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Alemite Carbon Shield CS-5700 Series Installation, Operation And Maintenance Manual

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CS-5700 S
ERIES
™
Carbon Shield
Installation,
Operation and
Maintenance
Manual

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Summary of Contents for Alemite Carbon Shield CS-5700 Series

  • Page 1 CS-5700 S ERIES ™ Carbon Shield Installation, Operation and Maintenance Manual...
  • Page 2 167 Roweland Drive Johnson City, TN 37601 Toll Free U.S.: 866-4-Alemite Toll Free Canada: 800-267-8022 International: 803-802-001 Fax U.S.: 800-648-3917 Fax Canada: 800-267-2880 Fax International: 803-802-0192 www.alemite.com...

  • Page 3: Table Of Contents

    Table Of Contents 1. Introduction ............1 2.
  • Page 4 Table Of Contents 6. Accessories ............16 Bulk Oil Storage Tank (BST) .
  • Page 5 Table Of Contents 10. Maintenance Check List..........32 11.

  • Page 6: Introduction

    Introduction formance parameters and digital communication Oil Mist Lubrication is a cost-effective technique for interface. Unlike any other system, CS units moni- lubricating gears, chains, rolling element bearings, tor every parameter and reports warnings to main- sleeve bearings, sliding surfaces and other critical tenance personnel.

  • Page 7: Agency Approvals

    Agency Approvals The Carbon Shield™ unit is UL -Listed under UL category BAYZ Lubrication-Dispensing Equipment www.ul.com. The CS units are suitable for use in Class I Divi- (Fig. 03). The lubricants dispensed by this equip- cations. BAYZ.E328442 - Lubricant-dispensing Equipment for Use in Hazardous Locations Page 1 of 1 BAYZ.E3 2 8 4 4 2 Lu br ica n t - dispe n sin g Equ ipm e n t for Use in H a za r dou s Loca t ion s...

  • Page 8: How The Carbon Shield™ (Cs) Unit Works

    How the Carbon Shield™ (CS) Unit Works The Carbon Shield™ system produces a continu- Oil Mist Density Monitoring The Carbon Shield™ (CS) units use a proactive ap- voir into the mist head where it is atomized into the proach to oil mist density monitoring. Unlike current air stream.

  • Page 9: System Components And Optional Features

    System Components and Optional Features The Carbon Shield (CS) system consists of three Enclosure distinctive systems: the Electrical Control System, The entire Oil Mist Generator (OMG) is housed in a NEMA 4x stainless steel enclosure. The enclosure They interact to produce, monitor and control the oil has center-locking, weather-sealed doors with a mist delivery to the lubrication point.

  • Page 10: Human-Machine Interface (Hmi)

    System Components and Optional Features The PLC receives Input signals from: HMI Password Information User names and passwords are assigned through • the HMI. They allow the appropriate access to the • two password protected screens in the HMI. Level •...

  • Page 11: Status Lights

    System Components and Optional Features Status Lights Red and Green Status (LED type) indicator lights are mounted on the top of each CS unit cabinet (Fig. 07). The status lights are controlled by the PLC. The green LED is illuminated when the sys- tem is operating normally and all operating param- eters fall within the expected range.

  • Page 12: Air Solenoid Valve

    System Components and Optional Features Air Solenoid Valve The Air Solenoid Valve is next downstream from the air regulator (Fig. 10). This solenoid protects the I/P transducer regulator from receiving air pressure while the PLC and control electronics are not en- ergized and therefore not in control of the system.

  • Page 13: Air Heater Package (Optiona Feature)

    System Components and Optional Features Air Heater Package (optional Feature) The Air Heater Package is an optional but popular feature. When installed, the pressure-regulated air from the I/P Transducer-Booster passes through based on the input from a thermocouple mounted close to the mist head inlet port . The PLC switches the corresponding relay so the air heater cycles ON and OFF.

  • Page 14: Loader Fitting

    System Components and Optional Features Loader Fitting Oil Level Sensor The Oil Level Sensor detects change in oil level as mist head allows oil to be added to the reservoir a function of change in capacitance between sen- sor probe and the shield as oil level changes. The chased (Fig.

  • Page 15: Mist Outlet

    The customer The oil level on the CS reservoir on both the main ing the tank using an Alemite Bucket Pump package side of the enclosure. (Fig. 16.a and Fig. 16.b). ting on the front face of the mist head (Fig. 14). The ing the oil mist production and distribution.
  • Page 16 System Components and Optional Features Filtered oil enters the reservoir of the main genera- package options installed, the oil level in the back- up reservoir can be restored by opening the manual required” signal from the level sensor. The current ball valve inside the backup unit enclosure.

  • Page 17: Optional Features

    Optional Features Some of the optional features in this section have already been mentioned above. This section pro- vides more detailed information on their compo- Backup Oil Mist Generator (BOMG) Important Note: nents and function. Air Heater Package The Air Heater Package is an optional but popular feature.

  • Page 18: Switching Oil Mist Generation From Main To Backup Unit

    Optional Features Switching Oil Mist Generation from Main to connect switch to the OFF position. All electrical Backup Unit devices in the main CS unit should now be OFF. Follow the steps below to switch the oil mist gen- However, the main reservoir is still pressurized eration from the main CS unit to the BOMG.

  • Page 19: Switching Oil Mist Generation Backup Unit To Main Unit

    Optional Features Switching Oil Mist Generation Backup Unit system lubrication issues were found, the adap- to Main Unit tive mode feature should be used to clear those Follow the steps below to switch the oil mist alarms. generation from the Backup to the Main Unit. present) will go away as soon as their actual right side of the main CS unit enclosure and values reach their set point values stored in...

  • Page 20: Enclosure Purge System

    (Fig. 25a). DCS Communication Alemite offers optional communication capabilities or Modbus TCP/IP (Ethernet). In all cases the unit communicates using standard Modbus RTU proto- Holding Registers). Alemite supplies a Modbus memory map of the operating variables and alarms.

  • Page 21: Accessories

    Alemite 388220. The OCCs are installed such that the inlet ports tion on a CS unit, an Alemite Bulk Oil Storage Tank are lower than the equipment vent/drain port. The (BST) is highly recommended (Fig 26). The BST...

  • Page 22: Oil Mist Manifold (Omm)

    It is important to note that in order to avoid Alemite 388252 Alemite’s Purge Mist Kit (PUK) contains all the nec- The OMM is composed of a hexagonal, stainless what is known as purge oil mist lubrication (or wet threaded port at the top.

  • Page 23: Oil Sight Glass (Osg)

    However, since the oil in the DLK reservoir is re- turned to the oil mist system for use in lubrication, Alemite 388253 In an oil mist system the main header/pipe should ting from the drain leg manifold to prevent con- be sloped towards the CS unit reservoir.

  • Page 24: Installation

    Installation AC Power Site Preparation Install your Carbon Shield™ unit in an area as space to accommodate: and Ground connection to each unit (i.e. main and backup units). The connection is made inside the • Opening of the enclosure door power disconnect switch (Fig.

  • Page 25: Air Supply - Drain Leg Kit (Dlk)

    Wiring Diagram section for more detail. DCS – Serial Communication The Bulk Oil Tank (BST) oil line connects to the Au- Alemite Carbon Shield™ units offer the option of (RTU) or ModBus TCP. See Communication and (Fig. 17). Electrical Wiring Diagram sections on this manual for more detail inside the CS main enclosure on the left side.

  • Page 26: Operation

    (Fig. 37). Check wiring and ensure terminal block screws are secure. The home page of the Alemite Carbon Shield™ The reservoir drain ball valve must be CLOSED be- unit is displayed (Fig 29). This indicates the end fore oil is loaded into the tank (Fig. 19).

  • Page 27: User Name And Password Set Up Procedure

    Operation 4. Check and adjust the Date and Time on the HMI CFM required for a particular installation is likely to screen as necessary. See section Date and Time be different that the “nominal” CFM value the unit is Set Up Procedure section for details. set from the factory.
  • Page 28 The Group Authority Levels, default user name and password are as follows: quired by the HMI-PLC Siemens software and it is not used by the Alemite Carbon Shield unit software. tap on an empty cell in the user column to create a new user name (Fig.

  • Page 29: Date And Time Set Up Procedure

    Operation Log On screen and press OK button (Fig. 33). See User Name and Password Procedure sec- tion for more detail tion screen to complete the process. 7. A new user name and password is now set up. Time screen to enter new date and time (Fig. 34). IMOPORTANT NOTE: Date and Time Set Up Procedure The CS unit is factory set to United States Eastern...

  • Page 30: Other Start/Setup Considerations

    Operation dure is very simple and the instructions are written the “PUSH TO ACCEPT” button on the Enter on Level Sensor Calibration screen. No physical in- New System Time screen (Fig. 36 ). teraction with the level sensor is required. The procedure is as follows: oil level is well below the ZERO-gallon mark.

  • Page 31: When Parameter Set Up Required

    In these cases, it is strongly recommended that this procedure be performed by an Alemite Application Engineer as this procedure is the key to a correct operation of the oil mist system.
  • Page 32 Operation Up screen. on the left side of the Flow Parameters screen (Fig 43). quired. See Level Sensor Calibration section for details. select YES for Air Heater. to NO. pare the volume shown on the main reservoir Change Parameters screen and select Air/Oil oil level sight glass.

  • Page 33: Monitor And Control Features

    Operation Monitor and Control Features ton to enter an administrator user name and cor- responding password. Enter the Setup screen Using Change Parameters Feature and press Setup Complete button. The blinking The Change Parameters feature allows an end square on the upper right corner showing SET UP should turn into System OK in green letters to change the system parameter set points.

  • Page 34: Using Adaptive Mode Feature

    (Fig 44). For most application, the feature is only used in special cases and under the advice of an Alemite Application Engineer. Using Adaptive Mode Feature The Adaptive Mode feature allows the end user...

  • Page 35: Alarms

    Alarms The PLC performs an ordered series of control set point checks for the maximum and minimum values 8. Low Air Temperature – Issued when the air thermocouple detects an air temperature and time stamps the fault if the current value ex- ceeds the maximum setting (high alarm) or is less than the minimum setting (low alarm).

  • Page 36: Oil Related Alarms

    Alarms Alemite representative. There is no time delay for and the oil level in the tank doesn’t increase after this alarm. Oil Related Alarms Other Alarms Check Oil Screw – Issued when the PLC detects Setup is not Finished Select Setup Done – Is-...

  • Page 37: Maintenance Checklist

    Maintenance Checklist supplies a Modbus memory map of the operating variables and alarms including the type, location, and size. To help keep your Carbon Shield™ system oper- nance schedule covering all major components. See Spare Part List section for require components. Weekly Inspect for air or oil leakage Clean the inside of enclosure and correct any...

  • Page 38: Troubleshooting Chart

    If you cannot resolve your issue through our Trou- To display alarm messages, press the “Alarm ble Shooting Section, please contact Alemite Cus- Screen” button on the main menu screen of the PROBLEM...
  • Page 39 Trouble Shooting Chart PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION Change over to the backup unit and adjust pressure as needed. cabinet set to less than CFM units) the main menu screen to display the mist Low mist pressure set too low. “Change Parameter”...
  • Page 40 Trouble Shooting Chart PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION the main menu screen to display the mist too high. “Change Parameter” button on the main menu, then the Air Flow Parameters, then the + or – buttons on the “Flow Parameters” screen adjust to the desired mist pressure level.
  • Page 41 Trouble Shooting Chart PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION the main menu screen to display the air tem- Low air temperature fer to Wiring Diagram) as needed. (Refer to Wiring Diagram) point are out of the scope of this manual. Please change over from the main unit to the backup unit.
  • Page 42 Trouble Shooting Chart PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION System are out of the scope of this manual. Please change over from the main unit to the High air temperature Control System backup unit. Turn off the power to the main malfunction.
  • Page 43 Oil heater Agency Approvals UL-Listed Hazardous Location Cut Off Rating Code T4 IEC Compliance Power Air Supply Control System PLC and HMI Security Two level password access Quality Instrument Air, Dry Comm. Options Modbus RTU or TCP Display Languages English Air heater Measurement Units English and Metric...

  • Page 44: Spare Parts List

    Spare Parts List Item No. Part No. Description Filter/Regulator w/ Gauge Gauge, Pressure - F/R (Replacement) Sensor, Pressure Sensor, Vacuum Gauge, Mist Pressure Sensor, Oil Level Filter Assembly Complete w/o Gauges Gauge, Pressure - Oil Filter Filter Element, Oil Filter (Replacement) Regulator, I/P Transducer Booster Gauge, Pressure - Booster...
  • Page 45 Spare Parts List Item No. Part No. Description Gauge, Air Temperature Thermocouple - Air/Nitrogen Temperature Mist Head HMI, Touch-Screen Display w/o Software Memory Card, HMI w/ Software (Replacement) Light, LED - Green (Replacement) Light, LED - Red (Replacement) Tube, Oil Pickup Screen, Oil Pickup Tube O-Ring, Mist Head - (4 pack) Screw, Oil Adjustment...

  • Page 46: Main Unit

    Spare Parts List Main Unit ON ENCLOSURE DOOR NOT SHOWN NOT SHOWN FRONT VIEW...

  • Page 47: Backup Unit

    Spare Parts List Backup Unit NOT SHOWN...

  • Page 48: Turnaround Kit

    Spare Parts List Turnaround Kit Nozzle Kit PLC Enclosure and Electronics...

  • Page 49: Site Preparation

    Site Preparation Recommended Enclosure Clearance 60’ ’ 90.0° FRONT BACKUP UNIT 136’ ’ MAIN UNIT FRONT 90.0°...

  • Page 50: Anchor Bolt Hole Pattern

    Site Preparation Anchor Bolt Hole Pattern...

  • Page 51: Wiring Diagrams

    Wiring Diagrams Main Unit Disconnect Switch TO F1 TO TB1 TO GND BUS BAR DISCONNECT SWITCH THE EXPLOSION PROOF CONDUIT SEALING FITTING MUST BE SEALED BEFORE TURNING ON THE POWER FOR THE FIRST TIME APPLY SEALANT COMPOUND PER MANUFACTURERS SPECIFICATIONS 3/4 CONDUIT COMPOUND MATERIAL SUPPLIED WITH THE UNIT (REF)

  • Page 52: Plc Enclosure Layout

    Wiring Diagrams PLC Enclosure Layout CPU PLC0 POWER SUPPLY GND BUS BAR 3.7A @ 24VDC MODBUS RTU OR TCP MODULE SET JUMPER ON THIS FACE TO POSITION A FOR THERMOCOUPLE THIS JUMPER MUST BE INSTALLED INPUT PRIOR TO INSTALLATION. WHEN WIRED FOR 120VAC SERVICE. REFER TO SHEET 5 FOR JUMPER MUST NOT BE INSTALLED ILLUSTRATION.

  • Page 53: Digital I/O

    Wiring Diagrams Digital I/O...

  • Page 54: Analog I/O

    Wiring Diagrams Analog I/O...

  • Page 55: Thermocouple Module

    Wiring Diagrams Thermocouple Module...

  • Page 56: Instrumentation Wiring

    Wiring Diagrams Instrumentation Wiring...

  • Page 57: Terminal Blocks

    Wiring Diagrams Terminal Blocks TERMİNAL ŞERİDİ L1 AC NO: X17 24VDC GÜÇ KAYNAĞI L1 HAVA ISITICISI R0/1 YAĞ ISITICISI R1/1 0.5A HAVA SOL. R2/1 SİSTEM DURUMU YEŞ IŞIK R3/1 YEDEK 0.5A YAĞ TEDARİK SOL. R5/1 SİSTEM DURUMU KIRMIZI UZAKTAN R4/8 PLC Q124.0 X12/22 0.5A R0 BOBİNİ...

  • Page 58: Modbus Rtu Module Connection

    Wiring Diagrams Modbus RTU Module Connection...

  • Page 59: Model Selection Chart

    Model Selection Chart Carbon Shield™ Nomenclature PLC and HMI, Modbus RTU communication, SS NEMA 4X enclosure, cabinet cooling option, Back-up...

  • Page 60: Carbon Shield™ General Arrangement Drawing

    Carbon Shield™ General Arrangement Drawing...

  • Page 61: Carbon Shield™ Typical Installation Drawing

    Carbon Shield™ Typical Installation Drawing...
  • Page 63 Chapter CS-5700 S ERISI ™ Carbon Shield Kurulum,...
  • Page 64 167 Roweland Drive Johnson City, TN 37601 Toll Free U.S.: 866-4-Alemite Toll Free Canada: 800-267-8022 International: 803-802-001 Fax U.S.: 800-648-3917 Fax Canada: 800-267-2880 Fax International: 803-802-0192 www.alemite.com...
  • Page 65 ............1 .
  • Page 66 ............16 .
  • Page 67 ..........32 .
  • Page 68 uygundur. Takviyeli CS Ünitesi...
  • Page 69 gundur.
  • Page 70 edilir.
  • Page 72 • • • • • • • • • • • • • • • gerekir.
  • Page 77 16 b).
  • Page 79 eklidir. reklidir.
  • Page 82 KAPAK...
  • Page 83 OCC gerekir.
  • Page 86 Kurulum AC Gücü • • • •...
  • Page 87 Kurulum edilir.
  • Page 88 bilir. emin olun. emin olun. olun.
  • Page 89 • • • • • •...
  • Page 90 abilirler...
  • Page 91 OK = TAMAM 32).
  • Page 92 OK = TAMAM...
  • Page 93 SETUP = KURULUM SETUP = KURULUM PUSH = BAS PUSH = BAS Alarms = Alarmlar Alarms = Alarmlar...
  • Page 94 SETUP = KURULUM PUSH = BAS Alarms = Alarmlar...
  • Page 95 ye edilir.
  • Page 96 41).
  • Page 99 • • • reklidir.
  • Page 100 Alarmlar...
  • Page 101 Alarmlar eder.
  • Page 102 edin.
  • Page 104 edin.
  • Page 105 girilir.
  • Page 107 olabilir. alarmda herhangi bir dolu leyin. 3. Uygulama madde...
  • Page 108 cm2) gerekir.
  • Page 109 387967 388135 387975 387840 387841 382064 387833 388016 387841 387413 391421 388180 387865 387866 339948 387831 387825 387927 387934 387823 388182 387345 387342...
  • Page 110 384876 388007 387831 387878 388192 388193 387893 387295 387365 131266 388096 388173 388100 388097 387907 387748 387747 388232 388177...
  • Page 111 MAHFAZADA KAPAK GÖSTERİLMEMEKTEDİR GÖSTERİLMEMEKTEDİR FRONT VIEW...
  • Page 112 GÖSTERİLMEMEKTEDİR...
  • Page 113 (Madde \ 42) (Madde 41) Ağızlık SİGORTALAR...
  • Page 114 60’ ’ 90,0° ÖN YEDEK ÜNİTE 136’ ’ ANA ÜNİTE ÖN 90,0°...
  • Page 115 Yedek Ünite Ayakları Her İki Ayak Seti de Aynıdır Ana Ünite Ayakları Mahfaza Dış Duvarları...
  • Page 116 L1 - F1 N - TB1 GND - GND TOPLAYICI ÇUBUK AÇIK ŞALTER KAPALI PATLAMAYA KARŞI DAYANIKLI İLETİM YALITIM TEÇHİZATI GÜÇ İLK KEZ VERİLMEDEN ÖNCE YALITILMALIDIR YALITIM BİLEŞİĞİ ÜRETİCİ TALİMATLARINA UYGUN KULLANILMALIDIR. BİLEŞİK 3/4 İNÇ İLETİM K MATERYALİ ÜNİTE İLE BİRLİKTE SAĞLANIR. (REF) ANA ÜNİTE MAHFAZA DUVARI AC GÜCÜ...
  • Page 117 CPU PLC0 GND TOPLAYICI GÜÇ KAYNAĞI 3.7A @ 24VDC ÇUBUK MODBUS RTU VEYA TCP KURULUMDAN ÖNCE TERMOKUPL BU ATLAMA KABLOSU 120VAC SERVİS GİRDİSİ İÇİN ATLAMA KABLOSUNU İÇİN KABLOLANDIĞINDA TAKILMALIDIR. BU YÜZDE KONUM A'ya AYARLAYIN. ATLAMA KABLOSU 240VAC SERVİS İÇİN GÖRSEL İÇİN DOSYA 5'E BAKIN. KURULMAMALIDIR.
  • Page 118 Çıkışlar PLC0 Slot X12 24 VDC içinde Hava Isıtıcısı Yağ Isıtıcısı Hava SOL. Yedek Sistem Alarm Yağ Takviyesi Yedek 1. Bir PLC modülü kurulurken kapalı bara konektörünü kullanarak arkaplan barasıyla bağlantı kurun.
  • Page 119 Vakum Sensörü Yağ Düzeyi Sensörü Buhar Basıncı Sensörü Yedek Yedek I/P Dönüştürücü Regülatörü...
  • Page 120 Notlar: 1. Dosya 1-11 müşteri ve dahili kullanım, Dosya 12 dahili ve panel kurucu kullanımı. 2. Bir PLC modülü kurulurken kapalı bara konektörünü kullanarak arkaplan barasıyla Beyaz bağlantı kurun. Hava Sıcaklığı Kırmızı J tipi Beyaz Yağ Sıcaklığı Kırmızı J tipi Yedek 24VDC Yaygın Termokupl modülünü...
  • Page 121 Yeşil Işık Sis Durum Kırmızı Beyaz Kırmızı Işık Yağ Tedarik Sol. Kontrol odasında ortak alarm bağlantısı Alemite OMG'de kuru iletişim setinin kullanılması Alemite OMG kapsam Müşteri kontrol sinyali Harici kablolama müşteri tarafından sağlanır Müşteri seçimli güç kaynağı (5 A maks)
  • Page 122 TERMİNAL ŞERİDİ L1 AC NO: X17 24VDC GÜÇ KAYNAĞI L1 HAVA ISITICISI R0/1 YAĞ ISITICISI R1/1 0.5A HAVA SOL. R2/1 SİSTEM DURUMU YEŞ IŞIK R3/1 YEDEK 0.5A YAĞ TEDARİK SOL. R5/1 SİSTEM DURUMU KIRMIZI UZAKTAN R4/8 PLC Q124.0 X12/22 0.5A R0 BOBİNİ...
  • Page 123 Pim 11: R(B)/T (B)+ giriş/çıkış Yakl. 3 ft uzunluk Veri Al-Ver (iki kablo modu) Atlama kablosu Belden 9842 M25 veya ¾ inç NPT bölme konektörü Alemite tarafından sağlanır. Modbus Modül Ayrıntılı Görünüm Müşteri tarafından sağlanan Kablo Rakoru uygulama için bölge 2/böl 2 tehlikeli lokasyon gerekliliklerini karşılamalıdır.
  • Page 124 Parça No. Örnek Genel Konfigürasyon Elektrik Konfigürasyonu Kontrol Hava İletişim Alan Rezervuar Kapasitesi Ağızlık CFM Kontrol Voltajı Isıtıcıları Seçeneği Tehlikeli 3 Galon Paslanmaz Çelik Ethernet/Modbus Yerel PLC ve HMI 5 Galon Paslanmaz Çelik Diğer Yok**...

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