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Alemite Carbon Shield Installation, Operation And Maintenance Manual

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INSTALLATION, OPERATION
AND MAINTENANCE MANUAL

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Summary of Contents for Alemite Carbon Shield

  • Page 1 INSTALLATION, OPERATION AND MAINTENANCE MANUAL...

  • Page 3: Alemite Carbon Shield Service Guide

    The multi-level password protected Human and knowledge related to the construction and Machine Interface (HMI) display panel on the operation of the Carbon Shield equipment and the Carbon Shield system offers touch access to a ™...
  • Page 4 Fig. 01 www.alemitecarbonshield.com...
  • Page 5 Carbon Shield Service Guide | Fig. 02 www.alemitecarbonshield.com...

  • Page 6: How It Functions

    How it functions Oil Mist Mist Pressure The Carbon Shield system produces a continuous Air is routed to a venturi in the mist head which ™ mixture of air-suspended oil particles in the 1.5 to 5 lowers the static pressure and lifts oil from the micron range.

  • Page 7: Table Of Contents

    ALEMITE CARbON SHIELD SERvICE SHEET | tAbLE of contEnts Product overview How it functions Oil Mist ..... . 3 Air Pressure ....3 Air Temperture .

  • Page 8: Table Of Contents

    | Table of Contents tAbLE of contEnts Air system Air Pressure Control ....12 Air Temperature Control ....13 Transducer-booster Assembly .
  • Page 9 ALEMITE CARbON SHIELD SERvICE SHEET | tAbLE of contEnts Electrical system (con’t) Connections for Remote Global Alarm ..19 Connection to Communication Modules ..19 Connection to Level Switch in bulk Storage Tank .
  • Page 10 Fig. 93 Schematic Diagram ....52 References Carbon Shield nomenclature ....53 ™...

  • Page 11: System Components And Features

    Electrical system digital as well as analog modules which provide the monitoring and control functions of the Carbon Shield™ system. The PLC also drives the Input power HMI which provides a visual display of system status, parameter values and alarm conditions Alemite’s Carbon Shield TM consoles operate...

  • Page 12: Human Machine Interface

    | alemite Carbon Shield Service Sheet Human Machine Interface (HMI) The touch screen on the front of the Carbon the PLc sends: Shield cabinet is an HMI (Fig.04) which provides ™ • 4-20 mA control signals to the transducer/ a color visual display of system status, parameter regulator for air pressure/mist pressure control values and alarm conditions.

  • Page 13: Mist Head Assembly

    ALEMITE CARbON SHIELD SERvICE SHEET | Mist Head Assembly Mist Pressure Within the mist head, (Fig. 05) oil is atomized The mist pressure sensor mounts on the PLC box by high-velocity air which creates tiny lubricant and connects to the top of the reservoir by rigid particles.

  • Page 14: Tank Assembly

    | alemite Carbon Shield Service Sheet Tank Assembly Oil Heater The tank assembly (Fig. 10) contains an oil reservoir The oil heater is an immersion-type rated at 500 which stores the oil for mist production, mist head watts. The oil heater is rated for 120 vAC or 240...

  • Page 15: Transducer-Booster Assembly

    ALEMITE CARbON SHIELD SERvICE SHEET | Air Heater Package Transducer-booster Assembly (optional) Once air passes through the 5 micron filter, it is The Carbon Shield console uses electronic closed ™ desirable that the air be temperature controlled loop feedback between a pressure transducer before reaching the mist head assembly.

  • Page 16: Bulk Oil Storage System

    | alemite Carbon Shield Service Sheet Fig. 17 Fig. 18 bulk Oil Storage System Oil Temperature (Accessory) The PLC monitors oil temperature by means of a thermocouple in the tank and maintains the The bulk oil storage system (Fig 17) operates temperature by cycling the oil heater on and off.

  • Page 17: Cabinet Purge (Optional)

    An optional cabinet cooling feature is available Red and green status LED indication lights are for Carbon Shield systems that operate in high mounted on the top of each Carbon Shield ™ ™ ambient temperature conditions. The cooling unit’s cabinet. (Fig.21) The status lights are controlled by integral vortex tube directs chilled air into the the PLC.

  • Page 18: Installation

    | alemite Carbon Shield Service Sheet installation Site Preparation Install your Carbon Shield cabinet in an area with ™ sufficient space (Fig. 22, 23) to accommodate: • The opening of the cabinet door • All system connections—electric, air, oil and distribution piping •...

  • Page 19: Systems Connections

    ALEMITE CARbON SHIELD SERvICE SHEET | Systems Connections With the console secured, the air, oil, and electrical systems can be connected. This equipment is designed to work in Class I, Division 2, Groups B, C, and D, Temperature Code T4 Hazardous Locations.

  • Page 20: Mist Oulet

    Power Mist Outlet (with backup unit) Customer provides incoming 120/240 vAC– 20/10 amp line power to the Carbon Shield console. The When a backup unit is provided, the customer mist power connection is made at the disconnect switch connection is at the 2 inch pipe “T” on the right in the lower left hand corner inside the cabinet.

  • Page 21: Connection To Communication Modules

    ALEMITE CARbON SHIELD SERvICE SHEET | Connections-DCS/ Control Room alarm DP-9 female connector and terminals for power A dry set of contacts is provided for the end user supply and functional ground are located beneath to connect an alarm light or other fault indicating the front cover of the PROFIbUS module (fig 32).

  • Page 22: Drain Connections

    20 | alemite Carbon Shield Service Sheet operation Drain Connections before start-up Inspect your Carbon Shield console ™ A single drain connection is provided on the • Make sure components, electrical and bottom of the main enclosure. The tank drain line mechanical, are securely connected.

  • Page 23: Start-Up Sequence

    3. As unit is starting up, observe HMI display. Four choices are displayed on the HMI. Transfer, Start, Control Panel and Task bar (Fig 41) 3a. Choose “Start,” or wait for the Alemite home screen to show. (Fig 42). Fig. 40 •...
  • Page 24 4. The 4 choices are displayed again, choose “Start” (Fig 44). Fig. 46 5. The home page of the Alemite Carbon Shield 7. Select “Main Menu”. Main Menu has 7 selections unit is displayed (Fig 45). available. “System Setup” is located in the 6.
  • Page 25 ALEMITE CARbON SHIELD SERvICE SHEET | 23 Fig. 49 Fig. 49 9a. Type the user name on the pop-up keypad and 9d. Select “Setup” button again. (Fig.52) then press the “Enter” key—the backward facing arrow on the keypad’s lower right corner.
  • Page 26 24 | alemite Carbon Shield Service Sheet 11. If the oil level is within 5% of the displayed level, the oil you are using is compatible with the factory default level calibration and your system requires no further calibration. 11a. Now you may elect to keep the 3 gallon (11.4 L) capacity setting or change to a...
  • Page 27 The nozzle capacity selection instructs the PLC to load default parameter values at 20 in H2O; which is the Alemite® system’s Design Manifold Pressure. Fig. 55 17. When oil level is within 5% of the displayed level, return to System Setup and turn Automatic Refill on.
  • Page 28 The bulk option should only be selected if the unit is equipped with an Alemite bulk oil tank system with a level switch. Enabling this option when the Alemite bulk oil system with level switch is not present will cause the system to issue false alarms.

  • Page 29: Using "Change Parameters" Feature

    Adjusting oil temperature also adjusts air temperature to the same value. (Fig.71) Fig. 68 2. The Carbon Shield controller allows the end user to adapt the system to the installation variables such as piping distance, and diameter, number of fittings and piping bends, etc. by selecting the “Change Parameters”...

  • Page 30: Using "Adaptive Mode" Feature

    28 | alemite Carbon Shield Service Sheet using “Adaptive Mode” feature The Adaptive Mode feature allows the end user to accept system operating settings different from the default values stored in the PLC. These differences can be produced by the actual installation conditions such as pressure drops due to the number of nozzles or length of the distribution pipes.

  • Page 31: Monitoring Function

    ALEMITE CARbON SHIELD SERvICE SHEET | 29 Monitoring functions Local Alarms The Carbon Shield unit is equipped with sensors The PLC performs an ordered series of control which monitor the different operating parameters set point checks for the maximum and minimum of the system.
  • Page 32 30 | alemite Carbon Shield Service Sheet Alarm List Air and Mist related alarms 1. blockage – Issued when a mist pressure 10. wrong cfM Hi – Issued when the mist increase from the set point value, equivalent pressure is at 20”H2O (or other chosen set to approximately 0.5 CFM, is detected by the...
  • Page 33 Determining the magnitude of this change is Issued when the PLC starts the oil refill system outside of the scope of the Carbon Shield control and the oil level in the tank doesn’t increase system design. The end user should investigate after 5 minutes.

  • Page 34: Remote Communication And Alarm

    (red LED light) Ethernet can also be offered per customer request. signal as the red light on top of the Carbon Shield For general information about Modbus, please Unit. The normally open set of contacts is made refer to http://www.modbus.org/.

  • Page 35: Plc Program Loading

    Carbon Shield Service Guide | 33 important note: The customer is responsible for connection to the communication module, interfacing and integration of the Carbon Shield PLC into the customer’s native DCS system. (Fig. 85) ETHERNET MODULE PLANT DCS SYSTEM...

  • Page 36: Switching From Main To Backup Generator

    34 | alemite Carbon Shield Service Guide Switching from Main to backup Generator Follow the process described below to dampen the transient pressure resulting when the main generator is shut down and backup generator starts: (Fig. 87) 1. Open the mist outlet valve of the backup unit 2.

  • Page 37: Maintenance Checklist

    Important Note: Always close the ball valve in the Weekly Carbon Shield™ cabinet and the air supply valve to the refill pump before changing the filter element. o Inspect for air and oil-mist leakage Follow the proper lockout/tagout procedures.

  • Page 38: Troubleshooting Chart

    36 | alemite Carbon Shield Service Guide tRoubLEsHootinG cHARt The following information provides general guidelines to identifying potential problems and possible solutions on the Carbon Shield system. For complete parts list, electrical schematics and component locations refer to the information contained in this manual.
  • Page 39 Carbon Shield Service Guide | www.alemitecarbonshield.com...
  • Page 40 38 | alemite Carbon Shield Service Guide troubleshooting chart Problem Possible cause Possible solution Not enough mist being 1. Reduced oil supply 1.1 Pull the relief valve ring. visually inspect produced resulting in lean oil mist quality. Good mist should resemble to air mixture.
  • Page 41 Troubleshooting Chart | 39 troubleshooting chart Problem Possible cause Possible solution Low mist pressure 1. Air supply pressure below 1.1 verify the air supply pressure is between 70 psi, or 4.92 kg/cm 70 and 150 psi (4.92 and 10.55 kg/cm (below 90 psi, or 6.33 kg/ Change over to the backup unit and , for 13 CFM &...
  • Page 42 40 | alemite Carbon Shield Service Guide troubleshooting chart Problem Possible cause Possible solution High mist pressure 1. Mist pressure set point 1.1 Press the “parameter values” button too high. on the main menu screen to display the mist pressure value. Factory default is 20 inches H O column or 50mbar.
  • Page 43 Troubleshooting Chart | troubleshooting chart Problem Possible cause Possible solution Low air temperature 1. Air Heater malfunction 1.1 Press the “Parameter values” button on the main menu screen to display the air temperature. Factory default is 100 °F (37.8° C). 1.2 Ensure that the air supply pressure is between 70 psi and 150 psi (4.92 and 10.55 kg/cm...
  • Page 44 42 | alemite Carbon Shield Service Guide troubleshooting chart Problem Possible cause Possible solution High air temperature 1. Air Heater and/or Control 1.1 Repairs to the Air Heater and/or Control System are out of the scope of this System malfunction.
  • Page 45 Insufficient amount of oil 1. Distribution line 1. Remove low spots in distribution line. mist or no mist produced obstruction 2. Consult with Alemite® Technical Service. (Potential problem may 2. Console Reservoir be unrelated to the 3. Clean distribution vent line(s).

  • Page 46: Reference

    Potentially Hazardous conditions May result in death, severe injury, or equipment damage. All electrical components are rated for Class I, Division 2 hazardous locations. Substitutions will void the hazardous locations rating of the Carbon Shield System. ™ Mechanical systems...

  • Page 47: Electrical Systems

    Carbon Shield Service Guide | 45 specifications Electrical systems voltage 120 vAC or 240 vAC Graphic Display Temperature, pressure, and mist density trending Current 20 A @ 120 vAC, Security Two level password 10 A @ 240 vAC access...

  • Page 48: Parts List

    46 | alemite Carbon Shield Service Guide Parts List commissioning two Years service common parts ALEMitE P/n notes service Parts List Parts List Gasket, Mist Oulet 387834 4 parts in package Mist Head Assembly Kit -1 SCFM 393797-1 Job specific Mist Head Assembly Kit - 2.3 SCFM...
  • Page 49 Carbon Shield Service Guide | 47 Parts List commissioning two Years service common parts ALEMitE P/n notes service Parts List Parts List electronics I/P TRANSDUCER REGULATOR 387865 RELaY 387907 SOCKET, RELAY 387908 Air solenoid valve and Oil solenoid valve...
  • Page 50 48 | alemite Carbon Shield Service Guide Parts List commissioning two Years service common parts ALEMitE P/n notes service Parts List Parts List accessories Manual Refill Pump 388034 Job specific Mist Collector Container 388235 Job specific bulk Oil Storage Tank...

  • Page 51: Wiring Diagrams

    Carbon Shield Service Guide | 49 wiring Diagrams PLC Analog Input/Output module wiring. (Fig. 90) Fig. 90 www.alemitecarbonshield.com...
  • Page 52 50 | alemite Carbon Shield Service Guide wiring Diagrams Thermocouple Module Wiring. (Fig. 91) Fig. 91 www.alemitecarbonshield.com...
  • Page 53 Carbon Shield Service Guide | wiring Diagrams Relay Wiring. (Fig. 92) Fig. 92 www.alemitecarbonshield.com...
  • Page 54 52 | alemite Carbon Shield Service Guide wiring Diagrams Schematic diagram. (Fig. 93) Fig. 93 www.alemitecarbonshield.com...

  • Page 55: References

    Purge Auto w/bST* none *Wired for Alemite Bulk Storage Tank (BST) with Level Switch. BST sold separately. Hazardous location, 5 gallon SS reservoir, 9.7 CFM nozzle, 120 vAC control voltage, 1000 W air heater, PLC and HMI, Modbus communication, SS NEMA 4X enclosure, cabinet cooling option, back-up unit, UL Listed for Class I Division 2 Groups bC &...
  • Page 56 54 | alemite Carbon Shield Service Guide References General Arrangement Drawing. (Fig 94) Fig. 94 www.alemitecarbonshield.com...
  • Page 57 References Installed Arrangement (Fig 95) Fig. 95 WWW.ALEMITECARbONSHIELD.COM...
  • Page 58 Key Benefits Applications Feedback How It Works 1057 521 Corporate Center Dr., Suite 100 Fort Mill, SC 29707 Toll Free U.S.: 866-4-Alemite Toll Free Canada: 800-267-8022 International: 803-802-0001 Fax U.S.: 800-648-3917 Fax Canada: 800-267-2880 Fax International: 803-802-0192 www.alemite.com LITXXX 03/12...

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