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CompAir BroomWade Cyclon 330 User Manual

Cyclon series air compressors
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CYCLON 330-345 AIR COMPRESSORS
Cyclon 330
8. Fault Finding
Appendix 1 - Electrical Connections
Appendix 2 - The Pressure Systems &
Transportable Gas Container
Regulations 1989
USER MANUAL
Serial Numbers from:
Cyclon 337
F167/0151
CONTENTS
Page
Illustrations
5
Control Panel
11
Air/Oil System
19
Regulation System On/Off Control
21
Regulation System Modulating Control
25
Negative Regulator Settings
35
Control Panel
47
Remote Start/Stop
57
Remote Load/Unload
61
Group Fault Relay - Example
63
Electrical Connection Diagrams
Air Compressor Circuit Diagrams
Cyclon Series User Manual
Cyclon Series User Manual
C20160-1576, Issue 3, March 1997
Cyclon 345
F168/0101
Page
13
15
16
17
33
38
44
44
45
51
55
62
64
page 1

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Summary of Contents for CompAir BroomWade Cyclon 330

  • Page 1: Table Of Contents

    Cyclon Series User Manual Cyclon Series User Manual C20160-1576, Issue 3, March 1997 USER MANUAL CYCLON 330-345 AIR COMPRESSORS Serial Numbers from: Cyclon 330 F166/0101 Cyclon 337 F167/0151 Cyclon 345 F168/0101 CONTENTS Page Illustrations Page 1. Safety Procedures Control Panel 2.
  • Page 2 Motor Serial Number: Year: Reclaimer Certificate Number: Maximum Pressure: Delivery Date: Motor rpm: Compressor Lubricant: Lubricant Capacity: V. Ph. Hz. Motor Bearing Grease: /min: (if applicable) LOCAL COMPAIR BROOMWADE DISTRIBUTOR Name: Address: Telephone: Fax: Contact Names: Parts: Service: page 2...

  • Page 3: Cyclon 330 F166/0101 Cyclon

    Cyclon 330 Cyclon 337 Cyclon 345 ASSOCIATED PUBLICATIONS Model Title Part No. Cyclon 105-345 Repair Manual AC20160-1606 (Issue 1) Cyclon 330 to 345 Parts List (Multi-Lingual) C20160-1575 (Issue 2) These publications may be obtained through CompAir BroomWade distributors. page 3...
  • Page 4 CompAir BroomWade Limited WARRANTY WARNING The conditions of the CompAir BroomWade Warranty are set out in the company’s standard Conditions of Sale available from the Distributor The use of replacement parts or supplying the machine. lubricating oils not supplied or approved...

  • Page 5: Safety Procedures

    Cyclon Series User Manual SAFETY PROCEDURES Page General Warnings, Cautions and Notes General Safety Precautions Installation Precautions Operational Precautions Maintenance and Repair Precautions Precautions in the Event of Fire page 5...

  • Page 6: General

    WARNING: CONSULT MANUAL unsafe and that there is no risk to persons or property. The standard build of all CompAir BroomWade products are not intended for use in either explosive or potentially explosive atmospheres as WARNING: RISK OF HIGH defined in Directive 94/9/EC.

  • Page 7: General Safety Precautions

    Cyclon Series User Manual – Safety Procedures GENERAL SAFETY PRECAUTIONS Ensure that the air delivery pipe from the compressor to the user’s pipework or receiver is If using compressed air for cleaning purposes, free to expand and that no flammable material is ensure safety regulations are complied with and within the vicinity.

  • Page 8: Maintenance And Repair Precautions

    CompAir BroomWade Limited Do not open the starter compartment or touch The ‘Noise at Work Regulations 1989’ suggest that electrical components while voltage is applied ear protectors should be worn where noise levels unless it is necessary for measurements, tests or are 85 dB(A) or higher.

  • Page 9: Precautions In The Event Of Fire

    Cyclon Series User Manual – Safety Procedures Use only lubricating oils and greases approved by After completion of repair or maintenance work CompAir BroomWade. Make sure that the selected ensure that no tools, loose items or rags are left on lubricants comply with all relevant safety or inside any part of the machine.
  • Page 10 CompAir BroomWade Limited page 10...

  • Page 11: General Description

    Cyclon Series User Manual GENERAL DESCRIPTION Page Compressor Air-End Electronic Controller Protection and Safety Equipment Relief Valve Blowdown System Minimum Pressure Non-return Valve Air/Oil System Description Operation Regulation System Description On/Off Control Modulating Control (Optional) page 11...

  • Page 12: Compressor

    CompAir BroomWade Limited GENERAL DESCRIPTION COMPRESSOR ELECTRONIC CONTROLLER The unit is a fully enclosed, air cooled, single- The electronic control system is microprocessor stage, rotary screw compressor. The compressor based with an LED display panel, incorporating air-end is belt driven by an electric squirrel-cage advanced control and monitoring features.
  • Page 13 Cyclon Series User Manual – General Description P1 bar T1 C P1 bar T1 C View Pressure (Delivery) Start Temperature Stop Hours Run Plus Hours Onload Minus Air Filter Alarm Reset Motor Fault Display Auto/Remote Start Emergency Stop Button Running Power On CONTROL PANEL page 13...

  • Page 14: Air/Oil System

    CompAir BroomWade Limited AIR/OIL SYSTEM Oil from the bottom of the separator flows under pressure to the oil cooler (10) and during normal 5.1 Description running the oil passes through the cooler to maintain the correct temperature. A thermostatic The air/oil system comprises an air intake filter,...
  • Page 15 Cyclon Series User Manual – General Description 1. Suction Regulator 8. Oil Filter 2. Intake Air Filter 9. Aftercooler 3. Minimum Pressure/NR Valve 10. Oil Cooler 4. Primary Oil Separator 11. Fan 5. Oil Separation Element 12. Delivery Air Outlet 6.

  • Page 16: Regulation System

    CompAir BroomWade Limited REGULATION SYSTEM suction regulator inlet valve fully open, or off-load with the inlet valve fully closed. 6.1 Description When the controller switches the compressor to run The compressor is regulated through a combination off-load, a run-on time sequence is activated. This...

  • Page 17: Modulating Control (Optional)

    Cyclon Series User Manual – General Description Rising pressure in the separator vessel will cause 6.3 Modulating Control (Optional) the output signal from the negative regulator to fall, progressively closing the inlet valve to match air In the ‘Modulating’ mode the opening and closing of flow to demand.
  • Page 18 CompAir BroomWade Limited page 18...

  • Page 19: Leading Particulars

    Cyclon Series User Manual LEADING PARTICULARS page 19...
  • Page 20 CompAir BroomWade Limited LEADING PARTICULARS Model Cyclon 330 Cyclon 337 Cyclon 345 Air-end Single stage oil injected screw Cyclon Total oil capacity: litres 17·0 17·5 18·5 Delivery air connection: without optional flexible pipe Rp 1 Rp 1 Rp 1 with optional flexible pipe...

  • Page 21: Installation

    Cyclon Series User Manual INSTALLATION Page Guidelines Installation Procedure page 21...
  • Page 22 3 m if necessary without the need for an additional fan. Details are available on request from Because in operation the compressor will release the local CompAir BroomWade distributor. heat into the surroundings the compressor room should be of adequate size and have good To allow adequate air circulation, provide a ventilation.
  • Page 23 Reposition the splitters to discharge equipped with optional equipment refer to the local vertically or horizontally as required. Secure CompAir BroomWade distributor. the fasteners. Using a fork lift, lift the compressor unit and Refit the starter compartment top cover and move it into position.
  • Page 24 CompAir BroomWade Limited page 24...

  • Page 25: Commissioning

    Cyclon Series User Manual COMMISSIONING Page Commissioning Procedure Preliminary Checks Pressure Calibration Checking/Altering Program Mode Values Final Checks Negative Regulator (Modulating Control Only) Commissioning Checklist page 25...

  • Page 26: Commissioning Procedure

    Inspect the motor and wiring connections to make sure they are Note: We recommend that commissioning is correct and secure. carried out by a CompAir BroomWade distributor. Check that all connections on the rear of the controller are correct and secure. Preliminary Checks Check that all protective blanks and tapes Check that the isolator switch is locked ‘OFF’...

  • Page 27: Pressure Calibration

    Cyclon Series User Manual – Commissioning Cyclon Series User Manual – Commissioning Pressure Calibration Note: The values shown throughout these procedures are examples only. Ensure set values are compatible with the compressor model. Action Reason Display Switch power ‘ON’ at the isolator 0.0 Bar and allow the controller to initialise.

  • Page 28: Checking/Altering Program Mode Values

    CompAir BroomWade Limited Checking/Altering Program Mode Values Note: The values shown throughout these procedures are examples only. Ensure set values relate to compressor model. Action Reason Display Switch power ‘ON’ at the isolator 0.0 Bar and allow the controller to initialise.
  • Page 29 Cyclon Series User Manual – Commissioning Action Reason Display Press PLUS or MINUS To adjust the displayed value 1500 or go to step 16 if no adjustment required. (pulsing display) Press STOP To program the new value 1500 into the controller memory (steady display) Press VIEW To step to the next option...

  • Page 30: Final Checks

    CompAir BroomWade Limited Action Reason Display Press VIEW To step to the next option Indicator L7 will light and the display 0 secs will show the Auto restart delay time. If the auto restart facility is required press PLUS or MINUS .
  • Page 31 Cyclon Series User Manual – Commissioning Action Reason Display Press STOP as soon as the 0.0 Bar motor begins to rotate. CAUTION: Do not allow prolonged running in the reverse direction as damage will be caused. If the direction of rotation ( marked by an arrow on the inside of the service panel) is incorrect, isolate the power supply and change over motor connections...
  • Page 32 CompAir BroomWade Limited Action Reason Display Check that the compressor automatically re-starts when pressure falls below the lower pressure set point P2. Run the compressor for 30 minutes. Check for air/oil leaks. (It will be necessary to remove the enclosure panels for short periods).

  • Page 33: Negative Regulator (Modulating Control Only)

    Cyclon Series User Manual – Commissioning NEGATIVE REGULATOR (Modulating Release the locknut on the negative regulator Control Only) spindle and turn the adjusting knob counter- clockwise until the inlet valve on the suction During commissioning or after a period it will be regulator starts to modulate.

  • Page 34: Commissioning Checklist

    CompAir BroomWade Limited COMMISSIONING CHECK LIST 13. Pressure set-points set..... Protective blanks and tapes 14. Controller model option set..... removed..... 15. Regulation air system isolating Pipework connected and checked. valve open..... (Isolating valve fitted)..... 16. Oil drain valve closed.
  • Page 35 Cyclon Series User Manual Cyclon Series User Manual 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 Program Mode Program Mode Routine Program Mode Setting Definitions Program Mode Settings...

  • Page 36: Operation

    CompAir BroomWade Limited OPERATION WARNING Refer to the safety procedures before Lethal voltages are used in this equipment. operating the compressor unit. Use extreme caution when carrying out electrical checks. Isolate the power supply before starting any maintenance work. ROUTINE OPERATION During the initial starting period, the drive motor starts in Star connection.

  • Page 37: Stopping

    Cyclon Series User Manual – Operation Stopping Indicator Display To stop the compressor press STOP (B3). This initiates a controlled shut down Delivery Pressure in Bar sequence. The compressor will unload, the drive motor will stop and the Start indicator Oil Temperature in C (L8) will flash slowly for the blowdown period.

  • Page 38: Alarms And Shutdown Trips

    CompAir BroomWade Limited Alarms and Shutdown Trips The oil temperature alarm and oil temperature trip conditions are shown by If an alarm condition occurs and service indicator (L2) flashing. Indicator (L2) will flash attention is required the appropriate alarm slowly for an alarm condition and the indicator will flash.

  • Page 39: Power Supply Failure Detection

    Cyclon Series User Manual – Operation Power Supply Failure Detection The controller is equipped with a power supply failure detection facility. If a power supply failure is detected, the compressor will stop, the controller will reset, and the display will show three horizontal lines in the left hand side of the display after the controller has re-initialised.

  • Page 40: Program Mode

    CompAir BroomWade Limited To alter a displayed setting, press PLUS PROGRAM MODE (B4) or MINUS (B5) to adjust the displayed Program Mode Routine value. The display will flash when an adjustment is made. When the display shows the required value, press STOP (B3) ‘Program mode’...

  • Page 41: Program Mode Setting Definitions

    Cyclon Series User Manual – Operation Program Mode Setting Definitions Indicator Setting Description Pressure set point P1 Pressure at which the compressor will unload. Oil temperature trip Temperature at which the compressor will shut down and indicate a high oil temperature trip. (The oil temperature alarm is set automatically at 10 C below the trip) Service interval time Maximum service interval time.

  • Page 42: Fixed Parameters

    CompAir BroomWade Limited Fixed Parameters After five seconds indicators L1 to L8 will flash four times to indicate that the controller The motor star/delta time and blowdown time are is now in pressure calibration mode. Release set automatically, depending on the compressor PLUS (B4), MINUS (B5) and STOP (B3) model programmed in the controller.

  • Page 43: Control Function Options

    Cyclon Series User Manual – Operation CONTROL FUNCTION OPTIONS Remote Start/Stop Facility Automatic Re-start 4.2.1 Remote Start Automatic re-start will allow the compressor to The remote start facility will enable the compressor start automatically after a break or failure in the to be started from a remote location.
  • Page 44 CompAir BroomWade Limited Controller Start Stop X01-4 X01-7 REMOTE START/STOP Controller Remote pressure X01-6 X01-5 switch or cascade panel REMOTE LOAD/UNLOAD When this option is selected the compressor The compressor will unload when the will load when terminal X01, pin 6 is...

  • Page 45: Remote Group Fault Output

    Cyclon Series User Manual – Operation Remote Group Fault Output 4.4.3 Group Fault Relay - Example 4.4.1 Group Fault Relay Remote wires (eg from a PLC or building management system) can be connected directly to The control card is fitted with a group fault relay, the control card group fault relay contacts available the relay contacts being available for switching on pins 9 and 10 of terminal X08.
  • Page 46 CompAir BroomWade Limited page 46...

  • Page 47: Maintenance

    Cyclon Series User Manual MAINTENANCE Page Routine Maintenance Cleanliness Recording Pressures and Temperatures Maintenance Record Electrical Connections Leaks Lubricating Oil Maintenance Schedule Separator Element Part Number Table Service Kit Part Number Table Drive Belt Part Number Table (50Hz) Drive Belt Part Number Table (60Hz) Maintenance Procedures Enclosure Filter Air Intake Filter...

  • Page 48: Cleanliness

    All CompAir BroomWade compressors are fitted Avoid damage to electrical wiring when working on with high performance filtration equipment. If the...

  • Page 49: Maintenance Schedule

    Cyclon Series User Manual – Maintenance MAINTENANCE SCHEDULE Regular maintenance should be carried out by your local CompAir BroomWade distributor as detailed in the Maintenance Schedule. The Schedule should be used as a general guide only. Item Action Weekly Oil System Check oil level.

  • Page 50: Cyclon

    CompAir BroomWade Limited 2.1 Separator Filter Part Number Table Model Qty. Max Rated Separator Cyclon Pressure Filter USE ONLY (Bar) 330/337 7·5 to 13 98262-223 7·5 to 13 98262-223 2.2 Service Kit Part Number Table GENUINE PARTS AUTHORISED SERVICE Model (Cyclon)

  • Page 51: Servicing Points

    Cyclon Series User Manual – Maintenance 1. Intake Air Filter 9. Oil Drain Valve 2. Suction Regulator 10. Control Air Isolating Valve 3. Oil Cooler 11. Oil Filler Cap 4. Drive Belt 12. Oil Level Sightglass 5. Motor Bearings 13. Air Cooler 6.

  • Page 52: Maintenance Procedures

    CompAir BroomWade Limited MAINTENANCE PROCEDURES WARNING Refer to the safety procedures before Close the shut-off valve to the user’s carrying out any maintenance or servicing pipework. work on the compressor unit. Switch the power supply ‘OFF’ at the Lethal voltages are used in this equipment.

  • Page 53: Oil System

    CompAir FG Lubricant meets the requirements of FDA regulation 21 CFR 178.3570 and is USDA H-1 approved. The local CompAir BroomWade distributor will assist in the selection of an appropriate lubricant and in many cases will also be able to arrange for...
  • Page 54 CompAir BroomWade Limited 3.4.3 To Change the Oil Filter: 3.4.5 To Change the Oil: The compressor must be stopped. To drain the oil, the system must (a) be pressurised or (b) an alternative source of Open the door to the service area.

  • Page 55: Drive Belt Adjustment

    Cyclon Series User Manual – Maintenance 11. Apply a film of clean oil to the seal of a new oil Remove the air supply and fitting from the filter element. Screw the element into the filler tube. housing until it contacts the gasket and tighten a further turn.

  • Page 56: Electrical System

    3.9 Minimum Pressure Valve 3.6 Electrical System The servicing of items 3.8 and 3.9 should be carried out by a CompAir BroomWade Distributor. 3.6.1 To Check the Electrical Connections: Carefully inspect all the electrical wiring and check 3.10 Flexible Hoses the security of all connections and terminals.
  • Page 57 Cyclon Series User Manual FAULT FINDING Page Fault Indications Trip Fault Indications Alarm Fault Indications Shutdown Faults Alarm Faults page 57...

  • Page 58: Fault Indications

    CompAir BroomWade Limited 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 Refer to the safety procedures before Lethal voltages are used in this equipment.

  • Page 59: Alarm Fault Indications

    Cyclon Series User Manual – Fault Finding 1.2 Alarm Fault Indications Display Meaning L2 Flashing Slowly High Temperature L3 Flashing Slowly Service Due L5 Flashing Slowly Change air filter SHUTDOWN FAULTS Fault Possible Cause Action Required Emergency Stop (1) Emergency Stop Switch (1) Establish reason and operated.

  • Page 60: Alarm Faults

    CompAir BroomWade Limited Fault Possible Cause Action Required Temperature sensor (1) Wire Connections. (1) Check all temperature sensor failure circuit wire connections. (2) Sensor failure. (2) Renew sensor. High Oil Carry Over (1) Separator element. (1) Fit new element. (2) Oil Drain Valve (2) Check valve closed.
  • Page 61 Cyclon Series User Manual APPENDIX 1 Electrical Connections page 61...
  • Page 62 CompAir BroomWade Limited page 62...
  • Page 63 Cyclon Series User Manual APPENDIX 2 The Pressure Systems and Transportable Gas Container Regulations 1989 page 63...
  • Page 64 CompAir BroomWade Limited APPENDIX 2 Note: The intervals between examination and THE PRESSURE SYSTEMS AND calibration of components, eg pressure vessels, TRANSPORTABLE GAS CONTAINER pressure relief valves etc, will be defined by the REGULATIONS 1989 ‘competent person’ preparing the written scheme.
  • Page 65 Cyclon Series User Manual 1. Air Intake Filter 9. Minimum Pressure Valve 2. Suction Regulator 10. Separator Filter 3. Venting Valve 11. Pressure Relief Valve 4. Negative Regulator 12. Separator Vessel 5. Unloader Solenoid Valve 13. Air-end 6. Shuttle Valve 14.
  • Page 66 CompAir BroomWade Limited page 66...

This manual is also suitable for:

Cyclon 337Cyclon 345

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