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ID-01 Periodic I&M Air Compressor
ID-01 Periodic I&M Air Compressor
L ANG TH
PT. GEMILANG THERMAL ENGINEERING
MI
E
ER
PT. G
NG
G
N
E
I NE E R I
TABLE OF CONTENT
ITEM PAGE
1. Cover 1
2. Table of Content 2
3. Introduction 3
4. Requirements and specific task 3
a. Materials 4
b. Tools 4
c. Safety/PPE 4
d. Training Requirement 4
e. Inspection and Maintenance 5
5. Appendix 7
I. Check List Maintenance Tasks
II. Opeartion, Maintenance and Part Manual NE Series Oil Free Screw Air Compressors
2
Periodic
3X18MW COAL FIRED POWER PLANT Inspection &
INDONESIA Maintenance
Compressor
Date: 8 Feb 2017 PACKAGE COMPRESSOR GTE-ID-17-01
Introduction
This recommended practice for Compressor periodic inspection & Maintenance for CKP
maintenance guideline. The application of any practice or guideline contained here in is
reffering to the Manual Book of Compressor ELGI selected for 3 x 18 Fired Coal Power
Plant Project Tanjung Bara, Sangatta. Any deviation between this guideline, please refer to
Manual Book by manufacture.
This guideline is intended to assist CKP Personel in performing basic maintenance &
inspection preocedures. The Compressor may be different, the procedures and steps described
in this document will not necessarily be applied to, nor required for, every CKP maintenence
and inspection procedure.
1. Frequency of conduct
Periodic inspection and maintenance task on the Compressor should be performed on
regulary scheduled intervals. The frequency of any task contained within periodic
maintenance and inspection should comply with all applicable state and local
regulation. Further, in the conduct of periodic inspection and maintenance programs,
frequencies for individual tasks may be established based on a number of additional
factors, including but not limitid to:
OEM recomended intervals
Industry experiences
Operationing environment/condition
Historical data
Performance requirements
Failure analysis
Task schedule usualy taken with specific period is mentioned in the check list routine
maintenance schedule attached.
DO & DONT
DO
1. Read the manual in detail and follow the instructions
2. Clean the air compressor package regulary
3. Keep the air filter clean
4. Use only genuine ELGI spares
5. Maintain correct oil level
6. Use proper tools
7. Attend immediately to anything unusual with the air compressor.
3
Periodic
3X18MW COAL FIRED POWER PLANT Inspection &
INDONESIA Maintenance
Compressor
Date: 8 Feb 2017 PACKAGE COMPRESSOR GTE-ID-17-01
DONT
1. Neglect the routine attention
2. Allow any leakage in the system
3. Keep any tools of loose item on the compressor/other modules
4. Meddle with any adjusments of settings
5. Use cleaning agents, when changing oil.
WARNING: Use only those cleaning products and lubricant proved safe and
autorized for use by CKP. Consult original equipement manufacturer (OEM) and
Material Safety Data Sheet (MSDS) references for suitability of each application to
prevent personal injury and damage to the equipment.
2.1 Materials
The following materials are normaly required for inspection and maintenance of
Compressor:
OEM manuals, including schematic and drawings
Cleaning solutions
Lubricants as approved by OEM
Compressed air / water, and
Filters and filterdryers as specified by OEM
2.2 Tools
The following tools are typically required for inspection and maintenance of
Compressor
Vacum pump
Mechanics toolbox
Temperature measuring device
Vibration meter*
Note: Tools marked with an asterik required calibration as specified by
CKP practices.
2.3 Safety / Personal protective equipment
Appropriate personal protective equipment, meeting minimum ANSI standards
and as required by local regulation, shall be worn at all times in the performance
of these inspection and maintenance task.
4
Periodic
3X18MW COAL FIRED POWER PLANT Inspection &
INDONESIA Maintenance
Compressor
Date: 8 Feb 2017 PACKAGE COMPRESSOR GTE-ID-17-01
5
PT. CITRA KUSUMA PERDANA
3 x 18 MW COAL FIRED POWER PLANT PROJECT
PREVENTIVE MECHANICAL MAINTENANCE CHECK LIST
UNIT: Equipment Name: -Compressor Work Permit Date:
Frequ ACTUAL OBSERVATION
S.NO. POINTS TO BE CHECKED DESIRED OBSERVTION REMARKS / CORRECTIVE ACTION TAKEN
ency
Notes:
We are confident, that the equipment you have purchased will give you
satisfactory service for its life.
We thank you for giving us an opportunity to serve you with our Compressor.
This Operation and Maintenance Manual has been specially designed keeping
you in mind, so that you can get the most out of ELGI Compressor. Before you
start using your compressor, do go through this manual thoroughly. It contains
vital information on operations and useful tips that will keep your compressor
running as good as new, year after year.
All information, illustrations and specifications in this manual are based on the
latest product development available at the time of supply. We reserve the
right to make changes in the product at any time without notice. We assure
you of the best service in maintaining uptime of the compressor through prompt
service and supply of spare parts as per your requirements.
This manual has been prepared with utmost care to help the user to understand
various systems involved in the compressor thoroughly through detailed
descriptions, working conditions and illustrations. This manual must be made
available to the compressor operating personnel at all times.
Please read the instructions very carefully, right to the end, as the operating life
and reliability of the compressor depends to a large extent on correct operation
and maintenance.
iii
User Information
Please read the instructions carefully and strictly adhere to the end as the
operating life and the reliability of the Compressor depends to a large extent on
correct operation and maintenance.
While communicating with ELGI Dealer/ Service Center/ Branch Office regarding
the Compressor you have, ensure all the details on Name Plate (format shown
below) are given. The nameplate is fixed on the Compressor canopy post. For
ordering spare parts, refer Recommended Spare Parts chapter in PARTS
MANUAL and provide Part Number along with quantity in addition to the name
plate data of Compressor.
vii
GUARANTEE
ELGI does not accept any liability for damages in transit and handling in transport.
Please inspect the Compressor immediately after delivery.
In the event of any other complaints, please inform us within six days after the
receipt of consignment. Preserve the Guarantee Certificate sent along with the
Compressor safely.
ELGI cannot accept any warranty for damages resulting from failure to observe
the operating instructions given in this manual. The warrantee will also expire
if you alter the Compressor yourself and perform improper repairs or insufficient
maintenance. Appropriate repair and maintenance also involve the exclusive
use of ELGI Genuine Spare Parts and ELGI operating materials.
We reserve the right for modification without notice in the interest of technology
progress.
viii
Safety Precautions
GENERAL
ELGI designs and manufactures its products for smooth and safe operation.
However, the responsibility of safe operation rests with those who use and
maintain these products. Following safety precautions and devices are offered
as guide and accessories respectively. These when followed will minimize the
accidents and failures through out the useful life of the equipment.
Air Compressor should be operated only by those who have been trained and
delegated to do so, and who have read and understood this OPERATION AND
MAINTENANCE MANUAL. Failure to follow the instructions, procedures and
safety precautions given in the Manual may increase the possibility of accidents
and failures.
Never start Air Compressor unless it is safe to do so. Do not attempt to operate
the air compressor with known unsafe condition. Tag the air compressor
and render it inoperative by disconnecting power supply so others who may not
know of unsafe condition will not attempt to operate it until the condition is
corrected.
This model of the ELGI Dry Screw NE Series Oil-free Screw Compressor is not
designed to be operated in an explosive area.
PRESSURE RELEASE
Manually pop-up the pressure relief valve when the Compressor is operating, at
least weekly, to make sure the pressure relief valve is not blocked, closed,
obstructed or otherwise inoperative.
Do not use tools that are rated below the maximum rating of this Compressor.
Select the tools, air hoses, pipes, valves, filters and other fittings accordingly.
Do not exceed manufacturers rated safe operating pressure for these items.
Secure all hose connections by wire, chain or other suitably retaining devices
to prevent hose ends from being accidentally disconnected.
ix
Safety Precautions
Open oil filler cap only when compressor is not running and is not pressurized.
Vent all internal pressure prior to opening any line, fitting, hose, valve, drain
plug, connection or other component, such as filters.
Keep personnel out of line with and away from the discharge opening of hoses
or tools or other points of compressed air discharge.
Do not use air at pressure higher than 2.5 kgf/cm2 for cleaning purpose.
Do not engage in horseplay with air hoses as death or serious injury may result.
Shut - off the air compressor and allow it to cool. Then keep sparks,
flames and other sources of ignition away and do not permit smoking in
the vicinity when checking or adding oil.
Keep electrical wiring and other terminals in good condition. Replace any
wiring that has cracked, cut, abraded or otherwise with degraded insulation;
keep all terminals clean and tight.
Keep grounded conductive objects such as tools away from exposed live
electrical parts such as terminals to avoid arcing, which might serve as a
source of ignition.
Keep oily rags, trash, dry leaves, litter or other combustibles out of and
away from the Compressor.
Do not operate the Compressor without proper flow of cooling air/ cooling
water or with inadequate flow of lubricant or with degraded lubricant.
x
Safety Precautions
MOVING PARTS
Keep hands, arms and other parts of the body and also clothing away
from couplings, fans and other moving parts.
Do not attempt to operate the Compressor with the fan, coupling or other
guards removed.
Wear snug fitting clothing and confine long hair when working around this
Compressor, especially when exposed to hot or moving parts.
Make sure all personnel are out of and/ or clear of the Compressor prior to
attempting to start or operate it.
Disconnect and lock out all power at source and verify at the Compressor
that the circuits are de-energized to minimize the possibility of accidental
start-up or operation, prior to attempting repairs or adjustments. This is
especially important when Compressor is remotely controlled.
Keep hand, feet, floors, controls and walking surfaces clean and free of
fluid, water or other liquids to minimize the possibility of slips and falls.
HOT SURFACES
Avoid bodily contact with hot oil, hot coolant, hot surfaces.
Keep all parts off the body away from all points of air discharge.
Keep a first aid kit handy. Seek medical assistance promptly in case of
injury. Dont ignore small cuts and burns as they may lead to infection.
xi
Safety Precautions
Oils, coolants and lubricants used in this Compressor are typical of the
industry. Care should be taken to avoid accidental ingestion and/or skin
contact. In the event of ingestion, seek medical treatment promptly. Wash
with soap and water in the event of skin contact.
DANGER
Death or serious injury may result from inhaling
compressed air without using proper safety equipment.
ELECTRICAL SHOCK
Keep all parts of the body and any hand held tools or other conductive
objects away from exposed live parts of the electrical system. Maintain
dry footing, stand on insulating surfaces and do not contact any other
portion of the compressor when making adjustments or repair to exposed
live parts of the electrical system. Make all such adjustments or repairs
with one hand only so as to minimize the possibility of creating a current
path through heart.
Attempt repairs only in clean, dry, well lighted and ventilated area.
xii
Safety Precautions
Disconnect, lock out and tag all power at source prior to attempting to
repairs or adjustments to rotate the machinery and prior to handling any
ungrounded conductors.
Compressed air used for breathing air must conform to all of applicable
laws, rules, regulations and codes, such as OSHA 29 CFR 1910. 134 (d)
(1).
Intake air must be of highest purity. The NE series does not use oil in
compression chamfer, however, a compressor can not remove toxic gas,
vapours or any other impurities that may be contained in the atmospheric
air.
xiii
Dos and Donts
Dos
Donts
xiv
1.0 Standard Specification
Model
Dischar ge
Descr iption
pr essur e
NE 90 NE 110 NE 135 NE 145 NE 170 NE 200E NE 200 NE 210 NE 250 NE 265 NE 275 NE 300
Motor output kW 90 SF 1.1 110 SF 1.1 132 SF1.1 160 160 SF1.2 200 200 SF1.1 250 250 275 275 315
m/m
7.0 bar (g) Capacity 16.2 19.1 24.4 24.9 30.5 35.4 38.5 41.5 43 47 48.5 52
in
Cooling water
m/h 12 14 15 18 24 23 23 28 30 34 35 38
flow
Motor output kW 90 SF 1.1 110 SF 1.1 132 SF1.1 160 160 SF1.2 NA 200 SF1.1 250 250 275 275 315
Capacity m/m 14.3 17 22.7 23.1 28 NA 35.4 39.1 40.2 44.2 45.6 48.3
8.0 bar (g)
in
Cooling water
m/hr 12 14 15 18 24 NA 23 28 30 34 35 38
flow
Motor output kW 90 SF 1.1 110 SF 1.1 132 SF1.1 160 160 SF1.2 NA 200 SF1.1 250 250 275 275 315
Capacity m/m 13.6 16 21.2 21.9 26.9 NA 34.8 37.5 38.7 41.2 44 46.7
8.8 bar (g)
in
Cooling water
m/hr 12 14 15 18 24 NA 23 28 30 34 35 38
flow
Oil tank capacity Liter 50 70 100
Notes :
1. The motor can produce up to 110% to 120% of maximum continuous output.
2. These specifications are subject to change without notice in order to effect
improvements.
1.0
2.0 Process of Compression
INLET
DISCHARGE
2.0
3.0 Standard Components
All the components are placed on a common base and the compressor
package is enclosed in a soundproof cover.
Compressor Airend (Fig.3-1) Two stage, oil free rotary screw design,
consisting of :
Rotors Male rotor has three lobes and female rotor has five grooves, a
unique design.
The timing gears prevent the rotors from contacting each other.
PTFE + PFA coating is applied on the surface for excellent corrosion and
heat resistance.
Timing gears Precision made timing gears are fitted on the end of the
rotors to maintain the rotors in the correct position avoid contact with
each other
Bearings The roller bearings support the radial loads and the four point
contact ball bearings support the axial loads. Highly reliable antifriction
bearings are used to reduce bearing loss and minimize the clearance
between the rotors.
Airend Casing The Airend casing has a water jacket which surrounds
the compression chamber and absorbs the heat of compression.
3.0
Shaft Seals Carbon rings and visco-type seals are fitted on the rotors.
The visco-type seals prevent the oil from invading from the bearing to the
compression chamber, The carbon rings also prevent the compressed air
from leaking along the rotor shaft.
The carbon rings are non-contact, lubrication free shaft seals having self-
lubricating and automatic alignment features.
Minimum clearance is accomplished between the rotor and the shaft seal
by accurate machining and surface finish to assure the least possible
leakage over a long period.
Main Motor (Fig.3.2) The main motor is totally enclosed fan cooled
type. Its Pole flange mounted induction motor.
Check valve (Fig.3.2) Check valve is located between the 2nd stage
Airend and the after cooler and stops back flow from the discharge line.
The check valve is of lift type. The check valve has such a lightweight
valve disk that it assures a high reliability against repeating action.
3.1
Lubrication System Consists of oil pump, oil pump motor, oil strainer,
oil filter, oil cooler and reservoir.
The oil pump pressurizes the oil to lubricate and cool the system.
3.2
Blow off silencer
After Cooler
Discharge Silencer
Main motor
II Stage airend
Inter cooler
I Stage airend
3.3
Fig. 3.3 General construction with soundproof cover
3.4
4.0 Material of Components
4.1 Airend
4.3 Cooler
4.0
4.4 Sound proof cover
4.5 Piping
Water piping ASTM A53 & IS 1978, + SAE Carbon steel pipe
100 R1DIN 20022
4.1
5.0 Flow System
1. Oil strainer having 150 mesh filter screen, which is installed inside the gear
casing and removes large particles from the oil.
4. Oil pressure regulator which keeps the oil pressure within 2.5 4.5 kgf/
cm2.
5. Oil filter having 10 micron filter element which improves the purity of oil.
6. Oil header in which oil branches to each part. The oil is, thus, injected to
the bearings, gears and rotors and returned to the oil reservoir after lubrication
and cooling.
5.0
Ventilating Air Flow (Fig. 5-1)
Due to heat generation by compressor and motor, the temperature inside the
soundproof cover will rise.
To remove the heat and to keep all the components cool, a ventilating fan is
mounted at main motor shaft.
If the internal pressure of gear casing rises, the oil will invade the main motor
and the compression chamber which consists of rotors and compressor casing.
To prevent the oil from invading them, a gear casing vent is provided to release
the air with oil mist to the outdoors.
The vent piping shall be installed from the flange attached on the soundproof
cover to the outdoors. The open end of the piping shall be bent down as per Fig.
5.2.
Main cooling water line has two branches. The first branch flows through the
inter cooler and then to the after cooler. The second branch flows through the oil
cooler, the water jacket of 1st stage Air end and 2nd stage Air end.
5.1
transmitter
transmitter
transmitter
transmitter
transmitter
transmitter
transmitter
5.2
WP
5.3
6. Safety Devices
During Operation
In addition to the safety valve, the compressor is equipped with the following switches, which
will trip the unit in order to protect it against abnormal running conditions.
* too low an oil pressure (LOPS) * too high a blow-off pressure (HBPS)
* motor over load (e1, e2) * too high a 2nd stage suction temperature (HISTS)
* too high a discharge temperature (HDTS) * too high / low a 1st discharge pressure (HISPS)
* too high oil temperature (HOTS) * too small a flow of cooling water (HISTS, HDTS, HOTS)
The following table shows the detector, predetermined value, and symbol of wiring diagram for each item.
item.
Predetermined Switch Comp.
No. Item Detector Symbol
value Position Condition
Feed Oil Pressure
1 LOPS 1.1 bar(g) ON Shutdown
pressure Transmitter
2nd Stage
Thermal
2 Suction HISTS 50 C more ON Shutdown
Transmitter
Temperature
Compressor
Thermal - .C or more
3 Discharge HDTS ON Shutdown
Transmitter (see *1)
Temperature
7.2 /8.2 / 9.0 Unload
Compressor OFF
Pressure bar(g) operation
4 Discharge UPS
Transmitter 6.7 / 7.7 / 8.5 Load
Pressure ON
bar(g) operation
Main Motor / Over current
5 `e1 / e2 Overload ON Shutdown
Oil Pump Relay
Compressor
Diff Pressure
6 intake - -625 mm water ON Alarm
Switch
Pressure
Compressor Set pressure 7.7/
7 Safety valve - - -
pressure High 8.7/9.5 bar(g)
Blow-off Pressure
8 HBPS 0.4 bar (g) ON Shutdown
Pressure switch
Feed Oil Thermal
9 HOTS 55 C or more ON Shutdown
Temperature Transmitter
1st Stage
10 discharge Temp Switch HDTS1 225.C or more ON Shutdown
Temperature
1st Stage
Pressure
compressor -bar(g)
11 Transmitter HISPS ON Shutdown
discharge (see *2)
(High )
pressure
Pressure
Water
12 Transmitter LWPS 1.1 bar(g) - -
pressure
(Low)
IInd stage inlet Pr. Transmitter LISPS bar (g) (see*2) ON Shutdown
13
pressure (Low)
6.0
*1
Discharge NE 90 NE110 NE135 NE 145 NE 170 NE200E NE200 NE210 NE 250 NE 265 NE 275 NE 300
pressure
7.0 bar (g) 200 200 200 200 200 200 200 200 200 200 200 200
8.0 bar (g) 225 225 225 225 225 225 225 225 225 225 225 225
8.8 bar (g) 225 225 225 225 225 225 225 225 225 225 225 225
*2
Model NE 90 NE110 NE135 NE 145 NE 170 NE200E NE200 NE210 NE 250 NE 265 NE 275 NE 300
1st Stage
Compressor 2.5 2.5 2.8 2.5 2.5 2.8 2.5 2.5 2.5 2.5 2.5 2.5
Discharge
pressure high
2nd Stage
Compressor 1.6 1.6 1.6 1.6 1.6 1.6 1.6 1.6 1.6 1.6 1.6 1.6
suction
pressure low
At starting
The protection system confirms that the unit meets the conditions for start-up.
6.1
7.0 Capacity Control
Elgi Capacity control system provides ON Line/ OFF line control with
blowing-off discharge pressure to atmosphere at part load or no load
condition. It is not a modulation control. When the air requirement by
the plant reduces or stops, the air line pressure increases and when it
reaches the upper set point of the unload pressure switch, the system
unloads the unit. When the air line pressure drops to the lower set point
of the unloader pressure switch, the system reloads the unit.
The unload pressure switch is connected to the discharge pipe
downstream of the aftercooler.
Standard factory setting for capacity control and starting unload is as
follows.
7.0
AT STARTING
The starting automatically works as follows. The suction butterfly valve is closed
while the unit stops. The 4-way solenoid valve is de-energized for a while after
the START button is pushed. The operating oil flows in the following direction.
P A B R
The operating oil is supplied from the oil hole 1 and delivered to oil hole 2
Then the suction butterfly valve is kept closed to reduce the starting load.
7.1
UNLOADING
When the air volume required by the plant reduces and the discharge air line
pressure reaches the upper set point of unload pressure switch, de-energizes
the 4-way solenoid valve and the operating oil flows in the following direction.
P A B R
The operating oil is supplied from the oil hole 1 and delivered to oil hole 2
Then the suction butterfly valve is closed to throttle the inlet air flow to the
Airend. At the same time the compressed air in the discharge air line is released
to atmosphere through the blow-off silencer, so the idling power is reduced.
LOADING
When the discharge air line pressure drops to the lower set point of unloader
pressure switch, the unload pressure switch energizes the 4-way solenoid valve
and the operating oil flows in the following direction.
P B A R
The operating oil is supplied from the oil hole 2 and delivered to oil hole 1 .
Then the suction butterfly valve is opened completely and the unit comes to
load condition.
AT STOPPING
When the unit is stopped, the route of operating oil flows is changed to the
same as the one of unloading. So the unit stops in the unload condition.
RECEIVER CAPACITY
This control system should not be in the unload condition frequently.
Be particularly careful when the compressor has only a small volume discharge
line.
7.2
Therefore the receiver capacity (required volume on the discharge line), which
determines the switching between load and unload operations, must be carefully
calculated as follows:
V = 16 x Qs where V = required capacity for compressor control (m)
Qs = flow rate handled by the compressor (m/sec)
7.3
8. Operation
Before starting the unit for the first time, an operator should become familiar
with all parts and assemblies.
Oil in the gear casing has been drained out before delivery. Remove the oil
filling cap, and fill the recommended oil to the upper line of the oil level gauge
(Fig.8.1) DO NOT MIX OIL BRANDS.
Oil flashing shall be performed if the induction of oil pressure gauge shows 1.5
kgf/cm2 or less.
Especially pay attention to the oil pressure gauge before the first start-up and
any start-ups during commercial operation when the unit has been put in the
following conditions.
b) Every overhaul.
The recommended oil shall be used as a flushing oil. It is not necessary to change
the oil after finishing the oil flushing. After the flushing oil is supplied to the oil
reservoir to the specified level, the flushing work is performed by the oil pump solo
operation. If there is a lot of dirt or rust in the system, they tend to clog the oil filter
and cause a drop of oil pressure. The flushing shall be continued until the oil
pressure exceeds 1.5 kgf/cm2, while the oil filter is cleaned at intervals. (Fig.8.2)
Make sure that the unit is provided with adequate electrical grounding.
Close the drain valves in the cooling water line (inlet and outlet) completely
(Fig. 8.3)
8.0
Open the inlet and outlet valves in the cooling water line (supplied by the
(customer) and check the flow rate and the water temperature.
Open the ball valve between the aftercooler and the receiver or other process
devices completely.
Make sure that the oil level is between red lines of the oil level gauge.
(Fig. 8.1)
Release the air trapped in the cooling water line by opening the water
release valves(Fig.8.1 & 8.2)
Be sure to check the smooth rotation of rotors by rotating the motor shaft
by hand from the motor inspection cover. (Fig. 8.2)
Turn on the main power and make sure that the OIL PUMP STOP light
and COMP STOP light stays lit.
Make sure that the ball valve in the discharge air line has been completely
opened.
8.1
Push the START button. Check the direction of rotation from the inspection
opening of main motor while INCHING the unit (approx. 1 sec.) (Fig. 8-2)
Start the unit again and recheck the direction of rotation. At first, the oil
pump is operated and the oil is pressurized.
. Make sure that the inlet oil pressure is 1.1 kgf/cm2 or more.
After the oil pressure reaches 1.1 kgf/cm2, 20 seconds after START button
is pushed, the unit starts running in the unload condition. Unloading is
carried out by throttling the suction of 1st stage and simultaneously blowing
off the compressed air discharged from 2nd stage to atmosphere.
8.2
Fig. 8.3 Piping
Run the unit for 30 minutes with the discharge ball valve completely opened
so that the unit runs at the lowest pressure.
When the compressor discharge pressure is lower than the rated pressure,
close the stop valve as slowly as possible until the compressor discharge
pressure reaches the rated pressure.
Check and confirm that the oil temperature gauge indicates 55 deg.C or
lower and the discharge temperature gauge indicates the temperature below
the set value.
8.3
8.2.3. Stopping
The contactor for main motor will open, and the solenoid valve of capacity
control device will be de-energized. Then the butterfly valve will be closed and
the blow-off line will be open and the unit will stop in the unload condition.
The oil pump will stop 3 minutes after the power of main motor is turned
off.
Close the stop valve between the aftercooler and the receiver or other
process devices.
Close the inlet valve in the cooling water line (Fig. 8.3)
If freezing weather is predicated, open the drain valve and drain off the
water in the system. Pay attention to the intercooler, the aftercooler and
the oil cooler.
8.4
8.2.5. Post Installation Storage
After running, drain off and dry out completely the water passage of coolers
and shut off the drain valves. (Fig. 8-3)
Mark the unit with a caution sign to declare the storage condition. The
sign warns an operator against potential hazards or unsafe practices.
In addition, there is a dry nitrogen purge method or a dry agent method for
long term storage.
ELGI will choose which of them is suitable for the local condition.
Make sure that the OIL PUMP STOP light and the COMP STOP light
stays lit (FIG.8.4)
Drain off the condensate in the Y-type strainers for intercooler and aftercooler
with the drain detection valve (FIG.8.3)
Release the air trapped in the cooling water line by opening the water
release valve (FIG.8.1, 8.2)
8.5
8.3.2 Starting
Check if the oil pressure gauge indicated 1.1 kgf/cm2 or higher 20 seconds
after the start. Normal oil pressure is 1.5 to 2.2 kgf/cm2 (FIG. 8.4)
Measure the cycle time of load-unload operation. Check if the cycle time
is 30 second or more.
Open the drain detection valve installed on the Y-type strainer and check
if the condensate flows through the orifice plate and the Y-type strainer
(FIG.8.3)
Confirm that no trapped air exist in the cooling water line by opening the
water release valves.
8.3.4 Stopping
Make sure that the pressure (discharge and inter stage)indicate zero after
the stop(FIG.8.4)
After the oil pump stops, shut off the cooling water line.
Open the drain valves to drain off the water in the unit. This action is
especially important to avoid freezing of the system in cold season.
(FIG.8.3)
8.6
8.3.5 Long Term Storage
Rotate the compressor shaft once in 7 days and ensure the free rotation
8.7
9.0 Piping
If the unit is operated in parallel, be sure to provide a stop valve and a drainage
opening in each discharge air line.
If the unit is operated in parallel with reciprocating compressor, the discharge
air line of the rotary screw unit shall be connected downstream of the air receiver.
9.0
Elevated Piping (FIG. 9.4)
If the discharge air line is elevated near the unit, be sure to provide drain valve
or drip leg to collect the condensate.
Choose the appropriate size for the receiver in accordance with the selection
guide of receiver described in SECTION.8 CAPACITY CONTROL.
The take-over points of cooling water line are at the base of unit, which consists
of one inlet line and one outlet line. Install a stop valve at each line. A motor
driven valve shall be selected to avoid water hammer if automatic type is required.
If a cooling tower supplies the cooling water to the unit, corrosion, scale or
slime may be a problem caused by :
c) Alage or bacterium.
9.1
2. Control of cooling water Quality
The life time of the cooling water system depends on the water quality. If the
cooling water Quality is not good, the cooler pipes can be corroded, or scale
can be generated. In order to prevent such a problem, sample the cooling water
periodically and test it to check if it meets the quality standard, correct if
necessary.
Condensate is separated from the compressed air with the mist separator
installed at the downstream of the tube bundle. The condensate is discharged
with a small amount of the compressed air through an orifice plate and the Y-
type strainer easily.
To release internal pressure, the gear casing has a vent pipe. The vent pipe
shall be extended to the outdoors as shown below so that oil fumes from the
gear casing do not enter into the compressor inlet.
The pipe size shall be 3 or more and the pressure drop shall be 5mmHg or less
at 800 l/min.
The piping shall have a gradient of 1/100 to 1/20 to return the oil, which condenses
on the way to the outlet, to the gear casing.
Use clean pipe for the vent piping, otherwise dirt or rust in the pipe can flow
back to the gear casing, which may cause clogging of the filter.
The outdoor opening shall be bent downward to avoid entering of rain or dirt.
The outlet of vent piping shall not be located near the inlet of any air duct.
9.2
All service piping must be installed so as to exert zero force of
! moment on the unit
CAUTION
9.3
10.0 Foundation
While the foundation for screw compressors need not be as massive as that for
reciprocating machinery, it shall have a strength sufficient to provide a support
for the unit. Since there are no unbalance forces such as reciprocating or shock
loads, all loads imposed on the foundation may be considered as static loads.
Setting of pad liner shall be finished 3 days before installing the unit to
shorten the working time.
The purpose of grouting is to solidly fill the space between the base and
the foundation and to give a uniform load-bearing surface for the unit.
10.0
Build a frame around the perimeter of the base.
When building the frame, prepare the space for removal of wedges, shims
or other leveling after the grout has set.
To obtain a good bond between the foundation and the grout, the foundation
shall be completely clean and free of any oil, water or other foreign matters
prior to pouring grout.
Prepare a minimum of 25mm of grout between the base and the foundation.
All air pockets and voids shall be removed from the grout. After grout has
set, remove the leveling devices. And then tighten the anchor bolts and fill
the void left by the leveling devices with the same grouting material.
10.2 Wiring
Wiring required at the site is the connection of power supply and grounding.
A grounding terminal is provided in the starter.
Note that an isolator is not provided on the unit. The isolator per the local
requirements shall be provided by the installer.
10.1
12. 0 Trouble Shooting
As a guide, the most likely problems with possible causes are listed in the
following chart.
Before doing any work on this unit, be sure the electrical supply has been cut
off and the entire compressor system has been vented off all pressure.
NOTE
In the case of shutdown of safety devices, the display shows
fault details . Find the case of shutdown, correct it and press the
RESET button.
Do not start the compressor again if the cause of shut-down is
unknown. Never perform a trial running to find the cause. Whenever
the cause is unknown, contact the nearest branch. Before starting
the compressor again, be sure to check for smooth rotation of
rotors by rotating the motor shaft by hand from the motor inspection
cover. Be sure main electrical power is off. If motor turns free,
reconnect power.
Then push the RESET button and the RUN button.
12.0
12.1 Trouble Shooting
12.1
CONDITION POSSIBLE CAUSE SUGGESTED REMEDY
3. High oil temperature a. Low cooling water flow a. See CONDITION 14.
6. Low discharge a. Air leak from the discharge line a. Locate and repair
pressure
7. High interstage a. Damaged 2 nd stage air end a. Contact the nearest branch *.
pressure
12.2
CONDITION POSSIBLE CAUSE SUGGESTED REMEDY
9. High interstage a. Low cooling water flow rate a. See CONDITION 14.
temperature
14. Low cooling water a. Failure of water supply a. Check and repair
flow rate
15. Discharge air a. Gear casing vent line clogged a. Check and clean.
containing oil
12.3
CONDITION POSSIBLE CAUSE SUGGESTED REMEDY
17. Oil level increased a. Water entering the oil a. Check and repair *.
12.4
11.0 Maintenance
The intervals shown there are a guide based on normal operating conditions. If
operated in a harsh environment, perform the service more frequently. Carry
out the maintenance work, based on either running hours or calendar time
whichever comes first.
Items marked with o should be performed by a user while the other marked
with * should be maintained by the nearest branch.
The actions mentioned in the schedule are repetitive unless otherwise specified,
the actions at 3,000 hours interval, as an instance, shall be carried out again
after 6,000 hours of operation.
The record also enables ELGI to find a potential cause of trouble and thereby
perform a suitable repair. Use the attached record form.
The maintenance instructions are summarized in Table 11.1. Before taking any
maintenance actions, read the concerned section. Time mentioned in the Table
11.1. are not a performance guarantee period.
11.0
TABLE 11-1 STANDARD CHECK AND MAINTENANCE SCHEDULE
Every year/
Sl no Activity Description Daily Monthly 2000 hrs Every two year
8000hrs
Pr ecautions
A. I f the compr essor kept idle for mor e than 8 Hour s
1. Close the Inlet and Outlet water valve.
2. Drain the Water from the Compressor System.
3. Close the Main Air outlet Valve.
B. I f the Compr essor kept idle for mor e than a week.
Apart from above points other precautions are
1. Rotate the compressor shaft once in 7 days and ensure free rotation of shaft.
2. Supply dry air at intercooler dry air inlet for 30 min
The above guidelines applicable to normal industrial environment. In the event of changes in the environment, consult ELGI
guidelines
id li on above
b
11.1
11.1 Intake Air Filter
Just after the dust indicator changes from green to red, clean the filter element
or replace it with a new one.
Remove the filter from the suction box panel. (FIG. 11.1)
Attach the suction box cover on the suction box panel to prevent dust or
dirt from entering the compressor inlet.
Blow the filter element with compressor air from inside to outside.
11.2
11. 2 Oil filter (FIG. 11.3, 11.4)
The Oil Filter which has a 10 micron filter screen is located between the oil
cooler and the air end. This is a full flow filter with a replaceable pleated element.
Servicing of oil filter element shall be done every 10,000 hours or 2 years
whichever comes first. The procedure for complete service of this filter is
explained below.
Disassembly
Disassemble the oil housing by removing the four hexagonal bolts holding
the head assembly to the main body.
Remove the body seal from the main body.
Dislodge the element from the head assembly.
Clean the head assembly and housing thoroughly.
Reassembly
Place the head assembly with attached filter back into the housing.
Head
Seal
Element
Spring washer
Housing
Hex. Nut
Drain plug
11.3
11.3 Oil strainer (FIG. 11.3, 11.5)
In the oil line, an oil strainer and an oil filter are provided.
The oil strainer, which has 150 mesh filter screen, is located in the gear casing.
The cleaning of oil strainer shall be made every 10,000 hours or every 2 years
(whichever comes first) at the same period as oil change.
The oil strainer can be removed from the gear casing containing oil. It is
unnecessary to drain the oil off.
Take off the flexible tube, which connects the gear casing with the oil pump.
Loosen the bolts of rectangular flange and pull the pipe with the oil strainer from
the gear casing.
After cleaning it, attach the pipe with the oil strainer on the gear casing.
Check the oil level daily. If necessary, fill the oil through the oil filling port at the
side of the gear casing.
Sample the oil from the gear casing every six months. Change the oil if necessary.
Place a drain pan under the oil drain opening at the left side of the unit.
Remove the cap of the oil filling port and open the oil drain valve.
Remove the plugs from the oil cooler and oil filter. Then drain the oil off.
Completely drain off the old oil. Open the inspection covers at both sides
of the gear casing, and clean and wipe the bottom of the gear casing with
clean cloth.
11.4
Attach the inspection cover and close the oil drain valve. Supply new oil
to the upper line of oil level gauge. Then operate only the oil pump for one
minute and add oil to the upper line.
11.5
11.4 Cooler Drain
Check the drain condition once in a day by opening the drain detection valve.
When a great deal of drainage is discharged from the drain detection valve, it is
considered that the orifice is clogged or the strainer is dirty. Remove the orifice
plate and the strainer and clean them at once. Overhaul the orifice plate and the
Y-type strainer once in a month. The drain increases in the rainy season so
check the drain condition at short intervals such as once in every two to three
hours during the season.
Cleaning Procedure
Slightly close the drain valve, which is attached inside the unit so that the
drain flowing from the orifice hole is slow.
Remove the drain detection valve and the plug. Disassemble the filter
element from the Y-type strainer.
Using an air nozzle held at a suitable distance, blow up and down the
clean side of the filer element.
Cleaning on the tube side once in every 2500 hrs (for the water quality
mentioned before).
If the water quality can be maintained as per our regular norms then it may
be extended to 5000 hrs also.
11.6
The above intervals are not mandatory & can vary according to the water
quality.
Chemical cleaning where the whole tube bundle is dipped into the chemical
bath to remove scales/dirt
Closed water cooling system can be used where DM water is used for
cooling purposes which avoids formation of scales.
The tubes can be cleaned with a tube brush. Use original Bloksma brushes
only; these have the correct dimensions and are of a suitable material. Other
brushes may damage the protective layer that is in the normal course of events
present on the tube walls.
11.7
The shell- as well as the tube side can be cleaned by circulating a chemical
solution through the heat exchanger. Another possibility is disassembling of
the bundle and submerging the tube bundle in a tank filled with a chemical
solution.
The shell-as well as the tube side can be cleaned by circulating a chemical
solution through the heat exchanger. Another possibility is disassembling of
the bundle and submerging the tube bundle in a tank filled with a chemical
solution.
After cleaning neutralize the tube bundle and the cleaning agent with a
special neutralizing fluid.
11.8
11.5.5 Chemicals can be used for cleaning:
A) Product number : 1
Add 3 liters of Accepta per 1000 liters system volume. Top up system as
required based on water losses.
B) Product number: 2
Ensure the system to be treated is clean, drain and flush. If the system is
heavily fouled consider cleaning the system.
Add 3 liters of Accepta per 1000 liters system volume. Top up system as
required based on water losses.
C) Product number: 3
11.9
Sublime is most effectively used by circulating through the equipment to
be cleaned. Sublime also is used by filling the equipment to be cleaned
and allowing it to set until scale has disappeared. The cleaning operation
normally takes two to six hours.
b) The color change at a pH of 5.8 to 6.0 which is well within the safe disposal
range of most of the current governmental waste regulations.
c) If the equipment is clean and SUBLIME has not changed color, we can
save it and use it again.
11.10
11.5.6 Shut down periods
During shut down periods longer than a week the heat exchangers has to be
drained completely and dried by means of preheated compressed air. In fact
this also has to be done during short shut down periods (longer than a day)
when there is risk of freezing, and it also applies when a corrosive medium is
used in the heat exchanger. After draining a corrosive medium, the heat
exchanger has to be rinsed with fresh water.
Stopping of the flows, cooling down and draining of the heat exchanger has to
be done in a manner to minimize thermal stresses on the heat exchanger.
Never stop one of the flows of the heat exchanger while the other one stays in
operation, because of the risk of boiling.
The circumference of one of the tube sheets is fitted with three grooves (fixed
tube sheet). The two outer grooves carry O-rings (seating between shell and
tube side). The middle groove of the fixed tube sheet is for the fixation of the
position of the tube bundle by means of fixation plates.
The other tube sheet (floating tube sheet) has no middle groove and is supposed
to slide according to eventual thermal dilatation.
11.11
Step 1: Assembling of the bundle
Move the tube bundle in the shell (let it stick out of the shell a bit). For big
bundle size, it is preferable (when possible) to insert the bundle vertically
in the shell. Tube bundle can be lifted vertically with the help of thread
holes in the tubes plates. For horizontal assembly bundle should be
supported under the baffle or support sheet.
Move the tube bundle further and let it stick out a bit on the other side of
the shell.
11.12
Hint : when it is difficult to move the tube bundle through the shell because the
already mounted O-ring is hard to compress, you can use a strip between tube
sheet and channel and then tighten bolts and nuts.
Mount the fixation plates to secure the bundle in the shell. Note that the
fixation plates of the cooler with an even number of tube passes should
always be mounted on the same side as the channel.
Make sure that the cold medium circulation is established first, followed
by the gradual introduction of the hot medium.
Vent both circuits again when the operating temperatures and pressures
are reached.
Drain the tube side circuit, by opening the drain in the lowest point and the
vent in the highest point
Mark the position of all parts that will be disassembled, so they can be
mounted in the correct position later on
Remove the water boxes by un-tightening the nuts (the fixation plates
come loose as well)
11.13
Mount the fixation plates again with the nuts (not necessary when the
tube bundle is going to be removed (see step 4))
Drain the shell side circuit, by opening the drain in the lowest point and the
vent in the highest point.
Move the tube bundle to one side until the inner O-ring shows (do not
move the tube bundle further than necessary) and remove this O-ring.
Refer methods.
Move the tube bundle to the other side and remove the outer O-ring on this
side as well.
Support the tube bundle under the baffles or support sheet when lifting it,
but we should handle careful not to bend the baffles (this would affect the
thermal performance of the heat exchanger)
11.14
11.15
11.16
Remarks
Copper fin is very fragile part of the cooler and should be handled with a
lot of caution
For casting design with a blind side, bundle is designed with a small and a big
tube sheet. The small tube sheet is inserted at first in the casting with the 4 O-
rings already mounted. Fixed tube sheet has to be placed always at the channel
side (for 2 pass execution).
O-rings: After disassembling the heat exchanger never use the old O-rings
again. Replace them with original Bloksma O-rings.
Check :
Whether the heat exchanger and the system have been properly vented
Whether the flows are according to the specification (check all valves,
lines and pumps, as well as the flow directions)
11.17
Whether the shell-as well as the tube side have been cleaned recently
(fouling can cause a drop in performance and an increased pressure loss;
an increased pressure drop is a good indication that cleaning is necessary).
The tubes are roller expanded into the tube sheet. It is either not possible
(finned tube bundles) or relatively complicated (un-finned tube bundles) to replace
a leaking tube, but it can be plugged with soft copper plugs (other materials are
too hard and may cause leakage of the adjacent tube-to-tube sheet connections)
in both tube ends. A maximum of approximately 10% plugged tubes will not
influence the thermal performance of the heat exchanger too much.
The oil pressure regulator maintains oil pressure adequate for the oil system.
At the correct setting, oil pressure gauge indicates 1.5 2.2 kgf/cm2.
When the pressure is lower, turn the adjustment control knob clockwise.
If the oil pressure drops to 1.1 kgf/cm2, the pressure switch shuts down the unit
automatically due to low oil pressure.
11.18
Fig 11.9 OIL PRESSURE RELIEF VALVE
Apply grease on the pinion gear and the rack of piston rod every six months
11.19
11.8 Blow-off Silencer
Check the blow-off silencer every 10,000 hours or every one and a half years,
whichever comes first. Replace the sound absorbing material or the entire blow-
off silencer with a new one if necessary.
Disassembling Procedure
Remove the top panel from the soundproof cover by loosening the corner
bolts.
Remove the blow-off silencer from the ventilation box.
Loosen the bolt installed at the top cover of the blow-off silencer.
After removing the top cover, check it for warping, deflection or cracks.
Remove the cartridge of sound absorbing material from the blow off silencer.
Check the dispersing condition of the sound absorbing material.
If a lot sound absorbing material is lost, it is necessary to replace the
sound absorbing material with a new one.
Assemble the blow-off silencer in the reverse order.
11.20
11.9 Disassembly of Soundproof Cover
The soundproof cover consists of several panels, doors and shaped steel.
They are bolted to each other so that it is easy to assemble or disassemble
them.
11.21
13.0 Lubrication Oil Specifications
The oil should have oxidation stability. It should contain deforming inhibitors
and shall be free of inorganic acids or alkalis. The oil should not have a tendency
to oxidize or form sludge when mixed with air and water.
Anti-wear Hydraulic Fluid must be used for forced lubrication system. Use the
lubrication oil that meets the following specification only, for the compressor
lubrication system.
TABLE 13.1
Most of the Oil companies are able to supply a lubricant suitable for our
compressors and meet the above specification. But it is not recommended to
mix different brands of oil to use in the system.
13.0
14.0 Installation
General
The condition of the compressor unit shall be carefully inspected after receiving
(FIG. 14.1
Any indication of damage due to the carrier shall be noted on the delivery
receipt.
Handling
The unit can be moved with a fork lift truck. After opening the door of container
box, draw the compressor unit from container box in a forklift Truck, steel wire
ropes can be used.
To move the unit with a shop crane, steel wire ropes can be used and spreader
bars shall be used together to prevent the wire ropes from imposing a force
against the top of the unit. Be sure to apply pad material to the unit to prevent
any damage.
14.0
FIG 14.2 DRAW ACOMPRESSOR UNIT
14.1
Location in Plant (SEC.16 INSTALLATION PLAN)
Locate the unit in a dry and well-ventilated area with sufficient room for proper
and safe inspection and maintenance. The unit shall never be installed in a
damp or dusty atmosphere or where corrosive vapors may enter the compressor
or the driver. For motor driven units, the heat radiated from the unit is
approximately twelve percent (12%) of the total horsepower. A ventilating fan
may be prepared for the room to keep the ambient temperature at 40C or lower.
Disassembly Work
After locating the unit, remove the desiccants from the suction box panel and
the control panel.
Remove the stud bolt from the end cover of air end. Connect the nylon tube for
Lube Oil. Remove the stud bolt from the gear casing and plug it.
Remove the plug from the safety valve and drain silencer.
14.2
2. Assembly Work
Put the oil piping in place of the stud bolts for end cover of 2nd stage air-end.
Put the plugs for end cover of 1st stage air-end and the plug for gear casing in
place of the stud bolts.
14.3
15.0 Cooling Water Quality
If the cooling tower supplies the cooling water to the unit, corrosion, scale or
slime may be a problem caused by :
1. Water has a high mineral content
2. Foreign matter like insects
3. Algae or bacterium
Use cooling water of as good a quality as possible, following the TABLE 14.1
The life-time of the cooling water system depends upon water quality. If the
cooling water quality is not good, the cooler pipes can be corroded, or scale can
be generated. In order to prevent problems, sample the cooling water used and
subject it to quality inspection periodically, correct if required.
15.0
TABLE 15-1 COOLING WATER QUALITY IN A CLOSED SYSTEM
15.1
16.0 Preservation
SCOPE : The preservation activity should be carried out when the machine is
kept under idle condition for more than six month from the date of dispatch.
This is also applicable for Machines which will be kept idle after commissioning.
Note: This preservation procedure is prepared assuming that the compressor
package is stored as per storage procedure
OPERATION DETAILS :
Ensure stability of the packing case of machine, before moving the compressor
package.
(a) Open the packing case and keep the compressor package in dry, levelled
surface in weather proof area.
(b) Do visual inspection to find if there is any rust formation on the critical
components such as Rotors( whever is getting exposed), first stage airblock
outlet pipe, second stage airblock suction pipe, Moisture separators stage
gears and timing gears. If rust found Contact HO service before proceeding
further.
(c) Rotate the coupling for more than fifty times by hand, ensuring the free
rotation of the shaft. The rotational direction is clockwise direction when
view from non-drive end side of main motor.
(e) Purge Dry air/Nitrogen for about 30 minutes through the provision provided
in the package. Repeat this activity for every 6 months.
(f) Replace all silica gel packs with new packs. Repeat this acivity for every
6 months.
(g) Cover or wrap the compressor to avoid dust, insect and moisture entry.
16.0
Compressor placed at intended location
(h) Follow the steps (b), (c), (d), (e) and (f).
(i) Check for any external / internal damages of the package. If found any
damages contact HO service pesonnel.
Drain the water completely from the compressor by opening the ball valves
in water headers.
Run the compressor for 5 minutes or rotate the compressor shaft for 50
times once in a week.
WI/SER/XXX/RXX
16.1
Index
Page
Installation 18.0
Technical Features 19.0
PLC Input Output Configuration 20.0
Main Menu Screen 21.0
Menu Structure 22.0
APPENDIX C: MODBUS Table 23.0
Electrical item part code list 24.0
17.0
17.1
Installation
Electrical
Customer must provide a switching fuse unit with pre connected slow blow main fuses
as per industrial safety regulations. The power supply should be 415V,50Hz Ac supply
with earthing
Fuse and cable specifications for 415V,50HZ power supplies are listed in the table
below.
Block Diagram
Elgi Oil Free Screw Air Compressor operation is controlled by PLC of Allen Bradley
Make. The Block Diagram below explains the entire accessories of PLC Micro Logics
1400 Model.
18.0
Installation
Power Supply
Power Supply unit is a Allen Bradley make and it requires 100 -240V, 50/60Hz AC
Input Supply and 24-28V DC as Output, 3.3 to 2.7A current respectively. Default
Factory set is 24.1V DC. NEC class2 Power supply. Operating temperature is -25 to
+60C
The output of 24V DC is used for PLC as well as for display panel view 400.
ML 1400
It is a PLC with 20 digital inputs and 10 relay outputs. This unit requires 24V DC
supply for its operation.
18.1
Installation
AI
It is an Analog Input unit. One module can process 4 numbers of Analog
inputs.Generally our machine uses 8 analog inputs and hence 2 Analog input (AI1 &
AI2) Module IF4 is used. The input type used is 4mA to 20mA.
RTD
This RTD module is optional which also has 4 inputs. The RTD modules can be
increased according to the requirement. The standard program contains 2 RTD modules
IR4.
18.2
Installation
18.3
Technical Features
Memory Flash/RAM
Standard 64 MB / 64 MB, Not expandable
Communication Port
RS232 and (1) USB Only or Ethernet, RS232, (1) USB, plus optional DH485, DH+,Or
Remote I/O modules, Control net and Device net modules
Power Consumption
19.0
PLC Input Output Configuration
Digital Inputs
20.0
PLC Input Output Configuration
Analog Inputs
20.1
PLC Input Output Configuration
Digital Output
20.2
PLC Input Output Configuration
Flow Charts Start Sequence
Start command
No
Check inlet
water pressure must be
greater than 1 bar + water Go to trip sequence
flow & pressure swich
must NC
Yes
Go to trip sequence
Switch on oil pump motor
Yes
Yes
Start output on
No
Is run fewd back
received
Go to trip sequence
Yes
20.3
PLC Input Output Configuration
Stop Sequence
Start command
Is No
machine on? Return
Yes
Delay
Load "Off"
No
Is
run feed back Go to trip sequence &
withdrawn? run oil pump
Yes
Ready
20.4
PLC Input Output Configuration
Is
machine Return
No
Yes
No
Is Is
DIS Pr < DIS Pr Return
Load pr < UL pr
No
Yes
Load 'OFF'
Is previous
load to new
load 5
seconds gap
provided
Yes
5 seconds
delay from Increment load
previous Load 'ON'
count
load
Stand by mode: In unload mode, if the pressure exceeds the set load pressure in
the preset stand by time, and is less than number of start/ stop cycles during that
time the compressor goes into standby mode. (or the compressor stops as per stop
sequence)
In stand by mode, if the pressure drops below the set load pressure, the compressor
starts automatically as per the start sequence.
20.5
Main Menu Screen
Startup Screen
Home Screen
21.0
Main Menu Screen
Note: The Operation of Functional Keys will differ from screen to screen.
21.1
Main Menu Screen
Keys and It's Function
21.2
Main Menu Screen
21.3
Menu Structure
View
View
No password required
In view parameters the setted parameters like pressure values, temp values, timer
settings, previous fault reports, last event report, remaining service hours due,
cumulative time details, I/O status, program version and compressor information
parameters can be viewed.
(Only viewing is permitted. Parameters cannot be altered through this menu)
22.0
Menu Structure
The threewinding
The three windingofofthe
themotor
motor and
Motor and
the the drive
Drive Endend
andand
Nonnon drive
drive End
View
Temperature Temperature
end temperaturecan can
be viewed in this
be viewed
in this screenscreen.
The
The recent faults of
recent faults of the
the machine
machine
View Fault Report cancan
bebe
seen in in
this screen
seen this screen
22.1
Menu Structure
This screen
This screen will will
helpshelps
to knowto
the
know the status of digital
status of Digital inputs/Outputs.
inputs/ outputs
RED Colour Indicates Unhealthy
View I/O Status
Red colour indicates unhealthy
Green Colour Indicates Healthy
conditions
Green colour indicates healthy
conditions
Compress Compressor
Compressor manufacturing
Manufacturing
View or information can
Information can bebe viewed
viewed in thisin
Information this screen screen.
22.2
Menu Structure
Operator
Password is mandatory for entering in to Operator Menu.
Follow the below mentioned sequence for entering into Operator Menu.
User Name : 0
Password : 9562
22.3
Menu Structure
In this menu, the operator parameters can be adjusted as per the requirement. Minimum
and maximum limits are fixed for all the value adjustment parameters. When the
settings exceeds these values, there will be an indication of " out of range"
The minimum and maximum limits are mentioned in the pop-up keypad.
To exit from the operator menu, use back key which reaches main menu and then
press F8 key to logout safely.
If the keypad is kept under rest till 60 seconds then the system will automatically
logout from the previous users login.
22.4
Menu Structure
Operator
Manual Standby
Unload Selection
Machine
This menu contains the following three parameters called Mode, Pressure & Set
Delay.
22.5
Menu Structure
Mode
This parameter is used to select the pressure unit and temperature unit.
Pressure Unit:-bar or kg/cm2 (Press F5 for selection)
Temperature Unit: - Degree celcius or Fahrenheit (Press F6 for selection)
Pressure
In this menu, the four different operating pressures (load and unload) can be fed by
the customer as per his requirement. The customer can then select any one of the
required operating pressure ranges.
22.6
Menu Structure
Set Delay
The load delay, stop delay and machine number of start/stop per hour can be limited
by using this menu according to customer's requirement.
When the machine is tried to start beyond the start/stop set value, then the machine
will not function and pop- up a caution message with remaining time of an hour.
Schedule
The customer can enable the pressure schedule according to his requirement. It is
possible to set the compressor working pressure throughout the week along with time
settings.
Select the required DAY using the corresponding function key, a new screen will pop
up where you can enter the time and compressor operating pressure range.
22.7
Menu Structure
Maintenance
Air filter, Oil filter, Oil and Regreasing remaining time can be viewed in this menu.
Decrement counter will run accordingly.
Warning message will pop-up when the preset time counting becomes zero.
Manual Unload
This function is provided to verify the function of the compressor with out loading.
If this mode is selected, the relay output (load / unload) will be de-energized continuously
and the compressor runs in unload mode. If the function is disabled, the compressor
runs as per pressure setting done in the PLC.
22.8
Menu Structure
Mode Selection
The compressor can be operated in three modes. Local, Remote and DCS.
Local
The compressor is on/off through start and stop button in the HMI.
Remote
The compressor is on/off through the digital input remote start/stop (IN7). By this
mode the compressor cannot the switched on/off through HMI.
DCS
In DCS mode the compressor can be operated through modbus only.
In all the modes compressor can be stopped through emergency push button.
22.9
Menu Structure
Standby Selection
When the compressor is running continuously in unload for a Saturn set time, it will
automatically shut down and restart automatically when the pressure demand exists.
Enable the standby selection and then set the required standby time in minutes.
When the power resumes, caution message pop up in the screen with decrement
counting of remaining set time in seconds and compressor will start functioning.
22.10
Menu Structure
Language Selection
The language can be selected using this menu. Default language set is English.
Service
These service menu parameters can be accessed by only our service engineers.
Set the next service due time for the replaced items.
22.11
Menu Structure
Edit the required date and time in the respective cells. Press F5 once and then press
F6 to save the changes.
Factory
The factory menu contains the following parameters. This will be set in the factory
itself.
Do not try to change the factory settings.
Compressor Information
In this screen, the machine manufacturing information will be entered by the authorised
person in the factory .
22.12
Menu Structure
Pressure configuration
All the pressure values for alarm and trip range will be fed in this screen.Based on this
setting, the compressor will perform alarm and trip operations.
The factory set limits are provided in the table on page 22.14
Temperature settings
All the temperature values for alarm and trip range will be fed in this screen. Based on
this setting the compressure will perform alarm and trip operation.
The factory set limits are provided in the table on page 22.14
The factory set limits are provided in the table on page 22.14
Flow settings
Compressor water flow alarm and trip values will be fed in this screen.
The factory set limits are provided in the table on page 22.14
22.13
Menu Structure
Max & Min Factory setting Values:
III FACTORY
1 Compressor Information
6.7 Motor Drive End Bearing Temp (DE) 30 - 110 0 -5 30 - 120 0 -10
Motor Non Drive End Bearing Temp 30 - 110 0 -5 30 - 120 0 -10
6.8 (NDE)
22.14
APPENDIX C: MODBUS Table
23.0
APPENDIX C: MODBUS Table
23.1
Electrical item part code list
24.0
General arrangement of OFSAC
25.0
General arrangement of OFSAC
25.1
Base System
25.2
Base System
25.3
Air Intake system
25.4
Air Intake system
25.5
Capacity control valve assembly
25.6
Capacity control valve assembly
25.7
Capacity control valve assembly
25.8
Capacity control valve assembly
25.9
Drive system
25.10
Drive system
25.11
Gearcase assembly
25.12
Gearcase assembly
25.13
Air block system
25.14
Air block system
25.15
Discharge system
25.16
Discharge system
25.17
Discharge system
25.18
Discharge system
25.19
Cooling system
25.20
Cooling system
25.21
Cooling system
25.22
Cooling system
25.23
Intercooler assembly
25.24
Intercooler assembly
25.25
Aftercooler assembly
25.26
Aftercooler assembly
25.27
Lubrication system
25.28
Lubrication system
25.29
Lubrication system
25.30
Lubrication system
25.31
Lubrication system
25.32
Lubrication system
25.33
Control system
25.34
Control system
25.35
Instrument system
25.36
Instrument system
25.37
Canopy system
25.38
Canopy system
25.39
Frame assembly
25.40
Frame assembly
25.41
Recommended Spares Parts for NE265 PLC Model
26.0
RECOMMENDED SPARES PARTS
26.1