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FC Curtis NX Series Operator's Manual

Oil – injected rotary screw compressor
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CAP-835
June, 2018
Rev. E
NX
Series
Oil
Injected Rotary Screw Compressor
–
Operator Manual
18 – 185 kW (25 – 250 HP)
WARNING
Personal injury and/or equipment damage will be result by failing to pay attention to the vital safety
information and instructions in this manual. Carefully read, understand, and retain all safety information and
instructions before operating this compressor.

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  • Page 1 CAP-835 June, 2018 Rev. E Series Injected Rotary Screw Compressor – Operator Manual 18 – 185 kW (25 – 250 HP) WARNING Personal injury and/or equipment damage will be result by failing to pay attention to the vital safety information and instructions in this manual. Carefully read, understand, and retain all safety information and instructions before operating this compressor.
  • Page 3 ◼ Information on these operating instructions unauthorized conversions ◼ These instructions enable you to use the technical modifications ◼ machine safely and efficiently. The instructions use of non-approved spare parts are a component part of the machine and must The actual scope of supply may differ from the be accessible for staff at all times.

  • Page 4: Table Of Contents

    Safety ......................................6 Symbols in these instructions ............................6 Proper use ..................................7 Safety devices .................................8 1.3.1 Position of the safety devices ............................9 1.3.2 Description of the installed safety devices .........................9 Environmental protection ............................... 10 Signage ..................................10 Transportation, packaging and storage ..........................12 Safety instructions for transportation ..........................
  • Page 5 Technical data ..................................30 Serial tag ..................................30 General specifications ..............................31 5.2.1 Operating conditions ..............................31 5.2.2 Oil .................................... 31 5.2.3 Oil Capacity ................................31 Operation ....................................32 Safety instructions for operation ............................. 32 Modulation Control ................................. 32 Maintenance ..................................... 33 Environmental protection ...............................

  • Page 6: Safety

    1 Safety This section is a summary of important safety covering with clean rags or plastic to prevent cross contamination. aspects to ensure optimum protection of the 12. Do not install a shut-off valve in the personnel and safe and trouble-free operation. discharge line without installing a pressure The owner, lessor or operator of this com- relief valve between the shut-off and the...

  • Page 7: Proper Use

    actions, results, lists, cross references and other elements: NOTICE! Marking Explanation This combination of symbol and signal word indicates a possibly Step-by-step instructions for hazardous situation which may actions cause material damage if not  Results of actions avoided or possible hazards for the References to sections of these environment.

  • Page 8: Safety Devices

    Claims of any type for damage due to misuse are excluded. 1.3 Safety devices WARNING! Danger to life from nonfunctional safety devices! If safety devices are not functioning or are disabled, there is a danger of injury or death. Check that all safety devices are fully functional and correctly installed before starting work.

  • Page 9: Position Of The Safety Devices

    Position of the safety Description of the installed 1.3.1 1.3.2 devices safety devices The following illustrations show the position of Emergency stop button the safety devices. Fig. 3: Emergency stop button By pressing the emergency stop button, the machine is stopped by an immediate switching off of the compressor.

  • Page 10: Environmental Protection

    Lubricants Lubricants such as greases and oils can contain harmful substances. They must not be allowed to escape into the environment. Dispose of lubricants in accordance with applicable local, state and federal regulations. 1.5 Signage WARNING! Danger of injury from illegible Fig.4: Pressure Relief Valve symbols! Do not change the pressure setting of the...
  • Page 11 Hazardous Voltage Brief instructions for operation This sticker is on the enclosure and contains brief instructions for operation. CAP-835...

  • Page 12: Transportation, Packaging And Storage

    2 Transportation, packaging and storage 2.1 Safety instructions for 2.3 Packaging About the packaging transportation The individual screw compressors are packaged Improper transport in cartons or sometimes on wooden frames and NOTICE! according to the anticipated transport conditions. Damage to property due to Only environmentally-friendly materials are used improper transport! for the packaging.

  • Page 13: Transportation

    ◼ Protect against moisture Storage temperature: 60 to 95F (15 to 35 °C). ◼ Relative humidity: max. 60 %. ◼ In case of storage for longer than 3 months, check the general condition of all parts and the packaging regularly. If necessary, refresh Protect packages against moisture and keep or replace the rust-proofing.

  • Page 14: Installation And Commissioning

    3 Installation and serious injuries or death for persons in the danger zone. commissioning Switch off all power supplies before starting work and make 3.1 Safety instructions for the sure they cannot be switched on again. Follow lockout/ tagout installation and procedure.

  • Page 15: Requirements In The Installation Location

    3.2 Requirements in the installation location Set up the screw compressor so that the following conditions are fulfilled: ◼ The installation location is level. ◼ The machine is easily accessible and can be accessed from all sides. ◼ There is sufficient lighting. ◼...

  • Page 16: Connection To The Compressed Air Network

    FSC base mounted compressor packages come NOTICE! with a mounted starter. Ensuring that the starter Risk of material damage from is mounted per national and local NEL condensation! requirements, it’s responsibility of the owner. Cooling air with moisture content can cause condensation. 1.

  • Page 17: Checking The Oil Level

    9. The grounding wire of a motor or system destroyed due to the drive turning must be reliably installed and grounding wire incorrectly. cannot be connected to air delivery pipe or Connect the power according to cooling water pipe. Air compressor must be the wiring diagram and check the reliably grounded to prevent danger from airend and motor for correct...

  • Page 18: Switching On After Installation

    4. Carefully open the shut-off valve downstream downtime, can cause significant of the discharge port between the screw material damage to the screw compressor and the compressed air network. compressor.  The screw compressor is now connected Add 0.5 quarts of oil directly in to the compressed air network.
  • Page 19 4. Check all oil and compressed air lines for If the compression temperature is leaks and tighten as necessary. sufficiently high, this ensures that the 5. Tighten screws where needed. air humidity taken in does not form 6. Check the oil level in the inspection glass condensation.

  • Page 20: Design And Function

    4 Design and function 4.1 Overview Screw compressor Fig. 9: Screw compressor Controller Enclosure panels Emergency stop button Air receiver (optional on 18 - 22 kW models) This chapter shows the screw compressors described in these instructions. The compressors differ primarily in size and the installed drive.
  • Page 21 Assemblies BELT DRIVEN (18-37 kW Fixed Speed Models) Fig. 10: Screw compressor 18–37 kW with V-belt (optional air receiver on 18–22 kW models) Air receiver Air after-cooler Compressor airend Intake air filter Oil separator tank 10 Drive motor Oil filter 11 Belt guard Air/oil separator 12 Electrical cabinet...
  • Page 22 DIRECT COUPLED (45-90 kW Variable Speed Models) Fig.11: Screw compressor 18-90 kW with direct drive, frequency converter and refrigeration dryer (optional) Compressor airend Drive motor Oil separator tank 10 Electrical cabinet Oil filter 11 Frequency converter Refrigeration dryer (optional) 12 Minimum pressure and non-return valve Cooling air fan 13 Safety valve Oil cooler...
  • Page 23 DIRECT COUPLED (45-185 kW Models) Fig.12:Screw compressor 45–185 kW with direct drive Compressor airend Electrical cabinet Oil separator tank Frequency converter (optional) Oil filter Minimum pressure and non-return valve Cooling fan 10 Safety valve Intake filter 11 Connection pipe Main motor 12 After cooler CAP-835...

  • Page 24: Brief Description

    their technical data and their functional principle 4.2 Brief description as follows: The fresh air supplied by the installed cooling air fan is filtered through the intake filter. The air flows through intake valve into compressor airend, where it is compressed together with the injected oil to the final pressure.

  • Page 25: Screw Compressor With V-Belt Drive

    Screw compressor with V- Intake filter 4.3.3 4.3.2.1.1 belt drive Fig.15: Intake filter The intake air filter (Fig. 15-1) is fitted above the drive motor. The air which the cooling air fan pulls into the enclosure is filtered by the intake filter and fed to the compressor airend through the inlet valve (Fig.

  • Page 26: Oil Separator Tank

    Oil separator tank 4.3.5 Air/oil separator 4.3.6 Fig.17: Oil separator tank with safety valve(18-37 kW models) Safety valve Fig.19: Air/oil separator (18-37 kW models) Filler nozzle The air/oil separator (Fig. 19-1) removes the Connection for oil heater (optional) residual oil from the compressed air. Sight glass Oil drain Oil separator tank...

  • Page 27: Minimum Pressure And Non-Return Valve

    Minimum pressure and non- Coolers 4.3.7 4.3.8 return valve Fig. 23: Air/oil Coolers (18-37 kW models) The compressed air is cooled in the air after- Fig.21: Minimum pressure and non-return valve (18- cooler (Fig. 23-2) before it leaves the screw 37 kW models) compressor via the discharge port (Fig.

  • Page 28: Oil Filter

    Cooling air fan 4.3.10 Oil filter 4.3.9 Fig.25: Oil filter (18-37 kW Models) Fig.27: Cooling air fan (18-37 kW models) Fig.26: Oil filter (45-185 kW Models) The oil filter (Fig.25-1, Fig.26-1) cleans the oil before it is injected into the compressor airend once again.

  • Page 29: Interfaces

    The following interfaces are found in the screw compressor: 4.4 Interfaces ◼ Air supply ⚫ Cooling air fan ⚫ Intake filter ⚫ Discharge port Fig.29: Flow diagram of screw compressor 18–37 kW with direct drive Fig.30: Flow diagram of screw compressor 45-185 kW with direct drive CAP-835...

  • Page 30: Technical Data

    5 Technical data For more information refer to the technical data sheet. 5.1 Serial tag Fig.31: Serial tag The serial tag can be found on the enclosure. It includes the following details: 1. Manufacturer 2. Part number 3. Serial number 4.

  • Page 31: General Specifications

    5.2 General specifications Oil Capacity 5.2.3 Operating conditions 5.2.1 Screw compressor type 18 - 185 kW models Environment Data Value Type Consumable Fill level Fixed speed +37 to +113F 4 US GAL. temperature range (+3 to +45°C) 4 US GAL. Variable speed +37 to +104F 5 US GAL.

  • Page 32: Operation

    6 Operation 6.1 Safety instructions for operation Improper operation WARNING! Danger of injury due to improper operation! Improper operation can cause serious injury and significant material damage. Carry out all operating steps in accordance with the information and notices in this manual. Pay attention to the following points before starting work: Fig.32: Changing the modulating valve setting...

  • Page 33: Maintenance

    7 Maintenance wear. For questions about maintenance work or 7.1 Environmental protection intervals contact an authorized distributor. Observe the following environmental protection instructions during maintenance work: * The change intervals refer to: ◼ In respect of all lubrication points supplied ◼...

  • Page 34: Service Kits

    7.4 Service kits Nx (18-90kW) MAINTENANCE SCHEDULE SERVICE INTERVALS (HOURS) DESCRIPTION PART# Check sump oil level (fill if  necessary) Check pressure operating point  and controls Check oil scavenger line for oil  flow Drain condensate from air  receiver Check pressure relief valve for 3...
  • Page 35 Nx (110-260 kW) MAINTENANCE SCHEDULE SERVICE INTERVALS (HOURS) DESCRIPTION PART# Check sump oil level (fill if  necessary) Check pressure operating point  and controls Check oil scavenger line for oil  flow Drain condensate from air  receiver  Check pressure relief valve for operation ...

  • Page 36: Maintenance Work

    7.5 Maintenance work 1. Close the shut-off valve on the pressure Necessary maintenance work network side and secure it to prevent it from Necessary maintenance work being opened again. appears on the display of the 2. Open and remove the enclosure panels with ...

  • Page 37: Checking The Build-Up Of Condensation

    the special wrench. 3. Use a drip pan to make sure that the leaking NOTICE! oil is collected. Risk of material damage from 4. Unfasten the filler nozzle (Fig. 34-1), remove condensate in the oil circuit! it and make sure that the gasket is not Condensate in the oil circuit can misplaced.

  • Page 38: Checking The Compressor Temperature

     ‘Checking Chapter 7.5.3 level/topping up the oil’ on page 36. Checking the drive unit 7.5.7 Checking the compressor 7.5.5 1. Close compressed air outlet side gate valve and secure against re-opening. temperature 2. Open and remove the enclosure panels with the special wrench.

  • Page 39: Replacing The Oil/Changing The Oil Filter

    7. Close the oil drain. 8. Screw the screw plug back in. NOTICE! Property damage due to incorrect oil! Mixing different oils or using incorrect oils causes significant property damage to the screw compressor. Only use the oil prescribed in the technical data.

  • Page 40: Replacing The Air/Oil Separator

    level/topping up the oil’ on page 36. oil is collected. Replacing the air/oil 7.5.10 separator Spin on/off separator 7.5.10.1 style for 18-37kW 1. Close the shut-off valve on the pressure outlet side and secure it to prevent it from being opened again. 2.

  • Page 41: Clean/Replace Return Line

    5. Clean the return line (Fig. 42-1) and nozzle. If necessary, replace them with original  spare parts ( Parts List). 6. Place the nozzle and return line (Fig. 42-1) back in position and tighten the screw connections. 7.7 Measures after maintenance has been performed After completion of the maintenance work and before switching the machine on, carry out the...

  • Page 42: Faults

    8 Faults The following section describes possible causes Improperly executed troubleshooting work of faults and the work to remedy them. WARNING! In case of faults that occur more than once, Danger of injury from improper shorten the maintenance intervals according to troubleshooting! the actual utilization.

  • Page 43: Fault Displays

    Before all work, make sure that Hot surfaces the compressor is not under WARNING! pressure; wait at least Danger of injury from hot 5 minutes. surfaces! Surfaces of components can heat Oil vapor up a lot during operation. Skin contact with hot surfaces will cause CAUTION! severe skin burns.

  • Page 44: Troubleshooting

    8.3 Troubleshooting Fault description Cause Remedy Compressor Intake or ambient Ventilate compressor room temperature too temperature too high high Cooling air intake or outlet Unblock cooling air intake or outlet sufficiently blocked  Chapter 7.5.9 ‘Replacing the Oil is degraded Change oil oil/changing the oil filter’...

  • Page 45: Work For Fault Clearance

    Fault description Cause Remedy  start key is Symbol "remote" flashes Remote control activated Controller pressed documentation Lacking voltage on the Check incoming voltage screw compressor Electrical fault in the Check controller  controller Controller documentation Switching times are Check switching and pressure times in the circuitry ...

  • Page 46: Index

    Index 9 Index Air/oil separator .............. 27 Maintenance Assemblies Changing the oil filter ..........41 Air/oil separator ............27 Checking the build-up of condensation ...... 38 Compressed air after-cooler ........28 Checking the oil level ..........37 Compressor airend ............. 26 Oil change ..............

  • Page 47: Appendix

    10 Appendix 10.1 Bolt tightening torque requirements Lock screw/nuts B 158/193/196/251 design or similar Thread Category 8.8 Unit Category 10.9 Unit 3.69 (5) lbf ft (Nm) 7.38 (10) lbf ft (Nm) 5.9 (8) lbf ft (Nm) 13.28 (18) lbf ft (Nm) 14.75 (20) lbf ft (Nm) 32.45 (44)

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