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page 1
Cyclon Series User Manual
USER MANUAL
CYCLON 330-345 AIR COMPRESSORS
Serial Numbers from:
Cyclon 330 F166/0101 Cyclon 337 F167/0151 Cyclon 345
F168/0101
CONTENTS
Page
1. Safety Procedures 52. General Description 113. Leading
Particulars 194. Installation 21
5. Commissioning 256. Operation 357. Maintenance 47
8. Fault Finding 57Appendix 1 Electrical Connections 61Appendix
2 The Pressure Systems &
Transportable Gas ContainerRegulations 1989 63
Illustrations Page
Control Panel 13Air/Oil System 15Regulation System On/Off
Control 16Regulation System Modulating Control 17Negative Regulator
Settings 33Control Panel 38Remote Start/Stop 44Remote Load/Unload
44Group Fault Relay Example 45Servicing Points 51Drive Belt
Adjustment 55Electrical Connection Diagrams 62Air Compressor
Circuit Diagrams 64
C20160-1576, Issue 3, March 1997
Cyclon Series User Manual
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CompAir BroomWade Limited
page 2
Air-end Serial Number:
Motor Serial Number:
Reclaimer Certificate Number:
Delivery Date:
OWNERSHIP DATA
TECHNICAL DATA
MODEL:
Serial Number:
Year:
Maximum Pressure:
kW:
Motor rpm:
V. Ph. Hz.
M3/min:
LOCAL COMPAIR BROOMWADE DISTRIBUTOR
Name:
Address:
Telephone: Fax:
Contact Names: Parts:
Service:
Compressor Lubricant:
Lubricant Capacity:
Motor Bearing Grease:(if applicable)
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Cyclon Series User Manual
MODEL DESIGNATION
The Model Designation code identifies specific models as
follows:
DESIGNATION CYCLON 3 3 0 0 7
A B B C C
A = AIR-END SIZE CYCLON 3B = MOTOR RATING (kW) 30KWC = NOMINAL
DELIVERY PRESSURE 75 BAR(110PSI)
This publication relates to all standard operating pressure
versions of the following models:
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.
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CompAir BroomWade Limited
page 4
WARRANTY
The conditions of the CompAir BroomWadeWarranty are set out in
the companys standardConditions of Sale available from the
Distributorsupplying the machine.
MAINTENANCE
To ensure the continued trouble-free operation ofthe compressor
unit it is important that periodicmaintenance and servicing are
carried out inaccordance with the information given in
theMaintenance section of this manual. If anyreplacement or repair
is needed use only CompAir-BroomWade Genuine Parts.
!! WARNING
GENUINE PARTSAUTHORISED SERVICE AGENTS
USE ONLY
l The use of replacement parts orlubricating oils not supplied
or approvedby CompAir BroomWade may lead tofailures in service
which would not becovered by warranty.
l Any unauthorised modifications orfailure to maintain this
equipment inaccordance with the maintenanceinstructions may make it
unsafe. Theuse of replacement parts not supplied orapproved by
CompAir BroomWade maycreate hazardous conditions over whichCompAir
BroomWade has no control.
l Such hazardous conditions may lead toaccidents that can be
life threatening,cause substantial bodily injury or resultin damage
to the equipment. CompAirBroomWade can bear no responsibilityfor
equipment in which unapprovedreplacement parts are included.
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Cyclon Series User Manual
SAFETY PROCEDURES
Page
General 6
Warnings, Cautions and Notes 6
General Safety Precautions 7
Installation Precautions 7
Operational Precautions 7
Maintenance and Repair Precautions 8
Precautions in the Event of Fire 9
1
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CompAir BroomWade Limited
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2. WARNINGS, CAUTIONS AND NOTES
2.1 Warnings
Warnings call attention to operations or proceduresinvolving
specific hazards which could cause injuryor death and are
identified by the following symbolson the unit and in the text of
the manual.
WARNING: RISK OF DANGER
WARNING: RISK OF ELECTRICSHOCK
WARNING: RISK OF HOTSURFACES
WARNING: CONSULT MANUAL
WARNING: RISK OF HIGHPRESSURE
WARNING: DRIVE BELT
2.2 Cautions
Incorrect operational procedures causing possibledamage to the
compressor unit are identified by aCAUTION in the text of this
manual.
2.3 Notes
Methods to make the job easier and points whichrequire
particular attention are identified by a Notein the text of the
manual.
1. GENERAL
Most accidents which occur during the operationand maintenance
of machinery are the result offailure to observe basic safety rules
or precautions.An accident can often be avoided by recognising
asituation that is potentially hazardous.
When handling, operating or carrying outmaintenance on the unit,
personnel must use safeengineering practices and observe all
relevantlocal health and safety requirements andregulations. The
attention of users in the UK isdrawn to the Health and Safety at
Work Act, 1974,the Regulations of the Institution of
ElectricalEngineers and the Pressure Systems andTransportable Gas
Container Regulations 1989.
CompAir BroomWade cannot anticipate everypossible circumstance
which might represent apotential hazard. The WARNINGS in this
manualare therefore not all-inclusive. If the user employsan
operating procedure, an item of equipment or amethod of working
which is not specificallyrecommended by CompAir BroomWade he
mustensure that the unit will not be damaged or madeunsafe and that
there is no risk to persons orproperty.
The standard build of all CompAir BroomWadeproducts are not
intended for use in eitherexplosive or potentially explosive
atmospheres asdefined in Directive 94/9/EC.
An explosive atmosphere is a mixture with air,under atmospheric
conditions, of flammablegases, vapours, hazes or dust in which,
afterignition has occured, combustion propagates tothe entire
unburned mixture and may cause ahazard.
A potentially explosive atmosphere is anatmosphere which could
become explosive due tolocal conditions.
Failure to observe the precautions given underSafety Procedures
may be considered dangerouspractice or misuse of the compressor
unit.
SAFETY PROCEDURES
!
!
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page 7
Cyclon Series User Manual Safety Procedures
3. GENERAL SAFETY PRECAUTIONS
If using compressed air for cleaning purposes,ensure safety
regulations are complied with andappropriate clothing and eye
protection is worn.
Never direct compressed air onto your skin or atother
people.
Never use compressed air to clean loose dirt fromclothing.
Before releasing compressed air through a hosemake sure that the
free end is held securely sothat it cannot whip and cause
injury.
Avoid injury by using a hoist to lift heavy loads.Check that all
chains, hooks, shackles and slingsare in good condition and are of
the correctcapacity. They must be tested and approvedaccording to
local safety regulations.
Cables, chains or ropes must never be applieddirectly to lifting
eyes. Always use an appropriateshackle or hook, properly
positioned. Arrangelifting cables so that there are no sharp
bends.
Use a spreader bar to avoid side loads on hooks,eyes and
shackles.
When a load is on a hoist stay clear of the dangerarea beneath
and around it. Keep liftingacceleration and speed within safe
limits andnever leave a load hanging on a hoist for longerthan is
necessary.
4. INSTALLATION PRECAUTIONS
Installation work must only be carried out bycompetent personnel
under a qualified supervisor.
A fused isolating switch must be fitted between themain power
supply and the compressor.
Ensure that air drawn into the air intake will not
becontaminated with flammable fumes or vapours,since this could
cause an internal fire or explosion.
Precautions must be taken to ensure that no injuryis caused to
passers-by through loose clothingbeing sucked into the air
intake.
Ensure that the air delivery pipe from thecompressor to the
users pipework or receiver isfree to expand and that no flammable
material iswithin the vicinity.
A shut-off valve must be fitted in the delivery airline to
enable the compressor unit to be isolated.This is particularly
important if more than one unitis to be coupled in parallel or
connected to anexisting air supply system.
The minimum pressure/non-return valve is notintended as an
isolating valve and should not berelied upon for this purpose. In
addition, it may benecessary to install shut-off valves elsewhere
inthe system to allow a dryer or other equipment tobe
by-passed.
A pressure relief valve must be installed betweenany compressor
unit and the shut-off valve/s. Apressure relief valve is fitted on
the reclaimervessel as standard equipment.
A pressure relieving device must be fitted to everypressure
vessel, or equipment containing air atabove atmospheric pressure,
when installeddownstream of the unit.
5. OPERATIONAL PRECAUTIONS
The compressor unit must only be operated bycompetent personnel
under a qualified supervisor.
Do not run the compressor with doors open orcovers removed.
Never remove or tamper with the safety devices,guards or
insulation materials fitted to the unit.
The compressor must only be operated at thesupply voltage and/or
frequency for which it isdesigned.
When mains power is switched on, lethal voltagesare present in
the electrical circuits and extremecaution must be exercised
whenever it isnecessary to carry out any work on the
electricalsystem.
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CompAir BroomWade Limited
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Do not open the starter compartment or touchelectrical
components while voltage is appliedunless it is necessary for
measurements, tests oradjustments. Such work should be carried out
onlyby a qualified electrician equipped with the propertools and
wearing appropriate body protectionagainst electrical hazards.
On a unit equipped with an Automatic Start/Stopsystem, attach a
sign stating THIS UNIT MAYSTART WITHOUT WARNING next to the
displaypanel.
On a unit equipped with an Automatic Restartdevice, attach a
warning notice stating THIS UNITHAS BEEN MODIFIED AND WILL
STARTAUTOMATICALLY ON APPLICATION OFPOWER next to the display panel
and on theinside of the unit next to the starter contactors.
If the unit is equipped with a Remote Controldevice, attach
warning notices stating THIS UNITCAN BE STARTED REMOTELY in
prominentlocations, one on the outside of the unit, the otherinside
the control compartment.
As a further safeguard, take adequate precautionsto make sure
there is no one checking or workingon the unit before attempting to
switch on remotelycontrolled equipment. Attach a CHECK THATALL
PERSONNEL ARE CLEAR OF THE UNITBEFORE STARTING or similar warning
notice tothe remote start equipment.
During normal operation no internal part of thecompressor unit
should reach a temperature above120C and protection devices are
fitted to preventexcessive temperatures occurring. If there is
anyindication that the compressor is overheating itmust be shut
down and the cause investigated.Beware of burns from hot metal
parts, hot oil andwater when working on a unit which has
recentlybeen shut down.
The compressor must not be operated atpressures above the
nominal pressure given onthe data plate.
The compressor must not be operated in ambienttemperatures
outside of those given underLeading Particulars.
The Noise at Work Regulations 1989 suggest thatear protectors
should be worn where noise levelsare 85 dB(A) or higher. With all
covers in place,the noise levels of the compressors described inthe
manual are substantially lower than this figureunless installed in
an already noisy environment.
Be aware that high noise levels can interfere
withcommunication.
6. MAINTENANCE AND REPAIRPRECAUTIONS
Maintenance, repairs or modifications must only becarried out by
competent personnel under aqualified supervisor.
If replacement parts are needed use only CompAirBroomWade
Genuine Parts.
Before removing any panels from the enclosure, iffitted, or
dismantling any part of the unit, carry outthe following
preparatory operations:-
1. Isolate the compressor unit from the mainelectrical power
supply. Lock the isolator inthe OFF position and remove the
fuses.
2. Attach a label to the isolator switch anddisplay panel
carrying the warning WORK INPROGRESS DO NOT APPLY VOLTAGEDo not
switch on electrical power or attemptto start the unit if a warning
label is attached.
3. Close the isolating valve between thecompressor unit and the
users pipework.Close the isolating valve in the cooling waterinlet
pipe. Attach a label to each valvecarrying the warning WORK IN
PROGRESS DO NOT OPEN
4. Ensure that the blowdown system hasoperated to release all
pressure from the oilseparator vessel.
5. Check that the pressure gauge registers zero.
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page 9
Cyclon Series User Manual Safety Procedures
Use only lubricating oils and greases approved byCompAir
BroomWade. Make sure that the selectedlubricants comply with all
relevant safetyregulations, especially with regard to the risk
ofexplosion or fire and the possibility ofdecomposition or the
generation of hazardousgases.
Always clean up oil spills from the surroundingfloor and outside
of the compressor unit beforeand after maintenance work.
Make sure that all instructions concerningoperation and
maintenance are strictly followedand that the complete unit, with
all accessoriesand safety devices, is kept in good running
order.
The accuracy of pressure and temperature gaugesmust be regularly
checked. They must be renewedwhen acceptable tolerances are
exceeded.
Protection devices must be tested as described inthe Maintenance
section of this manual.
Keep the compressor unit clean at all times.Protect components
and exposed openings bycovering with clean cloth or tape
duringmaintenance and repair work.
Protect the motor, air intake, electrical andregulation
components against the entry ofmoisture, e.g. when steam
cleaning.
Precautions must be taken when carrying out anyrepair operation
which generates heat, flames orsparks. The adjacent components must
always bescreened with non-flammable material and if theoperation
is to be carried out near any part of theoil system, or close to a
component which maycontain oil, the system must first be
thoroughlypurged, preferably by steam cleaning.
Never use a light source with an open flame toinspect any part
of the unit.
In no circumstances must any welding work orother modification
be carried out on the oilseparator or any other pressure
vessel.
Before dismantling of any part of the compressorunit ensure that
all heavy movable parts aresecured.
After completion of repair or maintenance workensure that no
tools, loose items or rags are left onor inside any part of the
machine.
Check the direction of rotation of the motor whenstarting up the
compressor initially and after anywork on the electrical
connections or switchgear.
Do not use any flammable liquid to clean valves,filter elements,
cooler air passages, air pipes orany component carrying a flow of
air during normaloperation. If chlorinated hydrocarbon
non-flammable fluids are used for cleaning, safetyprecautions must
be taken against any toxicvapours which may be released.
Do not use carbon tetrachloride.
Precautions must be taken when using acids,alkalis and chemical
detergents for cleaningmachine parts and components. These
materialscause irritation and are corrosive to the skin, eyes,nose
and throat. Avoid splashes and wear suitableprotective clothing and
goggles. Do not breathemists. Ensure that water and soap are
readilyavailable.
When disposing of condensate, old oil, used filterelements and
other parts and waste material of anykind make sure that there is
no pollution of anydrain or natural water-course and that no
burning ofwaste takes place which could cause pollution ofthe air.
Protect the environment by using onlyapproved methods of
disposal.
7. PRECAUTIONS IN THE EVENT OF FIRE
Use extreme caution when handling componentsthat have been
subjected to fire or very hightemperatures. Some components may
containfluoroelastomer materials which decompose underthese
conditions to form highly corrosive residues.Skin contact can cause
painful and penetratingburns resulting in permanent skin and
tissuedamage.
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CompAir BroomWade Limited
page 10
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Cyclon Series User Manual
GENERAL DESCRIPTION
Page
Compressor 12
Air-End 12
Electronic Controller 12
Protection and Safety Equipment 12Relief Valve 12Blowdown System
12Minimum Pressure Non-return Valve 12
Air/Oil System 14Description 14Operation 14
Regulation System 16Description 16On/Off Control 16Modulating
Control (Optional) 17
2
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CompAir BroomWade Limited
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GENERAL DESCRIPTION
1. COMPRESSOR
The unit is a fully enclosed, air cooled, single-stage, rotary
screw compressor. The compressorair-end is belt driven by an
electric squirrel-cageinduction motor. The drive belts are mounted
onpulleys fitted to the shafts of the drive motor andair-end.
The compressor unit consists of the drive motor,air-end, oil
separator vessel, oil separator filter, oilcooler, aftercooler,
cooling fan, starter assemblyand controller.
The complete compressor unit is mounted on abaseframe and is
housed in a steel panelledacoustic enclosure. A service panel
allows accessfor routine maintenance.
2. AIR-END (CYCLON 3)
The air is compressed in a single-stage, positivedisplacement,
oil injected rotary screw air-end. Theair-end is of the Cyclon type
and comprises anintermeshing pair of helical screw rotors, male
andfemale, mounted horizontally within an enclosedcasing with drive
being applied to the male rotor.
The male rotor in the Cyclon air-end is larger indiameter than
the female rotor and has four lobeswhich mesh with five flutes on
the female rotor. Therotors are asymmetric in profile to reduce
blowbackbetween the lobes on the compression cycle to aminimum,
thus maximising overall sealing andefficiency.
The rotors are fitted with bearings at each end toprovide radial
and axial support, maintain adequateshaft stiffness and to give
minimum clearance andlow leakage between the rotor tip diameter and
thecasing.
At the delivery end the male rotor is fitted with asingle taper
roller bearing and the female rotor hasa pair of matched taper
roller bearings. Thesebearings provide axial and radial support of
bothrotors and control the very fine end clearancesbetween the
rotors and the casing.
Heavy duty parallel roller bearings are fitted to bothrotors at
the inlet end to provide radial support andto sustain the drive
load of the male rotor.
3. ELECTRONIC CONTROLLER
The electronic control system is microprocessorbased with an LED
display panel, incorporatingadvanced control and monitoring
features.
4. PROTECTION AND SAFETY EQUIPMENT
In addition to the protection and warning circuitslinked to the
control panel the following protectiondevices are fitted:
4.1 Relief Valve
A pressure relief valve is mounted on the primaryoil separator.
If pressure continues to build upwhen the demand for compressed air
has ceased,the relief valve will open at a pre-set level
todischarge the excess pressure to atmosphere.
4.2 Blowdown System
Whenever the compressor shuts down, eitherautomatically or by
operation of a STOP switch, allpressure in the oil separator vessel
is automaticallyreleased by a blowdown system which vents
thepressure to atmosphere. This ensures that thecompressor is
restarted in a no-load condition.
4.3 Minimum Pressure/Non-return Valve
Fitted on the filter manifold, the minimum pressurevalve remains
closed until minimum pressure isreached. This ensures a rapid
build-up of pressurewhen the compressor first starts and also
preventshigh velocity, low pressure air reaching the userspipework
during the start-up period and carryingover excessive amounts of
oil.
When the compressor shuts down the non-returnvalve prevents the
pressure in the users pipeworkfeeding back into the oil separator
and ventingthrough the blowdown system.
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page 13
Cyclon Series User Manual General Description
B1 ViewB2 StartB3 StopB4 PlusB5 MinusB6 ResetD1 DisplayE
Emergency Stop Button
L1 Pressure (Delivery)L2 TemperatureL3 Hours RunL4 Hours
OnloadL5 Air Filter AlarmL6 Motor FaultL7 Auto/Remote StartL8
RunningL9 Power On
CONTROL PANEL
P1 bar
T1 C
P2
T1 C P1 bar
P2
L1
D1 B1
B2 E
B3
B4
B5
B6
L2L3L4L5L6L7L8L9
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CompAir BroomWade Limited
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5. AIR/OIL SYSTEM
5.1 Description
The air/oil system comprises an air intake filter,suction
regulator, air-end, oil separator vessel, oilseparator filter,
minimum pressure/non-returnvalve, aftercooler, oil cooler with
thermostaticbypass valve and an oil filter. The flow of oilthrough
the circuit is achieved through the pressuredifferential existing
between the primary oilseparator and the oil injection point in the
air-end.
5.2 Operation
Air enters the compressor unit through the intakefilter (2) and
open suction regulator (1) to the inletport of the air-end (7). The
air is trapped by theturning rotors and mixes with the oil which
entersthe casing through the oil injection point.
Continued rotor rotation increases the pressure andtemperature
of the air/oil mixture which passesfrom the air-end discharge pipe
into the oilseparator (4) where primary separation takes placeby
centrifugal force. Most of the oil is separated atthis stage and
drops to the bottom of the vessel.
The remaining air/oil mixture then passes throughan oil
separation element (5) where final separationtakes place. The
separated oil collects in thebottom of the filter and is scavenged
back into theair-end through a small diameter pipe.
The filtered air then passes from the oil separatorfilter by way
of the minimum pressure/ non-returnvalve (3). Provided the air
pressure at this stage isabove 3.5 to 40 bar the air passes through
theaftercooler (9) where it is cooled before passing tothe delivery
outlet.
If the air pressure in the primary separator vesselfalls below
3.5 to 40 bar the minimum pressurevalve will close. The valve also
incorporates a non-return valve which operates to prevent delivery
airpassing back into the separator when thecompressor is running
off-load.
Oil from the bottom of the separator flows underpressure to the
oil cooler (10) and during normalrunning the oil passes through the
cooler tomaintain the correct temperature. A thermostaticbypass
valve (14) is installed in the inlet manifold ofthe oil cooler.
When the compressor is started, the cold oil in thesystem
bypasses the cooler and flows through theoil filter (8) directly to
the air-end. As the oil and airmixture is compressed by the rotors
in the air-end,the temperature of the oil increases.
When the oil has reached its normal operatingtemperature the
bypass valve closes and the oil isdirected through the oil cooler.
The cooled oil thenflows to the oil filter where it is cleaned
beforeentering the air-end.
The quantity of oil injected into the air-end iscontrolled by a
restrictor orifice in the air-endcasing. Oil is injected under
pressure through therestrictor orifice into the rotors and a
gallerysupplies oil to the air-end bearings.
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page 15
Cyclon Series User Manual General Description
AIR/OIL SYSTEM
8. Oil Filter9. Aftercooler
10. Oil Cooler11. Fan12. Delivery Air Outlet13. Scavenge Line14.
Thermostatic Bypass Valve
1. Suction Regulator2. Intake Air Filter3. Minimum Pressure/NR
Valve4. Primary Oil Separator5. Oil Separation Element6. Discharge
Pipe7. Air-end
9
11
12 2 7 1 135 4
14
10
8
6
3
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CompAir BroomWade Limited
page 16
6. REGULATION SYSTEM
6.1 Description
The compressor is regulated through a combinationof electronic,
pneumatic, electrical and mechanicaldevices. Two modes of
regulation are used: On/Off is fitted as standard, and Modulating
as anoptional extra.
6.2 On/Off Control
In the On/Off mode, the compressor is regulatedby the pressure
transmitter, which continuouslymonitors the pressure in the users
pipework, a run-on time sequence within the controller and
anunloader solenoid valve.
The compressor operates in response to varying airdemand in
either the on-load condition with the
suction regulator inlet valve fully open, or off-loadwith the
inlet valve fully closed.
When the controller switches the compressor to runoff-load, a
run-on time sequence is activated. Thisallows the compressor to run
for a pre-set(adjustable) period of time in the off-load
condition.If this time elapses before the pressure in theusers
pipework has fallen to the lower set point,the compressor stops and
enters the Standbycondition.
The compressor will remain in the Standbycondition until the
pressure transmitter senses thatthe pressure in the users pipework
has fallen to thelower set point. The controller will then re-start
thecompressor.
If the pressure in the users pipework falls to thelower set
point before the run on time has elapsed,the controller will
re-initialise the time sequenceand switch the compressor to run
on-load.
8. Separator Filter9. Pressure Relief Valve
10. Separator Vessel11. Air-end12. Drive Motor13. Intake
Pressure Switch14. Air-end Discharge Temperature Sensor
1. Air Intake Filter2. Suction Regulator3. Venting Valve4.
Unloader Solenoid Valve5. Minimum Pressure/Non-return Valve6.
Pressure Transmitter7. Aftercooler
M
+ -
14
1
13
11 109
8
5 7
6
4
3
2
12
REGULATION SYSTEM ON/OFF CONTROL
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page 17
Cyclon Series User Manual General Description
6.3 Modulating Control (Optional)
In the Modulating mode the opening and closing ofthe suction
regulator inlet valve is controlled by thenegative regulator. As
the demand for compressedair rises and falls, the valve modulates
betweenfully open and fully closed.
When the compressor is started and runs up toload, the minimum
pressure valve opens and airunder pressure passes from the
separator vesselinto the users pipework. If the air pressure in
theusers pipework is below the setting of the negativeregulator,
the output signal from the negativeregulator will cause the suction
regulator inlet valveto open and the compressor will run
on-load.
M
1
15
13 1211
109
8
7
5
3
2
14 16
64
+ -
Rising pressure in the separator vessel will causethe output
signal from the negative regulator to fall,progressively closing
the inlet valve to match airflow to demand.
If the pressure in the users pipework rises abovethe setting of
the negative regulator and reachesthe upper set point, the
controller de-energises theunloader solenoid valve. The valve
closes, shuttingoff the regulation air supply to the suction
regulator.The suction regulator inlet valve closes and
thecompressor runs in the off-load condition.
When the pressure in the users pipework falls tothe lower set
point the compressor reverts torunning on-load.
1. Air Intake Filter2. Suction Regulator3. Venting Valve4.
Negative Regulator5. Unloader Solenoid Valve6. Shuttle Valve7.
Pressure Transmitter8. Aftercooler
9. Minimum Pressure / Non-return Valve10. Separator Filter11.
Pressure Relief Valve12. Separator Vessel13. Air-end14. Drive
Motor15. Intake Pressure Switch16. Air-end Discharge Temperature
Sensor
REGULATION SYSTEM MODULATING CONTROL
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CompAir BroomWade Limited
page 18
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page 19
Cyclon Series User Manual
LEADING PARTICULARS
3
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CompAir BroomWade Limited
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Model Cyclon 330 Cyclon 337 Cyclon 345
Air-end Single stage oil injected screw Cyclon 3 3 3
Total oil capacity: litres 170 175 185
Delivery air connection: without optional flexible pipe Rp 1 1/2
Rp 1 1/2 Rp 1 1/2with optional flexible pipe R 1 1/2 R 1 1/2 R 1
1/2
Ambient air temperature Minimum C 0 0 0operating range: Maximum
C 46 46 46
Delivery air pressure: Minimum (all models) bar 5 5 5Maximum
(see compressor data plate) bar 75-13 75-13 75-13
Typical delivery air temperature above ambient(full load
operation) C 4 - 5 6 7 - 8
Typical cooling air outlet temperature above ambient: C 20 23
27
Main drive motor Nominal Rating(for actual rating see motor data
plate) kW 30 37 45Nominal Speed rpm 2970 2970 2970
Typical total input power Note: For actual figures seecompressor
data plate kW 351 440 541
Approximate weight DPV kg 849 875 936of total package TEFV kg
939 945 1043
Dimensions: Length mm 1420 1420 1420Width mm 990 990 990Height
mm 1650 1650 1650
Average sound level at 1 m (CAGI PNEUROP) dB(A) 68 69 70
LEADING PARTICULARS
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page 21
Cyclon Series User Manual
4INSTALLATION
Page
Guidelines 22
Installation Procedure 23
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CompAir BroomWade Limited
page 22
! WARNING
INSTALLATION
l Lethal voltages are used in thisequipment. Use extreme caution
whencarrying out electrical checks. Isolate thepower supply before
starting anymaintenance work.
l Refer to the safety procedures beforeinstallation of the
compressor unit.
1. GUIDELINES
Study the installation information in the manual forthe
particular compressor concerned.
The compressor unit is supplied as a completepackage and does
not need securing to afoundation. However, the supporting floor
musthave a loading capacity sufficient to support theweight of the
unit (see Leading Particulars).
Because in operation the compressor will releaseheat into the
surroundings the compressor roomshould be of adequate size and have
goodventilation. The recommended minimum sizes ofroom and
ventilation openings can be estimated asfollows:
From Leading Particulars establish total inputpower (kW).
Room volume = 135 m3 per input kW
Ventilation opening = 0016 m2 per input kW
Note: An equivalent discharge opening will also benecessary.
Example:
Cyclon 337 input kW = 440
Room volume = 440 x 135 m3 = 594 m3
Ventilation opening = 440 x 0016 m2 = 07 m2
The ventilation inlet opening should be positionedas low down as
possible. The outlet opening shouldbe positioned as high up as
possible, preferably inthe roof or ceiling.
The air flow from the cooler outlet may be directedeither
vertically or horizontally simply by changingthe position of the
outlet duct which is secured byfasteners. The air can be ducted for
a distance ofup to 3 m if necessary without the need for
anadditional fan. Details are available on request fromthe local
CompAir BroomWade distributor.
To allow adequate air circulation, provide aminimum of 15 m
headroom above thecompressor and a minimum of 200 mm clearanceon
the RH side. Compressors with horizontalcooling air discharge must
have a minimum of 1 mand those with vertical discharge a minimum of
150mm clearance at the back. There should be noobstruction of
doorways, passages or walkways.
The only connections required to the compressorare as
follows:
1. Electrical power supply, 3-phase plus earth.
2. Air delivery outlet to the users main pipeworkusing a
flexible hose (optional) or solid pipe.
Model Flexible Hose
330/337/345 C26151-36
Note: If solid pipe is used it must be connecteddirectly to the
outlet of the aftercooler andsupported by the first clamp or
support, at least 1 mfrom the compressor discharge.
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page 23
Cyclon Series User Manual
If the compressor is to be coupled in parallel withanother
compressor or connected to an existing airsupply system, additional
steps must be taken asset out in the Safety Procedures section of
thismanual.
If air usage is intermittent or rapidly fluctuating sothat the
instantaneous demand for air is likely toexceed the compressor
output rating, and if thevolume of the users pipework is small, it
will benecessary to install a receiver of appropriatecapacity.
As a guide, if the volume of the users pipework isless than 1 m3
a receiver of 875 litres minimumcapacity should be installed.
To maintain rigidity during shipment, transportationfixings
(painted red) are fitted to the drive module,for removal after
installation.
2. INSTALLATION PROCEDURE
The following procedure gives guidance forinstalling a standard
compressor unit. For theinstallation details for non-standard units
or unitsequipped with optional equipment refer to the localCompAir
BroomWade distributor.
1. Using a fork lift, lift the compressor unit andmove it into
position.
Note 1: If the unit is to be located in a RH cornercarry out
items 5 and 6 before moving into position.
Note 2: The use of a pallet truck is notrecommended..
2. Lower the unit into place and check that itsettles level to
within 3 mm, using suitablepacking pieces under the baseframe
ifnecessary.
3 Release 1/4 turn fasteners and remove theenclosure panels and
packaging material togive access to the compressor.
4. Remove the transportation fixings (paintedred) from the drive
module. Remove allprotective blanking covers and tapes.
5. A gland plate is fitted to the RH side of thestarter box.
Open the starter door and rotatethe gland plate to the appropriate
gland size,or remove the plate and and drill a hole to therequired
size in the spare space.
6. Make sure that the power supply to thecompressor is taken
from a fused isolator.The switch must be locked OFF and thefuses
removed.
Connect the power supply to the compressorin accordance with the
diagram supplied,using cables which comply with the standardsof the
International ElectrotechnicalCommission (I.E.C.) or local
regulations.
Pass the cable through the hole in the outerpanel, then through
the gland and gland platebefore connection to the starter.
7. Connect the air delivery pipe to the userspipework through an
isolating shut-off valve.
8. Position the exhaust panel, blank panel andsplitters between
the top and bottom endpanels. Reposition the splitters to
dischargevertically or horizontally as required. Securethe
fasteners.
9. Refit the starter compartment top cover andenclosure panels,
or close the starter door.
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CompAir BroomWade Limited
page 24
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page 25
Cyclon Series User Manual
5COMMISSIONING
Page
Commissioning Procedure 26Preliminary Checks 26Pressure
Calibration 27Checking/Altering Program Mode Values 28Final Checks
30
Negative Regulator (Modulating Control Only) 33
Commissioning Checklist 34
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CompAir BroomWade Limited
page 26
COMMISSIONING
1. COMMISSIONING PROCEDURE
When commissioning a new compressor or re-commissioning a
compressor which has been outof service, carry out the following
proceduresbefore attempting to start:
Note: We recommend that commissioning iscarried out by a CompAir
BroomWade distributor.
1.1 Preliminary Checks
1. Check that the isolator switch is locked OFFand that all
pipework and electrical powerconnections are correct and tight.
2. Release 1/4 turn fasteners and remove the topand side panels
from the compressor.
3. Open the starter door and remove theperspex safety panel.
Check all screws andconnections in the starter area for
security.Check all electrical connections are madecorrectly and are
tight.
4. Ensure the main supply cables and fuseratings comply with
regulations.
5. Ensure the control transformer primarytapping connections are
correct for supplyvoltage.
6. Ensure main motor thermal overload is setcorrectly for motor
F.L.C. and supply voltage(if applicable).
7. Remove panels as required to gain access tomotor connections.
Inspect the motor andwiring connections to make sure they
arecorrect and secure.
8. Check that all connections on the rear of thecontroller are
correct and secure.
9. Check that all protective blanks and tapeshave been
removed.
10. Check the oil level and if necessary top upthe separator
vessel to the correct level withBroomWade approved lubricant
(seeChapter 7 Maintenance Procedures para3.4.2 ).
11. Refit panels as required. Refit perspex safetypanel in
starter compartment and closestarter door.
Note: The drive belt tension is set at the factoryand requires
no further attention.
l Refer to the safety procedures beforecommissioning the
compressor unit.
l Lethal voltages are used in this equipment.Use extreme caution
when carrying outelectrical checks. Isolate the power supplybefore
starting any maintenance work.
! WARNING
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page 27
Cyclon Series User Manual CommissioningCyclon Series User Manual
Commissioning
1.2 Pressure Calibration
Note: The values shown throughout these procedures are examples
only. Ensure set values are compatiblewith the compressor
model.
No. Action Reason Display
1. Switch power ON at the isolator 0.0 Barand allow the
controller to initialise.
2. Press the STOP button. 0.0 Bareven if the compressor is
alreadystopped.
3. Disconnect the air pipe To apply 0.0 Bar to the 0.0 Barfrom
the pressure transmitter. pressure transmitter
4. Press and hold the STOP, To enter the Pressure 0.0 BarPLUS
and MINUS buttons calibration modetogether.
5. After five seconds indicators To enter Pressure calibration
0.0 BarL1 to L8 will flash four times. mode. The 0.0 Bar
calibrationWhen the indicators start to set point is automatically
set whenflash release the STOP, PLUS pressure calibration mode
isand MINUS buttons. entered.
6. Apply an accurately known (example - 7.0 bar) 7.1
Barpressure, above 5.5 Bar, tothe pressure transmitter.
7. Press PLUS or MINUS until To calibrate the pressure 7.0
Barthe pressure display matches transmitter to the appliedthe
applied pressure. pressure.
8. Press STOP To enter the pressure calibration 7.0 barinto the
controller memory.(The display will return to normalrunning
mode).
9. Remove the slave air supply and 0.0 Barre-connect the air
pipe to thepressure transmitter.
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CompAir BroomWade Limited
page 28
1.3 Checking/Altering Program Mode Values
Note: The values shown throughout these procedures are examples
only. Ensure set values relate tocompressor model.
No. Action Reason Display
1. Switch power ON at the isolator 0.0 Barand allow the
controller to initialise.
2. Press the STOP button, even if 0.0 Barthe compressor is
already stopped.
3. Press and hold the PLUS and To enter Program mode 0.0
BarMINUS buttons together.
4. After five seconds indicators 0.0 BarL1 to L8 will flash four
times.When the indicators start toflash release the PLUS andMINUS
buttons.
5. Indicator L1 will light and the display 7.5 Barwill show the
upper pressureset point P1.
6. Press PLUS or MINUS To adjust the displayed value 7.0 baror
go to step 8 if no adjustmentrequired. (pulsing display)
7. Press STOP To program the new value 7.0 barinto the
controller memory
(steady display )
8. Press VIEW To step to the next option 115C
9. Indicator L2 will light and the display 115Cwill show the oil
temperature tripset point.
10. Press PLUS or MINUS To adjust the displayed value 110Cor go
to step 12 if no adjustmentrequired. (pulsing display)
11. Press STOP To program the new value 110Cinto the controller
memory
(steady display)
12. Press VIEW To step to the next option
13. Indicator L3 will light and the 2000display will show the
maximumservice interval timer setting.
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page 29
Cyclon Series User Manual Commissioning
No. Action Reason Display
14. Press PLUS or MINUS To adjust the displayed value 1500or go
to step 16 if no adjustmentrequired. (pulsing display)
15. Press STOP To program the new value 1500into the controller
memory
(steady display)
16. Press VIEW To step to the next option
17. Indicator L4 will light and the 5.0display will show the
solenoidvalve 'open' time setting.
18. Press PLUS or MINUS To adjust the displayed value 2.0or go
to step 20 if no adjustmentrequired. (pulsing display)
19. Press STOP To program the new value 2.0into the controller
memory
(steady display)
20. Press VIEW To step to the next option
21. Indicator L5 will light and the display 7.0 barwill show the
lower pressure setpoint P2.
22. Press PLUS or MINUS To adjust the displayed value 6.5 baror
go to step 16 if no adjustmentrequired. (pulsing display)
23. Press STOP To program the new value 6.5 barin to the
controller memory
(steady display)
24. Press VIEW To step to the next option
25. Indicator L6 will light and the display C215will show the
compressor model
26. Press PLUS or MINUS To adjust the displayed value C330until
the displayed modelmatches the model number (pulsing display)shown
on the compressordata plate.
27. Press STOP To program the new value C330in to the controller
memory
(steady display)
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CompAir BroomWade Limited
page 30
No. Action Reason Display
28. Press VIEW To step to the next option
29. Indicator L7 will light and the display 0 secswill show the
Auto restart delay time.
30. If the auto restart facility isrequired press PLUS or MINUS.
To adjust the displayed value 60 secsIf the facility is not
required setthe display to 0 seconds, this (pulsing display)will
disable the facility.
31. Press STOP To program the new value 60 secsin to the
controller memory
(steady display)
32. Press VIEW To step to the next option
33. Indicator L8 will light and the display 3 minswill show the
Run-on time.
34. Press PLUS or MINUS To adjust the displayed value 5 minsor
go to step 28 if no adjustmentrequired. (pulsing display)
35. Press STOP To program the new value 5 minsin to the
controller memory
(steady display)
36. Press RESET To exit Program mode. 0.0 Bar
1.4 Final Checks
No. Action Reason Display
1. Switch power ON at the isolator 0.0 barand allow the
controller to initialise.
2. Press START To start the compressor 0.0 Barand check
direction of rotation
CAUTION: Do not repeatedly start May cause motor overheating,and
stop the compressor. contactor damage or air-end
seizure.Note: The motor may appear to turnslowly for the first
few revolutions beforebeginning to run up to speed. This isnormal
and should not be considereda fault condition.
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page 31
Cyclon Series User Manual Commissioning
No. Action Reason Display
3. Press STOP as soon as the 0.0 Barmotor begins to rotate.
CAUTION: Do not allow prolongedrunning in the reverse direction
asdamage will be caused.
4. If the direction of rotation ( marked by anarrow on the
inside of the service panel)is incorrect, isolate the power
supplyand change over motor connectionsU1 and V1 on the main
contactorand connections U2 and V2 on thedelta contactor. Return to
step 1.
5. Press START and run the compressoronload until the oil has
reached workingtemperature. Check that the oil bypassvalve operates
correctly by feeling the risein temperature of the LH header of
theoil cooler (viewed from the service end) when the valve
opens.
6. Press STOP. Check that the blowdownsystem operates correctly
and that thepressure gauge registers zero whenblowdown ceases.
7. Top up the oil in the separator vessel tothe correct
level.
8. Simulate a demand for air by openinga drain valve of the
downstream airreceiver, if installed, or opening a valvein the
users pipework.
9. Replace all compressor enclosure panels.
CAUTION: The compressor will overheat if runwithout enclosure
panels for any length of time.
10. Press START and run the compressor.Check that the compressor
loads andunloads correctly according to theprogrammed pressure set
points.
11. Check that the drain solenoid (if applicable)operates
correctly according to the pre-setsolenoid open and closed
times.
12. Check that, after running off load for theprogrammed run-on
time, the compressorstops in to Standby mode.
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CompAir BroomWade Limited
page 32
No. Action Reason Display
13. Check that the compressor automaticallyre-starts when
pressure falls below thelower pressure set point P2.
14. Run the compressor for 30 minutes.Check for air/oil leaks.
(It will be necessary to remove the enclosurepanels for short
periods). Stop thecompressor and rectify any leaks.
WARNING: RISK OF HIGH PRESSURE
Do not use hands to locate leaks in thesystem. Always use a
piece of paper orcard for this purpose.
15. Stop the compressor and check that allenclosure panels are
secure.
!
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page 33
Cyclon Series User Manual Commissioning
2. NEGATIVE REGULATOR (ModulatingControl Only)
During commissioning or after a period it will benecessary to
adjust the delivery air pressure andthe negative regulator as
follows:
1. Open the shut-off valve to the users pipework.
2. Create a downstream air bleed to simulate ademand for air by
opening the drain valve ofthe downstream air receiver, if
installed, oropening a valve in the users pipework.
3. Remove the LH side panel to gain access tothe negative
regulator.
4. Switch the power supply ON at the isolator.
5. Use the Program Mode to set the P1 and P2set points.
Note: Set P2 at the required full flow deliverypressure and P1
at 0.4 bar above this pressure.
6. Start and run the compressor.
7. Release the locknut on the negative regulatorspindle and turn
the adjusting knob counter-clockwise until the inlet valve on the
suctionregulator starts to modulate.
8. Adjust the knob on the negative regulatorclockwise until the
suction regulator inlet valvemodulates between P1 and P2 set
points.
Note: The suction regulator must begin tomodulate at the P2 set
point (an example for 7.0bar working delivery pressure is shown
below).
9. Use the pressure display on the control panelfor fine
adjustment of the negative regulator.
10. Tighten the locknut on the negative regulatoradjusting
knob.
11. Refit the access door and close the receiverdrain valve or
other downstream valve used tosimulate compressed air demand.
Note: The suction regulator must begin tomodulate at, or before,
the maximum workingpressure rating of the compressor.
0102030405060708090
10069 70 71 72 73 74 75
P1SET POINT
P2SET POINT
PRESSUREBAR
SUCT
ION
REG
ULAT
OR
% M
ODU
LATI
ON
NEGATIVE REGULATOR SETTINGS
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CompAir BroomWade Limited
page 34
3. COMMISSIONING CHECK LIST
1. Protective blanks and tapesremoved. ............
2. Pipework connected and checked.(Isolating valve fitted).
............
3. All electrical connections checked. ............
4. All control system connectionschecked. ............
5. Cable and fuse ratings comply withregulations.
............
6. Control transformer input voltageset correctly.
............
7. Overload set correct for motorsize and voltage.
............
8. Oil level correct. ............
9. Air-end primed. ............
10. Drive belt tension correct. ............
11. Air-end and motor rotate freely. ............
12. Pressure transmitter calibrated. ............
13. Pressure set-points set. ............
14. Controller model option set. ............
15. Regulation air system isolatingvalve open. ............
16. Oil drain valve closed. ............
17. Motor rotation correct. ............
18. Corrosion inhibitor dispersed. ............
19. Compressor operation correct. ............
20. Oil/air fittings checked. ............
21. Oil temperature within limits. ............
22. Emergency stop checked. ............
23. Compressor test run for30 minutes. ............
24. Oil level topped up. ............
25. All settings and options recorded. ............
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page 35
Cyclon Series User Manual
6OPERATION
Page
Routine Operation 36Starting 36Standby Mode 36Stopping
37Emergency Stop 37Oil Temperature and Hours Run Display 37Service
Interval Timer 37Alarms and Shutdown Trips 38Power Supply Failure
Detection 39Control Panel Indicators 39
Program Mode 40Program Mode Routine 40Program Mode Setting
Definitions 41Program Mode Settings 41Fixed Parameters 42
Pressure Calibration Mode 42Pressure Calibration Routine 42
Control Function Options 43Automatic Restart 43Remote Start/Stop
Facility 43Remote Load/Unload 43Remote Group Fault Output 45
Cyclon Series User Manual
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CompAir BroomWade Limited
page 36
OPERATION
l Refer to the safety procedures beforeoperating the compressor
unit.
l Lethal voltages are used in this equipment.Use extreme caution
when carrying outelectrical checks. Isolate the power supplybefore
starting any maintenance work.
! WARNING
1. ROUTINE OPERATION
1.1 Starting
1. Switch mains power ON at the isolator. Thedisplay will show
the control programidentification and the Power on indicator
(L9)will light.
2. After a few seconds the Delivery pressureindicator (L1) will
light and the display willshow the delivery pressure in Bar. See
para1.5 Oil temperature and Hours run display.
3. The Remote start/Auto restart indicator (L8)will light if the
Remote start or Auto restartfacilities have been selected. See para
4Control Function Options. If a fault exists,one of the alarm or
trip indicators will flash.See para 1.9 Control Panel indicators
forpossible start-up faults.
4. To start the compressor press START (B2).
CAUTION: Do not repeatedly start and stop thecompressor.
Note: the compressor motor may appear to turnslowly for the
first few revolutions before runningup to speed. This is normal and
should not beconsidered a fault condition.
5. Provided pressure at the delivery point isbelow the P2
pressure set point thecompressor will start and run. If pressure
isabove the P2 set point the compressor willenter Standby mode and
the Start indicator(L8) will flash. The compressor
willautomatically start and run when deliverypressure falls below
the P2 set point.
6. The compressor will not start from the frontpanel if the
Remote start facility is enabled.
7. During the initial starting period, the drivemotor starts in
Star connection. Following theswitch from Star to Delta a two
seconds loaddelay time will occur before the compressorruns on
load. The compressor will load andunload according to the delivery
pressure setpoints P1 and P2.
Note: When the compressor is on-load, a smalllight will appear
in the lower left hand side of thedisplay to indicate the
compressor is in the loadedcondition. This is intended as a fault
diagnostic aidonly.
8. Initially the oil temperature will rise rapidly toworking
temperature, the thermostatic bypassvalve will then operate to
maintain thetemperature at normal working level.
9. Fault conditions are continuously monitoredfrom start-up and
an alarm or trip indicatorwill flash if a fault occurs.
10. To interrogate the Oil temperature or to viewthe Hours Run
press VIEW (B1). See para1.5 Oil temperature and Hours run
display.
1.2 Standby Mode
1. If the compressor is off-load for longer thanthe programmed
Run-on time, thecompressor will stop and the Start indicator(L8)
will flash slowly for a short period of timewhile the compressor
blows down.
2. The Start indicator will flash quickly toindicate the
compressor is in the Standbymode. The compressor will
startautomatically when the delivery pressure fallsbelow the P2
pressure set point.
!
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page 37
Cyclon Series User Manual Operation
1.3 Stopping
1. To stop the compressor press STOP (B3).This initiates a
controlled shut downsequence. The compressor will unload, thedrive
motor will stop and the Start indicator(L8) will flash slowly for
the blowdown period.See para 2.3 Program mode settings.
2. The compressor motor cannot be re-startedduring the blowdown
sequence. If START(B2) is pressed the start indicator will
flashquickly and the compressor will enter theStandby mode and
start automatically whenthe blowdown time expires.
CAUTION: The compressor should not be stoppedduring a start
sequence.
1.4 Emergency Stop
1. When EMERGENCY STOP is pressed, thecompressor will stop
immediately and the unitwill blow down.
2. Indicators L1 to L8 will flash to showEMERGENCY STOP has been
pressed.
3. If the EMERGENCY STOP button is resetand RESET (B6) pressed
during theblowdown time, the Start indicator will slowflash for the
remainder of the normalblowdown time.
CAUTION: The Emergency Stop button should beused only in a
genuine emergency and must notbe used as the normal method of
stopping thecompressor.
1.5 Oil Temperature and Hours Run Display
1. When the compressor is in normal runningmode indicator L1
will be lit and the displaywill show the delivery pressure in
Bar.
2. To interrogate the oil temperature, total hoursrun or hours
run onload, press VIEW (B1).
3. Each time VIEW is pressed the next indicatorin the sequence
L1 to L4 will light and thedisplay will show the corresponding
value.
Indicator Display
L1 Delivery Pressure in Bar
L2 Oil Temperature in C
L3 Total hours run
L4 Hours run on-load
The display will reset to show delivery pressure 60seconds after
VIEW is last pressed.
1.6 Service Interval Timer
The controller uses a countdown timer which canbe reset to
programmed maximum each time aservice is carried out. The maximum
reset hourscan be adjusted to suit site conditions and/orservice
schedule requirements. When the timerreaches zero hours, indicator
L3 will slow flash toindicate a service is due. When the service
hasbeen completed the service countdown timer canbe reset by
entering the program mode, selectingthe service interval hours
display (indicator L3),and pressing STOP. The service
intervalcountdown timer will reset to the hours displayedon the
program mode service interval setting. Theservice due alarm can be
reset by pressingRESET after the above procedure has
beencompleted.
The compressor must be stopped and the powerisolated to carry
out the required service (see'Safety Procedures'). On completion of
the servicethe service interval timer must be reset.
When in the normal running mode the 'hoursremaining until next
service due' can be viewed atany time. Press VIEW until indicator
L3 isilluminated and the display shows the total hoursrun. Press
and hold PLUS and the display willshow the hours remaining until
the next service isdue until PLUS is released.
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CompAir BroomWade Limited
page 38
1.7 Alarms and Shutdown Trips
1. If an alarm condition occurs and serviceattention is required
the appropriate alarmindicator will flash.
2. If a trip condition occurs the compressor willstop and the
appropriate trip indicator willflash. This can occur any time after
thecompressor has been started. See para 1.9Control panel
indicators.
3. The oil temperature alarm and oiltemperature trip conditions
are shown byindicator (L2) flashing. Indicator (L2) will
flashslowly for an alarm condition and thecompressor will continue
to run. Indicator (L2)will flash quickly for a trip condition and
thecompressor will shut down immediately.
4. The oil temperature alarm level isautomatically set 10C below
theprogrammed oil temperature trip level. Seepara 2 Program
mode.
B1 ViewB2 StartB3 StopB4 PlusB5 MinusB6 ResetD1 DisplayE
Emergency Stop ButtonL1 Pressure
L2 TemperatureL3 Hours RunL4 Hours OnloadL5 Air Filter AlarmL6
Motor FaultL7 Auto/Remote StartL8 RunningL9 Power On
CONTROL PANEL
P1 bar
T1 C
P2
T1 C P1 bar
P2
L1
D1 B1
B2 E
B3
B4
B5
B6
L2L3L4L5L6L7L8L9
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page 39
Cyclon Series User Manual Operation
1.8 Power Supply Failure Detection
The controller is equipped with a power supplyfailure detection
facility. If a power supply failure isdetected, the compressor will
stop, the controllerwill reset, and the display will show
threehorizontal lines in the left hand side of the displayafter the
controller has re-initialised.
If the power failure Auto-restart facility is enabled,the
compressor will automatically restart.
Note: This facility is designed to detect total loss ofpower,
not a drop in normal supply voltage.
1.9 Control Panel Indicators
Indicator When on (Steady) When flashing
L1 Display will show delivery pressure Excess pressure trip
L2 Display will show oil temperature High oil temp alarm (slow
flash)High oil temp trip (quick flash)
L3 Display will show total hours run Service due
L4 Display will show hours run on-load
L5 Change air filter alarm
L6 Drive motor trip
L7 Remote control / Auto restart enabled Auto restart
warning
L8 Compressor started Standby (quick flash)
Blowing down (slow flash)
L9 Main supply power ON
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CompAir BroomWade Limited
page 40
2. PROGRAM MODE
2.1 Program Mode Routine
Program mode is used to access, view and/oralter the operating
parameters and options storedin the memory of the controller.
1. To enter the Program mode press STOP(B3) then press and hold
PLUS (B4) andMINUS (B5) together.
2. After five seconds indicators L1 to L8 willflash four times
to indicate that the controllerhas entered Program mode. Release
PLUSand MINUS buttons when the indicators startto flash.
3. After the indicators have flashed four times,indicator L1
will remain lit and the display willshow the current upper pressure
set point P1.
4. When VIEW (B1) is pressed indicator L1 willextinguish and
indicator L2 will light. Thedisplay will now show the Oil
temperature tripsetting.
5. Each time VIEW is pressed the next indicatorin the sequence
L1 to L8 will light and thedisplay will show the appropriate
option.
6. To alter a displayed setting, press PLUS(B4) or MINUS (B5) to
adjust the displayedvalue. The display will flash when anadjustment
is made. When the displayshows the required value, press STOP
(B3)to enter the new value in to the controllermemory. The display
will show the newsetting as a steady value.
Note: Any adjustment that is not entered into thecontroller
memory by pressing STOP (B3) will beignored and the original value
maintained.
7. Press RESET (B6) to return to normalrunning mode.
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page 41
Cyclon Series User Manual Operation
2.2 Program Mode Setting Definitions
Indicator Setting Description
L1 Pressure set point P1 Pressure at which the compressor will
unload.
L2 Oil temperature trip Temperature at which the compressor will
shut down andindicate a high oil temperature trip. (The oil
temperature alarm isset automatically at 10C below the trip)
L3 Service interval time Maximum service interval time. Service
due countdown timerwill reset to this value each time a service is
carried out and thetimer reset.
L4 Solenoid 'open' time. Time in seconds that the valve opens
every cycle. The 'shut'time is fixed at 60 seconds.
L5 Pressure set point P2 Pressure at which the compressor will
load.
L6 Model Defines a number of fixed settings required by a
particularcompressor model. See para 2.4 Fixed Parameters.
L7 Auto Restart delay The time between power being restored
after a power failureand the compressor automatically re-starting.
(Set zero time toinhibit the Auto-restart function).
L8 Run-on time The time which the compressor will run in the
off-load statebefore the main motor stops and the compressor
entersStandby mode.
2.3 Program Mode Settings
Indicator Setting Unit Minimum Maximum Step Default
L1 Pressure set point P1 Bar 5.1 13.9 0.1 7.5L2 Oil temp trip C
90 120 1 115L5 Pressure set point P2 Bar 5.0 12.9 0.1 7.0L6 Model
Model C105 C345 option C215L7 Auto restart delay seconds 60 240 1
0L8 Run-on time minutes 3 15 1 3
CAUTION: The model option must be set to matchthe compressor
data plate.
The P1 pressure set point must not be set abovethe maximum
design pressure stated on the dataplate.
Note: The minimum Auto restart delay time is setaccording to the
normal blowdown time of thecompressor model.
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CompAir BroomWade Limited
page 42
2.4 Fixed Parameters
The motor star/delta time and blowdown time areset
automatically, depending on the compressormodel programmed in the
controller.
Parameter Unit Model
C330 C337 C345
Star/Delta time secs 50 55 60
Blowdown time secs 25 25 25
Note: The blowdown time occurs when the drivemotor stops. The
compressor cannot be startedduring the blowdown time.
3. PRESSURE CALIBRATION MODE
3.1 Pressure Calibration Routine
The pressure calibration routine is used tocalibrate the
controller to the pressure transmitterto obtain an accurate
pressure display readingwhen commissioning or re-commissioning
thecompressor and at each major service interval.The routine should
also be used when renewingthe controller or pressure
transmitter.
1. Stop the compressor and isolate thecompressor air delivery
from the userssystem.
2. Remove the air pipe from the pressuretransmitter to establish
a true zero pressurecondition.
Note: Calibration will be affected if the air pipe isnot removed
before entering calibration mode.
3. Press and hold PLUS (B4), MINUS (B5) andSTOP (B3)
together.
4. After five seconds indicators L1 to L8 willflash four times
to indicate that the controlleris now in pressure calibration mode.
ReleasePLUS (B4), MINUS (B5) and STOP (B3)when the indicators start
to flash.
5. The display will show 0.0 Bar. If the pressuretransmitter
signal is outside of acceptablelimits. The controller will
automatically returnto normal running mode and display apressure
transmitter fault.
6. Apply an accurately known pressure, above5.5 Bar, to the
pressure transmitter.
7. The display will not start to indicate a readinguntil the
applied pressure is above 5.5 Bar.
8. Use PLUS (B4) and MINUS (B5) to increaseor decrease the
display reading.
Note: The controller will not allow the display to beadjusted
outside of set maximum and minimumlimits. The display will show
four horizontal lines ifthe calibration limits are exceeded.
9. Press STOP (B3) when the pressure displaymatches the applied
pressure. The displaywill return to normal running mode.
10. Press RESET (B6) at any time to abandonthe calibration
sequence and return to normalrunning mode.
11. Remove the pressure applied at Step 6.
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Cyclon Series User Manual Operation
4. CONTROL FUNCTION OPTIONS
4.1 Automatic Re-start
Automatic re-start will allow the compressor tostart
automatically after a break or failure in themains power supply.
When this facility is enabledthe Remote start / Auto re-start
indicator (L8) willbe lit.
1. To enable Automatic re-start select anAutomatic restart delay
time of greater thanzero seconds using the Program Mode.
2. To disable Automatic restart select anautomatic restart delay
time of zero seconds.
3. When power is restored after a break orfailure of the main
supply power, the Remotestart / Auto re-start indicator (L8) will
flash forthe programmed Auto re-start delay time.This provides a
warning before thecompressor re-starts. The compressor motorwill
automatically re-start and continue to runafter the auto restart
delay time expires.
4. The compressor will only automatically re-start if the
compressor was in the On-load,Off-load or Standby mode when the
break orfailure in main supply power occurred.
4.1.1 Automatic Restart Delay Time
The Auto restart delay time can be adjusted usingthe Program
Mode.
In multiple compressor installations, staggeredrestarting can be
achieved by adjusting the delaytime of each compressor
differently.
Example - Four compressor installation:-
Compressor Autorestart delay time
1 60 seconds2 120 seconds3 180 seconds4 240 seconds
4.2 Remote Start/Stop Facility
4.2.1 Remote Start
The remote start facility will enable the compressorto be
started from a remote location.
1. When this option is selected, the Remotecontrol/Auto re-start
indicator (L8) will be litand the START button (B2) on
thecompressor panel is disabled; all STOPfunctions are
unaffected.
2. To enable the remote start facility connect alength of wire
between terminal X2/1 andcontroller terminal X01, pin 7.
3. The compressor can be remotely started ifremote start
terminal X01, pin 4, is connectedvia a remote normally open button
or otherswitching device, to terminal X2/1. Theconnection can be a
pulse of at least 05seconds or continuous.
4.2.2 Remote Stop
Note: Wire LK1 must be removed to enable theremote stop to
function.
The remote stop facility will enable the compressorto be stopped
from a remote location.
1. The remote stop is active at all times,regardless of the
remote start facility beingenabled.
2. The compressor can be stopped remotely bydisconnecting the
wire link between terminalsX2/1 and X2/2 via a remote, normally
closedbutton or other switching device.
4.3 Remote Load/Unload
The remote load/unload facility enables thecompressor to be
pressure controlled by a remotepressure switch, pressure control
system orcascade panel.
1. To enable the remote Load/Unload facilityconnect a length of
wire between terminalX2/1 and controller terminal X01, pin 5.
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CompAir BroomWade Limited
page 44
2. When this option is selected the compressorwill load when
terminal X01, pin 6 isconnected, via a remote pressure
switch,cascade control panel or other switchingdevice, to terminal
X2/1.
3. The compressor will unload when theconnection between X01,
pin 6 and X2/1 isbroken.
REMOTE START/STOP
REMOTE LOAD/UNLOAD
Controller
X01-6 X01-5Remotepressureswitch orcascadepanel
X2/1
Controller
X2/2
X2/1
StartN/O
StopN/C
X01-4 X01-7
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Cyclon Series User Manual Operation
4.4 Remote Group Fault Output
4.4.1 Group Fault Relay
The control card is fitted with a group fault relay,the relay
contacts being available for switchingremote facilities. The relay
contacts are rated for amaximum of 250V ac at 5A and are connected
tocontroller terminal X08, pins 9 and 10.
4.4.2 Group Fault Relay Operation
When power is switched ON, and no alarm or tripis detected, the
group fault relay will energise andthe contacts will close circuit.
If an alarm or fault isdetected or a power failure occurs, the
relay willde-energise and the contacts will open circuit. Therelay
will energise again when the controller isreset and no further
alarm or trip condition exists.
Controller
X08-9 X08-10+V~
Fault
0V~
Relay 98475-71Relay base 98475-72
1 4 2 3
5 7 68
X1/2
X1/1 1
36
82475
4.4.3 Group Fault Relay - Example
Remote wires (eg from a PLC or buildingmanagement system) can be
connected directly tothe control card group fault relay contacts
availableon pins 9 and 10 of terminal X08.
If the output is used for switching a remote faultlamp or
audible alarm, the group fault relaycontacts will be required to
operate in reverse. Inthis case an additional relay 98475-71 and
base98475-72 should be fitted, as shown in thediagram below. This
will give a normally openremote contact which will close when a
fault isdetected or power failure occurs.
Note: If the compressor has been out of operationfor a prolonged
period it is advisable to carry outthe full commissioning procedure
before starting.
GROUP FAULT RELAY EXAMPLE
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CompAir BroomWade Limited
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Cyclon Series User Manual
7MAINTENANCE
Page
Routine Maintenance 48Cleanliness 48Recording Pressures and
Temperatures 48Maintenance Record 48Electrical Connections 48Leaks
48Lubricating Oil 48
Maintenance Schedule 49Separator Element Part Number Table
50Service Kit Part Number Table 50Drive Belt Part Number Table
(50Hz) 50Drive Belt Part Number Table (60Hz) 50
Maintenance Procedures 52Enclosure Filter 52Air Intake Filter
52Oil Separator Filter 52Oil System 53Drive Belt(s) 55Electrical
System 56Electric Motors 56Suction Regulator 56Minimum Pressure
Valve 56Flexible Hoses 56
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CompAir BroomWade Limited
page 48
MAINTENANCE
l Refer to the safety procedures beforecarrying out any
maintenance orservicing work on the compressor unit.
l Lethal voltages are used in this equipment.Use extreme caution
when carrying outelectrical checks. Isolate the power supplybefore
starting any maintenance work.
! WARNING
1. ROUTINE MAINTENANCE
To ensure efficient operation of the compressorthe performance
must be checked regularly andadjustments made to maintain the
correct settings.This section gives the information needed for
thispurpose.
A condition of the Warranty cover is for the user toensure that
routine maintenance and regularservicing must be carried out as
recommended inthe Maintenance Schedule and an accuraterecord is
kept of the work.
All CompAir BroomWade compressors are fittedwith high
performance filtration equipment. If theworking environment is
particularly dusty the filterelements and the heat exchangers will
requiremore frequent attention.
1.1 Cleanliness
The compressor must be kept in a clean conditionat all times.
Make regular inspections for signs ofdamage, excessive wear and
security of fittings.Ensure that any oil spillage is wiped
upimmediately and any residual oil cleaned fromexternal
surfaces.
1.2 Recording Pressures and Temperatures
Keep a regular daily record of the compressoroperating pressure
and temperature by noting theindicator readings, together with
ambient airtemperature, in a record book.
The readings should be taken when conditions arestable and with
the compressor running on fullload.
1.3 Maintenance Record
Keep a careful record of all servicing, maintenanceand repair
work carried out on the compressorunit. The record will form a
useful reference.
1.4 Electrical Connections
Regularly check for loose connections or frayedwiring. Clean and
tighten all connections andrepair or replace all frayed or damaged
wires andcables before starting up.
Avoid damage to electrical wiring when working onthe compressor
and ensure no damage will becaused by chafing or contact with hot
surfaces.
1.5 Leaks
Inspect for leaks, loose pipe connections and dirtbuild up prior
to carrying out routine maintenance.
Tighten loose connections and repair or replacedamaged pipes or
hoses immediately.
WARNING: RISK OF HIGHPRESSURE
Do NOT use hands to locate leaks in the system.Always use a
piece of paper or card for thispurpose.
1.6 Lubricating Oil
It is essential to maintain the correct level of oiland to
change the oil completely at the specifiedintervals. Details are
given under MaintenanceProcedures.
!
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page 49
Cyclon Series User Manual Maintenance
Item Action
Weekly
Oil System Check oil level. Top up if necessary.Separator
Element Check separator element. Renew if on load pressure
differential is 1 bar or above.Aftercooler Check condition of
pre-filter and clean as necessary.
Minor Service Every 2000 hours or 6 months (whichever is
sooner)Minor Service Use correct Service kit for model.Oil System
Change oil if appropriate to type in use (see 3.4 Oil
System).Blowdown System Check operation.Electrical Wiring Check
connections and condition.Drain Solenoid Valve Check
operation.Starter Check connections and condition of
contactors.Aftercooler and Oil Cooler Clean externally.Drive
Belt(s) Check condition.Oil Filter Renew Oil Filter.Air Filter
Renew Air Filter.
Interim Service Every 4000 hours or 1 year (whichever is
sooner)Service Carry out Minor Service.Separator Element Renew
separator element.
Major Service Every 8000 hours or 2 years (whichever is
sooner)Major Service Use correct Major Service Kit for modelService
Carry out Interim Service.Minimum Pressure Valve Service
valve.Suction Regulator Service suction regulator.
Note: Renew the drive belt(s) every 16000 hours or 4 years,
whichever is sooner.
2. MAINTENANCE SCHEDULE
Regular maintenance should be carried out byyour local CompAir
BroomWade distributor asdetailed in the Maintenance Schedule.
TheSchedule should be used as a general guide only.
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CompAir BroomWade Limited
page 50
2.1 Separator Filter Part Number Table
Model Qty. Max Rated SeparatorCyclon Pressure Filter
(Bar)
330/337 1 75 to 13 98262-223345 2 75 to 13 98262-223
2.3 Drive Belt Part Number Table (50 Hz)
Model Qty. Maximum Rated Pressure
7.5 bar 8.2 bar 10 bar 13 bar
330 4 98080-152 98080-152 98080-152 98080-153337 4 98080-153
98080-154 98080-154 98080-155345 4 98080-155 98080-156 98080-156
98080-155
Note: See the compressor data plate for the compressor model and
the maximum rated pressure.
2.4 Drive Belt Part Number Table (60 Hz)
Model Qty. Maximum Rated Pressure
7.5 bar 8.2 bar 10 bar 13 bar
330 4 98080-151 98080-152 98080-153 98080-153337 4 98080-153
98080-153 98080-154 98080-153345 4 98080-153 98080-154 98080-153
98080-155
Note: See the compressor data plate for the compressor model and
the maximum rated pressure.
2.2 Service Kit Part Number Table
Model (Cyclon) Service Kit Major Service Kit
330/337 CK2003-2 CK8003-2345 CK2003-2 CK8003-3
Note: Use Service and Major Kit for Major Service
requirements
GENUINE PARTS
USE ONLY
AUTHORISED SERVICEAGENTS
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Cyclon Series User Manual Maintenance
1. Intake Air Filter2. Suction Regulator3. Oil Cooler4. Drive
Belt5. Motor Bearings6. Minimum Pressure/Non-return Valve7.
Separator Element8. Oil Filter Element
9. Oil Drain Valve10. Control Air Isolating Valve11. Oil Filler
Cap12. Oil Level Sightglass13. Air Cooler14. Display Panel15. Belt
Tensioner16. Blowdown Valve
SERVICING POINTS
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CompAir BroomWade Limited
page 52
3. MAINTENANCE PROCEDURES
l Refer to the safety procedures beforecarrying out any
maintenance or servicingwork on the compressor unit.
l Lethal voltages are used in this equipment.Use extreme caution
when carrying outelectrical checks. Isolate the power supplybefore
starting any maintenance work.
l Where a maintenance procedure belowincludes the warning The
compressormust be stopped the following steps mustbe taken before
work is commenced:
1. Close the shut-off valve to the userspipework.
2. Switch the power supply OFF at theisolator.
3. Ensure that the blowdown system hasoperated to release all
pressure from theoil separator.
Check that the pressure display and thepressure gauge(s) in the
service arearegister zero.
WARNING
3.1 Enclosure Filter
The compressor is provided with a coarse screenfilter which acts
as a pre-filter for the intake air.
Carry out a regular check on the condition of thepre-filter
material and if necessary clean asfollows:
1. Remove the LH starter side panel. Removethe filter element
and wash it carefully in amild detergent solution. Rinse thoroughly
andallow to dry.
2. Refit the element and refit the side panel.
3.2 Air Intake Filter
Clean intake air is essential for satisfactoryoperation of the
unit. Any ingress of unfiltered airwill result in a reduction in
the service life of theseparator element.
Particular care should be taken during routineservicing to
ensure that unfiltered air cannotbypass the air intake filter
element via unsoundjoints and defective trunking, etc.
3.2.1 To Change the Air Filter:
1. Release the 1/4 turn fasteners and remove theside panel to
gain access to the intake airfilter.
2. Remove the clips from the air intake filter andwithdraw the
element.
3. Fit the new element , secure the clip and refitthe side
panel.
3.3 Oil Separator Filter
The separator filter has a nominal service life of4000 hours
under normal operating conditions.
Adverse operating conditions or failure to carry outregular
maintenance and/or correct operatingprocedures will affect the
service life of theelement.
! !
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Cyclon Series User Manual
3.3.1 To Change the Separator Filter:
The compressor must be stopped.
1. Open the door to the service area to gainaccess to the
manifold block.
Note: Cyclon 345 has two separate filters both ofwhich must be
changed at the same time.
2. Unscrew the old separator filter(s) from themanifold block
and discard the filter andsealing ring.
3. Apply a light film of oil to the seal of the
newfilter(s).
4. To fit the new filter(s), screw into the manifoldblock until
the gasket contacts the sealingsurface. Then tighten a further 1/3
turn.
5. Close the service area door.
3.4 Oil System
3.4.1 Recommended Oil
The compressor is factory filled with BroomWade4000 HR Oil or
CompAir FG Lubricant.
1. BroomWade 4000 HR OilThis is a high performance oil with
excellentlubrication and cooling characteristicsformulated to
maintain internal cleanliness,reduce the build-up of deposits on
filterelements and extend component life.
2. CompAir FG LubricantA synthetic hydrocarbon based
lubricantwhich has been specially developed for usewhere discharge
air may come into contactwith foodstuffs or for reasons of health
orenvironment. CompAir FG Lubricant meetsthe requirements of FDA
regulation 21 CFR178.3570 and is USDA H-1 approved.
The local CompAir BroomWade distributor willassist in the
selection of an appropriate lubricantand in many cases will also be
able to arrange forregular sampling of the oil to monitor the
conditionof the compressor, and to determine the oil
changeintervals to ensure optimum performance.
3.4.2 To Check the Oil Level:
To view the oil level sightglass, remove the frontpanel of the
plant.
When stopped the mimimum level is indicatedwhen the sightglass
is less than half full. Themaximum level is indicated when the
sightglass isfull and the oil reaches the bottom threads in
thefiller neck.
When running on-load the minimum level isindicated when oil is
no longer visible in thesightglass.
If necessary top up the separator with oil asfollows:
The compressor must be stopped.
1. Open the door to the service area.
2. Unscrew the filler cap.
3. Fill to the correct level with BroomWadeapproved
lubricant.
4. Refit the filler cap and tighten by hand.
5. Close the service area door.
CAUTION: Always use the correct grade of oil anddo not mix oils
of different types.
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CompAir BroomWade Limited
page 54
3.4.3 To Change the Oil Filter:
The compressor must be stopped.
1. Open the door to the service area.
2. Unscrew the old oil filter from the manifoldblock and
discard.
3. Apply a light film of oil to the seal of the newelement and
prime the new filter with oil.
4. To fit the new element, screw it into themanifold block until
the gasket contacts thesealing surface. Then tighten a further 1/3
turn.
5. Close the service area door.
6. Check oil level during initial run and top up
ifnecessary.
3.4.4 Normal Oil Change
CAUTION: Always use the correct grade of oil anddo not mix oils
of different types.
1. BroomWade 4000 HR OilProvided the air-end discharge
temperaturedoes not normally exceed 85C CompAir4000 HR Oil should
be changed every 4000hours service or 1 year, whichever is
sooner.
Where the air-end discharge temperatureregularly exceeds 85C
then a change periodof 2000 Hours or 6 months is recommended.
2. CompAir FG LubricantProvided the air-end discharge
temperaturedoes not regularly exceed 85C CompAir FGLubricant should
be changed every 4000hours service or 1 year, whichever is
sooner.
Where the air-end discharge temperatureregularly exceeds 85C
then a change periodof 2000 Hours or 6 months is recommended.
Note: Where high dust levels and/or pollution arepresent the oil
must be changed more frequentlyand the condition of the intake
filtration systemexamined regularly.
3.4.5 To Change the Oil:
To drain the oil, the system must (a) bepressurised or (b) an
alternative source ofcompressed air must be available.
CAUTION: Always use the correct grade of oil anddo not mix oils
of different types.
Method (a)
1. Run the compressor on load to pressurise thesystem.
2. Open the door to the service area.
3. Close the control air isolating valve,fitted tothe side of
the manifold block (lever to thevertical position) and the
isolating valve in theuser's system.
Note: A minimum of 4 bar (60 psi) must bemaintained in the
compressor unit prior to carryingout the oil drain procedure.
4. Stop the compressor. Wait until the motor hasstopped rotating
before proceeding.
5. Remove the plug and connect a hose(minimum 10 mm bore) to the
drain tap andplace the open end into a suitable container.
l Risk of injury from hot oil under pressure.
6. Slowly open the drain tap and allow the oilto drain into the
container for disposal.
7. Close the drain tap, disconnect the hose, andremove the
container . Refit the drain tapplug.
8. Open the control air isolating valve (lever tothe horizontal
position) and allow anypressure to be released through the
normalblowdown process.
9. Remove and discard the old oil filter element.
10. Prime the new filter with oil.
WARNING! !
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page 55
Cyclon Series User Manual Maintenance
11. Apply a film of clean oil to the seal of a new oilfilter
element. Screw the element into thehousing until it contacts the
gasket andtighten a further 1/3 turn.
12. Fill the separator to the correct level withBroomWade
approved lubricant, refit the fillercap and tighten by hand.
13. Open the isolating valve to the user's system.
14. Run the compressor until it reaches workingtemperature to
ensure full circulation of the oil.
15. Check the oil level and top up as necessary.
Method (b)
1. Open the door to the service area.
2. Close the control air isolating valve, fitted tothe side of
the manifold block (lever to thevertical position) and the
isolating valve in theuser's system.
3. Ensure that all pressure has been releasedfrom the oil
separator, remove the filler plugand fit a suitable connector to
the neck of thefiller pipe for the air supply.
4. Apply pressure to the compressor unit(minimum of 4 bar or 60
psi).
5. Remove the plug and connect a hose(minimum 10 mm bore) to the
drain tap andplace the open end into a suitable container.
l Risk of injury from hot oil under pressure.
6. Slowly open the drain tap and allow the oil todrain into the
container for disposal.
7. Close the drain tap, disconnect the hose andremove the
container. Refit the drain tap plug.
8. Close the air supply through the filler tube,open the control
air isolating valve (lever tothe horizontol position) and allow
anypressure to be released through the normalblowdown process.
9. Remove the air supply and fitting from thefiller tube.
10. Remove and discard the old oil filter element.
11. Apply a film of clean oil to the seal of a new oilfilter
element. Screw the element into thehousing until it contacts the
gasket andtighten a further 1/3 turn.
12. Fill the separator to the correct level withBroomWade
approved lubricant, refit the fillercap and tighten by hand.
13. Open the isolating valve to the users system.
14. Run the compressor until it reaches workingtemperature to
ensure full circulation of the oil.
15. Check the oil level and top up as necessary.
3.5 Drive Belt(s)
The drive belt tension is set at the factory andrequires no
further attention.
When fitting a new belt adjust the tensionaccording to the
instructions below. Run thecompressor for 30 minutes to allow the
belt tosettle into the pulley grooves then stop thecompressor and
re-tension the belt.
CAUTION: Any further tensioning will affect the lifeof the
belt.
1.5 mm
1
3
4
2PI/97/035
DRIVE BELT ADJUSTMENT
WARNING! !
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CompAir BroomWade Limited
page 56
3.5.1 Adjustment After Fitting New Drive Belt(s):
1. Release the 1/4 turn fasteners and remove theLH side
panel.
2. Loosen the lock nut (1) and turn the nut (2)clockwise until
the adjuster (3) contacts thecut-out in the spring retainer
(4).
3. Screw the nut (2) back one turn and tightenthe lock nut
(1).
4. Check that the gap between the adjuster (3)and spring
retainer (4) is 1.5 mm.
5. Refit the side panel and secure the fasteners .
3.6 Electrical System
3.6.1 To Check the Electrical Connections:
Carefully inspect all the electrical wiring and checkthe
security of all connections and terminals.
3.7 Electric Motors
3.7.1 Motor Bearings
The main drive motor is fitted with grease nipplesand the
bearings must be lubricated every 4000hours.
The recommended grease for lubrication of themotor bearings is
Esso (Exxon) Unirex N3 or anequivalent lithium complex grease.
Note: The bearings must not be over-lubricated.
The compressor must be stopped.
1. Locate the grease nipples and remove thedust caps.
2. Inject clean grease into the nipples with agrease gun. Remove
excess grease.
3. Start the compressor and run for 5 minutes.
4. Remove excess grease and refit the dust caps.
3.7.2 Dust Contamination
If the compressor is operating in a dustyatmosphere it may be
necessary to clean themotor windings periodically. The motor should
beinspected at the service intervals to determine thecleaning
frequency.
3.8 Suction Regulator
3.9 Minimum Pressure Valve
The servicing of items 3.8 and 3.9 should becarried out by a
CompAir BroomWade Distributor.
3.10 Flexible Hoses
When fitting flexible hoses the nuts should betightened using
the torque appropriate to the nutsizes.
BSP Size Torque
0.5 in 44 Nm0.75 in 84 Nm
1.0 in 115 Nm1.25 in 189 Nm
1.5 in 244 Nm2.0 in 297 Nm
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Cyclon Series User Manual
8FAULT FINDING
Page
Fault Indications 58Trip Fault Indications 58Alarm Fault
Indications 59
Shutdown Faults 59
Alarm Faults 60
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CompAir BroomWade Limited
page 58
1. FAULT INDICATIONS
1.1 Trip Fault Indications
Display Meaning
L1 to L8 Flashing Quickly Emergency Stop
L1 Flashing Quickly Excess Pressure
L1 Flashing Quickly,Pressure Display shows (----) Pressure
Sensor Failure
L2 Flashing Quickly Excess Temperature
L2 Flashing Quickly,Temperature display shows (----) Temperature
sensor failure
L6 Flashing Quickly Drive Motor Fault
Display shows ( ) Power Failure
FAULT FINDING
In operation the compressor is protected by circuitswhich are
triggered when a fault arises and eithercause the compressor to
shut down or indicate thata servicing action is requi