Beruflich Dokumente
Kultur Dokumente
USER MANUAL
CYCLON 330-345 AIR COMPRESSORS
Serial Numbers from:
Cyclon 330
F166/0101
Cyclon 337
F167/0151
Cyclon 345
F168/0101
CONTENTS
Page
1. Safety Procedures
Illustrations
Page
Control Panel
13
2. General Description
11
Air/Oil System
15
3. Leading Particulars
19
16
4. Installation
21
17
5. Commissioning
25
33
6. Operation
35
Control Panel
38
7. Maintenance
47
Remote Start/Stop
44
8. Fault Finding
57
Remote Load/Unload
44
61
45
Servicing Points
51
55
62
64
63
page 1
OWNERSHIP DATA
TECHNICAL DATA
MODEL:
Serial Number:
Year:
Maximum Pressure:
Delivery Date:
kW:
Motor rpm:
Compressor Lubricant:
V. Ph. Hz.
Lubricant Capacity:
M3/min:
Name:
Address:
Telephone:
Contact Names:
Fax:
Parts:
Service:
page 2
MODEL DESIGNATION
The Model Designation code identifies specific models as follows:
DESIGNATION
CYCLON
A = AIR-END SIZE
B = MOTOR RATING (kW)
C = NOMINAL DELIVERY PRESSURE
CYCLON 3
30KW
75 BAR(110PSI)
This publication relates to all standard operating pressure versions of the following models:
Cyclon 330
Cyclon 337
Cyclon 345
ASSOCIATED PUBLICATIONS
Model
Title
Part No.
Cyclon 105-345
Cyclon 330 to 345
Repair Manual
Parts List (Multi-Lingual)
AC20160-1606 (Issue 1)
C20160-1575 (Issue 2)
page 3
WARRANTY
The conditions of the CompAir BroomWade
Warranty are set out in the companys standard
Conditions of Sale available from the Distributor
supplying the machine.
MAINTENANCE
To ensure the continued trouble-free operation of
the compressor unit it is important that periodic
maintenance and servicing are carried out in
accordance with the information given in the
Maintenance section of this manual. If any
replacement or repair is needed use only CompAirBroomWade Genuine Parts.
WARNING
USE ONLY
GENUINE PARTS
AUTHORISED SERVICE AGENTS
page 4
1
SAFETY PROCEDURES
Page
General
Installation Precautions
Operational Precautions
page 5
SAFETY PROCEDURES
1.
GENERAL
2.
2.1
Warnings
2.2
Cautions
2.3
Notes
page 6
3.
4.
INSTALLATION PRECAUTIONS
OPERATIONAL PRECAUTIONS
page 7
page 8
6.
2.
3.
4.
5.
7.
page 9
page 10
2
GENERAL DESCRIPTION
Page
Compressor
12
Air-End
12
Electronic Controller
12
12
12
12
12
Air/Oil System
Description
Operation
14
14
14
Regulation System
Description
On/Off Control
Modulating Control (Optional)
16
16
16
17
page 11
GENERAL DESCRIPTION
1.
COMPRESSOR
3.
ELECTRONIC CONTROLLER
The unit is a fully enclosed, air cooled, singlestage, rotary screw compressor. The compressor
air-end is belt driven by an electric squirrel-cage
induction motor. The drive belts are mounted on
pulleys fitted to the shafts of the drive motor and
air-end.
4.1
2.
AIR-END (CYCLON 3)
page 12
4.
Relief Valve
4.2
Blowdown System
4.3
P2
T1 C
P1 bar
D1
L1
L2
L3
L4
L5
L6
L7
L8
L9
B1
B2
B3
B4
B5
B6
D1
E
B1
P1 bar
B2
T1 C
B3
P2
B4
B5
B6
View
Start
Stop
Plus
Minus
Reset
Display
Emergency Stop Button
L1
L2
L3
L4
L5
L6
L7
L8
L9
Pressure (Delivery)
Temperature
Hours Run
Hours Onload
Air Filter Alarm
Motor Fault
Auto/Remote Start
Running
Power On
CONTROL PANEL
page 13
5.
AIR/OIL SYSTEM
5.1
Description
5.2
Operation
page 14
10
14
6
9
11
12
1.
2.
3.
4.
5.
6.
7.
Suction Regulator
Intake Air Filter
Minimum Pressure/NR Valve
Primary Oil Separator
Oil Separation Element
Discharge Pipe
Air-end
5
8.
9.
10.
11.
12.
13.
14.
13
Oil Filter
Aftercooler
Oil Cooler
Fan
Delivery Air Outlet
Scavenge Line
Thermostatic Bypass Valve
AIR/OIL SYSTEM
page 15
6.
REGULATION SYSTEM
6.1
Description
6.2
On/Off Control
3
6
+
5
1
13
9
12
1.
2.
3.
4.
5.
6.
7.
11
14
10
8.
9.
10.
11.
12.
13.
14.
Separator Filter
Pressure Relief Valve
Separator Vessel
Air-end
Drive Motor
Intake Pressure Switch
Air-end Discharge Temperature Sensor
page 16
6.3
3
7
1
9
15
10
11
14
1.
2.
3.
4.
5.
6.
7.
8.
13
16
12
9.
10.
11.
12.
13.
14.
15.
16.
page 17
page 18
3
LEADING PARTICULARS
page 19
LEADING PARTICULARS
Model
Air-end
Cyclon 330
litres
Cyclon
C
C
170
175
185
Rp 1 1/2
R 1 1/2
Rp 1 1/2
R 1 1/2
Rp 1 1/2
R 1 1/2
0
46
0
46
0
46
5
75-13
5
75-13
5
75-13
4-5
7-8
20
23
27
30
2970
37
2970
45
2970
kW
351
440
541
kg
kg
849
939
875
945
936
1043
mm
mm
mm
1420
990
1650
1420
990
1650
1420
990
1650
68
69
70
Nominal Rating
(for actual rating see motor data plate) kW
Nominal Speed
rpm
Approximate weight
of total package
DPV
TEFV
Dimensions:
Length
Width
Height
at 1 m (CAGI PNEUROP)
page 20
dB(A)
4
INSTALLATION
Page
Guidelines
22
Installation Procedure
23
page 21
INSTALLATION
1.
WARNING
GUIDELINES
Ventilation opening
2.
Example:
Model
Flexible Hose
Ventilation opening
= 440 x 0016 m2 = 07 m2
page 22
C26151-36
5.
6.
8.
1.
9.
2.
INSTALLATION PROCEDURE
4.
page 23
page 24
5
COMMISSIONING
Page
Commissioning Procedure
Preliminary Checks
Pressure Calibration
Checking/Altering Program Mode Values
Final Checks
26
26
27
28
30
33
Commissioning Checklist
34
page 25
COMMISSIONING
1.
WARNING
COMMISSIONING PROCEDURE
When commissioning a new compressor or recommissioning a compressor which has been out
of service, carry out the following procedures
before attempting to start:
6.
7.
8.
9.
10.
11.
1.1
1.
Preliminary Checks
Check that the isolator switch is locked OFF
and that all pipework and electrical power
connections are correct and tight.
2.
3.
4.
5.
page 26
1.2
Pressure Calibration
Note: The values shown throughout these procedures are examples only. Ensure set values are compatible
with the compressor model.
No.
Action
Reason
Display
1.
0.0 Bar
2.
0.0 Bar
3.
0.0 Bar
4.
0.0 Bar
5.
0.0 Bar
6.
7.1 Bar
7.
7.0 Bar
8.
Press STOP
7.0 bar
9.
0.0 Bar
page 27
1.3
Note: The values shown throughout these procedures are examples only. Ensure set values relate to
compressor model.
No.
Action
1.
0.0 Bar
2.
0.0 Bar
3.
4.
0.0 Bar
5.
7.5 Bar
6.
Press STOP
7.
Reason
Display
0.0 Bar
7.0 bar
(pulsing display)
7.0 bar
(steady display )
8.
Press VIEW
9.
10.
Press STOP
11.
115C
115C
110C
(pulsing display)
110C
(steady display)
12.
Press VIEW
13.
page 28
No.
Action
Reason
Display
14.
1500
Press STOP
15.
(pulsing display)
1500
(steady display)
16.
Press VIEW
17.
18.
Press STOP
19.
5.0
2.0
(pulsing display)
2.0
(steady display)
20.
Press VIEW
21.
22.
Press STOP
23.
7.0 bar
6.5 bar
(pulsing display)
6.5 bar
(steady display)
24.
Press VIEW
25.
26.
Press STOP
27.
C330
(pulsing display)
C330
(steady display)
page 29
No.
Action
Reason
28.
Press VIEW
29.
30.
31.
Display
0 secs
60 secs
(pulsing display)
60 secs
(steady display)
32.
Press VIEW
33.
34.
Press STOP
35.
5 mins
(pulsing display)
5 mins
(steady display)
Press RESET
36.
1.4
0.0 Bar
Reason
Display
Final Checks
No.
Action
1.
2.
Press START
page 30
0.0 bar
0.0 Bar
No.
Action
3.
Reason
Display
0.0 Bar
5.
6.
7.
8.
9.
10.
11.
12.
page 31
No.
Action
13.
14.
page 32
Reason
Display
2.
2.
3.
4.
5.
7.
8.
SUCTION REGULATOR
% MODULATION
6.
0
10
20
30
40
50
60
70
80
90
100
69
70
P2
SET POINT
71
72
PRESSURE
BAR
73
74
75
P1
SET POINT
page 33
3.
1.
2.
............
3.
............
4.
............
............
6.
............
14.
............
15.
............
16.
............
17.
............
18.
............
19.
............
20.
............
21.
............
22.
............
23.
............
............
5.
13.
............
............
8.
............
9.
Air-end primed.
............
24.
............
10.
............
25.
............
11.
............
12.
............
7.
page 34
6
OPERATION
Page
Routine Operation
Starting
Standby Mode
Stopping
Emergency Stop
Oil Temperature and Hours Run Display
Service Interval Timer
Alarms and Shutdown Trips
Power Supply Failure Detection
Control Panel Indicators
36
36
36
37
37
37
37
38
39
39
Program Mode
Program Mode Routine
Program Mode Setting Definitions
Program Mode Settings
Fixed Parameters
40
40
41
41
42
42
42
43
43
43
43
45
page 35
OPERATION
WARNING
1.
ROUTINE OPERATION
1.1
Starting
1.
2.
3.
4.
7.
9.
10.
6.
page 36
1.2
Standby Mode
1.
2.
1.3
1.
2.
Stopping
To stop the compressor press STOP (B3).
This initiates a controlled shut down
sequence. The compressor will unload, the
drive motor will stop and the Start indicator
(L8) will flash slowly for the blowdown period.
See para 2.3 Program mode settings.
The compressor motor cannot be re-started
during the blowdown sequence. If START
(B2) is pressed the start indicator will flash
quickly and the compressor will enter the
Standby mode and start automatically when
the blowdown time expires.
1.4
Indicator
Emergency Stop
1.
2.
3.
1.5
1.
2.
3.
Display
L1
L2
Oil Temperature in C
L3
L4
1.6
page 37
1.7
1.
2.
3.
4.
P2
T1 C
P1 bar
D1
L1
L2
L3
L4
L5
L6
L7
L8
L9
B1
B2
B3
B4
B5
B6
D1
E
L1
View
Start
Stop
Plus
Minus
Reset
Display
Emergency Stop Button
Pressure
B1
P1 bar
B2
T1 C
B3
P2
B4
B5
B6
L2
L3
L4
L5
L6
L7
L8
L9
CONTROL PANEL
page 38
Temperature
Hours Run
Hours Onload
Air Filter Alarm
Motor Fault
Auto/Remote Start
Running
Power On
1.8
1.9
Indicator
When on (Steady)
When flashing
L1
L2
L3
Service due
L4
L5
L6
L7
L8
Compressor started
L9
page 39
2.
PROGRAM MODE
2.1
6.
2.
3.
4.
5.
page 40
2.2
Indicator
2.3
Setting
Description
L1
L2
L3
L4
Time in seconds that the valve opens every cycle. The 'shut'
time is fixed at 60 seconds.
L5
L6
Model
L7
L8
Run-on time
The time which the compressor will run in the off-load state
before the main motor stops and the compressor enters
Standby mode.
Indicator
Setting
Unit
Minimum
Maximum
Step
Default
L1
Bar
5.1
13.9
0.1
7.5
L2
90
120
115
L5
Bar
5.0
12.9
0.1
7.0
L6
Model
Model
C105
C345
option
C215
L7
seconds
60
240
L8
Run-on time
minutes
15
page 41
2.4
Fixed Parameters
4.
5.
6.
7.
8.
Parameter
Unit
Model
C330
C337
C345
Star/Delta time
secs
50
55
60
Blowdown time
secs
25
25
25
3.
3.1
2.
page 42
10.
11.
4.
4.2
4.1
Automatic Re-start
2.
3.
4.
The compressor will only automatically restart if the compressor was in the On-load,
Off-load or Standby mode when the break or
failure in main supply power occurred.
2.
3.
2.
1
2
3
4
Remote Load/Unload
60 seconds
120 seconds
180 seconds
240 seconds
page 43
X01-4
X01-7
X2/1
X2/2
Controller
Start
N/O
Stop
N/C
REMOTE START/STOP
X01-6
X01-5
X2/1
Controller
Remote
pressure
switch or
cascade
panel
REMOTE LOAD/UNLOAD
2.
page 44
3.
4.4
X1/2
X1/1
Controller
X08-9
8
2
4
7
5
3
6
X08-10
+V~
5 7
Fault
0V~
1
Relay 98475-71
Relay base 98475-72
page 45
page 46
7
MAINTENANCE
Page
Routine Maintenance
Cleanliness
Recording Pressures and Temperatures
Maintenance Record
Electrical Connections
Leaks
Lubricating Oil
48
48
48
48
48
48
48
Maintenance Schedule
Separator Element Part Number Table
Service Kit Part Number Table
Drive Belt Part Number Table (50Hz)
Drive Belt Part Number Table (60Hz)
49
50
50
50
50
Maintenance Procedures
Enclosure Filter
Air Intake Filter
Oil Separator Filter
Oil System
Drive Belt(s)
Electrical System
Electric Motors
Suction Regulator
Minimum Pressure Valve
Flexible Hoses
52
52
52
52
53
55
56
56
56
56
56
page 47
MAINTENANCE
1.
WARNING
ROUTINE MAINTENANCE
1.3
Maintenance Record
1.4
A condition of the Warranty cover is for the user to
ensure that routine maintenance and regular
servicing must be carried out as recommended in
the Maintenance Schedule and an accurate
record is kept of the work.
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.
1.5
1.1 Cleanliness
The compressor must be kept in a clean condition
at all times. Make regular inspections for signs of
damage, excessive wear and security of fittings.
Ensure that any oil spillage is wiped up
immediately and any residual oil cleaned from
external surfaces.
page 48
Electrical Connections
Leaks
1.6
Lubricating Oil
2.
MAINTENANCE SCHEDULE
Action
Weekly
Oil System
Separator Element
Aftercooler
Note: Renew the drive belt(s) every 16000 hours or 4 years, whichever is sooner.
page 49
Qty.
330/337
345
1
2
Max Rated
Pressure
(Bar)
Separator
Filter
75 to 13
75 to 13
98262-223
98262-223
USE ONLY
GENUINE PARTS
Model (Cyclon)
Service Kit
330/337
345
CK2003-2
CK2003-2
CK8003-2
CK8003-3
AUTHORISED SERVICE
AGENTS
Note: Use Service and Major Kit for Major Service requirements
2.3
Model
330
337
345
Qty.
4
4
4
8.2 bar
10 bar
13 bar
98080-152
98080-153
98080-155
98080-152
98080-154
98080-156
98080-152
98080-154
98080-156
98080-153
98080-155
98080-155
Note: See the compressor data plate for the compressor model and the maximum rated pressure.
2.4
Model
330
337
345
Qty.
4
4
4
8.2 bar
10 bar
13 bar
98080-151
98080-153
98080-153
98080-152
98080-153
98080-154
98080-153
98080-154
98080-153
98080-153
98080-153
98080-155
Note: See the compressor data plate for the compressor model and the maximum rated pressure.
page 50
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
SERVICING POINTS
page 51
3.
MAINTENANCE PROCEDURES
WARNING
3.1
1.
2.
3.
Enclosure Filter
2.
1.
3.
2.
3.3
page 52
1.
3.
4.
5.
3.4
2.
3.
4.
5.
Oil System
2.
CompAir FG Lubricant
A synthetic hydrocarbon based lubricant
which has been specially developed for use
where discharge air may come into contact
with foodstuffs or for reasons of health or
environment. CompAir FG Lubricant meets
the requirements of FDA regulation 21 CFR
178.3570 and is USDA H-1 approved.
page 53
2.
3.
Method (a)
4.
5.
6.
1.
2.
3.
5.
2.
CompAir FG Lubricant
Provided the air-end discharge temperature
does not regularly exceed 85C CompAir FG
Lubricant should be changed every 4000
hours service or 1 year, whichever is sooner.
Where the air-end discharge temperature
regularly exceeds 85C then a change period
of 2000 Hours or 6 months is recommended.
6.
7.
8.
9.
10.
page 54
WARNING
9.
Method (b)
1.
2.
3.
4.
5.
WARNING
3.5
Drive Belt(s)
!
4
6.
7.
8.
2
PI/97/035
page 55
3.
1.
4.
2.
Loosen the lock nut (1) and turn the nut (2)
clockwise until the adjuster (3) contacts the
cut-out in the spring retainer (4).
3.7.2
3.
4.
5.
3.6
Electrical System
Dust Contamination
3.8
Suction Regulator
3.9
3.7
Electric Motors
2.
page 56
0.5 in
0.75 in
1.0 in
1.25 in
1.5 in
2.0 in
Torque
44 Nm
84 Nm
115 Nm
189 Nm
244 Nm
297 Nm
8
FAULT FINDING
Page
Fault Indications
Trip Fault Indications
Alarm Fault Indications
58
58
59
Shutdown Faults
59
Alarm Faults
60
page 57
FAULT FINDING
In operation the compressor is protected by circuits
which are triggered when a fault arises and either
cause the compressor to shut down or indicate that
a servicing action is required.
WARNING
1.
FAULT INDICATIONS
1.1
Display
Meaning
L1 to L8 Flashing Quickly
Emergency Stop
L1 Flashing Quickly
Excess Pressure
L1 Flashing Quickly,
Pressure Display shows (----)
L2 Flashing Quickly
Excess Temperature
L2 Flashing Quickly,
Temperature display shows (----)
L6 Flashing Quickly
Display shows (
Power Failure
page 58
1.2
2.
Display
Meaning
L2 Flashing Slowly
High Temperature
L3 Flashing Slowly
Service Due
L5 Flashing Slowly
SHUTDOWN FAULTS
Fault
Possible Cause
Action Required
Emergency Stop
Excess Pressure
(2)
Excess Temperature
Sensor failure.
page 59
Fault
Temperature sensor
failure
Possible Cause
3.
Action Required
ALARM FAULTS
Fault
High Temperature
Possible Cause
Action Required
Service due
page 60
APPENDIX 1
Electrical Connections
page 61
KM101
F101
U2 V2 W2
M101
3~
U1 V1 W1
101
102
F1
F2
F101
KM101
KM102
KM103
M101
P201
KM102
0V
24V
EARTH
BAR
0V
105
315A
F2
X1/2 X1/2
106
102
415/380V
220/230V
S101/1
Q101 101
108
X1/1
109
V
W
PE
X1/1
X1/2
X1/2
X1/2
X1/1
X1/1
7 8
X1/1
3 4
X1/1
1 2
X08
5 6
RELAY OUTPUTS
X1/2
X1/1
X1/3
X1/2
Q101
R201
S101
S201
T101
Y101
Y102
X1/2
X1/1
X1/4
9 10 11 12
1 2
X03
1
2
3
4
X01
5
7
DIGITAL INPUTS
a
T1
X14
MCB
Temperature Sensor
Emergency Stop Button
Air Filter
Control Transformer
Load Solenoid
Drain Solenoid Option
M101 Thermisters
C330-C345 ONLY
X1/2
110
KM101
121
GROUP FAULT
107
200
16A
201
F1
S101/2
103
REMOTE START
104
24V
REMOTE LOAD
0V
440/460V
REMOTE STOP
T101
X02
3 4
PI/97/052
ANALOG INPUTS
211
575V
KM102
KM103
115
ML1/1
ML1/2 Y101
203
F101
116
ML1/3
ML1/4 Y102
ML1/11 202
S201
ML1/12
204
X2/2
(LK1)
ML1/7 210
P201
- +
2 1
ML1/8
ML1/9 212
R201
ML1/10
page 62
213
REMOTE CARD
OPTION (IF FITTED)
KM103
APPENDIX 2
The Pressure Systems and Transportable Gas Container Regulations 1989
page 63
APPENDIX 2
Note: The intervals between examination and
calibration of components, eg pressure vessels,
pressure relief valves etc, will be defined by the
competent person preparing the written scheme.
3
6
+
5
1
13
9
12
1.
2.
3.
4.
5.
6.
7.
11
14
10
8.
9.
10.
11.
12.
13.
14.
Separator Filter
Pressure Relief Valve
Separator Vessel
Air-end
Drive Motor
Intake Pressure Switch
Air-end Discharge Temperature Sensor
page 64
3
7
1
9
15
10
11
14
1.
2.
3.
4.
5.
6.
7.
8.
13
16
12
9.
10.
11.
12.
13.
14.
15.
16.
page 65
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