SN SAFEWELL Safewell Solutions Ltd Document No QCD-6-2015 Project: Safewell Non Atex Breathing Air System for Aircraft Simulator Safewell Job Ref: 2458 INSTALLATION & COMMISSIONING, OPERATION, MAINTENANCE & CERTIFICATION Section Description 1 Overview of Requirements Installation & Commissioning Operation and Maintenance Manuals r + Rotary Screw Air Compressor + ALG10 Breathing Air Purifier 4 Drawings Chassis Plate Layout Drg No 15010550 sheet 4 of 6 Power Circuit Dry No 15010550 sheet 2 of 6 Power Circuit Drg No 15010550 sheot 3 of 6 Emergency Stop Relay Circuit Drg No 15010560 sheet 4 of 6 Control Circuit Drg No 15010550 sheet § of 6 Terminal Description Drg No 15010550 sheet 6 of 6 5 Certification Safewell ALG10 Breathing Air Purifier Safe Air Test Results EC Declaration of Conformity for Machinery ALG10 Breathing Air Purifier Declaration of Conformity Air End Safety Valve Inspection Certificate Receiver Declaration of Conformity Receiver Safety Valve Inspection Certificate COSHH & Material Safety Data Sheets ASL 2000 Oil Ultrasorp OX (CO Removal) Ultrasorp SP (Water Vapour Removal) Ultrasorp AK (Oil Vapour Removal) Rotary Screw Air Compressor Export Warranty Terms 8 Maintenance + Maintenance Operations * Service Log All technical and service enquiries contact www safewellsolutions co uk or call +44(0)1330 826978 Page 1 of 1SAFEWELL Safewell Solutions Ltd Document No QCD-6-2015 Project: Safewell Non Atex Breathing Air System for Aircraft Simulator Safewell Job Ref: 2458 OVERVIEW OF REQUIREMENTS Based on the enquiry received by e-mail on 05.01.2016, inital requirement specifications Brovided by e-mail on 06.01.2016 with several additional clarification e-mails thoreatisy up to date of purchase:- ‘The agreed user requirements summarised as follows: 1 No Electric breathing air compressor required, Available Power Supply is 415V/3PH/S0Hz Breathing Air quality in accordance with EN12021:2014 Oullet Flow Rate = 8 cubic feet per minute (226 litres per minute) Outlet Pressure = 90 PSI (Compressor rated for operation at 8 Barg) 250 L receiver with automatic drain {pstalled in air conditioned plant room, 25 “C maximum Ambient Temperature with 85% relative humidity Safe Area Installation — Non ATEX. Condensate treatment by others. NOOReNa on Fo meet the agreed requirements we have designed and manufactured a fully integrated breathing air system on a skid with forkift pockets supporting a rotary screw air compressor with breathing air purifier as shown in the following images. All technical and service enquiries contact www.safewellsolutions.co.uk or call +44(0)1330 826978 Page 1 ofSS SAFEWELL Safewell Solutions Ltd Document No QCD-6-2015 Project: Safewell Non Atex Breathing Air System for Aircraft Simulator Safewell Job R ‘Safewell ALG10 Breathing Air Purifier The breathing air purification barrier installed on the compressor is the Safewell SAFE - ALG10 purification system which is field proven in 1000's of respiratory protection applications worldwide. The unit was designed by Safewell and is manufactured exclusively for Safewell by Donaldson Filtration a global filtration company. The ALG10 consistently produces breathing air quality in accordance with the European standard for compressed breathing air EN12021:2014, ‘The SAFE-ALG10 purification barrier consists of: Cyclone Separator with automatic drain piped to condensate manifold 1S012500 validated Pre-Filter for particles and oil {Healless desiccant dryer with pneumatic control system to control pressure dewpoint to around -40 Deg C and also remove carbon dioxide to <500 mi/ m3 Catalyst to remove carbon monoxide to < 5 mi /m3 ‘Activated carbon adsorption to remove odour and any residual ol mist to a level of 0.003 ma/m3 13012500 validated particle fier to remove particulate matter before breathing The unit is easy to Service and maintain and provides a high margin of safety, NO on See section 3, For the operating and maintenance manual for the ALG10 breathing air Purifier. All technical and service enquiries contact uamw.safowellsolutions.co.uk or call +44(0)1330 826978 Page 3 of 3Avelair Important Commissioning Information: The information contained in this Manual is vital for the correct installation and commissioning procedure of your Avelair compressor. aS SAFEWELL A service@safewellsolutions.com +44(0) 1330 826978Avelair =» RED INDICATION LIGHT: Situated on the compressor fascia panel, the Red indicator light has two functions:- i e Compressor Stop Light and @ Fault Light = STOP LIGHT FUNTION: The Red indicator light will be illuminated when power is put onto the compressor. This will go out when the Start button is pressed. If the Stop button is pressed, then the light will illuminate. Note:] The light will not operate if the compressor has “timed out” and awaiting automatic re-start. ® FAULT LIGHT FUNCTION: The Red indicator light is linked in with the fault functions of the compressor i.e. over-temperature; over-load; thermistors (if fitted) and emergency stop operated. If the light does not go out when the Start button is pressed, then one of the above faults are present. Tel: 01359 272828 - Fax: 01359272829Avelair Avelair Semen: Installation Peaanements Moe Te Gable Size Cooting Air Flow: 16amp 2.5 me 1 000 Methour- teamp = 25mm® 1,000 Mhour 20amp mm 2,000 hour 11kKW 30: amp s2amp 6mm 2,000 MPihour 15kW = GOamp dd amp mm 2,600 wehour 185KW —G0amp — 40amp——s Smt 3,000 MYthour (22KW —B0amp Damp Sst ma® "3,000 M'/nour 30 kW 100amp 100amp ——t6mm* = 7.800 MPmour 37 KW 100amp —100amp 25 mm? 7,800 M¥/nour 45KW — 100amp —100amp 25 mm 7,800 MYfhour 55 kW “160 amp —_S3N160 mag asswa 9.850 Memhour 75KW —250amp —-S3N250 mag S0SWA 13,500 MYhour 90kW 250 amp +S3N260 260 mag 70sWwA ~— 46,500 Me/hour PS185/2197 Tel: 01359272828 - Fax: 01359 272829{ONG O€¢I Mlojsns‘spunwip3 ys Ang ‘sueis3Jeunsnpuy weysnoy ‘em ase9 pods ‘postu stony ~moleq ss0sppe ous oy Buluoyss}uiwio> Jo skep pT UIYRIM pouunaau pue *r9Ieule> JOU 5} a!mpayas AuyUo}ss}UiLuOD sI\p y pasiwouduioD aq Aew Aa “suonepuowwo2a: ssesm>ejnuew 0} Suypioa3e pat ‘Pa pu pods oq smu surypew aya poled sip soy “anoy T yo wnusutu € 40} uns 5] wn ay ‘Aojpeysnes BuyvorssyuED ye9yo— jenuBus suogeiodo panjeoes seworsns) eee ‘duo; Bury auyoe yeeyo— sex yeuigeo pansoas sowcisng a ‘Ouray aye} se Buyoor ‘uoaesodo Kvep yo eyo U1 uosiogs ve) Ya Yi anna peo} 40. u / sax ony 6804-24 obseyos1q eee Vo 81 Ya oi ana poo ng ou / 304 ‘Pony onfen oB1eyosiq T2199 9) ss01pp2 04g ypu 90100 uoyeiado 19w9 uO Uma _—_ eae soquinu suoydaya. ypays— 32109 UoHeved0 Bujpeoun sS_ —_—co_. ye0y— ‘unsaid peo| yo wnuxeyy —_____ Eee eee yoyo ‘ensse1d pe uo wnuipey ae woudindo A@juy TT se84— 'Pou109 vonsiedo dors pafejog senou! Jossardweo 0} fue 198 —— _sseippe pue eweu sewoysngy yo 301100 uonevedo dois 3 wr udu 0} a2 3190 yeu ——_pourpidxe squeweyinbes eoyuag, yoy 1281/00 uoR2I060 Bye /s8}5 ‘sdue— by yos}jeauge13 yeoyo— ——_dawosno o1pauimxe uonesodg, ooo 0ul09 Uo} Jo asueg ou) 904 ‘80008 oD,N98 uoYINg eae ‘fq ples iosseidwoc Yyooya— oeuoo wawUBye EN ou sof ‘dans o1no9i ajaeyns ~~ saousue Guuorsstumieg yoay 4994100 uossu 8g De. io} uorqure ays sossexdtuo0g) e}epuassuwi0, yoay 881100 86) 1 ou /soK Uuopequan oyenbopy oe sequinu jeuag yeoyo 1464 suon2euu0e jeownoer 200d / po08 ‘svonypu09 aus jeouap) ror pow ossadwog yea 1461 suopoeuuoo eouEyoopy ae ossaiduioo jo ecco siteIeq ewes OINGUISIG uoyss}w1H09 uonejreisu aanpacoud Stutuorsspuuos pun uonrjpoysuy JIDJOAYVSAFEWELL Safewell Solutions Ltd Document No QCD-6-2015. Project: Safewell Non Atex Breathing Air System for Aircraft Simulator Safewell Job Ref: 2458 INSTALLATION & COMMISSIONING, OPERATION, MAINTENANCE & CERTIFICATION Description 3 Operation and Maintenance Manuals. * Rotary Screw Air Compressor All technical and service enquiries contact ‘www safewelisolutions co uk or call +44(0)1330 826978 Page 1 of 1Avelair Avelair EDR/LER/EDN/RS/LE/ RMS/LS ROTARY SCREW AIR COMPRESSOR INSTRUCTION MANUAL, On line / Off line Control Serial Ne R4011C —S SAFEWELL service@safewellsolutions.com +44(0) 1330 826978 Please ensure you only use GENUINE Avelair service items, lubricant and spare parts to ensure long term reliability of the equipment and to ensure the warranty is valid.Avelair CONTENTS 1 INTERNATIONAL DIRECTIVES AND REGULATIONS SAFETY AND PREVENTION OF ACCIDENTS TRANSPORT, HANDLING AND PACKING. INSTALLATION START-UP AND STOPPING NORMAL OPERATION DECOMMISSIONING TECHNICAL DESCRIPTION MAINTENANCE SCHEDULE © P NBA YN 10. FAULT FINDER "1. SPECIFICATION This instruction manual gives all the necessary information required to install, start and operate the Avelair Rotary Screw Air Compressor. Maintenance instructions are also included and must be observed. Failure to adhere to the operating and maintenance instructions or unauthorised changes to the compressor may invalidate the warranty and result in an unsafe operating condition. We recommend that the unit is installed and commissioned by authorised technicians and advise that you request a scheduled maintenance agreement. For further information on your nearest Avelair agent please contact our customer service department on the following numbers:- Tel: 01359 272828 Fax: 01359 272829 Email: info@avelair.co.ukAvelair 2 SAFETY AND PREVENTION OF ACCIDENTS The following safety regulations and instructions must be strictly adhered to. These provisions apply to the Avelair Rotary Screw Air Compressor. Components supplied by other manufacturers are to be used in accordance with their own safety provisions. Please read the following safety instructions carefully and act accordingly when the compressor is transported, installed, operated, serviced, repaired or decommissioned. These instructions are in addition to the usual safety regulations to be observed for rotary screw air compressors, components and accessories. They support, not replace general Health And Safety legislation such as the Provision And Use Of Work Equipment Regulations, (PUWER). 1. The operating personnel must employ safe practices and observe all relevant safety regulations and operating instructions. 2. The operator is responsible for the machine to be kept in a safe operating condition. If parts and accessories are considered not to be in a suitable condition for safe operation, the machine must be taken out of service until the fault or potential fault has been rectified. 3. The unit must only be transported, installed, operated, serviced, repaired or decommissioned by authorised, trained and qualified personnel. 4. Limits i.e. pressure and temperature values, timer settings etc. must not be altered without written consent from the manufacturer. The values must remain permanently marked on the machine. 5. A copy of this instruction manual must be kept with the machine at all times. 6. If any of the above provisions (especially conceming safety) does not comply with local provisions of law, the safer provision must be appliedAvelair INSTALLATION In addition to operation according to general technical regulations of the local authorities, the following guide lines must be strictly observed 1 Use an appropriate fork lift truck complying with the local safety regulations to lift the compressor. Secure all loose and swinging parts such that they cannot be moved before ifting the machine. It is strictly forbidden to be in the danger area of a lifted load, The acceleration and deceleration of transportation must stay within permissible limits. It is essential that the compressor must be installed in a place where the ambient air is as cool and clean as possible. Never obstruct admission of air to the compressor. Ensure that moisture in the air is kept to a minimum. Intake air must not contain any corrosive or flammable vapours or exhaust vapours such as paint solvents. The presence of these gases could cause an internal fire or malfunction. !tis essential to ensure that an adequate flow of cooling air is provided and that the warm air discharged is not re-circulated into the cooling air inlet. Ensure that the compressed air discharge pipe from the compressor to the air system can expand with heating and does not come into contact with any flammable material The connection must be able to withstand compressor vibration throughout the foreseen life of the system, Ifa remote control unit is fitted, the compressor must be equipped with a clearly visible plate with the following lettering, WARNING: THIS UNIT IS OPERATED BY REMOTE CONTROL. AND COULD START WITHOUT ANY WARNING. As an additional protective measure, persons who start a compressor by remote control must ensure that all personnel are clear of the compressor and that it is in a safe condition to start. For this purpose, a corresponding plate must be provided at the remote control unit 7. 8 Connection must be made to the compressor discharge point via the fitting shown in the specification section. During installation, the isolator must be locked in its off position.Avelair IMPORTANT NOTES This instruction manual describes how the Avelair rotary screw air compressor must be operated in order to achieve safe operation, maximum efficiency and long, reliable service life Read the manual before starting the machine, so that safe and appropriate procedures are followed from the start. The maintenance schedule contains all the necessary measures required to keep the machine in good condition. Maintenance is simple but must be carried out regularly and by a competent person. Its important to ensure that a copy of the instruction manual is kept available for the operators of the compressor. All operating data, maintenance and service work should be entered into an operating log book Repairs and service should be carried out by competent personnel only. Always specify the model and the serial number in all correspondence. The manufacturer reserves the right to make technical changes without prior notice. The compressor must always be operated with the doors closed as these form the essential safety guarding of the machine. Only one key to open the cabinet is included, this must be guarded against improper use and only issued to the competent person via a permit to work procedure. The manufacturer assumes no responsibility for any damage or injury caused by ignoring these safety provisions, or by failing to exercise due care and attention during handiing, installation, operation, maintenance, repair or decommissioning, even if hazards are not expressly mentioned in this operating manual. 3 TRANSPORTATION, HANDLING AND PACKING The Avelair Rotary Screw Air Compressor is despatched in packing suitable for the chosen mode of delivery. Even though great care is taken at the factory, damage can occur to the compressor during transit. We therefore recommend that the unit is checked for damage. |f' damage has occurred during transportation we suggest the following: 1. Qutwardly visible damage must be officially noted on the carrier paperwork, then the carrier should immediately be informed by telephone and confirmed in writing, 2, If damage becomes apparent during unpacking, contact the carrier immediately and follow up the notification in writing, 3. Do not alter the condition of the damaged compressor until the carrier has been to inspect the damage or has declined to do so.Avelair The heat that is generated during compression must be carried away, and cool, fresh air supplied. It is possible to use the hot air generated to heat buildings provided local building regulations are observed, other legislation complied with and insurers informed. If the compressor room cannot be aired (windows, wall openings, etc.), then it is necessary to provide forced ventilation by means of room fans. In order to ensure good heat circulation, the air volume moved by these additional fans should be 15 to 20% greater than the sum total of the cooling air volumes of all the compressors located in the room. ‘The compressor is designed for ambient temperatures of +5°C to +40°C / +37°F to +104°F The required cooling air volume can be calculated by the following formula: oo Cp.dt Where: Q:: heat volume to be carried off (kJ s’ KW), Cp: 1.3kJ m*. K dt : Temperature rise (K), V : Volume flow (mm’s') COMPRESSED AIR CONNECTION The compressor must be connected to solid pipe-work by a flexible hose to ensure there is no transmission of vibration from the compressor. We also recommend the installation of a shut-off valve so that the compressor can be isolated from pressurised pipe-work during maintenance. For multiple compressor systems, it must be possible to pneumatically isolate each machine via a lockable valve during maintenance work. ELECTRICAL CONNECTION The compressor must be connected to a 400 Volt, Sphase, S0Hz supply. Unless othemise stated by manufacturer. The supply and earth conductors must be sized accordingly by a qualified electrician considering site specific measured values. The incoming supply shall be protected against over-current externally to the compressor by means of a motor rated overcurrent protective device. The suggested current rating and type of protective device for each machine are given in the specification section. Connection to the compressor is made via the isolator located in the control cabinet. An earth terminal marked PE beside the isolator must be used to make the earth connection. A neutral connection is only required if the machine has ancillary equipment, this requirement would be outlined on machine electrical drawingsAvelair 5 START-UP AND STOPPING PREPARATION FOR START UP Each Avelair rotary screw air compressor is operated in the factory and carefully tested before delivery. The test ensures that the compressor functions correctly, meets its specification and that all safety features are operable. The following tests are mandatory before running after installation or maintenance. LIVE WORKING Your attention is drawn to the PUWER regulations specifically LIVE WORKING regulation 14 Paragraphs 21 — 29 and the “Procedure For Working Safely On Electrical Equipment” guidelines within the IEC 60364-4-41 Ed.5.0 b.2005. This work should only be carried out by a competent person under a permit to work procedure with a “Safety watch person” present 1. For Avelair compressors, 4 - 45 kW, open the enclosure main door, open the discharge airline to the air system, turn on the isolators and check the sense of rotation of the compressor. This is done by pressing the start button and then immediately pressing the emergency stop button. Running the compressor in reverse for more than 2 seconds will result in air-end deterioration. The doors form part of the protective guarding of the machine. Whilst the door is open, no tool or body part may be allowed to enter the confines of the enclosure, Avelair compressors 55 - 90 kW are fitted with a sense of rotation protection device. if the electrical phases are wired incorrectly, the compressor will not start. 2, If the sense of rotation is correct as indicated by the decal on the air-end, close and lock the door before proceeding to step 3. If the sense of rotation is incorrect, electrically isolate the machine, swap two of the incoming electrical supply connections at the isolator and repeat step 1 For sequentially controlled machines, read the note in the sequential control manual, which relates to this aspect. Close and lock the guards and return the keys to a controlled access store. The machine must always be operated with the doors closed. 3. Operate the emergency isolation switch in and attempt to start the machine, the machine should not start. If the machine should start, then a fault has occurred in the stopping Circuit. Correct the fault before proceeding further. Release the emergency stop button by tuming the E. stop key clockwise. Ensure that the E-Stop key is returned to a controlled access store. Failure to correct a fault with the emergency stop control will result in that feature not being available during an emergency. Press the emergency stop switch in and attempt to start the machine, the machine should not start. If the machine should star, then @ fault has occurred in the stopping circuit. Correct the fault before proceeding further. Release the Emergency Stop button by tuming the emergency stop key clockwise. Ensure that the Emergency Stop key is returned to a controlled access store. BAvelair Led Indicators STATUS: Green, adjacent to Start and Stop buttons FAULT: Red, adjacent to Stop and Reset buttons. Indicator States: ON: Illuminated continuously, FF: Fast Flash: on/off four times pet second. ‘SF: Siow Flash: onfoff once per second, IF: Intermittent Flash: on/off every four seconds. OFF: Extinguished continuously, Weis vache Sate (Stata 7 | Siatiom era for 2 [ert at 7 Sirona | Saran conic Feng oSen | OFF Blowdown if (oad_request) FF else IF iF Start Motor In Star/Delta if (load_request) FF else IF Load Delay if (load_request) FF else IF 3 4 5 6 | Standby 7 3 2 Load ‘ON 10 | Reload Delay if (load_request) FF else IF 11 | Standby Run on Time iF 412 _ | Stop Run on Time SF “SF for Alarm condition 1sAvelair Operational Display Symbols: at N START-UP ‘Main motor running Compressor on load ‘Amount of time, timer Pressure set point indication (upper and lower set point indicators displayed independently) Condensate drain active (optional function) Power failure auto-restart enabled (optional function) Remote load or remote pressure regulation active Remote startistop Normal Operational: selected item locked as temporary default display ‘Menu Mode: page item locked (adjustment inhibited) The machine is now ready for its first run, release the emergency stop button by twisting the red mushroom headed button, and press the green start button. The machine wil initially start in star mode but will switch to delta mode after approximately 3 seconds. After a short delay, the machine will start compressing air.esetiat te tps of wr be cad ou Live etic] won ‘Sct enmied he asen is puritet ony tine seasae iacany elton ge erage [Veay tans caioner nal Bara) ‘tosuveycecune | [SORE PRE Sate glssen aan rst face sd a | abi, re Restart) cating (ruses ond ngseswatney | | “Tichtoreoveraa mate soo nacesects an arcane sak Site med carey 5. Useinnuata steving io ‘Thule ating one et [HEEanresase vem) iw Fevers halon sere | ‘hia eatery oes, mine Sica. aoe akeAvelair 6 NORMAL OPERATION CAUTION: 1. The compressor is automatically controlled and may start without notice. 2, Under all running conditions, all guards must be kept closed as they fulfil part of the protective guarding and noise reduction requirements. 3. The cooler will become hot during use; care must therefore be taken to avoid bodily contact. |n normal operation, the detected delivery pressure controls regulation of the compressor once the ‘compressor has been started by pushing the start button, or by a remote start command if enabled, The controller will perform safety checks and start the compressor if no inhibiting conditions are detected. If a start inhibiting condition exists the compressor will not enter the started condition and a start inhibit message is displayed. If a run inhibiting condition exists the compressor will enter the started condition but a main motor start is inhibited; the compressor will remain in the standby condition and a run inhibit message is displayed. If a load request is present, in accordance with internal pressure settings or by Femote command, the main motor is started in a staridelta sequence. When running in delta configuration, after the star/delta time (adjustable) has expired, the load delay time (adjustable) prevents loading for a period to allow motor speed to stabilise. The load delay time can be sot to one second if required. When the load delay time has expired the load valve output is energised and the compressor will load. If the unload pressure setting is reached, or a remote unload command is received, the load valve output is de-energised and the compressor will run officad for the standby run on time (adjustable) before the main motor stops and the compressor enters Standby mode. The compressor will oad again if pressure falls below the load setting before the standby run on time expires. If in Standby mode, a motor start sequence followed by the load delay time is executed before loading In the event of a motor stop, initiated by a stop command or when entering standby mode, a blow down timer (adjustable) is started. If a start request is made during the blow down time the compressor will enter standby mode until the blow down time expires. If already in standby mode, and a load request is resent, the compressor will remain in standby mode until the blow down time has expired. For units with internal pressure detection enabled, a minimum internal re-start pressure can also be set to prevent ‘@ motor start sequence before internal pressure is vented. In the event internal pressure fails to fall below the set minimum re-start pressure within two minutes after the set blow down time has expired, a blow down fault is generated and the compressor will shutdown. After an unload event a re-load timer (adjustable) is initiated that will prevent re-loading, this time can be adjusted to a minimum of one second if required. Normal automated operation is ended by Pushing the stop button, a remote stop command or in the event of a shutdown fault. When stopped Manually, or by a remote command, the load value is de-energised and the main motor allowed to run- on for the stop run on time (adjustable). This time can be adjusted to a minimum of one second if required. Safety checks are made continuously, if there is a condition detected that presents a hazardous or damaging situation an immediate stop is performed and the reason displayed as a shutdown error message. If a warning condition is detected an Alarm message is displayed and normal operation continues. 21Avelair Fao] [SB] © — [Fae Page 2 o— Tent Va 1 [Ese Sas | De ee Ite mn Ite Ve @] tema Vas @ Bed @| tens . Vat aed Ol tens vave © [Fass] @| tens, D— vate |O- tems Vas oa jc . i esmsaietter rier eee TTT Press ESCAPE at any time in menu mode to step backwards one stage in the navigation process. Pressing ESCAPE when the page number is flashing will exit menu mode and return the display to normal operational mode; page 0. Press and hold RESET for two seconds at any time to immediately exit menu mode and return to the normal operational mode display. Any value or option adjustment that has not been Confirmed and entered into memory will be abandoned and the original setting maintained. A flashing Key symbol displayed with any Item indicates the Item is locked and cannot be modified. This will occur if the Item is view only (non adjustable) or in instances where the item cannot be adjusted while the compressor is in the operational STARTED state. P00 User Menu The User menu shows normal operational values and information displays. This is the default display menu; no access code is required. ie | deserpion wats _[sep [nis [oa [aetna | aap 1 | sero = feel [- [- fe 2 | etveryairempertre | «CrP | no et] — ~ pra ssc 3 | datvery pressure [oust wosa]— |— | [pa asda 4 | internal pressure ‘bav/psi | mo_edit | — =a PL 13 ber S** | differential pressure | baripsi | no_edit | -— = — BOA bar: 6 | mmning hws a faocan{o [oss] am 1aa0 7 [tated tous » mene |o [oo] — Pe ans & | sevicehous a [mesa] 9999] 9999 | [ans 0570 ** only shown if internal pressure sensor function activated 2P01 Operation Menu Avelair Contains general operation parameters that may be modified by the User from time to time. emt | Description Units | step | min | max | Default | Display 1 [unload pressure | barfosi}or | pso2}ia0 }70 | pu 7.0ber 2 | toad pressure baripsi}o1 so |ruoz]ss | pL 65bar 3 | drainopentime | s a fa tao |s do 5s 4 | draininterval time | s 1 [30 [3600 | so fat cos 5 | standby run on time | « a fa | 3600 | 200 | rt 300s 6 | stoprunontime | a ]a [eo Jao |st 30s 7 | blowdowntime — | s a fa feo |a0 Bt 10s 8 ete ~ 1 |o 2 ° P> 0 O=bar/1=psi/ 2-kPA 8 ee - 1 fo 1 0 Po Minimum differential between load and unload set points is 0.2bar Pressure Settings: Trip cannot be adjusted above maximum sensor range Alarm can not be adjusted above (Shutdown ~ 0.2bar) or below (‘Pu’ Unload + 0.2bar) Unload can not be adjusted above Load cannot be adjusted above (‘Pu' Unload — 0,2bar) or below 5.0bar Pressure and Temperature Units: Selects the units for displayed values. (0.001bar) and mCelsius ( operating values. (Alarm — 0.2bar) or below (‘PL' Load + 0.2bar) Internally the controller operates using mBar 25 (0.001°C). The values displayed are calculated from the internalAvelair 5.0 Fault Messages Faults are abnormal operating condition states. Alarms are fault states that indicate normal operating conditions have been exceeded but do not present an immediate hazard or potentially damaging condition. Alarms are intended as a warning only and will not stop the Compressor or prevent the compressor from being started and run. Start inhibits are fault states that prevent the compressor from initially being starting. Start inhibit faults are conditions that may present a hazard or damaging situation if the compressor was to be started. A start inhibit will self reset when the condition being monitored returns to normal operational levels. Start inhibit conditions are only checked during the initial start Procedure and will not stop the compressor once started and in the ‘started’ state. Start inhibit conditions are not checked during an automated mator start from Standby. Run inhibits are fault states that prevent the compressor from starting and running the main motor. Run inhibit faults are conditions that may present a hazard or damaging situation if the main motor is run. A run inhibit will self reset when the condition being monitored returns to normal operational levels and the compressor will then be allowed to exit the standby condition and run without further manual intervention. Run inhibit conditions are checked prior to a main motor start sequence and will not stop the compressor motor once started. Run inhibit Conditions do not prevent the compressor from entering the ‘started’ state condition. Shutdown trip errors are fault states that present @ hazardous or damaging condition, the compressor is stopped immediately. The Shutdown trip error condition must be resolved, and the fault reset, before the compressor can be re-started. The different fault state conditions are indicated on the screen with specific codes; the last Character indicating the fault type: E = Shutdown Trip Error, A= Alarm, S = Start Inhibit, R Run Inhibit. Shutdown trip errors are divided into two different categories: immediate shutdown errors and controlled stop errors. Immediate shutdown errors stop the compressor instantly (Emergency stop button activated for example). Controlled stop errors stop the compressor in a controlled way using a normal Stop command; the motor will continue to run for the set stop un-on-time. Immediate shutdown errors have an error code where the first character is 0 (ero). Controlled stop faults have a “1" as the first character. Alarm faults are also divided into two different categories: alarms and service alarm messages. Alarms start with a "2", service alarm messages with a "4". Start Inhibit fault codes start with a "3" ofofo][e fault type fault description number input number Input location number fault type 20Avelair 5.1 Immediate Stop Shutdown Errors 5.1.1 Digital Input Errors Er:0010E Emergency Stop Er:0020E Spare Er:0040E Fan Motor overload £r:0080E Motor fault (fault relay contact, overload device contact or PTC thermistor) 5.1.2 Analogue Input Errors £r:0115E Delivery pressure sensor fault Er:0119E Delivery pressure high £r:0125E Delivery temperature sensor fault £n0129E Delivery temperature high £r:0131E Internal pressure below the set minimum limit ‘PR’ E0135 Internal pressure sensor fault £r:0139E Internal internal pressure high 5.1.3. Special Function Errors Er:0809E Differential pressure high Er:0814E — Blow-down timeout (internal pressure failed to fall below minimum level after 120 seconds) Er:0821£ Low resistance, short circuit or short circuit to earth condition exists on an analogue input or digital input (incorrect connection, cable fault or sensor fault) £10846 E Delivery pressure sensor range is set too low for default pressure settings to be applied, §r:0856E Internal pressure sensor range is set too low for default pressure settings to be applied. 5.2 Controlled Stop Shutdown Errors None 5.3 Alarms 5.3.1 Digital Input Alarms £r:2030A _ Air filter differential pressure switch 5.3.2 Analogue Input Alarms Er:2118A Delivery pressure £r:2128A Delivery temperature high Er:2138A Internal pressure high 5.3.3 Special Function Alarms £r:2808. Differential pressure high §r:2816 A Power failure occurred while compressor was in the Started state 298 TECHNICAL DESCRIPTION CONTENTS onmVOZE-ROC-TaArMIOOY Pneumatic & oil systems block diagram Airfoil circuit diagram Electrical circuit Air Filter Oil fiter Separator tank Separator cartridge Air-end Thermovaive Cooler Fan Temperature transmitter Pressure reading Hour counter Minimum pressure valve Pressure transmitter Intake control Safety devices 31 AvelairAvelair The Air-End draws in air through the intake valve which is compressed by the rotary screw action of the rotors and is mixed with lubricating oil. ‘The mixture of compressed air and oil is {transported into the separator tank where it hits a baffle. The subsequent decreasing of flow speed and change of direction causes most of the cil to be separated from the air and it drops to the bottom of the tank. The pressure within the tank causes the oil to flow around the Cooling circuit, first passing through the thermovalve and the either straight back through the oll fiter to the air end if the oil is cool, or if it is hot and has caused the thermo-valve to open, it 's released to the oil cooler before passing through the oil filter and back to the air-end. Meanwhile, the compressed air Passes out of the separator tank into the cartridge separator where the remaining oil mist is removed from the air. The clean air is then passed through the minimum pressure valve and into the air after-cooler before being discharged to the point of use. © ELECTRICAL cIRCUIT The compressor is powered by a three phase 380/415 Volt supply, this voltage is used across the motor via a star delta or direct on line starter with overload protection, and via three protective fuses across the electric fan. The control circuit operates at 24 Volts, this voltage being achieved by the use of a step down transformer placed across two of the main supply phases. The primary and secondary windings of the transformer are all fuse pr is therefore possible to isolate the control circuit by removing the secondary fuses. The emergency stop switch is normally closed, this is connected in series with the main start/stop switch. The start and stop switching actions are an integral part of the compressor Controller. All process safety sensors are monitored within the compressor controller. Provided there are no faults detected the controller will then initiate the start sequence for the direct on line or star delta process for the starting of the motor. Over-temperature protection is provided by the temperature sensor, and motor over-current is Provided by an overload. Continuous monitoring of these ensures that in the event of an over temperature or over current situation the control voltage to the contactors is cut. When contactor KM3 becomes energised; the controller then allows current to pass to the solenoid valve on the intake control. Once the compressor has reached pressure the controller will cut the power to the intake solenoid closing the intake valve and will initiate a run on timer, this will allow the compressor fo run in an unloaded mode for a pre-set period before cutting the control voltage to the contactors subsequently stopping the compressor. The compressor is then in a waiting state, indicated by a green light flashing on the controller; when there is a demand for air, the controller falls below its minimum setting, energises the solenoid and allows control voltage to the contactors and the machine back on line and producing compressed air. All models are set to a pre-set time which is activated when the stop button is depressed and allows the compressor to come off load before it is shut down. ‘An hours run meter logs total hours run by the machine on and off load. 33Avelair H AIREND The air-end is a positive displacement rotary screw compressor unit with oil injection. Two helical rotors, consisting of a male rotor which drives a female rotor are contained within a housing. Atmospheric air is drawn in through the intake regulator system and fills the cavity between the two rotors at one end of the helice. The rotary motion closes the intake aperture and pushes the air along the rotors into the ever diminishing space between the rotors and the housing. At the far end of the helice the pressurised air is discharged into the separator system. Oil is drawn into the rotor system which acts as a lubricant, a coolant and as an air seal between the rotors and the housing. Rotating the air-end in reverse would cause rapid air-end deterioration. 1 OIL THERMOVALVE The thermovalve is a three way vaive in the oil circuit which ensures that the oil temperature remains relatively stable. The optimum temperature for the oil in the rotary screw air compressor is between 70 and 80°C; below 65°C, condensation may form and above 100°C the air-end will overheat. AAt start-up, the oil is cool, the thermovalve is closed and oil passes through a cooler bypass. pipe. The compression process generates heat, as the oil heats up the thermovalve begins to open at 71°C allowing some of the warm oil to pass through the cooler system, At 83°C the thermovalve is fully open and all oil passes through the cooler. Movement of the piston within the thermovalve thus regulates the temperature within its optimum band provided the ambient conditions are suitable. J OIL COOLER / AIR AFTERCOOLER The combined cooler is connected to the air/oil circuit of the compressor. It is designed to provide operational reliability at ambient temperatures of up to 40°C subject to sufficient cooling air being provided. The air after-cooler cools the compressed air to between 10 and 20°C above ambient temperature subject to sufficient Cooling air being provided. For the separation of the resulting condensate, it is recommended that an automatic condensate drain is installed downstream of the cooler. Care must be taken to avoid contact with the cooler as it becomes hot in normal use. The compressor is labelled to indicate the hot surface. K COOLING FAN An axial fan blows cooling air through the combined cooler to reduce its temperature. The fan and its guard require servicing as described in the maintenance section. The terminal box contains connections at 380-415 Volts when the power is switched on; the terminal box cover must only be removed when the supply is isolated. 35Avelair Q INTAKE CONTROL The intake control is located on top of the air-end, it is solenoid operated by the controller. When the final pressure is below the lower pressure setting on the controller, the solenoid is energised allowing air into the air-end. When the higher pressure setting on the controller is reached, the solenoid is de-energised closing the intake and preventing further air being compressed. R_ SAFETY DEVICES The following parts have been fitted or modified to ensure safe operation of the compressor. EMERGENCY ISOLATION AND ELECTRICAL ISOLATOR The isolator is located on the door of the electrical cabinet. It serves several purposes, acting as an emergency isolation point when tured to the off position isolates the compressor from the energy source and therefore brings the compressor to an immediate uncontrolled stop. In the event of an emergency this switch should be used. The switch is also used as a supply disconnection device and as an interlock which ensures that the electrical cabinet door can only be opened with the machine electrically isolated. The lower terminals remain live even when the isolator is switched off but are covered by an insulating cover. Cutouts in the actuator enable the isolator to be locked in the off position by a padlock. PROTECTED EARTH TERMINAL Located adjacent to the isolator is a terminal marked PE. This terminal is where the incoming earth must be connected; it is electrically linked to the bonded earth circuit of the compressor. There is no neutral connection to the PE terminal, EMERGENCY STOP SWITCH Located on the facia plate, the emergency stop is easily identified by the red mushroom headed switch. It is provided as an additional stop mechanism to halt the mechanical action of the machine. Some parts of the control circuit inside the electrical cabinet still have the supply ‘and control voltages present after the emergency stop has been actuated. This switch should only be used for engineering purposes and is not classed as an emergency stop facility. ENCLOSURE AND LATCH KEY The enclosure forms the guarding of the machine, it is built of sufficiently substantial material that it will not deflect and create a hazard under normal body contact. The electrical cabinet door, rear and main guards are all fitted with latches which cannot be opened without the key provided. Controlled access to the key is therefore essential. 37Avelair MARKING The Serial number plate is located on the side of the Fan draught box. Various other labels are fitted to the machine to indicate hazards:~ ‘Safety Warning Labels Atl A Risk of Electric Shock Direction of Rotation High Temperature Moving Parts Air Unfit for Breathing High Pressure Fluid/Air Release WARNING Isolate machine EMERGENCY ISOLATION Te TCM CTs} guards SWITC! Warning! Unexpected Start Up Moving Parts Emergency Isolation 39Avelair A OILLEVEL The oil level in the oil container is an important factor for the operational reliability of the system. Checking intervals: 1. Before starting the u Figs A Figure B 2. Every 100 operating hours : § Checking procedu : Refer to Health & Safety note page 40 4 ‘Switch off the unit and prevent it from being switched on unintentionally. 2, Allow at least three minutes after stopping the compressor, unplug and open the hand valve situated on the side of the separator tank (models RS, RMS and LS only), or release pressure by unscrewing knurled cap to safety valve until all pressure is released.. Unscrew the oil filler plug (positioned on the separator tank) Check the oil as shown in the diagram above, Figure A where sight level glasses are not fitted Figure B where sight level glasses are fitted. Top up with oil of the same oil type up to the maximum level if required Tighten the screw cap manually, close hand valve on separator tank, fit plug and / or re-tighten knurled cap on safety valve. 7 Switch on the unit 8. ‘Check for leaks around the filler cap and replace the o-ring if required. 8 Check for leaks around the filler cap and replace the o-ring if required Note: If you check the oil level when the compressor is cold, it is recommended that the oil level is checked again after the compressor has reached full operational temperature. The screw-type filler cap is provided with a lateral safety hole from which oil or air may escape if residual pressure exists in the separator tank. It is essential that the compressor is allowed to bleed down to atmospheric pressure before attempting to unscrew the ail filer cap. The oil-filling pipe (except RMS models) is placed in a way that it is not possible to overfill the ‘screw compressor unit. Any excess oil will run out of the oil filler port. 4aAvelair OIL FILTER REPLACEMENT The oll filter should be changed after 50, then every 2000 operating hours. The oil must only be changed when the compressor has been isolated and allowed to bleed down to atmospheric pressure. 1. Drain the oil and remove the oil filter with a strap wrench. 2. Grease the gasket of the new filter. 3. Before mounting the new oil filter cartridge, hold it in upright position and fill it with the same type of oil as the separator tank. 5. The new oil filter should be fitted hand-tight. 6. Re-check the oil filter tightness after the unit has been run-up. 7. Disposal of the used oil filter cartridge must be carried out in accordance with local environmental regulations. 8. Make appropriate notes in the maintenance log book. CONDENSATE DRAIN The condensate content in the oil affects operating safety and life of the air-end. Operating the Compressor on a short run and consequently below the thermovalve opening temperature may allow condensate to accumulate in the oil system. Possible effects: Insufficient lubrication of the air-end Insufficient air/oil separation and high differential pressure in the separator cartridge Corrosion and rust formation Maintenance procedure: Drain the condensate regularly when the screw compressor unit is cold, ie. before start-up. 1, The condensate must only be drained when the compressor has been isolated and allowed to bleed down to atmospheric pressure. 2. Slowly unscrew the oi filler plug. Place a receptacle under the oil drain and carefully unscrew the oil drain plug. 4. ‘Slowly open the drain valve and drain the condensate from the ‘separator vessel until the oil starts to come out. Shut the valve and replace the plug. 5. Check the oil level in the separator tank and if necessary top up. Repeat this after 3 minutes of running. 6. Dispose of the condensate in accordance with local waste disposal legislation, 7. __ Ifa separate air receiver is part of the system, this should also be regularly drained. 8 Make appropriate notes in the maintenance log book. 6Avelair DRIVE BELT TENSIOI A= CENTRE DISTANCE te= DEFLECTION F = Force If the compressor is fitted with a motor slide plate, the drive belt tension is effected by rotating the lead-screw on the motor base which moves the motor relative to the air-end. A clamping ‘screw adjacent to the lead screw prevents unintentional movement. Belt tension should be checked at installation, after 2 hours, 50 hours and thereafter every 1000 hours. While checking belt tension, look for signs of wear or cracking that might indicate potential failure. If in doubt, replace the belts. If the compressor does not have a motor slide plate, the drive belt tension is effected by rotating the bolt push on the motor base which moves the motor relative to the air-end. A further bolt Pushing on the motor base on the opposite corner maintains the parallel axis of the motor relative to the gas end. Belt tension should be checked at installation, after 2 hours, 50 hours and thereafter every 1000 hours. While checking belt tension, look for signs of wear or cracking that might indicate potential failure. If in doubt, replace the belt Belt Replacement/Adjustment: 1. The belts must only be changed or adjusted when the compressor has been isolated and allowed to bleed down to atmospheric pressure 2. Loosen the lead-screw clamp. 3. Rotate the lead-screw enough to enable the belts to be removed, fit suitable replacement belts. 4. Rotate the lead-screw until the correct tension is achieved, tighten the clamp. 5. Make appropriate notes in the maintenance log book. 45Avelair ‘Maintenance Operations: Bofore Start Up '* Check Gil level in Tank ‘* Check drive belt tension ‘Check Emergency Stop operation ‘4000 Hour Service or once every 2 years, whichever is soonest 4000 Hour Service kit:- + Air filter, Ol filter, Oi filler plug seal, Separator and intake Regulator - (model dependent) + Avelair ASL Lubricant change + Air Filter Panel change” ‘Once within the first 200 Hours + Replace il Filter Check Oil level in oll tank «Check pipe connections and retighten + Check electrical connections and retighten + Check drive belt tension + Check Emergency Stop operation ‘6000 Hour Service ‘or once every 3 years, whichever is soonest {6000 Hour Service Kit:- «Air filter, Ol fiter, Oil filler plug seal, replace drive belts, ‘Minimum Pressure Valve service kit, Intake Control Block kit (model dependent) + Avelair ASI Lubricant change Air Filter Panel chonge* Every 100 Hours ‘Check Oil level in oll tank «Check Emergency Stop operation ‘8000 Hour Service or once every 4 years, whichever is soonest 4000 Hour Service Ki * Air filter, Oi filter, Oil filler plug seol, Separator and intake Regulator - (model dependent) + Avelair ASL Lubricant change += Air Filter Panel change* Every Service «Check electrical connections and retighten ‘+ Check drive belt condition and tension + Clean/blow out Cooler if necessary * Check and clean Oil Sight Glass if possible '* Check pipe connections and retighten «= Check Pressure setting + Lubricate Motor if necessary ** ‘Check Emergency Stop operation 110,000 Hour Service or once every 5 years, whichever is soonest 2000 Hour Service Kit:- Air filter, Oil filter, Oil filler plug seal ‘ Avelair ASL Lubricant change * Air Filter Panel change* 72000 Hour Service or once per year, whichever is soonest 2000 Hour Service Kit:- + Air filter, Oil filter, Oi filer plug seal ‘ Avelair ASL Lubricant change «Air Filter Panel change* 12,000 Hour Service ‘or once every 6 years, whichever is soonest 12,000 Hour Service Kit:- ‘Air filter, Oil iter, Oil filer plug seal, drive belts, Intake Regulator, Minimum Pressure Valve service kit, Intake Control Block kit - (model dependent) + Avelair ASL Lubricant change + Air Filter Panel change* NOTE: The drive shaft seal and air-end bearings should be changed as required. It ls recommended that oll analysis ‘checks are made on 2 regular basis to avoid premature bearing replacement. Motor bearings should be checked for vibration and changed as required. * Air Filter Panels may need to be replaced more often, dependent upon the environment *** Motor bearings to be greased as per motor manufacturer's recommendations Servicing intervals may change subject to site conditionsMOSS SAFEWELL SS Safewell Solutions Ltd Document No QCD-6-2015 Project: Safewell Non Atex Breathing Air System for Aircraft Simulator Safewell Job Ref: 2458 INSTALLATION & COMMISSIONING, OPERATION, MAINTENANCE & CERTIFICATION Section scr 3 Operation and Maintenance Manuals * ALG10 Breathing Air Purifier A\l technical and service enquiries contact Safewelisolutions co.uk or call +44(0)1330 826978 Page 1 of 1ALG10-2 Mk2 Breathing from a Compressor? This is essential PPE. Compressed Breathing Air Purification System Operation and Maintenance Manual ° — High margin of safety in accordance with EN12021 e — Supports two operatives using air fed masks * — Fully pneumatic operation * _ Includes carbon monoxide removal ° ATEX certified, Zone 2 ¢ Up to 16 bar working pressure ¢ Proven in offshore oil and gas operations worldwide ° Full service and spares ‘support * Four operative version available Manufactured exclusively for Safewell FERN SAFEWELL For servicing, spares and consumables: Tel +44(0)1330 826978/826069 or Fax +4(0)1330 825308 Email morag@safewellsolutions.com Sole Distributor and For Training, Service and Lifecycle Safety Support: ‘Safewell Solutions Ltd, Brathens Business Park, Banchory, Aberdeenshire, UK AB31 4BW. Tel +44(0) 1930 826978 e-mail info@safewellsolutons-com aA Qcp-5.090815 Donaldson,124 122 123 13 “4 144 142 143 144 Table of Contents ‘Table of Contents... Introduction Safety hints. ‘The Manufacturer Recommendations to the Work Protection... General Safety Information . Safety information for Transport and. installation Safety Measures during Operation, Dangers due to Desiccant. ft Safely Measures during Maintenance, Servicing and Repair Work. Environmental Protection ..... Requirements for the Operator. Requirements for Operating Staff. Warranty and Liability. Description of Function. ‘Adsorption Regeneratior Pressure build-up... ‘Switching-over Procedure m Parts ofthe unit with pneumatic controler Valves in the venting line. Pneumatic controller. Pressure Control Valve.. Operating parts of the pneumatic controller Before installation. Transport Safety hints conceming transport. Installation General Hints. Installation Hints Connection to the Compressed Air Network... Grounding instruction... Startup and Shutdown Faults and trouble shooting Possible causes of faults. Troubleshooting ... rasa Maintenance and Service ..nmnnnnnm ‘Servicing Table (During Operation) .. Sarvicig Table (Shutsown). Maintenance Filter, Technical Data, ‘Appenaix. 29 P&l Diagram... 29 General arrangement drawing nue Sete 229 Instrument & spare parts list. mast ‘| cia Manufacturer and accessory documentation ..ssoon fa 284 The Manufacturer ‘The manufacturer of the unit on behalf of Safewell is: Donaldson Filtration Deutschland GmbH Industrial Filtration Solutions Bissingstr. 1 42781 Haan If required, additional copies of the Operation Manual may be requested using the above contact Information, If writing oF telephoning, please give us the following data’ Dryer Type Serial Number * Year of Construction *) *)The serial number and year of construction can be found at the type plate of your unit. ‘The manufacturer reserves the right to make changes and improvements without prior notice!ise the appropriate tools! When servicing the unit, use tools that are appropriate and are in good condition, If special tools are required, approval must be given by the manufacturer beforehand. A Do not make any constructional chan: the u Consiructional changes to the unit may only be carried out by the manufacturer or after consultation of the manufacturer, All work on the pressure vessels and pipelines, such as welding, constructional changes, installation work, ete. without consuttation of the manufacturer and, if necessary, after consultation of the notified body, is forbidden and resuits in invalidity of the declaration of conformity. Failing to observe this prohibition can place you and your fellow-workers in danger. A Do not put any protective devices to the unit out of operation! Protective devices against exceeding the maximum allowable operating conditions such as pressure and temperature are not part of the standard scope of supply. Never disable the optional protective devices of the unit. Never attempt to by-pass the protective devices. Non-functional protective devices imply the greatest possible danger for you and your fellow-workers and can cause maifunctions in the unit. the temperature It must be ensured that the pressure of the components of the unit should under no circumstances be ‘able to exceed the maximum operating pressures. ‘As @ standard it is the responsibilty of the operator to secure protection against exceeding the pressure. it must be ensured that the pressure gonerating compressor and, should the occasion arise, the compressed air network downstream of the adsorption dryer are protected accordingly. The operating process ensures that the temperature at operating pressure cannot exceed the maximum allowable operating temperatures of the unit components. The operator must ensure that the temperature of the medium does not exceed the maximum operating data of the unit. If the pressure unit is under operating pressure, It must be guaranteed by suitable measures, that the allowable operating temperatures are not exceeded by the environment conditions at the place of installation. Pressure vessels — periodic approvals / alternation of stress Because of the cycle times of the pressure unit, the alternetion of loads per year is dependent on the type. The design takes a lifetime of 10 years into consideration Examination of all pressurised vessel walls (inner examination). Shorter test and examination intervals are valid when national regulations require shorter intervals.Never open the ball valves at the lower pipeline of the unit manually during operation. Failure to comply will result in severe personal injury. @® Noise during pressure release! ‘Wear ear protectors for safety precautions! Failure to comply could result in hearing damage. 5.4 Dangers due to Desiccant ‘The adsorbents are located in the absorbers). The type of adsorbent used depends on the type of processing unit. Only adsorbents from the manufacturer may be used, Adsorbents aro chemicals and thus, are subject to standard safety precautions (EN safety data sheet), The type of adsorbent used is not subject to any marking requirements as per the Hazardous Substances Ordinance. ‘Store the desiccant in a place accessible to authorized personnel only. Warning! Risk of injury through eye contact! + If the adsorbent gets into contact with the eyes, flush the eyes with clean water. Seek medical attention immediately. Warning! There are no restrictions on the type of extinguishing agent to be used in the event of a fire Nonetheless, the adsorbent strongly reacts with water or foam If pouring the desiccant, minimize the amount of dustin the surrounding area,itis secure. Only use suitable lifting gear and load-bearing members that are in perfect A ‘When replacing larger sections, carefully fasten the section to the lifting gear making sure condition and have adequate load-bearing capacity! If carrying out installation work above head height, use suitable and safe working platforms or other means to stand higher. Use safety lines to protect against falling when carrying out maintenance work at heights above 1.80 meters, 5.6 Environmental Protection Dispose of used items and materials properly. ‘Sort materials for disposal into categories to ease recycling. It is absolutely essential that the desiccant is disposed of in the correct manner. Disposal will be arranged by the manufacturers after-sales service. 5.7 Requirements for the Operator ‘The operator should ensure that the unit operated by trained personnel familiar with safety stipulations and the handling of the u il, these are as follows: Safety Accident prevention regulations Safety information (both general and specific to the unit) Safety devices of the unit Emergency procedures Operation of the unit © Unit start-up ‘© Troubleshooting © Unit shutdown 1.6 Description of Function ‘The description of function is done acc. to the P&l diagram (see Appendix 9) 6.1 Adsorption ‘The adsorption dryer ALG 10 SM is a dryer with alternating adsorption and regeneration phases. The medium will be alternately dried in the one adsorber while the other adsorber is being regenerated This procedure allows continuous operation The medium to be dried flows from the inlet (J) through the shuttle valve (6) and the prefilter (4) to one of the adsorbers (1). It flows trough the adsorber from bottom to top. In the upper part of the adsorber, the dried medium passes trough tho flow distributor and flows to the dry gas outlet (0) via the upper shuttle valve (6) and the adsorber (2) ‘The heat of the reaction during adsorption causes a slight increase in temperature at the dry gas outlet (O). Breathing air quality is generated by removing oil, CO, CO2, SO2 and NOX with help of special adsorbents in the dyrer adsorbers (MS/SP) and a special adsorbenticatalyst mix (AK/OX) in the 3rd adsorber. Solid particles are removed in the after filter downstream the 3rd adsorber. 6.2 Regeneration The regeneration of the moisture-laden desiccant is achieved with a partial low ofthe dried medium. At the start of rageneration, one of the valves (7) at the regeneration air outlet is opened. in this way the adsorber is brought down to atmospheric pressure. The compressed air passes out of the system through the silencers The amount of gas required for regeneration is limited by @ needle valve (11), mounted in the regeneration air bypase-line 63 Pressure build-up One of the valves (7) at the regeneration outlet is closed at the end of the regeneration phase, ‘The pressure in the regenerating adsorber will be built up via the bypass pipe in the upper piping. The regenerated adsorber remains in stand-by until the switching-over procedure is initiated. 6.4 Switching-over Procedure ‘The switching-over procedure will be adsorption time of 2,25 minutes. tiated by the pneumatic controller at the end of the fixed The switching-over procedure is done in the following stages, assuming that both vessels are already at operating pressure. 1. Open one of the 212-way valves (7); the shuttle valve (6) switches according to the pressure differential at the shuttle valve body. 2. Close one of the valves (7) after a regeneration time of 1,75 minutes. 3, Repeat the switching-over procedure after a pressure build-up time of 0,50 minutes, -13-Fig. 1 Design of the pneumatic controller Timer Pressurization Timer Regeneration Differential Pressure Switch 4/2-way-valves Air connection valve 1 (hose-@ 4mm) Air connection valve 2 (hose-@ 4 mm) Air connection control air (hose-2 6 mm) -15-8 8.1 Before Installation Transport Here you will find information on: ‘+ how to correctly and safely transport and set up the unit ‘The breathing air unit is packed in a box, which is delivered on a wooden pallet. Please make a note of the symbols on the packing. 8.2 Safety hints concerning transport A ‘Take special care in transporting or loading and unloading the unit. Never use force! Ensure that the maximum safe loading limits of the load-bearing members are never exceaded at the place of installation (see chapter 13 “Technical Data’) Boware of unequally-distributed loads! This can cause severe injuries when transporting with lifting gear! Ensure that the angle from the horizontal to the position of the ropes is never jess than 45°, Otherwise it could cause leaks in the piping of the unit and even lead to serious ‘malfunctioning to the dryer. Under no circumstances should the dryer be transported by the piping, as this could cause it leaks in the piping of the unit and even lead to serious malfunctioning of the dryer. SagRemoving the packing materials Remove the packing materials with care! Immediately report of any damaged machine parts or missing parts as a result of transport to the manufacturer and the transporting company, Document any unit damage and inform the manufacturer in detail Location si > If the ambient temperature at the installation site falls below +2 °C, the unit must be equipped with auxiliary heating to protect against frost (optional). Ensure that the installation site is clean and provides accessibility from all sides of the unit. Take special care that there is a sufficient room to swap over the unit or perform maintenance on it. > Ensure that the load-bearing weight of the floor is flat, level and can support the weight of the unit > Ensure that any vibration or pulsations from other units or machinery is not transmitted to the dryer. Bypass line (optional) A bypass line should be installed around the unit so the compressed air can still be supplied to the network if maintenance work is being performed on the unit. 9.3 Connection to the Compressed Air Network Properly connect the unit to the moist gas inlet and to the dry gas outlet. Check that all screw connections have been installed properly, Compressed air quality If sterile compressed air is required, a high-performance sterile filter should be installed after the dryer. -19-10 Startup and Shutdown 10.1 Initial Startup He oraer {© avoid mistakes in the intial startup, we recommend that the initial startup is done by Donaldson Uitrafiter. Carry out the initial startup in the sequence described below: * Adjust the control air pressure to 5,6 bar (max. 6 bar) Important! ‘A control air pressure > 6 bar can damage the pneumatic controller! * Check that valves A and B in the bypass line (optional) have been closed. * Slowly build up the pressure in the cryer by slowly opening valve A. Monitor the pressure on the Pressure gauges. Both adsorbers must be at working pressure. sreccontroller starts with the pressure build-up phase in both adsorbers. Finally, the regeneration Phase begins in one of the adsorbers and the adsorption phase in the other adsorber tre aia melsture from the ambient air can get into the desiccant as a result of transport or storage of the dryer. For that reason the dryer must be regenerated for at least 3 hours before the intial ay before valve 8 is opened to the com air network. * The dryer is integrated into the compressed air network by slowly opening valve B. ‘+ Close valve C if this had been opened during startup. -21-