Published by: Product Information Department Part Number: C20160-836 (Issue 4) 24 CompAir BroomWade CompAir BroomWade Limited Hughenden Avenue High Wycombe, Buckinghamshire England HP13 SSF Telephone: (01494) 465000 (01494) 510900 ‘Telex: 837371 Fax No: (01494) 462624 Printed in England Se RRR RRR RRR RRR eee eee eee eee eeeSEB BB BRB RP TR RPK BRET e eee ee eee eee OCUDN User Manual BroomWade 6040N & 6050N air compressors J CompAirCompAlr BroomWade Limited FOREWORD ‘These compressors are intended for compressing atmospheric alr and are not sultable for compressing any other gas. They are designed and manufactured to give optimum performance, with long life and reliability “This manual gives the user all the information required to install, commission end operate the compressors and carry out the regular schedules for servicing and maintenance which will ensure the maximum satisfactory service ite. Servicing facilities and the supply of genuine replacement parts are provided through a worldwide network of CompAlir BroomWade Distrioutors, backed up by the Service and Parts departments at High Wycombe. If replacement paris are needed, the user should contact the local Distributor in the first instance. “The information given in this manual was correct atthe time of printing but modifications to parts and procedures may be made without notice which ould affect the servicing requirements of the compressors. Before any servicing or maintenance work is undertaken the user is advised to contact the local CompAir BroomWade Distributor who is supplied with revised and up-dated information on microfiche. tn any communication conceming the compressor it i essential to quote the MODEL and SERIAL NUMBER. ‘Throughout this manual all pressures quoted are gauge pressure unless. otherwise specified. SR BRB BRR RRR ERB RRR RBBBGO40N & 6050N User Manual €20160-836, Issue 4, December 1994 USER MANUAL 6040N & 6050N AIR COMPRESSORS Serial Numbers trom: GO40N: F138/0101 6050N: F139/0501 CONTENTS Page __ illustrations Page 1. Safety Procedures 5 Control Panel 8 2, General Description 11 AivfOn System 15 3. Leading Particulars 19 Regulation System (Schematic) 7 4, Installation 21 Pressure Switch 28 5. Commissioning & Operation 25 Servicing Points 36 6. Maintenance 31 Reclaimer Cover Tightening 40 7. Fault Finding 45 Electrical Connection Diagram 49 ‘Appendix — The Pressure Systems & Ait Compressor Circuit Diagram 52 Transportable Gas Container Regulations 1989 8t age 1CompAir BroomWade Limited OWNERSHIP DATA TECHNICAL DATA MODEL: AIR-END SERIAL NUMBER: SERIAL NUMBER: MOTOR SERIAL NUMBER: YEAR: RECLAIMER CERTIFICATE NUMBER: MAXIMUM PRESSURE: DELIVERY DATE: kw: MOTOR RPM: COMPRESSOR LUBRICANT: V. PH. H2. LUBRICANT CAPACITY: wenn: QPapPLCASlay eet LOCAL COMPAIR BROOMWADE DISTRIBUTOR NAME: ADDRESS: TELEPHONE: FAX: CONTACT NAMES: PARTS: SERVICE: page 2BUBB RBBB RBBB RPP Pee Ree eee eee ee MODEL DESIGNATION ‘The Model Designation code identifies specitic models as follows: DESIGNATION BHO EHaH EH OLE NEE OEE tree a a;lsB}]se]Bic}]oi]ole | A= SERIES 6000 SERIES B = MOTOR RATING 40 HP C= MACHINE TYPE CYCLON AIR-END D = DELIVERY PRESSURE 75BAR £ = COOLING MEDIUM A= AIR COOLED This publication relates to the following models: 6040NO7A 6050N07A G040N10A B050N10A, 6040N13A 6050N13A ASSOCIATED PUBLICATIONS Model Title Part No. 6040N & 6050N Repair Manual 20160-1010 ‘BO40N & GO50N Parts List (Multi-Lingual) 20160-1098 These publications may be obtained through CompAir BroomWade Distributors. age 8(CompAir BroomWade Limited WARRANTY The conditions of the CompAir BroomWade ‘Warranty are set out in the company's standard Conditions of Sale available trom the Distributor supplying the machine. MAINTENANCE To ensure the cor the compressor unit its important that periodic ‘maintenance and servicing is carried out in accordance with the information given in the ‘Maintenance’ section of this manual. if any replacement or repair is needed use only ‘CompAir BroomWade Genuine Parts. A Warning A ‘The use of replacement parts or lubricating oils not supplied or approved by CompAir BroomWade may lead to failures in service which would not be ‘covered by warranty. Any unauthorised modifications or failure to maintain this equipment in accordance with the maintenance instructions may make it unsafe, The use of replacement parts not supplied or approved by CompAir BroomWade may create hazardous conditions over which CompAir BroomWade has no control. ‘Such hazardous conditions may lead to accidents that can be life threatening, ‘cause substantial bodily injury or result in damage to the equipment. CompAi BroomWade can bear no responsibility for equipment in which unapproved replacement parts are included. 2S CompAir BroomWade GENUINE PARTS page 4 BER RBBB BBR RBBB BRB BBRPRP RRR eee eee eeeSRB BRB BRB RB RBBB RB RBRPRSRBRBRBRBRBRRRReeeeeenV0ee ee 6040N & 6050N User Manual 1 SAFETY PROCEDURES General Wamings, Cautions and Notes General Safety Precautions Installation Precautions Operational Precautions. Maintenance and Repair Precautions Precautions in the Event of Fire Page 10 page 5(CompAir BroomV/ade Limited SAFETY PROCEDURES 1. GENERAL Most accidents which occur during the operation and maintenance of machinery are the result of failure to observe basic safety rules or precautions. ‘An accident can often be avoided by recognising a situation that is potentially hazardous. When handling, operating or carrying out maintenance on the unit, personnel must use safe engineering practices and observe alll relevant local health and safety requirements and regulations. ‘The attention of users in the UK is drawn to the Health and Safety at Work Act, 1974, and to the Regulations of the institution of Electrical Engineers. ‘CompAir BroomWade cannot anticipate every possible circumstance which might represent a potential hazard. The WARNINGS in this manual are therefore not all-inclusive. If the user employs ‘an operating procedure, an item of equipment or a method of working which is not specifically recommended by CompA\r BroomWade he must ‘ensure that the unit will not be damaged or made Unsafe and that there is no risk to persons or property. Failure to observe the precautions given under ‘Safety Procedures’ may be considered dangerous Practice or misuse of the compressor unit, 2. WARNINGS, CAUTIONS AND NOTES 2.1 Warnings Warnings call attention to operations or procedures: involving specific hazards which could cause injury or death and are identified by the following symbols con the unit and in the text of the manual. WARNING: RISK OF DANGER, WARNING: RISK OF ELECTRIC SHOCK WARNING: RISK OF HOT SURFACES WARNING: CONSULT MANUAL WARNING: RISK OF HIGH PRESSURE 22 Cautions Incorrect operational procedures causing possible damage to the compressor unit are identified by a ‘CAUTION’ in the text of this manual. 2.3 Notes Methods to make the job easier and points which require particular attention are identified by a ‘Note’ in the text of the manual page 6BEB RBBB RRP RRR RR RRP RRR RR eee eee eee ‘6040N & 6050N User Manual Safety Procedures 3. GENERAL SAFETY PRECAUTIONS When using cleaning solvents, local Health and Safety regulations must be complied with. Provide ‘good ventilation and use suitable protection such as a breathing filter mask, safety glasses, protective apron and gloves. Safety footwear should be compulsory in all workshops. Safety helmets must be worn if there is any tisk of falling objects. using compressed air for cleaning purposes, ensure safety regulations are complied with and appropriate clothing and eye protection is worn. Never direct compressed air onto your skin or at other people. Never use compressed air to clean loose dirt from clothing. Before releasing compressed air through a hose: make sure that the free end is held securely so that it cannot whip and cause injury. Avoid injury by using a hoist to lift heavy loads. Check that all chains, hooks, shackles and slings are in good condition and are of the correct ‘capacity. They must be tested and approved according to local safety regulations. Cables, chains or ropes must never be applied directly 0 lifting eyes. Always use an appropriate shackle or hook, property positioned. Arrange lifting ‘cables 50 that there are no sharp bends. Use a spreader bar to avoid side loads on hooks, eyes and shackles. When a toad is on a hoist stay clear of the danger area beneath and around it. Keep lifting acceleration and speed within safe limits and never leave a load hanging on a hoist for longer than is necessary. INSTALLATION PRECAUTIONS Installation work must only be cartied out by ‘competent personnel under a qualified supervisor. ‘A fused isolating switch must be fited between the main power supply and the compressor. Ensure that air drawn into the air intake will not be contaminated with flammable fumes or vapours, ‘since this could cause an internal fire or explosion. Precautions must be taken to ensure that no injury is caused to passers-by through loose clothing bbeing sucked into the air intake. Ensure that the air delivery pipe from the ‘compressor to the user's pipework or receiver is free to expand and that no flammable material is within the vicinity. A shut-off vaive must be fitted in the delivery air line to enable the compressor unit to be isolated. This is particularly important if more than one unit is to be coupled in parallel or connected to an existing alr ‘supply system. The minimum pressure/non-return valve is not intended as an isolating valve and should not be relied upon for this purpose. In addition, it may be ecessary to install shut-off valves elsewhere in the system to allow a dryer or other equipment to be. by-passed. A safety relief valve must be installed between any ‘compressor unit and the shut-off valvels. A safety relief valve is fitted on the reclaimer vessel as standard equipment. A pressure relieving device must be fitted to every Pressure vessel, or equipment containing air at above atmospheric pressure, when installed downstream of the unit. If raised platiorms are required to provide access to the unit they must not interfere with normal operation or obstruct access for lifting or dismantling components. Platforms and stairs should be of grid or plate construction with safety rails on all open sides. In order to control the risk of Legionnaires Disease, ‘CompAir BroomWade strongly advise against the Use of water cooling tower systems for water ‘cooled compressors. A closed circuit radiator system Is preferred (see Bulletin CBB 2083). page 7(CompAir BroomWade Limited 5. OPERATIONAL PRECAUTIONS ‘The compressor unit must only be operated by ‘competent personnel under a qualified supervisor. Do not run the compressor with doors open or covers removed. Never remove or tamper with the safety devices, ‘quards or insulation materials fitted to the unit. ‘The compressor must only be operated at the supply voltage and/or frequency for which itis designed, When mains power is switched on, lethal voltages are present in the electrical circuits and extreme caution must be exercised whenever itis necessary to carry out any work on the electrical system. Do not open the starter compartment or touch ‘electrical components while voltage is applied unless itis necessary for measurements, tests or adjustments. Such work should be carried out only by a qualified electrician equipped with the proper tools and wearing appropriate body protection against electrical hazards, ‘On a unit equipped with an Automatic Start/Stop system, attach a sign stating “THIS UNIT MAY ‘START WITHOUT WARNING? next to the display panel. ‘On a unit equipped with an Automatic Restart device, attach a warming notice stating ‘THIS UNIT HAS BEEN MODIFIED AND WILL START AUTOMATICALLY ON APPLICATION OF POWER? next to the display panel and on the inside of the unit next to the starter contactors. l#the unit is equipped with a Remote Control device, attach warning notices stating “THIS UNIT CAN BE STARTED REMOTELY’ in prominent locations, one on the outside of the unit, the other inside the control compartment. Asa further safeguard, take adequate precautions to make sure there is no one checking or working ‘on the unit before attempting to switch on remotely controlled equipment. Attach a ‘CHECK THAT ALL PERSONNEL ARE CLEAR OF THE UNIT BEFORE STARTING’ or similar waming notice to the remote start equipment. During normal operation no intemal part of the ‘compressor unit should reach a temperature above 100°C and protection devioes are fitted to prevent excessive temperatures occurring. On water cooled ‘models, the cooling water outlet pipe is likely to teach 80°C and must be painted or marked ‘according to the local safety code. The pipe must be guarded or insulated where injury to personnel ‘could occur. If there is any indication that the compressor is overheating it must be shut down and the cause investigated. Beware of bums from hot metal parts, hot oil and water when working on a unit which has recently been shut down. ‘The compressor must not be operated at pressures above the nominal pressure given on the data Plate. ‘The compressor must not be operated in ambient temperatures outside of those given under ‘Leading Particulars’. ‘The ‘Noise at Work Regulations 1989" suggest that ar protectors should be worn where noise levels are 85 dB(A) or higher. With all covers in place, the noise levels of the compressors described in the manual are substantially lower than this fi unless installed in an already noisy environment. Be aware that high noise levels can interfere with ‘communication. 6. MAINTENANCE AND REPAIR PRECAUTIONS Maintenance, repairs or modifications must only be ‘carried out by competent personnel under a qualified supervisor. replacement parts are needed use only CompAir BroomWade Genuine Paris. Before removing any panels from the enclosure, i fitted, or dismantling any part of the unit, carry out the following preparatory operatio 1. Isolate the compressor unit from the main electrical power supply. Lock the isolator in the ‘OFF’ position and remove the fuses. page 8 BERR BEER R RRR RRR RRR eee eeeSUB RB RBBB ERB BEB RB BERBER RRR eee eee 6040N & 6050N User Manual ~ Safety Procedures 2. Attach a label to the isolator switch and display panel carrying the warming ‘WORK IN PROGRESS - DO NOT APPLY VOLTAGE” Do not switch on electrical power or attempt to start the unit if a waming label is attached. 8. Close the isolating valve between the ‘compressor unit and the user's pipework. Close the isolating valve in the cooling water inlet pipe. Attach a label to each valve carrying the warning ‘WORK IN PROGRESS ~DO NOT OPEN’ 4, Ensure that the blowdown system has operated to release all pressure from the reclaimer, 5. Check that the pressure gauge registers zero, Release any remaining pressure from the delivery side of the reciaimer element by slackening the pipe connection to the differential pressure switch at the rectaimer fend, Release any residual pressure from the upstream side of the reclaimer element by slowly slackening the oil filler plug on the reciaimer. Tighten the plug. Keep a written record of all maintenance and repair ‘work carried out on the compressor unit. The frequency and nature of the work required over a period can reveal adverse operating conditions Which should be corrected. Use only lubricating oils and greases approved by CompAir BroomWade. Make sure that the selected lubricants comply with all relevant safety regulations, especially with regard to the tisk of explosion or fire and the possibilty of decomposition or the generation of hazardous gases. ‘Always clean up oil spills from the surrounding floor and outside of the compressor unit before and after ‘maintenance work. ‘Make sure that ail instructions conceming operation and maintenance are strictly followed and that the complete unit, with all accessories and safety devices, is kept in good running order. The accuracy of pressure and temperature gauges ‘and switching thermometers must be regularly checked, They must be renewed when acceptabie tolerances are exceeded. Protection devices must be tested as described in the ‘Maintenance’ section of this manual. Keep the compressor unit clean at al times. Protect ‘components and exposed openings by covering with clean cloth or tape during maintenance and repair work. Protect the motor, alr intake, electrical and regulation components against the entry of moisture, e.g. when steam cleaning, Precautions must be taken when carrying out ‘welding or any repair operation which generates heat, flames or sparks. The adjacent components must always be screened with non-tlammabie material and if the operation is to be carried out ear any part of the oil system, or close to a ‘component which may contain oil, the system must first be thoroughly purged, preferably by steam cleaning. Never use a light source with an open flame to inspect any part of the unit. In no circumstances must any welding work or other modification be carried out on the rectaimer ‘or any other pressure vessel. Before dismantling of any part of the compressor unit ensure that all heavy movable parts are secured, iter completion of repair or maintenance work ensure that no tools, loose items or rags are left on or inside any part of the machine. Check the direction of rotation of the motor when starting up the compressor initially and after any work on the electrical connections or switchgear. Do not use any flammable liquid to clean valves, fiter elements, cooler air passages, air pipes or any ‘component carrying a flow of air during normal operation. If chlorinated hydrocarbon non- flammable fluids are usad for cleaning, safety precautions must be taken against any toxic vapours which may be released. Do not use carbon tetrachloride.‘CompAir BroomVade Limited Precautions must be taken when using acids, alkalis and chemical detergents for cleaning machine parts and componenis. These materials ‘cause irtitation and are corrosive to the skin, eyes, ‘nose and throat. Avoid splashes and wear suitable protective clothing and goggles. Do not breathe ‘mists. Ensure that water and soap are readily available. When disposing of condensate, old oil, used fier elements and other parts and waste material of any kind make sure that there is no pollution of any drain or natural water-course and that no burning of waste takes place which could cause pollution of the air. Protect the environment by using only approved methods of disposal. 7. PRECAUTIONS IN THE EVENT OF FIRE Use extreme caution when handling components that have been subjected to fire or very high temperatures. Some components may contain fiuoroelastomer materials which decompose under these conditions to form highly corrosive residues. Skin contact can cause painful and penetrating burns resulting in permanent skin and tissue damage. age 10SEB BRR RBBB EBB RRB RRP eee eee eee eee eee 6040N & 6050N User Manual GENERAL DESCRIPTION Page ‘Compressor 12 Air-End 12 Control Panel 2 Protection and Safety Equipment 13 Relief Valve 13 Biowdown System 13 Minimum Pressure 8 Ait/Oil System 14 Description 14 Operation 14 Regulation System 16 Description 16 Operation 16 Stopping 18 ‘Automatic Starting and Stopping 18 page 11‘CompAir BroomWade Limited GENERAL DESCRIPTION 1, COMPRESSOR ‘The unit isa fully enclosed, air cooled, single- stage, rotary screw compressor. The compressor air-end is belt driven by an electric squirrel-cage induction motor. The drive belt being mounted on pulleys fitted to the shafts of the drive motor and airend. ‘The compressor unit consists of the drive motor, air-end, reclaimer, combinad air/oil cooler, co¢ ‘fan, starter assembly and control panel. ‘The complete compressor unit is mounted on a baseframe and is housed in a steel panelled acoustic enclosure. A hinged access door allows. access for routine maintenance. The air is compressed in a single-stage, positive displacement, of injected rotary screw air-end. The air-end is of the Cycion type and comprises an intermeshing pair of helical screw rotors, male and female, mounted horizontally within an enclosed ceasing with drive being applied to the male rotor. The male rotor in the Cyclon air-end is larger in diameter than the female rotor and has four lobes which mesh with five flutes on the female rotor. The rotors are asymmetric in profile to reduce blowback between the lobes on the compression cycle to a minimum, thus maximising the overall sealing and efficiency. ‘The rotors are fitted with bearings at each end to provide radial and axial support, maintain adequate shaft stiffness and to give minimum clearance and low leakage between the rotor tip diameter and the casing, Atthe delivery end the male rotor is fitted with a single taper roller bearing and the female rotor is provided with a matched pair of taper roller bearings. These bearings provide axial and radial support of both rotors and contol the very fine end clearances between the rotors and the casing. Heavy duty parallel roller bearings are fitted to both rotors at the inlet end to provide radial support and to sustain the drive ioad of the male rotor. 3. CONTROL PANEL ‘Tho Control Panel carries the following information displays and controls: 1. A‘POWER ON indicator which remains illuminated so long as power is applied. 2. Agreen ‘START’ switch which lights when the unit is ready to start and is extinguished when the switch is pressed. 3. A'STOP' switch, 4, A‘PRESSURE’ dial gauge showing air pressure on the delivery side of the reclaimer element. 5. An hourmeter showing TOTAL HOURS RUN’. 6. Two ‘FAULT lamps which light when the ‘compressor is shut down automatically by the action of the protection circuits and indicate respectively excessively high temperature of the air discharged from the air-end and over- heating of either the drive motor or the fan motor. 7. ‘RESET’ switch, This is used to reset the system after shut-down through the operation of the fault protection circuit or the ‘EMERGENCY STOP" switch. 8. An‘EMERGENCY STOP palm switch. This is latched when operated and is released by ‘tuming through 45°. The control system ‘cannot be reset or the compressor restarted until the ‘EMERGENCY STOP" switch is uunlatched. 9. _A‘TEST’ button. When held pressed it causes the pressure gauge to show the air pressure upstream of the oll reclaimer element. By ‘comparing this reading with the normal indication of delivery air pressure the pressure drop across the reciaimer element can be calculated. page 12 SERBS RRR ERR RRR eee eee eee eee eeeBEB BBB RBBB Pee eee ee ee eee eee eee le 6O40N & 6050N User Manual ~ General Description 1. Delivery Air Over-Temperature Indicator 2. Motor Over-Temperature Indicator 8, Reset Switch 4, Stop Switeh 5. Start Switch/Ready-To-Start Indicator 6. Power-On Indicator 7. Hours-Run Meter 8 Emergency Stop Switch 9. Air Pressure Gauge 10. Test Button CONTROL PANEL 4, PROTECTION AND SAFETY EQUIPMENT In addition to the protection and warning circuits linked to the control panel the following protection devices are fitted: 4A. Relief Valve ‘A pressure relief valve is mounted on the reciaimer. If pressure continues to build up when the demand for compressed air has ceased, the relief valve will ‘open at a pre-set pressure level to discharge the reclaimer to atmosphere. 4.2 Blowdown System Whenever the compressor shuts down, either automatically or by operation of a ‘STOP’ switch, all pressure in the reciaimer is automatically released by a blowdown system which vents the pressure to atmosphere. This ensures that the compressor is. restarted in a no-load condition, 4.3 Minimum Pressure Valve Fitted on the reclaimer cover in the delivery airline, the minimum pressure valve remains closed until minimum pressure is reached. This ensures a rapid build-up of pressure when the compressor first starts and also prevents high velocity, low pressure air reaching the user’s pipework during the start-up Period and carrying over excessive amounts of oil. ‘When the compressor shuts down it functions as a non-return valve which prevents the user's pipework pressure feeding back into the reclaimer and venting through the blowdown system. page 13‘CompAir BroomWade Limited 5, AIR/OIL SYSTEM 5.1 Description ‘The airfoil system comprises an air intake filter, ‘suetion regulator, air-end, reclaimer, reclaimer filter ‘element, minimum pressure non-retum valve, ‘combined air/il cooler, thermostatic bypass valve and an oil filter. The flow of oil through the circui achieved by means of the pressure differential existing between the reclaimer and the inlet of the air-end, 5.2 Operation Air enters the compressor unit through the intake filter (2) and open suction regulator (1) to the inlet ort of the air-end (7). The air is trapped by the ‘tuming rotors and mixes with the oil which enters the casing through a restrictor orifice. Continued rotor rotation increases the pressure and temperature of the air/oil mixture which passes through the discharge port of the air-end and onto the underside of the oil reclaimer element (6). Most of the oil is separated at this stage and drops to the bottom of the reclaimer vessel. ‘The remaining airfoil mixture then passes through the two stages of the reclaimer element where final separation takes place. The separated oil is collected in the bottom of the element and ‘scavenged back into the air-end via a strainer (14) and restrictor (15). The restrictor is sized to ensure that the air lost in scavenging is kept to a minimum. ‘The filtered air then passes out of the reclaimer by way of the minimum pressure valve (3). Provided the air pressure at this stage is above 4 bar the alr will be passed to the air section of the oiVair cooler (9) where the warm air is cooled and the resultant condensate automatically removed by the operation of an electronically controlled solenoid valve. The cooled, filtered air then passes to the delivery outiet. Ifthe air pressure in the reclaimer is at any time less than 4 bar the minimum pressure valve will close. The valve also incorporates a non-return valve which operates to prevent delivery air passing back into the reclaimer when the ‘compressor is running off-load. il from the reclaimer flows to the oil section of the airfoil cooler (8). During normal running the oil passes through the cooler to maintain its temperature at a correct level. A thermostatic bypass valve (12) is installed in the oil section of the airfoil cooler. ‘When the compressor is started, the cold oil in the ‘system bypasses the cooler and flows through the oil filter (8) directly to the air-end. As the oil and air mixture is compressed by the rotors in the air-end, the temperature of the oil increases. ‘Once the oil has reached its normal operating temperature the bypass valve closes and the oll is, directed through the oil section of the air/oil cooler. ‘The cooled oil then flows to the oll fter where itis ‘leaned before entering the air-end, ‘The quantity of ol injected into the air-end is ‘controlled by a restrictor office in the ait-end ‘casing, Oils injected under pressure through the restrictor orifice into the rotors and a gallery ‘supplies oil to the air-end bearings. age 14 SEB BRB RBBB RBBB RBBRBRBRBRRPReeeeneeeeeeaVweee eeeBUBB RB BBB RBBB BBE RBRBERB EBS RPERPRBeeeeeeeee eee GO4ON & 6050N User Manual - General Description 1 13, 14, Ts 3 2 : ‘ 15 : 5 1 7 12 € 1. Suction Regulator 9. AinOil Cooler 2 Intake Air Fier 10. Fan 3. Minimum Pressure Vave 41, Delivery Air Outlet 4. Reclaimer 12, Thermostatic Valve 5. Reciaimer Element 13, Scavenge Line 6. Discharge Pipe 44, Strainer 7. Arend 48, Restitor @ Ol Fier AIR/OIL SYSTEM page 15(CompAir BroomWade Limited 6 REGULATION SYSTEM 6.1 Description Control of the compressor unit is achieved through the combined operation of pneumatic, electrical and mechanical devices. The regulation system operates on the principle of full output (on-load) or no output (off-load). 62 Operation In the on-load condition, air passes through the compressor unit as described in ‘AirOll System’ and pressurises the user's pipework. When the pressure in the main system reaches a set level, a pressure switch connected to the air delivery ling is activated and the compressor automatically changes to the off-load operating conaiion. This is achieved by the closing of the suction regulator mounted on the inlet port of the air-end. Air pressure in the rectaimer will start to fall to the off-load pressure set by the regulation system. The ‘compressor will continue to run in this condition Until the main system pressure falls to the lower set point of the pressure switch. It will then ‘automatically change over to the on-load condition, Ifthe compressor continues to run in the offload condition for a pre-set period of time, a timer on the printed circuit board will operate to cutoff the ower to the drive motor. The compressor will stop, all pressure in the reciaimer will be released, and the unit will then be in the ‘standby’ conaition. ‘The unit will remain in the ‘standby’ condition until the pressure in the user's pipework falls to the lower setting of the pressure switch. The compressor will then be restart automatically. 6.2.1. Compressor Stopped; Power On ‘The suction regulator inlet valve (8) is held closed by the combined effect ofits return spring and the main diaphragm spring. The start valve (18) is closed. The bleed valve (2) is held closed and the blowdown valve (18) is open. The minimum pressure valve (10) is held closed by its spring and the unloader valve (4) is closed. Assuming no pressure in the user's pipework, the delivery air pressure switch contacts are closed. 6.2.2 Starting When the compressor is started, the drive belt ‘transmits power to start tuning the rotors in the air-end (14). A depression is created by the tuming rotors which opens the start (non-return) vaive (18) in the suction regulator. A small amount of air is drawn into the air-end to pressurise the reclaimer (12) as fat as the closed minimum pressure valve (10). The closed minimum pressure valve prevents air passing to the user's pipework. The blowdown valve (19) on the manifold is closed by the differential pressure that is now created across the valve diaphragm. The suction regulator inlet valve (3) remains closed. This is to ensure that the ‘compressor starts in the no-load condition. To minimise the starting current the motor control circuit ensures that the motor is run up to speed in the STAR mode. After approximately 3 seconds the control circuit switches the motor to the DELTA. mode. The motor will then continue to operate at full load current. ‘At the same time the control circuit energises the uunloader solenoid valve (4). The valve opens and reclaimer pressure enters the regulator diaphragm ‘chamber to open the suction regulator inlet valve (8). Reclaimer pressure also passes to the diaphragm chamber of the bleed valve (2) to keep the bleed valve closed. The compressor begins to run in the full load condition, ‘The air pressure in the reclaimer (12) rises quickly to 4 bar. At this point the minimum pressure valve (10) opens and delivery air passes out of the reclaimer, through the aftercooler (9) and into the user's pipework. The delivery air pressure switch (8) senses the increase in pressure. The Pressure increases until the upper set point of the pressure switch is reached. At this point the pressure switch contacts open to disconnect the electrical supply to the unloader valve solenoid (4). The de-energised solenoid valve inlet port closes and air in the diaphragm chambers. of the regulator (3) and bleed valve (2) is released to atmosphere by way of the solenoid valve ‘exhaust port. The suction regulator inlet valve closes and the bleed valve opens. page 16 aBRB RB RBBB RRB RBBB RBBB RBERPRPPeeeeeeeswee es a 6040N & 6050N User Manual - General Description \ e 18 " — 16 = / 15 14 13 (12 " 1. Intake Air Filter 10. Minimum Pressure Valve 2. Bleed Valve 11. Relief Valve 3. Suction Regulator 12. Reclaimer 4. Unloader Solenoid Valve 13, Blowdown Valve 5. Air Line Filter 14. Airend 6. Condensate Drain Solenoid Valve 15. Drive Motor 7. Strainer 16. Pressure Gauge 8. Pressure Switch 17. Differential Pressure Tost Button 8. Aftercooler 18. Start Valve REGULATION SYSTEM (SCHEMATIC) Air no longer flows to the rotors ofthe air-end and the pressure in the reclaimer (12) bleeds away through the open bleed valve (2). The minimum pressure valve (10), acting as a one way check valve, closes to isolate the user's pipework trom the reclaimer. ‘The air pressure in the reciaimer and regulation pipework will continue to decrease until the spring acting on the diaphragm in the bleed vaive closes the valve. This occurs when the pressure in the teclaimer is approximately 1-0 to 1-5 bar. This is the minimum pressure required to maintain oil circulation through the compressor. ‘When the pressure in the user's pipework falls to the lower set point of the pressure switch the unloader valve solenoid is energised to open the valve. Pressure from the reciaimer then passes to the diaphragm chambers of the suction regulator and bleed valve. The suction regulator inlet valve ‘opens to allow air to flow to the rotors and the ‘compressor reverts to full load operating condition, page 17CompAir BroomWade Limited 6.2.3 Stopping The compressor may be stopped through manual ‘operation of the stop switch or automatically by the electronic control circuit. In both cases, stopping the compressor results in the release ofall pressure in the reclaimer. The air in the reclaimer is released to atmosphere by way of the blowdown valve downstream of the reclaimer. This ensures that the compressor can start against minimum pressure. ‘When the compressor is stopped in the on-oad condition the pressurised air in the reciaimer (12) will low back through the air-end to act upon the back of the suction regulator inlet valve (8). The inlet valve will operate independently of the diaphragm assembly and, with the assistance of a spring, will close against its seat to seal the air inlet. At the same time the start valve (18) closes, preventing the air/oil mixture blowing back through ‘the suction regulator and intake fitter. ‘When the compressor is stopped inthe off-load condition the suction regulator inlet valve is already closed. A return spring closes the start valve to prevent blow back of the air/oll mixture through the intake fiter. 6.2.4 Automatic Starting and Stopping When the pressure switch contacts open the unloader solenoid valve is de-energised and a timer on the printed circuit board is started. The timer is set to operate for 3 minutes. At the end of this period the main contactors open to interrupt the Power supply and stop the compressor. When the air pressure in the user's pinework falis to the lower set point of the pressure switch the ‘compressor will start automatically. age 18 «page 19 GO4ON & 6050N User Manual LEADING PARTICULARS PRBS ES BRR R RRB RE HEE RHE ETS RRR eee eeeCompAir BroomWade Limited LEADING PARTICULARS Airend: Single Stage Oil injected Screw Method of Regulation: ‘Automatic Start/Stop Cooling: Air Cooled Oil Capacity: 26 litres, Recommended Oil: BROOMWADE 4000 HR Air Delivery Connection: Rp 1% ‘Condensate Connection: 10 mm o.d.Tube Delivery Air Pressure: Minimum Sbar Maximum, Reter to Model Designation *Delivery Air Temperature: 10 t0 12°C above ambient Ambient Temperature: Minimum oc Maximum 45°C Typical Cooling Air Outlet Temperature at Maximum Operating Pressure: 17°C above ambient Motor Horsepower Motor Rotation Motor Speed Fan Motor Power Fan Motor Rotation Total Power Input (Typical) Approx. Nett. Weight: Dimensions: Upper Limit Sound Pressure Level at 1 m (CAGI PNEUROP PNENTC2.2 1994) 6040N 6050N with IP22 motor with IP55 motor LxWxH Refer to Model Designation Anti-clockwise viewed from drive end 2950 rpm. +1 kW Anti-clockwise viewed from non-drive end 84.1 KW 424 KW 730 kg 837 kg 975 mm x 1075 mm x 1700 mm 78 dB(A) *The air temperature is a typical figure and rotates to an inlet air temperature of 20°C and standard atmospheric pressure of 1 bar a. Specific values for particular operating conditions can be supplied on request. page 20BEB BBB BEB BSRB BBR RSRPRBRBRPRBeeeeeeeeeee GO40N & 6O50N User Manual Guidelines Installation Procedure 4 INSTALLATION *Page 22 23 page 21‘CompAlr BroomWade Limited INSTALLATION A ® WARNING AA @ — Referto the safety procedures before stallation of the compressor unit © Lethal voltages are used in this equipment. Use extreme caution when carrying out electrical checks. Isolate the power supply before starting any maintenance work. 4. GUIDELIN ‘Study the installation information in the manual for ‘the patticular compressor concerned. ‘The compressor unit is supplied as a complete Package and does not require to be secured toa foundation. However, the supporting floor must have a loading capacity sufficient to support the weight of the unit (see ‘Leading Particulars’). Because in operation the compressor will release heat into the surroundings the compressor room should be of adequate size and have good ventilation. The recommended minimum sizes of room and ventilation openings can be estimated as follows: From ‘Leading Particulars’ establish total input power (kW). For air cooled machines: Room volume = 1.85 m®per input KW Ventilation opening = 0-016 m?per input KW Note: An equivalent discharge opening will also be necessary. Example: 6050N, input kW = 424 Room volume = 42-4 X 1.35 m= 57 me Ventilation opening = 42-4 x 0.016 mé= 0.7m? ‘The ventilation inlet opening should be positioned as low down as possible. The outlet opening should be positioned as high up as possible, preferably in the roof or calling. ‘The air flow from the cooler outlet may be ducted for a distance of up to 3 m if necessary without the eed for an additional fan. Details are available on request from the local CompAir BroomWade. distributor. ‘There should be a minimum of 1-5 m headroom above the compressor and a minimum of 1 m clearance on all sides to allow adequate air circulation and to give access for servicing. There should be no obstruction of doorways, passages or walkways. ‘The only connections required to the compressor are as follows: 1. Airdelivery outlet to the user’s main pipework. 2. Electrical power supply, 3-phase plus earth. 3. Condensate drain to the user's disposal system. It the compressor is to be coupled in parallel with another compressor or connected to an existing ait supply system, adcitional steps must be taken as set out in the ‘Safety’ section of this manual fair usage is intermittent or rapidly fluctuating so. that the instantaneous demand for air is likely to ‘exceed the compressor output rating, and if the volume of the user's pipework is small, it will be Necessary to install a receiver of appropriate capacity. page 22BEB BSS BRB RB RP RRB RRB RBBB ee eee eee eee ee \6O40N & B050N User Manual Installation ‘As a guide, if the volume of the user's pipework is less than 1 m? a receiver of 875 litres minimum, capacity should be installed. Before despatch from the factory all compressors. are inhibited against the effects of moisture. If all blanking covers and protective tapes remain secure and undamaged, the effective life of this process is +42 months from the date shown on the test card with the machine. ‘To maintain rigidity during shipment, transportation fixings (painted red) are fitted to the motor/air-end flexible mountings, for removal after installation 2. INSTALLATION PROCEDURE The following procedure gives guidance for installing a standard compressor unit. For the stallation details for non-standard units or units equipped with optional equipment refer to the local CompAir BroomWade distributor. Remove the plug from each end of the baseframe. Raise one end of the baseframe ‘from the pallet and support it on blocks. Repeat at the other end so that there is clear ‘space for iting forks. itt the compressor unit on a fork lift and move it into position. 3. Lower the unit into place so that all the supporting points make proper contact with the floor. Check that it settles level to within 3 mm, using sultable packing pieces under the supports if necessary. 4, Open both the side doors of the enclosure, tft them off the hinges and remove to give clear access to the compressor. Remove the transportation fixings from the motor/air-end. Remove all protective blanking ‘covers and tapes. Remove the starter ‘compartment cover below the display panel. 6, Remove the plain gland plates from the rear column and the side of the starter ‘compartment. Modify the plates to take the Power cable or fit suitably pierced plates. 7. Make sure that the power supply to the ‘compressor is taken from a fused isolator and that the switch is iocked ‘OFF and the fuses removed. Connect the power supply to the ‘compressor in accordance with the diagram supplied, using cables which comply with the standards of the Intemational Electrotechnical ‘Commission (ILE.C.), The cables must be suitably protected and clamped. 8, Connect the air delivery pipe to the user's Pipework through an isolating shut-off valve. 9. Connect the condensate drain discharge coupling to the user's waste disposal system. ‘The connecting pipe must not be more than ‘3 min length and must be of a material suitable for carrying emulsified oil and water. Note: Consult local regulations regarding the disposal of liquid waste. It may be necessary to install an oilwWater separator in the system. 10. Replace the starter compartment cover. Replace the side doors to the enclosure. page 23,BEB RBE RBBB BRB EBB eee ee ee eee CompAir BroomWade Limited page 24G0AON & 605ON User Manual 5 COMMISSIONING AND OPERATION ‘Commissioning/Starting Procedures Routine Starting Stopping Reset Pressure Adjustment Adjustment Procedure Page 26 27 27 27 28 28 page 25(CompAir BroomWade Limited COMMISSIONING AND OPERATION A® @ Refer to the safety procedures before commissioning or operating the compressor toni. WARNING HRA © Lethal voltages are used in this equipment. Use extreme caution when carrying out electrical checks. Isolate the power supply before starting any maintenance work. 1. COMMISSIONING / STARTING PROCEDURES When commissioning a new compressor or re- commissioning a unit which has been overhauled oF out of service, carry out the following procedures before attempting to star:- Note: We recommend that commissioning is carried out by a CompAir BroomWade distributor, 1. Check that the isolator switch is locked ‘OFF’ ‘and that all pipework and electrical power connections are tight. 2. Remove the two front panels of the ‘compressor enclosure and open the access doors on either side, 8. Check the electrical connections in the starter ‘compartment. 4. Inspect the motor and control wiring connections to make sure they are tight, 5. Charge the reclaimer with oil by removing the oil filer plug and filing with ‘BROOMWADE 4000 HR’ cil, or an approved alternative, until ‘the level just reaches the bottom threads of ‘he filler neck. 6. Prime the air-end with oil as follows: Slacken ‘the two clips securing the air intake flexible pipe and disconnect the pipe trom the suction regulator. Remove the intake air filter complete ‘to give access to the suction regulator intake. Pour into the suction regulator 1 litre of ‘BROOMWADE 4000 HA cil or an approved aternative. Refit the air intake fiter. Refit the flexible pipe to the suction regulator and tighten both clips. 7. Switch the power supply ‘ON’ at the isolator. (Check that the ‘POWER ON’ and ‘READY TO START lamps on the display panel are both illuminated. Open the isolating shut-off valve. 8. Check that the ‘EMERGENCY STOP" button is Unlatched to the extended position by turing it clockwise. 9. Check the direction of rotation of the drive motor by pressing the ‘START’ switch and then the ‘STOP" switch immediately afterwards and observing the direction in which the motor Kicks over. Ifthe direction of rotation is incorrect it indicates phase reversal. Switch ‘the power supply ‘OFF’ at the isolator and rectify the cable connections. CAUTION: Do not allow prolonged running in the reverse direction as damage will be caused, 10. When the direction of rotation is correct, switch the power supply ‘ON at the isolator and press. the ‘START switch. Run the compressor on load unt! the oli has reached working ‘temperature, Check that the bypass valve operates correctly by feeling the rise in temperature of the oil cooler header remote {rom the oil connections when the valve opens. Press the ‘STOP’ switch. Switch the Power supply ‘OFF at the isolator. page 26BEB RB BRP BBR BRB BRB RPRS RBBB RRR RRRRReees we 6040N & 6050N User Manual ~ Commissioning & Operation 1". 12. 13. 14. 15. 16. 7. 18. Check that the blowdown system operates correctly and the pressure gauge registers zero when the blowdown valve stops. exhausting. Slacken the drain plug at the base of the regulation airline fer to release any pressure in the system. Tighten the plug. ‘As an additional safeguard release any termaining pressure from the delivery side of the reclaimer element by slackening the pipe Connection to the manifold at the reciaimer end, Release any residual pressure from the upstream side of the reciaimer element by slowly slackening the of filler plug on the reclaimer. Top up the oll in the reclaimer to the correct, level. Refit the enclosure front panels and close the side doors. ‘Switch the power supply ‘ON’ at the isolator. ‘Check that the POWER ON’ and ‘READY TO START’ lamps on the display panel are both showing correctly. Press the ‘START’ switch and allow the compressor to build up to ‘working pressure, Simulate a demand for air by opening the drain valve of the downstream air receiver, it installed, of opening a vaive in the user's pipework. Check that the unit runs correctly on and off load under the influence of the pressure switch. Check that the compressor shuts down automatically through the action of the run-on timer after running offload for the pre-set time of 3 minutes. Check that the compressor restarts when delivery pressure falls to the cut- in setting of the pressure switch, If all functions are in order and the compressor operates correctly, close the receiver drain valve or other downstream valve used for the previous checks. Atter running for approximately 80 minutes note the pressure reading for future reference. 4.1 Routine Starting Note: Ifthe unit has not been in operation for an extended period it would be advisable to carry out the procedures detailed under ‘Commissioning! Starting Procedures’. 1. Switch the power supply ‘ON at the isolator. 2. Check that the ‘POWER ON’ and ‘READY TO START indicators on the Display Panel are showing correctly. Check that the isolating shut-off valve is open. 3. Press the ‘START’ switch. 1.2, Stopping Press the ‘STOP’ switch to shut down the ‘compressor in normai circumstances. It is not advisable to press the ‘STOP’ switch when the ‘compressor is running on-load. The ‘EMERGENCY STOP" switch should only be used in an emergency situation, CAUTION: Do not use the ‘EMERGENCY STOP" switch for a normal shut-down, Continued use will result in damage to the starter contacts. 1.3. Reset If the compressor has been shut down either automatically through the operation of a fault protection circuit or by the use of the "EMERGENCY STOP" switch it cannot be restarted Until the circuit has been reset. ‘Check that the ‘EMERGENCY STOP’ switch is unlatched and press the ‘RESET’ switch. The ‘compressor can then be restarted by the ‘START” ‘switch in the normal way. Note: If the compressor has stopped through the action of the protection circuits allow a cooling down period of 15 minutes before using the 'RESET’ switch to give time for the motor to cool andlor the temperature to drop at the discharge from the air-end, page 27Compair BroomW/ade Limited! 2, PRESSURE ADJUSTMENT AQ warning © This procedure is carried out with the ‘compressor running. Be sure that all Personnel concemed have read and Understand the ‘SAFETY PROCEDURES’ section of this Manual. ‘The cooling fan and drive belts are unguarded when the enclosure panels ‘and doors are removed. Stay clear of all moving parts and keep tools and all other items well away from the fan blades. CAUTION: Do not set the pressure switch to cut out at a higher pressure than the nominal operating pressure of the model concemed. Operation at higher pressures than nominal will overioad the drive motor and may cause damage. Such action will invalidate the Warranty. @ PRESSURE SWITCH ‘The correct setting of the pressure switch will give the following pressure figures. Nominal delivery pressure/ Cutin Cut-out pressure Pressure 7-5 bar 68 bar 10-0 bar 93 bar 13.0 bar 12:3 bar 24 Adjustment Procedure It, after a period of service, it becomes necessary 10 adjust the pressure switch follow the procedure below: 1. Open the isolating shut-off vaive, 2. Simulate a demand for air by opening the drain valve of the downstream air receiver, if installed, or opening a valve in the user's pipework. 3. Open the right hand side door of the enclosure to gain access to the pressure switch and remove the pressure switch cover. 4. Turn the pressure adjusting screw (2) 4 turns. counter-clockwise. This reduces the cut-out setting of the switch and ensures that the ‘maximum pressure rating of the compressor is not exceeded. The approximate pressure is indicated by the scales (8). 5. Switch the power supply ‘ON’ at the isolator. 6. Start the compressor and allow it to run until it reaches operating pressure as set by the cut- out adjustment in 4. above. It will then change to nun in the off-load condition. 7. Increase the operating pressure by gradually turing the adjusting screw (2) clockwise. This, will alter both cut-out and cut-in settings. together. As the cut-out setting is increased the compressor will revert to on-load running until the new cut-out pressure is reached. ‘Observe the pressure gauge reading at which ‘cut-out occurs and continue the adjustment Until the required setting is achieved. page 28 SERB BB RBRB RBBB B RRB BBR BRR B RBBB RBBPRPeeeeesBEB RBBB RBBB RBRBRBRBRBRBRB BRP BRBPRBRUOReeeeeeees BS ‘Adjust the cut-in pressure independently by turning the differential adjusting screw (4) which is geared to the differential cam (3). Turning clockwise will increase the cut-in pressure and thus reduce the differential between the cut-out and cut-in pressures. Turing the screw counter-clackwise will have the opposite effect. When the pointer (1) is at the lowest part of the cam, as illustrated, the differential is at the minimum. Observe the pressure gauge and continue adjustment until the compressor cuts Inat the required pressure. Refit the pressure switch cover. Close the side door of the enclosure and close the receiver drain vaive or other downstream valve which may have been used to simulate compressed air demand. .604ON & 6050N User Manual - Commissioning & Operation page 29SEER RB R ERB BERBER BRR BER eeeeeeeeeeeeeee! (CompAir BroomWade Limited age 80SEB RB BSB BRBRBRBRBRBRBRBRBRPRBPBPePeee seeeeespes GOAON & 6050N User Manvel MAINTENANCE Page Routine Maintenance 32 Cleanliness 32 Recording Pressures and Temperatures 32 Maintenance Record 32 Pressure Settings 33 Electrical Connections 33 Leaks 33 Scavenge Strainer and Regulation Air Line Filter 33 Regular Checks 33 Lubricating Oil 33 Maintenance Schedule a4 Recommended Maintenance Parts 37 Maintenance Procedures 38 Enclosure Fiter 38 Intake Air Filer 38 Reclaimer 39 Reclaimer Element 39 Scavenge Strainer 40 Condensate Drain 40 Regulation Air Line Fiter 41 il System a Electrical System 43 Electric Motors 43 Suction Regulator 44 Temperature Sensor (Thermistor) 44 Minimum Pressure Valve 44 Drive Belt 44 AiiOil Cooler 44 page 31CompAir BroomWade Limited MAINTENANCE A® @ Refer to the safety procedures before carrying out any maintenance or servicing work on the compressor unit, WARNING AA © Lethal voltages are used in this ‘equipment. Use extreme caution when ‘carrying out electrical checks. Isolate the Power supply before starting any maintenance work. 1. ROUTINE MAINTENANCE To ensure efficient operation of the compressor the ‘user must check the performance regularly and carry out the necessary adjustments to maintain the correct settings. This section gives the information needed for this purpose. Personnel familiar with servicing and maintaining mechanical equipment should have no difficulty in carrying out these tasks but if assistance is needed the user should refer to the local CompAir BroomWade Distributor, ‘A condition of the Warranty cover is for the user to ensure that itis properly maintained and adjusted, that all checks and services listed in the Schedule are carried out at the specified intervals and that an accurate record is Kept of the work, Routine maintenance and regular servicing must be carried out as recommended in the ‘Maintenance ‘Schedule’. All CompAir BroomWade compressors are fitted with high performance filtration equipment. If the working environment is particularly dusty the filter ‘elements and the heat exchangers will require ‘more frequent attention. 1.1 Cleanliness ‘The compressor must be kept in a ciean condition at all times. Make regular inspections for signs of damage, excessive wear and security of fitings. Ensure that any oil spillage is wiped up immediately and any residual oil cleaned from external surfaces. 1.2 Recording Pressures and Temperatures Keep a regular daily record of the compressor operating pressures and temperatures by noting the gauge and indicator readings, together with ambient air temperature, in a record book. The readings should be taken when conditions are stable and with the compressor running on full load. 1.3 Maintenance Record Keep a careful record of all servicing, maintenance and repair work carried out on the compressor unit ‘The record will orm a useful reference. ‘Any vatiation from normal operation will be noticeable immediately, alerting the user toa possible need for servicing or maintenance. Frequent recurrence of a particular repair tack could reveal an unsatisfactory operating condition which must be corrected. page $2 SERB BBR BBB BBB RBRBSBRBSRBRBRBRBRBRBPRBERBRBSBRBRSRBRBEE ES S-