1. Manuals
  2. Brands
  3. BeaconMedaes Manuals
  4. Air Compressor
  5. 4107 9006 25
  6. Installation, operation and maintenance instructions

BeaconMedaes 4107 9006 25 Installation, Operation And Maintenance Instructions

Scroll laboratory air compressor system
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Installation, Operation and Maintenance Instructions
Scroll Laboratory Air Compressor System (-10°C Dew Point)
Part number 4107 9006 25
Revision 11
September 15, 2020

Advertisement

Table of Contents
loading

Summary of Contents for BeaconMedaes 4107 9006 25

  • Page 1 Installation, Operation and Maintenance Instructions Scroll Laboratory Air Compressor System (-10°C Dew Point) Part number 4107 9006 25 Revision 11 September 15, 2020...
  • Page 2 1059 Paragon Way Rock Hill, SC 29730 Telephone: (888) 463-3427 Fax: (803) 817-5750 BeaconMedæs reserves the right to make changes and improvements to update products sold previously without notice or obligation. Part number 4107 9006 25 Revision 11 September 15, 2020...

  • Page 3: Table Of Contents

    8.1 Duplex Base Mount Scroll SPC Laboratory Air System 8.2 Triplex Base Mount Scroll SPC Laboratory Air System 8.3 Quadruplex Base Mount Scroll SPC Laboratory Air System 8.4 Pentaplex / Hexaplex Base Mount Scroll SPC Laboratory Air System 4107 9006 25.11...
  • Page 4 B.9 Dew Point Sensor Replacement Appendix C: TotalAlert Embedded Control System C.1 Board Confi gurations C.2 PCB1 (5.7” Display Controller) C.3 PCB2 (3.5” Display Controller) C.4 Password Access C.5 Testing Alarms C.6 Maintenance C.7 Remote Monitoring C.8 BACnet Activation 4107 9006 25.11...
  • Page 5 Do not attempt to service any part while machine is in operation. • To prevent automatic starting, disconnect all electrical power before performing any maintenance. • Do not operate unit without belt guards, shields or screens in place. 4107 9006 25.11...

  • Page 6: General Information

    The scroll case is constructed of diecast to each dryer includes a mounted prefi lter with aluminum. Maximum heat dissipation is achieved automatic drain and element change indicator. through an integral cooling fan and air ducting. 4107 9006 25.11...
  • Page 7 ASME Coded, National Board Certifi ed, and rated for a minimum 150 PSIG design pressure. The tank piping includes a liquid level gauge glass, safety relief valve, manual drain valve, and a zero loss automatic solenoid drain valve. 4107 9006 25.11...

  • Page 8: Electromagnetic Immunity

    The TotalAlert Embedded control system should not be used adjacent to other equipment. adjacent use is necessary, the TotalAlert Embedded control system should be observed to verify normal operation in the confi guration in which it will be used. 4107 9006 25.11...
  • Page 9 Power frequency magnetic fi elds should be at (50/60 Hz) magnetic levels characteristic of a typical location in a typical fi eld commercial or hospital environment. IEC 61000-4-8 NOTE: U is the a.c. mains voltage prior to application of the test level. 4107 9006 25.11...
  • Page 10 If abnormal performance is observed, additional measures may be necessary, such as reorienting or relocating the TotalAlert Embedded control system. Over the frequency range 150 kHz to 80 MHz, fi eld strengths should be less than 3 V/m. 4107 9006 25.11...

  • Page 11: Installation

    If the system must be separated, carefully label all electrical connections that are removed for easier re-assembling at the fi nal destination. Place units to ensure high visibility of indicators and gauges and for performing maintenance on the system. 4107 9006 25.11...

  • Page 12: Space Requirements

    However, the distribution pipe size should not be less Check all electrical connections within the air than the minimum pipe size shown above. system that may have loosened during shipment. 4107 9006 25.11...
  • Page 13 Three-phase power supplied from emergency generator(s) must match that of the normal supply to allow for correct direction of the motor rotation at all times. Alarm Electrical Data Wires Connection Connection Figure 2.1 Electrical/Alarm/Data Openings 4107 9006 25.11...

  • Page 14: System Operation

    Check the air receiver, dryers, controls, and compressors for damage. Check the drain valves on the air receiver and compressor modules. Check all valves for full open and full close travel. 4107 9006 25.11...

  • Page 15: Initial Start-Up

    Inside the control panel, make sure that all unit printed circuit boards are set to the manual override “Off ” position. This is indicated by the middle position “X” on the three-position sliding switch as shown in Figure 3.2. 4107 9006 25.11...
  • Page 16 “Automatic” position and testing rotation. Start each compressor by pressing “Automatic” on the touchscreen. See Figure 3.5. Allow each compressor module to operate for a short time (15 to 30 seconds) and check for any unusual noises 4107 9006 25.11...
  • Page 17 10°C. If dew point is below minus 10°C; both pressure gauges of the on-line dryer will read the same. Reset Button Figure 3.6 Main Screen - Reset Button Observe the system for normal operation. 4107 9006 25.11...

  • Page 18: Normal Start-Up

    “Automatic” mode to eff ectively control the switch condition. system. The controls monitor the system pressure condition (see the table 3-1), starts and stops the compressors depending on changing pressure conditions, and automatically alternates the lead position between compressor units. 4107 9006 25.11...

  • Page 19: Normal Shutdown

    0 psi (0 kPa) will close. In this condition, both towers will be approximately 100 psig (dependent upon tank pressure) and the dryer will not shift towers until the dew point is above -10°C (14˚F). 4107 9006 25.11...

  • Page 20: Emergency Shutdown / Alarms

    The condition should be checked immediately (see “High temperature alarm” in the Troubleshooting Section 4.0) to avoid a compressor shutdown. 4107 9006 25.11...
  • Page 21 “Dryer # Pressure” on the alarm screen will change from Green to Red and a remote set of contacts will change condition (refer to the wiring diagram that came with the unit for terminal numbers). 4107 9006 25.11...

  • Page 22: Trouble Shooting

    High temperature alarm Allow unit to cool; reset alarm & check for High temperature sensor activated over temperature condition Motor overheating Low voltage Check for proper supply voltage V-belt too tight Adjust belt tension Defective motor Contact BeaconMedæs 4107 9006 25.11...
  • Page 23 Adjust or replace Excessive belt wear Belt tension Adjust tension Belt alignment Realign compressor & motor sheaves Abnormal noise Mounting bolts loose Tighten bolts Belt tension Adjust tensions NOTE: For air dryer touble shooting, see Appendix A. 4107 9006 25.11...

  • Page 24: Maintenance

    Replace compressor tip seals and conditions grease pin crank bearings* * An authorized BeaconMedæs Service Technician should perform compressor lubrication and tip seals replacement. Please contact BeaconMedæs Customer Service department at 1-800-463-3427 prior to the maintenance interval. 4107 9006 25.11...

  • Page 25: Service Kits

    Service Kit 10-15 Hp Quadruplex 4107 4000 33 KIT - Scroll Basic Size E 10-15 Hp Pentaplex 10-15 Hp Hexaplex Note: 1-Year Unit Basic Service Kits required in addition to the above 1-Year System Basic Service Kit. 4107 9006 25.11...
  • Page 26 Note: 1-Year System Basic Service Kit required in addition to the above 1-Year Unit Basic Service Kits. (1) Unit Kit is required for each compressor unit. 5.2.3 2-Year System Sensor Kits KIT NUMBER WHERE USED DESCRIPTION CONTENTS 4107 4002 58 All Systems Dew Point Sensor (1) Dew Point sensor 4107 9006 25.11...
  • Page 27 Note: 3-Year Unit Extended Service Kits do not include 1-Year System Basic Service Kit or 1-Year Unit Basic Service Kits. These must be purchased in addition to the 3-Year Dryer Extended Service Kit and the 3-Year Unit Extended Service Kit. 4107 9006 25.11...
  • Page 28 OR with Tip Seal Kits used to support all systems IMPORTANT NOTE: Greasing of the bearings of the compressor element must be done with special grease and grease gun sold by BeaconMedaes below, and according to a specifi c procedure. Contact BeaconMedaes for service. KIT NUMBER...
  • Page 29 1 per unit Clean Rotor fi ns 4107 4000 58 Clean Stator fi ns ** Strokes: Number of strokes valid with recommended purchased grease pump from Grease Pump Kit 2903 0139 00 and Grease Cartridge 2892 6100 20 4107 9006 25.11...
  • Page 30 5 Hp 10 BAR must use kit 2902 0222 11 to replace) 4107 4018 43 Retrofi t Pump Kit 5 Hp 10 BAR 60 Hz 4107 4018 45 Retrofi t Pump Kit 10 Hp 10 BAR 60 Hz 4107 9006 25.11...

  • Page 31: Inspection/Replacement Procedures

    4107 6562 19 1/4” 4107 6544 20 9/32” 4107 6505 47 9/32” Figure 6.1 Belt Tension 6.1.2 V-Belt Tension Adjustment If necessary, adjust the V-belts until the average defl ections are within the values shown in Table 6-1. 4107 9006 25.11...
  • Page 32 2. Loosen the locking bolts securing the motor base. 3. Adjust the belt tensioning adjustment rods on the motor base to loosen tension on belts. 4. Remove the old belt(s). Figure 6.2 Belt Alignment - Straight Edge 4107 9006 25.11...

  • Page 33: Air Intake Filter

    5. Insert a new element. 6. Replace fi lter cover and secure by pushing the Element cover onto the housing until three audible Figure 6.3B Air Intake Filter (With Piped Inlet) snaps are heard. 7. Turn on the compressor. 4107 9006 25.11...

  • Page 34: Motor Lubrication

    Surface temperatures of motor enclosures may reach temperatures which can cause discomfort or injury. Protection should be used to protect against accidental contact with hot surfaces. Failure to observe this precaution could result in bodily injury. Figure 6.4 Sight Glass 4107 9006 25.11...

  • Page 35: Zero Loss Electronic Drain

    LED displays on the control panel. Valve Behind Electronic  Push the TEST button in order to verify Sight Glass Drain the operating status of the discharge and the correct operation of the valve. Figure 6.5 Electronic Drain Isolation Valves 4107 9006 25.11...
  • Page 36 Do not bend it and do not use it as a (1) Solenoid valve pilot lever. It contains electronic material. (1) Diaphragm Mechanical stresses, including moderate (1) Flow limiter ones, can give rise to irreparable (1) Flow limiter plastic ring malfunctions. 4107 9006 25.11...

  • Page 37: Backup Pressure Switch Set Point Adjustments

    ALWAYS check switch setting before making any adjustments. • DO NOT force slotted adjustment screw when it becomes diffi cult to turn. • ALWAYS isolate the pressure transducer before making any adjustments to the backup pressure switch. 4107 9006 25.11...

  • Page 38: General Inspections

    Items to inspect include all wiring, fl ex Figure 6.5 Backup Pressure Switch hoses, and other items. If a damaged item is viewed, call your local BeaconMedaes service technician for a thorough inspection and report of fi ndings. Adjusting Instructions 6.7.2 Every Six Months...

  • Page 39: Replacement Parts

    (803) 817-5750 A Parts List is available as a supplement to this Operation and Maintenance Manual. Please contact BeaconMedaes to have the Parts List sent to you or download an electronic version from the website at www.beaconmedaes.com. 4107 9006 25.11...

  • Page 40: Specifi Cations

    1-1/4” 1-1/2” Safety Valve Setting (psi) pump Max. Ambient Temperature 105°F 105°F 105°F 105°F Dimensions (inches) Length 66.00 66.00 72.00 72.00 Width 62.00 62.00 99.50 99.50 Height 81.90 81.90 85.10 85.10 Weight (lbs) 2101 2217 3052 3392 4107 9006 25.11...

  • Page 41: Quadruplex Base Mount Scroll Spc Laboratory Air System

    1-1/2” 1-1/2” 1-1/2” Safety Valve Setting (psi) pump Max. Ambient Temperature 105°F 105°F 105°F 105°F Dimensions (inches) Length 72.00 72.0 72.00 Width 138.00 138.00 138.00 138.00 Height 85.10 85.10 85.10 85.10 Weight (lbs) 4410 4838 4905 5445 4107 9006 25.11...

  • Page 42: Maintenance Record

    “Oil-Less” Scroll Laboratory Air 9.0 Maintenance Record Model Number Serial Number Installation Date Date of Service Hours Load Ambient Temp. Inlet Filter Belt Tension Misc. Serviced By Notes: 4107 9006 25.11...
  • Page 43 “Oil-Less” Scroll Laboratory Air 9.0 Maintenance Record Model Number Serial Number Installation Date Date of Service Hours Load Ambient Temp. Inlet Filter Belt Tension Misc. Serviced By Notes: 4107 9006 25.11...

  • Page 44: Appendix A: Desiccant Dryer

    One desiccant tower is always on-line in a drying cycle throughout normal dryer operation. The opposite, off -line tower is in a regeneration cycle for removal of the previously adsorbed moisture content or in a purge saving cycle at line pressure. 4107 9006 25.11...

  • Page 45: Operation

    10. Operate the dryer for fi ve to ten minutes with 3. Slowly OPEN the dryer inlet isolation valve. the source isolation valve closed. 4. Slowly OPEN the dryer outlet isolation valve. 5. Check operation of the dryer. 4107 9006 25.11...

  • Page 46: Trouble Shooting

    SHOCK HAZARD EXISTS. A qualifi ed maintenance shutdown instructions. electrical technician should conduct these checks. The dryer’s electrical power supply must be de-energized before any electrical maintenance or repair work is conducted. 4107 9006 25.11...
  • Page 47 Tighten or replace as necessary. Inspect the pre-fi lter automatic drain valve. Ensure that it is not clogged and is draining properly. Repair or replace as necessary, if a problem is noted. Purge muffl er restricted Replace muffl er. 4107 9006 25.11...
  • Page 48 Outlet check valve leaking Repair check valve NOTE: The presence of backpressure will result in insuffi cient regeneration followed by dew point degradation. An off -line chamber’s pressure MUST be less than 3 psig throughout all regeneration cycles. 4107 9006 25.11...

  • Page 49: Maintenance

    Tower o-ring Every 3 years Canister o-ring As needed Switching valve As needed Tower pressure gauge As needed Purge Poppit Valve Note: All service components are listed as parts within the service repair kits in Section 5.2 4107 9006 25.11...
  • Page 50 Appendix A: Desiccant Dryer Figure A.2 Desiccant Dryer Components Item Number Description Dryer Inlet Tower Pressure Gauge Dryer Pre-Filter Check Valve (2) Purge Muffl er Poppit Purge Valve 441® Switching Valve Dryer After-Filter Air System Outlet Canister O-Ring Tower O-Ring 4107 9006 25.11...

  • Page 51: Replace/Repair

    WARNING: Desiccant towers contain springs which release potential energy upon dismantle. 2. Remove hex nuts, washers and towers from manifold assembly. 3. Remove spring and perforated screen from top of canister. Figure A.3 Dryer Block Check Valves 4107 9006 25.11...

  • Page 52: Dryer Specifi Cations

    Capability @ 100 psig: Normal DP Operating -8°C (17.6°F) to -12°C (10°F) Range: Diff erential Pressure @ 2 to 8 psig 100 psig and 37.8°C (100°F): Desiccant: Activated Alumina Control: Fully automatic solid-state electric Power: 24VDC Power 4107 9006 25.11...

  • Page 53: Appendix B: Dew Point Transmitter

    If the dew point transmitter fl owmeter sample block is high enough to avoid long lead becomes clogged, dew point readings time lags in response to changes in moisture at the may be inaccurate, allowing moisture to sample source. accumulate undetected. 4107 9006 25.11...

  • Page 54: Alarms

    If this cannot be done, maintenance and testing of those parts discussed in this manual Replace Every 2 years See Section B.9 may be undertaken by a competent, trained Sensor individual having experience in the repair of devices of this nature. 4107 9006 25.11...

  • Page 55: Troubleshooting

    Verify that the online dryer (valve open) is in the “Automatic” position on the control panel and that the off -line dryer (valve closed) is in the “Off ” position on the control panel. Check fl ow Faulty sensor Replace sensor 4107 9006 25.11...

  • Page 56: Dew Point Sensor Calibration

    4107 6510 89 NOTE: The Dew Point Sensor is included in the 2-Year System Sensor Kits as shown in section 5.2.4. If ordering the 2-Year System Sensor Kits, there is no need to order the above Sensor as well. 4107 9006 25.11...

  • Page 57: Appendix C: Totalalert Embedded Control System

    RS485 & Power (6 Conductor Cable) PCB4 PCB4 PCB4 PCB4 PCB3 Dryer Dryer Pump Pump Master Controller Customer Ethernet Network Ethernet PCB3 & PCB4 Mounted on Back Panel Figure C.2 Duplex Medical Air Confi guration - Printed Circuit Boards 4107 9006 25.11...

  • Page 58: Board Confi Gurations

    5. Accept new fi rmware via the Ethernet jack when connected to a PC confi gured with genuine • PCB3 – (1) Master Controller BeaconMedaes software for reprogramming. • PCB4 – (4) One for each compressor (2) and one for each dryer (2) In a standard laboratory air quadruplex system, the PCB confi...
  • Page 59 ** Dryer Information (Medical Air with bottom version button will appear to allow Dryers Only) the user to check display board (PCB1) version information. 4107 9006 25.11...
  • Page 60 24 hours (240 data points – 6 min resolution) and 6 days (240 data points – • If the unit is unavailable and not running, that 0.6 hour resolution). color bar shows dark grey and the adjoining symbol shows “X”. 4107 9006 25.11...
  • Page 61 (optional). When the button is to switch (based on dewpoint in automatic pressed, the trend information is available for mode), the blue arrows are not visible. these temperatures. 4107 9006 25.11...
  • Page 62 These alarms are latched and are not cleared until a user presses the reset button on the alarms screen. This reset button will reset all Maintenance History Screen alarms for that given system. Figure C.10 Maintenance Screens 4107 9006 25.11...
  • Page 63 The system reset button will reset all stored for the system. system shutdown events for that given system (not Unit “X”). • Green shutdown condition indicates a normal status for that condition. • Red alarm shutdown indicates an abnormal status for that condition. 4107 9006 25.11...

  • Page 64: Pcb2 (3.5" Display Controller)

    3. Accept new fi rmware via the Ethernet jack when connected to a PC confi gured with genuine The settings screen (Figure C.14) allows the BeaconMedaes software for reprogramming. selection of various sub screens that pertain to system confi guration data. All value/adjustment C.3.2 3.5”...
  • Page 65 In the event of an emergency and the control system button appears to allow the user to check is not operating eff ectively, the manual override display board (PCB2) version information. switch can be moved from the Automatic position 4107 9006 25.11...
  • Page 66 The status screen (Figure C.20) shows the running hour meter values. C.3.7 3.5” Service Screen Manual Override Switch O - On Manual X - Off A - Automatic PCB4 with Manual Override switch On Figure C.19 Manual Override Figure C.21 3.5” Service Screen C-10 4107 9006 25.11...
  • Page 67 • Green shutdown condition indicates a normal status for that condition. • Red alarm shutdown indicates an abnormal status for that condition. Figure C.22 3.5” Alarms Screen 4107 9006 25.11 C-11...

  • Page 68: Password Access

    See section counter by pressing the item on the service C.5 for additional information. screen, selecting update, and entering the password when prompted. C-12 4107 9006 25.11...

  • Page 69: Testing Alarms

    Maintenance from the list of headings. activity is related to the particular unit. Press the Unit number to move to the service screen for that unit to fi nd the overdue activity. 4107 9006 25.11 C-13...

  • Page 70: Remote Monitoring

    PC with an Ethernet connection Master board. • PC with a web browser, such as Microsoft Internet Explorer 2. Verify the green LINK LED on the printed circuit board illuminates. • Cat5 or better Ethernet cable C-14 4107 9006 25.11...
  • Page 71 Note: To learn the IP address of the air system, go to the 5.7” main touchscreen, press the Settings icon, press Network from the listing and the IP address will appear in the second line underneath the method. See Figure C.28. 4107 9006 25.11 C-15...
  • Page 72 The web browser will request a username and password (Figure C.30). 3. The factory defaults are: Username: new Password: new Figure C.30 Login for Setup Pages 4. The left sidebar will now contain the setup links (Figure C.31). C-16 4107 9006 25.11...
  • Page 73 4. Enter the facility description. website. By selecting an auto-refresh interval, the web page will be refreshed automatically, keeping 5. Enter the contact information. all information current during a viewing period. 6. Click the Submit button. 4107 9006 25.11 C-17...
  • Page 74 The durations available to select are 6 hours, 24 2. Select Enable to enable the e-mail notifi cation hours, 2.5 days, and 10 days. tool. 3. Enter up to fi ve email addresses. C-18 4107 9006 25.11...
  • Page 75 Status: The Status page (Figure C.37)displays current information for both the overall system (run hours, pressure, ambient temperature, alarms, shutdown, and service) and the units (run hours, operation mode, run mode, sequence, alarms, shutdown, and service). 4107 9006 25.11 C-19...
  • Page 76 Maintenance page. Included on the page are the service item, the time interval for each time, and the part number and description of the service kit required to perform the maintenance function, specifi c to the medical air system installed. C-20 4107 9006 25.11...
  • Page 77 The log displays the date/time of the event and a description of the event (alarm/shutdown, reset, test). System Log page includes the option to create a downloadable text fi le of the log. Figure C.45 System Trend 4107 9006 25.11 C-21...
  • Page 78 fi les that list all of the events in descending order from most recent to oldest. See Figure C.47. The System Trend creates a CSV fi le (spreadsheet) that contains all of the trend information, decsending from most recent to oldest. See Figure C.48. C-22 4107 9006 25.11...
  • Page 79 “Oil-Less” Scroll Laboratory Air Appendix C: TotalAlert Embedded Control System Figure C.47 System Log Download Figure C.48 System Trend Download 4107 9006 25.11 C-23...

  • Page 80: Bacnet Activation

    Activation code must be entered at this time. Enter the code and press Submit. When the page is reloaded, the code will remain in place and the box to the right will show “Unlocked”. Figure C.50 BACnet Unlock C-24 4107 9006 25.11...
  • Page 81 1059 Paragon Way Rock Hill, SC 29730 (888) 4-MEDGAS (888) 463-3427 Fax (803) 817-5750 www.beaconmedaes.com...

Table of Contents