Mode as described in section 5.1 and test
the actual blow-off valve closing time on the BLOW-OFF VALVE screen No. 1.5.3.1
(Figure 5-4).
Note:
By setting a too short closing time, i.e. closing the blow-off valve too fast, there is a risk of
surging the compressor during start-up.
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Figure 10-4
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Figure 10-5
Note:
Changing the parameters Minimum Scaling or Maximum Scaling also requires the instrument range to be changed / recalibrated.
Do not change these settings without contacting your local STE representative or agent responsible.
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Figure 10-6
Changes to the alarm/trip parameters must be saved by clicking the Save Settings pushbutton.
Note:
Changing the trip parameters may result in damages to the compressor as well as personal
injuries. Do not change these settings without contacting your local STE representative or
agent responsible.
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Figure 10-7
Figure 10-8
Save settings
To save the current settings as the new default settings please follow the procedure described
below:
1. Log on with password level 3 (Figure 4-6)
2. Select the SAVE / RESTORE SETTINGS screen No. 2.1.1.1 (Figure 10-8)
3. Push the Save pushbutton.
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The current settings will now be saved as the new default settings. A running save procedure
is indicated as shown in Figure 10-9.
Figure 10-9
Restore settings
To restore the default settings as the current settings please follow the procedure described
below:
1. Log on with password level 3 (Figure 4-6)
2. Select the SAVE / RESTORE SETTINGS screen No. 2.1.1.1 (Figure 10-8)
3. Push the Restore pushbutton.
The default settings will now be restored as the current settings. A running restore procedure
is indicated as shown in Figure 10-10.
Figure 10-10
Note:
Saving and restoring settings require that password level 3 is logged on.
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11 Appendix
This appendix will provide the operator with detailed information about the screen navigation, compressor troubleshooting, and the HMI colour conventions.
11.1 Basic Screen Navigation Diagram
This section will provide the user with an overview of the basic HMI screens available and
their position in the screen hierarchy.
Legend:
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Note:
If more information about the screen hierarchy is needed then please refer to the detailed
document Navigation Diagram LCP Operator Interface.
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Message Text
17
19
25
33
34
Remedy
Re-establish safe conditions and deactivate the emergency stop button.
Reset the emergency stop on the start
screen and acknowledge the alarm message in the alarm message window.
Do not restart the compressor before a
thorough check of the lubrication system: Electrical/mechanical lube oil
pump, gear bearings, pressostates etc.
Perform a start in Test Local Mode to
check the lubrication system.
Water Cooling: Check water pressure,
water flow, water inlet temperature and
the function of the thermostatic control
valve. Clean the water cooler if necessary.
Air Cooling: Check cooling air temperature, airflow, the function of the ventilator, the function of the thermostat and
the set point to start the cooling fan.
Clean the air/oil cooler if necessary.
Perform a visual check of the lube oil
level. Check the function of the sensor.
If necessary refill the lube oil reservoir
to the normal indication on the dipstick.
NOTE! Check the lube oil system,
coolers, and pumps for leaks.
NOTE! Do not restart before a check of
the gear bearings/gaps, impeller and
coupling. Check the vibration system/set
point.
NOTE! Do not restart before a check of
the motor bearings (lubrication?) and
coupling. Check the vibration system/set
point. Lubricate bearings if necessary.
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Number
Message Text
Remedy
65
Compressor Surging HH
66
Compressor Recirculation HH
81
82
83
84
85
97
98
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Main Drive Motor Excessive Number of The maximum allowed number of starts
Starts. Please Wait.
within one hour has been exceeded.
Please Wait.
The compressor will automatically revert to its ready condition when the necessary time has expired.
Main Drive Motor Excessive Start Time The allowed main motor starting time
has been exceeded. Check the state of
the MCC (voltage, ampere and fuses).
99
100
101
105
106
107
108
Check motor cooling conditions (cooling air or water flow) and the motor
power consumption (overloading?).
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Number
113
114
115
148
Message Text
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Remedy
Main Drive Motor Bearing Temperature NOTE! Do not restart the compressor
HH
before a check of the bearings. Check
the bearings for adequate lubrication?
Check also the temperature sensor system and the set points.
Lube Oil Filter Differential Pressure H The lube oil filter is clogged. Replace
the filter bag inserts or clean them if
possible.
201
261
Inlet Isolation Valve Excessive Opening Check the mechanical state of the actuaTime
tor and the valve. See also O&M manual.
265
Inlet Guide Vane system Circuit Breaker Check the circuit breaker function and
Tripped
the set point. Check mechanical mobility
of IGV system and the power (ampere)
consumption.
273
Diffuser system Circuit Breaker Tripped Check the circuit breaker function and
the set point. Check mechanical mobility
of diffuser system and the power (ampere) consumption.
284
Blow-off Valve Excessive Closing Time Check the mechanical state of the blowoff valve and the actuator. See also
O&M manual.
285
Check the mechanical state of the blowoff valve and the actuator. See also
O&M manual.
293
Check the mechanical state of the actuator and the valve. See also O&M manual.
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Number
Message Text
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Remedy
435
443
451
483
499
507
515
523
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Colour
State Description
Example
White
Off
Fully Closed Position
Grey
On
Midway Position
Black
Black
Flashing
Abnormal Condition
Note:
Please use the <?> pushbutton in the navigation area of the screen to see the relevant help
text.
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Colour
State Description
Example
White
Off
Fully Closed Position
Grey
Available
Black
Reset
Red
Flashing
Abnormal Condition
Green
On
Fully Open Position
Blue
Midway Position
Yellow
Unavailable
1. Reset pushbutton
Note:
Please use the <?> pushbutton in the navigation area of the screen to see the relevant help
text.
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Copyright: The concepts and information contained in this document are the property of Siemens Turbomachinery Equipment A/S (STE). Use or copying of this document in whole or in part without the written permission of STE constitutes an infringement of copyright.
Disclaimer of Liability: We have checked the contents of this manual with the equipment described. Since
deviations cannot be precluded entirely, we cannot guarantee full agreement. However, the data in this manual
are reviewed regularly and any necessary corrections included in subsequent editions. Suggestions for improvements are welcomed.
Operations Manual
Master Control Panel
17-03-2008
Revision: 2.01
Document Control
Document Information
Title:
Number of Pages:
Revision:
Author:
File Name:
Last Printed:
Last Saved:
08/04/2008 14:37:00
04/04/2008 16:28:00
Revision History
Rev.
0.0
1.0
2.0
Date
08-09-2004
21-09-2004
16-01-2006
By
KJH
KJH
KJH
2.01
04-04-2008
LC
Approved Description
Original issue (for review)
AKOP
First release
AKOP
Sections 6.2, 7.1, 8.1 and 9.1 revised, 9.5
added
AKOP
HVT changed to Siemens
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Safety Instructions
Make sure that this Operations Manual is at the disposal of everybody who is involved in
operation, maintenance and repairs and that the contents have been understood.
If the operating instructions in this Operations Manual are not observed, the result may be
function interruptions and damages to the system as well as personal injuries, for which the
manufacturer does not undertake any responsibility.
The Operations Manual and the compressor handbook contain the necessary information for
the correct use of the functions described. They are intended for qualified personnel.
Qualified personnel in connection with the safety instructions in this Operations Manual is
either projecting personnel who is familiar with the safety regulations of automation
technology,
or service personnel who has an education qualified for the repair of such automation
technology equipment, respectively who is entitled to put electric circuits and devices/systems into operation according to the relevant safety standards.
The system is solely constructed for the application described in the scope of delivery (defined by the manufacturer of the equipment, application according to description). Any application beyond this is not according to description. The manufacturer is not responsible for
resulting damages. Only the user has the responsibility for this.
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To the application according to description also belongs the observation of the conditions of
operation, maintenance, and repair lain down by the manufacturer. The system must only be
used, serviced, and repaired by persons who are familiar with this and have been instructed
in the risk.
If work can only be carried out with an open control panel at voltage, corresponding safety
measures shall be taken.
Instructions for protection against accidents as well as other generally recognized safety and
work regulations shall be observed.
At maintenance work all automatic processes, controls and functions must stand still. They
have to be blocked and secured against unintentional restart.
It is a condition for the qualified maintenance and repair that all necessary devices and tools
are at disposal and that the condition of the tools is completely satisfactory.
Maintenance work or repairs must only be carried out in voltage-free condition by qualified
personnel.
In order to be clear the instruction does not include all details for all versions of the product
in question, and it can neither consider every imaginable way of installation, operation or
maintenance. If you wish further information or in case problems occur that have not been
described in enough details, necessary information can be obtained at STE.
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Contents
1
2
3
4
Preface ...............................................................................................................................1
Related Documents...........................................................................................................1
Definitions .........................................................................................................................2
General Information ........................................................................................................3
4.1 Basic Screen Design ....................................................................................................3
4.2 Screen Navigation........................................................................................................4
4.3 Language Selection......................................................................................................5
4.4 Password Protection.....................................................................................................5
4.5 Message System ..........................................................................................................8
5 Operation Modes ............................................................................................................12
5.1 Selecting Modes ........................................................................................................12
5.2 Off Mode ...................................................................................................................13
5.3 Automatic Mode ........................................................................................................13
6 Compressor/Priority allocation.....................................................................................14
6.1 Selecting Priorities.....................................................................................................14
6.2 Validating Priorities...................................................................................................15
7 Capacity Control ............................................................................................................17
7.1 Monitoring the Operation ..........................................................................................17
7.2 Start Compensation....................................................................................................18
7.3 The Load Controller ..................................................................................................19
7.4 Increasing Capacity ...................................................................................................20
7.5 Decreasing Capacity ..................................................................................................21
8 Abnormal Operating Conditions ..................................................................................22
8.1 General.......................................................................................................................22
8.2 Alarms/Trips ..............................................................................................................23
8.3 System Messages .......................................................................................................25
9 Settings ............................................................................................................................26
9.1 Setting the Load Controller .......................................................................................26
9.2 Adjusting the dynamics of the system .......................................................................28
9.3 Setting instrument scalings ........................................................................................29
9.4 Setting alarm set points..............................................................................................30
9.5 Save and restore settings............................................................................................31
10 Appendix .........................................................................................................................33
10.1 Basic Screen Navigation Diagram.............................................................................33
10.2 Troubleshooting Guide ..............................................................................................35
10.3 Colour Conventions ...................................................................................................37
10.3.1 Mono Version .....................................................................................................37
10.3.2 Colour Version....................................................................................................38
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Preface
Purpose:
This manual provides information about how to:
Operate the STE Compressors.
Handle abnormal operating conditions.
Change basic settings.
Audience:
This manual is designed for Operators and Maintenance personnel who have a general
knowledge about rotating machinery and instrumentation.
Scope of the Manual:
The information contained in this manual pertains in particular the following equipment:
STE Compressors, KA series
STE Master Control Panels
STE Human Machine Interfaces, mono edition
STE Human Machine Interfaces, colour edition
Note:
Not every option or Human Machine Interface screen in this manual is relevant for each
Master Control Panel.
The Human Machine Interface screens shown in this manual are all taken from a Master
Control Panel controlling 3 compressors (MCP-3). The functional descriptions contained
in this manual are, however, valid for Master Control Panels controlling any number of
compressors between 2 and 9.
Text Conventions:
The following text conventions are used throughout this manual:
Vibration system
<Off>
Further Support:
If you have any technical questions, please get in touch with your local STE representative or
agent responsible.
Related Documents
Refer to the following documentation for more detailed information about selected topics:
Navigation Diagram MCP Operator Interface
Circuit Diagram Master Control Panel
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Definitions
This section describes the important technical terms used in this manual.
Alarm
An Alarm signals that a process condition or process value is approaching a critical
value.
HMI
Human Machine Interface
HMI Screen
A HMI Screen is a group of logically related process data. A HMI Screen consists of e.g.
input and output fields, text, graphics and pushbuttons (Example Figure 4-2).
Load Controller
The Load Controller controls the capacity of the compressor system so the demand from
the process is met.
Local Control Panel (LCP)
Control panel connected to one compressor. The control panel is used to monitor the
conditions of the compressor and start/stop the compressor according to the automatic
sequence.
Master Control Panel (MCP)
Control panel connected to a group of compressors. The control panel is used to start and
stop the compressors according to the selected sequence and to regulate the compressor
capacity to match the airflow demanded by the process.
PLC
Programmable Logic Controller
Priority
A unique number assigned to every compressor. The priority determines the compressors place in the capacity control sequence.
Start Compensation
Start Compensation is an option that limits overshooting of the set point when a compressor is started.
System Message
System messages display states and faults of the HMI and the PLC.
Trip
A Trip signals that a process condition or process value has exceeded a critical value.
The compressor will make a quick shut down.
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General Information
This section provides basic information about the use of the compressor HMI from STE. Describing among others basic screen design, screen navigation, language selection, password
protection, and the message system.
4.1
Basic Screen Design
All the HMI screens are basically divided in three areas (Figure 4-1) the fixed area, the basic
area, and the navigation area.
Figure 4-1
Fixed Area:
The fixed area is used to provide general information about the status of the compressor system and the operation mode currently selected. The fixed area (Figure 4-2) is the same for all
HMI screens.
Basic Area:
The basic area is different for all HMI screens. Depending on the screen currently selected
the basic area provides access to process values, settings, start/stop pushbuttons, language
selection and links to other screens (Figure 4-2).
Figure 4-2
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Navigation Area:
The navigation area holds the pushbuttons used to navigate between the HMI screens in the
screen hierarchy. The number of pushbuttons in the navigation area depends on the position
of the current screen in the screen hierarchy.
The functions of the individual navigation pushbuttons are described in section 4.2.
4.2
Screen Navigation
The HMI screens are all arranged in a screen hierarchy that lay down how the individual
screens are linked together. Each HMI screen has a unique number according to its position
in the screen hierarchy. The screen number is shown in the lower right corner on every
screen. The screen numbering system is shown in Figure 4-3.
Figure 4-3
The pushbuttons in the navigation area of the HMI screens are used to move/navigate around
in the screen hierarchy. The functions of the individual navigation pushbuttons are described
in Figure 4-4.
Figure 4-4
For details about screen navigation please refer to the appendix in section 10.1.
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4.3
Language Selection
The STE HMI provides the possibility to let the user switch between two HMI languages.
The default HMI language is English. The second language is project dependent.
Figure 4-5
Switching the HMI languages is done on the MAIN SCREEN No. 1 (Figure 4-2) by clicking the FLAG pushbutton (Figure 4-5). The currently selected HMI language is shown in
the text field above the pushbutton.
4.4
Password Protection
Critical functions and settings are protected by passwords to avoid activation or change by
accident. The password level currently logged on can be seen on the MAIN SCREEN
No. 1 (Figure 4-2) and on the MAIN SCREEN No. 2 (Figure 4-12).
Password levels:
The HMI provides hierarchically organized password levels from level 0 to 9. If a user is
logged on with password level 3, for example, this user is authorized to execute the functions
of password levels 0 to 3.
The following password levels are used in the STE HMI:
Password level 0 is the default level i.e. the lowest level in the password hierarchy. A
password does not need to be entered to execute functions on password level 0.
Password level 3 is used to protect functions intended only for the plant maintenance
personnel. A password has to be entered in order to execute these functions.
Logging on:
Password log on can be done in two different ways:
Directly by using the SETTINGS: PASSWORD MANAGEMENT screen
No. 2.1.2 (Figure 4-6).
1. Enter the password in the Input Password field.
2. Click the <Log On> pushbutton (Figure 4-7).
3. Result: The password level is shown in the Current Password Level field.
Figure 4-6
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Figure 4-7
Figure 4-8
3.
4.
5.
6.
7.
8.
Figure 4-9
Logging off:
Password log off can be done in two different ways:
Automatically by the HMI after 15 minutes.
Manually by using the SETTINGS: PASSWORD MANAGEMENT screen
No. 2.1.2 (Figure 4-6).
1. Click the <Log Off> pushbutton (Figure 4-7).
2. Result: The password level is reset to 0.
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Password table:
The table below shows the default password for password level 3 when the HMI is shipped.
Password Level
User Name
Password
Changes Allowed
Plant
HVT
Yes
3
3
3
The empty rows in the table above can be used to keep record of new passwords created or
of changes to existing passwords.
Changing passwords:
When logged onto password level 3, changes can be made to the password levels 1 to 3 as
described below:
1. Navigate to screen No. 2.1.2 (Figure 4-6)
2. Log onto password level 3 as described in the section Password Protection (Logging
on directly).
3. Click in the relevant field in the Password column.
4. Result: The on-screen keyboard opens.
5. Enter the new password and click the <Enter> key.
6. Result: The on-screen keyboard closes and the password has been changed.
Creating passwords:
When logged onto password level 3, new passwords can be created for the password levels 1
to 3 as described below:
1. Navigate to screen No. 2.1.2 (Figure 4-6)
2. Log onto password level 3 as described in the section Password Protection (Logging
on directly).
3. Click an empty field in the User column.
4. Result: The on-screen keyboard opens.
5. Enter the new user name and click the <Enter> key.
6. Repeat step 3-5 for the Password and Level columns.
7. Result: The on-screen keyboard closes and the password has been created.
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4.5
Message System
The message system is responsible for reporting events or states that can occur in the compressor system or in the control system. The message system consist of the following components:
The message indicator.
The alarm messages window.
The alarm page.
The message buffers.
These components and the three message types that are distinguished between in the message system are described below.
Message Types:
Alarm messages display critical or hazardous operating and process states and require the operating personnel to react by issuing an acknowledgement.
Event messages display routine operating and process states.
System messages display states and faults of the HMI, the PLC or the communication between them. They are issued by the HMI or by the PLC and are automatically
displayed on the HMI when they occur.
Message Indicator:
As soon as an alarm message is arriving, the alarm message window (Figure 4-11) and the
message indicator (Figure 4-10) are displayed. The message indicator shows the number of
active alarm messages and will remain visible as long as alarm messages still are active (i.e.
not cleared). The message indicator can assume two states:
Flashing: As soon as at least one unacknowledged alarm message is queued.
Static: When all queued alarm messages have been acknowledged but at least one of
them is not yet cleared.
Figure 4-10
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Figure 4-11
Alarm Page:
The alarm page has the same layout and provides the same information as the alarm message
buffer (Figure 4-13). The alarm page, however, shows only currently active alarms and will
be empty when all alarms have cleared.
Message Buffers:
The message buffers provide access to historical alarm and event messages. All messages are
stored in chronological order in the message buffer. The most recent message is displayed at
the top of the message buffer. The message buffer is a First-In-First-Out buffer type i.e. the
first message stored in the buffer will be the first message to be deleted when the message
buffer is full.
Figure 4-12
Alarm and event messages are stored in separate buffers that can be accessed from HMI
screen No. 2 (Figure 4-12).
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Alarm Buffer:
The following information is provided in the alarm buffer (Figure 4-13):
No. column displays a unique alarm message number. Please inform this number
when calling STE for service support.
Time column displays the time when the status of the alarm changed.
Date column displays the date when the status of the alarm changed.
Status column displays the status of the alarm message:
- A: The message is Active
- C: The message is Cleared
- R: The message has been Reset/acknowledged
GR column displays the reset group that the alarm message belongs to.
Message text.
The following pushbuttons are available for handling alarm messages:
<Help>: Displays the help text to the selected alarm message (example Figure 4-14).
<Edit>: Triggers message specific functions (not used).
Figure 4-13
The help text linked to the alarm message provides useful guidelines when troubleshooting
the compressor system. In addition the alarm help text makes a reference to the relevant
page(s) in the Circuit Diagrams.
Figure 4-14
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Event Buffer:
The following information is provided in the event buffer (Figure 4-15):
No. column displays a unique event message number. Please inform this number
when calling STE for service support.
Time column displays the time when the status of the event changed.
Date column displays the date when the status of the event changed.
Status column displays the status of the event message:
- A: The message is Active
- C: The message is Cleared
Message text.
The following pushbuttons are available for handling event messages:
<Help>: Displays the help text to the selected event message.
<Edit>: Triggers message specific functions (not used).
Figure 4-15
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Operation Modes
This section explains the MCP operation modes, their selection and use. Each operation
mode is described by its definition, target audience, selection and the possible user actions.
5.1
Selecting Modes
The MCP operation modes are selected from the MODE SELECTION screen No. 1.1
(Figure 5-1). The modes are selected by clicking the pushbutton for the relevant operation
mode. The currently selected operation mode is shown in the fixed area.
Figure 5-1
The operation modes are linked together according to Figure 5-2. The MCP operation modes
can be selected without any restrictions.
Figure 5-2
Note:
Switching from Automatic Mode to Off Mode will stop all compressors running, i.e. the
complete compressor system will be stopped.
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5.2
Off Mode
Definition:
In Off Mode the MCP is permanently out of operation and the compressors are not started or
stopped by the MCP. The complete compressor system is out of operation and the automatic
capacity control is disabled. The compressors are, however, still available for local control
from the LCPs.
Target Audience:
Off Mode is intended for:
The every-day operator.
The plant maintenance personnel.
Selection: (Figure 5-2)
Off Mode can be selected when the compressors are in operation or out of operation from:
Automatic Mode.
Possible User Actions:
The user can perform the following tasks in Off Mode:
Acknowledge alarms.
Acknowledge trips.
5.3
Automatic Mode
Definition:
In Automatic Mode the MCP controls the compressors selected to Remote Mode on the LCP
HMI. The compressors are automatically started/stopped and the capacity controlled to meet
the airflow currently demanded by the process.
Target Audience:
Automatic Mode is intended for:
The every-day operator.
Selection: (Figure 5-2)
Automatic Mode can be selected when the compressors are in operation or out of operation
from:
Off Mode.
Possible User Actions:
The user can perform the following tasks in Automatic Mode:
Acknowledge alarms.
Acknowledge trips.
Allocate priorities to the compressors.
Select internal or external set point for the Load Controller.
Select manual or automatic mode for the Load Controller.
Select Start Compensation On/Off.
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Compressor/Priority allocation
This section provides information about the allocation of priorities to the compressors. The
section starts with a description on how to select priorities for the compressors. The section
is ended with a description of the procedure for priority validation.
6.1
Selecting Priorities
Each compressor is allocated a unique priority. The priorities selected determine the sequence in which the compressors are started by the MCP. The compressors are identified by
letters (A, B, C, etc.) and the priorities by numbers (0, 1, 2, 3, etc.). The priority numbers that
can be selected depends on the number of compressors controlled by the MCP:
2 Compressors Priorities 0, 1, 2
9 Compressors Priorities 0, 1, 2, 3, 4, 5, 6, 7, 8, 9
The MCP will not control a compressor allocated the priority 0. The compressor that is allocated the priority 1 will be the first one to be started and the compressor allocated the priority
9 will be the last one to be started.
The priorities are selected from the PRIORITY SELECTION screen No. 1.2.2 (Figure
6-1). The selection of priorities is described below.
Operator procedure:
1. Click the Select Compressor pushbuttons to select the compressor for which the
priority has to be allocated. A grey frame around the Accepted and Selected
fields indicates that the compressor is currently selected.
2. Click the Select Priority pushbuttons to change the priority for the currently
selected compressor.
Figure 6-1
The Accepted row in Figure 6-1 shows the priority sequence currently used by the MCP
when controlling the compressors.
The Selected row shows the priorities selected with the Select Priority pushbuttons.
Note:
It is recommended only to change the priorities for two compressors at a time to avoid upsetting the airflow to the process.
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6.2
Validating Priorities
The priority sequence selected (refer to section 6.1) needs to be validated before it can be
used in the compressor control. The rules for selecting priorities are described in the section
below.
Rules for selecting priorities:
The following rules need to be observed when selecting priorities:
Priority sequence must be selected without holes.
Priority numbers 1 to 9 must only be selected once.
Priority number 0 can be allocated to as many compressors as desired.
The tables below show examples of valid (Table 1) and not valid (Table 2) priority sequences.
Table 1: Examples of valid priority sequences (MCP-5)
Compressor
A
Compressor
A
Accepting priorities:
The priority sequence selected is accepted by clicking the pushbutton Accept Priorities on
the PRIORITY SELECTION screen No. 1.2.2 (Figure 6-1). Only a valid priority sequence
can be accepted.
The priorities in the Selected row will be copied to the Accepted row when they are accepted. The compressors will then be controlled according to the new priorities.
Note:
It is recommended only to change the priorities for two compressors at a time to avoid upsetting the airflow to the process.
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Priority failure:
If a not valid priority sequence has been selected then it is signalled on the PRIORITY SELECTION screen No. 1.2.2 (Figure 6-2) by:
Flashing priority fields in the Selected row.
Priority Failure in the status field of the fixed area.
Figure 6-2
Selecting valid priorities will automatically disable the flashing of the priority fields and enable the Accept Priorities pushbutton.
Note:
Only valid priorities can be accepted.
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Capacity Control
This section provides information about how the compressors are controlled to meet the airflow demanded by the process. The description covers monitoring of the operation, the function of the start compensation, the operation of the Load Controller and the increase and decrease capacity sequences.
7.1
Monitoring the Operation
The sequence of compressor start/stop when increasing or decreasing the capacity can be
monitored on the OPERATION screen No. 1.2 (Figure 7-1).
Figure 7-1
The OPERATION screen No. 1.2 (Figure 7-1) provides among others an overview of the
current operational status of each compressor. The status of each compressor is signalled
graphically as described below:
(Steady)
(Steady)
(Flashing)
(Steady)
(Flashing)
In addition the currently accepted priority numbers are shown for each compressor.
The OPERATION screen No. 1.2 (Figure 7-1) also provides information about the current
set point and the current process value.
The set point can be changed by clicking the set point input field. The prerequisite for changing the set point from the OPERATION screen is that internal set point mode has been selected on the LOAD CONTROLLER screen No. 1.2.1 (Figure 7-3)
The LOAD CONTROLLER screen No. 1.2.1 (Figure 7-3) and the PRIORITY SELECTION screen No. 1.2.2 (Figure 6-1) can both be accessed from the OPERATION screen
No. 1.2 by clicking the appropriate pushbutton.
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7.2
Start Compensation
Start Compensation is provided to limit overshooting of the set point when starting an additional compressor. The operation of the start compensation is described below:
1. The MCP sends a command to an LCP to start the attached compressor.
2. The compressor starts and the LCP returns an Operation signal to the MCP.
3. The MCP activates the start compensation on the compressor with the next lower priority number than the compressor just started.
Example: The compressor with priority number 2 starts Start Compensation is activated
on the compressor with priority number 1. The Start Compensation activates a timer and the
MCP controls the capacity of the compressor (priority number 1) down until the timer has
expired. The normal capacity control will be enabled again when the Start Compensation
time has expired.
The Start Compensation time can be adjusted through the SETTINGS: GENERAL screen
No. 2.1.3 (Figure 9-3).
Figure 7-2
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7.3
The Load Controller
The Load Controller is responsible for controlling the compressors so the airflow demanded
by the process is obtained. The compressors are normally controlled to keep a constant pressure in a main air header. The pressure in the air main header is measured by a pressure
transmitter and fed through the PLC to the Load Controller. The pressure set point can either
be set manually through the LOAD CONTROLLER screen No. 1.2.1 (Figure 7-3) or externally, e.g. from a process control system. The Load Controller is configured as a PI step
controller. Based on the measured pressure and the set point the Load Controller generates
signals to increase or decrease the capacity of the compressor system.
Figure 7-3
The LOAD CONTROLLER screen No. 1.2.1 (Figure 7-3) provides the following:
Pushbutton to select internal (SP INT) or external (SP EXT) set point.
Pushbuttons to increase/decrease the internal set point.
Pushbutton to select manual (MAN) or automatic (AUTO) controller mode.
Pushbuttons to increase/decrease the capacity of the compressor system in manual
controller mode.
Bargraph for display of the controller set point (SP).
Bargraph for display of the controller process value (PV).
Bargraph for display of the controller output (Out).
Pushbutton to access the controller parameters.
Pushbutton to access the controller trends of the set point and the process value.
Note:
No capacity control will be performed if the Load Controller is switched to manual mode.
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7.4
Increasing Capacity
When the current capacity of the compressor system does not meet the capacity demanded
by the process, the LOAD CONTROLLER will increase the capacity of the compressors in
operation and if necessary start additional compressors. The philosophy of the MCP is to
control the capacity of only one compressor at a time and then keep the rest of the compressors in operation at their maximum capacity.
Below a description of the sequence when the capacity is increased:
1. A start command will be sent to the priority 1 compressor as soon as Automatic
mode is selected on the MODE SELECTION screen No. 1.1 (Figure 5-1).
2. The capacity of the priority 1 compressor will be increased until the set point is
reached or the priority 1 compressor has reached its maximum capacity.
3. A start command will be sent to the priority 2 compressor when the LOAD CONTROLLER has generated the Number Of Pulses To Start set on the SETTINGS:
GENERAL screen No. 2.1.3 (Figure 9-3).
4. The capacity of the priority 1 compressor will be decreased when the priority 2 compressor signals that it is in operation. (Only if Start Compensation is switched On,
refer to section 7.2).
5. When the Start Compensation time (refer to Figure 9-3) has expired the capacity of
the priority 1 compressor is increased until the set point is reached or the compressor
has reached its maximum capacity.
6. The capacity of the priority 2 compressor will be increased until the set point is
reached or the priority 2 compressor has reached its maximum capacity.
7. A start command will be sent to the priority 3 compressor when the LOAD CONTROLLER has generated the Number Of Pulses To Start.
The above sequence will continue in the same way until the set point has been reached or all
compressors controlled by the MCP are in operation.
The current status of the compressors system can be monitored on the OPERATION
screen No. 1.2 (Figure 7-1).
Figure 7-4
Figure 7-4 shows the LOAD CONTROLLER in AUTO mode operating with an external
set point during a phase where the capacity is increased.
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7.5
Decreasing Capacity
When the current capacity of the compressor system is higher than the capacity demanded by
the process, the LOAD CONTROLLER will decrease the capacity of the compressors in operation and if necessary stop compressors. The philosophy of the MCP is to control the capacity of only one compressor at a time and then keep the rest of the compressors in operation at their maximum capacity.
Below a description of the sequence when the capacity is decreased:
1. The capacity of the priority 3 compressor will be decreased until the set point is
reached or the priority 3 compressor has reached its minimum capacity.
2. The capacity of the priority 2 compressor will be decreased until the set point is
reached or the priority 2 compressor has reached its minimum capacity.
3. The start command to the priority 3 compressor will be reset when the LOAD CONTROLLER has generated the Number Of Pulses To Stop set on the SETTINGS:
GENERAL screen No. 2.1.3 (Figure 9-3).
4. When the priority 3 compressor is out of operation, the capacity of the priority 1
compressor will be decreased until the set point is reached or the priority 1 compressor has reached its minimum capacity.
5. The start command to the priority 2 compressor will be reset when the LOAD CONTROLLER has generated the Number Of Pulses To Stop.
The above sequence will continue in the same way until the set point has been reached or
only the priority 1 compressor is in operation in its minimum capacity.
The MCP will not automatically stop the priority 1 compressor. The priority 1 compressor
can only be stopped by selecting Off Mode (refer to section 5.1) or by initiating a remote
stop command, e.g. from a process control system.
The current status of the compressors system can be monitored on the OPERATION
screen No. 1.2 (Figure 7-1).
Figure 7-5
Figure 7-5 shows the LOAD CONTROLLER in AUTO mode operating with an internal
set point during a phase where the capacity is decreased.
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This section explains how the compressor system and the MCP will react to abnormal operating conditions. The description covers the MCP alarms/trips and the HMI / PLC system
messages.
8.1
General
The MCP behaviour to different abnormal situations is described below.
MCP power failure:
When the MCP fails due to a power outage, the compressors running in Remote Mode will
automatically be switched to Local Mode and the compressors remain in operation at their
current capacity. The compressor capacity can then be controlled manually from the LCP.
When the power supply to the MCP is restored and it is in Automatic Mode then switch:
1. The priority 1 compressor to Remote Mode (When switched to Remote Mode the
compressor will stop. The MCP will restart the compressor when it is ready to start).
2. The priority 2 compressor to Remote Mode (only when the priority 1 compressor is
started by the MCP).
3. The priority 3 compressor to Remote Mode (only when the priority 2 compressor is
started by the MCP).
Continue the above sequence until the compressor with the highest priority number has been
switched to Remote Mode.
Total power failure (MCP + LCPs):
When the complete compressor control system (MCP + LCPs) fails due to a power outage
then all the compressors will stop instantly.
When the power supply to the MCP and LCPs has been restored, the MCP automatically
starts the priority 1 compressor and resumes capacity control to meet the airflow demanded
by the process.
Compressor trip:
When a compressor trips due to a critical operating or process state, the MCP automatically
starts the next compressor that is ready in the priority sequence.
Example with MCP-4:
1. The priority A=1 and priority B=2 compressors are in operation. The priority C=3
compressor is not ready for operation (e.g. in Local Mode). The priority D=4 compressor is not in operation.
2. The priority B=2 compressor trips due to a critical operating state.
3. The MCP automatically starts the priority D=4 compressor.
When the reason for the compressor trip has been found and rectified then the LCP will signal Ready to start to the MCP. The MCP will automatically restart the compressor when it
is ready again.
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8.2
Alarms/Trips
Two categories of alarm messages are defined in the MCP message system. The two categories are described below:
Alarms are operating and process states that require the operating personnel to react by issuing an acknowledgement but not require the compressor system to be stopped. Examples of
alarms that will not stop the compressor system are listed in the table below.
Number
81
82
83
84
85
86
97
98
131
139
147
155
163
Refer to the Troubleshooting Guide in section 10.2 or click the <Help> pushbutton in the
alarm buffer window to determine a possible cause of the alarm.
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Trips are critical or hazardous operating and process states that require the operating personnel to react by issuing an acknowledgement. Examples of trips are listed in the table below.
Number
17
18
19
20
21
22
33
34
Refer to the Troubleshooting Guide in section 10.2 or click the <Help> pushbutton in the
alarm buffer window to determine a possible cause of the trip.
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8.3
System Messages
This section contains a selection of the most important system messages that can be shown
on the HMI. System messages provide information about the HMI and the PLC operating
modes. System messages can range from information to serious errors. The table below indicates when the messages occur and how they, or their cause, can be cleared.
Note:
Not every message in the table is relevant for each MCP.
Number
4003
Effect/Cause
Remedy
If serious system messages are shown that are not in the table above, then please get in touch
with your local STE representative or agent responsible.
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Settings
This section provides information about how basic parameters for the operation of the compressor system are set or changed through the HMI. The section describes amongst others
how to set the parameters of the Load Controller, how to adjust the dynamics of the compressor system and how to set instrument scalings. Unless described otherwise changing the
settings in this section requires that password level 3 is logged on.
9.1
Setting the Load Controller
The Load Controller is responsible for controlling the compressors so the airflow demanded
by the process is obtained. The parameters of the Load Controller (Figure 9-1) have to be set
and fine-tuned during commissioning of the compressor system to obtain an optimum operation of the process. When the operation of the process is changed after commissioning of the
MCP then the Load Controller might need to be fine-tuned again. The Load Controller parameters are described below:
Internal Set Point
The Internal Set Point is used for control when internal set point mode (SP INT) is selected on the Load Controller screen No. 1.2.1 (Figure 7-3). The Internal Set Point is
entered in percent (of the process value span) and is additionally shown in the relevant unit.
Safety Set Point
The Safety Set Point is used for control when external set point mode (SP EXT) is selected on the Load Controller screen No. 1.2.1 (Figure 7-3) and the external set point
signal is interrupted. The Safety Set Point is entered in percent (of the process value
span) and is additionally shown in the relevant unit.
Dead Band
The Dead Band is applied on both sides of the set point and in this band the Load
Controller will not increase or decrease the capacity. It should be noted that the
steady-state deviation may be equal to the value of the dead band.
Proportional Gain
The Proportional Gain determines the response of the proportional component in the
Load Controller.
Integral Action Time
The Integral Action Time determines the time response of the integral component in
the Load Controller.
Figure 9-1
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Figure 9-2
The Load Controller Trend screen No. 1.2.1.2 (Figure 9-2) is selected by clicking the
<Trend> pushbutton on the Load Controller screen No. 1.2.1 (Figure 7-3).
Dead Band
Decrease the Dead Band if the process value requires more accurate control.
Increase the Dead Band if the process value requires further stabilization.
Note that the steady-state deviation between the set point and the process value may
have the same value as the dead band (i.e. the control becomes less accurate when the
dead band is increased).
Proportional Gain
Decrease the Proportional Gain if the process value requires a smaller control response.
Increase the Proportional Gain if the process value requires a greater control response.
Integral Action Time
Decrease the Integral Action Time if the process value requires a faster control response.
Increase the Integral Action Time if the process value requires a slower control response.
Note:
It is recommended only to change one of the above parameters at a time and then observe the
reaction of the Load Controller on the Load Controller Trend screen before changing further
parameters.
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9.2
Adjusting the dynamics of the system
The dynamic behaviour of the compressor system can be changed by means of the parameters on the SETTINGS: GENERAL screen No. 2.1.3 (Figure 9-3).
Figure 9-3
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9.3
Setting instrument scalings
The range for analog instruments is set by means of the parameters Minimum Scaling and
Maximum Scaling. Instrument scalings are grouped according to the physical location of the
instrument:
Air Header System (example in Figure 9-4)
Aeration System
Figure 9-4
Note:
Changing the parameters Minimum Scaling or Maximum Scaling also requires the instrument range to be changed / recalibrated.
Do not change these settings without contacting your local STE representative or agent responsible.
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9.4
Setting alarm set points
The alarm and trip set points are set through standardized HMI screens. An example for the
header air pressure is shown in Figure 9-5.
The following parameters can be set for alarms and trips:
Alarm Setpoint
Alarm Hysteresis
- High Alarm: Hysteresis below the set point
- Low Alarm: Hysteresis over the set point
Alarm Delay
Trip Setpoint
Trip Hysteresis
- High Trip: Hysteresis below the set point
- Low Trip: Hysteresis over the set point
Trip Delay
Note:
Setting trip parameters require that password level 6 is logged on.
Figure 9-5
Changes to the alarm/trip parameters must be saved by clicking the Save Settings pushbutton.
Note:
Changing the trip parameters may result in damages to the compressor as well as personal
injuries. Do not change these settings without contacting your local STE representative or
agent responsible.
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9.5
Save and restore settings
The changes made to settings as described in the previous sections are all automatically
stored in a non-volatile memory. This means that the settings will be available even after a
power failure. However the changes made to settings will not be available after a total system reset (i.e. the default settings will be re-loaded) unless the settings were saved as described below.
Figure 9-6
Figure 9-7
Save settings
To save the current settings as the new default settings please follow the procedure described
below:
1. Log on with password level 3 (Figure 4-6)
2. Select the SAVE / RESTORE SETTINGS screen No. 2.1.1.1 (Figure 9-7)
3. Push the Save pushbutton.
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The current settings will now be saved as the new default settings. A running save procedure
is indicated as shown in Figure 9-8.
Figure 9-8
Restore settings
To restore the default settings as the current settings please follow the procedure described
below:
1. Log on with password level 3 (Figure 4-6)
2. Select the SAVE / RESTORE SETTINGS screen No. 2.1.1.1 (Figure 9-7)
3. Push the Restore pushbutton.
The default settings will now be restored as the current settings. A running restore procedure
is indicated as shown in Figure 9-9.
Figure 9-9
Note:
Saving and restoring settings require that password level 3 is logged on.
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10 Appendix
This appendix will provide the operator with detailed information about the screen navigation, compressor troubleshooting, and the HMI colour conventions.
10.1 Basic Screen Navigation Diagram
This section will provide the user with an overview of the basic HMI screens available and
their position in the screen hierarchy.
Legend:
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Note:
If more information about the screen hierarchy is needed then please refer to the detailed
document Navigation Diagram MCP Operator Interface.
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Message Text
Remedy
18
19
21
34
65
66
67
68
69
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Number
Message Text
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Remedy
70
71
72
73
82
83
85
98
131
139
147
155
163
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Colour
State Description
Example
White
Off
Fully Closed Position
Grey
On
Midway Position
Black
Black
Flashing
Abnormal Condition
Note:
Please use the <?> pushbutton in the navigation area of the screen to see the relevant help
text.
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Colour
State Description
Example
White
Off
Fully Closed Position
Grey
Available
Black
Reset
Red
Flashing
Abnormal Condition
Green
On
Fully Open Position
Blue
Midway Position
Yellow
Unavailable
1. Reset pushbutton
Note:
Please use the <?> pushbutton in the navigation area of the screen to see the relevant help
text.
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Operating Manual
IP23
Three-Phase-Low-Voltage
Squirrel-Cage Machines
GB
Table of Contents
Chapter
1
Safety Instructions
Page
1.1
1.2
1.3
1.4
1.5
1.6
1.7
Important Instructions
2.1
2.2
2.3
2.4
2.5
2.6
Transportation
3.1
3.2
3.3
3.4
4.1
4.2
4.2.1
4.2.2
4.2.2.1
4.2.3
4.2.3.1
4.2.3.2
4.2.3.3
4.2.4
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
4.3.7
Table of Contents
Chapter
Page
Maintenance
5.1
5.2
5.3
5.3.1
5.3.2
5.4
5.5
5.5.1
5.7
Trouble shooting
6.1
6.2
6.3
Repair Instructions
Spare Parts
8.1
8.2
9.1
9.2
9.3
9.3.1
9.3.2
5.5.2
5.5.3
5.5.4
5.6
5.6.1
5.6.2
5.6.3
5.6.4
SM
Safety Instructions
1
Safety Instructions
1.1
General Instructions
1.2
Symbols
In this operating manual 4 symbols are used which must receive special attention:
Safety Instructions
1.3
Safety Regulations
Observe
1.4
Regulations, Standards
When working on the electrical machine observe all valid accident prevention
regulations and generally acknowledged technical rules!
VDE requirements
DIN VDE 0105
1.5
Conditions of Connection
Observe the regulations and conditions of connection laid down by the local electrical supply utility when connecting the electrical machine to the mains supply!
Safety Instructions
1.6
Comply with all instructions located on the electrical machine itself, such as, rotational direction arrows, instruction signs, inscriptions or warning signs, and keep
the same in a readable condition.
1.7
safety regulations,
accident prevention regulations,
guide lines and acknowledged technical rules
(e.g. VDE requirements, DIN standards).
be able to assess the work assigned to them and recognize and avoid possible
dangers.
be authorized by those responsible for the safety of the plant to carry out the required work.
Important Instructions
2
Important Instructions
2.1
Stipulated Usage
This operating manual is valid for ventilated-enclosures electrical machines designed for low-voltage use and of protection type IP 23, in accordance with
EN 60034 - Part V.
In explosive environments only electrical machines which possess a registered
explosion-protection type may be used.
Any other usage which goes above and beyond that stipulated is considered as
non-stipulated usage. Within the terms of his guarantee the manufacturer accepts
no liability for damage resulting from any such usage.
2.2
General Instructions
Use of this operating manual alleviates safe and proper transportation, assembly,
commissioning, maintenance and repair of the electrical machine.
We reserve the right to technical changes made through further development of
the electrical machine dealt with in this operating manual.
Illustrations and drawings presented in this operating manual are simplified portrayals. On account of improvements and changes it is possible that the illustrations do not agree exactly with the electrical machine operated by you. Technical
specifications and dimensions are not binding, and any possible claim cannot be
based thereupon.
We reserve all copyright to this operating manual and the drawings and other
documents contained there in.
negligent maintenance,
improper operation,
faulty installation,
wrong or inexpert connecting of the electrical machine.
which result directly or indirectly either from unilateral changes to the machine
by the user or from non-compliance with the manufacturers recommendations.
which arise from the use of spare parts / accessories not recommended or
supplied by the manufacturer.
Important Instructions
2.3
Installation
2.4
Ventilation
The distance between the air intake and any driven appliances, covers etc., must
be at least 1/4 of the diameter of the air intake aperture. As a rule, air stream flow is
from the drive side to the non-drive side.
The exhausting air stream must not be directly sucked in again. Keep the
air intake and exit apertures free from dirt.
Models with upward-facing shaft ends are to be fitted (to be undertaken by
the customer) with a suitable cover which prevents foreign objects falling
into the ventilation aperture and also protects against water penetration.
Cooling of the electrical machine must not be adversely affected by the
cover.
For pipe-ventilated electrical machines air intake and exit is effected, as a rule, via
a system of pipes. When supplied, the electrical machines correspond to protection type IP 00 (rating plate specification). Protection type IP 54 can be achieved
through suitable modifications to the piping system. In doing this, however, the
pressure drop in the outer circuit must not exceed the permitted values as stated in
the table.
Air-flow rate V and allowable pressure reduction p in the exterior circuit
Shaft
centre
height
Type
3000 [min-1]
V
p
[m3/min] [Pa]
1500 [min-1]
V
p
[m3/min] [Pa]
1000 [min-1]
V
p
[m3/min] [Pa]
750 [min-1]
V
p
[m3/min] [Pa]
180
KN7 180.-
11,0
70
8,0
20
5,5
15
4,5
200
KN7 200.-
12,0
70
9,0
20
6,0
20
5,0
10
225
KN7 225.-
15,0
60
14,0
40
7,0
20
6,5
15
250
KN7 250.-
21,0
90
19,0
40
13,0
30
9,0
20
280
KN7 280.-
23,0
60
26,0
50
17,0
40
13,5
30
315S/M
KN7 315.-
28,0
70
34,0
60
23,0
50
17,0
30
315L
KN7 315L-
34,01)
70
36,0
60
24,0
50
18,0
30
10
315X
KN7 315X-
39,0
80
38,0
70
25,5
50
19,0
30
355
KN7 355.-
50,0
100
51,0
80
34,0
50
25,0
30
Important Instructions
2.5
Electromagnetic Compatibility
2.6
Electrical machines with shaft heights of 180, 200, 250, 280 and 315 each have
only one housing length.
On the non-drive side the securing feet each have 2 drilled holes.
Secure the electrical machine in accordance with the model-size abbreviations, S,
M or M, L or L, X, which are cast into the base plate.
SM
or
M L
or
L X
Diag.2: Feet anchoring holes S,M or M,L or L,X
10
Transportation
3
Transportation
3.1
Safety Instructions
When raising and transporting the machine observe the applicable
accident prevention regulations and any generally acknowledged
technical rules!
DIN standards
DIN 15003
DIN 7540
DIN 82101
3.2
Lifting Eyes
Only suspend electrical machines from the lifting eyes provided.
Do not attach any additional load to the electrical machine; the lifting eyes
are only designed to take the weight of the electrical machine.
Other supplementary lifting eyes which may possibly be available, e.g. on
fan hoods, cooler fittings etc., are only suitable for the lifting of the respective individual parts.
3.3
Electrical machines fitted with cylindrical roller bearings are protected against
bearing damage by a transportation securing device.
Remove this device before commissioning and pack the securing hole with
the plug supplied.
Use the transportation securing device again if further transportation is
required.
11
Transportation
Securing procedures for
transportation, examples
2
Clamp fixing:
3
5
Clamp fixing:
3.4
Rod fixing:
Transport Damage
Document any transport damage and immediately inform the transport company,
insurance company and the manufacturer!
12
4.1
Safety Instructions
During assembly and commissioning observe the following:
safety instructions pages 5-7,
important instructions pages 8-10!
Assembly work may only be carried out by qualified personnel who, on
account of their professional training, experience and instruction, have
sufficient knowledge of
safety regulations,
accident prevention regulations,
guide lines and acknowledged technical rules
(e.g. VDE requirements, DIN standards).
The qualified personnel must
be able to assess the work assigned to them and recognize and
avoid possible dangers.
be authorized by those responsible for the safety of the plant to
carry out the required work.
13
Mechanical
4.2.1
Transmission Components
Only use flexible couplings;
rigid couplings require special bearings.
The keys located in the shaft ends are not particularly secured against falling out.
Should a machine with two shaft ends have no drive element fitted on one
of these shaft ends, ensure that the unused key cannot spin off the shaft. If
the machine is of balance type H then the key should be shortened by
half!
When using transmission components which cause radial or axial shaft
loadings (e.g. drive belt wheels, sprockets etc.), take care that the permitted
loading is not exceeded. Refer to the specifications given in our respective
applicable technical list.
Each rotor is dynamically balanced according to its balance type with a full, a half
or no key and, in accordance with ISO 8821, is labelled thus:
F = full key,
H = half key,
N = no key.
Rotors balanced with a full key balance the drive component with open
key groove.
Rotors balanced with a half key balance the drive component in a
ungrooved state.
Balance the drive component in accordance with the type of balance of the rotor. For shorter drive components machine off that part of the key which projects
beyond the drive component and above the surface of the shaft.
Before fitting the drive component onto the shaft remove the anti-corrosion film
on the shaft end with a suitable cleaning agent (e.g. naphtha).
Do not use emery or rub down the shaft to remove the protective film!
14
Lightly grease or oil all seating surfaces and fit the drive element.
In order to protect the roller bearing, the drive element should only
be fitted ( Diags.4 & 5) / dismantled ( Diag.6) with the aid of suitable tools.
If necessary heat (according to
amount of shrinkage needed) the
drive component prior to fitting.
Diag.6: Dismantling.
15
Machine Base
The kind of supporting surface required for the machine base is one which can
ensure machine operation which is shock-free, low in vibration and torsionally
rigid.
Idle Time
Rate of Vibration
up to 500 hrs
0,4 mm/s
0,2 mm/s
16
Should vibration values between the alarm and switch-off values become
apparent, operation of the electrical machine can continue under observation. The possibility of resultant damage to the electrical machine cannot be
excluded. If necessary, inform the manufacturer.
Alignment
Compensate for any differences by inserting plates. Ensure that any residual inaccuracy, in reference to a measured radial
diameter of 200 mm, does not exceed
0.03 mm.
4.2.3.2 Parallel Alignment (Diag.8)
17
In order to protect the electrical machine various accessories may be fitted or attached subject to order, e.g.:
18
Electrical
All work on the electrical machines electrical connections must only be
carried out by electricians (as defined in DIN VDE 0105 and IEC 364)!
4.3.1
Insulating Resistance
Do not touch the connection terminals either during or after measuring.
The terminal connections can carry high voltages! After carrying out
the check earth the terminal connections briefly (5 seconds).
Using a hand generator (max. D.C. voltage = 630V) measure the insulating resistance of each individual phase to earth. Continue measuring until the measured value is constant.
Repeat the measurement. With resistance values of > 0,5 M the electrical machine can be put into operation.
4.3.2
Observe the circuit details given on the rating plate and compare the operating
voltage to the mains voltage.
The permitted fluctuation in mains voltage amounts to 5%. Exceptions are specified on the rating plate.
19
Connection
Connect the connection cables in accordance with the applicable regulations of the local electricity supply utility and in accordance with:
the DIN VDE requirements
the safety regulations
the accident prevention regulations.
Connect mains feeds with care, so that the contact force required for an electrical connection will be maintained over a long period ( table on tightening
torques, terminal layout and special arrangement of securing nuts [see
Illustration]).
If no other precise specifications have been made, the following tightening torques are valid for normal connections of securing screws and nuts used for
electrical connections.
Tightening torques (Nm with a tolerance of 10%)
for thread sizes of
M5
M6
M8
M10
M12
M16
M20
M24
10
15,5
30
52
80
All electrical machines have a connection diagram on the inner side of the
terminal box cover.
The cable feed aperture can be turned by 90 or 180 .
20
Swapping the side-fitted terminal box position from RIGHT to LEFT or vice versa, is
not possible (with the exception of model size 315X and shaft height 355).
4.3.5
Direction of Rotation
Under normal conditions the electrical machines are suitable for operation in both
directions of rotation. Exceptions are indicated on the rating plate with a corresponding directional arrow. For each respective direction of rotation the following
stator connections are given:
U1 - V1 - W1
right (cw)
W1 - V1 - U1
left (ccw)
Check the direction of rotation by quickly switching the electrical machine (which has
been connected in accordance with the regulations) On / Off in its uncoupled state.
When checking the rotary field only the tester may remain in the danger
area of the machine / driven appliance. Switch on the machine and
check the direction of rotation (observe DIN VDE 0105).
Measures
21
Y/D -start
To avoid unpermitted transient current and torque impacts, the cross-over
from Y to may only be effected if the start current of the Y stage has decayed.
During the run-up phase the machine should only be switched off in an
emergency, in order to protect the switchgear and the machine itself.
4.3.7
Connect the built-in semi-conductor temperature sensor to the trigger mechanism in accordance with the circuit diagram.
Any possibly required continuity check of the temperature sensor should only
be carried out using a measuring bridge (max. 5V).
In order to achieve total thermal
protection of the machine, fit a
supplementary thermally-delayed
overload protector ( Bild 10).
Safety fuses alone tend to just protect the mains supply and not the
electrical machine.
+
Diag.10: Protection using over-current
relay,
thermistor protector and
fuse.
22
Maintenance
5
Maintenance
5.1
Safety Instructions
Maintenance work (except for greasing work) is only to be carried out
when the machine is standing idle.
Ensure that the machine is safeguarded against accidental switch-on
and is labelled with a corresponding warning sign.
Observe the safety regulations and accident prevention regulations of
the corresponding manufacturer when using oils and greases, cleaning
agents and spare parts!
Maintenance work on the machines electrical power supply or to the
electrical auxiliary / control supplies may only be carried out by electricians in compliance with DIN VDE 0105.
Ensure that the auxiliary power circuits e.g. space heater etc., are
switched so as not to be live.
23
Maintenance
5.2
Cleaning
Do not wash down the machine with water or other liquids.
In the event of severe dirt deposits dismantle the electrical machine and remove the deposits using suitable cleaning agents (e.g. superheated steam).
During these procedures observe the specifications on page 19 given under 4.3.1 Insulating resistance.
5.3
The operational safety of the electrical machine is dependent upon maintenance of the lubrication schedule.
As a standard feature all electrical machines are supplied with a lubricating
appliance which has a grease volume regulator.
Initial lubrication of the bearing is carried out at our factory. The lubricating
schedule and lubricant volumes are specified on the rating plate.
In the basic model the electrical machines are fitted with a button head
grease nipple, M10 x 1, in accordance with DIN 3404.
24
Maintenance
5.3.1
Grease Nipple
The use of special grease, provided that the special operational circumstances
were known at the time of ordering, can be taken from the rating plate specifications.
For basic model electrical machines the bearing can be re-filled (without cleaning)
using lithium-saponified roller bearing grease K3k in accordance with DIN 51825,
for example, SKF LGMT3, Shell Alvania G3, Esso Beacon 3 etc..
Clean the bearing assemblies thoroughly if changing over to a grade of
grease with a different saponification base. Take care that the roller bearing
grease to be used fulfils the following conditions:
5.3.2
Drop point
Ash content
Water content
approx. 190C
4%
0,3%
Changing over to a grade of grease with a different saponification base requires consultation with the machine manufacturer (specify lubricant plate).
Lubrication
Only carry out lubricating work when the machine is running:
Be careful of moving parts!
Clean the grease nipple and apply the corresponding amount of grease (using
the correct grade of grease) by means of a grease gun. To achieve this weight
the grease gun both before and after use.
25
Maintenance
5.4
without grease
Push on the sealing rings (3) and Vrings (1), e.g. using a screwdriver
whilst simultaneously turning the
shaft ( Diag. 12).
greased
greased
+ 0.5
V-ring type
Diag.11: 1
2
3
4
V-ring
Felt ring
Neoprene sealing ring
Labyrinth ring
Fitting dimensionX
(mm)
V-25 to V-38
9,0
-0,3
V-40 to V-65
11,0
-0,3
V-70 to V-100
13,5
-0,5
V-110 to V-150
15,5
-0,5
26
Maintenance
5.5
5.5.1
Dismantling Procedure for Drive and Non-drive Side Deep Groove Ball
Bearings ( Diag. 13)
(For drive side cylindrical roller bearing, see 5.5.3)
1. Loosen screws (2.1), (2.2), (16.1) and (16.2). Pull off the bearing shields (2)
and (16), together with the bearing seals (1) and (17), taking care not to tilt
them.
Take off the compensation washer (3) only present on electrical machines
AH200.
2. Loosen and pull off the spring clips (4) and (15) only present on electrical
machines AH225. Pull off the collar oilers (5) and (14). (Collar oilers fitted in
electrical machines of the range AH180 + AH200 have holes in the hub section
which can be used for pulling off).
3. Loosen and pull off the securing ring (13).
4. By using a pulling tool and heating the inner ring slightly, remove the deep
groove ball bearings (6) and (12).
Remove the pressure springs (9) only present on electrical machines
AH225.
5. Pull off the inner bearing covers (8) and (10) together with the seals (7) and
(11).
6. The rotor remains in the stator housing.
27
Maintenance
16
14
12
16.1
15
13
11
10
16.2
6
3
SM
1
9
2.1
2.2
SM
28
Maintenance
5.5.2
Assembly Procedure for Drive and Non-drive Side Deep Groove Ball
Bearing ( Diag. 13)
(For drive side cylindrical roller bearing, see 5.5.4)
All securing screws must be fitted with the spring washers provided
(DIN 6796)
1. Clean off the bearing seats with a suitable cleaning agent, check for any damage and measure the shaft with a micrometer after it has cooled (measurement
specifications refer to a temperature of 20C).
2. Remove the old grease from the inner bearing covers (8) and (10), wash them
out using a suitable cleaning agent and allow to dry.
Fill bearing covers (8) and (10) with new grease (note the correct grade of
grease) and push them (along with their seals [7] and [11]) onto the shaft.
Grease and set the pressure springs provided (9) into the drilled holes of the
bearing cover (8).
3. Heat the new bearing in an oil bath (or using inductive means de-magnetize
afterwards) to a temperature of 80-90C .
To ensure proper fitting push the heated bearings (6) and (12) onto their
shaft seating and press them against the shaft shoulder for approx. 10
secs.
After cooling, pack fresh grease into the bearing spaces (note the grade of
grease).
4. Push on the circlip (13) and secure it. Push on the collar oilers (5) and (14).
Push on and tighten up the spring clips provided (4) and (15).
5. Remove the old grease from the bearing cover (2) and (16), wash out using a
suitable cleaning agent and allow to dry. Pack fresh grease into the grease
drain bores and place the compensation washer provided in position on the
bearing shield hub.
6. For easy assembly screw in two studs (A) about 100 mm long into the
threaded holes in the inner bearing cover (8) and (10).
Push on the bearing shields (2) and (16) and screw down tightly using screws
(2.2) and (16.2), together with mounting plate 16.3).
Tighten up screws (2.1) and (16.1) (at this stage the studs (A) must be removed).
7. Fit the bearing seals (1) and (17) as described on page 26.
29
Maintenance
16
14
12
16.1
15
13
11
10
16.2
6
3
SM
1
9
2.1
2.2
SM
30
Maintenance
5.5.3
1. Loosen screws (2.1.1) and pull off the bearing cover (2.1) together with the
bearing seal (1.1).
2. Loosen and pull off the spring clip (4.1) only present on electrical machines
AH225. Pull off the collar oiler (5.1) (on electrical machines AH180 + AH200
the collar oilers have holes in their hub section which can be used for pulling
off).
3. Loosen screws (3.1.1) and pull off the bearing shield (3.1). Press the outer
bearing ring (6.1) out of the bearing shield hub.
4. Using a welding torch quickly heat up the inner bearing ring (6.2) and force off
using, for example, a screwdriver.
5. Pull off the bearing cover (8.1) together with the bearing seal (7.1).
5.5.4
1. Clean off the bearing seats with a suitable cleaning agent. Check for any damage and measure the shaft with a micrometer after it has cooled (measurement
specifications refer to a temperature of 20C).
2. Remove the old grease from the inner bearing cover (8.1), wash it out using a
suitable cleaning agent and allow to dry.
Fill the bearing cover with new grease (note the correct grade of grease) and
push it (complete with bearing seal [7.1]) onto the shaft.
3. Heat the new inner bearing ring (6.2) in an oil bath (or using inductive means de-magnetize afterwards) to a temperature of 80-90C.
To ensure proper fitting push the heated inner bearing ring (6.2) onto its
shaft seating and press it against the shaft shoulder for approx. 10 secs..
Lightly grease inner bearing ring (6.2) after cooling.
4. Wash out the hub of the bearing shield (3.1) using a suitable cleaning agent
and allow to dry.
5. Press a new outer bearing ring (6.1) into the bearing shield hub and fill the
bearing spaces with new grease (note the correct grade of grease).
6. For easy assembly screw in a stud (A) about 100mm long into the threaded
hole located in the bearing cover (8.1). Push on the bearing shield (3.1) and
tighten up using the screws (3.1.1).
31
Maintenance
7. Push on the collar oiler (5.1), push on and tighten up the spring clip (4.1) provided.
8. Remove the old grease from the bearing cover (2.1), wash out the cap using a
suitable cleaning agent, allow it to dry and pack the grease drain holes with
new grease. Push the bearing cover (2.1) onto the shaft and tighten up using
screws (2.1.1) (in doing this remove stud [A]).
9. Fit the bearing seal (1.1) as described on page 26.
16
12
13
14
15
16.1
11
10
16.2
8.1
7.1
6.1
3.1
1.1
4.1
2.1
SM
5.1
6.2
3.1.1
2.1.1
SM
32
Maintenance
5.6
5.6.1
Dismantling Procedure for Drive and Non-drive Side Deep Groove Ball
Bearings ( Diag. 15)
(For drive side cylindrical roller bearing, see 5.6.3)
1. Screw in two threaded rods into the threaded holes in the labyrinth plate (1.1)
and pull the plate away from the shaft end by means of the threaded rods.
Loosen screws (2.1.1/17.1.1) and pull off the bearing covers (2.1/17.1).
2. Loosen the locking screws (shaft nuts), unscrew the shaft nuts (4.1/15.1) using
a hook spanner and pull them off the shaft end.
Pull off the collar oiler (5.1/14.1), taking care not to damage the torque device
(5.1.1/14.1.1) (note fitting position).
Support the rotor at the shaft end! Make sure there is sufficient room to
pull out the bearing shield and bearing!
3. Loosen screws (3.1.1/16.1.1) and pull off the bearing shields (3.1/16.1). Dismantle the rotor supports and pull the bearing shield away from the shaft end.
Carefully lay down the rotor in the stator plates.
4. Using a pulling tool and whilst heating the inner ring slightly, pull off the deep
groove ball bearing (6.2/12.1). Remove the pressure spring (9.1) only on the
non drive side bearing cover (17.1).
5. Pull off the inner bearing covers (8.1/10.1) together with the seal (7.1/11.1).
6. The rotor remains in the stator housing.
33
Maintenance
17.1
16.1
17.1.1
15.1
14.1.1
14.1
12.1
10.1
11.1
16.1.1
9.1
8.1
5.1.1
3.1
4.1
7.1
SM
5.1
2.1
1.1
6.1
3.1.1
2.1.1
SM
34
Maintenance
5.6.2
Assembly Procedure for Drive and Non-drive Side Deep Groove Ball
Bearing ( Diag. 15)
(For drive side cylindrical roller bearing see 5.6.4)
All bearing shield securing screws must be fitted with the spring washers
provided, and bearing cover screws must be fitted with the sealing washers
provided!
1. Clean off the bearing seats with a suitable cleaning agent, check for any damage and after allowing it to cool measure the shaft with a micrometer (measurement specifications refer to a temperature of 20C).
2. Remove the old grease from the inner bearing covers (8.1/10.1), wash them
out using a suitable cleaning agent, allow to dry and then fill them with new
grease (note the correct grade of grease, rating plate). Push the bearing
covers (8.1/10.1) with their seals (7.1/11.1) onto the shaft. Set the pressure
springs provided (greased) into the drilled holes of the inner bearing cover
(10.1).
3. Heat the new bearing, either in an oil bath or using inductive means (de-magnetize afterwards) to a temperature of 80-90C.
To ensure proper fitting push the heated bearings (6.1/12.1) onto their
shaft seatings and press them against the shaft shoulder for approx. 10
secs..
After cooling, pack fresh grease into the bearing spaces (note the grade of
grease).
4. Push on the collar oilers (5.1/14.1). Place in the torque devices (5.1.1/14.1.1)
(Attention! Angled end towards the bearing!). Screw on the shaft nuts (4.1/
15.1), tighten them using a hook spanner and secure the shaft nuts by means
of the locking screws.
5. Remove the old grease from the outer bearing cover (2.1/17.1), wash out using
a suitable cleaning agent, allow to dry and pack fresh grease into the grease
drain bores.
6. For easy assembly screw in two studs (A) about 100 mm long into the
threaded holes in the inner bearing cover (8.1/10.1).
Push on the bearing shields (3.1/16.1) and screw down tightly using screws
(3.1.1/16.1.1) (with spring washers).
Push the outer bearing covers (2.1/17.1) onto the shaft and screw down tightly
using screws (2.1.1/17.1.1) (with sealing washers).
Pack the labyrinth ways in the bearing cover (2.1) with a small amount of
grease.
Heat the labyrinth plate to approx. 60-80C, and push it against the bearing
cover (2.1). Note the gap between the bearing cover (2.1) and the labyrinth
plate (1.1) ( page 26).
35
Maintenance
17.1
16.1
17.1.1
15.1
14.1.1
14.1
12.1
10.1
11.1
16.1.1
9.1
8.1
5.1.1
3.1
4.1
7.1
SM
5.1
2.1
1.1
6.1
3.1.1
2.1.1
SM
36
Maintenance
5.6.3
1. Screw in two threaded rods into the threaded holes in the labyrinth plate (1.1)
and pull the plate away from the shaft end with the threaded rods. Loosen
screws (2.1.1/17.1.1) and pull off the bearing covers (2.1/17.1).
2. Loosen the locking screws (shaft nuts), undo the shaft nuts (4.1/15.1) using a
hook spanner and pull them off the shaft end.
Pull off the collar oiler (5.1/14.1), taking care not to damage the torque device
(5.1.1/14.1.1) (note fitting position).
Support the rotor at the shaft end! Make sure there is sufficient room to
pull out the bearing shield and bearing!
3. Loosen screws (3.1.1/16.1.1) and pull off the bearing shields (3.1/16.1). Dismantle the rotor supports and pull the bearing shield away from the shaft end.
Carefully lay down the rotor in the stator plates!
4. Pull the outer ring of the cylindrical roller bearing (6.2), together with the bearing shield (3.1), from the inner bearing ring (6.3) and then press it out of the
bearing shield (3.1). Heat the inner ring of the cylindrical roller bearing and pull
it off the rotor shaft. After heating the inner ring slightly, pull off the deep groove
ball bearing (12.1) using a pulling tool.
5. Pull off the inner bearing covers (8.1/10.1) together with the seals (7.1/11.1).
6. The rotor remains in the stator housing.
37
Maintenance
17.1
16.1
17.1.1
15.1
14.1.1
14.1
12.1
10.1
11.1
16.1.1
9.1
8.1
5.1.1
3.1
4.1
6.2
7.1
SM
5.1
2.1
1.1
6.3
3.1.1
2.1.1
SM
38
Maintenance
5.6.4
1. Clean off the bearing seats with a suitable cleaning agent, check for any damage and after the shaft has cooled measure it with a micrometer (measurement
specifications refer to a temperature of 20C).
2. Remove the old grease from the inner bearing covers (8.1/10.1), wash them
out using a suitable cleaning agent, allow to dry and then fill them with new
grease (note the correct grade of grease, rating plate). Push the bearing
covers (8.1/10.1), together with their seals (7.1/11.1), onto the shaft.
3. Heat the new inner bearing ring (6.3) and deep groove ball bearing (12.1) either in an oil bath or using inductive means (de-magnetize afterwards) to a
temperature of 80-90C.
To ensure proper fitting push the heated inner bearing ring (6.3) and
deep groove ball bearing (12.1) onto their shaft seatings and press
them against the shaft shoulder for approx. 10 secs..
After cooling lightly grease inner bearing ring (6.3).
4. Clean the hubs of the bearing shields (3.1/16.1).
5. Push on the collar oiler (14.1). Place in the torque device (14.1.1) (Attention!
Angled end towards the bearing!). Screw on the shaft nut (15.1), tighten it using
a hook spanner and secure the shaft nut with locking screws.
6. For easy assembly screw in two studs (A) about 100 mm long into the
threaded holes in the inner bearing cover (10.1).
Push on the bearing shield (16.1) and screw down tightly using screws (16.1.1)
(with spring washers).
7. Remove the old grease from the outer bearing cover (17.1), wash out with a
suitable cleaning agent, allow to dry and pack the grease drain bores with
fresh grease. Push the outer bearing cover (17.1) into the centring of the bearing shield and screw down tightly using screws (17.1.1) (with sealing washers).
8. Press the new outer bearing ring (6.2) into the bearing shield hub (3.1) and
pack the bearing spaces with fresh grease (note correct grade of grease,
rating plate).
9. Screw two studs (A) about 100 mm long into the inner bearing cover (8.1)
and push the inner bearing cover to the inner bearing ring. Push the bearing
shield (3.1) and outer ring (6.2) over the rotor shaft and studs onto the inner
ring, whilst simultaneously raising the rotor shaft.
39
Maintenance
The rotor shaft should only be raised so far as to allow the bearing
shield (with outer ring) and the inner ring of the roller bearing to be
pushed on without tilting.
Tighten screws (3.1.1).
10. Push on the collar oiler (5.1). Place in the torque device (5.1.1) (Attention! Angled end towards the bearing!). Screw on the shaft nut (4.1), tighten it using a
hook spanner and secure the shaft nut with locking screws.
11. Push the outer bearing cover (2.1) onto the shaft and screw down tightly using
screws (2.1.1) (with sealing washers).
Pack the labyrinth channel with a small amount of grease, heat the labyrinth
plate to approx. 60-80C, and push it against the bearing cover (2.1). Note the
gap between the bearing cover (2.1) and the labyrinth plate (1.1) ( page 26).
17.1
16.1
17.1.1
15.1
14.1.1
14.1
12.1
10.1
11.1
16.1.1
9.1
8.1
5.1.1
3.1
4.1
6.2
7.1
SM
5.1
2.1
1.1
6.3
3.1.1
2.1.1
SM
40
Maintenance
5.7
COMPONENT
DAILY
Bearing
Heat
exchangerAirwa
ys
WEEKLY
EVERY 3
MONTHS
ANNUALLY(minor
overhaul)
For lubrication
deadlines see
rating plate
Check
EVERY 5 YEARS
(major overhaul)
- bearing change,
check shaft seals,
replace if
necessary;- remove
old grease;
Clean
Clean
Terminal
boxEarth
Stator winding
Measure insulating
resistance
Driven
appliance
(Observe the
manufacturers
specifications)
Check alignment
and that the
machine is secure
Auxiliary
monitoring
connections
Record
measurement
data
Check function
Check function
Motor as a
whole
Pay attention
to operating
noise and
quiet running
Re-tighten screws
Dismantle rotor;
check that the rotor
plates, fan and stator
plates are firmly
seated; Check that
rotor bars are not
broken; Clean
41
Trouble shooting
6
Trouble shooting
6.1
Safety Instructions
42
Trouble shooting
6.2
Malfunctions - Electrical
l l
l
l
l l l
l
l
l l
l
l l l l
l l l l
l
l
l
l
l
l
POSSIBLE CAUSES OF
MALFUNCTION
REMEDIAL MEASURES
Overload
Reduce load
43
Trouble shooting
6.3
Malfunctions - Mechanical
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l l
*
44
POSSIBLE CAUSES OF
MALFUNCTION
REMEDIAL MEASURES
Faulty alignment
Noisy gearbox
Bearing dirty
Insufficient lubrication
Bearing corroded
Renew bearing *
Renew bearing *
Repair Instructions
7
Repair Instructions
Only carry out repair work when the machine is standing idle.
Ensure that the machine cannot be accidentally switched on and that it
has been labelled with a corresponding warning sign.
Repair work may only be carried out by qualified personnel who, because of their professional training, experience and instruction, possess a comprehensive knowledge of
safety regulations,
accident prevention regulations,
guidelines and acknowledged technical rules
(e.g. VDE requirements, DIN standards).
Repair work carried out within the warranty period requires the prior agreement of the electrical machine manufacturer.
When winding damage occurs it is possible that the air guide plate (1) could be
partially or totally destroyed.
When replacing a winding take care that
the new winding specification corresponds to the original. If necessary, fit a
new air guide plate in the prescribed
manner.
SM
45
Spare Parts
8
Spare Parts
8.1
Order Details
When ordering spare parts be sure to specify the electrical machine type,
electrical machine number ( rating plate) and the exact description of the
parts (part numbers if applicable).
When replacing bearings, in addition to the bearing type, please note also
the engraved symbol for the bearing designation (can be read off from the
bearing when fitted, e.g. C3 or C4)!
8.2
Bearing shield DS
Grease nipple
Compensation washer
Collar oiler DS
10
11
12
Fan cover
13
Air baffle
13a
Securing clamp
14
15
Key
16
17
Fan
18
19
Sealing cover
20
21
22
23
46
Spare Parts
24
Collar oiler NS
25
26
Bearing shield NS
27
28
29
8
6
3
2
17
5
4
16
1
15
14
13
11
12
10
19
27
26
13a
23
24
25
22
21
SM
20
18
11
29
3
28
47
9.1
Storage Site
Store the machine (complete with its transportation packing) in a dry place which can
be heated and which is free from shock, and protect it from mechanical damage.
After long periods of standing (more than 1 year) check the bearings for
corrosion damage. Even the smallest amount of corrosion damage can reduce the bearings serviceable life.
9.2
If the electrical machine is fitted with cylindrical roller bearings, fix the rotor by
means of a suitable transportation securing device (for protection against scoring
of the rotor by shock see chapter 3.3).
If the electrical machines are despatched on vibration dampers, then they should
not be removed during the period of standing.
If drive sprockets, couplings etc. are already assembled onto the shaft ends, then
fit the transportation securing devices where possible or place the machine onto
vibration dampers.
9.3
9.3.1
Bearings
After long periods of standing (> 1 year) check the bearings. For dismantling and
assembly of the bearings pages 27 40.
Even the smallest amount of corrosion damage considerably reduces the
bearings serviceable life. If bearing change is not necessary, re-grease the
bearing.
48
9.3.2
Insulating Resistance
All work on the electrical machines electrical connections may only be
carried out by electricians (as defined in DIN VDE 0105 and IEC 364)!
Do not touch the connection terminals either during or after measurement. The connection terminals can carry high-voltages! After checking, earth the connection terminals for a short time (5 seconds).
Using a hand generator (max. DC voltage = 630V), measure the insulating resistance of each individual phase to earth continuously until the measured
value is constant.
Repeat the measurement. With resistance values of > 0.5 M the electrical
machine can be put into operation.
49
50
930940099UK
ACOUSTIC ENCLOSURE
Revision: 1
Page:
1 of (9)
Prepared by:
LHR
Latest revision: LHR
Date:
Date:
94.11.08
07.02.22
IMPORTANT:
Avoid loading the top of the acoustic enclosure with more than 100 kg at any
point.
Temperature inside the acoustic enclosure is not to exceed 40C during operation.
Prior to mounting of the acoustic enclosure, the components shall be kept indoor
to prevent water damage (rain, dew).
Having completed the assembly, the adhesive labels, included in the delivery, and
showing the necessity of using hearing protection as well as warning of automatic
start, shall immediately be pasted to the side panels (on the outside).
The mounted acoustic enclosure shall be connected to earth.
0.
Pre-assembly Instructions
Check that no components listed on the bill of delivery are missing and that all components are
undamaged.
First the compressor is erected and fixed to the base plate/floor, after which it is carefully
aligned in relation to the discharge pipe and the inlet channel (if any).
To ensure correct cabling, the electric cables and cooling water pipe(s) (if any) are mounted
after erection of the acoustic enclosure.
Silicone spray (L289), with which to grease sealing strips, is included in the delivery.
930940099UK
ACOUSTIC ENCLOSURE
Revision: 1
Page:
2 of (9)
An assembly drawing and seven A-4 drawings (No. 1, 2, 3, 4, 5, 6, 7) are delivered with the
Mounting Instructions for the plant in question.
A thin plastic film protects the surface of the components against damage during transport and
mounting. Therefore, remove this film as late as possible during the assembly. When the film
has been removed the parts must be treated with the utmost care to avoid damage to the
surface.
All item numbers of the Mounting Instructions, e.g. L232, are shown on the above-mentioned
drawings and the bill of delivery.
1.
2.
3.
Having laid out the profiles, weight them down with available heavy objects to avoid
dislocation during drilling of the 10 mm holes for Simplex expansion bolts (L275). The
holes are drilled 55mm and 65 mm, respectively, down in the base plate through the holes in
the floor profiles and the slide rail.
With a view to possible later adjustment, be careful to drill in the centre of the slide rail holes,
as reinforcement iron in the concrete may cause problems when positioning.
4.
930940099UK
ACOUSTIC ENCLOSURE
Revision: 1
Page:
3 of (9)
5.
6.
Even small openings in the joints will considerably reduce the damping effect of the
acoustic enclosure.
Now place sufficient number of washers (L277) on each expansion bolt (L275), so that the
profiles are raised approx. 9 mm above floor level.
Exactitude of alignment: 1 mm from theoretical horizontal level.
7.
8.
When placing top profiles follow Assembly Drawing closely; Put them up and fasten them to
posts with screws (L270) and washers (L278). The side top profiles are placed under the gable
top profiles. Fasten the 4 panels (L246, L247, L248, L249) in the gable next to the compressor
inlet. The gable panels (L246, L247, L248, L249) are held together by 4 screws (L271). There
are pop nuts in panels L246 and L247.
9.
10.
Now tighten up on nuts for expansion bolts (L275), and check that all posts are erect (vertical),
and that the angles are correct. Any slants and off-centres shall be corrected.
11.
As a safety measure all panels are shipped without mounted handles (L287). The handles are
fixed to the panels with UNBRACO screw M6 x 20 (L288). All panels are delivered prepared
for handles to be mounted.
930940099UK
ACOUSTIC ENCLOSURE
Revision: 1
Page:
4 of (9)
12.
13.
14.
Sealing of the connection between the inlet silencer and the acoustic enclosure is made with
Ikalon sealing strip (L282) 30 x 50 mm.
15.
See Assembly Drawing and Drawing No. 3 for Mounting of Baffle Plate and Motor Panel
The baffle plates (L262, L263) are mounted inside the acoustic enclosure on the wall panels
(L232, L233) with screw and washer (L271, L276) in the pop nuts already mounted in the
panel.
After thorough cleaning with degreasing agent, place the sealing strips as follows:
-
U-rail (L260)
Slide rail L259)
Upper motor panel (L257)
Lower motor panel (L258)
930940099UK
ACOUSTIC ENCLOSURE
Revision: 1
Page:
5 of (9)
Tilt lower motor panel (L258) and lower into floor rail (L259), then raise into vertical position
around motor's ventilation hood.
Place upper motor panel (L257) over motor's ventilation hood.
Press the 2 U-rails (L260) firmly into each side of the motor panel (L257/L258).
16.
17.
18.
19.
20.
930940099UK
Revision: 1
Page:
6 of (9)
ACOUSTIC ENCLOSURE
930940099UK
Revision: 1
Page:
7 of (9)
ACOUSTIC ENCLOSURE
930940099UK
Revision: 1
Page:
8 of (9)
ACOUSTIC ENCLOSURE
930940099UK
Revision: 1
Page:
9 of (9)
ACOUSTIC ENCLOSURE
Accessories
Coupling
Blow off Valve
Actuator for Blow off Valve
Check Valve
Actuators for Diffuser
Lube Oil Filter
Lube Oil Cooler
Air Filter Bags
Thermostats
Pressostat
Thermometer
Manometer
Surge Detector
Compensator
Cone Diffuser
Silencer for Blow of valve
Noise hood Fan
Thomas Rexnord
Wouter Witzel
Bernard
Cast Flow
Framo Unipush
FBO
Oiltech
Camfil
Danfoss
Danfoss
Sika
Wika
Siemens
Bredan
Siemens
Siemens
EMB Papst
SERIES 52 Couplings
Installation Instruction
(Metric Version)
Warning: All rotating power transmission products are potentially dangerous and must be
properly guarded in compliance with OSHA standards for the speed and applications for which
they are intended. It is the responsibility of the user to provide proper guarding.
Figure 1
89301E232a
05/01
within .001 inch per inch of the axial length between flex
elements.
NOTE:
If the driver or driven equipment alignment
specification is tighter than these recommendations, the
specification should be used. Also, be sure to
compensate for thermal movement in the equipment.
The coupling is capable of approximately six times the
above shaft misalignment tolerances. However, close
Figure 3
NOTE:
L=2N+Center Member Length.
C. Angular Alignment. Rigidly mount a dial
indicator on one hub or shaft, reading the face of
the other hub flange, as shown in Figure 2.
Rotate both shafts together making sure the
shaft axial spacing remains constant. Adjust the
equipment by shimming and/or moving so that
the indicator reading is within .001 inch per inch
of coupling flange diameter.
05/01
Coupling
Size
mm
94
110
138
144
168
198
221
246
267
287
327
367
406
464
503
546
584
635
Dimension "N"
Mini.
mm
6,9
7,4
9,4
9,4
12,2
13,0
13,7
15,2
16,0
18,5
20,1
23,4
25,1
30,5
32,0
33,8
36,1
38,4
Maxi.
mm
7,1
7,6
9,7
9,7
12,4
13,2
14,0
15,5
16,3
19,1
20,6
23,9
25,7
31,2
32,8
34,5
36,8
39,4
Axial
Capacity
Thread
Size
mm
0,9
0,9
0,9
0,9
1,1
1,3
1,4
1,6
1,7
1,8
2,1
2,3
2,6
2,9
3,2
3,5
3,7
4,0
Torque
Nm
18
18
34
34
41
54
129
176
237
271
353
475
454
576
759
1003
1288
2440
Alignment
Total Indicator
Reading
Angular
Parallel
mm
mm
0,10
0,10
0,13
0,15
0,18
0,20
0,23
0,25
0,28
0,30
0,33
0,36
0,41
0,46
0,51
0,56
0,58
0,64
Setscrew
89301E232a
125
M6x1
162
M6x1
200
M8x1
225
M8x1
262
M10x1
312
M11x1
350
M12x1,25
375
M14x1,5
425
M16x1,5
450
M18x1,5
500
M20x1,5
550
M22x1,5
Locknut Setscrew
600
M25x2
700
750
Thread
Torque
800
size
Nm
850
925
3/8-16
17
NOTE:
1. These torque values are approximate for steel bolts with lubricated threads. Modification will be necessary for stainless
steel. For stainless steel the tightening torque must be reduced to 60% of the values shown. BoIt and locknut threads
must also be liberally coated with molybdenum disulfide grease.
2. Bolts should be held from rotating while the Iocknuts are torqued to the values shown.
05/01
Table 2
Part Numbers and Quantity Required
Size
of
SR 52
Hub
Part
No.
128790
034406
234407
434408
Center Spool
One per Cplg.
Part
Dim.
No.
C
125
328791
4
162
634420
5
200
734421
5
225
834422
5
934422
7
262
634409
034423
5
134423
7
312
834410
234424
5
334424
7
350
034411
434425
6
534425
7
375
234412
634426
7
425
434413
734427
7
450
634414
834428
7
934428
8
500
834415
034429
9
550
034416
134430
10
600
234417
234431
10
700
434418
003125
11
750
663126
003131
11
800
850
925
Disc Pack
Two per Cplg.
TomStainaloy
less
Part
Part
No.
No.
910618
310618
710663
310663
210665
710665
210984
610984
Part
Qty.
Part
No.
No.
212706 16 916087
212706 24 916087
712610 32 116008
712610 32 116088
010985
210985
014762
32
010957
210957
017142
810952
010952
410943
810986
210987
420735
110962
710959
Not
available
Washer
Bolt
Locknut
Qty.
Qty
8
12
16
16
Part
No.
916504
916504
316505
316505
316089
16
716506
16
32
516090
16
116507
16
019099
32
716091
16
516508
16
610943
010986
410987
019101
019102
516100
32
32
32
916092
116093
316094
16
16
16
916509
316510
716511
16
16
16
620735
310962
910959
420803
921021
220851
020793
020958
711460
311750
612127
511413
111803
911800
611402
812176
32
32
32
32
32
32
32
32
516095
716096
916097
116098
316099
616200
816201
016202
16
16
16
16
16
16
16
16
116512
516514
020253*
020254*
020255*
020256*
020257*
913898
16
16
16
16
16
16
16
16
8
12
16
16
89301E232a
TEL: + 49 (0)231/82 94 - 0
FAX: + 49 (0)231/82 94 250
05/01
Modles / Models : OA, OAP, AS, ASP, BS, SRA, SRC, ASM
Gamme
Range
SD
SOMMAIRE
PAGE
1. SECURITE
2. MONTAGE
14
TABLE OF CONTENTS
PAGE
INTERNAL WIRING DIAGRAMS AND EXAMPLES OF POWER SUPPLY CIRCUITS
1. SAFETY INFORMATION
2. ASSEMBLY
10
10
11
12
13
14
1. SECURITE
Cet appareil rpond aux normes de scurit en vigueur. Toutefois, seule une
installation, une maintenance et une utilisation effectues par un personnel
qualifi et form permettront d'assurer un niveau de scurit adquat.
ATTENTION
Pour les servomoteurs antidflagrants, veuillez aussi lire
attentivement les instructions spcifiques TMS1132 avant de procder
au montage et au dmarrage.
Avant montage et dmarrage, lire attentivement l'ensemble de ce document.
2. MONTAGE
Le servomoteur doit tre boulonn sur lappareil motoriser.
Les servomoteurs BERNARD peuvent fonctionner dans nimporte quelle
position. Cependant, les presse-toupes ne devraient par tre orients vers
le haut (tanchit) et le moteur de prfrence pas plac en position basse
(condensation d'eau interne potentielle).
Note 1 : ne pas transporter les servomoteurs par le volant sous peine
dendommager le couple roue et vis.
Note 2 : si le servomoteur a t fourni mont sur la vanne, les rglages de
base ont en principe t effectus ; se reporter alors aux seuls 3,4 et 9.
Note 3 : voir .9 pour les prcautions de stockage avant mise en route.
3. COMMANDE MANUELLE ET DEBRAYAGE
Dans le cas gnral, le volant ne tourne pas pendant les manoeuvres
lectriques. Si le volant tourne, il est alors plein et exempt de parties
saillantes et ne prsente aucun risque pour l'oprateur.
De plus, pour les servomoteurs couple lev, le dispositif de limiteur d'effort
assure une protection complmentaire.
Modles OA :
Ils sont quips dune commande manuelle dbrayable manuellement.
Pour passer en mode manuel, il faut tourner le volant tout en tirant dessus
afin de lengager mcaniquement.
Le dbrayage du volant seffectue en le repoussant en bute vers le carter.
Modles AS100/AS200/AS400/SRA/SRC/ASM :
Ils disposent dune commande manuelle dbrayage automatique priorit
lectrique.
Pour passer en mode manuel, aligner la flche de la poigne dembrayage
avec le repre triangulaire situ sur le carter (il peut tre ncessaire de
tourner le volant de quelques degrs pour dgager les crabots).
Le retour en mode lectrique seffectue automatiquement au dmarrage du
moteur, ou bien manuellement si on le dsire.
AS100/AS200/AS400/SRA/SRC/ASM
Modles ASP/AS50/AS80 :
Certains de ces modles sont quips d'un levier de dbrayage du moteur
mont sur un tage de rduction intermdiaire.
En fin de manoeuvre manuelle, ne pas oublier de rembrayer le moteur.
Sinon, celui-ci tournera vide jusqu' l'activation de la protection thermique.
Si cet incident se rpte, un risque de dtrioration du moteur existe.
4. RACCORDEMENT ET TESTS LECTRIQUES
Si le servomoteur est quip d'une commande type INTEGRAL, MINIGAM
ou MINIGRAL, veuillez vous reporter aux documentations spcifiques.
Sinon, tous les fils lectriques venant des diffrents lments du
servomoteur sont ramens sur un bornier dont les bornes portent des
numros correspondant aux schmas de cblage inclus dans ce document.
Le contact de protection thermique du moteur et les deux contacts du limiteur
Charge maxi
admissible Ohm
150
750
1050
SHELL
MOBIL
ESSO
ALVANIA EP2
MOBILUX EP2
BEACON EP2
Stockage
Un servomoteur est compos dlments lectriques et dune partie mcanique lubrifie la graisse. Malgr
ltanchit de cet ensemble, les risques doxydation, de gommage et de grippage peuvent apparatre lors de
la mise en service du servomoteur, si son stockage na pas t correctement ralis.
Servomoteur stock en magasin
a) Les servomoteurs doivent tre stocks sous abri, dans un endroit propre et sec, et protg des
changements successifs de temprature. Eviter le stockage mme le sol.
b) Pour les servomoteurs quips de rsistance de chauffage, alimenter celle-ci dans le cas de prsence
dhumidit (tension standard 230 Volts, sauf prcision particulire la commande).
c) Vrifier que les bouchons plastiques provisoires des entres de cble soient bien en place. Sassurer de
la bonne tanchit des couvercles et des botiers renfermant les lments lectriques.
d) Dans le cas de vanne dont la leve de tige est importante, vrifier que le capot de protection est bien
mont sur le servomoteur. Sinon, monter celui-ci avec une pte joint.
Servomoteur install mais en attente de raccordement lectrique
Si une longue attente est prvue entre le montage du servomoteur et les travaux de raccordement lectrique:
a) Sassurer de la bonne tanchit des presses-toupe et des botiers lectriques,
b) Recouvrir la motorisation dun film plastique,
c) Pour les servomoteurs quips de rsistance de chauffage, alimenter celle-ci dans le cas de prsence
dhumidit (tension standard 230 Volts, sauf prcision particulire la commande).
Stockage des servomoteurs quips de composants lectroniques
Le stockage de long dure de composants lectroniques hors tension peut entraner des risques de mauvais
fonctionnement. Il est donc fortement dconseill de le pratiquer.
Dans les cas contraire, il y a lieu de faire rviser en usine les cartes lectroniques avant mise en service.
Contrle aprs stockage
a) Contrler visuellement lquipement lectrique,
b) Actionner manuellement contacts, boutons, slecteurs, ... pour en vrifier le bon fonctionnement
mcanique,
c) Procder quelques manoeuvres manuelles,
d) Vrifier la bonne consistance de la graisse,
e) Pour les servomoteurs quips de graisseurs, faire un apport de graisse neuve,
f) Procder la mise en service du servomoteur suivant les instructions jointes chaque appareil.
Moteur / Motor
Contact limiteur d'effort
ouverture /
Torque limit switch opening
Rsistance de chauffage /
Heating resistance
Fin de course fermeture /
Travel limit switch closing
2 fils / wires
12-32 VCC/VDC
2 ou 3 fils /
2 or 3 wires
3 PHASES
1 PHASE
EEx e d
Connection
version non pr-cble (*) / not valid for prewired versions (*)
Lgende : C1 = contacteur ouverture ; C2 = contacteur fermeture
Legend : C1 = opening contactor ; C2 = closing contactor
Relais thermique /
Thermal relay
Relais thermique /
Thermal relay
Note :
En monophas : le condensateur est
livr sparment /
In single phase, the capacitor is
supplied separately
Exemple 1 - Arrt en position ouverture et fermeture sur contact fin de course avec limiteur d'effort en scurit
avec rarmement. Schma valable pour toute la gamme SD sauf OA monophass pr-cbls (voir exemple 2).
Pour les servomoteurs modle OA, non quips de limiteurs d'effort : partie A du schma seulement./
Example 1 - Stop on travel limit switch on closing and opening directions, torque limit switch in safety action with
manual reset. Diagram valid for the entire SD range excepted the pre-wired one phase OA model (cf. example 2).
For OA actuators, not equipped with torque limit switch : side A of the diagram only.
A
Acquittement dfaut
d faut limiteur d'effort /
Torque limit default acknoledgement
E1
Lgende / Legend
E2
E1
E2
C1
C2
C3
FCO
FCF
LEO
LEF
LT
TR
B1
B2
TR
Arrtt / Stop
Arr
C3
Servomoteur /
Actuator
10
13
FCO
12
FCF
11
15
B1
Ouvert /
Open
C1
LEO
14
B2
E1
E2
C1
C2
C3
FCO
FCF
LEO
LEF
LT
TR
B1
B2
LEF
9
C2
C3
C3
C2
C1
Ferm /
Ferm
C1 Closed
C2
: Sectionneur + fusible
: Relais thermique
: Contacteur OUVERTURE
: Contacteur FERMETURE
: Contacteur DEFAUT
: Fin de course OUVERTURE
: Fin de course FERMETURE
: Limiteur d'effort OUVERTURE
: Limiteur d'effort FERMETURE
: Protection thermique moteur
: Transformateur
: Bouton poussoir OUVERTURE
: Bouton poussoir FERMETURE
Defaut /
Default
C3
Exemple 2 - Servomoteurs OA monophass pr-cbls - Arrt en position ouverture et fermeture sur fin de course /
Example 2 - Pre-wired one phase OA actuators - Stop on travel limit switch on both opening and closing directions
CABLAGE SERVOMOTEUR / ACTUATOR WIRING
Condensateur / Capacitor
10
11
12
ouvert / open
1
2
3
ferm / closed
Alimentation monophase /
Single phase power supply
OUVERT / OPEN
Contacts fin de course /
Travel limit switches
FERME / CLOSED
OUVERT / OPEN
FERME / CLOSED
Rsistance de chauffage /
Heating resistance
1. SAFETY INFORMATION
This device complies to current applicable safety standards.
Installation, maintenance and use of this apparatus will have to be done by
skilled and trained staff only.
Please read carefully the whole document prior to mounting and starting-up.
WARNING
For explosionproof actuators, please also read carefully the special
instructions TMS1132 prior to mounting and starting-up
2. ASSEMBLY
Actuator should be secured directly to the valve using proper bolts or via a
proper interface.
After assembly, the actuator can operate in any position. However, cable
glands should not be oriented upwards (loss of water tightness) and the
motor will preferably not be positioned at the bottom (potential internal
condensation trap)
Note 1 : do not handle the actuator by handwheel, it could damage the
gearworm.
Note 2 : if the actuator was delivered mounted on the valve, the basic settings
should have been done. In this case, refer to 3,4 and 9 only.
Note 3 : see .9 for details on storage precaution prior to starting-up.
3. HANDWHEEL OPERATION AND DECLUTCHING
In general, the handwheel does not turn during electrical operation. Even if
turning, the solid handwheel does not have any protruding part and therefore
does not present any risk of any kind for the operator. Moreover, for the
actuators with the highest torque, the torque limit system brings an additional
level of protection.
OA models :
These actuators are equipped with a manually declutchable handwheel.
To operate manually the actuator, turn while pulling the handwheel in order to
mechanically engage it.
To declutch the handwheel, just push it back towards the actuator body.
AS100/AS200/AS400/SRA/SRC/ASM models :
These actuators are provided with an automatic declutching handwheel, with
motor drive priority. In order to operate manually the actuator, turn the arrow
of the handwheel clutch button in front of the triangular sign on the housing
(it might be necessary to turn the handwheel by a few degrees to release the
claws). When the motor starts, it returns automatically into declutched
position.
AS100/AS200/AS400/SRA/SRC/ASM
OAP/OA15/ASP/AS50/AS80 models :
Some of these actuators are equipped with declutchable intermediate gears.
By moving the clutch lever, the motor is physically disengaged from the
gears. Once the manual handwheel operation has been completed, do not
forget to clutch the motor back. Otherwise, once started-up, it would run and
heat up until the motor thermal protection switch closes. If repeated, these
conditions can generate a motor breakdown .
4. ELECTRICAL CONNECTIONS AND PRELIMINARY TESTS
If the actuator is equipped with INTEGRAL, MINIGRAL or MINIGAM
commands, please report to the specific documentation for wiring details.
Otherwise, all components of the actuator are wired to a common terminal
strip. Remove the cover and pass the cables through the cable glands (M20).
Refer to the wiring diagram for details on the terminals numbering system.
Both torque and travel limit switches must be integrated into your control
10
11
12
SHELL
MOBIL
ESSO
ALVANIA EP2
MOBILUX EP2
BEACON EP2
Storage
The actuators includes electric equipment as well as grease lubricated gear stages. In spite of the
weatherproof enclosure, oxydising, jamming and other alterations are possible if actuator is not correctly
stored.
Actuators stored in a stock room
a) The actuators should be stored under a shelter, in a clean and dry place and protected from wide
temperature variations. Avoid placing the actuators directly on the floor.
b) For actuators equipped with an heating resistance, it is recommended to connect and power supply it
especially if the storage area is humid (standard 230 VAC, unless other specification).
c) Check that the temporary sealing plugs of the cable entries are well in place. Make sure that the covers
and the boxes are well closed to ensure weatherproof sealing.
d) In the case of a valve with rising stem having a long stroke, verify that the protection tube is well mounted
on the actuator. If not, fix it with sealing paste.
Actuators installed but waiting for electrical connection
If a long period of time is expected between the actuator mounting and the electrical wiring works :
a) Visually check the tightness of electrical box cover and cable glands.
b) Cover the device with a plastic protective film.
c) For actuators equipped with an heating resistance, it is recommended to connect and power supply it
especially if the storage area is humid (standard 230 VAC, unless other specification).
Storage of actuators equipped with electronic components:
Long term storage of electronic components which are not in service increases the malfunction risk. This
practice is therefore highly unadvisable.
If a long term storage is absolutely necessary, we strongly recommend a revision of the electronic boards in
our factory before actuator usage.
Control after storage :
a) Visually check the electric equipment,
b) Operate manually the microswitches, buttons, selectors, etc., to insure the correct mechanical function,
c) Operate apparatus manually,
d) Verify the correct grease consistency,
e) For actuators equipped with grease nipple, remember to complete with some fresh grease.
13
AUSTRALIA
fcx@fcxaustralia.com.au
AUSTRIA
hammermueller@IPU.co.at
BELGIUM
MALAYSIA
tcmeng@pc.jaring.my
MIDDLE-EAST
bernact@emirates.net.ae
BERNARD BENELUX SA
1190 BRUXELLES
Tel : +32 2 34 34 122
Fax : +32 2 34 72 843
BRAZIL
JCN
Av. Mutinga, 3188 - Pirituba
CEP 05110-000 Sao Paulo SP
Tel : +55 11 39 02 26 00
Fax : +55 11 39 02 40 18
jcn@jcn.com.br
CHINA
office@tadella.com
www.tadella.com
CZECH REPUBLIC
brno@fluidbohemia.cz
DENMARK
jh@armatec.dk
www.armatec.dk
FINLAND
info@soffco.fi
www.soffco.fi
GERMANY
bernard@deufra.de
www.deufra.de
GREECE
yanpap@acci.gr
HUNGARY
apagyi@elender.hu
INDIA
mail@ilpgt.com
ITALY
info.servomotori@bernard-italia.com
JAPAN
yoshiro.shimizu@pechiney.com
L. BERNARD
TADELLA LIMITED
B701, Hong-an mansion,
188 Chanoei Street, Dongcheng District,
BEIJING - CHINE 100010
Tel : +86 10 6517 0601 / 0602
Fax : +86 10 6517 0603
FLUIDTECHNIK BOHEMIA s.r.o.
Olomoucka 87
627 00 Brno
Tel : +420 548 213 233-5
Fax : +420 548 213 238
ARMATEC A/S
Mjolnersvej 4-8
DK 2600 Glostrup
Tel : +45 46 96 00 00
Fax : +45 46 96 00 01
THE NETHERLANDS
bernard.benelux@12move.nl
NORWAY
jer@fagerberg.no
www.fagerberg.no
POLAND
matzanke@pol.pl
PORTUGAL
import.export@pinhol.com.pt
SINGAPORE
acesin@singnet.com.sg
OY SOFFCO AB
Karapellontie 11
FIN-02610 ESPOO
Tel : +358 9 54 04 620
Fax : +358 9 54 04 6250
SOUTH-EAST ASIA
DEUFRA GMBH
Kasinostrasse 22
53840 TROISDORF
Tel : +49 22 41 98 340
Fax : +49 22 41 98 34 44
SPAIN
PI&MS
3 Pendelis Str. Pallini
153 51 Athnes - Hellas
Tel : +30 210 66 69 129
Fax : +30 210 66 69 130
SWEDEN
SWITZERLAND
INSTRUMENTATION LTD
Kanjikode West 678623
PALGHAT-KERALA
Tel : +91 491 56 61 27 / 56 61 28
Fax : +91 491 56 61 35 / 56 62 40
TURKEY
BERNARD SERVOMOTORI
Via Giuseppe di Vittorio 1
20017 MAZZO DI RHO (MI)
Tel : +39 02 93 90 60 22
Fax : +39 02 93 90 42 46
BERNARD JAPAN
c/o Pechiney Japan
29 Fl. Shinjuku Mitsui Bldg
2-1-1 Nishi Shinjuku, Shinjuku-ku, Tokyo
163-0429 JAPAN
Tel : +81 3 33 49 66 39
Fax : +81 3 33 49 67 50
HUMAN INFRASTRUCTURE TECH.
3 Fl. SungWon Building
813-1 Bangbae-Dong, Seocho-Gu
SEOUL 137-832
Tel : +82 2 532 2604
Fax : +82 2 3478 7089
pinvidic@ksc7.th.com
bernardservo@wanadoo.es
peter.fredriksson@fagerberg.se
www.fagerberg.se
info@matokem.com
www.matokem.com
cimtek@superonline.com
UNITED-KINGDOM
enquiries@zoedale.co.uk
www.zoedale.co.uk
USA
bernard.sales@bernardcontrols.com
www.bernardcontrols.com
BERNARD BENELUX NV
Sophialaan 5
3542 AR UTRECHT
Tel : +31 30 24 14 700
Fax : +31 30 24 13 949
FAGERBERG NORGE a.s
Pancoveien 28
1522 GRESSVIK
Tel : +47 69 35 55 30
Fax : +47 69 35 55 31
MARCO
Ul. Ksiezycowa 1
01-934 WARSZAWA
Tel : +48 22 864 94 21
Fax : +48 22 864 94 22
PINHOL, GOMES & GOMES LDA.
Caminho dos Confeiteiros, 41 - 41 A
Portela de Carnaxide
2790-051 Carnaxide
Tl : +351 21 425 68 50
Fax : +351 21 425 68 59
ACTUATION &CONTROLS ENG. (ASIA)
Block 2 Bukit Batok Street 24
N07-19 Skytech
SINGAPOUR 659480
Tel : +65 65 654 227
Fax : +65 65 650 224
BERNARD SOUTH-EAST ASIA
Liaison office Thailand
Bangkok 10110 Thailand
Tel : +66 1 814 57 30
Fax : +66 2 255 26 38
BERNARD SERVOMOTORES
C/ Valentin Beato, 11 - 1D
28037 MADRID
Tel : +34 91 30 41 139
Fax : +34 91 32 73 442
G. FAGERBERG AB
Postbox 12105
40241 GOETEBORG
Tel : +46 31 69 37 00
Fax : +46 31 69 38 00
MATOKEM AG
Binningerstrasse 86
CH - 4123 ALLSCHWIL
Tel : +41 61 483 15 40
Fax : +41 61 483 15 42
CIMTEK A.S.
Genclik Caddesi N9 Isiklar Binasi
TANDOGAN
06570 - ANKARA
Tel : +90 312 232 67 00
Fax : +90 312 232 53 64
EMIRATES HOLDINGS
P.O. Box 984
ABU DHABI
Tel : +97 12 644 73 73
Fax : +97 12 644 40 66
ZOEDALE Plc
Stannard Way / Priory Business Park
BEDFORD MK44 3WG
Tel : +44 12 83 28 32
Fax : +44 12 83 28 00
BERNARD CONTROLS Inc
15740 Park Row, Suite 100
HOUSTON - TEXAS 77084
Tel : +1 281 578 66 66
Fax : +1 281 578 27 97
14
TAM
Transmetteur de position
Position Transmitter
MINIGAM - MINIGRAL +
Commande lectronique monophas
One phase actuator electronic controls
INTEGRAL +
Commande lectronique
Electronic controls
Systmes bielle
Lever systems
ST Intelli+
Servomoteurs multi-tours intelligents
Multi-turn intelligent actuators
Catalogue n 114
Rgulation / Modulating
Prcision & usage intensif
High duty & precision
Catalogue n 103
FQ
Scurit positive retour par ressort
Failsafe spring-return actuators
Catalogue n 105
L. BERNARD
13
D8-20-113e/01.06
Mini 0
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14
*
The * marked dimensions specify the drive length, of a standard drive (that means stroke length 100mm and
transmission ratio 1-stage or 1:1). For longer stroke length and/or gear stages please add the corresponding
dimensions x and y from the table below.
Gear
x
Stroke length
y
100
0
150
50
Fixing version C
Fixing version D, E, F
*
*
Fixing version G
*
D8-20-114e1/11.06
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15
Dimensions options
Brake or
Encoder
Potentiometer
*
Brake and Potentiometer
D8-20-115e/01.06
*
Subject to technical changes
Framo Morat GmbH & Co. KG
Hchst 7 D-79871 Eisenbach
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16
deep
Adjustment ring
D8-20-116e/01.06
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17
Dimensions DC-version
Standard version: AC, stroke 100 mm, transmission ratio 1-stage or 1:1, fixing version A
DC fixing version A
DC fixing version C
DC fixing version D, E, F
D8-20-117e/01.06
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18
Motor
power
Duty cycle
min-1
1200
1200
1200
1200
1200
1200
1200
1200
1200
1200
1200
1200
kW
0,030
0,030
0,030
0,030
0,030
0,030
0,030
0,015
0,015
0,015
0,015
0,015
%
15
15
15
15
15
15
15
30-40
30-40
50-60
50-60
50-60
Motor
speed
Motor
power
Duty cycle
min-1
1600
2000
2000
2100
2300
2500
2600
2600
2600
kW
0,055
0,055
0,055
0,055
0,055
0,055
0,055
0,055
0,055
%
25
25
25
25
50
50
50
50
50
Planetary
gear
stages
1:1
1:1
1:1
1-st.
1-st.
1-st.
2-st.
2-st.
2-st.
3-st.
3-st.
3-st.
Trapezoidal
thread
Stroke
speed
mm
10x6 So
10x3 Sd
10x2 Sd
10x6 So
10x3 Sd
10x2 Sd
10x6 So
10x3 Sd
10x2 Sd
10x6 So
10x3 Sd
10x2 Sd
mm/s
120*
60*
40*
30*
15
10
8
4
2,7
2
1
0,7
Trapezoidal
thread
Stroke
speed
mm
10x6 So
10x3 Sd
10x2 Sd
10x6 So
10x3 Sd
10x2 Sd
10x6 So
10x3 Sd
10x2 Sd
mm/s
40*
25*
16*
14*
7,5
5,5
4,5
2,2
1,5
110
155
175
450
600
600
1000
1000
1000
1000
1000
1000
110
155
175
450
600
600
1000
1000
1000
1000
1000
1000
250
300
110
155
175
450
600
600
600
600
600
600
600
600
DC 24 V DC
Planetary
gear
stages
1-st.
1-st.
1-st.
2-st.
2-st.
2-st.
3-st.
3-st.
3-st.
450
600
600
900
1000
1000
1000
1000
1000
450
600
600
900
1000
1000
1000
1000
1000
250
300
450
600
600
600
600
600
600
600
600
D8-20-118e/01.06
* Brake requested.
Duty cycle applies to 10 min. duty time.
For tensile loading applies the maximum stroke force of the particular stroke speed.
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19
20
19
31
22
16
10
15
14
21
13
30
33
Item
1
2
4
7
9
10
13
14
15
16
17
19
20
21
22
Part name
Article-No.
Stator ..................................................................................................................Serial-No.
Rotor cpl..............................................................................................................Serial-No.
Grooved ball bearing ..........................................................................................00300100600383
Limit switch ........................................................................................................ 02450100000700
Terminal board cpl...............................................................................................Serial-No.
Pressure spring .................................................................................................. 8-2000-01.02
Connection head ................................................................................................ Serial-No.
Pressure disc ..................................................................................................... Serial-No.
Switch jack 1 with quadring and limit switch ...................................................... 8-2000-02.01N
Switch jack 2 with limit switch ............................................................................ 8-2000-03.00
Spindle cpl...........................................................................................................Serial-No.
Felt ring .............................................................................................................. 8-2001-01.12
Gear cover ......................................................................................................... Serial-No.
Bearing plate with quadring ................................................................................8-2000-01.12N
Spindlenut, piston tube .......................................................................................Serial-No.
30
31
33
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D8-20-119e/01.06
33
20
40
Potentiometer
50
Encoder
60
70
Part name
Article-No.
40
50
60
70
D8-20-120e/01.06
Item
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21
80
82
83
84
Part name
Article-No.
DC field .............................................................................................................. Serial-Nr.
DC armature .......................................................................................................8-2000-21.00
Bronze-carbon ....................................................................................................8-2000-10.05
Brush holder ....................................................................................................... 8-2000-10.03
Jack .................................................................................................................... 8-2000-10.04
D8-20-121e/01.06
Item
80
81
82
83
84
81
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D8-20-107e/01.06
Operating
Manual
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Before working on electrical lines, ensure that the electricity supply is disrupted and
secured against unintended turn-on.
Connect the actuator only to a circuit with working protective ground wire.
It is imperative to read the respective electrical connection diagrams.
Do not touch the actuator during operation, it can reach temperatures of up to 90C, failure
to abide may result in burns.
D8-20-108e1/11.06
Do not use the actuator in dangerously explosive areas. Our actuators are certified according to
directive 94 / 9 / EG (ATEX 95) and have the following symbols (optional):
EEx II 3D,
bck II T5
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D8-20-109e/01.06
Piston rod blocking through excessive stroke force or permanent stop forcing can damage the
actuator!
10
D8-20-110e/01.06
To minimize additional dangers, observe the usual care for technical products.
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11
D8-20-111e/01.06
6.2 If you would like to dispose of the actuator, you have to find an environmentaly friendly way and
abide by all legal regulations.
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55
D8-20-155e/01.06
Connection
diagrams
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56
D8-20-156e/04.06
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57
D8-20-157e/04.06
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58
01, 1, 2
D8-20-158e1/11.06
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59
01, 1, 2, 3
D8-20-159e1/11.06
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D8-20-101e/01.06
Technical
Description
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D8-20-102e/01.06
Framo Mini actuators with a rolled acme lead screw are predominantly dynamically self-locking.
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D8-20-103e/01.06
The conditions of actuator use prohibit the movement of loads whereby persons can be directly or
indirectly endangered.
The application of actuators in equipment intended to transport passengers is not permitted without first
consulting the manufacturer (or responsible representative).
In this context we refer to EU Machinery Directive 98 / 37 / EC and the Act on Technical Equipment
(Equipment Safety Act) where the user is responsible for the implementation of "protective
guards/barriers" to prevent touching (crushing hazard) during operation.
This also applies for the application of actuators with suspended loads where persons can be
endangered.
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16. Options
The following options allow individual applications:
1. Force-dependent shut-off (as protection for block movement or if a preset stroke force is exceeded)
2. Cushioned connecting head (e.g. approaching a permanent stop)
3. Adjustable connection head (for small changes to the attachment position)
4. Adjusting ring on piston rod (for simple retracting position adjustment)
5. Brake (for precise switch-off and non-self-locking actuators)
6. Mounting angles in combination with fixing version D (attachment bolts)
7. Integrated helical potentiometer (for travel monitoring and/or position control)
8. Rotary pulse encoder (for digital pulse processing for position and speed control)
9. Different fixing possibilities (installation conditions can be taken into account)
10. Humidification seal coating of rotor and stator and/or condensation hole (if there is danger of condensation).
11. Explosion proof according to directive 94 / 9 / EG (ATEX 95)
D8-20-104e/01.06
12. Connection cable motor and/or helical potentiometer shielded (for frequency converter operation etc.)
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Housing
Front cover
Switching jack
'Extended' position
Switching jack
'Retracting' position
Piston rod
System advantages:
No continuous contact of limit switch and piston rod
Improved insulation and more stability, no switching grooves
End of stroke damping through installed spring
Better control of the piston rod
Grub screws
D8-20-105e/01.06
Adjusting ring
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LAC
With AC motor adapted for industrial use
Installation and servicing manual
SE
GB
DE
FR
ES
Komponentfrteckning, Tillval/Tillbehr
Inledning ........................................................................................................................... 1
Skerhetsfreskrifter ......................................................................................................... 2
Beskrivning ....................................................................................................................... 4
Installation ......................................................................................................................... 5
Handhavande .................................................................................................................... 7
Frebyggande underhll ................................................................................................... 8
Underhll ........................................................................................................................... 9
Tekniska data .................................................................................................................. 11
Frskran om verensstmmelse ................................................................................... 12
Part list, Options/Accessories
Introduction ..................................................................................................................... 13
Safety instructions ........................................................................................................... 14
Description ...................................................................................................................... 16
Installation ....................................................................................................................... 17
Handling .......................................................................................................................... 19
Preventive maintenance ................................................................................................. 20
Maintenance ................................................................................................................... 21
Technical specification .................................................................................................... 23
Declaration of conformity ................................................................................................ 24
Komponentenverzeichnis, Sonderzubehr/Zubehr
Einleitung ........................................................................................................................ 25
Sicherheitsvorschriften .................................................................................................... 26
Beschreibung .................................................................................................................. 28
Installation ....................................................................................................................... 29
Bedienung ....................................................................................................................... 31
Vorbeugende Wartung .................................................................................................... 32
Wartung ........................................................................................................................... 33
Technische Daten ........................................................................................................... 35
bereinstimmungserklrung ........................................................................................... 36
Liste des composants, quipements en option/Accessoires
Introduction ..................................................................................................................... 37
Consignes de scurit .................................................................................................... 38
Description ...................................................................................................................... 40
Installation ....................................................................................................................... 41
Consignes demploi ......................................................................................................... 43
Entretien prventif ........................................................................................................... 44
Entretien .......................................................................................................................... 45
Caractristiques techniques ............................................................................................ 47
Dclaration de conformit ............................................................................................... 48
Lista de componentes, Equipamientos opcionales/Accesorios
Introduccin .................................................................................................................... 49
Instrucciones de seguridad ............................................................................................. 50
Descripcin ..................................................................................................................... 52
Instalacin ....................................................................................................................... 53
Modo de empleo ............................................................................................................. 55
Mantenimiento preventivo ............................................................................................... 56
Mantenimiento ................................................................................................................ 57
Caractersticas tcnicas .................................................................................................. 59
Declaracin de conformidad ........................................................................................... 60
C
Komponentfrteckning
A
B
C
D
E
F
G
H
I
*
Kylelement
Pluggar och gummistlbrickor
Ftter
Flkthus
Flktenhet*
Motorfste
Flktgaller
Elmotor
Flktenhet med ytterrotormotor
Utfrandet, fast eller lst nav, varierar med
kylarmodell.
A
B
C
D
E
F
G
H
I
*
Cooler matrix
Plugs and rubber steel washers
Support
Fan housing
Fan unit*
Motor attachment
Fan guard
Electric motor
Fan unit with outer rotor motor
The design, fixed or loose hub, is depending on
type of cooler.
A
B
C
D
E
F
G
H
I
*
Khlelement
Stopfen und Gummistahlscheiben
Fe
Lftergehuse
Lftereinheit*
Motorhalterung
Schutzgitter
Elektromotor
Lftereinheit mit Auenrotormotor
Die Ausfhrung mit starrer oder loser Nabe hngt
vom Khlermodell ab.
Part list
A
B
C
D
E
F
G
H
I
*
Komponentenverzeichnis
Radiateur
Bouchons et joints lvres
Pieds
Caisson ventilateur
Hlice complte*
Support moteur
Grille ventilateur
Moto-ventilateur
Unit ventilateur avec moteur rotor externe
La conception, moyeu fixe ou non fixe, varie
suivant le modle dchangeur.
Lista de componentes
A
B
C
D
E
F
G
H
I
*
Radiador
Tapn ciego con junta metalbuna
Patas
Caja del ventilador
Ventilador completo*
Suporte del motor
Rejilla de proteccin
Motor elctrico
Unidad compacta moto-ventilador
El asiento del ventilador, fijo o desmontable,
depender del tipo de intercambiador.
D
E
Tillval
A
B
C
D
E
*
Stenskydd
Dammskydd
S-Bypass, enpassage*
T-Bypass, tvpassage*
Termokontakt
Kan fs som tryckstyrd eller temperatur- och
tryckstyrd bypass.
Tillbehr
F
G
Lyftglor
Vibrationsdmpare
quipements en option
Options
A
B
C
D
E
*
Stone guard
Dust guard
S by-pass, single-pass
T by-pass, two-pass
Thermo contact
Pressure controlled or temperature and pressure
controlled by-pass valves are available.
A
B
C
D
E
*
Accessories
F
G
Lifting eye
Vibration dampener
Accessoires
F
G
Anneaux de levage
Patins antivibratoires
A
B
C
D
E
*
F
G
Cncamos de elevacin
Silent blocs
Sonderzubehr
A
B
C
D
E
*
Steinschutz
Staubschutz
S-Bypass, Einzeldurchlauf*
T-Bypass, Doppeldurchlauf*
Thermoschalter
Mit Drucksteuerung oder Temperatur- und
Drucksteuerung lieferbar.
Equipamientos opcionales
Zubehr
F
G
Hebesen
Vibrationsdmpfer
Grille de protection
Filtre antipoussire
Bypass type S, modle 1 passe*
Bypass type T, modle 2 passes*
Thermocontact
Disponible comme bypass command par
pression ou par temprature et pression.
Accesorios
2
A
3
A
A
A
4
B
C
D
A
B
A
D
3
Bl
Blue
Blau
Bleu
Azul
4
Gul/grn
Yellow/green
Gelb/grn
Jaune/vert
Amarillo/verde
Svart
Black
Schwarz
Noir
Negro
Brun
Brown
Braun
Marron
Maron
U1 = Svart
Black
Schwarz
Noir
Negro
U2 = Grn
Green
Grn
Vert
Verde
V1 = Bl
Blue
Blau
Bleu
Azul
V2 = Vit
White
Wei
Blanc
Blanco
W1 = Brun
Brown
Braun
Marron
Maron
W2 = Gul
Yellow
Gelb
Jaune
Amarillo
U1 = Svart
Black
Schwarz
Noir
Negro
U2 = Grn
Green
Grn
Vert
Verde
V1 = Bl
Blue
Blau
Bleu
Azul
V2 = Vit
White
Wei
Blanc
Blanco
W1 = Brun
Brown
Braun
Marron
Maron
W2 = Gul
Yellow
Gelb
Jaune
Amarillo
1)
2)
3)
4)
Y-koppling (3x400 V)
Y-connection (3x400 V)
Y-Anschluss (3x400 V)
Connexion en Y (3x400 V)
Conexin en Y (3x400 V)
D-koppling (3x230 V)
D-connection (3x230 V)
D-Anschluss (3x230 V)
Connexion en D (3x230 V)
Conexin en D (3x230 V)
10
11
12
Y-koppling
Y-connection
Y-Anschluss
Connexion en Y
Conexin en Y
D-koppling
D-connection
D-Anschluss
Connexion en D
Conexin en D
13
14
15
16
17
Introduction
The purpose of this manual is to serve as
a reference guide for installation,
maintenance and operation of the LAC
series of air oil coolers.
Keep the manual at hand. A lost manual
should be replaced as soon as possible.
For optimum performance and in order
to prevent incorrect use, please read this
manual carefully and observe all safety
precautions prior to putting the air oil
cooler into service.
Installation and maintenance work
should only be carried out by qualified
personnel. Oiltech/Olaer reserve the
right to make technical alternations
without notice.
Use
The LAC-series of air oil coolers is
designed to cool hydraulic fluids in
systems for industrial applications.
13
Safety instructions
The installation contractor as well as the
user should be aware of, understand and
observe all safety precautions in this
manual, including any information
mentioned on labels fixed to the product.
Important
This alerts you to an action or
procedure that, if performed
improperly, is likely to result in
damages to the product, process or
environment.
Additional information is marked as
follows.
Note!
Overall instructions
Lifting
Caution
Risk of bodily injury. To prevent
physical harm when lifting the unit,
ensure correct lifting technique.
Make sure that all lifting devices are
free from damage and approved for
the weight of the air oil cooler.
Installation
Precaution
This alerts you to an action or
procedure that, if performed
improperly, is likely to cause an
accident with physical harm.
Danger
Electrical shock hazard. All
electrical connections must be
made by a qualified electrician!
14
Important!
Static electricity. Fans generate static
electricity. Do not put sensitive
devices (electronics etc.) in the
immediate vicinity of the air oil cooler.
Antistatic fans are available on
request.
Caution
Risk of bodily injury. Before
disconnecting the hydraulic
connections, make sure the system
is depressurized.
Note!
Caution
Risk of severe burns. This indicates
danger from high temperature
surfaces. The oil cooler could
become extremely hot during
operation. Always make sure the
cooler is cool before touching.
Warning label
Precaution
Risk of bodily injury. If the air oil
cooler is fitted with a thermo
contact, the fan will start
automatically when the preset
temperature has been reached. Be
careful when standing close to
rotating units.
Precaution
This indicates a toxic hazard. To
prevent bodily injury, damage to
property or environment, used fluid
should be collected and taken to a
special dept.
15
Description
Principally the air oil cooler consists of a
cooler matrix, an AC-motor, a fan, a fan
housing and a fan guard. Depending on
electric motor size, the air oil cooler is
equipped with a motor bracket.
Different motor types are used on the
LAC-series of air oil cooler. Small
cooler fans are fitted with a single phase
or three phase outer-rotor motor. The fan
on larger air oil coolers is fitted with a
standard three phase asynchronous
inner-rotor, which meets the IEC 72 and
EN 60034 requirements.
The electrical motor should be connected
to the electricity supply system
according to instructions. See Electrical
connection. Connect the cooler matrix
to the hydraulic system using hydraulic
hoses.
16
Installation
Lifting
Mounting
Caution
Risk of bodily injury. To prevent
physical harm when lifting the unit,
ensure correct lifting technique.
Make sure that all lifting devices are
free from damage and approved for
the weight of the air oil cooler.
Precaution
Risk of bodily harm. Make sure that
the air oil cooler is securely fixed.
The air oil cooler can be mounted in any
position. However, an upright installation standing on its feet is recommended.
A free space corresponding to a minimum of half the height of the matrix (A)
should be available in front of and
behind the air oil cooler to allow for
good air flow, i.e. optimal cooling
capacity as well as low acoustic power
level. See Figure 3.
17
Electrical connection
Danger
Risk of electrical shock. All
electrical connections must be
made by a qualified electrician!
Prior to connecting the motor to the
electricity supply system, make sure the
information on the motor label
Note!
18
Handling
Prior to initial start-up
During operation
Caution
Risk of severe burns. The air oil
cooler could become extremely hot
during operation. Make sure that
the air oil cooler is cool before
touching.
Prior to start up
Check:
that all air oil cooler parts are free
from damages
that the fan rotates freely (use hand
force)
that all hydraulic connections are
tight
that the inside of the fan housing is
free from objects that could be
thrown around and cause bodily
injury or damage to property.
Note!
At start-up
Check:
that the direction of rotation of the
fan and the air flow corresponds to
indications on the fan housing
that the air oil cooler is free from
abnormal noise and vibrations.
19
Preventive maintenance
Preventive maintenance work must be
carried out at regular intervals.
Make sure:
that there is no abnormal noise or
vibrations
that air oil cooler is securely fixed
that the cooler matrix is clean debris will reduce the cooling
capacity
that the air oil cooler is free from
damage, replace damaged
components
that the air oil cooler is free from
leaks
that warning labels are in good
condition, replace any damaged/
missing label immediately.
Cooler matrix
The air fins of the matrix can be cleaned
by blowing through with compressed air.
If necessary a high-pressure washing
system and degreasing agent can be
used. When using a high-pressure
washing system point the jet parallel to
the air fins. See Figure 11.
Fan housing
Remove the cooler matrix when cleaning
the inside of the fan housing.
To clean the inside of the fan housing,
use compressed air. If necessary a
degreasing agent can be used.
Blow with compressed air from the
electric motor side through the fan
guard.
Cleaning
Danger
Risk of bodily injury. Prior to
cleaning, disconnect all motor
power supplies.
Note!
20
Maintenance
Removing the electric motor
and the fan
1
2
3
4
5
Warning
Risk of severe burns. The air oil
cooler could become extremely hot
during operation. Make sure the air
oil cooler is cool before touching.
Warning
Risk of severe burns. The air oil
cooler could become extremely hot
during operation. Make sure the air
oil cooler is cool before touching.
Warning
Risk of bodily injury. Disconnect the
motor power supply prior to
maintenance.
Warning
Risk of bodily harm. Prior to
maintenance, disconnect the
electric motor power supply.
The fan is balanced together with the
hub at delivery.
Note!
1
2
3
4
4
5
Note!
2
3
4
5
22
Technical specification
For further technical specification, refer to separate Technical data sheet, LAC air oil
cooler.
Cooler matrix
Maximum static working pressure:
21 bar
14 bar
Tested according to ISO/DIS 10771-1
6%
120 C
Fluid compatibility
Mineral oil:
Oil/water emulsion:
Water glycol:
Phosfatester:
Material
Cooler matrix:
Aluminium
Fan housing:
Steel
Fan blades/hub:
Fan guard:
Steel
Other parts:
Steel
Surface treatment:
LAC air oil coolers could have different material and surface treatments.
23
24
Olaer Industry
Olaer Mobile
Olaer Energy
Olaer Special
Olaer Services
The Olaer Group develops, manufactures and markets products and systems in six business areas.
Global perspective
and local entrepreneurial flair
The Olaer Group is a global player specialising in innovative, efficient system solutions for temperature optimisation and
energy storage. The Group develops, manufactures and markets products and systems for a number of different sectors, e.g.
the aircraft, engineering, steel and mining industries, as well as for sectors such as oil and gas, contracting and transport,
farming and forestry, renewable energy, etc. All over the world, our products operate in the most diverse environments and
applications. One constantly repeated demand in the market is for optimal energy storage and temperature optimisation.
We work at a local level with a whole world as our workplace
local entrepreneurial flair and a global perspective go hand in
hand. Our local presence, long experience and a wealth of knowledge combine with our cutting-edge expertise to give you the
best possible conditions for making a professional choice.
THE OLAER GROUP: AUSTRALIA Olaer FCH. Tel: +61 2 9981 6888. AUSTRIA Olaer Austria GmbH. Tel: +43 7229 80306. BELGIUM S.A. Olaer Benelux, Tel: +32 2 466 15 15.
CZECH REPUBLIC Olaer CZ s.r.o. Tel: +42 5 47125 601-8. DENMARK Oiltech DK. Tel: +45 86 69 20 38. FINLAND Oiltech Hydraulics OY. Tel: +358 9 413 755 00.
FRANCE Olaer Industries S.A. Tel: +33 1 41 19 17 00. GERMANY Olaer Industries GmbH. Tel: +49 6842 9204-0. HOLLAND Olaer Nederland B.V. Tel: +31 76 5412453.
NORWAY Oiltech AS. Tel: +47 64 91 11 80. POLAND Oiltech Polska. Tel: +48 22 6738162. SOUTH AFRICA FCH c/o Rolton Products CC. Tel: +27 11 474 3095.
SPAIN Olaer-Oiltech Iberica SAU. Tel: +34 933 368 900. SWEDEN Oiltech AB. Tel: +46 8 636 07 00. SWITZERLAND Olaer (Schweiz) AG. Tel: +41 26 492 70 00.
UK FCH Ltd. Tel: +44 1244 535515. USA Oil Air Hydraulics Inc. Tel: +1 713 937 89 00.
w w w. o i l t e c h . s e
20009201
INDIA FCH India. Tel: +91 802 6533587. ITALY Olaer Italiana S.p.A. Tel: +39 011 991 85 11. KOREA Hyundai Olaer Hydraulic Co. Tel: +82 31 499 0897.
LAC2 011-2-D
Date: 10-02-2009
Your reference: 62008043
Our reference:
Input data:
Hydraulic oil
Oil flow
Max. oil temperature
Air temperature
Altitude
Heat dissipation
Calculated data:
Inlet oil temperature
Outlet oil temperature
Outlet air temperature
Spec. heat dissipation
Oil pressure drop
Air flow
Motor capacity
LpA, 1 m
Protection standard, motor
Weight
Full load current
ISO VG 46
14,0
75
45
0
6,45
73
58
50
0,23
0,052
0,99
1,10
82
IP 55
25
2,5
l/min
C
C
m
kW
C
C
C
kW/C
bar
m/s
kW
dB(A)
kg
A
Information:
This calculation is based upon more parameters than in catalogue.
Subject to technical alterations.
_______________________________________________________________________________________________________________
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hi-flo
Extended Surface Multi-Pocket Air Filters
A 5-star rating indicates that this filter performs in the top 20% of all products of similar
construction in the HVAC industry. Factors of consideration include maintained efficiency, energy usage and resistance to air flow. Detailed evaluation information is
available from your Camfil Farr sales outlet or on the web at www.camfilfarr.com.
Camfil Farr
Product sheet
Hi-Flo
1203 - 0907
Performance
Hi-Flo filters are manufactured from microfine glass
fibers for consistent and long-term high efficiency
performance. They are available in fractional
efficiencies from 40% to 95% on particles as small as
0.3 micron in size. MERV values range from 9 to 14
when evaluated under ASHRAE Standard 52.2-1999.
Configurations for any Application
Camfil Farr Hi-Flos are available in a variety of
configurations to suit your air movement requirements.
Common configurations include from 3 to 12 pockets,
depths of 15" to 36", and up to 129 square feet of
effective media area.
When selecting a Hi-Flo for your system, you should
select a filter with the greatest effective media area
within the airflow parameters and space limitations for
your system. This will ensure a long filter life and a
consistent low resistance to airflow over the life of the
filter. Fewer filter changes will be required, thus
reducing replacement, labor and disposal costs. An
additional benefit includes reduced system horsepower
requirements, thus lowering the facilitys energy
expenditure.
Lowest Life Cycle Cost
All of these components combine for the lowest life
cycle cost, the lowest average pressure drop (energy
savings), and consistent high efficiency particulate
filtration throughout the life of the filter.
Low
Med
High
Low
MERV 14
MERV 13
Med
Med
High Low
MERV 11
MERV 9
High
Media
Area
(sq. ft.)
*/24/24/32/12
12
24 x 24 x 32
2000
2500
3000
*/24/20/32/9
24 x 20 x 32d
1500
1875
2250
*/24/12/32/6
24 x 12 x 32d
1000
1250
1500
*/20/20/32/9
20 x 20 x 32d
1250
1575
1875
81
*/24/24/15/12
12
24 x 24 x 15
1000
1500
2000
58
*/24/20/15/9
24 x 20 x 15
750
1100
1500
*/24/12/15/6
24 x 12 x 15
500
750
1000
*/20/20/15/9
20 x 20 x 15
650
950
1275
37
*/24/24/30/10
10
24 x 24 x 30
2000
2400
2800
101
*/24/20/30/8
24 x 20 x 30
1600
1900
2250
*/24/12/30/5
24 x 12 x 30
1000
1200
1400
*/20/20/30/8
20 x 20 x 30
1350
1625
1875
68
*/24/24/22/10
10
24 x 24 x 22
1500
1750
2000
73
*/24/20/22/8
24 x 20 x 22
1200
1400
1600
*/24/12/22/5
24 x 12 x 22
750
875
1000
36
*/20/20/22/8
20 x 20 x 22
1000
1175
1350
49
*/24/24/36/8
24 x 24 x 36d
2000
2400
2800
97
*/24/20/36/7
24 x 20 x 36d
1600
1900
2250
*/24/12/36/4
24 x 12 x 36d
1000
1200
1400
*/20/20/36/7
20 x 20 x 36d
1350
1625
1875
71
*/24/24/30/8
24 x 24 x 30
1600
2000
2400
81
*/24/20/30/7
24 x 20 x 30
1400
1750
2100
*/24/12/30/4
24 x 12 x 30
800
1000
1200
*/20/20/30/7
20 x 20 x 30
1150
1450
1750
59
*/24/24/22/8
24 x 24 x 22
1500
1750
2000
58
*/24/20/22/7
24 x 20 x 22
1300
1500
1750
*/24/12/22/4
24 x 12 x 22
750
875
1000
*/20/20/22/7
20 x 20 x 22
1100
1300
1450
43
*/24/24/36/6
24 x 24 x 36d
1500
1750
2000
76
*/24/20/36/5
24 x 20 x 36d
1300
1500
1700
*/24/12/36/3
24 x 12 x 36d
750
875
1000
*/20/20/36/5
20 x 20 x 36d
1050
1225
1400
53
*/24/24/30/6
24 x 24 x 30
1500
1750
2000
63
*/24/20/30/5
24 x 20 x 30
1300
1500
1700
*/24/12/30/3
24 x 12 x 30
750
875
1000
*/20/20/30/5
20 x 20 x 30
1050
1225
1400
44
*/24/24/22/6
24 x 24 x 22
1500
1750
2000
45
*/24/20/22/5
24 x 20 x 22
1300
1500
1700
*/24/12/22/3
24 x 12 x 22
750
875
1000
*/20/20/22/5
20 x 20 x 22
1050
1225
1400
HF
HF = Hi-Flo
SF = S-Flo
DATA NOTES:
a
Airflow Capacityb
MV14
Efficiency
129
0.40
0.29
0.54
0.45
0.54
0.46
0.48
0.45
0.47
0.60
0.54
0.49
0.69
0.54
0.69
0.60
0.57
0.54
0.56
0.71
0.72 0.30
0.70 0.20
0.84 0.36
0.64 0.30
0.84 0.36
0.77 0.30
0.68 0.32
0.64 0.29
0.67 0.31
0.85 0.39
0.40
0.34
0.46
0.36
0.46
0.40
0.38
0.35
0.37
0.46
0.29
0.21
0.27
0.18
0.22
0.23
0.20
0.18
0.19
0.22
65
44
29
81
50
58
85
49
70
40
51
29
63
38
52
31
38
23
32
24
24
22
Height
(nominal)
Width
(nominal)
Depth
(nominal)
Number
Of
Pockets
Options
MV14 = MERV 14
MV13 = MERV 13
MV11 = MERV 11
MV 9 = MERV 9
97
1 = UL Class 1
W = 1 1/8 header
Consult factory for
additional options.
Standard Hi-Flo includes 0.88 (1 nominal) header. For 1.12 (1 nominal) header add a W to the end of the model number.
Recommended final resistance is 1.0 w.g. The Hi-Flo may be operated to 1.5 w.g. without affecting performance.
Pocket loops are recommended for 32" & 36" deep filters.
The Hi-Flo is classified by Underwriters Laboratories as UL Class 2. Maximum operating temperature 158 F (70 C).
20 by 24 header size available, consult factory for pricing and availability. System resistance is the same as 24 by 20 listed in above chart.
Performance tolerances conform to Section 7.4 of ARI Standard 850-78.
Hi-Flo
Cambridge-Style Header
SPECIFICATIONS
1.0 General
1.1 - Air filters shall be high efficiency ASHRAE
extended surface pocket style filters consisting of high
loft air laid microfine glass media, a galvanized steel
header, galvanized steel pocket retainers, and
bonding agents to prevent air bypass and ensure leak
free performance.
1.2 - Sizes shall be as noted on drawings or other
supporting materials.
2.0 Construction
2.1 - Filter media shall consist of high-density air laid
lofted microfine glass media that is chemically bonded
to a permeable media support backing forming a lofted
filter blanket.
2.2 - Individual pockets shall contain a minimum of 40
stitching support points per square foot of media area.
All stitching centers shall be sealed through the use of
a foam based sealant that shall remain pliable
throughout the life of the filter. The sides and ends of
each pocket shall be sewn with a chain-link over lock
stitch.
2.3 - Pockets shall be formed into tapered pleats,
supported by controlled media space stitching, to
promote uniform airflow across the surface of the
media. At any point, the sizes of the upstream and
downstream passages shall be proportional to the
volume of filtered air.
http://www.camfilfarr.info
http://www.camfilfarr.com
hi-flo
22 Deep 8-Pocket High Efficiency Bag Filter
Camfil Farr
Technical Data
Hi-Flo 22 Deep
hi-flo
30 Deep 8-Pocket High Efficiency Bag Filter
Camfil Farr
Technical Data
Hi-Flo 30 Deep
Industrial Thermometers
Details of Design
Casings
Aluminum, V-shaped, completely polished, gold-coloured anodized (or silvercoloured upon request). Numerals of
reading scale printed on the right side.
Printing black-colored for easy readability. Adjustable to any desired viewing
position and locked by brass nut, spanner size 22 mm. Angle thermometers (90
degrees) have a grooved adapter piece
with set screw. Advantage: When mounting the thermometer, it is not necessary
to turn the casing.
Capillary Fluid
For standard executions from -60 to
+200 C, blue fluid and red fluid, respectively, for -60 C (code F). For
temperatures of more than +200 C, only
mercury columns (code Hg) are possible. Upon request, thermometers can be
delivered with mercury filling from -30 C
onwards.
Accuracy
About 1 % of maximum scale value,
for thermometers with mercury column.
The accuracy of thermometers with an
alcoholic fluid meets DIN 16 195 requirements and, consequently, corresponds
with the requirements for local reading
thermometers.
SIKA-Thermometers
Casing 110 x 30 mm gold-coloured anodized
DIN 16181 B, B1
DIN 16182 S, S1
Order-Example
174
Thermometer execution
straight
angle 90, backwards
angle 135, backwards
Immersion tube type
Ranges
2 35 1
B
Bdr1)
=
=
-30+50C =
0+60C =
0+100C =
0+120C =
0+160C =
0+200C =
Columns (Filling)
Blue fluid is standard for ranges
up to +200C
Optional: mercury
Thread connection
030
Type
174
175
176
2
6
35
06
10
12
16
20
1
2
F =
Hg =
30
40
63
100
160
250
400
1
2
=
=
=
=
=
=
=
G 3/8A/SW 22
G 1/2A/SW 27
M16 x 1,5/SW 22
M20 x 1,5/SW 27
Type
175 B
030
040
063
100
160
250
400
=
=
=
=
1
2
5
7
1
2
3
4
5
1)
Type
174 B
Bdr: Special execution of angle-type thermometer: After installation, casing can be turned by
360 in any direction. See page 9 for description and illustration.
Type
176 B
Mechanical
Pressure Measurement
Applications
! Intended for adverse service conditions where pulsating
or vibration exists
! Suitable for all gaseous and liquid media that will not
obstruct the pressure system or attack copper alloy
parts
! Mining industry
! Hydraulics
! Shipping industry
Special Features
!
!
!
!
Description
Design
EN 837-1
NS 100:
Nominal size
63 and 100 mm
Scale range
NS 50:
0 ... 1 up to 0 ... 600 bar
NS 63, 80, 100: 0 ... 0,6 up to 0 ... 1000 bar
Or other equivalent units of pressure or vacuum.
Operating temperature
Ambient:
-20 ... +60 C
Medium:
+60 C maximum
Accuracy class
NS 63: 1.6
NS 100:
1.0
Working pressure
NS 63:
Steady:
Fluctuating:
Short time:
Steady:
Fluctuating:
Short time:
Temperature effect
When temperature of the pressure element deviates from
reference temperature (+20 C):
Max. 0.3 %/10 K of true scale value.
Ingress of protection
IP 65 (EN 60 529 / lEC 529)
Pressure connection
Material:
brass forging
NS 63:
G B, 14 mm flats
NS 100:
G B, 22 mm flats
Page 1 of 2
Pressure element
NS 63:
< 60 bar: Cu-alloy, C-type, soft soldered
60 bar: Cu-alloy, helical type, soft soldered
NS 100:
< 100 bar: Cu-alloy, C-type, soft soldered
100 bar: stainless steel 1.4571, helical type, brazed
Movement
Cu-alloy
Case
Solid brass forging with integral entry stem
Pressure relief in case top
Ranges 0 ... 16 bar with case venting provision
Ranges < 0 ... 6 bar fully sealed
Bezel ring
Roll formed stainless steel
Liquid filling
Glycerine 99,7 %
Dial
NS 63:
white plastic, with pointer stop pin
NS 100:
white aluminium
With black lettering
Optional extras
! Other pressure connection
! Internal pressure compensation
! Medium temperature up to 100C with special soft
solder
! 3-hole surface or panel mounting flange
! Triangular bezel with clamp
Pointer
Black aluminium
Window
Non-splintering clear acrylic glass
Dimensions in mm
radial bottom pressure connection
NG
63
100
1034 839
1034 804
1034 812
Dimension in mm
b1
a
b
b2
D1
D2
12
13.5
56
86
62
99
62
99
10.5
11.5
30
G B 54
G B 87
36
53.5
36
53.5
Weight in kg
e1
SW
14
22
0.30
1.10
Standard pressure entry with parallel thread and sealing to EN 837-1 / 7.3
Ordering information
Pressure gauge model / Nominal size / Scale range / Location and size of connection / Optional extras required
Page 2 of 2
9019804 10/2005 GB
Specifications and dimensions given in this leaflet represent the state of engineering at the time of printing.
Modifications may take place and materials specified may be replaced by others without prior notice.
SIEMENS Compressors
Surge Controller SUC-3
Function
Sensor
: Inductive sensor.
Mounting
A:
B:
Blue (MINUS)
White (SIGNAL)
Brown (PLUS)
Inductive sensors
IGC209
IGB3008BAPKG/M/US
Inductive sensor
Metal thread M18 x 1
Plug and socket
Increased sensing range
gold-plated contacts
Sensing range 8 mm [f]
flush mountable
Electrical design
DC PNP
Output
normally closed
Operating voltage
[V]
Current rating
[mA]
Short-circuit protection
Reverse polarity protection
Overload protection
Voltage drop
[V]
Current consumption
[mA]
Real sensing range
Operating distance
Switch-point drift
Hysteresis
Switching frequency
Correction factors
Operating temperature
Protection
EMC
Housing material
Function display
Switching status
[mm]
[mm]
[% of Sr]
[% of Sr]
[Hz]
[C]
10...36 DC
100
pulsed
yes
yes
< 2.5
< 10
8 10 %
0...6.5
-10...10
3...15
400
mild steel = 1 / stainless steel approx. 0.7 / brass approx. 0.5 / Al approx. 0.4 / Cu
approx. 0.3
-25...70
IP 68 *), II
EN 61000-4-2 ESD:
4 kV CD / 8 kV AD
EN 61000-4-3 HF radiated: 10 V/m (80...1000 MHz)
EN 61000-4-4 Burst:
2 kV
EN 61000-4-6 HF conducted: 10 V (0.15...80 MHz)
EN 55011:
class B
housing: brass white bronze coated; active face: ceramics
LED
yellow (4 x 90)
Connection
Remarks
Accessories (included)
Wiring
ifm electronic gmbh Teichstrae 4 45127 Essen We reserve the right to make technical alterations without prior notice. GB IGC209 30.03.2004
930950031.UK
COMPENSATOR
DN100-DN600
Revision: 2
Page:
1 of (1)
Prepared by:
Latest revision:
FP
SJ
Date:
Date:
November 2, 1995
April 7, 2008
Materials
Bellow:
Guide tube:
Flanges:
2,5 bar
180C
Alignement
Reuirements
dz
dx
mm
mm
Compressor
DN
Ln
Di
MIN.
DCD
KA2
125
150
132
250
210
18
15
KA4/5
150
150
148
285
240
22
15
10
KA10
200
150
196
340
295
22
15
12
KA22
250
200
244
395
350
12
22
22
22
KA44
300
200
292
445
400
12
22
22
26
KA66
400
250
390
12
565
515
16
26
22
35
KA80
450
250
440
12
615
565
20
26
22
39
KA100
600
250
588
12
780
725
20
30
22
55
Flange Measures
kg
930910053UK
Revision:
3
Page:
1 of (1)
Prepared by:
Latest revision:
Material
Outside :
Inside :
OUTLET DIFFUSER
CONE - SILENCER
FW
LHR
1991
16.11.1993
Mild steel ANSI 1015, painted according to standard of Siemens Turbomachinery Equipment
A/S.
Mineral wool, covered by glass-fiber fabric and perforated plate.
B-E
Nxd
RxS
kg
KA2
KA2
125-250
125-300
700
850
210
210
250
250
350
400
395
445
26
26
24
24
8 18
8 18
12 22
12 22
55
65
KA4/5
KA4/5
KA4/5
150-250
150-300
150-350
600
800
1100
240
240
240
285
285
285
350
400
460
395
445
505
26
26
28
24
24
24
8 22
8 22
8 22
12 22
12 22
16 22
55
70
90
KA10
KA10
KA10
200-350
200-400
200-500
800
1100
1700
295
295
295
340
340
340
460
515
620
505
565
670
28
32
34
24
24
24
8 22
8 22
8 22
16 22
16 26
20 26
80
110
170
KA22
KA22
250-500
250-600
1400
1900
350
350
395
395
620
725
670
780
34
36
26
26
12 22
12 22
20 26
20 30
160
220
KA44
KA44
300-600
300-700
1700
2000
400
400
445
445
725
840
780
895
36
38
26
26
12 22
12 22
20 30
24 30
210
270
KA66
KA66
KA66
400-700
400-800
400-900
1700
2000
2500
515
515
515
565
565
565
840
950
1050
895
1015
1115
38
42
46
32
32
32
16 26
16 26
16 26
24 30
24 33
28 33
270
340
430
KA80
KA80
450-900
450-1000
2300
2700
565
565
615
615
1050
1160
1115
1230
46
52
34
34
20 26
20 26
28 33
28 36
420
520
KA100
KA100
600-1000
600-1200
2000
3000
725
725
780
780
1160
1380
1230
1455
52
56
36
36
20 30
20 30
28 36
32 39
480
720
Compressor
930910016UK
Revision:
4
Page:
1 (1)
Prepared by:
Latest revision:
Material:
SILENCER FOR
BLOW-OFF VALVE
FW
DRo
Date: 1991
Date: 1998.04.06
Compressor
Dn
N d
kg
KA2
65
390
220
100
145
185
18
4 18
14
KA4
80
440
230
100
160
200
20
8 18
17
KA5
100
490
245
100
180
220
22
8 18
21
KA10
125
580
255
100
210
250
24
8 18
26
KA22
150
670
285
100
240
285
24
8 22
40
KA44
200
860
320
150
295
340
24
8 x 22
70
KA66
250
1040
410
150
350
395
26
12 22
110
KA80
300
1240
445
150
400
445
26
12 22
150
KA100
350
1440
490
150
460
505
28
16 22
220
AC axial fans
S-Range, 500, direction of air flow "V"
- Material: impeller blades made of sheet aluminium
- Direction of rotation: counter-clockwise, seen on rotor
- Type of protection: IP 54 (please note mounting position and drilled condensate
discharges)
- Insulation class: "F"
- Motor protection: TOP brought out
- Product conforming to standard: CE
(1)
subject to alterations
Pa
400
400 Y
400
400 Y
400
400 Y
50
50
50
50
50
50
1330
1020
1360
1110
1330
980
0,83
0,56
0,69
0,49
0,64
0,42
1,65
0,98
1,43
0,86
1,26
0,74
160
100
160
105
180
100
-40..+60
-40..+60
-40..+90
-40..+90
-40..+60
-40..+60
n
P1
[min-1] [kW]
I
[A]
LpA
[dBA]
n
P1
[min-1] [kW]
LpA
[dBA]
1360
0,73
1,49
72
1165
0,44
0,74
68
1350
0,77
1,54
71
1135
0,47
0,79
67
1330
0,83
1,65
72
1110
0,49
0,86
66
1090
0,51
0,89
67
1375
0,50
1,09
71
1060
0,53
0,93
67
1360
0,54
1,13
72
1020
0,56
0,98
66
1330
0,64
1,26
72
1380
0,60
1,30
71
1105
0,37
0,65
66
1370
0,65
1,34
71
1060
0,39
0,69
66
1360
0,69
1,43
70
980
0,42
0,74
65
[Pa]
3
3
3
5
0,6
160
[in H O]
Characteristics
2
22
0,4
120
3
3
3
6
80
1
1
1
1
0,2
4
1
40
1
2
1250
2000
2500
3750
4000
6000
-10
46
I
[A]
5000
8000
-5
[CFM]
[m3/h]
0
kg
kg
kg
kg
11,0
12,8
18,8
13,5
5a)/5b)
11,0
12,8
18,8
13,5
5a)/5b)
8,5
10,3
14,3
11,0
5a)/5b)
Electr. connection
Mass S... A
kW
Mass W...
-10
min-1
Mass S... C
Hz
Mass A...
M4D094-HA
VAC
-5
Max.
current draw(1)
M4D110-GF
Max.
power input(1)
*4D 500
Speed/rpm(1)
M4D110-GF
Frequency
Motor
Nominal voltage
Blade angle
Nominal data
Type
Characteristic
ebm-papst Mulfingen
General information
AC axial
EC axial
Blade angle
Dimensions
S/A/B
"V"
A4D500-AD03 -01
S4D500-CD03 -01
W4D500-GD03 -01
S4D500-AD03 -01
"V"
-5
A4D500-AE03 -01
S4D500-CE03 -01
W4D500-GE03 -01
S4D500-AE03 -01
98 89 182,5 97 143 38 84
"V"
-10
A4D500-AZ14 -01
S4D500-CZ14 -01
W4D500-GZ14 -01
S4D500-AZ14 -01
92 78 186,5 91 147 32 88
ESM
*4D 500
Q-motor
Type
Cable exit
Selection
"V"
EC-SYSTEMS
"V"
Accessories
Cable gland
M20
6,5
Depth of screw
max. 12 mm
View X
Technology
"V"
47
Electr. connection
p. 286 f.
Contacts
"V"
W4D500-DE03-02
Nominal data
Type
W4D500-DE03-02
Motor
M4D110-GF
Phase
Nominal voltage
[V]
Connection
Frequency
[Hz]
3~
3~
3~
3~
3~
3~
400
400
400
400
480
480
50
50
60
60
60
60
ml
ml
ml
ml
ml
ml
CE
CE
CE
CE
CE
CE
1110
1500
1030
1600
1240
Power input
[min-1] 1360
[W]
690
490
1010
575
1100
740
Current draw
[A]
1.43
0.86
1.8
1.05
1.72
1.08
[Pa]
160
105
195
95
215
125
[C]
90
90
65
65
55
55
Air flow
8930
7760
10130
7760
10350
8710
Back pressure
[m3/h]
[Pa]
[dB(A)]
Speed
73
ml = max. load me = max. efficiency rfa = running at free air cs = customer specs cu = customer unit
Subject to alterations
W4D500-DE03-02
Technical features
Size
500 mm
Operation mode
Electrical leads
"A"
Insulation class
"F"
Cable exit
Axial
Bearing-motor
Ball bearing
Mass
21 kg
Material of impeller
Aluminum sheet
Motor protection
CE
Number of blades
Type of protection
IP 54
Protection class
W4D500-DE03-02
Product drawing
209,55
11
517
43
16
6151
120
656-3
W4D500-DE03-02
Connection screen
Delta
Star
L1
PE
L2
U1
V1
U2
V2
L3
TOP
W1
W2
U1
U2
V1
V2
W1
W2
=
=
=
=
=
=
=
BK
GN
BU
WH
BN
YE
GNYE
PE
L1
L2
U1
V1
W1
U2
V2
W2
L3
TOP
U1
U2
V1
V2
W1
W2
=
=
=
=
=
=
=
BK
GN
BU
WH
BN
YE
GNYE
W4D500-DE03-02
[Pa]
[in H O]
160
0,6
140
2
120
0,4
100
80
1
0,2
60
40
20
1250
2500
2000
4000
3750
6000
-10
P1
LwAss
[min-1]
[W]
[A]
[dB(A)]
1390
570
1.23
76
1380
62
1.29
77
1360
690
1.43
80
5000
8000
-5
[CFM]
[m3/h]
0
STCGO(71KA1KG) .............
(KA5SGK200)
Build number:
8043
Inlet Pressure:
0.88400 [bar]
Order Number:
62008043
Inlet Temperature:
308.15 [K]
Order Name:
Nevsehir
Relative Humidity:
60.0 [%]
Testmotor:
SCHORCH
Motor Speed:
2975. [1/min]
KN7315MAB01BZ
.750
240
.700
220
.650
200
08
.600
09
.550
160
.500
140
04
.450
120
05
.400
100
06
02
.350
.300
2000
180
80
00
3000
4000
5000
6000
7000
8000
9000
10000
60
11000
Inlet Pressure:
1.02540 [bar]
ISO5389/VDI2045
Inlet Temperature:
299.81 [K]
Relative Humidity:
3.6 [%]
ISO 51671:1991/Amd.1:1998(E)
Motor Speed:
2968. [1/min]
Accepted by:
HANSE07C
Test day:
18022009
STCGO(71KA1KG) .............
(KA5SGK200)
Build number:
8043
Inlet Pressure:
0.88400 [bar]
Order Number:
62008043
Inlet Temperature:
298.35 [K]
Order Name:
Nevsehir
Relative Humidity:
60.0 [%]
Testmotor:
SCHORCH
Motor Speed:
2975. [1/min]
KN7315MAB01BZ
.840
240
.780
220
.720
200
.660
08
.600
180
09
.540
140
04
.480
120
05
.420
100
06
02
.360
.300
2000
160
80
00
3000
4000
5000
6000
7000
8000
9000
10000
60
11000
Inlet Pressure:
1.02540 [bar]
ISO5389/VDI2045
Inlet Temperature:
299.81 [K]
Relative Humidity:
3.6 [%]
ISO 51671:1991/Amd.1:1998(E)
Motor Speed:
2968. [1/min]
Accepted by:
HANSE07C
Test day:
18022009
STCGO(71KA1KG) .............
(KA5SGK200)
Build number:
8043
Inlet Pressure:
0.88400 [bar]
Order Number:
62008043
Inlet Temperature:
274.15 [K]
Order Name:
Nevsehir
Relative Humidity:
60.0 [%]
Testmotor:
SCHORCH
Motor Speed:
2975. [1/min]
KN7315MAB01BZ
.910
240
.845
220
.780
200
08
.715
09
.650
160
.585
140
04
.520
120
05
.455
06
02
.390
.325
2000
180
100
80
00
3000
4000
5000
6000
7000
8000
9000
10000
60
11000
Inlet Pressure:
1.02540 [bar]
ISO5389/VDI2045
Inlet Temperature:
299.81 [K]
Relative Humidity:
3.6 [%]
ISO 51671:1991/Amd.1:1998(E)
Motor Speed:
2968. [1/min]
Accepted by:
HANSE07C
Test day:
18022009
STCGO(71KA1KG) .............
(KA5SGK200)
Build number:
8044
Inlet Pressure:
0.88400 [bar]
Order Number:
62008043
Inlet Temperature:
308.15 [K]
Order Name:
Nevsehir
Relative Humidity:
60.0 [%]
Testmotor:
SCHORCH
Motor Speed:
2975. [1/min]
KN7315MAB01BZ
.750
240
.700
220
.650
200
09
.600
180
.550
160
.500
140
.450
120
05
.400
.350
.300
2000
04
02
06
08
80
00
3000
4000
5000
100
6000
7000
8000
9000
10000
60
11000
Inlet Pressure:
1.02613 [bar]
ISO5389/VDI2045
Inlet Temperature:
296.66 [K]
Relative Humidity:
4.6 [%]
ISO 51671:1991/Amd.1:1998(E)
Motor Speed:
2969. [1/min]
Accepted by:
HANSE07C
Test day:
17022009
STCGO(71KA1KG) .............
(KA5SGK200)
Build number:
8044
Inlet Pressure:
0.88400 [bar]
Order Number:
62008043
Inlet Temperature:
298.35 [K]
Order Name:
Nevsehir
Relative Humidity:
60.0 [%]
Testmotor:
SCHORCH
Motor Speed:
2975. [1/min]
KN7315MAB01BZ
.825
240
.770
220
.715
200
.660
180
09
.605
160
.550
140
.495
120
.440
05
.330
2000
04
02
.385
06
08
80
00
3000
4000
5000
6000
7000
8000
9000
100
10000
60
11000
Inlet Pressure:
1.02613 [bar]
ISO5389/VDI2045
Inlet Temperature:
296.66 [K]
Relative Humidity:
4.6 [%]
ISO 51671:1991/Amd.1:1998(E)
Motor Speed:
2969. [1/min]
Accepted by:
HANSE07C
Test day:
17022009
STCGO(71KA1KG) .............
(KA5SGK200)
Build number:
8044
Inlet Pressure:
0.88400 [bar]
Order Number:
62008043
Inlet Temperature:
274.15 [K]
Order Name:
Nevsehir
Relative Humidity:
60.0 [%]
Testmotor:
SCHORCH
Motor Speed:
2975. [1/min]
KN7315MAB01BZ
.900
240
.840
220
.780
200
.720
09
180
.660
160
.600
140
.540
120
.480
05
.360
2000
04
02
.420
06
08
80
00
3000
4000
5000
6000
7000
100
8000
9000
10000
60
11000
Inlet Pressure:
1.02613 [bar]
ISO5389/VDI2045
Inlet Temperature:
296.66 [K]
Relative Humidity:
4.6 [%]
ISO 51671:1991/Amd.1:1998(E)
Motor Speed:
2969. [1/min]
Accepted by:
HANSE07C
Test day:
17022009
STCGO(71KA1KG) .............
(KA5SGK200)
Build number:
8045
Inlet Pressure:
0.88400 [bar]
Order Number:
62008043
Inlet Temperature:
308.15 [K]
Order Name:
Nevsehir
Relative Humidity:
60.0 [%]
Testmotor:
SCHORCH
Motor Speed:
2975. [1/min]
KN7315MAB01BZ
.750
220
.700
200
.650
180
.600
160
08
.550
09
140
.500
120
.450
100
.400
80
.300
2000
04
02
.350
05
06
60
00
3000
4000
5000
6000
7000
8000
9000
10000
40
11000
Inlet Pressure:
1.02410 [bar]
ISO5389/VDI2045
Inlet Temperature:
294.10 [K]
Relative Humidity:
4.6 [%]
ISO 51671:1991/Amd.1:1998(E)
Motor Speed:
2971. [1/min]
Accepted by:
HANSE07C
Test day:
17022009
STCGO(71KA1KG) .............
(KA5SGK200)
Build number:
8045
Inlet Pressure:
0.88400 [bar]
Order Number:
62008043
Inlet Temperature:
298.35 [K]
Order Name:
Nevsehir
Relative Humidity:
60.0 [%]
Testmotor:
SCHORCH
Motor Speed:
2975. [1/min]
KN7315MAB01BZ
.840
220
.780
200
.720
180
.660
160
08
.600
140
09
.540
120
.480
100
.420
80
.300
2000
04
02
.360
05
06
60
00
3000
4000
5000
6000
7000
8000
9000
10000
40
11000
Inlet Pressure:
1.02410 [bar]
ISO5389/VDI2045
Inlet Temperature:
294.10 [K]
Relative Humidity:
4.6 [%]
ISO 51671:1991/Amd.1:1998(E)
Motor Speed:
2971. [1/min]
Accepted by:
HANSE07C
Test day:
17022009
STCGO(71KA1KG) .............
(KA5SGK200)
Build number:
8045
Inlet Pressure:
0.88400 [bar]
Order Number:
62008043
Inlet Temperature:
274.15 [K]
Order Name:
Nevsehir
Relative Humidity:
60.0 [%]
Testmotor:
SCHORCH
Motor Speed:
2975. [1/min]
KN7315MAB01BZ
.910
240
.845
220
.780
200
.715
180
08
.650
09
.585
160
140
.520
120
.455
100
.325
2000
04
02
.390
05
06
80
00
3000
4000
5000
6000
7000
8000
9000
10000
60
11000
Inlet Pressure:
1.02410 [bar]
ISO5389/VDI2045
Inlet Temperature:
294.10 [K]
Relative Humidity:
4.6 [%]
ISO 51671:1991/Amd.1:1998(E)
Motor Speed:
2971. [1/min]
Accepted by:
HANSE07C
Test day:
17022009